Alfalaval Toftejorg TJ20G User manual

IM-TE91A600-EN2
Toftejorg TJ20G
Instruction Manual
ï
Return to menu

Contents
Contents .............................................................................................................................. 1
Introduction.......................................................................................................................... 3
General Description.............................................................................................................4
Functioning .................................................................................................................................... 4
Standard Configurations ................................................................................................................ 5
Standard Options ........................................................................................................................... 5
Accessories.................................................................................................................................... 6
Technical Data..................................................................................................................... 8
Performance Data.......................................................................................................................... 9
Installation and Normal Operation..................................................................................... 10
General Installation Instructions................................................................................................... 10
Normal Operation......................................................................................................................... 11
Maintenance and Repair ................................................................................................... 12
Preventive Maintenance............................................................................................................... 12
Turbine and Carrier Assembly ..................................................................................................... 14
Remaining Assemblies................................................................................................................. 16
Replacement of Ball Races.......................................................................................................... 19
Toftejorg TJ20G Service Kits and Tool kit......................................................................... 21
Minor Service Kit for Toftejorg TJ20G, all versions, article no. TE20G299 .................................. 21
Service Kit for Toftejorg TJ20G Nitronic, serial no. from 0604 001, article no. TE20G288 .......... 21
Service Kit for Toftejorg TJ20G PTFE, serial no. below 0101 001, article no. TE20G285 ........... 21
Service Kit for Toftejorg TJ20G PEEK, serial no. between 0101 001 and 0603 099,
article no. TE20G286 ................................................................................................................... 22
Standard Tool Kit for Toftejorg TJ20G ......................................................................................... 22
Trouble Shooting Guide .................................................................................................... 24
Symptom: Slow rotation or failure of machine to rotate................................................................ 24
Exploded View Drawing .................................................................................................... 27
Reference List of Parts...................................................................................................... 28
Toftejorg TJ20G, Parts List .......................................................................................................... 28
Cross Sectional Drawing ................................................................................................... 29
How to order Spare Parts and Claim Procedure............................................................... 30
How to contact Alfa Laval Tank Equipment A/S................................................................ 30
Service Card...................................................................................................................... 31
Claim Report Working Conditions ..................................................................................... 32
Instruction Manual, Toftejorg TJ20G Page 1
IM-TE91A600-EN2
ï
Return to menu

ï
Return to menu

Introduction
With a new revolutionary patented design, the Toftejorg TJ20G introduces a new generation of tank
cleaning machines.
Based on more than 30 years experience from practical tank cleaning and production, the Toftjeorg
TJ20G has been developed to meet the highest demands for efficiency, reliability and hygiene within
food and beverage, pharmaceutical and biochemical industry.
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 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.
Instruction Manual, Toftejorg TJ20G Page 3
IM-TE91A600-EN2
ï
Return to menu

General Description
The Toftejorg TJ20G is a media driven and media lubricated tank cleaning machine. No lubricating
substances such as oil, grease etc. are used. All materials are selected for contact with food, and the
machine is self-cleaning i.e. all internal and external surfaces are cleaned.
Functioning
The flow of the cleaning fluid into the machine passes through a turbine, which accordingly is set into
rotation. Through a gear set and a driver tube, the turbine rotation is transmitted to the Cleaner Head.
The combined motion of the machine Body and the Nozzles ensures a fully indexed tank cleaning
coverage. After 55/8 revolutions of the Hub cover with Nozzles (53/8 revolutions of the machine Body),
one coarse cleaning pattern is laid out on the tank surface and the first cycle has been made. During
the following cycles, this pattern is repeated 7 times, each of which is displaced, and the pattern
gradually becomes more dense. Finally, after 8 cycles - a total of 45 revolutions of the Hub Cover with
Nozzles (43 revolutions of the machine Body), a complete cleaning pattern has been laid out, and the
first pattern is repeated.
This is illustrated below for spherical tank with the machine placed in the centre:
1st cycle 2nd cycle 3rd cycle 4th cycle
The number of cycles needed to perform a proper cleaning depends on type of soilage, distance,
cleaning procedure and agent.
For substances that are easily mobilised, i.e. are easy to remove, one cycle could be sufficient while in
cases of more heavy soilage (high viscous, sticky substances, etc.) a more dense pattern/more cycles
will be needed.
The speed of rotation of the 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 machine has different turbines according to the Nozzle size.
Page 4 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

