[112-5 Maintenance Manual Instruction \ © Precaution in safety. @ How to disassemble Manual \ and reassemble. @ Maintenance and checkup procedure. @ Trouble shooting. MITSUBISHI SELFJECTOR I uture series FlE-2000-01-MM1IMPORTANCE | ‘The manual is edited for treating mineral oils such| as for purifying fuel oil or lubricating oil. aASELFJECTOR Instruction Manual Maintenance ManualA\warNING The instruction manual is a guidebook for using the automatic discharge type oil] |purifier , MITSUBISHI SELFJECTOR FUTURE SERIES (hereinafter referred to as SELFJECTOR). SELFJECTOR is a fast rotating centrifugal machine. Before using it, sufficiently be| | versed in details of the manual. (Handle it safely and so as to fully exhibit the function of SELFJECTOR. SELFJECTOR is basically available in the following three versions. The operation manual describes the operations and control devices of the individual versions separately from what is common to all. With this in mind, it is expected that the ‘manual will be read. No. ~~ Available Version | TypelD | Code* 1 Total discharge type Automatic specification |F Manual specification {2 Partial discharge type Automatic specification FP 3 | HIDENS type HIDENS specification FH @_| SUPER HIDENS ype ‘SUPER HIDENS spesification | SH] "These type codes are sutffixed to model designations to identify the respective ‘SELFJECTOR versions such as SJ10F, SJ10FP or SJ10SH. ‘The composition of instruction manual for SELFJECTOR is as follows. ‘The present manual is Part 5 "Maintenance manual’ Use each manual according to the particular purpose to sufficiently understand the information. OE EE JASELFIECTOR Instruction Manual Maintenance Manual[intended for Part Manual Description @lelo 1. | Aboard fitting-out procedure | Information for machine transport, handling and | O storage. Instructions on how to install and dimensions. ‘System diagram and connection diagram. 2 | Operation manual + Precautions in safety. Configuration and structure of SELFJECTOR. ° Motor, starter and control panel. Detector. 3 | Operation manual 2 Precautions in safety, Functions of component devices. ° Operation setting items and adjusting method. How to start and stop. fe) 4 | Operation manual 3A Precautions in safety. Functional, operational and maintenance information oO ‘Operation manual 3B Precautions in safety. Functional, operational and maintenance information ° Operation manual 3C Precautions in safety. Functional, operational and maintenance information oO Operation manual 3D. Precautions in safety. Functional, operational and maintenance information Oo Water Detector. Operation manual 3E Precautions in safety. Functional, operational and maintenance information oO Operation manual 3F Precautions in safety. Functional, operational and maintenance information fe) Water Detector. ei nance m ry 1S ee eae oe c oe tien oan woh oo | oe retteste ee | @ : for Design engineer. @ :for installer. @ : for Operator or Engine engineer. NOTE Relevant operation manual only is furnished out of Part 4 (Operation manual 3A to 3F) when. icated below is purchased. ‘SELFJECTOR with any types of the automatic specification: ‘Type of automatic specification : FSC , FBC , FSP , FSH, FSH-PA @ASELFJECTOR Instruction Manual Maintenance ManualCONTENTS 1 PRECAUTIONS IN SAFETY .. 1.1. SYMBOLS RELATED TO SAFETY asso To4 1.2 LABELS FOR SAFETY... 12 1.3 SAFETY PRECAUTIONS... 18 1.4 DEFINITION OF TERMS 16 2 DISASSEMBLY AND REASSEMBLY .... 2-1 2A DISASSEMBLY .nrcsesne 244 Trap. 212 Bowl. 21.3 Horizontal shatt. 248 2.4.4 — Water supplying device 224 21.5 Vertical shatt BOT 24.6 Gear pump... 231 2.2 REASSEMBLY. 294 22.1 Bowl. 2-36 222 Vertical shaft 2.08 22.3 — Water supplying device ..n..un 2-39 224 — Horizontal shat. 299 225 — Reassembly of trap 241 226 Gear pump... 242 3 MAINTENANCE INSPECTION PROCEDURES: ot 3.1 ROUTINE CHECKS 1 BA 3.2 LUBRICANT REPLACEMENT INTERVALS... 3-2 3.3. EXPENDABLE PARTS REPLACEMENT INTERVALS 3-3 3.4 BOWL OPENING INTERVALS (GUIDELINES) "°"*”” 35 3.5 OVERHAUL (GUIDELINES) "TT? 35 4 MAINTENANCE INSPECTION PROCEDURES. FOR MAJOR PARTS.. 4 4.1 BEARING REPLACEMENT INTERVALS....4-1 42 BOWL anne a4 4.2.1 Corrosion of bowl. At 4.2.2 Corrective steps for corrosion....4-2 42.3 Disct 43 4.24 — Bowl body 4.25 Bow! hood.. 4.2.6 Main seal ring 4.2.7 Distributor, 4.2.8 Various types of O rings of bow! 429 — Main cylinder... 47 4.2.10 Pilot valve assembly. 4.3 VERTICAL SHAFT SYSTEM... 43.1. Vertical shaft... 43.2 Upper springs... 48 43.3 Lower bearing block. 43.4 Flatspring.... 43.5 — Steel ball... 43.6 Lower spring 49 43.7 Height of vertical shaft 410 4.3.8 Installed height of flat spring (adjustment of spacer) 410 4.4 HORIZONTAL SHAFT SYSTEM ... ant 441 Spiral geatannnn 4a 4.4.2 Horizontal shaft. 44 443 Collar. Att 4.44 Friction block... aie 445 Friction pulley.... ool JASELFJECTOR Instruction Manual Maintenance Manual45 GEARPUMP: ANZ 45.1 Safety joint. ate 45.2 Drive gear, driven gear and bush -12 -12 453 Valvestem.. 4.8 LUBRICANT. 413 4.7 BRAKE EQUIPMENT..... 413 4.8 WATER SUPPLYING DEVICE.. 413 4.9 INSPECTION OF PROTECTIVE EQUIPMENT 414 4.9.1 Leakage Monitor (LM) ren 444 4.9.2 Discharge Detector (DD). a4 5 PERIODIC INSPECTION CHART 54 6 CAUSES OF TROUBLES AND CORRECTIVE STEPS. 64 6.1 ALARMS... 64 6.1.1 Types of alarms. 61 6.1.2 Alarm indications. 62 6.1.3 Processing sequence after ‘occurrence of alarm ...... 64 6.1.4 Self-diagnostic fnetion of detectors 65 6.2 OCCURRENCE OF Olt LEAKAGE. 66 6.2.1 Check the flow rates of valve opening and closing operating water and sealing water. 66 6.2.2 Checks to perform by disassembling bow! 6-7 623 Checks to perform by disassembling water supplying device. 67 624 OKC ren cece OF 6.3 OCCURRENCE OF ABNORMAL VIBRATION 69 JASELFJECTOR Instruction Manual 6.3.1 Check for unbalance in the bowl. 69 6.3.2 Checking for defects in vertical shaft system 69 63.3 Checking for defects in horizontal shaft system... 6.4 DOES NOT DISCHARGE SLUDGE EVEN IF 69 DISCHARGE PROCEDURES ARE PERFORMED a 6.5 MIXED FLOW OF WATER TOWARD LIGHT LIQUID courier 6-11 6.6 LOWFEEDING RATE OR NOTFED AT ALL 6.7 GEAROILMIXED WITH WATER... 6.8 POOR SEPARATION... 69 — LowsPEED. 6.10 SLUDGE UNEVENLY ACCUMULATED IN BOWL 612 6.11 MIXED FLOW OF OIL TOWARD HEAVY LIQUID. ouner... 6.12 ACCESSORIES 6.12.1 Solenoid valve unit for the operating water. 6.12.2 Solenoid valve for water . 612.3 Three-way raw 6.12.4 Leakage Monitor (LM)... 8-15 6.12.5 Discharge Detector (DD) 6.12.6 Detector fuse replacement procedures 6.12.7 Water Detector (WD)... Maintenance Manual1 Precautions in safety For correct use, carefully read the "Precautions in safety" beforehand. Precautions in safety given in the instruction manual are intended for safely and correctly using the product and avoiding danger or damage to user. Carefully read the precautions and do not operate, maintain or handle SELFJECTOR before you are fully versed in them. 1.1. Symbols related to safety In the manual, precautions are headed by the following marks. Be sure to observe them because they are important for ensuring the safety. A\warnine: indicates a potentially hazardous situation which ,if not heeded, could result in death or serious Injury. /\\caution indicates a hazardous situation which ,if not heeded ,may result in minor or| moderate injury or damage to the purifier or faci NOTE: indicate precautionary instructions that given contain what must be done without fail and what should be kept in mind as a guide in operat SELFJECTOR and doing related work. LS a@ASELFJECTOR Instruction Manual a Maintenance Manual1.2 Labels for safety There are 3 different labels for safety. The one shown in 11 is put in the spare part box. After fiting-out aboard, the person in charge of installation is requested to attach it on an easily visible place near SELFJECTOR. Pic 2, Pic 3are factory attached direct on SELFJECTOR. Do not smear them by painting but keep them visible at all times. Safety labels are available any time. Request them as required. SAPTY INSTRACTIONS KAOCRE sate aa ivan Oren THis \ PLUG » WHORX SRL? } JCTOR RUNNING. Jaatazo7 97am ND eeran, WASELFIECTOR Instruction Manual a Maintenance Manual4.3 Safety precautions A\ WARNING The bowl of SELFJECTOR produces a large centrifugal force when it rotates. Wrong handling is very dangerous. Pay utmost attention according to the manual for operation, disassembly, reassembly, maintenance, checkup, etc. Use of non-genuine parts might damage SELFJECTOR or impair human safety. Be sure to employ genuine parts. © Perfectly assemble. Many points of SELFJECTOR are connected by screws. When assembling, make sure tightening is complete, Running with poor tightening is very dangerous. Doubly make sure of secure tightening particularly of. (A) Bow! nut (B) Disk nut (C)_ Cap nut of Vertical shaft {D) Set bolt of Frame cover (E) Lock nut (hexagon) of inlet pipe Be sure that tally marks of the bowl and other so marked parts are aligned. If the tally mark is excessively mis-aligned when the Bowl nut is tightened, contact our company or service agency. AASELFJECTOR Instruction Manual AG Maintenance Manual‘© Immediately stop if vibration is excessive. Vibration of SELFJECTOR is caused by unbalance, ship oscillation, SELFJECTOR installation, etc, If the vibration is excessive, immediately stop SELFJECTOR without discharging sludge. Then, check for the cause and take necessary corrective action to ensure safety before restarting SELFJECTOR. To be more specific, if the vibration at the point A of Fig. 1-1 exceeds 100 1: m (peak to peak) at rated speed, stop SELFJECTOR Even if readings are below 100 x m, continuous cruising ship vibrations 4-5 times higher than registered when external vibrating forces are small, such as when the main engine is not in operation, could adversely affect the durability of SELFJECTOR. In such case, implement routine and periodic checkups to ensure that SELFJECTOR performs trouble-free as it should. CASELFIECTOR Inetucton Maral va Maintenance ManualA\warnine © Make sure of complete stoppage before loosening each section. Make sure the bow! has complete stopped rotating before loosening or disassembling each section. Whether completely stopped or not can be checked at the motor fan or Gear pump and Horizontal shaft connecting section (Safety joint) © Take care in handling the parts. SELFJECTOR is a precision machine. Handle it attentively away from impact and high temperature. Particularly never heat the bow! parts (Bowl body, Bow! hood, etc.) by open flame nor weld them. © Beware of corrosion and erosion. Periodically check whether any damage is produced by corrosion or erosion. For details, contact our company or service agency. © Others 1, Before disassembling, turn off the starter. Before treating a treating liquid other than specified initially, contact our company or service agency. ‘The bow is factory balanced. Never interchange bow! parts [Disc (1)] even wi the same model. For ambiguous points in the instruction manual, contact our company or service agency. _——— SS @SELFJECTOR Instruction Manual a Maintenance Manual1.4. Definition of terms Density (0): Mass per unit volume. Specific gravity (7°): Ratio of mass to mass of water of the same volume. Varies with temperature. Feed rate: Volume per unit time of untreated liquid upstream the purifier expressed in terms of Un or m'/h, Actual capacity: Purifier treating capacity based on SM Standard (eliminating sludge with 1.8 of specific gravity and 24m of diameter or more). (See "Feed rate" above.) Feed liquid: Untreated oil to feed to purifier. Light liquid: Oil treated by purifier or purified oil. Heavy liquid: Separated moisture and heavy ‘components in oil or simply "water’ Sludge: Solids accumulated in bow! in narrow sense. Mixture of solids, water and oll discharged from bowl in wide sense. Interface: Boundary surface between heavy and light liquids in bowl, Purifier operation (purifying operation): Operation of separating into 3 phases or liquid, liquid and solid or, here, water and solids. (See "Purifier operation") Clarifier operation (clarifying operation): Operation of separating into 2 phases or liquid and solid or, here, into oil and solids. (See "Clarifier operation",) Parallel operation: Operation with oil fed proportionally to several purifiers arranged in parallel. (See "Parallel operation") Series operation: Operation by several purifiers arranged in series. (See “Series operation") Total discharge type SJ Purifier designed to totally discharge all contained in the bow. Partial discharge type SJ Puri r designed to partially discharge water and solids only in the bowl. This type has the total discharge function as well, Abbreviations and units L: Liter: fh: Hour(s): min Unit of volume. Unit of time. Number of revolutions per minute. Hz: Number of frequency. (cyoles per second) $: — Unitof diameter in mm. mm?