ALFA Product No. Book No. LAVAL SEPARATION MAB 103B-24 Separator Manual sor145 0601 rerorte- 5 4: Alfa Laval6 Dismantling/Assembly ____ 62 Dismantiing 6.2 .Dismantling To avoid accidental start, switch off and lock 1 Power supply. DANGER A\ covopnotnea Make sure that rotating parts have come to a complete standstill before starting any dismantling work. The revolution counter and the motor fan indicates if separator parts are rotating or not. 6.2.1 Bowl 1. Be sure the bowl has stopped rotating. 2. Loosen the cap nuts and open the collecting cover. 796.2 Dismanting 80 Tighten both lock screws. The bow! parts can remain hot fora considerable time after the separator has come to a standstill. Unscrew the small lock ring by using the special tool, “Spanner for small lock ring”. Left hand thread! Unscrew the large lock ring by using the special tool; “Spanner for lock ring” and a tin hammer. Left hand thread! 6 Dismantling/Assembly i 86 Dismantiing/Assembly 6. Lift off gravity disc/clarifier disc. NOTE If the gravity disc has to be replaced owing to changed operating conditions, see “8.1.1 Gravity disc nomogram” on page 120. Lift out the top disc, disc stack and distributor. @ CAUTION LX carn The discs have sharp edges. 7. Unscrew the cap nut (1). Release the lock screws (2). Lift out the bow! body using the hand tool (3). | ones Disconnect the piping connections. 6.2 Dismantling => Cap nut Lock screws Lift bow! body from spindle 816.2 Dismantling 6 Dismantling/Assembly 9. Remove the outlet parts. —— ee 1 [ eS ] f | Gi Outlet parts = - suitable cleaning agent, see “5.4 Cleaning” “=> on page 66. Remove O-rings and replace SoS them with spares from the major service kit. -— v Check point “5.3.1 Corrosion” on page 52, 3.2 Erosion” on page 54, 3.3.3 Cracks” on page 55. 10. Soak and clean all parts thoroughly in a | | | 826 Dismantling/Assembly 6.2.2 Vertical driving device Remove the outlet housings, feed and discharge Pumps and raise the collecting cover. Remove also the separator bowl. Before dismantling, in the case of 8000 hours Service, or if the separator vibrates while running: V Check point 6.3.6 Radial wobble of bow! spindle” on Page 58. 1. Remove the pump assembly. Inspect the bushings and the wear of seals. 2. Loosen the screw for the revolution counter, and pull out the revolution counter. 6.2 Dismantiing, 6.2 Dismantling __6 Dismantiing/Assembly y 3. Force out the conical pin, using a tinhammer ©, as a holder-on for the worm wheel shaft. | 4. Use the puller-tool to first pull off the bearing and then the worm wheel. 5. Loosen the top bearing holder.6 Dismantling/Assembly 6. Fit the cap nut to the spindle top and lift the spindle. 7. Use the puller-tool to remove the bottom bearing from the spindle. 8. Loosen and inspect the buffer springs. 9. Pull off the upper ball breaking (together with sleeve). | NOTE Always discard a used bearing. 6.2 Dismantling6.2 Dismantling 6 Dismantling/Assembly 10. Every 3 years: clean the oil sump. 11. Clean all dismantled parts thoroughly in a degreasing agent and check for damage and corrosion. v Check point “6.3.1 Corrosion” on page 52. Replace all parts supplied in the spare parts kit.6 Dismantiing/Assembly 6.2.3 Horizontal driving device 1. Remove the motor. 2. Renew the pads on the friction blocks. When refiting the blocks make sure the @ arrow on each block points in the same direction of rotation. See the arrow on the frame. ‘Secure the blocks with washer and split pin. e@ Ifthe friction elements are worn: fit new ones. Replace all friction elements even if only one is worn, If the friction elements are only greasy: clean the friction elements and the inside of the coupling drum with a degreasing agent. 3. Loosen the three screws holding the sealing washer. Use a hexagon key. @ «Remove the worm whee! shat. 6.2 Dismantling 876.2 Dismantling 6 Dismantiing/Assembly 5. Use the puller too! to pull off the sealing rc washer. Protect end of worm wheel shaft with a washer. 