OWNER`S MANUAL
Contents
1. AH ANW AT 608 4 QUIL AD N A BBY MOL x Jofeuren uru AMI 91949 Kei OC ST dD 9IE MOJH 001 08 09 OV 07 0 0 _ 2005 90 OS 001 OST 007 SUISNOH 9 ZZON ENG 103 SI ep IV Z Jofewen JIEJUOI IO JILI YING si 0 IJ JUTYOBU Ho ds B Jo JIULUJOJJOA oa OSC JO Ajuo sosodind uonguurs 107 st ydery I 9JON EI u9 WS 00 SIOJ8IS WI X AH NEY MOJ SA 9INSS914 x jolturer DISA 2mssoiq dD Y MOJH 001 08 09 OV OT 0 0 L 2005 90 B SUISNOH 9 ZZON PNG B 103 SI LJep IV 10 8 S POPAS Aq PAJEJJP aq JJIM SOUPULIOHIOd xJ 7 OS SIO 8 S JUQJOJJIP JO FOVAAAV 918 sour oucurojiod Ajuo sasodmd uorjewsa 107 st y deso I 9JON 001 OST 007 OST DS 91 S EI 00 101815 d I PUR QIS A T 608 A AW 9IE MOJH SA ainssarg x jolturer DISd Wnssoig2. OWNER RSsMANUAL Gamajet Cleaning Systems Inc Tel 610 408 9940 604 Jeffers Circle Toll Free 877 GAMAJET Exton PA 19341 2524 Fax 610 408 9945 United States of America E mail sales gamajet com www gamajet com v 8 08 Gamajet Cleaning Systems Inc 2008 All Rights Reserved TABLE OF CONTENTS Le INTRODUCTION dass aia TEDESCRIP HON Stadt notices ati 1 1 2 ICONS USED IN THIS MANTUA LS nissan ondes 1 1 3 INSTALLATION OF NEW MACHINES a 2 1 3 ASO MEL ata taa lali 2 O NN A nv A 2 TO seo ahs LE De 2 1 32 OCA TION INSIDE TAN Saa 2 ON ER E u aan n a taa D w uta a au ata aiaa 3 LAON ESS EL D RATER Een S DS a RAS 3 RoT DILPEBSAND SLRATNERSS ASS a ha una upa usa 3 EROS CAPACITY OR SUPPLY PUMP I Qa ayunaq ukana amia iyun 3 TS INITIARSTARTU Oy a a a ADO MA 4 VAs SAW BAY aa A nhan dit nn 4 2 DISASSEMBLY REPAIR AND REASSEMBLY sm ZA TOOLS REQUIRED ia sai 5 22 GENERAL DISASSEMBEN uri 5 221 CH E RE EE 5 222 NOZZLE HOUSING EE 5 22 3 CNP AND GEAR TRAIN nissan ia ii it i bus 5 224 BODY ASSEMBLY EE 6 2 3 INSPECTION AND SERVICE OF COMPONENTS ss 6 2 91 STA TOR Sua aa q nku a i aa a n u aa ma aQ an awaspa Aa 6 EE 6 2 3 3 PLANETARY GEAR TRAIN ASSEMBLA ads 6 2 3 3 1 General Disassembly and Inspection nn 6 29 2 Geathead We EE H 2 3 3 3 Input Shaft and House ici EE a H 2 3 3 4 Gearhead Lower Bearing Housing and Output Shaft ss 7 2 94 NG ZZEE TIODSINGG S g tn aa q aio 8 2 3 5 TEE HOUSING AND TEE HOUSI
3. 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 risk of ignition or explosion it is imperative to have the Gamajet properly grounded using the provided location on the unit Gamajet X Owner s Manual v 8 08 4 2 Disassembly Repair and Reassembly 2 1 TOOLS REQUIRED Needle Nose Pliers 5 64 3 32 and 5 32 Hex Keys Allen Wrench AP Small and Slotted Screwdrivers AW 1 and 2 Phillips Screwdriver 11 32 Hex Socket and Ratchet or equivalent Nut Driver 4p Razor Blade Brass Pick 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 Notes The appropriate step s in Appendix C is are indicated at the beginning of each section Also for simplicity the 10 prefix to the part number has been eliminated in all of the following instructions 2 2 1 INLET COLLAR Step 21 If used loosen the Grounding Set Screw 163 with a 5 64 Hex Key minimum 2 turns Remove grounding safety wire from loop Loosen the Collar Set Screw 150 with a 3 32 Hex Key minimum 2 turns D DO NOT hold or turn on Tee Housing or Tee Housing Cap Doing so will Remove the Inlet Collar 108 and Stator 109 WARNING Hold or turn on Stem damage the gear train O 2 2 2 NOZZLE HOUSING v Step 20 Unscrew the No
4. In extreme cases 1t may be necessaty to use smaller nozzles on the Gamajet or even to operate it intermittently to allow time for draining 1 3 7 FILTERS AND STRAINERS All tank cleaning systems should be equipped with a filter or strainer that will trap solids 1 16 and larger as these will not pass through the Gamajet These particles can become caught in one of the internal passages of the machine and cause it to stop turning or reduce its cleaning effectiveness due to a loss of flow It will then be necessary to disassemble the Gamajet and remove the blockage In recirculated closed loop 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 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 using automatic self cleaning models 1 3 8 CAPACITY OF SUPPLY PUMP The Gamajet X can be used with either a centrifugal or positive displacement constant volume PD style pump In most cases if the X is to be used with a centrifugal pump the X should be configured so that the pump will operate close to its best efficiency point The end user must therefore take all of the plumbing elevation a
5. from the vessel If you still have puddling build up of the wash fluid so it covers the floor and shields the residues underneath use some form of pump to remove the effluent 4 4 OWNER S MANUAL UPDATES Please visit our web site www gamajet com for information on how to acquire updates to this manual Gamajet X Owner s Manual v 8 08 15 GHHSINHAA ATIVI 911 93dS SI H DIHM Let NVHL Y3HLO 3S OddNd ANY 4 O1 d3SN Y ON AILOSYIGNI YO AU OHIO 40 GHS OdSIC YO 1N31 38 LON TIVHS LNI WN 2 OG SIHL GALIGIH Odd SILNI wd 9Y SHIMOHH O4 NVHL 44HLO 3SN ANY SNOLLINA Odd38 DNI SIN3ISAS ONINVS19 13 VINVO dO AMHIdO d SHLS DNIMVHQ SIHL q Aemabessed ot ull 5uele O Samu GT 018 212 9 USEM IInd UI T4OT 1335 LHHSINOX13 VWVO INA AW OS doo Mayes puna54oj main PPY y 80 21 80 TOW ON DMA ey ZE xla v NV 5 G3HIO 3dS SSIMYSHLO SSTINN HSINI4 NOGA WALS U abu e43 80 AL 80 1 ON ind 43516 SST NIVIS OLE aGuel zs zzoN abueyD z 90 31 80 TON LHAHS LID u ya Sumexd man T 90 80 80 TOW ji S0007 XXX uondu gt sag Ae avd JINMVHQ VCSC IVE6l Vd YOXA OIC PPNO stet 09 ef ww 74 SNOISNANIQ ONI SNALSAS DNINVATO LALVINVD SON NI HV SNOISNAWIO 31419345 SIMHIHLO SSTINN doo 1a es punol g OISd 0S 0105 Bu ey aunssald Wd9 08 0102 93buey moj SLE O 03 10570 Woy abuey Sak JZzON sql S 6 1YBISM si
