Tank Cleaning Machine

Instruction Manual
Gunclean Toftejorg T-82
IM-TE91A052-EN1
June, 2005
Contents
Contents ....................................................................................................................1
Introduction................................................................................................................5
General Description...................................................................................................6
Functioning ......................................................................................................................... 6
Standard configurations ...................................................................................................... 7
Standard Options ................................................................................................................ 7
Technical data ...........................................................................................................8
For Gunclean Toftejorg T-82 Fixed ..................................................................................... 8
For Gunclean Toftejorg T-82 Portable .............................................................................. 10
Installation and Normal Operation...........................................................................12
General Installation Instructions........................................................................................ 12
Normal Operation.............................................................................................................. 13
Maintenance and repair............................................................................................14
Preventive Maintenance Guidelines and Service Kits ....................................................... 14
Maintenance intervals and Service Kits selection ............................................................. 14
Top Assembly ................................................................................................................... 16
Bottom Assembly .............................................................................................................. 18
Hub Subassembly............................................................................................................. 20
Stem Subassembly ........................................................................................................... 22
Gear Subassembly ........................................................................................................... 24
Replacement of Collar Bushes.......................................................................................... 26
Replacement of Ball Races............................................................................................... 28
Replacement of Main Collars ............................................................................................ 30
Tools ........................................................................................................................32
Standard Tool kit for Gunclean Toftejorg T-82, Article No. TE81B060.............................. 32
Sketch of Tools for Replacement of Main Collars ............................................................. 33
Trouble Shooting Guide ..........................................................................................34
Reference List of Parts, Gunclean Toftejorg T-82 Fixed..........................................36
Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed......................................37
Reference List of Parts, Gunclean Toftejorg T-82 Portable ....................................38
Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable .................................39
Service Kits..............................................................................................................40
TE55J000 Minor Service Kit T-82PT/FIX/MUD ................................................................. 40
TE55J010 Major Service Kit T-82PT/FIX/MUD ................................................................. 40
How to order spare parts and claim procedure.......................................................41
How to contact Alfa Laval Tank Equipment A/S......................................................41
Service Card............................................................................................................42
Claim Report Working Conditions ...........................................................................43
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 1
Introduction
This manual has been prepared as a guide for the persons who will be operating and maintaining your
tank cleaning machine. The key to long life for your tank cleaning machine will always be a system of
carefully planned maintenance; you will appreciate that a tank cleaning machine which has a rough and
dirty job to do will need more frequent attention than one working in ideal conditions.
It is in your own interest to get the best and most economical performance from your tank cleaning
machine. Neglect of maintenance means poor performance, unscheduled stoppages, shorter life and
expense. Good maintenance means good performance; no unscheduled stoppages and better total
economy.
You will find the information contained in this manual simple to follow, but should you require further
assistance, our Customer Service Department and worldwide 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 right to alter or modify any unit
specification on any product without prior notice or any obligation.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 5
General Description
The Gunclean Toftejorg T-82 is a media driven tank cleaning machine. The internal mechanical parts
are isolated by seals and lubricated by pre-packed grease.
Functioning
The flow of the cleaning fluid into the machine passes through a turbine, which is set into rotation. The
impeller rotation is through a gearbox transformed into a combined horizontal rotation of the machine
body and a vertical rotation of the nozzles.
The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning
coverage. After 11¼ revolutions 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 ¼ 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 repeated.
1st cycle
2nd cycle
3rd cycle
4th cycle
The speed of rotation of the impeller depends on the flow rate through the machine, which in turn
primarily depends on the nozzle diameter chosen. The higher the flow rate is, the higher the speed of
rotation will be. For a given flow rate, the RPM of the machine can be controlled by installing a stator or
no stator in front of the Impeller and by the gear configuration. No stator (0%) and E-gearing will give
the slowest rotation and longest jet throw length for a given flow rate.
Page 6
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
General description (continued)
Standard configurations
Connection
Without flange
Connection
Fixed with 127mm
o.d. Flange
Connection
Portable with 1½”
Turbine/Inlet Guide
Portable with 1½”
Article/Ref. No.
50%
2xø7
TE21F032
100%
2xø8
2xø9
TE21F042
TE21F044
0%
2xø10
TE21F050
Turbine/Inlet Guide
Nozzles (mm) (3/4” thread conn.)
Article/Ref. No.
