CMB Bodymaker

OPERATING AND SPARES MANUAL
5500 CANMAKER
Machine Code: 015047
B ook1
B ody maker
PUBLISHER
CarnaudMetalbox Engineering Limited

This manual contains confidential material included solely for
the benefit of our customers. No part of this manual may be
reproduced in any form, or by any means, without prior per-
mission in writing from CarnaudMetalbox Engineering Limited
Published by
Dockfield Road - Shipley - West Yorkshire - BDI7 7AY - England
Registered Office; Dockfield Road, Shipley, BD17 7AY United Kingdom, Registered in England No. 472767
Tel : +44 1274 846200 Fax : +44 1274 846201
OPERATING AND SPARES MANUAL
5500 CANMAKER
Machine Code: 015047
B ook1
B ody maker
CONTENTS
Preface
Section 1 Introduction
Section 2 Installation
Section 3 System Function
Section 4 Machine Controls
Section 5 Operation Procedure
Section 6 Fault Finding
Section 7 Maintenance and Setting
Section 8 Lubrication
Section 9 Proprietary Equipment
Section 10 Spares
PREFACE
Preface
This publication has been prepared to assist in installing, operating and maintaining CarnaudMetalbox
5500 Canmakers.
The publication is divided in to two books, each containing technically informative sections aiming to pro-
vide specific information for running the machine.
Book 1 covers information relating to the Bodymaker and Hydraulic Power Pack.
Book 2 covers information relating to the Trimmer Unit and interconnecting Conveyor.
The 5500 Canmaker is of CarnaudMetalbox design and manufacture and is subject to continuous develop-
ment. This manual may therefore not reflect the very latest innovations introduced during the manufacture
of a particular machine; these will be introduced into subsequent editions at the earliest opportunity.
Machinery manufactured by CarnaudMetalbox Engineering is safe and without risk provided that it is
installed and used for no other purpose than that intended and is in good working order in accordance with
our instructions and recommendations.
This publication contains confidential material included solely for the benefit of our customers. No part of
this publication may be reproduced in any form, or by any means, without prior permission in writing from
CarnaudMetalbox Engineering plc.
5500 Canmaker
Machine Usage
Correct Usage
The 5500 Canmaker comprises a 5000 Series Bodymaker machine integrated with a 550 Trimmer
machine, both manufactured by CarnaudMetalbox Engineering for installation in a can manufacturing
plant. Their function being to produce two piece steel or aluminium cans.
The machine is specifically built to suit customer requirements.
Improper Usage
The 5500 Canmaker should be used for no other purpose than that outlined in Correct Usage.
Use of the machine and auxiliary equipment in ways other than those described in this manual and Propri-
etary Equipment documents may result in injury to personnel or damage to the machine.
NOTE: Making unauthorized modifications.
Prior to any Technical Changes customers wishing to modify the machine must first obtain
written authorisation from CarnaudMetalbox Engineering Limited.
Unauthorized alterations can expose the operator and others to danger and must not be allowed.
edition August 2010

INTRODUCTION
SAFETY
ALL personnel should apply safe working proce-

dures at ALL times.
Reference to Safety herein should be applied in

conjunction with your factory procedures
INDEX: PAGE:
General Information 1
Can Travel 2
The Drive System 3
Hydraulic Circuit for Clutch and Brake Operation 4
Lubrication System 6
Coolant System 8
General Safety Notes 9
12/Feb/98
INTRODUCTION
1.1 General Information

The 5500 Canmaker is a horizontal, heavy duty double action press integrated with a 4 head rotary trimming
unit. It is designed and built to manufacture one piece, trimmed, can bodies from pre-drawn cups, maintain-
ing extremely close tolerances over long production runs.
The basic machine operating cycle consists of a forward and return stroke of the Ram as it is draws the cup
stock through the tooling to form the untrimmed can body.
A Rotary Cup Feed mechanism places a pre-drawn cup into the Cup Holder and the initial forward motion
of the reciprocating Ram forces the cup through a Redraw Die, reducing the inside diameter of the cup.
As the Ram continues it’s stroke the cup is then drawn progressively through three Ironing Dies to reduce the
wall thickness of the cup by ironing the wall between the outside diameter of the Ram Punch and the inside
diameter of the Die Rings, this to obtain the proper gauge and desired length of can body prior to trimming.
At the end of the Ram’s forward stroke the can body is forced against a Doming Die to form the can base.
Ironed can bodies are stripped from the Punch by segmented spring action fingers and Air Strip Assist as the
Ram commences its return stroke. Complete but untrimmed can bodies are then picked up by a Discharge
Turret that accelerates them away to the Interconnecting Conveyor for processing at the Trimming Unit.
At the Trimming Unit cans are fed into a Vacuum Infeed Turret from where they are transferred to the Main
Turret and loaded via a Pusher arrangement onto one of four self centring Tooling Heads. Within the Tool-
ing, Ejector Segments conform to the profile of the untrimmed can rim and the can is held stationary whilst
a Penetrating Disc moves eccentrically against an Outer Knife, trimming the can rim in one progressive
movement. On completion of the trimming operation the can exits the 5500 Canmaker via Guide Rails.
The basic machine design is such that it functions with a minimum of operator attention and maintenance. It
contains control devices to detect and automatically stop the machine should a malfunction occur.
A typical installation comprises a 5500 Canmaker machine, Electrical Controls and Cabinet, and lubrication
Hydrolube Unit.
February 2001 Page 1-1

INTRODUCTION
1.2 Can Travel
a. On the return stroke of the Bodymaker the Punch Sleeve and Redraw Blank Holder pull back together
until sufficiently clear of the Load Station area when the face of the Rotary Cup Feeder Cam starts to
push the incoming cup into position in the Cup Locator.
b. The Cup Feeder Cam is timed to the rest of the machine motion so that the cup is fully in position and
held by the ‘point’ of the Cam when the now forward travelling Blank Holder is approximately 1/8” clear
of the cup.
Can Body
Redraw
Die
Blank Holder
Punch
Motion
Dome Station
Punch
Sleeve
Stripper
c. The Blank Holder continues forward in advance of the Ram, entering the cup and carrying it forward
until it is just clamped against the face of the Redraw Die. At this point the nose of the Punch Sleeve
makes contact with the base of the cup in the Redraw Die. The base of the cup remains clamped between
the Blank Holder and the face of the Redraw Die throughout the redrawing operation. This is achieved
by allowing the redraw mechanism to overtravel on the constant motion Redraw Cams.
d. The Wall Ironing Punch continues its forward stroke and pushes in sequence the redrawn cup through
the first, second and third Wall Ironing Rings, which along with the Redraw Die are mounted in an as-
sembly called Cradle. Approximately sized spacers are located between the Redraw Dies and Wall Iron-
ing Rings so that the progressively elongated body cannot iron in two rings simultaneously.
e. The wall Ironing Punch continues its forward stroke pushing the wall ironed cans through the Mechan-
ical Stripper, through the Discharge Turret Pocket into the Dome Die to form the bottom profile.
f. The Wall Ironing Punch starts its return stroke and an Air Strip Assist is activated to induce air pressure
through the Ram and Wall Ironing Punch to blow the can off the Punch. A Mechanical Stripper, situated
in the Front Bulkhead, assists in removing the can from the Punch as it moves back.
g. The Discharge Turret picks the can up from the Dome Station and accelerates it away to the Discharge
Conveyor. The Turret is then positioned ready to pick up the next can.
h. The Wall Ironed Punch continues its return stroke, The Redraw Carriage is moved by cam operation
back and the Rotary Cup Feed delivers another cup and the cycle is repeated.
Page 1-2 12/Feb/98

INTRODUCTION
1.3 The Drive System
a. The Bodymaker consists of three drive sub assemblies, all driven by the same motor. The Motor drives
the Flywheel through a Pulley and Belt system. The Flywheel transmits the drive through a Hydraulic
Clutch and Brake Unit to the Crankshaft.
b. Drive to the Ram: The main drive to the Ram is taken from the Crankshaft and Crankshaft rotation is
transmitted into Swing Lever oscillation through the Primary Connecting Rod. The Swing Lever move-
ment is transmitted to the Slide Block through a Secondary Connecting Rod. The Slide Block is precisely
guided by the Slide Ways and Front Bushing to carry the Ram in a straight line
c. Drive to the Hold Down (Redraw Mechanism): The Hold Down drive is taken from the Cams secured
to, and revolving with the Crankshaft. The Cam Levers transfers the Cam Follower movement via a link-
age system to the Hold Down Push Rods to drive the Hold Down mechanism in a reciprocating motion.
The Cam Followers are held against the Cam by two Air Spring Arrangements.
d. Drive to the Power Take-Off Shaft: A 90 degree Bevel Box mounted onto the end of the Crankshaft pro-
vides change to the axis of drive for the Power Take-Off Shaft which is supported the full length of the
machine and drives the following units:
i. Electrical Timing Unit
ii. Rotary Cup Feed
iii. Discharge Turret
12/Feb/98 Page 1-3

INTRODUCTION
1.4 Hydraulic Circuit for Clutch and Brake Operation
8
Rotary 9 7
Joint
Hydraulic
Clutch & Brake
Coooling Oil Extent of Power Pack
11 L/Min
13 L/Min 4L
Accumulator 4
13 Precharge
EM 45BAR 45BAR
5
Cooling 3
water
Collection Tank 68BAR 6
12 2
11
11 L/Min
EM
2.2KW
HYDRAULIC CLUTCH / BRAKE CIRCUIT

1
11 L/Min
10
15
10BAR
14
75 Litres
Mobil: DTE Light VG32
There are two independent hydraulic circuits - pressure circuit and cooling circuit.
1.4.1 Description of Pressure Circuit
a. Double Pump (1).

This half of the pump delivers 11litres/min. of hydraulic oil to operate the clutch/brake at a nominal
pressure at the Hydrolube Unit of 70 BAR. Refer to instruction 1.4.2.a) for reference to double pump
(10)
b. Relief Valve (2).
This valve provides over pressure protection and diverts excess flow to the tank should its setting (70
BAR at the Hydrolube Unit) be exceeded
NOTE: No adjustment to this valve should be attempted to change the above pressure.
c. Accumulator (3).
The accumulator is required to store the high pressure oil to the clutch/brake. The nitrogen pressure
should be periodically checked and adjusted to 45 BAR. This should be done with a fully de-pressurised
hydraulic circuit.
d. Pressure Gauge (4).
Page 1-4 12/Feb/98

INTRODUCTION
This gauge gives the system pressure of 70 BAR.Pressure Switch (5).

If the Pressure drops below 65 BAR, this switch warns of low oil pressure. Should this occur do not op-
erate the clutch/brake, find the reason for low pressure and rectify immediately.
e. Drain Down Valve (6).
This valve should be permanently closed during normal clutch/brake operation.
IMPOTANT: For maintenance on the Power Pack it is necessary to de-pressurise the oil in the circuit
by opening this valve until the gauge (4) reads zero. This should be done with the pump motor switched
off. Before re-starting the pump this valve should be completely closed.
f. Orifice (7).
This is a fixed orifice mounted in the fittings (behind the pressure safety valve (Refer to machine Hy-
draulics Assembly). This orifice is required to prevent shock waves in the hydraulics reaching and dam-
aging the clutch/brake. Under no circumstances should this orifice be removed.
g. Press Safety Valve (8).
To ensure safe operation of the clutch/brake this valve is dual solenoid operated with Limit Switches on
each Spool. Should a fault occur on either solenoid the press safety valve will not function. During this
time the brake will be applied as the oil in the cylinder is exhausted to the tank. A message display on the
machine will display `Clutch Valve Fault’.
With a fault on the Press Safety Valve it will not be possible to operate the Clutch/Brake.
h. Rotary Joint (9).
The Rotary Joint at the end of the crankshaft delivers both pressure oil and cooling oil to the clutch/
brake.
It is essential that ALL gaskets are fitted when this item is removed or replaced.
1.4.2 Description of Cooling Oil Circuit
a. Double Pump (10).

This half of the double pump is used to supply cooling oil to the clutch/brake at a flow rate 11 litre/min.
b. Filter (11).
The oil for the filter is electrically monitored to warn of a blocked filter.
c. Cooler (12).
Before the oil is fed to the clutch/brake a water cooler reduces the temperature of the oil to ensure effi-
cient removal of heat from the clutch/brake.
1.4.3 Collecting Tank
All the oil returned from the clutch/brake housing is collected and pumped back to the main pressure pack
by a motorised Scavenging Pump (13). This is controlled by a float sensor and electrical timer in the collection
tank.
1.4.4 Power Pack
The power pack for the clutch/brake has a capacity of 75 litre. A sight glass, (14) allows nominal monitoring
of the oil level, whilst a float switch, (15) gives a warning of low oil level. The oil level in the power pack will
very depending on the oil level in the Accumulator and collecting tank.
1.4.5 Oil Type
It is essential that the oil used is of the correct type. Refer to the machine Lubrication chart on the side of the
Bodymaker (also shown in this manual, Section - Lubrication).
IMPORTANT The oil should be changed periodically using the same type of oil.
12/Feb/98 Page 1-5

INTRODUCTION
1.5 Lubrication System
3/8" I/Dia. Hose

0.030" Jet
3/8" I/Dia. Hose
0.048" Jet
3/8" I/Dia. Hose
0.022" Jet
3/8" I/Dia. Hose
0.048" Jet
Pressure
Gauge
Manifold PTO
Gearbox
Quill
Main Bearing
Main
Bearing
1/4"
1/4" I/Dia I / Dia
Hose Hose
Yoke Manifold
1/2" Dia with In-line Filter
Hose
Cam Lever Yoke Sub-Assembly Cam Lever
1 off 0.026" Jet
10 off 0.022" jets
Bearing Block (2off)
∅ 8Tube
0.038" Jet
Primary Primary
Bulkhead Bulkhead
Hydraulic Clutch / Brake

fitted to Crankshaft
Manifold
Rotary
Union
Pressure
Hydrostatic Manifold Switch
Hydrolube 3/4BSP Feed Line
Unit P4
1 1/4BSP Return Line
P8
P1 1 1/2BSP Suction Line
P9 P10 P14
Press
1/2" 1/2" 1/2" Safety
BSP BSP BSP Valve
Machine Sump
Clutch / Brake Return Line
Clutch Brake Cooling Line
Clutch / Brake Feed Line
Page 1-6 30/Aug/06

INTRODUCTION
Lubrication System: Lubrication for the Bodymaker is provided by means of a High Pressure Lubrication
System. A separate Hydraulic Power Pack, mounted on a chassis frame and positioned adjacent to the Bod-
ymaker, provides a means for oil conditioning and recycling back to the Bodymaker.
MACHINE CLUTCH
BODYMAKER
Clutch
Actuation
SUMP SUMP Pump

Clutch
Cooling
High Filter
Pressure
P1
Cooler
P10
P4
P9
P14
SUMP SUMP
HYDRAULIC POWER PACK
From the Power Pack ‘Clean’ Sump clean and thermostatically controlled cooled oil is pumped 76litres/min.
(20gpm) through a Filter to the Bodymaker. A Manifold Block on the side of the Bodymaker Crankcase di-
vides the system into two, and at this point the pressure is monitored and Safety Switches incorporated to
protect the system.
From this Manifold one High Pressure line is taken into the machine via the Swing Lever to lubricate the Pri-
mary Conn Rod Small End Bearing and also the Slide Block Hydrostatic Pads, ensuring that there is no metal
to metal contact between the Slide Block and Slideways.
A second line is taken via a Pressure Gauge Manifold on the Motor Mount Side Plate (Power Take-Off side
of the machine) from where the system is again divided to lubricate the Front Hold Down Push Rod Bearings
and Power Take-Off Gearbox, The Cam Levers, Crankshaft Main Bearing, Quill Main Bearing, and via the
Crankshaft, the primary Connecting Rod Big End Bearing.
Dirty’ oil is pumped from the Bodymaker back to the Power Pack where it is then pumped, 92litres/minute
(24gpm), through a Filter and Oil Cooler into a Pressurised Tank (‘Clean’ Sump).
Notes:
i. For recommended lubricants and additional manual oil and grease lubrication, refer to this man-
ual - Lubrication Section.
ii. For Hydraulic Power Pack additional information and General Arrangement Drawing refer to this
manual - Proprietary Equipment.
30/Aug/06 Page 1-7

INTRODUCTION
1.6 Coolant System
As applied to a Wall Ironing machine the term `Coolant’ means both a lubricating and temperature control-
ling liquid.
A relatively small percentage of lubrication is needed for the Drawing and Wall Ironing process whereas a rel-
atively large percentage of water is needed to dissipate the extreme heat generated in the Wall Ironing process.
Considerably more heat is generated in wall Ironing steel cans than aluminium cans. Therefore more ‘Cool-
ant’ is needed for steel - meaning more litres per minute, but not necessarily a high percentage of lubrication
material.
The coolant is supplied to the Bodymaker from a Conditioning Unit. The constant flow of coolant through
the tooling keeps it at a constant temperature. CONSTANT temperature is much more important than EX-
ACT temperature.
The Wall Ironing Punch and Wall Ironing Rings expand when heated - as do most metals.
The Coolant limits, or controls, the amount of expansion by keeping the heat of the tooling constant. Even
so, there is a slight expansion of the tooling between Wall Ironing the first can and the 5th and 6th cans. Dur-
ing that time, heat is generated above temperature of the Coolant but quickly levels off as the Bodymaker con-
tinues to run.
Recommended Coolant flow : Refer to machine installation drawing supplied with the machine (this manual
Section 2 refers.
Page 1-8 12/Feb/98

5500 Canmaker
1.7 Safety
The 5500 Canmaker machine has been designed to incorporate safety features which will safeguard per-
sonnel operating the machine. No system can however be fool-proof against all contingencies, in particu-
lar irresponsible actions of personnel operating and maintaining the machine.
Personnel should be fully conversant with the machine controls and have studied the following safety
instructions. National Safety Regulations must aso be observed.
If in doubt as to any safety aspect of the machine or operating and maintenance procedures then first seek
advice before starting work
1.7.1 5500 Canmaker - Bodymaker Safety
a When clearing wrecked cans from the machine it is important to wear safety gloves to avoid personnel
injury from the sharp edges of the damaged cans.
b To avoid injury caused by splashes from coolants used in the machine it is important to wear safety
glasses.
c Because of the nature of the machine, ie high noise level during the press function, it is essential to
wear hearing protection.
d Before machine maintence and working with the pneumatic system it important to first turn off the
machine air supply to discharge all the air from the machine.
e When Barring the machine by hand it is important to follow the correct Barring procedure.
Do not use the Barring Tool with a force that causes the Flywheel to spin at a speed that does not
allow the tool to be easily removed.
f When lifting the Tooling from the machine always use a Tool Rest to support the Tooling.
1.7.2 5500 Canmaker - Trimmer Safety.
a The Outside Knife of the Tooling Heads has a sharpened cutting edge and extra care should be taken
when handling. Always wear safety gloves when deemed necessary.
b The trimmed ring and trimmed edge of the can should be treat with respect because of their sharp
nature.
c When there are is no product present in the infeed or discharge trackwork, access can be made by hand
to the inside of the main guard and to moving machine components. It is important therefore that per-
sonnel are made aware of this possible risk.
The interface between machine and trackwork must be correctly guarded and is the responsibility of
the customer.
1.7.3 General Safety
a A Risk Assessment must be done once the machine has been installed and commissioned.
b All machine Guards must be in place and properly secured during operation.
c Maintenance:
i All work must be done by trained and competent engineers.
ii Guards may be removed for the purpose of maintenance when the machine is not operating and
E-STOPS’s are activated and all control power is locked out.
iii The Electrical Cabinet must be kept locked at all times
When it is necessary to access the cabinet then it must only be by trained personnel.
iv Isolate all source of energy prior to working on the machine.
v Components being removed or assembled on the machine must be handled with respect and if
uncertain of their weight should not be lifted single handed
d Operating the Machine:
i The operator must be fully conversant with the machine controls and know how to stop the
machine in case of an Emergency
ii Ensure that all safety devices are periodically checked
edition August 2010

section 1 page 9
5500 Canmaker
iii When turning the machine by hand it is important that the operator follows the correct procedure.
They must ensure that personnel are aware of what is intended and are clear of the machine.
e Clearing Machine Jams

i Do not rely solely on the machine interlock system. Use two means of preventing starting of the
machine when accessing the guard areas.
ii Always be aware of possible sharp edges, i.e. from jammed or damaged cans. Use pliers and
wear gloves when it is deemed necessary.
f Working Environment
i Personnel must be made aware of the risk of slipping on hazardous conditions as spillage or
leakage of oils, coolants, lacquers etc from machinery.
edition August 2010

section 1 page 10
INSTALLATION
SAFETY

dures at ALL times.

INDEX: PAGE:
Installation Drawing 1
Siting the 5000 Bodymaker 3
Services 4
Receipt of the Crated 5500 Canmaker 5
Off Loading and Handling 6
Bodymaker, Conveyor and Trimmer Unit Installation 8
Installing the Bodymaker on its Foundation 8
Levelling the Bodymaker 10
Cleaning 12
Electrical Cabinet Connection 12
Operator Console Connection 12
Compressed Air Connection 12
Coolant Connections 12
Vacuum Connection 12
Installation and Connection of Hydrolube Unit. 13
Hydraulic Clutch and Brake 14
Recommended Checks - Electrical 15
Recommended Checks - Mechanical 18
12/Feb/98
5500 Canmaker
Installation Drawing
Details Unavailable at time of Publication

INSTALLATION
2.1 Siting the 5000 Bodymaker
CarnaudMetalbox Engineering are able to provide drawings showing a recommended foundation inertia
block for the machine, together with a method of securing the machine to this block. However, many cus-
tomers prefer to use their own design of foundation.
The preparation and thickness of the concrete around the foundation will depend on the sub-structure of the
siting. If in doubt seek expert advice.
It is suggested that the foundation is prepared at least two weeks prior to machine installation to allow the
concrete to harden sufficiently.
The site should be planned in advance to accommodate the complete 5500 Canmaker System which includes
the machine itself (Bodymaker and Trimmer), Hydrolube Unit, and Electrical Control Cabinet.
12/Feb/98 Page 2-3

INSTALLATION
2.2 Services
The 5500 Canmaker requires electrical power, compressed air, cooling water and coolant as specified in the
following sections. (Refer to Installaion drawing for service connections)
2.2.1 Electrical Power
The 5500 Canmaker system comprises a total electrical power load of 85Hp. AC supply.
Electrical wiring and connections must be in accordance with specifications contained in the National Stand-
ards of the country concerned.
2.2.2 Compressed Air
Compressed air is required to operate the 5500 Canmaker system. The pneumatic system incorporates filters,
regulators, and lubricators to perform the required processing.
Air Supply is required for:-
a. Bodymaker: Supply from a regular ‘shop air’ system is satisfactory provided that a constant flow of 65
SCFM at 90psi (1.85m3/min. at 6.2 bar) is assured. Special filtering of the air supply is not required.
The components served are:
i. Hold down front and rear air bags.
ii. Air strip assist.
iii. Seal pack bleed-off.
iv. Guard interlock catches.
v. Cup stop piston.
vi. Toolpack clamp ring (if fitted).
vii. Dome station pistons (depending on Domer design).
b. Trimmer: Supply from a regular shop air system is satisfactory provided that a constant flow of 50 CFM
at 80psi (1.42m3 /min. at 5.5 bar) is assured. special filtering of the air supply is not required.
The components served are:
i. Trimmer Tooling Trim Ring ejection.
2.2.3 Vacuum
Factory Vacuum required for satisfactory operation is 43 CFM at 22” HG. Vacuum is required for:
a. Bodymaker/trimmer: Interconnecting Conveyor
b. Trimmer: Can Stop, Infeed Turret and Pusher.
2.2.4 Cooling Water
The Hydrolube Unit which supplies the hydraulics system on the Canmaker, requires cooling water to main-
tain the correct oil temperature.
The cooling water requirements are 56 litres/min. at 30˚C (14.8 US gallons/min. at 86˚F).
The cooling water is used as follows:

a. 50 litres/minute for cooling machine oil
b. 6 litres/minute for cooling clutch and brake oil
2.2.5 Coolant
The 5500 Canmaker requires a constant flow of coolant 80 - 120 litres/min. at 40˚C (21 - 32 US gallons/min.
at 104˚F). Special treatment of the coolant, other than standard industry practice, is not required.
Page 2-4 12/Feb/98

INSTALLATION
2.3 Receipt of the Crated 5500 Canmaker
The 5000 Bodymaker is prepared at Carnaud Metalbox Engineering Factory for shipment by commercial
freight carrier.
The equipment will generally be supplied in three cases:

a. Bodymaker
b. Trimmer complete with Interconnecting Conveyor and Bodymaker/Trimmer Link Guarding
c. Hydrolube Unit
d. Electrical Control Cabinet
2.3.1 Bills of Lading
These should be checked thoroughly when the shipment arrives at the customers plant and any discrepancy
notified to CarnaudMetalbox Engineering immediately.
12/Feb/98 Page 2-5

INSTALLATION
2.4 Off Loading and Handling
All procedures relative to the Off Loading and siting and subsequent handling of the Bodymaker system com-
ponents are the responsibility of the customer or his duly authorised receiving agent
2.4.1 5500 Canmaker Installation Notes
IMPORTANT: New 5000 Bodymakers are supplied with covers (1) and (2) fitted at the Bodymaker cup infeed
and interconnecting conveyor mounting point. These covers, painted red, must not be removed until ready
to connect the Factory Cup Infeed and Interconnecting Conveyor.
Infill Panel (3) fitted at the Trimmer discharge must not be removed until ready to link to the factory track-
work, when it will need to be removed and modified/replaced to suit this trackwork.
The interface between the machine and trackwork must be correctly guarded to comply with the National
Safety Standards of the country concerned. This is the responsibility of the customer.
NOTE: The Trimmer Unit has been supplied as part of the 5500 Canmaker and until it has been correctly in-
stalled (instruction 2.14 refers) it will not be completely guarded. attempts therefore MUST NOT be made to
run this unit as a separate machine.
‘A’
2
Bodymaker
Side View with Trimmer not shown

3
1
Bodymaker
Plan View on ‘A’
Trimmer
Page 2-6 October 2007

INSTALLATION
2.4.2 Lifting Instructions - Bodymaker (Lifting Equipment illustration refers)
The Bodymaker will normally be supplied with Lifting Beam, Chain and Shackles and Lifting Backplate.
There are four lifting points on the machine, two on the Lifting Backplate which should be attached to the
Crankcase between the Motor and rear of the Guards and other two via Shackles screwed into holes in the
top of the bed inside the Front guarding.
Circular Covers in the top of the Front Guarding need to be removed to gain access to the Shackle on the Can
Discharge side of the machine, and on the operator side the sliding door is required open (Secure in open
position) to enable connection of a Lifting Pillar.
Note: Before lifting the machine secure the front hinged guard in its closed position.
The Lifting Beam is adjustable so that the machine can be balanced with the lifting point over the centre of
gravity. The Flywheel offsets the centre of gravity of the machine quite significantly and the centre is towards
the Rear/Flywheel side. The Beam should be positioned with its Lifting Eye over this region. When setting the
machine down either onto the foundation or alongside it ensure that the levelling plates are placed under each
foot of the machine.
Lifting Beam
Safe working load (S.W.L.)2000 Kg 2 Off
4 Off
‘D’ Shackles ‘D’ Shackles
5000kg S.W.L 1000kg S.W.L
4 Off
Shortening Clutches
4 Off
Safety Hooks
4 Off
‘D’ Shackles
5000kg S.W.L
‘B’
View on ‘A’
Front Hinged Guard must be Secure Sliding door in

secured in closed position open position, for access, Leveling
when lifting the machine when lifting the machine Plates
Approximate Nett Weight:-

19” Stroke 5000 Bodymaker = 10650 Kg
21” Stroke 5000 Bodymaker = 11635 Kg
Lifting To access Lifting point 575mm Stroke 5000 bodymaker = 11635 Kg
Plate remove circular cover 26” Stroke 5000 Bodymaker = 11650 Kg
plates over guards
Lifting
Pillar
Crankcase
View ‘B’
‘A’
2 off
M30 x 80
Hex Hd Screws
October 2007 Page 2-7

INSTALLATION
2.4.3 Lifting Instructions - Interconnecting Conveyor and Trimmer
The Interconnecting Conveyor can be lifted by hand. two people are required to lift it into installation posi-
tion.
The Trimmer (approximate nett weight: 1600Kg) should be lifted and manoeuvred into its installation posi-
tion using a Fork-Lift Truck
Refer to installation instructions 2.5
2.5 Bodymaker, Conveyor and Trimmer Unit Installation
The 5500 canmaker is supplied as two units, a Bodymaker and a Trimmer complete with Interconnecting
Conveyor for taking cans from the discharge of the Bodymaker to the Trimmer Infeed.
Once the Bodymaker has been correctly installed (instruction 2.6 refers), the Trimmer and Interconnecting
Conveyor can then be fitted to the Bodymaker.
a. Position the Trimmer with Interconnecting Conveyor and link Guarding in its correct location in rela-
tion to the Bodymaker (refer to machine installation drawing for machine weights). Use a Fork-Lift
Truck to move the Trimmer and once positioned adjust the Trimmer levelling screws to give height re-
quirement.
b. Secure the Trimmer/Bodymaker Link Guarding to the Bodymaker.
c. Check the setting of the Trimmer Infeed Guides (canmaker Book 2, Section 4 refers)
d. Adjust the Conveyor Chain tension to remove slack. Do Not over tighten.
e. The flexible vacuum hose to the trimmer Infeed Turret will have been removed prior to despatch and
will require refitting. Connect the hose from the Vacuum Pump to the Air Duct on the Trimmer. secure
in place with jubilee clips.
2.6 Installing the Bodymaker on its Foundation
The site should have been pre-prepared with 10 foundation bolts set into the floor for fastening the machine
to the foundation (one bolt for each foot of the machine).
Before lifting the machine onto the foundation ensure that a levelling pad is placed over each foundation bolt
with the dished recess uppermost to locate the feet of the machine.
Place the machine carefully onto the foundation so that the foundation bolts pass up through the centre of
each foot. Fit the special washer and two retaining nuts (supplied with the machine) to the top of the bolts
protruding from each foot but do not tighten the nuts until the machine has been levelled (instruction 2.7
refers.
Page 2-8 October 2007

INSTALLATION
2.7 Levelling the Bodymaker
The Bodymaker must be levelled lengthways and from side to side to within 0.0005” per foot.
The machine should be levelled when cold using the Slideways as reference points. To take readings length-
ways use a precision spirit level on the ground surfaces of the Slideway side blocks (illustration refers).
Do not use the upper rails attached to the top of the Slideways as these are not ground flat. To take readings
from left to right, place a precision parallel on each slideway side block to allow the spirit level to span the
Slideways.
Caution : if the Slide Yoke needs to be moved at anytime, a liberal film of clean machine oil should be applied
to the contact areas before moving the Yoke. Movement of the Yoke should be kept to a minimum under
these conditions to avoid damaging the Slideways or Hydrostatic Pads.
Before making adjustments to the machine level ensure that the Bodymaker is sitting only on the 4 corner
adjusting screws and that these are seated properly in the levelling pads. The 6 centre adjusting screws should
be backed off so they are not carrying any of the weight. At this stage check that the machine is sitting at the
correct height above the floor level. This is important to ensure that any mating machinery and trackwork
align correctly. The height of the machine can be changed by adjusting the four corner screws by the same
amount. If this is done, ensure that the 6 centre screws remain free of any load.
Use the spirit level to take preliminary readings.
Determine which Bodymaker corner is the lowest and turn that adjusting screw clockwise to bring the corner
up. Continue to take readings in both directions and adjust the low-point screws until the machine is levelled
to the required accuracy.
Turn six centre adjusting screws down until they seat in the levelling pads. Tighten the screws firmly until
they take their share of the Bodymaker weight. Caution : To avoid loading the centre screws excessively and
disturbing the machine level attitude, use extreme care when tightening the centre screws.
Take final level readings along both slideways and across the slideways at both ends. If necessary, reposition
all six adjusting screws to level the Bodymaker laterally and longitudinally within 0.0005 inch per foot. When
taking final readings, turn the level end-for-end at each location to verify indication accuracy.
When satisfied that the correct machine level has been achieved, tighten the retaining Hex Nuts securely onto
the top of each foot. Tighten the second Lock Nut down onto the first Nut. Take machine level readings to
verify that machine level attitude has not changed. If readings do not repeat, loosen Hex Nuts and reposition
Adjusting Screws as required to bring the Bodymaker back to level. Tighten the Hex Nuts.
NOTE: After the machine has been in operation for six months or less, the level of the machine should be ver-
ified and the security of the floor studs and nuts be assured. This inspection should be performed at least every
six month. Unless there is evidence to suspect that the level is regularly being lost the level need only be
checked once a year. It is more important that the Anchor Bolts and Restraint Brackets are secure to prevent
machine vibration. If the level is checked it should be done with the machine oil at room temperature, this
may require the oil pumps to be turned off for a few hours.
Page 2-10 12/Feb/98

INSTALLATION
Levelling the Bodymaker

Note: Level the machine cold Spirit level readings to
be taken in 8 places as shown
Each reading is to be within
Parallel 0.0005” per foot
Parallel Parallel
CL
Slideways
(Front Elevation)
1 4
7 Parallel
Parallel
2 5
Parallel
3 6
CL Slideways
(Plan View)
12/Feb/98 Page 2-11

INSTALLATION
2.8 Cleaning
All brush coated (anti-corrosive) surfaces require cleaning; check all surfaces and clean as necessary with an
approved solvent, (e.g. Mobil Sevasol No. 5 or equivalent).
Care is needed with cleaning agents on the guarding. No chemicals should be allowed to contact the windows,
which are of polycarbonate material, as staining will occur.
It is advised that the interior of the Bed and Crankcase are washed using an air pressure wash gun and suitable
solvent to remove any debris which may have accumulated during shipment. Make sure all traces of solvent
are removed after spraying.
CAUTION
Most effective cleaning solvents are toxic when inhaled or ingested and prolonged skin contact can be harm-
ful. It is recommended that personnel working with strong solvents wear protective clothing, breathing
masks, eye protection and rubber gloves. These solvents are combustible when exposed to an open flame,
sparks or excessive heat and should be used only in an open well ventilated area. Situations that could initiate
combustion must be avoided
2.9 Electrical Cabinet Connection
The Control Cabinet should be permanently wired to the machine Main Junction box, using a suitable meth-
od which meets local and National Safety Standards and any other applicable standards. At all times refer to
the most current Electrical Schematics.
2.10 Operator Console Connection
The Operator console should be permanently wired to both the Machine Main Junction Box and Control
Cabinet using methods as above. The Console does not require to be connected to the factory power supply.
2.11 Compressed Air Connection (Installation Drg. at the start of this section refers)
Fittings are provided on both the bodymaker and trimmer for air connection. A standard 1” BSP (Female)
fitting is provided beneath the side guard on the can discharge side of the bodymaker and standard 1/2” BSP
(Female) fitting provided to the rear of the Trimmer Guarding. Connect the facility plumbing to the inlets
and check for air leaks.
2.12 Coolant Connections (Installation Drg. at the start of this section refers)
The 5000 bodymaker requires a constant flow of coolant through the Toolpack while making cans (120 litres/
min. at 40˚C or 32 US gallons/min. at 104˚F). The coolant feed connection is situated on the can discharge
side of the machine just behind the discharge point. The connection is 1” BSP (Female).
Coolant is drained from a collecting sump situated at the front of the machine under the Dome Station. The
drainage outlet is a 102mm (4”) o/d pipe to which a suitable connection should be made to take coolant away
for recycling.
2.13 Vacuum Connection (Installation drg. at the start of this section refers)
A 1” BSP (Female) fitting is provided on top of the trimmer guarding. Connect the factory vacuum and check
for flow rating of 80 CFM at 22” HG.
Page 2-12 03/Oct/00

INSTALLATION
2.14 Installation and Connection of Hydrolube Unit.
The Bodymaker has an independent hydraulic power pack which supplies all hydraulics on the machine. This
is referred to as the Hydrolube Unit. The Hydraulic systems supplied by the unit are the machine’s low pres-
sure lubrication system, the Hydrostatic Bearings, Ram Bushes & Slideways and the Hydraulic Clutch/Brake
Unit.
The Unit will be supplied with all hoses required for connection to the Bodymaker. There are 7 hoses in total
and these should be connected as shown on the Installation Drawing. A general arrangement drawing of the
Hydrolube unit is also given in Section 9 of this manual. The precise positioning of the Hydrolube Unit rel-
ative to the machine will depend on customer preference and the length of the hoses will have been tailored
to best suit the position chosen.
2.14.1Cooling Water Service to Hydrolube Unit
The Hydrolube Unit requires a supply of Cooling Water (56 litres/min. at 30˚C) to control the temperature
of the oil. Water ‘in’ should be plumbed into connection P6 and water ‘out’ into P7 (see Installation Drawing).
Both connections are 1” NPT Female). If ordered these will be supplied as 1”NPT (Female)
2.14.2.Electrical Connection to Hydrolube Unit
The Hydrolube Unit should be permanently wired to the Electrical Control Cabinet, using a method which
meets local and national safety standards and any other applicable standard. At all times refer to the most cur-
rent Electrical Schematics.
2.14.3.Filling Hydraulic System
The machine Hydraulics use two oils.

