KSP Poppet Manual 2011

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(1)FACTORY TRAINING KSP Poppet Manual. 2011.

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(3) Schwing Bioset Parts and Service (715) 247-3433 OR Fax (715) 247-3438. Paul Katka - Parts/Service Manager Dave Larson - Quality Control Specialist. Service Technicians Chris Kohnen Jack Koehler Jeff Joy John Christenson Mike Smith. Parts Brad Dopp Larry Larson Zach Anderson.

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(5) TABLE OF CONTENTS. SECTION 1. GENERAL. 1.1. PURPOSE OF THIS MANUAL .................................................................................. 1 - 1. 1.2. DESCRIPTION OF EQUIPMENT .............................................................................. 1 - 1 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.2.9 1.2.10. 1.3. INSTALLED EQUIPMENT LIST ................................................................................ 1 - 26 1.3.1 1.3.2 1.3.3 1.3.4 1.3.5 1.3.6 1.3.7 1.3.8 1.3.9 1.3.10 1.3.11. 1.4. General Description .................................................................................... 1 - 1 Sludge Pump With Poppet Valves.............................................................. 1 - 8 Sludge Flow Measuring System (SFMS®) - Poppet Valve KSP ................ 1 - 10 Screw Feeder ............................................................................................. 1 - 12 Hydraulic Power Pack................................................................................. 1 - 13 Material Pipeline ......................................................................................... 1 - 21 Sliding Frame Silos..................................................................................... 1 - 22 Push Floor .................................................................................................. 1 - 23 Pipeline Lubrication System ....................................................................... 1 - 24 Automatic Greaser System......................................................................... 1 - 25. General With Data Sheets .......................................................................... 1 - 26 Sliding Frame Receiving Bin....................................................................... 1 - 26 Receiving Bin Conveyor ............................................................................. 1 - 26 Sludge Pump - KSP 140 (HD)XL................................................................ 1 - 27 Screw Feeder - SD 500 HD ........................................................................ 1 - 27 Agitator Hopper - MODEL HHH.................................................................. 1 - 27 Hydraulic Power Pack - MODEL 2000, 200/150 HP................................... 1 - 27 Agitator Hopper - MODEL HHH.................................................................. 1 - 28 Hydraulic Power Pack - MODEL 230, 40 HP.............................................. 1 - 28 Pipeline Lubrication System ....................................................................... 1 - 28 Automatic Greaser System......................................................................... 1 - 28. SAFETY REGULATIONS .......................................................................................... 1 - 29. SECTION 2. SAFETY REGULATIONS. 2.1. SAFETY REGULATIONS .......................................................................................... 2 - 1. 2.2. SAFETY DURING INSTALLATION ........................................................................... 2 - 2. 2.3. SAFETY PRECAUTIONS - STARTUP ...................................................................... 2 - 3. 2.4. SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS ................................... 2 - 4. 2.5. SAFETY DURING MAINTENANCE ........................................................................... 2 - 4. SECTION 3. HYDRAULICS. 3.1. RULES OF HYDRAULICS ......................................................................................... 3 - 1. 3.2. HYDRAULIC PUMPS ................................................................................................ 3 - 8. KSP Poppet Training Manual. i.

(6) TABLE OF CONTENTS. 3.3. VALVES ..................................................................................................................... 3 - 12 3.3.1 3.3.2 3.3.3. 3.4. HYDRAULIC SYMBOLS ............................................................................................ 3 - 16. SECTION 4. OPERATION. 4.1. BEFORE OPERATING SLUDGE PUMPS IN ANY MODE - POPPET ...................... 4 - 1. 4.2. NOTES - POPPET ..................................................................................................... 4 - 2. 4.3. PREVENTIVE MAINTENANCE NOTES - POPPET .................................................. 4 - 2. 4.4. PRE-START-UP CHECKS ........................................................................................ 4 - 4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.5 4.4.6. 4.5. 4.6. General With Safety Precautions - Start-up................................................ 4 - 11 Starting and Stopping ................................................................................. 4 - 11 Emergency Stop ......................................................................................... 4 - 13. MATERIAL PUMP OPERATION ............................................................................... 4 - 14 4.6.1 4.6.2 4.6.3 4.6.4 4.6.5. 4.7. Sludge Pump .............................................................................................. 4 - 5 Screw Feeder ............................................................................................. 4 - 6 Hydraulic Power Pack ................................................................................ 4 - 7 Material Pipeline ......................................................................................... 4 - 8 Push Floor/Sliding Frames ......................................................................... 4 - 9 Pipeline Lubrication .................................................................................... 4 - 10. START-UP PROCEDURE ......................................................................................... 4 - 11 4.5.1 4.5.2 4.5.3. The Control Panel....................................................................................... 4 - 14 SFMS and Transition Pressure Setpoint Selection..................................... 4 - 15 Screw Feeder Modes ................................................................................. 4 - 16 Mode Selection ........................................................................................... 4 - 16 HMI Screens ............................................................................................... 4 - 18. LUBRICATION SYSTEM OPERATION ..................................................................... 4 - 25 4.7.1. Mode Selection ........................................................................................... 4 - 25. 4.8. MATERIAL PUMP AND SCREW FEEDER ALARM CONDITIONS ........................... 4 - 26. 4.9. LUBRICATION SYSTEM ALARM CONDITIONS ...................................................... 4 - 28. 4.10. ADJUSTMENTS AND CHECKS DURING OPERATION .......................................... 4 - 29 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.10.7 4.10.8 4.10.9. ii. Control Valves ............................................................................................ 3 - 12 Relief Valves............................................................................................... 3 - 12 The Basic Relief Valve ............................................................................... 3 - 14. Safety Instructions - Adjustments & Checks............................................... 4 - 29 Sludge Pump Output Adjustment - Electric ................................................ 4 - 29 Sludge Pump Output Adjustment - Manual Handwheel ............................. 4 - 30 Screw Feeder Output Adjustment - Electric................................................ 4 - 30 Screw Feeder Output Adjustment - Manual Handwheel............................. 4 - 31 Hydraulic System Checks - Rock Valve ..................................................... 4 - 32 Hydraulic System Checks/Adjust. - Poppet Valve ...................................... 4 - 32 Mechanical Checks .................................................................................... 4 - 32 Other Controls and Instruments ................................................................. 4 - 32. KSP Poppet Training Manual.

(7) TABLE OF CONTENTS. 4.11. SHUTDOWN PROCEDURE ...................................................................................... 4 - 33 4.11.1 4.11.2 4.11.3 4.11.4 4.7.5. SECTION 5. Shutdown For General Maintenance .......................................................... 4 - 33 Short-Term Shutdown................................................................................. 4 - 35 Long Term Shutdown ................................................................................. 4 - 35 Long-Term Storage..................................................................................... 4 - 36 EMERGENCY STOP.................................................................................. 4 - 37. PLANNED MAINTENANCE. 5.1. SAFETY DURING MAINTENANCE ........................................................................... 5 - 1. 5.2. PERIODIC MAINTENANCE SCHEDULE .................................................................. 5 - 3 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.5. 5.3. LUBRICANT RECOMMENDATIONS ......................................................................... 5 - 35 5.3.1 5.3.2 5.3.3. 5.4. Hydraulic oil recommendations (hydraulic power pack) ............................. 5 - 36 Gear-lubricant recommendations ............................................................... 5 - 37 Grease recommendations .......................................................................... 5 - 37. TROUBLESHOOTING ............................................................................................... 5 - 38 5.4.1 5.4.2 5.4.3. 5.5. General Maintenance ................................................................................. 5 - 7 Hydraulic power pack ................................................................................. 5 - 10 Push Floor Silo ........................................................................................... 5 - 18 Screw Feeder ............................................................................................. 5 - 21 Material Pump............................................................................................. 5 - 26 Pipeline Lubrication System ....................................................................... 5 - 33. Hydraulic Power Pack................................................................................. 5 - 38 Push Floor Silo ........................................................................................... 5 - 40 Screw Feeder ............................................................................................. 5 - 41. BOLT TORQUE TABLES ........................................................................................... 5 - 45 5.5.1 5.5.2. SECTION 6. Metric: normal threads ................................................................................ 5 - 45 Metric: fine threads ..................................................................................... 5 - 46. SPECIAL MAINTENANCE SERVICE AND REPAIR INSTRUCTIONS. 6.1. SAFETY DURING MAINTENANCE (From you O&M Manual) ................................... 6 - 2. 6.2. MAINTAINING HYDRAULIC SYSTEM PRESSURES................................................ 6 - 3. 6.3. SCREW FEEDER ....................................................................................................... 6 - 4 6.3.1. 6.4. Auger replacement ..................................................................................... 6 - 4. MATERIAL PUMP....................................................................................................... 6 - 6 6.4.1 6.4.2. Replacing piston heads .............................................................................. 6 - 6 Replacing poppet valves............................................................................. 6 - 14. KSP Poppet Training Manual. iii.

