KSP Poppet Manual 2011
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FACTORY TRAINING KSP Poppet Manual
2011
Schwing Bioset Parts and Service (715) 247-3433 OR Fax (715) 247-3438
Paul Katka - Parts/Service Manager Dave Larson - Quality Control Specialist
Service Technicians Chris Kohnen Jack Koehler Jeff Joy John Christenson Mike Smith
Parts Brad Dopp Larry Larson Zach Anderson
TABLE OF CONTENTS
SECTION 1
GENERAL
1.1
PURPOSE OF THIS MANUAL .................................................................................. 1 - 1
1.2
DESCRIPTION OF EQUIPMENT .............................................................................. 1 - 1 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10
1.3
INSTALLED EQUIPMENT LIST ................................................................................ 1 - 26 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.3.11
1.4
General Description .................................................................................... 1 - 1 Sludge Pump With Poppet Valves.............................................................. 1 - 8 Sludge Flow Measuring System (SFMS®) - Poppet Valve KSP ................ 1 - 10 Screw Feeder ............................................................................................. 1 - 12 Hydraulic Power Pack................................................................................. 1 - 13 Material Pipeline ......................................................................................... 1 - 21 Sliding Frame Silos..................................................................................... 1 - 22 Push Floor .................................................................................................. 1 - 23 Pipeline Lubrication System ....................................................................... 1 - 24 Automatic Greaser System......................................................................... 1 - 25
General With Data Sheets .......................................................................... 1 - 26 Sliding Frame Receiving Bin....................................................................... 1 - 26 Receiving Bin Conveyor ............................................................................. 1 - 26 Sludge Pump - KSP 140 (HD)XL................................................................ 1 - 27 Screw Feeder - SD 500 HD ........................................................................ 1 - 27 Agitator Hopper - MODEL HHH.................................................................. 1 - 27 Hydraulic Power Pack - MODEL 2000, 200/150 HP................................... 1 - 27 Agitator Hopper - MODEL HHH.................................................................. 1 - 28 Hydraulic Power Pack - MODEL 230, 40 HP.............................................. 1 - 28 Pipeline Lubrication System ....................................................................... 1 - 28 Automatic Greaser System......................................................................... 1 - 28
SAFETY REGULATIONS .......................................................................................... 1 - 29
SECTION 2
SAFETY REGULATIONS
2.1
SAFETY REGULATIONS .......................................................................................... 2 - 1
2.2
SAFETY DURING INSTALLATION ........................................................................... 2 - 2
2.3
SAFETY PRECAUTIONS - STARTUP ...................................................................... 2 - 3
2.4
SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS ................................... 2 - 4
2.5
SAFETY DURING MAINTENANCE ........................................................................... 2 - 4
SECTION 3
HYDRAULICS
3.1
RULES OF HYDRAULICS ......................................................................................... 3 - 1
3.2
HYDRAULIC PUMPS ................................................................................................ 3 - 8
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TABLE OF CONTENTS
3.3
VALVES ..................................................................................................................... 3 - 12 3.3.1 3.3.2 3.3.3
3.4
HYDRAULIC SYMBOLS ............................................................................................ 3 - 16
SECTION 4
OPERATION
4.1
BEFORE OPERATING SLUDGE PUMPS IN ANY MODE - POPPET ...................... 4 - 1
4.2
NOTES - POPPET ..................................................................................................... 4 - 2
4.3
PREVENTIVE MAINTENANCE NOTES - POPPET .................................................. 4 - 2
4.4
PRE-START-UP CHECKS ........................................................................................ 4 - 4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6
4.5
4.6
General With Safety Precautions - Start-up................................................ 4 - 11 Starting and Stopping ................................................................................. 4 - 11 Emergency Stop ......................................................................................... 4 - 13
MATERIAL PUMP OPERATION ............................................................................... 4 - 14 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5
4.7
Sludge Pump .............................................................................................. 4 - 5 Screw Feeder ............................................................................................. 4 - 6 Hydraulic Power Pack ................................................................................ 4 - 7 Material Pipeline ......................................................................................... 4 - 8 Push Floor/Sliding Frames ......................................................................... 4 - 9 Pipeline Lubrication .................................................................................... 4 - 10
START-UP PROCEDURE ......................................................................................... 4 - 11 4.5.1 4.5.2 4.5.3
The Control Panel....................................................................................... 4 - 14 SFMS and Transition Pressure Setpoint Selection..................................... 4 - 15 Screw Feeder Modes ................................................................................. 4 - 16 Mode Selection ........................................................................................... 4 - 16 HMI Screens ............................................................................................... 4 - 18
LUBRICATION SYSTEM OPERATION ..................................................................... 4 - 25 4.7.1
Mode Selection ........................................................................................... 4 - 25
4.8
MATERIAL PUMP AND SCREW FEEDER ALARM CONDITIONS ........................... 4 - 26
4.9
LUBRICATION SYSTEM ALARM CONDITIONS ...................................................... 4 - 28
4.10
ADJUSTMENTS AND CHECKS DURING OPERATION .......................................... 4 - 29 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.10.7 4.10.8 4.10.9
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Control Valves ............................................................................................ 3 - 12 Relief Valves............................................................................................... 3 - 12 The Basic Relief Valve ............................................................................... 3 - 14
Safety Instructions - Adjustments & Checks............................................... 4 - 29 Sludge Pump Output Adjustment - Electric ................................................ 4 - 29 Sludge Pump Output Adjustment - Manual Handwheel ............................. 4 - 30 Screw Feeder Output Adjustment - Electric................................................ 4 - 30 Screw Feeder Output Adjustment - Manual Handwheel............................. 4 - 31 Hydraulic System Checks - Rock Valve ..................................................... 4 - 32 Hydraulic System Checks/Adjust. - Poppet Valve ...................................... 4 - 32 Mechanical Checks .................................................................................... 4 - 32 Other Controls and Instruments ................................................................. 4 - 32
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4.11
SHUTDOWN PROCEDURE ...................................................................................... 4 - 33 4.11.1 4.11.2 4.11.3 4.11.4 4.7.5
SECTION 5
Shutdown For General Maintenance .......................................................... 4 - 33 Short-Term Shutdown................................................................................. 4 - 35 Long Term Shutdown ................................................................................. 4 - 35 Long-Term Storage..................................................................................... 4 - 36 EMERGENCY STOP.................................................................................. 4 - 37
PLANNED MAINTENANCE
5.1
SAFETY DURING MAINTENANCE ........................................................................... 5 - 1
5.2
PERIODIC MAINTENANCE SCHEDULE .................................................................. 5 - 3 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.5
5.3
LUBRICANT RECOMMENDATIONS ......................................................................... 5 - 35 5.3.1 5.3.2 5.3.3
5.4
Hydraulic oil recommendations (hydraulic power pack) ............................. 5 - 36 Gear-lubricant recommendations ............................................................... 5 - 37 Grease recommendations .......................................................................... 5 - 37
TROUBLESHOOTING ............................................................................................... 5 - 38 5.4.1 5.4.2 5.4.3
5.5
General Maintenance ................................................................................. 5 - 7 Hydraulic power pack ................................................................................. 5 - 10 Push Floor Silo ........................................................................................... 5 - 18 Screw Feeder ............................................................................................. 5 - 21 Material Pump............................................................................................. 5 - 26 Pipeline Lubrication System ....................................................................... 5 - 33
Hydraulic Power Pack................................................................................. 5 - 38 Push Floor Silo ........................................................................................... 5 - 40 Screw Feeder ............................................................................................. 5 - 41
BOLT TORQUE TABLES ........................................................................................... 5 - 45 5.5.1 5.5.2
SECTION 6
Metric: normal threads ................................................................................ 5 - 45 Metric: fine threads ..................................................................................... 5 - 46
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
6.1
SAFETY DURING MAINTENANCE (From you O&M Manual) ................................... 6 - 2
6.2
MAINTAINING HYDRAULIC SYSTEM PRESSURES................................................ 6 - 3
6.3
SCREW FEEDER ....................................................................................................... 6 - 4 6.3.1
6.4
Auger replacement ..................................................................................... 6 - 4
MATERIAL PUMP....................................................................................................... 6 - 6 6.4.1 6.4.2
Replacing piston heads .............................................................................. 6 - 6 Replacing poppet valves............................................................................. 6 - 14
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TABLE OF CONTENTS
SECTION 7 7.1
SLUDGE FLOW MEASURING SYSTEM (SFMS®) SET-UP .................................... 4 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9
SECTION 8 8.1
Overview of the SFMS® and the Schwing Pump ....................................... 4 SFMS® Calculations .................................................................................. 7 Throttle Valve Adjustment .......................................................................... 8 Throttle Check Valve Adjustment ............................................................... 9 Proximity Switch Set-up.............................................................................. 10 SFMS® Functional Test #1 -KSP ............................................................... 12 SFMS® Functional Test #2 - EKSP............................................................ 12 SFMS® Calibration ..................................................................................... 13 Testing and Calibration of SFMS® ............................................................. 14
KSP COMPONENTS
SCREW FEEDER COMPONENTS ........................................................................... 8 - 1 8.1.1
Screw Feeder Gear Box ............................................................................. 8 - 2
8.2
SCREW FEEDER SHAFT TIMING ............................................................................ 8 - 8
8.3
SLUDGE PUMP COMPONENTS .............................................................................. 8 - 27
SECTION 9
HYDRAULIC OIL & FILTERS
9.1
RESERVOIRS ........................................................................................................... 9 - 1
9.2
HYDRAULIC OILS AND LUBRICANTS ..................................................................... 9 - 1
9.3
FLUID CONTAMINATION AND CONTROL .............................................................. 9 - 3 9.3.1
Handling, Storing, and Dispensing of Lubricating Fluids ............................ 9 - 4
9.4
FILTERS .................................................................................................................... 9 - 6
9.5
TECHNICAL INFORMATION - FILTRATION RATINGS ........................................... 9 - 6 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5
9.6
Nominal Filtration Ratings .......................................................................... 9 - 6 Absolute Filtration Ratings.......................................................................... 9 - 6 Beta Filtration Ratio (bn)............................................................................. 9 - 6 Filter Facts .................................................................................................. 9 - 7 Technical Information - Beta Ratings ......................................................... 9 - 8
SCHWING BIOSET FILTERS ................................................................................... 9 - 9 9.6.1 9.6.2
KSP Return Filter........................................................................................ 9 - 9 Conditioning Loop Filter.............................................................................. 9 - 11
9.7
HYDRAULIC PUMPS ................................................................................................ 9 - 12
9.8
REXROTH VT 2000 AMPLIFIER CARD .................................................................... 9 - 18 9.8.1
9.9
Functional Description of the Rexroth VT2000 Amplifier Card ................... 9 - 18
PRESSURE SWITCHES ........................................................................................... 9 - 21 9.9.1
iv
INSPECTIONS & CALIBRATIONS
How To Set Pressure Switches .................................................................. 9 - 21
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9.9.2 9.9.3 9.9.4 9.9.5
Switch Adjustments .................................................................................... 9 - 26 Temperature Switch Adjustment................................................................. 9 - 29 Combination Level and Temperature Switch.............................................. 9 - 31 Dirty Oil Filter Switch .................................................................................. 9 - 32
9.10
TYPES OF HEAT EXCHANGERS ............................................................................ 9 - 35
9.11
HYDRAULIC SCHEMATIC SERIES - KSP POPPET ................................................ 9 - 38 9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.11.6 9.11.7
9.12
UNIT IS IN REVERSE ............................................................................................... 9 - 52 9.12.1
9.13
KSP Poppet Valve - Series #8.................................................................... 9 - 52
EXCESS ROCKING OIL CONDITION ....................................................................... 9 - 54 9.13.1
9.14
KSP Poppet Valve - Series #1.................................................................... 9 - 38 KSP Poppet Valve - Series #2.................................................................... 9 - 40 KSP Poppet Valve - Series #3.................................................................... 9 - 42 KSP Poppet Valve - Series #4.................................................................... 9 - 44 KSP Poppet Valve - Series #5.................................................................... 9 - 46 KSP Poppet Valve - Series #6.................................................................... 9 - 48 KSP Poppet Valve - Series #7.................................................................... 9 - 50
KSP Poppet Valve - Series #9.................................................................... 9 - 54
ADDING ROCKING OIL CONDITION ....................................................................... 9 - 56 9.14.1
SECTION 10
KSP Poppet Valve - Series #10.................................................................. 9 - 56
SPECIAL TOOLS
10.1
HYDRAULIC TROUBLE SHOOTING KITS ............................................................... 10 - 1
10.2
FLOW METERS AND ACCESSORIES ..................................................................... 10 - 2
10.3
MATERIAL CYLINDER ALIGNMENT TOOLS ........................................................... 10 - 3
10.4
PISTON INSTALLATION TOOLS .............................................................................. 10 - 4
10.5
ROD GLAND PACKING INSTALLATION TOOLS ..................................................... 10 - 5
10.6
RAM TOOLS .............................................................................................................. 10 - 6
10.7
TORQUE SPECIFICATIONS FOR METERIC BOLTS AND SCREWS USED ON SCHWING EQUIPMENT .......................................................................... 10 - 7 10.6.1 10.6.2 10.6.3
Dacromet 500 Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts)....................................... 10 - 8 Dacromet 500 Screws and Nuts DIN 6914, 6915 (HV Screws).................. 10 - 10 Black Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts)....................................... 10 - 11
10.8
CONVERSION CHART ............................................................................................. 10 - 13
10.9
FLUID POWER FORMULAS ..................................................................................... 10 - 16
10.10
DRILL SIZES FOR METRIC TAPS ............................................................................ 10 - 18
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KSP Poppet Training Manual
GENERAL
SECTION 1
SECTION 1 1.1
GENERAL
PURPOSE OF THIS MANUAL
This manual is designed to assist you in the Installation, Operation, and Maintenance of your custom designed Schwing Bioset Sludge Pump system. It describes storage, installation, start-up, normal operation, shut-down, periodic maintenance, and trouble shooting procedures. It also contains detailed layout drawings, hydraulic schematics, electrical schematics, and parts book drawings. The installers, operators, maintenance personnel, and everyone involved with these systems should study this manual carefully. We hope that it can help in your ongoing training and maintenance program.
1.2
DESCRIPTION OF EQUIPMENT
1.2.1
General Description
A specially sized and configured Sludge Pump System supplied by Schwing Bioset consists of one or more sets of the following equipment: • Hydraulically Driven Piston Pump • Screw Feeder/Agitator Hopper. • Hydraulic Power Pack, to power the pump and screw feeder/agitator hopper. • Special Feed hoppers or Hopper Adapters. • Material Pipeline, steel with pressure tight seals. (OPTIONAL) • Control Systems • Sliding Frames • Push Floors • Pipeline Lubrication System They are described further in the following paragraphs and detailed specifications for the installed equipment in your O&M manual. The system is custom designed to pump dewatered sludges or slurries through pressurized steel pipelines to dryers, incinerators, or distribution systems. The electric motor of the Hydraulic Power Pack drives hydraulic pumps that drive the cylinders of the Sludge Pump and the hydraulic motors of the Screw Feeder or Hopper Agitator. Custom controls, monitors and sensors are installed to specifications to provide automatic, dependable operation.
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1-1
SECTION 1
GENERAL
39000001
Figure 1.1 - Typical KSP Installation #1 (A10V Hydraulic Pumps) 1-2
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GENERAL
SECTION 1
Figure 1.2 - Typical KSP Installation #2 (A11VO Hydraulic Pumps)
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1-3
SECTION 1
GENERAL
39000002
Figure 1.3 - Typical KSP Installation #3 1-4
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GENERAL
SECTION 1
39000003
Figure 1.4 - Typical KSP Installation #4 KSP Training Manual
1-5
SECTION 1
GENERAL
39000004
Figure 1.5 - Typical KSP Installation #5 1-6
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GENERAL
SECTION 1
PUSH FRAME/SLIDE GATE CYLINDER
DIRECTIONAL VALVE PRESSURE SWITCH
FILTER
ELECTRIC MOTOR/PUMP ASSY. 39000237
Figure 1.6 - Typical KSP Installation #6
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1-7
SECTION 1
1.2.2
GENERAL
Sludge Pump With Poppet Valves
The sludge pump is designated with a "KSP" prefix and a size designation of 5, 10, 12, 17, 25, 40, 45, 50, 80, 140 or 220. It is a hydraulically driven, positive displacement, twincylinder reciprocating piston pump. The material cylinders are in line with the differential hydraulic cylinders that power the material piston head (ram) in suction and pressure strokes. Separating the material cylinders from the differential cylinders is a fluid filled chamber called the “Water Box". The fluid cools and lubricates the material ram as it moves in the material cylinder. The fluid also rinses and cools the differential cylinder rod as it passes through the water box. The chamber also provides access for checking pump wear and for changing the material piston head (ram).
POPPET VALVE CONTROL INTAKE PORT HOUSING
DISCHARGE PORT
WATER BOX
MATERIAL PISTON (RAM) MATERIAL CYLINDER
DIFFERENTIAL HYDRAULIC CYLINDERS 39000007
Figure 1.7 - Sludge Pump With Poppet Valves In operation the two cylinders move in opposite directions so that one cylinder is charged with material from the feed system while the other cylinder is pushing material into the pipeline. Flow of the material into and out of the cylinders is controlled by four (4) hydraulically actuated poppet valves, one discharge and one intake valve for each cylinder. They are activated in the following sequence: 1. The pumping pistons come to the end of their stroke, that is, one fully extended and one fully retracted. The hydraulic valve drive is activated and the open discharge poppet closes, and suction poppets change state respectively. 2. Both discharge poppets are now closed. Hydraulic pressure increases and the pistons start to operate in the opposite directions, one charging and one discharging. As the discharging piston moves forward, the sludge is compressed in the delivery cylinder. 3. At the moment when the compressed sludge in the discharging cylinder equals the pressure of the compressed sludge in the delivery line, the discharge poppet opens and material flows into the pipeline. Since the poppet valve for the discharging cylinder opens only when the cylinder contents are at the same pressure as the pipeline, no material can flow back into the pump. This minimizes shocks in the pipeline.
1-8
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OUTBOARD BEARING
TRANSITION PIECE
PRESSURE VALVE DISC
PRESSURE VALVE CYLINDER
DISCHARGE LINE
PRESSURE VALVE SEAL (SEAT) POPPET HOUSING
DRAIN
SUPPORT FRAME
SWITCHING VALVE
HYDRAULIC PISTON HEAD
STEEL ROD
DOUBLE SCREW
PACKING GLAND
GEAR BOX FILL PLUG
CHECK VALVE (SUBTRACT ROCKING OIL)
WATER BOX
RAM TRANSITION PIECE
MATERIAL PISTON
MATERIAL CYLINDER, INSIDE CHROMED TO .010" THICK (.25MM)
SUCTION POPPET
GEAR BOX
SIGHT GAUGE
HYDRAULIC DRIVE MOTOR
CHECK VALVE (ADD ROCKING OIL)
DIFFERENTIAL CYLINDER
SWITCHING VALVE
GENERAL SECTION 1
39000008
Figure 1.8 - Sludge Pump With Poppet Valve Cut-A-Way
1-9
SECTION 1
1.2.3
GENERAL
Sludge Flow Measuring System (SFMS®) - Poppet Valve KSP
Schwing Bioset’s Sludge Flow Measuring System, installed on a Poppet Valve Sludge Pump, monitors the pumping cycle time and calculates pump output. It compensates for pumping (filling) efficiency and relays the flow rate to control equipment or system monitors. The Sludge Flow Measuring System consists of two magnetic proximity sensors, two ring magnets mounted on the pressure poppet valve pistons, and special programming within the PLC that controls the Sludge Pump. The sensors are mounted on the sides of the valve cylinders to sense the closed position of the poppet valves. The poppet is closed when the piston is at the limit of its extended travel. See Fig. 1.10 below.
POPPET VALVE (Closed Position)
VALVE CYLINDER
MAGNETIC PROXIMITY SENSOR
RETRACT
PISTON
EXTEND
RING MAGNET PRESSURE POPPET VALVE HOUSING 39000009
Figure 1.9 - Pressure Poppet With SFMS® Sensor Schwing Bioset’s Sludge Pumps are designed such that at the end of each stroke both pressure poppet valves are closed. During the next stroke one of the poppets stays closed and one of the poppets opens to allow flow to the pipeline (discharge). Opening of this poppet is delayed until the material is compressed and the pumping cylinder pressure is the same as that of the pipeline. The end of the stroke is signaled when both poppets are again closed. By timing the full stroke and the compression phase of the stroke, the PLC is able to determine pumping efficiency, flow (in gallons per stroke, gallons per hour, etc.) and limited totalizing.
1 - 10
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GENERAL
SECTION 1
PLC Calculation Referring to the table below, the Cycle Time for one stroke is T1. The Compression Phase is the time between both poppets closed and one of the poppets opening. Pumping Time T2 is equal to T1 minus the compression time. T2 = T1 - COMPRESSION Pump Efficiency is Pumping Time divided by Cycle Time. EFF =
T2 T1
Flow Rate is Material Cylinder Volume times Efficiency divided by Cycle Time. FLOW = F
BOTH POPPETS CLOSED
X EFF ( VOLUME ) T1
DISCHARGE POPPET OPENS
Compression
BOTH POPPETS CLOSED
Pumping Time T2 Cycle Time T1 Time 39000010
Figure 1.10 - Cycle Time Table (SFMS®) See Appendix A for parts (Pressure Poppet Valve), and section 5.4 for adjustment procedure.
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SECTION 1
1.2.4
GENERAL
Screw Feeder
The Screw Feeder increases pump efficiency by pressurizing the material feed into the pump suction. It consists of a feed trough with twin rotating augers that receive material from a feed hopper and convey it through a transition housing to the intake of the Sludge Pump. The augers (or screws), are driven by a gear box with a hydraulic motor driven by the Power Pack.
Water Box
Control Housing (Poppet Valve)
Control Block w/Forward-Reverse Lever Operated Valve
Discharge End
Hydraulic Motor
External Screw Auger Bearings for Hopper Openings Greater Than 35 in (900 mm)
Screw Feeder Intake Opening
Double Screw Feeder Augers
39000011
Figure 1.11 - Screw Feeder
1 - 12
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GENERAL
1.2.5
SECTION 1
Hydraulic Power Pack
The Hydraulic Power Pack drives the Sludge Pump and its hydraulic control systems and auxiliary equipment such as a Screw Feeder or the Agitator Hopper augers. The power pack consists of an oil reservoir and steel frame with lifting eyes. The electric motor, hydraulic pump, flow control valves, and electric control enclosures are mounted on the power pack. Additional equipment and configurations vary with each installation and may include oil coolers, auxiliary hydraulic pumps, special valves or control instruments, sound covers, etc. Please see your O&M manual for details on the unit installed for this project.
ELECTRIC CONTROLS, LOCAL OR REMOTE LOCATED
RETURN LINE FILTER WITH INDICATOR SWITCH OIL LEVEL SWITCH
CLEAN-OUT COVER FILLER CAP
LIFTING EYES OIL TANK DRAIN HYDRAULIC PUMP FOR SCREW FEEDER
PRESSURE GAUGES
HIGH PRESSURE SWITCH ELECTRIC MOTOR
HIGH TEMPERATURE SWITCH
HYDRAULIC PUMP FOR SLUDGE PUMP VALVE FOR SLUDGE PUMP W/ ADJUSTABLE RELIEF VALVE & SOLENOID FOR LEVER CONTROLLED BYPASS VALVE.
VALVE FOR LEVER OPERATED SCREW FEEDER W/ FORWARD-REVERSE VALVE W/ ADJUSTABLE RELIEF VALVE
MOTOR COUPLING AND V-BELT DRIVE FOR AUX. PUMP
39000013
Figure 1.12 - Hydraulic Power Pack (A2 Hydraulic Pumps)
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SECTION 1
GENERAL
ELECTRIC CONTROLS, LOCAL OR REMOTE LOCATED OIL LEVEL AND TEMPERATURE SWITCH
CIRCULATION LOOP FILTER
RETURN LINE FILTER WITH INDICATOR SWITCH
CLEAN-OUT COVER
FILLER CAP
LIFTING EYES PRESSURE GAUGES
OIL TANK DRAIN
HIGH PRESSURE SWITCH
ELECTRIC MOTOR
HIGH TEMPERATURE SWITCH OIL COOLER
HYDRAULIC PUMP FOR SLUDGE PUMP
HYDRAULIC PUMP FOR CIRCULATION LOOP
HYDRAULIC PUMP FOR SCREW FEEDER
LEVER OPERATED W/ FORWARD-REVERSE VALVE W/ ADJUSTABLE RELIEF VALVE
SOLENOID OPERATED LOAD BY-PASS VALVE FOR SLUDGE PUMP W/ ADJUSTABLE RELIEF VALVE
39000014
Figure 1.13 - Hydraulic Power Pack (A10V Hydraulic Pumps)
1 - 14
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SLUDGE PUMP RELIEF VALVE
SLUDGE PUMP BY-PASS VALVE
SOLENIOD VALVE (WITH MANUAL OVER-RIDE)
PRESSURE GAUGE SHUT-OFF VALVE
SLUDGE PUMP PRESSURE GAUGE
SCREW CONVEYOR PRESSURE GAUGE
LIFTING EYES (FOR LIFTING DEVICES PROVIDED)
TEMPERATURE SWITCH
CLEAN OUT COVERS
HIGH OIL PRESSURE SWITCH
LOW OIL LEVEL SWITCH
SCREW CONVEYOR PRESSURE SWITCH
LIMIT SWITCH AND POTENTIOMETER FOR HYDRAULIC PUMPS
HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER
SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE)
SCREW CONVEYOR PRESSURE RELIEF VALVE
ELECTRICAL CONTROL PANEL
RETURN FILTER FOR HYDRAULIC OIL
OIL COOLER
DIRTY OIL FILTER PRESSURE SWITCH
GENERAL SECTION 1
39000015
Figure 1.14 - Electric Power Pack, Side View (A2 Hydraulic Pumps)
1 - 15
1 - 16
#1 MOTOR 480 VAC, 3 PHASE
VEE-BELT (MATCHED SET)
ROTEX COUPLING
VEE-BELT DRIVE
480 VAC, 3 PHASE #2 MOTOR (ADJUSTS HYDRAULIC FLOW FOR SLUDGE PUMP)
HYDRAULIC PUMP FOR SLUDGE PUMP
MECHANICAL ADJUSTMENT FOR FLOW OF HYDUALIC PUMP
480 VAC, 3 PHASE #3 ELECTRIC MOTOR (ADJUSTS HYDRAULIC PUMP FLOW FOR SCREW CONVEYOR)
SCREW CONVEYOR HYDRAULIC PUMP
SECTION 1 GENERAL
39000016
Figure 1.15 - Electric Power Pack, Top View (A2 Hydraulic Pumps)
KSP Training Manual
KSP Training Manual ELECTRIC MOTOR
ELECTRICAL CONTROL PANEL
LOW OIL LEVEL SWITCH
CLEAN OUT COVER & FILLER CAP
SCREW CONVEYOR PRESSURE RELIEF VALVE
HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER
LIFTING EYES (FOR LIFTING DEVICES PROVIDED)
SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE)
HIGH OIL PRESSURE SLUDGE PUMP
CONDITIONING LOOP FILTER
SLUDGE PUMP PRESSURE GAUGE
SCREW CONVEYOR PRESSURE GAUGE
RETURN FILTER FOR HYDRAULIC OIL
GENERAL SECTION 1
39000240
Figure 1.16 - Electric Power Pack, Side View (A10VO Hydraulic Pumps)
1 - 17
1 - 18
MILLTRONICS UNIT
BALL VALVE 1"NPT COOLER WATER DRAIN
BALL VALVE 1"NPT COOLER WATER SUPPLY
WATER-OIL COOLER
HYDRAULIC PUMP AA10VSO FOR SLUDGE PUMP
BYPASS/LOAD VALVE FOR SLUDGE PUMP SOLENOID CONTROLLED W/ ADJ. RELIEF VALVE
SCREW CONVEYOR HYDRAULIC PUMP AA10VSO28EL
FORWARD/REVERSE VALVE FOR SCREW FEEDER HAND LEVER CONTROLLED W/ ADJ. RELIEF VALVE
CONDITIONING LOOP PUMP
SECTION 1 GENERAL
39000241
Figure 1.17 - Electric Power Pack, Top View (A10VO Hydraulic Pumps)
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ELECTRICAL CONTROL PANEL
ELECTRIC MOTOR ROTEX COUPLING
LOW OIL LEVEL SWITCH
DIRTY OIL FILTER SWITCH
DRAIN SCREW CONVEYOR PRESSURE RELIEF VALVE
HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER
CLEAN OUT COVER & FILLER CAP
HIGH OIL PRESSURE SLUDGE PUMP
CONDITIONING LOOP FILTER
PRESSURE GAUGE SHUT-OFF VALVE
SLUDGE PUMP PRESSURE GAUGE
SCREW CONVEYOR PRESSURE GAUGE
LIFTING EYES (FOR LIFTING DEVICES PROVIDED)
SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE)
RETURN FILTER FOR HYDRAULIC OIL
GENERAL SECTION 1
39000238
Figure 1.18 - Electric Power Pack, Side View (A11VO Hydraulic Pumps)
1 - 19
1 - 20 BALL VALVE 1"NPT COOLER WATER DRAIN
WATER-OIL COOLER
BALL VALVE 1"NPT COOLER WATER SUPPLY
HYDRAULIC PUMP A11VO130EP2D
BYPASS VALVE
HYDRAULIC PUMP A11VO60EP2D
HYDRAULIC CONTROL BLOCK W/LEVER
HYDRAULIC PUMP V20101F8
SECTION 1 GENERAL
39000239
Figure 1.19 - Electric Power Pack, Top View (A11VO Hydraulic Pumps)
KSP Training Manual
GENERAL
1.2.6
SECTION 1
Material Pipeline
The pipeline used to convey the sludge from the pump to its destination may be supplied by Schwing Bioset or others. Generally it is pressure-tight steel pipe with bolted couplings. See Sludge Pump Installation drawing in your O&M manual for size and configuration of the discharge pipeline. Pump connection to the material pipeline must allow for safe disconnection from the pipeline to allow service of internal pump parts.
ANSI Flange Pipeline
2" Fully Ported Bleed Valve 1/2" Dutchman
Schwing Two Bolt Clamp
Schwing Sludge Pump Discharge
In-line Fully Ported Shut-off Valve
Spool Piece
39000017
Figure 1.20 - Recommended Pipeline Connection
KSP Training Manual
1 - 21
SECTION 1
1.2.7
GENERAL
Sliding Frame Silos
The Sliding Frame is a bridge-breaker; when in operation it ensures mass movement of material through the silo and into the receiving conveyor or pump. The Sliding Frame, which is inside the silo, is attached to the Extension Shafts which pass through the wall of the silo and attach to the cylinders which are on the outside. The silo wall openings are effectively sealed by means of the Stuffing Bpx seals on the Extension Shafts.
39000243
Figure 1.21 - Sliding Frame
1 - 22
KSP Training Manual
GENERAL
1.2.8
SECTION 1
Push Floor
The push floor system is designed to receive and temporarily store the large and periodic quantities of material. The push floor can take these uneven loads and provide a consistent discharge through the conveyors and pumps. The push floor moves the material to the inlet of the extraction screw conveyor. The screw conveyor will then move the material to the screw conveyor outlet. The push floor moves the material through the use of the moving frame sections. Hydraulic rams move a push bar down the length of the floor. The floor scrapers are designed to push material in one direction, while minimizing material movement on the return stroke. The floor sections are constantly moving, with the two outside sections moving in the opposite direction of the middle section for multiple scraper configuration.
39000244
Figure 1.22 - Push Floor
KSP Training Manual
1 - 23
SECTION 1
1.2.9
GENERAL
Pipeline Lubrication System
The pipeline is used to convey the sludge from the pumps to either the sludge loading station or the post liming station. Due to the nature of the material being pumped, pipeline pressure may build up under certain conditions. Wet biosolids sludge tend to pump well and does not usually require lubrication. The higher the solids concentration of the biosolids, the more resistance to pumping and higher the resulting pipeline pressure. The pipeline lubrication systems are provided to inject a layer of water in the pipeline, reducing fiction along the pipe walls, and reducing the pipeline pressure. The lubrication pumps supply a small quantity of water to a lubricating ring. The ring installed in the pipe injects a constant flow, forming a thin film of water along the inside surface of the pipe. The pump can be set to automatically start whenever the pipeline pressure exceeds a given pressure for a sustained time period. Initial setting for pump start-up is 300 psi.
39000259
Figure 1.23 - Pipeline Lubrication System
1 - 24
KSP Training Manual
GENERAL
1.2.10
SECTION 1
Automatic Greaser System
The automatic greaser system serves to minimize the need for frequent lubrication maintenance by supplying periodic injections of grease to the equipment. The lubrication system provides grease to the push floor hydraulic cylinders, bearings on the metering screw conveyors and the seals on the twin screw augers. The system is a simple electric pump that runs on a timer. Grease is pumped to the equipment based on a programmed timing interval. The time can be independently programmed for each of the application points.
30358024
Figure 1.24 - Automatic Greaser System
KSP Training Manual
1 - 25
SECTION 1
GENERAL
1.3
INSTALLED EQUIPMENT LIST PROJECT: Sample Only
1.3.1
General With Data Sheets
Equipment supplied: Qty Model
Description
1 --
Sliding Frame Recieving Bin - RBSF
2 --
Recieving Bin Conveyors - RBC-1, RBC-2
2 KSP140 (HD) XL
Sludge Pump, vertical horizontal configuration, with poppet valves, rock valve - RP-1, RP-2
2 SD500 HD
Screw Feeder with Outboard Bearings
HHH 2 200/150 HP HHH
Agitator Hopper Hydraulic Power Pack - RPPP Agitator Hopper
2 230/40 HP
Hydraulic Power Pack - RBSFPP
2 Milroy C Pumps
Pipeline Lubrication Pumps - PLP-1, PLP-2
1 Lincoln 1827
Automatic Greaser system
APPENDIX 'F' in the O&M manual contains data sheets with serial numbers, and other information, for the major components of the Sludge Pump System supplied. 1.3.2
Sliding Frame Receiving Bin
Refer to installation drawings (Section 6) in the O&M manual for the general arrangement and overall dimensions. See Section 9 for additional details. The hydraulic circuits for the sliding frame hydraulic rams are detailed in Section 7 in the O&M manual. Electrical details are included in Section 8 in the O&M manual. 1.3.3
Receiving Bin Conveyor
Refer to installation drawings (Section 6) and electrical drawings (Section 8) in the O&M manual. Detailed information on the conveyor is contained in Section 10 in the O&M manual.
1 - 26
KSP Training Manual
GENERAL
1.3.4
SECTION 1
Sludge Pump - KSP 140 (HD)XL
“V” Configuration: The Sludge Pump is configured with one cylinder above the other, that is, they are aligned in a vertical plane ("V"). The Installation Drawing in Section 6 in the O&M manual gives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. "H" configuration: The Sludge Pump is configured with one cylinder along side of the other, that is, they are aligned in a horizontal plane ("H"). The Installation Drawing in Section 6 in the O&M manualgives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. See Appendix A for Sludge Pump assembly drawings and Bills of Material for replacement parts. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.5
Screw Feeder - SD 500 HD
The installed Screw Feeder is configured as shown on the Assembly Drawing in Appendix B. The Installation Drawings in Section 6 give overall dimensions. The pressure settings are shown on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.6
Agitator Hopper - MODEL HHH
The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.7
Hydraulic Power Pack - MODEL 2000, 200/150 HP
The installed Hydraulic Power Pack is configured as shown on the Assembly Drawing. See Appendix C for Bills of Material and replacement parts. The installation drawings in Section 6 in the O&M manual give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.
KSP Training Manual
1 - 27
SECTION 1
GENERAL
Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.8
Agitator Hopper - MODEL HHH
The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.9
Hydraulic Power Pack - MODEL 230, 40 HP
The installation drawings in Section 6 give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.10
Pipeline Lubrication System
Refer to installation drawings (Section 6) in the O&M manual for the general arrangement. Electrical controls are detailed in Section 8 in the O&M manual. See Appendix I in the O&M manual for detailed information on the lubrication system. 1.3.11
Automatic Greaser System
See Appendix G (Catalog Cuts) in the O&M manual for detailed information on the Lincoln Automatic Greaser System.
1 - 28
KSP Training Manual
GENERAL
1.4
SECTION 1
SAFETY REGULATIONS
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations. ANSI standards "ANSI 2244.1-1952" set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
! WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel. Only Certified Licensed Electricians shall be allowed to work on electrical systems.
! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. Keep unauthorized personnel away from the work area during maintenance. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation. Other sections of this manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.
KSP Training Manual
1 - 29
SECTION 1
1 - 30
GENERAL
KSP Training Manual
SAFETY REGULATIONS
SECTION 2 2.1
SECTION 2
SAFETY REGULATIONS
SAFETY REGULATIONS
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations. OSHA standards 1910.147 (subpart J) set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection. Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel. Only Certified Licensed Electricians shall be allowed to work on electrical systems.
! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED, machines might have multiple sources. Check for voltage before touching any electrical point. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.
WARNING
Multiple power sources. Check for voltage before touching any point. 30333417 A
39000018
Figure 2.1 - Warning Decal (P/N 30333417)
KSP Training Manual
2-1
SECTION 2
SAFETY REGULATIONS
Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.
! WARNING! DANGER - CONFINED SPACE! When entering a silo to perform any work, follow the guidelines below. Serious injury or death may occur if proper guidelines are not followed. ALWAYS -Establish a confined space entry program. Perform a confined space hazard analysis and follow local regulations dealing with confined space entry. ALWAYS -Clean the silo of material to prevent hazardous gases or collapse of bulk materials. ALWAYS -Wear personal protective equipment required (hard hat, boots, respirator, hearing protection, etc.). ALWAYS -Have a rescue plan established BEFORE a person enters a confined space. Safety lines attached to the person working in the confined space, and a means to pull them to safety, can prevent a rescuer from being exposed to the same hazard encountered by the worker. ALWAYS -Provide adequate ventilation of fresh air. Natural ventilation alone may not be sufficient to maintain breathable quality air. ALWAYS -Have air quality tested by a qualified person BEFORE entering a confined space, and continually monitor until the work is completed. ALWAYS -Have at least two (2) persons present when performing work in confined spaces; one (1) person must stay outside of confined space as an observer in case of emergency. Keep unauthorized personnel away from the work area during maintenance. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation. Other sections of the O&M manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.
2.2
SAFETY DURING INSTALLATION
Supplementary recommendations: • Read and review the O & M Manual and relevant contract drawings for installation information. • Lifting equipment, cables, chains, etc. are to be connected only at the lifting points provided.
2-2
KSP Training Manual
SAFETY REGULATIONS
SECTION 2
• Keep unauthorized personnel away from the work area during positioning of equipment or installation. • Installation work should only be done by qualified, authorized personnel. • Only Certified Licensed Electricians shall be allowed to work on electrical systems.
! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. • Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately
2.3
SAFETY PRECAUTIONS - STARTUP
Before start-up the operator shall perform all necessary pre-start-up checks as described in Section 2.4, Page 2 - 4 if this is a testing start-up, first time start-up, restart after maintenance, or restart after Long Term Shutdown At start-up observe the following safety precautions: • Keep area clear of unauthorized personnel. • Be observant for leaks or unusual noises. • DOUBLE CHECK THAT ALL HAND VALVES ARE IN NEUTRAL POSITION and/or BYPASS SWITCH IS IN "BYPASS" (NOTE INDICATOR LIGHT) BEFORE STARTING. • Review the "Sequence of Operation" that is included on the Electrical Schematic in Section 8 to understand what happens at start-up of system.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). • All covers, guards and safety decals must be in place before start-up.
KSP Training Manual
2-3
SECTION 2
2.4
SAFETY REGULATIONS
SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS
Only trained and authorized personnel shall perform adjustments to the sludge pump and related equipment. Read and study all of the adjustment procedures before making any adjustment. One adjustment may have an effect on another. Covers for rotating parts must be in place during adjustments and checks. All personnel shall know the location and operation of EMERGENCY CONTROLS. See the sequence of operation and control layout drawings on the electrical schematic in your O&M manual.
2.5
SAFETY DURING MAINTENANCE
When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following are some supplementary recommendations: Read and review this O & M Manual and relevant contract drawings for maintenance information. Keep unauthorized personnel away from the work area during maintenance. Maintenance work should only be done by qualified, authorized personnel. Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). Only Certified Licensed Electricians shall be allowed to work on electrical systems.
! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in OFF or NEUTRAL position.
2-4
KSP Training Manual
SAFETY REGULATIONS
!
SECTION 2
WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.
Sludge discharge lines are operating under high pressure. Extreme caution and proper safety practices should be followed whenever the flanges are being loosened or the clamps removed from the sludge discharge line. To relieve the pressure in a sludge discharge line, follow these steps: 1. Place the screw conveyor or conical hopper in the reverse position. 2. Tighten down the throttle valves until they are completely closed, then open them 1/2 turn. (Located on the control block) NOTE: If your pump is equipped with the SFMS® (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydraulic cylinders. 3. On manually operated control blocks (older models) place the S-1 spool in the reverse position and let the pump kit stroke in reverse for a short period of time. 4. Observe the hydraulic cylinder rods for the discharge poppets to verify that they are moving. (If they are not moving assume that the line is still pressurized.) 5. Observe the hopper to see if any sludge is coming from the pump into the hopper. Also observe the discharge line pressure gauge to see if it is dropping (if so equipped). 6. Open the pressure bleed off valve to release any residual pressure remaining (if so equipped). 7. Shut the pumping unit off and disconnect all power sources. Remove the flanges and clamps, using the proper safety procedures. Do not install or repair damaged pipes, fittings or hoses. Replace damaged hydraulic hoses immediately. Lifting equipment, cables, chains, etc., are to be connected only at the lifting points provided. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.
KSP Training Manual
2-5
SECTION 2
SAFETY REGULATIONS
Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.
ANSI Flange Pipeline
2" Fully Ported Bleed Valve 1/2" Dutchman
Schwing Two Bolt Clamp
Schwing Sludge Pump Discharge
In-line Fully Ported Shut-off Valve
Spool Piece
39000017
Figure 2.2 - Recommended Pipeline Connection
! WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.
2-6
KSP Training Manual
KSP Training Manual
460V 316189
338672)
30311258 30314576 303555x6 303555x7 303555x8 303555x9
Screw feeder:
Accumulator:
Slide gate:
Slide frame:
Push floor:
Hydraulic:
KSP pumpkit (Typical)
30311257
8
27
WARNING: Safety Guard is missing 30337004 (in the waterbox, under the guard)
WARNING: Starts automatically 30337069
Use 311262 for table 2, 4, 6, 8)
Sludge pump:
4. Pressure labels:
other
322670
Write in number
575V 317932
(Use 311263 for table 1, 3, 5, 7;
3. Rev/Fwd: Use #
2. Motor rating:
311211
Write in number
Assignments:
(Choose between:
1. Bypass: Use #
Date:
Label Assignment by:
Job Name:
Job Number:
9
WARNING: Do not put hands in waterbox 30319872
Lift here 30317940 4
6
1
26
CHANGE / E.C.O #
NAME
Drawn By
RE
Date
08/23/01
Approved
Decal Location Dwg.-1 of 5 KSP w/ Power Pack
30358014
Fwd/Rev - 3 11262 or Rev/Fwd - 3 11263
14 15
WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672
or
WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670
or
WARNING: Bypass-Load does not stop screw feed - 30311211
30358014
REV.
n/a
Lettering per hydraulic schematic
DATE
36
29
11
WARNING: Do not put hands in hopper 30319869 (Both sides of material cylinders)
Main ID tag 30301733
Main ID tag 30301733
REV.
