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SST 40A Manual TOFTEJORG PDF
SST 40A Manual TOFTEJORG PDF
IM-TE91A550-EN1
October 2005
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
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
Page 1
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 and
serial 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.
Page 3
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 (10 3/4 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 cleaning
pattern 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
Page 5
Technical data
Weight of system
L = 1000 mm
L = 5000 mm
Working pressure
Working temperature
Max. temperature
Materials in media contact
Other materials
:
:
:
:
:
:
:
Principal dimensions in mm
Page 6
Flow rate
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
RPM of drive unit/
cleaner unit
1.0
1.5
2.0
2.5
3.0
60 sec.
40 sec.
30 sec.
24 sec.
20 sec.
One cycle
No. rev.
Time
10 3/4
10.7 min.
10 3/4
7.2 min.
10 3/4
5.4 min.
10 3/4
4.3 min.
10 3/4
3.6 min.
Complete pattern
No. rev.
Time
43
43 min.
43
28.7 min.
43
21.5 min.
43
17.2 min.
43
14.8 min.
Page 7
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).
Page 8
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
1
1
2
3
6
9
RPM
RPM
RPM
RPM
RPM
RPM
15 sec.
10 sec.
8 sec.
5 sec.
3 sec.
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.
9.
Page 9
Pos
006
010
025
028
029
Pos
005
009
012
016.9
016.14
021
022
Qty x P/n
1 x TE51T033
1 x TE21A367
1 x TE51C206
1 x TE73A762
1 x TE51T066
Desc.
O-ring
Worm Wheel
Circlip
Shear Pin
Lip Seal
Qty x P/n
1 x TE51T017
1 x TE51T052
1 x TE51T016
1 x TE448
1 x TE73B509
1 x TE51T018
2 x TE51T053
Desc
O-ring
Lip Seal
O-ring
Cotter Pin
Lip Seal
O-ring
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.
Pos
001
003
009
010
011
023
024
032
-
Pos.
006
016.7
016.8
-
Page 10
Qty x P/n
1 x TE73D501
1 x TE51T032
3 x TE21A585
1 x TE21A367
1 x TE829
1 x TE51L002
2 x TE51L003
1 x TE51L001
1 x TE55E700
Desc.
Airmotor
O-ring
Collar Bush
Worm Wheel
Ball bearing
Journal bearing
Journal bearing
Journal bearing
Minor Service Kit
SSt 40A Drive Unit
Qty x P/n
1 x TE51L101
2 x TE20G376
2 x TE20G574
1 x TE55E730
Desc.
Ball Bearing
Ball retainer w. balls
Ball race
Minor Service Kit Cl. Unit
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 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 this
manual.
Never assemble components without previous cleaning. This is especially important at all mating
surfaces. Work in a clear well lighted work area.
Page 11
2.
Reassembling
1.
Important: Use only an original Shear Pin from Alfa Laval Tank Equipment.
2.
Page 12
Page 13
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.
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.
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.
Page 14
Page 15
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).
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 the
Stem (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) is
used 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.
Page 16
Page 17
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.
Note: Left-hand thread
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.
Page 18
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.
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.
Page 19
Action
Drive Unit
Page 20
- Blank page
Page 21
Ref.No.
1
2
3
4
5
6
7
8
9
10
10.1
12
13
14
15
16
16.1
16.2
16.3
16.4
16.5
16.6
16.7
16.8
16.9
16.10
16.11
16.12
16.13
16.14
16.15
17
18
19
20
21
22
TE51A112
TE73A372
TE73A775
TE73A772
TE51T017
TE51L101
TE73A771
TE73A766
TE51T052
TE73A6xx *)
TE51C056
TE51T016
TE51B023
TE51A130
TE73A4xx *)
TE73A310
TE20G565
TE20G563
TE73A560
TE73A513
TE20G578
TE20G570
TE20G376
TE20G574
TE448
TE724-2-16
TE73B527
TE50B00x *)
TE73B510
TE73B509
TE73A759
TE651
TE73A758
TE156
TE73A773
TE51T018
TE51T053
No/Unit
2
1
1
1
1
1
1
1
1
1
1
1
6
6
1
1
1
1
1
1
2
1
2
2
1
1
1
2
1
1
1
3
4
4
1
1
2
Description
Remarks
Screw
Cap
Chain
Bearing Cap
O-ring
Ball bearing
Bearing housing
Gasket
Lip seal
Driver shaft, complete
Tubular rivet
O-ring
Washer
Screw
Inlet housing complete
Cleaner unit
Retainer spring
Retaining ring
Stem
Body
Liner
Stem nut w. ball race
Ball retainer w. balls
Ball race
Cutter pin
Hub nozzle part
Hub
Nozzles
Hub nut w. ball race
Lip seal
Screw
Locking wire
Screws
Spring washer
Seal insert
O-ring
Lip seal
Spare part
Spare part
Spare part
Spare part
Spare part
Wear part
Spare part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Spare part
Spare part
Wear part
Wear part
Wear part
Wear part
Spare part
Spare part
Spare part
Spare part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
Wear part
*) Customer specific
Page 22
Page 23
Page 24
Page 25
:
:
:
:
:
Air consumption
Air conditioning
Note: It is very important that the air used for the Air Motor is clean, dry and lubricated.
