(Reference) S-PS140UC #5016 Maintenance Manual M144-7294

Copy No.
Original Maintenance Manual

Document Number . . . . . . . . . : M144- 7294
Issue . . . . . . . . . . . . . . . . . . . . . . : 01
Date of Issue . . . . . . . . . . . . . . . : 2015- 05- 20
Model No. . . . . . . . . . . . . . . . . . : S- PS140UC

Serial No. . . . . . . . . . . . . . . . . . . : 5016
Year of Construction . . . . . . . : 2015
Manufactured by . . . . . . . . . . . : Shikoku Kakoki Co., LTD.
Customer . . . . . . . . . . . . . . . . . . :
Importer . . . . . . . . . . . . . . . . . . . : Elopak AS
Elopak Corporate Offices
Industriveien 30
N- 3431 Spikkestad,
Norway
Publisher . . . . . . . . . . . . . . . . . . : Shikoku Kakoki Co., LTD.

10- 1 Aza- Nishinokawa,
Tarohachisu, Kitajima- cho,Itano- gun,
Tokushima Japan
ISSUE NOTE
This is Issue 01
All rights reserved. No part of this manual may be reproduced in any form without the prior written permission
of SHIKOKU KAKOKI CO., LTD.
The contents of this manual may be revised without prior notice.
The contents of this manual shall not be copied or altered without the prior written permission of SHIKOKU
KAKOKI.
All efforts have been made to ensure the accuracy of all information in this manual.
However, if you notice any part of this manual is unclear, incorrect, omitted etc., please contact SHIKOKU
KAKOKI or the representative.
SHIKOKU KAKOKI assumes no liability in all cases where the machine is used in a manner not specified in
this manual.
Any manual which has missing pages or which is incorrectly collated will be replaced.
Copyright 2015 SHIKOKU KAKOKI CO., LTD.

Table of Contents
TABLE OF CONTENTS
0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 1
0.1 EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 3

0.2 Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 4
0.3 Use of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 4
0.4 Purpose of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 6
0.5 Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 7
0.6 Abbreviation used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 8
0.7 Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 9
0.8 Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 10
0.9 Jig and tool lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 11
0.9.1 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 11
0.9.2 Tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 12
0.10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 13
0.10.1 Packing condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 13
0.10.2 Lifting packed machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 14
0.10.3 In case of storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 17
0.10.4 In case of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 19
0.10.5 Lifting unpacked machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 20
0.10.6 Installation condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 22
0.10.7 Installation of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 23
0.10.8 Installation of auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 28
0.10.9 Utility connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 38
0.10.10 Basic check after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 41
0.11 Main shaft encoder zero setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 43
0.12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.1 Hydrogen peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.2 Vacuum pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.3 UV- lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.4 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.5 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.6 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.13 Machine dismantle for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 45
0.14 Machine recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 45
0.15 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 46
1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
1.1 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3

1.1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3
1.1.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
1.1.3 Safety signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.1.4 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.1.5 Safety label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 13
M144- 7294 Issue 01 III

Table of Contents
1.2 Emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 16

1.2.1 Emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 18
1.2.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 20
1.3 Machine stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 24
1.3.1 Machine stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
1.4 Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 28
1.4.1 If doors or covers are opened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 29
1.4.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 32
1.5 Fixed covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 38
1.6 Safety system in magazine section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 39
1.6.1 Stable supply of blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 40
1.6.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 44
1.7 Check safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.1 Check emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.2 Check machine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.3 Check doors and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.4 Check magazine empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.5 Check loader covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.6 Check filling section doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.7 Check safety sensor in basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.8 Check safety sensor for UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 51
1.7.9 Check quick exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 51
1.8 Staff hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 52
1.9 Chemical hazards (Caustic, Acid, Sterilant, Hydrogen peroxide, Ethanol, Oil, Grease) 1- 53
1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 54
1.9.2 Caustic and Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 55
1.9.3 Sterilant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.4 Hydrogen peroxide (H2O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.5 Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.6 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.10 Fire hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.11 Mandatory safety equipment check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.12 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 58
2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
2.1.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
2.1.2 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 12
2.1.3 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 15
2.1.4 Mechanical timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 17
2.1.5 Electrical timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 19
2.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 28
2.2.1 Drive arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 28
2.2.2 Main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 30
2.2.3 JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 36
2.3 Carton flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 44
2.4 HEPA clean air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 46
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2.4.1 Before check & replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 47

2.4.2 Pre- filter - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 48
2.4.3 HEPA filter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 49
2.4.4 HEPA filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 51
2.5 Spray sanitising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 53
2.5.1 Spray ethanol diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 54
2.5.2 Solenoid valves and pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 56
2.5.3 Regulator standard pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 58
2.6 Automatic CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 60
2.6.1 Automatic CIP unit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 60
2.6.2 Automatic CIP equipment arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 62
2.6.3 Stroke of aseptic valve manufactured by APV - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 63
2.7 Joint box arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 64
2.7.1 Joint box arrangement (under bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 64
2.7.2 Joint box arrangement (carton feeding section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 66
2.7.3 Joint box arrangement (above bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 68
2.8 How to order parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 70
2.9 Maximum tightening torque of bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 71
2.10 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 72
3 CARTON FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 3
3.1.1 Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.1.2 Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.1.3 Carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.2 Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
3.2.1 Opening finger and retainer plate - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 10
3.2.2 Size change block position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 12
3.2.3 Safety sensor and fibre sensor - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 14
3.3 Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 18
3.3.1 Tie- rod length - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 19
3.3.2 Rod end in picker section - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 19
3.3.3 Dimension in carton basket and vacuum head position - Check . . . . . . . . . . . . . . . . . . . . . 3- 20
3.3.4 Picker vacuum switch timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 22
3.3.5 Vacuum head open- close timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 22
3.3.6 Vacuum cup - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
3.3.7 Vacuum nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
3.3.8 Vacuum filter - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 24
3.3.9 Picker clutch on- off timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
3.3.10 Clearance between stopper and cover - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
3.3.11 Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 26
3.3.12 Clearance between stopper and cover - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 27
3.3.13 Light beam sensor for detecting safe position of picker lever after MAGAZINE EMPTY alarm -
Check & Adjust / Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 28
3.4 Carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 30
3.4.1 Carton guide dimension - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
3.4.2 Roller - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
3.4.3 Loader belt tension - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
3.4.4 Loader belt - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 36
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3.4.5 Loader pusher position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 38

3.4.6 Loader pusher - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 40
3.4.7 Incorrect timing of loader operation - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.8 Loader blocking and miss picking - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.9 Miss picking - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.10 Sensor sensitivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 43
3.4.11 Loader shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 46
3.4.12 Servo manual operation of carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 48
4 BOTTOM FORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3
4.1.2 Bottom heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
4.1.3 Bottom breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
4.1.4 Folding rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.1.5 Bottom sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.1.6 Carton dust cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.2 Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
4.2.1 Mandrel index unit backlash - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
4.2.2 Rotary joint - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
4.2.3 Position between mandrel and index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 11
4.3 Bottom heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 12
4.3.1 Bottom preheater position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.2 Bottom preheater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.3 Bottom preheater element - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.4 Bottom preheater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4.3.5 Bottom heater position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4.3.6 Bottom heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 16
4.3.7 Bottom heater element - Heating pattern check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 18
4.3.8 Bottom heater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20
4.3.9 Bottom heater carton positioning bolt - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20
4.3.10 Pre- filter element for bottom heater blower - Clean & Replace . . . . . . . . . . . . . . . . . . . . . 4- 21
4.3.11 Filter element for bottom heater air- Clean & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 21
4.3.12 Bottom heater blower pressure - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 22
4.3.13 Bottom heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 23
4.4 Bottom breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 26
4.4.1 Wing position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 28
4.4.2 Folding arm position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 29
4.4.3 Pusher position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 30
4.4.4 Carton holder position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 30
4.4.5 J- flap breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 31
4.4.6 Carton holder timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 32
4.4.7 Wing breaking timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 32
4.5 Folding rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 33
4.5.1 Summary of checking, adjustment values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 33
4.6 Bottom sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 34
4.6.2 Dimension between pressure pad and 5th panel - Check & Adjust . . . . . . . . . . . . . . . . . . 4- 35
4.6.3 Emboss wear - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
4.6.4 Seal pressure - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
4.7 Carton dust cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 38
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4.7.1 Filter element for carton dust cleaner - Clean & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 39
4.8 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 40
5 UNLOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
5.1.1 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.1.2 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.1.3 Unloader guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.2 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 6
5.2.1 Horizontal movement timing of vacuum head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7
5.2.2 Vacuum on- off timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7
5.2.4 Top position of vacuum cup in forward position - Check & Adjust . . . . . . . . . . . . . . . . . . . . 5- 8
5.2.8 Height of bottom position of unloader pusher - Check & Adjust . . . . . . . . . . . . . . . . . . . . . 5- 11
5.3 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 12
5.3.1 Position between mandrel and turret - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 14
5.3.2 Position between turret guide and carton holder - Check & Adjust . . . . . . . . . . . . . . . . . . . 5- 16
5.3.3 Position between turret guide and carton holder in perpendicular direction - Check . . . . 5- 18
5.3.4 Bevel gear - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 20
5.4 Unloader guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 22
5.4.1 Unloader guide timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 22
5.4.2 Jammed carton detection timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 23
5.4.3 Photoelectric switch for detecting jammed carton - Check / Replace . . . . . . . . . . . . . . . . . 5- 23
5.5 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 24
6 CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
6.1.1 Carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.2 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.3 Bottom rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.4 Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.2 Carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
6.3 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 8
6.3.1 Carton holder - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 10
6.3.2 Centring of carton holder - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 12
6.3.3 Conveyor chain tension - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 14
6.4 Bottom rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 15
6.4.1 Bottom rail height - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 16
6.4.2 Bottom rail height - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 18
6.4.3 Carton holder position - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 21
6.4.4 Servo manual operation of carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 22
6.5 Empty carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 30
6.5.1 Empty carton pusher height - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 31
6.5.2 Empty carton pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 31
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Table of Contents
6.6 Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 32

6.6.2 Reject gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 34
7 CARTON DECONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1
7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 3
7.1.1 Carton decontamination diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 6
7.1.2 Hydrogen peroxide spray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 7
7.1.3 UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
7.1.4 Hydrogen peroxide drying heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
7.2 Hydrogen peroxide spray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 10
7.2.1 List of solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 14
7.2.3 Hydrogen peroxide spray standard flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 14
7.2.4 Compulsory air purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
7.2.5 Hydrogen peroxide spray - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 18
7.2.6 Hydrogen peroxide spray nozzle position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 7- 20
7.2.7 Hydrogen peroxide spray injection needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 22
7.2.8 Spray nozzle - Check & Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23
7.3 UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 24
7.3.1 UV- lamp lifetime - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 26
7.3.2 UV- lamp - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 27
7.3.3 Initialisation of the UV- lamp monitor intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 28
7.3.4 UV- monitor intensity - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 29
7.3.5 UV- lamp intensity - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 30
7.3.6 Reflection board lifetime - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 34
7.3.7 Glass breakage detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 36
7.4 Hydrogen peroxide drying heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 40
7.4.1 Drying heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 42
7.4.2 Plate of drying heater - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.3 Drying heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.4 Pre- filter element for drying heater blower - Clean & Replace . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.5 Drying heater blower pressure - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 45
7.4.6 HEPA filter element for drying heater air - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . 7- 46
7.5 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 48
8 PRODUCT FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.1.1 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.2 Carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.2 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.2.1 Manual cleaning and check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.2.2 Start procedure after DIAPHRAGM ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 26
8.2.3 Diaphragm - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 29
8.2.4 Float switch for detecting broken diaphragm - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 35
8.2.5 Timing belt tension - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 36
8.2.6 Servo manual operation of filler piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 38
8.2.7 Suck back device - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 40
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8.2.8 Suck back membrane - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 43

8.2.9 Filler nozzle position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 44
8.2.10 Rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 46
8.2.11 Rotary valve - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 48
8.2.12 Start procedure after SHAFT SEAL LEAK ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 50
8.2.13 Jig description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 52
8.2.14 Rotary valve timing - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 57
8.2.15 Servo manual operation of rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 60
8.2.17 Filling section shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 62
8.3 Carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 64
8.3.1 Carton jam in filling section detection timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 65
8.4 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 74
9 TOP FORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
9.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 4
9.2 1st. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 6
9.2.1 1st. top breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
9.2.2 Anvil position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
9.2.3 Pad position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
9.2.4 Carton stopper position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
9.2.5 Wing angle - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
9.2.6 Carton pusher position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 11
9.3 Carton dust remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 12
9.3.1 Cover position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 13
9.3.2 Air nozzle position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
9.3.3 Nozzle spray timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
9.4 Carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 16
9.4.2 Pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 17
9.5 2nd. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 18
9.5.1 Breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 20
9.5.3 Breaking timing (fork) - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 21
9.5.4 Breaking timing (wing) - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 21
9.6 Top heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 22
9.6.1 Top heater height - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.2 Top heater - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.3 Top heater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.4 Top heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.5 Top heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 26
9.6.6 Air filter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 28
9.6.7 Cooled guide position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 33
9.7 Top sealing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 34
9.7.1 1st. top sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 36
9.7.2 2nd. top sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 49
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Table of Contents
10 CAP APPLICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 1
10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 3

10.1.1 Cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.2 Cap separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.3 Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.4 Cap detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.2 Cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 8
10.2.1 Cap track position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 9
10.2.2 Photoelectric switch - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 9
10.2.3 Photoelectric switch sensitivity for detecting caps - Check & Adjust/Replace . . . . . . . . . . 10- 10
10.3 Cap separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 12
10.3.2 Cap pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 13
10.4 Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 14
10.4.1 Escaped position of anvil - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 18
10.4.2 Horn position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 20
10.4.3 Anvil and horn position check with jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 22
10.4.4 Seal position - Clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 24
10.4.5 Parallel contact between anvil and horn - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 10- 28
10.4.6 Anvil and horn position relative to carton flow - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 29
10.4.8 Fibre sensor sensitivity for detecting timing belt cut - Check . . . . . . . . . . . . . . . . . . . . . . . . 10- 31
10.4.9 Servo manual operation of cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 32
10.4.10 Horn timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 32
10.4.11 Installing horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 33
10.5 Cap detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 34
10.5.1 Cap detected position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 35
10.5.2 Detecting timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 35
10.5.3 Fibre sensors sensitivity for detecting caps - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 36
11 PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1
11.1 Pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

11.1.1 Details A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4
11.1.2 Details B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 7
11.1.3 Details C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
11.1.4 Details D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
11.1.5 Details E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 9
11.1.6 Details F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 9
11.1.7 Details G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 10
11.1.8 Details H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 11
11.2 Graphic symbols for pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 12
11.2.1 Standard graphic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 12
11.2.2 Shikoku’s in- company symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 14
11.3 Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 15
11.3.1 Pneumatic diagram A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 15
11.3.2 Pneumatic diagram B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 16
11.3.3 Pneumatic diagram C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 18
11.3.4 Pneumatic diagram D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 20
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11.3.5 Pneumatic diagram E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 22

11.3.6 Pneumatic diagram F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 23
11.3.7 Pneumatic diagram G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 24
11.3.8 Pneumatic diagram H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 25
11.3.9 Pneumatic diagram J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 26
11.3.10 Pneumatic diagram K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 27
11.3.11 Pneumatic diagram L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 28
11.3.12 Pneumatic diagram M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 29
11.3.13 Pneumatic diagram N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 30
11.3.14 Pneumatic diagram P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 31
11.3.15 Pneumatic diagram Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 32
11.3.16 Pneumatic diagram R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 33
11.3.17 Pneumatic diagram S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 34
11.4 Solenoid valve purpose list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 35
11.5 Solenoid valve ON- OFF list - Related to carton size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 42
11.6 Standard pressure list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 44
11.7 Pressure switch & float switch & flow sensor list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 46
11.7.1 Air cylinder manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 47
11.8 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 48
12 COOLING WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 1
12.1 Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 4

12.2 UV- lamp for decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 6
12.2.1 Quartz sleeve of UV- lamp unit - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 8
12.2.2 Alarm Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 12
12.2.4 UV- lamp - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 15
12.2.5 UV- lamp after cleaning - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 17
12.3 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 18
13 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 1
13.1 Manual greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3

13.1.1 Manual greasing - Check & Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3
13.1.2 Grease terminals for bottom heater, carton loader, bottom breaker and bottom sealer . . 13- 6
13.1.3 Grease terminals for cap applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 8
13.1.4 Grease terminals for encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 9
13.1.5 Manual greasing with grease brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10
13.2 Manual operation for automatic greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11
13.2.1 Grease manual supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11
13.2.2 Grease clogged alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 12
13.3 Automatic greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 14
13.3.1 Examples of discharge amount from distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 17
13.3.2 Lubrication parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 18
13.3.3 Automatic greasing diagram (from master distributor to secondary distributors) . . . . . . . 13- 24
13.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 30
13.5 Oil - Check/ Refill/ Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 31
13.5.1 Oil for speed reducer (for main drive) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35
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13.5.2 Oil for mandrel index unit - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35

13.5.3 Oil for bottom sealer gearbox - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
13.5.4 Oil for cooling water rotary joint - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
13.5.5 Oil for vacuum pumps - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 37
13.5.6 Oil filter for vacuum pump - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 38
14 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 1
14.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 3

14.2 Daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 4
14.2.1 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 4
14.2.2 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 5
14.3 Weekly check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 8
14.4 100 hours or 2 weeks check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 10
14.5 200 hours or monthly check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 11
14.6 450 hours or 2 months check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 12
14.7 500 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 12
14.9 1000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.10 1200 hours or 6 months check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.11 2400 hours or 1 year check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.12 2500 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 15
14.13 4800 hours or 2 years check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 16
14.13.1 Accumulated grease in the mandrel gearbox - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 16
14.14 5000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 17
14.14.1 Carton decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 17
14.15 6000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 19
14.15.1 Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 19
14.15.2 Heater assembly - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 20
14.15.3 Heater element - Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 21
14.16 9000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 22
14.16.1 Potable water decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 22
14.18 Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 28
14.19 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 38
15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 1
15.1 Incorrect carton feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 3

15.1.1 Blanks are not fed from magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 3
15.1.2 Unopened blank in picker section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 4
15.1.3 Cartons are incorrectly loaded onto mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 4
15.2 Incorrect bottom forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.1 Bottom flap is folded in outward direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.2 Insert flap is folded outside of bottom flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.3 Bottom flap is not folded along the score lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 6
15.3 Poor bottom sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
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15.3.1 Unevenly heated carton bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7

15.3.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.3.3 Incorrect bottom forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.4 Carton is retained by mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.4.1 Carton is not pulled out at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.4.2 Carton is not pulled out completely from mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.5 Carton is jammed in loading cycle between turret and conveyor . . . . . . . . . . . . . . . . . . . . 15- 9
15.5.1 Carton bottom is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 9
15.6 Abnormal filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.1 Fluctuations of filling amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.2 Filling into empty carton holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.3 Foaming causes poor top seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
15.6.4 Carton is jammed between carton guide and carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
15.6.5 Product splashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 12
15.6.6 Product dripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 12
15.7 Incorrect top forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 13
15.7.1 Top flap is not folded along score lines correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 13
15.7.2 Top flap is folded in outward direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 14
15.7.3 Gap on top flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 14
15.8 Poor carton top sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.1 Unevenly heated carton top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.3 Incorrect top forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.9 Trouble in carton decontamination system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.9.1 Incorrect quantity of hydrogen peroxide flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.9.2 Incorrect intensity and cooling temperature of UV- lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.10 Trouble in cap applicator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.10.1 Caps are not fed from cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.10.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.11 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 18
16 MISCELLANEOUS EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 1
16.1 Main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 4

16.1.1 Brake gap - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 6
16.1.2 Brake gap - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 6
16.2 Worm gear speed reducer (Main drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 8
16.2.1 Oil level - Check & Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 9
16.3 Worm gear speed reducer (Carriage conveyor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 10
16.4 Mandrel index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 11
16.5 Mecha lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 12
16.5.1 Mecha lock - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 13
16.5.2 Mecha lock - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 13
16.6 Pneumatic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 14
16.6.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 14
16.6.2 Mist separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 16
16.6.3 Air pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 18
M144- 7294 Issue 01 XIII

Table of Contents
16.7 Air cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 22

16.7.1 Repair parts (CG1 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 23
16.7.2 Repair parts (CM2 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 26
16.7.3 Repair parts (CQ2 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 27
16.8 Air pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 28
16.8.1 Air pressure switch (ISE 40, ZSE40, ZSE50F TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 28
16.8.2 Air pressure sensor (PI 2095, PI 2098 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 29
16.9 Heater blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 30
16.9.1 Cleaning and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 32
16.10 Automatic grease pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 33
16.10.1 Grease level in grease pot - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
16.10.2 Grease pot - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
16.10.3 Grease pot - Air purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 35
16.11 Vacuum line equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 36
16.11.1 Vacuum pump (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 36
16.11.2 Vacuum pump (for diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 38
16.12 Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 40
17 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 1
17.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 3

17.2 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 4
1. Document No. : M214- 055- 109

High pressure mercury lamp surface sterilizer Instruction manual Iwasaki Electric Co., Ltd.
2. Document No. : M214- 131- 459
WEDECO Aquada Installation and Maintenance Instructions Xylem Inc.
XIV M144- 7294 Issue 01

List of Figures
LIST OF FIGURES
Fig. 0-1. Cartons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 6

Fig. 0-2. The lamp will turn on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 7
Fig. 0-3. The lamp will flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 7
Fig. 0-4. The lamp will turn off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 7
Fig. 0-5. Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 9
Fig. 0-6. Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 10
Fig. 0-7. Packing condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 13
Fig. 0-8. Lifting wooden box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 14
Fig. 0-9. Bad lifting example 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 15
Fig. 0-10. Bad lifting example 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 15
Fig. 0-11. Bad lifting example 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 16
Fig. 0-12. Remove contents from wooden box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 19
Fig. 0-13. Lifting unpacked machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 20
Fig. 0-14. Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 21
Fig. 0-15. Required space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 23
Fig. 0-16. Lowering the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 24
Fig. 0-17. Roller skates position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 24
Fig. 0-18. Machine legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 25
Fig. 0-19. Jack point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 25
Fig. 0-20. Discharge level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 26
Fig. 0-21. Level machine - length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 26
Fig. 0-22. Level machine - width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 27
Fig. 0-23. Remove bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 27
Fig. 0-24. Installation of auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 28
Fig. 0-25. Assemble filler parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 30
Fig. 0-26. Assemble ladder and plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 30
Fig. 0-27. Assemble HEPA unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 31
Fig. 0-28. Assemble handrail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 31
Fig. 0-29. Assemble cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 32
Fig. 0-30. Assemble bottom heater piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 32
Fig. 0-31. Assemble CIP piping including auto valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 33
Fig. 0-32. Assemble CIP recovery pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 33
Fig. 0-33. Assemble grease pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 34
Fig. 0-34. Assemble magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 34
Fig. 0-35. Assemble tank for hydrogen peroxide spray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 35
Fig. 0-36. Hang doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 35
Fig. 0-37. Assemble UV- lamp for potable water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 36
Fig. 0-38. Utility connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 38
Fig. 0-39. Utility connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 41
Fig. 0-40. Hand crank machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 41
Fig. 0-41. Emergency stop buttons & guard switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 41
Fig. 0-42. Alerting features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 42
Fig. 1-1. Danger of fall hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7

Fig. 1-2. Warning of electrical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
Fig. 1-3. Warning of electrical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8
M144- 7294 Issue 01 XV

List of Figures
Fig. 1-4. Warning of mechanical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8

Fig. 1-5. Warning of mechanical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 9
Fig. 1-6. Warning of chemical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 9
Fig. 1-7. Warning of UV light hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 10
Fig. 1-8. Caution of burn hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 10
Fig. 1-9. Caution of electrical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 11
Fig. 1-10. Caution of high temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 11
Fig. 1-11. Caution of splashing water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 12
Fig. 1-12. Caution of compression hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 12
Fig. 1-13. Safety label locations (1of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 13
Fig. 1-14. Safety label locations (2of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 14
Fig. 1-15. Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 15
Fig. 1-16. Locations of emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 16
Fig. 1-17. EMERGENCY STOP button 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 18
Fig. 1-19. Alarm light and buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 18
Fig. 1-20. SAFETY CIRCUIT RESET button and alarm light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 19
Fig. 1-21. PRODUCTION STATUS screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 19
Fig. 1-23. ALARM LIST screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 20
Fig. 1-31. No.1 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 24
Fig. 1-32. MACHINE STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
Fig. 1-33. SAFETY CIRCUIT RESET button and tower light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
Fig. 1-35. MACHINE STOP button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 26
Fig. 1-38. Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 28
XVI M144- 7294 Issue 01

List of Figures
Fig. 1-55. Fixed covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 38

Fig. 1-56. Safety system in magazine section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 39
Fig. 1-64. SAFETY CIRCUIT RESET button and tower light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 43
Fig. 1-66. CARTON FEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 44
Fig. 1-68. Alarm help screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 45
Fig. 1-77. Safety equipment for personnel use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
Fig. 2-1. Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 15

Fig. 2-2. Mechanical timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 18
Fig. 2-3. Drive arrangement under bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 28
Fig. 2-4. Main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 30
Fig. 2-5. Main motor handle position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 31
Fig. 2-6. Light beam sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 32
Fig. 2-7. Remote controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 36
Fig. 2-8. MAIN MOTOR JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 37
Fig. 2-9. Remote controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 38
Fig. 2-10. Remote controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 38
Fig. 2-11. Remote controller connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 40
Fig. 2-12. SERVO MOTOR key switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 41
Fig. 2-14. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 41
Fig. 2-15. SELECT SERVO MANUAL OPERATION window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 42
Fig. 2-16. L. SERVO MANUAL OPERAT. screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 42
Fig. 2-17. Carton flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 44
Fig. 2-18. Number emboss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 45
Fig. 2-19. HEPA unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 46
Fig. 2-20. HEPA FAN switch on the back side of the No.1 panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 47
Fig. 2-21. Pre- filter and HEPA filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 48
Fig. 2-22. Differential pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 49
Fig. 2-24. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 49
Fig. 2-25. VIEW CONDITION screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 50
Fig. 2-26. GENERAL SETTING screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 50
Fig. 2-27. Spray ethanol diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 54
M144- 7294 Issue 01 XVII

List of Figures
Fig. 2-28. Solenoid valves and pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 56

Fig. 2-29. Automatic CIP unit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 60
Fig. 2-30. Automatic CIP equipment arrangement (Example : L- side) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 62
Fig. 2-31. Stroke of aseptic valve manufactured by APV (Product valve) . . . . . . . . . . . . . . . . . . . . . . . . . 2- 63
Fig. 2-32. Joint box (under bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 64
Fig. 2-33. Joint box (carton feeding section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 66
Fig. 2-34. Joint box (above bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 68
Fig. 3-1. Carton feeder (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 4

Fig. 3-2. Carton feeder (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 5
Fig. 3-3. Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
Fig. 3-4. Openinng finger and retainer plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 10
Fig. 3-5. Size change block position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 12
Fig. 3-6. Safety sensor and fibre sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 14
Fig. 3-7. Safety sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 15
Fig. 3-8. Fibre sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 16
Fig. 3-9. Fibre sensor amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 17
Fig. 3-10. Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 18
Fig. 3-11. Dimension in carton basket and vacuum head position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 20
Fig. 3-12. Dimension in carton basket and vacuum head position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 21
Fig. 3-13. Vacuum cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
Fig. 3-14. Vacuum nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 23
Fig. 3-15. Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 24
Fig. 3-16. Vacuum filter position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 24
Fig. 3-17. Clearance between stopper and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
Fig. 3-18. Bushing replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 26
Fig. 3-19. Light beam sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 28
Fig. 3-20. Picker lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 28
Fig. 3-21. Carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 30
Fig. 3-22. Carton guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
Fig. 3-23. Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
Fig. 3-24. Loader belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
Fig. 3-25. Loader belt replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 36
Fig. 3-26. Loader pusher position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 38
Fig. 3-27. Loader pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 40
Fig. 3-28. Photoelectric switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 43
Fig. 3-31. Loader shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 46
Fig. 4-1. Bottom former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 4

Fig. 4-2. Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
Fig. 4-3. Mandrel index unit backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
Fig. 4-4. Rotary joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
Fig. 4-5. Bottom heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 12
Fig. 4-6. Bottom preheater position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
Fig. 4-7. Bottom preheater nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
Fig. 4-8. Bottom heater position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
Fig. 4-9. Bottom heater element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 16
Fig. 4-10. Bottom heater element heating pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 18
Fig. 4-11. BOTTOM HEATER SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 19
XVIII M144- 7294 Issue 01

List of Figures
Fig. 4-12. Carton positioning bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20

Fig. 4-13. Pre- filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 21
Fig. 4-14. Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 22
Fig. 4-15. BOTTOM HEATER SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 22
Fig. 4-17. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 23
Fig. 4-18. ADJUST HEATERS (1/3) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 23
Fig. 4-19. Numeric keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 24
Fig. 4-20. Bottom breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 26
Fig. 4-21. Wing position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 28
Fig. 4-22. Folding arm position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 29
Fig. 4-23. Pusher position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 30
Fig. 4-24. Carton holder position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 30
Fig. 4-25. J- flap breaker position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 31
Fig. 4-26. Folding rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 33
Fig. 4-27. Bottom sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 34
Fig. 4-28. Pressure pad position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 35
Fig. 4-29. Pressure pad position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 35
Fig. 4-30. Emboss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
Fig. 4-31. Seal pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
Fig. 4-32. Carton dust cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 38
Fig. 4-33. Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 39
Fig. 5-1. Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4

Fig. 5-2. Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 6
Fig. 5-3. Vacuum cup position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 8
Fig. 5-4. Vacuum cup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 9
Fig. 5-5. Vacuum nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 9
Fig. 5-6. Vacuum filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 10
Fig. 5-7. Vacuum filter position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 10
Fig. 5-8. Unloader pusher position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 11
Fig. 5-9. Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 12
Fig. 5-10. Relation between the mandrel and the turret (1/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 14
Fig. 5-11. Position between mandrel and turret (2/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 15
Fig. 5-12. Position between mandrel and turret (3/3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 15
Fig. 5-13. Position between turret guide and carton holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 16
Fig. 5-14. Bevel gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 20
Fig. 5-15. Unloader guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 22
Fig. 6-1. Conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 4

Fig. 6-2. Carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
Fig. 6-3. Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 8
Fig. 6-4. Carton holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 10
Fig. 6-5. Centring of carton holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 12
Fig. 6-6. Conveyor chain tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 14
Fig. 6-7. Bottom rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 15
Fig. 6-8. Bottom rail height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 16
Fig. 6-9. Adjustment for 1,000ml . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 18
Fig. 6-10. Adjustment for 750ml . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 19
M144- 7294 Issue 01 XIX

List of Figures

Fig. 6-13. Carton holder position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 21
Fig. 6-14. Clip position of the carriage conveyor (correct) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 23
Fig. 6-15. Clip position of the carriage conveyor (not correct) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 23
Fig. 6-16. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 24
Fig. 6-21. Empty carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 30
Fig. 6-22. Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 32
Fig. 6-24. Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 34
Fig. 7-1. Carton decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 4

Fig. 7-2. Carton decontamination diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 6
Fig. 7-3. Hydrogen peroxide spray assembly (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 10
Fig. 7-4. Hydrogen peroxide spray assembly (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 11
Fig. 7-5. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
Fig. 7-6. SET MODE window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
Fig. 7-7. MANUAL screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
Fig. 7-8. CARTON DECONTAMINATION SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 17
Fig. 7-9. CARTON DECONTAMINATION SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 18
Fig. 7-10. MANUAL screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 18
Fig. 7-11. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 18
Fig. 7-13. DECONTAMINATION SECTION (2/3) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 19
Fig. 7-14. Hydrogen peroxide spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 20
Fig. 7-15. Hydrogen peroxide spray injection needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 22
Fig. 7-16. Spray nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23
Fig. 7-17. UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 24
Fig. 7-19. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 26
Fig. 7-20. RUNNING HOURS (1/4) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 26
Fig. 7-21. UV- lamp unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 27
Fig. 7-22. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 28
Fig. 7-23. SYSTEM CLEARANCE screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 28
Fig. 7-26. CARTON DECONTAMINATION SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 29
Fig. 7-27. Jig for UV- lamp meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 30
Fig. 7-28. Measure the intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 31
Fig. 7-29. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 32
Fig. 7-30. SET MODE window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 32
Fig. 7-32. Glass breakage detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 36
Fig. 7-34. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 38
Fig. 7-36. DECONTAMINATION SECTION (3/3) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 39
Fig. 7-37. Hydrogen peroxide drying heater (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 40
XX M144- 7294 Issue 01

List of Figures
Fig. 7-38. Hydrogen peroxide drying heater (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 41

Fig. 7-40. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 42
Fig. 7-43. Drying heater element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
Fig. 7-45. CARTON DECONTAMINATION SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 45
Fig. 7-47. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 46
Fig. 7-49. TOP SEAL SECTION (1/3) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 47
Fig. 8-1. Product filling (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4

Fig. 8-2. Product filling (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 5
Fig. 8-3. Horizontal carton guide (with caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 8
Fig. 8-4. Horizontal carton guide (No- caps) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 8
Fig. 8-5. Vertical carton guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 9
Fig. 8-6. In case of screen nozzle (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 9
Fig. 8-7. In case of rubber nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 10
Fig. 8-8. Filler tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 11
Fig. 8-9. Screen nozzle (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 12
Fig. 8-10. Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 13
Fig. 8-11. In case of screen nozzle (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 14
Fig. 8-12. Nozzle cap orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 14
Fig. 8-13. Nozzle alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 14
Fig. 8-14. Sequence of screen and spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 15
Fig. 8-15. Details of screen and spacer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 16
Fig. 8-16. Rubber nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 17
Fig. 8-17. Temporary placement of servo motor and speed reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 18
Fig. 8-18. Housing assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 20
Fig. 8-21. Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 22
Fig. 8-22. Filler tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 24
Fig. 8-23. Pressure switch and float switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 26
Fig. 8-31. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 29
Fig. 8-33. Creating space for diaphragm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 30
Fig. 8-34. Diaphragm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 32
Fig. 8-36. alarm light and buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 33
Fig. 8-37. Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 34
M144- 7294 Issue 01 XXI

List of Figures
Fig. 8-39. Float switch for detecting broken diaphragm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 35

Fig. 8-40. Timing belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 36
Fig. 8-41. The regulator for changing suck back air pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 40
Fig. 8-42. FILLING SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 40
Fig. 8-43. Liquid leaks from the rubber nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 41
Fig. 8-44. Air is taken in from the rubber nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 41
Fig. 8-46. FILLER SUCKBACK SETTING window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 42
Fig. 8-47. Checking and replacing of suck back membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 43
Fig. 8-48. Filler nozzle position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 44
Fig. 8-49. Rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 46
Fig. 8-50. Rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 48
Fig. 8-51. Level switch case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 50
Fig. 8-55. Jig for fitting seal (Step 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 52
Fig. 8-60. Jig for inserting rotary plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 55
Fig. 8-61. Jig for fitting O- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 56
Fig. 8-62. Rotary valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 57
Fig. 8-65. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 58
Fig. 8-68. Rotary valve timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 59
Fig. 8-70. Filling section shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 62
Fig. 8-71. Filling section shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 63
Fig. 8-72. Carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 64
Fig. 8-73. Fibre sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 65
Fig. 8-74. Fibre sensor amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 66
Fig. 8-75. Carton guide position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 66
Fig. 8-76. Lifter rod position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 67
Fig. 8-77. Stripper height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 67
Fig. 8-79. Stripper position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 70
Fig. 8-82. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 72
Fig. 8-85. Carton lifter rod and stripper height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 73
Fig. 9-1. Top former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 5

Fig. 9-2. 1st. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 6
Fig. 9-3. 1st. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
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List of Figures
Fig. 9-4. Anvil position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9

Fig. 9-5. Pad position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
Fig. 9-6. Carton stopper position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
Fig. 9-7. Wing angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
Fig. 9-8. Carton pusher position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 11
Fig. 9-9. Carton dust remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 12
Fig. 9-10. Cover position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 13
Fig. 9-11. Air nozzle position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
Fig. 9-12. Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
Fig. 9-13. Carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 16
Fig. 9-14. 2nd. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 18
Fig. 9-15. 2nd. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 20
Fig. 9-16. Top heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 22
Fig. 9-17. Top heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 24
Fig. 9-19. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 26
Fig. 9-22. Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 28
Fig. 9-24. TOP HEATER SECTION STATUS window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 30
Fig. 9-26. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 31
Fig. 9-28. TOP SEAL SECTION (1/3) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 32
Fig. 9-29. Cooled guide position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 33
Fig. 9-30. Top sealing section (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 34
Fig. 9-31. Top sealing section (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 35
Fig. 9-32. 1st. top sealer (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 36
Fig. 9-33. 1st. top sealer (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 37
Fig. 9-34. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 39
Fig. 9-37. TOP HEATERS/TOP SEAL window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 40
Fig. 9-38. Sealer jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 40
Fig. 9-40. Pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 42
Fig. 9-41. Pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 42
Fig. 9-42. Pattern 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 43
Fig. 9-43. Pattern 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 43
Fig. 9-44. Pattern 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 44
Fig. 9-45. Sealing pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 44
Fig. 9-46. Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 45
Fig. 9-47. Toggle joint angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 46
Fig. 9-48. Top sealer jaw position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 48
Fig. 9-49. 2nd. top sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 49
Fig. 9-50. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 50
Fig. 9-54. Sealer jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 51
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List of Figures
Fig. 9-56. Sealer jaw position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 52

Fig. 9-57. 2nd. top sealer jaw escape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 54
Fig. 10-1. Cap applicator (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 4

Fig. 10-2. Cap applicator (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 5
Fig. 10-3. Cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 8
Fig. 10-5. Cap pusher position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 12
Fig. 10-6. Cap sealer (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 14
Fig. 10-7. Cap sealer (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 15
Fig. 10-8. Escaped position of anvil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 18
Fig. 10-9. Horn position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 20
Fig. 10-10. Anvil and horn position check with jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 22
Fig. 10-11. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 24
Fig. 10-12. SET MODE window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 24
Fig. 10-13. MANUAL screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 24
Fig. 10-14. CAP SEAL window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 25
Fig. 10-15. Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 25
Fig. 10-16. Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 26
Fig. 10-17. Horn and anvil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 26
Fig. 10-18. CAP SEAL window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 27
Fig. 10-19. Disassemble a spigot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 28
Fig. 10-20. Parallel contact between anvil and horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 28
Fig. 10-21. Anvil and horn position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 29
Fig. 10-22. Timing belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 30
Fig. 10-23. Fibre sensor amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 31
Fig. 10-24. Installing horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 33
Fig. 10-25. Cap detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 34
Fig. 10-26. Fibre sensor amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 36
Fig. 11-1. Pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

Fig. 11-2. Section A in Fig. 11- 1. (for control box) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4
Fig. 11-3. Section H in Fig. 11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 5
Fig. 11-4. Section J in Fig. 11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 5
Fig. 11-5. Section H1 in Fig. 11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 5
Fig. 11-6. Section J1 in Fig 11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 5
Fig. 11-7. Section K in Fig.11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6
Fig. 11-8. Section L in Fig. 11- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 6
Fig. 11-9. Section B in Fig. 11- 1. (for general lower part of bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 7
Fig. 11-10. Section C in Fig 11- 9. & 11- 1. (for cap applicator, L- side) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
Fig. 11-11. Section D in Fig 11- 9. & 11- 1. (for cap applicator, R- side) . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
Fig. 11-12. Section E in Fig 11- 9. & 11- 1. (for broken diaphragm detection and top sealer, L- side) . . 11- 9
Fig. 11-13. Section F in Fig 11- 9. & 11- 1. (for broken diaphragm detection and top sealer, R- side) . 11- 9
Fig. 11-14. Section G in Fig. 11- 1. (for filler nozzle suck back) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 10
Fig. 11-15. Section H in Fig.11- 1. (for carton holder) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 11
Fig. 11-16. Standard graphic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 12
Fig. 11-17. Standard graphic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 13
Fig. 11-18. In- company symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 14
Fig. 11-19. Pneumatic diagram A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 15
Fig. 11-20. Pneumatic diagram B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 16
Fig. 11-21. Pneumatic diagram C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 18
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List of Figures
Fig. 11-22. Pneumatic diagram D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 20

Fig. 11-23. Pneumatic diagram E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 22
Fig. 11-24. Pneumatic diagram F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 23
Fig. 11-25. Pneumatic diagram G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 24
Fig. 11-26. Pneumatic diagram H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 25
Fig. 11-27. Pneumatic diagram J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 26
Fig. 11-28. Pneumatic diagram K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 27
Fig. 11-29. Pneumatic diagram L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 28
Fig. 11-30. Pneumatic diagram M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 29
Fig. 11-31. Pneumatic diagram N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 30
Fig. 11-32. Pneumatic diagram P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 31
Fig. 11-33. Pneumatic diagram Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 32
Fig. 11-34. Pneumatic diagram R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 33
Fig. 11-35. Pneumatic diagram S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 34
Fig. 11-36. Air cylinder manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 47
Fig. 12-1. Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 4

Fig. 12-2. UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 6
Fig. 12-3. MAIN MOTOR buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 8
Fig. 12-4. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 8
Fig. 12-6. OPERATION POWER buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 9
Fig. 12-7. OPERATION POWER buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 10
Fig. 12-9. UV- lamp controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 12
Fig. 12-10. PRODUCTION STATUS screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 14
Fig. 12-11. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 14
Fig. 12-12. RUNNING HOURS (1/4) screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 14
Fig. 12-13. MAIN MOTOR buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 15
Fig. 12-14. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 15
Fig. 12-16. OPERATION POWER buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 16
Fig. 12-18. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 17
Fig. 13-1. Main motor hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3

Fig. 13-3. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3
Fig. 13-8. Grease terminals for bottom heater, carton loader, bottom breaker and bottom sealer . . . . 13- 6
Fig. 13-9. Grease terminals for cap applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 8
Fig. 13-10. Grease terminals for encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 9
Fig. 13-11. Manual greasing for cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10
Fig. 13-12. Manual greasing for gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10
Fig. 13-13. Manual greasing for chain and sprocket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10
M144- 7294 Issue 01 XXV

List of Figures
Fig. 13-14. MANUAL screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11

Fig. 13-15. GREASE window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11
Fig. 13-17. Alarm light and buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 12
Fig. 13-18. ALARM LIST screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 12
Fig. 13-19. Alarm help screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 13
Fig. 13-20. Automatic greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 14
Fig. 13-21. Cycle M switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 15
Fig. 13-22. Block signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 16
Fig. 13-23. Detail of master distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 16
Fig. 13-24. Secondary distributor and tertiary distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 17
Fig. 13-25. Lubrication parts arrangement (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 18
Fig. 13-26. Lubrication parts arrangement A (Lower part of the bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 21
Fig. 13-27. Lubrication parts arrangement B (Bottom sealing section) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 22
Fig. 13-28. Lubrication parts arrangement C (Filling section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 23
Fig. 13-29. Automatic greasing diagram (Main diagram) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 25
Fig. 13-30. Grease diagram (General) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 26
Fig. 13-31. Secondary distributor C diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 27
Fig. 13-32. Secondary distributor D diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 27
Fig. 13-33. Secondary distributor E diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 28
Fig. 13-34. Secondary distributor G diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 28
Fig. 13-35. Secondary distributor K diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 29
Fig. 13-36. Secondary distributor L diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 29
Fig. 13-37. Lubrication arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 31
Fig. 13-38. Main motor hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 32
Fig. 13-40. MENU screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 32
Fig. 13-45. Oil replacement for speed reducer (for main drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35
Fig. 13-46. Oil replacement for mandrel index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35
Fig. 13-47. Oil replacement for bottom sealer gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
Fig. 13-48. Oil refill for cooling water rotary joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
Fig. 13-49. Oil replacement for vacuum pump (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . 13- 37
Fig. 13-50. Oil replacement for vacuum pump (for diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 37
Fig. 13-51. Oil replacement for vacuum pump (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . 13- 38
Fig. 14-1. LAMP TEST button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 4

