battioni Pagani KPS 490 Instruction Manual For Use And Maintenance Download Page 41

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Instruction Manual

for WPT, KTS, KPS, KTM, WSM series use and maintenance

pag. 65

ENGLISH

11.0 - PUTTING OUT OF SERVICE AND DEMOLITION

Before demolishing the Rotary blades vacuum pump the following materials should be separated:

• lubricating oil;
• parts in rubber and plastic;
• parts in cast iron and steel;
and disposed of correctly.

Do not discard the Rotary blades vacuum pump in the environment.

For disposal of the lubricating oil make use of specialised treatment services.

Summary of Contents for KPS 490

Page 1: ...SM IT GB MANUALE ISTRUZIONI PER L USO E LA MANUTENZIONE INSTRUCTION MANUAL FOR USE AND MAINTENANCE NOTICE D EMPLOI ET D ENTRETIEN GEBRAUCHS UND WARTUNGSANLEITUNGEN HANDLEIDING VOOR HET GEBRUIK EN HET ONDERHOUD FR DE NL ...

Page 2: ...s et sur les flasques versions MFR MAFR DFR PFR HFR GFR GAFR versione MFR MAFR versione DFR versione HFR versione PFR Die WPT Serie bietet Vakuum Derhpumpen mit Lamellen für lan dwirtschaftliche Verwendung mit ähnlichen Anwendungen an die sen von der Serie STAR und MEC aber besonders bietet Vakuum Derhpumpen mit Lamellen für schwere Verwendungen da sie ha ben auch eine Wasserkühlungsanlage durch e...

Page 3: ...e di serie esenti amianto Blades as series in special material heat resistant without asbestos Palettes de série en matériel spécial résistant à la chaleur et sans amiante hitzebeständigen Schaufeln aus Spezialmaterial ausgestattet ohne Asbest Paletas de material especial resistentes al calor de serie exentes de amianto Palhetas em material especial resistentes ao calor e sem amianto de série WPT ...

Page 4: ...ettent une longue utilisation continue Cette série peut être montée soit sur les camions que sur des gros tonneaux agricoles Die Serie KTS besteht aus 3 Modellen KTS 840 KTS 960 KTS 1080 in den Versionen MFR MAFR PFR DFR HFR GFR GAFR mit Förderleistungen von 14100 l min bis 18000 l min Serienmäßig sind sie mit einer automatischen Schmieranlage ausgestattet und mit einer Wasserkühlanlage auf dem Zy...

Page 5: ... zwischen den Rotor und den Körper treten sollten Posibilidad de deslizamiento de los platos para evitar rotu ras ante la presencia de elementos extraños entre el rotor y cuerpo de la bomba Possibilidade de deslizamento do flange para evitar que bras em caso de presença de elementos estranhos entre o rotor e o corpo da bomba Elevata resistenza ad usura grazie a ghisa ad alta durezza Big wearing re...

Page 6: ...ent une longue utilisation continue Cette série peut être montée soit sur les camions que sur des gros tonneaux agricoles Die Serie KPS besteht aus 3 Modellen KPS 490 KPS 550 KPS 670 in den Versionen MFR MAFR PFR DFR HFR KFR KAFR GFR GAFR mit Förderleistungen von 13520 l min bis 18620 l min Serienmäßig sind sie mit einer automatischen Schmieranlage ausgestattet und mit einer Wasserkühlanlage auf d...

Page 7: ...zamento do flange para evitar que bras em caso de presença de elementos estranhos entre o rotor e o corpo da bomba Elevata resistenza ad usura grazie a ghisa ad alta durezza Big wearing resistance thanks to cast iron with elevated hardness Resistance à l usure élevée suivant à fonte avec dureté élevée Hohe Festigkeit zu Abnutzung für Gußeisen mit hohe Härte Fundición de alta resistencia que garant...

Page 8: ... utilisation continue Il y sont disponibles plusieurs ac cessoires pour le complètement de l application Die hergestellte Serie KTM WSM wurde unter Anwendung der mo dernsten technischen Lösungen und Materialien höchster Technolo gie entwickelt und gebaut Diese Serie besteht aus 6 Modellen KTM 1200 KTM 1500 KTM 1800 KTM 2300 WSM 2700 WSM 3300 mit Förderleistungen von 21 500 l min bis 56000 l min un...

Page 9: ...lubrificação automática de série Raffreddamento ad acqua su corpo e flange Watercooling in the body and flanges Refroidissement par eau sur le corps et sur les flasques Wasserkühlung im Körper und in den Flanschen Refrigeración por agua de cuerpo y platos Arrefecimento por água no corpo e nas flanges Elevata resistenza ad usura grazie a ghisa ad alta durezza Big wearing resistance thanks to cast i...

