Operation Manual

Separator
KYDH204SD-23
 Foreword
KYDH204SD-23 disk separator machine can be used in ships and the areas of
other national economy departments for removing the moisture and mechanical
impurities in fuel oil or lubricating oil to reduce the abrasion of diesel engine and
other separators and increase the service life.

KYDH204SD-23 separator machine can also separate two mutually insoluble

liquids of different gravities from each other; or separate the solid particles from the
liquid. The bowl and the material contacting elements of the separator are made of
martensitic stainless steel (2Cr13), so the separator is not recommended for the
liquid which has a corrosive action or an instable influence to martensitic stainless
steel, but please contact us if it is necessary.

This type of separator machine is automatic with simple and easy operation
which could greatly reduce the labor intensity of the operator. The separator has
been precisely dynamically balanced, and the vibration is negligible.

This manual, in which the functions, structure, operating principle, separating

mode, using and maintaining, minor failure solution and so on are described, is
supplied to the operator for reference to ensure the optimal performance, correct
operation and maintenance of the separator, prolong the service life, and ensure the
long-term and fault-free operation.
 Safe Operation Rules for the Separator
The separator machine is a kind of high-speed machinery, and tremendous
centrifugal force could be generated in the bowl during operation. In order to ensure
the safety of the operator and the equipment, the rules below should be strictly
followed in operating.

1. The separator can't be started up unless the main lock ring of bowl is tightly
locked, and the liquid in-and-out device and other fastening screws are fastened
before the braking screw is loosened.
2. Any part of the separator can not be loosened before the bowl has safety
stopped.
3. If abnormal or excessive vibration occurs, immediately fill the bowl full with
liquid, and then shut down the separator and cut off the power supply.
4. Flame is prohibited to heat or repairing-weld the major parts of the bowl
especially the body, the cover of the bowl, the piston and the main locking ring.
5. The bowl parts can not be exchanged with the ones of other separators even
with the same model.
6. When the assembly mark “ △ ” on the main locking ring exceeds the
corresponding mark on the bowl body over 25'', the equipment should not be
used anymore, and please contact us.
7. The separator is not recommended to separate the liquid with stronger
corrosiveness, larger density and different characteristics except the specified
liquid. But please contact us if it is necessary.
8. Check for corrosion and abrasion of the bowl parts every 4 months, especially
the impurity outlet, and screw thread of the main locking ring; if the medium is
corrosive, the check should be implemented more frequently.
9. Please only use the original elements and spare parts supplied by us.
 Content
1. Technology parameter

2. Basal principle

3. Structure and function

4. Installation

5. Adjust

6. Operation

7. Failure

8. Lubrication

9. Special use implement

10. Servicing

11. Spare Parts List

12. Appendix
 Technology parameter 1
Separate the machine main technology specification parameter
Bowl Speed r/min 7300
Fixed treatment amounts l/h 2000
Arrange residue way all row residues
Rotational speed of the speed-counter r/min 120±5（50HZ）
Start time min 2~5
Power motor kw 4
Delivery pressure of the centripetal Mpa ≤0.2
Gravity water box altitude m 2.5~3
Single weight Kg ≈320

The recommendation of the separate condition and actual processing

capacity of various mineral oils are shown as the table below
Nanjing AF Laval separator Co , Ltd. Strictly implements National standards of Marine disc separator products
Recommendation of the separating condition and actual handling capacity of various mineral oil
Lube oils
Type of oil Diesel oils heave Heave fuel oils Low speed Low speed Turbine oil
machine oil machine oil

viscosity
2
mm /s (50 ℃) ℃
mm2/s (40 )
13 20.5 36.2 80 180 380 460 600 100~120 65
2
Kg/m (50 )℃
Density
≤900 900~991 880~900 900
Separation
temperature( ) ℃ 40 60 80 98 80 75

The ratio of
actual handling
capacity to rated 110 100 60~65 45~50 35~40 20~25 50~60 25~30 80~85
handling
capacity(%)
Note
1. The ratio of actual handling capacity to rated handling capacity is calculated with the handling capacity of GB445 RC3-30
heavy diesel fuel is the rated handling capacity
2. The actual handling capacity of fuel in the list applies to single-stage separating of separator
3. The actual handling capacity of lubricant in the table applies to the working condition of by pass continuous separation

The product is manufactured and accepted according to Marine Disc

Separator machine GB/T5745-2010
Basal principle 2

1、
、Separate principle
The separator makes the oil, water or mechanical impurity of the compound
with different specific gravity get different centrifugal force under the effect of
centrifugal force field to complete the separation through high-speed rotation of the
separation cylinder.
1) Purification device
The purification plant is also called water diversion device which will generate
three phases of oil, water and separation impurity. During operation, when the
piston is sealed, the separation cylinder must be injected with water to form a water
seal layer. The dirty oil runs into the separation cylinder through the hole at the bevel
of the reel end, and a part of seal water is drained out, and then the pressure
balance of the two different liquids with different density in the centrifugal force field
is reached. Then the dirty oil runs into the space between the discs through the hole
on the bevel of the reel end, and is separated under the centrifugal force. The light
oil flows to the center along the external surface of the disc, and is output by the
centripetal pump; the heavy water and solid particle move outwards along the inner
surface of the disc; continuously replacing the water of the water seal will enable the
water to be thrown out from the caliber of the gravity ring and to be drained out
from the sewage port. After passing through the water seal layer, small amount of
solid impurity will be taken away by the water, large amount of it will gather on the
wall of the impurity basket and will be vented during impurity-removing.
2) Clarification system
Clarifying system is also called impurity diversion device which will generate two
phases of oil and impurity respectively after separation. During operation, the
build-in impurity baffle ring of the ring channel on the coping of the disc will block
the water outlet. So during impurity-diverting, water mustn’t be injected in for
sealing, otherwise the separation effect will be affected, and great amount of oil spill
will appear and the separating will be interrupted.
During impurity-diverting, only in the caliber of the gravity ring there is no water
being thrown out, while the separation principle of the clean oil and impurity is
identical with that of the purification device. Clean water is also output from the
centripetal pump.
Principle of charification

