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Service & Maintenance manual

High Speed Separator


AFPX 513XGD-14/74CG

Product No.
Book No.

881135-21-01/5
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

1.1 Warning signs in text

14

1.2 Environmental issues

15

1.3 Requirements of personnel

16

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

2.6.1

Vibration analysis

2.7 Common maintenance directions

43

2.7.1

Ball and roller bearings

43

2.7.2

Before shutdowns

47

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

42

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

3.3.19

Limits switch

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

3.5 Major Service (MS), dismantling

103
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

Index

87

127

3.7.1

Introduction

127

3.7.2

Horizontal driving device

128

3.7.3

Vertical driving device

133
145

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.

1 Safety Instructions

Kinetic energy is high

Great forces are generated

Stopping time is long

G0010421

The centrifuge includes parts that rotate at high


speed. This means that:

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.

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.

Use only Alfa Laval genuine spare parts


and the special tools supplied.

S0151211

The following basic safety instructions therefore


apply:

1 Safety Instructions

When power cables are connected,


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

If excessive vibration occurs, stop


separator and keep bowl filled with
liquid during rundown.

Use the separator only for the purpose


and parameter range specified by
Alfa Laval.

Check that the gear ratio is correct for


power frequency used. If incorrect,
subsequent overspeed may result in a
serious break down.

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.

Wear on the large lock ring thread must


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

Inspect regularly for corrosion and


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

S01512G1

S0151241

S01512L1

S01512P1

S01512N1

S01512F1

Disintegration hazards

10

1 Safety Instructions

Entrapment hazards

Make sure that rotating parts have come


to a complete standstill before starting
any dismantling work.

To avoid accidental start, switch off and


lock power supply before starting any
dismantling work.
Assemble the machine completely
before start. All covers and guards must
be in place.

S0151261

S01512O1

Follow local regulations for electrical


installation and earthing (grounding).

To avoid accidental start, switch off and


lock power supply before starting any
dismantling work.

S0151271

Electrical hazard

Crush hazards

S01512M1

Use correct lifting tools and follow lifting


instructions.

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

When using chemical cleaning agents,


make sure you follow the general rules
and suppliers recommendation
regarding ventilation, personnel
protection etc.

Use of lubricants in various situations.

12

S01512D1

Skin irritation hazards

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
MS
IS

IS

Installation

18

IS

IS

3S
MS

MS
IS

1st year

IS

IS

IS

IS

2nd year

IS

IS

IS

3rd year

2 Maintenance Directions

2.1.3

2.1 Periodic maintenance

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

2.1.4

2 Maintenance Directions

Service kits

Special service kits are available for Intermediate


Service (IS) and Major Service (MS), as well as
for servicing the frame feet (3S).

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.
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

S0021021

For other services the spare parts have to be


ordered separately.

Kits are available for Intermediate Service, Major


Service and for servicing the frame feet

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 Operators 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

2.2.4

2 Maintenance Directions

Intermediate Service (IS)

Name of plant:
Separator:

Local identification:
AFPX 513XGD-14/74CG

Manufacture No./Year:

Total running hours:

Product No:

Date:

Signature:

Main component and activity

Part

881135-21-01/4

Page

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


body nave

67

Operating mechanism

71, 79,
80, 80,

Paring chamber
Check

Renew

22

Corrosion

68

Cracks

70

Erosion and wear liners

71

Galling of guide surface

76

Disc stack pressure

97

O-rings and sealings

Notes

2 Maintenance Directions

Main component and activity

2.2 Maintenance Logs

Part

Page

Notes

Operating liquid device


Clean and check

Operating liquid device

Renew

O-rings

Check

Worm wheel and worm

30

Renew

Oil in gear housing

33

See sign on motor

Safety label on hood

Direction of rotation arrow

Power supply frequency

Horizontal driving device


Worm wheel shaft and gear housing

Electrical motor
Lubrication (if nipples are fitted)
Signs and labels on separator
Check attachment and legibility

Monitoring equipment
Function check

Vibration sensor

82

Speed sensor

82

Cover interlocking switch


(option)

83

Note: Renew all parts included in the Intermediate Service kit (IS).

23

2.2 Maintenance Logs

2.2.5

2 Maintenance Directions

Major Service (MS)

Name of plant:
Separator:

Local identification:
AFPX 513XGD-14/74CG

Manufacture No./Year:

Total running hours:

Product No:

Date:

Signature:

Main component and activity

Part

881135-21-01/4

Page

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


body nave

67

Operating mechanism

71, 79,
80, 80,

Paring chamber
Check

Renew

24

Corrosion

68

Cracks

70

Erosion and wear liners

71

Galling of guide surface

76

Disc stack pressure

97

Height position of outlet


paring disc

101

O-rings and sealings

Notes

2 Maintenance Directions

Main component and activity

2.2 Maintenance Logs

Part

Page

Notes

Operating liquid device


Clean and check

Operating liquid device

Check

Height position

88

Renew

O-rings

Bowl spindle

Vertical driving device


Clean and check

Buffer springs and ball


bearing housing

122

Check

Radial wobble of bowl spindle

135

Renew

Spindle bearings, sealings


and rubber buffers

129

Worm wheel and worm

30

Radial wobble of worm wheel


shaft

128

Bearings, O-rings and


sealings

114

Oil in gear housing

33

Clean and check

Spring and brake shoe

121

Renew

Friction pad

120

Axial play of elastic plates

126

Horizontal driving device


Worm wheel shaft and gear housing
Check

Renew

Brake

Flexible coupling
Check
Electrical motor
Lubrication (if nipples are fitted)

See sign on motor

Safety label on hood

Direction of rotation arrow

Power supply frequency

Signs and labels on separator


Check attachment and legibility

Monitoring equipment
Function check

Vibration sensor

82

Speed sensor

82

Cover interlocking switch


(option)

83

Note: Renew all parts included in the Intermediate Service kit (IS) and Major Service kit (MS).

