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Alfa Laval Gunclean Toftejorg T-82, Instruction Manual

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Alfa Laval Gunclean Toftejorg T-82 Instruction Manual Download Page 7

Instruction Manual, Gunclean Toftejorg T-82 

Page 5 

Standard machines and machines delivered with ATEX certification 
in accordance with Directive 94/9/EC 
IM-TE91A052-EN4 

If ordered with ATEX certificate: 

ATEX Marking 

The Gunclean Toftejorg T-82 is certified as category I components. The certification is carried out by 
the notified body Baseefa, who has issued the certificate no. 10ATEX0188X. The marking on the ATEX 
certified Gunclean Toftejorg TZ-82 is as follows: 
 

 

 

 

 
 
Changes to the machine are  not allowed without approval by the person responsible for the ATEX 
certification at Alfa Laval Tank Equipment A/S. If changes are made – or spare parts other than Alfa 
Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no 
longer valid.  
 

Important 

ATEX 

information: 

Also see page 22  regarding special conditions for repair of ATEX certified 
machines. 

 

 

 

 

Summary of Contents for Gunclean Toftejorg T-82

Page 1: ...Instruction Manual Gunclean Toftejorg T 82 IM TE91A052 EN4 Date of issue December 28 2011 Covering Standard Machines Machines delivered with ATEX Certification in accordance with Directive 94 9 EC ...

Page 2: ......

Page 3: ...e 94 9 EC 20 Maintenance and repair 22 Service and Repair of ATEX Approved Machines 22 Preventive Maintenance Guidelines and Service Kits 23 Maintenance intervals and Service Kits selection 23 Top Assembly 26 Bottom Assembly 28 Hub Subassembly 30 Stem Subassembly 32 Gear Subassembly 34 Replacement of Collar Bushes 36 Replacement of Ball Races 38 Replacement of Main Collars 40 Tools 42 Trouble Shoo...

Page 4: ......

Page 5: ...net of Distributors will be pleased to help you Please quote the type and serial number with all your enquiries this will help us to help you The type and serial number are placed on the gear house of the tank cleaning machine Note The illustrations and specifications contained in this manual were effective at the date of printing However as continuous improvements are our policy we reserve the ri...

Page 6: ...nts and trademarks This Instruction Manual is published by Alfa Laval Tank Equipment A S without any warranty Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment A S without prior notice Such changes will however be incorporated in new editions of this Instruction Manual Alfa Laval Tank Equipment A S 2011 All rights reserved The Alfa Laval logot...

Page 7: ...eefa who has issued the certificate no 10ATEX0188X The marking on the ATEX certified Gunclean Toftejorg TZ 82 is as follows Changes to the machine are not allowed without approval by the person responsible for the ATEX certification at Alfa Laval Tank Equipment A S If changes are made or spare parts other than Alfa Laval original spare parts are used the EC Type Examination certification the ATEX ...

Page 8: ...tions of Hub with nozzles 103 4 revolutions of the machine body one coarse cleaning pattern is laid out on the tank surface During the following rounds this pattern is repeated 3 times each of which is displaced of the mesh in the pattern After a total of 45 revolutions of the Hub with nozzles 43 revolutions of the machine body a complete cleaning pattern has been laid out and the first pattern is...

Page 9: ...ine Inlet Guide Nozzles mm 3 4 thread conn Article Ref No Portable with 1 NPT Nipple 50 2xø7 TE21F262 100 2xø8 2xø9 TE21F272 TE21F274 0 2xø10 TE21F280 The hub of the machine is equipped with a clutch in the hub which gives the possibility of rotation by hand the nozzles when the machine is to be lifted out through a tank opening Standard Options Machines with nozzle extensions for longer throw len...

