Instruction Manual Gunclean Toftejorg i270€¦ · Instruction Manual, Gunclean Toftejorg i270 Page 3 - 45° - 0° - 180° IM-TE91A816-EN1 Introduction This manual has been prepared

Instruction Manual

Gunclean ToftejorgTM i270 -45° - 0° - 180°

IM-TE91A816-EN1 Date of issue: March 15, 2013

First published: March 15, 2013

Instruction Manual, Gunclean Toftejorg i270 Page 1 - 45° - 0° - 180° IM-TE91A816-EN1

Contents

Contents ....................................................................................................................................................... 1 Handling of loads .......................................................................................................................................... 2 Introduction ................................................................................................................................................... 3 Intended Use ................................................................................................................................................ 3 Patents and trademarks................................................................................................................................ 4 General Description ...................................................................................................................................... 4 Technical Description ................................................................................................................................... 8

Drive Unit ................................................................................................................................................................... 8 Principal Drawing ....................................................................................................................................................... 9 Manual Override ...................................................................................................................................................... 10 Cleaner Unit Working Principle ................................................................................................................................ 10 Cleaner Unit ............................................................................................................................................................. 11

Rating plate ................................................................................................................................................. 12 Technical Data ............................................................................................................................................ 13

General Data ........................................................................................................................................................... 13 Flow rate .................................................................................................................................................................. 14 Max. throw length .................................................................................................................................................... 15 Installation Data, Standard ....................................................................................................................................... 16 Installation Data, JIS Flange Standard .................................................................................................................... 17

Installation and Normal Operation .............................................................................................................. 17 Before Installation .................................................................................................................................................... 18 Before Use ............................................................................................................................................................... 18 Programming ........................................................................................................................................................... 18 Programming Knob .................................................................................................................................................. 20 Speed Adjustment ................................................................................................................................................... 21 How to calculate cleaning time ................................................................................................................................ 22 To Remove Cover .................................................................................................................................................... 24 Cleaning ................................................................................................................................................................... 25

Maintenance and Repair ............................................................................................................................ 28 Preventive Maintenance Guidelines and Service Kits .............................................................................................. 28 Maintenance Intervals and Service Kits Selection ................................................................................................... 28 How to Fill Oil ........................................................................................................................................................... 32

Reference Lists of Parts and Drawings ...................................................................................................... 34 Drive Unit: Gear Unit ................................................................................................................................................ 34 Drive Unit: Inlet Housing Assy ................................................................................................................................. 40 Drive Unit: Lifting Rod Assy ..................................................................................................................................... 42 Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed ................................................................................................. 44 Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable ......................................................................................... 46 Cleaner Head ........................................................................................................................................................... 48

Tools ........................................................................................................................................................... 51 How to Order Spare Parts .......................................................................................................................... 52 Claim Procedure ......................................................................................................................................... 52 How to contact Alfa Laval Tank Equipment A/S ......................................................................................... 52 Service Card ............................................................................................................................................... 53 Claim Report - Working Conditions ............................................................................................................ 54

Handling of loads

Back position of the centre of gravity: L/2 H/2 D/2

Warning: Do not walk under hanging loads!


Introduction

This manual has been prepared as a guide for the persons who will be operating and maintaining your tank cleaning machine. The key to long life for your tank cleaning machine will always be a system of carefully planned maintenance; you will appreciate that a tank cleaning machine which has a rough and dirty job to do will need more frequent attention than one working in ideal conditions.

Note: Get the best and most economical performance from your tank cleaning machine. Insufficient preventive maintenance means poor performance, unscheduled stops, shorter lifetime and extra costs. Good preventive maintenance on the contrary means good performance, no unscheduled stops and superior total economy.

You will find the information contained in this manual simple to follow, but should you require further assistance, our Customer Support Department and world-wide net of Distributors will be pleased to help you. Please quote the type and serial number with all your enquiries; this will help us to help you. The type and serial number are placed on the gear house of the tank cleaning machine.

Note: The illustrations and specifications contained in this manual were effective at the date of printing. However, as continuous improvements are our policy, we reserve the right to alter or modify any unit specification on any product without prior notice or any obligation.

© 2013 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. Alfa Laval Corporate AB will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.

Intended Use

It is to be verified by the end-user: - that the tank cleaning machine is in conformity with respect to tank, vessel or container size in which it will

be used. - that the construction materials (both metallic and non-metallic) are compatibility with product, flushing

media, cleaning media, temperatures and pressure under the intended use.

Page 4 Instruction Manual, Gunclean Toftejorg i270 - 45° - 0° - 180° IM-TE91A816-EN1

Patents and trademarks

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.

© Alfa Laval Tank Equipment A/S, 2013. All rights reserved.

The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. Gunclean Toftejorg™ is trademark or registered trademark of Alfa Laval Tank Equipment A/S. Other products or company names mentioned herein may be the trademarks of their respective owners. Any rights not expressly granted herein are reserved.

