HYDRAULIC PUMP HY85-160 DRAGFLOW Ee om ULTIMATE EFFICIENCY vA "ia Paes — 46048 Roverbella (MN) - Tel. +39 03761685400 — Fax +39 03761685499 [email protected] - www.dragflow.itDRAGFLOW may ULTIMATE EFFICIENCY HYDRAULIC PUMP HY85-160 INSTRUCTIONS HANDBOOK @ PRESENTATION. WARRANTY REGULATIONS. 1.0 DESCRIPTION. 2.0 TRANSPORT, ASSEMBLY AND DEMOLITION 3.0 STARTING AND OPERATION............0:c0seseeee 4.0 MAINTENANCE AND CLEANING. 5.0 NOISE... HYDRAULIC CONNECTIONS............ 6.0 SAFETV....... SPARE PARTS. WEAR SPAREG............. Ed 08/17DRAGFLOW HYDRAULIC PUMP HY85-160 @ eee INSTRUCTIONS HANDBOOK Ed 08/17 PRESENTATION This instructions manual has been conceived and structured for rapid and easy consultation, thanks to the index ordered by subjects, and explanatory figures and tables GENERAL WARNINGS This instructions manual must be studied by the owner of the machine, the technical personnel within the factory, the operators, that is, all those that will be using the machine, the maintenance technician The manual is an integral part of the machine and contains information on its use, technical characteristics, as well as instructions for handling, installation, assembling, regulation and maintenance. Italso contains a section for trouble-shooting, if necessary, and for the ordering of spares The DRAGFLOW S.r.l. technicians are always available, by telephone, fax or e-mail, to supply all the explanations that may be needed. This manu: ~ must be considered as integral part of the machine until it is taken to the breakdown yard; - must be kept in an easily accessible place and suitable for its preservation; - must be consulted each time that there are problems or doubts on the operation of the machine; - must be carefully followed for whatever regards the necessary maintenance operations set out in it In case itis lost, apply for a copy directly tram DRAGFLOW S.r.l. DRAGFLOW S.r.L. reserves the right to carry out all modifications to update the machine or instructions manual according to the technological progress and the state of the art. This constitutes no obligation to carry dut modifications to the machines that have already been sold. If the machine is ceded to a third party, itis recommended that of the instructions manual follow it DRAGFLOW S.R.L. RETAINS ITSELF FREE FROM LIABILITY OF ANY KIND, AND ESPECIALLY FOR: - improper use of the machine, - _ use of the machine by personnel not trained to used it, - power supply defects; - maintenance defects - unauthorized and unforeseen modifications; - use of spares that are not original or not specific for the model, = nan observance of the instructions; The uses of the machine for different purposes are to be considered dangerous for the operator and for the machine. Likewise, modalities of installation and utilizations different from that indicated in the present manual could cause damage to persons and/or to the machine itself.DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 WARRANTY REGULATIONS DRAGFLOW S. material defects guarantees the original user that the machine will be reasonably free from factory and This warranty lasts for 12 (twelve ) months from the invaice date, and refers to the repairing of any defect that will be recognized by DRAGFLOW S.r.. as being subject to warranty. The warranty does not apply to those parts that result defective because of incorrect use, handling or bad observance of the use and maintenance instructions supplied by DRAGFLOW S.r.I. The warranty is not applied for those listed parts subject to normal wearing: - seals and gaskets, Shaft sleeves, impeller, stirrer, wear-plates, casing, discharge adapter, excavator teeth and electrical components, The warranty on the electric motor is applied only if the standard