6. To replace coupling drum or worm wheel shaft force out the spring pin and gently knock out the shaft. 7. Knock out the horizonta! spindle. - 88 ¥6 Dismantiing/Assembly 6.3 Assembly 6.3 Assembly Clean all parts in a degreasing agent and replace Parts supplied in the Spare parts kits. v Check point “5.3.1 Corrosion’ on page 52, ‘5.3.2 Erosion” on page 54, “5.3.3 Cracks” on page 55, “5.3.11 Top bearing springs” on page 62, “5.3.12 Ball bearing housing” on page 62, '5.3.13 Worm wheel and worm; wear of teeth” on page 63. 6.3.1 Vertical driving device - Before assembling the bowl spindle, make sure the relevant checks have been carried out. Wipe off and oil the bearing seat betore fitting the ball bearing. Inspect the tapered end of the bowl spindle and assemble ball bearings. Heat the new ball bearings in oil to maximum 125°C. NOTE Always fit new bearings. @ L 1. Fit the bearing onto the shaft. CAUTION Z\ Burn hazards Use protective gloves when handling the heated bearings.6.3 Assembly Lower the spindle into position. Apply some Loctite 242 onto the threads of the screw. ‘Check for impact marks on the spindle cone and in the bow! body nave. Check point “5.3.7 Bowl spindle cone and bow! body nave" on page 59. 6.3.2 Horizontal driving device 1 90 Clean the worm wheel shaft and the inner surface of the worm wheel nave thoroughly. Make sure seal ring in sealing washer is turned in the right direction. Force bearing onto shaft, but stop when sealing washer is approx. 10 mm from bottom position. 6 Dismantling/Assembly ‘Stop forcing bearing when A=10 mm6 Dismantling/Assembly 3. Push the worm wheel into its position on the shaft on top of the bearing. Knock with a brass sleeve on end of wheel. Observe holes for spring pin. Count the number of teeth! See Chapter ““8 Technical Reference” on page 115. DANGER ZN Disintegration hazard When replacing the gear, always make sure that the new worm wheel and worm have the ‘same number of teeth as the old ones. 4, Check with the conical pin to get the larger side of holes in same direction, when holes coincide, mark the parts to facilitate the fitting. Remove worm wheel from shaft. 5. Clean the ball bearing housing in the frame and oil the outer race of the ball bearing. Force the worm wheel shaft into its position in the frame, so that the ball bearing enters correctly into its seat. __6.3 Assembly | 916.3 Assembly 6. 92 . Knock the bearing into position with the |. Fit the revolution counter. Tighten screws of sealing washer. Fit the worm wheel and knock conical pin into holes. mounting tool and a hammer. Lock it with the lock screw. 6 Dismanting/Assembly6 Dismantling/Assembly 10. Fit pump and shear pin coupling. See “6.4.1 Exchange of shear pin coupling” on page 98. 11. Ifthe coupling disc has been loosened without first marking its position on the motor shaft, the correct position for position of coupling disc must be determined again. Vv Check point “5.3.8 Coupling disc of motor” on page 60. 12. Fit the motor. DANGER AN Disintegration hazards ‘When power cables have been connected, always check direction of rotation. If incorrect, vital rotating parts could unscrew causing disintegration of the machine. 6.3 Assembly 936.3 Assembly 6.3.3 Bowl Make sure that the check points are carried out before and during assembly of the separator bowl. V Check points “6.3.7 Bowl spindle cone and bow! body. nave" on page 59. 1. Wipe off spindle top and nave bore in the bow! body. Apply a few drops of oil onto the taper, smear it over the surface and wipe it off with a clean cloth. Fit the bow! body on the spindle. Be careful not to damage the spindle cone. ‘Screw cap nut onto the spindle. Tighten firmly. 2. Before assembling the bow! discs, check the threads of the bow! hood and bow! body. v Check point 5.3.5 Lock ring; wear and damage” on page 56. 