50%
2xø7
TE21F002
100%
2xø8
2xø9
TE21F012
TE21F014
0%
2xø10
TE21F020
Turbine/Inlet Guide
Nozzles (mm) (3/4” thread conn.)
Article/Ref. No.
50%
2xø7
TE21F202
100%
2xø8
2xø9
TE21F212
TE21F214
0%
2xø10
TE21F230
BSP Nipple
Connection
Nozzles (mm) (3/4” thread conn.)
Turbine/Inlet Guide
Nozzles (mm) (3/4” thread conn.)
Article/Ref. No.
50%
2xø7
TE21F262
100%
2xø8
2xø9
TE21F272
TE21F274
0%
2xø10
TE21F280
NPT Nipple
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 length can be supplied as an option. Same article no.
with index no. –22. e.g. TE21F002-22.
Machines with e-gear and nozzle extension: Same article no. with index no. -62, e.g. TE21F002-62.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 7
Technical data
For Gunclean Toftejorg T-82 Fixed
Weight of machine
Working pressure
Recommended inlet pressure
Working temperature max.
Materials
:
:
:
:
:
7.0 kgs (15,4 lb)
5-12 bar (75-175 psi)
5-10 bar (75-150 psi)
78° (173° F)
Stainless steel, polymer, elastomer, carbon
Principal dimensions in mm
Page 8
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Technical data (continued)
For Gunclean Toftejorg T-82 Fixed
Flow rate
Throw length
Note: Throw lengths are 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 supply lines between pump
and machine must be taken into consideration.
Cleaning Time f. complete Pattern (= 4 cycles)
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 9
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Weight of machine
Working pressure
Recommended inlet pressure
Working temperature max.
Materials
:
:
:
:
:
7.0 kgs (15,4 lb)
5-12 bar (75-175 psi)
5-10 bar (75-150 psi)
78° (173° F)
Stainless steel, polymer, elastomer, carbon
Principal dimensions in mm
Page 10
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Technical data (continued)
For Gunclean Toftejorg T-82 Portable
Flow rate
Throw length
Note:: Throw lengths are 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 supply lines between pump
and machine must be taken into consideration.
Cleaning Time f. complete Pattern (= 4 cycles)
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 11
Installation and Normal Operation
General Installation Instructions
The tank cleaning machine should be installed in vertical position (upright or upside down). It is
recommended to install a filter in the supply line in order to avoid large particles to clog inside the
machine. Before connecting the machine into the system, all supply lines and valves should be flushed
to remove foreign matter.
For fixed machines it is recommended to secure bolted connection between machine and down pipe
against loosening to vibrations. Use locking wire, naps or equivalent for the actual application.
Warning:
If the machine is used in potential explosive atmospheres, tapes or joint sealing
compounds which are electrical insulators must not be used on threads or joints. In
addition, connecting pipe work must be electrically conductive and earthed to the tank
structure.
This is essential to avoid the build-up of static electricity on the machine.
Note: The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards.
Precautions shall be made to prevent starting of the cleaning operation, while personnel are inside the
tank or otherwise can be hit by jets from the nozzles.
In EU-countries the complete system must fulfil the EU-machine directive and shall be CE-marked.
It is recommended to mount bumpers on portable tank cleaning machines.
The machine as delivered has been tested at the factory before shipping. For transportation reasons,
the nozzles have been removed prior to shipment. Before installation and use, the nozzles should be
attached and secured appropriately for the application intended.
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 clockwise. If any resistance is recognized,
the machine should be disassembled to localize the cause.
Page 12
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only media compatible with stainless steel, elastomer, polymer and carbon. Please note that some
of the polymer parts are in PEEK, which is not resistant to concentrated sulfuric acid. Normal
detergents, moderate solutions of acids and chemicals at elevated temperatures, as well as
hypochlorids should be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment
sales office.
After Use Cleaning
After use flush the machine with fresh water. Cleaning solutions should never be allowed to dry or setup 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 gradually. Do not exceed 12 bar inlet pressure.
Recommended inlet pressure appears from Technical Data (page 8-11). High pressure in combination
with high flow rate will increase consumption of wear parts.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 13
Maintenance and repair
Preventive Maintenance Guidelines and Service Kits
By using Alfa Laval Tank Equipment Preventive Maintenance Guidelines and Service Kits you are
enabled to ensure the availability of your equipment at all times. You are able to plan your operating
budget and your downtime. The risk of breakdowns due to component failure is virtually eliminated and
in the long term your operating costs are reduced.