electronic control console foreseen has been installed It the Purchaser tries, either to repair any fault that is under guarantee, or obtain direct supply of the spare part without previous written consent of DRAGFLOW S.r.L the latter will not be responsible for the results of the repair and will not be held to reimburse the expenses sustained by the Purchaser. Any claim for warrantable failures shall be sent in writing to DRAGFLOW S.r.l. prior to the expiry of the warranty period As soon as the spare is ready, the Client will make the defective part available to DRAGFLOW S.r.l. The warranty is applied in ane of the following ways and at the discretion of DRAGFLOW S.r. - replacement of defective part with a new one, made available in the offices of the Purchaser at the lowest transport rate; - repair of defective part, after this has been returned to DRAGFLOW S. prepaid with transport expenses DRAGFLOW S.1. declines all responsability for the expenses due to “down-time”, business costs and losses deriving there from This warranty is the sole warranty provided by DRAGFLOW S.r.1. There are no other warranties, explicit or implied, or of merchantability or fitness for a particular purpose. pg. 3DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 1.0 DESCRIPTION STRUCTURAL DESCRIPTION OF THE MACHINE (Fig. The Dragflow hydraulic pumps are made of high quality materials and undergo severe controls before leaving the factory. They are essentially composed of a caver 1, on which the hydraulic motor 2 is fitted Inside the ail housing 3 is housed the group of seals 4 preventing the water from passing to the motor. On the main shaft 10, inside the casing 5, there is a keyed impeller 6, made in high chrome content anti-wear materials, Awear plate 7, made with the same material, partially closes the impeller inlet. Inside the strainer protection 8 houses a cutter 9 that rotates and stirs the mixture of solids in the water to be pumped ( or/A GFLoW fj) ___ ume _seeciricarion ___[@ sae) pac a BE —— row Ess Rem Cee el ihe “Coe c€ pg. 4 aDRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 2.0 TRANSPORT, ASSEMBLY AND DEMOLITION Dragfiow pumps are generally transported encased inside a crate to avoid damage to the pump or parts of it The crate is arranged for unloading with a foriclift truck, whose capacity must be able to sustain the weight of the pump ( see data sheet enclosed in this instructions handbook ) as shown in Fig. 2. The pump is placed inside the crate as seen in Fig. 3, it must be freed from the packing and lifted with ropes hooked to the appropriate liting plate A. Pg.DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 INSTALLATION 1) Connect the delivery pipe. - The delivery pipes must never form siphons (Fig. 5) pag. 6, to avoid prablems due to the formation of air pockets or deposits of solid material Before connecting then pump to the hydraulic supply source, make sure that all the data on the rating plate correspond ( max. pressure, etc. ) Fig. 4 Fig. 5 Pg.DRAGFLOW HYDRAULIC PUMP HY85-160 @ SS INSTRUCTIONS HANDBOOK Ed 08/17 Connect the oil supply pipes to the pump as indicated in Fig. 6. DISMANTLING Before doing anything on the pump, be sure to disconnect the hydraulic supply and the delivery pipes Warning: the machine that is considered completely useless must be removed from the department and collected by the manufacturer or any other firm specialized in demolition. Remember that dismantling the machine in your establishment will “produce” different materials ( metals, plastics, ail, etc. ) whose disposal will be done in compliance with the legislative regulations in force in the state where the machine is found (DELIVERY) (RETURN) PIPE 1” %-350 bar PIPE 1” 2-100 bar (DRAINAGE) PIPE %” return free at the tank Fig. 6 The drainage oil must be collected in non-pressurized tanks. “Free return” means that there must be nothing that impedes the drainage ( narrowing, valves, filters, etc. ) pg. 7DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 3.0 STARTING AND OPERATION STARTING The pump has been created to pump suspended matter, even with solid parts, as long as water is always present. It can be used for civil and industrial purposes, as long as conditions described in this manual are observed Check the direction of rotatian: by passing very short impulses and check that the direction of rotation is that indicated on the rating plate 1) Immerse the pump in clear water. 2) If any priming prablems should come up, stop and wait far about 30 seconds, leaving it immersed, until all the air has been eliminated 3) Check that when pumping only water H2O, the operating pressure always stays at least 20 - 30% below the set maximum pressure. 4) Slowly lower the pump until it comes into contact with the material 5) Check the percentage of solid to avoid exceeding the maximum pressure threshold 6) When clean water is not avallable, but only mud and ather mixtures, check that the pump does nat go over the maximum pressure indicated on the rating plate (Fig. 7); however, if this does happen, create a further load loss, by doing what is set out below. = by adding pipes. =by creating bottlenecks, Traising the discharge height, 7) Before stopping the pump, it is always a good rule to pump water with very little solid in it, so that the pipes are washed EMERGENCY SITUATIONS The correct use of the machine excludes the possibility of emergencies happening during Operation or during cleaning and maintenance, unless the latter have nat been done in compliance | ar/A\erto | with this instructions manual. ') ©| prflcroW Lm i | If there is any imminent mechanical danger, stop, or have the pump stopped by disconnecting it fram Saar eS the hydraulic supply. An accurate search for the ao el fault, or anomaly that caused the danger, must be carried out soon afterwards, and once detected, Max (ome 7) [ar a | competent personnel from another firm carry out = ae any repairs or work. role et see to resetting the operation of the machine and PRESSURE of the protection set-up. mess Lele Itnecessary, have DRAGFLOW S.r.. Service or a | aT | Al) Cosme (| Ce) bo | Fig. 7 pg. 8DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 4.0 MAINTENANCE AND CLEANING Warr ig: Maintenance and cleaning of the machine must be done after having stopped the machine 1) Check the tightness of the fastening screws every 50 hours of pump operation 2) Remove the 2 (two) plugs marked by the labels GREASE, Fig. 8, and restore the grease with 50 grams of it for each greaser, using a hand grease gun. Seals zone must be greased every 8 hours. 3) Every 150 hours check the clearance between the impeller 47 and the lower wear plate 48 is as follaws (see Fig. 9). (Use the torque table for tightening) - keep the pump in a vertical position; - dismantle the side strainer 53 by removing the screws in position 24 - check that the clearance is not more than 1,5 mm, if itis wider proceed as follows. - slacken of the fastening screws 52, - take the wear plate 48 at a distance of about 1,5 mm fram the impeller 47, by turing the adjustment screws 81 and locknuts 83; - check that it rotates freely; - fasten both the lacknuts 83, the adjustment screws 81 and the fastening screws 52 4) For customers that work with particularly abrasive materials having a very fine particle size, we advise passing a jet of water under pressure, connecting it ta the prepared threaded connector indicated with H20 (Fig. 8). The pressure must be greater than that exerted by