Exhibit_G_JWC_Environ_Muffin_Monster_Grinder_Pump_Control_Panel.pdf

OPERATION and MAINTENANCE MANUAL

30004T MUFFIN MONSTER® IN-LINE GRINDER

Released October 2019

JWC Environmental Inc.

2600 S. Garnsey

Santa Ana, CA 92707 www.jwce.com JWC Environmental Inc. shall not be liable for any commercial losses, loss of revenues or profits, loss of goodwill, inconve-nience, or exemplary, special, incidental, indirect or consequen-tial damages whatsoever, or claims of third parties, regardless of the form of any claim that may result from the use of this practice.

©2019 JWC Environmental Inc. JWCE’s Santa Ana and Costa Mesa California facilities are registered by UL to ISO9001:2008 #10001313 QM08. JWC International Congleton, UK is registered by QAS to ISO9001:2008 File #A13056. U.S. patents apply:

5,320,286; 5,333,801; 5,354,004; 5,478,020; 5,505,388; 5,593,100; 6,176,443; 6,332,984; 7,073,433; 7,080,650; 7,081,171;

7,086,405; 7,383,842; 7,771,589; 7,854,850 RE37,550E; RE37,349E; RE40,422; RE39,948E. Additional patents pending and interna-tional patents also apply.

30004T GRINDER

i

TABLE OF CONTENTS

SECTION 1 GENERAL INFORMATION

1.1 INTRODUCTION........................................................................................................................ 1-1

1.2 DESCRIPTION........................................................................................................................... 1-1

1.3 MECHANICAL SPECIFICATIONS............................................................................................. 1-1

1.4 LIMITATION OF USE................................................................................................................. 1-1

1.5 DESIGN COMPLIANCE............................................................................................................. 1-1

1.6 REPAIRS AND RETURNS......................................................................................................... 1-2

SECTION 2 SAFETY INSTRUCTIONS

2.1 INTRODUCTION........................................................................................................................ 2-1

SECTION 3 INSTALLATION AND CHECKOUT

3.1 INTRODUCTION........................................................................................................................ 3-1

3.2 UNPACKING AND STORAGE................................................................................................... 3-1

3.3 INSTALLATION.......................................................................................................................... 3-1

3.4 STARTUP................................................................................................................................... 3-2

3.5 LONG TERM AND PERMANENT SHUTDOWNS .................................................................... 3-2

3.5.1 Permanent Shutdown ...................................................................................................... 3-3

SECTION 4 MAINTENANCE

4.1 INTRODUCTION........................................................................................................................ 4-1

4.2 MAINTENANCE REQUIREMENTS ........................................................................................... 4-1

4.3 INSPECTION/MAINTENANCE .................................................................................................. 4-7

4.3.1 Visual............................................................................................................................... 4-8

4.3.2 External Fasteners .......................................................................................................... 4-8

4.3.3 Drive Assembly and Coupling ......................................................................................... 4-8

4.3.4 Cutter Stack..................................................................................................................... 4-8

4.3.5 Seal Cartridge Assembly ................................................................................................. 4-8

4.3.6 Grinder Drive Gears ........................................................................................................ 4-8

4.4 LUBRICATION ........................................................................................................................... 4-8

4.4.1 Grinder Drive Couplings .................................................................................................. 4-8

4.4.2 Drive Gears ..................................................................................................................... 4-8

4.4.3 Speed Reducer................................................................................................................ 4-8

4.5 PARTS INFORMATION ............................................................................................................. 4-8

SECTION 5 TROUBLESHOOTING

5.1 INTRODUCTION........................................................................................................................ 5-1

SECTION 6 REMOVAL AND REPLACEMENT

6.1 INTRODUCTION........................................................................................................................ 6-1

6.2 GRINDER REMOVAL ................................................................................................................ 6-1

6.3 GRINDER COMPONENT REMOVAL AND REPLACEMENT ................................................... 6-2

6.3.1 Cutter Cartridge Removal................................................................................................ 6-2

6.3.2 Cutter and Spacer Removal ............................................................................................ 6-3

6.3.3 End Housing Removal..................................................................................................... 6-4

6.3.4 Stacking Cutters and Spacers ......................................................................................... 6-4

6.3.5 Drive Gear, Driven Gear and Shaft Removal and Replacement ..................................... 6-6

6.3.6 Seal Cartridge Removal and Inspection .......................................................................... 6-6

6.4 GRIND TEST.............................................................................................................................. 6-7

APPENDIX A ELECTRIC DRIVE ASSEMBLY MAINTENANCE INSTRUCTIONS

ii

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LIST OF FIGURES

FIGURE 3-1 INSTALLATION CONFIGURATIONS ............................................................................ 3-1

FIGURE 3-2 SUGGESTED CLEARANCE ......................................................................................... 3-2

FIGURE 3-3 GRINDER LIFT POINTS ............................................................................................... 3-2

FIGURE 6-1 CUTTER CARTRIDGE REMOVAL ............................................................................... 6-2

FIGURE 6-2 MAINTENANCE FLANGE OPTIONS ............................................................................ 6-3

FIGURE 6-3 CUTTER ORIENTATION ............................................................................................... 6-5

FIGURE 6-4 CUTTER STACKING ..................................................................................................... 6-5 iv v

LIST OF TABLES

TABLE 1-1 CONFIGURATION GRINDER SPECIFICATIONS ........................................................ 1-2

TABLE 1-2 STANDARD CONFIGURATION MATERIALS USED .................................................... 1-2

TABLE 4-1 FIVE YEAR MAINTENANCE SCHEDULE ..................................................................... 4-2

TABLE 4-2 RECOMMENDED LUBRICANTS and LUBRICATION SCHEDULE .............................. 4-7

TABLE 5-1 GRINDER TROUBLESHOOTING GUIDE .................................................................... 5-1

TABLE 5-2 GRINDER MOTOR TROUBLESHOOTING GUIDE ....................................................... 5-3 vi

1-1

SECTION 1 GENERAL INFORMATION

1.1 INTRODUCTION

SECTION 1 describes and defines the operation, specifications, options, and support information related to the 30004T In-Line Muffin Monster grinder and components. Details about the drive assembly are found in the Electric Drive Assembly Maintenance Instructions (Appendix A). Refer to the grinder configuration and assembly drawings for all grinder configurations and dimensions.

