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

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 9
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Technical data (continued)
Gunclean Toftejorg TZ-750 Portable
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°(200°F)
Ambient temperature
0 – 140°C (95°C – 140°C when not operated)
Materials
:
Stainless steel, carbon, polymer
Principal dimensions in mm

Page 10 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 (continued)
Flow rate

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 11
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Technical data (continued)
Throw length
Note: Throw lengths are measured as max. horizontal throw length at static condition. Vertical throw
length upwards is approx. 1/3 less.
Effective throw length varies depending on jet transverse speed over surface, substance to be
removed, cleaning procedure and agent.
The inlet pressure has been taken immediately before the machine inlet. In order to achieve the
performance indicated in the curves, the pressure drop in the supply lines between pump and
machine must be taken into consideration.
Option: The Gunclean Toftejorg TZ-750 Fixed can be supplied with nozzle extensions and E-gearing
for longer throw length.

Page 12 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 (continued)
Cleaning Time, f. Complete Pattern (= 4 cycles)

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 13
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Installation and Normal Operation
General Safety and Installation Instructions
The tank cleaning machine should be installed in vertical position (upright or upside down). It is
recommended to install a filter in the supply line in order to avoid large particles to clog inside the
machine. Before connecting the machine into the system, all supply lines and valves should be flushed
to remove foreign matter.
For fixed machines it is recommended to secure the bolted connection between machine and down
pipe against loosening to vibrations. Use Locking wire, nabs or equivalent for the actual application.
ATEX
Warning: If the machine is used in potential explosive atmospheres, tapes or joint sealing compounds which are electrical insulators must not be used on threads or joints, unless
an electrical connection is otherwise established to ensure an effective earthing. In
addition, connecting pipe work, must be electrically conductive and earthed to the tank
structure. The resistance between the nozzles and the tank structure should not exceed
20,000 Ohm. This is essential to avoid the build-up of static electricity on the machine.
For further information see DS/CLC/TR 50404:2003 Safety of Machinery, guidance and
recommendations for the avoidance of hazards due to static electricity.
Electrical equipment such as magnetic valves and electric actuators must not be installed in Ex-zones
without type approval and marking, corresponding to the EX-class in question.
Note:The machine shall be installed in accordance with national regulations for safety and other
relevant regulations and standards.
Precautions shall be made to prevent starting of the cleaning operation, while personnel are inside the
tank or otherwise can be hit by jets from the nozzles.
In EU-countries the complete system must fulfil the EU-Machine Directive and depending of
application, the EU-Pressure Equipment Directive, the EU-ATEX Directive and other relevant
Directives and shall be CE-marked before it is set into operation.
Note:To protect your tank coating it is recommended to mount bumpers on the portable tank cleaning
machine.
The machine as delivered has been tested at the factory before shipping. For transportation reasons,
the nozzles have been screwed off after the test. In order to secure the nozzles against falling off due to
vibrations and other external strains it is important that the nozzles are tightened properly after mounting. If
not, the nozzles may be blown off during tank cleaning and cause severe damage on tank, valves and pump.
This is especially important if machines are fixed installed in tanks and vessels within the transportation
sector in trucks, railcars and onboard ships.
Normally it is sufficient to tighten the nozzles with the specified torque. However depending on the
application and local policies an extra securing may be preferred.

Page 14 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
Installation and Normal Operation (continued)
Subject to the intended use environment and any inhouse user requirements or policies, a liquid threadlocker
such as Loctite No. 243 or equivalent could be used. Other methods could be acceptable and subject to
customer preference. For detailed instruction on pre-cleaning and application of the product carefully follow
the instruction on the used locking system.
1. Clamp machine firmly in a vice: Place
machine on top of vice with Hub w. nozzles
down wards as illustrated on the figure.
Clamp on the Hub. To protect machine use
rubber jaws on the vice.
2.
Set torque wrench at the specified tightening
torque.
3. Tighten nozzle with the torque wrench.
Recommended tightening torque: 75 Nm
Check that the machine is in operating condition by inserting 3/16" hex Screwdriver (tool No. TE134A)
in screw in top of Turbine shaft and easily turn Turbine shaft clockwise. If any resistance is recognised,
the machine should be disassembled to localise the cause.

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 15
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Installation and Normal Operation (continued)
Normal Operation
Cargo and Cleaning Media: Use only media compatible with stainless steel, polymer and carbon.
Normal detergent, moderate solutions of acis and alkalics will be acceptable. Agressive chemicals,
excessive concentrations of chemicals at elevated temperatures, as well as certain dissolvents and
hypochlorids should be avoided. If you are in doubt, contact the local Alfa Laval Tank Equipment
distributor.
After Use Cleaning: After use flush the machine with fresh water. Cleaning solutions should never be
allowed to dry or set-up in the system due to possible "salting out" or "scaling" of the cleaning
ingredient. If cleaning media contains volatile chloride solvents, it is recommended not to flush with
water after use, in case this can create hydrochloric acid.
Pressure: Avoid Hydraulic shocks. Put on pressure gradually. Do not exceed 12 bar inlet pressure.
Recommended inlet pressure appears from Technical Data (page 8-9). High pressure in combination
with high flow rate will increase consumption of wear parts.
ATEX
Warning: If stream cleaning is done through the machine, the steam pressure must not cause the machine to rotate.
ATEX
Warning: If the machine is drained using compressed air, then the compressed air pressure must not cause the machine to rotate.
Temperature: In accordance with the ATEX specifications regarding special conditions for safe use,
see page 16.
ATEX
Warning: Tanks with capacities greater than 100 m3that could contain a flammable atmosphere should not be steam cleaned, as steam issuing from a nozzle could contain charged
droplets.
Tanks smaller than this may be steam cleaned providing that: the steam nozzles and
other metal parts of the system are reliably earthed and grounded to the tank
structure.
ATEX
Warning: In potentially explosive atmospheres, the temperature must not exceed the maximum surface temperature according to the temperature class for the combustible gas or
liquid.

