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Initial commissioning

2010-9015-017
04-2015

7

Initial commissioning

7.1

Special personnel qualification required for initial commissioning

Initial commissioning must be performed by trained personnel in accordance
with the safety instructions.

Read the section Safety - Personnel qualifications.

7.2

Safety instructions for initial commissioning

Warning!

Do not start this product until the initial commissioning checklist is
completed.

Warning!

PTO driveline must always be activated when the agitator propeller is
immersed in manure. Running the agitator out of manure may result
in damage.

Caution!

Unexpected movements may happen if tractor hydraulic connections
are mixed up.

The first start steps intend to test the product in order to validate its functionality
and efficiency before handing it over to the customer. Therefore, the dealer
along with the customer must operate the product as well as the operating
elements.

7.3

Hydraulic control valve setup

7.3.1

Relief valve

1

The relief valve (1) on PTO agitators is preset to 1500 PSI by the manufacturer
of the valve. If hydraulic pressure is not sufficient to operate one or many
agitator functions, adjust the relief valve (1) by screwing the nut gradually until
the agitator operates properly.

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Summary of Contents for Lagoon Agitator

Page 1: ...Lagoon Agitator PTO Agitator Instruction Manual Installation Instructions Original instructions 2010 9015 017 04 2015 engineering for a better world GEA Farm Technologies ...

Page 2: ... 22 6 Handling and assembly 23 6 1 Special personnel qualification required for handling 23 6 2 Safety instructions for handling and assembly 23 6 3 Preparation 23 6 4 Packing material disposal 24 6 5 Handling the product and accessories 24 6 6 Lagoon Agitator assembly 25 7 Initial commissioning 31 7 1 Special personnel qualification required for initial commissioning 31 7 2 Safety instructions fo...

Page 3: ... 10 5 Check oil level in oil bath 54 10 6 Check oil level in oil tank 54 10 7 Grease the PTO driveline 54 10 8 Grease driving shaft bearings 55 10 9 Grease swivel hitch 55 10 10 Grease undercarriage pivot points 55 10 11 Grease bearing housing 56 10 12 Clean the equipment 56 10 13 Replace propeller knife 56 11 Decommissioning 57 11 1 Special personnel qualification required for decommissioning 57 ...

Page 4: ...most recent version can be obtained through the dealer or directly from the manufacturer Pictograms used This pictogram indicates information that will be helpful toward a better understanding of the working processes This symbol indicates another document or section to refer to All manuals have a reference number The 4 middle digits specify the language of the instruction manual language language...

Page 5: ...please contact your nearest dealer There is a comprehensive dealer Internet search function on our website at the following address www gea farmtechnologies com European contact information GEA Farm Technologies GmbH Siemensstraße 25 27 D 59199 Bönen 49 0 2383 93 70 49 0 2383 93 80 contact gea com www gea farmtechnologies com US contact information GEA Farm Technologies Inc 1880 Country Farm Dr Na...

Page 6: ...ower General rules relating to systems Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology Safety of machinery Basic concepts general principles for design Part 2 Technical principles Safety of machinery Risk assessment Part 1 Principles Safety of machinery Risk assessment Part 2 Practical guidance and examples of methods Graphical symbols Safety c...

Page 7: ... in material or workmanship for a period of twelve 12 months from the date of delivery of the equipment to the Purchaser This written warranty takes precedence over any other written warranty included in previous versions of the Company s manuals Any equipment used for commercial usage commercial lease on one or more farms is warranted for a reduced period of thirty 30 days only Components from th...

Page 8: ...e parts of the equipment free of charge where installed or at the business place of the Dealer or the Company at its sole discretion 1 5 3 Extent of limited warranty This limited warranty DOES NOT cover Defects caused by negligence of the Purchaser in the maintenance of the equipment improper use resulting from failure to adhere strictly to the Company s manuals or non compliance with prescribed m...

Page 9: ...luding without limitation labor costs and costs related to concrete or excavation Claims arising from repairs or replacements made by the Purchaser without the prior written consent of the Company The Purchaser shall not remove or alter any safety device guard or warning sign If the Purchaser fails to comply with any of its obligations referred to in this paragraph the Purchaser agrees to save the...

Page 10: ...ONSEQUENTIAL INCIDENTAL 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 do not allow the exclusion or limitation of incidental or consequential damages and so it is possible that these limitations or exclusions may not apply 1 5 5 General statements TH...