General Description

Gunclean Toftejorg i270 (fixed turbine driven) tank cleaning unit consists of two main parts: the Cleaner Unit (CU) and the Drive Unit (DU). The CU is mounted in the deck, protrudes into the tank and directs the liquid jet. The DU is the drive and operation unit and is permanently mounted on the CU inlet housing. The DU gets its driving power from the turbine fitted in the inlet housing. The turbine rotates by power generated by the cleaning fluid. The Gunclean Toftejorg i270 has an inlet housing where the turbine is mounted horizontally. The rotation speed of the DU normally varies between 0.5 rpm and 3 rpm depending on the nozzle dia and line pressure at the inlet housing but some adjustments can be carried out. The basic model of the Drive Unit has four programmes to choose from, all pre-programmed to give a tighter spray pattern in the bottom of the tank. One further advantage with this Drive Unit is the possibility to program the pitch angle of the nozzle to suit the actual tank in which the machine is fitted. The elevation of the nozzle in the vertical level is indicated by the nozzle angle scale, and the direction of the nozzle in the horizontal plane is shown by the direction of the tab on top of the lifting rod. The Gunclean Toftejorg i270 Drive Unit is designed for easy operation and easy service. The cover is easily removed to get access to the moving parts of the Drive Unit for service and inspection.

Note: Service must be carried out by trained or authorised staff.

Caution: Before operation the cover must be put back.


General Description (continued)

Three main parts:

1. Programmable Drive Unit. Consisting of Gear Unit and Inlet Housing 2. Down Pipe. 3. Cleaner Unit: Consisting of Cleaner Head.

PROGRAMMABLE DRIVE UNIT

CLEANER UNIT

D102599

GEAR UNIT

INLET HOUSING

DOWN PIPE

CLEANER HEAD



The Cleaning Liquid Flow

The liquid of the jet comes from the tank cleaning supply line. Passes through the shut-off valve, proceeds into the inlet housing, past the turbine, turns downwards into the down pipe through the deck, then through the down pipe down to the vertical housing which rotates around a vertical axis. From the vertical housing the liquid turns 90° into the nozzle housing which rotates around a horizontal axis, turns 90° again, passes through the nozzle tube, the flow guide, out through the nozzle as a compact jet of liquid in order, finally, with great power, to hit the surface to be cleaned.

Cleaning Pattern with Programmed Pitch

Danger: Tank cleaning must be made according to IMO and/or owners instructions.



Cleaning Liquid Flow

D102643

Inlet Housing

Down Pipe

Vertical housing

Nozzle housing


Technical Description

Drive Unit

Drive Unit Working Principle

By using the fluid in the lines, a turbine fitted in the inlet housing drives the lower one way clutch and rocker which is transmitting power to the turning worm gear, connected to the lifting rod. The lifting rod is fitted with a long key and can slide up and down inside the turning worm gear hub. The lifting worm gear screw is connected to the turning gear worm screw by a programmable gearing. On the lifting worm screw the upper one way clutch and rocker assy is fitted. The turning worm screw has a cam. This cam lifts the upper rocker and turns the lifting worm screw an amount corresponding to the stroke the rocker is allowed to do. The stroke is regulated by the programming knob and adjusting screw. Due to the one way clutch the lifting worm screw only rotates one way. The lifting worm gear rotates a crank shaft where the crank-pin is moving inside a lifting yoke fitted to the lifting rod. The lifting yoke is journalled on the lifting rod and only transmits lifting and lowering movements to the lifting rod. The programmable gearing is used to make it possible to choose a pitch angle suitable for most jet lengths required. A pitch giving a distance of max. 0.5 m height between two jets on the surface with the longest distance from the gun can be used as a guide when choosing the pitch angle. The programmable pitch and the pre-programmed lifting pattern giving a tighter pattern at the bottom of e.g. the tanks make the Drive Unit extremely easy to use. No change of programme is required once the pitch angle is programmed. Hand-crank the nozzle to the desired starting angle shown on the nozzle angle scale, open the valve and the Drive Unit is running. One cycle from top to bottom is usually all that is needed. The rotation speed can vary between 0.5 rpm to 3 rpm depending on the nozzle dia and line pressure. Some adjustments of the rotation speed can be carried out by adjusting the turbine mounted in the inlet housing.

D102644


Technical Description (continued)

Principal Drawing



Manual Override

An extension of the lifting gear screw is accessible from the outside of the Drive Unit. By turning this shaft with a handle the nozzle can be manually cranked to the starting point or during cleaning moved forward in its programme.

Cleaner Unit Working Principle

Above deck the inlet housing is mounted onto the doubling flange welded on deck. In the inlet housing the turbine is fitted. The turbine drives the Drive Unit. The upper part of the lifting rod is radically connected to the Drive Unit, turning gear screw by a key, and axially fixed to the lifting yoke with the top screw. The Drive Unit rotates and lifts or lowers the lifting rod simultaneously. The lower part of the lifting rod is fixed to the rack. The rack transmits the turning moment to the vertical housing and the lifting moment to the horizontal housing by the gear. The vertical housing rotates 360° around the vertical axis and horizontal housing moment is around the horizontal axis from -45° - 0°-180° - 0°- -45°. The nozzle is fitted to the horizontal housing. Consequently, the lifting rod is lifting or lowering the nozzle at the same time as it is rotation around the vertical axis.



