SSt 40A Manual TOFTEJORG.pdf

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IM-TE91A550-EN1October 2005

Gunclean Toftejorg SSt40A

Instruction Manual


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Contents

Contents ....................................................................................................................1

Introduction ...............................................................................................................3

General Description...................................................................................................4

Technical data ...........................................................................................................5

Technical data ...........................................................................................................6

Installation and Normal Operation.............................................................................8

General Installation Instructions.............. ............................................................ ................ 8

Normal Operation....................................................... ....................................................... .. 8

Maintenance and Repair .........................................................................................10

Preventive Maintenance Guidelines and Service Kits....................................................... 10

Replacement of Shear Pin ................................................ ................................................ 12

Replacement of Lipseal and Ball Bearing ...................................................... ................... 14

Cleaner Unit Assembly .................................................. ................................................... 16

Replacement of Liners and Ball Races ......................................................... .................... 19

Trouble Shooting Guide...........................................................................................20

Trouble Shooting Guide...........................................................................................20

Reference List of Parts ............................................................................................22

Gunclean Toftejorg SSt40A, Parts List ................................................ ............................. 22

Cross Sectional Drawing .........................................................................................23

Portable Drive Unit...................................................................................................24

General Description ................................................ ....................................................... ... 24

Technical Data.................................................... ..................................................... ......... 25

Installation...................................... ....................................................... ............................ 27

Reference List of Parts .................................................... ................................................. 28

Cross Sectional Drawing............................................................ ....................................... 29

Maintenance and Repair.............. ....................................................... .............................. 30

Service Kits..............................................................................................................32

TE55E700 Minor Service Kit SSt40A Drive Unit .......................................................... ..... 32

TE55E710 Major Service Kit SSt40A Drive Unit .......................................................... ..... 32

TE55E730 Minor Service Kit SSt40A Cleaner Unit........................ ................................... 32

TE55E740 Major Service Kit SSt40A Cleaner Unit........................ ................................... 32

Oil Specifications .....................................................................................................33

How to order spare parts and claim procedure .......................................................34

How to contact Alfa Laval Tank Equipment A/S......................................................34

Service Card ............................................................................................................35

Claim Report - Working Conditions .........................................................................36

Instruction Manual, Gunclean Toftejorg SSt40A Page 1

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Introduction

This manual has been prepared as a guide for the persons who will be operating and maintaining your

Gunclean Toftejorg Single Stage air driven machine, SSt40A. The key to long life for your Gunclean Toftejorg

SSt40A 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.

It is in your own interest to get the best and most economical performance from your tank cleaning machine.

Neglect of maintenance means poor performance, unscheduled stoppages, shorter life and expense. Good

maintenance means good performance, no unscheduled stoppages and better total economy.

You will find the information contained in this manual simple to follow, but should you require further

assistance, our Customer Service 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, art andserial number are placed on a rating plate.

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.


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General Description

The Gunclean Toftejorg SSt40A is driven by an externally mounted portable air motor placed on the top of Inlet

Housing. The cleaning fluid enters through the connection flange, passes the inlet Pipe down to the Cleaning

Unit and out through the Nozzles. The air motor rotates the Cleaning Unit by rotating the connected shafts,

running inside the Inlet Pipe. The horizontal rotation of the Cleaning Unit is through a bevel gear transformed to

a simultaneously vertical rotation of the nozzle head.

From the deck you can control the rotation speed at bottom cleaner by means of a by-pass valve. The rotation

speed can be verified on the build-in revolution indicator.

The combined motion of the cleaner unit body and the nozzles ensures a fully indexed tank cleaning coverage.

After 11 1/4 revolutions of the Hub with nozzles (103/4 revolutions of the machine body), one coarse cleaning

pattern is laid out on the tank surface and the first cycle has been made. During the following cycles, this

pattern is repeated 3 times, each of which is displaced and the pattern gradually becomes more dense. Finally,

after 4 cycles - a total of 45 revolutions of the Hub with nozzles (43 revolutions of Body), a complete cleaningpattern has been laid out, and the first pattern is repeated.