Fig. 14-2. Drain water from the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 13
Fig. 14-3. Check excessive grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 16
Fig. 14-4. Grease removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 16
Fig. 14-5. Replacement of UV- lamp (for cartons) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 18
Fig. 14-6. Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 19
Fig. 14-7. Heater element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 20
Fig. 14-8. UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 23
Fig. 14-9. MAIN MOTOR buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 23
Fig. 14-10. SETUP screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 24
XXVI M144- 7294 Issue 01

List of Figures
Fig. 14-13. No.2 panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 25

Fig. 14-15. UV- lamp controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 26
Fig. 15-1. Carton bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5

Fig. 15-2. Carton bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
Fig. 16-1. Main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 4

Fig. 16-2. Worm gear speed reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 8
Fig. 16-3. Worm gear speed reducer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 10
Fig. 16-4. Mandrel index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 11
Fig. 16-5. Roller gear cam mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 11
Fig. 16-6. Working principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 12
Fig. 16-7. Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 14
Fig. 16-8. Replacing filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 15
Fig. 16-9. Mist separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 16
Fig. 16-10. Replacing the element and O- ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 17
Fig. 16-11. Air pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 18
Fig. 16-12. Air cylinder (CG1 lN  26 ~ 63 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 24
Fig. 16-13. Air cylinder (CG1 lA  20 ~ 63 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 24
Fig. 16-14. Air cylinder (CG1 lA  80 ~ 100 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 25
Fig. 16-15. Air cylinder (CM2 Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 26
Fig. 16-16. Air cylinder (CQ2 type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 27
Fig. 16-17. Air pressure switch - Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 28
Fig. 16-18. Air pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 29
Fig. 16-19. Heater blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 30
Fig. 16-20. Automatic grease pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 33
Fig. 16-21. Grease pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
Fig. 16-22. Grease pot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
Fig. 16-23. Inlet filter (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 36
Fig. 16-24. Vacuum pump (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 37
Fig. 16-25. Inlet filter (for diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 38
Fig. 16-26. Vacuum pump (for diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 39
Fig. 16-27. Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 40
Fig. 16-28. Heater element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 42
M144- 7294 Issue 01 XXVII

List of Figures
Personal Notes:
XXVIII M144- 7294 Issue 01

List of Tables
LIST OF TABLES
Table 0-1. Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 11

Table 0-2. Tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 12
Table 2-1. Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 15

Table 2-2. Electrical timing chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 20
Table 2-6. Solenoid valve purpose list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 57
Table 2-7. Regulator standard pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 58
Table 2-8. Maximum tightening torque of bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 71
Table 7-4. Regulator standard pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 19
Table 10-1. Torque specified . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 33
Table 11-1. Solenoid valve purpose list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 35

Table 11-2. Solenoid valve ON- OFF list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 42
Table 11-3. Standard pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 44
Table 11-4. Pressure switch & float switch & flow sensor list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 46
Table 13-1. Grease supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 5

Table 13-2. Recommended food grade grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 5
Table 13-3. Oil refill / replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 31
Table 13-4. Recommended oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 34
Table 13-5. Recommended food grade oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 34
Table 14-1. Resistance of the heater element in normal and damaged condition . . . . . . . . . . . . . . . . . . 14- 21
Table 16-1. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 5

Table 16-2. Brake gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 6
Table 16-6. Bolt tightening torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 13
Table 16-10. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 22
Table 16-14. Resistance of the heater element in normal and damaged condition . . . . . . . . . . . . . . . . . 16- 41
M144- 7294 Issue 01 XXIX

List of Tables
Personal Notes:
XXX M144- 7294 Issue 01

0 Introduction
0 INTRODUCTION
M144- 7294 Issue 01
M144- 7294 Issue 01 0- 1

0 Introduction
0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 1
0.1 EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 3

0.2 Contents of the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 4
0.3 Use of manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 4
0.4 Purpose of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 6
0.5 Symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 7
0.6 Abbreviation used in this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 8
0.7 Machine orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 9
0.8 Workstation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 10
0.9 Jig and tool lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 11
0.9.1 Jig list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 11
0.9.2 Tool list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 12
0.10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 13
0.10.1 Packing condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 13
0.10.2 Lifting packed machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 14
0.10.3 In case of storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 17
0.10.4 In case of installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 19
0.10.5 Lifting unpacked machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 20
0.10.6 Installation condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 22
0.10.7 Installation of machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 23
0.10.8 Installation of auxiliary equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 28
0.10.9 Utility connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 38
0.10.10 Basic check after installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 41
0.11 Main shaft encoder zero setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 43
0.12 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.1 Hydrogen peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.2 Vacuum pump filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.3 UV- lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.4 Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.5 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.12.6 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 44
0.13 Machine dismantle for transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 45
0.14 Machine recycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 45
0.15 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 46
0- 2 M144- 7294 Issue 01

0 Introduction
0.1 EC DECLARATION OF CONFORMITY according to Machinery Directive

2006/42/EC Original EC Declaration of Conformity
Manufacturer: Authorised Person to compile with the Techni-
cal File:
Shikoku Kakoki Co., Ltd.
No.10- 1 Nishinokawa, Tarohachisu, Siegfried Hochbein
Kitajima- Cho, Itano- Gun, Shikoku Kakoki Co., Ltd.
Tokushima Prefecture, Japan. Schiess- Straße 55, 40549
Düsseldorf, Germany
TEL:+49 211 520 2460
Description and Identification of Machinery:
Generic Denomination Cardboard Filling Machine

Machine Function The machine is intended to fill and pack liquid food products into cartons.
Machine Type Shikoku Pure- Pak Standard Carton Filling Machine
Machine Model S- PS140UC
Machine Serial Number 5016
Commercial Name ElopakR S- PS140UC
It is expressly declared that the machinery fulfils all the relevant provisions of the following EU Direc-
tives and relevant standards:
2006/42/EC DIRECTIVE 2006/42/EC OF THE EUROPEAN PARLIAMENT AND OF THE

COUNCIL of 17 May 2006 on machinery, and amending Directive 95/16/EC
COUNCIL of 15 December 2004 on the approximation of the laws of the
Member States relating to electromagnetic compatibility and repealing Direc-
tive 89/336/EEC
COUNCIL of 29 May 1997 on the approximation of the laws of the Member
States concerning pressure equipment
COUNCIL of 16 September 2009 relating to simple pressure vessels
EN1672- 2:2005+A1:2009 Food processing machinery - Basic concepts - Part 2: Hygiene requirements
EN ISO 12100:2010 Safety of machinery - General principles for design - Risk assessment and
risk reduction (ISO 12100:2010)
EN ISO 13850:2008 Safety of machinery - Emergency stop - Principles for design (ISO
13850:2006)
EN ISO 13857:2008 Safety of machinery - Safety distances to prevent hazard zones being
reached by upper and lower limbs (ISO 13857:2008)
EN ISO 14122- 2:2001 Safety of machinery - Permanent means of access to machinery -
EN ISO Part 2: Working platforms and walkways (ISO 14122- 2:2001)
14122- 2:2001/A1:2010
EN ISO 14122- 3:2001 Safety of machinery - Permanent means of access to machinery -
EN ISO Part 3: Stairs, stepladders and guard- rails (ISO 14122- 3:2001)
14122- 3:2001/A1:2010
M144- 7294 Issue 01 0- 3

0 Introduction
INTRODUCTION TO THE MANUAL
0.2 Contents of the manual

This manual provides the information for maintenance of the machine. It consists of mechanical descriptions
and maintenance procedures. All maintenance personnel must thoroughly read the manual before mainte-
nance. Please refer to the Parts Manual for information about arrangements and ordering of parts. ”Safety
Information” must be thoroughly read for the safe use of the machine. As for maintenance procedures, each
maintenance item is given in the manual. Referring to the bold- faced procedures, you can perform mainte-
nance work easily.
0.3 Use of manual

Maintenance procedures are provided in a way of explaining each maintenance item with illustration.
”Table of contents” is useful in taking a necessary information easily and quickly. Another table of contents
applied for each chapter is useful in checking the structure of the chapter.
Page Numbering
The pages are numbered consecutively within each chapter, prefixed by the chapter number, as illustrated
below. The grey area is an illustration of a page footer.
Document # and Issue # 5-14
Chapter number 5
The pages are num-
bered consecu-
tively within each
chapter
Page number 14
Questionnaire for feedback
Thanking you in advance, we urge you to complete and return the questionnaire on the next page to Elopak
and let us know your remarks and suggested improvements to this manual.
If anything in this manual appears unclear, please contact your superior or your Elopak contact.
0- 4 M144- 7294 Issue 01

0 Introduction
ELOPAK EQS GmbH Name:

Firm:
Technical Documentation Dept.
Hanns- Martin- Schleyer- Str. 17
Address:
41199 Mönchengladbach
Germany Country:
E- mail: techdoc@elopak.com
Your Opinion is of Interest to us !
Please use this form and let us have your comments:
Poor Satisfactory Good
Organisation of content - - -
Page and text layout - - -
Is it easy to find what you are looking for in the manual - - -
Level of detail in descriptions - - -
Phrasing (is it complicated to understand the meaning of the text) - - -
Quality of paper, print, binder, etc. - - -
In reading this manual, have you come across any inaccuracies or errors?
Comments:
M144- 7294 Issue 01 0- 5

0 Introduction
0.4 Purpose of the machine

This filling machine is intended to pack liquid food
products for human consumption only.
No food product may be packed on this filling ma-
chine without prior written agreement from Elopak.
The products must only be filled into required (ap-
proved) cartons, manufactured by Elopak. No other
carton may be used without prior written agree-
ment from Elopak.
The machine requires cleaning and sanitising ac-
cording to instructions in this manual prior to filling
of any product.
The filling machine has 2 conveyors, 1 (L- side), 2
(R- side). The conveyors index the cartons through
the guarding at a maximum speed of 3,500 in-
dexes per hour, giving a maximum output of
14,000 cartons per hour, when both sides are run-
ning.
The machine can fill a variety of commercial prod-
ucts into cartons.
Fig. 0-1. Cartons The Programmable Logical Controllers (PLC) auto-
matically set the carton feed and load, conveyor
and filling sections for the carton size selected.
The filling machine has 4 operating modes, PRO-
DUCTION, CIP, END and MANUAL mode.
(The Manual mode is not required to operate the
filling machine. This mode is only for use by autho-
rised personnel.)
0- 6 M144- 7294 Issue 01

0 Introduction
0.5 Symbol
The following symbols for switch indicate;
The lamp will turn on.
Fig. 0-2. The lamp will turn on
The lamp will flash.
Fig. 0-3. The lamp will flash
The lamp will turn off.
Fig. 0-4. The lamp will turn off
M144- 7294 Issue 01 0- 7

0 Introduction
0.6 Abbreviation used in this manual
approx. approximately
AT Auto Tuning
AV Actual Value
CIP Cleaning In Place
CPU Central Processing Unit
E/M Electrical Manual
ESL Extended Shelf Life
FOF Forced Opening Filler
GP Graphic Panel
L- side Left side
LED Light Emitting Diode
MANU. Manual
max. maximum
min. minimum
M/M Maintenance Manual
O/M Operator’s Manual
OPE. Operation
PE Polyethylene
PLC Programmable Logic Controller
PLS Pulse
P/M Parts Manual
R- side Right side
RST Reset
SIP Sanitising In Place
SSR Solid State Relay
SV Set Value
Temp. Temperature
UC Ultra Clean
0- 8 M144- 7294 Issue 01

0 Introduction
0.7 Machine orientation
R- side
(1)
(2)
(3)
L- side
(2) (1)
(3)
Fig. 0-5. Machine orientation
No. Orientation
(1) Carton feed
(2) Carton discharge
(3) Carton flow
M144- 7294 Issue 01 0- 9

0 Introduction
0.8 Workstation
13000
600
2310
1100
6000
1604
Fig. 0-6. Workstation
The grey area represents the workstation. Depending on the operator’s needs, the workstation can be
broadened.
0- 10 M144- 7294 Issue 01

0 Introduction
0.9 Jig and tool lists
0.9.1 Jig list

Note ! Refer to the Parts Manual for additional information.
Page IND No. Section Intended use Refer to

No.
Transportation locking Transportation locking M/M 0.10.1
03012 063,064, Frame cover Lifting bracket M/M 0.10.5
067,068,
093
UV- lamp unit Jig for the UV- lamp intensity meter (Op- M/M 7.3.5
tion)
31010 046 Filler piston section Jig for installing the diaphragm M/M 8.2.1.5,
8.2.3
062 Jig for replacing the spline nut
31040 001 Combifiller Jig for inserting rotary plug M/M 8.2.13
Inserting ES31C002 into ES31C003 in-
002
side ES31C001
501
502
003 Jig for fitting seal
Fitting ES31C007, 008, 009, 503, 504,
004
507 to ES31C006
007
005 Jig for inserting rotary plug
503 Positioning ES31C001
006 Jig for fitting O- ring
Fitting ES31C506 to ES31C004
31020 097 Jig for temporary replacement of servo M/M 8.2.1.5,
motor and speed reducer for driving 8.2.3
(31022) 099
rotary valve
32030 047 Filler nozzle section Jig for nozzle alignment M/M 8.2.1.2
38142 050 Cap applicator Jig for spigot alignment M/M10.4.3
(anvil side)
41050 014 Top seal Jig for adjusting toggle angle in the 1st. M/M 9.7.1.5
top sealing section
(41052) 015
Table 0-1. Jig list Part 1 of 1
M144- 7294 Issue 01 0- 11

0 Introduction
0.9.2 Tool list

Note ! Refer to the Parts Manual for additional information.
Page No. IND Section Intended use Refer to

No.
A set of disassembly
tools
27030 555 Hydrogen peroxide Cleaning tool for the hydrogen peroxide M/M 7.2.8
spray section spray nozzle (AKIJET)
(Repair Parts Manual Page 90240
IND.No.9)
32030 038 Filler nozzle section Special spanner for nozzle tip M/M 8.2.1.2
M/M 8.2.1.4
001 Nozzle cap removal Disassembly jig for nozzle cap removal O/M 6.1.3.22
M/M 8.2.1.2
002
003
004
005
32070 518 CIP box Spanner for tightening the nut (IND No. O/M 6.4.1
517) when installing the CIP box Step 8
38160 010 Cap applicator Spanner for tightening the horn, booster, M/M 10.4.11
(horn side) converter
Torque wrench:KON730- 020- 001
41042 509 Top seal Wrench for adjusting spring pressure in M/M 9.7.1.3
the 1st. top sealing section
41050 505 Top seal Spanner for adjusting sealer jaws in the M/M 9.7.1
1st. top sealing section
Table 0-2. Tool list Part 1 of 1
0- 12 M144- 7294 Issue 01

0 Introduction
0.10 Installation
0.10.1 Packing condition
(1)
(3) (2) (3)
Fig. 0-7. Packing condition
Filler tanks, piping of bottom heaters, guarding doors, piping for the filler tanks, HEPA units, discharge con-
veyor and magazines are removed from the machine for shipment. These units are packed separately in
wooden boxes.
The gravity centre is marked on the wooden boxes (blue sheet) as shown in the above drawing.
The packing list showing the size and weight is attached on the wooden box of the machine.
No.
(1) Wooden box
(2) Centre of gravity
(3) Transportation locking
0.10.1.1 Packing list
Note ! Packing list shows the weight of each box as example below.
Case No. Description of goods (L×W×H) Net (kg) Gross (kg)

1 Main body 1023×283×334 cm 14,700 17,700
2 Accessories 477×207×220 cm 1,700 2,400
M144- 7294 Issue 01 0- 13

0 Introduction
Case No. Description of goods (L×W×H) Net (kg) Gross (kg)

3 Accessories 97×197× 170 cm 160 360
4 Accessories 207×187×136 cm 300 500
0.10.2 Lifting packed machine
Lift and move the packed machine and equipment with special care to avoid any damage.
Use only chains, slings or wires long enough to ensure lifting angle requirements.
Note ! Contact specialists for lifting the wooden box.
Note ! When lifting the wooden box, various external forces are applied to it. If excessive external
forces are applied, the wooden box can be damaged.
Note ! Shipping mark and packing list (1) are attached on the wooden box. Check that the descrip-
tion matches the order.
B
A
(2)
C
(1)
Fig. 0-8. Lifting wooden box
0- 14 M144- 7294 Issue 01

0 Introduction
0.10.2.1 Caution when lifting wooden box
1. A crane with a minimum lifting capacity of 20

tons must be used to lift the packed machine.
Note ! If you use a truck- mounted crane, a

minimum lifting capacity of 50 tons is
recommended. For more detail, con-
tact specialists.
2. Lifting position (2) is shown on the wooden box.

Tighten chains, slings or wires at the correct
position. Refer to Fig. 0-8.
3. Lifting angles A, B of chains, slings or wires
should be less than 60_ in principle.
Refer to Fig. 0-8.
a) If the lifting position of chains, slings or wires is

too wide, the load is applied at the centre of the
wooden box. The wooden box bends upward.
Fig. 0-9. Bad lifting example 1
b) If the lifting position of chains, slings or wires is

too narrow, the load is applied at both sides of
the wooden box. The wooden box bends down-
ward.
M144- 7294 Issue 01 0- 15

0 Introduction
4. When tightening chains, slings or wires, com-

pression force is applied to the top surface of
the wooden box, causing damage to the wood-
en box. Compression force becomes stronger if
chains, slings or wires are short. Protect the
points C by use of proper reinforcement materi-
als. Refer to Fig. 0-8.
a) Damage can be caused by use of short chains,

slings or wires.
5. When lifting and lowering the wooden box with

a crane, special care should be taken to avoid
excessive vibration and shock (grounding
shock).
Note ! Ensure the grounding area surface is

flat, leveled and strong enough to han-
dle the load, before lowering the
wooden box onto it.
0- 16 M144- 7294 Issue 01

0 Introduction
0.10.3 In case of storage

0.10.3.1 Short term storage (less than 3 months)
The machine and the auxiliary equipment should be stored in a proper warehouse with a controllable envi-
ronment.
Note ! The machine and the auxiliary equipment are protected by barrier packaging in the wooden
boxes. It is effective approximately in first 6 months for indoor storage and 3 months for
outdoor storage. However, the proper measures should be taken as described below.
A good warehouse or storage place has:
 A stable temperature, preferably in the range from 10_C to 50_C. If the anti- condensation heaters are
energised, and the surrounding air is above 50_C, make sure that the machine and the auxiliary equip-
ment are not overheated.
 Low relative air humidity, preferably below 75%. The temperature of the machine should be kept above
dew point to prevent moisture from condensing inside the wooden boxes.
 A stable support free from excessive vibrations and shocks. If vibrations are suspected to be too high, the
wooden boxes should be isolated by placing suitable rubber blocks under wooden boxes.
 Air which is ventilated, clean and free from dust and corrosive gases.
 Protection against harmful insects and vermin.
To store the machine outdoors:
 Cover the wooden boxes to prevent rain from entering them. The cover should allow ventilation of the
wooden boxes.
 Place the wooden boxes on at least 100mm high rigid supports. This prevents moisture from entering the
wooden boxes from below.
 Use anti- condensation heaters or alternative method of heating for heating the wooden boxes and pre-
venting moisture from condensing in the wooden boxes.
 Protect from harmful insects and vermin.
0.10.3.2 Long term storage (3 - 6 months)
In addition to the measures described in 0.10.3.1, some extra measures need taken depending on whether
the machine is stored indoors or outdoors.
Storage indoors
To store the machine indoors:
 Keep on taking measures described in 0.10.3.1.
Storage outdoors
To store the machine outdoors:
 Take all measures described in Storage indoors above.

 Cover the machine completely with a big enough waterproof cover.
 Unpack the wooden boxes.
 Protect the bare shaft surfaces and non painted parts with anti corrosive agent except the parts made of
stainless steel.
M144- 7294 Issue 01 0- 17

0 Introduction
0.10.3.3 Very long term storage (over 6 months)
Clean all the protected surfaces listed in 0.10.3.1 and 0.10.3.2 and renew the anti- corrosive treatment every
12 months. Otherwise follow the instructions for shorter storage periods.
0.10.3.4 Regular checks during storage
The following checks should be made regularly during storage.
Every month:
 Check that the anti- condensation heaters or alternative method of heating the machine is working.
 Check that the ventilation works.
Every 3 months:
 Check that there is no corrosion on the surfaces. If corrosion is observed, remove the corrosion and pro-
tect the surfaces.
 Check that the anti- corrosion agents have not cracked.
0.10.3.5 Storage and care after installation
If the machine will not be in operation for a longer period of time after installation, the same measures as in
0.10.3.1 should be applied. Remember to rotate the main shaft 10 revolutions at least every 3 months.
0- 18 M144- 7294 Issue 01

0 Introduction
0.10.4 In case of installation
0.10.4.1 Unpacking the machine
1. Open up the wooden boxes of the machine and

auxiliary equipment by use of suitable tools.
Note ! The auxiliary equipment and/or parts

removed for shipping purposes are to
be found in the wooden boxes.
Fig. 0-12. Remove contents from wooden box
0.10.4.2 Recycle of material required for

transport
After unpacking the machine and auxiliary equip-

ment, the wooden boxes have to be removed. The
wooden boxes can be recycled or burned. The
plastic material around the machine can be re-
cycled.
The transportation locking is made of steel and can
be recycled. Transportation locking can also be
stored for possible reuse.
The sea trial package to some countries has spe-
cial requirements, and is made of e.g. impregnated
wood that must be recycled in accordance with the
local regulations.
M144- 7294 Issue 01 0- 19

0 Introduction
0.10.5 Lifting unpacked machine
(4)
(1)
(2)
(3)
B
C A
Fig. 0-13. Lifting unpacked machine
No. Parts CAUTION !

Before lifting the machine onto the foundation,
(1) Centre of gravity
check the foundation. Place the machine on a
(2) Chain flat, stable, vibration- free surface that is strong
(3) Bracket enough to support its weight. 7
Machine weight : 15,020 kg
(4) Hoisting jig
Machine legs : 10
Load for one foot : more than 1,502 kg.
Standard
A 8,931 mm
B 3,650 mm
C 2,080 mm
0- 20 M144- 7294 Issue 01

0 Introduction
Note ! The load on each foot varies due to

the centre of gravity.
Note ! A crane with a minimum lifting capac-

ity of 20 tons must be used to lift the
machine.
Note ! Lifting chains must not rub against

sides of the machine.
Position the hoisting jig (4) between
the chains, clamp chains to the hoist-
ing jig and slowly tighten the chains.
Note ! If the lifting position of chains, slings

or wires is too wide, the load is ap-
plied at the centre of the machine.
The machine bends upward.
Note ! If the lifting position of chains, slings

or wires is too narrow, the load is ap-
plied at both sides of the machine.
The machine bends downward.
Each bracket (3) (refer to Fig. 0-13. ) has 40mm

hole (5) in diameter at the tip so that the machine
can be lifted by a crane.
Refer to the Parts Manual (Page No. 03012, Index
No. ES03A063, 064, 067, 068, 093).
(3) (5)
No. Parts
(5) 40mm hole
Note ! Lifting brackets are dimensioned for

the weight of the machine. Do not ap-
Fig. 0-14. Bracket ply extra loads.
Note ! Check that lifting brackets are undam-

aged before lifting.
Note ! Lifting brackets fixing bolts must be

tightened before lifting.
M144- 7294 Issue 01 0- 21

0 Introduction
0.10.6 Installation condition
The machine is transported and lifted as one unit

onto the foundation.
Refer to Fig. 0-13. and Fig. 0-15.
CAUTION !
The customer is responsible for machine
installation (unless mentioned otherwise in the
contract). Shikoku Kakoki cannot be held re-
sponsible for damage which may occur to the
machine or to surrounding equipment subse-
quent to:
S Excessive transmitted vibrations.

S Poor design of foundations and/or structures.
S Poor installation.
S Alignment fault.
S Poor storage conditions.
S Non- respect of check instructions before start-
up.
S Incorrect electrical connection.
In order to ensure a long and satisfactory lifetime
of the machine, the machine has to be properly
installed.
Note ! The installation of the machine is to

be supervised by Elopak personnel.
Note ! Before the machine arrives, take ac-

count of the access into the building.
Note ! The machine should be installed in

non- corrosive, non- flammable, and
non- explosive atmosphere.
Refer to the machine specifications
2.1.
Note ! Electrical connection must be done by

authorised personnel when the ma-
chine is at rest.
0- 22 M144- 7294 Issue 01

0 Introduction
0.10.7 Installation of machine
0.10.7.1 Required space
C D
A
B
Fig. 0-15. Required space
Reserve enough space for production and main- Standard

tenance work.
Projected space : 55.2 m2 A 11,530 mm
Space for maintenance : 78.0 m2
B 13,000 mm
C 4,800 mm
D 6,000 mm
E 5,000 mm
M144- 7294 Issue 01 0- 23

0 Introduction
0.10.7.2 Installation procedure
WARNING
NEVER STAND UNDER THE MACHINE
WHEN IT IS BEING LIFTED FOR TRANS-
PORTATION. THE MACHINE MAY FALL,
CAUSING ACCIDENTS RESULTING IN
DEATH OR INJURY.
1. Slowly raise the machine off the truck, turn and

lower until machine legs (1) are approximately
150 mm from the ground.
No. Parts
(1) Leg
(1)
A Standard
A 150 mm
Fig. 0-16. Lowering the machine
2. Position 6 roller skates at positions (2) (3) and

(4) on both sides of the machine.
Note ! Do not use a fork lift truck to push the

machine into position, only use to pull
the machine with ropes attached to
the brackets (refer to Fig. 0-13. (3)) , or
to act as a brake when moving ma-
chine down a slope.
Slowly and carefully move the machine into final

position.
(4)
(3)
(2)
Fig. 0-17. Roller skates position
0- 24 M144- 7294 Issue 01

0 Introduction
3. Lower the machine ensuring the legs are lo-

cated in the centre of the roller skates (5).
CAUTION !
(5) Machine weight : Approximately 16,000kg
(without option).
Ensure the equipment (rollers) used for ground
transportation can handle the load before low-
ering the machine onto it.
Note ! Secure the machine in position before

Fig. 0-18. Machine legs next step.
No. Parts
(5) Roller skate
4. Using min. 2 jacks with min. 15 tons capacity,

raise one side of the machine evenly. Remove
one roller at the time and adjust the leg height.
Position the machine feet (7) under the leg (1).
Slowly lower the machine evenly ensuring the
legs are located correctly in the machine feet.
Repeat the step on the other side.
Note ! Use proper machine feet.

(6)
No. Parts
(6) Stand
(7) Foot
(8) Jack point
(9)
(9) Locknut
(1)
(7)
(8)
Fig. 0-19. Jack point
M144- 7294 Issue 01 0- 25

0 Introduction
Note ! Standard discharge level (B) is ap-

proximately 986 mm from the ground.
5. Check the height of discharge level.

If it is not the standard value, continue with the
next step.
Standard
B 986 mm
6. Using the jacks, raise the discharge end evenly

to correct height. Adjust legs (1) by turning.
7. After adjustment, remove the transportation
lockings (10).
B
(10) (1)
Fig. 0-20. Discharge level
8. Using the jack and spirit level (11) adjust the

legs so that the machine is level from the carton
picker to the discharge section.
No. Parts
(11) Spirit level
(11)
Fig. 0-21. Level machine - length
0- 26 M144- 7294 Issue 01

0 Introduction
9. Using the jack and spirit level (11) adjust the

legs so that the machine is level across its
width. Check the level from the carton picker to
the discharge sections.
(11)
Fig. 0-22. Level machine - width
10.After adjustment lock the legs with the locknuts

(9). Refer to Fig. 0-19.
11.After adjustment, remove the lifting equipment.

(12) Remove 20 bolts (12) to detach 10 brackets.
Refer to Fig. 0-14.
No. Parts
(12) Bolt
12.Attach 20 bolts to the machine frame.
Fig. 0-23. Remove bracket
M144- 7294 Issue 01 0- 27

0 Introduction
0.10.8 Installation of auxiliary equipment
(4)
(5)
(13)
A
(3) (7) (2) (1) (6) (14) (12) (11) (8)
(9)
C
(10)
Fig. 0-24. Installation of auxiliary equipment
Note ! Install the auxiliary equipment (Filler tanks, bottom heater piping, etc.) to the machine.
Note ! The auxiliary equipment may not be always at the same location as in Fig. 0-24.
Note ! For packing list case No, refer to 0.10.1.1.
0- 28 M144- 7294 Issue 01

0 Introduction
No. Parts Approx. No. Parts Approx.

weight(kg) weight(kg)
(1) Filler tanks (2 tanks in total) 200 (8) Bottom heater piping 200
(2) Piping around the tank (in- 60 (9) CIP piping including the auto valves 40
cluding valves) (AV4, AV5, AV9, and AV10 on the
discharge side)
(3) Tank bracket (in total) 83 (10) CIP recovery pump 35
(4) Ladder for the platform 65 (11) Cover 7.5
(5) Plate (in total) 30 (12) Grease pan (in total) 110
(6) HEPA unit (for filling section) 150 (13) Magazine (4 magazines) 180
(7) Handrail for the platform (in 100 (14) Doors with tempered glass window 150
total) in stainless steel frames (in total)
 Machine dimensions
Standard CAUTION
A 11,530 mm
B 4,800 mm BECAUSE OF THE WEIGHT OF THE
COMPONENTS, AUTHORISED PER-
C 3,955 mm
SONNEL SHOULD HANDLE HEAVY
COMPONENTS TO PREVENT DANGER-
OUS SITUATIONS.
Note ! Some of the auxiliary equipment is

equipped with lifting eyes.
The lifting eyes are dimensioned for
the weight of the equipment.
Do not apply extra loads.
Note ! Check that lifting eyes are undamaged

before lifting.
Note ! Lifting eyes must be tightened before

lifting.
Note ! Some of the auxiliary equipment re-

quires electrical connection that must
be done by authorised personnel.
Note ! Electrical connections must be done

according to electrical documentation
supplied with the machine.
M144- 7294 Issue 01 0- 29

0 Introduction
1. Assemble filler tank (1), piping and valves (2).
Note ! The filler tank has grips (15) to be

used for lifting.
(2)
(16)
No. Parts
(1) Filler tank
(2) Piping around the tank (including valves)
(1)
(15) (3) Tank bracket
(15) Grip
(16) Tank lid
(3)
Fig. 0-25. Assemble filler parts
2. Assemble ladder (4) and plate (5).
No. Parts
(4) Ladder for platform
(4) (5) (5) Plate
(5) (5)
Fig. 0-26. Assemble ladder and plate
0- 30 M144- 7294 Issue 01

0 Introduction
3. Assemble HEPA units (6).
(17) (6) (17) Note ! The HEPA unit has eye bolts (17) on
the top to be used for lifting.
No. Parts
(6) HEPA unit
(17) Eye bolt
Fig. 0-27. Assemble HEPA unit
4. Assemble handrail (7) for the platform.

(7)
No. Parts
(7) Handrail
Fig. 0-28. Assemble handrail
M144- 7294 Issue 01 0- 31

0 Introduction
5. Assemble cover (11).
No. Parts
(11) (11) Cover
Fig. 0-29. Assemble cover
6. Assemble bottom heater piping (8).

(18) (20) (8) (19)
No. Parts
(8) Bottom heater piping
(18) Heater blower
(19) Pre- filter
(20) Air filter
Fig. 0-30. Assemble bottom heater piping
0- 32 M144- 7294 Issue 01

0 Introduction
7. Assemble CIP piping including auto valves (9).
No. Parts
(9) CIP piping including auto valves
(9)
Fig. 0-31. Assemble CIP piping including auto

valves
8. Assemble CIP recovery pump (10).
No. Parts
(10) CIP recovery pump
(10)
Fig. 0-32. Assemble CIP recovery pump
M144- 7294 Issue 01 0- 33

0 Introduction
9. Assemble grease pan (12).
No. Parts
(12) Grease pan
(12)
Fig. 0-33. Assemble grease pan
10.Assemble magazine (13).
No. Parts
(13) Magazine
(13)
Fig. 0-34. Assemble magazine
0- 34 M144- 7294 Issue 01

0 Introduction
11.Assemble tank (21) for hydrogen peroxide

spray.
No. Parts
(21)
(21) Tank for hydrogen peroxide spray
Fig. 0-35. Assemble tank for hydrogen peroxide

spray
12.Hang doors (14).
No. Parts
(14) Guarding door
(14) (14)
Fig. 0-36. Hang doors
M144- 7294 Issue 01 0- 35

0 Introduction
13.Assemble UV- lamp (22) for potable water.
(22)
No. Parts
(22) UV- lamp
Fig. 0-37. Assemble UV- lamp for potable water
0- 36 M144- 7294 Issue 01

0 Introduction
Remark ! The rest of the page is intentionally left blank !
M144- 7294 Issue 01 0- 37

0 Introduction
0.10.9 Utility connection
(5)
(10)
(10)
(5)
Y X
(7)
(6) (9)
(11)
(3)
(1)
(2) (13)
(8) (4)
(12)
View Y View X
Fig. 0-38. Utility connection
0- 38 M144- 7294 Issue 01

0 Introduction
Connect the customer utilities to the inlets on the

machine.
No. Parts
(1) Compressed air inlet
(2) Potable water inlet
(3) Chilled water inlet
(4) Chilled water return
(5) Product / CIP inlet
(6) Product drain
(7) CIP recovery
(8) Drain water outlet
(9) ELOFOAM inlet
(10) Cooling water inlet
(11) Cooling water outlet
(12) Ethanol inlet
(13) Electrical source
CAUTION !
Install the piping in order not to flow back the
drain water to the machine.
Note ! For pipe size, refer to the specifica-

tions in chapter 2.
Follow the procedures described below to sanitise

the potable water piping before connecting it to
potable water inlet (2).
1. Prepare the following sanitiser.

Recommended chemical : Oxonia active
Condition Criteria
Concentration 1.0%
Fluid volume 200 L
Temperature 20~40 _C
CAUTION !
Note the above recommended concentration
and temperature. Sanitising effect will be re-
duced if concentration is less than 1.0% and/or
temperature is less than 20_C.
M144- 7294 Issue 01 0- 39

0 Introduction
WARNING
ALWAYS WEAR PROTECTIVE GEAR
(FULL FACE MASK, GOGGLES, RUBBER
GLOVES, RUBBER APRON AND RUB-
BER BOOTS, ETC.) TO AVOID CONTACT
WITH EYES AND SKIN.
CAUTION !
Discard oxonia active in accordance with the
local regulations.
2. Open the valve for potable water (3).

(Refer to Fig. 0-39. )
3. Keep supplying the prepared sanitiser from the
potable water inlet (2) with a pump.
Condition Criteria
Average flow 5 L/min
Supply time More than 20 min
If the average flow is not around 5 L/min, adjust the

flow by the hand valve (3).
4. Sanitising is completed at 20 minutes after it
starts.
0- 40 M144- 7294 Issue 01

0 Introduction
0.10.10 Basic check after installation
1. Open the valves for air (1), chilled water (2),

and potable water (3), and turn on the main cir-
cuit breaker in No.2 panel, and then turn the
operation power on.
(2) (3) (1)
Fig. 0-39. Utility connection
Note ! The machine must be indexed man-

ually prior to commissioning.
2. Slowly hand crank (4) the machine forward

(clockwise) through one cycle while checking
that all mechanical parts function without inter-
(4) ference.
CAUTION !
Do not turn the hand crank counter- clockwise.
doing so will damage the machine.
Fig. 0-40. Hand crank machine
3. Check that all emergency stop buttons (5) and

all non- contact sensors (6) are functioning.
(5)
(6)
Fig. 0-41. Emergency stop buttons & guard

switches
M144- 7294 Issue 01 0- 41

0 Introduction
4. Check that the buzzer (7) and tower light (8)

(8) function as alerting features.
(7)
Fig. 0-42. Alerting features
5. Check that the conveyor chain tension.

If the chain stretch has occurred, adjust the
conveyor chain.
(Refer to 6.3.3)
0- 42 M144- 7294 Issue 01

0 Introduction
0.11 Main shaft encoder zero

setting
Set the main synchro encoder to the home posi-
tion; 0 degree. (Refer to the following chapter de-
scribed in the Main Touch Panel Operation Manual
in the Electrical Manual)
D- 2 Main Shaft Encoder
S D- 2- 1 Auto ZERO (Home) Setting
S D- 2- 2 Manual ZERO (Home) Setting
M144- 7294 Issue 01 0- 43

0 Introduction
0.12 Disposal
0.12.1 Hydrogen peroxide 0.12.5 Oil and grease
Dilute hydrogen peroxide with water until the pH is

greater than 6 before disposal.
0.12.2 Vacuum pump filter

WARNING
1. Remove the exhaust filters and place in a poly- ALWAYS WEAR PROTECTIVE GEAR
ethylene bag. (FULL FACE MASK, GOGGLES, RUBBER
2. Remove the oil filter and place in a polyethylene BER BOOTS, ETC.) TO AVOID CONTACT
bag. WITH EYES AND SKIN.
3. Contact waste management specialists to col-
lect the waste for recycle.
CAUTION !
0.12.3 UV- lamps Oil and grease are hazardous wastes. Discard
the used oil and grease in accordance with the
Note ! UV- lamps contain a minor quantity of local regulations.
mercury.
1. Drain oil and grease from the machine.
1. 2 UV- lamps are used for carton decontamina- 2. Contact waste management specialists to col-
tion, and 1 UV- lamp for potable water decon- lect the waste for recycle or disposal.
tamination. Handle the lamp with care when
removing it.
0.12.6 Battery
2. Carefully package the lamps.
3. Contact waste management specialists to col- CAUTION !
lect the waste for recycle. Battery is a hazardous waste. Discard the used
battery in accordance to the local regulations.
0.12.4 Filters
Note ! The following applies to batteries for:
Note ! The following applies to: - PLC
- HEPA filter - Motion controller
- Pre- filter - Encoder unit
- Hydrogen peroxide filter - Servo amplifier
- Mist separator/odour removal filter
- Exhaust muffler filter 1. Remove the batteries (Lithium batteries) and
- Dust filter (carton dust cleaner, bot- place in a polyethylene bag.
tom former)
lect the waste for recycle or disposal.
1. Remove the filter and place in a polyethylene
bag.
0- 44 M144- 7294 Issue 01

0 Introduction
0.13 Machine dismantle for

transportation
CAUTION
BECAUSE OF THE WEIGHT OF THE
COMPONENTS, AUTHORISED PER-
SONNEL SHOULD HANDLE HEAVY
COMPONENTS TO PREVENT DANGER-
OUS SITUATIONS.
1. “Lock Out” the air valves and depressurise the

air system.
2. Disconnect the incoming power supply to the
machine.
3. Disconnect the utilities, and drain water with
compressed air.
4. Lift and remove the machine.
Refer to 0.10.5.
5. Wrap utility ports with vinyl after draining water.
6. Put drying reagent inside the wooden box for
packing of long term sea transportation of the
machine.
0.14 Machine recycle

1. Most machine components are made of materi-
als which can be recycled in accordance with
the local regulations.
M144- 7294 Issue 01 0- 45

0 Introduction
0.15 Personal notes
0- 46 M144- 7294 Issue 01

1 Safety information
1 SAFETY INFORMATION
M144- 7294 Issue 01
M144- 7294 Issue 01 1- 1

1 SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 1
1.1 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3

1.1.1 Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3
1.1.2 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 5
1.1.3 Safety signs and labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 6
1.1.4 Safety labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7
1.1.5 Safety label locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 13
1.2 Emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 16
1.2.1 Emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 18
1.2.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 20
1.3 Machine stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 24
1.3.1 Machine stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 25
1.4 Guarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 28
1.4.1 If doors or covers are opened . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 29
1.4.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 32
1.5 Fixed covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 38
1.6 Safety system in magazine section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 39
1.6.1 Stable supply of blanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 40
1.6.2 Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 44
1.7 Check safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.1 Check emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.2 Check machine stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.3 Check doors and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.4 Check magazine empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.5 Check loader covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.6 Check filling section doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.7 Check safety sensor in basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 50
1.7.8 Check safety sensor for UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 51
1.7.9 Check quick exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 51
1.8 Staff hygiene . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 52
1.9 Chemical hazards (Caustic, Acid, Sterilant, Hydrogen peroxide, Ethanol, Oil, Grease) 1- 53
1.9.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 54
1.9.2 Caustic and Acid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 55
1.9.3 Sterilant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.4 Hydrogen peroxide (H2O2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.5 Ethanol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 56
1.9.6 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.10 Fire hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.11 Mandatory safety equipment check list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 57
1.12 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 58
1- 2 M144- 7294 Issue 01

1.1 Check items
1.1.1 Safety precautions
FOR SAFETY, NOTE THE FOLLOWING. IF NOT, SEVERE PERSONAL INJURY, DEATH OR MACHINE
DAMAGE MAY OCCUR.
1. Only operators who have received operator’s training or are thoroughly familiar with this machine are al-
lowed to operate the machine.
2. Be sure to read this manual thoroughly and fully understand how to operate the machine before use.
3. Installation or relocation of the machine should be supervised by authorised engineer.
4. Be sure to follow the operation procedures described in this manual. If not, serious accidents may occur.
5. Warnings and cautions are included in this manual, and the safety labels are attached to the dangerous
areas in the machine. Please read and follow the instructions.
6. Never modify the machine without our agreement and permission.
7. When doing maintenance on and around the main drive section, be alert and pay special attention to any
orange- painted levers as they operate close to the floor.
8. Do the following before handling machine trouble.
b) Turn off the power.
c) Close the air inlet valve.
9. Stop the main motor before;
a) opening any doors or covers.
b) supplying blanks to the empty basket.
c) removing the blanks from the basket and magazine.
d) changing carton size.
e) cleaning the machine manually.
f) inspecting and doing maintenance work.
10.Be sure to confirm the SAFE lamp is ON for one side during production on the other side before;
a) opening the door of filling section on non- production side.
b) opening the loader cover on non- production side.
c) supplying blanks to the empty basket on non- production side.
d) removing the blanks from the basket and magazine on non- production side.
e) changing carton size on non- production side.
11.Check all safety systems function always before operating the machine.
12.Check the safety guarding is closed before operating the machine.
13.Check the hand crank is not inserted before operating the machine.
14.Jog the main motor before starting to ensure the machine operates normally.
15.Do not touch any moving parts of the machine during operation.
16.Do not open the doors and covers during operation.
17.In case of an emergency, push any of the EMERGENCY STOP buttons immediately.
M144- 7294 Issue 01 1- 3

18.Be aware that intended or unintended stops of the main motor can cause fire in cartons located under the
heaters, remove cartons if possible.
19.When trouble occurs, stop the main motor and then inspect the troubled section.
20.Do not touch the filler piping during CIP/SIP and hot water sanitising.
21.When you service the heater sections, be careful of hot surfaces.
22.Do the following before manual lubrication.
a) Turn off the power.
b) Close the air inlet valve.
23.Only authorised electrical engineer should inspect and maintain the electrical components.
24.Turn off the main circuit breaker before opening the electrical panels.
25.Turn off the main circuit breaker before replacing electrical components or tightening electrical connec-
tions.
26.Do not hose the electrical panels, switches and heaters.
27.When maintenance work is done by two or more personnel, watch out/communicate with each other for
safety.
28.Use stepladder for high- place work and wear suitable protective gear such as helmet.
29.When replacing parts, be sure to use the recommended genuine parts. Use of other parts may cause a
malfunction of the machine.
30.Check leaks from the sanitary piping frequently.
31.When you use hydrogen peroxide or work in UV- lamp radiation area, always wear protective gear (hel-
met/ full face mask, goggles, rubber gauntlets, rubber gloves, rubber apron and rubber boots, etc.).
32.Lock the main air valve and the main circuit breaker with a padlock during maintenance and service.
33.Before selecting production mode, make sure that the UV- lamp unit for cartons is not lifted. During pro-
duction mode, do not start the main motor with the UV- lamp unit for cartons lifted.
34.Before opening the hydrogen peroxide tank and ethanol tank, make sure that pressure inside the tank is 0
MPa. If not, close the main air inlet valve, open the relief valve to release the air from the tank, and open
the tank lid.
1- 4 M144- 7294 Issue 01

1.1.2 Cautions
NOTE THE FOLLOWING CAUTIONS. IF NOT, DAMAGE TO THE MACHINE MAY OCCUR.
1. Do not change the following settings;

a) Timing
b) Air regulator
c) Pressure switch
d) Frequency inverter
e) Temperature controller
f) Photoelectric switch
g) Flow switch
2. If an abnormal sound is heard, stop the main motor and find the cause.
3. If you cannot turn the hand crank smoothly, do not turn it by force but find the cause.
4. Check that no parts or tools are left in the machine before operation.
5. Check that all parts are correctly reassembled and that bolts are tightened firmly after reassembly.
M144- 7294 Issue 01 1- 5

1.1.3 Safety signs and labels
Pay attention to DANGER, WARNING, and CAUTION signs in the manual. Damages are classified into 2
categories; damage to personnel, or damage to the machine or product. Safety labels are attached to the
dangerous areas in the machine. If the safety labels become damaged or dirty, replace with new ones. When
new safety labels are necessary, please contact the machine supplier.
1. Damage to personnel
DANGER, WARNING, and CAUTION are in the box.
DANGER
GIVES NOTICE OF AN IMMINENT RISK
HAZARD OR UNSAFE PRACTICE, WHICH
COULD RESULT IN DEATH OR SEVERE
PERSONAL INJURY, IF YOU DO NOT
FOLLOW THE OPERATING PROCEDURES.
WARNING
GIVES NOTICE OF A MEDIUM RISK HAZ-
ARD OR UNSAFE PRACTICE, WHICH
COULD RESULT IN SEVERE PERSONAL
INJURY, IF YOU DO NOT FOLLOW THE
OPERATING PROCEDURES.
CAUTION
GIVES NOTICE OF A LOW RISK HAZ-
ARD OR UNSAFE PRACTICE, WHICH
COULD RESULT IN MINOR PERSONAL
INJURY, IF YOU DO NOT FOLLOW THE
OPERATING PROCEDURES.
2. Damage to the machine or product

CAUTION and Note are not in the box.
CAUTION !
gives notice of a risk that can cause damage to the machine or product.
Note ! gives useful information.
1- 6 M144- 7294 Issue 01

1.1.4 Safety labels
The safety labels are attached to the dangerous

areas in the machine. Please fully understand the
contents and follow the instructions.
1. Danger of fall hazard

This label shows fall hazard. Be careful when
working in high place and wear suitable protective
gear.
Fig. 1-1. Danger of fall hazard
2. Warning of electrical hazard

This label shows dangerous voltage orange cables
and terminal points are LIVE even with the main
circuit breaker OFF.
Fig. 1-2. Warning of electrical hazard
M144- 7294 Issue 01 1- 7

3. Warning of electrical hazard

This label shows where dangerous voltage termi-
nal points are LIVE.
Fig. 1-3. Warning of electrical hazard
4. Warning of mechanical hazard

This label shows hazardous mechanical moving
parts.
Fig. 1-4. Warning of mechanical hazard
1- 8 M144- 7294 Issue 01

5. Warning of mechanical hazard

This label shows hazardous mechanical moving
parts.
Fig. 1-5. Warning of mechanical hazard
6. Warning of chemical hazard

This label shows chemical hazard. Contact with
chemicals can burn eyes and skin. Always wear
protective gear.
Fig. 1-6. Warning of chemical hazard
M144- 7294 Issue 01 1- 9

7. Warning of UV light hazard

This label shows UV light hazard. UV radiation is
harmful to eyes and skin. Always wear protective
gear.
Fig. 1-7. Warning of UV light hazard
8. Caution of burn hazard

This label shows hot surfaces. Always wear protec-
tive gear.
Fig. 1-8. Caution of burn hazard
1- 10 M144- 7294 Issue 01

9. Caution of electrical hazard

This label shows where dangerous voltage termi-
nal points are LIVE. Contact with dangerous volt-
age can cause severe burns.
Fig. 1-9. Caution of electrical hazard
10.Caution of high temperature

The colour- changing thermo tapes are attached to
the piping where the temperature can rise. Do not
touch the piping when the colour changed to
brownish purple.
[Be careful when the colour changed.]
[Red < 70_C < Dark brownish purple]
Fig. 1-10. Caution of high temperature
M144- 7294 Issue 01 1- 11

11.Caution of splashing water

Do not hose the heaters.
Splashing water could cause damage to heater
elements.
Fig. 1-11. Caution of splashing water
12.Caution of compression hazard

Can cause severe injury.
Shut off source and depressurise device before
servicing.
Fig. 1-12. Caution of compression hazard
1- 12 M144- 7294 Issue 01

1.1.5 Safety label locations
(8) (11) (4) (8) (11) (9) (4) (9) (8)(10) (11) (8) (3) (9)
(9)
(3)
(11)
(11)
(2)
(3) (11) (3) (6) (12) (7) (8) (10) (4) (9) (8) (10) (8) (9) (10) (8)
(8) (10)
(4) (9)
(4)
(4)
(4)
(9) (1)
(10) (8)
(9) (11) (9) (10) (8) (9) (11) (9)(3) (8) (11) (8)
(8)
(9)
Y X
(9)
(3)
(11) (3)
(8) (10) (8) (10) (4) (8) (10) (4) (8)(10) (7) (4) (3) (11) (4)
Fig. 1-13. Safety label locations (1of 2)
M144- 7294 Issue 01 1- 13

(9)
(3)
(9) (9)
(3) (3)
(5)
(9)
(12)
(4) (4)
View X
(9) (9)
(3) (3)
(11) (11)
(4) (4)
View Y
Fig. 1-14. Safety label locations (2of 2)
1- 14 M144- 7294 Issue 01

(1) (3) (4)
(2)
(6) (7)
(5) (8)
(10)
(9) (11) (12)
Fig. 1-15. Safety labels
The safety labels are attached to the dangerous areas. Please fully understand the contents and follow the
instructions.
No. Safety label No. Safety label

(1) Danger of fall hazard (7) Warning of UV light hazard
(2) Warning of electrical hazard (8) Caution of burn hazard
(3) Warning of electrical hazard (9) Caution of electrical hazard
(4) Warning of mechanical hazard (10) Caution of high temperature
(5) Warning of mechanical hazard (11) Caution of splashing water
(6) Warning of chemical hazard (12) Caution of compression hazard
M144- 7294 Issue 01 1- 15

1.2 Emergency stop system
(1) (2)
(1) (1)
(3)
(2)
(5) (6)
(4) (3)
(1)
(1)
Fig. 1-16. Locations of emergency stop system
The machine is equipped with an emergency stop system.
No. Parts No. Parts

(1) Emergency stop button 1 (4) Buzzer
(2) Emergency stop button 2 (5) Safety circuit reset button
(3) Alarm light (6) Graphic panel
1- 16 M144- 7294 Issue 01

M144- 7294 Issue 01 1- 17

1.2.1 Emergency stop system
1. In case of an emergency, push the EMER-

GENCY STOP button 1 or 2. The colour of LED
(1) (1) will change to red.
Fig. 1-17. EMERGENCY STOP button 1
a) The machine stops.