25

2.2 Maintenance Logs

2.2.6

2 Maintenance Directions

3-year Service (3S)

Renew the frame feet as described below. The 3year 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

G0258921

When lifting a separator it must always hang


securely. See separate instruction in chapter
Lifting instructions in the Installation Manual.

4. Renew the vibration dampers (3, 4).


5. Lower the frame. Check that the bolts do not
press against the edges of the holes.
6. Tighten the nut (2) to 20 Nm.
7. Hold the nut (2) firmly and secure with the lock
nut (1).
8. Connect the previously disconnected pipes,
hoses and cables.
.

26

1.
2.
3.
4.

Lock nut
Nut
Vibration damper, upper
Vibration damper, lower

2 Maintenance Directions

2.3

Cleaning

2.3.1

Cleaning agents

2.3 Cleaning

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

2.3.2

2 Maintenance Directions

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.

Many operators believe that these motors are


sealed, and normally they are not.

A water jet played on these motors will


produce an internal vacuum, which will suck
the water between the metal-to-metal contact
surfaces into the windings, and this water
cannot escape.

G0545121

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:

Never wash down a separator with a direct water


stream or playing a water jet on the motor

Water directed on a hot motor may cause


condensation resulting in short-circuiting and
internal corrosion.

G0545131

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).

Use a sponge or cloth and a brush when cleaning

28

2 Maintenance Directions

2.3.3

2.3 Cleaning

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.

2. Let the discs remain in the cleaning agent


until the deposits have been dissolved. This
will normally take between two and four
hours.

G0065831

1. Remove the bowl discs from the distributor


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

Put the discs one by one into the cleaning agent

G0065841

3. Finally clean the discs with a soft brush.

Clean the discs with a soft brush

29

2.4 When changing oil

2.4

When changing oil

2.4.1

Worm wheel and worm;


wear of teeth

2 Maintenance Directions

To check at each oil change

Replace both worm wheel and worm at the


same time, even if only one of them is worn.

To avoid damaging the teeth when lifting the


bowl spindle: push the worm wheel to one
side first.
Position the spindle in correct place before
fitting the worm wheel.

G0205311

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.

1
2

Worm
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

G0205411

Check that gear ratio is correct for power


frequency used. If incorrect, subsequent
overspeed may result in a serious
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.
G0538711

Good contact surfaces will form on the teeth when


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

Worn teeth:

the wear is uniform over the whole of the flank


of a tooth

and all teeth are worn in the same way.

G0538811

Permissible wear is as a rule 1/3 of the thickness


of the upper part of a tooth, provided that

Worn teeth

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

G0538911

Spalling:

Spalling

Pitting:

G0539011

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
check at short intervals is of imperative
importance.
Pitting

32

2 Maintenance Directions

2.4.2

2.4 When changing oil

Oil change procedure

NOTE

G0134411

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.

1.
2.
3.

Cover
Sight glass
Oil drain plug

1. Place a collecting tray under the drain hole,


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

G0035921

CAUTION
Burn hazards
Lubricating oil and various machine surfaces
can be sufficiently hot to cause burns.

Burn hazards: The drained oil may be hot

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.

G0262011

Suitable oil brands can be found in 2.5.3


Recommended oil brands on page 37.

NOTE
During operation the oil level must be slightly
below the middle of the sight glass.

The oil level must not be above 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

2.5

Lubricants

2.5.1

Lubrication chart, general

2 Maintenance Directions

Alfa Laval ref. 553216-01, rev. 6

Lubricating points

Lubricants

Bowl spindle ball bearings and buffers are


lubricated by oil mist.

Lubricating oil as specified in 2.5.2


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 manufacturers 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 suppliers 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

2.5.2

2 Maintenance Directions

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


group

Time in operation
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

2.5.3

2.5 Lubricants

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)
Viscosity index VI (ISO 2909)

VG 320
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

2.5.4

2 Maintenance Directions

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

Fuchs Lubritech

Gleitmo 805K
Gleitmo 705

Dow Corning

Molykote 1000 (Paste)


Molykote 1000 (Paste)
Molykote G-rapid plus (Paste)

Rocol

Dry Moly Paste


MT-LM

Klber

Wolfracoat C (Paste)

Alfa Laval No

537086-02 (1000 g)
537086-03 (100 g)
537086-04
(50 g)

Bonded coatings:
Manufacturer

Designation

Fuchs Lubritech

Gleitmo 900 (Varnish or spray)

Dow Corning

Molykote D321R (Spray)


Molykote D321R (Varnish)
Molykote D321R (Paste)

38

Alfa Laval No

535586-01 (400 ml)


535586-02 (60 ml)
535586-80 (25 ml)

2 Maintenance Directions

2.5 Lubricants

Pastes for hygienic applications (NSF


registered H1 is prefered):
Manufacturer

Designation

Fuchs Lubritech Gleitmo 805

Hygienic Comment
DVGW (KTW) approval
for drinking water
(TZW prfzeugnis)

Geralyn 2

NSF Registered H1
(3 sep 2004)

Bremer &
Leguil, Fuchs
Lubritech

Rivolta F.L.A

NSF Registered H1
(15 Feb 2003)
German 5 Absatz 1
LMBG approved

Dow Corning

Molykote TP 42
Molykote D

Klber

Rocol

Alfa Laval No

Molykote P1900

NSF Registered H1
(7 Jan 2004)

Klberpaste 46 MR 401

White; contains no
lead, cadmium, nickel,
sulphur nor halogens.

