Mobile hydraulic oil cleaning system

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Book No.: 1817243-02 V1

Alfa Laval reserve the right to make changes at any
time without prior notice.

Any comments regarding possible errors and omissions

or suggestions for improvement of this publication
would be gratefully appreciated.
Copies of this publication can be ordered from your
local Alfa Laval company.
Published by: Alfa Laval Marine & Power AB
S - 147 80 Tumba
Sweden

© Copyright Alfa Laval Marine & Power AB 2000.

Contents
1 Safety instructions 7

2 Application 9

3 Description of main parts 10

3.1 System overview 10

3.2 Hoses 12
3.3 Separator 13
3.4 Pump 13
3.5 Starter / control unit for separator and pump 14
3.6 Heater 14
3.7 Starter / control unit for heater 15
3.8 Collecting tank 17

4 Working principle of the separator 18

4.1 Introduction 18
4.2 Clarifier operation 19
4.3 Purifier operation 19
4.4 Changing operation mode 20

5 Operating instructions 23

5.1 Separation time 23

5.2 Separation mode 23
5.3 Before start 25
5.4 Start 28
5.5 Operation 35

3
 5.6 Stop 37
5.7 How to drain hoses and heater 39

6 Trouble shooting 40

6.1 Cleaning system/separator does not start

or stops shortly after start 40
6.2 Pump does not start 40
6.3 Heater does not start 41
6.4 Pump stops 41
6.5 Separator stops 42
6.6 Noise 42
6.7 Separator vibrates 43
6.8 Insufficient separation result 43
6.9 No flow from pump 44
6.10 Flow too low 44
6.11 No flow either through clean oil outlet
or through drain to collecting tank 45
6.12 Some oil escaping through drain outlet
to collecting tank 45
6.13 Oil flow through drain outlet to collecting
tank only 46
6.14 Oil leakage through drain outlet to collecting
tank when separator is not running 46
6.15 Collecting tank overflowing but pump
does not stop 46
6.16 Separation temperature too low 46
6.17 Heater trips 47
6.18 Oil leaks from heater 47

4
7 Maintenance 48

7.1 Cleaning 48
7.2 Once per year 49
7.3 Every second year 49
7.4 Dismantling - assembly instructions for
separator 49
7.5 Repair instructions 62

8 Technical data 63

9 Diagrams 64

9.1 Starter / control unit for separator and pump 64

9.2 Starter / control unit for heater 66

10 Lifting instruction 68

10.1 Cleaning unit 68

10.2 Heater 69

11 Spare parts 70

11.1 Separator 70
11.2 Other parts 72

12 Installation 74

12.1 Installation alternatives 74

Appendix
IMO pump, Maintenance and Service Instructions 77

5
6
 Safety instructions

1 Safety instructions

Study this instruction manual and observe the

warnings before installation, operation, service
and maintenance.
Not following the instructions can result in
serious accidents.

The centrifugal separator, which is the major part of the cleaning unit, includes
parts that rotate at high speed.
Incorrect operation and maintenance of the cleaning unit can result in serious
damage and/or injury.
The following basic safety instructions therefore apply:
• Use the cleaning unit only for the purpose and parameter range
specified by Alfa Laval.
• Only use the cleaning unit in non-explosion environment.
• Strictly follow the instructions for installation, operation and
maintenance.
• Ensure that personnel are competent and have sufficient knowledge of
maintenance and operation.
• Use only Alfa Laval genuine spare parts and the special tools supplied.

DANGER
Electrocution risk

Switch off the power supply and remove the electric cables from the sockets
before opening the starter/control units for separator and/or heater.

7
Safety instructions

WARNING
Disintegration hazard

• The separator is supplied with a safety yoke and a magnetic safety

switch. Modifications to the machine which put the safety devices out
of operation can lead to serious injury or damage.

• If excessive vibrations occur, stop the separator.

Entrapment hazard

• Make sure that rotating parts inside the separator have come to a
complete standstill before moving the cleaning unit or starting any
dismantling work.

• To avoid accidental start, switch off the power supply and remove the
electric cable from the socket before starting any dismantling work.

Warning labels
A warning label is placed on the
separator hood.
The interpretation of the label is:
S00687B1

STOP! Read the instruction manual

before installation, operation and
Warning label located on separator hood
maintenance. Consider inspection
intervals.

Another warning label is placed on

the door for the heater control unit.
The interpretation of the label is:
S0138611

Switch off the power before opening

the cover. Warning label on cabinet door for heater control

8
 Application

2 Application
The emmie hydraulic oil cleaning system is restricted to the removal of solids and
water from mineral hydraulic, gear and sterntube lube oils with a maximum
temperature of +65 °C and with a maximum viscosity (VG) of 150 cSt at 40 °C.

WARNING
Disintegration hazard

The cleaning unit must not be operated in an explosion environment.

Do not use the cleaning unit for separating any other oils or liquids than
those specified.

NOTE
Thorough flushing of the separation system may be necessary when
cleaning different types of oils. When in doubt consult the oil supplier.

NOTE
Never use emmie on engine lube oils as any small amount of remaining
engine lube oil in the system can seriously affect and change the properties
of the hydraulic oil if mixed.

NOTE
Never connect emmie to a pressurized system with the same or higher
pressure than the pressure switch set point (50 kPa). Otherwise the safety
function of the switch will be overridden, which implies that the pump and
heater can operate without flow.

9
Description of main parts

3 Description of main parts

3.1 System overview
The emmie unit consists of the following parts (numbered in process order):
Parts marked with *) are further described on pages 12 - 17.
1. Coupling device fitted in hydraulic oil tank
2. Inlet hose (1/2”) from tank to pump *)
3A.Feed pump for the hydraulic oil *)
3B.Frequency converter regulating the speed (capacity) of the feed pump *)
4. Hose (1/2”) from pump to heater *)
5. Heater *)
6. Hose (3/8”) from heater to check valve on trolley *)
7. Check valve before separator
8. Separator *)
Removes water and sludge from the hydraulic oil.
9. Check valve after separator (fitted in pressure switch housing at inlet side)
10. Pressure switch at separator outlet
If the counter pressure after the separator does not reach at least 50 kPa
within one minute the pump is stopped.
11. Regulating valve
For setting the correct counter pressure in the outlet line (abt 60-90 kPa).
12. Hose (3/8”) from separator to tank *)
13. Collecting tank (20 litres) *)
Collects the bowl drain oil and the water separated out from the hydraulic oil
(at purification).
14. Starter / control unit for separator and pump *)
For starting, stopping and supervising the cleaning unit (except heater).
15. Starter / control unit for heater *)
For starting, stopping and supervising the heater.

10
 Description of main parts

G0908331
G0908131

Connect the by-pass hose as

shown if not using the heater
G0909041

11
Description of main parts

3.2 Hoses
The hoses before the heater (cold
side) are 1/2” and the hoses after the
heater (warm side) are 3/8”.

NOTE
When the two coupling halves are
fitted into each other, remember to
secure the coupling by turning the
locking ring until it engages.

G0906711
A. Locking ring in unlocked position
B. Locking ring in locked position

NOTE
When the coupling halves are
disengaged, the protective caps
must be fitted to protect the
couplings and the hydraulic oil
from impurities.
G0906911

When removing the left protecting cap, first

pull back the outer ring

12
 Description of main parts

3.3 Separator
The separator has a safety yoke (3)
over the hood (2) and connection
housing (1) as a safety device. A
magnet (4) in contact with a safety
switch indicates if the yoke is in
correct position. If not, no power is
supplied to the motor.
For a description of how the
separator operates, see chapter ‘‘4
Working principle of the separator” on
page 18.

