Instruction Manual

Alfa Laval TJ40G Rotary Jet Head

Covering: Standard Machines, Heavy duty (HD),

Q-doc - Equipment Doc (3.1 Inspection Certificate - EN 10204)
Machines delivered with ATEX/IECEx Certification in accordance with Directive 2014/34/EU
TE91A725, First published: 2017-01

ESE03480-EN4 2017-09
Original manual
 Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

1. EU Declaration of conformity ....................................................................... 5

2. Safety .................................................................................................... 6
2.1. Important information ............................................................................. 6
2.2. Warning signs ..................................................................................... 6

3. Introduction ............................................................................................ 7
3.1. Introduction ........................................................................................ 7
3.2. Intended use ...................................................................................... 7
3.3. Patents and trademarks ......................................................................... 8
3.4. Marking ............................................................................................ 8
3.5. ATEX/IECEx marking ............................................................................. 9
3.6. ATEX/IECEx temperature class and code ...................................................... 10
3.7. Quality system .................................................................................... 10

4. Installation .............................................................................................. 11
4.1. General description ............................................................................... 11
4.2. Functioning ........................................................................................ 11
4.3. General safety and installation instructions ..................................................... 13
4.4. Specific conditions for safe use in accordance with ATEX/IECEx certification .............. 14

5. Operation ............................................................................................... 16
5.1. Normal operation ................................................................................. 16
5.2. Safety precautions ................................................................................ 17

6. Maintenance ........................................................................................... 18
6.1. Preventive maintenance .......................................................................... 18
6.2. Service and repair of ATEX/IECEx certified machines ......................................... 18
6.3. Maintenance Intervals and service Kits ......................................................... 19
6.4. General assembly/disassembly recommendations ............................................ 20
6.5. Disassembly tools ................................................................................ 20
6.6. Disassembly instructions ......................................................................... 21
6.7. Assembly instructions ............................................................................ 23

7. Trouble shooting guide ............................................................................... 26

8. Technical data ......................................................................................... 27

8.1. Performance data for TJ40G .................................................................... 28
8.2. Performance data for TJ40G-HD ............................................................... 31

9. Product programme .................................................................................. 34

9.1. Standard Configurations ......................................................................... 34
9.2. Standard Configurations, Burst ................................................................. 35
9.3. Available Add-ons ................................................................................ 36
9.4. Available add-ons for spare parts ............................................................... 36
9.5. Available welding and thread adaptors ......................................................... 37
9.6. Overview of guide and turbine combinations - 4 nozzles ..................................... 38
9.7. Overview of guide and turbine combinations - 2 nozzles ..................................... 39

10. Parts drawings, parts lists, service kits and tools ............................................... 40
10.1. Alfa Laval Toftejorg TJ40G ....................................................................... 40
10.2. Alfa Laval Toftejorg TJ40G-HD .................................................................. 42
10.3. Tools ............................................................................................... 44

3
Table of contents

The information herein is correct at the time of issue but may be subject to change without prior notice

11. General information ................................................................................... 45

11.1. Service and repair ................................................................................ 45
11.2. How to order spare parts ........................................................................ 45
11.3. How to contact Alfa Laval Kolding A/S ......................................................... 45

12. Miscellaneous .......................................................................................... 46

12.1. Declaration of Conformity, EN 10474, sub clause 2.2 Test Report .......................... 46
12.2. Declaration of Complaince with 10/2011 – Food contact materials ......................... 48

4
 1 EU Declaration of conformity

The Designated Company

Alfa Laval Kolding A/S

Company Name

Albuen 31, DK-6000 Kolding, Denmark

Address

+45 79 32 22 00
Phone No.

hereby declare that

Tank Cleaning Machine

Designation

Alfa Laval TJ40G & TJ40G-HD Rotary Jet Head

Type
From serial number 2016-0001 to 2030-99999

is in conformity with Machinery Directive 2006/42/EC and the following harmonized standard is used:
DS/EN ISO 12100:2011 Safety of Machinery - Risk Assessment

is in conformity with (Ex / ATEX) Directive 2014/34/EU and the following harmonized standards are used:
EN ISO 80079-36:2016, EN ISO 80079-37:2016, DS/EN ISO/IEC 80079-34:2011, Annex A, paragraph A.5.3 Rotating machines

EC Type Examination Certificate no. Baseefa17ATEX0018X and IECEx BAS 17.0017X

II 1G Ex h IIC 85ºC... 175ºC Ga

Marking:
II 1D Ex h IIIC T85ºC... T140ºC Da

Baseefa Ltd., Certification body number 1180, Rockhead Business Park, Staden Lane, Buxton, Derbyshire SK17 9RZ, United Kingdom

The person authorised to compile the technical file is the signer of this document.

Global Product Quality Manager

Pumps, Valves, Fittings and Tank Equipment Lars Kruse Andersen
Title Name Signature

Kolding 2017-09-01
Place Date

This Declaration of Conformity replaces Declaration of Conformity dated 2017-03-01

5
2 Safety
Unsafe practices and other important information are emphasized in this manual.
Warnings are emphasized by means of special signs.
Always read the manual before using the tank cleaning machine!

2.1 Important information

WARNING
Indicates that special procedures must be followed to avoid serious personal injury.

CAUTION
Indicates that special procedures must be followed to avoid damage to the tank cleaning machine

NOTE
Indicates important information to simplify or clarify procedures.

2.2 Warning signs

General warning:

ATEX/IECEx warning

6
 3 Introduction
TJ40G

3.1 Introduction

Based on more than 30 years’ experience from practical tank cleaning and production, the Alfa Laval Toftejorg TJ40G Rotary Jet
Head has been developed to meet the highest demands for efficiency, reliability and hygiene within food and beverage, pharma-
ceutical and biochemical industry.

This manual has been prepared as a guide for installing, operating and maintaining your Alfa Laval Toftejorg tank cleaning machine.
Should you require further assistance, our Technical Sales Support department and worldwide net of sales offices are pleased
to help you. Please quote the type, article and serial numbers with all of your enquiries; this helps us to help you. The type and
serial number are placed on the body of the tank cleaning machine.

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

If the Alfa Laval Toftejorg TJ40G stops rotating unintentionally within the warranty period, please return the machine to Alfa Laval.
Please do not try to fix any mechanical problems before shipping.

Important Before installing the machine and setting it into operation, carefully read the General safety and installation
information: instructions (page 13) and the specific conditions for safe use in accordance with ATEX/IECEx directive
2014/34/EU (page 14) and take all necessary precautions according to your application and local regulations.

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.

The English version of the instruction manual is the original manual. We make reservations in regard to possible mistranslations in
language versions of the instruction manual. In case of doubt, the English version of the instruction manual applies.

3.2 Intended use

The end-user should verify:

- that the tank cleaning machine is in conformity with respect to tank, vessel or container size in which it is used.
- that the construction materials (both metallic and non-metallic) are compatibility with product, flushing media, cleaning
media, temperatures and pressure under the intended use.

The tank cleaning machine is intended for use in closed tank, vessel or container. If used in open environment see 4.3 General
safety and installation instructions (page 13).

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3 Introduction
TJ40G

3.3 Patents and trademarks

This Instruction Manual is published by Alfa Laval without any warranty. Improvements and changes to this Instruction Manual
may at any time be made by Alfa Laval without prior notice. Such changes are incorporated in new editions of this Instruction
Manual.

Alfa Laval Kolding A/S. All rights reserved.

The Alfa Laval logotype is a trademark or a registered trademark of Alfa Laval Corporate AB. "Toftejorg" is a trademark or reg-
istered trademark of Alfa Laval. The Alfa Laval Toftejorg™ TJ40G product has a pending patent in the EPO member states (EP
14199732.0), in the US and in other countries. Other products or company names mentioned herein may be the trademarks of
their respective owners. Any rights not expressly granted herein are reserved.

3.4 Marking

Alfa Laval tank cleaning machines are marked to allow for recognition of type of machine, machine name, serial number and
manufacturing address.

