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Service & Maintenance manual

High Speed Separator


AFPX 513XGD-14/74CG

Product No. 881135-21-01/5


Book No. 1271468-02 Rev. 3
Published By:
Alfa Laval Tumba AB
SE-147 80 Tumba, Sweden
Telephone: +46 8 530 650 00
Telefax: +46 8 530 310 40

© Alfa Laval Tumba AB 02 May 2006


This publication or any part there of may not be
reproduced or transmitted by any process or
means without prior written permission of
Alfa Laval Tumba AB.
Contents
1 Safety Instructions 9

1.1 Warning signs in text 14


1.2 Environmental issues 15
1.3 Requirements of personnel 16

2 Maintenance Directions 17

2.1 Periodic maintenance 17


2.1.1 Introduction 17
2.1.2 Maintenance intervals 17
2.1.3 Maintenance procedure 19
2.1.4 Service kits 20
2.2 Maintenance Logs 21
2.2.1 Daily checks 21
2.2.2 Lubrication of electric motor 21
2.2.3 Oil change 21
2.2.4 Intermediate Service (IS) 22
2.2.5 Major Service (MS) 24
2.2.6 3-year Service (3S) 26
2.3 Cleaning 27
2.3.1 Cleaning agents 27
2.3.2 External cleaning 28
2.3.3 Cleaning of bowl discs 29
2.4 When changing oil 30
2.4.1 Worm wheel and worm; wear of teeth 30
2.4.2 Oil change procedure 33
2.5 Lubricants 34
2.5.1 Lubrication chart, general 34
2.5.2 Recommended lubricating oils 36
2.5.3 Recommended oil brands 37
2.5.4 Recommended lubricants 38
2.6 Vibration 42

3
2.6.1 Vibration analysis 42
2.7 Common maintenance directions 43
2.7.1 Ball and roller bearings 43
2.7.2 Before shutdowns 47

3 Dismantling/Assembly 49

3.1 Introduction 49
3.1.1 General directions 49
3.1.2 References to checkpoints 50
3.1.3 Tools 50
3.1.4 Tightening of screws 50
3.2 Intermediate Service (IS), dismantling 51
3.2.1 Inlet/outlet and frame hood 51
3.2.2 Bowl hood and disc stack 56
3.2.3 Bowl body and operating mechanism 62
3.2.4 Operating liquid device (IS) 66
3.3 Intermediate Service (IS), checkpoints 70
3.3.1 Introduction 70
3.3.2 Bowl hood seal ring 70
3.3.3 Bowl spindle cone and bowl body nave 71
3.3.4 Corrosion 72
3.3.5 Cracks 74
3.3.6 Dosing ring 75
3.3.7 Erosion and wear liners 75
3.3.8 Guide surfaces 79
3.3.9 Inlet pipe threads and paring disc 81
3.3.10 Lock ring; wear and damage 82
3.3.11 Operating mechanism 83
3.3.12 Operating slide 84
3.3.13 Springs for operating mechanism 84
3.3.14 Sliding bowl bottom 85
3.3.15 Worm wheel and worm; wear of teeth 85
3.3.16 Speed sensor 86
3.3.17 Vibration sensor 86
3.3.18 Cover interlocking switch (option) 87

4
3.3.19 Limits switch 87
3.4 Intermediate Service (IS), assembly 88
3.4.1 Introduction 88
3.4.2 Lubrication 88
3.4.3 Operating liquid device 89
3.4.4 Bowl body and operating mechanism 93
3.4.5 Bowl hood and disc stack 96
3.4.6 Inlet/outlet and frame hood 103
3.5 Major Service (MS), dismantling 107
3.5.1 Introduction 107
3.5.2 Horizontal driving device 118
3.6 Major Service (MS), checkpoints 122
3.6.1 Introduction 122
3.6.2 Lock ring; priming 122
3.6.3 Brake 124
3.6.4 Buffer springs and ball bearing housing 126
3.7 Major Service (MS), assembly 127
3.7.1 Introduction 127
3.7.2 Horizontal driving device 128
3.7.3 Vertical driving device 133

Index 145

5
6
Read and understand instruction manuals
and observe the warnings before installation,
operation, service and maintenance.

Not following the instructions can result in


serious accidents.

In order to make the information clear only foreseeable conditions


have been considered. No warnings are given, therefore, for
situations arising from the unintended usage of the machine and its
tools.

7
8
1 Safety Instructions

The centrifuge includes parts that rotate at high


speed. This means that:
• Kinetic energy is high
• Great forces are generated

G0010421
Stopping time is long

Manufacturing tolerances are extremely fine.


Rotating parts are carefully balanced to reduce
undesired vibrations that can cause a breakdown.
Material properties have been considered
carefully during design to withstand stress and
fatigue.
The separator is designed and supplied for a
specific separation duty (type of liquid, rotational
speed, temperature, density etc.) and must not be
used for any other purpose.
Incorrect operation and maintenance can result in
unbalance due to build-up of sediment, reduction
of material strength, etc., that subsequently could
lead to serious damage and/or injury.
The following basic safety instructions therefore
apply:
• Use the separator only for the purpose
and parameter range specified by
Alfa Laval.
• Strictly follow the instructions for
installation, operation and maintenance.
• Ensure that personnel are competent and
have sufficient knowledge of maintenance
and operation, especially concerning
emergency stopping procedures.
S0151211

• Use only Alfa Laval genuine spare parts


and the special tools supplied.

9
1 Safety Instructions

Disintegration hazards

• When power cables are connected,


always check direction of motor rotation.
If incorrect, vital rotating parts could
unscrew.

S01512F1
• If excessive vibration occurs, stop
separator and keep bowl filled with
liquid during rundown.

S01512N1
• Use the separator only for the purpose
and parameter range specified by
Alfa Laval.

S01512P1
• Check that the gear ratio is correct for
power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.

S01512L1
• Since the separator is equipped with a
frequency controlled motor, it is
extremely important to ensure that the
motor speed does not exceed the
allowed maximum speed. A serious
break down may be the consequence.
• Welding or heating of parts that rotate
can seriously affect material strength.
S0151241

• Wear on the large lock ring thread must


not exceed safety limit. φ-mark on lock
ring must not pass opposite φ-mark by
more than specified distance.
S01512G1

• Inspect regularly for corrosion and


erosion damage. Inspect frequently if
process liquid is corrosive or erosive.
S01512H1

10
1 Safety Instructions

Entrapment hazards

• Make sure that rotating parts have come


to a complete standstill before starting
any dismantling work.

S01512O1
• To avoid accidental start, switch off and
lock power supply before starting any
dismantling work.

S0151261
Assemble the machine completely
before start. All covers and guards must
be in place.

Electrical hazard

• Follow local regulations for electrical


installation and earthing (grounding).
• To avoid accidental start, switch off and

S0151271
lock power supply before starting any
dismantling work.

Crush hazards

• Use correct lifting tools and follow lifting


instructions.
S01512M1

Do not work under a hanging load.


S01512Y1

11
1 Safety Instructions

Noise hazards

• Use ear protection in noisy


environments.

S0151291
Burn hazards

• Lubrication oil and various machine


surfaces can be hot and cause burns.

S01512A1
Skin irritation hazards

• When using chemical cleaning agents,


make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
S01512D1

protection etc.
• Use of lubricants in various situations.

12
1 Safety Instructions

Cut hazards

• Sharp edges on bowl discs and threads


can cause cuts.

S01512B1
Flying objects

• Risk for accidental release of snap rings


and springs when dismantling and
assembly.

S01512C1
Health hazard

• Risk for unhealthy dust when handling


friction blocks/pads. Use a dust mask to
make sure not to inhale any dust

S01512V1

13
1 Safety Instructions

1.1 Warning signs in text


Pay attention to the safety instructions in this
manual. Below are definitions of the three grades
of warning signs used in the text where there is a
risk for injury to personnel.

DANGER

Type of hazard

DANGER indicates an imminently


hazardous situation which, if not avoided,
will result in death or serious injury.

WARNING

Type of hazard

WARNING indicates a potentially


hazardous situation which, if not avoided,
could result in death or serious injury.

CAUTION

Type of hazard

CAUTION indicates a potentially


hazardous situation which, if not avoided,
may result in minor or moderate injury.

NOTE
NOTE indicates a potentially hazardous
situation which, if not avoided, may result
in property damage.

14
1 Safety Instructions

1.2 Environmental issues

Unpacking
Packing material consists of wood, plastics,
cardboard boxes and in some cases metal straps.
Wood and cardboard boxes can be reused,
recycled or used for energy recovery.
Plastics should be recycled or burnt at a licensed
waste incineration plant.
Metal straps should be sent for material recycling.

Maintenance
During maintenance oil and wear parts in the
machine are replaced.
Oil must be taken care of in agreement with local
regulations.
Rubber and plastics should be burnt at a licensed
waste incineration plant. If not available they
should be disposed to a suitable licensed land fill
site.
Bearings and other metal parts should be sent to
a licensed handler for material recycling.
Seal rings and friction linings should be disposed
to a licensed land fill site. Check your local
regulations.
Worn out or defected electronic parts should be
sent to a licensed handler for material recycling.

15
1 Safety Instructions

1.3 Requirements of
personnel
Only skilled or instructed persons are allowed to
operate the machine, e.g. operating and
maintenance staff.
• Skilled person: A person with technical
knowledge or sufficient experience to enable
him or her to perceive risks and to avoid
hazards which electricity/mechanics can
create.
• Instructed person: A person adequately
advised or supervised by a skilled person to
enable him or her to perceive risks and to
avoid hazards which electricity/mechanics
can create.
In some cases special skilled personnel may
need to be hired, like electricians and others. In
some of these cases the personnel has to be
certified according to local regulations with
experience of similar types of work.

16
2 Maintenance Directions

2.1 Periodic maintenance

2.1.1 Introduction
Periodic (preventive) maintenance reduces the
risk of unexpected stoppages and breakdowns.
Follow the maintenance logs on the following
pages in order to facilitate the periodic
maintenance.

WARNING

Disintegration hazards

Separator parts that are either worn beyond


their safe limits or incorrectly assembled may
cause severe damage or fatal injury.

2.1.2 Maintenance intervals


The following directions for periodic maintenance
give a brief description of which parts to be
cleaned, checked and renewed at different
maintenance intervals.
The maintenance logs for each maintenance
interval later in this chapter give detailed
enumeration of the check points that must be
done.
Daily checks consist of minor check points to
carry out for detecting abnormal operating
conditions.

Oil change
The oil change interval is every 1000-1500 hours
or at least once every year if the total number of
operating hours is less than 1000-1500 hours.

17
2.1 Periodic maintenance 2 Maintenance Directions

Intermediate Service (IS)


Intermediate Service consists of an overhaul of
the separator bowl, inlet/outlet and operating
device every 3 months or 2000 operating hours.
Seals in bowl and gaskets in inlet/outlet device
are renewed.

Major Service (MS)


Major Service consists of an overhaul of the
complete separator and includes an Intermediate
Service every 12 months or 8000 operating
hours. Seals and bearings in the bottom part are
renewed.

3-year Service (3S)


3-year Service consists of renewing the frame
feet. The feet get harder with increased use and
age.

Periodic maintenance schedule


Oil change
Intermediate Service = IS
Major Service = MS
3-year Service = 3S
3S
MS MS MS
IS IS IS IS IS IS IS IS IS IS IS IS

Installation 1st year 2nd year 3rd year

18
2 Maintenance Directions 2.1 Periodic maintenance

2.1.3 Maintenance procedure


At each Intermediate and Major Service, take a
copy of the maintenance log and use it for
notations during the service.
An Intermediate and Major Service should be
carried out in the following manner:
1. Dismantle the parts as mentioned in the
maintenance log and described in chapter ‘‘3
Dismantling/Assembly” on page 49.
Place the separator parts on clean, soft
surfaces such as pallets.
2. Inspect and clean the dismantled separator
parts according to the maintenance log.
3. Fit all the parts delivered in the service kit
while assembling the separator as described
in chapter ‘‘3 Dismantling/Assembly” on page
45. The assembly instructions have
references to check points which should be
carried out before and during the assembly.

19
2.1 Periodic maintenance 2 Maintenance Directions

2.1.4 Service kits


Special service kits are available for Intermediate
Service (IS) and Major Service (MS), as well as
for servicing the frame feet (3S).
For other services the spare parts have to be
ordered separately.

S0021021
Note that the parts for IS are not included in the
MS kit and parts for IS and MS are not included
in the 3S kit. Kits are available for Intermediate Service, Major
Service and for servicing the frame feet
The contents of the service kits are described in
the Spare Parts Catalogue.

NOTE
Always use Alfa Laval genuine parts as
otherwise the warranty will become invalid.
Alfa Laval takes no responsibility for the safe
operation of the equipment if non-genuine
spare parts are used.

WARNING

Disintegration hazards

Use of imitation parts may cause severe


damage.