6. gear train gt If used reattached the grounding safety wire to the unit using the location provided Tighten the Grounding Set Screw 163 using a 5 64 Hex Key This completes the reassembly process Gamajet X Owner s Manual v 8 08 li 3 Preventive Maintenance Note A rigorously implemented preventative maintenance program will significantly reduce repair costs over the life of the Gamajet The foundation of such a program is regularly scheduled inspections to discover and replace worn or damaged parts before they can cause the failure of other more costly components The inspection intervals required will depend on the severity of the application but a complete internal inspection at 100 hours of operation is recommended initially Note Part numbers appearing below may be used to identify parts in Appendix C 3 1 STORAGE The Gamajet should be washed out with clean water after each use to remove any foreign material or soft substances left in the machine that may harden during storage and cause the Gamajet to seize or lock up A clean water rinse through the Gamajet will also wash out any residues of chemical cleaners or recirculated wash water that could adversely affect the seals and O rings during prolonged contact in storage The best position to store the Gamajet is to stand it up with the inlet connection facing down 3 2 EXTERNAL INSPECTION INTERVALS Before every shift the Stator 109 and the Nozzles 107 s
7. reassembly Gamajet X Owner s Manual v 8 08 9 2 4 2 GEAR TRAIN v v v V YYVYV Steps 4 5 7 and 9 Turn to Step 4 Insert the Gearbox Screws 154 through the Gearhead 113 Push the Input Shaft Step 3 through the Input Shaft Lower Bearine Housing Step 2 While installing the Lower Bearing Housing onto the 113 ensure the Input Pinion meshes properly with the top layer of gears Using a 1 Phillips screw the 154 into the Lower Bearing Housing Step 2 Turn to Step 5 Install the Planetary Gearhead Step 4 back into the Gearbox 101 After aligning the screw holes thread the Gearhead Screws E 853 back into the Gearhead using a 2 Phillips screwdriver Make hand tight Turn to Step 7 Install the Gearbox Seals E 826 into Gearbox Step 5 The seal s internal spring should be face out and be visible Install the Upper Step 1 and Lower Step 6 Bearing Housings into the proper ends of the Gearbox Step 5 by using equal pressure around parts They will snap into place Turn to Step 9 Place the Rotor E 810 Step 8 over the end of the Input Shaft E 822 Install the Lockwasher 8 544 and Nut 8 545 using an 11 32 socket Hold the E 810 stationary with a pair of pliers while tightening the 448 545 Place the Output Shaft 112 into the output side of the gear train assembly Ensure the slot of the 112 is aligned with the flats on the Gearhead s shaft 2 4 3 BODY ASSEMBLY VVVV WV Step 14 Slide
8. the Tee Housing Bevel Gear 117 Step 13 over the end of the Stem 103 Step 10 Align the hole in the 117 with the Pin E 866 Place the first Tee Housing Bearing 131 and Seal 135 spring side up onto the 103 Push the Tee Housing 104 Step 11 over it until it is flush and fully seated Install the second 135 spring side down over the 103 Tip Now Place the second Tee Housing Bearing 131 into Stem Base 130 Step 12 aligning its hole with the Beating Locating Pin 164 Now invert the 104 103 assembly and place it over 131 130 assembly This technique ensures correct alignment of 131 and 164 Apply pressure to 130 to drive it 131 and 135 into 104 Align the through holes of the 130 with the threaded holes in the top of the 103 Using a 5 32 Hex Key thread Cap Screws 146 and Lockwasher E 847 into the 103 Tighten in a star pattern Thread the Tee Housing Cap 114 to the end of the 104 Note This is a Left Hand thread 2 4 4 GEAR TRAIN INSTALLATION gt Step 15 Insert the Gear Train Step 9 from section 2 4 2 into the Body Assembly Step 14 of 2 4 3 Rotate the Tee Housing 104 until the Output Shaft 112 falls into the slot of the Tee Housing Cap 114 Gamajet X Owner s Manual v 8 08 10 gt Thread the Cap 102 into the Body Assembly Be sure to use the flats provided on the 102 Tighten WARNING Hold or turn on Stem DO NOT hold or turn on Tee Housing or Tee Housing Cap Doing so
