Alfalaval Gunclean Toftejorg TZ-750 User manual

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Instruction Manual
Gunclean Toftejorg™ TZ-750
IM-TE91A400-EN
ESE02855EN
Date of issue: January 8, 2015
First published: 1988
Covering ▪Standard Machines
▪Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
Original manual

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 1
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Contents
Contents...................................................................................................................................1
Introduction...............................................................................................................................3
Intended Use............................................................................................................................4
Patents and trademarks............................................................................................................4
ATEX Marking...........................................................................................................................5
General Description ..................................................................................................................6
Functioning................................................................................................................................................6
Standard Configurations............................................................................................................................7
Options ......................................................................................................................................................7
Available add-ons......................................................................................................................................7
Technical Data..........................................................................................................................8
Gunclean Toftejorg TZ-750 Fixed..............................................................................................................8
Gunclean Toftejorg TZ-750 Portable..........................................................................................................9
Flow rate..................................................................................................................................................10
Throw length............................................................................................................................................11
Cleaning Time, f. Complete Pattern (= 4 cycles)......................................................................................12
Installation and Normal Operation ...........................................................................................13
General Safety and Installation Instructions.............................................................................................13
Normal Operation.....................................................................................................................................15
Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC..............16
Maintenance and repair...........................................................................................................17
Service and Repair of ATEX Approved Machines....................................................................................17
Maintenance and repair...........................................................................................................18
Preventive Maintenance Guidelines and Service Kits..............................................................................18
Maintenance intervals and Service Kits selection....................................................................................18
Top Assembly..........................................................................................................................................20
Bottom Assembly.....................................................................................................................................22
Hub Subassembly....................................................................................................................................24
Stem Subassembly..................................................................................................................................26
Gear Subassembly..................................................................................................................................28
Replacement of Collar Bushes................................................................................................................30
Replacement of Ball races.......................................................................................................................32
Replacement of Main Collar.....................................................................................................................34
Tools ......................................................................................................................................36
Sketch of tool for replacement of Main collar...........................................................................................37
Trouble Shooting Guide..........................................................................................................38
Gunclean Toftejorg TZ-750 Fixed............................................................................................40
Reference List of Parts............................................................................................................................40
Cross Sectional Drawing..........................................................................................................................41
Gunclean Toftejorg TZ-750 Portable.......................................................................................42
Reference List of Parts............................................................................................................................42
Cross Sectional Drawing..........................................................................................................................43

Service Kits.............................................................................................................................44
TE55M000 Minor Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX..................................................................44
TE55M010 Major Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX..................................................................44
General Information ................................................................................................................45
How to Order Spare Parts........................................................................................................................45
Service and Repair..................................................................................................................................45
How to contact Alfa Laval Tank Equipment.............................................................................................45
EC Declaration of conformity...................................................................................................46

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 3
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Introduction
This manual has been prepared as a guide for the persons who will be operating and maintaining your
tank cleaning machine. The key to long life for your tank cleaning machine will always be a system of
carefully planned maintenance; you will appreciate that a tank cleaning machine which has a rough
and dirty job to do will need more frequent attention than one working in ideal conditions.
It is in your own interest to get the best and most economical performance from your tank cleaning
machine. Neglect of maintenance means poor performance, unscheduled stoppages, shorter life and
expense. Good maintenance means good performance; no unscheduled stoppages and better total
economy.
You will find the information contained in this manual simple to follow, but should you require further
assistance, our Customer Service Department and 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.
© Alfa Laval Corporate AB
This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing
intellectual property and thereto related rights. It is the responsibility of the user of this document to
comply with all applicable intellectual property laws. Without limiting any rights related to this
document, no part of this document may be copied, reproduced or transmitted in any form or by any
means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the
expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB will enforce its rights
related to this document to the fullest extent of the law, including the seeking of criminal prosecution.

Page 4 Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Intended Use
It is to be verified by the end-user:
- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in
which it will be used.
- that the construction materials (both metallic and non-metallic) are compatibility with product,
flushing media, cleaning media, temperatures and pressure under the intended use.
Patents and trademarks
This Instruction Manual is published by Alfa Laval Kolding A/S without any warranty. Improvements
and changes to this Instruction Manual may at any time be made by Alfa Laval Kolding A/S without
prior notice. Such changes will, however, be incorporated in new editions of this Instruction Manual.
© Alfa Laval Kolding A/S. All rights reserved.
The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean
ToftejorgTM is a trademark or registered trademark of Alfa Laval Kolding A/S. Other products or
company names mentioned herein may be the trademarks of their respective owners. Any rights not
expressly granted herein are reserved.