Klberpaste UH1 96-402

NSF Registered H1
(25 Feb 2004)

Foodlube Multi Paste

NSF Registered H1
(13 Apr 2001)

561764-01

(50 g)

39

2.5 Lubricants

2 Maintenance Directions

Silicone grease for rubber rings:


Manufacturer Designation

Follows according. to
Manufacturer

Dow Corning

Molykote 111
(Compound)
Molykote 111
(Compound)

Conform to the FDA


539474-02
regulations (21 CFR
539474-03
178.3570) for occasional
food contact. Certified:
National Water Council UK
and WRC, UK. Certified:
food industry as per
Chemical Testing Laboratory
Dr. Bhm, Munich.

(100 g)

Molykote Foodslip
SR grease

Former USDA H1 approved. 569415-01

(50 g)

Chemplex 750

DVGW approved according


to the German KTWrecomendations for drinking
water.

Bremer & Leguil


Rivolta F.L.G MD2

NSF Registered H1
(15 Feb 2003)

Unisilkon L 250 L

Complies with German


Environmental Agency on
hygiene requirements for tap
water. Certified by DVGWKTW, 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
valve seal

NSF Registered H1
(19 June 2002)

MMCC

ALCO 220

NSF Registered H1
(25 March 2002)

Rocol

Foodlube Hi-Temp

NSF Registered H1
(18 April 2001)

Fuchs
Lubritech

Klber

40

Alfa Laval No

(25 g)

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

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
Petroleum

Rembrandt EP2

Shell

Alvania EP 2
Albida EP2

SKF

LGEP 2
LGMT 2

Total

Multis EP2

Alfa Laval No

41

2.6 Vibration

2.6

2 Maintenance Directions

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
G0120431

The level of vibration should not exceed


9,0 mm/s at full speed.

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

2.7.1

Ball and roller bearings

2.7 Common maintenance directions

Special-design bearings for the bowl spindle

G0587321

The bearings used for the bowl spindle are


specified to withstand the speed, vibration,
temperature and load characteristics of highspeed separators.
Only Alfa Laval genuine spare parts should be
used.
A bearing that appears equivalent to the genuine
may differ considerably in various respects: inside
clearances, design and tolerances of the cage
and races as well as material and heat treatment.

1
2
3
4

Outer race
Ball/roller
Inner race
Cage

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.

NOTE

G0587411

The puller should be accurately centred during


dismantling; otherwise, it is easy to damage the
seating.
For bearings where no driving-off sleeve is included in
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.

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
should be supported or suspended in the oil
bath.

44

G0587611

Use only clean oil with a flash point above


250 C.

The bearing must not be in direct contact with the


container

2 Maintenance Directions

2.7 Common maintenance directions

WARNING
Burn hazards
Use protective gloves when handling the
heated bearings.

Never directly strike a bearings 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

There are several basic rules for assembling


cylindrical bore bearings:

Use a driving-on sleeve for bearings that are not


heated

Always fit single-row angular contact ball bearings


with the wide shoulder of the inner race facing the
axial load (upwards on a bowl spindle).

G0587211

Angular contact ball bearings

The wide shoulder of the inner race must face the


axial load

45

2.7 Common 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 Maintenance Directions

2.7.2

2.7 Common maintenance directions

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

48

2 Maintenance Directions

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 frame hood and heavy bowl parts must be


lifted by hoist. Position the hoist directly above the
bowl centre. Use an endless sling and a lifting
hook with catch.

G0246221

The revolution counter and the motor fan


indicate if separator parts are rotating or not.
The revolution counter indicates if the separator still is
rotating

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

3.1.2

3 Dismantling/Assembly

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

50

Thread

Torque
(stainless steel)
Nm

M6

M8

18

M10

35

M12

64

M16

157

M20

304

M24

500

3 Dismantling/Assembly

Intermediate Service
(IS), dismantling

3.2.1

Inlet/outlet and frame hood

G0808721

3.2

3.2 Intermediate Service (IS), dismantling

1.
2.
3.
4.
5.
6.
7.
8.

Nipple
Rectangular ring
Inlet pipe
O-ring
Cap nut
Washer
Coupling nut
Connecting sleeve

9.
10.
11.
12.
13.
14.
15.
16.

Rectangular ring
Diaphragm
Pressure gauge
Discharge cover
Screw
Guide ring
Height adjusting rings
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.

G0806011

2. Remove the rectangular rings.

3. Loosen the paring disc from the discharge


cover by turning the inlet pipe.

G0806111

S0072821

Left-hand thread!

G0806211

4. Remove the inlet pipe.

52

3 Dismantling/Assembly

3.2 Intermediate Service (IS), dismantling

G0807511

5. Unscrew the nuts holding the discharge


housing and remove it from the frame hood.

G0806921

6. Unscrew the hook screws holding the frame


hood.

7. Lift the frame hood with lifting straps attached


to the handles.

G0807021

Remove the O-ring.

53

3.2 Intermediate Service (IS), dismantling

3 Dismantling/Assembly

In case of major service.

G0807121

8. Unscrew the hook screws holding the frame


ring.

9. Lift off the frame ring.

G0807321

10. Remove the O-ring.

54

3 Dismantling/Assembly

3.2 Intermediate Service (IS), dismantling

55

3.2 Intermediate Service (IS), dismantling

Bowl hood and disc stack

G0923691

3.2.2

3 Dismantling/Assembly

56

3 Dismantling/Assembly

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

3.2 Intermediate Service (IS), dismantling

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.

S0103111

G0809421

Left-hand thread!

2. Remove
paring chamber top part,

paring disc top and bottom part,

gravity disc,

paring chamber lower part,

Remove all O-rings.

