Instruction Manual for Gunclean Toftejorg SSt40A

Instruction Manual
Gunclean Toftejorg SSt40A
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
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

IM-TE91A550-EN1
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.

IM-TE91A550-EN1
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

IM-TE91A550-EN1
General Description (continued)

IM-TE91A550-EN1
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
:
:
:
:
:
:
:
24 kgs (53 lb)

79 kgs (174 lb)
2-12 bar (30-175 psi)
Max. 95 (200 F)
140 C (285F)
Stainless steel, alloy, polymer
Polymer
Principal dimensions in mm
Page 6

IM-TE91A550-EN1
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
RPM of drive unit/
cleaner unit
Time for one

revolution
1.0
1.5
2.0
2.5
3.0
60 sec.
40 sec.
30 sec.
24 sec.
20 sec.

IM-TE91A550-EN1
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
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).
Page 8

IM-TE91A550-EN1
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
1
1
2
3
6
9
Time lag between edges
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.
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.

IM-TE91A550-EN1
Page 9
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) is
recommended to be replaced every 250 working hours o4r 2 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
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.
TE55E710 Major Service Kit SSt40A

Drive Unit contains:
TE55E740 Major Service Kit SSt40A

Cleaner Unit contains:
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

IM-TE91A550-EN1
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.
Additional maintenance recommendations
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 this
manual.
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.

IM-TE91A550-EN1
Page 11

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.
Page 12

IM-TE91A550-EN1

Replacement of Shear Pin

IM-TE91A550-EN1
Page 13

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).
Page 14

IM-TE91A550-EN1

Replacement of Lipseal and Ball Bearing

IM-TE91A550-EN1
Page 15

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 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

IM-TE91A550-EN1


IM-TE91A550-EN1
Page 17

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.
Page 18

IM-TE91A550-EN1

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.

IM-TE91A550-EN1
Page 19
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 page
30.
Foreign Material or material build-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 rotation
of 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.
Page 20

IM-TE91A550-EN1
- Blank page

IM-TE91A550-EN1
Page 21
Reference List of Parts

Gunclean Toftejorg SSt40A, Parts List
Pos.
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

IM-TE91A550-EN1
Cross Sectional Drawing

IM-TE91A550-EN1
Page 23
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.
Page 24

IM-TE91A550-EN1
Portable Drive Unit (continued)

Technical Data

IM-TE91A550-EN1
Page 25

Technical Data
Weight of Drive Unit
Working pressure
Rotation speed
Hose inside diameter
Materials
:
:
:
:
:
7.5 kgs (16.5 lb)

5 - 8 bar (75-115 psi)
Adjustable 0-9 RPM
13 mm (")
Brass, bronze, stainless steel, aluminium
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

IM-TE91A550-EN1

Installation
Connect " 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.

IM-TE91A550-EN1
Page 27

Reference List of Parts
Article No. TE73D005
Pos.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
37
38
39
40
41
42
43
44
45
46
47
48
49
50
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

IM-TE91A550-EN1

Cross Sectional Drawing
Article No. TE73D005

IM-TE91A550-EN1
Page 29

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.
Page 30

IM-TE91A550-EN1

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.

IM-TE91A550-EN1
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
TE55E710 Major Service Kit SSt40A Drive Unit

Pos
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
TE55E730 Minor Service Kit SSt40A Cleaner Unit

Pos
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
TE55E740 Major Service Kit SSt40A Cleaner Unit

Pos
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

IM-TE91A550-EN1
Oil Specifications
Recommended Oil Quality for Gearbox
Part no.
TE51O000
Description
Shell Tivela SD
Volume
Approx. 0.2 l
Recommended Airline Oil for Lubricator

Part no.
TE51O016
Description
Airline Oil, 1 l.

IM-TE91A550-EN1
Page 33
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 01
www.alfalaval.com
www.toftejorg.com
Contact details for all countries are continually updated on our websites.
Page 34

IM-TE91A550-EN1
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.
Machine put into operation
V. 94.2

IM-TE91A550-EN1
Page 35
Claim Report - Working Conditions

Page 1/2
Ref. Claim Case
Machine/Cleaner Type
Serial No.:
Configuration
- Nozzles
- Turbine/Inlet Guide
mm
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
Is sterilising being used?
Procedure (media/temp.)?
Is steam injection being used for heating?
Recirculation?
Yes
No
Yes
No
Time: __________
Temperature: __________
V. 98.1
Page 36

IM-TE91A550-EN1
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
Yes
Is tank cleaner flushed with clean water after tank cleaning?
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:

IM-TE91A550-EN1
Sign.:
Page 37

Instruction Manual for Gunclean Toftejorg SSt40A

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Instruction Manual for Gunclean Toftejorg SSt40A

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Instruction Manual

Gunclean Toftejorg SSt40A

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

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

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

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

Instruction Manual, Gunclean Toftejorg SSt40A

Instruction Manual, Gunclean Toftejorg SSt40A

Instruction Manual, Gunclean Toftejorg SSt40A

General Description (continued)

Instruction Manual, Gunclean Toftejorg SSt40A

24 kgs (53 lb)

Instruction Manual, Gunclean Toftejorg SSt40A

Technical data (continued)

Max. horizontal throw length at static condition

Time for one

Instruction Manual, Gunclean Toftejorg SSt40A

Installation and Normal Operation

Instruction Manual, Gunclean Toftejorg SSt40A

Installation and Normal Operation (continued)

Time lag between edges

Close washing line valve.

Remove Drive Unit from Drive Shaft Housing.

10. Mount Cap.

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair

TE55E700 Minor Service Kit SSt40A

TE55E730 Minor Service Kit SSt40A

TE55E710 Major Service Kit SSt40A

TE55E740 Major Service Kit SSt40A

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Always replace all parts included in the Service Kit.

Additional maintenance recommendations

Good maintenance is careful and regular attention!

Disassemble machine as described on the following pages.

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Remove the Clutch housing (Pos. 26).

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

Mount Clutch, align holes and mount new Shear Pin.

Mount the Clutch housing.

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Unscrew the Cap (Pos. 2).

Draw out Ball Bearing (Pos. 6).

Clean all components.

Screw on Cap (Pos. 2).

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Note: Left-hand thread

Note: Left-hand thread

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Instruction Manual, Gunclean Toftejorg SSt40A

Maintenance and Repair (continued)

Turn Hub Nozzle Part and check unrestricted rotation.

Instruction Manual, Gunclean Toftejorg SSt40A