10112677

Index
1 General information ............................................................................................................... 3

- Introduction - ................................................................................................................................ 3
1.1 How to use this manual .......................................................................................................... 3
- 1.1.1 Symbols description - ............................................................................................... 3
- 1.1.2 Keeping this instructions manual- ........................................................................... 3
1.2 Machine identifying data ........................................................................................................ 4
- 1.2.1 Marking - .................................................................................................................... 4
1.3 Technical features ................................................................................................................... 5
- 1.3.1 Overall dimensions - ................................................................................................. 5
- 1.3.2 Consumption according to use - ............................................................................. 5
- 1.3.3 Electrical features - ................................................................................................... 6
- 1.3.4 Environment features - ............................................................................................. 6
- 1.3.5 Noise emission - ....................................................................................................... 6
- 1.3.6 Technical data ........................................................................................................... 7
1.4 Description of the machine ................................................................................................... 8
- 1.4.1 Intended use - ............................................................................................................ 8
1.5 Safety devices and protections ............................................................................................ 9
- 1.5.1 Preventive measures to be carried out - ............................................................... 9
- 1.5.2 Safety valve - ...........................................................................................................10
- 1.5.3 Emergency stop push button - ............................................................................... 11
1.6 Warranty conditions ..............................................................................................................12
2 General instructions ............................................................................................................13
2.1 Machine delivery...................................................................................................................13
- 2.1.1 Moving the machine - .............................................................................................13
- 2.1.2 Storage of the machine - ........................................................................................15
2.2 Installing the machine ...........................................................................................................16
- 2.2.1 Instructions for placing the machine - ....................................................................16
- 2.2.2 Connecting between Product and fluids piping- ..................................................16
- 2.2.3 Electric connections - .............................................................................................18
2.3 Disposal ................................................................................................................................20
3 Instructions for the operators ...........................................................................................21
3.1 Instructions for the use .........................................................................................................21
- 3.1.1 Description of the control devices - ......................................................................21
- 3.1.2 Machine starting up - .............................................................................................22
- 3.1.3 Emergency stop - ....................................................................................................22
- 3.1.4 Instructions for the washing procedure - ...............................................................23
3.2 Troubleshooting ...................................................................................................................24
- 3.2.1 Function anomalies - ..............................................................................................24
- 3.2.2 Safety valve operation - ..........................................................................................25
NOTES .........................................................................................................................................26
- 3.2.3 Signalling pilot lamps and electric anomalies - ...................................................26
4 Maintenance ...........................................................................................................................27
4.1 General principles ................................................................................................................27
- 4.1.1 List of recommended spare parts to be kept in store - ......................................27
- 4.1.2 Instructions for checks and ordinary maintenance - ............................................28
- 4.1.3 Programmed maintenance - ..................................................................................29
4.2 Transmission belts ...............................................................................................................35
- 4.2.1 Replacing the belts .................................................................................................35
1
- 4.2.2 Tensioning the belts - ..............................................................................................36

- 4.2.3 Attention - .................................................................................................................36
- 4.3 Lubrication oil change - .............................................................................................37
- 4.3.1 Reducers - .......................................................................................................................38
- 4.3.2 Pump body - ............................................................................................................39
4.4 Maintenance special equipment .........................................................................................40
4.5 Ordinary maintenance: pumping group ..............................................................................41
- 4.5.1 Pumping group composition - ...............................................................................41
- 4.5.2 Components of pumping group that get worn out - .............................................42
- 4.5.3 Maintenance of pumping pistons, gaskets ch and guiding bands - ..................43
4.6 Valve groups .........................................................................................................................46
- 4.6.1 Composition of the valve group - ..........................................................................46
- 4.6.2 Components of the valve group that can get worn out- .......................................47
- 4.6.3 Maintenance of the supply valve group - ..............................................................48
- 4.6.4 Maintenance of the suction valve group - .............................................................50
4.7 Safety valve ...........................................................................................................................52
- 4.7.1 Composition of safety valve - ................................................................................52
- 4.7.2 Components of the safety valve that can get worn out - ......................................52
- 4.7.3 Maintenance of the safety valve - ..........................................................................53
5 Spare parts tables and instructions for replacing the components .......................54
5.1 How to read the spare parts tables - ..................................................................................54
5.2 Spare parts order form - ......................................................................................................55
5.3 Spare parts tables ................................................................................................................56
- 5.3.1 Pistons and head table - ........................................................................................56
- 5.3.2 Homogenizing chamber table - .............................................................................58
- 5.3.3 Safety valve table - ..................................................................................................59
- 5.3.4 Pump body table - ...................................................................................................60
- 5.3.5 Motor table - ............................................................................................................62
Notes ............................................................................................................................................63
- 5.3.6 Hydro-pneumatic system table - ............................................................................64
- 5.3.7 Inlet product union group table - ............................................................................66
- 5.3.8 Outlet product union group table - .........................................................................67
5.4 Recommended torque for fastening studs - ......................................................................68
5.5 Electric system .....................................................................................................................69
1 GENERAL INFORMATION
- INTRODUCTION Dear Client,
We thank you very much for your preference and with the occasion we are please to
assure our complete disposal in order to allow you to use our machine in the best possible
way.
1.1 HOW TO USE THIS MANUAL

This manual contains all information the user needs to install correctly and safely the machine, to start it up and use it, to localize any eventual trouble and to carry out maintenance operations on the machines manufactured by FBFITALIA s.r.l. This manual is divided into chapters
containing paragraphs relative to the argument treated in the chapter.
All our technical staff remains at your complete disposal for any further information.
- 1.1.1 Symbols description -
Follow carefully the instructions contained in this instructions manual,

paying PARTICULAR ATTENTION to that information bearing DANGER
warning and the symbol here by, in order to assure the operators safety.
D A N G E R
!
ATTENTION
Read carefully the notes introduced by this symbol bearing the write
ATTENTION! in order to avoid dangerous operations for the machines
equipment.
This symbol accompanies warnings and important information, furthermore suggests to use the machine in the best possible way.
This symbol is positioned on the machine casings. It means that
manual cleaning, greasing, repair and adjustment of the moving
device are prohibited.
This symbol is positioned on the machine casings. It means that the
machine safety protections must not be removed.
This symbol is positioned on the machine compression head.

It informs the operator that the use of protective gloves is compulsory,
in order to avoid any injury to hands due to high temperatures.
This symbol is positioned on the machine compression head.
It indicates the high temperature of the surfaces on which it is located.
This symbol is positioned on the electric panel cover of the machine.
It indicates the presence of possible electric discharges.
- 1.1.2 KEEPING THIS INSTRUCTIONS MANUALKeep this manual safe for any future reference in a safety place and always at the operator disposal. In case the machine should be sold, remember to handle this manual to the new
owner, since this manual is an integral part of the machine.
1.2 MACHINE IDENTIFYING DATA

- 1.2.1 MARKING The machine is supplied free from identifying label and without electrical board.
Therefore you are not allowed to install the machine untill the machine or the plant of
which it will become part is identified or declared in accordance with the regulations in force.
1.3 TECHNICAL FEATURES

- 1.3.1 OVERALL DIMENSIONS -
Fig. 1.3.a Dimensioni dingombro - Overall dimensions -
DIMENSIONI INGOMBRO - OVERALL DIMENSIONS

A
1.280 mm
990 mm
970 mm
PESO TOTALE - TOTAL WEIGHT - Kg 420
- 1.3.2 CONSUMPTION ACCORDING TO USE -
CONSUMI - CONSUMPTIONS
UNITA' DI MISURA MEASURE UNIT
VALORE - VALUE
Acqua - Water
m3/h
0,12
Forza motrice - Motive power
kW
8,6
Aria compressa - Compressed air
Nl/h
Irrilevante - Irrelevant
OGGETTO - SUBJECT
- 1.3.3 ELECTRICAL FEATURES DATI ELETTRICI - ELECTRICAL DATA

Alimentazione - Feeding
440 Vac
Fasi - Phases
3 + PE
Frequenza - Frequency
60 Hz
Potenza nominale installata - Installed nominal power
8,6 kW
Corrente nominale - Nominal current
14,7 A
Corrente effettiva ai valori massimi di portata e pressione

Real current at maximum capacity and pressure values
12,8A
- 1.3.4 ENVIRONMENT FEATURES The machine has to be installed in a suitable and covered place (at temperature between +5...+45 C, with relative humidity <90% condensation free).
- 1.3.5 NOISE EMISSION In the figure below are indicated the noise values measured around the machine perimeter, at 1 metre away from the machine and at 1,6 metres of height. The premises where the
measurement has been carried out presented the same features as any other industry building having a cement flour. The noise emitted by the machine will obviously change according
to the characteristics of the premises where the machine will be installed.
70 db A
1 m Machine front rear
H from ground =
1,6 m
1m
70 db A
71 db A
1m
1m
72 db A
Fig. 1.3.c Rilevamento livelli acustici - Acoustic level values -
- 1.3.6 TECHNICAL DATA