SAFETY REGULATIONS SECTION 2
Figure 2.3 - Typical Decal Location - KSP
2-7
2-8
CHANGE / E.C.O.
Power Pack Serial Number Plate - 30304314 3
35
NAME
Fwd / Rev - 30311262
8
14
C A B
Texaco HD 46 (get # from decal) 5
WARNING:Bypass-Load does not stop screw feed - 30311211
Safety Instructions: Safety rules 30312298
36
or
29
or
11
19 8
WARNING: Starts
Hydraulic Pressure (generic) - 30355569
Push Floor Pressure - 30355568
Slide Frame Pressure - 30355567
Slide Gate Pressure - 30355566
Screw Feeder Pressure - 30311258
Accumulator Pressure - 30314576
Drawn By
WARNING: Do not operate without training - 30337013
30358014
Attn: One- Way
RE
Date
080901
Approved
Decal Location Dwg . - 2 of 5 KSP w/ Power P ack
30358014
RE V.
A
WARNING:Hyd. 30 Accumulator-30324 599 (units with accumulators) (locate here and
2
34 Warning: Hazardous voltage
7
One or more of these, located under pressure gauges
WARNING:Stored Hyd. energy - 30334976 (units with accumulators)
WARNING: Hyd. Accumulator - 30324599 (units with accumulators)
Safety Instructions: Accumulator rules - 30314115
Sludge Pump Pressure - 30311257
28
30
31
Safety Instructions: Accumulator rules -30314 115 31 (units with accumulators)(locate here and near accumulator)
IMPO R TAN T: Reorder info 33 30333269
WARNING:Screw feeder and sludge pump have separate Bypass-Load switches - 30338672
WARNING:Bypass-Load stops both screw feeder and sludge pump - 30322670
Lettering per hydraulic schematic
SCHWING
21
ATTENTION: Change filter - 30314050
DATE
WARNING:This Equip. starts Automatically 30337069 (both Sides)
(Inside of Elec. panel) WARNING: multiple power sources-30333417
POWER PACK (Typical)
RE V.
SECTION 2 SAFETY REGULATIONS
Figure 2.4 - Typical Decal Location - Power Pak
KSP Training Manual
KSP Training Manual 16
Lift here 30317940 4
WARNING: Keep Hands Out Of Screw Feeder-30311264 (Both Sides)
WARNING: Starts Automatically-30337069 (Both sides of housing, if exposed)
NAME
DATE
RE
Date
080901
Approved
Decal Location Dwg. - 3 of 5 KSP w/ Power P ack
30358014
WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672
or
REV .
n/a
30358014
WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670
or
WARNING: Bypass-Load does not stop screw feed - 30311211
Lettering per hydraulic schematic
Drawn By
29
(Typical) 8
WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672
36
or
WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670
or
WARNING: Bypass-Load does not stop screw feed - 30311211
CHANGE / E.C.O. #
29
11
REV.
11
18
WARNING: Keep Hands Out Of Agitator Assy.-30312297 (If Equipped with hopper) (Both Sides)
Screwfeeder
9
WARNING: Safety Guard is Missing 30337004 (As Req'd)
SAFETY REGULATIONS SECTION 2
Figure 2.5 - Typical Decal Location - Screw Feeder
2-9
2 - 10
SAFETY INSTRUCTIONS: Safety operating instructions - KSP 30312298
IMPORTANT: Reorder info 30337013
19
7
WARNING: Do not operate without training 30337013
WARNING: Machine may start at any time 30337069 7
8
LUBE PUMP CONTROL PANEL
33
8
34
35
IMPO R TAN T: Documentation ordering info 30333269
WARNING: Machine may start at any time 30337069
WARNING: Harzardous voltage inside 30336368
WARNING: Multiple power sources 30333417
IMPORTANT: 33 Documentation ordering info 30333269
SAFETY INSTRUCTIONS 19 Safety operating instructions - KSP 30312298
REV.
NAME
Drawn By
RE
Date
080901
Approved
REV.
n/a
30358014
30358014
DATE
Decal Location Dwg. - 4 of 5 KSP w/ Power P ack - Lube pumps
CHANGE / E.C.O. #
SECTION 2 SAFETY REGULATIONS
Figure 2.6 - Typical Decal Location - Lube Pumps
KSP Training Manual
SAFETY REGULATIONS
SECTION 2
ELECTRICAL DISCONNECTS SHOULD HAVE PADLOCKS ACCESSIBLE TO REPAIR PERSONNEL OR SET-UP MECHANICS. 39000022
Figure 2.7 - Safety Reminder - Electrical Disconnections
SUITABLE GUARDS AND SHROUDS HELP PREVENT OPERATORS FROM INJURING THEMSELVES. 39000023
Figure 2.8 - Safety Reminder - Guards And Shrouds KSP Training Manual
2 - 11
SECTION 2
SAFETY REGULATIONS
CONSTANT ATTENTION TO SAFETY AND GOOD HOUSEKEEPING IS THE BEST WAY TO PREVENT COSTLY ACCIDENTS. 39000024
Figure 2.9 - Safety Reminder - Good Housekeeping
2 - 12
KSP Training Manual
HYDRAULICS
SECTION 3 3.1
SECTION 3
HYDRAULICS
RULES OF HYDRAULICS
1. Hydraulic pressure always takes path of least resistance.
2. Hydraulic pressure is created equal in all directions (Pascal's Law).
Pascal's Law 2 A 10 pound force applied to a stopper with a surface area of one square inch......
1 The bottle is filled with a liquid, which is not compressible
3 Results in 10 pounds of force on every square inch (pressure) of the container wall
4 If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.
3. Liquids (oil) are relatively incompressible.
OIL
AIR
KSP Training Manual
1000 lbs of Force
1000 lbs of Force
OIL
AIR
3-1
SECTION 3
HYDRAULICS
4. When hydraulic pressure and flow is not converted into work it is converted into heat.
Open relief (Heat)
5. When oil is heated it will expand (5% or more).
Atmospheric pressure forces water past seals
Vacuum formed as hydraulic oil cools
Seals
Hydraulic Cylinder Water Box
6. When oil is heated the viscosity of it changes.
6 bar 3-2
KSP Training Manual
HYDRAULICS
SECTION 3
7. In industrial applications the recommended maximum fluid velocity is 17 FPS (Feet Per Second).
M 35 psi
ΔP
8. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) operates.
0 GPM
10 GPM
9. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actuator.
10,000 LBS LOAD
10 gallon maximum capacity cylinder
10 inch of area on cylinder piston
1000 PSI
KSP Training Manual
3-3
SECTION 3
HYDRAULICS
10. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.
U.S. F = FORCE (in pounds) (lb)
F=PxA P = F /A
F P
A
A = F /P
P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in 2 )
METRIC F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm 2 ) A = AREA (in square centimeters) (cm 2 )
GENERAL POWER =
QxP CONSTANT
Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area)
U.S. HP = HORSEPOWER HP =
GPM x PSI 1714
GPM = GALLONS PER MINUTE PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT
METRIC KW = KILOWATTS KW =
LPM x BAR 600
LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT
3-4
KSP Training Manual
HYDRAULICS
SECTION 3
Mechanical Versus Hydraulic
1. An input force of 10 lb.(44.48 N) on a one square inch 2 (6.45 cm ) piston...
COMPARISON OF MECHANICAL FORCES VERSUS HYDRAULIC FORCES
100 lb. (444.82 N)
10 lb. (44.48 N) 1 sq. in. (6.45 cm 2 )
2. will balance 100 lb (444.82 N) here...
1. Ten pounds (44.48 N) here...
3. This pressure will support a 100 lb. (444.82 N) weight if this is a 10 sq. in. (64.52 cm2) piston.
10 sq. in. (64.51 cm 2 )
2. develops a pressure of 10 pounds per square inch(psi) (.69 bar) (68.94 kilopascals) throughout the container. 100 lb. (444.82 N) 10 lb. (44.48 N)
INPUT 4. this arm.
3. if this arm is 10 times as long as...
4. The forces are proportional to the piston areas.
OUTPUT
100 lb. (444.82 N) 10 lb. (44.48 N) = 10 sq. in (64.52 cm2 ) 1 sq. in (6.45 cm 2 )
A. SIMPLE MECHANICAL LEVER
B. SIMPLE HYDRAULIC PRESS
Transfer of Energy ENERGY CAN NEITHER BE CREATED NOR DESTROYED 1. Moving the small piston 10 in. 0.25 m) displaces 10 cu. in. (163.87 cm 3 ) of liquid. (1 sq. in. x 10 in. =10 cu. in.) (6.45 cm 2 x 25.40 cm = 163.87 cm 3 )
2. 10 cu. in. (163.8 cm 3 ) of liquid will move the larger piston only 1 in. (2.54 cm) (10 sq. in. x 1 in. = 10 cu. in.) (64.52 cm x 2.54 cm = 163.87 cm )
100 lb. (444.82 N)
10 lb. (44.48 N) 1 sq. in. (6.45 cm 2 )
10 sq. in. (64.51 cm2 ) 1 in (0.02 m) 10 in (0.25 m)
3. The energy transfer here equals 10 lb. x 10 in. (44.48 N x 0.25 m) or 100 in. lb. (11.30 Nm)
KSP Training Manual
4. The energy transfer here also is 100 in. lb. (11.30 Nm) (1 in. x 100 lb. = 100 in. lb.) (.02 m x 444.82 N = 11.30 Nm)
3-5
SECTION 3
HYDRAULICS
Hydraulic Jack
8"
HYDRAULIC ROD
PISTON
Linear & Rotary Actuators LINEAR ACTUATOR
1.The pump pushes the hydraulic liquid into lines.
ROTARY ACTUATOR
2. Lines carry the liquid to actuators which are pushed to cause a mechanical output to move a load.
4. Rotary actuators or motors give the system rotating output. They can be connected to pulleys, gears,rack-and-pinions, conveyors, etc.
MOTOR
PUMP LOAD
PUMP
PISTON & ROD TO RESERVOIR
ROTARY DRIVE SHAFT
3. Some actuators operate in a straight line (linear actuators). They are called cylinders or rams. They are used to lift weight, exert force, clamp, etc.
3-6
KSP Training Manual
HYDRAULICS
SECTION 3
Basic Hydraulic Components
Check Valve
Throttle Valve
Throttle Check Valve
Switching Valve
KSP Training Manual
3-7
SECTION 3
3.2
HYDRAULICS
HYDRAULIC PUMPS
Hydraulic pumps are used to create flow (GPM) in a hydraulic system. (Hydraulic pumps do not create pressure) There are 4 basic designs of hydraulic pumps: 1 Piston Pumps: a. Radial Piston b. Axial Piston I. Bent Axis II. Swash Plate STYLES: Fixed Displacement Variable Displacement
AVAILABLE CONTROLS 1. Manual 2. Horse-power regulated 3. Pressure Compensated 4. Pressure cut-off
Piston pumps are rated in CC (Cubic Centimeters) or CID (Cubic Inch Displacement) per revolution. The efficiency of this pump design remains high throughout its pump life. The efficiency drops off very quickly at the end of the pumps life. They are designed for high pressure and high range of RPM. 2 Gear Pumps: a. External Gear b. Internal Gear I. Gerotor II. Crescent Gear pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. They are generally designed for medium range hydraulic pressure and RPM. The efficiency of this pump design declines gradually throughout its pump life. It is so gradual that it is hardly noticeable until it has deteriorated considerably. 3 Vane Pumps: Vane pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. they are generally designed for medium range pressure and RPM. The efficiency of this pump remains high throughout its pump life and drops quickly at the end of the pumps life. 4 Screw Pumps: These pumps operate at various pressure ranges and RPM's. There design is mainly used when a hydraulic system can't tolerate any hydraulic pulsations.
3-8
KSP Training Manual
HYDRAULICS
SECTION 3
Screw
Vane
Gear
Piston
Figure 2.10 - Different Types of Pumps
Bent Axis
Swash Plate
Figure 2.11 - Different Types of Axial Piston Pumps
KSP Training Manual
3-9
SECTION 3
HYDRAULICS
Universal link Piston rod
Cylinder block
Rotating shaft causes pistons to reciprocate
Piston
Oil forced to outlet as piston is pushed back into cylinder
from inlet
Piston is withdrawing from bore at inlet to outlet
39000040
Figure 2.12 - Pumping Action In Bent-axis Pumps
Maximum piston stroke
Reduced stroke
Maximum angle
Less angle
No stroke
No angle
39000041
Figure 2.13 - Increasing/Decreasing Piston Pump Output
3 - 10
KSP Training Manual
HYDRAULICS
SECTION 3
External Gear Pump
(3) (4)
OUTLET
...and forced out of pressure port as teeth go back into mesh.
Outlet pressure against teeth causes heavy side-loading on shafts as indicated by arrows.
Drive Gear
(2)
(1)
Oil is carried around housing in chambers formed between teeth, housing, & side plates... INLET
Vacuum is created here as teeth unmesh. Oil enters from reservoir.
Internal Gear Pump
(1)
Oil entering here....
(6)
(5)
(2)
through this port.
to this point, where constant meshing of two gears forces the oil...
by the constant withdrawal of teeth on this inner gear...
(3)
from the spaces between the teeth of this inner gear...
Cresent seal
(4)
is carried in these spaces...
39000042
Figure 2.14 - Internal and External Gear Pumps KSP Training Manual
3 - 11
SECTION 3
HYDRAULICS
3.3
VALVES
3.3.1
Control Valves
Control valves are designed to direct and control the flow of oil to or from the work in a hydraulic circuit. These operating mechanisms of the valves are: 1 MANUAL OPERATED: a. Hand lever b. Push button c. Pedal operated 2 SOLENOID OPERATION: a. AC coils b. DC coils 3 PILOT OPERATED a. Hydraulic pilot b. Air pilot 3.3.2
Relief Valves
Relief valves are designed to regulate the maximum amount of pressure that can be built in a hydrauic circuit. They are built in three designs: 1. Direct acting 2. Pilot operated 3. Solenoid operated.
3 - 12
KSP Training Manual
HYDRAULICS
SECTION 3
A
B
P
T
Push Button
Manually Actuated
A
B
P
T
A
B
P
T
Foot Pedal or Treadle
Hand Lever
A
B
P
T
Hydraulic Pilot
A
B
A
B
P
T
P
T
Mechanically Actuated Symbol
A
B
P
T
Air Pilot
39000043
Solenoid
Figure 2.15 - Different Types of Activation Devices
A
B
P
T
Pressure to "b" port, "a" port to tank
A
T
B
Pressure to "a" port, "b" port to tank
A
P
B
P
T 39000044
Figure 2.16 - Typical Spool-type 4 Way Valve
KSP Training Manual
3 - 13
SECTION 3
3.3.3
HYDRAULICS
The Basic Relief Valve
This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.
Pressure
Tank
39000045
Figure 2.17 - Direct Acting Non-adjustable Relief Valve This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.
Pressure
Tank
39000046 39000046
Figure 2.18 - Direct Acting Adjustable Relief Valve
3 - 14
KSP Training Manual
HYDRAULICS
SECTION 3
This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controling it. Once this pilot poppet opens we lose our hydraulic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.
Pressure
Pressure
Tank
39000047
Figure 2.19 - Pilot Operated Adjustable Relief Valve
KSP Training Manual
3 - 15
SECTION 3
3.4
HYDRAULICS
HYDRAULIC SYMBOLS
A.N.S.I.
D.I.N.
A.N.S.I.
D.I.N.
A.N.S.I. = AMERICAN NATIONAL STANDARDS INSTITUTE DIN = DEUTSCHE (GERMAN) INDUSTRIAL NORM
Figure 2.20 - American-German Symbol Comparison
3 - 16
KSP Training Manual
HYDRAULICS
SECTION 3
LINES CROSSING
PRESSURE RELIEF VALVE
LINES JOINING
FOUR WAY VALVE, TWO POSITION MANUALLY OPERATED
LINE, WORKING (MAIN)
FOUR WAY VALVE, THREE POSITION, LEVER OPERATED, W/ DETENT
T L
LINE, PILOT (FOR CONTROL)
OIL LEVEL SIGHT GLASS W/ THERMOMETER
PORT
FOUR WAY VALVE, THREE POSITION, SOLENOID AND PILOT OPERATED, SPRING RETURN
LINE W/ THROTTLE VALVE
TANK VENT
CHECK VALVE W/ NO SPRING
TEMPERATURE MONITOR
CHECK VALVE W/SPRING RETURN
FLOAT-TYPE SWITCH
TANK
SWITCHING VALVE
FILTER
THROTTLE CHECK VALVE
DOUBLE ACTING CYLINDER ROD END CYLINDER
SHUT-OFF VALVE
PUMP,VARIABLEDISPLACEMENT, NON-COMPENSATED UNIDIRECTIONAL
PRESSURE SWITCH
HYDRAULIC MOTOR, BI-DIRECTIONAL
OIL COOLER
PRESSURE GAUGE
M
ELECTRIC MOTOR
Figure 2.21 - Hydraulic Symbols - Sheet 1
KSP Training Manual
3 - 17
SECTION 3
HYDRAULICS
TO LOAD
SVLE VALVE
TANK
PRESSURE
PL
P G1
TANK G2
COMPENSATED PUMP
M1 S
L
TANK
A
ACCUMULATOR UNLOADING (SEQUENCER)
P
TANK
Figure 2.22 - Hydraulic Symbols - Sheet 2
3 - 18
KSP Training Manual
HYDRAULICS
SECTION 3
1500 PSI
D 15 PSI
HIGH PRESSURE LOW PRESSURE ZERO PRESSURE
1500 PSI
D
HIGH PRESSURE 15 PSI
LOW PRESSURE ZERO PRESSURE
39000061
Figure 2.23 - Basic Piston Pump - Series #1 KSP Training Manual
3 - 19
SECTION 3
HYDRAULICS
1500 PSI
D
HIGH PRESSURE 15 PSI
LOW PRESSURE ZERO PRESSURE
1500 PSI
D
HIGH PRESSURE 15 PSI
LOW PRESSURE ZERO PRESSURE
39000063
Figure 2.24 - Basic Piston Pump - Series #2 3 - 20
KSP Training Manual
HYDRAULICS
SECTION 3
1500 PSI
D 15 PSI
HIGH PRESSURE LOW PRESSURE ZERO PRESSURE
1500 PSI
D
HIGH PRESSURE 15 PSI
LOW PRESSURE ZERO PRESSURE
39000065
Figure 2.25 - Basic Piston Pump - Series #3 KSP Training Manual
3 - 21
SECTION 3
HYDRAULICS
1500 PSI
D
HIGH PRESSURE 15 PSI
LOW PRESSURE ZERO PRESSURE
39000064
Figure 2.26 - Basic Piston Pump - Series #4
3 - 22
KSP Training Manual
HYDRAULIC FITTINGS HIGH PRESSURE HOSES
DOCUMENT #699000
350 SMC Drive Somerset, WI 54025 Tel 715-247-3433 Fax 715-247-3438 www.schwingbioset.com
REV. 05/17/08
TABLE OF CONTENTS Fitting Assembly Instruction NS Style Profile - Dull Green Colored ........................................................3 Direct Assembly ..........................................................................................................................................3 Wrench and Coupling for Walterscheid Fittings on Schwing Equipment ..................................................5 Hydraulic Fittings Chart ..............................................................................................................................6 CAP NUTS .................................................................................................................................................7 FERRULES .................................................................................................................................................7 GES .............................................................................................................................................................8 GES...NPT ...................................................................................................................................................8 GS ................................................................................................................................................................9 WS ...............................................................................................................................................................9 TS ..............................................................................................................................................................10 S ................................................................................................................................................................10 GSS ...........................................................................................................................................................11 WSS ..........................................................................................................................................................11 RSWS ........................................................................................................................................................12 RSTS .........................................................................................................................................................12 EWSD .......................................................................................................................................................13 ETSD .........................................................................................................................................................13 ELSD .........................................................................................................................................................14 MAS ..........................................................................................................................................................14 GAS/GFS ..................................................................................................................................................15 WFS ..........................................................................................................................................................15 REDS ........................................................................................................................................................16 REDS-R ....................................................................................................................................................17 REDS-R ....................................................................................................................................................17 P-EGES & FGESD ...................................................................................................................................18 P-VK .........................................................................................................................................................18 P-VK .........................................................................................................................................................19 P-VK .........................................................................................................................................................19 HIGH PRESSURE HOSE DN 6 ...............................................................................................................20 HIGH PRESSURE HOSE DN 8 ...............................................................................................................20 HIGH PRESSURE HOSE DN 13 .............................................................................................................21 HIGH PRESSURE HOSE DN 16 .............................................................................................................22 HIGH PRESSURE HOSE DN 20 .............................................................................................................23 HIGH PRESSURE HOSE DN 25 .............................................................................................................23 HIGH PRESSURE HOSE DN 32 .............................................................................................................24
TABLE OF CONTENTS
Fittings Book
Fitting Assembly Instruction NS Style Profile - Dull Green Colored NOTE! The Walterscheid profile ring fittings are coated with a clear sliding agent which reduces friction and avoids the need to additionally oil the fittings components. In order to ensure positive assembly, WALTERSCHEID fittings should always be pre-assembled using a spare mating fitting. After pre-assembly, discharge the spare fitting. In case of repair, direct assembly in the pre-assembly adapter is also possible
Direct Assembly 1. Saw off the tube at right angles and debur it. Do not use a tube cutter, but a sawing machine, if possible. Lightly debur tube ends at inside and outside.
699001.ai
2. Place the nut and profile ring on the tube as shown.
699002.ai
3. Press tube into fitting body up to tube abutment. tighten nut by hand.
699003.ai
Service Manual
27
Fittings Book
TIGHTENING TORQUE
4. Tighten nut until ferrule grips tube which is felt by a noticeable increase in torque.
0
1/2 TURNS OF NUT
1 699004.ai
5. Final assembly by 1 turn. Important: Hold fitting body firmly by means of a spanner. Application of deviating numbers of tightening turns reduces the nominal pressure rating and the life of the fitting which causes leakages or displacement of the tube.
699005.ai
6. Check penetration of cutting edge. A visible ring of material should fill the space in front of the profile ring end face. Profile ring may turn tube but should not be capable of axial displacement.
699003.ai
28
Service Manual
Fittings Book
Wrench and Coupling for Walterscheid Fittings on Schwing Bioset Equipment Table 1: STRAIGHT FITTINGS CAPNUT
COUPLIN G BODY
AMERICAN CAP NUT
AMERICAN COUPLING BODY
8MM
17MM
17MM
11/16”
11/16”
12MM
22MM
19MM
7/8”
3/4”
16MM
30MM
27MM
1 - 3/16”
1 - 1/16”
20MM
36MM
32MM
1 - 7/16”
1 - 1/4”
25MM
46MM*
41MM
1 - 13/16”
1 - 5/8”
38MM
60MM
55MM
2 - 3/8”
2 - 3/16”
FITTING/TUBE SIZES
* If a hose is connected to this size body, both hose end and body size are 41mm.
Table 2: BANJO FITTINGS FITTING/ TUBE SIZES
CAPNU T
COUPLIN G BODY
END CAP
AMERICA N CAP NUT
AMERICAN COUPLING BODY
END CAP
8MM
17MM
22MM
19MM
11/16”
7/8”
3/4”
12R - 1/4MM
22MM
22MM
19MM
7/8”
7/8”
3/4”
12R - 1/4MM
22MM
27MM
22MM
7/8”
1 - 1/16”
7/8”
16MM
30MM
32MM
27MM
1 - 3/16”
1 - 1/4”
1 - 1/16”
20MM
36MM
41MM
32MM
1 - 7/16”
1 - 5/8”
1 - 1/4”
25MM
46MM
50MM
41MM
1 - 13/16”
2”
1 - 5/8”
38MM
60MM
--
55MM
2 - 3/8”
--
2 - 3/16”
Service Manual
29
Fittings Book
Hydraulic Fittings Chart
!
"
%
!
" !
!
#!
#
" $!
$ #$!
&$
'
#
$!
" %!
#
!
"!
!
30
!
Service Manual
!
(
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 1 CAP NUTS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Description CAP NUT M 6 LL ....................................................................................................................................................... CAP NUT M 8 LL ....................................................................................................................................................... CAP NUT M 6 L ......................................................................................................................................................... CAP NUT M 8 L ......................................................................................................................................................... CAP NUT M 12 L ....................................................................................................................................................... CAP NUT M 18 L ....................................................................................................................................................... CAP NUT M 22 L ....................................................................................................................................................... CAP NUT M 28 L ....................................................................................................................................................... CAP NUT M 8 S.......................................................................................................................................................... CAP NUT M 16 S........................................................................................................................................................ CAP NUT M 20 S........................................................................................................................................................ CAP NUT M 25 S........................................................................................................................................................ CAP NUT M 30 S........................................................................................................................................................ CAP NUT M 38 S........................................................................................................................................................
Part No. 10001763 10008617 10001760 10001755 10001748 10000316 10000321 10000326 10008618 10001743 10001741 10001738 10001720 10001722
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 2 FERRULES Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description RING CUTTER S - R - 6 - LL (K - R - 6 - LL) .......................................................................................................... RING CUTTER S - R - 8 - LL (K - R - 8 - LL) .......................................................................................................... RING PROFILED P - R - 6 - L/S (K - R - 6 - L/S)..................................................................................................... RING PROFILED P - R - 8 - L/S (K - R - 8 - L/S)..................................................................................................... RING PROFILED P - R - 10 - L/S (K - R - 10 - L/S)................................................................................................. RING PROFILED P - R - 12 - L/S (K - R -12 - L/S).................................................................................................. RING PROFILED P - R - 18 - L (K - R - 18 - L)........................................................................................................ RING PROFILED P - R - 22 - L (K - R - 22 - L)........................................................................................................ RING PROFILED P - R - 28 - L (K - R - 28 - L)........................................................................................................ RING PROFILED P - R - 14 - S (K - R - 14 - S) ........................................................................................................ RING PROFILED P - R - 16 - S (K - R - 16 - S) ........................................................................................................ RING PROFILED P - R - 20 - S (K - R - 20 - S) ........................................................................................................ RING PROFILED P - R - 25 - S (K - R - 25 - S) ........................................................................................................ RING PROFILED P - R - 30 - S (K - R - 30 - S) ........................................................................................................ RING PROFILED P - R - 38 - S (K - R - 38 - S) ........................................................................................................
Service Manual
Part No. 10001724 10008615 10001726 10001728 10009296 10001730 10000117 10000119 10000212 10034742 10001732 10001733 10001734 10001735 10001736
31
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 3 GES Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Description FITTING STR GES - 6 - LLR 1/8”............................................................................................................................. FITTING STR GES - 6 - L/R 1/4” .............................................................................................................................. FITTING STR GES - 8 - LR 1/4” ............................................................................................................................... FITTING STR GES - 12 - LR 1/4” ............................................................................................................................. FITTING STR GES - 12 - LR 3/8” ............................................................................................................................. FITTING STR GES - 12 - LR 1/2” ............................................................................................................................. FITTING STR GES - 22 - LR 3/4” ............................................................................................................................. FITTING STR GES - 12 - SR 3/8” ............................................................................................................................. FITTING STR GES - 16 - SR 1/2” ............................................................................................................................. FITTING STR GES - 20 - SR 3/4” ............................................................................................................................. FITTING STR GES - 25 - SR 1” ................................................................................................................................ FITTING STR GES - 30 - SR 1 1/4” .......................................................................................................................... FITTING STR GES - 38 - SR 1 1/2” .......................................................................................................................... FITTING STR GES - 8 - LM 12 X 1.5 ....................................................................................................................... FITTING STR GES - 8 - L/M 14 X 1.5 ...................................................................................................................... FITTING STR GES - 8 - L/M 22 X 1.5 ...................................................................................................................... FITTING STR GES - 12 - LM 16 X 1.5 ..................................................................................................................... FITTING STR GES - 12 L/M 18 X 1.5 ...................................................................................................................... FITTING STR GES - 12 L/M 22 X 1.5 ...................................................................................................................... FITTING STR GES - 14 SM 20 X 1.5........................................................................................................................ FITTING STR GES - 16 SM 22 X 1.5........................................................................................................................ FITTING STR GES - 16 SM 27 X 2........................................................................................................................... FITTING STR GES - 20 SM 27 X 2........................................................................................................................... FITTING STR GES - 25 SM 33 X 2........................................................................................................................... FITTING STR GES - 30 SM 42 X 2........................................................................................................................... FITTING STR GES - 38 - SR 1 1/2” - WD ................................................................................................................
Part No. 10008090 10008085 10008095 10008100 10009282 10030252 10008113 10009266 10008108 10008110 10008115 10008117 10008118 10008066 10008061 10009276 10009302 10008071 10009262 10034740 10009300 10016112 10008077 10008079 10008081 10008120
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 4 GES...NPT Item 1 2 3 4 5 6 7 8
32
Description FITTING STR GES - 12 - L 7/16 - 20 UNF SAE #4.................................................................................................. FITTING STR GES - 16 - S 7/8 - 14 UNF 5/8”, SAE #10 ......................................................................................... FITTING STR GES - 16 - S 1/2” NPT........................................................................................................................ FITTING STR GES 12 L 1/4” NPT ............................................................................................................................ FITTING STR GES - 12 - L 1/2 NPT PARKER GE 12-PL /1/2NPT ........................................................................ FITTING STR GES - 12L 3/8” NPT PARKER NO. GE12S3/8NPTA3C ................................................................. FITTING STR GES - 20 - S 3/4” NPT........................................................................................................................ FITTING STR GES - 25 - S 1” NPT...........................................................................................................................
Service Manual
Part No. 10015242 10009260 10009264 10001483 30307883 30325817 30303164 30302618
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 5 GS Item 1 2 3 4 5 6 7 8 9 10 11 12 13
Description FITTING STR GS - 6 - L ............................................................................................................................................ FITTING STR GS - 8 - L ............................................................................................................................................ FITTING STR GS - 10 - L .......................................................................................................................................... FITTING STR GS - 12 - L .......................................................................................................................................... FITTING STR GS - 16 - S........................................................................................................................................... FITTING STR GS - 20 - S........................................................................................................................................... FITTING STR GS - 25 - S........................................................................................................................................... FITTING STR GS - 30 - S........................................................................................................................................... FITTING STR GS - 38 - L .......................................................................................................................................... FITTING STR GS 16 - S/12 L .................................................................................................................................... FITTING STR K - GV 20 S/12 L................................................................................................................................ FITTING STR K - GV 25/20 S ................................................................................................................................... FITTING STR K - GV 38/25 S ...................................................................................................................................
Part No. 10008064 10008074 10008078 10008083 10008088 10008093 10008149 10008098 10008101 10008132 10000353 10024716 10009280
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 6 WS Item 1 2 3 4 5 6
Description FITTING EL WS - 12 - L............................................................................................................................................ FITTING EL WS - 22 - L............................................................................................................................................ FITTING EL WS - 16 - S ............................................................................................................................................ FITTING EL WS - 20 - S ............................................................................................................................................ FITTING EL WS - 25 - S ............................................................................................................................................ FITTING EL WS - 38 - S ............................................................................................................................................
Service Manual
Part No. 10008084 10008096 10008087 10008091 10008099 10015214
33
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 7 TS Item 1 2 3 4 5 6 7 8 9
Description FITTING TEE TS - 6 - L............................................................................................................................................. FITTING TEE TS - 8 - L............................................................................................................................................. FITTING TEE TS - 12 - L........................................................................................................................................... FITTING TEE TS - 16 - S........................................................................................................................................... FITTING TEE TS - 20 - S........................................................................................................................................... FITTING TEE TS - 25 - S........................................................................................................................................... FITTING TEE TS - 38 - S........................................................................................................................................... FITTING TEE TS - 25 S/25 S/12 L ............................................................................................................................ FITTING TEE TS - 16 S/16 S/12 S ............................................................................................................................
Part No. 10008050 10008052 10008054 10008056 10008058 10008063 10008067 10008069 10021957
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 8 S Item 1 2 3
34
Description FITTING X KS - 12 - L .............................................................................................................................................. FITTING X KS - 22 - L .............................................................................................................................................. FITTING X KS - 16 - S...............................................................................................................................................
Service Manual
Part No. 10008136 10008141 10012226
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 9 GSS Item 1 2 3 4 5 6 7
Description FITTING STR GSS -10 - L ......................................................................................................................................... FITTING STR GSS - 12 - L KSP 17 R ....................................................................................................................... FITTING STR GSS - 16 - S ........................................................................................................................................ FITTING STR GSS - 20 - S ........................................................................................................................................ FITTING STR GSS - 25 - S ........................................................................................................................................ FITTING STR GSS - 30 - S ........................................................................................................................................ FITTING STR GSS - 38 - S ........................................................................................................................................
Part No. 10008105 10008109 10008112 10008001 10008122 10008125 10008127
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 10 WSS Item 1 2 3
Description
Part No.
FITTING EL WSS - 20 - S.......................................................................................................................................... 10008107 FITTING EL WSS - 25 - S.......................................................................................................................................... 10008114 FITTING EL WSS - 30 - S.......................................................................................................................................... 10009278
Service Manual
35
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 11 RSWS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Description FITTING EL RSWS - 8 - LR 1/4” .............................................................................................................................. FITTING EL RSWS - 12 - LR 1/4” ............................................................................................................................ FITTING EL RSWS - 12 - LR 3/8” ............................................................................................................................ FITTING EL RSWS - 22 - LR 3/4” ............................................................................................................................ FITTING EL RSWS - 8 - SR 1/4” .............................................................................................................................. FITTING EL RSWS - 12 - SR 3/8” ............................................................................................................................ FITTING EL RSWS - 16 - SR 1/2” ............................................................................................................................ FITTING EL RSWS - 20 - SR 3/4” ............................................................................................................................ FITTING EL RSWS - 25 - SR 1”................................................................................................................................ FITTING EL RSWS - 30 - SR 1 1/4” ......................................................................................................................... FITTING EL RSWS - 38 - SR 1 1/2” ......................................................................................................................... FITTING EL RSWS - 6 - LLM 10 X 1....................................................................................................................... FITTING EL RSWS - 8 - LLM 10 X 1....................................................................................................................... FITTING EL RSWS - 8 - LM 12 X 1.5 ...................................................................................................................... FITTING EL RSWS - 8 - L/M 14 X 1.5 ..................................................................................................................... FITTING EL RSWS - 12 - L/M 16 X 1.5 ................................................................................................................... FITTING EL RSWS - 12 - L/M 18 X 1.5 ................................................................................................................... FITTING EL RSWS - 22 - LM 26 X 1.5 .................................................................................................................... FITTING EL RSWS - 16 - SM 22 X 1.5..................................................................................................................... FITTING EL RSWS - 20 - SM 27 X 2........................................................................................................................ FITTING EL RSWS - 25 - SM 33 X 2........................................................................................................................ FITTING EL RSWS - 30 - SM 42 X 2........................................................................................................................
Part No. 10008018 10008023 10008022 10008027 10008019 10008024 10008025 10008026 10008028 10008029 10008030 10029401 10008008 10008007 10008009 10008011 10008012 10008015 10008013 10008014 10008016 10008017
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 12 RSTS Item 1
36
Description
Part No.
FITTING TEE RSTS - 12 - LR ................................................................................................................................... 10008006
Service Manual
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 13 EWSD Item 1 2 3 4 5 6 7 8 9 10
Description FITTING EL EWSD - 6 - L......................................................................................................................................... FITTING EL EWSD - 8 - L......................................................................................................................................... FITTING EL EWSD - 10 - L....................................................................................................................................... FITTING EL EWSD - 12 - L....................................................................................................................................... FITTING EL EWSD - 22 - L....................................................................................................................................... FITTING EL EWSD - 16 - S....................................................................................................................................... FITTING EL EWSD - 20 - S....................................................................................................................................... FITTING EL EWSD - 25 - S....................................................................................................................................... FITTING EL EWSD - 30 - S....................................................................................................................................... FITTING EL EWSD - 38 - S.......................................................................................................................................
Part No. 10008042 10008043 10026589 10018570 10008049 10019122 10018850 10018417 10065682 10018530
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 14 ETSD Item 1 2 3 4 5 6
Description FITTING TEE ETSD - 8 - L ....................................................................................................................................... FITTING TEE ETSD - 12 - L ..................................................................................................................................... FITTING TEE ETSD - 16 - S...................................................................................................................................... FITTING TEE ETSD - 20 - S...................................................................................................................................... FITTING TEE ETSD - 25 - S...................................................................................................................................... FITTING TEE ETSD - 38 - S......................................................................................................................................
Service Manual
Part No. 10008038 10019730 10008040 10008041 10008046 10008037
37
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 15 ELSD Item 1 2 3 4 5 6 7
Description FITTING TEE ELSD -10 - L ....................................................................................................................................... FITTING TEE ELSD - 12 - L ..................................................................................................................................... FITTING TEE ELSD - 22 - L ..................................................................................................................................... FITTING TEE ELSD - 16 - S ..................................................................................................................................... FITTING TEE ELSD - 20 - S ..................................................................................................................................... FITTING TEE ELSD - 25 - S ..................................................................................................................................... FITTING TEE ELSD - 38 - S .....................................................................................................................................
Part No. 10009275 10019121 10008034 10018848 10008033 10008035 10008036
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 16 MAS Item 1 2 3
38
Description FITTING STR MAS - 8 - LR 1/4” .............................................................................................................................. FITTING STR MAS - 12 - LR 3/8” ............................................................................................................................ FITTING STR MAS - 12 - LR 1/2” ............................................................................................................................
Service Manual
Part No. 10008147 10008142 10008144
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 17/18 GAS/GFS Item 1 2 3 4 5
Description FITTING STR GAS - 8 - LR 1/4”............................................................................................................................... FITTING STR GAS - 12 - LR 1/4”............................................................................................................................. FITTING STR GAS - 22 - LR 3/4”............................................................................................................................. FITTING STR GAS - 20 - SR 3/4” ............................................................................................................................. FITTING STR GFS - 18 - 35 ......................................................................................................................................
Part No. 10008057 10009267 10009269 10012225 10008004
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 19 WFS Item 1 2 3 4
Description FITTING STR WFS 16 - S / 35................................................................................................................................... FITTING STR WFS 22 - L / 40 .................................................................................................................................. FITTING STR WFS 20 - S / 55................................................................................................................................... FITTING STR WFS 25 - S / 55...................................................................................................................................
Service Manual
Part No. 10008072 10008076 10009272 10012216
39
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 20 REDS Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
40
Description FITTING STR K - REDS - V 8/6 - L.......................................................................................................................... FITTING STR K - REDS - V 12/8 - L........................................................................................................................ FITTING STR K - REDS - V 18/8 L .......................................................................................................................... FITTING STR K - REDS - V 22/12 L ........................................................................................................................ FITTING STR REDSD 20/16S................................................................................................................................... FITTING STR K - REDS - 25/16 - S.......................................................................................................................... FITTING STR K - REDS - 25/20 - S.......................................................................................................................... FITTING STR K - REDS - 30/20 - S.......................................................................................................................... FITTING STR K - REDS - 30/25 - S.......................................................................................................................... FITTING STR K - REDS - 38/16 - S.......................................................................................................................... FITTING STR K - REDS - 38/20 - S.......................................................................................................................... FITTING STR K - REDS - 38/25 - S.......................................................................................................................... FITTING STR - REDSD - 38/30 - S........................................................................................................................... FITTING STR REDS 8/12 .......................................................................................................................................... FITTING STR REDS - 16S/12L ................................................................................................................................. FITTING STR K - REDS - 20 - S - 12 - L.................................................................................................................. FITTING STR K - REDS - 20/25 - S.......................................................................................................................... FITTING STR K - REDS - V 22 - L/25 S .................................................................................................................. FITTING STR K - REDS - V 25 - S/8 L .................................................................................................................... FITTING STR K - REDS - 25S/12L........................................................................................................................... FITTING STR K - REDS - 25/25 S ............................................................................................................................ FITTING STR K - REDS - V 25/30 S ........................................................................................................................ FITTING STR K - REDS - 38 - S/12 - L (USE 8137 & 19729).................................................................................
Service Manual
Part No. 10008145 10008062 10008073 10008089 10018849 10008121 10008124 10008130 10008133 10008137 10008139 10008140 10095380 10024587 10019729 10008080 10008086 10008092 10008111 10008119 10008126 10008128 10008135
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 21 REDS-R Item 1 2 3 4 5
Description FITTING STR RED-R 1/2” / R 1/4” ........................................................................................................................... FITTING STR RED-R 3/4” R 3/8” ............................................................................................................................. FITTING STR RED-R 1” / R 1/2” .............................................................................................................................. FITTING STR RED-R 1 1/2” / R 1/2” ........................................................................................................................ FITTING STR RED-R 1 1/2” / R 1” ...........................................................................................................................
Part No. 10001581 10001567 10000328 10010632 10001541
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 22 REDS-R Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Description FITTING STR RED-R 1/4” / R 3/8” ........................................................................................................................... FITTING STR RED-R 3/8” / R 1/4” ........................................................................................................................... FITTING STR RED-R 3/8” / R 1/2” ........................................................................................................................... FITTING STR RED-R 1/2” / R 3/8” ........................................................................................................................... FITTING STR RED-R 1/2” / R 3/4” ........................................................................................................................... FITTING STR RED-R 3/4” / R 1/2” ........................................................................................................................... FITTING STR RED-R 3/4” / R 1” .............................................................................................................................. FITTING STR 032530 RED-R 1” / R 3/4” ................................................................................................................. FITTING STR RED-R 1” / R 1 1/4” ........................................................................................................................... FITTING STR RED-R 1” / R 1 1/2” ........................................................................................................................... FITTING STR 032533 RED-R 1 1/4” / R 1” .............................................................................................................. FITTING STR RED-R 1 1/4” / R 1 1/2” ..................................................................................................................... FITTING STR RED-R 1 1/2” / R 1 1/4” ..................................................................................................................... FITTING STR RED-M 42 X 2/R 1” ........................................................................................................................... FITTING STR RED-R 1 1/4” / R 3/4” ........................................................................................................................
Service Manual
Part No. 10006655 10000329 10000331 10001530 10018487 10001520 10010633 10001505 10066278 10000332 10001492 10001474 10000334 10001455 10001556
41
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 23 P-EGES & FGESD Item 1 2 3 4 5 6 7 8
Description FITTING STR - EGESD - 12 - LR 1/4” WD.............................................................................................................. FITTING STR - EGESD - 12 - LR 3/8” WD.............................................................................................................. FITTING STR EGES - 6 - SR - WD........................................................................................................................... FITTING STR SN - EZEV 8SR-OR........................................................................................................................... FITTING STR EGESD - 16 - SR - WD...................................................................................................................... FITTING STR EGESD - 20 - SR - WD...................................................................................................................... FITTING STR EGESD - 25 - SR - WD...................................................................................................................... FITTING STR EGESD - 38 - SR - WD......................................................................................................................
