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Alfa Laval OS12, Instruction Manual

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Alfa Laval OS12 Instruction Manual Download Page 25

5 Maintenance

S

Stteepp 55
Disassembling of gearbox

1. Remove pump casing studs.

2. Place a tray under the oil drain to collect the waste lubricant.

3. Remove the oil drain plug and seal and allow lubricant to drain.

4. Remove the gearbox end cover bolts and washers.

5. Pull out the whole axial bearing & shaft unit from the gearbox. To assist removal, tap shaft ends with a soft mallet.

6. Remove the gearbox O-ring. If this needs to be replaced.

3205-0016

3205-0017

25

CONTACT CSI FOR MORE INFORMATION  |  CSIDESIGNS.COM  |  [email protected]  |  417.831.1411

Summary of Contents for OS12

Page 1: ...3205 0000 100000817 EN2 2021 03 Original manual Instruction Manual Alfa Laval OS Twin Screw Pump...

Page 2: ...This page intentionally left blank CONTACT CSI FOR MORE INFORMATION CSIDESIGNS COM SALES CSIDESIGNS COM 417 831 1411...

Page 3: ...14 4 3 Flushing seal arrangement and pre start up checks 18 5 Maintenance 20 5 1 Cleaning in place CIP 20 5 2 Maintenance schedule 21 5 3 Dismantling 22 5 4 Assembly 30 5 5 Maintenance seals Single Se...

Page 4: ...CONTACT CSI FOR MORE INFORMATION CSIDESIGNS COM SALES CSIDESIGNS COM 417 831 1411...

Page 5: ...S12 OS14 OS16 OS22 OS24 OS26 OS32 OS34 OS36 OS42 OS44 OS46 Type From serial number 10 000 to 1 000 000 is in conformity with the following directive with amendments Machinery Directive 2006 42 EC The...

Page 6: ...Pump Casing C Seal Housing D Gearbox E Coupling Guard F Motor G Baseplate 3205 0049 F G A B C D E P Pu um mp p d du ut ty y c co on nd diit tiio on ns s The pump should only be used for the duty for...

Page 7: ...all f fo or r t th he e s su up pp plliie ed d p pr ro od du uc ct t S Sk kiilllls s f fo or r p pe er rs so on na all O Op pe er ra at to or rs s T Th he e o op pe er ra at to or rs s s sh ha allll...

Page 8: ...he e m ma an nu ua all b be ef fo or re e u us siin ng g t th he e p pu um mp p 3 2 Warning signs G Ge en ne er ra all w wa ar rn niin ng g D Da an ng ge er ro ou us s e elle ec ct tr riic ca all v vo...

Page 9: ...r when sterilising In certain operating conditions external surfaces of the pump and or ancillary equipment may exceed 80oC As such users should avoid touching the pump and or ancillary equipment duri...

Page 10: ...niit t N Ne ev ve er r lift or elevate in any way other than described in this manual A Allw wa ay ys s drain the pump head and accessories of any liquid A Allw wa ay ys s ensure that no leakage of l...

Page 11: ...machine are replaced All metal parts should be sent for material recycling Worn out or defective electronic parts should be sent to a licensed handler for material recycling Oil and all non metal wear...

Page 12: ...clear during the lifting operation The diagram below show examples of how the equipment can be lifted however the user is to ensure this can be done safely with the equipment at hand Pump with drive...

Page 13: ...t or dusty atmosphere is used for storage further protect the pump or unit with a suitable cover A clean dry storage location free from vibration and without direct sunlight or UV light should be sele...

Page 14: ...least 1 m for pump access maintenance all around the pump Do not subject rotary lobe pumps to rapid temperature changes as pump seizure can result from thermal shock P Piip pe ew wo or rk k The pump...

Page 15: ...e retaining bolts To provide a permanent rigid support for securing the pump unit a foundation is required which will also absorb vibration strain or shock on the pumping unit Methods of anchoring the...

Page 16: ...height adjustable feet When used E En ns su ur re e the floor is level and is able to support the weight of the complete unit E En ns su ur re e the unit is supported by all feet equally 3 3A A A Ap...

Page 17: ...ar rd d s su up pp plly y c co ou up plliin ng gs s o on nlly y P Pa ar ra alllle ell m miis sa alliig gn nm me en nt t Measure 4 positions at 90 around coupling C Co ou up plliin ng g s siiz ze e D D...

Page 18: ...pt Connection OS1x G 1 4 1 4 NPT OS2x G 1 4 1 4 NPT OS3x G 1 4 1 4 NPT OS4x G 1 2 1 2 NPT S St te ep p 4 4 F Fllu us sh hiin ng g f fllu uiid d The choice of flushing fluid is dependent upon the fluid...