1.2 DESCRIPTION

The grinder is a two shafted in-line grinding system designed for installation on the suction side of pumps that pulverizes influent solids into a particle size acceptable to sewage type pumps. Solids reduction facilitates free flow and easy disposal of sludge eliminating the need for treatment plant bar screens, rakes, and other related equipment.

The other components of a typical grinding system are a motor drive mounted to the grinder which provides rotary power for the grinder shafts and a separate motor controller which provides operator and automatic controls for the grinder motor. Refer to the appropriate manual or instructions for details on other components.

Model number breakdown for the Muffin Monster 30004T-XXYY grinder is:

• 30004T - grinder model type.

• XX - cutting chamber height in inches.

• YY - flange diameter in inches.

1.3 MECHANICAL SPECIFICATIONS

The grinder inlet and outlet flanges can accommodate the following:

• American National Standards Institute Stan-dards (ANSI) B16.42-1979 Class 150: 4, 6, 8 and 10 inch (102, 152, 202 and 252 mm) pipe-line.

• Australian Standard A100, A150, A200, A250.

• British Standard 4504, Section 3.1, 1989, Table 11, PN16: 150 mm nominal pipe diameter.

• British /International Standards Organization

(ISO) B100, B150, B200, B250.

• International Standards Organization (ISO) 2084-1974 (E), Table 2, NP16: 150 mm nomi-nal pipe diameter.

• Japanese Industrial Standards (JIS) B2210- 1984, Nominal Pressure 10K: J100, J150, J200, J250 mm nominal pipe diameter.

• Japanese Water Authority (JWA) 7.5K:

JWA100, JWA150, JWA200, JWA250 mm nominal pipe diameter.

Grinder specifications are shown in TABLE 1-1;

TABLE 1-2 shows grinder materials.

1.4 LIMITATION OF USE

JWCE considers that the buyers and users of this equipment limit the use of the equipment to the purpose and intent defined at time of sale.

Applications of the equipment must be in compliance with all applicable local, federal, and area safety rules, regulations, and guidelines.

1.5 DESIGN COMPLIANCE

JWCE considers the equipment described in this manual satisfies the design criteria for same and/or similar types of equipment. JWCE also considers that the buyers and users of this equipment comply and ensure compliance with the warnings, cautions and notes included in this manual to avoid the potential for injury and/or equipment damage.

30004T GRINDER GENERAL INFORMATION

1-2

1.6 REPAIRS AND RETURNS

Return Authorization must be made by calling JWCE if repairs are required. Be prepared to give the model number and serial number, located on the nameplate on the grinder top cover, to the JWCE representative. Returned item(s) must be securely packaged and shipped to JWCE.

Contact JWCE Customer Service or the local sales/service representative for answers to service questions.

JWC Environmental 2600 S. Garnsey St.

Santa Ana, CA 92707

800-331-2277 949-833-3888

714-549-4007 (fax)

TABLE 1-1 CONFIGURATION GRINDER SPECIFICATIONS

Horsepower 3 (2.2 kW), 5 (3.7kW)

Voltage 460 VAC

Frequency 60 Hz

Duty Continuous

Temperature Rating Operating 23°F (-5°C) to 105°F (40°C) Storage 40°F (5°C) to 105°F (40°C)

Speed Reducer Ratio 29:1

Shaft speed 60 rpm (drive shaft), 44 rpm (driven shaft)

Motor Service Factor 1.15

TABLE 1-2 STANDARD CONFIGURATION MATERIALS USED

GRINDER COMPONENT MATERIAL USED

End Housings ASTM A536-77 ductile iron

Top and Bottom Covers ASTM A536-77 ductile iron

Cutters and Spacers Alloy steel

Shafts 4140 alloy steel

Seal Faces Tungsten Carbide

2-1

SECTION 2 SAFETY INSTRUCTIONS

2.1 INTRODUCTION

Operations and maintenance personnel must read and understand the safety instructions listed in this section and throughout this manual before operating or maintaining the grinder. WARNINGS (double boxed, upper case), Cautions (single boxed, title case), and NOTES inform operations and maintenance personnel of safety concerns and important information crucial to the operation and maintenance of this equipment.

Safety instructions are based on properly trained personnel using good safety practices at all times.

JWC Environmental shall not be held liable for any ignorance or disregard of applicable OSHA, federal, state, or local regulations. JWC Environmental shall not be held liable for any damages resulting from controller functions that are triggered as a result of wiring misconnections, wiring shielding errors, and/or other wiring errors not in compliance with OSHA, federal, state, or local regulations.

DO NOT WEAR LOOSE FITTING

CLOTHING NEAR GRINDER.

KEEP PERSONNEL AND UNAUTHORIZED

MATERIAL CLEAR OF GRINDER CUTTING

CHAMBER.

WEAR EYE AND EAR PROTECTION WHEN

STEAM CLEANING COMPONENTS.

COMPLY WITH ALL OSHA AND OTHER

REGULATORY AGENCY SAFETY

REQUIREMENTS.

DO NOT LIFT HEAVY EQUIPMENT

OVERHEAD OF PERSONNEL. ENSURE

THAT ADEQUATE ASSISTANCE IS

AVAILABLE AND UTILIZED WHEN LIFTING

AND TRANSPORTING EQUIPMENT,

TOOLS, AND SUPPORT MATERIALS.

ELECTRICAL HAZARDS EXIST. DO NOT

TAKE ELECTRICAL MEASUREMENTS

ALONE. VERIFY AND ENSURE POWER TO

THE MOTOR CONTROLLER IS REMOVED,

LOCKED OUT, AND TAGGED BEFORE

PERFORMING ANY INSTALLATION,

SERVICE, OR MAINTENANCE TASK

INCLUDING THE REMOVAL OR

ATTEMPTING TO REMOVE ANY

OBSTRUCTION(S) FROM THE GRINDER.