1st cycle 2nd cycle 3rd cycle 4th cycle

The number of cycles needed to perform a proper cleaning depends on type of soilage, distance, cleaning

procedure, agent and the peripherical speed of the jet over the surface. For substances that are easily

mobilised, i.e. are easy to remove, one cycle with relatively high rotation speed could be sufficient while in

cases of more heavy soilage (high viscous, sticky substances, etc.) a more dense pattern/more cycles and

slower rotation speed will be needed. The speed of rotation is adjustable at the Drive Unit.

Page 4 Instruction Manual, Gunclean Toftejorg SSt40A

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General Description (continued)


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Technical data

Weight of system L = 1000 mm : 24 kgs (53 lb)

L = 5000 mm : 79 kgs (174 lb)

Working pressure : 2-12 bar (30-175 psi)

Working temperature : Max. 95° (200° F)

Max. temperature : 140° C (285°F)

Materials in media contact : Stainless steel, alloy, polymer

Other materials : Polymer

Principal dimensions in mm


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Technical data (continued)

Flow rate Max. horizontal throw length at static condition

Note: Throw lengths are measured as horizontal throw length at static condition.

Vertical throw length upwards are approx. 1/3 less.

The inlet pressure has been taken immediately before Cleaner Unit inlet. To achieve the performance

indicated in the curves, allowance must be made for pressure drop in the supply lines between pump

and Cleaner Unit.

Cycle time

One cycle Complete patternRPM of drive unit/

cleaner unit

Time for one

revolution No. rev. Time No. rev. Time

1.0 60 sec. 10 3/4 10.7 min. 43 43 min.

1.5 40 sec. 10 3/4 7.2 min. 43 28.7 min.

2.0 30 sec. 10 3/4 5.4 min. 43 21.5 min.

2.5 24 sec. 10 3/4 4.3 min. 43 17.2 min.

3.0 20 sec. 10 3/4 3.6 min. 43 14.8 min.


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Installation and Normal Operation

General Installation Instructions

The Gunclean Toftejorg SSt40A should be installed in vertical position. It is recommended to install a filter in

the supply line in order to avoid large particles, scale etc. to clog inside the Cleaner Unit. It is essential to avoid

fine solid particles, such as fine sand, in cleaning fluid as they will dramatically increase wear.

It is recommended that fluid inlet valve fitted is of a type that prevents hydraulic shocks, which can cause

severe damage on the whole installations.

Before connecting the Gunclean Toftejorg SSt40A, all supply lines and valves should be flushed to remove

foreign matter.

Warning: If the Gunclean Toftejorg SSt40A is used in potential explosive atmospheres, connection to deck,

it must be electrically conductive and earthed to the tank structure. This is essential to avoid the

build-up of static electricity on the Gunclean Toftejorg SSt40A.

Note: The machine shall be installed in accordance with national regulations for safety and other relevant

regulations and standards.

Precautions shall be made to prevent starting of the cleaning operation, while personnel are inside the tank or

otherwise can be hit by jets from the nozzles.

In EU-countries the complete system must fulfil the EU-machine directive and shall be CE-marked.

The Gunclean Toftejorg SSt40A as delivered has been tested at the factory before shipping. Check that the

Cleaner Unit is in operating condition by turning the Drive shaft on the top of the Inlet Housing by hand. If any

resistance is recognised, the system should be disassembled to localise the cause.

Normal Operation

Cleaning Media

Use only cleaning fluids compatible with stainless steel AISI 316L and PTFE. If you are in doubt, contact your

local Alfa Laval Tank Equipment sales office.

1. Unscrew Cap and mount drive Unit on Top Flange. Connect clutch to Drive Shaft, push over the three

Locking bolts and turn clockwise.

2. Connect air hose to the Quick Connection on top of the Drive Unit.

Note: Before the hose is connected to Drive Unit make sure that it is clean without dirt and condensed water.

Check filter and lubrication (see page 25).


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Installation and Normal Operation (continued)

Normal Operation

3. Open washing line valve. Note: Never open the washing line valve before Drive Unit is mounted.

4. Open Air Control Valve. Turn counter clockwise to open and clockwise to close.

5. Check Cleaner rotation speed through the holes in the side of the Drive Unit. The rotation speed can be

checked by measuring the time lag between the passes of edges of the squared clutch part.