The machine Crankcase and main Hydrolube tank are filled with oil used for the general machine lubrication
and for the Hydrostatic Slideways and Ram Bushes.
The Hydraulic Clutch/Brake and Flywheel Bearings have an independent oil supplied from a smaller tank sit-
uated on the front of the Hydrolube Unit.
To fill the Crankcase and Main Hydrolube tank proceed as follows.
Fill the Crankcase to a level of 350mm from the bottom of the Crankcase. Check direction of rotation of the
circulating pump on the Hydrolube unit and switch on to draw oil from the machine sump into the Hydrol-
ube Tank. Add oil to the Crankcase as tank is filling to compensate for the drop in oil level. Ensure at all times
that the oil level does not drop below the level of the suction pipe to prevent air being drawn through the
pump. The system is self bleeding but if necessary air can be bled from the tank via the plug fitted on top.
Approximately 455 Litres of oil will be required in total.
To fill the Hydraulic Clutch/Brake system, fill the small tank (capacity 75 litres) on the front of the Hydrolube
Unit to the maximum oil level mark. Check direction of rotation of the Clutch supply pump on Hydrolube
Unit and switch on to fill the system. The system is self bleeding but the tank will need to be topped after the
pump has run.
NOTE:
For additional information on installation of the Hydrolube Unit refer to this manual Section 9 - Proprietary
Equipment in this manual
For the Oil specifications refer to this manual Section 8- Lubrication
03/Oct/00 Page 2-13

INSTALLATION
2.15 Hydraulic Clutch and Brake
The recommended operating pressure for the Clutch and Brake unit is 70 bar (1015psi).
Reduced pressure (below 65bar) will result in reduced clutch performance and increased clutch plate wear.
Pressure can be adjusted by the on line pressure relief valve on the Clutch and Brake Power Pack Tank.
Page 2-14 03/Oct/00

INSTALLATION
2.16 Recommended Checks - Electrical Comments:
Warning:
Contact with sources of Electrical Energy can cause death or serious

injury. Only trained personnel who understand these dangers and the
precautions which must be taken to avoid them should carry out work
on the electrical systems of this or any other machine. the main dis-
connect feeding the control panel should be locked off during any
maintenance operation. Use safe working practices at all times.
2.16.1Static Checks
Carry out these checks with the Main Disconnect locked off
NOTE: It is assumed that the Control Panel has been fully tested after
manufacture and therefore this section does not include a full set of
checks on the Control Panel.
1. Machine and Control Panel:
Check that the machine and Control Panel have not been dam-
aged during transit or installation.
2. Protection:
Check that the incoming terminals of the Main Disconnect are
shrouded to prevent accidental contact.
3. Installation Wiring:
Check that all the wiring has been correctly installed according
to all the drawings, standards and specifications as applicable.
Pay particular attention to the sizing of power conductors and
ground wires.
Ensure that all connections are correctly numbered and tight.
Ensure as far as possible that there is no damage to insulation of

wiring.
Depending on local practice it may be advisable to test the Phase

to Phase’ and ‘Phase to Ground’ resistance of all power cables, or
obtain satisfactory proof from others e.g. The Installation Con-
tractor) that this has been done.
4. Door Interlocks
Check that the Control Panel Door Interlocks operate correctly,

but can be defected by the use of a tool.
5. Motor Circuit Breakers/Overloads
Record the full load current on each Motor Nameplate, and en-
sure that all thermal protective devices on the Control Panel are
correctly set. Comments
2.16.2Checks with Power applied
1. Keep the Main Disconnect locked off at this stage.
Open all circuit breakers in the control panel and remove 480v
fuses (if any).
12/Feb/98 Page 2-15

INSTALLATION
Check the incoming supply voltage, and if appropriate, phase ro-

tation. If this is correct, the Main Disconnect may now be closed.
proceed through the panel in a logical order closing those circuit

breakers associated with AC & DC control voltage supplies.
Check and record the value of all AC & DC control voltage, ad-
justing transformer tappings and DC power supplies if neces-
sary.
2. Safety Circuits
Check that the circuits involved with personnel safety operate

correctly, i.e.:-
a. Emergency Stops
b. Guard Switches
3. PLC Input/Output Checks
NOTE Lock off all Motor Circuit Breakers before proceeding.
Without putting the PLC into RUN operate all the devices on the
machine (push-button, limit switches, proximity sensors etc.) in
order to check that they operate correctly and the signals reach
the PLC input cards.
Check, if practicable at this stage, that all PLC controlled output

devices on the machine operate correctly.
4. Motor Checks
Close motor circuit breakers and briefly operate each contactor

to check direction of rotation.
5. Variable Speed Drives
NOTE: Remove Drive Belts to guard against Machine rotation.
Set up variable speed drive as for as possible at this stage. It may

not be possible to complete this until the machine is running and
able to process cans.
6. PLC Program Checks
Having carried out the above checks to ascertain as far as possi-

ble that all the hard wired systems operate correctly, load the
PLC program and switch the PLC to ‘RUN’.
The PLC program may already have been ‘bench tested’ or prov-
en elsewhere. The engineer responsible should use his discretion
in deciding which tests should be repeated.
NOTE: Before fitting the Main Motor Belts and running the ma-
chine, the lubrication system must be checked to ensure it is op-
erating correctly. Visual checks for oil should be made, to ensure
that the electrical monitoring system is working correctly.
A full test would include:
Fault Simulation:
Page 2-16 12/Feb/98

INSTALLATION
Simulate every fault that is detected by the PLC program, check

that the appropriate message is displayed in each case, and that
the machine responds appropriately to the fault.
a. Recirculating Pump Overload tripped Main Pump Over-
load tripped Clutch Pump Overload tripped Scavenger
Pump Overload tripped Main Motor over-temp.
b. Sump low level Lubrication Oil under temp Lubrication
Oil over temp.
c. Low Pressure Hydrolube Filter Switch fault Low Pressure
Hydrolube Filter blocked High Pressure Hydrolube filter
Switch 1 fault High Pressure Hydrolube Filter Switch 2
fault High Pressure Hydrolube Filter blocked Clutch Oil
Filter Switch fault Clutch Oil Filter blocked Lubrication
High Pressure Warning Switch fault Lubrication High
Pressure Off Switch fault Hydrolube Pressure below 985psi
Hydrolube Pressure below 1085 psi
d. Clutch Oil Level Low Clutch Oil Pressure Low
e. Low Pressure Lubrication Switch fault Low Pressure Lubri-
cation below Pressure Emergency Stop Button Operated
Flywheel Motion Sensor fault Clutch solenoid fault Motion
or Timing Unit fault Cam Follower Air Pressure Switch
fault Bar Air Pressure Switch fault Main Air Pressure low
Cam Follower Air Pressure low Bar Air Pressure low
f. Toolpack Lid open Toolpack Lid not clamped Sliding
Guard open Front Left guard open Front Right Guard open
Slideway Guard open Flywheel Guard open Swing Lever
Guard open Discharge Guard open Dome Door open
g. Coolant Flow Switch fault Coolant Flow fault
h. Short Can Sensor not calibrated (If applicable),
Short Can,
Can Jam/Short Can Sensor fault.
i. Infeed Low level
Infeed Reverse Cup
Discharge Gate jam
Trimmer stopped
Line Control stop.
7. Normal Operation
Check the machine in normal operation in each of its operation

modes:-
BAR INCH SINGLE STROKE CONTINUOUS
Ensure that it responds correctly to System Start and Stop Com-

mands and the Line Control Interlocks.
Check that the Flywheel Guards cannot be opened unless the

Flywheel is at rest, and that none of the other guards can be
opened if the Clutch is engaged.
Check particularly those systems which detect Jams or Lubrica-

tion failures.
12/Feb/98 Page 2-17

INSTALLATION
2.17 Recommended Checks - Mechanical Comments:
2.17.1Visual Inspection of Installation
Check that the following have been completed:

1. All electrical connections to the Machine, Cabinet, Console and
Hydrolube Unit.
2. Hydraulic connections between Machine and Hydrolube Unit.
3. Cooling water connections to Hydrolube Unit.
4. Air and coolant connections to the machine.
2.17.2Cleaning the machine
1. Use an approved solvent (Mobil Sevasol No. 5 or equivalent) to

remove any anti-rust compound from bare metal surfaces.
2. Remove any debris from interior of the machine and wipe inter-
nal surfaces.
3. Clean exterior of the machine.
NOTE: Grit and debris in the machine may cause damage to internal
components and should be avoided.
2.17.3Flushing of Lubrication system
NOTE: Movement of the Yoke Slide Block in the Slideways and the
Ram in the Hydrostatic Bushes should be avoided if the hydrostatic
oil is not flowing. If movement of these components is necessary, a
liberal film of oil should be applied to the contact surfaces.
1. Remove filter from the manifold block on the Yoke Slide. (1 re-
quired. Refer to Swing Lever Assembly) and before starting any
pumps disconnect the oil pipes from the main bearings, the oil
supply pipe to the yoke slide (tie down pointing down into the
machine) and the supply pipes to the front bushings.
2. Check the condition of all filters on the Hydrolube Unit, replace
if necessary.
3. Check direction of rotation of the Hydrolube Circulating Pump.
4. Start the Circulating Pump and check the system for leaks.
5. Check that the level of oil is 350mm above the bottom of the
Crankcase.
6. Check direction of rotation of Hydrolube Main Pumps.
7. Start Main Pump and check system for oil leaks.
8. Leave both pumps running for 30 minutes to flush out oil ways.
9. Shut down both pumps and reconnect all pipes.
10. Start Circulating and Main Pumps and check for leaks at Lee Jet
points. Leave pumps running to warm oil.
11. The temperature Control Unit should be set as follows:
a. Temperature control level 45˚C (113˚F)
b. High level alarm 55˚C (131˚F)
c. Low level alarm 35˚C (95˚F)
12. Check that the cooling water solenoid opens at 45˚C and main-
Page 2-18 12/Feb/98

INSTALLATION
tains this temperature.

13. When oil is up to temperature, ensure that the circulating pres-
sure is at 50psi and main pressure at 1500psi.
14. Leave Circulating Pump running continuously to maintain oil
temperature
15. Arrange for Low Pressure Lubrication Pump on the machine to
be started independently of Main Drive Motor.
16. Start Low Pressure Pump and check the low pressure system for
oil leaks.
17. Check that oil is flowing at the following points:
a. Crankshaft Main Journals
b. Primary Con Rod Big End.
c. Cam Follower Pins
2.17.4Machine Setting and Alignment Checks
NOTE: See Section 7 (Maintenance and Setting) of this manual for de-
tailed checking and realignment procedures.
1. Install Punch on Ram Spigot.
2. With Main Hydrolube Pump running, check Tool Cradle cen-
trality and squareness. Realign if necessary.
3. Check Cradle height.
4. Check alignment of Redraw Sleeve and squareness of front face.
5. Check setting of Cup Locator.
6. Check Cup Feed Cam timing and clearance relative to the cup.
7. Check Stripper alignment (if relevant).
8. Check Domer alignment
2.17.5Primary Operational Checks
Ensure that the following are operational.

1. Tool Pack Clamp Ring (if fitted).
2. Toolpack Coolant Flow.
3. Bar Mode functions.
4. Cup Feed Torque Limiter.
2.17.6Starting Main Drive Motor
1. Check tension of Main Drive Belts.

2. With Circulating and Main Hydrolube Pumps running, ensure
that the `Start Main Drive” message is displayed.
3. Switch Speed Selector to low speed and start Main Drive.
4. Check operation of high speed drive.
5. Check electric breaking of Drive Motor and ensure that Flywheel
Guard Door cannot be opened until Flywheel has stopped turn-
ing.
12/Feb/98 Page 2-19

INSTALLATION
2.17.7Basic Machine Operations
Check that the following functions are operational:

1. Inch Mode
2. Single Stroke - Slow speed.
3. Single Stroke - High speed.
4. Continuous Operation Mode - Low speed
5. Continuous Operation Mode - High speed
6. Backstop position
2.17.8Safety Checks
Check the following safety and fault detection features. Where rele-
vant ensure that appropriate fault message is displayed.
1. Safety Interlock Catches.
2. Guard Safety Switches.
3. Die Cover open (if relevant).
4. Short can.
5. Dome Door open.
6. Low pressure fault on High and Low Pressure Lubrication Sys-
tems.
7. Hydrolube Filter blocked.
8. Oil Sump level low.
9. Main air pressure low.
10. Rear Hold Down pressure low.
11. Flywheel Motion Detector.
12. Emergency Stop.
13. Electrical failure.
2.17.9Control Settings
These will depend on various factors including machine speed but the
following settings are good starting points.
1. Doming Hold Down 60psi.
2. Air Strip Assist 40psi.
3. Cup Hold Down 40psi
4. Main Air Pressure 85psi
2.17.10Die Progression Checks
1. Install Toolpack and allow coolant to flow for a few minutes to

heat the Tooling
2. Take a set of Die progressions.
3. Measure wall thickness and can length at each progression.
4. Ensure that ironing is not taking place in more than one Die at a
time.
Page 2-20 12/Feb/98

INSTALLATION
2.17.11Can Quality - Continuous Operation
Check the following at low and high speeds.

1. Thickwall and Thinwall variation
2. Can length
3. Flatness of untrimmed can edge.
4. Roundness of cans.
5. Scratching - internal and external.
6. Wrinkles or saw tooth edges at open end of can.
7. Dome depth and quality.
12/Feb/98 Page 2-21

SYSTEM FUNCTION
SAFETY

dures at ALL times.

INDEX: PAGE:
Forward Stroke 1
Return Stroke 1
Operation Modes 2
Stopping the machine 3
February 2009
SYSTEM FUNCTION
System Function
Barring
Tool
Guards Unlock
Bar Motor Start System Start / Inch System Reset Bar Run Bar
BAR SYSTEM GUARDS UNLOCK BAR

MOTOR START SYSTEM RESET
START/INCH BAR RUN
RGEN
ME
MOTOR STOP SYSTEM STOP CUP FEED SINGLE STROKE
INCH CONT
CY
E
S TOP
Emergency Stop
Motor Stop System Stop Cup Feed Single Stroke

Inch Continuous
System Function: The Bodymaker machine forms one-piece aluminium or steel can bodies from pre-drawn
cups.
The operating cycle consists of forward and return stroke of the Ram as it is draws the cup stock through the
tooling to form the can body.
3.1 Forward Stroke

The initial forward motion of the reciprocating Ram, forces a pre-drawn cup through a Redraw Die to reduce
the inside diameter of the cup.
As the Ram continues its stroke, the cup is drawn through three progressive Ironing Dies to reduce the wall
thickness, by ironing the wall between the outside diameter of the Ram Punch and the inside diameter of the
Die Ring, to obtain the proper gauge and desired length of can body.
3.2 Return Stroke
Ironed can bodies are stripped from the Punch by segmented spring action stripper fingers and an Air Strip
as the Ram commences its return stroke.
The completed, but untrimmed, can bodies are then picked up by a Discharge Turret that accelerates them
away to the Discharge Conveyor for processing at the Trimmer.

SYSTEM FUNCTION
3.3 Operation Modes
The Bodymaker can be operated in any of the following modes:

a. Bar
b. Inch
c. Single Stroke
d. Continuous
3.3.1 Bar Mode
The Bar operation mode is used to turn (bar) the Bodymaker manually during maintenance and setup oper-
ation, or in the event of a main drive system malfunction.
The use of a Barring Tool, supplied with the machine, to bar the Bodymaker is possible with the Flywheel
Guard sliding door open and with the BAR push-button(s) held depressed. In this situation the clutch is en-
ergised and the Brake released
Depending on customer specification, a second BAR push-button is located on the Operator Control Panel
and both must be held depressed together, necessitating a second person to assist in barring the Bodymaker
WARNING: When Barring the Bodymaker with the Guard Doors open it is important that the operator is
vigilant and follows the correct procedure, ensuring that personnel are aware of what is intended and are clear
of the machine.
To Bar the Bodymaker:

a. Press the SYSTEM STOP push-button, stopping the machine.
b. Press the MOTOR STOP Push-button to stop the Main Motor. The Lubrication and Clutch Pumps
MUST be kept running
c. Switch the GUARDS UNLOCK / BAR / RUN selector to BAR.
d. Open the Bodymaker sliding guard door and remove any cup stock from the Cup Locator.
e. Press the SYSTEM RESET push-button.
f. Open the Flywheel Guard Sliding Door. This will not open until the Flywheel has stopped and all the air
has been exhausted from the Rear Hold Down Cylinder.
g. Insert the Barring Tool into the Plunger arrangement on the Flywheel.
h. Press and keep the BAR push-button(s) depressed to engage the clutch. The Bodymaker can now be
barred.
3.3.2 Inch Mode
The Inch operation is used to operate the Bodymaker through partial cycles to position the Ram for mainte-
nance and setting operations.
a. Switch the INCH/ SINGLE STROKE / CONTINUOUS selector to INCH
b. Hold the SYSTEM START / INCH push-button depressed and the Ram will travel a short distance.
In this mode the various protective safety devices are fully operational (see Section 4)
3.3.3 Single Stroke Mode
The Single stroke operation mode is used to operate the Bodymaker through one full cycle to check opera-
tional set-ups and Bodymaker infeed and delivery functions.
a. Switch the INCH / SINGLE STROKE / CONTINUOUS selector to SINGLE STROKE
Page 3-2 February 2009

SYSTEM FUNCTION
b. Depress the SYSTEM START push-button and the Bodymaker will operate through a single operating
cycle and stop at the end of the return stroke.
To produce a can in the Single stroke mode first press the CUP FEED push-button before the SYSTEM
START push-button.
NOTE: On the first Single Stroke after pressing CUP FEED push-button a cup will be loaded into the ma-
chine, but a can will not be made until the second operation in Single Stroke. To make cans on successive
strokes in Single Stroke mode it is necessary to press CUP FEED and SYSTEM START / INCH alternatively.
3.3.4 Continuous mode
The Bodymaker is operated in this mode for normal operation. (Section 5 refers).
Bodymaker operation will be continuous until one or more of the following events occur:
a. SYSTEM STOP push-button is depressed.
b. EMERGENCY STOP push-button is depressed.
c. One or more of the protective safety devices operates an EMERGENCY STOP or SYSTEM STOP in con-
junction with the related message display.
NOTE: In all cases conditions for Continuous mode operation must be established to resume Bodymak-
er operation.
d. The Line Controls tell the Bodymaker to stop. In this case the Bodymaker will re start automatically
when the Line Controls allow.
3.4 Stopping the machine
In normal operation the Bodymaker stops with the Ram in the rear position at the end of the return stroke
when the SYSTEM STOP push-button is depressed.
When the EMERGENCY STOP push-button is depressed an immediate stop is effected and the Ram may be
at any position in the operating cycle.
Refer to Sections 4 and 5 for more detailed information on Machine Controls and Operation procedure.

MACHINE CONTROLS
SAFETY

dures at ALL times.

INDEX: PAGE:
Operators Controls 1
February 2009
MACHINE CONTROLS
Machine Controls
Barring
Tool
Guards Unlock

START/INCH BAR RUN
RGEN
ME
INCH CONT
CY
E
S TOP
Emergency Stop

Inch
4.1 Operators Controls
The Operator Controls Panel located on the sliding door on the operator’s side of the machine comprises the
following:.
a. Motor Start Green Push-button
This single button is used for starting most of the motors on the bod-
ymaker. Each operation of this button will start the next motor in se-
quence, as follows:
i.Main Pump - this starts the main pump motor which will draw oil
back from the machine to the Hydraulic Power Pack, but it does not
send oil at high pressure to the machine until the button is pressed
again
ii.Load Main Pump - this energises a valve which sends high pressure
oil to the machine
iii.Clutch Pump
iv.Main Motor
At every stage the operator is prompted to start the next motor by a
message such as START MAIN PUMP

MACHINE CONTROLS
b. Motor Stop Red Push-button

This single button is used for stopping most of the motors on the bod-
ymaker. Each operation of this button will stop the next motor in the
reverse sequence to the starting sequence, i.e.
i.Main Motor
ii.Clutch Pump
iii.Unload Main Pump
iv.Main Pump
c. Bar / Guards Unlock / Run Selector Switch
This selects BAR Mode or RUN Mode of operation, but also unlocks
the guards as follows.
i.In the RUN position, all guards are locked and the Main Motor may
be started
ii.In the GUARDS UNLOCKED position the Slideway Guard and the
Front Sliding and Hinged Guards may be opened
iii.In the BAR position the above two guards may be opened immedi-
ately and the Flywheel Guard may be opened only after the Fly-
wheel has come to rest.
Note: Moving this selector switch from RUN to any other position
while the machine is running will cause an Emergency Stop to the
ram and the Main Motor will also stop.
d. Bar Orange Push-button

Functional when the Bar Mode is selected on the Bar/Run selector
switch. When Bar is selected and the Bar push-button s are pressed to-
gether, the clutch is energised. This allows the machine to be turned
over manually by means of a Barring Tool on the machine Flywheel.
e. Inch/Single Stroke/Continuous Selector Switch:

Permits selection of Single, Inch or Continuous modes of operation.
f. System Reset Yellow Push-button

When depressed removes all fault messages that signalled faults, and
permits restarting of the machine. (Providing faults have been
cleared).
g. Cup Feed Black Push-button

This button is used in Single Stroke Mode only to control the Cup
Stop. In Single Stroke mode the Cup Stop is normally closed. Pressing
the CUPFEED push-button will open the Cup Stop and allow one cup
into the machine, pressing SYSTEM START / INCH will then cause
this cup to be loaded ready to make a can. Pressing SYSTEM START
/ INCH a second time will cause a can to be made. To make a succes-
sion of cans in Single Stroke, it is necessary to press CUP FEED and
SYSTEM START / INCH alternately
h. System Start/Inch Green Push-button:

MACHINE CONTROLS
When depressed with SINGLE STROKE or INCH previously selected

on the INCH/SINGLE STROKE/CONTINUOUS Selector Switch,
the clutch is energized to either Inch or Single Stroke the machine.
When depressed with CONTINUOUS previously selected on the

INCH/SINGLE STROKE/CONTINUOUS SELECTOR Switch, the
machine will run in continuous cycle.
i. System Stop Yellow Push-button:

Functional when the system is in the continuous mode. Will stop the
Ram at the backstop position.
j. Emergency Stop Illuminated and Retained Push-button:

When depressed, stops all motors and engages the Brake. The Ram
could be in any part of its stroke.
The Trimmer is also Emergency stopped.
k. ‘Touch Screen Controls The touch screen is located obove the operator controls. As its name
suggests it provides a HMI (Human Machine Interface) with a screen
which is pressed by the operator to interact with the machine. The
HMI is used to display currant status, production information, faults
etc. and can be used to enter specific machine parameters such as
speeds.
l. AMCI PLS Tming Unit:
The programmable limit switch is mounted in the Control Panel
(mounted in the plc rack).
A Readout on the HMI displays the machine speed and position.

OPERATION PROCEDURE
SAFETY

dures at ALL times.

INDEX: PAGE:
Safety Checks 1
System Check 1
Start Procedure 2
Warm-up procedure 2
Automatic Cycling 2
Operational Check-Out 2
Shut Down 3
Clean Up Following Shut-Down 3
February 2009
OPERATION PROCEDURE
Operating Procedure
Barring
Tool
Guards Unlock

START/INCH BAR RUN
RGEN
ME
INCH CONT
CY
E
S TOP
Emergency Stop

Inch
5.1 Safety Checks
Before start-up and operation of the Bodymaker, ensure that all guards and covers are in place and firmly se-
cured.
Ensure that no personnel are working on the machine or in a potentially dangerous area.
Check that no damaged or jammed cans are in the following areas.

a. Cup Infeed Station
b. Tool Pack Die Rings
c. Front Piston Blank Holder.
d. Body Discharge Turret / Conveyor.
5.2 System Check
Ensure that the Electrical Power, Compressed Air, Coolant, Lubrication Oil and Cooling Water are connected
Verify the following air pressures at the Pneumatic Control Panel

a. Strip Assist 20 - 40psi
b. Cup Hold Down 40 - 60psi

OPERATION PROCEDURE
c. Coolant Supply 30 - 60psi

d. Doming Hold Down (Pride Dome Station only) 60 - 80psi
Note: the above figures may vary within different can plants.
5.3 Start Procedure
a. Turn the BAR / RUN selector to RUN

b. Press the SYSTEM RESET push-button
c. Press the MOTOR START push-button to start each of the motors in turn as prompted by the Display.
Wait if necessary for the oil to reach minimum operating temperature 35˚ before proceeding.
5.4 Warm-up procedure
a. Position the INCH / SINGLE STROKE / CONTINUOUS selector switch to INCH and depress the SYS-
TEM START / INCH push-button.
Inch the machine through sufficient operating cycles to confirm that it functions normally.
b. Follow the Automatic Cycle Procedure as described below.
5.5 Automatic Cycling
a. Position the Mode Selector Switches as follows:

i. BAR/ GUARDS UNLOCK / RUN to RUN
ii. INCH /SINGLE STROKE / CONTINUOUS to CONTINUOUS
b. Press the MOTOR START push-button as required to start the machine motors as prompted by the Dis-
play
c. Depress the SYSTEM START / INCH push-button and the machine will enter Automatic Cycle with the
following components energised:
i. Main Clutch
ii. Coolant Solenoid
iii. Cup Feed Solenoid
d. Stop Automatic Cycling by depressing the SYSTEM STOP push-button. This will stop the Ram at the
rear of its stroke.
5.6 Operational Check-Out
a. Run cups through the Bodymaker, checking each can produced for indications of the following:
i. Short Cans
ii. Wrinkles or Saw Edges
iii. Scratches caused by Stripper Fingers
iv. Out of Roundness
v. Non standard variations in Wall thickness
b. Check the Cup Feed in relation to the Ram travel. A cup should be fed on the back stroke of the Ram,
when the end of the Punch is positioned between the second and third Ironing Dies.
c. Check the Short Can Sensors as follows:
i. Manually inhibit the Cup Feed ensuring that the cup is held by the Cup Stop cannot enter the ma-
chine.
ii. Turn the INCH / SINGLE STROKE / CONTINUOUS to SINGLE STROKE and depress the CUP
FEED push-button

OPERATION PROCEDURE
iii. Ensure that the INFEED SENSOR is covered.

iv. Press the SYSTEM START / INCH push-button. The machine will make one stroke.
Press the SYSTEM START / INCH push-button. The machine will make another stroke but should
stop with the message MISFEED TEAR OFF OR NO CAN MADE
5.7 Shut Down
When shutting down for an extended period proceed as follows:

a. Press the SYSTEM STOP push-button. Check that the Ram is fully back.
b. Press the MOTOR STOP push-button repeatedly stopping each of the motors in turn.
c. Turn off the Main Air Supply
d. Turn off the Coolant Supply
5.8 Clean Up Following Shut-Down
When shutting down for an extended period clean up the Tool Pack as follows:
a. Remove the Punch Sleeve from the Ram and remove the Ironing and Redraw Dies from the Tool Pack.
These should be carefully cleaned and then examined and stored.
b. Make sure that no soapy residue is left on the die.
c. Remove all metal scrap fragments from the machine.
d. Blow out the Tool Pack with compressed air and make sure that the coolant passages are clear.
e. Using warm water wash down the Tool Pack, Doming Die, Discharge Turret / Conveyor and Coolant
Drip Pan.
Note: refer to Section 3 for operator instructions on the following:

a. Barring (turning) the machine by hand.
b. Inch mode operation; operating the machine through partial cycles.
c. Single Stroke operation; operating the Bodymaker through one full cycle.

FAULT FINDING
SAFETY

dures at ALL times.

