Alfa Laval GJ 7 Instruction Manual
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Alfa Laval GJ 7 Instruction Manual

Alfa Laval GJ 7 Instruction Manual

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Instruction Manual
Alfa Laval GJ 7
Covering:
Standard Machines
First published: 2015-08
ESE032025-EN1
2015-08
Original manual

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Summary of Contents for Alfa Laval GJ 7

  • Page 1 Instruction Manual Alfa Laval GJ 7 Covering: Standard Machines First published: 2015-08 ESE032025-EN1 2015-08 Original manual...

  • Page 3: 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. Introduction ………............................3.1.

  • Page 4: Ec Declaration Of Conformity

    1. EC Declaration of Conformity 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 7...

  • 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! 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

    Alfa Laval Tank Equipment, Inc. Failure to comply with this restriction will void the warranty!! In order to handle the broadest possible range of applications, the stainless steel Alfa Laval GJ 7 is available with dual or triple nozzles, and an extensive selection of nozzle sizes, stators (non-rotating turbine) O-ring material and gear ratios.

  • Page 8: Installation

    4. Installation 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

    Inlet Connections The Alfa Laval GJ 7 is supplied with a ½” NPT/ BSP female inlet connection. It is recommended that the mating male thread should be wrapped with PTFE pipe joint tape prior to mounting. This will minimize any chance of leakage and will make subsequent removal much easier.
  • Page 10 Do not confuse the maximum operating pressure of a 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 7 and the plumbing system. If a PD pump is used, the Alfa Laval GJ 7 should be sized to, first, match the flow capability of the pump and, second, not exceed the pump's maximum operating pressure (taking the plumbing system into account, also).

  • Page 11: Recycling Information

    - At end of use, the equipment must be recycled according to relevant, local regulations. Beside the equipment itself, any hazardous residues from the process liquid must be considered and dealt with in a proper manner. When in doubt, or in the absence of local regulations, please contact your local Alfa Laval sales company.

  • Page 12: Operation

    When using a pressure washer to feed the unit, Alfa Laval Tank Equipment Inc. strongly recommends running the pressure washer at the beginning of each use, without the Alfa Laval GJ 7 attached, for a period of time of about one minute. Alfa Laval Tank Equipment has noted, through our testing with pressure washers, a high level of dirt in the initial wash fluid.

  • Page 13: Trouble Shooting

    5. Operation Pay attention to possible faults Read the instructions carefully. Trouble Shooting - Cracked Input Pinion (pos. 51) - Section 6.4 Inspection and Service of Components Does Rotor (pos. - Damaged planetary gearhead (pos. 26) - Section 6.4 Inspection and Service of 10) turn freely by Components hand?
  • Page 14 TIGHT CLEARANCES A newly overhauled Alfa Laval GJ 7 may fail to operate when first returned to service. If the machine seems otherwise fine, try running it with at least one Nozzle 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 or Improperly Installed Seals Excessive leakage from the Tee Housing or Nozzle Housing usually indicates worn Housing Bearings and Seals (61), (59) and (36). Inspect them for wear (sealing lips are worn to a smooth surface) or damaged lips or loss of spring tension (indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring), and replace as required.

  • 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 8.8 Minor Service Kit & 8.9 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...

  • 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 Inlet Collar Set Screw (38) with the 5/64” (2 mm) Hex Key, minimum 2 turns. Remove the Inlet Collar (1) and Stator (9).

  • Page 21: Inspection And Service Of Components

    Also, examine the main internal ring gear for bent or sharp teeth. If any damage is found contact Alfa Laval Tank Equipment Inc. immediately. Please note, the gears, at the mid and lower level are interchangeable.
  • Page 22 (34), therefore, it may be worthwhile to make or obtain press tools for pressing (34) out of (5). The press tools are available from Alfa Laval Tank Equipment Inc. Before installing new (34), clean the housing bores and remove any burrs resulting from...
  • Page 23 (32), therefore, it may be worthwhile to make or obtain press tools for pressing (32) out of (4). The press tools are available from Alfa Laval Tank Equipment Inc. Before installing new (32), clean the housing bores and remove any burrs resulting from (32) 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. Unless otherwise stated, apply a dab of a Teflon-based anti-seize compound to all threads when reassembling; this will prevent galling of threads and ease any future disassembly.
  • Page 25 Turn to (drawing 7): Place the Output Shaft (12) over the output shaft of the (26). Align the flat with the Output Shaft Set Screw (39). Alfa Laval Tank Equipment Inc. recommends using a new (39) during reassembly. Using a 0.050” (1.27 mm) Hex Key, screw into the (12).

  • 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 7 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 0.100 Noz.

  • 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 Dimensions...

  • Page 29: Trax Simulation Tool

    TRAX simulation tool TRAX is an unique software that simulates how the Alfa Laval GJ 7 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 7 Tank Cleaning Machine AL GJ 7 View GJ0700...