Alfa Laval Tank Cleaning Equipment Service Kits contain All you need. They comprise genuine Alfa
Laval spare parts, manufactured to the original specifications.
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 250 working hours or 2 ½ years, whichever
comes first.
TE55J000 Minor Service Kit T-82 contains:
Pos.
5
6
8
11
12
15
25
30
35
37
Qty x P/n
1 x TE51T153
2 x TE825
1 x TE21F507
3 x TE21A585
2 x TE21A367
1 x TE21D563
1 x TE21B549
2 x TE829
1 x TE807
3 x TE651
Description
Mechanical Seal
O-ring
Bushing
Collar Bush
Worm Wheel
Packing
Lip Seal
Ball Bearing
O-ring
Locking Wire
Major Service kit is recommended to be replaced every 1000 working hours or 10 years, whichever
comes first.
TE55J010 Major Service Kit T-82 contains:
Pos
7
9.1
19.1
21
33
23
27
29
34
36
Page 14
Qty x P/n
1 x TE21F510
1 x TE826-1
1 x TE826-1
1 x TE826-1
1 x TE826-1
1 x TE448
2 x TE21A380
1 x TE828Z
1 x TE827G2
1 x TE827G1
1 x TE55J000
Description
Turbine Shaft
Ball race
Ball race
Ball race
Ball race
Cotter Pin
Ball retainer with balls
Horizontal Shaft
Main Collar, Lower
Main Collar, Upper
Service Kit Minor T-82
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
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 programme
accordingly.
General recommendations
•
•
Always read the instruction and maintenance manuals before undertaking the service.
Some kits contain a small quantity of parts not needed for each tank cleaning machine model.
These are not included in the price and may be disregarded.
•
Always replace all parts included in the Service Kit.
Additional maintenance recommendations
Good maintenance is careful and regular attention!
Always use only proper tools. Use standard tool kit. Never force, hammer or pry components
together or apart. Always perform all assembly/disassembly steps in the order described in this
manual.
Never assemble components without previous cleaning. This is especially important at all mating
surfaces. Work in a clear well lighted work area.
1.
Clean the machine with White spirit/kerosene or similar.
2.
Disassemble machine as described on the following pages.
3.
Clean 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 grease of grade 2. (The machine is delivered
lubricated with grease Shell Alvania WR 2).
5.
Assemble machines as described in the following pages.
6.
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 clockwise. If any resistance
is recognized, the machine should be disassembled to localize the cause.
Service Card
For your registration of maintenance carried out, fill in service card which you will find at the back of this
manual.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 15
Maintenance and repair (continued)
Top Assembly
Disassembly
1.
Remove Screw (pos. 17). Loosen with Key (tool No. TE134) and unscrew with Screwdriver (tool
No. TE134A).
2.
Lift off Nipple (pos. 1).
3.
Remove Guide/Guide ring (pos. 2). The Guide has a groove in the outer diameter. The Guide is
easily lifted out of the Stem by means of two ordinary Screwdrivers inserted into the groove.
4.
Remove Screw (pos. 17), Spring washer (pos. 18) and Washer (pos. 14). To secure Impeller
against rotation, insert carefully Screwdriver (tool No. TE134A), through Impeller (pos. 4) into a
hole in the Stem.
5.
Pull off Impeller (pos. 4) by means of two Screwdrivers (tool No. TE134A), inserted in the two
holes on side of Impeller.
6.
Carefully draw out the “rotating” part (including Spring and O-ring) of Mechanical Seal (5).
Note:: Take care not to damage the Sliding faces 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 a seal. Never put lubricant on the sliding
faces – mount only in a completely dry, dust free and clean state.
2.
Reinstall Impeller (pos. 4). Make sure that Impeller is correctly rotated to be pushed onto Turbine
shaft. Do not try to hammer Impeller in position, as this will damage Ball bearing under the Turbine
shaft.
3.
Mount Washer (pos. 14), Spring washer (pos. 18) and Screw (pos. 17) and tighten. To secure
Impeller against rotation insert carefully Screwdriver (tool No. TE134A) through Impeller (pos. 4)
into a hole in the Stem.
4.
Reinstall Guide/Guide ring (pos. 2).
5.
Mount Nipple (pos. 1). Make sure that it is in correct position over Guide/Guide ring (pos. 2).
Rotate Nipple to align holes in Nipple and Stem.
6.
Mount Screws (pos. 17) with Screwdriver (tool No. TE134A). Tighten with Key (tool No. TE134).
