Klargester Biodisc BB - Self Repair

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Mark Townshend

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I have recently purchased a Cottage, the previous owner had died a year or so ago, and the Sewage plant (a Klargester Biodisc BB) has been neglected for some time.

The Motor is missing along with the belt.
The Nylon bearings (Bushes more like) at each end are rather worn so there is a lot of play in the shaft.

Has anyone replaced the bushes on one of these?
The drive end looks easy enough, unbolt the drive pulley, slide of the bush, and install a new one.
The non drive end is tucked down the side of the disc close to the back of the enclosure.
This is a 2 part bush.
Does the entire disc assemble need lifting out to do the bushes?
 
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Well, answered my own question today.
Yes the rotor needed to come out.
The sump for the driven sprocket has been flooded and the bolts all rusted out.
Whoever serviced it last put the bearings on the wrong ends - 1 part on the non drive end, and the 2 part on the drive end.
Made a Pergola and used a couple of chain blocks to pull it out.
IMG_20210225_152951_838.jpg
 
Good thinking, and a lot cheaper than a crane! (We have some huge ones serving small villages, attended a job where they need to lift the disc assembly out for repairs. Weight was estimated at 7 tonnes, crane was on its limit of 11 tonnes when it picked the disc assembly up!)

Any option for greasing the bearings/bushes to prolong their life? Simple and effective plants, look after it and it'll look after you.
 
Question to Mark. If the bearings had been installed correctly, should it be possible to replace them and the drive pulley without lifting the bio disc out of the tank. Our unit is working, but the bearings are quite worn, have obtained the replacements and am considering how best to tackle the job. Thanks.
 
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From the parts diagram the one piece bush is on the drive end, probably as it has more load on it with the belt tension.
So you would need the pulley of to change it, and my bolts were so rusty I had to grind them off.
The pulley actually runs within the water level of the outlet section, in a sump so awkward to get at the bolts.
Definitely a job to do after the tank is emptied.
The non drive end I could lift up enough to put bushes on but it's awkward with 1 foot on each ledge and leaning over the disc.
Drive end is easily accessible if you can get the pulley bolts put. (My sump was full of water, so didn't help the bolts!)
 
Thanks for that Mark, from looking at the drawing I thought it should be possible if somewhat awkward. Will give it a go and hope that my bushes are the right way round. Have got a new set of pulleys and drive belt, so no probs to grind off old bolts if necessary.
 
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