operation & maintenance manual · 2017. 10. 8. · manual 4” flump serial #16061 hispamerica...

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OPERATION & MAINTENANCE

MANUAL

4” FLUMP

SERIAL #16061

HISPAMERICA WORLD INC

Owner: Central Azucarero Portuguesa SA

JANUARY 2011

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SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867

TABLE OF CONTENTS

___________________________________________________ SECTION 1 - INTRODUCTION & WARRANTY 5

INTRODUCTION 6 WARRANTY 7 GENERAL LAYOUT DRAWING 8

PUMP CURVE 9

HYDRAULIC SCHEMATIC 10 FLUMP ELECTRICAL SCHEMATIC 11

SECTION 2 - ASSEMBLY 16

INITIAL INSPECTION 17 INITIAL ASSEMBLY 18 PROPER ROTATION TESTING 19 SLUDGE PUMP MOTOR SPECIFICATIONS 20 POWER UNIT MOTOR SPECIFICATIONS 21 BALDOR MOTOR O&M 22 SEW EURODRIVE SPECIFICATIONS 41 LAUNCHING INSTRUCTIONS 52 TRAVERSE SYSTEM SET UP 54 DISCHARGE PIPE & ELECTRICAL CORD 58 INSTALLATION INSTRUCTIONS

I

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SECTION 3 - OPERATION & MAINTENANCE 63

FLUMP SAFETY GUIDELINES 64 DAILY START UP 65 OPERATIONAL TIPS 66

OPERATING INSTRUCTIONS 68

LATERAL POSITIONING INSTRUCTIONS 71 FLUMP LUBRICATION INSTRUCTIONS 73 WINCH MOUNTING CODE DESIGNATION 75 WINCH LUBE POINTS 85 RECOMMENDED LUBRICATION & MAINTENANCE SCHEDULE 87 TRAVERSE CABLE INSPECTION 89 TROUBLESHOOTING 93 PUMP TROUBLESHOOTING 95

SECTION 4 - SERVICE 97

BEARING FRAME 98 MECHANICAL SEALS 101 IMPELLER 104

VOLUTE 107

UPPER SHAFT HOUSING 108 FLEXIBLE SHAFT COUPLER 110

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CUTTERHEAD MOTOR & DRIVE COUPLER 112 WATER LUBE BEARING 113 POWER UNIT 115 TORQUE SPECS 117

SECTION 5 - PARTS LISTS 118

SLUDGE PUMP 119 PUMP COLUMN 121 CUTTERHEAD 122 POWER UNIT 124 HOIST WINCH 126 TRAVERSE WINCH 128 TRAVERSE GUIDE & ROLLER SHEAVE ASSEMBLY 129 RECOMMENDED SPARE PARTS LIST 130 WORK ORDER NUMBERS 131

III

5


SECTION 1 - INTRODUCTION, WARRANTY & SPECIFICATIONS

INTRODUCTION 6 WARRANTY 7 GENERAL LAYOUT DRAWING 8

PUMP CURVE 9

HYDRAULIC SCHEMATIC 10 FLUMP ELECTRICAL SCHEMATIC 11

6


INTRODUCTION SLUDGE REMOVAL SYSTEM In our continuing effort to provide excellence in low maintenance, easy to operate Sludge Removal Systems, we have assembled this Operations and Maintenance Man-ual. Contained in this manual is the information necessary to properly install, operate and maintain the Crisafulli Sludge Removal System. SRS Crisafulli Inc., Sludge Removal Systems are effectively handling sludge for a vari-ety of operations, which vary in size and handling requirements. Because of different requirements, the operator of each system must develop additional operational and safety guidelines, which will cover the specific site hazards of the individual operations. We are dedicated to providing excellence in Sludge Removal Systems and after sale service. If you should have any questions or comments concerning your Sludge Re-moval System, please call us at 1-800-442-7867. We would appreciate hearing from you. Sincerely, The Employees of SRS CRISAFULLI, INC. This manual checked by: ______________________________

Engineering Department

8

12’

8’

102”

21’

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SECTION 2 - ASSEMBLY

INITIAL INSPECTION 17 INITIAL ASSEMBLY 18 PROPER ROTATION TESTING 19 SLUDGE PUMP MOTOR SPECIFICATIONS 20 POWER UNIT MOTOR SPECIFICATIONS 21 BALDOR MOTOR O&M 22 SEW EURODRIVE SPECIFICATIONS 41 LAUNCHING INSTRUCTIONS 52 TRAVERSE SYSTEM SET UP 54 DISCHARGE PIPE & ELECTRICAL CORD 58 INSTALLATION INSTRUCTIONS

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INITIAL INSPECTION

The Flump was shipped in good condition but must be inspected for any damage that may have occurred during shipping and handling. Note and advise the factory of any damage immediately at the following address:

SRS Crisafulli Inc. P.O. Box 1051 Glendive, MT 59330 (U.S.A.)

Phone: 406-365-3393 Fax: 406-365-8088

E-mail: [email protected]

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INITIAL ASSEMBLY

TRAVERSE MOTOR The traverse motor is installed on the Flump in a shipping only configuration. This electric winch motor and pulley assembly is attached to the Flump structure using four 1/2” bolts at the base of the traverse winch-mounting bracket. There is also an electri-cal cord clamp for the traverse winch cord. The assembly must be rotated one-half turn before the traverse cable can be attached. There is no need to disconnect the electrical cord during this set-up operation; however caution must be exercised to prevent cord damage during the following procedure. POSITIONING INSTRUCTIONS 1. The electric cord must be temporarily positioned to prevent unintentional damage

during the assembly’s rotation to the operating position. 2. Remove the four 1/2” attaching bolts at the base of the traverse winch mount. 3. Rotate the traverse winch assembly so that the winch motor is to the outside of

the flump and the cable sheaves are to the inside of the flump. 4. Align the four holes in the winch base with the four holes on the flump platform, re-

install the four 1/2” attaching bolts and torque to 75 Ft Lb. 5. Reattach the electrical cord and clamp.

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PROPER MOTOR ROTATION TESTING

Refer to General Layout Drawing

The Flump was tested at the factory prior to shipping to ensure proper rotation of all electric motors. In order to ensure that the control panel has been wired correctly on site, the rotation of one or more electric motors should be checked. 1. Press the Hoist winch “Lower” button. 2. Observe the direction that the pump column is moving. If the pump is moving in

same direction that the panel button indicates , then the motor is rotating correctly. 3. If the motor is not rotating in the proper direction, push the opposite button Hoist

winch “Raise” to return the pump column to its original position. 4. Disconnect main power from source and unhook power cable. 5. Change wiring to control panel and recheck motor for proper rotation by repeating

steps 1-3. 6. Once the motor is rotating in the proper direction, it may be shut down until it is

needed for operation. If the depth winch electric motor is rotating correctly, then all of the electric motors on the Flump are correct.

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SRS Crisafulli, Inc. PO Box 1051 1610 Crisafulli Drive Glendive, MT 59330-1051 Phone: 1-800-442-7867

Electric Motor Specifications

Brand Name: Baldor Electric Company Catalog number: M4316T

Description: 75 Hp, 1770 RPM, 3 Ph, TEFC, 365T NEMA Ship Weight: 874 lbs.

