o
4 Maintenance inspection procedures for major parts
4.1 Bearlng replacement Intervals
A wenrrrrrrrc
For the veical and horlzontal shafts, qse bearlngs that are up to speclflcatlon. The upper
bearlng of the vertical s h aft in partlcular is im porta nt lf an o ut-of-s pecification bearing is u sed,
personal safety could beleopardized because of reduced bearinq life.
!\ cnuroru
For the sake of safety, replace the bearlhgs of the vertical and horizontal shafts before the
elapse ol2 years regardless ofwhether they have been in service or not''
The bearings are expendable parts. Place separate ordors for bearings other than supplied as spare
4.2 Bowl
4.2.1 corrosion of bowl
Th6 bowl perts except some are made of special stainless steel. Under stringeht operating condition,
howevar, corrosion might occur in the form of pitting.
Since the bowl is exposed under a high stress, a very fine crack originating in the pitting could occur.''
Be very carefulwhen you check.
a What to do to prevent corrosion
Corrosion readily occurs in the portions that are in
contact wath sludge. Perform the following steps to
prevent corrosion,
(1) Set proper discharge intervals.
(2) Clean those portions when the bowl is opehed. _,- Sealing surface
, Main cylinder
Bowl body
1
Bowl hood
Sludge outletport ''
.
Fig.,l-1
4-1AsErrlecron lnstruotion
Manual Maintersr Lalld
Perform checks with special stess on the following portions on which sludge is deposited.
(1) Seat podnrr d mah cylirder.
(2) Slrdge dischdge port
(3) Heavy r,ryid c+|ar5er (SJ4OF-SJ80F).
Ncte: FfVFP/SH typ€s are the same value as F brpe.
a Ch€ck Drocedr-es
(1) Thoro€hly dean to remove deposits.
(2) Vrsualcheck
(3) tf anyhing Mo.rg was found under (1) and (2), perform color check test.
41.2 Corrective steps for corrosion
II , GAUTION
To prevent distortion of the base mate als and alleEtion of tfieh compositioh, never make
repairs bywelding cracks, pinholes or corroded pordons.
lf lhere is pitting in a part, remove the cofioded portion by a grinder. Perform visual check and color
check test for confirmation. lfthere is nothing wrong, continued use of the part is allowed. The margih
removable by a grinder should be limited to 0.5mm maximum (except the main cylinder for FO). After
grinding, do buffing (#250 or more).
a Vvhen there is a line defect lcrack).
. Vvhen more than 0.5mm grinder firishing is necessary,
it is necessary to replace the parts with new ones and perform balance adjustnents. Contact our
company of service agency.
AseLr.lecton hsutur H
E2
Ldntenance Manual
4.2.3 Disc 1
!\ ceurron
Do not make repairs by welding cracks, pinholes or
corrodEd
Replace the disc 1 with a new one
When corrosion is evident
When two or more adjoining aperture pieces are out
of position
When a crack is evident
Addition of disc
Over a long period ot service, the seating ol the disc
top disc. Add a disc, while referring to the Fig. 2-68
Points to note when handling disc (1)
Fig.4-2
(l) willcreate a gap between the disc (1) and
t
(1)
\21
(3)
a
!\ ceurror,r
a Stgre lhe cleaning agent in a cool, dark place.
When handling the cleaning agent, observe the lollowing points
a Never put the cleaning agent in your mguth.
o Wear protective glasses or prolective gloves, etc. to prevent eye or skin contaci.
a lf the cleaning agent was deposited on your skin, immediately wash away in water.
a Since the cleaning ageni containa an otganic solvent, make aure that the room is
ventilated well.
Remove the sludge deposited on the disc (1) by use of a cleaning oil and a waste cloth or a soft copper
wire brush. Avoid using a scraper or any other thing that damages the surface.
lmmerse the disc in our companys cleaning solution at 50 to 70"C for about 3 hours before cleaning.
The deposits will be easier to remove.
Asglrlgcron Instruction l\4anual 4-3 Mainleia,.E Maaual
4.2.4 Bowl body
(1) Clean the O dng g:cove. ii fie groove is
rough_ .epa.f 1 .r-i:r a ine emery cloth
i=320,. if.ou!..ess ca.not be repaired by
an emery ala:. co !.nachining to widen the
groove v/jca. s.cvided that the machining
margin is i-a:ed to 0.5mm maximum.
