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GEA Futuro, Instruction Manual And Installation Instructions

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GEA Futuro Instruction Manual And Installation Instructions Download Page 96

Maintenance

Scheduled maintenance responsibilities

2007-9015-001
03-2014

96 / 108

Check insulated gate valve oil level

Note!

Use hydraulic oil.

Refer to section on Lubricant specifications.

● Remove the filling cap of the

insulated gate valve.

● Fill up the tube up with hydraulic oil.

● Put the filling cap back on and clean.

Filling cap

Summary of Contents for Futuro

Page 1: ...Futuro Underground Manure Pumps Instruction Manual Installation Instructions Original instructions 2007 9015 001 03 2014 engineering for a better world GEA Farm Technologies...

Page 2: ...for transportation 39 4 4 Lifting and moving the pump 40 4 5 Lifting and moving the hydraulic power unit 40 4 6 Storage conditions 40 4 7 Information on disposing of packing material 40 5 Installation...

Page 3: ...8 3 Troubleshooting possible faults 84 9 Maintenance 87 9 1 Special personnel qualification required for maintenance work 87 9 2 Safety instructions for maintenance 87 9 3 Scheduled maintenance respo...

Page 4: ...cialist terminology are explained in more detail in the Appendix These instructions are part of the supply They should be kept close at hand and remain with the equipment even if the equipment is sold...

Page 5: ...cate the language as follows language language language 9000 German 9013 Dutch 9032 Serbian 9001 English United Kingdom 9015 English North American 9034 Slovakian 9002 French France 9016 Polish 9035 C...

Page 6: ...lease contact your nearest authorized technical dealer There is a comprehensive dealer Internet search function on our website at the following address www gea farmtechnologies com European Contact In...

Page 7: ...ines and specifications EN ISO 13857 2008 06 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs EN ISO 14121 1 2007 12 Safety of machinery Risk assessm...

Page 8: ...T THAT THE EQUIPMENT IS SOLD OR OTHERWISE TRANSFERRED 1 5 2 Condition of the limited warranty The Company through its GEA authorized dealers only hereinafter referred to as Dealer reserves the right t...

Page 9: ...ditions including without limitation damages caused by fire lightning flood or other natural disaster damages caused by the use of sand litter or other abrasive or inadequate material including withou...

Page 10: ...AL PUNITIVE OR EXEMPLARY DAMAGES IN ANY KIND OR CHARACTER INCLUDING INDIRECT COSTS LOSS OF PRODUCTION LOSS OF REVENUES OR PROFITS AND OTHER DISBURSEMENTS WHICH MAY OCCUR Some states or jurisdictions d...

Page 11: ...compacted sand bed on the bottom of trench before installing the Steel Evacuation Line 1 6 2 Prorated Warranty Against Corrosion The Steel Evacuation Line is warranted against perforation due to corro...

Page 12: ...s and warnings A Danger TOXIC GASES sign is posted at the eye level at the entry of the pit area Make sure this sign remains visible at all times No one must enter into a manure pit at any time except...

Page 13: ...or the farm These must be especially adapted to the conditions of the business once again expressly taking account of safety aspects The product is only used for its intended purpose should only be op...

Page 14: ...he indication Danger signals immediate danger to life or health of personnel Death or serious injury will result if the danger is not avoided Warning The indication Warning signals danger to life or h...

Page 15: ...ional Safety and Health Administration www osha gov In European Union European Agency for Safety and Health at Work www europe osha eu int Danger As manure produces toxic gases that may cause death it...

Page 16: ...n livestock farms has inherent risks Read and follow the instructions carefully especially the section on Safety to ensure your own safety The chapter on Technical data gives the permissible working c...

Page 17: ...be performed by qualified personnel only in accordance with slinging techniques Any work in a reservoir must only be carried out by qualified personnel having knowledge on safety procedure in confine...

Page 18: ...99 4721 000 Warning American model Always turn off main power before maintenance and service Never adjust the equipment while it is running Keep all shields and guards in place Keep hands and loose cl...

Page 19: ...arting the pump American model Never operate the pump without manure part no 2099 4724 010 Make sure that both valves under the tank are opened before operating the power unit American model Change th...

Page 20: ...trical motor on the equipment which does not match the motor technical specifications provided in this manual The equipment is not designed to use any other type of motor than those listed Improper mo...

Page 21: ...ety reasons do not carry out any unauthorized modifications Planned changes must be approved by the manufacturer in writing Any unauthorized modifications to the product will invalidate the warranty a...

