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Summary of Contents for Alfa Laval GJ 10
- Page 1 Instruction Manual Alfa Laval GJ 10 Covering: Standard Machines First published: 2015-07 ESE032025-EN1 2015-07 Original manual...
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Page 3: Table Of Contents
..............................….. 8.1. AL GJ 10 View 8.2. Assembly Drawings – 1, 2, 3 & 4 ….. -
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 10... -
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
The Alfa Laval GJ 10 is designed for both portable and CIP (Clean in Place) applications. If the Alfa Laval GJ 10 is permanently mounted inside a tank, we strongly recommend inspecting the unit every few hundred 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 Remove any packing materials Step 3 Inspect the tank cleaning machine for visible transport damage... -
Page 9: Installation
Inlet Connections The standard inlet connection for the Alfa Laval GJ 10 is a 1-1/2” NPT female or 1-½” BSP. Others 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 PD pump with the actual operating pressure, the actual operating pressure is dictated by the fixed flow rate of the pump and the Alfa Laval GJ 10 / plumbing system. If a PD pump is used, the Alfa Laval GJ 10 should be sized to, first, match the flow capability of the pump and, second, not exceed the Alfa Laval GJ 10’s or pump's maximum operating pressure (taking the pressure rating of the plumbing system into account, also).
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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
Initial Startup Every Alfa Laval GJ 10 that ships is accompanied by a Birth Certificate. This document indicates how the machine performed in our testing tank before it shipped based on the operating conditions supplied to Alfa Laval Gamajet. To ensure the longest possible life of the machine, please verify the operating conditions and, most importantly, the machine’s cycle time. -
Page 13: Trouble Shooting
5 Operation Pay attention to possible faults Read the instructions carefully 5.2 Trouble Shooting Cracked Input Pinion (pos. 56) – Section 6.4 Inspection and Service of Components Does Rotor Damaged Planetary Gearhead (pos. 12) – Section 6.4 Inspection and Service of (pos. -
Page 14: Cleaning Solution Leakage
Insufficient Flow The Alfa Laval GJ 10 was configured to meet certain operating conditions outlined at the time of the initial sale, such as flow rate (m^3/hr)(GPM), pressure (bar)(PSI), temperature, chemical content of the wash fluid, cycle time, etc. If the Nozzle (8) size is too small and/or the opening at the bottom of the Stator (10) is too large, the Tee Housing (4) will not turn. -
Page 15: 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 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 16: 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. 5.5 Recommended Cleaning Step 1 Caustic danger! Always handle lye and acid with great care. -
Page 17: 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 8.10 Minor Service Kit & 8.11 Major Service Kit) Ordering spare parts: Contact your local Alfa Laval Sales company. -
Page 18: General Dismantling Setup
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 O-rings during prolonged contact in storage. -
Page 19: General Dismantling
Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. 6.3 General Dismantling Step 1 Inlet Collar If used, loosen the Grounding Set Screw (33) with a 5/64” Hex Key, minimum 2 turns. Remove grounding / safety wire from loop. -
Page 20: Inspection And Service Of Components
The Bottom and Top Stage Planetary Gears (61) and (60) must be reinstalled in their respective locations. The Mid-Stage Planetary Gears (62) are interchangeable, however. During reassembly, Alfa Laval Gamajet Equipment recommends the Gearhead Assembly (drawing 4) be lightly repacked using food-grade grease. Please contact Alfa Laval Gamajet Equipment for a specific grease recommendation. - Page 21 (23), therefore, it may be worthwhile to make or obtain press tools for pressing a (23) out of the (5). The press tools are available from Alfa Laval Gamajet Equipment. Before installing a new (23), clean the housing bores and remove any burrs resulting from (23) removal.
- Page 22 (21), therefore, it may be worthwhile to make or obtain press tools for pressing a (21) out of the (4). The press tools are available from Alfa Laval Gamajet Equipment. Before installing a new (21), clean the housing bores and remove any burrs resulting from (21) removal.
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Page 23: 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. Also, it may cause misalignment of parts and the potential for premature failure. - Page 24 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Drawing 21 Nozzle Housing Place the first Nozzle Housing Bearing (22) and Seal (25) (spring side out) onto the nose of the Tee Housing (4). Ensure the Bearing Locating Pin (34) is aligns with the hole in the (22).
