Instruction Manual
Alfa Laval GJ 10
Covering: Standard Machines First published: 2015-07
ESE032025-EN1
2015-07
Original manual
Page 1: ...Instruction Manual Alfa Laval GJ 10 Covering Standard Machines First published 2015 07 ESE032025 EN1 2015 07 Original manual ...
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Page 3: ...lution Leakage 14 5 4 Poor Cleaning Performance 15 5 5 Recommended Cleaning 16 6 Maintenance 17 6 1 General Maintenance 17 6 2 General Dismantling Setup 18 6 3 General Dismantling 19 6 4 Inspection and Service of Components 20 6 5 Reassembly 23 7 Technical Data 25 7 1 Technical Data 25 7 2 Performance Data 26 7 3 Dimensions 27 7 4 Trax Simulation Tool 28 8 Parts List and Service Kits 29 8 1 AL GJ ...
Page 4: ... 100 to X xxxx is in conformity with the following regulations and directives with amendments The Machinery Directive 2006 42 EC DS EN ISO 12100 2011 The Pressure Directive 97 23 EC According to its own volume and the rated pressure range the product is regarded an Article 3 paragraph 3 Equipment The person authorised to compile the technical file is the signer of this document Executive VP Operat...
Page 5: ...cleaning machine 2 1 Important Information WARNING Indicates that special procedures must be followed to avoid serious personal injury CAUTION Indicates that special procedures must be followed to avoid damage to the tank cleaning machine NOTE Indicates important information to simplify or clarify procedures 2 2 Warning Signs General warning Dangerous electrical voltage Caustic agents ...
Page 6: ...n an Alfa Laval Gamajet is operating there should be covers over every tank opening These covers should be sealed well enough to withstand the full force of the jet striking the cover plate If the cleaning solution were hot corrosive or toxic a leak would present a serious hazard to any personnel in the immediate vicinity or to any exposed electrical equipment Warning Any tank cleaning machine can...
Page 7: ...r high pressures and or flow rates The performance capabilities of these options are detailed in Section 7 Technical Data 3 2 Intended Use It is to be verified by the end user That the tank cleaning machine is in conformity with respect to tank vessel or container size in which it will be used That the construction materials both metallic and non metallic are compatible with product flushing media...
Page 8: ...UTION Alfa Laval cannot be held responsible for incorrect unpacking Check the delivery for 1 Complete Cleaning Machine 2 Delivery note Step 2 Remove any packing materials Step 3 Inspect the tank cleaning machine for visible transport damage Inspection ...
Page 9: ...torage tanks USTs Alfa Laval Gamajet recommends the use of its UST Lance or Hose Insertion Assembly Either device will ensure a proper insertion depth sealing of the riser pipe Also the UST Lance includes a lanyard loop that provides a means to attach a safety line between the Alfa Laval GJ 10 UST Lance and the safety loop on the Alfa Laval Gamajet We do not recommend attaching the machine to a ho...
Page 10: ... Gamajet pumps valves and other system components Filters properly installed and maintained will more than pay for themselves with lower overall operating costs in these applications Furthermore to ensure that clogged filters or strainers are cleaned we recommend using automatic self cleaning models Step 9 Capacity of Supply Pump The Alfa Laval GJ 10 can be used with either a centrifugal or positi...
Page 11: ...energy recovery Plastics should be recycled or burnt at a licensed waste incineration plant Metal straps should be sent for material recycling Maintenance All metal parts should be sent for material recycling Scrapping At end of use the equipment must be recycled according to relevant local regulations Beside the equipment itself any hazardous residues from the process liquid must be considered an...
Page 12: ...med in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Gamajet To ensure the longest possible life of the machine please verify the operating conditions and most importantly the machine s cycle time The cycle time can be measured by first picking a fixed point inside of a vessel as a reference and second timing how long it takes the same nozzle to pass b...
Page 13: ...onents Damaged Planetary Gearhead pos 12 Section 6 4 Inspection and Service of Components Worn Tee Housing Bearing pos 20 and Nozzle Housing Bearings pos 22 Section 6 4 Inspection and Service of Components Worn Tee Housing Cup pos 21 and Nozzle Housing Cup pos 23 Section 6 4 Inspection and Service of Components Does only Tee Housing pos 4 index Worn Tee Housing Bevel Gear pos 14 or Nozzle Housing ...
Page 14: ...ine to run normally with the Nozzles reinstalled Step 3 Debris Inside Remove the Collar 8 and then lift out the Stator 9 Look for and remove any debris caught in the Stator 9 and the vanes of the Rotor 10 Remove any material wound around the Rotor Shaft 20 In addition check for any debris caught in the outlet holes of the Stem 3 the nose of the Tee Housing 4 the Nozzle Housing 5 and the Nozzles 7 ...
Page 15: ...ating is necessary also check that the solution is at the proper temperature Plugged Nozzles Unscrew the Nozzles 8 and inspect for any debris Slow or no Rotation of the Housings This will result in partial or erratic washing coverage Refer to previous sections for more information Alfa Laval GJ 10 Configuration Determine if the deposit being cleaned requires greater jet impact or longer jet dwell ...