Page 22: ...oses and the intake flapper opens to fill the evacuation chamber with slurry During the evacuation cycle down stroke the intake flapper closes and the discharge flapper opens to move the slurry from t...

Page 23: ...Pump 1 2 3 4 5 6 7 8 9 10 11 Legend 1 Hydraulic cylinder 2 Grease lines 3 Manual lever guillotine valve 4 Reversing mechanism 5 Pumping Tube 6 Discharge guillotine valve 7 Spring housing 8 Access door...

Page 24: ...Description Main View 2007 9015 001 03 2014 24 108 Legend 1 Intake flapper valve 2 Flapper door seal 3 Downstroke lever 4 Piston 5 Discharge flapper valve 6 Discharge valve spring...

Page 25: ...Main View 2007 9015 001 03 2014 25 108 3 5 2 Hydraulic Power Unit 2 3 4 4 1 7 6 5 8 Legend 1 Oil reservoir 2 Reservoir cap 3 Oil sight gauge 4 Ball valve 5 Oil filter 6 Motor 7 Chain joint guard 8 Hyd...

Page 26: ...he length of the suction pipe is limited and based upon the consistency of the manure slurry The suction pipe elbow may be position up or down depending on the relationship between the elevation of th...

Page 27: ...gate valve must be installed to prevent manure flow into the air line 1 5 6 2 3 4 Legend 1 Air valve 2 50 mm 2 Relief valve 6 mm 3 Cap 6 150 mm 4 Gate valve 6 150 mm 5 Air flush riser 6 Flow direction...

Page 28: ...305 cm valve 16 406 cm valve Dimensions do not include lever extensions If lever extensions are used add the extension length to these dimensions Manual lever and lever extension 12 305 mm or 16 406...

Page 29: ...ow back as long as manure remains consistent enough to seal the flapper The flapper valve may leak if manure becomes watery or if a piece of material gets stuck between the flapper and the valve housi...

Page 30: ...m Maximum evacuation line length Varies based on manure consistency Maximum length of suction pipe Varies based on manure consistency Pump without intake or discharge accessories Perform a manure cons...

Page 31: ...iption Technical Data 2007 9015 001 03 2014 31 108 12 315 mm steel elbows 15 Elbow 30 Elbow 45 Elbow 60 Elbow 75 Elbow 90 Elbow 16 406 mm steel elbows 15 Elbow 30 Elbow 45 Elbow 60 Elbow 75 Elbow 90 E...

Page 32: ...1 22 m X 15 15 4 57m needle 20 6 1m needle A 180 4 57 m A 240 6 1 m B 37 93 99 cm and less B 53 1 35 m and less C 48 1 22 m C 48 1 22 m X 15 X 15 75 long radius elbow with rising pipe 15 X 5 long 75 l...

Page 33: ...less D 24 61 cm and more D 24 61 cm and more X 15 X 15 75 Flapper valve with rising pipe 15 X 5 long 75 Flapper valve with rising pipe 15 X 10 long A 108 2 74 m A 168 4 27 m B 32 81 3 cm and less B 48...

Page 34: ...pressure 54 PSI 1200 PSI in hydraulic circuit Noise level 62 dBA Pump without intake or discharge accessories Perform a manure consistency test Metric chart Slurry consistency Maximum evacuation dist...

Page 35: ...kW 50 Hz 1450 PLP 20 14 5 5 20 7 1800 124 1 PLP 20 16 6 3 24 1440 99 3 PLP 20 20 8 30 3 1200 82 7 5 HP 60 Hz 1740 PLP 20 14 6 6 24 8 1500 103 4 PLP 20 16 7 6 28 8 1200 82 7 PLP 20 20 9 6 36 3 1000 68...

Page 36: ...rent No special requirements Efficiency min 80 Power Factor No special requirements General data Standard specifications NEMA IEC Frame sizes required 184T 213T 215T 112 132 Type of construction B3 We...

Page 37: ...ff switch meet all motor specifications provided in this manual meet local electrical requirements Special specifications The control panel protection devices must be designed to avoid any unexpected...

Page 38: ...6 7 Bolt torque chart Bolt Mat Bolt diametre 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 1 SAE 2 LCS 8Nm 6ft lb 16Nm 12ft lb 27Nm 20ft lb 44Nm 32ft lb 64Nm 47ft lb 94Nm 69ft lb 130Nm 96ft lb 210Nm 155ft l...

