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2. Safety

Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of

special signs.

Always read the manual before using the tank 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:

Содержание GJ 8

Страница 1: ...Instruction Manual Alfa Laval GJ 8 Covering Standard Machines First published 2015 08 ESE032025 EN1 2015 08 Original manual...

Страница 2: ......

Страница 3: ...2 5 4 Poor Cleaning Performance 13 5 5 Recommended Cleaning 14 6 Maintenance 15 6 1 General Maintenance 15 6 2 General dismantling set up 16 6 3 General dismantling 17 6 4 Inspection and Service of Co...

Страница 4: ...001 to E 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 ow...

Страница 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...

Страница 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...

Страница 7: ...for either low or high pressures and or flow rates A complete description of the technical specifications and materials of construction of the Alfa Laval GJ 8 is contained in section 8 Parts list and...

Страница 8: ...eaning machine before operation 4 1 Unpacking delivery Step 1 CAUTION Alfa Laval cannot be held responsible for incorrect unpacking Check the delivery for 1 Complete Cleaning Machine 2 Delivery note S...

Страница 9: ...joint tape prior to mounting This will minimize any chance of leakage and will make subsequent removal much easier Step 4 Mounting Before mounting the Alfa Laval GJ 8 make sure the supply line has bee...

Страница 10: ...y covering any soils underneath Wherever possible the tank floor should be pitched toward the drain and the drainage opening should be large enough to eliminate or reduce any liquid buildup or puddlin...

Страница 11: ...PD pump is used the Alfa Laval GJ 8 should be sized to first match the flow capability of the pump and second not exceed the pump s maximum operating pressure taking the pressure rating of the plumbin...

Страница 12: ...ur testing tank before it shipped based on the operating conditions supplied to Alfa Laval Tank Equipment Inc To ensure the longest possible life of the Alfa Laval GJ 8 please verify the operating con...

Страница 13: ...bushing pos 32 Section 6 4 Inspection and Service of Components Worn Tee Nozzle housing bearing and cup pos 29 31 Section 6 4 Inspection and Service of Components Loose nozzle housing cup pos 30 Sect...

Страница 14: ...fail to operate when first returned to service If the machine seems otherwise fine try running it with at least one Nozzle Tip removed The reduction in pressure and additional flow will invariably be...

Страница 15: ...30 for excessive wear grooved or scored particularly near the inside flange where they contact the 31 Seals Replace any that show distinct grooves Worn Static Seal Contact Surfaces Inspect the Bearin...

Страница 16: ...cleaned If heating is necessary also check that the solution is at the proper temperature Plugged Nozzles Unscrew the Nozzles 7 and inspect for any debris Slow or no Rotation of the Housings This will...

Страница 17: ...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 Dan...

Страница 18: ...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...

Страница 19: ...t in storage The best position to store the Alfa Laval Gamajet is to stand it up with the inlet connection facing down Step 3 EXTERNAL INSPECTION INTERVALS Before every shift the Stator 9 and the Nozz...

Страница 20: ...emove them along with the Lockwashers 41 Pull the Stem Collar 2 from the Rotor Shaft Upper Bearing Housing 26 Step 4 Gear Train Assembly Remove the Gear Train Assembly from the body by tapping on the...

Страница 21: ...r Shaft 21 Remove the Rotor 10 from 21 Use a slotted screwdriver for assistance Check that the Carbide Bushing pressed into 10 protrudes slightly Turn to drawing 22 Remove the Rotor Shaft Upper Bearin...

Страница 22: ...etary Ring Gear on tier at a time Turn to drawing 31 Inspect the Input Pinion 39 for hairline cracks on the end face or for worn damaged or sharp pointed teeth The assembly of 39 the Rotor Shaft Carbi...

Страница 23: ...ats Check the water outlets on the nose and the CIP holes of 4 they should be free of debris Inspect the Tee Housing Bevel Gear 17 for worn damaged or sharp pointed teeth Turn to drawing 6 Inspect 19...

Страница 24: ...until it is fully seated Place the second Tee Housing Seal 31 spring side down over 3 Tip First Place the second Tee Housing Bearing 29 into 28 aligning its hole with the Bearing Locating Pin 58 Now i...

Страница 25: ...into the 26 with the keyway in the 1 Turn to drawing 20 Put the Rotor 10 carbide bearing down onto 21 Place the Lockwasher 51 and Nut 52 onto 21 Hold 10 stationary while tightening 52 with an 11 32 so...

Страница 26: ...20 bar 50 300 PSI Cleaning 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 n...

Страница 27: ...ata during installation operation and maintenance Inform personnel about the technical data 7 2 Performance Data Flow Rate Impact Throw Length Inlet Pressure Wetting Impact cleaning W e t t i n g I m...

Страница 28: ...onnel about the technical data 7 3 Dimensions Dimensions Dimensions 180 directional version Dimensions A B C D E F G H I mm 281 202 215 51 118 216 248 121 165 in 11 06 7 95 8 46 2 01 4 64 8 50 9 76 4...

Страница 29: ...that simulates how the Alfa Laval GJ 8 performs in a specific tank or vessel The simulation gives information on wetting intensity pattern mesh width and cleaning jet velocity This information is use...

Страница 30: ...8 Parts List and Service Kits 27 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine 8 1 GJ8 View GJ0900...

Страница 31: ...The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine 8 2 Assembly Drawings 1 2 B A GJ0902 A Drawing 1 Completed Assembly A Drawing 2 B Never hold or turn on tee housing cap during removal of 8 Dra...

Страница 32: ...t and Service Kits 29 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine 8 3 Assembly Drawings 3 4 5 6 7 8 Drawing 3 Output Pinion Assembly Drawing 4 Idler Shaft Assembly A Drawing 5 Idler Gear A...

