Crane no-10 Maintenance

Crane no-10 Bucket maintenance

AGIE
REV. 0

AGITATOR FOR THICKNER

MANUAGITATORS INSTRUCTION MANUAL Pag.16 di 18

Sede Commerciale e Stabilimento: Vi a S.Per t ini , 41 50019 Sesto Fiorent i no (Fi renze) - I t a l ia
Uf f icio Commerci ale Lombardi a : V ia R. Leoncaval lo, 2 0 20131 Mi lano I tal ia
Central O f f ice and Plant : Str . S. Per t i n i , 41 - 50019 Sesto F.no (Fl orence ) - I t a l y
Sales department (Region of Lombardia) : St r. R. Leoncava l l o , 20 20131 Milan I t aly

5. MAINTENANCE
CAUTION!! See section 2.1 Safety instructions
All maintenance operations must be performed after
cutting off the power supply. All measures must be
taken so as not to operate within the equipment
when the latter is running.
The equipment must be adequately cleaned as
suggested by the installer according to the features of
the installation environment. Do not use solvents
and/or abrasive products for cleaning, because these
substances may affect the agitators safe operation.
The agitator shall not be dry-operated (unless designed for this
kind of operation) for periods over one minute, and in any case it
may be dryoperated only during the running-in or testing stages.
During operation, the agitator does not require any special
maintenance, provided that all the recommendations
contained in this manual are observed.
After the first 500 hours of operation, change the oil of
the agitators gearbox (if the latter is of the oillubricated
type) and flush the full system after
discharging the used oil. Gearboxs lubricated with
synthetic grease or with oil for life are maintenancefree.
Regularly check the lubricant level on the
gearbox and change it every 4.000 operating hours,
unless otherwise specified.
The lubrication of bearings (except for watertight
bearings, that are maintenance-free) must be
performed by adding grease through the specially
designed grease nipples.
The grease inside bearings must be changed when the
agitator is inoperative and disconnected from the mains.
To guarantee a longer life of the equipment, the
latter must be serviced with care, replacing all
parts that are more subject to wear, such as
bearings, oil seals, seals, bottom bushings, etc.
All disassembly and assembly operations must be
performed by qualified staff operating with the utmost
care in a clean environment.
5.1 Agitators Components outside the tank
FREQUENCY MAINTENANCE OPERATION
MOTOR: Follow the maintenance instructions provided by the manufacturer
GEARBOX: Follow the maintenance instructions provided by the manufacturer
VARIATOR: Follow the maintenance instructions provided by the manufacturer
MECHANICAL SEAL Follow the maintenance instructions provided by the manufacturer
monthly PACKING SEAL
Check the tightening of the stuffing box.
monthly
PRESSURIZATION TANK
Check the fluid level
Check for leaks on gaskets.
every 3
months
AGITATORS BEARINGS
Check for leaks from the grommets of the bearing
housing.
monthly
AGITATORS BEARINGS

Apply the right amount of grease inside the bearing

cases using the grease nipples.
every 6
months
V-BELTS (antistatic type)
Verify the conditions of V-belts and replace them
with new belts if signs of wear, stretches or tears are
found.
every 6
months
FLEXIBLE COUPLINGS:
Check and replace the flexible parts of the coupling,
if worn.
every 6
months
AGITATOR:
Check the tightening of the bolts connecting the
agitators flange to the tanks flange.
Check the tightening of all bolts fitted onto motiontransferring
components.

5.2 Agitators Components inside the tank

FREQUENCY MAINTENANCE OPERATION
every 3
months
BOTTOM DRAIN::
Check the shafts guide bushing for wear conditions
and replace it, if necessary.
every 6
months
IMPELLERS:
Check the tightening of the mounting supports.
every 6
months
SHAFT-TO-SHAFT CONNECTION FLANGE:
Check the tightening of the mounting supports.
every 6
months
SCRAPER RINGS:
Check the Teflon scraper rings for wear and replace
them if necessary.
yearly
AGITATOR:
Check for corrosion on the parts coming in contact
with the processed products.