JWCE CONTROLLER PANEL CONTROLS

DO NOT REMOVE POWER FROM THE

CONTROLLER ENCLOSURE. DO NOT USE

ANY START/STOP PUSHBUTTON AS A

POWER DISCONNECT. SERVICE JWCE

CONTROLLERS AND CONNECTED

DEVICES ONLY WHEN POWER TO THE

CONTROLLER HAS BEEN TURNED OFF,

LOCKED OUT AND TAGGED.

30004T GRINDER SAFETY INSTRUCTIONS

2-2

DO NOT ATTEMPT ANY MAINTENANCE

ON THE EQUIPMENT DURING A POWER

LOSS. THE GRINDER MAY START, STOP,

REVERSE, OR RESTART

AUTOMATICALLY AFTER POWER LOSS

AND RECOVERY. ELECTRICAL LOCKOUT

PROCEDURES MUST BE PERFORMED

PRIOR TO SERVICING ANY EQUIPMENT

OR CONNECTED EQUIPMENT.

PERSONAL AND MECHANICAL HAZARDS

EXIST DURING THE PERFORMANCE OF

THE GRIND TEST.

PERFORM ALL SURFACE PREPARATION

AND PAINTING IN A WELL VENTILATED

NON-SMOKING AREA THAT IS IN

COMPLIANCE WITH ALL APPLICABLE

SAFETY REGULATIONS. AVOID

PROLONGED EXPOSURE TO VAPORS.

USE AN AIR RESPIRATOR/AIR MASK AND

CHEMICAL SAFETY GOGGLES/FACE

SHIELD.

Cutters And Spacers Are Sharp.

Appropriate Gloves Must Be Worn When Installing Or Handling Cutters And Spacers To Prevent Injury During Handling.

3-1

SECTION 3 INSTALLATION AND CHECKOUT

3.1 INTRODUCTION

SECTION 3 describes the installation, checkout, and start-up procedure of the 30004T grinder.

Review all safety instructions before installing the grinder.

No special equipment, tools, or test equipment is required for grinder installation (or maintenance).

Make sure any lifting and handling devices are rated for a load capacity greater than the weight of the grinder. Refer to TABLE 1-3 for standard grinder weights (other factors, such as type of motor will impact the overall weight of the motor).

3.2 UNPACKING AND STORAGE

The grinder is carefully packaged for shipment to the installation site. Do not remove any components from the shipping crate/carton until an inventory is taken.

1. Inspect the shipping container. Report all shipping container damage immediately to the carrier and send a copy to the company representative.

2. Inspect the grinder for missing, loose, or damaged components. The grinder is shipped completely assembled and ready to install.

Contact JWCE or local representative if parts are loose, missing, or damaged.

3. Inspect the grinder options included with the equipment as defined in the customer order. If parts are missing, loose, or damaged, contact

JWCE.

4. Close and seal all shipping containers after inspection for shortages and damage. Store in the shipping containers until time of installation indoors in an environment between 40° F (5° C) and 105° F (40° C). Try not to re-open the storage container until installation. If it is necessary to store the equipment outdoors, make sure the crates are covered to protect from moisture.

The motor and speed reducer have been lubricated at the factory. Extended storage may cause grease to separate. A small amount of light lubricant may leak from greased areas. Unless leakage is excessive - more than one (1) tablespoon - it does not cause any problems. The grease homogenizes to its original consistency when the gears are run.

If possible, rotate the drive assembly at least 15 revolutions every 3 months, minimum, to redistribute bearing lubricant. A rust preventive coating to the cutter stack is factory-applied but should also be liberally reapplied after every 6 months of storage.

3.3 INSTALLATION

Perform the following procedure to install the grinder in line with the existing piping FIGURE 3-1 and FIGURE 3-2 show the 30004T installation configurations and suggested clearance. A minimum amount of civil work is required during installation. A minimum of five pipe diameters should be allowed between the grinder discharge and the pump suction if the grinder is installed upstream of a pump. Standard tools, a multimeter and lifting equipment with the proper load rating are required. All drive components are factory greased and ready for operation. For hydraulic powered grinders refer to the Hydraulic Power Pack manual.

Read and understand the associated motor controller manual before operating the grinder.

FIGURE 3-1 INSTALLATION

CONFIGURATIONS

30004T GRINDER INSTALLATION AND CHECKOUT

3-2

FIGURE 3-2 SUGGESTED CLEARANCE

FIGURE 3-3 GRINDER LIFT POINTS

1. Verify that electrical power to the grinder is shutoff and tagged out.

2. Locate the flow directional arrows found on top of the grinder gear housing and on the main housing. Arrows point in the direction of flow.

3. Attach lifting cables to both grinder lifting eyebolts or lugs as shown in FIGURE 3-3 to position the grinder into its installation site.

4. Install the flange gaskets and bolt the grinder flanges to their mating flanges in the piping.

Bolts and gaskets are supplied by others.

5. Connect the electrical power from the grinder drive assembly to the motor controller panel.

(Connect the grinder to the HPP for hydraulic grinders.) Refer to the motor controller wiring diagram and site installation drawing for more information.

6. Verify that all electrical and mechanical connections are connected and secure.

7. Complete any required customer/user inspection records and forms.

3.4 STARTUP

The motor controller controls grinder operation.

Refer to the associated motor controller manual to perform grinder startup.

3.5 LONG TERM AND PERMANENT

SHUTDOWNS

Perform the following if the grinder is to be removed from service either permanently or for an extended time. For shutdowns longer than one (1) year, contact JWCE Customer Service for instructions.

For a long term shutdown remove and lock out electrical power to the motor controller and isolate the grinder from both upstream and downstream flow.

3-3

Perform the following procedure for shutdowns from six (6) months to twelve (12) months:

1. Remove the grinder from its installation site if possible.

2. Steam clean all parts (except the drive assembly) to clean and disinfect.

3. Clean the grinder using an appropriate solvent.

4. Completely fill the speed reducers with lubricant.

5. Rotate the grinder drive assembly for one (1) to five (5) minutes every three (3) months by hand if possible or for at least 15 revolutions. If the grinder cannot be operated manually, temporarily apply the appropriate power to the grinder drive assembly for one (1) to five (5) minutes. Check for lubricant leakage.

3.5.1 Permanent Shutdown

The following guidelines should be followed when the grinder is being taken out of service and not scheduled to return to service.