/S: unit of kinetic viscosity of oil. ISO: Standards established by International ‘Standardization Organization. VG: Indication of viscosity of lubricating oil in accordance with ISO. JASELFJECTOR Instruction Manual Maintenance Manual2 Disassembly and reassembly 2.1 Disassembly Points to remember when disassembling AN WARNING © Check to ensure that the machine is in the completely stopped state. Check the fan of the motor to determine whether the machine is stationary. ‘© fan optional Discharge Detector is provided, the LED will flash during rotation, and will light when the machine stops, enabling you to determine that the machine has stopped. (The Discharge Detector is standard equipment on the automatic specifications FSH-1A, FSP-1A, FSH-PA.) © Tum off the power supply of the starter to eliminate the possibility of sudden rotation of the SELFJECTOR. Close the valves of feed liquid inlet and light liquid outlet. When a steam type oil heater is provided, close the steam supply pipe. © The piping and main body (the bow in particular) are heated to a high temperature by the treatment liquid. To prevent burns, take proper steps such as wearing protective gloves. © Donot attempt any further scope of disassembly than covered in this manual. © Make sure that the SELFJECTOR is always operated with the main body fully assembled. Never operate the machine with the bow! exposed by removing the cover, as accidents could result. NOTE |All the screws used in the SELFJECTOR are “threaded clockwise”. .SELFJECTOR Instruction Manual Maintenance Manual 2A list of required tools a ° 817 °° < . Jack (10) 801 Dismantling stand Cap nut spanner O— 818 dl Hook spanner 809 Jack (3) for wt alo i s10 Push bolt Main sealing cutter — Bow! nut handle = FB on iH = ee 808 bolt 2 Jack (1) — . al } Protective plate ooo 7 804 Disc nut handle 813 Jack (4) Jack 6) (| 805 Light liquid chanber handle a 822 Jack (6) ack (9) Bee (ss40F~S180F) VO c 823 816 handle (1) Jack(7) Disc clamp plate 816 U Jack ®) B24 shackle aASELFJECTOR Instruction Manual Maintenance Manual244 Trap Remove the plug mounted in the lateral direction of the bracket to remove the oil from inside the piping. (Automatic specification machine) Loosen the cap nuts at the top and bottom of the sealing water tube (408) and remove the top of the sealing water tube. (Manual specification machine) Remove the measuring hopper together with the globe valve. Remove the cap nuts of the connecting pipes (2) (324) and connecting tube (2) with the hook spanner (818). Loosen the union nuts (326) at the bottom of the connection pipes and tube with the hook spanner (818) and direct them sideways to make sure that when the trap is removed, they do not get in the way. 9-1) Use care to prevent loss of the flow rate regulating orifice inserted in the portion indicated by the arrow. (Fig. 2-2) Remove the cover nut (317) with a spanner. (Fig. 2-2) Using a spanner, remove the nut (820) tightening the inlet pipe. (Fig. 2-3) Loosen the socket set screw (313) (M6). Use care to prevent loss. (Fig. 2-4) @aSELFJECTOR Instruction Manual Maintenance Manual 23LLightty strike the top of the inlet pipe with a wooden hammer to detach the tightly held taper portion. (Fig. 2-5) Remove the socket cap screws (302) (in four places) locking the frame and trap. Use care to prevent loss of the socket cap screws. (Fig. 2-6) Thread the jack (6) (814) into the threaded portion of the upper hood and mount the handle (823). (Fig. 2-7) A CAUTION When it is withdrawn by the chain block, use care to make sure that the wire does not get out of the handle. A CAUTION Don't install the wire on the grip of the trap (301) to 'withdraw the trap {Models SJ10F~30F (FH/FP/SH types, are the same as F type}. Damage to the trap may result. Install the wire on the handle of the jack (6) and withdraw the sludge cover (trap) (301) in the vertical direction through use of the chain block. (Fig. 2-8) SELFJECTOR Instruction Manual 24 Maintenance Manual21.2 Bowl Refer to the Bow! Assembly Drawing (Fig. 2-31,Fig. 2-32) 2.1.2.4 Removing gravity disc Mount the disc nut handle (804) on the disc nut (122) and hold it down by hand to make sure that it does not go up, and strike it with a hammer counter-clockwise to remove it. (Fig. 2-9) Remove the heavy liquid chamber (134), impeller (2) (321), packing (133) and gravity disc (121). (Fig. 2-10) On the Models SJ10F~30F (FH/FP/SH types are the same as F type,), the heavy liquid chamber, impeller (2) and packing are not provided. 116 ‘The gravity disc can be replaced after disassembly up to this step. Mount the light liquid chamber handle (805) to the light liquid chamber (120), hold it down by hand to make sure that it does not go up, and strike it with a hammer to remove it. (Fig. 2-11) Fig. 2-11 @ASELFJECTOR | Instruction Manual Maintenance Manual 25Pull and remove th by hand, (Fig. 2-12) ipeller (1) (322) and inlet pipe (319) 2.1.2.2 Withdrawing bow! Secure the dismantling stand (801) on the dismantiing site Fig. 242 through use of the drilled holes in four places. (Fig. 2-13) Remove the cap nut (124) tightening the bowl on the eal vertical shaft, using the cap nut spanner (808). (Fig. 2-14) >< How to use cap nut spanner Insert the cap nut spanner in the bowi, set the spanner on the cap nut, and thread the threaded rod of the spanner into the threaded hole at the head of the cap nut (a), turn the handle of the spanner (b), and draw it up. The bow! can then be removed with the cap nut (124) mounted. Fig. 2-43 124 Fig. 2-14 wASELFJECTOR Instruction Manual Maintenance Manual 26Mount the jack (4) (821) by threading it into the threaded portion of the distributor (108). (Fig. 2-15) Turn down the handle of the jack (4) (821) until the bow! is slightly raised. (Fig. 2-16) NOTE When the push bolt is brought into contact with the end| lof the vertical shaft by rotation of the handle, the resistance of the handle will increase. The bowl is held| tightly against the vertical shaft by the taper portion. To loosen the bowl, further rotate the handle by striking| with a hammer, and turn it down until the bowl is| slightly raised. A. CAUTION If the bow! held tightly against the vertical shaft by the| {taper portion is directly lifted, the vertical shaft will also be drawn up, and damage to parts may result. Mount the shackle (824) to the handle of the jack (4) (821) and slowly draw up the bow! in the vertical direction by use of the chain blook. (Fig. 2-17) NOTE The bowl might be withdrawn with the bow bush attached. Fig. 2-16 Fig. 2-17 JASELFJECTOR Instruction Manual 27 Maintenance ManualA CAUTION When the bowl is placed on the dismantling stand, use care to make sure that your hands are not caught. Place the lifted bowl on the dismantiing stand (801). In this case, make sure that the four pins of the dismantling stand fit in the holes at the bottom of the bowl. Remove the jack (4) (821). (Fig. 2-18) 24.2.3 Detaching bow! nut and withdran Thread the disc clamp plate (807) into the distributor (108) and tighten it with the nut. (Fig. 2-19) (Turn down the nut firmly by striking with a hammer.) Before tightening the nut, check to ensure that the disc clamp plate bolt has been threaded all the way into distributor. The bowl nut can be removed easily compressing the disc (1). NOTE If the bowl nut is removed directly without use of the [disc clamp plate, application of undue pressure may cause damage to the bow! hood and body. Make sure| {that the above-mentioned procedures are followed. AASELFJECTOR Instruction Manual 28 Maintenance ManualAfter securing the bow! nut handle (802) on the bow! nut (119) with the nut, rotate it by striking with a hammer to remove the bow! nut. (Fig. 2-20) NOTE ft the bow! nut handle is not secured with the nut, when it is struck with a hammer, it may lift and cause| damage to the pins. NOTE When the bow! nut does not rotate even if lightly| struck with a hammer, it means that the disc (1) shown| in Fig. 2-19 has not be fully tightened. Do not attempt! to remove the bow! nut by forcibly striking with al hammer. Damage to the bow! parts and tools may| result. Loosen the nut to remove the disc clamp plate (807). Place the protective plate (812) on the top of the distributor. (Fig. 2-21) Place the jack (1) (803) on the bow! hood. (Fig. 2-22) Fig, 2-22 @ASELFJECTOR Instruction Manual ne ‘Maintenance Manual‘Secure it with the disc nut (122). (Fig. 2-23) Turn the push bolt (819) to raise the bow! hood. (Fig. 2-24) Install the wire and remove the bow! hood with a chain block. {If the top disc (113) comes out with the hood, remove it by lightly striking with a wooden hammer.) [NOTE ‘The main seal ring (108) is provided under the bowl) |hood. When the bow! hood is removed, use care to) prevent damage to the seal surface. NOTE Withdraw the bow! hood vertically. If it is removed with an undue force in a tilted state, the fitting portion might be damaged, making reassembly difficult. Fig. 2-24 AASELFJECTOR Instruction Manual 240 Maintenance Manual3 Main seal ring removal procedures AY CAUTION In this case, care should be taken not to damage the main seal ring groove (its side surfaces in particular) ‘on the bow! hood side. Liquid leakage may result. Turn the bowl hood (115) over, and cut the main seal ring with the main seal ring cutter (810), using a hammer. Cut the main seal ring in two places 1 to 2om apart and remove the cut piece. Then lift the ring with a screwdriver. By so doing, the main seal ring can be removed relatively easily. (Fig. 2-25) Mount the jack (4) (821) in the distributor and lift i, Then the disc (1) (111), upper dises (112) and top disc (113) will come out in the condition that they were mounted in the distributor. (Fig. 2-26) ‘The uppermost portion of the disc (1) accommodates three upper discs (112) which do not have any fringe in their circumferential portions. 810 115 SS @ASELFJECTOR Instruction Manual ant Maintenance Manual2.1.2.4 — Removing main cylinder VA \ CAUTION Use care to prevent damage to the sheet surface and sliding portions. NOTE @ To remove the main cylinder, mount the jack (1) and then strike the jack evenly all around with a protective rod or something else in between to lower the main cylinder all the way. Then draw up the main cylinder by use of the tool. © Spray a penetrating lubricant against the inside| and outside circumferential sliding portions of the main cylinder beforehand. An effective auxiliary| means is to put cubes of ice inside the main cylinder ( indicated by the arrow ) and remove them 2 or 3 minutes later. After installing the protective plate (612) in the cap nut installing portion of the bow! body, secure the jack (1)(803) ‘on the main cylinder with the socket cap screw. (Fig. 2-27) ‘Turn down the jack with the push bolt (819) and handle(1) (828) to remove it. (Fig. 2-28) NOTE There is only a slight clearance between the main cylinder and body. When the main cylinder is removed, if it is only slightly inclined, it can no longer be| |withdrawn, When the handle resists, do not blindly continue to rotate the handle. Each time the handle resists, strike {the top of the push bolt with a hammer, or temporarily back it off. By so doing, withdraw the main cylinder little by little. (Hammering will correct the inclination of the main cylinder and will also eliminate the ty of the tool.) leccent Fig. 2-27 JASELFJECTOR Instruction Manual 242 Maintenance Manual2.1.25 Withdrawing pilot valve Using a hexagon rod spanner, remove the valve nut (132). (Fig. 2-29) NOTE Be sure to insert the hexagon rod spanner securely in the hexagon hole of the valve nut. Otherwise damage to the hexagon hole might| result. Hold the jack (8) (809) against the pilot valve portion, thread the dismantling bolt into the pilot valve (128), and then turn down the nut to remove it. Withdraw the other one by the same procedures. (Fig. 2-30) Remove the jack (3) and withdraw the pilot valve (128) and valve sheet (130) from the valve guide (125). Dismanting bolt ° Fig. 2-30 Hee eel (ASELFJECTOR Instruction Manual 213 Maintenance Manual122 121 118 120 323 322 319 119 115 118 114 113 132 Fig. 2-31 Bowl Assembly Drawing (SJ10F, 15F, 30F) NOTE: FH/FP/SH types are the same as F type. JASELFJECTOR Instruction Manual Maintenance Manual 244Bow! Parts List Table 2-4 101 | Bowl bod) 1] 119 | Bow nut 1 402 | 0 ring 1 | 120 | Light liquid chamber 1 403 | Knock pin 1 | 121 | Gravity dise ‘iset 104 | Drain nozzle 2 | 122 | Disc nut 1 4105 | Main cylinder 4 | 423 | Bow! bush 1 106 | Spring pin 2) 124 | Cap nut 1 107 | Oring 1 | 125 | Valve guide 2 108 | Distributor 1 | 426 | 0 ring 4 409 | Pin 41 | 427 | Oring 4 110 | Key 1 | 128 | Pitot vaive 2 111 | Dise (1) iset | 129 [Oring 2 412 | Upper disc 3 | 130 | Vaive sheet 2 113 | Top diso 1] 131 [Oring 2 114 | 0 ring 1} 132 | Valve nut 2 115 | Bowl hood 1 | 319 | inlet pipe 1 116 | 0 ring 1 | 322 | impetter (1) 4 117 | 0 ring 1 | 323 | o ring 1 118 | Main seal ring 4 When ordering parts, let us know the parts Nos. and names shown in the finished drawing manual, not the numbers in the above list. Seen aaa (ASELFJECTOR Instruction Manual 2415 Maintenance ManualFig. 