Bowl part Liquid

Solid discharge Centrifugal force field

Prin principle of purification

Centrifugal force field Bowl part

Light phase liquid Solid discharge

Dirty oil Heavy phase liquid

2. Option of the separating devices
When there is lots of moisture and a little mechanical impurity in the oil, the
water diversion device is suggested to choose.
When there is a little moisture and lots of mechanical impurity, the impurity
diversion device is suggested to choose.
The separation method is determined according to the content of the moisture
and mechanical impurity in the oil. So the analyses result of the oil must be provided
before the assembly of the bowl.
When the content of the moisture and mechanical impurity in the oil is unknown,
generally the water diversion device is suggested to choose. When there is great
amount of moisture and mechanical impurity in the oil simultaneously, it is suggested
to use the water diversion device to remove the moisture and most of the impurity
first, and then use the impurity diversion device to remove the remained impurity in
the oil.

3. The Principle of Impurity-Removing, and the Operation of the

Control Valve
Seal of the bowl:
The control water is led in bowl which is spinning with high speed and then get
into the seal cavity at the under part of the piston; the generated centrifugal
pressure pushes up the piston to impact the seal ring on the cover of the bowl; thus
the bowl is sealed.
Impurity removing of the bowl:
The control water is led into the upper cavity of the piston through the control
valve; the generated centrifugal pressure pushes down the piston. The water in the
lower cavity of the piston is drained out quickly; the lower cavity of the piston
decompress quickly; the piston falls and gets open; the collected sewage is vented
from the drain port on the circle of the bowl body.
 The operating procedure of the control valve is described by steps as follows:
(1) SEALING: Open the Seal Ring valve with the water proportioning pan, the water
is sprayed into the rotating lower cavity of the influence baffle through the water
proportioning pan, and gets into the lower cavity of the piston under the effect of
the centrifugal force through the water proportioning pan and the hole in the bowl
body, and pushes up the piston, the redundant water flows out and gets into the
sewage draining passage after the lower cavity of the return pipe is filled with water.
(2) IMPURITY REMOVING: When opend the Seal Ring valve and clesed the return
pipe valve core with the water proportioning pan.. Because The return pipe is unable
the backwater so the water proportioning pan will bring the water to the Functional
sliding block of the influence baffle, and pushes the functional sliding block to under, Seal
water come back. Because the hydraulic pressure area of upper part of the piston is
higher than that of the lower part of the piston, thus a pressure difference will be
generated to push down the piston and extrude the water of the lower cavity of the
piston, and the piston will get open, the impurity will be thrown out.
When the impurity removing is completed, and the second seal is being carried
out, the water in the upper cavity of the piston will be drained out, the piston is
pushed up by the pressure of the seal water in the lower cavity of the piston.
In order to ensure the seal and normal startup of the bowl, the following items
must be paid much attention to:
(1) Keep the control water clean; prevent the passage from being jammed
because the mud, rust and other impurities get into the bowl.
(2) The control water tank must be installed according to the prescribed height
(in respect to the water surface of the water tank), the distance from the control
water tank to the control valve should be 2.5~3m, i.e. the pressure of the control
water is ensured as 0.25×10 ~0.3×10 Pa.
Structure and function 3
Disc style separates the machine composition structure
1、 Device passing in and out of material
2、 Bowl
3、 Match water device
4、 Perpendicularity axis department
5、 Level axis department
6、 Measure the fast device
7、 Electric motor

1. Mechanical transmission
Mechanisms of centrifugal friction coupling, speeding-increasing helical gear unit,
lubricating oil tank, radial or axial buffer spring unit, speed counter and oil pump
driving gear and so on are installed in the frame. See the details in the figure below
(Figure 4, Figure 5).

Figure 4
The electromotor drives the horizontal shaft through the friction coupling; the
big helical gear on the horizontal shaft drives the small helical gear on the vertical
shaft, thus a pair of gearing-up is formed with an increasing speed ratio of 14:71; the
worm on the right side of the big helical gear drives the small worm gear of the
speed counter, thus a pair of gearing-down is formed with a reduction ratio of 12：1,
so when the rotate speed of the speed counter is 120 ± 5r/min, the oil separator
reaches the top speed.。The transmitting gear on the right side of the horizontal shaft
drives the oil pump.
A group of radial buffer springs, which has been pressure-deformation tested,
are installed on the vertical shaft to absorb the radial vibration from the high-speed
bowl. The
 This group of springs has past the pressure and deformation testing. When the
same group of springs that installed in the separator are compressed to the same
regulated length, the differential pressures of the springs in a same group installed in
the machine is within 49N at the same specific pressed length, so all the springs in a
same group should be changed if one of them is broken.
Another buffer spring is installed at the end of the vertical shaft to absorb the
vibration form the helical drive.