9. to Gamajet To ensure the longest possible life of the X please verify the operating conditions and most importantly the machine s cycle time The cycle time can be measured by first picking a fixed point inside of a vessel as a reference and second timing how long it takes the same nozzle to pass back over that point in the vessel This naturally will not be the exact same spot because the spray pattern is indexing The measured time in seconds directly corresponds to the machines full cycle time in minutes In other words a single 10 second rotation translates to a 10 minute full cycle time 1 4 SAFETY When a Gamajet is operating there should be covers over every tank opening These covers should be sealed well enough to withstand the full force of the jet striking the cover plate If the cleaning solution were hot corrosive or toxic a leak would present a serious hazard to any personnel in the immediate vicinity or to any exposed electrical equipment For cleaning of USTs Gamajet recommends purchasing the optional UST Lance or Hose Insertion Assembly Each device is specifically designed for sealing against the 4 tiset pipe while allowing the supply hose to properly sit at grade level In either case a grounding safety loop is provided on the X for easy attachment of a cable This will ensute proper dissipation of static electricity and eliminate the possibility of accidental detachment of the X while in the UST WARNING
10. uuosselg PUL sonseld SIULA 8 8T SS OTE JINVHVIII NIN Ove S9JON OL peJJUL LAN 7 I 1 Appendix B Spare Part List GAMAJET X Complete Bill Of Materials SEI 10 101 GEARBOX 1 10 102 CAP 10 103 STEM 1 1 1 1 10 104 EE HOUSING 10 105 INOZZLE HOUSING INOZZLE HOUSING TAPER 10 105 TC CAP 10 106 INOSE PLATE 10 107 INOZZLE 10 108 INLET COLLAR 10 109 STATOR 10 112 OUTPUT SHAFT N 10 113 LANETARY GEARHEAD 10 114 EE HOUSING CAP 10 117 EE HOUSING BEVEL GEAR INOZZLE HOUSING BEVEL 10 118 GEAR 1 INOZZLE HOUSING BEVEL 10 119 GEAR RETAINING RING 1 INPUT SHAFT UPPER 10 128 BEARING HOUSING 1 GEARHEAD LOWER BEARING 10 129 HOUSING 1 10 130 STEM BASE 1 10 131 EE HOUSING BEARING 2 10 132 EE HOUSING CUP 2 10 133 NOZZLE HOUSING BEARING 2 10 134 NOZZLE HOUSING CUP 2 10 135 EE HOUSING SEAL 2 10 136 NOZZLE HOUSING SEAL 2 10 146 STEM SCREWS 4 10 150 COLLAR SET SCREW 1 10 151 NOSE PLATE SCREW 2 10 152 NOSE PLATE WASHER 2 NOZZLE HOUSING TAPER 10 153 CAP SCREWS 2 PLANETARY GEARBOX 10 154 SCREW 4 10 160 STREAM STRAIGHTENER 2 10 163 GROUNDING SET SCREW 1 10 164 BEARING LOCATING PIN 4 Gamajet X Owner s Manual v 8 08 GAMAJET X Complete Bill Of Materials ROTOR INPUT SHAFT INPUT SHAFT BEARING HOUSING STATIC SEAL OUTPUT S
11. HAFT UPPER SEAL GEARBOX STATIC SEAL INPUT SHAFT LOWER BEARING HOUSING INPUT SHAFT CARBIDE OUTPUT SHAFT UPPER CARBIDE BEARING INPUT SHAFT WASHER OUTPUT SHAFT LOWER CARBIDE BEARING OUTPUT SHAFT RETAINING RING STEM amp TAPER CAP SCREW LOCKWASHER 6 GEARHEAD SHORT SCREW 4 E 863 COLLAR STEM O RING 1 DOWEL PIN 1 INPUT SHAFT SEAL 1 SMALL COLLAR O RING amp EE HOUSING CAP O RING OUTPUT SHAFT SEAL GEARBOX PIN NOZZLE O RING INPUT PINION INPUT SHAFT LOWER BEARING HOUSING O RING INPUT SHAFT LOCKWASHER 8 545 INPUT SHAFT NUT 1 Gamajet X Owner s Manual v 8 08 B 2 Appendix C Assembly Disassembly Steps Gamajet X Owner s Manual v 8 08 GAMAJET X ASSEMBLY PROCEDURE STEP 1 INPUT SHAFT BEARING HOUSING E 839 f Press Fit 6 166 Press Fit STEP 2 INPUT SHAFT LOWER BEARING HOUSING E 827 3 Er A 4 Press Fit TD y uy WA Spring GAMAJET X ASSEMBLY PROCEDURE STEP 3 INPUT SHAFT GAMAJET X ASSEMBLY PROCEDURE STEP 4a GEARHEAD 10 113 ASSEMBL Y Top Stage 17 teeth Bottom Stage 14 Teeth Main Ring Gear GAMAJET X ASSEMBLY PROCEDURE STEP 5 GEARBOX a 101 e su een STEP 4 STEP 6 GEARHEAD LOWER BEARING HOUSING d Y 8 2 D Y GAMAJET X ASSEMBLY PROCEDURE STEP 7 GEARTRAIN HOUSING STEP 8 ROTOR E 839 Press Fit GAMAJET X ASSEMBLY PROCED
12. NG CAP ananas 8 230 STEMAND STEM BASE ta aaa SN 9 Gamajet X Owner s Manual v 8 08 ZARB SS E ed A A A Ad 9 ANENE e spa 9 AD G AR ERA N Seen 10 AO AUA A MAA MUM 10 VAWG ARERAINFINSTALEA NEE 10 IAE NGOZI HO INC A RR NN lya nO 11 DAG COMPLETED ASSEMBIY E OE Sa 11 3 PREVENTIVE MAINTENANCE occcooccncccnnnonnnnncnnannnnnnnnonannananinnannananinns 12 SS PORN ada 12 3 2 EXTERNAL INSPECTION INTERVALS En 12 3 3 INTERNAL INSPECTION INTERVALS E 12 E D a i een MANA NA mask ass 12 4 TROUBLESHOOTING GUIDE a nnsnssssssssssaa 13 4 1 MACHINE DOES NOT ROTATE Si tard 13 4 1 1 INSPECTION FLOW CHART FOR MECHANICAL PROBLEMS cu 13 NAAA O Ki 14 AICA CL ARAN OE aia 14 O mu maqa as aes 14 4 2 CLEANING SOLUTION CEA KA GE 000 ac 14 ADA WORN BEARING EEN 14 ADO ORDO USING CUPS wiih E ree ar tn AA 14 AD I WORN COLLAR O REIN O aed i Sen Pat dal a 14 4 3 POOR CLEANING PERFORMANCE sisi iii 15 4 3 1 INADEQUATE FLOW AND PRESSURE ssssssssssssssssssssssssssssssessssssssssetsnsssesse 15 4 3 2 CHEMICAL CONCENTRATION AND TEMPERATURE cr 15 KIS PLUGGED NOS me cal catch chain de Mn venue 15 4 3 4 SLOW OR NO ROTATION OF THE HOUSINGS cn 15 4 3 5 GAMAJET CONPIGURATION a aannnnnnnnanssasasasanasannnnasaasaa 15 436 INADEQUATE DRAINA CE dit 15 Gamajet X Owner s Manual v 8 08 ii 4 4 OWNER S MANUAL UPDATES APPENDIX A OPERATING PARAMETERS APPENDIX B SPARE PART LIST APPENDIX C ASSEMBLY DISASSEMBLY STEPS APPENDI