INDEX: PAGE:
Introduction 1
Mechanical Malfunctions 1
Common Mechanical Failures 2
Can Defect Troubleshooting 3
Sample can Defects 4
12/Feb/98
FAULT FINDING
6.1 Introduction
The importance of this section of the manual cannot be over-emphasised because failure to know what to do
when defects occur can prove to be very costly in terms of poor quality, lost production and customer com-
plaints.
Consequently, the information in the following pages should be carefully studied so that the necessary
adjustments can be made.
One of the most effective ways to locate Bodymaker problems is to examine defective can bodies. The cans
usually present accurate clues to the source of trouble, which may stem from a single malfunction or a series
of inter-related malfunctions.
Careful attention of defects and a logical interpretation of the damage is required to establish the true cause
of the problem. Even though the Bodymaker has been accurately set according to instructions in this man-
ual, there will still be occasions when machine adjustments are necessary to overcome operating difficulties.
There are several important rules an Engineer must know before adjustments are made:
• You should not be too hasty in adjusting a machine that has been running well just because a wreck
occurs.
• Analyse the wreck carefully before making any adjustments, they can tell you a lot.
• An adjustment made to correct a manufacturing defect must be returned to its original position if it does
not correct that defect.
• Avoid making more than one adjustment at a time and do not experiment.
6.2 Mechanical Malfunctions

The causes of most machine malfunctions are obvious to the operator and can be corrected easily. However,
he must always be alert to the possibility of some hidden problem causing the malfunction.
The following examples are typical malfunctions that can occur, in the System, during an operational cycle:
a Mismatched Tooling: the Tooling must be properly matched to make an acceptable can.
b Alignment: Proper alignment of Tooling is essential for uniform can wall. NOTE tooling must not be
re-aligned unless absolutely necessary.
c Lubrication: The machine will shut down in the Safety Shutdown mode if the lubrication pressure falls
below the specified limits. Check the sight glass for the presence of oil.
d Loose fittings: The machine is fitted with locking devices (locknuts, pins etc.) to prevent loosening of
fittings and bolts. However, constant operation and vibration may cause these to work loose. Keep bolts
and fittings tight to prevent machine damage.
e Electrical failures: Electrical failures can be traced by referring to theoretical circuit drawings supplied
with the machine control cabinet.
f Common Mechanical Failures: The table on the following page lists those failures most commonly
encountered.
12Feb98 page 1
FAULT FINDING
6.3 Common Mechanical Failures
Symptoms Probable Cause Remedy

Cups not timed properly Adjust Rotary Cup Feed Cam
setting
CUPS NOT POSITIONED
PROPERLY IN FRONT OF Cup not aligned with Punch Check Cup Locator
THE RAM Excessive coolant flow disturb- Reduce flow rate.
ing cup
Uneven air pressure Adjust air pressure.
RAM JAMS IN EXTENDED Cup misfeed or ruptured in the Remove Rotary Cup feed cover
POSITION Re-draw Die; can tearing in the plate, remove damaged cups,
Die. retract Ram and remove all
damaged metal from Dies.
Inspect tooling for damage
before re-starting
COOLANT IN HYDRO- Scored Ram, damaged Wipers Replace Ram, Wiper and Seals.
STATIC and Seals.
BRAKE SLIPS Oil on Brake bands Repair or replace
Worn Brake Bands
BRAKE DRAGS Insufficient air pressure Check main air pressure.
IMPROPER STRIPPING OF Material build-up of Punch Polish or replace

CANS
Score marks on Punch Replace Punch
Stripper segments worn or bro- Replace Stripper

ken
Low air pressure at Bodymaker Adjust air pressure 80psi

Air Reservoir (5.6Kg/cm2)
CANS JAM ON PUNCH Insufficient coolant Check and regulate Coolant Sys-
tem.
Stripper Fingers sticking or bro- Check and replace Stripper

ken Assembly if necessary
page 2 12Feb98
FAULT FINDING
6.4 Can Defect Troubleshooting

One of the most efficient ways to locate Bodymaker problems is to examine defective cans. The cans usually
present accurate clues to the source of the trouble, which may stem from a single malfunction or a series of
inter-related malfunctions.
6.4.1 Trouble Shooting Procedure
The following procedure lists the general steps and the methods used to locate the cause of can defects:
a Obtain several good examples of the defective cans.
b Separate the cans according to the Bodymaker which produced them.
Use the identification mark made by the bottom form die along the edge of the dome shaped part of the
bottom to identify the Bodymaker.
c Estimate the rate of production of defective cans during the sampling period.
d Separate the defective cans according to type (tear-offs, splits, short trim etc.) for each Bodymaker.
e If all types of defects occur in approximately the same percentages for each Bodymaker on the line, the
defects are probably not produced in the Bodymakers. Look for a common factor, such as the Cup
quality, the Die Lubrication System or the Cupping Press.
f If a type of defect occurs more often on one of the Bodymakers than the others, a malfunction is almost
certainly located in that Bodymaker.
g The position of a defect in a formed can, is very useful in determining the cause.
Note the position of a defect (1) relative to the height of the can, (2) relative to the identification mark
on the bottom and (3) relative to the rolling direction of the metal.
If the location is consistent on all cans, it is possible that machine elements are the cause for (1) and (2)
and base stock defects are the cause for (3).
h Establish if surface blemishes in the base stock are causing defects, by marking the blemishes on the
stock with a felt pen and running the stock through the Bodymakers.
Examine the can bottom (which is the original undrawn base stock) to see if any defects in the stock
can be co-related with defects in the adjacent side- wall.
i Use a quality control microscope to assist in examinations for defects which cannot be seen with the
naked eye.
12Feb98 page 3
FAULT FINDING
6.5 Sample can Defects

UNEVEN CAN HEIGHT Misalignment of tooling Re-align tooling
Improperly ground Dies Return Dies to Toolroom
Material build-up on Punch Polish or replace.
TEAR/OFF REDRAW DIE Insufficient air pressure at Cur Increase air pressure
Hold Down Station
Defective Redraw Die Replace or polish Die
Misalignment of Cup Hold- Realign

down Mechanism
TEAR/OFF 1ST IRON Redraw Die too small Return Die to Tool Store.
Die improperly ground or has Return Die to Tool Store.

material build-up
Metal Gauge too thick Change Dies to conform.
Build-up on Cupping Press Dies Clean and polish Press Dies

causing cup damage
page 4 12Feb98
FAULT FINDING

CLIPPING Improperly ground Dies Return tooling to Tool Store.
Improper Lubrication Check flow, percentage and

temperature
Scrap in Dies
Clean
Incorrect tooling reduction
Return tooling to Tool Store.
Build-up on Dies
Polish or replace
SHALLOW BOTTOMS Air pressure incorrect Adjust air pressure
Bottom Die not properly aligned Align Die

Short stroke Check stroke length
Punch does not fit Bottom Die Return Punch and/or Bottom
properly Die to Tool Store
SCRATCHES INSIDE CAN Scoring on surface of Punch Replace or polish
Scrap of metal on Punch or Clean as necessary

inside cup
Replace or polish
Material build-up on Stripper
and Punch
12Feb98 page 5
FAULT FINDING

DENTED BOTTOM Scrap on Bottom die Remove and check Die surface
LAMINATION OR OCCLU- Quality of cups received from Examine cups received from
SION cupping press or quality of the cupping press and if necessary,
base stock the base stock material
page 6 12Feb98
MAINTENANCE & SETTING
SAFETY

dures at ALL times.

INDEX: PAGE:
Maintenance Procedures 1
Safety Precautions 2
Turning (`Barring’) the Bodymaker by hand 3
Preventative Maintenance 4
Toolpack Removal and Replacement 10
Tool Pack Clamp Cover Alignment Procedure 11
Ram Removal and Replacement 12
Cradle Positioning - Toolpack Checks 15
Front Bushing Seal Pack Removal and Replacement 16
Hold Down Mechanism 18
Cup Locator/Blank Holder Alignment 26
Rotary Cup Feed Cam - Removal and Replacement 27
Cup Stop Setting 30
Removal / Replacement and Timing the Discharge Turret 31
Stripper / Cradle Alignment 32
Swing Lever - Dual Stroke Setting 33
Setting the Dome Station 34
Stripper Set-up 36
Clutch and Brake Removal and Replacement 38
Flywheel Removal and Replacement 40
Accumulator Testing and Charging Instructions 42
Oct07
7.1 Maintenance Procedures

For efficient operation of the 5000 Bodymaker it is essential that the machine components are correctly
maintained. This section of the manual sets out the necessary checks and maintenance required and
should be consulted before planning any machine maintenance.
Reproduced in the manual are sample Preventative Maintenance Sheets. It is recommended that copies of
these are completed and kept as a record of all maintenance and repairs done to the machine.
Information on major equipment produced by Sub-Contractors to the machine manufacturer is available

and will normally be included in an edited version of the 5000 manual supplied with the machine
Notes:
a. Clutch and Brake: Extreme care MUST be taken when maintaining the Clutch and Brake - refer to
Clutch and Brake manufacturers instructions.
b. Primary Connecting Rod: When the machine is built the Primary Conn Rod Big End Securing Screws
are torque tightened to 614Nm (453lbf Ft). If they are removed or slackened during machine mainte-
nance then they MUST be replaced with new Screws and Nuts and torque tightened by the correct
amount.
It is also IMPORTANT that these Primary Conn Rod Screws and Nuts are replaced on a regular basis,
their designated MAXIMUM life being two years.
c. Hydraulic Power Pack: When performing any maintenance work, such as changing oil filters, the
Power Pack electrical supply must first be isolated and the Accumulator discharged.
03/Oct/00 page 7-1

7.2 Safety Precautions

SAFETY: Whenever setting or adjustment is required, please exercise caution and observe safe working
procedures.
Always ensure that after machine maintenance:

a. All adjusted parts have been properly secured.
b. No tools have been left on the machine.
c. The machine is properly set.
d. All Guard doors are closed and fixed Guard Covers have been securely fitted.
Note: The Guards use key operated interlocking systems and it is important that all keys are kept in a
secure place with responsible personnel.
For some maintenance inspections it may be necessary to momentarily turn on the electrical power and air
pressure supplies to the Bodymaker. Ensure that personnel are aware of what is intended and that they are
clear of the machine before power is turned on.
As an additional precaution against accident Start Up, WARNING TAGS should be attached to the appro-
priate Machine Controls and Valves. Such Tags should be clean and should not be left on the equipment
when their purpose is fulfilled.
page 7-2 11/1/07

7.3 Turning (`Barring’) the Bodymaker by hand

Turning the Bodymaker by hand is achieved by use of the Bar Mode of operation. Refer to this manual Sec-
tion 3, instruction Barring Procedure.
Note: When Barring the Bodymaker it is important that the operator is vigilant and follows the correct
procedure.
WARNING: When barring the Bodymaker with Guards open ensure that personnel are aware of what is
intended and are clear of the machine.
11/1/07 page 7-3

7.4 Preventative Maintenance

The following recommended ‘Daily’, ‘Weekly’ and ‘Monthly’ Preventative Maintenance Check Sheets are
included in this manual to be used as masters for copying. It is recommended that copies of completed
Check Sheets should be kept as a record of all maintenance and repairs done to the machine.
Page 7-4 11/1/07

Table 1: 5000 Bodymaker Machine Serial No......................Preventative Maintenance - Daily (Sheet 1 of 2)
Ref
Procedure Result / Comment Sign date
.
1 Check the oil in the machine Crankcase for coolant contamination and check for cor-
rect oil level, top up as required (Refer to Machine Lubrication Chart). Management
of the machine oil is important and checks should be made regularly for build up of
sludge on the Slideways.
2 Check the Slideways for marking/scoring
3 Check the surface of the Ram for evidence of scoring
4 Check all Air and Oil Hoses to the Rear Hold Down, Swing Lever, Yoke Slide, Front
Piston and Dome Station for damage.
5 Check Cams and Cam Followers.
6 Check the Air Spring in the Rear Hold Down for leakage (Switch the Main Pump off
and listen for leakage
7 Check the Die Cover Sensor for correct operation by using a steel rule to operate the
sensor
8 Check the Toolpack Clamp Mechanism for damage and ensure correct seal of Clamp
Block to Coolant Spacer
9 Check the condition of the Discharge Turret Unloader Pockets and check the Drive
Chain tension.
10 Check the Stripper Fingers for ease of movement and damage/wear. Clean and pol-
ish.
11 Check the Cup Locator, Blank Holder, Cup Feed Guides and Cup Feed Cam for dam-
age.
12 Check the Cup Feed Guide Finger for tension.
13 Check the Coolant Spacer faces, Toolpack, Wear Bars and Stripper Plate face for
damage.
14 Check tension of the Rotary Cup Feed Drive Chain and Drive Chain from P.T.O.
08/March/01
Table 1: 5000 Bodymaker Machine Serial No......................Preventative Maintenance - Daily (Continued) (Sheet 2 of 2)
Ref
.
15 Check that the Discharge Steady Brush is in the correct position and not damaged.
16 Check the Oil Pressure on the Lubrication System on the Hydraulic Power Pack:
An indication of operating pressure range is given on the nameplate adjacent to each
valve and its dedicated pressure gauge.
17 Check Air Pressures at the Air Console.
18 Clear any wreckage from the Discharge, Front Piston and dome Station areas.
19 Clean the Dome Door Stops and Guide Pads.
20 Check the Air Filters for condition and drainage.
21 Check the Air Line Lubricator (refer to machine Lubrication Chart) it should deliver
1 to 2 drops of oil per minute.
22 For any new machine, during the first month in production, check security of nuts
securing the Bodymaker to its foundation Bolts. (Nuts are tightened to 814Nm
(600lbf Ft) torque and secured with Locknuts. Check also condition of the founda-
tions.
23 Check operation of the EMERGENCY STOP push-buttons
24 Check operation of all Guard switches.
08/March/01
Table 2: 5000 Bodymaker Machine Serial No......................Preventative Maintenance - Weekly
Ref
.
1 Using 0.0015” Feeler Gauge, check the Yoke Slide for clearance in the Slideways.
Check all round the Hydrostatic Pads. If experiencing lubrication problems clean Lee
Jets, 10 off, and check for correct size (0.021”) and oil flow.
2 Check all Discharge Drive Assembly Chain Sprockets for damage or wear.
3 Remove the Discharge Turret and grease the Turret Bore, Bearings and Gears. (Refer
to machine Lubrication Chart).
4 Check the timing of the Discharge Turret to the Ram.
5 Check the Air Spring in the Front Hold Down for leakage.
6 Check the Blank Holder for wear, scratching and pick-up. Polish if required and reset
7 Check security of Nuts securing the Bodymaker to its Foundation Bolts. (Nuts are
tightened to 814Nm (600lbf Ft) torque and secured with Locknuts). Check also con-
dition of foundations.
8 Bleed air from the Rear Hold Down Accumulator.
9 Clean the exterior of the machine. NOTE: Grit and debris in the machine may cause
damage to internal components and should be avoided.
10 Check all electrical connections to the Machine. Cabinet and Hydraulic Power Pack.
11 Check connections and condition of Hydrolube Hoses between the Bodymaker and
Hydraulic Power Pack.
12 Check Cooling Water connections to the Hydraulic Power Pack.
13 Check Air and Coolant connections to the Bodymaker.
08/March/01
Table 3: 5000 Bodymaker Machine Serial No. .....................Preventative Maintenance - Monthly (Sheet 1 of 2)
Ref
.
1 Check machine security. Check Guards for correct operation and for loose, broken or
missing bolts.
2 Check the Front Bushing Seal Pack for damage. If excessive leakage of oil/coolant back
through the Seal bleed system, change the Seal Pack. (As a preventative measure change
every two months.)
3 Check the Autotech programme. Check that the setting of 0 degrees is when the Ram is
fully back.
4 Check alignment of the Cup Locator to the Blank Holder.
5 Check the timing of the Cup Feed Cam.
6 Check alignment of the Stripper to the Tool Cradle.
7 Check alignment of the Dome Die to the Ram centre line
8 Check condition of the Short Can Sensor.
9 Check Main Drive Belts for condition and tension
10 Check operation of the Dome Jam Sensor
11 Check Hold Down Assembly Connecting Link Ball Joints for play and the Push Rods
for scoring.
12 Lubricate the machine. Refer to machine Lubrication Chart.
13 Check the tension of the Interconnecting Conveyor Belt
14 Primary Conn Rod Securing Screws and Nuts; taking into account that their designated
life expectancy is two years, replace the Screws and Nuts at regular intervals.
Torque tighten new Screws to 614Nm (453lbf Ft.). (DO NOT re-tighten existing, or re-
use previously used Primary Conn Rod Screws and Nuts)
April/03
Table 3: 5000 Bodymaker Machine Serial No. .....................Preventative Maintenance - Monthly (Sheet 2 of 2)
Ref
.
15 If experiencing can quality or oil flow problems then clean the Lee Jets and check their
correct size:
Yoke slide, 10 off (0.022"),
Yoke Slide/Secondary Conn. Rod, 1 off (0.026"),
Swing Lever Mid Point, 1 off (0.038"),
Secondary Conn. Rod - Swing Lever Top Point, 1 off (0.026")
Crankshaft Bearing Quill 1 off (0.048")
Crankshaft Main Bearing 1 off (0.048")Cam Spindles1 off (0.022")
Push Rod Bearings (0.030")
16 Remove and clean the Drip Drain Leg Filter and Filter Bowl for the ‘DFI Microdomer’
April/03
7.5 Toolpack Removal and Replacement

To remove the Toolpack comprising Redraw Ring, Coolant Spacers and all Ironing Die Rings:
a. Bar the machine to the rear of its stroke.
b. Open the Toolpack Clamp Cover. An Electrical Sensor set below the lid will initiate switching off the
Main Drive Motor and shut off the Coolant and Air Supply.
SAFETY NOTE: Ensure that the Cover is fully open (beyond top dead centre) and passed the latch.
c. The Toolpack can now be removed from the machine.
d. Replace in reverse order.
Reference Information
For component details refer to the following assembly in Section 10:
Tooling Assembly (Sheet 53)
page 7-10 11/1/07

7.6 Tool Pack Clamp Cover Alignment Procedure

SAFETY NOTE: When working with the Tool Pack Clamp Cover open ensure that it is opened beyond
top dead centre and passed the securing latch.
To centralize the Tool Pack Clamp Block

a. Secure the Die Clamp Block (1) to the Tool Pack Clamp Cover (2)
b. Slacken the four M10 Hex Hd Screws (3) in the Hinge Blocks (4).
c. Place all the Coolant Spacers and Dies in the Cradle and close the Tool Pack Cover.
d. With the Cover in the closed position and the Latch (5) engaged re-tighten the Hinge Block Screws,
ensuring that the Latch Pin remains free to engage and disengage
.
3
4 2
1
Cradle Assembly (Sheet 13)
11/1/07 page 7-11

7.7 Ram Removal and Replacement
7.7.1 Ram Removal

a Turn off the Coolant.
b Remove the Redraw Coolant Spacers, Redraw Ring and all Ironing Dies from the Toolpack.
c Loosen by two turns the Clamp Ring Retaining Screws and tap the Clamp Ring to loosen the Locking
Element.
d Unscrew the Ram from the Ram Locator and withdraw it through the front of the machine.
Continued .............
edition March 2010

section 7 page 12
7.7.2 Ram Replacement

a Lightly oil the Ram Locator (1) thread and location diameter, also the Locking Element (2).
b Using the Ram Clamp Ring (3) and Locking Element (2) assemble the Ram Locator to the Alignment
Setting Fixture (illustration refers). Evenly tighten the Clamp Ring screws (4) in a diametrical
sequence to 35Nm (25lbf Ft)
5 3
4 Front Bushing
Alignment
Yoke Slide Setting Fixture
c With the assembled Ram Locator and Alignment Setting Fixture mounted in the machine Ram Bushes
check the seating of the Ram Locator against the Yoke Slide and adjust for a minimum 90% contact,
adjust the Yoke Slide Spacer for correction.
d Assemble the Ram Locator to the Yoke Slide using Screws (5) and torque tighten to 45Nm (33lbf Ft).
e Remove the Alignment Setting Fixture by releasing the Clamp Ring Screws (3) by two turns and tap-
ping the Clamp Ring to loosen the Locking Element (2).
Unscrew the Alignment Setting Fixture and withdraw it from the Ram Bushes.
f Install the Ram from the front of the
machine using the Seal Fitting Tool (illustra-
tion refers).
g Fit the Ram Clamp Ring (2) onto the Ram. Seal Fitting Tool
h Torque tighten the Ram to the Ram Locator
(1) to 400Nm (300lbf Ft) using the Hexagon
in the front end of the Ram.
Front Bushing
i Torque tighten the Ram Clamp Ring Screws
(4) evenly in a diametrical sequence to
35Nm (25lbf Ft)
Note: this should be done with the Punch Ram
Sleeve fitted and the RAm Alignment Fix-
ture in the Tool Cradle.
edition March 2010

section 7 page 13
7.8 Cradle Positioning - Toolpack Checks

Under normal circumstances it should not be necessary to re adjust the Tool Cradle after the machine has
been built. Checks for horizontal and vertical alignment of the Toolpack to the Ram should only be
required after component replacement.
Before starting any Tool Cradle alignment checks, first ensure the following:
a. The High Pressure Oil is set to 1500 psi.
b. The whole machine is up to working temperature of 40˚C. (Oil Temperature of 45˚C [113˚F]).
c. The Ram, fitted with a ‘Test Punch’ has been in the fully back position and is hot along the whole of its
length.
Note: After alignment checks have been made return the Ram to the fully back position to keep hot.
To check and adjust Cradle alignment proceed as follows:

-
Alignment Fixture
tighten to tighten to
Alignment Marks (4 off at 90 deg.) 46Nm (34 lbf Ft)
610Nm
(450 lbf Ft) DATUM Register Block
‘A’
Adjusting Stud
Wear Bar Gibb
Wear Bar Spacers VIEW ‘A’
a. Place the Ram Alignment Fixture (supplied as part of the machines special tools) into the Tool Cradle
and locate at the Third Iron position (Stripper Plate end), and with the Fixture Alignment marks posi-
tioned as shown in the illustration. Connect the Fixture to its digital monitor.
Note: Before using the Fixture ensure that it has first been calibrated.
b. Slacken the Cradle fixing screws and bar the Ram (fitted with Punch) forward into the Alignment Fix-
ture.
c. Centralize the Cradle by means of Adjusting Stud, checking Cradle alignment by rotating the Align-
ment Fixture from the power take off to operator side of the machine. Check centrality to within
0.013mm (0.0005") TIR.
d. Tighten the Gib Securing Screws to 46Nm (34 lbf Ft) and Cradle Fixing Screws to 610Nm (450 lbf Ft).
e. Calculate and take note of adjustment required to the thickness of the Spacer under the Wear Bar to
bring the Toolpack centreline to the correct datum height (illustration refers).
f. With the Cradle secured in place, move the Alignment Fixture to the Redraw position and take note of
any adjustment required to the Register Blocks to achieve correct parallelism of the Cradle to the Ram.
g. Remove the Wear Bar Spacers and have them both ground to the calculated thickness for height
adjustment (instruction e. refers). Adjustment ratio =1:1 (for every 0.001” height adjustment required
grind the Spacers by that amount).
NOTE: at the time of machine build the Wear Bar Spacers will have been marked (etched) on each side
‘Bottom’ or ‘PTO side’ to identify them as a further small amount of adjustment can be made to each
Spacer. Ensure that the Spacers are re fitted at the correct position.
h. Slacken Cradle and Gib securing screws and adjust the Register Blocks by the required amount
(instruction f. refers). Adjustment ratio = 3:1 (for every 0.001" adjustment required grind the Register
Block by 0.003"). If the run is towards the power take off side of the machine, grind the Register Block
on the machine operator side and if the run is towards the operator side of the machine then grind the
Register Block on the power take off side of the machine.
11/1/07 page 7-15

7.9 Front Bushing Seal Pack Removal and Replacement
7.9.1 To remove the Seals from the Primary and Secondary Housing Assembly:-
a. Stop the Bodymaker

b. Stop the Main Drive Motor
c. Remove the Ram Instruction 7.7 refers.
d. Remove four M5 Soc. Hd Cap Screws (1) securing Retaining Ring (2) to the Ram Housing and remove
the Retaining Ring with Slipper Seal (3) from the machine.
e. The Parker Seals (4) and Spacer (5) can now be removed
f. Remove four M6 Soc. Hd Cap Screws (6) securing End Cap (7) to the Ram Housing and remove End
Cap together with Slipper Seal (8) from the machine.
Note: to give room for this operation it will be necessary to pull the Front Hold Down forward, this
will need to be done by hand as there is no air supplied to the Rear Hold Down when the machine is in
Bar mode
6 4
8 2
1
page 7-16 Nov. 07

7.9.2 To replace the Seals:-
NOTE: To avoid damage to the Seals when the machine is running, care must be taken with their replace-
ment.
When fitting the Seals, sharp edge tools e.g. screwdrivers should not be used.
a. With the old Seals removed check that the Seal Housing, Retaining Ring and End Cap are clean and
without burrs or sharp edges.
b. Place the Parker Seals (4) and Spacer (5) in the Seal Housing, ensuring that the Seals are positioned
correctly, as shown in illustration below
6 3
8 5
7 1
c. Place the Slipper Seals (3) and (8) in the Retaining

Ring (2) and the End Cap (7
NOTE: To help replacement of the Slipper Seals

warm water can be used to soften them.
Calibration
After fitting the Slipper Seals they can be re-sized Mandrel
(calibrated) using a Special tool (Calibration Man-
drel) DO NOT use the Ram for this purpose. the Cal-
ibration Mandrel should be oiled and inserted from
the oil side. Twisting the Mandrel during insertion
will assist calibration.
d. Re-fit the Retaining Ring and End cap to the machine.
For Component details refer to the following assemblies in Section 10:
Primary and Secondary Housing Assembly (Sheet 28)
Nov07 page 7-17

7.10 Hold Down Mechanism

The complete Hold Down Mechanism consists of two Assemblies,
Rear Hold Down Assembly (Instruction 7.10.1 refers)
Front Hold Down Assembly (Instruction 7.10.2 refers).
For component details refer to the following assemblies in the Spares Section of this manual
Hold Down Assembly - Rear (Sheet 12)
Hold Down Assembly - Front (Sheet 27)
edition March 2010

section 7 page 18
7.10.1 Rear Down Assembly

A Rear Hold Down Assembly, comprises an Air Accumulator, Rear Air Spring Arrangement, Cam Fol-
lowers and Levers, and Connecting Links to the Front Hold Down Assembly.
Connecting Link
(Front Hold Down Assembly)
Crankshaft
Redraw Cams
Rear Hold Down Assembly
For component details refer to the following assemblies in the Spares Section of this manual
Hold Down assembly - Rear (Sheet 12)
edition March 2010

section 7 page 19
Rear Hold Down Assembly Removal and Replacement:-.

a. Position the Hold Down Assembly as far forward as possible (approx. 52°)
b. Turn off all the Pumps
c. Disconnect the oil hose to the Cam Follower Pin (1)
d. Turn off the air, then disconnect the Air Line connection to relieve air from the Accumulator (2).
e. Remove the Accumulator (2) from the machine, secured to its Mounting Plate (3) by eight M12 Hex
Hd Screws (4).
f. Disconnect the oil pipe fittings to the Cam Follower Pins (1).
g. Remove Pivot Pin (5), held in place by External Circlip, and push Connecting Links (6) away from
the Cam Levers.
h. Support the weight of the Cam Levers (7) with a Portable Hoist.
i. Remove Nuts (8) securing the Air Bag (9) to the Mounting Plate (3)
j. Remove twelve M10 Hex Hd Screws (10) securing the Mounting Plate (3) to Spring Housing (11)
and carefully lift it from the machine.
k. Remove three M10 Hex Hd Screws (12) securing the Guide Stop Plate (13) and remove it along with
the Guide Bush Housing (14)
l. Using an extended Allen Key and by access from the Rear Spring Housing (11) remove four M10 Soc
Hd cap Screws (15) securing each Rod End (16) to its Connecting Flange Assembly (17).
m. Remove Connecting Flange (17) and Air Bag (9) together from the Spring Housing (11).
n Remove four M6 Soc. hd Cap Screws (18) releasing each `Ringfeder’ Locking Element (19) (The
screws on the Flywheel side of the machine are accessible by removing the Rear End Cover from the
Flywheel Guard).
o Remove six M10 Hex Hd Screws (20) and using Jacking Holes provided remove each Pivot Housing
(21). Take care not to damaged `O’ Rings (22).
p Lift Cam Levers (7), complete with Cam Followers (23) and Pivots (24), from the machine.
q To replace the Rear Hold Down Assembly reverse the procedure a) to j), carefully checking the fol-
lowing:
r If fitting new Bearings (25) ensure a correct preload of 0.025/0.05mm (0.001”/0.002”) on the Bearing
by grinding the Spacer (26).
s Ensure that the Flat and Oilways of Cam Follower Pin (1) are facing toward the Rear Air Spring.
t Ensure that Air Bag Guidance Arrangement (14,27 & 28) is assembled before tightening the `Ring-
feder’ Locking Screws (18) to 17Nm (12.5lb/Ft) in accordance with manufactures instructions. Check
that 0.3/0.2 mm axial clearance has been maintained.
u Ensure that all twenty four screws supplied with Air Spring (9) are marked by the fitting personnel,
such that when fully assembled it can be guaranteed that they will sit in the correct orientation and thus
not puncture the Air Spring (9).
v Using Fixture GT1485502. Press Bush (28) into Guide Bush Housing (27) so that it is flush with the
Housing face
w Assemble Connecting Flange Assembly (17) with 6mm diameter air escape hole at bottom as shown.
edition March 2010

section 7 page 20
6 6
‘A’
5
10 13 9 11 17 7
3
8
2 4
‘C’ ‘C’
14
12
Section ‘A’ - ‘A’
‘B’ ‘B’
Correct
‘A’
Incorrect
15 17 16
7 24 25 22
18 23 Section ‘C’ - ‘C’ (enlarged)
21
Section ‘B’-‘B’ (enlarged) 20
18
19 26 19
1
Pin shown rotated through 90°
(oil holes should be pointing to the
bottom of the Crankcase). 0.175 / 0.075 axial clearance
on cam Follower (each side)
0.3 / 0.2 axial clearance

on Flanged Bush (both sides)
Rear Hold Down Assembly
edition March 2010

section 7 page 21
7.10.2 Front Hold Down Assembly

The Front Hold Down Assembly comprises a Front Air Spring Arrangement, Redraw Guide Rods and
Links to the Rear Hold Down Assembly.
Cam Lever - Rear Hold Down
Plan View
Connecting Links
Air Spring Arrangement
Redraw Guide Rods
For component details refer to the following assemblies in the Spares Section of this Manual
edition March 2010

section 7 page 22
Front Hold Down Assembly - Removal and Replacement:-
Torque Tighten
46Nm (34lbf FT)
3 8 7
Plan View
11
12
4 5 6 10 1 2 9
Torque Tighten
200Nm (150lbf FT)
Removal:
a Remove the Ram (Instruction 7.7 refers)
b Disconnect Air Line to the Air Spring Housing (1)
c Unscrew Locknuts (2) (use Special Torque Spanner 2390507C, supplied with the machine toolkit)
d Remove the Pivot Pins (3) (use Pin Extractor Tool 199881D, supplied with the machine toolkit) held in
place by External Circlip then push the Connecting Links (4) away from the Redraw Guide Rods
Clevis (5)
e Support the weight of the Front Air Spring Arrangement (1) with a portable hoist.
f Withdraw the Redraw Guide Rods (6) from the Bearing Blocks (7) and the Air Spring Housing.
Important: Care must be taken not to intermix the Spacers (8), it is important that these are refit as
removed.
g Lift the Air Spring Housing from the machine.
Replacement:
a Check that the Bearing Block Guide Bushes (9) are the same vertical height, within 0.002mm
(0.001”), as the Guide Bushes (10) in the Primary Bulkhead.
To check, ensure that the Bearing Block Securing Screws (11) are correctly torque tightened and check
the measurement from the Bed using a Dial Test Indicator. Adjust the height the Bearing Block (7) by
adjusting the Spacers (12) located below the Bearing Blocks.
b With the Guide Rods (6) located in the Primary Bulkhead align the Bearing Blocks (9) horizontally to
achieve free movement of the Guide Rods both rotationally and laterally. After setting re torque
tighten the Bearing Block Securing Screws.
c Slide the Redraw Guide Rods (6) through the Air Spring Housing (1) and Bearing Blocks (7)
d Lightly tighten the Locknuts (2) and check for easy lateral movement of the complete Guide Rod / Air
Spring Housing.
e Re connect the Connecting Links (4) to the Redraw Guide Rods Clevis (5)
continued --------
edition March 2010

section 7 page 23
f With air on the Rear hold Down, loosen the two Guide
Rod Locknuts (2), allowing the Air Spring Housing (1) to
freely align its location with the Guide Rods (6) and
release the two Spacers (8).
Gently move the Air Spring Housing (1) along the Guide
Rods (6) to make contact with the Spacers (8). 6 8 2
Torque Tighten
Measure the gap that exists between one of the Spacers 200Nm (150lbf Ft)
and the housing and adjust the opposite Spacer thickness
by the same amount to ensure absolute squareness of the
Housing to the Guide Rods when the Locking Screws are
tightened (torque tighten to 200Nm (150lfb Ft)
g With the Blank Holder checked for concentricity and
squareness and the air pressure set to 40psi on the Front
Piston, ensure correct overtravel of the Blank Holder and
Blank Holder
face of the Redraw Die when the Front Hold Down is fully
forward. 1
8 2
Grind opposite Spacer

to remove the gap
edition March 2010

section 7 page 24
Blank Holder Alignment and Overtravel Checks:-

Alignment of the Blank Holder (Squareness):
A Spacer (13) located behind the Blank Holder provides the
means of adjusting the alignment and squareness required of
the front face of the Blank Holder, within a tolerance of
0.25mm (0.001”) TIR.
Blank Holder /
a Check alignment of the Air Spring Housing (1). Dome Alignment
b Ensure that air is on to both the Front and Rear Hold Down Fixture
then using the Blank Holder / Dome Alignment Fixture 13