(8) TABLE OF CONTENTS. SECTION 7 7.1. SLUDGE FLOW MEASURING SYSTEM (SFMS®) SET-UP .................................... 4 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9. SECTION 8 8.1. Overview of the SFMS® and the Schwing Pump ....................................... 4 SFMS® Calculations .................................................................................. 7 Throttle Valve Adjustment .......................................................................... 8 Throttle Check Valve Adjustment ............................................................... 9 Proximity Switch Set-up.............................................................................. 10 SFMS® Functional Test #1 -KSP ............................................................... 12 SFMS® Functional Test #2 - EKSP............................................................ 12 SFMS® Calibration ..................................................................................... 13 Testing and Calibration of SFMS® ............................................................. 14. KSP COMPONENTS. SCREW FEEDER COMPONENTS ........................................................................... 8 - 1 8.1.1. Screw Feeder Gear Box ............................................................................. 8 - 2. 8.2. SCREW FEEDER SHAFT TIMING ............................................................................ 8 - 8. 8.3. SLUDGE PUMP COMPONENTS .............................................................................. 8 - 27. SECTION 9. HYDRAULIC OIL & FILTERS. 9.1. RESERVOIRS ........................................................................................................... 9 - 1. 9.2. HYDRAULIC OILS AND LUBRICANTS ..................................................................... 9 - 1. 9.3. FLUID CONTAMINATION AND CONTROL .............................................................. 9 - 3 9.3.1. Handling, Storing, and Dispensing of Lubricating Fluids ............................ 9 - 4. 9.4. FILTERS .................................................................................................................... 9 - 6. 9.5. TECHNICAL INFORMATION - FILTRATION RATINGS ........................................... 9 - 6 9.5.1 9.5.2 9.5.3 9.5.4 9.5.5. 9.6. Nominal Filtration Ratings .......................................................................... 9 - 6 Absolute Filtration Ratings.......................................................................... 9 - 6 Beta Filtration Ratio (bn)............................................................................. 9 - 6 Filter Facts .................................................................................................. 9 - 7 Technical Information - Beta Ratings ......................................................... 9 - 8. SCHWING BIOSET FILTERS ................................................................................... 9 - 9 9.6.1 9.6.2. KSP Return Filter........................................................................................ 9 - 9 Conditioning Loop Filter.............................................................................. 9 - 11. 9.7. HYDRAULIC PUMPS ................................................................................................ 9 - 12. 9.8. REXROTH VT 2000 AMPLIFIER CARD .................................................................... 9 - 18 9.8.1. 9.9. Functional Description of the Rexroth VT2000 Amplifier Card ................... 9 - 18. PRESSURE SWITCHES ........................................................................................... 9 - 21 9.9.1. iv. INSPECTIONS & CALIBRATIONS. How To Set Pressure Switches .................................................................. 9 - 21. KSP Poppet Training Manual.

(9) TABLE OF CONTENTS. 9.9.2 9.9.3 9.9.4 9.9.5. Switch Adjustments .................................................................................... 9 - 26 Temperature Switch Adjustment................................................................. 9 - 29 Combination Level and Temperature Switch.............................................. 9 - 31 Dirty Oil Filter Switch .................................................................................. 9 - 32. 9.10. TYPES OF HEAT EXCHANGERS ............................................................................ 9 - 35. 9.11. HYDRAULIC SCHEMATIC SERIES - KSP POPPET ................................................ 9 - 38 9.11.1 9.11.2 9.11.3 9.11.4 9.11.5 9.11.6 9.11.7. 9.12. UNIT IS IN REVERSE ............................................................................................... 9 - 52 9.12.1. 9.13. KSP Poppet Valve - Series #8.................................................................... 9 - 52. EXCESS ROCKING OIL CONDITION ....................................................................... 9 - 54 9.13.1. 9.14. KSP Poppet Valve - Series #1.................................................................... 9 - 38 KSP Poppet Valve - Series #2.................................................................... 9 - 40 KSP Poppet Valve - Series #3.................................................................... 9 - 42 KSP Poppet Valve - Series #4.................................................................... 9 - 44 KSP Poppet Valve - Series #5.................................................................... 9 - 46 KSP Poppet Valve - Series #6.................................................................... 9 - 48 KSP Poppet Valve - Series #7.................................................................... 9 - 50. KSP Poppet Valve - Series #9.................................................................... 9 - 54. ADDING ROCKING OIL CONDITION ....................................................................... 9 - 56 9.14.1. SECTION 10. KSP Poppet Valve - Series #10.................................................................. 9 - 56. SPECIAL TOOLS. 10.1. HYDRAULIC TROUBLE SHOOTING KITS ............................................................... 10 - 1. 10.2. FLOW METERS AND ACCESSORIES ..................................................................... 10 - 2. 10.3. MATERIAL CYLINDER ALIGNMENT TOOLS ........................................................... 10 - 3. 10.4. PISTON INSTALLATION TOOLS .............................................................................. 10 - 4. 10.5. ROD GLAND PACKING INSTALLATION TOOLS ..................................................... 10 - 5. 10.6. RAM TOOLS .............................................................................................................. 10 - 6. 10.7. TORQUE SPECIFICATIONS FOR METERIC BOLTS AND SCREWS USED ON SCHWING EQUIPMENT .......................................................................... 10 - 7 10.6.1 10.6.2 10.6.3. Dacromet 500 Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts)....................................... 10 - 8 Dacromet 500 Screws and Nuts DIN 6914, 6915 (HV Screws).................. 10 - 10 Black Screws and Nuts DIN 912, 931, 933, 934 (Hexagon, Machine Screws, and Hexagon Nuts)....................................... 10 - 11. 10.8. CONVERSION CHART ............................................................................................. 10 - 13. 10.9. FLUID POWER FORMULAS ..................................................................................... 10 - 16. 10.10. DRILL SIZES FOR METRIC TAPS ............................................................................ 10 - 18. KSP Poppet Training Manual. v.

(10) TABLE OF CONTENTS. vi. KSP Poppet Training Manual.

(11) GENERAL. SECTION 1. SECTION 1 1.1. GENERAL. PURPOSE OF THIS MANUAL. This manual is designed to assist you in the Installation, Operation, and Maintenance of your custom designed Schwing Bioset Sludge Pump system. It describes storage, installation, start-up, normal operation, shut-down, periodic maintenance, and trouble shooting procedures. It also contains detailed layout drawings, hydraulic schematics, electrical schematics, and parts book drawings. The installers, operators, maintenance personnel, and everyone involved with these systems should study this manual carefully. We hope that it can help in your ongoing training and maintenance program.. 1.2. DESCRIPTION OF EQUIPMENT. 1.2.1. General Description. A specially sized and configured Sludge Pump System supplied by Schwing Bioset consists of one or more sets of the following equipment: • Hydraulically Driven Piston Pump • Screw Feeder/Agitator Hopper. • Hydraulic Power Pack, to power the pump and screw feeder/agitator hopper. • Special Feed hoppers or Hopper Adapters. • Material Pipeline, steel with pressure tight seals. (OPTIONAL) • Control Systems • Sliding Frames • Push Floors • Pipeline Lubrication System They are described further in the following paragraphs and detailed specifications for the installed equipment in your O&M manual. The system is custom designed to pump dewatered sludges or slurries through pressurized steel pipelines to dryers, incinerators, or distribution systems. The electric motor of the Hydraulic Power Pack drives hydraulic pumps that drive the cylinders of the Sludge Pump and the hydraulic motors of the Screw Feeder or Hopper Agitator. Custom controls, monitors and sensors are installed to specifications to provide automatic, dependable operation.. KSP Training Manual. 1-1.

(12) SECTION 1. GENERAL. 39000001. Figure 1.1 - Typical KSP Installation #1 (A10V Hydraulic Pumps) 1-2. KSP Training Manual.

(13) GENERAL. SECTION 1. Figure 1.2 - Typical KSP Installation #2 (A11VO Hydraulic Pumps). KSP Training Manual. 1-3.

(14) SECTION 1. GENERAL. 39000002. Figure 1.3 - Typical KSP Installation #3 1-4. KSP Training Manual.

(15) GENERAL. SECTION 1. 39000003. Figure 1.4 - Typical KSP Installation #4 KSP Training Manual. 1-5.

(16) SECTION 1. GENERAL. 39000004. Figure 1.5 - Typical KSP Installation #5 1-6. KSP Training Manual.

(17) GENERAL. SECTION 1. PUSH FRAME/SLIDE GATE CYLINDER. DIRECTIONAL VALVE PRESSURE SWITCH. FILTER. ELECTRIC MOTOR/PUMP ASSY. 39000237. Figure 1.6 - Typical KSP Installation #6. KSP Training Manual. 1-7.

