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Instruction Manual
Gunclean ToftejorgTM i270 -45° - 0° - 180°
IM-TE91A816-EN1 Date of issue: March 15, 2013
First published: March 15, 2013
Instruction Manual, Gunclean Toftejorg i270 Page 1 - 45° - 0° - 180° IM-TE91A816-EN1
Contents
Contents ....................................................................................................................................................... 1 Handling of loads .......................................................................................................................................... 2 Introduction ................................................................................................................................................... 3 Intended Use ................................................................................................................................................ 3 Patents and trademarks................................................................................................................................ 4 General Description ...................................................................................................................................... 4 Technical Description ................................................................................................................................... 8
Drive Unit ................................................................................................................................................................... 8 Principal Drawing ....................................................................................................................................................... 9 Manual Override ...................................................................................................................................................... 10 Cleaner Unit Working Principle ................................................................................................................................ 10 Cleaner Unit ............................................................................................................................................................. 11
Rating plate ................................................................................................................................................. 12 Technical Data ............................................................................................................................................ 13
General Data ........................................................................................................................................................... 13 Flow rate .................................................................................................................................................................. 14 Max. throw length .................................................................................................................................................... 15 Installation Data, Standard ....................................................................................................................................... 16 Installation Data, JIS Flange Standard .................................................................................................................... 17
Installation and Normal Operation .............................................................................................................. 17 Before Installation .................................................................................................................................................... 18 Before Use ............................................................................................................................................................... 18 Programming ........................................................................................................................................................... 18 Programming Knob .................................................................................................................................................. 20 Speed Adjustment ................................................................................................................................................... 21 How to calculate cleaning time ................................................................................................................................ 22 To Remove Cover .................................................................................................................................................... 24 Cleaning ................................................................................................................................................................... 25
Maintenance and Repair ............................................................................................................................ 28 Preventive Maintenance Guidelines and Service Kits .............................................................................................. 28 Maintenance Intervals and Service Kits Selection ................................................................................................... 28 How to Fill Oil ........................................................................................................................................................... 32
Reference Lists of Parts and Drawings ...................................................................................................... 34 Drive Unit: Gear Unit ................................................................................................................................................ 34 Drive Unit: Inlet Housing Assy ................................................................................................................................. 40 Drive Unit: Lifting Rod Assy ..................................................................................................................................... 42 Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed ................................................................................................. 44 Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable ......................................................................................... 46 Cleaner Head ........................................................................................................................................................... 48
Tools ........................................................................................................................................................... 51 How to Order Spare Parts .......................................................................................................................... 52 Claim Procedure ......................................................................................................................................... 52 How to contact Alfa Laval Tank Equipment A/S ......................................................................................... 52 Service Card ............................................................................................................................................... 53 Claim Report - Working Conditions ............................................................................................................ 54
Handling of loads
Back position of the centre of gravity: L/2 H/2 D/2
Warning: Do not walk under hanging loads!
Instruction Manual, Gunclean Toftejorg i270 Page 3 - 45° - 0° - 180° IM-TE91A816-EN1
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.
Note: Get the best and most economical performance from your tank cleaning machine. Insufficient preventive maintenance means poor performance, unscheduled stops, shorter lifetime and extra costs. Good preventive maintenance on the contrary means good performance, no unscheduled stops and superior total economy.
You will find the information contained in this manual simple to follow, but should you require further assistance, our Customer Support Department and world-wide 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.
© 2013 Alfa Laval Corporate AB This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related 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 Corporate AB. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.
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 compatibility with product, flushing
media, cleaning media, temperatures and pressure under the intended use.
Page 4 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Patents 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, 2013. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean Toftejorg™ is trademark or registered trademark of Alfa Laval Tank Equipment A/S. Other products or company names mentioned herein may be the trademarks of their respective owners. Any rights not expressly granted herein are reserved.
General Description
Gunclean Toftejorg i270 (fixed turbine driven) tank cleaning unit consists of two main parts: the Cleaner Unit (CU) and the Drive Unit (DU). The CU is mounted in the deck, protrudes into the tank and directs the liquid jet. The DU is the drive and operation unit and is permanently mounted on the CU inlet housing. The DU gets its driving power from the turbine fitted in the inlet housing. The turbine rotates by power generated by the cleaning fluid. The Gunclean Toftejorg i270 has an inlet housing where the turbine is mounted horizontally. The rotation speed of the DU normally varies between 0.5 rpm and 3 rpm depending on the nozzle dia and line pressure at the inlet housing but some adjustments can be carried out. The basic model of the Drive Unit has four programmes to choose from, all pre-programmed to give a tighter spray pattern in the bottom of the tank. One further advantage with this Drive Unit is the possibility to program the pitch angle of the nozzle to suit the actual tank in which the machine is fitted. The elevation of the nozzle in the vertical level is indicated by the nozzle angle scale, and the direction of the nozzle in the horizontal plane is shown by the direction of the tab on top of the lifting rod. The Gunclean Toftejorg i270 Drive Unit is designed for easy operation and easy service. The cover is easily removed to get access to the moving parts of the Drive Unit for service and inspection.