13. URE STEP 9 GEARTRAIN 8 545 11 32 Hex GAMAJET X ASSEMBLY PROCEDURE STEP 10 STEM 10 132 Press Fit 10 164 Press Fit GAMAJET X ASSEMBLY PROCEDURE STEP 12 STEM BASE 10 164 Press Fit STEP 13 TEE HOUSING BEVEL GEAR GAMAJET X ASSEMBLY PROCEDURE STEP 14 BODY ASSEMBLY ES 10 135 y f Z t 10 146 5 32 Hex 10 114 Left Hand Threads During Disassembly Complete Step 15 Before Removing GAMAJET X ASSEMBLY PROCEDURE STEP 15 INSTALL GEARTRAIN amp CAP DO NOT hold or turn on Tee Housing or Tee Housing Cap during removal of 10 102 GAMAJET X ASSEMBLY PROCEDURE STEP 16 NOZZLE HOUSING 10 160 Part will stick out from Nozzle when installed GAMAJET X ASSEMBLY PROCEDURE STEP 18 NOZZLE HOUSING ASSEMBL Y E E 847 10 105 TC Ka a f O ji pe d STEP 19 NOSE PLATE 10 106 10 164 Press Fit GAMAJET X ASSEMBLY PROCEDURE STEP 20 INSTALL NOZZLE HOUSING f 10 136 So x Q ET Sud pring GAMAJET X ASSEMBLY PROCEDURE STEP 21 COMPLETED ASSEMBL Y 10 150 3 32 Hex Hold or turn on Stem during removal of 10 108 10 163 5 64 Hex DO NOT hold or turn on Tee Housing or Tee Housing Cap during removal of 10 108 Appendix D Performance Curves Gamajet X Owner s Manual v 8 08 dD 9IE MOTA 001 06 08 OL 09 OS Lasel oul 219 9 papueuuosal LUNWIUILU spesox3 og di
14. X D PERFORMANCE CURVES FLOW RATE VS TYPICAL FULL CYCLE TIME PRESSURE VS EN EE Gamajet X Owner s Manual v 8 08 1 Introduction 1 1 DESCRIPTION The Gamajet X is a fluid driven turbine driven 360 rotary nozzle machine designed for cleaning the interior surfaces of a wide variety of process vessels with a minimum opening of 4 00 inches 101 6 mm in diameter It is powered entirely by the cleaning solution and it requires no electricity compressed air or lubricant for operation The Gamajet X is designed for both portable and CIP Clean In Place applications If the Gamajet X is permanently mounted inside a tank we strongly recommend inspecting the unit every few hundred hours of operation See Section 3 Preventative Maintenance for more information WARNING Under no conditions whatsoever should the Gamajet X kd ever be immersed in anything unless you have prior approval from Gamajet Cleaning Systems Inc Failure to comply with this O restriction will void the warranty In order to handle the broadest possible range of applications the stainless steel Gamajet X is available with an extensive selection of nozzle sizes stators non rotating turbine and O ring materials The nozzles are available in several interchangeable sizes that range from 1 4 to 3 8 The Gamajet wash cycle time can be adjusted for special applications by changing the stator and or nozzle size Interchangeable stators and nozzle size
15. aged 113 Section 2 3 3 2 DUSIAES DOE gt Worn 131 amp 132 Section 2 3 4 index when FE gt Worn 133 amp 134 Section 2 3 5 810 is turned Does only Tee Housing 104 Section 2 3 4 amp 5 index gt Cracked Loose 111 Section 2 3 3 3 gt Damaged 113 Section 2 3 3 2 Gamajet X Owner s Manual v 8 08 13 4 1 2 INSUFFICIENT FLOW The Gamajet was configured to meet certain operating conditions outlined at the time of the initial sale such as flow rate GPM pressure PSI temperature chemical content of the wash fluid cycle time etc If the Nozzle size is too small and or the opening at the bottom of the Stator is too large the Tee Housing will not turn Look for restrictions in the fluid supply such as a clogged filter kinked hose or deposits in the piping 4 1 3 TIGHT CLEARANCES A recently overhauled Gamajet X may fail to operate when first returned to service If the machine seems otherwise fine try running it with at least one Nozzle removed The reduction in pressure and additional flow will invariably be enough to overcome the extra resistance of new Bearings and Seals Twenty minutes of operation should loosen the machine to run normally with the Nozzles reinstalled 4 1 4 DEBRIS INSIDE Loosen the Collar Set Screw 150 remove the Collar 108 and then lift out the Stator 109 Look for and remove any debris caught in the Stator and the vanes of the Rotor HE 810 Remove any material wound
16. around the Input Shaft E 822 In addition check for any debris caught in the outlet holes of the Stem 103 the nose of the Tee Housing 104 the Nozzle Housing 105 and the Nozzles 107 4 2 CLEANING SOLUTION LEAKAGE 4 2 1 WORN BEARINGS amp SEALS Leakage from the Tee Housing or Nozzle Housing usually indicates worn Housing Bearings and Seals Inspect them for wear sealing lips are worn to a smooth surface or damaged lips or loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring and replace as required 4 2 2 WORN HOUSING CUPS Inspect the Housing Cups 134 and 132 for excessive wear grooved or scored Replace any that show distinct grooves 4 2 3 WORN COLLAR O RINGS Severe leakage between the Collar 108 and Cap 102 may indicate worn or damaged Collar O rings 7 458 V and E 862 Remove the Collar as described in Section 2 and inspect the O rings for signs of damage or wear Gamajet X Owner s Manual v 8 08 14 4 3 POOR CLEANING PERFORMANCE 4 3 1 INADEQUATE FLOW AND PRESSURE Check the pressure at the Gamajet inlet under actual operating conditions The supply piping and hoses must be large enough to handle the flow rate required for the nozzle size being used to ensure adequate pressure Insufficient pressure may also result from line losses when the machine is far from the pump If this is the case the line size must be increased accordingly for long ru