.2 lf the op€ratitg v?ater passage hole or any of
the -water pressure chambers is clogged
with scale. do dtorough cleaning.
13) When the bowt body was subjected to an
abnomal shock by allowing it to fall, or by
the fail of a healy object, let our company or
service agency check it.
CAUTION
tf the bowl body and bowr bush are in poof contact, vibration could occur. rf tne contact area ot
the contact surface is less than two thirds ot the whole, replace the bowl bush with a new one.
l7)
check the litted portions of the bowr body and bowr bush and check the condition ot contact with
the vertical shaft. Check to ensure that the contact area of the contact surface is more than 2/3
of the whole.
Check for scratches caused by slipping. lf there are scratches, remove the scratches with an
emery cloth (#320) and appty finishes with potishing paper (#600).
Check the threaded portion for the bowl nut. lf scoring is evident, make repairs with set files.
check the sludge discharge port for wear. If the wear is ress than o.5mm, conrinued use of the
port is allowed. lf the wear is more than that, Iet our company or service agency check jt.
Check the main cylinder sliding surface fof scratches. lf there are scratches, repair them with an
emery cloth (#320) and then appty tinishes wjth potishing paper (#600).
Check he knock pin for deformation. lf deformation is evident, replace the knock pjn wjth a new
one.
_t l
(
(5)
(6)
(8)
II
a ^-, -.-^-^- .-^JtrLFJEU t UH Insru(io- Vai_-a
Maintenance l\ranual
4.2.5 Bowl hood
Check the followjng portions of the bowl hood
for scratches.
(1) Bowl nut fitting portion
e) Bowl body fitting portion
(3) Threaded portion
(4) Light liquid chamber fltting portion
(5) O ring groove (when the O ring was
removed)
(6) Knock pin groove
lf there are scratches on the above-mentioned
portions, make repairs by use of set files,
grinding stone, emery cloth (#320), etc.
4-2,6 Main seal ring
Fig. 4.4
D
Wjth the main seal ring mounted on the bowl hood, clean
and carefully check the seal surface. Normally, the main
seal ring is deformed as shown jn Fig.4_5. In the followjng
cases, replace the main seal ring with a new one.
(1) When dimension A is O.smm ormore
(2) When the seal surface is galled by metajlic power
more than 6070 of its length B.
Fig.4-5
NOTE
When the main seal ring ia removed, use care not to damage its bowl hood side groove
(especially ihe side surface). Damaged groove cause a leakaqe.
ASerr;eCrOR h.rrt^,"r''"" i/"^,"1
4-5 Mainteiaice Maxrd
'',f
4,2.7 Distibutor
(1 ) lf the top end of the key is deformed, correct or replace
(2) Check the threaded porton for scratches.
(3) check the knock pin which might have been deformed.
4.2.8 Varlous types of O rlngs of bowl
Recommendation is to replace the O rings in keeping with the bowl
opening intervals. Before installing an O ring, be sure to clean llle
O ring groove.
( 1).
-: n''
ELFJECTOR lrs|.Eln krld
,:--,
\.r,-;- -- r\J
- Frgr +6
Maintenance l\4anual
t
1-6
4.2,9 Main cylinder
(1) Check the seal surface (that
surface which makes contact
with the main seal ring) for
scratches. lf there are scratches,
damage to the main seal ring and
leakage of sealing water will
result, making normal operation
impossible- Scratches are often
made on the suaface at the time
Fig. 4-7
ofdisassembly. Thereforc, be careful when handling it.
In the case of the main cylinder for lubrication oil, repaif small scratches by use of an oil
stone or something else. ln the case of the main cylinder for fuel oil (C heavy oil), contact
our company or setuice agency, as the seal sudace has a special coating.
(2) Check the bowl body sliding surface for scratches. lf there are scratches, the O ring will
wear down ea.lier. Repair the scratches with an emery c,oth (#320) and then apply finishes
with polishing paper (#600).
(3) Clean the O ring groove. lf the groove is rough, make repairs with an emery cloth.
4.2.10 Pilot valve assembly
(1) Check the valve guide and bowl body sliding
surfaces fof scratches. lf therc are small scratches,
make rcpairs with an oil stone or something else.