Страница 33: ...s List and Service Kits 30 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine A Drawing 7 Stem Collar Screws washer Drawing 6 Ring Gear A Align the flats and press flush Drawing 8 Stem Collar Ass...

Страница 34: ...leaning Machine 8 4 Assembly Drawings 9 10 11 12 13 14 15 16 17 Drawing 9 Gear train Assembly A Drawing 20 Drawing 12 Nozzle Housing Assembly A Drawing 16 A Drawing 11 Nose Plate A Press fit Drawing 1...

Страница 35: ...val GJ 8 Tank Cleaning Machine Drawing 13 Tee Housing Bevel Gear A Press fit Drawing 14 Nozzle Housing Drawing 15 Nozzle A Press flush with the bottom edge A Drawing 17 Idler Shaft Base Drawing 16 Hou...

Страница 36: ...GJ 8 Tank Cleaning Machine 8 5 Assembly Drawings 18 19 20 21 22 23 24 25 Drawing 18 The Housing Assembly A Drawing 33 Drawing 20 Geartrain A Drawing 22 Drawing 19 Tee Housing Bevel Gear A Press fit Dr...

Страница 37: ...e drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 22 Geartrain Housing A Drawing 26 Drawing 23 Input Shaft Bearing Housing A Press fit Drawing 25 Output Shaft Bearing Housing A Press fit D...

Страница 38: ...arts List and Service Kits 35 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine 8 6 Assembly Drawings 26 27 28 29 Drawing 26 Geartrain Assembly A Drawing 28 Drawing 27 Planetary Gearbox Assembly...

Страница 39: ...8 Parts List and Service Kits 36 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 28 Install Geartrain Cap A Drawing 32 Drawing 29 Input Geartrain Housing Assembly A...

Страница 40: ...List and Service Kits 37 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine 8 7 Assembly Drawings 30 31 32 33 34 Drawing 31 Input Shaft assembly Drawing 30 Geartrain Assembly A Drawing 29 B Draw...

Страница 41: ...nk Cleaning Machine Pos Description Qty 1 18 TEETH PLANET GEAR BOTTOM BASE 1 2 10 TEETH PLANET GEAR 6 3 17 TEETH PLANET GEAR BASE 1 4 17 TEETH PLANET GEAR BASE 1 5 17 TEETH PLANET GEAR 3 6 PLANET GEAR...

Страница 42: ...8 Parts List and Service Kits 39 The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 33 Stem Assembly Drawing 34 Tee Housing Assembly For Directional Machine refer to Appendix A...

Страница 43: ...OR 3 7 7 9614604207 E807ASVHV3 8 NOZZLE ASSEMBLY VITON 3 8 BORE SIZE 2 OR 3 7 8 9614604208 E807ASVHV5 16 NOZZLE ASSEMBLY VITON 5 16 BORE SIZE 2 OR 3 7 9 9614604209 E807ASVHV7 16 NOZZLE ASSEMBLY VITON...

Страница 44: ...HOUSING BEARING 4 30 9614608701 E 832 TEE NOZZLE HOUSING CUP 4 31 9614608801 E 835 TEE NOZZLE HOUSING SEAL 4 32 9614608901 E 837 IDLER GEAR BUSHING 2 33 9614609001 E 838 IDLER SHAFT BUSHING 2 34 9614...

Страница 45: ...R STEM SMALL O RING VITON 1 56 2 9614610802 E 862 E COLLAR STEM SMALL O RING EP 1 56 3 9614610803 E 862 K COLLAR STEM SMALL O RING KALREZ 1 57 1 9614610901 E 863 V COLLAR STEM LARGE O RING VTION 1 57...

Страница 46: ...614608601 E831 GJ VIII TEE HOUSING BEARING 4 pcs 31 9614608801 E835 GJ VIII TEE HOUSING SEAL 4 pcs 32 9614608901 E837 GJ VIII IDLER GEAR BUSHING 2 pcs 33 9614609001 E838 GJ VIII IDLER SHAFT BUSHING 2...

Страница 47: ...831 GJ VIII TEE HOUSING BEARING 4 pcs 31 9614608801 E835 GJ VIII TEE HOUSING SEAL 4 pcs 32 9614608901 E837 GJ VIII IDLER GEAR BUSHING 2 pcs 33 9614609001 E838 GJ VIII IDLER SHAFT BUSHING 2 pcs 56 9614...

Страница 48: ...H BEARING CUP 4 pcs 62 9614611501 E871 GJ VIII OUTPUT SHAFT SCREW 1 pcs 63 9614611601 E872 GJ VIII OUTPUT SHAFT LOCK SCR 1 pcs Article no 9614612101 EHV8MAJEPDMKIT ALFA LAVAL GJ 8 MAJOR KIT EPDM Pos n...

Страница 49: ...CUP 4 pcs 62 9614611501 E871 GJ VIII OUTPUT SHAFT SCREW 1 pcs 63 9614611601 E872 GJ VIII OUTPUT SHAFT LOCK SCR 1 pcs Article no 9614612601 EHV8MAJTEFLON ALFA LAVAL GJ 8 MAJOR KIT TEFLON Pos no Part N...

Страница 50: ...9 Appendix A 47 Drawing A1 Directional Nozzle Housing Removal Drawing A2 Directional Nozzle Housing Removal The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine 9 Appendix A...

Страница 51: ...9 Appendix A 48 The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A3 Directional Nozzle Housing Removal...

Страница 52: ...9 Appendix A 49 The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A4 Directional Tee Housing Removal Drawing A5 Directional Tee Housing Dis Assembly...

Страница 53: ...9 Appendix A 50 The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A6 Directional Stem Assembly Drawing A7 Directional Tee Housing Assembly...

Страница 54: ...art 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 o...

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