2-32 Bowl Assembly Drawing (SJ40F, 50F, 80F) NOTE: FH/FP/SH types are the same as F type. Oe AASELFJECTOR Instruction Manual Maintenance Manual 216Bow! Parts List Table 2-2 101 | Bow! body 1 | 120 | Light liquid chamber 1 102 |O ring 1 | 121 | Gravity dise ‘set 103 | Knock pin 1 | 122 | Disc nut 1] 104 | Drain nozzle 2 | 123 | Bow! bush. 1 405 | Main cylinder 1] 124 | Cap nut 4] 406 | Spring pin 1] 125 | Valve guide 2 107 |O ring 1] 126 | 0 ting 4 108 | Distributor 1] 127 | Oring 4| 109 | Pin 1 | 128 | Pitot valve 2 110 | Key 1 | 128 | 0 ting 2 111 [Disc (1) ‘iset | 130 | Valve sheet 2\ 112 | Upper disc 3 | 131 | Oring 2 113 | Top disc 4 | 432 | Vaive nut 2 114 [Oring 1 | 133 | Packing 4 115 | Bow! hood 4 | 134 | Heavy liquid chamber 4 116 [Oring _ 4 | 319 | intet pipe 4 117 [Oring 4 | 321 | impetier (2) 1| 118 [Main seal ring 1 | 322 | impeller (1) 1| 119 [Bowl nut 1 | 323 | 0 ring 1] When ordering parts, let us know the parts Nos. and names shown In the finished drawing manual, not the numbers in the above list. SELFJECTOR Instruction Manual 247 Maintenance Manual2.4.3 Horizontal shatt /A\ WARNING Re-check that the power supply of the starter has been turned off, Refer to the Horizontal Shaft Assembly Drawing (Fig. 2-46), and Gear Pump Assembly Drawing (Fig. 2-63). Remove the drain plug to remove the lubricant from inside the gear case. (Fig. 2-33) A\ CAUTION When the motor is to be lifted, mount the chain block jjust above the eyebolt for the sake of safety. Disconnect the motor, lit and support it by the chain block, and then remove the bolts and withdraw the motor. (Fig. 2-34) (In this case, pay heed to the friction block which might come off and fall down.) Remove the friction block (621) inserted in the friction boss (619) mounted in the motor. (Fig. 2-35) Fig. 2-35 AASELFJECTOR Instruction Manual 248 Maintenance ManualWhen the proximity switch of the Discharge Detector (standard equipment on the automatic specifications FSH- 1A, FSP-1A, FSH-PA) is provided on the pump housing, remove the cover (G07) located on the top of the housing, and remove the lock nut of holder tightening the proximity ‘switch and remove the proximity switch, NOTE Handle the proximity switch with great care, as it is a precision machine. NOTE Before removing the gear pump, remove the oil [collected before and behind the gear pump piping (by use of the drain cock, etc.). In addition, place a tray under the pump to receive the oil. Remove the cap nuts of the connecting tubes (1) (connecting tube(2)) at the gear pump. (Fig. 2-36) (Place an oil receiving container under the pump beforehand.) Remove the bolts tightening the gear pump with the hexagon rod spanner (M10), and remove the gear pump from the main body. (Fig. 2-37) Remove the gear cover and remove the socket cap screws (M8) (626) securing the bearing retainer (611) to the bearing housing (3) (608). (Fig. 2-38) Remove the bolts (612) tightening the bearing housing (3) (608) and use them as push bolts to remove the bearing housing (3). (Fig. 2-39) aASELFJECTOR Instruction Manual 219Remove the lock nut (604) and lock washer (605) securing the friction pulley (618) on the horizontal shaft. (Fig. 2-40) Using the jack (5), bolt (811) , push bolt (819) and handle (823), withdraw the friction pulley. (Fig. 2-41) NOTE Check to ensure that the brakes are free. Withdraw the horizontal shaft toward the pump side. (Fig. 2-42). If the horizontal shaft is hard to withdraw, hold a copper rod ‘or wooden board against the friction pulley side of the horizontal shaft and lightly strike it, while using care to make sure that the oil seal (625), etc. are not damaged by the threaded portion of the horizontal shaft and the keys (603) of the friction pulley. (When the horizontal shaft is withdrawn, there is danger of damage to the spiral gear (616). Therefore, it is desirable that the horizontal shaft be supported by another person when itis struck.) Remove the bolt securing the spiral gear on the gear boss to remove the spiral gear. ELFJECTOR Instruction Manual 2-20 Fig. 2-42 Maintenance Manualsocket set screw (628) A CAUTION a (628) @ Do not re-use the removed bearing. — © Do not remove the bearing except when it has to be replaced lh — (606) Remove the socket set screw (607) securing the safety joint to remove the safety joint. Then remove the retaining ring (C) (606) Loosen the socket set screw (628) securing the collar (2) (627). (Fig. 2-43) Using the jack (5) (813), jack (8) (816), bolt (611), \ push bolt (819) and handle (823), remove the pump side bearing (602) together with the collar (2) (627). |. 2-44) NOTE Fig, 2-44 Set the protective plate (812) between the end of| the horizontal shaft and the bolt (819) to prevent! damage to the end of the horizontal shaft. Remove the pulley side key (602). ‘Support the gear boss with a pipe or something else and strike it with a copper hammer from the friction pulley side of the horizontal shaft to remove the friction pulley side bearing (602), collar (1) (617) and gear boss (613) from the horizontal shaft, (Fig. 2-45) Fig. 2-45 SN reemeel JASELFJECTOR Instruction Manual Maintenance Manual 221619 \ a0 610 et Fig. 2-46 Horizontal Shaft Assembly Drawing 2ASELFJECTOR Instruction Manual Maintenance Manual 2.22Horizontal Shaft Parts List Table 2-3 601 | Horizontal Shaft 1 | 616 | Spiral gear 1 602 | Ball bearing (1) _ 2 | 617 | Collar (1) 4 603 | Key 2 | 618 | Friction pulley 4 |_604 | Lock nut 1 | 619 | Friction boss 4 605 | Lock washer 1 | 620 | Socket set screw 4 606 | Retaining ring (C) 1 | 621 | Friction block 50Hz 4 607 | Socket cap screw 1 Friction block 60Hz 3 608 | Bearing housing (3) 1 | 622 | Bearing housing (4) 1 609 | Oil seal 1 | 623 | Bott 4 610 | 0 ring 1 | 624 | 0 ring 4 614 | Bearing retainer 1 | 625 | oil seal 4 612 | Bolt 4 | 626 | Bolt 2 613 | Gear boss 1 | 627 | Collar (2) 4 614 | Bott 3 | 628 | Socket set screw 1 615 | Spring washer 3 When ordering parts, let us know the parts Nos. and names shown In the finished drawing manual, not the numbers in the above list. SS WASELFJECTOR Instruction Manual 2:23 Maintenance Manual2.1.4 Water supplying device Refer to the Water Supplying De\ (Fig. 2-52) Remove the bow! bush mounted in the tapered portion of the upper part of the vertical shaft, using the jack (5) (813), push bolt (819), handle (823), bolt (811) and jack (10) (817) (Fig. 2-47) -¢ Assembly Drawing Loosen the socket set screw (710) with the hexagon rod spanner (M6). (Fig. 2-48) Loosen the cap nut to remove the operating water tube (Teflon tube) mounted on the operating water disc (701) (Fig. 2-49) Remove the socket cap screws (702) located in three places of the operating water disc, using the hexagon rod spanner (M8). (Fig. 2-50) ee AASELFJECTOR Instruction Manual Maintenance Manual 2.24Place the jack (5) on the head of the vertical shaft, and set up the push bolt (819), handle (823) and bolt (811). Then thread the end of the bolt (811) into the chamber cover (709) and turn down the handle. The whole of the water supplying device will then go up and get out of the vertical shaft. (Fig. 2-51) Remove the bolts (706) located in four places of the operating water chamber (705), using a spanner. Using a hexagon rod spanner, remove the socket cap screw (704) located under the water supplying device. Remove the operating water nozzle (703) from the operating water chamber (705). Use care to prevent loss of small parts like bolts, washers, ete, Fig. 2-51 SS aASELFJECTOR Instruction Manual 2-25 Maintenance ManualWater Supplying Device Parts List_Table 2-4 701 | Operating water disc 1 702 | Socket cap screw 703 | Operating water nozzle 704 | Socket cap screw 705 | Operating water chamber 706 | Bott 707 | Tongued washer 708 | Oring 709 | Chamber cover 710 | Socket set screw 711 | Packing | [a | fa [a [= Jo [+ fo When ordering parts, let us know the parts Nos. and names shown in the finished drawing ‘manual, not the numbers in the above list. Fig. 2-52 Water Supplying Device Assembly Drawing AASELFJECTOR Instruction Manual Maintenance Manual 2.262.41.5 Vertical shaft Refer to the Vertical Shaft Assembly Drawing (Fig. 2-57). (Now, already withdraw the water supplying device and bow! bush.) Withdraw the mist cover (522). Using a T-shaped wrench, remove the three bolts (514) of the bearing cover (1) (513), and take out the bearing cover (1) together with the bearing cap (1) (Fig. 2-53). When they are taken out, the O ring (505) might come out together. Use care to prevent loss of the O ring. Take out the bearing cap (2) (518), flat spring (520) and spacer (1) (621) as well Withdraw the bearing housing (1) Remove the spring retainer (1) (506), and withdraw the upper spring (508), spring case (507) and bearing sleeve (509). NOTE © Before the vertical shaft is lifted, check to ensure that the spiral gear or the whole of the horizontal shaft has been removed. © When the vertical shaft alone is to be withdrawn without disassembly of the horizontal shatt, remove the spiral gear from the gear boss. Remove the gear cover. Using a spanner, remove the three bolts (614) tightening the spiral gear (616). Using a wooden hammer, remove the spiral gear from the gear boss (613). (The spiral gear will come off from the motor side toward the bearing housing (3). ) Shift the position of the spiral gear toward the bearing housing (3) to make sure that it does not interfere when the vertical shafts lifted. Hold the top thread of the vertical shaft and Pull out the vertical shaft above. The vertical shaft will come out with the bearing and bearing case attached.(SJ10F~30F) Mount the jack (7) (822) on the top thread of the vertical shaft, and slowly withdraw the vertical shaft in the vertical direction by the chain block. The vertical shaft will come out with the bearing and bearing case attached. (Fig. 2-54) (SJ40F~80F) Take out the bearing case (1) (510) by striking with a copper or lead hammer to prevent damage. Fig. 2-54 ‘SJ40F 50F,80F AASELFJECTOR Instruction Manual 227 Maintenance ManualTake out the steel ball (536), spring seat (536) and lower spring (539) from inside the bearing housing (2) (523). NOTE When the vertical shaft was disassembled, be sure {to carefully check the bearing. ‘Thread two push bolts (5) equally into the bearing case (3) (631) to withdraw the bearing case (3). Remove the ‘spacer (2) (534). (Fig. 2-55) /A\ CAUTION © "Do not re-use the removed bearing. © Donot remove the bearing except when it has to be replaced. Assemble the jack (7) (815), jack (5) (613), bolt (811), push bolt (819) and handle (823), and withdraw the bearing case (2) (528), bearing cover (2) (537), collar (638), bearing (2) (529) and ball bearing (3) (532) together. (Fig. 2-56) Remove the lock nut located at the top, using the hook spanner (818). Remove the ball bearing (1) located at the top by striking the inner race through use of a chisel to prevent damage to the vertical shaft. Fig. 2-65, Fig. 2-66 SN eel JASELFJECTOR Instruction Manual 2.28 Maintenance ManualFig. 2-57 Vertical Shaft Assembly Drawing NT wASELFJECTOR Instruction Manual Maintenance Manual 229Vertical Shaft Parts List Table 2-5 501 | Vertical shaft 1 | 524 | Spacer (1) 1 502 | Lock washer 1 | 522 | Mist cover 4 503 | Look nut 1 | 523 | Bearing housing (2) 4 504 | Bearing housing (1) 4 | 524 | Oring 1| 505 | 0 ring 2 | 625 | Bott 4| 506 | Spring retainer (1) 6 | 526 | Spring washer 4| 507 | Spring case 6 | 527 | Washer 4 508 | Upper spring 6 | 528 | Bearing case (2) 1] 509 | Bearing sleeve 1 | 529 | Bearing (2) 4 510 | Bearing case (1) 1 | 530 | Key 1 511 | Ball bearing (1) 1 | 531 | Bearing case (3) 1 512 | Key 1 | 532 | Ball bearing (3) 1 513 | Bearing cover (1) 4 | 533 | Spring pin 2 514 | Bolt 3 | 534 | spacer (2) 1 515 | Spring washer 3 | 535 | Spring seat 1 516 | Bearing cap (1) 1 | 536 | Stee! ball 1| 517 |O ring 41 | 537 | Bearing cover (2) 1 518 | Bearing cap (2) 1 | 538 | Collar 4 519 [0 ring 1 | 539 | Lower spring 1 520 | Flat spring 4 When ordering parts, let us know the parts Nos. and names shown In the finished drawing manual, not the numbers in the above list. LN enn WASELFJECTOR Instruction Manual 2-30 Maintenance Manual24.6 Gear pump Refer to the Gear Pump Assembly Drawing & (Fig. 2-63). Remove the socket cap screws (G13) located in four ac places to remove the valve case (G12). (Fig. 2-58) Fig. 2-58 Lightly strike the safety joint side of the drive gear with a copper hammer to withdraw the valve case side bush (G11) and driven gear (G10) together with the drive gear. (Fig. 2-59) Withdraw the safety joint side bush (G11). (Fig. 2-60) Normally, the valve stem need not be removed. When it is disassembled, however, measure the dimension A with the lock nut removed. When it is reassembled, be sure to turn down the adjusting ‘screw until the dimension A is reached. (Fig. 2-61) einiinn EB Hi Fig. 2-60 Fig. 2-61 ARSELFJECTOR Instruction Manual Maintenance Manual 2:313 Replacement of safety joint Socket set screw ‘When the safety joint only is to be replaced, the gear — pump need not be removed from the bearing housing 3). After removing the socket set screw with a a hexagon rod spanner, push the safety joint toward the Horizontal horizontal shaft, and directly pull it sideways to shaft remove it and replace it with a new one. Safety joint Fig. 2-62 el AASELFJECTOR Instruction Manual Maintenance Manual 2:32Pump Parts List Table 2-6 G01 [Pump housing 1 |@12 [Valve case 4 G02 | ring 1 |@13 | Socket cap screw 4 03 | Oil seal 1 [14 | Spring washer 4 G04 [Retaining ring (C) 1 [Gis | 0 ring 1 G05 | Socket cap screw 4 |16 | vaive stem a G06 | Gasket 2 |G17 | Adjusting screw 4 G07 | Cover 1 Jats | Nut 1 G08 | Set screw (3) 2 [ata | Valve spring 1 G09 | Drive gear 1 |@20 | Cap nut 4 Gio | Driven gear 1 |@21 | 0 ring 4 att [Bush 4 |a22 | Safety joint 4 When ordering parts, let us know the parts Nos. and names shown in the finished drawing manual, not the numbers in the above list. G22 Gos | ¢0s 325 Fig. 2-63 Gear Pump Assembly Drawing 2s. 0s Gos \ AASELFJECTOR Instruction