H.P. PUMP MODEL FBF008/P - SERIAL NUMBER 10112677
CAPACITY...........................................................................................LpH
900
MAXIMUM WORKING PRESSURE ................................................Kg/Cm 2 (bar)
200
N REV/MIN. CRANKSHAFT
178
PUMPING PISTON STROKE ..........................................................mm
48
PUMPING PISTON DIAMETER ......................................................mm
28
SUPPLY MINIMUM PRESSURE REQUESTED ...........................Kg/Cm 2 (bar)
ELECTRIC MOTOR PULLEY
116.SPZ118-3/C
REDUCER PULLEY
116.SPZ280-3/C
TRANSMISSION BELT
115.SPZ1287/A
PRODUCTS TREATED
Eggs
MAIN ELECTRICAL MOTOR
SIEMENS 1LE10021CB222AA4 - 3 Phases - 60 Hz - 8,6 kW - 460 Vac - 1.750 Rpm - 14,7 A - Cl.Is. F - IP55 - Poles 4
SERVOFAN FOR MAIN MOTOR

SECONDARY FAN MOTOR
WINSTRO C35 IL 2 2 - 3 Phases - 60 Hz - 148 W - 380/575 Vac - 0,24 A - Cl. Is. F - IP66 - Poles 4
OIL PUMP MOTOR

REDUCER
ROSSI RI080 UP3A /4,17
TEST AND INSPECTION CERTIFICATE
Test method used: The machine is tested with water at operating pressure and capacity, fed at a constant
pressure of 2 bar for a period of 12 hours
SURVEY
VALUE
ACTUAL CAPACITY IN ABSENCE OF PRESSURE

ACTUAL CAPACITY IN PRESENCE OF PRESSURE
N REV/MIN. IN PRESSURE ON THE REDUCER
OIL PRESSURE ON THE LUBRICATING SYSTEM
AIR PRESSURE ON THE PNEUMATIC SYSTEM
POWER IN THE LINE WITH MACHINE IN ABSENCE OF PRESSURE
POWER IN THE LINE WITH MACHINE IN PRESENCE OF PRESSURE
N REV/MIN. OF MAIN MOTOR WITH MACHINE IN PRESSURE
SUPPLY VOLTAGE
NOTES: MACHINE TESTED AT 400 VAC 60 HZ
CONTROL SIGNATURE
1.4 DESCRIPTION OF THE MACHINE

The positive-displacement pump has the specific function of conveying the product inside the
plant assuring a volumetric capacity at a constant pressure.
The machine is covered by stainless steel panels that provide to fair and to eliminate the noise
provoked by the rotating parts of the moving organs of the machine (such as electrical motors,
transmission belts, pulley, etc.) and specially they provide to avoid any danger for the
personnel in charge of operations.
The uncovered part of the panels is called compression head where the product to be
treated will be conveyed into.
The pumping pistons are installed in the inner part of the compression head and their
function is that of pumping the product under pressure; the suction and delivery valves and
the homogenizing valve, where the product is homogenized, are also installed inside the
compression head.
The control panel bears the start and stop controls, the control to regulate the homogenizing pressure and the pilot lamps.
The machine always bears an emergency stop push button on the front rear.
The main switch is placed on the electric board; it can be used both to cut off power
supply to the machine and to stop the machine in case of emergency.
The machine is supplied with a complete set of gaskets for the compression head and
safety valve, N 6 Recovery springs for heads valves, N1 safety valve seat, N1 safety valve
ball, a set of wrenches and tools to carry out regular maintenance operations.
- 1.4.1 INTENDED USE This machine has been calibrated to treat the product indicated in the technical card,
such product must not contain hard particles or strange bodies. It is convenient to install a
filter upstream the machine for filtering adequately the product treated.
!
ATTENTION!
Never use the machine to treat products different from those indicated
in the paragraph 1.3.6 TECHNICAL FEATURES - TECHNICAL DATA (density, dimension of subparticles, viscosity, etc...). Furthermore, the
operating conditions have to be fully respected, as indicated in the
technical card.
FBF ITALIA srl will not to be hold responsible for damaged caused for having treated
other product than those indicated in the technical card. The constructor, in any case, remains at your complete disposal for any further information regarding this argumentation and
will suggest the eventual modifications that needs to be carried out in case the user intends
to process other product different from the initial one for which the machine was originally
calibrated.
1.5 SAFETY DEVICES AND PROTECTIONS

- 1.5.1 PREVENTIVE MEASURES TO BE CARRIED OUT Only qualified personnel is to be allowed to operate this machine, according to the regulation in force.
The machine is not at all dangerous for the operator when used correctly and according to the instructions contained in this manual. Never
tamper or disengage safety devices.
!
ATTENTION!
!
DANGER!
!
DANGER!
!
DANGER!
!
DANGER!
When carrying out maintenance operations on electrical or mechanical

parts it is COMPULSORY to cut off the power to the control board by
means of the main switch (see paragraph 3.1 INSTRUCTIONS FOR THE
OPERATORS - DESCRIPTION OF THE CONTROL DEVICES - to locate
the afore mentioned switch).
All rotating and moving elements are equipped with protections, which
can be removed only by means of special tools and ONLY after having
SWITCHED OFF the power supply to the machine by using the special
external handle of the main switch.
When the machine operates with products at high temperatures, the feeding and sending piping (which has to be installed by the installer or user)
and those machines parts where the product get conveyed in, reach
such high temperatures as to provoke burns when touched. Should this
be the case, the user has to install suitable protections in order to avoid
the operator to get burnt or, otherwise, to install the machine in such a
way so to avoid any damage to the operator.
Before to proceed to any maintenance operation, wear the safety devices

(Ex.: glowes, glasses, masks, etc...) in the way to avoid every damage for
the operators.
Our technical staff remains at your complete disposal for any further information.
- 1.5.2 Safety valve This valve, located on the sending piping of the compression head, is already calibrated
to a value higher than the maximum pressure admitted and operates only in case of
overpressure by draining the product out.
For further information regarding this valve operating mode see the paragraph 4.8.3.
Never tamper/modify the calibration of the valve!
D A N G E R
ATTENTION
This valve protects the integrity of the head; for the product draining
piping mounted in the user premises it will be convenient to install , in
case of risk of overpressure, a suitable safety device in order to avoid
any danger.
Make sure the final part of the valve A draining pipe is always directed
to any area far from the operators.
!
ATTENTION
The product discharged by the valve has to be collected and disposed

off according to the regulations in force in the Country where the machine is installed in; particular attention need to be paid in case of toxic
and/or polluting substances.
A
Fig. 1.5.a Product safety valve
10
- 1.5.3 EMERGENCY STOP PUSH BUTTON The machine is equipped with one or more emergency stop push-buttons. The mushroom head push-button is red and surrounded by a yellow ring. This push-button is selfblocking, that is to say that when pressed it remains blocked in this position. To unblock the
push-button pull it.
The operator must press, IMMEDIATELY and WITHOUT HESITATION, the

emergency stop push-button every time a dangerous situation, no matter
if for the operator and/or for the machine, occurs.
DANGER!
In case any other machine or equipment have to be installed near the

machine, the operator needs to make sure the push-button area remains
easily accessible in case of dangerous situation.
ATTENTION!
Fig. 1.5.b Pulsante di emergenza - Emergency stop button -
11
1.6 WARRANTY CONDITIONS

This document certifies that FBF ITALIA srl warrants that its product(s) are free from defects
of materials used and are manufactured under the conditions and limitations here below specified.
FBF ITALIA srl will not to be hold responsible for latent defect or malfunctioning of any
commercial components used, no matter that the manufacturer might be a national or international leader company, which are not constructed by FBF ITALIA srl .
Should this case happened, FBF ITALIA srl will recognize to the Client the same warranty that the manufacturer of the components supplies and will provide to supply all the necessary assistance to the users.
The pieces to be repaired or replaced will have to be sent to our factory by the Client,
free of charge, only after having received acceptance of warranty from our company.
What is covered by the warranty
The warranty covers the costs for replacing faulty parts, for repairing or replacing them with
equivalents parts according to the convenience of every single case.
A part or product have to be considered faulty, and therefore covered by the warranty, when
it has been proved that the congenital defects of the part(s) already existed at the time of the
delivery.
What is not covered by the warranty
This warranty does not cover parts or products which become damaged during transport, installation or repairing, or those that become damaged due to not regular use of the
parts or products, overload, negligence, insufficient lubrication, normal wear of parts, use of
not original FBF ITALIA srl spare parts, or any other damages caused by improper use,
accident or negligence on having follow the instructions contained in this use and maintenance instructions manual.
The warranty does not cover also any damage caused by irresponsible users or in case of
modifications that FBF ITALIA srl considers might have caused or worsen the eventual damages or in case the eventual seals have been removed or regulations modified.
The warranty does not cover any other accidental costs, should those be consequential
or connected costs: for example transport expenses for any eventual spare parts shipped
covered by warranty, travel expenses of technical assistance personnel, extraordinary expenses due to difficult accessibility of the installed machinery, missing profit, waste of time,
harm or damages caused to other parts or goods that are not of FBF ITALIA srl manufacture
indicated in this warranty.
FBF ITALIA srl does not authorize third parties to charge other responsibilities regarding the sale of FBF ITALIA srl s products than those established in this warranty.
Period of warranty
FBF ITALIA srl warrants the machine for a period of twelve months both mechanic and
electric parts.
The warranty starts from the date the machine is tested on the production line or, at the latest,
after 4 months from the delivery date to the first owner.
Operations carried out before delivering
Before leaving our factory all our products are carefully tested to make certain they satisfy all FBF ITALIA srl s specifications and quality standards.
Production modifications
FBF ITALIA srl reserves the right to modify, any time, the products manufactures and
sold, without any previous notice and without any obligation to update the products already
constructed or sold.
12
2 GENERAL INSTRUCTIONS
2.1 MACHINE DELIVERY
- 2.1.1 MOVING THE MACHINE To transport and move the machine is required the use of a fork lift truck with such a
loading capacity as it will be suitable to lift and handle the machine. Refer to the figure 2.1.a
for information on the machines dimensions and weight.
DIMENSIONI IMBALLO
PACKING DIMENSIONS
A
1.600mm
1.150 mm
1.300 mm
PESO - WEIGHT Kg 165
Fig. 2.1.a Dimensioni imballo - Packing dimensions-
The length of the forks must be the same or even longer than the machines depth or that
of the packaging containing the machine itself.
To move the machine carry out the following instructions.
Machine without packaging
Carry out the following operations:
- The forks have to be positioned between the supporting feet and as near to them as
possible.
- The machine has

