Alfa Laval GJ 9 Instruction Manual
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Alfa Laval GJ 9 Instruction Manual

Alfa Laval GJ 9 Instruction Manual

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Instruction Manual
Alfa Laval GJ 9
Covering: Standard machines
First published: 2015-07
ESE03154-EN2
Original manual
2017-02
4119-0000

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Summary of Contents for Alfa Laval GJ 9

  • Page 1 Instruction Manual Alfa Laval GJ 9 4119-0000 Covering: Standard machines First published: 2015-07 ESE03154-EN2 2017-02 Original manual...

  • Page 3: Table Of Contents

    Table of contents The information herein is correct at the time of issue but may be subject to change without prior notice 1. EC Declaration of Conformity ............... 2. Safety ....................2.1. Important information ................2.2. Warning signs ..................2.3. Safety precautions ................3.

  • Page 4: Ec Declaration Of Conformity

    +45 79 32 22 00 Phone No. hereby declare that Tank Cleaning Machine Designation Alfa Laval GJ 9 Type From serial numbers from T-0100 to T-XXXX is in conformity with the following directive with amendments: Machinery Directive 2006/42/EC - DS/EN ISO 12100:2011...

  • Page 5: Safety

    2 Safety Unsafe practices and other important information are emphasised in this manual. Warnings are emphasised 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 in order to avoid serious personal injury. CAUTION Indicates that special procedures must be followed in order to avoid damage to the tank cleaning machine.

  • Page 6: Safety Precautions

    Any tank cleaning machine can develop a static electricity charge while in operation. If the tank being cleaned contains a combustible liquid or vapour having a risk of ignition or explosion, it is imperative to have the Alfa Laval GJ 9 properly grounded using the provided location on the unit. Operation Always read the technical data thoroughly, see section 7 Technical data.

  • Page 7: Introduction

    The Alfa Laval GJ 9 is designed for both portable and CIP (Clean In Place) applications. If the Alfa Laval GJ 9 is permanently mounted inside a tank, we strongly recommend inspecting the unit every 200-300 hours of operation.

  • Page 8: Installation

    4 Installation 4.1 Unpacking/delivery Step 1 CAUTION Check the delivery for: Alfa Laval cannot be held responsible for incorrect unpacking. 1. Complete cleaning machine. 2. Delivery note. Step 2 Inspect! 1. Remove any packing materials. 2. Inspect the tank cleaning machine for visible transport damage.

  • Page 9: Installation

    Inlet connections The standard inlet connections for the Alfa Laval GJ 9 is a ¾" NPT female/1-¼" male camlock adapter and ¾" BSP/1-¼" male camlock adapter. Other inlets are available. It is recommended that when using the pipe thread, the mating male thread should be wrapped with PTFE pipe joint tape prior to mounting.
  • Page 10 All tank cleaning systems should be equipped with a filter or strainer that will trap solids 0.006" (150 micron, 100 mesh) or larger, as these will not pass through the Alfa Laval GJ 9. These particles can become caught in one of the internal passages of the machine and cause it to stop turning or reduce its cleaning effectiveness due to a loss of flow.

  • Page 11: Recycling Information

    Alfa Laval GJ 9 / plumbing system. If a PD pump is used, the Alfa Laval GJ 9 should be sized, first, to match the flow capability of the pump and then, to not exceed the Alfa Laval GJ 9’s or pump’s maximum operating pressure (taking the pressure rating of the plumbing system...

  • Page 12: Operation

    Initial startup Every Alfa Laval GJ 9 that ships is accompanied by a birth certificate. This document indicates how the Alfa Laval GJ 9 performed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval. To ensure the longest possible life of the 9, please verify the operating conditions and, most importantly, the machine’s cycle time.

  • Page 13: Troubleshooting

    5 Operation Pay attention to possible faults. Read the instructions carefully. 5.2 Troubleshooting Does impeller (23) turn freely - Damaged planetary gearhead (28) – see section 6.4 Inspection and service of components. by hand? - Cracked/loose input pinion (21) – see section 6.4 Inspection and service of components. Do nozzle (46) - Damaged planetary gearhead (28) –...
  • Page 14 INSUFFICIENT FLOW The Alfa Laval GJ 9 was configured to meet certain operating conditions outlined at the time of the initial sale, such as flow rate /h)(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 guide (40) is too large, the tee housing (3) will not turn.

  • Page 15: Cleaning Solution Leakage

    Read the instructions carefully. 5.3 Cleaning solution leakage Cleaning solution leakage The Alfa Laval GJ 9 is a self-flushing machine and thus has 2-3% leakage designed into the machine. Excessive leakage may indicate a larger issue. Worn bearings & seals...

  • Page 16: Poor Cleaning Performance

    - Inadequate drainage Ensure that the vessel drains the effluent (used wash fluid) as fast as it’s being sprayed in through the Alfa Laval GJ 9. The floor of the vessel should be sloped or pitched toward the drain. The drainage opening should be large enough to gravity-drain the effluent from the vessel.

  • Page 17: Recommended Cleaning

    5 Operation The tank cleaning machine is designed for 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 Caustic hazard! Always handle lye and acid with great care. Always use rubber gloves! Always use protective goggles! Step 2...