Figure 5: Vertical section drawing of the oil separator

2. Friction coupling
The centrifugal friction coupling ensures the oil separator start up tardily to
reduce the startup load of the electrical motor.
When the separator is being started up, the friction coupling gets heating and
smoking; when the separator is being stopped, the friction coupling sends out short
clank. These are all normal phenomena. When the startup is completed, the bowl
reaches the normal rotation speed, the friction coupling stops heating and gradually
cools to room temperature.
The friction surface of the parabolic cylinder block of the friction coupling should
be prevented from being interfused with oil, grease lubricant and other substance,
otherwise, slipping will be caused, and the bowl can not reach the full speed.
4. Braking device
A brake is installed on the base of the oil separator, when the oil separator can
not work normally and needs to be stopped, the braking device can be activated to
shorten the shut-down period after the power supply is cut off.
The braking device can also be used in normal shutting-down, but it must be
used after the slowdown of the rotation speed of the oil separator, otherwise the
friction disk will be burnt out and worn.
5. Bowl
The bowl is one of the most important components of the oil separator. The
separating of the liquids is implemented in the bowl.
The bowl mainly consists of components such as: bowl body, piston, disc, reel,
reel base, end cover, main locking ring, gravity lock ring, etc.
There is a piston between the body of the bowl and the reel. The automatic
impurity-removing oil separator separates depending on the rising (seal) of the
piston, and removes the impurity depending on the falling (startup) of the piston.
On the surface of the top circle of the piston, there is a seal ring which is used to
prevent the leakage of the control water from the upper and lower cavity of the
piston, if the seal ring is destroyed and the control water is leaked, the piston will
automatically open, then the oil separator can not work normally.
The bowl has been dynamical balanced. Every main component after the
dynamical balance is marked. When the bowl is assembled for the second time, it is
forbidden to change the components, and the bowl should be assembled in strict
corresponding to the original assembling marks. In addition, the weight-adjusting
part on the head cover and the drum body can not be changed. When more than
one oil separator with the same mode is to be assembled, more precaution should
be taken to ensure components of one bowl will not be fixed onto another one.
Otherwise the balance of the bowl will be destroyed, strong vibration will occur
when the oil separators work.
4.1 Bowl structure
Bowl is to separate machine's if the important component, pursuing what be
shown, lock ring locking is in the bowl body and bowl cover by the host together.
The bowl inner pretends to have the distributor and the disc module. The disc is
disc neck cover on the set. Disc neck cover and the liquid place ring are
composed of looking at and appraising a pump chamber gently. Disc neck cover
and pump chamber cover are composed of weight looking at and appraising a
pump chamber. Interior dress of pump specific gravity ring having the interface
adjusting fringe benefit again each other. The bowl inner still has a piston , bowl
pretends to have effect smooth piece and spring seat on the lower part ,
pretends to have a group of spring between effect smooth piece and spring
seat.
* Upper part is composed of bowl and effect smooth piece opening the water
cavity
* Bowl and the piston body are composed of the hermetic sealing cavity
5、 Control valve
The control valve, by which sealing, starting up and other processes are completed, is
the main operation component when the oil separator is working.
Installation 4
When the oil separator is being installed on the shipping, the horizontal shaft of the
separator should be accordant with the head-end direction of the ship in order to
reduce the affection on the separator from the vibration of the ship.
1. Installation of the separator
a. The external dimensions, installation dimension (Figure 1) and the system diagram
(Figure 2) are as follows.
 Figure 1

