Alfalaval GJ 7 User manual

Instruction Manual
Alfa Laval GJ 7
Covering:
Standard Machines
First published: 2015-08
ESE032025-EN1 2015-08
Original manual

The information herein is correct at the time of issue but may be subject to change without prior notice
1.EC Declaration of Conformity .................................................................................................................... 1
2. Safety............................................................................................................................................................... 2
2.1. Important information ………......................................................................................................................... 2
2.2. Warning signs ……….................................................................................................................................... 2
2.3. Safety precautions ………............................................................................................................................. 3
3. Introduction ……….......................................................................................................................................... 4
3.1. Description ……….......................................................................................................................................... 4
3.2. Intended Use……….......................................................................................................................................... 4
3.3. Patents and trademarks…............................................................................................................................... 4
3.4. Marking….. ………............................................................................................................................................. 4
4. Installation ………........................................................................................................................................... 5
4.1. Unpacking/delivery ……….............................................................................................................................. 5
4.2. Installation ………........................................................................................................................................... 6
4.3. Recycling Information………........................................................................................................................... 8
5. Operation ………............................................................................................................................................... 9
5.1. Operation/Control ………................................................................................................................................. 9
5.2. Trouble Shooting... ………............................................................................................................................... 10
5.3. Cleaning Solution Leakage ………................................................................................................................... 12
5.4. Poor Cleaning Performance ………................................................................................................................. 13
5.5. Recommended Cleaning ………...................................................................................................................... 14
6. Maintenance ………........................................................................................................................................... 15
6.1. General Maintenance………............................................................................................................................ 15
6.2. General dismantling set up ……….................................................................................................................. 16
6.3. General dismantling......................................................................................................................................... 17
6.4. Inspection and Service of Components ………............................................................................................... 18
6.5. Reassembly ………......................................................................................................................................... 21
7. Technical Data ………...................................................................................................................................... 23
7.1. Technical Data………..................................................................................................................................... 23
7.2. Performance Data………............................................................................................................................... 24
7.3. Dimensions ………......................................................................................................................................... 25
7.4. Trax Simulation Tool ………........................................................................................................................... 26
8. Parts List and Service Kits ……….................................................................................................................. 27
8.1. GJ7 View ………............................................................................................................................................. 27
8.2. Assembly Drawings –1, 2, 3 & 4…………...................................................................................................... 28
8.3. Assembly Drawings –5, 6 & 7 ………............................................................................................................. 30
8.4. Assembly Drawings –8, 9, 10 & 11………...................................................................................................... 32
8.5. Assembly Drawings –12, 13 & 14………........................................................................................................ 35
8.6. Assembly Drawings –15 & 16……….............................................................................................................. 37
8.7. Parts List ………............................................................................................................................................ 38
8.8. Minor Service Kit ……….................................................................................................................................. 41
8.9. Major Service Kit ……….................................................................................................................................. 42
Appendix A …………………….……….................................................................................................................. 43

1
1. EC Declaration of C onformity
The designated company
Alfa Laval Tank Equipment Inc.
Company name
604 Jeffers Circle –Exton, PA –19341, United States
Address
[phone]
Phone no.
hereby declare that
Tank Cleaning Machine
Alfa Laval GJ 7
Denomination
Type
From serial numbers from BZ-001 to BZ-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
2
Unsafe practices and other important information are emphasized in this manual. Warnings are emphasized by means of
special signs.
Always read the manual before using the tank cleaning machine!
2.1 Important information
WARNING
Indicates that special procedures must be followed to avoid serious personal injury.
CAUTION
Indicates that special procedures must be followed to avoid damage to the tank cleaning machine.
NOTE
Indicates important information to simplify or clarify procedures.
2.2 Warning signs
General warning:
Dangerous electrical voltage:
Caustic agents:

2. Safety
3
All warnings in 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 machine are
avoided.
2.3 Safety Precautions
Installation:
Always read the technical data thoroughly. (See chapter 7 Technical Data)
Any tank-cleaning machine can develop a static electricity charge while in operation.
If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to have
the Alfa Laval Gamajet properly grounded using the provided location on the unit.
Operation:
Always read the technical data thoroughly. (See chapter 7 Technical Data)
Necessary precautions must be taken if leakage occurs as this can lead to hazardous situations.
Always handle lye and acid with great care.
When an Alfa Laval Gamajet is operating, there should be covers over every tank opening.
These covers should be sealed well enough to withstand the full force of the jet striking the cover plate.
If the cleaning solution were hot, corrosive, or toxic, a leak would present a serious hazard to any personnel
in the immediate vicinity or to any exposed electrical equipment.
Warning: Any tank-cleaning machine can develop a static electricity charge while in operation. If the tank being
cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to
have the Alfa Laval Gamajet properly grounded using the provided location on the unit.
Maintenance:
Always read the technical data thoroughly. (See chapter 7 Technical Data).
Never service the tank cleaning machine when it is hot.
Always use Alfa Laval genuine spare parts.
Transportation of the tank cleaning machine:
Always drain the tank cleaning machine head and accessories of any liquid
Always use original packaging or similar during transportation.

4. Installation
4
3.1 D escript i on
The Alfa Laval GJ 7 is a fluid-driven (turbine-driven) 360° rotary nozzle machine designed for cleaning the interior surfaces of a
wide variety of small process and storage barrels, drums or containers with a minimum opening of 1-½“(38.1 mm) in diameter.
It is powered entirely by the cleaning solution; it requires no electricity, compressed air or lubricant for operation. The Alfa
Laval GJ 7 is designed primarily for portable service; however, the unit may also be permanently installed in a vessel. If the
Alfa Laval GJ 7 is permanently mounted inside a tank, we strongly recommend inspecting the unit every few hundred hours of
operation. (See Chapter 6 - Maintenance for more information.)
WARNING: Under no conditions, whatsoever, should the Alfa Laval GJ 7 ever be immersed in anything, unless you
have prior approval from Alfa Laval Tank Equipment, Inc. 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 7 is available with dual or triple
nozzles, and an extensive selection of nozzle sizes, stators (non-rotating turbine) O-ring material and gear ratios. Alfa Laval
Gamajet nozzles are available in several interchangeable sizes ranging from 0.070" to 0.100” (1.7 mm to 2.5 mm). The Alfa
Laval Gamajet wash cycle time can be adjusted for special applications by changing the stators and 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 Chapter 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.
© Alfa Laval Tank Equipment. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. "Gamajet" is a trademark or
registered trademark of Alfa Laval Tank Equipment. The Alfa Laval GJ 7 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 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
5
4.1 Unpacking/Delivery
Step 1
CAUTION
Alfa Laval cannot be held responsible for incorrect unpacking.
Check the delivery for:
1. Complete Cleaning Machine
2. Delivery note
Step 2
Remove any packing material.
Step 3
Inspect the tank cleaning machine for visible transport damage. Inspection!

4. Installation
6
Read the instructions carefully and pay special attention to the warnings! Always check the tank cleaning machine before
operation.
4.2 Installation
Step 1
Always read the technical data thoroughly.
(See chapter 7 Technical Data)
Step 2
Assembly
Every Alfa Laval Gamajet is operationally tested before shipment and is ready to run after unpacking. No assembly is required
prior to use. The Alfa Laval Gamajet has been configured to meet the operating conditions (at the Alfa Laval Gamajet, not at
the pump) given to us, e.g., pressure, flow, temperature, cycle time, chemical adders, etc.
Note: Any change to the original operating conditions will affect the Alfa Laval Gamajet accordingly.
WARNING: Do not force Tee (4) & Nozzle Housing (5) to rotate. Doing so will damage internal components.
Step 3
Inlet Connections
The Alfa Laval GJ 7 is supplied with a ½” NPT/ BSP female inlet connection. It is recommended that 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 7, make sure the supply line has been adequately flushed. It should be mounted on a rigid
½” (12.7 mm) pipe using a 1-1/8” (28.5 mm) open-end or adjustable wrench. In most applications, the Alfa Laval GJ 7 will be
mounted with the inlet connection pointing down; however, the Alfa Laval Gamajet will function at any orientation. 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 Gamajet’s position should the unit become unbalanced due to clogging of the
nozzles. In addition, we do not recommend using a Triple Nozzle machine with a flexible supply line. The dynamic imbalance of
the Triple Nozzle will affect the Alfa Laval Gamajet’s performance accordingly.
WARNING: When attaching the Alfa Laval GJ 7 onto the supply pipe, ALWAYS use the wrench flats on the Inlet Collar
at the top/inlet of the unit. Never use a wrench on Stem or Tee Housing to tighten the unit onto the pipe. Doing so
risks internally damaging the machine. Please refer to Drawing 16.
Step 5
Location inside Tank
Generally, a single Alfa Laval Gamajet should be positioned in the approximate center of the vessel in order to equalize the
cleaning radius in all directions. Some vessels 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 Gamajet 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 completely avoid shadow problems.

