Alfalaval Gj 10 User manual

Instruction Manual

Alfa Laval GJ 10

Cover

Standard Machines

First

published: 2015-07

ESE032025-EN1

2015

Original manual

Table of Contents

The

information herein

is correct at the

time

issue

but may be subject to changewithout prior

1. EC Declaration of Conformity

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2. Safety

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2.1.

Information

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2.2.

Warning Signs

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2.3.

Safety Precautions

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3. Introduction

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3.1.

Description

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3.2. Intended Use

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3.3.

Patents and Trademarks

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3.4.

Marking

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4. Installation

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4.1.

Unpacking/Delivery

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4.2.

Installation

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4.3.

Recycling

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5. Operation

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5.1.

Operation/Control

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5.2.

Trouble Shooting

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5.3.

Cleaning Solution

Leakage

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5.4. Poor

Cleaning

Performance

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5.5. Recommended Cleaning

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6. Maintenance

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6.1.

General Maintenance

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6.2.

General Dismantling

Setup

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6.3.

General Dismantling

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6.4.

and

Service

of Components

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6.5.

Reassembly

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7. Technical Data

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7.1.

Technical

Data

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7.2.

Performance

Data

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7.3.

Dimensions

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7.4.

Trax Simulation Tool

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8. Parts List and Service Kits

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8.1. AL

GJ 10 View

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8.2.

Assembly Drawings

–1, 2, 3 & 4 ….. …… …… …… ….. …… ….. …… ….. …… ….. 30

8.3.

Assembly Drawings

–5, 6, 7, 8, 9 & 10 ..… ….. …… ….. …… ….. …… ….. ……. …. 31

8.4.

Assembly Drawings

–11, 12, 13, 14 & 15 ….. ……. …… ….. …… ….. …… ….. .. 33

8.5.

Assembly Drawing

–16 ….. …… ….. …… ….. …… ….. ……. ….. …… ….. …… ….. 35

8.6.

Assembly Drawings

–17, 18, 19 & 20 ….. …… ….. ……. ….. …… ….. ……. ….. …... 36

8.7.

Assembly Drawing

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8.8.

Assembly Drawing

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8.9.

Parts List ...... ……. ….. …… ….. …… ….. …… …… …… ….. …… ….. …… ….. …… ……

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Minor Service Kit ….. …… ….. …… ….. …… ….. …… …… …… ….. …… ….. …… ….. ...

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Major Service Kit ….. …… ….. …… ….. …… …… …… …. …… …… …… …… …… …….

EC Declaration of Conformity

The designated company

Alfa Laval Tank Equipment Inc.

Company name

604 Jeffers Circle –Exton, PA –19341, United States

Address

+1 610 408 9940

Phone no.

hereby declare that

Tank Cleaning Machine

Alfa Laval GJ 10

Denomination

Type

From serial numbers from X-100 to X-xxxx

is in conformity with the following regulations and directives with amendments:

- The Machinery Directive 2006/42/EC

DS/EN ISO 12100:2011

- The Pressure Directive 97/23/EC

According to its own volume and the rated pressure range the product is regarded an Article 3, paragraph 3 Equipment

The person authorised to compile the technical file is the signer of this document.

Executive VP Operations

Andrew Delaney

Title

Name

Signature

2015-05-18

Exton, United States

Date

Place

2 Safety

Unsafe

practices and other important

information

are

emphasized in this m

Warnings

are

emphasized

by meansof

special

signs.

Always

read the

manual

before using the tank cleaning machine!

2.1 Important Information

Indicates

that

special

proceduresmust be followedto avoid

serious personal

njur

Indicates

that

special

proceduresmust be followedto avoiddamageto the tank

cleaning

machine.

NOTE

Indicates

important

information

simplify

clarify

procedures.

2.2 Warning Signs

General

warning:

Dangerous

electrical

voltage:

Caus

2 Safety

All

warnings

the

manual

are

summarized

on this page.

Pay

special

attention to the

instructions

below so that

severe personal injury

and/or damage to the tank

cleaning m

ach

are avoided.