Features: Ball bearings

Suitable for mounting any position

Heavy cast iron frame

Performance Data: Rating – Nominals

Characteristics:

Rated Output 75 HP

Volts 230/460

Full Load Amps 172/86

Speed 1770

Hertz 60

Phase 3

NEMA Design Code A

LR KVA Code H

Efficiency 94.1

Power Factor 86

Service Factor 1.15

Rating – Duty 40C AMB-CONT

Full Load Torque 221 lb-ft

Break Down Torque 700 lb-ft

Locked-Rotor Torque 429 lb-ft

Starting Current (Amps) 621

No-Load Current (Amps) 30.4

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SRS Crisafulli, Inc. PO Box 1051 1610 Crisafulli Drive Glendive, MT 59330-1051 Phone: 1-800-442-7867

Electric Motor Specifications

Brand Name: Baldor Electric Company Catalog number: VEM3770T

Description: 7.5 Hp, 1770 RPM, 3 Ph, TEFC, 213TC NEMA Ship Weight: 170 lbs.

Features: Ball bearings

Locked drive end bearing

Heavy gauge steel frame

Performance Data: Rating – Nominal

Characteristics:

Rated Output 7.5 Hp

Volts 230/460

Full Load Amps 19/9.5

Speed 1770

Hertz 60

Phase 3

NEMA Design Code A

LR KVA Code J

Efficiency 91.7

Power Factor 81

Service Factor 1.15

Rating – Duty 40C AMB-CONT

Full Load Torque 22.1 lb-ft

Break Down Torque 69.8 lb-ft 315.8% of F.L. Torque

Locked-Rotor Torque 42.2 lb-ft

Starting Current (Amps) 68

No-Load Current (Amps) 4.18

Line-line Resistance @ 25 C 1.43

Temperature Rise, C @ FL (in deg) 42

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LAUNCHING INSTRUCTIONS

Refer to Drawing # 03206 The inspection, initial assembly and proper rotation testing procedures should be com-pleted prior to launching the Flump. A crane is required to remove the Flump from the shipping platform. The Flump weighs approximately 4000 pounds. Attach four lifting slings of equal length, at least 15 feet in length, to the four Flump lifting eyes using a clevis at each eye. Attach each of the four lifting slings to the lifting ring of the crane or the hoist. Carefully raise the Flump and position the unit over a suitable launch site with at least 18 inches of freestanding water to float the Flump. Slowly lower the Flump into the water and temporarily secure the Flump to a minimum of two anchor stakes at an accessible location in the dredging area.

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TRAVERSE SYSTEM SETUP INSTRUCTIONS

Refer to Drawing # 20390 1. Locate four anchor rod base plates (1), twelve anchor rods (3), five Griphoist cable

tensioners (2), four lateral cables with hooks (6), two tension triangles (5), one trav-erse cable with hook (4), one tensioning cable (7), one 3/8” cable hook, two 3/8” cable thimbles, and six 5/16” cable clamps provided.

2. Position the four-anchor rod base plates (1) at each corner of the rectangular area

to be dredged. Position each anchor rod base plate in the same configuration as shown in Figure 1.

3. Drive one anchor rod (3) through each small hole in each of the four base plates (1)

until the D-ring is within one inch of the anchor rod base plate. 4. Attach one of the Griphoist cable tensioners (2) to the D-ring on the anchor rod (3)

at each of the four base plate (1) locations using the anchor pin in the Griphoist base (see Figure 2).

5. Release the Griphoist (2) by first depressing the small yellow latch on the side of

the Griphoist frame and move the large yellow handle down and toward the anchor pin end until it latches in place.

6. Unroll one of the lateral cables (6). Feed the tapered free end of the cable through

the small Griphoist (2) frame hole in the end opposite the anchor pin. Continue to feed cable through the Griphoist until at least 18 inches of cable are exposed. Re-peat this procedure at the other three corner locations.

7. Connect the hooks on the lateral cables (6) to their respective tension triangles (5)

for each end. NOTE: Lateral cables are long enough to reach from one anchor location to

the other anchor location on the same end of the dredging area. Tension triangles are located on the ends of the dredging area. Ca-ble attached to a tension triangle should originate at the anchor lo-cations on the same end of the dredging area.

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SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 8. Position the tension triangles (5), one at each end of the dredging area, so that a

line from one triangle to the other triangle is as close as possible to the centerline of the Flump in its secured location.

9. Pull any excess cable through the Griphoist (2) and coil loosely on the ground. 10. Latch all four Griphoists (2) by pushing straight down on the large yellow handle. 11. Attach the 3/8” cable hook to one end of the traversing cable (4) and make a small

loop in the other end of the traversing cable. 12. Feed the tapered end of the tensioning cable (7) through the remaining Griphoist.

Attach the loop end of the traversing cable (4) to the other end of the Griphoist. The tensioning Griphoist may be placed at either end of the pond.

13. Route the traverse cable (4) through the traverse winch on-board the Flump by re-

moving the nylon rollers, positioning the cable on the sheaves and reinstalling the nylon rollers (see Drawing # 20352).

14. Attach the hook on the tensioning cable (7) to one tension triangle (5) and attach

the hook on the traversing cable (4) to the other tension triangle. 15. Adjust the tension in the traverse cable (4) with the Griphoist (2) that is attached to

the tensioning cable until the traverse cable remains 6 to 8 inches above the water surface.

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DISCHARGE PIPING AND ELECTRICAL CORD INSTALLATION INSTRUCTIONS

Refer to Drawing # 20400

DISCHARGE PIPING

NOTE: Installation of the discharge piping should be accomplished after

the Flump has been set into the pond.

The integral discharge system consists of flexible hose (1) and rigid pipe (2) sections. These sections are coupled together with ringlock clamps (3). When assembling the discharge piping, a flexible section MUST be attached at the Flump discharge (4) and at the shore discharge location (5). The discharge piping should be assembled with alternating rigid and flexible sections. NOTE: It may be necessary to couple two pipe sections or two flexible sec-

tions together in order to accommodate the use of flexible sections attached at the Flump and shore connections.

Procedure for assembling the discharge piping. 1. Attach one flexible section (1) to the Flump discharge (4). 2. Attach the electrical cords to their respective terminals on the Flump junction box

(6)(see Electrical Cord section on the following page). CAUTION: Before working with electrical equipment, ensure that the power

source is locked out. 3. Secure the electrical cord to the Flump via the strain reliefs (8). There is an eyebolt

provided on the Flump, near the discharge (4), for attaching the strain reliefs.

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SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 DISCHARGE PIPING CONT. 4. Adjust the strain reliefs (8) so that there is a minimal amount of slack between the

strain reliefs and the junction box (6). 5. Assemble alternating sections of discharge pipe as described above on the edge of

the shoreline. 6. Secure the electrical cord to the discharge piping with the elastic straps (see Draw-

ing # 20378, “Manual Flump Power Cord Straps”). The electrical cord should be attached to the rigid pipe (2) only.

7. After the electrical cord has been attached to the entire length of discharge piping,

couple the end of the discharge piping to the shore discharge station (5). 8. Connect the electrical cord to its terminal in the control panel (7)(see Electrical

Cord section below). NOTE: Coil any excess electrical cord on the shore beside the control

panel. 9. The entire discharge piping and electrical cord assembly can now be placed into

the lagoon.