General Description (continued)
Apart from the main flow flushing the gear and the
Hub, and thereafter forming the jets through the
Nozzles, fluid is flushed through all internal areas,
through bevel gear, Ball bearings and gabs
between moving parts and is finally also used for
cleaning of the outside surfaces of the machine.
The areas behind the Screws on the Cone are
cleaned through small spray holes behind the
Screws. In the bottom of the Body, the machine is
equipped with a hole to ensure self-draining. This
self-draining is only ensured, if the machine is
installed in upright position.
Standard Configurations
Connection Nozzles (mm) Article No.
1" BSP, Female
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G000
TE20G002
TE20G004
1" NPT, Female
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G020
TE20G022
TE20G024
1" BSP, Female Sanitary
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G050
TE20G052
TE20G054
Standard Options
Connection Nozzles (mm) PEEK Impeller Article No.
1" BSP, Female
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G595
TE20G596
TE20G597
TE20G000-02
TE20G002-02
TE20G004-02
1" NPT, Female
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G595
TE20G596
TE20G597
TE20G020-02
TE20G022-02
TE20G024-02
1" BSP, Female
Sanitary
4 x ø3,9
4 x ø4,6
4 x ø5,5
TE20G595
TE20G596
TE20G597
TE20G050-02
TE20G052-02
TE20G054-02
Instruction Manual, Toftejorg TJ20G Page 5
IM-TE91A600-EN2
ï
Return to menu

General Description (continued)
Accessories
Welding adapter with sealing assembly between Down pipe, Welding
adapter and machine.
Pipe Dimension in mm
Connection
thread Article no.
1“ ISO thread pipe: ø33.7 x 3.25 1” BSP TE52D030
1“ ANSI Sch.40S: ø33.4 x 3.38 1” NPT TE52D031
1 ½” ISO Dairy pipe: ø38 x 1.2 1” BSP TE52D032
1 ½” SWG pipe: ø38 x 1.6 1” NPT TE52D033
1“ ANSI Sch.40S: ø33.4 x 3.38 1” BSP TE52D034
For devices with tapered thread connections to the down pipe, it is
recommended that you secure the connection in a manner appropriate
for the application. Subject to the intended use environment and any
inhouse user requirements or policies, an adhesive such as Loctite No.
243 or equivalent could be used. Other methods could be acceptable
and subject to customer preference.
Sanitary connection
Use Cone with Gasket.
Page 6 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

- Blank -
Instruction Manual, Toftejorg TJ20G Page 7
IM-TE91A600-EN2
ï
Return to menu

Technical Data
Weight of machine : 5,1 kgs (11,2 lb)
Working pressure : 3-8 bar (40-115 psi)
Recommended inlet pressure : 5-7 bar (70-100 psi)
Working temperature max. : 95°C (200°F)
Max. temperature : 140°C (284°F)
Materials : Stainless Steel AISI 316L, Non-Galling Alloy, SAF 2205,
PFA, PEEK, PVDF, A4/EPDM
Principal dimensions in mm
Minimum required passage: ø110 mm (4.33 inch) at flange thickness 25 mm (0.98 inch)
Otherwise ø150 mm (5.90 inch)
Page 8 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Technical Data (continued)
Performance Data
Flow Rate Horizontal Throw length at static condition
Cleaning time, complete pattern
Effective throw length is defined as impact in
centre of jet 250 mm water column (50 lbs/sq.ft.).
However, effective throw length varies depending
on jet transverse speed over surface, substance
to be removed, cleaning procedure and agent.
Note: Throw lengths are measured as horizontal
throw length at static condition.
Vertical throw length upwards are approx. 1/3
less.
The inlet pressure has been measured
immediately at the machine inlet. In order to
achieve the performance indicated in the curves,
pressure drop in the supply lines between pump
and machine must be taken into consideration.
Instruction Manual, Toftejorg TJ20G Page 9
IM-TE91A600-EN2
ï
Return to menu