Note: Service must be carried out by trained or authorised staff.
Caution: Before operation the cover must be put back.
Instruction Manual, Gunclean Toftejorg i270 Page 5 - 45° - 0° - 180° IM-TE91A816-EN1
General Description (continued)
Three main parts:
1. Programmable Drive Unit. Consisting of Gear Unit and Inlet Housing 2. Down Pipe. 3. Cleaner Unit: Consisting of Cleaner Head.
PROGRAMMABLE DRIVE UNIT
CLEANER UNIT
D102599
GEAR UNIT
INLET HOUSING
DOWN PIPE
CLEANER HEAD
Page 6 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
General Description (continued)
The Cleaning Liquid Flow
The liquid of the jet comes from the tank cleaning supply line. Passes through the shut-off valve, proceeds into the inlet housing, past the turbine, turns downwards into the down pipe through the deck, then through the down pipe down to the vertical housing which rotates around a vertical axis. From the vertical housing the liquid turns 90° into the nozzle housing which rotates around a horizontal axis, turns 90° again, passes through the nozzle tube, the flow guide, out through the nozzle as a compact jet of liquid in order, finally, with great power, to hit the surface to be cleaned.
Cleaning Pattern with Programmed Pitch
Danger: Tank cleaning must be made according to IMO and/or owners instructions.
Instruction Manual, Gunclean Toftejorg i270 Page 7 - 45° - 0° - 180° IM-TE91A816-EN1
General Description (continued)
Cleaning Liquid Flow
D102643
Inlet Housing
Down Pipe
Vertical housing
Nozzle housing
Page 8 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Description
Drive Unit
Drive Unit Working Principle
By using the fluid in the lines, a turbine fitted in the inlet housing drives the lower one way clutch and rocker which is transmitting power to the turning worm gear, connected to the lifting rod. The lifting rod is fitted with a long key and can slide up and down inside the turning worm gear hub. The lifting worm gear screw is connected to the turning gear worm screw by a programmable gearing. On the lifting worm screw the upper one way clutch and rocker assy is fitted. The turning worm screw has a cam. This cam lifts the upper rocker and turns the lifting worm screw an amount corresponding to the stroke the rocker is allowed to do. The stroke is regulated by the programming knob and adjusting screw. Due to the one way clutch the lifting worm screw only rotates one way. The lifting worm gear rotates a crank shaft where the crank-pin is moving inside a lifting yoke fitted to the lifting rod. The lifting yoke is journalled on the lifting rod and only transmits lifting and lowering movements to the lifting rod. The programmable gearing is used to make it possible to choose a pitch angle suitable for most jet lengths required. A pitch giving a distance of max. 0.5 m height between two jets on the surface with the longest distance from the gun can be used as a guide when choosing the pitch angle. The programmable pitch and the pre-programmed lifting pattern giving a tighter pattern at the bottom of e.g. the tanks make the Drive Unit extremely easy to use. No change of programme is required once the pitch angle is programmed. Hand-crank the nozzle to the desired starting angle shown on the nozzle angle scale, open the valve and the Drive Unit is running. One cycle from top to bottom is usually all that is needed. The rotation speed can vary between 0.5 rpm to 3 rpm depending on the nozzle dia and line pressure. Some adjustments of the rotation speed can be carried out by adjusting the turbine mounted in the inlet housing.
D102644
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Technical Description (continued)
Principal Drawing
Page 10 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Description (continued)
Manual Override
An extension of the lifting gear screw is accessible from the outside of the Drive Unit. By turning this shaft with a handle the nozzle can be manually cranked to the starting point or during cleaning moved forward in its programme.
Cleaner Unit Working Principle
Above deck the inlet housing is mounted onto the doubling flange welded on deck. In the inlet housing the turbine is fitted. The turbine drives the Drive Unit. The upper part of the lifting rod is radically connected to the Drive Unit, turning gear screw by a key, and axially fixed to the lifting yoke with the top screw. The Drive Unit rotates and lifts or lowers the lifting rod simultaneously. The lower part of the lifting rod is fixed to the rack. The rack transmits the turning moment to the vertical housing and the lifting moment to the horizontal housing by the gear. The vertical housing rotates 360° around the vertical axis and horizontal housing moment is around the horizontal axis from -45° - 0°-180° - 0°- -45°. The nozzle is fitted to the horizontal housing. Consequently, the lifting rod is lifting or lowering the nozzle at the same time as it is rotation around the vertical axis.
Instruction Manual, Gunclean Toftejorg i270 Page 11 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Description (continued)
Cleaner Unit
D102645
Vertical housing Nozzle housing
Nozzle extension
Nozzle
Rack
Page 12 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Rating plate
The Rating plate is placed at the gear box. The Rating plate contains all identifications for the machine. The information is very useful, e.g. when ordering service or spare parts.