Figure 2

b. The base plate for the installation of the separator must be straight and flat. If the
base plate is not flat, the base of the separator will be deformed, dislocation and
deviation of the friction coupling will occur, and the startup load will increase with
strong vibration, or even the separator can not be started up. Therefore, it must be
ensured that the central-line misalignment of the friction sleeve and the parabolic
cylinder blocks of the friction coupling is less than 0.08 mm and the end face
deviation is less than 0.15 °, after the separator has been installed.
c. In order to prevent the vibration of the oil separator being transmitted to the
surrounding machines, or the vibration of the vessel being transmitted to the oil
separator, a shock absorber should be installed between the engine bed of the oil
separator and the base. Anchor nuts should be locked after the foundation bolts of
the oil separator with a shock absorber are tightly screwed.
d. The sewage draining passage, the input and outlet pipeline of the oil pump,
sewage pipe, wash pipe and so on should be connected with tubes.
2. Equipments
a. An oil heater should be equipped for the heating the oil to be separated.
b. Hot freshwater pipeline should be equipped for the water supply of water seal.
c. A high positioned water tank with a capacity of 35 L must be equipped, and the
water surface should be 2.5-3m above the control valve. Ensure the cleanness of the
control freshwater so as to prevent rust, mud and other impurity getting into the
control valve, blocking up the control water passage and making the piston out of
order.
Adjust 5
Refer to Part IV "assemble" separation machine system picture.
1、Adjust front preparation
The interface according to oil density, the caliber choosing rightly adjusts the
ring (specific gravity is encircled by), consults to pursue 6. :
Examine a machine , examine if gear case inner already add the
appropriate amount lube, whose oil level responds to reach carve line location,
only should not exceed very many;
Examine that if the high position water box are full of water, and open the
pipeline discharging a valve , examining that whether or not flooding;
Examine that the filth paints/ nothing but the oil pipe road, open the
absolute entrance valve;
Start filth oil transporting a pump, open the heater steam valve, heat the
separation temperature needed by oil and adjustment to.
2、Start separation machine
That the direction and rotation rate examining that the counter measuring
the fast device rotates, affirm the machine travel is whether or not regular. If
abnormal vibration and noise happened in the machine, respond to the
machine assembling condition parking immediately, being put into use putting
on the brakes, and then examining that.
Open the valve sealing off water, enter the state sealing off water making
bowl assume hermetic sealing.
3、The water closing/ displacement water yield is adjusted
Open water closing/ displacing the water valve , make water closing/
displace the water rate of flow by the fact that water measures water
outlet ,and use water closing/ to displace water regulating valve adjustment
reaching 0.1 L/ till water closing/ displaces a water flow adjust second, not to
arbitrarily after the personnel adjusts whose rate of flow from mode.
Water closing/ displaces water pouring the bowl inner in, if the cinder notch
observing a row leak, "the trouble removal" indicating that bowl seals up
completely, examines and the trouble shoot, details see.
4、Filth oil handles the amounts adjustment
Open water closing/ displacing the water valve, displace the water valve till
again each other, the water outlet producing water, closing water closing. Hand
movement changes the pneumatic three direct links valve, the inner adds filth
oil to bowl. Handle amounts according to the breed processing oil's and
required properness, find out corresponding pressure value in pressure one rate
of flow form, by the fact that the oil adjusting a filth imports the front valve of
pump or the filth oil bypass valve, the piezometer adjusting filth oil pipe on the
way accords with corresponding numerical value, is to handle amounts rightly.
5、Absolute oil exports the pressure adjustment
Absolute oil exports the pressure regulating valve all open up, from absolute
oil making note of pressure value on the piezometer being in charge of outlet,
this value being that the minimum conveys pressure Pmin.
Close the small outlet pressure regulating valve slowly, the pressure
increasing absolute oil outlet, is to stop the pressure value being on the move,
making note of until painting pressure, oil juat now, flowing out of the water
outlet, reducing a bit, this value is maximal output pressure Pmax, destroy if the
still continuous outflow of oil, measures water closing, the gravity ring caliber is
slightly big.
For sure, absolute oil exports high = high-handed warning pressure value P
Pmax-(0.05 ~ 0.07 MPa) , P is taller than = generally 0.25 ~ 0.3 MPa.
Low pressure gives an alarm for sure absolute oil outlet low = pressure P
Pmin + (0.8 ~ 0.1 MPa).
Regular actuating pressure P1 adjusting absolute oil outlet = (high + P of P is
low) X 0.5, is that P2 should be in P height and be 0.18 ~ 0.2 MPa like low P
centre location.
Operation 6
1、 Handle
Start front:
Examine that if machine assemble is correct;
Examine that the interface adjusts a ring whether or not rightly;
The oil level examining gear case inner lube is correct or not;
Examine that if the operation water box are full of water.
Start an oil pump
Examine that the filth is oily circulatory system is regular or not again;
If the valve mouth examining that filth oil transports pump front open up.
Start and part for:
Start separation machine, should park immediately, examine that bowl
assembles condition if that the machine vibrates is abnormal;
Examination measures the fast device counter rotation rate;
Open the valve sealing off water entering the state sealing off water, bowl
assuming hermetic sealing;
Open water closing/ displacing the water valve, the extremely important
water-entering water appearance water outlet produces water , close water
closing displacing the water valve , examine that bowl seals off state is whether
or not regular;
Change the pneumatic three direct links valve, add filth oil to bowl inner;
Adjust the filth oil entrance valve, adjust right treatment amounts
The pressure giving an alarm , entrance adjusting export pressure and high
absolute low pressure separate state regularly.
Arrange a residue:
Entire 73 seconds of row residue period.
Change the pneumatic three direct links valve , open water closing at the
same time/ displacing 20 seconds of water valve , highball;
Close water closing/ displacing the water valve, since opening the water
valve, hear be closed down when arranging residue sound, general 3 5 seconds
of Time Opening;
About 30 second opens up the 4th, 5, 6, 7 procedure sealing off the water
valve, sealing off bowl, circulation "getting it in gear and parting for" the day
after tomorrow.
Stop：
Close a heater , change the pneumatic valve of three direct links , filth oil
painting a chest by the fact that circulatory system returns to precipitayion;
Close the valve sealing off water:
Open water closing/ displacing 20 seconds of water valve;
Dozen, open the water valve, arrange a residue, repeat the drum arranging
the residue procedure triple, cleaning row racing;
Open the valve sealing off water;
Open water closing/ displacing the water valve producing water till weight
looks at and appraises a water outlet and close that;
Close an electric motor, can be put into use putting on the brakes after gap
period of time, can't can motor stoppage natural.
（）
Pay attention to: 1 Bowl floats water motor stoppage stable.
（2 ） Bowl has not loosened any fastener on the machine before
complete stop.
2. Option of Gravity Rings:
Each oil separator is matched with gravity rings with different calibers that can
be chosen to use. The water diversion device can separate the compound of oil and
water with different specific gravities by changing the caliber of the gravity ring.
Generally speaking, in condition that the inner water seal of the bowl is not
destroyed, the best separation effect can be gotten by using the gravity ring with
large caliber.
The interface of oil and water, which gets liquid balance under the effect of
centrifugal force field, can not reach the surroundings of the wall of the bowl or stay
in the outer fringe of the head cover. Once this phenomenon occurs, the water seal
will be destroyed, the oil will flow out with the water through the outer fringe of the
head cover and cause serious leakage at the water outlet.
To choose the caliber of the gravity ring, figure 6 can be referred to.
When the specific gravity of the oil that is to be separated under certain
temperature and the selected separating temperature are known, the proper caliber
of the gravity ring can be found out from the figure.
For example, firstly, in the left table of figure 6 draw upwards a vertical line from
35 ℃ , intersect with the 0.840 horizontal specific gravity line, from the point of
intersection, draw the parallel of the diagonal to intersect with the parting line, then
from the point of the intersection draw right the parallel of the curve and intersect
with the vertical line of the separating temperature 55 ℃ . Finally, from this point
draw right a horizontal line to intersect with the right vertical axis, this reading is the
caliber of the gravity ring ≈φ114.
If the specific gravity of the oil can not be determined, then it is necessary to test
for several times to determine it. <0}
 {Figure 6 Option of gravity rings
3. Temperature and Viscosity of the Separating Oil
The separating amount and effect depend on the oil viscosity, specific gravity and the
separating temperature. Generally, the lower the oil viscosity and the specific gravity
are, the better the separating effect is. The viscosity and the specific gravity of the oil
descend as the temperature rises, so, raise the separating oil temperature will
improve the separator capability and effect. But when the oil temperature exceeds
90℃, the moisture in the oil is easy to boil away and cause the separate condition
gets worsened. Therefore, it’s better that the separate temperature does not exceed
90℃，and keeps invariable throughout the whole separate process.
The oil viscosity requirement (it means the oil viscosity before entering the
separator) of the oil separator is 3~5 engler degree. On condition that the top
separate temperature is not exceeded, it’s better to make the oil that is to be
separated meet this requirement to improve the separate effect
4、、Arrange residue gap time choice
Arranging long residue gap time possibility may produce bowl holding the
rapid and intense congeries of residue cavity inner residue , arousing the row
residue smooth and rotating the drum to produce balance, is able to have
separating machine producing the danger damaging if this kind of unbalanced
amounts are very big. A lot of factor affects row of residue gap time, is put into
use therefore kind concretely ought to ascertain right gap time according to
experience to every.
Following lists various different oil row residue gap recommendation value.
Degree recommending if value be appropriate to ought to examine the bowl
cleaning behind using a period of time for examining these. Examine that using
time in the front depends on separating oil and handling condition.
Form fuel oil is recommended
Rotate the bowl first
Oil kind Recommend gap time
examining time
The boat uses diesel
2 hours 1 week
oil 13 cst / 400C
Highly value quality
0.25 hour 1 week
fuel oil
Make light of quality
4 hours 4 week
oil 1.5 – 5.5 cst /400