Page 11: ...he equipment needs to be towed on public road the owner must adapt the equipment in accordance with local towing safety regulations The owner must ensure a safe environment by providing this instruction manual with this product adequate lighting in all areas where activities in connection with this product are performed A minimum of 200 lux is required to ensure visibility of the equipment the con...

Page 12: ... 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 potential danger to life or health of personnel Death or serious injury may result if the danger is not avoided Caution The indication Caution signals dangerous situations Minor or moderate injury may result if the danger is not avoided Attention ...

Page 13: ...his product unless they are performing instructions included in this manual When near this product keep body parts such as hands feet hair as well as clothing away from dangerous parts such as rotating parts articulated parts sharp edges etc Use this product only when in perfect working condition and for the sole purpose for which it was designed Do not use damaged worn or defective parts on this ...

Page 14: ... workers of those rules maintenance and methods Qualified personnel Qualified personnel refers to those having obtained the academic knowledge of a specific field of work This personnel has followed a training and subsequently obtained a certification diploma or any other official document provided by a recognized academic facility in the country of study An equivalence may be required when operat...

Page 15: ... driveline Part No 2010 7606 910 American Protective guard for power take off driveline Part No 2018 4701 630 European Cylinder lock Part No 2010 7620 000 Stabilizing leg Part No 2010 7612 440 2 5 2 Safety labels The labels affixed on this product inform the user of the potential dangers the prohibited manoeuvres the proper procedures and applications when performing activities in connection with ...

Page 16: ...uipment The manufacturer expressly points out that only original parts and original accessories supplied by GEA Houle are adapted tested and authorized to be used with this product or equipment Do not use other supplier s parts or equipment with GEA Houle product unless otherwise approved in writing by GEA Houle The manufacturer does not accept any liability toward injured people or animals or dam...

Page 17: ... view 4 1 Lagoon Agitator 1 2 3 4 5 6 Reinforcement truss available in option Draw bar 3 ft longer available in option Double wheels on lagoon agitator undercarriage available in option Legend 1 Propeller 4 Cylinder lock 2 Knife 5 Jack 3 Undercarriage 6 Draw bar ...

Page 18: ...Main view Lagoon Agitator 2010 9015 017 04 2015 18 64 4 1 1 Options 1 2 3 Legend 1 Heavy duty undercarriage 3 Articulated propeller 2 Multipurpose undercarriage ...

Page 19: ...t 1765 lbs 800 kg 2130 lbs 965 kg 2845 lbs 1290 kg 3220 lbs 1460 kg 3860 lbs 1750 kg Agitator center of gravity Lifting point location Propeller diameter 24 610 mm 24 610 mm pitch 24 610 mm 32 813 mm pitch 5 2 Hydraulic hoses I D O D 0 58 0 86 1 10 Quantity of braids 2 2 2 Service pressure 400 bar 5800 psi 276 bar 4000 psi 207 bar 3000 psi 5 3 Undercarriage Standard undercarriage Height 60 1 52 m ...

Page 20: ...rcarriage 2010 9015 017 04 2015 20 64 Heavy duty undercarriage Height 91 2 31 m Width overall 106 2 69 m Weight 1080 lbs 490 kg Heavy duty XL undercarriage Height 91 2 31 m Width overall 154 3 92 m Weight 1265 lbs 575 kg ...

Page 21: ...98 m Weight 1850 lbs 840 kg 5 4 Tire Tire model Ply Pressure Tire dimensions inches mm Weight tire without rim 16 5L X 16 1 8 26 psi 1 8 bar Diameter 30 3 770 Width 10 7 272 31 lbs 14 kg 5 5 Tractor specifications Tractor power 99 HP or less 24 610 mm propeller pitch 100 HP or more 32 813 mm propeller pitch PTO RPM required 540 RPM ...

Page 22: ...382ft lb 796Nm 587ft lb SAE 8 MCAS 19Nm 14ft lb 39Nm 29ft lb 64Nm 47ft lb 106Nm 78ft lb 161Nm 119ft lb 229Nm 169ft lb 312Nm 230ft lb 515Nm 380ft lb 814Nm 600ft lb 949Nm 700ft lb Socket Head Cap Screw AS HT 22Nm 16ft lb 45Nm 33ft lb 73Nm 54ft lb 114Nm 84ft lb 170Nm 125ft lb 244Nm 180ft lb 339Nm 250ft lb 542Nm 400ft lb 868Nm 640ft lb 1315Nm 970ft lb 5 8 Lubricant specifications Lubricant type Brands...