6. By means of the Air Control Valve, adjust to decided rotation speed - recommended 1 to 5 RPM,

depending of distance and substance to be removed. See diagram below:

Rotation speed of cleaner unit body Time lag between edges

1 RPM 15 sec.

1½ RPM 10 sec.

2 RPM 8 sec.

3 RPM 5 sec.

6 RPM 3 sec.

9 RPM 2 sec.

7. After use flush system with fresh water. Cleaning solutions should never be allowed to dry or set-up in

Gunclean Toftejorg SSt40A due to possible "salting out" or "scaling" of the cleaning ingredient. If cleaning

media is a volatile chloride solvent, it is recommended not to flush with water after use, since this can

create hydrochloric acid.

8. Close washing line valve.

9. Remove Drive Unit from Drive Shaft Housing.

10. Mount Cap.

Disconnect air hose from Drive Unit, dry Drive Unit and store in dry area.


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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 SSt40A are available at two main levels: Minor Service

and Major Service for both Drive unit and Cleaner unit. Minor Service kit for Drive unit (above deck) isrecommended to be replaced every 250 working hours o4r 2 ½ years, whichever comes first. Minor Service kit

for Cleaner (below deck) is recommended to be replaced every 500 working hours or 5 years, whichever

comes first.

TE55E700 Minor Service Kit SSt40A

Drive Unit contains:

TE55E730 Minor Service Kit SSt40A

Cleaner Unit contains:

Pos Qty x P/n Desc. Pos Qty x P/n Desc

006 1 x TE51T033 O-ring 005 1 x TE51T017 O-ring

010 1 x TE21A367 Worm Wheel 009 1 x TE51T052 Lip Seal

025 1 x TE51C206 Circlip 012 1 x TE51T016 O-ring

028 1 x TE73A762 Shear Pin 016.9 1 x TE448 Cotter Pin

029 1 x TE51T066 Lip Seal 016.14 1 x TE73B509 Lip Seal

021 1 x TE51T018 O-ring

022 2 x TE51T053 Lip Seal

Major Service kit for Drive unit (above deck) is recommended to be replaced every 500 working hours or 5

years, whichever comes first. Major Service kit for Cleaner (below deck) is recommended to be replaced every

1000 working hours or 10 years, whichever comes first.

TE55E710 Major Service Kit SSt40A

Drive Unit contains:

TE55E740 Major Service Kit SSt40A

Cleaner Unit contains: Pos Qty x P/n Desc. Pos. Qty x P/n Desc.

001 1 x TE73D501 Airmotor 006 1 x TE51L101 Ball Bearing

003 1 x TE51T032 O-ring 016.7 2 x TE20G376 Ball retainer w. balls

009 3 x TE21A585 Collar Bush 016.8 2 x TE20G574 Ball race

010 1 x TE21A367 Worm Wheel - 1 x TE55E730 Minor Service Kit Cl. Unit

011 1 x TE829 Ball bearing

023 1 x TE51L002 Journal bearing



- 1 x TE55E700 Minor Service Kit

SSt 40A Drive Unit


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Maintenance and Repair (continued)

All Major Service kits includes the corresponding Minor Service Kits parts. Each kit contains a maintenance

guide.

The above recommended preventive maintenance is based on one machine working under average conditions.

However, a system that has a rough and dirty job to do, will need more frequent attention than one working

under ideal conditions. We trust that you will adjust your maintenance programme accordingly.

General recommendations

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

• Some kit contains a small quantity of parts not needed 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.

Addi tional main tenance recommendat ions

Good maintenance is careful and regular attention!

Always use only proper tools. Use standard tool kit. Never force, hammer or pry components

together or apart. Always perform all assembly/disassembly steps in the order described in thismanual.

Never assemble components without previous cleaning. This is especially important at all mating

surfaces. Work in a clear well lighted work area.

Disassemble machine as described on the following pages.


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Replacement of Shear Pin

Disassembly

To prevent damage or overload, a Shear Pin (Pos. 28) is mounted in the Outlet Shaft. The Shear pin will break

and must be replaced, if the Cleaning Unit is blocked.

