service manual - JA WATERTECHNIC A/S
Contents
1. FA TCM M20 C I P 1 JA ENGINEERING A S 11 13 15 TABLE OF CONTENTS TABLE OF CONTENTS SERVICE MANUAL SPARES TOOLS SERVICE PART LIST INLET ASSEMBLY WITH 2103S INLET ASSEMBLY WITH 2103R BOTTOM COVER AND PRIMARY SHAFT ASSEMBLY INTERNAL GEARFRAME GEARFRAME ASSEMBLY HUB ASSEMBLY STEM AND CLUTCH ASSEMBLY SERVICE MANUAL T C M TANK CLEANING MACHINES When delivered the Tank Cleaning Machine is ready for immediate use Care should be taken during use Before connecting flush all liquid lines and valves to purge the system of foreign matter which could cause blockage of liquid flow It may be advisable to provide a filter MESH 0 1 0 2mm prior to the machine or suction side of the supply pump f the system is prone to such occurrences IMPORTANT When connecting top cone thread to supply pipe use OMNIFIT 100M one part water proof glue or a similar product to secure the TC Machine from unintentional loosening from supplypipe All piping or hose must a minimum of 1 1 2 38mm 1 0 to insure adequate volume and pressure are available at the machine Operating pressure can vary between 3 5 and 10 bar 50 to 150 p s 1 depending on the nozzle configuration to attain desired thru put radius of cleaning and cycle time Please refer to the Capacities Chart in this manual when order2. 1 Valve for 2133C Bottom Cover Portable Model Hexhead Screw 3 16 x 1 2 SS Material SS Stainless Steel TC Teflon Compound T Teflon C Carbon ASSEMBLY PICTURES AND DESCRIPTIONS INLET ASSEMBLY WITH 21035 DISASSEMBLY 1 Remove six screws 2 5 from INLET NIPPLE 2 2 Lift off INLET NIPPLE 3 Remove GUIDE 3 4 After inserting a screwdriver through the vanes of the IMPELLER 5 to prevent rotation Using HEXKEY REMOVE SCREW 18S and WASHER 19 from PRIMARY SHAFT 11 5 Remove IMPELLER 5 ASSEMBLY INREVERSE ORDER NOTE Please never use exessive force or heavy blows to remove or assemble parts Many parts are designed with close tolerances and damaged parts as well as worn parts may cause the unit to be inoperable IMPORTANT When reassembling secure the six screws 2FS with OMNIFIT 100M one part waterproof glue or a similar product INLET ASSEMBLY WITH 2103R DISASSEMBLY Ze 3 4 5 Remove six screws 2FS from INLET NIPPLE 2 Lift off INLET NIPPLE Remove GUIDE RING 3R After inserting a screwdriver through the vanes of the IMPELLER 5 to prevent rotation Using HEXKEY REMOVE SCREW 18S and WASHER 19 from PRIMARY SHAFT 11 Remove IMPELLER 5 ASSEMBLY INREVERSE ORDER NOTE Please never use exessive force or heavy blows to remove or assemble parts Many parts are designed with close tolerances and damaged parts as well as worn parts may
3. This can be done by placing and firmly holding the PRIMARY SHAFT 11 horizontally onto and engaging the PRIMARY WORMGEAR thus preventing rotation of the WORMGEAR and SECONDARY HORIZONTAL SHAFT 28S Proceed to loosen all screws 1 the assembly Thereafter disengage the PRIMARY SHAFT and all parts can easily be disassembled 1 PINION GEAR 14 SECONDARY WORMGEAR 16S and PINION SLEEVE 17 can be withdrawn after removing the SCREW amp WASHER 18S amp 19 2 SECONDARY HORIZONTAL SHAFT 28S and PRIMARY WORMGEAR 16S can be withdrawn after removing the SCREW amp WASHER 18S amp 19 3 Release SHAFTBEARING 29C by removing four SCREWS 185 from BEARING SUPPORT COVER 31 ASSEMBLY Inspect and reassemble in reverse order after replacing parts as necessary If WORMGEAR 16P or 16S 1s extreemly worn replace the WORMGEAR COLLARBUSH 15 If I D is 13 4 mm or more and or worn oval it must be replaced as follows Press out the COLLAR BUSH with a wooden dowel support below the gearframe when squeezing out the collar bush Remove residue from glue and clean the bore gearframe Put on OMNIFIT 230L or similar on the new collar bush and squeeze it into place Check BEARING 29C If bore 1 1 15 10 4 mm or more and or worn oval replace bearing Also check axial surface of the bearing f worn 0 5 mm deep or more replace bearing Inspect HORIZONTAL SHAFT 28S and PINION GEAR 14 1f worn in gear and bearing