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Page 25: Technical Data
Inform personnel about the technical data. Technical Data The Alfa Laval GJ 10 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. -
Page 26: 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 It is important to observe the technical data during installation, operation and maintenance. Inform personnel about the technical data. -
Page 27: 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 10.7... -
Page 28: Trax Simulation Tool
TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ 10 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 29: Parts List And Service Kits
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine AL GJ 10 View GJ1000... -
Page 30: Assembly Drawings - 1, 2, 3
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawings – 1, 2, 3 & 4 GJ1001 GJ1002 Drawing 1 – Input Shaft Upper Bearing Housing Drawing 2 – Input Shaft Lower Bearing Housing... -
Page 31: Assembly Drawings - 5, 6, 7, 8, 9 & 10
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawings – 5, 6, 7, 8, 9 & 10 GJ1005 GJ1006 Drawing 5 – Gearhead Drawing 6 - Gearbox A: Drawing 2 A: Drawing 5... - Page 32 8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine GJ1008 Drawing 8 – Geartrain Housing A: Drawing 1 B: Drawing 6 C: Drawing 7 D: Spring GJ1009 GJ1010 Drawing 9 – Rotor Drawing 10 - Geartrain...
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Page 33: Assembly Drawings - 11, 12, 13, 14
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawings – 11, 12, 13, 14 & 15 GJ1011 Drawing 11 – Stem A: Spring B: Press Fit GJ1012 Drawing 12 – Tee Housing... - Page 34 8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine GJ1013 Drawing 13 – Stem Base A: Press Fit GJ1015 GJ1014 Drawing 14 – Tee Housing Bevel Gear Drawing 15 – Body Assembly A: Press Fit...
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Page 35: Assembly Drawing - 16
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawing – 16 GJ1016 Drawing 16 – Install Geartrain and Cap A: Drawing 10 B: Drawing 15... -
Page 36: Assembly Drawings - 17, 18, 19
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawings – 17, 18, 19 & 20 GJ1018 GJ1017 Drawing 17 – Nozzle Housing Drawing 18 - Nozzle A: Press Fit A: Part will stick out when installed... -
Page 37: Assembly Drawing - 21
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawing – 21 GJ1021 Drawing 21 – Install Nozzle Housing A: Drawing 16 B: Drawing 19 C: Drawing 20 D: Spring... -
Page 38: Assembly Drawing - 22
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ 10 Tank Cleaning Machine Assembly Drawing – 22 GJ1022 Drawing 22 – Completed Assembly A: Drawing 21... -
Page 39: Parts List
8 Parts List and Service Kits Parts List Pos. AL No. Gamajet No. Description 9614641001 10-101 Gearbox 9614641101 10-102 9614641201 10-103 Stem 9614641401 10-104 Tee Housing 9614641701 10-105 Nozzle Housing 9614642101 10-105-TC Nozzle Housing Taper Cap 9614642201 10-106 Nose Plate Nozzle –... - Page 40 8 Parts List and Service Kits Pos. AL No. Gamajet No. Description 9614611101 E-866 Dowel Pin 9614611201 E-867 Input Shaft Seal 52.1 9614636801 7-458 Small Collar / Tee Housing Cap O-ring - EPDM 52.2 9614636802 7-458-K Small Collar / Tee Housing Cap O-ring - Kalrez Small Collar / Tee Housing Cap O-ring –...
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Page 41: Minor Service Kit
8 Parts List and Service Kits 8.10 Minor Service Kit Article no: 9614689001 10VITONKIT ALFA LAVAL GJ 10 KIT - VITON Pos. no. Part No. Gamajet Part No. Description 9614644601 10131 GJ 10 TEE HOUSING BEARING EACH 9614644901 10133 GJ 10 NOZZLE HOUSING BEARING... -
Page 42: Major Service Kit
8 Parts List and Service Kits 8.11 Major Service Kit Article no: 9614689101 10VITONMAJKIT ALFA LAVAL GJ 10 MAJOR KIT - VITON Pos. no. Part No. Gamajet Part No. Description 9614644601 10131 GJ 10 TEE HOUSING BEARING EACH 9614644901 10133... - Page 43 © 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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