Alfalaval Gunclean Toftejorg TZ-75 User manual

Instruction Manual
Gunclean Toftejorg™ TZ-75 Portable
IM-TE91A251-EN3
Date of issue: January 24, 2011
Covering ▪Standard Machines
▪Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 1
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Contents
Contents ........................................................................................................................................ 1
Introduction.................................................................................................................................... 3
Intended Use ................................................................................................................................. 4
Patents and trademarks ................................................................................................................ 4
ATEX Marking ............................................................................................................................... 5
General Description....................................................................................................................... 6
Functioning................................................................................................................................................6
Standard configurations.............................................................................................................................7
Options ......................................................................................................................................................7
Available add-ons ......................................................................................................................................7
Technical Data............................................................................................................................... 8
Installation and Normal Operation............................................................................................... 12
General Safety and Installation Instructions.............................................................................................12
Normal Operation.....................................................................................................................................14
Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC..............15
Maintenance and repair................................................................................................................ 16
Service and Repair of ATEX Approved Machines....................................................................................16
Recommended Service Intervals.............................................................................................................16
Preventive Maintenance Guidelines and Service Kits..............................................................................17
Maintenance intervals and Service Kits selection....................................................................................17
Top Assembly..........................................................................................................................................20
Bottom Assembly.....................................................................................................................................22
Hub Subassembly....................................................................................................................................24
Stem Subassembly..................................................................................................................................26
Gear Subassembly ..................................................................................................................................28
Replacement of Collar Bushes.................................................................................................................30
Replacement of Ball races.......................................................................................................................32
Replacement of Main Collars...................................................................................................................34
Tools............................................................................................................................................ 36
Trouble Shooting Guide............................................................................................................... 38
Reference List of Parts................................................................................................................ 40
Cross Sectional Drawing............................................................................................................. 41
Service Kits.................................................................................................................................. 42
TE55M000 Minor Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX..................................................................42
TE55M010 Major Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX..................................................................42
How to order spare parts and claim procedure........................................................................... 43
How to contact Alfa Laval Tank Equipment A/S.......................................................................... 43
Service Card................................................................................................................................ 44
Claim Report Working Conditions ............................................................................................... 45
Declaration of Conformity............................................................................................................ 47

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 3
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
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.
© 2011 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.

Page 4 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
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.
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, 2011. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean
Toftejorg TM is a 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.

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 5
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
If ordered with ATEX certificate:
ATEX Marking
The Gunclean Toftejorg TZ-75 Portable is certified as category I components. The certification is
carried out by the notified body Baseefa, who has issued the certificate no. 10ATEX0188X. The
marking on the ATEX certified Gunclean Toftejorg TZ-75 Portable is as follows:
Changes to the machine are not allowed without approval by the person responsible for the ATEX
certification at Alfa Laval Tank Equipment A/S. If changes are made – or spare parts other than Alfa
Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no
longer valid.
Important
ATEX
information:
Also see page 16 regarding special conditions for repair of ATEX certified
machines.

Page 6 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
General Description
The Gunclean Toftejorg TZ-75 is a media driven and media lubricated tank cleaning machine. As it is
self-lubricating, there is no lubricating substance such as oil, grease etc. in the machine which needs to
be regularly changed.
Functioning
The flow of the cleaning fluid into the machine passes through a guide and a turbine, which is set into
rotation. The turbine 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 (10 3/4revolutions 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 turbine depends on the flow rate through the machine. The higher the flow rate
is, the higher the speed of rotation will be. In order to control the RPM of the machine for a wide range
of flow rates, the efficiency of the turbine can be changed (100% and 0% Turbine/Inlet guide).
Apart from the jet flow through the nozzles, fluid is leaking through the top of the machine, at the hub
and through the bottom cover. The leakages between the moving parts at the top and at the hub are
cleaning the gabs and thus preventing build-up of material that might cause extra friction. The flow
through the bottom cover is due to the fact that the machine is media lubricated, and that accordingly a
flow through the gearbox is needed.

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 7
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
General description (continued)
Standard configurations
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.
Connection Turbine/Inlet Guide Nozzles (mm) (1” thread conn.) Article/Ref. No.
Nipple:
2” NPT
100% 2xø11
2xø12 TE22B112 TE22B114
0 % 2xø12
2xø13
2xø14
2xø15
TE22B128
TE22B130
TE22B132
TE22B134
Nipple:
2” BSP
100% 2xø11
2xø12 TE22B162 TE22B164
0 %
2xø12
2xø13
2xø14
2xø15
TE22B168
TE22B180
TE22B182
TE22B184
Nipple:
2½” ASA, Male
di: ø55mm
100% 2 x ø11
2 x ø12 TE22B212 TE22B214
0% 2 x ø12
2 x ø13
2 x ø14
2 x ø15
TE22B228
TE22B230
TE22B232
TE22B234
Options
Machines with Nozzle extensions for longer throw length can be supplied as an option. Same article
no. with index no. -22, e.g. TE22B162-22.
Machines with Nozzle extensions and E-gear: Same article no. with index no. -62, e.g. TE22B162-62.
Gunclean Toftejorg TZ-75 machines with PEEK wear parts: TE22Bxxx-06.
Available add-ons
- ATEX, category 1 for installation in zone 0/20
TE22BXXX-70 ATEX
TE22BXXX-22-70 ATEX + nozzle extension
TE22BXXX-62-70 ATEX + nozzle extension and E-gear
Explanation to Add-ons
ATEX, category 1 for installation in zone 0/20 in accordance with Directive 94/9/EC