1. Remove the Clutch housing (Pos. 26).

2. Carefully knock out the broken Shear Pin (Pos. 28).

Reassembling

1. Mount Clutch, align holes and mount new Shear Pin.

Important: Use only an original Shear Pin from Alfa Laval Tank Equipment.

2. Mount the Clutch housing.


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Replacement of Shear Pin


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Replacement of Lipseal and Ball Bearing

Disassembly

1. Unscrew the Cap (Pos. 2).

2. Carefully knock out the Tubular rivet (Pos. 10.1) and remove Clutch part (Pos. 10.2).

3. Remove the six screws (Pos. 14) and washers (Pos. 13) and lift off Bearing Cap (Pos. 4), Bearing housing

(Pos. 7) and seal insert (Pos. 15).

4. Draw out Ball Bearing (Pos. 6).

5. Check the O-ring (Pos. 5) and O-ring (Pos. 21), the Ball bearing (Pos. 6), Black Lip seal (Pos. 9), Blue Lip

seals (Pos. 22) and Gasket (Pos. 8). Replace if necessary.

6. Withdraw Gasket (Pos. 8) and the worn Black Lip seal (Pos. 9) or Blue Lip seals (Pos. 22).

Note: Lip seals are easily damaged by withdrawing. Withdraw only if they are to be replaced.

Reassembly

1. Clean all components.

2. Carefully insert new Black Lip seal (Pos. 9), Blue Lip seals (Pos. 22) and Gasket (Pos. 8).

3. Reinsert Seal insert (Pos. 20) and Bearing housing with O-ring (Pos. 21) into Top flange (Pos. 15.1) and

the Ball bearing (Pos. 6) into the Bearing housing.

4. Place O-ring (Pos. 5) and reinsert the Bearing cap (Pos. 4) in the Bearing housing (Pos. 7).

5. Remount Washers (Pos. 13) and Screws (Pos. 14) and tighten.

6. Mount Clutch part (Pos. 10.2) on top of the Drive Shaft (Pos. 10) and turn until holes are aligned. Mount

Tubular rivet (Pos. 10.1).

7. Screw on Cap (Pos. 2).


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Replacement of Lipseal and Ball Bearing


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Cleaner Unit Assembly

Disassembly

1. Unscrew Deck Cover Plate from deck and Connection Flange from washing line. Lift Gunclean Toftejorg

SSt40A out of tank.

2. Remove nozzles (Pos. 16.12). Nozzles are untightened with a wrench on the faces of the Nozzles.

3. Hold Body (Pos. 16.4) and unscrew Hub nut w. Ball Race (Pos. 16.13) with Caliper (Tool No. TE369).

Note: Left-hand thread

Withdraw Hub (Pos. 16.4) together with Ball Retainer w. Balls (Pos. 16.7) and Lipseal (Pos. 16.14).

4. Remove Locking wire (Pos. 17) and unscrew the screw (Pos. 16.15).

5. Remove Locking wire (Pos. 17), screws (Pos. 18) and Spring Washers (Pos. 19) and pull off the Cleaner

Unit Assembly.

Note: Do not pull or wring the Drive shaft (Pos. 10) as the Ball bearing and Lip seals in the Drive shaft

housing can be damaged.

6. Remove Retainer Spring (Pos. 16.1). Use a small screwdriver to lift Retainer Spring out of groove in theStem (Pos. 16.3). Lift off Retaining Ring (Pos. 6.2).

7. Hold Body (Pos. 16.4) against table and unscrew Stem nut w. Ball Race (Pos. 16.6) with Caliper (Tool No.

TE369). Withdraw Stem together with Ball Retainer w. Balls (Pos. 16.7)

8. Remove Cotter Pin (Pos. 16.9). Unscrew Hub (Pos. 16.11), freeing Hub Nut w. Ball Race (Pos. 16.13),

Ball Retainer w. Balls (Pos. 6.7) and Lip seal (Pos. 16.14).