20
2 Maintenance Directions 2.2 Maintenance Logs

2.2 Maintenance Logs

2.2.1 Daily checks


The necessary daily checks to be carried out for a
safe operation are enumerated in chapter
Running in the Operator´s Manual.

2.2.2 Lubrication of electric motor


The bearings of the electric motor shall be
greased with intervals that is dependent of the
motor speed (50 or 60 Hz), ambient temperature
and if the bearing is located on the driving end or
non driving end.
The recommended interval can vary from 250 up
to 5000 operating hours.
Correct lubrication interval and recommended
type of grease can be found on a plate fixed on
the motor. The information can also be found in
chapter Motor specifications in the Installation
Manual.

2.2.3 Oil change


The oil change and check of worm gear should be
carried out every 1000-1500 hours of operation.
Note: In a new installation, or after replacement
of gear, change the oil after 200 operating hours
and clean the gear housing.

Main component and activity Part Page Notes


Horizontal driving device
Worm wheel shaft and gear housing
Check Worm wheel and worm 30
Renew Oila) in gear housing 33
When the separator is running for short periods, the
lubricating oil must be changed every 12 months even
if the total number of operating hours is less than
1000-1500 hours (2000 h).
a)
See chapter ‘‘2.5 Lubricants” on page 34 for
further information.

21
2.2 Maintenance Logs 2 Maintenance Directions

2.2.4 Intermediate Service (IS)


Name of plant: Local identification:
Separator: AFPX 513XGD-14/74CG Manufacture No./Year:
Total running hours: Product No: 881135-21-01/4
Date: Signature:

Main component and activity Part Page Notes


Inlet and outlet
Clean and inspect Connecting housing –
Threads of inlet pipe 77
Paring disc -
Separator bowl
Clean and check Lock ring 78
Bowl hood 66
Bowl discs 29
Distributor –
Distributing cone –
Sliding bowl bottom 81
Bowl body –
Guide surfaces 75
Bowl spindle cone and bowl 67
body nave
Operating mechanism 71, 79,
80, 80,
Paring chamber
Check Corrosion 68
Cracks 70
Erosion and wear liners 71
Galling of guide surface 76
Disc stack pressure 97
Renew O-rings and sealings –

22
2 Maintenance Directions 2.2 Maintenance Logs

Main component and activity Part Page Notes


Operating liquid device
Clean and check Operating liquid device –
Renew O-rings –
Horizontal driving device
Worm wheel shaft and gear housing
Check Worm wheel and worm 30
Renew Oil in gear housing 33
Electrical motor
Lubrication (if nipples are fitted) See sign on motor –
Signs and labels on separator
Check attachment and legibility Safety label on hood -
Direction of rotation arrow -
Power supply frequency -
Monitoring equipment
Function check Vibration sensor 82
Speed sensor 82
Cover interlocking switch 83
(option)
Note: Renew all parts included in the Intermediate Service kit (IS).

23
2.2 Maintenance Logs 2 Maintenance Directions

2.2.5 Major Service (MS)

Name of plant: Local identification:


Separator: AFPX 513XGD-14/74CG Manufacture No./Year:
Total running hours: Product No: 881135-21-01/4
Date: Signature:

Main component and activity Part Page Notes


Inlet and outlet
Clean and inspect Connecting housing –
Threads of inlet pipe 77
Paring disc -
Separator bowl
Clean and check Lock ring 78
Bowl hood 66
Bowl discs 29
Distributor –
Distributing cone –
Sliding bowl bottom 81
Bowl body –
Guide surfaces 75
Bowl spindle cone and bowl 67
body nave
Operating mechanism 71, 79,
80, 80,
Paring chamber
Check Corrosion 68
Cracks 70
Erosion and wear liners 71
Galling of guide surface 76
Disc stack pressure 97
Height position of outlet 101
paring disc
Renew O-rings and sealings –

24
2 Maintenance Directions 2.2 Maintenance Logs

Main component and activity Part Page Notes


Operating liquid device
Clean and check Operating liquid device –
Check Height position 88
Renew O-rings –
Vertical driving device
Clean and check Bowl spindle –
Buffer springs and ball 122
bearing housing
Check Radial wobble of bowl spindle 135
Renew Spindle bearings, sealings 129
and rubber buffers
Horizontal driving device
Worm wheel shaft and gear housing
Check Worm wheel and worm 30
Radial wobble of worm wheel 128
shaft
Renew Bearings, O-rings and 114
sealings
Oil in gear housing 33
Brake
Clean and check Spring and brake shoe 121
Renew Friction pad 120
Flexible coupling
Check Axial play of elastic plates 126
Electrical motor
Lubrication (if nipples are fitted) See sign on motor –
Signs and labels on separator
Check attachment and legibility Safety label on hood -
Direction of rotation arrow -
Power supply frequency -
Monitoring equipment
Function check Vibration sensor 82
Speed sensor 82
Cover interlocking switch 83
(option)
Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS).

25
2.2 Maintenance Logs 2 Maintenance Directions

2.2.6 3-year Service (3S)


Renew the frame feet as described below. The 3-
year service should be carried out in conjunction
with a Major Service (MS). The extent of the 3-year
service is the same as for a major service plus
renewing the parts included in the 3-year Service kit
(3S).

Frame feet, renewal


1. Disconnect pipes, hoses and cables connected
to the separator.
2. Remove the nuts (1, 2).
3. Lift the separator.

NOTE
When lifting a separator it must always hang
securely. See separate instruction in chapter
Lifting instructions in the Installation Manual.

G0258921
4. Renew the vibration dampers (3, 4).
5. Lower the frame. Check that the bolts do not 1. Lock nut
press against the edges of the holes. 2. Nut
3. Vibration damper, upper
6. Tighten the nut (2) to 20 Nm. 4. Vibration damper, lower

7. Hold the nut (2) firmly and secure with the lock
nut (1).
8. Connect the previously disconnected pipes,
hoses and cables.
.

26
2 Maintenance Directions 2.3 Cleaning

2.3 Cleaning

2.3.1 Cleaning agents


When using chemical cleaning agents, make sure
you follow the general rules and suppliers’
recommendations regarding ventilation,
protection of personnel, etc.

For separator bowl, inlet and outlet


A chemical cleaning agent must dissolve the
deposits quickly without attacking the material of
the separator parts.

CAUTION

Skin irritation hazard

Read the instructions on the label of the


container before using the chemical cleaning
agent.
Always wear safety goggles, gloves and
protective clothing as the liquid is alkaline
and dangerous to skin and eyes.

For operating mechanism


Use 10% acetic acid solution to dissolve lime
deposits. The acid should be heated to 80 °C.

For parts of the driving devices


Use white spirit, cleaning-grade kerosene or
diesel oil.

Oiling (protect surfaces against corrosion)


Protect cleaned carbon steel parts against
corrosion by oiling. Separator parts that are not
assembled after cleaning must be wiped and
coated with a thin layer of clean oil and protected
from dust and dirt.

27
2.3 Cleaning 2 Maintenance Directions

2.3.2 External cleaning


The external cleaning of the frame and motor
should be restricted to brushing, sponging or
wiping while the motor is running or is still hot.
Never wash down a separator with a direct water
stream. Totally enclosed motors can be damaged
by direct hosing to the same extent as open
motors and even more than those, because:
• Many operators believe that these motors are
sealed, and normally they are not.

G0545121
• A water jet played on these motors will
produce an internal vacuum, which will suck Never wash down a separator with a direct water
the water between the metal-to-metal contact stream or playing a water jet on the motor
surfaces into the windings, and this water
cannot escape.
• Water directed on a hot motor may cause
condensation resulting in short-circuiting and
internal corrosion.
Be careful even when the motor is equipped with
a protecting hood. Never play a water jet on the
ventilation grill of the hood (if any).

G0545131
Use a sponge or cloth and a brush when cleaning

28
2 Maintenance Directions 2.3 Cleaning

2.3.3 Cleaning of bowl discs


Handle the bowl discs carefully so as to avoid
damage to the surfaces during cleaning.

NOTE

Mechanical cleaning is likely to scratch the


disc surfaces causing deposits to form
quicker and adhere more firmly.
A gentle chemical cleaning is therefore
preferable to mechanical cleaning.

CAUTION

Cut hazard

Sharp edges on the separator discs may


cause cuts.

1. Remove the bowl discs from the distributor


and lay them down, one by one, in the
cleaning agent.

G0065831
2. Let the discs remain in the cleaning agent
until the deposits have been dissolved. This Put the discs one by one into the cleaning agent
will normally take between two and four
hours.
3. Finally clean the discs with a soft brush.
G0065841

Clean the discs with a soft brush

29
2.4 When changing oil 2 Maintenance Directions

2.4 When changing oil

2.4.1 Worm wheel and worm;


wear of teeth
To check at each oil change
Check the teeth of both the worm wheel and
worm for wear. Examine the contact surfaces and
compare the tooth profiles with the ‘‘ Tooth
appearance examples” on page 32. The gear may
operate satisfactorily even when worn to some
degree.
• Replace both worm wheel and worm at the
same time, even if only one of them is worn.

G0205311
To avoid damaging the teeth when lifting the
bowl spindle: push the worm wheel to one
side first. 1 Worm
Position the spindle in correct place before 2 Worm wheel
fitting the worm wheel.
When replacing the gear, always make sure that
the new worm wheel and worm have the same
number of teeth as the old ones. See chapter
Technical data in the Installation Manual for
correct number of teeth.

WARNING

Disintegration hazards

Check that gear ratio is correct for power


frequency used. If incorrect, subsequent
overspeed may result in a serious
G0205411

breakdown.

Check the gear ratio (number of teeth) when replacing


the gear

NOTE
Presence of metal chips in the oil bath is an
indication that the gear is wearing
abnormally.

30
2 Maintenance Directions 2.4 When changing oil

Important!
When using mineral-type oil in the worm gear
housing, the presence of black deposits on the
spindle parts is an indication that the oil base has
deteriorated seriously or that some of the oil
additives have precipitated. If pitting is found on
the worm gear, the cause could be that the
additives are not suitable for this purpose.
In all these cases it is imperative to change to a
high-temperature oil.
For further information, see chapter ‘‘2.5
Lubricants” on page 34.

31
2.4 When changing oil 2 Maintenance Directions

Tooth appearance examples

Satisfactory teeth:
Uniform wear of contact surfaces. Surfaces are
smooth.
Good contact surfaces will form on the teeth when

G0538711
the gear is subjected to only moderate load
during its running-in period.
Satisfactory teeth

Worn teeth:
Permissible wear is as a rule 1/3 of the thickness
of the upper part of a tooth, provided that
• the wear is uniform over the whole of the flank

G0538811
of a tooth
• and all teeth are worn in the same way. Worn teeth

Spalling:
Small bits of the teeth have broken off, so-called
spalling. This is generally caused by excessive
load or improper lubrication. Damage of this type

G0538911
may not necessitate immediate replacement, but
careful checking at short intervals is of imperative
importance. Spalling

Pitting:
Small cavities in the teeth, so-called pitting, can
occur through excessive load or improper
lubrication. Damage of this type need not
necessitate immediate replacement, but careful
G0539011

check at short intervals is of imperative


importance.
Pitting

32
2 Maintenance Directions 2.4 When changing oil

2.4.2 Oil change procedure

NOTE
Before adding or renewing lubricating oil in
the worm gear housing, the information
concerning different oil groups, handling of
oils, oil change intervals etc. given in chapter
‘‘2.5 Lubricants” on page 34 must be well
known.

G0134411
1. Cover
2. Sight glass
3. Oil drain plug

1. Place a collecting tray under the drain hole,


remove the drain plug (3) and then drain off
the oil.

CAUTION

G0035921
Burn hazards

Lubricating oil and various machine surfaces Burn hazards: The drained oil may be hot
can be sufficiently hot to cause burns.

2. Fill new oil in the worm gear housing. The oil


level should be slightly above middle of the
sight glass.
Oil volume: approx. 8 litres.
Suitable oil brands can be found in ‘‘2.5.3
Recommended oil brands” on page 37.
G0262011

NOTE
The oil level must not be above the middle of the sight
During operation the oil level must be slightly glass
below the middle of the sight glass.
If the oil level is too high, the lifetime of the
rolling bearings will be reduced due to high
temperature.

33
2.5 Lubricants 2 Maintenance Directions

2.5 Lubricants

2.5.1 Lubrication chart, general


Alfa Laval ref. 553216-01, rev. 6

Lubricating points Lubricants

Bowl spindle ball bearings and buffers are Lubricating oil as specified in ‘‘2.5.2
lubricated by oil mist. Recommended lubricating oils” on page 36.

Bowl spindle taper. Lubricating oil (only a few drops for rust
protection).

Metal buffers of bowl spindle. Lubricating oil.

Bowl: Pastes as specified in ‘‘2.5.4 Recommended


lubricants” on page 38.
Sliding contact surfaces and pressure loaded
surfaces such as lock rings, threads of lock rings,
bowl hood, and cap nut.