Page 39: ...d support points for transport Also read the chapter on Safety Special transport hazards Sharp edges may cause injuries Suspended loads can fall resulting in severe injuries or even death If load susp...

Page 40: ...hydraulic power unit Using a fork lift Insert forks under the power unit motor base to lift it 4 6 Storage conditions Attention Risk of corrosion When storing the goods supplied the location must pro...

Page 41: ...n Before installation look for any damage caused during transport Do not use damaged components Use only the special tool indicated for assembly Special hazards during installation Injury can be cause...

Page 42: ...trical wiring diagrams Foundation plan Special tools Description Purpose Fork lift truck To lift the equipment Chain hoist To lift the equipment Safety chains To lift the equipment Hammer drill To mak...

Page 43: ...al purchased items Provided by the owner Safety fences installed around the equipment reservoir to prevent fall PVC pipe rated at 150 psi 10 3bar minimum An electric motor meeting technical specificat...

Page 44: ...ns of the pit do not include a stairway for pump maintenance Refer to your engineer or architect in order to design a stairway that gives access to the pit Note Evacuation pipe must be installed throu...

Page 45: ...r pump with a hopper and with an air riser Refer to section on Installing a 6 15 cm riser for air flush The length of pit is applicable to all configurations of intake and discharge adaptors with or w...

Page 46: ...preparations 2007 9015 001 03 2014 46 108 Pit for pump with a suction pipe and without an air riser The length of pit is applicable to all configurations of intake and discharge adaptors with or with...

Page 47: ...with an air riser Refer to section on Installing a 6 15 cm riser for air flush The length of pit is applicable to all configurations of intake and discharge adaptors with or without guillotine valve...

Page 48: ...e Technical Data Section on Concrete Anchor Bolt To tighten bolts adequately refer to the Technical Data Section on Bolt Torque Chart 5 5 1 Positioning the pump Lift the pump and position it in the pi...

Page 49: ...impeded lever movement and operator convenience Lever extension The pump pit can be covered for added safety and convenience In this case the valve levers are raised above the floor by using a lever e...

Page 50: ...st be turned down with hydraulic agitation option added to prevent plugging Refer to section on Minimum pit dimensions for installing the pump in a service pit The maximum length of the suction line i...

Page 51: ...g the hydraulic agitator use a lifting equipment having a minimum capacity of 200 lbs 90 kg to hold the hydraulic agitator Using 2 U bolts 7 16 x 3 5 x 4 375 round U bolts install the agitator on supp...

Page 52: ...ll scratches with tar to protect from corrosion Attention Pipes must be surrounded with sand and carefully backfilled under the frost level Attention All gate valves with insulated rod and PVC elbows...

Page 53: ...must refer to local authorities for proper specifications regarding the size the orientation and the spacing of the blocks C A B A Evacuation line inlet B Insulated gate valve C Concrete thrust block...

Page 54: ...female PVC Male steel to male PVC A G B C G Male steel to male steel Male steel to female steel C D G D G Male PVC to female SS Male steel to female SS B E F G E F G Legende A PVC pipe collar G Thread...

Page 55: ...f the evacuation line Refer to section on Dimensions of GEA Houle steel components prior to install the discharge pipe Install the discharge pipe in the bottom of the manure storage pit according to t...

Page 56: ...o seal the flapper The flapper valve may leak if manure becomes watery or if a piece of material gets stuck between the flapper and the valve housing Manure storage pit In a sand bedding operation if...

Page 57: ...the evacuation line 2007 9015 001 03 2014 57 108 Remove the filling cap of each insulated gate valve and fill the tube with hydraulic oil to protect it against frost and to prevent corrosion Then put...

Page 58: ...flush sand from the evacuation line using air pressure and a straw bullet Evacuation line Air riser One riser is required every 200 60 m Note Some evacuation lines require extra risers where potentia...

Page 59: ...ume of compressed air Refer to the table below to find appropriate air tank size required to flush the full length of evacuation line 12 3 4 315 mm evacuation line Air Pressure Length of evacuation li...

Page 60: ...79 m 290 88 m 320 98 m 350 107 m Minimum size of air tank 125 psi 8 6 bar 210 g 790 L 335 g 1263 L 460 g 1739 L 585 g 2211 L 710 g 2684 L 835 g 3160 L 960 g 3633 L 1085 g 4105 L 1210 g 4581 L 1336 g 5...

Page 61: ...long the buried line The following instructions prolong the life of the steel equipment significantly Each steel pipe must be free of scratches on its coating Scratches greatly amplify the corrosion p...