Gunclean Toftejorg i270 - Rating plate
Instruction Manual, Gunclean Toftejorg i270 Page 13 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Data
General Data
The Gunclean Toftejorg i270 equipment is generally operated in a range of 7-12 kg/sqcm media supply. Depending on the pressure and nozzle diameter the media flow and jet will be according to the diagrams on page 14 and 15. Normal leakage approximately 2%.
Weight : Gun with 2.5 meters length of Down pipe : 110 kg Per additional meter of Down pipe : 20 kg Servicing space : Minimum 350 mm radius from centre of unit for handling and servicing. Sound pressure : The sound pressure level at workstations will not exceed 70dB(A)
Page 14 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Data (continued)
Flow rate
Instruction Manual, Gunclean Toftejorg i270 Page 15 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Data (continued)
Max. throw length
Note: Throw lengths are measured as max. horizontal throw length at static condition. The curve above shows our design throw length. However, the maximum throw length is approximately 30-40% longer.
In general, 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.
Page 16 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Data (continued)
Installation Data, Standard
YARD SUPPLY
M20 STUD, WASHER AND NUT
ELASTOMER GASKET
DOUBLING RING TO CLASSIFICATION SOCIETIES REQUIREMENTS
D102646
INLET FLANGE ADAPTED TO ISO 7005 DN80 PN16 FLANGE STANDARD
Instruction Manual, Gunclean Toftejorg i270 Page 17 - 45° - 0° - 180° IM-TE91A816-EN1
Technical Data (continued)
Installation Data, JIS Flange Standard
INLET FLANGE ADAPTED TO JIS 16K-80A FLANGE STANDARD
YARD SUPPLY
M20 STUD, WASHER AND NUT
ELASTOMER GASKET
DOUBLING RING TO CLASSIFICATION SOCIETIES REQUIREMENTS
D102648
Page 18 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation
Before Installation
Make sure that the pipes have been properly flushed before installation of the machine. We know from experience that welding rods, plastic bags, rags and other debris will block the turbine. This may result in damage and poor performance.
Before Use
Fill oil in Drive Unit.
Programming
The i270 Drive Unit has a four programme devise build in. Those programmes control the spacing of the helical pattern, the pitch angle. The pitch angle is the angle the nozzle rises or lowers for each revolution of the nozzle in the horizontal plane. Because of the pre-programmed, varying helical pattern, the Drive Unit automatically makes the helical pattern closer at the lower angles (0° to 30°). The steps between the programmes are fixed and not adjustable. The step between programme 1 to 2 is 1° pitch 2 to 3 is 1° pitch 3 to full is 5.5° pitch All values valid at 90° lift The basic pitch angle, the pitch angle of programme 1, can be pre-set within certain limits by turning the adjusting screw on the programming unit. Because of the fixed steps between the different programmes, adjusting programme 1 also affects the other programmes. The useful angle of programme 1 is 0° to 1.5°.
Instruction Manual, Gunclean Toftejorg i270 Page 19 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
To pre-set pitch angles
1. Turn programming knob to programme 1.
2. With the handle turn first worm screw until the rocker assy rests on the highest point of the cam.
3. Turn the adjusting screw to the point where the rocker starts to lift from the cam. This setting will give programme 1 a pitch angle of 0°. Turning the adjusting screw down (clockwise) 0.75 revolutions rises the pitch angle to 1°. Other settings, see table page 20.
Pitch angle/rev
D102649
Page 20 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
Programming Knob
Turns of the adjusting screw from 0° pitch
Turns Pitch
0 0° 0.375 0.5° 0.75 1° 1.1 1.5°
Programmes with four different basic settings will give the pitch angle shown in the table below. Intermediate settings are of course also possible. Factory setting is shaded.
Degrees
Programme 1 0° 0.5° 1° 1.5°
Programme 2 1° 1.5° 2° 2.5°
Programme 3 2° 2.5° 3° 3.5°
Programme full 7.5° 8° 8.5° 9.0°
A basic 0° programme 1 (or very close) pitch angle can be useful if there is a dirty area around ullage level to be cleaned. A pitch giving a distance of 0.5 m height between two jets on the surface with the longest distance from the gun can be used as a guide when choosing the pitch angle for programme 1, 2 or 3 depending on type of cleaning used. See table below. Programme “full” can be used for flushing.
