Alfa Laval Toftejorg TZ-79 Instruction Manual
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Alfa Laval Toftejorg TZ-79 Instruction Manual

Covering standard machines, machines delivered with atex certification in accordance with directive 94/9/ec
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Instruction Manual
Toftejorg™ TZ-79
Covering ▪ Standard Machines
▪ Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
IM-TE91A350-EN9
ESE01798EN
Date of issue: January 8, 2015
First published: 1988
Original manual
www.sks-online.com
www.sks-webshop.com

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Summary of Contents for Alfa Laval Toftejorg TZ-79

  • Page 1 Instruction Manual Toftejorg™ TZ-79 Covering ▪ Standard Machines ▪ Machines delivered with ATEX Certification in accordance with Directive 94/9/EC IM-TE91A350-EN9 ESE01798EN Date of issue: January 8, 2015 First published: 1988 Original manual www.sks-online.com www.sks-webshop.com...
  • Page 2 www.sks-online.com www.sks-webshop.com...

  • Page 3: Table Of Contents

    Replacement of Ball races ........................32 Replacement of Main Collars ........................34 Tools ............................36 Standard Tool kit for Toftejorg TZ-79 ....................... 36 Sketch of tools for replacement of Main collars ..................37 Trouble Shooting Guide ......................38 Reference List of Parts ......................40 Cross Sectional Drawing ......................
  • Page 4 www.sks-online.com www.sks-webshop.com...

  • Page 5: Introduction

    © 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.

  • Page 6: Intended Use

    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.

  • Page 7: Atex Marking

    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.

  • Page 8: General Description

    General Description The Toftejorg TZ-79 is a media driven and media lubricated tank cleaning machine. As it is self lubricating, there is no lubricating substances such as oil, grease etc. in the machine which needs to be regularly changed. Functioning The flow of the cleaning fluid into the machine passes through a guide and a turbine, which is set into rotation.

  • Page 9: Standard Configurations

    General description (continued) Standard configurations Turbine/ Nozzles (mm) Connection Inlet Guide (3/4” thread connection) Article No. Top cone: 4xø8 TE22D110 2” NPT, 100% 4xø9 TE22D112 Female 2xø11 TE22D116 4xø9 TE22D130 4xø10 TE22D132 Top cone: 4xø8 TE22D210 2” BSP, 100% 4xø9 TE22D212 Female 2xø11...

  • Page 10: Technical Data

    Technical data Weight of machine 13 kgs (28,6 lb) Working pressure 2-12 bar (30-175 psi) Recommended inlet pressure 3-8 bar (45-120 psi) Working temperature max. 95° (200° F) Ambient temperature 0 – 140°C (95°C – 140°C when not operated) Materials Stainless steel AISI 316/316L, PTFE, Tefzel, PVDF, Carbon, Teflon TFM, PEEK Principal dimensions in mm...
  • Page 11 Technical data (continued) Flow rate www.sks-online.com www.sks-webshop.com...
  • Page 12 Technical data (continued) Throw length Note: Throw lengths are measured as horizontal throw length at static condition. Vertical throw length upwards is approx. 1/3 less. Effective throw length is defined as impact centre of jet 250 mm water column (50 lbs/sq.ft). Effective throw length varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent.
  • Page 13 Technical data (continued) Cleaning Time f. complete Pattern (= 8 cycles) www.sks-online.com www.sks-webshop.com...

  • Page 14: Installation And Normal Operation

    Installation and Normal Operation General Installation and Safety 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.
  • Page 15 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.

  • Page 16: Normal Operation

    Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures, as well as certain hypochlorids should be avoided. If you are in doubt, contact your local Alfa Laval Tank Equipment sales office. After Use Cleaning After use flush the machine with fresh water.

  • Page 17: Special Conditions For Safe Use In Accordance With The Atex Certification, Directive 94/9/Ec

    Installation and Normal Operation (continued) Temperature In accordance with the ATEX specifications regarding special conditions for safe use, see page16. ATEX Tanks with capacities greater than 100 m that could contain a flammable atmosphere Warning: should not be steam cleaned, as steam issuing from a nozzle could contain charged droplets.
  • Page 18 Installation and Normal Operation (continued) Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC 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 100m Tanks larger than 100 m³...

  • Page 19: 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.

  • Page 20: Preventive Maintenance

    We trust that you will adjust your maintenance programme to suit. Always use only proper tools. Use Toftejorg TZ-79 standard tool kit. Never force, hammer or pry components together or apart. Always perform all assembly/disassembly steps in the order described in this manual.
  • Page 21 Maintenance and Repair (continued) Preventive Maintenance Check Worm wheels (pos. 13 and pos. 14). If extremely worn, they should be replaced. Check Main bush (pos. 6). If worn oval to max. diameter more than 15.4 mm, it should be replaced. Assemble machines as described in the following pages.

  • Page 22: Top Assembly

    Maintenance and Repair (continued) Top Assembly Disassembly Remove Screws (pos. 19). Loosen and unscrew with a Socket wrench (tool No. TE962A). Lift off Top cone (pos. 1). Remove Guide/Guide ring (pos. 2). The Guide has a groove in the outer diameter. The Guide is easily lifted out of the Stem by means of two ordinary Screwdrivers inserted into the groove.
  • Page 23 Maintenance and Repair (continued) Top Assembly www.sks-online.com www.sks-webshop.com...