Cooling tower maintenance

MAINTENANCE
The most frequent operations, to be carried out at intervals determined by the operating
conditions, are the following:
Water distribution system
TAL cooling towers are equipped with a water distribution system without nozzles but with
non-clogging, stainless steel construction diffusers which do not require special
maintenance.
We recommend to check periodically the condition of the diffusers and their position through
the specific inspection door.
The hole in the clip fastening the diffuser to the pipe should be concentric with the pipe hole
and should not obstruct it; the perforated plate beneath the outlet hole shall be clean and all
holes shall be unobstructed.
Access to the diffusers for dismantling and/or reassembling is obtained through the
inspection door, proceed as follows:
- take note of the arrangement of the individual sections, remove the first layer of the
wet deck surface and also the second, only when necessary.

- Place a wooden plank on the remaining surface.

- Proceed along the plank on the remaining surface.
- Proceed along the plank to the diffusers, arrange, adjust or dismantle and/or put them
in place as before.
- Put back in place the wet deck surface if it has been removed; do not confuse the
cross section which may vary from one layer to another.
Beware: for reasons of safety, it is absolutely forbidden to walk or tread directly on the wet
deck which may give way in addition to being damaged.
Pag. 10
Wet deck surface replacement
The standard wet deck surface may not repaired or cleaned; when it is torn and/or blocked, it
must be replaced.
Although the upper layer of the wet deck surface is mechanically stronger, solid matter
contained in the recirculation water or clogged nozzles, may tear the PVC baffles forming the
sections of the wet deck surface.
A good water treatment will make the occurrence of salt deposits on the wet deck surface
less likely but not altogether impossible, because like a wet filter, the water washes the air
and will capture most of the solid matter (pollen, insects, dust etc.) which will then be settled
on the wet deck surface.
Obviously all sections of the wet deck surface where the smooth passage of water/air is not
ensured must be replaced; also the section where the flow seems to be alright, but actually
exceed the weight of 40/45 kg/m must be replaced.
To replace the wet deck surface, enter the tower by removing all the sections that make up
the wet deck surface, taking care to note their layout.
Insert the new surface, taking care to keep the original layout.
In particular, make sure that the flows are positioned vertically and ensure that the
shockresistant
layer is the first to be hit by the water.
Remember that in these towers the pack is supported by two or more supports and it cannot
support a person; therefore for obvious safety reasons, when going inside, always and only
walk on the wooden plank that you have installed for this purpose.
Pag. 11
Motor bearings
Every 5000/8000 hours of operation, (according to size) it is a good idea to check and
maintain the motor bearings, by greasing them properly.
As the bearings are not normally provided with a lubricating nipple, the operation must be
carried out by a specialized workshop (see chapter electric motor).
Electric motor
Unless otherwise stated at the time of ordering, the electric motor will be of the type supplied
without a connection box, connected instead by a special protected waterproof sheathed
cable, which exits from a sleeve or cable clamp and reaches the connection box placed
outside the fan.
The standard construction features are: V6 mounting arrangement, F class insulation, IP55
or IP56 protection on the whole motor.
For larger sizes, there is hole for discharge of condensation and water.
When rewinding the motor and/or replacing the bearings, it should be ensured that the
original protection level is retained by the reconditioned motor.
Fan
A periodical check of the impeller must be carried out to verify the condition of the impeller
blades and to check their hub retaining bolts.
- Check the impeller motor connection.
- Check the tightness of the sealing bolt on the drive shaft.
- Any abnormal vibrations caused by the impeller may damage the motor.

Pag. 12
The following checks must also be carried out periodically for the towers provided
with a water sump.
Float valve calibration
Malfunctioning of the float valve may cause the water level in the sump to fall which, in turn,
would cause the pump to draw air or produce an unnecessary increase in water consumption
by drawing more water from the mains supply and discharging it at the overflow.
- Above all, ensure that the supply pressure is contained within the values allowed (as
an average, between 1.5 and 3 bar).
- Check that the position of the float is correct to maintain the desired level (about 2 cm
below the overflow fitting).
- Check the condition of the float and its secure fixing to the rod.
- Check that the valve closes at the required level.
Cleaning water and sump strainer
A large amount of impurities contained in the air are trapped by the water and, together with
those which have entered the tower, are collected in the towers basin, possibly obstructing
the metal filters (with larger particles) supplied with the equipment.
Periodically, after emptying the sump, remove the water strainer and clean it with running
water, taking care not to damage the zinc-plating.
At the same time, clean the sump thoroughly, washing off and removing any foreign matter
and sludge.
Pag. 13
IDENTIFICATION PLATES
Each tower is supplied with at least one identification plate, normally positioned near the
furthest right inlet fitting.
On the plate, next to the Tower Model, is stamped our Internal Reference Number, this
number must always be stated when asking for any information concerning the tower.
IDENTIFICATION DATES
N. 1 COOLING TOWER model TAL 168 US
N. 2 COOLING TOWER model TAL 319 US
YOUR ORDER N3377T / H1597 OF 13/06/2008
OUR ACKNOLEDGMENT 08T0841 OF 20/06/2008