Page 16 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
Installation and Normal Operation (continued)
Special Conditions for Safe Use in accordance with the ATEX Certification,
Directive 94/9/EC
ATEX Warning: The unit may be operated, in a hazardous area, only when filled with the
process fluid.
ATEX Warning: The maximum permitted process fluid temperature and ambient temperature
when the machine is operating is 95°C.
When the machine is not operating, the maximum permitted ambient
temperature is 140°C.
ATEX Warning: The maximum permitted flush or cleaning fluid pressure difference across the
machine is 12 bar.
ATEX Warning: The unit must not be operated in a vessel having an enclosed volume of greater
than 100m3.
Tanks larger than 100 m³
To use Tank Cleaning Machines in tanks larger than 100m³ is possible under
certain conditions.
It is necessary to know the current factors such as tank size, cleaning solvent
and product.
Additives can be used in the cleaning solvent, or, for example, the tank can be
filled with nitrogen. The basic rules are described in the guide "CLC / TR
50404:2003“.
Following a guidance document such as "CLC / TR 50404:2003“ to establish
safe use of machinery and process is the users own responsibility and is not
covered by the ATEX certification for this product.
ATEX Warning: The user must address the electrostatic hazards generated from the process of
the equipment in accordance with guidance document CLC/TR 50404:2003.
In addition to the above mentioned precautions relating to the ATEX guidelines Directive 94/9/EC of
March 23 1994, the Safety Precautions on page 13 must be observed.

Instruction Manual, Gunclean Toftejorg TZ-750 Fixed & Portable Page 17
Standard machines and machines delivered with ATEX certification
in accordance with Directive 94/9/EC
IM-TE91A400-EN7
Maintenance and repair
Service and Repair of ATEX Approved Machines
In order to ensure compliance with the ATEX regulations for service and repair in accordance with EN
60079-19, all service and repair of ATEX approved machines should be performed by Alfa Laval Tank
Equipment, Kolding, Denmark.
Warning: ATEX requirements regarding repair of ATEX approved machines according to EN
60079-19.
A tag with the following labelling information must be attached to the machine:
- Repair symbol R
- Alfa Laval logo and address
- Repair number
- Date of repair
- Machine serial number
The tag must be laminated and attached to the machine-downpipe outside the tank
using a cable tie.
If a customer wishes to carry out service or repair himself, it is the responsibility of the repair shop to
ensure that the ATEX requirements are met in any way possible. After performing service or repair, the
repair shop thus carries the full responsibility for the ATEX approval of the machine.

Page 18 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
Maintenance and repair
Preventive Maintenance Guidelines and Service Kits
By using Alfa Laval Tank Equipment Preventive Maintenance Guidelines and Service Kits you are
enabled to ensure the availability of your equipment at all times. You are able to plan your operating
budget and your downtime. The risk of breakdowns due to component failure is virtually eliminated and
in the long term your operating costs are reduced.
Alfa Laval Tank Cleaning Equipment Service Kits contain All you need. They comprise genuine Alfa
Laval spare parts, manufactured to the original specifications.
See page 17 regarding special conditions for repair of ATEX certified machines.
Maintenance intervals and Service Kits selection
Alfa Laval Service Kits for Tank Cleaning Machine type, TZ-750FIX is available in two levels: Minor
Service and Major Service.
Minor Service Kit is recommended to be replaced every 250 working hours or 2½ years, whichever
comes first.
TE55M000 Minor Service Kit contains:
Pos.
Qty x P/n
Description
6
1 x TE609P
Main bush
12
3 x TE615K
Collar bush
13 1 x TE22A360 Worm wheel
14
1 x TE22A360
Worm heel
19
4 x TE651
Locking wire
30
2 x TE929K
Slide bearing
Major Service kit is recommended to be replaced every 1000 working hours or 10 years, whichever
comes first.
TE55M010 Major Service Kit contains:
Pos.
Qty x P/n
Description
7
1 x TE911K
Turbine shaft
8.1
1 x TE126-1
Ball race
20.1
1 x TE126-1
Ball race
21.1
1 x TE126-1
Ball race
28.3
1 x TE126-1
Ball race
23.1
1 X TE624-11
Hub liner
24
1 x TE448
Cotter pin
27
2 x TE126S
Ball retainer with balls
28.1
1 x TE127Z1
Main collar, upper
28.2
1 x TE127Z2
Main collar, lower
28.4
1 x TE127-3
Collar, hub
29
1 x TE128Z
Horizontalshaft
1 x TE55M000
Service Kit Minor, TZ-75FIX/
TZ-75PT/TZ-750FIX