(supplied with the machine tools) located onto the Tool
Cradle Wear Bars, check the front face of the Blank
Holder, take readings at the top, bottom, left and right. If
the squareness is outside the required tolerance mark the
Blank Holder
Spacer (13) at the top before proceeding.
c To correct out of squareness remove and grind the Spacer 14
(13) located behind the Blank Holder to the required taper. 1 15
d Using the Blank Holder Alignment Fixture, reposition the
Dial test indicator and check the concentricity of the o/dia.
of the Blank Holder. Adjustment is provided by four M8
Soc. Set Screws (14) which can be locked by four locknuts
(15) when concentricity within 0.25mm (0.001”) TIR is
achieved.
Check of Overtrave:-l
To Ensure overtravel of the Blank Holder and face of the
Redraw Die when the Front Hold Down is fully forward pro-
ceed as follows. 8
a With the Toolpack in place, bar the machine forward until 0.075 / 0.200mm
the Punch Nose is 3mm short of the Redraw Die Front (0.003” /0.008”)
Face. Set the air pressure to 40 psi on the Front Hold Blank Holder
Down. Take note of machine position, approximately. 30,
for future reference, this can be obtained from the Machine 16
Timing Device Read-out.
b pull the Air Spring Housing (1) forward manually, then
close all machine guards and engage air to the Rear and
Front Hold Down
Open the machine guard and measure the gap between the 0.075 / 0.200mm
(0.003” /0.008”)
Air Spring Housing (1) and Sleeve (16). This should be
0.075 / 0.200mm (0.003” / 0.008”) at this position.
If the gap is not within the stated tolerance 0.075 / 1
0.200mm it will be necessary to adjust the Split Spacers
(8) equally to achieve the correct overtravel.
Re-check the Blank Holder concentricity and squareness
Note: Overtravel on new machines can diminish during 8
initial production due to ‘bedding in’ of machine compo-
nents.
Reference Information:
For component details refer to the following assemblies in the Spares Section in this manual:
edition March 2010

section 7 page 25
7.11 Cup Locator/Blank Holder Alignment

To set the Cup Locator to the Blank Holder:
a. Check the setting of the Blank Holder (Instruction 7.10.3 refers)
b. Bar the machine on a forward stroke to a position where the Blank Holder with a cup on it is under the
Cup Feed Cam and in the Cup Locator.
NOTE: It will be necessary to pull the Front Hold Down Assembly forward by hand as there is no air
supplied to the Rear Hold Down when the machine is in the Bar mode.
c. Adjust the three M8 Soc. Hd Cap Screws in the Cup Locator Support to position the Cup Locator,
(Change Part) to achieve 0,05mm/0,08mm (0.002"/0.003") clearance between and around the Cup
Locator and the Cup.
Cup
Cup Locator
Adjusting Screws 0.05mm /0.08mm (0.002" / 0.003")
Rotary Cup Feed Assembly (Sheet 18 & Sheet 51)
page 7-26 11/1/07

7.12 Rotary Cup Feed Cam - Removal and Replacement.
5 4 3
1
7
X 8
12
2
a. Bar the Ram to the fully back position

b. Remove the End Cover (1) secured in position by three M6 Screws
c. Release tension of the Cup Feed Cam Drive Chain (2) by slackening the M8 Hex. Hd. Screw retaining
the Tension Arm (3) and back off the Arm using the Adjusting Block Arrangement. (4)
d. Remove the Cup Stop and Cup Stop Support (5) secured by two M8 Soc. Hd Cap Screws
e. Remove the Top Guide R. H. (7) secured by two M8 Soc. Hd Cap Screws and 8mm dia. extractable
dowels.
f. Remove the Stripper Finger (8) secured by two M6 Hex Hd Screws.
g. Remove the Cup Feed Drive Chain (2).
h. Remove End Cover (9) secured by three M6 Soc. Hd Cap Screws
i. With a Spanner on the Shoulder Bolt (10) 12
13
and 10mm Allen Key holding the Eccen-
tric Pin (11), release the Shoulder Bolt.
j. Take the weight of the Cam (12) and
unscrew the Eccentric Pin (11)
9
k. The Cam can now be removed from the
Cup Feed Plate (13).
11
l. To replace the cam reverse removal pro-
cedure. For setting of the Cam refer to
instructions 7.12.1 and 7.12.2
10
Enlarged Section X-X
Nov. 07 page 7-27

7.12.1 Setting the Cam Clearance
14
13
0.4mm
[0.1mm with cup on the Blank Holder]
a. Check the setting of the Cup Locator / Blank Holder (instruction 7.11 refers)
b. Bar the machine forward on a forward stroke to a position where the Blank Holder with a cup on it is
under the Cup Feed Cam.
Note: It will be necessary to pull the Front hold Down Assembly forward by hand as there is no air
supplied to the Rear Hold Down when the machine is in Bar mode.
c. Slacken four M10 Soc. Hd Cap Screws (14)
clamping the Cam (12) and position the Cam 13 12
with its highest point above the centre line of the
Blank Holder (illustration refers). 14
d. Whilst holding the Shoulder Bolt (10) adjust the
Eccentric Pin (11) to achieve a 0.1mm (0.004”) 9
clearance between the tip of the Cup Feed Cam
and the Cup on the Blank Holder.
11
e. When the correct clearance has been achieved
hold the Allen Key in the Eccentric and tighten
the shoulder Bolt.
10
page 7-28 Nov. 07

7.12.2 Setting the Cam Timing
4
3
X
25mm deflection
Cup
a. Adjust the Cup Feed Drive Chain to the correct tension.(Incorrect tension can lead to chain failure
and premature wear of the Sprockets). To adjust slacken the Tension Arm (3) retaining screw and ten-
sion of the chain using the Adjusting Block Arrangement (4). When the correct tension (25mm deflec-
tion) is achieved tighten the Tensioner Arm (3) Retaining Screw.
b. Bar the machine forward to the position where the Blank Holder is 3mm (0.125”) clear of a cup seated
against the face of the Redraw Die.
c. Check the position of the Cam (12), if timing is
13 12
correct the Cam high point should be on the cen-
tre line of the Cup (illustration refers).
d. If the Cam requires adjusting, slacken the four 14
M10 Soc. Hd Cap Screws (14) clamping the Cam
(12) and re-position the Cam with its highest 9
point above the centre line of the Cup / Blank
Holder. Torque tighten the four clamping screws 11
(14) to 92Nm (68lbf Ft).
10
For component details refer to the following assembly

in Section 10
Rotary Cup Feed Assembly (Sheet 18 and Sheet 51)
Nov. 07 page 7-29

7.13 Cup Stop Setting.
a. Bar the Ram until the high point of the Rotary

Cup Feed Cam (1)is at the centre point of the
Cup Infeed Chute.
b. Slacken the two M8 Soc. Hd. Cap Screws (2)
and position the Cup Stop Support to a posi-
tion where when the Can Stop plunger (3) is
activated it locates inside the Cup and holds it
approximately 3mm away from the Rotary
Cup Feed Cam (4). 1 2
Reference Information 3
For component details refer to the following
assembly in Section 10
Rotary Cup Feed Assembly (Sheet 18)
4 3mm
page 7-30 Nov. 07

7.14 Removal / Replacement and Timing the Discharge Turret
7.14.1 Turret Removal / Replacement

Discharge Brush
a. Release the catches securing the Discharge (open)
Conveyor and Discharge Brush and pivot them Dome Door
Discharge Unloader (open)
away from the Turret Turret Pocket
b. Open the Dome Door. Punch
c. Slide the Discharge Hub and Turret Sub
Assembly off the Gear Shaft.
d. To replace the Turret reverse removal instruc-
tions
NOTE: When the Ram is at back dead centre 3mm
the two Arrows, one on the Discharge Hub, the (Finger nearest Stripper)
other on the Discharge Turret should be in line.
7.14.2 Timing the Discharge Turret
a. Bar the Ram on to its return stroke (approximately 235 degrees) with the Punch Nose above the
Unloader Pocket Inside Finger (Finger nearest the Stripper).
b. Slacken the Turret Drive Gear Shaft
Locking Arrangement and rotate the
Turret, setting the gap between the
Unloader Pocket
Punch Nose and the Unloader Pocket Inside Finger
Inside Finger to 3mm. Lock the Shaft
in this position
Turret Drive
Gear Shaft
Turret Drive Shaft

Locking Assay.
For component details refer to the following assembly in Section 10
Discharge Drive Assembly (Sheet 14)
Nov. 07 Page 7-31

7.15 Stripper / Cradle Alignment
a. When fitted to the Stripper Housing Assembly, the bore of the Stripper Assembly must be concentric
within a tolerance of 0.025mm (0.001”) TIR.
b. Place the Blank Holder / Dome Alignment fixture in the Tool Cradle and with a Dial Test Indicator
read from the inner bore of the Stripper Assembly, checking that it is concentric. If necessary slacken
M8 Soc Set Screw and adjust the Stripper to the required tolerance by means of two Eccentric Bushes
(2).
c. Secure the position of the Stripper Assembly and re-check concentricity
M8 Soc Set Screw
Stripper Housing
Eccentric Bush
Stripper Housing Assembly (Sheet 37)
page 7-32 11/1/07

7.16 Swing Lever - Dual Stroke Setting

When changing the machine stroke on a dual stroke machine it is necessary to make changes to the Swing
Lever set-up.
The Primary Conn Rod Sleeve (1) is centred to the

Swing Lever by Pivot Pin (2) and secured by a
SUPERBOLT® Jamnut Tensioner1 (3).
3
The Swing Lever has a location hole above and below
this Pivot Pin (2) and by rotating the Sleeve (1) to 5
reposition the Location Pin hole in the Sleeve in-line
with either of the these holes will set the Swing lever 4
for a different machine stroke.
Lower position = 26” Stroke. 1
Upper position = 575mm Stroke.
2
To change the machine stroke:
Location
a. Bar the machine to the 10 degree position (Fig. 2) holes
Fig.1
b. Using Torque wrench (@35Nm) and 6mm Allen
Key bit, follow the manufacturers recommended
procedure and remove the Jamnut Tensioner1 (4)
from the Positioning Pin (5). Ensure that the
Washer is also removed at this stage.
c. Remove the Access Cover, secured by ten M8 Hex
Hd Screws, on the side of the Crankcase and then
bar the machine to the 90 degree position, where
the centre bore of the Swing Lever is accessible
(Fig. 3)
d. Remove the Oil Pipe and Banjo Fitting. 4 5
e. Loosen (Do Not Remove) the Jamnut1 Tensioner Fig.2
(3) on the Pivot Pin (2).
f. To avoid possible injury due to moving parts
ensure that nobody is working on the machine,
then using a Slide Hammer (M8 thread) remove
the Positioning Pin (5).
g. Using Special Tool (2384676B), supplied with the 2 3
machine, rotate the Pivot Pin (2) by 180 degrees
until the Sleeve location holes align with the
required hole in the Swing Lever. 5
h. Replace the Location Pin (5) in its new location
and secure with the Jamnut Tensioner1 (4).
i. Torque tighten the jack bolts in both Jamnut Fig.3
Tensioners1 (3) and (4) to 35Nm.
j. Ensure that the Dome Station is in the correct position for the Stroke of the Swing Lever now set.
k. Bar the machine through one complete cycle to ensure all aspects of the machine settings are correct.
For component details refer to the Swing Lever Assembly (Sheet7) in Section 10
1. For SUPERBOLT® Jamnut Tensioner loosening - tightening - maintenance instructions refer to Section 9
Proprietary Literature.
Oct. 07 page 7-33

7.17 Setting the Dome Station

Depending on can size and Ram stroke the Dome Station requires assembling to give the correct can dis-
charge position. This is achieved by adding or removing a Location Plate (1) and Location Plate Spacer (2)
in front of the Dome Door.
Correct Dome Tooling and can diameter Change Parts also require fitting.
Dome Tooling:
Dome Die (3)
Hold Down Ring Sub Assembly (4)
Diameter Change parts:
Front Plate Assembly (5)
Stop Pad (6)
Dome Die Body (7)
Dome Die Spacer (8)
NOTE: The Rear Plate (9) is set to align the Dome Station to the punch. This is done when the machine is
built and the Plate is then secured in place by two M12 Soc. Hd Cap Screws (10). Removal of these Screws
will lose the Domer alignment setting.
It is important therefore to observe the following instructions when changing the Dome Station set-up.
a. To remove the Dome Tooling, first remove the Front Plate Assembly (5) secured by eight M12 Hex.
Hd. Bolts (11) and Nuts (12).
b. The Hold Down Ring Assembly (4) can then be removed.
c. Removal of four M8 Soc. Hd. Cap Screws (13) will then allow the Dome Die Assembly to be removed.
d. To set the Dome Station for correct can size / Ram stroke refer to instructions 7.17.1 to 7.17.2
e. When replacing parts reverse the removal instructions.
1 2
13
12 11
6
11
12
4
A
3
8
7
A
10
Section A-A 5
9 Fig. 1
For component details refer to the following assemblies in Section 10:
Dome Station Assembly Basic machine parts and Diameter Change Parts (Sheet 36)
Dome Station Set-up Adaptor parts (Sheet 36/1)
Tooling Assembly (Sheet 53)
page 7-34 Oct. 07

7.17.1 Set-up for 26” Stroke with Long Ram

(20oz, 24oz, and 50cl can)
a. The set-up for this range of cans is as shown in the illus-

tration (Fig.2)
In this set-up a Location Spacer (1) and Spacer (2) are
not required.
Fig. 2
7.17.2 Set-up for 26” Stroke with Short Ram

(204 diameter and 16oz. cans).
The set-up for this range of cans is as shown in the illustra-

tion (Fig. 3)
a. To move the Dome Station forward (by 25.30mm) fit a
Location Plate (1) in front of the Dome Door and secure
using two M10 Soc. Hd Cap Screws (14).
This Location Plate also aligns the Dome. This can be
set using the Dome Housing (15) located in the Rear
Plate (9).
b. The Dome Tooling can be changed as described in
instruction 7.17 15
25.30mm
9 1
14 Fig. 3
7.17.3 Set-up for 575mm Stroke with Short Ram

(8.4oz and 12oz. 211 diameter cans
and 9.1oz. 204 diameter cans)
The set-up for this range of cans is as shown in the illustra-

tion (Fig. 4)
a. In addition to Location Plate (1) (instruction 7.17.2
refers), for shorter can lengths it is also necessary to
move the Dome Station further forward (by 36.70mm).
This is achieved by fitting a Location Plate Spacer (2) in
front of the Location Plate (1).
b. The Dome Tooling can be changed as described in
instruction 7.7
1 36.70mm
2
Fig. 4
Oct. 07 page 7-35

7.18 Stripper Set-up
7 x
5 8
14
12
3 13
2 14.0mm
1 x
Section X -X
Fig. 1
Assembly showing Set-up for:
211 DIA. x 12oz. cans on a 575mm Stroke
211 DIA x 16oz. cans on a 26” Stroke
Dual Stroke machine with 260mm long Cradle and Short Ram
44.0mm
9
x 21.0mm
5
11
10
16
3
6
12
1 x 15
Section X -X
Fig. 2
Assembly showing Set-up for:

211 DIA. x 8.4oz. cans on a 575mm Stroke
Dual Stroke machine with 260mm long Cradle and Short Ram
page 7-36 Oct. 07

Stripper Set-up
Depending on can size and Ram stroke, the Stripper Assembly requires assembling as described below.
7.18.1 Set-up for 211dia. x 12oz and 16oz cans
The set-up as shown in the illustration (Fig. 1) allows 12oz. and 16oz. cans to be made using a Short Ram.
Note: For 12 oz. cans a 575mm stroke setting is required.

For 16oz. cans a 26” stroke setting is required.
7.18.2 Set-up for 211dia. x 8.4oz can
The set-up as shown in the illustration (Fig. 2) allows 8.4oz. cans to be made using a Short Ram.
To convert the Stripper set-up Fig.1) for 8.4oz. can production:

a. Remove six M10 Soc. Hd. Cap Screws (1) and remove the Stripper Adaptor (2) complete with Stripper
and Guide Ring from the Stripper Housing.
b. Remove the Stripper Finger Assembly (3) and Guide Ring (4), secured in place by four 10UNC Soc.
Hd. Cap Screws (5) and fit these parts into the Stripper Adaptor (6) for the 8.4oz. can (Fig 2 refers)
c. Fit this completed assembly into the Stripper Housing and secure using the six M10 Soc. Hd Cap
Screws (1)
d. Replace Extension Block (7), secured by two M6 Soc. Hd. Cap Screws (8) and Washers, with Extension
Block (9) and Spacers (10) for the 8.4oz. can. Secure with two M6 Soc. Hd Cap Screws (11) of the cor-
rect length and Washers.
e. Remove the Short Can Sensor Bracket (12), secured by two M8 Soc. Hd Cap Screws (14) and Washers,
and replace the Spacers (13) with Spacers (15) for the 8.4oz. can. Secure with two M8 Soc. Hd Cap
Screws (16) of the correct length and Washers.
For component details refer to the following Assembly in Section 10
Stripper Assembly (Sheet 54)

Stripper Adaptor Parts (Sheet 55)
Oct. 07 page 7-37

7.19 Clutch and Brake Removal and Replacement
Flywheel
Cover
Bearing Housing
Sub Assy
Rotary Union
Ringfeder
Locking Assy
Clutch and Brake Unit
To remove and replace the Clutch and Brake Unit:

a. Stop the machine production, use Lockout procedure for safety.
i. Bar machine into a position where the mechanism is in its natural stable state and will not rotate
when the Clutch and Brake is removed.
ii. With the flywheel sliding access door in open position shut the machine down and isolate all elec-
tric power at the main isolator switch. Post a warning notice and lock the isolator switch.
iii. Open the accumulator drain down valve on the Clutch and Brake Hydraulic Power Pack. Check
that the clutch oil pressure falls to zero on gauge. (refer to the hydraulic pack drawing. for loca-
tion)
b. Remove the Flywheel Guard
i. Disconnect and drain all hydraulic hoses connecting the Rotary Union on end of the Crankshaft,
Clutch and Brake Sol. Valve and Hydraulic Power Pack.
ii. Disconnect pipe work and all electrics to the Clutch and Brake Sol. Valve.
iii. Disconnect pneumatic line to interlock on flywheel sliding access door.
iv. Remove fixed access panels on the front and R.H. side of the flywheel guard
v. Unscrew the main body of the flywheel guard from backplate and remove complete.
c. Remove the Clutch and Brake
i. Remove six M8 Hex Nuts and remove the Rotary Union, taking care not to damage gaskets.
ii. Remove Bearing Housing (Outboard Bearing, if fitted). and Oil Seal.
iii. Remove 12 off M16 x 40 Cap Hd Screws securing the Cover to the flywheel.
page 7-38 11/1/07

iv. Support the weight of the Outer Casing from above in a rope
sling (illustration refers) and remove by sliding along the Clutch
Flywheel
and Brake Unit over the Clutch Plate Splines..
v. Carefully loosen & remove Ringfeder Locking Assy.
vi. Remove twelve M16 Soc. Hd Screws securing the Brake Hub to
the Brake Anchor Hub and remove by sliding the Brake Hub
over the Clutch Plate Splines
vii. The Clutch & Brake Unit is now ready to be removed.
Support the weight of the Clutch and Brake Unit from above in
a rope sling and screw two M16 Soc. cap screws, approx. 150mm long into M16 holes provided in
the face of the clutch.(these are used as handles to manipulate the Clutch and Brake).
viii. If the Clutch and Brake is free on the Crankshaft slide the unit along the shaft to remove. If how-
ever the unit is tight on the crankshaft it may be necessary to use special pulling equipment and
hydraulic jack to assist in removal.
d. Re-assemble the Clutch & Brake; Reverse the removal procedure, taking note of the following:
i. Fit new "O" Rings in the Clutch bore
ii. Ensure that holes in the Crankshaft line up with holes in the Clutch and Brake before tightening
the Ringfeder Locking assy.
iii. Ringfeder Torque sequence in accordance with manufacturers instructions
iv. When replacing the Clutch Cover it is IMPORTANT to orientate Plug
the Plug in the Cover in line with the Clutch Anchor Plate (illustra-
tion refers) so that the inspection hole in the Clutch drive spline
lines up to enable the Clutch air gap to be measured through the
Plug.
Jacking
Hole
Anchor Plate
NOTES:
Weight of the Clutch & Brake Unit is approximately 210 kg
Recommended operating pressure for Clutch & Brake: 70 bar (1015psi)

Adjust by on line pressure relief valve mounted on the Clutch & Brake Power Pack tank.
Note: reduced pressure will result in reduced clutch performance and increased clutch plate wear.
Extreme care MUST be taken when maintaining the Clutch and Brake - refer to Clutch and Brake manu-
facturers instructions.
Flywheel Assembly (Sheet 4)
11/1/07 page 7-39

7.20 Flywheel Removal and Replacement

It may at some time during machine maintenance, when checking for play in the Flywheel bearings, be
necessary to remove the Flywheel.
To remove:
Flywheel
Quill
Brake Anchor Hub
Shimpack
‘B’
a. First remove the Clutch and Brake Unit (Instruction 7.17 refer)
b. Release tension on the Motor Drive Belts
c. Remove Motor Drive Belt
d. Take the weight of the Flywheel by passing a rope sling through one of two
38mm dia holes in the Flywheel rim (illustration refers)
NOTE: Flywheel weight is 1200kg
Flywheel
e. Remove ten M20 Soc Hd Cap Screws retaining the Brake Anchor Hub.
Remove the Hub and Shimpack.
f. Gently rock the Flywheel to release the Outer Bearing Cone and whilst still
supported from above move the Flywheel along the Crankshaft to remove,
taking care not to damage Seals and Bearings.
To replace:
a. Reverse the removal procedure, using recommended torques on all securing screws (refer to Flywheel
assembly drawing).
b. When fitting new bearings fit the Outer Races in the Fly- ‘A’
wheel and check that they are feeler tight on the back Flywheel
face. Clamp the Inner Races in position using Fixture Bearing
GT 1485011/AD (available from the machine supplier)
to apply the correct pre-load.
c. Measure the distance over the Bearings in three 120˚
spacings to find the average distance (‘A’) GT 1485011/A-D
d. Measure the distance of the Flywheel Quill spigot (‘B’).
e. Calculate the size of Shim required (‘A’ - ‘B’) + 0.18mm
This will allow a Bearing running clearance of 0.13mm / 0.18mm (0.005” / 0.007”).
page 7-40 11/1/07

f. With the Flywheel fitted, use a hydraulic jack to lift the Flywheel and check that it does not lift verti-
cally more than 0.05mm (0.002”). Check using a DTI on the Brake Anchor Hub.
Dial Test Indicator
Brake Anchor Hub
Jack
g. With the Clutch re-fitted measure the run-out at surface ‘X’ to confirm that the total indicated reading
is within the maximum of 0.010mm (0.004”)
‘X’
Clutch Cover

Flywheel Assembly (Sheet 4)
11/1/07 page 7-41

7.21 Accumulator Testing and Charging Instructions
page 7-42 11/1/07

7.21.1 Preparation for Testing:-
a. Stop the Clutch Pump

b. Drain the oil in the system (normally 60/65 Bar) by opening Drain Valve on the Hydraulic Power
Pack.
c. Check the oil Pressure is now at zero at Gauge on the Power Pack.
d. From the Accumulator remove Protective Cap (S) and Cap Nut (H).
e. Take the Testing Unit and ensure that Valve (A) is fully open and Valve (B) is fully closed. Screw Nut
(D) by hand onto the Accumulator Gas Valve and turn the Unit to a position where the Gauge can eas-
ily be read. Now fully tightened Nut (D) with a wrench.
f. Screw down Valve (A) fully then the pressure in the Accumulator can be read.
g. Before removing the Testing Unit, firstly open Valve (A) and then fully open Valve (B) to release any
pressure trapped in the unit. The Testing Unit can then be removed from the Accumulator.
7.21.2 Increasing the Pressure in the Accumulator:-
IMPORTANT NOTE: Charge ONLY with LIQUID NITROGEN.

a. Repeat the Preparation for Testing Procedure listed above to a stage where the pressure can be read.
b. If the pressure is below 40 Bar it should be recharged to a recommended 45 Bar. This is done as fol-
lows:
i. Connect the Flexible Charging Hose to the Pressure Relief Valve on a commercially available
Nitrogen Bottle by means of Cap Nut (G1). (For Nitrogen Bottle connections from different coun-
tries an appropriate adaptor will be required.). Cap Nut (M) of the Charging Hose is for connect-
ing to fitting (C) of the Charging and Testing Unit. By opening the Shut Off Valve on the Nitrogen
Bottle, with Spindle (A) screwed in, slowly release nitrogen into the Accumulator, to ensure better
pressure compensation and to prevent damage to the Gas Valve Insert. Close the Shut Off Valve
on the Nitrogen Bottle and check the charging pressure on the gauge.
ii. Repeat the above process until the required pre-charge pressure is reached. After a period of
approximately 5 minutes, during which time temperature compensation takes place (for higher
charging quantities a longer period has to be allowed), re check the pressure and adjust if neces-
sary.
iii. When the required pre-charge pressure is reached, unscrew Spindle (A) so that the Gas Valve in
the Accumulator closes. Check the Gas Valve on the Accumulator for leakages by means of sealing
spray or soapy water.
iv. Screw Cap Nut (H) and Protective Cap Screw (S) onto the Gas Valve of the Accumulator.
c. Completion: close the Accumulator Drain Valve on the Power Pack.
11/1/07 page 7-43

LUBRICATION
SAFETY
ALL personnel should apply safe working procedures

at ALL times.
Reference to Safety herein should be applied in con-

junction with your factory procedures
INDEX: PAGE:
Chart No: Lub 321 (Sht 1 of 2) 1

Chart No: Lub 321 (Sht 2 of 2) 2
Chart No. Lub 260 3
Oil Jet Location 4
For additional Information regarding the Hydraulic Power Pack refer to this manual Section 9
12/Feb/98
Chart No: Lub 321 Sheet 1 of 2
Lubrication Instructions Machine: 5000 Bodymaker Refer to Sheet 2 for

Hydraulic Power Pack
Code: 015.043
Warning Check Daily:-

Do not mix brands or mix grades.
Remove
1. Crankcase
Check level
(1)
fordaily
Cover
and top when required,
access
Remove Cover
FZ *X Steel Can production
Stop machine before lubricating. Capacity: 455 Liters (100 Imperial Gallons)
4 DX Aluminium Can production
Oil cans and grease guns must only *X For Steel can production ONLY Use Mobil - Mobilgear XMP 150
1
be filled up by the storekeeper. DX For Aluminium can production ONLY Use Mobil - Mobilgear
600 XP 150, Shell - Omala S2 G 150 or equivalent
‘A’
Frequency HX 2. Air Lubricator (1)
Check level daily and top up when required.
W Every Four Hours Use Shell - Tellus S2 M 32 , Mobil - DTE Light or equivalent
X Daily *X OIl Tank (Hydraulic Clutch and Brake)

Refer to Sheet 2
Use Mobil - DTE Light VG 32
Y Weekly
11
Z Monthly
Z
Lubricate Monthly:-
3. Discharge and Cup Feed Drive Chains (3) *Z
Number of points shown in brackets
* Use Clare - P80 Chain and Rope Lubricant
(combined mineral and synthetic oil) or equivalent.
F FZ GZ
CarnaudMetalbox Type
Remove any machine Coolant from the chains and apply lubricant to
dry chains.
*Z
Grade 12 7 3 9
FZ 4. Cup Feed Cam Drive (2)
D 5. Dome Station Assembly (1, Depending on Dome Station type)
Medium Gear Oil
General Purpose Grease
6. Dome Door Hinge Pins (2)
7. Power Take Off Shaft Universal Joints (2)
‘A’
F
8. Discharge Turret (1)
G Open Gear Grease
Grease with Shell - Gadus S2 V100 1, Mobil - Mobilux EP2
H Hydraulic Oil or equivalent.
Special Lubricant
* Special Purpose Oil
GZ 9. Discharge Turret Drive Gears (2)
10. Discharge Turret (remove and grease gear) (1)
* Special Purpose Oil Use Shell - Gadus S2 OG 40, Mobil - Mobilgear OGL 461
Oil Level &
Temperature Gauge
2
* Special Purpose Oil

or equivalent
HX
* *Z 11. Rotary Union (Hydraulic Clutch and Brake) (1)
Use 4 to 5 drops SAE 30 Motor Oil

8 5 FZ
Issue Drawn FZ 6
Lubricate Once a Year:
F 12. Main Drive Motor (2)
17 Feb. 98 S. H. 10 GZ
Grease with Shell - Gadus S2 V100 1, Mobil - Mobilux EP2
11 Nov. 99 M.D. or equivalent
04 Oct. 06 S.H. View ‘A’

23 March. 2011 S.H.
CarnaudMetalbox Engineering Ltd Refer to Lub Chart 260 for Company Standard Recommendations
Chart No: Lub 321 Sheet 2 of 2
Lubrication Instructions Machine: 5000 Bodymaker

Code: 015.043
Pressure Gauge
Warning Pressure Gauge Accumulator (Conditioning Circuit Pressure)
Drain Down Valve
Do not mix brands or mix grades. (Clutch Oil Supply Pressure)
Pressure Gauge *
Stop machine before lubricating. (Hydrostatic Pump Oil) Filter (lubrication recycle)
Pressure Gauge
Oil cans and grease guns must only (Clutch Cooling Oil Pressure) Pressure Gauge
be filled up by the storekeeper. (Bearing Remove
Oil Supply Cover
Pressure)
for access
Frequency
W Every Four Hours *
Filter -
X Daily Water Removal
Y Weekly *Filter (Clutch)

Z Monthly *Filter (H.P. Lube)
Number of points shown in brackets
CarnaudMetalbox
Type
Special Purpose Oil
* Use Mobil DTE Light VG 32.
Oil Level
Gauge
Clutch Tank
Drain Point ‘Pressurised’ Tank
Drain Point
Oil Tank (Hydraulic Clutch and Brake Only)

*X Capacity: 75Litres (16.5 Imperial Gallons)
Check Level Daily and top up as required
Hydraulic Power Pack
Change Filter Elements when required.
Use Mobil DTE Light VG 32.
Visual indication on Bodymaker control panel message display will indi-
cate when blocked
Issue Drawn
IMPORTANT: Prior to removing filter bowls to replace filter elements the
S.H. Power Pack electrical supply must be isolated and Accumulator discharged
23 March2011 (open Accumulator Drain Down Valve fully anti-clockwise - check for no
*For Replacement Element Part Number refer to pressure on pressure gauge)
5500 Canmaker Operating & Spares Manual - Propri- Do Not over tighten any of the filter bowls, only minimum tightening force
etary Equipment is required.
For Power Pack maintenance procedure refer to machine manual.

CarnaudMetalbox Engineering plc
Chart No. Lub 260
Recommended Lubricants for Customers Sht 1 of 1
SUPPLIERS
CMB
NOTES BP CASTROL GULF TEXACO SHELL MOBIL KLUBER
GRADE
A SPINDLE OIL ENERGOL HPL 10 HYSPIN HYDRASIL RANDO TELLUS VELOCITE CRUCOLAN
AWS 10 10 HD 10 R 10 No. 6 10
B
REFER TO INDIVIDUAL MACHINE LUBRICATION CHARTS FOR
LIGHT GEAR ENERGOL HYSPIN SECURITY REGAL VITREA VACUOLINE 128 KLUBEROIL
OIL CS 68 AWS 68 68 R & O 68 68 GEM 1-68
C CONSTANT LOSS ENERGOL MAGNA SECURITY OMNIS MORLINA VACTRA CRUCOLON

OIL CS 100 100 100 100 S1 B 100 EXTRA HEAVY 100
RECOMMENDED LUBRICATION GRADE LETTERS
D MEDIUM GEAR ENERGOL ALPHA EP LUBE MEROPA OMALA MOBILGEAR KLUBEROIL

OIL GR-XP 150 SP 150 HD 150 150 S2G 150 600 XP 150 GEM 1-150
E HEAVY GEAR ENERGOL ALPHA EP LUBE MEROPA OMALA MOBILGEAR KLUBEROIL

OIL GR-XP 320 SP 320 HD 320 320 S4 GX 320 600 XP 320 GEM 1-320
F GENERAL PUR- ENERGREASE SPHEEROL GULFCROWN MULTIFAX GADUS MOBILUX CENTOPLEX

POSE GREASE LS 2 MP 2 GREASE No. 2 AFB 2 S2 V100 1 EP 2 2
G OPEN GEAR ENERGREASE IMPERVIA LUBCOTE CRATER GADUS MOBILGEAR GRAFLOSCON

GREASE OG MDX 1 2 S2 OG 40 OGL 461 GSG ULTRA
H HYD/OIL &
AIR MIST
ENERGOL
HLP 32
HYSPIN
VG 32
* HYDRASIL * REGAL TELLUS
S2M 32
DTE LIGHT
or
CRUCOLAN
32
32 R & O 32
LUBRICATORS NUTO H32 *
K WHITE OIL ENERGOL WHITEMOR NO GRADE WHITE OIL ONDINA MARCOL 82 PARALIQ
(FOOD USE) WM 2 WOM 14 SPECIAL 15 EL P 40
P SLIDEWAY OIL MACCURAT MAGNA SLIDEWAY WAYLUBE TONNA VACTRA LAMORA

D 68 BD 68 68 X 68 S2M 68 No. 2 D 68
S GREASE ENERGREASE IMPERVIA GULFCROWN NOVATEX GADUS MOBILUX CENTOPLEX

(SOFT) CA TR LIGHT GREASE No. 0 EP EP 1 S2V220 0 EP0 1 DL
T GREASE ENERGREASE SPHEEROL GULFCROWN MULTIFAK GADUS MOBILUX CENTOPLEX

(MEDIUM) LS 3 MP3 GREASE No. 3 PREMIUM 3 S2 V100 2 EP 3 3
* NOTE:-
GULF HYDRASIL 32,TEXACO REGAL R & O 32 & MOBIL NUT0 H32 products are
advised as suitable for silver plated components present in some Lucas and Vickers
Issue Date
Hydraulic Pumps. Any customer wishing to use any of thes grades should obtain assur-
7 July 2010 ances from these companies before using them.
Sheet 1 of 1
Oil Jet Location 5000 Series Bodymaker
Main Bearing, Quill Bearing, Push Rods and Cam Spindles 3 Yoke Slide & Slideways
0.022"
4
0.026"
0.030"
1 0.048" 0.022" 0.048"
Push Rod Brgs.
2 3 2 0.022"
Quill Brg. Cam Spindles Main Brg. 3
5
0.026"
Item Part Number Description Qty Secondary

Conn Rod
1 23249727 Jet Fluid Restrictor FR-M6-1-30 1
2 23249876 Jet Fluid Restrictor FR-M6-1-48/50 2 6
0.038"
3 23249714 Jet Fluid Restrictor FR-M6-1-20/22 11
4 23249875 Jet Fluid Restrictor FR-M6-1-24/26 1 Swing Lever

PROPRIETARY EQUIPMENT
SAFETY

dures at ALL times.