4. Installation
7
Read the instructions carefully and pay special attention to the warnings! Always check the tank cleaning machine before
operation.
Step 6
Entry Openings
When using the Alfa Laval GJ 7, the vessels being cleaned must provide entry openings large enough to avoid interference
during insertion and removal. The minimum opening size required for the Alfa Laval GJ 7 is 1-½” (38.1 mm) in diameter for
free-hand installation, and 1-15/16” (49.2 mm) for fixed-centerline 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 Gamajet, or even to operate it intermittently to allow time for draining.
Step 8
Filters and Strainers
As an accessory, Alfa Laval Tank Equipment, Inc. sells a strainer to be used in conjunction with the machine. The main
component is a heavy duty Y-Strainer that allows for on-line cleaning of the screen without disassembly of the surrounding
plumbing. By simply opening the included ball valve, the heavy particulate that has collected on the screen can be blown-down.
The screen can also be visually inspected by simply removing the cover of the strainer and, again, without disassembly of the
piping.
If Alfa Laval Gamajet’s strainer is not used, the systems should be equipped with a filter or strainer that will trap solids 0.004”/
0.1 mm (100 micron/ 140 mesh) or larger. The use of a filter ensures adequate removal of particles and debris that can come
from hard water, dirty heating coils, line sediment, and well water. A supply of clean wash fluid to the Alfa Laval GJ 7 and, more
importantly, the vessel is a must.
Step 9
Capacity of Supply Pump
In the majority of cases a positive displacement (PD) style pump (i.e. a pressure washer, piston pump, plunger pump, and
mechanical diaphragm pump) will supply the wash fluid to the Alfa Laval GJ 7. PD pumps are fixed volume pumps whose flow
rate is dependent upon the speed of the pump; the pumps also have a pressure rating which is the maximum operating
pressure. 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, the Alfa Laval GJ 7 and the plumbing system. If a PD pump is
used, the Alfa Laval GJ 7 should be sized to, first, match the flow capability of the pump and, second, not exceed the pump's
maximum operating pressure (taking the plumbing system into account, also).
Centrifugal pumps are not designed for use with the Alfa Laval GJ 7, because of the high pressure (300+ psig/ 20+ Bar) and
low flow rate (2 to 8 gpm/ 0.45 to 1.8 m3/Hr) operating conditions of most applications. If a centrifugal pump must be used it will
not damage the Alfa Laval GJ 7; however, the life expectance of the pump will be greatly reduced. Please contact Alfa Laval
Tank Equipment, Inc. for consultation before using an Alfa Laval GJ 7 with a centrifugal pump.
Step 9
Safety
When Alfa Laval Gamajets are operating, there should be covers over any tank openings. These covers should be sealed well
enough to withstand the full force of the jet striking the cover plate. If the cleaning solution were hot, corrosive, or toxic, a leak
would present a serious hazard to any personnel in the immediate vicinity or to any exposed electrical equipment.
WARNING: Any tank-cleaning machine can develop a static electricity charge while in operation. If the tank being
cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to have the Alfa
Laval Gamajet properly grounded.