Page 16: ...mended Cleaning Step 1 Always handle lye and acid with great care Caustic danger Always use rubber gloves Always use protective goggles Step 2 Never touch the pump or the pipelines when sterilizing Step 3 Danger of burns Always rinse well with clean water after using a cleaning agent NOTE Cleaning agents must be stored disposed of in accordance with current regulations directives Always rinse Clea...
Page 17: ... Always keep Minor spare parts kit in stock 6 1 General Maintenance Step 1 Always read the technical data thoroughly see chapter 7 Technical Data Step 2 Recommended spare parts Order service kits from the service kits list See 8 10 Minor Service Kit 8 11 Major Service Kit Ordering spare parts Contact your local Alfa Laval Sales company ...
Page 18: ...ulated wash water that could adversely affect the O rings during prolonged contact in storage The best position to store the machine is to stand it up with the inlet connection facing down Step 3 External Inspection Intervals Before every shift the Stator 10 and the Nozzles 8 should be inspected for debris Examine the 10 by loosening the Collar Set Screw 27 while holding on the flats of the Cap 2 ...
Page 19: ...g 19 from the nose of the Tee Housing 4 Remove the inner Nozzle Housing Seal 25 and Bearing 22 Step 3 Cap and Geartrain Using pliers on the flats of the Cap 2 unthread it from the body drawing 15 Warning Hold or turn on Stem 3 DO NOT hold or turn on Tee Housing 4 or Tee Housing Cap 13 Doing so will damage the Geartrain drawing 10 Pull the Geartrain drawing 10 from the remainder of the body Step 4 ...
Page 20: ...re removed remove them at this time Warning To reduce the likelihood of scratching any sealing surface use a pick made from brass Inspect the 39 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required Turn to drawing 6 Using a 2 Phillips screwdriver unscrew the Gearhead Short Screws 47 from the Gearbox 1 Remove the Pla...
Page 21: ...put Shaft Retaining Ring 45 using a small slotted screwdriver Pry out the old 45 using a brass pick and replace it with a new one Ensure that the seal is square to the Gearhead Lower Bearing Housing 18 when installing it The new 38 should be installed with the spring facing out and visible after it is installed Reinstall the 45 Drawings 17 21 Nozzle Housing Turn to drawing 19 Unscrew the Nozzle Ho...
Page 22: ... but the Cups 21 should be replaced if they are grooved in the seal contact area A good maintenance program will require replacing many 21 therefore it may be worthwhile to make or obtain press tools for pressing a 21 out of the 4 The press tools are available from Alfa Laval Gamajet Equipment Before installing a new 21 clean the housing bores and remove any burrs resulting from 21 removal Press t...
Page 23: ...ing 6 by using equal pressure around parts They will snap into place Turn to drawing 10 Place the Rotor 35 drawing 9 over the end of the Input Shaft 36 Install the Input Shaft Lockwasher 58 and Nut 59 using an 11 32 socket Hold the 35 stationary with a pair of pliers while tightening the 59 Place the Output Shaft 11 into the output side of the Geartrain drawing 10 Ensure the slot of the 11 is alig...
Page 24: ... with the hole in the 22 Using the 7 22 assembly push the 25 into the annular space between the 4 and Nozzle Housing Cup 23 Using a slotted screwdriver screw the Nose Plate Screws 28 and Washers 29 into the 4 Drawing 22 Completed Assembly Rotate the Rotor 35 using a Hex Key It should spin easily and its veins must not strike the walls of the Cap 2 Continue turning the 35 several dozen times The No...
Page 25: ...ded pressure F3 5 18 5 bar 50 270 PSI Cleaning Pattern First Cycle Full Pattern The above drawings show the cleaning pattern achieved on a cylindrical horizontal vessel The difference between the first cycle and the full pattern represents the number of additional cycles available to increase the density of the cleaning Certificate 2 1 Material Certificate PHYSICAL DATA Materials 1 4404 316L PPS F...
Page 26: ...chnical data during installation operation and maintenance Inform personnel about the technical data 7 2 Performance Data It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data ...
Page 27: ... important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 7 3 Dimensions Dimensions A B C D E F G mm 272 204 93 42 98 100 138 in 10 7 8 3 7 1 7 3 9 3 9 5 4 ...
Page 28: ... specifications TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ 10 performs in a specific tank or vessel The simulation gives information on wetting intensity pattern mesh width and cleaning jet velocity This information is used to determine the best location of the tank cleaning device and the correct combination of flow time and pressure to implement A TRAX de...
Page 29: ...8 Parts List and Service Kits 29 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 1 AL GJ 10 View GJ1000 ...
Page 30: ... 1 Input Shaft Upper Bearing Housing Drawing 2 Input Shaft Lower Bearing Housing A Press Fit A Press Fit B Spring Drawing 3 Input Shaft Drawing 4 Gearhead Assembly 12 A Press Fit A Typical Note The 56 must be completely perpendicular to the 36 or it will not press on correctly and damage the 56 or 36 GJ1001 GJ1002 GJ1003 GJ1004 ...