G0907911
3.4 Pump
The pump motor is connected to a
frequency converter controlling the
motor speed.
The pumping capacity of the self-
priming screw pump can be regulated
in the following way:

• The flow is controlled by turning

the knob on the frequency
converter. G0930541

Should a further reduction of the

flow be necessary this can be
done by adjusing the screw on the
pump, which controls the internal
leakage and thereby the pump
capacity.
The function is further described
in chapter ‘‘5.4 Start” on page 28.
G0906011

13
Description of main parts

3.5 Starter / control unit for separator and pump

The unit supervises the following
system functions:
− frequency converter
− motor load
− separator cover interlock
− amount of liquid in the
collecting tank
− counter pressure at outlet
− water seal in bowl (only at
purifier operation).

G0908641
The yellow control lamp on top of the
box is lit when any of the above 1. Starter / control unit for separator and
functions are activated. pump
2. Cable connection for heater
3. Cable connection for separator

3.6 Heater

A. Cover

1. Outlet
2. Inlet
G0908221

14
 Description of main parts

3.7 Starter / control unit for heater

The interlocking cable must be
connected to the starter / control unit
for the separator and pump in order to
provide power supply to the unit for
operation, see 3.5 earlier in this
chapter.

Control panel:

A. OVER TEMP (red) *

B. LOW HEAT (orange)
C. HIGH HEAT (orange)
D. RESET (both buttons)
E. DOWN (temperature)
F. UP (temperature)
G. Temperature controller, see
description below
H. Switch for heating regulation

G0905941
1. INDICATION (no heat)
2. LOW HEAT (lamp B lights)
3. HIGH HEAT (lamps B, C light)
* When lamp (A) is lit the oil
temperature has exceeded 90 °C.
The display of the temperature
controller (G) is flashing and the
heater is switched off.
When the temperature has
decreased to below 90 °C, push
the reset button (D) to start the
heater again.
If the heater does not start after
reset, the thermoswitch (TS1)
could be tripped if the
temperature has reached 110 °C.
G0930611

If so the switch must be reset

manually, see the illustration.
Where to reset the thermoswitch (TS1).
Use a small screw driver or similar.

15
Description of main parts

Temperature controller:
The temperature controller has advanced PID-regulating functions, giving
precise temperature control.
When the power is switched ON, the controller runs through a self-test sequence
for about three seconds and then displays the measured temperature.

Because the heating process is slow acting, the controller will cut the output
power in order to prevent overshoot.

OP1 Output 1. When lit, this

indicates that the logic output
is on.
OP2 Output 2. Not used for this
application.

Reset. Press both buttons

simultaneously to reset the
heater when tripped for
overheating (90 °C).
Down. Press and release to
view the setpoint. Keep

G0907311
pressed to decrease the
temperature setpoint.
Up. Press and release to view
the setpoint. Keep pressed to
increase the temperature
setpoint (max. possible
temperature is 65 °C).

WARNING
Disintegration hazard

The controller is correctly configured at delivery. Trying to alter the

configuration could result in damage to the process being controlled and/or
personal injury.

16
 Description of main parts

3.8 Collecting tank

The tank stands on a support under
the separator which is held in its
upper position by a spring with
adjustable tension. The spring can be
adjusted by the handle (1) on the
underside of the support. When the
collecting tank is nearly full the weight
will overcome the spring tension and
a limit switch is actuated. The signal
goes to the control unit which stops
the pump. The lamp on the control
unit lights up.

G0906431
If the collecting tank is nearly full,
reuse it by first stopping the pump
and then connecting the enclosed
filler cup to the separator inlet.
Replace the collecting tank with a
bucket or similar vessel to avoid any
oil/water spill.
Open the valve (1) located on bottom
of the filler cup and pour the contents
of the collecting tank into the filler

G0906111
cup.
1. Valve under filler cup in open position

Always remove the filler cup when not

used and fit the protective cap (1) on
to the connection.
G0906211

17
Working principle of the separator

4 Working principle of the separator

4.1 Introduction
Separation takes place in a bowl (1), which rotates at high speed generating
powerful centrifugal forces.
The speed of the electric motor (6) driving the bowl spindle (3) is controlled by a
frequency converter (7). The converter also acts as brake when the separator is
stopped.
The bowl (1) and motor (6) are suspended on three vibration dampers (5).
If the unseparated hydraulic oil contains water the separator should be operated
as a purifier. Otherwise clarifier operation is recommended.

Figure text also valid for next page

1. Bowl
2. Particles (sludge)
3. Bowl spindle
4. Conical discs
5. Vibration dampers
6. Electric motor
7. Frequency converter
G0450541

A. Dirty oil inlet

B. Clean oil outlet
C. Water outlet to collecting tank
(purifier operation).
When the separator is stopped the
bowl is drained via this outlet.

NOTE
At delivery the separator is assembled for clarifier operation.
The separator can be operated either as a clarifier or as a purifier.
Choose clarifier operation when oil contains no or only traces of water.
Choose purifier operation when the oil contains much water.
The differences between the two modes are further described on next page.

18
 Working principle of the separator

4.2 Clarifier operation

The unseparated hydraulic oil continuously enters at (A) and flows into the bowl
(1). The particles (2) are separated and deposited on the bowl wall.
The cleaned hydraulic oil is forced inwards to the centre of the bowl and up to a
paring disc (not illustrated). Since the oil is rotating, the stationary paring disc
acts as a pump which forces the oil out through outlet (B) under a constant
pressure.
The particles accumulated on the bowl wall are removed periodically (every 1-3
days) by hand.

4.3 Purifier operation

When operating the separator as a purifier a water seal must be established
before the oil feed is started. If not, oil will flow out through the water outlet (C).
How to proceed is described in ‘‘5.4 Start’’ on page 29.
Otherwise the separation principle is similar to clarification except that the
separated water, which is heavier than the oil, leaves through the underside of
the bowl at (C) down into the collecting tank.
G0519251

G0519241

Clarifier bowl Purifier bowl

19
Working principle of the separator

4.4 Changing operation mode

When changing operating mode from
clarifier to purifier, or vice versa,
proceed as follows:
1. Dismantle the separator in the
same way as when cleaning the
bowl, see 7.4.2 on page 50.
2. Remove the level ring, O-ring,
lower part of paring chamber and
the wing insert.

G05191G1
3. Unscrew the centre screw.

G05191E1

4. Lift out the bowl insert. If it is

difficult to get the insert loose from
the bowl spindle, then first remove
the splash guard (the white plastic
ring) to get a better grip on the
bowl bottom.
G05191D1

20
 Working principle of the separator

5. Exchange one complete bowl insert (as shown below) for the other.

View from below

G0908921
Clarifier bowl insert (fitted as delivered) Purifier bowl insert
1. Bowl bottom (clarifier), no holes 3. Bowl bottom (purifier) with
2. Bottom disc (purifier) three holes (*)

6. When fitting the insert, check that

the cylindrical pin (1) is not missing
in the shaft.
Check that the pin enters the guide

G0907011
in the bottom of the insert.

G05191D1

21
Working principle of the separator

7. Tighten the centre screw.

Check that one washer is fitted
under the screw.

G05191C1
8. Fit the wing insert, lower part of
paring chamber, level ring (black)
and O-ring.

NOTE
See the instructions in 7.4.2 on

G05191G1
pages 52-53 how to fit the level ring
and O-ring correctly.
These pages also describe the rest
of the assembly of the separator.

22
 Operating instructions

5 Operating instructions

5.1 Separation time

It is recommended that the oil
volume (V) in the complete system,
not only the tank volume, is V×5
T = -------------
separated at least five times. 100
The separation capacity will normally
be adjusted to about 100 litres per T = Minimum running time
hour. V = Volume in complete system (in litres)

Calculate the minimum running time Formula for calculating minimum

(T) by using the adjacent formula. separation time

NOTE
If separating emulsified oil it could
be necessary to separate the total
volume up to 35 - 50 times.