The marking is placed on the body of the tank cleaning machine.

Serial number explanation

Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number

4116-0000
Marking area

8
 3 Introduction
TJ40G

3.5 ATEX/IECEx marking

The Alfa Laval Toftejorg TJ40G is certified as category I component. The certification is carried out by the notified body Baseefa,
who has issued the certificate no. 17ATEX0018X and IECEx BAS 17.0017X.

Note
Explosion protection type is constructional safety “c”.

The marking on the ATEX/IECEx certified Alfa Laval Toftejorg TJ40G is as follows:

Serial number explanation:

Machines supplied with or without normal documentation:
yyyy-xxxxx: serial number
yyyy: year
xxxxx: 5 digit sequential number

9
3 Introduction
TJ40G

3.6 ATEX/IECEx temperature class and code

The maximum surface temperature depends mainly on operating conditions which are the temperature of the process fluid and
the ambient temperature.

Group II EPL Ga
The gas temperature class is corrected with a safety margin of 80% due to a requirement for Group ll EPL Ga equipment.
The gas temperature class depends on the process fluid temperature or the ambient temperature, whichever of the two is
the highest.

Table for determining temperature class (gas atmospheres)

Process fluid Temperature, Ambient temperature,

Temperature Class
Tp (°C) Tamb (°C)

85°C (T6) ≤ +68°C ≤ +68°C

100°C (T5) ≤ +80°C ≤ +80°C
135°C (T4) ≤ +108°C ≤ +108°C
175°C ≤ +140°C ≤ +140°C

Group III EPL Da

The dust temperature class depends on the process fluid temperature or the ambient temperature, whichever of the two is
the highest.
No dust layer is considered.

Table for determining temperature class (dust atmospheres)

Process fluid temperature, Ambient temperature,

Temperature code
Tp (°C) Tamb (°C)

T85°C ≤ +85°C ≤ +85°C

T100°C ≤ +100°C ≤ +100°C
T135°C ≤ +135°C ≤ +135°C
T140°C ≤ +140°C ≤ +140°C

Example of gas class determination

Process fluid temperature is 67°C and ambient temperature is 75°C.
Gas class = T5

ATEX/IECEx marking on the equipment:

II 1G Ex h IIC 85°C…175°C Ga
II 1D Ex h IIIC T85°C…T140°C Da

3.7 Quality system

The Alfa Laval Toftejorg TJ40G is designed to be best-in-class on hygienic design using recognised principles of hygienic design
wherever feasible. It is produced according to Alfa Laval Kolding’s ISO-9001 international Standard certified quality system. All
parts are made from certified material and all non-metal parts are made from FDA and EU 10/2011 complaint materials.

10
 4 Installation
TJ40G

4.1 General description

The Alfa Laval Toftejorg TJ40G is a media driven and media lubricated tank cleaning machine. No lubricating substances such
as oil, grease etc. are used. All materials are selected for contact with food, and the machine is self-cleaning i.e. all internal and
external surfaces are cleaned during normal operation.

For use in explosive hazard zones the ATEX/IECEx version can be used, provided it is installed according to safety instructions
in local regulations.

4.2 Functioning

The flow of cleaning fluid into the machine passes through a turbine, which accordingly is set into rotation. Through a gear set,
the turbine rotation is transmitted to the cleaner head.

The combined motion of the machine body and the nozzles ensures a fully indexed tank cleaning coverage. After 5 5/8 rev-
olutions of the hub cover with nozzles (5 3/8 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 7 times, each of which is
displaced, and the pattern gradually becomes more dense. Finally, after 8 cycles - a total of 45 revolutions of the hub cover with
nozzles (43 revolutions of the machine body), a complete cleaning pattern has been laid out, and the first pattern is repeated
(figure 1).

First cycle Second cycle Third cycle Forth cycle

Figure 1: Build up of pattern for cylindrical tank with the machine placed in the centre

The number of cycles needed to perform a proper cleaning depends on type of soilage, position of the tank cleaning machine,
cleaning procedure, cleaning temperature and cleaning agent.

For substances that are easily mobilised, i.e. are easy to remove, one cycle could be sufficient while in cases of more heavy
soilage (high viscous, sticky substances, etc.) a more dense pattern (more cycles) are needed.

The rotation speed of the turbine depends on the flow rate through the machine. The higher the flow rate, the higher the
speed of rotation. In order to control the RPM of the machine for a wide range of flow rates, the machine has different turbines
according to the nozzle size.

11
4 Installation
TJ40G

4116-0002
Apart from the main flow flushing the gear and the hub, and thereafter
forming the jets through the nozzles, fluid is flushed through all inter-
nal areas, through bevel gear, ball bearings and gaps between moving
parts and finally also used for cleaning of the outside surfaces of the
machine. In the bottom of the body, a drain hole is present to ensure
self-draining. This self-draining is only ensured, if the machine is in-
stalled in upright position.

The cone is cleaned from the patent pending design of the hub; this
is by impact and sheeting action.

4116-0003
4116-0004

The threaded connection between downpipe and machine is not a A: Down pipe
product contact surface as it is enclosed using two seals and the B: Welding adapter
welding adaptor. If needed, a welding adaptor, depending on downpipe C: Seal PTFE
dimensions, must be ordered separately (see page 37ff). D: Seal EPDM

For all versions:

For devices with tapered thread connections to the down pipe, it is
recommended that you secure the connection in a manner appropriate
for the application. Subject to the intended use environment and any
inhouse user requirements or policies, an adhesive such as Loctite No.
2046 or equivalent could be used. Other methods could be acceptable
and subject to customer preference.

12
 4 Installation
TJ40G

4.3 General safety and installation instructions

During handling and installation handle the machine with care in order not to damage the surface finish of the machine.

Upon arrival check that the machine is in operating condition using an 8 mm socket wrench on the turbine shaft and easily turn
the turbine shaft anti-clockwise. If resistance is recognized, disassembled the machine to localize the cause.

NOTE
Do not try to turn the hub with hub nozzles by hand, since this may damage the gear. The hub with nozzles can be turned by
blowing compressed air through the inlet connection or using a socket wrench on top of the turbine shaft.

Before connecting the machine to the system, all supply lines and valves should be flushed for removal of foreign particles.

The tank cleaning machine should be installed in vertical position (upright or upside down). The installation and operation shall be
made so that the self-draining of the machine is ensured.

The machine should be screwed tightly onto the supply line using a 65 mm flat jawed spanner (tool No. TE81B147) on the flats,
machined on the inlet cone. Subject to the environment of intended use and any in-house user requirements or policies adhesives
such as Loctite no. 2046 could be used to prevent the connection from loosening due to excessive vibration in the system.

In order to separate the CIP system from the process it is recommended to install a shutoff valve close to the machine inlet.
This also prevents back-flow of liquid from the tank through the machine in case the machine is submerged and there is
an over-pressure inside the tank.

It is recommended that the fluid valve fitted is of a type that prevents hydraulic shocks. Hydraulic shocks may cause severe
damage to the machine and/or the entire installation. Ideally, use a frequency controlled pump with a ramp function for start-up
to supply the cleaning liquid.

Larger particles may get trapped in the nozzles, while smaller particles may be get trapped in the smaller clearances of the
machine and increase wear. Magnitude of the issues relies on the particle shape and properties (e.g. soft vs. hard). Experience
shows that Alfa Laval tank cleaning machines may operate with strainer sizes larger than recommended below. Contact your
local Alfa Laval office for support.

For low amounts of particles in the recirculating CIP liquid larger particles should be avoided and in this case a 3 mm strainer
may be sufficient for a reliable operation.

For high amounts of particles in the recirculating CIP liquid it is recommended to install a strainer according to the smallest
clearance in the machines. For the TJ40G a strainer of 0.1 mm is recommended and for the TJ40G-HD a strainer of 1 mm is
recommended.

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 depending
of application, the EU-Pressure Equipment Directive, the EU-ATEX/IECEx Directive and other relevant Directives and shall
be CE-marked before it is set into operation.

