Alfa Laval Gunclean Toftejorg TZ-75 Instruction Manual
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Alfa Laval Gunclean Toftejorg TZ-75 Instruction Manual

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Instruction Manual
Gunclean Toftejorg™ TZ-75 Portable
Covering ▪ Standard Machines
▪ Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
IM-TE91A251-EN3
Date of issue: January 24, 2011

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Summary of Contents for Alfa Laval Gunclean Toftejorg TZ-75

  • Page 1 Instruction Manual Gunclean Toftejorg™ TZ-75 Portable Covering ▪ Standard Machines ▪ Machines delivered with ATEX Certification in accordance with Directive 94/9/EC IM-TE91A251-EN3 Date of issue: January 24, 2011...

  • Page 3: Table Of Contents

    TE55M000 Minor Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX ..............42 TE55M010 Major Service Kit TZ-75FIX/TZ-75PT/TZ-750FIX ..............42 How to order spare parts and claim procedure ................43 How to contact Alfa Laval Tank Equipment A/S ................43 Service Card ..........................44 Claim Report Working Conditions ....................45 Declaration of Conformity ......................

  • Page 5: Introduction

    © 2011 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 Tank Equipment A/S without any warranty. Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Tank Equipment 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 A/S. 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other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer valid.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 Gunclean Toftejorg TZ-75 is a media driven and media lubricated tank cleaning machine. As it is self-lubricating, there is no lubricating substance 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

    -22, e.g. TE22B162-22. Machines with Nozzle extensions and E-gear: Same article no. with index no. -62, e.g. TE22B162-62. Gunclean Toftejorg TZ-75 machines with PEEK wear parts: TE22Bxxx-06. Available add-ons ATEX, category 1 for installation in zone 0/20...

  • Page 10: Technical Data

    Working temperature max. 95° (200° F) Ambient temperature 0 – 140°C Materials Stainless steel, polymer, carbon Principal dimensions in mm Page 8 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 11 Technical data (Continued) Flow rate Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 12 Option: The Gunclean Toftejorg TZ-75 Portable can be supplied with nozzle extensions and E- gearing for longer throw length. Curves for flow rate and throw length are currently not updated accordingly.
  • Page 13 Technical data (Continued) Cleaning Time f. complete Pattern (= 4 cycles) Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 14: Installation And Normal Operation

    For detailed instruction on pre-cleaning and application of the product carefully follow the instruction on the used locking system. Page 12 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 15 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-75 Portable Page 13 Standard machines and machines delivered with ATEX certification...

  • Page 16: Normal Operation

    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.

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

    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 12 must be observed. Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 15 Standard machines and machines delivered with ATEX certification...

  • Page 18: 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 A/S, Ishoej, Denmark.

  • Page 19: Preventive Maintenance Guidelines And Service Kits

    See page 16 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-75PT 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.
  • Page 20 For your registration of maintenance carried out, fill in service card which you will find at the back of this manual, see page 44. Page 18 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 21 - Blank page - Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 19 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 22: Top Assembly

    Rotate Nipple to align holes in Flange and Stem. Mount Screws (pos. 10) with Screwdriver (tool no. TE135A) and Key (tool no. TE135). Page 20 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 23 Maintenance and repair (continued) Top Assembly Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 21 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 24: Bottom Assembly

    Gear Subassembly or the Gear wheel. Place Bottom cover (pos. 33). Mount Spring washers (pos. 16) and Screws (pos. 17) and tighten crosswise. Page 22 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 25 Maintenance and repair (continued) Bottom Assembly Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 23 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 26: Hub Subassembly

    If blue teflonliner inside Hub is extremely worn, it can be replaced. This part requires that a precise procedure be followed to accomplish installation. It is suggested that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary. However, should the customer insist that they perform the installation, please contact your nearest Service Center for a copy of the procedure.
  • Page 27 Maintenance and repair (continued) Hub Subassembly Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 25 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 28: Stem Subassembly

    If blue liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure be followed to accomplish installation. It is suggested that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary. However, should the customer insist that they perform the installation, please contact your nearest Service Center for a copy of the procedure.
  • Page 29 Maintenance and repair (continued) Stem Subassembly Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 30: Gear Subassembly

    Hold Turbine shaft (pos. 7) against 1st stage Worm wheel and tighten Screws (pos. 17) in Horizontal shaft (pos. 29) and Pinion (pos. 11). Check rotation on Turbine shaft. Page 28 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 31 Maintenance and repair (continued) Gear Subassembly Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 29 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 32: Replacement Of Collar Bushes

    To hold Collar bushes in correct position, insert fixtures (tool no. TE81B032, see page 36) and let harden according to instructions. Page 30 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 33 Maintenance and repair (continued) Replacement of Collar Bushes Removal of old Collar bushes Mounting of new Collar bushes Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 34: Replacement Of Ball Races

    Clean surfaces and press in new Ball race. Ball race must be pressed fully home. Press parallel. Do not damage surface of Ball race. Page 32 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...
  • Page 35 Maintenance and repair (continued) Replacement of Ball races Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • 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 distributor do the replacement. Main collar Upper Place Body (pos.
  • Page 37 Maintenance and repair (continued) Replacement of Main Collars Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 35 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 38: Tools

    Tools Standard Tool kit for Gunclean Toftejorg TZ-75, Article No. TE81B065 Tool No. Description TE134 Unbraco Key for Screw TE134A Unbraco Screwdriver for Screw TE135 Unbraco Key for Screw TE135A Unbraco Screwdriver for Screw TE369 Caliper, 5mm Available on request: TE81B031 Pusher for Gear frame, 2”...
  • Page 39 Tools (continued) Sketch of tool for replacement of Main collars Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 40: Trouble Shooting Guide

    Remove foreign material/material build-up on Stem and inside Main Collars. Clean Ball Races and Ball retainer with balls. Also clean Main bush. Page 38 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 41 Hub to check that Bevel gears can work together. If damaged: Replace Stem and/or Bevel gear. Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 39 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC...

  • Page 42: Reference List Of Parts

    Nozzle extension Stainless steel Spare part Configuration as delivered marked  ) See remarks page 24 and 26. Page 40 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 43: Cross Sectional Drawing

    Cross Sectional Drawing Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 44: Service Kits

    28.2 TE127Z2 Main collar, lower 28.4 TE127-3 Collar, hub TE128Z Horizontal shaft TE55M000 Service Kit Minor, TZ-75FIX/ TZ-75PT/TZ-750FIX Page 42 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 45: How To Order Spare Parts And Claim Procedure

    Claim Procedure In case of failure that needs assistance from Alfa Laval Tank Equipment A/S, it is essential for our evaluation that the problem, as well as the working conditions of the machine are described as detailed as possible.

  • Page 46: Service Card

    Guide No. of Working Maintenance Actions/ Remarks Sign. Date Hours Exchanged Parts Machine put into operation V. 94.2 Page 44 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 47: Claim Report Working Conditions

    Is sterilising being used? Procedure (media/temp.)?   Is steam injection being used for heating? Time: __________ Temperature: __________ V. 98.1 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 45 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 48 Contains hard particles/fibres   High viscous Crystallizing   Is tank cleaner submerged in material? Other information/Remarks Date: Sign.: Page 46 Instruction Manual, Gunclean Toftejorg TZ-75 Portable Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...

  • Page 49: Declaration Of Conformity

    Declaration of Conformity Instruction Manual, Gunclean Toftejorg TZ-75 Portable Page 47 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A251-EN3...
  • Page 50 How to contact Alfa Laval Contact details for all countries are continually updated on our website. Please visit www.alfalaval.com to access the information direct.

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