2.3 Safety Precautions

nstallation

Alwaysread the

technical

data thoroughly.

(

See

chapter 7

Technical

Data)

Any

tank-cleaning machine

can

develop

a static

electricity

chargewhilein operation.

the tank being

cleaned contains

combustible liquid

or vapor

having

a risk of

ignition

explosion, it is imperative

have

the

Alfa Laval Gamajet properly

grounded usingthe provided

location

on the unit.

Operation:

Alwaysread the

technical

data thoroughly.

(

See

chapter 7

Technical D

ta)

ecessary

precautions

must be taken

if leakage

occurs as this can leadto

hazardous

situations.

Always

handlelyeand acid with great

car

When

Alfa Laval Gamajet

operating,

there

should

be covers over

every

tank opening.

These

covers

should

sealed

wellenoughto withstand the

full

force of the

jet striking

the coverplate.

If the

cleaning solution

werehot,

corrosive,

toxic,

leak

would presenta

serious hazard

to anypersonnel

the

ediate

cinit

xposed

electr

cal

equipment.

Warning: Any

tank-cleaning machine

can

develop

a static

electricity

chargewhilein operation. If the tank b

eing

ean

containsa combustibleliquidor vapor

having

a risk of

ignition

explosion, it is imperative

to havethe

Alfa Laval Gamajet properly

grounded using the

provided location

on the unit.

Maintenance:

Alwaysread the

technical

data thoroughly.

(

See

chapter 7

Technical D

ver

service

the tank

cleaning machine

when

it is

hot.

Alwaysuse Alfa

Laval genuine

spare parts.

Transportation

of the tank

cleaning

machine:

Alwaysdrain the tank

cleaning machine

head and

accessories

of anyliquid

Alwaysuse

original packaging

similar during

port

3 Introduction

3.1 Description

The Alfa Laval GJ 10 is a fluid-driven (turbine-driven) 360° rotary nozzle machine designed for cleaning the interior surfaces of

a wide variety of process vessels with a minimum opening of 101.6mm (4.00 inches) in diameter. It is powered entirely by the

cleaning solution and it requires no electricity, compressed air or lubricant for operation. The Alfa Laval GJ 10 is designed for

both portable and CIP (Clean in Place) applications. If the Alfa Laval GJ 10 is permanently mounted inside a tank, we strongly

recommend inspecting the unit every few hundred hours of operation.

Warning: Under no conditions, whatsoever, should the Alfa Laval GJ 10 ever be immersed in anything, unless you

have prior approval from Alfa Laval Gamajet Equipment. Failure to comply with this restriction will void the

warranty!!

In order to handle the broadest possible range of applications, the stainless steel Alfa Laval GJ 10 is available with an

extensive selection of nozzle sizes, stators (non-rotating turbine), and O-ring materials. The nozzles are available as 6.4mm,

7.9mm, and 9.5mm (1/4”, 5/16”, and 3/8”). The Alfa Laval Gamajet wash cycle time can be adjusted for special applications by

changing the stator and/or nozzle size. Interchangeable stators and nozzle sizes are available for either low or high pressures

and/or flow rates. The performance capabilities of these options are detailed in Section 7 –Technical Data.

3.2 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 compatible with product, flushing media,

cleaning media, temperatures and pressure under the intended use.

3.3 Patents and Trademarks

This Instruction Manual is published by Alfa Laval Tank Equipment without any warranty. Improvements and changes to this

Instruction Manual may at any time be made by Alfa Laval Tank Equipment without prior notice. Such changes will, however,

be incorporated in new editions of this Instruction Manual.

The Alfa Laval logotype is a trademark or the registered trademark of Alfa Laval Corporate AB. “Gamajet” is a trademark or

registered trademark of Alfa Laval Tank Equipment. The Alfa Laval GJ 10 product has patent in the US (US 6,123,271). Other

products or company names mentioned herein may be the trademarks of their respective owners. Any rights not expressly

granted herein are reserved.