Warning: 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.

For information on use in potential explosive atmospheres see paragraph 4.4 Specific conditions for safe use in accordance with
ATEX/IECEx certification page 14.

13
4 Installation
TJ40G

4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification

Directive 2014/34/EU

NOTE
Explosion protection type is constructional safety “c”.

Warning: Temperature class and ambient temperature range

The temperature class and ambient temperature range are shown in paragraph 3.6 ATEX/IECEx temperature
class and code, page 10.

Warning: Surface temperature

The maximum surface temperature depends mainly on operations conditions which is the temperature of the
process fluid and ambient temperature, see paragraph 3.6 ATEX/IECEx temperature class and code, page 10.

Warning: Draining using compressed air

Draining using compressed air must not be done in ex classified zone.
Draining using compressed air is possible in non ex classified zones (see page 16).

Warning: Earthing
All metal and other conductive or dissipative material should be connected to earth with the exception of very
small items.
For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards,
guidance. With focus on clause 6.2.3, 7.2.1, 7.3, 7.9.2, 13.

Warning: Steaming tanks greater than 100 m³

Tanks with capacities greater than 100 m³ that could contain a flammable atmosphere should not be steam
cleaned, as steam cleaning tanks produces an electrostatically charged mist. Tanks smaller than 100 m³ may
be steam cleaned. For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1:
Electrostatic hazards, guidance. With focus on clause 7.10 and 8.5.

Warning: Earthed when in use

The unit must be effectively earthed at all times when in use.

Warning: Process generated electrostatic

The user must address the electrostatic hazards generated from the process of the equipment in accordance
with guidance document IEC/TS 60079-32-1:2013.

14
 4 Installation
TJ40G

Warning: Electrostatically charged liquid

Liquids can become electrostatically charged when they move relative to contacting solids or the spraying of
liquids can also create a highly charged mist or spray. The cleaning solvent must be made electrically conductive
by additives or otherwise.
For further information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards,
guidance. With focus on clause 7.1.3, 7.1.4, 7.2.1, 7.2.4.

NOTE
The tank cleaning machine has been certified by accredited notified body and can operate in tanks having an enclosed volume
up to 100 m³ as long as all ATEX warnings in the instruction manual are complied with.
General guidelines for tanks larger than 100 m3:
Tanks larger than 100 m³ must not be steam cleaned – See guide IEC/TS 60079-32-1:2013 clause 8.5.
To use the unit in tanks larger than 100m³ is possible under certain conditions.
It is necessary to know the current factors such as tank size, cleaning solvent and product.
Additives can be used in the cleaning solvent, or, for example, the tank can be filled with nitrogen. The basic guidelines are
described in the guide IEC/TS 60079-32-1:2013.
It must be ensured that the equipotential bonding of all conductive metal objects is in accordance with national regulations
for use.

The process fluid conductivity must correspond to the products in the group “High conductivity”,cf. IEC/TS 60079-32-1:2013
clause 7.1 and 7.2.

High conductivity > 10 000 pS/m

Medium conductivity between 25 × εr pS/m and 10 000 pS/m
Low conductivity < 25 × εr pS/m

For liquids with a dielectric constant of around 2, (e.g. hydrocarbons), these classifications reduce to:

High conductivity > 10 000 pS/m

Medium conductivity between 50 pS/m and 10 000 pS/m
Low conductivity < 50 pS/m

Following a guidance document such as IEC/TS 60079-32-1:2013 to establish safe use of machinery and process is the users
own responsibility and is not covered by the ATEX/IECEx certification for this unit except for tanks up to 100 m3. For further
information see IEC/TS 60079-32-1:2013 Explosive atmospheres – Part 32-1: Electrostatic hazards, guidance with focus on
clause 7.1.3, 7.1.4, 7.2.1, 7.2.4.

Warning: Appropriate cleaning fluid

The cleaning fluid should be appropriate for the application (e.g. so no chemical reaction can take place between
the cleaning fluid and the residue of process fluid/compound which can generate heat).

Warning: Fluid pressure

The maximum permitted process fluid pressure is 12 bar.

In addition to the above mentioned precautions relating to Directive 2014/34/EU, the Safety Precautions on page 13 must
be observed.

15
5 Operation
TJ40G

5.1 Normal operation

Cleaning Media
Use only media compatible with Stainless Steel AISI 316, SAF 2205, PEEK, PFA HP and EPDM. Normal detergents, moderate
solutions of acids and alkalics are acceptable. Aggressive chemicals, excessive concentrations of chemicals at elevated
temperatures, as well as certain hypochlorids should be avoided. If in doubt, contact your local Alfa Laval sales office.

NOTE
Do not try to turn the hub with nozzles by hand, since this may damage the gear. The hub with nozzles can be turned by
blowing compressed air through the inlet connection or by using a socket wrench on top of the turbine shaft.

PEEK is not resistant to concentrated sulphuric acid.

Product
In cases where the machine is submerged in, or in other ways exposed to, product the compatibility between stainless steel
AISI 316, SAF 2205, PEEK, PFA HP and EPDM and the product must be considered carefully.

NOTE
EPDM swells significantly exposed to fatty materials.

Pressure
Avoid hydraulic shocks. Increase pressure gradually. Do not exceed 12 bar inlet pressure. Recommended inlet pressure: 5-7
bar. High pressure in combination with high flow rate increase consumption of wear parts. High pressure also reduces
the cleaning effect.

Draining using compressed air

If the machine is drained using compressed air, then the compressed air pressure must not cause the machine body rotation to
exceed 4.5 rpm (corresponding to appx. 13 sec pr. rev of the body) in order to avoid risk of machine breakdown.
Draining should always be done inside the tank.
See paragraph 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification (page 14).

Steam cleaning
If stream cleaning is done through the machine, the steam pressure must not cause the machine body rotation to exceed 10
rpm (corresponding to appx. 6 sec pr. rev of the body) in order to avoid risk of machine breakdown. See paragraph 4.4 Specific
conditions for safe use in accordance with ATEX/IECEx certification (page 14).

16
 5 Operation
TJ40G

Temperature
The maximum recommended process liquid temperature is 95oC. The maximum recommended steam temperature is 140oC.
The maximum ambient temperature is 140oC.
See paragraph 4.4 Specific conditions for safe use in accordance with ATEX/IECEx certification (page 14).

After use cleaning

After use flush the machine with fresh water. Cleaning media should never allow to dry or settle in the system due to possible
"salting out" or "scaling" of the cleaning media. If cleaning media contains volatile chloride solvents, it is recommended not to
flush with water after use, as this might create hydrochloric acid.

5.2 Safety precautions

The machine is intended for use inside a tank only. As peak velocity of main jets reaches 40 m/s, The Alfa Laval Toftejorg TJ40G
must not be operated in open air or when tank is open.

Warning: Hot chemicals and steam under pressure may be used for cleaning and sterilising. Protect against scalding
and burning. Never tamper with or try to open clamps or other connections while system is in operation. Make
sure that system is de-pressurised and drained before disassembly.

The cleaning jets impinging the tank surface are a source of noise. Depending on pressure and distance to the tank walls, noise
level may reach up to 85 dB.

Warning: Tanks may contain poisonous/hazardous products or products which represent an environmental or safety
risk. Never open tank and dismount the machine without checking previous tank contents and necessary
precautions.

See also 3.6 ATEX/IECEx temperature class and code, page 10.

17
6 Maintenance
TJ40G

6.1 Preventive maintenance

Following the Alfa Laval Preventive Maintenance Guidelines and using the Alfa Laval Service Kits ensures the availability of your
equipment at all times and enables you to plan your operating budget and your downtime. The risk of unscheduled 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, traceable Alfa Laval spare parts,
manufactured to the original specifications.