4. if at least a half service is still available for a particular part This will reduce maintenance cost by unnecessary and premature replacement of useable parts For in plant maintenance as described we recommend Minimum Item No Part No Description 1 9 2109 Primary Shaft Bushing 1 1 2111P Primary Shaft 1 16P 2116PTZ Wormgear Primary 1 165 211658 Wormgear Secondary 1 26BR 2126BR Thrust Balls amp Retainer 2 26R 2126R Thrust Race 1 285 21285 Secondary Shaft Horizontal 2 29C 2129C Shaftbearing 4 18S 21185 Socket Screw 3 16 1 2 Stainless 4 33H 2133H Hexhead Screw 3 16 x 1 2 Stainless Please Never substitute steel screws for stainless steel as supplied with the machine Corrosive and aggressive products may cause rapid deterioration and make repair difficult and costly Note Periodically a factory service check 1s recommended Not later than 500 hours TOOLS Hexagonal screw driver SW4 or 5 32 Open Ended or Socket Wrench SW8 or 5 16 Hexagonal Key 2mm for HUB set screw Pin Spanner 21m Capacity x 3 16 pins Screwdriver SERVICE Whenever the machine ceases functioning and prior to a general overhaul or returning to the factory for service please make sure there are no obstructions or blockage from debris preventing flow of cleaning fluid Disconnect the machine and unscrew the NOZZLES to remove any debris Also remove the INLET NIPPLE and GUIDE so that the IMPELLER can be rotated and any obstructions remove
5. or a similar product NOTE BODY 27 BUSHING 27U 27L and 27H are factory service 15 7542 5 E 16
6. surface replace the worn parts including PINION SLEEVE 17 11 HUB ASSEMBLY DISASSEMBLY l Remove NOZZLE 23 2 Remove six SCREWS 33H in HUB COVER 21 3 Withdraw HUB ASSEMBLY HUB 24 HUB COVER 21 GASKET 216 THRUST BALLS 26BR BEVELGEAR 22 and HUB CONNECTOR 24 4 Remove SET SCREW 24S from HUB This will allow the HUB to be unscrewed from the HUB CONNECTOR Two holes are provided in the HUB CONNECTOR for the use of a pin spanner Holding the HUB in a vise with jaw protectors to prevent damage to polished parts and rotating the HUB CONNECTOR counter clockwise with the pin spanner the balance of this assembly can be taken adrift 5 Inspect the two RACES 26R and BALL RETAINER 26BR in particular If the RACES are severely grooved and the assembly does not rotate smoothly they may require replacement First try replacing the BALL RETAINER and check again If still no improvement then replace both RACES and BALL RETAINER Ordinarily these parts may deteriorate due to exessive grit and solids in the cleaning media There 15 another set of races in the body See STEM amp CLUTCH ASSEMBLY Unless special care and tools are used to prevent damage to the races during removal and reinstallation it is suggested that the machine be returned to the factory for replacement ASSEMBLY INREVERSE ORDER IMPORTANT When reassembling secure the six screws 21H and nozzle 23 with OMNIFIT 100M or a
7. cause the unit to be inoperable IMPORTANT When reassembling secure the six screws 2FS with OMNIFIT 100M one part waterproof glue or a similar product BOTTOM COVER amp PRIMARY SHAFT ASSEMBLY DISASSEMBLY 1 machine up side down 2 Remove four SCREWS 33H in BOTTOM COVER 33C 3 Remove BOTTOM COVER 33C 4 Dran 5 Remove four SCREWS 185 in BEARINGCOVER 31 6 Press out PRIMARY SHAFT 11 from opposite end along with SCREW 18S WASHER 19 SHAFTBEARING 29C and BEARINGCOVER 31 Further disassemble this assembly to check SHAFTBEARING 29C ASSEMBLY INREVERSE ORDER If bore I D is 10 4 mm or more and or oval replace bearing If horizontal bearing surface 1s worn 0 75 mm or more deep and or oval replace bearing IMPORTANT When reassembling secure the four SCREWS 33H with OMNIFIT 100M or a similar product INTERNAL GEARFRAME DISASSEMBLY 1 Remove four SCREWS 18S around the circumference of the GEARFRAME 30 2 Turn GEARFRAME about 10 mm 1 2 clockwise and lift out of body 3 Observe the function and condition of the wormgears horizontal shaft and bearings 4 Ifdeemed necessary proceed further with the procedure in the following illustration GEARFRAME ASSEMBLY Otherwise proceed to HUB ASSEMBLY Wear limits see GEARFRAME ASSEMBLY 10 GEARFRAME ASSEMBLY DISASSEMBLY It is necessary to prevent rotation of parts while removing screws from this assembly