INDEX:
Lubrication Hydraulic Power Pack

Superbolt - Pretensioning System
OPERATING AND MAINTENANCE
INSTRUCTIONS
FOR
MARK 3 HYDROLUBE POWER UNITS
FOR 5000 BODYMAKER
Supplied by:
Primary Fluid Power Limited
Table of Contents
1. Declaration of incorporation
2. Description of system
3. Description of operation
4. Operating instructions
5. Maintenance instructions
6. Recommendations and regulations
7. Installation instructions
8. Parts list
9. Recommended Spares
Appendix A – Test certificate
Appendix B – GA & Circuit Drawings
Appendix C – Electrical Installation Details
Appendix D – Trouble Shooting Guide
Appendix E – Technical Data Sheets

1. Declaration of incorporation
Manufacture’s Name: Primary Fluid Power Ltd

Manufacture’s Address: Caddick Road,
Knowsley Business Park,
Knowsley,
Merseyside, L34 9HP
Contact Name: Peter Broom

Title: Design Manager
Customer: CarnaudMetalbox Engineering Plc

Dockfield Road
Shipley
West Yorkshire
England
Purchase Order No: 25297Z
Model and/or Serial No: 5729718A to 5729718H
Description of Assembly: Hydraulic Power Units
We declare that the above equipment has been manufactured in accordance with the
Safety of Machinery Standards set out in prEN982 and BS EN292 Part 1 and Part 2
and has been tested to the specification contained in the “Test Certificate” in this
document.
No installation, commissioning, or service of the Hydraulic assembly should be

undertaken unless the recommendations contained in this document are followed in
conjunction with the appropriate Safety of Machinery Standards for its incorporation
within the provision of the directive.
Signed:
……………………………………………………………………………………
Date: …………………………………
2. Description of System
2.1 General
The Hydraulic Power Unit comprises of a hollow section steel framework mounted
upon a fabricated tank / drip tray, this framework carries all the motors, pumps,
manifolds and control valves. The whole unit is in turn mounted upon castors for
ease of positioning and accessibility for maintenance purposes. The system
operating pressure gauges are mounted on the manifold assembly with relief valves
mounted adjacent to them. All the system filters are mounted towards the outside of
the pack for ease of access. The tank / drip tray fabrication has been designed such
that oil spillage during maintenance is directed to an easily accessible drain valve.
2.10 Specification Power Unit

2.11 Media: Mineral Oil
2.12 Viscosity: ISO VG 150
2.13 Make: Mobil
2.14 Ref No: XMP 150
2.15 Reservoir Capacity: 200 Litre
2.10 Specification Clutch Unit
2.11 Media: Mineral Oil
2.12 Viscosity: ISO VG 32
2.13 Make: Mobil
2.14 Ref No: DTE Light VG32
2.15 Reservoir Capacity: 75 Litre
2.16 Pumps Make: MARZOCCHI

Type: ALPA3-D94+ALPP3-D80
2.17 Displacement: 61 and 52 cc/rev
2.18 Max Pressure: 117 Bar/10 Bar
2.19 Speed: 1465 rpm
2.20 Control: Fixed Displacement
2.16 Pumps Make: MARZOCCHI
Type: ALPA2-D9+ALPP2-D9
2.17 Displacement: 6.4 and 6.4 cc/rev
2.18 Max Pressure: 69 Bar/10 Bar
2.19 Speed: 1425 rpm
2.20 Control: Fixed Displacement
2.21 Electric Motor Model: WEG EFF1

2.22 kW Rating: 17.02
2.23 Speed: 1465
2.24 Enclosure: TEFV
2.25 Voltage: 400-3-50
2.26 Mounting: Foot & B5 Flange
2.21 Electric Motor Model: WEG EFF1
2.22 kW Rating: 2.024
2.27 Speed: 1425
2.28 Enclosure: TEFV
2.29 Voltage: 400-3-50
2.30 Mounting: Foot & B5 Flange
3. Description of Operation
The following description should be read in conjunction with the general arrangement
drawing 5729718G1 and circuit drawing 5729718C1.
When the Hydrolube Power Unit is connected to a “Bodymaker” machine, oil is drawn
from the bodymaker machine reservoir, by the large delivery section of the tandem
pump (item 4) at 107 LPM via the suction connection “P1”. The delivery side of this
pump section feeds oil through a large 12 micron filter (item 27) and then through an
oil cooler (item 36). This cleaned and cooled oil is then fed to the integral tank of the
power unit. A pressure gauge (item 24b) monitors oil pressure within this
“conditioning loop”. Excess oil not required for other pump feeds is discharged back
to the bodymaker machine tank through connection “P7”. Filter (item 27) is fitted with
an 3.5 Bar bypass and 2.4 Bar switch assembly. When the filter starts to become
blocked this switch operates giving a warning that the filter element should be
changed as soon as practical, another indication of a clogged filter element, is also
given by the raised pressure registered at the gauge (item 24b). A non-return valve
(item 45) is provided to stop oil back feeding from the power pack tank when
changing components within the conditioning loop.
Cooling water is supplied to the cooler (item 34) via a solenoid operated water control
valve (item 33). This valve is in turn operated by a temperature sensor in the power
pack reservoir, such that when the oil temperature rises above a pre-set point, the
cooling water is allowed to flow and likewise, when the oil temperature falls below a
pre-set point the cooling water flow is stopped. This action ensures a good control of
oil temperature whilst at the same time limiting the volume of cooling water used and
thus avoiding waste. The aforementioned pump (item 4) is driven by an 17 KW
electric motor (item 1) via a flexible drive coupling (item 3) housed in a bellhousing
(item 2). This bellhousing provides an exact alignment of the pump to motor shaft
whilst at the same time providing safe operation by enclosing all of the rotating parts.
The 2nd pump of the tandem pump (4) – 91 LPM, takes cleaned and cooled oil from
the tank and delivers it via a further filter (28a) – 15 micron rated and a relief valve
(25) to the bodymaker machine lubrication system via connection “P4”. Flow to the
machine is set at valve (41) and excess flow not required by the machine is diverted
through the relief valve and back to the pressurised tank. Pressure can be monitored
at gauges (23b) – “bearing oil pump pressure” and (23c) – “bearing oil supply
pressure”. A pressure switch (26b) is provided alongside gauge (23c) and should the
“bearing oil supply pressure” fall below a pre-set limit this switch operates and
provides a signal to the control system. The relief valve (25a) is fitted with a solenoid
operated unloading valve (25b). When an electrical signal is received at this valve
flow is diverted at near zero pressure directly to the bodymaker machine tank. This
has the effect of reducing both the power drawn from the electric motor and the heat
input into the system (and thus of course required cooling water flow) whenever this
valve is operated. The valve can only be unloaded when the bodymaker is not
running.
A water removal filter is fitted to this power pack and operates on a continuous basis.
This filter bleeds a small amount of oil from the 91lpm pump. This filter is fitted with
an pressure switch (46) to monitor the element condition. Should the indicator signal
a fault, then the filter element should be changed as soon as practical – see
Appendix E).
The hydraulic clutch / brake system is fed from a completely separate tank housed
within the confines of the power pack but in no way connected to the services
described previously. Oil is drawn from the “clutch side” tank by a double output gear
pump (12). Each section of this pump provides 11 LPM oil flow. Pump (12) is driven
by an electric motor (9) via a flexible drive coupling (11), which is housed inside a
bellhousing (10). This bellhousing also provides alignment and safe operation as
described previously. The first oil supply from the double pump is directed through a
non-return valve (16) into the “accumulator circuit” and to connection “P9”, this circuit
is provided with overpressure protection by a relief valve (21) which diverts excess
flow to tank should its setting be exceeded. This part of the circuit is also provided
with an accumulator drain down valve (31), - THIS VALVE MUST BE OPENED
WHENEVER ANY MAINTENANCE IS BEING PERFORMED ON THE POWER
PACK.
The accumulator (29) stores oil under pressure such that the clutch / brake can be
operated at any time when the power pack is running and demands more oil flow
than the pump alone can supply.
A pressure gauge (23a) monitors pressure within the accumulator circuit and a
pressure switch (26a) is included to indicate insufficient pressure for correct
operation should this fall below a pre-set threshold. The second oil supply from the
pump is directed to a 15 micron filter (28b) via a pressure relief valve (14) and
pressure gauge (24a) and then through an oil cooler (13) to connection “P10”. This
filtered and cooled oil flow provides cooling oil for the hydraulic clutch / brake
assembly. Cooling water is supplied to the cooler via a flow control valve (32) and is
monitored by a flow meter (15) – this device enables the cooling water flow to be set
accurately to provide continuous efficient cooling to the clutch / brake unit and its
hydraulic circuitry. A return connection to tank – “P14” is provided to take returned oil
from the clutch / brake system via the collection tank and scavenge system mounted
upon the bodymaker. The clutch / brake system tank is fitted with a level switch
which will indicate when the level falls below a pre-set point and fresh oil needs to be
introduced as soon as practical. A filler / breather (19) is provided for the introduction
of top-up fluid (this ideally should be filtered into the tank). A level gauge (17) is
provided for ease of filling and also of course monitoring prior to the last resort of the
level switch operating. Returning oil to the clutch / brake tank is passed through a
strainer (36) – this device serves as a coarse filter to protect the double pump and
also helps to remove any entrapped air from within the collected oil.
Drain valves (18a,b & c) are provided to the clutch system tank, the main
“pressurised” tank and the drip tray section for ease of maintenance. Both tanks are
also supplied with access panels (oil must be drained before removing the main tank
panel) – these panels enable the tanks to be thoroughly cleaned prior to the
introduction of new fluid at any major service etc’.
4. Operating Instructions
4.1 Set-up Procedure
4.1.1 BEFORE STARTING
Before proceeding further carefully read the data sheets in the

appendix relating to the electric motors, accumulator and solenoid
vales. All aspects relating to hazards and safe operating procedures
as laid down in these data sheets take precedence over all other
instructions in this manual.
Before starting the power unit, check the following:
a. The fluid level in both reservoirs is correct.

b. The correct grade of operating fluid is used.
c. All fittings are connected and tight.
d. The pressure relief valve is set at its lowest setting (only required for
initial set-up).
e. Ensure that it is safe to start the machine and that all personnel are
clear of any moving parts.
f. Electrical connections have been correctly completed.
4.1.2 START UP
It is important that these setting up instructions are followed in sequence: -
1 Wind the flow control valve fully out (anti-clockwise) (Item 41).
2 Briefly switch on the electric motor (Item 1) to check rotation is correct.

(clockwise when viewed on fan end)
3 Run pump (Item 4).
4 Wind the flow control valve (Item 41) in until the required flow is
achieved.
5 Turn off pump.
6 Open accumulator drain down valve (anti-clockwise) (Item 31)
7 Briefly switch on the electric motor (Item 9) to check rotation is correct.

(clockwise when viewed on fan end)
8 Run Pump.
9 Slowly close accumulator drain down valve while monitoring pressure

at gauge 23a
10 Pressure will rise slowly to a maximum operating pressure of 69 Bar

which is the setting on the relief valve.
11 Ensure accumulator drain down valve is firmly closed.
12 The power pack should now be ready for operation as all relief valve
settings have been pre-set to correct values.
Check for leaks, high temperatures, excessive noise and that the electric
motor current is within the manufacturer's recommendations.
Monitor the fluid level and condition in the reservoir. Should a substantial loss
in fluid be observed switch the unit off immediately. RUNNING THE PUMP
DRY WILL RESULT IN DAMAGE OF THE PUMPS.
5. Maintenance Instructions
It is the user's responsibility to ensure compliance with the statutory health and
safety regulations including risk assessment. Qualified personnel should
undertake all routine service and maintenance work.
5.1 Introduction
This section sets out the recommended minimum requirements for the
maintenance of a modern hydraulic system, supplied by Primary Fluid Power
Limited.
Reference to equipment not fitted to your system should be ignored.
5.2 Maintenance Levels
The extent and depth of any maintenance operation on a hydraulic system is

usually dictated by:
Available manpower
Experience and knowledge of maintenance staff
Tooling and test facilities
Acceptable downtime on production machines
The most economic use of manpower and materials, with minimum disruption
to production can be best achieved by adopting the three level maintenance
system. First level maintenance tasks are described in this manual. Higher
levels as described in sections 5.4 and 5.5 are beyond the scope of this
manual.
5.3 First Level Maintenance
In order to retain maximum machine productivity, maintenance tasks at this

level should be limited to:
a) Routine inspections
b) Fault diagnosis and rectification
c) Replacement of defective components
d) Re-setting and adjusting system components
e) Replacement of damaged hoses and pipes
f) Oil changes and system flushing
The stripping and repair of components on the machine should not normally
be attempted at this level.
5.4 Second Level Maintenance
The extent of maintenance operations at this level will be determined by the

availability of a hydraulic "clean room", test and measuring facilities, and the
skills and experience of the maintenance staff. Maintenance at this level
should normally be limited to:
a) Repair and minor overhaul of hydraulic components
b) Testing of components and assemblies
c) Minor modifications of components
5.5 Third Level Maintenance
Equipment requiring facilities beyond the capability of the user's workshop

(second level) should be returned to a major overhaul facility. The hydraulic
equipment suppliers can usually offer these facilities.
At this level, major overhaul requiring the use of special tools and test
equipment is carried out. Overhauled components will be brought to a
condition whereby all parts are within the original manufacturer's
specifications.
5.6 FIRST LEVEL MAINTENANCE TASKS
Daily Inspection:
Before start-up:
Check reservoir fluid level and replenish if necessary with correct grade
of fluid. The fluid level in the reservoir should be checked at regular
intervals. Initially, this should be quite frequent until experience indicates
an optimum inspection period. The cause of excessive fluid losses
must be corrected as soon as possible. Losses of oil are made up by
the additions of the particular oil but losses of fire resistant fluids must
be made up by taking the appropriate action recommended by the fluid
supplier. Contaminated fluid must be changed immediately. All top-up
fluid should be filtered into the reservoir at the correct cleanliness level.
The main reservoir operates on a system where oil level is automatically
set to maximum level by the spillage of excess fluid back to the
bodymaker machine tank and hence oil levels for this part of the system
must be monitored and adjusted at the bodymaker.
Check accumulator pre-charge pressures and recharge if necessary (if
applicable). The fluid pressure must be completely discharged from the
system via the drain down facility when this verification is made.
Check for fluid leaks, loose connections and rectify where necessary.
After start-up:
Check reservoir fluid temperature.
Check for fluid leaks, loose connections and rectify where necessary.
Filter indicators should be inspected at regular intervals and if these
indicate "clogging", new elements to the same manufacture and
specification must be fitted as replacements, as failure to do so could
well invalidate warranty.

Monthly Inspection:
(Or concurrent with other scheduled maintenance)
As above in DAILY inspection.
Check all components for security of attachment and signs of leakage.
Inspect pipework for damage and inspect pipe connections for leakage.
Check pipework for abrasion especially where pipes run through
bulkheads or close to other equipment.
Periodic Maintenance:
After some time in service, all hydraulic power units should be subjected to a
thorough overhaul. Depending on the type of unit and local operating
conditions, the interval between such overhauls will vary between one and
five years, but both shorter and longer periods may be found necessary.
The fluid in the system should be drained and stored in suitable clean
containers. A fluid sample should be sent to a reputable oil analysis laboratory
for analysis, depending of the state of the fluid it should either be purified or
replaced.
The air filter element in the filler breather should be inspected, if there is signs
of clogging it should be replaced. The reservoir lid should be removed and the
inside of the reservoir should be cleaned using a suitable solvent. The suction
strainer and return line filter elements should be replaced. It is important to
ensure that no dirt enters the system during this overhaul. Seals, packing and
damaged or worn parts should be renewed as necessary. Inspect pipe
anchoring and connections, renew and tighten where necessary. Inspect the
pressure line hose assembly for deterioration; this is especially likely if the
system is operating at high temperature.
5.7 Replacement of Defective Components
Components which are damaged or which are causing a system malfunction

(suspected or real) should be removed and replaced with a known
serviceable component of the same type. Components removed from the
system should be clearly labelled as faulty, and returned to a properly
equipped hydraulic repair facility for investigation and repair. The repair of
hydraulic components should not be attempted in-situ unless in an
emergency.
5.8 Safety Precautions
Ensure that all hydraulic pressure is dissipated before

commencing any maintenance operations. (Discharge
accumulators).
Know and thoroughly understand the operation and function of the
machine and hydraulic system before operating any control.
Always apply barrier cream to exposed skin before working with
hydraulic fluids.
Allow system to cool before dismantling any part of the system.
Systems operating at normal temperatures can scald.
Ensure that fire extinguishers of the correct type (foam or powder)
are near at hand.
Do not dismantle any part of the hydraulic system near naked
flame.
Do not allow naked flame near a dismantled system. Put up
Warning signs.
Alert fire brigade if you consider that any possibility of fire may
exist.
Mop up spilt fluid immediately. (Fire and personnel hazard).
Dispose of oil soaked rags.
Switch off electric power and attach warning signs to power switch
before dismantling any part of the hydraulic system.
Should electric power be required whilst a part of the system is
isolated, ensure that all bare wires are correctly insulated.
Do not stand or work under hydraulically supported loads (support
load mechanically).
5.9 Trouble Shooting
Hydraulic systems that have been correctly designed to meet the required
operating conditions and have been properly installed, give many years of
trouble-free service. However, when trouble does occur, it is essential to find
the cause and rectify it as quickly as possible (refer to appendix D).
Troubleshooting is simplified if a hydraulic circuit diagram of the system is
available (refer to appendix B). Access to observe the flow of return fluid will
further assist in troubleshooting.
6. Recommendations and Regulations
6.1 Hydraulic Fluids
Your Hydraulic Power Unit is shipped from our factory in a dry

condition, i.e.: no fluid is supplied with the unit.
In any hydraulic system the hydraulic oil must perform 3 basic functions:
1. Transmit power effectively

2. Lubricate the hydraulic components
3. Transmit heat away from hydraulic components
There are several characteristics used to describe the characteristics of oil:
• Viscosity Index – Expresses change in viscosity with change in

temperature. The higher the viscosity index (V.I.) the smaller the change
in viscosity with a given change in temperature.
• Specific Gravity – The ratio of the weight of any volume of a substance to
the weight of and equal volume of water.
• Pour point – An indication of the relative ability of an oil to flow at low
temperature.
• Flash Point – The temperature to which an oil must be heated in order
that its vapour will form a flammable mixture in air.
• Viscosity – The measure of an oils resistance to flow (its internal
resistance to shear). This in considered to be hydraulic oil’s most
important characteristic. If a hydraulic oil does not have the right viscosity,
it cannot perform satisfactorily, no matter how superior it may be in other
respects. Viscosity is measured in centistokes, cst
6.2 Filtration
Regardless of fluid choice, once the fluid is in the system it must be cared for
if best results are to be maintained. Cleanliness has probably the most
influence on the life of system components. Ensure that filter elements are of
the correct type and are replaced regularly.
6.3 Operating Temperature
Try to keep operating temperatures to around 40 degrees C; this is where

most fluids perform at their best. Do not operate the system at very low
temperatures as this may result in cavitation and damage to the hydraulic
pump. When the system operates at too higher temperature the hydraulic
seals may become damaged.
6.4 COSHH
The equipment shall be operated taking account of the COSHH regulations

and any local regulations. In the case of hydraulic equipment, these normally
relate to the system fluid, which, in the majority of cases, will be a mineral oil.
In the case of synthetic or fire resistant fluids, the manufacturer of the
particular fluid should be consulted for COSHH Information since fluid
types and hazards vary widely. All manufacturers of hydraulic fluids now
produce information leaflets on each type of their product, with full COSHH
requirements.
For mineral oils, the hazards can be summarised as follows, although we

recommend that the manufacturer's data be obtained wherever possible.
Although hydraulic mineral oils contain various additives, mineral oils can be
considered to be the most hazardous component. There is no significant
health hazard when properly used.
a. Ingestion
Only slight oral toxicity - do not induce vomiting due to risk of ingestion -
administer half a pint of milk and seek medical attention.
b. Inhalation
Due to low volatility, there is no risk of vapour, except in open systems at

elevated temperatures - avoid build-up of oil mists. In the event of over-
exposure, move to fresh air, loosen clothing, and keep patient warm and
resting.
c. Skin and Eye Contact
Frequent or prolonged skin contact can cause dermatitis. Splashes to the

eyes may cause irritation. Good standards of industrial hygiene are
recommended and use of gloves, barrier creams, goggles and regular
changes of contaminated clothing. Wash well with soap and water in the
event of direct skin contact. Splashes to the eyes should be flushed clean
with copious amounts of clean water.
d. Aspiration
o o
This is dependent on viscosity. Above 40 C and below 7 C ST is highly
hazardous and can cause pneumonitis. At higher viscosities and low
temperature, the risk is only slight. If aspiration occurs, admit to hospital
immediately, requesting an ambulance with oxygen facilities.
e. Storage and Housing
In a clear dry place, protected from extremes of temperature. Store barrels

horizontally to prevent ingress of water. Avoid prolonged or repeated skin
contact.
f. Fire Extinguishing
Carbon dioxide and/or dry chemical foams.

g. Spillage
Soak up with absorbent material; do not allow contaminating water supplies.
h. Waste Disposal
In accordance with the Licensing and Regulation in the Control of Pollution

Act 1974 and the Environmental Protection Act 1990 (EPA 1990)
7. Installation of the Power unit
7.1 Location
When positioning the hydraulic power unit, ensure that there is sufficient
space around the unit for maintenance, incoming services (electrical supply
etc) and pipework to and from the machine actuators. Position the unit on a
clean, well-ventilated area and shield from heat sources. Do not lift the unit
by any of the components on the reservoir, always use the lifting points.
When the power unit is located in position, check that it is on a firm, level
foundation. If shimming is required, ensure that these cannot work loose.
7.2 Interconnecting Pipework
The interconnecting pipework between the power unit and machine should
always be installed by qualified hydraulic pipe fitters.
Leave the outlet and return blanking plugs on the power unit in place as long
as possible to help prevent the ingress or dirt.
Consult the circuit diagram for recommended pipe diameters. Avoid elbows
and keep bends to a minimum. Also, use as few fittings as possible; each
fitting is a potential leak point.
Steel pipework should be supported at regular intervals and should not be

stressed or sprung into position. Flexible hoses should be assembled to the
manufacturer's recommendations, taking care not to have too short a hose,
resulting in stress at the hose ends. (Hoses contract when pressurised.)
Consider the use of short flexible hoses to a suitable point on the machine,
this will reduce transmitted vibration and noise and will eliminate the need for
accurate pipework.
The steel pipe ends must be square, free of burrs and clean. If compression
fittings are used, parallel threads with bonded washers or captive seals are
recommended. The use of tapered threads with tape or liquid sealant is not
recommended.
With welded installations, care must be taken to ensure that there is no weld
slag or scale on the inside of the pipe. (Pickling after welding or flushing with
an inert gas during welding are options to consider.)
All carbon steel pipework should be degreased and given at least one coat of
rust inhibitor primer paint.
Ensure pipework can be easily dismantled later if required and that steel tube
cross sections are not reduced when bent.
Keep pipework clean.

7.3 Flushing
The system should be clean when supplied but the following should be
observed after installation. It is preferable to flush the system, although this is
not always feasible. The best flushing method is to use a separate
motor/pump/filter unit, as the power unit should have been delivered clean
from the manufacturer. The flushing pump should be able to generate greater
velocity in the pipework than the system pump. Actuators and sensitive
valves should be by-passed by temporary bridging loops or bridging plates.
The flushing fluid should be preferably the same as the fluid used in the
system.
If the system pump has to be used for flushing, before starting the pump, see
the section on Start-up-Procedure before continuing and follow the following
instructions.
a. Always flush at low pressure.

b. Ensure that the fluid is clean and is compatible with the system fluid.
c. Check filter indicators regularly. If by-pass is indicating, change
elements immediately.
d. Fit new filter elements when flushing are complete.
7.4 Filling the System
The reservoir will have been supplied in a clean condition. Ensure that it is
still clean and, if necessary, clean inside before filling.
To avoid contamination, always fill with a separate pump unit incorporating a

filter or through a filter in the system. Even new oil must be filtered into the
reservoir.
Make sure that the reservoir is filled to the correct level, remember that the
fluid level will fall when the system is first run as the fluid fills the pipework and
actuators. Check this regularly.
Always check that the correct fluid is being used (see Circuit Diagram).
The cleaner the system, the more efficient it will be, with less failures and
longer life.
If in doubt, consult your power unit supplier.
Do not mix fluid types or grades.
7.5 Electrical Connections
See Appendix C for wiring instruction

8. Parts List
Please see BOM PLH5729718
GA drawing number 5729718G1
Hydraulic Circuit drawing number 5729718C1

9. Recommended Spares
Item Qty Part Number Description

4 1 ALPA3-D94+ALPP3-D80 PUMP
12 1 ALPA2-D9+ALPP2-D9 PUMP
14 1 RDDA-LSN RELIEF VALVE
19 1 ABB-10N FILLER BREATHER
21 1 RDDA-LBN RELIEF VALVE
25A 1 RVEA-LHN RELIEF VALVE
25B 1 770-224 COIL FOR ITEM 25
26 1 PK6522 PRESSURE SWITCH
29A 1 FP-90535 4ltr BLADDER FOR ITEM 29
33B 1 042N7551 COIL FOR ITEM 33
36 1 LHA LSE-227 SUCTION STRAINER
43A 1 HC9601FDT13H ELEMENT FOR ITEM 28A
43B 1 HC9601FDT8H ELEMENT FOR ITEM 28B
44 1 UE619AS40Z ELEMENT FOR ITEM 27
48 1 800-026 ELEMENT FOR ITEM 47
45 1 CV8A-05 IN LINE CHECK VALVE; 1in BSP
2M PFP6mm ‘O’ RING CORD (INSPECTION COVER)
409 1 RDDA-LAN RELIEF VALVE
Appendix A – Test Certificate
Parts List PLH5729718
Customer: CMB Order Number 25297Z

Originator: STEVE GOULDING Date 10/11/2010
Approved By: Issue 1
Issued By: Sheet No. 2 OF 4
Item Qty Description Product No. Supplier Ord No. Req Ack Rec Remarks
2 SUCTION ELBOW LHE08X30A 5015240 CIOCCA
2 PRESSURE ELBOW LHE08X30S 5015241 CIOCCA
13 1 COOLER PWO B8-20 5067336 FAWCETT
14 1 RELIEF VALVE RDDA-LSN SUN FITTED IN BLOCK 402
15 1 WATER FLOWMETER FM-26-222-222 5067378 PARKER
16 1 CHECK VALVE CXDA-XAN SUN FITTED IN BLOCK 402
17 1 OIL LEVEL GAUGE LG5T 5015231 LHA
18 4 BALL VALVE BV08B 5001860 LHA
19 1 FILLER BREATHER ABB-10N 5000831 LHA
21 1 RELIEF VALVE RDDA-LBN SUN FITTED IN BLOCK 402
23 3 PRESSURE GAUGE LPL63-160S 5015533 LHA
24A 1 PRESSURE GAUGE LPL63-25S 5015536 LHA
24B 1 PRESSURE GAUGE LPL63-60S 5015548 LHA
25A 1 RELIEF VALVE RVEA-LHN SUN FITTED IN BLOCK 403
25B 1 SOLENOID VALVE DAAL-MHN-224 SUN FITTED IN BLOCK 403
26 AB 2 PRESSURE SWITCH PK6522 5067867 IFM
2 COVER E30094 5067868 IFM
2 CABLE EVC004 5069869 IFM
27 1 SCAVENGE FILTER UR619CC24AS40ZGM 5076070 PALL
28A 1 LUBE FILTER HH9681S20DTTWM 5079180 PALL
28B 1 CLUTCH FILTER HH9681S20DTSWM 5079181 PALL
29 1 ACCUMULATOR 0400-00-341 PRE-CHARGE TO 45 BAR 5030923 FAWCETT
30 1 ACCESS COVER PART OF FABRICATION 5067723 LYNWOOD

Issued By: RJ Sheet No. 3 OF 4
31 1 DRAIN DOWN VALVE NFBC-LCN SUN FITTED IN BLOCK 402
1 HANDWHEEL 991-222 5066264 SUN
32 1 GATE VALVE 3/4" BSP TAPER 10033 5033170 ISIS
33 1 WATER SOLENOID VALVE EV220B 20B G3/4" EVS1 20 5056929 CROSSLING
1 24VDC COIL EVS1 COIL 24V DC 15W 42N7551 5056572 CROSSLING
1 EVS1 TERMINAL BOX 42N0156 5030931 CROSSLING
34 1 TWO PASS COOLER PWO B28HX65/2P-SC-S 5067335 FAWCETT
2 CLAMP 2130062 B25/B27 5067494 FAWCETT
34A 1 RELIEF VALVE RPGC-LEN-CAW SET AT 25 BAR 5075505 SUN
35 1 CHECK VALVE BRASS BARREL 2" BSP 343606 5067545 ISIS
36 1 SUCTION STRAINER LSE227 5015611 LHA
37 1 PRESSURE SWITCH 0184-45803-1-042 SET AT 4 BAR RISING 5028303 PVL
41 1 FLOW CONTROL FDEA-LAN SUN FITTED IN BLOCK 403
43A 1 ELEMENT FOR 28A HC9601FDT13H 5007998 PALL
43B 1 ELEMENT FOR 28B HC9601FDT8H 5008002 PALL
44 1 ELEMENT FOR 27 UE619AS40Z 5068644 PALL
45 1 CHECK VALVE CV8A-05 5003071 LHA
47 1 WATER REMOVAL FILTER 810-011 (HS-410-CM-B6L) 5067374 HTI
47B 1 WATER REMOVAL FILTER ELEMENT 800-026 5071988 HTI
47C 1 RELIEF VALVE RPEC-LEN-FAU 5020601 SUN
400 1 TANK AND FRAME DRG. NOS. 5721516F1 5721516F2 5721516T1 PRIMARY

Issued By: RJ Sheet No. 4 OF 4
402 1 MANIFOLD "A" COMPRISING (BRAKE/CLUTCH) B004-298-J03 5079338 SUN
1 RDDA-LSN FITTED IN BLOCK 402
1 RDDA-LBN FITTED IN BLOCK 402
1 CXDA-XAN FITTED IN BLOCK 402
1 NFBC-LCN FITTED IN BLOCK 402
403 1 MANIFOLD "B" COMPRISING (COOLER) B004-308-J03-B 5079340 SUN
1 RVEA-LHN FITTED IN BLOCK 403
1 DAAL-MHN-224 FITTED IN BLOCK 403
1 FDEA-LAN FITTED IN BLOCK 403
404 2 Z-DIODE SUPPRESSION PLUG 24VDC 5068296 MURRELETR.
7000-29001-0000000
405 1 MANIFOLD 5714075 M1 5079215 PRIMARY
406 1 MANIFOLD 5714075M2 5079216 PRIMARY
407 1 SET OF LABELS HOWES
408 1 SET OF HOSES FITTINGS AND PIPEWORK
409 1 PUMP RELIEF VALVE RDDA-LAN SUN FITTED IN BLOCK 403
410 1 GRUB SCREW 1/8 NPT WITH ORIFICE 1 mm PFP FITTED TO MS COUPLING
Appendix C – Electrical Installation Details
Electric Motor (1 & 9)
Ensure that a qualified electrician wires the electric motor and that it is
connected in the correct configuration and to the correct supply and that it is
compatible with the supply frequency and type in your area.
Three phase electric motors can be wired in either ‘star’ or ‘delta’

configuration, ensure that the electrical connections are correct for the
operating voltage in your area. Typical wiring configurations are shown below:
Terminal markings, stator windings

If the supply is connected to the motor’s stator
terminals which are marked U,V and W, and the
phase sequence of the supply is 1,2 and 3, the
direction of rotation will be clockwise when
viewed from the D-end.
If anti-clockwise direction of rotation is required,

two of the three conductors which are connected
to the starter or the motor are changed
Fig. 7.5.1
Electrical terminal box fitted to a typical
3-phase electric motor
Note that the required wiring configuration

for 3 phase AC motors is indicated on
the nameplate attached to the motor.
Relief Unloading Valve (25a)
24VDC 26.2 ohms
The solenoid operated pressure relief valves that may be fitted to your power
unit accept a Hirchmann plug, to DIN 43650. Ensure that these are wired
correctly and that the control supply is correct for the solenoid type and
voltage that is fitted to your hydraulic power unit.
A typical 3 pin electrical solenoid connector

plug.
Supply Potential
Terminals
Ground Terminal
Terminal Arrangement
Pressure Switch (26)
Operating voltage [V] 9.6…..32 DC

Current Rating [mA] 2 x 250
Accuracy of switch point < +/- 2.5
Repeatability < +/- 0.5
Filters (27, 28A & 28B)
Electrical Switch Ratings:

4 amp @ 110 VAC, 28 VDC (resistive)
2 amp @ 110 VAC, 28 VDC (inductive)
SPDT, automatic reset
Electrical Switch Circuit:
A NORMALLY CLOSED
B NORMALLY OPEN
Electrical Clogging Indicators
When the element is contaminated an electrical switch is operated which can

be wired either as opening or closing contacts.
Supply Potential
Terminals
Ground Terminal
Terminal arrangement
Water Valve Coil (33B)
9 W AC 15 W 24VDC
Supply Potential
Terminals
Ground Terminal
Terminal Arrangement
Pressure Switch (46)
Terminals Pressure switch connector pin
Natural differential at low setting 0.5 bar (7.25psi)

Natural differential at high setting 0.5 bar (7.25psi)
Appendix D – Trouble Shooting Guide
PROBLEM POSSIBLE CAUSE

Low Pressure at Gauge (23a) A Lack of oil in clutch / brake tank.
B Motor (9) not running.
C Accumulator drain down valve (31) malfunction.
D Clutch operating valve malfunction.
E Damaged pump drive coupling (11).
F Worn pump (12).
G Relief valve (21) incorrectly set.
H Relief valve (21) damaged or contaminated.
I Damaged pressure gauge.
Low Pressure at gauge (24a) A Lack of oil in clutch / brake tank.