Page 19: ...obstructions have been removed from pipework and pump Check pump connections and pipework joints are tight Check lubrication levels are correct Check seal flushing is connected if applicable Check all...

Page 20: ...when handling caustic agents A Allw wa ay ys s store discharge cleaning agents in accordance with current rules directives C CI IP P p pr ro oc ce es ss s u us siin ng g s se ep pa ar ra at te e C CI...

Page 21: ...tion Checks should be carried out when the pump is not operational and any electrical supply has been safely disconnected and locked so accidental operation cannot occur In certain operational circums...

Page 22: ...to safety precautions See exploded view drawings chapter 7 Parts list Removing pump cover and pump casing 1 Remove front cover nuts washers front cover front cover elastomer and pump casing 3205 0010...

Page 23: ...0011 A A Plastic wooden block 2 Remove feed screw nuts feed screw nut elastomer and feed screws NOTE the identification marking on the screws and the shafts 3 Remove the pump casing elastomer and sha...

Page 24: ...evering against the gearcase and back of seal assembly if necessary 3205 0014 S St te ep p 4 4 Removing seal housing 1 Remove the seal housing retention screws 2 Tap both sides of the seal housing wit...

Page 25: ...in plug and seal and allow lubricant to drain 4 Remove the gearbox end cover bolts and washers 5 Pull out the whole axial bearing shaft unit from the gearbox To assist removal tap shaft ends with a so...

Page 26: ...als 3 Remove needle bearing snap ring 4 Tap the needle bearings outer races out of their seat 3205 0018 S St te ep p 7 7 Disassembling of bearing housing shaft assembly 1 Remove bearing retainer bolts...

Page 27: ...ith soft jaws taking care not to damage the shaft assembly 2 Bend up locking tab on washer from bearing nut 3 Loosen the bearing nut with a C spanner by tapping sharply and remove it 3205 0020 A B A L...

Page 28: ...tool positively located against the needle bearing inner race and apply pressure to the top of the shaft so that the shaft moves through the bearing 4 Remove gear key from shaft Remove snap ring from...

Page 29: ...emove lip seal from gearbox end cover 1 Extract the lip seal from the gearbox end cover It is essential to renew the lip seal prior to assembly 3205 0024 CONTACT CSI FOR MORE INFORMATION CSIDESIGNS CO...

Page 30: ...S St te ep p 1 1 Assembly of adjustable gear 1 Lubricate the inner diameter of the adjustable timing gear with oil 2 Slide the timing gear onto the gear sleeve with the threads facing the collar 3 Pl...

Page 31: ...3205 0027 8 Heat the 3 angular contact ball bearings up to 110 C 230 F and slide over the shaft N No ot te e The bearing positioning is dependent on the suction and discharge direction Two bearings fa...

Page 32: ...d cover 1 Install lip seal in gearbox end cover 3205 0031 S St te ep p 4 4 Fitting shaft assembly in gearbox end cover Ensure correct torques are used 1 Slide drive and auxiliary shaft assembly in gea...

Page 33: ...eals 4 Fit filler plug 5 Fit oil sight glass 6 Fit drain plug and washer 3205 0033 S St te ep p 6 6 Assembling of gearbox Ensure correct torques are used 1 Fit gearbox O Ring use grease to keep it in...

Page 34: ...ientation 4 Install the seal housing retention screws and tighten them 3205 0035 3205 0036 S St te ep p 8 8 Installing primary seal components Ensure correct torques are used 1 Lubricate external elas...

Page 35: ...kings on the shafts 2 Fit both feed screws onto the shafts simultaneously and push them till they make contact with the mechanical seal sleeve To make the splines fit you may need to rotate the shafts...

Page 36: ...e 2 Turn the drive shaft and check the clearance between the feed screw flanks Use feeler gauges to make sure the clearance is evenly divided between the flanks Refer to Pump head clearance Informatio...

Page 37: ...ump casing 5 Fit front cover nuts washers and torque them to their recommended value N NO OT TE E If a new pump casing if being fitted or if the pump is being modified due to reversed flow direction t...

Page 38: ...in Technical Data See chapter 6 Technical data S St te ep p 1 13 3 Adding lubricant 1 Pour the recommended oil lubricant into the gear top cover opening See section 6 Technical data for correct oil q...

Page 39: ...ng fitting of the seal Ensure seal faces are clean throughout the fitment If a need to be cleaned use acetone or similar solvent sprayed onto lint free tissue Equipment to be used Acetone compatible l...