Part No. 10018571 10018568 10000336 10010634 10020109 10019728 10015029 10006780
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 24 P-VK Item 1 2 3 4 5 6 7 8 9 10
42
Description ADAPTER S - VK - 6 - II ........................................................................................................................................... ADAPTER P - VK - 6 - L ........................................................................................................................................... ADAPTER P - VK - 8 - L ........................................................................................................................................... ADAPTER P - VK - 10 - L ......................................................................................................................................... ADAPTER P - VK - 12 - L ......................................................................................................................................... ADAPTER P - VK - 16 - S ......................................................................................................................................... ADAPTER P - VK - 20 - S ......................................................................................................................................... ADAPTER P - VK - 25 - S ......................................................................................................................................... ADAPTER P - VK - 30 - S ........................................................................................................................................ ADAPTER P - VK - 38 - S .........................................................................................................................................
Service Manual
Part No. 10070900 10070901 10070902 10070903 10070904 10070906 10070907 10070908 10070909 10070910
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 25 P-VK Item 1 2 3 4 5 6 7 8
Description PLUG LOCKING VS 6 L/S ........................................................................................................................................ PLUG LOCKING VS 8 L/S ........................................................................................................................................ PLUG LOCKING VS 12 L/S ...................................................................................................................................... PLUG LOCKING VS 16 S.......................................................................................................................................... PLUG LOCKING VS 20 S.......................................................................................................................................... PLUG LOCKING VS 25 S.......................................................................................................................................... PLUG LOCKING VS 30 S.......................................................................................................................................... PLUG LOCKING VS 38 S..........................................................................................................................................
Part No. 10016807 10016806 10016804 10016803 10016789 10016790 10016801 10016791
AVAILABLE SIZES FOR STYLE SHOWN IN FIG. 26 P-VK Item 1 2 3
Description
Part No.
LOCKING SCREW VS-R 1/4” WD ........................................................................................................................... 10006658 PLUG LOCKING 1/2” VS-R 1/2” WD....................................................................................................................... 10044494 PLUG G 1 1/2 VS-R-WD VS-R 1 1/2” - WD/PN 400 ................................................................................................ 10146056
Service Manual
43
HIGH PRESSURE HOSE DN 6 Item 1 2 3 4
Description HOSE, HIGH PRESSURE 350 BAR DN 6/2 X 570 DKO - L M 14 X 1.5 ............................................................... HOSE, HIGH PRESSURE 350 BAR DN 6/2 X 715 DKO - L M 14 X 1.5 ............................................................... HOSE, HIGH PRESSURE DN 6/2 X 1200 ................................................................................................................ HOSE, HIGH PRESSURE DN 6/2 X 2400 ................................................................................................................
Part No. 10120862 10123138 10031361 10133086
HIGH PRESSURE HOSE DN 8 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
44
Description HOSE, HIGH PRESSURE DN 8/2 X 300 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 350 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 400 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 450 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 500 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 550 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 600 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 650 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 700 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 750 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 800 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 850 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 900 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 950 DKO M 18 X 1.5 ..................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1000 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1100 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1200 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1250 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1300 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1350 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1400 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1450 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1500 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1600 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1650 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1700 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 1800 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 2100 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 2300 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 2400 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 2600 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 3200 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 3350 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 3500 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 5000 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 5700 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 6400 DKO M 18 X 1.5 ................................................................................... HOSE, HIGH PRESSURE DN 8/2 X 13300 DKO M 18 X 1.5 ................................................................................. HOSE, HIGH PRESSURE 8 X 34 FT. LG ................................................................................................................. O-RING 9 X 2 .............................................................................................................................................................
Service Manual
Part No. 10045794 10052338 10050167 10050168 10025113 10050169 10025656 10050170 10018484 10050171 10050172 10095632 10018483 10050173 10050174 10025658 10050175 10050176 10050177 30341777 30380078 10050178 10050179 10018482 30341778 10050180 10058430 10050181 10050182 10059237 10093579 10050183 30325047 10067704 10018485 10056385 30314105 10068024 30323985 10061731
HIGH PRESSURE HOSE DN 13 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
Description HOSE, HIGH PRESSURE DN 13/4 X 400 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 500 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 550 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 650 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 700 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 800 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 900 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 13/4 X 1000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1100 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1200 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1300 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1350 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1450 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1700 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 1800 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 2000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 2100 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 2400 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 3200 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 3600 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 5000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 5700 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 6400 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 13/4 X 13300 DKO-S ............................................................................................... O-RING 13 X 2............................................................................................................................................................
Service Manual
Part No. 10049900 10049901 10049902 10049903 10049904 10062202 10018480 10049905 10024672 10049906 10049907 30380084 10049908 10049909 10049910 10049911 10049912 10049913 10081340 10064293 10030099 10036328 30314106 10063940 10061730
45
HIGH PRESSURE HOSE DN 16 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25
46
Description HOSE, HIGH PRESSURE DN 16/4 X 300 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 400 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 500 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 550 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 600 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 650 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 700 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 800 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 900 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 16/4 X 1000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1100 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1200 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1300 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1350 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1500 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1600 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1700 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 1800 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 2000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 2100 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 2400 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 3200 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 3400 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 16/4 X 4500 DKO-S ................................................................................................. O-RING 17 X 2.5.........................................................................................................................................................
Service Manual
Part No. 10049938 10049939 10049940 10049941 10049942 10025659 10019736 10049943 10029729 10049944 10049945 10049946 10049947 10049948 10049949 10049950 10049951 10024682 10049952 10000135 30302244 30319319 10035195 10049953 10061729
HIGH PRESSURE HOSE DN 20 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Description HOSE, HIGH PRESSURE DN 20/4 X 400 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 500 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 550 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 650 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 700 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 800 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 900 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 20/4 X 1000 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1100 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1200 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1250 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1300 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1350 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1500 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1600 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1650 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1700 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 1800 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20/4 X 2100 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 20 X 34 FT. LG ........................................................................................................ HOSE, HIGH PRESSURE DN 20 X 44 FT. LG ........................................................................................................ O-RING 22 X 2.5 ........................................................................................................................................................
Part No. 10049954 10049955 10049956 10049957 10018481 10079398 10049958 10049959 10049960 10049961 10049962 10019735 10049963 10049964 10049965 10049966 10049967 10049968 10013234 30323984 30333983 10061728
HIGH PRESSURE HOSE DN 25 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14
Description HOSE, HIGH PRESSURE DN 25/4 X 500 DKO-S.................................................................................................... HOSE, HIGH PRESSURE DN 25/4 X 750 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 25/4 X 900 DKO-S................................................................................................... HOSE, HIGH PRESSURE DN 25/4 X 1100 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1200 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1300 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1400 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1500 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1600 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1700 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1800 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 1900 DKO-S................................................................................................. HOSE, HIGH PRESSURE DN 25/4 X 2100 DKO-S................................................................................................. O-RING 27 X 2.5 ........................................................................................................................................................
Service Manual
Part No. 10000182 10049976 10049977 30347674 10062367 30347675 30349285 10140372 10031891 10124716 30349287 30347676 30347677 10077249
47
HIGH PRESSURE HOSE DN 32 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
48
Description HOSE, HIGH PRESSURE DN 32/4 X 500 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 550 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 650 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 700 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 780 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 800 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 870 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 900 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 950 DKO-S ................................................................................................... HOSE, HIGH PRESSURE DN 32/4 X 1000 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1100 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1200 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1350 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1450 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1500 DKO-S ................................................................................................. HOSE, HIGH PRESSURE DN 32/4 X 1600 DKO-S ................................................................................................. HOSE, HIGH PRESSURE 32 X 44 FT.......................................................................................................................
Service Manual
Part No. 10000194 10000195 10000197 10000202 10001128 10000213 10001131 10000217 10000220 10000226 10000230 10000231 10000232 10000233 10000234 10000236 30323982
OPERATION
SECTION 4 4.1
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 4
OPERATION
BEFORE OPERATING SLUDGE PUMPS IN ANY MODE POPPET
1. Check Water Boxes for water. If continuous flushing is used, make sure that the water supply valves are in the “ON” position, allowing a moderate flow of water. Water should completely cover the cylinder openings. 2. Make sure that all ballcock handles on the hydraulic lines are open. 3. Check level of 90W gearlube in sight gauges on the screw feed gearboxes. Oil level should be at the bottom of the sight gauge when the machine is turned “OFF.” 4. Check the level of the hydraulic fluid in the sight gauges on the hydraulic power packs. The level should be at the top gauge. Add oil, if needed 5. Visually inspect units for hydraulic leaks, worn V-belts, structural cracks, or anything else that may impair the safe, efficient operation of the equipment. Repair if possible. If you’re unsure about anything, call Schwing Service Department, at 1-715247-3433. 6. Make sure that the proper valves in the pipeline are open. 7. Place the selector switch to control manual/auto in the desired position 8. Place the selector switch to Hydraulic Pump Bypass/Load in the Bypass position. 9. Place the Disconnect switches in the “ON” position. 10. Make sure that all Emergency Stop buttons are pulled out. The Amber or Green lights for “Power On” will be illuminated. 11. Make sure that the water supply valves are open and that there is a moderate flow of water to the hydraulic oil coolers. Verify by water flow. 12. Make sure the Screw Feeder control handle is in the “Forward” position. 13. Select the mode of operation with selector switch Control Manual/Auto and start the unit per instructions. (Refer to Control Panel Instruction for proper procedures.) 14. Place “Load/Bypass” Selector Switch into the “Load” Position. Place the S-1 Control Valve (if equipped) on the Pump into the “Forward” Position. 15. If the unit is being operated in the manual mode, the operator must watch the hopper level. If the hopper level continues to rise, adjust the speed controls upward. If the hopper level falls, adjust the speed control downward. The ideal situation is when you are pumping out exactly as much as you put in. The screw feeder output rate should never be lower than the sludge pump pumping rate, or the result will be low pumping efficiency. (The cylinders do not get a complete fill.) 16. When you’re done pumping, put the (S-1) control lever handles in the “Neutral” position. 17. Put the “Screw Feeder” control handles in the “Neutral” position. KSP Training Manual
4-1
SECTION 4
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OPERATION
18. Put the “Load/Bypass” switch in the “Bypass” position. 19. Shut down the unit using the motor stop button. NOTE: If panels and/or electrical motor are equipped with heaters the emergency stop buttons and disconnect switches must remain on. 20. Shut off the water supply to the water box and drain and flush them. “Drain it within 1/2 hour of shutting down the pump.”
4.2
NOTES - POPPET
1. If units are not being operated, the S-1 control handle on the unused unit MUST be in the “Neutral” position. The “Load/Bypass” Selector Switch should be placed in the “Bypass” position. 2. At 4 hour intervals, check the Water Box and be sure that the water is at the correct level. The Pump Log sheet should be filled out at this time. 3. If the units turn off because of one of the built-in safety devices, note which trouble light is on and look in that area for trouble. If in doubt, call the Schwing Service Department at 1-715-247-3433. NOTE: Keep an eye on the temperature of the oil in the hydraulic power packs. 4. Please note that the units have a built-in temperature sensor, which will shut off at 160 Degrees F (70 Degrees C) before damage can occur to the machine. 5. If any trouble is seen, push the “Emergency Stop” buttons in. 6. If the Operator wants to temporarily stop pumping, they should place the “Load/ Bypass” Selector Switch in the “Bypass” position and if equipped place the S-1 Control Valve in the “Neutral” position.
4.3
PREVENTIVE MAINTENANCE NOTES - POPPET
1. If continuous water flow to the water boxes is used, at two week intervals one of the work shift’s should drain and flush the Water Box. Refill the Box and start the unit according to the Operating Instructions with no water flowing through the Box. At the end of the shift (every eight (8) hours), or as instructed in your O&M manual, check the Water Box for oil floating on the top of the water. Drain the water out and check for sludge accumulation in the bottom of the Box. If oil is present, or if 2" or more of sludge has built up in the bottom of the Box, preventive maintenance will be necessary. WARNING! When the pump is shut down, and will not be in use for a 1/2 hour or more, it is very important to drain the waterbox to prevent water from contaminating the hydraulic system. As the hydraulic oil cools it contracts, when the pump is idle there is no where for the cylinders to get the additional oil. The vacuum created causes a negative pressure on the chevron seals and allows material, either, air or water (if present) to pass into the differential cylinders hydraulic area (See Figure 3.1, Page 4 - 3). 4-2
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OPERATION
ALWAYS DRAIN WATER BOX WHEN SHUTTING UNIT DOWN VACUUM FORMED AS HYDRAULIC OIL COOLS
SECTION 4
ATMOSPHERIC PRESSURE FORCES WATER PAST SEALS
SEALS
HYDRAULIC CYLINDER
WATER BOX
39000071
Figure 3.1 - Draining Water Box 2. NEVER run the unit without water in the Water Box. You will destroy the rubber rams within minutes.The waterbox is used to lubricate the back side of the material rams, and also to rinse and cool the differential rods. 3. If the “Dirty Filter” light comes on when the oil is at or above 85 Degrees F (20 Degrees C), replace the filter as soon as possible. There is NO filtering being done if the light is on. Dirty oil is the major cause of component wear. The light may come on if the oil temperature is below 85 Degrees F (20 Degrees C). You can test this by pushing the reset button after the oil has warmed to 85 Degrees F (20 Degrees C). If the filter is dirty, the light will come back on, but if the oil was cold, the light will just stay off. 4. If the pumps can no longer keep up with the normal flow rate of the sludge, the poppet valves are probably worn out. These valves are normal wear parts and will require periodic replacement. Pumping without sludge, or pumping with water will dramatically increase the wear on these valves, because the sludge dampens the force of each cycle. 5. Adjustment of the throttle valves for correct poppet valve sequence is critical for long poppet wear and efficient pumping. Untrained personnel should not be allowed to make these adjustments. See “Throttle Valve Adjustment” in Special Maintenance Section. 6. Remember to grease the Screw Feeders daily.
KSP Training Manual
4-3
SECTION 4
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OPERATION
7. After the unit has been shut down for a period of 8 hours (minimum), open the Hydraulic reservoir drain and drain off any water that may be present. 8. If the coloration of oil changes, then it will require immediate attention. 9. The Panel Lights should be tested occasionally to insure safe operation. 10. Structural cracks, worn hoses, loose clamps, and leaks should be reported to maintenance immediately. 11. If the V-belts(on older power packs) start to squeal, they require immediate attention. 12. Before opening the pipeline for any reason, the line should be cleaned out or sucked back into the hopper by operating the sludge pumps and screw feeders in the “Reverse” position. The Sludge Line Pressure Gauge should read zero. NOTE: If your pump is equipped with the SFMS® (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydraulic cylinders. 13. There is no need to clean out the pipeline if the pump is to be idle overnight, for the weekend, or for several days for repairs to related equipment. The only danger to restarting the equipment comes from dry sludge. Sludge can not dry out in the pump or the pipeline UNLESS it is exposed to air. If all connections and valves are closed and air tight, the sludge will move just as easily on restart as it did when shut off. Exceptions: a. The hopper is always exposed to air. Before shutting down for any significant time, the hopper should be cleaned out. Before restarting, you should look in the hopper. If any dry sludge is seen, it should be thoroughly soaked and allowed to mix with the screw feeder blades before pumping begins.
4.4
PRE-START-UP CHECKS
This section covers operation from start-up to shut-down with adjustments and checks that may need to be done during operation. Use the pre-start-up procedures below if you are attempting one of the following: 1. Test start-up. (To be done only by a Schwing Bioset Service Technician.) 2. First time start-up. (To be done only by a Schwing Service Technician.) 3. Restart after maintenance. 4. Restart after long term shutdown
4-4
KSP Training Manual
OPERATION
4.4.1
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SECTION 4
Sludge Pump
Pre-Start-up Checks: ___ • Review Safety Instructions. ___ • Check that mounting of pump and screw feed at anchor bolts to assure they are secure and properly leveled. ___ • PLACE MAIN CONTROL VALVE LEVER(S) IN NEUTRAL. ___ • Check all Hydraulic connections and hoses for tightness. ___ • Check routing of hydraulic lines (i.e. “A” line on power pack is connected to “A” line ball valve on pump, etc.). ___ • Fill water box with fresh clean water. ___ • If the unit is tested without pumping material, the material side of the material piston head (ram) should be submersed in water or sprayed regularly to keep it wet. Testing for more than 20 minutes at the maximum pump speed of 20 strokes per minute will cause damage to the material piston head (ram) and poppet valves. Testing by pumping in reverse is recommended. ___ • Open Ball Valves on hydraulic lines if supplied. ___ • Check that all Material Pipeline valves are OPEN. ___ • Lubricate equipment at lubrication points: grease poppet valves and oil linkage of S-1 control valve on pump.
KSP Training Manual
4-5
SECTION 4
4.4.2
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OPERATION
Screw Feeder
Pre-Start-up Checks: ___ • Check that bolted connection to Sludge Pump and feed hopper is properly aligned. ___ • Check hydraulic connection and hoses for tightness. ___ • Check hydraulic lines for proper routing. ___ • Open Ball Valves on hydraulic lines if supplied. ___ • Check Gear Box lubricant level. ___ • Grease the bearings.
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KSP Training Manual
OPERATION
4.4.3
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SECTION 4
Hydraulic Power Pack
Pre-Start-up Checks: ___ • Check Hydraulic fluid level after all hoses and lines are full, and refill as required (See your O&M manual for Oil/Lubricant Recommendations). Fill the tank through the filler breather cap or a clean-out cover. Observe level in sight gauge on the side of the tank. Be careful not to let any moisture or contaminants enter the system. Ideally, the oil supply used must have a final filter (10 micron) in the fill hose. ___ • If restarting the system after a long shutdown, take an oil sample and test it for contamination by water and for degradation of quality. Change the hydraulic oil and main filter if necessary. ___ • Check hydraulic connections and hoses for tightness. ___ • Check hydraulic hoses to be sure they are long enough and properly routed to avoid tight bends in the hoses. They should be supported to protect against kinking, crushing or scuffing. Hoses should not rub against each other during operation. ___ • Electrical connections for power and control wiring must be checked by a certified licensed electrician. ___ • Check the rotation of the electric motor by quickly switching the unit on and off. The correct rotation is marked on the hydraulic pump. ___ • Open Ball Valves on hydraulic lines if supplied. ___ • Review Start-up and Adjustment procedure sections of this manual BEFORE START-UP. ___ • Check V-belts for tightness and check the condition of the coupling between the electric motor and the hydraulic pump. See Section 4.24 of your O&M manual for adjustment procedure. ___ • Check that the mounting of the power pack at the anchor bolts are leveled properly and secure. ___ • Remove long term storage package, if supplied.
KSP Training Manual
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SECTION 4
4.4.4
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OPERATION
Material Pipeline
Pre-Start-up Checks: ___ • Check connection to sludge pump ___ • Check all pipeline connections for tightness and alignment ___ • The pipeline should be supported to prevent movement and vibrations. ___ • The pipeline must not cause any loading on the discharge end of the pump. It must be fully supported. ___ • IMPORTANT: The material piping connected to the discharge of the Sludge Pump must be fully supported so as to not cause weight loading on the Sludge Pump. It must also be aligned properly to avoid torsional loading of the Sludge Pump. The pipeline must be within 1/8 inch for proper assembly. ___ • Verify that pipeline valves are in the OPEN position and that valve actuators are fully operational.
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KSP Training Manual
OPERATION
4.4.5
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SECTION 4
Push Floor/Sliding Frames
Pre-Start-up Checks: ___ • Check all hydraulic connections and hoses for tightness. ___ • Hydraulic cylinders filled and air bled. ___ • Check floor of silo for foreign objects. ___ • Test open/close operation of gates and valves. ___ • Test operation of extraction screw conveyor. ___ • Check operation of sliding frame prior to filling silo with material. ___ • Lubricate stuffing box seals. Check automatic greaser system if included. ___ • Grease bearings of the extraction screw conveyor.
KSP Training Manual
4-9
SECTION 4
4.4.6
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OPERATION
Pipeline Lubrication
Pre-Start-up Checks ___ • Check that pump is securely anchored and piping is completely installed. ___ • Check oil in both pump reservoirs. Review to the lubrication section of this manual for the proper lubricant if additional lubricant is required. ___ • Check correct installation of lubrication rings. Directional arrow must point with the pipe flow direction. ___ • Check discharge piping to assure that the pipeline is properly supported and secured. ___ • Check the charge on the accumulator. Add nitrogen if required. ___ • Electrical connections for power and control wiring must be checked by a certified licensed electrician. ___ • Check the rotation of the electrical motor by quickly switching the unit on and off. ___ • Check the ball valves on the water supply line. Verify that water supply is available and there is adequate supply pressure. ___ • Check the pressure relief valve by closing the discharge valve and pumping water until water exits from the relief valve. Verify that relief valve is set according to settings on the project drawings.
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OPERATION
4.5
SECTION 4
START-UP PROCEDURE
This section covers the procedure for normal start-up in day-to-day operation. The Pre-start-up Procedures in Section 4.4 should be done for testing start-up, first time startup, restart after maintenance, or restart after Long Term Shutdown. The drawing noted above is the Electrical Schematic located in your O&M manual. It contains the Sequence of Operation for the electrical controls. 4.5.1
General With Safety Precautions - Start-up
Before start-up the operator shall perform all necessary pre-start-up checks as described in Section 4.4 if this is a testing start-up, first time start-up, restart after maintenance, or restart after Long Term Shutdown At start-up observe the following safety precautions. Keep area clear of unauthorized personnel. Be observant for leaks or unusual noises. Double check that all hand valves are in neutral position and/or bypass switch is in “bypass” (note indicator light) before starting.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
! WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). All covers, guards and safety decals must be in place before start-up. 4.5.2
Starting and Stopping
To START system: 1. Fill water box with fresh, clean water. 2. Turn ON the main electrical power supply to the hydraulic Power Pack. Selector switch "___" is provided to start unit under NO LOAD. Place "___" in BYPASS position for starting with NO LOAD. See Section 8, Electrical Schematic EEE, Sheet __ of __. 3. Press the "Motor Start" button on the door of the electrical control enclosure. 4. Press the "Motor Start" button on the door of the electrical control enclosure for the appropriate conveyors. KSP Training Manual
4 - 11
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SECTION 4
OPERATION
5. Select the direction of the horizontal conveyor by moving the “Forward/Reverse” switch if supplied. 6. Test speed control (if supplied) by varying the speed control from 0% to 100%. Time revolutions at full speed. Operate empty a maximum of 5 minutes to prevent damage to liners. 7. Check proper position of pipeline valves. 8. Put the Hand Valve lever on the Sludge Pump control block into ON position marked "FORWARD". 9. Put the Hand Valve lever for the auxiliary equipment located on the power pack into ON position marked "FORWARD". To STOP system: 1. Press the “Motor Stop” button for each of the conveyors on the door of the electrical control. 2. Turn OFF the main electrical power supply to the conveyor control panel. 3. Perform pre-start checks again. 4. Put the Hand Valve lever for the auxiliary equipment (Screw Feeder or Hopper Agitator) into OFF position marked "NEUTRAL". 5. Put the Hand Valve lever for the Sludge Pump into OFF position marked "NEUTRAL". 6. Turn LOAD/BYPASS selector switch to “BYPASS.” 7. Press the "Motor Stop" button on the door of the electrical control. 8. Turn OFF the main electrical power supply to the hydraulic Power Pack. 9. Drain the water box if this is the end of the operation cycle for the day.
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OPERATION
4.5.3
SECTION 4
Emergency Stop 1. Press EMERGENCY STOP button. It is located on the door of the electric control enclosure as a red mushroom shape.
Figure 3.2 - Emergency Stop Pushbutton 2. Put all valve levers in OFF position marked "NEUTRAL". NOTE: To restart after emergency shutdown turn the emergency stop button to reset it. All control enclosure lights will flash intermittently at this time.
KSP Training Manual
4 - 13
SECTION 4
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4.6
Material pump operation
4.6.1
The control panel
OPERATION
1. Turning the disconnect switch to the on position will apply power to the system. Pulling out the E-stop will illuminate the control power on lamp and apply power to the control system.
Figure 1 The disconnect switch on the material-pump control panels
2. The graphic interface on the control panel is used to energize the motor and control all aspects of the pump’s functioning.
Figure 2 The graphic interface on the control panel (HMI)
3. Pushing the pump motor start button, will cause the control system to energize the motor starter. The motor will start and the pump-motor running light will illuminate.
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SECTION 4
4. The motor will start in a no-load condition (3-second delay). (If the load setting has already been selected, the motor will start and go into load after the 3-second delay.)The pump motor stop button will shut down the electric motor and illuminate the pump-motor off light. 5. The speed of both the material pump and the screw feeder is set on the graphic interface (HMI) on the control panel. 6. The emergency stop push-button mounted on the control panel or the material pump will shut down the entire system. It will remove all control power except power to the PLC and the HMI. 7. The alarm silence / reset button will reset the alarm conditions. Refer to the section on alarm conditions. Technical note: To control the proportional valves, the control system uses a pulsewidth modulated output at 100 Hz from about 0.2 - 0.6 amps. 4.6.2
Sludge-flow measuring and transition-pressure-setpoint selection
The PLC calculates the sludge-cake flow rate based on the fill efficiency of the pump. The fill efficiency of the pump is affected by two things: the consistency of the sludge and the screw-feeder transition pressure. Select the transition pressure setpoint on the graphic interface to maintain a good fill efficiency without causing the screw feeder to run at maximum speed. (The purpose of the screw feeder is to compress the sludge at the pump inlet and improve the fill efficiency.) Experience will help to determine the optimum transition-pressure setpoint. 1. With dry sludge cake, the pressure in the transition will normally run higher and the setpoint needs to reflect that. With dry sludge cake, raise the transition pressure setpoint until the fill efficiency is within the normal range. If the fill efficiency is good and the screw feeder can maintain the transition pressure, there is no need to adjust the transition pressure setpoint. 2. When the sludge is very wet, the screw feeder will not develop enough pressure to maintain the setpoint that it can for drier sludge cake. With wet sludge cake, lower the transition pressure setpoint to prevent the screw feeder from operating at full speed while trying to maintain a pressure it cannot because of the sludge-cake consistency. The operator must determine a setpoint that maintains good fill efficiency yet doesn't overdrive the screw feeder. 3. In summary, the transition pressure setpoint must be set to provide good fill efficiency without overdriving the screw feeder and causing the conveyor to oscillate between off and maximum speed. For normal operating conditions, the pumping system should settle on a steady-state condition where the screw feeder is operating at consistent speeds less than 100 % and the fill efficiency is good.
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SECTION 4
4.6.3
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OPERATION
Screw feeder modes
The Screw Feeder has 3 different modes of Operation. The Modes of Operation are done via the Screw Feeder Mode Selector Switch. Pressure Mode- This is the normal mode of operation for the Screw Feeder. In this mode, the Screws will move at 100% speed until it reaches the Transition Set Point Pressure determined by the Transition Pressure Set Point Setting on the Screw Feeder Control Screen. The ideal environment is to have the Sludge convey to the pump at good fill efficiency without running the screws at 100%. Manual Mode- In this mode, the Screw Feeder output is operated by the Speed Increase and Decrease pushbuttons on the Local Control Panel, or by setting the Local Desired Speed on the HMI Screen. Tracking Mode- In this mode, the Screw Feeder speed will track with the Pump Speed. This will not get you the best fill efficiency; however, it will give you enough output to pump at a decent rate. Note: If the Transition Pressure Transmitter goes bad the Screw Feeder Control Circuit will automatically switch the mode from Pressure to Tracking Mode. 4.6.4
Mode selection
Maintenance mode Only maintenance personnel should use the maintenance mode to perform pump maintenance and troubleshooting. When in maintenance mode, the pump rams can be jogged in forward or reverse. Operations are completely controlled by the local controls on the pump itself. Follow all safety precautions carefully in this mode.
Figure 3 Jogging the material pump in the maintenance mode
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KSP Training Manual
OPERATION
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SECTION 4
Local-hand mode 1. When the pump is in the local position, the control system is completely controlled by the Schwing Bioset local control panel. The customer's external controls (DCS) will not have any effect on the operation of the unit (except the E-stops). 2. Start the material-pump motor with the pump motor start button; stop the materialpump motor with the pump motor stop button on the HMI. 3. The material-pump speed is controlled by the speed increase and speed decrease buttons on the HMI. 4. When the control system is in the local mode and bypass is selected, the control system de-energizes (directing the hydraulic oil back to the hydraulic oil tank, bypassing the pump). When load is selected, the control system energizes (directing oil to the hydraulic circuit and allowing the pump hydraulic circuit to operate. 5. The screw-feeder speed may be adjusted by the speed increase and speed decrease buttons on the control panel’s graphic interface HMI. Remote mode In the remote mode, the control system passes control to the remote customer's controller. Only the E-stop and alarm silence / reset push-buttons and the flow setpoint selector switch will function on the Schwing Bioset local control panels. The materialpump start and stop control functions are now controlled by the facility DCS (Distributed Control System). The pump operates the same as it does in the local mode with the following exceptions. These exceptions are all remotely controlled by the network communication. • Power unit is started and stopped. • Pump loading is controlled. • Pump speed is set. When the hopper level falls to the low level the pump will go into bypass after a time delay of 60 sec. It will automatically start pumping when the level is above the low hopper level.
KSP Training Manual
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SECTION 4
4.6.5
OPERATION
HMI Control Screens
Main Screen
Pump System Screen
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KSP Training Manual
OPERATION
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SECTION 4
Screw Feeder System Screen
Lube Pump System Screen
KSP Training Manual
4 - 19
SECTION 4
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OPERATION
Pipeline Pressure Screen
Low Hopper Bypass Screen
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KSP Training Manual
OPERATION
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SECTION 4
PLC Inputs Screen
PLC Outputs Screen
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OPERATION
Analog IO Screen
Flow Data Screen
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OPERATION
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SECTION 4
Hour Meter and Starts Screen
Login-Logout Screen
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4 - 23
SECTION 4
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OPERATION
Alarm Screen
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OPERATION
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4.7
Lubrication system operation
4.7.1
Mode selection
SECTION 4
Manual Mode In MANUAL mode, the operator can start & stop the lube pump from the local panel. This mode is used mainly for maintenance of the lubrication system. Auto mode The lubrication system will turn on when the material pump starts pumping and turn off when the pump stops pumping. The permissive comes from the pump control panel. The lube pump tries to maintain a set pipeline pressure. Pressure set point is set in the HMI unit.
KSP Training Manual
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SECTION 4
4.8
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
OPERATION
Material-pump and screw-feeder alarm conditions
High oil pressure, material pump System shutdown, reset needed The pressure switch opens and the control system initiates an automatic shutdown procedure. This circuit has a time delay preventing a shutdown during momentary spikes. If a high pressure is sensed, the system will shut off the electric motor, the common alarm lamp will illuminate, the HMI will display the alarm, the pump motor will stop, and the horn will sound. You must find the cause of the high pressure in the material pump hydraulic circuit, correct it, and then push the alarm reset button on the HMI before you can restart the hydraulic pump motor. Hydraulic pump motor fault System shutdown, reset needed The hydraulic-pump motor fault originates from the customer-provided MCC. Check the MCC to determine the fault and correct it. This alarm will shut down the pumping system. The common alarm light will illuminate, the HMI will display the alarm, the system will stop pumping, and the horn will sound, You must find the cause of alarm, correct it, and then push the alarm reset button on the HMI before you can restart the system. Hydraulic high oil temperature System shutdown, reset needed When the high oil temperature switch opens, the control system initiates an automatic shutdown procedure. The oil in the hydraulic tank is too hot. The common alarm lamp will illuminate, the HMI will display the alarm, the pumping system will shut down, and the horn will sound. The oil has to cool down before the system will start. You must find the cause of the problem, correct it, let the oil cool down, and then push the alarm reset button the HMI before you can restart the system. Low hydraulic oil level System shutdown, reset needed When the low oil-level switch opens, the control system initiates an automatic shutdown procedure. The oil in the hydraulic tank is too low. The common alarm lamp will illuminate, the HMI will display the alarm, the pumping system will shut down, and the horn will sound. Add oil to the system. You must find the cause of the problem, correct it, and then push the alarm reset button on the HMI before you can restart the system.
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KSP Training Manual
OPERATION
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SECTION 4
Dirty oil filter Warning, reset needed The pressure switch opens, and the control system initiates an automatic warning alarm. The dirty oil filter alarm has a time delay preventing the alarm from activating during momentary spikes. The common alarm light will illuminate, the horn will sound, the HMI will display the alarm, and the pump motor will stay running. You must replace the filter and then push the alarm reset button. Greaser fault Warning, reset needed The greaser has a fault. It is not greasing the equipment. The common alarm lamp will illuminate, the HMI will display the alarm, and the horn will sound. Check the greaser and find the fault, correct it, and then push the alarm reset button on the HMI. E-stop not reset Shutdown, no reset needed One of the E-stop’s is pushed in. The system will not run. Only the PLC, the HMI, and Ethernet communication is working. The HMI will display the alarm. You must reset the E-Stop. PLC battery low Warning, reset needed The PLC battery is low. The common alarm lamp will illuminate, the HMI will display the alarm, the system will continue to operate, and the horn will sound. The PLC battery needs to be changed. Push the alarm reset button on the HMI to clear this alarm. Transition pressure sensor fault Shutdown, reset needed The control system monitors the screw-feeder transition sensor. If the system detects a sensor fault it will illuminate the common alarm light, the HMI will display the alarm, and the horn will sound. The pump will stop pumping and the pump motor will shut down. Find the cause of the fault, correct it, and then push the alarm reset button on the HMI. Maintenance mode active Remote shutdown / warning, no reset needed Maintenance mode is selected on JB01 (see drawing 30356312). The pump can be in any mode when maintenance mode is selected. This alarm warns the operator that maintenance mode has been selected and pumping control is located on JB01. The pump motor must be started and running. Using the controls on JB01, the operator can
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SECTION 4
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OPERATION
stroke the pump at low speed during maintenance on the material pump. The common alarm lamp will illuminate, and the HMI will display the alarm. Flow system data error Warning, reset needed The control system monitors the flow sensors. If the control system detects a sensor fault, it will illuminate the common alarm light, the HMI will display the alarm, and sound the horn. The pump will continue to run but it will not display any flow data on the HMI. You will need to find the cause of the fault, correct it, and then push the alarm reset button on the HMI.
4.9
Lubrication system alarm conditions
Pump motor fault System shutdown, reset needed The motor starter has detected a fault. The common alarm lamp will illuminate and the lube pump motor will stop. You must find the cause of the problem, correct it, reset the motor starter fault, and then push the “alarm silence/reset” push button on the HMI before you can restart the lube pump motor.
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KSP Training Manual
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OPERATION
4.10
SECTION 4
ADJUSTMENTS AND CHECKS DURING OPERATION
After starting the Sludge Pump and related equipment the system must be checked for proper operation. This includes monitoring of gauges and lights, and adjusting the output if necessary. 4.10.1
Safety Instructions - Adjustments & Checks • Only trained and authorized personnel shall perform adjustments to the sludge pump and related equipment. • Read and study all of the adjustment procedures before making any adjustment. One adjustment may have an effect on another. • Covers for rotating parts must be in place during adjustments and checks. • All personnel shall know the location and operation of EMERGENCY CONTROLS. See sequence of operation and control layout drawings on the electrical schematic in Section 8 of your O&M manual.
4.10.2
Sludge Pump Output Adjustment
To adjust the material output rate of the pump, pushbutton controls are provided on the door of the control panel. They operate by increasing or decreasing the flow of oil from the hydraulic pumps to the pumping cylinders. CONTROL PANEL
SLUDGE PUMP SPEED INCREASE
SLUDGE PUMP SPEED DECREASE
39000073
Figure 3.3 - Push-button Controls for Hydraulic Pump
KSP Training Manual
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SECTION 4
4.10.3
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
OPERATION
Sludge Pump Output Adjustment - HMI Screen
To adjust the Material Output rate of the Pump with an HMI Panel, go to the Sludge Pump Control Screen and set pump at the Local Desired Pump Speed Setting. This will only change the output if in the Local Mode. Remote speed setting will be done from the Remote Station.
Figure 3.4 - Local Pump Speed Control with HMI Screen We recommended that on initial start-up output be set at no greater than 50% of maximum until the material pipeline is full. 4.10.4
Screw Feeder Output Adjustment
To adjust the material output rate of the screw feeder, push-button controls are provided on the door of the control enclosure. They operate by increasing or decreasing the flow of oil from the hydraulic pumps to the screw feeder hydraulic motor.
4 - 30
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OPERATION
SECTION 4
CONTROL PANEL SLUDGE PUMP SPEED INCREASE
SLUDGE PUMP SPEED DECREASE 39000075
Figure 3.5 - Push-button Controls for Screw Feeder Normal operating speed for a screw feeder is between 20 and 30 rpm. Speed is determined by counting and timing the revolutions. 4.10.5
Screw Feeder Output Adjustment - HMI Screen
To manually adjust the Screw Feeder Output with the HMI Screen, go to the Screw Feeder Control Screen and place the Screw Feeder Mode to Manual. Then set the Screw Feeder Speed at the Desired Local Screw Feeder Speed Setting.
Figure 3.6 - Local Screw Feeder Speed Control with HMI Screen
KSP Training Manual
4 - 31
SECTION 4
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
OPERATION
Normal operating speed for a screw feeder is between 2 and 30 rpm. Speed is determined by counting and timing the revolutions. 4.10.6
Hydraulic System Checks/Adjust. - Poppet Valve ___ • Check hydraulic lines and fittings for leakage. ___ • Check hydraulic oil level and temperature. During normal operation, oil temperature should be between 100-140ºF. ___ • Check the switching operation of the poppet valves as the pump cycles. The poppet valves should operate in the proper sequence and should close with a audible click. If the sound is too light, or too harsh, the adjustment procedure in your O&M manual should be followed to attain proper operation. In general the procedure involves opening or closing throttle valves located on the main valve block of the sludge pump. If the valves are closing -too softly (light sound) then close the throttle valve further by turning CLOCKWISE. -too hard (loud sound) then open the throttle valve further by turning COUNTER-CLOCKWISE. ___ • Both valves must be equally open.
4.10.7
Mechanical Checks ___ • Check the material discharge couplings on the sludge pump for leakage. Tighten or repair as required. ___ • Check all equipment for unusual noise or vibration. ___ • Inspect hoses for rubbing or chafing. ___ • Check for structural cracks on equipment frames.
4.10.8
Other Controls and Instruments
The control system for the sludge pump and related equipment has been custom designed to meet project specifications. Follow manufacturers instructions for calibration and adjustment which are found in your O&M manual. Items to check and/or adjust for these controls include flow meters, hopper feed level indicators, etc. (see Appendix G of your O&M manual for applicable catalog instructions)
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KSP Training Manual
OPERATION
4.11
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 4
SHUTDOWN PROCEDURE
Pump shutdowns may occur for many reasons. The shutdowns may be very brief to allow for a quick adjustment, or longer to perform periodic maintenance, or they may last for weeks or months while the plant is being worked on. 4.11.1
Shutdown For General Maintenance
For General or Periodic maintenance that requires equipment shutdown follow these steps, making sure that the equipment cannot be accidentally restarted while it is being worked on: WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag-out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. 1. Put the Screw Feeder Directional Control Valve Lever (Screw Feeder or Hopper Agitator) into CENTER/NEUTRAL position and/or place the BYPASS/LOAD Switch on the electrical control panel in the bypass position (if applicable). 2. Put the Directional Control Valve lever for the Sludge Pump into OFF position marked "CENTER/NEUTRAL" and/or place the BYPASS/LOAD Switch on the electrical control enclosure in BYPASS position. 3. Check that all Selector Switches on Control enclosure are in “OFF” or “BYPASS” positions. 4. Press the " Emergency Motor Stop" button on the door of the electrical control enclosure and TURN OFF the breaker switch. 5. Turn off the main power supply to the hydraulic Power Pack. 6. SECURE all controls from accidental operation by unauthorized personnel.
! WARNING! DANGER OF AMPUTATION! Use a lock-out procedure that is approved for your plant by O.S.H.A. or similar concerned government agency.
! WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes. Sludge discharge lines are operating under high pressure. Extreme caution and proper safety practices should be followed whenever the flanges are being loosened or the clamps removed from the sludge discharge line.
KSP Training Manual
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SECTION 4
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
OPERATION
To relieve the pressure in a sludge discharge line, follow these steps: 1. Place the screw conveyor or conical hopper in the reverse position. 2. Tighten down the throttle valves until they are completely closed, then open them up 1/2 turn. (Located on the control block) NOTE: If your pump is equipped with the SFMS® (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydraulic cylinders. 3. Place the S-1 spool in the reverse position and let the pump kit stroke in reverse for a short period of time. 4. Observe the hydraulic cylinder rods for the discharge poppets to verify that they are moving. (If they are not moving assume that the line is still pressurized.) 5. Observe the hopper to see if any sludge is coming from the pump into the hopper. Also observe the discharge line pressure gauge to see if it is dropping (if so equipped). 6. Open the pressure bleed off valve to release any residual pressure remaining (if so equipped). 7. Shut the pumping unit off and disconnect all power sources. Remove the flanges and clamps, using the proper safety procedures.
Do not install or repair damaged pipes, fittings or hoses. Replace damaged hydraulic hoses immediately. Lifting equipment, cables, chains, etc., are to be connected only at the lifting points provided. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.
4.11.2
Short-Term Shutdown
If the related equipment are to be shutdown for a period of one to three months, observe the following procedures: 4 - 34
KSP Training Manual
OPERATION
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SECTION 4
1. Follow the standard procedure for stopping the equipment. 2. Empty the Sludge Pump, conveyors, hoppers, feeders and pipelines of all material. This may be done by pumping or flushing clean water through the system, and completely draining the equipment. 3. Check the surfaces of feeder and hopper auger blades, pumping cylinders, material piston heads (rams), rock valve seals or poppet valves (as equipped), and pipeline for wear or damage. Repair as required. 4. Lubricate all bearings and drives. 5. Hand turn conveyor screw to check for alignment. 6. The equipment must be protected from weather, moisture, and extreme temperatures. If the equipment is to be covered with plastic sheeting, leave the bottom open for air circulation. 7. Coat all exposed metal surfaces with a rust preventative coating. 8. Schwing Bioset, Inc., recommends that the lubrication fluid supply is stopped whenever the sludge pumping process stops. This can be done by closing the ball valve of the lubrication fluid source (on the suction side of the lubrication pump). For systems without this ball valve present, Schwing America, Inc., recommends installing either a manually or electrically actuated valve. For automation, an electrically actuated solenoid valve may be installed, interlocked, and incorporated into the sequence of operation of the sludge pumping process. 9. Prior to restart, follow the pre-start-up procedures.. 4.11.3
Long Term Shutdown
If the sludge pump and related equipment are to be shutdown for a period of one to three months observe the following procedures: 1. Follow the standard procedure for stopping the pump in section 3.4.1. 2. Empty the pump, hoppers, feeders and pipelines of all material. This may be done by pumping or flushing clean water through the system, and completely draining the equipment. 3. Check the surfaces of feeder and hopper auger blades, pumping cylinders, material piston heads (rams), rock valve seals or poppet valves (as equipped), and pipeline for wear or damage. 4. Lubricate all bearings and drives.