To unscrew Hub (Pos. 16.11), Hub Nozzle Part (Pos. 16.10) is held in a vice. Caliper (Tool No. TE369) isused for the unscrewing using the two holes in the face of Hub (Pos. 16.11)

If Ball Races (Pos. 16.8) on Stem and Hub as well as Stem/Hub nut w. Ball Race (Pos. 16.2 and Pos. 16.3) are

heavily worn, they should be replaced as well as Ball Retainer w. Balls (Pos. 16.7). See page 19.

If Liner (Pos. 16.5) or Lip seal (Pos. 16.14) are worn, they can easily be replaced. Replacement of Liner. See

page 19.


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Reassembly

Before assembly make sure that all parts are clean without deposits or build-up of foreign matter.

1. Insert Stem (Pos. 16.3) together with Ball Retainer w. Balls (Pos. 16.7). Mount Stem nut w. Ball Race

(Pos. 16.6) with Caliper (Tool No. TE369) and tighten.

2. Place Retaining Ring (Pos. 16.2) over Stem (Pos. 16.3) and push on Retainer Spring (Pos. 16.1) and

"click" into groove in Stem.

3. Hold Cleaner Unit under the Flange (Pos. 15.2). Mount Drive shaft (Pos. 10) in the Body (Pos. 16.4) over

the Stud. Make sure that the slot in Clutch part on Driver shaft is mounted over the rim in the Body.

4. Fit Cleaner Unit into the Flange (Pos. 15.2), mount Spring Washers (Pos. 19) and Screws (Pos. 18) and

secure with Lockingwire (Pos. 17).

5. Secure Driver shaft in Cleaner unit: Screw in the screw (Pos. 16.5) and secure with Locking wire (Pos. 12).

6. Assemble Hub (Pos. 16.11), Ball Retainer w. Balls (Pos. 16.7), Lip seal (Pos. 16.14) and Hub Nut w. Ball

race (Pos. 16.13). Screw on Hub Nozzle Part (Pos. 16.10) and tighten with Caliper (Tool No. TE369) until

holes are aligned to pass Cotter Pin (Pos. 16.9). Insert Cotter Pin and split (preferably new Cotter Pin).

7. Mount Hub assembly into Body with Caliper (Tool No. TE369) and tighten.


Turn Hub Nozzle Part and check unrestricted rotation.

8. Screw on Nozzles (Pos. 16.12) and tighten with wrench. Secure with Loctite No. 243 or equivalent.

9. Replace Gunclean Toftejorg SSt40A in the tank and screw on Deck Cover Plate and connect washing line.


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Replacement of Liners and Ball Races

The Liner are designed as open split rings, held in position on Stem respectively by the Ball race.

When Ball race has been removed, Liner can be exchanged directly.

1. Place Stem (16.3) or Hub (16.11) in a support ring and press off Ball race (16.8). Press parallel. Use press

or vice. Be careful not to damage teeth and opposite endface of Stem.

2. Remove Liner (16.5).

3. Clean surfaces. Mount new Liner and slide on Ball race as far as possible. Make sure that Liner is kept in

correct position with collar in groove in Stem.

4. With mandrel press Ball race fully home. Press parallel. Use press or vice. Do not damage surface of Ball

race.


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Trouble Shooting Guide

Symptom: Failure of Cleaner Unit to rotate

Possible causes Action

No or insufficient liquid flow a). Check if supply valve is fully open

b). Check if the air hose is bend or blocked

c). Check if filter is blocked

d). Check if filter is blocked

e). Check if quick connection is correct mounted.

Drive Unit Without mounting Drive Unit, open air control

valve (turn clockwise) and check if the shaft-end

from drive unit is rotating steady. If not, see page30.

Foreign Material or material bui ld-up Remove drive shaft housing (see page 14) and

turn the clutch part on driver shaft by hand. If

resistance is recognised, disassemble Cleaner

Unit to localise the cause.

a). Stem or Hub jammed/sluggish Remove Stem and Hub (see page 16). Remove

foreign material/material build-up on Stem, Hub,

Liners and inside Nuts w. Ball Race. Assemble

Stem/Hub, Ball Retainer w. Balls and Stem/Hub

nut w. Ball Race and check unrestricted rotationof ball bearing. If restriction is recognised

disassemble and check for material build-up

behind liners.

b). Bevel gears jammed Remove Stem and Hub (see page 16). Clean

teeth on Stem and Hub.

c). Damaged teeth on damaged teeth on bevel

gear

Inspect teeth on Stem and Hub for deformation.