5.2 Separation mode

Introduction
To learn the correct running strategy, first read the information below carefully
before starting the separation process.
1. Decide if the separator will be operated as clarifier or purifier. The difference
between them is described in chapter 4 on page 19.
At delivery the separator is assembled as a clarifier.
2. If the amount of water and sludge in the oil is unknown, start the separation in
clarifier mode (how to change operation mode is described in chapter 4.4 on
page 20.
Run for 1 - 2 hours.

23
Operating instructions

Control of water content

Stop the separator and drain content
(about 1 litre) into the enclosed filler
cup (2). Remove the hose outlet (1)
from the collecting tank to the filler
cup.
Pour over the content to a glass bottle
or similar to check the water content.
If water is found, operate the
separator as a purifier.

G0907631
Control of sludge content
Dismantle the separator and measure
the thickness (A) of the sludge
collected on the bowl shell, see ‘‘7.4.2
Cleaning of bowl” on page 50. The
thickness should never exceed
10 mm.
Max. recommended cleaning interval

G0907411
is 3 days. A longer interval can result
in a sludge cake that is hard and A. Max. thickness = 10 mm
difficult to remove. Too long interval (corresponds to 0.6 litre)
can also result in that sludge enters
the disc stack and hinders separation. 1. Sludge
Oil overflow and vibration can also 2. Bowl shell
occur.
When cleaning very contaminated oil,
bowl cleaning every 20 - 30 minutes
could be necessary.

24
 Operating instructions

5.3 Before start

1. The separator is set up as clarifier
when delivered. In case purifier
mode is needed, please convert
the bowl as described in chapter
‘‘4.4 Changing operation mode”
on page 20.
2. Never start the separator with
sludge remaining in the bowl.

WARNING

Disintegration hazard

Unevenly spaced sludge cake will

result in heavy vibration with
possible damage to the separator.

3. When using the unit onboard a

ship, first fasten it firmly with
straps (A) or similar to fixing
points.

G09080A1

25
Operating instructions

4. Connect all hoses as described on

page 11. Secure the connections
(described in ‘‘3.2 Hoses” on page
12). Pay special attention that the
hoses to the pump are correctly
connected.

WARNING

Burn hazard

If the heater contains hot oil, care

should be taken to avoid contact
with any oil spill when connecting
or disconnecting hoses.

NOTE
Use the heater for best separation
result.

G0912421
Never separate an unfiltered
system without a strainer fitted to
Suction pipe (½”) with built-on strainer
the pump inlet. In such a case,
use the special suction pipe with
the built-on strainer.
Do not connect the return outlet to a pressurized system with the same or
higher pressure than the pressure switch set point (50 kPa). Otherwise the
safety function of the switch will be overridden, which implies that the pump
and heater can operate without flow.

26
 Operating instructions

5. Connect the cable (2) from the

heater to the separator control
unit (1).
The cable (3) from the separator is
normally always connected.
6. Connect the power cables to the
mains. If running the heater in
HIGH HEAT min. amperage
needed is 16 A. If only 10 A is
available connect the separator
unit and the heater to separate
fuse groups.
See also information in chapter ‘‘8

G0908641
Technical data” on page 63.

NOTE
Be sure the mains fulfil the voltage
requirement. The frequency
converter fitted in the separator
will cut off the power at voltage
spikes or at too high/low voltage
(±10%).

7. Make sure that the three hood

screws (3) and the knob (1) are
firmly tightened and that the
safety yoke (2) is in closed
(vertical) position.
G0908811

27
Operating instructions

5.4 Start

1. Fully open the pressure regulat-

ing valve fitted at the separator
outlet (turn anti-clockwise).

G0908511
2. Set the switch on the heater
control panel in pos. 1.
3. Connect the power supply for
both the heater and separator -

G0905811
pump.
4. Start the separator (keep the
button pressed 3 - 4 seconds).
The lamp on top of the control
unit and the lamp in the starter
pressbutton indicate that the
separator is running.
5. Wait 15 seconds (the separator
must reach full speed).

G09065D1

WARNING
Disintegration hazard

Some vibrations can occur for short periods during the start phase when the
separator passes through the critical speed. This is normal and passes over
without danger. If the vibrations become very severe or continue at full
speed, stop the separator immediately. See ‘‘6.7 Separator vibrates” on
page 43 for possible causes.

28
 Operating instructions

6. For purifier mode only!

(Purifier mode is described in
chapter 4 on page 18.
Fill the filler cup with water and
add it at the separator inlet by
opening the valve (1).

G0906111
When the filler cup is empty, close
the valve, remove the filler cup
and fit the protective cap (1) on to
the connection.

G0906211
7. Set the knob regulating the pump
speed in position START.

G0930541

8. Check that the screw fitted in the

pump is turned max. clockwise
(closed = no internal
recirculation).
G0906011

29
Operating instructions

9. Start the pump.

The lamp on top of the control unit
is unlit and the lamp indicating that
the pump is running is switched
on.

NOTE
Make sure that oil is available
when starting the pump. Running

G09065E1
dry for a longer period can
damage the pump.

10. When oil starts to flow through the

pump the counter pressure will
increase about 20 - 30 kPa.

NOTE
If the counter pressure is higher,

G0908421
this could indicate that the return
hose is connected to a pressu-
rized system with excessively high
counter pressure. This is not per-
mitted. The safety function of the
pressure switch will be overridden
allowing the pump and heater to
operate without flow.

NOTE
If the separator stops during this
sequence (normally because of
too high power consumption), see
‘‘6.5 Separator stops” on page 42.

30
 Operating instructions

NOTE
If the pump starts to emit cavita-
tion noise (e.g. when the oil is of
high viscosity or cold) turn the
screw anti-clockwise to increase
the internal leakage, which will
eliminate the cavitation.

11. Set the knob regulating the pump

speed in the position giving the
desired flow for heated oil. If not
known, the procedures how to
choose correct flow and
temperature are described in
points 14 and 18 on pages 32 and
33.
The figures in the illustration
indicate the approximate flow in
litres/hour when the oil has correct

G0930561
temperature for separating.
12. Adjust the counter pressure at the
separator outlet to 60 - 90 kPa.
If the counter pressure does not
reach at least 50 kPa within one
minute, the pump will be stopped
automatically.
G0908411

If this happens, restart the pump

and the pump will run for another
minute to set the correct counter
pressure.
13. When correct counter pressure
has been adjusted, set the heater
switch in position HIGH HEAT.

NOTE
G0905831

Starting the heater without flow

can cause overheating.

31
Operating instructions

14. The recommended sep-

aration temperature
depends on the oil vis-
cosity. See the curve for
correct separation tem-
perature.

G0907121
A. Separating temperature in °C
B. Viscosity grade (VG) of oil at 40 °C
C. Example: An oil with VG68 requires a sep-
aration temperature of 50 °C

Adjust the preset value

by keep pressing the UP
or DOWN button until
correct value is set.

NOTE
If separating emulsified oil, always
separate at 65 °C. Also separate
the total system volume at least
35 - 50 times.

15. Check the counter pressure dur-

ing the period the oil temperature
is increasing to the preset value.
G0908411

32
 Operating instructions

16. For purifier mode only!

Check that no oil is leaking from
the separator via the water outlet
(1) down into the collecting tank.
Use a torch for checking.
If there is a leakage, see trouble
shooting chapter ‘‘6.12 Some oil
escaping through drain outlet to
collecting tank” on page 45.

17. The spring tension (2) and the

limit switch for the tank support
should be checked regularly as
shown in ‘‘3.8 Collecting tank” on
page 17.

G0907581
The pump can not be started
when the switch is activated.

18. When the oil tempera-

ture has reached the set
point, check the through-
put of the separated oil.
For recommended
throughput see the
G0929311
adjacent table.

