maintenance manual intenseclean hygienic

Maintenance manual IntenseClean HygienicSeries 5TB

Maintenance Instructions

Introduction 3

Overview maintenance package 3

Assembly tools 4

Maintenance parts 5

Position of the maintenance parts 6

Disassembly connection piece 7-8

Proper inspection of the gearbox 12

Disassembly spray head unit 13-17

Disassembly nozzle seat 18-19

Assembly 20

Mounting nozzle seat 20-22

Assembly spray head unit 23-32

Assembly connection piece 33

CONTENT

3

INTRODUCTION

This manual shows the maintenance of the solid jet High Impact Tank Cleaning Machine Series 5TB from Lechler GmbH.

We recommend performing maintenance a minimum of every 300 operating hours. Depending on the operating conditions, corresponding maintenance intervals are recom-mended. For example, under harsh operating conditions, the time in between maintenance intervals should be reduced. Always visually inspect the parts for wear at each maintenance interval. O-rings should be replaced after each time a sealing point is opened.

Notes: � While assembly tools can be reused, new maintenance parts are required for

each maintenance interval.� Use compatible lubricant for EPDM O-rings.

OVERVIEW MAINTENANCE PACKAGEThe maintenance parts and the assembly tools are both needed for the maintenance of the 5TB. The assembly tool package includes the tools and maintenance parts required for maintenance. Since the assembly tools can be reused, it is possible to order the maintenance parts separately.

Order number Assembly tool package incl. maintenance parts: 5TB.400.31.22.19.0Order number maintenance parts: 5TB.400.31.22.24.0

4

ASSEMBLY TOOLS

As shown below, the current version differs visually from the previous version. Due to these differences, the tools required for maintenance of each version are slightly different.For the current 5TB, Tool 2-4 are required. For maintenance of the previous version, you need the assembly tools 5TB Tool 1, 3 + 4. In addition, auxiliary equipment such as a vice with protective jaws and the following tools are required for maintenance:Square adapter for 5TB Tool 2 (wrench size 1 inch), O-ring assembly tool, soft edge hammer, fork wrench (size 13) if necessary, allen wrench.

current series

Assembly tool

Description Photo Description Photo

5TB Tool 1 (previous series)

5TB Tool 4

5TB Tool 2(current series)

5TB Tool 3

previous series

5

MAINTENANCE PARTS

Maintenance parts

Description Product number Quantity Description Photo

5TB Box 1 5TB.400.20.11.50.0 4 pieces O-ring Ø 57 x 2

5TB Box 2 5TB.400.30.63.09.0 2 pieces O-ring Ø 60 x 1

5TB Box 3 5TB.400.30.63.10.0 1 piece O-ring Ø 52 x 1

5TB Box 4 5TB.400.30.53.72.0 2 pieces O-ring Ø 26 x 1.5

5TB Box 5 5TB.400.30.07.14.0 2 pieces Bearing Ø 48.5 x Ø 31.5 x 5

5TB Box 6 5TB.400.30.00.94.0 1 piece Sealing ring Ø 35 x Ø 30 x 4

5TB Box 7 5TB.400.30.00.95.0 1 piece Sealing ring Ø 29.7 x Ø 25.8 x 3

5TB Box 8 5TB.400.30.07.15.0 2 pieces Bearing Ø 42x Ø 27 x 5

6

POSITION OF THE MAINTENANCE PARTS

Ans

chlu

ssst

ück

/ Con

nect

ion

Pie

ce5T

B.4

00.3

0.60

.39.

0W

erks

toff:

1.4

404

Mat

eria

l: 31

6L

Antri

ebse

inhe

it / D

rive

Uni

t5T

B.4

00.3

0.39

.47.

0W

erks

toff:

1.4

404,

PE

EK, Z

rO2

Mat

eria

l: 31

6L, P

EE

K, Z

rO2

O-R

ing

Ø57

x25T

B.4

00.2

0.11

.50.

0W

erks

toff:

Mat

eria

l:E

PDM

Geh

äuse

/ H

ousi

ng5T

B.40

0.30

.60.

36.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L G

etrie

be /

Gea

rbox

5TB

.400

.30.

20.1

3.0

Wer

ksto

ff: 1

.440

4, P

EE

K, Z

rO2

Mat

eria

l: 31

6L, P

EEK

, ZrO

2

O-R

ing

Ø57

x25T

B.4

00.2

0.11

.50.

0W

erks

toff:

Mat

eria

l:E

PDM

Lage

rgeh

äuse

/ Be

arin

g H

ousi

ng5T

B.4

00.3

0.60

.38.

0W

erks

toff:

1.4

404

Mat

eria

l: 31

6L

Lage

r / B

earin

g5T

B.40

0.30

.07.