Form slide oil is recommended:

Rotate the bowl first
Oil kind Recommend gap time
examining time
Crosshead tube Crosshead tube
shape shape
Betoken slide oil
1 hour 1 week
system
Filling box system 5 hours
Host slide oil system
0.5 hour 1 week
continues parting for

Degree examining that bowl is clean

If bowl holds a residue the cavity is clean, can be appropriate to prolong row
residue gap time; The cavity is dirty if bowl holds a residue , row of residue gap
time must shorten then.
5. Water wash of oil
When the oil separator is used as water diversion device, it is useful for water
wash.
When the moisture content of the oil is less than 40%, the soluble acid, organic
acid and some compounds of natrium can be washed off with hot water.
The temperature of the injected hot freshwater should be higher (generally
about 5℃) than that of the oil which is to be separated.
The amount of the injected hot freshwater is generally 1%~2% of the separate
amount.
It must be explained that when the lubricant that is to be separated contains
water-soluble additive, it can not be washed by water, or the additive in the oil will
be separated and the performance of the lubricant will be affected.
Failure and Troubleshooting
Serial
Failure General reasons
No.
(1) There is no water in the
high-level water tank;
(2) Leakage at the control
valve, the pipeline is
jammed.
Open the Seal Ring (3) The seal ring of the
valve or not piston is destroyed;
1 completely (4) The nylon seal ring is
destroyed;
(5) The height of the vertical
shaft is improper;
(6) The pore at the top circle
of the piston is jammed.
Closed the Return The examinations are
pipe and The identical with the above
2 switch cannot mentioned（1） （2） （3）. (1) To replace the old seal
open or the bowl (1)The seal ring on the base ring with a new one.
part of not of the reel is destroyed.
(1) Improper ring dam;
(2)The separate oil
Unfavorable temperature is too low;
3
separate effect (3) Too much residue in the
bowl.
(1) The filling valve is opened
suddenly, the water seal is
destroyed;
- {}- (2) Seal water is insufficient;
(3) The caliber of the ring
Serious oil dam is too big;
4 leakage at the (4) The temperature of the
water outlet oil that is being separated is
too low;
(5) The centripetal pump has
lost working capability.
(1) The filling valve is opened
Overflow of the too quickly, oil feeding is too
5
bowl ,recognized sudden;
7
Eliminating Methods
(1) Inject control water;
(2) Repair and make it be
free of leakage and jam;
(3) Replace it with a new
one;
(4) Replace it with a new
one;
(5) Adjust it to the proper
height;
(6) To dredge.
(1) Replace the old ring
dam with a proper one;
(2) Raise it to the proper
separate oil temperature;
(3) Increase the times of
residue removing and
wash.
(1) Have Water seal once
more, open the
filling valve tardily;
(2) Increase the seal
water;
(3) Adjust and replace
the ring dam;
(4) Raise it to the proper
oil temperature;
(5) Examine and repair
the centripetal pump.
(1) Close the valve, and
feed oil tardily;
(2) Feed oil after the
 by dirty oil (2) Long separate time and
discharging at the too much residue;
clean-oil out let (3) Large separate amount
and small caliber of ring
dam.
(1) Parts of the bowl are not
put in the right place, or
not aligned with the
assembling marks
(2) The mating gears or the
rolling bearing is
damaged;
(3) Part of the firmwares get
loose;
(4) The bowl brushes up
Abnormal
against the machine
vibration or noise
6 cover or against the
occurs
water proportioning
pan;
(5) The residue removing is
not complete, the
dirt retention in the
bowl is not
symmetrical;
(6) Dry milling of the gear
(1) The filter is jammed;
Insufficient (2) Leakage of safety valve,
vacuity, pressure or the spring of the safety
or discharge valve is too weak;
7
capacity of the oil (3) The end face clearance of
pump the oil pump is too
wide.
residue is removed;
(3) Reduce the flux and
change the ring dam.
(1) Examine and correct
the assembling mistakes;
(2) Replace the damaged
parts;
(3) Clamp the firmwares
properly;
(4) Adjust and make it be
free of collision;
(5) Clean out the dirt
retention;
(6) Add oil into the tank
lubricator.
(1) Clean out;
(2) Clean and rub the
valve seat; adjust
the spring pressure
to the required
scope;
(3) Adjust the clearance;