to be suitably
protected (for example with plastic protections)
against
any
eventual collision
or
abrasion
caused by a frontal impact with
the lift truck.
The fork has to project

over the machine
- The homogenizing head will have to be positioned facing the lift truck so to balance
better the load.
The head is to be positioned facing the lift truck
The forks have to be positioned between the feet and as near to them as
possible
Fig. 2.1.b Movimentazione macchina - Machine transport -
13
Packed machine.
Carry out the instructions described here bellow:
The fork has to project

over the machine
- The forks have to be inserted under the packaging, between the supporting beams
and as near to them as possible.
The forks have to be positioned

between the beams and as near
to them as possible
Fig. 2.1.c Movimentazione imballo - Packing transport -
In both cases the machine has to be hoisted and transported only after being sure the
way is free from any obstacle.
14
Handling with a crane or bridge crane.

In case the machine will be moved by means of a crane or bridge crane, the loading
capacity of transport means will have to be suitable to lift the machine itself (refer to Fig.
2.1.a); it is also compulsory to tighten the machine by using ropes or belts, as shown in the
Fig. 2.1.d.
To lift the machine it will be necessary to use a rocker arm which will be fixed to the
machine by means of ropes or belts; following this procedure you will avoid any possible
damages to the machines framework.
= 60
Rocker arm
Rope or belt
Machine
hoisting
Hoisting with
packaging
Rocker arm
Fig. 2.1.d Movimentazione con gru - Transport with crane-
In case the machine is packed it will be enough to fix ropes or belts, as shown in the
figure, having a vertex angle not bigger than =60. The typology (diameter, material etc.,) of
rope or belt has to be selected according to the admitted safety load which is punched marked
on approved lifting equipment.
- 2.1.2 STORAGE OF THE MACHINE In case the machine has to be stored longer than 3 months before being installed, it is
necessary to keep it in a covered and dry place (free from humidity), mainly to protect electric
and electrical components mounted within the machine.
Further more you need to:
- disassemble the pumping piston placed within the compression head in order to avoid
that the pistons, remaining in static contact with their relative gaskets CH, could get worn out.
- loosen the transmission belts by means of the tightening devices.
Pistons should be mounted back when installing the machine and so

should the belts be tightened.
ATTENTION!
Read carefully the paragraph 4.3 REPLACING THE COMPONENTS in order to carry
out the correct operations.
15
2.2 INSTALLING THE MACHINE

- 2.2.1 INSTRUCTIONS FOR PLACING THE MACHINE The machine has to be installed in a suitable place (temperature +5...+45 C, relative
humidity <90%), taking in consideration the weight and dimensions of the machine (see Chap.
1.3.1) and in a place not higher than 1000 over sea level.
Position the machine paying attention to level it by means of the adjustable feet. This
operation is very important since if the machine is well levelled there will not be vibrations
which might provoke negative consequences for the plant where the machine is going to be
installed. Leave 1 m at least around the machine perimeter in order to facilitate any eventual
maintenance or functioning operation on the machine.
The machine is supplied ready to be installed in line and it does not need any further
adjustment or calibration since it has already been regulated during accurate general test
that every one of our machines undergoes in our factory under simulated regular working
conditions.
- 2.2.2 CONNECTING BETWEEN PRODUCT AND FLUIDS PIPINGRefer to Fig. 2.2.a:
- Connect the compressed air (pressure in the line 5-6 bar), for starting the pressure
regulator located on the homogenizing valve.
- Connect the deminiralized water for the lubrication and cooling of pumping pistons
(to produce sterile condensation inside the machine when working in aseptic conditions).
- Connect the water or condensation draining.
- Connect the product inlet and outlet joints to the product line. To obtain a correct
performance, the product in the upstream line of the machine must be air-free and
kept at a constant supplying pressure as indicated in the paragraph 1.3.6 TECHNICAL DATA -
The inside of the product inlet pipe, before being connected, has to be
carefully washed to remove any eventual residual or slag (for example
caused by welding).
ATTENTION!
The product outlet pipe MUST ABSOLUTELY NOT BE intercepted by

opening and/or throttling devices (for example valves).
DANGER!
The outlet piping from the safety valve has to discharge downward, in
order to avoid dangerous situations for the operators. When the product
to be treated is a polluting one, make sure it is disposed off according
to the regulations in force.
The valve protects only the integrity of the head and homogenizing
valves; in case of installing a product outlet piping added while assembling, it will be necessary to install a suitable safety device just in case it
could cause overpressure.
ATTENTION!
DANGER!
16
Vista posteriore - Rear view

Vista da sotto - Bottom view
A - Product intlet SMS 1,5 B - Product outlet counterflange D.26 C - Electric cables inlet E - Water inlet, internal thread G1/4 F - Water drain, internal thread G1/4 G - Adjustable foot H - Control panel -
Fig. 2.2.a Connections placement and overall dimensions -
17
- 2.2.3 ELECTRIC CONNECTIONS -
ATTENTION!
The machine is equipped without electrical board.

All its electrical components (motor, electrovalves, push button. etc..) have been
connected into a suitable shunting box to faciloitate the connection with the
relative electrical board (see chapter relative to the electrical scheme).
The connection between machine and electrical board have to be effected in
accordance to regulations in force.
THE MACHINES FRAME MUST BE CONNECTED TO THE MAIN

OF THE ELECTRICAL BOARD.
USE THE CONNECTIONS POINT ON THE SHUNTING BOX (REF. CH.
5.5 MACHINES ELECTRICAL BOARD PAGE 01)
Fig. 2.2.b - Connessione TERRA - Connection EARTH -
18
Electric connections have to be carried out by electricians only.
ATTENTION!
When the machine has been connected to the supply system, make sure the
sense of rotation of the electric motors is correct.
ATTENTION!
!
DANGER!
To carry out this check it is necessary to remove the machines external

protections (panels). This way the moving mechanical components
represent a serious danger for the personnel in charge. It is
recommended to pay particular attention while carrying out this
operation.
Carry out a general check of the machine functioning and test the protections
functioning conditions (emergency, irregular oil pressure, magneto-thermic
switch, etc.)
To carry out this check it is necessary to operate with the control board
open. This way the voltage represents a real danger for the personnel
in charge. It is recommended to pay particular attention while carrying
out this operation.
DANGER!
19
- 2.2.4 TROUBLE-SHOOTING FOR SERVOVENTILATION In case the servoventilator of the main motor (M1) fails it is possible to execute an emergency
procedure which allows to run the machine from the maxicum capacity to half the
revolutions of the motor maintaning the
correct safety conditions.
To execute the said emergency procedure carry
A
out the following operations:
Cut off power supply to the machine.
Remove the machines protection panels
(See figure 3.1.1).
Remove the protection cap B (see figure 2.2.4b) of the forced ventilation (which you
find on the opposite side of the pulley) of the
main motor (M1) (see figure 2.2.4b). Disconnect the electrical connections of the
servoventilation motor, insulate the electrical
cables and remove the servoventilation kit
(motor+fan).
Fig.2.2.4a Original cooling fan supplied with the
Assemble the original cooling fan A (see
servicing box figure 2.2.4b) (which you find in the maintenance
box supplied with the machine) on the shaft of
the main motor (M1); then assemble back in position the protection cap B (see figure 2.2.4b).
Assemble back in position the machines protection panels and fasten them correctly
by means of the relative fastening screws.
Start up the machine again paying good attention at the litimitions afore described.
Fig.2.2.4b Main motor M1 + servoventilation kit -
20
NOTES
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21
2.3 DISPOSAL
Premise
The FBF ITALIA srl machines do not contaminate and do not cause any harm to the
environment, but during the phase of installation, maintenance or disposal there can be produced some waste that if not correctly disposed of can be actually harmful for the environment or can not be used to produce raw material.
Therefore assuring the maximum preservation of the environment has

to be the first main goal
Mineral or synthetic oil used

These are special wastes that must be given directly to those special societies in charge
for the disposal of this kind of waste.
Machinery and appliances deteriorated and obsolete
These are special wastes that must be given for scrapping according to the different
type of waste, metal alloys or plastic.
Packaging
These type of waste are assimilable and can be disposed in the installations in charge of
disposing of urban waste (first category dumps) without causing greater damage to men and
environment.
22
3 INSTRUCTIONS FOR THE OPERATORS