G0807831

G0520121

3. Apply the brake.

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.
G0581911

The compressing tool is hydraulic and is fitted


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.

G0582321

Only slight distortion can make it impossible


to refit.

6. Remove the compressing tool


a. Release the pressure in the compressing
tool. Turn the switch (1) to position 0.
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

b.

59

3.2 Intermediate Service (IS), dismantling

3 Dismantling/Assembly

NOTE
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.

G0531521

S0078211

7. Fit the lifting eyes and remove the large lock


ring with a hoist.

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


not to scratch the bowl hood seal ring.

CAUTION
Crush hazard

9. Remove the O-ring and seal ring on the bowl


hood.
10. Remove the top disc.

60

G0497031

If the top disc is stuck into the bowl hood,


remove it now before it accidentally falls out.

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

S0090311

G0497121

Sharp edges on separator discs may cause


cuts.

61

3.2 Intermediate Service (IS), dismantling

3.2.3

3 Dismantling/Assembly

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

17. Screw
18. Nozzle *)

*) Secured with Loctite 242

62

G0923651

16. Dosing ring

3 Dismantling/Assembly

3.2 Intermediate Service (IS), dismantling

1. Remove the cap nut using the hook spanner.

G0807611

Left-hand threads!

G0810011

2. Fit the lifting tool to the distributing cone and


lift it out.

3. Fit the lifting tool to the sliding bowl bottom


and lift it out with a hoist.

G0810111

Remove the rectangular ring by blowing


compressed air through hole on underside of
sliding bowl bottom.

G0810211

4. Remove the three screws in the bottom of the


bowl.

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


back the lifting eye to allow the three screws
to be properly screwed down.

G0810311

Tighten the three screws to the bowl. Ease off


the bowl body from the bowl spindle top by
tightening the central screw (lifting eye).

63

3.2 Intermediate Service (IS), dismantling

3 Dismantling/Assembly

G0810421

6. Lift out the bowl body using a hoist.

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

G0615821

Support the bowl body when turning to


prevent it from rolling.

G0810611

8. Loosen the screws holding the dosing ring i


place.

64

3 Dismantling/Assembly

3.2 Intermediate Service (IS), dismantling

G0810711

S0078111

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


lift it off.

10. Remove the O-rings on the bowl body and


operating slide.

G0810811

11. Lift off the operating slide.

12. The insert ring should normally not be


removed. But if, loosen the screws holding
the insert ring and remove the ring.

G0810911

13. Remove deposits and clean all parts


thoroughly in a suitable cleaning agent. See
chapter 2.3 Cleaning on page 27.

65

3.2 Intermediate Service (IS), dismantling

3.2.4

3 Dismantling/Assembly

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

G0878031

12. O-ring

66

3 Dismantling/Assembly

3.2 Intermediate Service (IS), dismantling

G0131721

1. Slacken the screws of the paring disc with a


hexagon wrench and unscrew with a suitable
screw driver.

G0588011

2. Lift out the paring disc device.

G0681261

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


the operating liquid pipes.

67

3.2 Intermediate Service (IS), dismantling

3 Dismantling/Assembly

4. Unscrew the screws and lift up the distributing


cover including the liquid pipes.

G0588111

Then separate the pipes from the cover.

G0588211

5. To dismantle the paring disc device turn it


upside down and remove the screws.

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.

G0589211

7. Check the parts for damage and corrosion.

69

3.3 Intermediate Service (IS), checkpoints

3.3

Intermediate Service
(IS), checkpoints

3.3.1

Introduction

3 Dismantling/Assembly

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.

G0206211

Renew the bowl hood seal ring at each


Intermediate Service (IS).

Max. permitted indentation of the seal ring is 1 mm

G0206311

Knock out the old ring by means of a pin inserted


in the holes intended for this purpose.

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
G0206411

If the new ring is too narrow, place it in hot


water (70-80 C) for about 5 minutes.
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

G0547921

Always use a scraper with great care. The


cone shape must not be deformed.

Remove impact marks from the nave and cone

71

3.3 Intermediate Service (IS), checkpoints

3.3.4

3 Dismantling/Assembly

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

Inspect regularly for corrosion damage.


Inspect frequently if the process liquid is
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

G0206111

Disintegration hazard

Main bowl parts to check for corrosion

3 Dismantling/Assembly

3.3 Intermediate Service (IS), checkpoints

Stainless steel

Exposed to a stationary solution.

In a crevice.

Covered by deposits.

Exposed to a solution that low pH.

S0020611

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
corrosion is higher if the surface is:
Example of chloride corrosion in stainless steel

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.

WARNING

S0020511

2. Polish dark-coloured spots and other


corrosion marks with a fine grain emery cloth.
This may prevent further damage.
Polish corrosion marks to prevent further damage

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

3.3.5

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 Dismantling/Assembly

3.3.6

3.3 Intermediate Service (IS), checkpoints

Dosing ring

Clean the nozzles (1) with a soft iron wire and


polish the surface (2) with steel wool.

G0537021

Inspect the surface (3) in contact with the


operating slide. Remove any marks with a
whetstone or fine emery cloth (grain size 240).

1.
2.
3.

3.3.7

Nozzles
Surface inside the dosing ring
Surface in contact with the operating slide

Erosion and wear liners

WARNING

G0205221

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.

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.

G0808641

Look carefully for any signs of erosion damage.


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

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:

G0207611

The wear liners are made of stainless steel


according to the adjoining illustration.

S0032011

1. Remove the old liner and place the new liner


blank in the wall pillar.

G0298611

2. Fasten the mounting tool between the wall


pillars as shown in the illustration. Clamp the
wear liner with the tool.