Rubber seal rings. Grease as specified in ‘‘2.5.4 Recommended


lubricants” on page 38.

Friction coupling ball bearings. The bearings are packed with grease and
sealed and need no extra lubrication.

Electric motor (if nipples are fitted). Follow manufacturer’s instructions.

NOTE
The Lubrication chart, general can be complemented with more detailed charts, showing the
lubrication points in detail and what type of lubricant to use.
Instructions related to a specific design of the machine, refer to the general assembly drawings.
Some application processes demand special lubrication.
If not specified otherwise, follow the supplier’s recommendation about method of application.

34
2 Maintenance Directions 2.5 Lubricants

Alfa Laval Lubricating Oil Groups


• Group A oil: a high quality gear oil on paraffin base with stable AW
(anti wear) additives.
• Group B oil: a high quality gear oil on paraffin base with stable EP
(extreme pressure) additives.
• Group D oil: a synthetic base oil with additives stable at high operating
temperatures.
• Group E oil: Characteristics as a group D-oil but suitable at a higher
operation power (≤55 kW)
• Do not mix different oil brands or oils from different oil groups.
Always use clean vessels when handling lubricating oil.
Great attention must be paid not to contaminate the lubricating oil. Of
particular importance is to avoid mixing of different types of oil. Even a
few drops of motor oil mixed into a synthetic oil may result in severe
foaming.
Any presence of black deposits in a mineral type oil is an indication that
the oil base has deteriorated seriously or that some of the oil additives
have precipitated. Always investigate why black deposits occurs.
• If it is necessary to change from one group of oil brand to another it is
recommended to do this in connection with an overhaul of the
separator. Clean the gear housing and the spindle parts thoroughly
and remove all deposits before filling the new oil.

NOTE
Always clean and dry parts (also tools) before lubricants
are applied.

CAUTION

Check the oil level before start. Top up


when necessary.
Oil volume = see “Technical Data”.

• It is of utmost importance to use the lubricants recommended in our


documentation.
This does not exclude, however, the use of other brands, provided they
have equivalently high quality properties as the brands recommended.
The use of oil brands and other lubricants than recommended, is done
on the exclusive responsibility of the user or oil supplier.
Applying, handling and storing of lubricants
• Always be sure to follow lubricants manufacturer's instructions.

35
2.5 Lubricants 2 Maintenance Directions

2.5.2 Recommended lubricating oils


Alfa Laval ref. 553219-08, rev. 0

Type of frame X 10 with motor 25-45 kW.


One group of lubricating oil is approved for this separator. It is
designated as lubricating oil group B.
The numerical value after the letter states the viscosity grade.
The corresponding commercial oil brands are found in chapter ‘‘2.5.3
Recommended oil brands” on page 37.
Ambient temperature (°C) Alfa Laval lubricating oil Time in operation
group Oil change interval

between +5 and +45 B/320 1 500 h

Note:
• In a new installation or after change of gear transmission,
change oil after 200 operating hours.
• When the separator is operated for short periods, lubricating oil
must be changed every 12 months even if the total number of
operating hours is less than stated in the recommendations
above.
• Check and prelubricate spindle bearings on separators which
have been out of service for 6 months or longer.
• In seasonal operation: change oil before every operating period.

36
2 Maintenance Directions 2.5 Lubricants

2.5.3 Recommended oil brands

Paraffinic mineral lubricating oil, category


(ISO-L-) CKE 320.
Alfa Laval ref. 553218-07, rev. 3

NOTE
The following is a list of recommended oil brands.
Trade names and designations might vary from country to country.
Please contact your local oil supplier for more information.

Alfa Laval lubrication oil group B

Viscosity grade VG (ISO 3448/3104) VG 320


Viscosity index VI (ISO 2909) VI >90

Manufacturer Designation

ChevronTexaco Texaco/Caltex Meropa 320

Shell Omala 320


(Omala RL 320) * Synthetic

* These oils must be used when the frame


temperature is above 80 °C.
If the temperature can't be measured, a rough
estimate is that 80 C is when one
can touch the surface of lower part of frame
only for a short time.

The list of recommended oil brands are not


complete. Other oil brands may be used as long
as they have equivalently quality as the brands
recommended. The oil must have the same
viscosity class and shall follow the requirements
in one of the standards below. The oil must also
be endorsed for worm gear with brass worm
wheel. The use of other lubricants than the
recommended is done on the exclusive
responsibility of the user or oil supplier.

Standard Designation

ISO 12925-1, (ISO 6743/6) ISO-L-CKC/CKD/CKE/CKT 320

DIN 51517 part 3 DIN 51517 - CLP 320

37
2.5 Lubricants 2 Maintenance Directions

2.5.4 Recommended lubricants


553217-01, rev. 10

NOTE
The data in below tables is based on supplier information in regards to lubrication properties.
Trade names and designations might vary from country to country. Please contact your local
supplier for more information.
Brands with Alfa Laval article number are approved and recommended for use.

Pastes for non-food applications:

Manufacturer Designation Alfa Laval No

Fuchs Lubritech Gleitmo 805K


Gleitmo 705

Dow Corning Molykote 1000 (Paste) 537086-02 (1000 g)


Molykote 1000 (Paste) 537086-03 (100 g)
Molykote G-rapid plus (Paste) 537086-04 (50 g)

Rocol Dry Moly Paste


MT-LM

Klüber Wolfracoat C (Paste)

Bonded coatings:

Manufacturer Designation Alfa Laval No

Fuchs Lubritech Gleitmo 900 (Varnish or spray)

Dow Corning Molykote D321R (Spray) 535586-01 (400 ml)


Molykote D321R (Varnish) 535586-02 (60 ml)
Molykote D321R (Paste) 535586-80 (25 ml)

38
2 Maintenance Directions 2.5 Lubricants

Pastes for hygienic applications (NSF


registered H1 is prefered):

Manufacturer Designation Hygienic Comment Alfa Laval No

Fuchs Lubritech Gleitmo 805 DVGW (KTW) approval


for drinking water
(TZW prüfzeugnis)

Geralyn 2 NSF Registered H1 561764-01 (50 g)


(3 sep 2004)

Bremer & Rivolta F.L.A NSF Registered H1


Leguil, Fuchs (15 Feb 2003)
Lubritech German §5 Absatz 1
LMBG approved

Dow Corning Molykote TP 42


Molykote D

Molykote P1900 NSF Registered H1


(7 Jan 2004)

Klüber Klüberpaste 46 MR 401 White; contains no


lead, cadmium, nickel,
sulphur nor halogens.

Klüberpaste UH1 96-402 NSF Registered H1


(25 Feb 2004)

Rocol Foodlube Multi Paste NSF Registered H1


(13 Apr 2001)

39
2.5 Lubricants 2 Maintenance Directions

Silicone grease for rubber rings:


Manufacturer Designation Follows according. to Alfa Laval No
Manufacturer
Dow Corning Molykote 111 Conform to the FDA 539474-02 (100 g)
(Compound) regulations (21 CFR
Molykote 111 178.3570) for occasional 539474-03 (25 g)
(Compound) food contact. Certified:
National Water Council UK
and WRC, UK. Certified:
food industry as per
Chemical Testing Laboratory
Dr. Böhm, Munich.
Molykote Foodslip Former USDA H1 approved. 569415-01 (50 g)
SR grease
Fuchs Chemplex 750 DVGW approved according
Lubritech to the German KTW-
recomendations for drinking
water.
Bremer & Leguil NSF Registered H1
Rivolta F.L.G MD2 (15 Feb 2003)
Klüber Unisilkon L 250 L Complies with German
Environmental Agency on
hygiene requirements for tap
water. Certified by DVGW-
KTW, WRC, AS4020, ACS.
Paraliq GTE 703 NSF Registered H1 (25 Feb
2004) Complies with LMBG
and the European standard
EN 1672, part2.
Bel-Ray No-Tox Silicone NSF Registered H1
valve seal (19 June 2002)
MMCC ALCO 220 NSF Registered H1
(25 March 2002)
Rocol Foodlube Hi-Temp NSF Registered H1
(18 April 2001)

40
2 Maintenance Directions 2.5 Lubricants

Greases for ball and roller bearings:

NOTE
Always follow the specific recommendation for lubrication as advised by the
manufacturer.

Manufacturer Designation Alfa Laval No

BP Energrease MP-MG2
Energrease LS2
Energrease LS-EP2

Castrol APS 2
Spheerol EPL 2

Chevron Texaco Chevron Dura-Lith Grease EP2


Texaco Multifak AFB 2

Dow Corning Molykote G-0101


Molykote Multilub

ExxonMobil Beacon EP2


Unirex N2
Mobilith SHC 460
Mobilux EP2

Fuchs Lubritech Lagermeister EP2

Q8/Kuwait Rembrandt EP2


Petroleum

Shell Alvania EP 2
Albida EP2

SKF LGEP 2
LGMT 2

Total Multis EP2

41
2.6 Vibration 2 Maintenance Directions

2.6 Vibration
NOTE
The data in below tables is based on supplier information in regards to lubrication properties.
Trade names and designations might vary from country to country, contact your local supplier for
more information.
Brands with Alfa Laval article number are approved and recommended for use.

2.6.1 Vibration analysis


Excessive vibration or noise indicates a malfunction.
Stop the separator and identify the cause.
Use vibration analysis instrument to periodically
check and record the level of vibration. See the
illustration where to take measurements.

NOTE
The level of vibration should not exceed
9,0 mm/s at full speed.

G0120431
Measuring points for vibration analysis

WARNING

Disintegration hazards

If excessive vibration occurs, keep bowl


filled and stop separator.
The cause of the vibration must be identified
and corrected before the separator is
restarted. Excessive vibration can be due to
incorrect assembly or poor cleaning of the
bowl.

42
2 Maintenance Directions 2.7 Common maintenance directions

2.7 Common
maintenance
directions

2.7.1 Ball and roller bearings


Special-design bearings for the bowl spindle
The bearings used for the bowl spindle are
specified to withstand the speed, vibration,
temperature and load characteristics of high-
speed separators.

G0587321
Only Alfa Laval genuine spare parts should be
used.
1 Outer race
A bearing that appears equivalent to the genuine 2 Ball/roller
may differ considerably in various respects: inside 3 Inner race
clearances, design and tolerances of the cage 4 Cage
and races as well as material and heat treatment.

NOTE
Using an incorrect bearing can cause a
serious breakdown with damage to
equipment as a result.
Do not re-fit a used bearing. Always replace
it with a new.

Dismantling
For bearings where no driving-off sleeve is
included in the tool kit, remove the bearing from
its seat by using a puller. If possible, let the puller
engage the inner ring, then remove the bearing
with a steady force until the bearing bore
completely clears the entire length of the
cylindrical seat.
The puller should be accurately centred during
dismantling; otherwise, it is easy to damage the
G0587411

seating.

For bearings where no driving-off sleeve is included in


NOTE the tool kit, use a puller when removing bearings
Do not strike with a hammer directly on the
bearing.

43
2.7 Common maintenance directions 2 Maintenance Directions

Cleaning and inspection


Check shaft (spindle) end and/or bearing seat in
the housing for damage indicating that the
bearing has rotated on the shaft (spindle) and/or
in the housing respectively. Replace the damaged
part(s), if the faults cannot be remedied by
polishing.

Assembly
• Leave new bearings in original wrapping until
ready to fit. The anti-rust agent protecting a
new bearing should not be removed before
use.
• Maintain the greatest cleanliness when
handling the bearings.
• To facilitate assembly and also reduce the
risk of damage, first clean and then lightly oil
the bearing seating on shaft (spindle) or
alternatively in housing, with a thin oil.

G0587511
Clean and oil the bearing seating before assembly

• When assembling ball bearings, the bearings


must be heated in oil to max. 125 °C.

NOTE
Heat the bearing in a clean container.
Use only clean oil with a flash point above
250 °C.
G0587611

The bearing must be well covered by the oil


and not be in direct contact with the sides or
the bottom of the container. The bearing The bearing must not be in direct contact with the
should be supported or suspended in the oil container
bath.

44
2 Maintenance Directions 2.7 Common maintenance directions

WARNING

Burn hazards

Use protective gloves when handling the


heated bearings.

• There are several basic rules for assembling


cylindrical bore bearings:
− Never directly strike a bearing’s rings,
cage or rolling elements while
assembling. A ring may crack or metal
fragments break off.
− Never apply pressure to one ring in order
to assemble the other.
− Use an ordinary hammer. Hammers with
soft metal heads are unsuitable as
fragments of the metal may break off and
enter the bearing.
− Make sure the bearing is assembled at a
right angle to the shaft (spindle).
• If necessary use a driving-on sleeve that
abuts the ring which is to be assembled with
an interference fit, otherwise there is a risk
that the rolling elements and raceways may
be damaged and premature failure may
follow.