The oil level of the dirty oil

tank is too low;
(1) Add oil into the oil
(2) The oil viscosity is too
tank;
high, oil coagulates in the
(2) Heat up the oil to
The dirty sludge pipeline;
reduce its viscosity;
8 oil pump can not (3) Blow-by of the suction
(3) Repair the pipeline to
pump. line;
ensure its seal;
(4) The taper pin of the
(4) Replace the taper pin.
transmitting gear of the oil
pump gets broken off.
9 The bowl does (1) The brake has not been (1) Loose the brake;
 not come up to loosened; (2) Clean or replace the
rated speed or (2) There is grease interfused friction disk;
takes too long to into the friction (3) Examine the electrical
do so. coupling; abrasion and motor and the electrical
slipping of the friction devices.
disk;
(3) Failure of the electrical
motor or of the electrical
devices.
Lubrication 8
Lubrication is an important chain which guarantees the normal operation of the
separator. Users must pay special attention to the fact that many factors can cause
the depravation of lubrication condition and serious result, such as inappropriate
brand of lubricant, overfull or insufficient oil content of lubricant, oil quality change
of the lubricant, etc.
When the oil separator is running, the oil that is splashed by the rotation of the
screw gear lubricates the axletree of the horizontal shaft and the axletree of the
vertical shaft, at the same time, it also lubricates the transmitting gear.
Generally, N68 （ GB443-84 ） mechanical oil (is equivalent to the previous
GB443-64 40 and GB443-64 50 mechanical oil) is adopted as the lubricating oil in the
gear case. When the oil separator is working in hot environment or separating hot oil,
the temperature of the gear case will rise obviously, at this time, lubricant with
comparatively higher viscosity should be adopted.
The oil surface in the gear case should keep at 2/3 height of the window glass of the oil level
observation cover, it’s better that the lubricant submerge half or one gear of the large screw gear.
Overfull or insufficiency of the lubricating oil will cause the raise of oil temperature and power
consumption.
The first time of oil change of the oil separator should be carried out after the separator has
operated for 250h; the later time limit of the lubricant use depends on the quality of the
lubricant and the use situation, when change the oil, the bottom of the oil tank should be
cleaned up carefully.
The gear oil pump is lubricated by the oil that is running pass the pump when
the separator is working, so this pump can not run without load for long time, before
the oil separator begin to work, grease lubricant must be injected into the oil cup of
the oil pump in advance.
When the bowl is reconfigured after being disassembled, all the following parts
should be lubricated with lubricant or lubricating oil.
Special use implement 9

1. Bowl
(1) Open the braking device to prevent the bowl from rotation.
(2) Clockwise screw out the main locking ring with the spanner (figure 9) of the
main locking ring. If the ring dam needs to be replaced, the ring dam should be
screw out clockwise with the spanner (figure 10) of the ring dam first.

Figure 9 Figure 10
(3) Loosen off the bowl cover, the ring dam can be used as hoisting tool.
(4) Use the handle bolt (I) to sling out the reel and disc group.
 Handle Bolt (I)

Bowl Handle Handle Screw (II)

(5) Clockwise screw out the nut of the vertical shaft with the spanner, take out
the base of the reel, Use the handle screw (II) to remove the piston, and use the
Bowl Handle to screw it in, then the bowl can be removed after the vertical shaft is
loosen off.(6) The assembly of the bowl can be carried out on the counter sequence,
please pay attention to the following items in assembly:
A. Whether the rubber seal ring is damaged or bulgy.
B. Whether the cover of the nylon seal ring is destroyed.
C. In the course of assembly, the marks and directions must be aligned with.

2. Horizontal shaft and Vertical shaft

(1) Loosen off the control valve of the oil pump, electrical motor and its
protective cover, side cover, transmission mechanism of the speed counter and the
bowl.
(2) Take down the bearing together with the whole set of horizontal shaft from
the left side of the machine.
(3) Take down the water proportioning pan, cover and water thrower
(4) Loosen off the screw nut of the vertical shaft with special spanner. See figure
13.