A. Recommended flow in litres/hour

B. Viscosity grade (VG) of oil at 40 °C
C. Example: VG68 oil has a recommended
throughput of 105 - 110 litres/hour

33
Operating instructions

With a recommended throughput

of 100 l/h, the enclosed filler cup
will be filled within 25 - 30
seconds.
Proceed as follows:
− Stop the pump.
− Loosen the return hose fitted to

G0912611
the oil tank and connect the
special return pipe.
G0912431

Return pipe

− Start the pump and fill the cup.

− When the cap is filled, stop the
pump and pour the oil back into
the oil tank or proceed as
described on page 17.

19.Turn the knob regulating the

speed of the pump motor to adjust
the throughput.
The figures in the illustration
indicate the approximate flow
when the oil has correct
temperature.
G0930561

34
 Operating instructions

20.When a very low throughput is

necessary this can be set by
turning the screw fitted on the
pump.
Turning anti-clockwise will
decrease the flow.
The counter pressure must be
adjusted simultaneously.

G0906011
This screw should normally be
closed = turned max. clockwise.

5.5 Operation

NOTE
Never run the unit longer than 3
days between bowl cleaning. It is
important to follow instructions
‘‘Control of sludge content” on
page 24.

1. Check the cleaning unit for correct

operation (temperature, counter
pressure and vibration). This is
especially important the first time
the cleaning unit is run after
installation or dismantling and G0907311

assembly. Recommended separation temperature

for a VG68-oil is 50 °C
G0908411

Recommended counter pressure is

60 - 90 kPa

35
Operating instructions

2. For purifier mode only!

Check that no oil is leaking out via
the water outlet (1). Preferably use
a torch for checking.
If leakage is occurring, see the
trouble shooting chapter ‘‘6.12
Some oil escaping through drain
outlet to collecting tank” on page
45.
3. When the collecting tank is nearly
full, the pump is stopped
automatically and the lamp on the
control unit is lit.
Empty the tank and restart the

G0907571
pump to continue the cleaning.
It is possible to recover any oil by
proceeding as described in ‘‘3.8
Collecting tank” on page 17.

36
 Operating instructions

5.6 Stop

NOTE
After each stop of the cleaning
unit, the separator bowl must be
well cleaned. Otherwise an
unevenly spaced sludge cake will
at next start result in heavy
vibration and damage can be
caused.

1. Switch off the heater by turning

the switch to pos. 1.

G0905811
2. Wait about 15 minutes for the
heater to cool down.
Then stop the pump.

NOTE
If stopping the pump earlier, the
overheating protection for the
heater can trip.

G09065G1

3. Stop the separator.

When the separator has nearly
stopped rotating, the contents of
the bowl will be drained out by
gravity into the collecting tank
(both for purifier and clarifier
versions).
G09065F1

37
Operating instructions

4. Disconnect both hoses connected

to the hydraulic oil tank.

NOTE
If the check valves are not sealing
properly, there is a risk that oil may
be siphoned from the hydraulic oil

G0906911
tank and drained via the separator
into the collecting tank.

38
 Operating instructions

5.7 How to drain hoses and heater

It is possible to drain the heater and the hoses (except the hoses from pump to
separator and from separator to tank) by switching the hoses in following way:

1. Switch off the heater by turning the

switch to pos. 1, or remove the
contact from the wall socket.

G0905811
2. Stop the pump.
3. Disconnect the hose fitted at the
pump outlet (2) and the hose fitted at
the tank suction pipe (3).
Connect these two coupling halves
(2M - 3F).
4. Disconnect the hose coming from the
heater fitted at the separator inlet (1).
5. Fit the short by-pass hose (C) (not
used during normal operation if using
the heater) between the pump outlet

G0909121
(2F) and separator inlet (1M).
6. To allow air to enter the hoses (A), fit Before switching the hoses
the return pipe (B) or similar with a 3/
8” connection on the free end of the
hose (1F). Place the pipe inlet at a
sufficient height to prevent oil from
flowing out.
7. Start the pump.
The heater and the hoses will now be
drained. If possible, check the oil flow.
Stop the pump and separator when
the system has been depressurized.
G0909221

Ready for draining the heater and hoses

39
Trouble shooting

6 Trouble shooting

6.1 Cleaning system/separator does not start or stops

shortly after start
Possible cause Action
No power supplied Check the mains switch, fuses and
supply line
Safety yoke is not in correct position Position the yoke correctly
Defective magnetic safety switch Check that the switch opens and
indicating the position of the safety closes when safety yoke is moved up
yoke and down
Incorrect assembly after cleaning. Dismantle and check
The bowl and motor shaft can not
rotate freely
Defective motor or frequency See ‘‘7.4.6 Replacement of frequency
converter converter” on page 61
Voltage protection on frequency card Check the voltage. If unstable
trips because of too low/high voltage voltage, connect a transformer.
or voltage spikes
Fuse in mains circuit has wrong If the fuse has tripped/blown, reduce
amperage (16 A needed for trolley the heating to LOW HEAT or connect
unit and heater on max. load) the heater and the trolley unit to two
separate fuse groups (min. 2 x 10 A)
Separator stops See ‘‘6.5 Separator stops” on page 42

6.2 Pump does not start

Possible cause Action
Microswitch for filled collecting tank Empty the tank or adjust the spring
activated tension for the tank support

40
 Trouble shooting

6.3 Heater does not start

Possible cause Action
Interlocking cable from heater unit is Connect the interlocking cable
not connected to the separator control
unit
No power supplied Check the mains switch, fuses and
supply line
Defective controller Replace the controller
Circuit breaker(s) F1 and/or F2 Reset the circuit breaker(s)
tripped (located in heater control
cabinet)
Thermoswitch TS1 tripped (located in Reset the thermoswitch (see page 15
heater control cabinet) how to proceed)

6.4 Pump stops

Possible cause Action
Collecting tank filled Empty the tank and start the pump
Counter pressure at separator outlet is • Check that suction inlet is not
lower than 50 kPa above surface in tank

• Adjust the counter pressure using

the regulating valve and/or adjust
the flow through the pump by
turning the adjustment screw fitted
in pump
Overload caused by obstructed inlet or Check that the feed through the whole
outlet side system is sufficient

41
Trouble shooting

6.5 Separator stops

Possible cause Action
Overload due to high throughput Reduce the flow rate
Overload due to high viscosity Reduce the flow so the oil temperature
reach the set temperature quicker, see
the temperature diagram on page 32
Safety yoke out of correct position Reposition the yoke
Overload due to clogged disc stack Clean the separator disc stack
Overload due to incorrect assembly Check the bowl assembly
Tripped frequency converter due to Check the voltage.
too low or too high supplied voltage If too low voltage, set heater switch in
(>±10% of nominal voltage) pos. 2 “LOW HEAT” or connect the
heater to a separate wall socket
connected to another circuit.
Also see possible causes and actions in ‘‘6.1 Cleaning system/separator does
not start or stops shortly after start” on page 40
Defective motor or frequency See ‘‘7.4.6 Replacement of frequency
converter converter” on page 61
Too high counter pressure Reduce counter pressure, see point
12 on page 31

6.6 Noise
Possible cause Action
Cavitation in pump Reduce the flow by turning the
adjustment screw fitted in pump anti-
clockwise, see ‘‘3.4 Pump” on page 13
Vibration dampers in separator are Fit new dampers
worn
Incorrect assembly of separator bowl Dismantle and check
Bearings damaged Fit new bearings

42
 Trouble shooting

6.7 Separator vibrates

WARNING
Disintegration hazard

If excessive vibrations occur, stop the separator

Possible cause Action

Bowl out of balance due to:
• Insufficient or incorrect cleaning Dismantle and clean the separator
(sludge in disc stack) bowl. Be sure that the separator is
assembled correctly.
• Unevenly spaced sludge cake
(bowl not cleaned prior to start)

• Incorrect assembly
Vibration dampers in separator are Fit new dampers
worn
Damaged bearings Replace the bearings

6.8 Insufficient separation result

Possible cause Action
Separation temperature too low Switch to HIGH HEAT or adjust the
setting on the heater control unit
Separator disc stack clogged Clean separator bowl and disc stack
Too high flow rate Reduce the flow by adjusting the
screw fitted in pump. Check that
counter pressure is correct.