(2)
b) The red colour of alarm light (2) flashes and
the buzzer (3) turns on. The buzzer will auto-
matically turn off after 3 seconds.
(3)
Fig. 1-19. Alarm light and buzzer
1- 18 M144- 7294 Issue 01

2. The SAFETY CIRCUIT RESET button (4) in the

No.1 panel and the blue colour of alarm light (5)
SAFETY CIRCUIT flash at 1- second intervals.
(4)
RESET
(5)
Fig. 1-20. SAFETY CIRCUIT RESET button and

alarm light
3. If the machine is in the PRODUCTION mode,

(6) EMERGENCY STOP (6) and VIEW ALARM (7)
flash on the PRODUCTION STATUS screen.
SERVO SYSTEM SETUP (8) appears in the
lower right of the screen.
(8)
(7)
Fig. 1-21. PRODUCTION STATUS screen
M144- 7294 Issue 01 1- 19

1.2.2 Reset
WARNING
BEFORE RESETTING THE MACHINE,
CONTACT AUTHORISED PERSONNEL.
1. After an emergency stop, manually remove all

cartons remaining in the bottom forming section
and carton loader section.
2. Check the filling section for any jammed car-
tons. Remove all jammed cartons.
3. If the doors and covers are open, close them.
4. Push VIEW ALARM (1) on the PRODUCTION

STATUS screen. The ALARM LIST screen ap-
pears.
(1)
5. EMERGENCY STOP (2) appears on the

(2) ALARM LIST screen.
Fig. 1-23. ALARM LIST screen
1- 20 M144- 7294 Issue 01

6. Turn the EMERGENCY STOP button 1 or 2

clockwise. The colour of LED (3) will change to
(3) green.
M144- 7294 Issue 01 1- 21

7. The SAFETY CIRCUIT RESET button (4) and

the blue colour of alarm light (5) turn on.
SAFETY CIRCUIT
(4)
RESET
(5)

alarm light
8. Push RESET (6) on the ALARM LIST screen.

(2) EMERGENCY STOP (2) disappears. The PRO-
DUCTION STATUS screen appears.
(6)
1- 22 M144- 7294 Issue 01

9. Push the SAFETY CIRCUIT RESET button.

The lamp and the blue colour of alarm light turn
SAFETY CIRCUIT off.
RESET

alarm light
10.Push ON (7) in the SERVO SYSTEM SETUP.

a) The servo system setup starts.
b) During setup, ON flashes.
c) After the setup is completed, the lamp stops
flashing and turns on.
11.Push and hold the MAIN MOTOR start button.
(7)
12.Cartons in the carriage conveyor are dis-

charged automatically one side at a time, start-
ing from the L- side. “MACHINE IS DIS-
CHARGING ALL CARTONS” appears in the
message box (8) on the PRODUCTION STA-
TUS screen. After the cartons are discharged,
the main motor stops.
(8) Note ! Ensure that the cartons are dis-

charged smoothly at the discharge
section.
Fig. 1-30. PRODUCTION STATUS screen 13.Check that no cartons are left in the machine
and no caps are left on the spigot or in the horn.
14.Reject all unsealed or damaged cartons dis-
charged from the machine.
M144- 7294 Issue 01 1- 23

1.3 Machine stop system
(1)
(3)
(2)
Fig. 1-31. No.1 panel
The machine is equipped with a machine stop system.
No. Parts No. Parts

(1) Graphic panel (3) Safety circuit reset button
(2) Machine stop button
1- 24 M144- 7294 Issue 01

1.3.1 Machine stop system
1. When the MACHINE STOP button is pushed,

the colour of LED (1) will change to red.
(1) The machine stops after the cartons are dis-
charged.
Fig. 1-32. MACHINE STOP button

No.1 panel and the blue colour of tower light (3)
SAFETY CIRCUIT flash at 1- second intervals.
(2)
RESET
(3)

tower light

“MACHINE STOPPED” appears in the message
box (4) on the PRODUCTION STATUS screen.
(4)
M144- 7294 Issue 01 1- 25

4. Turn the MACHINE STOP button clockwise.

The colour of LED (1) will change to green.
(1)
Fig. 1-35. MACHINE STOP button

SAFETY CIRCUIT
(2)
RESET
(3)

alarm light
1- 26 M144- 7294 Issue 01


SAFETY CIRCUIT off.
RESET

alarm light
M144- 7294 Issue 01 1- 27

1.4 Guarding
(2) (3) (2)
(4) (7) (4) (4)

(1) (2) (3) (7) (2)
(5)
(4) (4)
(5)
(6)
Detail (7) Detail (6)
(4)
View X
Fig. 1-38. Guarding
The guarding (1) covers the machine to maintain a safe and clean operation condition inside the machine.
The doors (2) (3) and covers (4) (5) are attached to the guarding. Do not open the doors and covers during
operation. However, only as long as SAFE lamp (6) or (7) is ON, the loader cover (5) and the filling section
door (3) for the non- production side can be opened while production is performed on the other side.
1- 28 M144- 7294 Issue 01

1.4.1 If doors or covers are opened
1.4.1.1 In case the machine is not operating
1. If the doors and covers are opened, the servo

power turns off except for the filler pump.
SAFETY CIRCUIT
(1) No.1 panel and the blue colour of alarm light (2)
flash at 1- second intervals.
RESET
(2)

alarm light
1.4.1.2 In case the machine is operating (Main

motor rotates, CIP/SIP, size change,
mode change, etc.)
1. If the doors and covers are opened, the servo

power turns off except for the filler pump.
2. The red colour of alarm light (1) flashes and the

(1) buzzer (2) turns on. The buzzer will automati-
cally turn off after 3 seconds.
(2)
3. The SAFETY CIRCUIT RESET button and the

blue colour of alarm light flash at 1- second in-
tervals. Refer to Fig. 1-39.
M144- 7294 Issue 01 1- 29


DOOR/COVER (3) and VIEW ALARM (4) flash
(3) on the PRODUCTION STATUS screen.
SERVO SYSTEM SETUP (5) appears in the
lower right of the screen.
(5)
(4)
1.4.1.3 In case the machine is in production

on one side and the carton feed is
SAFETY CIRCUIT stopped on the other side
Note ! You can open the filling section door

with the SAFE lamp ON when the car-
RESET
riage conveyor is stopped by pushing
the SAFE lamp switch on the No- car-
ton feed side.
Note ! The machine performs emergency

stop for safety if the loader cover or
filling section door is opened with the
SAFE lamp OFF.
1. If the loader cover (5) is opened on the No- car-

ton feed side with the SAFE lamp (6) ON, the
SAFETY CIRCUIT RESET button and the blue
colour of alarm light flash at 2- second intervals.
2. If the filling section door (3) on the No- carton
alarm light
feed side is opened with the SAFE lamp (7) ON,
the SAFETY CIRCUIT RESET button and the
blue colour of alarm light flash at 2- second in-
tervals.
1- 30 M144- 7294 Issue 01

M144- 7294 Issue 01 1- 31

1.4.2 Reset
1.4.2.1 In case the machine is not operating
SAFETY CIRCUIT 1. Close the doors and covers. The SAFETY CIR-
(1) CUIT RESET button (1) and the blue colour of
alarm light (2) turn on.
RESET
(2)

alarm light

a) The lamp and the blue colour of alarm light
SAFETY CIRCUIT
turn off.
b) The servo power automatically turns on.
c) The servo system setup automatically starts.
RESET

alarm light
1- 32 M144- 7294 Issue 01

3. The present machine status appears in the

TUS screen.
(3)
M144- 7294 Issue 01 1- 33

1.4.2.2 In case the machine is operating (Main

motor rotates, CIP/SIP, size change,
mode change, etc.)
1. After unintended stop, manually remove all car-

tons remaining in the bottom forming section
and carton loader section.
(6)
pears.
(1)
4. DOOR/COVER OPEN (2) appears on the

(2) ALARM LIST screen.
5. Close the doors and covers. The SAFETY CIR-

CUIT RESET button (3) and the blue colour of
SAFETY CIRCUIT alarm light (4) turn on.
(3)
RESET
(4)

alarm light
1- 34 M144- 7294 Issue 01


(2) DOOR/COVER OPEN (2) disappears and the
PRODUCT STATUS screen appears.
Note ! If you want to reset the alarm without

displaying ALARM LIST screen de-
scribed in steps 3 and 4, push DOOR/
COVER RESET (6) on the PRODUC-
(5) TION STATUS screen (Fig. 1-46. ).

SAFETY CIRCUIT
turn off.
RESET

alarm light
8. Push ON (7) in the SERVO SYSTEM SETUP.

a) The servo system setup starts.
b) During setup, ON flashes.
c) After the setup is completed, the lamp stops
flashing and turns on.
9. Push and hold the MAIN MOTOR start button.
(7)
M144- 7294 Issue 01 1- 35



section.
1- 36 M144- 7294 Issue 01

1.4.2.3 In case the machine is in production

on one side and the carton feed is
stopped on the other side
1. Close the filling section doors and loader cov-

ers.

SAFETY CIRCUIT
turn off.
c) The servo system setup automatically starts.
RESET

alarm light
3. The present machine status appears in the

TUS screen.
(1)
M144- 7294 Issue 01 1- 37

1.5 Fixed covers
(2) (2) (2)
(1)
(1) (2)
Fig. 1-55. Fixed covers
CAUTION !
WARNING
Do not operate without fixed covers (2). Water
may splash onto the parts under the covers,
causing parts failure.
DO NOT OPERATE WITHOUT FIXED
COVERS (1). IT IS VERY DANGEROUS.
1- 38 M144- 7294 Issue 01

1.6 Safety system in magazine section
(8)
(5)
(5) Z
View Y View X
(6) View Z
(4) X (8)
(5) (2)
(10)
(1)
(7)
(9) (3)
Fig. 1-56. Safety system in magazine section

No. Parts
A stable supply of blanks is necessary to operate (1) Carton level sensor
the machine smoothly.
(5) Zero level sensor
The sensors (1) (5) (8) (9) are attached to some
locations in the magazine section for a stable sup- (8) Safety sensor
ply of blanks and for safe operation of the machine. (9) Picker lever sensor
M144- 7294 Issue 01 1- 39

1.6.1 Stable supply of blanks
1.6.1.1 If carton level sensors detect blank

decrease
1. If the carton level sensors (1) detect blank de-

crease, blanks have decreased on the maga-
zine (2).
(11)
2. The yellow lamp (11) flashes on the PRODUC-
TION STATUS screen.
3. VIEW ALARM (12) flashes on the PRODUC-
TION STATUS screen.
(12)
(13) 4. The yellow colour of alarm light (13) flashes and

the buzzer (14) turns on. The buzzer will auto-
(14)

STATUS screen.
The ALARM LIST screen appears.
6. Supply blanks.
(Refer to Operator’s Manual 4.6.1.2)
7. If the blanks are not supplied, the picker (3) and
loader (4) on each side operate 140 times
(changeable) and then stop.
1- 40 M144- 7294 Issue 01

1.6.1.2 If blanks decrease in the basket
1. The motor (7) operates to feed blanks from the

magazine to the basket automatically by count-
ing machine cycle. (Refer to Fig. 1-56. )
1.6.1.3 If safety sensors detect magazine

empty
1. If the safety sensors (8) detect magazine empty,

there are not enough blanks in the basket (6).
(11)
2. The red lamp (11) flashes on the PRODUC-
TION STATUS screen.
TION STATUS screen.
(12)
4. The red colour of alarm light (13) flashes and

(13) the buzzer (14) turns on. The buzzer will auto-
5. The picker (3) and loader (4) stop.
(14)

STATUS screen.
Note ! In normal condition, the picker and

loader on each side operate 140 times
(changeable) after low carton level
and then stop.
M144- 7294 Issue 01 1- 41

1.6.1.4 If zero level sensors detect blanks
1. If the zero level sensors (5) detect blanks at the

same time that the safety sensors (8) detect
blanks or dummy block (10), blanks are forced
to be fed as long as you push and hold the
CARTON FEED button.
The picker (3) stops when the zero level sen-
sors (5) stop detecting blanks. All cartons in the
picker and loader sections are transferred to the
mandrels by the loader (4).
2. Follow the same steps 2 to 6 in 1.6.1.3.
1.6.1.5 If picker lever sensors detect picker

lever
1. If the picker lever sensors (9) detect picker le-

ver movement due to malfunction when no
blanks or dummy block are in the basket, the
main motor stops immediately.
a) The machine stops.

(13)
b) The red colour of alarm light (13) flashes
and the buzzer (14) turns on. The buzzer will
automatically turn off after 3 seconds.
(14)
1- 42 M144- 7294 Issue 01

2. The SAFETY CIRCUIT RESET button (15) in

the No.1 panel and the blue colour of tower light
SAFETY CIRCUIT (13) flash at 1- second intervals.
(15)
RESET
(13)

tower light
3. The red lamp (11) and VIEW ALARM (12) flash

on the PRODUCTION STATUS screen.
(11)
(12)
M144- 7294 Issue 01 1- 43

1.6.2 Reset
1.6.2.1 If carton level sensors detect blank

decrease
1. Supply blanks to the magazine.

2. When the blanks are supplied to the magazine,
the alarm will be reset automatically. The
ALARM LIST screen will change to the PRO-
DUCTION STATUS screen.
3. Push the CARTON FEED button only when the

picker stops.
The white lamp turns on.
L.CARTON FEED R.CARTON FEED
Fig. 1-66. CARTON FEED
1.6.2.2 If safety sensors detect no blanks or

no dummy block in basket
1. Wait until the SAFE lamp turns on before ac-

(1) cess to the carton supply section. (Refer to 1.4.)
2. Supply blanks to the magazine.
3. Push L1. MAGAZINE EMPTY (1) on the
ALARM LIST screen.
1- 44 M144- 7294 Issue 01

4. The Alarm help screen appears.

Push RESET (2). Only indicated alarm is reset.
The alarm list and the alarm lamp will turn off (re-
set).
Push END HELP (3) to return to the PRODUC-
TION STATUS screen.
(3) (2)
Fig. 1-68. Alarm help screen
1.6.2.3 If zero level sensors detect magazine

empty with detection of blanks or
dummy block by safety sensors
1. Wait until the SAFE lamp turns on before ac-

(1) cess to the carton supply section. (Refer to 1.4.)
2. Remove the dummy block (10) and supply
blanks to the magazine. (Refer to Fig. 1-56. )
3. Push L1. MAGAZINE EMPTY (1) on the
ALARM LIST screen.
4. The Alarm help screen appears.

Push RESET (2). Only indicated alarm is reset.
The alarm list and the alarm lamp will turn off (re-
set).
Push END HELP (3) to return to the PRODUC-
TION STATUS screen.
(3) (2)
M144- 7294 Issue 01 1- 45

1.6.2.4 If safety sensors detect picker lever
WARNING
BEFORE RESETTING THE MACHINE,
CONTACT AUTHORISED PERSONNEL.
1. Remove all cartons remaining in the bottom

forming section and carton loader section.
3. If the doors and covers are open, close them.

pears.
(1)
5. L1.MAGAZINE EMPTY (2) appears on the

ALARM LIST screen.
(2)
6. Place blanks or dummy block in the basket.
1- 46 M144- 7294 Issue 01


SAFETY CIRCUIT
(3)
RESET
(4)

alarm light

L1.MAGAZINE EMPTY (2) disappears.
The PRODUCTION STATUS screen appears.
(2) (5)
M144- 7294 Issue 01 1- 47


SAFETY CIRCUIT off.
10.Push and hold the MAIN MOTOR ON button on
the No.1 panel.
RESET

alarm light


section.
1- 48 M144- 7294 Issue 01

M144- 7294 Issue 01 1- 49

1.7 Check safety circuit

Check all safety systems function daily before op-
eration.
1.7.1 Check emergency stop 1.7.4 Check magazine empty
1. Push the EMERGENCY STOP button in each 1. Place blanks (approximately 50mm) into the
section during operation. basket.
2. Check that the machine stops immediately. 2. Reset the alarm and check that the alarm dis-
appears on the ALARM LIST screen .
3. Check that the red colour of alarm light flashes
and the buzzer turns on. 3. Remove blanks from the basket.
4. Check that the alarm appears on the ALARM 4. The carton sensors are activated. Check that
LIST screen. the alarm appears on the ALARM LIST screen.
5. Check that the machine does not start before
the EMERGENCY STOP button is reset. 1.7.5 Check loader covers
1.7.2 Check machine stop 1. Check that the carton feed stops on one side
during production on the other side. Check that
the SAFE lamp turns on.
1. Push the MACHINE STOP button during opera-
tion. 2. Open the loader cover on one side.
2. Check that the machine stops at the index posi- 3. Check that production can continue on the oth-
tion. er side.
the MACHINE STOP button is reset. 1.7.6 Check filling section doors
1.7.3 Check doors and covers 1. Check that the carton feed stops on one side
during production on the other side.
1. Open the doors and covers during machine op- 2. Push the SAFE lamp switch to stop the carriage
eration. conveyor when all cartons are discharged from
one side of the machine. Check that the SAFE
2. Check that the machine stops immediately.
lamp turns on.
3. Check that the SAFETY CIRCUIT RESET but-
3. Open the filling section door.
ton and the blue colour of alarm light flash.
4. Check that production can continue on the oth-
4. Check that the alarm appears on the ALARM
er side.
LIST screen.
5. Check that the machine does not start while the 1.7.7 Check safety sensor in basket
doors and covers are open.
1. Check that the carton feed stops on one side
during production on the other side. Check that
the SAFE lamp turns on.
2. Remove all blanks from the basket where the
SAFE lamp is ON.
3. Check that production can continue on the oth-
er side.
1- 50 M144- 7294 Issue 01

1.7.8 Check safety sensor for

UV- lamp
1. Open the UV- lamp.

2. Check that the alarm appears on the ALARM
LIST screen.
3. Check that UV- lamp does not turn on while
UV- lamp is open.
4. Check that the carton feed does not start while
UV- lamp is open.
1.7.9 Check quick exhaust valve
1. Open the doors and covers during machine op-

eration.
2. Check that the air pressure is reduced quickly
and shows zero MPa in the gauge of the valve
for the cap applicator.
the doors and covers are closed and the safety
circuit is reset.
M144- 7294 Issue 01 1- 51

1.8 Staff hygiene

As a basis for personal hygiene in food processing
and packaging lays the general requirement to all
staff working with food manufacturing (EEC Hy-
giene Directive 92/46/EEC, FDA, PMO, 2009). This
implies that the company has to organise perma-
nent training in hygiene for all staff handling food.
The following items are highlighted for staff in-
volved with food packaging.
Personal clothing
Personal effects and clothing has to be left outside
areas where food is handled, and should not be
found in food packaging regions.
Personal cleanliness
Staff should at all times show the strictest possible
personal hygiene. They must wear protective cloth-
ing, in particular head- gear and shoes at all times.
Clothing must be easy to clean and kept in a state
of cleanliness compatible with the strict require-
ment in a food processing area.
Staff behaviour
Activities like eating and smoking or other unhy-
gienic activities in the process area is prohibited.
Washing of hands
Hands should be washed with a suitable disinfec-
tant soap before work commences and after each
visit to the toilet or touching unhygienic items.
Gloves
Whenever gloves are used, they should meet strict
hygienic requirements. Wearing gloves does not
change the requirement to wash hands carefully.
Visitors
Whenever visitors are allowed in the food proces-
sing/packaging area, the same requirement out-
lined for the staff should be met.
1- 52 M144- 7294 Issue 01

1.9 Chemical hazards (Caustic, Acid, Sterilant, Hydrogen peroxide,

Ethanol, Oil, Grease)
DANGER WARNING
FOLLOW THE MANUFACTURER’S CHEMICALS USED FOR CLEANING OR
INSTRUCTIONS FOR HANDLING, STORING SANITISING CAN BURN EYES AND
AND DISCARDING CHEMICAL. SKIN.
(HELMET/FULL FACE MASK, GOGGLES,
RUBBER GAUNTLETS, RUBBER
DANGER BER BOOTS, ETC.) BEFORE HANDLING
CHEMICAL.
DO NOT MIX CHEMICALS.

HEAT MAY BUILD UP QUICKLY AND GAS
MAY BE GENERATED.
CAUTION
BE AWARE OF THE FIRST AID TREAT-
MENT IN CASE OF AN EMERGENCY.
CAUTION !
Do not discard chemicals into the drains.
CAUTION !
Discard chemicals in accordance with the local
regulations.
M144- 7294 Issue 01 1- 53

1.9.1 General
Before starting to operate the filling machine, you

MUST be:
 Aware of and completely understand the haz-
ards of the chemicals used for cleaning and sa-
nitising
 Aware of and observe the recommended prac-
tices for handling and working with the cleaning
and sanitising chemicals
 Completely familiar with the immediate action to
be taken in case of a chemical emergency
 Aware of the hazards of mixing chemicals
together
1- 54 M144- 7294 Issue 01

1.9.2 Caustic and Acid

Caustic and Acid are the chemicals used to clean  Cause damage to airways and lungs if the va-
the filler tank, pipe lines, and fillers. These chemi- pours are inhaled
cals present a potential personal health hazards  Immediately move to fresh air
when used in both a concentrated form and in a
diluted form.  Seek immediate medical attention
These chemicals are hazardous. You must there- When working in areas where Caustic and Acid are
fore be aware of the First Aid Treatment in case of located, for example removing an empty plastic
an emergency. container of Caustic, you MUST wear:
Caustic and Acid in a concentrated form:  Combined helmet/full face mask
 Are harmful if allowed to get into the mouth or  Rubber/plastic gauntlets

swallowed and can be fatal  Rubber/plastic apron
 Rinse the mouth immediately with water and  Rubber boots
spit out
 Drink one or two large glasses of water - do
not induce vomiting
 Seek immediate medical attention WARNING
 Are dangerous if splashed in the eyes
 Immediately flush with plenty of cool running
water DO NOT MIX CAUSTIC OR ACID WITH
EACH OTHER OR ANOTHER CHEMICAL.
 Remove contact lenses and continue to
flush for at least 15 minutes holding the eye- DO NOT POUR CAUSTIC OR ACID INTO
lids apart to ensure rinsing of the entire eyes HOT WATER.
 Seek immediate medical attention
DO NOT POUR WATER INTO CAUSTIC.
 Cause severe burns and leaves scars
 Immediately flush skin with water for at least
15 minutes while removing contaminated Carrying out any of the above DO NOT’s will gen-
clothing and shoes erate an explosion due to the quick build up of
 Seek immediate medical attention heat. The resulting high temperature fumes will
 Wash clothing and shoes before reuse burn the eyes and skin.
M144- 7294 Issue 01 1- 55

1.9.3 Sterilant
Sterilant is the chemical used to sanitise the filler

tank, pipe lines, and fillers. This chemical presents
a potential personal health hazards when used in
both a concentrated form and in a diluted form.
WARNING
This chemical is hazardous. You must therefore be
aware of the First Aid Treatment in case of an DO NOT MIX STERILANT WITH EACH
emergency. OTHER CHEMICAL.
Sterilant in a concentrated form: DO NOT POUR STERILANT INTO HOT
 Is harmful if allowed to get into the mouth or WATER.
swallowed
 Rinse the mouth immediately with water and
Carrying out any of the above DO NOT’s will gen-
spit out
erate an explosion due to the quick build up of
 Drink one or two large glasses of water - do heat. The resulting high temperature fumes will
not induce vomiting burn the eyes and skin.
 Seek immediate medical attention
 Is dangerous if splashed in the eyes 1.9.4 Hydrogen peroxide (H2O2)
 Immediately flush with plenty of cool running
water The filling machine uses a solution of 2% hydrogen
peroxide (H2O2) to decontaminate the cartons and
 Remove contact lenses and continue to does not present a personal health hazard. Diluted
flush for at least 15 minutes holding the eye- H2O2 will cause slight temporary bleaching and
lids apart to ensure rinsing of the entire eyes skin irritation/itching.
 Seek immediate medical attention The laboratory does however use a 35% strength
 Causes a temporary bleaching effect H2O2 that does present a potential personal health
 Immediately flush skin with cool running wa- hazard, very similar to Sterilant.
ter for at least 15 minutes while removing
contaminated clothing and shoes 1.9.5 Ethanol
 Seek immediate medical attention if contact
was prolonged


Wash clothing and shoes before reuse
Causes irritation to the respiratory system WARNING
 Immediately move to fresh air
 Seek immediate medical attention ETHANOL IS FLAMMABLE.
DO NOT SPRAY ETHANOL DIRECTLY
When working in areas where Sterilant is located,
ON THE SURFACES OF THE HEATERS.
for example connecting the pipe from a full plastic
container to the metering pump, you MUST wear:
 Combined helmet/full face mask
 Rubber/plastic gauntlets
 Rubber/plastic apron
 Rubber boots
1- 56 M144- 7294 Issue 01

1.9.6 Oil and grease
WARNING
(FULL FACE MASK, GOGGLES, RUBBER
BER BOOTS, ETC.) TO AVOID CONTACT
WITH EYES AND SKIN.
CAUTION !
Oil and grease are hazardous wastes. Discard
the used oil and grease in accordance with the
local regulations.
1.10 Fire hazards

Tests carried out on leaving a carton under the bot-
tom heater for 5 minutes did not catch fire, it only
smouldered.
Note ! When an emergency stop is activated,

power is isolated from the heaters.
However in the unlikely event of a fire, you must

use a Fire Extinguisher suitable for electrical fires.
1.11 Mandatory safety equipment

check list
DO NOT ATTEMPT TO START OPERATING THE
FILLING MACHINE BEFORE THE FOLLOWING
SAFETY EQUIPMENT IS AVAILABLE FOR
YOUR PERSONAL USE.
d Combined helmet/full face mask
d Goggles
d UV protective glasses
d Rubber gauntlets
d Rubber gloves
Fig. 1-77. Safety equipment for personnel use d Rubber apron
d Rubber boots
d Heat resistant gloves
d Personnel eye wash bottle
d Plenty of cool running water for flushing eyes
or skin
M144- 7294 Issue 01 1- 57

1.12 Personal notes
1- 58 M144- 7294 Issue 01

2 General
2 GENERAL
M144- 7294 Issue 01
M144- 7294 Issue 01 2- 1

2 General
2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 1
2.1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
2.1.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 3
2.1.2 Electrical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 12
2.1.3 Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 15
2.1.4 Mechanical timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 17
2.1.5 Electrical timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 19
2.2 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 28
2.2.1 Drive arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 28
2.2.2 Main drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 30
2.2.3 JOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 36
2.3 Carton flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 44
2.4 HEPA clean air unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 46
2.4.1 Before check & replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 47
2.4.2 Pre- filter - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 48
2.4.3 HEPA filter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 49
2.4.4 HEPA filter - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 51
2.5 Spray sanitising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 53
2.5.1 Spray ethanol diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 54
2.5.2 Solenoid valves and pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 56
2.6 Automatic CIP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 60
2.6.1 Automatic CIP unit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 60
2.6.2 Automatic CIP equipment arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 62
2.6.3 Stroke of aseptic valve manufactured by APV - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 63
2.7 Joint box arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 64
2.7.1 Joint box arrangement (under bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 64
2.7.2 Joint box arrangement (carton feeding section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 66
2.7.3 Joint box arrangement (above bed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 68
2.8 How to order parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 70
2.9 Maximum tightening torque of bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 71
2.10 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 72
2- 2 M144- 7294 Issue 01

2 General
2.1 Specifications
2.1.1 General specifications
1. Capacity Up to 14,000 cartons per hour.

Note ! Maximum speed for the products to be determined
based on running tests and/or field experience.
2. Filling volume 1000ml, 750ml, 500ml
3. Carton size 1000ml, 750ml, 500ml

Carton size can be chosen for four sizes (250ml, 500ml, 750ml, 1000ml) by
automatic size change.
4. Blank configuration 1000ml

Standard Classic Pure- PakR(70 x 70), B- style, skived 5th panel, tuck bot-
tom with J- flap. Drawing number 74481010
Standard Pure- PakR Curve (70 x 70), B- style, skived 5th panel, tuck bot-
tom with J- flap. Drawing number 51014305
Note ! One combination of carton blank configuration can be
chosen from the followings;
- Classic with/without Pure- Pak Curve or
- Diamond with/without Pure- Pak Curve
The machine is only adjusted to run one combination of
carton blank configuration before shipping. The ma-
chine needs to be mechanically readjusted to run an-
other combination of carton blank configuration.
Note ! Refer to inspection report for carton configuration used
for adjustment before shipping.
The machine is only adjusted to run one combination of carton blank config-
uration before shipping. The machine needs to be mechanically readjusted
to run another combination of carton blank configuration.
5. Cap configuration Selected option: Elo- cap U4
6. Board quality The machines are capable of being set up to run all commercially released
board/blank qualities within the normal operating ranges.
PE/EVOH board
Machines will be delivered set up and adjusted for one board quality: PE/
EVOH or AL. Running PE/EVOH and AL board with same setup may re-
duce seal quality.
M144- 7294 Issue 01 2- 3

2 General
7. Fillable products Filling temperature: 2~ 6C

Standard product pressure: 0.02 ~ 0.1 MPa
Fresh cream, milk, juices and fermented milk products with small particles
with standard rubber nozzles.
Selected option:
Screen nozzles for low viscosity product.
Milk, juices and fermented milk products without particles
with screen nozzles. Square etched plate screen (EPS) noz-
zles. Viscosity up to 150 cps.
Selected special order:
Combifiller.
High viscosity products like yogurts with and without fruit
pieces.
Maximum particle size approximately 10 x 10 x 10mm. (De-
pends on type of particle and type of base product).
Note ! The air contained in the products upstream of product
tank must be removed by customer, otherwise the filler
might be impossible to perform proper filling.
The material contacting to product is AISI304, silicon,
EPDM, EPR, PTFE, glass.
Not allowed to supply product which may cause these
material to corrode.
All materials and articles intend to come into contact
with food comply with REGURATION (EC)No.1935/2004.
8. Electrical power 400V, 50Hz, 3phase+N+PE.

Permissible voltage variation within10%
Maximum ampere : Approx. 195A
9. Standard electrical requirement

Based on 50Hz/400V
Main drive motor 5.5 kW
Vacuum pump (picker, unloader) 2.2 kW
Vacuum pump (filler diaphragm) 0.6 kW
Carton magazine motors 0.16 kW (0.04kW x 4)
Carton loader drive motor 2.0 kW (1.0 kW x 2)
Bottom heaters
Bottom 1st. heaters 16.2 kW (8.1 kW x 2)
Bottom 2nd. heaters 43.8 kW (10.95 kW x 4)
Bottom heater blowers 2.6 kW (1.3 kW x 2)
Top heaters 43.8 kW (10.95 kW x 4)
2- 4 M144- 7294 Issue 01

2 General
Top heater blowers 2.6 kW (1.3 kW x 2)

Filler drive motors 4.0 kW (1.0 kW x 4)
Lifter drive motors 7.0 kW (3.5 kW x 2)
Conveyor drive motors 4.0 kW (1.0 kW x 4)
Fan for carton dust suction 2.3 kW
Discharge conveyor drive motors 0.4 kW (0.2 kW x 2)
Cooling water recovery (booster) pump 0.43 kW
Mandrel cooling water pump 0.43 kW
HEPA air fan for filling section 1.5 kW
Carton decontaminating system 19.4 kW
UV- lamp (1.6 kW x 2)
Hot drying heater (8.1 kW x 2)
Cap applicator system 10.8 kW
Ultrasonic unit (2.2 kW x 4)
Rotary anvil capper drive motor (1.0 kW x 2)
UV- lamp system for potable water 0.055 kW
ELOFOAM (ELOPAK unit) 4.0 kW (separate supply)
Control system (Approx.) 1.55 kW
Total Approximately 175.325 kW
Average electrical consumption (without options): 72 kW
9- 1. Heat dissipation from machine to environment: 120 kW

(Theoretical value at 100% heater efficiency calculated from heaters)
9- 2. Electrical requirement for options and special order

Filler rotary valve drive motors 6.0 kW (1.5 kW x 4)
CIP recovery pump 4.0 kW
Total Approximately 10.0 kW
10. Compressed air

Supply pressure: 0.6 MPa (for main air)
Maximum supply pressure: 0.7 MPa (for main air)
Minimum supply pressure: 0.5 Mpa (for external foam
cleaning unit)
M144- 7294 Issue 01 2- 5

2 General
Maximum supply pressure: 1.0 MPa (for external foam

cleaning unit)
Air consumption: 2,500 NL/min. (for main air)
200- 450 NL/min.
(separate supply for external
foam cleaning unit)
Connection: R 3/4 (for main air)
Note ! Refer to INSTRUCTION MANUAL, provided by

ELOPAK, for connection of External foam cleaning
unit.
Machine is verified for no leakage of compressed air with supplied pressure

0.7MPa for 50 seconds before shipping.
Clean dry air is required for efficient and reliable machine operation.
Requirements to compressed air supplied to the machine:
Maximum number of particles 0.1- 0.5m
100/m3 ISO 8573- 1: 2001 class 1
Water pressure dew point
- 20C ISO 8573- 1: 2001 class 3
Maximum oil content(incl. vapor)
0.01 mg/ m3 ISO 8573- 1: 2001 class 1
No traceable amounts of organic solvents.
Pressure dew point must be at least 10C lower than the lowest occurring
ambient temperature in the production facilities.
11. Chilled water Supplied to chain guide rails, top folding guide, carton rails, H2O2 tank and
2nd. top sealer jaws.
Average flow: 35 L/min
Minimum temperature: 0.5 _C
Maximum temperature: 3.0 _C
Supply pressure: 0.2 MPa
Maximum pressure: 0.3 MPa
Supply connection: R 1/2
Return connection: R1
Heat dissipation through chilled water: To be measured
2- 6 M144- 7294 Issue 01

2 General
11- 1. Option requiring additional consumption:

Selected option:Triple wall filler tank with cooling jacket and product temp.
sensor.
Cooling water for triple wall product tank
Supply connection: R1
Return connection: R1
Supply pressure: 0.1 - 0.15 MPa
Note ! The return pipe must be opened to relieve the inner

pressure in case that the filler tank is heated up.
12. Temp. controlled water Supplied to bottom folding rails, bottom pressure pads, bottom seal tie-
rods, chain guide rails, UV- lamp unit, top sealer jaws and mandrels.
Note ! Temperature- controlled water circuit has been con-

nected to the mandrel cooling circuit so that it is not
necessary for customer to supply temperature- con-
trolled water.
13. Potable water Supplied for lubrication/cooling of conveyor chains and flushing of carton
lifter rods.
Average flow: 10 L/min
Recommended temperature: Ambient.
Supply pressure: 0.2 MPa
Maximum pressure: 0.3 MPa
Connection: R 1/2
UV- lamp system for potable water is included.
Recommended water quality:
Drinking water, free of pathogenic germs and coliform mi-
cro- organisms according to DIRECTIVE 98/83/EC of 3
November 1998 on the quality of water intended for hu-
man consumption.
The complete water system must be decontaminated before start up.
Flush 400- 500ppm paracetic acid by pump with liquid temperature 25_C
and flow 5L/min. for 20 minutes by one- pass. Please refer to 0.10.9 in
Maintenance Manual for the procedure to sanitise the system.
5 micron sediment filter must precede disinfection system.
M144- 7294 Issue 01 2- 7

2 General
14. External foam cleaning and sanitising

External foam cleaning unit which has monitoring system for concentration,
flow, temperature, and pressure of the detergents shall be prepared by cus-
tomer.
City water
supply pressure: 0.2 – 1.0 MPa
Minimum water supply: 200 L/min.
Maximum water sup- 300 L/min.
ply:
For external foam cleaning and sanitising, following detergents shall be
used.
Caustic wash: Topax 12 (Ecolab)
Acid wash: Topax 56 (Ecolab)
Sanitising: Topax 99 (Ecolab)
Customer shall provide following signals to machine.
Machine master)
Input to machine: concentration, flow, temperature, pres-
sure signals(4- 20mA) and digital signals.
Output to foam cleaning unit: digital signals and pump
control signal(4- 20mA).
Machine slave)
Input to machine: start signal.
Output to foam cleaning unit: ready signal.
Note ! Wiring and piping between machine and external foam
cleaning unit should be prepared by customer.
Note ! Concentration, flow, temperature and pressure of
each detergent shall be discussed between customer
and Ecolab.
Note ! Customer is required to install flow meter at water in-
let to set frequency inverter of pump.
2- 8 M144- 7294 Issue 01

2 General
15. CIP cleaning Machine is ready for connection to plants central CIP system or separate
CIP unit.
All valves to be in contact with product and CIP to be APV and MICRO
ZERO valves including APV product inlet valves.
Breathing pipe to be opened by APV valve.
Customer shall provide following signals to machine.
Machine master)
Input to machine: concentration, flow, temperature, pres-
sure signals(4- 20mA) and digital signals.
Output to plants central CIP system or separate CIP unit:
digital signals.
Machine slave)
Input to machine: start signal.
Output to plants central CIP system or separate CIP unit:
ready signal.
Please refer to HACCP document and P&ID sent separately.
16. CIP/SIP fluid supply Supply pressure: 0.13 – 0.15 MPa

Operating flow at product/CIP/SIP inlet: 20,000 L/hour at the product inlet
for one lane.
CIP flow to be verified before
shipping machine.
Note ! Equal distribution to each side must be provided if
only one supply.
Inlet pressure shall not exceed 0.15 MPa at zero flow.
Minimum capacity of CIP recovery pump is 20,000L/hour.
Note ! ”CIP READY” signal will be off when the guarding

door with safety switch in the filling section is
opened. CIP fluid supplying pump must stop with no
signal of ”CIP READY” for safety.
CIP = cleaning in place, SIP = sanitising in place.
M144- 7294 Issue 01 2- 9

2 General
17. Vacuum supply Vacuum is provided by vacuum pumps which are included.
Vacuum pumps, continuously running during production, are installed inside
the machine for picker, unloader and filler diaphragm.
One vacuum pump is for picker and unloader, the other is for filler dia-
phragm.
Vacuum pumps are kept ”ON” at production mode and CIP mode (after sent
out READY signal).
Vacuum pump for filler diaphragm is switched ”ON” and ”OFF” by monitor-
ing vacuum pressure at END mode and operation power- off.
Vacuum capacity for picker and unloader: 63 m3/h
Vacuum capacity for filler diaphragm: 10 m3/h
18. Hydrogen peroxide 24 liter hydrogen peroxide supply tank underneath machine bed.
Concentration: 2.0 % (Food grade)
Consumption: 2.4 L/hour
19. Spray sanitising Supplied to bottom breaker, bottom sealer, 1st top breaker, cap applicator
anvil, filler nozzle, 2nd. top breaker and top sealer sections.
70% ethanol for spray sanitising.
700 ml for spray sanitising of all sections.
8 liter ethanol supply tank at front end of right panel.
Tank level is monitored by level sensor.
20. Sound level A- weighted equivalent continuous sound pressure level lower than
80.0dBA.
The measurement is based on International Standard, DIS/ISO 11202.
21. Machine dimensions Refer to Chapter 0.10.8.
Minimum wall opening for transport of machine : Width 2.5m x Height (2.9m
+ transport- roller height)
22. Floor space Projected space: 55.2 m2 (4.8m x 11.5m)
Space for maintenance: 78.0 m2 (6.0m x 13.0m)
Refer to Chapter 0.10.7.1.
23. Machine weight Net weight: Approximately 16,000 kg (without option)
2- 10 M144- 7294 Issue 01

2 General
24. Painting colors Frames in bottom forming section are painted with white (Munsell No.5GY
8.5/0.5).
Mild steel parts not being visible are painted with grey corrosion protective
paint.
Pipe Colors: Water Green
Compressed air Blue
Compressed air exhaust lines Grey
Vacuum Black
Vacuum, leak detect Clear
Peroxide Stainless steel instrument tube
and/or clear teflon tube
25. Name plate English
26. Packing The machine is shipped in wooden boxes.