Page 16
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Top Assembly
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 17
Maintenance and repair (continued)
Bottom Assembly
Disassembly
1.
Turn machine upside down.
2.
Remove Screws (pos. 17) and Spring washer (pos. 18) from Bottom cover (pos. 32).
3.
Remove Bottom cover (pos. 32).
4.
Remove Screws (pos. 17) in Bearing cover (pos. 16). Carefully push out Turbine shaft (pos. 7)
from opposite end. Do not try to hammer out Turbine shaft, since this can damage Ball bearing.
5.
Remove Screws (pos. 17) and Spring washers (pos. 18) along the circumference of Gear frame
(pos. 31). Turn Gear frame clockwise about 1 cm (½"). Draw out Gear Subassembly (holes in
Gear frame are excellent 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 the whole Gear Subassembly or the Gear wheel.
2.
Reinsert Turbine shaft (pos. 7) with Ball bearing carefully through Gear wheel (pos. 9). Push
carefully Ball bearing (pos. 30) into position. Mount Bearing cover (pos. 16) with Screws (pos. 17).
Tighten crosswise.
3.
Pump grease (Shell Alvania WR 2 or equivalent) into the three access holes in the gear frame
(pos. 31). Ensure that the grease is clearly visible the whole way around the edge of the gear
frame.
4.
Place Bottom cover (pos. 32).
5.
Mount Spring washers (pos. 18) and Screws (pos. 17) and tighten crosswise.
Page 18
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Bottom Assembly
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 19
Maintenance and repair (continued)
Hub Subassembly
Disassembly
1.
Remove Nozzles (pos. 22). Nozzles are untightened with a wrench on the faces of the nozzles.
2.
Remove Screws (pos. 17) and Spring washers (pos. 18) from Hub cover (pos. 20).
3.
Draw out Hub Subassembly. If Hub cover (pos. 20) clings into Body, knock carefully with plastic
hammer on outer diameter to loosen.
4.
Remove Cotter pin (pos. 23). Unscrew contra clockwise Hub conical part (pos. 24) freeing Hub
cover (pos. 20), Ball retainer w. balls (pos. 27) and Bevel gear (pos. 19). To unscrew Hub conical
part (pos. 24), Hub nozzle part (pos. 26) is held in a vice. 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 28.
5.
Remove Lipseal (pos. 25) and check for wear. If the lipseal is worn, it has to be replaced.
Reassembly
1.
Mount the Lipseals (pos. 25).
2.
Mount Bevel gear (pos. 19), Ball retainer with balls (pos. 27) and Hub cover (pos. 20) on Hub
conical part (pos. 24). Screw on Hub nozzle part (pos. 26). Note: Left-handed thread. To tighten,
place Hub nozzle part in a vice and use Caliper (tool No. TE369). Tighten until holes are aligned to
pass Cotter pin (pos. 23). Insert Cotter pin and split (preferably new Cotter pin).
3.
Slide on Hub Subassembly, fit Hub cover (pos. 20) into Body and mount Spring washers (pos. 18)
and Screws (pos. 17).
4.
Screw on Nozzles (pos. 22) and tighten with wrench.
Page 20
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Hub Assembly
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 21
Maintenance and repair (continued)
Stem Subassembly
Disassembly
1.
Place machine in upside-down position. Remove and discard the grease. Clean internal surfaces
to allow inspection.
2.
Remove Screws (pos. 17) in Gear wheel (pos. 10). To prevent rotation of Stem (pos. 3) mount two
3/16" screws in two holes opposite one another in BIG end of Stem. Place Stem in a vice held by
the heads of the two screws.
3.
Draw out Gear wheel with ball race (pos. 10) and Ball retainer with balls (pos. 29).
4.
Push out Stem (pos. 3).
5.
If worn, press out Main bush (pos. 8).
If Ball races in Body (pos. 26.3) and on Gearwheel (pos. 9.1) are extremely worn they should be
replaced together with Ball retainer with balls (pos. 29). How to replace Ball races see page 28.
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 Service Centre for a copy of the procedure.
Reassembly
1.
Replace O-ring seals (pos. 35) located in the upper collar, and (pos. 6) on Stem (pos. 3) lubricate
the seals slightly with the recommended grease.
2.
If replaced, press Bush (pos. 8) into Stem (pos. 3).
3.
Push Stem into Body. Turn machine upside-down.
4.