Cleaner Unit

D102645

Vertical housing Nozzle housing

Nozzle extension

Nozzle

Rack


Rating plate

The Rating plate is placed at the gear box. The Rating plate contains all identifications for the machine. The information is very useful, e.g. when ordering service or spare parts.

Gunclean Toftejorg i270 - Rating plate


Technical Data

General Data

The Gunclean Toftejorg i270 equipment is generally operated in a range of 7-12 kg/sqcm media supply. Depending on the pressure and nozzle diameter the media flow and jet will be according to the diagrams on page 14 and 15. Normal leakage approximately 2%.

Weight : Gun with 2.5 meters length of Down pipe : 110 kg Per additional meter of Down pipe : 20 kg Servicing space : Minimum 350 mm radius from centre of unit for handling and servicing. Sound pressure : The sound pressure level at workstations will not exceed 70dB(A)


Technical Data (continued)

Flow rate



Max. throw length

Note: Throw lengths are measured as max. horizontal throw length at static condition. The curve above shows our design throw length. However, the maximum throw length is approximately 30-40% longer.

In general, effective throw length varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent. The inlet pressure has been taken immediately before the machine inlet. In order to achieve the performance indicated in the curves, the pressure drop in the supply lines between pump and machine must be taken into consideration.



Installation Data, Standard

YARD SUPPLY

M20 STUD, WASHER AND NUT

ELASTOMER GASKET

DOUBLING RING TO CLASSIFICATION SOCIETIES REQUIREMENTS

D102646

INLET FLANGE ADAPTED TO ISO 7005 DN80 PN16 FLANGE STANDARD



Installation Data, JIS Flange Standard

INLET FLANGE ADAPTED TO JIS 16K-80A FLANGE STANDARD

YARD SUPPLY

M20 STUD, WASHER AND NUT

ELASTOMER GASKET

DOUBLING RING TO CLASSIFICATION SOCIETIES REQUIREMENTS

D102648


Installation and Normal Operation

Before Installation

Make sure that the pipes have been properly flushed before installation of the machine. We know from experience that welding rods, plastic bags, rags and other debris will block the turbine. This may result in damage and poor performance.

Before Use

Fill oil in Drive Unit.

Programming

The i270 Drive Unit has a four programme devise build in. Those programmes control the spacing of the helical pattern, the pitch angle. The pitch angle is the angle the nozzle rises or lowers for each revolution of the nozzle in the horizontal plane. Because of the pre-programmed, varying helical pattern, the Drive Unit automatically makes the helical pattern closer at the lower angles (0° to 30°). The steps between the programmes are fixed and not adjustable. The step between programme 1 to 2 is 1° pitch 2 to 3 is 1° pitch 3 to full is 5.5° pitch All values valid at 90° lift The basic pitch angle, the pitch angle of programme 1, can be pre-set within certain limits by turning the adjusting screw on the programming unit. Because of the fixed steps between the different programmes, adjusting programme 1 also affects the other programmes. The useful angle of programme 1 is 0° to 1.5°.


Installation and Normal Operation (continued)

To pre-set pitch angles

1. Turn programming knob to programme 1.

2. With the handle turn first worm screw until the rocker assy rests on the highest point of the cam.

3. Turn the adjusting screw to the point where the rocker starts to lift from the cam. This setting will give programme 1 a pitch angle of 0°. Turning the adjusting screw down (clockwise) 0.75 revolutions rises the pitch angle to 1°. Other settings, see table page 20.

Pitch angle/rev

D102649



Programming Knob

Turns of the adjusting screw from 0° pitch

Turns Pitch

0 0° 0.375 0.5° 0.75 1° 1.1 1.5°

Programmes with four different basic settings will give the pitch angle shown in the table below. Intermediate settings are of course also possible. Factory setting is shaded.

Degrees

Programme 1 0° 0.5° 1° 1.5°

Programme 2 1° 1.5° 2° 2.5°

Programme 3 2° 2.5° 3° 3.5°

Programme full 7.5° 8° 8.5° 9.0°

A basic 0° programme 1 (or very close) pitch angle can be useful if there is a dirty area around ullage level to be cleaned. A pitch giving a distance of 0.5 m height between two jets on the surface with the longest distance from the gun can be used as a guide when choosing the pitch angle for programme 1, 2 or 3 depending on type of cleaning used. See table below. Programme “full” can be used for flushing.