Box sizes depend on options selected.
27. CE conformity For EC DECLARATION OF CONFORMITY, refer to Chapter 0.1.

28. Production environment
Ambient temperature: 5 - 35C
Humidity: Less than 75%RH with no con-
densation
Air ventilation: 85% recirculation, 15% exhaust/
replenishment according to
EHEDG guidelines
To compensate generating heat
quantity from equipments, such
as, heaters and motors, minimum
ventilation air volume is 34260
m3/h
Maximum altitude: 1000 m above sea level
Atmosphere: Non corrosive, flammable and ex-
plosive
Rules and procedures: To comply with EC 852/2004
29. Service steps Service steps are included as standard.

30. Manuals Following manuals are provided as standard.
Operator’s Manual
Maintenance Manual
Electrical Manual
Parts Manual
M144- 7294 Issue 01 2- 11

2 General
2.1.2 Electrical specifications
1. Applied standard Manufactured according to EN60204- 1 : (2006)5th.
2. Layout No.1 panel (left panel) 1 pc.

No.2 panel (right panel) 1 pc.
No.3 panel (trans panel) 1 pc.
No.4 panel (servo panel) 1 pc.
3 Electrical power 400V, 50Hz, 3phase + N + PE. (Voltage variation within10%)
4. Control voltage 24V DC (where necessary 230V 50Hz)
5. Color coding
5- 1. Electrical panel Outside Stainless steel

Inside Zinc galvanising
5- 2. Push button switches and signal lamps

According to EN60204- 1: (2006)5th.
ex.
(1) Push button switch ON White (with light)
OFF Black
Emergency OFF Red
Reset White / Blue
Jog Black
(2) Signal lamp (Alarm light) Emergency Red
Abnormal Yellow
Mandatory Blue
Normal Green
Neutral White
5- 3. Wiring Main circuit Black

Control circuit Red (for AC)
Control circuit Blue (for DC)
Protective wire Yellow/Green
Interlock Orange
2- 12 M144- 7294 Issue 01

2 General
6. PLC Mitsubishi brand Q26UDEHCPU- series
7. Photoelectric switch Sick/Optex/Omron brand PNP type, 3- wire, 24 VDC. with LED
8. Safety door switch JOKAB brand Adam (E), Eva (E)
9. Safety sensor JOKAB brand SPOT10
10. Safety controller JOKAB brand Pluto B46- 6
11. Heater control Mitsubishi Q- series temperature control unit

SSR’s are made by Mitsubishi electric company
12. Emergency stop switches JOKAB brand INCA 1 TINA / Smile Tina
EATON brand M22- PVT
13. Machine stop switch JOKAB brand, INCA 1S TINA
14. Circuit breaker Moeller Electric brand
15. Switches, lamps Moeller Electric brand / Eao brand
16. Cable inlet With cable glands
17. Electrical equipment marking

According to EN60204- 1 : (2006)5th.
18. Alarm lamps Alarms are shown on main graphic control panel. Alarm light and buzzer on
No.3 panel.
19. Drawings According to IEC60617
20. External wiring cable According to EN60204- 1 : (2006)5th.
21. Frequency inverter Mitsubishi FR- E series
22. Servo control system Mitsubishi Q173D servo control system / Motion controller
M144- 7294 Issue 01 2- 13

2 General
23. Operator panels (graphic panels)

Main graphic panel: Mitsubishi GT1695M- STBD
Rear graphic panel: Mitsubishi GT1550- QLBD
The main graphic panel is located on the door of the left panel and the rear
graphic panel is located on the left and right side of the servo panel at the
carton exit end.
24. Carton counter Two counters are provided:

Carton counter: This counter counts the number of car-
tons picked (detected in the loader
chute).
Product counter: This counter counts the number of car-
tons filled.
The number of cartons to be produced can be preset for each magazine on
the main graphic control panel.
25. JOKAB safety PLC programming software

According to IEC61131- 3
2- 14 M144- 7294 Issue 01

2 General
2.1.3 Noise emission
Fig. 2-1. Noise emission
The following noise pressure levels were measured on the machine when running 14,000 cartons per hour
with all systems ON. The noise emission levels below were measured at A through to Q according to ISO
11202 Noise emitted by machinery and equipment and DIRECTIVE 2006/42/EC OF THE EUROPEAN PAR-
LIAMENT AND OF THE COUNCIL.
Corrected sound pressure level (A- weigh- Instantaneous C- Weighted sound pres-
Position
ted) (dBA) sure levels (dBC)
A 74.6 94.8
B 73.7 93.1
C 76.3 95.3
D 77.2 94.6
E 75.5 96.3
F 74.3 101.4
G 70.7 95.7
H 70.4 91.6
J 74.2 96.2
K 75.7 97.7
L 76.6 96.8
Table 2-1. Noise emission Part 1 of 2
M144- 7294 Issue 01 2- 15

2 General
Corrected sound pressure level (A- weigh- Instantaneous C- Weighted sound pres-
Position
ted) (dBA) sure levels (dBC)
M 78.1 94.8
N 75.2 94.0
P 73.8 92.6
Q 77.9 100.7
Table 2-1. Noise emission Part 2 of 2
2- 16 M144- 7294 Issue 01

2 General
2.1.4 Mechanical timing - Check
CAUTION
DO NOT ADJUST ANY MECHANICAL
TIMING PRESET IN THE FACTORY.
ADJUSTMENT OF TIMING SHOULD
ONLY BE DONE BY QUALIFIED PERSON-
NEL.
1. Stop the main motor.

2. Set each component to the operation start point
with dial indicator by hand cranking the
machine.
3. Check that an angle indicated by the dial at-
tached to the main shaft is the same as the me-
chanical timing chart.
4. If not, adjust the cam whose timing is incorrect.
M144- 7294 Issue 01 2- 17

2 General
MANDREL
TURRET 0_
PICKER 275 _
CARTON LOADER 165 _ SERVO MOTOR
BOTTOM HEATER 130 _
BOTTOM BREAKER 85 _
J- FLAP BREAKER 75 _
BOTTOM SEAL 140 _
UNLOADER 170 _
CARRIAGE CONVEYOR
ANVIL ROTATE 300_ SERVO MOTOR
(14000 c/h)
CARRIAGE CONVEYOR
ANVIL ROTATE 305_ SERVO MOTOR
(12000 c/h)
1st. TOP BREAKER 103_
HORN- ANVIL
120_
MOVEMENT
LOW VISCOSITY
FILLER RUBBER NOZZLE 88 _ SERVO MOTOR
(1000ml, 14000 c/h)
LOW VISCOSITY
CARTON LIFTER
RUBBER NOZZLE
95 _ SERVO MOTOR
(1000ml, 14000 c/h)
LOW VISCOSITY
ROTARY ROTATE
RUBBER NOZZLE
61 _ SERVO MOTOR
(1000ml, 14000 c/h)
HIGH VISCOSITY
FILLER RUBBER NOZZLE
(1000ml, 14000 c/h)
95 _ SERVO MOTOR
HIGH VISCOSITY
CARTON LIFTER
RUBBER NOZZLE 100_ SERVO MOTOR
(1000ml, 14000 c/h)
HIGH VISCOSITY
58 _
ROTARY ROTATE
RUBBER NOZZLE SERVO MOTOR
(1000ml, 14000 c/h)
TOP HEATER 105 _
TOP SEAL 115 _
Fig. 2-2. Mechanical timing chart
2- 18 M144- 7294 Issue 01

2 General
2.1.5 Electrical timing - Check
CAUTION
DO NOT CHANGE ANY ELECTRICAL
TIMING PRESET IN THE FACTORY.
ADJUSTMENT OF TIMING SHOULD
ONLY BE DONE BY QUALIFIED PER-
SONNEL.
To check electrical timing, refer to the Data Setting

List for Product in the Electrical Manual.
Adjust the timing if required.
M144- 7294 Issue 01 2- 19

2 General
Timing in table below is nominal value as general information. Minor variance to the figures may occur to
make the machine running in an optimal way. Refer to the inspection report.
Bank No. Mode Section ON OFF

No.
Bank No.1 1 Main fixing position 10_ 40_
14,000 c/h
2 Picker vacuum 95_ 320_
3 Carton feeder blocking 320_ 340_
4 Picker vacuum head open- close 315_ 160_
5 Picker clutch 120_ 150_
6 Shift for “Picking miss” alarm 30_ 60_
7 Unloader vacuum head open- close 90_ 290_
8 Unloader vacuum head move 100_ 260_
9 Unloader vacuum 240_ 100_
10 Carton detection (for unloader) 240_ 270_
11 Unloader blocking 350_ 10_
13 Carton incorrectly pushed onto mandrel trouble 0_ 20_
detection
14 Machine speed 230_ 260_
15 Mandrel shift (for unloader) 275_ 305_
18 Carton counter / Picking miss 270_ 300_
19 Picker clutch alarm detection 250_ 280_
20 1st. top sealer clutch on 10_ 50_
21 2nd. top seal on 130_ 265_
22 Carton pusher (cap section) 90_ 200_
24 Bottom breaker wing 150_ 200_
25 Bottom breaker carton holder 130_ 305_
32 2nd. top breaker (fork) 85_ 200_
33 2nd. top breaker (wing) 160_ 230_
34 Carton pusher (Discharge section) 50_ 150_
35 Main motor not safety position 80_ 70_
38 Unloader guide 135_ 235_
39 Carton dust blower 150_ 300_
40 Cap detection 250_ 280_
42 Lifter push down rod alarm 50_ 70_
Table 2-2. Electrical timing chart Part 1 of 2
2- 20 M144- 7294 Issue 01

2 General

No.
Bank No.1 43 Cap pusher 180_ 250_
14,000 c/h
44 Horn escape 40_ 70_
46 Ultrasonic start trigger 150_ 255_
48 M/C stop for bottom sampling 300_ 320_
50 Anvil, Horn forward 40_ 70_
52 Check carton after filler 1 45_ 65_
59 L. filler vacuum timing
60 R. filler vacuum timing
M144- 7294 Issue 01 2- 21

2 General

No.
13,000 c/h
detection
21 2nd. top seal on 165_ 265_
2- 22 M144- 7294 Issue 01

2 General

No.
13,000 c/h
M144- 7294 Issue 01 2- 23

2 General

No.
12,000 c/h
detection
21 2nd. top seal on 165_ 265_
2- 24 M144- 7294 Issue 01

2 General

No.
12,000 c/h
M144- 7294 Issue 01 2- 25

2 General

No.
10,000 c/h
detection
21 2nd. top seal on 165_ 265_
2- 26 M144- 7294 Issue 01

2 General

No.
10,000 c/h
M144- 7294 Issue 01 2- 27

2.2
2.2.1
2- 28
2 General
Drive
(26) (4) (3) (2) (1) (32) (31) (19) (17) (12) (6) (7) (8)
Drive arrangement
Fig. 2-3. Drive arrangement under bed

(28),(29) (30) (25) (27) (24) (23) (21) (22) (20) (18) (15) (16) (14) (13) (10) (9) (11) (5)
M144- 7294 Issue 01

2 General
The drive unit consisting of the main motor (1) and speed reducer (3) rotates the main shaft (4) by transmit-
ting the drive through the chain. Each section is driven by main shaft rotation.
No. Parts No. Parts

(1) Main motor (17) Lever (Bottom sealer)
(2) Hand crank (18) Cam (J- flap breaker)
(3) Speed reducer (19) Lever (J- flap breaker)
(4) Main shaft (20) Servo motor (Carton lifter)
(5) Encoder (21) Air cylinder (2nd. top breaker)
(6) Cam (Picker and Bottom heater) (22) Lever (2nd. top breaker)
(7) Lever (Picker) (23) Cam (Top heater)
(8) Servo motor (Carton loader) (24) Lever (Top heater)
(9) Cam (Unloader) (25) Lever (Top sealer)
(10) Lever (Unloader) (26) Cam (Top sealer)
(11) Lever (Bottom heater) (27) Air cylinder (Top sealer)
(12) Bevel gear (Mandrel) (28) Servo motor (Carriage conveyor)
(13) Cam (1st. top breaker) (29) Speed reducer (Carriage conveyor)
(14) Lever (1st. top breaker) (30) Air cylinder (Carriage conveyor)
(15) Cam (Bottom breaker and Bottom sealer) (31) Cam (Cap sealer)
(16) Lever (Bottom breaker) (32) Lever (Cap sealer)
M144- 7294 Issue 01 2- 29

2 General
2.2.2 Main drive
(11) (6) (7)
(10) (8)
A
(9)
B
(5)
(4) (3) (1)

(2)
Fig. 2-4. Main drive
Main drive consists of the main motor (1) and the No. Parts
speed reducer (2) connected by the belt (3).
In case of any overload, the torque is limited by (1) Main motor
monitoring the current from the frequency inverter.
(2) Speed reducer
When the hand crank (4) is inserted in the main
motor, it is detected by the light beam sensors (5) (3) Belt
and the brake will be released. Then, the main
shaft can be hand cranked. (4) Hand crank
(5) Light beam sensor
(6) Nut
(7) Bolt
(8) Chain
(9) Nut
(10) Bolt
(11) Bolt
2- 30 M144- 7294 Issue 01

2 General
(1) 2.2.2.1 Main motor handle position
Before operation, return the handle (1) to the han-

dle holder (2).
CAUTION !
If the handle (1) is not returned to the handle
holder (2), the machine cannot be stopped at
the proper position.
(2) (1)
Fig. 2-5. Main motor handle position
M144- 7294 Issue 01 2- 31

2 General
2.2.2.2 Light beam sensor

(2)
 Function indication
Green LED on the transmitter (power) means pow-
(1) er supply OK.
Green LED on the receiver status:

ON: Alignment OK.
Safety circuit closed.
Flashing: Alignment OK.
Earlier safety circuit open.
Fig. 2-6. Light beam sensor OFF: Beam interrupted.
Safety circuit open.
 Check & Replace

1. Insert the hand crank (4) in the holder on the
main motor (1).
2. If alarm occurs, it is under proper working con-
dition. If alarm does not occur, continue with the
next step.
3. The light beam sensors have been disabled.
a) Check that the hand crank is in a detect-

able position.
b) When the function cannot be restored, re-
place it with a new one.
4. Replace the light beam sensors with new ones

if the LED is OFF when nothing is present be-
tween sensors.
 Adjust
The LED on the receiver is ON when the receiver
is aligned with the transmitter. By moving the trans-
mitter up/down and left/right the best alignment can
be found.
Note ! When using laser aligner, do not look

directly into the laser. Observe all nec-
essary precautions when using laser
devices. If not, eye damage may oc-
cur.
No. Parts
(1) Transmitter/Receiver
(2) Indicator (LED)
2- 32 M144- 7294 Issue 01

2 General
2.2.2.3 Belt tension - Check
Refer to Fig. 2-4.

1. Push the centre of the belt (3) with a force of
28.2N.
2. Check the dimension A. If it is not the standard
value, continue with the next step.
Standard
A 4.5 mm
3. Loosen the nut (6).

4. Turn the bolt (7) and adjust the dimension A.
5. After adjustment, tighten the nut.
2.2.2.4 Chain tension - Check
Refer to Fig. 2-4.

1. Push the chain (8) in the centre by hand and
check that it deflects dimension B.
Standard
B 5.3 mm
2. If it is not the standard value, continue with the

next step.
4. Turn the bolt (10) and adjust the dimension B.
2.2.2.5 Belt - Replace
Refer to Fig. 2-4.

1. Select the MANUAL mode.
2. Loosen the bolt (11).
3. Turn the bolt (7) and loosen the belt.
4. Replace the belt (3) with a new one.
5. Turn the bolt (7) and adjust the tension.
(Refer to 2.2.2.3)
6. Tighten the bolt (11).
M144- 7294 Issue 01 2- 33

2 General
WARNING
DO NOT INSERT THE HAND CRANK
WHILE THE MACHINE IS RUNNING.
LIGHT BEAM SENSOR WILL BE ACTU-

ATED AND THE MAIN MOTOR CIRCUIT
WILL BE DISCONNECTED FOR SAFETY
WHEN THE HAND CRANK IS INSERTED
IN THE PROPER POSITION.
MOTOR BRAKE WILL BE AUTOMATI-

CALLY RELEASED WHEN THE HAND
CRANK IS INSERTED IN THE PROPER
POSITION.
BE CAREFUL WHEN HAND CRANKING

THE MACHINE AFTER AN EMERGENCY
STOP BECAUSE OF FORCES GENER-
ATED BY THE CAM DRIVES.
DO NOT TURN THE HAND CRANK

COUNTER- CLOCKWISE. DOING SO
WILL DAMAGE THE MACHINE.
2.2.2.6 Main shaft encoder zero setting
Set the main synchro encoder to the home posi-

tion; 0 degree. (Refer to the following chapter de-
in the Electrical Manual)
D- 2 Main Shaft Encoder
 D- 2- 1 Auto ZERO (Home) Setting
 D- 2- 2 Manual ZERO (Home) Setting
2- 34 M144- 7294 Issue 01

2 General
M144- 7294 Issue 01 2- 35

2 General
2.2.3 JOG
(3)
(2)
(1)
Fig. 2-7. Remote controller connectors
The remote controller connecters for JOG operation are attached on the following panels.
No. Parts No. Parts

(1) No.1 panel (3) No.4 panel (R- side)
(2) No.4 panel (L- side)
2- 36 M144- 7294 Issue 01

2 General
2.2.3.1 Main motor on No.1 panel - JOG
1. Turn the MAIN MOTOR key switch to the JOG

position.
MAIN MOTOR
JOG SAFE RUN 2. Push the MAIN MOTOR JOG button.
The main motor starts.
CAUTION !
Make sure that you hear no abnormal sounds
during jog.
If no abnormalities are found, continue with the
2.2.3.2.
Fig. 2-8. MAIN MOTOR JOG
M144- 7294 Issue 01 2- 37

2 General
2.2.3.2 Main motor with remote controller -

JOG
1. Connect the remote controller to the connectors

(3). (Refer to Fig. 2-10. )
2. Push the jog start button (1) while pushing the
enable switch (2).
(1) (2)
3. After adjustment, disconnect the remote con-
troller from the connector.
No. Parts
(1) Jog start button
(2) Enable switch
Fig. 2-9. Remote controller
(3) Connector
(4) Graphic panel
(4)
(3)
(3) No.4 panel (L- side)
(3)
No.1 panel
No.4 panel (R- side)
2- 38 M144- 7294 Issue 01

2 General
M144- 7294 Issue 01 2- 39

2 General
2.2.3.3 Servo motor with remote controller -

JOG
The following is an overview of the operation. For

details, refer to D Servo Manual Operation de-
in the Electrical Manual.
1. Connect the remote controller to the connectors
(1).
Note ! Regarding how to use the Jokab servo

jog controller, refer to the following
chapters described in the Main Touch
Panel Operation Manual.
D- 1 Jokab Servo Jog Controller

 D- 1- 1 Controls overview
 D- 1- 2 How to use the Jokab servo jog control-
ler
 D- 1- 3 Servo jog operation of opening a door
(1)
(1)
No.4 panel (L- side)
(1)
No.1 panel
No.4 panel (R- side)
2- 40 M144- 7294 Issue 01

2 General
2. Turn the SERVO MOTOR key switch to the

MANU. position.
SERVO MOTOR
OPE. MANU.
Fig. 2-12. SERVO MOTOR key switch
3. Push MENU (2) on the PRODUCTION STATUS

screen.
The MENU screen appears.
(2)
4. Push SERVO MANUAL OPERAT. (3) on the

MENU screen.
Note ! Service key in the No.1 panel is neces-

sary.
The SELECT SERVO MANUAL OPERATION win-

dow appears.
(3)
Fig. 2-14. MENU screen
M144- 7294 Issue 01 2- 41

2 General
5. Push and hold LEFT LANE (4) on the SELECT

SERVO MANUAL OPERATION window.
The L. SERVO MANUAL OPERAT. screen ap-
pears.
Note ! If the main motor is ON, stop the main

(4) motor, or push and hold CONVEYOR
STOP (5) to stop the carriage convey-
(5) or.
Note ! If you want to restart the carriage con-

veyor after stopping it, push and hold
Fig. 2-15. SELECT SERVO MANUAL OPERA- the MAIN MOTOR start button. The red
TION window colour of alarm light flashes for 3 sec-
onds, and at the same time the buzzer
turns on for 3 seconds. Then the car-
riage conveyor starts.
6. Select the servo motor button you want to oper-

ate from SELECT AXIS (6).
[ Example ]
(6)
Push 1:L. 1st. LIFTER, then the lamp will turn
on.
7. Push JOG by JOG DEVICE (7).
(7) a) The lamp turns on.

b) The manual operation by the remote control-
ler is enabled.
Fig. 2-16. L. SERVO MANUAL OPERAT. screen 8. Push the jog start button (1) while pushing the
enable switch (2). (Refer to Fig. 2-9. )
9. After adjustment, disconnect the remote con-
10.Turn the SERVO MOTOR key switch to the
OPE. position.
2- 42 M144- 7294 Issue 01

2 General
M144- 7294 Issue 01 2- 43

2 General
2.3 Carton flow

(4) (3) (2) (1)
(4) (2)
(3) (1)
(3) (1)
(4)
(2)
(3) (1)
(4)
(3)
(2)
(4) (1)
(4)
(3) (2)
(4) (2)
(3)
(1)
(4) (2)
(3)
(1)
(4)
(3) (2)
(1)
(3) (2)
(4) (1)
(4) (1)
(3) (2)
(2)
(4) (1)
(3) (2)
(4)
(1)
(3) (2)
(4) (1)
(2)
(3)
(4) (1)
(2)
(3) (1)
Fig. 2-17. Carton flow
2- 44 M144- 7294 Issue 01

2 General
The carton flow is identified by a number (5) on its

bottom. One of the numbers (number emboss 1, 2,
3, 4) is pressed and marked on the carton bottom
by the bottom sealer to distinguish 4 magazines of
the machine.
(5)
Fig. 2-18. Number emboss
M144- 7294 Issue 01 2- 45

2 General
2.4 HEPA clean air unit
(3) (1) (2)
Fig. 2-19. HEPA unit

Air is taken in from the pre- filter (1) by the fan (2), No. Parts
is cleaned by passing through the HEPA filter (3)
and is supplied to the filling section and carton de- (1) Pre- filter
contamination chamber.
(2) Fan
(3) HEPA filter
2- 46 M144- 7294 Issue 01

2 General
2.4.1 Before check & replacement
DANGER DANGER
WHEN CHECKING AND REPLACING THE DO NOT REMOVE THE FILTER DURING
FILTER IN A HIGH PLACE, USE A LADDER OPERATION OF THE HEPA UNIT.
AND PLATFORM WITH HANDRAIL FOR BEFORE REPLACING THE FILTER, BE
SAFETY. SURE TO TURN OFF THE HEPA FAN
THE FILTER IS HEAVY. SWITCH ON THE BACK SIDE OF THE NO.1
BE CAREFUL WHEN HANDLING. PANEL.
HEPA FAN
OFF
ON
Back side of the No.1 panel
Fig. 2-20. HEPA FAN switch on the back side of the No.1 panel.
M144- 7294 Issue 01 2- 47

2 General
2.4.2 Pre- filter - Check & Replace
(4) (2) (1) (3)
Fig. 2-21. Pre- filter and HEPA filter
Note ! Do not remove the pre- filter during 1. Check the pre- filters (1) every two weeks.
operation of the HEPA unit. 2. If the pre- filters (1) are blocked or dirty, remove
Before replacing the pre- filter, be sure them in the following steps and rinse with water.
to turn off the HEPA FAN switch on the
back side of the No.1 panel. 3. Remove the bolts and detach the cover (3).
(Refer to 2.4.1) 4. Pull out the pre- filter (1).
5. If dirt persists, wash them with mild detergent.
6. After washing, let pre- filter dry sufficiently.
7. If they are damaged, install new pre- filters in
reverse order.
No. Parts
(1) Pre- filter
(2) HEPA filter
(3) Cover
(4) Unit cover
2- 48 M144- 7294 Issue 01

2 General
2.4.3 HEPA filter - Check
(5) Check that the HEPA filter (2) is not blocked and
that the differential pressure of pressure sensor (5)
indicates less than standard value on the graphic
panel. (Refer to Fig. 2-21. )
Parts Standard
Differential pressure
Less than 400 Pa
(filling section)
Fig. 2-22. Differential pressure

screen. The MENU screen appears.
(6)
2. Push VIEW CONDITION (7) on the MENU

screen. The VIEW CONDITION screen ap-
pears.
(7) Note ! Service key in the No.1 panel is neces-

sary.
M144- 7294 Issue 01 2- 49

2 General
3. Push GENERAL SETTING (8) on the VIEW

CONDITION screen. The GENERAL SETTING
screen appears.
(8)
Fig. 2-25. VIEW CONDITION screen
4. Check the differential pressure (9) on the GEN-

ERAL SETTING screen.
(9)
Fig. 2-26. GENERAL SETTING screen
2- 50 M144- 7294 Issue 01

2 General
2.4.4 HEPA filter - Replace
If differential pressure exceeds 300Pa, continue

with the next step to replace HEPA filter.
DANGER
WHEN CHECKING AND REPLACING THE
HEPA FILTER IN A HIGH PLACE, USE A
LADDER AND PLATFORM WITH HANDRAIL
FOR SAFETY.
THE HEPA FILTER IS HEAVY.
BE CAREFUL WHEN HANDLING.
Note ! Do not remove the HEPA filter during

operation of the HEPA unit.
Before replacing the HEPA filter, be
sure to turn off the HEPA FAN switch
on the back side of the No.1 panel.
(Refer to 2.4.1)
1. Remove the HEPA unit cover (4).

2. Loosen the bolts and remove the HEPA filters
(2). (Refer to Fig. 2-21. )
3. Install new HEPA filters in reverse order.
M144- 7294 Issue 01 2- 51

2 General
2- 52 M144- 7294 Issue 01

2 General
2.5 Spray sanitising
CAUTION
ETHANOL TANK IS UNDER PRESSURE.
ALWAYS DEPRESSURISE TANK BY
CLOSING AIR SUPPLY VALVE AND
OPEN AIR RELIEF VALVE BEFORE
STARTING TO REMOVE COMPONENTS
FROM THE TANK.
Spray sanitising of each section is automatically

performed. Compressed air is used for supplying
ethanol to the nozzles and for spraying. Ethanol is
mixed with compressed air in the nozzles and is
sprayed to each section.
Refer to the Parts Manual for additional information

(Spray position):
Page Exploded views of the:

62010 Ethanol tank
62030 Filling section
62040 1st. top breaker section
62050 Top sealer section
62060 Bottom forming section
62070 2nd. top breaker section
62080 Cap applicator
M144- 7294 Issue 01 2- 53

R- side
2.5.1
2- 54
(6) (6) (6) (6) (6) (6) (6)
2 General
Y216R Y215R Y214R Y213R Y212R Y211R Y210R
(14) (13) (12) (11) (10) (9) (8)
Fig. 2-27. Spray ethanol diagram

Spray ethanol diagram
Y206R Y205R Y204R Y203R Y202R Y201R Y200R
(7) (7) (7) (7) (7) (7) (7)

G34 (1)
(6) (6) (6) (6) (6) (6) (6)
Y216L Y215L Y214L Y213L Y212L Y211L Y210L
(2)
(9) (8) G35
(14) (13) (12) (11) (10)
(3)
Y206L Y205L Y204L Y203L Y202L Y201L Y200L

(4) (5) (15)
(7) (7) (7) (7) (7) (7) (7)
L- side
M144- 7294 Issue 01

2 General
No. Parts No. Parts

(1) Regulator (for ethanol spray nozzle) (9) Spray nozzle (for bottom sealer)
(2) Regulator (for ethanol tank) (10) Spray nozzle (for 1st. top breaker)
(3) Ethanol tank (11) Spray nozzle (for cap applicator)
(4) Pump (12) Spray nozzle (filler nozzle)
(5) Strainer (13) Spray nozzle (for 2nd. top breaker)
(6) Solenoid valve (for air) (14) Spray nozzle (for top sealer)
(7) Solenoid valve (for ethanol) (15) Ball valve
(8) Spray nozzle (for bottom breaker)
M144- 7294 Issue 01 2- 55

2 General
2.5.2 Solenoid valves and pneumatic parts arrangement
Y216R Y214R Y212R Y210R Y216L Y214L Y212L Y210L

Y215R Y213R Y211R Y215L Y213L Y211L
G34
View X- X
G35
Y206R Y204R Y202R Y200R Y206L Y204L Y202L Y200L

Y205R Y203R Y201R Y205L Y203L Y201L
X X
Fig. 2-28. Solenoid valves and pneumatic parts arrangement
2- 56 M144- 7294 Issue 01

2 General
2.5.2.1 Solenoid valve purpose list
Solenoid valve No. Description

Y200L Bottom breaker Ethanol
Y201L Bottom sealer Ethanol
Y202L 1st. top breaker Ethanol
Y203L Cap applicator Ethanol
Y204L Filler nozzle Ethanol
Y205L 2nd. top breaker Ethanol
Y206L Top sealer Ethanol
Y210L Bottom breaker Air
Y211L Bottom sealer Air
Y212L 1st. top breaker Air
Y213L Cap applicator Air
Y214L Filler nozzle Air
Y215L 2nd. top breaker Air
Y216L Top sealer Air
Y200R Bottom breaker Ethanol
Y201R Bottom sealer Ethanol
Y202R 1st. top breaker Ethanol
Y203R Cap applicator Ethanol
Y204R Filler nozzle Ethanol
Y205R 2nd. top breaker Ethanol
Y206R Top sealer Ethanol
Y210R Bottom breaker Air
Y211R Bottom sealer Air
Y212R 1st. top breaker Air
Y213R Cap applicator Air
Y214R Filler nozzle Air
Y215R 2nd. top breaker Air
Y216R Top sealer Air
Table 2-6. Solenoid valve purpose list Part 1 of 1
M144- 7294 Issue 01 2- 57

2 General
2.5.3 Regulator standard pressure

Refer to Fig. 2-28.
Gauge No. Description Standard

G34 Ethanol spray nozzle 0.1~0.2 MPa
G35 Ethanol tank 0.1~0.2 MPa
Table 2-7. Regulator standard pressure Part 1 of 1
2- 58 M144- 7294 Issue 01

2 General
M144- 7294 Issue 01 2- 59

2 General
2.6 Automatic CIP

2.6.1 Automatic CIP unit diagram
L- side R- side
(4) (19)
(2) (17)
(3) (1) (16) (18)

(5) (20)
(13) (6) (21) (28)
(8) (7) (22) (23)

(12) (27)
(9) (24)
(15) (14) (29) (30)
(10) (25)
(11) (26) A
(33) B
(31) (32)
(35)
(42)
(40) (41)
(36) (37) (38)
(39)
(34)
Fig. 2-29. Automatic CIP unit diagram
2- 60 M144- 7294 Issue 01

2 General
A: Prepared by SHIKOKU
B: Prepared by customer as example
No. Parts No. Parts

L- side R- side
(1) Product / CIP supply (16) Product / CIP supply
(2) Auto valve (AV1) (17) Auto valve (AV6)
(5) Filler tank (20) Filler tank
(6) Filler pump (21) Filler pump
(10) Filler nozzle (25) Filler nozzle
(11) CIP box (26) CIP box
(12) Check valve (27) Check valve
Both sides
(31) Sanitary pump
(32) Product drain
(33) CIP return
(34) Drain
(35) Water
(36) Hot water
(37) Acid
(38) Caustic
(39) CIP pump
(40) Steam
(41) Hot water (70 _C)
(42) Acid, Caustic (60~70 _C)
M144- 7294 Issue 01 2- 61

2 General
2.6.2 Automatic CIP equipment arrangement
(11) (5) (4) (3) (1) (2)
(14) (13)
(8)
(12) (15)
(6) (10) (9) (7)
Fig. 2-30. Automatic CIP equipment arrangement (Example : L- side)
No. Parts No. Parts

(1) Auto valve (AV1) (9) Filler nozzle
(2) Auto valve (AV2) (10) CIP box
(4) Filler tank (12) Check valve
(5) Filler pump (13) Auto valve (AV4)
(7) Auto valve (AV51) (15) Sanitary pump
(8) Auto valve (AV40)
2- 62 M144- 7294 Issue 01

2 General
2.6.3 Stroke of aseptic valve

manufactured by APV - Check
 AV2
1. Check the dimension A.
Standard
A A 15.0 mm
Fig. 2-31. Stroke of aseptic valve manufactured

by APV (Product valve)
M144- 7294 Issue 01 2- 63

2 General
2.7 Joint box arrangement
2.7.1 Joint box arrangement (under bed)
(2)
(1)
(4)
(3)
(6)
(9)
(7)
(8) (10)
(5)
(11) (12)
Fig. 2-32. Joint box (under bed)
2- 64 M144- 7294 Issue 01

2 General
No. Parts
(1) Joint box 3
(2) Joint box 4
(3) Joint box 5
(4) Joint box 6
(5) Joint box 8
(6) Joint box 9
(7) Joint box 10
(8) Joint box 10A
(9) Joint box 11
(10) Joint box 11A
(11) Joint box 12
(12) Joint box 13
For details regarding the joint boxes, refer to the

Electrical Manual.
M144- 7294 Issue 01 2- 65

2 General
2.7.2 Joint box arrangement (carton feeding section)
(1)
Y X
(2),(3)
(1)
(3) (2)
View Y View X
Fig. 2-33. Joint box (carton feeding section)
No. Parts For details regarding the joint boxes, refer to the
Electrical Manual.
(1) Joint box 1
(2) Joint box 3
(3) Joint box 4
2- 66 M144- 7294 Issue 01

2 General
M144- 7294 Issue 01 2- 67

2 General
2.7.3 Joint box arrangement (above bed)
(10) (3) (6)
(8) (4) (1) (2) (9) (5) (7)
(10)
View X
Fig. 2-34. Joint box (above bed)
2- 68 M144- 7294 Issue 01

2 General
No. Parts
(1) Joint box 14
(2) Joint box 15
(3) Joint box 16
(4) Joint box 18
(5) Joint box 28
(6) Joint box 29
(7) Joint box 30
(8) Joint box 31
(9) Joint box 40
(10) Joint box 51
For details regarding the joint boxes, refer to the

Electrical Manual.
M144- 7294 Issue 01 2- 69

2 General
2.8 How to order parts

Complete the order form while referring to the
Parts Manual and send it to Elopak representative.
Refer to the Parts Manual chapter 0 introduction,
0.3.4 order of parts.
2- 70 M144- 7294 Issue 01

2 General
2.9 Maximum tightening torque

of bolts
Type Steel Stainless steel

M5 7.94 N·m 1.76 N·m
M6 13.4 N·m 3.04 N·m
M8 32.7 N·m 7.35 N·m
M10 64.9 N·m 14.5 N·m
M12 113 N·m 25.3 N·m
M14 180 N·m 40.2 N·m
M16 281 N·m 62.7 N·m
Table 2-8. Maximum tightening torque of bolts
Note ! The torque value in the list is only a

guide, it is different depending on the
condition.
M144- 7294 Issue 01 2- 71

2 General
2.10 Personal notes
2- 72 M144- 7294 Issue 01

3 Carton feeder
3 CARTON FEEDER
M144- 7294 Issue 01
M144- 7294 Issue 01 3- 1

3 Carton feeder
3 CARTON FEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 1
3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 3
3.1.1 Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.1.2 Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.1.3 Carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 6
3.2 Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 8
3.2.1 Opening finger and retainer plate - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 10
3.2.2 Size change block position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 12
3.2.3 Safety sensor and fibre sensor - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 14
3.3 Picker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 18
3.3.1 Tie- rod length - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 19
3.3.2 Rod end in picker section - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 19
3.3.3 Dimension in carton basket and vacuum head position - Check . . . . . . . . . . . . . . . . . . . . . 3- 20
3.3.4 Picker vacuum switch timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 22
3.3.9 Picker clutch on- off timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
3.3.10 Clearance between stopper and cover - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 25
3.3.11 Bushing - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 26
3.3.12 Clearance between stopper and cover - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 27
3.3.13 Light beam sensor for detecting safe position of picker lever after MAGAZINE EMPTY alarm -
Check & Adjust / Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 28
3.4 Carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 30
3.4.1 Carton guide dimension - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
3.4.2 Roller - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 32
3.4.3 Loader belt tension - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 34
3.4.4 Loader belt - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 36
3.4.5 Loader pusher position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 38
3.4.6 Loader pusher - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 40
3.4.7 Incorrect timing of loader operation - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.8 Loader blocking and miss picking - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.9 Miss picking - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 42
3.4.11 Loader shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 46
3.4.12 Servo manual operation of carton loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 48
3- 2 M144- 7294 Issue 01

3 Carton feeder
3.1 Description
The carton feeder consists of the following ele-
ments:
Chapter Elements
3.1.1 Magazine
3.1.2 Picker
3.1.3 Carton loader
Cartons are taken from the basket by the picker,

opened and squared in the guide rail, and then
loaded onto the mandrels.
M144- 7294 Issue 01 3- 3

3 Carton feeder
(21)
(22) (20) (19)
(3)
(5) (6)
(20)
(22)
(19)
(16) (4)
Y (5)
(6) (3) (1)
(2)
(17)
(14) (15) (13) (18) (12)

Fig. 3-1. Carton feeder (1 of 2)
3- 4 M144- 7294 Issue 01

3 Carton feeder
(22) (17) (19)
(21)
(17)
(20)
(18)
(22) (16) (16)

View Y
(15)
(11) (10)
(9)
(8)
(7)
View X
Fig. 3-2. Carton feeder (2 of 2)
M144- 7294 Issue 01 3- 5

3 Carton feeder
3.1.1 Magazine
The magazine consists of the following components:
No. Parts No. Parts

(1) Magazine (4) Basket
(2) Motor (5) Safety sensor (for detecting blank decrease in
basket)
(3) Photoelectric switch (carton level sensor) (6) Fibre sensor (zero level sensor)
(for detecting blank decrease and controlling (for detecting basket empty)
blank feed)
3.1.2 Picker
The picker consists of the following components:
No. Parts No. Parts

(7) Cam (12) Carton guide
(8) Cam follower (13) Vacuum head
(9) Lever (14) Vacuum cup
(10) Tie- rod (15) Light beam sensor (Picker lever sensor)
(for detecting safety position of picker lever)
(11) Picker clutch
3.1.3 Carton loader

The carton loader consists of the following components:
No. Parts No. Parts

(16) Loader pusher (20) Safety sensor (for detecting opening/closing of
loader shutter)
(17) Loader belt (21) Air cylinder
(18) Servo motor (22) Photoelectric switch (for detecting carton
incorrectly pushed onto mandrel)
(19) Photoelectric switch (for detecting loader
blocking, miss picking and wrong carton type)
3- 6 M144- 7294 Issue 01

3 Carton feeder
M144- 7294 Issue 01 3- 7

3 Carton feeder
3.2 Magazine
(7)
(6)
(8)
(6)
(2)
View Y
(3) (5) (1)
View X
Y
(4)
(2)
Fig. 3-3. Magazine
3- 8 M144- 7294 Issue 01

3 Carton feeder
Function: To support and feed blanks to the

picker.
The magazine (1) is equipped with a timing belt (2)

which can hold 850 blanks. The induction motor (4)
operates to feed blanks so as to avoid blank de-
crease in the basket (3). When the CARTON FEED
(ON) button is pushed, the motor feeds blanks for
1 second per 22 times of picker operation (change-
able).
The photoelectric switch (5) detects blank de-
crease on the timing belt. When the blanks have
decreased, the yellow colour of alarm light flashes
and buzzer turns on. The basket is equipped with a
retainer plate (6) and opening fingers (7) (8), and
can hold blanks.
If you select any carton size, the opening fingers
(7) are automatically positioned by the air cylinder
depending on the carton size.
No. Parts
(1) Magazine
(2) Timing belt
(3) Basket
(4) Induction motor
(5) Photoelectric switch
(6) Retainer plate
(7) Opening finger
(8) Opening finger
M144- 7294 Issue 01 3- 9

3 Carton feeder
3.2.1 Opening finger and retainer plate - Check & Adjust
(2)
(1)
(3)
Fig. 3-4. Openinng finger and retainer plate
3- 10 M144- 7294 Issue 01

3 Carton feeder
1. Check the dimensions A, B and C.

If they are not within the standard values, con-
tinue with the next step.
Standard
A 2.01.0 mm
B 5.01.0 mm
C 5.01.0 mm
2. Loosen the bolts of retainer plate (1) and open-

ing fingers (2) (3). Then, adjust the dimensions.
3. After adjustment, tighten the bolts.
No. Parts
(1) Retainer plate
(2) Opening finger
(3) Opening finger
M144- 7294 Issue 01 3- 11

3 Carton feeder
3.2.2 Size change block position - Check & Adjust
(2)
(3)
(1)
(4)
(9) (8)
(7) (6)
(5)
Fig. 3-5. Size change block position
3- 12 M144- 7294 Issue 01

3 Carton feeder
Set the blanks of 1000ml, 750ml, 500ml and 250ml

on the L- side, and set the blanks of 1000ml,
750ml, 500ml and 250ml on the R- side.
Check the dimensions A and B.
If they are not within the standard values, adjust
the size change block (1) position.
Standard
1,000 ml 297.01.0 mm
750 ml 253.01.0 mm
A
500 ml 204.01.0 mm
250 ml 151.01.0 mm
B 0.10.2 mm
3.2.2.1 For 1000ml and 750ml carton - Adjust
1. Loosen the nuts (3), turn the nuts (4) and adjust
the slider (2) position.
2. After adjustment, tighten the nuts (3).
3.2.2.2 For 500ml carton - Adjust
1. Loosen the nut (5), turn the bolt (7) and adjust
the stopper (6) position.
2. After adjustment, tighten the nut (5).
3.2.2.3 For 250ml carton - Adjust
1. Loosen the set screw (8), move the collar (9)

and adjust the Slider (2) position.
2. After adjustment, tighten the set screw (8).
No. Parts
(1) Size change block
(2) Slider
(3) Nut
(4) Nut
(5) Nut
(6) Stopper
(7) Bolt
(8) Set screw
(9) Collar
M144- 7294 Issue 01 3- 13

3 Carton feeder
3.2.3 Safety sensor and fibre sensor - Check & Adjust
(1)
(7)
(1)
Y
(1)
(7)
Z View X
(7)
Fig. 3-6. Safety sensor and fibre sensor
3- 14 M144- 7294 Issue 01