Place Ball retainer with balls (pos. 29) and Gearwheel (pos. 10) into Body on Ball race. Rotate
gearwheel to check free rotation. Mount gearwheel with Screws (pos. 17) and tighten crosswise.
To prevent rotation of Stem (pos. 3) mount two 3/16" screws in two holes opposite one another in
BIG end of Stem. Place Stem in a vice held by the heads of the two screws.
Page 22
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Stem Subassembly
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 23
Maintenance and repair (continued)
Gear Subassembly
Disassembly
1.
To make a backstop, remount Turbine shaft (pos. 7) with Slide bearing (pos. 30) into Gear frame
(pos. 31). Mount Bearing cover (pos. 16) with Screws (pos. 17).
2.
Hold Turbine shaft (pos. 7) against 1st stage Worm wheel (pos. 12) with one hand and loosen
Screws (pos. 17) in Pinion (pos. 10) and Horizontal shaft (pos. 29) with the other hand.
3.
Remove Screws (pos. 17) in Bearing cover (pos. 16) and take out Turbine shaft (pos. 7).
4.
Draw out Horizontal shaft (pos. 29) and 1st stage Worm wheel (pos. 12) after removal of Screw
(pos. 17), Spring washer (pos. 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 against rotation.
Warning:
Do not damage driver faces on Turbine shaft. Use only proper tools providing a firm
grip such as a wrench or a vice.
How to replace Collar bushes (pos. 11), see page 26.
Reassembly
1.
Mount Ball bearing (pos. 30) on Turbine shaft (pos. 7) and secure with Washer (pos. 14), Spring
washer (pos. 18) and Screw (pos. 17). Hold Turbine shaft in vice or with wrench on driver faces
and tighten screw.
2.
Push Ball bearing (pos. 30) for Horizontal shaft (pos. 29) into Gear frame (pos. 31) and fix Bearing
cover (pos. 16) with Screws (pos. 17). Tighten crosswise.
Page 24
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Gear Subassembly
3.
Insert 2nd stage Worm wheel (pos. 12), Pinion (pos. 10) and Journal (pos. 13). Mount Washer
(pos. 14), Spring washer (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 Pinion (pos. 10).
7.
Remove Turbine shaft (pos. 7) with Ball bearing (pos. 30) before Gear subassembly is inserted in
machine body.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 25
Maintenance and repair (continued)
Replacement of Collar Bushes
1.
Place Gear frame (pos. 31) upside down with a firm support under the flange. Use for instance
jaws of a vice. Do not clamp on machined surfaces. With Pusher (tool No. TE81B033, see page
32) 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
Warning:
4.
and hold over support. Knock out Collar bush with Pusher.
To avoid risk of deforming Gear frame, it is utmost important that it is supported
while the Collar bushes are being knocked out.
Clean holes and push in new Collar bushes into Gear frame
Page 26
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Replacement of Collar Bushes
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 27
Maintenance and repair (continued)
Replacement of Ball Races
In Body
1.
A. With big end downwards knock several times Body with bearings (pos. 28) hard against firm
wooden support until Ball race (pos. 33) drops out.
1.
B. If it is not possible to knock out Ball race in this way, it is necessary first to screw out Main collar
lower (pos. 34) - see page 30. Carefully push off old Ball race without damaging Main collar lower.
Use mandrel and firm support.
Before mounting of new Ball race, main collar lower (pos. 34) must be remounted into Body - see
page 30.
2.
Clean surfaces and place Ball race (pos. 33) on Main 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 Ball race (pos.
9.1). With mandrel press off old Ball race.
2.
Clean surfaces and press on new Ball race. Ball race must be pressed fully home on Gear. Press
parallel. Use press or vice. Do not damage surface of Ball race.
In Hub cover
1.
Place Hub cover with ball race (pos. 19) on support. Carefully knock out old Ball race by means of
small mandrel or if desired screwdriver. Knock several times around the circumference to avoid
tilting.
2.
Clean surfaces and press in new Ball race. Ball race must be pressed fully home. Press parallel.
Do not damage surface of Ball race.
Page 28
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Replacement of Ball races
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 29
Maintenance and repair (continued)
Replacement of Main Collars
Although normally exposed to very limited wear, it is possible to replace Main collars (pos. 36 and 34)
in Body. The procedure to do this is described below.
Main collar upper
1.
Place Body (pos. 28) in a vice in upright position. Do not clamp on machined faces. Insert Tool
(see page 33) into Main collar upper (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 that main collar is fully home: Install Stem, Ball retainer with balls and Gear wheel (see
page 22). Check that there is sufficient axial clearance to allow for free rotation of Stem.
