Instruction Manual
Alfa Laval GJ A2
Covering: Standard Machines First published: 2015-07
ESE032025-EN1
2015-07
Original manual
Page 1: ...Instruction Manual Alfa Laval GJ A2 Covering Standard Machines First published 2015 07 ESE032025 EN1 2015 07 Original manual...
Page 2: ......
Page 3: ...3 5 3 Cleaning Solution 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 Ins...
Page 4: ...X 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...
Page 5: ...leaning 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 avoi...
Page 6: ...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 clea...
Page 7: ...at 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...
Page 8: ...TION 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 cleani...
Page 9: ...1 4 camlock plug is available Appropriate tri clamp gaskets and clamps are required for the wash fluid 2 adjustable tank connection is standard Step 4 Mounting Before attaching the supply plumbing to...
Page 10: ...the Alfa Laval GJ A2 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 Step...
Page 11: ...nergy 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 re...
Page 12: ...ument indicates how the machine performed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Gamajet Equipment To ensure the longest possible life of the Al...
Page 13: ...Input Pinion pos 6 Section 6 4 Inspection and Service of Components Damaged Planetary Gearhead drawing 8 Section 6 4 Inspection and Service of Components Worn Upper and Lower Tee Housing Bearing pos...
Page 14: ...the bottom of the Stator 4 is too large the Tee Housing 39 will not turn Look for restrictions in the fluid supply such as a clogged filter kinked hose or deposits in the piping Step 4 Tight Clearance...
Page 15: ...Alfa Laval Gamajet Equipment if assistance is required Chemical Concentration and Temperature Verify that the cleaning solution is the correct compound and in the concentration needed for the deposit...
Page 16: ...ended 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 Ste...
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...
Page 18: ...ed wash water that could adversely affect the Seals and O rings during prolonged contact in storage Step 3 External Inspection Intervals Before every shift the Stator 4 and the orifices of the Nozzle...
Page 19: ...The 35 is a Left Hand Thread Unscrew the Tee Housing Assembly drawing 12 from the Flow Thru A2 Stem 50 Tip Again this is a Left Hand Thread Unscrew the Nozzle Housing Cap 41 with a slotted screwdrive...
Page 20: ...ntil it comes free If the Dowel Pin 52 that is inserted into the Output Shaft Assembly drawing 3 is bent it should be replaced The 44 and the 52 must be removed in order to further disassemble the Gea...
Page 21: ...nable to accomplish this complete assemblies are available from Alfa Laval Tank Equipment Inspect the 21 for signs of scoring and wear Replace the 21 if wear or scoring has visually decreased the diam...
Page 22: ...ver the 24 Align the smallest holes in the gasket over the small through holes for the Upper Stem Small Screws 28 Place the Upper Stem 1 8 holes down toward the 24 6 holes up over this assembly being...
Page 23: ...led back into the gearhead in their original order Place the Planetary Gearhead Top Washer 29 onto the top layer of Planet Gears 15 drawing 5 Position the Body Gasket 32 over the Upper Stem 1 aligning...
Page 24: ...40 Rotate the Tee Housing Assembly slightly to mesh the Bevel Gears 45 and 46 Failure to ensure that the Bevel Gears have properly mated could damage them Place the 49 onto the nose of the 39 push it...
Page 25: ...0 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 rep...
Page 26: ...7 Technical Data 26 It is important to observe the technical data during installation operation and maintenance Inform personnel about the technical data 7 2 Performance Data...
Page 27: ...ant 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 H mm 503 343 431 31 30 47 47 61 in 19...
Page 28: ...specifications TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ A2 performs in a specific tank or vessel The simulation gives information on wetting intensity patter...
Page 29: ...8 Parts List and Service Kits 29 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 1 AL GJ A2 View GJA200...
Page 30: ...val GJ A2 Tank Cleaning Machine 8 2 Assembly Drawings 1 2 3 4 5 6 7 Drawing 1 Gearhead Upper Flange Drawing 2 Gearhead Lower Flange A Press Fit A Press Fit Drawing 3 Output Shaft Drawing 4 Planet Gear...
Page 31: ...val GJ A2 Tank Cleaning Machine Drawing 5 Planet Gear A Press Fit Drawing 7 Rotor A Press Fit Drawing 6 Input Shaft A Press Fit Note The 6 must be completely perpendicular to the 9 or it will not pres...
Page 32: ...Service Kits 32 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 3 Assembly Drawing 8 Drawing 8 Planetary Geartrain A Drawing 7 E Drawing 5 B Drawing 1 F Drawing 3 C Drawing 6 G Drawing 2 D...
Page 33: ...nd Service Kits 33 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 4 Assembly Drawings 9 10 11 12 Drawing 9 Stem Drawing 10 Stem Cap A Press Fit Drawing 11 Nozzle Housing A Press Fit GJA209...
Page 34: ...8 Parts List and Service Kits 34 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Drawing 12 Nozzle Housing A Drawing 9 B Drawing 11 C Large Chamfer on Flange D Drawing 10 GJA212...
Page 35: ...8 Parts List and Service Kits 35 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 5 Assembly Drawing 13 Drawing 13 Tee Housing Cap A Drawing 12...
Page 36: ...8 Parts List and Service Kits 36 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 6 Assembly Drawing 14 Drawing 14 Stem and Cap A Drawing 8 B Drawing 13...
Page 37: ...8 Parts List and Service Kits 37 The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine 8 7 Assembly Drawing 15 Drawing 15 Completed Assembly A Drawing 14...
Page 38: ...3 E Collar Small O ring EPDM 1 26 2 9614626902 6 153 V Collar Small O ring Viton 1 26 3 9614626903 6 153 Z Collar Small O ring Kalrez 1 27 1 9614627001 6 154 E Collar Large O ring EPDM 1 27 2 96146270...
Page 39: ...pper Bearing 1 55 9614636001 7 440 Tee Housing Bevel Gear Pin 1 56 1 9614637001 7 461 E Tee Housing O ring EPDM 1 56 2 9614637101 7 461 K Tee Housing O ring Kalrez 1 56 3 9614637201 7 461 V Tee Housin...
Page 40: ...cs 58 1 9614686501 7751E GJ VII STEM CAP SMALL O RING 1 pcs 61 2 9614662003 422170 642 3E GEARBOX STEM O RING E 3 pcs Article no 9614695401 7NJFTK ALFA LAVAL GJ A2 KIT KALREZ Pos no Part No Gamajet Pa...
Page 41: ...UPPER TEE HOUSING LAB SEAL 1 pcs 48 9614693701 7233 ALPHA FP NOZZLE HSG BEARING 1 pcs 49 9614693801 7233MD NANOJET NOZZLE HSG BEARING 1 pcs 56 1 9614637001 7461 STEM CAP O RING EPDM 1 pcs 58 1 961468...
Page 42: ...PER TEE HOUSING LAB SEAL 1 pcs 48 9614693701 7233 ALPHA FP NOZZLE HSG BEARING 1 pcs 49 9614693801 7233MD NANOJET NOZZLE HSG BEARING 1 pcs 56 2 9614637101 7461K STEM CAP O RING KALREZ 1 pcs 58 2 961468...
Page 43: ...ated 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...