Page 8 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Technical Data
Weight of machine : 13 kgs (28.6 lb)
Working pressure : 2-12 bar (30-175 psi)
Recommended inlet pressure : 5-10 bar (75-150 psi)
Working temperature max. : 95°(200°F)
Ambient temperature 0 – 140°C
Materials : Stainless steel, polymer, carbon
Principal dimensions in mm

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 9
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Technical data (Continued)
Flow rate

Page 10 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Technical data (Continued)
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 t
he curves, the pressure drop in the supply lines between pump and
machine must be taken into consideration.
Option: The Gunclean Toftejorg TZ-75 Portable can be supplied with nozzle extensions and E-
gearing for longer throw length. Curves for flow rate and throw length are currently not updated
accordingly.

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 11
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Technical data (Continued)
Cleaning Time f. complete Pattern (= 4 cycles)

Page 12 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Installation and Normal Operation
General Safety and 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.
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, unless
an electrical connection is otherwise established to ensure an effective earthing. In
addition, connecting pipe work, must be electrically conductive and earthed to the tank
structure. The resistance between the nozzles and the tank structure should not exceed
20,000 Ohm. This is essential to avoid the build-up of static electricity on the machine.
For further information see DS/CLC/TR 50404:2003 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex-zones
without type approval and marking, corresponding to the EX-class in question.
Note:The machine shall be installed in accordance 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 depending of
application, the EU-Pressure Equipment Directive, the EU-
ATEX Directive and other relevant
Directives and shall be CE-marked before it is set into operation.
To protect your tank coating it is recommended to mount bumpers on the tank cleaning machine.
The machine as delivered has been tested at the factory before shipping. For transportation reasons,
the nozzles have been screwed off after the test. In order to secure the nozzles against falling off due to
vibrations and other external strains it is important that the nozzles are tightened properly after mounting. If
not, the nozzles may be blown off during tank cleaning and cause severe damage on tank, valves and pump.
This is especially important if machines are fixed installed in tanks and vessels within the transportation
sector in trucks, railcars and onboard ships.
Normally it is sufficient to tighten the nozzles with the specified torque. However depending on the
application and local policies an extra securing may be preferred.
Subject to the intended use environment and any inhouse user requirements or policies, a liquid threadlocker
such as Loctite No. 243 or equivalent could be used. Other methods could be acceptable and subject to
customer preference. For detailed instruction on pre-cleaning and application of the product carefully follow
the instruction on the used locking system.

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 13
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Installation and Normal Operation (continued)
1. Clamp machine firmly in a vice: Place machine on
top of vice with Hub w. nozzles down wards as
illustrated on the figure. Clamp on the Hub. To
protect machine use rubber jaws on the vice.
2.
Set torque wrench at the specified tightening
torque.
3. Tighten nozzle with the torque wrench.
Recommended tightening torque: 75 Nm
4. Check that the machine is in operating condition by inserting 3/16" hex Screwdriver (tool No.
TE134A) in screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance
is recognised, the machine should be disassembled to localise the cause.

Page 14 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Installation and Normal Operation (continued)
Normal Operation
Cargo and Cleaning Media: Use only media compatible with stainless steel, polymer and carbon.
Normal detergent, moderate solutions of acis and alkalics will be acceptable. Agressive chemicals,
excessive concentrations of chemicals at elevated temperatures, as well as certain dissolvents and
hypochlorids should be avoided. If you are in doubt, contact the local Alfa Laval Tank Equipment
distributor.
After Use Cleaning: After use flush the machine with fresh water. Cleaning solutions should never be
allowed to dry or set-up in the system due to possible "salting out" or "scaling" of the cleaning
ingredient. If cleaning media contains volatile chloride solvents, it is recommended not to flush with
water after use, in case this can create hydrochloric acid.
Pressure: Avoid Hydraulic shocks. Put on pressure gradually. Do not exceed 12 bar inlet pressure.
Recommended inlet pressure appears from Technical Data (page 8-9). High pressure in combination
with high flow rate will increase consumption of wear parts.
ATEX
Warning: If stream cleaning is done through the machine, the steam pressure must not cause
the machine to rotate.
ATEX
Warning: If the machine is drained using compressed air, then the compressed air pressure
must not cause the machine to rotate.
Temperature: In accordance with the ATEX specifications regarding special conditions for safe use,
see page 15.
ATEX
Warning: Tanks with capacities greater than 100 m3that could contain a flammable atmosphere
should not be steam cleaned, as steam issuing from a nozzle could contain charged
droplets.
Tanks smaller than this may be steam cleaned providing that: the steam nozzles and
other metal parts of the system are reliably earthed and grounded to the tank
structure.
ATEX
Warning: In potentially explosive atmospheres, the temperature must not exceed the maximum
surface temperature according to the temperature class for the combustible gas or
liquid.