3.1 INSTRUCTIONS FOR THE USE
- 3.1.1 DESCRIPTION OF THE CONTROL DEVICES -
H
E
D
B
F
A - Safety valve with drain pipe B - Product inlet C - Compression head D - Oil level control E - Pressure gauge H - Emergency Stop push-button F - Product outlet I - Casing G - Adjustable foot -
Fig. 3.1.1 Identificazione componenti - Identification of components
23
- 3.1.2 MACHINE STARTING UP -
MACHINE IN
TENSION
EMERGENCY STOP
PUSH BUTTON
Fig. 3.1.2 Command devices on the machinery
How to start the machine

- Open the water supply valve upstream the machine.
- Make sure the machine is correctly fed airless and must have a constant minimum
pressure of at least as indicated in the technical data table cap. 1.3.
- Start the machine by your command pannel.
- Make sure that the whole surface of the pumping pistons, in the rear part of the compression head, is covered by a film of water in order to assure the correct cooling and
lubrication of the pistons.
Should it become necessary to regulate the water flow, use the tap installed inside the machine (see chap.5.3.7).
To avoid the water entering in contact with the oil in the pump body, the shaft of
the guiding piston must not be wet.
How to start the machine

-
24
Stop the machine by your command pannel.
- 3.1.3 EMERGENCY STOP If, in case of emergency, the machine has to be stopped, press the emergency stop
push-button located on the machine or on the electric board.
Please remember that the above mentioned devices have to be used

only in case of real emergency and not to stop the machine during
regular functioning operations.
ATTENTION!
At the end of the emergency, after having made sure no part of the machine is failing, reset
the emergency stop push-button by turning it counter clockwise, and start up the machine
again.
Fig. 1.5.b Pulsante di emergenza - Emergency stop button -
25
NOTES
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26
- 3.1.4 INSTRUCTIONS FOR THE WASHING PROCEDURE -
This chapter contains important information, therefore you have to read

it very carefully.
ATTENTION!
The machine must be washed periodically, taking in consideration the product treated
and the working needs. However we advise to do it at the end of every production
cycle.
The washing is normally a close cycle carried out while the machine is running and
only after having set to zero the homogenizing pressure. This procedure helps to
avoid possible damages to the homogenizing heads.
If the machine is equipped to be used at variable capacities, the washing will be
carried out at the maximum speed.
The operator must wear suitable clothes and/or accident prevention protections
related to the temperatures and the products used.
To carry out washing cycle there could be used both acid and basic solutions, but
what is more important is to make sure that the solutions do not contain a quantity
of nitric acid superior to 2%.
We recommend not to use washing solutions containing chlorine, specially with
sodium hypochlorite, since in presence of acid (even very weak ones) the chlorine
decomposes and has an oxidating effect. This oxidating effect, favoured by the temperature, the time, the light and by the presence of heavy metals (such as nickel,
chromium, etc..), increases the concentration of the Cl- ions and tends to lower the
PH from basic values towards neutral values. This condition favours the pitting
corrosion and the danger increases when the environment becomes a little acid.
So in consideration to these facts, we are compelled to decline any responsibility
for any relevant damages caused by the use of solutions containing chlorine, even
during the period the machine is still covered by warranty.
We recommend to respect the norms in force in the Country where the machine will
be installed for that what regards the biodegradability of the washing product and
the discharging of waste water.
PRODOTTI PER LAVAGGIO - WASHING PRODUCT

PRODOTTO - PRODUCT
max concentr.
max temper.
3%
90 C
130 C
Acido nitrico - Nitric acid
2%
72 C
Acido fosforico - Phosphoric acid
3%
86 C
90 C
Soda caustica - Caustic soda

Vapore - Steam
Acqua - Water
27
3.2 TROUBLESHOOTING
- 3.2.1 Function anomalies TROUBLE-SHOOTING
TYPE OF ANOMALY
CAUSE
REMEDY OR CONTROL
THE MACHINE DOES NOT START

UP
The emergency stop pushbuttons are engaged
Control the relative push-buttons on the control

panel of the machine and on the electrical board.
The electric protection has been

energized due to a short circuit
or to a thermal over-heating.
Check inside the electric board, having as a

reference the electrical diagram:
- the protection devices.
THE MACHINE SUDDENLY

STOPS
The oil pressure inside the
lubricating circuit is not
sufficient.
Control in the lubricating circuit the following

items:
-Piping and joints for oil leaking.
-The level of oil when the machine is not
running.
-If the filter is clogged.
-That the pump works properly .
-That the heat exchanger does not leak or is
not clogged.
Control furthermore that the secondary fan
inside the machine is working correctly.
If, once these controls have been carried out,
the malfunctioning continues, control that the
mechanical rotating parts are not abnormally
worn out.
Control the capacity upstream the machine: it has to
be slightly superior to the nominal capacity of the
machine itself.
Insufficient feeding to the

machine
Control if the feeding pressure to the machine is

enough (paragr. 1.3.6).
Control if the product fed to the machine is airless.
NOT ENOUGH CAPACITY
The rotating speed of the main

motor is lower than normal
The seals of the valves inside

the compression head are
leaking.
Control the number of revolution of the main motor

comparing this value to the main test values
(paragr. 1.3.6)
Control that the sealing surfaces of the valves

(chap. 4.6.3 - 4.6.4) and the valves' seats (chap.
4.6.5) are not worn out.
Control that there are no strange bodies between
the valves and seats afore mentioned. Should be
this the case, remove the strange bodies and clean
carefully the surfaces.
Control the return valves springs (chap. 4.6.1).
28
- 3.2.2 Safety valve operation This valve, located on the supply pipe of the compression head, is already calibrated to
a value superior to the maximum pressure admitted and operates only in case of overpressure by draining out the product. The safety valve starts operating whenever the machine
goes overpressure due to:
- Under feeding of the machine or air bubbles inside the product. In this case the safety
valve will automatically stop operating as soon as the regular conditions are reset.
Nevertheless is most important to reset the underfeeding situation as soon as possible since many parts of the machine get stressed by this conditions and could be
prematurely worn out (pressure indicator, valves and valves seats, springs, etc...).
- Extreme working pressures. To reset the right safety valve functioning can be
necessary to stop the machinery for few seconds.
Fig. 3.2.a - Safety valve
29
- 3.2.3 SIGNALLING PILOT LAMPS AND ELECTRIC ANOMALIES The control panel, with all controls, pilot lamps and control devices, is placed in the front
side of the machine (see paragraph 3.1.1 DESCRIPTION OF THE CONTROL DEVICES ).
CONTROL FOR SIGNALLING PILOT LAMPS

DENOMINAZIONE
DESCRIPTION
30
DESCRIPTION OF PILOT
LAMPS
INDICATIONS
CONTROLS TO BE CARRIED OUT
WHITE PILOT LAMP 'TENSION' ON
The machine is in
tension
None - All is correct
4 MAINTENANCE
4.1 GENERAL PRINCIPLES
An accurate maintenance program will allow to obtain best performance of the machine
with minimum costs:
We recommend to follow the base maintenance diagrams described below, mean for
the normal use of the machine.
!
DANGER!
Before carrying out any maintenance operation, it is compulsory to cut

off the power supply to the machine by means of the main switch (see
paragraph 3.1.2 - DESCRIPTION OF THE CONTROL DEVICES - to locate
the afore mentioned switch).
- 4.1.1 LIST OF RECOMMENDED SPARE PARTS TO BE KEPT IN STORE PEZZI DI RICAMBIO CONSIGLIATI - LIST OF RECOMMENDED SPARE PARTS
Q.TA'
Q.TY
DENOMINAZIONE - DESCRIPTION
PISTONE POMPANTE - PUMPING PISTON
GUARNIZIONE CH - CH GASKET
SERIE COMPLETA GUARNIZIONI TESTATA E VALVOLA DI

SICUREZZA
CODICE N
CODE No
001.04318/C
004.0006/MRR
212.PST028BCTSTD
COMPLETE SET OF HEAD AND SAFETY VALVE GASKETS

6
SEDE VALVOLA - SEAT VALVE
001.00016/T
VALVOLA - VALVE
007.0018
MOLLA - SPRING
001.00043
INDICATORE DI PRESSIONE - PRESSURE GAUGE
015.0020
SERIE COMPLETA GUARNIZIONI CORPO POMPA COMPLETE SET OF PUMP BODY GASKETS
213.FBF008/080
CINGHIA DI TRASMISSIONE - TRANSMISSION BELT
115.SPZ1287/A
31
- 4.1.2 INSTRUCTIONS FOR CHECKS AND ORDINARY MAINTENANCE -
!
DANGER!
We recommend to follow the following base maintenance programs (forseen for

a normal use of the machine) paying particular attention to the expiries of the
lubricating oil of the rotating parts. An accurate maintenance program will allow
to obtain best performance of the machine with minimum costs.
In case of doubts regards the necessity to replace or not a part of the machine,
we advise to proceed with the replacement of it because the sudden impossibility
to start or to conclude a production implies very higher costs to the user.
The fastening of the above mentioned flanges has to be carried out by

means of a dynamometric wrench; it will be necessary to respect the
values given in the table you find at the beginning of the paragraph 5.4
REPLACING AND ASSEMBLING OF COMPONENTS.

