Professional Documents
Culture Documents
SERVICE MANUAL
TECMON S.r.l.
Via Leonardo Da Vinci, 11/b 20060 Cassina dè Pecchi (MI) ITALY
Tel. +39 02/95299106 Fax +39 02/95299315
e-mail tecmon@tin.it
http://www.tecmon.it
TABLE OF CONTENTS 6.5 Recommended lubricant table 32
Chapter 5B START-UP
Chapter 6 MAINTENANCE
6.1 Cleaning 30
6.2 Cleaning of the machine 30
6.3 Extraordinary maintenance 31
6.4 Lubrications 31
2
Chapter 1 GENERAL INFORMATION
3
1.1 GENERAL NOTICE Bold is used for emphasis or
Bold paragraph titles.
Details and/or drawings within this publication,
information regarding materials and the
technologies of the processes, as well as the
rights deriving from the ideas, and inventions, 1.3 SCOPE OF THE MANUAL
and patents are the exclusive property of The
manufacturer This manual has been drawn by the
manufacturer and is enclosed with the
The reproductions and the divulgement of the machine.
drawings and information to third parties
without previous written authorization of The The information contained is intended for
manufacturer is strictly forbidden. unskilled (inexperienced) and skilled operators.
Photographs and drawings are provided for This manual defines the purpose for which the
example only ; the maker’s policy of constant machine has been manufactured and contains
development and updating may lead to all necessary information for safe, correct use.
modifications without prior notice. Carefully consult this manual before carrying
out any service of the machine.
1.2 SYMBOLS AND CONVENTIONS
Constant observance of the stated standards
The following conventions are used throughout guarantees booth the machine and personnel
this manual : safety, economic running and longer working
life.
WARNING messages indicate
►
NOTE contain important
information set off from the
text.
4
The following date can be found on the plate :
1.5 MANUFACTURER IDENTIFICATION SERIAL NUMBER : progressive number
of the construction
The machines and their accessories are TYPE : Model of the machine
produced by the manufacturer printed on the WEIGHT : weight of the machine
label. YEAR : Year of production
►
applying to The manufacturer
for information or when
ordering spare parts.
VLAV/104
2003 360
2211
VLE/026
2007
1960
5
1.8 REVISION HISTORY
Document approval :
- Edited : MG/mt
- Date : June 2007
6
Chapter 2 SAFETY PRECAUTIONS
7
2.1 USER SAFETY RECOMMENDATIONS Pay strict attention to all caution, warning and
danger signs on the machine.
In addition to the known specifications, safety
and carefulness recommendations are used Always use original spare parts. Failure to
here in order to call the operators and replace broken or worn parts with factory
technicians attention to the possible dangers replacement parts or poor quality parts could
which might derive from the incorrect operation cause serious damage to the equipment
of the machine. and/or injury to personnel.
Make safety a habit!
▲
WARNING – Failure to comply
with the safety 2.2 ELECTRICAL DEVICE PRECAUTIONS
recommendations and/or the
▲
machine incorrect utilization
WARNING – SHOCK HAZARD
may imply the risk of injuring
Only qualified personnel
yourself or other people.
familiar with the equipment are
permitted to install, operate
and maintain the device.
Before starting the machine operation,
utilization and maintenance, it is absolutely
necessary to read this instruction manual A qualified person is someone who is familiar
carefully. with all safety notes and established safety
practices with the installation, operation and
Do not attempt to operate any machine until maintenance of this equipment and the hazard
you understand how it functions. If you are not involved.
certain after studying the manual, contact our
Technical Assistance Department. System documentation must be available and
observed at all times.
Before starting the working cycle, the operator
must make sure that nobody and nothing is All non-qualified personnel must keep at a safe
within the machine’s working range. distance from the equipment.
Never operate the machine unless all guards The system must be installed in accordance
are in place and do not attempt to make any with local regulations.
safety device inoperative. Don’t clean, oil,
repair machinery or make any mechanical Immediate replace electric cables if they are
adjustment during the cycle. damaged.
8
2.3 SUPERVISOR RECOMMENDATIONS
WARNING – Any
▲
modification, alteration,
replacement of parts with
different types of parts can
seriously affect the safety of
the operators.
