APA-140E Chopper Agitator Pump (851-00-141) Installation, Maintenance and Repair

The APA Series pumps are low pressure units (less than 30 psi) designed to deliver liquid manure slurry from a collection pit to a staging pit, separator, above ground storage tank, waste pond, or tank mounted distribution wagon.  The APA Series provides both agitation and pumping for larger collection pits and possess aggressive chopping characteristics to handle all materials normally contained in manure waste.

APA Pumps feature Agpro, Inc.’s reliable oil bath drive line.  This drive line utilizes large ball and roller bearings running in a complete oil bath retained by our simple, reliable seal.  Each unit is equipped with a low oil sensing switch to prevent operation without lubricant for maximum bearing life.  APA Pumps are designed for high duty cycle, continuous use on commercial dairy operations.  Overall low maintenance is a hallmark of these units.  When reparis are required, the simple design and use of common parts allows quick, easy service for minimum down time.  The APA Pumps feature Agpro’s exclusive replaceable stainless steel housing liner to significantly increase the life of the pump housing even in the harshest conditions.

APA units provide vigorous, continuous mechanical agitation to stir tanks up to 100,000 liters.  This effective direct agitation quickly brings settled manure particles into suspension for complete tank pump out without gear boxes, additional wear points, or additional equipment.

Manure Slurry Piping

Underground piping using an Agpro Drain Back Vavle:

Pipe lines from pump to final discharge point should be as straight as possible with a minimum of turns. If turns are required use sweep ells and provide cleanouts at each turn. Pipes should be routed to allow use of an Agpro Drain Back valve in the collection tank as in Figure 1; this is typical of below ground piping situations.

(1) APA-Pump

(2) Manure Tank

(3) Ground

(4) Drain Back Valve

(5) Pump Supply Line

chopperagitatorRefer to project plans regarding manure pit construction and pump positioning.

Lower the pump assembly into position over the opening in the cover and bolt the pump unit to the platform using holes provided in base.

Check and tension the drive belts. Do not over tighten!

Attach discharge piping to pump outlet using a 300 to 450 mm length of flexible rubber hose near the discharge of the pump to isolate the piping from pump vibration. Use two hose clamps at each end to secure the rubber hose to the couplers.

Note: The pump discharge is flanged to match either a 100 to 150 mm flange provided in customer piping system. Normal installation would include a flanged coupler, flexible hose and a second coupler to remainder of piping system.

Using normal electrical code procedures, a qualified electrician should now connect motor to main control panel, being sure to ground pump intake and drive tube assembly to the main control panel and connect main power source to electrical panel. Note that the oil level sensing switch must be wired to controls to preclude operation when low oil level is detected and the on/off probe control must also be properly wired.
Fill oil reservoir with 20 weight non-foaming hydraulic fluid and start motor to check direction of rotation. Rotation for APA pumps should be counter-clockwise (CCW) looking down into the pit. If clockwise rotation is observed electrician must reverse connection leads in control box to correct for counterclockwise rotation. The pump is now ready for use.
CAUTION – ALWAYS TURN MAIN DISCONNECT “OFF” BEFORE SERVICING UNIT. THIS IS AN AUTOMATIC UNIT AND CAN START AT ANY TIME.

Upon initial use check pump oil reservoir and fill with 20 weight non-foaming hydraulic fluid daily. Oil usage should be very low. Initially check at least daily. After approximately one week of no oil usage, inspections may be reduced to weekly.

If the pump begins using oil, it is important to find and stop the leak. If it is a loose joint or the mechanical seal under the surface of the slurry, materials can get into the bearings and cause severe damage. The unit is equipped with a low oil level switch which will prevent operation without oil. This should be utilized as a backup only to normal oil level inspections. If the unit is allowed to run out of oil, bearing damage will occur.

Grease motor bearing(s) with one-quarter ounce Shell Cyprine No. 3 or other high quality lithium bearing grease every three months.