C Operating temperature too high.
D Damaged pump drive coupling (11).
E Worn pump (12).
F Relief valve (14) incorrectly set.
G Relief valve (14) damaged or contaminated.
H Damaged pressure gauge.
Low Pressure at Gauge (23b) A Lack of oil in main tank / body maker.
E Worn pump (4).
F Relief valve (25) incorrectly set / unloaded.
G Relief valve (25) damaged or contaminated
H Damaged pressure gauge.
Low Pressure at Gauge (24b) A Lack of oil in main tank / body maker.
E Worn pump (4).
F Damaged pressure gauge.
High Pressure at Gauge (24b) A Filter element blocked

B Operating temperature too low.
Temperature too High A Thermostat not set correctly.

B Thermostat malfunction.
C Solenoid valve (33) malfunction.
D Insufficient cooling water supply.
""
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\ P&S Tensioning Systems Ltd.
Rickenstrasse 55
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CH-8735 St.Gallenkappel
Switzerland
-
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Tel. +41-(0)552846464
"'" '"
"" Fax +41-(0)55
Internet:
E-Mail:
284
www.p-s.ch
info@p-s.ch
64 69
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.
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NEW: These instructions are also available as information film (VHS or CD).
All up-to-date instructions are accessible from our wesite.
~
1. Tighteningprocedure
1.1 Check:
Which jackbolt torque?
M = 100% of recommended torque, see - your internal directives
- P&S cerficate
- P&S data sheet
Attention: The engraved jackbolt torque is the maximum value typically allowed and can
be unsuitable for your application.
1.2 Which tools?

- suitable torque wrench
- matching socket, heavy duty line
- lubricant
1.3 Prepartion:
- Clean main thread and contact areas and lubricate well with suitable anti-seize lubricant.
- Make certain that the jackbolts on the SUPERBOLT tensioner do not protrude beyond
the load surface and are well lubricated. If neccessary, relubricate with the recommended
SUPERBOLT lubricant (see cerficate).
- Firmly tightentensionerby hand,if neccessaryby usinga screwdriverstuck betweenthe
jackbolts or the like.
- Afterwardsturn back approx.1/4 turn. Dependingon size the gap will be approx.
1 to 3 mm wide.
- The actual tightening occurs in a few steps:
Tighten 4 jackbolts by hand or using a small

wrench to center the main thread and to eliminate
backlash. Tighten bolts crosswise.
.
Step 2: Now tighten these 4 jackbolts crosswise with
50% of the recommended jackbolt torque.
Step 3: 3( \4 Tighten the same 4 jackbolts crosswise

with 100%.
-=--
2
Step 4: Now change to circular tightening and tighten all
jackbolts with 100% of the recommended jackbolt
torque.
Step 5: 7 3 Repeat step 4 until all jackbolts are equally

tightened (less than 20° remaining movement).
Normally 2 to 3 passes are sufficient, with long
bolts accordingly more.
5
P()w~r t()()l~ ~~n ~~v~ tim~ ~~~ it~m ~~
2. Loosening procedure
Attention: Loosening requires an exact procedure. The jackbolts must be unloaded stepwise!
Under no circumstances unload single screws completely. The remaining screws would have
to carry the entire load and, therefore, would be difficult to loosen. In extreme cases the
jack bolts could mushroom and make loosening impossible!
2.1 Usage at normal temperatures (under 1000 C)

Preparation: Before loosening apply penetrating oil, especially with any rust formation.
Starting with N° 1 loosen every jackbolt in a

circular pattern approx. 1/4 turn (breaking loose
is sufficient). After the first round jackbolt N° 1
will be tightened again, however, on a lower level
of loading.
Note: Should several tensioners be loosened,
i.e. on a flange, perform step 1 on all tensioners
before moving to step 2.
In a 2nd round repeat step 1, again on all

tensioners.
Repeat step 1 in a 3rd round.
Relieve jackbolts completely. Now the tensioner

can be removed by hand.
Note: Long screws expand more and, therefore, may require one or two passes more.
Attention: Before re-using follow maintenance instructions!
2.2 Usage at high temperatures (over 1000 C)

Preparation: At higher temperatures the petroleum base of the lubricant evaporates, thereby
increasing the effort for loosening.
'r
If possible, already apply penetrating oil during
cooling of the installation (at approx. 1500 C).
At even higher temperatures use synthetic oil.
Step 2: Starting with N° 1 break loose each jackbolt of

one tensioner in a circular pattern.
Note: Do not loosen beyond break loose point,
and break loose all jackbolts of all tensioners of
7 3 a joint first.
The actual loosening occurs according to the

procedure described under item 2.1 (normal case),
5 beginning with step 1.
Note: For high temperature applications bolts with bores are often used. Through the use
of heating rods the loosening of SUPERBOLT tensioners can be substancially facilitated.
Five minutes of heating are already sufficient to accelerate loosening.
3. Lubrication and tools
3.1 Lubricant
Jackbolts: The jackbolts are delivered pre-lubricated and are ready for use. Refer to the
cerficate for the lubricant. For jackbolts use only SUPERBOLT lubricants or substitutes
permitted by P&S.
Hardened washers: For the upper side (contact with jackbolts) use the correct SUPERBOLT
lubricant. For the bottom side you may use any suitable anti-seize lubricant.
Main thread: Any suitable anti-seize lubricant including SUPERBOLT lubricants may be
used. Apply with brush or spray.
3.2 Sockets
For tightening the jackbolts only high quality tools in good working order should be used.
Heavy duty sockets for use with impact tools are best suited. Worn sockets are dangerous
and should be disposed of.
3.3 Power tools
Air impact tools have prooven to be most suitable, however, with SUPERBOLT jackbolts
they reach only 30-50% of their rated output (lack of displacement). Therefore, the largest
possible air lines and couplings (i.e. hydraulic couplings from Stiiubli) should be used.
Because of the high forces and for repeated usages only heavy duty products should be
chosen (i.e. Ingersoll Rand, Dino Paoli, Atlas Copco). Verifying the torque output of an
air impact tool is easy: Tighten until tool stalls, then measure the torque with a torque
wrench (preferably with electronic gauge).
For regulating the tightening torque simply install a service unit directly in front of the air
impact tool (filter, controller, oiler). Adjust the pressure at the controller and, thereby,
the power of the air impact tool. Tighten a SUPER BOLT jackbolt to the desired torque with
a torque wrench. Then, apply the air impact tool and increase the pressure until the jackbolt
starts turning again. Check the controller if the pressure decreases when starting the air
impact. This indicates an unwanted pressure drop in the air duct. Therefore, use generously
dimensioned air ducts! For regular usage of air impact tools the use of a control unit pays
off (available upon request).
When tightening air impact tools are especially suited for steps 2 through 5 and should
be adjusted to approx. 90 to 100% of the rated torque.
Note: Because of the lower accuracy of power tools, the last tightening round should
always be manually performed with a precision torque wrench.
Note: During loosening caution is mandatory: Use normal air impact tools only for step 4
(complete loosening), but never for steps 1 through 3!
A special air impact tool for loosening SUPERBOLT tensioners is newly available from P&S:
It turns only 1/4 of a turn, and is applicable for steps 1 through 3 .
Notes for the use of air impact tools:

- Network pressure min. 6.5 bar
- up to 70 Nm 3/8" impact tool or air ratchet
- 70-130 Nm 1/2" impact tool, derated (Attention: Do not overshootl)
- 130-200 Nm 1/2" impact tool
- 200-270 Nm 1/2" impact tool (handy) or 3/4"
- nvAr?70 Nm ~/4" imn"".,t tnnl
4. Maintenance
4.1 Regular checks
SUPERBOLTtensioners do not loose their preload force even after several years in service
provided that they are correctly tightened. During revisons (after several years) the preload
force shouldbe checkednevertheless.Usea torquewrenchadjustedto 100% of the
permitted jackbolt torque according to the cerficate or your installation procedure.
Shouldsomejackboltsunexpectedlyhavelost someof the preloadforce the following

procedure is recommended:
- Unload tensioner slightly by loosening the jackbolts according to loosening procedure.
However, only 1 turn! Thus, the nut remains tensioned.
- Now retension according to tightening procedure - step 5, meaning:
Tighten in circular pattern with full jackbolt torque, until all jackbolts are tightened.
4.2 Preventive maintenance
i.e.for removal for maintenance purposes:

- Relieve according to loosening procedure.
- Clean thread and end of the SUPERBOLTjackbolts and treat with lubricant according
to cerficate. Do not use molybdenum sulfide (MoS2)unless expressly specified in the
cerficate.
- SUPERBOLT hardened washer may be re-used despite indentations simply by turning
over. Depressions of a few 1/100 mm are normal.
- Retighten according to tightening procedure.
4.3 If you encounter problems
Jackbolts cannot be loosened:

- Tryto free at leastone jackbolt.
- Remove,lubricatewell and tightenwith 110% of the recommendedjackbolttorque.
- The two neighboringjackboltsshouldbecomefree.
- Removealso, lubricateand tightenwith 110%.
- Againthe next two jackboltsshouldbecomefree.
- And so on.
- Afterwardsrelieveall jackboltsaccordingto looseningprocedure.
Hardened washers are damaged i.e. after a long time in service:

- Exchange against original SUPERBOLT hardened washers.
Jackbolts are damaged or missing:

- ExchangeagainstoriginalSUPERBOLT jackbolts.
Do not usecommerciallyavailablescrewsbecausethey are not suitable
for such high loads.
Other problems:
- Please contact your supplier or directly P&S Tensioning Systems Ltd.
5. General notes
5.1 Tensioners with only 4 or 6 jackbolts
Tightening - Step 1: Tighten all jackbolts by hand crosswise.
Step 2: Tighten 2 opposite jackbolts with 50% of recommended torque.
Step 3: Tighten 2 other opposite jackbolts with 100%.
Step 4: Tighten jackbolts in circular pattern with 100% until they are tightend.
5.2 Tightening of long tie rods

To accelerate tightening of long tie rods it pays off to perform step 4 with increased
jackbolt torque (approx. 110-125%).
Attention: In final rounds always check jackbolt torque by hand with 100% to prevent
overloading.
5.3 Gaskets with large elastic displacements

It does not matter if some jackbolts (or tensioners on the circumference) become loose
during tensioning. This is normal, because in the beginning only those bolts carry loads that
are being tightened. Do not spin down loose tensioners, otherwise there will be problems
later during loosing. Preferably adjust jackbolts with power tools.
5.4 Tensioning large flanges or joints

For tensioning large flanges/joints preferably work with 2 men 1800 apart or 4 men 900 apart.
5.5 Usage of spacers

Tensioners should be positioned on the outer end of a bolt. This protects the main thread.
It can be tensioned easier (no extensions neccessary) and the expansion is improved. Place
suitable spacer or several heavy washers under the hardened washer. Thereby you can
bridge over areas that have been damaged by other tightening techniques.
5.6 Retensioning for high temperature applications

If tensioned properly it should not become neccessary to retension SUPERBOLTtensioners.
If regular retensioning should nonetheless become necessary, please inform us so that we
can re-examine the joint.
5.7 Recutting of the bolt threads

Recutting of the bolt threads can become neccessary on bolts that have deformed during
years of service, especially at higher temperatures. Likewise on bolts of earlier manufacture
that were manufactured with other tolerances:
5.8 Installation tools

Apart from a variety of standard tools for tensioning of SUPERBOLT tensioners simple special
tools are available, which facilate the installation of large nuts or bolts.
5.9 Protective caps

Protective caps from vinyl, steel or stainless steel are available to protect the tensioners
for differentapplications.Filledwith grease they offergood potectionagainstrust at normal
temperatures.
6. Consultation and exclusion of liability

~
0
For further information on possible uses, applications and maintenance of SUPERBOLT m
(!)
pretensioning systems please contact your supplier or directly P&S Tensioning Systems Ltd. fO
'9
P&S excludes all liability for unsuitable product selection, improper use as well as damage "'
.,;
resulting from disregarding our instructions and directives. Changes due to technical progress
are reserved. ~
SPARES
Ordering Spares
Section 1 Basic Machine:-
1 Crankcase Assembly
2 Bed Assembly
3 Motor Mount Assembly
4 Flywheel Assembly
5 Crankshaft Assembly
6 Primary Conn Rod Assembly
7 Swing Lever Assembly
8 Secondary Conn Rod Sub Assy.
9 Yoke Slide Assembly
10 Yoke Assembly
11 Power Take-Off Assembly
12 Hold Down Assembly - Rear
13 Cradle Assembly
14 Discharge Drive Assembly
15 Lubrication Assembly
16 Pneumatic Assembly
16/1 Pneumatic Panel Sub-Assy.
16/2 Pneumatic Assembly - Calibrated Gauges
16/3 Pneumatics - Dome Station
17 Hydraulics Assembly
18 Rotary Cup Feed Assembly
Section 2 Alternative Equipment:-

26 Encoder Assembly (Power Take-Off)
27 Front Hold Down Assembly
28 Primary and Secondary Housing Assembly
29 Coolant Assembly
29/1
29/2 Coolant Monitoring Assembly
29/3 Cup Spray Assembly
30 Guards Assembly
31 Guard Switch assembly
32 Main Drive Motor
33 Motor Pulley, Belts & T/Lock Bush
34 Ram Assembly
35 Dome Door & Dome Station Mounting Assembly
36 Dome Station Assembly
37 Stripper Housing Assembly
38 Nameplates Assembly
39 Toolkit
40 Special Purpose Tools
41 Scavenging Pump
42 Hydrolube Hoses
43 Hydrolube Unit
44 NPT Adaptors for Service Inlet
45 Accumulator Charging Kit
46 Portable Filtration Unit
Section 3 Change Parts:-

51 Rotary Cup Feed Change Parts
52 Cup Locator Support Assembly
53 Tooling
54 Stripper Assembly
55 Stripper Adaptor Parts
56 Turret & Hub Assembly
57 Discharge Turret & Hub Assembly
58 Microdomer Stroke Adaptor Parts
ORDERING SPARE PARTS
Spares for your machine can be supplied from our Spares Machine Manufacturer:
Store at Shipley - England or from CarnaudMetalbox Engi-
neering - Connecticut USA. CarnaudMetalbox Engineering Limited
Parts for your machine can be ordered via our sales adminis- Dockfield Road Shipley,
trators or through the company’s Internet web site using the West Yorkshire
on-line parts ordering service SPARES DIRECT. BD17 7AY England
By using a web browser you can enquire on the cost and avail- Tell: +44 1274 846200
ability of spare parts, and also order them. This service is free Fax: +44 1274 846201
and available 24 hours a day. For more information about the
Internet Service contact Spare Parts - UK or visit our website
at www.canlinespares.com and register online Spare Parts - UK:
Important, only authorised Spare Parts must be used. CarnaudMetalbox Engineering Limited
Dockfield Road Shipley,
The following information is required to ensure that your West Yorkshire
order is processed as quickly as possible. BD17 7AY England
Tel.: +44 1274 846300

MECHANICAL SPARES: Fax: +44 1274 846301
Please State:- www.canlinespares.com
• Component Part Number (stamped on component and Spare Parts - USA:

quoted in lists in the machine spares manuals)
• Component description (quoted in lists in the machine 79 Rockland Road, Norwalk
spares manuals). Connecticut 06854
United States
• Quantity required
• Machine type and description, and the Machine Serial Tel.: +1 203 853 7325
Number Fax: +1 203 866 7627
• When the component identity is in doubt, supply a clear

photograph. Do Not send the worn or broken part.
ELECTRICAL SPARES AND ALL PROPRIETARY

ITEMS:
• In addition to supplying the above information, state full
electrical details and Serial Number on the Control Cabi-
net.
• State the eight digit coded part number (quoted in lists in
the machine spares manuals)
• For Electric Motors, state the Component Part Number
(quoted in lists in the machine spares manuals) and the
Motor Serial Number (shown on the motor).
• For information on Electrical Spares not contained
within the machine spares manual contact the Machine
Manufacturer - Electrical Engineering Department.
5000 Machine : 5000 Bodymaker Machine Code : 015043 Sheet :
1
Assembly : CRANKCASE ASSEMBLY
Drawing No : 2389584F BOM No : 5002-001/02 Issue : 22. 02. 2010

1
Assembly : CRANKCASE ASSEMBLY
Item Part No. Description Qty.
1 2006066F CRANKCASE 1
2 1984269C COVER 1
3 2004263C COVER 1
4 1299739B LEVELLING PLATE 4
5 1987885C OIL RETURN BAFFLE 1
6 1996091D SUMP FILTER SCREEN 1
10 23183208 SEAL,CORD,GACO 3MM DIA 2,250.00000 MM
11 23668205 FLUID LEVEL/TEMP GAUGE,UCC UC-FLT-31321 1
(IT IS ACCEPTABLE TO SUPPLY UC-FLT-321
IN PLACE OF THIS PART)
13 23461208 PLUG,SOLID,CRANE 148 1 2
15 27541211 SCREW,HEX HD SET,S/LOC,M8 X 12 GDE 8-8 4
16 27521214 SCREW,HEX HD SET,M8 X 25 GRADE 8-8 20
18 27576824 WASHER,ANTI-VIBRATION,NORDLOCK NL8 24
20 27683542 DOWEL,EXTRACTOR,20MM X 60 1
2
Assembly : BED ASSEMBLY
5002-002/10 Issue : 21. 04. 2010

Drawing No : 2389581F BOM No :
5002-002/08
2
Assembly : BED ASSEMBLY
5002-002/10 Issue : 21. 04. 2010

5002-002/08
BOM NO. COMMON PARTS FOR 21", 575MM & 26" STROKE MACHINES:-
2 2015033D PRIMARY BULKHEAD C/W BUSHES 1

3 2386132D SECONDARY BULKHEAD-SUB ASSY 1
4 1994284B SECONDARY BULKHEAD SPACER 2
5 1299739B LEVELLING PLATE 6
6 2006464D FILTER SUB-ASSEMBLY 1
7 2006461B CANOPY 1
10 23183208 SEAL,CORD,GACO 3MM DIA 2,340.00000 MM
11 23183107 O RING MATERIAL,PARKER SERIES 2. 88.00000 IN
1/4 DIA.
12 23136677 SEAL,OIL,SYNTHETIC,CHICAGO CRW1R-19630 2
16 27681575 DOWEL,STD,HARD AND GROUND, 25MM X 70 1
20 27511319 BOLT,HEX HD,M16 X 75 GRADE 8-8 4
25 27111358 SCREW.SOC CAP,M20 X 70 14
29 27576720 WASHER.NORDLOCK,PRIMATRONIC,GLUED PAIRS 3
NL6 (M6)
30 27576726 WASHER,NORDLOCK,PRIMATRONIC,GLUED PAIRS 10
NL8 (M8)
NL16 (M16)
32 27576750 WASHER,NORDLOCK,PRIMATRONIC GLUED PAIRS 14
NL20 (M20)
BOM NO. 5002-002/08 PARTS FOR 575MM AND 26" DUAL STROKE MACHINE:
1 2386632F BED 575 AND 26 DUAL STROKE 1

5000 Machine : 5000 Bodymaker Machine Code : 015.043 Sheet :
3
Assembly : MOTOR MOUNT ASSY
Drawing No : 2001156F BOM No : 5002-003 Issue : 06. 05. 99

5000 Machine : 5000 Bodymaker Machine Code : 015.043 Sheet :
3
Assembly : MOTOR MOUNT ASSY
Drawing No : 2001156F BOM No : 5002-003 Issue : 06. 05. 99
1 2001154D SIDE PLATE (POWER TAKE-OFF SIDE) 1

2 2001153D SIDE PLATE (FLYWHEEL SIDE) 1
3 2001152D CROSS BAR 1
4 1984302B TENSIONING SCREW 2
5 2001149D SLIDE ANGLE (POWER TAKE-OFF SIDE) 1
6 2001150D SLIDE ANGLE ( FLYWHEEL SIDE) 1
7 2003169C SUPPORT STRAP 2
16 27561044 NUT,FULL,GRADE 8-8,M16 2
17 27571644 WASHER,HEAVY FLAT,M16 2
19 27561050 NUT,FULL,GRADE 8-8,M20 12
20 27571650 WASHER,HEAVY FLAT,M20 8
5000 Machine: 5000 Bodymaker Machine Code : 015043 Sheet:
4
Assembly : FLYWHEEL ASSEMBLY
Drawing No: 2017913F BOM No : 5002-004/03 Issue: 26.11.2010
1 1299758B SPACER 2
2 1299759B ADJUSTING SCREW 2
3 1299760B SPACER 2
4 2003046B RETAINING WASHER 24
5 1994085B PLUNGER HOUSING 8
6 1992216B PLUNGER 8
7 1992251B BARRING TOOL 1
8 1984691B BRACKET FOR BARRING TOOL 1
(DRESS WELDS BLAKODIZE AND PART MARK)
9 2003044D RETAINING RING 1
10 1995810D BEARING HOUSING - SUB ASSY 1
13 2003045D OUTER CASING 1
16 1996707F BACKPLATE 1
17 1987565B SHIMPACK 1
18 1999970F BRAKE ANCHOR HUB 1
19 1994095F FLYWHEEL 1
20 2017912B HYDRAULIC CLUTCH AND BRAKE UNIT 1
21 1993470B MANIFOLD 1
22 1992229B SPRING GUIDE 8
24 27667286 PIN,ROLL,STEEL,6MM X 30 1
25 25651476 BEARING,ROLLER,TIMKIN 38880-38820 2
26 26726433 SPRING,COMPRESSION FLEXO M266314 8
27 23633411 ROTARY UNION,ORTLINGHAUS 1
0-088-226-22-001-040
(ALUMINIUM BODY)
Spares available for this item
(Quantities listed are for 1 off above):-
26349205 O RING,ORTLINGHAUS 8-6-16-12-330 4
26349732 BEARING,ORTLINGHAUS,8-4-06-25-060 1
26349231 GASKET,ORTLINGHAUS 1-088-550-22-001 1
TO SUIT ROTARY UNION 23633411 & 23633410
26349731 BEARING,ORTLINGHAUS,8-4-06-25-057 1
26349541 SEAL,ORTLINGHAUS,8-4-37-60-054 1
End of Spares for this item..............
28 26575918 LOCKING ASSY,RINGFEDER RFN7012x160x210 1

32 23114517 O RING,2293-57 METRIC BS4578 1
33 23114543 O RING,3393-57 METRIC BS4518 1
34 23114559 O RING,4393-57 METRIC BS4518 1
35 23115552 O RING,DOWTY 208-956-4470 1
36 23145614 SEAL,0IL,BSL 165 X 190 X 13 R6 1
37 2009197B DRIVE BUSH SPACER 12
38 2009198B DRIVE BUSH 12
40 23145583 SEAL,OIL,ACRYONITRILE BUTADIENE RUBBER 1
BA 150x180x13 ARTICLE No 00009505
FREUDENBERG SIMRIT
XXX NO ALTERNATIVE PERMISSIBLE XXX
41 23172054 SEAL,HEADLAND,VEE RING,VA0550 1
45 27171195 SCREW,SOC CAP,S/LOC,M6 X 60 2
46 27111212 SCREW,SOC CAP,M8 X 16 2
47 27111214 SCREW,SOC CAP,M8 X 25 6
48 27111313 SCREW,SOC CAP,M16 X 45 36
49 27111356 SCREW,SOC CAP,M20 X 60 10
50 27111362 SCREW,SOC CAP,M20 X 90 10
56 27511364 BOLT HEX HD, M20 X 110 GRADE 8-8 12
58 27511283 BOLT,HEX HD,M12 X 90 2
4
Assembly : FLYWHEEL ASSEMBLY
Drawing No : 2017913F BOM No : 5002-004/03 Issue : 26.11.2010

58 27511283 BOLT,HEX HD,M12 X 90 2
GRADE 8-8
61 27122216 SCREW,SOC SET CUP PT,M8 X 35 6
64 27564026 NUT,NYLOC/WEDGLOK,M8 6
NL20 (M20)
NL16 (M16)
NL8 (M8)
69 27576738 WASHER,,NORDLOCK,PRIMATRONIC,GLUED PAIRS 4
NL12 (M12)
70 27177186 SCREW,SOC CSK HD,S/LOC,M6 X 16 4
72 23215273 ELBOW,ADAPTOR,ENOTS 36-0541-45 HOBBS 1
73 23215285 LOCKNUT,CONED,HOBBS,ENOTS 36-0540-06 1
74 23211074 ADAPTOR,MALE,ENOTS 36-0530-45 METRIC 1
75 23241068 NUT,TUBING,ENOTS 36-0500-08 METRIC 2
76 23242068 SLEEVE,TUBING,ENOTS 36-0501-08 METRIC 2
77 23215229 SEAL,HOBBS,ENOTS 34-0156-06 1
78 46514509 TUBE,NYLON,16MM BLACK 1.50000 MT
5
COMPLETE CRANKSHAFT ASSEMBLY - 575mm AND 26in DUAL STROKE M/C WITH
Assembly :
SPECIAL 120 DEG FALL CAMS
Drawing No : 2386647F BOM No : 5002-005/12 Issue : 05. 03.2009

5
Assembly :

5
Assembly :

5
Assembly :
1 1999924F BEARING 1
2 1998874F QUILL 1
3 1984779F OIL RETURN FLANGE 1
4 1987951B PLATE 1
5 1984501C/1 SHIM, 0.025MM THICK (PURPLE) 1
5 1984501C/2 SHIM, 0.050MM THICK (DARK BLUE) 1
5 1984501C/3 SHIM, O.O75MM THICK (GREEN) 1
5 1984501C/4 SHIM, 0.125MM THICK (BROWN) 1
5 1984501C/5 SHIM, 0.250MM THICK (WHITE) 3
6 2000564C/1 SHIM, 0.025 THICK (PURPLE) 1
6 2000564C/2 SHIM, 0.050MM THICK (DARK BLUE) 1
6 2000564C/3 SHIM, 0.075 THICK (GREEN) 1
6 2000564C/4 SHIM, 0.125 THICK (BROWN) 1
6 2000564C/5 SHIM, 0.250 THICK (WHITE) 3
10 23183158 O RING MATERIAL,NITRILE RUBBER 3MM DIA 2.00000 MT
20 27111313 SCREW,SOC CAP,M16 X 45 6
21 27111356 SCREW,SOC CAP,M20 X 60 6
22 27111363 SCREW,SOC CAP,M20 X 100 4
26 27122181 SCREW,SOC SET,CUP PT,M6 X 5 8
30 27683540 DOWEL, EXTRACTABLE, 20MM X 50 2
33 23461501 PLUG,PRESSURE,SOC HD, 1/8 BSPT 2
NL6 (M6)
NL12 (M12)
NL16 (M16)
NL20 (M20)
39 1999977F CRANKSHAFT - 26 STROKE 1
40 2386642D REDRAW CAM - PTO SIDE 1
41 2386643D REDRAW CAM - FLY SIDE 1
42 1987762C BALANCE WEIGHT 2
6
Assembly : PRIMARY CONN ROD ASSEMBLY
Drawing No : 2000650D BOM No : 5002-006 Issue : 27. 10. 2006

6
Assembly : PRIMARY CONN ROD ASSEMBLY
Drawing No : 2000650D BOM No : 5002-006 Issue : 27. 10. 2006
2000650D PRIMARY CONN ROD ASSEMBLY (COMPLETE) 1
NOTE: THE PRIMARY CONN ROD SHOULD BE PURCHASED AS A COMPLETE

COMPONENT COMPRISING THE FOLLOWING ITEMS:-
1 2000643F CONN ROD SEMI-FINISHED 1

2 1299562C SPLIT BUSH 1
3 1299563C BUSH - CONN ROD 1
4 2008217B PRIMARY CONN ROD BOLT 4
5 2008218B PRIMARY CONN ROD NUT 4
6 2010094B NUT PLATE 2
7 27683354 DOWEL EXTRACTOR 10MM X 20 1
8 27182268 SCREW,SOC SET CUP PT,S/LOC,M12 X 12 1
9 2008208B BOLT RETAINING PLATE 2
NL20 (M20)
IMPORTANT
ITEMS 4 & 5 SHOULD NOT BE REUSED AFTER THEY HAVE BEEN
TORQUE TIGHTENED AND MUST BE REPLACED WITH NEW PARTS IF
RE ASSEMBLING THE CON ROD CAP.
7
Assembly : SWING LEVER ASSEMBLY
5002-007/40 Issue : 23. 02. 2011

5002-007/41
7
5002-007/40 Issue : 23. 02. 2011

5002-007/41
7
5002-007/40 Issue : 23. 02. 2011

5002-007/41
8
Assembly : CONNECTING ROD SUB-ASSY 19", 21" & 26" STROKE MACHINES
Drawing No : 2383135D BOM No : 5002-008/04 Issue : 27. 04. 2007

8
Assembly : CONNECTING ROD SUB-ASSY 19", 21" & 26" STROKE MACHINES
1 2383132D SECONDARY CONN-ROD 1

2 2004404B BUSH-SECONDARY CONN ROD 1
3 2383141B BUSH SECONDARY CONN-ROD 1
4 2383134B RESTRICTOR ADAPTOR 1
5 23249882 SCREW,JET,FLUID RESTRICTORS FRM6-1-26 1
6 23182175 SEAL,BONDED,400-023-4490-41 1
9
Assembly : YOKE SLIDE ASSEMBLY
Drawing No : 2019781F BOM No : 5002-009/- Issue : 05. 12. 2006

9
Assembly : YOKE SLIDE ASSEMBLY
Drawing No : 2019781F BOM No : 5002-009/- Issue : 05. 12. 2006
BOM NO. 5002-009/15 YOKE SLIDE ASSEMBLY - 19", 21", 575MM STROKE MACHINES:
1 1299590C SLIDEWAY - 19 & 21 STROKE 2

2 1299591C UPPER & LOWER RAIL - 19 OR 21 INCH 4
3 27111365 SCREW,SOC CAP,M20 X 120 10
NL16 (M16)
NL20 (M20)
BOM NO. 5002-009/16 YOKE SLIDE ASSEMBLY - 26" STROKE MACHINES:
1 1988374C SLIDEWAY - 26 STROKE M/C 2