Page 10: ...om imperfections and it is mandatory where these imperfections are clearly attributable to the manufacturing process and the materials use to repair it or based on their final decision to replace defective pieces In any case the costs of labour travel and transport and any customs expenses shall be paid by the Purchaser The seller is not responsible for compensating any damages except in case of f...

Page 11: ...uum pump and always check their efficiency every time the machine is used Any work on the machine must be carried out while it is not running Failure to comply with the instructions given in this manual may lead to the following dangers Danger of being crushed by the Rotary blades vacuum pump mass during handling and transport Danger of getting entangled in the shaft transmission parts if the nece...

Page 12: ...OUNTING INSTALLATION 41 3 4 COOLING SYSTEM 43 3 4 1 GENERAL INFORMATION 43 3 4 2 COOLING CIRCUIT 43 3 4 3 COOLING CIRCUIT WITH RADIATOR AND ELECTRIC FAN 43 3 4 4 THERMOSTAT 43 3 4 5 INSTRUCTIONS 44 3 4 6 DIAGRAM OF THE COOLING CIRCUIT WITH RADIATOR AND ELECTRIC FAN 44 3 5 HYDRAULIC DIAGRAM H VERSION 45 3 6 HYDRAULIC MOTOR USE AND MAINTENANCE INSTRUCTIONS 45 3 7 UNINSTALLATION 47 3 8 DISASSEMBLY 48...

Page 13: ...8 6 PERSONAL PROTECTIVE EQUIPMENT TO BE USED 59 9 0 TROUBLESHOOTING 60 10 0 MAINTENANCE INSPECTIONS AND CHECKS REPAIRS TECHNICAL ASSISTANCE 61 10 1 CLEANING 61 10 1 1 BODY WASHING 61 10 1 2 FLUSHING KIT KPS 61 10 1 3 OIL TANK WASHING 61 10 1 4 VALVES WASHING AND CLEANING 61 10 2 VALVES CHECKING 61 10 3 BLADES GENERALITIES 61 10 3 1 BLADES INSPECTION 62 10 3 1 1 BLADES INSPECTION WPT KTS M MA 62 10...

Page 14: ...ry blades vacuum pump by the identification plate and by the stamping placed on the gearbox cover P VERSION FOR PULLEY APPLICATION Pthe power take off is actuated trough pulley and belts This version can be recognised by the cylindrical shaft with key of the power take off and by the plate P pulley application D VERSION DIRECT DRIVE D the power take off is actuated through a cardan shaft directly ...

Page 15: ... rpm and it is designed to drive a pump unit 2 or unit 3 The version is recognisable by the hydraulic pump support and the identification plate KAthe PTO is driven by means of a cardan shaft at 1000 rpm and it is designed to drive a pump unit 2 or unit 3 The version is recognisable by the hydraulic pump support by the identification plate and by the punching placed on the upper part of the box 1 1...

Page 16: ...dures concerning Rotary blades vacuum pump versions G GA are given in the GARDA LEDRAgroup manual 3 1 INSTALLATION DRAFT Warning Do not move the KPS using the 4 eyebolts filter cover but only and exclusively for the eye bolts on the body The Rotary blades vacuum pump should be Strapped with metal hooks to be inserted in the gripping hole or with a band Lifted with a hoisting truck if on pallet bri...

Page 17: ... enough space for suction and delivery hoses A 5 maximum longitudinal slope of the Rotary blades vacuum pump with respect to the horizontal plane must not be exceeded 2 Bolt the Rotary blades vacuum pump using screws and nuts passing through the specially provided slots or holes in the feet 3 M To install M version connect the tractor s cardan shaft at 540 rpm to the Rotary blades vacuum pump powe...

Page 18: ...nsmission is under tension If the force exceeds the maximum force value the transmission is tenser than it should be However a new transmission can be initial stretched twice the value of min strength to allow normal tension adjustment while operating WPT KTS KPS SERIES Then connect the Intake Compression pipe of the tank to the Rotary blades vacuum pump tightening it to the adjustable elbow using...

Page 19: ...o unscrew the iron plug placed on the top of the pump body and put in water through the feed tank until it overflows form the previously mentioned hole 3 4 3 COOLING CIRCUIT WITH RADIATOR AND ELECTRIC FAN The circuit with radiator and electric fan can be supplied with 12 V or 24 V power supply is described below This circuit is to be preferred for prolonged continuous use The characteristics of th...