The recommended preventive maintenance program is based on tank cleaning machines working in average conditions. How-
ever, a tank cleaning machine, exposed to heavy soiling and recirculation CIP liquid containing abrasives and/or particulates (see
section 4.3 General safety and installation instructions for strainer recommendations), needs more frequent attention than one
exposed to light/no soiling and recirculation with ordinary CIP liquid. Alfa Laval Kolding A/S recommends that you adjust the
maintenance program to suit the cleaning task in hand. Contact your local Alfa Laval sales office for discussion.

For further information regarding Alfa Laval Service Kits and service intervals, see paragraph 6.3 Maintenance Intervals and service
Kits on page 19 of this manual or the Spare Parts Manual.

NOTE
Handle the Alfa Laval Toftejorg machine with care. Take proper action to protect surfaces from being damaged.

Always use only proper tools and the Alfa Laval Toftejorg TJ40G standard tool kit (page 20). Never use force, hammer or pry
components together or apart. Always perform all assembly/disassembly steps in the order described in this manual.

Clean all surfaces prior to assembling. Especially take care of the mating surfaces. Work in a clear well-lighted work area.

According to “Regulation (EC) No 1935/2004 - Article 17” effective from 27th of October 2006, producers of food shall ensure
traceability of the materials and articles intended to come into contact with foodstuffs. It is recommended that a traceability
system is setup for replacement of wear parts and spare parts. This makes it possible to identify into which machine a given
wear part or spare part has been inserted.

6.2 Service and repair of ATEX/IECEx certified machines

All service and repair of ATEX/IECEx certified machines can be performed by Alfa Laval Kolding A/S, Denmark, or by an Alfa Laval
service center approved by Alfa Laval Kolding A/S.

Changes to the machine are not allowed without approval by the person responsible for the ATEX/IECEx certification at Alfa Laval.
If changes are made – or spare parts other than Alfa Laval original spare parts are used - the EC Type Examination certification
(the ATEX/IECEx Directive) is no longer valid.

Warning: In order to ensure compliance with the ATEX/IECEx regulations and keep the machine ATEX/IECEx certification
valid the service or repair must be performed by an authorized person with knowledge of the ATEX/IECEx
requirements and regulations.
All spare parts must be original Alfa Laval spare parts and the repair or service must be done according to the
instructions in the related manual.
If a customer wishes to carry out service or repair himself, it is the responsibility of the repair shop to ensure that
the ATEX/IECEx requirements are met in any way possible. After performing service or repair, the repair shop
thus carries the full responsibility for traceability of all relevant documents in order to ensuring the retention of the
ATEX/IECEx certification of the machine.

18
 6 Maintenance
TJ40G

6.3 Maintenance Intervals and service Kits

It is recommended that the wear parts are checked every 500 working hours for machine working under normal conditions. There
are Minor and Major service kits for the Alfa Laval Toftejorg TJ40G (see parts lists and drawings page 40 ff).

Service intervals

500 hour 500 hour 500 hour

Minor Service Kit: Minor Service Kit: Minor Service Kit:

96900031XX
96900031XX or 96900031XX
Major Service Kit
96900062XX
96900065XX

Every 500 working hours

(#) refers to position numbers on page 40.
1. Disassemble machine as described on the following pages.
2. Clean material build-up and deposits from internal parts with Scotch-brite, S-Ultra-fine, eventually chemical media and
fine abrasive cloth.
3. Check bearing for body (9) for wear. If the hole is worn oval to a max. diameter of more than 10.4 mm, it should be replaced.
4. Check bearing for turbine shaft top (26) in cone. If hole is worn oval to a max. diameter of more than 10.4 mm, Bearing
should be replaced. If the bearing is loose in a horizontal direction, the bearing should be replaced.
5. Check planet gear carrier bearing (17). If worn oval to a max. diameter of more than 15.3 mm, it should be replaced.

Note: Timely replacement of bearings prevents costly damage to the gearbox.

6. Check gear wheels (15 and 16). They must rotate easily on the shafts. If restriction or too much clearance on shafts is felt,
planet wheels should be dismounted for inspection of bearing surfaces and shafts for planet wheel (14). Max diameter of
holes: 6.8 mm. Check tooth wear. If replacement is necessary, planet wheels must be replaced as a pair.
7. Check unrestricted rotation of ball bearings. Inspect for build-up of foreign material on stem nut (12) and hub nut (6), in
ball retainers (5) and ball races (4).
8. Inspect the nozzle vanes (28) for foreign objects (e.g. product pulp, threads, etc.) and if necessary clean with care –
damaging nozzles (or fouled nozzles) decrease the throw length of the machine. Clean using compressed air or tweezers.
9. Replace gaskets if damaged.
10. Check if ball races (5) on stem and hub (3) as well as stem/hub nut w. ball race (12 and 6): If heavily worn, they should be
replaced. Also the ball retainer w. balls (5) should be replaced if heavily worn.
11. Assemble machine as described in the following pages.
12. Check that the hub (3) is not stuck on hub nut - it should be possible to shift hub (3) a little both clockwise and anticlockwise.
13. Check that the machine is in operating condition by using a socket wrench (8 mm) on top of turbine shaft, and easily turn
turbine shaft anticlockwise. If resistance is recognised, disassembled machine in order to localise the cause.

Apart from the parts specifically mentioned above, all the remaining wear parts should regularly be inspected for wear. Which
parts that are wear parts appear from the Spare Part Manual, available from the on-line Alfa Laval product catalogue Anytime or
the Close at hand spare part catalogue.

19
6 Maintenance
TJ40G

6.4 General assembly/disassembly recommendations

• Always read the instruction and maintenance manuals carefully before service.
• Always replace all parts included in the Service Kit.
• Prior to assembly/disassembly clean all tools and fixtures to ensure that scratches and marks and trace of soil/corrosion
from tools are avoided.
• Do not scratch or damage the surfaces of the machine.
• Always place components on soft material

Check surfaces for product residues and clean all parts before assembly. Assembly of the machine is described on the
following pages.

6.5 Disassembly tools

Disassembly tools needed for maintenance and repair

(For toolkit see page 44).

- Caliper
- Fork key NV65
- Fork key NV24
- Pin punch ø8 mm
- Extended socket wrench ø8 mm
- Torque wrench
- Support ring (only for changing ball races) - e.g. a piece of pipe with an inner diameter of ø67 - ø80
- Bench vice (large enough to secure the body of the TJ40G)
- Rubber hammer

Special tool needed for disassembly turbine assembly

- Fixture for impeller

Standard toolkit
- Item no. TE81B149 (see page 44)

20
 6 Maintenance
TJ40G

6.6 Disassembly instructions

Warning: During disassembly and assembly the threads can gall. If any resistance is felt when screwing/unscrew-
ing parts, proceed with caution.

(#) refers to position numbers on page 40.

Step 1
Remove the four nozzles (27) using fork key NV24.
a. If damaged remove O-rings (29) from nozzles (27).

Step 2
Fasten the machine in a bench vice using the surfaces where the
nozzles (27) are attached to the machine.

Step 3
Using a socket wrench (ø8 mm) on the top of the turbine to rotate the turbine shaft until the machine is more-or-less in vertical
position (by hand support the body (1) of the machine to aid the rotation).

Step 4
If damaged remove gasket (30) from inside the cone (24).

Step 5
Loosen and remove cone (24) using fork key NV65.

Step 6
Remove guide (25), turbine assembly and planet gear assembly. NB: guide maybe inside cone when removing the cone.

a. If damaged remove O-ring (22) from the guide.

b. If worn too much remove bearing (26) from guide using drift punch.
c. If worn too much or if gear wheels (15 and 16) need to be inspected remove bushing (17) from planet gear
frame (13).
i. Remove gear wheels (15 and 16) from planet gear frame (13).
d. If O-rings (20) on turbine assembly needs replacement disassemble it.
i: Mount fixture (TE20J591) in bench vise.
ii: Insert impeller shaft (18) end of assembly into fixture (TE20J591).
iii: Loosen shaft end (21) of assembly using socket wrench (ø8 mm).
iv: Remove impeller (19).
v: Remove O-ring (20) from impeller (19).

Step 7
Remove O-ring (22) from stem (11).