  • Page 31: Assembly Drawings - 1, 2, 3

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Assembly Drawings – 1, 2, 3 & 4 Drawing 1: Rotor Shaft Bearing Housing Assembly Drawing 2: Output Shaft Seal Housing Assembly...
  • Page 32 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 3: Gearhead Installation Drawing 4: Rotor Shaft Lower Bearing Housing (For Low Pressure Applications, refer to Appendix A)

  • Page 33: Assembly Drawings - 5, 6

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Assembly Drawings – 5, 6 & 7 Drawing 5: Rotor Shaft Assembly Drawing 6: Rotor Assembly...
  • Page 34 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 7: Gear Train Assembly (For Low Pressure Applications, refer to Appendix A) A: Drawing 6 D: Drawing 5 B: Drawing 1 E: Drawing 3...

  • Page 35: Assembly Drawings - 8, 9, 10

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Assembly Drawings – 8, 9, 10 & 11 Drawing 8: Stem Assembly...
  • Page 36 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 9: Tee Housing Assembly Drawing 10: Idler Shaft Base Assembly...
  • Page 37 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 11: Body Assembly A: Drawing 8 B: Drawing 9 C: Drawing 10...

  • Page 38: Assembly Drawings - 12, 13

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Assembly Drawings – 12, 13 & 14 Drawing 12: Idler Gear Assembly Drawing 13: Idler Shaft Base Assembly...
  • Page 39 8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Drawing 14: Installing Gear Train into Body A: Drawing 7 C: Drawing 12 B: Drawing 11 D: Drawing 13...

  • Page 40: Assembly Drawings - 15

    8. Parts List and Service Kits The drawing shows Alfa Laval GJ 7 Tank Cleaning Machine Assembly Drawings – 15 & 16 Drawing 15: Nozzle Housing Assembly (For Low Pressure Applications, refer to Appendix A) Drawing 16: Completing the Assembly...

  • Page 41: Parts List

    8. Parts List and Service Kits Parts List Pos. AL No. Gamajet No. Description 9614680301 7-701-S INLET COLLAR 9614680401 7-702-S STEM CAP STEM GUIDE – OPTIONAL, FOR LP ONLY 9614680501 7-703-E 9614680601 7-703-L STEM 9614680701 7-704 TEE HOUSING 9614681101 7-705-DT DUAL NOZZLE HOUSING DUAL NOZZLE HOUSING –...
  • Page 42 8. Parts List and Service Kits 9614683101 7-722 INPUT SHAFT 9614683501 7-723-S INPUT SHAFT SEAL 9614683601 7-724-S OUTPUT SHAFT UPPER SEAL 9614683701 7-725 OUTPUT SHAFT LOWER SEAL 9614683801 7-726 GEARHEAD 9614684001 7-727-T ROTOR SHAFT LOWER BEARING w/ BEARING 9614684101 7-728-E BASE 9614684201 7-729...
  • Page 43 8. Parts List and Service Kits NOZZLE O-RING – EPDM - FOR LP ONLY 52.1 9614687101 7-757-E 2 or 3 NOZZLE O-RING – VITON - FOR LP ONLY 52.2 9614687102 7-757-V 2 or 3 9614687201 7-758 GEARHEAD PIN ROTOR SHAFT HOUSING O-RING – EPDM 9614687501 7-763-E 9614687601...

  • Page 44: Minor Service Kit

    8. Parts List and Service Kits 8.8 Minor Service Kit Article no: 9614688001 7ZE ALFA LAVAL GJ 7 KIT - EPDM Pos. no. Part No. Gamajet Part No. Description 7723S GJ VII INPUT SHAFT SEAL pcs. 9614683501 7724S GJ VII OUTPUT SHAFT SEAL pcs.

  • Page 45: Major Service Kit

    8. Parts List and Service Kits 8.9 Major Service Kit Article no: 9614688101 7ZEMAJKIT ALFA LAVAL GJ 7 MAJOR KIT - EPDM Pos. no. Part No. Gamajet Part No. Description 7723S GJ VII INPUT SHAFT SEAL pcs. 9614683501 7724S GJ VII OUTPUT SHAFT SEAL pcs.

  • Page 46: Appendix A

    8. Parts List and Service Kits Appendix A AL GJ 7 (For Low Pressure Applications)
  • Page 47 8. Parts List and Service Kits Drawing 4A: Rotor Shaft Lower Bearing Housing Drawing 7A: Gear Train Assembly A: Drawing 6 D: Drawing 5 B: Drawing 1 E: Drawing 3 C: Drawing 4A F: Drawing 2...
  • Page 48 8. Parts List and Service Kits Drawing 15A: Nozzle Housing Assembly Drawing 16A: Completing the Assembly A: Drawing 15A B: Drawing 14...
  • Page 49 © 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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