Manual 2-33 Maintenance Manual2.2 Reassembly Points to note at reassembly AN WARNING © Thoroughly perform all the steps required for reassembly. The SELFJECTOR has many screw coupled parts. At the time of reassembly, check to ensure that all these parts have been thoroughly tightened. Remember that operation of the SELFJECTOR in a loosely tightened state could be very dangerous. Re-check that the following parts in particular have been thoroughly tightened, (A) Bowl nut (8) Disc nut (C) Cap nut of vertical shaft (D) Frame cover (trap) tightening bolt > Refer to P2-4 Fig. 2-6 {E) Inlet pipe tightening nut — Refer to P2-41 Fig. 2-79 © Pay heed to corrosion and erosion Check for damage caused by corrosion or erosion at regular intervals. If there are questionable points, contact our company or service agency. © Never interchange bowl parts ( except the disc (1) ) even if the models are same. SELFJECTOR Instruction Manual Maintenance Manual 2:34© Confirmation of tally marks (On the bow! and other parts which have tally marks, be sure to check that the tally marks are in alignment. When the bow! nut has been tightened, if the tally| marks are out of alignment, please notify our company] or service agency. The following parts have tally marks. Check the parts for confirmation. (Refer to Fig. 2-64) ID Bow! body @ Bow! nut (@ Light liquid chamber I@ Heavy liquid chamber (0SJ40F~SJ80F) NOTE: FH/FP/SH types are the same as F type. ‘© Nut (320) /A\ CAUTION When the bow! nut has been tightened by threading it into the bow! body, if the tally mark gone more than| 20mm ahead in the turning direction, notify our| [company or service agency. (Fig. 2-65) ‘The reassembly sequence is reversal of the disassembly sequence. The points to note at reassembly are described below. Prior to reassembly, thoroughly remove the dust and deposits from all the parts and carefully check the parts. If there are defective parts, replace them. For detailed information on the standard dimensions at reassembly, refer to the maintenance inspection proce- dures. SJ40F~SJ100F _“” (FHIFPISH types are ‘\.-*5\ the same as F type.) Tally mark Fig. 2-64 More than 20mm out of alignment Fig. 2-65 aASELFJECTOR Instruction Manual 2:35 Maintenance Manual2.24 Bowl (1) Make sure that when all of the O rings are mounted, they are not twisted. To install O ring evenly in the valve guide, apply a coat of machine oil to it and the groove. (2) Be sure to check the tapered portion of the bow! body. If there are scratches, correct them by an oil stone or something else. (3) To install the pilot valve, apply a machine oil to its outer circumferential portion, and slowly press the pilot valve in by hand. If it is installed by striking with a hammer or something else, damage to the O ring will result. NOTE Note that if the pilot valve is installed in a tilted state by applying an undue pressure, its sliding surface will be damaged. When installing the MOLYCOAT. (4) Main seal ring installation procedures Press the main seal ring in the main seal ring groove of the bow! hood by hand. @The main seal ring will be placed in a state where it is lifted from the groove. Place a wooden board (50 to 400mm wide) across the main seal ring and strike it ilot valve assembly, do not use Fig. 2-66 NS B with a hammer to install the main seal ring. }ow! hood /// A\ caution (A If the sheet plane of the main seal ring is wavy, oll e : wy Fig. 2-67 leakage will result. Install the main seal ring in such a way that the sheet plane will be fiat. (5) To install the main eylinder in the bow! body, apply a lubricant to the sliding surfaces of the main cylinder. Line up the positions of the knock pins and install the main cylinder, while using care to make sure that itis not tilted. (6) Make sure that the threaded portion of each of the parts is coated with the MOLYCOAT. (7) Make sure that all of the knock pins and keys are completely lined up. (8) When the disc (1) is installed, the upper discs which do not have a fringe should be installed in the uppermost position. install the other disc by pressing one at a time in the order that they were installed whenever possible. (Fig. 2-68) Fig. 2-68 aASELFJECTOR Instruction Manual 2-36 Maintenance ManualA WARNING If the machine is operated with the discs in a loose state, large vibration could occur. (9) The discs tend to produce some looseness because of their seating phenomenon. In such a case, add an appropriate number of spare discs according to Fig. 2-68 (to the extent that the discs are exposed 0 to 2mm from the distributor). (10) Bow! nut tightening procedures (@) Securely tighten the bow! hood with the disc clamp plate (807).(Fig. 2-69) (b) Tighten the nut of the disc clamp plate (807) so that the bowl nut can be tumed smoothly by hand until the distance between the tally marks of the bow! nut and bow! body reaches 10 to 15mm. (Fig. 2-70) (c) Tighten the bow! nut with the bow! nut handle by use of a hammer until the tally marks are in alignment. (Fig. 2-71) (11) When the bow! is to be installed in the main body of the machine, apply a lubricant to the operating water chamber of the water supplying device to prevent the O ring of the operating water chamber from being caught. Do not apply MOLYCOAT to the tapered portions of the bowl body and vertical shaft (12) After the bow! has been installed in the main body, tighten the cap nut firmly through use of the cap nut spanner and hammer. (13) When the light liquid chamber is to be threaded in, thread it in by hand to prevent damage to the threaded portion. As a final step, tighten it with the light liquid chamber handle. (14) When the heavy liquid chamber is installed, line up its Fig. 2-71 tally mark with the tally mark of the bowl body. (15) Check the installed height of the bowl. (Refer to Fig. 4-14 and Table 4-6.) AASELFJECTOR Instruction Manual Maintenance Manual 2.372.2.2 Vertical shaft (1) Install the vertical shaft in the main body before installing the horizontal shaft ‘\ CAUTION Install the vertical shaft correctly in the direction of the ball bearing (3). (2) Install the flat spring and ball bearing (3) without confusion of their up and down sides. (Fig. 2-72, Fig. 2-73) < To install a new bearing, put it in a 80 to 90°C oil for about 20 minutes before installing it onto the shaft. NOTE When the bearing is installed in the bearing case © Ifthe bearing is forced in a tilted state by applying an undue pressure, damage to the bearing might| result. © After the bearing has been installed, if the inner race can be turned by hand, replace the vertical] shaft. Install the bearing in the bearing case by equally striking the inner ring with a hammer. Before installing the O ring under the bearing housing (1), apply grease to several places of the groove. By so doing, the O ring won't come off and fall. Before installing the flat spring, install a spacer on the top of the bearing housing (1). Two types of spacers (1) 0.5mm and 1.0mm thick will be supplied. Use a spacer (1) of appropriate thickness to adjust the dimension A of Fig, 2-74 to the value shown in Table 2-7. Measure the dimension A with the O ring removed from under the bearing housing (1). (3) Firmly tighten the spring retainer (1) on the bearing housing (1). (4) After installation in the main body, check to ensure that the vertical shaft can be lightly turned by hand. Flat spring Bearing No. Fig. 2-73 {Vertical shatt ‘ Flat spring 7 Spacer \ Spring case | | Bearing housing (1) Bearing case (1) Fig. 2-74 Table 2-7 Model No__ | SJ10F~SJ80F yension A 05~1.0 (FHIFP/SH types are the same as F type.) ST aASELFJECTOR Instruction Manual 7 2-38 Maintenance Manual2.2.3. Water supplying device (11) When the © ring is installed on the operating water chamber, use care to make sure that the O ring is not twisted. (2) After the water supplying device has been installed on the vertical shaft, tighten the socket set screw of the chamber cover and check to ensure that the water supplying device rotates with the vertical shaft as a single unit. (Fig. 2-75) 2.2.4 Horizontal shaft (1) After the vertical shaft has been installed, install the horizontal shaft (2) Before installing the bearing, install the bearing retainer in such a way that it will be positioned between the spiral gear and bearing. (3) Make sure that the mounting surfaces of the spiral gear and gear boss are in tight contact. (4) When the horizontal shatt is installed in the main body, use care to prevent damage to the lip surface of the oil seal. Apply grease to the lips before inserting the horizontal shaft. (5) Evenly tighten the bearing retainer when installing it. 1% el (2 WARNING For cleaning, avoid using a highly volatile oil such as |gas oll which could cause a fire. (6) foils are deposited on the inside surface of the friction pulley and the lining of the friction block, wipe them away. (7) The bearing housings (8) and (4) have a drilled hole. Install the bearing housings so that the drilled holes will be faced down. (Fig. 2-76) Socket sot scrow Drilled hole Fig. 2-76 Socket Set screw (Never install the colar with the socket set screw on the opposite side.) A CAUTION Avoid confusion of collars (1) and (2) when installing them. © Make sure that the collars are installed with the socket set screw side toward you. (8) After the collar (2) on the bearing housing (8) side has been installed on the horizontal shaft, be sure to tighten the socket set screw. (Fig. 2-77) JASELFJECTOR Instruction Manual 2.39 Maintenance Manual(9) To install the oil seal, hold a protective plate against the end surface and lightly strike it with a hammer to force the oil seal in little by little. (10) When the friction block installed in the friction boss is to be installed in the main body, secure the friction block with a rubber ring or something else to prevent the fall of the friction block intermediately during installation. (11) After the horizontal shaft has been installed, check to ensure that it can be turned lightly by hand. SE eee el wASELFJECTOR Instruction Manual Maintenance Manual 2-402.25 Reassembly of trap (1) To make sure that the trap does not hit the inlet pipe ‘when it is placed on the frame, check to ensure that the socket set screw (313) on the top of the trap has been loosened. (Fig. 2-78) AN CAUTION |The nut and cover nut are of double nut construction to prevent looseness. Make sure that they are fully tightened. (2) Tum down the nut with a spanner and tighten it with a hammer unti the tally marks are in alignment. (Fig. 2-79) [NOTE The tally mark of the nut (320) will tend to go ahead of that of the upper hood because of the seating or wear of the tapered portion of the impeller. Even if the tally marks are slightly out of alignment, no problem will be caused. Therefore, turn down the nut all the way with a hammer. Tighten the nut to the following torque. SJ10F~SJ30F : 700 kg * cm SJ40F~SJ100F : 1,000 kg > em (FH/FP/SH types are the same value as F type.) If the tally marks are more than 180° out of alignment, replace the impeller (1) with a new one. (3) When the inlet pipe is to be installed, do not forget to install_the orifice put in the arrow mark portion (DS) of Fig. 2-81 according to the installing direction shown in Fig. 2-80. (Unless the orifice is correctly installed, the flow meter won't indicate a correct flow rate.) (4) The trap, upper frame (SJ10F ~ SU30F) and heavy liquid bracket (SJ40F~SJ100F) are provided with plugs for inspection, Fig. 2-79 ©] stamped ] mark \|< di Purifire | | Piping side side || IN weSELFJECTOR | Instruction Manual 241 Maintenance Manual/\ WARNING Check to ensure that the plugs of the bracket have| been fully tightened. If the liquid is supplied with the| plugs not fully tightened, ejection of a high temperature| treatment liquid could cause burns. (Refer to Fig. 2-82) (5) Fully tighten the plugs of the bracket. 2.2.6 Gear pump (1) When the bush is to be installed in the pump housing, face the internally grooved side inward (toward the gear side). (Fig. 2-83) (2) Before installation of the gears, apply grease or machine oil to the gear tooth surfaces and bush. (3) When the drive gear is installed, use care to prevent damage to the oil seal lips. (4) Turn down the adjusting screw of the valve stem up to the predetermined position. Measure the tightened position at disassembly. Turn down the screw up to that position. (5) Ifthe gear pump is provided with a proximity switch for the Discharge Monitor, install it to the bearing housing (8) and check that the proximity switch-to-horizontal shaft clearance is correct (normally 1.8mm). After reassembly, turn the shaft by hand to check that it can be lightly turned. Then install the gear pump in the SELFJECTOR. Seen el JASELFJECTOR Instruction Manual 2.42 Maintenance Manual3 Maintenance inspection procedures ‘Z!\, WARNING ‘The SELFJECTOR is a high speed rotating machine. Always be careful of its vibrating condition, Be careful of its operating sound, sludge discharge sound, etc. as well. If any change occurs, stop the machine, locate the cause, and take corrective action. If} the cause cannot be located, do not operate the machine but ask our company or service agency. A\ WARNING ‘When parts are replaced, make sure that the genuine parts are used. If non-genuine| parts are used, the SELFJECTOR could be damaged and personal safety could be jeopardized. Z!