G0298711

3. Tighten the tool nut with a spanner until the


liner is firmly pressed to its seat.

G0298921

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


outside of the bowl wall using a drift.

77

3.3 Intermediate Service (IS), checkpoints

3 Dismantling/Assembly

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

G0670221

6. Remove the liner and cut the shank so that it


ends 0,5-1,5 mm (A) from the bowl wall.

S0031811

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.

G0298821

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.

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.

G0923661

When renewing the wear liner also renew the


O-rings (3 and 5).

1.
2.
3.
4.
5.
6.

78

Screw
Fixing ring
O-ring
Wear liner
O-ring
Sliding bowl bottom

3 Dismantling/Assembly

3.3.8

3.3 Intermediate Service (IS), checkpoints

Guide surfaces

Repair of galling on guide surfaces; see following


pages. Before fitting the sliding bowl bottom,
clean (do not degrease) the contact surfaces (1).
Apply Alfa Laval lubricating paste or Molykote
1000 Paste with a well-cleaned brush on surfaces
(1 and 2).

G0378281

Check surfaces indicated (1 and 2) for burrs or


galling. Rectify when necessary.

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).

G0378291

The slide-lacquered surfaces will be


destroyed if the surfaces are degreased.

Bowl body

G0378271

Lubricate the O-ring and the seal ring with


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

G0378261

Operating slide

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.
G0205511

The example below describes the repair of the


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.

G0205611

1. Clean the surface thoroughly with a


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

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.

G0205711

Remove the high spots on the surface. Do not


use rotating files or similar. Remove the high
spots only - not the undamaged material.

80

3 Dismantling/Assembly

3.3 Intermediate Service (IS), checkpoints

G0205811

3. An emery cloth of 240 grade should be used


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

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.

3.3.9

G0205911

Prime the repaired area with slide lacquer. Read


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.

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

Wear on large lock ring thread must not


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

G0535211

Disintegration hazards

1.
2.

Lock ring
O-ring for the bowl hood

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
the bowl body by punching in a new mark.

If the marks become illegible, an Alfa Laval


representative should be contacted immediately
to inspect thread wear and for determining the
position of new alignment marks.

82

(MAX 25 )
The -mark on the lock ring must not pass the -mark
on the bowl body by more than 25

G0578131

If the original mark on the lock ring passes the


mark on the bowl body by more than 25 (which
corresponds to A=123 mm), an Alfa Laval
representative must be contacted immediately.

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).

G0537221

If the damage is considerable, use a fine singlecut file, followed by a whetstone.

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.

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

Reasons for dirt or deposits:

1.
2.
3.
4.
5.

Bowl body
Valve plug
Operating slide
Nozzles
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.

G0536811

Check the guiding surface (2) in contact with the


dosing ring. Remove any marks with a whetstone
(grain size 240).

1.
2.

Bowl body sealing surfaces in contact with the


valve plugs
Operating slide guide surface in contact with the
dosing ring

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

G0536911

Correct height of plugs: 14,5 mm.

Tap in new valve plugs

3.3.13 Springs for operating


mechanism
Defective or broken springs may prevent
complete closing of the bowl.

G0536111

Renew those springs which differ from other


springs in regard to length or are defective in
other respects.

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

Wear safety goggles.

G0207511

Risk for eye injury


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


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.

G0778411

For technical reference, see chapter Speed


sensor in the Installation Manual.

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.

1. Check that the contact surfaces on the sensor


and separator frame are clean.
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

G0778311

If the sensor, for any reason, has to be replaced,


fit it in the following way:

Vibration sensor

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
the two black wires are open circuit.

Check also the reverse when the button not


pressed.

See the illustration for exact measurement


when the button is operated.

B.
C.
D.

Cable:
Colour: Grey
Leads area: 0,75 mm2
Material: PVC
Switching points
Contact closed
Contact open

C
D
G0636471

A.

Wire colour codes:


BK

Black

BN

Brown

GN-YE

Green-Yellow

Measurements for operation range of the cover


interlocking switch button

For technical reference, see chapter Cover


interlocking switch (option) in the Installation
Manual.

87

3.4 Intermediate Service (IS), 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 Orings 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 Dismantling/Assembly

3.4.3

3.4 Intermediate Service (IS), assembly

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.

G0588111

2. Put the distributing cover with liquid pipes in


place.

G0589311

3. Fasten the distributing cover.

G0681261

4. Connect the operating liquid hoses (1) onto


the pipes.

89

3.4 Intermediate Service (IS), assembly

3 Dismantling/Assembly

G0601911

5. Assemble the paring disc device. Do not


forget the gasket on its underside.

G0589421

6. Align the three holes (1) in the control paring


disc with the three holes (2) in the distributing
cover.

G0588011

7. Fit the paring disc device in its place.

90

3 Dismantling/Assembly

3.4 Intermediate Service (IS), assembly

G0131721

8. Tighten the screws of the control paring disc.

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

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.

After adjustment rotate the spindle. If a


scraping noise occurs, re-adjust.

92

G0581721

Measurement of height position of operating paring


disc
1. Height adjusting ring(s)

The height position can be adjusted with height


adjusting rings (1)

3 Dismantling/Assembly

3.4.4

3.4 Intermediate Service (IS), assembly

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.

G0810911

2. Fasten the insert ring if it has been removed.


Tighten the screws crosswise and firmly.

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.

G0810811

Check that the guide pin in the bowl body


enters the hole in the operating slide.

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.

Note! Aligned by uneven hole spacing. The


three digits on the ring should line up with
corresponding ones on the operating slide.

G0810711

6. Lift dosing ring in place.

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.

G0522611

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.