3 Carton feeder
3.2.3.1 Safety sensor - Check & Adjust
When sufficient blanks/dummy block are/is in the

(4) basket during normal operation, the lever (2) turns
clockwise using the bolt (3) as a pivot point.
At this time, the safety sensors (1) detect that
(1) blanks/dummy block are/is in the basket.
(3) If the blanks/dummy block on the lever (2) are/is
removed, the lever turns counter- clockwise by the
weight of safety sensor using the bolt (3) as a pivot
(2) point.
At this time, the safety sensors (1) detect that
blanks/dummy block are/is not in the basket.
The red colour of alarm light flashes and buzzer
turns on for 3 seconds. Blank feed stops and the
”MAGAZINE EMPTY” alarm appears on the graph-
ic panel.
(Refer to 1.6 Safety system in magazine section)
If you supply a stack of blanks in the basket but the
(5) (6) alarm remains on the graphic panel, continue with
View Y the next step.
1. Lightly turn the lever (2) by hand and check that
the lever turns smoothly.
Fig. 3-7. Safety sensor
2. Check that the cable connector of the safety
sensor (1) is not loose or disconnected.
3. After checking the above, supply blanks again
and check that the alarm disappears.
4. If the alarm does not disappear, replace the
safety sensors with new ones.
No. Parts
(1) Safety sensor
(2) Lever
(3) Bolt
(4) Size change block
(5) Opening finger
(6) Blank
M144- 7294 Issue 01 3- 15

3 Carton feeder
3.2.3.2 Fibre sensor - Check & Adjust
(7)
(10)
(11) (9)
(11)
(7)
(8)
(12)
(13)
View Z
Fig. 3-8. Fibre sensor
Fibre sensors (7) detect that blanks are not left in 1. Lightly turn the lever (8) by hand and check that
the basket. When sufficient blanks are in the bas- the lever turns smoothly.
ket during normal operation, the lever (8) turns
2. Check that the connector of fibre sensor (7) is
clockwise using the pin (9) as a pivot point. At this
not loose or disconnected.
time, the fibre sensors (7) detect that blanks are in
the basket. 3. After checking the above, supply blanks again
If the blanks on the lever (8) are removed, or the and check that the alarm disappears.
dummy block is placed in the basket, the lever
4. If the alarm does not disappear, replace the
turns counter- clockwise by the weight of the block
fibre sensors with new ones.
(10) using the pin (9) as a pivot point. At this time,
the fibre sensors (7) detect that blanks are not in
the basket. The red colour of alarm light flashes No. Parts
and buzzer turns on for 3 seconds. Blank feed
stops and the ”MAGAZINE EMPTY” alarm appears (7) Fibre sensor
on the graphic panel. (Refer to 1.6 Safety system (8) Lever
in magazine section)
(9) Pin
If you supply a stack of blanks in the basket but the
alarm remains on the graphic panel, continue with (10) Block
the next step. (11) Bracket
(12) Carton guide
(13) Retainer plate
3- 16 M144- 7294 Issue 01

3 Carton feeder
3.2.3.3 Fibre sensor sensitivity - Check &

(1) (3) Adjust/Replace
Note ! The fibre sensor amplifier is located in

the joint box 1. Refer to Fig. 2-33.
For more details, refer to the Electrical
(2) (4) Manual.
1. Check for the illuminations of the red (1) and

green (2) indicator lamps.
2. If the red indicator lights up and the green indi-
cator does not, check for the illumination of the
green indicator by rotating the sensitivity adjust-
er (3).
3. If the green indicator does not light up, replace
the switch with a new one.
No. Parts
(1) Input indicator (Red)
(2) Stable indicator (Green)
(3) Sensitivity adjuster
Fig. 3-9. Fibre sensor amplifier
(4) Mode selector
M144- 7294 Issue 01 3- 17

3 Carton feeder
3.3 Picker
(2)
(3)
X
(1)
(6) (10) (9) (11)
(9)
(12) (8) (4) (7) (5) (11) (12)
View X
Fig. 3-10. Picker
3- 18 M144- 7294 Issue 01

3 Carton feeder
Function: To pick, open and place the blanks in 3.3.1 Tie- rod length - Check
the carton guides.
The vacuum head (1) moves up and down and If it is not within the standard value, continue
picks blanks held in the basket (2) along the guide with the next step.
(3), and makes them square. The vacuum head is
Standard
divided into 3 vacuum sections, which are automat-
ically selected depending on the carton size. A 1911.0 mm
When the carton is released from the vacuum
head, vacuum air is switched to compressed air to 2. Loosen the nuts (9) and adjust the dimension
control the release timing. by rotating the tie- rod (10).
If an operator pushes the CARTON FEED (ON) 3. After adjustment, tighten the nuts.
button, the pin (4) is pushed forward by the air cyl-
inder (5). The drive lever (6) is connected to the 3.3.2 Rod end in picker section -
driven lever (7) and the vacuum head starts opera-
tion. If an operator pushes the CARTON FEED Replace
(OFF) button, the vacuum head is stopped in re-
verse order. 1. Select the MANUAL mode.
The proximity switch (8) detects that the carton 2. Loosen the reamer bolts (11) to remove the tie-
feed timing is synchronised with the pin operation rod (10).
timing. If the proximity switch detects abnormal 3. Replace the rod ends at both ends of tie- rod
timing, the machine will stop immediately. with new ones.
The light beam sensors (12) detect that the picker 4. Adjust the dimension A and supply grease to
lever (7) is in a safe position after the MAGAZINE the rod ends. (Refer to 3.3.1)
EMPTY alarm has appeared. If picker lever mal-
function is detected, the main motor stops immedi- 5. Assemble in reverse order.
ately.
Note ! If the timing is not correct, do not op-

erate the machine.
No. Parts
(1) Vacuum head
(2) Basket
(3) Guide
(4) Pin
(5) Air cylinder
(6) Drive lever
(7) Driven lever (picker lever)
(8) Proximity switch
(9) Nut
(10) Tie- rod
(11) Reamer bolt
M144- 7294 Issue 01 3- 19

3 Carton feeder
3.3.3 Dimension in carton basket and vacuum head position - Check
D
B©
F
B¡
H C
E
G
(3)
C B¡
A D
View Y View X
(2)
(1)
Fig. 3-11. Dimension in carton basket and vacuum head position
3- 20 M144- 7294 Issue 01

3 Carton feeder

2. Set the drive shaft to 15_~25_.
3. Check the dimensions A, B, C, D, E, F, G, and
H.
4. Set the drive shaft to 150_.
5. Check the dimensions A and H.
6. Loosen the bolts (4) and insert shims (5) as re-

quired to adjust the dimensions A and H.
7. Loosen the bolts (6) to adjust the dimensions B,
C, D, E, F, and G.
(5)
Dimension Standard
(4)
A 22.01.0 mm
¡ 25.01.0 mm
B
© 24.01.0 mm
C C≧ D+1.0 mm
D 47.01.0mm
E 24.02.0mm
F F≧ G+1.0 mm
G 47.01.0 mm
(6) H 12.01.0 mm
No. Parts
Fig. 3-12. Dimension in carton basket and vacu- (1) Vacuum head
um head position
(2) Basket
(3) Roller
(4) Bolt
(5) Shim
(6) Bolt
M144- 7294 Issue 01 3- 21

3 Carton feeder
3.3.4 Picker vacuum switch timing -

Check
The function of this solenoid valve is to switch from

vacuum air to compressed air.
Refer to the electrical timing (2.1.5) and the sole-
noid valve purpose list (11.4).
Refer to the Electrical Manual.
Magazine No. Mode No. Solenoid No.

1,2 Y6L
02
3,4 Y6R
3.3.5 Vacuum head open- close

timing - Check
The function of this solenoid valve is to open or

close each vacuum section of the vacuum head

1 Y1L, Y4L, Y209L
2 Y2L, Y3L, Y208L
04
3 Y1R, Y4R, Y209R
4 Y2R, Y3R, Y208R
3- 22 M144- 7294 Issue 01

3 Carton feeder
3.3.6 Vacuum cup - Check & Replace
1. Check vacuum cups (1) for wear and cuts

around the centre and/or edges.
(1) 2. Check the vacuum cups for excessive wear at

the vacuum cup edges. If damaged, replace the
cup with a new one.
3. Turn off the operation power, manually pull up
the vacuum head, and replace the vacuum cup.
Fig. 3-13. Vacuum cup No. Parts

(1) Vacuum cup
3.3.7 Vacuum nozzle - Clean
1. Remove all dust from the vacuum nozzle (1) by

(1)
periodical air blow.
No. Parts
(1) Vacuum nozzle
Note ! Blockage in the nozzle may cause car-

ton feed problem.
Fig. 3-14. Vacuum nozzle
M144- 7294 Issue 01 3- 23

3 Carton feeder
3.3.8 Vacuum filter - Check &

(1) Replace
1. Open the cover of the carton feeder and check

the vacuum filters (1) on both sides every two
weeks. If necessary, clean or replace the vacu-
um filter.
Note ! If you replace the filter, pay attention

to the orientation.
Fig. 3-15. Vacuum filter
No. Parts
(1) Vacuum filter
(1)
Fig. 3-16. Vacuum filter position
3- 24 M144- 7294 Issue 01

3 Carton feeder
3.3.9 Picker clutch on- off timing -

Check
When an operator pushes the CARTON FEED

(ON) button, the picker clutch is engaged by the
solenoid valve.
CAUTION !
Do not run the machine in case that the clutch
does not operate at regular timing.
If you run the machine, the pin on the clutch
will hit the drive lever.

1,2 Y31L, Y32L
05
3,4 Y31R, Y32R
3.3.10 Clearance between stopper and

cover - Check
(1)
1. Push the CARTON FEED (ON) button and
place the picker in the bottom position by jog.
2. Open the carton feeder cover and check the
dimension A between the stopper (1) and the
A cover (2).
Standard
(2) A 0 mm (Just touching)
No. Parts
(1) Stopper
(2) Cover
Fig. 3-17. Clearance between stopper and cover
M144- 7294 Issue 01 3- 25

3 Carton feeder
3.3.11 Bushing - Replace
WARNING
(6) THE LEVER MOVES DOWN DUE TO THE
SELF- WEIGHT IN SLIDING.
BE CAREFUL NOT TO GET YOUR
FINGER CAUGHT BY THE LEVER OF
THE PICKER HEAD.
(3)
1. Remove the block (1) with the air cylinder (2)
(2) (1) (4) and the pin (3).
2. Remove the bushing (4) and replace it with a
(5)
new one.
3. After replacement, assemble in reverse order.
No. Parts
(1) Block
Fig. 3-18. Bushing replacement
(2) Air cylinder
(3) Pin
(4) Bushing
(5) Driven lever
(6) Drive lever
3- 26 M144- 7294 Issue 01

3 Carton feeder
3.3.12 Clearance between stopper and

cover - Adjust
1. Push the CARTON FEED (ON) button and

place the vacuum head in the bottom position
by jog. (Refer to Fig. 3-10. , Fig. 3-11. and
Fig. 3-17. )
2. Check that machine timing is between 135_ and
275_.
3. Disconnect the air tubes from the air cylinder
(2). (Refer to Fig. 3-18. )
4. Insert the tube, from which air is blowing, into
the cylinder fittings alternately to operate the air
cylinder which moves the pin back and forth.
5. Check that the pin (3) can reciprocate quick and
smooth. (Refer to Fig. 3-18. )
If not, continue with the next step.
6. Remove the air cylinder (2) from the block (1)
on the driven lever (5). (Refer to Fig. 3-18. )
7. Align the bore of the driven lever (5) bushing
with the bore of the drive lever (6) bushing (Re-
fer to Fig. 3-18. )with the stopper (1) for the vac-
uum head. (Refer to Fig. 3-17. )
8. Fasten the air cylinder (2) to the block (1) on
the driven lever (5). The air cylinder (2) must be
carefully positioned and fixed. (Refer to
Fig. 3-18. )
9. Check that the pin (3) can reciprocate quick and
free. Refer to step 4 above. (Refer to
Fig. 3-18. )
10.Check the clearance between the stopper (1)
and the cover (2) according to 3.3.10. (Refer to
Fig. 3-17. )
M144- 7294 Issue 01 3- 27

3 Carton feeder
3.3.13 Light beam sensor for detecting

(2) safe position of picker lever
after MAGAZINE EMPTY alarm -
(1) Check & Adjust / Replace
 Function indication
Green LED on the transmitter (power) means pow-
er supply OK.
Green LED on the receiver status:

ON: Alignment OK.
Safety circuit closed.
Fig. 3-19. Light beam sensor Flashing: Alignment OK.
Earlier safety circuit open.
OFF: Beam interrupted.
Safety circuit open.
 Check
Check that the sensor indicator turns off when the
plate (4) attached to the picker driven lever (3) in-
terrupts the light from the light beam sensor (5).
(3)
Check that the indicator turns on again when the
lever moves and light is no longer interrupted.
 Adjust
The LED on the receiver is ON when the receiver
is aligned with the transmitter. By moving the trans-
mitter up/down and left/right the best alignment can
be found.
Note ! When using laser aligner, do not look

directly into the laser. Observe all nec-
essary precautions when using laser
devices. If not, eye damage may oc-
cur.
(5)  Replace
Replace the light beam sensors with new ones if
(4) the LED is OFF when nothing is present between
sensors.
Fig. 3-20. Picker lever No. Parts

(1) Transmitter/Receiver
(2) Indicator (LED)
(3) Picker driven lever
(4) Plate
3- 28 M144- 7294 Issue 01

3 Carton feeder
M144- 7294 Issue 01 3- 29

3 Carton feeder
3.4 Carton loader
(4)
(5)
(1)
(5)
Y View Y
(4)
(3)
(5)
View X
(3) (2)
(3)
X
(1) (2)
Fig. 3-21. Carton loader
3- 30 M144- 7294 Issue 01

3 Carton feeder
Function: To load the cartons onto the mandrels.
The loader belt (1) is driven by the servo motor (2)

and transfers cartons in three steps.
Cartons opened by the picker enter the carton
guide and are loaded onto the mandrels by the
loader pusher (3).
The photoelectric switches (4) detect that a carton
is incorrectly pushed onto the mandrel. Then the
picker and the loader belt stop.
The photoelectric switches (5) detect the wrong
type of carton. Then the picker and the loader belt
stop.
The photoelectric switch (5) detects loader block-
ing and miss picking. Then the picker and the load-
er belt stop.
No. Parts
(1) Loader belt
(2) Servo motor
(3) Loader pusher
(4) Photoelectric switch (for detecting carton
incorrectly pushed onto mandrel)
(5) Photoelectric switch (for detecting loader
blocking, miss picking and wrong type car-
ton)
M144- 7294 Issue 01 3- 31

3 Carton feeder
3.4.1 Carton guide dimension -

Check & Adjust
1. Check the dimension A between the mandrel

(1) (2) (3) (1) and the roller (2).
If it is not within the standard value, continue
with the next step.
Standard
A
A 1.0~1.25 mm
A
2. Loosen the bolts for the carton guide (3) and

A
adjust the dimension A.
A 3. After adjustment, tighten the bolts.
No. Parts
(1) Mandrel
(3) (2)
(2) Roller
(3) Carton guide
Fig. 3-22. Carton guide
3.4.2 Roller - Replace

2. Loosen the bolt and remove the rollers (1). Re-
place the rollers with new ones.
3. Assemble in reverse order.
(1)
No. Parts
(1) Roller
(1)
Fig. 3-23. Roller
3- 32 M144- 7294 Issue 01

3 Carton feeder
M144- 7294 Issue 01 3- 33

3 Carton feeder
3.4.3 Loader belt tension - Check & Adjust
(2)
(3)
(1)
(1)
(2) (3)
(3)
View X
Fig. 3-24. Loader belt tension
3- 34 M144- 7294 Issue 01

3 Carton feeder
1. Lift up the centre of the loader belt (1) with a

force of 16.95 to 21.27N.
2. Check the dimensions A. If they are not the
standard values, continue with the next step.
Standard
A 21.0 mm
3. Loosen the bolts (2) and turn the nut (3) to ad-
just the dimension A. After adjustment, tighten
the bolts (2).
No. Parts
(1) Loader belt
(2) Bolt
(3) Nut
M144- 7294 Issue 01 3- 35

3 Carton feeder
3.4.4 Loader belt - Replace
(2)
(3)
(1)
(1)
(2) (3)
(3)
View X
Fig. 3-25. Loader belt replacement
3- 36 M144- 7294 Issue 01

3 Carton feeder
CAUTION !
When excessive wear on loader belt is found,
or running hour exceeds the following stan-
dard, it should be replaced.
Standard
Replacement cycle 1,200 hours

2. Loosen the bolts (2), turn the nut (3), and loos-
en the belt (1).
3. Replace the belt (1), adjust the tension by fol-
lowing the steps in 3.4.3, and tighten the bolts
(2).
No. Parts
(1) Loader belt
(2) Bolt
(3) Nut
M144- 7294 Issue 01 3- 37

3 Carton feeder
3.4.5 Loader pusher position - Check & Adjust
(2)
A
X (1)
Detail X
(3)
(3)
Fig. 3-26. Loader pusher position
1. Check the dimensions A and B. If they are not 2. Loosen the nut (1) and turn the bolt (2) to adjust
the standard values, continue with the next the dimension A. After adjustment, tighten the
step. nut (1).
Standard 3. Loosen the bolts (3) and adjust the dimension

B. After adjustment, tighten the bolts (3).
A 3.9 mm
B 41.01.0 mm No. Parts
(1) Nut
(2) Bolt
(3) Bolt
3- 38 M144- 7294 Issue 01

3 Carton feeder
M144- 7294 Issue 01 3- 39

3 Carton feeder
3.4.6 Loader pusher - Replace
(6)
(5) (2)
(4)
(6) Detail A (3) View Z (4) (3)
(1) View Y
(6)
Z
(2)
Y
View X
(3)
Fig. 3-27. Loader pusher
3- 40 M144- 7294 Issue 01

3 Carton feeder

2. Loosen the bolts (1) and remove the loader
pusher (2).
3. Loosen the bolts (3) and remove the bracket
(4).
4. Remove the E- shaped retaining ring (5) from
the bracket (4), and remove the loader pusher
(6).
5. Replace the loader pushers (2) (6) with new
ones, and assemble in reverse order.
No. Parts
(1) Bolt
(2) Loader pusher
(3) Bolt
(4) Bracket
(5) E- shaped retaining ring
(6) Loader pusher
M144- 7294 Issue 01 3- 41

3 Carton feeder
3.4.7 Incorrect timing of loader

operation - Check
Refer to the electrical timing (2.1.5).


1,2,3,4 13 -
3.4.8 Loader blocking and miss

picking - Check


1,2,3,4 03 -
3.4.9 Miss picking - Check


1,2,3,4 18 -
3- 42 M144- 7294 Issue 01

3 Carton feeder
3.4.10 Sensor sensitivity
3.4.10.1 Photoelectric switch for detecting

loader blocking and miss picking -
Check & Adjust / Replace
1. Adjust the photoelectric switch sensitivity by

rotating the sensitivity adjuster (3).
2. If the output indicator (1) or stable indicator (2)
(1) (2) (3) (4) does not light up during detection, replace it. (If
the light is set to light up during detection.)
Note ! Turn the sensitivity adjuster slowly. If

it is turned hard, it may cause dam-
age.
Note ! Depending on the setting of “light ON”

(light is set to ON during detection) or
“dark ON” (light is set to OFF during
detection), the output indicator light
(orange) turns ON or OFF reversely.
No. Parts
(1) Output indicator (Orange)
Fig. 3-28. Photoelectric switch
(3) Sensitivity adjuster (4 tune (endless))
(4) L/ON, D/ON selector
M144- 7294 Issue 01 3- 43

3 Carton feeder

wrong carton type - Check & Adjust /
Replace
1. Check for the illuminations of the orange (1)

and green (2) indicator lamps.
2. If the orange indicator lights up and the green
(1) (2) (3) (4) indicator does not, check for the illumination of
the green indicator by rotating the sensitivity
adjuster (3).
(1) Set the detectable object at

the detection position and turn
the potentiometer from MIN
toward MAX until the output
indicator (orange) lights up.
A
Call it position A.
(2) Remove detectable object
B and turn the potentiometer
from MAX toward MIN posi-
tion where the output indicator
Fig. 3-29. Photoelectric switch (orange) is extinguished.
Call it position B.
(3) B Point C midway between A
and B is the optimum sensitiv-
C ity position. The position A
and B may reverse by types
A and detecting situation.
Note ! Turn the sensitivity adjuster slowly. If

it is turned hard, damage may occur.
Note ! Depending on the setting of “light ON”

(light is set to ON during detection) or
“dark ON” (light is set to OFF during
detection), the output indicator light
(orange) turns ON or OFF reversely.
No. Parts
(1) Output indicator (Orange)
(4) L/ON, D/ON selector
3- 44 M144- 7294 Issue 01

3 Carton feeder

carton incorrectly pushed onto
mandrel - Check & Replace
 Check
SICK photoelectric switches do not require any
maintenance. We recommend that you clean the
external lens surfaces and check the screw con-
nections and plug- in connections at regular inter-
vals.
 Replace
If malfunction is found, replace the photoelectric
switch with a new one.
M144- 7294 Issue 01 3- 45

3 Carton feeder
3.4.11 Loader shutter
X
(4) (1)
(4)
(3) (3)
(2)
(5)
(4) (4)
Detail X
Fig. 3-31. Loader shutter
3- 46 M144- 7294 Issue 01

3 Carton feeder
3.4.11.1 Structure of loader shutter
1. Basically the loader shutter (2) is always closed.

When the CARTON FEED (ON) button is pu-
shed, the shutter will be opened, driven by the
air cylinder (1). After the last carton is loaded
onto the mandrel, the loader shutter will be
closed again.
2. The safety sensors (4) detect opening or clos-
ing of the loader shutter.

1,2 - Y41L, Y42L
3,4 - Y41R, Y42R
3.4.11.2 Safety sensor - Replace
Before replacing the safety sensors (4), it is neces-

sary to remove the collars (black) (5) from only the
side where the screws are inserted.
No. Parts
(1) Air cylinder
(2) Loader shutter
(3) Mandrel
(4) Safety sensor
(5) Collar
M144- 7294 Issue 01 3- 47

3 Carton feeder
3.4.12 Servo manual operation of carton

loader
Refer to the following chapters described in the

Main Touch Panel Operation Manual in the Electri-
cal Manual, and set the carton loader to the home
position.
D- 6 Left Lane Carton loader (11 axes)
S D- 6- 1 Jog
3- 48 M144- 7294 Issue 01

4 Bottom former
4 BOTTOM FORMER
M144- 7294 Issue 01
M144- 7294 Issue 01 4- 1

4 Bottom former
4 BOTTOM FORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 1
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 3
4.1.2 Bottom heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
4.1.3 Bottom breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 5
4.1.4 Folding rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.1.5 Bottom sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.1.6 Carton dust cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 6
4.2 Mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 8
4.2.1 Mandrel index unit backlash - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
4.2.2 Rotary joint - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 10
4.2.3 Position between mandrel and index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 11
4.3 Bottom heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 12
4.3.1 Bottom preheater position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.2 Bottom preheater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.3 Bottom preheater element - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 14
4.3.4 Bottom preheater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4.3.5 Bottom heater position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 15
4.3.6 Bottom heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 16
4.3.7 Bottom heater element - Heating pattern check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 18
4.3.8 Bottom heater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20
4.3.9 Bottom heater carton positioning bolt - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20
4.3.10 Pre- filter element for bottom heater blower - Clean & Replace . . . . . . . . . . . . . . . . . . . . . 4- 21
4.3.11 Filter element for bottom heater air- Clean & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 21
4.3.12 Bottom heater blower pressure - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 22
4.3.13 Bottom heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 23
4.4 Bottom breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 26
4.4.2 Folding arm position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 29
4.4.4 Carton holder position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 30
4.4.5 J- flap breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 31
4.4.6 Carton holder timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 32
4.4.7 Wing breaking timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 32
4.5 Folding rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 33
4.5.1 Summary of checking, adjustment values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 33
4.6 Bottom sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 34
4.6.2 Dimension between pressure pad and 5th panel - Check & Adjust . . . . . . . . . . . . . . . . . . 4- 35
4.6.3 Emboss wear - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
4.6.4 Seal pressure - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 36
4.7 Carton dust cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 38
4.8 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 40
4- 2 M144- 7294 Issue 01

4 Bottom former
4.1 Description
The bottom former consists of the following ele-
ments:
Chapter Elements
4.1.1 Mandrel
4.1.2 Bottom heater
4.1.3 Bottom breaker
4.1.4 Folding rail
4.1.5 Bottom sealer
4.1.6 Carton dust cleaner
Refer to Fig. 4-1.

The hub (4) is equipped with 8 mandrels (5).
The carton bottom on the mandrel is heated by the
electrical heaters (8) (16), folded by bottom break-
er and the folding rails (40), and sealed by the
pressure pad (46). The suction nozzles (47) collect
paper dust and PE dust which are generated dur-
ing carton transfer. Then, the cartons are trans-
ferred to the unloader.
M144- 7294 Issue 01 4- 3

4 Bottom former
(19) (22)
(20)
(7)
(21)
(34)
(28)
View X
(32)
(17)(18) (16)
(27) (10)
(40) Y
(8)
(29)
(33) (5)
(9)
X
(45)
(4)
(47)
(46)
(6)
(44) (3)
(43)
(26)
(48)
(42)
(36) Z
(37)
(35) (25) (24) (23) (41) (2) (1) (15) (14) (12) (11) (13)
(30) (31)
(39)
(38)
(49) (50)
View Z View Y
Fig. 4-1. Bottom former
4- 4 M144- 7294 Issue 01

4 Bottom former
4.1.1 Mandrel
The mandrel consists of the following components:
No. Parts No. Parts

(1) Bevel gear (5) Mandrel
(2) Shaft (6) Mandrel cap
(3) Index unit (7) Rotary joint
(4) Hub
4.1.2 Bottom heater

The bottom heater consists of the following components:
No. Parts No. Parts

(8) Electric heater (16) Electric heater
(9) Heater nozzle (17) Heater nozzle
(10) Thermocouple (18) Thermocouple
(11) Cam (19) Heater fan
(12) Cam follower (20) Air filter
(13) Lever (21) Pressure switch
(14) Tie- rod (22) Air filter
(15) Air cylinder
4.1.3 Bottom breaker

The bottom breaker consists of the following components:
No. Parts No. Parts

(23) Cam (Bottom breaker and bottom sealer) (32) Lever
(24) Cam follower (Bottom breaker) (33) Tie- rod
(25) Lever (Bottom breaker) (34) J- flap breaker
(26) Tie- rod (35) Cam (J- flap breaker)
(27) Lever (36) Cam follower (J- flap breaker)
(28) Tie- rod (37) Lever (J- flap breaker)
(29) Folding arm (38) Carton holder
(30) Rotary actuator (39) Air cylinder
(31) Wing
M144- 7294 Issue 01 4- 5

4 Bottom former
4.1.4 Folding rail

The folding rail consists of the following components:
No. Parts No. Parts

(40) Folding rail
4.1.5 Bottom sealer

The bottom sealer consists of the following components:
No. Parts No. Parts

(23) Cam (Bottom breaker and bottom sealer) (44) Spring case
(41) Cam follower (Bottom sealer) (45) Gearbox
(42) Lever (Bottom sealer) (46) Pressure pad
(43) Tie- rod
4.1.6 Carton dust cleaner

The carton dust cleaner consists of the following components:
No. Parts No. Parts

(47) Suction nozzle (49) Suction fan
(48) Air filter (50) Silencer
4- 6 M144- 7294 Issue 01

4 Bottom former
M144- 7294 Issue 01 4- 7

4 Bottom former
4.2 Mandrel
A (4)
(2)
(10)
(3)
(1)
(6)
(9) (11)
(12)
(5)
Detail A
(8)
(7)
Fig. 4-2. Mandrel
4- 8 M144- 7294 Issue 01

4 Bottom former
Function: To form and transfer the blanks from

the loader section to the unloader sec-
tion.
There are 4 mandrel hubs (1), and each hub has 8

mandrels (2). The mandrel shaft (3) is driven by
the 8- stop index unit (4). The index unit is driven
by the vertical shaft (5) which is connected to the
coupling (6), and the main drive shaft (7) which is
connected to the bevel gear (8).
Mandrel needs to be cooled down after passing

through the place in high temperature. To prevent
condensate, temperature- controlled water circu-
lates inside the mandrels through the holes (9).
Cover (12) is attached to prevent water from enter-

ing the index unit (4).
No. Parts
(1) Mandrel hub
(2) Mandrel
(3) Mandrel shaft
(4) Index unit
(5) Vertical shaft
(6) Coupling
(7) Main shaft
(8) Bevel gear
(9) Hole
(10) Gearbox
(11) Bolt
(12) Cover
M144- 7294 Issue 01 4- 9

4 Bottom former
4.2.1 Mandrel index unit backlash -

Check
CAUTION !
Do not run the machine when backlash at man-
drel end exceeds +/- 0.5mm.
1. Stop the mandrel (1) at the stop position manual-

ly.
2. Check that the backlash is within +/- 0.5mm.
(1) 3. If it exceeds this range, contact authorised per-
sonnel.
No. Parts
(1) Mandrel
Fig. 4-3. Mandrel index unit backlash
4.2.2 Rotary joint - Check & Replace

(5) (4)
(6)
1. Check for water leakage from the rotary joint (1).
(3)
2. If leakage is found, continue with the next step.
3. Remove the bolt (2) and then washer (3).
(2)
4. Remove the shaft (4) to check that all O- rings (5)
(6) are in good condition.
5. If necessary, replace them with new ones.
6. Assemble them in reverse order.
No. Parts
(1) (1) Rotary joint

(2) Bolt
(3) Washer
Fig. 4-4. Rotary joint (4) Shaft
(5) O- ring
(6) O- ring
4- 10 M144- 7294 Issue 01

4 Bottom former
4.2.3 Position between mandrel and

index unit
Refer to Fig. 4-2.

1. Check the dimension A between the mandrel
hub (1) and the index unit (4).
next step.
Standard
A 32 mm
2. Open the gearbox (10) and loosen the bolt (11)

on the mandrel hub (1).
3. After adjusting to the dimension A, tighten the
bolts (11) on the mandrel hub (1).
M144- 7294 Issue 01 4- 11

4 Bottom former
4.3 Bottom heater
(4) (2)
(4) (1)
(3)
Fig. 4-5. Bottom heater
4- 12 M144- 7294 Issue 01

4 Bottom former
Function: To heat polyethylene by hot air on car-

ton bottom panels to the sealing tem-
perature.
WARNING
SOON AFTER THE HEATERS STOP RUN-
NING, HEATERS AND THEIR SUR-
ROUNDS ARE VERY HOT.
BE CAREFUL WHEN ADJUSTING.
CARE MUST BE TAKEN WHEN CHECK-

ING THE FILTER ELEMENT AS IT IS
PLACED IN A HIGH PLACE.
WHEN COMPRESSED AIR IS TURNED

OFF, THE HEATER HEAD ASSEMBLY
WILL SINK BY GRAVITY.
The bottom heater section consists of the fixed

preheater as bottom preheater (1) and the mov-
able bottom heater as bottom heater (2).
Firstly, the bottom preheater preheats the carton
bottom which has been loaded onto the mandrel
(3).
Then, the preheated carton is transferred under the
bottom heater. The bottom heater is lowered using
the pivot arm to heat the carton bottom, and poly-
ethylene on carton bottom panels is softened by
hot air. The hot air temperature is detected by the
thermocouple (4).
Then, the carton is transferred to the next section
after the bottom heater returns to the original posi-
tion.
When the machine stops, the bottom heater re-
tracts one step further from the mandrel to avoid
overheating of the mandrel.
No. Parts
(1) Bottom preheater
(2) Bottom heater
(3) Mandrel
(4) Thermocouple
M144- 7294 Issue 01 4- 13

4 Bottom former
4.3.1 Bottom preheater position -

Check & Adjust
(1) 1. Check the dimension A.
(2) If it is not within the standard value, continue with
the next step.
A
(4) Standard
(3)
A 49.01.0 mm
Fig. 4-6. Bottom preheater position
2. Loosen the bolt (1).
3. Adjust the dimension by moving the heater nozzle
(2).
4. After adjustment, tighten the bolt (1).
No. Parts
(1) Bolt
(2) Heater nozzle
(3) Bolt
(4) Heater
4.3.2 Bottom preheater element -

Replace
1. Loosen the bolt (3), and remove the heater (4).

Refer to Fig. 4-6.
2. Replace the heater element with a new one.
Refer to Fig. 14-6.
4.3.3 Bottom preheater element -

Check

2. Run the machine at standby speed until the bot-
tom heaters are up to the temperature.
3. If the heater temperature does not reach the set
temperature after more than15 minutes have
elapsed, the element may be damaged.
If the element damage occurs after reaching the
set temperature, the alarm appears and the
buzzer turns on.
4. If any of the above occurs, follow the proce-
dures in 4.3.2.
4- 14 M144- 7294 Issue 01

4 Bottom former
4.3.4 Bottom preheater nozzle -

Clean
(2)
WARNING
(1)
CHECK THAT THE HEATER NOZZLE
HAS COOLED DOWN.
Fig. 4-7. Bottom preheater nozzle

2. Loosen the bolt (1) and remove the nozzle (2).
3. Remove paper dust etc. from the nozzle.
4.3.5 Bottom heater position - Check

& Adjust
(4)
1. Place the heater nozzle (1) in the lowest position

by jog.
If it is not within the standard value, continue with
the next step.
(3)
(1) (2) Standard
A
A 3.01.0 mm
Fig. 4-8. Bottom heater position
3. Loosen the bolts (2) and nut (3).
4. Adjust the dimension by rotating the bolt (4).
5. After adjustment, tighten the bolts and nut.
No. Parts
(1) Heater nozzle
(2) Bolt
(3) Nut
(4) Bolt
M144- 7294 Issue 01 4- 15

4 Bottom former
4.3.6 Bottom heater element -

(1)
Replace
1. Loosen the bolt (1), and remove the heater (2).

Refer to 16.12.
(2)
Fig. 4-9. Bottom heater element
4- 16 M144- 7294 Issue 01

4 Bottom former
M144- 7294 Issue 01 4- 17

4 Bottom former
4.3.7 Bottom heater element - Heating pattern check
3 2
3 2
Fig. 4-10. Bottom heater element heating pattern
4- 18 M144- 7294 Issue 01

4 Bottom former

2. Run the machine at standby speed until the bot-
tom heaters are up to the temperature.
3. Select BOTTOM SAMPLING ON (1). The main

drive will automatically stop after a carton is
picked and passes through the bottom pre-
heater and the bottom heater.
Note ! The mandrels must stop in their

approximate mid index position be-
(1)
tween the bottom heater and the bot-
tom breaker to avoid additional heat-
ing which could affect the heating
pattern.
Fig. 4-11. BOTTOM HEATER SECTION STATUS 4. Cut the heated carton, remove from the man-
window drel and open up.
5. Check the heating pattern.
S Correct heating pattern (A)
S Bad example (B)
Actual heated area (2) must follow theoretical
heating line (3). Only continue with the following
step if the heating pattern is incorrect, for
example as in (B) where the actual heated area
is not to the heating line for the bottom heater.
CAUTION
SOON AFTER THE HEATERS STOP
RUNNING, HEATERS AND THEIR
SURROUNDS ARE VERY HOT.
BE CAREFUL WHEN CHECKING.
6. Select BOTTOM HEATERS OFF on the MAN-

UAL screen and wait until the heaters have
cooled down.
7. Adjust the position of the heater to obtain the
correct heating pattern.
8. Repeat steps 3 through to 5.
M144- 7294 Issue 01 4- 19

4 Bottom former
4.3.8 Bottom heater nozzle - Clean
1. Loosen the wing nuts (1) and remove the heat-

er nozzle unit (2).
Refer to Fig. 4-12.
2. Remove paper dust etc. from the nozzle.
4.3.9 Bottom heater carton

positioning bolt - Check &
Adjust
(3) 1. Loosen the wing nut (1) and remove the heater
nozzle unit (2).
with the next step.
Standard
A 34.01.0 mm
A (1) 3. Loosen the nut (3).

(2)
4. Adjust the dimension by rotating the carton
(4)
positioning bolt (4).
Fig. 4-12. Carton positioning bolt
No. Parts
(1) Wing nut
(2) Heater nozzle unit
(3) Nut
(4) Carton positioning bolt
4- 20 M144- 7294 Issue 01

4 Bottom former
4.3.10 Pre- filter element for bottom

(2) (3)
heater blower - Clean &
(1) Replace
1. Check the pre- filter element (1) for the bottom

heater blower (2) every 2 weeks.
2. If the pre- filter element is blocked or dirty, rinse
it with water.
3. If dirt persists, wash it with mild detergent.
After washing, let pre- filter element dry suffi-
ciently.
Fig. 4-13. Pre- filter element
4. If it is damaged, replace it with a new one.
No. Parts
(1) Pre- filter element
(2) Bottom heater blower
4.3.11 Filter element for bottom heater

air- Clean & Replace
CAUTION !
Filter elements are water sensitive. Clean them
with air spray only.
1. Check the filter element (3) for the bottom heater

blower (2) every 3 months.
2. If the filter element is blocked or dirty, clean the fil-
ter element by spraying air.
3. If it is damaged, replace it with a new one.
No. Parts
(3) Filter element
M144- 7294 Issue 01 4- 21

4 Bottom former
4.3.12 Bottom heater blower pressure

- Check
Pressure sensors for the bottom heater are at-

(1) (2) (3) (4) (5) (6) tached as shown in Fig. 4-14.
No. Parts
(1) Pressure sensor (Bottom heater R1)
(2) Pressure sensor (Bottom heater R2)
(3) Pressure sensor (Bottom preheater R)
(4) Pressure sensor (Bottom heater L1)
(5) Pressure sensor (Bottom heater L2)
(6) Pressure sensor (Bottom preheater L)
Fig. 4-14. Pressure sensor
1. Push (7) on the PRODUCTION STATUS

screen. Air pressure values for the bottom pre-
(8) heaters are shown in (8), and air pressure val-
ues for the bottom heaters are shown in (9).
(9)
(7) 2. Check each heater air pressure value.
Standard
Pressure (8), (9) 0.8~1.3 kPa
If pressure values (8) (9) are not within the stan-

Fig. 4-15. BOTTOM HEATER SECTION STATUS dard value, check the filter for blockage.
window
4- 22 M144- 7294 Issue 01

4 Bottom former
4.3.13 Bottom heater temperature -

Adjust

screen.
(1)
2. Push ADJUST HEATERS (2) on the MENU

screen.
The ADJUST HEATERS (1/3) screen appears.
(2)
3. Push (3) on the ADJUST HEATERS (1/3)

screen.
The numeric keypad appears.
(3)
Fig. 4-18. ADJUST HEATERS (1/3) screen
M144- 7294 Issue 01 4- 23

4 Bottom former
4. Input the set temperatures for the bottom pre-

(5) heater (4) and bottom heaters 1, 2 (5).
Push Enter (6) to complete the setting.
(4)
5. Click the cross mark [X] in the top right corner
(6) to close the numeric keypad.
(5) Standard
Bottom preheater (4) 200~500 _C
Bottom heaters 1, 2 (5) 300~500 _C
Fig. 4-19. Numeric keypad
4- 24 M144- 7294 Issue 01

4 Bottom former
M144- 7294 Issue 01 4- 25

4 Bottom former
4.4 Bottom breaker
(11)
(13)
(12)
(9)
(17)
(16)
View X
(15)
(14)
(6) (7)
(8)
(18)
(3)
X
(1)
(4) (5) (2) (7)
Fig. 4-20. Bottom breaker
4- 26 M144- 7294 Issue 01

4 Bottom former
Function: To break the carton bottom panels

along the score lines.
The bottom breaker consists of the cam driven

folding arms (1), wings (2), and J- flap breakers (3).
After a carton, which is properly positioned in the
previous process of the bottom heater section, is
transferred to the bottom breaker section, the fold-
ing arms, wings, and J- flap breaker start operating
to break the carton bottom panels along the score
lines while the carton holder (15) driven by the air
cylinder (17) retains the carton against the mandrel
(14).
No. Parts
(1) Folding arm
(2) Pusher
(3) J- flap breaker
(4) Nut
(5) Tie- rod
(6) Bolt
(7) Roller
(8) Bracket
(9) Wing
(10) Lever
(11) Tie- rod
(12) Lever
(13) Air cylinder
(14) Mandrel
(15) Carton holder
(16) Nut
(17) Air cylinder
(18) Tie- rod
M144- 7294 Issue 01 4- 27

4 Bottom former
4.4.1 Wing position - Check & Adjust
Refer to Fig. 4-20.

1. Select MANUAL mode.
3. Check the dimension A, B, C.
If they are not within the standard value, contin-
ue with the next step.
Standard
A 25.03.0 mm
B 1.02.0 mm
C 38.03.0 mm
A
4. Loosen the bolt (19) and adjust the dimensions

B B A~C.
5. After adjustment, tighten the bolt (19).
C
(19)
No. Parts
Fig. 4-21. Wing position
(19) Bolt
4- 28 M144- 7294 Issue 01

4 Bottom former
4.4.2 Folding arm position - Check &

Adjust
Refer to Fig. 4-20.

3. Check the dimension D, E, F, G, H, J.
(23) If they are not within the standard value, contin-
(24)
Standard
(22)
(25) D 12.02.0 mm
H E 12.02.0 mm
J F 0.2.0 mm
D (20)
G 0.2.0 mm
E (21) H 24.02.0 mm
G
J 38.02.0 mm
F
4. Loosen the bolts (6) and adjust the dimension D.

Fig. 4-22. Folding arm position
5. After adjustment, tighten the bolts (6).
6. Loosen the bolt (20) attached the bracket (21)
and adjust the dimension E.
No. Parts 7. After adjustment, tighten the bolt (20).
(20) Bolt 8. Loosen the nut (4) and adjust the dimension F
(21) Bracket by rotating the tie- rod (5).
(22) Bolt 9. After adjustment, tighten the nut (4).
(23) Bolt 10.Loosen the bolt (22) attached the bracket (21)
(24) Bracket and adjust the dimension G.
(25) Bolt 11.After adjustment, tighten the bolt (22).

12.Loosen the bolt (23) attached the bracket (24)
and adjust the dimension H.
13.After adjustment, tighten the bolt (23).
14.Loosen the bolt (25) attached the bracket (24)
and adjust the dimension J.
15.After adjustment, tighten the bolt (25).
M144- 7294 Issue 01 4- 29

4 Bottom former
4.4.3 Pusher position - Check &

Adjust
Refer to Fig. 4-20.

L 3. Check the dimension K, L.
(26)
Standard
K 30.03.0 mm
L 4.03.0 mm
K
4. Loosen the bolts (6) and adjust the dimension

K.
L.
Fig. 4-23. Pusher position
No. Parts
(26) Bolt
4.4.4 Carton holder position - Check

& Adjust
Refer to Fig. 4-20.

3. Check the dimension M.
Standard
M (Push) 0~0.5 mm
(16)
4. Loosen the nut (16) and adjust the dimension
M.
M (Push)
Fig. 4-24. Carton holder position
4- 30 M144- 7294 Issue 01

4 Bottom former
4.4.5 J- flap breaker position - Check

& Adjust
Refer to Fig. 4-20.

(27)
3. Check the dimension N, P.
Standard
N 23.03.0 mm
P 37.03.0 mm
4. Loosen the nut (27) and adjust the dimension

N, P.
N No. Parts
(27) Nut
Fig. 4-25. J- flap breaker position
M144- 7294 Issue 01 4- 31

4 Bottom former
4.4.6 Carton holder timing - Check
Refer to Fig. 4-24.


1,2 Y85L
25
3,4 Y85R
4.4.7 Wing breaking timing - Check
Refer to Fig. 4-21.


1,2 87L,88L
24
3,4 87R,88R
4- 32 M144- 7294 Issue 01

4 Bottom former
4.5 Folding rail
Function: To fold the carton bottom.
Folding rails (1) are designed to fold the carton bot-

(2) (1) tom panels which have been broken along the
score lines in the previous process. After a carton
A passes through this folding rail, bottom is already
formed. Then, the carton is transferred to the next
bottom sealing section.
No. Parts
(1) Folding rail
(2) Nut
B (3) Pressure pad
(3)
Fig. 4-26. Folding rail
4.5.1 Summary of checking,

adjustment values
Refer to Fig. 4-26.