2 1988375C UPPER & LOWER RAIL - 26 INCH STROKE 4
3 27111365 SCREW,SOC CAP,M20 X 120 10
NL16 (M16)
NL20 (M20)
BOM NO. 5002-009/17 YOKE SLIDE ASSEMBLY - 30" STROKE MACHINES:
1 2016055D SLIDEWAY - 30 STROKE 2

2 2016056C UPPER & LOWER RAIL - 30 STROKE 4
3 27111365 SCREW,SOC CAP,M20 X 120 12
NL16 (M16)
NL20 (M20)
10
Assembly : YOKE ASSEMBLY 2.3/4" DIA RAM

10
Assembly : YOKE ASSEMBLY 2.3/4" DIA RAM
1 2014341F SLIDE YOKE 1

2 2007822D YOKE SHAFT 1
3 2007823B CLAMP PLATE 1
4 2007824B BUSHING (YOKE) 1
5 2018777B RAM SPACER 1
7 23249714 SCREW JET,FLUID RESTRICTORS FRM6-1-20/22 10
9 23249755 PLUG,LEE,PLGA 3431010A 4
10 23249762 PLUG,LEE,PLGM 0600010A 8
11 23249771 PLUG - LEE PLGM0400010A (ALUMINIUM) 2
14 23272385 PLUG,BLANKING,ERMETO VSTI R 1/8 - ED 11
17 25881377 LOCKNUT,BEARING,IEC FU06SS(M30 X 1,5) 1
(LOW CARBON STEEL SS400 or EQUIVALENT)
20 27681354 DOWEL,STD,HARD & GROUND,10MM X 20 1
NOTE: THE COMPLETE YOKE ASSEMBLY 2019783F IS A RECOMMENDED SPARE

AND SHOULD BE HELD BY THE CUSTOMER
11
Assembly : POWER TAKE-OFF ASSEMBLY -

11
Assembly : POWER TAKE-OFF ASSEMBLY -
* 1 2390925F POWER TAKE-OFF GEARBOX 1

6 1999882C GASKET 1
9 27683360 DOWEL,STD,H&G,EXTRACTOR,10MM X 30 1
16 27111213 SCREW,SOC CAP,M8 X 20 4
17 27111216 SCREW,SOC CAP,M8 X 35 4
20 27561026 NUT,FULL,GRADE 8-8,M8 4
NL8 (M8)
NL10 (M10)
NL16 (M16)
* REFER TO SHEET 11/1
BOM NO: 5002-011/03 PARTS FOR 26 INCH STROKE MACHINES:-
5 26355881 UNIVERSAL JOINT, CLARKE, PROP SHAFT, 1

35A040448-1918, WORKING LENGTH 1938mm
26355901 KIT,UNIVERSAL JOINT,CLARKE 35-0405 1
11/1
Assembly : POWER TAKE-OFF GEARBOX
Drawing No: 2390925F BOM No : 5002-011/09 Issue: 28. 09. 2010

11/1
Assembly : POWER TAKE-OFF GEARBOX

12
HOLD DOWN ASSEMBLY - REAR (19,21,575mm,26 & 575/26 DUAL STROKE MACHINES)
Assembly :
REVISED AIR BAG GUIDANCE, LESS CONNECTING LINKS,PINS & BRG’S

12
Assembly :

12
Assembly :
1 1299651C PIVOT 2
2 1299653B THRUST FLANGE 4
3 1299671D ACCUMULATOR 1
4 1299833B BEARING SPACER 2
5 1984165B BUSH-LONG 4
6 1984285C PIVOT HOUSING 2
7 1989319B PIN - OIL DRAIN 2
8 1990802D HOUSING (AIR SPRING) 2
9 2018974D MOUNTING PLATE 2
10 1995458B GASKET 2
11 2008443B GUIDE PIN 2
12 1996684B GUIDE STOP PLATE 2
14 2008441C GUIDE SUPPORT 2
17 2000359B LOCATING PIN 4
18 2004163D CONNECTING FLANGE 2
20 2004170D CAM LEVER 2
21 2004186D ROD END 2
22 2004210B FLANGED BUSH 4
24 2006153C PIN 2
25 2006152B OIL RESTRICTOR 2
26 2006120B TRACK ROLLER 2
F-140498B
27 2008440B GUIDE BUSH HOUSING 2
28 2008442B PIVOT PIN 4
31 23114066 O RING RM 0251-16 2
32 23114290 O RING,0795-30 METRIC BS4518 2
33 23114314 O RING,1195-30 METRIC BS4518 2
34 23114384 O RING,2295-30 METRIC BS4518 2
35 23114543 O RING,3393-57 METRIC BS4518 2
36 25512321 BEARING,PLAIN,OILITE CM27 X 16mm 4
37 23212913 ADAPTOR,PARKER 4-4 F40 XS 2
38 23272389 PLUG,BLANKING,ERMETO VSTI-R3/4-ED 2
40 23461212 PLUG,SOLID,CRANE 148 1.1/2 1
41 23678063 BAG,AIR,FIRESTONE TYPE FS7431-22 2
43 25652078 BEARING,ROLLER,FAG 33010 4
47 26575846 ELEMENT,LOCKING,RINGFEDER RFN 8006 40X45 4
48 26575993 SLEEVE,SPACER,RINGFEDER DB40 4
49 25881381 LOCKNUT,BEARING,IEC FU10SS(M50 X 1.5) 2
50 27111186 SCREW,SOC CAP,M6 X 16 8
51 27111187 SCREW,SOC CAP,M6 X 20 12
52 27111190 SCREW,SOC CAP,M6 X 35 16
53 27111242 SCREW,SOC CAP,M10 X 30 8
55 27111311 SCREW,SOC CAP,M16 X 35 2
57 27113241 SCREW,SOC SHDR,M10 X 12 X 25 4
65 22468618 NUT,SIMMONDS TYPE, 5/16 UNF 24
NL6 (M6)
12
Assembly :
NL8 (M8)
NL10 (M10)
NL12 (M12)
NL16 (M16)
71 23182708 SEAL,BONDED,HYDROCOUPLIN SB-007-7 24
(5/16 BOLT)
13
CRADLE ASSEMBLY - COMMON PARTS FOR 21 INCH 575mm 575mm EXT & 26 INCH
Assembly :
CRADLES

13
Assembly :
CRADLES

13
Assembly :
CRADLES

13
Assembly :
CRADLES
BOM NO. 5002-010/31 COMMON PARTS FOR 21", 575MM EXT & 26" CRADLES:-
1 1299706B GIB 2
2 2006232B SENSOR MOUNT 1
3 1299752B CLAMP WASHER 1
4 1984483B HINGE PIN 2
5 1984486C SWING BOLT 2
6 1984487B SWING PIN 2
7 1991889B SPECIAL WASHER 2
8 2003427B DOME DOOR SHIM 8
9 2004293B DOME DOOR BUTTON 8
20 2004437B PLUNGER 1
21 2004436C KEY 2
22 2004439B PLUNGER PLATE 1
23 2006348B REGISTER BLOCK 2
24 2004445B STEM (12mm) 1
25 2004450B HINGE BLOCK 2
26 2004431B ADJUSTER STUD 1
27 2006006B SENSOR BRACKET 1
28 2006036B SEAL HOUSING 1
29 2006080B BALL LEVER 1
30 2006125B PLUNGER HOUSING 1
31 2014545B LATCH BLOCK 1
32 24113650 LOCK,SLAM-LOCK,DIRAK 229-9001 (DZUS) 1
33 23114252 O RING,0355-30 METRIC BS4518 VITON 1
34 23114263 O RING,0415-30 METRIC BS4518 1
36 24147474 KNOB,BALL,RENCOL 352 M10 THRD 1
BLACK,BRASS INSERT
37 24147477 KNOB,BALL,RENCOL 354 M12 THRD 1
BLACK,BRASS INSERT
39 25513751 BEARING,PLAIN,OILITE FBM20 X 25 2
(AL 2532)
40 25514734 BEARING,PLAIN THRUST,BOSTON 18884 2
42 26726397 SPRING,COMPRESSION,FLEXO M246205 METRIC 4
43 26726509 SPRING,COMPRESSION,FLEXO M326308 1
45 27111185 SCREW,SOC CAP,M6 X 12 10
46 27111190 SCREW,SOC CAP,M6 X 35 4
47 27111199 SCREW,SOC,CAP,M6 X 80 2
48 27111213 SCREW,SOC CAP,M8 X 20 2
49 27111219 SCREW,SOC CAP,M8 X 50 8
50 27111271 SCREW,SOC CAP,M12 X 25 4
51 27111316 SCREW,SOC CAP,M16 X 60 6
52 27111411 SCREW,SOC CAP,M24 X 80 1
53 27182211 SCREW, SOC SET,CUP PT,S/LOC, M8 X 12 4
54 27111414 SCREW,SOC CAP,M24 X 100 3
56 27111318 SCREW,SOC CAP M16 X 70 2
59 27561062 NUT,FULL,GRADE 8-8,M30 2
60 27561038 NUT,FULL,GRADE 8-8,M12 2
61 27562038 NUT,LOCK,GRADE 8-8,M12 1
NL12SP (M12 FOR SLOTS)
NL6 (M6)
13
Assembly :
CRADLES

NL8 (M8)
NL10 (M10)
NL12 (M12)
NL16 (M16)
73 27683363 DOWEL,EXTRACTABLE,10MM X 35 2
76 27665293 PIN,SPIROL,6MM X 45MM MBK 2
BOM NO. 5002-010/40. 575MM & 26" IN DUAL STROKE MACHINE

CRADLE LENGTH 263/2773MM (TO SUIT 6" & 8" TOOLING):-
11 2389732F CRADLE 575-26 DUAL STROKE 263-273 CRADLE 1

12 2013371D SUPPORT BRACKET 1
13 2018833C PISTON PLATE - CLAMP BLOCK 1
14 2389667D TOOLPACK SUPPORT BLOCK 575-26 DUAL 1
STROKE
15 23114384 O RING,2295-30 METRIC BS4518 1
16 2389734F CLAMP COVER 575-26 DUAL STROKE 263-273 1
CRADLE
17 1999572B PIVOT PIN - CRADLE 1
18 27511655 BOLT,HEX HD,M30x270 1
14
Assembly : DISCHARGE ASSEMBLY

14

14
BOM NO 5000-012/25. COMMON PARTS FOR 21", 575MM, 26" AND 575MM - 26" DUAL STROKE MACHINES:-
1 1299702B TORQUE LIMITER 1

2 2389816C BEARING HOUSING R.H. 1
3 2389815D L.H. BEARING HOUSING 1
7 2006812B TORQUE LIMITER SPACER 1
13 2004366B SPACER 1
14 2006321C GEAR SHAFT 1
15 2006312C DISCHARGE DRIVE GEAR 1
16 2004371B SPACER 1
17 2006314B LOCKING CAP 1
18 2006320C GEAR-DISCHARGE 1
19 2004375B DISCHARGE SPROCKET 1
20 2004399B TENSIONER ARM 3
21 2004405B CAP - UPPER 1
22 2004407B CAP - LOWER 1
23 2004408B COVER PLATE 1
24 2004410C COVER PLATE 1
25 2389795D PLATE - DISCHARGE DRIVE 1
26 2006814C PTO - SPROCKET SHAFT 1
27 2004422B WASHER 4
28 2004448B COVER 1
32 2006030B ADJUSTMENT BLOCK 1
36 2006158B PIVOT BLOCK 1
37 2006164D DISCHARGE BRUSH 1
38 2006813B SPACER 1
39 2006310F BACKING PLATE 1
40 2006326B END WASHER 1
47 24174150 U/TOOLING,JIG WASHERS,WDS 400-202 3
49 25117638 BEARING,BALL,FAG 6207 2RSR 1
50 25121704 BEARING,BALL,FAG 6308 2RS 2
51 25122069 BEARING,BALL,C/W SNAP RING, FAG 3
6306.2RSRNR
52 25671139 BEARING,BALL,SELF ALIGNING, 2
2310-2RS-TVH
55 25611922 RING,INNER,INA IR 170 X 185 X 45 2
58 25881355 LOCKNUT,BEARING,IEC FUO5SC 1
62 26121082 CHAIN,RENOLD,110046 82 PITCHES 1
INCLUDING SPLIT LINK
63 26121100 CHAIN,RENOLD,110046 100 PITCHES ICLUDING 1
SPLIT LINK
66 26287718 SPROCKET,IDLER,CROSS&MORSE ISO8B18 3
69 26422461 KEY,PARALLEL,METRIC,8 X 7 X 32 BER 2
72 26431804 COLLAR,CLAMPTITE,ONE PIECE 25MM ID 1
74 26441328 CIRCLIP,EXT,ANDERTON 1400-50 DIN 1
75 26451536 CIRCLIP,INT,ANDERTON D1300-0900 90MM 1
76 26451619 CIRCLIP,INT,ANDERTON D1300-1100 1
78 26576166 LOCKING ASSEMBLY,SIMPLATROLL R7-189494 1
(R8-627104)
80 27111212 SCREW,SOC CAP,M8 X 16 1
82 27111215 SCREW,SOC CAP,M8 X 30 8
14
84 27111218 SCREW,SOC CAP,M8 X 45 8

85 27111225 SCREW,SOC CAP,M8 X 80 4
86 27111411 SCREW,SOC CAP,M24 X 80 7
89 27117158 SCREW,SOC CSK HD,M5 X 10 3
90 27117130 SCREW,SOC HD CSK,M4 X 8 6
93 27131187 SCREW,SOC CAP,SS,M6 X 20 5
97 27511189 HEX.HD.BOLT M6 X 30 2
115 27561026 NUT,FULL,GRADE 8-8,M8 3
116 27561232 NUT,FULL,STAINLESS,M10 1
117 27564220 NUT,NYLOC/WEDGLOK,SS,M6 5
120 27571220 WASHER,STD FLAT,STAINLESS 316 M6 5
NL6 (M6)
NL8 (M8)
NL10 (M10)
NL12 (M12)
NL16 (M16)
NL24 (M24)
BOM NO. 5002-012/30.

PARTS FOR 575MM - 26" DUAL STROKE MACHINES, 250-260 & 263-273 LONG CRADLE :-
139 2389812D DRIVE SHAFT - 575-26 DUAL STROKE 1

140 2389774F DISCHARGE PLATE 575-26 DUAL STROKE 1
141 2013358B PIVOT SHAFT 1
144 2386656B STAY BAR 1
145 2013357B BRUSH STOP PIN 1
146 2386667B BRUSH STOPS 1
147 25611922 RING,INNER,INA IR 170 X 185 X 45 1
148 2389771D DISCHARGE PLATE FILLER PIECE 1
149 27111246 SCREW,SOC CAP,M10 X 50 6
NL10 (M10)
151 2386668B BRUSH STOP 1
152 2389824B BRUSH STOP 1
15
LUBRICATION ASSEMBLY
Assembly : Sht 1 of 3
FOR MACHINES WITH FRONT BUSHING COMPOSITE BUSHING

15
Drawing No : 2014802F BOM No : 5002-022/05 Issue : 23 02. 2010

15

15
Assembly :
1 2014794C PRESSURE GUAGE MANIFOLD 1

2 2012603B MANIFOLD BLOCK 1
5 2004264B HOSE ASSEMBLY 1
9 1996287B MOUNTING ADAPTOR-LEVEL SENSOR 1
11 2014663B HOSE ASSEMBLY - CAM SPINDLE 1
12 2014664B HOSE ASSEMBLY - QUILL 1
14 2014665D HOSE ASSEMBLY - MAIN BEARING 1
15 2014803B HOSE ASSEMBLY - PUSH ROD BUSHES 1
17 23231214 BANJO,SINGLE,ERMETO,SWVE8-PLR 8
18 23232251 BANJO,DOUBLE,ERMETO,DSVT8-PLR 4
DSVT8-PLR NOW OBSOLETE CAN USE TH-8-PLR
21 23272385 PLUG,BLANKING,ERMETO VSTI R 1/8 - ED 2
22 23461502 ELBOW,MALE STUD,ERMETO WE10-PLR 1
23 23228981 TEE,MALE,PIRTEK CBJ-09-09-04 1
24 23223520 CONNECTOR,MALE,PARKER, F40 XS8-1/4 3
(BODY ONLY)
25 23214722 ADAPTER,SWIVEL,PARKER,F63 XS8-1/4 3
26 23212903 CONNECTOR,MALE,PARKER F40 XS8-1/4 8
27 23217920 ELBOW,SWIVEL NUT,PARKER C6 X210 4
28 27111248 SCREW,SOC CAP,M10 X 60 2
29 27111220 SCREW,SOC CAP,M8 X 55 2
NL8 (M8)
32 23243005 CLIP,TUBING,ENOTS 34-0218-05 SINGLE 4
33 27111158 SCREW,SOC CAP,M5 X 10 4
37 23212961 ADAPTOR,PARKER 3/8 BSP TO 3/4-16 JIC 1
8F40XS
38 23212235 ADAPTOR,EQUAL,HYDROCUPLIN AD-BB-2-J 1
1.1/4 BSP
39 23212236 ADAPTOR,EQUAL,HYDROCUPLIN AD-BB-2-K 1
40 23212232 ADAPTOR,EQUAL,HYDROCUPLIN AD-BB-2-F 1
41 23212233 ADAPTOR,EQUAL,HYDROCUPLIN AD-BB-2-D 1
42 23212226 ADAPTER,EQUAL,HYDROCUPLIN AD-BB-2-CD 1
43 23182175 SEAL,BONDED,400-023-4490-41 1
44 23182168 SEAL,BONDED,DOWTY 400-032-4490-02 1
47 23182715 SEAL,BONDED,HYDROCUPLIN SB-027-F 1
48 23182194 SEAL,BONDED,DOWTY,400-513-4490-02 1
49 43517200 BUNDY TUBING,8MM OD 6.00000 MT
50 23249727 SCREW JET,FLUID RESTRICTORS FRM6-1-30 1
52 23249876 SCREW JET,FLUID RESTRICTOR,FR-M6-1-48/50 2
16
Assembly : PNEUMATICS ASSY

16

16

16
Assembly : PNEUMATIC ASSEMBLY
1 * PNNEUMATICS SUB ASSEMBLY

2 * MECHANICAL AIR STRIP VALVE ASSEMBLY
3 2003891B STUD 3
4 2004198B SPACER 3
8 23676344 REGULATOR,AIR LINE,NORGREN R07-200-RNKG 2
(N.B.! 23676344 WAS FOR R06-200-RNKD
WHICH IS OBSOLETE.PARTS INTERCHANGEABLE)
12 23628612 VALVE,RELIEF,SNUBBER BUDENBURGH 130 1/4 1
16 23651621 VALVE,NON-RETURN,JOUCOMATIC 34600124-1/8 1
19 23616901 BALL VALVE,AVS 3831 1/4 1
22 74186083 VALVE,SOLENOID, D2773-6011,24VDC (1 BSP) 1
(ROSS)
74171411 PILOT KIT,ROSS 946K87 1
75493203 SOLENOID COIL,24V.DC,ROSS 411B04B 1
74171451 BODY KIT,ROSS 496K87 1
23 23642226 AIR SILENCER,ROSS D5500A6003 1
25 23224202 CONNECTOR,STRAIGHT MALE,METALWORK 1
2001002 (4mm-1/8)
2001007 (6mm-1/8)
2001008 (6mm-1/4)
28 23224232 C0NNECTOR,STRAIGHT FEMALE,METALWORK 1
2002002 (4mm-1/4)
29 23224236 CONNECTOR,STRAIGHT FEMALE,METALWORK 2
2002006 (6mm-1/4)
30 23228883 TEE CONNECTOR,METALWORK 2005003 (6mm) 5
31 23228884 CONNECTOR,TEE,METALWORK 2005004 (8mm) 1
32 23224193 NIPPLE,METALWORK 2007003 (6MM) 5
33 23224194 NIPPLE,METALWORK 2007004 (8mm) 1
34 23219708 CONNECTOR,MALE ELBOW,METALWORK 4
2031009 (6mm-1/4)
2031011 (8mm-1/4)
2031018 (12mm-1/2)
38 23224806 CONNECTOR,BULKHEAD,SMC KQE06-00 (6mm) 2
39 23219717 CONNECTOR,MALE ELBOW,METALWORK 2031017 1
(12mm-3/8)
41 23218522 ELBOW,UNION,SMC KQL06-00 1
42 23218482 STEM ELBOW CONNECTOR,SMC,KQL06-99 (6mm) 4
44 23218460 CONNECTOR,ELBOW,SMC KQL06-01S (6-1/8) 6
45 23218458 CONNECTOR,ELBOW,SMC KQL06-02S (6-1/4) 4
48 23481699 BUSH,HEX RED,CRANE J40 1.1/2 TO 1/2 1
56 23215084 ELBOW ADAPTOR,ENOTS 36-0331-10 METRIC 1
* FOR PNEUMATICS SUB ASSEMBLY REFER TO SHEET 16/1

* FOR MECHANICAL AIR STRIP VALVE ASSEMBLY REFER TO SHEET 16/4
16
Assembly : PNEUMATIC ASSEMBLY

2031008 (6mm-1/8)
62 23243004 CLIP,TUBING,ENOTS 34-0218-04 SINGLE 32
63 23243015 CLIP,TUBING,ENOTS 34-0219-04 DOUBLE 6
64 23243099 SCREW,TUBING CLIP,ENOTS 48-0034-24 38
65 23218044 ELBOW,ENOTS,36-0548-04 1
66 23214042 ADAPTOR,NIPPLED,ENOTS 36-0557-04 METRIC 2
71 23287941 PUSH-LOK,SWIVEL,FEMALE,PARKER 30682-4-4S 1
72 23214737 ADAPTOR,PARKER 39182-2-4B 1
73 23212881 ADAPTOR,MALE,PARKER F3XS6-1/4 1
80 23289951 ADAPTOR,MALE,PIRTEK A-16-16 1
81 23289969 SWIVEL,FEMALE,ADAPTOR,PIRTEK AAM-16-16 1
85 27561044 NUT,FULL,GRADE 8-8,M16 3
86 27576720 NORDLOCK WASHER NL6 1
89 46514004 TUBE,NYLON,ENOTS 40-1002-002 4MM OD 1.00000 MT
90 46514430 TUBE,NYLON ENOTS 40-1005-04 6MM BLACK 25.00000 MT
92 46514433 TUBE,NYLON,ENOTS 40-1005-07 12MM BLACK 3.50000 MT
94 23287870 HOSE,PARKER 801-4 0.50000 IN
16/1
Assembly : PNEUMATIC PANEL SUB ASSY
Drawing No: 2390831f BOM No : 5002-024/33 Issue: 20. 09. 2010

16/1

16/1

5000 Machine : 5000 bodymaker Machine Code : 015043 Sheet :
16/2
PNEUMATICS ASSEMBLY - GAUGES CALIBRATED PSI-BAR
Assembly :
(FUNCTIONS-STRIP ASSIST, CUP HOLD DOWN & DOME HOLD DOWN)
Drawing No : No drawing BOM No : 5002-018/04 Issue : 10. 12. 2002
23671622 GLYCERINE FILLED PRESSURE GAUGE 63MM 3

FACE,1/4 BSP CENTRE BACK CONNECTION,
PANEL MOUNTING. SCALE: PSI-BAR
(0-200 PSI) BEWICK P/No 024-01688B
16/3
PNEUMATICS - ADDITIONAL TO COMPLETE DF-1 MICRODOMER (CAN ALSO BE USED
Assembly :
FOR PRIDE DOMER)

16/3
PNEUMATICS - ADDITIONAL TO COMPLETE DF-1 MICRODOMER (CAN ALSO BE USED
Assembly :
FOR PRIDE DOMER)

17
Assembly : HYRAULICS ASSEMBLY (21ins,575mm & 26ins STROKE MACHINES)

17
Assembly : HYRAULICS ASSEMBLY (21ins,575mm & 26ins STROKE MACHINES)
1 2386516C FLANGE-WELDED BOSS 1

4 26349511 VALVE,PRESS SAFETY,ORTLINGHAUS 1
0-086-076-01-000-000, 24 VOLT DC
5 1996442C VALVE MOUNTING BRACKET 1
6 1996287B MOUNTING ADAPTOR-LEVEL SENSOR 2
7 1996427B JET HOLDER 1
8 1993340B MOTOR MOUNT BRACKET 1
9 1995745B HOSE ASSY 1
11 1995747B SUCTION PIPE 1
12 1996434B JET (3.2mm) 1
16 23182194 SEAL,BONDED,DOWTY,400-513-4490-02 5
18 23183158 O RING MATERIAL,NITRILE RUBBER 3MM DIA 1.00000 MT
28 23215600 ELBOW,ADAPTOR,PARKER 4-4C3XS 1
29 MC12-12T ADAPTOR,MALE 3/4 O/D TUBE - 3/4 BSPT 1
30 12F3MK4S ADAPTOR,EQUAL,PARKER 3/4 BSPP - 1
60 DEG-3/4 BSPT
35 23287870 HOSE,PARKER 801-4 60.00000 IN
45 27561026 NUT,FULL,GRADE 8-8,M8 6
47 27571026 WASHER,STANDARD FLAT,M8 14
18
Assembly : ROTARY CUP FEED ASSEMBLY COMMON PARTS

18
1 2389739D PLATE - ROTARY CUP FEED 1

2 2006187D COVER PLATE 1
3 1299736C SPROCKET HUB 1
4 1299734B HOUSING 1
5 1299737B CLAMP RING 1
6 1995402B END COVER 1
7 1994531B SHIMPACK 1
8 1299733B ECCENTRIC PIN 1
9 2004423B SHOULDER BOLT 1
10 2004488B CUP GUIDE EXTENSION 1
11 2004480C GUIDE SUPPORT 2
12 1988995B TRACK STIRRUP SPACER 2
13 2000622B CAN STOP CYLINDER - 15 STROKE 1
(SMC DRG.No.RSQB20D-M0565-15)
14 2004485B CUP STOP SUPPORT 1
15 2007176C LEAF SPRING 1
16 2006268B BAFFLE PLATE 1
17 2389738B ECCENTRIC ADJUSTER 1
18 2007177B CLAMP 1
19 2007178B ANVIL 1
21 26723667 SPRING,COMPRESSION,FLEXO 163216 1
24 24485034 INDUSTRIAL BRUSH T 7/8-5/16 BACKING 1
27mm TRIM LENGTH 80mm LONG
26 25131925 BEARING,BALL,FAG 7205-B-TVP-UO 2
28 23172233 SEAL,HEADLAND VEE RING,VS0130 1
29 23172014 SEAL,HEADLAND VEE RING,VA0025 WAS V25A 1
31 23247538 NIPPLE,GREASE, KINGFISHER 608601 M6 X 1 1
33 26121125 CHAIN,SIMPLE,RENOLD 110046 125P 1
INLUDING SPLIT LINK
49 27111161 SCREW,SOC CAP,M5 X 20 2
50 27111184 SCREW,SOC CAP,M6 X 10 2
51 27111186 SCREW,SOC CAP,M6 X 16 12
53 27111245 SCREW,SOC CAP,M10 X 45 4
59 27115159 SCREW,SOC RD HD,M5 X 12 2
NL5 (M5)
NL6 (M6)
NL8 (M8)
NL10 (M10)
18

NL12 (M12)
26
Assembly : POWER TAKE-OFF ENCODER ASSEMBLY TYPE - AMCI HT-20S

26
Assembly : POWER TAKE-OFF ENCODER ASSEMBLY TYPE - AMCI HT-20S
1 2386223C MOUNTING FLANGE 1

5 26351186 COUPLING,FENNER 070 METRIC HUB 968B2019 1
IMPERIAL HUB 968B1020 CENTRE ELEMENT TO
SUIT BOTH ENDS
9 26411133 KEY,PARALLEL,3/16 X 3/16 X 1 BER 1
12 21111115 SCREW,SOC CAP,1/4 UNC X 7/8 4
NL6 (M6)
27
Assembly : HOLD DOWN ASSY - FRONT

27

27
BOM NO: 5002-015/31 COMMON PARTS:-
1 1994305F HOUSING - AIR SPRING (C/W BUSH AND DOWEL) 1

2 2389780D PLATE - BLANK HOLDER 1
3 2000998C HOUSING RETAINER 1
4 2000985C SLEEVE 1
5 2391106B SPACER 1
6 2389567D BEARING BLOCK 2
7 2389573B GUIDE BUSH 2
8 2389665B BEARING RETAINER 2
9 2000337B PIVOT PIN 2
10 2004211B PIVOT PIN 2
11 1990807B COVER 1
12 1994268B MANIFOLD 1
13 1299654B SPACER 2
14 2000341B SPACER 8
15 2389575B SPACER 2
16 2389807B WASHER 2
19 25881379 LOCKNUT,IEC FU08SS, (M40 X 1,5 PITCH) 2
20 23678066 SPRING,AIRIDE,FIRESTONE W01-358-7022 1
1.3/4 LONG BOLTS, 19(B)
INT-NOTE CHECK QTY TO ORDER RE-DISCOUNT
21 25767956 BEARING,SHERICAL,PLAIN,ELGES GE 45 DO-C2 4
(MUST BE RADIAL CLEARANCE GROUP C2)
22 26448730 CIRCLIP,EXT,SMALLEY DNS-45 4
23 26451432 CIRCLIP,INT,ANDERTON 1300-68 DIN 8
28 23114305 O RING,1045-30 METRIC BS4518 1
29 23117146 SEAL,WIPER,GACO RS30407 4
33 27111212 SCREW,SOC CAP,M8 X 16 4
36 27111218 SCREW,SOC CAP,M8 X 45 10
38 27122219 SCREW,SOC SET,CUP PT M8 X 50 LG 4
40 27561026 NUT,FULL,GRADE 8-8,M8 4
NL8 (M8)
45 23215010 ELBOW,ADAPTOR,ENOTS 36-0005-10 METRIC 1
2031009 (6mm-1/4)
50 43517120 BUNDY TUBING,6MM OD 1.00000 MT
2031008 (6mm-1/8)
52 23228325 ADAPTOR, SWIVEL, SIDE TEE, NORGREN, 1
PNEUFIT - 102680618
BOM NO: 5002-015/28 PARTS FOR 26" & 26"/575MM DUAL STROKE MACHINES:-
54 2389663D CONNECTING LINK - 26 AND 575-26 DUAL 2
STROKE
55 2389574D REDRAW GUID ROD SUB-ASSY 2
28
Assembly : PRIMARY & SECONDARY HOUSING ASSEMBLY
Drawing No: 2390174F BOM No : Issue: 20. 09. 2010

28
Assembly : PRIMARY & SECONDARY HOUSING ASSEMBLY
Drawing No: 2390174F BOM No : Issue: 20. 09. 2010
BOM NO: 5002-016/34 COMMON PARTS FOR 2 & 2.3/4 INCH DIA. RAMS:-
10 23114302 O RING,0995-30 METRIC BS4518 2

11 23114320 O RING,1295-30 METRIC BS4518 2
15 27111159 SCREW,SOC CAP,M5 X 12 4
16 27111187 SCREW,SOC CAP,M6 X 20 4
17 27111218 SCREW,SOC CAP,M8 X 45 4
NL5 (M5)
NL6 (M6)
NL10 (M10)
NL8 (M8)
24 23210838 ADAPTOR,SWIVEL ELBOW,102471038, 2
M10-3/8BSP PAR,NORGREN PNEUF
25 46514432 TUBE, NYLON ,ENOTS 40-1005-06 10MM BLACK 1.00000 MT
26 2388544C COOLANT MANIFOLD RING 1
BOM NO: 5002-016/46 PARTS TO SUIT 2.1/2 INCH DIA. RAMS:-
1 2388568D 2.1/2 INCH RAM HOUSING ASSEMBLY 1

2 2388542C END CAP 2.1/2 INCH RAM 1
3 2015817B RETAINING RING - 2.1/2 RAM 1
4 2388520C HOUSING- FLOATING SEAL PACK 2 1/2 RAM 1
5 2388523C SEAL CARRIAGE 1
7 23114293 O RING,0845-30 METRIC BS4518 2
8 23136637 SEAL,OIL,SYNTHETIC,PARKER 31202500 3
POLYMITE ORANGE
(PSA-31202500 Z4651)
9 24551031 SEAL,SLIPPER,SC006350-SL 2
CARBON GRAPHITE WITH VITON ENERGISER
SEAL RING CO
BOM NO: 5002-016/49 PARTS TO SUIT 2 INCH DIA. RAMS:-
1 2388959D 2 INCH RAM HOUSING ASSEMBLY 1

2 2388958C END CAP - 2 INCH RAM 1
3 2015818B RETAINING RING - 2 RAM 1
4 2390165C HOUSING - FLOATING SEAL PACK 2 DIA RAM 1
5 2390168C SEAL CARRIAGE - 2 DIA RAM 1
7 23114287 O RING,0745-30 METRIC BS4518 2
8 23136638 SEAL,OIL SYNTHETIC PARKER 31202000 3
POLYPAK MAT-POLYMATE
9 24551036 SEAL,SLIPPER,SC005070-SL 2
CARBON GRAPHITE WITH VITON ENERGISER
SEAL RING CO
29
Assembly : COOLANT ASSEMBLY