3. Fit bowl hood into position. Make sure guides are correctly located. 94 6 Dismantling/Assembly6 Dismantling/Assembly 4. Degrease lock ring threads, contact and locating faces (see arrows above). Apply Molykote 1000 paste to the threads and faces stated. Brush in the paste according to the manufacturer's direction. 5. Secure the bow! from rotating. Screw in both lock screws. 6. Tighten lock ring counter-clockwise (left-hand. > thread) until bow! hood lies tightly against bow! body (in a new bow! marks will now be in line with each other - see above). Left-hand thread! WARNING AN Disintegration hazard The assembly mark on the bow! hood must never pass the mark on the bow! body by more than 25° (or 25 mm). v Check point “6.3.4 Disc stack pressure” on page 56. 63 Assembly 956.3 Assembly 7 _ 6 Dismantling/Assembly 7. Release both lock screws (A) and tighten both cap nuts (B) to a maximum torque of 12 Nm. NOTE The two lock screws must be fully released to prevent risk for damage to bow! body. | 8. Fit the connecting hoses if they have been removed. Make sure to fit their gasket rings. 968 Technical Reference 8.7 Lubricants 8.7.3 Recommended oil brands Alfa Laval lubricating oll group A/220 5921601 rox 2 | 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. Alfa Laval lubrication oil group A ——$<$__ osity grade VG (ISO 3448/3104) 220 Viscosity index VI (ISO 2908) >92 Manufacturer Designation Castrol Alpha ZN 220 ELF Polytelis 220 Esso/Exxon Nuto 220 Tersso 220 Terrestic 220 Mobil DTE Oil BB ‘Optimot Ultra 220 Shell Morlina 220 Tellus 220 Texaco/Caltex Regal Oil 220 Paper Machine Oil Premium 220 135& Technical Reference 8.7 Lubricants Greases for ball and roller bearings: NOTE | Always follow the specific recommendation for lubrication as advised by the manufacturer. Manufacturer] Designation ‘Alfa Laval No BP Energrease MM-EP2 e Energrease LS2 Castrol APS 2 Grease EPL2 Dura-Lith Grease EP2 Chevron ® El Epexa 2 Esso/Exxon Beacon EP2 . Unirex N2 Fina Marson EPL 2A Mobil Mobilith SHC 460 Mobilux EP2 Gulf Gulflex MP2 Q8/Kuwait Rembrandt EP2 Petroleum Shell AWvania EP Grease 2 @ Albida Grease EP2 SKF LGEP2 or LGMT2 Texaco Muttifak AFB 2 @ wm 1398.8 Drawings 8 Technical Reference 8.8 Drawings Cross-section 8.8.1 Cross-section of separator 14188 Drawings 8 Technical Reference 8.8.2 Exploded view | | Exploded view of separator frame 1428 Technical Reference 8.8.3 Water adding device (option) 8.8 Drawings8.8 Drawings 8 Technical Reference 8.8.4 Pump Inlet and outlet pump, cross-section ‘Alla Laval ret 529209 1448.8 Drawings 8 Technical Reference 8.8.7 Electric motor Ata aval. 681897 rov 9 | A Knockout openings for cable glands on both sides 2 x 023 B_ Sheet-steel fan hood e Manufacturer ABB Motors “Type of mounting Degree of protection Manufacture drawing Cat. BA/Marine motors lec a-7 Ec 348 GB 98-05 Standards IEC 34-series, 72, 79, 85. Size IEC 80B QR | mio Type M2AA 80B Weight 10 kg D IM 3001 IPSS Poles 4 Qa Insulation class F 2108 Lk) Bearings D-end 6204-2, "8 Neend 6203 22/63 U msost Method of cooling —_IC.411 (IEC 34-6) Totally enclosed 3-phase motor for marine e service» 9) The motors can be designed to fulfill requirements of following Classification Societies: (Essential Service if required) 6 oyds Register of shipping ro) Det Norske Veritas (Dnv) Germanischer Lioyd (ey) Bureau Veritas (By) American Bureau of shipping (ABS) Registro Italiano Navale (RINA) Nippon Kaiyi Kyoka (NK) Korean Register of Shipping (KR) Polski Rejester Statkow (PRS) China Classification society (ccs) Indian Register of shipping (IRS) Maritime Register of Shipping (RMS) 148Product No. Book No. A LAVAL § Spare parts catalogue Reservdelskatalog Ersatzteilkatalog Catalogue de piéces de rechange Catalogue de piezas de recambio Karanor sanachbix yacten 861145-09-01 1270118-02 v2 EPA