Page 23: ... with the safety instructions Read the section Safety Personnel qualifications 6 2 Safety instructions for handling and assembly Warning Do not stand under suspended loads Falling loads can cause fatal injuries Caution Sharp edges may cause injuries Read the section Safety 6 3 Preparation 6 3 1 Handling tools Attention To lift the equipment use a lifting device with a minimum capacity of 4425 lbs ...

Page 24: ...o your local rules and regulations on waste disposal Please refer to your local resources for any questions Recycle if possible 6 5 Handling the product and accessories To lift the agitator insert a fork of a forklift truck in the axle collar 1 under the beam and insert the other fork of the forklift truck in the channel welded under the beam 1 To lift the agitator in the case of a split frame ins...

Page 25: ...ake sure universal joints 3 are in the same position on both agitator sections If needed rotate the shaft 4 4 4 3 3 Apply silicone all over the flange 6 Using the crane carefully move and align the agitator section to insert the driving shaft 4 through the bearing 5 Place the sleeve 2 over the drive shaft end 4 between the bearing 5 and the universal joint 3 Note the sleeve is attached to the univ...

Page 26: ...and heavy duty XL undercarriages Fix the hubs to the undercarriage frame then install the wheels Once the undercarriage is assembled lift the agitator over the undercarriage Using a brush apply all purpose grease over the pivot section 7 Lift the agitator to align it with the axle collar then bolt both collars together using provided hardware Torque 7 ...

Page 27: ...ssembly Lagoon Agitator assembly 2010 9015 017 04 2015 27 64 Install the cylinder s and the lock cylinder s as illustrated hereafter Install the tension arms on both sides of the agitator HD and HD XL undercarriages ...

Page 28: ...en install the wheels Once the undercarriage is assembled lift the agitator over the undercarriage Using a brush apply all purpose grease over the pivot section 7 Lift the undercarriage to align it with the axle collar then bolt both collars together using provided hardware Torque 7 Install the cylinder s and the lock cylinder s as illustrated hereafter ...

Page 29: ...ed hardware When the agitator is connected to the tractor install the jack to the transportation support 8 8 Stabilizing leg on Lagoon Agitator with standard heavy duty and heavy duty XL undercarriages only Install the stabilizing leg as illustrated hereafter At this point the Lagoon Agitator can stand safely on the ground by adjusting the jack and the stabilizing leg adequately ...

Page 30: ...g and assembly Lagoon Agitator assembly 2010 9015 017 04 2015 30 64 Hydraulic hoses support Install the support Insert the hydraulic hoses in the rings 9 Install the hydraulic connectors in the support 10 9 10 ...

Page 31: ...sed in manure Running the agitator out of manure may result in damage Caution Unexpected movements may happen if tractor hydraulic connections are mixed up The first start steps intend to test the product in order to validate its functionality and efficiency before handing it over to the customer Therefore the dealer along with the customer must operate the product as well as the operating element...

Page 32: ...system The beyond plug 3 is required for tractor equipped with a closed hydraulic system also called load sensing in some cases 2 3 Note A new equipment always comes with two plugs a standard plug installed on the valve and a beyond plug supplied separately Make sure to install the appropriate plug Plug change Attention Oil leak will occur when changing the plug Note Make sure the undercarriage an...

Page 33: ...antity 1 6 splines 2010 7505 710 16NC x 1 8 2 1 20 splines 2010 7505 720 16NC x 1 2 2 7 5 Initial commissioning checklist This checklist must be completed by the dealer and the customer to validate that the product is assembled and or installed according to the manufacturer s instructions and that it is safe for use Note Additional information necessary to complete the checklist can be found in th...

Page 34: ...Initial commissioning Initial commissioning checklist 2010 9015 017 04 2015 34 64 ...

Page 35: ... tires are inflated at appropriate pressure The tractor draw bar is adjusted to minimum length while respecting the PTO limitations The PTO shaft is installed The owner is instructed on the PTO driveline instructions The spare safety shear bolts are removed from the PTO guards The equipment component provided by the owner comply with the specifications contained in section Technical data Options D...

Page 36: ...Initial commissioning Initial commissioning checklist 2010 9015 017 04 2015 36 64 ...