D A N G E R ! the operators.
CONTROLS
Frequency
Daily
checks
Controls
Check the oil level and if necessary refill by means of the
special observation glass located in the frontal part of the
machine.
Verify that no noise and/or anomalous vibrations are emitted
by the machine equipment.
Verify that no fluids and/or product leak from the gaskets.
Weekly
checks
After the
first 100
hours
32
Make sure the seal of the pumping pistons works correctly

Verify that the fastening elements (screws, bolts, etc.) are not
loosen, paying particular attention to the heads closing
flanges.
Control belts tightening
- 4.1.3 PROGRAMMED MAINTENANCE -
PROGRAMMA DI MANUTENZIONE - MAINTENANCE PROGRAM

Intervallo
frequency
1500
Operatore
operator
Data - date
Replacing lubricating oil of pump body
............................
Worn out and tensioning control and eventual replacing of

the transmission belts
ore - hours Firma - signed
3000
Controlli - check-in list
............................
Check/replacing the valves and valves seats
Data - date
............................

............................
Raplace springs of valve groups
Data - date
4500
............................
ore - hours
Firma - signed

............................
Data - date
............................

6000
............................
Raplace springs of valve groups
Data - date
7500
............................
ore - hours
Firma - signed

............................
33

Intervallo
frequency
9000
Operatore
operator
Data - date
............................

Firma - signed
ore - hours
............................

Replacing springs of valve groups
Replacing the motoreducer oil
10500
Data - date
............................

12000
............................
Check and replacing of homogenizing valve
Data - date
............................

34
............................
Data - date
13500
............................
ore - hours
Firma - signed

............................

Intervallo
frequency
15000
Operatore
operator
Data - date
............................

16500
Check and replacing of homogenizing valve
Data - date
............................

19500
............................
Data - date
............................

............................
Data - date
............................

............................
18000
............................
Data - date
21000
............................
ore - hours
Firma - signed

............................
35

Intervallo
frequency
22500
Operatore
operator
Data - date
............................

............................
Data - date
24000
............................
ore - hours
Firma - signed

............................
Data - date
............................

25500
27000
............................
Data - date
............................


............................
36


Intervallo
frequency
28500
Operatore
operator
Data - date
............................

30000
............................
Data - date
............................

31500
ore - hours
33000
............................
Data - date
............................
Firma - signed

............................
Data - date
............................


............................

37

Intervallo
frequency
...........
Operatore
operator
Data - date
............................

..........
............................
Data - date
............................

............................
Data - date
..........
............................
ore - hours
Firma - signed

............................
Data - date
............................

..........
Firma - signed
ore - hours
............................

38
Data - date
..........
............................
ore - hours
Firma - signed

............................
4.2 TRANSMISSION BELTS

The transmission used is the trapezoidal belts type. Follow the operation described
below to carry out correct and safe assembling operations.
We recommend to carry out assembling/disassembling operations and
the check of the belts state, only when THE MACHINE IS OFF and the
starting device blocked with the key.
!
ATTENTION!
Fig. 4.3.a Trasmissione a cinghie Belts transmission -
- 4.2.1 REPLACING THE BELTS

- Loosen the nut A
- Loosen the nuts B and C
- Turn the tension rod D
counter clockwise to
loosen tension and be
able to disassemble the
belts.
-
Remove the belt and replace it with the new one

that will be placed into the
pulley seat
- Turn the tension rod D

clockwise to tighten the
belts.
C
A
B
Fig. 4.3.b Tensionatore cinghie - Belts stretcher-
- Tighten the belts correctly,

as described, and then
tighten the bolt A and nuts B and C, as in figure 4.3.b.
39
- 4.2.2 TENSIONING THE BELTS -
The ideal tensioning is slightly bigger than the sliding limit of the belts. The overtensioning reduces the belts and shafts bearings life.
Before tightening as described later on, identify the installed belt type in the technical
card (Chapter 1.3.6)
Tensioning used belts

See fig.4.3.c and carry out the following instructions:
- Find out where the free space T of
the belt is
- Apply a force M (by means of a
dynamometer) of
2 - 3 Kg for belts SPZ
- Tension the belts, by means of the
reaction arm, so that the flection of belt
F be of 6 mm.
Lenght
of the
free spa
ce T
M
Force
Tab. 4.3.c Belts tension values
Tensioning new belts

See fig.4.3.c and carry out the following instructions:
- Find out where the free space T of the belt is
- Apply a force M (by means of a dynamometer) of 3 - 4 Kg for belts SPZ .
- Tension the belts, by means of the reaction arm, so that the flection of belt F be of 6
mm.
BELT TENSIONING TABLE

Flexion f
Belt SPZ
USED
Belt SPZ
NEW
6 mm
2 - 3 Kg
3 - 4 Kg
- 4.2.3 ATTENTION Before mounting the belts check the alignment of the pulleys by using a limit block and
then make sure they are clean.
Furthermore to assure good performance and reliability:
- Mount only new belts, never combine new ones with old ones, since it will be not
possible to tension them correctly so endangering the reliability of the transmission.
- Mount belts of the same trademark and check on the belt back that they belong the
same production lot. In fact, belts of the same trademark, with the same nominal
development, but belonging to different lots, may present little dimension differences
which will reduce the transmission life.
40
- 4.3 LUBRICATION OIL CHANGE The oils provided into the reducer and into the pump body are for a functioning with
environmental temperatures of 0 - 45 C.
In presence of different evironmental temperatures, please contact our technical
department.
OILS QUANTITIES TABLE

USAGE
QUANTITY
KIND OF OIL USED
REDUCER'S OIL
1,5 Lt.
SHELL OMALA HD
PUMP BODY'S OIL
4 Lt.
SHELL TELLUS S100
- CHARACTERISTICS OF LUBRICATION OILS SHELL OMALA HD

CARATTERISTICHE TIPICHE (VALORI MEDI INDICATIVI)
TIPYCAL FEATURES (INDICATIVE AVERAGE VALUES)
GRADAZIONE ISO
220
POUR POINT C
-48
FLASH POINT C
268
VISCOSIT cSt A 40C
218
INDICE DI VISCOSITA'
162
SHELL TELLUS S100

CARATTERISTICHE TIPICHE (VALORI MEDI INDICATIVI)
TIPYCAL FEATURES (INDICATIVE AVERAGE VALUES)
GRADAZIONE ISO
100
POUR POINT C
-27
FLASH POINT C
230
VISCOSIT cSt A 40C
100
INDICE DI VISCOSITA'
98
- EQUIVALENTS OF LUBRICATION OILS CORRISPONDENTI OLIO DI LUBRIFICAZIONE SHELL OMALA HD

EQUIVALENTS LUBRICATION OILSHELL OMALA HD
MARCA
COMPANY
TIPO OLIO
OIL TYPE
MOBIL
SHC 630
BP
ENERSYN EPX 220
CASTROL
ALPHASYN EP 220
ELF
REDUCTELF SYNTHESE 220
KLBER
KLBERSYNTH EG4
i
!
CORRISPONDENTI OLIO DI LUBRIFICAZIONESHELL TELLUS S100

EQUIVALENTS LUBRICATION OIL SHELL TELLUS S100
MARCA
COMPANY
TIPO OLIO
OIL TYPE
BP
BARTRAN HV100
ESSO
NUTO HP100
CASTROL
HYSPIN ZZ100
MOBIL
DTE EXCEL 100
Make sure to use the quantity of oil recommended since too much oil could
result in over heating the oil while if the oil is not enough the rotating components will not be correctly lubricated.
FBF ITALIA srl will not to be held responsible for any eventual damages
caused by oil having characteristics different from those indicated
afore.
ATTENTION!
41

the operators.
DANGER!
Before to proceed with these operations: oil change in the reducer, oil
change in the pump body, pump body oils cartridge substitution and
pump body oils pipes substituion, waiting untill the lubrication oils temD A N G E R ! perature cant be dangerous for for the operator.
- 4.3.1 REDUCERS C
Change the oil every 9000 hours; quantity of oil needed: 5 litres.
See fig.4.3.d, to change the oil carry out the

following operations :
- Cut power supply to the machine by means
of the main switch.
- Remove the upper, back and left side panels.
- Remove the transmission belts (see

chap.4.2) from pulley A.
- Unscrew screws E and screw them on

holes F until pulley A is free on the reducer shaft.
- Remove pulley A.
- Remove upper cover B by unscrewing

screws C.
Fig. 4.3.d Reducer
- Place a suitable container under tap D to collect the oil and remove the tap by unscrewing counter clockwise.
- Once the oil has been completely emptied screw in position tap D and refill the reducer
using oil Shell Omala HD or another one having the same features through hole B.
- Assemble back the cover B and apply the special sealing paste between the cover and
the reducer seat.
- Tighten the screws as indicated in table of chap.5.4
- Assemble the pulley and block it on the reducer shaft by screwing the screws E clockwise; make sure the pulley is in line with the other one mounted on the electric motor.
- Assemble the belts by following the procedure described in chapter 4.2.
- Assemble back in position the panels, be sure to screw em with the bolts before to restart
the machine.
42
- 4.3.2 PUMP BODY The machine is supplied already with Shell Tellus S100.
Change the oil for the first time after 1.500 working hours, and then every 1.500
working hours at least.
To change the oil carry out the following operations:
- Cut power supply to the machine by means of the main switch.
- Remove the upper, back and theleft side panel, remove the rubber pipe form the block
fig.4.3.e , unscrew the conical tap A and place a suitable container under it to collect the
oil.
- Once the oil discharge is completed screw down in position the tap A and mount the
pipe in the block; then fill up with oil SHELL TELLUS S100 or another one having the same
features the pumping body, fig. 4.3.f, by unscrewing the orange plug B.
- Make sure the oil reaches the black mark (which corresponds to the maximum level admitted) by means of the level control on the frontal side of the machine.
- Assemble back in position the panels, be sure to screw em with the bolts before to restart
the machine.
Fig. 4.3.f
A
Fig. 4.3.e
43
4.4 MAINTENANCE SPECIAL EQUIPMENT