Step 8
Remove O-ring (23) from stem (11).

Step 9
Loosen stem nut (12) using caliper. If needed use rubber hammer on caliper.

21
6 Maintenance
TJ40G

Step 10
Remove stem (11) along with ball retainer w. balls (5) and stem nut (12) from the machine.

a. Remove stem nut (12) from stem (11).

b. Remove ball retainer w. balls (5) from stem (11).
c. If worn remove ball race (4) from stem (11) using pin punch to pry it loose.

Step 11
Loosen the 3 screws (10) attaching the gear ring (7) to the machine.

Step 12
Remove the gear ring (7).

a. If worn too much remove bearing (9) from gear ring (7) using pin punch.

Step 13
Remove the machine from the bench vise.

Step 14
Hold body (1) against table and loosen hub nut (6) using caliper. If needed use rubber hammer on caliper.

Note: Left-hand thread

NB: Body (1) can also be fixed in bench vise, but care should be taken a) not to damage the outside surface
roughness and b) not apply too much pressure from the jaws to the body (1) as this can deform the body.

Step 15
Remove hub (3) along with ball retainer w. balls (5) and hub nut (6) from the machine.

a. Remove O-ring (2) from body (1).

b. Remove hub nut (6) from hub (3).
c. Remove ball retainer w. balls (5) from hub (3).
d. If worn remove ball race (4) from hub (3) using pin punch to pry it loose.

22
 6 Maintenance
TJ40G

6.7 Assembly instructions

Warning: During disassembly and assembly the threads can gall. If any resistance is felt when screwing/unscrew-
ing parts, proceed with caution.

(#) refers to position numbers on page 40.

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

Inspect the nozzle vanes (28) for foreign objects (e.g. product pulp, threads, etc.) and if necessary clean with care - damaging
nozzles (or fouled nozzles) decreases the throw length of the machine. Clean using compressed air or tweezers.

Planet gear assembly (if it has been disassembled)

Step 1
Put gear wheels (15 and 16) on each planet gear shaft (14).

Note: The two planet wheels are different: on gear wheel I (15), teeth of upper an lower gearing are aligned, while they
are displaced ½ tooth on gear wheel II (16).

Step 2
Mount planet gear bushing (17) in top of planet gear frame (13) – eg. use impeller shaft (18) to apply pressure to the planet gear
bushing (17).

Turbine assembly (if it has been disassembled)

Step 3
Insert an O-ring (20) on either side of the impeller (19).

Step 4
Mount the impeller with O-rings onto the impeller shaft (18).

Step 5
It is recommended to slightly grease the thread with food grade/FDA compliant grease. The grease reduces the risk of galling in
threads. The grease is enclosed between O-rings and, therefore, it will no come into contact with the cleaning media.

Step 6
Screw the shaft end (21) into the impeller shaft (18). Tighten to metal-to-metal stop (10-12 Nm). Use tool TE20J591 to fixate the
impeller shaft (18).

Guide assembly (if it has been disassembled)

Step 7
Insert bearing for turbine shaft top (26) into the guide (25) and press it in.

Nozzle assembly (if it has been disassembled)

Step 8
Mount O-ring (29) into O-ring groove just after the threads on the nozzle (27).

23
6 Maintenance
TJ40G

Ball race (if replaced during maintenance)

Step 9
Mount ball race (4) on hub (3) using support ring – press together in bench vise.

Step 10
Mount ball race (4) on stem (11) using support ring – press together in bench vise.

Gear ring assembly (if it has been disassembled)

Step 11
Mount seal ring (8) in gear ring (7).

Step 12
Mount bearing for body (9) on the gear ring (7). Use pin punch between bearing for body (9) and rubber hammer to apply
pressure. NB: Ensure bottom of bearing for body (9) is flush with the bottom of the gear ring (7) after insertion.

Machine assembly

Step 13
Put ball retainer w. balls (5) around hub (3).

Step 14
Mount O-ring (2) over body (1).

Step 15
Put hub nut (6) around hub (3).

Step 16
Mount the hub (3) (with ball retainer and hub nut) into the hub part
of the body (1). After screwing in the hub nut (6) almost all the way
(left hand thread), move the O-ring (2) from around the body (1)
into the O-ring groove on the body (1). Tighten the hub nut (6) to
the body (1). NB: make sure O-ring (2) is in the O-ring groove. NB:
Wet the surface of the O-ring (2) with water to ease the assembly.
Tighten to metal-to-metal stop. IMPORTANT: No lubricants and
lock tight to be used.

Step 17
Mount the hub (3) in bench vise and turn the body (1) so the stem
part of the body (1) is upwards.

Step 18
Insert gear ring (7) into body (1) and fasten it using the 3 screws for body (10) with a torque of 4.5-5 Nm. NB: It may be necessary
to rotate the gear ring (7) so the holes fits with the thread holes in the body (1).

Step 19
Insert stem (11) into the body (1).

Step 20
Place ball retainer w. balls (5) around stem (11).

Step 21
Place stem nut (12) around the stem (11) and tighten the stem nut (12) into the body (1) (right hand thread). IMPORTANT: No
lubricants and lock tight to be used. (It may be necessary to lift the stem (11) a little while turning the stem nut (12).

24
 6 Maintenance
TJ40G

Step 22
Place O-ring (23) around the stem (11).

Step 23
Insert planet gear assembly into stem (11) and into the gear ring (7). NB: it may be necessary to wiggle the machine a little to
get the planet gear assembly to fall in place.

Step 24
Insert O-ring (22) into the O-ring groove on top of the stem (11).

Step 25
Insert impeller assembly into the planet gear assembly – rotate the impeller (19) by hand to ensure that it rotates freely. (By
hand support the body (1) of the machine to aid the rotation).

Step 26
Mount guide (25) onto top of stem (11) (and the O-ring).

Step 27
Insert O-ring (22) into the O-ring groove on top of the guide (25) (right hand thread).

Step 28
It is recommended to slightly grease the thread with food grade/FDA compliant grease. The grease reduces the risk of galling in
threads. The grease is enclosed between O-rings and, therefore, it will no come into contact with the cleaning media.

Step 29
Mount the cone (24) over the guide assembly and catch the thread
on the stem (11) and tighten the cone (24) on to the stem (11).
NB: make sure O-rings are in the O-ring grooves. NB: Wet the
surface of the O-rings with water to ease the assembly. Tighten
to metal-to-metal stop.

Step 30
Insert gasket (30) into top part of cone (24).

Step 31
Remove the assembly from the bench vise.

Step 32
Mount nozzle w. gaskets (27) into the hub (3). NB: Make sure
O-rings are in the O-ring grooves. E.g. use a finger to push O-ring
in guide back in place while fastening the cone.NB: Wet the
surface of the O-rings with water to ease the assembly. Tighten
to metal-to-metal stop – torque of 70 Nm. IMPORTANT: No
lubricants and lock tight to be used.

After reassembly check if the turbine rotates freely using an 8 mm socket wrench at the top of the turbine and turn it
anticlockwise, while holding the machine by the cone. The hub with nozzles should rotate very slowly.

25
7 Trouble shooting guide
TJ40G

Symptom: Slow rotation or failure of the machine to rotate:

Possible Causes Fault finding

No or insufficient liquid flow a). Check if supply valve is fully open.
b). Check if inlet pressure to machine is correct.
c). Check supply line/filter for restrictions/clogging.
d). Remove nozzles and check for clogging. If blocked, carefully clean nozzle
without damaging nozzles vanes and nozzle tip.
e). Remove cone (see page 21) and check for clogging in guide and impeller
area.
If large particles repeatedly get jammed in the machine, install filter or reduce
mesh size of installed filter (1 mm) in supply line or contact Alfa Laval for other
solutions.