Figure 13
(5) Unfix the bearing bonnet of the buffer with double-ended spanner, take out
the whole set of vertical shaft from the upper part. Clockwise screw out the bearing
clamp nut of the vertical shaft with double-ended spanner, take out the bearing with
the gravity bushing.
(6) When reassembling, the height of the vertical shaft can be adjusted with the
screw below the base of the machine.
(7) For special tools list, see Table 2
Table 2
Serial
Code Title Quantity
No
1 AF204.29.00.00 Spanner of the main locking ring 1
Reel Handle and Reel base
2 AF204.21.00.00 1
（M24X3）Left
3 AF204.15.00.00 Piston Handle（M55X2）Left 1
5 AF204.27.00.00 Ring Dam Spanner 1
6 AF204.31.00.00 Bar Copper 1
7 AF204.20.00.00 Bowl Handle M33X2 1
8 AF204.16.00.00 Nutwrench of the Vertical Shaft 1
Servicing 10
(1) The separator should be washed with hot freshwater each time after using,
and the impurity should be rinsed out from the bowl, at the same time, the sewage
sediment in the filter should be removed frequently.
(2) Regularly (about 2 months) check whether each water proportioning hole is
jammed, and clean it.
(3) The control valve should be examined regularly, and should be lubricated
with oil to prevent rust.
(4) The validity period of the oil seal of the oil separator after leaving the factory
is one year; it should be resealed with oil if the oil seal is expired or the separator is
stopped and won’t be used for a long time.
Parts Catalog 11
Serial
Code Title Quantity Remark
No.
1 AF204.07.07.00 Little Spring 6

2 AF204.10.05.00 Brake Disk 1

3 AF204.06.03.00 Friction Rubber 2

4 AF204.07.02.00 Big Spring 6

5 AF204.01.05.00 Disc 3

6 AF204.01.08.00 Nylon Ring 2

7 GB1235-76 O Seal Ring ￠40X3.1 5

8 GB1235-76 O Seal Ring￠30X3.1 5

9 GB1235-76 O Seal Ring￠50X3.1 2

10 GB1235-76 O Seal Ring ￠80X3.1 2

11 GB1235-76 O Seal Ring ￠105X3.1 2 Generic

12 GB1235-76 O Seal Ring￠110X3.1 2 Generic

13 GB1235-76 O Seal Ring ￠42X3.5 2 Radial Pump

14 GB1235-76 O Seal Ring ￠56X3.5 2 Axial Pump

15 GB1235-76 O Seal Ring￠113X96X4.5 2 Ring Dam

16 GB1235-76 O Seal Ring￠170X4 2

17 GB1235-76 piston seal ring￠264.5X6X6 2

18 AF204.01.16.00 gravity ring 3

19 AF204.01.23.00 Tskating block spring 18

20 Hexagon Ring Spanner（M8） 1

21 AF204.01.20.00 Nylon valve core 3
22 AF204.11.15.00 observation glass
appendix
chassis assembly

NO. Name Figure No. Qty.

1 Chassis AF204.05.01.00 1
2 Bearing house AF204.05.06.00 1
3 O ring ￠60X5.7 1

4 Stop moving a washer ￠50 GB858-1988 1

5 Chassis nut M50X1.5 1

6 Bearing end cover AF204.05.07.00 1
7 O ring ￠80X3.1 1
8 Oil seal 30X40X7 HG4-692-67 1
9 Bearing NSK6208 1
10 Big spiral gear AF204.03.03.00 1
11 Friction drum AF204.03.01.00 1
12 Horizontal axis AF204.03.02.00 1
13 Cylindrical pin 8X80 GB117-76 1
14 Bearing NSK6205 1
15 Stop moving a washer 25 GB858-88 1
16 Axis end nut M25X1.5 GB810-76 1
17 Pad AF204.05.13.00 1
18 Horizontal axis end cover AF204.04.01.00 1
19 Bolt M8X25 GB/T5783-2000 6
20 Screw 8 GB848-85 6
21 Spring screw 8 GB93-87 6
22 Motor connection flange AF204.05.08.00 1
23 Bolt M12X35 GB/T70.1-2000 4
24 Screw AF204.05.14.00 1
25 Spring house AF204.07.09.00 1
26 Small spring AF204.07.07.00 6
27 Movable chassis AF204.07.06.00 1
28 Cotter pin 1.6X18 GB/T91-2000 2
29 Observation glass AF204.05.11.00 1
30 Observation seal ring AF204.05.15.00 1
31 Observation cover AF204.05.10.00 1
32 Screw M6x10 GB/T818-2000 3
33 Oil discharge hole plate AF204.05.02.00 1
34 Oil discharge hole bolt AF204.05.03.00 1
0000
electric motor starting assembly

NO. Name Figure No. Qty.

1 Friction chassis AF204.06.01.00 1

2 Friction cover AF201.06.04.00 1
3 Bolt M6X20 GB/T5783-2000 3
4 Friction block AF204.06.02.00 2
5 Friction plate AF204.06.03.00. 2
6 Brake screw AF203.03.03.06 8
7 Motor key AF204.06.06.00 1
8 Electric motor Y112M-4-H 1
9 Bolt M12X30 GB/T5783-2000 4
vertical axis assembly

NO. Name Figure No. Qty.