Height 0.5 m
Pitch angle 3° 1.5° 1°
Distance 10 m 20 m 30 m
Instruction Manual, Gunclean Toftejorg i270 Page 21 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
Speed Adjustment
Type 1
Before the speed can be adjusted the Drive Unit and turbine must be drained from oil. Loosen the nut on the turbine shaft and adjust the turbine to desired position. Reduce measure A to reduce speed. Increase measure A to increase speed. The turbine speed depends on the liquid flow, which in turn depends on the supply pressure and nozzle dia. Type 2
Loosen the lock nut and turn on the adjusting screw. Clockwise to increase the speed. Anti-clockwise to reduce the speed. When desired speed is set, tighten up the lock nut. Standard settings:
Nozzle ø ø18 Ø19 Ø20 Ø21 Ø22 Ø23 Ø24 Ø25 Ø26 Ø27 Ø28 Ø29 Ø30
Turbine 201079 201080 201080 201080 201080 201062 201062 201062 201062 201081 201081 201081 201081
Measure A 107mm 115mm 114mm 109mm 108mm 107mm 106mm 104mm 103mm 108mm 106mm 106mm 105mm
Page 22 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
How to calculate cleaning time
The cleaning time depends on pitch angle and rotation speed. A full cycle –45° - 0° - 180° - 0° - -45° (450°) with 1.5° pitch angle and 1 rpm takes 300 minutes. Because of varying pitch angles and small changes in rotation speed during cleaning, all figures are approximate. The RPM is preset at factory based on the specified pressure. If the actual pressure is higher than what originally has been specified, the nozzle will move faster and the total cleaning time will be reduced accordingly.
The tolerance for the RPM setting is 15 sec./rev. depending on the actual position of the gun.
Instruction Manual, Gunclean Toftejorg i270 Page 23 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
Calculating formula
Pitch angle (elevation per rev) = A Rotation speed rpm = B Washing angle (angle to be washed) = C Washing time, minutes = D
Washing time, minutes = D = C
AxB
Example A: Pitch angle = 3° B: Rotation speed = 1 rpm C: Washing angle 20° - 50° = 30° D: Washing time:
C = D 30 = D = 10 min.
AxB 3x1
Page 24 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
To Remove Cover
For programming, spot cleaning and service the cover has to be removed. 1. Loosen the two screws on top of Drive Unit.
2. Unscrew the hand crank screw on the side of the Drive Unit and remove the programming knob, fitted with a grub screw.
3. Lift the cover.
Note: The hand crank screw must be thoroughly tightened when the cover is refitted to avoid loosening when cleaning.
Warning: Service must be made by trained or authorised staff.
Caution: Before operation the cover must be put back.
Use lever to remove cover
Instruction Manual, Gunclean Toftejorg i270 Page 25 - 45° - 0° - 180° IM-TE91A816-EN1
Installation and Normal Operation (continued)
Cleaning
1. Turn the programming knob to desired programme.
2. Crank the Drive Unit to the starting angle
Note: Open arrows for down, filled arrows for up, see fig.
3. Slowly open the valve to start cleaning
Note: After cleaning, the Drive Unit must be hand cranked to 0°, the resting position
To clean glass from oil and condensed water: See To remove cover page 24.
Screw head Indicating nozzle direction
Nozzle angle scale Indicating nozzle angle.
Page 26 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
-45°
Installation and Normal Operation (continued)
Figure 1 shows the actual movement of the nozzle in a double wash. 1. The Drive Unit is hand cranked to 0° up.
2. The valve is opened and the cleaning starts. The Drive Unit rotates and lifts then nozzle to 180° from where the nozzle starts to turn downwards.
3. At 0° down a double top and bottom wash is completed. The cleaning is continued and at -45° the nozzle turns upwards and at 0° up a fourfold bottom wash is completed.
4. Unless the closest pitch programme is used for the top wash, a lower programme can be used to give an even more effective bottom wash if desired.
Figure 1
180°
0°
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Page 28 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
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 Gunclean Toftejorg i270 are available at two main levels for the Drive unit: Minor Service and Major Service. A single Service Kit covers the Cleaner Unit. Minor Service kit for Drive unit (above deck) is recommended to be replaced every 250 working hours or 2 ½ years, whichever comes first.
Major Service kit for Drive unit (above deck) is recommended to be replaced every 500 working hours or 5 years, whichever comes first. TE55A700 Minor Service Kit Drive Unit Contains
TE55A710 Major Service Kit Drive Unit Contains
Pos. Qty. x P/n. Description Pos. Qty. x P/n Description
011 1 x TE201047-6 Packing 027 1 x TE104192 Spring 012 1 x TE900513 O-ring 005 2 x TE201065 Washer 013 2 x TE900542-M8 Washer 017 2 x TE201074 Washer 020 1 x TE914310 O-ring 007 1 x TE201075 Turbine shaft 016 2 x TE914319 O-ring 003 1 x TE51L035 One way clutch 003 1 x TE916325 O-ring 025 2 x TE900511 One way clutch 013 1 x TE914396 O-ring 015 2 x TE900516 Rubber seal 019 1 x TE916306 O-ring 009 1 x TE900535 Bearing 002,016 4 x TE916319 O-ring 004 1 x TE900630 Radial bearing 003 1 x TE51L035 Roller Clutch 003 1 x TE900631 Radial bearing
020 1 x TE910850 Screw 021 1 x TE201071-1 Turbine bearing 008 1x TE900483 Pin 018 1x TE918226 O-ring - 1 x TE55A700 Service Kit Minor
Drive Unit
Instruction Manual, Gunclean Toftejorg i270 Page 29 - 45° - 0° - 180° IM-TE91A816-EN1
Maintenance and Repair (continued)
Service Kit for Cleaner (below deck) is recommended to be replaced every 500 working hours or 5 years, whichever comes first. TE55A730 Service Kit Cleaner Unit Contains
Qty. x P/n Description
1 x TE65S581 Bushing 2 x TE27G501 Roll for turning pin 1 x TE65S736 Bearing for rack 1 x TE27G518 Bearing vertical 1 x TE27G511 Lip seal
All Major Service kits includes the corresponding Minor Service Kits parts.