ELECTRICAL CORD

One electrical cord supplies power to all the Flump components. Cord : 2 gauge – 4 conductor; this cord is used to power the control panel and

thereby the entire flump. The Cord runs from the shore power source to the control panel on the dredge. The female connector attaches to the male plug on the control panel.

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SECTION 3 - OPERATION & MAINTENANCE

FLUMP SAFETY GUIDELINES 64 DAILY START UP 65 OPERATIONAL TIPS 66

OPERATING INSTRUCTIONS 68

LATERAL POSITIONING INSTRUCTIONS 71 FLUMP LUBRICATION INSTRUCTIONS 73 WINCH MOUNTING CODE DESIGNATION 75 WINCH LUBE POINTS 85 RECOMMENDED LUBRICATION 87 & MAINTENANCE SCHEDULE TRAVERSE CABLE INSPECTION 89 TROUBLESHOOTING 93 PUMP TROUBLESHOOTING 95

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FLUMP SAFETY GUIDELINES GENERAL

Review complete manual before operating this Sludge Handling System.

The installation, operation, and maintenance of the SRS Crisafulli Flump require practices & procedures that ensure personal safety and the safety of others. This equipment is to be installed, operated, and maintained only by qualified persons in accordance with this manual and all applicable codes.

Information presented in this manual pertains to equipment design, installation, operation, and maintenance, which should be read, understood, and practiced for safe operation of the Flump.

The warning signs attached to Flump MUST be observed and practiced at all times. Replace any Warning stickers that are illegible or missing. Inquire at your local Crisafulli dealer or call SRS Crisafulli Incorporated at 1-800-442-7867.

SAFETY ALERT NOTICES

The following safety alert signal words are used throughout this manual to call attention to and identify different levels of hazards and special instruction.

These safety alert signal words, Warning and Caution, call attention to the safety statements.

Warning - Statements identify procedures or practices, which must be fol-

lowed to avoid serious personal injury or loss of life.

Caution - Statements identify procedures or practices, which must be fol-lowed to avoid, personal injury or damage to equipment.

Important- Statements identify special instructions necessary for the most ef-

ficient operation of this equipment.

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DAILY START UP

Keep the following in mind during normal daily operation:

1. Ensure that discharge piping and electrical cords are properly secured. 2. Maintain and follow lubrication schedules. 3. Check for hydraulic leaks.

Possible leakage areas: Fittings, hoses, shaft seals and hydraulic reser-voir.

4. Check hydraulic oil level every day and check temperature periodically

during operation.

5. If a leak is found, wipe area clean of oil and dirt so leak can be located. Tighten fittings or replace.

During warm up period check for leaks at hoses and fittings. If leaks are de-tected; shut power unit off immediately and determine cause of leak. Repair as necessary.

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OPERATIONAL TIPS

These tips are provided to aid the operator in maximizing the performance and effi-ciency of the equipment. All applications are different, these tips are only suggestions and guidelines as to how this equipment should be run. Should any questions arise as to how the equipment should be performing, please consult the factory. CUTTERHEAD DEPTH

For most applications, the cutterhead should be placed into approximately 12 inches of material. Depending on the viscosity of the material, this value may vary. As the op-erator becomes familiar with the material being pumped, he/she will be able to adjust the cutting depth according to the desired performance. TRAVERSING When traversing forward, tension must be maintained on the hoist winch cable at all times. When the cutterhead is adjusted properly it will be cutting a swath through the material that is parallel to the basin floor. If the tension is too loose, the cutterhead may start to dig into the material thereby burying itself and creating the potential for damage to the Flump. If the tension is too much, the cutterhead may be only skimming the material. While dredging, the Flump should be slightly higher on the front end than on the rear. After the desired cutterhead depth has been achieved, the traverse speed should be adjusted to achieve the desired slurry concentration. DISCHARGE LINE Observing the discharge line is one of the more accurate means of determining if your slurry concentration is adequate. During normal dredging operations the discharge line should be about 25% – 33% submerged. If the discharge line begins to sink, the slurry concentration is too high. To remedy this, either the cutterhead can be raised up or the traverse speed can be decreased.

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OPERATING INSTRUCTIONS FOR FLUMP

Refer to Drawing # 04002/04004

NOTE: Before operating the Flump, make sure all daily start up procedures

has been performed.

NOTE: The panel can be used with either the radio remote or the panel, not both. When the panel is set to radio, all functions on the remote are locked out at the panel. The panel cannot be switched between panel and remote while the Flump is running.

Radio Remote Operating Instructions The radio remote has all the main dredge functions onboard. To use the radio remote, turn the Control Selector Switch to “Radio”. Turn on the power of the remote using the Transmitter Off/On switch. The Sludge Pump and Power Unit can be activated by moving their respective toggle switches toward the “ON” position. Once the motor has started, release the toggle switch. The motor will stay engaged until the toggle switch is moved to the off position. To engage the Traverse, depress the switch in the desired direction and then release. The traverse will continue to move after the button has been released. To stop the traverse, move the toggle switch in the current direc-tion of travel. NOTE: Always place the traverse in the stop position before reversing di-

rection.

The Traverse Slow/Fast and Hoist Winch are momentary switches and need to be held until the desired result has been achieved. There is an E-stop on the top of the remote. Activate it by depressing the button. To clear the E-stop, cycle the remote power by using the transmitter Off/On switch. NOTE: The remote power can be turned off during a long traverse without

interrupting unit function. Turning the remote off when not in use can significantly extend battery life.

WARNING: The Emergency Stop switch on the remote will not function if the remote control is turned “OFF”.

If remote does not work or works intermittently, try replacing the remote battery to re-store function.

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Dredge Startup Instructions

1. Turn Main Switch disconnect to the “ON” position.

2. With the Radio/Panel switch in the Radio position, lower cutterhead to desired depth by using the Hoist Winch “Lower” button.

3. Engage cutterhead rotation using Cutterhead “Start” button, allow cutterhead to run 3-5 minutes to warm the hydraulic system. Warning: The water lubricated bearing on the cutterhead must be submerged

to function properly. The cutterhead should be AT LEAST 12 INCHES below the water surface before starting the auger. If it is necessary to start the auger at a shallower depth, caution must be taken in order to prevent the floatline from becoming entangled in the auger.

4. Engage dredge pump using Dredge Pump “Start” button.

5. Set desired dredge depth by using the Hoist Winch “Raise” or “Lower” but ton.

6. Begin forward travel using the Traverse Winch “Forward” button.

7. When the desired forward travel has been completed, stop the Flump with the Traverse Winch “Stop” button.

8. Raise the cutterhead to about 12 inches below the water surface by using the Hoist Winch “Raise” button. 9. Stop the cutterhead with the Cutterhead “Stop” button. 10. Allow the dredge pump to run for 30-60 seconds in order to flush out the dis charge piping system. Stop dredge pump by using the Dredge Pump “Stop” button.

NOTE: The Flump will continue to pump light material in the reverse direc-

tion. If light material is being pumped, steps 8-10 may be skipped.

11. Reverse travel with the Traverse Winch Reverse button.

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SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 12. When the desired travel has been achieved, stop reverse movement with the Traverse Winch “Stop” button. 13. If the dredge pump is still running at this point, follow steps 8-10. 14. If a lateral move is desired, refer to the Lateral Positioning Instructions. NOTE: The Flump should NEVER be moved laterally with the cutterhead in the down

position.