Page 31: ...awing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 3 Assembly Drawings 5 6 7 8 9 10 Drawing 5 Gearhead Drawing 6 Gearbox A Drawing 2 A Drawing 5 B Drawing 3 Drawing 7 Gearhead Lower Bearing Housing A Press Fit B Spring GJ1005 GJ1006 GJ1007 ...
Page 32: ...ts 32 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Drawing 8 Geartrain Housing A Drawing 1 B Drawing 6 C Drawing 7 D Spring Drawing 9 Rotor Drawing 10 Geartrain A Press Fit A Drawing 9 B Drawing 8 GJ1008 GJ1009 GJ1010 ...
Page 33: ...ts List and Service Kits 33 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 4 Assembly Drawings 11 12 13 14 15 Drawing 11 Stem A Spring B Press Fit Drawing 12 Tee Housing A Press Fit GJ1012 GJ1011 ...
Page 34: ...ows Alfa Laval GJ 10 Tank Cleaning Machine Drawing 13 Stem Base A Press Fit Drawing 14 Tee Housing Bevel Gear Drawing 15 Body Assembly A Press Fit A Drawing 11 B Drawing 14 C Spring D Drawing 12 E Drawing 13 F Left Handed Thread GJ1013 GJ1014 GJ1015 ...
Page 35: ...8 Parts List and Service Kits 35 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 5 Assembly Drawing 16 Drawing 16 Install Geartrain and Cap A Drawing 10 B Drawing 15 GJ1016 ...
Page 36: ...ank Cleaning Machine 8 6 Assembly Drawings 17 18 19 20 Drawing 17 Nozzle Housing Drawing 18 Nozzle A Press Fit A Part will stick out when installed Drawing 19 Nozzle Housing Assembly Drawing 20 Nose Plate A Drawing 18 A Press Fit B Drawing 17 GJ1018 GJ1017 GJ1019 GJ1020 ...
Page 37: ...8 Parts List and Service Kits 37 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 7 Assembly Drawing 21 Drawing 21 Install Nozzle Housing A Drawing 16 B Drawing 19 C Drawing 20 D Spring GJ1021 ...
Page 38: ...8 Parts List and Service Kits 38 The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine 8 8 Assembly Drawing 22 Drawing 22 Completed Assembly A Drawing 21 GJ1022 ...
Page 39: ...2 24 9614645401 10 135 Tee Housing Seal 2 25 9614645601 10 136 Nozzle Housing Seal 2 26 9614646201 10 146 Stem Screws 4 27 9614646601 10 150 Collar Set Screw 1 28 9614646701 10 151 Nose Plate Screw 2 29 9614646801 10 152 Nose Plate Washer 2 30 9614646901 10 153 Nozzle Housing Taper Cap Screws 2 31 9614647001 10 154 Planetary Gearbox Screw 4 32 9614647201 10 160 Stream Straightener 2 33 9614647401 ...
Page 40: ...2102 643 V Nozzle O ring Viton 2 55 4 9614662101 643 T Nozzle O ring Teflon 2 56 9614674601 8 512 Input Pinion 1 57 1 9614677701 8 539 Input Shaft Lower Bearing Housing O ring Viton 1 57 2 9614677702 8 539 EP Input Shaft Lower Bearing Housing O ring EPDM 1 57 3 9614677703 8 539 K Input Shaft Lower Bearing Housing O ring Kalrez 1 58 9614678201 8 544 Input Shaft Lowckwasher 1 59 9614678301 8 545 Inp...
Page 41: ...O RING KALREZ 2 EACH 56 9614674601 8512 GJ V VIII INPUT PINION 1 EACH 57 1 9614677701 8539 GJ V GB NS VIII RSLBH O RING 1 EACH Article no 9614689301 10KALREZKIT ALFA LAVAL GJ 10 KIT KALREZ Pos no Part No Gamajet Part No Description No 20 9614644601 10131 GJ 10 TEE HOUSING BEARING 2 EACH 22 9614644901 10133 GJ 10 NOZZLE HOUSING BEARING 2 EACH 24 9614645401 10135 GJ 10 TEE HOUSING SEAL 2 EACH 25 961...
Page 42: ...OUSING CUP 2 EACH 23 9614645301 10134 GJ 10 NOZZLE HOUSING CUP 2 EACH 36 9614607401 E822A GJ VIII ROTOR SHAFT ASSEMBLY 1 EACH Article no 9614689401 10KALREZMAJKIT ALFA LAVAL GJ 10 MAJOR KIT KALREZ Pos no Part No Gamajet Part No Description No 20 9614644601 10131 GJ 10 TEE HOUSING BEARING 2 EACH 22 9614644901 10133 GJ 10 NOZZLE HOUSING BEARING 2 EACH 24 9614645401 10135 GJ 10 TEE HOUSING SEAL 2 EAC...
Page 43: ...lated rights It is the responsibility of the user of this document to comply with all applicable intellectual property laws Without limiting any rights related to this document no part of this document may be copied reproduced or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise or for any purpose without the expressed permission of Alfa Laval Corpor...