17. cked or worn Check for signs of scoring and wear on E 822 Replace if the coating has been chipped or cracked Turn to Step 2 Inspect the Input Shaft Seal E 867 inside the Input Shaft Lower Bearing Housing E 827 for wear by placing the E 822 back through it There will be drag if the E 867 is still good If it needs to be replaced pry out the old E 867 using a brass pick and replace it with a new one Ensure that the seal is as square as possible to the E 827 when installing it The internal spring should be up and visible Tip Use a soft object such as a pencil s eraser to apply even pressure when installing E 867 Check the Lower Bearing Housing O ring 8 539 and Seal E 823 for deterioration or damage replace using a brass pick to remove the old components if necessary The E 823 should be installed so its internal spring is up and visible Viewing Step 1 The Pin 6 166 should be firmly pressed into the Input Shaft Upper Bearing Housing 128 The carbide E 839 in the 128 should protrude slightly In addition its running surfaces should be smooth flat and free of chips and cracks 2 3 3 4 Gearhead Lower Bearing Housing and Output Shaft Steps 6 and 9 Gamajet X Owner s Manual v 8 08 7 AN gt Turn to Step 9 Check the Output Shaft 112 for signs of scoring or wear especially in the area of contact with the Output Shaft Upper Seal E 824 Replace if worn gt Turn to Step 6 Examine the E 824 for
18. dening and replace if necessary 2 3 3 PLANETARY GEAR TRAIN ASSEMBLY 2 3 3 1 General Disassembly and Inspection VV YV v Steps 5 to 9 Turn to Step 9 Pull the Output Shaft 112 from the Planetary Gearhead Step 7 Unscrew the Rotor Nut 8 545 with an 11 32 socket and remove it with the Lockwasher 48 544 from the gear train Remove the Rotor E 810 Step 8 If needed use a slotted screwdriver for assistance Turn to Step 8 Ensure the Carbide E 839 pressed into E 810 protrudes slightly and is not chipped or cracked Viewing Step 7 Pull and twist the Gearhead Lower Bearing Housing 129 Step 6 and Input Shaft Upper Bearing Housing 128 Step 1 from the Gearbox 101 Step 5 If the Gearbox Seals E 826 did not come out of the 101 when the 129 and 128 were removed remove them at this time WARNING To reduce the likelihood of scratching any sealing surface use a pick made from brass Inspect the E 826 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required Turn to Step 5 Using a 2 Phillips screwdriver unscrew the Gearbox Screws E 853 from the Gearbox 101 Remove the Planetary Gearhead Step 4 from 101 by pushing on its output shaft Gamajet X Owner s Manual v 8 08 6 J 2 3 3 2 Gearhead Internals Steps 4 4a Tip To prevent the internal components of the Planetary Gearhead from unexpectedly spilling out
19. er to equalize the cleaning radius in all directions Some vessels however may have specific cleaning problems such as coils or heavy deposits such as the liquid level line Gamajet X Owner s Manual v 8 08 2 O bathtub ring In these situations the Gamajet should be located closer to the difficult area for the best cleaning results Tanks with internal mechanisms or structures such as an agitator shaft 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 avoid shadow problems or striping 1 3 5 ENTRY OPENINGS When using the Gamajet X the vessels being cleaned must provide entry openings large enough to avoid interference during insertion and removal The minimum opening size required for the Gamajet X is 4 00 inches in diameter 101 6 mm for free hand installation 1 3 6 VESSEL DRAINAGE If it is necessary to clean the floor of a vessel 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 connected to the drain to suck out the excess wash fluid
20. hould be inspected for debris Examine the 109 by loosening the Collar Set Screw 150 while holding on the flats of the Cap 102 remove the main section of the machine from the Collar 108 Look into each Nozzle for signs of debris or build up When using the UST Lance inspect the lanyard wire and rubber plug for deterioration Replace as needed 3 3 INTERNAL INSPECTION INTERVALS An interval of 100 hours is recommended initially If all of the components are found to be in acceptable condition after the first 100 hours the Gamajet may then be inspected and routine preventive maintenance should be performed every 500 to 700 hours of operation depending on the severity of use 3 4 TIPS All the Bearings Bushings Seals and O rings are wear parts Ideally they should all be replaced as a group every 500 to 700 hours of operation depending on the severity of use If just one Bearing or Seal is worn or damaged replace both it and its mate not just the worn or damaged part Gamajet X Owner s Manual v 8 08 12 4 Troubleshooting Guide 4 1 MACHINE DOES NOT ROTATE 4 1 1 INSPECTION FLOW CHART FOR MECHANICAL PROBLEMS All possible causes are listed in order of likelihood gt Cracked 8 512 Section 2 3 3 3 gt Damaged 113 Section 2 3 3 2 Does Rotor E 810 turn freely by Hand Do Nozzle 105 gt Cracked Loose 8 512 Section 2 3 3 3 ce ie gt Dam
