GEA CAJ1 Series Operation Manual And Installation Instructions
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GEA CAJ1 Series Operation Manual And Installation Instructions

8” flush pump, electric pump
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8" Flush Pump
Electric Pump
Operation Manual / Installation Instructions
(Original instructions)
2019-9015-003
01-2017
gea.com

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Summary of Contents for GEA CAJ1 Series

  • Page 1 8” Flush Pump Electric Pump Operation Manual / Installation Instructions (Original instructions) 2019-9015-003 01-2017 gea.com...

  • Page 2: Table Of Contents

    ......GEA Farm Technologies Canada Inc. / Division GEA Houle - General equipment warranty .
  • Page 3 Starting for the first time ..........Special personnel qualification required for initial commissioning .

  • Page 4: Preface

    Preface About this manual Preface This is a GEA product. GEA is the manufacturer of the Houle product line. This product was formerly known under HOULE trademark. About this manual The manufacturer reserves the right to make changes due to technical developments in the data and illustrations in this manual.

  • Page 5: Manufacturer's Address

    Preface Customer service Manufacturer's address GEA Farm Technologies Canada Inc. / Division GEA Houle 4591 boul. St-Joseph Drummondville, Qc, J2A 0C6 +1 819 477 - 7444 +1 819 477 - 5565 geahoule@gea.com www.gea.com Customer service Authorized Technical Dealer If necessary, please contact your nearest dealer.

  • Page 6: Ec - Declaration Of Conformity For Machines In Accordance With Ec Machinery Directive 2006/42 /Ec, Annex Ii 1. A

    EC - Declaration of conformity for machines in accordance with EC Machinery Directive 2006/42 /EC, Annex II 1. A Manufacturer: GEA Farm Technologies Canada Inc. / Division GEA Houle 4591 boul. St-Joseph Drummondville, Qc, J2A 0C6 We, as manufacturer, declare in sole responsibility that the machinery...
  • Page 7 Preface EC - Declaration of conformity for machines Authorized person for compiling and handing over Josef Schröer technical documentation: GEA Farm Technologies GmbH Siemensstraße 25-27 D-59199 Bönen ' +49 (0) 2383 / 93-70 Drummondville, 1 March 2010 Yann Desrochers (Head of Research and Development)

  • Page 8: Gea Farm Technologies Canada Inc. / Division Gea Houle - General Equipment Warranty

    Preface GEA Farm Technologies Canada Inc. / Division GEA Houle - General equipment warranty GEA Farm Technologies Canada Inc. / Division GEA Houle - General equipment warranty Important notice! THIS GENERAL WARRANTY APPLIES TO ALL EQUIPMENT SOLD UNDER THE HOULE TRADEMARK.
  • Page 9 Preface GEA Farm Technologies Canada Inc. / Division GEA Houle - General equipment warranty 1.5.3 Extent of limited warranty This limited warranty DOES NOT cover: ● Defects caused by negligence of the Purchaser in the maintenance of the equipment, improper use resulting from failure to adhere strictly to the...
  • Page 10 Preface GEA Farm Technologies Canada Inc. / Division GEA Houle - General equipment warranty 1.5.4 Warranty limitations and exclusion NO WARRANTY, ORAL OR WRITTEN, EXPRESS OR IMPLIED, OTHER THAN THE ABOVE WARRANTY IS PROVIDED IN RESPECT OF THE EQUIPMENT SOLD.

  • Page 11: Safety

    If component(s)/equipment not manufactured by GEA is/are added to this GEA product, consider that new risk(s) may arise from this addition. Make sure the equipment and the environment surrounding the equipment remain safe.

  • Page 12: Explanation Of Safety Symbols

    Safety Explanation of safety symbols Explanation of safety symbols The safety symbols draw attention to the importance of the adjacent text. The design of the notifications is based on ISO 3864-2 and ANSI535.6. Safety symbols and key words Danger! The signal word ”Danger” indicates an immediate threat to the lives or health of personnel.