G0587711

Use a driving-on sleeve for bearings that are not


heated

Angular contact ball bearings


Always fit single-row angular contact ball bearings
G0587211

with the wide shoulder of the inner race facing the


axial load (upwards on a bowl spindle).
The wide shoulder of the inner race must face the
axial load

45
2.7 Common maintenance directions 2 Maintenance Directions

Lubrication

NOTE
Since roller bearings are normally treated
only with rust protection oil from the factory,
an initial lubrication of new bearings must
always be performed whenever bearings are
replaced.
The initial lubrication implies adding a few
drops of lube oil to the bearings. Use the
same oil type as in the separator worm gear
housing.

46
2 Maintenance Directions 2.7 Common maintenance directions

2.7.2 Before shutdowns


Before the separator is shut-down for a period of
time, the following must be carried out:
• Remove the bowl, according to instructions in
chapter ‘‘3 Dismantling/Assembly” on page
45.

NOTE
The bowl must not be left on the spindle
during standstill for more than one week.
Vibration in foundations can be transmitted to
the bowl and produce one-sided loading of
the bearings. The resultant indentations in
the ball bearing races can cause premature
bearing failure.

• Protect cleaned carbon steel parts against


corrosion by oiling. Separator parts that are
not assembled after cleaning must be wiped
and protected against dust and dirt.
• If the separator has been shut-down for more
than 3 months but less than 12 months, an
Intermediate Service (IS) has to be made. If
the shut-down period has been longer than
12 months, a Major Service (MS) should be
carried out.

47
2.7 Common maintenance directions 2 Maintenance Directions

48
3 Dismantling/Assembly

3.1 Introduction

3.1.1 General directions


The separator must be dismantled regularly for
cleaning and inspection.
The recommended intervals are stated in chapter
‘‘2.1.2 Maintenance intervals” on page 17.

WARNING

Entrapment hazard

Make sure that rotating parts have come to a


complete standstill before starting any
dismantling work.
The revolution counter and the motor fan
indicate if separator parts are rotating or not.

G0246221
The revolution counter indicates if the separator still is
The frame hood and heavy bowl parts must be rotating
lifted by hoist. Position the hoist directly above the
bowl centre. Use an endless sling and a lifting
hook with catch.
These parts must be handled carefully.
Do not place parts directly on the floor, but on a
clean rubber mat, fibreboard or a suitable pallet.

NOTE
Never interchange bowl parts
To prevent mixing of parts, e.g. in an
installation comprising several machines of
the same type, the major bowl parts carry the
machine manufacturing number or its last
three digits.

49
3.1 Introduction 3 Dismantling/Assembly

3.1.2 References to checkpoints


In the beginning of each sub-chapter describing
the assembly you will find references to the check
point instructions included in separate chapters.
The references appear in the text as in the
following example:
✔ Check point
‘‘3.3.2 Bowl hood seal ring” on page 70
It is assumed that these check points are done
before starting the assembly.

3.1.3 Tools
Special tools from the tool kit must be used for
dismantling and assembly. The special tools are
specified in the Spare Parts Catalogue and are
shown as illustrations together with the
dismantling/assembly instructions.

NOTE
When lifting parts without weight
specifications, always use lifting straps with
the capacity of at least 500 kg.

3.1.4 Tightening of screws


When tightening screws, use the torques stated in
the table below unless otherwise stated. The
figures apply to oiled, stainless screws tightened
with a torque wrench.

METRIC THREAD
Torque
(stainless steel)
Thread Nm
M6 7
M8 18
M10 35
M12 64
M16 157
M20 304
M24 500

50
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

3.2 Intermediate Service


(IS), dismantling

3.2.1 Inlet/outlet and frame hood

G0808721
1. Nipple 9. Rectangular ring
2. Rectangular ring 10. Diaphragm
3. Inlet pipe 11. Pressure gauge
4. O-ring 12. Discharge cover
5. Cap nut 13. Screw
6. Washer 14. Guide ring
7. Coupling nut 15. Height adjusting rings
8. Connecting sleeve 16. Frame hood

51
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

1. Unscrew the coupling nuts for inlet hose and


outlet hose. Disconnect the in- and outlet
pipes.
2. Remove the rectangular rings.

G0806011
3. Loosen the paring disc from the discharge
cover by turning the inlet pipe.
Left-hand thread!
S0072821

G0806111
4. Remove the inlet pipe.

G0806211

52
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

5. Unscrew the nuts holding the discharge


housing and remove it from the frame hood.

G0807511
6. Unscrew the hook screws holding the frame
hood.

G0806921
7. Lift the frame hood with lifting straps attached
to the handles.
Remove the O-ring.
G0807021

53
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

In case of major service.


8. Unscrew the hook screws holding the frame
ring.

G0807121
9. Lift off the frame ring.
10. Remove the O-ring.

G0807321

54
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

55
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

3.2.2 Bowl hood and disc stack

G0923691

56
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

1. Small lock ring

2. Paring chamber top part

3. O-ring

4. Gasket

5. Paring disc complete (2 pieces)

6. Gravity disc

7. O-ring

8. Paring chamber, lower part

9. O-rings

10. Lock ring

11. O-ring

12. Bowl hood

13. Seal ring

14. O-ring

15. Top disc

16. Bowl discs (thinner caulks than other discs in the disc stack)

17. Bowl discs

18. Wing insert

19. Bottom bowl disc (caulks on both sides)

20. Distributor

A. Purifier, Bowl no: 558927-02, -09

B. Purifier, Bowl no: 558927-05, -12

C. Purifier, Bowl no: 558927-04, -11

D. Concentrator, Bowl no: 558927-03, -10

E. Concentrator, Bowl no: 558927-01, -08

F. Concentrator, Bowl no: 558927-06, -07, -13, -14

H. Concentrator, Bowl no: 558927-16

57
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

1. Unscrew and remove the lock ring using the


spanner.
Left-hand thread!

G0809421
S0103111

2. Remove
− paring chamber top part,
− paring disc top and bottom part,
− gravity disc,
− paring chamber lower part,
− Remove all O-rings.

G0807831
3. Apply the brake.

G0520121

58
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

4. Compress the disc stack


a. Fit (1) the lifting tool on the bowl hood.
b. Fit the compressing tool on the lifting tool.
Use the lever arm to screw (2) the
threaded pillar of the tool into the
distributor. The switch on the
compressing tool should be in position 0.
c. Turn the switch (3) to position 1 for
compression.
d. Compress the disc stack by pumping (4)
with the lever arm.
The compressing tool is hydraulic and is fitted

G0581911
with a relief valve.

5. Unscrew the large lock ring using the spanner


and tin hammer.
Left-hand threads!

NOTE
The large lock ring must be placed resting on
a flat and horizontal surface to avoid
distortion.

Only slight distortion can make it impossible


to refit.

G0582321
6. Remove the compressing tool
a. Release the pressure in the compressing
tool. Turn the switch (1) to position 0.
b. Loosen the compressing tool from the
bowl hood. Use the lever arm to screw (2)
the threaded pillar of the tool out of the
distributor.
G0581921

59
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

7. Fit the lifting eyes and remove the large lock


ring with a hoist.

S0078211

NOTE

G0531521
The large lock ring must be placed resting on
a flat and horizontal surface to avoid
distortion.
Only a slight distortion can make it
impossible to refit.

8. Lift off the bowl hood with a hoist. Be careful


not to scratch the bowl hood seal ring.

CAUTION

Crush hazard

If the top disc is stuck into the bowl hood,


remove it now before it accidentally falls out.

G0497031
9. Remove the O-ring and seal ring on the bowl
hood.
10. Remove the top disc.

60
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

11. Fit the lifting tool into the distributor and lift
the distributor with disc stack out of the bowl
body with a hoist.

CAUTION

Cut hazard

Sharp edges on separator discs may cause


cuts.

G0497121
S0090311

61
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

3.2.3 Bowl body and operating


mechanism

1. Cap nut

2. O-ring

3. Distributing cone
A. Purifier bowl
B. Concentrator bowl

4. Sliding bowl bottom

5. O-ring

6. Screw

7. O-ring

8. Bowl body

9. Wear protection

10. O-ring

11. Rectangular ring

12. Valve plug

13. Operating slide

14. Screw

15. Insert ring

16. Dosing ring


G0923651

17. Screw

18. Nozzle *)

*) Secured with Loctite 242

62
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

1. Remove the cap nut using the hook spanner.


Left-hand threads!

G0807611
2. Fit the lifting tool to the distributing cone and
lift it out.

G0810011
3. Fit the lifting tool to the sliding bowl bottom
and lift it out with a hoist.
Remove the rectangular ring by blowing
compressed air through hole on underside of
sliding bowl bottom.

G0810111
4. Remove the three screws in the bottom of the
bowl.

G0810211

5. Fasten the lifting tool to the bowl body. Screw


back the lifting eye to allow the three screws
to be properly screwed down.
Tighten the three screws to the bowl. Ease off
the bowl body from the bowl spindle top by
tightening the central screw (lifting eye).
G0810311

63
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

6. Lift out the bowl body using a hoist.

G0810421
7. Remove the O-ring on the bowl body nave.
Thread a strap through two sludge ports and
turn the bowl body upside down with a hoist.

WARNING

Crush hazards

Support the bowl body when turning to


prevent it from rolling.

G0615821
8. Loosen the screws holding the dosing ring i
place.
G0810611

64
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

9. Fit the lifting eye bolts to the dosing ring and


lift it off.

S0078111

G0810711
10. Remove the O-rings on the bowl body and
operating slide.
11. Lift off the operating slide.

G0810811
12. The insert ring should normally not be
removed. But if, loosen the screws holding
the insert ring and remove the ring.
13. Remove deposits and clean all parts
thoroughly in a suitable cleaning agent. See
chapter ‘‘2.3 Cleaning” on page 27.

G0810911

65
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

3.2.4 Operating liquid device (IS)

1. Hydraulic piston

2. Rectangular ring

3. O-ring

4. O-ring

5. Cover

6. Screw

7. Paring disc

8. Gasket

9. O-ring

10. Cover

11. Distributing cover

12. O-ring

G0878031

66
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

1. Slacken the screws of the paring disc with a


hexagon wrench and unscrew with a suitable
screw driver.

G0131721
2. Lift out the paring disc device.

G0588011

3. Loosen and undo the liquid hoses (1) from


the operating liquid pipes.
G0681261

67
3.2 Intermediate Service (IS), dismantling 3 Dismantling/Assembly

4. Unscrew the screws and lift up the distributing


cover including the liquid pipes.
Then separate the pipes from the cover.

G0588111
5. To dismantle the paring disc device turn it
upside down and remove the screws.

G0588211

68
3 Dismantling/Assembly 3.2 Intermediate Service (IS), dismantling

6. Remove deposits and clean all parts


thoroughly in a suitable cleaning agent. Pay
special attention to the channels. See chapter
‘‘2.3 Cleaning” on page 27.
7. Check the parts for damage and corrosion.

G0589211

69
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3 Intermediate Service


(IS), checkpoints

3.3.1 Introduction
This chapter consists of checkpoints that can be
done when the separator has been dismantled for
Intermediate Service but before it is assembled.
Other checkpoints that can be done only in the
conjunction with the assembly are described in
the assembly sections.

3.3.2 Bowl hood seal ring


Poor sealing between the bowl hood seal ring and
the sealing edge of the sliding bowl bottom will
cause a leakage of process liquid from the bowl.
Renew the bowl hood seal ring at each
Intermediate Service (IS).

G0206211
Max. permitted indentation of the seal ring is 1 mm

Knock out the old ring by means of a pin inserted


in the holes intended for this purpose.
G0206311

Removal of the seal ring

70
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

Fit the new ring as follows:


Press the ring into the groove with a straight
wooden board placed across the ring.
.

NOTE
If the new ring is too narrow, place it in hot
water (70-80 °C) for about 5 minutes.

G0206411
If it is too wide, it will shrink after drying at
80-90 °C for about 24 hours.
Fitting of the seal ring

3.3.3 Bowl spindle cone and bowl


body nave

Impact marks on the spindle cone or in the bowl


body nave may cause poor fit and out-of-balance
vibrations.
The bowl spindle and the nave should also be
checked if the bowl spindle has been dismantled
or if the bowl runs roughly.
Corrosion may cause the bowl to stick firmly to
the spindle cone and cause difficulties during the
next dismantling.
• Remove any impact marks with a scraper
and/or whetstone.
Rust can be removed by using a fine-grain emery
cloth (e.g. No. 320).
Finish with polishing paper (e.g. No. 600).

NOTE
Always use a scraper with great care. The
cone shape must not be deformed.
G0547921

Remove impact marks from the nave and cone

71
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3.4 Corrosion
Evidence of corrosion attack should be looked for
and rectified each time the separator is
dismantled. Main bowl parts such as the bowl
body, bowl hood and lock ring must be inspected
with particular care for corrosion damage.