Height 0.5 m

Pitch angle 3° 1.5° 1°

Distance 10 m 20 m 30 m



Speed Adjustment

Type 1

Before the speed can be adjusted the Drive Unit and turbine must be drained from oil. Loosen the nut on the turbine shaft and adjust the turbine to desired position. Reduce measure A to reduce speed. Increase measure A to increase speed. The turbine speed depends on the liquid flow, which in turn depends on the supply pressure and nozzle dia. Type 2

Loosen the lock nut and turn on the adjusting screw. Clockwise to increase the speed. Anti-clockwise to reduce the speed. When desired speed is set, tighten up the lock nut. Standard settings:

Nozzle ø ø18 Ø19 Ø20 Ø21 Ø22 Ø23 Ø24 Ø25 Ø26 Ø27 Ø28 Ø29 Ø30

Turbine 201079 201080 201080 201080 201080 201062 201062 201062 201062 201081 201081 201081 201081

Measure A 107mm 115mm 114mm 109mm 108mm 107mm 106mm 104mm 103mm 108mm 106mm 106mm 105mm



How to calculate cleaning time

The cleaning time depends on pitch angle and rotation speed. A full cycle –45° - 0° - 180° - 0° - -45° (450°) with 1.5° pitch angle and 1 rpm takes 300 minutes. Because of varying pitch angles and small changes in rotation speed during cleaning, all figures are approximate. The RPM is preset at factory based on the specified pressure. If the actual pressure is higher than what originally has been specified, the nozzle will move faster and the total cleaning time will be reduced accordingly.

The tolerance for the RPM setting is 15 sec./rev. depending on the actual position of the gun.



Calculating formula

Pitch angle (elevation per rev) = A Rotation speed rpm = B Washing angle (angle to be washed) = C Washing time, minutes = D

Washing time, minutes = D = C

AxB

Example A: Pitch angle = 3° B: Rotation speed = 1 rpm C: Washing angle 20° - 50° = 30° D: Washing time:

C = D 30 = D = 10 min.

AxB 3x1



To Remove Cover

For programming, spot cleaning and service the cover has to be removed. 1. Loosen the two screws on top of Drive Unit.

2. Unscrew the hand crank screw on the side of the Drive Unit and remove the programming knob, fitted with a grub screw.

3. Lift the cover.

Note: The hand crank screw must be thoroughly tightened when the cover is refitted to avoid loosening when cleaning.

Warning: Service must be made by trained or authorised staff.

Caution: Before operation the cover must be put back.

Use lever to remove cover



Cleaning

1. Turn the programming knob to desired programme.

2. Crank the Drive Unit to the starting angle

Note: Open arrows for down, filled arrows for up, see fig.

3. Slowly open the valve to start cleaning

Note: After cleaning, the Drive Unit must be hand cranked to 0°, the resting position

To clean glass from oil and condensed water: See To remove cover page 24.

Screw head Indicating nozzle direction

Nozzle angle scale Indicating nozzle angle.


-45°


Figure 1 shows the actual movement of the nozzle in a double wash. 1. The Drive Unit is hand cranked to 0° up.

2. The valve is opened and the cleaning starts. The Drive Unit rotates and lifts then nozzle to 180° from where the nozzle starts to turn downwards.

3. At 0° down a double top and bottom wash is completed. The cleaning is continued and at -45° the nozzle turns upwards and at 0° up a fourfold bottom wash is completed.

4. Unless the closest pitch programme is used for the top wash, a lower programme can be used to give an even more effective bottom wash if desired.

Figure 1

180°

0°


- Blank -


Maintenance and Repair

Preventive Maintenance Guidelines and Service Kits

By using Alfa Laval Tank Equipment Preventive Maintenance Guidelines and Service Kits you are enabled to ensure the availability of your equipment at all times. You are able to plan your operating budget and your downtime. The risk of breakdowns due to component failure is virtually eliminated and in the long term your operating costs are reduced. Alfa Laval Tank Cleaning Equipment Service Kits contain All you need. They comprise genuine Alfa Laval spare parts, manufactured to the original specifications.

Maintenance Intervals and Service Kits Selection

Alfa Laval Service Kits for Tank Cleaning Machine type Gunclean Toftejorg i270 are available at two main levels for the Drive unit: Minor Service and Major Service. A single Service Kit covers the Cleaner Unit. Minor Service kit for Drive unit (above deck) is recommended to be replaced every 250 working hours or 2 ½ years, whichever comes first.

Major Service kit for Drive unit (above deck) is recommended to be replaced every 500 working hours or 5 years, whichever comes first. TE55A700 Minor Service Kit Drive Unit Contains

TE55A710 Major Service Kit Drive Unit Contains

Pos. Qty. x P/n. Description Pos. Qty. x P/n Description

011 1 x TE201047-6 Packing 027 1 x TE104192 Spring 012 1 x TE900513 O-ring 005 2 x TE201065 Washer 013 2 x TE900542-M8 Washer 017 2 x TE201074 Washer 020 1 x TE914310 O-ring 007 1 x TE201075 Turbine shaft 016 2 x TE914319 O-ring 003 1 x TE51L035 One way clutch 003 1 x TE916325 O-ring 025 2 x TE900511 One way clutch 013 1 x TE914396 O-ring 015 2 x TE900516 Rubber seal 019 1 x TE916306 O-ring 009 1 x TE900535 Bearing 002,016 4 x TE916319 O-ring 004 1 x TE900630 Radial bearing 003 1 x TE51L035 Roller Clutch 003 1 x TE900631 Radial bearing

020 1 x TE910850 Screw 021 1 x TE201071-1 Turbine bearing 008 1x TE900483 Pin 018 1x TE918226 O-ring - 1 x TE55A700 Service Kit Minor

Drive Unit


Maintenance and Repair (continued)

Service Kit for Cleaner (below deck) is recommended to be replaced every 500 working hours or 5 years, whichever comes first. TE55A730 Service Kit Cleaner Unit Contains

Qty. x P/n Description

1 x TE65S581 Bushing 2 x TE27G501 Roll for turning pin 1 x TE65S736 Bearing for rack 1 x TE27G518 Bearing vertical 1 x TE27G511 Lip seal

All Major Service kits includes the corresponding Minor Service Kits parts.