Mount Hub and Stem in Body. Hold body in

upside-down position and rotate Hub to check that

Bevel gears can work together. If damaged,

Replace Stem and/or Hub.


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Reference List o f Parts

Gunclean Toftejorg SSt40A, Parts List

Pos. Ref.No. No/Unit Description Remarks

1 TE51A112 2 Screw Spare part

2 TE73A372 1 Cap Spare part

3 TE73A775 1 Chain Spare part

4 TE73A772 1 Bearing Cap Spare part

5 TE51T017 1 O-ring Spare part

6 TE51L101 1 Ball bearing Wear part

7 TE73A771 1 Bearing housing Spare part

8 TE73A766 1 Gasket Wear part

9 TE51T052 1 Lip seal Wear part

10 TE73A6xx *) 1 Driver shaft, complete Wear part

10.1 TE51C056 1 Tubular rivet Wear part

12 TE51T016 1 O-ring Wear part

13 TE51B023 6 Washer Wear part14 TE51A130 6 Screw Wear part

15 TE73A4xx *) 1 Inlet housing complete Wear part

16 TE73A310 1 Cleaner unit Wear part

16.1 TE20G565 1 Retainer spring Wear part

16.2 TE20G563 1 Retaining ring Wear part

16.3 TE73A560 1 Stem Spare part

16.4 TE73A513 1 Body Spare part

16.5 TE20G578 2 Liner Wear part

16.6 TE20G570 1 Stem nut w. ball race Wear part

16.7 TE20G376 2 Ball retainer w. balls Wear part

16.8 TE20G574 2 Ball race Wear part

16.9 TE448 1 Cutter pin Spare part

16.10 TE724-2-16 1 Hub nozzle part Spare part

16.11 TE73B527 1 Hub Spare part16.12 TE50B00x *) 2 Nozzles Spare part

16.13 TE73B510 1 Hub nut w. ball race Wear part

16.14 TE73B509 1 Lip seal Wear part

16.15 TE73A759 1 Screw Wear part

17 TE651 3 Locking wire Wear part

18 TE73A758 4 Screws Wear part

19 TE156 4 Spring washer Wear part

20 TE73A773 1 Seal insert Wear part

21 TE51T018 1 O-ring Wear part

22 TE51T053 2 Lip seal Wear part

*) Customer specific


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Cross Sectional Drawing


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Portable Drive Unit

General Description

The drive unit consists of three main elements (page 29).

a). Air treatment equipment

b). Air motor

c). Gear system

a). Air treatment equipment includes filter/lubricator, valve for regulating revolutions and various fittings.

The filter is mounted with automatic draining system to secure an empty container at each start. The

lubricator provides sufficient lubrication of motor. It is important to adjust oil flow to recommended level as

too much oil will stop the motor and not sufficient oil cannot protect against corrosion. For oil specification,please see page 26.

b). Air motor is a compact unit mounted on gear system with two screws. The motor can be dismounted

without disassembling the gear system. Working conditions of the motor is indicated in fig. 2.

c). Gear system is built-up as a two-stage worm wheel including a gear wheel at output shaft. The gear is

filled with oil, securing long life independent of ambient temperature. Gear housing is made of anodised

aluminium, which is corrosion resistant in marine environment. Output shaft is made of stainless steel,

protecting against corrosion on gasket.


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Portable Drive Unit (continued)

Technical Data


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Technical Data

Weight of Drive Unit : 7.5 kgs (16.5 lb)

Working pressure : 5 - 8 bar (75-115 psi)

Rotation speed : Adjustable 0-9 RPM

Hose inside diameter : ø13 mm (½")

Materials : Brass, bronze, stainless steel, aluminium

Ai r consumption

Ai r condi tion ing

Note: It is very important that the air used for the Air Motor is clean, dry and lubricated.

Oil lubricating : 1 - 2 drops/min.