WARNING

Disintegration hazard

G0206111
Inspect regularly for corrosion damage.
Inspect frequently if the process liquid is Main bowl parts to check for corrosion
corrosive.

Always contact your Alfa Laval representative if


you suspect that the largest depth of the
corrosion damage exceeds 1,0 mm or if cracks
have been found. Do not continue to use the
separator until it has been inspected and given
clearance for operation by Alfa Laval.
Cracks or damage forming a line should be
considered as being particularly hazardous.

Non-stainless steel and cast iron parts


Corrosion (rusting) can occur on unprotected
surfaces of non-stainless steel and cast iron.
Frame parts can corrode when exposed to an
aggressive environment.

72
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

Stainless steel
Stainless steel parts corrode when in contact with
either chlorides or acidic solutions. Acidic
solutions cause general corrosion. The chloride
corrosion is characterised by local damage such
as pitting, grooves or cracks. The risk of chloride

S0020611
corrosion is higher if the surface is:
• Exposed to a stationary solution. Example of chloride corrosion in stainless steel
• In a crevice.
• Covered by deposits.
• Exposed to a solution that low pH.
Corrosion damage caused by chlorides on
stainless steel begins as small dark spots that
can be difficult to detect.
1. Inspect closely for all types of damage by
corrosion and record these observations
carefully.
2. Polish dark-coloured spots and other
corrosion marks with a fine grain emery cloth.

S0020511
This may prevent further damage.

Polish corrosion marks to prevent further damage


WARNING

Disintegration hazard

Pits and spots forming a line may indicate


cracks beneath the surface.
All forms of cracks are a potential danger and
are totally unacceptable.
Renew the part if corrosion can be
suspected of affecting its strength or
function.

Other metal parts


Separator parts made of materials other than
steel, such as brass or other copper alloys, can
also be damaged by corrosion when exposed to
an aggressive environment. Possible corrosion
damage can be in the form of pits and/or cracks.

73
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3.5 Cracks
Cracks can initiate on the machine after a period
of operation and propagate with time.
• Cracks often initiate in an area exposed to
high cyclic material stresses. These are
called fatigue cracks.
• Cracks can also initiate due to corrosion in an
aggressive environment.
• Although very unlikely, cracks may also occur
due to the low temperature embrittlement of
certain materials.
The combination of an aggressive environment
and cyclic stresses will speed-up the formation of
cracks. Keeping the machine and its parts clean
and free from deposits will help to prevent
corrosion attacks.

WARNING

Disintegration hazard

All forms of cracks are potentially dangerous


as they reduce the strength and functional
ability of components.
Always replace a part if cracks are present.

It is particularly important to inspect for cracks in


rotating parts and especially the pillars between
the sludge ports in the bowl wall.
Always contact your Alfa Laval representative if
you suspect that the largest depth of the damage
exceeds 1,0 mm. Do not continue to use the
separator until it has been inspected and cleared
for operation by Alfa Laval.

74
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

3.3.6 Dosing ring


Clean the nozzles (1) with a soft iron wire and
polish the surface (2) with steel wool.
Inspect the surface (3) in contact with the
operating slide. Remove any marks with a
whetstone or fine emery cloth (grain size 240).

G0537021
1. Nozzles
2. Surface inside the dosing ring
3. Surface in contact with the operating slide

3.3.7 Erosion and wear liners


Erosion can occur when particles suspended in
the process liquid flow along or strike against a
surface. Erosion can become intensified locally by
flows of higher velocity.

G0205221
WARNING
Max. permitted erosion

Disintegration hazard

Inspect regularly for erosion damage. Inspect


frequently if the process liquid is erosive.

Always contact your Alfa Laval representative if


the largest depth of any erosion damage exceeds
1,0 mm. Valuable information as to the nature of
the damage can be recorded using photographs,
plaster impressions or hammered-in lead.
Erosion is characterised by:
• Burnished traces on the material.
• Dents and pits having a granular and shiny
surface.

75
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

Surfaces particularly subjected to erosion are:


1. The outlet paring disc.
2. The top disc.
3. The pillars between the sludge ports in the
bowl wall.
4. The sealing edge of the bowl body for the
seal ring in the sliding bowl bottom.
5. The underside of the distributor in the vicinity
of the distribution holes and wings.
6. The surface of the sliding bowl bottom that
faces the conical part of the distributor.
7. The sealing edge of the sliding bowl bottom.

Look carefully for any signs of erosion damage.


Erosion damage can deepen rapidly and
consequently weaken parts by reducing the
thickness of the metal.

G0808641
WARNING
Surfaces particularly subjected to erosion
Disintegration hazard

Erosion damage can weaken parts by


reducing the thickness of the metal.
Pay special attention to the pillars between
the sludge ports in the bowl wall.
Renew the part if erosion is suspected of
affecting its strength or function.

76
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

Wear liners in the bowl


The wear liners protect both the wall pillars in the
bowl body and the sliding bowl bottom. They must
be replaced before the liners have been
perforated by erosion.

Wear liners in wall pillars


When fitting new liners keep in mind that they will
be subjected to a very high service stress. Forces
up to 10 000 G are not unusual at the bowl
periphery. It is essential, therefore, that the liners
are being mounted carefully and in full agreement
with the following instructions:
The wear liners are made of stainless steel
according to the adjoining illustration.

G0207611
1. Remove the old liner and place the new liner
blank in the wall pillar.

S0032011
2. Fasten the mounting tool between the wall
pillars as shown in the illustration. Clamp the
wear liner with the tool.

G0298611

3. Tighten the tool nut with a spanner until the


liner is firmly pressed to its seat.
G0298711

4. Bend the shank (1) at right angles to the


outside of the bowl wall using a drift.
G0298921

77
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

5. Back off the nut of the tool and remove it.


6. Remove the liner and cut the shank so that it
ends 0,5-1,5 mm (A) from the bowl wall.

G0670221
7. Fit the wear liner in the wall pillar and clamp it
with the tool. Knock the shank flat against the
wall of the pillar.

S0031811
8. Remove the tool and check that the wear liner
is well attached and that the shank (1) does
not protrude beyond the bowl periphery. Fit
the other liners as described above.

G0298821
Wear liner in sliding bowl bottom
When fitting a new wear liner (4) in the sliding
bowl bottom (6), dismantle and assemble as
illustrated.
The wear liner can preferably be pressed out of
the sliding bowl bottom by using two screw drivers
or similar. Normally the wear liner will be
destroyed when removed.
When renewing the wear liner also renew the
O-rings (3 and 5).
G0923661

1. Screw
2. Fixing ring
3. O-ring
4. Wear liner
5. O-ring
6. Sliding bowl bottom

78
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

3.3.8 Guide surfaces


Check surfaces indicated (1 and 2) for burrs or
galling. Rectify when necessary.
Repair of galling on guide surfaces; see following
pages. Before fitting the sliding bowl bottom,
clean (do not degrease) the contact surfaces (1).

G0378281
Apply Alfa Laval lubricating paste or Molykote
1000 Paste with a well-cleaned brush on surfaces
(1 and 2). Sliding bowl bottom

NOTE
To avoid the risk of galling, the contact
surfaces (1) should be primed with a slide
lacquer at every Major Service (MS).
The slide-lacquered surfaces will be
destroyed if the surfaces are degreased.

G0378291
Bowl body

Lubricate the O-ring and the seal ring with


silicone grease making sure they are not
damaged and lie properly in their grooves.

G0378271
Operating slide

G0378261

Dosing ring

1 & 2. Lubricated with Molykote 1000 Paste

79
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

Repair of galling on guide surfaces


Galling (friction marks) may appear on guide
surfaces in the operating system, the bowl body
and the sliding bowl bottom. Surfaces subject to
repair are indicated by an arrow.
The example below describes the repair of the

G0205511
lower guide surface of the bowl body nave.

Guide surface in the bowl body

Recommended tools for correction of galling:


- Emery cloth, 240 grade.
- Small power drill
- Degreasing agent.
- Fibre brush, ∅ 25mm.
- Fibre brush, ∅ 50 mm.
- Very fine single-cut file.

1. Clean the surface thoroughly with a


degreasing agent, i.e. white spirit. This is
important.

G0205611
2. If the galling is excessive, first use the fine
single-cut file. The file should be used with
caution so that the damage is not made
worse.
Remove the high spots on the surface. Do not
use rotating files or similar. Remove the high
spots only - not the undamaged material.
G0205711

80
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

3. An emery cloth of 240 grade should be used


to smooth the edges and to remove any
burnt-in foreign matter.

G0205811
4. Finish off by polishing the damaged spot with
the fibre brushes and brush wax. It is
recommended that the whole area where
galling may occur is polished. Polishing will
help smooth the whole of the damaged area,
even in the deepest parts.

Prime the repaired area with slide lacquer. Read

G0205911
the correct procedure under checkpoint ‘‘3.6.2
Lock ring; priming” on page 122. Apply Alfa Laval
lubricating paste or Molykote 1000 Paste to the
surface after priming.

3.3.9 Inlet pipe threads and paring


disc
Damage to the inlet pipe threads may cause the
paring disc to scrape against the paring chamber
cover even if the height has been adjusted
correctly.
Screw the inlet pipe into the paring disc and
check that the inlet pipe turns easily.

81
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3.10 Lock ring; wear and damage


Excessive wear or impact marks on threads,
guide and contact surfaces of the lock ring, bowl
hood and bowl body may cause hazardous
galling.
Check the thread condition by tightening the lock
ring (1) after removing the disc stack and bowl
hood O-ring (2) from the bowl.

WARNING

Disintegration hazards

G0535211
Wear on large lock ring thread must not
exceed safety limit. The φ-mark on lock ring 1. Lock ring
must not pass opposite φ-mark by more than 2. O-ring for the bowl hood
the specified distance.

In a new bowl the alignment marks on the lock


ring and the bowl body are exactly opposite each
other.
If thread wear is observed, mark the lock ring at
the new position opposite the alignment mark on A
the bowl body by punching in a new mark.
If the original φ−mark on the lock ring passes the
φ−mark on the bowl body by more than 25° (which
corresponds to A=123 mm), an Alfa Laval
representative must be contacted immediately.
If the marks become illegible, an Alfa Laval G0578131

representative should be contacted immediately (MAX 25 )


to inspect thread wear and for determining the
The φ-mark on the lock ring must not pass the φ-mark
position of new alignment marks.
on the bowl body by more than 25°

82
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

Damage
The position of the threads, contact and guide
surfaces are indicated by arrows in the illustration.
Clean the threads, contact and guide surfaces
with a suitable degreasing agent.
Check for burrs and protrusions caused by
impact. Watch your fingers for sharp edges.
If damage is established, rectify using a
whetstone or fine emery cloth (recommended
grain size 240).
If the damage is considerable, use a fine single-
cut file, followed by a whetstone.

G0537221
Clean and check thread, contact and guide surfaces
of the lock ring

3.3.11 Operating mechanism


Dirt and lime deposits in the operating
mechanism may cause poor discharge function or
no function at all.
Clean and polish surfaces with steel wool if
necessary.

Reasons for dirt or deposits:


• Hard or unclean operating water. Change
water supply or install a water softener or a
fine filter.
• Sludge has been sucked down into bowl
casing and into the operating system. Check
the installation and the venting system of both
the sludge tank and bowl casing drain.
G0547111

1. Bowl body
2. Valve plug
3. Operating slide
4. Nozzles
5. Dosing ring

83
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3.12 Operating slide


Poor sealing between the valve plugs on the
operating slide and bowl body may prevent
complete closing of the bowl.
Examine the sealing surfaces (1) of the bowl body
in contact with the valve plugs. Remove any
marks and lime deposits with a very fine grain
emery cloth.
Check the guiding surface (2) in contact with the
dosing ring. Remove any marks with a whetstone
(grain size 240).

G0536811
1. Bowl body sealing surfaces in contact with the
valve plugs
2. Operating slide guide surface in contact with the
dosing ring

Remove all the valve plugs. Tap in the new plugs.


Correct height of plugs: 14,5 mm.

G0536911
Tap in new valve plugs

3.3.13 Springs for operating


mechanism
Defective or broken springs may prevent
complete closing of the bowl.
Renew those springs which differ from other
springs in regard to length or are defective in
other respects.
G0536111

Check for defective or broken springs

84
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

3.3.14 Sliding bowl bottom


Poor sealing between the bowl hood seal ring and
the sealing edge of the wear liner fitted in the
sliding bowl bottom will cause a leakage of
process liquid from the bowl.
Check the sealing edge of the wear liner. If
damaged either through corrosion or erosion,
replace the liner as described in ‘‘3.3.7 Erosion
and wear liners” on page 75.
If the seal ring for the sliding bowl bottom is to be
renewed, turn the sliding bowl bottom upside
down and inject compressed air through the hole
on the underside. This will press the ring
outwards far enough to be gripped easily.