1. Check the dimension A, B.
Standard
A 11.01.0 mm
B 5.01.0 mm
2. Adjust the dimensions by loosening the nut (2).

Caution!
Dimensions A and B are measured at 60_ of the
main drive shaft angle.
Dimensions A and B are measured at the same
height as the upper surface of the mandrel.
M144- 7294 Issue 01 4- 33

4 Bottom former
4.6 Bottom sealer
(5) (1) (2)
(3)
(7)
(6) (4)
(9)
(8)
Fig. 4-27. Bottom sealer
Function: To seal the carton bottom.
The pressure pad (1) moves forward and seals the No. Parts
carton bottom on the mandrel (2). The pressure (1) Pressure pad
pad is driven by the mechanism of rack (3) and
(2) Mandrel
pinion (4) inside the box (5). The pinion is operated
by the lever (8) through the tie- rod (7) which incor- (3) Rack
porates spring case (6). The lever still moves up- (4) Pinion
ward after the pressure pad contacts the carton
bottom. This causes disc spring (9) to contract in (5) Box
the spring case and creates the sufficient force to (6) Spring case
seal. When the pressure pad touches the heated
(7) Tie- rod
carton bottom, temperature will rise. Temperature-
controlled water circulates to keep proper tempera- (8) Lever
ture. (9) Disc spring
4- 34 M144- 7294 Issue 01

4 Bottom former
4.6.1 Dimension between pressure

(4) (3) A
pad and mandrel - Check &
Adjust
1. Move the pressure pad (1) to the closest posi-

tion to the mandrel (2) by hand cranking.
2. Check the dimension A between the pressure
pad and the mandrel.
with the next step.
(1) (2)
Standard
A 0.05~0.2 mm
3. Loosen the bolt (3) and adjust the dimension by

rotating the pinion (4).
No. Parts
(1) Pressure pad
(2) Mandrel
Fig. 4-28. Pressure pad position (3) Bolt
(4) Pinion
A 4.6.2 Dimension between pressure

(1)
pad and 5th panel - Check &
Adjust
(3)
1. Check the dimension A between the 5th panel

(5) (1) of the carton and the score line.
(4) If it is not within the standard value, continue
with the next step.
(2)
Standard
A 0 ~ 0.8 mm
Fig. 4-29. Pressure pad position
2. Loosen the bolts (2) and adjust the pressure
pad (3).
No. Parts
(1) 5th panel
(2) Bolt
(3) Pressure pad
(4) Carton
(5) Emboss
M144- 7294 Issue 01 4- 35

4 Bottom former
4.6.3 Emboss wear - Check
1. Check the emboss for wear.

2. If worn, replace the emboss with a new one.
Fig. 4-30. Emboss
4.6.4 Seal pressure - Check & Adjust
1. Check the dimensions A and B.

If they are not the standard values, continue
with the next step.
The greater value of the dimension B gives
(2) more seal pressure.
The smaller value of the dimension B gives less
(1) seal pressure.
(4) Standard
B A 2.0 mm
A B 291.1 mm
2. Loosen the nuts (1) (2) (3).

(5) 3. Adjust the dimension A by holding the body (4)
and rotating the nut (5).
(3)
5. Adjust the dimension B by rotating the body (4).
6. After adjustment, tighten the nuts (2) (3).
Fig. 4-31. Seal pressure

No. Parts
(1) Nut
(2) Nut
(3) Nut
(4) Body
(5) Nut
4- 36 M144- 7294 Issue 01

4 Bottom former
M144- 7294 Issue 01 4- 37

4 Bottom former
4.7 Carton dust cleaner
(1)
(3)
(2)
(4) X
(5)
(4)
(6) (5) (7)
View Y View X
Fig. 4-32. Carton dust cleaner
4- 38 M144- 7294 Issue 01

4 Bottom former
Function: To remove paper dust and PE dust.
When a carton bottom is folded by the folding rail

(1), or when a carton is transferred to the bottom
sealer (2) for the next process, paper dust and PE
dust may be scattered and stick to some parts. To
remove dust, a suction nozzle (3) is installed as a
paper dust cleaner under the bottom section of the
folding rail. The suction nozzle is connected to the
suction fan (5). The air filter (4) is installed between
the suction nozzle and the suction fan on the L-
side of the machine.
No. Parts
(1) Folding rail
(2) Bottom sealer
(3) Suction nozzle
(4) Air filter
(5) Suction fan
(6) Filter element
(7) Silencer
4.7.1 Filter element for carton dust

cleaner - Clean & Replace
(6)
CAUTION !
Filter elements are water sensitive.
(Clean them with air spray only)
1. Check that the carton dust cleaner is effectively

running. If not, continue with the next step.
2. Remove the air filter (4). (Refer to Fig. 4-32. )
Clean the filter element (6) by spraying air.
Fig. 4-33. Air filter
3. If dirt persists or the filter is damaged, replace it
with a new one.
4. After replacement, assemble the parts in re-
verse order.
M144- 7294 Issue 01 4- 39

4 Bottom former
4.8 Personal notes
4- 40 M144- 7294 Issue 01

5 Unloader
5 UNLOADER
M144- 7294 Issue 01
M144- 7294 Issue 01 5- 1

5 Unloader
5 UNLOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 1
5.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 3
5.1.1 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.1.2 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.1.3 Unloader guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 5
5.2 Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 6
5.2.1 Horizontal movement timing of vacuum head - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7
5.2.2 Vacuum on- off timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 7
5.2.4 Top position of vacuum cup in forward position - Check & Adjust . . . . . . . . . . . . . . . . . . . . 5- 8
5.2.8 Height of bottom position of unloader pusher - Check & Adjust . . . . . . . . . . . . . . . . . . . . . 5- 11
5.3 Turret . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 12
5.3.1 Position between mandrel and turret - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 14
5.3.2 Position between turret guide and carton holder - Check & Adjust . . . . . . . . . . . . . . . . . . . 5- 16
5.3.3 Position between turret guide and carton holder in perpendicular direction - Check . . . . 5- 18
5.3.4 Bevel gear - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 20
5.4 Unloader guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 22
5.4.1 Unloader guide timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 22
5.4.2 Jammed carton detection timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 23
5.4.3 Photoelectric switch for detecting jammed carton - Check / Replace . . . . . . . . . . . . . . . . . 5- 23
5.5 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 24
5- 2 M144- 7294 Issue 01

5 Unloader
5.1 Description
The unloader consists of the following elements:
Chapter Elements
5.1.1 Unloader
5.1.2 Turret
5.1.3 Unloader guide
Refer to Fig. 5-1.

Cartons are removed from the mandrels by the
vacuum cups (8) of the unloaders and transferred
into the turret guides (14).
The cartons are turned 90_ and pushed down into
the carriage conveyor.
M144- 7294 Issue 01 5- 3

5 Unloader
(10)
(6) (8)
(7)
(5)
(11)
(12)
(14)
(13)
(9)
(15) (16)
(17)
(4)
(1)
(3) (2)
Fig. 5-1. Unloader
5- 4 M144- 7294 Issue 01

5 Unloader
5.1.1 Unloader
The unloader consists of the following components:
No. Parts No. Parts

(1) Cam (6) Air cylinder
(2) Cam follower (7) Vacuum head
(3) Lever (8) Vacuum cup
(4) Tie- rod (9) Unloader pusher
(5) Rod
5.1.2 Turret
The turret consists of the following components:
No. Parts No. Parts

(10) Bevel gear (13) Turret
(11) Bevel gear (14) Turret guide
(12) Shaft (15) Photoelectric switch (for detecting unloader
blocking)
5.1.3 Unloader guide
The unloader guide consists of the following components:
No. Parts No. Parts

(16) Guide (17) Air cylinder
M144- 7294 Issue 01 5- 5

5 Unloader
5.2 Unloader
(6)
(9)
(8)
(1) (6)
(5)
(4)
(2) (7)
(3)
Fig. 5-2. Unloader
5- 6 M144- 7294 Issue 01

5 Unloader
Function: To unload the cartons from the man- 5.2.1 Horizontal movement timing of
drels to the turret and then from the vacuum head - Check
turret to the carton holder.
The unloader section has 2 functions: One is to noid valve purpose list (11.4).
transfer a carton from the mandrel (1) to the turret Refer to the Electrical Manual.
guide (2), and the other is to transfer a carton from
the turret guide (2) to the carton holder (3).
Firstly, when the cartons on the mandrels have
been transferred above the turret guides (2), the air 1,2,3,4 08 Y29L, Y29R
cylinder (4) drives the vacuum head (5), causing
the vacuum cups (6) to contact with the cartons.
Then the vacuum cups start to suck the cartons
and lower them through the rod (7) driven by the
cam under the bed, thereby transferring the car-
tons into the turret guides (2). The unloader push- 5.2.2 Vacuum on- off timing - Check
ers (8) are installed through the bracket (9) which
is attached to the rod (7). The unloader pushers The function of this solenoid valve is to switch from
push down the cartons into the carton holders (3). vacuum air to compressed air.
No. Parts noid valve purpose list (11.4).
(1) Mandrel
(2) Turret guide
(3) Carton holder Magazine No. Mode No. Solenoid No.
(4) Air cylinder 1,2,3,4 09 Y7
(5) Vacuum head

(6) Vacuum cup
(7) Rod
(8) Unloader pusher
(9) Bracket
M144- 7294 Issue 01 5- 7

5 Unloader
5.2.3 Vacuum head open- close

timing - Check
The function of this solenoid valve is to open or

close each vacuum section of the vacuum head

1,2,3,4 07 Y5L, Y5R
5.2.4 Top position of vacuum cup in

(2)
(4) forward position - Check &
A
Adjust
(6) 1. Check the dimensions A and B when the vacu-
B um cups (1) contact the mandrel (2).
(5) (1) If they are not within the standard values, con-
(3)
Standard
A 30.01.0 mm
B 23.01.0 mm

A.
3. Loosen the nut (4), turn the rod (5) of the air
cylinder (6) and adjust the dimension B.
4. After adjustment, tighten the bolts and nut.
No. Parts
Fig. 5-3. Vacuum cup position (1) Vacuum cup

(2) Mandrel
(3) Bolt
(4) Nut
(5) Rod
(6) Air cylinder
5- 8 M144- 7294 Issue 01

5 Unloader
5.2.5 Vacuum cup - Check & Replace

(1)
1. Check the vacuum cups (1) for wear and cuts
around the centre and/or edges.
2. Check the vacuum cups for excessive wear at
the cup edges.
3. If damaged, replace the cup with a new one.
No. Parts
(1) Vacuum cup
Fig. 5-4. Vacuum cup
CAUTION !
Always keep the vacuum cup free from dirt or
dust, which may cause trouble in unloading
cartons.
5.2.6 Vacuum nozzle - Clean
1. Remove all dust from the vacuum nozzle (1) by

(1)
periodical air blow.
No. Parts
(1) Vacuum nozzle
Note ! Blockage in the nozzle may cause car-

ton feed problem.
Fig. 5-5. Vacuum nozzle
M144- 7294 Issue 01 5- 9

5 Unloader
5.2.7 Vacuum filter - Check &

(1) Replace
1. Open the cover of the carton feeder and check

the vacuum filters (1) on both sides every two
weeks. If necessary, clean or replace the vacu-
um filter.
Note ! If you replace the filter, pay attention

to the orientation.
Fig. 5-6. Vacuum filter
No. Parts
(1) Vacuum filter
(1)
Fig. 5-7. Vacuum filter position
5- 10 M144- 7294 Issue 01

5 Unloader
5.2.8 Height of bottom position of

unloader pusher - Check &
Adjust
(3)
1. Move the unloader pusher (1) to the lowest

position.
2. Check the dimension A between the bottom rail
(2) and the unloader pusher.
3. Place the carton on the bottom rail, and check
the dimension B between the carton top and the
unloader pusher.
B If they are not within the standard values, con-
Standard
(1)
A (1,000ml) 257.61.0 mm
A B 3.0.1.0 mm
(2)
4. Loosen the bolt (3) and adjust the dimensions A

and B.
5. After adjustment, tighten the bolt.
Fig. 5-8. Unloader pusher position
No. Parts
(1) Unloader pusher
(2) Bottom rail
(3) Bolt
M144- 7294 Issue 01 5- 11

5 Unloader
5.3 Turret
(4) (2) (3)
(7)
(5)
(5) (5)
X
(5)
(8)
(1)
(6) (1)
(8)
View X
Fig. 5-9. Turret
Function: To turn the cartons 90_ and push No. Parts

them into the carton holders.
(1) Turret
The turret (1) turns 90_clockwise through the bevel
(2) Bevel gear
gear (2) installed on the mandrel shaft (3). Carton
bottom is formed on the mandrels (4) on both (3) Mandrel shaft
sides, and then 2 cartons are pushed down into the
turret by the vacuum heads (5), turned 90_ , and (4) Mandrel
transferred above the carton holders (6). Then the (5) Vacuum head
cartons are pushed down into the carton holders
by the unloader pushers (7). (6) Carton holder
(7) Unloader pusher
(8) Carton
5- 12 M144- 7294 Issue 01

5 Unloader
M144- 7294 Issue 01 5- 13

5 Unloader
5.3.1 Position between mandrel and turret - Check & Adjust
(1)
A
(2)
B
B
(2)
(1)
Fig. 5-10. Relation between the mandrel and the turret (1/3)
No. Parts
(1) Mandrel
(2) Turret guide
5- 14 M144- 7294 Issue 01

5 Unloader
1. Check the dimensions A between the mandrel

(1) and the turret guide (2).
with the next step.
(1)
Standard
A A
A 74.5~76.0 mm
2. Loosen the nuts (3) and insert shims between

the turret guide (2) and the turret (4) to adjust
the dimension A.
4. Check the dimension B between the mandrel
(1) and the turret guide (2).
with the next step. (Refer to Fig. 5-10. )
(2) Standard
B 1.0~1.25 mm
(4) (3)
No. Parts
Fig. 5-11. Position between mandrel and turret (3) Nut
(2/3)
(4) Turret
5. Loosen the nut (5), and adjust the dimension B

(6)
with the tie- rod (6) and the bracket (7).
(7)
No. Parts
(5) (5) Nut

(6) Tie- rod
(7) Bracket
Fig. 5-12. Position between mandrel and turret

(3/3)
M144- 7294 Issue 01 5- 15

5 Unloader
5.3.2 Position between turret guide and carton holder - Check & Adjust
(3) (1)
D
E B
(2)
(4)
Fig. 5-13. Position between turret guide and carton holder
Note ! In case that you adjust the carton No. Parts

holder, operate the machine and
check the carton top fin alignment. (1) U- shape turret guide
(Refer to 9.7.1.2) (2) L- side carton holder
(3) R- side carton holder
(4) L- shape turret guide
5- 16 M144- 7294 Issue 01

5 Unloader
1. Check the dimension A between the discharge

side U- shape turret guide (1) and the L- side
carton holder (2).
If it is not within the standard value, adjust the
L- side carton holder (2). (Refer to 6.4.3.1)
Standard
A 0.30.3 mm
2. Check the dimension B between the carton

feed side U- shape turret guide and the R- side
carton holder (3).
R- side carton holder (3).
Standard
B 0.30.3 mm
3. Check dimension C between the discharge side

L- shape turret guide (4) and the R- side carton
holder (3).
If it is not within the standard value, bend the
lower part of the L- shape turret guide and ad-
just the dimension.
Standard
C 0.30.3 mm
4. Check the dimension D between the carton

feed side L- shape turret guide and the L- side
carton holder.
If it is not within the standard value, bend the
lower part of the carton feed side L- shape tur-
ret guide and adjust the dimension.
Standard
D 0.30.3 mm
5. Turn the turret 90_. Check the dimensions A

and B.
If they are not within the standard values, bend
the lower part of the turret guide and adjust the
dimensions.
M144- 7294 Issue 01 5- 17

5 Unloader
5.3.3 Position between turret guide

and carton holder in
perpendicular direction - Check
1. Check that the centres of turret guide and the

carton holder are aligned in the perpendicular
direction.
2. If not, align the centres of the turret guide and
the carton holder referring to 6.3.2. At this time,
the carton holder width should be the dimension
E.
Standard
E 75.0~77.0 mm
5- 18 M144- 7294 Issue 01

5 Unloader
M144- 7294 Issue 01 5- 19

5 Unloader
5.3.4 Bevel gear - Check & Adjust
(5)
(6)
(2)
(3) (4)
(1)
Fig. 5-14. Bevel gear
No. Parts
(1) Turret guide
(2) Nut
(3) Bolt
(4) Bolt
(5) Bevel gear
(6) Bevel gear
5- 20 M144- 7294 Issue 01

5 Unloader
1. Check that backlash is within the standard val-

ue at the tip of the turret guide (1).
with the next step.
Standard
Backlash 0.5 - 1.0 mm
2. When backlash is large:

Loosen the nut (2). Slightly loosen the bolt (3).
Then, as you gradually tighten the bolt (4),
backlash becomes smaller.
When the position is set, fix the bolt (3) by tight-
ening the bolt (3) and nut (2). Finally tighten the
bolt (4).
3. When backlash is small:
Slightly loosen the bolt (4). Loosen the nut (2).
As you gradually tighten the bolt (3), the back-
lash becomes larger.
When the position is set, fix the bolt (3) by tight-
ening the nut (2). Finally tighten the bolt (4).
M144- 7294 Issue 01 5- 21

5 Unloader
5.4 Unloader guide
Function To stabilise cartons while they are

transferred to the carton holder.
The unloader guides (1) are driven by the air cylin-

ders (2).
The air cylinders are extended and the guides sup-
(1) port cartons when the cartons are pushed down
into the carton holders. Photoelectric switches (3)
detect a jammed carton when the cartons are
transferred from the turret guides to the carton
(2) holders.
No. Parts
(1) Unloader guide
(3) (2) Air cylinder
Fig. 5-15. Unloader guide
5.4.1 Unloader guide timing - Check


1,2,3,4 38 Y57L, Y57R
5- 22 M144- 7294 Issue 01

5 Unloader
5.4.2 Jammed carton detection

timing - Check
Refer to Fig. 5-15.

The photoelectric switches (3) detect unloader
blocking.
Magazine No. Mode No. Section

1,2,3,4 11 Unloader blocking
1,2,3,4 10 Carton detection
5.4.3 Photoelectric switch for

detecting jammed carton -
Check / Replace
 Check
vals.
 Replace
If malfunction is found in the above check, replace
the photoelectric switch with a new one.
M144- 7294 Issue 01 5- 23

5 Unloader
5.5 Personal notes
5- 24 M144- 7294 Issue 01

6 Conveyor
6 CONVEYOR
M144- 7294 Issue 01
M144- 7294 Issue 01 6- 1

6 Conveyor
6 CONVEYOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 1
6.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 3
6.1.1 Carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.2 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.3 Bottom rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.1.4 Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 5
6.2 Carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 6
6.3 Conveyor chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 8
6.3.1 Carton holder - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 10
6.3.2 Centring of carton holder - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 12
6.3.3 Conveyor chain tension - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 14
6.4 Bottom rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 15
6.4.1 Bottom rail height - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 16
6.4.2 Bottom rail height - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 18
6.4.3 Carton holder position - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 21
6.4.4 Servo manual operation of carriage conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 22
6.5 Empty carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 30
6.5.1 Empty carton pusher height - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 31
6.5.2 Empty carton pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 31
6.6 Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 32
6.6.2 Reject gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 34
6- 2 M144- 7294 Issue 01

6 Conveyor
6.1 Description
The conveyor consists of the following elements:
Chapter Elements
6.1.1 Carriage conveyor
6.1.2 Conveyor chain
6.1.3 Bottom rail
6.1.4 Discharge conveyor
The conveyor carries the cartons through each

process and discharges them from the machine.
M144- 7294 Issue 01 6- 3

6 Conveyor
(6)
(5)
(10)
X X
View X
(3)
(15)
(9)
(14) (2) (1)
(7)
(11)
(12)
(8)
(4)
(13)
Fig. 6-1. Conveyor system
6- 4 M144- 7294 Issue 01

6 Conveyor
6.1.1 Carriage conveyor
The carriage conveyor consists of the following components:
No. Parts No. Parts

(1) Servo motor (4) Carton holder
(2) Speed reducer (5) Air cylinder
(3) Sprocket (6) Sprocket
6.1.2 Conveyor chain
The conveyor chain consists of the following components:
No. Parts No. Parts

(7) Conveyor chain (9) Guide rail
(8) Chain rail
6.1.3 Bottom rail
The bottom rail consists of the following components:
No. Parts No. Parts

(10) Bottom rail
6.1.4 Discharge conveyor
The discharge conveyor consists of the following components:
No. Parts No. Parts

(11) Motor (14) Drive pulley
(12) Belt (15) Air cylinder
(13) Drive pulley
M144- 7294 Issue 01 6- 5

6 Conveyor
6.2 Carriage conveyor
(4) X (7)
(3)
(1) (2)
(5) (6)
View X
Fig. 6-2. Carriage conveyor
6- 6 M144- 7294 Issue 01

6 Conveyor
Function: To transfer the cartons from the un-

loader section to the discharge con-
veyor.
Carriage conveyor is driven by the servo motor (1)

located on the discharge side. The conveyor chain
(5) is driven by the sprocket (4), which is con-
nected via the shaft (3) to the servo motor. Carton
holders (6) are attached to the carriage conveyor in
order to transfer cartons on the bottom rail (7).
If the carriage conveyor is overloaded, the servo
motor will turn off and trigger the alarm.
After eliminating the trouble, push the ALARM RE-
SET on the graphic panel.
No. Parts
(1) Servo motor
(2) Speed reducer
(3) Shaft
(4) Sprocket
(5) Conveyor chain
(6) Carton holder
(7) Bottom rail
M144- 7294 Issue 01 6- 7

6 Conveyor
6.3 Conveyor chain
(3) (4) (2) (1)
View X
Fig. 6-3. Conveyor chain
Function: To transfer the cartons from the un- No. Parts

loader section to the discharge sec-
tion. (1) Carton holder
(2) Conveyor chain
The carton holders (1) are attached to a pair of (3) Chain rail
conveyor chains (2) so that cartons are transferred (4) Guide rail
from the unloader to the discharge conveyor.
The conveyor chains are supported by the Ultra
High Molecular Weight Polyethylene chain rails (3)
and the Stainless Steel guide rails (4). The guide
rails and the conveyor chains are lubricated with
potable water.
6- 8 M144- 7294 Issue 01

6 Conveyor
M144- 7294 Issue 01 6- 9

6 Conveyor
6.3.1 Carton holder - Check
(2)
X
(3) (1)
(3) (2)
(1)
View X
Fig. 6-4. Carton holder
No. Parts
(1) Conveyor chain
(2) Carton holder
(3) Clip
6- 10 M144- 7294 Issue 01

6 Conveyor
6.3.1.1 Joint - Check & Replace
1. Check that the conveyor chain (1) is connected

to the carton holder (2) with the clip (3).
Note ! Check clips for damage. If clips have

been damaged, clips may fall off and
holders become loose from chains.
2. Connect the carton holder to the conveyor

chain with the clip.
3. If you find defective parts, replace with new
ones.
6.3.1.2 Carton holder damage - Check &

Replace
1. Check that the top of the holder (2) is not bent

or damaged.
If bent or damaged, continue with the next step.
Note ! If the top of the carton holders (2) are

not smoothly curved, cartons cannot
be correctly transferred from the man-
drel to the carriage conveyor. It may
damage the cartons.
2. Set the holder to normal condition.

3. If it cannot be easily fixed, replace it with a new
one.
M144- 7294 Issue 01 6- 11

6 Conveyor
6.3.2 Centring of carton holder - Check & Replace
(3) (2)
(1)
(3)
D,E B,C A
Fig. 6-5. Centring of carton holder
6- 12 M144- 7294 Issue 01

6 Conveyor
1. Check that the bottom rail (1) is located in the

centre between the carton holders (2).
2. Check the dimensions A, B, C, D and E.
Standard
A: Unloader 75.0~77.0 mm
B: Drying heater 75.01.0 mm
C: Filler 75.01.0 mm
D: Top heater 73.01.0 mm
E: Top sealer 72.01.0 mm

between the carton holders.
No. Parts
(1) Bottom rail
(2) Carton holder
(3) Bolt
M144- 7294 Issue 01 6- 13

6 Conveyor
6.3.3 Conveyor chain tension - Adjust
(2)
(1)
Fig. 6-6. Conveyor chain tension
6.3.3.1 Chain tension - Adjust 6.3.3.2 Carton holder position - Check
1. Loosen the bolts (1) Check that the carton holder is correctly positioned
relative to the turret guide.
2. The air cylinder extends when the bolts (1) are
loosened.
6.3.3.3 Carton holder at top sealing position -
3. When the air cylinder (2) stops extending, tigh- Check
ten the bolts (1).
Check the position of the carton holder at the top
No. Parts sealing position.
(1) Bolt
(2) Air cylinder
(Refer to the INSPECTION REPORT)
6- 14 M144- 7294 Issue 01

6 Conveyor
6.4 Bottom rail
(1)
X
(3) (2)
(4)
View X
Fig. 6-7. Bottom rail
Function: To maintain the appropriate height for

the selected carton size.
The bottom rail (1) is located in the centre between

the carton holders (2).
The conveyor chain (3) intermittently transfers car-
tons on the bottom rail (1) from the unloader to the
discharge section.
The height of the bottom rail is automatically con-
trolled by the air cylinder (4) depending on the se-
lected carton size .
If the height is not correct, it will affect the filling
and top sealing operation.
No. Parts
(1) Bottom rail
(2) Carton holder
(3) Conveyor chain
(4) Air cylinder
M144- 7294 Issue 01 6- 15

6 Conveyor
6.4.1 Bottom rail height - Check
C,D
E,F B A
(1)
F E D C B A
Fig. 6-8. Bottom rail height
WARNING
DO NOT PLACE YOUR HANDS NEAR
THE BOTTOM RAIL OR AIR CYLINDERS
FOR DRIVING CONVEYOR WHEN
CHANGING CARTON SIZE. THEY MOVE
COMPLICATEDLY UNTIL THEY ARE SET
IN CORRECT POSITIONS.
6- 16 M144- 7294 Issue 01

6 Conveyor
1. Select the carton size of 1,000ml. Standard

2. Check the heights of the bottom rail (1) at the 1,000ml 125.01.0 mm
positions A, B, C, D, E and F.
750ml 170.01.0 mm
3. Select the carton size of 750ml. A
4. Check the heights of the bottom rail (1) at the 500ml 219.01.0 mm
positions A, B, C, D, E and F. 250ml 271.01.0 mm
5. Select the carton size of 500ml. U family 3.02.0 mm
6. Check the heights of the bottom rail (1) at the B XE family 8.02.0 mm
positions A, B, C, D, E and F.
OPTIMA 4.42.0 mm
7. Select the carton size of 250ml.
1,000ml 117.01.0 mm
8. Check the heights of the bottom rail (1) at the
positions A, B, C, D, E and F. 750ml 162.01.0 mm
C
500ml 211.01.0 mm
A: 1st. top breaker
250ml 263.01.0 mm
B+C: Cap sealer
1,000ml 117.01.0 mm
D: Filler
750ml 162.01.0 mm
E: 2nd. top breaker D
500ml 211.01.0 mm
F: Top sealer
250ml 263.01.0 mm
1,000ml 117.01.0 mm
No. Parts
750ml 162.01.0 mm
(1) Bottom rail E
500ml 211.01.0 mm
250ml 263.01.0 mm
1,000ml 117.01.0 mm
750ml 162.01.0 mm
F
500ml 211.01.0 mm
250ml 263.01.0 mm
M144- 7294 Issue 01 6- 17

6 Conveyor
6.4.2 Bottom rail height - Adjust
(2)
(1)
(3)
Fig. 6-9. Adjustment for 1,000ml
6.4.2.1 For 1,000ml - Adjust
1. Select the carton size of 1,000ml.

3. Adjust the height of the bottom rail (2) by rotat-
ing the bolt (3).
No. Parts
(1) Nut
(2) Bottom rail
(3) Bolt
6- 18 M144- 7294 Issue 01

6 Conveyor
6.4.2.2 For 750ml - Adjust

3. Adjust the height of the bottom rail by rotating
the bolt (5).
(5) No. Parts
(4) (4) Nut

(5) Bolt
Fig. 6-10. Adjustment for 750ml

the bolt (7).
(7) No. Parts
(6) (6) Nut

(7) Bolt
M144- 7294 Issue 01 6- 19

6 Conveyor

the bolt (9).
No. Parts
(9) (8) Nut
(9) Bolt
(8)
6- 20 M144- 7294 Issue 01

6 Conveyor
6.4.3 Carton holder position - Check
6.4.3.1 Unloader turret and carton holder

(1) (2)
position - Check & Adjust
1. Check that cartons are smoothly transferred

from the unloader turret to the carton holder. If
not, continue with the next step.
2. Loosen the bolts (1).
3. Adjust the carton holder by rotating the sprocket
(2).
No. Parts
(1) Bolt
(2) Sprocket
Fig. 6-13. Carton holder position
6.4.3.2 Carton holder and related sections

positions - Check
1. Check that the unloader turret is correctly posi-

tioned relative to the carton holder.
2. Check that the carton holder is correctly posi-
tioned to the following sections.
Refer to Section
9.2.1 1st. top breaker
10.4.6 Cap sealer
8.2.9 Filler
9.5.1 2nd. top breaker
9.6.2 Top heater
9.7.1.7 Top sealer jaw position
M144- 7294 Issue 01 6- 21

6 Conveyor
6.4.4 Servo manual operation of

carriage conveyor

cal Manual, and set the carriage conveyor to the
home position.
D- 5 Left Lane Carriage Conveyor (7 axes)
S D- 5- 1 Jog
After performing the procedures in D- 5- 2 or

D- 5- 3, visually check the clip position of the car-
riage conveyor.
Normally the clips (1), (2) should be aligned in a
straight line as shown in Fig. 6-14.
If the clips (1), (2) are not correctly aligned as
shown in Fig. 6-15. , continue with the steps 1 to 6.
6- 22 M144- 7294 Issue 01

6 Conveyor
(1)
(2)
Fig. 6-14. Clip position of the carriage conveyor (correct)
(1)
(2)
Fig. 6-15. Clip position of the carriage conveyor (not correct)
M144- 7294 Issue 01 6- 23

6 Conveyor
[Example : L- side]
(3)
1. Push SERVO MANUAL OPERAT. (3) on the MENU screen.
6- 24 M144- 7294 Issue 01

6 Conveyor
(4)
Fig. 6-17. SELECT SERVO MANUAL OPERATION window
2. The SELECT SERVO MANUAL OPERATION window appears.

Push and hold LEFT LANE (4).
M144- 7294 Issue 01 6- 25

6 Conveyor
(5)
Fig. 6-18. L. SERVO MANUAL OPERAT. screen
3. The L. SERVO MANUAL OPERAT. screen appears.

Push 7:L1. CONVEYOR (5).
6- 26 M144- 7294 Issue 01

6 Conveyor
(6) (7)
4. (6) appears. Push CONVEYOR 88.9mm JOG (7) to automatically align the holder.
CONVEYOR 88.9mm JOG (7) flashes during alignment.
M144- 7294 Issue 01 6- 27

6 Conveyor
(8) (9)
5. After CONVEYOR 88.9mm JOG (7) stops flashing, visually check the clip position again.
If the clip position is still not correct, perform the step 4.
6. After confirming the correct clip position, push MANUAL (8).
Finally push CONFIRM (9).
6- 28 M144- 7294 Issue 01

6 Conveyor
M144- 7294 Issue 01 6- 29

6 Conveyor
6.5 Empty carton pusher
(2)
(1)
(7)
(6)
(3)
(1) (5) (4)
Fig. 6-21. Empty carton pusher
6- 30 M144- 7294 Issue 01

6 Conveyor
Function: To push the empty cartons to the dis-

charge conveyor.
The empty carton pusher (1), driven by the air cyl-

inder (2), is located at the inlet of the discharge
conveyor. This pushes empty cartons (3) smaller
than 750ml from the bottom rail (4) to the dis-
charge conveyor guide (5).
No. Parts
(1) Empty carton pusher
(2) Air cylinder
(3) Carton
(4) Bottom rail
(5) Discharge conveyor guide
(6) Nut
(7) Cylinder rod
6.5.1 Empty carton pusher height -

Check & Adjust

3. Check the dimension A. If it is not within the
standard value, continue with the next step.
Standard
A 102.5 mm
4. Loosen the nut (6) fixing the pusher.

5. Turn the cylinder rod (7) and adjust the pusher
height.
6.5.2 Empty carton pusher timing -

Check


1,2 Y109L
34
3,4 Y109R
M144- 7294 Issue 01 6- 31

6 Conveyor
6.6 Discharge conveyor
(7) (1) (5) (6)
(3)
(4)
(2)
Fig. 6-22. Discharge conveyor

Function: To discharge the cartons onto the cus- No. Parts
tomer conveyor.
(1) Motor
Discharge conveyor speed is automatically (2) Belt

changes according to the product. The conveyor (3) Drive pulley
speed can also be manually changed by the fre-
quency inverter in the No.2 panel. (4) Driven pulley
Cartons are discharged at a fixed level for all sizes. (5) Photoelectric switch
If any jammed carton is detected by the photoelec- (6) Air cylinder
tric switches, the machine will stop.
(7) Reject gate
The reject gate (7) removes unacceptable cartons
detected by the machine before being transferred
to the customer conveyor.
6- 32 M144- 7294 Issue 01

6 Conveyor
6.6.1 Sensor sensitivity
6.6.1.1 Photoelectric switch sensitivity for

detecting discharge section blocking
- Check & Adjust / Replace
 Check
Push and hold the teach button (1) for more than 2
seconds when no object is in the light beam. The
orange lamp (2) flashes. Upon releasing the but-
ton, the lamp turns on. When a carton is set in the
detecting position, the orange lamp turns off. The
lamp turns on when there is no carton.
 Adjust
(2) (3)
vals.
(1)  Replace
If malfunction is found during the above check, re-
Fig. 6-23. Photoelectric switch place the photoelectric switch with a new one.
No. Parts
(1) Teach button
(2) Orange lamp
(3) Green lamp
M144- 7294 Issue 01 6- 33

6 Conveyor
6.6.2 Reject gate
(2)
(3) (1) (5)
(4)
Fig. 6-24. Discharge conveyor
When machine trouble has occurred, unacceptable position while the unacceptable cartons are being
products may be produced (due to insufficient fill- rejected. After rejecting unacceptable cartons, the
ing volume, poor cap sealing etc.). reject gate automatically returns to the A position.
In this case, the filling machine stops feeding No. Parts
blanks immediately, and the reject gate (1) con-
nected to the air cylinder (2) operates in accor- (1) Reject gate
dance with the preset program to reject unaccept- (2) Air cylinder
able cartons (4) detected by the machine from the
product line. (3) Acceptable carton
Normally the reject gate (1) is in the A position as (4) Unacceptable carton
shown in Fig. 6-24. , however it moves to the B (5) Customer conveyor
6- 34 M144- 7294 Issue 01

7 Carton decontamination
7 CARTON DECONTAMINATION
M144- 7294 Issue 01
M144- 7294 Issue 01 7- 1

7 CARTON DECONTAMINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 1
7.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 3
7.1.1 Carton decontamination diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 6
7.1.2 Hydrogen peroxide spray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 7
7.1.3 UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
7.1.4 Hydrogen peroxide drying heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 8
7.2 Hydrogen peroxide spray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 10
7.2.1 List of solenoid valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 14
7.2.3 Hydrogen peroxide spray standard flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 14
7.2.4 Compulsory air purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 16
7.2.5 Hydrogen peroxide spray - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 18
7.2.6 Hydrogen peroxide spray nozzle position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 7- 20
7.2.7 Hydrogen peroxide spray injection needle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 22
7.2.8 Spray nozzle - Check & Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 23
7.3 UV- lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 24
7.3.2 UV- lamp - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 27
7.3.3 Initialisation of the UV- lamp monitor intensity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 28
7.3.4 UV- monitor intensity - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 29
7.3.5 UV- lamp intensity - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 30
7.3.6 Reflection board lifetime - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 34
7.3.7 Glass breakage detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 37
7.4 Hydrogen peroxide drying heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 40
7.4.1 Drying heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 42
7.4.2 Plate of drying heater - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.3 Drying heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.4 Pre- filter element for drying heater blower - Clean & Replace . . . . . . . . . . . . . . . . . . . . . . 7- 44
7.4.5 Drying heater blower pressure - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 45
7.4.6 HEPA filter element for drying heater air - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . 7- 46
7.5 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 48
7- 2 M144- 7294 Issue 01

7.1 Description
The carton decontamination section consists of the
following elements:
Chapter Elements
7.1.2 Hydrogen peroxide spray assembly
7.1.3 UV- lamp
7.1.4 Hydrogen peroxide drying heater
Firstly, the inside of the cartons are sprayed with

hydrogen peroxide.
Secondly, the cartons are decontaminated by ultra-
violet rays from the UV- lamps.
Lastly, hot air dries and removes hydrogen perox-
ide from the inside of the cartons.
M144- 7294 Issue 01 7- 3

F G
C B A
Fig. 7-1. Carton decontamination
7- 4 M144- 7294 Issue 01

The hydrogen peroxide spray assembly A sprays

hydrogen peroxide into cartons, and the cartons
are decontaminated with ultraviolet rays from UV-
lamp B. Then the hydrogen peroxide drying heater
C dries residual hydrogen peroxide inside the car-
tons with hot air. The cartons will then be trans-
ferred to the next process.
The units A, B and C are equipped with hydrogen
peroxide tank D, heater blower E, pre- filter F, and
HEPA filter G.
Section Description
A Hydrogen peroxide spray assembly
B UV- lamp
C Hydrogen peroxide drying heater
D Hydrogen peroxide tank
E Heater blower (for hydrogen peroxide drying heater and top heater)
F Pre- filter (for hydrogen peroxide drying heater and top heater)
G HEPA filter (for hydrogen peroxide drying heater and top heater)
M144- 7294 Issue 01 7- 5

(55) B15LMP (57)
7- 6
7.1.1
(60) (59)
(38)
(37)
Y304
G37
(56) (36)
(58)
(39)
(34)
(33)
(50) Y303 G36
(32)
(35)
(29) (28)
(43) Y302
(47) B84RP (27)
(42)
(48)
(41) (26)
(49)
(25)
Fig. 7-2. Carton decontamination diagram

(22) (21)
Y301
(31) (30) B84LP (20)
(44)
Carton decontamination diagram
(19)
(8)
(18)
(61) B15RMP (63)

(6) (7)
(24) (23)
(9) (5) (4) (40)
G38
(66) (65) B81RF B82RF
(16) (17) (10)
(13)
(62) (64)
(54)
(43)
(51)
(52) (42) (14) (15) (12) (11) (1)
(45) B81LF B82LF
(53)
(3) (2)
(46)
M144- 7294 Issue 01

7.1.2 Hydrogen peroxide spray assembly
The hydrogen peroxide spray assembly consists of the following components:
No. Parts No. Parts

(1) Hydrogen peroxide container (prepared by (21) Solenoid valve (for hydrogen peroxide spray
customer) of L- side)
(2) Main compressed air (22) Pressure switch (for hydrogen peroxide
spray of L- side)
(3) Clean air (23) Spray nozzle (for mandrel No.2)
(4) Strainer (24) Spray nozzle (for mandrel No.1)
(5) Air pump (25) Air operated valve (for hydrogen peroxide
spray of mandrel No.4)
(6) Air regulator (for hydrogen peroxide tank) (26) Air operated valve (for hydrogen peroxide
(7) Gauge (for hydrogen peroxide tank) (G38) (27) Air regulator (for hydrogen peroxide spray of
R- side)
(8) Level sensor (28) Solenoid valve (for hydrogen peroxide spray
of R- side)
(9) Relief valve (29) Pressure switch (for hydrogen peroxide
spray of R- side)
(10) Hydrogen peroxide tank (30) Spray nozzle (for mandrel No.4)
(11) Ball valve (for hydrogen peroxide drain) (31) Spray nozzle (for mandrel No.3)
(12) Filter assembly (32) Air regulator (for air curtain of L- side)
(13) Air operated valve (for hydrogen peroxide (33) Gauge (for air curtain of L- side) (G36)
filter air vent)
(14) Flow sensor (for mandrel No.2) (34) Solenoid valve (for air curtain of L- side)
(15) Flow sensor (for mandrel No.1) (35) Air curtain nozzle (for L- side)
(16) Flow sensor (for mandrel No.4) (36) Air regulator (for air curtain of R- side)
(17) Flow sensor (for mandrel No.3) (37) Gauge (for air curtain of R- side) (G37)
(18) Air operated valve (for hydrogen peroxide (38) Solenoid valve (for air curtain of R- side)
(19) Air operated valve (for hydrogen peroxide (39) Air curtain nozzle (for R- side)
(20) Air regulator (for hydrogen peroxide spray of (40) Ball valve
L- side)
M144- 7294 Issue 01 7- 7

7.1.3 UV- lamp
The UV- lamp consists of the following components:
No. Parts No. Parts

(41) UV- lamp (for L- side) (44) Chamber (for L- side)
(42) Temp. controlled water (45) UV- lamp (for R- side)
(43) Temp. controlled water return (46) Chamber (for R- side)
7.1.4 Hydrogen peroxide drying heater
The Hydrogen peroxide drying heater consists of the following components:
No. Parts No. Parts

(47) Hydrogen peroxide drying heater (57) Pre- filter (for hydrogen peroxide drying
(for L- side) heater of L- side)
(48) Thermocouple (for hydrogen peroxide drying (58) Heater blower (for hydrogen peroxide drying
heater of L- side) heater of L- side)
(49) Plate of hydrogen peroxide drying heater (for (59) Pressure sensor (for top heater of L- side)
L- side)
(50) Pressure switch (for hydrogen peroxide dry- (60) Top heater (for L- side)
ing heater of L- side)
(51) Hydrogen peroxide drying heater (61) Differential pressure sensor (for hydrogen
(for R- side) peroxide drying heater of R- side)
(52) Thermocouple (for hydrogen peroxide drying (62) HEPA filter (for hydrogen peroxide drying
heater of R- side) heater of R- side)
(53) Plate of hydrogen peroxide drying heater (for (63) Pre- filter (for hydrogen peroxide drying
R- side) heater of R- side)
(54) Pressure switch (for hydrogen peroxide dry- (64) Heater blower (for hydrogen peroxide drying
ing heater of R- side) heater of R- side)
(55) Differential pressure sensor (for hydrogen (65) Pressure sensor (for top heater of R- side)
peroxide drying heater of L- side)
(56) HEPA filter (for hydrogen peroxide drying (66) Top heater (for R- side)
heater of L- side)
7- 8 M144- 7294 Issue 01

M144- 7294 Issue 01 7- 9

7.2 Hydrogen peroxide spray assembly
B81LF B82LF B81RF B82RF

(14) (15) (16) (17)
(13)
G38
(7) (3)
(9)
(5) (12)
View X
(32)
(2) (5) G38 (8) G36 (34)Y303

(13) (7) (33) (36)
(40) G37 (38)Y304
(37)
(20)
(21)Y301
(22) B84LP
(28)Y302
(29) B84RP
(27)
X
(6)
(1)
(12) (11) (10)
Fig. 7-3. Hydrogen peroxide spray assembly (1 of 2)
7- 10 M144- 7294 Issue 01

(23) (24)
(30) (31)
(35)
(39)
(18) (19)
(25) (26)
Fig. 7-4. Hydrogen peroxide spray assembly (2 of 2)
M144- 7294 Issue 01 7- 11

Function: To spray hydrogen peroxide for carton

decontamination.
CAUTION
HYDROGEN PEROXIDE TANK IS UN-
DER PRESSURE. ALWAYS DEPRESSU-
RISE TANK BY CLOSING AIR SUPPLY
VALVE AND OPEN AIR RELIEF VALVE
BEFORE STARTING TO REMOVE COM-
PONENTS FROM THE TANK.
Refer to Fig. 7-2. , Fig. 7-3. and Fig. 7-4.