Anyone who carries out such
operations, without previous
authorisation from The
manufacturer becomes
responsible according to the
laws in force, for any
consequence.
9
2.4 SAFETY STICKERS
Whenever the stickers need replacing, it is
It is fundamental to pay attention to the safety necessary to order a complete set of stickers
signs on the machine. from our Spare Parts Department.
Therefore, the user is recommended to keep The following stickers can be found on the
all stickers in readable condition. machine:
10
2.5 INFORMATION ON THE RESIDUAL
RISK
►
maintenance and cleaning
operations and each tine
before the start-up make
sure that all safety devices
have been installed and do
function.
11
Chapter 3 TECHNICAL SPECIFICATIONS
12
3.1 TECHNICAL DATA STEAM CONNECTION
►
vary according to the type of
product or the fruit variety
and container size to be
processed.
ELECTRICAL EQUIPMENT
COMPRESSED AIR
Consumption 0 Nl/h
Supply pressure 6 bar
Connections not present
WATER CONNECTION
Consumption :
To fill the washing tank about 1.000 l
To replace the water about 300 lit /h
Supply pressure 2 bar
Connections :
Water main entrance 1” pipe
Water main discharge valve Ø 2 inch
The washing operation will be handled
manually
13
3.3 DESCRIPTION OF THE MACHINE
- Elevator speed through a ratio motor The measurement is taken 1 mt far from the
- Inclination of the inlet water machine
- Quantity of new water
- Residence time of the product VALUES TAKEN
Measurement
3.4 OPERATING CYCLE LA eq = > 70 dBA
14
line, the operator should repeat the
phonometric surveys with the machine in
normal operating conditions, to check that the
limits foreseen by the laws in force are not
exceeded. If the noise is above such limits, the
machine could be harmful for the operator’s
safety. If this happens, it is necessary to :
15
Chapter 4 SHIPPING AND ASSEMBLING
16
4.1 SHIPPING AND UNPACKING 4.2 LIFTING THE MACHINE
▲
previously acquired the equipment suitable for
precautions during machine moving the machines and accessories that
lifting and carriage. Keep out make up the plant.
of the suspended loads
and/or anyway the range of
the fork lift.
17
IMPORTANT : Before proceeding to lift the Check the levelling using a simple level or
machine make sure that nobody is standing “water pipe level” correspondence to the
in the machine’s operating range. positions relative to the machines of the line.
A person must give instructions on the
operations to be done. Carry out the electrical connections taking care
to verify that the frequency and voltage of the
Caution : Respect the minimum distances electric panels (if installed) and of the motors
from the surrounding walls or from any are the same as those of the network.
items that are obstacles, in order to allow
easy access around the machines for
NOTE – It is advisable to place
operations.
vibration damper elements
Lifting using a lift truck
Check the load bearing capacity of the truck.
See the technical data table with relevant
► between the feet of the machine
and the resting plane, in order to
reduce the vibrations and noise
produced by the machine as
weights of the machine to be lifted.
crossing the structures, these
could affect the good
functioning of the other
4.3 CHECKING ON ARRIVAL
machines and/or delicate
equipment and could damage
Before starting to position and fix the machine,
the personnel’s safety and
ensure that the machine conforms to that
wellbeing.
which was requested on the contract.
- That the whole machine is in perfect After having positioned the machine, rinse it
condition of preservation. inside and out with clean water to remove any
dust deposit. Make all the necessary
- That the pack includes all the equipment connection to the other machines in the line.
required by the contract. (See Main Lay-out).
▲
immediately contact The manufacturer WARNING – SHOCK HAZARD
For the electric connection
After checking that the machine and its fittings apply to a skilled electrician.
are in excellent condition, proceed to locate
and level the machine.
Connect the motor to the electric panel board
4.4 GENERAL NOTIONS ON THE following the instructions indicated on the
FOUNDATION TECHNIQUES general wiring and in Chapter 3, “Technical
specifications”, complying with the safety rules
The machine does not need any particular in force for electrical equipments.
interventions on the foundations; it is however
necessary to ascertain whether such
foundations are able to support the load of the
machine.