For returns, clean and disinfect the grinder prior to return to JWCE.

For on-site disposal, clean and disinfect the grinder. Disassemble the grinder as described in SECTION 6. Clean and disinfect the grinder components. Dispose of the motor and components in accordance with local, federal, and national safety and disposal regulations and standards. Apply warning and safety labels to materials and containers.

3-4

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30004T GRINDER MAINTENANCE

4-1

SECTION 4 MAINTENANCE

4.1 INTRODUCTION

SECTION 4 defines maintenance guidelines and identifies the lubricants, parts, and drawings required to support the 30004T grinder. Review all safety instructions before performing maintenance of the grinder. Refer to SECTION 5 for troubleshooting guidelines. Refer to SECTION 6 for removal and replacement instructions, the grinder exploded view for parts location and the parts list. Refer to the associated motor controller manual and the Electric Drive Assembly Maintenance Instructions - Appendix A for drive assembly maintenance and troubleshooting.

Contact JWCE Customer Service or local service representative for any maintenance information questions.

4.2 MAINTENANCE REQUIREMENTS

The following paragraphs describe the grinder scheduled maintenance activities. Recommended maintenance is required to make sure the grinder operates in peak condition. Refer to TABLE 4-1 for a five year summary of maintenance tasks and TABLE 4-2 for recommended lubricants and lubrication schedule. Refer to the Hydraulic Power Pack (HPP) manual for hydraulic fluid information.

Contact JWCE Customer Service or local service representative for questions on lubrication requirements, guidelines or recommended lubricants. Avoid mixing brands and/or types of lubricants.

Tasks are written for personnel experienced in same and/or similar equipment who are familiar with the basic operation, safety, emergency procedures, and use of plant tools/maintenance equipment. Time periods are based on normal operation usage and can be adjusted by the individual users depending on equipment usage and the operational environment. More frequent inspections may be required for grinders operating in harsh, extreme hot or extreme cold environments or processing abrasive or corrosive material.

4-2

TABLE 4-1 FIVE YEAR MAINTENANCE SCHEDULE

Maintenance Schedule - One Year

1 Year

ITEM 3 Months 6 Months 9 Months 12 Months

Grinders

Inspect cutters

Check stack tight-ness

Inspect seal car-tridges for leaks

Tighten loose exter-nal fasteners

Electric Drive

Inspect motor

Inspect speed reducer (Sumitomo)

Inspect speed reducer (Nord)

Inspect equipment coupling

Hydraulic Drive

Inspect torque motor

Inspect speed reducer (hi-torque models)

Inspect equipment coupling

Hydraulic Power Pack

Inspect oil quality Inspect oil quality Inspect oil quality

Replace hydraulic oil and filter every 12 mos. or 8000 service hours

Clean suction strainer

Clean suction strainer

Clean suction strainer

Clean suction strainer fedebra Line fedebra Line

4-3

Maintenance Schedule - Two Year

2 Years

ITEM 15 Months 18 Months 21 Months 24 Months

Grinders

Inspect cutters

Check stack tight-ness

Inspect seal car-tridges for leaks

Tighten loose exter-nal fasteners

Electric Drive

Inspect motor

Inspect speed reducer (Sumitomo)

Inspect speed reducer (Nord)

Inspect equipment coupling

Hydraulic Drive

Inspect torque motor

Inspect speed reducer (hi-torque models)

Inspect equipment coupling

Hydraulic Power Pack

Inspect oil quality Inspect oil quality Inspect oil quality

Replace hydraulic oil and filter every 12 mos. or 8000 service hours

Clean suction strainer

Clean suction strainer

Clean suction strainer

Clean suction strainer fedebra Line

4-4

Maintenance Schedule - Three Year

3 Years

ITEM 27 Months 30 Months 33 Months 36 Months

Grinders

Inspect cutters

Check stack tight-ness

Inspect seal car-tridges for leaks

Tighten loose exter-nal fasteners

Inspect gears/ grease quality (int.

operation)

Electric Drive

Inspect motor

Inspect speed reducer (Sumitomo)

Inspect speed reducer (Nord)

Inspect equipment coupling

Hydraulic Drive

Inspect torque motor

Inspect speed reducer (hi-torque models)

Inspect equipment coupling

Hydraulic Power Pack

Inspect oil quality Inspect oil quality Inspect oil quality

Replace hydraulic oil and filter every 12 mos. or 8000 ser-vice hours

Clean suction strainer

Clean suction strainer

Clean suction strainer

Clean suction strainer fedebra Line

4-5

Maintenance Schedule - Four Year

4 Year

ITEM 39 Months 42 Months 45 Months 48 Months

Grinders

Inspect cutters

Check stack tight-ness

Inspect seal car-tridges for leaks

Tighten loose exter-nal fasteners

Inspect gear grease quality if not changed at 36 mos.

Electric Drive

Inspect motor

Inspect speed reducer (Sumitomo)

Inspect speed reducer (Nord)

Inspect equipment coupling

Hydraulic Drive

Inspect torque motor

Inspect speed reducer (hi-torque models)

Inspect equipment coupling

Hydraulic Power Pack

Inspect oil quality Inspect oil quality Inspect oil quality

Replace hydraulic oil and filter every 12 mos. or 8000 ser-vice hours

Clean suction strainer

Clean suction strainer

Clean suction strainer

Clean suction strainer fedebra Line

4-6

Maintenance Schedule - Fifth Year

5 Year

ITEM 51 Months 54 Months 57 Months 60 Months

Grinders

Inspect cutters

Check stack tight-ness

Inspect seal car-tridges for leaks

Tighten loose exter-nal fasteners

Replace gear grease if not replaced earlier.

Electric Drive

Inspect motor

Inspect speed reducer (Sumitomo)

Inspect speed reducer (Nord)

Inspect equipment coupling

Hydraulic Drive

Inspect torque motor

Inspect speed reducer (hi-torque models)

Inspect equipment coupling

Hydraulic Power Pack

Inspect oil quality Inspect oil quality Inspect oil quality

Replace hydraulic oil and filter every 12 mos. or 8000 ser-vice hours

Clean suction strainer

Clean suction strainer

Clean suction strainer

Clean suction strainer fedebra Line

4-7

TABLE 4-2 RECOMMENDED LUBRICANTS and LUBRICATION SCHEDULE

4.3 INSPECTION/MAINTENANCE

The following paragraphs describe the inspection guidelines, preparation for inspection, and the inspection/maintenance defined for the grinder.