3.4 Marking

Alfa Laval Gamajet tank cleaning machines are all marked to allow recognition of machine type, machine name, Serial

number and manufacturing address. The marking is placed on the body of the tank cleaning machine.

Alfa Laval Tank Equipment –Exton, PA

Patent #: 6,123,271

4 Installation

4.1 Unpacking/Delivery

Step 1

CAUTION

Alfa Laval

cannot be held

responsible

for

incorrect

unpacking.

Check the

delivery

for:

Complete Cleaning

Machine

Delivery

note

Step 2

Remove

any packing materials

Step 3

spect

the tank

cleaning machine

for

visible

transport damage

4 Installation

Read

the

instructions carefully

and pay

special

attentionto the warnings!

Always

check the tank

cleaning machine

before

operation.

4.2 Installation

Step 1

Always

read the

technical

data

(See

chapter 7

Technical

Data)

Step 2

Assembly

Every Alfa Laval Gamajet

operationally

tested beforeshipmentand

readyto run after unpacking. No

assembly

is required

prior

o use.

The Alfa Laval Gamajet

has been

configured

to meet the operatingconditions (atthe

Alfa Laval Gamajet,

not at the

)

given

to us, e.g.

pressure,

flow,

temperature,

cycle

time, chemical

adders, etc.

Note: Anychangeto the

original operating conditions will

affect the

Alfa Laval Gamajet

accordingly

Warning: Do not force Tee&NozzleHousing, Pos.4 & 5 to rotate.

Doing

so may damage the

internal

components.

Step 3

Inlet Connections

The standard inlet connection for the Alfa Laval GJ 10 is a 1-1/2” NPT female or 1-½” BSP. Others inlets are available. It is

recommended that when using the pipe thread the mating male thread should be wrapped with PTFE pipe joint tape prior to

mounting. This will minimize any chance of leakage and will make subsequent removal much easier.

Step 4

Mounting

Before mounting the Alfa Laval GJ 10, make sure the supply line has been adequately flushed. It can be mounted on a rigid

1-1/2” pipe using a pipe wrench. In most applications, the Alfa Laval GJ 10 will be mounted with the inlet connection pointing

up; however, the Alfa Laval GJ 10 will function at any orientation. In the cleaning of underground storage tanks (USTs), Alfa

Laval Gamajet recommends the use of its UST Lance or Hose Insertion Assembly. Either device will ensure a proper

insertion depth, sealing of the riser pipe. Also, the UST Lance includes a lanyard loop that provides a means to attach a

safety line between the Alfa Laval GJ 10 UST Lance and the safety loop on the Alfa Laval Gamajet.

We do not recommend attaching the machine to a hose while in the inverted or horizontal orientation. This form of mounting

is not rigid and, thus, will not maintain the Alfa Laval GJ 10’s position should the unit become unbalanced due to clogging of

the nozzles.

Warning: When attaching the Alfa Laval GJ 10 onto the supply pipe, ALWAYS apply the wrench to the Inlet Collar (9)

at the top/inlet of the unit. Never use a wrench on Stem (3), Tee Housing (4), or Tee Housing Cap (13) to

tighten the unit onto the pipe. Doing so risks internally damaging the machine. Refer to Drawing 22 for an

illustration.

Step 5

Location inside Tank

Generally, a single Alfa Laval Gamajet machine will be positioned in the approximate center of the vessel in order to equalize

the cleaning radius in all directions. Some vessels, however, may have specific cleaning problems such as coils or heavy

deposits such as the liquid level line (bathtub ring). In these situations the Alfa Laval GJ 10 should be located closer to the

difficult area for the best cleaning results.

Tanks with internal mechanisms or structures such as an agitator shaft, impellers or baffles will require careful positioning to

minimize the “shadow” on areas which do not receive direct jet impact. Sometimes, more than one machine, or, more than

one placement of a single machine, may be necessary to avoid shadow problems or “striping.”

4 Installation

Read

the

instructions carefully

and pay

special

attentionto the warnings!