KSP Training Manual
4 - 35
SECTION 4
FOR EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
OPERATION
5. The equipment must be protected from weather, moisture, and extreme temperatures. If the equipment is to be covered with plastic sheeting, leave the bottom open for air circulation. 6. Coat all exposed metal surfaces with a rust preventative coating. 7. Prior to restart, follow the start-up procedures contained in section 3.1 of your O&M manual. 4.11.4
Long-Term Storage
Procedures for Long-term Storage Follow these additional procedures if the equipment is to be stored inside for three months or longer before installation: Note: Sludge Pump and Power pack must be operational to prepare equipment for longterm storage. 1. Remove the rams. Store them on end in a dark and dry location. 2. Completely retract the differential cylinders; completely extend the suction poppet cylinders. 3. Coat all exposed cylinder rods, the poppet valve seats and discs, the S-1 spool and detent pin, and the interior of the material cylinders with a rust inhibitor such as LPS 3, Zep Iron Clad, or Texaco Rust Proof Compound. 4. Add desiccant (moisture absorbers) to electrical panels and install industrial corrosion inhibiting tape within electrical enclosure. This tape must be replaced yearly. 5. Plug all electrical knockouts. 6. Loosen the V-belts for the auxiliary hydraulic pump. 7. Add an overflow system to the clean-out covers on the hydraulic reservoir. 8. Completely fill the hydraulic reservoir with the same grade of hydraulic fluid that is already in the reservoir. 9. Close the ball valves on the water box. 10. Cover all exposed openings on the Sludge Pump such as the water box, poppet suction valve inlet, and the pipe discharge. 11. Store equipment on wooden blocks out of contact with the floor or ground surface.
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OPERATION
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SECTION 4
12. Cover pipe connections and other openings with easily removable plugs, stoppers, or flange covers. 13. Grease all bearings that have grease fittings. 14. Rotate screws every 2 weeks. 15. Schwing Bioset, recommends that the lubrication fluid supply is stopped whenever the sludge pumping process stops. This can be done by closing the ball valve of the lubrication fluid source (on the suction side of the lubrication pump). For systems without this ball valve present, Schwing Bioset, recommends installing either a manually or electrically actuated valve. For automation, an electrically actuated solenoid valve may be installed, interlocked, and incorporated into the sequence of operation of the sludge pumping process. 16. Prior to restart, reverse the above procedures and follow the start-up procedures contained in section 3.1 of this manual. Equipment can be shipped prepared for long-term storage at the factory if Schwing is given adequate notification by the owner. 4.11.5
EMERGENCY STOP 1. Press "EMERGENCY STOP" button. It is located on the door of the control enclosure 2. Put all valve hand levers in OFF position marked "NEUTRAL". CONTROL PANEL EMERGENCY STOP
Figure 3.7 EMERGENCY STOP PUSHBUTTON None of panel lights should be illuminated. None of the control buttons or switches should be functional and no controls for this panel should be functional from any remote location.
KSP Training Manual
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SECTION 4
4 - 38
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OPERATION
KSP Training Manual
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EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 5
SECTION 5
PLANNED MAINTENANCE
This section contains information on routine maintenance procedures that must be performed on all Schwing Bioset equipment. This section is divided into 5 subsections: • Safety during maintenance • Periodic maintenance • Lubricant recommendations • Troubleshooting • Bolt torque tables For more involved service-and-repair procedures, please refer to the Special maintenance section. Note: Do not allow anyone but an authorized service dealer to service or recondition hydraulic pumps, valves, and motors.
5.1
SAFETY DURING MAINTENANCE
Be certain to follow the safety regulations of the responsible contractor, facility manager, and liability-insurance company whenever you install, operate, or service Schwing equipment. Observing these regulations is the responsibility of the contractor and operator. Some supplementary safety recommendations follow. Before performing maintenance, first read and review this operations-and-maintenance manual and all relevant contract drawings. Keep unauthorized personnel away from the work area during maintenance. Allow only authorized, qualified personnel to perform maintenance. Whenever doing any maintenance on the inside of the material pump, e.g., replacing poppet valves or piston heads, first disconnect the material-pump discharge from the pipeline.
!
WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.
!
WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.
KSP Training Manual
5-1
SECTION 5
!
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (whether rock valve or poppet valves).
Only Certified Licensed Electricians shall be allowed to work on electrical systems.
!
WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag-out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.
Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in OFF or NEUTRAL position. Before working on material pipelines RELIEVE THE PRESSURE on the line.
!
WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE ALL THE PRESSURE on the line by operating the material pump in reverse.
Material discharge lines operate under high pressure. Use extreme caution and follow proper safety practices when loosening the flanges or clamps on the sludge discharge line. To relieve the pressure in a sludge discharge line, refer to the Planned maintenance section (material pump) under the heading “Cleaning the pump before performing maintenance:” Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately. Connect all lifting equipment, cables, chains, etc., only at the lifting points provided. Establish and maintain an active safety and accident- prevention program for operators and maintenance personnel. Good preventative-maintenance programs are essential for the safe operation of the equipment. Use good-housekeeping practices for all equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and prevent interference with its operation.
5-2
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5.2
SECTION 5
PERIODIC MAINTENANCE SCHEDULE
PERIODIC MAINTENANCE SCHEDULE - SLUDGE PUMP WITH ROCK VALVEWITH POPPET VALVES, SCREW FEEDERAGITATOR HOPPER No.
Description
D
W
3M 6M
Y
1
PP
Check Hydraulic Oil Level and Temperature.
2
PP
Change Hydraulic Oil - Schwing Bioset recommends periodic sampling and testing of hydraulic oil. Test results will give best indication of need to replace hydraulic oil or every 8000 hours.
3
PP
Replace Return Line Hydraulic Oil Filter every 2000 hours or 3 months whichever comes first.
4
PP
Inspect conditioning loop oil filter.
5
PP
Change conditioning loop oil filter every 3 months or 2000 hours whichever comes first.
6
PR
Check water level in Water Box.
7
PR
Change water in Water Box. Drain box at the end of each day's shift.
8
PR
Check for contamination in the Water Box.
9
AH
Check Oil Level in Agitator Gear for Agitator Hopper.
10
SF
Check Oil Level in Screw Feeder Gear Box.
11
M
Accumulator maintenance instructions
12
P
Check setting of Throttle Valves.
13
PP
Accumulator Service
14
AH
Lubricate bearings on the Agitator Hopper.
15
SF
Lubricate screw shafts on the Screw Feeder.
16
AH
Change Oil in Agitator Gear for Agitator Hopper.
17
SF
Change Oil in Screw Feeder Gear Box.
18
R
Lubricate all grease points on Rock Valve.
19
P
Check Poppet Valves for Wear.
KSP Training Manual
5-3
SECTION 5
No.
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Description
D
W
M
20
R
Check bolts on Rock Valve cover for tightness.
21
R
Adjust the adjusting nut of Rock Valve Pivot for 1.5 to 2 mm clearance. See The Rock Valve book for proper procedure.
22
R
Check cutting ring of Rock Valve for wear and rotate the ring if necessary.
23
PP
Service Electric Motors.
24
PP
Check Panel Lights.
25
P
Check setting of Throttle Valves.
26
Lubricate all levers and linkages (with oil can).
PR
Check bolts of material piston head (ram).
28
PP
Drain condensed water from Hydraulic Oil Reservoir and allow enough shut down time for water to settle to the bottom of the reservoir.
Check visually for any damage or wear.
Check function and setting of SAFETY and EMERGENCY Control and Devices.
30
PP
31
Check all bolts and nuts for Tightness.
32
PP
Check Pressure setting of RELIEF VALVE Sludge Pump.
33
PP
Check Pressure setting of RELIEF VALVE Screw Feeder.
34
PP
Check Pressure setting of PRESSURE SWITCH.
35
PP
Check V-belt drive (if necessary).
36
PP
Clean Air-Oil Cooler (if necessary).
37
SF
Check/Adjust screw feeder packings (if necessary).
38
LB
On lubrication system, change hydraulic oil and gear drive oil every 200 hours or 3 months whichever comes first.
39
P
Grease 3-way water valve
5-4
Y
27
29
3M 6M
KSP Training Manual
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- Operator
SECTION 5
- Maintenance Personnel
KEY: D-Daily W-Weekly M-Monthly 3M-3 Months 6M-6 Months Y-Yearly PP - Power Pack, AH - Agitator Hopper, SF - Screw Feeder, P - Cake Pump, R - Rock Valve Pump, SC - Extraction Screw Conveyor, SL - Sliding Frame, GV - Gate Valve
PERIODIC MAINTENANCE SCHEDULE - SLIDING FRAME/PUSH FLOOR BUNKER No.
Description
D
W
M
3M 6M
Y
1
SL
Check stuffing box for leakage. Check grease canister.
2
SL
Lubricate rod eye bearing. Grease trunnions.
3
GV
Manully operate to full open and full closed positions.
4
SL
Check condition of internal surfaces for wear.
5
SL
Check internal surface of walls and repair as needed.
KSP Training Manual
5-5
SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! PERIODIC MAINTENANCE SCHEDULE - SCREW CONVEYOR
No.
Description
D
W
M
Y
1
SC
Check screw section and trough
2
SC
Repack bearing
3
SC
Check coupling
4
SC
Tighten stuffing box
5
SC
Inspect bolts
5-6
3M 6M
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5.2.1
SECTION 5
General maintenance
Maintenance procedures Component
Description
Schedule
All equipment
Check visually for any damage or wear
Weekly
All equipment
Check function of emergency controls
Monthly
All equipment
Lubricate all levers and linkages (with oil can)
Monthly
All equipment
Check all bolts and nuts for tightness and wear
3 months
Table 1 Periodic maintenance for all Schwing Bioset equipment and systems, listed in order of frequency. Daily procedures appear first and more infrequent procedures appear later.
5.2.1.A
Check visually for any damage or wear
Make a visual inspection of the equipment to check for anything out of the ordinary. Often a simple adjustment or correction can prevent a major problem from developing somewhere down the road. Check the equipment both when operating and when stopped. ___ • Practice good housekeeping; clean and tidy-up surrounding areas ___ • Check for any chafing or abrasion of hydraulic hoses ___ • Watch and listen for unusual vibrations or noises. Tighten loose covers and guards ___ • Check for oil leaks ___ • Check for loose bolts or nuts ___ • Check for structural cracks ___ • Look for damage from other plant equipment, e.g., fork lifts
KSP Training Manual
5-7
SECTION 5
5.2.1.B
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Check function of emergency controls
Everyone should know the location and function of all emergency controls. The controls must be tested with the unit operating. For each control, start the motor and the equipment being tested, then press the emergency stop to shut-down all functions (see Figure 1). If the test succeeds, reset the control and restart the equipment. If the control fails, shut down the system using standard controls or the main power switch and repair the failed control before restarting.
Figure 1 An emergency stop is located on the control enclosure for each piece of equipment.
5-8
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5.2.1.C
SECTION 5
Lubricate all levers and linkages
Apply oil to hand-valve levers on the hydraulic power pack and hand-valve linkages on the material pump (see Figure 2 ). Hand lever
Oil locations
Figure 2 Hand lever on main control valve
5.2.1.D
Check all bolts and nuts for tightness
When checking for tightness, pay special attention to the following items. ___ • Electric-motor mounting bolts ___ • Hydraulic-pump mounting bolts ___ • Frame-mounting bolts for material pump, power pack, screw feeder, and agitator hopper ___ • Pipeline brackets ___ • Bolts for covers and guards ___ • Material cylinder bolt Tighten all nuts and bolts to the torque specified in the bolt torque tables.
KSP Training Manual
5-9
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 5
5.2.2
Hydraulic power pack
Maintenance procedures Component
Description
Schedule
Hydraulic power pack
Check hydraulic oil level and temperature
Daily
Hydraulic power pack
Check operation of control-enclosure lights
Daily
Hydraulic power pack
Drain condensed water from hydraulic oil reservoir (after allowing enough shut-down time for water to settle to the bottom)
Monthly
Hydraulic power pack
Replace return-line hydraulic oil filter when the warning light appears (approximately 2,000 hours of operation or 3 months, whichever comes first) and after 200 hours when new)
3 months
Hydraulic power pack
Check strainer on water/oil-cooler inlet and clean if necessary
3 months
Hydraulic power pack
Check pressure setting of pressure switch
6 months
Hydraulic power pack
Service electric motors
6 months
Hydraulic power pack
Change hydraulic oil every 8,000 hours; sample and test oil periodically to give the best indication of need for replacing
Yearly
Conditioning loop
Inspect conditioning-loop oil filter
Weekly
Conditioning loop
Change conditioning loop oil filter every 3 months or 2,000 hours, whichever comes first
3 months
Table 2 Periodic maintenance for the hydraulic power pack, listed in order of frequency.
5.2.2.A
Check hydraulic-oil level and temperature
The sight gauge on the side of the hydraulic-oil reservoir serves as both a level indicator and a thermometer. The oil level must lie between the top and bottom marks on the sight glass (see Figure 3). If it does not, fill the reservoir using the same grade of oil. Add the oil through the filler-breather cap using a filter cart with a minimum 10-micron filter. The level can be checked with the motor on or off. The normal operating temperature is 100 to 140 °F (38 to 60 ºC). The maximum oil temperature is 160 ºF (70 ºC).
5 - 10
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SECTION 5
Cleanout cover
Fill level Temperature gauge
Figure 3 Hydraulic-oil reservoir-level gauge and thermometer
5.2.2.B
Check operation of control-enclosure lights
If a unit is equipped with a PLC, all lights on the control enclosure will flash briefly when the main power or E-stop is reset. Identify inoperative lights and replace them as necessary. Some panels have a lamp-test push button or push-to-test lights. 5.2.2.C
Drain condensed water from hydraulic-oil reservoir
Turn off the hydraulic power pack for at least 8 hours before draining the reservoir; this will allow water in the hydraulic oil to settle to the bottom. After the 8 hours, slowly open the drain valve located on the bottom of the reservoir. See Figure 4. (Many hydraulic tanks will have more than one drain.) Collect the water-oil mixture, observing it as it drains. When the flow becomes a clear oil, without water or bubbles, shut off the valve. Drain valve
Drain tube
Figure 4 Hydraulic-reservoir drain valve
KSP Training Manual
5 - 11
SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
Refill the reservoir to the proper level by referencing the sight glass. Add the hydraulic oil through the filler-breather cap (see Figure 9) or a clean-out cover. Use a filter cart with a minimum 10-micron filter when adding oil to the reservior. Precautions for refilling • To prevent contamination, store and handle hydraulic oil properly. Always store hydraulic oil indoors. • Do not mix oils from different manufacturers. Mixing oils may reduce the oil quality. Refer to “Hydraulic-oil recommendations (hydraulic power pack)” on page 36 for recommended hydraulic fluids. (The oil provided by the factory is Texaco Rando HD 46-G.) • Maintain the oil temperature in the operating range of the hydraulic-oil manufacturer’s specification. The normal operating temperature is 100 to 140 °F (38 to 60 ºC). The maximum oil temperature is 160 ºF (70 ºC). Note the color or clarity of the hydraulic oil. Cloudy or dark oil may require changing. Check service records and schedules for the last change. Schwing Bioset recommends the owner establish a sampling program to periodically confirm oil quality. Lab testing oil samples every 3 months will give the best indication of the need for a change. Oil samples should have an ISO cleanliness code of 16/13. 5.2.2.D
Replace return-line hydraulic oil filter
The hydraulic oil filter must be changed whenever the oil is changed or when the filter warning light appears and remains on even after the oil has warmed up. The filter must also be changed after the first 200 hours of the power pack’s operation. Procedure 1. Turn off and secure all equipment against accidental starts. 2. Remove the 4 wing nuts on the filter cover and set aside. Remove the old filter element. (See Figure 5 and Figure 6.)
5 - 12
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SECTION 5
Figure 5 Filter-housing on the hydraulic oil reservoir
3.Lightly oil the O-rings of the new filter element and carefully insert it.
Figure 6 Removing and replacing the filter element on the hydraulic oil reservoir
4. While the cover is still off, replace or add oil through the filter to bring the reservoir up to the proper level. 5.Check the O-ring on the cover for wear or damage and replace it if necessary. Lightly oil the threads and O-ring before reassembling. 6.Replace the filter cover and tighten it manually. 7.Never operate the machine without a filter element!
KSP Training Manual
5 - 13
SECTION 5
5.2.2.E
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Check strainer on water-oil-cooler inlet
Remove the strainer on the water inlet and check it for debris or clogging. Spray the strainer clean with water before replacing it. 5.2.2.F
Check setting of pressure switches
The pressure switch responds to hydraulic-line pressure. If the pressure exceeds a preset value, it will shut down the electrical system and stop the equipment following a preset time delay. The time delay avoids erratic shutdowns caused by pressure spikes. Refer to Figure 7 for the location of the adjusting ring. See the drawings in the hydraulics section of the manual for the proper settings of the installed equipment. If necessary, adjust the pressure switch to the setting specified in the hydraulic drawings. Only qualified, trained maintenance personnel should set pressures on Schwing Bioset KSP equipment.
Pressureswitch adjusting ring for the material pump
Figure 7 Pressure switches on the hydraulic power pack: material pump on left; screw feeder on right
5.2.2.G
Service electric motors
The electric motor requires periodic maintenance to ensure a long service life. Maintenance tasks include the draining of condensed water within the enclosure and the greasing of bearings. Refer to the motor manufacturer’s maintenance recommendations in the appendices.
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5.2.2.H
SECTION 5
Change hydraulic oil
Equipment list • A sufficient quantity of new oil of the proper make and grade; refer to the installation or hydraulic drawings for the reservoir capacity; use oil fresh from the manufacturer; if not possible, use properly stored oil to avoid contamination • A drain hose and receiving containers for the used oil • A new main hydraulic oil filter; see Hydraulic power pack section for filter descriptions and part numbers • A seal kit of O-rings, available from Schwing Bioset • A new conditioning-loop oil filter; see the Hydraulic power pack section for filter descriptions and part numbers. • A corrosion-inhibitor additive; use approximately one 16-oz. (0.47 L) bottle per 50 - 80 gallons (189 - 227 L); see Hydraulic Power Pack sections for part numbers and specific quantities Procedure 1. Turn off and secure the equipment against accidental starts. The hydraulic oil should not be hot. Do not drain hot oil! It can cause serious burns. 2.Attach the hose to the drain tube on the bottom of the reservoir and run it to the receiving container. Use a drain tube with an ID (internal diameter) of 3/4". 3.Open the drain valve on the bottom of the reservoir (see Figure 8). Be sure to close the valve once the oil is completely drained. 4.Clean the interior of the hydraulic oil reservoir if necessary. Drain valve
Drain tube
Figure 8 Hydraulic-reservoir drain valve
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SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
5.Replace all hydraulic-oil filters, using an original-equipment replacement. For more information, see the maintenance procedure titled “Replacement of return-line hydraulic oil filter.” 6.Refill the hydraulic reservoir to the proper level by referencing the sight glass. Add the hydraulic oil through the filler-breather cap (see Figure 9) or a clean-out cover. Use a filter cart with a minimum 10-micron filter when adding oil to the reservior. Cleanout cover Filler breather cap
Hydraulic reservoir
Figure 9 Oil-reservoir clean-out cover and filler-breather
7. Add corrosion inhibitor to the full tank of new oil. Use approximately one 16-oz. (0.47 L) bottle per 50 - 80 gallons (189 - 227 L). See the Hydraulic power pack section for part numbers and specific quantities. Precautions • Store and handle the oil supply properly to avoid contamination. • Do not mix oils from different manufacturers. Mixing oils may reduce the oil quality. Refer to “Hydraulic-oil recommendations (hydraulic power pack)” on page 36 for recommended hydraulic fluids. (The oil provided by the factory is Texaco Rando HD 46-G.) 5.2.2.I
Inspect conditioning-loop oil filter
Check the indicator pop-up button on top of the filter housing. If the indicator continues to pop up after being reset, change the conditioning-loop oil filter. Procedure 1. The equipment must be turned off and secured against accidental starts. 2.Remove oil filter using an oil-filter wrench. 3.Put a film of oil on the rubber seal of the new replacement filter.
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SECTION 5
4.Spin on the new filter. 5.When starting equipment after servicing, check for leaks and tighten fittings if necessary. 5.2.2.J
Clean air/oil cooler
Units equipped with an air/oil cooler must have their fins vacuumed or blown off at specified intervals to maintain their heat-transfer efficiency. Dusty locations may require more frequent service.
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SECTION 5
5.2.3
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Push-floor silo
Maintenance procedures Equipment
Description
Schedule
Push floor
Check stuffing box for leaking
Weekly
Push floor
Check greaser on stuffing box
Weekly
Push floor
Lubricate rod-eye bearing
Monthly
Push floor
Check for wear from push floor hold-downs
Yearly
Push floor
Check and repair internal walls of silo
Yearly
Table 3 Periodic maintenance for the push-floor bunker, listed in order of frequency.
5.2.3.A
Check stuffing box for leakage
Check the drip tray under the stuffing box(es) for leaking material. If necessary, tighten the packing gland by turning the 8 bolts on the inner collar 1/4 - 1/2 turn (see Figure 10). Adjust all the bolts evenly and do not overtighten them; overtightening will shorten the life of the packing. The packings must be replaced when the retaining ring can no longer be adjusted.
Grease fittings Adjusting bolts for the packing gland
Figure 10 Bolts for tightening the push floor packing gland
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5.2.3.B
SECTION 5
Check greaser on stuffing box
• The grease fitting is located on top of the stuffing box. Grease lubricates the push floor piston as it passes into the silo (see Figure 10.) The stuffing box must be kept full of grease at all times. See “Grease recommendations” on page 37 for a list of appropriate greases. Schwing Bioset has 4 options for greasing the stuffing box: • A zerk that must be manually filled using a grease gun • A spring-loaded disposable cartridge • A direct mounted autogreaser • An autogreaser mounted on the screw feeder and plumbed to the push floor stuffing box No matter which option is used, the grease level in the stuffing box must be kept full at all times. Use a grease gun, replace the cartridge, or top off the autogreaser, whichever is appropriate for the equipment. Use a grease specified in “Grease recommendations” on page 37. 5.2.3.C
Lubricate rod-eye bearing
Shut down the push floor and remove the external cover above the clevis on the push floor piston. Note the grease zerk on top of the clevis (see Figure 11). This zerk will lubricate both the pin and the rod-eye bearing. Use a grease gun to manually grease the zerk. Use a grease specified in “Grease recommendations” on page 37.
Grease fitting for rod-eye bearing
Figure 11 Clevis on push floor piston
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SECTION 5
5.2.3.D
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Check for wear from push floor hold-downs
The hold-downs hold the push floor in place as it moves across the silo floor (see Figure 12). Over time, the hold downs may abrade the steel on the push floor channels. Check the push floor for abrasion and reweld if necessary.
Holddowns
push floor channel
Figure 12 Hold-downs for push floor
5.2.3.E
Check and repair internal wall surfaces
Check the shell walls of the silo wherever they come into contact with the push floor. Wear or abrasion more than 1 mm deep must be welded back to its original thickness to maintain the structural integrity of the silo.
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5.2.4
SECTION 5
Screw feeder
Maintenance procedures Equipment
Description
Schedule
Screw feeder
Inspect and adjust packings
Daily
Screw feeder
Lubricate screw shafts (manual lubrication systems only)
Daily
Screw feeder
Check oil level in gear box
Weekly
Screw feeder
Change oil in gear box
3 months
Screw feeder
Check the end bearings for wear every 3 months or 2,000 hours, whichever comes first
3 months
Screw feeder
Check shafts and flights for wear
3 months
Screw feeder
Check pressure setting of relief valve
6 months
Table 4 Periodic maintenance for the screw feeder, listed in order of frequency.
5.2.4.A
Inspect and adjust packings
Visually inspect seals where the screw shafts penetrate the screw feeder tub (see Figure 13). If sludge is leaking into the gear-box side of the seal, the packings need adjustment. Tighten the 2 packing adjustment nuts on each screw until the leakage stops. Do not overtighten the nuts; this will shorten the life of the packings. The packings must be replaced when the retaining ring can no longer be adjusted.
Adjusting nut
Retaining ring
Figure 13 Adjusting nuts for screw-feeder packings
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SECTION 5
5.2.4.B
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Lubricate screw shafts
If the screw feeder is not set up with an autogreaser, the bearings must be greased manually. Grease fittings are located on the discharge end (see Figure 14) of the screw feeder.
Grease fittings
Figure 14 Grease fittings on the discharge end of the screw feeder (with outboard bearings)
Use the standard grease gun provided in the tool box to apply 8 - 10 pumps per fitting for each 8-hour operating shift. Use a grease specified in “Grease recommendations”. 5.2.4.C
Check oil level in gear box
Oil should be visible in the oil-level sight glass on the side of the gear box (see Figure 15). If not visible, add lubricant through the fill port on top of the box (use SAE 90-weight industrial gear lubricant (refer to “Grease recommendations”). Add oil until it appears in the middle of the sight glass.
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SECTION 5
Sight glass
Figure 15 Sight glass on screw-feeder gear box
5.2.4.D
Change oil in gear box
Remove the oil drain-plug on the bottom of the gear box (see Figure 16) and the oil fillplug on top of the gear box. Catch the old oil and dispose of it properly. Replace the drain plug and add new oil through the fill port until it appears in the level sight glass on the side of the gear box. Replace the filler plug and tighten firmly, being careful not to crush the seal or strip the plug threads.
Drain plug
Figure 16 Screw-feeder gear box
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SECTION 5
5.2.4.E
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Check end bearings for wear
Check the screw-feeder end bearings for wear every 3 months or 2,000 hours, whichever comes first. Open the screw feeder transition, then remove the bearings cover plates held in place by 1 bolt each (see Figure 17). Notice the wear on the bottom half of the bushing and wear sleeve. If the bushing has worn more than 50 %, replace both bushing and wear sleeves.
Bearing cover plate
Figure 17 Screw-feeder with hanger end bearings
5.2.4.F
Check pressure setting of screw-feeder relief valve
The hydraulic relief valve for the standard screw feeder is usually located on the hydraulic power pack, normally part of the forward/reverse valve. (See Figure 18.).
Pressure relief valve manual override
Figure 18 Relief valve located on the hydraulic power pack
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SECTION 5
The relief valve protects the system from high pressures. When pressure in the line from the hydraulic pump to the screw-feeder hydraulic motor exceeds the set pressure, the relief valve opens, allowing the oil to bypass the hydraulic motor and return to the reservoir. See the hydraulic drawings in the main hydraulic-system section of this manual for the proper settings of the installed equipment. If necessary, adjust the pressure switch to the setting specified in the hydraulic drawings.
KSP Training Manual
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SECTION 5
5.2.5
Material pump
Maintenance procedures Equipment
Description
Schedule
Material pump
Fill water box at the start of each shift
Daily
Material pump
Check water box for contamination
Daily
Material pump
Check bolts and connection of material pistons
Monthly
Material pump
Clean the pump before performing any maintenance on the poppet valves
Material pump
Check poppet valves for wear
3 months
Material pump
Check setting of throttle valves
3 months
Material pump
Check pressure setting of relief valve
6 months
Table 5 Periodic maintenance for the material pump, listed in order of frequency
5.2.5.A
Fill water box at the start of each shift
The water box (see Figure 19) must be filled before the material pump can be operated. At the start of each shift, fill the box completely with clean water and secure the cover. Do not operate the material pump with the water box open! 5.2.5.B
Check water box for contamination
Standard procedure At the end of each operating shift (8 hours), drain the water box completely, check it for floating oil and sediment and flush it clean.
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SECTION 5
Overflow outlet
Water box
Drain valve
Figure 19 Water-box drain-valve location on the material pump
1. Shut off material pump and secure it from operation. 2. Remove the water-box cover and check the water surface for floating oil. Oil on the surface indicates improperly sealed differential cylinders. Refer to Material pump section for more information. 3.Open the drain valve on the water box (see Figure 19); allow the water to drain completely. 4.Check for sediment on the bottom of the box. If more than 1 - 2'' (25 - 50 mm) is present, the rams are worn and must be replaced. Refer to the Material pump section for more information. (The sediment level can also be checked with the water box full, provided the sediment is allowed sufficient time to settle to the bottom. 5.Flush box with clean water and close the drain valve. 6.Refill the box with clean water just before using it again. See Figure 20 for the location of the water inlet.
KSP Training Manual
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SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
Water box Water inlet
Figure 20 Water-box inlet location on the material pump
5.2.5.C
Clean the pump before performing maintenance on the poppet valves
The material pump must be cleaned before any maintenance is performed on the poppet valves. Before cleaning the pump, the main line must be depressurized. Follow the procedures listed below carefully. 1. Close the valves in the material pipeline to prevent the backflow of material when the pump is put into reverse. 2. Run the material pump in reverse to depressurize the line. In the maintenance mode, use the jog button and the hand lever to reverse the pump until the line is cleared and the pressure gauge reads near zero. The screw feeder must also be run in reverse; use the hand valve on the screw feeder or the hydraulic power pack.
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SECTION 5
Figure 21 Running the pump in reverse to depressurize the line
3. If the length of your material pipeline requires you to reverse the pump at a high speed, please contact Schwing Bioset for the proper procedure. 4. Open the bleed-off valve on the pipeline adapter at the end of the pump. Be sure to stand clear of the valve when opening it; if you have not sufficiently depressurized the line it may expel material explosively. 5. Turn off the motor by pushing the motor stop button on the electrical control panel and securing the controls from accidental starting by switching off the electrical-control main disconnect and locking and tagging it. Follow your facilities “lock-out” procedures for locking and tagging the equipment. 6. Disconnect and drain the water-supply line to the water box. Do the same for the loopflushing system, if present. 7. Remove the 6 bolts from the transition housing. 8. Remove the pipeline adaptor at the end of the pump. 9. Pull the pump away from the screw feeder. If the material pump is on casters, raise it before moving it back from the screw feeder. 10.Open the transition housing and spray it clean using a water hose. Do not use a highpressure hose; it will splatter the material excessively. Wear gloves, goggles, rubbersoled boots during the cleaning. Be aware that floors may become slippery. 11.Reverse this process to return the material pump to service. 5.2.5.D
Check bolts and connection of material pistons
The material piston heads (rams) are attached to the piston rods with clamps or bolts. Check the connections in each material cylinder for tightness.
KSP Training Manual
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SECTION 5
5.2.5.E
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE! Check pressure setting of relief valve
The pressure-relief valve for the material pump is located on the hydraulic power pack (see Figure 23). The electric solenoid-operated valve limits the hydraulic pressure in the material pump; it also functions as a bypass valve. When the solenoid is energized, the valve engages and directs all the hydraulic pump flow to the material pump. When the solenoid is de-energized, the valve directs all the hydraulic pump flow back to the reservoir. The relief valve protects the system from high pressures. When pressure in the hydraulic circuit exceeds the set pressure, the relief valve opens, allowing oil to bypass the pump and return to the reservoir. Note: The valve is equipped with a manual override that can be pushed to engage it.
Relief setting Manual override
Figure 22 Pressure-relief (load / bypass) valve on hydraulic power pack
Relief setting
Manual override
Figure 23 Pressure-relief (load / bypass) valve (Sun)
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SECTION 5
Only qualified, trained maintenance personnel should set pressures on Schwing Bioset KSP equipment. Afterward, be certain to return the pressure and pump adjustments to the original settings specified in the drawings. See the hydraulic drawings in Section 7 of the manual for the proper relief setting of the installed equipment. Sludgepump pressure gauge
Shut-off valve
Figure 24 Sludge-pump pressure gauge
The shut-off valve for the gauge (see Figure 24) must be open for the gauge to register. 5.2.5.F
Check poppet valves for wear
Open the poppet-valve housing and check for unusual wear at the valve seat. See the Special maintenance section in this manual for service and repair instructions for poppet valves. 5.2.5.G
Check setting of throttle valves
The throttle valves are located on the main control block of the material pump (See Figure 25). They regulate the pressure on the poppet-valve cylinders, which open and close the poppet valves. Closing one or both of the throttle valves will increase the pressure on the poppet valves. Closing the throttle valves too much will retard the poppet valve (S-2 spool) switchover at the end of the pumping stroke. This results in overpressure, which will cause the pressure switch to shut down the system or bypass oil through the safety valve.
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SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
Procedure 1. With the motor on, put the material-pump hand lever in neutral. On manually operated models, the hand lever is located on the control block near the throttle valves. On automatic models, the hand lever is located on a separate control block. 2. Close both throttle valves by turning clockwise.
Throttle valve controls
Figure 25 Throttle-valve locations on the control block
3. Open both valves 2 turns counter-clockwise. 4.On manual models, put the sludge-pump hand lever in forward. On automatic models, set the switches on the control enclosure to local mode and load. (Refer to the Special maintenance section in this manual if the unit is equipped with the Sludge Flow Measuring System.[SFMS®]). 5.Listen for the poppet valve opening and closing at switchovers (the end of each pump stroke). The valves should seat firmly with an audible but not excessively loud sound. • If the valves are closing too softly or quietly, close both throttle valves further by turning them clockwise. • If the valves are closing too hard or loudly, open both throttle valves further by turning counter-clockwise.The objective is to achieve a fast, solid switchover without overpressure and without excessive wear on the poppet valves. If the valves require further adjustment, refer to the Special maintenance section. 6.After adjusting the throttle valves, put the sludge-pump hand-valve in neutral and turn the motor off. 7. Lock the throttle valves down using the clamps or set screws on the valve knobs.
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5.2.6
SECTION 5
Pipeline lubrication system
Maintenance procedures Equipment
Description
Schedule
Lubrication system
Change hydraulic oil and gear-drive oil every 4000 hours or 1 year, whichever comes first
1 year
Lubrication system
Calibrate the flow of lubrication system
1 year
Table 6 Periodic maintenance for the pipeline lubrication system, listed in order of frequency.
5.2.6.A
Change lubrication system oil
Change the hydraulic oil and gear-drive oil every 4000 hours or 1 year, whichever comes first. Note the breather hole shown in Figure 26, located between the hydraulic chamber and the gear box. Do not fill either cavity above the breather hole or the fluids will become contaminated. For more information, refer to the Milton Roy metering-pump catalog under the Lubrication tab of this manual. Hydraulic chamber
Breather hole
Gear box
Figure 26 Hydraulic chamber and gear box inside the lubrication- system pump
5.2.6.B
Calibrate the flow of lubrication system
Open the water valve and fill the calibration chamber, shown in Figure 27. Note the water level. Open the flow valve and time the outflow of the water for a 1-minute period. Shut off the flow and note the difference in the water level on the calibration column, read in gallons per hour.
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SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
Figure 27 Calibration column on the lubrication pump
Calibrate the lubrication system at the 100 %, 50 %, and 10 % settings. Use the starvalve shown in Figure 28 to set the percentages. Refer to the Lubrication tab to identify the proper flow rate for your equipment.
Figure 28 Star valve on the lubrication pump
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5.3
SECTION 5
Lubricant recommendations
This section contains information on oils and lubricants required for the maintenance of Schwing Bioset equipment. Use them when performing the maintenance procedures described previously. If these products are not available, others can be used, provided they meet the specifications of the standard codes noted. The selection and order of the products does not necessarily indicate their quality. Standard codes used MIL-L American military standards for lubricants API
American Petroleum Institute
DIN
Deutche Industrie Norm (German Industry Norm)
ISO
International Standardization Organization
SAE
Society of Automotive Engineers
CLP
An industrial gear-lubricant oil with additives to improve corrosion protection, aging stability, and protection against wear from many types of friction; also increases gear stability under load; meets DIN 51517.
HLP
A hydraulic oil with additives to improve corrosion protection, aging stability, and protection against wear from many types of friction; meets DIN 51524; temperature range: 0 to 180 °F (-18 to 82 °C).
HV
A hydraulic oil with low-viscosity-temperature dependence, otherwise similar to HLP; meets DIN 51524; temperature range: -30 to 180 °F (-34 to 82 °C).
KP 2 K
Grease for high-pressure load in working temperature range from -4 to 284 °F (-20 °C to 140° C), worked penetration from 265 to 295, and minor or no changes in the presence of water
MIL-L 2105BMotor-vehicle gear-lubricant oil for hypoid-bevel-gear lubrication under the mostly highly demanding circumstances for gears and axles; roughly corresponds to API-GL 5. VDL
Mineral oil for air compressors. VDL contains additives to improve corrosion protection and aging stability; coke residue after aging is no more than 3% in accordance with DIN 51532
VG
Viscosity in mm3/s at 104 °F (40 °C)
VG 32
Oil viscosity for winter conditions in northern US or central Europe
VG 46
Oil viscosity for summer conditions in northern US or central Europe
VG 68
Oil viscosity for very high temperatures, e.g., in the tropics or in very hot enclosed rooms
VG 220
Corresponds approximately to SAE 90 for industrial gear lubrication
KSP Training Manual
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SECTION 5
5.3.1
Hydraulic-oil recommendations (hydraulic power pack)
Hydraulic oils ISO viscosity DIN quality
VG 32 HLP
HV
VG46 HLP
Amoco
HV
VG 68 HLP
HV
AW 46
BP: Energol
HLP 32
Exxon: Nuto
H32
Exxon: Univis
SHF 32
HLP 46
SHF 46
H46 I 32
HLP 68 H68
N56
N56
Mobil: DTE
24
13 M
25
15 M
26
16M
Shell: Tellus: oil
32
T 32
46
T 46
68
T68
Texaco: Rando oil HD
A-32
AZ-32
*B-46
C-68
CZ-68
Table 7 *Texaco Rando HD 46 is supplied standard in most Schwing Bioset equipment. It is rated down to 25 °F (4 °C). DTE 24 is rated down to 5 °F (-15 °C). DTE 26 is rated for use at higher temperatures. Contact the oil supplier for temperature recommendations.
Do not mix hydraulic oils from different manufacturers. It may reduce the oil quality.
If using the hydraulic oil of another manufacturer or a different type of oil (e.g., HV instead of HLP), a complete oil change is necessary. In some cases, mixing different viscosities of oil from the same manufacturer is permissible. Consult the oil manufacturer to be sure; note that the new viscosity will depend on the mixing ratios. Note: Schwing Bioset recommends the use of a corrosion inhibitor to protect the hydraulic oil reservoir. Schwing Bioset recommends VCI-326 from the Cortec Corporation. See the Hydraulic power pack section for part numbers and quantities.