  • Page 13: Basic Safety Instructions

    Safety Basic safety instructions Basic safety instructions ● Only trained personnel can operate this product to ensure safe operating methods. Make sure the personnel performing activities in connection with this product have the skills when special qualifications are required. Read the section Safety - Personnel qualifications.

  • Page 14: Personnel Qualifications

    Safety Personnel qualifications Personnel qualifications The manufacturer intends to determine the difference between trained personnel and qualified personnel. Trained personnel The operator was trained by the manufacturer or its legal representative to follow all safety rules, cleaning method, general maintenance as well as the operating methods.

  • Page 15: Protective Devices

    Safety Safety labels Protective devices This product is equipped with safety parts protecting the user against dangerous elements. Those parts must be in perfect working condition and remain in place at all times. Replace if damaged, worn and/or defective. Refer to the part number. Safety guard for drive belt (part no.
  • Page 16 Safety Safety labels Read the operator's manual for safety information before service and maintenance. (European model) Part no 2099-4725-130 Always turn off and lock main power before service and maintenance. (European model) Part no 2099-4725-150 Refer to section 11.1 - Appendix - Label position. 2019-9015-003 16 / 72 01-2017...

  • Page 17: Description

    Description Intended Use Description Intended Use This product is exclusively designed to: ● Transfer flush liquid having a maximum consistency of 1/8” (3mm) Refer to section 11.3 - Appendix - Consistency test. ● Operate in a well-ventilated environment free of explosive gases. ●...

  • Page 18: Product Changes

    Description Functional Description Product Changes Unauthorized product modifications can have a negative impact on the safety, service life and functionality of the product. Any modifications not described in the product documentation are deemed to be prohibited. For safety reasons, do not carry out any unauthorized changes! Planned changes must be approved by the manufacturer in writing.

  • Page 19: Technical Data

    Technical data Minimum pit opening Technical data Pump geometric data Pump height* 112” [2.85m] to 206” [5.23m] Maximum total weight 2000 lbs [910kg] * The geometric data change according to the pump length. Minimum pit opening 4.2.1 Fixed support Left Front Right Dimension...
  • Page 20 Technical data Minimum pit opening 4.2.2 Sliding and tilting support Minimum opening dimensions required in the reception pit cover to install a pump using the sideways tilting axis of the sliding and tilting support. Pump using the sideways tilting axis 8”...
  • Page 21 Technical data Minimum pit opening Pump using the backward tilting axis 8” Flush Total pump Height of the Length Y Pump* length barn ceiling Backward tilting 7 ft [2.1 m] 48” [1168 mm] 6 ft Top view [1.8 m] 10 ft 8 ft [2.4 m] 40”...

  • Page 22: Pump Performance Data (S.a.e.)

    Technical data Pump performance data (S.A.E.) Pump performance data (S.A.E.) Maximum manure consistency 1/8” Maximum pressure 33.9 - 53.8 5°C [41°F] Operating temperature Note! It is important to consider the manure consistency, the type of bedding and the quantity of bedding contained in the manure because these elements affect the performance of the pump.
  • Page 23 Technical data Pump performance data (S.A.E.) 8” Flush pump used for maximum pumping head 50 HP 40 HP 30 HP 25 HP 20 HP 15 HP Motor size Motor RPM 1760 RPM (60Hz) Pump RPM 1168 1053 Belts (4x)5VX690 (4x)BX73 (4x)BX68 (4x)BX71 (3x)BX68...

  • Page 24: Performance Data (Metric)

    Technical data Performance data (Metric) Performance data (Metric) Maximum manure consistency Maximum pressure 2.28 - 3.64 5°C [41°F] Operating temperature Note! It is important to consider the manure consistency, the type of bedding and the quantity of bedding contained in the manure because these elements affect the performance of the pump.
  • Page 25 Technical data Performance data (Metric) 8” Flush pump used for maximum pumping head 37 kW 30 kW 22 kW 18.5 kW 15 kW 11 kW Motor size Motor RPM 1465 RPM (50Hz) Pump RPM 1155 1037 Belts (4x)5Vx670 (3x)5vx710 (3x)5vx650 (3x)5vx650 (2x)5vx690 (2x)5vx710...