\ CAUTION For the sake of safety, be sure to perform routine checks and periodic disassembly, cleaning and inspection. Perform maintenance inspection according to the inspection table (Section 5 of this manual) ‘and parts inspection procedures (Section 4 of this manual), although the intervals vary with the properties of treatment cil, operating environment, etc. 3.1. Routine checks The routine check items are the items to check every day when patrolling at regular intervals. Table 3-4 Cheok Item: Description Feed rate Has it changed with respect to the set Feed rate? Feed thermometer Has it changed with respect to the set temperature? Pressure of light liquid outlet | Does it coincide roughly with the set pressure of the Leakage Frame vibration Hasn't vibration increased? Operation noise Isn't a strange sound generated (from the bearing, gear pump. etc.)? Current Isn't the rated current exceeded or changing? Gear pump Isn't the oil quantity low? Safety joint of Gear pump _| Isn'tit deformed or broken? Pipe joint Aren't there oil leaks? Leakage Monitor Is the Adjust pressure LED (green) lit or flashing? Discharge Monitor Is the Indicate revolution LED (green) flashing? AASELFJECTOR Instruction Manual Maintenance Manual 343.2. Lubricant replacement intervals Z!\ CAUTION If replacement of the oil is neglected, wear of the spiral gear and damage to the bearing could result. Replace the lubricant of the SELFJECTOR at regular intervals according to Table 3-2. NOTE To replace the lubricant, remove the gear cover, and thoroughly clean the inside of] the oil tank before installing a fresh oll. _ Table 3-2 Number of times: Replacement intervals | Remarks First time ‘After two weeks of operation | It takes about two weeks before (After approx. 300 hours) _| seating of the contact surfaces _ ____| of gears. Second time After a month of operation (atter approx. 600 hours) _ ‘Third and subsequent times | Every three months NOTE1) When the spiral gear has been replaced, replace the lubricant at intervals, beginning with the first time. NOTE2) Ifthe oil is badly contaminated, replace it with a fresh one at shorter intervals than shown in Table 3-2. NOTES) If water, sludge, etc. are contained in the oil tank, remove the oil, clean the inside of the oil tank, and install a fresh oil NOTES) Avoid mixed use of different types or brands of lubricants. NOTES) When the types of lubricants are to be changed, clean the inside of the frame and the parts of the shafts before replacement. NOTE6) When the machine has been overhauled, replace the lubricant. For information on the lubricant replacement procedures, refer to the “Operation Manual 2”. @QSELFJECTOR Instruction Manual Maintenance Manual 323.3. Expendable parts replacement intervals To prevent occurrence of troubles in the SELFJECTOR and operate it in normal condition at all times, it is necessary to replace the expendable parts at regular intervals. A /:\, CAUTION The wear of parts varies with the properties of treatment oil, operating condition, etc. Perform checks according to the inspection procedures described in Section 5. If there is anything wrong, replace the parts for the sake of safety even before the! specified intervals. 3X The replacement intervals for the expendable parts in the following table are shown for general guidance and are not intended to guarantee the replacement Intervais. __Name of part Replacement intervals Remarks 2 Bowl _Main seal ring 6 months (© ring and the like 6 months Valve sheet 6 months Frame, Trap (Cover) ( ring and the like 12 months. 24 months on those used to seal the upper and zl lower frames Gasket 12 months: 24 months on gaskets for gear cover and oil {for piping) jauge Rubber plate 24 months. _Sludge pipe 24 months © Vertical shaft, Water supplying device (© ring and the like 42 months 24 months on those used for bearing housing @ Upper spring _ 412 months. Lower spring 24 months Flat spring 24 months Spring case 24 months Gasket 42 months Bearing 24 months Spring seat | 24 months _ Steel ball 24 months dASELFJECTOR Instruction Manual Maintenance Manual 33Name of part Replacement intervals Remarks © Horizontal shaft Oil seal 42 months _ O ring and th 24 months: _| Bearing 24 months |___Friction block: 12 months Friction fining 24 months Gear pump | Oil seal 412 months Safety joint 12 months (Oring and the like 12 months Bush 24 months. 1, It is advisable to replace the expendable parts of the bowl with new ones in keeping with the bowl opening intervals. 2. On parts not supplied as spare parts, place orders with our company. For spare parts to be furnished with SELFJECTOR, see the spare parts list submitted by us. aASELFJECTOR Instruction Manual 34 Maintenance Manual3.4 Bowl opening intervals (guidelin« To operate the SELFJECTOR in normal condition at all times, it is necessary to open and clean the bow! at regular intervals. Although the opening intervals vary with the properties of treatment oil, operating condition, etc., the general opening intervals are shown below for general guidance. ) (NOTE 1) The rotor opening intervals which vary with the operating condition are shown for general guidance and are not intended to guarantee the intervals, © First ime to open the bow! — A month after trial run Since the inside contamination varies with the properties of oil, ete., open the bowl and check the inside after the first month (whether unevenly deposited sludge exists or not, contaminated discs, etc.), and determine whether the discharge intervals are appropriate or not. © Second and subsequent times — Open, check and clean every 6 months (longest). I the bow! opening intervals are too long, contamination might affect separation or even cause vibration. Set the proper opening intervals suitable for the type of oil When the SELFJECTOR is used for cleaning the trunk piston engine lubricant, the bow! is generally contaminated earlier. It is therefore advisable to set shorter intervals (2 to 3 months). ‘The opening intervals may be extended (longest interval is 1 year) by joint use of a cleaning equipment. However, it is necessary to check the effectiveness of cleaning before determining the opening intervals. 3.5_ Overhaul (guidelines) “"2) CAUTION When increased vibration is evident, check and maintenance the machine according to the| inspection procedures described in Section 5 even before the overhaul intervals for the| |sake of safety. If there is anything wrong, replace the part: A CAUTION Although the overhaul **® intervals vary with the operating cond maintenance according to the inspection procedures described in Se Intervals, overhaul the machine every 2 years (longest) at least. {NOTE 2) Overhaut intervals which vary with the operating condition are shown for general guidance and are not intended to guarantee the intervals. (NOTE 3) Overhaul refers to disassembly of all of the parts of the bow, vertical and horizontal shaft systems, Inspection and cleaning according to the inspection procedures described in Section 5, and replacement of expendable and defective parts. SS dASELFJECTOR Instruction Manual Maintenance Manual 354 Maintenance inspection procedures for major parts 4.1 Bearing replacement intervals A\ WARNING For the vertical and horizontal shafts, use bearings that are up to specification. The upper bearing of the vertical shaft in particular is important. If an out-of-specification bearing is used, personal safety could be jeopardized because of reduced bearing life. /\ CAUTION For the sake of safety, replace the bearings of the vertical and horizontal shafts before the [elapse of 2 years regardless of whether they have been in service or not. The bearings are expendable parts. Place separate orders for bearings other than supplied as spare ones. 4.2 Bowl 4.2.1 Corrosion of bow! ‘The bow! parts except some are made of special stainless steel. Under stringent operating condition, however, corrosion might occur in the form of pitting Since the bow! is exposed under a high stress, a very fine crack originating in the pitting could occur. Be very careful when you check. © What to do to prevent corrosion Corrosion readily occurs in the portions that are in contact with sludge. Perform the following steps to prevent corrosion. (1). Set proper discharge intervals. (2) Clean those portions when the bow! is opened. AASELFJECTOR Instruction Manual Maintenance Manual 44Perform checks with special stress on the following portions on which sludge is deposited. (1). Seat portion of main cylinder. (2) Sludge discharge port. (3) Heavy liquid chamber (SJ40F ~SJBOF). Note: FH/FP/SH types are the same value as F type. © Check procedures (1) Thoroughly clean to remove deposits. (2) Visual check. (3) If anything wrong was found under (1) and (2), perform color check test. 4.2.2 Corrective steps for corrosion JN CAUTION ‘To prevent distortion of the base materials and alteration of their composition, never make repairs by welding cracks, pinholes or corroded portions. If there is pitting in a part, remove the corroded portion by a grinder. Perform visual check and color check test for confirmation. If there is nothing wrong, continued use of the part is allowed. The margin removable by a grinder should be limited to 0.8mm maximum (except the main cylinder for FO). After atinding, do buffing (#250 or more). © When there is a line defect (crack), © When more than 0.5mm grinder finishing is necessary, it is necessary to replace the parts with new ones and perform balance adjustments. Contact our company or service agency. @ASELFJECTOR Instruction Manual Maintenance Manual 4-2423 Dise1 !\ CAUTION Do not make repairs by welding cracks, pinholes or| corroded portions. © Replace the disc 1 with a new one (1), When corrosion is evident (2) When two or more adjoining aperture pieces are out @ of position (8) When a crack is evident Fig. 4-2 © Addition of dise Over a long period of service, the seating of the disc (1) will create a gap between the disc (1) and top disc. Add a disc, while referring to the Fig. 2-68 © Points to note when handling disc (1) A CAUTION When handling the cleaning agent, observe the following points ‘© Never put the cleaning agent in your mouth. Wear protective glasses or protective gloves, etc. to prevent eye or skin contact. If the cleaning agent was deposited on your skin, immediately wash away in water. Since the cleaning agent contains an organic solvent, make sure that the room is| ventilated well. ©. Store the cleaning agent in a cool, dark place. Remove the sludge deposited on the disc (1) by use of a cleaning oil and a waste cloth or a soft copper wire brush. Avoid using a scraper or any other thing that damages the surface. Immerse the disc in our company's cleaning solution at 50 to 70°C for about 3 hours before cleaning. The deposits will be easier to remove. SS aASELFJECTOR Instruction Manual Maintenance Manual 43424 a) (@) (3) (4) Bowl body Clean the O ring groove. If the groove is rough, repair it with a fine emery cloth (#320). If roughness cannot be repaired by an emery cloth, do machining to widen the groove width, provided that the machining margin is limited to 0.5mm maximum. I the operating water passage hole or any of the water pressure chambers is clogged with scale, do thorough cleaning. When the bow! body was subjected to an abnormal shock by allowing it to fall, or by the fall of a heavy object, let our company or service agency check it. A\ CAUTION If the bowl body and bow! bush are in poor contact, vibration could occur. If the contact area of the contact surface is less than two thirds of the whole, replace the bowl bush with a new one. (5) (6) @ (8) Check the fitted portions of the bowl body and bowl bush and check the condition of contact with the vertical shaft. Check to ensure that the contact area of the contact surface is more than 2/3 of the whole. ‘Check for scratches caused by slipping. If there are scratches, remove the scratches with an ‘emery cloth (#320) and apply finishes with polishing paper (#600). Check the threaded portion for the bow! nut. If scoring is evident, make repairs with set files. Check the sludge discharge port for wear. If the wear is less than 0.5mm, continued use of the port is allowed. If the wear is more than that, let our company or service agency check it. Check the main cylinder sliding surface for soratches. If there are scratches, repair them with an emery cloth (#320) and then apply finishes with polishing paper (#600). Check the knock pin for deformation. If deformation is evident, replace the knock pin with a new one. JASELFJECTOR Instruction Manual Maintenance Manual 4442.5 Bowl hood Check the following portions of the bow! hood for scratches. (1) Bow! nut fitting portion (2) Bow! body fitting portion (8) Threaded portion (4) Light liquid chamber fitting portion (5) 0 fing groove (when the O ring was removed) (6) Knock pin groove If there are scratches on the above-mentioned portions, make repairs by use of set files, grinding stone, emery cloth (#320), etc. (3) 6) J 4.2.6 Main seal ring NOTE When the main seal ring is removed, use care not to damage its bowl hood side groove| (especially the side surface). Damaged groove may cause a leakage. With the main seal ring mounted on the bow! hood, clean and carefully check the seal surface. Normally, the main seal ring is deformed as shown in Fig. 4-5. In the following cases, replace the main seal ring with a new one. Bow! hood Main seal ring (1) When dimension A is 0.5mm or more (2) When the seal surface is galled by metallic power more than 60% of its length B. ES wASELFUECTOR Instruction Manual Maintenance Manual 454.2.7 Distributor (1) Ifthe top end of the key is deformed, correct or replace. (2) Check the threaded portion for scratches. (3) Check the knock pin which might have been deformed, 4.2.8 Various types of O rings of bowl Recommendation is to replace the O rings in keeping with the bow! ‘opening intervals. Before installing an O ring, be sure to clean the O ring groove. dASELFJECTOR Instruction Manual Maintenance Manual 464.29 Main cylinder a) (2) Check the seal surface (that surface which makes contact with the main seal ring) for scratches. If there are scratches, damage to the main seal ring and leakage of sealing water will result, making normal operation impossible. Scratches are often made on the surface at the time of disassembly. Therefore, be careful when handling it. In the case of the main cylinder for lubrication oil, repair small scratches by use of an oil stone or something else. In the case of the main cylinder for fuel oil (C heavy oil), contact ‘our company or service agency, as the seal surface has a special coating. Check the bow! body sliding surface for scratches. If there are scratches, the O ring will wear down earlier. Repair the scratches with an emery cloth (#320) and then apply finishes with polishing paper (#600). (3) Clean the © ring groove. If the groove is rough, make repairs with an emery cloth. 