Air blower maintenance

25

Quenching basin pump 01PS02A & 01PS01B

3202

CARE AND MAINTENANCE

Service/Inspection
ITT Flygt recommends a preventive maintenance
program based on Intermediate and Major Services
at regular intervals. For standard sewage
applications where the temperature of the pumped
liquid is 40 C (104 F) or less an Intermediate
Service should be performed every 8000 hours or
every 2 years, whichever occurs first.
The time between Major Service could vary considerably
depending on operating conditions and the need for a
Major Service will be determind during the regular
Intermediate Services.
However, a minimum of 20 000 hours of operation could
be anticipated.
For applications other than sewage water or for specific
operating conditions, other service intervals may be
recommended.
Pump Intermediate Service
running 8 000 h or 2 years
Junction box Check that it is clean and dry.
Terminal board Check that the connections
are properly tightened.
Insulation check Check that the resistance
between earth and phase lead is
more than 5 MConduct phase
to phase resistance check.
Cable Check that the rubber sheating
(jacket) is undamaged.
Seal housing Fill up with new coolant if necessary.
Check freezing point
(lower than -13 C (9 F)).
Inspection Drain all liquid if any. Check
chamber the resistance of FLS10.
Normal value approx.1200 ,
alarm approx. 430 .
O-rings Always replace the O-rings of
the filling plugs and at the
junction cover. Always grease
new O-rings.
Thermal Check the resistance.
contacts Normally closed circuit;
interval 0 - 1 .
Thermistor Check the resistance 20 - 250 ,
(measuring voltage max 2 V DC).
Impeller Check impeller clearance and
adjust if necessary.
Lifting handle Check the screws and the condition
of the lifting handle.
Rotation Check the rotation of the
direction impeller.
Lifting device Check that local safety regulations
are followed.
Voltage and Check running values.
amperage
Pumpstation Intermediate Service

running 8 000 h or 2 years

Electrical Check that they are clean and dry.
cabinets/panels
Connection to Check that the connections are
power properly tightened.
Overload and Check correct settings.
other protections
Personnel safety Check guard rails, covers and
other protections
Level regulators Check condition and function.
Pump Major Service
Support and main Replace with new bearings.
bearing.
Mechanical seal Replace with new seal units.
unit.
Pump stations same as Intermediate Service. 22

Direct circuit basin pump 01PS02A & 01PS02B

CARE AND MAINTENANCE

Safety precautions
WARNING!
Before starting work on the pump,
make sure that the pump is isolated
from the power supply and cannot
be energized.
NOTE! This applies to the control circuit as well.
The following points are important in connection with
work on the pump:
make sure that the pump has been thoroughly
cleaned.
observe good personal hygiene.
beware the risk of infection.
follow local safety regulations.
The pump is designed for use in liquids which can be
hazardous to health. In order to prevent injury to the
eyes and skin, observe the following points when
working on the pump:
Always wear goggles and rubber gloves.
Rinse the pump thoroughly with clean water before
starting work.
Rinse the components in water after disassembly.
Hold a rag over the oil casing screw and the inspection
screw when removing them. Otherwise,
pressure that may have built up in the pump due to
the leakage of pumped liquid into the pump may
cause splatter into the eyes or onto skin.
Proceed as follows if you get hazardous chemicals in
your eyes:
rinse immediately in running water for 15 minutes.
Hold your eyelids apart with your fingers.
contact an eye doctor.
on your skin:
remove contaminated clothes.
wash skin with soap and water.
seek medical attention if required.

