CSI GamaJet V Bedienungsanleitung

V. 3/03C

GamaJet V

OWNER'S MANUAL

MANUFACTURING,

SALES & SERVICE

TABLE OF CONTENTS

1. Introduction

1.1 Description

1.2 Installation of New Machines

1.2.1 Assembl

1.2.2 Inlet Connections

1.2.3 Mounting

1.2.4 Location inside the Tan

1.2.5 Entry Openin

1.2.6 Drainage

1.2.7 Filters or Strainers

1.2.8 Capacity of Supply Pum

1.3 Safety

2. Disassembly, Repair, and Reassembly

2.1 Tools required

2.2 General Disassembly

2.3 Inspection & Service of Components

2.3.1 Nozzle Housing

2.3.2 Tee Housing

2.3.3 Gearbox

2.3.4 Gearbox Nose

2.3.5 Stem

2.4 Reassembly

3. Preventative Maintenance

3.1 Storage

3.2 Gearbox Maintenance

3.3 Inspection Interval

3.4 Tips

4. Troubleshooting Guide

4.1 Tee Housing does not rotate

4.2 Nozzle Housing rotates slowly or not at all

4.3 Cleaning Solution leakage

4.4 Poor cleaning performance

5. Appendi

A. Dimensional Data & Technical Specifications

B. Parts List & Exploded View

C. Performance Data

1© Gamajet Cleaning Systems, Inc. 10/24/01

1. INTRODUCTION

1.1 DESCRIPTION

The Gamajet V is a fluid-driven (turbine-driven) 360° or 180°

Directional rotary nozzle

machine designed for cleaning the interior surfaces of a wide variety of small process,

transport and storage tanks or tanks with a minimum opening of 3 inches (76.2 mm) in

diameter. It is powered entirely by the cleaning solution; it requires no electricity or

compressed air or lubricant for operation. The Gamajet V is designed primarily for

portable service; the unit may also be permanently installed in a vessel. If the Gamajet V

is permanently mounted inside a tank, we strongly recommend that you inspect the unit

every few hundred hours of operation (see section 3 for details about Preventative

Maintenance).

WARNING:Under no conditions whatsoever should the Gamajet V ever be

immersed in anything. Failure to comply with this restriction will void the

warranty!!

To handle the broadest possible range of applications, the Gamajet V is available in

stainless steel construction with dual and triple nozzles, and an extensive selection of

nozzle sizes, stators, O-ring material and gear ratios. Gamajet nozzles are available in

seven interchangeable sizes - 0.110", 0.125", 0.135", 0.150", 0.165", 0.187", and 0.200".

Longer nozzles are available for tougher deposits but require a 3-1/2" opening; optional

smaller and larger orifice diameters are also available. The standard 0.187" nozzle is

recommended for normal use in tank cleaning. The Gamajet wash cycle time can be

adjusted for special applications by changing the stators, nozzle sizes, and gears.

Interchangeable stators (non-rotating turbine), nozzle sizes, and gears are available for

either low or high pressures and/or flow rates. The performance capabilities of these

options are detailed in Appendix C. A complete description of the technical

specifications and materials of construction of the Gamajet V is contained in Appendix

1.2 INSTALLATION OF NEW MACHINES

1.2.1 ASSEMBLY

Every Gamajet is operationally tested before shipment and is ready to run after

unpacking. No assembly is required prior to use. Your Gamajet has also been

configured to meet the operating conditions that you have given us, e.g. pressure,

flow, temperature, cycle time, etc.

1.2.2 INLET CONNECTIONS

The Gamajet V is supplied with a 1-1/4" NPT female inlet connection. It is

recommended that the mating male thread should be wrapped with PTFE pipe

2© Gamajet Cleaning Systems, Inc. 10/24/01

joint tape prior to mounting. This will minimize any chance of leakage and will

make subsequent removal much easier.

1.2.3 MOUNTING

While the dual nozzle unit is hydraulically balanced, the Gamajet V should be

mounted on a rigid pipe. In most applications, the Gamajet V will be mounted in

the "upright" position (inlet connection pointing up); however, if required, the

Gamajet will function equally well inverted or horizontally. We do not

recommend this form of mounting since the hose is not rigid and, thus, will not

maintain the Gamajet's position should it become unbalanced due to clogging of

the nozzles.

NOTE: When attaching the Gamajet V onto the supply pipe, ALWAYS use the

wrench flats on the Inlet Collar at the top or inlet of the unit. Never place the

wrench on the outside of the gearbox, or bottom, of the unit to tighten the

unit onto the pipe. If you do, you'll unscrew the unit or break internal screws or

both.