Page 37: ...remain in place to ensure safety the lubricants such as grease oil etc are at an appropriate level there are no leaks all bolts are tight Refer to section Technical data Bolt torque chart the product works perfectly 7 7 Handing over to the owner Hand over warranty registration form The warranty registration form must be completed and signed by the customer and the dealer The warranty registration ...

Page 38: ...ng the agitator in the pit Move the tractor backward at low speed Never leave the agitator in operation without the supervision of a qualified operator The tractor must be immobilized with parking brakes or wheel chocks to keep it from entering in manure storage During operation it is strictly forbidden to stand in the working area Read the section Safety 8 3 Checks before operating The safety dev...

Page 39: ...t side 3 Articulated propeller down 8 5 Connecting the Lagoon Agitator 8 5 1 Draw bar connection Insert the tractor draw bar in the Lagoon Agitator hitch Insert a 1 hitch pin through the draw bar to lock it in place Order the part No 2018 3802 420 1 hitch pin if needed Secure the pin using a cotter pin Refer to tractor operating instructions and make sure the chains are attached according to your ...

Page 40: ...erating or transporting the equipment Never use the safety chains to secure the PTO when disconnected from the tractor Maximum extension and retraction While operating the agitator never exceed the maximum point indicated by the adhesive tapes on the male guard The minimum retraction indicator 1 must never disappear underneath the female guard 1 2 The maximum extension indicator 2 must never be co...

Page 41: ...bar can be adjusted up and down to observe the maximum angle of PTO joints 8 5 4 Component connection Caution Connect the hydraulic hoses properly to ensure safe operation Refer to section Appendix Hydraulic diagrams Connect the Lagoon Agitator hydraulic hoses to the tractor Double check all connections for safety purpose Connect the electrical outlet of the Lagoon Agitator to the tractor if appli...

Page 42: ...arm tractor If the equipment needs to be towed on public road the owner must adapt the equipment in accordance with local towing safety regulations For long distance transportation use a truck or truck and trailer approved for public roads 8 6 1 Basic preparation steps before moving the agitator Make sure the undercarriage cylinder s is are in locked position 1 Disconnect the PTO 2 and install it ...

Page 43: ...erform steps in section Basic preparation steps before moving the agitator 8 7 Positioning the agitator 8 7 1 In a lagoon Make sure the undercarriage cylinder s is are in unlocked position Connect the PTO Move the agitator backward into the lagoon Immerse the propeller into the manure Once the agitator is positioned apply tractor safety brakes ...

Page 44: ... leg if applicable 8 7 2 In a concrete reservoir using the multipurpose undercarriage only Make sure the undercarriage cylinder s is are in unlocked position Connect the PTO Swivel the undercarriage for the front wheels to touch the ground Move the agitator backward until the front wheels touch the wall ...

Page 45: ...04 2015 45 64 Swivel the undercarriage in vertical position Extend the telescopic legs until they touch the bottom of the pit Move the agitator backward Immerse the propeller into the manure Once the agitator is positioned apply tractor safety brakes ...

Page 46: ...46 64 8 8 Agitation mode Engage the PTO at minimum RPM Gradually increase the PTO up to 540 RPM Once the manure is homogenized decrease RPM Stop the PTO The articulated propeller option makes manure homogenization faster See the operating mode below ...

Page 47: ...abilizing leg if applicable Raise the propeller out of manure Remove tractor safety brakes Move the agitator forward Make sure the undercarriage cylinder s is are in locked position Install the PTO 1 on transportation support 1 From a concrete reservoir Stop the PTO Raise the propeller out of manure Remove tractor safety brakes ...

Page 48: ...agitator forward until the front wheels touch the wall Retract the telescopic legs Swivel the undercarriage legs up Move the agitator forward Swivel the undercarriage for the rear wheels to touch the ground Make sure the undercarriage cylinder s is are in locked position ...

Page 49: ...Operating Removing the agitator 2010 9015 017 04 2015 49 64 Install the PTO 1 on transportation support 1 ...

Page 50: ...ust be performed by trained personnel in accordance with the safety instructions Read the section Safety Personnel qualifications 9 2 Safety instructions for troubleshooting Warning HYDRAULIC LINE UNDER PRESSURE Do not use your fingers to check for leaks Fluids can penetrate skin and cause serious or fatal injuries Hold a piece of cardboard to check for leaks Read the section Safety ...