Every machine is equipped with a tool box containing the tools necessary to carry out maintenance operations. The table here bellow contains a list of the tools.
Remember that before carrying out any maintenance operation it will

be compulsory TO STOP THE MACHINE by cutting off power supply.
!
D A N G E R
8
5
1
6
2
7
3
Fig. 4.4.a - Utensili in dotazione - Tool kit -
LISTA UTENSILI - DOTAZIONE STANDARD

TOOLS LIST - STANDARD EQUIPMENT
44
SERIE CHIAVI A FORCHETTA - FORK KEY TOOLS
17 - 19 - 24
SERIE CHIAVI A BRUGOLA - SOCKET HEAD TOOLS SERIE
5 - 6 - 10
TUBO INTRODUTTORE GUARNIZIONI CH - TUBE FOR CH GASKET
001.03591
PROLUNGA ESTRAZIONE PISTONE - EXTENSIONS FOR PISTONS EXTRACTION
001.03551/1, /2, /3
ESTRATTORE SEDI VALVOLE - VALVE SEAT EXTRACTOR
001.02211
LEVA (PER FLANGE, ECC...) - LEVER
072.0007
TONDO PVC (PER GUARNIZIONI, ECC..) - PVC GASKET INTRODUCER
001.03146
MOLLA - SPRING
001.00043
10
VALVOLA A SFERA - SPHERA VALVE
007.0015
11
SEDE VALVOLA DI SICUREZZA - SAFETY VALVE SEAT
001.04076
4.5 ORDINARY MAINTENANCE: PUMPING GROUP

- 4.5.1 PUMPING GROUP COMPOSITION -
F
A
G
C
H
E
B
D1 D2 D3 D2
E
F
G
Fig. 4.3.1 - Esploso del gruppo pistoni pompanti Exploded view of the pumping pistons group
See fig. 4.3.1; every pumping group is composed by:

- pumping piston A
- guiding band B
- guiding bushing C
- gasket CH D (formed by 4 rings: D1 - D2 - D3 - D2)
- gasket block spacer E
- gasket F
- frontal flange G
- nuts H
45
- 4.5.2 COMPONENTS OF PUMPING GROUP THAT GET WORN OUT Pumping piston A
This component should be replaced when the surface is visibly so worn out that the gasket
CH D needs to be replaced too often.
Guiding band B
This component should be replaced when coupling the guiding bushing C (that contains the
band) and the pumping piston A you feel there si too much light (more that a tenth of mm).
It should be remembered that the guiding band does not has a fundamental function in the
machine operations but makes the movement of the pumping piston to become axial so
allowing the piston and the gaskets CH D to last longer.
Gasket CH D
This component should be replaced when product comes out on the back rear of the compression head or as a preventive maintenance.
As for this last case, the preventive maintenance should be decided by the user once controlled the average operative time of the actual production (type of product, homogenizing pressure, temperature, cooling water hardness, etc...).
Gasket F
This component should be replaced when product comes out on the frontal part of the compression head or as a preventive maintenance (as for gaskets CH).
46
- 4.5.3 MAINTENANCE OF PUMPING PISTONS, GASKETS CH AND GUIDING

BANDS -
Remember that before carrying out any maintenance operation it will be

compulsory TO STOP THE MACHINE by cutting off power supply.
DANGER!
Prepare, in addition to the usual tools, the dynamometric wrench, the pistons extractor kit, the
pipe for introducing the gaskets CH and a tube of lubricant suitable to be used for food stuff.
- Disassembling operations - See fig. 4.3.1 e 4.3.2, remove the nuts H screwing them counter clockwise using the
supplied key.
- Remove the flange G and the spacer E.
- Remove the transparent protection over the compartment where the pumping pistons rods
are placed by unscrewing counter clockwise the fastening nuts.
- See fig. 4.3.2, loosen the screws R of the union
clamps P between pistons A the pumping
pistons rods ; in case the clamp can not be removed screw in a Allen screw TCEI M8 in point
T to open the clamp and help removing it.
To avoid the risk of abrasion wear

gloves while carrying out the following operations:
T
R
ATTENTION!
- See fig. 4.3.3, turn manually the transmission pulleys until a piston will reach the superior dead
point.
Fig. 4.3.2
- Turn farther the pulleys until the shaft reaches the

lower dead point (while the piston will keep on
the upper dead point) and remove the clamp.
- Repeat this operation until every clamp will be removed.
- Now take the pistons extractor kit for pistons 3
of fig.4.2.1 in page 42. The kit is composed by
extensions with progressive length.
Fig. 4.3.3
47
- See fig. 4.3.4, these extractors have a niche, at

one extremity, suitable to be introduce in the rods
of the guiding pistons S.
- Mount the short extension on a rod and, turning
manually the pulleys, carry out a complete cycle
of the rod (ahead and back). It will cause a first
phase of piston expulsion.
- Repeat the operation on the same rod using the

other extension in length progression, and if necessary, combine them in series to each other, until
you are able to hold the piston with your the hands
and pull so it comes out easily.
- Take the CH D gaskets pack and the guide bush
C away from the piston.
Fig. 4.3.4
.- Assembling operations - See fig. 4.3.1, apply a very thin film of lubricant
suitable to be used for food stuff on:
pumping piston A, guide band B, gaskets CH
D, gasket F and in the gasket seat of flange
G.
- See 4.3.5, couple the rod S with pumping piston
A by means of the clamp P, without tightening
the screws R.
- See fig. 4.3.1, insert the guiding bushing C
paying attention that the bushing holes are facing the gaskets CH D.
i
!
R
P
Fig. 4.3.5
It is most important that the bushing is placed correctly since the holes allow the
passage of water that cool down the pumping piston.
If the guiding bushing is not placed correctly the water will not flow and the pumping pistons, the gaskets CH and the guiding bands could get worn out abnormally.
To avoid the various mechanical parts getting faulty, carry out the
following operations carefully:
ATTENTION!
- See fig. 4.3.5, make sure the plane surface of the pumping piston A touches the plane
surface of the rod S and fasten the screws R of clamp P using a pair of as indicated
in table of chap. 5.4.
48
- See fig. 4.3.6, using the supplied special introducer ref. 5 fig. 4.2.1, introduce the various rings
that compose the gasket CH D for 3-4 cm inside the head.
The gasket CH is composed by 4 rings

that must be introduce in the following
order:
A
5
V ring with plane bottom D1; the rings plane

surface must face the guiding bushing C.
V rubber-cloth ring D2.
- V rubber-cloth ring D3.
Fig. 4.3.6
- V rubber-cloth ring D2.

- See fig. 4.3.6, once all rings have being placed, lay the special introducer on the last V
ring that has being inserted and press on the introducer (eventually and if necessary use a
hammer), place the gaskets CH on the guiding bushing already installed.
- See fig. 4.3.7, insert the pack spacer E paying attention that the V side faces the
gaskets CH
Insert gasket F in the frontal flange G

and control it does not get kinked. If the
gasket F kinks it will get worn out
easily.
- Mount the flange G with the gasket F inserted

in the compression head.
A
- Screw the nuts H clockwise and tighten them
using the force indicated in table chapter 5.4.
H
C D
F G
Fig. 4.3.7
Before starting again the machine:
turn manually the bigger pulley 6/
7 turns to control that all pistons execute their strokes without problems.
ATTENTION!
!
DANGER!
Assemble all protection panels.