14.0

Wer

ksto

ff: P

TFE

, 1.4

404

Mat

eria

l: P

TFE

, 316

L

O-R

ing

Ø60

x15T

B.4

00.3

0.63

.09.

0W

erks

toff:

Mat

eria

l:E

PDM

Dic

htrin

g / S

ealin

g R

ing

5TB

.400

.30.

00.9

4.0

Wer

ksto

ff:

Mat

eria

l:

Lage

rring

/ B

earin

g R

ing

5TB

.400

.30.

63.1

5.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

O-R

ing

Ø26

x1,5

5TB.

400.

30.5

3.72

.0W

erks

toff:

Mat

eria

l:E

PD

M

Ant

riebs

einh

eit /

Driv

e un

it5T

B.40

0.30

.63.

17.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

Ant

riebs

wel

le /

Driv

e S

haft

5TB.

400.

30.6

3.07

.0W

erks

toff:

1.4

404

Mat

eria

l: 31

6L

O-R

ing

Ø52

x15T

B.40

0.30

.63.

10.0

Wer

ksto

ff:M

ater

ial:

EP

DM

Geh

äuse

/ H

ousi

ng5T

B.40

0.30

.49.

19.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

Zahn

rad

/ Spu

r Gea

r5T

B.40

0.30

.63.

16.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

Lage

r / B

earin

g5T

B.40

0.30

.07.

15.0

Wer

ksto

ff: P

TFE

, 1.4

404

Mat

eria

l: PT

FE, 3

16L

Lage

r / B

earin

g5T

B.40

0.30

.07.

15.0

Wer

ksto

ff: P

TFE

, 1.4

404

Mat

eria

l: PT

FE, 3

16L

Dic

htrin

g / S

ealin

g R

ing

5TB.

400.

30.0

0.95

.0W

erks

toff:

Mat

eria

l:

Lage

rring

/ B

earin

g R

ing

5TB

.400

.20.

11.4

2.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

Düs

e / N

ozzl

e5T

B.40

0.31

.13.

22.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

Düs

enau

fnah

me

/ Noz

zle

Sea

t5T

B.40

0.31

.06.

73.0

Wer

ksto

ff: 1

.440

4M

ater

ial:

316L

PTF

E

PTF

E

7

� Clamp 5TB at the wrench flats of the main housing in a vice with protective jaws.� Make sure that the housing is not deformed.� Using a suitable open-ended or pliers wrench (5TB Tool 4), the connector unscrewed from

the housing.

1

DISASSEMBLY CONNECTION PIECE

Note: All threads of the 5TB, except the bearing ring with the product number5TB.400.20.11.42.0 (see page 54 step 14 and page 55 step 15), are right hand threads.

Note:When clamping in a vice, make sure that the respective components are not deformed.

Width flatConnection pieceWidth across flats 55

Width flatmain housingflats 63

8

� Remove the connection piece.

2

� Remove O-ring Ø 57 x 2.

� Remove O-ring Ø 57 x 2. � Remove drive unit.

DISASSEMBLY CONNECTION PIECE

9

DISASSEMBLY SPRAY HEAD UNIT

� Using a suitable fork or pliers wrench (5TB Tool 4), attach to the width flats of the bearinghousing (5TB.400.30.60.38.0), unscrew and remove the spray head.

Width flatbearing housingflats 64

Width flatmain housingflats 63

3

� Align the 5TB with the spray headunit (housing 5TB.400.30.49.19.0)facing upwards and clamp the widthflats of the main housing (housing5TB.400.30.60.36.0) in a vice withprotective jaws.

� Make sure that the housing is notdeformed.

10

4

� Remove O-rings Ø 57 x 2 from the spray head housing and from the main housing.

� Remove drive shaft.


4

11


� Remove gearbox (5TB.400.30.20.13.0).

12

� To check whether the gearbox is stilloperational, the gear wheel of the turbineunit must be inserted into the gearbox.The next step is to turn the spindle of theturbine unit for a few revolutions. It shouldwork with minimum effort and shouldrotate smoothly and without much effortand friction. If it cannot be turned byhand, small particles, such as sand, mayhave accumulated between the gears.These small particles can be removedby soaking and rinsing or by using anultrasonic bath. Do not use excessiveforce, as it may destroy the gear unit. Ifthe gear unit cannot be turned by hand, itmust be replaced.

PROPER INSPECTION OF THE GEARBOX

5

� To check the function of the turbine, turnthe beige part while holding the blue part.The rotation should be done with minimalfriction. The clearance in the turbine unitshould be very small.

� If the turbine cannot be turned easily byhand or if the turbine is worn out, it mustbe replaced.