Page 10: ... IM TE91A052 EN4 Technical data For Gunclean Toftejorg T 82 Fixed Weight of machine 7 0 kgs 15 4 lb Working pressure 5 12 bar 75 175 psi Recommended inlet pressure 5 10 bar 75 150 psi Working temperature max 78 C 173 F Ambient temperature 0 140 C 78 C 140 C when not operated Materials Stainless steel polymer elastomer carbon Principal dimensions in mm ...

Page 11: ...l Gunclean Toftejorg T 82 Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Fixed Flow rate ...

Page 12: ... Vertical throw length upwards is approx 1 3 less Effective throw length varies depending on jet transverse speed over surface substance to be removed cleaning procedure and agent The inlet pressure has been taken immediately before the machine inlet In order to achieve the performance indicated in the curves the pressure drop in the supply lines between pump and machine must be taken into conside...

Page 13: ...org T 82 Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Fixed Cleaning Time f Complete Pattern 4 cycles ...

Page 14: ...91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Weight of machine 7 0 kgs 15 4 lb Working pressure 5 12 bar 75 175 psi Recommended inlet pressure 5 10 bar 75 150 psi Working temperature max 78 C 173 F Ambient temperature 0 140 C 78 C 140 C when not operated Materials Stainless steel polymer elastomer carbon Principal dimensions in mm ...

Page 15: ...Gunclean Toftejorg T 82 Page 13 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Flow rate ...

Page 16: ...e measured as max horizontal throw length at static condition Vertical throw length upwards is approx 1 3 less Effective throw length varies depending on jet transverse speed over surface substance to be removed cleaning procedure and agent The inlet pressure has been taken immediately before the machine inlet In order to achieve the performance indicated in the curves the pressure drop in the sup...

Page 17: ...rg T 82 Page 15 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Technical data continued For Gunclean Toftejorg T 82 Portable Cleaning Time f Complete Pattern 4 cycles ...

Page 18: ...y on the machine For further information see DS CLC TR 50404 2003 Safety of Machinery guidance and recommendations for the avoidance of hazards due to static electricity Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex zones without type approval and marking corresponding to the EX class in question Note The machine shall be installed in accordance wi...

Page 19: ... down wards as illustrated on the figure Clamp on the Hub To protect machine use rubber jaws on the vice 2 Set torque wrench at the specified tightening torque 3 Tighten nozzle with the torque wrench Recommended tightening torque 40m 4 Check that the machine is in operating condition by inserting 3 16 hex Screwdriver tool No TE134A in screw in top of Turbine shaft and easily turn Turbine shaft clo...

Page 20: ... Use Cleaning After use flush the machine with fresh water Cleaning solutions should never be allowed to dry or set up in the system due to possible salting out or scaling of the cleaning ingredient If cleaning media contains volatile chloride solvents it is recommended not to flush with water after use in case this can create hydrochloric acid Pressure Avoid Hydraulic shocks Put on pressure gradu...

Page 21: ... ATEX Warning Tanks with capacities greater than 100 m3 that could contain a flammable atmosphere should not be steam cleaned as steam issuing from a nozzle could contain charged droplets Tanks smaller than this may be steam cleaned providing that the steam nozzles and other metal parts of the system are reliably earthed and grounded to the tank structure ATEX Warning In potentially explosive atmo...

Page 22: ...fe Use in accordance with the ATEX Certification Directive 94 9 EC ATEX Warning The unit may be operated in a hazardous area only when filled with the process fluid ATEX Warning The maximum permitted process fluid temperature and ambient temperature when the machine is operating is 78 C When the machine is not operating the maximum permitted ambient temperature is 140 C ATEX Warning The maximum pe...

Page 23: ...w the current factors such as tank size cleaning solvent and product Additives can be used in the cleaning solvent or for example the tank can be filled with nitrogen The basic rules are described in the guide CLC TR 50404 2003 Following a guidance document such as CLC TR 50404 2003 to establish safe use of machinery and process is the users own responsibility and is not covered by the ATEX certif...