Each kit contains a maintenance guide. General recommendations

Always read the instruction and maintenance manuals before undertaking the service.

Some kit contains a small quantity of parts not need for each tank cleaning machine model. These are not included in the price and may be disregarded.

Always replace all parts included in the Service Kit.



Additional maintenance recommendations

Internal parts in the drive unit are preserved for storage up to six months from delivery. Before use:

The drive unit must be filled with oil

Grease gears

Preserve internals, parts which is not covered by oil due to condensation

See recommended oils, greases and preservers below. Every two months or before each cleaning, whichever comes first:

Loosen drain plug and check for the presence of water, drain if necessary

Check oil level

Check greasing of gears

Check preserver Replenish as necessary. Complete drainage and oil change is recommended every 18 months. A vertically mounted machine requires 3.5 litres of oil for a full oil change. If the machine is tilted, less oil is required. See page 32 and 33 for oil level. Recommended oil and grease:

Oil Grease

BP GR-XP 68 Energrease LS EP 2 Castrol Alpha SP 68 Spheerol EPL 2 Chevron Borate EP LUB 68

Synlube CLP 150 Dura-Lith Grease EP 2

ELF ELF EPONA Z 68 EPEXA Mo2 , CERAN WR 2 ESSO Spartan EP 68 Ladex 2 Famm Regal R&O 68 Code 40702 Multifak EP 2 Code 40995 Gulf Multipurpose Gear Lubricant 80 Gulfcrown Grease EP no. 2 Mobil Mobil Gear 626 Mobilux EP 2

Mobil Mobil SHC 626 Mobilith SHC 460 Nynäs GL-10 (Epona 268) FL3-62 HF/EP Shell Omala Oil 68 Rhodina 2 Tellus T68 Alvania EP 2 Texaco Meropa 68 Multifak EP 2 Total Carter EP 68 Multis EP-22 Total/Fina/Elf Epona Z 68 Ceran WR 2

Preserve Drive Unit with: TECTYL 506 or equivalent


- Blank page -



How to Fill Oil

To fill oil in Drive Unit or to clean glass, the cover has to be removed, see instructions on page 24.

Caution: Oil leak can cause slippery floor!

Caution: Before operation the cover must be put back!

Use lever to remove cover



For guns tilted more than 15° Oil shall be filled to a level above the pipe to the turbine housing to secure the lubrication of the turbine. Gears above oil level shall be greased and all other parts rust protected, see page 30.


Reference Lists of Parts and Drawings

Drive Unit: Gear Unit

Article no. TE27G307-F

Pos. Ref. No. No/Unit Description Material Notes

1 TE101174 1 Programming knob SS 5204 12 TE900513 1 O-ring Elastomer 13 TE900542-M8 2 Washer Stainless steel/elastomer 14 TE910568 2 Screw Stainless steel 15 TE900516 2 Rubber seal Rubber 16 TE104224 1 Washer Stainless steel 17 TE104330-12 1 Glass Polymer 18 TE104209 1 Gasket for glass Rubber 19 TE900518 1 Nut Brass 20 TE914310 1 O-ring Elastomer 21 TE900545 1 Drain plug Brass 28 TE51A956 1 Grub screw Stainless steel 31 TE51A575 1 Screw Stainless steel 35 TE104129 1 Cover Stainless steel

TE104331-12 1 Glass kit Pos. 17, 18 and 19


Reference Lists of Parts and Drawings (continued)



21

20

35

12

3116 15

13

14

15

13

14

19

18

17 28

1

27GXXXXXXXXX-F manual top





Pos. Ref. No. No/Unit Description Material

1 TE27G527-F 1 Worm gear lift -45° - 0° - 180° Steel 2 TE104431 1 Scale -45° - 0° - 180° Aluminium 3 TE900520 1 Screw Steel 4 TE51L152 1 Bearing Brass 5 TE104169 1 Wheel Steel 6 TE27G546 1 Worm Gear rotation Steel 7 TE27G548 1 Bracket Steel

13 TE27G536 1 Lifting yoke Steel 18 TE910412 6 Screw Stainless steel 19 TE900480 2 Washer Stainless steel 21 TE27G549 1 Carrier for drive shaft Steel 22 TE910565 1 Screw Stainless steel