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5.3.2
SECTION 5
Gear-lubricant recommendations
Industrial gear lubricants SAE Viscosity ISO Viscosity DIN Quality Temperature Range
90-weight industrial gear lube VG 220 CLP 15 to 105 °F (-10 to 40 °C)
BP
Energol GR-XP 220
Exxon
Spartan EP 220
Mobil
Mobilgear 630
Shell
Omala Oil 220
Table 8 Note: Equipment serial plates also list the appropriate gear-lubricants
5.3.3
Grease recommendations
Lithium-base high-pressure grease KP 2 K according to DIN 51502, without moly Manufacturer BP
Energrease LS2
Exxon
Multi-purpose grease
Mobil
Mobilith AW 2
Shell
Alvania grease EP-2
Texaco
Multifak 20
Table 9
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SECTION 5
5.4
Troubleshooting
5.4.1
Hydraulic power pack
PROBLEM
CAUSE
SOLUTION
No hydraulic pressure
a) Motor not running
a) Start equipment
b) Hydraulic pump is defective or cavitating from clogged suction line or lack of oil in the reservoir.
b) Replace the hydraulic pump and clean entire system; fill reservoir with oil; remove obstruction or replace suction line
c) Relief valve is defective; problem could be in pressure valve or pressure cartridge; also, the solenoid of a magnetic relief valve (if so equipped) may not be energized
c) Replace the relief valve or its cartridge; press manual override on the end of the valve solenoid—if the system operates, replace the valve
d) Electrical control is defective
d) Replace electrical control
e) Pressure regulator or flow valve on pump is defective
e) Replace regulator or flow valve
f) Hydraulic pump has failed
f) Flow check the hydraulic pump
g) The coupling between the electric motor and the hydraulic pump is defective
g) Replace the coupling; check the alignment carefully
a) The hydraulic oil in the motor is too cold (20 °C or less)
a) Use heaters to warm the hydraulic oil above 20 °C before starting the motor
b) Check suction line for leaks or collapsing
b) Tighten clamps or replace the suction hose
c) The hydraulic oil is too thick for the application
c) Change oil to a lower viscosity using the lubricant recommendations in this section
d) Contaminated oil
d) Replace oil
a) The hydraulic reservoir is low on oil
a) Fill reservoir with proper fluid to full level on sight gauge
b) Wrong hydraulic fluid
b) Replace oil with proper oil using the lubricant recommendations in this section
c) The hydraulic fittings or clamps on the suction line leak
c) Tighten or replace hydraulic couplings
Cavitation of the hydraulic pump with noise or foaming of oil
Foam or air pockets in the hydraulic fluid
d) Hydraulic pump failed
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d) Flow test the hydraulic pump; replace if necessary
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SECTION 5
PROBLEM
CAUSE
SOLUTION
Mechanical vibration
a) Coupling between motor and pump is poorly aligned, loose, or worn
a) Align and tighten the coupling; replace if necessary
b) Vibration comes from the hydraulic pipeline
b) Tighten the pipeline clamps and brackets
c) Hydraulic pump is cavitating
c) Check oil level; if OK, flow test the hydraulic pump
d) Damaged hydraulic pump
d) Repair or replace hydraulic pump and clean entire system
a) Worn or damaged hydraulic pump
a) Repair or replace the hydraulic pump
b) The hydraulic oil is too thin for the application
b) Change oil to a higher viscosity using the lubricant recommendations in this section
c) Oil cooler not operating
c) Check cooler operation; clean fins or core and remove other blockages to air flow
d) Incorrect setting of the relief valves and pressure switches
d) Check relief-valve settings and pressure-switch setting to ensure they are correct
a) Defective electric motor
a) Replace the coupling or the electric motor
b) Defective hydraulic pump
b) Flow-check hydraulic pump
c) Incorrect setting of the relief valves and pressure switches
c) Check relief-valve setting and pressure-switch settings to ensure they are correct
d) Pressure regulator or flow valve on the material pump is defective
d) Replace the regulator or the flow-control valve
e) Electrical control circuit to the flow-control valve is not operating properly
e) Check out and troubleshoot the electrical portion of the control circuit
a) Relief or other valve doesn't close because of dirt or defect
a) Clean valve; repair or replace as necessary
b) Vibration has caused pressure setting to change from original
b) Reset the pressure and lock the setting
c) Damaged cylinder bore, piston rod, or piston seals
c) Replace or repair the cylinder
d) Pressure regulator or flow valve on the material pump is defective
d) Replace the regulator or the flow-control valve
e) Electrical control circuit to the flow-control valve is not operating properly
e) Check out and troubleshoot the electrical portion of the control circuit
Hydraulic fluid temperature is higher than normal
The hydraulic-oil output is too low
Low oil flow caused by leaking from the pressure side into the return line
Table 10
KSP Training Manual
5 - 39
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 5
5.4.2
Push floor silo
PROBLEM
CAUSE
SOLUTION
High hydraulic pressure during stroke
a) Hydraulic valve is closed
a) Open valve
b) Foreign object is blocking frame
b) Clean out silo and remove obstruction
c) Hydraulic lines for opposing cylinders are plumbed incorrectly
c) Plumb hydraulic lines according to SAI hydraulic schematic
a) Proximity switch is not sensing the target
a) Adjust proximity switch or brackets
b) Faulty proximity switch or wiring
b) Replace proximity switch
a) Hydraulic rod is scored
a) Repair or replace hydraulic rod
High hydraulic pressure at end of stroke
Premature leaking of hydraulic-cylinder seals
Stuffing box leaks
Frame will not stroke
5 - 40
b) Hydraulic cylinder is not properly aligned with the extension rod
b) Re-align the hydraulic cylinder to the extension shaft (+/-3 mm)
a) Packing is loose
a) Tighten compression ring
b) Packing has worn
b) Replace packing
c) Insufficient lubricant
c) Ensure auto greaser is functioning properly
d) Hydraulic cylinder is not properly aligned with the extension rod
d) Re-align the hydraulic cylinder with the extension shaft (+/-3 mm)
a) Faulty directional valve
a) Replace directional valve
b) Hydraulic-pump or powerpack fault
b) See power-pack troubleshooting section
KSP Training Manual
FOR PLANNED MAINTENANCE
EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
PROBLEM
CAUSE
SOLUTION
The hydraulic-oil input is too low
a) Defective electric motor (in which case there may be no oil)
a) Replace the coupling or the electric motor
b) Defective hydraulic pump
b) Flow-check hydraulic pump
c) Incorrect setting of the relief valves and pressure switches
c) Check relief-valve setting and pressure-switch settings to ensure they are correct
a) Relief or other valve doesn't close because of dirt or defect
a) Clean valve; repair or replace as necessary
b) Vibration has caused pressure setting to change from original
b) Reset the pressure and lock the setting
c) Damaged cylinder bore, piston rod, or piston seals
c) Replace or repair the cylinder
d) Pressure regulator or flow valve on the material pump is defective
d) Replace the regulator or the flow-control valve
e) Electrical control circuit to the flow-control valve is not operating properly
e) Check out and troubleshoot the electrical portion of the control circuit
Problem
Cause
Solution
Feeder augers do not turn
a) Ball valves in hydraulic lines are closed
a) Open both ball valves
b) Drive coupling broken or damaged
b) Replace coupling
c) Object is jammed in auger spirals
c) Remove object
d) Auxiliary hydraulic pump is faulty and not providing enough pressure
d) Repair or replace hydraulic pump
e) Low hydraulic pressure
e) Reset hydraulic pressure
Improper or inadequate greasing
Grease according to the maintenance procedures listed previously in this section
Low oil flow caused by leaking from the pressure side into the return line
SECTION 5
Table 11
5.4.3
Screw feeder
Premature bearing failure
KSP Training Manual
5 - 41
SECTION 5
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
Problem
Cause
Solution
Leaking through the stuffing box of the drive
Worn packings
Adjust packing retainer ring (see the Screw feeder section); when tightening the ring does not stop the leak or the ring bottoms out, replace the packing
Material pump strokes properly and feeder augers rotate but the discharge volume remains too low
a) Screw feeder is set at too low speed
a) Increase speed of the screw feeder
b) Material may not be feeding into the material pump; dry blockage in transition from screw feeder to material pump
b) Shut down material pump and clear the blockage
c) Bridging in the hopper
c) Shut down material pump and break loose the bridged material
Table 12
5 - 42
KSP Training Manual
FOR PLANNED MAINTENANCE
EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
5.4.4
SECTION 5
Material pump
PROBLEM
CAUSE
SOLUTION
At the stroke change-over, the pressure increases sporadically up to the setting of the relief valve, and the oil heats up faster than normal
a) Either or both throttle valves are closed too much, limiting the oil arriving at the S2 valve to switch it over; the full flow of oil from the pumps bypasses through the relief valve and causes heat to build up
a) Adjust both throttle valves so that the pressure spikes are approximately 1/2 second in length
b) Material or items caught between the valve body and the piston valve slow or block the piston in the S2 control valve
b) Check the oil filtration system; disassemble S2 valve and clean; also check seals
c) 1/4 turn valve for soft switch is shut
c) Open 1/4 turn valve
d) Reversing valve not operating properly
d) Clean, repair, or replace reversing valve
e) Soft switch relief valve (if equipment has one) setting incorrect
e) Check setting and adjust
a) An object is caught in a poppet valve between the ring and seat or the sealing surface between the valve disc and seat is damaged
a) Open the valve-discharge housing or the hopper-intake housing and remove the jammed object; refer to the Special maintenance section for instructions on poppetvalve maintenance
b) Material piston may be stuck at one end or possibly disconnected
b) Reattach the piston head
c) Screw feeder is not operating properly
c) Verify proper operation of screw feeder
The material pump stops at the end of a stroke and hydraulic pressure builds to safety pressure; poppet valve cylinders do not move
The S2 valve of the main control block on the material pump did not switch
a) The S-2 spool is binding
At end of stroke, cylinders only move forward and reverse in very short strokes
Check valve is damaged or stuck in open position
Unit delivers only half the expected output; pumping with only one cylinder; very low pressure on idle stroke
KSP Training Manual
b) Defective 1/4 turn valve c) Orifices to S-2 are plugged Clean or replace the check valve
5 - 43
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 5
S3
S2
S1
Figure 29 S1, S2, and S3 valves on main control blocks
Material pump (continued) Problem
Cause
Solution
Material pump strokes properly but the discharge volume is too low
a) Pressure poppet valve is damaged and allows flow from pressure cylinder to enter the other cylinder instead of the delivery line
a) Replace the valve disc, cone, or the whole valve
b) Suction poppet valve is damaged and allows flow from pressure cylinder to enter the suction cylinder instead of the delivery line
b) Replace the valve disc, cone, or the whole valve
c) Material piston head (ram) disconnected
c) Reinstall the piston-head mounting bolts
d) Poppet valve is jammed by a foreign body
d) Remove foreign body
e) Screw feeder is set at too low speed
e) Increase speed of the screw feeder
f) Material may not be feeding into the material pump; dry blockage in transition from screw feeder to material pump
f) Shut down material pump and clear the blockage
g) Screw-feeder transitionpressure sensor reading too high
g) Repair or replace the sensor
Table 13
5 - 44
KSP Training Manual
FOR PLANNED MAINTENANCE
EXACT PROCEDURES CONSULT THE O&M MANUAL FOR THE UNIT YOU OPERATE!
5.5
SECTION 5
Bolt torque tables
The tightening torque for a bolt depends on the size and grade (8.8, 10.9, 12.9) of the bolt, thread friction, and bolt-head seat. The grade (quality) of metric bolts is usually marked on the bolt head. The following torques are for reference only. Tighten bolts to these torques unless otherwise noted in operating or maintenance instructions. The torques are for hex-head bolts, according to DIN 13, with 0.14 coefficient of friction and dry or lightly oiled threads. 5.5.1
Metric: normal threads
Bolt thread Dimension
Wrench or socket size (mm)
Torque 8.8 ft-lb (N-m)
10.9 ft-lb (N-m)
12.9 ft-lb (N-m)
M6
10
7 (10.5)
11 (15.5)
12 (18)
M8
13
17 (25)
26 (37)
30 (44)
M 10
17
35 (50)
51 (73)
60 (86)
M 12
19
60 (86)
87 (125)
100 (145)
M 14
22
94 (135)
140 (200)
165 (235)
M 16
24
150 (210)
215 (310)
256 (360)
M 18
27
210 (300)
300 (430)
350 (500)
M 20
30
300 (430)
420 (610)
500 (710)
M 22
32
400 (580)
575 (830)
670 (970)
M 24
36
510 (730)
720 (1,040)
850 (1,220)
M 27
41
750 (1,080)
1,080 (1,550)
1,250 (1,800)
M 30
46
1,000 (1,450)
1,460 ((2,100)
1,700 (2,450)
M 33
50
1,400 (2,000)
1,940 (2,800)
2,300 (3,300)
M 36
55
1,750 (2,500)
2,500 (3,600)
2,900 (4,200)
M 39
60
2,300 (3,300)
3,260 (4,700)
3,800 (5,500)
Table 14
KSP Training Manual
5 - 45
FOR EXACT PROCEDURES CONSULT THE PLANNED MAINTENANCE O&M MANUAL FOR THE UNIT YOU OPERATE!
SECTION 5
5.5.2
Metric: fine threads
Bolt thread dimension
Wrench or socket size (mm)
Torque 8.8 ft-lb (N-m)
10.9 ft-lb (N-m)
12.9 ft-lb (N-m)
M8x1
13
19 (27)
28 (40)
33 (47)
M 10 x 1.25
17
37 (53)
53 (77)
63 (91)
M 12 x 1.25
19
65 (94)
97 (140)
110 (160)
M 12 x 1.5
19
62 (90)
90 (130)
108 (155)
M 14 x 1.5
22
100 (145)
150 (215)
170 (250)
M 16 x 1.5
24
160 (225)
230 (330)
270 (390)
M 18 x 1.5
27
240 (340)
330 (480)
400 (570)
M 20 x 1.5
30
330 (470)
460 (670)
550 (790)
M 22 x 1.5
32
440 (640)
620 (900)
740 (1,060)
M 24 x 2
36
550 (800)
790 (1,140)
940 (1,350)
M 27 x 2
41
800 (1,160)
1,150 (1,650)
1,350 (1,950)
M 30 x 2
46
1,110 (1,600)
1,600 (2,300)
1,870 (2,700)
M 33 x 2
50
1,530 (2,200)
2,150 (3,100)
2,500 (3,600)
M 36 x 3
55
1,870 (2,700)
2,650 (3,800)
3,100 (4,500)
M 39 x 3
60
2.430 (3,500)
3,500 (5,000)
4,000 (5,800)
Table 15
5 - 46
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
SECTION 6
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
This section contains service-and-repair instructions for the major components of your Schwing pumping system. • Hydraulic system: maintaining pressures • Screw-feeder Auger replacement Trough liner replacement • Material pump Replacing piston heads Poppet-valve service and repair • Sludge-flow-measuring-system (SFMS): set-up, service, and adjustment Note: Review each procedure completely before starting any maintenance on Schwing equipment. Also have all parts on hand before starting. Refer to the Material pump section of this manual for the required replacement parts. GENERAL INSTRUCTIONS REVIEW THIS PROCEDURE COMPLETELY BEFORE STARTING MAINTENANCE. Review relevant parts lists in Appendix A of the O & M manual for replacement parts needed. Have all parts on hand before starting maintenance.
KSP Training Manual
6-1
SECTION 6
6.1
SPECIAL MAINTENANCE
SAFETY DURING MAINTENANCE (From your O&M manual)
Be certain to follow the safety regulations of the responsible contractor, facility manager, and liability-insurance company whenever you install, operate, or service Schwing equipment. Observing these regulations is the responsibility of the contractor and operator. Some supplementary safety recommendations follow.
!
Before performing any maintenance, first read and review this operations-andmaintenance manual and all relevant contract drawings.
!
Warning! danger of amputation! Keep hands and feet out of the water box.
!
Warning! danger of amputation! Keep hands out of the screw feeder and agitator hopper.
!
Warning! danger of amputation! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves).
Keep unauthorized personnel away from the work area during maintenance. Allow only authorized, qualified personnel to perform maintenance. Whenever doing any maintenance on the inside of the material pump, e.g., replacing poppet valves or piston heads, first disconnect the material-pump discharge from the pipeline. Allow only certified licensed electricians to work on electrical systems.
!
Warning! Danger of electrocution! before working on electrical systems, be sure that the main circuit breakers are turned off and secured. Use a lock-out/ tag-out procedure approved for your plant by OSHA or similar regulatory agency.
!
Warning! Danger of injury from rapidly expelled material! Before working on the material pipelines, relieve all the pressure on the line by operating the material pump in reverse.
Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in the off or neutral position Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately.
6-2
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
6.2
SECTION 6
Maintaining hydraulic system pressures
Maintenance procedures should only be performed by qualified, trained personnel. Refer to the Hydraulic system section in this manual to identify the proper hydraulic circuit.
AA10VSO
Pressure Compensator
Figure 1 Model A10VS0 hydraulic pump
The Hydraulic pumps, standby, and compensator pressure adjustments are sealed. Do not remove the seals without first consulting Schwing. Unauthorized removal of any seal will void the warranty.
010101 Serial number
A10VS
Model number
XXX
Spec. number
Rexroth P/N
Rexroth
Rpm Rotation
Yr
A10VSO
Axial piston unit (variable swashplate design for industrial use)
Mode of operation Pump, in open circuit
Figure 2 Nameplate data for the A10VSO hydraulic pump. When ordering parts or requesting information, be certain to use the serial number, specification number, and part number to avoid confusion or errors.
KSP Training Manual
6-3
SECTION 6
SPECIAL MAINTENANCE
6.3
Screw feeder
6.3.1
Auger replacement
The screw feeder augers must be replaced when the blades of the augers are worn out and the feeder does not provide material efficiently to the material pump. Check the gland packings on the gear-drive end of the augers daily. Adjust as necessary by tightening the packing retainer ring to remove play. Replace the gland packings when the retainer ring bottoms out. 6.3.1.A
Auger replacement procedure
1. Turn off and secure the motor. Put all hand levers in the neutral or off position.
!
Warning! Danger of amputation! Use a lock-out/tag-out procedure approved for your plant by OSHA or similar concerned governing agency.
2. Remove the shaft end bolts on the gear drive end of the augers. 3. Remove the bolts between the transition housing and the screw-feeder hopper. Remove the bolts between the transition housing and the material pump. 4. Pull the transition housing off of the end of the augers and set it on the ground. The transition housing contains the bearings for the augers. 5. With the housing and the end bolts removed, the augers may now be removed from the feeder trough. Pull them out together and note the orientation of the paddles for right and left or top and bottom. 6. When installing the new augers, align the keyways at the gear end of the shaft with the bearings. Install the shaft-end bolts to secure the new augers. 7. Replace the bushings and packing in the transition housing, following the procedure below. a)Remove the bearing end cap b)Remove the bushing retaining set screw for each shaft c)Tap out old bushings and remove grease seals d)Wipe interior of bearing housing clean e)Install new bushings and seals and lock in place with set screw 8. Install new wear sleeves and O-rings to the auger bearings with the retaining set screws.
6-4
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
9. Reinstall the transition housing over the ends of the augers. Make sure the gasket seal is in place and all bolts are tightened securely. 10.With the bearing housing end plates still removed, pack the housing with grease and then install cover plate and seal. 6.3.1.B
!
Packing replacement at gear-box end of augers Warning! Danger of amputation! Use a lock-out/tag-out procedure approved for your plant by OSHA or a similar governing agency.
1. Turn off and secure the motor. Put all hand levers in the neutral or off position. Turn the main electrical switch off and secure. Lock-out and tag-out the electrical system. 2. Remove the gear-box mounting bolts. 3. Remove the auger-shaft end bolts and slide the gear box 4 - 6'' along the shafts, away from the hopper. 4. Remove the 19-mm nuts in order to remove the packing retaining ring. 5. Remove old gland packings (5 pieces [3 on older models]). 6. Install new gland packings (5 pieces [3 on older models]). 7. Complete the procedure by reinstalling the packing retaining ring, auger-shaft end bolts, and gear-box mounting bolts. Apply generous amounts of anti-seize to auger shaft and gear box.
KSP Training Manual
6-5
SECTION 6
SPECIAL MAINTENANCE
6.4
Material pump
6.4.1
Replacing piston heads
The material pistons (rams) must be replaced when they allow too much material to leak into the water box. It is normal to have 1 - 2” of sediment daily. If greater amounts accumulate, the piston head or ram needs replacing. • The replacement process involves working with the hydraulic differential cylinders and rams accessible through the water-box housing. Periodically during the process, the electric drive motor must be turned on—but only when the cylinders need to move. Before turning the motor on and engaging the hand valve on the material-pump control block, check that no tools are in the water box, and keep hands out of the box while the motor is on. The instructions will call for turning off and securing the motor whenever any work must be done in the water-box housing. This means turning off the motor by pushing the motor stop button on the electrical control panel and securing the controls from accidental starting by switching off the electrical-control main disconnect and locking and tagging it. Follow your facilities “lock-out” procedures for locking and tagging the equipment. Carefully follow the steps listed below to replace the material pistons. 1. Turn the motor on and adjust the hydraulic pump output to minimum. Warning! Danger of amputation! The next step is critical for your personal safety when replacing the material piston. You must put your hands in the waterbox during this procedure, and you are at great risk if the motor is running or if pressure exists in the hydraulic system or the material (sludge) side of the piston. The material-pump discharge must be isolated from the material pipeline (close materialpipeline ball valve and bleed discharge pressure). Material cylinders must be empty before proceeding to the next step. These safety steps must be performed several times during the replacement of the material piston. Do not skip them the first time, or any other time.
!
2. Stop the motor by pushing the motor stop button and emergency stop button. Turn off and lock the disconnect switch. Put the key in your pocket, and a do not operate tag over the switch. Do not continue with the procedure until this is done. 3. Poppet valve: Close one of the throttle valves on the hydraulic lines from the control block to the poppet valves. See Figure 3. Close the throttle by turning it clockwise. This will prevent poppet-valve motion during the maintenance procedure.
6-6
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Throttle valves
Material pump control block
Figure 3 Throttle valves on the material-pump control block
4. Drain the water from the water box. Remove the cover of the water box and the water chamber attached to the water box housing. This chamber is used on material pumps configured with one cylinder on top of the other—the “V” or vertical design. See Figure 4.
Figure 4 Water box on material pump
5. Turn motor on. With one hand of the jog button and the other hand of the forward-reverse button, move one piston towards the water box, almost to the end of its stroke.
KSP Training Manual
6-7
SECTION 6
SPECIAL MAINTENANCE
Figure 5 The material pistons can only be moved with both hands outside of the water box
6. The spacer coupling (dogbone) must be visible and accessible through the opening.
!
Stop the motor by pushing the motor stop button and emergency stop button. Turn off and lock the disconnect switch. Put the key in your pocket, and a do not operate tag over the switch. Do not continue with the procedure until this is done.
The material piston head or ram cannot be replaced until it is accessible in the water box. To make the material piston accessible, the spacer coupling must first be removed. Loosen and remove the bolts and nuts of the spacer coupling. See Figure 6 and Figure 7. 7. Use an open-end wrench on the shaft of the spacer to position and hold the shaft in place.
Figure 6 Loosening the nuts on the spacer coupling
6-8
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Leave this bolt loosely attached
Figure 7 Removing the bolts on the spacer coupling
8. Leave one bolt loosely attached to prevent the spacer coupling from falling on the hydraulic cylinder rod below it. 9. Turn the motor on and carefully move the hydraulic cylinder rod away from coupling approximately 1/2” (towards the hydraulic cylinder). This allows clearance for removal of spacer coupling. Remove the one remaining bolt. See Figure 8
Figure 8 Removing the last bolt just before removal of the spacer coupling
10.Stop the motor by pushing motor-stop button and the emergency-stop button. Turn off and lock the disconnect switch. Put the key in your pocket, and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.
!
11.Remove the spacer coupling. See Figure 9.
KSP Training Manual
6-9
SECTION 6
SPECIAL MAINTENANCE
Figure 9 Removal of spacer coupling after the hydraulic cylinder has been retracted
12.Turn the motor on and move the hydraulic cylinder rod slowly toward the material piston until contact is made. See Figure 10.
Figure 10 Extending the hydraulic cylinder to contact the material ram
13.Stop the motor by pushing the motor-stop button and emergency-stop button.
!
Turn off and lock the disconnect switch. Put the key in your pocket and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.s
14.Drop the supporting pin into the slot on the top of the hydraulic cylinder rod and the ram. It should fit in place snugly. This will allow you to draw the material piston back into the water box. See Figure 11.
6 - 10
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Figure 11 Material piston and hydraulic cylinder rod being connected
15.Turn the motor on and move the hydraulic cylinder rod and material piston toward the hydraulic cylinder. See Figure 12. Stop when the material piston is free and clear of the material cylinder and the mounting bolts are accessible.
Figure 12 Withdrawing the old material piston
16.Stop the motor by pushing the motor-stop button and emergency-stop button. Turn off and lock the disconnect switch. Put the key in your pocket and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.
!
17.Unbolt and remove the old piston (Figure 13). Clean and check all components.
KSP Training Manual
6 - 11
SECTION 6
SPECIAL MAINTENANCE
Figure 13 Removing the old material piston
Reassembly procedure 18.Apply a thick coat of grease to the new piston and the cylinder walls. 19.Attach the new material piston head to the end of the hydraulic cylinder rod 20.Turn motor on, move material piston slowly into the pumping cylinder. Stop while the bolts are still accessible. (See Figure 14.)
Figure 14 Moving the new material piston into the material cylinder
21.Stop the motor by pushing the motor-stop button and the emergency-stop button. Turn off and lock the disconnect switch. Put the key in your pocket and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.
!
22.Unbolt the piston rod from the material piston head.
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KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
23.Turn the motor on and move the hydraulic cylinder rod away from the material piston head far enough to insert the spacer coupling. See Figure 15.
Figure 15 Making room for replacing the spacer coupling
24.Stop the motor by pushing the motor-stop button and the emergency-stop button. Turn off and lock the disconnect switch. Put the key in your pocket and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.
!
Insert and bolt the spacer coupling to the end of the material piston head. See Figure 16. Use Loctite® cleaner and primer and Loctite® Blue (242) bolt sealant when assembling. Attach the spacer coupler to the material piston head first! Do not attach to the hydraulic cylinder first.
Figure 16 Re-attaching the spacer coupler
KSP Training Manual
6 - 13
SECTION 6
SPECIAL MAINTENANCE
Note: Schwing recommends replacing the bolts after the first re-use. 25.Turn motor on and move the rod slowly toward the piston until the couplings touch. 26.Stop the motor by pushing the motor-stop button and the emergency-stop button. Turn off and lock the disconnect switch. Put the key in your pocket and put a “do not operate” tag over the switch. Do not continue with the procedure until this is done.
!
27.Bolt the hydraulic cylinder rod to the spacer coupling. Use Loctite® cleaner and primer and Loctite® Blue bolt sealant when assembling. Repeat these steps in their entirety for the other cylinder. When the other cylinder has been replaced, reverse the initial steps in the process to put the material pump back into operation. • Fill and cover the water box. Refer to Step 4. • Re-open the throttle valve. Refer to Step 3. • Open the shut-off valve on the hydraulic line. Refer to Step 3. • Turn on the disconnect switch and reset the emergency-stop and motor stop buttons. Refer to Step 2. • Readjust the hydraulic output. Refer to Step 1. 6.4.2
Replacing poppet valves
1. Turn the motor off and secure the pump from accidental start by shutting off the electrical-control main disconnect. 2. Disconnect the material pump from the discharge pipeline or intake hopper, or both, depending on which poppet valves need service. 3. Move intake hopper or discharge line to create working room and provide access to poppet housings. 6.4.2.A
Replacing discharge-housing poppets
For additional information, including parts lists, part numbers, and drawings, refer to the pressure-valve cylinder assembly in the Material pump section of this manual. 4. Loosen discharge-housing mounting bolts (see Figure 17).
6 - 14
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Figure 17 Discharge housing mounting bolts
5. Swing open the discharge housing. See Figure 18.
Figure 18 Opening the discharge housing
6. Remove the poppet-retaining bolts. These bolts have been assembled using Loctite® and should be loosened carefully. See Figure 19.
KSP Training Manual
6 - 15
SECTION 6
SPECIAL MAINTENANCE
Figure 19 Removing the poppet-retaining bolts
7. Clean the bolts thoroughly and treat with Loctite® primer. Use Loctite® Grade AV Blue bolt sealant when reassembling. 8. Remove the poppet cone, shown in Figure 20. (The cone is referred to as a “disc” in the parts list).
Poppet cone (disc)
Figure 20 Removing the poppet cone
Remove worn valve seats for replacement. Figure 21 shows the valve seat being removed with a bar.
6 - 16
KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Valve seat
Figure 21 Removing the valve seat
Note the O-ring around the perimeter in Figure 22. Do not reuse it; a new O-ring must be used on the replacement valve seat.
O-ring for valve seat
Figure 22 Valve seat and O-ring
With retaining bolts and poppet cone (disc) removed, remove the pressure and valve discs from the piston rods. Use a long bar to tap the discs free from both piston rods. See Figure 23.
KSP Training Manual
6 - 17
SECTION 6
SPECIAL MAINTENANCE
Figure 23 Tapping free the pressure and valve discs
9. Pry apart the pressure and valve discs with a screwdriver. Replace the valve disc and both O-rings shown in Figure 24 and Figure 25. Grease the O-rings lightly on reassembly.
poppet cone (disc)
Valve disc Pressure disc
Figure 24 O-ring between the two halves of the valve disc
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KSP Training Manual
SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS
SECTION 6
Pressure disc O-ring
Figure 25 O-ring inside the pressure disc sealing the piston rod
10.Replace the O-ring between the discharge housing and the main suction housing and apply a coating of grease. See Figure 26.
Figure 26 O-ring between discharge housing and main suction housing.
11.Reassemble poppet valve and valve seats in the reverse order. 12.After the poppet valve has been reassembled, apply a silicone plug into the bolt heads (see Figure 27). This protects them from corrosion while the pump operates. The plug can be easily removed with a screwdriver before future maintenance procedures.
KSP Training Manual
6 - 19
SECTION 6
SPECIAL MAINTENANCE
Figure 27. Applying a silicone plug
6.4.2.B
Replacing suction-housing poppet
1. After removing the intermediate plate shown in Figure 28, follow the same procedure described above to replace the suction poppet valves. Refer to suction valve cylinder parts list and drawings in the Material pump section of this manual.
Suction poppets
Intermediate plate
Figure 28 Suction poppet valves
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KSP Training Manual
INSPECTIONS & CALIBRATIONS
SECTION 7
SECTION 7
INSPECTIONS & CALIBRATIONS
! WARNING! DANGER OF AMPUTATION! The next step is critical for your personal safety. You will have to put your hands in the waterbox during this procedure, and you are at great risk if the motor is running, or if there is pressure in the hydraulic system. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. 1. To visually inspect the alignment, put a trouble light in the waterbox, at the opening to the cylinder being aligned (See Figure 7.1). Be careful with fingers and hands in the waterbox. Put the trouble light in the waterbox, then remove your hand BEFORE proceeding to the next step.
Figure 7.1 - Inspecting Alignment
KSP Training Manual
7-1
SECTION 7
INSPECTIONS & CALIBRATIONS
2. Select the “forward” mode of the S1 valve, AT THE SLOWEST POSSIBLE SPEED! Look into the material cylinder from the valve end. The gap between the alignment tool and the cylinder wall should be seen as even rays of light (See Figure 7.2). When the cylinder gets fully extended, the alignment tool may drop a small amount or even barely touch the material cylinder wall
LIGHT RAYS
CYLINDER WALL
ALIGNMENT TOOL
39000143
Figure 7.2 - Alignment Inspection
! CAUTION! If the alignment tool should contact the cylinder wall at any time, return the pump to neutral immediately! Damage may occur to cylinder wall. 3. If, for example, the alignment tool contacts the cylinder on the lower side, loosen the mounting bolts at the waterbox a little bit, then tighten the LOWER bolts first (See Figure 7.3). This will lower the bottom of the material cylinder. When the alignment is close, tighten the top bolts and recheck the alignment. When the alignment is within specification, the alignment tool will travel the entire length of the cylinder without touching the cylinder wall. If the alignment tool is not always located exactly in the middle of the cylinder during the travel, but DOES NOT TOUCH, then realignment is not necessary. Minor misalignments are compensated for with the rubber ram. Repeat procedure for the other cylinder.
7-2
KSP Training Manual
INSPECTIONS & CALIBRATIONS
SECTION 7
NOTE: If proper alignment cannot be achieved otherwise, tightening torques may be exceeded by 10% over the charts specs. If further alignment problems persist, please contact the Schwing Bioset Service Department.
MOUNTING BOLTS 39000144
Figure 7.3 - Mounting Bolts 4. Grease new o-rings and insert in the valve housing. 5. Carefully slide the valve housing onto the material cylinders, and rest the valve housing on the machine frame. 6. Bolt the valve housing and material cylinder flanges together making sure that the alignment is being maintained. 7. Bolt the valve housing to the machine frame. 8. Check alignment with the tool once more, at slowest possible speed.
! CAUTION! IMPORTANT! If a squeaking sound indicates the alignment tool is dragging on the material cylinder, turn off the pump IMMEDIATELY! 9. If there is no dragging, you may proceed to step 11. If dragging does happen, repeat the visual checks. 10. Loosen the bolts on the material cylinders and valve housing, and at the machine frame, and repeat the alignment procedure. 11. Check the mounting and shimming of the pump kit and its mounting to the pump kit frame. 12. Tighten all bolts. 13. Complete the reassembly of valves, and install the rubber rams. 14. Reopen the ballcock or throttle valves NOTE: The poppet valve housing must be off to do this alignment procedure. Also when the rod gets fully extended, it may touch the cylinder walls.
KSP Training Manual
7-3
SECTION 7
7.1
INSPECTIONS & CALIBRATIONS
SLUDGE FLOW MEASURING SYSTEM (SFMS®) SET-UP
The following SFMS® procedure is to be performed concurrently with poppet maintenance or if erroneous meter readings are suspected. 7.1.1
Overview of the SFMS® and the Schwing Bioset Pump
The SFMS® system functions with the Schwing Bioset pump to provide accurate sludge flow readings. The Schwing Bioset pump operates with rams (material pistons) that reciprocate. For illustrative purposes, SFMS® operation of a single cylinder pump with a gravity-fed conical hopper as a feed system will be used as an example. Furthermore, a material pipeline pressure of 500 psi will be used for this discussion. The KSP model pumps have 2 rams, the EKSP models have only one ram. When the pump is in forward, and the ram is fully extended toward the poppet end of the material cylinder, the pump shuts the pressure poppet and opens the suction poppet (See Figure 7.4).
LED IS ON
SLUDGE
500 PSI
WATER BOX
39000145
Figure 7.4 - Suction Poppet Open
7-4
KSP Training Manual
INSPECTIONS & CALIBRATIONS
SECTION 7
As the ram retracts, the suction poppet allows sludge to flow into the cylinder. (See Figure 7.5).
LED IS ON
SLUDGE
WATER BOX
500 PSI
39000146
Figure 7.5 - Sludge Flow into Material Cylinder The suction poppet closes after the ram reaches the water box at the end of the suction stroke. Please note the pressure poppet is not opened at this point due to sludge line back pressure and the throttle check valve on the pressure poppet hydraulic line (See Figure 7.6).
LED IS ON
SLUDGE
500 PSI
WATER BOX
39000147
Figure 7.6 - Closed Suction Poppet
KSP Training Manual
7-5
SECTION 7
INSPECTIONS & CALIBRATIONS
The ram then begins the discharge stroke. The pressure poppet is temporarily held closed by a force equal to the material discharge line pressure (for example 500 psi) (See Figure 7.7).
LED IS ON
SLUDGE
500 PSI
39000148
WATER BOX
Figure 7.7 - Discharge Stroke The pressure poppet remains closed while the ram compresses the sludge cake in the material cylinder. When the material pressure in the cylinder exceeds the pipeline pressure, the pressure poppet opens (See Figure 7.8) .
LED IS OFF
500 PSI
SLUDGE
GREATER OR EQUAL TO 500 PSI
WATER BOX 39000149 39000149
Figure 7.8 - Ram Compressing Sludge
7-6
KSP Training Manual
INSPECTIONS & CALIBRATIONS
7.1.2
SECTION 7
SFMS® Calculations
Information is read, stored, and processed by a Programmable Logic Controller (PLC). This information includes the volumetric capacity of the material cylinder, the time base (time from stroke start to end), and the percentage of sludge vs. air. In order to send information to the PLC, a magnet on the end of the hydraulic piston and a proximity switch on the exterior of the discharge poppet are installed. The proximity switch senses the position of the pressure poppet throughout the pumping cycle and it relays this information to the PLC. The PLC correlates this positional information to the time base of the cycle and determines cylinder filling efficiency and sludge flow (See Figure 7.9).
PROXIMITY SWITCH (MAGNETIC PICK-UP)
MAGNET
39000150
Figure 7.9 - Magnet and Proximity Switch
KSP Training Manual
7-7
SECTION 7
7.1.3
INSPECTIONS & CALIBRATIONS
Throttle Valve Adjustment
While operating under normal conditions, the throttle check valves (located on the pressure poppet hydraulic cylinder, see below) need to be at least 1 turn open. The throttle valves, located on the control block, must be adjusted equally. 1. Adjust the throttle valves, located on the control block, until an audible click sound is heard at switchover. This sound is the poppets closing (not a banging sound). Tighten the hose clamps to lock the valves down (See Figure 7.10).
T hrottle V a lve s
Manually Operated Control Block
T hrottle V a lve s
Hydraulically Operated Control Block
39000277
39000151
Figure 7.10 - Throttle Valve Adjustment
7-8
KSP Training Manual
INSPECTIONS & CALIBRATIONS
7.1.4
SECTION 7
Throttle Check Valve Adjustment
The throttle check valves, located on the pressure poppet hydraulic cylinder, need to be adjusted after the throttle valves on the control block have been set. 1. Close the valves completely and then open (1/2 to 1 turn). This restricts the hydraulic oil from opening the pressure poppet prematurely at switchover. This allows the pressurized sludge to push the discharge poppet open (See Figure 7.11).
3
MARK
2 1 87654321
THROTTLE CHECK VALVES
39000152
Figure 7.11 - Throttle Check Valve Location
KSP Training Manual
7-9
SECTION 7
7.1.5
INSPECTIONS & CALIBRATIONS
Proximity Switch Set-up
The proximity switch has a limited range in which it can detect the magnet; it is important to locate the switch correctly to guarantee SFMS® accuracy. The LED on the proximity switch is illuminated only when the switch is relatively close to the magnet in the poppet cylinder. The switch’s function is to detect when the poppet is closed, therefore, the following adjustments can only be performed when the respective material cylinder is on the suction stroke and the poppet is closed. These adjustments should be performed during normal operating conditions (See Figure 7.12).
LED POPPET HOUSING
SET SCREWS
39000153
Figure 7.12 - Proximity Switch Set-up The first step is determining the location of the “breaking point.” The breaking point is the position nearest the poppet housing where the LED turns on while the poppet is closed. The final location of the switch or the “set point” will be determined by the location of the breaking point. 1. Loosen the set screws on the clamp. 2. Slowly move the proximity switch toward the poppet housing until the LED light goes off. Let the pump cycle a few times and verify that LED remains off.
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KSP Training Manual
INSPECTIONS & CALIBRATIONS
SECTION 7
3. Slide the switch slowly toward the end of the cylinder. As the proximity switch moves toward the end of the pressure poppet hydraulic cylinder, the LED light on the switch will illuminate. STOP. This is the “breaking point”. (See Figure 7.13).
LED OFF
39000154
Magnet
Figure 7.13 - Sliding Proximity Switch 4. Wait until the pump cycles once; mark where the switch is (See Figure 7.14).
MARK THIS LOCATION
LED ON
STOP
MAGNET
39000155
Figure 7.14 - Marking Switch Location for Breaking Point 5. Move the switch toward the poppet housing and verify that the LED goes off. Move switch back to the “breaking point”.
KSP Training Manual
7 - 11
SECTION 7
INSPECTIONS & CALIBRATIONS
This procedure should be repeated for a few consecutive strokes, always noting the location closest to the poppet housing. This determines the farthest breaking point the magnet will move during its cycle. Locate the switch at the furthest breaking point. Slide the switch 3/16-1/4” farther away from the poppet housing and lock it down with set screws. This is the “setpoint”. NOTE: This procedure must be repeated for the second pressure poppet on a dual cylinder pump (KSP). 7.1.6
SFMS® Functional Test #1 -KSP
To test KSP (dual material pistons), check the distance of the proximity switches from the poppet housing. They should be located within 1/8” of each other. When the unit shifts, both LED’s will simultaneously illuminate, followed by only one. During the next shift, the opposite LED should remain lit. If the unit is equipped with a filling efficiency meter, a simple test is to: 1. Note the filling efficiency 2. Put the screw/agitator in reverse. 3. After several strokes, the filling efficiency should drop. 4. Put the unit back into forward. Within several strokes, the filling efficiency should rise to near its previous value. The unit is now ready to operate, measure output, and be calibrated. 7.1.7
SFMS® Functional Test #2 - EKSP
When a EKSP pump is operating correctly and is in the process of pumping material you can watch the LED located on the discharge poppet hydraulic cylinder and note its operation. The LED should be illuminated as the material piston is in its suction stroke (material piston moving towards the water box) and should at least stay illuminated for a split second or more as the pump is in its discharge stroke.
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KSP Training Manual
INSPECTIONS & CALIBRATIONS
7.1.8
SECTION 7
SFMS® Calibration
The following need only be completed if calibration is a contract requirement. The following test must only be performed after the SFMS® is checked and adjusted. To properly calibrate the SFMS®, the following equipment and materials needed. 1. A large container, preferably a dump truck, is needed to pump the material into. This container must be weighed before it is filled, after it is filled, and again after it is emptied to obtain accurate weights of the material to be pumped.. 2. A certified scale must be available to weigh the material that is pumped. 3. We will also need the accurate weight of 1 gallon of the sludge to be pumped. This weight needs to come from a reputable source such as a laboratory. 4. The pump must be in good mechanical operating condition, The valve seats and disks need to be in very good condition, Throttle valves and throttle check valves must be in good working order also. Excessively worn rams, valve seats and disks will have an adverse effect on the systems accuracy, Prior to the test the pump should be opened up by the service technician and the seats and disks should be inspected. If they are worn they will have to be replaced, so please make sure you have all the required spare parts available, in the event they are required. Schwing Bioset SFMS measures the volumetric displacement from each material cylinder by determining filling efficiency. The PLC located in the main control panel uses a material density input to qualify the material flow on a mass basis in pounds per minute or pounds per hour. The PLC is also configured to accumulate flow. In order to confirm the accuracy of our system we need an established density in pounds per cubic foot. This variable MUST be supplied prior to any testing and will serve as the basis of the PLC’s flow calculations. A truck must be positioned below the discharge from the cake line. Run the pump at approximately 6-7 strokes per minute for a period of not less that 1.0-1.5 hours; this equates to approximately 23,000 pounds of sludge cake. After we have pumped for the 1.0 - 1.5 hour period we will calculate the mass flow determined by our SFMS by multiplying the total volume displaced by the density input supplied by plant staff. This value will be compared to the tare weight of the loaded truck. The amount of material weighed within the truck will then be compared to the flow calculated through Schwing Bioset’s PLC based SFMS. This first run is in essence Trial or Iteration No. 1. In the event the SFMS meets the +/- 5 percent accuracy, we will conclude that all pump calibration and throttle valve settings are correct and proceed with testing pump number at 2 at the same speed and density settings. In the event the system shows a level of inaccuracy greater than +- 5 percent, we will change the theoretical gallon per stroke (GPS) set point in the PLC program. The theoretical GPS is factory set on a KSP 45VL. After the set point is changed, the above referenced testing procedure shall be repeated. Upon certifying the accuracy on the first pump, proceed with the second.
KSP Training Manual
7 - 13
SECTION 7
INSPECTIONS & CALIBRATIONS
Testing and Calibration of SFMS®
7.1.9
Project/Owner: ________________________________
Date: _________________
Contract Number: _______________________________________________________ Location of Pump: ______________________________________________________ Pump Model Number: ___________________________________________________ Serial Number of Pump: __________________________________________________ PLC Calibration Set Point for Gallons/Per/Stroke: ______________________________ TEST RESULTS 1
TEST NUMBER
2
3
4
1.
Length Test Time
____
_____
_____
____
2.
Flow onto (Wt.) Belt Press
____
_____
_____
____
3.
Strokes Per Min.
____
_____
_____
____
4.
% Of Fill Material Cyl.
____
_____
_____
____
5.
Accumulative (Gal.) End of Test (PLC)
____
_____
_____
____
6.
Accumulative (Gal.) Start of Test (PLC)
____
_____
_____
____
7.
Volume Pumped (Gal.) (6-5)
____
_____
_____
____
8.
Calculated (Lab) Wt./Gal
____
_____
_____
____
9.
Total Cal. Wt Pumped (7 X 8)
____
_____
_____
____
10.
Measured Wt. Actual
____
_____
_____
____
11.
% Accuracy
____
_____
_____
____
Tester
Witness
Name:
___________________
_____________________
Signature:
___________________
_____________________
7 - 14
KSP Training Manual
KSP COMPONENTS
SECTION 8 8.1
SECTION 8
KSP COMPONENTS
SCREW FEEDER COMPONENTS
There are 3 models of screw feeds: • SD-250 • SD-350 • SD-500 The model designation's are decided by the diameter of the auger's, in millimeters. (250 m/m, 350 m/m and 500 m/m.) The screw feed size is designed for each specific job. The screw feed opening's and the length of the screw feeds are determined by the job specification's. The purpose of the screw feeder is to feed the material to be pumped into the sludge pump material cylinders. Because the sludge's are of a heavy viscosity, they won't freely flow into the sludge pump. The screw feed is constructed with two interlocking screw augers, that are mounted to a reduction gear box, which in turn is driven by a fixed hydraulic motor. The hydraulic motor is driven by a variable displacement hydraulic pump, located on the power pack. By utilizing a variable displacement hydraulic pump we have the capability of changing the rpm of the screw feed augers to the desired rpm. Depending on the electrical design of the project specification's, some systems are designed so that the speed of the screw feed is automatically matched to the speed of the pump. The screw feed forces the material into the pump under a positive pressure. The proper speed of the screw feeder can be observed (providing you can visually see the augers) by watching for the roll over of the sludge on the discharge end of the hopper opening. What should be observed is a slight roll over of the sludge. If you see a very active roll over of sludge you are running the screw feed to fast. What is occurring is that there is a lot of slippage occurring in the discharge, positive area of the screw feed. Depending on the amount of abrasives, grit, etc., you can be unnecessarily causing wear of the screw feed component.
KSP Training Manual
8-1
SECTION 8
KSP COMPONENTS
The screw feeder is controlled by a directional control valve mounted on the power pack. The control valve determines whether or not the screw feed is operating in forward or reverse. Forward can be determined when the top of the augers are rotating towards the center of the screw feed and down (See Figure 8.1).
