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Summary of Contents for Alfa Laval GJ A2
- Page 1 Instruction Manual Alfa Laval GJ A2 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 A2 View 8.2. Assembly Drawings – 1, 2, 3, 4, 5, 6 & 7 ... -
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 Gamajet 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
Any tank-cleaning machine can develop a static electricity charge while in operation. If the tank being cleaned contains a combustible liquid or vapor having a risk of ignition or explosion, it is imperative to have the Alfa Laval Gamajet properly grounded using the provided location on the unit. Operation: Always read the technical data thoroughly. -
Page 7: Introduction
The Alfa Laval GJ A2 is a fluid-driven (turbine-driven) 360° rotary tank cleaning machine designed to clean the interior surfaces of tanks and vessels. The Alfa Laval GJ A2 is powered entirely by the cleaning solution and it requires no electricity, compressed air or lubricant for 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 A2 is a 1” or 1-1/2” tri-clamp connection. 1-1/2” butt weld, ¾” FNPT / 1- 1/4” camlock plug is available. Appropriate tri-clamp gaskets and clamps are required for the wash fluid. 2” adjustable tank connection is standard. - Page 10 The Alfa Laval GJ A2 can be used with either a centrifugal or positive displacement (constant volume), PD, style pump. In most cases, if the Alfa Laval GJ A2 is to be used with a centrifugal pump, the Alfa Laval Gamajet should be configured so that the pump will operate close to its best efficiency point.
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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
Alfa Laval Gamajet Equipment. To ensure the longest possible life of the Alfa Laval GJ A2, 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 Damaged Planetary Gearhead (drawing 8) – Section 6.4 Inspection and Service of Does Rotor (pos. 5) turn Components Damaged Input Pinion (pos. 6) – Section 6.4 Inspection and Service of Components freely by Worn/Cracked Planetary Output Bearing Housing (pos. -
Page 14: Cleaning Solution Leakage
Long Term Storage If the Alfa Laval GJ A2 has not been used for over a month, it may be reluctant to initially start because of the natural “set” that occurs with the dynamic parts. To remedy this, loosen the Collar Set Screw (60), remove the Collar (3), and lift out the Stator (4). -
Page 15: Poor Cleaning Performance
Inadequate Flow and Pressure Check the pressure at the Alfa Laval GJ A2 inlet under actual operating conditions. The supply piping and hoses must be large enough to handle the flow rate required for the nozzle size being used to ensure adequate pressure. -
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 8.9 Minor Service Kit & 8.10 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 Seals and O-rings during prolonged contact in storage. -
Page 19: General Dismantling & Installation
Holding the Geartrain (drawing 8) and the Stem (drawing 13), remove the Geartrain and Output Shaft (21) from the unit. Remove the Stem Large Gasket (33) from the assembly and set it aside. Alfa Laval Gamajet Equipment recommends replacing all Gaskets after dismantling. - Page 20 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Step 4 Nozzle Housing Remove the Snap Ring (47) if needed to remove the Nozzle Housing Bevel Gear (46). Note: There is no need to remove the (46) if it is not damaged.
- Page 21 However, it is important that all new pieces be fully pressed into and perpendicular to their mates. If you are unable to accomplish this, complete assemblies are available from Alfa Laval Tank Equipment. Inspect the (21) for signs of scoring and wear. Replace the (21) if wear or scoring has visually decreased the diameter of the (21).
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Page 22: Inspection And Service Of Components
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 to be serviced. Also, it may cause misalignment of parts and the potential for premature failure. - Page 23 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Drawings 1 - 8 Geartrain Continued Alternate Tip: An alternate procedure is to build up the geartrain outside of the Planetary Ring Gear (12). Place the Planetary Output Shaft Washer (20) onto the shaft of the Output Shaft Assembly (21;...
- Page 24 6 Maintenance Read the instructions carefully. The items refer to the parts list and service kits section. Drawing 12 Tee Housing Slide the Tee Housing Bevel Gear (45) over the end of the Stem (38; drawing 9). Align the hole in the (45) with the Dowel Pin (55) in the (38).