Foreign material or material build-up Insert socket wrench on top of turbine shaft and easily turn turbine shaft anticlock-
wise. If any resistance is recognised, disassemble machine to localise cause.
a). Impeller jammed Remove turbine shaft assembly and planet gear assembly (see page 21) and
remove foreign material.
b). Turbine shaft sluggish in bearing Remove turbine shaft assembly (see page 21) and clean bearing.
c). Planet gear jammed/sluggish Remove foreign material from planet wheels and internal gears. Check rotation
of planet wheels. If restriction is recognised, disassemble Pplanet gear assembly
(see page 21) and remove material build up, especially on shafts and bushes in
planet wheels.
d). Stem or hub jammed/sluggish Remove planet gear assembly (see page 21). Turn hub and check unrestricted
rotation. Remove stem and hub (see page 21 ff). Remove foreign material/mate-
rial build-up on stem, hub and inside nut. Clean Ball races and ball retainer with
balls. Assemble stem/hub, ball retainer with balls and stem/hub nut.
e). Bevel gears jammed Remove stem and hub (see page 21 ff). Clean teeth on stem and hub.

Wear
a). Slide bearings See page 19.
b). Bearings for turbine shaft See page 19.
c). Planet wheels See page 19.
d). Shafts for planet wheels Check clearance of planet wheels on shafts. Transverse movement should not
exceed 0.3 mm.
e). Turbine shaft Check clearance in planet gear bearing and bearing for turbine shaft. Transverse
movement should not exceed 0.3 mm. Also inspect teeth for wear.

Mechanical defects
a). Planet wheels. Teeth broken Replace planet wheel.
b). Planet wheel can not rotate on shafts/shafts Replace planet gear frame.
bent
c). Damaged teeth on bevel gear Inspect teeth on stem and hub for deformation. Mount hub and stem in body
(See page 23). Hold body in upside down position and rotate hub to check that
bevel gears can work together. If damaged: Replace stem and/or hub.
d). Damage on stem and hub-nut If hard particles get stuck between stem nut and stem or hub nut and hub, the
particles will damage the parts. The damaged parts should be replaced.

26
 8 Technical data
TJ40G

Weight of machine: 6.3 kg (13.9 lb)

6.7 kg (14.8 lb) including welding adapter
Recommended inlet pressure: 5-7 bar (70-100 psi)
Max. inlet pressure: 12 bar (174 psi)
Max. recommended working liquid temperature 95°C (200°F)
Max. recommended working steam temperature 140°C (284°F)
Ambient temperature: 140°C (284°F) when not operated
Materials: Stainless Steel AISI 316, SAF 2205, PFA HP, PEEK, EPDM
Max. permitted process fluid pressure: 12 bar.

Principal dimensions in mm

4116-0005

Minimum required passage: Tilted ～ 30°: ø167 mm (6.6 inch). Otherwise ø187 mm (7.4 inch).

27
8 Technical data
TJ40G

8.1 Performance data for TJ40G

Article numbers 96900003XX (TJ40G)

Flow rate
m3/h USgpm Nozzles mm
65 4116-0025

280
60 260 4x ø11.2

55 240
4x ø10
50 220

45 200 4x ø9

40 180 4x ø8.1
160
35 2x ø11.2
4x ø7.3
140
30 2x ø10
4x ø6.6
120
25 4x ø6 + fast
100
20
80
15
60
10 40
5 20

0 0
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

Article numbers 96900004XX (TJ40G Burst)

Burst machines: + 5 m3/h

28
 8 Technical data
TJ40G

Article numbers 96900003XX (TJ40G)

Impact throw length

m ft. Nozzles mm
32 105 4116-0010

4x ø11.2
29.5
4x ø10
4x ø9
90 4x ø8.1
27
4x ø7.3
4x ø6.6
24.5
4x ø6
75
22

19.5
60 4x ø11.2
17 4x ø10
4x ø9
4x ø8.1
4x ø7.3
14.5 4x ø6.6
45 4x ø6

12

9.5
30
A
7 B

4.5 15
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

A: Max. static

TD523321 B: Effective

Note: Throw lengths are measured as horizontal throw length at static condition. Vertical throw length upwards is approx. 1/3
less. Throw lengths are defined and measured as given in Alfa Laval Technical Specification 93P003. Effective throw length
varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent. The inlet
pressure has been taken immediately before the machine inlet. In order to achieve the performance indicated in the curves, the
pressure drop in the supply lines between pump and machine must be taken into consideration.

29
8 Technical data
TJ40G

Article numbers 96900003XX (TJ40G)

Cleaning time for complete pattern (= 8 cycles)

Sec. pr. rev. PTM (Pattern Time Munutes)

[sec] [min] Nozzles mm
4116-0027
55.0
40 52.5
50.0
47.5
35
45.0
42.5
30 40.0
37.5
35.0
25 32.5
30.0 2x ø11.2
27.5
20
25.0
22.5
15 20.0
17.5 2x ø10
15.0 4x ø11.2
10 12.5 4x ø10
4x ø9
10.0 4x ø8.1
7.5 4x ø7.3
5 4x ø6.6
4x ø6
5.0 4x ø6 fast
2.5
0 0
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

30
 8 Technical data
TJ40G

8.2 Performance data for TJ40G-HD

Article numbers 96900002XX (TJ40G-HD)

Flow rate
m3/h USgpm Nozzles mm
65
4116-0026

280 4x ø11.2
60
260
55 240 4x ø10

50 220
4x ø9
45 200
4x ø8.1
40 180
160 2x Ø11.2
35 4x ø7.3
140 2x Ø10
30 4x ø6.6
120 4x ø6 + fast
25
100
20
80
15
60
10 40
5 20

0 0
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

Article numbers 96900001XX (TJ40G-HD Burst)

Burst machines: + 5 m3/h

31
8 Technical data
TJ40G

Article numbers 96900002XX (TJ40G-HD)

Impact throw length

m ft. Nozzles mm
32 105 4116-0010

4x ø11.2
29.5
4x ø10
4x ø9
90 4x ø8.1
27
4x ø7.3
4x ø6.6
24.5
4x ø6
75
22

19.5
60 4x ø11.2
17 4x ø10
4x ø9
4x ø8.1
4x ø7.3
14.5 4x ø6.6
45 4x ø6

12

9.5
30
A
7 B

4.5 15
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

A: Max. static

TD523321 B: Effective

Note: Throw lengths are measured as horizontal throw length at static condition. Vertical throw length upwards is approx. 1/3
less. Throw lengths are defined and measured as given in Alfa Laval Technical Specification 93P003. Effective throw length
varies depending on jet transverse speed over surface, substance to be removed, cleaning procedure and agent. The inlet
pressure has been taken immediately before the machine inlet. In order to achieve the performance indicated in the curves, the
pressure drop in the supply lines between pump and machine must be taken into consideration.

32
 8 Technical data
TJ40G

Article numbers 96900002XX (TJ40G-HD)

Cleaning time for complete pattern (= 8 cycles)

Sec. pr. rev. PTM (Pattern Time Munutes)

[sec] [min] Nozzles mm
4116-0028
50.0
40 47.5
45.0

35 42.5
40.0
37.5
30
35.0
32.5
25 30.0
27.5 2x ø11.2

25.0
20
22.5
20.0
15 17.5
2x ø10
15.0 4x ø11.2

10 12.5 4x ø10
10.0 4x ø9
4x ø8.1
7.5 4x ø7.3
5 4x ø6.6
5.0 4x ø6
4x ø6 fast
2.5
0 0
0 25 50 75 100 125 150 175
psi
0 1 2 3 4 5 6 7 8 9 10 11 12 bar

Inlet pressure

33
9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.1 Standard Configurations