Weekly Check List

Check Oil Level – Fill as required. If excessive find and fix leak
Belt Tightness – Tighten as required
Vibration – Check outside cutter for damage or debris. Remove debris and/or replace if needed

Monthly Check List

Controls – Call Electrician if required
Belt Guard – Reinstall if not in place
Top Bearing – Spray w/water to remove debris

Quarterly Check List

Motor Bearings – Grease

Yearly Check List

Inspect impeller – Replace if needed
Inspect shear plate – Replace if needed
Inspect outer cutter/agitator – Replace if needed

Danger no boarder
WARNING! READ THIS CAREFULLY!
Poisonous gases are present in manure storage. DO NOT ENTER! Remove equipment from manure pit for servicing. FAILURE TO HEED COULD RESULT IN DEATH.
Poisonous gases are present in manure storage which can kill or seriously injure. These gases include, but are not limited to; carbon monoxide, methane, and hydrogen sulfide. DO NOT enter manure storage to service equipment or retrieve dropped tools or parts. Remove the equipment from hazardous environments to service.
Enter manure storage areas ONLY as a last resort to rescue another person who may have fallen into the manure storage. First, attempt to rescue the individual from manure storage by tossing them a rope tide in a bowline knot which they can slip over their head and shoulders and place the loop beneath their arms. Then proceed to pull the person out.
If the person is unconscious and requires rescue you may have to enter the manure storage. Open all possible openings to the manure storage and ventilate with a fan to remove hazardous gases. Before entering, the atmosphere should be tested for the presence of hazardous gases. If in doubt us a National Institute of Occupational Safety and Health (NIOSH) approved breathing apparatus before entering.
Under no circumstances enter the manure storage area without a third person present who is able to perform a rescue should you be overcome by hazardous manure gases. Before entering the pit put a rescue rope over your head and shoulders, placing the rope beneath your arm pits. Then put on a NIOSH approved self contained breathing apparatus (SCBA) with oxygen tank. DO NOT use a respirator or breathing filter, this WILL NOT protect you from hazardous gases present in manure storage.
The following materials should be present at all times within easy access of the manure storage area:
– Rope of adequate length and strength to perform a rescue (Preferably, one end will be tied in a loop, using a bowline knot, large enough to go around the largest person which might require a rescue.)
– Ladder long enough to reach the bottom of the pit.
– NIOSH approved SCBA
– Fan of adequate size to perform complete ventilation of the manure storage area
– Emergency phone numbers of the local rescue team

MANURE GASES ARE DEADLY. PLEASE PROCEED WITH CAUTION. IF YOU MUST ENTER A MANURE STORAGE AREA TO PERFORM A RESCUE, PLEASE FOLLOW THE PRECAUTIONS ABOVE.

WARNING: TO AVOID INJURY, USE EXTREME CAUTION WHEN REMOVING OR INSTALLING THE PUMP IMPELLER. NEVER ROTATE THE SHAFT WITHOUT FIRST BEING SURE FINGERS, TOOLS AND OTHER POSSIBLE OBSTRUCTIONS ARE CLEAR.

Danger no boarderWARNING! READ THIS CAREFULLY!
Poisonous gases are present in manure storage. DO NOT ENTER! Remove equipment from manure pit for servicing. FAILURE TO HEED COULD RESULT IN DEATH.
Poisonous gases are present in manure storage which can kill or seriously injure. These gases include, but are not limited to; carbon monoxide, methane, and hydrogen sulfide. DO NOT enter manure storage to service equipment or retrieve dropped tools or parts. Remove the equipment from hazardous environments to service.
Enter manure storage areas ONLY as a last resort to rescue another person who may have fallen into the manure storage. First, attempt to rescue the individual from manure storage by tossing them a rope tide in a bowline knot which they can slip over their head and shoulders and place the loop beneath their arms. Then proceed to pull the person out.
If the person is unconscious and requires rescue you may have to enter the manure storage. Open all possible openings to the manure storage and ventilate with a fan to remove hazardous gases. Before entering, the atmosphere should be tested for the presence of hazardous gases. If in doubt us a National Institute of Occupational Safety and Health (NIOSH) approved breathing apparatus before entering.
Under no circumstances enter the manure storage area without a third person present who is able to perform a rescue should you be overcome by hazardous manure gases. Before entering the pit put a rescue rope over your head and shoulders, placing the rope beneath your arm pits. Then put on a NIOSH approved self contained breathing apparatus (SCBA) with oxygen tank. DO NOT use a respirator or breathing filter, this WILL NOT protect you from hazardous gases present in manure storage.
The following materials should be present at all times within easy access of the manure storage area:
– Rope of adequate length and strength to perform a rescue (Preferably, one end will be tied in a loop, using a bowline knot, large enough to go around the largest person which might require a rescue.)
– Ladder long enough to reach the bottom of the pit.
– NIOSH approved SCBA
– Fan of adequate size to perform complete ventilation of the manure storage area
– Emergency phone numbers of the local rescue team

MANURE GASES ARE DEADLY. PLEASE PROCEED WITH CAUTION. IF YOU MUST ENTER A MANURE STORAGE AREA TO PERFORM A RESCUE, PLEASE FOLLOW THE PRECAUTIONS ABOVE.