(18) SECTION 1. 1.2.2. GENERAL. Sludge Pump With Poppet Valves. The sludge pump is designated with a "KSP" prefix and a size designation of 5, 10, 12, 17, 25, 40, 45, 50, 80, 140 or 220. It is a hydraulically driven, positive displacement, twincylinder reciprocating piston pump. The material cylinders are in line with the differential hydraulic cylinders that power the material piston head (ram) in suction and pressure strokes. Separating the material cylinders from the differential cylinders is a fluid filled chamber called the “Water Box". The fluid cools and lubricates the material ram as it moves in the material cylinder. The fluid also rinses and cools the differential cylinder rod as it passes through the water box. The chamber also provides access for checking pump wear and for changing the material piston head (ram).. POPPET VALVE CONTROL INTAKE PORT HOUSING. DISCHARGE PORT. WATER BOX. MATERIAL PISTON (RAM) MATERIAL CYLINDER. DIFFERENTIAL HYDRAULIC CYLINDERS 39000007. Figure 1.7 - Sludge Pump With Poppet Valves In operation the two cylinders move in opposite directions so that one cylinder is charged with material from the feed system while the other cylinder is pushing material into the pipeline. Flow of the material into and out of the cylinders is controlled by four (4) hydraulically actuated poppet valves, one discharge and one intake valve for each cylinder. They are activated in the following sequence: 1. The pumping pistons come to the end of their stroke, that is, one fully extended and one fully retracted. The hydraulic valve drive is activated and the open discharge poppet closes, and suction poppets change state respectively. 2. Both discharge poppets are now closed. Hydraulic pressure increases and the pistons start to operate in the opposite directions, one charging and one discharging. As the discharging piston moves forward, the sludge is compressed in the delivery cylinder. 3. At the moment when the compressed sludge in the discharging cylinder equals the pressure of the compressed sludge in the delivery line, the discharge poppet opens and material flows into the pipeline. Since the poppet valve for the discharging cylinder opens only when the cylinder contents are at the same pressure as the pipeline, no material can flow back into the pump. This minimizes shocks in the pipeline.. 1-8. KSP Training Manual.

(19) KSP Training Manual. OUTBOARD BEARING. TRANSITION PIECE. PRESSURE VALVE DISC. PRESSURE VALVE CYLINDER. DISCHARGE LINE. PRESSURE VALVE SEAL (SEAT) POPPET HOUSING. DRAIN. SUPPORT FRAME. SWITCHING VALVE. HYDRAULIC PISTON HEAD. STEEL ROD. DOUBLE SCREW. PACKING GLAND. GEAR BOX FILL PLUG. CHECK VALVE (SUBTRACT ROCKING OIL). WATER BOX. RAM TRANSITION PIECE. MATERIAL PISTON. MATERIAL CYLINDER, INSIDE CHROMED TO .010" THICK (.25MM). SUCTION POPPET. GEAR BOX. SIGHT GAUGE. HYDRAULIC DRIVE MOTOR. CHECK VALVE (ADD ROCKING OIL). DIFFERENTIAL CYLINDER. SWITCHING VALVE. GENERAL SECTION 1. 39000008. Figure 1.8 - Sludge Pump With Poppet Valve Cut-A-Way. 1-9.

(20) SECTION 1. 1.2.3. GENERAL. Sludge Flow Measuring System (SFMS®) - Poppet Valve KSP. Schwing Bioset’s Sludge Flow Measuring System, installed on a Poppet Valve Sludge Pump, monitors the pumping cycle time and calculates pump output. It compensates for pumping (filling) efficiency and relays the flow rate to control equipment or system monitors. The Sludge Flow Measuring System consists of two magnetic proximity sensors, two ring magnets mounted on the pressure poppet valve pistons, and special programming within the PLC that controls the Sludge Pump. The sensors are mounted on the sides of the valve cylinders to sense the closed position of the poppet valves. The poppet is closed when the piston is at the limit of its extended travel. See Fig. 1.10 below.. POPPET VALVE (Closed Position). VALVE CYLINDER. MAGNETIC PROXIMITY SENSOR. RETRACT. PISTON. EXTEND. RING MAGNET PRESSURE POPPET VALVE HOUSING 39000009. Figure 1.9 - Pressure Poppet With SFMS® Sensor Schwing Bioset’s Sludge Pumps are designed such that at the end of each stroke both pressure poppet valves are closed. During the next stroke one of the poppets stays closed and one of the poppets opens to allow flow to the pipeline (discharge). Opening of this poppet is delayed until the material is compressed and the pumping cylinder pressure is the same as that of the pipeline. The end of the stroke is signaled when both poppets are again closed. By timing the full stroke and the compression phase of the stroke, the PLC is able to determine pumping efficiency, flow (in gallons per stroke, gallons per hour, etc.) and limited totalizing.. 1 - 10. KSP Training Manual.

(21) GENERAL. SECTION 1. PLC Calculation Referring to the table below, the Cycle Time for one stroke is T1. The Compression Phase is the time between both poppets closed and one of the poppets opening. Pumping Time T2 is equal to T1 minus the compression time. T2 = T1 - COMPRESSION Pump Efficiency is Pumping Time divided by Cycle Time. EFF =. T2 T1. Flow Rate is Material Cylinder Volume times Efficiency divided by Cycle Time. FLOW = F. BOTH POPPETS CLOSED. X EFF ( VOLUME ) T1. DISCHARGE POPPET OPENS. Compression. BOTH POPPETS CLOSED. Pumping Time T2 Cycle Time T1 Time 39000010. Figure 1.10 - Cycle Time Table (SFMS®) See Appendix A for parts (Pressure Poppet Valve), and section 5.4 for adjustment procedure.. KSP Training Manual. 1 - 11.

(22) SECTION 1. 1.2.4. GENERAL. Screw Feeder. The Screw Feeder increases pump efficiency by pressurizing the material feed into the pump suction. It consists of a feed trough with twin rotating augers that receive material from a feed hopper and convey it through a transition housing to the intake of the Sludge Pump. The augers (or screws), are driven by a gear box with a hydraulic motor driven by the Power Pack.. Water Box. Control Housing (Poppet Valve). Control Block w/Forward-Reverse Lever Operated Valve. Discharge End. Hydraulic Motor. External Screw Auger Bearings for Hopper Openings Greater Than 35 in (900 mm). Screw Feeder Intake Opening. Double Screw Feeder Augers. 39000011. Figure 1.11 - Screw Feeder. 1 - 12. KSP Training Manual.

(23) GENERAL. 1.2.5. SECTION 1. Hydraulic Power Pack. The Hydraulic Power Pack drives the Sludge Pump and its hydraulic control systems and auxiliary equipment such as a Screw Feeder or the Agitator Hopper augers. The power pack consists of an oil reservoir and steel frame with lifting eyes. The electric motor, hydraulic pump, flow control valves, and electric control enclosures are mounted on the power pack. Additional equipment and configurations vary with each installation and may include oil coolers, auxiliary hydraulic pumps, special valves or control instruments, sound covers, etc. Please see your O&M manual for details on the unit installed for this project.. ELECTRIC CONTROLS, LOCAL OR REMOTE LOCATED. RETURN LINE FILTER WITH INDICATOR SWITCH OIL LEVEL SWITCH. CLEAN-OUT COVER FILLER CAP. LIFTING EYES OIL TANK DRAIN HYDRAULIC PUMP FOR SCREW FEEDER. PRESSURE GAUGES. HIGH PRESSURE SWITCH ELECTRIC MOTOR. HIGH TEMPERATURE SWITCH. HYDRAULIC PUMP FOR SLUDGE PUMP VALVE FOR SLUDGE PUMP W/ ADJUSTABLE RELIEF VALVE & SOLENOID FOR LEVER CONTROLLED BYPASS VALVE.. VALVE FOR LEVER OPERATED SCREW FEEDER W/ FORWARD-REVERSE VALVE W/ ADJUSTABLE RELIEF VALVE. MOTOR COUPLING AND V-BELT DRIVE FOR AUX. PUMP. 39000013. Figure 1.12 - Hydraulic Power Pack (A2 Hydraulic Pumps). KSP Training Manual. 1 - 13.

(24) SECTION 1. GENERAL. ELECTRIC CONTROLS, LOCAL OR REMOTE LOCATED OIL LEVEL AND TEMPERATURE SWITCH. CIRCULATION LOOP FILTER. RETURN LINE FILTER WITH INDICATOR SWITCH. CLEAN-OUT COVER. FILLER CAP. LIFTING EYES PRESSURE GAUGES. OIL TANK DRAIN. HIGH PRESSURE SWITCH. ELECTRIC MOTOR. HIGH TEMPERATURE SWITCH OIL COOLER. HYDRAULIC PUMP FOR SLUDGE PUMP. HYDRAULIC PUMP FOR CIRCULATION LOOP. HYDRAULIC PUMP FOR SCREW FEEDER. LEVER OPERATED W/ FORWARD-REVERSE VALVE W/ ADJUSTABLE RELIEF VALVE. SOLENOID OPERATED LOAD BY-PASS VALVE FOR SLUDGE PUMP W/ ADJUSTABLE RELIEF VALVE. 39000014. Figure 1.13 - Hydraulic Power Pack (A10V Hydraulic Pumps). 1 - 14. KSP Training Manual.