43
Trouble shooting

6.9 No flow from pump

Possible cause Action
Incorrect setting of flow control (too Start with max. flow (knob in START
low speed of pump) position), see page 29
The screw fitted in pump is not closed Turn the adjustment screw clockwise,
(internal leakage too high) see ‘‘3.4 Pump” on page 13.
Air leakage on suction side between Check that the inlet is below surface in
tank and pump tank. Check that couplings are
correctly fitted.

6.10 Flow too low

Possible cause Action
Low feed flow Increase the flow by adjusting the
knob on the pump control unit. Check
for correct counter pressure.
Too high counter pressure at outlet Reduce the counter pressure with the
regulating valve (60 - 90 kPa is
recommended)
Leakage caused by incorrect • The three screws fastening the
assembly bowl hood or the paring disc knob
(the upper part of the separator)
are not completely tightened.

• Dismantle and check the separator

bowl parts. Especially check that
no O-rings are missing, are
defective or incorrectly fitted.
Ensure that the separator is
assembled correctly.

44
 Trouble shooting

6.11 No flow either through clean oil outlet or through

drain to collecting tank
Possible cause Action
No open inlet at suction end (closed Fit suction pipe or similar
check valve in hose connection)
Separator or pump stopped Check function
Inlet and outlet hoses for pump Swap the hose connections
wrongly connected
Strainer before separator clogged Clean strainer
(if fitted)

6.12 Some oil escaping through drain outlet to collecting

tank
Possible cause Action
Too high counter pressure at outlet • Reduce the counter pressure with
the regulating valve (60 - 90 kPa is
recommended)

• Reduce the flow by adjusting the

screw fitted in pump
Clogged disc stack Clean the bowl and disc stack
If operating in purifier mode:
Insufficient sealing between bottom Dismantle and check the separator
disc and bowl bottom in separator (O- bowl. Be sure that the separator will be
rings may be missing) assembled correctly.
The three screws fastening the bowl Tighten the screws and /or the knob
hood or the paring disc knob (the
upper part of the separator) are not
completely tightened, causing leakage

45
Trouble shooting

6.13 Oil flow through drain outlet to collecting tank only

Possible cause Action
If operating in purifier mode; • Stop the pump and add water
broken liquid seal in separator bowl through the inlet at top of the
separator, see page 29 point 6
Obstruction in cleaned oil feed line • Check that regulating valve is open
• Check that outlet end to tank is
open (no closed check valve in
hose connection)

6.14 Oil leakage through drain outlet to collecting tank

when separator is not running
Possible cause Action
Oil is siphoned from oil tank due to Disconnect both hoses connected to
siphon effect the oil tank
Leaking check valve (at inlet and/or Replace
outlet side)

6.15 Collecting tank overflowing but pump does not stop

Possible cause Action
Adjustment of the spring tension for Adjust the setting. See description in
the tank support is incorrect ‘‘3.8 Collecting tank” on page 17

6.16 Separation temperature too low

Possible cause Action
Heater switch in position LOW HEAT Switch to HIGH HEAT
Throughput too high Reduce the flow

46
 Trouble shooting

6.17 Heater trips

Possible cause Action
Circuit breaker(s) F1 and/or F2 tripped Reset the circuit breaker(s)
(located in heater control cabinet)
Thermoswitch TS1 tripped (located in Reset the thermoswitch
heater control cabinet)

6.18 Oil leaks from heater

Possible cause Action
Oil leaking from between control box Remove the cover and tighten the four
and heater screws holding the electric cartridges.
See ‘‘3.6 Heater” on page 14.

47
Maintenance

7 Maintenance
WARNING
Entrapment hazard

Switch off the power supply, remove the electric cables from the sockets
and make sure that rotating parts have come to a complete standstill
before starting any dismantling work.

NOTE
Never use cleaning agents with a pH below 6 or above 9 as they can
damage the metal surfaces.

7.1 Cleaning

7.1.1 Separator
The separated sludge collected inside the separator bowl must be removed
manually. The length of the cleaning interval depends on the oil flow rate and on
the amount of sludge, but the interval must never exceed 72 operating hours
(3 days). When cleaning very contaminated oils, bowl cleaning every 20 - 30
minutes could be necessary. For further information on max. permitted amount
of sludge and other limitations, see ‘‘5.2 Separation mode” on page 23.
‘‘7.4.2 Cleaning of bowl” on page 50 explains how to proceed.

7.1.2 Strainer
When using the suction pipe with built-
on strainer, this has to be cleaned
G0912421

regularly. How often depends on the

amount of coarse particles.
During the initial period, open and inspect once every day to determine the
necessary cleaning interval.

48
 Maintenance

7.2 Once per year

7.2.1 Separator
Replace the O-rings with new ones included in the O-ring service kit. Their
positions are shown in ‘‘11 Spare parts” on page 70.
See ‘‘7.4.3 Replacement of O-rings in purifier bowl” on page 54 and ‘‘7.4.4
Replacement of O-rings in clarifier bowl” on page 56 for how to proceed.
Check the condition of discs in the bowl, replace if necessary.

7.3 Every second year

7.3.1 Separator
Check/replace the disc stack to maintain the separation efficiency.
See ‘‘7.4.3 Replacement of O-rings in purifier bowl” on page 54 and ‘‘7.4.4
Replacement of O-rings in clarifier bowl” on page 56 how to proceed.

7.4 Dismantling - assembly instructions for separator

7.4.1 Introduction
The illustrations on the following pages describe step by step how to dismantle,
clean, replace and assemble the various parts of the separator.
The illustrations have symbols only to indicate the actions required. The key to
the symbols is given below.

Remove Screw or turn Press or Clean

clockwise move in the
direction of
S-00439-1-1
S-00442-1-1 S-00438-1-1
arrow S-00443-1-1

Fit, Screw or turn Check, Safety

insert counter- make sure
clockwise
S-00444-1-1 S-00441-1-1 S-00440-1-1 S-00003-1-1

49
Maintenance

7.4.2 Cleaning of bowl

Comments to illustrations on opposite page.

Illustration 4:
Before dismantling the separator, wait
until the rotating parts have come to a
complete standstill, which will take up
to two minutes.
To be sure, open the front cover and
check that the rotation of the electric
motor shaft has stopped.

G0908711
NOTE
If the separator is opened too soon, the following could happen:
− The pin on the inside of the connecting housing breaks.
− The pin inside the top of the paring disc breaks.
− Excessive wear of top of level ring.

Illustration 8:
A few drops of oil will normally leak from the connecting housing when the bowl
hood is opened.
If oil continues to leak, the cause could be a non-sealing check valve while the
separator is connected to an oil tank with an oil level higher than the separator
(siphon effect).

Illustration 15:

NOTE
Never use sharp or metallic tools when cleaning the bowl wall. This can
damage the coating and later on cause pitting corrosion. Always use soft
rags.

Cleaning of the disc stack in not normally necessary unless sludge has
accumulated and entered the stack (cleaning interval too long).

50
 Maintenance

Dismantling

G0449171

See comments on opposite page

51
Maintenance

Comments to illustrations on opposite page.

Illustration 16:
When fitting the bowl shell, press
firmly downwards with both hands to
overcome the resistance from the
O-ring fitted on the bowl bottom. A
“clicking” sound will be heard.