15. When lateral movement is complete, repeat above steps. NOTE: The cutterhead depth and traverse speed are adjustable while using the auto-

mode sequence. The operator is encouraged to fine-tune the flump perform-ance by using the Hoist Winch Raise/Lower or Traverse Speed Fast/Slow while the Flump is in motion.

71


LATERAL POSITIONING INSTRUCTIONS


Moving the Flump laterally requires the adjustment of all four Griphoist cable tension-ers. To move the Flump laterally, the two Griphoists on one side must be loosened, while the two Griphoists on the other side are tightened. The following is an example for moving the Flump 8 feet down according to the layout in Drawing # 20390. 1. Release 8 feet of cable from Griphoist A. 2. Release 8 feet of cable from Griphoist C. 3. Pull in 8 feet of cable at Griphoist B. 4. Pull in 8 feet of cable at Griphoist D. The Griphoists are infinitely adjustable and can be used to move the Flump any dis-tance in either direction. The Griphoists should be moved evenly in order to maintain the correct amount of tension in the traverse system and to prevent the Flump from skewing. NOTE: If desired, the Griphoists can be adjusted so that the Flump will

dredge diagonally.

73

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75

SRS CRISAFULLI INC. P.O. Box 1051 Glendive, MT 59330 1-800-442-7867

SEW EURODRIVE WINCH MOUNTING POSITION AND LUBRICATION CHECK POINTS

Check winch oil level at least every month. It is recommended that the oil be changed every 10,000 hours or every two years, whichever comes first. Below is the winch des-ignation, mounting location, lubricant volume. Please refer to the mounting position sheets for location of breather valve, oil level plug, and oil drain plug. For additional information, see the attached lubrication schedule for SEW-Eurodrive gear units. All gear reducers are of type R.

Winch Mounting Location Lubricant Amount Gallons/Liter Traverse Winch M1 0.63 / 2.4 Hoist Winch M1 0.29 / 1.1 Lateral Traverse Winch M4 2.03 / 7.70

Recommended Lubricant - Mobilgear 630

87

RECOMMENDED LUBRICATION & MAINTENANCE SCHEDULE

DAILY:

WEEKLY:

EVERY 100 HOURS:

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

88

EVERY 400 HOURS:

EVERY 600 HOURS:

EVERY 1200 HOURS:

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

Hydraulic reservoir

Drain oil and refill, clean filler-breather (Exxon NUTO H46)

Main dredge pump

Check and tighten mounting bolts in suction flange and base

Electrical system

Check indicator lights, fuses and switches

Cutterhead seals

Check and replace if necessary

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

DESCRIPTION OF

CHECK & MAINTENANCE

REMARKS

89


TRAVERSE CABLE INSPECTION

A cabling system is only as strong as the weakest point, be it a wire rope, hook, or con-nection. Timetables for replacement intervals of wire rope are not applicable. The proper way to determine if replacement is necessary is through a documented inspec-tion process. The following instructions will describe how, when, and what to look for during an inspection as well as the documentation needed. Any degradation of the wire rope severely reduces the load capacity. Abrasion, bending, and crushing are the ABC’s of rope inspection to discover early conditions that allow for safe replacement. Each inspection needs to be completed by a competent person. Periodic inspections need to be conducted and documented on a set schedule. The inspection duration depends on the amount of service the cabling system in enduring. The following intervals are a guide to use for inspection intervals. These intervals are only a guide and should be deemed as such; additional inspections should be con-ducted whenever appropriate.

WIRE ROPE INSPECTION SCHEDULE

HEAVY SERVICE (35+ HOURS/WEEK) ---- WEEKLY INTERMITENT SERVICE (10-35 HOURS/WEEK) ---- MONTHLY

LIGHT SERVICE (LESS THAN 10 HOURS/WEEK)---- EACH USE

INSPECTION GUIDELINES 1) Maintain inspection records in accordance with above schedule 2) Prior to each use a walk-around inspection needs to be conducted, addressing the

following items. a) Check all equipment functions related to the traverse system b) Visual inspection for unsafe conditions, i.e., broken wires, kinking, twisting,

or corrosion. Attention needs to be directed toward any new damage. c) Function and ease of cable movement should be verified. d) Inspect all end connections such as hooks, splices, and snatch blocks for

excessive wear or distortion.

3) An annual inspection and report of all traverse related components needs to be conducted.

90

SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 4) The utmost in care must be taken during inspection of all components. Safety is

the number one priority and must be at the forefront of each person’s mind while on or around equipment.

WIRE ROPE INSPECTION The following is a general list of inspection criteria; the main types of failure are cov-ered. If additional inspection data or procedures are desired contact the American Iron and Steel Institute. The listed criteria are to be used as a guide and not a substitute for a competent inspector. Occasionally a single wire will break after installation. If no other breaks occur at the same time, there is no need for concern. However, if other breakages occur, the cause should be carefully investigated. 1) ABRASION Wire rope (cable) abrades as it moves through abrasive mediums or over drums

and sheaves. Most standards require removal from service if the outer wire diame-ter wear exceeds 1/3 of the original wire diameter. This is not easy to measure. Other listed inspections will provide evidence of abrasion also.

2) ROPE STRETCH

All wire rope stretches as loads are applied. The amount of stretch and the rate at which that occurs can be used as a judge to determine replacement time. As rope degrades, continued application of a constant load will produce varying amounts of stretch. By recording and paying attention to the amount of tightening required, one may judge the condition of the rope. Stretch occurs in three phases:

Phase 1: Initial stretch, during beginning of service, caused by setup and ad-justments to operation.

Phase 2: Service life, after break-in a long period of minimal stretch will occur. The stretch results from normal wear and fatigue.

91


Phase 3: Warning period, an accelerated rate of stretch occurs during this pe-riod. The rope has reached the point of rapid degradation. The system should be removed from service and the rope should be replaced.

3) REDUCTION IN DIAMETER

Any reduction in diameter indicates that some form of degradation has taken place. Some forms are: excessive external abrasion internal or external corrosion loosening or tightening of rope lay inner wire breakage rope stretch An evaluation of the rope diameter needs to be started immediately upon putting the cable into service. Readings will need to be taken in accordance with inspec-tion schedule, in the same spots and under similar loading each time the rope is measured. After initial loading the diameter of the rope should be measured and recorded. The diameter after initial reduction will soon stabilize and only a small decrease will occur during the life of the cable. If a sizable reduction in diameter is found, use should stop immediately. While a reduction in the diameter is one judge of cable strength it should not be used alone. A cable may not have had a sizable reduction in diameter but may be unsafe due to other existing conditions. The rope diameter is only one criterion for replacement and should be used with the other listed inspections in determining the replacement time for the wire rope.

4) CORROSION

One of the most serious yet difficult to evaluate forms of degradation is corrosion. The usual cause for corrosion on wire ropes stems from a lack of lubrication. An oxidation inhibiting, alkali free, nonwater soluble, viscous lubricant with high film strength should be used. Corrosion will occur internally before there are any visual signs on the surface. Pitting on the surface is cause for immediate replacement. Severe rusting can lead to premature failure. SRS Crisafulli uses galvanized wire rope to deter corrosion. In cases where corrosion is still occurring a stainless steel rope may need to be used.

