Alfa Laval GJ 8 Instruction Manual
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Alfa Laval GJ 8 Instruction Manual

Alfa Laval GJ 8 Instruction Manual

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Instruction Manual
Alfa Laval GJ 8
Covering:
Standard Machines
First published: 2015-08
ESE032025-EN1
Original manual
2015-08

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Summary of Contents for Alfa Laval GJ 8

  • Page 1 Instruction Manual Alfa Laval GJ 8 Covering: Standard Machines First published: 2015-08 ESE032025-EN1 2015-08 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 ....................... …… EC Declaration of Conformity ……...

  • Page 4: Ec Declaration Of Conformity

    EC Declarat ion of Conf ormity The designated company Alfa Laval Tank Equipment Inc. Company name 604 Jeffers Circle – Exton, PA – 19341, United States Address +1 610 408 9940 Phone no. hereby declare that Tank Cleaning Machine Alfa Laval GJ 8...

  • Page 5: Safety

    2. Safety 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.

  • Page 6: Safety Precautions

    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.

  • Page 7: Introduction

    In order to handle the broadest possible range of applications, the stainless steel Alfa Laval GJ 8 is available with dual or triple nozzles, and an extensive selection of nozzle sizes, stators (non-rotating turbine), and O-ring materials. The nozzles are available in six interchangeable sizes - 1/4", 9/32", 5/16", 3/8"...

  • Page 8: Installation

    Read the instructions carefully and pay special attention to the warnings! Always check the tank cleaning machine before operation. 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 Remove any packing material Step 3 Inspect the tank cleaning machine for visible transport damage.

  • Page 9: Installation

    Mounting Before mounting the Alfa Laval GJ 8, make sure the supply line has been adequately flushed. It should be mounted on a rigid 1-½” pipe using an adjustable or pipe wrench. In most applications, the Alfa Laval GJ 8 will be mounted in the upright position (inlet connection pointing up);...
  • Page 10 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.

  • Page 11: Recycling Information

    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 8 and the plumbing system. If a PD pump is used, the Alfa Laval GJ 8 should be sized to, first, match the flow capability of the pump and, second, not exceed the pump's maximum operating pressure (taking the pressure rating of the plumbing system into account, also).

  • Page 12: Operation

    Initial Startup Every Alfa Laval GJ 8 that ships is accompanied by a Birth Certificate. This document indicates how the Alfa Laval GJ 8 performed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Tank Equipment Inc.

  • Page 13: Trouble Shooting

    5. Operation Pay attention to possible faults Read the instructions carefully Trouble Shooting - Cracked Input Pinion (pos. 39) - Section 6.4 Inspection and Service of Components Does Rotor (pos. - Damaged planetary gearhead (pos. 13) - Section 6.4 Inspection and Service of 10) turn freely by Components hand?
  • Page 14 TIGHT CLEARANCES A newly overhauled Alfa Laval GJ 8 may fail to operate when first returned to service. If the machine seems otherwise fine, try running it with at least one Nozzle Tip removed. The reduction in pressure and additional flow will invariably be enough to overcome the extra resistance of new Bearings and Seals.

  • Page 15: Cleaning Solution Leakage

    5. Operation Pay attention to possible faults Read the instructions carefully Cleaning Solution Leakage - Worn Bearings & Seals Water exiting from the CIP holes in the Tee Housing will cause a slight spray to exit around the Tee and Nozzle Housing. However, excessive leakage from the Tee Housing or Nozzle Housing usually indicates worn Housing Bearings (29), and Seals (31).

  • Page 16: Poor Cleaning Performance

    - 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.

  • Page 17: Recommended Cleaning

    5. Operation 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. Recommended Cleaning Step 1 Caustic danger! Always handle lye and acid with great care.

  • Page 18: Maintenance

    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 8.9 Minor Service Kit & 8.10 Major Service Kit) Ordering spare parts: Contact your local Alfa Laval Sales Company.

  • Page 19: General Dismantling Set Up

    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 will also wash out any residues of chemical cleaners or recirculated wash water that could adversely affect the seals and O-rings during prolonged contact in storage.

  • 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 Loosen the Collar Set Screw (45) with the 1/8" Hex Key. Unthread the Collar (8) and remove the Stator (9). Tip: If (8) does not unthread easily, remove (45) and spray a generous amount of liquid lubricant into the threaded hole.