Standard Heavy Duty (HD) Documentation

Configuration Item number Item number Q-Doc ATEX/IECEx
4 x Ø6, fast 9690 - 0003 - 01 9690 - 0002 - 01
4 x Ø6 9690 - 0003 - 02 9690 - 0002 - 02
4 x Ø6.6 9690 - 0003 - 03 9690 - 0002 - 03
4 x Ø7.3 9690 - 0003 - 04 9690 - 0002 - 04
4 x Ø8.1 9690 - 0003 - 05 9690 - 0002 - 05
4 x Ø9 9690 - 0003 - 06 9690 - 0002 - 06
4 x Ø10 9690 - 0003 - 07 9690 - 0002 - 07
4 x Ø11.2 9690 - 0003 - 08 9690 - 0002 - 08
4 x Ø6, fast 9690 - 0003 - 09 9690 - 0002 - 09 x
4 x Ø6 9690 - 0003 - 10 9690 - 0002 - 10 x
4 x Ø6.6 9690 - 0003 - 11 9690 - 0002 - 11 x
4 x Ø7.3 9690 - 0003 - 12 9690 - 0002 - 12 x
4 x Ø8.1 9690 - 0003 - 13 9690 - 0002 - 13 x
4 x Ø9 9690 - 0003 - 14 9690 - 0002 - 14 x
4 x Ø10 9690 - 0003 - 15 9690 - 0002 - 15 x
4 x Ø11.2 9690 - 0003 - 16 9690 - 0002 - 16 x
4 x Ø6, fast 9690 - 0003 - 17 9690 - 0002 - 17 x
4 x Ø6 9690 - 0003 - 18 9690 - 0002 - 18 x
4 x Ø6.6 9690 - 0003 - 19 9690 - 0002 - 19 x
4 x Ø7.3 9690 - 0003 - 20 9690 - 0002 - 20 x
4 x Ø8.1 9690 - 0003 - 21 9690 - 0002 - 21 x
4 x Ø9 9690 - 0003 - 22 9690 - 0002 - 22 x
4 x Ø10 9690 - 0003 - 23 9690 - 0002 - 23 x
4 x Ø11.2 9690 - 0003 - 24 9690 - 0002 - 24 x
4 x Ø6, fast 9690 - 0003 - 25 9690 - 0002 - 25 x x
4 x Ø6 9690 - 0003 - 26 9690 - 0002 - 26 x x
4 x Ø6.6 9690 - 0003 - 27 9690 - 0002 - 27 x x
4 x Ø7.3 9690 - 0003 - 28 9690 - 0002 - 28 x x
4 x Ø8.1 9690 - 0003 - 29 9690 - 0002 - 29 x x
4 x Ø9 9690 - 0003 - 30 9690 - 0002 - 30 x x
4 x Ø10 9690 - 0003 - 31 9690 - 0002 - 31 x x
4 x Ø11.2 9690 - 0003 - 32 9690 - 0002 - 32 x x
2 x Ø10 9690 - 0003 - 39 9690 - 0002 - 39
2 x Ø10 9690 - 0003 - 47 9690 - 0002 - 47 x
2 x Ø10 9690 - 0003 - 55 9690 - 0002 - 55 x
2 x Ø10 9690 - 0003 - 63 9690 - 0002 - 63 x x
2 x Ø11.2 9690 - 0003 - 40 9690 - 0002 - 40
2 x Ø11.2 9690 - 0003 - 48 9690 - 0002 - 48 x
2 x Ø11.2 9690 - 0003 - 56 9690 - 0002 - 46 x
2 x Ø11.2 9690 - 0003 - 64 9690 - 0002 - 64 x x

34
 9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.2 Standard Configurations, Burst

Standard, Burst Heavy Duty (HD), Burst Documentation

Configuration Item number Item number Q-Doc ATEX/IECEx
4 x Ø6, fast 9690 - 0001 - 01 9690 - 0004 - 01
4 x Ø6 9690 - 0001 - 02 9690 - 0004 - 02
4 x Ø6.6 9690 - 0001 - 03 9690 - 0004 - 03
4 x Ø7.3 9690 - 0001 - 04 9690 - 0004 - 04
4 x Ø8.1 9690 - 0001 - 05 9690 - 0004 - 05
4 x Ø9 9690 - 0001 - 06 9690 - 0004 - 06
4 x Ø10 9690 - 0001 - 07 9690 - 0004 - 07
4 x Ø11.2 9690 - 0001 - 08 9690 - 0004 - 08
4 x Ø6, fast 9690 - 0001 - 09 9690 - 0004 - 09 x
4 x Ø6 9690 - 0001 - 10 9690 - 0004 - 10 x
4 x Ø6.6 9690 - 0001 - 11 9690 - 0004 - 11 x
4 x Ø7.3 9690 - 0001 - 12 9690 - 0004 - 12 x
4 x Ø8.1 9690 - 0001 - 13 9690 - 0004 - 13 x
4 x Ø9 9690 - 0001 - 14 9690 - 0004 - 14 x
4 x Ø10 9690 - 0001 - 15 9690 - 0004 - 15 x
4 x Ø11.2 9690 - 0001 - 16 9690 - 0004 - 16 x
4 x Ø6, fast 9690 - 0001 - 17 9690 - 0004 - 17 x
4 x Ø6 9690 - 0001 - 18 9690 - 0004 - 18 x
4 x Ø6.6 9690 - 0001 - 19 9690 - 0004 - 19 x
4 x Ø7.3 9690 - 0001 - 20 9690 - 0004 - 20 x
4 x Ø8.1 9690 - 0001 - 21 9690 - 0004 - 21 x
4 x Ø9 9690 - 0001 - 22 9690 - 0004 - 22 x
4 x Ø10 9690 - 0001 - 23 9690 - 0004 - 23 x
4 x Ø11.2 9690 - 0001 - 24 9690 - 0004 - 24 x
4 x Ø6, fast 9690 - 0001 - 25 9690 - 0004 - 25 x x
4 x Ø6 9690 - 0001 - 26 9690 - 0004 - 26 x x
4 x Ø6.6 9690 - 0001 - 27 9690 - 0004 - 27 x x
4 x Ø7.3 9690 - 0001 - 28 9690 - 0004 - 28 x x
4 x Ø8.1 9690 - 0001 - 29 9690 - 0004 - 29 x x
4 x Ø9 9690 - 0001 - 30 9690 - 0004 - 30 x x
4 x Ø10 9690 - 0001 - 31 9690 - 0004 - 31 x x
4 x Ø11.2 9690 - 0001 - 32 9690 - 0004 - 32 x x
2 x Ø10 9690 - 0001 - 39 9690 - 0004 - 39
2 x Ø10 9690 - 0001 - 47 9690 - 0004 - 47 x
2 x Ø10 9690 - 0001 - 55 9690 - 0004 - 55 x
2 x Ø10 9690 - 0001 - 63 9690 - 0004 - 63 x x
2 x Ø11.2 9690 - 0001 - 40 9690 - 0004 - 40
2 x Ø11.2 9690 - 0001 - 48 9690 - 0004 - 48 x
2 x Ø11.2 9690 - 0001 - 56 9690 - 0004 - 46 x
2 x Ø11.2 9690 - 0001 - 64 9690 - 0004 - 64 x x

35
9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.3 Available Add-ons

Explanation to Add-ons

Equipment Documentation includes:

- EN 1935/2004 DoC
- EN 10204 type 3.1 inspection Certificate and DoC
Q-doc - FDA DoC
(Equipment Documentation) - GMP EC 2023/2006 DoC
- EU 10/2011 DoC
- ADI DoC
- QC DoC

ATEX/IECEx includes:
ATEX/IECEx certified machine for use in explosive atmospheres. Category 1
ATEX/IECEx for installation in zone 0/20 in accordance with directive 2014/34/EU.
II 1G Ex h IIC 85°C…175°C Ga
II 1D Ex h IIIC T85°C…T140°C Da

9.4 Available add-ons for spare parts

Item no. Description

Q-doc including
Q-doc - EN 1935/2004 DoC
9690003102 - EN 10204 type 3.1 inspection Certificate and DoC
or - FDA DoC
9690006202 - GMP EC 2023/2006 DoC
- EU 10/2011 DoC
or - ADI DoC
9690006502 - QC DoC

36
 9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.5 Available welding and thread adaptors

Welding adapter (see right) with sealing assembly between down pipe, welding adapter and machine. Welding connections
are ordered separately. For use with sanitary connection cones use cone with seal (seals are included for machines with
sanitary cone).
A: Down pipe
Item no.:* Down pipe** B: Welding adapter
9690006601 2"ISO pipe