TE27G306-F 1 Worm gear elevation assy -45° - 0° - 180° Pos 1,2 and 3





1

2

5 4 3

18

18

6

18

7 18

19

19

18

21

13

22

27GXXXXXXXXX-F manual gear






1 TE27G557 1 Gear frame i270 Cast steel Left side

2 TE27G306-F 1 Worm gear for elevation assy Right side

4 TE51L152 3 Bearing Brass

5 TE104169 1 Wheel Steel

6 TE27G531 1 Center shaft Steel

8 TE27G532 1 Worm upper Steel

9 TE27G533 1 Worm lower Steel

10 TE104194 1 Programme cam Brass

11 TE27G521 1 Washer for programme shaft Steel

14 TE27G522 1 Programme shaft Stainless steel

15 TE900521 1 Grub Screw Stainless steel

16 TE914003 1 Nut Stainless steel

17 TE27G523 1 Washer center shaft Steel

18 TE910108 1 Screw Steel

19 TE27G305 1 Rocker Assembly Steel

21 TE913042 1 Circlip Steel

22 TE27G529 2 Shaft end worm screw Steel

23 TE27G530 2 Distance washer worm screw Brass

24 TE104213 1 Rocker rotation Steel

25 TE900511 2 One way clutch Stainless steel

27 TE104192 1 Spring Spring steel

28 TE104215 1 Shaft Steel

29 TE900606 2 Retaining pin Steel

30 TE51A956 1 Set screw Stainless steel

31 TE914033 1 Locking nut Stainless steel

32 TE51A576 2 Screw Steel

33 TE51L035 2 Roller clutch

34 TE27G555 1 Spring spring steel

35 TE914032 2 Lock nut Stainless steel





27

4

4

15

16

1

17 18

30

10

34 14

11

3129

29

282433

35

1933

21835

23

23

25

22

22

252

64

5

9

32

3229

27G307-F manual



Drive Unit: Inlet Housing Assy


1 See table below* 1 Inlet housing

2 TE916319 2 O-ring Rubber


4 TE910394 3 Screw steel

5 TE910218 1 Screw Stainless steel

6 TE27G550 1 Key Stainless steel

7 See page 42 Lifting rod assy

8 TE208341 1 Location sleeve Stainless steel

9 See page 44 1 Turbine ASSY


11 TE201047-6 1 Gasket Sealing material


13 TE900374 1 Sealing ring Rubber

14 TE27G309-XX** 1 Down pipe Stainless steel

15 TE201078-1 1 Tube Bronze


17 TE900605 1 Hose clip Stainless steel

18 TE918332 1 Bearing Bronze

19 TE914128 6 Washer Stainless steel

The article number depends on machine configuration and material choice.

Inlet Housing* Galvanized, article no. Epoxy, article no.

DIN 2501-DN80 PN16 201014-20 201014-22 JIS 16K-80A 201014-21 201014-23 ASME B16.5, 3” Class 150 201014-24 201014-25

Down pipe** -XX = Length of down pipe

(Example: Length of down pipe = 3.5 meter: Ref. no. TE27G309-35).

See the Rating Plate for specific information regarding length of down pipe and article number for inlet housing. The Rating plate is depicted on page 12 of this instruction manual.



Drive Unit: Inlet Housing Assy



Drive Unit: Lifting Rod Assy


20 See table below 1 Lifting rod assy Stainless steel

43 TE51A518 2 Nut Stainless steel


53 TE27G551 1 Upper lifting shaft Stainless steel

54 TE51A207 1 Screw Stainless steel

The article number depends on machine configuration and material choice.

Lifting rod assy Index for TCM length

(e.g. -10 = 1 meter, -15 = 1.5 meter -10 -15 -20 -25 -30

-35 -40 -45 -50

Machine type Ref. no.

No split TE20G308-XX

1 split TEXXXXXX-XX

2 split TEXXXXXX-XX

See the Rating Plate for specific information regarding length of down pipe. The Rating plate is depicted on page 12 of this instruction manual.



Drive Unit: Lifting Rod Assy

46

43

20

43

53

54



Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed

Galvanized or Epoxy Coated

Article no. complete Turbine unit Galvanized Epoxy coated

Fixed TE201073-20 TE201129

Bill of material for complete Turbine unit, Fixed

Pos. Ref. No. No/Unit Description Material Note

1 TE201072-6 1 Turbine housing Cast iron Galvanized TE201128 1 Turbine housing Cast iron Epoxy coated

3 TE900631 1 Bearing Glycodur 4 TE900630 2 Bearing Glycodur 5 TE201065 2 Washer Steel 6 TE201058 1 Excenter Steel 7 TE201075 1 Turbine shaft Stainless steel 8 TE900483 1 Pin Stainless steel 9 TE900535 1 Bearing Glycodur

10 TE201052 1 Bearing house Steel 11 TE201076 1 Shaft Steel 12 TE201077 1 End Cover Bronze 13 TE914396 1 O-ring Rubber 14 TE900629 2 Drain plug Brass 15 TE916306 2 O-ring Rubber 16 TE914016 1 Nut Stainless steel 17 TE201074 2 Washer Polymer 18 TE918226 1 O-ring Rubber 19 TE916306 1 O-ring Rubber 20 TE910850 1 Grub screw Stainless steel 21 TE201071-1 1 Turbine bearing Stainless steel

Pos. 22 – 25, Turbine

Pos Ref. No. No/Unit Description Material

22 TE201062 1 Turbine for nozzle ø23 – ø26 Stainless steel 23 TE201079 1 Turbine for nozzle ø18 Stainless steel 24 TE201080 1 Turbine for nozzle ø19 – ø22 Stainless steel 25 TE201081 1 Turbine for nozzle ø27 – ø32 Stainless steel

Note! Only one turbine per turbine unit. Note! Pos. 22 – 25: Turbine distance settings depending of nozzle size and turbine design, see page 21.