Page 24: ...rk Warning ATEX requirements regarding repair of ATEX approved machines according to EN 60079 19 A tag with the following labelling information must be attached to the machine Repair symbol R Alfa Laval logo and address Repair number Date of repair Machine serial number The tag must be laminated and attached to the machine downpipe outside the tank using a cable tie If a customer wishes to carry o...

Page 25: ...ertified machines Maintenance intervals and Service Kits selection Alfa Laval Service Kits for Tank Cleaning Machine type T 82 are available in two levels Minor Service and Major Service Minor Service kit is recommended to be replaced every 300 working hours or 2 years whichever comes first TE55J000 Minor Service Kit contains TE21B292 Minor Service Kit for Hub Deflector version contains Pos Qty x ...

Page 26: ...Minor T 82 All Major Service kits includes the corresponding Minor Service Kits parts Each kit contains a maintenance guide The above recommended preventive maintenance is based on one machine working under average conditions However a system that has a rough and dirty job to do will need more frequent attention than one working under ideal conditions We trust that you will adjust your maintenance...

Page 27: ...ean material build up and deposits from internal parts with Scotchbrite S Ultrafine eventually chemical cleaner and fine abrasive cloth 4 Replenish Lubricant The quantity of grease required to reach Normal Filling is 0 75 l whereby the gear frame is just covered The quality of lubricant is USDA approved grease NLGI grade 2 The machine is delivered lubricated with grease Shell Alvania WR 2 5 Assemb...

Page 28: ...aces on Mechanical seal Reassembly 1 Carefully put on the stationary seat of Mechanical seal including O ring into the house When inserting the stationary seats be careful to apply even pressure and use only water or alcohol to reduce O ring friction Note Absolute cleanliness and care is essential when fitting mechanical seals Dirt and damage to sliding faces and O rings jeopardise the function of...

Page 29: ...ction Manual Gunclean Toftejorg T 82 Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Top Assembly ...

Page 30: ...t for holding Gear Subassembly Reassembly 1 Reinsert Gear subassembly in bottom of machine body Turn Gear Frame pos 31 to align holes in Gear frame and 3 16 threads in Body Mount Spring washers pos 18 and Screws pos 17 along circumference of Gear frame pos 31 Tighten screws crosswise Note To secure meshing between Gear wheel pos 9 and Pinion pos 10 it might be necessary to rotate slightly either t...

Page 31: ...ion Manual Gunclean Toftejorg T 82 Page 29 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Bottom Assembly ...

Page 32: ...ce Caliper tool No TE369 is used for the unscrewing using the two holes in end face of Hub conical part Note Left hand thread If Ball races in Hub cover pos 21 and in Bevel gear pos 19 1 are extremely worn they should be replaced as well as the Ball retainer with balls pos 27 How to replace Ball races see page 38 5 Remove Lipseal pos 25 and check for wear If the lipseal is worn it has to be replac...

Page 33: ...ction Manual Gunclean Toftejorg T 82 Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Hub Assembly ...

Page 34: ... pos 29 How to replace Ball races see page 38 If Liners on Stem are extremely worn they can be replaced This part requires that a precise procedure is followed to accomplish installation It is suggested that an authorised Alfa Laval Tank Equipment Service Centre perform the replacement if necessary However should the customers insist that they perform the installation please contact your nearest S...

Page 35: ...ion Manual Gunclean Toftejorg T 82 Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Stem Subassembly ...

Page 36: ...18 and Washer pos 14 5 Draw out Pinion pos 10 and 2nd stage Worm wheel pos 12 also freeing Journal pos 13 after removal of Screw pos 17 Spring washer pos 18 and Washer pos 14 6 Remove Bearing cover pos 16 and Ball bearing pos 30 after removal of Screws pos 17 7 Remove Screw pos 17 Spring washer pos 18 Washer pos 14 and Ball bearing pos 30 from Turbine shaft pos 7 Use faces on Turbine shaft to hold...