4.2.10 Pilot valve assembly a) (2) (3) (4) Check the valve guide and bow! body sliding surfaces for scratches. If there are small scratches, make repairs with an oil stone or something else. When the pilot valve assembly is disassembled and reassembled, use care to prevent damage to the ring. (Apply a lubricant to the sliding surfaces for easier reassembly.) Check the seal surface (that surface which makes contact with the valve sheet) for scratches. If there are small scratches, make repairs with an oil stone or something else. ‘Take out the valve sheet from the valve guide, and clean and carefully check the seal surface. If the valve sheet has caught a foreign substance or is deformed (0.3mm or more), replace it with a new one. After cleaning and before installing in the bowl, complete the pilot valve assembly and check to ensure that pilot valve is moved smoothly by hand. 23) nae wASELFJECTOR Instruction Manual 47 Maintenance Manual4.3 Vertical shaft system 4.3.1 Vertical shaft (1) Carefully check the portion above the upper bearing fitting portion, as there is a high likelihood of corrosion. If the dimension A shown in Fig. 4-9 is more than 1mm smaller in diameter than the value ‘shown in Table 4-1, replace the vertical shaft with a new one. Table 4-4 | Model No. ‘SJ10F ‘SU40F ‘susoF | SJ80F ‘SJ15F ‘SJ100F ‘SJ30F Dimension A 34 44 47 59 FHIFP/SH types are the same value as F type. (mm) ; (2) If there are partial scratches in the bowl bush fitting portion, make Vy repairs with set files or an emery cloth (#320). If there is a ring-like l: ue (5) continuous groove flaw, replace the vertical shaft with a new one. (2) If there is a localized flaw like @ pounding in the threaded portion, make repairs to smooth it out, using set files, emery cloth (#320), 1] ete, (4) In regard to the secular wear of the bearing fitting portion, if the inner race of the bearing slips, replace the vertical shaft with a new ‘ one, Fig. 4-9 (6) Ifthe pinion tooth surface is rough and is lightly worn, make repairs with set files, emery cloth (#320), oil stone, ete. (6) Measure the runout of the shaft center in three places, the straight portion at the end of the shaft, the middle portion of the shaft, and bearing fitting portion, with the upper and lower bearing fitting portions supported by the measuring jigs. The runout should be limited to 5/100mm maximum. If the runout is larger than that, replace the vertical shaft with a new one. 4.3.2. Upper springs (1) If there is even a broken or cracked upper spring, replace all of them with new ones. (2) Measure the free length of each of the upper springs. If any of them is more than 1mm shorter than the dimension A, replace all of the upper springs. Six upper springs equal in free length A (dimension A) are grouped as a set. (Refer to Table 4-2) ,_4A_ Table 4-2 Ul) Model No ‘SJ10F ‘SJ40F sveor | SJ15F ‘SJ50F SJ100F ‘SJ30F Dimension A. 34 44 [ 46 | FHIFPISH types are the same value as F type. (rm) SS @ASELFJECTOR Instruction Manual Maintenance Manual 484.3.3. Lower bearing block If the dimension A shown in Fig. 4-11 with the lower spring retainer, steel ball and bearing case (2) put together is more than ‘1mm smaller than the value shown in Table 4-3, re-check all of these parts, and replace a defective part with a new one. (Referto << Fig, 4-14, Table 4-3) Table 4-3 Model No. SJ10F ‘SU40F ‘SJ80F SU1SF ‘SJ50F ‘SJ100F SJ30F Dimension A. 5 83.5 90.5 FH/FPISH types are the same value as F type. (mm) 434 Flat spring (4) A broken or cracked flat spring should be replaced with a new one. (2) Measure the spring height as shown in Fig. 4-12. If it is less than the A mm, replace the flat spring with a new ‘one. (Refer to Table 4-4) Table 4-4 Model No, SJ10F SJ40F SJ80F SUIS SJSOF SJ100F SJ30F Dimension A 45 65 75 FH/FPISH types are the same value as F type. (mm) 4.3.5 Steel ball A steel ball with a deep ring-like groove flaw in those portions which make contact with the lower spring retainer, etc. or a deformed one should be replaced with a new one. 4.3.6 Lower spring (1) A broken or cracked lower spring should be replaced with a new one. (2) Measure the free length. If it is more than 1mm smaller than the dimension A, replace the lower spring. (Refer to Table 4-6) Table 4-5 ‘Model No. SJ10F ‘SJ40F ‘SJ80F SUISF SJ50F ‘SJ100F Su30F 32.5 55.5 60.5 FHI/FPISH types are the same value as F type. (mm) Fig. 4-13 SS AASELFJECTOR instruction Manual 49 Maintenance Manual43.7 Height of vertical shaft f A\ WARNING 5 If the height of the vertical height is out of the standard limits (Table 4-6), re-check the vertical shaft system to locate the cause. If the cause cannot be located, do not Joperate the machine but contact our company or service agency. . 1 After installation of the vertical shaft, the standard height shown. in Fig. 4-14 should be as shown in Table 4-6. Table 4-6 Model No. SJ10F SJ30F ‘SU40F ‘SU50F ‘SU80F SUSE SJ100F jensionA| 801.0 931.0 1431.0 1201.0 1301.0 imensionB| 391.0 391.0 7441.0 63£1.0 6921.0 FH/FP/SH types are the same value as F type. (mm) 4.3.8 Installed height of flat spring (adjustment of spacer) When the parts like the lower spring retainer, bearing case, steel ball and flat spring have been replaced, or when the installed height of the flat spring (dimension A of Fig. 4-15) is out of range the dimension A of Table 4-7, change spacers (1) to adjust the compression force of the flat spring. Table 4-7 || vertical shatt Model No. SJ10F~SJ100F Spacer Fiat spring Dimension A 0.5~1.0 ck vA aaa | FHIFPISH types are the same value as F type. ! rc LT AT Nace Bearing case (1) Bearing housing (1) Fig. 4-15 .SELFJECTOR Instruction Manual Maintenance Manual 4104.4 Horizontal shaft system 4441 Spiral gear (1) The life of the spiral gear cannot be sweepingly determined, as it depends on various conditions. For general guidance, however, consider that the life of the spiral gear is over when it is in good contact and is normally worn to the extent that the groove width is reduced to 2/8 (about 3mm) of the normal dimension. If the spiral gear is worn more than that, replace it with a new one. (2) During initial operation or when the spiral gear has been replaced, its wear will be temporarily accelerated until the contacting surfaces of the gear are seated. A while later the wear will cease to be accelerated. This is a normal phenomenon. If the wear is excessively accelerated, something wrong is suspected in the other parts. Check the other parts. (8) If there are burrs or high spots on the tooth surface, remove them with set files or emery cloth (#320). 4.4.2 Horizontal shaft (1) If there is a localized flaw like a pounding on the threaded portion, make repairs to smooth it out, using set files, emery cloth (#320), etc. (2) In regard to the secular wear of the bearing fitting Portion, if the inner race slips, replace the horizontal shaft with a new one. (8) If the key-way is wider because of wear, replace the horizontal shaft with a new one. 443° Colla Up to two thirds < (approx. 3mm) of the normal dimension Ae Fig. 4-16 (1) (2) @) 8) (3) byt fetta —t t t Collar(1) Collar(2) Fig. 4-17 If the diameter of the oil seal and collar sliding surface is more than 0.5mm wom than the specified dimension, replace the collar with a new one. (Refer to Table 4-8) Table 4-8 ‘SJI0F ‘SJ40F SU80F SJISF ‘SJ50F SJ100F ‘SJ30F ‘Motor side (1) 45 50, 55 Gear pump side (2) 45 50. 55, FH/FP/SH types are the same value as F type. (mm) el @ASELFJECTOR Instruction Manual Maintenance Manual4.4.4 Friction block - The life of the friction block cannot be sweepingly determined, as it depends on the frequency of starts € and stops. If any of the linings 6mm thick is worn to 3mm, replace all of the blocks. (Fig, 4-18) 44.5 Friction pulley Check the inside surface of the friction pulley for wear. If it is ‘worn more than 1mm, replace it with a new one. (Fig. 4-19) ‘The inside surface of the friction pulley allows machining up to ‘mm deep to eliminate roughness. 4.5 Gear pump 45.1 Safety joint ‘Check the gear pump visually for distortion, wear, damage, etc. without being removed, and replace if necessary. 45.2 Drive gear, driven gear and bush i, _ : = i + ef "| 3 Fig. 4-18 g é j= asa | ¥ | | | a J boo Fig. 4-19 If the shaft is producing abnormal sound, disassemble the gear pump, and check whether the gears are in good contact, the spacing between the shaft and bush, wear or foreign substances which might have been caught. If repairs cannot be made, replace. 45.3. Valve stem When the capacity is insufficient or the suction is impossible, it is often due to foreign substances caught by the valve stem. Disassemble and thoroughly clean. In this case, itis necessary that the position of the adjusting screw (dimension A of Fig. 4-20) is confirmed beforehand (adjusting pressure 0.4MPa {4.0kg/om®)). If the screw is over-tightened, the pressure will become needlessly high, and overload could result. If it is under-tightened, a poor suction will result. If there are small scratches, repair the tooth surfaces with an oil stone. [en | <— Fig. 4-20 el AASELFJECTOR Instruction Manual 412 Maintenance Manual48 Lubricant © For information on the lubricant replacement intervals, refer to Section 3.2. © For information on the lubricant replacement procedures, refer to Section 3.4 in Operation Manual 1. Fig. 4-21 4,7 Brake equipment The life of brake lining cannot be sweepingly determined, as it varies widely, depending on the number of times it has been used. It is therefore necessary to check the brake lining at regular intervals. If the brake lining 10mm thick is worn to 5mm, replace the brake lining with a new one. 48. Water supplying device The water supplying device is designed to supply operating water to the bowl opening and closing mechanism which automatically discharges the sludge accumulated in the bow. If itis clogged by scale or the gasket or O ring is damaged, a low water pressure or a low water flow rate will result, and the mechanism might fail to open or close the bow ‘When the bow! is disassembled, be sure to check and clean the water supplying device. SNe el aASELFJECTOR Instruction Manual Maintenance Manual 4134.9 Inspection of protective equipment Check to ensure that a detector alarm is correctly output. 49.1 Leakage Monitor (LM) The Leakage Monitor essentially determines that the outflow is abnormal as it detects the fall of the pressure at the outlet side of the SELFJECTOR. Create this state by simulation. (1) Check that the SELFJECTOR is in automatic operation and that the liquid is being fed. (2) Loosen the pressure control valve at the light liquid outlet side to reduce the pressure, Reduce the pressure to a level below a Pressure Drop ( Ap) from Set Pressure. (3) Check to ensure that an alarm is output after the elapse of the set time of the feeding timer. 