Drive Unit: Inlet Housing, Turbine Unit Assy, Fixed


21

17

17

18

20

19

15

14

4

5

13

4

1415

12

56

8910

1

11

7

3

16

D102652



Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable


Article no. Complete Turbine unit Galvanized Epoxy coated

Adjustable TE27A320 TE27A322

Bill of material for complete Turbine unit, Adjustable

Pos. Ref. No. No/Unit Description Material Note

1 TE900631 1 Bearing Glycodur 2 TE900630 2 Bearing Glycodur 3 TE201065 1 Washer Steel 4 TE900483 1 Spring pin Stainless steel 5 TE900535 1 Slide bearing Glycodur 6 TE201076 1 Shaft Steel 7 TE914396 1 O-ring Rubber 8 TE900629 1 Drain plug Brass 9 TE914306 1 O-ring Rubber

10 TE914016 1 Nut Stainless steel 11 TE918226 1 O-ring Rubber 12 TE916306 1 O-ring Rubber 13 TE910850 1 Grub screw Stainless steel 14 TE201071-1 1 Turbine bearing Stainless steel 15 TE27A522 1 Turbine housing w. 6 holes Steel Epoxy coated

TE27A520 1 Turbine housing w. 6 holes Steel Galvanized 16 TE201092 1 Turbine shaft Stainless steel 17 TE201093 1 Lock nut Bronze 18 TE201094 1 Distance ring Steel 19 TE201089 1 Bearing housing Steel 20 TE201095 1 Excentric Steel 21 TE201088 1 End plate Bronze 22 TE201091 1 Adjusting screw Bronze 23 TE900693 1 Plug ½” Bronze 24 TE914318 1 O-ring Elastomer 25 TE201074 1 Washer Polymer 26 TE918133 1 Pin Stainless steel

Pos. 27 – 30, Turbine

Pos Ref. No. No/Unit Description Material

27 TE201062 1 Turbine for nozzle ø23 – ø26 Stainless steel 28 TE201079 1 Turbine for nozzle ø18 Stainless steel 29 TE201080 1 Turbine for nozzle ø19 – ø22 Stainless steel 30 TE201081 1 Turbine for nozzle ø27 – ø32 Stainless steel

Note! Only one turbine per turbine unit. Note! Pos. 22 – 25: Turbine distance settings depending of nozzle size and turbine design, see page 21.



Drive Unit: Inlet Housing, Turbine Unit Assy, Adjustable


14 1310

112

6

11 25

15

3

22

2 4 19 18 526 7 20

24

1721 1623

9

8

2

27A320

27 28 29 30


Reference List of Parts and Drawing (continued)

Cleaner Head

Article no. TE27G302


1 TE65S581 1 Carbon bushing Carbon 2 TE51A518 2 Locking Nut Stainless steel 3 TE65S736 1 Bearing for rack in LF. Cl.head Carbon 4 TE65S740 1 Lock ring bottom Stainless 5 TE910214 1 Screw Stainless steel 6 TE27G510 1 Vertical housing Stainless steel 7 TE27G303 1 Nozzle housing assy Stainless steel 8 TE27G517 1 Ball race for lip seal Stainless steel 9 TE27G515 1 Ball race outside vertical Stainless steel

10 TE27G508 2 Lock ring outside Stainless steel 11 TE27G507 2 Lock ring inside Stainless steel 12 TE27G502 1 Turning pin Stainless steel 13 TE27G501 2 Roll for turning pin Stainless steel 14 TE27G516 2 Lock washer Stainless steel 15 TE27G512 1 Rack Stainless steel 16 TE27G518 1 Bearing vertical upper Cl.head Polymer 17 TE27G511 1 Lip seal Polymer 18 TE27G304 2 Ball retainer w. balls Polymer 19 TE27G514 2 Ball race vertical inside Stainless steel 20 TE27G559 1 Nozzle extension for i270 Stainless steel 21 TE74A562 1 Nozzle vane assy Stainless steel 22 TE27G554-XX 1 Nozzle Stainless steel *

Note! * -XX = Nozzle size (Example: Nozzle diameter = 25 mm: Ref. no. TE27G554-25)

The article number depends on machine configuration and material choice. See the Rating Plate for specific information regarding nozzle size. The Rating plate is depicted on page 12 of this instruction manual.