(25) KSP Training Manual. SLUDGE PUMP RELIEF VALVE. SLUDGE PUMP BY-PASS VALVE. SOLENIOD VALVE (WITH MANUAL OVER-RIDE). PRESSURE GAUGE SHUT-OFF VALVE. SLUDGE PUMP PRESSURE GAUGE. SCREW CONVEYOR PRESSURE GAUGE. LIFTING EYES (FOR LIFTING DEVICES PROVIDED). TEMPERATURE SWITCH. CLEAN OUT COVERS. HIGH OIL PRESSURE SWITCH. LOW OIL LEVEL SWITCH. SCREW CONVEYOR PRESSURE SWITCH. LIMIT SWITCH AND POTENTIOMETER FOR HYDRAULIC PUMPS. HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER. SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE). SCREW CONVEYOR PRESSURE RELIEF VALVE. ELECTRICAL CONTROL PANEL. RETURN FILTER FOR HYDRAULIC OIL. OIL COOLER. DIRTY OIL FILTER PRESSURE SWITCH. GENERAL SECTION 1. 39000015. Figure 1.14 - Electric Power Pack, Side View (A2 Hydraulic Pumps). 1 - 15.

(26) 1 - 16. #1 MOTOR 480 VAC, 3 PHASE. VEE-BELT (MATCHED SET). ROTEX COUPLING. VEE-BELT DRIVE. 480 VAC, 3 PHASE #2 MOTOR (ADJUSTS HYDRAULIC FLOW FOR SLUDGE PUMP). HYDRAULIC PUMP FOR SLUDGE PUMP. MECHANICAL ADJUSTMENT FOR FLOW OF HYDUALIC PUMP. 480 VAC, 3 PHASE #3 ELECTRIC MOTOR (ADJUSTS HYDRAULIC PUMP FLOW FOR SCREW CONVEYOR). SCREW CONVEYOR HYDRAULIC PUMP. SECTION 1 GENERAL. 39000016. Figure 1.15 - Electric Power Pack, Top View (A2 Hydraulic Pumps). KSP Training Manual.

(27) KSP Training Manual ELECTRIC MOTOR. ELECTRICAL CONTROL PANEL. LOW OIL LEVEL SWITCH. CLEAN OUT COVER & FILLER CAP. SCREW CONVEYOR PRESSURE RELIEF VALVE. HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER. LIFTING EYES (FOR LIFTING DEVICES PROVIDED). SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE). HIGH OIL PRESSURE SLUDGE PUMP. CONDITIONING LOOP FILTER. SLUDGE PUMP PRESSURE GAUGE. SCREW CONVEYOR PRESSURE GAUGE. RETURN FILTER FOR HYDRAULIC OIL. GENERAL SECTION 1. 39000240. Figure 1.16 - Electric Power Pack, Side View (A10VO Hydraulic Pumps). 1 - 17.

(28) 1 - 18. MILLTRONICS UNIT. BALL VALVE 1"NPT COOLER WATER DRAIN. BALL VALVE 1"NPT COOLER WATER SUPPLY. WATER-OIL COOLER. HYDRAULIC PUMP AA10VSO FOR SLUDGE PUMP. BYPASS/LOAD VALVE FOR SLUDGE PUMP SOLENOID CONTROLLED W/ ADJ. RELIEF VALVE. SCREW CONVEYOR HYDRAULIC PUMP AA10VSO28EL. FORWARD/REVERSE VALVE FOR SCREW FEEDER HAND LEVER CONTROLLED W/ ADJ. RELIEF VALVE. CONDITIONING LOOP PUMP. SECTION 1 GENERAL. 39000241. Figure 1.17 - Electric Power Pack, Top View (A10VO Hydraulic Pumps). KSP Training Manual.

(29) KSP Training Manual. ELECTRICAL CONTROL PANEL. ELECTRIC MOTOR ROTEX COUPLING. LOW OIL LEVEL SWITCH. DIRTY OIL FILTER SWITCH. DRAIN SCREW CONVEYOR PRESSURE RELIEF VALVE. HYDRAULIC RESERVIOR SIGHT GAUGE AND THERMOMETER. CLEAN OUT COVER & FILLER CAP. HIGH OIL PRESSURE SLUDGE PUMP. CONDITIONING LOOP FILTER. PRESSURE GAUGE SHUT-OFF VALVE. SLUDGE PUMP PRESSURE GAUGE. SCREW CONVEYOR PRESSURE GAUGE. LIFTING EYES (FOR LIFTING DEVICES PROVIDED). SCREW CONVEYOR CONTROL VALVE (FORWARD, NEUTRAL, REVERSE). RETURN FILTER FOR HYDRAULIC OIL. GENERAL SECTION 1. 39000238. Figure 1.18 - Electric Power Pack, Side View (A11VO Hydraulic Pumps). 1 - 19.

(30) 1 - 20 BALL VALVE 1"NPT COOLER WATER DRAIN. WATER-OIL COOLER. BALL VALVE 1"NPT COOLER WATER SUPPLY. HYDRAULIC PUMP A11VO130EP2D. BYPASS VALVE. HYDRAULIC PUMP A11VO60EP2D. HYDRAULIC CONTROL BLOCK W/LEVER. HYDRAULIC PUMP V20101F8. SECTION 1 GENERAL. 39000239. Figure 1.19 - Electric Power Pack, Top View (A11VO Hydraulic Pumps). KSP Training Manual.

(31) GENERAL. 1.2.6. SECTION 1. Material Pipeline. The pipeline used to convey the sludge from the pump to its destination may be supplied by Schwing Bioset or others. Generally it is pressure-tight steel pipe with bolted couplings. See Sludge Pump Installation drawing in your O&M manual for size and configuration of the discharge pipeline. Pump connection to the material pipeline must allow for safe disconnection from the pipeline to allow service of internal pump parts.. ANSI Flange Pipeline. 2" Fully Ported Bleed Valve 1/2" Dutchman. Schwing Two Bolt Clamp. Schwing Sludge Pump Discharge. In-line Fully Ported Shut-off Valve. Spool Piece. 39000017. Figure 1.20 - Recommended Pipeline Connection. KSP Training Manual. 1 - 21.

(32) SECTION 1. 1.2.7. GENERAL. Sliding Frame Silos. The Sliding Frame is a bridge-breaker; when in operation it ensures mass movement of material through the silo and into the receiving conveyor or pump. The Sliding Frame, which is inside the silo, is attached to the Extension Shafts which pass through the wall of the silo and attach to the cylinders which are on the outside. The silo wall openings are effectively sealed by means of the Stuffing Bpx seals on the Extension Shafts.. 39000243. Figure 1.21 - Sliding Frame. 1 - 22. KSP Training Manual.

(33) GENERAL. 1.2.8. SECTION 1. Push Floor. The push floor system is designed to receive and temporarily store the large and periodic quantities of material. The push floor can take these uneven loads and provide a consistent discharge through the conveyors and pumps. The push floor moves the material to the inlet of the extraction screw conveyor. The screw conveyor will then move the material to the screw conveyor outlet. The push floor moves the material through the use of the moving frame sections. Hydraulic rams move a push bar down the length of the floor. The floor scrapers are designed to push material in one direction, while minimizing material movement on the return stroke. The floor sections are constantly moving, with the two outside sections moving in the opposite direction of the middle section for multiple scraper configuration.. 39000244. Figure 1.22 - Push Floor. KSP Training Manual. 1 - 23.

(34) SECTION 1. 1.2.9. GENERAL. Pipeline Lubrication System. The pipeline is used to convey the sludge from the pumps to either the sludge loading station or the post liming station. Due to the nature of the material being pumped, pipeline pressure may build up under certain conditions. Wet biosolids sludge tend to pump well and does not usually require lubrication. The higher the solids concentration of the biosolids, the more resistance to pumping and higher the resulting pipeline pressure. The pipeline lubrication systems are provided to inject a layer of water in the pipeline, reducing fiction along the pipe walls, and reducing the pipeline pressure. The lubrication pumps supply a small quantity of water to a lubricating ring. The ring installed in the pipe injects a constant flow, forming a thin film of water along the inside surface of the pipe. The pump can be set to automatically start whenever the pipeline pressure exceeds a given pressure for a sustained time period. Initial setting for pump start-up is 300 psi.. 39000259. Figure 1.23 - Pipeline Lubrication System. 1 - 24. KSP Training Manual.

(35) GENERAL. 1.2.10. SECTION 1. Automatic Greaser System. The automatic greaser system serves to minimize the need for frequent lubrication maintenance by supplying periodic injections of grease to the equipment. The lubrication system provides grease to the push floor hydraulic cylinders, bearings on the metering screw conveyors and the seals on the twin screw augers. The system is a simple electric pump that runs on a timer. Grease is pumped to the equipment based on a programmed timing interval. The time can be independently programmed for each of the application points.. 30358024. Figure 1.24 - Automatic Greaser System. KSP Training Manual. 1 - 25.