Main Collar Lower
Place Body in a vice in upside down position, and repeat procedure described above.
Warning:
Page 30
Thread on Main collar lower is left-handed.
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Maintenance and repair (continued)
Replacement of Main Collars
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 31
Tools
Standard Tool kit for Gunclean Toftejorg T-82, Article No. TE81B060
Tool No.
TE134
TE134A
TE369
Description
Unbraco key for Screw
Unbraco screw driver
5 mm Caliper
Number
1 pcs.
2 pcs.
1 pcs.
Available on request:
TE81B033
Pusher for 1½” Collar bush
Sketch of Tools for replacement of Collar bush:
81B033 Pusher for 1½” Collar bush:
Page 32
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Tools (continued)
Sketch of Tools for Replacement of Main Collars
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 33
Trouble Shooting Guide
Symptom: Slow rotation or failure of the machine to rotate
Possible causes
Action
No or insufficient liquid flow
a). Check if supply valve is fully open.
b). Check if inlet pressure to machine is correct.
c). Check supply
clogging.
line/filter
for
restrictions/
d). Remove nozzles and check for clogging. If
blocked, carefully clean nozzle without
damaging stream straighteners and nozzle
tip.
e). Remove Flange/Nipple, Guide and Impeller
(see page 16) and check for clogging in
Impeller area.
If large particles repeatedly 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 16) and
remove foreign material.
b). Turbine shaft sluggish in Bush or Ball bearing
Remove Turbine shaft (see page 18) and clean
Bush. Check Ball bearing. Replace, if necessary.
c). Bevel gears jammed
Remove Flange/Nipple and Hub Subassembly (see
page 20). Clean teeth on Stem and Bevel gear.
d). Stem jammed/sluggish
Remove Gear subassembly (see page 18). Check
free rotation of Stem. Remove Stem (see page 22).
Remove foreign material/material build-up on Stem
and inside Main Collars. Clean Ball Races and Ball
retainer with balls. Also clean Bush in Stem.
Page 34
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Trouble Shooting Guide (continued)
Possible causes
Action
e). Gearbox jammed/sluggish
Remove foreign material from Gearbox. Check
rotation of shafts. If restriction is recognized,
disassemble gearbox (see page 24) and remove
material build up, especially on 2nd stage Worm
wheel and mating Collar bushes. Also check Ball
bearing.
f).
Disassemble Hub Subassembly (see page 20).
Remove foreign material inside Hub. Clean Ball
races and Ball retainer with balls. Also clean nose
of Body.
Hub jammed/sluggish
Wear
a). Ball bearings
Check that Ball bearings have only minor axial or
radial movement and can be rotated freely without
any resistance.
b). Bush in Stem
See page 14 - 15.
c). Worm wheels
See page 14 - 15.
d). Collar bushes
See page 14 - 15.
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. Transverse
movement should not exceed 0.5 mm. Also inspect
worm for wear.
Mechanical defects
a). Worm wheel/Teeth broken
Replace Worm wheel.
b). Worm wheel can rotate on Horizontal
shaft/Pinion due to damaged driver faces.
Replace Worm wheel.
c). Damaged teeth on Gear
Inspect teeth on Stem and Bevel gear for
deformation. Mount Hub and Stem in Body (see
page 20 and 22). Hold Body in upside down
position and rotate Hub to check that Bevel gears
can work together. If damaged: Replace Stem
and/or Bevel gear.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 35
Reference List of Parts, Gunclean Toftejorg T-82 Fixed
Pos.
1
Ref. No.
TE21B510
2
TE703
TE703-50
TE803-0
TE21F328
TE21F505
TE21F506
TE705
TE705-50
TE51T153
TE825
TE21F510
TE21F507
TE21F330
TE826-1
TE814
TE21A585
TE21A367
TE21A364
TE817
TE719A
TE21D563
TE731
TE118
TE156
TE722S
TE826-1
TE21B340
TE826-1
TE50B007
TE50B008
TE50B009
TE50B010
TE448
TE21B536
TE21B549
TE724-2-15
TE21A380
TE21F500
TE828Z
TE21A550
TE829
TE730
TE21F504
TE826-1
TE827G2
TE807
TE827G1
TE164
TE651
TE50B101
3
3.1
3.2
4
5
6
7
8
9
9.1
10
11
12 + 39
13
14
15
16
17
18
19
19.1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
40
No/
Unit
1
1
1
1
1
1
1
1
2
1
1
1
1
3
2
2
1
4
1
2
38
18
1
1
2
2
2
2
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
6
3
2
Description
Flange
Without flange
Guide 100%
Guide 50%
Guide ring 0%
Stem f. mech. seal
Top liner
Bottom liner
Impeller 100%
Impeller 50%
Mechanical shaft seal
O-ring
Turbine shaft
Bush
Gear wheel w. ball race
Ball race
Pinion
Collar bush
Worm wheel w. reinf..