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Page 25: Technical Data
Inform personnel about the technical data. Technical Data The Alfa Laval GJ A2 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... -
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 19.8 13.5 18.1... -
Page 28: Trax Simulation Tool
TRAX Simulation Tool TRAX is a unique software that simulates how the Alfa Laval GJ A2 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 A2 Tank Cleaning Machine AL GJ A2 View GJA200... -
Page 30: Assembly Drawings - 1, 2, 3, 4, 5, 6
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawings – 1, 2, 3, 4, 5, 6 & 7 GJA201 GJA202 Drawing 1 – Gearhead Upper Flange Drawing 2 – Gearhead Lower Flange... - Page 31 8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine GJA205 Drawing 5 – Planet Gear A: Press Fit GJA206 Drawing 6 – Input Shaft A: Press Fit Note: The (6) must be completely perpendicular to the (9) or it will not press on correctly and damage the (6) or (9).
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Page 32: Assembly Drawing - 8
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawing – 8 GJA208 Drawing 8 – Planetary Geartrain A: Drawing 7 E: Drawing 5 B: Drawing 1 F: Drawing 3 C: Drawing 6... -
Page 33: Assembly Drawings - 9, 10, 11 & 12
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawings – 9, 10, 11 & 12 GJA210 GJA209 Drawing 9 – Stem Drawing 10 – Stem Cap A: Press Fit GJA211 Drawing 11 – Nozzle Housing... - Page 34 8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine GJA212 Drawing 12 – Nozzle Housing A: Drawing 9 B: Drawing 11 C: Large Chamfer on Flange D: Drawing 10...
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Page 35: Assembly Drawing - 13
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawing – 13 Drawing 13 – Tee Housing Cap A: Drawing 12... -
Page 36: Assembly Drawing - 14
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawing – 14 Drawing 14 – Stem and Cap A: Drawing 8 B: Drawing 13... -
Page 37: Assembly Drawing - 15
8 Parts List and Service Kits The Drawing shows Alfa Laval GJ A2 Tank Cleaning Machine Assembly Drawing – 15 Drawing 15 – Completed Assembly A: Drawing 14... -
Page 38: Parts List
8 Parts List and Service Kits Parts List Gamajet No. Description Pos. AL No. 9614620002 6-101-3A Upper Stem 9614620202 6-102-3A 9614621205 6-108-TC Collar Stator – HV 9614621301 6-109-HV Stator – MV 9614621303 6-109-MV Stator – STD 9614621304 6-109-STD Stator – LV 9614621302 6-109-LV 9614621401... - Page 39 8 Parts List and Service Kits Gamajet No. Description Pos. AL No. 9614693001 7-212-FT Output Shaft Extension 9614693101 7-217 Tee Housing Bevel Gear 9614693201 7-218 Nozzle Housing Bevel Gear 9614693301 7-219 Snap Ring 9614693701 7-233 Nozzle Housing Lower Bearing 9614693801 7-233-MD Nozzle Housing Upper Bearing 9614694001...
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Page 40: Minor Service Kit
8 Parts List and Service Kits Minor Service Kit Article no: 9614695601 7NJFTEKIT ALFA LAVAL GJ A2 KIT - EPDM Pos. no. Part No. Gamajet Part No. Description 9614623501 6127 PLANETARY GEARHEAD BUSHING 12 pcs. 9614625501 61423A PL OUTPUT SHAFT UPR BSG-3A pcs. -
Page 41: Major Service Kit
8 Parts List and Service Kits 8.10 Major Service Kit Article no: 9614695701 7NJFTEMAJKIT ALFA LAVAL GJ A2 MAJOR KIT - EPDM Pos. no. Part No. Gamajet Part No. Description 9614623501 6127 PLANETARY GEARHEAD BUSHING 12 pcs. 9614625501 61423A PL OUTPUT SHAFT UPR BSG-3A pcs. - Page 42 8 Parts List and Service Kits Article no: 9614695501 7NJFTKMAJKIT ALFA LAVAL GJ A2 MAJOR KIT - KALREZ Pos. no. Part No. Gamajet Part No. Description 9614623501 6127 PLANETARY GEARHEAD BUSHING pcs. 9614625501 61423A PL OUTPUT SHAFT UPR BSG-3A pcs.
- 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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