4. Installation
8
Read the instructions carefully and pay special attention to the warnings! Always check the tank cleaning machine before
operation.
4.3 Recycling Information
• Unpacking
-Packing material consists of wood, plastics, cardboard boxes and in some cases metal straps.
-Wood and cardboard boxes can be reused, recycled or used for energy recovery.
-Plastics should be recycled or 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 in doubt, or in the
absence of local regulations, please contact your local Alfa Laval sales company.

5. Operation
9
Read the instructions carefully and pay special attention to the warnings! Always check the tank cleaning machine before
operation.
5.1 Operation/Control
Step 1
Always read the technical data thoroughly. See chapter 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 liquids.
Step 3
Initial Startup
When using a pressure washer to feed the unit, Alfa Laval Tank Equipment Inc. strongly recommends running the pressure
washer at the beginning of each use, without the Alfa Laval GJ 7 attached, for a period of time of about one minute. Alfa Laval
Tank Equipment has noted, through our testing with pressure washers, a high level of dirt in the initial wash fluid. This
procedure will lessen the buildup of debris inside the Alfa Laval GJ 7 and potential for premature wear of components.
Every Alfa Laval GJ 7 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 Tank Equipment Inc. To ensure the
longest possible life of the Alfa Laval GJ 7, please verify the operating conditions and, most importantly, the machines cycle
time. The cycle time is determined by picking a fixed point inside of a vessel (i.e. bung hole of a wine barrel) as a reference,
and timing how long it takes the same nozzle to pass back over that fixed point in the vessel. (This, naturally, will not be the
exact same spot because the spray pattern is indexing.) This timed value in seconds corresponds directly to the full cycle time
in minutes.

5. Operation
10
Pay attention to possible faults
Read the instructions carefully.
5.2 Trouble Shooting
Yes
No
Does Rotor (pos.
10) turn freely by
hand?
-Cracked Input Pinion (pos. 51) - Section 6.4 Inspection and Service of Components
- Damaged planetary gearhead (pos. 26) - Section 6.4 Inspection and Service of
Components
- Damaged Rotor Shaft Housing O- Ring (pos. 54) - Section 6.4 Inspection and Service
of Components
- Bent stem (pos. 3) - Section 6.4 Inspection and Service of Components
No
Yes
- Loose output shaft set screw (pos. 39) - Section 6.4 Inspection and Service of
Components
-Cracked/Loose Input Pinions (pos. 51) - Section 6.4 Inspection and Service of
Components
- Worn gear bushing (pos. 31) - Section 6.4 Inspection and Service of
Components
- Worn output shaft lower seal (pos. 25) - Section 6.4 Inspection and
Service of Components
- Worn Tee & Nozzle housing bearing (pos. 35, 36) - Section 6.4 Inspection and
Service of Components
- Bent stem (pos. 3) - Section 6.4 Inspection and Service of Components
- Loose nozzle & tee bearing cup (pos. 32, 34) - Section 6.4 Inspection and Service
of Components
Do Nozzle (pos.
5) and Tee
Housing (pos.
4) both index
when Rotor
(pos. 10) is
turned?
Yes
No
Does only Tee
Housing
(pos. 4) index?
- Worn Tee/ Nozzle housing bevel gear (pos. 17, 18) - Section 6.4 Inspection and
Service of Components
- Broken Drive Pin (pos. 45) - Section 6.4 Inspection and Service of Components
- Worn rotor shaft bearing O- Ring (pos. 49) - Section 6.4 Inspection and
Service of Components
- Cracked/Loose input pinion (pos. 51) - Section 6.4 Inspection and Service of
Components
- Very loose output shaft set screw (pos. 39) - Section 6.4 Inspection and Service of
Components