250 350 500
SCREW FEEDER AUGERS (GEAR BOX END)
39000156
Figure 8.1 - Screw Feeder Augers Mounted in the base plate of the screw feed control valve is the relief valve, which limits the maximum hydraulic pressure in the screw feed circuits. By the electrical design for the specific projects, some screw feed circuits incorporate an electrical pressure switch which will shut the power pack down with an alarm condition for high hydraulic pressure. 8.1.1
Screw Feeder Gear Box
There are 4 different gear boxes used on the SD-250 screw feeders. 3 of the boxes look very similar (Dorstener part #324053, FZN part #500006 and Segler part #309169). The Dorstener gear box (part #324053) is identified by a tag attached to it saying "Rochling". By looking at the face of the gear box you can identify this gear box by the location of some bore plugs or as illustrated in Figure 8.2, Page 8 - 3.
8-2
KSP Training Manual
KSP COMPONENTS
SECTION 8
BORE PLUGS
39000157
Figure 8.2 - Screw Feeder Gear Box (Dorstener) The FZN gear box (part #500006) can also be identified by the tag attached to it. By looking at the face of the gear box it has bore plugs in the same location as the Dorstener. An additional difference is the seal area for the output shafts of the gear box. The seal is mounted in a seal carrier, rather than being mounted directly in the gear housing. This difference is hard to see until the gearbox is removed from the screw feeder assembly. The Segler gear box (part #309169) can be identified by looking at the face of the gear box, there are no bore plugs in the face of this gear box as illustrated in Figure 8.2. The Hub City gear box (part #328015) is easily identified by the tag attached to it. The spur gear box, where the screw auger's are mounted, has an external mounted gear reducer attached to it. The SD-350 utilizes only one gear box which is built by Dorstener. The HD-350 and 500 are both manufactured by Stiebel.
SD 350
SD 350HD
SD 500HD 39000257
When ordering parts for the screw feeder gear boxes it is important that you are using the parts book for that specific serial #.
KSP Training Manual
8-3
8-4
GREATER THAN 35 INCHES (900 MM)
ON THIS END FOR HOPPER LENGTHS
HAVE OUTBOARD BEARING MOUNTED
SHAFTS OF SCREW FEEDER
CLEAN-OUT COVER
DISCHARGE END
CONTROL HOUSING (POPPET VALVES)
INTAKE OPENING
SCREW FEEDER
WATER BOX
HYDRAULIC CYLINDER
SUCTION POPPET
S3
S1
BOX
GEAR
MOTOR
HYDRAULIC
DOUBLE SCREWS
S2
LEVER OPERATED VALVE
WITH FORWARD/REVERSE
CONTROL BLOCK
SECTION 8 KSP COMPONENTS
39000158
Figure 8.3 - Overhead View of Sludge Pump Parallel to Screw Feeder
KSP Training Manual
KSP Training Manual GEAR BOX
CLEAN-OUT COVER
HYDRAULIC CYLINDER
PRESSURE POPPET
DISCHARGE END
HYDRAULIC CYLINDER
SUCTION POPPET
DIFFERENTIAL CYLINDERS
HYDRAULIC MOTOR
CONVEYOR INTAKE OPENING
DOUBLE SCREWS
FOR OUT BOARD BEARINGS
GREASE FITTINGS
PUMPING CYLINDERS
WATER BOX
KSP COMPONENTS SECTION 8
39000159
Figure 8.4 - Overhead View of Sludge Pump Perpendictular to Screw Feeder
8-5
SECTION 8
KSP COMPONENTS
WHEN THE TENSION RING IS CLOSE TO THE STUFFING BOX, SEAL RING REPLACEMENT IS REQUIRED
ADJUSTING NUT KEYWAY FOR GEAR BOX
PACKING
WHEN REPLACING PACKING, ALL PACKING RINGS SHOULD BE REPLACED AT THE SAME TIME WEAR SLEEVE STUFFING BOX
TENSION RING
SD 250 ADJUSTING NUT PACKING
WEAR SLEEVE STUFFING BOX
TENSION RING
SD 350/500 NOTE: SOME SLEEVES ARE REMOVABLE, OTHERS ARE WELDED ON. IF THE SLEEVE IS WELDED ON, AND YOU ARE REPLACING IT, PLEASE CONTACT THE FACTORY FOR PROCEDURE.
WHEN INSTALLING THE GEAR BOX BACK ONTO THE SHAFT, USE SUFFICIENT AMOUNTS OF NEVER SEIZE TO CONNECT BOTH SHAFTS AND THE BORES OF THE GEAR BOX.
39000140 39000140
Figure 8.5 - Typical Screw Auger Shaft Stuffing Box Assembly 8-6
KSP Training Manual
KSP Training Manual
HARDENED WEAR SLEEVE
BUSHING
INSTALL THE LOCKING SCREW WITH A THREAD LOCK
LOCK SCREW
SPACER
SPACER SEAL
LOCK SCREW
SCREW SHAFT
THE SPACER AND ITS TWO SEALS MUST BE INSTALLED IN THE CORRECT DIRECTION
WHEN INSTALLING THE LOCKING SCREW, USE AN APPROPRIATE SIZE DRILL BIT AND DRILL INTO THE BUSHING SO THE LOCKING SCREW WILL ENGAGE INTO THE BUSHING. WHEN INSTALLING THE LOCKING SCREW USE NEVER SEIZE.
SEAL
WHEN INSTALLING THE LOCKING SCREW, POSITION THE SLEEVE ON THE SHAFT AND USING THE APPROPRIATE SIZE OF PILOT DRILL, DRILL INTO THE SHAFT SO THE LOCKING SCREW ENGAGES INTO THE SHAFT.
KSP COMPONENTS SECTION 8
39000139
39000139
Figure 8.6 - Typical Outboard Bearing Assembly
8-7
SECTION 8
8.2
KSP COMPONENTS
SCREW FEEDER SHAFT TIMING
BEFORE THE GEAR BOX IS REMOVED FROM THE SCREW FEEDER ASSEMBLY, MAKE SURE THAT BOTH KEYWAYS ARE IN THE THREE O’CLOCK POSITION. BEFORE INSTALLING THE GEAR BOX, USE SUFFICIENT AMOUNTS OF NEVER SIEZE IN THE SHAFTBORES NOTE: SD 250 GEAR BOX TIMING IS 9 O’CLOCK AND 3 O’CLOCK SOME GEAR BOXES WERE TIMED AT 3 AND 3 O’CLOCK AND OTHERS WERE TIMED AT 9 O’CLOCK AND 3 O’CLOCK, SO MAKE SURE YOU KNOW THE CORRECT TIMING BEFORE DISASSEMBLY. 39000160
Figure 8.7 - Front View Screw Feeder Gear Box - SD 350 8-8
KSP Training Manual
KSP COMPONENTS
SECTION 8
KSP Training Manual
8-9
SECTION 8
KSP COMPONENTS
39 38
1
36 37
2
35
3
6
4
9 5
34 7
6
33
7
32
8
31
9
30
10
29
11
11
12
28
13
27
14 15 16 17
15
18 19 20
20
19 26
21
15
15 20
19
25
24
23
20
22
30324053
Figure 8.8 - Gear Box, Dorstener Double Screw Feeder - SD 250 8 - 10
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Dorstener Double Screw Feeder - SD250 Part #30324053 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
1 1 1 1 1 2 2 1 2 1 2 1 1 1 4 1 1 1 3 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Description ...................................................................................................................................PINION ....................................................................................................................... SPUR-WHEEL ........................................................................................................................................KEY ............................................................................... TAPERED ROLLER BEARING DIN 720 ...................................................................................................................... SIGHT GAUGE ......................................................................................... SAFETY RING, 80 X 2.5 DIN 472 ........................................................................................... AXIAL BALL BEARING DIN 711 .............................................................................................................................. BUSHING ....................................................................................................................................... CAP ......................................................................................................................................RING ............................................................................... TAPERED ROLLER BEARING DIN 720 ......................................................................................................................PINION SHAFT ....................................................................................................................................... CAP ....................................................................................................................... SPUR WHEEL ......................................................................................................................................SEAL ................................................................................................................................... SHAFT ........................................................................................................................................KEY ............................................................................... TAPERED ROLLER BEARING DIN 720 ................................................................................................................................ SPACER ................................................................................... GROOVED BALL BEARING DIN 625 ................................................................................................................................... SHAFT ............................................................................... TAPERED ROLLER BEARING DIN 710 ........................................................................................................................................KEY ....................................................................................................................... SPUR-WHEEL ......................................................................................................................... DRAIN PLUG .............................................................................................................................. BUSHING ....................................................................................................................... SPUR-WHEEL ....................................................................................................................... SPUR WHEEL ........................................................................................................................................KEY ............................................................................... TAPERED ROLLER BEARING DIN 720 ................................................................................................................................... SHAFT ....................................................................................................................... SPUR WHEEL ....................................................................................................................... SPUR WHEEL ......................................................................................................................PINION SHAFT ...................................................................................................................................FILLER ......................................................................................................... HEX HD. CAP SCREW .......................................................................................... SAFETY RING, 110 X 4 DIN 472 ...................................................................................................................................... DISC ........................................................................................................................... LIFTING EY
KSP Training Manual
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SECTION 8
KSP COMPONENTS
54 53 51 52 30 49 50 8 9 10 7 12 31 32 48 47 46 45 44 43 42 41 33 38 40 39 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
23 36
24
35
21
38
25
37
23
23 36
20
35 34
33
31 32
24
21 29 30
28
27
26
24
30500006
Figure 8.9 - Gear Box, FZN Double Screw Feeder - SD 250 8 - 12
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, FZN Double Screw Feeder - SD 250 30500006 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 1 1 1 1 1 2 2 AR 2 1 2 1 1 1 AR 1 1 1 2 4 1 4 8 1 1 1 1 1 2 17 17 2 1 2 2 1 AR 1 1 1 1 1 2 2 1
Description ....................................................................................................................... SPUR WHEEL ............................................................................................................................ GEAR, T72 .......................................................................................................................... PINION, T17 .............................................................................................. KEY, B 12 X 8 X 20, DIN 6885 ................................................................................. TAPERED ROLLER BEARING, 32008 ................................................................................................................. OIL LEVEL, R 3/4" ................................................................................. TAPERED ROLLER BEARING, 30208 ......................................................................................... SAFETY RING, 80 X 2.5 DIN 472 ...................................................................................................................... SHIM RING, 80 ....................................................................................................................................... CAP .............................................................................................................................. BUSHING ..................................................................................................................... O-RING, 70 X 3 ............................................................................................................................ GEAR, T67 ................................................................................................................... O-RING, 100 X 3 .......................................................................................... SAFETY RING, 110 X 4 DIN 472 .................................................................................................................... SHIM RING, 110 ....................................................................................................................................... CAP ................................................................................. TAPERED ROLLER BEARING, 30212 ............................................................................................................................ GEAR, T34 .......................................................................... AXIAL GROOVED BALL BEARING, 51120 ...................................................................................................................... SPACER DISC .......................................................................................... KEY, B 28 X 16 X 140, DIN 6885 ......................................................................... RADIAL SEALING RING, A 100 X 130 X 12 ............................................................................... DEEP GROOVE BALL BEARING, 6020 .............................................................................................................................. BUSHING .............................................................................................................................. HOUSING ............................................................................................ KEY, B 28 X 16 X 70, DIN 6885 ............................................................................................ GEAR, T27, LEFT INTERLOCK .................................................................................................. PLUG, M 22 X 1.5, DIN 910 ............................................................................. SEALING RING DIN 7603, A 22 X 27 CU ............................................................................................ SCREW DIN 912 M 10 X 70 8.8 .................................................................................. SPRING WASHER DIN 7980, 10 FST ......................................................................................... SAFETY RING, 150 X 4, DIN 472 ................................................................................................................ HOUSING COVER ................................................................................................................... O-RING, 140 X 2 ..............................................................................................................................RING, 130 ...............................................................................................................SPACER BUSHING .................................................................................................................... SHIM RING, 150 ..........................................................................................GEAR, T27, RIGHT INTERLOCK .............................................................................................................................. BUSHING ............................................................................................................................ GEAR, T38 ................................................................................. TAPERED ROLLER BEARING, 32012 .......................................................................................................................... PINION, T18 ............................................................................................ KEY, B 18 X 11 X 40, DIN 6885 ..................................................................................... PARALLEL PIN, 12 M 6 X 55, DIN 7 ................................................................................. TAPERED ROLLER BEARING, 32208
KSP Training Manual
8 - 13
SECTION 8
KSP COMPONENTS
54 53 51 52 30 49 50 8 9 10 7 12 31 32 48 47 46 45 44 43 42 41 33 38 40 39 24
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
23 36
24
35
21
38
25
37
23
23 36
20
35 34
33
31 32
24
21 29 30
28
27
26
24
30500006
Figure 8.9 - Gear Box, FZN Double Screw Feeder - SD 250 (Cont.) 8 - 14
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, FZN Double Screw Feeder - SD 250 (Cont.) 30500006 Pos
Qty.
47 48 49 50 51 52 53 54
1 1 1 1 1 1 1 1
Description .................................................................................................................................. PINION ............................................................................................................................ GEAR, T18 ....................................................................................................................... VENT SCREW .............................................................................................................. EXTENSION PIECE .......................................................................................... SCREW DIN 912, M 12 X 35, 8.8 .................................................................................. SPRING WASHER DIN 7980, 12 FST ...................................................................................................................................... DISC ................................................................................................ RING BOLT, AM 16, DIN 580
KSP Training Manual
8 - 15
SECTION 8
KSP COMPONENTS
32 1
31 6
2 30
3 4
29
5
28 6
27 26 25
7
24
8
23
9
11
10 11 12 13
22
14
21 15
15 11
16 12 11
20 19
18
17 30309169
Figure 8.10 - Gear Box, Segler DoubleScrew Feeder - SD 250
8 - 16
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Segler DoubleScrew Feeder - SD 250 Part #30309169 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
1 1 1 1 1 2 1 1 1 1 8 2 1 1 4 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1
Description ..........................................................................................................................SPUR GEAR ...............................................................................................................................BEARING ........................................................................................................................................KEY ......................................................................................................................PINION SHAFT ................................................................................................................OIL PLUG W/SEAL ...............................................................................................................................BEARING .............................................................................................................................. BUSHING ....................................................................................................................... SPUR WHEEL ...............................................................................................................................BEARING ......................................................................................................................PINION SHAFT ...............................................................................................................................BEARING ...............................................................................................................................BEARING ................................................................................................................................... SHAFT ........................................................................................................................................KEY ............................................................................... RADIAL SEAL RING, A 100 X 130 X 12 ................................................................................................................................... SHAFT .............................................................................................................................. HOUSING ....................................................................................................................... SPUR-WHEEL ........................................................................................................................................KEY .............................................................................................................................. BUSHING ....................................................................................................................... SUPR-WHEEL ....................................................................................................................... SPUR-WHEEL .............................................................................................................................. HOUSING ....................................................................................................................... SPUR-WHEEL ........................................................................................................................................KEY ...............................................................................................................................BEARING ...............................................................................................................................BEARING ................................................................................................................................... SHAFT ....................................................................................................................... SPUR-WHEEL ......................................................................................................................................RING ....................................................................................................................... SPUR-WHEEL ................................................................................................................................... VALVE ................................................................................................................................. SCREW
KSP Training Manual
8 - 17
SECTION 8
KSP COMPONENTS
39
43
58
36
56,57
47
4
27
20
20
44
35
35
24
3
8
23
44
51
52
38,40
19
7
50
5
32
6
9
34
22
37
42
10
12
46
17
33
31
18
48
30
13
11
45
48
30
21
48
41
14
21
17
17
31
30
30
48
45
49 54
15 2
38,40
18
25, 53
1
16
39000247
Figure 8.11 - Gear Box, Stiebel DoubleScrew Feeder - SD 350
8 - 18
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Stiebel DoubleScrew Feeder - SD 350 Part #10050833 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 AR AR AR 2 1 1 1 1 1 1 1 1 8 2 1 1 1 2 1 2 20 1 20 2 1 2 1 1 1
Description .............................................................................................................................. HOUSING ................................................................................................................ HOUSING COVER .............................................................................................................. PINION GEAR Z=17 ........................................................................................................................... GEAR Z=72 .............................................................................................................. PINION GEAR Z=24 ...............................................................................................................................GEAR=18 ...............................................................................................................................GEAR=67 ................................................................................................................................ SPACER .............................................................................................................. PINION GEAR Z=20 ........................................................................................................................... GEAR Z=38 ............................................................................................................... OUTPUT SHAFT “I” ........................................................................................................................... GEAR Z=39 ................................................................................................................ THRUST SPACER .............................................................................................................. OUTPUT SHAFT “II” ........................................................................................................................... GEAR Z=39 ................................................................................................................................ SPACER ............................................................................................................... THRUST WASHER ......................................................................................... SHIM 150 AS NEEDED AT ASSY ......................................................................................... SHIM 110 AS NEEDED AT ASSY ........................................................................................... SHIM 80 AS NEEDED AT ASSY ................................................................................................................... SEALRETAINER .......................................................................................................... BEARING COVER 110 ............................................................................................................ BEARING COVER 80 .......................................................................................................... BEARING COVER 100 ....................................................................................................... PLUG 2 22X1.5 DIN 910 ......................................................................................................... VENTILATION SCREW ..........................................................................................................LEVEL SIGHT GUAGE .......................................................................................................................... EXTENSION ........................................................................................................................ NAME PLATE ............................................................................................................BALL BEARING 6020 .................................................................................................... THRUST BEARING 51120 .................................................................................................... ROLLER BEARING 30212 .................................................................................................... ROLLER BEARING 30212 .................................................................................................... ROLLER BEARING 32208 .................................................................................................... ROLLER BEARING 32208 .................................................................................................... ROLLER BEARING 32208 ................................................................................................ DOWEL PIN 12M6X55 DIN 7 ............................................................................. SOC HD CAO SCREW M10X85 DIN 912 ............................................................................................... LIFTING EYE AM 16 DIN 580 .......................................................................................................... WASHER 10 DIN 7980 ................................................................................................. SNAP RING 150X4 DIN 472 ................................................................................................. SNAP RING 150X4 DIN 472 ................................................................................................ SNAP RING 80X2.5 DIN 472 .................................................................................................. KEY B 28X16X70 DIN 6885 .................................................................................................. KEY B 18X16X70 DIN 6885 .................................................................................................... KEY B 12X8X20 DIN 6885
KSP Training Manual
8 - 19
SECTION 8
KSP COMPONENTS
39
43
58
36
56,57
47
4
27
20
20
44
35
35
24
3
8
23
44
51
52
38,40
19
7
50
5
32
6
9
34
22
37
42
10
12
46
17
33
31
18
48
30
13
11
45
48
30
21
48
41
14
21
17
17
31
30
30
48
45
49 54
15 2
38,40
18
25, 53
1
16 39000247
Figure 8.11 - Gear Box, Stiebel DoubleScrew Feeder - SD 350
8 - 20
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Stiebel DoubleScrew Feeder - SD 350 HD Part #10050833 Pos
Qty.
47 48 49 50 51 52 53 54 55 56 57 58
4 2 1 1 1 2 2 4 1 1 1 1
Description ......................................................................................................................................SEAL ...................................................................................................................... O-RING 140X2 ...................................................................................................................... O-RING 100X3 ........................................................................................................................ O-RING 70X3 ........................................................................................................................ O-RING 90X3 ............................................................................................................................... WASHER ............................................................................................ SET SCREW M 5 X 16 DIN 553 ...............................................................................................................RIVET 2X6 DIN 123 ............................................................................................ SCREW DIN 912, M 12X35, 8.8 .................................................................................. SPRING WASHER DIN 7980, 12 FST ...................................................................................................................................... DISC ..........................................................................................................................SPUR GEAR
KSP Training Manual
8 - 21
SECTION 8
KSP COMPONENTS
27
35,36
11
12
46 50,52
48,49 47
6 13
2
38,39,40
43,44,45 1
35,36 28,29,30,31 37,38 24
14
32
34
21 4 15 10 25 22 3 9 26
5 18 8
17 19
20 16 23 10182269
Figure 8.12 - Gear Box, Stiebel DoubleScrew Feeder - SD 350/500 HD
8 - 22
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Stiebel DoubleScrew Feeder - SD 350/500 HD Part #10182269 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46
1 2 1 1 1 2 1 1 1 1 1 1 2 2 2 AR 2 1 2 1 1 1 1 4 1 4 1 1 1 1 1 2 4 16 24 24 34 18 18 1 3 4 4 4 1
Description .......................................................................................................... TORQUE STABILIZER ......................................................................................................... SPACER RING SD 500 ......................................................................................................... SPACER RING SD 500 ......................................................................................................... SPACER RING SD 500 ......................................................................................................... SPACER RING SD 500 ............................................................................................................. COUPLING SDL 500 .............................................................................................................. BOLT SD 500 X 197 .............................................................................................. GEARBOX HOUSING SD 500 ................................................................................................DRIVE SHAFT SD 500 X 895 ......................................................................................................DRIVE SHAFT 500 X 490 ........................................................................................................SUPPORTING FLANGE .................................................................................................. GEARBOX COVER SD 500 ..................................................................................................................... COVER SD 500 ......................................................................................SPUR WHEEL SD 500 M=10, Z=36 ......................................................................................RETAINING RING DIN 471 120 X 4 ........................................................................................ROUND CORD 5 70 SHORE NBR .................................................RADIAL PACKING RING AS 120X150 X 12 DIN 3750 - NB ......................................................................................................................... SHAFT SEAL ........................................................................................ SELF-ALIGNING BALL BEARING .................................................................. DEEP GROOVE BALL BEARING DIN 625 6026 .................................................................. DEEP GROOVE BALL BEARING DIN 625 6022 ............................................................................. AXIAL GROOVED BALL BEARING 5112 ........................................................................... AXIAL GROOVED BALL BEARING 51126 .......................................................................... FEATHER KEY DIN 6885 A 28 X 16 X 110 .......................................................................... FEATHER KEY DIN 6885 A 28 X 16 X 150 .................................................................................... ADJUSTING SPRING 32 X 18 X 300 ...................................................................................................VENTILATION FILTER 1/2” ................................................................................ DOUBLE NIPPLE DIN 2982 1/2” X 100 ........................................................................................................ SOCKET DIN EN 10242 ..............................................................................................SCREW PLUG DIN 908 R 1/2” .............................................................................. SEALING RING DIN 7603 A 21 X 26 CU .....................................................................................................................OIL LEVEL EYE ............................................................................................................................................... ............................................................................. PARALLEL PIN DIN 7 10M 6 X 45 ST 50 ................................................................ HEXAGON BOLT DIN 933 M 10 X 16 - 8.8 - A2C ....................................................................................SCREW RETAINER SKM 10 DT 320 .....................................................CHEESE HEAD SCREW DIN 912 M 16 X 80 - 8.8 - A2C ....................................................................................SCREW RETAINER SKM 16 DT 320 ................................................................ HEXAGON BOLT DIN 931 M 16 X 65 - 8.8 - A2C ................................................................................ HEXAGON NUT DIN 985 M 16 8 - A2C ................................................................................................................. HOLDING SHEET .............................................................. HEXAGON BOLT DIN 931 M 36 X 180 - 8.8 - A2C .............................................................. HEXAGON BOLT DIN 931 M 36 X 180 - 8.8 - A3C ............................................................................................................. NUT DIN 934 M 36 8 ...................................................................................... LOCK WASHER DIN 127 B 36 FST ..................................................................................... GEARBOX 5623 IEC 225, i=54.11:1
KSP Training Manual
8 - 23
SECTION 8
KSP COMPONENTS
27
35,36
11
12
46 50,52
48,49 47
6 13
2
38,39,40
43,44,45 1
35,36 28,29,30,31 37,38 24
14
32
34
21 4 15 10 25 22 3 9 26
5 18 8
17 19
20 16 23
10182269
Figure 8.12 - Gear Box, Stiebel DoubleScrew Feeder - SD 350/500 HD
8 - 24
KSP Training Manual
KSP COMPONENTS
SECTION 8
Gear Box, Stiebel DoubleScrew Feeder - SD 350/500 HD Part #10182269 Pos
Qty.
47 48 49 50 51 52 53 54 55
1 4 4 1 1 4 4 4 4
Description ......................................................................................... FIXED DISPLACEMENT MOTOR ......................................................CHEESEHEAD SCREW DIN 912 M 12 X 40 - 8.8 - A2C .................................................................................... SCREW RETAINER SKZ 12 DT 320 .................................................................................................. MOTOR ADAPTER SD 500 .............................................................................................................. ELASTIC BUSHING ................................................................ HEXAGON BOLT DIN 933 M 16 X 40 - 8.8 - A2C ................................................................ HEXAGON BOLT DIN 933 M 12 X 40 - 8.8 - A2C ............................................................................................................. NUT DIN 985 M 20 8 ....................................................................................SCREW RETAINER SKM 20 DT 320
KSP Training Manual
8 - 25
SECTION 8
KSP COMPONENTS
UNIT TO BE FILLED BY SCHWING BIOSET WITH MOBILUBE H.D 80W-90 (BOTH RESERVOIRS)
SPUR GEAR LEVEL
GEAR DRIVE WEIGHT, APPROXIMATELY 810 LBS.
DRAIN
ADJUST ALL BEARINGS TO .000 - .002 END CLEARANCE INSTALL MOLYKOTE G-M PASTE (P/N #30336101) ON I.D AND O.D. OF BUSHING
FILL AND VENT
GEAR REDUCTION LEVEL
DRAIN
APPLY GASKET ELIMINATOR ACCESS HOLES OVER BOTH SHAFTS
39000161
Figure 8.13 - Hub City Gear Box 8 - 26
KSP Training Manual
KSP COMPONENTS
8.3
SECTION 8
SLUDGE PUMP COMPONENTS
39000162
Figure 8.14 - Material Cylinder Components
PISTON SEALING RINGS
O-RING (PISTON TO ROD SEAL)
PISTON (BRASS)
CYLINDER BARRELL
CYLINDER ROD
ROD GLAND SEAL AND BACK-UP RING
ROD GLAND
SHIMS
ROD PACKING
WIPER SEAL 39000163
Figure 8.15 - Hydraulic Cylinder Components KSP Training Manual
8 - 27
SECTION 8
KSP COMPONENTS
13
22 16 17 14
23 21
1 8 6 31 3 34 36, 37 25, 35
13 24, 25 14 9
6 2
10
30
15
25 26, 35
38, 24, 25 4 5
39, 40
13 7 12
17 20 19 18
1
33 29 28 11 13
5 10073757
Figure 8.16 - Control Block “The Brain” Single Circuit - Manual 8 - 28
KSP Training Manual
KSP COMPONENTS
SECTION 8
Control Block “The Brain” Single Circuit - Manual Part #10073757 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
1 1 1 1 1 2 1 3 1 1 2 2 14 4 1 3 3 2 2 2 4 8 8 16 24 4 1 16 16 2 4 1 2 1 1 1 1 1 2 2
Description ........................................................................................... CONTROL-BLOCK END PLATE ......................................................................................................... CONTROL-BLOCK S-2 ......................................................................................................... CONTROL-BLOCK S-3 ......................................................................................................... CONTROL-BLOCK S-1 ......................................................................................... PLATE BOTTOM WITH SOCKET ................................................................................................................................. PISTON ................................................................................................................................. PISTON .................................................................................................................................. COVER ............................................................................................................. HOUSING SETTING .................................................................................................................................. COVER .................................................................................... COVER FOR VAVLE S2 LEFT SIDE ........................................................................ RING GROOVED SEALING SET, 30/38 X 7 ..................................................................................................................... O-RING, 38 X 4 ..................................................................................................................... O-RING, 40 X 3 ............................................................................................. SCRAPER, 30 X 38 X 7 P 6-30 ............................................................................. SEALING RING DIN 7603, A 22 X 27 CU .......................................................................................... SCREW DIN 908, M 22 X 1.5 5.8 .............................................................................................. SCREW LOCKING M 20 X 1.5 ....................................................................................... SPRING PRESSURE, 5.5 X 1 24M ..................................................................................................... BALL STEEL, 8 DIN 5401 ................................................................................................ ANCHOR BOLT, M 12 X 350 ................................................................................. SPRING WASHER DIN 127, A 12 FST .......................................................................................................... NUT DIN 1587, M 12 6 ........................................................................................... SCREW DIN 912, M 12 X 35 8.8 .................................................................................. SPRING WASHER DIN 7980, 12 FST ........................................................................................... SCREW DIN 912, M 12 X 90 8.8 .................................................................................. COVER FOR VALVE S2 RIGHT SIDE ........................................................................................... SCREW DIN 912, M 10 X 65 8.8 .................................................................................. SPRING WASHER DIN 7980, 10 FST ......................................................................................... RING SAFETY, 30 X 1.5 DIN 471 .................................................................. RING GROOVED SEALING SET, 30 X 38.5 X 7 .................................................................................................................................. COVER .................................................................................................................................. COVER ..................................................................................... COVER FOR APPROACH SWITCH ........................................................................................... SCREW DIN 912, M 12 X 80 8.8 ............................................................................. SEALING RING DIN 7603, A 24 X 29 CU .......................................................................................... SCREW DIN 908, M 24 X 1.5 5.8 ........................................................................................... SCREW DIN 912, M 12 X 30 8.8 .....................................................................................................PIPE PLUG DIN 910, R 1" ............................................................................. SEALING RING DIN 7603, A 35 X 41 CU
KSP Training Manual
8 - 29
KSP COMPONENTS
16
20
10
7
4
10
3
9
8
6
2
9
5
17
11
18
19
1
14
12
9
13
3
9
21
6
4
15
8
7
19
10
18
10
17
20
SECTION 8
10182435
Figure 8.17 - Control Block “The Brain” Single Circuit - Hydraulic
8 - 30
KSP Training Manual
KSP COMPONENTS
SECTION 8
Control Block “The Brain” Single Circuit - Hydraulic - HiFlow Part #10190495 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1 1 2 2 1 2 2 2 4 16 1 3 2 2 1 1 2 2 8 1 2
Description ................................................................................... CONTROL-BLOCK HOUSING S1/S2 ............................................................................................................................ SPOOL S-1 ...................................................................................................................................... DISC ..................................................................................... PRESSURE SPRING 36 X 4 71 MM ............................................................................................................................ SPOOL S-2 .............................................................................................. GROVED RING 40 X 48.5 X 7 .................................................................................................................................. COVER .................................................................................................................................. COVER ............................................................................................................ O-RING 56.74 X 3.53 .....................................................CHEESE HEAD SCREW DIN 912 M 12 X 70 - 8.8 - A2C ................................................................................ MINIMESS SCREW-TYPE COUPLING .................................................................................................. SQUARE RING 29.74 X 3.4 ................................................................................................ SQUARE RING 44.04 X 3.40 .............................................................................................................. LIFTING EYE BOLT ................................................................................................................. VALVE HOUSING ............................................................................................................................. SPOOL S3 .................................................................................................................................. COVER ............................................................................................GROOVED RING 40 X 48.5 X 7 ........................................................................................ CHEESE HEAD SCREW DIN 912 .......................................................................................................................SCREW PLUG .................................................................................................................... LOCKING PLUG
KSP Training Manual
8 - 31
SECTION 8
KSP COMPONENTS
Figure 8.18 - Check Valve 8 - 32
KSP Training Manual
KSP COMPONENTS
SECTION 8
Figure 8.19 - Switching Valve KSP Training Manual
8 - 33
SECTION 8
KSP COMPONENTS
8 - 34
KSP Training Manual
KSP COMPONENTS
SECTION 8
10-30 V DC 400 mA
SENSOR
BROWN WIRE POSITIVE 24 V DC
BLACK WIRE SIGNAL
S-2 SPOOL
CENTERING HOLE SHOULD BE FILLED UP BY WELDING
BLUE WIRE NEGATIVE
END COVER
COPPER SEALING RING 39000164
Figure 8.20 - Stroke Counter Switch
KSP Training Manual
8 - 35
SECTION 8
KSP COMPONENTS
30323583
Figure 8.21 - Large Poppet with SFMS®
8 - 36
KSP Training Manual
KSP COMPONENTS
SECTION 8
Standard Poppet with SFMS® Part #30323583 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
1 1 3 1 1 1 1 2 2 1 1 2 1 2 4 1 1 3 1 1 3 3 3 1 1 2 1 1 1 1 1 2 4 1 1
Description ......................................................................................................................... VALVE SEAT ................................................................................................ POPPET PRESSURE CONE .......................................................................................... SCREW DIN 912, M12 X 130 8.8 ................................................................................................................... O-RING, 190 X 5 ..........................................................................................................................VALVE DISC ................................................................................................... DISC PRESSURE, DN 150 .................................................................................................................. GUIDE BUSHING ..................................................................................................................... O-RING, 52 X 4 ..................................................................................................................... O-RING, 74 X 3 ....................................................................................SCRAPER, NO. 1040 40/52.1 X 7.14 .............................................................................................................................. BUSHING ..................................................................................................................... O-RING, 60 X 4 .............................................................................................. PISTON ROD, 40 X 510/12-22 ..................................................................................................................... O-RING, 40 X 3 .......................................................................................... PISTON RING, SG 65/59.2 X 2.5 ................................................................................................................................. PISTON .....................................................................................................PISTON CAP ASSEMBLY .......................................................................... SCREW M 12 X 100 DIN 912-A2, SST 304 ..................................................................................................................... O-RING, 58 X 4 .................................................................................................................................. COVER ....................................................................................... ROD TIE HYDRAULIC CYLINDER ............................................................................................................ NUT DIN 985, M 16 8 ......................................................................................................... DISC DIN 125, B 16 ST .................................................................................................................. CYLINDER TUBE .......................................................................................... BRACKET PROXIMITY SWITCH ................................................. SET SCREW - ALLEN HD OVAL PT, #10-32 NF X 1/2" LG ................................................................................................. SHCS #8-32 NC X 1 1/4" LG .............................................. SENSOR POSTION MAGNET 24 V, USE TO MAKE 324150 ......................................................................... SEALING GLAND SET, 40/52 X 22.5 E1-40 ........................................................................................... GUIDE BUSHING, 41 X 60/26-8 .............................................................................................................................. BUSHING ................................................................................................................... O-RING 39 X 6.5 ...........................................................................................................................BACK-RING .............................................................................................................................. BUSHING ..................................................................................................................... O-RING, 85 X 3
KSP Training Manual
8 - 37
SECTION 8
KSP COMPONENTS
30500332
Figure 8.22 - XL Poppet Assembly with SFMS®
8 - 38
KSP Training Manual
KSP COMPONENTS
SECTION 8
XL Poppet Assembly with SFMS® 30500332 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 1 3 1 1 1 1 2 3 1 1 2 1 2 1 1 1 3 2 1 4 4 4 1 1 2 1 1 1 1 1 1 2 1 1 2
Description ............................................................................................................VALVE SEAT DN 250 ...........................................................................................................VALVE CONE DN 250 ................................................................................................ SCREW M 16 X 200 8.8 A2C ................................................................................................................. O-RING, 315 X 10 ............................................................................................................ VALVE DISC DN 250 .................................................................................................... PRESSURE DISC DN 250 .................................................................................................... GUIDE BAND FAI 63 X 24 ..................................................................................................................... O-RING, 85 X 4 .............................................................................................................. RING 0.3 X 84 / 114 ............................................................................................. SCRAPER, 63 X 73 X 7 P 6-63 ........................................................................................................... BUSHING SUMMARY ..................................................................................................................... O-RING, 72 X 4 ....................................................................................................... PISTON ROD F63 X 826 ..................................................................................................................... O-RING, 63 X 4 ...............................................................................................PISTON SEAL 80 / 64.5 X 6.3 ................................................................................................................................. PISTON .......................................................................... PISTON CAP ASSEMBLY WITH MAGNET .............................................................................................................. SCREW M 16 X 120 ......................................................................................... BACK-RING PTFE, 80/73.6 X 1.5 .................................................................................................................................. COVER ....................................................................................................................... TIE ROD M 24 ............................................................................................................ NUT DIN 985, M 24 8 ......................................................................................................... DISC DIN 125, B 25 ST .............................................................................................................................CYLINDER .......................................................................................... PROXIMITY SWITCH BRACKET ................................................. SET SCREW - ALLEN HD OVAL PT, #10-32 NF X 1/2" LG ................................................................................................. SHCS #8-32 NC X 1 1/4" LG .............................................. SENSOR POSTION MAGNET 24 V, USE TO MAKE 324150 .............................................................. SEALING GLAND SET, 63/83 X 37 E2-63/SM5-63 .................................................................................................................. GUIDE BUSHING ..................................................................................................................... TENSION RING ....................................................................................................... GUIDE BAND FI 63 X 24 ....................................................................................................LIP SEAL 63/79 X 10.5 CH ................................................................................................................... O-RING, 148 X 5 ..............................................................................................................................DISC D 63 ................................................................................................ SEAL, GUIDE, 80 X 2.5 X 15
KSP Training Manual
8 - 39
SECTION 8
KSP COMPONENTS
1 2 3 4 5 6 7 8
9 10 9 5 11 9
10 9 12 13 14
15 16
23 17 18 24
30
19
31
20
32
21 22
25
33 34
26 29
27
35 36
28 37
48 41 42 46 47
45
43 44
40
39
38 30322540
Figure 8.23 - Small Poppet Assembly with SFMS®
8 - 40
KSP Training Manual
KSP COMPONENTS
SECTION 8
Small Poppet Assembly with SFMS® Part #30322540 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
1 1 1 1 2 1 1 2 4 2 1 1 1 2 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 3 3 3 1 1 1 2
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
Description .............................................................................................................O-RING 148.6 X 6.99 ............................................................................................................VALVE SEAT DN 100 ...................................................................................................................................... DISC ............................................................................................................ VALVE DISC DN 100 ..................................................................................................................... O-RING, 44 X 3 ................................................................................................................. DISC PRESSURE .......................................................................................................O-RING NITRILE, 27 X 3 ........................................................................................... SCREW DIN 912, M 8 X 90 10.9 .................................................................................................................BACK-RING PTFE ..................................................................................................................... O-RING, 28 X 5 .................................................................................................................. GUIDE BUSHING ........................................................................................................SCRAPER 28 X 40 X 10 ..................................................................................................................... RING TENSION ......................................................................................................... DISC SPACING, ST 52 .............................................................................................PISTON ROD, T 28 X 370/8-14 ......................................................................... SEALING GLAND SET, 28/40 X 22.5 E1-28 ..................................................................................................................... O-RING, 46 X 3 ......................................................................................................................... GUIDE RING ........................................................................................... PISTON GUIDE, D 40/36 X 10.2 ................................................................................................................ PISTON, KSP 5-25 ......................................................................................... PISTON SEALING, D 40/29 X 4.2 ................................................................................... PISTON CAP W/MAGNET, KSP 5-25 ......................................................... SHCS M 8 X 1.25 X 90 MM LG, DIN 912-A2 304 SST .......................................................... SHCS,M8 X 1.25 X 70MM LG., DIN 912-A2 304 SST .......................................................... SHCS,M8 X 1.25 X 40MM LG., DIN 912-A2 304 SST .........................................................................PIPE COUPLING BODY, K-GES 12 LR 1/4" .................................................................................. THROTTLE CHECK VALVE, MK6-G1 ............................................................................. SCREW JOINT, EGESD 12 L/R 1/4"-WD ............................................................................ PIPE COUPLING BODY, K - GES 12 LR I ................................................................................................. SCREW DIN 908, R 1/2" 5.8 ............................................................................. SEALING RING DIN 7603, A 21 X 26 CU ............................................................................................CYLINDER, POPPET KSP 5-25 ............................................................................. SEALING RING DIN 7603, A 17 X 21 CU ................................................................................................. SCREW DIN 908, R 3/8" 5.8 .................................................................................................................. O-RING, 34.2 X 3 .................................................................................................................................. COVER .................................................................................................. SEALING RING, DKAZ 3/8" .............................................................................. PIPE COUPLING BODY, K-DSTS 12 LR ................................................. HOSE HIGH PRESSURE, DN 8/2 X 1000 DKO M 18 X 1.5 ............................................................................................................ NUT DIN 985, M 16 8 ......................................................................................................... DISC DIN 125, B 16 ST ............................................................................................. ROD TIE HYD. CYL. KSP 5-25 ................................................................................................. SHCS #8-32 NC X 1 1/4" LG ................................................. SENSOR POSTION MAGNET 24 V, MAKE FROM 321877 .......................................................................................... BRACKET PROXIMITY SWITCH ................................................. SET SCREW - ALLEN HD OVAL PT, #10-32 NF X 1/2" LG
KSP Training Manual
8 - 41
SECTION 8
KSP COMPONENTS
1 2 3 4 5 6 7 8
9 10 9 5 11 9
10 9 12 13 14
15 16
23 17 18 24
30
19
31
20
32
21 22
25
33 34
26 29
27
35 36
28 37
48 41 42 46 47
45
43 44
40
39
38 30322540
Figure 8.23 - Small Poppet Assembly with SFMS® (Cont.)
8 - 42
KSP Training Manual
KSP COMPONENTS
SECTION 8
Small Poppet Assembly with SFMS® (Cont.) Part #30322540 Pos
Qty.