G0912141
Illustration 17:
If the level ring (1) and O-ring (2)
have been removed, first fit the level
ring and then the O-ring outside the
level ring. Finally press down the
O-ring by pressing the cover (3)
firmly with both hands.

G0912121
G0907211

Illustration 18:
Check that the distance illustrated is max. 0.5 mm. If not, the reason could be:
1. The O-ring outside the level ring is not in the downwards position or the
O-ring is located under the level ring.
2. Two washers are fitted under the centre screw fixing the bowl to spindle.

Illustration 20:
Only tighten by hand. Never overtighten when assembling parts.

52
 Maintenance

Illustration 22:

NOTE
Always screw home the knob fitted on the connecting housing before
tightening the screws shown in illustration 23. Otherwise there is a risk that
the pin inside the connecting housing could break.

Assembly

G0449251

See comments on opposite page and at top of this page

53
Maintenance

7.4.3 Replacement of O-rings in purifier bowl

How to convert from purifier to clarifier bowl or vice versa is described in point ‘‘5
Exchange one complete bowl insert (as shown below) for the other.” on page 21.
Comments to illustrations on opposite page.
Illustration 3:
Take care of the washer.

Illustration 12:
Check that the washer is fitted. Otherwise there is a risk that the bowl will not
make firm contact with the spindle.
If two or more washers are fitted accidentally this will prevent the top parts of the
bowl from being positioned correctly.

Illustration 13:

NOTE
Fit the upper O-ring outside the
level ring, see comments to
illustration 17 on page 52.

54
 Maintenance

First dismantle the separator bowl as described in ‘‘7.4.2 Cleaning of bowl” on

page 50.

G0449351

See comments on opposite page

55
Maintenance

7.4.4 Replacement of O-rings in clarifier bowl

How to convert from purifier to clarifier bowl or vice versa is described in point ‘‘5
Exchange one complete bowl insert (as shown below) for the other.” on page 21.
Comments to illustrations on opposite page.
Illustration 3:
Take care of the washer.

Illustration 12:
Check that the washer is fitted. Otherwise there is a risk that the bowl will not
make firm contact with the spindle.
If two or more washers are fitted accidentally this will prevent the top parts of the
bowl from being positioned correctly.

Illustration 13:

NOTE
Fit the upper O-ring outside the
level ring, see comments to
illustration 17 on page 52.

56
 Maintenance

First dismantle the separator bowl as described in ‘‘7.4.2 Cleaning of bowl” on

page 50.

G05191H1

See comments on opposite page

57
Maintenance

7.4.5 Replacement of motor bearings

First dismantle the separator bowl as described in ‘‘7.4.2 Cleaning of bowl” on
page 50.

G0449431

58
Maintenance

G0449541

59
Maintenance

G0449641

See ‘‘ Assembly” on page 53 for how to assemble the rest of the separator.

60
 Maintenance

7.4.6 Replacement of frequency converter

NOTE
Check that the earth contact between the
frequency converter and frame is
sufficient.
G0449841

61
Maintenance

7.5 Repair instructions

7.5.1 Replacing temperature controller in

heater control unit

1. Force out the two locking ears

(A) carefully (not more than
necessary) and pull out the
controller (B).
2. Fit the new controller.

G0905711
WARNING
Disintegration hazard

The controller is correctly configured at delivery. Attempting to alter the

configuration could result in damage to the process being controlled and/or
personal injury.

7.5.2 Pump

For maintenance and service of the

pump, see the separate pump
instruction in the Appendix starting
on page 77.
G0933111

62
 Technical data

8 Technical data
Type designation: emmie – mobile hydraulic oil cleaning system
Application: Use is restricted to removal of solids and water from
mineral hydraulic, gear and sterntube lube oils with the
following specifications:
Process media: Mineral oil
Viscosity grade (VG): 15 - 150
Separation temperature: +15 – +70 °C
Recommended separation temperature is 40 - 65 °C
depending on the oil viscosity grade (VG)
Recommended
operating flow: 50 - 120 litres/hour
Max. ambient
temperature: +55 °C
Power supply: 230/110 V (±10%), 1 phase, 50/60 Hz
Amperage: - Trolley unit excl. heater; Max. 4 A
- Heater; 6/10 A (low/high load)
Heating power: 1.3 + 0.7 / 0.7 + 0.3 kW E2 + E1 (230/110 V)
Oil volume in heater: 1 litre
Sound: Sound power: Max. 8.9 Bel(A), ISO 3744
Sound pressure level: Max. 75 dB(A), ISO 3744
Pressure switch: Set point for tripping: 50 kPa
Quality requirement of
water for liquid seal in
bowl (purification): pH value: 6-9
Weight: - Trolley unit excl. heater; 59 kg
- Heater; 34 kg
Dimensions (L x H x W): - Trolley unit excl. heater; 620 x 1140 x 515 mm
- Heater; 1370 x 490 x 295 mm

63
Diagrams

9 Diagrams

9.1 Starter / control unit for separator and pump

9.1.1 Interconnection diagram

G0906631
Power Pressure Tank level Pump Cable from Cable from
supply switch separator heater

230/110 V AC, 1~ A. Pump control unit

64
 Diagrams

9.1.2 Circuit diagram

Separator
Stop Start

Cover switch

Pump
Stop Start

Pump
control
unit and
pump,
see
page
64
Separator

G0933721
Module

F1. Fuse L. Lamp

F2. Overload relay M. Motor
K1. Contactor S. Push button
K2. Aux. contactor X. Terminal
K3. Time delay relay

65
Diagrams

9.2 Starter / control unit for heater

9.2.1 Interconnection diagram

G0933511
Power Interlocking Thermo- Heaters
supply switch element

66
 Diagrams

9.2.2 Circuit diagram

G0912821

E1. Heater, low (0.7 kW for 230 V) R1. Temperature controller (regulator)
(0.3 kW for 110 V) SS1. Solid state relay for low heat
E2. Heater, high (1.3 kW for 230 V) SS2. Solid state relay for high heat
(0.7 kW for 110 V) SW1. Stepswitch for heat regulating
F1. Fuse, 20 A TE1. Thermoelement for actual value of
F2. Circuit breaker oil temperature
IS1. Interlocking switch connection TS1. Thermoswitch, overheat (100 °C)
(fitted in control unit for separator)
H1. Lamp (red), tripping for overheat
H2. Lamp (yellow), low heat
H3. Lamp (yellow), high heat

67
Lifting instruction

10 Lifting instruction

10.1 Cleaning unit

Attach two lifting straps (1) to the

lifting hooks.
The distance between the lifting
hooks and crane hook should be min.
1 metre (A).

NOTE
Weight of unit is approx. 59 kg.

WARNING
Entrapment hazard

Only attach the lifting straps to the

two lifting hooks when lifting the
cleaning unit.
A falling unit can cause accidents
resulting in serious injury to per-
sons and damage to equipment.
G0912331

Lifting procedure for cleaning unit

68
 Lifting instruction

10.2 Heater

Attach a lifting strap (1) as illustrated.

NOTE
Weight of unit is approx. 34 kg.