1.2.4 LOCATION INSIDE THE TANK

Generally, a single Gamajet should be positioned in the approximate center of the

tank in order to equalize the cleaning radius in all directions. Some tanks may

have specific cleaning problems such as coils or heavy deposits such as the liquid

level line (bathtub ring). In these situations the Gamajet will need to be located

closer to the difficult area for the best cleaning results.

Tanks with internal mechanisms or structures such as an agitator shaft or

impellers or baffles will require careful positioning to minimize the "shadow" on

areas which do not receive direct jet impact. Sometimes, more than one machine

or more than one placement of a single machine may be necessary to completely

avoid shadow problems or “striping.”

Refer to Appendix A for dimensions describing the Gamajet's operating

clearances.

1.2.5 ENTRY OPENINGS

When using the Gamajet V, the tanks being cleaned must provide entry openings

large enough to avoid interference during insertion and removal. The minimum

opening size required for the Gamajet V is 3.0 inches in diameter (76.2 mm).

1.2.6 DRAINAGE

If it is necessary to clean the floor of a tank, remember that standing liquid will

diminish the effectiveness of the jet by covering any soils underneath. Wherever

possible, the tank floor should be pitched toward the drain and the drainage

opening should be large enough to eliminate or reduce any liquid buildup or

puddling. If gravity alone is insufficient, a scavenger or stripper pump should be

3© Gamajet Cleaning Systems, Inc. 10/24/01

connected to the drain to suck out the wash fluid as fast as the Gamajet is putting

it in. In extreme cases, it may be necessary to mount smaller nozzles on the

Gamajet, or even to operate it intermittently to allow time for draining.

1.2.7 FILTERS OR STRAINERS

All tank cleaning systems should be equipped with a filter or strainer that will trap

solids 1/16" or larger, as these will not pass through the Gamajet. These large

particles will not harm the machine, but they can become caught in the turbines or

nozzles and cause it to stop turning or to reduce its cleaning effectiveness due to

loss of flow. It will then be necessary to disassemble the Gamajet and remove the

blockage.

In recirculating cleaning or any other application where the cleaning solution may

carry abrasive solids in suspension, adequate filtration is a must. These particles

can be extremely destructive to the Gamajet, as well as pumps, valves, and other

system components. Filters, properly installed and maintained, will more than pay

for themselves with lower overall operating costs in these applications.

Furthermore, to ensure that clogged filters or strainers are cleaned, we recommend

that you use automatic self-cleaning models.

1.2.8 CAPACITY OF SUPPLY PUMP

The Gamajet V should be sized to match the pressure and flow capability of the

supply pump at its best efficiency point (BEP). For example, if the pump is rated

for 23 GPM at 250 PSI, then the nozzles for the Gamajet V must be configured

for the same 23 GPM at 250 PSI. If not, then you will increase the probability of

experiencing premature failure of Gamajet V parts as well as shaft seals on the

pump the farther away from the BEP that you operate the pump. You may void

the Gamajet V warranty.

For high-pressure applications (over 300 psig), the pump must “ramp up”

slowly (at least 15 seconds) to its operating pressure. If the pump goes from a

standstill to operating pressure in about 1 second or less and if there is no

dampening or slow-opening valve between the pump and the Gamajet, you will

experience premature failure of Gamajet V parts (most likely, certain gears). This

is because of a water hammer effect or a pressure spike.

1.3 SAFETY

When Gamajets are operating, there should be covers over any tank openings. These

covers should be sealed well enough to withstand the full force of the jet striking the

cover plate. If the cleaning solution is hot, corrosive, or toxic a leak would present a

serious hazard to any personnel in the immediate vicinity or to any exposed electrical

equipment.

4© Gamajet Cleaning Systems, Inc. 10/24/01

WARNING

Any tank cleaning machine can develop a static electricity charge while in

operation. If the tank being cleaned contains a combustible liquid or

vapor having a considerable risk of ignition or explosion, it is imperative

to that the Gamajet be properly grounded.

5© Gamajet Cleaning Systems, Inc. 10/24/01

2. DISASSEMBLY, REPAIR, AND REASSEMBLY

2.1 TOOLS REQUIRED

Point Head Pliers (Needle Nose Pliers)

9/64", 7/64", and 5/64” Hex Ball-point L-wrenches (7/64" Allen Wrench)

Screwdrivers (both Slotted (flat blade) & Phillips)

11/32" Hex Deep Socket

7/16" Hex Deep Socket

Socket Wrench Ratchet Handle

2" Socket Extension

Bench Vise (4-6" jaw opening)

No. 3 Arbor Press (3 ton) or Hammer

Micrometer (0-6" Digital or Dial Calipers)

2.2 GENERAL DISASSEMBLY

Note: The reference numbers appearing below may be used to identify parts in the

exploded view (numbers enclosed in circular box) in Appendix B.