  • Page 26: Motor Specifications

    Technical data Motor specifications Motor specifications GEA provides specifications and wiring diagrams related to Baldor motor(s). For any other motor brand, contact the manufacturer. Motor type Farm duty motor NEMA Standard specifications 213T, 215T, 254T, 256T, 132, 160, 180, 200,225S...

  • Page 27: Control Panel Specifications

    Technical data Hydraulic hoses Control panel specifications The control panel must: ● comply with the following requirements: 2006/95/CE directives (Electrical equipment designed for use within certain voltage limits) 92/31/CEE directives (Electromagnetic compatibility) ● comply with the following harmonized standards: EN 60204-1 (Safety of machinery - Electrical equipment of machines); EN 61082-1 (Documents used in electrotechnology);...

  • Page 28: Bolt Torque Chart

    Technical data Lubricant specifications Bolt torque chart Bolt diameter Bolt Mat. 1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 3/4” 7/8” 1” SAE 2 16Nm 27Nm 44Nm 64Nm 94Nm 130Nm 210Nm 279Nm 420Nm (6ft-lb) (12ft-lb) (20ft-lb) (32ft-lb) (47ft-lb) (69ft-lb) (96ft-lb) (155ft-lb) (206ft-lb) (310ft-lb) SAE 5...

  • Page 29: Handling And Assembly

    Handling and assembly Preparation Handling and assembly Special personnel qualification required for handling Handling must be performed by a qualified forklift operator and/or qualified overhead crane or hoist operator. Installation work must be performed by trained personnel in accordance with the safety instructions.

  • Page 30: Packing Material Disposal

    ● An electric motor meeting the technical specifications provided in this manual. Refer to section 4.5 - Technical Data - Motor specifications. ● A GEA control panel. Refer to section 4.6 - Technical Data - Control panel specifications. Packing material disposal Handle the packing material properly and dispose according to your local rules and regulations on waste disposal.

  • Page 31: Anchor Bolt Installation Procedure

    Handling and assembly Anchor bolt installation procedure Anchor bolt installation procedure Attention! Wait at least 7 days before drilling into concrete so that the slab has harden sufficiently. Bolt diameter 3/8” [10mm] 1/2” [13mm] 3/4” [19mm] 3” [76mm] 2 3/4” [70mm] 3 3/4”...

  • Page 32: Pump Handling

    Handling and assembly Pump handling Pump handling Warning! Do not stand under or near a lifted load, a falling load can cause death! Attention! To lift this product use a lifting device with a minimum lifting capacity of 2000 lbs [1 000 kg] Assembly handling Installation and maintenance handling ●...

  • Page 33: Motor Support Assembly

    Handling and assembly Motor support assembly Motor support assembly ● Assemble the motor support; ● Make sure to place the U-bolt (1) over the stop bar (2); ● Torque to 90 ft-lb [130Nm]. 2019-9015-003 33 / 72 01-2017...

  • Page 34: Remote Grease Lines Assembly

    Handling and assembly Remote grease lines assembly Remote grease lines assembly ● Assemble the remote grease lines, as illustrated; ● Snug fit, do not torque. 2019-9015-003 34 / 72 01-2017...

  • Page 35: Installation And Assembly Of A Pump Having A Fixed Support

    Handling and assembly Installation and assembly of a pump having a fixed support Installation and assembly of a pump having a fixed support Warning! Do not stand under or near a lifted load, a falling load can cause death! Caution! Sharp edges can cut.
  • Page 36 Handling and assembly Installation and assembly of a pump having a fixed support Floor mounted support Wall mounted support ● Install the fixed support on the concrete ● Place the wall bracket even with the top floor using 4 anchor bolts (1/2” x 3 3/4” of the wall.
  • Page 37 Handling and assembly Installation and assembly of a pump having a fixed support Attention! Position the U-bolts under the hoses, directly on the pump frame to prevent damaging the grease lines. Attention! To lift this product use a lifting device with a minimum lifting capacity of 2000 lbs [1 000 kg] ●...