Oil quality : ISO VG 15-46

After use the Drive Unit should be stored in dry area to prevent corrosion.


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Installation

Connect ½" air hose and fill up oil on lubricator. Oil flow must be 1 -2 drops per min. at pressure of 7 bar. Adjust

if necessary.

A combined filter and water trap separate water and particles from the air supply and must be cleaned and

emptied regularly. The interval depends on the quality of the air.

A lubricator is incorporated to ensure satisfying lubrication of the motor. Furthermore, the oil prevents corrosion

at standstill. It is important to adjust oil flow at recommended level, as too much oil will stop the motors.

Insufficient oil flow will not protect against corrosion. It is imperative that the oil level in the lubricator is checked

before each start.

When cleaning containers to filter and lubricator, do not use any solvents as they will damage the containers.

Material of container: Polycarbonate.

Air motor will be continuously lubricated and no maintenance is required, see trouble shooting guide of air motor.


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Reference List of Parts

Ar ticle No. TE73D005

Pos. Ref.No. No/Unit Description Material

1 TE73D501 1 Air motor

2 TE51A007 2 Pointed screw Stainless steel

3 TE51T032 1 O-ring Elastomer

4 TE118L 4 Screw Stainless steel

5 TE73D515 1 Cover for Gear house Alu

6 TE51T033 1 O-ring Elastomer

7 TE51A100 4 Screw Stainless steel

8 TE830 1 Gear frame Bronze

9 TE21A585 3 Collar bush Polymer

10 TE21A367 2 Worm wheel, complete Stainless steel/polymer

11 TE829 1 Ball bearing Stainless steel/polymer12 TE118 6 Screw Stainless steel

13 TE156 2 Spring washer Stainless steel

14 TE719A 2 Washer Stainless steel

15 TE814 1 Pinion Stainless steel

16 TE817 1 Journal Stainless steel

17 TE828Z 1 Horizontal shaft Stainless steel

18 TE831 1 Bearing cover Bronze

19 TE73D516 1 Gear house Alu

20 TE73D525 1 Inlet shaft Stainless steel

21 TE812-13-1 1 Gear wheel machined Bronze


23 TE51L002 1 Journal bearing Bronze


25 TE51C206 1 Circlip Stainless steel

26 TE73A380 1 Clutch housing Stainless steel

27 TE73D521 1 Clutch part Stainless steel

28 TE73A762 1 Shear pin Stainless steel

29 TE51T066 1 Lip seal Elastomer


31 TE73D517 1 Outlet shaft Stainless steel


33 TE51U358 1 Quick coupling female w. hose tail Brass


35 TE51U359 1 Quick coupling, male Brass

37 TE73D550 1 Mountings Stainless steel

38 TE51U125 1 Air unit PC

39 TE51U349 1 Fitting, revolving elbow Brass

40 TE73D535 1 Hose Polymer


42 TE51U202 1 Needle valve Brass

43 TE51U124 1 Muffler Brass

44 TE51U350 1 Elbow fitting Brass

45 TE73D514 1 Handle Stainless steel

46 TE51O000 Oil 0.2L Shell Trivela. SD

47 TE51U230 1 Plug with Valve breather cap Technopolymer

48 TE51Y008 1 Hexagon nipple Brass

49 TE51Y103 1 Nipple socket Brass

50 TE51Y104 1 Hexagon nipple, conical Brass


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Cross Sectional Drawing

Ar ticle No. TE73D005


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Maintenance and Repair

In case of oil leakage at output shaft (Pos. 31), replace oil sealing ring (Pos. 29). Dismount clutch housing (Pos.

26), then remove shear pin (Pos. 28) by using a mandrel. Dismount the clutch (Pos. 27), oil sealing ring is

capsized by hitting the edge with a screwdriver. Then it can easily be removed and a new be mounted. Clutch,

shear pin and clutch housing are remounted and drive unit is ready for use. When replacing gasket, or in case

of leakage, check oil level and refill if necessary.