WARNING

Risk for eye injury

G0207511
Wear safety goggles.
Removal of the seal ring in sliding bowl bottom using
compressed air

3.3.15 Worm wheel and worm;


wear of teeth
As described in ‘‘2.4.1 Worm wheel and worm;
wear of teeth” on page 30 in this chapter.

85
3.3 Intermediate Service (IS), checkpoints 3 Dismantling/Assembly

3.3.16 Speed sensor


• Check that the electrical connections are not A
damaged.
• Check that the distance (A) between the
sensor and the rotating coupling disc is
2 +0,5 mm, see the illustration.
• Check that the sensor and its bracket are well
attached. The tightening torque of the nuts
fixing the sensor in the bracket is 50 Nm.
For technical reference, see chapter Speed
sensor in the Installation Manual.

G0778411
Measurement of the air gap (A) between sensor and
coupling disc
3.3.17 Vibration sensor
• Check that the electrical connections are not
damaged.
• Check that the sensor is well attached to the
frame. If the sensor has to be tightened, see
below.
• For function check of the sensor and the
belonging monitoring equipment, see
separate instruction manual.
If the sensor, for any reason, has to be replaced,
fit it in the following way:

G0778311
1. Check that the contact surfaces on the sensor
and separator frame are clean. Vibration sensor
2. Mount the screw in the frame, if removed, and
secure with Loctite 242.
3. Mount the vibration sensor. Adjust with
washer(s) in order to get the cable
downwards.
Tightening torque: 35 Nm.
For technical reference, see chapter Vibration
sensor in the Installation Manual.

86
3 Dismantling/Assembly 3.3 Intermediate Service (IS), checkpoints

3.3.18 Cover interlocking switch


(option)

3.3.19 Limits switch


• Check that the electrical connections are not
damaged.
• Check that the screws fixing the switch to the
frame are tightened.
• When the button is pushed, check that the
brown and blue wires are short-circuited and A
the two black wires are open circuit.
Check also the reverse when the button not
pressed.
See the illustration for exact measurement B
when the button is operated.

A. Cable:
– Colour: Grey
– Leads area: 0,75 mm2
– Material: PVC C
B. Switching points D
C. Contact closed
D. Contact open

G0636471
Wire colour codes:
Measurements for operation range of the cover
BK Black
interlocking switch button
BN Brown
GN-YE Green-Yellow

For technical reference, see chapter Cover


interlocking switch (option) in the Installation
Manual.

87
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

3.4 Intermediate Service


(IS), assembly

3.4.1 Introduction
Before starting the assembly first carry out the
Intermediate Service check points starting on
page 70.

NOTE
Renew all parts included in the IS-kit. the O-
rings and other seal rings should be
lubricated with grease of silicone type.

3.4.2 Lubrication

NOTE
The separator are designed for use in food
application and requires lubricants in food
areas that are approved for this application.

Lubricate the O-rings, rectangular rings, threads


and guide surfaces before assembly, see ‘‘2.5.4
Recommended lubricants” on page 38.

88
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

3.4.3 Operating liquid device


An exploded view of the operating liquid device
can be found on page 66.
✔ Check point
‘‘3.3.11 Operating mechanism” on page 83
1. Fit the operating liquid pipes into the
distributing cover.
2. Put the distributing cover with liquid pipes in
place.

G0588111
3. Fasten the distributing cover.

G0589311

4. Connect the operating liquid hoses (1) onto


the pipes.
G0681261

89
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

5. Assemble the paring disc device. Do not


forget the gasket on its underside.

G0601911
6. Align the three holes (1) in the control paring
disc with the three holes (2) in the distributing
cover.

G0589421
7. Fit the paring disc device in its place.
G0588011

90
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

8. Tighten the screws of the control paring disc.

G0131721

91
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

Alfa Laval ref. 541423, rev. 1

9. Check the height position of the operating


device relative to the bowl spindle in the
following way:
• Use two steel rules or a depth gauge for
measuring.
• Measure the distance (A) according to the
illustration.The distance (A) should be
210 ±0,5 mm.

G0809221
Measurement of height position of operating paring
disc
1. Height adjusting ring(s)

• The height position is adjusted by adding or


by removing height adjusting rings (1) under
the distributing cover.
• After adjustment rotate the spindle. If a
scraping noise is heard, re-adjust.
• The operating liquid device should be
assembled and fitted.
G0581721

• After adjustment rotate the spindle. If a


scraping noise occurs, re-adjust.
The height position can be adjusted with height
adjusting rings (1)

92
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

3.4.4 Bowl body and operating


mechanism
✔ Check point
‘‘3.3.3 Bowl spindle cone and bowl body nave”
on page 71
‘‘3.3.4 Corrosion” on page 72
‘‘3.3.5 Cracks” on page 74
‘‘3.3.7 Erosion and wear liners” on page 75
‘‘3.3.6 Dosing ring” on page 75
‘‘3.3.8 Guide surfaces” on page 79
‘‘3.3.11 Operating mechanism” on page 83
‘‘3.3.12 Operating slide” on page 84
‘‘3.3.14 Sliding bowl bottom” on page 85
‘‘3.3.13 Springs for operating mechanism” on
page 84

An exploded view of the Bowl body and operating


mechanism can be found on page 62.
1. Except lubrication of the parts mentioned in
chapter ‘‘3.3.8 Guide surfaces” on page 79,
also lubricate the guide pin fitted in the bottom
of the bowl body with Molykote 1000 Paste.
2. Fasten the insert ring if it has been removed.
Tighten the screws crosswise and firmly.

G0810911
3. Lubricate the guide surfaces of the operating
slide and O-ring with lubricating paste.
Fit the O-ring to operating slide.
Fit the operating slide onto the bowl body.
Check that the guide pin in the bowl body
enters the hole in the operating slide.
G0810811

93
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

4. Lubricate the guide surfaces of the dosing


ring with lubricating paste.
5. Fit O-ring to the bowl body at the location of
the dosing ring.
6. Lift dosing ring in place.
Note! Aligned by uneven hole spacing. The
three digits on the ring should line up with

G0810711
corresponding ones on the operating slide.
Tighten the dosing ring screws first
diametrically, then symmetrically around the
bowl.
Tightening torque: 20 Nm
If torque is too low, there is a risk that the
bolts will loosen by themselves when the
separator is in operation. If torque is too high,
the dosing ring as well as the bolts will be
deformed. This may lead to sticking of the
operating slide which moves inside the dosing
ring.
7. Wipe off the spindle top and nave bore in the
bowl body. Lubricate the tapered end of the
spindle and wipe it off with a clean cloth.

G0522611
8. Turn the bowl body using a hoist to its up-right
position with a strap threaded through two
sludge ports.
Fit O-ring to the bowl body nave.

WARNING

Crush hazards

Support bowl body when turning to prevent it


from rolling.

9. Lubricate the guide surfaces and threads of


G0615821

bowl body. See chapter ‘‘3.3.8 Guide


surfaces” on page 79 and

94
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

10. Fit the lifting tool into the bowl body bottom
with the three screws.
Turn the handle at the top of the lifting tool so
that the central screw is home.
11. Lower the bowl body using hoist until the
central screw rests on the spindle top. Then
screw up the central screw so that the bowl
body sinks down onto the spindle.
Remove the tool.

G0810421
12. Rotate the bowl body and align it so that the
three screw holes in the bowl body bottom
are exactly above the three holes in the
distributing ring.
Tighten the three screws firmly.

G0810211
13. Lubricate the guide surfaces of the bowl body
and sliding bowl bottom with lubricating
paste.

G0810111
14. If wear liner has been removed fit O-rings
under the wear liner fixing ring.
Fit the rectangular ring to the sliding bowl
bottom.
15. Fit the lifting tool to the sliding bowl bottom
and lift it into the bowl body using a hoist.
16. Fit the distributing cone onto the sliding bowl
bottom.
Make sure that it fits in the guiding lugs in
bowl body.
G0810011

95
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

17. Lubricate the cap nut threads. Fit the packing.


18. Screw on the cap nut counter-clockwise and
tighten firmly.
Left-hand threads!

G0807611
3.4.5 Bowl hood and disc stack
✔ Check point
‘‘3.3.4 Corrosion” on page 72
‘‘3.3.7 Erosion and wear liners” on page 75
‘‘3.3.5 Cracks” on page 74
‘‘3.3.2 Bowl hood seal ring” on page 70
‘‘3.3.10 Lock ring; wear and damage” on page
82
‘‘3.6.2 Lock ring; priming” on page 122

A complete exploded view of the bowl hood and


disc stack can be found on page 56
1. Assemble the discs one by one on the
distributor, start with the bottom bowl disc
(19) which has caulks also on its underside.
The distributor has one guide rib for the
correct positioning of the discs.

CAUTION

Cut hazard

Sharp edges on the separator discs may


G0603111

cause cuts.

For correct number of discs above and below


the wing insert when the machine was new,
see the Spare Parts Catalogue.
The number of bowl discs above the wing
insert may be increased to adjust the disc
stack pressure.

96
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

G09236A1
16. Bowl discs (thinner caulks) A. Purifier, Bowl no: 558927-02, -09
17. Bowl discs B. Purifier, Bowl no: 558927-05, -12
18. Wing insert C. Purifier, Bowl no: 558927-04, -11
19. Bottom bowl disc (caulks on both sides) D. Concentrator, Bowl no: 558927-03, -10
20. Distributor E. Concentrator, Bowl no: 558927-01, -08
F. Concentrator, Bowl no: 558927-06, -07, -13, -14
H. Concentrator, Bowl no: 558927-16

Bowl A, D and E Bowl C


− Start with the bottom disc (19) which has − Start with the bottom disc (19) which has
caulks on both sides. caulks on both sides.
− Continue with the discs that have thicker − Continue with 68 discs (17).
caulks than the six upper discs (17).
− Fit the wing insert (18).
− Complete the disc assembly with the six − Fit the other 87 discs.
upper discs (16).
− Complete the disc stack assembly by
fitting the six upper discs (16).
Bowl B Bowl F and H
− Start with the bottom disc (19) which has − Start with the bottom disc (19) which has
caulks on both sides. caulks on both sides.
− Continue with 68 discs (17). − Continue with the other discs (17).
− Fit the wing insert (18).
− Complete the disc stack assembly with
the other 87 discs (17).

97
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

2. Fit the lifting tool to the distributor and lift the


distributor with disc stack into the bowl with a
hoist.
The φ-mark on the bowl body must be between
the two drill marks in the top of the distributor.
Make sure that the distributor has entered its
position on the distributor cone.

CAUTION

Cut hazard

Sharp edges on separator discs may cause


cuts.

G0497121
S0090311

3. Fit the top disc onto the distributor. Align the drill
mark on its upper side between the two drill
marks on the distributor ribs.
4. Fit the lifting tool to the bowl hood and lift it with a
hoist. Check that the O-ring and the seal ring of
the bowl hood are properly fitted and lubricated.
Lower the bowl hood, check that the guide recess
on the bowl hood enters the guide lug on the bowl
body. Be careful not to scratch the bowl hood seal
ring.
Do not remove the tool yet.
5. Lubricate the lock ring threads, contact and guide
surfaces with lubricating paste.
6. Check that the guide recess on the bowl hood
G0497031

enters the guide lug in the bowl body.


G0535621

98
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

7. Remove the lifting tool.


8. Lubricate the lock ring threads, contact and
guide surfaces with lubricating paste.

G0544721
9. Fit two eye bolts and lift the lock ring with a
hoist onto the bowl body.
S0078211

10. Tighten the lock ring by hand.

G0531521
11. Apply the brake.

G0520121

99
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

12. Compress the disc stack


a. Fit (1) the lifting tool on the bowl hood.
b. Fit the compressing tool on the lifting tool.
Use the lever arm to screw (2) the
threaded pillar of the tool into the
distributor. The switch on the
compressing tool should be in position 0.
c. Turn the switch (3) to position 1 for
compression.
d. Compress the disc stack by pumping (4)
with the lever arm.
The compressing tool is hydraulic and is fitted

G0581911
with a relief valve.

13. Tighten the lock ring using the spanner for


lock ring.
Left-hand threads!

G0582311
14. Tighten until the assembly marks are at least
in line.

NOTE A
The assembly marks must never pass each
other more than 25° which corresponds to
A=123 mm.
G0578131

NOTE
(MAX 25 )
Ensure that the disc stack pressure is
sufficient to maintain bowl balance.

Insufficient pressure in the disc stack can


cause vibration and reduce life of ball
bearings.

100
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

15. Check the disc-stack pressure

NOTE
Ensure that the disc stack pressure is
sufficient to maintain bowl balance.
Insufficient pressure in the disc stack can
cause vibration and reduce lifetime of ball
bearings.

• The lock ring (1) should press the bowl hood


(2) firmly against the bowl body (3). The hood

G0544411
in turn should exert a pressure on the disc
stack (4), clamping it in place.
1. Lock ring
2. Bowl hood
3. Bowl body
4. Disc stack

• Correct pressure is obtained when it is


possible to tighten the lock ring so far by hand
that the φ-mark on the lock ring is positioned
60° - 90° before the mark on the bowl body.