1 Vertical axis AF204.02.01.00 1

2 Vertical gear AF204.02.02.00 1
3 Plate AF204.02.03.00 1
4 Bearing SKF2305 1
5 Stop moving a washer 25 GB858-88 1
6 Axis end nut M25X1.5 GB810-76 1
7 Bearing house AF204.07.04.00 1
8 Bearing SKF6309 1
9 Vertical axis bottom nut AF204.02.04.00 1
 10 Buffer box AF204.07.01.00 1
11 Spring housing AF204.07.03.00 6
12 Big spring AF204.07.02.00 6
13 Buffer screw AF204.07.08.00 6
14 Bolt M10X45 GB/T5783-2000 3
15 Washer 10 GB848-85 3
16 Spring washer 10 GB93-87 3
17 Buffer cover AF204.07.05.00 1
18 Screw M6X10 GB/T819.2-1997 3
19 Vertical axis up nut AF204.02.05.00 1
20 O ring ￠50X5.7 1
21 Throwing water sheet AF204.02.06.00 1
22 Buffer cover screw M6X10 3

water distribution assembly

NO. Name Figure No. Qty.

1 Water supply house AF204.08.02.00 1

2 Distributor pressing nut AF204.08.04.00 1
3 Nylon pad AF204.08.09.00 1
4 Register pin AF204.08.08.00 1
5 Distributor pad AF204.08.10.00 1
6 Distributor register pin AF204.08.08.00 1
7 Distributor AF204.08.03.00 1
8 O seal ring ￠110X3.1 1
9 O seal ring ￠100X3.1 1
10 The water distributing plate AF204.01.24.00 1
11 Thread ring AF204.08.05.00 1
12 Spring washer 10 GB93-87 6
13 Washer 10 GB848-85 6
14 Bolt M10X90 GB/T70.1-2000 6
15 Water supply house seal ring AF204.08.06.00 1
bowl assembly

NO. Name Figure No. Qty.

1 Bowl body AF204.01.01.00 1

2 Bowl set pin AF204.01.21.00 1
3 Skating block AF204.01.22.00 1
4 O seal ring ￠170X4. 1
5 Nylon valve AF204.01.20.00 3
6 Piston register pin 6X20 1
7 Skating block spring AF204.01.23.00 18
8 O seal ring ￠105X3.1 1
9 Spring house AF204.01.18.00 1
10 Bolt M8X25 GB/T5781-2000 3
11 Screw AF204.01.19.00 3
12 Register block AF204.01.12.00 1
13 Piston AF204.01.02.00 1
14 Piston seal ring AF204.01.09.00 1
15 O seal ring ￠50X3.1 1
16 The bottom of disc frame AF204.01.03.00 1
17 Register pin AF204.01.10.00 1
18 Vertical nut AF204.01.25.00 1
19 Register pin ￠6X20 1
20 Disc frame assembly AF204.01.04.00 1
21 Disc assembly AF204.01.05.00 95
22 Level ring AF204.01.07.00 1
23 O seal ring ￠80X3.1 1
24 Centrifugal pump of light liquid AF203.21.08.00 1
25 Disc top cover AF204.01.06.00 1
26 Bowl body cover AF204.01.14.00 1
27 Nylon ring AF204.01.08.00 1
28 O seal ring ￠110X5 1
29 Gravity ring AF204.01.16.00 1
30 Gravity ring washer AF204.01.27.00 1
31 Centrifugal pump pipeline AF204.11.02.00 1

32 Centrifugal pump of heavy liquid AF204.14.00.00 1

33 O seal ring ￠56X3.5 1

34 O seal ring ￠42X3.5 1
35 O seal ring ￠40X3.1 1
36 Gravity lock ring AF204.01.17.00 1
frame assembly

NO. Name Figure No. Qty.

1 Chassis AF204.05.01.00 1
2 Washer AF204.05.14.00 1

3 Sludge frame AF204.08.01.00 1

4 bolt M12X35 GB/T5783-2000 6
5 O seal ring ￠480x5.7 1
6 Hook AF204.13.00.00 1
7 pin AF204.08.01.02A 4
8 pull rod AF204.08.01.02 2
9 Compact a claw AF204.08.01.03 4
10 Compact a nut AF203.17.06.00 4
11 Control valve AF204.12.01.00 1
12 O seal ring ￠26x2.4 1
13 Bolt stud M10X35 GB901-88 2
14 Nut M10 GB/T41-2000 2
15 Braking plate house AF204.10.06.00 1
16 Braking spring AF30410.04.00 1
17 Braking rod AF204.10.07.00 1
18 Braking handle AF30410.03.00 1
19 Handle pin AF204.10.02.00 1
20 cotter pin AF204.10.08.00 1
21 Braking cover AF30410.01.00 1
22 Bolt M10X30 GB/T5783-2000 4
23 Washer 10 GB848-85 4
24 The spring washer GB93-87 4
25 Detector assembly AF204.09.00.00 1
inlet & outlet liquid assembly

1 Outlet liquid chassis AF204.11.01.00 1

2 Bolt M8X25 GB/T5783-2000 4
3 Inlet liquid nipple AF204.11.02.00 1
4 O seal ring ￠30X3.1 2
5 O seal ring ￠42X3.5 1

6 Centrifugal pump pull rod AF204.11.04.00 1

7 Observation nut AF204.11.15.01 1

8 Nylon washer AF204.11.16.00 8
9 Observation glass AF204.11.15.00 1
10 Observation window AF204.11.14.00 1
11 Metal hose L-300 2
00
12 Nipple AF204.11.17.00 3
13 Metal hose L-200 1
00
14 Ball valve G 1/2” 1