18
CAUTION – Upon
connection, carefully check
that the network tension is
the same as that for which
the electric panel has been
constructed and that the
supply line and all the
equipment connected to it,
are dimensioned to
withstand the maximum
load required by the
machine.
(See “Electrical diagram”)
B) rinser water
EARTHING PLANT
Grounding earthing
Photo 3
19
C) Overflow water discharge (Photo 4)
20
PRODUCT CONNECTION
Photo 1
21
Chapter 5A CONTROL PANEL
AND SAFETY DEVICES
22
5A.1 OPERATOR’S CONTROL PANELS
23
Chapter 5B START - UP
24
5B.1 CHECKS BEFORE START-UP - the lubricant level in all components
(variators, reducers, etc.) is correct;
WARNING – All the
25
5B.2 FIRST START OF THE MACHINE CAUTION - Before every start-up, make
sure that all the fluid feedings are open
(compressed air, water, steam, etc.).
CAUTION - Before each
start of the machine, Remember that these operations must only
make sure that the water carried out by personnel trained for the
infeed device has been operations,. And no-one-else.
opened.
Before starting check again there are not
At the end of the installation and the impediments to prevent the natural movement
adjustments, of the mechanical parts of the machine and no-
start the machine, proceeding as follows: one touches any part of the machine during
- Make sure that all the checks, described in the test.
the
paragraph "Checks before start up" , have
been
carried out;
The machine is not equipped with an own
electric panel board so control once again of
the wiring is well done.
The operating controls are located in the
general
electric panel board of the preparation line.
The electric panel board description is inserted
in the
instruction manual of the line.
OPERATIONS
Rotations direction test
26
Chapter 5C CHECK AND ADJUSTMENT
27
- Remove the discharge tap ;
5C.1 CHECK AND ADJUSTMENT
OPERATIONS - Open the charge tap ;
- when all the oil is discharged close the
CAUTION - These discharge tap ;
operations have to be - Add oil just to cover the window
carried out by specialized - Close the charge tap
personnel, very carefully
and in safety conditions 5C.2 TROUBLE SHOOTING
of the machine
This section lists some of the problems that
may be encountered in the field and some of
ADJUSTING THE MACHINE
the likely solutions to the problems.
If it’s possible to increase or decrease the NOTE - This, in no way
elevator speed to change the residence time of implies that you will have
the product, to do this it is necessary to similar trouble, or that if
►
operate through an ratio motor placed on the you do they will have to be
belt.. the same causes.
This outline is merely a
Belt tension guide to assist you in
locating the difficulty.
After the first days of working the belt try to
became longer due to the effect of the
machine bedding. To adjust the belt tension
please adjust the slides of the belt shaft Attention _ In order not to
screwing of the dedicate screw. This operation compromise the good
could be make after the first days of working functioning of the machine,
and after once a week. do not overload with
. product too much.
After the first 100 working hour it is necessary Problem : unusual noises from the centrifugal
to substitute the oil pump
28
Chapter 6 MAINTENANCE
6.1 Cleaning
6.2 Cleaning of the machine
6.3 Extraordinary maintenance
6.4 Lubrications
6.5 Recommended lubricant table
29
6.1 CLEANING 6.2 CLEANING OF THE MACHINE
This information should be requested directly These operations have the scope to remove all
from the Technical Service Department of the the residues from processing and dirt in
detergent producers. general, which could favour the proliferation of
micro organisms.
NOTE - A correct cleaning and
disinfection programme, If a complete disinfection is necessary the
carried out regularly and disinfect-ant should be applied to the cleaned
which respects the and rinsed surfaces. We also recommend
regulations for the these operations before starting after long
►
safeguarding of the periods of inactivity.
atmosphere, is the condition
necessary to ensure in time WARNING - Make sure not to
▲
the maintenance of product wet the electric panel installed
hygienic and quality beside the machine, during the
standards, the maximum washing operation.
safety for the machine
operators and the regular
functioning of the machines, CAUTION – Use exclusively non-
with less necessity for caustic detergents (do not use
supplementary maintenance caustic soda). Do not heat the
and consequently a higher washing liquid to a temperature
production yield of the plants. above 80°C.