Page 51: ...erheats or erratic operation Wrong connection Read instruction and consult tractor manual Vibration in the driveline The PTO joints are out of alignment Refer to section Operating PTO driveline connection Vibration Foreign material wrapped on propeller Remove foreign material Long straw not chopped Propeller knife not cutting Replace propeller knife Hydraulic articulations elements do not work Tra...

Page 52: ...and stationary parts It is strictly forbidden to stand in the danger zone Turn off the tractor and apply the hand brake before lubricating cleaning or servicing the equipment Warning Always remove the equipment from the lagoon reservoir before servicing Warning HYDRAULIC LINE UNDER PRESSURE Do not use your fingers to check for leaks Fluids can penetrate skin and cause serious or fatal injuries Hol...

Page 53: ...inspection X Trained personnel Check oil level in oil bath optional X Check oil level in oil tank X Grease the PTO driveline X Grease the swivel hitch X X Grease driving shaft bearings X X Grease undercarriage pivot points X Grease bearing housing X X Clean the equipment X Replace propeller knife X Attention When operating this GEA Houle product using other manufacturer s components and or product...

Page 54: ...flat and firm surface Remove the oil bath filling plug and measure the oil level as shown Add SAE 80W90 gear oil if necessary Do not overfill Put the plug back on 10 6 Check oil level in oil tank Every 5 hours of operation Make sure the oil in the oil tank is at proper level Add SAE 80W90 gear oil if necessary 10 7 Grease the PTO driveline Note Use specified grease or equivalent TRC 880 Crown and ...

Page 55: ...uivalent TRC 880 Crown and Chassis grade 0 2010 4300 790 Replace the cover Repeat this procedure for each driving shaft cover 10 9 Grease swivel hitch After each working day and every 10 hours of operation Add grease in the hitch grease fitting 1 Use all purpose grease 1 10 10 Grease undercarriage pivot points After each working day Add grease in the undercarriage grease fittings 1 Use all purpose...

Page 56: ...exceed 2000 psi 105 bar when using a pressure washer and keep the nozzle at a distance of 1 ft 30 cm from the surface to be cleaned Pressure wash the entire equipment Open the drain on the agitator 10 13 Replace propeller knife Warning Turn off the tractor apply parking brake and remove the PTO driveline before replacing the propeller knife Caution Always wear safety gloves when handling the prope...

Page 57: ...e tractor Always hook them on their supports Read the section Safety 11 3 Temporary decommissioning Storage To store the equipment place it on a horizontal flat and firm surface Install whell chocks to prevent the equipment from moving Make sure the maintenance schedule that can be found in section Maintenance has been followed Once the equipment is lubricated and cleaned spray a thin layer of bio...

Page 58: ...9015 017 04 2015 58 64 12 Appendix 12 1 Label position A B C D E E E F G A 2099 4720 010 US B 2099 4720 020 US C 2099 4721 020 US 2099 4725 100 EU D 2010 4701 590 US E 2003 4701 240 US EU F 2099 4725 310 US EU G 2010 4703 430 US EU ...

Page 59: ...omotive Engineers USA United States of America WWW World Wide Web Units Explanation Units Explanation A ampere kg kilogram AC alternative current kPa kilopascal cm centimeter kW kilowatt degree km h kilometres per hour C degree Celsius lpm liter per minute F degree Fahrenheit lb pound DC direct current m meter ft foot min minute ft lb foot pound mph miles per hour gal gallon mm millimeter gpm gall...

Page 60: ...dix Hydraulic diagrams 2010 9015 017 04 2015 60 64 12 3 Hydraulic diagrams 12 3 1 Hydraulic diagram of a Lagoon Agitator with standard undercarriage Undercarriage cylinder Articulated propeller option Option ...

Page 61: ...Appendix Hydraulic diagrams 2010 9015 017 04 2015 61 64 12 3 2 Hydraulic diagram of a Lagoon Agitator with heavy duty undercarriage Undercarriage cylinder Articulated propeller option Option ...

Page 62: ...endix Hydraulic diagrams 2010 9015 017 04 2015 62 64 12 3 3 Hydraulic diagram of a Lagoon Agitator with multipurpose undercarriage Undercarriage cylinder Articulated propeller option Option Telescopic leg ...

Page 63: ...Appendix Hydraulic diagrams 2010 9015 017 04 2015 63 64 ...

Page 64: ... 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 company is one of the largest providers of innovative equipment and process technology GEA Group is listed in the STOXX Europe 600 index 2010 9015 017 04 2015 We reserve the right to modify the construct...

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