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, scale etc.- to clog
inside the machine. It is essential to avoid fine solid particles, such as fine sand, in cleaning fluid as
they will increase wear considerably.
In general a filter with 3 mm holes is recommended in the supply line. In case of fine solid particles
below 500 μm in the cleaning fluid, choose filter size accordingly.
It is recommended that the fluid valve fitted is of a type that prevents hydraulic shocks, which may
cause severe damage to the entire installation.
Before connecting the machine onto the system, all supply lines and valves should be flushed in order
to remove foreign particles.
The machine should be screwed tightly onto its supporting supply line using a 36 mm flat jawed
spanner (tool No. TE81B040) and the flats machined on the inlet Cone.
For devices with tapered thread connections to the down pipe, it is recommended that you secure the
connection in a manner appropriate for the application. Subject to the intended use environment and
any inhouse user requirements or policies, an adhesive such as Loctite No. 243 or equivalent could be
used. Other methods could be acceptable and subject to customer preference.
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 CENELEC R044-001 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
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.
The machine has been tested at the factory before shipping. Check that the machine is in operating
condition by inserting Screwdriver in top of Turbine shaft and easily turn Turbine shaft anti-clockwise. If
any resistance is recognised, the machine should be disassembled in order to localise the cause.
Page 10 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Installation and Normal Operation (continued)
Normal Operation
Cleaning Media
Use only media compatible with Stainless Steel AISI 316L, Non-Galling Alloy, SAF 2205, PFA, PEEK,
PVDF, A4/EPDM. Please note that PEEK is not resistant to concentrated sulphuric acid. Normal
detergents, moderate solutions of acids and alkalics will be acceptable. Aggressive chemicals,
excessive concentrations of chemicals at elevated temperatures, as well as certain hypochlorids should
be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment sales office.
Pressure
Avoid hydraulic shocks. Increase pressure gradually. Do not exceed 8 bar inlet pressure.
Recommended inlet pressure: 5-7 bar. High pressure in combination with high flow rate will increase
consumption of wear parts. High pressure will also reduce the cleaning effect.
After Use Cleaning
After use flush the machine with fresh water. Cleaning media should never be allowed to dry or set-up
in the system due to possible "salting out" or "scaling" of the cleaning media. If cleaning media contains
volatile chloride solvents, it is recommended not to flush with water after use, as this might create
hydrochloric acid.
Instruction Manual, Toftejorg TJ20G Page 11
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair
Preventive Maintenance
In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning
operations, it is essential to maintain its high performance by following a simple preventive
maintenance programme, which will always keep your tank cleaning machine in good condition.
Good maintenance is careful and regular attention!
The following recommended preventive maintenance 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.
Always use only proper tools. Use Toftejorg TJ20G 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.
Every 500 working hours
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultra-fine, eventually
chemical media and fine abrasive cloth.
3. Check Slide bearing (Pos. 14, page 17 for wear. If end face of Slide bearing is worn more than 1
