Alfa Laval Rodem Toftejorg TZ-66 Instruction Manual
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Alfa Laval Rodem Toftejorg TZ-66 Instruction Manual

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Instruction Manual
Toftejorg™ TZ-66
Covering ▪ Standard Machines
▪ Machines delivered with ATEX Certification in accordance with
Directive 94/9/EC
IM-TE91A300-EN9
ESE01795EN
Date of issue: January 8, 2015
First published: 1990
Original manual

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Summary of Contents for Alfa Laval Rodem Toftejorg TZ-66

  • Page 1 Instruction Manual Toftejorg™ TZ-66 Covering ▪ Standard Machines ▪ Machines delivered with ATEX Certification in accordance with Directive 94/9/EC IM-TE91A300-EN9 ESE01795EN Date of issue: January 8, 2015 First published: 1990 Original manual...

  • Page 3: Table Of Contents

    Service Kits ..........................42 General Information ........................44 How to Order Spare Parts ........................44 Service and Repair ..........................44 How to contact Alfa Laval Tank Equipment ..................... 44 EC Declaration of conformity ....................... 45 Instruction ManualToftejorg TZ-66 Page 1...

  • Page 5: Introduction

    © 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 Kolding A/S without any warranty. Improvements and changes to this Instruction Manual may at any time be made by Alfa Laval Kolding 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. 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other than Alfa Laval original spare parts are used - the EC Type Examination certification (the ATEX Directive) is no longer valid.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 Toftejorg TZ-66 is a media driven and media lubricated tank cleaning machine. As it is self lubricating, there is no lubricating substances 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

    General description (continued) Standard configurations Turbine/ Nozzles (mm) Connection Inlet Guide (3/4” thread connection) Article No. 4xø8 TE22C110 4xø9 TE22C112 Nipple: 100% 2xø11 TE22C116 2xø12 TE22C150 2” NPT, Male 4xø9 TE22C130 di: ø44mm 4xø10 TE22C132 2xø14 TE22C152 4xø8 TE22C260 100% 4xø9 TE22C262 Nipple:...

  • Page 10: Technical Data

    Technical data Weight of machine 13 kgs (28.6 lb) Working pressure 2-12 bar (30-175 psi) Recommended inlet pressure 3-8 bar (45-120 psi) Working temperature max. 95° C (200° F) Ambient temperature 0 – 140°C (95°C – 140°C when not operated) Materials Stainless steel AISI 316/316L, PTFE, Tefzel, PVDF, Carbon, PEEK...
  • Page 11 Technical data (continued) Flow rate Instruction Manual, Toftejorg TZ-66 Page 9 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...
  • Page 12 Technical data (continued) Throw length Note: Throw lengths are measured as horizontal throw length at static condition. Vertical throw length upwards is approx. 1/3 less. Effective throw length is defined as impact centre of jet 250 mm water column (50 lbs/sq.ft). Effective throw length varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent.
  • Page 13 Technical data (continued) Cleaning Time f. complete Pattern (= 8 cycles) Instruction Manual, Toftejorg TZ-66 Page 11 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...
  • Page 14 - Blank page - Page 12 Instruction ManualToftejorg TZ-66 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 15: Installation And Normal Operation

    Installation and Normal Operation General Safety and Installation Instructions The tank cleaning machine should be installed in vertical position (upright or upside down). It is recommended to install a filter in the supply line in order to avoid large particles to clog inside the machine.
  • Page 16 Installation and Normal Operation (continued) Clamp machine firmly in a vice. Protect machine with rubber pad under the machine and use rubber jaws on the vice. Mount jaws upside down to ensure firm grip on the machine. Set torque wrench at the specified tightening torque. Hold one nozzle with flat spanner to counteract while tightening the opposite nozzle with the torque wrench.