2.2.1 Remove the Stem Collar Retainer Screw #36 with the appropriate Hex Ball-point

L-wrench. If not removed, be sure to unscrew the Retainer Screw far enough so that

its top extends beyond the surface of the Inlet Stem Collar.

Do not mistake or confuse the Gearhead Retainer Screw #2, at the bottom of the unit,

with the Stem Collar Retainer Screw, at the top. If you do, immediately tighten the

Gearhead Retainer Screw before twisting or rotating any parts of the unit.

2.2.2 Unscrew the Inlet Stem Collar #37 from the Stem #24.

WARNING:This is a left-hand thread, so turn the Collar CLOCKWISE to

unscrew it! The unit must be in the vertical position, standing on its base when

unscrewing the Inlet Stem Collar; otherwise, the threads will gall.

If the Collar feels like it is binding on the threads, DO NOT force the Collar to turn by

applying more force with a wrench as you will damage the threads; rather, keep spraying

a Teflon-based penetrating solution into the threads and work the solution into the threads

by turning the collar back and forth until it works loose. Lift out the Stator #28.

2.2.3 Insert a Screwdriver between the vanes of the Rotor #25 (to prevent it from

turning) and unscrew the Rotor Retaining Nut #27 with 11/32" Deep Socket and 2"

Extension. Lift out the Rotor with the Pliers or invert the machine and shake it out.

2.2.4 Lift the Tee Housing #35 (#55 for Directional) off the Stem #24. If the Tee

Housing cannot be removed easily, pry carefully at the gap between the Tee Housing and

the Gearbox Nose #14.

6© Gamajet Cleaning Systems, Inc. 10/24/01

2.2.5 Remove the two Nameplate Screws #47 with a Slotted Screwdriver and pull the

Nozzle Housing #44 (#56 for Directional) off the Tee Housing #35/#55. If tight Bearings

prevent removal, pry carefully between the Nozzle Housing and Tee Housing.

2.2.6 Unscrew the four Gearbox Screws #22 with a 7/64" Hex Ball-point L-wrench and

pull the Gearbox #1 off the Gearbox Nose #14.

2.2.7 Unscrew the four Gearbox Nose-Stem Screws #10 with a 7/64" Hex Ball-point L-

wrench and pull the Gearbox Nose #14 off the Stem #24.

2.3 INSPECTION AND SERVICE OF COMPONENTS

2.3.1 NOZZLE HOUSING #44/#56

2.3.1.1 Nozzle #45

Unscrew the Nozzle Tips with a 7/16" Socket and inspect for debris

plugging the Stream Straightener #49. Remove the Stream Straighteners

for cleaning by pressing them out with a small rod inserted through the

Nozzle bore.

The Nozzle bores must be smooth, round, and free of damage (especially

any nicks) for maximum jet impact. Replace worn or oversized nozzles if

the original flow rate is required. The Stream Straighteners must be

reinstalled in the Nozzle Tips if they were removed for cleaning.

2.3.1.2 Bevel Gear #42 (#58 Spur Gear in Directional)

Remove the Bevel Gear Retaining Ring #41 with a Slotted Screwdriver

and lift off the Nozzle Housing Bevel Gear #42/#58. Inspect the Bevel

Gear for wear such as sharp/pointed or broken teeth, and replace as

required.

2.3.1.3 Clutch O-ring #43 [Not Used in New Production]

Removing the Nozzle Housing Bevel Gear #42/#58 will expose the Clutch

O-ring #43 on the Nozzle Housing. Inspect the O-ring and replace it if it

is worn out (deeply sunken into its groove or chemically eroded), or if it

has become hardened or deformed. Inspect also for wear (such as the

presence of metal shavings) caused by slippage between the Nozzle

Housing Bevel Gear and the Nozzle Housing #44/#56. Slippage can result

from incorrectly installed Nozzle Housing Bearings #38/#59 (#59 for

Directional), deposit build-up, or anything else that could make the Nozzle

Housing difficult to turn.

2.3.1.4 Nozzle Housing Bearings #38/#59

Inspect the Nozzle Housing Bearings #38/#59 and discard any that are

broken, cracked, or deeply scored. Clean any deposits from the bearings

7© Gamajet Cleaning Systems, Inc. 10/24/01

and check their fit in the Nozzle Housing Cup #40 (#60 for Directional

Machine). While they should turn freely in their Cups, the Nozzle

Housing Bearings should be replaced if the diameter of the outside wall is

less than 0.990" to avoid shortening the life of the Seals or Bevel Gears.