Refer to the motor controller manual for controller inspection guidelines and procedures. Refer to SECTION 6 for removal/replacement instructions, grinder exploded view and grinder parts list. The following guidelines should be observed during maintenance.

• Clean all gasket surfaces of all gasket material before installing a new gasket.

• Thoroughly clean end housing bores with suitable solvent. Replace housing if bores are scored, pitted, or other damage is identified.

• Avoid mixing brands and/or types of lubricants.

If the lubricant identified does not meet the requirements identified in this manual, contact the factory.

• Rinse and steam sanitize the grinder parts except the drive assembly. Solvent clean the exterior of the drive assembly.

• Inspect all components for cracks, damages, or evidence of excessive wear. Replace as required.

• Complete all required customer/user inspection records and forms.

TASK TYPE MANUFACTURER

Cutter stack lubrication Zep 45 Aerosol Lubricant*

WD-40 Aerosol Lubricant

Zep 45 Manufacturing

WD-40 Corp.

O-ring and seal cartridge replace-ment

MPG All Purpose Super Grease*/ white lithium grease

Nichels Engineering

Greasing of couplings and drive gears

Intermediate support collars

Mystic JT-6 Hi-Temp*

Lubriplate 930-AA

Mobil Temp No. 1, 2 or 78

Industrial Grease

Citgo

Fiske Bros. Refining

Mobil Oil

Chevron-Texaco

Grinder long term service removal LPS 3® Rust Inhibitor* LPS Laboratories

Lubricate gears Every 48 - 60 mos [Paragraph 4.4.2]

*OEM recommended

OPEN, LOCK OUT, AND TAG POWER TO

THE CONTROLLER PER SAFETY

PROCEDURES.

ISOLATE FLOW THROUGH THE PIPELINE

AS REQUIRED TO AVOID INJURY AND/OR

DAMAGE FROM FLOW PRESSURES AND/

OR INFLUENT. RELIEVE PRESSURE BY

CRACKING OPEN ONE OF THE GRINDER

FLANGES.

KEEP PERSONNEL AND UNAUTHORIZED

MATERIAL CLEAR OF GRINDER CUTTING

CHAMBER.

4-8

4.3.1 Visual

Check grinder for leakage, vibration, noise, or solids buildup on cutters and side rails. Check grinder output for proper solids reduction.

4.3.2 External Fasteners

Check grinder external fasteners - tighten if loose.

4.3.3 Drive Assembly and Coupling

Check that the grinder drive is free of contaminants and there are no signs of damage, overheating or lubricant leakage. Check the hardware securing the drive to the grinder for tightness. Using the drive plug inspection port, check for excessive wear on the coupling halves or if a gap exists between the halves.

4.3.4 Cutter Stack

Isolate flow from grinder. Check the grinder cutters for damage or wear. Damaged or worn cutters must be replaced if solids are not being properly reduced or if the grinder jams excessively.

Check cutter stack tightness by inserting a long screwdriver or similar tool in between adjacent cutters on each shaft and moving the tool up and down. Verify none of the cutters or spacers shift along the shaft axes when pushed. Cutters must be removed, cleaned, restacked and lubricated if any cutters or spacers shift along the shaft axes.

4.3.5 Seal Cartridge Assembly

Remove the drive assembly and the cutter cartridge per SECTION 6. Then remove the top and bottom covers. Check inside of the end housings for contaminants and leakage around or through the seal cartridge assembly. Check for a damaged O-ring where the seal cartridge assembly contacts the end housing bore if any leakage is present. Replace the entire seal cartridge assembly if influent leakage or contaminants are noted.

Clean end housing bores with a suitable solvent.

Replace the housing if bores are scored, pitted, or other damage is identified.

4.3.6 Grinder Drive Gears

Remove the grinder top cover per SECTION 6.

Check drive gears for cracks, broken teeth or excessive wear. Check the drive gear grease for contamination. Replace drive gear grease per Paragraph 4.4.2 if required.

4.4 LUBRICATION

Observe the following when lubricating the grinder:

• Set the motor controller switch to OFF. Open any controller circuit breaker or disconnect switch, then remove and tag out supply power before lubricating equipment.

• Avoid mixing brands and/or types of lubricants.

4.4.1 Grinder Drive Couplings

Remove the drive per SECTION 6 instructions.

Carefully remove old grease if necessary, and replace with new grease per Table 4-2.

4.4.2 Drive Gears

Remove top cover per SECTION 6 instructions.

Carefully remove the old grease and replace with new grease per Table 4-2. Apply grease in the recess between the coupling lobes. Replace the top cover.

4.4.3 Speed Reducer

The speed reducer is filled with grease at the factory and is ready for installation and operation.

JWCE uses maintenance-free, Cyclo-driven speed reducers.

4.5 PARTS INFORMATION

The parts lists included in SECTION 6 identify the parts for the standard configurations of the grinder.

JWCE does not recommend stocking of parts as spares which may or may not be used.

INSPECTION PORTS ARE NOT INTENDED

FOR HAND ACCESS.

30004T IN-LINE GRINDER

5-1

SECTION 5 TROUBLESHOOTING

5.1 INTRODUCTION

SECTION 5 describes 30004T grinder troubleshooting. Review all safety instructions before troubleshooting the grinder. TABLE 5-1 is a troubleshooting guide for the grinder. TABLE 5-2 is a troubleshooting guide for the grinder motor. Refer to SECTION 6 for the appropriate removal and replacement instructions based on troubleshooting results. Refer to the motor controller manual for causes and possible solutions not related to the grinder.

The grinder normally operates smoothly and quietly. Verify main power is available before troubleshooting. Power off and tag out main power to the motor controller if any excessive noise or temperature rise is observed and prior to grinder inspection.

PERSONAL AND MECHANICAL HAZARDS

EXIST WHEN THE GRINDER IS RUNNING.