Oil lubricating
Oil quality
:
:
1 - 2 drops/min.
ISO VG 15-46
After use the Drive Unit should be stored in dry area to prevent corrosion.
Page 26
Page 27
Page 28
Ref.No.
TE73D501
TE51A007
TE51T032
TE118L
TE73D515
TE51T033
TE51A100
TE830
TE21A585
TE21A367
TE829
TE118
TE156
TE719A
TE814
TE817
TE828Z
TE831
TE73D516
TE73D525
TE812-13-1
TE51A112
TE51L002
TE51L003
TE51C206
TE73A380
TE73D521
TE73A762
TE51T066
TE51A118
TE73D517
TE51L001
TE51U358
TE51A061
TE51U359
TE73D550
TE51U125
TE51U349
TE73D535
TE51A109
TE51U202
TE51U124
TE51U350
TE73D514
TE51O000
TE51U230
TE51Y008
TE51Y103
TE51Y104
No/Unit
1
2
1
4
1
1
4
1
3
2
1
6
2
2
1
1
1
1
1
1
1
6
1
2
1
1
1
1
1
4
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
Description
Air motor
Pointed screw
O-ring
Screw
Cover for Gear house
O-ring
Screw
Gear frame
Collar bush
Worm wheel, complete
Ball bearing
Screw
Spring washer
Washer
Pinion
Journal
Horizontal shaft
Bearing cover
Gear house
Inlet shaft
Gear wheel machined
Screw
Journal bearing
Journal bearing
Circlip
Clutch housing
Clutch part
Shear pin
Lip seal
Screw
Outlet shaft
Journal bearing
Quick coupling female w. hose tail
Screw
Quick coupling, male
Mountings
Air unit
Fitting, revolving elbow
Hose
Screw
Needle valve
Muffler
Elbow fitting
Handle
Oil 0.2L
Plug with Valve breather cap
Hexagon nipple
Nipple socket
Hexagon nipple, conical
Material
Stainless steel
Elastomer
Stainless steel
Alu
Elastomer
Stainless steel
Bronze
Polymer
Stainless steel/polymer
Stainless steel/polymer
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Bronze
Alu
Stainless steel
Bronze
Stainless steel
Bronze
Bronze
Stainless steel
Stainless steel
Stainless steel
Stainless steel
Elastomer
Stainless steel
Stainless steel
Bronze
Brass
Stainless steel
Brass
Stainless steel
PC
Brass
Polymer
Stainless steel
Brass
Brass
Brass
Stainless steel
Shell Trivela. SD
Technopolymer
Brass
Brass
Brass
Page 29
Page 30
1.
Air pressure
2.
Motor rotating?
3.
Gear broken
4.
Page 31
Service Kits
TE55E700 Minor Service Kit SSt40A Drive Unit
Pos
Part number
6
10
25
28
29
TE51T033
TE21A367
TE51C206
TE73A762
TE51T066
No./kit
1
1
1
1
1
Desc.
O-ring
Worm Wheel
Circlip
Shear Pin
Lip Seal
Part number
1
3
9
10
11
23
24
32
-
TE73D501
TE51T032
TE21A585
TE21A367
TE829
TE51L002
TE51L003
TE51L001
TE55E700
No./kit
1
1
3
1
1
1
2
1
1
Desc.
Airmotor
O-ring
Collar Bush
Worm Wheel
Ball bearing
Journal bearing
Journal bearing
Journal bearing
Minor Service Kit SSt 40A Drive Unit
Part number
5
9
12
16.9
16.14
21
22
TE51T017
TE51T052
TE51T016
TE448
TE73B509
TE51T018
TE51T053
No./kit
1
1
1
1
1
1
2
Desc.
O-ring
Lip Seal
O-ring
Cotter Pin
Lip Seal
O-ring
Lip Seal
Part number
6
16.7
16.8
-
TE51L101
TE20G376
TE20G574
TE55E730
Page 32
No./kit
1
2
2
1
Desc.
Ball Bearing
Ball retainer with balls
Ball race
Minor Service Kit SSt 40A Cleaner Unit
Oil Specifications
Recommended Oil Quality for Gearbox
Part no.
TE51O000
Description
Shell Tivela SD
Volume
Approx. 0.2 l
Description
Airline Oil, 1 l.
Page 33
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.
Page 34
Service Card
Type of Machine
Serial No.
Configuration
Date
No. of Working
Hours
0
Nozzle diameter
mm
Impeller
Guide
Maintenance Actions/
Exchanged Parts
Remarks
Sign.
V. 94.2
Page 35
Machine/Cleaner Type
Serial No.:
Configuration
- Nozzles
- Turbine/Inlet Guide
mm
Working Conditions
Inlet pressure at machine/cleaner
Yes
No
Yes
No
hours
Cleaning Programme
Cleaning media and conc.
Temperature
Time
Procedure (media/temp.)?
Recirculation?
Yes
No
Yes
No
Time: __________
Temperature: __________
V. 98.1
Page 36
High viscous
Soluble
Sticky/tenacious
Low viscous
Solidifying
Crystallizing
Yes
Mesh size:
mm
No
Yes
No
Nature of material:
Volatile/explosive
Sticky/tenacious
Low viscous
Solidifying
High viscous
Crystallizing
Yes
No
Other information/Remarks
Date:
Sign.:
Page 37