Page 62: ...or indirectly to the equipment protected For example if the concrete floor wire mesh the stalls and the evacuation line are linked together to the same ground wire sacrificial anodes will have to pro...

Page 63: ...equired to make a single loop around the bolt Hook the stripped wire to the bolt between 2 washers Do not overlap the wire since it may cut itself when tightening the nut copper wire of the sacrificia...

Page 64: ...owder in the cardboard tube must be saturated with water before burying the sacrificial anode Using a knife make a cut in the plastic cap and fill the tube with water The cardboard will disintegrate w...

Page 65: ...e from a supplier other than the manufacturer it is mandatory to verify components compatibility Make sure motors and or control panels match the equipment specifications Refer to the Technical Data s...

Page 66: ...n motor shafts as shown below Using the appropriate bolt pattern install the motor on the support Position the motor shaft in line with the pump shaft and tighten motor bolts Install the chain to main...

Page 67: ...square cut The saw must be equipped with a blade capable of cutting through the wire reinforcement layers Attention Dirt is the worst enemy of any hydraulic system To prevent dirt from entering into t...

Page 68: ...be protected from freezing temperatures Choose a location that will minimize the length of hydraulic lines required Allow sufficient clearance around the hydraulic unit to permit service and routine m...

Page 69: ...ate energy when under pressure If the hose is too tight a tension will be apply to the fitting and connection point Where a hose must be bent into a curve the curve must be smooth with no twists in th...

Page 70: ...ically bloc the potential stray voltage transfer between the hydraulic power unit and the equipment Note Some installation may require to use hydraulic hose extensions In this case keep the orange hos...

Page 71: ...revent damage to property and or life threatening injury to personnel always follow these instructions Before starting for the first time check that all tools and other parts have been removed from th...

Page 72: ...ully read understand and act in accordance with the instructions All stationary components are securely anchored to the floor All grease zerks have been lubricated All guards and covers are in place A...

Page 73: ...ted and secured Pump Clean and lubricate the reversing mechanism with fine oil Make sure the distance between the adjustable finger and the bottom finger does not exceed the maximum Adjust finger if n...

Page 74: ...nt the springs must force the trigger to complete its down stroke If the trigger does not complete its stroke automatically repeat the first step Evacuation cycle Siphoning cycle Spacers Bolts Piston...

Page 75: ...on on Lubricant specifications Check the oil level in the hydraulic power unit Inspect all hydraulic fittings for leaks If the oil level has dropped check for leaks Defective parts may need to be repa...

Page 76: ...personnel always follow these instructions Only fit or use the product for its intended purpose Also read the chapter on Safety Special dangers involved in operation Incorrect use may lead to serious...

Page 77: ...re are no unnecessary object or material is located in the working area Check and make sure that the working area has been cleaned from oil grease parts Make sure the hydraulic circuit of the hydrauli...

Page 78: ...lose the valve Open Closed Lever lock To lock the valve in the open position raise the lever and swing the lock bar down and rest it on top of the cylinder This will prevent the valve from accidentall...

Page 79: ...en the handle is far from the line The gate valve is only installed if the elevation of the top of the manure storage reservoir is higher than the cap on the air flush riser Gate valve 6 152 mm Relief...

Page 80: ...and stop the pump Note It is recommended to close and open valves periodically to make sure they are in good condition and installed as a safety measure in case of emergency Open the hydraulic guillo...

Page 81: ...e pressure is relieved completely before removing the cap The compressed air inside pipes would propel the cap with force Before removing the cap open the ball valve to relieve pressure Note If you ar...

Page 82: ...y required to clear obstructions that have clogged the suction pipe Stop the pump and close the intake guillotine valve Open the air injection valve for 10 seconds Close the air injection valve Open t...

Page 83: ...ing injury to personnel always follow these instructions First of all prevent the product from being restarted accidentally Secure the range of action of all moving parts Also read the chapter on Safe...

Page 84: ...e evacuation line Suction line clogged Flush the suction line Intake and or discharge flapper valve not opening and closing properly Lubricate the valves Inspect the rubber seal on the flapper valves...

Page 85: ...sists perform a fluid and filter change Hydraulic fluid is foamy or bubbly Pump is cavitating See symptom Pump cavitating Hydraulic pump Symptom Possible cause Remedy Pump cavitating Low fluid level i...

Page 86: ...tem operated with burnt old or contaminated fluid Determine and eliminate the sources of contaminated fluid Never use used fluid or fluid from dirty unknown or open containers Pump cavitating See symp...