WARNING: TO AVOID INJURY, USE EXTREME CAUTION WHEN REMOVING OR INSTALLING THE PUMP IMPELLER. NEVER ROTATE THE SHAFT WITHOUT FIRST BEING SURE FINGERS, TOOLS AND OTHER POSSIBLE OBSTRUCTIONS ARE CLEAR.

APA 140E Exploded ViewGeneral
Use drawing of parts breakdown as a pump repair guide and for replacement parts orders. There are four special “tools” required for assembly of the manure pump which are included in a package with a new unit. These tools may be supplied by Agpro upon request if lost or destroyed.
This guide covers both AP and APA units. These pumps are basically alike with only one difference; the outer cutter on APA units has “fins” for agitation. The AP outer cutter has no fins. All other parts are interchangeable.

REPAIRS

Pump Removal
Turn off electrical power at circuit breaker panel and lock disconnect switch on control box to off.
Remove belt guard from assembly.
Loosen motor mounting bolts and belts so belts can be removed from sheave.
Disconnect oil reservoir hose and cap end so oil will not run out.
Disconnect pump assembly from discharge pipe. Attach lifting device.
Remove the large “U” bolts that hold the chopper-agitator assembly to the pump and motor base.
Lift the chopper-agitator assembly from the pit. Be careful not to damage the shaft at the top and watch the agitator-cutter as it comes up through the hole and pump base.

While near the manure tank it is recommended the unit be cleaned with water and a stiff bristle brush. Pressure washing if available will facilitate cleaning. Do not use diesel fuel or kerosene as a solvent for cleaning as this will restrict proper

lubrication when reassembled. Move this assembly to the cleanest and most convenient place possible for maintenance.

Lower End Disassembly/Repairs
Use parts drawing as a guide to indicate order and placement of items.

Insert a rod (wooden dowel preferred) through a hole in the shear plate to keep shaft from turning.

Remove large bottom nut #37 and slide outer agitator-cutter #36 off shaft. This may require two small pry bars and gentle tapping with a hammer. There will be a series of shims under cutter (#34).

Remove six socket head cap screws #15 from shear plate #35. Remove shear plate.

Remove lower shims #34. Impeller-cutter #33 can now be removed. Remove upper shims #31.

Pay attention to lower seal parts, these must be kept in place for reuse upon reassembly or replacement if required.

At this point lower end can be rebuilt without further disassembly. This includes replacement of impeller, shear plate, outer cutter/agitator, lower seal and housing liner. Simply replace parts and proceed to appropriate steps in reassembly procedure. For lower seal replacement, refer to step #9 of Assembly of Pump Drive Line.

Drive Line Repairs
Remove sheave from agitator drive shaft. To remove the taper lock bushing from the shaft, take the two set screws out of the bushing. Put one set screw in the center hole that has threads on the bushing side. Tighten the set screw and tap on the hub. This should separate the bushing from the sheave.

Remove bolts to allow removal the main discharge tube assembly from the drive unit.
You are now ready to conduct major repairs to the drive line. Follow the Assembly of Pump Drive Line Instructions, pay careful attention to clearances and tolerances.

Operation with Agpro, Inc. Control Panel

Panel is three phase-380 volt-60 HZ for 40HP pump.  Complete and wired including motor starter, disconnect, fuses, external controls, water protected enclosure, service hour meter, and low oil sensing switch.
Agpro AP Pump Panels are designed for automated operation with a Liquid Level Control On/Off Probe and will start automatically when the control switch is in the “auto” position. The pump will start when the liquid level in the pit rises to the top float and activates the switch. The pump will continue to run until the liquid level falls below the bottom float. This float position should be adjusted in a manner to virtually empty the pit yet still retain enough slurry to prevent air intake prior to pump shut down.

Check the operation sequence and make sure it operates correctly. If the pump starts operating when the liquid reaches the low float, reverse the wires on the terminal block for proper operation.

Panel and pump must be grounded.

The pump can be started manually by turning the control switch past “off” to the “hand” position. The pump will continue to run until the switch is moved to the “off” position.