When the pilot valve assembly is disassembled and
reassembled, use care to prevent damage to the O
ring.
(Apply a lubricant to the sliding surfaces fof easier
reassembly.)
(2) Check the seal surface (that surface which makes
contact with the valve sheet) fo. scratches. lf there
are small scratches, make repails with an oil stone
or something else.
(3) Take out the valve sheet from the valve guide, and
clean and carefully check the seal surface.
lf the valve sheet has caught a foreign substance or
1 is deformed.(0.3mm or more), replace it with a new
(2),(3)
Fig.4-8
one.
(4) After cleaning and before installing in the bowl,
complete the pilot valve assembly and chreck to
ensure that pjlot valve is rnbved smoothly by hand.
o
I
(2) , (3)
i-
AserrleCrOn Instruction l\.,lanual
4-7
Maintenance lranual
4.3 Vertical shaft system
4.3.1 Vertical shaft
(''1) Carefully check the portion above the upper bearing fitting portion
as there is a high likellhood of corrosion lf the dimension A shown
in Fig. 4-9 is more than ''lmm smaller in diameter than the value
shown in Table 4-1, rePlace the vertical shaft with a new one
tr1/a\ ff\v/
ii1/\''l-!
it
---
-;-
Fig.4-9
\2)
(4)
FH/FP/SH types are the same value as F type (mm)
lf tnere a''e Pamal scratches In tne bowl bush fltthg portion ''nake
repairs with set fles or an emery cloth (#320)'' lf there is a ring-like
continuous groove flaw, replace the vertical shaft with a new one''
lf there is a localized flaw like a pounding in the threaded portion
make repairs to smooth it out'' using set files, emery cloth (#320)''
etc.
(6) +
(6)
t(5)
(4)
(5) lf the pinion tooth surface is roLlgh and is lightly worn'' make repairs
4.3.2 UPPer sPings
(1) If there is even a broken or cracked upper spring'' replace all of
them with new ones''
(2) Measure the froe length of 6ach of the upper springs lf any of
them is more than 1mm shorter than the dimension A'' replace all
:. of the upper springs slx LrpDer springs equal in free length
f ,Cim.nsron A) are grouPed as a set {Refer to Table 4-2 I
| ''>,.
wiih setfiles, emery cloth (#320), oilstone etc
(6) Measure the runout of the shaft center in three places'' the straight portion at the end of the shatt''
the middle portion of the shaft and bearing fitting portion with the upper and lower bearing fittrng
porhons supporled by ihe measunng jigs The runout should be limitld tQ 5/100mm maximum lf
the runout is larger than that replace the vertical shaft with a new one
- .--
ln regad to the secLllar wear
inner race of the bearlng sllps,
of the beering fitting portion, if the
replace the vertical shaft with a new
Table 4-2
Model No.
SJ15F
SJ40F SJSOF
sJ100F
Dimensron A 34 44 46
FH/FP/SH Wpes are the same value as F type
Flq.4-10
\)
\t,-"-//
Table 4-1
SJSOF
sJ100F
SJlOF
SJ15F
l\,4odel No.
Dimension A
lnstruciion Manual 4€
tmm)
Maintenance IVlanual^"=01]t-o
_)
4.3.3 Lower bea.ing block
lf the dimensjon A shown in Fig.
.etainer, steel ball and bearing case
1mm smaller than the value shown
these parts, and replace a defedive
Fig. 4-11, Tabte 4-3)
4-11 with the lower spring
(2) put together is more than
in Table 4-3, re-check all of
part with a new one. (Refeato
Table 44
(mm)
I 7- Tabre 4-3
FH/FPISH types are the same value as F tvoe. (mm)
4.3.4 Flat spring
(1) A broken or cracked flat spring should be replaced
with a new one.
(2) l\4easure the spring height as shown in Fig. 4-12. tf it
is less than the A mm, replace the ffat spring with a new
one. (Refer to Table 4.4)
a\l''"1
l---s{
Fig. 4-12
til,
i.oJ
Fig. 4.13
Fig.4-11
[4odel No. SJlOF
SJl5F
SJ3OF
lsJ40F
SJ50F
SJ8OF
SJl OOF
Dimension A 4.5
FH/FP/SH types are the same value as F type.