Worm wheel w. reinf. E-gear
Journal
Washer
Bottom gasket
Bearing cover
Screw
Spring washer
Bevel gear w. ball race
Ball race
Hub cover w. ball race
Ball race
Nozzle ø 7
Nozzle ø 8
Nozzle ø 9
Nozzle ø 10
Cotter pin
Hub conical part
Lip seal
Hub nozzle part
Ball retainer w. balls
Body
Horizontal shaft
Horizontal shaft, E-gear
Ball bearing
Gear frame
Bottom cover
Ball race
Main collar lower
O-ring
Main collar upper
Screw
Locking wire
Nozzle extension
Material
Stainless steel
Remarks
Spare part
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Polymer
Polymer
Stainless steel
Stainless steel
Carbon/Stainless steel
Elastomer
Stainless steel
Polymer
Stainless steel
Stainless steel
Stainless steel
Polymer
Polymer/Stainless steel
Polymer
Stainless steel
Stainless steel
Polymer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Polymer
Stainless steel
Polymer/Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel/Polymer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Elastomer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Spare part
Spare part
Spare part
Spare part
Wear part
Wear part
Spare part
Spare part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Spare part
Wear part
Wear part
Wear part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Spare part
Wear part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Spare part
Wear part
Not available
Wear part
Wear part
Wear part
Spare part
Spare part
Spare part
Spare part
Wear part
Wear part
Spare part
Wear part
Spare part
Please note that some of the polymer parts are in PEEK material. PEEK is not PEEK is not resistant to
concentrated sulfuric acid
Configuration as delivered marked ⌧
**
) See remarks page 22.
Page 36
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Cross Sectional Drawing, Gunclean Toftejorg T-82 Fixed
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 37
Reference List of Parts, Gunclean Toftejorg T-82 Portable
Pos.
1
2
3
3.1
3.2
4
5
6
7
8
9
9.1
10
11
12
13
14
15
16
17
18
19
19.1
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Ref. No.
TE21B500
TE21B501
TE703
TE703-50
TE803-0
TE21F328
TE21F505
TE21F506
TE705
TE51T153
TE825
TE21F510
TE21F507
TE21F330
TE826-1
TE814
TE21A585
TE21A367
TE817
TE719A
TE21D563
TE731
TE118
TE156
TE722S
TE826-1
TE21B340
TE826-1
TE50B007
TE50B008
TE50B009
TE50B010
TE448
TE21B536
TE21B549
TE724-2-15
TE21A380
TE21F500
TE828Z
TE829
TE730
TE21F504
TE826-1
TE827G2
TE807
TE827G1
TE801A
TE50B101
No/
Unit
1
1
1
1
1
1
1
1
2
1
1
1
1
3
2
1
4
1
2
38
18
1
1
2
2
2
2
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
Description
Nipple 1½” BSP
Nipple 1½” NPT
Guide 100%
Guide 50%
Guide ring 0%
Stem f. mech. seal
Top liner
Bottom liner
Impeller 100%
Mechanical shaft seal
O-ring
Turbine shaft
Bush
Gear wheel w. ball race
Ball race
Pinion
Collar bush
Worm wheel w. reinforcem.