Inspection
Regular inspection and preventive maintenance
ensure more reliable operation.
The pump should be inspected at least twice a year,
more frequently under severe operating conditions.
Under normal operating conditions, the pump should
have a major overhaul in a service shop after 10 000
hours of operation or at least every second year.
This requires special tools and should be done by an
authorized service shop.
When the pump is new or when the seals have been
replaced, inspection is recommended after one week
of operation.
Service contract
ITT Flygt or its agent offers service agreements in
accordance with a preventive maintenance plan. For
further information, please contact your ITT Flygt
representative.
Inspection warm liquid versions
Pumps in warm liquid applications shall, depending on
the time they have been submerged in the warm
liquid, undergo inspection or overhaul at a service shop
as follows:
Temp. Mode of Inspection Shop
operation overhaul
70C Continuous 1000 hours 4000 hours
(160F)
70C Intermittent 4 times a year 6000 hours
(160C)

Thickener sludge feed pump 01PS03A,01PS03B

Operation &
Maintenance Manual
Pump
RD
14/28 Edition 2 HSC 02-W51 782-030-GB

7. MAINTENANCE
7.1 General
Always disconnect the pump from the
mains before inspection or disassembly.
Clean the pump thoroughly.
The motor housing can be hot when the
pump is just switched off.
Ensure that the pump is fully supported to
prevent it from falling over!

7.2 Maintenance schedule

* After the first 20 running hours:
- Check the oil (see chapter 7.5).
If there is more than a few drops of water
in it, contact your dealer.
* Every 6 months or 500 running hours:

- Check the oil (see chapter 7.5).

If there is more than a few cm3 water in it,
contact your dealer.
- Refresh the oil every year or when it is no
longer transparant. (see chapter 7.6)
- Check cable for damages.
* Every year:
- Check suspension bracket and lifting chain for
damages and corrosion.
* Every 5 years:
- A complete overhaul is advised.

7.3 Lubricants
* The bearings are greased for life and need
no refill.
* The oil reservoir is filled with SHELL VITREA
ISO-VG 46.
Viscosity: 46 cSt.
When another kind of oil is used this is
marked on a label on the pump.
Oil quantaties:
RD 20: 0,6 L.
RD 40: 1,5 L.
RD 60: 2,4 L.

Channel flushing pump (01PS04) , Sand filters basin pump (04PS05A,04PS05B)

Operation &
Maintenance Manual
Pump
RW
782-001-GB HSC 05-W24 Edition 3 17/32

7. MAINTENANCE
7.1 General
Always disconnect the pump from the
mains before inspection or disassembly.
Clean the pump thoroughly.
The motor housing can be hot when the
pump is just switched off.

7.2 Maintenance schedule

* After the first 20 running hours:
- Check the oil level (see chapter 7.5).
If there is more than a few drops of water
in it, contact your dealer.
* Every 6 months or 500 running hours:
- Check the oil and oil level (see chapter 7.5).
If there is more than a few cm3 water in it,
contact your dealer.
- Refresh the oil every year or when it is no
longer transparent. (see chapter 7.6)
- RW80: refresh the grease of the main bearing every
10,000 running hours.

7.3 Lubricants
* The bearings are greased for life and need
no refill (except RW80).

Main bearing RW80: SHELL ALBIDA EP 2.

* The oil reservoir is filled with SHELL
VITREA ISO-VG 46 .
Viscosity: 46 cSt.
When another kind of oil is used this is
marked on a label on the pump.
Oil quantities:
RW 20: 0.6 L
RW 40: 1.5 L
RW 60: 2.4 L
RW 80: 7.3 L

Sludge scraper

Book -3 ,page no-21

ECOMACCHINE S.P.A.
CD 07 4859-em50078b.doc 21
Description 1 Month 3 Months
1000
Hours
Procedure Notes
Buttons and control
units
C
Check
operating by
start-up
For replacement the extraordinary maintenance is
needed.
Bolts and nuts C
Tighten the
bolts if
necessary
Use suitable wrenches
Control unit oil level C R
Check oil
level on the
feeding plug
rod
Use BP ENERGOL HLP - HM 46 Oil or similar
Safety labels C
Replace if
necessary
Hydraulic pressure C
Check on the
pressure
gauge
Adjust, if necessary, the screw of the maximum

pressure valve
Scum rubber lips R
Replace the
worn rubber
lips into the
machine
stopped
Use the suitable wrench to untighten the bolts
and take off the rubber lips

C = CHECK R = REPLACE

ON-OFF BUTTERFLY AUTOMATIC VALVE

Maintenance
Long time outdoor usage can cause gaskets to become brittle after some time. Safe operation can only be
guaranteed
with leak-proof boxes.
Seals should be exchanged immediately if they are damaged, or at least after five years.
Seals and other parts can be ordered at all times.