2.3.1.5 Nozzle Housing Seals #39 (#61 for Directional)

Examine the Nozzle Housing Seals #39/#61 for loss of spring tension

(indicated by excessive dry deposits of dirty or abrasive cleaning solution

on the spring) or excessive wear on the sealing lips (the sealing lips are

worn smooth) and replace as required. When installing the Seal, make

sure that the spring side of the Seal faces towards the Nozzle Housing Cup

#40/#60.

2.3.1.6 Nozzle Housing Cups #40/#60

Clean any deposits from the Cups and examine for excessive wear. Light

scoring is acceptable, but the Cups should be replaced if they are grooved

in the seal contact area or if the diameter of their inside wall is greater

than 1.020".

If you have many Gamajet units (about 2 dozen or more), you will be

replacing many cups as part of a good maintenance program. Therefore, it

may be worthwhile to make or obtain press tools for pressing the Cups off

of the Nozzle Housing. The press tools are available from Gamajet

Cleaning Systems as part of the repair kit.

Before installing new Cups, clean the housing bores and remove any burrs

resulting from Cup removal. Lubricate the outside of the new Cups and

press them in so that their flanges are fully and flush-seated against the

Housing.

2.3.1.7 Reassembly

If the Nozzle Housing Bearing Cups #40/#60 need to be replaced, refer to

section 2.3.1.6 for installation. If the Clutch O-ring #43 was removed,

replace the old one with a new one and use a flat screwdriver blade to

press it evenly all the way around into its groove. Place the Nozzle

Housing Bevel Gear #42/#58 on the Nozzle Housing, install the Bevel

Gear Retaining Ring #41 and verify that it is fully seated in its groove all

the way around; also verify that the I.D. of the Ring does not extend

inwards into the path of the teeth of the Bevel Gear. Screw in the Nozzle

Tip #45 and tighten with a 7/16" socket. The Nozzle Housing Bearings

#38/#59 and Nozzle Housing Seals #39/#61 will be assembled later when

the Nozzle Housing #44/#56 is remounted onto the Tee Housing #35/#55;

refer to steps 2.4.3 to 2.4.6 for details.

2.3.2 TEE HOUSING #35/#55

2.3.2.1 Disassembly

Remove the Ring Gear Retaining Ring #29 with a Slotted Screwdriver and

lift out the Ring Gear #30. If the Gear is tight in the Tee Housing #35/#55,

carefully pry it out with flat screwdrivers. Next, lift out the Tee Housing

Bevel Gear #31, Tee Housing Bearings #32, and Tee Housing Seals #33.

2.3.2.2 Tee Housing #35/#55

Inspect the Tee Housing #35/#55 for damage to the Tee Housing key way

that engages the Ring Gear #30. If the Ring Gear was difficult to remove,

check to see if the Tee Housing is out-of-round (as the result of an external

blow, such as dropping) where the Gear seats.

2.3.2.3 Bevel Gear #31

Inspect the Tee Housing Bevel Gear #31 for worn, damaged or

sharp/pointed teeth, and for damage to the key that engages the slot on the

Gearbox Nose #14.

2.3.2.4 Ring Gear #30

Inspect the Ring Gear #30 for worn, damaged or sharp/pointed teeth, and

for damage to the key that engages the slot on the Tee Housing #35/#55.

2.3.2.5 Tee Housing Bearing #32

Inspect the Tee Housing Bearings #32 and discard any that are broken,

cracked, or deeply scored. Clean any deposits from the Bearings and

check their fit in the Tee Housing Bearing Cups #34. While they should

turn freely in their Cups, the Tee Housing Bearings should be replaced if

the diameter of the outside wall is less than 1.490" to avoid shortening

the life of the Seals or Bevel Gears.

2.3.2.6 Tee Housing Seals #33

Examine the Seals for loss of spring tension (indicated by excessive dry

deposits of dirty or abrasive cleaning solution on the spring) or excessive

wear on the sealing lips (the sealing lip is worn to a smooth surface) and

replace as required. When installing the Seals, make sure that the spring

side of the Seal faces towards the Tee Housing Bearing Cup #34.

2.3.2.7 Tee Housing Bearing Cups #34

Clean any deposits from the Cups and examine for excessive wear. Light

scoring is acceptable, but the cups should be replaced if they are grooved

in the seal contact area or if the diameter of their inside wall is greater

than 1.520". If the Bearing Cups require replacement, follow the

procedure given for the Nozzle Housing Cups #40/#60 in section 2.3.1.6.

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