92

SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 5) FATIGUE FAILURE

Fatigue fractures are easy to identify, the ends of the broken wires are square frac-tures and the surface of the wire will show little or no wear. The fractures occur on the crown of the strands or in the valleys between strands where contact is made. Replacement of wire rope is based upon the number of breaks found in the cable. Replacement should occur when one strand has 3 or more breaks and/or one lay has 6 or more breaks.

6) VALLEY BREAKS Valley breaks can also occur as a result of a core failure. When one valley break is

found in the attaching end of a rope, the rope should immediately be replaced. When two or more valley breaks are found elsewhere on the rope replacement should be immediate.

7) SHEAVE INSPECTION When inspecting the traverse cable it is also important to check the sheaves on the

dredging unit. The sheaves need to be checked for proper alignment and to deter-mine if each sheaves turns freely. The groove and working surfaces of each sheave and drive need to be checked for proper diameter and to determine if corru-gations are forming.

93


FLUMP TROUBLESHOOTING

SYMPTOM COMPONENT CHECK FOR

Reduced Performance SLUDGE PUMP Pump speed

Proper submergence

Plugged suction

Air pocket in suction

Direction of impeller rotation

Foreign material in cutterhead

Viscosity of material

Lack of flow Plugged cutterhead or discharge line

Excessive wear on impeller

Pump speed

Proper submergence

Drive Motor over loaded

Specific gravity or viscosity

Low voltage

Total dynamic head too low

Foreign material in cutterhead

Misaligned or bent shaft

Insufficient Discharge Pressure

Air pocket in suction

Pump speed too low

Direction of rotation

Total dynamic head too high

Specific gravity or viscosity differ-ent from design

Impeller damage

Excessive Noise Impeller plugged

Worn bearings

Impeller retaining nut loose

Cavitation

Direction of rotation

Proper Submergence

Impeller damage

Bent Shaft

Misalignment of rotating parts

Worn bearing seals

Misalignment of rotating parts

Contaminated bearings

Insufficient lubrication

Bent shaft

94

Electric motor failure PRIME MOVER Power source characteristics

Electrical connection

Bearing failure

Insufficient cooling

Rapid wear on coupling cushion

Misalignment or rotating parts

Bent shaft

No Cutterhead Rotation CUTTERHEAD Check oil level in power unit

Check drive coupling (drive bolt & keyway)

Check outboard bearing

Check for foreign material in cutter-head

Check rotation of electric motor on power unit

Power Unit Inoperative POWER UNIT Power supply

Power unit running, no hydraulic power being supplied

Oil level in reservoir

Drive coupling

Suction screen

Hydraulic pump

Flump won’t traverse TRAVERSE WINCH Power supply

Traverse cable tension

Cutterhead won’t raise or lower HOIST WINCH Power supply

Hoist winch cable


FLUMP TROUBLESHOOTING CONT.

SYMPTOM COMPONENT CHECK FOR

95

SRS CRISAFULLI INC. P.O. BOX 1051 Glendive, Montana 59330 1-800-442-7867

PUMP TROUBLESHOOTING GUIDE

SYMPTOMS

CAUSES

CORRECTIONS

Failure to pump

Pump not primed. Pump speed too low or head too high. Air leak. Plugged suction. Pump or suction pipe not completely filled with liquid. Air pocket in suction. Inlet of suction insufficiently submerged

Prime pump. Consult SRS Crisafulli, Inc. Check and rework suction line. Remove obstacle. Check supply. Locate and correct. Increase suction pipe submergence.

Reduced perform-ance

Obstructed suction line or impeller. Insufficient submergence of the suction. Excessively worn impeller or wear ring. Direction of impeller rotation wrong. Speed too low or head too high.

Remove obstruction. Increase suction pipe submergence. Replace impeller and/or wear ring. Reverse rotation. See start-up instructions. Consult SRS Crisafulli, Inc.

Driver over loaded

Speed higher than design. Liquid specific gravity too high. Too large an impeller diameter. Low voltage. Total head lower than design. Foreign material in impeller. Misalignment.

Reduce speed. Consult SRS Crisafulli, Inc. Consult SRS Crisafulli, Inc. Consult power company. Consult SRS Crisafulli, Inc. Remove foreign matter. Realign.

Insufficient pres-sure developed

Excessive amount of air or gas in liquid. Speed too low. Direction of impeller rotation wrong. Head too high. Viscosity of liquid different from design. Impeller damaged.

Check for suction leak. Check Electrical - Consult SRS Crisafulli, Inc. Reverse rotation. See start-up instructions. Consult SRS Crisafulli, Inc. Consult SRS Crisafulli, Inc. Replace impeller.

96

SRS CRISAFULLI INC. P.O. BOX 1051 Glendive, Montana 59330 1-800-442-7867

PUMP TROUBLESHOOTING GUIDE

SYMPTOMS

CAUSES

CORRECTIONS

Excessive noise

Misalignment. Material lodged in impeller. Worn bearings. Impeller bolt loose or broken. Cavitation. Direction of impeller rotation wrong. Suction improperly submerged. Operation at very low capacity. Shaft bent. Impeller damaged. Rotor out of balance, causing vibration.

Align rotating parts. Remove Material. Replace bearings. Replace bolt. Raise cutterhead to dilute slurry. Reverse rotation. See start-up instructions. Submerge suction further. Consult SRS Crisafulli, Inc. Replace shaft. Replace impeller. Balance or replace rotor.

Premature bearing failure

Grease line plugged or pinched. Worn bearing protection seals. Misalignment. Bent shaft. Water or contaminates entering bearings. Inadequate bearing lubrication. Wrong type of lubrications.

Repair or replace. Replace. Align all rotating parts. Replace shaft. Protect pump from environment. See lubrication schedule, Section 5. See lubrication schedule, Section 5.

Electric motor fail-ure

High or low voltage. Electric surge. Poor electric connection. Overloads. Bearing failure. Cooling vent plugged

Check voltage. Monitor voltage and consult power Company. Turn power off, clean and check connections. Check amperage. Do not exceed nameplate full load amperage. Change bearings in motor. Install proper screens.

Rapid wear on coupling cushion

Misalignment. Bent shaft.

Align. Replace shaft.

97


SECTION 4 - SERVICE

BEARING FRAME 98 MECHANICAL SEALS 101 IMPELLER 104

VOLUTE 107

UPPER SHAFT HOUSING 108 FLEXIBLE SHAFT COUPLER 110 CUTTERHEAD MOTOR & DRIVE COUPLER 112 WATER LUBE BEARING 113 POWER UNIT 115