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

9. Lubricate the guide surfaces and threads of


bowl body. See chapter 3.3.8 Guide
surfaces on page 79 and

94

G0615821

Support bowl body when turning to prevent it


from rolling.

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.
G0810421

Remove the tool.

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.

G0810211

Tighten the three screws firmly.

G0810111

13. Lubricate the guide surfaces of the bowl body


and sliding bowl bottom with lubricating
paste.

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.

G0810011

Make sure that it fits in the guiding lugs in


bowl body.

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.

G0807611

Left-hand threads!

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

Sharp edges on the separator discs may


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

G0603111

Cut hazard

3.4 Intermediate Service (IS), assembly

G09236A1

3 Dismantling/Assembly

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


caulks on both sides.

Start with the bottom disc (19) which has


caulks on both sides.

Continue with the discs that have thicker


caulks than the six upper discs (17).

Continue with 68 discs (17).

Fit the wing insert (18).

Complete the disc assembly with the six


upper discs (16).

Fit the other 87 discs.

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


caulks on both sides.

Start with the bottom disc (19) which has


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 -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

S0090311

Sharp edges on separator discs may cause


cuts.

G0497121

Cut hazard

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.

G0535621

6. Check that the guide recess on the bowl hood


enters the guide lug in the bowl body.

G0497031

5. Lubricate the lock ring threads, contact and guide


surfaces with lubricating paste.

98

3 Dismantling/Assembly

3.4 Intermediate Service (IS), assembly

7. Remove the lifting tool.

G0544721

8. Lubricate the lock ring threads, contact and


guide surfaces with lubricating paste.

S0078211

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

G0531521

10. Tighten the lock ring by hand.

G0520121

11. Apply the brake.

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.
G0581911

The compressing tool is hydraulic and is fitted


with a relief valve.
13. Tighten the lock ring using the spanner for
lock ring.

G0582311

Left-hand threads!

14. Tighten until the assembly marks are at least


in line.

NOTE

NOTE
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

(MAX 25 )

G0578131

The assembly marks must never pass each


other more than 25 which corresponds to
A=123 mm.

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
in turn should exert a pressure on the disc
stack (4), clamping it in place.

G0544411

1.
2.
3.
4.

Lock ring
Bowl hood
Bowl body
Disc stack

Correct pressure is obtained when it is


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

If the -marks do not reach or pass each


other, the reason could be an incorrectly
assembled bowl or too many discs in the disc
stack. Reassemble and check.

G0135811

To achieve this, add an appropriate number of


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

-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.

S0103111

G0809421

Left-hand threads!

102

3 Dismantling/Assembly

3.4.6

3.4 Intermediate Service (IS), assembly

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)

G0807311

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


the frame ring.

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.

G0807131

Torque screw (3) to 80 Nm.

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

103

3.4 Intermediate Service (IS), assembly

3 Dismantling/Assembly

G0807021

4. Lift on the frame hood with lifting straps


attached to the handles.

G0806921

5. Tighten the hook screws holding the frame


hood.

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
50,5 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)

G0807521

7. Fit the discharge housing. Fit and tighten the


nuts.

105

3.4 Intermediate Service (IS), assembly

3 Dismantling/Assembly

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

G0806221

9. Fit the inlet pipe to the paring disc.

10. Tighten the inlet pipe.


Left-hand thread!

G0806121

S0072811

11. Fit the rectangular rings for the inlet and


outlet hose.

G0806021

12. Connect the in- and outlet pipes. Tighten the


coupling nuts.

106

3 Dismantling/Assembly

3.5

Major Service (MS),


dismantling

3.5.1

Introduction

3.5 Major Service (MS), dismantling

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

G0788611

Vertical driving device

108

3 Dismantling/Assembly

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.

3.5 Major Service (MS), dismantling

Screw
Protecting plate
O-ring
Protecting collar
Screw
Guard
Nut
Cover for spring housing
Gasket
Oil fan
O-ring
Stud bolt
Buffer
Spring
Screw plug
Bowl spindle
Lock ring
Ball bearing
Spring support
Spring
Spring support
Spacing sleeve
Ball bearing
Ball bearing housing
Buffer
Split pin
Wear ring
Spring
Spring support
Spring casing
Gasket
Round nut
Lock washer
Ball bearing
Spring
Spacing sleeve
Ball bearing
Worm
Conveyor
Ball bearing
Washer
Lock washer
Round nut
O-ring
Bottom bearing housing
Screw

109

3.5 Major Service (MS), dismantling

3 Dismantling/Assembly

1. Drain off the oil from the gear housing.

CAUTION

Lubricating oil and various machine surfaces


can be hot and cause burns.

G0035921

Burn hazards

G0127911

2. Remove the cover before starting any


dismantling.

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

G0207911

The worm wheel is quite heavy. Hold it firmly


when dismantling. Risk for jamming injury.

110

3 Dismantling/Assembly

3.5 Major Service (MS), dismantling

G0187411

4. Push the worm wheel with the clamping


element aside.

5. Remove the hood above the top bearing.

G0482811

6. Remove the protecting plate.

7. Remove the O-ring.

G0482911

Remove the throw-off collar with the special


tool.

111

3.5 Major Service (MS), dismantling

3 Dismantling/Assembly

G0483011

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

G0483121

9. Loosen the screw plugs half-a-turn using the


screw spanner and a hammer.

G0483211

10. Unscrew the six nuts and remove the spring


housing cover and packing.

112

3 Dismantling/Assembly

3.5 Major Service (MS), dismantling

11. Unscrew the oil fan clockwise.

G0499311

Left-hand thread!

G0499411

12. Loosen the lock ring half-a-turn counterclockwise.

G0483311

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

113

3.5 Major Service (MS), dismantling

3 Dismantling/Assembly

G0483411

14. Use some pieces of wood for support.

G0483511

15. Remove the packing and if necessary, the


stud bolts.