POWER OFF AND TAG OUT GRINDER

PRIOR TO TROUBLESHOOTING

ELECTRICAL HAZARDS EXIST WHEN

TAKING VOLTAGE AND CURRENT

MEASUREMENTS. DO NOT TAKE

ELECTRICAL MEASUREMENTS ALONE.

TABLE 5-1 GRINDER TROUBLESHOOTING GUIDE

Symptom Possible Cause Solution

Grinder making noise.

Cutter stack loose.

Check stack tightness. If loose, remove, inspect, clean, and replace all cutters and spacers. Replace any damaged or worn cutters and spacers.

Damaged cutter(s) or spacer(s). Replace damaged cutter(s) or spacer(s).

Seal or bearing failure. Replace failed grinder seal cartridge.

Drive gears not sufficiently greased.

Clean and re-grease gears (replace gears if damage or excessive gear wear has occurred).

Cutter drive shaft not rotating.

Broken drive shaft below drive gear.

Replace drive shaft and check for ancillary damage. Return part to JWCE.

Cutter driven shaft not rotating.

Driven gear key failure.

Replace key if broken or missing. Contact factory if gear or shaft keyway is damaged.

Broken driven shaft.

Replace driven shaft and check for ancillary damage (return to factory).

30004T IN-LINE GRINDER TROUBLESHOOTING

5-2

Both cutter drive and driven shafts not rotating.

Drive coupling key failure.

Replace coupling key(s) if broken or missing. Contact JWCE if shaft keyways are damaged.

Drive coupling failure, drive lugs worn.

Replace coupling assembly. Check coupling keys for damage or wear.

Broken drive shaft.

Replace drive shaft and check for ancillary damage. Return part to JWCE.

Grinder gear reducer failure. Replace gear reducer.

Grinder motor failure. Refer to TABLE 5-2.

Grinder motor coupling key failure.

Replace coupling key(s) if broken or missing. Contact JWCE if shaft keyways are damaged.

Grinder motor coupling failure.

Replace coupling assembly. Check coupling keys for damage or wear.

Head drop across grinder excessive.

Downstream water conditions different from what was originally provided at application stage.

Refer to performance flow curve to determine required flow conditions.

Contact JWCE for assistance.

Grinder reverses excessively, but continues to run.

Cutters are worn and cannot effectively grind material.

Replace cutters and spacers.

Excessive solids loading or duty cycle.

Reduce solids loading or decrease duty cycle.

Grinder current sensor reverse threshold set too low.

Contact JWCE for assistance.

Excessive friction on components. Refer to symptom: Grinder making noise.

Debris buildup on drive shaft spacers.

Cutters excessively worn. Replace worn cutters.

Motor Controller indicates Grinder Overload.

Unusually large or troublesome solids entered grinder chamber.

Locate and remove troublesome solids from waste stream; reset controller and restart grinder per the controller O&M.

Excessive solids loading or duty cycle.

Reduce solids loading or decrease duty cycle.

Cutters excessively worn. Replace worn cutters.

Motor Controller indicates Grinder Motor Overload.

The grinder motor current draw exceeds the duration established by the controller.

Excessive solids loading or duty cycle.

Reduce solids loading or decrease duty cycle.

Excessive friction on components. Refer to symptom: Grinder making noise.

TABLE 5-1 GRINDER TROUBLESHOOTING GUIDE (Cont’d)

5-3

TABLE 5-2 GRINDER MOTOR TROUBLESHOOTING GUIDE

Symptom Possible Cause Solution

Motor does not start.

Line trouble such as single phasing at motor starter.

Check power source, overloads, fuses, controls, etc.

Hydraulic motor does not start.

Hydraulic Power Pack (HPP) not working.

Check HPP per appropriate manual.

Loose, disconnected or blocked hose.

Check hydraulic hose connections to the grinder and HPP.

Excessive humming.

High voltage. Check line connections.

Eccentric air gap. Contact factory to have motor serviced.

Hydraulic motor noisy or vibrating

Air in hydraulic fluid lines. Check HPP per appropriate manual.

Wrong type of hydraulic fluid used.

Verify the recommended hydraulic fluid was used to fill HPP.

Motor overheating.

Overloading of motor due to excessive friction or duty cycle.

Remove unwanted friction in motor;

reduce the duty cycle of equipment.

Single phasing or unbalanced voltage.

Verify the current for each motor leg. The current for each leg should be approximately equal, if not, isolate and correct.

Improper ventilation.

Verify cooling fan is operating correctly;

increase ventilation of motor; reduce ambient heat on motor.

Rotor rubbing on stator. Contact JWCE to have motor serviced.

Over or under voltage. Check input voltage on each leg.

Open stator winding. Check voltage on all legs.

Grounded winding.

Perform dielectric test and repair as required.

Improper connections.

Inspect all electrical connections for proper termination, clearance, mechanical strength, and electrical continuity. Refer to motor lead connections.

5-4

6-1

SECTION 6 REMOVAL AND REPLACEMENT

6.1 INTRODUCTION

SECTION 6 describes 30004T grinder assembly and component removal and replacement. Review all safety instructions before removing and replacing grinder assembly or components.

Grinder components can be reused unless broken or worn. Contact JWCE for questions regarding grinder service.

The following guidelines must be observed when removing and reinstalling the grinder.

• Clean end housing bores thoroughly with suitable solvent.

• Verify that all parts/components being assembled are clean and free of excess lubricants and gasket material.

• Inspect drive and driven shaft top and bottom seal assemblies. Mating surfaces must be clean and polished.

• Inspect all parts for cracks, nicks, burrs, excessive wear, or obvious signs (or suspected areas) of damage. Replace all damaged/suspected parts. Sealed bearings cannot be re-greased.

• Complete all required customer/user inspection records and forms if required.

6.2 GRINDER REMOVAL

The grinder can be removed from the installation without any disassembly or component removal.

The following procedure describes the removal of the grinder from the installation. Refer to the drawings at the back of this manual for part identification and location.

ISOLATE THE GRINDER FROM FLOW

THROUGH THE PIPELINE AND RELIEVE

ANY REMAINING PRESSURE.