Oil in gear box must be changed once a year. The drive unit must be dismounted so that condition of bearings

and gear wheel can be checked. When separating dismount carrier handle (Pos. 46) and cover plate for gear

housing (Pos. 5), then disassemble shaft (Pos. 20) and gear frame (Pos. 8). Drain off the oil, clean gear

housing and gear frame with diesel oil and check system for wear. If necessary, replace the worn parts. Fill up

with oil in gear housing, reassemble drive unit and test it.

Oil quality, see page 33.


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Trouble Shooting Guide

If drive unit does rotate or works irregularly, check the following:

1. Air pressure Dismount hose between motor and lubricator, and

connect compressed air at clutch. Then air should pass

freely through filter and lubricator.

2. Motor rotating? When checking motor function, remove it from gear by

loosening two screws (Pos. 2) and the motor can be

dismounted. Connect air to filter and motor revolutions

can be regulated by using valve (Pos. 42).

If motor runs irregularly or has stopped, it is

necessary to disassemble and repair/clean it. In this

case please contact Alfa Laval Tank Equipment or

your local sales office as special tools are required for

that kind of repair.

If motor runs satisfactorily, check gear of shear pin.

3. Gear broken Check gear by using screwdriver to rotate inlet shaft

(Pos. 20). If it turns easily and outlet shaft is turning at

the same time, gearing 1:973, the gear is OK. On the

contrary, if shaft turns slowly, disassemble gear and

repair. Dismount carrier handle (Pos. 46), dismount

gear frame (Pos. 8) and when oil is drained, it is

possible to locate the defect and replace the worn parts.

4. Shear pin broken For repair see page 12.


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Service Kits

TE55E700 Minor Service Kit SSt40A Drive Unit

Pos Part number No./kit Desc.

6 TE51T033 1 O-ring

10 TE21A367 1 Worm Wheel

25 TE51C206 1 Circlip

28 TE73A762 1 Shear Pin

29 TE51T066 1 Lip Seal

TE55E710 Major Service Kit SSt40A Drive Unit


1 TE73D501 1 Airmotor

3 TE51T032 1 O-ring

9 TE21A585 3 Collar Bush

10 TE21A367 1 Worm Wheel

11 TE829 1 Ball bearing

23 TE51L002 1 Journal bearing



- TE55E700 1 Minor Service Kit SSt 40A Drive Unit

TE55E730 Minor Service Ki t SSt40A Cleaner Unit


5 TE51T017 1 O-ring

9 TE51T052 1 Lip Seal

12 TE51T016 1 O-ring

16.9 TE448 1 Cotter Pin

16.14 TE73B509 1 Lip Seal

21 TE51T018 1 O-ring22 TE51T053 2 Lip Seal

TE55E740 Major Service Kit SSt40A Cleaner Unit


6 TE51L101 1 Ball Bearing

16.7 TE20G376 2 Ball retainer with balls

16.8 TE20G574 2 Ball race

- TE55E730 1 Minor Service Kit SSt 40A Cleaner Unit


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Oil Specifications

Recommended Oil Quality for Gearbox

Part no. Description Volume

TE51O000 Shell Tivela SD Approx. 0.2 l

Recommended Airline Oil for Lubricator

Part no. Description

TE51O016 Airline Oil, 1 l.


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How to order spare parts and claim procedure

How to Order Spare Parts

On the Cross Sectional Drawing as well as on all instruction drawings, the individual parts have a position

number, which is the same on all drawings. From the pos. number. the part is easily identified in the Reference

Lists of Parts, page 22 and 28.

Individual parts should always be ordered from the Reference Lists of Parts, page 22 and 28. Ref. number and

Description should be clearly stated.

Please also quote the type of machine and serial number This will help us to help you. The type and serial

numbers are stamped on the body 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 are 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 01www.alfalaval.com

www.toftejorg.com

Contact details for all countries are continually updated on our websites.


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Service Card

Type of Machine :

Serial No. :

Configuration : Nozzle diameter : mm

Impeller : %

Guide : %

DateNo. of WorkingHours

Maintenance Actio ns/Exchanged Parts

Remarks Sign.

0 Machine put into operation

V. 94.2


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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


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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.:

SSt 40A Manual TOFTEJORG.pdf

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Transcript of SSt 40A Manual TOFTEJORG.pdf