The inside of the carton is sprayed with hydrogen
peroxide solution mixed with clean air. Hydrogen
peroxide is delivered by the air pump (5) from hy-
drogen peroxide tank (10) through the strainer (4).
The hydrogen peroxide level in the tank is detected
and maintained by the level sensor (8).
Check flow volumes with the flow sensors (14) (15)
(16) (17). If necessary, adjust air pressure, which
pressurises the hydrogen peroxide tank, using the
air regulator (6) to keep correct flow volume .
The hydrogen peroxide flows through air operated
valves (18) (19) (25) (26), and air for spraying hy-
drogen peroxide flows through the solenoid valves
(21) (28). The hydrogen peroxide and air are mixed
and flow into the spray nozzles (23) (24) (30) (31).
The air curtain nozzles (35) (39) are attached on
both sides of the hydrogen peroxide spray section
to avoid leakage into other sections.
7- 12 M144- 7294 Issue 01

No. Parts No. Parts

(1) Hydrogen peroxide container (prepared by (22) Pressure switch (for hydrogen peroxide
customer) spray of L- side) (B84LP)
(2) Main compressed air (23) Spray nozzle (for mandrel No.2)
(3) Clean air (24) Spray nozzle (for mandrel No.1) (B84RP)
(5) Air pump (25) Air operated valve (for hydrogen peroxide
(6) Air regulator (for hydrogen peroxide tank) (26) Air operated valve (for hydrogen peroxide
(7) Gauge (for hydrogen peroxide tank) (G38) (27) Air regulator (for hydrogen peroxide spray of
R- side)
(8) Level sensor (28) Solenoid valve (for hydrogen peroxide spray
of R- side) (Y302)
(9) Relief valve (29) Pressure switch (for hydrogen peroxide
spray of R- side)
(10) Hydrogen peroxide tank (30) Spray nozzle (for mandrel No.4)
(11) Ball valve (for hydrogen peroxide drain) (31) Spray nozzle (for mandrel No.3)
(12) Filter assembly (32) Air regulator (for air curtain of L- side)
(13) Air operated valve (for hydrogen peroxide (33) Gauge (for air curtain of L- side) (G36)
filter air vent)
(14) Flow sensor (for mandrel No.2) (34) Solenoid valve (for air curtain of L- side)
(Y303)
(15) Flow sensor (for mandrel No.1) (35) Air curtain nozzle (for L- side)
(16) Flow sensor (for mandrel No.4) (36) Air regulator (for air curtain of R- side)
(17) Flow sensor (for mandrel No.3) (37) Gauge (for air curtain of R- side) (G37)
(18) Air operated valve (for hydrogen peroxide (38) Solenoid valve (for air curtain of R- side)
spray of mandrel No.2) (Y304)
(19) Air operated valve (for hydrogen peroxide (39) Air curtain nozzle (for R- side)
(20) Air regulator (for hydrogen peroxide spray of (40) Ball valve
L- side)
(21) Solenoid valve (for hydrogen peroxide spray
of L- side) (Y301)
M144- 7294 Issue 01 7- 13

7.2.1 List of solenoid valves

Refer to Fig. 7-3.
Solenoid valve No. Section

(21) Y301 For hydrogen peroxide spray on L- side
(28) Y302 For hydrogen peroxide spray on R- side
(34) Y303 For air curtain on L- side
(38) Y304 For air curtain on R- side
Table 7-1. List of solenoid valves
Refer to the solenoid valve purpose list in chapter 11 for the solenoid valve which controls air operated valve.
7.2.2 Regulator standard pressure

Refer to Fig. 7-3.
Pressure switch Section Standard

Gauge No.
(7) G38 Hydrogen peroxide tank 0.07~0.14 MPa
(22) B84LP Hydrogen peroxide spray on L- side 0.2 MPa
(29) B84RP Hydrogen peroxide spray on R- side 0.2 MPa
(33) G36 Hydrogen peroxide air curtain on L- side 0.1~0.2 MPa
(37) G37 Hydrogen peroxide air curtain on R- side 0.1~0.2 MPa
Table 7-2. Regulator standard pressure
7.2.3 Hydrogen peroxide spray standard flow

Refer to Fig. 7-3.
Flow sensor No. Section Standard

(14) B81LF Flow monitoring of hydrogen peroxide for mandrel No.2
(15) B82LF Flow monitoring of hydrogen peroxide for mandrel No.1
10 ml/min
(16) B81RF Flow monitoring of hydrogen peroxide for mandrel No.4
(17) B82RF Flow monitoring of hydrogen peroxide for mandrel No.3
Table 7-3. Flow monitoring of hydrogen peroxide
7- 14 M144- 7294 Issue 01

M144- 7294 Issue 01 7- 15

7.2.4 Compulsory air purge
1. Push SET MODE (1) on the SETUP screen.

The SET MODE window appears.
(1)
Fig. 7-5. SETUP screen
2. Select the MANUAL mode (2) of RIGHT LANE

and LEFT LANE on the SET MODE window.
Push and hold CONFIRM to complete the set-
ting. The MANUAL screen appears.
(2)
sary when selecting MANUAL mode.
Fig. 7-6. SET MODE window
3. Push carton decontamination section (3).

The CARTON DECONTAMINATION SECTION
STATUS window appears.
(3)
Fig. 7-7. MANUAL screen
7- 16 M144- 7294 Issue 01

4. Push AIR PURGE ON (4) on the CARTON DE-

CONTAMINATION SECTION STATUS window.
a Air remaining in the hydrogen peroxide line
will be discharged to the nozzle side compul-
(4)
sorily.
b While AIR PURGE ON is lit, the air purge is
performed by the automatic program.
Fig. 7-8. CARTON DECONTAMINATION SEC-

TION STATUS window
M144- 7294 Issue 01 7- 17

7.2.5 Hydrogen peroxide spray -

Check & Adjust
1. Push MANUAL ON (1) on the CARTON DE-

CONTAMINATION SECTION STATUS window.
Refer to 7.2.4.
Hydrogen peroxide spray starts.
(1)

TION STATUS window
2. Flow sensors (14) (15) (16) (17) in Fig. 7-3.

monitor the flow volume of hydrogen peroxide.
Check the flow volume of each flow sensor on
the graphic panel.
a Push MENU (2) on the MANUAL screen. The
MENU screen appears.
(2)
b Push VIEW CONDITION (3) on the MENU

screen. The VIEW CONDITION screen ap-
pears.
(3)
sary.
7- 18 M144- 7294 Issue 01

c Push DECONT. SECTION (4) on the VIEW

CONDITION screen.
The DECONTAMINATION SECTION screen
appears.
(4)
d Check the flow of hydrogen peroxide on the

flow sensors (5) on the DECONTAMINATION
SECTION (2/3) screen. Check the standard
(6) flow volume in Table 7-3. If the flow volume is
not correct, continue with the next step.
(5)
Fig. 7-13. DECONTAMINATION SECTION (2/3)

screen
3. Refer to Fig. 7-3.

Adjust the clean air pressure, which pressurises
the hydrogen peroxide tank (10), to be the stan-
dard pressure in the following table using the air
regulator (6) while observing the gauge (7).
Gauge No. Section Standard

(7) Hydrogen peroxide 0.07~0.14
G38 tank MPa
Table 7-4. Regulator standard pressure
Check that the flow volume of hydrogen perox-

ide is equal to the standard value by performing
step 2.
4. The pressure switches (22) (29) in Fig. 7-3.
monitor the spray air pressure of hydrogen per-
oxide. (Refer to 16.8.1.) Check the spray air
pressure (6) on the DECONTAMINATION SEC-
TION (2/3) screen (Fig. 7-13. ). Check the stan-
dard spray air pressure in Table 7-2. If the
spray air pressure is not correct, adjust the
spray air pressure using the air regulators (20)
(27).
M144- 7294 Issue 01 7- 19

X
7.2.6 Hydrogen peroxide spray
(1) nozzle position - Check &
Adjust
(4)
1. Check the dimensions A and B.
If they are not within the standard values, contin-
B
Standard
A (2) A 350.02.0 mm
(1,000 ml)
B 10.02.0 mm
(3)
2. Check that the spray nozzles (1) are directed to
the centre of each carton.
3. Check that the nozzles are installed perpendicu-
lar to the carton flow.
4. Loosen the bolts (2) (3) (4) to adjust the spray
View X nozzles.
Fig. 7-14. Hydrogen peroxide spray nozzle 5. After adjustment, tighten the bolts.
No. Parts
(1) Spray nozzle
(2) Bolt
(3) Bolt
(4) Bolt
7- 20 M144- 7294 Issue 01

M144- 7294 Issue 01 7- 21

7.2.7 Hydrogen peroxide spray injection needle
(2)
(3)
(1)
Detail X
Fig. 7-15. Hydrogen peroxide spray injection needle
1. The flow sensors (14) to (17) and the pressure 3. Next, remove the piping joint (3) and remove
switches (22) (29) in Fig. 7-2. detect clogging the injection needle (1).
in the hydrogen peroxide spray injection needle.
4. After replacing the injection needle with a new
When clogging is detected, carton feed stops
one, assemble it again.
immediately. However, hydrogen peroxide spray
does not stop at this time. 5. Check that the clogging alarm, caused by the
error signal from the flow sensor and pressure
Note ! After the cartons remaining inside the switch, has disappeared. If no abnormalities are
machine have passed through the hy- found, restart production.
drogen peroxide spray section, air No. Parts
supply for spraying hydrogen perox-
ide stops. (1) Injection needle
(2) Nut
2. Check that the air supply stops. Then loosen
(3) Piping joint
the nut (2) of the piping joint and pull out the
tube.
7- 22 M144- 7294 Issue 01

7.2.8 Spray nozzle - Check & Clean

(6- 1)
1. Loosen the nozzle body (1), and remove the
adapter (2).
2. Loosen the plug (3).
3. Remove the nozzle tip (4) and O- ring (5) using
(6- 2) the special tool (6- 1).
4. Clean each element of the disassembled spray
nozzle by air blow.
5. Clean the nozzle tip (4) using the special tool
(6- 2).
6. Check the nozzle body (1), nozzle tip (4) and O-
ring (5).
(3) If they deteriorate or are damaged, replace them
(2)
with new ones.
(5)
7. After cleaning, assemble the spray nozzle in re-
verse order.
(1) No. Parts
(1) Nozzle body
(4)
(2) Adapter
(3) Plug
(4) Nozzle tip
(7) (5) O- ring
(6- 1) Special tool
(6- 2) Special tool
(8)
(7) Sleeve
(8) Packing
Fig. 7-16. Spray nozzle
M144- 7294 Issue 01 7- 23

7.3 UV- lamp

(3) (7)
(5)
(4)
View X (6)
(8)
X
(2) (1)
Fig. 7-17. UV- lamp
7- 24 M144- 7294 Issue 01

Function: To expose the cartons to ultraviolet
CAUTION
irradiation for carton decontamination.
After hydrogen peroxide is sprayed, the inside of
the cartons are decontaminated by ultraviolet rays
from the UV- lamps (1).
THE UV- LAMP CAN CAUSE SERIOUS
The UV- lamp is covered with reflection boards (2)
BURNS TO UNPROTECTED EYES AND
and quartz glass (3). Opening or closing of the
SKIN.
shutter is driven by air. Air enters from the air inlet
(4) and is discharged from the air outlet (5).
(HELMET/FULL FACE MASK,
GOGGLES, RUBBER GAUNTLETS,
RUBBER GLOVES, RUBBER APRON Note ! If the shutter opening/closing speed is
AND RUBBER BOOTS, ETC.) WHILE set too fast, damage may occur. Set
HANDLING UV- LAMP. the shutter to the proper speed (Shut-
NEVER LOOK DIRECTLY AT AN ILLUMI- ter opening/closing speed should be
NATED UV- LAMP. more than 0.5 seconds.)
WHEN PERFORMING ANY WORK ON
THE UV- LAMP, ALWAYS UNPLUG THE Cooling water for the lamp enters from the inlet of
UV- LAMP UNIT FIRST. cooling water (6) and is discharged from the outlet
NEVER OPERATE THE UV SYSTEM of cooling water (7).
WHILE THE UV- LAMPS ARE OUTSIDE
THE UV- LAMP HOUSING.
Note ! Cooling water at 15 to 25 _C should
flow at 2 to 3 litres/min. During the
startup of the lighting, start cooling
Note ! For handling details of the UV- lamp, after the standby signal is output from
refer to the ”Document No.: the power unit. After the lamps turn
M214- 131- 459, High pressure mercu- off, be sure to allow the lamps to cool
ry lamp surface sterilizer, Instruction more than 4 minutes (after cool). (For
manual, Iwasaki Electric Co., Ltd.” in- more details, refer to M214- 131- 459.)
cluded in the Chapter 17 APPENDIX.
The UV- lamp unit is equipped with a UV monitor
(8). However intensity measured by the intensity
meter is not related to this UV monitor. (The UV
monitor only monitors the light near the lamp elec-
trode.)
The glass breakage detector, which is installed on
the UV- lamp unit, detects breakage of the quartz
glass by air flow.
Note ! You cannot confirm the UV- lamp tem-

perature. The thermo switch attached
to the UV- lamp unit only sends nor-
mal temperature signal.
No. Parts No. Parts

(1) UV- lamp (5) Air outlet (shutter close)
(2) Reflection board (6) Inlet of cooling water
(3) Quartz glass (7) Outlet of cooling water
(4) Air inlet (shutter open) (8) UV monitor
M144- 7294 Issue 01 7- 25

7.3.1 UV- lamp lifetime - Check
Note ! When the time to replace the UV-

lamps comes, the ”CONFIRM RUN-
NING HOURS (1/4)” message appears
in the message box (1) on the PRO-
Check for total hours of the UV- lamp
according to the following proce-
dures.
(1) (2)
screen.
2. Push RUNNING HOURS (3) on the MENU

screen.
(3) The RUNNING HOURS (1/4) screen appears.
Note ! Total hours of the UV- lamps can be

checked with UV LAMP for CARTON
HOURS (4) on the RUNNING HOURS
(1/4) screen .
3. When the time to replace the UV- lamp comes,

(4) replace the lamps with new ones.
4. After replacement, push and hold RST (5) to
reset the total hours of UV- lamp.
Refer to the Main Touch Panel Operation Manu-
al in the Electrical Manual.
(5) Standard
Lifetime 2,500 hours
Note ! Even if the intensity of UV- lamp

Fig. 7-20. RUNNING HOURS (1/4) screen shows the standard value or more, re-
place all UV- lamps with new ones
when their lifetime expires and the
alarm appears.

sary.
Note ! Refer to 14.14.1 for replacement of the

UV- lamp.
7- 26 M144- 7294 Issue 01

7.3.2 UV- lamp - Replace

(4) (4)
1. Stop the power, air and water supply.
2. Remove the electric wiring from the UV- lamp
unit (1).
(2) 3. Remove the cooling water piping (2) and air
piping (3) at the couplers. When removing cool-
ing water piping, be careful of the residual liquid
inside the piping on the plug side.
(3)
4. Remove the bolts (4), turn the handles (5) and
remove the UV- lamp unit (1) from the machine.
Note ! For replacement procedures of lamp,

(5) (5) reflection board, and quartz glass, re-
fer to the ”Document No.:
M214- 131- 459, High pressure mercu-
(1) ry lamp surface sterilizer, Instruction
manual chapter 5, Iwasaki Electric Co.,
Ltd.” included in the Chapter 17 AP-
PENDIX.
WARNING
IF YOU USE THE INTENSITY METER IN
AN ENVIRONMENT EXCEEDING ITS WA-
TER PROOF CAPACITY, SERIOUS ACCI-
DENT CAN OCCUR.
IF YOU TOUCH THE HOT UV- LAMP
UNIT, SERIOUS ACCIDENT CAN OCCUR.
CAUTION
Fig. 7-21. UV- lamp unit
IF YOU HANDLE A BROKEN UV- LAMP
WITH BARE HANDS, SKIN IRRITATION
OR INJURY CAN OCCUR.
5. After replacement, perform the above steps in

reverse order to assemble the UV- lamp unit (1)
to the machine.
M144- 7294 Issue 01 7- 27

7.3.3 Initialisation of the UV- lamp

monitor intensity
[Method of use]
1. Push SYSTEM CLEARANCE (1) on the MENU

screen.
The SYSTEM CLEARANCE screen appears.
(1)
2. Push SHUTTER ATUO (2) to open the shutter.
(2)
Fig. 7-23. SYSTEM CLEARANCE screen
3. Push the lamp illumination OFF (3) and it dis-

plays ON. The UV- lamp turns on.
(3)
Fig. 7-24. SYSTEM CLEARANCE screen
7- 28 M144- 7294 Issue 01

4. Push Set 100% (4) when the water temperature

has reached the set temperature and the moni-
tor intensity has stabilised. It takes several min-
utes for the monitor value to stabilise.
Note ! Always perform the work above with

the shutter open. If the shutter is
(4) closed, then the monitor intensity will
rise and the lifetime of the UV- lamp
will be affected.
Note ! Perform the work above immediately

Fig. 7-25. SYSTEM CLEARANCE screen after a UV- lamp replacement.
7.3.4 UV- monitor intensity - Check
1. Push (1) on the PRODUCTION STATUS

screen. UV- intensity value for the carton de-
contamination section is shown in (2).
2. Check the UV- intensity value.
(2)
Standard
UV- intensity (2) >70%
(1) 3. UV- monitor intensity is displayed in %.

Replace the UV- lamp when the value falls be-
Fig. 7-26. CARTON DECONTAMINATION SEC- low 70 %.
TION STATUS window
M144- 7294 Issue 01 7- 29

7.3.5 UV- lamp intensity - Check
(1)
(1) (4)
(2)
(3)
(2)
Fig. 7-27. Jig for UV- lamp meter
No. Parts No. Parts

(1) UV- intensity meter (5) Handle
(2) Jig (6) Grip
(3) Jig (7) UV- lamp unit
(4) Screw
7- 30 M144- 7294 Issue 01

(3) (1)
(5) (5)
(7) (6)
(3) (1) (3) (1)
Fig. 7-28. Measure the intensity
1. Insert the UV intensity meter (1) into the jig (2). 3. Set the jig (3) with the intensity meter in the car-
Insert it into the jig (3) and fix with screws (CS) ton holder. Check that the carton holder is at
(4). the carton stopping position.
2. Turn the handle (5) in the direction of the arrow 4. Hold the grip and slowly lower the UV- lamp
and release the lock. Hold the grip (6) and lift housing.
the UV- lamp housing.
Note ! Measure the intensity after approxi-
Note ! Before the intensity check of the UV- mately 10 minutes have elapsed. Do
lamps, clean the quartz glass surfaces not measure immediately after lighting
with an ethanol soaked cloth or with up as the intensity is not yet stable.
soapy water. Then, wipe the quartz
glass with a soft dry cloth.
M144- 7294 Issue 01 7- 31


(8)

Push and hold CONFIRM (10) to complete the
setting. The MANUAL screen appears.
(10)
(9)
7. Change CARTON UV LAMP (11) from OFF to

ON on the MANUAL screen. The UV- lamp
turns on.
(11)
Note ! After finishing the intensity check,
change CARTON UV LAMP from ON to
OFF on the MANUAL screen.
7- 32 M144- 7294 Issue 01

8. Check the intensity of the UV- lamp(s).

Intensity when replacing
(A) 20 mW/cm2
Note ! Check the intensity in the centre of the

lamp.
9. If the measured value falls bellow the intensity

in (A), replace the UV- lamp(s) with a new
one(s).
CAUTION !
Intensity meter and jig for the intensity meter
are optionally available. When you order the
intensity meter, order the jig for the intensity
meter as well.
M144- 7294 Issue 01 7- 33

7.3.6 Reflection board lifetime -

Check
Note ! Lifetime of the reflection board de-

pends on the UV- lamp hours. Replace
the reflection board approximately
once every 2 times of UV- lamp repla-
cement.
Standard
Note ! Refer to 14.14.1 for replacement of the

reflection board.
7- 34 M144- 7294 Issue 01

M144- 7294 Issue 01 7- 35

7.3.7 Glass breakage detector
(9) (2)
(4) (6)
(1) (3)
B71LF
(5)
B71RF
Y192 Y193
(7) (8)
Detail A (3) Detail B
Fig. 7-32. Glass breakage detector
7- 36 M144- 7294 Issue 01

The quartz glass (2) is installed on the closed

space (1).
The piping is connected to the vacuum pump from
the air inlet connection (3) through the filter (4), the
flow sensor (5), the check valve (6) and the sole-
noid valve (7).
If the solenoid valve is ON, the closed space (1) is
pressurised approximately - 0.1 MPa by the vacu-
um pump.
If the quartz glass (2) of UV- lamp unit (9) is bro-
ken, the flow sensors(5) detect abnormal flow vo-
lume.
At the same time, the alarm appears on the graph-
ic panel, and the solenoid valves (7) shut off vacu-
um air even when the UV- lamp unit (9) is not oper-
ating.
Note ! For replacement procedures of quartz

glass, refer to the ”Document No.:
ry lamp surface sterilizer, Instruction
manual chapter 5, Iwasaki Electric Co.,
Ltd.” included in the Chapter 17 AP-
PENDIX.
CAUTION
IF THE GLASS IS EXPOSED TO EXCES-
SIVE SHOCK, THE GLASS CAN BREAK.
THE UV- LAMP UNIT DOSE NOT HAVE
A PRESSURE DETECTION FUNCTION.
No. Parts
(1) Closed space
(2) Quartz glass
(3) Air inlet connection
(4) Filter
(5) Flow sensor
(6) Check valve
(7) Solenoid valve
(8) Silencer
(9) UV- lamp unit
M144- 7294 Issue 01 7- 37

7.3.7.1 Air flow check of glass breakage

detector
1. Push MENU (11) on the PRODUCTION STA-

TUS screen.
(11)

screen.
The VIEW CONDITION screen appears.
(12)

sary.
3. Push DECONT. SECTION (13) on the VIEW

CONDITION screen. The DECONTAMINATION
SECTION screen appears.
(13)
7- 38 M144- 7294 Issue 01

4. Check the air flow of glass breakage detector

on the flow sensor (14) on the DECONTAMINA-
TION SECTION (3/3) screen.
Standard
Flow 0.0 L/min
(14)
Fig. 7-36. DECONTAMINATION SECTION (3/3)

screen
M144- 7294 Issue 01 7- 39

7.4 Hydrogen peroxide drying heater
(4)
(7)
(6)
(14)
(5)
(14) (4) (9) (10) (7)

(15)
View X (7)
(9) (10) (8) (8)
(4)
(16) (16)
(6)
Detail Y
X (5)
(1)
(13)
Fig. 7-37. Hydrogen peroxide drying heater (1 of 2)
7- 40 M144- 7294 Issue 01

(17) (2) (1)
(3)
(12) (11)
Fig. 7-38. Hydrogen peroxide drying heater (2 of 2)
No. Parts No. Parts

(1) Hydrogen peroxide drying heater (10) Pressure sensor (HEPA filter differential
pressure for R- side)
(2) Thermocouple (11) Pressure sensor (Drying heater blower pres-
sure for L- side)
(3) Plate of hydrogen peroxide drying heater (12) Pressure sensor (Drying heater blower pres-
sure for R- side)
(4) Pre- filter (13) Top heater
(5) Pre- filter element (14) Wing bolt
(6) Heater blower (15) Nut
(7) HEPA filter (16) Locknut
(8) HEPA filter element (17) Cover
(9) Pressure sensor (HEPA filter differential
pressure for L- side)
Function: To dry out residual hydrogen peroxide

inside the cartons.
The inside of cartons is dried with hot air from the The pressure sensors (11) (12), attached under the
hydrogen peroxide drying heater (1). bed, monitor the air pressure of the hydrogen per-
Air flows through the pre- filter (4), the heater blow- oxide drying heater. The pressure sensors (9) (10)
er (6) and the HEPA filter (7). Air is cleaned by are attached to the upper part of the top heater on
passing through the pre- filter and HEPA filter. L- side of the machine and monitor the HEPA filter
Clean air is separately supplied to the top heater blockage. The hot air temperature is detected by
(13) and the hydrogen peroxide drying heater (1). the thermocouple (2). Air pressure and heater tem-
perature can be checked on the graphic panel.
M144- 7294 Issue 01 7- 41

7.4.1 Drying heater temperature

- Adjust
WARNING

screen.
(1)

(2) screen.
7- 42 M144- 7294 Issue 01

3. Push set temperature (3) from the ADJUST

HEATERS (1/3) screen. The numeric keypad is
displayed.
(3)
4. Input the set temperature for the drying heater,

and push Enter (4) to complete the setting.
5. Click the cross mark [X] (5) in the top right cor-
(5) ner to close the numeric keypad.
Standard
(4) Drying heater 220~240 _C
M144- 7294 Issue 01 7- 43

7.4.2 Plate of drying heater - Clean

Check the plate of hydrogen peroxide drying
heater (3) every week
2. Remove the cover (17).
3. Remove the plate of hydrogen peroxide drying
heater (3).
4. Remove paper dust etc. from the plate of
hydrogen peroxide drying heater.
7.4.3 Drying heater element -

Replace
(1) (3) (2)
1. Loosen the bolts (1) (2), and remove the heater
(3).
Refer to 16.12.
Fig. 7-43. Drying heater element
7.4.4 Pre- filter element for drying

heater blower - Clean &
Replace

Check the pre- filter element (5) for heater blow-
er (6) every two weeks.
2. If the pre- filter element is blocked, loosen the
wing bolt (14), pull out the pre- filter in the direc-
tion of the arrow, and wash it with water.
After washing, let pre- filter element (5) dry suffi-
ciently.
4. If it is damaged, replace with a new one.
7- 44 M144- 7294 Issue 01

7.4.5 Drying heater blower pressure -

Check
The pressure sensors for the hydrogen peroxide

drying heater are attached at the positions (9) (10)
in Fig. 7-37.
1. Push the carton decontamination section (1) on

(1) the PRODUCTION STATUS screen.
The CARTON DECONTAMINATION SECTION
STATUS window appears.
2. Air pressure values for the hydrogen peroxide

drying heater are shown in (2).
(2) 3. Check drying heater air pressure value.
Standard
Pressure (2) 0.8~2.8 kPa
If pressure (2) is not within the standard value,

check the filter for blockage.

TION STATUS window
M144- 7294 Issue 01 7- 45

7.4.6 HEPA filter element for drying

heater air - Check & Replace
Refer to Fig. 7-37.

Check that the HEPA filter (7) is not blocked and
that the differential pressure values of the pressure
sensors (9) (10) indicate less than the standard
value on the graphic panel.
Standard
< 300 Pa
(9) (10)
Note ! The standard value is only an estimate

of the time to replace the filter. More
precisely, replace the filter when the
differential pressure reaches twice as
much as the initial value.
Check the differential pressure (initial
value) when you replace the filter.

screen.
(1)

screen.
(2)
sary.
7- 46 M144- 7294 Issue 01

3. Push TOP SEAL SECTION (3) on the VIEW

CONDITION screen. The TOP SEAL SECTION
(1/3) screen appears.
(3)
4. Check the differential pressure values (4) on the

TOP SEAL SECTION (1/3) screen. If the differ-
ential pressure values exceed the standard val-
ue, continue with the next step to replace HEPA
filter.
(4)
Fig. 7-49. TOP SEAL SECTION (1/3) screen
5. Loosen the nut (15) and locknut (16), and pull

out the HEPA filter element (8) in the direction
of the arrow. (Refer to Fig. 7-37. )
DANGER
HEPA FILTER IN A HIGH PLACE, PREPARE
THE LADDER AND PLATFORM WITH
HANDRAIL FOR SAFETY.
6. Install new HEPA filter element in reverse order.
CAUTION !
Do not wash the HEPA filter element.
M144- 7294 Issue 01 7- 47

7.5 Personal notes
7- 48 M144- 7294 Issue 01

8 Product filling
8 PRODUCT FILLING
M144- 7294 Issue 01
M144- 7294 Issue 01 8- 1

8 Product filling
8 PRODUCT FILLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 1
8.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 3
8.1.1 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.1.2 Carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 6
8.2 Filler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.2.1 Manual cleaning and check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 7
8.2.2 Start procedure after DIAPHRAGM ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 26
8.2.3 Diaphragm - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 29
8.2.4 Float switch for detecting broken diaphragm - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 35
8.2.6 Servo manual operation of filler piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 38
8.2.7 Suck back device - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 40
8.2.8 Suck back membrane - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 43
8.2.9 Filler nozzle position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 44
8.2.10 Rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 46
8.2.11 Rotary valve - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 48
8.2.12 Start procedure after SHAFT SEAL LEAK ALARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 50
8.2.13 Jig description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 52
8.2.14 Rotary valve timing - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 57
8.2.15 Servo manual operation of rotary valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 60
8.2.17 Filling section shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 62
8.3 Carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 64
8.3.1 Carton jam in filling section detection timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 65
8.4 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 74
8- 2 M144- 7294 Issue 01

8 Product filling
8.1 Description
The product filling consists of the following ele- Rotary valves (16) are driven by servo motor (17)
ments: for Combifiller system. A drain valve is fitted on
each of rotary valves to drain products in filler tank
and also provide additional flow through filler dur-
Chapter Elements
ing CIP.
8.1.1 Filler The filler tank (8) is triple- walled with a cooling
8.1.2 Carton lifter jacket. The product temperature is monitored by
the resistance temperature detector (10).
Refer to Fig. 8-1. and Fig. 8-2. This system enables to achieve two different ways
to control the level in filler tank.
Totally 4 horizontal filler pumps (6) with double dia-
phragm pistons (4) are driven by servo motor (1). a) Product level in filler tank is controlled by pro-
Filler pumps are mounted inside machine guard- portional closing motion of auto valve.
ing. When diaphragm (5) is broken, the pressure b) Product level in filler tank is controlled by pro-
switch and float switch detect an abnormal condi- portional motion of supplying pump with auto
tion. valve being fully opened.
Bottom- up filling for all sizes. One time filling. The product supply to the filler tank is controlled by
The lifter rods (20), driven by the servo motors a normally closed aseptic valve (7) with actuator.
(18), lift empty cartons up until the nozzle tips A pressure sensor (9) is mounted on the top of the
come close to the bottom of the cartons. A stripper filler tank to protect the filler tank from over- pres-
(22) retains the cartons lifted. sure.
The cartons are lowered while keeping the preset
distance between the nozzle tips and the product The product level in the filler tank is controlled by
surfaces to minimise foaming. the level probe (14).
The filler pistons, lifter rods and strippers are auto-
matically positioned on size selection.
Filling volume is automatically controlled after size
change.
The filling section is connected to the CIP system
which is prepared by the customer.
M144- 7294 Issue 01 8- 3

8 Product filling
(13) (14)
(11)
(7) (10)
(6) (1) (2) (4) (8)
(16)
(3) (5)
(15)
(22) (23)
(20)
(21)
Detail X
(18) (19)
Fig. 8-1. Product filling (1 of 2)
8- 4 M144- 7294 Issue 01

8 Product filling
(14)
(9)
(7)
(8)
(13)
(10) (9) (11)
(12)
(7)
(16)
(17)
Fig. 8-2. Product filling (2 of 2)
M144- 7294 Issue 01 8- 5

8 Product filling
8.1.1 Filler
The filler consists of the following components:
No. Parts No. Parts

(1) Servo motor (10) Resistance temperature detector
(2) Timing belt (11) Auto valve
(3) Ball screw (12) Spray ball
(4) Filler piston (13) Auto valve
(5) Diaphragm (14) Level probe
(6) Filler pump (15) Filler nozzle
(7) Aseptic valve (16) Rotary valve
(8) Filler tank (17) Servo motor
(9) Pressure sensor
8.1.2 Carton lifter
The carton lifter consists of the following components:
No. Parts No. Parts

(18) Servo motor (21) Rod
(19) Timing belt (22) Stripper
(20) Lifter rod (23) Vertical carton guide
8- 6 M144- 7294 Issue 01

8 Product filling
8.2 Filler
Function: To lift up the cartons, and then to fill a
product into cartons while lowering the
cartons.
8.2.1 Manual cleaning and check
Note ! Use suitable cleaning equipment.

DANGER Immerse the disassembled parts into the caustic
solution.
FOLLOW THE MANUFACTURER’S Condition Criteria

INSTRUCTIONS FOR HANDLING, STORING
AND DISCARDING CHEMICAL. Caustic concentra- 1~2%
tion
Temperature Hot
Immersion time Approximately 30 minutes
WARNING After the solution has well penetrated into the soil,
rinse the parts with water.
CHEMICALS USED FOR CLEANING OR Note ! Place the disassembled parts on a

SANITISING CAN BURN EYES AND rubber mat not to cause damage to
SKIN. ALWAYS WEAR PROTECTIVE the parts.
GEAR (HELMET/FULL FACE MASK,
GOGGLES, RUBBER GAUNTLETS, RUB-
BER GLOVES, RUBBER APRON AND Note ! Be careful not to lose the parts when
RUBBER BOOTS, ETC.) BEFORE HAN- you disassemble them.
DLING CHEMICAL.
Note ! Make sure that there are no foreign
objects on the parts after manual
cleaning.
WARNING
CIP/SIP LIQUID MAY REMAIN IN THE
FILLER AND PIPES IF CIP IS INTERRUP-
TED.
CAUTION
DILUTED CHEMICALS REMAINING IN
THE FILLERS AND PIPES.
M144- 7294 Issue 01 8- 7

8 Product filling
8.2.1.1 Removal of filler nozzle
1. Loosen the wing bolt (1) and remove the hori-

zontal carton guide (2).
(2) (1)
(2) (1)
Fig. 8-3. Horizontal carton guide (with caps)
(2) (1)
(2) (1)
Fig. 8-4. Horizontal carton guide (No- caps)
8- 8 M144- 7294 Issue 01

8 Product filling
2. Loosen the wing bolt (3) and remove the verti-

cal carton guide (4).
(4)
(3)
Fig. 8-5. Vertical carton guide
3. Remove the nozzles from the filler tube (5).
[In case of screen nozzle (Option)]

A. Loosen the nozzle nut (6) and remove the
(5) nozzle cap (7).
B. Remove the nozzle nut.
(6)
(7)
Fig. 8-6. In case of screen nozzle (Option)
M144- 7294 Issue 01 8- 9

8 Product filling
[In case of rubber nozzle]

A. Remove the rubber nozzle (8).
(5) B. Loosen and remove the nozzle nut (6).
(6)
(8)
Fig. 8-7. In case of rubber nozzle
8- 10 M144- 7294 Issue 01

8 Product filling
(11) (11)
View X (12)
(10)
(13) (10) (10)
(13)
X
(9) (9) (9)

(5)
(12)
Fig. 8-8. Filler tube
4. Remove the clamps (9) (10), and remove the 6. Pull the filler tube (5) up out of the CIP box.
upper piping (13).
5. Loosen the bolts (11). Unlock the plates (12)
which fix the filler tube (5) by turning.
M144- 7294 Issue 01 8- 11

8 Product filling
8.2.1.2 Screen nozzle (Option) - Check & Clean
(6)
(10)
(2)
(7)
(11)
(8)
(1)
(3) (9)
(4)
(5)
Fig. 8-9. Screen nozzle (Option)
No. Parts No. Parts

(1) Filler tube (7) Nozzle adapter
(2) Tool (8) O- ring
(3) O- ring (9) Screen and spacer
(4) Nozzle nut (10) Nozzle cap
(5) Packing (11) Jig
(6) Packing
8- 12 M144- 7294 Issue 01

8 Product filling
CAUTION !
Clean and disinfect your hands before handling
any parts.
CAUTION !
Disassemble, clean and check the screen
nozzle during CIP.
Refer to Operator’s Manual 6.4.
Note ! Ultrasonic cleaning is recommended

for the screens and spacers.
1. Disassemble the screen nozzle.

Note ! Place the disassembled parts on a

rubber mat not to cause damage to
the parts.
Note ! Be careful not to lose the parts when

you disassemble them.
2. Use the disassembly tool (12) when you re-

(10) move the screens and spacers (9) from the
nozzle cap (10) at the top of the nozzle.
(9)
Note ! Screen nozzle can be easily disas-

sembled without damage by use of the
tool.
3. Check screens and spacers etc. for damage. If

damaged, replace with new ones.
(12) 4. Clean all parts.
5. Install all parts without the nozzle cap.
6. Install the nozzle cap.
(Refer to next page.)
Fig. 8-10. Tool
M144- 7294 Issue 01 8- 13

8 Product filling
[Install the nozzle in case of screen nozzle

(1) (Option)]
a) Slightly screw the nozzle nut (2) into the filler
tube (1).
(2)
b) Install the screen and spacer in the nozzle cap
(10). (Refer to 8.2.1.3)
c) Install the nozzle cap (10) to the nozzle nut (2).
d) Tighten the nozzle nut.
(10)
Fig. 8-11. In case of screen nozzle (Option)
Note ! The screen nozzle has a rectangle

nozzle cap. Pay attention to the orien-
tation when you install the nozzle cap.
The nozzle cap has an arrow which
shows the carton flow.
Fig. 8-12. Nozzle cap orientation
e) Place the jig (11) on the nozzle cap (10) to

(10) check the orientation of the nozzle cap.
(11)
Fig. 8-13. Nozzle alignment
8- 14 M144- 7294 Issue 01

8 Product filling
8.2.1.3 Sequence of screen and spacer
(7) (3)
(8) (8)
(4) (6)
(8) (8)
(7) (2)
(8) (8)
(4) (5)
(8) (8)
(6) (1)
(8)
Fig. 8-14. Sequence of screen and spacer
No. Parts No. Parts

(1) Screen (#12) (5) Screen (#14)
(2) Screen (#14) (6) Screen (#17)
(3) Screen (#17) (7) Screen (#26)
(4) Screen (#26) (8) Spacer (t1)
M144- 7294 Issue 01 8- 15

8 Product filling
(1) (2) (3) (4)
(5) (6) (7) (8)
Fig. 8-15. Details of screen and spacer
8- 16 M144- 7294 Issue 01

8 Product filling
8.2.1.4 Rubber nozzle - Check & Clean
(6) (7)
(2)
(1)
(3)
(8)
(4)
(5)
Fig. 8-16. Rubber nozzle
No. Parts No. Parts

(1) Filler tube (5) Packing
(2) Tool (6) Nozzle nut (for high viscosity)
(3) O- ring (7) Nozzle nut (for low viscosity)
(4) Packing (8) Rubber nozzle
Note ! Use the proper nozzle nut depending 1. Check all parts for damage.
on the high or low viscosity of the If damaged, replace with new ones.
product to be filled. 2. Clean all parts.
3. Install all parts without the rubber nozzle.
CAUTION !
Clean and disinfect your hands before handling 4. Install the rubber nozzle.
any parts.
CAUTION !
Disassemble, clean and check the rubber
nozzle during CIP.
Refer to Operator’s Manual 6.4.
M144- 7294 Issue 01 8- 17

8 Product filling
8.2.1.5 Filler piston drive section - Check & Replace
(7)
(4) (5)
(8) (3)
X
Y
(9)
(8)
(10) View X
(1)
(11)
(2)
(6)
(7)
(12)
(13)
View Y
Fig. 8-17. Temporary placement of servo motor and speed reducer
8- 18 M144- 7294 Issue 01

8 Product filling
CAUTION !
any parts.
CAUTION !
Disassemble and check the housing assembly
monthly.
1. Remove the covers (3) (4) (5) surrounding the

rotary valve (1) and the servo motor (2).
2. Install the jig (tray) (7) on which the servo motor
and speed reducer (6) should be temporarily
placed.
3. Loosen and remove the bolts (8) and the timing
belt (9).
Note ! Be careful not to drop the servo motor

and speed reducer from the jig.
4. Disconnect the clamps at the rotary valve inlet

(11), at the rotary valve outlet (12), and at the
tank drain port (13).
No. Parts
(1) Rotary valve
(2) Servo motor
(3) Cover
(4) Cover
(5) Cover
(6) Speed reducer
(7) Jig (tray)
(8) Bolt
(9) Timing belt
(10) Clamp
(11) Rotary valve inlet
(12) Rotary valve outlet
(13) Tank drain port
M144- 7294 Issue 01 8- 19

8 Product filling
(17)
(2)
(6)
(16) (15)
(14)
(10)
(1)
(9)
(8)
Fig. 8-18. Housing assembly
No. Parts No. Parts

(1) Rotary valve (10) Clamp
(2) Servo motor (14) Diaphragm
(6) Speed reducer (15) Piston
(8) Bolt (16) Cylinder
(9) Timing belt (17) Tool
Note ! It is not necessary to disassemble the section marked with A for check.
8- 20 M144- 7294 Issue 01

8 Product filling
5. Disconnect the vacuum tube shown in

Fig. 8-34. (21) from the cylinder (16).
6. The lamp (18) on the PRODUCTION STATUS

(18) screen turns on.
TION STATUS screen.
(19)
8. The red colour of alarm light (20) flashes and

(21)
9. Disconnect the clamp (10). Take out the rotary

valve (1) together with all the attached parts
from the machine.
Note ! Be careful not to drop the rotary valve.
10.Then, disassemble the rotary valve.

(Refer to 8.2.10)
11.Check all parts for damage.

If damaged, replace with new ones.
M144- 7294 Issue 01 8- 21

8 Product filling
12.Assemble the housing assembly.

(17) (14)
Note ! Be careful not to let the diaphragm
(15) (14) crease when you install it to the
piston (15).
Note ! Diaphragm can be easily installed

without creasing by use of the tool
(17).
Note ! Install diaphragm with the smooth

Fig. 8-21. Tool side out.
8- 22 M144- 7294 Issue 01

8 Product filling
M144- 7294 Issue 01 8- 23

8 Product filling
8.2.1.6 Filler tank - Check & Clean
(1)
(11) (5)
(4)
(12)
(1)
(7)
(2)
(9)
(6)
(8)
(6)
(10)
Fig. 8-22. Filler tank
8- 24 M144- 7294 Issue 01

8 Product filling
DANGER
CHECK THAT NO PERSON IS ON THE
WORKSTATION UNDER THE FILLER TANK,
WHEN MAINTAIN THE FILLER TANK ON
THE PLATFORMS.
CAUTION !
Clean and disinfect your hands before clean-
ing.
CAUTION !
Disassemble, clean and check the filler tank
every three months.
1. Remove the air tube from the auto valve (1) and
regulator valve (12).
2. Remove all parts from the filler tank (10).
3. Check the parts for damage.
If damaged, replace with new ones.
4. Clean all parts.
5. Install all parts.
6. Connect the air tube to the auto valve and regu-
lator valve.
No. Parts
(1) Auto valve
(2) Proximity switch
(3) Tank lid
(4) Pressure sensor
(5) Resistance temperature detector
(6) Clamp
(7) Packing
(8) Spray ball
(9) Pin
(10) Filler tank
(11) Level probe
(12) Regulator valve
M144- 7294 Issue 01 8- 25

8 Product filling
8.2.2 Start procedure after

DIAPHRAGM ALARM
 When the diaphragm is broken, the pressure

switches (1) and float switches (2), which are
attached under the bed in the filling section, will
detect an abnormal condition.
(Refer to 8.2.4 and 16.8.1.)
(2)
(1)
Fig. 8-23. Pressure switch and float switch
 When the pressure switches detect any ab-

normality
(3) STATUS screen. (Refer to Fig. 8-30. )
Before resetting the alarm, check the following.
S Damage, which can cause leakage, is not found
on the piping of the vacuum line (from the cylin-
der (22) to the pressure switch (1)).
(Refer to Fig. 8-23. and Fig. 8-34. )
S The vacuum tubes (21) (Refer to Fig. 8-34. )
Fig. 8-24. ALARM LIST screen are correctly connected.
S The clamp (14) (Refer to Fig. 8-34. ) is correctly
tightened.
S The diaphragms (19) (23) are not broken.
If broken, replace with new ones.
(Refer to 8.2.3)
2. Push L1. FILLER DIAPHRAGM ALARM (3) on

the ALARM LIST screen.
The Alarm help screen appears.
8- 26 M144- 7294 Issue 01

8 Product filling
3. Push ON (4) in DIAPHRAGM VACUUM on the

(4) Alarm help screen.
CAUTION !
Check no creases on the diaphragm.
(6)
4. Push RESET (5) on the Alarm help screen.

a) The related alarm on the alarm list is reset.
b) The ALARM LIST screen is reset.
c) The lamp (6) turns off.
(5) (Refer to Fig. 8-25. , Fig. 8-29. )
5. Push OFF (7) in DIAPHRAGM VACUUM on the

Alarm help screen.
(7)
Note ! Do not push OFF (7) until all vacuum
alarms are reset.
6. Push END HELP (8) to return to the PRODUC-

(8) TION STATUS screen.
M144- 7294 Issue 01 8- 27

8 Product filling
 When the float switches detect any abnor-

mality
(3) STATUS screen. (Refer to Fig. 8-30. )
S The diaphragms (19) (23) are not broken.
(Refer to 8.2.3)
Fig. 8-28. ALARM LIST screen S The float switches are not broken.
(Refer to 8.2.4)
2. Push L1. VACUUM POT FILLED (3) on the

ALARM LIST screen.
3. Push ON (4) in DIAPHRAGM VACUUM on the

Alarm help screen.
(4)
CAUTION !
Check no creases on the diaphragm.
4. Follow the same procedures as steps 4 to 6 of

8.2.2., in “When the pressure switches detect
any abnormality”.
(6)
8- 28 M144- 7294 Issue 01

8 Product filling
8.2.3 Diaphragm - Replace
Note ! When the time to replace the dia-

phragm comes, the ”CONFIRM RUN-
Check for working hours of the dia-
phragm according to the following
procedures.
(1) (2)
screen.