Assemble the transparent protections on top of the pumping pistons
rod compartment and fasten it in position by screwing the two relative
nuts clockwise.
49
4.6 VALVE GROUPS

- 4.6.1 COMPOSITION OF THE VALVE GROUP -
Fig. 4.4.1 -Esploso gruppo valvola - Valve group exploded view
Every pumping group is composed by two valve groups:

- suction valve group (located inside the compression head, under the relative pumping
group)
- supply valve group (located inside the compression head, over the relative pumping
group)
The upper and lower valve groups are perfectly interchangeable.
See fig. 4.4.1, every valve group is composed by:
- valve guide A
- spring B
- ball valve C
- valve seat D
- gasket E
50
- 4.6.2 COMPONENTS OF THE VALVE GROUP THAT CAN GET WORN OUTSpring B
This component should be replaced when broken or when the surface that contacts the ball
valve C is clearly worn out.
Ball valve C
This component should be replaced when its surface is not perfectly spherical (and therefore
is not capable of adhering perfectly against the sealing surface of the valve seat D) or when
even regularly worn out, the diameter of the valve is smaller than 17 mm (the diameter of a
new valve is 19 mm).
We advise to use only original spare parts to replace the parts of the ball valve
since the market offers also not original spares with very low sphere accuracy.
Be aware that the use of unsuitable ball valves will result in the valves and seats
getting worn out to soon.
Valve seat D
The sealing surfaces (the conical one that bears the ball valve) that present incisions, cuts or
that are not perfectly circular should be changed.
A practical and extremely efficient method to value the correct sealing of the
valve seat/ball valve is composed by the following phases:
Wash accurately the valve seat and the ball valve.
Put the lower side of the valve seat (the one where the gasket E is installed) against your lips and lay the ball valve on the sealing surface of the
valve seat.
Suck with your mouth and make sure that no air passes through the coupling
between the valve and the valve seat. Control the operating state of the whole
surface of the ball valve by turning it with two fingers while carrying out the
described operations.
Gasket E
When the gasket of the lower valve group is too worn out, product comes out of the compression head O and of the suction collector P ref. fig.4.4.3
Gasket E of the supply valve group gets worn out less easily than the one located on the
lower valve group and must be replaced as a prevention every four-five changes of the lower
valve group.
51
- 4.6.3 MAINTENANCE OF THE SUPPLY VALVE GROUP The supply valve group is composed by
the same components as for the valve
groups and so the components that get
worn out are the same. Therefore apart
from the components indicated in the
previous chapter there are a few other
components, in this valve group that get
worn out and need to be replaced:
Pressure indicator T
This component has to be replaced
when does not indicate the pressure
correctly or when the membrane located in the lower part of the component (near gasket M in fig. 4.4.2) is
broken.
Gasket F e M
This component is to be replaced when
product comes out in between the upper flange and the head.
Gasket P
The function of this component is that
of cleaning and therefore will need to
be replaced only when broken.
L
M
I
A
B
C
D
E
I
F
Fig. 4.4.2 - Esploso gruppo valvola di mandata Supply valve group exploded view
Disassembling the supply valve group

- See fig. 4.4.2, unscrew counter clockwise the nuts
H.
- Lift the upper flange G and the flange that stops

the pressure indicator N and remove them.
- Remove the guide of valve A, the spring B, and
the ball valve C.
- See fig. 4.4.3, insert the point of the special extractor, rif.6 fig. 4.2.1, a little under the valve D
seat, widen the points of the extractor (hold the
lower point of the extractor and turn the handle
clockwise) until it adheres to the valve seat, then
remove the valve seat.
- Remove the gasket E only in case it needs to
be replaced.
52
Fig. 4.4.3
- Assembling the supply valve group - See fig. 4.4.1 e 4.4.2, assemble the supply valve group and insert it in the special seats of
the upper part of the compression head O.
- Insert gasket F in the special seat of the compression head.
- Insert the upper flange G and block it by means of nuts H (to be screwed up clockwise
and using a pair as indicated in table of chapter 5.4).
- Insert the tablet of the pressure indicator I on the gasket F (already mounted in the
compression head).
- See fig. 4.4.2, insert the relative pressure indicator T in the relative fastening flange N.
- Place the fastening washer of the pressure indicator L (half moon shaped) inside the
fastening flange of the pressure indicator.
- Insert gasket F in the pressure indicator.
- Insert the whole assemble in the compression head (the pressure indicator will get centred on the relative tablet I already mounted in the compression head).
- Screw nuts H clockwise and tighten them using a pair as indicated in table of chapter
5.4.
53
- 4.6.4 MAINTENANCE OF THE SUCTION VALVE GROUP Disassembling the suction valve group
- See fig. 4.4.6 for maintenance of suction valve
group disassembling the product inlet pipe P
by unscrewing nuts G counter clockwise.
- In case just the suction valve group needs to be
maintained carry out the following operations:
inset the extremity of the special extractor, fig.
4.4.4, a little under the valve D seat; widen the
extractor extremities (hold the lower point of the
extractor and turn the handle clockwise) until it
adheres to the valve seat, then remove the valve
seat located in the compression head.
D
E
Fig. 4.4.4
Since this operation could easily damage the suction valve seat, we advise to
carry out the following operations:
- See fig. 4.4.5, the suction valve group can be removed from the supply valve seat but you need
to remove the pumping piston and the supply
valve group first. Then insert the special percussion bar (made of red plastic rif.8 fig.4.2.1) in the
upper part of the head, pass through the piston
chamber and lay it on the suction valve guide.
Use a hammer given light mallet blows on the
percussion bar and carefully remove the suction
valve group (place a container under the valve
group to avoid that the component might fall during the extracting operations).
A
B
D
E
C
Fig. 4.4.5
54
- Assembling the suction valve group - See fig. 4.4.6, assemble back the
gaskets E and the complete suction valve group and mount it back
in the head.
- Press the gasket E so that it holds

the valve group inside the head.
A
- Mount the suction collector and
tighten the nuts turning them clockwise using a pair as indicated in
table of chap. 5.4.
B
C
D
E
Q
Fig. 4.4.6 - Suction valve group exploded view
55
4.7 SAFETY VALVE

- 4.7.1 Composition of safety valve See fig. 4.8.a, the safety valve is composed by:
- safety valve seat A
- ball valve B
- gasket C
- shutter guide D
- shutter gasket E
- shutter group F
- blocking flange G
- valve support I
- screws W
D B AC
Fig. 4.8.a Exploded view of the safety valve
- 4.7.2 Components of the safety valve that can get worn out Safety valve seat A / ball valve B
Both the valve and its seat can get worn out due to vibrations/strong impacts the valve
undergoes when being operated during long periods of time. If these components are worn
out product will come out of the product pipe even if the machine is working at a regular
pressure.
Gasket C
The reasons why this gasket gets worn out are the same as for the previous paragraph,
but in this case if the gasket is worn out the product comes out of the fastening flange.
Shutter gasket E
The function of this component is that of protecting the valve boy (avoiding that the product
enters in the valve) and will need to be replaced when showing worn out signals during
maintenance operations of other components.
56
- 4.7.3 Maintenance of the safety valve When the safety valve is operating, the product comes out of the relative drain pipe. Find
out what is causing the anomaly as described in chap. 3.2.2.
If product has come out for a short time or a very small quantity has been drained, it is
possible to end production before carrying out the washing cycle.
Maintenance of the safety valve is very simple:
- Remove pipe X and the safety valve by unscrewing screws W counter clockwise.
- Remove the components listed before and wash them carefully using suitable cleaning
products.
- If product has been drained for a short time you can mount back the components of
the safety valve without further operations.
- If product has been drained for a long time, no matter the homogenizing pressure is
within regular operating values, it will be necessary to replace the worn out components.
- Assemble back all components of the safety valve as described in fig.4.8.a.
- Mount the valve and fasten it by screwing the nuts W clockwise in a cross section
and then tighten them using a pair as described in table of chap.5.4.
X
Fig. 4.8.b How to orientate the
drain pipe of the safety valve
ATTENTION
To avoid being splashed by the product in case of intervention of the

safety valve, we advise to block pipe X by means of the relative pulley,
paying attention that the drain hole faces the internal part of the machine.
57
5 SPARE PARTS TABLES AND INSTRUCTIONS FOR REPLACING

THE COMPONENTS
5.1 HOW TO READ THE SPARE PARTS TABLES To order correctly the spare parts follow the instructions given below:
- Identify the pieces you need on the spare parts tables which are indicated in the
relative table with a position number.
- See the description list enclosed to the table and look for the number you need and
read in the relative line the description and code number of the component.
- Then, list the description of the components with their relative code and add the desired quantity.
- Complete the request adding the data relative to the machine type and its serial
number.
LISTA PARTI - SPARE PARTS LIST

POS.
ITEM
58
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
SUPPORTO VALVOLA
001.04439
GUARNIZIONE
001.00075
SEDE VALVOLA
001.04076
VALVOLA SFERA
007.0015
GRUPPO OTTURATORE
001.04077
VITE
030TE12X045
FLANGIA BLOCCAGGIO
001.04220
GUARNIZIONE
003.3100
5.2 SPARE PARTS ORDER FORM Please copy this form and fill in data then send it by fax or mail.
FBFITALIA s.r.l.
Via Are N 2
43038 Sala Baganza
(Parma) Italy
Tel.: ++39 (0)521 804412
Fax : ++39 (0)521 804692
Company : .................................................................................................................
serial number of homogenizer : ...............................................................................
telephone : .................................................................................................................
address : ....................................................................................................................
PAG.
PAG
POS.
ITEM
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
59
5.3 SPARE PARTS TABLES