the pump to have continuous cleaning of the area of the seals and so less wear. Itis compulsory to grease the area of the seals at the end of each shift or every 8 working hours, use water resistant grease with LIQUILON. Fig. 8 = REASE -greasing every 150 hours- oe “GREASE” (red plug) -gteasing every 8 hours- “WASHER" water washing thickness blocking screws pg. 9DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 5) Check the level and the deterioration of the oil every 8 hours of operation by removing the plug labelled “WATER' “OIL” (Fig. 10). For a total ail change ar topping up. water the following steps have to be taken washing a) Itis good practice to empty the pump completely of the remaining oil. The exhausted lubricant must be disposed of in conformity with the laws in force in the country where the machine is used, since its dispersal in the ground will pollute the water beds This is not necessary if the oil is simply topped up. b) Remove the plug marked “OIL”. ¢) Top up until completely full using a funnel an side up to the indicated "OIL LEVEL’ (Fig. 11), approx 5 Kg of oil having the characteristics as in the table following oiltype iso | PERSi¥ At) cstaorc | YiSCOSY | sore | iv. | FSP POM |pour point °c epsz0 [320] 0900 | 330 25.8 2a | 96 240 “17 ) Before closing the plug change the copper washer to prevent leaks and water seeping in Ifthe oil is “milky” white color the seals must be replaced. "OIL" ot fing Top up with funnel - BS > pg. 10DRAGFLOW Sree Orne crrceNCy HYDRAULIC PUMP HY85-160 INSTRUCTIONS HANDBOOK @ REPLACING THE SEALS - Completely empty the oil from the oil chamber. - Remove the filter 53 (Fig. 12) by unscrewing the screws 21 - Unscrew the cutter 54 by hitting it smartly in an anticlock- wise direction as shown in Fig. 13; make sure the impeller 47 (Fig. 12) is blocked with an iron rod - Remove the connection 86 (Fig. 12a), then the nut 57 and the spacer 58. - Extract the flange on the suction side 50 (Fig. 12) after having removed the screws 52. With the flange pos. 50 the lower wear plate 48 also will come down - Remove the casing 45 (Fig. 12) after having removed the screws 42 - Extract the impeller 47 using two levers “A” (Fig. 12) Ifit sticks use an extractor, taking care nat to damage the threaded part of the motor shaft. - Remove the key 59 (Fig. 12) and immediately after the sleeve 20 (Fig. 14). To remove the upper wear plate 46 unscrew the screws 42a - Remove the seals housing 67 and 66 after having removed the screws 78 with the ring 68 - Change the seals 27 (n° 1) and 34 (n° 1) with their wear sleeve 39 (n° 1) and the o-ring 40 (n° 1). Then change the seals 66 (n° 1), 41 (n° 3) and 36 (n° 2), the two lower shaft sleeve 31 and 20, the three o-rings "OR" 28, 23 and 26 as shown in Fig. 14 taking care nat to damage any spare a2 40 [Tf Ed 08/17 N.B. First block the impeller pg. 11DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ INSTRUCTIONS HANDBOOK ULTIMATE EFFICIENCY Ed 08/17 - To reassemble follow the instructions in the reverse order keeping the pump in vertical position. Remember to adjust the lower wear plate 48 (Fig. 9 pag. 9) as indicated in paragraph 3), before closing the pump definitely. Top up with new all, accarding to the instructions of paragraph 5) pag. 10. Periodically, check the state of the hydraulic system ( pipes, pipe fittings, etc. ). If parts of the hydraulic equipment are to be replaced, only use components with characteristics that are equal, or at least similar, to those of the original components. PUTTING THE MACHINE OUT OF SERVICE It for any reason whatsoever the machine should be temporarily placed out of service, it is important to disconnect the hydraulic supply source, clean the fittings of pump and hydraulic motor and caver