Page 40: ...p 9 9 Spray acetone or similar solvent onto lint free tissue and wipe the sealing surfaces of the rotary face 73 and static face 72 clean NOTE Do not spray acetone directly onto the sealing surfaces...

Page 41: ...f the seal Ensure seal faces are clean throughout the fitment If a need to be cleaned use acetone or similar solvent sprayed onto lint free tissue Equipment to be used Acetone compatible lubricant and...

Page 42: ...y acetone directly onto the sealing surfaces S St te ep p 1 10 0 Turn the rotary assembly upside down and slide the sleeve carefully into the static assembly mating the sealing surfaces together S St...

Page 43: ...taken not to chip these components during fitting of the seal Ensure seal faces are clean throughout the fitment If a need to be cleaned use acetone or similar solvent sprayed onto lint free tissue Eq...

Page 44: ...tted in the drive ring 75 then firmly press the static face 76 down fully home into the seal housing bore 74 S St te ep p 1 13 3 Spray acetone or similar solvent onto lint free tissue and wipe the sea...

Page 45: ...time Carefully fit the mechanical seal onto the shaft and into the pump housing making sure the lug of the seal housing aligns with the slot in the pump housing and fit seal retaining screw and gland...

Page 46: ...ring fitting of the seal Ensure seal faces are clean throughout the fitment If a need to be cleaned use acetone or similar solvent sprayed onto lint free tissue Equipment to be used Acetone compatible...

Page 47: ...ubricate the static face profile elastomer 82 with suitable lubricant compatible with the application and fit into seal housing 74 groove S St te ep p 1 12 2 Align the slots in the static face 72 with...

Page 48: ...time Carefully fit the mechanical seal onto the shaft and into the pump housing making sure the flat of the seal housing aligns with the flat in the pump housing and fit seal retaining screw and gland...

Page 49: ...pump models in the table H He ea at tiin ng g C Co on nn ne ec ct tiio on ns s S Siiz ze e OS12 OS14 OS16 G1 4 1 4 NPT OS22 OS24 OS26 G1 4 1 4 NPT OS32 OS34 OS36 G1 4 1 4 NPT OS42 OS44 OS46 G1 2 1 2 N...

Page 50: ...skets seals should conform to country specific hygienic regulations such as 3A For sizes please see diagram and table below B R W M H A M Mo od de ell D Diim me en ns siio on n m mm m O OS S1 12 2 O O...

Page 51: ...al face and elastomer temp limitations Fluid temp below rated figure Increase fluid temperature Clean the system Unexpected solids in fluid Fit strainer to suction line Check for obstructions i e clos...

Page 52: ...00 2500 3300 2200 3000 1800 2500 100 2800 3300 2500 3300 2200 3000 1800 2500 250 2800 2930 2500 2930 2200 2930 1800 2500 500 2135 2135 2135 2135 2135 2135 1800 2135 1000 1570 1570 1570 1570 1570 1570...

Page 53: ...que Ibft 14 8 14 8 14 8 14 8 Socket Size mm 13 13 13 13 Torque Nm 18 18 18 18 Gearbox end cover bolt 43 Torque Ibft 13 3 13 3 13 3 13 3 Socket Size mm 8 8 10 13 Torque Nm 7 7 11 26 Gear sleeve bolts 9...

Page 54: ...R 6 8 70 0 min 74 000 min 0 105 min 0 185 min 0 1175 0 085 O OS S 1 14 4 1 12 2 B BA AR R 8 5 70 0 min 74 000 min 0 105 min 0 185 min 0 1175 0 085 O OS S 1 16 6 8 8 B BA AR R 17 8 70 0 min 74 000 min...

Page 55: ...7 Parts list 7 1 Twin Screw Pump Range All Models CONTACT CSI FOR MORE INFORMATION CSIDESIGNS COM SALES CSIDESIGNS COM 417 831 1411...

Page 56: ...27 26 25 24 22 56 21 23 28 23 54 30 6 14 35 34 47 45 50 39 40 41 42 38 1 3 3 2 8 10 11 12 9 55 13 57 7 37 16 15 36 46 44 43 52 4 C Ca ar rt tr riid dg ge e S Se ea all CONTACT CSI FOR MORE INFORMATIO...

Page 57: ...sing Studs 31 1 Seal Housing 32 2 Gland Guard 33 4 Flush Plugs 34 1 Foot 35 1 Gearbox 36 1 Gearbox End Cover 37 1 Gearbox End Cover O Ring 38 1 Gearbox Top Cover O Ring 39 1 Gearbox Top Cover 40 4 Gea...

Page 58: ...of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmit...

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