- 5.3.1 PISTONS AND HEAD TABLE -
60

POS.
ITEM
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
INDICATORE DI PRESSIONE - PRESSUREGAUGE
015.0020
GUARNIZIONE - GASKET
003.0321/R
FLANGIA BLOCCAGGIO - FASTENING FLANGE
001.04311
RONDELLA BLOCCAGGIO - FASTENING WASHER
001.00056
PRIGIONIERO - STUD
001.04313
GUIDA VALVOLA - VALVE GUIDE
001.00039
FLANGIA SUPERIORE CIECA - BLIND UPPER FLANGE
001.04129
MOLLA - SPRING
001.00043
VALVOLA A SFERA - BALL VALVE
007.0001
10
SEDE VALVOLA - VALVE SEAT
001.00016/T
11
001.00075
12
PISTONE - PISTON
001.04318/C
13
COLLETTORE - COLLECTOR
001.04132
14
PRIGIONIERO - STUD
001.01549
15
VITE - SCREW
030.TE08x025
16
FLANGIA - FLANGE
001.04131
17
FASCIA DI GUIDA - GUIDE BAND
054.0043
18
BOCCOLA ANELLO GUIDA - GASKET BLOCK SPACER
001.04317
19
004.0006/MRR
20
DISTANZIERE PACCHETTO - GASKET BLOCK SPACER
001.04316
21
003.0321
22
PRIGIONIERO - STUD
001.01548
10
23
DADO - NUT
044.016
18
25
001.00189
27
PASTIGLIA INDICATORE DI PRESSIONE - PRESSURE GAUGE PAD
001.04312
28
001.00188
30
TESTATA - HEAD
001.04124
31
GUARNIZIONE OR - OR GASKET
003.4028
32
TAPPO - CAP
001.05163
33
FLANGIA - FLANGE
001.05162
34
VITE - SCREW
030.TE12x040
61
NOTES
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
..........................................................................................................................................................
62
- 5.3.2 Safety valve table -

POS.
ITEM
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
001.00075
SEDE VALVOLA - VALVE SEAT
001.04076
VALVOLA A SFERA - BALL VALVE
007.0015
GRUPPO OTTURATORE - SHUTTER
206.V.SIC01-04-N
VITE - SCREW
030.TCEI12x040
FLANGIA BLOCCAGGIO - FASTENING FLANGE
001.04220
003.3100
GUIDA OTTURATORE - SHUTTER GUIDE
001.04082
11
003.4075
63
- 5.3.4 PUMP BODY TABLE -
64

POS.
ITEM
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
VITE - SCREW
046.TCEI10x020
12
003.4450
VITE - SCREW
046.TE08x020
10
COPERCHIO - COVER
001.04133
CORPO POMPA - PUMP BODY
001.04098
10
STELO PISTONE - PISTON SHAFT
001.04111
11
006.0045
12
RASCHIATORE - SCRAPPER
006.0041/DCT
13
003.0164
14
VITE - SCREW
030.TCEI08x025
12
15
DISCO PARASPRUZZI - WATER SHIELD RING
001.05156
16
MORSETTO - CLAMP
001.04106
17
VITE - SCREW
030.TCEI08x020
18
PISTONE GUIDA - GUIDE PISTON
001.04097/P
19
SEEGER - SEEGER
008.0012
20
SPINOTTO - PIN
001.04206
21
DADO - NUT
044.020
22
PRIGIONIERO - STUD
001.04230
23
BIELLA - ROD
001.04100
24
PARAOLIO - OIL RETAINER
006.0027
25
003.4150
26
DISTANZIERE - SPACER
001.04105
27
LINGUETTA - TONGUE
037.0036
28
ALBERO A GOMITO - CRANK SHAFT
001.04101
29
003.A1100
30
BRONZINA - BEARING BRASS
001.04102
32
CUSCINETTO - BEARING
009.0022
33
FLANGIA - FLANGE
001.04103
34
FLANGIA - FLANGE
001.04099/RG
35
FLANGIA - FLANGE
001.04104
36
TAPPO - CAP
066.0015
65
- 5.3.5 MOTOR TABLE MOTOR

POS.
ITEM
66
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
MOTORE - MOTOR
025.1006/ST
RIDUTTORE - REDUCER
056.0011
TENDITORE - TIGHTENER
056.0011/B
PULEGGIA - PULLEY
116.SPZ280-3/C
CALETTATORE - SPLINER
117.BC2517/024
CINGHIA - BELT
115.SPZ1287/A
PULEGGIA - PULLEY
116.SPZ118-3/C
CALETTATORE - SPLINER
117.BC2012/038
SET GUARNIZIONI RIDUTTORE - GASKETS SET FOR REDUCER
214.RI080
- 5.3.6 HYDRO-PNEUMATIC SYSTEM TABLE -
Water IN : Tap water inlet

Water OUT : Water outlet to heat exchanger

POS.
ITEM
DENOMINAZIONE
DESCRIPTION
RUBINETTO - TAP
FILTRO - FILTER
VALVOLA - VALVE
FLUSSOSTATO - FLUXMETER
IMMAGINE - PICTURE
CODICE N
CODE No.
061.0002
010.0010
061.0018
022.0005
Q.T
Q.TY
1
67
- 5.3.7 INLET PRODUCT FLANGE TABLE -

POS.
ITEM
68
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
GUARNIZIONE OR - OR GASKET
003.4137
FLANGIA - FLANGE
001.03547
054.0007
GIRELLA - UNION
002.0068
RACCORDO - UNION
002.0067
BOCCHETTONE - UNION
002.0066
- 5.3.8 OUTLET PRODUCT COUNTERFLANGE TABLE -

POS.
ITEM
DENOMINAZIONE
DESCRIPTION
CODICE N
CODE No.
Q.T
Q.TY
001.00075
FLANGIA - FLANGE
001.04738
PRIGIONIERO - STUD
001.02822
DADO - NUT
044.012
69
5.4 RECOMMENDED TORQUE FOR FASTENING STUDS -
Torque for fastening studs

DIMENSIONS TORQUE (in Nm)
DIMENSIONS TORQUE (in Nm)
M8
20-25
M8
15-20
M10
40-50
M10
20-30
M12
75-90
M12
60-75
M16
160-180
M16
130-150
M20
200-230
M20
150-180
M24
280-310
M24
M27
320-350
M27
M30
430-480
M30
M33
550-600
M33
!
ATTENTION!!
70
Torque for fastening screws
Studs are made of special material and must be replaced only with
original ones.
5.5 ELECTRIC SYSTEM
71

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Index

1 General information ............................................................................................................... 3

- 4.2.2 Tensioning the belts - ..............................................................................................36

1.1 HOW TO USE THIS MANUAL

- 1.1.1 Symbols description -

Follow carefully the instructions contained in this instructions manual,

This symbol is positioned on the machine compression head.

1.2 MACHINE IDENTIFYING DATA

1.3 TECHNICAL FEATURES

Fig. 1.3.a Dimensioni dingombro - Overall dimensions -

DIMENSIONI INGOMBRO - OVERALL DIMENSIONS

PESO TOTALE - TOTAL WEIGHT - Kg 420

- 1.3.2 CONSUMPTION ACCORDING TO USE -

Forza motrice - Motive power

Aria compressa - Compressed air

- 1.3.3 ELECTRICAL FEATURES DATI ELETTRICI - ELECTRICAL DATA

Potenza nominale installata - Installed nominal power

Corrente nominale - Nominal current

Corrente effettiva ai valori massimi di portata e pressione

1 m Machine front rear

Fig. 1.3.c Rilevamento livelli acustici - Acoustic level values -

- 1.3.6 TECHNICAL DATA

MAXIMUM WORKING PRESSURE ................................................Kg/Cm 2 (bar)

PUMPING PISTON STROKE ..........................................................mm

PUMPING PISTON DIAMETER ......................................................mm

SUPPLY MINIMUM PRESSURE REQUESTED ...........................Kg/Cm 2 (bar)

ELECTRIC MOTOR PULLEY

SERVOFAN FOR MAIN MOTOR

OIL PUMP MOTOR

ACTUAL CAPACITY IN ABSENCE OF PRESSURE

NOTES: MACHINE TESTED AT 400 VAC 60 HZ

1.4 DESCRIPTION OF THE MACHINE

1.5 SAFETY DEVICES AND PROTECTIONS

When carrying out maintenance operations on electrical or mechanical

Before to proceed to any maintenance operation, wear the safety devices

Never tamper/modify the calibration of the valve!

The product discharged by the valve has to be collected and disposed

The operator must press, IMMEDIATELY and WITHOUT HESITATION, the

In case any other machine or equipment have to be installed near the

Fig. 1.5.b Pulsante di emergenza - Emergency stop button -

1.6 WARRANTY CONDITIONS

PESO - WEIGHT Kg 165

Fig. 2.1.a Dimensioni imballo - Packing dimensions-

- The machine has

The fork has to project

The head is to be positioned facing the lift truck

Fig. 2.1.b Movimentazione macchina - Machine transport -

The fork has to project

The forks have to be positioned

Fig. 2.1.c Movimentazione imballo - Packing transport -

Handling with a crane or bridge crane.

Fig. 2.1.d Movimentazione con gru - Transport with crane-

Pistons should be mounted back when installing the machine and so

2.2 INSTALLING THE MACHINE

The product outlet pipe MUST ABSOLUTELY NOT BE intercepted by

Vista posteriore - Rear view

Fig. 2.2.a Connections placement and overall dimensions -

- 2.2.3 ELECTRIC CONNECTIONS -

The machine is equipped without electrical board.

THE MACHINES FRAME MUST BE CONNECTED TO THE MAIN

Electric connections have to be carried out by electricians only.

To carry out this check it is necessary to remove the machines external

Fig.2.2.4b Main motor M1 + servoventilation kit -

Therefore assuring the maximum preservation of the environment has