16. Make a wooden support to be used during


certain sub-operations.

G0499011

Open the lock washer and remove the nut


using the hook key.

G0483611

17. Pull off the complete worm including spring


and ball bearings with a puller. The ball
bearing and conveyor will also become loose.

114

3 Dismantling/Assembly

3.5 Major Service (MS), dismantling

G0483711

18. Remove plugs, springs and buffers. Pull out


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

G0483811

19. Remove the lock ring and replace it with the


puller tool

G0504011

S0083111

20. Remove the ball bearing housing with


bearings using the puller.

115

3.5 Major Service (MS), dismantling

3 Dismantling/Assembly

G0483911

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


holder, spacing sleeve and ball bearing.

G0486411

22. Remove the axial buffer.

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.

G0484121

G0484131

Knock loose and remove the bearings, spring


and spacing sleeve from the worm by using
the special driving off tool.

117

3.5 Major Service (MS), dismantling

Horizontal driving device

G0246561

3.5.2

3 Dismantling/Assembly

Worm gear end


1.
2.
3.
4.
5.

Round nut
Frame bottom part
Bearing housing
Round nut
Large ball bearing

6.
7.
8.
9.
10.

Lock ring
Worm wheel
Clamp element
Small ball bearing
Tolerance ring

11.
12.
13.
14.

Gasket
Worm wheel shaft
Bearing shield
Screw

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

118

Screw
Stop screw
Brake pulley
Elastic plate
Screw
Spring washer
Washer
Coupling disc
Screw
Spring washer
Motor adapter

G0778221

Drive motor end

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

S009711

G0212451

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.

G0212531

S0092911

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

26. Disconnect the motor cables. Note the


positions of cables in the terminal box to reconnect correctly (for correct direction of
rotation).
27. Remove the motor and the three elastic
plates. Use a hoist.

G0777611

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.

S0092221

Fit the tool in the three holes (A).

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.

S0092911

G0777711

30. Fit the puller tool illustrated below and pull off
the coupling disc.

31. Remove the lock ring on the worm wheel


side.

G0192311

Left-hand thread!

G0213411

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.

33. Unscrew the round nut fixing the ball bearing.

G0212611

The nut is locked with Loctite 242.

120

3 Dismantling/Assembly

3.5 Major Service (MS), dismantling

G0212711

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.

121

3.6 Major Service (MS), checkpoints

3.6

Major Service (MS),


checkpoints

3.6.1

Introduction

3 Dismantling/Assembly

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.

Degreasing agent

Slide lacquer Molykote D321 R (varnish or


spray)

Small power drill

2 fibre brushes

G0544711

Recommended agents for priming procedure:

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.

G0206911

1. Clean the lock ring thoroughly with a


degreasing agent and wipe it off.

G0207011

2. Spray the threads, guide and contact


surfaces with slide lacquer Molykote 321 R.
Let the lacquer air-cure for about 15 minutes.

G0207311

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.

123

3.6 Major Service (MS), checkpoints

3 Dismantling/Assembly

G0207211

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


dry for about 15 minutes.

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

G0207311

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.

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
G0134111

The screws are slotted in both ends.

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
G0134211

Identify the cause of oily friction pad. If oil is


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:

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.

Oil the spring when assembling.

CAUTION

G0134311

Formation of rust on brake parts may cause the


brake to jam.

1.
2.
3.

Contact surface on the brake shoe for the spring


Guide surface in the cap for the brake shoe
Spring

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

3.6.4

3 Dismantling/Assembly

Buffer springs and ball bearing


housing

G0283421

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).

Top bearing springs

Cut view of ball bearing housing

G0283521

In case of spring fracture, the complete set of springs


should be replaced, even if only one spring is broken.

Ball bearing housing

G0283641

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.

Max. permitted indentations (A) made by radial buffers

126

3 Dismantling/Assembly

3.7

Major Service (MS),


assembly

3.7.1

Introduction

3.7 Major Service (MS), assembly

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.

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

G0192411

WARNING

3 Dismantling/Assembly

3.7 Major Service (MS), assembly

G0191611

3. Apply some Loctite 242 on the threads of the


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

4. Clean the ball bearing housing in the frame


and oil the outer race of the ball bearing.

G0213511

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.

5. Fit the lock ring. Tighten it with the pin


spanner.

G0246011

Left-hand thread!

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


worm wheel shaft enters into the recess in
the nave of the disc.

G0777711

7. Lock the coupling disc in its position by


means of the plain washer, spring washer
and centre screw.

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.

G0485911

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.

9. Check the three elastic plates. Clean or


renew, if needed.

G0777621

10. Fit the electric motor, using a hoist.

Check the axial play between two of the flexible


plates. Correct measure (A) is 4 +2 mm.

G0633821

The measure can be adjusted by moving the


pulley (1) axially on the motor shaft.

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:

G0191921

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.

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.

G0213811

Slip the clamping element onto the worm


wheel. The tightening is described later in this
assembly instruction.

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.

G0485611

15. Clean the bearing seat in the bearing shield.


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.

G0485741

If necessary, pull it into position using the


screws or tap its centre with the tin hammer.

131

3.7 Major Service (MS), assembly

3 Dismantling/Assembly

CAUTION
Crush hazard

S009711

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.

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

G0246131

Excessive wobble on the worm wheel shaft


may cause vibration and noise.

Measurement of the radial wobble

132

3 Dismantling/Assembly

3.7.3

3.7 Major Service (MS), assembly

Vertical driving device

Check point
3.3.15 Worm wheel and worm; wear of
teeth on page 85

G0189011

1. Wipe off and oil the bearing seat before fitting


the ball bearing.