To achieve this, add an appropriate number of


discs to the top of the disc stack beneath the
top disc.

If the φ-marks do not reach or pass each


other, the reason could be an incorrectly

G0135811
assembled bowl or too many discs in the disc
stack. Reassemble and check.
φ-marks on bowl body and lock ring in line
16. Release the pressure in the compressing tool
by turning the switch to position 0 and then
remove the compressing and lifting tools.
17. Remove the compressing tool, lifting tool for
bowl hood and spanner for lock ring.

101
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

18. Fit
− O-rings
− paring chamber bottom part
− gravity disc
− paring disc top and bottom part
− paring chamber top part

G0807831
19. Fit and tighten the small lock ring.
Left-hand threads!

G0809421
S0103111

102
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

3.4.6 Inlet/outlet and frame hood


The figures in brackets refer to the exploded view
on page 51.

In case of major service (step 1-3)


1. Fit the O-ring to the frame top part and lift on
the frame ring.

G0807311
2. Tighten the hook screws holding the frame
ring. Proceed in the following way:
• Thread the screw (4) into the lower clamp
piece (1).
• Mount the clamp assembly (1,2,3 and 4)
on the frame, and hand tighten the screw
(3) so that the two clamping parts (1 and
2)
are in contact with the frame hood (5) and
the frame casing (6).
• Set the screw (4) so that the surfaces (A)
on the frame hood and (B) on the frame
casing are parallel.
• Torque screw (3) to 80 Nm.
G0807131

3. Fit the O-ring on top of the frame ring.

103
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

4. Lift on the frame hood with lifting straps


attached to the handles.

G0807021
5. Tighten the hook screws holding the frame
hood.

G0806921

104
3 Dismantling/Assembly 3.4 Intermediate Service (IS), assembly

6. Check the height position of the paring disc.


Alfa Laval ref. 537756, rev. 0

• Measure the distance (A) according to the


illustration. The distance should be
5±0,5 mm.
• Adjust the distance by adding or removing
height adjusting rings (1).
With inlet and outlet parts mounted:
• Revolve the worm wheel shaft by hand. If it
turns heavily or if a scraping noise is heard,
wrong height adjustment or wrong fitting of
the inlet pipe may be the cause.

G0809031
Measurement of height position (A) of parting disc
1.Height adjusting ring(s)

7. Fit the discharge housing. Fit and tighten the


nuts.
G0807521

105
3.4 Intermediate Service (IS), assembly 3 Dismantling/Assembly

8. Fit the O-ring to the inlet pipe.


9. Fit the inlet pipe to the paring disc.

G0806221
10. Tighten the inlet pipe.
Left-hand thread!
11. Fit the rectangular rings for the inlet and
outlet hose.
S0072811

G0806121
12. Connect the in- and outlet pipes. Tighten the
coupling nuts.
G0806021

106
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

3.5 Major Service (MS),


dismantling

3.5.1 Introduction
When carry out a Major Service an Intermediate
Service is always included. By that reason it is
assumed that the dismantling for Intermediate
Service, starting on page 51 is already done.

107
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

Vertical driving device

G0788611

108
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

1. Screw
2. Protecting plate
3. O-ring
4. Protecting collar
5. Screw
6. Guard
7. Nut
8. Cover for spring housing
9. Gasket
10. Oil fan
11. O-ring
12. Stud bolt
13. Buffer
14. Spring
15. Screw plug
16. Bowl spindle
17. Lock ring
18. Ball bearing
19. Spring support
20. Spring
21. Spring support
22. Spacing sleeve
23. Ball bearing
24. Ball bearing housing
25. Buffer
26. Split pin
27. Wear ring
28. Spring
29. Spring support
30. Spring casing
31. Gasket
32. Round nut
33. Lock washer
34. Ball bearing
35. Spring
36. Spacing sleeve
37. Ball bearing
38. Worm
39. Conveyor
40. Ball bearing
41. Washer
42. Lock washer
43. Round nut
44. O-ring
45. Bottom bearing housing
46. Screw

109
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

1. Drain off the oil from the gear housing.

CAUTION

Burn hazards

G0035921
Lubricating oil and various machine surfaces
can be hot and cause burns.

2. Remove the cover before starting any


dismantling.

G0127911
3. On the horizontal driving device, loosen the
screws in the clamping element uniformly and
in the order shown in the figure. In the first
round, do not loosen them more than 1/4 turn
to avoid wryness in the clamping rings. Do
not unscrew the screws entirely.

CAUTION

Crush hazard

The worm wheel is quite heavy. Hold it firmly


when dismantling. Risk for jamming injury.
G0207911

110
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

4. Push the worm wheel with the clamping


element aside.

G0187411
5. Remove the hood above the top bearing.
6. Remove the protecting plate.

G0482811
7. Remove the O-ring.
Remove the throw-off collar with the special
tool.

G0482911

111
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

8. Remove the protecting hood and the O-ring.

G0483011
9. Loosen the screw plugs half-a-turn using the
screw spanner and a hammer.

G0483121
10. Unscrew the six nuts and remove the spring
housing cover and packing.
G0483211

112
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

11. Unscrew the oil fan clockwise.


Left-hand thread!

G0499311
12. Loosen the lock ring half-a-turn counter-
clockwise.

G0499411
13. Fit the lifting eye bolt. Lift out the spindle unit
carefully and place it horizontally.
G0483311

113
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

14. Use some pieces of wood for support.

G0483411
15. Remove the packing and if necessary, the
stud bolts.

G0483511
16. Make a wooden support to be used during
certain sub-operations.
Open the lock washer and remove the nut
using the hook key.

17. Pull off the complete worm including spring G0499011

and ball bearings with a puller. The ball


bearing and conveyor will also become loose.
G0483611

114
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

18. Remove plugs, springs and buffers. Pull out


the spindle unit with ball bearing housing from
the spring holder.

G0483711
19. Remove the lock ring and replace it with the
puller tool

G0483811
20. Remove the ball bearing housing with
bearings using the puller.
S0083111

G0504011

115
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

21. Push out ball bearing, sleeve, springs, spring


holder, spacing sleeve and ball bearing.

G0483911
22. Remove the axial buffer.

G0486411

116
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

23. Dismantle the complete worm by opening the


lock washer and remove the nut and washer.
Knock loose and remove the bearings, spring
and spacing sleeve from the worm by using

G0484131
the special driving off tool.

G0484121

117
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

3.5.2 Horizontal driving device

G0246561
Worm gear end

1. Round nut 6. Lock ring 11. Gasket


2. Frame bottom part 7. Worm wheel 12. Worm wheel shaft
3. Bearing housing 8. Clamp element 13. Bearing shield
4. Round nut 9. Small ball bearing 14. Screw
5. Large ball bearing 10. Tolerance ring

Drive motor end

1. Screw
2. Stop screw
3. Brake pulley
4. Elastic plate
5. Screw
6. Spring washer
7. Washer
8. Coupling disc
9. Screw
10. Spring washer
G0778221

11. Motor adapter

118
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

24. Remove the bearing shield: ease it off by


means of two of the fastening bolts.

CAUTION

Crush hazard

The shield is quite heavy. Hold the shield


firmly or use two longer screws without
heads as guide pins to prevent dropping it
during dismantling. These screws are
included in the tool kit.

G0212451
S009711

25. Fit the puller tool and pull off the ball bearing
from the worm wheel shaft.
S0092911

G0212531
26. Disconnect the motor cables. Note the
positions of cables in the terminal box to re-
connect correctly (for correct direction of
rotation).
27. Remove the motor and the three elastic
plates. Use a hoist.
28. If the brake pulley has to be dismantled, use
the tool illustrated below together with a
washer to protect the threaded hole in the
motor shaft.
G0777611

Fit the tool in the three holes (A).


S0092221

119
3.5 Major Service (MS), dismantling 3 Dismantling/Assembly

29. To remove the coupling disc, unscrew the


centre screw and remove the plain washer.
Then tighten the screw again to protect the
worm wheel shaft during next operation.
30. Fit the puller tool illustrated below and pull off
the coupling disc.

G0777711
S0092911

31. Remove the lock ring on the worm wheel


side.
Left-hand thread!

G0192311
32. Knock loose the worm wheel shaft by means
of a piece of wood and a tin hammer. Use
light blows from the motor side.

G0213411

33. Unscrew the round nut fixing the ball bearing.


The nut is locked with Loctite 242.
G0212611

120
3 Dismantling/Assembly 3.5 Major Service (MS), dismantling

34. Remove the ball bearing. Put some cotton


twist into the tool to avoid damage to the
shaft. The pressure should be applied to the
inner race of the ball bearing.

G0212711

121
3.6 Major Service (MS), checkpoints 3 Dismantling/Assembly

3.6 Major Service (MS),


checkpoints

3.6.1 Introduction
This chapter consists of checkpoints that can be
done when the separator has been dismantled for
Major Service but before it is assembled.
Other checkpoints that can be done only in the
conjunction with the assembly are described in
the assembly sections.

NOTE
At Major Service the check points for
Intermediate Service starting on page 70
should also be carried out in conjunction with
the checkpoints in this chapter.

3.6.2 Lock ring; priming


The arrows indicate positions of threads, guide
and contact surfaces to be primed.
Recommended agents for priming procedure:
• Degreasing agent
• Slide lacquer Molykote D321 R (varnish or
spray)
• Small power drill

G0544711

2 fibre brushes

Threads, guide and contact surfaces to be primed

122
3 Dismantling/Assembly 3.6 Major Service (MS), checkpoints

This instruction describes how to treat with


Molykote spray D321R.

1. Clean the lock ring thoroughly with a


degreasing agent and wipe it off.

G0206911
2. Spray the threads, guide and contact
surfaces with slide lacquer Molykote 321 R.
Let the lacquer air-cure for about 15 minutes.

G0207011
3. Use a fibre brush to polish the slide lacquer
into the surface. The black spray will look like
well-polished leather when properly finished.

G0207311

123
3.6 Major Service (MS), checkpoints 3 Dismantling/Assembly

4. Spray the lock ring a second time and let it


dry for about 15 minutes.

G0207211
5. Polish the slide lacquer to a black shiny
surface which will now last about a year.
Proceed in the same way with the threads of
the bowl body and with the guide surfaces of
the bowl hood and bowl body.

CAUTION
Inhalation hazard

G0207311
When handling friction blocks/pads use a dust
mask to make sure not to inhale any dust.
Do not use compressed air for removal of
any dust. Remove dust by vacuum or wet
cloth.
See Safety instructions for environmental
issues regarding correct disposal of used
friction blocks/pads.

3.6.3 Brake
A worn or oily friction pad will lengthen the
braking period.
If the friction pad is worn:
• Remove the screws and exchange the friction
pad.

NOTE
The screws are slotted in both ends.
G0134111

Friction pad is fastened with screws

124
3 Dismantling/Assembly 3.6 Major Service (MS), checkpoints

If the friction pad is oily:


• Clean the friction pad and the coupling drum
with a suitable degreasing agent.
• Roughen the friction surface of the friction pad
with a coarse file.

NOTE
Identify the cause of oily friction pad. If oil is

G0134211
leaking from the gear housing, renew the
sealing ring between the two parts.
Actions to be taken when the brake friction pad is oily

Checking of spring and brake shoe:


Formation of rust on brake parts may cause the
brake to jam.
• Remove any rust from the surface (1) of the
brake shoe and the corresponding guide
surface in the cap (2).
• Rub in Molykote Paste on the surfaces.
• Replace the spring (3) if it has been weak. This
is indicated by chattering from the spring when
the brake is in released position.

G0134311
• Oil the spring when assembling.
1. Contact surface on the brake shoe for the spring
2. Guide surface in the cap for the brake shoe
3. Spring
CAUTION
Inhalation hazard

When handling friction blocks/pads use a dust


mask to make sure not to inhale any dust.
Do not use compressed air for removal of
any dust. Remove dust by vacuum or wet
cloth.
See Safety instructions for environmental
issues regarding correct disposal of used
friction blocks/pads.

125
3.6 Major Service (MS), checkpoints 3 Dismantling/Assembly

3.6.4 Buffer springs and ball bearing


housing
Weakened or broken buffer springs or defective contact
surfaces for the buffers on the ball bearing housing may
give rise to separator vibration (rough bowl run).

G0283421
Cut view of ball bearing housing
Top bearing springs
In case of spring fracture, the complete set of springs
should be replaced, even if only one spring is broken.

G0283521
Ball bearing housing
Examine the contact surface for the buffers on the ball
bearing housing. In case of defects (indentations
deeper than A=0,5 mm), renew the housing as well as
buffers and springs.
G0283641

Max. permitted indentations (A) made by radial buffers

126
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

3.7 Major Service (MS),


assembly

3.7.1 Introduction
Before starting the assembly first carry out the
Intermediate service checkpoints starting on
page 70 and Major Service checkpoints starting
on page 122.
When mounting ball bearings on the spindle as
described below, the bearings must be heated in
oil to max. 125 °C.