  • Page 24: Bottom Assembly

    Maintenance and Repair (continued) Bottom Assembly Disassembly Turn machine upside down. Remove Screws (pos. 34) from Bottom cover (pos. 33). Remove Bottom cover (pos. 33) and Gasket (pos. 35). Remove Screw (pos. 17) and Spring washers (pos. 16) along the circumference of Gear frame (pos.
  • Page 25 Maintenance and Repair (continued) Bottom Assembly www.sks-online.com www.sks-webshop.com...

  • Page 26: Hub Subassembly

    If blue liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure is followed to accomplish installation. It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary.
  • Page 27 Maintenance and Repair (continued) Hub Assembly www.sks-online.com www.sks-webshop.com...

  • Page 28: Stem Subassembly

    If blue liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure is followed to accomplish installation. It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary.
  • Page 29 Maintenance and Repair (continued) Stem Subassembly www.sks-online.com www.sks-webshop.com...

  • Page 30: Gear Subassembly

    Maintenance and Repair (continued) Gear Subassembly Disassembly Hold Turbine shaft (pos. 7) against 1st stage Worm wheel (pos. 14) with one hand and loosen Screws (pos. 17) in Pinion (pos. 11) and Horizontal shaft (pos. 29) with the other hand. Draw out Turbine shaft (pos.
  • Page 31 Maintenance and Repair (continued) Gear Subassembly Insert 1st stage Worm wheel (pos. 14) and Horizontal shaft (pos. 29). Mount Washer (pos. 18), Spring washer (pos. 16) and fix with Screw (pos. 17). Check rotation. Insert Turbine shaft (pos. 7). Mount Washer (pos. 18), Spring washer (pos. 16) and fix with Screw (pos.

  • Page 32: Replacement Of Collar Bushes

    Maintenance and Repair (continued) Replacement of Collar Bushes Place Gear frame (pos. 31) upside down with a firm support under the flange. Use for instance jaws of a vice. Do not clamp on machined surfaces. With Pusher (tool no. TE81B031, see page 36) knock out Collar bush.
  • Page 33 Maintenance and Repair (continued) Replacement of Collar Bushes Removal of old Collar bushes Mounting of new Collar bushes www.sks-online.com www.sks-webshop.com...

  • Page 34: Replacement Of Ball Races

    Maintenance and Repair (continued) Replacement of Ball races In Body A. With big end downwards knock several times Body with bearings (pos. 28) hard against firm wooden support until Ball race (pos. 28.3) drops out. B. If it is not possible to knock out Ball race in this way, it is necessary first to screw out Main collar lower (pos.
  • Page 35 Maintenance and Repair (continued) Replacement of Ball races www.sks-online.com www.sks-webshop.com...

  • Page 36: Replacement Of Main Collars

    28.2) in Body. The procedure to do this is described below. Warning: Replacement of Main collars involves risk of damaging the special threads and accordingly the body. It is recommended to let an authorized Alfa Laval Tank Equipment sales office do the replacement. Main collar upper Place Body (pos.
  • Page 37 Maintenance and Repair (continued) Replacement of Main Collars www.sks-online.com www.sks-webshop.com...

  • Page 38: Tools

    Tools Standard Tool kit for Toftejorg TZ-79 Article no. TE81B075 Tool No. Description TE134 Unbraco key for screw 1 pcs. TE134A Unbraco Screwdriver 1 pcs. TE135 Unbraco key for screw 1 pcs. TE135A Unbraco screw driver 1 pcs. TE462 Open-end spanner 1 pcs.

  • Page 39: Sketch Of Tools For Replacement Of Main Collars

    Tools (continued) Sketch of tools for replacement of Main collars www.sks-online.com www.sks-webshop.com...

  • Page 40: Trouble Shooting Guide

    Trouble Shooting Guide Symptom: Slow rotation or failure of the machine to rotate Possible causes Action No or insufficient liquid flow a). Check if supply valve is fully open. b). Check if inlet pressure to machine is correct. c). Check supply line/filter restrictions/...
  • Page 41 Trouble Shooting Guide (continued) Possible causes Action e). Gearbox jammed/sluggish Remove foreign material from Gearbox. Check rotation of shafts. If restriction is recognized, disassemble Gearbox (see page 28) and remove material build-up, especially on 2nd stage Worm wheel and mating Collar bushes. Hub jammed/sluggish Disassemble Hub Subassembly (see page 24).

  • Page 42: Reference List Of Parts

    Reference List of Parts Pos. Ref. no. No./unit Description Material Remarks  TE22D500 Top cone 2” BSP Stainless steel Spare part  TE22D501 Top cone 2” NPT Stainless steel Spare part  TE603 Guide 100% Stainless steel Spare part  TE103-0 Guide ring 0% Stainless steel Spare part...

  • Page 43: Cross Sectional Drawing

    Cross Sectional Drawing www.sks-online.com www.sks-webshop.com...

  • Page 44: Service Kits

    Locking Wire 4 pcs. TE929K Slide bearing 2 pcs. * Locking wire is only used in fixed version and can be disregarded Service Kit Minor for Toftejorg TZ-79 (PEEK) Article No. TE55M001 Part No. Description TE22B575 Main bush 1 pcs.
  • Page 45 TE127-3 Collar, hub 1 pcs. TE128Z Horizontal shaft 1 pcs. TE55M000 Service Kit Minor 1 pcs. Service Kit Major for Toftejorg TZ-79 (PEEK) Article No. TE55M011 Qty x P/n Description TE911K Turbine shaft 1 pcs. TE126-1 Ball race 4 pcs.

  • Page 46: General Information

    Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to guarantee a quick execution of your request. You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions closely.

  • Page 47: Ec Declaration Of Conformity

    EC Declaration of conformity www.sks-online.com www.sks-webshop.com...
  • Page 48 © 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.

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