Always

check the tank

cleaning machine

before

operation.

Step 6

Entry Openings

When using the GJ 10, the vessels being cleaned must provide entry openings large enough to avoid interference during

insertion and removal. The minimum opening size required for the GJ 10 is 4.00 inches in diameter (101.6 mm) for free-hand

installation.

Step 7

Vessel Drainage

If it is necessary to clean the floor of a vessel, remember that standing liquid will diminish the effectiveness of the jet by

covering any soils underneath. Wherever possible, the tank floor should be pitched toward the drain and the drainage opening

should be large enough to eliminate or reduce any liquid buildup or puddling. If gravity alone is insufficient, a scavenger or

stripper pump should be connected to the drain to suck out the excess wash fluid. In extreme cases, it may be necessary to

use smaller nozzles on the Alfa Laval GJ 10, or even to operate it intermittently to allow time for draining.

Step 8

Filters and Strainers

All tank cleaning systems should be equipped with a filter or strainer that will trap solids 1/16” and larger (150 micron, 100

mesh), as these will not pass through the Alfa Laval GJ 10. These particles can become caught in one of the internal

passages of the machine and cause it to stop turning or reduce its cleaning effectiveness due to a loss of flow. It will then be

necessary to disassemble the Alfa Laval GJ 10 and remove the blockage.

In recirculated (closed-loop) cleaning, or, any other application where the cleaning solution may carry abrasive solids in

suspension, adequate filtration is a must. These particles can be extremely destructive to the Alfa Laval Gamajet, pumps,

valves, and other system components. Filters, properly installed and maintained, will more than pay for themselves with lower

overall operating costs in these applications. Furthermore, to ensure that clogged filters or strainers are cleaned, we

recommend using automatic self-cleaning models.

Step 9

Capacity of Supply Pump

The Alfa Laval GJ 10 can be used with either a centrifugal or positive displacement (constant volume), PD, style pump. In

most cases, if the unit is to be used with a centrifugal pump, the Alfa Laval Gamajet should be configured so that the pump

will operate close to its best efficiency point. The end user must, therefore, take all of the plumbing, elevation, and Alfa Laval

GJ 10 pressure/flow rate requirements into account.

If a PD style pump (i.e. piston pump, plunger pump, or mechanical diaphragm pump, etc.) will supply the wash fluid to the Alfa

Laval GJ 10, a different set of rules apply. PD pumps are fixed volume pumps whose flow rate is dependent upon the

rotational speed of the pump; the pumps also have a pressure rating which is the maximum operating pressure. Note: Do

not confuse the maximum operating pressure of a PD pump with the actual operating pressure, the actual operating

pressure is dictated by the fixed flow rate of the pump and the Alfa Laval GJ 10 / plumbing system. If a PD pump is

used, the Alfa Laval GJ 10 should be sized to, first, match the flow capability of the pump and, second, not exceed the Alfa

Laval GJ 10’s or pump's maximum operating pressure (taking the pressure rating of the plumbing system into account, also).

Warning: For high-pressure applications {over 10.3 bar (150 psig)}, the pressure of the system must "ramp up" to its

operating pressure. If the system experiences a pressure spike or pressure increases at a rate of more

than 10.3 bar (150 psi) per second, the machine may be damaged and parts will wear out prematurely.

Damage resulting from this phenomenon is not covered by the warranty.

4 Installation

Read

the

instructions carefully

and pay

special

attentionto the warnings!

Always

check the tank

cleaning machine

before

operation.

4.3 Recycling Information

•

Unpacking

Packing material

consists of wood, plastics,cardboard boxes and

some cases

metal

straps.

-Wood and cardboard boxes can be reused,recycledor used for

energy

recovery.

Plastics should

be recycledor burnt at a

licensed

waste

incineration

plant.

-Metal straps should be sent for

material

recycling.

•

Maintenance

All

metal parts

should

be sent for

material

recycling.

•

Scrapping

-At end of use, the equipment must be

recycled

according to

relevant,

local regulations.