G0912211

Lifting procedure for heater

69
Spare parts

11 Spare parts

11.1 Separator
Item Part No. Denomination
A 554603-01 O-ring kit
A-1 223404-52
A-2 223403-56
A-3 223403-29
A-4 546198-29
A-5 223403-55
A-6 223406-93
A-7 260104-93
A-8 223403-02
A-9 260104-66
A-10 260168-07
B 554603-02 Vibration damper kit
C 554603-03 Disc stack kit, purifier
554603-04 Disc stack kit, clarifier
D 554603-06 Motor service kit

1 554072-01 Knob
2 554027-01 Inlet pipe
3 554416-80 Paring disc
4 553982-02 Bowl wall
5 564962-02 Level ring, black
6 553925-01 Sleeve with wings
7 554192-01 Inlet cone
8 553921-02 Pin for bowl disc
9 560480-01 Bottom disc, clarifier
10 554203-01 Bottom disc, purifier
11 554151-01 Magnetic switch
12 562255-80 230 V frequency converter
562255-81 110 V frequency converter

70
Spare parts

G0851341

71
Spare parts

11.2 Other parts

Item Part No. Denomination
1 1777369-80 Inlet hose to separator
2 1777368-80 Outlet hose from separator
3 1777370-80 By-pass hose
4 99991056-81 Coupling, male, 3/8”
99991056-84 Coupling, male, 1/2”
5 99991056-82 Coupling, female, 3/8”
99991056-83 Coupling, female, 1/2”
– 99991056-85 Service kit for 3/8” coupling (O-rings + support ring)
– 99991056-86 Service kit for 1/2” coupling (O-rings + support ring)
6 1777376-80 Hydraulic hose with 3/8” couplings, 3 metres
1777374-80 Hydraulic hose with 3/8” couplings, 4 metres
7 1777377-80 Hydraulic hose with 1/2” couplings, 3 metres
1777375-80 Hydraulic hose with 1/2” couplings, 4 metres
8 99991056-80 Level switch
9 1766867-01 Complete pump* with motor, 230 V, 50/60 Hz
1766867-02 110 V, 50/60 Hz
10 99991056-75 Check valve before separator inlet
11 99991056-76 Check valve after separator outlet
(fitted in pressure switch housing at inlet side)
12 1764481-80 Filler cup
13 99991056-03 Fuses (5x25, 6.3 AT), 230
99991056-55 Fuses (5x25, 10 AT), 110 V
14 99991057-09 Push button set (green and red buttons)
15 99991057-08 Lamp, complete
99991056-89 Globe, plastic (yellow)
99991056-02 Lamps for starter / control unit (7 W), 230 V
99991056-54 110 V
16 1766708-02 Knob, complete
17 1766705-01 Frequency converter circuit board, 230 V AC
1766705-02 Frequency converter circuit board, 110 V AC
18 99991056-79 Pressure switch
19 99991056-77 Pressure gauge
20 1778372-80 Return pipe (3/8”)
21 1778342-80 Suction pipe (1/2”) with built-on strainer

* Spare parts for pump, see Appendix starting on page 77.

72
 Spare parts

Item Part No. Denomination

22 1777670-80 Filler cap
23 99991056-88 Controller in heater control box
24 99991056-78 Solid state relay (SS1 + SS2) in heater control box

G0912961

73
Installation

12 Installation

12.1 Installation alternatives

The emmie cleaning unit can be connected to a hydraulic oil tank in the three
ways described below. The third alternative normally needs no preparations for
using the cleaning unit (except maybe removing a cover). However, for the two
other alternatives the hydraulic oil tanks must be prepared as described below.
Common recommendations for all three alternatives are:

NOTE
− Never separate an unfiltered system unless a strainer is fitted in the
suction line. When separating an unfiltered system, use the diver tube
with fitted strainer as described in 12.1.3 on next page.
− When connecting emmie to a hydraulic oil tank as described in 12.1.1 and
12.1.2, it is assumed that the content has been filtered.
− Never connect the return outlet to a pressurized system (which can give
too high counter pressure).

12.1.1 Replacement of filler cap

The suction and return hoses are

connected to the emmie cap which
has replaced the filler cap normally
fitted on the tank.
G0912011

74
 Installation

12.1.2 Connection to drain hole in tank

The suction hose is connected to an

outlet fitted into the tank drain hole,
while the return hose is connected to
a hole on the opposite side of the
tank.
A shut-off valve must be connected
between the tank and the quick-

G0912711
coupling for the outlet.
Inside the tank the return pipe should
be located about 100 mm (A) below
the oil surface to prevent aeration of
the oil in the tank.

12.1.3 Using separate suction and return pipes

The suction and return hoses are

connected to separate pipes which
are inserted into a barrel or similar as
shown.
G0912421

Suction pipe (1/2”) with built-on strainer

G091243

Return pipe (3/8”)

These pipes should preferably also

be used when filling a hydraulic oil
G0912511

system with new oil.

75
Installation

76
 Screw pumps

LPD
Maintenance and Service
Instruction
LPD1 © IMO AB

This instruction is valid for all LPD pump models shown on page 2
Contents Page
List of components 2
Exploded view/Ordering code 3
Service intervals and inspection 4
Sectional view 5
Useful tools/Shaft seal assembly drawing 6
Dismantling 7
Reassembly 9
Pressure relief valve 11

1
LPD 0603GB
LPD 0603GB
September
September1999
1999
 Before commencing any work, read this instruction carefully!
! Failure to comply with these instructions may cause damage and personal injury!

For more information about the pumps identification code, technical data and performance we refer to the
LPD Product description.
Fore more information about the pumps installation, start-up and trouble shooting we refer to the IMO
Installation and Start-up instruction for low pressure pumps.

List of components
Valid for all LPD pumps, size 015 and 020. Rotor lead and generation: N1
With version codes: N } V } B } P} The version code is composed of the letters in
the 4 columns.
Example of pump designations std: LPD 020 N1 NVBP

Spare parts set:

Pos Part Qty G011 G050 G053 G054 G057 G070 Note
No Denomination Rotor Shaft Minor Major Joint Valve
set seal kit kit kit element
1010 Power rotor 1 x x
134 Locking screw 1 x x x x 1
162 Shaft sleeve 1 x x x x 1
201 Idler rotor 2 x x
401 Pump body 1
453 Screw 4
509 Mechanical seal 1 x x x
514 Retaining ring 1
520 Front cover 1
521 O-ring 1 x x x
551 Rear cover 1
556 Gasket 1 x x x
605 O-ring 1 x x x x
608 Valve set screw 1 x x
608A Locking clamp 1 x x
608B Screw 2 x x
608C Pin 1 x x
6120 Regulating nut 1 x x
(613) Tension pin 1 x x
614 Valve piston 1 x x
615 Spring 1 x x
622 Screw 2
623 Plate 1

Note: 1) Included in 1010

When ordering spare parts, please state the I

LPD2 © IMO AB

complete pump identification according to its

name plate and required spare part set or the
required parts position number.

Name plate of the pump

LPD 0603GB 2
September 1999
Exploded view
LPD
453
605 551
608 556
608A
6120
615 622
614
608C

608B
623
613
401

201

134
1010
162

509
LPD1 © IMO AB

521

520
514

Fig. 1

Ordering code
Pos Spare parts sets Part numbers, sizes
Recommendation:
No 015 For maintenance the fol-
020
G011 Rotor set (CCW rotation) 190767 lowing spare part sets are
190768
recommended:
G050 Complete shaft seal - version code xVxx 190334 190334 Set: / To be used:
G053 Minor kit 190783 190783 G057 Joint kit
For dismantling of the
G054 Major kit=G011+G053+G070 pump.
G057 Joint kit 190740 190740 G053 Minor kit
G070 Valve element 190743 190743 For service
G054 Major kit
Fig. 2 Ordering example: For repair after damage or
For IMO-pump LPD 020N1 NVBP, serial number greater wear.
456789: Shaft seal pos G050 p/n 190334

3 LPD 0603GB
September 1999
Service intervals !
If the pumps operating temperature ex-
ceeds 60°C let the pump cool off before any
The intervals for inspection and replacement of wear
service, maintenance or dismantling work
parts vary greatly with the properties of the pumped
is commenced to avoid burn injury.
liquid and can only be determined by experience.
All internal parts of the LPD-pump are lubricated by
the pumped liquid. Pumping liquid which contains
abrasive materials, or liquid that is corrosive, will All work carried out on the pump has to be
significantly reduce service life and call for shorter ! performed in such a manner that risks for
service intervals. personal injury are observed!
Wear in the pump may be indicated by:
• Vibration
• Noise When handling liquids that may harm skin
! use gloves and/or protective clothing.
• Loss of capacity
• Reduction in flow/pressure
• Leakage
In installations where unplanned shut downs must When handling liquids which may involve
! fire hazards appropriate precautions to
be avoided, it is advisable to have a complete pump
available for replacement, should any malfunction avoid danger are to be taken.
occur. Furthermore we recommend planned inspec-
tion and overhaul at regular intervals, not exceeding
3 years.
In case of failure for a system with elevated
It is recommended always to have the spares in- ! pressure, fluid jets may cause injury and/or
cluded in minor spare part kit available.
damage.