4.3,5 Steel ball
A steel ball wjth a deep rjng,tike g.oove flaw in those portions which ma
contact with the lower spring retainer, etc. or a deformed one should
replaced with a new one.
4.3.6 Lowerspring
drmension A, replace the lower spring. (Refer to Table 4_S)
Table 4-5
Model No. SJl OF
SJ15F
SJ30F
SJ40F
SJ50F
SJSOF
sJ100F
Dimension A 60.5
FH/FPISH types are the same value as F type. (mm)
ke
be
l
(''l ) A broken or cracked lowerspring shoutd be replaced with a new one.
(2) Measure the free length. lf it is more than 1mm smaller than the
l,4odel No. SJlOF
SJ15F
SJ3OF
SJ4OF
SJ50F
SJSOF
SJ lOOF
Dimension A 71.5 M.5 90.5
As er-rl Ecron r n"t.af iii,.,a- Mainter€rEe Matal
l+ -4r A:
4,3.7 Heighl of verlical shaft
!\ wanHna
It the height of the vertical height is out ot the slandard
limib Cfable 4{), re.check the vertical shaft sysiem to
locate the cause. ll the cause cannot be located, do nol
operate the machine but contact our company or
seruce agency.
After installation of the vertical shaft, the standard height shown
in Fig.4-14 should be as shown in Table 4-6.
Fig.4-14
FH/FP/SH types are the same value as F type. {mm,
! l-v
4.3.8 Instalted heighl of tlat spring (adiustment of spacer)
When the parts like the lower spring retainer, bearing case, steel ball and flat spring have been
replaced, or when the installed height of the flat spring (dimehsion A of Fig. 4-15) is out of range the
dimension A of Table 4.7, change spacers (1) to adjust the compression force of the flat spring.
Table 4-7
Model No. SJ10F-SJ100F
Dimension A 0.5-''1.0
FH/FP/SH types are the same value as F type.
t
i\,,-
,r11t,/F 0-r )-\|-;
, ,t llLL''.:t O ring Spring case
Bealng case 1t1 Bearing housing (1)
Fig. +15
Model No. SJl OF
11311.0 120r 1.0Dimension A 80t 1.0 130r 1.0
Dimension B 74t1.0
,,Vertical shaft
l-)/ spacer ,Flat spring
Asgngcron Instrudici'' vanEl +10 Maifienanc€ Manual
,1,
4.4 Horizontal shaft system
4.4.1 Spiralgear
(1) The life of the spiral gear cannot be sweepingly
determined, as it depends on various conditions. For
general guidance, however, consider that the Jife of the
spiral gear is over when it is in good contact and is
normally worn to the extent that the groove width is
reduced to 2/3 (about 3mm)of the normal dimension. f
the spiral gear is worn more than that, replace it with a
new one.
(2) During initial operation or when the spiral gear has
been replaced, its wear will be temporarily accelerated
untilthe contacting surfaces of the gear are seated. A
while later the wear will cease to be acceldrgted. This
is a normal phenomenon.
lf the wear is excessively accelerated, something
wrong is suspected in the other parts. Check the other
parts.
(3) lf there are bu.rs or high spots on the tooth surface,
remove them with set files or emery cloth (''#320).
4.4.2 Ho?izontalshaft
(1) lf there is a localized flaw like a pounding on the
threaded portion, make repairs to smooth tt oul, usrng
set files, emery cloth {#320), etc.
(2) In regard to the secular wear of the bearing fitting
portion, if the inner race slips, replace the horizontal
shaft with a new one.
(3) lf the key-way is wider because of wear, replace the
horizontal shaft with a new one.
Up to iwo thirds -(app
rox. 3mm) of thenor|1lal
d ine ns ion.
Fig.4-16
(1) /a\ (2)t_il
r\l Collar(1)
FiE. 4_17
4.4.3 Collar
lf the diameter of the oil seal and collar sliding surface is more than O.5mm worn than the specified
dimension, replace the collar with a new one. (Retbrto Table 4-8)
Table 4-8
SJlOF
SJ15F
SJ3OF
SJ4OF SJBOF
SJl OOF
l\4otor side {1) 45 55
Gear oumD side 12) 45 50
FH/FPISH types are the same value as F type. (mm)
Collat(2)
t-
ASefflgCfon lnrtrr"tionj,r",",.,"l N,la:.:e-a-:e l,la ra
I
4,4.4 Friction block
The life of the fiction block cannot be sweepingly
determined, as it depends on the frequency of siarts
and stops. lf any of the linings 6mm thjck is worn to
3mm, replace all of the blocks.