45 46 47 48
1 1 1 1
Description ..................................................................................................................CLAMP, CGB 193 .............................................................................ENCLOSURE BOX, HOFFMAN A-604NF .................................................................... TERMINAL STRIP, 10 POLE, W/BACK PLATE .................................................................................... DECAL - SLURRY PUMP PATENTS
KSP Training Manual
8 - 43
SECTION 8
KSP COMPONENTS
8 - 44
KSP Training Manual
KSP COMPONENTS
SECTION 8
39000165
Figure 8.24 - Typical Ram and Connection
(TO BE REMOVED UPON INSTALLATION)
ANGULAR LUBE RING
30323712
Figure 8.25 - Pipeline Lubrication Ring KSP Training Manual
8 - 45
SECTION 8
KSP COMPONENTS
Figure 8.26 - Sliding Frame Assembly
8 - 46
KSP Training Manual
KSP COMPONENTS
SECTION 8
Sliding Frame Assembly Part #30351603 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1 1 1 1 1 1 2 2 2 2 2 1 4 4 8 2 20 20 20 1 2 28 28 28 1 1 1 1
Description ................................................................................................................... SLIDING FRAME ..................................................................................................................... CENTER TUBE ......................................................................................... EXTENSION SHAFT-CHROMED ................................................................................................ STUFFING BOX ASSEMBLY ..............................................................................................................CLEVIS ASSEMBLY ................................................................................. HYDRAULIC CYLINDER 5.5 X 3 X 36” .......................................................................................................... TRUNNION BRACKET .............................................................................................................. GUIDE WELDMENT ......................................................................................................................... SHIM PLATE ........................................................................................................... PROXIMITY SENSOR ..............................................................................................................SENSOR BRACKET ................................................................................................................ SENSOR TARGET .................................................................................................................... SHCS M10 X 30 ....................................................................................................................... NUT HEX M10 .............................................................................................................. DISC WASHER A10 .................................................................................................................... SHCS M10 X 55 .................................................................................................................... HHCS M20 X 60 ....................................................................................................................... NUT HEX M20 ............................................................................................................. DISC WASHER A 20 ................................................................................................................ENCLOSURE BOX ................................................................................................ WASHER - CYL. TRUNNION .................................................................................................................. HHCS M16 X 200 ....................................................................................................................... NUT HEX M16 ............................................................................................................. DISC WASHER A 16 ..................................................................................................... STUFFING BOX FLANGE .......................................................................................... SILO, STRUCTURAL SUPPORT ................................................................................................................... SLIDING FRAME ........................................................................................................ TRANSPORT FIXTURE
KSP Training Manual
8 - 47
SECTION 8
KSP COMPONENTS
Figure 8.27 - Stuffing Box Assembly
8 - 48
KSP Training Manual
KSP COMPONENTS
SECTION 8
Stuffing Box Assembly Part #30352618 Pos
Qty.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
1 1 1 1 1 1 1 1 2
.................................................................................................................... SEAL HOUSING ................................................................................................... STUFFING BOX CARRIER ................................................................................................................. PACKING GLAND ................................................................................................... PACKING GLAND INSERT ..................................................................................................... STUFFING BOX FLANGE ................................................................................................................ CARRIER INSERT ............................................................................................................................. SCRAPER ............................................................................................ PACKING 3/4 X 3/4 - SET OF 4 .................................................................................................................... O-RING 173 X 7
1
................................................................................................................................ GASKET
8 8 8 8
...................................................................................................... SHCS DIN 912 M10 X 30 .................................................................................................................... SHCS M12 X 80 ...............................................................................................LOCK WASHER A10 DIN 127 .............................................................................................. LOCK WASHER M12 DIN 127
8 8 16
............................................................................................................ HHCS 5/8-11 X 2” SS ...................................................................................................................... NUT 5/8-11 SS ........................................................................................................ FLAT WASHER 5/8” SS
KSP Training Manual
8 - 49
SECTION 8
KSP COMPONENTS
Figure 8.28 - Push Floor Assembly
8 - 50
KSP Training Manual
KSP COMPONENTS
SECTION 8
Push Floor Assembly Part #30353597 Pos
Qty.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13 14
3 6 6
....................................................................................................... HYDRAULIC CYLINDER ............................................................................................................ PROXIMITY SWITCH .......................................................................................... PROXIMITY SWITCH BRACKET
3 6 6 6 6 24 24 24 3 6
........................................................................................................................... CLEVIS PIN ...................................................................................................SPACER FOR CLEVIS PIN .......................................................................................... RETAINER PLATE FOR CLEVIS ....................................................................................... CLAMP BEAM TO STRUT PANEL .................................................................................................. SCREW DIN 912 M 12 X 30 .........................................................................................................HHCS 1/4-20 NC X 3/4” ..................................................................................................... NUT HEX 1/4-20 316 SST ............................................................................................................. WASHER LOCK 1/4” ................................................................................................... TARGET FOR PROXIMITY .......................................................................................... SCREW DIN 912 M 10 X 55 10.9
KSP Training Manual
8 - 51
SECTION 8
KSP COMPONENTS
4 9
9
8
2 3
12 13,14
13
6
16
15
16 11
1 5,10
7
13 17
Figure 8.29 - Pipeline LubeMilroyal “C” Lube
8 - 52
KSP Training Manual
KSP COMPONENTS
SECTION 8
Pipeline Lube Milroyal “C” Lube Part #30351585 Pos
Qty.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
2 1 1 1 1 1 1 3 3 1 1 1 3 2 1 2 2
Description ...................................................................................................................1/2’ BALL VALVE .............................................................................................................. 1/2” RELIEF VALVE ....................................................................................................... RELIEF VALVE SPRING ................................................................................................................... ACCUMULATOR ............................................................................................................. PRESSURE GAUGE ....................................................................................................BACK PRESSURE VALVE ...........................................................................................................................ELBOW 1/2” ........................................................................................................................ TEE 1/2” NPT ............................................................................................................................ 1/2” UNION ............................................................................................ REDUCER BUSHING 1/2 X 1/4 ................................................................................................................FLOW INDICATOR .................................................................................. SUPPORT PIPELINE LUBE SYSTEM ..................................................................................................................... 1” BALL VALVE .................................................................................. ADAPTER 1/2” FEMALE TO 1” MALE ......................................................................................... STRAINER Y TYPE SUCTION 1” ........................................................................................................................... TEE 1” NPT ................................................................................................................ ELBOW 1” 90 NPT
KSP Training Manual
8 - 53
SECTION 8
KSP COMPONENTS
Figure 8.30 - Spool Slip in 8” Assembly
8 - 54
KSP Training Manual
KSP COMPONENTS
SECTION 8
Spool Slip In 8” Assembly Part #30345277 Pos
Qty.
Description
1 2 3 4 5 6 7 8 9 10 11 12 13
1 1 1 3 3 4 2 1
............................................................................................................................. SLIP RING ............................................................................................................... O-RING 11” X 3/16” ........................................................................................... CONNECTOR 3/8” NPT TO 3/8” .................................................................. ADAPTER FITTING 3/8” M NPT TO 3/8” M NPT ......................................................................................................................CHECK VALVE .......................................................................SWIVEL CONNECTOR 3/8 NPT TO 3/8 NPT ................................................................................................................... FITTING TEE 3/8 .............................................................................................................NEEDLE VALVE 3/8”
1 1 3
.......................................................................................................... HOSE ASSEMBLE 36” ...................................................................................................... 3/8 FLUID CONNECTOR .......................................................................................................... HOSE ASSEMBLY 36”
KSP Training Manual
8 - 55
SECTION 8
KSP COMPONENTS
LUBRICATION FLOWRATE (GPM) PIPELINE FLOWRATE (GPM)
LUBRICATION FLOWRATE (GPM) (AS PERCENTAGE OF THE PIPELINE FLOWRATE)
1/2%
1%
1-1/2%
2%
2-1/2%
3%
3-1/2%
4%
20
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
40
0.2
0.4
0.6
0.8
1.0
1.2
1.4
1.6
60
0.3
0.6
0.9
1.2
1.5
1.8
2.1
2.4
80
0.4
0.8
1.2
1.6
2.0
2.4
2.8
3.2
100
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
150
0.8
1.5
2.3
3.0
3.8
4.5
5.25
6.0
200
1.0
2.0
3.0
4.0
5.0
6.0
250
1.25
2.5
3.75
5.0
300
1.5
3.0
4.5
6.0
LUBRICATION FILM THICKNESS (INCHES) NOMINAL PIPELINE DIAMETER (INCHES)
1/2%
1%
1-1/2%
2%
2-1/2%
3%
3-1/2%
4%
6"
0.0084"
0.0169"
0.0253"
0.0422"
0.0338"
0.0506"
0.0590"
0.0674"
8"
0.0109"
0.0219"
0.0328"
0.0547"
0.0437"
0.0656"
0.0765"
0.0874"
10"
0.0136"
0.0273"
0.0409"
0.0682"
0.0546"
0.0819"
0.0955"
0.1091"
12"
0.0161"
0.0323"
0.0484"
0.0807"
0.0645"
0.0968"
0.1129"
0.1290"
14"
0.0177"
0.0354"
0.0531"
0.0885"
0.0708"
0.1062"
0.1239"
0.1416"
LUBRICATION FLOWRATE (GPM) (AS PERCENTAGE OF THE PIPELINE FLOWRATE)
30323714
8 - 56
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9 9.1
SECTION 9
HYDRAULIC OIL & FILTERS
RESERVOIRS 1. Storage place for the hydraulic oil. 2. Hydraulic oil supply for the pumps and circuit. 3. Cleaning place for the oil. A. Contaminants are allowed to settle out because of low turbulence (sediment, water component particles). B. Air that is entered into the system is allowed to purge. 4. Cooling of the oil. 5. They are sized for maximum flow the hydraulic circuit.
9.2
HYDRAULIC OILS AND LUBRICANTS 1. Always follow the equipment manufacturer’s recommendation for oil and lubricants.
NOTE: The lubricants recommended by the manufacturer have been analyzed and recommended based on pour points, viscosity index, anti-foaming additives, oxidation resistance and rust inhibitors. 2. Purchase only quality lubricant. 3. Avoid mixing lubricants of different manufacturers. 4. Store lubricants properly. 5. Check hydraulic level daily. 6. Set-up a preventative maintenance program, utilizing oil analysis programs. 7. Use only clean containers for oil handling. NOTE: Filter carts equipped with a 10 micron maximum filter are recommended for the handling of hydraulic oils.
KSP Training Manual
9-1
SECTION 9
HYDRAULIC OIL & FILTERS
OIL LEVEL AND TEMPERATURE GAUGE
CLEAN OUT COVER
RETURN LINE FILTER
BAFFLE
LIFTING EYE
HYDRAULIC OIL RESERVOIR
HYDRAULIC RESERVOIR DRAIN SUCTION HOSE
DIRTY OIL FILTER SWITCH
CLEAN OUT COVER & FILLER CAP
LOW OIL LEVEL SWITCH
HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER
RETURN FILTER FOR HYDRAULIC OIL LIFTING EYES (FOR LIFTING DEVICES PROVIDED)
SCREW CONVEYOR PRESSURE GAUGE SLUDGE PUMP PRESSURE GAUGE PRESSURE GAUGE SHUT-OFF VALVE ELECTRICAL CONTROL PANEL
CONDITIONING LOOP FILTER HIGH OIL PRESSURE SLUDGE PUMP
DRAIN ELECTRIC MOTOR ROTEX COUPLING
SCREW CONVEYOR PRESSURE RELIEF VALVE
SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE)
39000166
Figure 9.1 - Typical Hydraulic Power Packs 9-2
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.3
SECTION 9
FLUID CONTAMINATION AND CONTROL
The sources of contamination in hydraulic and lubricating systems are divided into three general categories. The degree of importance of each source depends on system design, operating environment, and maintenance practices.
PRIMARY SOURCES OF CONTAMINATION BUILT-IN CONTAMINATION (dirt, shavings, slag, and etc. that may be present during assembly). INGRESSED CONTAMINATION (is an environmental type which happens during routine servicing or from lack of maintenance). INTERNALLY GENERATED CONTAMINATION (occurs from the rubbing and grinding of all moving parts inside each and every component of the system). 39000167
Figure 9.2 - Primary Sources of Contamination
CONTROL METHODS BUILT-IN
• Clean all components before installation. • Flush new systems with high efficient filters. • Use high quality seals in all systems components.
INGRESSED
• Always keep maintenance environment clean • Pre-filter the new oil prior to dispensing to tank.
INTERNALLY GENERATED
KSP Training Manual
• Always use fine “Silt Control” filters. • Use specified lubricants for components. • Eliminate water from the system to reduce rust.
9-3
SECTION 9
9.3.1
HYDRAULIC OIL & FILTERS
Handling, Storing, and Dispensing of Lubricating Fluids
To obtain optimum performance from oil, proper handling, storing and dispensing is required. These steps are necessary to preserve the integrity of the product. It is uneconomical to buy a high quality lubricant and then permit degradation through contamination. Unless simple precautions are observed, contamination of lubricants can occur during storage; or during transfer of oil from the original container to the dispensing equipment; or during dispensing of oils to the equipment to be lubricated. Pumps, oil cans, measures, funnels and other dispensing equipment must be kept clean at all times and covered when not in use. Storing oil drums, fill carts, or other containers outside of climate controlled areas is a poor practice. Water and moisture may get into the drum around the bungs and contaminate or destroy the drum’s contents. A drum standing on end with the bungs facing up can collect rain water or condensation inside the chime. This water can gradually be drawn in around the bungs by the breathing of the drum as the ambient temperature rises and falls. This can occur even with bungs drawn tight and the tamper-proof seals in place. In addition, the dirt and rust that can accumulate inside the chime and around the bungs may contaminate the drum’s contents when the drum is opened for use. As a general rule, lubricants in drums smaller than 16 gallon capacity should never be stored outside. However if drums must be stored outside, a temporary shelter or lean-to, and/or a waterproof tarpaulin is highly recommended for protecting the drum from rain and snow. The proper storing position of an oil drum is: drum should be laid on it’s side with the bungs approximately horizontal and at the lowest point. In this position, water and moisture cannot collect in the chime and because the bungs are below the level of the drum’s contents, the incidence of water being drawn into the drum from normal breathing is greatly reduced. For maximum protection, drums should be stood on end with bungs down on a well-drained surface. In circumstances when all the aforementioned storing methods are impractical, drum covers should be used. Covers are available in both metal and plastic. Drums with a bung on the side should be stored either on their end, or on their side with the bung facing down. Regardless of the position, drums should always be placed on blocks or racks several inches from the ground to avoid contact with moisture or standing water. When drums must be stored outside with the bung end upward, they should be blocked up in a manner that will keep the drum teetered to provide sufficient draining of water. The drum should be rotated on the blocks so that any water collecting on the top of the drum surface does not come in contact with or submerge the bung openings. Before opening a drum that has been stored outside, the bung and chime areas should be cleaned thoroughly to eliminate the hazard of collected rust, scale and dirt from falling into the drum. Always use the oldest oil first. The probability of oxidation, contamination and attack by heat and cold, increase with age. If the oil quality is suspect due to long periods of storage, have the oil analyzed before using it.
9-4
KSP Training Manual
HYDRAULIC OIL & FILTERS
RAIN
chime
air space
COOL
Clean oil in sealed drum as delivered and then stored outside standing on end
SECTION 9
standing water
SUN
bungs
air space reduced
WARM
Oil and air in drum expand from heat exposure forcing air out through top
powerful suction created
water
COOLING
Contaminating water is drawn into drum through the bungs when oil and air cools and contracts
39000168
Figure 9.3 - Poor Storage Practices
KSP Training Manual
9-5
SECTION 9
9.4
HYDRAULIC OIL & FILTERS
FILTERS
Filters are the most important part of the hydraulic circuit. As a result, it requires the most maintenance. The filters have two ratings, micron and beta. They are designed in relation to the maximum flow of the circuit and the micron size of the particles that the hydraulic components can tolerate.
9.5
TECHNICAL INFORMATION - FILTRATION RATINGS
9.5.1
Nominal Filtration Ratings • An arbitrary micrometer value indicated by the filter manufacturer. Due to lack of reproducibility, this rating is deprecated.
9.5.2
Absolute Filtration Ratings • The diameter of the largest hard spherical particle that will pass through a filter under specified test conditions. This is an indication of the largest opening in the filter element.
9.5.3
Beta Filtration Ratio (bn) • The ratio of the number of particles greater than a given size (n) in the influent fluid to the number of particles greater than the same size (n) in the effluent fluid.
IN
OUT
b=
IN OUT
PARTICLES > 5m FILTER
IN
OUT
b5
FILTER A
10,000
5000
2
FILTER B
10,000
100
100
FILTER C
10,000
1
10,000 39000169
Figure 9.4 - How Beta Works
9-6
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
The filtration ratio or Beta is calculated by dividing the number of particles entering the filter by the number of particles exiting the filter. b5 represents the filtration ratio at 5 micrometers or the ratio of upstream to the downstream particles larger than 5 micrometers 9.5.4
Filter Facts • OEM Recommended Filters Have Low DP (Delta P) • OEM Recommended Filters Have Long Life • OEM Recommended Filters Remove Silt, Not Additives • Harmful Particles Can Not Be Seen • 1 Micron Nominal Filters Pass 10 Micron Particles • Metal Mesh Breathers Allow Airborne Ingression • New Oil Can Be Very Dirty
KSP Training Manual
9-7
SECTION 9
9.5.5
HYDRAULIC OIL & FILTERS
Technical Information - Beta Ratings
BETA RATINGS Particles in this range (and smaller) should pass through the filter.
Particles in this range (and larger) should be removed by the filter.
b X = 200
{
{
example: b12 = 200. This means that for every 200 particles of 12 microns or larger that hit the media, 1 will make it through.
UPSTREAM
DOWNSTREAM FLOW
b X = 75
example: b12 = 75. This means that for every 75 particles of 12 microns or larger that hit the media, 1 will make it through. (225 particles shown entering, 3 coming out)
UPSTREAM
DOWNSTREAM
FLOW 39000170
Figure 9.5 - Beta Ratings
9-8
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
9.6
SCHWING BIOSET FILTERS
9.6.1
KSP Return Filter COVER
O -R IN G
12 P S I PRESSURE S W IT C H
F ILT E R H O U S IN G
S P R IN G TO P FILT E R P E TA L
IN L E T PORT
BYPASS V A LV E 15 P S I
O -R IN G O -R IN G
O -R IN G
MAGNET
FILT E R P A P E R 10 M IC R O N S
O IL L E V E L
O -R IN G F IL TE R R E T A IN E R P LA TE
39000171
Figure 9.6 - KSP Return Filter - Style #1 • Filter Unit Part #30311774 • Element Part #10069594 (Paper Media) • Oil Filter Seal Kit Part #30326561 KSP Training Manual
9-9
SECTION 9
HYDRAULIC OIL & FILTERS
39000172
Figure 9.7 - KSP Return Filter - Style #2 • Filter Unit Part #30330645 • Element Part #30330646
9 - 10
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.6.2
SECTION 9
Conditioning Loop Filter
39000084
Figure 9.8 - Conditioning Loop Filter • Filter Unit Part #30327177 • Element Part #30327178 • Indicator Part #30321107 Filter Housing is equipped with a back flow check valve to prevent the tank from drawing when the filter element is removed.
KSP Training Manual
9 - 11
SECTION 9
9.7
HYDRAULIC OIL & FILTERS
HYDRAULIC PUMPS
ELECTRIC POSITIONING MOTOR FOR ROTARY GROUP
POTENTIOMETER AND LIMIT SWITCH ASSEMBLY
PANETARY GEAR REDUCTION AND SLIP CLUTCH 39000173
Figure 9.9 - A2V-250 EL Rexroth Pump
9 - 12
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
PART #30331627 COUPLING PART #30331628
PART #30331822
NOTE: USE THE CORRECT SIZE SCREWDRIVER TO ADJUST THE INTERNAL LIMIT SWITCH OR DAMAGE CAN OCCUR TO THE SWITCH
39000174
Figure 9.10 - A2V-250 Rexroth Pump - Programmable Control Assembly KSP Training Manual
9 - 13
SECTION 9
HYDRAULIC OIL & FILTERS
HYDRAULIC PRESSURE ADJUSTMENT DELTA P. ADJUSTMENT (CONSULT SERVICE DEPARTMENT BEFORE ADJUSTING)
39000175
Figure 9.11 - A10V Rexroth Pump with Pressure Regulator Pressure adjustments on these pumps are sealed with lead wire. The tampering of these seals without factory authorization will void the warranty. Before adjusting the pressures on hydraulic pumps that are stacked or piggyback, consult the Schwing Bioset Service Department for through-torque specifications.
9 - 14
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
39000248
Figure 9.12 - A11VO Rexroth Pump The A11VO is a variable displacement pump of axial piston swashplate design for use in open circuit hydrostatic drives. Designed principally for use in mobile applications. A wide variety of controls are available. Setting of the constant power control is possible via external adjustments, even when the unit is operating. The pump is available with a through drive to accept a gear pump or a second axial piston pump up to the same size (100% through drive).
Output flow is proportional to drive speed and pump displacement and is steplessly variable between maximum and zero.
KSP Training Manual
9 - 15
SECTION 9
HYDRAULIC OIL & FILTERS
39000249
Figure 9.13 - Cut-away of A11VO Hydraulic Pump
9 - 16
KSP Training Manual
HYDRAULIC OIL & FILTERS
KSP Training Manual
SECTION 9
9 - 17
SECTION 9
HYDRAULIC OIL & FILTERS
9.8
REXROTH VT 2000 AMPLIFIER CARD
9.8.1
Functional Description of the Rexroth VT2000 Amplifier Card
The amplifier card is used by the Schwing Bioset Control System to interface the PLC (Programmable Logic Controller) with the hydraulic flow control system. This is accomplished by generating a variable output voltage from the PLC, and sending it to the input for the amplifier card. (This is typically a 2-7 VDC signal, but may vary slightly, depending upon the application). The amplifier card then proportionally converts this input voltage into an output current which powers the proportional flow control solenoid valve, mounted on the hydraulic pump. An increase in this current results in an increase in pumpkit strokes per minute or screw feeder R.P.M.'s. A decrease in current results in a decrease in strokes per minute or screw feeder R.P.M.s.
9 - 18
KSP Training Manual
TERMINAL STRIP
R1 - MINIMUM CURRENT
FUSE - 2 AMP, FAST BLOW R4 - RAMP TIME “DOWN”
R2 MAXIMUM CURRENT
R3 - RAMP TIME “UP”
HYDRAULIC OIL & FILTERS
KSP Training Manual
SECTION 9
39000178
Figure 9.14 - Rexroth VT 2000 Prop-Amplifier Card
9 - 19
SECTION 9
HYDRAULIC OIL & FILTERS
39000253
Figure 9.15 - HED Cards
PWR
MAX
MIN PWM%MAX
MIN
HAU*SF**VALVE DRIVER HIGH COUNTRY NEVADA CITY, CA SERIAL #******
RAMP DITHER AMP DITHER FREQ
+POWER
-COIL
+COIL
PWR COM
CUR
SIG COM
VOLT
REF
FUSE CURRENT LOOP CONTROL INPUT
+ -
+ VALVE COIL
OR
VOLTAGE CONTROL INPUT OR
EXTERNAL 10K POT CONTROL INPUT
+ -
-
PW P9V
POWER SUPPLY
P0V
39000254
Figure 9.16 - High Country Card 9 - 20
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.9
PRESSURE SWITCHES
9.9.1
How To Set Pressure Switches
SECTION 9
When Installing operating or servicing Sludge Pump Equipment, the safety regulations of the contractor, facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the operator and the maintenance personnel. The following paragraphs contain some supplementary recommendations. ANSI standards “ANSI 2244.1-1952” set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.
! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out / tag-out procedure that is approved for your plant by O.S.H.A. or similar governing agency.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the waterbox.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.
! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves).
! WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes. NOTE: Only qualified trained maintenance personnel should set pressure switches on Schwing Bioset KSP equipment. First refer to your hydraulic prints for the specific unit or with Schwing Bioset’s Service Department, to determine what your pressure switch and your relief valve pressures settings are. (The pressure switch setting should always be lower than the relief valve setting.) As an example, let us use: Example: 1500 PSI = Pressure Switch Trip Setting 1700 PSI = Relief Valve Setting The flow of the hydraulic pump (sludge pump, screw feeder, etc.) should be adjusted to minimum. It may be necessary to increase the speed to 5% or 10% if adequate oil flow is not achieved at the minimum setting. You should now verify that the hydraulic control valves are in the neutral positions.
KSP Training Manual
9 - 21
SECTION 9
HYDRAULIC OIL & FILTERS
Example: The bypass/load switch is in the bypass position for the sludge pump (if so equipped) and the forward/neutral/reverse lever is in neutral for the screw feeder (if so equipped). NOTE: All auxiliary circuits should also be in their neutral positions. After verifying that the power pack is turned off (lockout - tagout), close the ball valves (located at the hose to power pack connection) for the hydraulic circuit you want to adjust or check. You should reduce the pressure setting of the relief valve before starting the power pack. To reduce the pressure setting you must first locate the relief valve. Then turn the pressure relief adjustment counter clockwise until no spring tension is felt. Now turn the pressure switch adjustment so that the switch indicates a higher setting then specified in the applicable hydraulic schematic. (In our example you would need to be higher than 1500 PSI.) By looking at the electrical print a electrician should be able to determine if the wiring is hooked up to the normally opened or normally closed contacts. In either case, we are looking for a change of state to indicate when the switch has tripped. With the power off, the electrician should hook a volt meter on the non-common terminal (Normally Open or Normally Closed) and to a ground or neutral. When we do our settings later in this article we will need to monitor this meter. After checking to make sure that the area is clear of personnel and that the unit is safe to use, start the unit according to the instructions in the O&M manual. With the unit running you should check the pressure gauge for that hydraulic circuit and it should be at basically zero pressure (See Figure 9.17). If this is true you can proceed to the next step which is to pressurize the circuit. Example: For sludge pump circuits place the bypass/load switch in the load position (If so equipped). For the screw feeder, place the hand lever in the forward or reverse position (If so equipped).
HYD PRESSURE 0 PSI
RELIEF PRESSURE
SWITCH NOT TRIPPED
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000179
Figure 9.17 - Zero Relief Pressure
9 - 22
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
You will now watch the hydraulic pressure gauge. It should read less then your pressure switch trip setting. (Refer to the hydraulic print or Schwing Bioset Service Department.) **In our example it should be less then 1500 PSI**.
HYD PRESSURE 1500 PSI
RELIEF PRESSURE
SWITCH NOT TRIPPED
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000180
Figure 9.18 - Raise Relief Pressure to 1500 PSI Raise the relief valve pressure (turn adjustment clockwise) to the switch trip setting pressure (See Figure 9.18). **In our example it is 1500 PSI**
HYD PRESSURE 1500 PSI
RELIEF PRESSURE
SWITCH WILL TRIP
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000181
Figure 9.19 - Slowly Lower Switch Setting Now go to the pressure switch and slowly lower the setting (See Figure 9.19). At the same time, you should watch the volt meter. When you have lowered it to our pressure switch trip setting, the volt meter will change state (Stop adjusting when the meter changes state). After about three seconds the power pack should shut down and the alarm will sound (if so equipped). Reset the alarm (if so equipped) and lower the pressure relief setting (approximately 1 turn counter-clock wise).
KSP Training Manual
9 - 23
SECTION 9
HYDRAULIC OIL & FILTERS
HYD PRESSURE IS RISING
RELIEF PRESSURE
SWITCH WILL TRIP AT 1500 PSI
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000182
Figure 9.20 - Slowly Raise Relief Pressure With the relief valve pressure now lower then the pressure switch trip setting, you can restart the power pack and pressurize the hydraulic circuit again (See Figure 9.20). Slowly raise the pressure relief while watching the volt meter for a change in state. When the meter changes states, STOP ADJUSTING and look at the pressure gauge. If done correctly, the pressure gauge should be reading the same pressure as the pressure switch setting. The unit will again shut off and you will need to lower the pressure relief valve setting. With the power disconnected the electrician will need to temporarily disable the pressure switch. With this switch disabled you will now be able to raise the pressure relief above the pressure switch trip setting with out the switch shutting the power pack off (See Figure 9.21).
HYD PRESSURE 1700 PSI
RELIEF PRESSURE SWITCH SETTING
SWITCH DISABLED 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000183
Figure 9.21 - Raise Pressure When Switch Is Disabled With the switch disabled you can restart the power pack and again pressurize the hydraulic circuit. You will now need to raise the relief valve adjustment to its proper setting (again you will get this setting from the hydraulic prints for the specific unit or from Schwing Bioset’s Service Department) and lock it in place. (In our example we need 1700 PSI) With the power disconnected the electrician must re-connect the pressure switch that was disabled earlier and make sure that all electrical enclosures are closed.
9 - 24
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
HYD PRESSURE 1700 PSI
RELIEF PRESSURE
SWITCH TRIPPED AT 1500 PSI
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
*UNIT WILL SHUT DOWN IN ABOUT THREE SECONDS
39000184
Figure 9.22 - Pressure Switch Test - Shut Down In 3 Seconds You can now repower the unit and repressurize the circuit. If you watch the gauge for the hydraulic pressure you should see the pressure has passed the switch’s pressure setting (in our example 1500 PSI) and go to the relief pressure setting (in our example 1700 PSI) and then stopped. When it has past the switch’s trip setting a timer starts and the unit should shut off in about three seconds (See Figure 9.22). If the unit does not shut down in three seconds, contact the Schwing Bioset Service Department. You should make sure that the unit is de-energized and check that all ball valves are returned to the open position. The process is now complete.
HYD PRESSURE BELOW 1500 PSI
RELIEF PRESSURE
SWITCH HAS NOT TRIPPED
SWITCH SETTING 2000 PSI
1700 PSI
1500 PSI
0 PSI
39000185
Figure 9.23 - Normal Operating Pressure Is Below 1500 PSI Under normal operation the relief valve pressure will be less than the pressure switch trip setting for most of the stroke (See Figure 9.23).
KSP Training Manual
9 - 25
SECTION 9
9.9.2
HYDRAULIC OIL & FILTERS
Switch Adjustments
THUMBWHEEL ADJUSTMENT
39000186
Figure 9.24 - Thumb Wheel Adjustment for Pressure Switch • Part #30325230 (200 to 3000 PSI) • Part #30326614 (2000 to 4700 PSI) Remove cover, check wire connections for N.O or N.C. configuration of switch (See Figure 9.24). To increase pressure settings turn thumb wheel to the right, to decrease pressure setting turn thumb wheel to the left. When setting pressures, pressures must be set using the pressure gauge of the hydraulic circuit. The decal on the switch is for reference only.
9 - 26
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
ADJUSTMENT SCREW
39000187
Figure 9.25 - Adjustment Screw for Pressure Switch • Pressure Switch Part #30311658 • Rebuilt Part #30326635 Remove cover, check wire connections for N.O. or N.C. configuration of switch (See Figure 9.25). Remove screw cover from top of switch for access to adjusting screw. turn screw clockwise to increase pressure. to decrease pressure turn screw counterclockwise. When setting pressures, pressures must be set using the pressure gauge of the hydraulic circuit. The decal on the switch is for reference only.
KSP Training Manual
9 - 27
SECTION 9
HYDRAULIC OIL & FILTERS
39000188
Figure 9.26 - Remove the Inspection Cover • Pressure Switch Part #30320880 (150 to 1600 PSI) • Pressure Switch Part #30312512 (500 to 3200 PSI) • Pressure Switch Part #30311709 (1500 to 6000 PSI) • Pressure Switch Part #30318485 (700 to 2500 PSI) Remove the inspection cover and you should be able to see the adjustment wheel (See Figure 9.26). Do not make adjustments to this switch when the hydraulic circuit is pressurized. To determine if the switch is hooked up N.O. or N.C. you must open the electrical junction box or consult the specific hydraulic print for that unit. NOTE: Do not adjust the pressure switch while it is under pressure. Adjustment while under pressure will result in damage to the adjustment screw
ADJUSTMENT WHEEL
PRESSURE PORT 1/4-18 NPT
DO NOT MAKE ADJUSTMENTS TO THE SWITCH WHEN IT IS PRESSURIZED DAMAGE TO THE ADJUSTING SCREW WILL OCCUR
* DO NOT ADJUST SWITCH WHILE UNDER PRESSURE
39000189
Figure 9.27 - Switch Adjusting Location 9 - 28
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.9.3
SECTION 9
Temperature Switch Adjustment
39000190
Figure 9.28 - Temperature Switch • Temperature Switch Part #30325231 Temperature switches are preset at factory for 160×F. Consult the factory before adjusting.
KSP Training Manual
9 - 29
SECTION 9
HYDRAULIC OIL & FILTERS
THUMBWHEEL ADJUSTMENT
39000191
Figure 9.29 - Thumb Wheel Adjustment for Temperature Switch • Temperature Switch Part #30311660 NOTE: Before adjusting the temperature switch, contact the Schwing Bioset Service Department. Open the cover and note the dial setting (See Figure 9.29). Using a digital thermometer place the probe next to the thermocouple well in the tank. Close the 1/4 turn valves on the power pack, this will allow the relief valve to heat the oil. Monitor the temperature, at 160× (check the hydraulic print for the proper setting) set the temperature switch to match this setting.
9 - 30
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.9.4
SECTION 9
Combination Level and Temperature Switch
39000192
Figure 9.30 - Combination Level and Temperature Switch • Part #30330644 (Has N.O. contacts and is used in PLC machines.) • Part #30334499 (Has N.C. contacts and is used in relay machines.) This switch has both the temperature and level switches integral in the same device. You can determine which you have by looking at the temperature marking engraved in the stem, a odd temperature number denotes normally open contacts and a even temperature number denotes normally closed contacts.
39000193
Figure 9.31 - Oil Level Float Switch • Oil Level Float Switch Part #30326820
KSP Training Manual
9 - 31
SECTION 9
9.9.5
HYDRAULIC OIL & FILTERS
Dirty Oil Filter Switch
39000188
Figure 9.32 - Dirty Oil Filter Switch • Dirty Oil Filter Switch Part #30325229 (12 PSI) • Dirty Oil Filter Switch Part #30334709 (20 PSI) The dirty oil filter pressure switch is factory preset at 12 PSI or 20 PSI, depending on the type used. The three wire leads are: • Brown = Common • Blue = NO • Red = NC
9 - 32
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
39000194
Figure 9.33 - Dirty Oil Filter Switch - Canister Style • Part #318484 (Stainless) • Part #311659 (Aluminum) Before trying to adjust this style of pressure switch you should contact the Schwing Bioset Service Department for instructions (See Figure 9.33).
KSP Training Manual
9 - 33
SECTION 9
HYDRAULIC OIL & FILTERS
39000255
Figure 9.34 - Transition Pressure Sensor - Sigmagnetics • Part# 3034448 The Transition Pressure Sensor measure the amount of pressure in the discharge pipeline. A pressure setting is entered into the PLC (ex. 15 psi). The screw feeder will try to maintain that pressure. If it goes below the specified pressure, the screw feeder will operate faster, if the pressure goes above the set pressure, the screw feeder will slow down. Display MODE/ENTER
SET
PSI
Programming Buttons
Microprocessor
Diaphragm Ceramic Pressure Sensing Element
Measuring Electrodes
Reference Electrode Base
39000287
Figure 9.35 - Pressure Transducer - Efector • Part# 30359728 9 - 34
KSP Training Manual
HYDRAULIC OIL & FILTERS
9.10
SECTION 9
TYPES OF HEAT EXCHANGERS
Air Flow Electric Motor
Fan Blade 39000195
Figure 9.36 - Air Cooled Heat Radiator With Electric Fan Motor
OIL CONNECTION
SHELL TUBES
TEMPERATURE CONTROL VALVE OIL CONNECTION
WATER CONNECTIONS
BAFFLE 39000196
Figure 9.37 - Water Cooled Shell and Tube Heat Exchanger
KSP Training Manual
9 - 35
SECTION 9
HYDRAULIC OIL & FILTERS
OFFSET MISALIGNMENT
ANGULAR MISALIGNMENT
FLEXIBLE COULPING TO PUMP SHAFT
MISALIGNMENT ON A PUMP OR MOTOR CAN ALSO DAMAGE THE HYDRAULIC PUMP SHAFT SEAL
39000197
Figure 9.38 - Pump Alignment 9 - 36
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
O-RING 18.72 x 2.62 C - PART #10000361 BACK-UP RING 19.5 x 24 x 1 C - PART #10002827
T SVP
P
O-RING 25.12 x 1.78 C - #10000442 39000198
Figure 9.39 - Screw Feeder Relief Valve - SD 250/350 • NG 10 - Part #10007793
O-RING 32.92 x 3.53 PART #10068689 2.5mm ALLEN WRENCH
SVP GROOVE RING 25 x 33 x 6 PART #10073703
39000199
Figure 9.40 - Sludge Pump Relief Valve - SD 250/350 • NG 16 - Part #10054809
KSP Training Manual
9 - 37
SECTION 9
HYDRAULIC OIL & FILTERS
9.11
HYDRAULIC SCHEMATIC SERIES - KSP POPPET
9.11.1
KSP Poppet Valve - Series #1 1. S-1 spool in forward, load bypass valve is energized. 2. S-3 spool is shifted. 3. S-2 spool is shifted and is being held over by hydraulic pressure via throttle valve TV2. 4. Hydraulic pressure is being applied to piston side of the lower differential, moving it down conveying material out past poppet valve PP2. 5. The lower suction poppet SP2 is being held closed by hydraulic pressure applied on the piston side of the hydraulic cylinder.
NOTE: The poppet cylinders are connected in a series alternating from rod side to piston side. 6. The lower pressure poppet PP2 is being opened by hydraulic pressure being applied to the rod side of the hydraulic cylinder. Also, the flow of material out of the material cylinder into the discharge line is assisting in the opening of the pressure poppet valve PP2. 7. Switching valves SV1 and SV2 are not operating because of springs, pressure ratios, and equal hydraulic pressure on both sides. 8. Check valves CV1 and CV2 are not operating because of springs, pressure ratios, and equal hydraulic pressure on both sides. 9. Check valve CV3 is being held closed by hydraulic pressure. oil from rod side of lower cylinder is being transferred to the upper cylinder via the rock oil loop. the upper cylinder is retracting and the material cylinder is being filled. 10. The upper pressure poppet PP1 is being held closed by hydraulic pressure being applied to the piston side of the poppet cylinder. 11. The suction poppet is being opened by hydraulic pressure applied to the rod side of the poppet cylinder. This allows the screw feeder or conical hopper to push the material into the material cylinder as the hydraulic cylinder retracts.
9 - 38
KSP Training Manual
KSP Training Manual
PP2
PP1
T P
SP2
SP1
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000200
Figure 9.41 - KSP Poppet Valve - Series #1
9 - 39
SECTION 9
9.11.2
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #2 1. S-1 spool is in forward, load bypass valve is energized. 2. Lower cylinder has extended and reached maximum travel. 3. When the lower cylinder reaches maximum travel the cylinder piston goes past a pilot oil port in the cylinder barrel which allows the hydraulic pressure to pass through the switching valve SV1 to the lower end of the S-3 spool, causing the S-3 spool to shift. The oil on the opposite end side of the S-3 spool has to escape when the spool shifts into the void in the end cap, which was previously filled with oil. This oil flows back to tank via the check valve CV4. 4. S-3 spool is now shifted and all 4 poppet valves will start to change position. The hydraulic pressure is relatively low during poppet cylinder movement. Hydraulic pressure is being applied to the throttle valve TV1. Because the pressure is low, the flow of oil is not sufficient enough to shift S-2. TV2 is also sensing flow and is resisting letting the oil flow to the tank.
9 - 40
KSP Training Manual
KSP Training Manual
PP2
PP1
T
SP2
SP1
P
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000201
Figure 9.42 - KSP Poppet Valve - Series #2
9 - 41
SECTION 9
9.11.3
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #3 1. S-1 spool is in forward, load bypass valve is energized. 2. Lower cylinder has reached maximum travel. 3. S-3 spool has switched. 4. The poppet valve cylinders have completed their movement and the hydraulic pressure will increase. This pressure has increased and oil flow is now passing through TV1 causing the S-2 spool to move. As the S-2 spool moves, the oil on the opposite side of the S-2 spool is displaced by the spool itself. This oil will flow past the TV2 valve and return to tank. 5. SP1 (suction poppet #1) is closed and held closed hydraulically. 6. PP1 (pressure poppet #1) is open or will open as soon as material is forced out of the material cylinder by the material ram. 7. PP2 (pressure poppet #2) is closed and held closed hydraulically. 8. SP2 (suction poppet #2) is open allowing material to flow into the lower material cylinder from the screw feeder.
9 - 42
KSP Training Manual
KSP Training Manual
PP2
PP1
T
SP2
SP1
P
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000202
Figure 9.43 - KSP Poppet Valve - Series #3
9 - 43
SECTION 9
9.11.4
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #4 1. S-1 spool is in forward position, load bypass valve is energized. 2. S-3 spool is shifted. 3. S-2 spool is shifted and is being held over by hydraulic pressure via the TV1 valve. 4. The upper cylinder has hydraulic flow and pressure applied to it, via S-2 spool, causing the cylinder to extend which discharges the material out of the cylinder into the pipeline. Oil from the rod side of the upper cylinder is transferred to the lower cylinder via the rocking oil loop causing the lower cylinder to retract. 5. SP1 is closed, preventing material from flowing back into the screw feeder. 6. PP1 is open, it can be opened hydraulically. If the back pressure in the line was to great to be overcome by the hydraulic force, as soon as the pressure, exerted upon the material by the material ram, exceeds the pressure in the discharge line it will open the PP1 and flow out into the discharge line. 7. PP2 is closed and being held closed hydraulically. 8. SP2 is opened hydraulically. as the lower cylinder is retracting the screw feeder is forcing material into the material cylinder as the ram moves back towards the water box. 9. CV4 is being held closed by hydraulic pressure 10. CV1, CV2, CV3, SV1 and SV2 are held closed by springs and pressure ratios.
9 - 44
KSP Training Manual
KSP Training Manual
PP2
PP1
T P
SP2
SP1
SV1
S-2
S-3
CV1
S-1
S-1
CV3
CV4
TB1
PRESSURE SWITCH
LOAD BYPASS VALVE
SV2
CV2
CV5
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000203 39000203
Figure 9.44 - KSP Poppet Valve - Series #4
9 - 45
SECTION 9
9.11.5
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #5 1. S-1 spool is in forward, load bypass valve is energized. 2. Upper cylinder has extended to where the hydraulic piston has traveled past a hydraulic port in the cylinder allowing the hydraulic pressure and flow to pass through CV1 and pressurize the rock oil loop. 3. The lower cylinder at this same time should have retracted allowing the hydraulic piston to travel past a port in the cylinder allowing hydraulic pressure to react upon SV2 (switching valve #2) and send the switching signal to the S-3 spool causing it to shift.
NOTE: If at the time the lower hydraulic cylinder piston has not traveled past the hydraulic port allowing the hydraulic pressure to react on the SV2, the oil will continue to flowing through the CV1 and finish retracting the lower cylinder to where the hydraulic piston of the lower cylinder does travel past this hydraulic port. 4. As S-3 spool shifts, the oil on the opposite end of the spool is displaced by the spool. This oil returns to tank via CV3 (check valve #3) 5. SP1, PP1, PP2 and SP2 are all going to change position (open or close). But during the travel of the cylinder, the pressure is low. Pressure is being sensed by TV2 (throttle valve #2), but because the pressure is low it has not passed through TV2. when the poppet cylinders complete their travel and the hydraulic pressure in the circuit starts to build, pressure will pass through TV2 and cause S-2 to shift. as S-2 spool shifts the oil on the opposite end of the spool will be displaced by the spool itself. This oil returns to tank via TV1. NOTE: It is by the throttle valve adjustment that we meter the hydraulic oil to the S-2 spool. By doing this, we determine when the S-2 shifts and how much pressure we apply to the poppet valves to open or close them. The size of the throttle valve opening determines at what pressure the oil flows and how fast. It is also necessary that both throttle valves are adjusted equally.
9 - 46
KSP Training Manual
KSP Training Manual
PP2
PP1
T P
SP2
SP1
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000204
Figure 9.45 - KSP Poppet Valve - Series #5
9 - 47
SECTION 9
9.11.6
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #6 1. S-1 spool is in forward, load bypass valve is energized. 2. S-3 spool is shifted. 3. All the poppet valves have changed position. SP2 has closed preventing the material from flowing back into the screw feeder. PP2 is open allowing the material to flow into the discharge pipe PP1 is closed preventing the material from flowing from the discharge pipe into the material cylinder. SP1 is open allowing material to flow from the screw feeder into the material cylinder. All cylinders have reached the limits of their travel and hydraulic pressure is building up in the poppet cylinder circuit. 4. As the pressure builds up in the hydraulic circuit and it equals the setting of the throttle valve TV2, oil starts flowing to the S-2 spool causing it to shift and is being held over by this hydraulic pressure. 5. With S-2 shifted the lower cylinder now has hydraulic oil acting upon it which will cause it to extend. 6. CV1 is sensing hydraulic pressure from the rocking loop oil on the back side of the CV1 but flow is blocked from escaping to tank. 7. CV3 has pressure on the backside and is blocking flow from shifting S-3. 8. SV2 has hydraulic pressure on the back side of the valve which is holding the valve closed preventing pressure from reacting on the S-3 valve. 9. SV1 is held closed by a spring and a pressure ratio difference and it is preventing any pressure from reacting upon the S-3 spool. 10. The upper cylinder will start retracting allowing the screw feeder to fill the upper material cylinder.