Page 37: ...asher pos 18 and fix with screw pos 17 Check rotation 4 Insert 1st stage Worm wheel pos 12 and Horizontal shaft pos 29 Mount Washer pos 14 Spring washer pos 18 and fix with Screw pos 17 Check rotation 5 Reinstall Turbine shaft pos 7 in Gear frame as mentioned under Disassembly point 1 6 Hold Turbine shaft pos 7 against 1st stage Worm wheel and tighten Screws pos 17 in Horizontal shaft pos 29 and P...

Page 38: ...ce jaws of a vice Do not clamp on machined surfaces With Pusher tool No TE81B033 see page 42 knock out Collar bush 2 Turn Gear frame to upright position and hold over support such as flat steel bar clamped in a vice Knock out Collar bush with Pusher 3 Turn Gear frame 90 and hold over support Knock out Collar bush with Pusher Warning To avoid risk of deforming Gear frame it is utmost important that...

Page 39: ...nual Gunclean Toftejorg T 82 Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Collar Bushes ...

Page 40: ...n collar lower pos 34 Press by hand as long as possible By means of a tube mandrel or if desired wooden block carefully hammer Ball race home Ball race must not project over of Main collar lower To avoid tilting mandrel must push along the whole circumference of Ball race Do not damage surface of Ball race On Gear wheel 1 Place Gear wheel with ball race pos 9 and 9 1 on support Support only under ...

Page 41: ...anual Gunclean Toftejorg T 82 Page 39 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Ball races ...

Page 42: ...r pos 36 Unscrew Main collar 2 Carefully clean thread and recess in Body Do not damage special thread in Body Recess must be absolutely clean 3 Make sure that new Main collar is clean and free from impurities 4 Screw in new Main collar Attention should be given to make sure that thread is in correct engagement before screwing in Main collar 5 Tighten Main collar fully home and tighten up 6 Check t...

Page 43: ...nual Gunclean Toftejorg T 82 Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Maintenance and repair continued Replacement of Main Collars ...

Page 44: ...d Tool kit for Gunclean Toftejorg T 82 Article No TE81B060 Tool No Description Number TE134 Unbraco key for Screw 1 pcs TE134A Unbraco screw driver 2 pcs TE369 5 mm Caliper 1 pcs Available on request TE81B033 Pusher for 1 Collar bush TE81B034 Fixture set f Collar bush Sketch of Tools for replacement of Collar bush TE81B033 Pusher for 1 Collar bush TE81B034 Fixture set f Collar bush ...

Page 45: ...ual Gunclean Toftejorg T 82 Page 43 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Tools continued Sketch of Tools for Replacement of Main Collars ...

Page 46: ...dly get jammed in the machine install filter or reduce mesh size of installed filter in supply line Foreign Material or Material Build up Insert hex Screwdriver in screw in top of Turbine shaft and easily turn Turbine shaft clockwise If any resistance is recognized disassemble machine to localize the cause a Impeller jammed Remove Guide and Impeller see page 26 and remove foreign material b Turbin...

Page 47: ...that Ball bearings have only minor axial or radial movement and can be rotated freely without any resistance b Bush in Stem See page 23 24 c Worm wheels See page 23 24 d Collar bushes See page 23 24 e Turbine shaft Check clearance in Bush and in Ball bearing Transverse movement in Bush should not exceed 0 5 mm Also inspect worm for wear f Horizontal shaft Check clearance in Collar bushes Transvers...

Page 48: ...ess steel Spare part 19 TE722S 1 Bevel gear w ball race Stainless steel Spare part 19 1 TE826 1 Ball race Stainless steel Wear part 20 TE21B340 1 Hub cover w ball race Stainless steel Spare part 21 TE826 1 Ball race Stainless steel Wear part 22 TE50B007 2 Nozzle ø 7 Stainless steel Spare part TE50B008 2 Nozzle ø 8 Stainless steel Spare part TE50B009 2 Nozzle ø 9 Stainless steel Spare part TE50B010...