  • Page 17: Normal Operation

    Installation and Normal Operation (continued) Normal Operation Cargo and Cleaning Media: Use only cleaning fluids compatible with Stainless Steel AISI 316/316L, Carbon, PTFE, Tefzel, PVDF and PEEK. Please note that PEEK is not resistant to concentrated sulfuric acid. Normal detergents, moderate solutions of acids and alkalics will be acceptable. Aggressive chemicals, excessive concentrations of chemicals at elevated temperatures, as well as certain dissolvents and hypochlorids should be avoided.

  • Page 18: Special Conditions For Safe Use In Accordance With The Atex Certification, Directive 94/9/Ec

    Installation and Normal Operation (continued) Special Conditions for Safe Use in accordance with the ATEX Certification, Directive 94/9/EC ATEX Warning: The unit may be operated, in a hazardous area, only when filled with the process fluid. ATEX Warning: The maximum permitted process fluid temperature and ambient temperature when the machine is operating is 95°C.

  • Page 19: 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, Kolding, Denmark.

  • Page 20: Maintenance And Repair

    Maintenance and Repair Preventive Maintenance In order to keep your tank cleaning machine servicing you as an efficient tool in your tank cleaning operations, it is essential to maintain its high performance by following a simple preventive maintenance programme, which will always keep your tank cleaning machine in good condition. Good maintenance is careful and regular attention! The following recommended preventive maintenance is based on tank cleaning machines working in average conditions.
  • Page 21 Maintenance and Repair (continued) Preventive Maintenance Check Worm wheels (pos. 13 and pos. 14). If extremely worn, they should be replaced. Check Main bush (pos. 6). If worn oval to max. diameter more than 15.4 mm, it should be replaced. Assemble machines as described in the following pages.

  • Page 22: Top Assembly

    Maintenance and Repair (continued) Top Assembly Disassembly Remove Screws (pos. 10). Loosen with Key (tool No. TE135) and unscrew with Screwdriver (tool No. TE135A). Lift off Nipple (pos. 1). Remove Guide/Guide ring (pos. 2). The Guide has a groove in the outer diameter. The Guide is easily lifted out of the Stem by means of two ordinary Screwdrivers inserted into the groove.
  • Page 23 Maintenance and Repair (continued) Top Assembly Instruction Manual, Toftejorg TZ-66 Page 21 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 24: Bottom Assembly

    Maintenance and Repair (continued) Bottom Assembly Disassembly Turn machine upside down. Remove Screws (pos. 17) and Spring washer (pos. 16) from Bottom cover (pos. 33). Remove Bottom cover (pos. 33). Remove Screws (pos.17) and Spring washers (pos. 16) along the circumference of Gear frame (Pos.
  • Page 25 Maintenance and Repair (continued) Bottom Assembly Instruction Manual, Toftejorg TZ-66 Page 23 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 26: Hub Subassembly

    If blue liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure is followed to accomplish installation. It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary.
  • Page 27 Maintenance and Repair (continued) Hub Assembly Instruction Manual, Toftejorg TZ-66 Page 25 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 28: Stem Subassembly

    If blue liners on Stem are extremely worn, they can be replaced. This part requires that a precise procedure is followed to accomplish installation. It is highly recommended that an authorized Alfa Laval Tank Equipment Service Center perform the replacement when necessary.
  • Page 29 Maintenance and Repair (continued) Stem Subassembly Instruction Manual, Toftejorg TZ-66 Page 27 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 30: Gear Subassembly

    Maintenance and Repair (continued) Gear Subassembly Disassembly Hold Turbine shaft (pos. 7) against 1st stage Worm wheel (pos. 14) with one hand and loosen Screws (pos. 17) in Pinion (pos. 11) and Horizontal shaft (pos. 29) with the other hand. Draw out Turbine shaft (pos.
  • Page 31 Maintenance and Repair (continued) Gear Subassembly Instruction Manual, Toftejorg TZ-66 Page 29 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 32: Replacement Of Collar Bushes