Beside

the equipment itself, any

hazardous residues

from the process

liquid

must be

considered

and dealt

with in

a proper manner. When

doubt, or

the

absence

local regulations, please

contact your local

Alfa Laval sales

company.

5 Operation

Read the instruction carefully and pay special attention to the warnings!

5.1 Operation/Control

Step 1

Always

read the

technical

data

thoroughly.

Seechapter 7

Technical

Data

CAUTION

Alfa Laval

cannot be held

responsible

for

incorrect

operation/control.

Step 2

Never

touch the tank

cleaning machine

or the

pipelines

when pumping hot

liqu

ds.

Step 3

Initial Startup

Every Alfa Laval GJ 10 that ships is accompanied by a Birth Certificate. This document indicates how the machine performed

in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Gamajet. To ensure the longest

possible life of the machine, please verify the operating conditions and, most importantly, the machine’s cycle time. The cycle

time can be measured by, first, picking a fixed point inside of a vessel as a reference and, second, timing how long it takes

the same nozzle to pass back over that point in the vessel. (This, naturally, will not be the exact same spot because the

spray pattern is indexing.) The measured time in seconds directly corresponds to the machines full cycle time in minutes. In

other words, a single 10-second rotation translates to a 10 minute full cycle time.

5 Operation

Pay attentionto possiblefaults

Readthe

instructions

carefully

5.2 Trouble Shooting

Does Rotor

(pos. 35)

turn freely

by hand?

- Cracked Input Pinion (pos. 56) –Section 6.4 Inspection and Service of Components

- Damaged Planetary Gearhead (pos. 12) –Section 6.4 Inspection and Service of

Components

Do Nozzle

(pos.8) and

Tee

Housing

(pos. 4)

both index

when Rotor

(pos. 35) is

turned?

- Cracked/Loose Input Pinion (pos. 56) –Section 6.4 Inspection and Service of Components

- Damaged Planetary Gearhead (pos. 12) –Section 6.4 Inspection and Service of

Components

- Worn Tee Housing Bearing (pos. 20) and Nozzle Housing Bearings (pos. 22) –Section 6.4

Inspection and Service of Components

- Worn Tee Housing Cup (pos. 21) and Nozzle Housing Cup (pos. 23) –Section 6.4

Inspection and Service of Components

Does only

Tee

Housing

(pos. 4)

index?

- Worn Tee Housing Bevel Gear (pos. 14) or Nozzle Housing Bevel Gear (pos. 15) –Section

6.4 Inspection and Service of Components

- Cracked/Loose Input Pinion (pos. 56) –Section 6.4 Inspection and Service of Components

- Damaged Planetary Gearhead (pos. 12) –Section 6.4 Inspection and Service of

Components

Yes

5 Operation

Pay attentionto possiblefaults

Readthe

instructions

carefully

Step 1

Insufficient Flow

The Alfa Laval GJ 10 was configured to meet certain operating conditions outlined at the time of the initial sale, such as flow

rate (m^3/hr)(GPM), pressure (bar)(PSI), temperature, chemical content of the wash fluid, cycle time, etc. If the Nozzle (8)

size is too small and/or the opening at the bottom of the Stator (10) is too large, the Tee Housing (4) will not turn. Look for

restrictions in the fluid supply such as a clogged filter, kinked hose, or deposits in the piping.

Step 2

Tight Clearances

A recently overhauled Alfa Laval GJ 10 may fail to operate when first returned to service. If the machine seems otherwise

fine, try running it with at least one Nozzle (8) removed. The reduction in pressure and additional flow will invariably be

enough to overcome the extra resistance of new Bearings and Seals. Twenty minutes of operation should loosen the machine

to run normally with the Nozzles reinstalled.

Step 3

Debris Inside

Remove

the

Collar

and then

lift

out the Stator (9). Look for and remove any debris caught in the Stator (9) and the vanes of

the Rotor (10). Remove any material wound around the Rotor Shaft (20). In addition, check for any debris caught in the outlet

holes of the Stem (3), the nose of the Tee Housing (4), the Nozzle Housing (5), and the Nozzles (7).