5. Operation
11
Pay attention to possible faults
Read the instructions carefully
Step 1
INSUFFICIENT FLOW
The Gamajet was configured to meet certain operating conditions outlined at the time of the initial sale, such as flow rate
(m3/Hr/ GPM), pressure (Bar/ PSI), temperature, chemical content of the wash fluid, cycle time, etc. If the Nozzle size is too
small and/or the opening at the bottom of the Stator is too large, the Tee Housing 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 newly overhauled Alfa Laval GJ 7 may fail to operate when first returned to service. If the machine seems otherwise fine, try
running it with at least one Nozzle removed. The reduction in pressure and additional flow will invariably be enough to
overcome the extra resistance of new Bearings and Seals. Fifteen minutes of operation should loosen the machine to run
normally with the Nozzles reinstalled.
Step 3
DEBRIS INSIDE
Loosen the Inlet Collar Set Screw (38), and remove the Inlet Collar (1), then lift out the Stator (9). Look for and remove any
debris caught in the vanes of Stator and Rotor (10). Remove any material wound around the Input Shaft (22). In addition, check
for any debris caught in the outlet holes of the Stem (3), the nose of the Tee Housing (4), and the Nozzle Housing (5).

5. Operation
12
Pay attention to possible faults
Read the instructions carefully.
5.3 Cleaning Solution Leakage
- Worn or Improperly Installed Seals
Excessive leakage from the Tee Housing or Nozzle Housing usually indicates worn Housing Bearings and Seals (61), (59) and
(36). 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 Bearing Cups
Inspect the Bearing Cups (34) and (32) for excessive wear (grooved or scored), particularly near the inside flange where they
contact the Bearings and Seals (61), (59) and (36). Replace any that show distinct grooves.
- Worn Static Seal Contact Surfaces
Inspect the Bearing and Seal contact surfaces of the Stem (3) and the nose of the Tee Housing (4). If these are worn or
grooved, new Bearings and Seals will be ineffective. Replace the damaged parts as required.
- Worn Stem Cap O-Rings
Severe leakage between the Inlet Collar (1) and Stem Cap (2) may indicate worn or damaged Stem Cap O-rings (47) and (48).
Remove the (1) as described in Chapter 6, and inspect the O-rings for signs of damage or wear.

5. Operation
13
Pay attention to possible faults
Read the 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
large enough to 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, so 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 more flow. Proper mechanical operation (the unit turns) is NOT the same thing as effective cleaning (the soils
have been removed)!
-Chemical Concentration and Temperature
Verify that the cleaning solution is the correct compound and in the concentration needed for the deposit being cleaned. If
heating is necessary, also check that the solution is at the proper temperature.
-Plugged Nozzles
Inspect the orifices in the nozzle (5) for debris.
-Slow or no Rotation of the Housings
This will result in partial or erratic washing coverage. Refer to previous sections for more information.
-Alfa Laval Gamajet Configuration
Determine if the deposit being cleaned requires greater jet impact or 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 a Alfa Laval Tank Equipment Inc.
representative if assistance is required.
-Inadequate Drainage
Ensure that the vessel drains the effluent or used wash fluid as fast as it’s being sprayed in through the Alfa Laval Gamajet.
The floor of the vessel should be sloped or pitched toward the drain and the drainage opening should be large enough to
gravity-drain the effluent from the vessel. If you still have puddling (build-up of the wash fluid so it covers the floor and shields
the residues underneath), use some form of pump to suck out the effluent.

5. Operation
14
The Tank Cleaning machine is designed for cleaning in place (CIP). CIP = Cleaning In Place. Study the instructions carefully
and pay special attention to the warnings! NaOH = Caustic Soda, HNO3 = Nitric Acid.
5.5 Recommended Cleaning
Step 1
Always handle lye and acid with great care.
Caustic danger!
Always use rubber gloves! Always use protective goggles!
Step 2
Never touch the pump or the pipelines when sterilizing.
Danger of burns!
Step 3
Always rinse well with clean water after using a cleaning agent.
NOTE
Cleaning agents must be stored/disposed of in accordance with
current regulations/directives.
Always rinse!
Clean Water Cleaning agent

6. Maintenance
15
Maintain the Tank Cleaning Machine with care. Read the instructions carefully and pay special attention to the warnings!
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 8.8 Minor Service Kit & 8.9 Major Service Kit)
Ordering spare parts:
Contact your local Alfa Laval Sales Company.