Each kit contains a maintenance guide. General recommendations
Always read the instruction and maintenance manuals before undertaking the service.
Some kit contains a small quantity of parts not need 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.
Page 30 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Maintenance and Repair (continued)
Additional maintenance recommendations
Internal parts in the drive unit are preserved for storage up to six months from delivery. Before use:
The drive unit must be filled with oil
Grease gears
Preserve internals, parts which is not covered by oil due to condensation
See recommended oils, greases and preservers below. Every two months or before each cleaning, whichever comes first:
Loosen drain plug and check for the presence of water, drain if necessary
Check oil level
Check greasing of gears
Check preserver Replenish as necessary. Complete drainage and oil change is recommended every 18 months. A vertically mounted machine requires 3.5 litres of oil for a full oil change. If the machine is tilted, less oil is required. See page 32 and 33 for oil level. Recommended oil and grease:
Oil Grease
BP GR-XP 68 Energrease LS EP 2 Castrol Alpha SP 68 Spheerol EPL 2 Chevron Borate EP LUB 68
Synlube CLP 150 Dura-Lith Grease EP 2
ELF ELF EPONA Z 68 EPEXA Mo2 , CERAN WR 2 ESSO Spartan EP 68 Ladex 2 Famm Regal R&O 68 Code 40702 Multifak EP 2 Code 40995 Gulf Multipurpose Gear Lubricant 80 Gulfcrown Grease EP no. 2 Mobil Mobil Gear 626 Mobilux EP 2
Mobil Mobil SHC 626 Mobilith SHC 460 Nynäs GL-10 (Epona 268) FL3-62 HF/EP Shell Omala Oil 68 Rhodina 2 Tellus T68 Alvania EP 2 Texaco Meropa 68 Multifak EP 2 Total Carter EP 68 Multis EP-22 Total/Fina/Elf Epona Z 68 Ceran WR 2
Preserve Drive Unit with: TECTYL 506 or equivalent
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Page 32 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Maintenance and Repair (continued)
How to Fill Oil
To fill oil in Drive Unit or to clean glass, the cover has to be removed, see instructions on page 24.
Caution: Oil leak can cause slippery floor!
Caution: Before operation the cover must be put back!
Use lever to remove cover
Instruction Manual, Gunclean Toftejorg i270 Page 33 - 45° - 0° - 180° IM-TE91A816-EN1
Maintenance and Repair (continued)
For guns tilted more than 15° Oil shall be filled to a level above the pipe to the turbine housing to secure the lubrication of the turbine. Gears above oil level shall be greased and all other parts rust protected, see page 30.
Page 34 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings
Drive Unit: Gear Unit
Article no. TE27G307-F
Pos. Ref. No. No/Unit Description Material Notes
1 TE101174 1 Programming knob SS 5204 12 TE900513 1 O-ring Elastomer 13 TE900542-M8 2 Washer Stainless steel/elastomer 14 TE910568 2 Screw Stainless steel 15 TE900516 2 Rubber seal Rubber 16 TE104224 1 Washer Stainless steel 17 TE104330-12 1 Glass Polymer 18 TE104209 1 Gasket for glass Rubber 19 TE900518 1 Nut Brass 20 TE914310 1 O-ring Elastomer 21 TE900545 1 Drain plug Brass 28 TE51A956 1 Grub screw Stainless steel 31 TE51A575 1 Screw Stainless steel 35 TE104129 1 Cover Stainless steel
TE104331-12 1 Glass kit Pos. 17, 18 and 19
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Reference Lists of Parts and Drawings (continued)
Drive Unit: Gear Unit
Article no. TE27G307-F
21
20
35
12
3116 15
13
14
15
13
14
19
18
17 28
1
27GXXXXXXXXX-F manual top
Page 36 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Gear Unit
Article no. TE27G307-F
Pos. Ref. No. No/Unit Description Material
1 TE27G527-F 1 Worm gear lift -45° - 0° - 180° Steel 2 TE104431 1 Scale -45° - 0° - 180° Aluminium 3 TE900520 1 Screw Steel 4 TE51L152 1 Bearing Brass 5 TE104169 1 Wheel Steel 6 TE27G546 1 Worm Gear rotation Steel 7 TE27G548 1 Bracket Steel
13 TE27G536 1 Lifting yoke Steel 18 TE910412 6 Screw Stainless steel 19 TE900480 2 Washer Stainless steel 21 TE27G549 1 Carrier for drive shaft Steel 22 TE910565 1 Screw Stainless steel