5.3 Cleaning Solution Leakage

-Worn Bearings and Seals

Leakage from the Tee Housing (4) or Nozzle Housing (5) usually indicates worn Housing Bearings and Seals. Inspect

them for wear (sealing lips are worn to a smooth surface) or damaged lips or loss of spring tension (indicated by excessive

dry deposits of dirty or abrasive cleaning solution on the spring), and replace as required.

-Worn Housing Cups

Inspect the Housing Cups (23) and (21) for excessive wear (grooved or scored).

Replace any that show distinct grooves.

-Worn Collar O-rings

Severe leakage between the Inlet Collar (9) and Cap (2) may indicate worn or damaged Collar O-rings (52) and (48).

Remove the (9) as described in Section 6.3 –General Dismantling, and inspect the (52) and (48) for signs of damage or

wear.

5 Operation

Pay attentionto possiblefaults

Readthe

instructions

carefully

5.4 Poor Cleaning Performance

-Inadequate Flow and Pressure

Check the

pressure

at the

Alfa Laval Gamajet inlet

under actual operating

conditions.

The

supply

piping and hoses must be

enoughto

handle

the flow rate

required

for the

nozzle size

being used to

ensure adequate

pressure.

Insufficient pressure

may also

result

from

line losses

when the

machine is

far from the pump. If this is the case, the

line

size

must be

increased accordingly

for

long

runs.

Although

the

Alfa Laval Gamajet will

rotate at

low flow

rates,

effective cleaning

may require

considerably

flow.

Proper

mechanical operation

(

unit

urns

)

is NOT

the same thing as

effective cleaning

(

soils have been removed)! Contact

Alfa Laval Gamajet Equipment if assistance

is required.

-Chemical Concentration and Temperature

Verify

that the

cleaning solution is

the correct compound and

the

concentration

needed for the deposit being cleaned.

heating

is necessary,

alsocheck that the solution

at the proper temperature.

-Plugged Nozzles

Unscrewthe

Nozzles (8)

and

inspect

for any debris.

-Slow or no Rotation of the Housings

This will

resultin

partial

erratic washing

coverage.

Refer

previous sections

for more

orm

tion

-Alfa Laval GJ 10 Configuration

Determine if

the deposit being

cleaned requires greater

jet

impact

longer jet dwell time (slower rotation)

for more thorough

scrubbing.

Confirm

that the

Alfa Laval Gamajet nozzle

size, turbine, and

gearing

are correct for the specific application.

Refer

to the machine’s Birth

Certificate

for

specific information regarding its

configuration. Contact an

Alfa Laval Gamajet Equipment

representative

assistance

is required.

-Inadequate Drainage

Ensure

that the

vessel drains

the

effluent (used

wash

fluid)

as fast as

t’

being sprayed

through the Alfa Laval Gamajet. The

floor

of the

vessel

should be sloped or pitched toward the

drain

and the

drainage opening should

large enough

gravity-

drain

the

effluent

from the vessel. If you still

have

puddling

(

build-u

p of the wash

fluid

covers the

floor

and

shields

the

residues

underneath),

use some form of pump to

remove

the effluent.

5 Operation

The Tank Cleaning machine is designed

for

cleaning in

place

(CIP). CIP

Cleaning In Place.

Study the

instructions carefully

and

pay

special

attentionto the warnings! NaOH=

Caustic

Soda.

HNO3 = Nitric acid.

5.5 Recommended Cleaning

Step 1

Always handle

lyeand acid with greatcare.

Caustic

danger!

Alwaysuse rubber

gloves!

Always

use protectivegogg

es!

Step 2

Never

touch the pump or the

pipelines

when sterilizing.

Step 3

Danger

of burns!

Always rinse well

with

clean

water afterusinga

cleaning

agent.

NOTE

Cleaning

agentsmust be stored/disposed of

accordance with

current

rectives.