TORQUE SPECS 117

98


BEARING FRAME ASSEMBLY AND DISASSEMBLY INSTRUCTIONS

Refer to Drawing # B20380-A

DISASSEMBLY Remove the cutterhead assembly. Remove the impeller retaining nut (15). Withdraw the impeller (19) from the pump volute case (20). Note: (2) 5/8-16 set screws may be removed from impeller base plate to allow use of bar type puller. Separate the pump volute case from the bearing frame. Remove the upper 1/2" pipe plug for access to facilitate removal of the two setscrews in the coupling. Remove the flange bolts be-tween the bearing frame and the upper chamber and separate these two components. Remove the snap ring (10a) and the outboard mechanical seal (13) (See Mechanical Seal Removal and Installation Instructions). Remove the setscrews (3) from the bear-ing frame housing (2). Remove the outboard stationary seal holder (12), the O-ring seal (7a) and the spacer ring (11). Remove the snap ring (10b) and the inboard me-chanical seal (9). Remove the inboard stationary seal holder (8)(See Mechanical Seal Removal and Installation Instructions) and the O-ring seal (7b). The entire shaft assembly will now slide out through the pump end of the bearing frame. Press off the single row bearing (4). Remove the bearing nut (16) and press off the double row bearing (6). The shaft should be inspected for excessive run-out. Thoroughly clean the inside of the bearing frame prior to reassembly. REASSEMBLY Reassemble the bearing frame in the reverse order of the disassembly. The shaft bear-ing assembly must slide into place easily. The stationary seal holders must slide into place. The eight (8) allenhead setscrews should be coated with NEVER SEIZE, and tightened to 8 lbs.-ft. The impeller-retaining nut should be coated with LOCTITE 242 (or equal). The completed assembly must rotate freely without vibration. The completed assem-bly must be checked for leaks. The assembly must be pressurized to 3 PSI for a mini-mum of 20 minutes. Remove one of the pipe plugs between the primary and secondary seals and apply 3 psi to the assembly.

99


REASSEMBLY CONT. Check both seal areas thoroughly with a soap and water solution. After successful leak test, reattach bearing frame to upper shaft housing, using .030" paper gasket.

101


MECHANICAL SEAL REMOVAL & INSTALLATION

Refer to Drawing #20380 OUTBOARD SEAL REMOVAL

1. Remove pump impeller as outlined in impeller removal instructions. 2. Remove any burrs or foreign material from shaft. 3. Remove seal retaining ring (10). Using an external snap ring pliers. 4. Remove rotating assembly of outboard mechanical seal (13) by pulling assembl

out by hand. The rotating part consists of a spring holder, the spring, an elas tomer bellows, a driving band, a disc, a retainer and a primary ring. Some force may be required as the elastomer bellows can adhere to the shaft.

5. Remove the eight setscrews (3) from the bearing frame housing.

6. Remove the outboard stationary seal holder (12) and the O-ring (7). A hole has

been drilled and tapped on each side of the seal holder to allow for insertion of a pair of 1/4" threaded rods. Insert a threaded rod, at least 18" long, into each hole to assist in removal of the seal holder.

7. Remove the mating ring and the O-ring from the stationary seal holder. OUTBOARD SEAL INSTALLATION

1. Remove any burrs, corrosion, or foreign material from the bearing frame shaft

and its housing.

2. Clean the seal chamber (housing & shaft), the stationary seal holder and the seal retaining ring with solvent.

Note: The seal chamber must be dry and clean before continuing

seal installation.

102


OUTBOARD SEAL INSTALLATION CONT. 3. Install the mating ring and the O-ring into the stationary seal holder. Apply a

light oil lubricant to the O-ring to ease installation. Note: Avoid cutting or rolling the O-ring during installation. Do not touch or scratch the seal faces. Do not force or strike any seal parts. 4. Install the O-ring (7) into the housing. Apply a light oil lubricant to the O-ring.

Care must be taken not to cut, twist or roll the O-ring.

5. Install the stationary seal holder (12). Using 18" threaded rods will ease install lation. While installing the holder be careful not to hit the mating ring on the shaft, as this can lead to seal failure.

6. Reinstall the eight setscrews. Coat set screws with Loctite. Tighten setscrews

evenly to 8 lb.-ft. 7. Reinstall the rotating seal parts. A lubricant of mild soap and water can be ap

plied to the elastomer bellows to ease installation. A seal pusher is used to evenly push rotating assembly into place.

8. Reinstall the seal-retaining ring. Inspect ring for wear and damage, replace as

necessary. 9. Reinstall the impeller as outlined in impeller installation instructions. INBOARD SEAL REMOVAL

1. Remove the outboard seal as indicated in Outboard Seal Removal Section

above. 2. Remove the spacer ring (11).

3. Remove the seal retaining ring (10). 4. Remove the rotating assembly consisting of the inboard seal (9) as stated in

Step 4 of outboard seal removal instructions.

103


INBOARD SEAL REMOVAL CONT. 5. Remove the inboard stationary seal holder (8) and the O-ring (7) as outlined in

step 6 of outboard seal removal instructions.

6. Remove the mating ring and the O-ring from the stationary seal holder. INBOARD SEAL INSTALLATION

1. Remove any burrs, corrosion, or foreign material from bearing frame shaft and

housing.

2. Clean the seal chamber (housing & shaft), the stationary seal holder and the seal retaining ring with solvent.

Note: Seal chamber must be dry and clean before continuing seal

installation. 3. Install the mating ring and the O-ring into the stationary seal holder. Apply a

light oil lubricant to the O-ring to ease installation. Note: Avoid cutting or rolling the O-ring during installation. Do not touch or scratch the seal faces. Do not force or strike any seal parts. 4. Install the O-ring (7) into the housing. Apply a light oil lubricant to the O-ring.

Care must be taken not to cut, twist or roll the O-ring. 5. Install the stationary seal holder (8). Using 18" threaded rods will ease installa-

tion. While installing the holder be careful not to hit the mating ring on the shaft, as this can lead to seal failure.

6. Reinstall the rotating seal parts. A lubricant of mild soap and water can be ap-

plied to the elastomer bellows to ease its installation. A seal pusher, (supplied), is used to evenly push rotating assembly into place.

7. Reinstall the seal retaining ring. Inspect the ring for wear and damage and re-

place if necessary.

107


VOLUTE REMOVAL AND INSTALLATION INSTRUCTIONS


VOLUTE REMOVAL CAUTION: Ensure adequate lifting devices are used. 1. Lockout the power source. 2. Remove the cutterhead. 3. Remove the impeller. 4. Remove volute from bearing frame and discharge column. VOLUTE INSTALLATION 1. Bolt replacement volute to the bearing frame flange. Use .030" paper gasket at

bearing frame and standard 150# flange gasket on discharge. 2. Reinstall impeller. 3. Reinstall cutterhead.

108


UPPER SHAFT HOUSING ASSEMBLY AND DISASSEMBLY


REMOVAL AND DISASSEMBLY 1. Remove the cutterhead. 2. Remove the impeller. 3. Remove the volute. 4. Remove the 1/2" pipe plugs located in the bearing frame to allow for removal of

setscrews in shaft coupler. 5. Remove the setscrews from the shaft coupling. 6. Remove the bearing frame. 7. Remove the motor and the motor coupling. 8. Remove the bearing shaft collar and the flange bolts. 9. Slide the thrust bearing off of the shaft. Remove the O-ring from the shaft. 10. Remove the column support bolts. 11. Move the shaft housing away from the baseplate. 12. Remove the shaft from the bottom of the housing. 13. Remove the coupling. 14. Press the bronze bushing out of the housing. (Mark the location of bushings)

109

SRS CRISAFULLI INC. P.O. Box 1051 Glendive, Montana 59330 1-800-442-7867 REASSEMBLY 1. Press the new bronze bushings to previous locations determined above. 2. Install shaft coupling and key on shaft. Coupling goes onto shaft 1/2 its length

minus 1/8". Install set screws. Do not use Loctite. 3. Slide the shaft into the housing from the bottom. 4. Place the housing against the baseplate. 5. Slide the O-ring onto the top of the shaft. 6. Slide the bearing onto the shaft. Bolt through baseplate to upper housing

flange. Do not tighten shaft collar. 7. Replace the column support bolts. 8. Assemble the bearing frame to the lower housing flange. Do not tighten cou-

pling set-screws. 9. From the motor end push the upper shaft against the bearing frame shaft tightly,

then withdraw 1/4". 10. Tighten the setscrews in the bearing frame coupling and the bearing shaft collar. 11. Install the motor, the motor coupling, and the guard. 12. Reinstall the volute. 13. Reinstall the impeller. 14. Reinstall the cutterhead.