30
- Start up the elevator and clean it. Periodically check the oil level of the reducers
when not in function, and top it up with the
- Finally wait until all the parts of the machine brand indicated on the same reducer so as to
are perfectly dry before reassembling achieve the correct level. Substitute the oil in
everything. the periods indicated by the manufacturers,
using the correct quality of lubricant.
Note : if it is advisable to grease all the parts,
do it before starting the production again. NOTE - If the oil is thrown
away or badly burned, it can
6.3 EXTRAORDINARY MAINTENANCE cause serious damage to
►
the environment. If instead it
As extraordinary maintenance it will be is collected correctly, it
possible to replace totally or partially Intralox doesn’t damage the
belt. To carry out this operation follow the environment and it can be
instruction on “Attachment 3” recuperated. So, to prevent
this happening, used oils
6.4 LUBRICATIONS must not be mixed with oil
that can not be regenerated
A correct lubrication is an essential factor for or with toxic substances
the perfect functioning of the machine; and must be consigned to
therefore we recommend that strict checking special authorised disposal
and substitutions that have been foreseen are centres.
to be respected with lubrication pauses when
necessary.
31
LUBRICATION PROCEDURES
32
APPLICATION SUPPLIER TYPE U.S.D.A.
CLASS
Hydraulic oil for oleodynamic AGIP ARNICA 46 ----
equipment CASTROL HYSPIN AWH 46 ----
CHEVRON MECHANISM LPS 46 ----
ELF HYDRELF DS 46 H2
ESSO INVAROL EP 46 (HV 46) ----
FINA HYDRAN 46 ----
KLÜBER KLÜBER 4 UH1 46 H1
KLÜBER LAMORA 46 ----
IP HYDRUS OIL 46 ----
IP HI 46 ----
MOBIL DTE 15 / DTE 25 ----
REINACH EHT 14 H ----
SHELL TELLUS OIL T 46 H2
TEXACO RANDO HD 46 / HD-Z 46 ----
TEXACO CYGNUS HYDRAULIC OIL 46 H1
33
APPLICATION SUPPLIER TYPE U.S.D
.A.
CLAS
S
Permanent oil for reducers and AGIP BLASIA S 220 ----
variators (for general use; verify CASTROL ALPHA SN 150 ----
the details that are indicated on CHEVRON GEAR COMPOUND EP 220 ----
the reducer's plate and technical ELF REDUCTELF SYNTHESE 220 H2
documentation of the suppliers) ESSO SPARTAN SYNTHETIC EP 220 ----
KLÜBER KLÜBEROIL 4 UH1 220 H1
KLÜBER SYNTHESO D 220 EP ----
IP TELIUM F ----
SHELL TIVELA OIL WB H2
TEXACO SYNLUBE CLP 220 ----
TEXACO CYGNUS GEAR OIL 220 H1
Lubrication oil with drop oiler for AGIP-ROCOL FOODLUBE CHAIN FLUID H1
motorized chains and cinematic ELF REDUCTELF SYNTHESE 220 H2
motion ESSO FEBIS K 68 ----
KLÜBER KLÜBEROIL 4 UH1 220 H1
KLÜBER STRUCTOVIS FHD H2
IP TELESIA OIL 220 ----
SHELL TONNA OIL TX 220 H2
SHELL ONDINA OIL 68 H1
34
APPLICATION SUPPLIER TYPE U.S.D.A.
CLASS
Grease for heavy jobs (ball-bearing AGIP GR SM ----
and gear with high load capacity AGIP-ROCOL FOODLUBE GREASE 2 H1
and high speed) CASTROL SPHEEROL LMM ---
CHEVRON MOLY GREASE 2 ----
ELF EPEXELF MO2 H2
ESSO MULTIPURPOSE GREASE ----
FINA MARSON LM ----
KLÜBER PARALIQ GA 343 H1
KLÜBER KLÜBERPLEX BE 31-102 H2
IP BIMOL GREASE 481 ----
MOBIL GREASE SPECIAL ----
MOLYDAL GRAISSE 1495 H2
REINACH SFERUL LC/MP ----
SHELL RETINAX AM H2
TEXACO MOLYTEX 2 ----
35
Chapter 7 DISMANTLING
7.1 Introduction
7.2 Waste disposal
7.3 Machine demolition
36
7.1 INTRODUTION 7.3 MACHINE DEMOLITION
All elements, objects or substances resulting To demolish and then scrap the machine in
from human activities will at some time be your possession, please follow the follow
turned into waste following the natural steps:
biological cycle.