them to protect them from dust. To put it back into service again follow the instructions for starting up. 5.0 NOISE The machine was designed and manufactured while at the same time keeping in due consideration air noise hazards. The canstruction techniques used allow ta limit the noise level within tolerable limits in compliance with the Machine Directive 2006/42/CE Air noise detection was effected by placing the probe two meters from the machine, along the whole perimeter and at a meter from the floor. The noise was measured under vacuum. This because the machine itself does not require any specific operation position fixed by the operator since it is normally immersed in water and therefore the values are non-influencing The observations were done with a model HD9020K1 DELTA OHM PRECISION INTEGRATOR NOISE METER in conformity with the’ IEC 51 class 1 standard IECB04 class 1 1EC225 filters 1/3 octave The instrument was calibrated with a DELTA OHM HH9101 calibrator conforming to the IEC942-1986 class 1 pg. 12DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 HYDRAULIC CONNECTIONS pg. 13DR/ \GFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 - The DRAGFLOW pumps are only supplied with piston hydraulic motors, suitable for circuits where the continuous operating pressure may reach 300 bar. These pressures can only be reached in the worst conditions Make sure that in the hydraulic power unit, the safety valve is set from 300 up to 350 bar according to the Dragflow pump model The drainage pipe trom the motor must be connected directly to the tank without filters or any ather restriction in between - Start the pump out of the liquid to be pumped and check the direction of rotation and the speed with a revolution counter. The speed must be adapted to the working conditions ( around 1500 rpm, the length of the pipes, vertical height abave the water, etc. ), since good operation and the best duration of the pump are obtained by working in the flow rate/nead range corresponding to the model concemed (see the pump curve enclosed in this instructions handbook ) pg. 14DRAGFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 6.0 SAFETY Introduction Dragflow s.r.1. has designed and built the machine keeping in mind the results of a preventive and accurate analysis of the risks connected to the use of the machine. The protections and devices applied, therefore, represent the profuse commitment by the Dragflow S.r.l. technicians to achieve the aim of safety sanctioned by the specific directives issued by the EEC. The protections and devices are illustrated below with drawings Other instructions and information on the safety of the machine are contained in the paragraphs which deal with the use, maintenance and repair. All the organs in movement are segregated inside the pump structure. The only rotating mechanical part is the agitator 54 ( Fig. 16 ), that for functional reasons cannot be protected in any way. In fact its specific function is that of cleaning the strainer 53 and stirring the solid bodies present in order to set them in suspension in the liquid to be pumped ( Fig. 16 ) On the pump there is a warning plate ( Fig. 15 ) to remind us of this danger. When about to operate the pump, keep clear of this rotating part in order to avoid accidents. The strainer 53 ( Fig. 16 ) is made according to the suction capacity of the pump, and does not allow the passage of particles of over 60 mm diameter. Itis a good rule not to come close to the pump when it is immersed in water to avoid dangerous situations. Do not open without having first releasing the hydraulic pressure. On the pump there is a warning plate to remind us of this danger ( Fig. 15 ). The driving hydraulic motor is fed oil under