(36) SECTION 1. GENERAL. 1.3. INSTALLED EQUIPMENT LIST PROJECT: Sample Only. 1.3.1. General With Data Sheets. Equipment supplied: Qty Model. Description. 1 --. Sliding Frame Recieving Bin - RBSF. 2 --. Recieving Bin Conveyors - RBC-1, RBC-2. 2 KSP140 (HD) XL. Sludge Pump, vertical horizontal configuration, with poppet valves, rock valve - RP-1, RP-2. 2 SD500 HD. Screw Feeder with Outboard Bearings. HHH 2 200/150 HP HHH. Agitator Hopper Hydraulic Power Pack - RPPP Agitator Hopper. 2 230/40 HP. Hydraulic Power Pack - RBSFPP. 2 Milroy C Pumps. Pipeline Lubrication Pumps - PLP-1, PLP-2. 1 Lincoln 1827. Automatic Greaser system. APPENDIX 'F' in the O&M manual contains data sheets with serial numbers, and other information, for the major components of the Sludge Pump System supplied. 1.3.2. Sliding Frame Receiving Bin. Refer to installation drawings (Section 6) in the O&M manual for the general arrangement and overall dimensions. See Section 9 for additional details. The hydraulic circuits for the sliding frame hydraulic rams are detailed in Section 7 in the O&M manual. Electrical details are included in Section 8 in the O&M manual. 1.3.3. Receiving Bin Conveyor. Refer to installation drawings (Section 6) and electrical drawings (Section 8) in the O&M manual. Detailed information on the conveyor is contained in Section 10 in the O&M manual.. 1 - 26. KSP Training Manual.

(37) GENERAL. 1.3.4. SECTION 1. Sludge Pump - KSP 140 (HD)XL. “V” Configuration: The Sludge Pump is configured with one cylinder above the other, that is, they are aligned in a vertical plane ("V"). The Installation Drawing in Section 6 in the O&M manual gives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. "H" configuration: The Sludge Pump is configured with one cylinder along side of the other, that is, they are aligned in a horizontal plane ("H"). The Installation Drawing in Section 6 in the O&M manualgives overall dimensions of the equipment. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. See Appendix A for Sludge Pump assembly drawings and Bills of Material for replacement parts. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.5. Screw Feeder - SD 500 HD. The installed Screw Feeder is configured as shown on the Assembly Drawing in Appendix B. The Installation Drawings in Section 6 give overall dimensions. The pressure settings are shown on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.6. Agitator Hopper - MODEL HHH. The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.7. Hydraulic Power Pack - MODEL 2000, 200/150 HP. The installed Hydraulic Power Pack is configured as shown on the Assembly Drawing. See Appendix C for Bills of Material and replacement parts. The installation drawings in Section 6 in the O&M manual give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual.. KSP Training Manual. 1 - 27.

(38) SECTION 1. GENERAL. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.8. Agitator Hopper - MODEL HHH. The installed Agitator Hopper is configured as shown on the Assembly Drawing in Appendix B. The installation drawing in Section 6 in the O&M manual gives overall dimensions. The pressure settings are given on the hydraulic schematic in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.9. Hydraulic Power Pack - MODEL 230, 40 HP. The installation drawings in Section 6 give overall dimensions. The pressure settings are given on the hydraulic schematics in Section 7 in the O&M manual. Refer to Installation Drawings (Section 6), Hydraulic Drawings (Section 7), and Electrical Drawings (Section 8) in the O&M manual for further information. 1.3.10. Pipeline Lubrication System. Refer to installation drawings (Section 6) in the O&M manual for the general arrangement. Electrical controls are detailed in Section 8 in the O&M manual. See Appendix I in the O&M manual for detailed information on the lubrication system. 1.3.11. Automatic Greaser System. See Appendix G (Catalog Cuts) in the O&M manual for detailed information on the Lincoln Automatic Greaser System.. 1 - 28. KSP Training Manual.

(39) GENERAL. 1.4. SECTION 1. SAFETY REGULATIONS. When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations. ANSI standards "ANSI 2244.1-1952" set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.. ! WARNING! DANGER OF AMPUTATION! Keep hands out of the screw feeder and agitator hopper.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel. Only Certified Licensed Electricians shall be allowed to work on electrical systems.. ! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. Keep unauthorized personnel away from the work area during maintenance. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation. Other sections of this manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.. KSP Training Manual. 1 - 29.

(40) SECTION 1. 1 - 30. GENERAL. KSP Training Manual.

(41) SAFETY REGULATIONS. SECTION 2 2.1. SECTION 2. SAFETY REGULATIONS. SAFETY REGULATIONS. When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following paragraphs contain some supplementary recommendations. OSHA standards 1910.147 (subpart J) set down minimum safety requirements covering lockout or tagout of energy sources for personal safety. These should be reviewed before any maintenance or inspection. Operation and maintenance of this equipment shall be performed only by trained, capable, and authorized personnel. Only Certified Licensed Electricians shall be allowed to work on electrical systems.. ! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED, machines might have multiple sources. Check for voltage before touching any electrical point. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency.. WARNING. Multiple power sources. Check for voltage before touching any point. 30333417 A. 39000018. Figure 2.1 - Warning Decal (P/N 30333417). KSP Training Manual. 2-1.

(42) SECTION 2. SAFETY REGULATIONS. Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.. ! WARNING! DANGER - CONFINED SPACE! When entering a silo to perform any work, follow the guidelines below. Serious injury or death may occur if proper guidelines are not followed. ALWAYS -Establish a confined space entry program. Perform a confined space hazard analysis and follow local regulations dealing with confined space entry. ALWAYS -Clean the silo of material to prevent hazardous gases or collapse of bulk materials. ALWAYS -Wear personal protective equipment required (hard hat, boots, respirator, hearing protection, etc.). ALWAYS -Have a rescue plan established BEFORE a person enters a confined space. Safety lines attached to the person working in the confined space, and a means to pull them to safety, can prevent a rescuer from being exposed to the same hazard encountered by the worker. ALWAYS -Provide adequate ventilation of fresh air. Natural ventilation alone may not be sufficient to maintain breathable quality air. ALWAYS -Have air quality tested by a qualified person BEFORE entering a confined space, and continually monitor until the work is completed. ALWAYS -Have at least two (2) persons present when performing work in confined spaces; one (1) person must stay outside of confined space as an observer in case of emergency. Keep unauthorized personnel away from the work area during maintenance. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation. Other sections of the O&M manual contain specific safety recommendations for INSTALLATION, STARTUP, ADJUSTMENTS & CHECKS, AND MAINTENANCE. See the Table of Contents and study and review these sections also.. 2.2. SAFETY DURING INSTALLATION. Supplementary recommendations: • Read and review the O & M Manual and relevant contract drawings for installation information. • Lifting equipment, cables, chains, etc. are to be connected only at the lifting points provided.. 2-2. KSP Training Manual.

(43) SAFETY REGULATIONS. SECTION 2. • Keep unauthorized personnel away from the work area during positioning of equipment or installation. • Installation work should only be done by qualified, authorized personnel. • Only Certified Licensed Electricians shall be allowed to work on electrical systems.. ! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. • Do not install or repair damaged pipes, fittings, or hoses. Replace damaged hydraulic hoses immediately. 2.3. SAFETY PRECAUTIONS - STARTUP. Before start-up the operator shall perform all necessary pre-start-up checks as described in Section 2.4, Page 2 - 4 if this is a testing start-up, first time start-up, restart after maintenance, or restart after Long Term Shutdown At start-up observe the following safety precautions: • Keep area clear of unauthorized personnel. • Be observant for leaks or unusual noises. • DOUBLE CHECK THAT ALL HAND VALVES ARE IN NEUTRAL POSITION and/or BYPASS SWITCH IS IN "BYPASS" (NOTE INDICATOR LIGHT) BEFORE STARTING. • Review the "Sequence of Operation" that is included on the Electrical Schematic in Section 8 to understand what happens at start-up of system.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). • All covers, guards and safety decals must be in place before start-up.. KSP Training Manual. 2-3.