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 15
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Installation and Normal Operation (continued)
Special Conditions for Safe Use in accordance with the ATEX Certification,
Directive 94/9/EC
ATEX
Warning: The unit may be operated, in a hazardous area, only when filled with the process fluid.
ATEX
Warning: The maximum permitted flush or cleaning fluid temperature is 95°C, with an ambient
temperature range of 0°C to 140°C.
ATEX
Warning: The maximum permitted flush or cleaning fluid pressure difference across the machine
is 3 bar.
ATEX
Warning: The unit must not be operated in a vessel having an enclosed volume of greater than
100m3.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive 94/9/EC of
March 23 1994, the Safety Precautions on page 12 must be observed.

Page 16 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Maintenance and repair
Service and Repair of ATEX Approved Machines
In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN
60079-19, all service and repair of ATEX approved machines should be performed by Alfa Laval Tank
Equipment A/S, Ishoej, Denmark.
Warning: ATEX requirements regarding repair of ATEX approved machines according to EN
60079-19.
A tag with the following labelling information must be attached to the machine:
- Repair symbol R
- Alfa Laval logo and address
- Repair number
- Date of repair
- Machine serial number
The tag must be laminated and attached to the machine-downpipe outside the tank
using a cable tie.
If a customer wishes to carry out service or repair himself, it is the responsibility of the repair shop to
ensure that the ATEX requirements are met in any way possible. After performing service or repair, the
repair shop thus carries the full responsibility for the ATEX approval of the machine.
Recommended Service Intervals
Inspection every 500 working hours. After 2000 working hours: inspection every 200 hours.
A service consists of:
0. At a pressure of 0.3 bar open a hatch in the tank to verify rotation and liquid fans are emerging
from all slots. ATTENTION: Use only pure water at normal temperature for safety reasons.
If needed proceed to 1).
1. Un-install the machine
2. Visual inspection for foreign objects. Remove any objects and clean before rotation verification.
3. Rotation verification by hand for free rotation.
4. Reinstall machine
5. Fill in the Service Log

Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 17
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Maintenance and repair (continued)
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.
See page 16 regarding special conditions for repair of ATEX certified machines.
Maintenance intervals and Service Kits selection
Alfa Laval Service Kits for Tank Cleaning Machine type, TZ-75PT is available in two levels: Minor
Service and Major Service.
Minor Service Kit is recommended to be replaced every 250 working hours or 2½ years, whichever
comes first.
TE55M000 Minor Service Kit contains:
Pos.
Qty x P/n
Description
6
1 x TE609P
Main bush
12
3 x TE615K
Collar bush
13 1 x TE22A360 Worm wheel
14 1 x TE22A360 Worm heel
19 4 x TE651 Locking wire
30 2 x TE929K Slide bearing
Major Service kit is recommended to be replaced every 1000 working hours or 10 years, whichever
comes first.
TE55M010 Major Service Kit contains:
Pos.
Qty x P/n
Description
7
1 x TE911K
Turbine shaft
8.1
1 x TE126-1
Ball race
20.1
1 x TE126-1
Ball race
21.1
1 x TE126-1
Ball race
28.3
1 x TE126-1
Ball race
23.1
1 X TE624-11
Hub liner
24 1 x TE448 Cotter pin
27 2 x TE126S Ball retainer with balls
28.1 1 x TE127Z1 Main collar, upper
28.2 1 x TE127Z2 Main collar, lower
28.4 1 x TE127-3 Collar, hub
29
1 x TE128Z
Horizontal shaft
1 x TE55M000
Service Kit Minor, TZ-75FIX/ TZ-75PT/TZ-750FIX

Page 18 Instruction Manual, Gunclean Toftejorg TZ-75 Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A251-EN3
Maintenance and repair (continued)
All Major Service kits includes the corresponding Minor Service Kits parts. Each kit contains a
maintenance guide.
The following recommended preventive maintenance programme is based on tank cleaning machines
working in average conditions. However, 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. We
trust that you will adjust your maintenance programme to suit.
General recommendations
•Always read the instruction and maintenance manuals before undertaking the service.
•Some kit contains 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.
Note: Recommended tightening torque for all screws: 4-5 Nm.
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.
Disassemble machine as described on the following pages.
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotchbrite, S-Ultrafine, eventually
chemical cleaner and fine abrasive cloth.
3. Assemble machines as described in the following pages.
4. Check that the machine is in operating condition by inserting 3/16" hex Screw-driver (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, see page 44.