mm into Slide bearing, it should be replaced.
4. Check bearing for Turbine shaft top (Pos. 24, page 15) in Cone and Body. If holes are worn oval to
a max. diameter of more than 10.4 mm, Bearings should be replaced. Thickness of collar is to be
min. 3.5 mm for Bearing in Body. If the Bearings are loose in a horizontal direction, the bearings
should be replaced.
5. Check Carrier bearing (Pos. 15.3, page 15). If worn oval to a max. diameter of more than 15.8
mm, it should be replaced.
Note: Timely replacement of Slide bearings and bearings for Turbine shaft will prevent costly
damage to the gearbox.
Page 12 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Preventive Maintenance
6. Check Planet wheels (Pos. 15.4 and 15.5, page 15) while still mounted in planet gear carrier (Pos.
15.6, page 15). They must rotate easily on Shafts. If restriction or much clearance on Shafts is felt,
Planet wheels should be dismounted for inspection of bearing bushes and Shafts for Planet wheel
(Pos. 15.2, page 15). Max diameter of holes: 6.2 mm.
Check tooth wear.
If replacement is necessary, Planet wheels must be replaced as a pair.
7. Check unrestricted rotation of Ball bearings. Inspect for build-up of foreign material on Stem nut
(Pos. 9) and Hub nut (Pos. 18), in Ball retainers (Pos. 10, page 17) and Ball races.
8. Assemble machines as described in the following pages.
9. Check that the machine is in operating condition by inserting Screwdriver in top of Turbine shaft,
and easily turn Turbine shaft anti-clockwise. If any resistance is recognised, the machine should
be disassembled in order to localise the cause.
Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be
inspected for wear. Wear parts are specified in the Reference List of Parts, page 28.
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, Toftejorg TJ20G Page 13
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Turbine and Carrier Assembly
Disassembly
1. Remove M5 Screws (Pos. 8). Loosen and unscrew with a socket wrench (tool No. TE462A).
2. Lift off Cone (Pos. 1).
3. Withdraw Turbine shaft (Pos. 2) with Impeller. If necessary, turn Turbine shaft left and right.
4. Remove Circlip (Pos. 4) and pull off Impeller (Pos. 5).
5. Withdraw Carrier assembly (Pos. 15) while turning/rocking carrier left and right.
6. Remove Cotter pins (Pos. 15.7), pull out Shafts (Pos. 15.2) and remove Planet wheels (Pos. 15.4
and 15.5). If necessary, push out Carrier bearing (Pos. 15.3)
7. If necessary, push out Bearing for Turbine shaft top (Pos. 24) from Cone (Pos.1).
Reassembly
Before reassembly, make sure that all parts are clean without deposits or build-up of foreign matter.
1. Insert Bearing for Turbine shaft top (Pos. 24) in top of Cone (Pos. 1).
2. Insert Carrier bearing (Pos. 15.3) and push with thumb. Insert Planet wheels (Pos. 15.4 and 15.5)
and Shafts (Pos. 15.2) and secure with Cotter pins (Pos. 15.7). Check free rotation of Planet
wheels.
Note: The two Planet wheels are different: on Planet wheel 1, teeth of upper an lower gearing
are aligned, while they are displaced ½ tooth on Planet wheel 2.
3. Insert Carrier Assembly (Pos. 15), into Body: Insert through Stem (Pos. 16, page 17). Hold Body in
one hand and use the other to turn Hub Cover (Pos. 19) left and right with small rocking
movements until carrier falls through Internal gear (Pos. 13, page 17). Check that carrier is fully
home on Bearing for Turbine shaft top (Pos. 24) in Body: Rotate Carrier Assembly by hand a few
rotations to check correct position and function.
4. Mount Impeller (Pos. 5) on Turbine shaft (Pos. 2) and secure with Circlip (Pos. 4).
5. Insert Turbine shaft with Impeller through Carrier Assembly. Rotate Impeller to ensure correct