Page 20: ...ansit or stop in the moving or hot pump area WPT KTS KPS VERSIONS Left rotation direction of the pump Right rotation direction of the pump Always put antifreeze liquid in the cooling circuit at the rate recommended by the suppliers Fill the cooling circuit completely putting in water through the feed tank Make sure that there is no air in the circuit as this would hinder the water circulation prev...

Page 21: ...ons Check that the coupling flange correctly aligns the user shaft and the motor shaft 3 6 HYDRAULIC MOTOR USE AND MAINTENANCE INSTRUCTIONS Make sure with unidirectional motors that the rotation direction is consistent with the circuit connections Check that the coupling flange correctly aligns the user shaft and the motor shaft 1 2 HYDRAULIC SYSTEM 3 5 7 4 6 M 1 WPT KTS KPS KTM WSM 2 3 4 5 6 7 UN...

Page 22: ...e oil in the tank always using a filter Bleed the circuit to assist in filling Set the pressure relief valves to the lowest possible setting Turn on the system for a few moments at minimum speed then bleed the circuit again and check the level of oil in the tank If the difference between pump or motor temperature and fluid temperature exceeds 10 C rapidly switch the system on and off to heat it up...

Page 23: ...from the sleeve 3 remove the tube connecting the Rotary blades vacuum pump to the tank cart loosening the metal clamp and slipping the tube from the sleeve 3 remove the tube connecting the Rotary blades vacuum pump to the tank cart loosening the metal clamp and slipping the tube from the sleeve 4 remove any hydraulic connection 4 remove any hydraulic connection 4 remove any hydraulic connection 5 ...

Page 24: ...f the cooling liquid by unscrewing the 2 cap placed at the bottom of the body and then turn upside down the Rotary blades vacuum pump for series WPT WSM KTS KPS M MA P D 1 unscrew the screws of the gearbox cover 1 slide the pulley off the front pin 1 remove the guard by unscrewing the clamp ing screws if present 2 use two screws for screwing into the threaded extraction holes until the cover is re...

Page 25: ...coupling flange to the body with a torque set ting of 80 Nm 4 tighten the clamping screws of the front flange to the body with a torque setting of 80 Nm 4 tighten the clamping screws of the front flange to the body with a torque setting of 80 Nm 5 remove the dowel pins 5 remove the dowel pins 5 remove the dowel pins 6 fix the gearbox to the coupling flange with screws 6 attach the front cover to t...

Page 26: ... Assemble the bearing on the flange by using a buffer and insert the compensating ring and insert the Seeger ring 6 Assemble the bearing on the flange by using a buffer and insert the compensating ring and insert the Seeger ring 7 Insert the spacer and assemble the pinion on the shaft 7 Reassemble the front cover on the flange 7 Reassemble the front cover on the flange 7 Reassemble the hydraulic m...

Page 27: ...insert the lubrication or cooling pump shaft in the connector joint 8 tighten the four screws that fix the cover to the back flange 9 connect the delivery tubes of the lubrication pump inserting them in the connecting piece and pressing then until the quick clamping hooks snaps 10 fit the lateral tank support at the pump body 11 attach the feeding tube from the later tank to the lubrication pump K...

Page 28: ...crews of the manifold 5 insert the rubber ball on its seat 6 fit the valve cover tightening the screws 7 put the reversing gear in checking that the flat part of the reversing gear is positioned at 90 to the power take off 8 put the spring on the reversing gear 9 apply the manifold cover gasket 10 place the manifold cover and fasten it with screws 11 insert the selector 12 screw the handle pin on ...

Page 29: ... bearings and inside the Rotary blades vacuum pump without manual adjustment and saving a considerable amount of oil 5 1 AUTOMATIC LUBRICATION With this system the pump is lubricated both during the intake and the compression phase by a piston pump with adjustable flow rate placed on the back and actuated by the rotor Oil is injected directly in the pump eliminating manual adjustment and saving a ...

Page 30: ...eral oils Figure 4 Figure 5 KTM WSM KTS KPS WPT KTM WSM SERIES The minimum and maximum levels are indicated by the vertical level indicator placed on either side of the tank The oil temperature and Rotary blades vacuum pump overheating can be controlled by a thermometer inside the level indicators see Figure 4 WPT KTS KPS SERIES The minimum and maximum oil levels are indicated by indicator placed ...

Page 31: ...LUBRICATING OIL QUANTITY During the Rotary blades vacuum pump operations check that amount of oil indicated in table 3 drops from the regulating cock These amounts are valid for the Automatic Lubrication When necessary to add in the tank put only new and clean oil VERSIONE M MA K KA the first gearbox oil change is to be done after about 100 hours of actual work the following changes can be done ev...