  • Page 21: 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 Drawing 1 Stator Inspect all the openings through the Stator (9) to be sure that they are clear and free of debris. Drawing 4, 5 Base Assembly Inspect the Output Pinion (11) and Idler Gears (16) for worn, damaged, or sharp/pointed teeth.
  • Page 22 Once dry, the Planetary Gears can be lightly hand - packed with grease. Alfa Laval Tank Equipment recommends using a Chevron FM NLGI 2 grease for food grade applications and a Fuch’s ST-80 grease for aggressive chemical environments.
  • Page 23 (30) out of (5). The press tools are available from Alfa Laval Tank Equipment Inc. Before installing new (30), clean the housing bores and remove any burrs resulting from (30) removal.

  • Page 24: Reassembly

    All parts must be cleaned thoroughly before reassembling. Any deposits remaining on the parts can cause difficult disassembly the next time the Alfa Laval Gamajet needs servicing. Apply a dab of a Teflon-based anti-seize compound, except when otherwise noted, to all threads when reassembling; this will prevent galling of threads and ease any future disassembly.
  • Page 25 6. Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Drawing 20- 31 Gear Train Turn to (drawing 30): Place the Rotor Shaft (21) assembly partially into the Rotor Shaft Lower Bearing Housing (25). Insert them into the Planetary Gearhead (13), ensuring that the Input Pinion (39) has properly meshed with the gears inside of (13).

  • Page 26: Technical Data

    It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. Technical Data The Alfa Laval GJ 8 Tank Cleaning Machine is a highly efficient machine at a range of pressures and flows. The instruction manual is part of the delivery. Read the instructions carefully. TECHNICAL DATA Lubricant .

  • Page 27: Performance Data

    7. Technical Data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. Performance Data Flow Rate Impact Throw Length Inlet Pressure Inlet Pressure - - - Wetting, --- Impact cleaning Cleaning Time Flow Rate —...

  • Page 28: Dimensions

    7. Technical Data It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. Dimensions Dimensions 180˚ directional version Dimensions Dimensions 11.06 7.95 8.46 2.01 4.64 8.50 9.76 4.76 6.50 Dimensions 180˚ directional version 11.05 8.54 2.02...

  • Page 29: Trax Simulation Tool

    TRAX simulation tool TRAX is an unique software that simulates how the Alfa Laval GJ 8 performs in a specific tank or vessel. The simulation gives information on wetting intensity, pattern mesh width and cleaning jet velocity. This information is used to determine the best location of the tank cleaning device and the correct combination of flow, time, and pressure to implement.

  • Page 30: Parts List And Service Kits

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine GJ8 View GJ0900...

  • Page 31: Assembly Drawings - 1

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings - 1 & 2 GJ0902 Drawing 1 - Completed Assembly Drawing 2 – Base Assembly A: Drawing 2 A : Drawing12 B: Never hold or turn on tee housing cap during removal of (8)

  • Page 32: Assembly Drawings - 3, 4, 5, 6, 7

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings – 3, 4, 5, 6, 7 & 8 Drawing 3 – Output Pinion Assembly Drawing 4 – Idler Shaft Assembly Drawing 5 – Idler Gear...
  • Page 33 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 7 – Stem Collar Screws & washer Drawing 6 – Ring Gear A: Align the flats and press flush Drawing 8 – Stem Collar Assembly...

  • Page 34: Assembly Drawings - 9, 10, 11, 12, 13, 14, 15, 16

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings – 9, 10, 11, 12, 13, 14, 15, 16 & 17 Drawing 10 – Nozzle Housing Assembly Drawing 9 – Gear train Assembly Drawing 11 –...
  • Page 35 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 14 – Nozzle Housing Drawing 13 – Tee Housing Bevel Gear Drawing 15 – Nozzle A : Press fit A : Press flush with the bottom edge Drawing 16 –...

  • Page 36: Assembly Drawings - 18, 19, 20, 21, 22, 23, 24 & 25

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings – 18, 19, 20, 21, 22, 23, 24 & 25 Drawing 18 – The Housing Assembly A : Drawing 33 Drawing 19 – Tee Housing Bevel Gear A : Press fit Drawing 20 –...
  • Page 37 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 23 – Input Shaft Bearing Housing A : Press fit Drawing 22 – Geartrain Housing A : Drawing 26 Drawing 25 – Output Shaft Bearing Housing Drawing 24 –...

  • Page 38: Assembly Drawings - 26, 27, 28

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings – 26, 27, 28 & 29 Drawing 26 – Geartrain Assembly Drawing 27 – Planetary Gearbox Assembly A : Drawing 28...
  • Page 39 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 29 – Input Geartrain Housing Assembly Drawing 28 – Install Geartrain & Cap A : Drawing 32...