Always

Clean Water

Cleaning

gent

6 Maintenance

Maintain

the

Tank Cleaning

Machine

with

care. Readthe

instructions carefully

and pay

special

attention to the

war

Always

keep Minor spare parts kit in stock.

6.1 General Maintenance

Step 1

Always

read the

technical

data

thoroughly. (see

chapter 7

Technical

Data)

Step 2

Recommended

spare parts:

Order

service kits

from the

service kits

list

(See

8.10 Minor

Service

Kit & 8.11 Major

Service

Kit)

Ordering

spare parts:

Contact your

local

Alfa

Laval Sales

company.

6 Maintenance

Maintain

the

Tank Cleaning

Machine

with

care. Read the

instructions carefully

and pay

special

attention to the

war

Always

keep Minor spare parts kit in stock.

6.2 General Dismantling Set

Step 1

Note

rigorously implemented preventative maintenance

program will

significantly

reduce

repair

costs over the

life

of the

Alfa Laval

Gamajet

. The foundation of such a program is

regularly scheduled inspections

discover

and

replace

worn or damaged parts

before

they

can

cause

the

failure

of other, more costly, components.

The inspection intervals required will

depend on the

severity

of the

application,

but a

complete internal inspection

at 100 hours of

operation is

recommended

nitially

Step 2

Storage

The

Alfa Laval Gamajet should be washed out with clean water after each use to remove any foreign material or soft

substances left in the machine that may harden during storage and cause the Alfa Laval Gamajet to seize or lock up. A clean

water rinse through the Alfa Laval Gamajet will also wash out any residues of chemical cleaners or recirculated wash water

that could adversely affect the O-rings during prolonged contact in storage. The best position to store the machine is to stand

it up with the inlet connection facing down.

Step 3

External Inspection Intervals

Before every shift, the Stator (10) and the Nozzles (8) should be inspected for debris. Examine the (10) by loosening the

Collar Set Screw (27), while holding on the flats of the Cap (2), remove the main section of the machine from the Inlet Collar

(9).

Look into each Nozzle (8) for signs of debris or build-up.

When using the UST Lance, inspect the lanyard wire and rubber plug for deterioration.

Replace as needed.

Step 4

Internal Inspection Intervals

interval

of 100 hours

recommended

initially. If all

of the components are found to be in acceptable condition after the

first

100 hours, the

Alfa Laval Gamajet

may then be

inspected

and

routine preventive maintenance

should be performed

every 5

00 to

700 hours of operation,dependingon the

severity

of use.

Step 5

Tips

All

the

Bearings, Bushings, Seals

and O-rings are wear parts.

Ideally,

they should

all

replaced,

as a group,

every 5

00 to 700

hours of

operation,

dependingon the

severity

of use.

If just

one

Bearing

Seal is

worn or damaged,

replace

both it and

mate,

not just the worn or damagedpart.

6 Maintenance

Read

the

instructions

carefully.Theitems

refer

to the parts

list

and

service

kits section.

6.3 General

Dism

ant

Step 1

Inlet Collar

If used, loosen the Grounding Set Screw (33) with a 5/64” Hex Key, minimum 2 turns. Remove grounding / safety wire from

loop.

Loosen the Collar Set Screw (27) with a 3/32” Hex Key, minimum 2 turns.

Remove the Inlet Collar (9) and Stator (10).

Warning: Hold or turn on Stem (3). DO NOT hold or turn on Tee Housing (4) or Tee Housing Cap (13). Doing so will

damage the Geartrain (drawing 10).

Step 2

Nozzle Housing

Unscrew the Nose Plate Screws (28) with a ¼” slotted screwdriver.

Pull the Nozzle Housing (drawing 19) from the nose of the Tee Housing (4).

Remove the inner Nozzle Housing Seal (25) and Bearing (22).

Step 3

Cap and Geartrain

Using pliers on the flats of the Cap (2), unthread it from the body (drawing 15).

Warning: Hold or turn on Stem (3). DO NOT hold or turn on Tee Housing (4) or Tee Housing Cap (13). Doing so will

damage the Geartrain (drawing 10).