insertion into Bearing for Turbine shaft (Pos. 3) in Body. Check unrestricted rotation.
6. Mount Cone (Pos. 1) over Turbine shaft and Retaining ring. Mount and tighten Screws (Pos. 8)
with Socket wrench (tool No. TE462A).
Page 14 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Turbine and Carrier Assembly
Instruction Manual, Toftejorg TJ20G Page 15
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Remaining Assemblies
Disassembly
1. Remove Retainer spring (Pos. 6). Use small Screwdriver to lift Retainer spring out of groove in
Stem (Pos. 16). Lift off Retaining ring (Pos. 7).
2. Hold Body against table and unscrew Stem nut w. ball race (Pos. 9) with Caliper (tool No. TE369).
Withdraw Stem (Pos. 16) together with Ball retainer w. balls (Pos. 10).
3. Remove M5 Screws (Pos. 12) with a socket wrench (tool No. TE462A) and draw out Internal gear
(Pos. 13).
4. Insert a 13 mm spanner (tool No. TE81B041) into Body, hold Cap nut (Pos. 23) and by hand
screw off Hub cover (Pos. 19), and remove Washer (Pos. 22).
5. Hold Body against table and unscrew Hub nut w. ball race (Pos. 18) with Caliper (tool No. TE369).
Note: Left-hand thread
Withdraw Hub (Pos. 17) together with Ball retainer w. balls (Pos. 10).
6. With screwdriver lift Slide bearing (Pos. 14) and Bearing for Turbine shaft top (Pos. 24) out of
Body.
7. Unscrew Nozzles (Pos. 21) with 11 mm spanner (tool No. TE81B041). Be careful not to damage
Nozzle vanes (Pos. 20) as this will severely reduce Nozzle performance. Nozzle vanes should not
be removed unless they need to be replaced.
If Ball races (Pos. 16.2 and 17.2) on Stem and Hub as well as Stem/Hub nut w. Ball race (Pos. 9 and
18) are heavily worn, they should be replaced as well as Ball retainer w. balls (Pos. 10), see page 19.
Page 16 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Remaining Assemblies
Instruction Manual, Toftejorg TJ20G Page 17
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Remaining Assemblies
Reassembly
Before reassembly make sure that all parts are clean without deposits or build-up of foreign matter.
1. If necessary insert new Nozzle vanes (Pos. 20, see drawing page 17). Be careful not to damage
Nozzle vanes. Mount Nozzles (Pos. 21) and tighten with spanner.
2. Place Slide bearing (Pos. 14) in Body and push in Bearing for Turbine shaft (Pos. 3) with thumb.
Make sure that Bearing is fully home.
3. Inset Hub (Pos. 17) together with Ball retainer w. balls (Pos. 10). Mount Hub nut w. Ball race (Pos.
18) with Caliper (tool No. TE369) and tighten.
Note: Left-hand thread
4. Place Washer (Pos. 22) on threaded pin on Hub cover and mount Cap nut (Pos. 23). Insert
spanner (tool No. TE81B041) into Body, hold Cap Nut (Pos. 23) and by hand screw on Hub cover
(Pos. 19) and tighten. Check free rotation of Hub.
5. Insert Internal gear (Pos. 13), mount Screws (Pos. 12) and tighten with Socket wrench (tool No.
TE462A).
6. Insert Stem (Pos. 16) together with Ball retainer w. balls (Pos. 10). Mount Stem nut w. ball race
(Pos. 9) with Caliper (tool No. TE369) and tighten. Turn Hub cover and check unrestricted rotation.
7. Place Retaining ring (Pos. 7) over Stem (Pos. 16) and push on Retainer spring (Pos. 6) and "click"
into groove in Stem. Check free rotation.
Page 18 Instruction Manual, Toftejorg TJ20G
IM-TE91A600-EN2
ï
Return to menu

Maintenance and Repair (continued)
Replacement of Ball Races
1. Place Stem or Hub complete (Pos. 16 or 17, see page
27) in a support ring and press off Ball race. Press
parallel. Use press or vice. Be careful not to damage
teeth and opposite end face of Stem.
2. With mandrel press Ball race fully home. Press
parallel. Use press or vice. Be careful not to damage
surface of Ball race.
Instruction Manual, Toftejorg TJ20G Page 19
IM-TE91A600-EN2
ï
Return to menu