  • Page 18: Maintenance

    The Alfa Laval GJ 9 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 GJ 9 to seize or lock up. A clean water rinse through the Alfa Laval GJ 9 will also wash out any residue from the chemical cleaners or recirculated wash water that could adversely affect the seals and O-rings during prolonged contact in storage.
  • Page 19 An interval of 100 hours is recommended initially. If all of the components are found to be in acceptable condition after the first 100 hours, the Alfa Laval GJ 9 may then be inspected and undergo routing preventive maintenance every 300 to 500 hours of operation, depending on the severity of use.

  • Page 20: General Dismantling

    6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. 6.3 General dismantling Step 1 Inlet collar 1. Loosen the collar set screw (42) with a 5/64” hex key, minimum 2 turns. 2. Remove the inlet collar (41) and guide (40). 4119-0013 WARNING Hold or turn on stem (1).
  • Page 21 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 3 Cap and gear train 1. Using a 7/64” hex key, remove the cap screws (37) from the stem (1). 2. Remove the cap (36) from the body. 3.
  • Page 22 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 4 Body assembly 1. Remove the tee housing base screws (12) with a 3/32” hex key and the tee housing base from the tee housing. 4119-0052 2.

  • Page 23: Inspection And Service Of Components

    6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. 6.4 Inspection and service of components Guide ’Inspect the guide’s (40) trough holes to be sure that they are clear. Collar O-rings Inspect the small and large collar O-rings, (39 and (38), for damage (clipped or cut) or deterioration (compression set or hardening) and replace if necessary.
  • Page 24 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. 4. Unscrew the impeller nut (25) with an 11/32” socket and remove it with the lockwasher (24) from the input shaft upper bearing housing (13). 5.
  • Page 25 4. Examine the gears of the four different stages for any worn or broken teeth. Also, examine the main internal ring gear for bent or sharp teeth. If any damage is found, contact Alfa Laval immediately. 5. The gears of the bottom (17 teeth) and top (14 teeth) stages must be reinstalled in their respective locations.
  • Page 26 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Input shaft and housings 1. Inspect the input pinion (21) for hairline cracks on the end face or for worn, damaged or sharp/pointed teeth. hould be tightly secured to the input shaft (20) and the input pinion washer (22).
  • Page 27 (45) out of (44). The press tools are available from Alfa Laval. Before installing new (45), clean the housing bores and remove any burrs resulting from the removal of (45).
  • Page 28 (4), therefore, it may be worthwhile to make or obtain press tools for pressing (4) out of (3). The press tools are available from Alfa Laval. Before installing new (4), clean the housing bores and remove any burrs resulting from the removal of (4).

  • Page 29: Reassembly

    All parts must be cleaned thoroughly before reassembling. Any deposits remaining on the parts can cause difficulty when coming to disassemble the Alfa Laval GJ the next time it needs to be serviced. Also, it may cause misalignment of parts and the potential for premature failure.
  • Page 30 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 3 1. To facilitate installation of this assembly into the planetary gearhead (28), extend the (20) slightly so the engagement of the input pinion (21) with the top gears of the (28) is visible.
  • Page 31 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 5 1. Place the output shaft (56) over the shaft of the (28). 2. Install the lower (55) into the (33). The seal’s internal spring should not be visible.
  • Page 32 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 2 1. Align the through holes of the stem base (7) with the threaded holes in the top of the (1). 2. Using a 9/64” hex key, screw the cap screws (11) and lockwashers (10) into the (1).
  • Page 33 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Gear train installation Step 1 1. Insert the geartrain assembled in section 6.4 Inspection and service of components into the body assembly from above step.
  • Page 34 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 3 1. Rotate the impeller (23) using a hex key. It should spin easily and its veins must not strike the walls of the cap (36). Continue turning the impeller (23).
  • Page 35 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Completed assembly Step 5 1. Place the second (43) onto the nose of the (3); push it into the annual space between the (3) and the (45). Lubrication of the internal O-ring is recommended.

  • Page 36: Technical Data

    Inform personnel about the technical data. 7.1 Technical data The Alfa Laval GJ 9 tank cleaning machine is a highly efficient machine with a range of pressures and flows. The instruction manual is part of the delivery. Read the instructions carefully.

  • Page 37: Performance Data

    Technical data It is important to monitor the technical data during installation, operation and maintenance. Inform personnel about the technical data. 7.2 Performance data Flow rate Impact throw length /h USgpm Nozzle Nozzle 3.8mm (.150”) 19.5 5.7mm (.225”) 5.1mm (.200”) 4.7mm (.187”) 16.5 3.4mm (.135”)

  • Page 38: Dimensions

    Technical data It is important to monitor the technical data during installation, operation and maintenance. Inform personnel about the technical data. 7.3 Dimensions Dimensions 8.77 6.96 1.88 2.78 2.80 3.77 NOTE: 3/4" FNPT/1-1/4" camlock or 1-1/2" Tri-Clamp...

  • Page 39: Parts List And Service Kits

    8 Parts list and service kits It is important to monitor the technical data during installation, operation and maintenance. Inform personnel about the technical data. 8.1 Parts list and service kits...
  • Page 40 8 Parts list and service kits It is important to monitor the technical data during installation, operation and maintenance. Inform personnel about the technical data. Parts list Pos. Denomination Stem Drive pin Tee housing  Tee housing cup Tee housing bevel gear ♦▲...
  • Page 41 8 Parts list and service kits It is important to monitor the technical data during installation, operation and maintenance. Inform personnel about the technical data. Service kits Denomination Item no. Gamajet no. Minor service kits ♦ EPDM ............9614618201 9MINEPDMKIT ▲...
  • Page 42 © 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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