4.9.2 Discharge Detector (DD) A CAUTION When alarm check is performed by the following procedures, the machine will come to a stop. without discharging the oil from inside the bowl. When the machine is restarted and the sludge is discharged, the oll will flow out. Therefore, perform operations with due consideration to, safety. (1) Check to ensure that the SELFJECTOR is in automatic operation and that the liquid is being fed. (2) Close the source vaive of the operating water solenoid vaive unit to stop the supply of all operating water. (3) Press the "DISCHARGE TEST” button of the control panel (4) Check to ensure that an alarm is output after the elapse of the discharge process time. TRSeLFIECTOR Instron Marval Maintenance Manual 4145 Periodic inspection chart AN CAUTION For the sake of safety, perform periodic Inspection according to the following chart, repair or replace a defective parts. (Inspection service) The chart describes the parts to check, the details to check for, and the check intervals (longest). Check intervals. Parts to check Details to check for (months) Corrective | Remarks | Check Every | Every | Every | action mark 3 6 12 Frame, trap (cover) Inside of frame Deposited sludge, Oo — Contamination Operating water drain | Deposited sludge, ° o outlet Contamination Heavy liquid passage of | Contamination 3 snor~ | trap 30F Oil gauge. Contamination ° ol] Foundation bolt Looseness ° Oo} impeller Contamination, oO Contact damage, oO Deformation, Corrosion Inside of frame gear case | Contamination ° ial Sludge pipe Deteriorated rubber fe) ol Upper hood & Damage, ° o Lower hood O ring Wear, Hardened Rubber plate Sagging ° ol Brake lining Wear oO ou NOTE Be sure to check the frame and trap (cover) not only at the intervals specified in the chart but| |also when the bow! Is opened. SS aASELFJECTOR Instruction Manual Maintenance Manual 54Check intervals Parts to check | Details to check for (months) Corrective | Remarks | Check Every | Every | Every | action mark ioualedods|ania. Bowl _ © Whole of Deposited sludge, ° Refer to oO inside of bow! | Corrosion 424, 422 Deposited sludge, ° Refer to Oo Corrosion, Cracks, 423 Deformation Aperture piece Loss ° oO No. of discs. Height of discs. © Oo © Bowl body ‘Sludge outlet port _| Corrosion, Wear ° Refer tol | Oring groove Damage ° 424 ol Operating water Clogging ° oO Passage _ Bowl bush fitting | Damage, Scoring, ° Oo Portion Fit, Wear __| Main cylinder sliding | Damage ° oO Portion Knock pin Deformation 3 oO © Bowl nut _ Threaded portion | Damage, Coring _ O Refer to o Bow/ fitting portion _| Damage. oO 424 oO Groove Contamination, oO a Clogging © Bowl hood Bow! nut fiting Bow! body fitting ° Refer to ao Portion ___| portion 425 Bow! body fitting | Damage 3 a portion Threaded portion _| Scoring o Oo Light liquid chamber | Damage C o fitting portion | Oring groove Damage, ° oO | Contamination | Knock pin groove | Damage, ° o __| deformation ae | AASELFIECTOR Instruction Manual 52 Maintenance ManualCheck intervals. Parts to check Details to check for (months) Corrective | Remarks [Check action mark Every | Every | Every oe | tere |pr2 Bowl ‘© Main seal ring Seal surface Damage, ° Refer to oO Deterioration 426 Seal surface dimension | Deformation ° Ee) ” @ © Distributor Keywa) Deformation oO Refer to oO Threaded portion Damage 3 427 go Knock pin Deformation ° o| © Various types of O | Deterioration, ° Refer to el tings of bow! Cracks, Wear 428 © Main cylinder Main seal ring seal | Damage, Wear, ° Refer to Oo surface Corrosion 429 Bowl body sliding portion | Damage, Wear, ° oO Peeled plating O ring groove Contamination o ol © Pilot valve Bowl body sliding portion | Damage o Refer to o Valve sheet seat surface | Damage, 3 4.2.10 a Deformation, Foreign substances caught © Light liquia Contamination, 3 a chamber Worn threaded portion, Corrosion © Heavy liquia Contamination, ° Su40F~ 1 chamber Corrosion, Cracks et © Gravity disc Contamination, ° oO Corrosion, Cracks *® Bowl bush Contact with bow! 9 Oo ‘© Drain nozzle Clogging Q ol SELFJECTOR Instruction Manual Maintenance Manual 53Check intervals Parts to check | Details to check for (months) Corrective | Remarks | Check every | Every | Every | action mark 3 | 6 | 12 Vertical Shaft © Vertical shaft Upper portion Corrosion, Wear oO Refer to o (above bearing (1)) 434 Bowl bushing fitting | Damage, Corrosion, ° Oo portion Fit Threaded portion _| Damage oO oO Bearing fitting Wear oO oO portion Pinion tooth surface _| Wear o 0 ‘Whole of shaft Center runout ° Overhaul |] interval ‘Shaft height ‘Assembled O | Refer to Oo Dimension 437 © Upper spring Whole Broken, Cracks © [Refer to o Dimension Free length O 1432 oO © Bearing cover | Damage, ° oO a) Contamination, Corrosion © Bearing case (1 Whole Damage, Scoring, °O oO Wear Dimension Free length o oO © Flat spring Whole. Broken, Cracks O TRefer to oO Dimension Spring height O 143.4 oO ‘© Installed ‘Assembled O [Refer to Oo height of Dimension 438 flat spring © Bearing case (2) Whole Damage, Scoring, ° Oo Wear Dimension Free length ° oO (@ Bearing case (3) Whole Damage, Scoring, ° o Wear Dimension Free length o o © Stee! ball Deformation, © [Refer to Oo Grooved damage 4.3.5 ASELFJECTOR Instruction Manual Maintenance ManualCheck intervals (months) Parts to check Details to check for [Every | Every | Every | Comective | Remarks [Check 3 6 12_|_ action mark Vertical Shaft © Lower spring Whole Broken, Cracks O_]Refer to o Dimension Spring height O_|436 oO | © _ Spring seat Wear ° oO © Be ‘Assembled O [Refer to o dimension 433 © Bearing Corrosion ° a Broken a case Horizontal Shaft e _Horizontal shaft ‘Threaded portion Damage [Refer to Oo Bearing fitting portion _| Wear Oo |442 ee Keyway Wear oO Oo | Safety joint groove Wear, Deformation Q oO © Spiral gear Wear, Burr O [Refer to oO 444 © Collar Wear O [Refer to oO 4.43 © Friction block Wear O [Refer to ao 444 ‘© Friction pulley Wear O [Refer to Oo 445 © Ollseal Leakage ° oO ‘© Bearing housing (3) Bearing fitting portion Wear oO eae ‘© Bearing housing (4) Bearing fitting portion Wear 9 Oo © Bearing Corrosion ° Oo Broken a case @ASELFJECTOR Instruction Manual 55 Maintenance ManualCheck intervals Parts to check | Details to check for (months) Corrective | Remarks | Check Every | Every | Every | action mark 3 | 6 | 2 Water Supplying Device Operating water | Contamination, 3 Refer to o nozzle Clogged drilled 48 Oo Operating water hole, Damage chamber Oring Damage, oO Oo Deterioration, Deformation Gear Pump Safety joint Damage oO Refer to o 45.4 Bush Damage, Wear O _|Referto oO | Gear tooth surface_| Damage, Wear Oo 452 g Drive gear, Wear ° oa il seal contact QO surface E Valve stem Operating pressure ©. Refer to a 453 Solenoid Valve Diaphragm Deterioration, ° Oo Deformation, Broken, Contamination Inside of valve Deposited scale, ° ia Damage ‘Seal part Leakage o fea Reducing Valve Diaphragm Deterioration, ° Oo Deformation, Broken Inside of valve, Deposited scale, ° oO Sheet surface Damage Seal part Leakage 3 oO Pressure gauge _| Pressure indication o oO Y-Type Strainer _ Strainer Contamination, Oo [Clogging @XSELFJECTOR Instruction Manual Maintenance Manual 56Check intervals (months) Parts to check Details to check for | Every | Every | Every | Comective | Remarks [Chock 3 6 | 12 | action mark Constant Flow Valve Inside of valve Deposited scale, Oo o _ Contamination Piston Piston stuck oO Leakage Monitor (LM) Funetion ‘Alarm check ° Refer to a 49.1 Discharge Detector (DD) Function Alarm check Oo Refer to oO 49.2 aASELFJECTOR Instruction Manual 57 Maintenance Manual6 Causes of troubles and corrective steps /'\ WARNING Before performing opening checks, check to ensure that the SELFJECTOR has come to a jcomplete stop. Whether the SELFJECTOR has come to a stop can be checked by watching the| safety joint section at the horizontal shaft gear pump side or the fan of the motor. JN CAUTION When an alarm occurs, perform checks and remove the cause of the alarm before re-starting the machine. 6.1. Alarms 6.1.1. Types of alarms Table 6-1 ‘Automated type FSC-1A | FBC-1A | FSH-1A | FSP-1A | FSH-PA| FAP-11 |Manual | Operation detector FBC-2A Cilleakage | O ° ° ° ° ° © | Leakage Monitor (um) No opening | 4 a ° ° ° Discharge Detector of bow! (Dd) Hidens ° ° Water Detector alarm (wo) A = option © Ollleakage When the SELFJECTOR fails to operation and causes either of the following phenomena, it regards ‘the phenomenon as “Oil leakage" and outputs an alarm. (1). The treatment liquid (cil) flows out from the heavy liquid side. (2) The treatment liquid (oil) flows out because of insufficient sealing of the sludge outiet of the bowl. © No opening of bow! Despite the fact that the “discharge sludge" procedures were performed, no sludge has been ‘actually discharged. The SELFJECTOR regards it as a No opening of bow! and outputs an alarm, © Hidens alarm The HIDENS system configuration machine (FSH-1A, FSH-PA specification) equipped with a Water Detector outputs an alarm when the discharge instruction resulting from a rise in the water value is generated frequently, The alarm contains the “CPU ABNORMAL" and "A/D CONVERTER ABNORMAL" of the Water Detector control unit. To define a Hidens alarm, the time and frequency are set for use as the criteria for comparison. aASELFJECTOR Instruction Manual Maintenance Manual 16.1.2. Alarm indications ALM No. [Types of alarms 02 No opening bowl | (NO-D1S) 03 Hidens alarm (HI-AL) Check the LEDs on the operational indication panel. ON ON Alarm nunber (ALM No. ) a FSH-1A, FSH-PA Fig. 6-1 dASELFJECTOR Instruction Manual Maintenance Manual 62FBO-1A FBC-2A Check the LEDs on the CPU unit. AR a m1 90000 wi 00000 Lenk "1S yee LMP vier Lenk "1S rye LMP vie Thea ME® No opening bow! (Nis) (ithen option is provided. ) Fig. 6-2 .SELFJECTOR Instruction Manual Maintenance Manual 63Oil leakage ~ TT Goorensese Govaeneacarana FAP-H1 Fig. 6-3 6.1.3 Processing sequence after occurrence of alarm The processing sequence after occurrence of an alarm is shown in Fig. 6-4 for the FSC-1A, FBC-1A, FBC-2A, FSH-1A, FSP-1A and FSH-PA and Fig. 6-5 for the FAP-11. ii leakage jo opening of dens alarm _| bow! } Oilleakage i |Substitution| I Discharge Water solenoid valve - Closed Feed vale + Circulation side Feed valve — Circulation side Selfjector motor Selfjector motor stoppé continues operation. Fig. 6-4 Fig. 6-5 FSC-1A, FBC-1A, FBC-2A FAP FSH-1A, FSP-1A, FSH-PA wASELFJECTOR Instruction Manual Maintenance Manual 646.1.4 Self-diagnostic fnction of detectors 6.1.4.1 Leakage Monitor (LM) ‘Trouble display When fed with an abnormally high voltage of 450 kPa {4.5 kaflom?}, rE ee the pressure sensor recognizes it as a detector failure and causes the trouble display LED (red) to light through feeding timer. At the ‘same time, an error output is generated and the oil purifier is stopped after a sludge discharge. The LED display and error output are held so that you can ‘acknowledge the detector failure. In this case, the error cannot be reset unless power is turned off and then on. Fig. 6-6 6.1.4.2 Discharge Detector (DD) As a self-diagnostic function, the LED lights any of the following cases. 1 @ The output corresponds to 2500 r-p.m. of speed or higher eee (A circuit failure is suspected.) epee ® The proximity switch input signal is unstable ay (The proximity switch may be out of position.) Correct its position. This LED goes out as soon as its input | signal has been stabilized. DD (When adjusting and confirming the position of the proximity | switch, refer to 5. Discharge Detector in the Operation Manual 2. ) Unlike the Leakage Monitor, no alarm signal is delivered when the LED lights. Fig. 6-7 NOTE When the SELFJECTOR Is in the process of being started or stopped, the Trouble display LED may temporarily come on, but this should not be taken to mean that the detector Is out of order. @ASELFJECTOR Instruction Manual Maintenance Manual62 Occurrence of oil leakage (The ol flows out from the sludge outlet or heavy liquid outlet.) 6.2.4 Check the flow rates of valve openins and closing operating water and sealing water. je Remove the flange of the water connecting tube and place the manual handle of the solenoid valve in the “OPENED” position and measure the flow rate of valve closing operating water. (Fig. 6-8,Fig. 6-9-1) The pressure to set for the pressure reducing regulator is 0.02MPa (0.2kgf/cm®). (Flow rate of valve closing operating water is over 200cc/sec.) © When the water flow rate is low, clean the Y-type strainer and piping line. © Extend the time of the valve closing operating water timer. (30 sec. max.) © Check the flow rate of sealing water (SV3): Automatic specification Disconnect the sealing water tube, place the manual handle of the solenoid valve in the "OPENED" position, and measure the flow rate of sealing water. (Fig. 6-8,Fig. 6-9-2) Flow rate of sealing water for ‘SJ10F, 15F, 30F, 40F 12 L/min SJSOF,80F, 100F = 16 L/min FH/FP/SH types are the same value as F type. © When the flow rate is low, clean the piping line. © Adjust the sealing water timer in keeping with the flow rate of sealing water. (Refer to OM2: "Sealing Water",) * Dynamic pressure (A state where water is flowing) fe Check the amount of partial discharge: Operate the partial charge type purifier to perform a discharge test with water kept running and measure the amount of partial discharge through the Discharge Detector. ‘© Adjust the reduction valve for partial discharge. (Fig. 6-9—8) (OM2: Refer to [Partial Discharge Measurement].) ‘OM1: Operation Manual 1 sys su Sua Me) ‘a A ay Fig. 6-8 FSC-1A,FBC-1A,FBC-2A,FSH-1A, dASELFJECTOR | Instruction Manual Reducing valve for closing bow! ‘M2: Operation Manual 2 MM1: Maintenance Manual Fig. 6-9 FSP-1A, FSH-PA ‘Maintenance Manual 666.2.2 Checks to perform by disassembling bowl le Check for a flaw on the sheet surface of | If the seal surface is galled by metallic powder more the main seal ring. (Fig. 6-10—5) than 60% of its length, replace the main seal ring. l@ Check for a flaw on the O ring of the | If there is a flaw, replace the O ring with a new one. valve case. (Fig. 6-10~6) l¢ Check for a flaw on the valve