Inspection of shaft seal

As the seal faces of a mechanical shaft seal are Oil leakage may make the floor slippery
lubricated by the fluid a certain leakage will always ! and cause personal injury.
be present. Ten drops per hour can be considered as
acceptable.
An external visual inspection of the pump is advis-
able at least every two days to assure that the shaft Inspection of rotors
seal is not leaking too much. If an indication of a worn pump is noticed (see
Excessively leaking shaft seals should be replaced service intervals above), a brief inspection of the
without delay, as the leakage normally will grow idler rotors is recommended.
worse and cause additional damage. A quick inspection of the idler rotors can be made
Follow the instructions in the dismantling/reassem- simply by removing the rear cover. Note that the
bly session. driver must be deenergized and the pump hydrauli-
When working with a shaft seal, cleanliness is of cally isolated before the rear cover is removed.
utmost importance. Avoid touching the seal faces. If Internal clearances in the pump, which are vital for
necessary, the seal faces should be cleaned immedi- its proper function, may have been affected by wear.
ately prior to assembly, using a dustfree cloth and Acceptable wear can be determined only by experi-
clean solvent. ence of the actual application. As a rule of thumb the
Never use grease on the seal faces. following max clearance values may apply:
O-rings • Between rotor and bores or bushings: 0.2 mm
• Between rotor flanks: 0.4 mm
All O-rings found to be hard or damaged shall be
For light duties (low pressure, medium viscosity)
replaced.
even bigger clearances may be acceptable but for
low visc./high pressure duties the limit will be
lower.
ATTENTION Also check if there are major scratches on these
parts.
Use appropriate vessels to collect oil spillage
when removing and opening the pump. If a more thorough investigation is needed, proceed
as under ”Dismantling and reassembly”.

LPD 0603GB 4
September 1999
Sectional view

LPD

Fig. 3

5 LPD 0603GB
September 1999
Useful tools
Before any maintenance work, ensure that
! the driver is deenergized and the pump
hydraulically isolated.
LPD5 © IMO AB

Connecting and disconnecting of electric

Allen Oil can cables must be done only by personnel
key authorized to do such work.
2.5 mm
A pair 2 pcs of 2 pcs of
of pliers screw screw
spanner driver
13 mm

Fig. 4

Shaft seal – assembly drawing

Shaft seal G050 (509)

Version code NVBP S2 S1 S5

S1 Seat
S2 O-ring
S5 Rotating member
LPD6 © IMO AB

509

Fig. 5

LPD 0603GB 6
September 1999
Dismantling
A. B.
Motor
OFF ON fastening
screw

• Turn the electricity OFF.

Closed

LPD8 © IMO AB
• Close the valves.
LPD7 © IMO AB

134
• Remove pump
from the system.

• Turn the el-motor fan till the stop screw is

ATTENTION visible in any of the flange ports.
Use appropriate vessels to collect oil • Untighten the locking screw 134.
spillage when removing and opening the
pump. • Remove the motor fastening screws.
• Remove the motor and the angle bracket.

Fig. 6 Fig. 7

C. D.

514

134
LPD9 © IMO AB

LPD10 © IMO AB

• To ease dismantling hide the locking screw

134 into the shaft by turning it clockwise. • Remove the retaining ring 514.

Fig. 8 Fig. 9

7 LPD 0603GB
September 1999
 E.
520

• Remove the front cover 520 by pressing it up

with two screw drivers.
LPD11 © IMO AB

Fig. 10

F. 520

509

1010
• Remove the power rotor 1010 including the
shaft seal 509.
• Remove the seat and O-ring.
LPD12 © IMO AB

Fig. 11

G.

1010
1020
• Place the rotor 1010 into the jaw vice with soft
jaws or a column drilling machine.
LPD13 © IMO AB

• Push with two screw drivers as shown on the

sketch, to remove the rotating member S5.

Fig. 12

LPD 0603GB 8
September 1999
 H. I. 453

201 I
201
551

556

LPD17 © IMO AB
LPD14 © IMO AB

• Open the cover 623, hiding the pressure

relief valve set screw.
• Remove the idler rotors 201.
• Release the valve spring tension by turning
• Inspect all parts. Only minute and evenly the set screw CCW.
distributed wear marks should be allowed.
Replace defective parts. • Remove the screws 453, the rear cover 551,
the gasket 556 and the valve assembly.
• Clean all parts that are going to be used
again. • Fit the rear cover with at least two screws
but without gasket.
Fig. 13 Fig. 14

Reassembly
A. B.

509

1010

201
201
LPD16 © IMO AB
LPD15 © IMO AB

• Lubricate the idler rotors 201 and fit them • Fit the new shaft seal parts 509 onto the
into the pump body. power rotor 1010 as shown on the sketch.
• Lubricate the power rotor 1010 and fit it into
the pump body.
Fig. 15 Fig. 16

9 LPD 0603GB
September 1999
 C.
514

520

521
LPD18 © IMO AB

• Fit the o-ring 521 onto the front cover 520 and
fit the front cover 520 as shown on the sketch.
• Fit the retaining ring 514.

Fig. 17

D.

Motor fastening screw

556
551

I
LPD19 © IMO AB

453
134

• Fit the electric motor and the angle bracket. • Fit the gasket 556 and put the rear cover
Make sure that the locking screw 134 has 551 back in place. The tension pin 613
entered the motor shaft key slot. must fit into the groove in the pumpbody.
• Tighten the motor fastening screws. • Tighten the screws 453 crosswise.
• Tighten the locking screw 134. • Put the pump back into the system. Pro-
• Remove the rear cover 551. ceed according to the instructions in the
IMO AB Installation and Start-up instruc-
• Push the valve assembly into its position in tion for low pressure pumps.
the rear cover (o-ring grip).

Fig. 18

LPD 0603GB 10
September 1999
Pressure relief valve

A. 453 605

I 623 608

551 608A
6120
608B
605 615 613

6120 614
LPD20 © IMO AB

LPD21 © IMO AB
• Open the cover 623, hiding the pressure relief
valve set screw 608.
• Release the valve spring tension by turning the
set screw CCW.
• Remove the screws 453.
• Remove the rear cover 551 and the gasket 556.
(The valve is mounted into the rear cover 551)
• Bend up the wings of the locking clamp 608A.
Remove the screws 608B.
• Pull out the valve assembly.

• Replace the valve parts if necessary and reassem-

ble the valve unit and push it into the rear cover
551 (o-ring grip).
• Fasten the screws 608B and bend the wings of
the locking clamp 608A over the screws 608B.
• Fit the gasket 556 and the rear cover 551 with the
screws 453. Tight the screws crosswise.
NOTE!
The tension pin 613 must fit into the groove in
the pump body.

Fig. 19

11 LPD 0603GB
September 1999
Alfa Laval Marine & Power AB
Alfa Laval Marine & Power AB. S-147 80 Tumba, Sweden
Telephone: +46 8 53 06 50 00. Telefax: +46 8 53 03 45 55
www.alfalaval.com