Page 32: ...ise to increase the oil flow Turn the screw anticlockwise to decrease the oil flow see Figure 10 this operation must be done for all the lubrication pump pistons Remove the screwdriver and close the plug Figure 10 Automatic lubrication pump KTM 1800 2300 WSM 2700 3300 6 0 OVERPRESSURE VALVES AND VACUUM ADJUSTMENT VALVES The following diagram describes the valves as series O on demand X and not ava...

Page 33: ...ng pressure 2 absolute bar 1 relative bar Vacuum a too high vacuum may cause ovality and waviness of the body or breaking of the blades It is therefore advisable to use a vacuum regulator valve D The abovementioned valves can be mounted on the pumps manifold or on the manifold cover The working vacuum grade is 0 80 bar The regulation of the valves is done by acting on the throttle placed on the va...

Page 34: ...xceed the speed and power limits set in this manual Avoid overloads and under load functioning of the power take off Check the following operating parameters PARAMETER WORKING RATE WORKING RATE Speed M G K rpm 450 500 600 Speed P D H rpm 1000 1200 for KPS 1200 1400 for KPS Speed WSM 2700 3300 P rpm 800 1000 Speed MA GA KA rpm 800 1000 Pressure bar 0 5 1 1 5 Vacuum 80 95 Cylinder external temperatu...

Page 35: ...on selection made with the handle must be operated with the Rotary blades vacuum pump not running 8 5 PROTECTIVE DEVICES The Rotary blades vacuum pump when being installed on a machine must be equipped with a protective device to isolate the moving parts of the transmission and prevent access to them by the operators M MA K KA D versions are equipped with a CE marked plastic protective device It i...

Page 36: ...harge curve Malfunctioning of valves Check valves Smoke comes out of discharge tube Excessive lubrication Adjust lubrication Water leaks from blanking caps or fittings Insufficient tightening Tighten until there is no more leakage No lubricating oil circulation for automatic lubrication versions Air intake at pipe fittings Replace pipe fittings Lubrication tube badly inserted in pipe fittings Inse...

Page 37: ...t will be provided with plastic tank and tap to place on the tank for such operation Lacking the kit just remove the 1 1 2Gas cap on the manifold and input the diesel fuel from the top hole causing it to fall out from the output curve 10 1 3 OIL TANK WASHING Wash the oil tank at least once a year with appropriate detergent 10 1 4 VALVES WASHING AND CLEANING Wash and clean the valves at least once ...

Page 38: ...the state of wear of the blades in the Rotary blades vacuum pump proceed as follows 1 remove the threaded inspection plug see Figure 11 2 turn the rotor until a blade is aligned with the inspection hole 3 measure the distance between the external surface of the rotor and the external side of the blade 4 if this distance is greater than 10 15 of the original blade height replace the complete set of...

Page 39: ...evision kit containing in a single blister pack Original Battioni Pagani blades gaskets and oil seals 10 3 3 BLADES DIMENSION MODEL NUMBER OF BLADES BLADES SIZE WPT 480 6 300x73x7 5 WPT 600 6 400x73x7 5 WPT 720 6 500x73x7 5 KTS 840 6 500x80x6 7 KTS 960 6 570x80x6 7 KTS 1080 6 640x80x6 7 KPS 490 5 460x60x6 5 MODEL NUMBER OF BLADES BLADES SIZE KPS 550 5 410x82 5x7 5 KPS 670 5 500x82 5x7 5 KTM 1200 6...

Page 40: ...mpressed air preventing the dirt from falling inside the collector move the plate to verify proper operation reassemble all parts Once a week Check oil level in tank Use the oil level outside the tank Once a week Check that the over pressure and vacuum regulator valves are working correctly Remove valves Once a month Check that the overflow valves are working correctly Remove valves Once a month L...

Page 41: ...fore demolishing the Rotary blades vacuum pump the following materials should be separated lubricating oil parts in rubber and plastic parts in cast iron and steel and disposed of correctly Do not discard the Rotary blades vacuum pump in the environment For disposal of the lubricating oil make use of specialised treatment services ...

Page 42: ...rovato Autorizzato Battioni Pagani si riserva il diritto di approntare modifiche ai dati e alle caratteristiche illustrate nel catalogo La riproduzione anche parziale del presente catalogo è vietata ai termini di legge Battioni Pagani reserve the right to modify without notice the data features shown in this catalogue The reproduction even partial of this catalogue is fobidden by law ...

Page 43: ...es vacuum pump Centrifugal pump Rotary postive displacement lobes pump Rotary postive displacement lobes pump Rotary lobes vacuum pump Via Cav Enzo Ferrari 2 43058 Ramoscello di Sorbolo PR Italy Ph 39 0521 663203 Fax 39 0521 663206 www bapag it info bapag it ...

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