TROUBLE SHOOTING GUIDE

This section lists common problems that may be encountered during the operation of the Model 360 tank cleaning machine. Many problems – such as slow cycle times or if the nozzle housing does not rotate – are easy to solve. Proper operating environment and preventative maintenance can prevent many problems. The following sections describe problems that you might encounter and provides diagnostic instructions and possible solutions. A brief explanation of the problem & solution is followed by directions of where to look in the Operation & Maintenance Manual for further assistance or explanation. It is suggested that you have the exploded view available for reference

when trouble shooting.

Visually inspect the bearing for cracks or signs of corrosion. Check the bearing clearance between the I.D. of the cup (631 & 633) and the O.D. of the bearing. The normal clearance between the cup and bearing are held to close tolerances to allow for bearing wear, and to maintain the proper backlash of the bevel gears (617 & 618). If the bearings show signs of wear from deposits, sediment or other foreign matter, or have excessive side to side movement in the bearing cup, replacement is recommended. Refer to Disassembly Procedure – pages 3-5 and Assembly Procedure – pages 5 & 8 as necessary.

If there is excessive side to side play of one of the gear shafts (615, 616 or 622-SA) and one of the mating bearings (626-A, 627, 628, 629, 630) then replacement is recommended. Refer to Disassembly Procedure pages 4-5: Gearbox Cover Removal, Geartrain Removal, Final Drive Gear Shaft Disassembly and Gearbox Disassembly. NOTE: While it may appear that the gearbox bearings are standard off-the-shelf bearings, they have all been modified by the manufacturer to meet the design specifications set forth by the manufacturer. Replacement of these bearings by any type other than the O.E.M parts can compromise the performance of the machine. Refer to page 7 – Gearbox Cover Sub-Assembly for installation procedures.

Is there sufficient pump pressure or water flow at the tank cleaner? Minimum operating pressure is 30-40 psi measured at the inlet of the machine. Minimum pipe or hose diameter is 1 ½” I.D. Check to see that the pump is not cavitating or that the pump seals have not failed.

Upon inspection of the nozzle housing bearings (633), is there a buildup of deposits, sand or scale? Inspect the seals (636-TG) for signs of wear. If they are worn out, they will allow particles in the cleaning solution in between the cups and bearings, which may alter the performance of the machine. Replace bearings, cups and seals as necessary. Often times, a thorough cleaning of the machine will eliminate slow rotation problems. The nozzle housing cups, bearings and seals can be used as a gage for the condition of the tee housing cups, bearings and seals. If the nozzle housing cups, bearings and seals need replacement or cleaning , it follows that the tee housing cups, bearings and seals will also need the same. Refer to pages 3-5 of Disassembly Procedure and pages 5-8 of Assembly Procedure.

If you are able to observe the machine in operation and notice the nozzle housing rotating, then stopping briefly, then rotating again, this could be symptoms of

the following:

• Clutch o-ring is worn or corroded and is not seating completely against the nozzle housing bevel gear. Replace as necessary, refer to page 8 of Assembly Procedure.
• Damaged bevel gears (617 & 618): inspect the bevel gears for bent or excessively worn teeth. If the teeth are worn down approximately 25%, or if one or more teeth are bent, then the bevel gear(s) should be replaced. Refer to page 5 – Tee housing and page – 8 Nozzle Housing Sub-Assembly.

Inspect the clutch o-ring (637) condition. Remove the nozzle housing and disassemble as described on page 4 of the Disassembly Procedure. If the clutch o-ring is cracked, or if corrosion has shrunken it in size and it is not filling the o-ring groove on the nozzle housing completely, then replacement is recommended. Refer to page 8 – Nozzle Housing Sub-Assembly.

Inspect the nozzles for obstructions by solid particles trapped in the stream straighteners (608). Unscrew the nozzles and remove the particles as necessary. Use anti-seize compound or Teflon tape on nozzle threads prior to re-assembly.

Verify that the rotor / stator combination, nozzle size & gear ratio are configured properly for the type of cleaning required. Heavy deposits (paint, polymers, scale, etc.) require more dwell time from the nozzle streams (slower RPM’s) to be effective. Conversely, some cleaning applications only require a rinse of the tank, and therefore a faster moving nozzle stream can be more effective. Refer to performance data sheets for flow rates, cycle times and the related machine configurations. Contact your local distributor or representative for further recommendations.

Check to see that the proper concentration and type of chemicals is being used for the material being cleaned, and that the solution is heated to the proper temerature.

SLOW ROTATION OR DOES NOT ROTATE

Check supply pressure as described in Poor Cleaning Performance, on page 11.

Check to see that the rotor retaining nut (654) is properly tightened on the rotor shaft. If the rotor nut is loose, the rotor may be rotating on the shaft, instead of rotating the rotor shaft through the geartrain. Tighten the rotor nut as described in the Rotor Installation page 8. Torque setting should be 80 in/lbs for bronze & 100 in/lbs for stainless steel.

• Misalignment of the carbide rotor shaft bearings (660-L & 660-U) as described on page 6: Gearbox Sub-Assembly can prevent smooth rotation of the rotor shaft bearing with Tool # T-5, then check the alignment once again.
• Foreign material jammed in geartrain. Remove gearbox cover (602) for inspection. Refer to Disassembly Procedure page 4. Remove foreign material, reassemble geartrain (page 6) and install gearbox cover (602) as described on page 7.

This is an indication of possible geartrain malfunction. If the rotor shaft pinion gear or any of the gearsets (623) are worn out, then the tee housing will not rotate. Remove gearbox cover (602) for inspection, replace worn gears as necessary. Refer to Disassembly Procedure page 4-5, and Assembly Procedure pages 7 & 8.