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 5
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
If ordered with ATEX certificate:
ATEX Marking
The Gunclean Toftejorg TZ-750 Fixed & Portable are certified as category I components. The
certification is carried out by the certified body Baseefa, who has issued the certificate no.
10ATEX0188X. The marking on the ATEX certified Gunclean Toftejorg TZ-750 Fixed & Portable is as
follows:
“TZ-xx”: TZ machine type
Serial number explanation
Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number
Changes to the machine are not allowed without approval by the person responsible for the ATEX
certification at Alfa Laval Tank Equipment. If changes are made – or spare parts other than Alfa Laval
original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer
valid.
Important
ATEX
information:
Also see page 17 regarding special conditions for repair of ATEX certified
machines.

Page 6 Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
General Description
The Gunclean Toftejorg TZ-750 is a media driven and media lubricated tank cleaning machine. As it is
self lubricating, there are no lubricating substances such as oil, grease etc. in the machine which need
to be regularly changed.
Functioning
The flow of the cleaning fluid into the machine passes through a turbine, which is set into rotation. The
turbine rotation is through a gearbox transformed into a combined horizontal rotation of the machine
body and a vertical rotation of the nozzles.
The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning
coverage. After 11¼ revolutions of the Hub with nozzles (10 3/4revolutions of the machine body), one
coarse cleaning pattern is laid out on the tank surface. During the following rounds, this pattern is
repeated 3 times, each of which is displaced ¼ of the mesh in the pattern. After a total of 45 revolutions
of the Hub with nozzles (43 revolutions of the machine body), a complete cleaning pattern has been
laid out, and the first pattern is repeated.
1
st
cycle 2
nd
cycle 3
rd
cycle 4
th
cycle
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 efficiency of the turbine can be changed (50% - 100% - 0% Turbine/Inlet
guide).
Apart from the jet flow through the nozzles, fluid is leaking through the top of the machine, at the hub
and through the bottom cover. The leakages between the moving parts at the top and at the hub are
cleaning the gabs and thus preventing build-up of material that might cause extra friction. The flow
through the bottom cover is due to the fact that the machine is media lubricated, and that accordingly a
flow through the gearbox is needed.

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 7
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
General description (continued)
Standard Configurations
Machines without flange for direct mounting on extension pipe (requires special flange on extension
pipe).
Connection
Nozzles (mm)
(1" thread conn.)
Article No.
Fixed with special
GuncleanToftejorg
Flange
2 x ø15
2 x ø17
2 x ø19
2 x ø21
TE22E084
TE22E086
TE22E088
TE22E090
Fixed with flange:
D0: ø127 mm
di: ø50 mm
PC: ø98,5 mm
2 x ø15
2 x ø17
2 x ø19
2 x ø21
TE22E034
TE22E036
TE22E038
TE22E040
Portable
with 2½” ASA nipple
2 x ø15
2 x ø17
2 x ø19
2 x ø21
TE22E114
TE22E116
TE22E118
TE22E120
Portable
with 2½” BSP nipple
2 x ø15
2 x ø17
2 x ø19
2 x ø21
TE22E124
TE22E126
TE22E128
TE22E130
Portable
with 2½” NPT nipple
2 x ø15
2 x ø17
2 x ø19
2 x ø21
TE22E134
TE22E136
TE22E138
TE22E140
The machine is equipped with a clutch in the hub, which gives the possibility of rotating by hand the
nozzles, when the machine is to be lifted out through a tank opening.
Options
•Machines with Nozzle extensions for longer throw length can be supplied as an option. Same
article no. with index no. -22, e.g. TE22E084-22.
•Machines with Nozzle extensions and E-gear, e.g. TE22E084-62.
•Machines with PEEK wear parts, TE22Exxx-06.
Available add-ons
, category 1 for installation in zone 0/20
TE21EXXX-70 ATEX
TE21EXXX-22-70 ATEX + nozzle extension
TE21EXXX-62-70 ATEX + nozzle extension and E-gear
Explanation to Add-ons
ATEX, category 1 for installation in zone 0/20 in accordance with Directive 94/9/EC

Page 8 Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Technical Data
Gunclean Toftejorg TZ-750 Fixed
Weight of machine
:
16 kgs (35,3 lb)
Working pressure
:
2-12 bar (30-175 psi)
Recommended inlet pressure
:
5-10 bar (75-150 psi)
Working temperature max.
:
95°C (200°F)
Ambient temperature
0 – 140°C (95°C – 140°C when not operated)
Materials
:
Stainless steel, carbon, polymer
Principal dimensions in mm