13

6

� Clamp the assembly tool 5TB Tool 3.� Place the spray head on the assembly tool and snap into the four grooves provided.


14

8

� Using a suitable fork or pliers wrench (5TB Tool 4) to the position and release the spannerflats of the housing (5TB.400.30.60.38.0). Unscrew afterwards.

� Tap the nozzle with a soft-face hammer to loosen the nozzle holder. Reposition the nozzleholder lightly by hand. Do not yet remove the nozzle holder from the 5TB.

� Unscrew all four nozzles and lay them down. Wrench size 13.

7


15


9

� Clamp the spray head in the vice and make sure that the housing is not deformed.� Place assembly tool 5TB Tool 2 on the hexagon (wrench size 58) of the bearing ring and

loosen. Use a 1 inch square adapter.

10

� Unscrew bearing ring(5TB.400.30.63.15.0) and remove theassembly.

16


11

� Remove O-ring Ø 60 x 1 and O-Ring 52 x 1.

� Remove O-ring Ø 26 x 1.5.

17

� Remove 1 x sealing ring Ø 35 x Ø 30 x 4 and 1 x bearing Ø 48.5 x Ø 31.5 x 5.


18

� Unscrew the already loosened nozzleseat (5TB.40031.06.73.0) Hold theinternal gear wheel (5TB.400.30.50.02.0)firmly.

12

DISASSEMBLY NOZZLE HOLDER

� Remove and deposit parts of the assembly.

13

19

� Clamp the spray head in the vice andmake sure that the housing is notdeformed.

� Insert assembly tool 5TB Tool 3 into thecontour of the bearing ring (CAUTION,left-hand thread).

14 (optional)Note:For standard maintenance the bearing ring (5TB.400.20.11.42.0) does not have to be unscrewed. If the bearing ring must nevertheless be unscrewed, thiscan be done as shown to the left anddescribed below.

Bearing ring has a left-hand thread (5TB.400.20.11.42.0).

DISASSEMBLY NOZZLE HOLDER

20

MOUNTING NOZZLE SEAT

The assembly of the 5TA is carried out in thereverse order of disassembly.

Requirements for assemblyAfter disassembly of the 5TB, all parts must be cleaned carefully. In the course of main-tenance, we recommend always replacing all parts included in the maintenance package.In the following assembly instructions, theparts are described with reference to the box number in which they are located.

When assembling the high impact tankcleaning machine, make sure that sufficientlubrication, especially the threads and O-rings, is observed. Since the 5TB isdelivered with EPDM seals as standard, alubricant compatible with the material mustbe used.

EPDM O-rings are not resistant toVaseline and mineral oil-based lubricants!

15 (optional)


� Screw in the bearing ring manually,ATTENTION, left-hand thread.

� Insert 5TB Tool 3, bearing ring(5TB.400.20.11.42.0) tighten with atightening torque of 45 Nm.

Note:Bearing ring (5TB.400.20.11.42.0) has a left-hand thread tightening torque of 45 Nm.

ASSEMBLY

21

� Pre-assemble the bearing ring assembly of the nozzle holder, taking care to align thegroove of the sealing ring (groove to gear wheel)!

� Insert bearing Ø 42 x Ø 27 x 5 (Box 8).� Insert sealing ring Ø 29.7 x Ø 25.8 x 3 (Box 7).


16

� Groove alignment of the sealing ring.

22

New maintenance parts:� 1 x sealing ring Ø 29.7 x Ø 25.8 x 3 (Box 7) Product number 5TB.400.30.00.95.0� 2 x bearing Ø 42 x Ø 27 x 5 (Box 8) Product number 5TB.400.30.07.15.0

� Insert bearing Ø 42x Ø 27 x 5 (Box 8).� Insert pre-assembled assembly.

17

� Screw in nozzle seat(5TB.400.31.06.73.0) hand-tightwhile holding the internal spur gear(5TB.400.30.63.16.0).


23

� Pre-mount bearing Ø 48.5 x Ø 31.5 x 5 (Box 5)� Pre-assemble sealing ring Ø 35 x Ø 30 x 4 (Box 6), making sure that the groove of the

sealing ring is aligned (groove to the gear wheel).

ASSEMBLY SPRAY HEAD UNIT

� Mount the O-rings on the bearing ring� 1 x O-ring 60 x 1 (Box 2) product number

5TB.400.30.63.09.0� 1 x O-ring 52 x 1 (Box 3) product number

5TB.400.30.63.10.0

18

24

New maintenance parts:� 1 x O-ring 26 x 1.5 (Box 4) Product number 5TB.400.30.53.72.0� 1 x bearing Ø 48.5 x Ø 31.5 x 5 (Box 5) Product number 5TB.400.30.07.14.0� 1 x sealing ring Ø 35 x Ø 30 x 4 (Box 6) Product number 5TB.400.30.00.94.0� 1 x O-ring 60 x 1 (Box 2) Product number 5TB.400.30.63.09.0� 1 x O-ring 52 x 1 (Box 3) Product number 5TB.400.30.63.10.0

� Mount O-ring 26 x 1.5 (Box 4).