  • Page 38: Installation And Assembly Of A Pump Having A Sliding And Tilting Support

    Handling and assembly Installation and assembly of a pump having a sliding and tilting support 5.10 Installation and assembly of a pump having a sliding and tilting support Warning! Do not stand under or near a lifted load, a falling load can cause death! Caution! Sharp edges can cut.
  • Page 39 Handling and assembly Installation and assembly of a pump having a sliding and tilting support ● Assemble the tilting support over the slider; ● The lower bolt (1” x 2 1/2” bolt) is used as a tilting pivot. The upper bolt (3/4”...

  • Page 40: Control Panel Installation

    Handling and assembly Control panel installation 5.11 Control panel installation Danger! High voltage! Rick of electric shock! All electric connections must be performed by a qualified electrician. Follow local and national electric standards. Warning! Risk of electric shock! Connect the control panel and all conductive equipments to an equipotential bond.

  • Page 41: Electric Motor Installation And Connection

    Electric motor installation and connection 5.12 Electric motor installation and connection Attention! GEA provides specifications and wiring diagrams related to Baldor motor(s). For any other motor brand, contact the manufacturer. 5.12.1 Motor installation ● Loosen bolt (1); ● Pull the support;...
  • Page 42 Handling and assembly Electric motor installation and connection ● Insert the motor bolts (2) behind the table; ● Secure the motor in place using lock washers (3) and nuts (4); ● Tighten. Refer to section 4.9 - Technical data - Bolt torque chart. 2019-9015-003 42 / 72 01-2017...
  • Page 43 Handling and assembly Electric motor installation and connection Double motor ● Insert the bolts (2) behind the motor support; ● Place the adaptor over the motor support; ● Secure using lock washers (3) and nuts (4); ● Tighten; ● Insert the bolts (5) behind the adaptor; ●...
  • Page 44 Handling and assembly Electric motor installation and connection 5.12.2 Motor direction of rotation Warning! Risk of electric shock! Electric wiring and connection must be performed by an electrician. Attention! Make sure the motor rotates in the direction indicated on the label apposed on the pump shaft. Inverted rotation can unscrew the impeller and cause a major breakdown.
  • Page 45 Handling and assembly Electric motor installation and connection 5.12.3 Lower guard assembly Caution! Risk of injuries! Always install the sliding plate over the lower guard to restrain access to the pulleys. ● Remove the segments of the sliding plate as indicated in the following table. Motor (HP Segments to be removed 7½...
  • Page 46 Handling and assembly Electric motor installation and connection 5.12.4 Pulleys assembly Warning! Risk of inadvertent start resulting in finger entanglement! Shutdown is required! Shut the main power supply and lock with a locking device. Post a sign on the panel stating: ”Do not turn on, electric work in progress”...
  • Page 47 Handling and assembly Electric motor installation and connection 5.12.5 Motor belt installation Caution! Pinch point hazard! Wear protective gloves when handling the belts and pulleys. ● Install the belt (12); ● Pull the motor support to hold the belts on the pulleys. ●...

  • Page 48: Oil Tank Vented Cap Installation

    Handling and assembly Oil tank vented cap installation 5.12.6 Protective guard installation ● Insert the guard support (20) into the post (21). Make sure the support does not contact the hubs (22); ● Place the upper guard (23) over the support and secure with washers and nuts.

  • Page 49: Connecting The Discharge To The Evacuation Line

    Handling and assembly Holding area flush pit connection 5.14 Connecting the discharge to the evacuation line 5.14.1 Top discharge pipe ● Install elbow discharge and position the opening towards the evacuation line. Using locking handles, lock the elbow on the top discharge making sure the O-ring is well seated.