  • Page 40: Assembly Drawings - 30, 31, 32, 33

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Assembly Drawings – 30, 31, 32, 33 & 34 Drawing 31 – Input Shaft assembly Drawing 30 –Geartrain Assembly A : Drawing 29 B : Drawing 32...
  • Page 41 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Pos. Description Qty. 18 TEETH PLANET GEAR BOTTOM BASE 10 TEETH PLANET GEAR 17 TEETH PLANET GEAR BASE 17 TEETH PLANET GEAR BASE 17 TEETH PLANET GEAR...
  • Page 42 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 8 Tank Cleaning Machine Drawing 33 –Stem Assembly Drawing 34 –Tee Housing Assembly *For Directional Machine, refer to Appendix A...

  • Page 43: Parts List

    8. Parts List and Service Kits Parts List Pos. AL No. Gamajet No. Description 9614602801 E-801 GEARBOX 9614602901 E-802 STEM COLLAR 9614603002 E-803-HV STEM 9614603101 E-804-HV TEE HOUSING 9614603201 E-805-ASD-HV DUAL NOZZLE HOUSING ASSEM. (805-HV-DN, 2 x 832-HV) 9614603301 E-805-AST-HV TRIPLE NOZZLE HOUSING ASSEM.
  • Page 44 8. Parts List and Service Kits 9614605801 E-814 BASE 9614606101 E-815 IDLER SHAFT 9614606201 E-816 IDLER GEAR 9614606401 E-817 TEE HOUSING BEVEL GEAR 9614606801 E-818-HV NOZZLE HOUSING BEVEL GEAR 9614607101 E-820 RING GEAR 9614607201 E-821 RING GEAR RETAINING RING 9614607401 E-822-A ROTOR SHAFT ASSEMBLY (822, 8-512, 841) 9614607501...
  • Page 45 8. Parts List and Service Kits 50.1 9614677901 8-541-V ROTOR SHAFT O-RING, VITON® 50.2 9614677902 8-541-EP ROTOR SHAFT O-RING, EP 50.3 9614677903 8-541-K ROTOR SHAFT O-RING, KALREZ® 9614678201 8-544 ROTOR / OUTPUT PINION LOCKWASHER 9614678301 8-545 ROTOR / OUTPUT PINION NUT E-858 PLANETARY GEARHEAD STAINLESS FLANGE 2 OR...

  • Page 46: Minor Service Kit

    8. Parts List and Service Kits 8.9 Minor Service Kit Article no: 9614612701 EHV8VITONKIT ALFA LAVAL GJ 8 KIT - VITON Pos. no. Part No. Gamajet Part No. Description 9614607501 E823 GJ VIII RS STATIC SEAL pcs. 9614607601 E824 GJ VIII OS UPPER SEAL pcs.
  • Page 47 8. Parts List and Service Kits Article no: 9614612501 EHV8TEFLONKIT ALFA LAVAL GJ 8 KIT - TEFLON Pos. no. Part No. Gamajet Part No. Description 9614607501 E823 GJ VIII RS STATIC SEAL pcs. 9614607601 E824 GJ VIII OS UPPER SEAL pcs.

  • Page 48: Major Service Kit

    8. Parts List and Service Kits 8.10 Major Service Kit Article no: 9614612801 EHV8MAJVITONKIT ALFA LAVAL GJ 8 MAJOR – KIT -VITON Pos. no. Part No. Gamajet Part No. Description 9614607501 E823 GJ VIII RS STATIC SEAL pcs. 9614607601 E824 GJ VIII OS UPPER SEAL pcs.
  • Page 49 8. Parts List and Service Kits Article no: 9614612401 EHV8MAJKALREZ ALFA LAVAL GJ 8 MAJOR KIT - KALREZ Pos. no. Part No. Gamajet Part No. Description 9614607501 E823 GJ VIII RS STATIC SEAL pcs. 9614607601 E824 GJ VIII OS UPPER SEAL pcs.

  • Page 50: Appendix A

    9. Appendix A The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine 9. Appendix A Drawing A1: Directional Nozzle Housing Removal Drawing A2: Directional Nozzle Housing Removal...
  • Page 51 9. Appendix A The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A3: Directional Nozzle Housing Removal...
  • Page 52 9. Appendix A The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A4: Directional Tee Housing Removal Drawing A5: Directional Tee Housing Dis-Assembly...
  • Page 53 9. Appendix A The drawing shows Alfa Laval GJ 8 Directional Tank Cleaning Machine Drawing A7: Directional Tee Housing Assembly Drawing A6: Directional Stem Assembly...
  • Page 54 © 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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