21. imize any chance of leakage and will make subsequent removal much easier 1 3 3 MOUNTING Before mounting the Gamajet X make sure the supply line has been adequately flushed It can be mounted on a rigid 1 1 2 pipe using a pipe wrench In most applications the Gamajet X will be mounted with the inlet connection pointing up however the X will function at any orientation In the cleaning of under ground storage tanks USTs Gamajet recommends the use of its UST Lance or Hose Insertion Assembly Either device will ensure a proper insertion depth sealing of the riser pipe Also the UST Lance includes a lanyard loop that provides a means to attach a safety line between the X UST Lance and the safety loop on the X We do not recommend attaching the machine to a hose while in the inverted or horizontal orientation This form of mounting is not rigid and thus will not maintain the Gamajet s position should the unit become unbalanced due to clogging of the nozzles WARNING When attaching the Gamajet X onto the supply pipe ALWAYS apply the wrench to the Inlet Collar 10 108 at the top inlet of the unit Never use a wrench on Stem 10 103 Tee Housing 10 104 or Tee Housing Cap 10 114 to tighten the unit onto the pipe Doing so risks internally damaging the machine Refer to Step 21 in Appendix C for an illustration 1 3 4 LOCATION INSIDE TANK Generally a single Gamajet will be positioned in the approximate center of the vessel in ord
22. loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring Also ensure that it still has interference with the 112 by passing the 112 through the center of the seal There will be a noticeable drag if the seal is still good If the E 824 must be replaced remove the Retaining Ring E 843 using a small slotted screwdriver Pry out the old E 843 using a brass pick and replace it with a new one Ensure that the seal is square to the 129 when installing it The new E 824 should be installed with the spring facing out and visible after it is installed Reinstall the E 843 2 3 4 NOZZLE HOUSING Steps 16 to 18 and 20 gt Turn to Step 18 Unscrew the Taper Cap Screws 153 with a 5 32 hex key gt Pull the Nozzle Housing Taper Cap 105 TC from the Nozzle Housing Step 16 assembly Inspect the 105 TC for excessive damage If it is no longer protecting the nozzles replace it gt Unscrew the Nozzles 107 with pliers and inspect for debris caught on the Stream Straightener 160 or in the nozzle orifice The inside diameter of 107 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 and pressure are required gt Verify the 160 is tight in the bore of the 107 gt Inspect the Nozzle O ring 643 for compression set or deterioration Replace if needed gt Turn to Step 16 Inspect
23. make sure that all steps are done with the input side of the assembly facing up gt gt Using a 1 Phillips screwdriver unscrew the Gearhead Screws 154 from the Gearhead 113 Remove the Input Shaft Lower Bearing Housing E 827 from the 154 WARNING If you suspect that the 113 requires service proceed with caution If at any time you do not feel completely comfortable servicing 113 contact Gamajet Cleaning Systems immediately Using a needle nose pliers carefully remove the internal components of the 113 Examine the gears of the four different stages for any worn or broken teeth Also examine the main internal ring gear for bent or sharp teeth If any damage is found contact Gamajet immediately The gears of the bottom 14 teeth and top 17 teeth stages must be reinstalled in their respective locations The gears in the second and third level 18 teeth are interchangeable however During reassembly Gamajet recommends the gearhead be lightly repacked using food grade grease Please contact Gamajet for a specific grease recommendation 2 3 3 3 Input Shaft and Housings gt Steps 1 to 3 Turn to Step 3 Inspect the Input Pinion 8 512 for hairline cracks on the end face or for worn damaged or sharp pointed teeth 8 512 should be tight to the Input Shaft E 822 and the Input Shaft Washer E 841 E 841 should not be able to spin on the E 822 Press 8 512 back onto E 822 if it has slipped or replace if cra
24. nd X pressure flow rate requirements into account If a PD style pump i e piston pump plunger pump or mechanical diaphragm pump etc will supply the wash fluid to the Gamajet X a different set or rules apply PD Gamajet X Owner s Manual v 8 08 3 pumps are fixed volume pumps whose flow rate is dependent upon the rotational speed of the pump the pumps also have a pressure rating which is the maximum operating pressure Note Do not confuse the maximum operating pressure of a PD pump with the actual operating pressure the actual operating pressure is dictated by the fixed flow rate of the pump and the Gamajet X plumbing system Ifa PD pump is used the Gamajet X should be sized to first match the flow capability of the pump and second not exceed the X s or pump s maximum operating pressure taking the pressure rating of the plumbing system into account also WARNING For high pressure applications over 150 psig the pressure of the system must ramp up to its operating pressure If the system experiences a pressure spike or pressure increases at a rate of more than 150 psi per second the machine may be damaged and parts will wear out prematurely Damage resulting from this phenomenon is not covered by the watranty 1 3 9 INITIAL STARTUP Every X that ships is accompanied by a Birth Certificate This document indicates how the X performed in our testing tank before it shipped based on the operating conditions supplied