110


FLEXIBLE SHAFT COUPLING REPLACEMENT


1. Lock out the power source. 2. Disconnect the power cord from the electric motor (1). 3. Remove the 5/16” bolts (4) holding the coupling shield (5) in place and remove

the coupling shield. 4. Remove the 5/8” motor mount bolts (6). Slide the motor back far enough to al-

low room for removal of the flexible coupling (2). Note the location of any shims under motor footpads.

5. Loosen the setscrews (3) on the coupling halves and remove the halves from

the shafts taking note where the old coupling halves were on the shaft. Mark lo-cation before disassembly.

6. Inspect the components and replace if necessary. 7. To reassemble unit, follow the above steps in reverse order. 8. Tighten the 5/8” motor mount bolts. Check the coupling for alignment. Adjust if

necessary. 9. Tighten the 5/8” motor mount bolts to 80 lb.-ft. (Gr. 2 bolt), or 140 lb.-ft. (Gr. 5). 10. Replace the coupling guard and reconnect the power supply to the motor.

112


REMOVAL & INSTALLATION OF CUTTERHEAD MOTOR & DRIVE COUPLER


REMOVAL OF THE CUTTERHEAD MOTOR AND DRIVE COUPLER 1. Remove the Flump from the lagoon. 2. Stabilize the cutterhead. 3. Support the auger (19) from within shroud (8) with a lifting device. 4. Remove the water lubricated bearing (30) per removal instructions. 5. Remove the two 3/8” bolts (5) and washers (6,7) and remove the hydraulic hose

cover (9). 6. Remove the hydraulic hoses - plug and cap all hydraulic hoses and ports. 7. Remove the 3/4" Nyloc nut (21) and drive bolt (20) from auger. 8. Remove the four 1/2" bolts (11) and washers (10). 9. Remove the hydraulic motor (14), motor mounting disk (16), and drive coupler

(15). REMOVAL OF DRIVE COUPLING FROM MOTOR

A. Remove the 1"- 20 Crush Lock retaining nut (18) from the motor. B. Remove the drive coupler from the motor shaft. INSTALLATION OF DRIVE COUPLER & CUTTERHEAD MOTOR Note: Installation of drive coupler and cutterhead motor can be accomplished by re-

verse sequence of steps.

113


REMOVAL & INSTALLATION WATER LUBRICATED BEARING


REMOVAL OF WATER LUBRICATED BEARING 1. Remove the Flump from the lagoon. 2. Stabilize the cutterhead. 3. Support the auger (19) from within the shroud (8) with a lifting device. 4. Remove the four 1/2” attaching bolts (12) nuts (13) and washers (24). 5. Remove the bearing mount (31) with the bearing (30) from the auger tube. 6. A press is required to remove the bearing from the mount. INSTALLATION OF WATER LUBRICATED BEARING 1. Press the new water lubricated bearing into the bearing mount. The bearing

must not protrude from the bearing mounting tube. 2. Slide the bearing mount onto the auger tube shaft. 3. Reposition the bearing mount and align the fastener holes. 4. Install four 1/2” bolts, nuts, and washers and tighten.

115


HYDRAULIC POWER UNIT ASSEMBLY AND DISASSEMBLY INTRUCTIONS

Refer to Drawing # CPC-9525EXP4 DISASSEMBLY 1. Lock out the power source and disconnect cord from the electric motor (15). 2. Remove the two hydraulic lines that are attached to the power unit. 3. Cap and plug all exposed hydraulic lines and ports to prevent contamination. 4. Unbolt and remove the reservoir from Flump (if necessary). 5. Remove the 5/16” bolts (14) and remove the hydraulic cover (9) along with the elec-

tric motor (15) and the hydraulic pump (6) assembly. 6. Uncouple the pressure line (20) from the hydraulic pump (6). 7. Remove the suction strainer (21). 8. Loosen the setscrews in coupling halves (8) and (11). 9. Remove the 3/8” bolts (7) and remove the hydraulic pump (6). 10. Remove the coupling halves (8) and (11). 11. Remove the ½” bolts (2) and separate the electric motor (15) from the suction

cover (9). 12. Clean and inspect all components for wear and replace as necessary. ASSEMBLY 1. Assemble the power unit in reverse order of disassembly.

117

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08

86,1

90-6

4,6

43

118


SECTION 5 - PARTS LISTS

SLUDGE PUMP 119 PUMP COLUMN 121 CUTTERHEAD 122 POWER UNIT 124 HOIST WINCH 126 TRAVERSE WINCH 128 TRAVERSE GUIDE & ROLLER SHEAVE ASSEMBLY 129 RECOMMENDED SPARE PARTS LIST 130 WORK ORDER NUMBERS 131

120

PA

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DG

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P/N

1006833

R

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#

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(BE

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98

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8

1

SE

CO

ND

AR

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L H

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DE

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98

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-6

9

1

2-1

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ME

CH

. S

EA

L C

AR

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N/N

I-

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T F

AC

E T

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1 (

INB

OA

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)

10

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09

1

0

2

2

-1/4

" E

XT

. R

ET

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ING

SN

AP

RIN

G

10

002

94

1

1

1

B

EA

RIN

G F

RA

ME

SP

AC

ER

9

81

98

-7

121

100

07

02

100

07

04

100

07

05

100

07

03

100

67

88

100

67

95

100

01

87

100

06

55

100

06

64

100

06

60

100

09

16

100

06

27

100

06

61

n/a

3/8

” X

1/2

” L

ON

G

10

123

RE

F #

QT

Y

D

ES

CR

IPT

ION

PA

RT

#

RE

F #

Q

TY

DE

SC

RIP

TIO

N

P

AR

T #

1

4

1/2

" H

YD

. H

OS

E C

LA

MP

1000680

18

1

1”

NF

CR

US

H L

OC

K N

UT

1000759

2

2

5/1

6”

X 1

” N

C B

OL

T

1000935

19

1

AU

GE

R

1001498

3

4

5/1

6”

FL

AT

WA

SH

ER

1000936

20

2

3/4

" X

6"

NC

BO

LT

1000930

4

2

5/1

6”

NC

LO

CK

NU

T

1000937

21

2

3/4

" N

C N

UT

, L

OC

K, 3/4

, N

Y-

LO

C

1000739

5

2

3/8

" X

2 1

/4”

NC

BO

LT

1000932

22

36

CO

BR

A A

UG

ER

TIN

ES

(8

)

RIG

HT

, (8

) L

EF

T

1000034 /

1000035

6

4

3/8

” L

OC

K W

AS

HE

R

1000934

23

28

1/2

" X

1 1

/4"