  • Page 50: Bottom Sediment Removal Installation

    Handling and assembly Bottom sediment removal installation 5.16 Bottom sediment removal installation Optional Manifold Vacuum Base The manifold vacuum base allows the pumps intake to draw directly from the bottom of the pit, reducing sediment buildup on the bottom of the pit. Install the manifold vacuum base at the dimension shown.

  • Page 51: Starting For The First Time

    Starting for the first time Safety instructions for initial commissioning Starting for the first time Special personnel qualification required for initial commissioning Initial commissioning must be performed by trained personnel in accordance with the safety instructions. Read the section Safety - Personnel qualifications. Safety instructions for initial commissioning Warning! Do not operate this product until the initial commissioning checklist is...

  • Page 52: Initial Commissioning Checklist

    Starting for the first time Initial commissioning checklist Initial commissioning checklist This checklist must be completed by the dealer and the customer. The initial commissioning steps intend to test the product to validate its functionality. Therefore, the dealer and the customer must operate the product to make sure the product is assembled and/or installed according to the manufacturer's instructions.

  • Page 53: Checks After Initial Commissioning

    Hand over warranty registration form The warranty registration form must be completed and signed by the customer and the dealer. The warranty registration form must be returned to GEA Farm Technologies Canada Inc. / Division GEA Houle to validate the warranty.

  • Page 54: Operation

    Operation Operating Operation Special personnel qualification required for operation Operation must be performed by qualified personnel in accordance with the safety instructions. Read the section Safety - Personnel qualifications. Safety instructions for operation Read the section Safety. Description of the operating elements Operating 7.4.1 Flush mode...

  • Page 55: Operating Faults

    Operating faults Troubleshooting possible faults Operating faults Special personnel qualification required for troubleshooting Troubleshooting must be performed by trained personnel in accordance with the safety instructions. Read the section Safety - Personnel qualifications. Safety instructions for troubleshooting Warning! Shutdown is required! shut the main power supply and lock with a locking device.
  • Page 56 Operating faults Troubleshooting possible faults Symptom Possible cause Solution Pump operates The directional valve Contact your dealer. but does not control lever is damaged pump. A foreign object blocks the Contact your dealer. pump inlet. Pump is working Electrical motor incorrectly Check motor rotation.

  • Page 57: Maintenance

    Maintenance Safety instructions for maintenance Maintenance Special personnel qualification required for maintenance work Maintenance work must be performed by trained personnel in accordance with the safety instructions. Electric work must be performed by an electrician. Read the section Safety - Personnel qualifications. Safety instructions for maintenance Warning! Shutdown is required! shut the main power supply and lock with a...

  • Page 58: Scheduled Maintenance Responsibilities

    Scheduled maintenance responsibilities Scheduled maintenance responsibilities Note! When operating this GEA Houle product using other manufacturer's components and/or products such as a PTO, a tractor, a motor, a pump, etc., ALWAYS perform maintenance of the component and/or product as recommended by its manufacturer.

  • Page 59: Motor Support Threaded Bolts Lubrication

    Maintenance Sliding and tilting component lubrication Motor support threaded bolts lubrication Note! To prevent seizing of metal parts, apply a significant coat of grease when performing the following maintenance. ● Apply PRECISION™ general purpose EP2 grease each threaded rod of the motor support. Agitation nozzle height adjustment screw lubrication ●...

  • Page 60: Bearing Housing Lubrication

    Maintenance Visual inspection Bearing housing lubrication Note! Adding grease into the grease chamber prevents contaminants from entering the bearing housing. ● Wipe clean the grease fitting of the remote grease lines; ● Fill the bearing housing with 10 grams of PRECISION™ general purpose EP2 grease.

  • Page 61: Upper Bearing Lubrication

    Maintenance Bearing housing seals inspection 9.11 Upper bearing lubrication Attention! Slowly lubricate this bearing to avoid applying significant pressure on the seals. Applying too much pressure will damage the seals inside the bearing. Note! Avoid splashing water over the bearing unit! If water contacts the bearing unit, wipe clean the bearing and grease immediately to prevent premature wear.