WARNING

Burn hazards

Use protective gloves when handling the heated


bearings.

NOTE
If any doubt how to mount roller bearings in a
correct way, see the detailed description in
chapter ‘‘2.7.1 Ball and roller bearings” on page
41.

NOTE
Since roller bearings are normally treated only
with rust protection oil from the factory, an initial
lubrication of new bearings must always be
performed whenever bearings are replaced.
The initial lubrication implies adding a few drops
of lube oil to the bearings. Use the same oil type
as in the separator worm gear housing.

127
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

NOTE
Renew all O-rings and other parts included in the
MS-kit. Lubricate the O-rings with grease of
silicone type.

3.7.2 Horizontal driving device


An exploded view of the horizontal driving device
can be found on page 118.

NOTE
Renew all parts included in the MS-kit.

1. Clean and oil the seat of the large ball


bearing on the worm wheel shaft.
2. Fit the large ball bearing. If necessary, knock
the ball bearing into its seat with the
driving-on sleeve tool and the ring.
When mounting the ball bearing on the worm
wheel shaft, the bearing must be heated in oil
to max. 125 °C.

WARNING

G0192411
Burn hazards

Use protective gloves when handling the


heated bearings.

NOTE
If any doubt how to mount roller bearings in a
correct way, see the detailed description in
chapter ‘‘2.7.1 Ball and roller bearings” on
page 41.

128
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

3. Apply some Loctite 242 on the threads of the


round nut. Lock the ball baring in its position
by tightening the nut.

G0191611
4. Clean the ball bearing housing in the frame
and oil the outer race of the ball bearing.
Force the worm wheel shaft into its position in
the frame so that the ball bearing enters
correctly into its seat. Use the driving-on
sleeve and the ring forcing the outer race of
the ball bearing.

G0213511
5. Fit the lock ring. Tighten it with the pin
spanner.
Left-hand thread!

G0246011

6. Fit the coupling disc. Check that the key in the


worm wheel shaft enters into the recess in
the nave of the disc.
7. Lock the coupling disc in its position by
means of the plain washer, spring washer
and centre screw.
G0777711

129
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

8. If the brake pulley has been removed, first


lubricate the motor shaft with Molykote Paste
1000. Then knock the disc on to the motor
shaft as far as possible using a piece of wood
and a hammer.
Screw the tool illustrated into the motor shaft
as far it goes and apply some grease to its
washer. Then turn the tool until the coupling
disc is in position. Lock with the lock screw.

G0485911
9. Check the three elastic plates. Clean or
renew, if needed.
10. Fit the electric motor, using a hoist.

G0777621
Check the axial play between two of the flexible
plates. Correct measure (A) is 4 +2 mm.
The measure can be adjusted by moving the
pulley (1) axially on the motor shaft.
G0633821

Where to measure the axial play (A) in the rigid


coupling

130
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

11. Worm wheel assembly:


If the rubber buffers (1) have been replaced in
the worm wheel, apply some Loctite 270 on
the six screws (A). Then tighten crosswise
with 25 Nm.

G0191921
12. Clean the worm wheel shaft and the inner
surface of the worm wheel nave thoroughly
with a clean cloth.
Carefully push the worm wheel into its
position on the shaft.
13. Clean the inner surface of the clamping
element and oil it. The oil must be of the
same quality as is used in the gear housing.
Slip the clamping element onto the worm
wheel. The tightening is described later in this
assembly instruction.

G0213811
14. Mount the ball bearing (not heated) on the
free end of the shaft. Apply the mounting tool
and hit a few blows on the latter to ascertain
that the bearing is in the correct position.

15. Clean the bearing seat in the bearing shield.


G0485611

Check that the tolerance ring is position


(renewed at Major Service).
16. Renew the gasket and fit the bearing shield.
Note that the shield can be fitted in one
position only.
If necessary, pull it into position using the
screws or tap its centre with the tin hammer.
G0485741

131
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

CAUTION

Crush hazard

The shield is quite heavy. Hold the shield


firmly or use two longer screws without
heads as guide pins to prevent dropping it
during assembly. These screws are included
in the tool kit.
S009711

17. Check the radial wobble of the Worm wheel


shaft by first clamping a dial indicator in a
magnetic support and fasten it to the surface
for the worm wheel guard. Turn the worm
wheel shaft by hand.

Permissible radial wobble is maximum 0,10


mm.

If the wobble is greater, the worm wheel shaft


must be removed from the frame for closer
examination. Get in touch with your Alfa Laval
representative as the worm wheel shaft may
need to be renewed.

NOTE
Excessive wobble on the worm wheel shaft
may cause vibration and noise.
G0246131

Measurement of the radial wobble

132
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

3.7.3 Vertical driving device


✔ Check point
‘‘3.3.15 Worm wheel and worm; wear of
teeth” on page 85
1. Wipe off and oil the bearing seat before fitting
the ball bearing.

G0189011
2. Fit the ball bearing, spacing sleeve, spring
holder, springs, spring holder and ball bearing
in the ball bearing housing.

G0486111

Note! The deep groove ball bearing (A) is to


be mounted in the upper housing and the
angular ball bearing (B) in the lower one.
Note! Turn the angular ball bearing (B) the
right way - IMPORTANT! The wider shoulder
of the inner race must face upwards.
G0486011

133
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

3. Heat the complete unit to 125 °C.

NOTE
If any doubt how to mount roller bearings in a
correct way, see the detailed description in
chapter ‘‘2.7.1 Ball and roller bearings” on
page 41.

4. Fit the unit on the spindle while still hot.


Lock with the oil fan.
Left-hand thread!

G0486311
5. Fit the axial buffer in the spring housing.
It is recommended to support the spring
housing so the spindle is free below.

G0486411

134
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

6. Place the spindle unit in the spring housing.

G0486511
7. Fit buffers, springs and screw plugs.

G0486611

135
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

8. Heat ball bearings (3) and (6) to 125 °C.


Fit the ball bearing (6), spacing sleeve (5),
spring (4), ball bearing (3), lock washer (2),
and round nut (1) onto worm and lock with
washer.

G0486731
9. Fit the worm with spring component to the
spring housing.

G0486811

10. Fit the conveyor with the drill marks facing the
threads of the spindle.
G0486911

11. Heat the ball bearing to 125 °C and fit it to the


spindle.
G0487031

136
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

12. Fit the intermediate washer, the lock washer,


the round nut and lock the washer.

G0487111
13. Fit a new packing and O-ring. If the stud bolts
have been removed, refit them and lock with
Loctite 270.

G0508111
14. Fit the lifting eye on the spindle top. Carefully
lower the spindle into the frame.
Guide the bottom bearing into the bottom
sleeve. If it does not completely enter its seat,
tap the spindle top gently with a tin hammer.

G0487311
15. Fit the packing and spring housing cover.
Secure the spindle unit in the frame with the
nuts. Lock them with Loctite 242.

G0483211

137
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

16. Knock down the spindle with a few taps on


the spindle top with the tin hammer. Tighten
the screw plugs.
Rotate the spindle a few turns to make sure
that there is no obstruction.

G0483121
17. Fit O-ring and protecting hood.

G0483011
18. Fit the throw-off collar.
Left-hand thread!
Fit the O-ring and protecting plate. Rotate the
spindle again to make sure that there is no
obstruction.
G0487711

138
3 Dismantling/Assembly 3.7 Major Service (MS), assembly

19. Fit the hood above the top bearing and rotate
the spindle once more to check for clearance.
20. Rotate the spindle by rotating the coupling
drum by hand and check for smooth run. No
scraping or other jarring sounds must be
heard.

G0681911
21. Check the radial wobble of the bowl spindle.

NOTE
Spindle wobble will cause rough bowl
running. This leads to vibration and reduces
lifetime of ball bearings.

• Fit a dial indicator in a support and fasten it to


the frame.

G0191521

Measurement of the radial wobble

• Use the coupling drum to revolve the spindle


manually.
• Measure the wobble at the top of the tapered
end of the spindle. Permissible radial wobble
is maximum 0,04 mm.
• If wobble is too large, renew all the ball
bearings on the spindle.
• Measure wobble after assembly. If it is still
G0681911

excessive, the spindle is probably damaged


and must be renewed.

139
3.7 Major Service (MS), assembly 3 Dismantling/Assembly

22. Fit the oil drain plug and pour oil into worm
gear housing. The oil level should be slightly
above middle of the sight glass.
Oil volume: approx. 8,5 litres
Suitable oil brands can be found in ‘‘2.5.3
Recommended oil brands” on page 37.
23. Fit the worm gear cover and its gasket
covering the worm gear housing.
Also fit the coupling cover (with the brake) if
removed.

WARNING

G0485831
Disintegration hazards

When power cables have been connected,


always check direction of rotation. The

S006882
direction of the motor fan must correspond to
the arrow on the plate fixed on the motor
flange. If incorrect, vital rotating parts could
unscrew causing disintegration of the
machine.

140
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Fax: +46 8 530 310 40.

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Product: AFPX 513XGD-14/74CG Book No.: 1271468-02 Rev. 3

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141
142
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Product: AFPX 513XGD-14/74CG Book No.: 1271468-02 Rev. 3

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143
144
Index

A Repair of galling 80
Sliding bowl bottom 85
Assembly Speed sensor 86
General directions 49 Springs for operating mechanism 84
Inlet/outlet anf frame hood 103 Vibration analysis 42
Tools (special) 50 Vibration sensor 86
Vertical driving device 127 Wear liners 75
Worm wheel and worm - wear of teeth 30
B Cleaning
Bowl discs 29
Bearings Cleaning agents 27
Maintenance directions 43 External cleaning 28
Replacement on horizontal driving device 118 Corrosion 72
Bowl Coupling
Dismantling 56 Axial play 130
Bowl body and operating mechanism Cover interlocking switch (option)
Dismantling 62 Check point 87
Bowl discs Cracks 74
Cleaning 29
Disc stack pressure 101
Bowl spindle
D
Assembly 127 Daily checks 21
Check point 71, 139 Dismantling
Dismantling 108 Bowl body and operating mechanism 62
Radial wobble 139 Bowl hood and disc stack 56
Brake General directions 49
Renewing of friction pad 124 Tools 50
Vertical driving device 108
C Dismantling.Vertical driving device 110
Check points
Ball and roller bearings 43
E
Before shutdowns 47 Erosion 75
Bowl hood seal ring 70 Exploded views
Brake 124 Bowl body and operating mechanism 62
Buffer springs and ball bearing housing 126 Bowl hood and disc stack 56
Cleaning agents 27 Horizontal driving device 118
Cleaning of bowl discs 29 Operating water device 66
Corrosion 72
Coupling, axial play 130 F
Cover interlocking switch (option) 87
Cracks 74 Frame feet
Dosing ring 75 Replacement 26
Erosion 75
External cleaning 28 G
Guide surfaces 79
Lock ring - priming 122 Gear
Oil change procedure 33 Wear of teeth 30
Operating mechanism 83 Guide surfaces
Operating slide 84 Intermediate Service 79
Repair of galling 80

145
H O
Horizontal driving device Oil. See Lubricants
Check point 30, 132 Operating liquid device
Dismantling 118 Dismantling 66

I S
Intermediate Service Safety Instructions 9
Dismantling 51 Service kits 20
Intermediate service 17, 22 Shutdown 47
Spare parts 20
L Speed sensor
Check point 86
Lock ring
Priming 122 T
Wear and damage 82
Lubricants Tightening torques
Lubrication chart, general, oil groups 34 Frame feet 26
Oil change interval 36 Holder for rubber buffers on worm wheel 131
Oil change procedure 33 Screws, common 50
Oil level 33 Speed sensor 86
Recommended lubricating oils 36 Vibration sensor 86
Recommended oil brands 37
Lubrication of electric motor 21 V
M Vertical driving device
Assembly 127
Maintenance intervals 18 Check point 71, 139
Maintenance logs Dismantling 108
3-year Service (3S) 26 Vibration
Daily checks 21 Vibration analysis 42
Intermediate Service (IS) 22 Vibration sensor
Major Service (MS) 24 Check point 86
Oil change 21
Maintenance, general information W
Ball and roller bearings 43
Before shutdowns 47 Warning signs 14
Cleaning 27 Wear liners in bowl, check point 75
Maintenance intervals 17 Worm gear
Maintenance procedure 19 Wear of teeth 30
Oil change procedure 33 Worm wheel shaft
Service kits 20 Radial wobble 132
Vibration analysis 42
Major service 17, 24
Metal surfaces
Cleaning and cleaning agents 27, 28
Corrosion 72
Cracks 74
Erosion 75
Motor
Cleaning 28
Lubrication 21

146