� Merge assembly.


25

19


� Screw in the parts group hand-tight,holding the parts group upwards witha suitable tool (Allen key), otherwise theparts group will fall apart.


� Place 5TB Tool 2 onto the hexagon of the bearing ring (5TB.400.30.63.15.0).� Tighten bearing ring to a tightening torque of 75 Nm. Wrench size 58.

20

Note:Bearing ring (5TB.400.30.63.15.0). Tightening torque 75 Nm. Wrench size = 58.

26

21

� Mount 1 x O-ring 26 x 1.5 (Box 4)product number 5TB.400.30.53.72.0

� Mount 1 x bearing Ø 48.5 x Ø 31.5 x 5(Box 5) product number5TB.400.30.07.14.0


� Mount bearing housing(5TB.400.30.60.38.0) and screw it inhand-tight, firmly securing it to the nozzleseat.

27

� Clamp 5TB tool 03, put on spray head.� Place pliers wrench on the spanner flat of the bearing housing, tighten bearing housing

with a torque of approx. 70 Nm.

New maintenance parts:� 1 x O-ring 26 x 1.5 (Box 4) Product number 5TB.400.30.53.72.0� 1 x bearing Ø 48.5 x Ø 31.5 x 5 (Box 5) Product number 5TB.400.30.07.14.0

� ATTENTION: Prior to mounting the bea-ring housing, take care to assure the 26 x1.5 O-ring inside bearing housing is in thecorrect (parallel) position. Failure to do socould result in a damaged O-ring. If theO-ring should snap out a little as shownin the picture to the left, it can be easilypushed back into the groove.


28


22

� Screw in all four nozzles and tighten with a torque of approx. 15 Nm.� Wrench size 13.� Tap the nozzle with a soft-face hammer to tighten the nozzle seat.

29

Note:The grooves in the housing for the gear unit as well as for the drive unit have different widths!


� Insert gear unit (5TB.400.30.20.13.0) into the narrow internal groove in the housing(5TB.400.30.60.36.0).

� Mount 1 x O-ring Ø 57 x 2 (Box 1) in the housing in the groove provided.

23

30

� Assemble 1 x O-ring Ø 57 x 2 (Box 1) onspray head.

New maintenance parts:� 2 x O-ring 57 x 2 (Box 1) Product number 5TB.400.20.11.50.0


� Clamp the housing (5TB.400.30.60.36.0)by the wrench flats in the vice, makingsure that the housing is not deformed.

� Insert the drive shaft into the gearbox.

31


� Screw the spray head 5TB.400.30.49.19.0 hand-tight into the housing while turning thenozzle seat, making sure that the upper end of the drive shaft fits into the groove of thespray head.

32

24

� Using a suitable spanner or pliers wrenchwith a wrench size of 64, place it onthe spanner flat of the bearing housing(5TB.400.30.60.38.0) and screw totightening torque of approximately 65 Nm.

� Insert the drive unit into the groovesprovided in the housing (wide groove)(5TB.400.30.60.36.0).

25


� Place 1 x O-ring Ø 57 x 2 (Box 1) inthe groove provided in the housing(5TB.400.30.60.36.0).

New maintenance part:� 1 x O-ring 57 x 2 (Box 1) Product number 5TB.400.20.11.50.0

33

� Screw in connection piece and tighten with a torque of approx. 65 Nm. Wrench size 55.

26

� Mount 1 x O-ring Ø 57 x 2 (Box 1) in thegroove provided on the connection piece.

New maintenance part:� 1 x O-ring 57 x 2 (Box 1) Product number 5TB.400.20.11.50.0

ASSEMBLY CONNECTION PIECE

Ed

itio

n 05

/20

· 095

.009

.78.

17.9

3.0

· D

E/EN

· S

ubje

ct to

tech

nica

l mod

ifica

tion.

LECHLER WORLDWIDE

Lechler, Inc. · Precision Nozzles · Nozzle Systems445 Kautz Rd. St. Charles, IL 60174 · Phone: 800-777-2926 · Fax: 630-377-6657 [email protected] · www.lechlerusa.com

LECHLER WORLDWIDE

World Headquarters Lechler Companies Sales Offices

maintenance manual intenseclean hygienic

Documents