Journal
Washer
Bottom gasket
Bearing cover
Screw
Spring washer
Bevel gear w. ball race
Ball race
Hub cover w. ball race
Ball race
Nozzle ø 7
Nozzle ø 8
Nozzle ø 9
Nozzle ø 10
Cotter pin
Hub conical part
Lip seal
Hub nozzle part
Ball retainer w. balls
Body
Horizontal shaft
Ball bearing
Gear frame
Bottom cover
Ball race
Main collar lower
O-ring
Main collar upper
Handle 1½” BSP
Nozzle extension
Material
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Polymer
Polymer
Stainless steel
Carbon/Stainless steel
Elastomer
Stainless steel
Polymer
Stainless steel
Stainless steel
Stainless steel
Polymer
Polymer /Stainless steel
Stainless steel
Stainless steel
Polymer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Polymer
Stainless steel
Polymer/Stainless steel
Stainless steel
Stainless steel
Stainless steel/Polymer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Elastomer
Stainless steel
Bronze
Stainless steel
Remarks
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Wear part
Spare part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Spare part
Wear part
Wear part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Spare part
Wear part
Spare part
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Spare part
Wear part
Not available
Wear part
Wear part
Spare part
Spare part
Spare part
Spare part
Wear part
Wear part
Wear part
Spare part
Please note that some of the polymer parts are in PEEK material. PEEK is not PEEK is not resistant to
concentrated sulfuric acid
Configuration as delivered marked ⌧
**
) See remarks page 22.
Page 38
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Cross Sectional Drawing, Gunclean Toftejorg T-82 Portable
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 39
Service Kits
TE55J000 Minor Service Kit T-82PT/FIX/MUD
Pos.
5
6
8
11
12
15
25
30
35
37
Part number
TE51T153
TE825
TE21F507
TE21A585
TE21A367
TE21D563
TE21B549
TE829
TE807
TE651
No./kit
1
2
1
3
2
1
1
2
1
3
Description
Mechanical Seal
O-ring
Bushing
Collar Bush
Worm Wheel
Packing
Lip Seal
Ball Bearing
O-ring
Locking Wire
TE55J010 Major Service Kit T-82PT/FIX/MUD
Pos
Part number
7
9.1
19.1
21
33
23
27
29
34
36
-
TE21F510
TE826-1
TE826-1
TE826-1
TE826-1
TE448
TE21A380
TE828Z
TE827G2
TE827G1
TE55J000
Page 40
No./kit
1
1
1
1
1
1
2
1
1
1
1
Description
Turbine Shaft
Ball race
Ball race
Ball race
Ball race
Cotter Pin
Ball retainer with balls
Horizontal Shaft
Main Collar, Lower
Main Collar, Upper
Service Kit Minor T-82PT/FIX/MUD
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
How to order spare parts and claim procedure
How to Order Spare Parts
On the Cross Sectional Drawings as well as on all instruction drawings, the individual parts have a
position number, which is the same on all drawings. From the position number the part is easily
identified in the Reference Lists of Parts, page 36-38.
Individual parts should always be ordered from the Reference Lists of Parts, page 36-38. Ref. number
and Description should be clearly stated.
Please also quote the 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 the working conditions, fill in copy of Claim Report - Working Conditions, which you
will find at the back of this manual.
How to contact Alfa Laval Tank Equipment A/S
For further information please feel free to contact:
Alfa Laval Tank Equipment A/S
Baldershoej 19
P.O. Box 1149
2635 Ishoej
Denmark
Phone no.: +45 43 55 86 00
Fax no.:
+45 43 55 86 01
www.alfalaval.com
www.toftejorg.com
Contact details for all countries are continually updated on our websites.
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 41
Service Card
Type of Machine
:
Serial No.
:
Configuration
:
Date
No. of Working
Hours
0
Nozzle diameter
:
mm
Impeller
:
%
Guide
:
%
Maintenance Actions/
Exchanged Parts
Remarks
Sign.
Machine put into operation
V. 94.2
Page 42
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1
Claim Report Working Conditions
Page 1/2
Ref. Claim Case
:
Machine/Cleaner Type
:
Serial No.:
Configuration
- Nozzles
:
xø
- Turbine/Inlet Guide
:
%
mm
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
Is sterilising being used?
:
Procedure (media/temp.)?
:
Is steam injection being used for heating?
:
Recirculation?
Yes
No
Yes
No
Time: __________
Temperature: __________
V. 98.1
Instruction Manual, Gunclean Toftejorg T-82
IM-TE91A052-EN1
Page 43
Claim Report Working Conditions (continued)
Page 2/2
Condition of Cleaning Media
Clean
Contaminated with (nature and description)
Chemicals/Solvents ___________________________
High viscous
Soluble
Sticky/tenacious
Low viscous
Solidifying
Hard particles/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/explosive
Sticky/tenacious
Contains soft particles
Low viscous
Solidifying
Contains hard particles/fibres
High viscous
Crystallizing
Is tank cleaner submerged in material?
Yes
No
Other information/Remarks
Date:
Page 44
Sign.:
Instruction Manual Gunclean Toftejorg T-82
IM-TE91A052-EN1