OPEN, LOCKOUT, AND TAG POWER AT

THE DISCONNECT (OR CIRCUIT

BREAKER) TO THE CONTROLLER

BEFORE ANY DISASSEMBLY OR

REASSEMBLY PROCEDURES.

WEAR EYE AND EAR PROTECTION WHEN

STEAM CLEANING COMPONENTS.

COMPLY WITH ALL OSHA AND OTHER

REGULATORY AGENCY SAFETY

REQUIREMENTS.

DO NOT WEAR LOOSE FITTING

CLOTHING NEAR THE GRINDER.

USE EXTREME CARE WHEN USING ANY

SOLVENT.

Cutters And Spacers Are Sharp.

Appropriate Gloves Should Be Worn When Installing/Handling Cutters And Spacers To Prevent Injury During Handling.

Use Both Hoisting Rings/Lugs Mounted In The Grinder Top Cover To Lift The Grinder From The Installation.

30004T GRINDER REMOVAL AND REPLACEMENT

6-2

1. Verify that main power is removed from the motor controller. Disconnect any wiring to the grinder motor.

2. Attach lifting cables to the two hoisting rings or lugs on the top cover.

3. Maintain lifting tension and disconnect the grinder at the inlet and outlet flanges.

4. Lift the grinder. Place the grinder on the housing base on a level surface.

Replacing the grinder in the installation after assembly and/or maintenance is the same as the grinder installation instructions in SECTION 3.

6.3 GRINDER COMPONENT REMOVAL

AND REPLACEMENT

The following paragraphs contain procedures to remove grinder components. Replacement instructions are the reverse order of the removal instructions unless noted otherwise. Place removed components on a clean, flat, work surface to avoid damage and facilitate inspection.

Make sure that all mating surfaces are clean during grinder component replacement. Clean any gasket residue and replace gasket if required.

6.3.1 Cutter Cartridge Removal

The cutter cartridge can be removed from the main housing as a complete assembly (refer to FIGURE 6-1).

If required, an optional maintenance flange with or without a bar screen can be installed in the main housing if flow is to be reestablished through the grinder housing during cutter cartridge maintenance (refer to FIGURE 6-2).

Remove the cutter stack by attaching lifting cables to both eyebolts/lugs. Remove the screws securing the cutter cartridge at the top of the unibody housing and at the bottom of the housing. Slowly and steadily lift the cutter cartridge assembly clear of the main housing.

FIGURE 6-1 CUTTER CARTRIDGE REMOVAL

DO NOT LIFT HEAVY EQUIPMENT

OVERHEAD OF PERSONNEL. MAKE SURE

THAT ADEQUATE ASSISTANCE IS

AVAILABLE AND UTILIZED WHEN LIFTING

AND TRANSPORTING EQUIPMENT,

TOOLS, AND SUPPORT MATERIALS.

The Cutter Cartridge Assembly May Tip During Removal. Place The Cartridge Assembly On Wood Blocks Or Equivalent.

6-3

If the optional maintenance flange is being used, verify the base stand section is dry before installing a new main housing gasket on the main housing flange and a lower end housing gasket on the base stand.

FIGURE 6-2 MAINTENANCE FLANGE OPTIONS

6.3.2 Cutter and Spacer Removal

Perform the following procedure to remove and replace the cutters and spacers. Refer to Paragraph 6.3.4 for correct cutter and spacer stacking.

1. Remove the drive assembly following the directions in the Electric Drive Assembly Maintenance Instructions, Appendix A.

2. Remove the cutter cartridge assembly from the main housing per Paragraph 6.3.1.

3. Remove the drive coupling and its key from the drive shaft.

4. Stand the cutter assembly on the bottom end housing.

5. Remove the stack nut access cover.

6. Remove the shaft tightening access pipe plug.

7. Lock the drive shaft hex nut through the access port with a 2¼ inch wrench.

8. Loosen the socket headed cap screw.

9. Remove the top cover from the gear housing.

10. Remove the oil seal from the top cover.

11. Remove the hex nut from the drive shaft.

12. Remove the socket headed cap screw and stack washer from the driven shaft.

13. Remove the drive and driven gears followed by the bushing spacers located on each shaft.

14. Remove the gear keys from the drive and driven shafts.

15. Remove the gear housing from the upper end housing.

16. Remove the upper end housing.

17. Remove the compression disks from the drive and driven shafts.

18. Carefully note the spacer/cutter stacking configuration and the helical pattern of the cutter stack prior to disassembly to ease the restacking of the cutters and spacers.

19. Remove all cutters and spacers. For the 24 inch cutter stack, an intermediate shaft support assembly is installed in the center of the cutter stack to provide additional support.

20. Place the lower end housing with the drive and drives shafts still installed on its side using wood blocks to support the drive and driven shafts.

21. Remove the retaining rings.

22. Remove the gib key from the drive and driven shafts.

Cutters And Spacers Are Sharp.

Appropriate Gloves Must Be Worn When Installing Or Handling Cutters And Spacers To Prevent Injury During Handling.

MAINTENANCE

FLANGE WITH

BAR SCREEN

MAINTENANCE

FLANGE

6-4

23. Remove the lower end housing from the two shafts and place on a clean, flat surface for inspection.

24. Remove the seal rings from both ends of the drive and driven shafts.

25. Remove the compression disk from the drive and driven shafts.

26. During replacement, the compression disc must be installed prior to installing the seal O-ring to prevent tearing the seal O-ring. Apply a light coat of grease (Nichels Engineering MPG All Purpose Super Grease or white lithium grease) on the seal ring.

27. Ensure the end housing bushing deflectors are at the influent (feed flow) side when replacing the upper end housing over the end of the drive and driven shafts.

28. Verify the flow arrow is pointed in the correct direction before lowering the main housing onto the standard base.

6.3.3 End Housing Removal

Disassembly of the top and bottom housing is the same (with the exception of the bearing spacers installed in the top housing) and performed as described in the following procedure. Replace the seal cartridge assembly if there is leakage, when bearing(s) do not rotate in the seal cartridge, or if resistance is encountered during bearing rotation.