8. d Back flush with air or water to completely evacuate any foreign materials Reas semble the machine and test by putting into service If unsuccessful perform an overhaul as per instructions or return to JA ENGINEERING A S for routine service MODEL 20 PARTS LIST Item No 2FB 2FS 2MS 3 3R 33H Part No 2102FB 2102FS 2102MS 21035 2103 2104V 21055 2109 2111P 2112 2113 2114 2115 2116PTZ 2116S8 2117 21185 2119 2121ND 2121G 2122 2123 Nozzle 2124C 2124MD2 2124MD4 2124MD6 21245 2126BR 2126R 2127 2127 1Q 2127 2Q 212730 21288 2129C 2130 2131 2133C 2133V 2133L 2133H Description Inlet Nipple Female BSPS Thread Socket Screw 3 16 x 3 4 Socket Screw 3 16 x 1 2 Guide Standard Guide Ring optional high truput Stem Impeller Standard Primary Shaft Bushing Primary Shaft Gearwheel Clutch Pinion Gear Collar Bush Wormgear Primary Wormgear Secondary Pinion Sleeve Socket Screw 3 16 x 1 2 Washer Hub Cover Hub Cover Gasket Bevelgear various Orifice 6 7 8 10 14mm Hub Connector Hub 2 Nozzle Hub 4 Nozzle Hub 6 Nozzle Set Screw for MD Hub Thrust Balls amp Retainer Thrust Race 2 per set Material SS Body with Bushings Factory Service SS Body Bushing Upper Factory Service SS Body Bushing Lower Factory Service SS Body Bushing Hub Factory Service Secondary Shaft Horizontal Shaftbearing Gearframe Bearing Support Cover Bottom Cover
9. ing or putting the machine into operation Inadequate as well as excessive pressure will adversely effect performance Operating temperatures can vary between 2 to 95 deg C 35 to 200 deg F Above freezing and below boiling temperature The machine is Liquid Hydraulically Motivated and no attempt should be made to operate it with steam air or gas After each use the machine should be flushed and allowed to drain completely Entrapped water may cause severe damage in freezing atmosphere Always open liquid supply valve slowly to avoid hydraulic shock from entrapped air etc Repeated shock and surges can cause damage to piping hose and other equipment as well as to the Tank Cleaning Machine The following information on your machine s should be documented and referred to when inquiring for information or ordering spare parts etc 1 Model number 2 Serial number 3 Parts a Quantity required b Item No c Parts No d Description SPARES Maintenance and repair of Tank Cleaning Equipment as described and illustrated herein 15 not difficult If you choose to maintain the equipment rather than return to us for overhaul we recom mend a minimum of spare parts be stocked at your facility This will minimize the down time of 15 very important cleaning function Most importantly maintenance personnel can compare the wear of various parts the machine with the new parts In this way it can be determined on site
10. similar product 13 14 STEM amp CLUTCH ASSEMBLY DISASSEMBLY To prevent rotation of the stem during disassembly and reassembly insert a screwdriver through the water passage holes in STEM 4 so that it engages the body l N Remove six SCREWS 18S from CLUTCH 13 Pull out GEARWHEEL 12 together with its THRUST RACE 26R THRUST BALLS amp RETAINER 26BR and CLUTCH 13 Inspect the two RACES 26R and BALL RETAINER 26BR particular If the RACES are severely grooved and the assembly does not rotate smoothly they may require replacement First try replacing the BALL RETAINER and check again If still no improvement then replace both RACES and BALL RETAINER Ordinarily these parts may deteriorate due to exessive grit and solids in the cleaning media There 15 another set of races in the body See HUB ASSEMBLY Unless special care and tools are used to prevent damage to the races during removal and reinstallation it is suggested that the machine be returned to the factory for replacement Press out STEM 4 With a wood dowel or other relatively soft object drive out the PRIMARY SHAFT BUSHING 9 in direction illustrated Check condition of bore in PRIMARY SHAFT BUSHING 9 If bore I D is 13 4mm or more and or worn oval replace PRIMARY SHAFT BUSHING Glue PRIMARY SHAFT BUSHING into stem with OMNIFIT 230L or a similar product IMPORTANT When reassembling secure the six SCREWS 18S with OMNIFIT 100M
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