NC

BO

LT

1001499

7

4

3/8

” F

LA

T W

AS

HE

R

1000933

24

28

1/2

" N

C N

UT

1000946

8

1

CU

TT

ER

HE

AD

SH

RO

UD

1001948

25

32

1/2

" L

OC

K W

AS

HE

R

1000947

9

1

HY

DR

AU

LIC

HO

SE

GU

AR

D

1000797

26

1

RO

CK

GU

AR

D

1000797

10

4

1/2

” H

IGH

CO

LL

AR

LO

CK

WA

SH

ER

1000761

27

1

SE

AL

, L

IP, 4.0

00”S

HA

FT

1002877

11

4

1/2

" X

2 1

/2”

NC

BO

LT

1000948

28

1

O-R

ING

, B

UN

A R

UB

BE

R

1000038

12

4

1/2

" X

3"

NC

SH

CS

1000760

29

1

GR

EA

SE

ZE

RK

, 1/8

”

1000040

13

4

1/2

" N

C N

UT

1000946

30

1

WA

TE

R L

UB

E B

EA

RIN

G

1000042

14

1

WH

ITE

HY

DR

AU

LIC

MO

-

TO

R

1000008

31

1

WA

TE

R L

UB

E B

EA

RIN

G

HO

LD

ER

1000976

15

1

DR

IVE

CO

UP

LIN

G

1000794

32

2

FIT

TIN

G, H

YD

, 5/8

” X

1/2

" JI

C

1000758

16

1

DR

IVE

MO

UN

TIN

G D

ISK

1002881

33

2

3/8

" X

3/4

” N

C B

OL

T

1000943

34

1

SH

AF

T C

OU

PL

ING

1000794

P

AR

TS

LIS

T F

OR

CO

BR

A C

UT

TE

RH

EA

D,

102”, F

LU

MP

P/N

1002892

125

PARTS LIST FOR POWER UNIT P/N 1001161

1

-

HYDRAULIC RESERVOIR

99202 (dwg no.)

2

4

1/2" -13 UNC-1" BOLT

SHOP STOCK

3

4

1/2" LOCK WASHER

SHOP STOCK

4

4

3/8"-16 UNC NUT

SHOP STOCK

5

4

3/8" LOCK WASHER

SHOP STOCK

6

1

HYDRAULIC PUMP

1000414

7

4

3/8"-16 UNC-1-1/2" BOLT

SHOP STOCK

8

1

COUPLING HALF 1-3/8" BORE

1001154

9

1

HYDRAULIC COVER

99202 (dwg no.)

10

1

HYD. RESERVOIR FILLER BREATHER CAP

1000613

11

1

COUPLING HALF 9/16" BORE

1001153

12

1

COUPLING ELEMENT BUNA

1001155

13

16

5/16" LOCK WASHER

SHOP STOCK

14

16

5/16"-18 UNC-3/4" BOLT

SHOP STOCK

15

1

7.5 HP MOTOR, 230/460V, 213TC , C-FACE

1001159

16

1

TEMPERATURE/SIGHT GAUGE

1000594

17

1

3/4" MAGNETIC DRAIN PLUG

1000593

18

1

PRESSURE RELIEF VALVE

1004594

19

1

HYDRAULIC RETURN FILTER

(REPLACEMENTMENT ELEMENT)

1000612

(1005426)

20 1 PRESSURE LINE HHDW028DANDJNKC

21

1

SUCTION STRAINER

1001152

22

1

3/4" NIPPLE 12" LONG

1000619

25

1

3/4" HYDRAULIC NIPPLE

1000623

26

1

3/4" MB-1/2" FP SWIVEL

1001157

27

1

3/4" MB-1/2" FP SWIVEL

1001156

28

1

1/2" NIPPLE

1001158

29

1

1/2" MJ –3/4” MP 90

1000840

30

1

1/2" MJ –1/2” MP 90

1000841

127

PARTS LIST FOR HOIST WINCH P/N 1000765

1

1

ELECTRIC WINCH GEAR MOTOR

1004781

2

1

HOIST WINCH DRUM

1000578

3

1

WIRE ROPE CLAMP

1000843

4

1

RETAINING WASHER

1000488

5

1

1/2"-13 UNC-1-1/2" BOLT & LOCK WASHER

SHOP STOCK

6

4

1/2"-13 UNC-2" BOLT, LOCK WASHER & NUT

SHOP STOCK

7

17 FT

5/16" DIAMETER GALVANIZED WIRE ROPE

1000844

128

1000755

1002975

1002959

129

1002794

1002975

130

SRS CRISAFULLI, INC. P.O. BOX 1051 Glendive, Montana 59330 1-800-442-7867

RECOMMENDED PUMP SPARE PARTS LIST 4” J-SERIES FLUMP

ITEM QTY DESCRIPTION & PART NUMBER 1. 1 11” Impeller #1000732 2. 1 Sure-flex Coupler Sleeve #1000705 3. 1 Seal, Mechanical, 2-1/4” Type 2 #1000310 4. 1 Seal, Mechanical, 2-1/4” Type 21 #1000309 5. 2 Oil Cup #1000627 6. 2 Hydraulic Filter #1005426 7. 1 Waterlube Bearing #1000042 To quickly order spare parts, call toll-free 1-800-442-7867. When placing your phone order, please give the Sludge System Serial Number and Part Numbers.

131

Manufacturing Work Order Numbers ITEM PART NUMBER JOB NUMBER DESCRIPTION

1 1007226 23494-0000 4" Flump

2 1002892 23494-0001 Cutterhead

3 1000991 23494-0002 Shroud

4 1000787 23494-0003 Auger

5 1000796 23494-0004 Hydraulic Hose Cover

6 1000797 23494-0005 Rock Guard

7 1000784 23494-0006 Cutterhead to Pump Adapter

8 1001161 23494-0007 Electric-Hydraulic Power Unit

9 1007266 23494-0008 Floating Platform

10 1002975 23494-0009 7” Traverse Sheave

11 1007293 23494-0010 4” VD Pump

12 1007267 23494-0011 Volute

13 1000732 23494-0012 Impeller

14 1000661 23494-0013 Shaft Coupler

15 1002968 23494-0014 Coupler Guard

16 1007261 23494-0015 Vertical Pump Hinge

17 1002961 23494-0016 Traverse Winch Assembly

18 1000606 23494-0017 Traverse Winch Base

19 1002959 23494-0018 Traverse Winch Drum

20 1002975 23494-0019 7” Traverse Sheave

21 1004780 23494-0020 Hoist Winch Assembly

22 1000578 23494-0021 Hoist Winch Drum

23 1007270 23494-0022 Adapter 8” M QC to 8” Pipe

24 1007289 23494-0023 Onboard Control Panel Mount

25 1004971 23494-0024 Master Disconnect Stand

132

SERIAL #16061

P.O. Box 1051

1610 Crisafulli Drive

Glendive, MT 59330

www.crisafulli.com

Phone: 1-406-365-3393

Fax: 1-406-365-8088

Toll Free: 1-800-442-7867

FLOATING SLUDGE

DREDGE

133

OPERATION & MAINTENANCE MANUAL 4” Severe Duty Flump #16061

Hispamerica World Inc.

OPERATION & MAINTENANCE MANUAL 4” Severe Duty Flump #16061


OPERATION & MAINTENANCE MANUAL

4” Severe Duty Flump #16061











operation & maintenance manual · 2017. 10. 8. · manual 4” flump serial #16061 hispamerica...

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