29
Assembly : COOLANT ASSEMBLY
1 2012479C FLOW METER BRACKET 1

2 2006276B SPECIAL FIXED SOCKET 1
3 2015000B CONE SEAL 2
5 22213078 SCREW,HEX HD SET,S/LOC,3/8 UNC X 5/8 4
15 23219323 ADAPTOR, ELBOW, NORGREN, 10 247 0618 1
16 23215011 ELBOW,ADAPTOR,ENOTS 36-0005-11 METRIC 1
17 23219310 ELBOW ADAPTOR,90 DEG SWIVEL,NORGREN 1
102470848 (1/2 BSPP - 8mm O/D TUBE)
18 23219308 ELBOW,ADAPTOR,NORGREN, 101470828 1
(1/4 BSPT - 8mm O/D TUBE)
19 23215146 SEAL,HOBBS,ENOTS 36-0545-08 2
OBSOLETE NOW HYDROCUPLIN SEAL RING
HL-HW-2-H
20 23215286 LOCKNUT,CONED,HOBBS,ENOTS 36-0540-08 2
OBSOLETE NOW HYDROCUPLIN LOCKNUT
HL-PELN-2-H
23 23289969 SWIVEL,FEMALE,ADAPTOR,PIRTEK,AAM-16-16 1
24 23289967 SWIVEL,FEMALE,ADAPTOR,PIRTEK,AAM-08-08 1
25 23289911 SOCKET,FEMALE FIXED, PIRTEK WP-16-16 1
26 23289921 ADAPTOR,MALE, PIRTEK AH-16-16 4
27 23289931 ADAPTOR,90 ELBOW, PIRTEK CLPP-16-16 2
28 23289891 ADAPTOR,BULKHEAD MALE,PIRTEK BWL-16-16 2
29 23289951 ADAPTOR,TAPER MALE, PERTEK A-16-16 1
30 23289966 SWIVEL,FEMALE,90 DEG, ELBOW ADAPTOR, 1
PIRTEK CVDP-08-08
32 23289922 ADAPTOR,MALE,PIRTEK,AH-20-16 2
33 23289975 TEE,ADAPTOR SWIVEL,PIRTEK, EPFP-16-16-08 1
(1 BSP X 1 BSP X 1/2 BSP)
34 23658987 VALVE,BALL,NORGREN 3384100 1
(NORGREN 604112188)
35 74186807 VALVE, PILOT/SPRING, 2/2, SINGLE 1
ACTUATED NC FOR USE WITH OIL.
(NUMATICS)
36 23658164 VALVE,BALL,NORGREN, 604112148 (1/2 BSPT) 1
37 74833041 PADDLEWHEEL MODULE STAINLESS 1
S030 1,1/4 BSP 424007N BURKERT
39 74833043 PADDLEWHEEL MODULE LOW FLOW S/STEEL 1

S030 1/2 BSP MALE 44029X BURKERT
42 27523240 SCREW,HEX HD SET,SS,M10 X 20 GRADE 18-8 2
NL10 (M10)
50 23111121 O RING,BS121(R3106) 1
53 23271010 WASHER,LUBE,ENOTS 48-0213-08 COPPER 1
55 46615910 TUBE,NYLON COPELY DEVELOPMENTS LTD 0.30000 MT
NMF-28mm CLEAR
29/2
Assembly : COOLANT ASSEMBLY - ADDITIONAL PARTS FOR COOLANT MONITORING OPTION
Drawing No: 1999978C BOM No : 5002-019/05 Issue: 20. 09. 2010

29/2
Assembly : COOLANT ASSEMBLY - ADDITIONAL PARTS FOR COOLANT MONITORING OPTION
Drawing No: 1999978C BOM No : Issue: 20. 09. 2010
BOM NO: 5002-019/05 COOLANT MONITORING ASSEMBLY:-
2 1989506B MANIFOLD BLOCK (THERMOMETER) 1

4 23289921 ADAPTOR,MALE, PIRTEK AH-16-16 1
5 23668094 THERMOMETER,ROTOTHERM BL102-40-0/100-B 1
DUAL CALIBRATED IN CELCIUS/FAHRENHEIT
6 23271004 WASHERS,LUBE,ENOTS 48-0213-04 COPPER 1
7 23320087 ADAPTOR, SWIVEL, PRESSURE GUAGE, 1
AD-MFBG-2-B-SW (1/4 BSP TO 1/4 GAUGE)
BOM NO: 5002-019/08 COOLANT MONITORING - PRESSURE GAUGE (PSI & Kpa):-
1 23671626 GLYCERINE FILLED PRESSURE GAUGE 63MM 1

DIRECT MOUNTING, SCALE: PSI-Kpa
(0-200 PSI) BEWICK P/No 024-01669A
BOM NO: 5002-019/09 COOLANT MONITORING - PRESSURE GAUGE (PSI & Kg.Cm2):-

FACE,1/4BSP CENTRE BACK CONNECTION,
DIRECT MOUNTING.SCALE: PSI-Kg/Cm.sq
(0-200 PSI) BEWICK P/No 024-01670A
BOM NO: 5002-019/10 COOLANT MONITORING - PRESSURE GAUGE (PSI & BAR):-

DIRECT MOUNTING, SCALE: PSI-BAR
(0-200 PSI) BEWICK P/No 024-01668A
29/3
Assembly : CUP SPRAY ASSEMBLY

29/3
Assembly : CUP SPRAY ASSEMBLY
1 1986189B ELBOW ADAPTOR BLOCK 1

3 24481637 NOZZLE,DELAVAN 1/8 AN5 BRASS 1
5 23213046 ADAPTOR,STRAIGHT,ENOTS 36-0505-05 1
6 23211299 ADAPTOR,STRAIGHT MALE,ENOTS 36-0504-11 1
7 23222035 CONNECTOR,STEM,ENOTS 36-0625-05 1
8 23633685 JOINT,SLOW ROTATING,ENOTS 04-0175-00 1
13 23658779 VALVE,RESTRICTOR,METALWORK MRFT/V 1
9021109
2031011 (8mm-1/4)
30
Assembly : MACHINE GUARDS

30

30
1 2386903F P.T.O GUARD 1

2 2013825F SLIDEWAYS GUARD ASSEMBLY 1
3 2386905F DUAL STROKE DISCHARGE GUARD 1
4 2006283B CONDUIT 1
5 2387653B SLIDING PANAL 1
6 2014675B PNEUMATICS ENCLOSURE 1
7 2390119F FLYWHEEL GUARD 1
8 2017763B DISPLAY PANEL 1
9 2391442B MOUNTING STUD 2
10 2386918D SCRAP CHUTE 1
11 2386920C SCRAP CHUTE EXTENSION 1
15 1990868B SPACER 8
(REF - FITS TO HINGED DOORS & BULKHEAD)
16 2006171B FLYWHEEL GUARD SPACER 2
17 2006484B OIL DEFLECTOR 2
20 23184086 SEAL, GASKET, KLINGER SEALEX - 1
1 SPOOL (7mm X 2.5mm X 15 MT.)
24 27578822 WASHER,MUDGUARD,SS,M8 (25 O/D X 1,5 THK) 58
28 27111212 SCREW,SOC CAP,M8 X 16 8
31 27115211 SCREW,SOC RD HD,M8 X 12 8
32 27115213 SCREW,SOC RD HD,M8 X 20 6
33 27135211 SCREW,SOC RD HD,SS,M8 X 12 2
44 27561020 NUT,FULL,GRADE 8-8,M6 4
NL6 (M6)
NL8 (M8)
31
Assembly : GUARD SWITCHES ASSEMBLY - 5000 GUARDMASTER TITAN

31

31
1 2006049B ACTUATOR MOUNTING BRKT. 1

2 2006050B ACTUATOR COVER 1
3 2006051B SWITCH MOUNTING PLATE 1
4 2006307B ACTUATOR BRACKET 1
5 2006369B ACTUATOR PLATE 1
6 2006388B ACTUATOR SPACER 1
7 2006400B SAFETY SWITCH SPACER 1
11 27111160 SCREW,SOC CAP,M5 X 16 4
12 27111161 SCREW,SOC CAP,M5 X 20 4
13 27111162 SCREW,SOC CAP,M5 X 25 2
14 27111163 SCREW,SOC CAP,M5 X 30 2
15 27111165 SCREW,SOC CAP,M5 X 40 2
16 27111185 SCREW,SOC CAP,M6 X 12 4
17 27111187 SCREW,SOC CAP,M6 X 20 2
18 27111212 SCREW,SOC CAP,M8 X 16 2
22 27571720 WASHER,HEAVY,FLAT,STAINLESS,M6 2
NL5 (M5)
NL6 (M6)
28 75677035 INTERLOCK SWITCH, GUARDMASTER, TITAN 3
TLS-3 GD2 M20 24V DC CAT No. 27134
(CHANGED FROM TLS-1 CAT No. 27121)
AB PART No. 440G-T27134
29 TITAN_27011 STANDARD ACTUATOR TO BE USED WITH 2
TITAN, GUARDMASTER INTERLOCK SWITCH
TLS-3 (SEE PART No. 75677035)
30 75677020 FLEXIBLE ACTUATOR TO BE USED 1
TITAN GUARDMASTER INTERLOCK
SWITCH. CAT NO 440G-A27143
32
Assembly : MAIN DRIVE MOTOR
Drawing No: NO DRAWING BOM No : 5002-032/33 Issue: 30.11.2010
1 2389989B MAIN DRIVE MOTOR 1

EFF1 TROPICALISED
2 2012510F MOTOR MOUNTING PLATE 1
3 22112397 BOLT,HEX HD,3/4UNC X 2.1/2 LG 4
NL20 (M20)
33
MOTOR PULLEY, BELT AND TAPER LOCK BUSH - 375 CPM AT (1475 F.L. SPEED)
Assembly :
65mm DIA MOTOR DRIVE SHAFT
Drawing No: BOM No : 5002-027/16 Issue: 23. 02. 2011
1 1995270C MOTOR PULLEY (305.08 PCD) 1

2 26573499 T/LOCK BUSH,FENNER 029J0065 3525 65MM 1
3 26516588 BELT,VEE,OPTI BRAND SPB-5 4820MM LG 1
34
LIGHTWEIGHT RAM ASSEMBLY - DUAL STROKE, 575/26 STROKE, FRONT REMOVAL,
Assembly :
2.1/2 DIA SHORT, C/W AIR STRIP TUBE FOR ALUCAN PACKAGING - NIGERIA.
Drawing No: 2391802D BOM No : 5002-026/92 Issue: 23. 02. 2011
1 2391801D RAM - 575mm DUAL STROKE SHORT 1

2 2390162C RAM LOCATOR 1
3 2390163C RAM CLAMP RING 1
4 27575849 LOCKING ELEMENT RFN.8006-63 X 71 1
6 27111213 SCREW,SOC CAP,M8 X 20 6
7 27111244 SCREW,SOC CAP,M10 X 40 6
10 2383940B TUBE SUPPORT-AIR STRIP 1
11 2383941B END SUPPORT-AIR STRIP TUBE 2
12 2383942B TUBE - AIR STRIP 2
NL8 (M8)
NL10 (M10)
35
DOME DOOR & DOME STATION MOUNTINGS ASSY 575 - 26 DUAL STROKE FOR DF1
Assembly :
MICRO DOMER VARY TO SUIT DUAL STROKE M/C.

35
DOME DOOR & DOME STATION MOUNTINGS ASSY 575 - 26 DUAL STROKE FOR DF1
Assembly :
MICRO DOMER VARY TO SUIT DUAL STROKE M/C.
1 2389764F DOME DOOR DF-1 MICRO DOMER 1

2 2004293B DOME DOOR BUTTON 8
3 2003427B DOME DOOR SHIM 8
4 1984481B FLANGED BUSH 2
6 23247015 NIPPLE,GREASE,TECALEMIT NA5704 2
15 27562032 NUT,LOCK,GRADE 8-8,M10 4
NL10 (M10)
36
MICRO DOMER DF-1 C/W SENSOR BRACKET, BUT LESS TOOLING.SUITABLE FOR ALL
Assembly :
STROKE LENGHTS INCLUDING 575/26 DUAL.

36
MICRO DOMER DF-1 C/W SENSOR BRACKET, BUT LESS TOOLING.SUITABLE FOR ALL
Assembly :
STROKE LENGHTS INCLUDING 575/26 DUAL.
1 2007218D DOME HOUSING 1

2 2007220C DIE HOLDER 1
3 2008873C FRONT PLATE ASSEMBLY 1
4 27665283 PIN,SPIROL,6mm X 25mm MBK 1
5 2388505C DF1 - REAR PLATE 1
6 2007226B DOME SPRING 1
7 2007231B NUT 1
8 2007239B DOME DIE SPACER 1
9 2008860B STOP PAD 1
10 2008874B SENSOR BRACKET 1
11 2013261C DOME DIE BODY 1
12 2013263B DOME DIE SPACER 1
13 2387407C DOME STATION TO DISCHARGE GUIDE 1
14 25557183 BEARING,PLAIN,GLACIER MB4030DU 1
17 25578530 BEARING TAPE, CROSFLON 905-15 500.00000 MM
15mm WIDE X 1.5mm THK X 477mm LG
19 27111094 SCREW,SOC CAP,M3 X 20 2
20 27111186 SCREW,SOC CAP,M6 X 16 2
22 27111213 SCREW,SOC CAP,M8 X 20 6
23 27111215 SCREW,SOC CAP,M8 X 30 4
24 27111242 SCREW,SOC CAP,M10 X 30 3
26 27111284 SCREW,SOC CAP,M12 X 90 2
27 27561038 NUT,FULL,GRADE 8-8,M12 8
28 27571608 WASHER,HEAVY FLAT M3 2
NL6 (M6)
NL8 (M8)
NL10 (M10)
NL12 (M12)
33 23461501 PLUG,PRESSURE,SOC HD, 1/8 BSPT 1
37
STRIPPER HOUSING ASSEMBLY - 575-26 DUAL STROKE BODYMAKERS FITTED WITH
Assembly :
SMART TYPE SHORT CAN SENSOR BRAKET.

37
STRIPPER HOUSING ASSEMBLY - 575-26 DUAL STROKE BODYMAKERS FITTED WITH
Assembly :
SMART TYPE SHORT CAN SENSOR BRAKET.
1 2384287F STRIPPER HOUSING 1

2 2384307C ADJUSTMENT SPACER 1
3 1992732B BRACKET - SHORT CAN SENSOR 1
4 2006550B DISCHARGE GUIDE EXTENSION 1
12 27177185 SCREW,SOC CSK HD,S/LOC M6 X 12 6
14 27111189 SCREW,SOC CAP,M6 X 30 1
15 27111213 SCREW,SOC CAP,M8 X 20 2
20 27521194 SCREW,HEX HD SET M6 X 55 GRADE 8-8 1
22 27561020 NUT,FULL,GRADE 8-8,M6 1
NL6 (M6)
NL8 (M8)
38
NAME PLATES ASSEMBLY (5000 & 5500) - ENGLISH (LESS CE MARK PLATE,M/C
Assembly :
SER.NO. PLATE AND DECALS)

38
NAME PLATES ASSEMBLY (5000 & 5500) - ENGLISH (LESS CE MARK PLATE,M/C
Assembly :
SER.NO. PLATE AND DECALS)
1 1984782B OIL SPECIFICATION PLATE 1

2 1984785B FLYWHEEL DOOR PLATE 1
3 1994720B NAME PLATE-LUBE POINT 3
4 1989851B YOKE SLIDE JET SIZES 1
5 1997390B BARRING WARNING PLATE 1
6 2014876B MAIN BRG JET SIZE NAMEPLATE 1
13 1984786B FLYWHEEL MAX SPEED PLATE 2
14 1999950B NAMEPLATE - COOLANT FLOW 1
15 1984470B NAMEPLATE - AIR CONSOLE 1
18 1994152B HOSE NAMEPLATES 1
20 2000355B LIFTING POINT PLATE 2
23 2006555B TIMING POINT NAMEPLATE 1
28 1984781B IDENTITY PLATE 1
40 22663051 SCREW,GKN TYPE AB,PAN HD,NO 6 X 1/2 48
41 27641159 RIVET,POP,3MM X 6MM 38
42 27115185 SCREW,SOC RD HD,M6 X 12 2
43 27561020 NUT,FULL,GRADE 8-8,M6 2
NL6 (M6)
47 45455SC LUBRICATION CHART HOLDER 1
39
Assembly : TOOLKIT ASSEMBLY - STANDARD ( 1 SET PER MACHINE )
Drawing No : BOM No : 5002-017-S/01 Issue : 21. 04. 2010
1984634B LEE JET TOOL 1

24228258 SPANNER,SOCKET KEY,UNBRAKO 3MM AF LONG 1
52000002 5000-048/01 PART TOOLKIT.1-OFF EACH 1
8,10,13,17,19,24,30,36MM -5/16,3/4 INCH
A/F C/VANADIUM COMBINATION SPANNERS
1 24218031 SPANNER,AF COMBINATION,C/VANADIUM,8MM 1
GEDORE
GEDORE
GEDORE
4 24218049 SPANNER,AF,COMBINATION,C/VANADIUM,17MM 1
GEDORE ONLY PLEASE
GEDORE
GEDORE
GEDORE
GEDORE
9 24218208 SPANNER,AF COMBINATION,C/VANADIUM,5/16 1
A/F
10 24218240 SPANNER,AF COMBINATION,C/VANADIUM,3/4 1
A/F
52000006 5000-048/01 PART TOOLKIT.1-OFF EACH 1
2.5,3,4,5,6,8,10,12,14,17,19 MM & 3/32,
1/8,5/32,7/32,3/8 INCH A/F SOCKET KEYS.
1 24228207 SPANNER,SOCKET KEY,UNBRAKO --- 2.5 A/F 1
2 24228208 SPANNER,SOCKET KEY,UNBRAKO --- 3 A/F 1
8 24228220 SPANNER,SOCKET KEY,UNBRAKO --- 12.A/F 1
11 24228227 SPANNER,SOCKET KEY,UNBRAKO---19 A/F 1
12 24228019 SPANNER,SOCKET KEY,UNBRAKO W3 3/32 AF 1
52000007 5000-048/01 & /03 PART TOOLKIT. 1 OFF EA 1
3/4 A/F DRIVE SOCKET SET PARTS - SLIDING
TEE BAR SSD212,EXTN.BAR SES212L,SOCKET
WRENCHES,36A/F(LSM236),46A/F(K32L-30)
1 24223732 SPANNER,SLIDING TEE BAR KING DICK SSD212 1
2 24224949 SPANNER,SOCKET EXTENSION,K/DICK SES 212L 1
3 24224456 SPANNER,SOCKET,3/4 DRIVE 36 A/F 1
4 24224489 SPANNER,SOCKET IMPACT,3/4 DRIVE 46MM A/F 1
,GEDORE K32L-30
24334854 WRENCH,ADJUSTING,HEPCO AT-54 1
2389106B GLAZING TOOL KIT 1
IN32-19 3/4 DRIVE 19MM ALLEN SOCKET 1
39
Assembly : TOOLKIT ASSEMBLY - STANDARD ( 1 SET PER MACHINE )
Drawing No : BOM No : 5002-017-S/01 Issue : 21. 04. 2010
22012129622 3/4 DRIVE 17MM ALLEN SOCKET 1

22012129623 3/4 DRIVE 14MM ALLEN SOCKET 1
KEN-582-8060K 3/4 DRIVE 8 INCH LONG EXTENSION 1
40
Assembly : SPECIAL PURPOSE TOOLS
Drawing No: BOM No : Issue: 05. 01. 2011
BOM NO: 5002-017-CP/78

RAM LOCATOR ALIGNMENT FIXTURE - 2.1/2 INCH DIA LIGHTWEIGHT FRONT INSTALLED RAM:-
1 2390700D RAM LOCATOR ALIGNMENT - SETTING FIXTURE 1
BOM NO: 5002-017-SP/27

2.1/2 INCH DIA RAM TO SEAL FITTING TOOL, FOR RAM INSTALLED FROM FRONT:-
1 2390702B RAM TO SEAL FITTING TOOL 1
BOM NO: 5002-017-SP/36

DFI MICRO DOMER SEAL CALIBRATION TOOLS FOR 211 DIA BEVERAGE BASE CAN PROFILE:-
1 2390565B INNER SEAL CALIBATION MANDREL 1

2 2390564B OUTER SEAL CALIBRATION RING 1
BOM NO: 5002-017-SP/05 SPECIAL TOOLS KIT - STANDARD:-
1999881D PIN EXTRACTOR 1

2016483C TEE-BAR SWING LEVER TOP PIN 1
29700003 SOCKET FOR BEARING LOCKNUT IEC M30 1
2019100B SPECIAL IEC LOCKNUT SOCKET 1
2390507C TORQUE SPANNER BEARING LOCKNUT 25881 1
3789
2390747B MOD TO SOCKET FOR BEARING LOCKNUT 1
NBD5551453C TORQUE WRENCH HANDLE, NORBAR 1
60 TO 300 Nm
24682652 GAUGE,SMALL HOLE,TYPE FRIX NO.1 1
.010 INCHES TO .040 INCHES IN .OO1 INCH
DIVISIONS
BOM NO. 5002-017-SP/07, TOOL FOR 575-26 DUAL STROKE MACHINE:
2384676B TOOL - STROKE CHANGE 1
BOM NO. 5002-017-EX/07

HYDRAULIC CLUTCH AND BRAKE AND ANCHOR HUB SEAL FIXTURES:-
1 2390822B CLUTCH AND BRAKE FIXTURE SUB-ASSEMBLY 1

2 2390825C BRAKE ANCHOR HUB FIXTURE 1
41
SCAVENGING PUMP/MOTOR SET 400V,3PH,50Hz IEC FRAME,WEG EFF1,IP55,TROP.
Assembly :
MOTOR (SUPPLIER No -----)
Drawing No: No drawing BOM No : 5002-033/32 Issue: 23. 02. 2011
1 2391956B SCAVENGING PUMP/MOTOR SET 1

42
HYDROLUBE HOSES - MK3 STYLE POWER PACK NONE STANDARD POSITION
Assembly :
SPECIAL FOR BALL PACKAGING EUROPE-HASSLOCH

42
HYDROLUBE HOSES - MK3 STYLE POWER PACK NONE STANDARD POSITION
Assembly :
SPECIAL FOR BALL PACKAGING EUROPE-HASSLOCH

7 2013796B HOSE NAME TAGS 1
8 1996831B HOSE DIRECTION ARROW 6
9 71507012 TIE, CABLE, TY-RAP, TY5232M 24
NYQUIST ELEC COMPONENTS
43
Assembly : MK3 HYDROLUBE UNIT (5000 MK2 BODYMAKER)
Drawing No : BOM No : 5002-031/57 Issue : 23. 02. 2011
1 2391953C HYDROLUBE UNIT 1
FOR FURTHER INFORMATION REFER TO SECTION 9 PROPRIETARY EQUIPMENT

44
NPT ADAPTORS FOR SEVICE INLET CONNECTIONS ON BODYMAKER ONLY. (BSP TO
Assembly :
NPT PNEUMATIC & COOLANT INLETS)
Drawing No: 2010030C BOM No : 5002-053 Issue: 21. 09. 2010

44
NPT ADAPTORS FOR SEVICE INLET CONNECTIONS ON BODYMAKER ONLY. (BSP TO
Assembly :
NPT PNEUMATIC & COOLANT INLETS)
Drawing No: 2010030C BOM No : 5002-053 Issue: 21. 09. 2010
1 23212210 ADAPTOR,MALE,HYDROCUPLIN AD-TN-2-H 1

( 1 BSP TAPER X 1 NPT )
2 23212218 ADAPTOR,MALE,HYDROCUPLIN AD-BN-2-H 1
45
ACCUMULATOR CHARGING KIT & ADAPTOR
Assembly :
(HYDRAULIC CLUTCH AND BRAKE CIRCUIT)
Drawing No: BOM No : 5002-017-CP/45 Issue: 22. 09. 2010

5002-017-CP/49
1994376B ACCUMULATOR CHARGING KIT 1
2018006B ADAPTOR - ACC CHARGE KIT.- ROMANIA 1

46
Assembly : PORTABLE FILTRATION UNIT (380-420 VOLTS 50Hz, 440-485 VOLTS 60Hz)
Drawing No: BOM No : 5002-055/02 Issue: 22. 09. 2010
1 74335109 PORTABLE FILTRATION UNIT, TELL TALE 1

FILTERS LTD 6-A-74W-10C-1. MAINS
VOLTAGE 460V. 60Hz.
51
CHANGE PARTS FOR ROTARY CUP FEED CUP O/D 92.61mm, CUP HEIGHT 28.32mm.
Assembly :
CUP LOCATOR TO SUIT STEPPED REDRAW DIE. ALL PARTS IN POLY ACETAL.

52
CHANGE PARTS - CUP LOCATOR SUPPORT (ROTARY CUP FEED ASSEMBLY) LEADER
Assembly :
PIN H/DOWN,STEPPED REDRAW DIE

52
CHANGE PARTS - CUP LOCATOR SUPPORT (ROTARY CUP FEED ASSEMBLY) LEADER
Assembly :
PIN H/DOWN,STEPPED REDRAW DIE
110 2386311F LOCATOR SUPPORT 1

111 1999147C REDRAW DIE HOLDER 1
112 2003491C CLAMP RING TOOLPACK 1
114 23114317 O-RING 1245-30 METRIC BS4518. 1
115 23114348 O RING,1545-30 METRIC BS4518 1
117 27111214 SCREW,SOC CAP,M8 X 25 4
121 27562026 NUT,LOCK,GRADE 8-8,M8 3
NL8 (M8)
53
Assembly : PART TOOLING ASSY. 211 DIA X 33cl 263 LG CRADLE, 6ins DIES IN 8ins HOLDERS I

53
Assembly : PART TOOLING ASSY. 211 DIA X 33cl 263 LG CRADLE, 6ins DIES IN 8ins HOLDERS
1 2391819D CARBIDE REDRAW SLEEVE - 211 DIA 1

9 1999879C IRONING DIE HOLDER 3
11 2391852C 1st COOLANT SPACER ASSEMBLY 1
12 2388371C 2nd COOLANT SPACER ASSEMBLY 1
13 2385511C 3rd COOLANT SPACER ASSEMBLY 1
16 AC008-10-04-0109_2 DOMER DIE 211 CAN 1
17 2391822B HOLD DOWN RING SUB ASSY 1
20 23117315 SEAL,RING,MINESOTA Q4163 3
22 24331399 BOLT,EYE,COLLAR TYPE,3/8 UNC X 9/16 ID 3
77 2389750B WEAR BARS MADE IN PAIRS 1.00000 PR
78 2389751C WEAR BAR SPACER MATCHED AND PAIRED 1.00000 PR
79 27111213 SCREW,SOC CAP,M8 X 20 8
NL8 (M8)
81 2391851D MOD TO DIE CLAMP BLOCK 1
82 2390247B SHIM - TOOLPACK CLAMP 3
83 27111187 SCREW,SOC CAP,M6 X 20 6
NL6 (M6)
54
STRIPPER ASSEMBLY - STANDUN TYPE 211 DIA SPIGOTED BACK (C/W FINGERS)
Assembly :
SPIGOT TO HARMONIZE WITH 202 DIA STRIPPER.
Drawing No: 2386197C BOM No : 5002-041/29 Issue: 08.10.2010

54
STRIPPER ASSEMBLY - STANDUN TYPE 211 DIA SPIGOTED BACK (C/W FINGERS)
Assembly :
SPIGOT TO HARMONIZE WITH 202 DIA STRIPPER.
Drawing No: 2386197C BOM No : 5002-041/29 Issue: 08.10.2010

55
CHANGE PARTS - STRIPPER ADAPTOR PARTS (211 DIA X 330ml ALUM CANS) 575mm
Assembly :
- 26ins DUAL STROKE MACHINE 263mm CRADLE AND SHORT 2.5 INCH RAM.
Drawing No: 2391086D BOM No : 5002-042/41 Issue: 08.10.2010

55
CHANGE PARTS - STRIPPER ADAPTOR PARTS (211 DIA X 330ml ALUM CANS) 575mm
Assembly :
- 26ins DUAL STROKE MACHINE 263mm CRADLE AND SHORT 2.5 INCH RAM.
1 1999278C EXTENSION BLOCK 1

3 2390202B SPACER BLOCK - SENSOR 1
5 2391085C STRIPPER ADAPTOR PLATE 1
7 2381774B GUIDE RING BLANK 1
13 27111216 SCREW,SOC CAP,M8 X 35 2
15 27111243 SCREW,SOC CAP,M10 X 35 3
NL6 (M6)
NL8 (M8)
NL10 (M10)
56
CHANGE PARTS-DISCHARGE TURRET & HUB ASSY
Assembly :
575 - 26 DUAL STROKE M/C, 211 X 355ML

56
CHANGE PARTS-DISCHARGE TURRET & HUB ASSY
Assembly :
575 - 26 DUAL STROKE M/C, 211 X 355ML
1 2386742F DISCHARGE TURRET 1

2 2386740C DISCHARGE HUB 1
3 23247221 NIPPLE,GREASE,TECALEMIT NA7206 45 DEG 2
NL8 (M8)
6 27665363 PIN, SPIROL,10mm x 35mm MBK 24
24 2006556B TIMING POINT INDICATOR NAMEPLATE 1
57
CHANGE PARTS - DISCHARGE ASSEMBLY UNLOADER POCKETS - 211 DIA X 33CL,
Assembly :
211 DIA X 35.5CL, 211 DIA X 37.5CL AND 209 DIA X 35.5 CL. 26 INCH STROKE

57
CHANGE PARTS - DISCHARGE ASSEMBLY UNLOADER POCKETS - 211 DIA X 33CL,
Assembly :
211 DIA X 35.5CL, 211 DIA X 37.5CL AND 209 DIA X 35.5 CL. 26 INCH STROKE
1 2386162D UNLOADER POCKET 6

58
Assembly : CHANGE PARTS DF-1 MICRODOMER STROKE ADAPTOR

58
Assembly : CHANGE PARTS DF-1 MICRODOMER STROKE ADAPTOR
10 2390100C LOCATION PLATE 1

20 2387783C LOCATION PLATE SPACER 1
70 27511298 HEX,HD,BOLT M12 215 LG 6
80 27111255 SCREW,SOC CAP,M10 X 100 2
90 27111284 SCREW,SOC CAP,M12 X 90 2
100 27111294 SOC,HD,CAP SCREW, M12 X 155 LG 2
120 27561038 NUT,FULL,GRADE 8-8,M12 6
NL10 (M10)
NL12 (M12)

CMB Bodymaker

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OPERATING AND SPARES MANUAL

CarnaudMetalbox Engineering Limited

edition August 2010

ALL personnel should apply safe working proce-

Reference to Safety herein should be applied in

1.1 General Information

February 2001 Page 1-1

1.2 Can Travel

Page 1-2 12/Feb/98

1.3 The Drive System

12/Feb/98 Page 1-3

1.4 Hydraulic Circuit for Clutch and Brake Operation

Collection Tank 68BAR 6

HYDRAULIC CLUTCH / BRAKE CIRCUIT

a. Double Pump (1).

Page 1-4 12/Feb/98

This gauge gives the system pressure of 70 BAR.Pressure Switch (5).

a. Double Pump (10).

12/Feb/98 Page 1-5

1.5 Lubrication System

3/8" I/Dia. Hose

Bearing Block (2off)

Hydraulic Clutch / Brake

Clutch / Brake Feed Line

Page 1-6 30/Aug/06

SUMP SUMP Pump

HYDRAULIC POWER PACK

30/Aug/06 Page 1-7

1.6 Coolant System

Page 1-8 12/Feb/98

edition August 2010

e Clearing Machine Jams

edition August 2010

ALL personnel should apply safe working proce-

Reference to Safety herein should be applied in

Details Unavailable at time of Publication

2.1 Siting the 5000 Bodymaker

12/Feb/98 Page 2-3

The cooling water is used as follows:

Page 2-4 12/Feb/98

2.3 Receipt of the Crated 5500 Canmaker

The equipment will generally be supplied in three cases:

12/Feb/98 Page 2-5

2.4 Off Loading and Handling

Side View with Trimmer not shown

Plan View on ‘A’

Page 2-6 October 2007

2.4.2 Lifting Instructions - Bodymaker (Lifting Equipment illustration refers)

Front Hinged Guard must be Secure Sliding door in

Approximate Nett Weight:-

October 2007 Page 2-7

2.4.3 Lifting Instructions - Interconnecting Conveyor and Trimmer

Refer to installation instructions 2.5

2.5 Bodymaker, Conveyor and Trimmer Unit Installation

2.6 Installing the Bodymaker on its Foundation

Page 2-8 October 2007

2.7 Levelling the Bodymaker

Use the spirit level to take preliminary readings.

Page 2-10 12/Feb/98

Levelling the Bodymaker

12/Feb/98 Page 2-11

2.9 Electrical Cabinet Connection

2.10 Operator Console Connection

Page 2-12 03/Oct/00