• Inspect the seals (635-TG) for signs of wear. If they are worn out, they will allow particles in the cleaning solution in between the cups and bearings, which will alter the performance of the machine. Replace bearings, cups and seals as necessary. Often, a thorough cleaning of the machine will eliminate slow rotation problems.
• Install an inline strainer between the pump and the machine to filter out sediment in the cleaning solution.

If you are able to observe the machine in operation and notice the tee housing rotating, then stopping briefly, then rotating again, this could be due to improperly installed ring gear. The ring gear notch (see photo # 4, page 7) must be locked into the tee housing tab (photo # 3, page 7), in order to rotate the tee housing. With some of the models of ring gears, it is possible to install the ring gear into the tee housing without having the notch and tab lined up. The ring gear can then rotate within the tee housing, instead of rotating the tee housing. Refer to page 6 of the Assembly Procedure for ring gear installation.

Remove stator retaining ring (645-3) and lift out stator (609). Remove any foreign objects from the stator or rotor that could be altering the normal flow of cleaning solution. Refer to page 3 of the Disassembly Procedure.

NOTE: In the CIP version of the Model 360 tank cleaners, some water leakage at the gap between the tee housing & gearbox and at the gap between the nozzle housing & tee housing is normal. There are two small holes in the tee housing that rinse the bevel gears, ring gear and the inside of several of the castings to prevent a buildup of deposits or sediment that could promote bacteriological growth.

If the Model 360 is allowed to operate for a prolonged period of time after the seals have worn out, sediments and foreign particles will lodge between the inlet stem and the tee housing bearings and cups and cause abrasive wear on these parts. Corrosive chemicals can also have an affect on the sealing effectiveness; they can cause corrosion of the cups or castings. If the grooves or corrosion is severe, even new seals will not seal completely due to the uneven sealing surface.

Excessive water leakage at the top and bottom of the tee housing indicates a sealing problem which can be caused by:

• Seals worn out; no longer functioning properly. Replace worn seals, refer to page 5 of Assembly Procedure.
• Seals improperly installed. The spring side of the seal (the open section of the seal) faces the ports on the inlet stem. As the cleaning solution comes in contact with the seal, it spreads it apart so that contact is made against the tee housing bearing cup and the O.D. of the inlet stem. Refer to photo # 1 in the Assembly Procedure section.
• Inlet Stem (603) casting or tee housing cups (632) have wear grooves which prevent the seals from sealing. Replace the cups as outlined in Disassembly Procedure page 5 and Assembly Procedure also on page 5. Reassemble the machine and then check for excessive leakage. If there is still excessive leakage after installing new cups and seals, the inlet stem may have to be replaced.

If the Model 360 is allowed to operate for a prolonged period of time after the seals have worn out, sediments and foreign particles will lodge between the tee housing nose and the nozzle housing bearings and cups and cause abrasive wear on these parts. Corrosive chemicals can also have an affect on the sealing effectiveness; they can cause corrosion of the cups or castings. If the grooves or corrosion is severe, even new seals will not seal completely due to the uneven sealing surface.

Excessive water leakage around the nozzle housing indicates a sealing problem which can be caused by:

• Seals worn out; no longer functioning properly. Replace worn seals, refer to page 8 of Assembly Procedure.
• Seals improperly installed. The spring side of the seal (the open section of the seal) faces the ports on the nose of the tee housing. As the cleaning solution comes in contact with the seal, it spreads it apart so that contact is made against the nozzle housing bearing cup and the O.D. of the nose of the tee housing.
• Tee housing (604) or nozzle housing cups (632) has wear grooves which prevent the seals from sealing. Replace the cups as outlined in Disassembly Procedure page 3 and Assembly Procedure also on page 8. Reassemble the machine and then check for excessive leakage. If there is still excessive leakage after installing new cups and seals, the tee housing may have to be replaced.

If there is no free play (in and out movement) of the nozzle housing (605) on the axis of the tee housing (604) check one of the following:

• Scale or deposit buildup between nozzle housing cups (634) and bearings (633). Remove the nozzle housing assembly (605) from the tee housing (604) as described in the Disassembly Procedure page 3. Inspect the bearings (633) and cups (634) for deposits and / or scale buildup. Remove the scale or deposit buildup from the cups and bearings. Inspect the nozzle housing seals (636-TG) for wear, replace as necessary, then reassemble the nozzle housing to the tee housing. Refer to Assembly Procedure page 8; Assembly - Nozzle Housing to Tee Housing. Inspect once again for free play. NOTE: If the nozzle housing cups (634) and bearings (633) are in need of cleaning or replacement, then it follows that the tee housing bearings (631) and cups (632) will also need the same.
• Improperly assembled: remove the nozzle housing assembly (605) from the tee housing (604) as described in the Disassembly Procedure page 3. Inspect the nozzle housing bearing (633) that is seated against the tee housing. Refer to Assembly Procedure page 8; Assembly – Nozzle Housing to Tee Housing.

If there is no free play (up and down movement) of the tee housing (604) check one of the following:

• Scale or deposit buildup between tee housing cups (632) and bearings (631). Inspect the nozzle housing bearings and cups as described above for deposits and / or scale buildup. If the nozzle housing bearings and cups are in need of cleaning or replacement, the tee housing bearings (631) and cups (632) will also need the same. Dismantle the machine and remove the scale or deposit buildup from the cups and bearings. Inspect the tee housing seals (635-TG) for wear, replace if necessary. Reassemble the machine as described in Assembly Procedure page 5; test for free play once again.
• Improperly assembled: dismantle machine and note whether the ring gear (620) or bevel gear (617) are properly assembled in the tee housing. Remove the tee housing (604) from the inlet stem (603), inspect to see that the upper (631) bearing flange is seated flush against the inlet stem. Reassemble the machine as described in the Assembly Procedure on page 5.