(44) SECTION 2. 2.4. SAFETY REGULATIONS. SAFETY INSTRUCTIONS - ADJUSTMENTS AND CHECKS. Only trained and authorized personnel shall perform adjustments to the sludge pump and related equipment. Read and study all of the adjustment procedures before making any adjustment. One adjustment may have an effect on another. Covers for rotating parts must be in place during adjustments and checks. All personnel shall know the location and operation of EMERGENCY CONTROLS. See the sequence of operation and control layout drawings on the electrical schematic in your O&M manual.. 2.5. SAFETY DURING MAINTENANCE. When Installing, Operating or Servicing Sludge Pump equipment, the safety regulations of the responsible Contractor, Facility Management and Liability Insurance Company must be followed. The observation of these regulations shall be the responsibility of the contractor and operator. The following are some supplementary recommendations: Read and review this O & M Manual and relevant contract drawings for maintenance information. Keep unauthorized personnel away from the work area during maintenance. Maintenance work should only be done by qualified, authorized personnel. Whenever doing any maintenance on the inside of the pump, i.e. replacing poppet valves or piston heads, the pump discharge must be disconnected from the pipeline prior to starting work on the pump.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the water box.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the screw feeder and agitator hopper.. ! WARNING! DANGER OF AMPUTATION! Keep hands and feet out of the discharge valve housing (rock valve or poppet valves). Only Certified Licensed Electricians shall be allowed to work on electrical systems.. ! WARNING! DANGER OF ELECTROCUTION! Before working on electrical systems, be sure that the main circuit breakers are TURNED OFF and SECURED. Use a lock-out/tag out procedure that is approved for your plant by O.S.H.A. or similar concerned governing agency. Before working on hydraulic systems, depressurize the whole system and secure the electrical and hydraulic controls in OFF or NEUTRAL position.. 2-4. KSP Training Manual.

(45) SAFETY REGULATIONS. !. SECTION 2. WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.. Sludge discharge lines are operating under high pressure. Extreme caution and proper safety practices should be followed whenever the flanges are being loosened or the clamps removed from the sludge discharge line. To relieve the pressure in a sludge discharge line, follow these steps: 1. Place the screw conveyor or conical hopper in the reverse position. 2. Tighten down the throttle valves until they are completely closed, then open them 1/2 turn. (Located on the control block) NOTE: If your pump is equipped with the SFMS® (Sludge Flow Measuring System) you must fully open the throttle check valves located on the discharge poppet hydraulic cylinders. 3. On manually operated control blocks (older models) place the S-1 spool in the reverse position and let the pump kit stroke in reverse for a short period of time. 4. Observe the hydraulic cylinder rods for the discharge poppets to verify that they are moving. (If they are not moving assume that the line is still pressurized.) 5. Observe the hopper to see if any sludge is coming from the pump into the hopper. Also observe the discharge line pressure gauge to see if it is dropping (if so equipped). 6. Open the pressure bleed off valve to release any residual pressure remaining (if so equipped). 7. Shut the pumping unit off and disconnect all power sources. Remove the flanges and clamps, using the proper safety procedures. Do not install or repair damaged pipes, fittings or hoses. Replace damaged hydraulic hoses immediately. Lifting equipment, cables, chains, etc., are to be connected only at the lifting points provided. Establish and maintain an active Safety and Accident Prevention program for operators and maintenance personnel. Good Preventative Maintenance programs are essential for a good Safety Program.. KSP Training Manual. 2-5.

(46) SECTION 2. SAFETY REGULATIONS. Practice good housekeeping for equipment and surrounding areas. Keep the area around the equipment clean and free of obstacles to provide easy access and to avoid interference with its operation.. ANSI Flange Pipeline. 2" Fully Ported Bleed Valve 1/2" Dutchman. Schwing Two Bolt Clamp. Schwing Sludge Pump Discharge. In-line Fully Ported Shut-off Valve. Spool Piece. 39000017. Figure 2.2 - Recommended Pipeline Connection. ! WARNING! DANGER OF INJURY FROM RAPIDLY EXPELLED MATERIAL! Before working on the material pipelines, RELIEVE THE PRESSURE on the line by selecting the reverse position of the pump for several strokes.. 2-6. KSP Training Manual.

(47) KSP Training Manual. 460V 316189. 338672). 30311258 30314576 303555x6 303555x7 303555x8 303555x9. Screw feeder:. Accumulator:. Slide gate:. Slide frame:. Push floor:. Hydraulic:. KSP pumpkit (Typical). 30311257. 8. 27. WARNING: Safety Guard is missing 30337004 (in the waterbox, under the guard). WARNING: Starts automatically 30337069. Use 311262 for table 2, 4, 6, 8). Sludge pump:. 4. Pressure labels:. other. 322670. Write in number. 575V 317932. (Use 311263 for table 1, 3, 5, 7;. 3. Rev/Fwd: Use #. 2. Motor rating:. 311211. Write in number. Assignments:. (Choose between:. 1. Bypass: Use #. Date:. Label Assignment by:. Job Name:. Job Number:. 9. WARNING: Do not put hands in waterbox 30319872. Lift here 30317940 4. 6. 1. 26. CHANGE / E.C.O #. NAME. Drawn By. RE. Date. 08/23/01. Approved. Decal Location Dwg.-1 of 5 KSP w/ Power Pack. 30358014. Fwd/Rev - 3 11262 or Rev/Fwd - 3 11263. 14 15. WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672. or. WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670. or. WARNING: Bypass-Load does not stop screw feed - 30311211. 30358014. REV.. n/a. Lettering per hydraulic schematic. DATE. 36. 29. 11. WARNING: Do not put hands in hopper 30319869 (Both sides of material cylinders). Main ID tag 30301733. Main ID tag 30301733. REV.. SAFETY REGULATIONS SECTION 2. Figure 2.3 - Typical Decal Location - KSP. 2-7.

(48) 2-8. CHANGE / E.C.O.. Power Pack Serial Number Plate - 30304314 3. 35. NAME. Fwd / Rev - 30311262. 8. 14. C A B. Texaco HD 46 (get # from decal) 5. WARNING:Bypass-Load does not stop screw feed - 30311211. Safety Instructions: Safety rules 30312298. 36. or. 29. or. 11. 19 8. WARNING: Starts. Hydraulic Pressure (generic) - 30355569. Push Floor Pressure - 30355568. Slide Frame Pressure - 30355567. Slide Gate Pressure - 30355566. Screw Feeder Pressure - 30311258. Accumulator Pressure - 30314576. Drawn By. WARNING: Do not operate without training - 30337013. 30358014. Attn: One- Way. RE. Date. 080901. Approved. Decal Location Dwg . - 2 of 5 KSP w/ Power P ack. 30358014. RE V.. A. WARNING:Hyd. 30 Accumulator-30324 599 (units with accumulators) (locate here and. 2. 34 Warning: Hazardous voltage. 7. One or more of these, located under pressure gauges. WARNING:Stored Hyd. energy - 30334976 (units with accumulators). WARNING: Hyd. Accumulator - 30324599 (units with accumulators). Safety Instructions: Accumulator rules - 30314115. Sludge Pump Pressure - 30311257. 28. 30. 31. Safety Instructions: Accumulator rules -30314 115 31 (units with accumulators)(locate here and near accumulator). IMPO R TAN T: Reorder info 33 30333269. WARNING:Screw feeder and sludge pump have separate Bypass-Load switches - 30338672. WARNING:Bypass-Load stops both screw feeder and sludge pump - 30322670. Lettering per hydraulic schematic. SCHWING. 21. ATTENTION: Change filter - 30314050. DATE. WARNING:This Equip. starts Automatically 30337069 (both Sides). (Inside of Elec. panel) WARNING: multiple power sources-30333417. POWER PACK (Typical). RE V.. SECTION 2 SAFETY REGULATIONS. Figure 2.4 - Typical Decal Location - Power Pak. KSP Training Manual.

(49) KSP Training Manual 16. Lift here 30317940 4. WARNING: Keep Hands Out Of Screw Feeder-30311264 (Both Sides). WARNING: Starts Automatically-30337069 (Both sides of housing, if exposed). NAME. DATE. RE. Date. 080901. Approved. Decal Location Dwg. - 3 of 5 KSP w/ Power P ack. 30358014. WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672. or. REV .. n/a. 30358014. WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670. or. WARNING: Bypass-Load does not stop screw feed - 30311211. Lettering per hydraulic schematic. Drawn By. 29. (Typical) 8. WARNING: Screw feeder and sludge pump have separate Bypass-Load switches - 30338672. 36. or. WARNING: Bypass-Load stops both screw feeder and sludge pump - 30322670. or. WARNING: Bypass-Load does not stop screw feed - 30311211. CHANGE / E.C.O. #. 29. 11. REV.. 11. 18. WARNING: Keep Hands Out Of Agitator Assy.-30312297 (If Equipped with hopper) (Both Sides). Screwfeeder. 9. WARNING: Safety Guard is Missing 30337004 (As Req'd). SAFETY REGULATIONS SECTION 2. Figure 2.5 - Typical Decal Location - Screw Feeder. 2-9.

(50) 2 - 10. SAFETY INSTRUCTIONS: Safety operating instructions - KSP 30312298. IMPORTANT: Reorder info 30337013. 19. 7. WARNING: Do not operate without training 30337013. WARNING: Machine may start at any time 30337069 7. 8. LUBE PUMP CONTROL PANEL. 33. 8. 34. 35. IMPO R TAN T: Documentation ordering info 30333269. WARNING: Machine may start at any time 30337069. WARNING: Harzardous voltage inside 30336368. WARNING: Multiple power sources 30333417. IMPORTANT: 33 Documentation ordering info 30333269. SAFETY INSTRUCTIONS 19 Safety operating instructions - KSP 30312298. REV.. NAME. Drawn By. RE. Date. 080901. Approved. REV.. n/a. 30358014. 30358014. DATE. Decal Location Dwg. - 4 of 5 KSP w/ Power P ack - Lube pumps. CHANGE / E.C.O. #. SECTION 2 SAFETY REGULATIONS. Figure 2.6 - Typical Decal Location - Lube Pumps. KSP Training Manual.