(Fig.4ng)
4.4,5 Friction pulley
Check the inside surface of the triction pulley for wear. lf it is
worn more than 1mm, replace it with a new one. (Fig,4-19)
The inside surface of the friction pulley allows machining up to
1mm deep to eliminate roughness.
Fig. 4.18
4,5 Gear pump'':
4.5.1 Safery ioint
Check the gear pump visually for distortion, wear, damage, etc.
without being removed, and replace if necessary. Fig.4-19
4.5.2 Drive gear, driven gear and bush
lf the shaft is producing abnormal sound, disassemble the gear pump, and check whether the gears
are jn good contact, the spacing between the shaft and bush, wear or foreign substances which
might have been caught. lf there are small scratches, repair the tooth surfaces with an oil stone.
ll repairs cannot be made, replace.
4.5.3 Valve stem
When the capacity is insufficient or the suction is impossible, it
is otten due to foreign substances caught by the valve stem.
Disassemble and thoroughly clean. In this case, it is necessary
that the position of the adjusting screw (dimension A ot Fig.
+20) is confrrmed beforehand (adiusting pressure O.4l\4pa
{4.0k9/cm1). ll the screw is over-tightened, the pressure wi
become needlessly high, and overload could result. lf it is
under-tightened, a poor suction will result. Fig.4-20
tJ
^i
,ISELFJECTOR lnstrutur U''rd.4
+12 Maintenance Manual
4.6 Lubricant
. For information on the lubricant replaceme;t intervals,
refer to Section 3-2.
a For information on the lubricant replacement procedures.
refer to Section 3.4 in Operation Manual 1.
4.7 Brake equipment
The life of brake lihing cannot be sweepingly determined, as it
varies widely, dependjng on the number of times it has beeh used.
It is therefore necessary to check the brake lining at regular
intervals. lf the brake lining 1omm thick is worn to Smm. reDlace the
brake lining with a new one.
4.6 Water supplying devlce
The water supplyjng device is designed to supply operating water
to the bovvl opening and closing mechanism which automatically
discharges lh6 sludge accumulated jn the oowr.
lf it is clogged by scale or th€ gasket or O ring is damaged, a low
water pressure or a low water flow rate will result, and the
mechanism mightfailto open or close the oowr.
When the bowl is disassembled, be sure to check and clean the
water supplying device.
ELFJECTOR Instuction Manual
Flg.1-22
-itttgnCoaegrd''t-,,.
t+13
4.9 Inspection of protective equipment
Check to ensure that a detector alarm is correcty output.
4.9.1 Leakage Monitor (LM)
The Leakage Monitor essentially determines that the outflow is abnormal as it detects the fall of the
pressure at the outlet side ofthe SELFJECTOR. Create lhis state by simulation.
(1) Ch6ck that the SELFJECTOR is in automatic operation and that the liquid is being fed.
(2) Loosen the plessurqclDtrol valve at the light liquid outlet side to reduce ihe pressure. Reduce the
pressure to a level below a Pressure Drop (Ap) from Set Pressure.
(3) Check to ensure that an alarm is output after the elapse ofthe set time ofthe feeding timer.
4.9.2 Discharge Detector (DD)
!\ cnurrou
When alarm check is performed by the following procedures, the machine will come to a stop
without discharging the oilfrom inside the bowl. When the machine is restarted and the sludge
is discharged, the oil will flow out. Therefore, perform operatlons witfi due consideration to
safety.
YJ(
(1) Check to ensure that the SELFJECTOR is in automatic operation and that the liqu,d is being fed.
(2) Close the source valve ofthe operating water solenoid valve unit to stop the supply of all opefating
(3) Press the "DISCHARGE TEST" bLttton ofthe controlpanel.
(4) Check to onsure that an alarm is output after the elapse of the discharge process tjme.
Jl,
Asrrrlgcroa lnstruo- \ta-ra Maiate''1ance Manual
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