RATION Catalogo de pecas sobressalentes Varaosaluettelo Katadoyoo AVTAAAGKTIKWVY Catalogo parti di ricambio Reserveonderdelen- catalogus Reservedelskatalog Alfa Laval1.2. Translation list Oversattningslista Ubersetzungsliste Liste de traduction Lista de traducciones 1 Read this first @® reservdel gelitert Resendeenummer | TebN Numéro do pibce Poza No, ‘ria neat Quant ‘Canta ‘De 2 | Benamni zeict snomination in ens Betenung oe Devo eae ores [Netes 2 | anmatningae Aamertangen Remarquee Nous Maskinyp Maschinenyp Type de machine Tipo de maquina Produkine Prodiknummer Numéro de proaut’ | Nimero de producto Maskiniocksbendmning | Bezeicnung dos Dénominatin de parte | Descipctn de soccin |eeeeroton | Masctinenblocs de machine ola néquina | Machine unit _] Maskinblocksnr ‘Maschinenblock Nr. Partiede machine n& —_| No, de seccién de | maquina ‘Underguppabenimning | Bozeihung der Denomination de Descrpcion do Unteronppe soverensemblo subconjnto "| Uncersrepane Unterarape Ne [Nd sous-ensombie | Nimere do eubconunio 7) Sesian Sihe See Voi page Vase apna Fiouhindening Bichinweo Rat doi. Retorencia de gua Prodan Prodirame Nom a prod Nombre dl producto Utyieeéavindogér | Austavecheforden | Lovemplacement | Elraartio require a wl | oméalanseng aviulan | Wederauswuehing dr | nécosso te reogulvad alle oes Trees! ‘Béqulorage abot : £ | so wepart Sihe sopaala Vor at iparte dos | Véace lint de plezae jparetist | rosorcaata Exseteltste pboes derechange” | eepareda “Wot delivered ae spare | Lovereas ojeom Nichals Ereatte | Non iré comme pico | Noe entega con derechange pieza de recambio 19MAB 103B-24 2. Frame with collecting cover | 7 | | 549377- Ref PartNo Description2 Frame with collecting cover 232.1 Driving device horizontal 2 Frame with collecting cover 2.1 Driving device horizontal i [Machine unit amber or | Subassembiy description | i | 549376- | Ref PartNo Description [203 -04 ‘Notes elege ‘Bal bearir snag 827768_ 90 Coupling iso f ee S Ce cane Bh 2 [Screw {Washer2 Frame with collecting cover 252.2 Feed and discharge pump 2 Frame with collecting cover 2.2 Feed and discharge pump Machine unt umber of Sibassemby desciption | | 529209- i Ref PartNo Description 182 -83 ‘Notes 529206 01 Steve 223406 14! 1595797 01 (Bushing 5485101 using 262 Frame with collecting cover2.3 Frame hood 2 Frame with collecting cover 2.3 Frame hood ‘Machine unit number or 7 ‘Subassembly description | 531484- | Ref PartNo ‘Description 1 1581484 80 \Colleting cover aioe ‘atte os a 23 223406 13 'O-ring2 Frame with collecting cover 29MAB 1038-24 3 Separator bowl T Machine unt number or ! Subassembly description i ! 524700- Ref PartNo Description 88 . 1 1 ‘546701 01 Bowl body 1522981 01 !Lock ting ES 22983 08.|Gravit ‘828198 03 Gravily dso 1528198 07 iGravily dso B+C BRS3 Separator bowl 31MAB 103B-24 4 Parts for mounting of motor Ref 32 PartNo Description 2773 “Motoradaper youes_'Sha 2 [Was lut T ‘Machine unit number oF ‘Subassembly description 548783-4 Parts for mounting of motorMAB 103B-24 5 Set of fittings (for machine without pre-heater) ‘Machine unit number oF ‘Subaseembly description 533365- 1 | - 902 05 |Pug 1587598 80 Connecting 590001 01 fTube 0208: 546229 08 Rectang ing 58999 01 Hexagon able ran dtMAB 103B-24 8 Set of tools Ref PartNo Description 30282 [Bowl spanner 67028 Bowl spann S24717 01 [Serow + 225308 08 [Laing eye nu 40 Machine unit number or ‘Subassembly description 549379-8 Set of tools 3 | 6 7 8 9 10 " 12 13 4 15 16 7 18 19 20 21 _| 41MAB 103B-24 9 Major service kit Machine unit nariber oF T Subassembly description | 549286- | :! it __Ref___ PartNo ‘Description ‘Quanity : 1 ee ; . ee lasts 1 | oo pe ee cats deMAB 1038-24 10 Water adding device | Maahine a amiboroe——] : | ‘Subassembly description 1 | | 517842- | ! Ref PartNo Description i i Fo) 817080 81 20608 Rectangular 6 517846 01 Noodle le 252612 02 Hose nipple10 Water adding device