  • Page 62: Decommissioning

    Decommissioning Final decommissioning/disposal Decommissioning 10.1 Special personnel qualification required for decommissioning Decommissioning may only be performed by specially qualified personnel in accordance with the safety instructions. Read the section Safety - Personnel qualifications. 10.2 Safety instructions for decommissioning Read the section Safety. 10.3 Final decommissioning/disposal After final decommissioning, handle all components properly and dispose of...

  • Page 63: Appendix

    Appendix Label position Appendix 11.1 Label position US + EU 2099-4720-010 2099-4721-000 2010-4700-400 2099-4725-240 2099-4725-210 US + EU 2099-4725-110 2099-4725-100 2099-4725-130 US + EU US + EU 2099-4700-390 2099-4725-150 2099-4725-010 US = American label / EU = European label 2019-9015-003 63 / 72 01-2017...

  • Page 64: Pumping Head Calculation

    Appendix Pumping Head Calculation 11.2 Pumping Head Calculation Note! Read the following information before calculating and filling the Pumping Head Formula. 11.2.1 Transfer rate ● In SAE, the transfer rate is expressed in US GPM. ● In metric, the transfer rate is expressed in Liters per minute. 11.2.2 Elevation (X) The elevation is the height difference between the reception pit bottom and the top of the storage pit.
  • Page 65 * PVC adaptor 45 ' 12¾” to 15” PVC adaptor 304,8 mm to 14 m 381 mm * For 12” [300 mm] GEA Houle steel components, use the Friction Loss Coefficient for PVC pipes. 2019-9015-003 65 / 72 01-2017...
  • Page 66 Appendix Pumping Head Calculation 11.2.6 Friction Loss Coefficient of PVC Piping Liquid and manure consistency Litres per Diametre Gallons 1/8” 1/4” 1/2” 3/4” minute Water per minute (3mm) (6mm) (12mm) (18mm) 0.0526 0.0599 0.0710 0.1041 0.1519 0.0980 0.1117 0.1323 0.1940 0.2832 3”...
  • Page 67 Appendix Pumping Head Calculation 11.2.7 Friction Loss Coefficient for Flexible Hoses and Steel Piping Liquid and manure consistency Litres per Diametre Gallons 1/8” 1/4” 1/2” 3/4” minute Water per minute (3mm) (6mm) (12mm) (18mm) 0.0682 0.0777 0.0920 0.1350 0.1970 0.1271 0.1448 0.1715 0.2516...
  • Page 68 Appendix Pumping Head Calculation 11.2.8 Pumping Head Formula INFORMATION FORMULA Type of Linear TOTAL Intended transfer Evacuation line Manure Friction lost piping and equivalence or rate diameter consistency coefficient material pipe/hose length 1200 USGPM 0.976' 90º steel 8” [203mm] 32' [9.75m] 0.0305 elbow [0.30m]...

  • Page 69: Consistency Test

    11.3 Consistency test GEA Houle determined the following method to verify if the viscosity of the liquid manure is suitable for this product. 1. Set a pail on a level surface and install a 24” [60cm] round plate at the center of the pail.

  • Page 70: Abbreviations

    Appendix Abbreviations 11.4 Abbreviations Terms Explanation Terms Explanation Ø diameter European Community clockwise counterclockwise facsimile I.D. inside diameter Inc. Incorporated national coarse O.D. outside diameter power take off polyvinyl chloride Society Automotive Quebec Engineers United States of America World Wide Web Units Explanation Units...
  • Page 71 Appendix Abbreviations 2019-9015-003 71 / 72 01-2017...
  • Page 72 Excellence • Passion • Integrity • Responsibility • GEA-versity GEA Group is a global engineering company with multi-billion euro sales and operations in more than 50 countries. Founded in 1881, the company is one of the largest providers of innovative equipment and process technology.

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