(51) SAFETY REGULATIONS. SECTION 2. ELECTRICAL DISCONNECTS SHOULD HAVE PADLOCKS ACCESSIBLE TO REPAIR PERSONNEL OR SET-UP MECHANICS. 39000022. Figure 2.7 - Safety Reminder - Electrical Disconnections. SUITABLE GUARDS AND SHROUDS HELP PREVENT OPERATORS FROM INJURING THEMSELVES. 39000023. Figure 2.8 - Safety Reminder - Guards And Shrouds KSP Training Manual. 2 - 11.

(52) SECTION 2. SAFETY REGULATIONS. CONSTANT ATTENTION TO SAFETY AND GOOD HOUSEKEEPING IS THE BEST WAY TO PREVENT COSTLY ACCIDENTS. 39000024. Figure 2.9 - Safety Reminder - Good Housekeeping. 2 - 12. KSP Training Manual.

(53) HYDRAULICS. SECTION 3 3.1. SECTION 3. HYDRAULICS. RULES OF HYDRAULICS. 1. Hydraulic pressure always takes path of least resistance.. 2. Hydraulic pressure is created equal in all directions (Pascal's Law).. Pascal's Law 2 A 10 pound force applied to a stopper with a surface area of one square inch....... 1 The bottle is filled with a liquid, which is not compressible. 3 Results in 10 pounds of force on every square inch (pressure) of the container wall. 4 If the bottom has an area of 20 square inches and each square inch is pushed on by 10 pounds of force, the entire bottom recieves a 200 pound push.. 3. Liquids (oil) are relatively incompressible.. OIL. AIR. KSP Training Manual. 1000 lbs of Force. 1000 lbs of Force. OIL. AIR. 3-1.

(54) SECTION 3. HYDRAULICS. 4. When hydraulic pressure and flow is not converted into work it is converted into heat.. Open relief (Heat). 5. When oil is heated it will expand (5% or more).. Atmospheric pressure forces water past seals. Vacuum formed as hydraulic oil cools. Seals. Hydraulic Cylinder Water Box. 6. When oil is heated the viscosity of it changes.. 6 bar 3-2. KSP Training Manual.

(55) HYDRAULICS. SECTION 3. 7. In industrial applications the recommended maximum fluid velocity is 17 FPS (Feet Per Second).. M 35 psi. ΔP. 8. GPM (Gallons Per Minute) only determine the speed at which the actuator (motor or cylinder) operates.. 0 GPM. 10 GPM. 9. P.S.I. (Pounds Per Square Inch) determine only the amount of force exerted upon the load by the actuator.. 10,000 LBS LOAD. 10 gallon maximum capacity cylinder. 10 inch of area on cylinder piston. 1000 PSI. KSP Training Manual. 3-3.

(56) SECTION 3. HYDRAULICS. 10. The resistance created in a hydraulic circuit, whether by the amount of the load on the actuator and/or the pressure drop in a circuit, is what determines how much work is required.. U.S. F = FORCE (in pounds) (lb). F=PxA P = F /A. F P. A. A = F /P. P = PRESSURE (in pounds per square inch) (P.S.I.) A = AREA (in square inches) (in 2 ). METRIC F = FORCE (in kilograms) (Kg) P = PRESSURE (in kilograms per square centimeter) (Kg/cm 2 ) A = AREA (in square centimeters) (cm 2 ). GENERAL POWER =. QxP CONSTANT. Q = FLOW RATE (unit of volume per time period) P = PRESSURE (unit of force per unit of area). U.S. HP = HORSEPOWER HP =. GPM x PSI 1714. GPM = GALLONS PER MINUTE PSI = POUNDS PER SQUARE INCH 1714 = KNOWN CONSTANT. METRIC KW = KILOWATTS KW =. LPM x BAR 600. LPM = LITERS PER MINUTE BAR = METRIC UNIT OF PRESSURE 600 = KNOWN CONSTANT. 3-4. KSP Training Manual.

(57) HYDRAULICS. SECTION 3. Mechanical Versus Hydraulic. 1. An input force of 10 lb.(44.48 N) on a one square inch 2 (6.45 cm ) piston.... COMPARISON OF MECHANICAL FORCES VERSUS HYDRAULIC FORCES. 100 lb. (444.82 N). 10 lb. (44.48 N) 1 sq. in. (6.45 cm 2 ). 2. will balance 100 lb (444.82 N) here.... 1. Ten pounds (44.48 N) here.... 3. This pressure will support a 100 lb. (444.82 N) weight if this is a 10 sq. in. (64.52 cm2) piston.. 10 sq. in. (64.51 cm 2 ). 2. develops a pressure of 10 pounds per square inch(psi) (.69 bar) (68.94 kilopascals) throughout the container. 100 lb. (444.82 N) 10 lb. (44.48 N). INPUT 4. this arm.. 3. if this arm is 10 times as long as.... 4. The forces are proportional to the piston areas.. OUTPUT. 100 lb. (444.82 N) 10 lb. (44.48 N) = 10 sq. in (64.52 cm2 ) 1 sq. in (6.45 cm 2 ). A. SIMPLE MECHANICAL LEVER. B. SIMPLE HYDRAULIC PRESS. Transfer of Energy ENERGY CAN NEITHER BE CREATED NOR DESTROYED 1. Moving the small piston 10 in. 0.25 m) displaces 10 cu. in. (163.87 cm 3 ) of liquid. (1 sq. in. x 10 in. =10 cu. in.) (6.45 cm 2 x 25.40 cm = 163.87 cm 3 ). 2. 10 cu. in. (163.8 cm 3 ) of liquid will move the larger piston only 1 in. (2.54 cm) (10 sq. in. x 1 in. = 10 cu. in.) (64.52 cm x 2.54 cm = 163.87 cm ). 100 lb. (444.82 N). 10 lb. (44.48 N) 1 sq. in. (6.45 cm 2 ). 10 sq. in. (64.51 cm2 ) 1 in (0.02 m) 10 in (0.25 m). 3. The energy transfer here equals 10 lb. x 10 in. (44.48 N x 0.25 m) or 100 in. lb. (11.30 Nm). KSP Training Manual. 4. The energy transfer here also is 100 in. lb. (11.30 Nm) (1 in. x 100 lb. = 100 in. lb.) (.02 m x 444.82 N = 11.30 Nm). 3-5.

(58) SECTION 3. HYDRAULICS. Hydraulic Jack. 8". HYDRAULIC ROD. PISTON. Linear & Rotary Actuators LINEAR ACTUATOR. 1.The pump pushes the hydraulic liquid into lines.. ROTARY ACTUATOR. 2. Lines carry the liquid to actuators which are pushed to cause a mechanical output to move a load.. 4. Rotary actuators or motors give the system rotating output. They can be connected to pulleys, gears,rack-and-pinions, conveyors, etc.. MOTOR. PUMP LOAD. PUMP. PISTON & ROD TO RESERVOIR. ROTARY DRIVE SHAFT. 3. Some actuators operate in a straight line (linear actuators). They are called cylinders or rams. They are used to lift weight, exert force, clamp, etc.. 3-6. KSP Training Manual.

(59) HYDRAULICS. SECTION 3. Basic Hydraulic Components. Check Valve. Throttle Valve. Throttle Check Valve. Switching Valve. KSP Training Manual. 3-7.

(60) SECTION 3. 3.2. HYDRAULICS. HYDRAULIC PUMPS. Hydraulic pumps are used to create flow (GPM) in a hydraulic system. (Hydraulic pumps do not create pressure) There are 4 basic designs of hydraulic pumps: 1 Piston Pumps: a. Radial Piston b. Axial Piston I. Bent Axis II. Swash Plate STYLES: Fixed Displacement Variable Displacement. AVAILABLE CONTROLS 1. Manual 2. Horse-power regulated 3. Pressure Compensated 4. Pressure cut-off. Piston pumps are rated in CC (Cubic Centimeters) or CID (Cubic Inch Displacement) per revolution. The efficiency of this pump design remains high throughout its pump life. The efficiency drops off very quickly at the end of the pumps life. They are designed for high pressure and high range of RPM. 2 Gear Pumps: a. External Gear b. Internal Gear I. Gerotor II. Crescent Gear pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. They are generally designed for medium range hydraulic pressure and RPM. The efficiency of this pump design declines gradually throughout its pump life. It is so gradual that it is hardly noticeable until it has deteriorated considerably. 3 Vane Pumps: Vane pumps have a nominal rating in GPM at 1000 PSI and 1200 RPM. they are generally designed for medium range pressure and RPM. The efficiency of this pump remains high throughout its pump life and drops quickly at the end of the pumps life. 4 Screw Pumps: These pumps operate at various pressure ranges and RPM's. There design is mainly used when a hydraulic system can't tolerate any hydraulic pulsations.. 3-8. KSP Training Manual.