Page 87: ...must be limited to qualified personnel that perfectly knows and follows safety procedures in confined spaces Permanent ventilation must be active in each structure surrounding the main storage to evac...

Page 88: ...Note the special information in this manual for the individual components All warnings and warning signs must be present and legible Immediately replace components that are not in perfect condition A...

Page 89: ...ants solvents can cause injury if they come into direct contact with the skin and could make the floor surface slippery which could result in dangerous fall Hydraulic hoses failures may cause unexpect...

Page 90: ...il of hydraulic power unit Check Replace maintenance technician Every year Clean the equipment Clean Operator Check insulated gate valves oil level Check fill Operator Change oil of hydraulic power un...

Page 91: ...e the oil above the pump piston is at proper level Add oil as needed Replace oil when it becomes dirty 2 5 cm 9 3 2 Every 50 hours or weekly Lubricate the equipment Note Use general purpose grease Ref...

Page 92: ...ance responsibilities 2007 9015 001 03 2014 92 108 Use grease zerks to lubricate the flapper door pivot of the Futuro pump Grease zerks Operate gate valves Operate the gate valves to ensure they open...

Page 93: ...ed Never let the fluid level drop to where it isn t visible in the sight gauge Look for changes in the appearance of the fluid i e dark cloudy etc Oil sight gauge Attention Wipe up any oil spills Safe...

Page 94: ...ricant specifications Place a large container under the oil filter in order to recuperate oil more than 16 US gallons 60 litres Close 2 ball valves under the power unit reservoir A Remove the oil filt...

Page 95: ...er when cleaning with a pressure washer Keep the pressure washer nozzle at least 12 30 cm from the surface to be cleaned Clean the Futuro pump with a pressure washer Clean the complete reversing mecha...

Page 96: ...01 03 2014 96 108 Check insulated gate valve oil level Note Use hydraulic oil Refer to section on Lubricant specifications Remove the filling cap of the insulated gate valve Fill up the tube up with h...

Page 97: ...e care when loosing the bolts The spring is under tension and can be expelled the housing cover with force Always wear proper eye protection Failure to do so may lead to injury Note In order to get ac...

Page 98: ...issioning Leaking lubricants solvents could cause injury if they come into direct contact with the skin and could make the floor surface slippery which could result in dangerous fall Components which...

Page 99: ...nt specifications Grease all parts labeled with Refer to section on Label position To prevent corrosion spread all moving parts with an environmentally friendly anti corrosion product 10 4 Final decom...

Page 100: ...formed to find the viscosity of well agitated slurry Set a 24 60cm disc over a pail Slowly pour enough slurry to get overflow all around the disc After 1 minute of rest measure the thickness of slurry...

Page 101: ...21 010 US D 2099 4724 010 US E US EU 2099 4701 240 F 2099 4725 190 EU G 2099 4725 130 EU H 2005 4703 560 US EU I 2099 4721 000 US J 2099 4724 030 US K 2099 4725 240 EU L EU 2099 4725 420 M 2099 4700 3...

Page 102: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 102 108 11 3 Hydraulic diagrams 11 3 1 Futuro pump Reversing valve Pump cylinder...

Page 103: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 103 108 11 3 2 Futuro pump with guillotine valve option Pump cylinder Guillotine valve cylinder Reversing valve Selection valve Guillotine valve...

Page 104: ...9015 001 03 2014 104 108 Legend 1 Hydraulic reservoir 2 Shut off valves 3 Oil filter 4 Hydraulic pump 5 Selector valve 6 Reversing valve 7 Power unit 8 Optional cylinder on guillotine 9 Cylinder on g...

Page 105: ...Appendix Hydraulic diagrams 2007 9015 001 03 2014 105 108 11 3 3 Futuro with optional hydraulic agitator Pump cylinder Reversing valve Hydraulic agitator motor...

Page 106: ...temperature HT Heat Treated fax Facsimile LCS Low Carbon Steel ft Feet MCS Medium Carbon Steel gal Gallon MCAS Medium Carbon Alloy Steel GPM Gallons per minute NC National coarse thread Hp Horsepower...

Page 107: ...Appendix Abbreviations 2007 9015 001 03 2014 107 108...

Page 108: ...ur values Excellence Passion Integrity Responsibility GEA versity GEA Group is a global engineering company with multi billion euro sales and operations in more than 50 countries Founded in 1881 the c...

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