    Maintenance and Repair (continued) Replacement of Collar Bushes Place Gear frame (pos. 31) upside down with a firm support under the flange. Use for instance jaws of a vice. Do not clamp on machined surfaces. With Pusher (tool no. TE81B031, see page 36) knock out Collar bush.
  • Page 33 Maintenance and Repair (continued) Replacement of Collar Bushes Removal of old Collar bushes Mounting of new Collar bushes Instruction Manual, Toftejorg TZ-66 Page 31 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 34: Replacement Of Ball Races

    Maintenance and Repair (continued) Replacement of Ball races In Body A. With big end downwards knock several times Body with bearings (pos. 28) hard against firm wooden support until Ball race (pos. 28.3) drops out. B. If it is not possible to knock out Ball race in this way, it is necessary first to screw out Main collar lower (pos.
  • Page 35 Maintenance and Repair (continued) Replacement of Ball races Instruction Manual, Toftejorg TZ-66 Page 33 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • 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 authorised 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, Toftejorg TZ-66 Page 35 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 38: Tools

    Tools Standard Tool kit for Toftejorg TZ-66, Article no. TE81B080 Tool No. Description TE134 Unbraco key for screw 1 pcs. TE134A Unbraco screw driver 1 pcs. TE135 Unbraco key for screw 1 pcs. TE135A Unbraco screw driver 1 pcs. Available on request: TE81B031 Pusher for 2”...
  • Page 39 Tools (continued) Sketch of tools for replacement of Main collars TE81B131: Tool for Upper collar TE81B132: Tool for Lower collar Instruction Manual, Toftejorg TZ-66 Page 37 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 40: Trouble Shooting Guide

    Trouble Shooting Guide Symptom: Slow rotation or failure of the machine to rotate Possible causes Action No or insufficient liquid f low a). Check if supply valve is fully open. b). Check if inlet pressure to machine is correct. c). Check supply line/filter restrictions/...
  • Page 41 Trouble Shooting Guide (continued) Possible causes Action e). Gearbox jammed/sluggish Remove foreign material from Gearbox. Check rotation of shafts. If restriction is recognized, disassemble Gear box (see page 28) and remove material build-up, especially on 2nd stage Worm wheel and mating Collar bushes. Hub jammed/sluggish Disassemble Hub subassembly (see page 24).

  • Page 42: Reference List Of Parts

    Reference List of Parts No./ Pos. Ref. no. Unit Description Material Remarks TE22B500 Nipple 2” BSP Stainless steel Spare part TE22B501 Nipple 2" NPT Stainless steel Spare part TE22B502 Nipple 2½” ASA-B26 Stainless steel Spare part TE603 Guide 100% Stainless steel Spare part TE103-0 Guide ring 0%...

  • Page 43: Cross Sectional Drawing

    Cross Sectional Drawing Instruction Manual, Toftejorg TZ-66 Page 41 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...

  • Page 44: Service Kits

    Service Kits Service intervals 300 hour 300 hour 300 hour Service Kit: Service Kit: Service Kit: TE55M000, TE55M000, TE55M000, TE55M001 (PEEK) TE55M001 (PEEK) TE55M001 (PEEK) TE55M400 (E-GEAR) TE55M400 (E-GEAR) TE55M400 (E-GEAR) Major Service Kit Major Service Kit Major Service Kit TE55M010 TE55M010 TE55M010...
  • Page 45 Service Kits (continued) Service Kit Major for Toftejorg TZ-66 (PEEK) Article No. TE55M011 Qty x P/n Description TE911K Turbine shaft 1 pcs. TE126-1 Ball race 4 pcs. TE624-11 Hub liner 1 pcs. TE448 Cotter pin 1 pcs. TE126S Ball retainer w balls. 2 pcs.

  • Page 46: General Information

    Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to guarantee a quick execution of your request. You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions closely.

  • Page 47: Ec Declaration Of Conformity

    EC Declaration of conformity Instruction Manual, Toftejorg TZ-66 Page 45 Standard machines and machines delivered with ATEX certification in accordance with Directive 94/9/EC IM-TE91A300-EN9...
  • Page 48 © 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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