G0486111

2. Fit the ball bearing, spacing sleeve, spring


holder, springs, spring holder and ball bearing
in the ball bearing housing.

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.

G0486011

Note! Turn the angular ball bearing (B) the


right way - IMPORTANT! The wider shoulder
of the inner race must face upwards.

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.

G0486311

Left-hand thread!

5. Fit the axial buffer in the spring housing.

G0486411

It is recommended to support the spring


housing so the spindle is free below.

134

3 Dismantling/Assembly

3.7 Major Service (MS), assembly

G0486511

6. Place the spindle unit in the spring housing.

G0486611

7. Fit buffers, springs and screw plugs.

135

3.7 Major Service (MS), assembly

3 Dismantling/Assembly

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

G0486731

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.

G0486811

9. Fit the worm with spring component to the


spring housing.

G0486911

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

G0487031

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


spindle.

136

3 Dismantling/Assembly

3.7 Major Service (MS), assembly

G0487111

12. Fit the intermediate washer, the lock washer,


the round nut and lock the washer.

G0508111

13. Fit a new packing and O-ring. If the stud bolts


have been removed, refit them and lock with
Loctite 270.

14. Fit the lifting eye on the spindle top. Carefully


lower the spindle into the frame.

G0487311

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.

G0483211

15. Fit the packing and spring housing cover.


Secure the spindle unit in the frame with the
nuts. Lock them with Loctite 242.

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.

G0483121

Rotate the spindle a few turns to make sure


that there is no obstruction.

G0483011

17. Fit O-ring and protecting hood.

18. Fit the throw-off collar.


Left-hand thread!

G0487711

Fit the O-ring and protecting plate. Rotate the


spindle again to make sure that there is no
obstruction.

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.

G0681911

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.

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

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


excessive, the spindle is probably damaged
and must be renewed.

G0681911

Measurement of the radial wobble

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.

When power cables have been connected,


always check direction of rotation. The
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

S006882

Disintegration hazards

G0485831

WARNING

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143

144

Index

A
Assembly
General directions
Inlet/outlet anf frame hood
Tools (special)
Vertical driving device

49
103
50
127

B
Bearings
Maintenance directions
43
Replacement on horizontal driving device
118
Bowl
Dismantling
56
Bowl body and operating mechanism
Dismantling
62
Bowl discs
Cleaning
29
Disc stack pressure
101
Bowl spindle
Assembly
127
Check point
71, 139
Dismantling
108
Radial wobble
139
Brake
Renewing of friction pad
124

C
Check points
Ball and roller bearings
Before shutdowns
Bowl hood seal ring
Brake
Buffer springs and ball bearing housing
Cleaning agents
Cleaning of bowl discs
Corrosion
Coupling, axial play
Cover interlocking switch (option)
Cracks
Dosing ring
Erosion
External cleaning
Guide surfaces
Lock ring - priming
Oil change procedure
Operating mechanism
Operating slide

43
47
70
124
126
27
29
72
130
87
74
75
75
28
79
122
33
83
84

Repair of galling
Sliding bowl bottom
Speed sensor
Springs for operating mechanism
Vibration analysis
Vibration sensor
Wear liners
Worm wheel and worm - wear of teeth
Cleaning
Bowl discs
Cleaning agents
External cleaning
Corrosion
Coupling
Axial play
Cover interlocking switch (option)
Check point
Cracks

80
85
86
84
42
86
75
30
29
27
28
72
130
87
74

D
Daily checks
Dismantling
Bowl body and operating mechanism
Bowl hood and disc stack
General directions
Tools
Vertical driving device
Dismantling.Vertical driving device

21
62
56
49
50
108
110

E
Erosion
Exploded views
Bowl body and operating mechanism
Bowl hood and disc stack
Horizontal driving device
Operating water device

75
62
56
118
66

F
Frame feet
Replacement

26

G
Gear
Wear of teeth
Guide surfaces
Intermediate Service
Repair of galling

30
79
80

145

H
Horizontal driving device
Check point
Dismantling

O
30, 132
118

I
Intermediate Service
Dismantling
Intermediate service

51
17, 22

122
82
34
36
33
33
36
37
21

M
Maintenance intervals
Maintenance logs
3-year Service (3S)
Daily checks
Intermediate Service (IS)
Major Service (MS)
Oil change
Maintenance, general information
Ball and roller bearings
Before shutdowns
Cleaning
Maintenance intervals
Maintenance procedure
Oil change procedure
Service kits
Vibration analysis
Major service
Metal surfaces
Cleaning and cleaning agents
Corrosion
Cracks
Erosion
Motor
Cleaning
Lubrication

146

66

L
Lock ring
Priming
Wear and damage
Lubricants
Lubrication chart, general, oil groups
Oil change interval
Oil change procedure
Oil level
Recommended lubricating oils
Recommended oil brands
Lubrication of electric motor

Oil. See Lubricants


Operating liquid device
Dismantling

18
26
21
22
24
21

Safety Instructions
Service kits
Shutdown
Spare parts
Speed sensor
Check point

9
20
47
20
86

T
Tightening torques
Frame feet
Holder for rubber buffers on worm wheel
Screws, common
Speed sensor
Vibration sensor

26
131
50
86
86

V
Vertical driving device
Assembly
Check point
Dismantling
Vibration
Vibration analysis
Vibration sensor
Check point

127
71, 139
108
42
86

W
43
47
27
17
19
33
20
42
17, 24
27, 28
72
74
75
28
21

Warning signs
Wear liners in bowl, check point
Worm gear
Wear of teeth
Worm wheel shaft
Radial wobble

14
75
30
132