Disconnect the machine from the mains
Refuse is split into three main categories : electricity supply and compressed air supply.
With machine power supply off, check the
- Solid urban refuse : This category compressed air circuit is not pressurised.
comprises all refuse produced by human Consult the authority responsible for the
activities such as paper, cloths, plastics, cans, registration and certification of demolished
bottles, etc. machines according to the legal provisions
applicable in the country in which the machine
- Special refuse : This category comprises all is installed.
refuse produced by industrial manufacturing
processes (chemical industry, refineries, Drain, store and consequently dispose as
tanneries etc.) light industries (car workshops, provided for by law of the “Special” and “Toxic
small factories, etc.) farming activities (animal or harmful” substances (oils, greases, liquid
husbandry, feed mills etc.) that may not be coolants and lubricant, etc.) present in the
mixed with urban refuse due to their quantities lubrication tanks and mechanical and
and qualities. lubrication cooling (gear reducers, variable
speed gears, gearboxes, etc.)
- Toxic or harmful refuse : This category
comprises all toxic or harmful refuse that is Dismantle the machine making sure to divide
either contaminated or partly contains any of its component material by their chemical
the substances listed in DPR 915/82. properties (iron, aluminium, bronze, plastic,
wood etc.)
7.2 WASTE DISPOSAL
By following the legal provisions applicable in
Special care must be taken with “Special” and the country in which the machine is installed,
“Toxic or harmful” refuse. scrap the various materials and dispose of the
various “Special” and “Toxic or harmful”
This refuse must be disposed of in compliance components.
with directives applicable in the user’s country
on environmental protection;
37
Appendix A FORMS
38
A.1 USER COMMENT SHEET
TECMON SRL
Technical Publication Department
VIA LEONARDO DA VINCI, 11/B
20060 CASSINA DE’ PECCHI (MI) - ITALY
Telefono : +39 02 95299106
Telefax : +39 02 95299315
E mail : tecmon@tin.it
39
To: Tecmon srl - TECHNICAL PUBLICATION DEPARTMENT
From: Name
Company ..........................................................................................................
Address ...........................................................................................................
Errors found in this publication (please list reference page, table, or figure numbers) ............................
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A.2 ADDITIONAL DOCUMENTATION REQUEST
FORM
TECMON SRL
Spare Parts Department
VIA LEONARDO DA VINCI, 11/B
20060 CASSINA DE’ PECCHI (MI) - ITALY
Telefono : +39 02 95299106
Telefax : +39 02 95299315
E mail : tecmon@tin.it
41
To: Tecmon srl - SPARE PARTS DEPARTMENT
Company …................................................................................................
Address .......................................................................................................
Please send us your offer for the following documentation concerning the above machine:
Description Quantity
...............................................................................................................................................................
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A.3 SPARE PARTS REQUEST FORM
43
KEY TO PARTS FOR washing unit
2
5
1
Fig.1
44
When ordering spare parts, to our Spare Parts
Department, please always supply the
following information :
- Machine model
- Machine serial number
- Year of production
- Table number
- Item reference number
- Denomination
- Item code
- Required quantity
- Way of shipment
TECMON SRL
Spare Parts Department
VIA LEONARDO DA VINCI, 11/B
20060 CASSINA DE’ PECCHI (MI) - ITALY
Telefono : +39 02 95299106
Telefax : +39 02 95299315
E mail : tecmon@tin.it
45
To: Tecmon srl - SPARE PARTS DEPARTMENT
Company .......................................................................................................................
Address .........................................................................................................................
Please send us your offer for the following parts concerning the above machine:
46
OWNERS NOTES
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ATTACHEMENTS
Intralox belt
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INTRALOX BELT
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