25. ngs 131 and Seals 135 Clean any deposits from the exterior of 131 and check their fit in the Tee Housing Cups 132 While they should Gamajet X Owner s Manual v 8 08 8 VV YV Y gt turn freely 131 should be replaced if the thickness of the flange is 0 095 or less to avoid shortening the life of the Bevel Gears Inspect the interior of 135 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required Inspect the Tee Housing Cap O ring 7 458 V for compression set or deterioration Replace if needed Turn to Step 13 Inspect the Tee Housing Bevel Gear 117 for worn damaged or sharp pointed teeth Ensure that the Pin 164 is pressed firmly into 117 Turn to Step 11 Clean any deposits from 132 and examine for excessive wear Light scoring is acceptable but the Cups should be replaced if they are grooved in the seal contact area A good maintenance program will require replacing many 132 therefore it may be worthwhile to make or obtain press tools for pressing 132 out of 104 The press tools are available from Gamajet Cleaning Systems Before installing new 132 clean the housing bores and remove any burrs resulting from 132 removal Press them in so that their flanges are flush against 104 Ensure that the Pin 164 is pressed firmly into 104 2 3 6 STEM AND STEM BASE VV VY Steps 10 and 12 Turn to Step 12 The Pin 164 sh
26. ns Although the Gamajet will rotate at low flow rates effective cleaning may require considerably more flow Proper mechanical operation the unit turns is NOT the same thing as effective cleaning the soils have been removed Contact Gamajet if assistance is required 4 3 2 CHEMICAL CONCENTRATION AND TEMPERATURE Verify that the cleaning solution is the correct compound and in the concentration needed for the deposit being cleaned If heating is necessary also check that the solution is at the proper temperature 4 3 3 PLUGGED NOZZLES Unscrew the Nozzles 107 and inspect for any debris 4 3 4 SLOW OR NO ROTATION OF THE HOUSINGS This will result in partial or erratic washing coverage Refer to previous sections for more information 4 3 5 GAMAJET CONFIGURATION Determine if the deposit being cleaned requires greater jet impact or longer jet dwell time slower rotation for more thorough scrubbing Confirm that the Gamajet nozzle size turbine and gearing are correct for the specific application Refer to the machine s Birth Certificate for specific information regarding its configuration Contact a Gamajet representative if assistance is required 4 3 6 INADEQUATE DRAINAGE Ensure that the vessel drains the effluent used wash fluid as fast as it s being sprayed in through the Gamajet The floor of the vessel should be sloped or pitched toward the drain and the drainage opening should be large enough to gravity drain the effluent
27. ould be firmly pressed into the 130 Turn to Step 10 Inspect the water outlets of the Stem 103 they should be free of debris The Pin E 866 should be firmly pressed into the 103 Examine the Output Shaft Seal 7 150 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring Also ensure that it still has interference with the Output Shaft 112 by passing the 112 through the center of the seal There will be a noticeable drag if the seal is still good If the 7 150 must be replaced pry it out using a brass pick and replace it with a new one The new 7 150 should be installed with the spring facing in and not visible after it is installed 2 4 REASSEMBLY 2 4 1 GENERAL NOTES gt All parts must be cleaned thoroughly before reassembling Any deposits remaining on the parts can cause difficult disassembly the next time the Gamajet needs to be serviced Also it may cause misalignment of parts and the potential for premature failure Unless otherwise stated apply a dab of a Teflon based anti seize compound to all threads when reassembling this will prevent galling of threads and ease any future disassembly To ease installation of all O rings they should be lubricated prior to reassembly Lithium based grease is acceptable for Viton O rings however a Silicon based lubricant must be used for EP O rings Refer to the illustrations in Appendix C for clarification during