Page 49: ...n Manual Gunclean Toftejorg T 82 Page 47 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Cross Sectional Drawing Gunclean Toftejorg T 82 Fixed ...

Page 50: ...l Spare part 17 TE118 38 Screw Stainless steel Spare part 18 TE156 18 Spring washer Stainless steel Spare part 19 TE722S 1 Bevel gear w ball race Stainless steel Spare part 19 1 TE826 1 Ball race Stainless steel Wear part 20 TE21B340 1 Hub cover w ball race Stainless steel Spare part 21 TE826 1 Ball race Stainless steel Wear part 22 TE50B007 2 Nozzle ø 7 Stainless steel Spare part TE50B008 2 Nozzl...

Page 51: ...Manual Gunclean Toftejorg T 82 Page 49 Standard machines and machines delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Cross Sectional Drawing Gunclean Toftejorg T 82 Portable ...

Page 52: ... 11 3 x TE21A585 Collar Bush 12 2 x TE21A367 Worm Wheel 12 2 x TE21A367 Worm Wheel 15 1 x TE21D563 Packing 15 1 x TE21D563 Packing 25 1 x TE21B549 Lip Seal 25 1 x TE52D062 Lip Seal 30 2 x TE829 Ball Bearing 30 2 x TE829 Ball Bearing 35 1 x TE807 O ring 35 1 x TE807 O ring 37 3 x TE651 Locking Wire TE55J010 Major Service Kit T 82PT FIX MUD Pos Qty x P n Description 7 1 x TE21F510 Turbine Shaft 9 1 ...

Page 53: ...he type of machine and serial number This will help us to help you The type and serial numbers are stamped on the body of the tank cleaning machine Claim Procedure In case of failure that needs assistance from Alfa Laval Tank Equipment A S it is essential for our evaluation that the problem as well as the working conditions of the machine are described as detailed as possible For description of th...

Page 54: ...delivered with ATEX certification in accordance with Directive 94 9 EC IM TE91A052 EN4 Service Card Type of Machine Serial No Configuration Nozzle diameter mm Impeller Guide Date No of Working Hours Maintenance Actions Exchanged Parts Remarks Sign 0 Machine put into operation V 94 2 ...

Page 55: ...zles x ø mm Turbine Inlet Guide Working Conditions Inlet pressure at machine cleaner Type of Valve in inlet line Can hydraulic shock be disregarded Yes No Inlet line flushed before installation of tank cleaner Yes No Working hours before failure hours Cleaning Programme Cleaning media and conc Temperature Time Recirculation Is sterilising being used Yes No Procedure media temp Is steam injection b...

Page 56: ...rticles size _____________________________ Crystallizing Soft particles size ______________________________ Has filter been installed in inlet line Yes Mesh size mm No Is tank cleaner flushed with clean water after tank cleaning Yes No Type of Soilage Tank Contents to be removed Name formula concentration of material to be removed from tank What is material soluble in Nature of material Volatile e...

Page 57: ...2100 2 EN 1672 2 The pressure directive According to its own volume and the rated pressure range the product is regarded an Article 3 par 3 Equipment The ATEX Directive For machines with item nos TE21F0XX 70 TE21F2XX X2 70 DS EN 1127 1 DS EN 13463 1 DS EN 13463 5 DS EN 13980 Annex A paragraph A 5 3 Rotating machines ATEX Certification EC Type Examination Certificate no Baseefa10ATEX0188X Marking I...

Page 58: ...Machinery Directive DS EN ISO 12100 1 DS EN ISO 12100 2 EN 1672 2 The pressure directive According to its own volume and the rated pressure range the product is regarded an Article 3 par 3 Equipment The ATEX Directive For machines with item nos TE21F2XX 70 TE21F2XX 22 70 DS EN 1127 1 DS EN 13463 1 DS EN 13463 5 DS EN 13980 Annex A paragraph A 5 3 Rotating machines ATEX Certification EC Type Examin...

Page 59: ...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 Corporate AB Alfa Lava...

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