sheet. (Fig. | If there is a flaw, replace the valve sheet with a new 6-10—7) one. le Check the pilot valve for contamination | Thoroughly clean the pilot valve. Set it in the valve and operation. (Fig. 6-10—8) case and check whether it can be operated by hand. le Check the drain nozzle for clogging. | Clean. (Fig. 6-10—9) le Check for a flaw on the sheet surface of | If there is a fine scratch, repair it with an oil stone. the main cylinder. (Fig. 6-10—10) (Refer to MM1: "Main Cylinder*.) (The main cylinder for C heavy oil has a special coating, If there is a flaw, replace the main cylinder with a new one.) le Check all the O rings for a flaw or loss of | Replace if defective. elasticity (Particularly the O ring on the outside of the main cylinder) (Fig. 6-10-11) le Check the diameter of the gravity disc. | Use a gravity disc suitable the specific gravity of the (Fig. 6-10-12) oll. Check whether the oil temperature and the oil feeding rate are appropriate. (Refer to the OM2: “Gravity Disc Selecting Procedures”) 6.2.3 Checks to perform by disassembling water supplying device © Check the drilled hole of the water] Clean. supplying device for clogging. (Fig. 6-11-18) © Check the O ring for a fiaw or loss of | Replace if defective, elasticity. (Fig. 6-11-19) © Check for water leakage from the | Re-tighten the cap nut of the joint. operating water Teflon tube. (Fig. 6-11— | Replace the Teflon tube with a new one. 20) 62.4 Other © Check for a flaw and loss of elasticity on | Replace if defective. the O ring of the upper and lower hood. (OM1: Operation Manual 1 ES aASELFJECTOR Instruction Manual ‘M2: Operation Manual 2. MM1: Maintenance Manual Maintenance Manual 67SJ4OF, S0F and 80F ONLY _/ (FHIFP/SH types are / the same as F type.) Fig. 6-11 JASELFJECTOR | Instruction Manual Maintenance Manual 686.3 Occurrence of abnormal vibration 6.3.1_Check for unbalance in the bowl. Isn't there an unevenly accumulated sludge in | Clean the inside of the bowl. the bowl? (Fig. 6-10-13) Adjust the discharge intervals properly. (Refer to the OM2: "Discharge Intervals") Check for low valve opening operating water pressure. (0.2~0.5MPa {2.0~5.0kgficm’}) ‘© Aren't the discs insufficient because of the | Add if insufficient. seating phenomenon? (Refer to the MM1: "Maintenance inspection’) (Fig. 6-10-14) © Have you replaced the major parts of the bow! | Balance adjustment is necessary. {the bow! body, bow! hood, distributor, main | (Contact our company or service agency.) cylinder, heavy liquid chamber or light liquid chamber)? © Aren't the tally marks of the bowl nut, light | Reassemble them with their tally marks in liquid chamber and heavy liquid chamber out | alignment with the tally marks of the bow! body. of alignment? (Fig. 6-10—15) (Refer to the MM1: "Reassembly",) ‘© Is the bow! bush in good contact? If there is a fine scratch, repair or replace. (Fig. 6-10-16) (Refer to the MM1: "Maintenance Inspection") 6.3.2 Checking for defects in vertical shaft system [eCheck the upper spring, lower spring and fiat |Measure the dimensions. If they are out of the| spring for deformation. (Fig. 6-12—21) specified values, replace. |(Refer to the MM1: "Maintenance Inspection’.) le Check the bearing for wear. (Fig. 6-12—22) _|Replace if defective. © Check the vertical shaft and bearing case |Replace if defective. fiting portions for wear. (Fig. 6-12-23) l@ Check the portions with which the steel balls Replace if defective. of the ball bearing case make contact, the spring seat and steel ball for wear and deformation. (Fig. 6-12~24) 6.3.3 Checking for defects in horizontal shaft system [eCheck the bearing for wear. (Fig. 6-13-27) [Replace if defective. le Check the friction block for uneven wear. (Fig. |Replace if defective. 6-13-28) le Are the quantity and position of friction blocks |Correct if incorrect. correct? (Fig. 6-13-28) (Refer to the MM1: “Friction Block".) OM1: Operation Manual 1 OM2: Operation Manual 2. MM1: Maintenance Manual SS aASELFJECTOR Instruction Manual Maintenance Manual 6-9Fig. 6-13 SELFJECTOR Instruction Manual Maintenance Manual6.4 _Does not discharge sludge even if discharge procedures are performed. [eCheck the solenoid valve (SV1) for operation. | Replace defective parts. (Fig. 6-8,Fig. 6-9-3) l@ Check the solenoid valve for partial discharge (SV9) for operation. (Fig. 6-9) le Check the strainer of the operating water | Clean. piping for clogging. (Fig. 6-8,Fig. 6-9-4) le Check the O ting of the water supplying | Replace if defective. device for defective sealing, (Fig. 6-11-19) le Check the pilot valve assembly for | Clean. contamination. (Fig. 6-10-17) le Check the O ring for defective sealing. Replace if defective. le _ Check for low operating water pressure. 0.2~0.5MPa {2~Skgticm?}. 6.5 Mixed flow of water toward light liquid outlet [e Aren't the sealing water and substitution water | Measure the flow rates of sealing water and| flow rates excessive? substitution water. if they are in excess of the| specified flow rates, adjust the timers. (Refer to the MM1.) leis the diameter of the gravity Use a gravity disc suitable for the properties of the| appropriate? (Fig. 6-10-12) oil. (Refer to the MM1.) le Check the solenoid valve (SV3) for defective | Replace defective parts. sealing. (Fig. 6-8,Fig. 6-9-2) le _ Is the sludge discharged? Corrective steps in Section 6.4 le Check the heavy liquid outlet of the bow! for | Clean. clogging. 6.6_Low feeding rate or not fed at all fe Check the gear pump for reduced capability. | Disassemble and check. Replace defective parts. Je Isn't the suction capacity of the gear pump | Suction pressure ~4m. exceeded? [e _ Isn't the suction piping of the pump too thin? _| Use a piping diameter suitable for the flow rate. le Isn't the air absorbed at an intermediate point | Check and re-tighten the joint. of the suction piping? le Isnt the strainer at the inlet side clogged?__| Clean. je _ Isn't the safety joint broken? (Fig. 6-13-29) _| Replace. OM1: Operation Manual 1 OM2: Operation Manual ES wRSELFJECTOR Instruction Manual 2 MM1: Maintenance Manual Maintenance Manual 6116.7_ Gear oil mixed with water je _ Isn't the operating water drain pipe clogged? _| Clean _ je Isn't the operating water supplied when the | Check the solenoid valve and replace defective| SELFJECTOR is in the stopped state? parts. Note) Keep the source valve closed. [© Check the © ring of the bearing housing (1) | Replace if defective. for defective sealing, (Fig. 6-12—25) le Check the O ring of the bearing cap for | Replace if defective. defective sealing. (Fig. 6-12-26) 6.8 Poor separation le Isn't the treatment temperature low? ‘Adjust to the proper temperature. (Refer to the MM1: "Treatment Temperature") le Isn't the inside diameter of the gravity disc too | Replace the gravity disc with an appropriate one. small? (Fig. 6-10-12) (Refer to the MM1: ‘Gravity Disc Selecting| Procedures") le Isn't the treatment quantity too large? ‘Adjust the treatment quantity properly. (Refer to the MM1: "Feeding Rate") je Isn't the speed low? Check the power transmission system, including] the friction clutch. j@ Aren't the discs clogged with sludge? (Fig. | Clean. 6-10-14) 6.9 Low speed [eCheck the friction block for wear. (Fig. 6-13— ] Replace. 28) le Is the bow! valve closed? Disassemble and check the bow. Check the valve opening and closing operating| water system, le Motor out of order. Check and repair. 6.10 Sludge unevenly accumulated in bow! le Aren't the sludge discharge intervals too | Shorten the discharge intervals. fong?_ (Reter to the MM1: "Discharge Intervals”) Je Isn't the valve opening operating water | Adjust the valve opening operating water pressure| pressure low? to more than 0.2MPa {2.0kgf/cm?}. Clean the| strainer. l@ Are both of the pilot valves performing well? | Check and clean the pilot valves. (Fig. 6-10—8) eCheck the drain nozzle for clogging. (Fig. | Check and clean the drain nozzle. 6-109) ‘OMI: Operation Manual 1 OM2: Operation Manual 2. MM1: Maintenance Manual SN 2ASELFJECTOR Instruction Manual Maintenance Manual 6126.11 Mixed flow of oil toward heavy liquid outlet le Isn't the inside diameter of the gravity disc too | Replace the gravity disc with an appropriate one, large? (Fig. 6-10-12) (Refer to the MM1: “Gravity Disc Selecting] Procedures") Je Isn't the flow rate of sealing water low? Clean the strainer. Measure the flow rate off sealing water and adjust the timer. of the light | Replace. Je Isn't there leakage from the O liquid chamber. (Fig. 6-10—31) 6.12 Accessories 6.12.1 Solenoid valve unit for the operating water 6.12.1.1_Low flow rate le Check the operating water piping for clogging. | Flush the piping. |Check the strainer for clogging. (Fig. 6-9,Fig. 6-8, | Clean. 6-14,Fig. 6-15—4) 6.12.2 Solenoid valve for w 6.12.2.1 Leaky le Isn't the diaphragm broken? Replace if defective. (Fig. 6-14, Fig. 6-14-30) Je Check the valve sheet surface for a flaw or a [Check and clean. Replace if defective. foreign substance caught. (Fig. 6-15,Fig. 6-14-30) 6.12.2.2 Does not operate. (Does not open the valve.) ‘© _ Isn't there a defect in electric wiring? Check the wiring. (© _ Isn't the coil damaged by heat? Replace if defective. M1: Operation Manual 1 OM2: Operation Manual 2. MM1: Maintenance Manual sve SH s¥3 TH, pill for closing bow! Reducing val Fig. 6-14 forelonce Fig. 6-15 wASELFJECTOR Instruction Manual ‘Maintenance Manual6.12.3 Three-way raw liquid valve 6.12.3.1_ Valve does not switch over. je Isn't the supply of compressed air insufficient? | Check the three-way solenoid valve. [© Isn'tthe air pressure low? ‘Adjust the air pressure properly. | (0.5~0,9MPa {5.0~9.0kgt/cm?}) Je Isn't there air leakage? Check the O ring of the piston assembly. Replace if defective. 6.12.3.2_Leaky [eCheck the valve sheet or disc for damage. _| Check. Replace defective parts. NS WASELFJECTOR Instruction Manual Maintenance Manual e146.12.4 Leakage Monitor (LM) [Refer to the OM2: ‘Leakage Monitor"] 6.12.4.1_Incorrect alarm is generated. le Isnt the discharge pressure lower than the alarm pressure? ‘Adjust the discharge pressure to the set pressure. pressure? le _Isn'tthe feeding timer too short? ‘Adjust the feeding timer. (Normally 30~60 sec.) le Isn't the fluctuation timer too short? ‘Adjust the fluctuation timer. (Normally 10~20 sec.) le Aren't there large fluctuations in discharge | Remove the cause of fluctuations. 6.12.4.2 No alarm is output. Isn't the "Feeding" signal line open-circuited? [Isnt there a defect in the electrical wiring to | Check the wiring. the contro! panel? le ‘Check the wiring. 6.12.4.3 Alarm output during discharge process [e Board out of order. Replace the detector. 6.12.4.4 Trouble display LED "Trouble" lights. le Board out of order. (Fig. 6-16) Replace the detector. 6.12.45 Does not operate when the power switch is set to ON. le Blown fuse. (Fig. 6-18) Check and replace fuse. Trouble Fig. 6-16 SS a@ASELFJECTOR Instruction Manual 61 Maintenance Manual 56.12.5 Discharge Detector (DD) Refer to the OM2: "Discharge Detector” 6.12.5.1_ Incorrect alarm is generated. fe Is the proximity switch mounted at the right Position? Adjust the mounting position, (The normal proximity switch-to-horizontal shaft clearance is 1.8| mm) 6.12.5.2 Trouble display LED "Trouble" lights. [e Is the proximity switch mounted at the right position? (Fig. 6-17) le Board out of order. ‘Adjust the mounting posi Replace the detector. 6.12.5.3_Alarm is output during discharge process. Board out of order. Replace the detector. 6.12.5.4_ Does not operate when the power swit ich is set to ON. [@ _ Blown fuse. (Fig. 6-19) Check and replace the fuse. Trouble Fig. 6-17 AARSELFUECTOR Instruction Manual Maintenance Manual 6-166.12.6 Detector fuse replacement procedures Spare fuse Fig. 6-19 Discharge Detector Fig.6-18 Leakage Monitor @ Remove the fuse from the fuse box. Push the fuse until the bars get out, and then slide and pull it out. 1, Remove the fuse from the fuse box. Push the fuse until the bars get out. @ Replace the fuse with a new one and push the new fuse into the fuse box. Slide and pull the fuse out. Ce ede eae 2. Replace the fuse with a new one. _——s —r 3. Insert the fuse into the fuse box. Click!! Push the fuse in until a click is heard. Fig. 6-20 SN EEE @ASELFJECTOR Instruction Manual Maintenance Manual 6176.12.7 Water Detector (WD) [Refer to the OM2: "Water Detector] 6.12.7.1 Alarm is frequently generated. (FSH-1P) le No back pressure is applied to the light liquid side. Apply a back pressure of 0.18~0.20MPa {1.8~ 2.0kgflom?. le Large variations from settings. Make adjustments so that the variations will Back pressure + 0.01MPa (0. tkgf/em?) Oil temperature | +5 Flow rate £5% Je Incorrect settings of control panel Re-enter correct settings according to the "Operation Manual 3D, 36". (OMI: Operation Manual 1 (M2: Operation Manual 2 MM1: Maintenance Manual NOTE ithe "Operation Manual 3A~3F”. For information on the "Causes of Troubles and Corrective Steps" of the control panel, refer to WASELFJECTOR Instruction Manu: 6-18 Maintenance Manualaa MITSUBISHI KAKOKI KAISHA, LTD HEAD OFFICE 2-1, OHKAWA-CYO, KAWASAKI-KU, KAWASAKI CITY, JAPAN 7210-8560 MACHINERY SALES DEPT. KAWASAKI TEL. +81-(0)44-333-5381 FAX.+81-(0)44-355-1627 MKK EUROPE B.V. SPINNERIJ 41, 1185ZS AMSTELVEEN, ‘THE NETHERLANDS. TEL.+31-(0)20-4560666 FAX.+31-(0)20-4560635