TE27G306-F 1 Worm gear elevation assy -45° - 0° - 180° Pos 1,2 and 3
Instruction Manual, Gunclean Toftejorg i270 Page 37 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Gear Unit
Article no. TE27G307-F
1
2
5 4 3
18
18
6
18
7 18
19
19
18
21
13
22
27GXXXXXXXXX-F manual gear
Page 38 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Gear Unit
Article no. TE27G307-F
Pos. Ref. No. No/Unit Description Material Notes
1 TE27G557 1 Gear frame i270 Cast steel Left side
2 TE27G306-F 1 Worm gear for elevation assy Right side
4 TE51L152 3 Bearing Brass
5 TE104169 1 Wheel Steel
6 TE27G531 1 Center shaft Steel
8 TE27G532 1 Worm upper Steel
9 TE27G533 1 Worm lower Steel
10 TE104194 1 Programme cam Brass
11 TE27G521 1 Washer for programme shaft Steel
14 TE27G522 1 Programme shaft Stainless steel
15 TE900521 1 Grub Screw Stainless steel
16 TE914003 1 Nut Stainless steel
17 TE27G523 1 Washer center shaft Steel
18 TE910108 1 Screw Steel
19 TE27G305 1 Rocker Assembly Steel
21 TE913042 1 Circlip Steel
22 TE27G529 2 Shaft end worm screw Steel
23 TE27G530 2 Distance washer worm screw Brass
24 TE104213 1 Rocker rotation Steel
25 TE900511 2 One way clutch Stainless steel
27 TE104192 1 Spring Spring steel
28 TE104215 1 Shaft Steel
29 TE900606 2 Retaining pin Steel
30 TE51A956 1 Set screw Stainless steel
31 TE914033 1 Locking nut Stainless steel
32 TE51A576 2 Screw Steel
33 TE51L035 2 Roller clutch
34 TE27G555 1 Spring spring steel
35 TE914032 2 Lock nut Stainless steel
Instruction Manual, Gunclean Toftejorg i270 Page 39 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Gear Unit
Article no. TE27G307-F
27
4
4
15
16
1
17 18
30
10
34 14
11
3129
29
282433
35
1933
21835
23
23
25
22
22
252
64
5
9
32
3229
27G307-F manual
Page 40 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing Assy
Pos. Ref. No. No/Unit Description Material
1 See table below* 1 Inlet housing
2 TE916319 2 O-ring Rubber
3 TE916325 1 O-ring Rubber
4 TE910394 3 Screw steel
5 TE910218 1 Screw Stainless steel
6 TE27G550 1 Key Stainless steel
7 See page 42 Lifting rod assy
8 TE208341 1 Location sleeve Stainless steel
9 See page 44 1 Turbine ASSY
10 TE910572 6 Screw Stainless steel
11 TE201047-6 1 Gasket Sealing material
12 TE910580 2 Screw Stainless steel
13 TE900374 1 Sealing ring Rubber
14 TE27G309-XX** 1 Down pipe Stainless steel
15 TE201078-1 1 Tube Bronze
16 TE916319 2 O-ring Rubber
17 TE900605 1 Hose clip Stainless steel
18 TE918332 1 Bearing Bronze
19 TE914128 6 Washer Stainless steel
The article number depends on machine configuration and material choice.
Inlet Housing* Galvanized, article no. Epoxy, article no.
DIN 2501-DN80 PN16 201014-20 201014-22 JIS 16K-80A 201014-21 201014-23 ASME B16.5, 3” Class 150 201014-24 201014-25
Down pipe** -XX = Length of down pipe
(Example: Length of down pipe = 3.5 meter: Ref. no. TE27G309-35).
See the Rating Plate for specific information regarding length of down pipe and article number for inlet housing. The Rating plate is depicted on page 12 of this instruction manual.
Instruction Manual, Gunclean Toftejorg i270 Page 41 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing Assy
Page 42 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Lifting Rod Assy
Pos. Ref. No. No/Unit Description Material
20 See table below 1 Lifting rod assy Stainless steel
43 TE51A518 2 Nut Stainless steel
46 TE910222 1 Screw Stainless steel
53 TE27G551 1 Upper lifting shaft Stainless steel
54 TE51A207 1 Screw Stainless steel
The article number depends on machine configuration and material choice.
Lifting rod assy Index for TCM length
(e.g. -10 = 1 meter, -15 = 1.5 meter -10 -15 -20 -25 -30
-35 -40 -45 -50
Machine type Ref. no.
No split TE20G308-XX
1 split TEXXXXXX-XX
2 split TEXXXXXX-XX
See the Rating Plate for specific information regarding length of down pipe. The Rating plate is depicted on page 12 of this instruction manual.