6. Maintenance
16
Maintain the Tank Cleaning Machine with care. Read the instructions carefully and pay special attention to the warnings!
Always keep Minor spare parts kit in stock.
6.2 General dismantling set up
Step 1
NOTE
A 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 to 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 initially.
Note: Part numbers appearing below may be used to identify parts in Chapter 8.
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 followed by a short (1 to 2 seconds maximum) air blow down, will purge any
residues of chemical cleaners or recirculated wash water that could adversely affect the seals and O-rings during the prolonged
contact of storage.
Step 3
DAILY INSPECTION
Before every shift, ensure that the Name Plate (6) is tight. The Tee Housing (4) should not have any axial play. If it does,
retighten the Tee Housing Bevel Gear Screws (44) that hold down the Bevel Gear (17). Also, the Stator (9) and the orifices in
the Nozzle Housing (5) should be inspected for debris. Look into each orifice for signs of debris or build-up. Examine the Stator
by loosening the Inlet Collar Set Screw (38) and removing the main section of the machine from the Inlet Collar (1).
Note: One does not have to remove the Alfa Laval Gamajet from the supply pipe when performing this check.
Step 4
INTERNAL INSPECTION INTERVALS
The Alfa Laval Gamajet should be internally inspected every 100-200 hours of operation, depending on the severity of use, or
after a season of use and before the unit is placed into long term (over a month) storage. Regardless, the unit should be
inspected after the first 100 hours of operation, or the first season.
Step 5
TIPS
All the Bearings, Bushings, Seals and O-rings are wear parts. Ideally, they should all be replaced, as a group, every 150-200
hours of operation, depending on the severity of use. At first, an interval of 150 hours is recommended.
For balance and wear uniformity, if just one Bearing or Seal is worn or damaged, replace both it and its mate, not just the worn
or damaged part.

6. Maintenance
17
Read the instructions carefully. The items refer to the parts list and service kits section.
6.3 General dismantling
Step 1
Inlet Collar
Loosen the Inlet Collar Set Screw (38) with the 5/64” (2 mm) Hex Key, minimum 2 turns.
Remove the Inlet Collar (1) and Stator (9).
Step 2
Base Assembly
Remove the Socket Head Cap Screws (SHCS) (40) with a 7/64”(2.8 mm) Hex Key, the Lockwashers (41), and Base (28) from
the Tee Housing.
Remove the Nut (43) with a 3/16”(4.76 mm) socket and Lockwasher (42) from the Output Shaft (12).
Using needle nose pliers, remove the Idlers Shafts (15), Idler Gear Assemblies (16), and the Output Pinion (11). Be careful not
to mare the gears or shafts with the pliers.
Step 3
Stem Cap and Gear Train Assembly
Unscrew the Stem Cap Screw (37) with 3/32” (2.3 mm) Hex Key, and remove them.
Pull the Stem Cap (2) from the Rotor Shaft Bearing Housing (57).
Remove the Gear Train Assembly from the body by tapping on the Ouput Shaft at the Base end of the machine with the handle
of a screw driver.
Step 4
Nozzle Housing
Unscrew the Name Plate Screw (6) with a 1/4”(6.35 mm) slotted screwdriver.
Pull the Nozzle Housing (5) off the nose of the Tee Housing.
Remove the inner Nozzle Housing Bearing & Seal (36).
Tip: Use a small slotted screwdriver to get under the flange of (36).
Step 5
Tee Housing
Using a 1/8” (3.17 mm) slotted screwdriver, remove the Ring Gear Retaining Ring (21), and pullout the Ring Gear (20).
Unscrew the Phillips Pan Head Screws (44), and remove the Idler Shaft Base (29).
Tip: if the Idler Shaft Base is difficult to remove, screw the SHCS (40) back into the base and use them for leverage.
Remove the second set of Phillips Pan Head Screws (44), and pull out the Tee Housing Bevel Gear (17). Be careful not to strip
the heads of the screws, they should have a mild thread lock on them.
Pull the Tee Housing (4), lower Tee Housing Seal (59) and lower Bearing (35) from the Stem.