Reference List of Parts and Drawing (continued)

Cleaner Head

Article no. TE27G302

23

9

11

1619

18

10

2 14 13

12 13

14 2

7 10 17 8 18 19 1 11

5

15

43

22

21

20

208524


Service Kits

TE55A700 Minor Service Kit i270 Drive Unit

Pos Part number No./kit Description

3 TE916325 1 O-ring 3 TE51L035 1 Roller Clutch

11 TE201047-6 1 Packing 12 TE900513 1 O-ring 13 TE900542-M8 2 Washer 13 TE914396 1 O-ring

2, 16 TE916319 4 O-ring 19 TE916306 1 O-ring 20 TE914310 1 O-ring

TE55A710 Major Service Kit i270 Drive Unit


3 TE51L035 1 One way Clutch 3 TE900631 1 Radial bearing 4 TE900630 1 Radial bearing 5 TE201065 2 Washer 7 TE201075 1 Turbine shaft 8 TE900483 1 Pin 9 TE900535 1 Bearing

15 TE900516 2 Rubber seal 17 TE201074 2 Washer 18 TE918226 1 O-ring 20 TE910850 1 Screw 21 TE201071-1 1 Turbine bearing 25 TE900511 2 One way Clutch 27 TE104192 1 Spring

- TE55A700 1 Service Kit Minor i270 Drive Unit

TE55A730 Service Kit i270 Cleaner Unit


9 TE65S581 1 Bushing 11 TE27G501 2 Roll for turning pin 14 TE65S736 1 Bearing for rack 18 TE27G518 1 Bearing vertical 24 TE27G511 1 Lip seal


Tools

Part No. TE55A900

For Drive Unit TE27G307

Pos. Part no. No./unit Description Notes

1 TE900080 1 Tool box 2 TE900523 1 Adjustable spanner 3 TE900524 1 Screw driver 4 TE900083 1 Hexagon bar wrench 5 TE900526 1 Hexagon bar wrench 6 TE900086 1 Hexagon bar wrench 7 TE900088 1 Hexagon bar wrench 8 TE900525 1 Retaining ring pliers 9 TE900529 1 Hand crank 10 TE900600 1 Socket 11 TE900548 1 Extension 12 TE81B160 1 Lever for i270, for Cover


How to Order Spare Parts

On all instruction drawings the individual parts have a position number, which is the same on all drawings. From the pos. no. the part is easily identified in the Reference Lists of Parts, page 34 -48. Individual parts should always be ordered from the Reference Lists of Parts, page 34 -48.. Ref. no. and Description should be clearly stated. Please also quote the type of machine and serial No. This will help us to help you. The type and serial Nos. are stamped on the Gear house of the tank cleaning machine.

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 is described as detailed as possible. For description of the working conditions, fill in copy of Claim Report - Working Conditions, which you will find at the back of this manual.

How to contact Alfa Laval Tank Equipment A/S

For further information please feel free to contact: Alfa Laval Tank Equipment A/S Baldershoej 19 P.O. Box 1149 2635 Ishoej Denmark Phone no.: +45 43 55 86 00 Fax no.: +45 43 55 86 01 www.alfalaval.com www.toftejorg.com Contact details for all countries are continually updated on our websites.


Service Card

Type of Machine :

Serial No. :

Configuration : Nozzle diameter : mm

Impeller : %

Guide : %

Date

No. of Working Hours

Maintenance Actions/ Exchanged Parts

Remarks Sign.

0 Machine put into operation

v. 94.2


Claim Report - Working Conditions

Page 1/2

Ref. Claim Case :

Machine/Cleaner Type : Serial No.:

Configuration

- Nozzles : x ø mm

- Turbine/Inlet Guide : %

Working Conditions

Inlet pressure at machine/cleaner :

Type of Valve in inlet line :

Can hydraulic shock be disregarded: : Yes No

Inlet line flushed before installation of tank cleaner? : Yes No

Working hours before failure : hours

Cleaning Programme

Cleaning media and conc. Temperature Time Recirculation?

Is sterilising being used? : Yes No

Procedure (media/temp.)? :

Is steam injection being used for heating? : Yes No

Time: __________

Temperature: __________

V. 98.1


Claim Report - Working Conditions (continued)

Page 2/2

Condition of Cleaning Media

Clean

Contaminated with (nature and description)

Chemicals/Solvents ___________________________ High viscous

Soluble Sticky/tenacious

Low viscous Solidifying

Hard particles/size _____________________________ Crystallizing

Soft particles/size ______________________________

Has filter been installed in inlet line? Yes

Mesh size: mm

No

Is tank cleaner flushed with clean water after tank cleaning? Yes No

Type of Soilage/Tank Contents to be removed

Name, formula/concentration of material to be removed from tank :

What is material soluble in :

Nature of material:

Volatile/explosive Sticky/tenacious Contains soft particles

Low viscous Solidifying Contains hard particles/fibres

High viscous Crystallizing

Is tank cleaner submerged in material? Yes No

Other information/Remarks

Date: Sign.:

Documents

Instruction Manual Gunclean Toftejorg i270€¦ · Instruction Manual, Gunclean Toftejorg i270 Page 3 - 45° - 0° - 180° IM-TE91A816-EN1 Introduction This manual has been prepared