Instruction Manual, Gunclean Toftejorg i270 Page 43 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Lifting Rod Assy
46
43
20
43
53
54
Page 44 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed
Galvanized or Epoxy Coated
Article no. complete Turbine unit Galvanized Epoxy coated
Fixed TE201073-20 TE201129
Bill of material for complete Turbine unit, Fixed
Pos. Ref. No. No/Unit Description Material Note
1 TE201072-6 1 Turbine housing Cast iron Galvanized TE201128 1 Turbine housing Cast iron Epoxy coated
3 TE900631 1 Bearing Glycodur 4 TE900630 2 Bearing Glycodur 5 TE201065 2 Washer Steel 6 TE201058 1 Excenter Steel 7 TE201075 1 Turbine shaft Stainless steel 8 TE900483 1 Pin Stainless steel 9 TE900535 1 Bearing Glycodur
10 TE201052 1 Bearing house Steel 11 TE201076 1 Shaft Steel 12 TE201077 1 End Cover Bronze 13 TE914396 1 O-ring Rubber 14 TE900629 2 Drain plug Brass 15 TE916306 2 O-ring Rubber 16 TE914016 1 Nut Stainless steel 17 TE201074 2 Washer Polymer 18 TE918226 1 O-ring Rubber 19 TE916306 1 O-ring Rubber 20 TE910850 1 Grub screw Stainless steel 21 TE201071-1 1 Turbine bearing Stainless steel
Pos. 22 – 25, Turbine
Pos Ref. No. No/Unit Description Material
22 TE201062 1 Turbine for nozzle ø23 – ø26 Stainless steel 23 TE201079 1 Turbine for nozzle ø18 Stainless steel 24 TE201080 1 Turbine for nozzle ø19 – ø22 Stainless steel 25 TE201081 1 Turbine for nozzle ø27 – ø32 Stainless steel
Note! Only one turbine per turbine unit. Note! Pos. 22 – 25: Turbine distance settings depending of nozzle size and turbine design, see page 21.
Instruction Manual, Gunclean Toftejorg i270 Page 45 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed
Galvanized or Epoxy Coated
21
17
17
18
20
19
15
14
4
5
13
4
1415
12
56
8910
1
11
7
3
16
D102652
Page 46 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable
Galvanized or Epoxy Coated
Article no. Complete Turbine unit Galvanized Epoxy coated
Adjustable TE27A320 TE27A322
Bill of material for complete Turbine unit, Adjustable
Pos. Ref. No. No/Unit Description Material Note
1 TE900631 1 Bearing Glycodur 2 TE900630 2 Bearing Glycodur 3 TE201065 1 Washer Steel 4 TE900483 1 Spring pin Stainless steel 5 TE900535 1 Slide bearing Glycodur 6 TE201076 1 Shaft Steel 7 TE914396 1 O-ring Rubber 8 TE900629 1 Drain plug Brass 9 TE914306 1 O-ring Rubber
10 TE914016 1 Nut Stainless steel 11 TE918226 1 O-ring Rubber 12 TE916306 1 O-ring Rubber 13 TE910850 1 Grub screw Stainless steel 14 TE201071-1 1 Turbine bearing Stainless steel 15 TE27A522 1 Turbine housing w. 6 holes Steel Epoxy coated
TE27A520 1 Turbine housing w. 6 holes Steel Galvanized 16 TE201092 1 Turbine shaft Stainless steel 17 TE201093 1 Lock nut Bronze 18 TE201094 1 Distance ring Steel 19 TE201089 1 Bearing housing Steel 20 TE201095 1 Excentric Steel 21 TE201088 1 End plate Bronze 22 TE201091 1 Adjusting screw Bronze 23 TE900693 1 Plug ½” Bronze 24 TE914318 1 O-ring Elastomer 25 TE201074 1 Washer Polymer 26 TE918133 1 Pin Stainless steel
Pos. 27 – 30, Turbine
Pos Ref. No. No/Unit Description Material
27 TE201062 1 Turbine for nozzle ø23 – ø26 Stainless steel 28 TE201079 1 Turbine for nozzle ø18 Stainless steel 29 TE201080 1 Turbine for nozzle ø19 – ø22 Stainless steel 30 TE201081 1 Turbine for nozzle ø27 – ø32 Stainless steel
Note! Only one turbine per turbine unit. Note! Pos. 22 – 25: Turbine distance settings depending of nozzle size and turbine design, see page 21.