(61) HYDRAULICS. SECTION 3. Screw. Vane. Gear. Piston. Figure 2.10 - Different Types of Pumps. Bent Axis. Swash Plate. Figure 2.11 - Different Types of Axial Piston Pumps. KSP Training Manual. 3-9.

(62) SECTION 3. HYDRAULICS. Universal link Piston rod. Cylinder block. Rotating shaft causes pistons to reciprocate. Piston. Oil forced to outlet as piston is pushed back into cylinder. from inlet. Piston is withdrawing from bore at inlet to outlet. 39000040. Figure 2.12 - Pumping Action In Bent-axis Pumps. Maximum piston stroke. Reduced stroke. Maximum angle. Less angle. No stroke. No angle. 39000041. Figure 2.13 - Increasing/Decreasing Piston Pump Output. 3 - 10. KSP Training Manual.

(63) HYDRAULICS. SECTION 3. External Gear Pump. (3) (4). OUTLET. ...and forced out of pressure port as teeth go back into mesh.. Outlet pressure against teeth causes heavy side-loading on shafts as indicated by arrows.. Drive Gear. (2). (1). Oil is carried around housing in chambers formed between teeth, housing, & side plates... INLET. Vacuum is created here as teeth unmesh. Oil enters from reservoir.. Internal Gear Pump. (1). Oil entering here..... (6). (5). (2). through this port.. to this point, where constant meshing of two gears forces the oil.... by the constant withdrawal of teeth on this inner gear.... (3). from the spaces between the teeth of this inner gear.... Cresent seal. (4). is carried in these spaces.... 39000042. Figure 2.14 - Internal and External Gear Pumps KSP Training Manual. 3 - 11.

(64) SECTION 3. HYDRAULICS. 3.3. VALVES. 3.3.1. Control Valves. Control valves are designed to direct and control the flow of oil to or from the work in a hydraulic circuit. These operating mechanisms of the valves are: 1 MANUAL OPERATED: a. Hand lever b. Push button c. Pedal operated 2 SOLENOID OPERATION: a. AC coils b. DC coils 3 PILOT OPERATED a. Hydraulic pilot b. Air pilot 3.3.2. Relief Valves. Relief valves are designed to regulate the maximum amount of pressure that can be built in a hydrauic circuit. They are built in three designs: 1. Direct acting 2. Pilot operated 3. Solenoid operated.. 3 - 12. KSP Training Manual.

(65) HYDRAULICS. SECTION 3. A. B. P. T. Push Button. Manually Actuated. A. B. P. T. A. B. P. T. Foot Pedal or Treadle. Hand Lever. A. B. P. T. Hydraulic Pilot. A. B. A. B. P. T. P. T. Mechanically Actuated Symbol. A. B. P. T. Air Pilot. 39000043. Solenoid. Figure 2.15 - Different Types of Activation Devices. A. B. P. T. Pressure to "b" port, "a" port to tank. A. T. B. Pressure to "a" port, "b" port to tank. A. P. B. P. T 39000044. Figure 2.16 - Typical Spool-type 4 Way Valve. KSP Training Manual. 3 - 13.

(66) SECTION 3. 3.3.3. HYDRAULICS. The Basic Relief Valve. This is a direct acting non adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style pressure relief is not adjustable except by changing the internal spring.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring. When this direct acting design relieves it causes pulsations in the system.. Pressure. Tank. 39000045. Figure 2.17 - Direct Acting Non-adjustable Relief Valve This is a direct acting adjustable relief valve. When the oil has enough pressure to over take the spring the relief poppet will start to move out of the way and allow the excess pressure to be relieved to tank. This style is adjustable though a external control which varies the spring tension on the relief poppet.The maximum system pressure that this style can be used for is limited because the spring must directly act upon system pressure and thus higher pressures would require a larger spring.. Pressure. Tank. 39000046 39000046. Figure 2.18 - Direct Acting Adjustable Relief Valve. 3 - 14. KSP Training Manual.

(67) HYDRAULICS. SECTION 3. This is a pilot operated adjustable relief valve. The relief poppet has a small orifice in it that allows the hydraulic pressure to also be applied on the back side of the poppet. This internal chamber is hydraulically locked and it will hold the main poppet closed as long as it has equal pressure on the front side and the back side. There is also a much smaller pilot poppet, that is operator adjustable. This smaller poppet, with a smaller area, can have a smaller spring controling it. Once this pilot poppet opens we lose our hydraulic lock, the pressure is reduced on the back side and thus the main poppet can relieve the excess pressure to tank. With this design we are able to control large volumes of oil at high pressures with minimal sized springs.. Pressure. Pressure. Tank. 39000047. Figure 2.19 - Pilot Operated Adjustable Relief Valve. KSP Training Manual. 3 - 15.

(68) SECTION 3. 3.4. HYDRAULICS. HYDRAULIC SYMBOLS. A.N.S.I.. D.I.N.. A.N.S.I.. D.I.N.. A.N.S.I. = AMERICAN NATIONAL STANDARDS INSTITUTE DIN = DEUTSCHE (GERMAN) INDUSTRIAL NORM. Figure 2.20 - American-German Symbol Comparison. 3 - 16. KSP Training Manual.

(69) HYDRAULICS. SECTION 3. LINES CROSSING. PRESSURE RELIEF VALVE. LINES JOINING. FOUR WAY VALVE, TWO POSITION MANUALLY OPERATED. LINE, WORKING (MAIN). FOUR WAY VALVE, THREE POSITION, LEVER OPERATED, W/ DETENT. T L. LINE, PILOT (FOR CONTROL). OIL LEVEL SIGHT GLASS W/ THERMOMETER. PORT. FOUR WAY VALVE, THREE POSITION, SOLENOID AND PILOT OPERATED, SPRING RETURN. LINE W/ THROTTLE VALVE. TANK VENT. CHECK VALVE W/ NO SPRING. TEMPERATURE MONITOR. CHECK VALVE W/SPRING RETURN. FLOAT-TYPE SWITCH. TANK. SWITCHING VALVE. FILTER. THROTTLE CHECK VALVE. DOUBLE ACTING CYLINDER ROD END CYLINDER. SHUT-OFF VALVE. PUMP,VARIABLEDISPLACEMENT, NON-COMPENSATED UNIDIRECTIONAL. PRESSURE SWITCH. HYDRAULIC MOTOR, BI-DIRECTIONAL. OIL COOLER. PRESSURE GAUGE. M. ELECTRIC MOTOR. Figure 2.21 - Hydraulic Symbols - Sheet 1. KSP Training Manual. 3 - 17.

(70) SECTION 3. HYDRAULICS. TO LOAD. SVLE VALVE. TANK. PRESSURE. PL. P G1. TANK G2. COMPENSATED PUMP. M1 S. L. TANK. A. ACCUMULATOR UNLOADING (SEQUENCER). P. TANK. Figure 2.22 - Hydraulic Symbols - Sheet 2. 3 - 18. KSP Training Manual.

(71) HYDRAULICS. SECTION 3. 1500 PSI. D 15 PSI. HIGH PRESSURE LOW PRESSURE ZERO PRESSURE. 1500 PSI. D. HIGH PRESSURE 15 PSI. LOW PRESSURE ZERO PRESSURE. 39000061. Figure 2.23 - Basic Piston Pump - Series #1 KSP Training Manual. 3 - 19.

(72) SECTION 3. HYDRAULICS. 1500 PSI. D. HIGH PRESSURE 15 PSI. LOW PRESSURE ZERO PRESSURE. 1500 PSI. D. HIGH PRESSURE 15 PSI. LOW PRESSURE ZERO PRESSURE. 39000063. Figure 2.24 - Basic Piston Pump - Series #2 3 - 20. KSP Training Manual.

(73) HYDRAULICS. SECTION 3. 1500 PSI. D 15 PSI. HIGH PRESSURE LOW PRESSURE ZERO PRESSURE. 1500 PSI. D. HIGH PRESSURE 15 PSI. LOW PRESSURE ZERO PRESSURE. 39000065. Figure 2.25 - Basic Piston Pump - Series #3 KSP Training Manual. 3 - 21.

(74) SECTION 3. HYDRAULICS. 1500 PSI. D. HIGH PRESSURE 15 PSI. LOW PRESSURE ZERO PRESSURE. 39000064. Figure 2.26 - Basic Piston Pump - Series #4. 3 - 22. KSP Training Manual.

(75) HYDRAULIC FITTINGS HIGH PRESSURE HOSES. DOCUMENT #699000. 350 SMC Drive Somerset, WI 54025 Tel 715-247-3433 Fax 715-247-3438 www.schwingbioset.com. REV. 05/17/08.

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