4116-0004
9690006602 DN65R2 C: Seal PTFE
9690006603 2½"Dairy pipe D: Seal EPDM
9690006604 2"NPT (male)
9690006605 DN50R2
9690006606 DN40R1
9690006607 2"Dairy pipe
9690006608 1½"ISO pipe
9690006609 1½"NPT (male)
9690006610 1½"ISO (male)
9690006611 1½” ISO (female)
9690006612 2” ISO (female)
9690006613 1½" NPT (female)
9690006614 2” NPT (female)

* Includes gaskets for sanitary installation

** Either Dimension or existing thread on pipe

37
9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.6 Overview of guide and turbine combinations - 4 nozzles

4116-0012

38
 9 Product programme
This manual covers the product program for Alfa Laval Toftejorg TJ40G tank cleaning machine

9.7 Overview of guide and turbine combinations - 2 nozzles

4116-0024

39
10 Parts drawings, parts lists, service kits and tools
TJ40G

10.1 Alfa Laval Toftejorg TJ40G

31

32

30

24

26

22

25

21

20

19

23

18

17

15

16

14

13

12

22

11

8 4116-0001

7
10 1 27 28 29 3 4 2 6

40
 10 Parts drawings, parts lists, service kits and tools
TJ40G

Parts list Service kits

Denomination
Pos. Qty Denomination
Service kits
1 1 Body
2 1 Minor service kit TJ40G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9690003101
 O-ring
3 1 Hub Minor service kit TJ40G - Q-Doc . . . . . . . . . . . . . . . . . . . . . 9690003102
4  2 Ball race Major service kit TJ40G. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9690006201
5  2 Ball retainer w. balls Major service kit TJ40G-HD - Q-Doc . . . . . . . . . . . . . . . . . 9690006202
6  1 Hub nut
7 1 Gear ring
8 6 Seal ring
9  1 Bearing f. body
10 3 Screw f. body
11 1 Stem
12  1 Stem nut
13 1 Gear frame
14 2 Shaft f. planet gear
15  1 Gear wheel I
16  1 Gear wheel II
17  1 Bushing f. planet gear
18 1 Impeller shaft
19  1 Impeller
20 2 O-ring
21 1 Shaft end
22  2 O-ring
23  1 O-ring
24 1 Cone
25  1 Guide
26  1 Bearing f. turbine top
27.1  4/2 Nozzle
 4/2 Nozzle, Burst
27.2  0/2 Blind cap
28 20/10 Nozzle vane
29  4 O-ring
30 1 Gasket f. cone - inside

¬ Configuration according to delivery note/order.

Parts marked with  are included in the Minor Service Kit for TJ40G: 96900031XX
Parts marked with ˆ are included in the Major Service Kit for TJ40G: 96900062XX

See page 36 for more information on available add-ons.

41
10 Parts drawings, parts lists, service kits and tools
TJ40G-HD

10.2 Alfa Laval Toftejorg TJ40G-HD

31

32

30

24

26

22

25

21

20

19

23

18

17

15

16

14

13

12

22

11

8 4116-0001

7
10 1 27 28 29 3 4 2 6

42
 10 Parts drawings, parts lists, service kits and tools
TJ40G-HD

Parts list Service kits

Denomination
Pos. Qty Denomination
Service kits
1 1 Body
2 1 Minor service kit TJ40G-HD . . . . . . . . . . . . . . . . . . . . . . . . . . 9690003101
 O-ring
3 1 Hub Minor service kit TJ40G-HD - Q-Doc . . . . . . . . . . . . . . . . . 9690003102
4  2 Ball race Major service kit TJ40G-HD . . . . . . . . . . . . . . . . . . . . . . . . . . 9690006501
5  2 Ball retainer w. balls Major service kit TJ40G-HD - Q-Doc . . . . . . . . . . . . . . . . . 9690006502
6  1 Hub nut - HD
7 1 Gear ring
8 6 Seal ring
9  1 Bearing f. body
10 3 Screw f. body
11 1 Stem
12  1 Stem nut - HD
13 1 Gear frame
14 2 Shaft f. planet gear
15  1 Gear wheel I
16  1 Gear wheel II
17  1 Bushing f. planet gear
18 1 Impeller shaft
19  1 Impeller
20 2 O-ring
21 1 Shaft end
22  2 O-ring
23  1 O-ring
24 1 Cone
25  1 Guide
26  1 Bearing f. turbine top
27.1  4/2 Nozzle
 4/2 Nozzle, Burst
27.2  0/2 Blind cap
28 20/10 Nozzle vane
29  4 O-ring
30 1 Gasket f. cone - inside

¬ Configuration according to delivery note/order.

Parts marked with  are included in the Minor Service Kit for TJ40G-HD: 96900031XX
Parts marked with ˆ are included in the Major Service Kit for TJ40G-HD: 96900065XX

See page 36 for more information on available add-ons.

43
10 Parts drawings, parts lists, service kits and tools
TJ40G

10.3 Tools

Alfa Laval Toftejorg TJ40G Tool kit

Article number TE81B149

Denomination Qty x tool item number

Fixture f. Impeller 1 x TE20J591
5 mm calipers 1 x TE369
Ring fork key NV24 1 x TE81B140
NV8 socket long 1 x TE81B157
Torque wrench 1/4" 5 - 25 Nm 1 x TE81B156
Pin punch ø8 1 x TE81B148
Ring fork key NV65 1 x TE81B147

Other tools f. TJ40G

Denomination Item number

Ball race tool f. TJ40G 9690007801
Nut tool 9690007901
Socket f. TJ40G nozzles 9690008001
4116-0032

44
 11 General information
TJ40G

11.1 Service and repair

Upon every return of a product, no matter if for modifications or repair, it is necessary to contact your local Alfa Laval office to
guarantee a quick execution of your request.

You will receive instructions regarding the return procedure from your local Alfa Laval office. Be sure to follow the instructions
closely.

11.2 How to order spare parts

On the parts drawings as well as on all instruction drawings, the individual parts have a position number, which is the same on all
drawings. From the position number, the part is easily identified in the parts lists, page 40 ff.

Individual parts should always be ordered from the parts lists, page 40 ff. Item number and denomination should be clearly
stated. Please refer to the Spare Part Manual for information on item numbers. The Spare Part manual is available from the
on-line Alfa Laval product catalogue Anytime or the Close at hand spare part catalogue.

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.

In cases where spare parts are ordered for machines originally delivered with 3.1 certificates, please state this information on
your ordering form together with the machine type and serial number. This is to ensure full traceability henceforward.

11.3 How to contact Alfa Laval Kolding A/S

For further information please feel free to contact:

Alfa Laval Kolding A/S

31, Albuen - DK 6000 Kolding - Denmark
Registration number: 30938011
Tel switchboard: +45 79 32 22 00 - Fax switchboard: +45 79 32 25 80
www.toftejorg.com, www.alfalaval.dk - info.dk@alfalaval.com

Contact details for all countries are continually updated on our websites

45
12 Miscellaneous
TJ40G

12.1 Declaration of Conformity, EN 10474, sub clause 2.2 Test Report

46
 12 Miscellaneous
TJ40G

47
12 Miscellaneous
TJ40G

12.2 Declaration of Complaince with 10/2011 – Food contact materials

48
49
How to contact Alfa Laval
Contact details for all countries are
continually updated on our website.
Please visit www.alfalaval.com to access the information directly.

© Alfa Laval Corporate AB

This document and its contents is owned by Alfa Laval Corporate AB and protected by laws governing intellectual property and thereto related rights. It is the responsibility of the user of this
document to comply with all applicable intellectual property laws. Without limiting any rights related to this document, no part of this document may be copied, reproduced or transmitted in any
form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the expressed permission of Alfa Laval Corporate AB. Alfa Laval Corporate AB
will enforce its rights related to this document to the fullest extent of the law, including the seeking of criminal prosecution.