Instruction Manual, Gunclean Toftejorg i270 Page 47 - 45° - 0° - 180° IM-TE91A816-EN1
Reference Lists of Parts and Drawings (continued)
Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable
Galvanized or Epoxy Coated
14 1310
112
6
11 25
15
3
22
2 4 19 18 526 7 20
24
1721 1623
9
8
2
27A320
27 28 29 30
Page 48 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Reference List of Parts and Drawing (continued)
Cleaner Head
Article no. TE27G302
Pos. Ref. No. No/Unit Description Material Notes
1 TE65S581 1 Carbon bushing Carbon 2 TE51A518 2 Locking Nut Stainless steel 3 TE65S736 1 Bearing for rack in LF. Cl.head Carbon 4 TE65S740 1 Lock ring bottom Stainless 5 TE910214 1 Screw Stainless steel 6 TE27G510 1 Vertical housing Stainless steel 7 TE27G303 1 Nozzle housing assy Stainless steel 8 TE27G517 1 Ball race for lip seal Stainless steel 9 TE27G515 1 Ball race outside vertical Stainless steel
10 TE27G508 2 Lock ring outside Stainless steel 11 TE27G507 2 Lock ring inside Stainless steel 12 TE27G502 1 Turning pin Stainless steel 13 TE27G501 2 Roll for turning pin Stainless steel 14 TE27G516 2 Lock washer Stainless steel 15 TE27G512 1 Rack Stainless steel 16 TE27G518 1 Bearing vertical upper Cl.head Polymer 17 TE27G511 1 Lip seal Polymer 18 TE27G304 2 Ball retainer w. balls Polymer 19 TE27G514 2 Ball race vertical inside Stainless steel 20 TE27G559 1 Nozzle extension for i270 Stainless steel 21 TE74A562 1 Nozzle vane assy Stainless steel 22 TE27G554-XX 1 Nozzle Stainless steel *
Note! * -XX = Nozzle size (Example: Nozzle diameter = 25 mm: Ref. no. TE27G554-25)
The article number depends on machine configuration and material choice. See the Rating Plate for specific information regarding nozzle size. The Rating plate is depicted on page 12 of this instruction manual.
Instruction Manual, Gunclean Toftejorg i270 Page 49 - 45° - 0° - 180° IM-TE91A816-EN1
Reference List of Parts and Drawing (continued)
Cleaner Head
Article no. TE27G302
23
9
11
1619
18
10
2 14 13
12 13
14 2
7 10 17 8 18 19 1 11
5
15
43
22
21
20
208524
Page 50 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Service Kits
TE55A700 Minor Service Kit i270 Drive Unit
Pos Part number No./kit Description
3 TE916325 1 O-ring 3 TE51L035 1 Roller Clutch
11 TE201047-6 1 Packing 12 TE900513 1 O-ring 13 TE900542-M8 2 Washer 13 TE914396 1 O-ring
2, 16 TE916319 4 O-ring 19 TE916306 1 O-ring 20 TE914310 1 O-ring
TE55A710 Major Service Kit i270 Drive Unit
Pos Part number No./kit Description
3 TE51L035 1 One way Clutch 3 TE900631 1 Radial bearing 4 TE900630 1 Radial bearing 5 TE201065 2 Washer 7 TE201075 1 Turbine shaft 8 TE900483 1 Pin 9 TE900535 1 Bearing
15 TE900516 2 Rubber seal 17 TE201074 2 Washer 18 TE918226 1 O-ring 20 TE910850 1 Screw 21 TE201071-1 1 Turbine bearing 25 TE900511 2 One way Clutch 27 TE104192 1 Spring
- TE55A700 1 Service Kit Minor i270 Drive Unit
TE55A730 Service Kit i270 Cleaner Unit
Pos Part number No./kit Description
9 TE65S581 1 Bushing 11 TE27G501 2 Roll for turning pin 14 TE65S736 1 Bearing for rack 18 TE27G518 1 Bearing vertical 24 TE27G511 1 Lip seal
Instruction Manual, Gunclean Toftejorg i270 Page 51 - 45° - 0° - 180° IM-TE91A816-EN1
Tools
Part No. TE55A900
For Drive Unit TE27G307
Pos. Part no. No./unit Description Notes
1 TE900080 1 Tool box 2 TE900523 1 Adjustable spanner 3 TE900524 1 Screw driver 4 TE900083 1 Hexagon bar wrench 5 TE900526 1 Hexagon bar wrench 6 TE900086 1 Hexagon bar wrench 7 TE900088 1 Hexagon bar wrench 8 TE900525 1 Retaining ring pliers 9 TE900529 1 Hand crank 10 TE900600 1 Socket 11 TE900548 1 Extension 12 TE81B160 1 Lever for i270, for Cover
Page 52 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
How to Order Spare Parts
On all instruction drawings the individual parts have a position number, which is the same on all drawings. From the pos. no. the part is easily identified in the Reference Lists of Parts, page 34 -48. Individual parts should always be ordered from the Reference Lists of Parts, page 34 -48.. Ref. no. and Description should be clearly stated. Please also quote the type of machine and serial No. This will help us to help you. The type and serial Nos. are stamped on the Gear house 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 is 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 i270 Page 53 - 45° - 0° - 180° IM-TE91A816-EN1
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 54 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1
Claim Report - Working Conditions
Page 1/2
Ref. Claim Case :
Machine/Cleaner Type : Serial No.:
Configuration
- Nozzles : 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 being used for heating? : Yes No
Time: __________
Temperature: __________
V. 98.1
Instruction Manual, Gunclean Toftejorg i270 Page 55 - 45° - 0° - 180° IM-TE91A816-EN1
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: Sign.:
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