28. s are available for either low or high pressures and or flow rates The performance capabilities of these options are detailed in Appendix D A three view cut sheet of the Gamajet X is contained in Appendix A 1 2 ICONS USED IN THIS MANUAL Warning The information associated with this icon could cause damage O to the machine vessel it is contained within or the operator Note useful piece of information worth remembering AN Assembly Disassembly Tip The following information is a tip from Gamajet that will aid you in working on the machine Gamajet X Owner s Manual v 8 08 1 1 3 INSTALLATION OF NEW MACHINES 1 3 1 ASSEMBLY Every Gamajet is operationally tested before shipment and is ready to run after unpacking No assembly is required prior to use The Gamajet has been configured to meet the operating conditions at the Gamajet not at the pump given to us e g pressure flow temperature cycle time chemical adders etc Note Any change to the original operating conditions will affect the Gamajet accordingly WARNING Do not force Tee amp Nozzle Housing 10 104 amp 410 105 to rotate Doing so will damage internal components 1 3 2 INLET CONNECTIONS The standard inlet connection for the Gamajet X is a 1 1 2 NPT female Others inlets are available It is recommended that when using the pipe thread the mating male thread should be wrapped with PTFE pipe joint tape prior to mounting This will min
29. se Plate Screws 151 with a Vs slotted screwdriver Pull the Nozzle Housing Step 18 from the nose of the Tee Housing Remove the inner Nozzle Housing Seal 136 and Bearing 133 2 2 3 CAP AND GEAR TRAIN Step 15 Using pliers on the flats of the Cap 102 unthread it from the body Step 14 ti WARNING Hold or turn on Stem DO NOT hold or turn on Tee Housing or Tee Housing Cap Doing so will damage the gear train Pull the Gear Train Step 9 from the remainder of the body Gamajet X Owner s Manual v 8 08 5 2 2 4 BODY ASSEMBLY gt gt Step 14 Unthread the Tee Housing Cap 114 from the Tee Housing Step 11 Note This is a Left Hand thread Remove the Stem Screws 146 with a 5 32 Hex Key and Stem Base Step 12 from the Tee Housing Step 11 Remove the Tee Housing Step 11 by pulling it from the Stem Step 10 The upper Tee Housing Seal 135 and Bearing 131 will pull of with the Tee Housing Remove the lower 135 131 and Bevel Gear Step 13 2 3 INSPECTION AND SERVICE OF COMPONENTS 2 3 1 STATOR Step 21 gt Inspect the through holes of the Stator 109 to be sure that they ate clear 2 3 2 COLLAR O RINGS Step 15 Inspect the Small and Large Collar O rings 7 458 V and E 862 for damage clipped of cut or deterioration compression set or hardening and replace if necessary Inspect the Collar Stem O ring E 863 for damage clipped or cut or deterioration compression set or har
30. the Nozzle Housing Bevel Gear 118 for wear such as sharp pointed or worn teeth If it needs to be replaced remove the Bevel Gear Retaining Ring 119 with a small slotted screwdriver and pry 118 from the Nozzle Housing 105 gt Clean any deposits from 134 and examine for excessive wear Light scoring is acceptable but the 134 should be replaced if they are grooved in the seal contact area A good maintenance program will require replacing many 134 therefore it may be worthwhile to make or obtain press tools for pressing 134 out of 105 The press tools are available from Gamajet Cleaning Systems Before installing new 134 clean the housing bores and remove any burrs resulting from 134 removal Press them in so that their flanges are flush against 105 gt Turn to Step 20 Inspect the Nozzle Housing Bearings 133 and Seals 136 Clean any deposits from the exterior of 133 and check their fit in the 134 While they should turn freely 133 should be replaced if the thickness of the flange is 0 086 or less to avoid shortening the life of the Bevel Gears Inspect the interior of 136 for loss of spring tension indicated by excessive dry deposits of dirty or abrasive cleaning solution on the spring replace as required 2 3 5 TEE HOUSING AND TEE HOUSING CAP Steps 11 13 and 14 gt Turn to Step 14 Check the water outlets on the nose of the Tee Housing 104 they should be free of debris gt Inspect the Tee Housing Beari
31. will damage the gear train 2 4 5 NOZZLE HOUSING Steps 20 gt Place the first Nozzle Housing Bearing 133 and Seal 136 spring side out onto the nose of the Tee Housing 104 Ensure the Pin 164 is aligns with the hole in the 133 Push the Nozzle Housing Assembly Step 18 onto the nose of the 104 Rotate the Nozzle Housing Assembly slightly to mesh the Bevel Gears 117 and 118 Failure to ensure that the Bevel Gears have properly mated could damage them Place the outer 136 spring side in over the nose of the 104 Install the second 133 into the Nose Plate 106 Step 19 Ensure the Pin 164 aligns with the hole in the 133 Then using the 106 133 push the 136 into the annular space between the 104 and Nozzle Housing Cup 134 gt Using a 1 2 slotted screwdriver screw the Nose Plate Screws 151 and Lockwashers 152 into the 104 v v Yv VM 2 4 6 COMPLETED ASSEMBLY Step 21 gt Rotate the Rotor E 810 using a Hex Key It should spin easily and its veins must not strike the walls of the Cap 102 Continue turning the Rotor several dozen times The Nozzle and Tee Housing will slowly rotate if every thing has been assembled correctly gt Insert the Stator 109 into the 102 gt Screw on the Collar 108 hand tight only and tighten the Collar Set Screw 150 with a 3 32 Hex Key WARNING Hold or turn on Stem DO NOT hold or turn on Tee Housing or Tee Housing Cap Doing so will damage the
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