Pull the Geartrain (drawing 10) from the remainder of the body.

Step 4

Body Assembly

Unthread the Tee Housing Cap (13) from the Tee Housing (drawing 12). Note: This is a Left Hand thread.

Remove the Stem Screws (26) with a 5/32” Hex Key, and Stem Base (drawing 13) from the Tee Housing (drawing 12).

Remove the Tee Housing (drawing 12) by pulling it from the Stem (drawing 11). The upper Tee Housing Seal (24) and

Bearing (20) will pull off with the Tee Housing (drawing 12).

Remove the lower (24), (20) and Bevel Gear (drawing 14).

6 Maintenance

Read

the

instructions

carefully.Theitems

refer

to the parts

list

and

service

kits section.

6.4 Inspection and Service of Components

Drawing

Inlet Assembly

spect

the trough

holes

of the Stator (10) to be surethat they areclear.

Drawing

Collar O-rings

Inspect the Small and Large Collar O-rings, (52) and (48), for damage (clipped or cut) or deterioration (compression set or

hardening) and replace if necessary.

Inspect the Collar-Stem O-ring (49) for damage (clipped or cut) or deterioration (compression set or hardening) and replace if

necessary.

Drawings 4-10

Planetary Geartrain Assembly

General Disassembly

and

nspection

Tip: Disassemble the Planetary Gear Train Assembly (drawing 10) over a container or a confined space. There are

several small components inside of the Gear Train, which may spill out if you are unfamiliar with its contents.

Turn to drawing 10: Pull the Output Shaft (11) from the Gearhead Housing (drawing 8)

Unscrew the Input Shaft Nut (59) with an 11/32” socket and remove it with the Input Shaft Lockwasher (58) from the geartrain.

Remove the Rotor #E-810 (Step 8). If needed, use a slotted screwdriver for assistance.

Turn to drawing 9: Ensure the Input Shaft Carbide (41), pressed into Rotor (35), protrudes slightly, and is not chipped or

cracked.

Turn to drawing 8: Pull and twist the Gearhead Lower Bearing Housing (18; drawing 7) and Input Shaft Upper Bearing

Housing (17; drawing 1) from the Gearbox (1; drawing 6).

If the Gearbox Seals (39) did not come out of the (1) when the (18) and (17) were removed, remove them at this time.

Warning: To reduce the likelihood of scratching any sealing surface, use a pick made from brass. Inspect the (39) for

loss of spring tension (indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring), replace as

required.

Turn to drawing 6: Using a #2 Phillips screwdriver, unscrew the Gearhead Short Screws (47) from the Gearbox (1).

Remove the Planetary Gearhead (drawing 5) from (1) by pushing on its output shaft.

General Internals

Tip: To prevent the internal components of the Planetary Gearhead from unexpectedly spilling out, make sure that all

steps are done with the input side of the assembly facing up.

Using a #1 Phillips screwdriver, unscrew the Planetary Gearbox Screws (31) from the Planetary Gearhead (12).

Remove the Input Shaft Lower Bearing Housing (40) from the (31).

Warning: If you suspect that the Planetary Gearhead (12) requires service, proceed with caution. If at any time you do

not feel completely comfortable servicing (12), contact Alfa Laval Gamajet Equipment immediately.

Using a needle nose pliers carefully remove the internal components of the (12). Examine the gears of the four different

stages for any worn or broken teeth. Also, examine the Main Ring Gear (67) for bent or sharp teeth. If any damage is found,

contact Alfa Laval Gamajet Equipment immediately.

The Bottom and Top Stage Planetary Gears (61) and (60) must be reinstalled in their respective locations. The Mid-Stage

Planetary Gears (62) are interchangeable, however.

During reassembly, Alfa Laval Gamajet Equipment recommends the Gearhead Assembly (drawing 4) be lightly repacked

using food-grade grease. Please contact Alfa Laval Gamajet Equipment for a specific grease recommendation.

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