1. Place the end housings on a clean, flat work surface.

2. Remove bearing spacer (top end housing only) and press the seal cartridge out of the housing bearing bore.

3. Check each seal cartridge for damage and for ease of rotation.

4. Remove the end housing O-rings.

5. Thoroughly clean housing bores with solvent.

Inspect the end housing bores for signs of damage or wear. Contact JWCE or local representative if the bores are damaged, scored, pitted, or show signs of wearing, otherwise, store the end housing in a secure location to prevent damage until reassembled.

6. Coat the end housing bores with a thin film of grease (Nichels Engineering MPG All Purpose Super Grease or white lithium grease) when installing O-rings.

7. Lightly coat the seal cartridge assembly with grease during reassembly.

8. Make sure the seal cartridge notches line up with the dowel pins before pressing into the housing.

6.3.4 Stacking Cutters and Spacers

The meshed, helical stack of cutters is formed by alternately placing a cutter and a spacer on the grinder drive and driven shafts. An intermediate shaft support assembly is installed in the center of the 32 inch cutter stack to provide additional support for the shafts. The following procedure describes the installation of the cutters, spacers and intermediate shaft support assembly.

1. Clear and clean the work space around the assembled end housing.

2. Verify that the correct quantity of cutters and spacers for the grinder are on hand. Refer to the drawings at the back of this manual.

3. Verify all cutters and spacers are clean, free of cracks, signs of excessive wear, and/or other obvious signs of damage.

4. Verify the cutter drive and driven shafts are free of any burrs. File and clean off any burrs.

5. Install two dowel pins into the standard base and install a gasket on the standard base.

Install the bottom end housing with the drive and driven shafts (shafts are vertical). The dowel pins will fit loosely in the bottom end housing.

6. Verify one cutter tooth on each cutter is marked with an indexing mark (dimple or

Verify That Foreign Material Does Not Become Trapped Between the Stack Components. Trapped Material Can Affect Stack Height and Cutter Meshing Tolerance.

6-5 notch) used to properly assemble the cutters during stacking.

7. Refer to FIGURE 6-3 for orientation of the cutters on the drive and driven shafts. Ensure correct cutter installation by maintaining proper shaft orientation during the stacking process.

The drive shaft is numbered clockwise and driven shaft is numbered counterclockwise.

FIGURE 6-3 CUTTER ORIENTATION

8. Install a cutter on the drive shaft with the index mark at position 1.

9. Install a spacer on the driven shaft and a spacer on the drive shaft.

10. Install a cutter on the driven shaft with the index mark at position 1.

11. Install the next cutter on the drive shaft with the index mark (dimple or notch) at position 2 and then install a spacer on the driven shaft.

12. Install a cutter on the driven shaft with the index mark (dimple or notch) at position 2 and then install a spacer on the drive shaft.

13. Repeat steps 8 through 12, rotating the index mark of the cutter one position at a time until the stack is complete. Verify the cutting stack ends with a spacer on the drive shaft and a cutter on the driven shaft and forms a helical pattern “V” shape. Refer to FIGURE 6-4.

14. Inspect stack for correct quantity or required cutters and spacers on the drive and drive shafts. Refer to the drawings at the back of this manual.

15. Install washers and apply Loctite adhesive to the drive and driven shaft stack screw threads.

Install the drive and driven shaft stack screws.

Torque the drive and driven stack screws to 135 ft. lbs. (184 Nm).

16. Verify cutter stack tightness. Refer to Paragraph 4.3.4.

FIGURE 6-4 CUTTER STACKING

Ensure Components Are Stacked Correctly To Prevent Damage. The Drive Shaft Is Always Started With A Cutter And The Driven Shaft Is Always Started With A Spacer.

INFLUENT

INDEXING

DIMPLE

INDEXING

NOTCH

INSTALLATION

ORDER OF CUTTERS:

(1, 2, 3, 4, 5, 6, 1, 2, ETC.)

ROTATION OF

SHAFT WHILE

OPERATING

ROTATION OF

SHAFT WHILE

OPERATING

6-6

6.3.5 Drive Gear, Driven Gear and Shaft

Removal and Replacement

All cutters and spacers must be removed per Paragraph 6.3.2 before the bearings can be inspected or the drive gears removed and replaced.

1. Turn the assembly over and clamp the drive and driven shafts in a vise to prevent the shafts from dropping free during gear removal.

2. Remove the socket headed screws from the top cover.

3. Remove the top cover with the oil seal, outboard roller bearing outer race and end housing gasket.

4. Remove the end housing gasket material from the top cover and end housing mating surfaces.

5. Inspect the drive and driven outboard bearing outer races for evidence of wear or damage.

JWCE does not recommend removal of the outboard roller bearing. Contact JWCE if the outboard roller is worn or damaged.

6. Verify that the drive and driven shafts are clamped (Step 1) and remove the snap ring retainers from the drive and driven shafts.

7. Slide the inner races off the shafts. Inspect the inner races for evidence of wear or damage.

JWCE does not recommend removal of the outboard roller bearing. Contact JWCE if the outboard roller is worn or damaged.

8. Remove the gear spacers from the drive and driven shafts.

9. Remove the drive and driven gears and gear keys from the drive and driven shafts. Clean and inspect the gears. Replace the gear(s) if there are signs of wear, cracks, or if other obvious damage is noted.

10. Remove the gib key from the drive and driven shafts.

11. With a slow, even pull, remove the drive and driven shafts from the top end housing. Place the shafts on a clean, flat work surface. Inspect the shafts for cracks, excessive wear, and/or other obvious signs of damage. Contact JWCE if shafts are damaged or if damage is suspected.

12. Inspect the drive and driven shaft O-rings.

Replace O-rings if worn or damaged.

During replacement, support the top end housing and drive shafts to prevent damage to the shafts, O-rings and seal cartridge assembly when inserting the shaft into the top end housing seal cartridge assembly. Avoid damaging the O-rings when replacing the cutter assembly shafts into the housings. Apply grease (Nichels Engineering MPG All Purpose Super Grease or white lithium grease) to the O-ring. Replace the O-ring if it is damaged.

6.3.6 Seal Cartridge Removal and Inspection

Remove the seal support plate from the top end housing. Remove the seal cartridge assemblies from the top end housing. A hydraulic press may be needed to remove the seal cartridge assemblies.

Inspect the seal cartridge for…