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KSP Training Manual
KSP Training Manual
PP2
PP1
T
SP2
SP1
P
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000205
Figure 9.46 - KSP Poppet Valve - Series #6
9 - 49
SECTION 9
9.11.7
HYDRAULIC OIL & FILTERS
KSP Poppet Valve - Series #7 1. S-1 spool is in forward, load bypass valve is energized. 2. S-3 spool is shifted 3. All poppet cylinders have reached the limits of their travel. 4. S-2 spool is shifted and being held in place. 5. Lower hydraulic cylinder is extending causing material to flow out of the material cylinder into the discharge line. 6. Oil from the rod side of the lower cylinder is being transferred to the upper cylinder via the rocking oil loop. 7. As the oil enters the upper cylinder it causes it to retract and allow the screw feeder to fill the material cylinder.
NOTE: At this point, we have completed one cycle.
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KSP Training Manual
KSP Training Manual
PP2
PP1
T
SP2
SP1
P
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000206
Figure 9.47 - KSP Poppet Valve - Series #7
9 - 51
SECTION 9
HYDRAULIC OIL & FILTERS
9.12
UNIT IS IN REVERSE
9.12.1
KSP Poppet Valve - Series #8 1. S-1 is shifted into the reverse position and the oil is redirected into the hydraulic circuit.
NOTE: Screw feeder or conical hopper should be in reverse 2. Now that the oil flow has been reversed in the hydraulic circuit, TV1 will sense the pressure and allow the oil to flow to the S-2 spool causing it to shift. 3. In the forward condition the lower cylinder was extending, but now that the oil has been redirected, The S-2 spool must shift and the lower cylinder will still be extending. 4. The upper cylinder will be retracting. 5. All poppet valves will change position due to the redirection of the oil flow with the S-1 spool SP1 will close preventing material from flowing into the material cylinder. SP2 is open allowing material to flow back into the screw feeder. PP1 will open allowing material to flow form the discharge line into the material cylinder as the cylinder retracts. PP2 is closed preventing material from flowing into the discharge pipe. NOTE: Because the material cylinder now has to be filled by the vacuum forces cause by the retracting material piston, the efficiency of the pumping action drops. 6. The lower cylinder is extending forcing the material back into the screw feeder.
9 - 52
KSP Training Manual
HYDRAULIC OIL & FILTERS
SECTION 9
39000207
Figure 9.48 - KSP Poppet Valve - Series #8 KSP Training Manual
9 - 53
SECTION 9
HYDRAULIC OIL & FILTERS
9.13
EXCESS ROCKING OIL CONDITION
9.13.1
KSP Poppet Valve - Series #9 1. The upper cylinder is fully retracted and has mechanically come to a stop. 2. The lower cylinder has not fully extended so that the sv1 can sense and send the pilot signal to S3. 3. The rocking oil loop or slave oil has to much oil in it. 4. The upper cylinder is fully retracted and the piston has moved past the port in the cylinder that goes to CV2. The CV2 will open and allow the excess rocking oil to be removed from the loop and returned to the tank. With the excess rocking oil being removed, the lower cylinder is allowed to continue extending until the piston passes the cylinder port to SV1. This allows the SV1 to send the pilot signal to S3 and shift. 5. While the rocking oil is being removed, the hydraulic pressure increases to maximum because the demand for flow has decreased. RV1 lets the excess oil flow back to tank. 6. This condition can be observed on the sludge pressure gauge. What you observe is a sudden increase from normal hydraulic pressure to full system pressure, before you here the poppets switch. It can also be observed in the water box. The upper cylinder is stopped and the lower cylinder is extending slowly.
NOTE: If this maximum pressure continues for longer than three seconds, the unit will shut down indicated by the high pressure alarm.
9 - 54
KSP Training Manual
KSP Training Manual
PP2
PP1
T P
TROUBLESHOOTING EXCESS ROCKING OIL CONDITION
SP2
SP1
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000208
Figure 9.49 - KSP Poppet Valve - Series #9
9 - 55
SECTION 9
HYDRAULIC OIL & FILTERS
9.14
ADDING ROCKING OIL CONDITION
9.14.1
KSP Poppet Valve - Series #10 1. The upper cylinder has fully extended and has mechanically come to a stop. 2. The lower cylinder has not retracted enough for the pilot signal to be delivered to the S3 valve via SV2. 3. When the upper cylinder becomes fully extended, the piston has moved past the port to CV1. Oil is now allowed to flow through the CV1 into the rod side of the upper cylinder, through the rocking oil loop, and into the rod side of the lower cylinder. As the oil flows into the rod side of the lower cylinder, it causes it to retract until the port to the SV2 is opened, allowing the pilot signal to switch the S3 valve and subrings the cylinders into synchronization. 4. When this condition is occurring, there is a sudden increase in hydraulic pressure to maximum. RV1 has shifted, allowing the excess oil to flow back to tank and controlling the maximum pressure. 5. This condition can be observed on the sludge pump pressure gauge. What you observe is a sudden increase from normal pumping pressure to full system pressure, before you here the poppets switch. It can also be observed in the water box. The upper cylinder is fully extended and stopped and the lower cylinder is slowly retracting.
NOTE: If the maximum pressure continues for longer than three seconds, the unit will shutdown indicated by the high pressure alarm.
9 - 56
KSP Training Manual
KSP Training Manual
PP2
PP1
T P
TROUBLESHOOTING ADDING ROCKING OIL
SP2
SP1
SV1
CV1
S-2
S-3
S-1
SV2
CV2
TB1
PRESSURE SWITCH
CV5
LOAD BYPASS VALVE
S-1
CV3
CV4
B
T
A
P
S2
RV1
S3
TB1
TB1 ENERGIZED
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
FILTER BYPASS VALVE
HYDRAULIC OIL & FILTERS SECTION 9
39000209
Figure 9.50 - KSP Poppet Valve - Series #10
9 - 57
HYDRAULIC OIL & FILTERS
B
T
A
P
S-1
CV3 SV2
CV4 CV2
SP2
SV1
CV1
PP2
PP1
SP1
Material Flow Measuring System
S2
S3
TV2
TV1
0.7mm ORFICE DRILLED IN SPOOL
SECTION 9
39000210
Figure 9.51 - KSP Poppet Valve Series #11 9 - 58
KSP Training Manual
SPECIAL TOOLS
SECTION 10 10.1
SECTION 10
SPECIAL TOOLS
HYDRAULIC TROUBLE SHOOTING KITS
39000225
Figure 10.1 - Trouble Shooting Kit • Trouble Shooting Kit Part #30308552 (For BPA 750’s). • Trouble Shooting Kit Part #30308553 (Shown, For All BPA and BPL Models Except BPA 750’s). • Trouble Shooting Kit Part #30403182 (For all units including KSP Sludge Pumps) These kits contain a 0-600 Bar pressure gauge, a 0-40 Bar pressure gauge, plus all the necessary fittings, locking plugs, manitrol valves, and hoses to plumb the gauges into any hydraulic circuit on the unit. These kits include the heavy duty foam lined carrying case.
KSP Training Manual
10 - 1
SECTION 10
10.2
SPECIAL TOOLS
FLOW METERS AND ACCESSORIES
Protecting Cover
39000226
Figure 10.2 - Flow MeterY223 Model HT200 • Flow Meter Part #30314787 (Only) Specifications: Maximum Flow (G.P.M.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 Flow Ranges-High Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U.S.G.P.M 25-200 t/min. 100-750 Flow Ranges-Low Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . U.S.G.P.M 5-40 t/min 20-150 Maximum Operating Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345 Bar (5000 psi) Temperature Scale Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100°-250° F (40°-120° C) Port Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2" SAE (split flange) Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 lbs. (13.6kg) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Length 15 7/8" (403.47mm) Width 13 1/4" (336.55mm) Height 6 3/4" (171.45mm)
Accessories: • AC/DC Power Supply Part #30314788 • Blow-out Disc Part #30314789 • Adapter Flange Part #30303384 (SAE to BSP) • Calibrator Part #30328467 Schwing Bioset offers the flow meter with or without the calibrator. Please contact our Spare Parts Department for current pricing. 10 - 2
KSP Training Manual
SPECIAL TOOLS
10.3
SECTION 10
MATERIAL CYLINDER ALIGNMENT TOOLS
Rod Diameter
Material Cylinder Diameter
39000227
Figure 10.3 - Material Alignment Tool Schwing Bioset offers a tool which aligns the material cylinders after rotation or replacement has been completed. To determine which tool your machine requires, measure the O.D. of your differential rod and the I.D. of the material cylinders installed. To order one of these tools, find the proper tool from the following chart, and contact our Spare Parts Department .
Ordering Chart Rod Diameter
Cylinder Diameter
Item Number
50 mm
115 mm
30379545
KSP 5(K)
50 mm
150 mm
30379547
EKSP 10, KSP 10(S), KSP 10(K), EKSP 17, KSP 17(S), KSP 17(K)
50 mm
180 mm
30339165
KSP 12(S), KSP 12(K), KSP 25(S), KSP 25(K),
80 mm
115 mm
30379546
KSP 5(HD)
80 mm
150 mm
30379541
KSP 10(HD), KSP 17(HD)
80 mm
180 mm
30379548
KSP 12(HD), KSP 12(HD)L, KSP 25(HD), KSP 25(HD)L,
Pumpkit Model Number
KSP 25(HD)XL, KSP 40(K) 80 mm
200 mm
30379542
KSP 50(S), KSP 50(K)
80 mm
230 mm
30379543
KSP 80(S), KSP 80(K)
90 mm
180 mm
30379549
KSP 40(HD)
90 mm
200 mm
30379550
KSP 50(HD), KSP 50(HD)XL
85 mm
250 mm
30364756
KSP 120H(K)R MatClyCharteps
Figure 10.4 - Material Alignment Tool Part Number Table
KSP Training Manual
10 - 3
SECTION 10
10.4
SPECIAL TOOLS
PISTON INSTALLATION TOOLS For Differential Cylinders
39000228
Figure 10.5 - Piston Installation Tool Because the differential cylinders are designed with a counter bore, it is extremely difficult to install the differential piston while compressing the piston rings at the same time. These piston installing tools have a taper at the mouth of tool to help compress the piston rings and keep them compressed until the piston is completely installed. Attempting to install the piston without this tool can cause damage to the piston rings. To order one of these tools, find the proper tool from the following chart, and contact our Spare Parts Department. .
Piston Diameter
Item Number
70 mm 80 mm 90 mm 120 mm 125 mm 130 mm 150 mm 200 mm
10061734 10061732 10061733 10061737 10061736 10061375 10103894 30356636
Description PISTON INSTALLING TOOL 70MM PISTON INSTALLING TOOL 80MM PISTON INSTALLING TOOL 90MM PISTON INSTALLING TOOL 120MM PISTON INSTALLING TOOL 125MM PISTON INSTALLING TOOL 130MM PISTON INSTALLING TOOL 150MM PISTON INSTALLING TOOL 200MM
Figure 10.6 - Piston Installation Tool Part Number Table
10 - 4
KSP Training Manual
SPECIAL TOOLS
10.5
SECTION 10
ROD GLAND PACKING INSTALLATION TOOLS For Differential Cylinders
39000229
Figure 10.7 - Rod Gland Packing Installation Tool The rod gland packing tool is designed to aid in installing the gland packings (chevrons) into the guide bushing of the diff cylinder. The tool has a "V" groove machined into one end to fit the shape of the packings. To properly use the tool, one section of the packing set must be slid onto the piston rod and then the tool is slid onto the rod mating the "V" groove with the curvature of the packing section. Using a rubber mallet, strike the flat end of the tool to start the packing into the guide bushing. Once the edge of the packing has cleared past the mouth of the guide bushing, the packing section can be forced completely into position by using the tool as a slide-hammer. To do this, first lubricate the rod surface that the tool will be sliding on with light oil. Then slide the tool along the rod surface, drawing away from the packing and then back to the packing; again and again until the packing section is home. Repeat this procedure for the remaining sections of the packing set. (NOTE: to avoid trapping air or oil between the packing sections, it is recommended to lightly lubricate only the outer edge of the packings allowing air to escape by the rod surface). To order one of these tools, find the proper sized tool from the following chart, and contact our Spare Parts Department. Bushing Diameter of Differential Cylinder
90 mm 125 mm 120 mm 150 mm 200 mm
Rod Diameter of Differential Cylinder
Item Number Guide Tool
Item Number Packing Tool
50 mm 80 mm 80 mm 90 mm 140 mm
30378922 30378923 30378924 30378925 30356635
30378926 30378927 30378928 30378929 30356634
Figure 10.8 - Rod Gland Packing Installation Tool Part Number Table KSP Training Manual
10 - 5
SECTION 10
10.6
SPECIAL TOOLS
RAM TOOLS ASSEMBLY - RAM TOOL KSP 65 List No.: 30600083
SECTION
5
5 SHAFT END
5 4
3 6 2
1 4 3
6
30373896
STUD 3/8 X 1 1/4
1
5
30356639
SCREW - HHCS, 1/2"-13 UNC-2A X 1-1/4 LG. - 316 S.S.
2
4
30305602
WASHER - FLAT 1/2" A-325
2
3
30320434
SCREW - HHCS, 1/2"-13 UNC-2A X 1 3/4" LG. - 316 S.S.
2
2
30367948
PLATE - 1/4" - 304 S.S.
1
1
30367947
PLATE - 3/4" - 304 S.S.
ITEM
PART NO.
1 DESCRIPTION
QTY
BILL OF MATERIALS
Drawing size: AI-A
REV:
08-24-04
Figure 10.9 - Ram Tool Assembly, KSP 65
10 - 6
KSP Training Manual
SPECIAL TOOLS
10.7
SECTION 10
TORQUE SPECIFICATIONS FOR METERIC BOLTS AND SCREWS USED ON SCHWING EQUIPMENT
When performing maintenance that requires removal or replacement of bolts, it is very important to adhere to the torque specifications that applies to that bolt. The graph below illustrates what will happen to a bolt if not properly torqued. The dashed line represents the prestress that the bolt feels when sitting idle. As the component that uses the bolt goes through its normal operation, the bolt in example “A” gets stretched and relaxed very duty cycle. This is because the bolt has been prestressed under the maximum force produced by the operation of the component. In example “B,” the prestress has been raised to more than the maximum force of the duty cycle. Consequently, the bolt in example “B” never feels the maximum force produced by the operation of the component. The result is that the bolt in example “B” would last much longer than the bolt in example “A.”
B Force
Force
A
Time
INCORRECT
Time
CORRECT
Figure 10.10 - Showing the effects that proper and improper prestressing has on a bolt. Schwing Bioset uses bolts that are coated with Dacromet 500, which gives the bolt a silver color. Bolts without this coating will be black in color. Dacromet 500 is a Teflon coating and gives the bolts a lower friction coefficient. In use, Dacromet 500 will allow the bolt to reach the proper prestress level at a lower torque rating then bolts used without it. The following chart gives the general torque values for Dacromet 500 coated bolts and black bolts for both normal and fine pitch threads. Depending on the equipment, some components have a different duty cycle which would require a special torque value. Following the table on general torques, is a table on specific torques for on bolts used on the Rotex slewing bearing. The Rotex bearing is used on the KVM 32XL, KVM 36M, KVM 36X, KVM 42M, KVM 52M, as well as other models. Also, special torques are used on the hydraulic cylinders for the booms and pump kits.
! WARNING! Do not use other standard metric bolt torque tables when torquing metric bolts on Schwing Bioset equipment. Use only Schwing Bioset specified torque values for torques specific to Schwing Bioset equipment. Do not use these torque specifications on bolts for anything other then Schwing Bioset equipment.
KSP Training Manual
10 - 7
SECTION 10
10.7.1
SPECIAL TOOLS
Dacromet 500 Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts) Normal/Regular Thread * Torque Rating - Ft-Lbs (Nm) Property Class Nominal Thread Size
8.8 Ft-Lbs
10.9
(Nm)
Ft-Lbs
12.9
(Nm)
Ft-Lbs
(Nm)
M4
1.6
2.2
2.7
3.2
2.8
3.8
M5
3.2
4.3
4.7
6.4
5.5
7.5
M6
5.5
7.5
8.0
10.8
9.4
12.8
M8
13
18.0
20
27.0
23
31.5
M10
27
36.0
39
53.1
46
62.1
M12
46
62.1
66
90.0
80
108.0
M14
73
99.0
106
144.0
126
171.0
M16
113
153.0
166
225.0
193
261.0
M18
163
220.5
229
310.5
269
364.5
M20
227
308.0
325
441.0
379
513.0
M22
312
423.0
438
594.0
518
702.0
M24
392
531.0
559
758.0
651
882.0
M27
578
783.0
830
1125.0
963
1305.0
M30
797
1080.0
1129
1530.0
1295
1755.0
* Torque rating is based on 90% of the maximum. Nm X 0.737562 = FT/LBS Dacromet 500 means coated with teflon or silver colored. The values in this chart are also valid for black screws that are assembled with mounting paste like Cu, Al, or MOS2.
10 - 8
KSP Training Manual
SPECIAL TOOLS
10.7.1
SECTION 10
Dacromet 500 Screws and Nuts (Cont.) DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts) Fine-Pitch Thread * Torque Rating - Ft-Lbs (Nm) Property Class Nominal Thread Size
8.8 Ft-Lbs
10.9
(Nm)
Ft-Lbs
12.9
(Nm)
Ft-Lbs
(Nm)
M8 X 1
15
19.8
21
28.8
25
33.3
M10 X 1
29
39.6
43
57.6
50
68.4
M10 X 1.25
28
37.8
41
55.8
48
64.8
M12 X 1.25
50
67.5
73
99.0
86
117.0
M12 X 1.5
48
64.8
70
94.5
83
112.5
M14 X 1.5
80
108.0
116
157.5
133
180.0
M16 X 1.5
120
182.0
176
238.5
239
279.0
M18 X 1.5
179
243.0
256
346.5
299
405.0
M20 X 1.5
249
337.5
352
477.0
412
558.0
M20 X 2
-
-
-
-
-
-
M22 X 1.5
339
459.0
478
648.0
559
758.0
M24 X 2
433
587.0
598
810.0
697
945.0
M27 X 2
611
828.0
863
1170.0
1030
1395.0
M30 X 2
863
1170.0
1244
1685.0
1428
1935.0
* Torque rating is based on 90% of the maximum. Nm X 0.737562 = FT/LBS Dacromet 500 means coated with teflon or silver colored. The values in this chart are also valid for black screws that are assembled with mounting paste like Cu, Al, or MOS2.
KSP Training Manual
10 - 9
SECTION 10
10.7.2
SPECIAL TOOLS
Dacromet 500 Screws and Nuts DIN 6914, 6915 (HV Screws) Normal/Regular Thread * Torque Rating - (Nm) Property Class Nominal Thread Size
8.8
10.9
12.9
(Nm)
(Nm)
(Nm)
M8 X 1
-
90
-
M10 X 1
-
225
-
M10 X 1.25
-
405
522
M12 X 1.25
-
585
-
M12 X 1.5
-
720
-
M14 X 1.5
-
1125
-
M16 X 1.5
-
1485
-
* Torque rating is based on 90% of the maximum. Nm X 0.737562 = FT/LBS Dacromet 500 means coated with teflon or silver colored. The values in this chart are also valid for black screws that are assembled with mounting paste like Cu, Al, or MOS2.
10 - 10
KSP Training Manual
SPECIAL TOOLS
10.7.3
SECTION 10
Black Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts) Normal/Regular Thread * Torque Rating - Ft-Lbs (Nm) Property Class Nominal Thread Size
8.8 Ft-Lbs
10.9
(Nm)
Ft-Lbs
12.9
(Nm)
Ft-Lbs
(Nm)
M4
2.0
2.7
3.0
4.0
3.4
4.6
M5
3.9
5.3
5.8
7.8
6.6
9.0
M6
6.6
9.0
10.0
13.5
12.0
16.2
M8
17
22.5
24
32.4
29
38.7
M10
35
44.1
48
64.8
56
75.6
M12
56
76.5
83
112.5
96
130.5
M14
90
121.5
133
180.0
156
211.5
M16
139
189.0
206
279.0
242
328.5
M18
199
270.0
286
367.0
332
450.0
M20
282
382.5
405
549.0
472
639.0
M22
385
522.0
551
747.0
644
873.0
M24
485
657.0
697
945.0
810
1098.0
M27
731
990.0
1030
1305.0
1196
1620.0
M30
963
1305.0
1395
1890.0
1627
2205.0
* Torque rating is based on 90% of the maximum. Nm X 0.737562 = FT/LBS Dacromet 500 means coated with teflon or silver colored. The values in this chart are also valid for black screws that are assembled with mounting paste like Cu, Al, or MOS2.
KSP Training Manual
10 - 11
SECTION 10
10.7.3
SPECIAL TOOLS
Black Screws and Nuts (Cont.) DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts) Fine-Pitch Thread * Torque Rating - Ft-Lbs (Nm) Property Class Nominal Thread Size
8.8 Ft-Lbs
10.9
(Nm)
Ft-Lbs
12.9
(Nm)
Ft-Lbs
(Nm)
M8 X 1
18
24.3
26
35.1
31
41.4
M10 X 1
37
54
54
72.9
63
85.5
M10 X 1.25
36
46.8
50
68.4
60
81.0
M12 X 1.25
62
83.7
90
121.5
106
144.0
M12 X 1.5
59
80.1
86
117.0
103
139.5
M14 X 1.5
96
130.5
143
193.5
169
229.5
M16 X 1.5
149
202.5
219
297.0
259
351.0
M18 X 1.5
226
306.0
322
436.5
379
513.0
M20 X 1.5
315
427.5
452
612.0
525
711.0
M20 X 2
-
-
-
-
-
-
M22 X 1.5
432
585.0
611
828.0
697
945.0
M24 X 2
531
720.0
764
1035.0
897
1215.0
M27 X 2
764
1035.0
1096
1485.0
1295
1755.0
M30 X 2
1096
1485.0
1561
2115.0
1827
2475.0
* Torque rating is based on 90% of the maximum. Nm X 0.737562 = FT/LBS Dacromet 500 means coated with teflon or silver colored. The values in this chart are also valid for black screws that are assembled with mounting paste like Cu, Al, or MOS2.
10 - 12
KSP Training Manual
SPECIAL TOOLS
10.8
SECTION 10
CONVERSION CHART Abbreviation ft-lb/sec ft-lb/sec G G G G G G N/A G N/A g g hp hp ps hp hp in in kg kg kg/cm2 kg/cm2 kg/cm2 kg/m2 kw kw l l l l l m m m µm mm mm mm N Nm Nm oz oz lb lb lb lb lb-ft PSI PSI
TO CONVERT foot-pounds/second foot-pounds/second gallons gallons gallons gallons gallons gallons gallons (imp.) gallons (U.S.) gallons of water grams grams horsepower horsepower horsepower (metric) horsepower horsepower inches inches kilograms kilograms kilograms/square centimeter kilograms/square centimeter kilograms/square centimeter kilograms/square meter kilowatts kilowatts liters liters liters liters liters meters meters meters microns millimeters millimeters millimeters newtons newton meters newton meters ounces ounces pounds pounds pounds pounds pound-feet pounds/square inch pounds/square inch
MULTIPLY BY 0.001818 0.001356 3,785. 0.1337 231. 0.003785 0.004951 3.785 1.20095 0.83267 8.337 0.001 0.03527 42.44 33,000. 0.9863 1.014 0.7457 2.540 25.4 2.2046 0.001 0.9678 0.9807 14.22 0.00009807 56.92 1.341 1000 61.02 0.001 0.001308 0.2642 3.281 39.37 1.094 0.000001 0.003281 0.03937 0.001 0.2248 8.850252 0.7375621 28.3498 0.0625 453.597 4.4484552 .453597 16 0.1383 0.06804 0.06895
TO OBTAIN horsepower kilowatts cubic centimeters cubic feet cubic inches cubic meters cubic yards liters U.S. gallons imperial gallons pounds of water kilograms ounces (avdp.) british thermal units/min. foot-pounds/min. horsepower horsepower (metric) kilowatts centimeters millimeters pounds metric tons atmospheres bars pounds/square inch bars brit. thermal units/min. horsepower cubic centimeters cubic inches cubic meters cubic yards gallons (U.S. liquid) feet inches yards meters feet inches meters pounds inch-pounds foot-pounds grams pounds grams newtons kilograms ounces meter-kilograms atmospheres bars
Abbreviation hp kw cc or cm3 ft3 in3 m3 yd3 l G N/A N/A kg oz btu/min ft-lbs/min hp ps kw cm mm lb N/A A b PSI b btu/min hp cc or cm3 in3 m3 yd3 G ft in yd m ft in m lb in-lbs ft-lbs g lb g N kg oz m-kg A b
39000232
Figure 10.11 - Conversion Table KSP Training Manual
10 - 13
SECTION 10
SPECIAL TOOLS
Abbreviation PSI cm2 in2 in2 in2 m2 mm2 N/A N/A N/A T w w w w yd
TO CONVERT
MULTIPLY BY
pounds/square inch square centimeters square inches square inches square inches square meters square millimeters tons (metric) tons (metric) tons (metric) tons (short) (U.S.) watts watts watts watts yards
0.0703 0.1549997 6.4516 645.1626 0.0007716 10.7639 0.00155 1000 2204.6 1.1023 0.907194 0.05688 44.27 0.0013405 0.001 0.9144
TO OBTAIN kilograms/sq. centimeter square inches square centimeters square millimeters square yards square feet square inches kilograms pounds tons (short) (U.S.) tons (metric) british thermal units/min. foot-pounds/min. horsepower kilowatts meters
Abbreviation kg/cm2 in2 cm2 mm2 yd2 ft2 in2 kg lb T N/A btu/min ft-lb/min hp kw m
39000233
Figure 10.11 - Conversion Table (Cont.)
10 - 14
KSP Training Manual
SPECIAL TOOLS
SECTION 10
METRIC TO AMERICAN AND VICE-VERSA Abbreviation A A A b b b b btu btu/min btu/min cm cm cm cm cc or cm3 cc or cm3 cc or cm3 cc or cm3 ft3 ft3 ft3 ft3 in3 in3 in3 in3 in3 m3 m3 m3 m3 m3 m3/hr yd3 yd3 yd3 yd3 yd3 yd3/hr daN daN ft ft ft ft ft-lb ft-lb ft-lb
TO CONVERT atmospheres atmospheres atmospheres bars bars bars bars british thermal units british thermal units/min. british thermal units/min. centimeters centimeters centimeters centimeters cubic centimeters cubic centimeters cubic centimeters cubic centimeters cubic feet cubic feet cubic feet cubic feet cubic inches cubic inches cubic inches cubic inches cubic inches cubic meters cubic meters cubic meters cubic meters cubic meters cubic meters/hour cubic yards cubic yards cubic yards cubic yards cubic yards cubic yards/hour dekanewtons dekanewtons feet feet feet feet foot-pounds foot-pounds foot-pounds
MULTIPLY BY 1.0132739 1.0333 14.7 0.9869 1 0.98069 14.50377 778.16 .0003929 0.01757 .03281 0.3937 10. 0.01 0.001 0.000001 0.00003531 0.06102 28,320. 1,728. 0.03704 7.48052 16.39 0.0005787 0.00002143 0.004329 0.01639 1,000,000. 35.31 1.308 1,000. 264.2 1.308 764,600 27. 46,656. 764.526 202. 0.764526 1. 14.50377 30.48 0.0003048 0.3048 304.8 0.001286 0.1383 1.356
TO OBTAIN bars kilograms/sq. centimeter pounds/sq. inch atmospheres deka newtons kilograms/sq. centimeter pounds/sq. inch foot-pounds horsepower kilowatts feet inches millimeters meters liters cubic meters cubic feet cubic inches cubic centimeters cubic inches cubic yards gallons (U.S. liquid) cubic centimeters cubic feet cubic yards gallons (U.S. liquid) liters cubic centimeters cubic feet cubic yards liters gallons (U.S. liquid) cubic yards/hour cubic centimeters cubic feet cubic inches liters gallons (U.S. liquid) cubic meters/hour bars pounds/sq. inch centimeters kilometers meters millimeters british thermal units kilogram.-meters newton-meters
Abbreviation b kgs./cm2 PSI A daN kgs/cm2 PSI ft-lbs hp kw ft in mm m l m3 ft3 in3 cc or cm3 in3 yd3 G cc or cm3 ft3 yd3 G l cc or cm3 ft3 yd3 l G yd3/hr cc or cm3 ft3 in3 l G m3/hr b PSI cm km m mm btu kg-m Nm
39000234
Figure 10.12 - Conversion of Metric to American and Vise Versa
KSP Training Manual
10 - 15
SECTION 10
10.9
SPECIAL TOOLS
FLUID POWER FORMULAS The following represent some of the formulas commonly used when working with piston pumps and related equipment. No attempt has been made to list all possible applications for these formulas.
*The diagram below relates 3 formulas regarding force, pressure, and area:
U.S. F = FORCE (in pounds) (lb)
P
P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in 2 )
F=PxA P = F /A
F A
METRIC
A = F /P
F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm2 ) A = AREA (in square centimeters) (cm 2 ) *The following relates to power required by a hydraulic system
GENERAL POWER =
QxP CONSTANT
Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area)
U.S. HP = HORSEPOWER HP =
GPM x PSI 1714
GPM = GALLONS PER MINUTE PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT
METRIC KW = KILOWATTS KW =
LPM x BAR 600
LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT
The above state only the power drawn by the system, and make no allowance for the efficiency of the components. To determine the power needed to drive a specific system, the answer to the formula must be divided by the efficiency factor.
REQUIRED POWER =
QxP CONSTANT
E = EFFICIENCY FACTOR
E The rule of thumb for figuring efficiencies is: E = 0.7 for internal combustion engines, or E = 0.85 for electric motors. It would be the same in Metric as in U.S. calculations. *The following relates to theoretical flow rates by a hydraulic pump Q=
Q (in GPM) =
Q (in liters/min.) =
RPM x PUMP DISPLACEMENT CONVERSION FACTOR RPM x CUBIC INCHES/REV.
GENERAL
U.S.
231 = number of cubic inches in 1 gallon
METRIC
1000 = number of cubic centimeterss in 1 liter
231 RPM x CUBIC CENTIMETERS/REV. 1000
Figure 10.13 - Common Formulas Used With Piston Pumps
10 - 16
KSP Training Manual
SPECIAL TOOLS
SECTION 10
Torque and Horsepower relations: T=
P x CONSTANT
P=
RPM =
T=
T=
T x RPM CONSTANT
P = POWER RPM = REVOLUTIONS PER MINUTE
T HP x 5252
U.S.
RPM
T = TORQUE (in foot-pounds) (ft-lb) HP = HORSEPOWER
T x RPM
5252 = K NOWN CONSTANT
5252 HP x 5252 T KW x 9543 RPM
METRIC T = TORQUE (in newton-meters) (Nm) KW = KILOWATTS
T x RPM 9543
KW = RPM =
T = TORQUE
P x CONSTANT
HP =
RPM =
GENERAL
RPM
9543 = K NOWN CONSTANT
KW x 9543 T
Torque and Displacement relations:
U.S. T = TORQUE (in foot-pounds) (ft-lb)
T=
D = DISPLACEMENT (in cubic inches per revolution) (in 3 /rev.)
DxP 24 π
P = PRESSURE (in pounds per square inch) (PSI) π = Pi (3.1415927)
Finding pressure on material being pumped
U.S.
Rubber Ram
Piston
PC = PRESSURE ON THE MATERIAL (In PSI) PA = PISTON AREA (In square inches) (in 2 )
Rod
(PA)
(RRA) (RSA)
RA = ROD AREA (In square inches) (in2 ) RSA = ROD SIDE AREA (In square inches) (in 2 )
(RA)
RRA = RUBBER RAM AREA (In square inches) (in 2 ) (on piston side) PC =
(on rod side) PC =
RSA =
PA x MAX. P RRA RSA x MAX. P RRA
MAX. P = MAXIMUM HYDRAULIC OIL PRESSURE (In PSI) (relief valve setting) EXAMPLE: Piston diameter 4.72 inches (120mm), Rod diameter 3.15 inches (80mm), Rubber ram diameter 9.05 inches (230mm), relief valve set at 4,350 PSI (300 bar). Area of the piston = 17.5 in 2 . Area of the rod = 7.79 in 2 . Area of the rubber ram = 64.33 in 2.
PA - RA (on rod side) PC =
(17.5 - 7.79) x 4350 64.33
(on rod side) PC = 656.6 PSI
39000236 39000236
Figure 10.13 - Common Formulas Used With Piston Pumps (Cont.)
KSP Training Manual
10 - 17
SECTION 10
DRILL SIZES FOR METRIC TAPS RECOMMENDED DRILL SIZE
M1.5 x 0.35 M1.6 x 0.35 M1.8 x 0.35 M2.0 x 0.45 M2.0 x 0.40 M2.2 x 0.45 M2.3 x 0.40 M2.5 x 0.45 M2.6 x 0.45 M3.0 x 0.60 M3.0 x 0.50 M3.5 x 0.60 M4.0 x 0.75 M4.0 x 0.70 M4.5 x 0.75 M5.0 x 1.00 M5.0 x 0.90 M5.0 x 0.80 M5.5 x 0.90 M6.0 x 1.00 M6.0 x 0.75 M7.0 x 1.00 M7.0 x 0.75 M8.0 x 1.25 M8.0 x 1.00 M9.0 x 1.25 M9.0 x 1.00 M10 x 1.50 M10 x 1.25 M10 x 1.00 M11 x 1.50 M12 x 1.75 M12 x 1.50 M12 x 1.25 M14 x 2.00 M14 x 1.50 M14 x 1.25 M15 x 1.50 M16 x 2.00 M16 x 1.50 M17 x 1.50
1.2272 1.3272 1.5272 1.6492 1.6882 1.8492 1.9882 2.1492 2.2492 2.5324 2.6147 3.0324 3.4154 3.4544 3.9154 4.2206 4.2988 4.3764 4.7988 5.2206 5.4154 6.2206 6.4154 7.0258 7.2206 8.0258 8.2206 8.8308 9.0258 9.2206 9.8308 10.6360 10.8308 11.0258 12.4413 12.8308 13.0258 13.8308 14.4413 14.8308 15.8308
1.20 1.30 1.50 1.65 1.65 1.85 1.95 2.15 2.25 2.50 2.60 3.00 3.40 3.40 3.90 4.20 4.25 4.30 4.75 5.20 5.40 6.20 6.40 7.00 7.20 8.00 8.20 8.80 9.00 9.20 9.80 10.50 10.80 11.00 12.40 12.80 13.00 13.80 14.25 14.75 15.75
CLOSET AMERICAN DRILL SIZE
SIZE
MILLIMETER EQUIVALENT
3/64 55 53 52 52 49 5/64 45 44 39 38 32 30 29 23 19 19 11/64 3/16 5 3 C D I 9/32 5/16 P 11/32 S 23/64 W Z 27/64 27/64 31/64 1/2 1/2 17/32 9/16 37/64 39/64
1.1913 1.3208 1.5113 1.6129 1.6129 1.8542 1.9837 2.0828 2.1844 2.5273 2.5781 2.9464 3.2639 3.4544 3.9116 4.2164 4.2164 4.3662 4.7625 5.2197 5.4102 6.1468 6.2484 6.9088 7.1450 7.9375 8.2042 8.7325 8.8392 9.1286 9.8044 10.4902 10.7162 10.7162 12.3037 12.7000 12.7000 13.4950 14.2875 14.6837 15.4787
BASEC ON APPROX. 75% THREAD RECOMMENDED DRILL SIZE
METRIC TAP SIZE & PITCH
THEORETICAL BORE SIXE IN MM
BASED ON APPROX. 60% THREAD
THEORETICAL BORE SIXE IN MM
10.10
SPECIAL TOOLS
1.1590 1.2590 1.4590 1.5612 1.6102 1.7615 1.9102 2.0615 2.1615 2.4155 2.5184 2.9155 3.2693 3.3180 3.7693 4.0257 4.1235 4.2204 4.6235 5.0257 5.2693 6.0257 6.2693 6.7823 7.0257 7.7823 8.0257 8.5385 8.7823 9.0257 9.5385 10.2950 10.5385 10.7823 12.0516 12.5385 12.7823 13.5385 14.0516 14.5385 15.5385
1.15 1.25 1.45 1.55 1.60 1.75 1.90 2.05 2.15 2.40 2.50 2.90 3.25 3.30 3.75 4.00 4.10 4.20 4.60 5.00 5.25 6.00 6.25 6.75 7.00 7.75 8.00 8.50 8.75 9.00 9.5 10.00 10.50 10.50 12.00 12.50 12.70 13.50 14.00 14.50 15.50
CLOSET AMERICAN DRILL SIZE
SIZE
MILLIMETER EQUIVALENT
57 3/64 54 53 1/16 51 49 46 45 3/32 40 33 30 30 26 22 20 19 14 9 5 15/64 D H I N 5/16 Q 11/32 S 3/8 Y Z 27/64 15/32 31/64 1/2 17/32 35/64 9/16 39/64
1.0922 1.1913 1.3970 1.5113 1.5875 1.7018 1.8542 2.0574 2.0828 2.3825 2.4892 2.8702 3.2639 3.2639 3.7338 3.9878 4.0894 4.2164 4.6228 4.9784 5.2197 5.9537 6.2484 6.7564 6.9088 7.6708 7.9375 8.4328 8.7325 8.8392 9.5250 10.2616 10.4902 10.7162 11.9075 12.3037 12.7000 13.4950 13.8912 14.2875 15.4787
Figure 10.14 - Specification - Drill Sizes For Metric Taps 10 - 18
KSP Training Manual
SPECIAL TOOLS
SECTION 10
M30 x 3.50
RECOMMENDED DRILL SIZE
M28 x 2.00
SIZE
MILLIMETER EQUIVALENT
16.0513 16.4413 16.8308 17.0513 18.0513 18.4413 18.8308 20.0513 20.4413 20.8308 21.6619 22.4413 22.8308 23.4413 23.8308 23.6619 24.6619 25.4413 25.6619
16.00 16.25 16.75 17.00 18.00 18.25 18.75 20.00 20.25 20.75 21.50 22.25 22.75 23.25 23.75 23.50 24.50 25.25 25.50
5/8 41/64 21/32 21/32 45/64 23/32 47/64 25/32 51/64 13/16 27/32 7/8 57/64 59/64 15/16 59/64 31/32 1 1
15.8750 16.2712 16.6700 16.6700 17.8587 18.2557 18.6538 19.8425 20.2413 20.6358 21.4325 22.2250 22.6212 23.4163 23.8125 23.4165 24.6075 25.4000 25.4000
26.4413
26.25
1 1/32
26.1925
27.2720
27.25
1 1/16 5
BASEC ON APPROX. 75% THREAD THEORETICAL BORE SIXE IN MM
M18 x 2.50 M18 x 2.00 M18 x 1.50 M19 x 2.50 M20 x 2.50 M20 x 2.00 M20 x 1.50 M22 x 2.50 M22 x 2.00 M22 x 1.50 M24 x 3.00 M24 x 2.00 M24 x 1.50 M25 x 2.00 M25 x 1.50 M26 x 3.00 M27 x 3.00 M27 x 2.00 M28 x 3.00
RECOMMENDED DRILL SIZE
METRIC TAP SIZE & PITCH
THEORETICAL BORE SIXE IN MM
BASED ON APPROX. 60% THREAD
SIZE
MILLIMETER EQUIVALENT
15.5643 16.0516 16.5385 16.5643 17.5643 18.0516 18.5385 19.5643 20.0516 20.5385 21.0773 22.0516 22.5385 23.0516 23.5385 23.0773 24.0773 25.0516 25.0773
15.50 16.00 16.50 16.50 17.50 18.00 18.50 19.50 20.00 20.50 21.00 22.00 22.50 23.00 23.50 23.00 24.00 25.00 25.00
39/64 5/8 41/64 41/64 11/16 45/64 23/32 49/64 23/32 51/64 53/64 55/64 7/8 29/32 59/64 29/32 15/16 63/64 63/64
15.4787 15.8750 16.2712 16.2712 17.4625 17.8587 18.2557 19.4462 19.8425 20.2413 21.0337 21.8288 22.2250 23.0175 23.4163 23.0175 23.8125 25.0038 25.0038
26.0516
26.00
25.7962
26.9875
26.5900
26.50
1 1 /64 1 1/32 1 1/16 1 3/32 1 1/ 8 1 11/64 1 5/32 1 11/64 1 7/32 1 13/64 1 17/64 1 19/64 1 21/64 1 21/64 1 3/ 8 1 13/32 1 23/64
CLOSET AMERICAN DRILL SIZE
M30 x 3.00
27.6619
27.50
1 /64
27.3837
27.0773
27.00
M30 x 2.00
28.4413
28.25
1 7/64
28.1788
28.0516
28.00
1 9/64 1 3/16 1 3/16 1 13/64 1 15/64 1 7/32 1 9/32 1 5/16 1 11/32 1 23/64 1 13/32 1 7/16 1 15/32
28.9712
28.5900
28.50
30.1625
30.0516
30.00
30.1625
29.5900
29.50
30.5587
30.0773
30.00
31.3538
31.0516
31.00
30.9575
30.5900
30.50
32.5425
32.1028
32.00
33.3375
33.0773
33.00
34.1325
34.0516
34.00
34.5288
34.1028
34.00
35.7175
35.1028
35.00
36.5125
36.0773
36.00
37.3075
37.0516
37.00
M32 x 3.50
29.2720
29.25
M32 x 2.00
30.4413
30.25
M33 x 3.50
30.2720
30.25
M33 x 3.00
30.6619
30.50
M33 x 2.00
31.4413
31.25
M34 x 3.50
31.2720
31.25
M36 x 4.00
32.8822
32.75
M36 x 3.00
33.6619
33.50
M36 x 2.00
34.4413
34.25
M38 x 4.00
34.8822
34.75
M39 x 4.00
35.8822
35.75
M39 x 3.00
36.6619
36.50
M39 x 2.00
37.4413
37.25
CLOSET AMERICAN DRILL SIZE
26.1925 26.9875 27.7813 28.5750 29.7663 29.3675 29.7663 30.9575 30.5587 31.7500 32.9413 33.7337 33.7337 34.9250 35.7175 36.9087
Figure 10.14 - Specification - Drill Sizes For Metric Taps (Continued) KSP Training Manual
10 - 19
SECTION 10
10 - 20
SPECIAL TOOLS
KSP Training Manual
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