pressure, therefore keep to the safety rules in the table Fig. 15DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 SPARE PARTS HY85-160 pg. 16DRAGFLOW HYDRAULIC PUMP HY85-160 @ INSTRUCTIONS HANDBOOK may ULTIMATE EFFICIENCY Ed 08/17 pg. 17DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 pg. 18DRAGFLOW HYDRAULIC PUMP HY85-160 @ may ULTIMATE EFFICIENCY INSTRUCTIONS HANDBOOK Ed 08/17 pg. 19DRAGFLOW HYDRAULIC PUMP HY85-160 @ INSTRUCTIONS HANDBOOK may ULTIMATE EFFICIENCY Ed 08/17 pg. 20DRAGFLOW iy ULTIMATE EFFICIENCY HYDRAULIC PUMP HY85-160 INSTRUCTIONS HANDBOOK @ Ed_ 08/7 Pos. | a. PART NUMBER DESCRIPTION 6 4 ‘2501066 SCREW 7 4 ‘A2527004 ‘SEAL WASHER a 2 ‘A6502018 GREASE NIPPLE 3 [16 ‘2501071 SCREW 10 [24 ‘2527005 ‘SEAL WASHER i 1 Aioo1110 BALL BEARING 16 [1 A1501125 O-RING 7 [2 ‘A1501126 O-RING ie [1 F21168 OIL CHAMBER ig [6 ‘2501006 SCREW 20 [4 42939 WEARING SPACER 2 [4 A2501076 SCREW 22 [4 ‘A6504065 PLUG 23 [4 ‘1501096 O-RING 25 [4 F23171 GREASE SPACER 26 [1 Ais01097 O-RING a7 [4 ‘6503044 SEAL 28 [4 ‘1501108 O-RING 23 [4 ‘A1504019 WASHER 31 1 F42936-1 LOWER SHAFT SLEEVE aa tt ‘6503044 SEAL 3 [1 ‘1003010 THRUST BEARING 36_[ 2 ‘AG503011 SEAL a7 fi ‘Aio01097 BALL BEARING 3a ft ‘1001098 BALL BEARING 39 [4 ‘A6503005 UPPER SHAFT SLEEVE 40_[ 1 ‘1501098 O-RING a 3 AISO2114 SEAL a2 [32 A2501022 SCREW at F20637 BEARINGS FLANGE “1 F20636 SPACER a FI9789/S6 CASING 461 F19790 UPPER WEAR PLATE a FI9795 IMPELLER a Fig792 TOWER WEAR PLATE so | 1 FI9791VOI SUCTION COVER =2_ | 6 2501072 SCREW a3 [i G24193 ‘STRAINER STAND sa [1 Fi9602 AGITATOR a5 | 1 AD501048 AGITATOR SCREW se [1 F19798/1 AGITATOR CONNECTIVE a7 | 4 Fige00/1 AGITATOR NUT sa | 1 F19805/1 AGITATOR SPACER 33 [1 25181 10 KEY eo | i POTS2401 DISCHARGE ADAPTER 0200 (A) eo | 1 0152400 DISCHARGE ADAPTER 250 (B) Pg. 241DRA\GFLOW HYDRAULIC PUMP HY85-160 @ SS INSTRUCTIONS HANDBOOK Ed. 08/17 pos. | a. | PARTNUMBER DESCRIPTION as 3510006 WASHER 2 [8 2501105 SCREW 4 [4 ‘1002085 ROLLER BEARING 65 [1 F42937 SEALS HOUSING 66 [1 AS503046 SEAL e7_[ 1 F42936 LOWER SEALS FLANGE 68 | 6 2627016 SEAL WASHER 78 [6 (A2601003 SCREW. e1_| 10 (A2501023 SCREW 3 [10 (A2508025 NUT ee [2 F 2044412 LIFTING PLATE eo [1 F39298 MOTOR SUPPORT 90_|_4 639297 MAIN SHAFT 94 | 4 F39299 O-RING 96 [1 a51702071 HYDRAULIC MOTOR 97_[41 F24509 SPACER 98_|_1 (2019025 SPRING WASHER 99 [1 F39296 SPACER pg. 22DRAGFLOW HYDRAULIC PUMP HY85-160 @ ee INSTRUCTIONS HANDBOOK Ed 08/17 SAFETY SPARE PARTS DRAGFLOW S.r.I. produces dredging pumps, they're equipment for abrasive and heavy job. These kinds of applications naturally wear the consumable parts of the machine. The wearing of the consumable parts will get the performances of the machine lower such as the pumped solid materials little by little will be less To avoid to stop the equipment and lost time, DRAGFLOW S.r.l. qualified as your expert witness suggests to keep ready at site or placed in your workshop the fallowing spare parts Pos. | @. PART NUMBER DESCRIPTION 1 1 ‘1001110 BALL BEARING 15 1 ‘A1501125 O-RING 7 | 2 ‘A1501126 O-RING 20 1 F42939) WEARING SPACER 23 1 ‘A1501096 O-RING 26 1 ‘A1501097 O-RING 2 1 ‘Ag503044 SEAL 28 1 ‘A1501108 O-RING 31 1 F42936-1 LOWER SHAFT SLEEVE 34 1 A6503044 SEAL 35 1 ‘A1003010 THRUST BEARING 36_[ 2 ‘A6503011 SEAL 37. 1 ‘A1001097 BALL BEARING 38 1 ‘A1001098 BALL BEARING 39) 1 ‘A6503005 UPPER SHAFT SLEEVE 40 1 ‘A1501098 O-RING at 3 A1S02114 SEAL 47 1 19795 IMPELLER 48 1 F1g9792, LOWER WEAR PLATE 5a. 1 F19802 AGITATOR: 55, 1 (A2501048 AGITATOR SCREW 56 1 F19798/1 AGITATOR CONNECTIVE 57, 1 F19800/ AGITATOR NUT 58. 1 F19805/1 AGITATOR SPACER 60 1 Po1s2401 DISCHARGE ADAPTER 2200 (A\ 60 1 0152400 DISCHARGE ADAPTER @250 (B 64 1 ‘A1002085 ROLLER BEARING 66 1 ‘A6503048 SEAL 67 1 F42936 LOWER SEALS FLANGE 94 1 F39299) O-RING pg. 23