(3) screen.
The RUNNING HOURS (1/4) screen appears.
3. Working hours of the diaphragm can be

checked at the FILLER DIAPHRAGM HOURS
(4) on the RUNNING HOURS (1/4) screen.
Replacement of diaphragm (19)

(4) (Refer to Fig. 8-34. )
Every 450 hours
Replacement of diaphragm (23)

Fig. 8-32. RUNNING HOURS (1/4) screen Every 1200 hours
M144- 7294 Issue 01 8- 29

8 Product filling
(11)
(8) (9)
(7)
X
Y (12)
(12) (13)
(14)
View X
(5)
(15)
(5)
(17)
(6) (10)
(18)
(16)
(11)
View Y
Fig. 8-33. Creating space for diaphragm replacement
8- 30 M144- 7294 Issue 01

8 Product filling
 Creating space for diaphragm replacement

4. Remove the covers (7) (8) (9) surrounding the
rotary valve (5) and the servo motor (6).
5. Install the jig (tray) (11) on which the servo mo-
tor and speed reducer (10) should be tempo-
rarily placed.
6. Loosen and remove the bolts (12) and the tim-
ing belt (13).
Note ! Be careful not to drop the servo motor

and speed reducer from the jig.
7. Disconnect the clamps at the rotary valve inlet

(15), at the rotary valve outlet (17), and at the
tank drain port (16).
No. Parts
(5) Rotary valve
(6) Servo motor
(7) Cover
(8) Cover
(9) Cover
(10) Speed reducer
(11) Jig (tray)
(12) Bolt
(13) Timing belt
(14) Clamp
(15) Rotary valve inlet
(16) Tank drain port
(17) Rotary valve outlet
(18) Upper part of suck back device
M144- 7294 Issue 01 8- 31

8 Product filling
(20) (26)
(19)
(14)
(5)
(25)
(24)
(23)
(22)
(21)
Fig. 8-34. Diaphragm replacement
No. Parts
(5) Rotary valve
(14) Clamp
(19) Diaphragm
(20) Filler piston
(21) Vacuum tube
(22) Cylinder
(23) Diaphragm
(24) Retainer
(25) Clamp
(26) Tool
8- 32 M144- 7294 Issue 01

8 Product filling
 Diaphragm replacement
CAUTION !
any parts.
8. Disconnect the vacuum tube (21) from the cylin-

der (22).
9. The lamp (27) on the PRODUCTION STATUS

(27) screen turns on.
10.VIEW ALARM (28) flashes on the PRODUC-
TION STATUS screen.
(28)
11.The red colour of alarm light (29) flashes and

(30)
Fig. 8-36. alarm light and buzzer
12.Disconnect the clamp (14). Take out the rotary

valve (5) together with all the attached parts
from the machine.
Note ! Be careful not to drop the rotary valve.
M144- 7294 Issue 01 8- 33

8 Product filling
13.Replace the diaphragm (19) by use of the tool

(26) (19) (26).
(20) Note ! Be careful not to let the diaphragm

(19) crease when you install it to the
piston (20).
Note ! Diaphragm can be easily installed

without creasing by use of the tool
(26).
Fig. 8-37. Tool Note ! Install diaphragm with the smooth

side out.
14.Reset the DIAPHRAGM ALARM referring to

8.2.2.
15.After replacing the diaphragm, push and hold

RST (31) to reset the working hours of diaph-
ragm.
Refer to the Main Touch Panel Operation Manu-
(31)
Fig. 8-38. RUNNING HOURS (1/4) screen
16.After replacement, assemble in reverse order of

disassembly.
8- 34 M144- 7294 Issue 01

8 Product filling
8.2.4 Float switch for detecting

broken diaphragm - Check
(2)
1. Connect the pipe (1) and pipe (2). Separate the
float switch (3) from the vacuum line.
2. Remove the clamp (4).
(4)
(1) 3. Push up the lower part of the float switch and
check that alarm sounds. if not, replace the lev-
(3) el sensor with a new one.
Fig. 8-39. Float switch for detecting broken dia-
phragm
No. Parts
(1) Pipe
(2) Pipe
(3) Float switch
(4) Clamp
M144- 7294 Issue 01 8- 35

8 Product filling
8.2.5 Timing belt tension - Check & Adjust
(1) (1) (3) (1) (6)
(2) (6)
(1)
(4)
(1) (6)
(8) (8)
(7)
(5)
(5)
A
X (7)
(9)
(10)
(4)
(1)
(12)
(11) View X
Fig. 8-40. Timing belt tension
8- 36 M144- 7294 Issue 01

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1. Loosen the bolts (1), and remove the covers (2) No. Parts
(3) (4).
(1) Bolt
2. Loosen the bolts (5), and pull out the cover (6)
of the filling section frame into the carton de- (2) Cover
contamination section through the space (3) Cover
created by removing the covers (2) (3). (4) Cover
3. Check the dimension A when pushing the tim- (5) Bolt
ing belt (7) with a force of 7.07N~9.42N. If it is
not the standard value, continue with the next (6) Cover
step. (7) Timing belt
Standard (8) Bolt
A 3.12 mm (9) Nut

(10) Bolt
Note ! Use push / pull scale of 7.07N~9.42N (11) Grease pan
force. (12) Bolt

5. Loosen the nut (9), and adjust the timing belt
tension with the bolt (10).
6. After adjustment, tighten the nut and bolts.
7. Check the grease pan (11). If grease has accu-
mulated, loosen the bolts (12), remove the
grease pan and wipe the grease with a clean
cloth.
After cleaning, install the grease pan in reverse
order.
8. Install all the covers.
M144- 7294 Issue 01 8- 37

8 Product filling
8.2.6 Servo manual operation of filler

piston
CAUTION
STOP THE MAIN MOTOR BEFORE
MANUAL OPERATION.
DO NOT TOUCH THE MOVING PARTS.
YOUR FINGER CAN BE CAUGHT DUR-
ING SERVO MOTOR JOG.

cal Manual, and set the filler piston to the home
position.
D- 4 Left Filler Position (Mandrel Side, 2 axes)
S D- 4- 1 Jog
8- 38 M144- 7294 Issue 01

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M144- 7294 Issue 01 8- 39

8 Product filling
8.2.7 Suck back device - Adjust
(1)
Fig. 8-41. The regulator for changing suck back air pressure
Air pressure for the suck back device is preset for
each product. However, if liquid leakage or air in-
take from the rubber nozzle tip is found, continue
with the next steps.
No. Parts
(1) Regulator
(2) Suck back pressure adjustment button
(3) Rubber nozzle
(2)
Fig. 8-42. FILLING SECTION STATUS window
8- 40 M144- 7294 Issue 01

8 Product filling
 When liquid leaks from the rubber nozzle
1. Push the suck back pressure adjustment button

(2) on the FILLING SECTION STATUS window,
and set the larger value than the present value
again on the displayed numeric keypad.
2. When liquid leakage from the rubber nozzle (3)
stops, do not change the air pressure.
(3) Note ! If air pressure is set too high, air is

taken in.
Fig. 8-43. Liquid leaks from the rubber nozzle
 When air is taken in from the rubber nozzle
1. Push the suck back pressure adjustment button

(2) on the FILLING SECTION STATUS window,
and set the smaller value than the present val-
ue again on the displayed numeric keypad.
2. When air intake from the rubber nozzle (3)
stops, do not change the air pressure.
(3) Note ! If air pressure is set too low, liquid

leaks from the rubber nozzle.
Fig. 8-44. Air is taken in from the rubber nozzle
M144- 7294 Issue 01 8- 41

8 Product filling
Note ! If you want to change suck back pres-

sures for the multiple products at a
time, push FILLER SUCKBACK (4) on
the VIEW CONDITION screen and you
can change the suck back pressures
on the displayed window (5).
(4)
(5)
Fig. 8-46. FILLER SUCKBACK SETTING window
8- 42 M144- 7294 Issue 01

8 Product filling
8.2.8 Suck back membrane - Check

& Replace
1. Remove the clamps (1) (2), and remove the

piping (3).
2. Remove the clamps (4) (5), and check the suck
back membrane of the suck back device (6) for
damage.
If damaged, replace with a new one.
Check Cycle
Suck back membrane Weekly
3. After checking / replacing, assemble in reverse

order of disassembly.
(1)
(6)
No. Parts
(1) Clamp
(4)
(2) Clamp
(5) (3) Piping
(4) Clamp
(3) (5) Clamp
(6) Suck back device
(2)
CAUTION !
Clean and disinfect your hands before check-
ing and replacing.
CAUTION !
Disassemble and check the suck back device
weekly.
CAUTION !
Fig. 8-47. Checking and replacing of suck back If air is not supplied to the regulator when the
membrane
operation power is ON, the regulator vibrates,
causing regulator life to be shortened.
During maintenance, be sure to stop the main
air or turn off the operation power.
M144- 7294 Issue 01 8- 43

8 Product filling
8.2.9 Filler nozzle position - Adjust
(8)
(3) (7)
(4)
(7)
(8) Section X- X
(5)
Y
(7) (7)
(2)
(8)
(3)
(8)
(5)
(1)
X
(11)
(4) X (6)
(9) (9)
(10) (10)
(6)
Y
View Y- Y
Fig. 8-48. Filler nozzle position
8- 44 M144- 7294 Issue 01

8 Product filling
8.2.9.1 Filler nozzle position perpendicular to

carton flow - Adjust
1. Remove the clamp (2) which connects the filler No. Parts
nozzle.
(1) Filler nozzle unit
2. Loosen the bolts (3) (4).
(2) Clamp
3. Move the filler nozzle unit (1) perpendicular to
(3) Bolt
the carton flow direction and set the filler nozzle
unit in place. (4) Bolt
4. After adjustment, tighten the bolts (3) (4). (5) Bolt
5. Finally tighten the clamp (2). (6) Bolt
(7) Nut
8.2.9.2 Carton flow direction - Adjust (8) Bolt
(9) Nut
1. Remove the clamp (2) which connects the filler
nozzle. (10) Bolt
2. Loosen the bolts (5) (6). (11) O- ring
3. Loosen the nut (7) (9), and adjust the carton
flow direction with the bolt (8) (10).
4. After adjustment, tighten the nut (7) (9) and the
bolts (5) (6).
5. Finally tighten the clamp (2).
Note ! To adjust the filler nozzle unit (1), use

the bolts (8) (10) on both sides in or-
der to move the filler nozzle unit paral-
lel.
8.2.9.3 O- ring of lid of CIP box - Replace
1. Check the O- ring (11).

2. If damaged, replace it with a new one.
M144- 7294 Issue 01 8- 45

8 Product filling
8.2.10 Rotary valve
(4)
(3) (6)
(2)
(5)
(8)
(1)
(7)
Fig. 8-49. Rotary valve
8- 46 M144- 7294 Issue 01

8 Product filling
The rotary valve (1) is driven by the servo motor

(2) through the timing belt (6) between the drive
pulley (4) and driven pulley (5).
Power transmitted from the timing belt rotates the
rotary plug (7) through the shaft (8).
Rotation speed of the servo motor is controlled
properly by the speed reducer (3).
Rotation direction of the rotary valve is not one
way. The rotary valve rotates towards the filler tank
and towards the filler nozzle alternately. When the
rotary valve rotates towards the filler tank, it opens
to receive product from the filler tank. When the
rotary valve rotates towards the filler nozzle, it
opens to send the product into the filler nozzle.
No. Parts
(1) Rotary valve
(2) Servo motor
(3) Speed reducer
(4) Drive pulley
(5) Driven pulley
(6) Timing belt
(7) Rotary plug
(8) Shaft
M144- 7294 Issue 01 8- 47

8 Product filling
8.2.11 Rotary valve - Check & Replace
(2)
(3)
(1)
(4)
(5)
(17)
(6)
(18)
(7)
(8) (19)
(9) (20)
(10)
(21)
(11) (23) (24)
(22)
(12)
(13)
(14)
(15) (25) (26)
(16)
(27)
Fig. 8-50. Rotary valve
8- 48 M144- 7294 Issue 01

8 Product filling
No. Parts No. Parts

(1) Pulley (15) Cover
(2) Power lock (16) O- ring
(3) Plate (17) Shaft
(4) Nut (18) Key
(5) Nut (19) O- ring
(6) C- shaped retaining ring (20) Rotary plug
(7) Bearing (21) O- ring
(8) Spacer (22) Bolt
(9) Bearing (23) O- ring
(10) Spacer (24) Ring
(11) Shaft seal (25) Ring
(12) O- ring (26) O- ring
(13) Spacer (27) Housing
(14) Shaft seal
CAUTION !
CAUTION Disassemble and check the rotary valve month-
ly.
DISASSEMBLE AND CHECK THE COM- 1. Check all parts for damage.
PONENTS OF THE ROTARY VALVE. If damaged, replace with new ones.
CLEAN AND DISINFECT YOUR HANDS
BEFORE HANDLING ANY PARTS. Check Cycle
All parts 1000 hours
2. Install all parts.
Note ! When reassembling the rotary valve,

install the parts with proper jigs refer-
ring to 8.2.13.
Replacement of shaft seals (11) (14)

Every 1000 hours
Replacement of O- rings (23) (26)

Every 1000 hours
Replacement of rings (24) (25)

Every 2400 hours
M144- 7294 Issue 01 8- 49

8 Product filling
8.2.12 Start procedure after SHAFT SEAL LEAK ALARM
(1)
Fig. 8-51. Level switch case
 When the shaft seal are broken, the level switch

(1) , which is attached frame in the filling sec-
tion, will detect an abnormal condition.
8- 50 M144- 7294 Issue 01

8 Product filling
 When the level switch detect any abnormali-

ty

STATUS screen.
S The shaft seals (11) (14) are not broken.
(Refer to 8.2.11)
(2)
S The level switch is not broken.

2. Push ROTARY VALVE SHAFT SEAL LEAK (3)

on the ALARM LIST screen.
(3)
3. Push RESET (4). Only indicated alarm is reset.

The alarm list and the alarm lamp will turn off
(5)
(reset).
TION STATUS screen.
(4)
M144- 7294 Issue 01 8- 51

8 Product filling
8.2.13 Jig description
 Jig for fitting seal

1. Fit the seal (3) to the cover (2) by using the jig
(1).
No. Parts
(1) (1) Jig
(2) Cover
(3) Seal
(2)
(3)
Fig. 8-55. Jig for fitting seal (Step 1)
2. After fitting the spacer (4), O- ring (5), seal (6)

and spacer (7) to the cover, insert the jig (8)
and tighten them with the nuts (9) (10).
(8)
No. Parts
(10)
(4) Spacer
(9) (5) O- ring
(6) Seal
(2) (7) Spacer
(7) (8) Jig
(6)
(9) Nut
(10) Nut
(5) (4)
8- 52 M144- 7294 Issue 01

8 Product filling
3. Insert the shaft (12) fitted with the jig (11) into
the cover (2) assembled as in Fig. 8-56.
Note ! The jig (11) prevents the seals (3) (6)

from being damaged when the shaft is
(11) inserted into the cover.
No. Parts
(11) Jig
(2) (12) Shaft
(6)
(12)
(3)
4. After removing the nuts (9) (10) from the cover

(2) referring to Fig. 8-56. , remove the jigs (8)
(11)
(11).
(8)
M144- 7294 Issue 01 8- 53

8 Product filling
5. Fit the bearings (13) (14) and the spacer (15),

and tighten them with the nuts (9) (10).
(13) No. Parts

(13) Bearing
(14) Bearing
(10)
(15) Spacer
(9)
(15)
(14)
8- 54 M144- 7294 Issue 01

8 Product filling
 Jig for inserting rotary plug
(6)
(6)
(2)
(2) (5)
(4) (3)
(1)
(1)
(4)
(7)
(2)
(6)
Fig. 8-60. Jig for inserting rotary plug
Use the jigs (1) (2) when rotary plug (5) is inserted No. Parts
into the housing (3) with the rings (4) attached.
(1) Jig
By using the jigs (1) (2), the rings can keep correct
positions relative to the housing (3). Then the (2) Jig
rotary plug can be inserted into the housing. (3) Housing
(4) Ring
Note ! When tightening the bolts (6), the jigs (5) Rotary plug
(1) may rotate. As a result, the upper
and lower jigs (1) may not contact with (6) Bolt
the rotary plug (5) in the same way. (7) Jig
In this case, use the jig (7) to prevent
the jigs (1) from rotating when tighten-
ing the bolts.
M144- 7294 Issue 01 8- 55

8 Product filling
 Jig for fitting O- ring
(4)
(3) (2)
(1)
(5)
Fig. 8-61. Jig for fitting O- ring
The jig (1) is used to hold the cover (3) on the work No. Parts
table (5) when fitting the O- ring (2) between the
cover and the housing (4). (1) Jig
(2) O- ring
Note ! Because the grooves for O- ring are (3) Cover
only on the cover, the O- ring may fail
(4) Housing
to be fitted correctly without the jig.
(5) Work table
8- 56 M144- 7294 Issue 01

8 Product filling
8.2.14 Rotary valve timing - Check &

Adjust
(4)
1. View the rotary valve from the front, and check
(3) the positions of the arrows (1) marked on the
shaft (2) and the plate (3).
2. The positions are correct if they are the same
as in Fig. 8-62. If not, continue with the next
step.
No. Parts
(1) Arrow
(2) Shaft
(3) Plate
(4) Clamp
(2)
(1)
Fig. 8-62. Rotary valve timing

MANU. position.
SERVO MOTOR
OPE. MANU.

screen.
(5)
M144- 7294 Issue 01 8- 57

8 Product filling

MENU screen.

sary.
The SELECT SERVO MANUAL OPERATION win-

dow appears.
(6)

pears.
(7)
Fig. 8-66. SELECT SERVO MANUAL OPERA-

TION window
7. Select axis ROTARY VALVE (8) on the L. SER-

VO MANUAL OPERAT. screen.
8. Push JOG by JOG DEVICE (9).

(8)
a) The lamp turns on.
(9) b) The manual operation by the remote control-
ler is enabled.

Remove the clamp (4) at the top of the rotary
valve, and view the flange section from above.
8- 58 M144- 7294 Issue 01

8 Product filling
(11) 10.Align the rotary plug (10) hole perfectly with the
housing (11) hole as A in Fig. 8-68. by jog op-
eration.
No. Parts
(10) (10) Rotary plug
(11) Housing
Fig. 8-68. Rotary valve timing
11.Push the jog start switch while pushing the en-

able switch.
Refer to 8.2.15 (D- 8- 1).
12.After aligning the rotary plug and housing posi-
tion, perform rotary valve Manual ZERO
(Home) Setting or Auto ZERO (Home) setting in
8.2.15 to set the home position.
13.After adjustment, disconnect the remote con-
14.Turn the SERVO MOTOR key switch to the
OPE. position.
M144- 7294 Issue 01 8- 59

8 Product filling
8.2.15 Servo manual operation of

rotary valve

cal Manual, and set the rotary valve to the home
position.
D- 8 Left Rotary Valve (15 axes)
S D- 8- 1 Jog
8- 60 M144- 7294 Issue 01

8 Product filling
(4) (1) (3) (2)
(1)
(6) (5) (4) (1)

1. Loosen the bolts (1) and remove the cover (2) 8.2.16.1 Timing belt - Replace
to check the timing belt (3) tension.
2. Check the dimension A when pushing the 1. Refer to Fig. 8-69.
centre of the timing belt with a force of Loosen the bolts (1) and remove the cover (2).
79.8N~102.7N. Loosen the bolts (4) and nut (5).
If it is not the standard value, continue with the Loosen the timing belt (3) by turning the bolt (6)
next step. 2. Replace the timing belt with a new one.
Assemble all parts in reverse order.
Standard
A 3.5 mm
3. Loosen the bolts (4) and nut (5).
Adjust the belt tension by turning the bolt (6).
4. After adjustment, assemble all parts in reverse
order.
No. Parts
(1) Bolt
(2) Cover
(3) Timing belt
(4) Bolt
(5) Nut
(6) Bolt
M144- 7294 Issue 01 8- 61

8 Product filling
8.2.17 Filling section shutter
(2) (1) (3)
Fig. 8-70. Filling section shutter
The filling section shutter (1) functions as the safe- No. Parts
ty cover. The shutter is closed when the safety
switch is pushed to stop the carriage conveyor on (1) Shutter
one side during the production on the other side. (2) Air cylinder
The shutter is driven by the air cylinder (2).
(3) Safety sensor
Opening or closing of the filling section shutter is
monitored by the safety sensors (3).
8- 62 M144- 7294 Issue 01

8 Product filling
8.2.17.1 Shutter - Check & Adjust
(3)
(2)
(1) (3) (2)
A
(5)
(4)
Fig. 8-71. Filling section shutter
1. Check the dimension A. 5. If the dimension A is still not the standard value,
adjust the plate (5) by loosening the bolts (4)
and then repeat the steps 4 and 5.
next step.
3. Loosen the nut (1). Then, loosen and remove No. Parts
the reamer bolt (2), and rotate the rod- end (3). (1) Nut
Standard (2) Reamer bolt
A 6 mm (3) Rod- end
4. After adjustment, tighten the reamer bolt and (4) Bolt

nut. (5) Plate
M144- 7294 Issue 01 8- 63

8 Product filling
8.3 Carton lifter
(3)
(4)
(2)
(5)
(1)
(6)
(7)
(9)
(8)
Fig. 8-72. Carton lifter

When filling carton with a product, the rod (1) lifts No. Parts
up a carton (2). The stripper (3) lowers the carton
in proportion to the product level in the carton and (1) Rod
returns it onto the bottom rail (5). The rod (1) is (2) Carton
connected to the rod (4). The rod (4) is attached to
(3) Stripper
the timing belt (9) which connects the pulleys (7)
(8). The rod (4) repeats reciprocating (up and (4) Rod
down) movement. (5) Bottom rail
(6) Servo motor
(7) Pulley
(8) Pulley
(9) Timing belt
8- 64 M144- 7294 Issue 01

8 Product filling
8.3.1 Carton jam in filling section detection timing - Check
(1) (1)
Fig. 8-73. Fibre sensor
If cartons are not correctly placed in the carton Refer to the electrical timing (2.1.5).
holders in the filling section, the cartons are not
transferred to the next section. The fibre sensors
(1) detect that the cartons have not been trans-
ferred and indicate carton jam. Magazine No. Mode No. Solenoid No.
No. Parts 1, 3 52 -
(1) Fibre sensor (for detecting jammed carton 2, 4 53 -
in the filling section)
M144- 7294 Issue 01 8- 65

8 Product filling
8.3.1.1 Fibre sensor sensitivity for detecting

(5) (7) (1) (2) jammed carton in filling section -
Check
the joint box 14. Refer to Fig. 2-34.
(6) (8) (3) (4) Manual.
1. If the actual value (7) does not exceed the set
value when light is received, check the wiring
and correctly position the fibre sensors in pairs.
2. The sensitivity (set value) (8) of the fibre sen-
sors can be adjusted with the adjust button (1)
(2). However, if you cannot, replace the pair of
fibre sensors with a new one.
Note ! For the preset value, refer to the Set-
ting Lists of Equipment Photo Sensor
Set Value in the Inspection Report.
No. Parts
(1) Adjust button (Up)
Fig. 8-74. Fibre sensor amplifier (2) Adjust button (Down)
(3) Mode button
(4) Teaching button
(5) 1CH output indicator (Orange)
(7) Actual value (Displayed in red)
(8) Set value (Displayed in green)
8.3.1.2 Carton guide position - Check

(2)
1. Check the dimension A between the carton
guides (1). If it is not within the standard value,
(1) adjust the carton guide.
Standard
A 75.0±1.0 mm
No. Parts
A A
(1) Carton guide
(2) Stripper
(1)
Fig. 8-75. Carton guide position
8- 66 M144- 7294 Issue 01

8 Product filling
8.3.1.3 Carton lifter rod height - Check
(2) 1. Check the dimension B between the end of the

lifter rod (1) and the upper surface of the bottom
B rail (2).
(3) If it is not within the standard value, adjust the
lifter rod.
(1) (2)
Detail X Standard
B 0~0.5 mm
View Y
Refer to 8.3.1.7
Y
No. Parts
X (1) Lifter rod
(2) Bottom rail
(1)
(3) Carton
Fig. 8-76. Lifter rod position
8.3.1.4 Stripper height - Check
1. Change the carton size to 1,000ml.

(2)
2. Check the dimension C between the upper sur-
face of the bottom rail (1) and the lower surface
(3) of the stripper (2).
carton guide.
Standard
C C 256.01.0 mm
Refer to 8.3.1.7
No. Parts
(1) (1) Bottom rail
(2) Stripper
(3) Carton
Fig. 8-77. Stripper height
M144- 7294 Issue 01 8- 67

8 Product filling
8.3.1.5 Timing belt tension - Check & Adjust
(1) (1)
(4) (5)
(2)
(3)
(6)
Detail X
(7)
8- 68 M144- 7294 Issue 01

8 Product filling
1. Check the dimension D when pushing the tim-

ing belt (1) with a force of 28.4N~37.2N. If it is
not the standard value, continue with the next
step.
Standard
D 6.8 mm
Note ! Use push / pull scale with 28.4~37.2N

force.
2. Loosen the nuts (2).

Move the shaft (4) with the pulley (5) up and
down by turning the bolt (7), and adjust the tim-
ing belt tension.
No. Parts
(1) Timing belt
(2) Nut
(3) Nut
(4) Shaft
(5) Pulley
(6) Nut
(7) Bolt
M144- 7294 Issue 01 8- 69

8 Product filling
8.3.1.6 Stripper position - Adjust
(5)
(3) 1. Place the carton (2) into the carton guide (1).
Check the position of the stripper (3).
If the position is not correct, continue with the
(1) next step.
2. Loosen the bolts (4) and adjust the stripper ac-
cording to the direction of carton flow. Loosen
the bolts (5) and adjust the stripper perpendicu-
lar to the direction of carton flow.
(2)
3. After adjustment, tighten the bolts (4) (5).
No. Parts
(1) Carton guide
(2) Carton
(1) (3) Stripper

(4) Bolt
(4)
(5) Bolt
Fig. 8-79. Stripper position adjustment
8- 70 M144- 7294 Issue 01

8 Product filling
8.3.1.7 Carton lifter rod and stripper height

- Adjust
CAUTION
MANUAL OPERATION.

MANU. position.
SERVO MOTOR
OPE. MANU.
2. Select the carton size of 1,000ml.

screen.
(1)
M144- 7294 Issue 01 8- 71

8 Product filling

MENU screen.
SERVO. MANUAL OPERAT. screen appears.
(2) Note ! Service key in the No.1 panel is neces-

sary.

pears.
(3)
Fig. 8-83. SELECT SERVO MANUAL OPERA-

TION window
6. Select 1:L. LIFTER (4) on the L. SERVO

MANUAL OPERAT. screen.
(4) 7. Adjust the bottom rail (7) upper surface to the

same height as the carton lifter rod (8) upper
surface by jog. Refer to 8.3.1.8.
(5) 8. Push MANUAL (5) on the L. SERVO MANUAL

OPERAT. screen.
(6)
9. Push and hold CONFIRM (6) on the L. SERVO
MANUAL OPERAT. screen for 3 seconds.
8- 72 M144- 7294 Issue 01

8 Product filling
10.Loosen the bolt (9) and adjust the height of

stripper (10).
No. Parts
(7) Bottom rail
(9) (10)
(8) Lifter rod
(11) (9) Bolt
(10) Stripper
(11) Rod
(7)
(8)
Fig. 8-85. Carton lifter rod and stripper height
8.3.1.8 Servo manual operation of carton lifter

cal Manual, and set the carton lifter to the home
position.
D- 3 Left Filling Lifter (1 axis)
S D- 3- 1 Jog
M144- 7294 Issue 01 8- 73

8 Product filling
8.4 Personal notes
8- 74 M144- 7294 Issue 01

9 Top former
9 TOP FORMER
M144- 7294 Issue 01
M144- 7294 Issue 01 9- 1

9 Top former
9 TOP FORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 1
9.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 4
9.2 1st. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 6
9.2.1 1st. top breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 8
9.2.2 Anvil position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
9.2.3 Pad position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 9
9.2.4 Carton stopper position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
9.2.5 Wing angle - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 10
9.3 Carton dust remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 12
9.3.1 Cover position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 13
9.3.2 Air nozzle position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
9.3.3 Nozzle spray timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 14
9.4 Carton pusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 16
9.4.2 Pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 17
9.5 2nd. top breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 18
9.5.1 Breaker position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 20
9.5.3 Breaking timing (fork) - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 21
9.5.4 Breaking timing (wing) - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 21
9.6 Top heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 22
9.6.1 Top heater height - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.2 Top heater - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.3 Top heater nozzle - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.4 Top heater element - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 25
9.6.5 Top heater temperature - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 26
9.6.6 Air filter - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 28
9.6.7 Cooled guide position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 33
9.7 Top sealing section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 34
9.7.1 1st. top sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 36
9.7.2 2nd. top sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9- 49
9- 2 M144- 7294 Issue 01

9 Top former
M144- 7294 Issue 01 9- 3

9 Top former
9.1 Description
The top former consists of the following elements:
No. Elements
(1) 1st. top breaker
(2) Carton dust remover
(3) Carton pusher
(4) 2nd. top breaker
(5) Top heater
(6) 1st. top sealer
(7) 2nd. top sealer
The carton top is formed through breaking, heating

and sealing processes.
9- 4 M144- 7294 Issue 01

9 Top former
(5)
(7) (6) (4) (3) (2) (1)
Fig. 9-1. Top former
M144- 7294 Issue 01 9- 5

9 Top former
9.2 1st. top breaker
(9) (11)
X
(9)
(8)
(12)
(10) (6)
(10)
(4)
(7)
(3)
(5)
(2)
(1)
View X
Fig. 9-2. 1st. top breaker
9- 6 M144- 7294 Issue 01

9 Top former
Function: To pre- break the carton top along the

score lines.
The 1st. top breaker is driven by the cam (1) under

the bed through the tie- rod (4). The 1st. top breaker
moves down in 2 steps.
Firstly, the 1st. top breaker moves down until it
touches the stopper (5) and stops when the anvil (6)
top comes to the score line position.
Secondly, the 1st. top breaker moves further down
using spring pressure (7). In this second step, the
wing (8) pre- breaks the carton top along the score
lines through the tie- rod (9) and the lever (10). The
carton stopper (11) prevents cartons from being
pulled up by the anvil.
In the next section, the carton pusher (12) installed
on the 1st. top breaker pushes the cartons onto the
bottom rail.
No. Parts
(1) Cam
(2) Cam follower
(3) Lever
(4) Tie- rod
(5) Stopper
(6) Anvil
(7) Spring
(8) Wing
(9) Tie- rod
(10) Lever
(11) Carton stopper
(12) Carton pusher
M144- 7294 Issue 01 9- 7

9 Top former
9.2.1 1st. top breaker position - Check & Adjust
(1) (4)
(3)
(2)
Fig. 9-3. 1st. top breaker

1. Check that the anvil (1) is placed in the centre
of the carton holders (2).
2. Loosen the bolt (3) and adjust the anvil accord-
ing to the direction of carton flow.
4. Loosen the bolt (4) and adjust the anvil perpen-
dicular to the direction of carton flow.
No. Parts
(1) Anvil
(2) Carton holder
(3) Bolt
(4) Bolt
9- 8 M144- 7294 Issue 01

9 Top former
9.2.2 Anvil position - Check & Adjust
1. Jog the machine and stop at a position where

(2) the plate (3) touches the stopper (2).
Refer to Fig. 9-5.
(1) and the anvil top (2).
with the next step
Standard
A (1,000 ml) 195.01.0 mm
A
3. Loosen the nut (1) and adjust it by rotating the

stopper (2). Refer to Fig.9- 5.
(1) 4. After adjustment, tighten the nut.
No. Parts
(1) Bottom rail
(2) Anvil top
Fig. 9-4. Anvil position
9.2.3 Pad position - Check & Adjust
1. Check the dimension A between the plate (3)

and the pad (4).
(3) (4) If it is not within the standard value, continue
with the next step.
Standard
(2)
A 22.01.0 mm
A
(1) 2. Loosen the nuts (6) on both sides of the tie- rod
(5) and adjust it by rotating the tie- rod.
3. After adjustment, tighten the nuts.
No. Parts
(1) Nut
(6) (2) Stopper
(3) Plate
(5) (4) Pad
(5) Tie- rod
(6) Nut
Fig. 9-5. Pad position
M144- 7294 Issue 01 9- 9

9 Top former
9.2.4 Carton stopper position -

Check & Adjust
(1)
stopper (1) and the bottom rail (2).
with the next step.
Standard
A (1,000 ml) 259.01.0 mm
2. Loosen the bolt (3) and adjust it.

A
No. Parts
(3) (1) Carton stopper

(2) Bottom rail
(3) Bolt
(2)
Fig. 9-6. Carton stopper position
9.2.5 Wing angle - Check & Adjust

(3) (1)
(1) 1. Check the angle A of the wing (1).

(2) If it is not within the standard value, continue
with the next step.
A
Standard
A 90.01.0_
2. Loosen the bolt (2) and adjust the angle.

Fig. 9-7. Wing angle
No. Parts
(1) Wing
(2) Bolt
(3) Anvil
9- 10 M144- 7294 Issue 01

9 Top former
9.2.6 Carton pusher position - Check

& Adjust
(2) (3)
(1) and the carton pusher (2).
with the next step.
Standard
A (1,000 ml) 249.01.0 mm
A
(1)
A.
No. Parts
(1) Bottom rail
(2) Carton pusher
(3) Bolt
Fig. 9-8. Carton pusher position
M144- 7294 Issue 01 9- 11

9 Top former
9.3 Carton dust remover
(6)
(1) (12)
(2) (2)
(3) (3)
(4) (4)
(7)
(5)
(5) (8)
(9) (10)
(11)
Fig. 9-9. Carton dust remover

Function: To blow paper dust etc. inside the car- No. Parts
ton (4) with clean air from the air
nozzle (2), which moves up and down (1) Support
in synchronisation with the 1st. top (2) Air nozzle
breaker (12). Dust is then removed by
suction fan from the cover (3), which (3) Cover
is located above the opened carton. (4) Carton
The air filter (8) is installed between
(5) Bottom rail
the air nozzle and the suction fan on
the L- side of the machine. (6) Air tube
(7) Stand
(8) Air filter
(9) Filter element
(10) Suction fan
(11) Silencer
9- 12 M144- 7294 Issue 01

9 Top former
9.3.1 Cover position - Check &

(5) (6) (5)
Adjust
1. Check the dimension A between the cover (1)

and the bottom rail (3).
If it is not within the standard value, loosen the
wing bolts (5) and adjust the cover height.
(5) (5)
Standard
(1) A 244.5 mm
B 2. After adjustment, tighten the wing bolts (5).

3. Check the dimension B between the cover and
the carton (2).
A (6) If it is not within the standard value, loosen the
bolts (6) and adjust the cover in the carton flow
direction.
(4) (2) (3) Standard

B 4.0 mm

Fig. 9-10. Cover position
No. Parts
(1) Cover
(2) Carton
(3) Bottom rail
(4) Stand
(5) Wing bolt
(6) Bolt
M144- 7294 Issue 01 9- 13

9 Top former
9.3.2 Air nozzle position - Adjust

(4) (4)
Loosen the bolts (4), and adjust the air nozzle (1)
position perpendicular to the carton flow.
No. Parts
(3)
(1) Air nozzle
(2) Support
(1) (2)
(5) (3) Bracket
(4) Bolt
(6) Bottom rail
(6)
Fig. 9-11. Air nozzle position
9.3.3 Nozzle spray timing


1,2 39 Y251
3,4 39 Y253
9.3.4 Filter element for carton dust

cleaner - Clean & Replace
(9)
CAUTION !
Filter elements are water sensitive.
(Clean them with air spray only)
1. Check that the carton dust cleaner is effectively

running. If not, continue with the next step.
2. Remove the air filter (8). (Refer to Fig. 9-9. )
Clean the filter element (9) by spraying air.
3. If dirt persists or the filter is damaged, replace it
with a new one.
4. After replacement, assemble the parts in re-
verse order.
9- 14 M144- 7294 Issue 01

9 Top former
M144- 7294 Issue 01 9- 15

9 Top former
9.4 Carton pusher
(5)
B B
(3)
(2) (4) (8)

(8) (7) (5)
(8) (8)
(7)
(5) (6)
(3)
(4)
(1)
Fig. 9-13. Carton pusher

Function To push the cartons down to the bot- No. Parts
tom rail
(1) Bottom rail
(2) Cap applicator
Bottom rail (1) lowers after the cap applicator (2)
before hydrogen peroxide spray. For more stable (3) Carton
transfer, cartons (3) can be pushed deeper into the (4) Carton holder
carton holders (4) by the carton pusher (5) until
carton bottom touches the bottom rail. The carton (5) Carton pusher
pusher is driven by the air cylinder (6). (6) Air cylinder
9- 16 M144- 7294 Issue 01

9 Top former
9.4.1 Carton pusher position - Check

& Adjust

pusher (5) and the bottom rail (1).
with the next step.
Standard
A (1,000 ml) 250.01.0 mm

A.
4. Check that both of the dimensions B are equal.
5. If not, loosen the bolts (8) and adjust it.
No. Parts
(7) Bolt
(8) Bolt
9.4.2 Pusher timing - Check


1,2 22 Y21L
3,4 22 Y21R
M144- 7294 Issue 01 9- 17

9 Top former
9.5 2nd. top breaker
(5) (9)
(9)
(5) (4)
(4) (5) (9) (5) (8)
(7)
(3)
(1)
(8)
(6) (7)
(2)
(6) View X
Fig. 9-14. 2nd. top breaker
9- 18 M144- 7294 Issue 01

9 Top former
Function: To break the carton top along the

score lines.
In the previous process, the 1st. top breaker pre-

breaks the carton top along the score lines.
In this process, the 2nd. top breaker breaks the
carton top again. The 2nd. top breaker is located
behind the filling section and consists of the
breakers (wings) (5) driven by the air cylinder (1),
and the breaker (fork) style breaker (9) driven by
the air cylinder (6). When a carton arrives at this
section, the breaker (fork) folds its 1st. and 3rd
panels. Then, the breakers (wings) fold the 2nd.
and 4th. panels.
No. Parts
(1) Air cylinder
(2) Lever
(3) Tie- rod
(4) Lever shaft
(5) Breaker (wing)
(6) Air cylinder
(7) Tie- rod
(8) Lever shaft
(9) Breaker (fork)
WARNING
M144- 7294 Issue 01 9- 19

9 Top former
9.5.1 Breaker position - Check & Adjust
(9) (1) (5) (11) (8)

(9) (9) (5) (7)
D
B (14) (14)
(12) (12)
(4)
(10)
(6)
A C
(10) (12) (10) (3) (10) (3)
(10)
(13)
(2)
Fig. 9-15. 2nd. top breaker
No. Parts No. Parts

(1) Breaker (fork) (8) Set screw
(2) Bottom rail (9) Breaker (wing)
(3) Bolt (10) Bolt
(4) Nut (11) Nut
(5) Lever shaft (12) Lever shaft
(6) Tie- rod (13) Tie- rod
(7) Bolt (14) Bolt
9- 20 M144- 7294 Issue 01

9 Top former
1. Check the dimension A between the breaker 3. Adjust the height of the lever shaft (12) by rotat-
(fork) (1) and the bottom rail (2). ing the tie- rod (13).
4. After adjustment, tighten the bolt and the nut.
with the next step.
5. Check the dimension D between the top ends
Standard of both breakers (wings) (9).
A (1,000 ml) 270.02.0 mm If it is not within the standard value, continue
with the next step.
2. Loosen the bolt (3) and the nut (4) on both Standard
sides of the tie- rod (6).
D 20.03.0 mm
3. Adjust the height of the lever shaft (5) by rotat-
ing the tie- rods.
6. Loosen the bolt (14), and adjust the dimension
4. After adjustment, tighten the bolt and the nut. D.
5. Check the dimension B between the breaker 7. After adjustment, tighten the bolts.
(fork) and the carton.
If it is not within the standard value, continue 9.5.3 Breaking timing (fork) - Check
with the next step.
Standard Refer to the electrical timing (2.1.5) and the sole-

B 8.51.0 mm
6. Loosen the bolt (7) and adjust the dimension B.
1,2 Y105L
8. Check that the breaker (fork) pushes the centre 32
of the 1st. and 3rd panels. 3,4 Y105R
9. If not, continue with the next step.
10.Loosen the set screws (8) and adjust the break- 9.5.4 Breaking timing (wing) - Check
er (fork).
11.After adjustment, tighten the set screws. noid valve purpose list (11.4).
9.5.2 Wing position - Check & Adjust
1. Check the dimension C between the top end of Magazine No. Mode No. Solenoid No.
the breakers (wings) (9) and the bottom rail (2). 1,2 Y107L
If it is not within the standard value, continue 33
with the next step. 3,4 Y107R
Standard
C (1,000 ml) 227.03.0 mm
2. Loosen the bolts (10) and the nuts (11) on both

sides of the tie- rod (13).
M144- 7294 Issue 01 9- 21

9 Top former
9.6 Top heater
(1)
(10) (10) (7)
(9) (5)
(6)
(8)
(4)
(3)
(2)
Fig. 9-16. Top heater
9- 22 M144- 7294 Issue 01

9 Top former
Function: To heat polyethylene by hot air on car-

ton top panels to the sealing tempera-
ture.
Top heater section consists of two heaters (1) on

each side. The polyethylene on carton top panels
is preheated and heated with hot air by two heat-
ers.
The hot air temperature is detected by the thermo-
couples (10).
Top heaters are moved up and down by tie- rod (5)
driven by the mechanical cam (2). When a carton
(6) comes beneath the top heater, the heater low-
ers until the heater nozzle (7) moves into the car-
ton top.
When the machine temporarily stops, the heaters
are lifted higher than usual for safety by air cylinder
(8) to prevent its surrounds from being overheated.
The cooled guides (9) maintain the carton top di-
mension at the top heater section.
No. Parts
(1) Heater
(2) Cam
(3) Cam follower
(4) Lever
(5) Tie- rod
(6) Carton
(7) Heater nozzle
(8) Air cylinder
(9) Cooled guide
(10) Thermocouple
WARNING
M144- 7294 Issue 01 9- 23

9 Top former
(9) (19)
(10)
(11)
(10)
(9) (19)
(15) (1) (17) (18) (12) (14)
(13) (16)
(5)
X
B (4) (6) (7) (6) (6)

A
(7) (5)
(3)
(8) (2)
View X
(4)
Fig. 9-17. Top heater
9- 24 M144- 7294 Issue 01

9 Top former
9.6.1 Top heater height - Check & 4. Loosen the nut (12) and the wing nut (13), and
Adjust adjust the top heater nozzle perpendicular to
the carton flow direction by rotating the bolt
(14).
1. Check the dimension A between the heater
nozzle (1) and bottom rail (2). 5. After adjustment, tighten the wing nut, nut, and
If it is not within the standard value, continue bolt.
with the next step.
9.6.3 Top heater nozzle - Clean
Standard
A 234.01.0 mm 1. Loosen the wing nut (13) and remove the heat-
er nozzle unit (15).
2. Loosen the nuts (4) on both sides of the tie- rod 2. Remove the carton dust from the nozzle sur-
(3) and adjust the dimension by rotating the tie- face and heating pore.
rod.
3. After cleaning, assemble in reverse order.
3. Loosen the bolt (5) and the nut (6), and adjust
the heater nozzle parallel to the bottom rail by No. Parts
rotating the bolt (7).
(8) Carton
4. Tighten the bolts and the nuts after confirming (9) Bolt
the heater nozzle height and angle.
(10) Nut
No. Parts (11) Bolt
(1) Heater nozzle (12) Nut
(2) Bottom rail (13) Wing nut
(3) Tie- rod (14) Bolt
(4) Nut (15) Heater nozzle unit
(5) Bolt (16) Bolt
(6) Nut (17) Bolt
(7) Bolt (18) Heater
(19) Frame
9.6.2 Top heater - Check & Adjust
9.6.4 Top heater element - Replace
1. Check that the top heater nozzle (1) is placed in
the centre of the carton (8).
If not, continue with the next step. 1. Loosen the bolts (16) (17) and remove the heat-
er (18).
2. Loosen the bolts (9) and the nuts (10), and ad-
just the unit position in the carton flow direction. 2. Replace the heater element with a new one.
During adjustment, turn the bolts (11) to move Refer to 16.12
away from the frames (19) so that the bolts (11) 3. Assemble in reverse order.
and frames will not touch each other. After ad-
justment, tighten the bolts (9) and nuts (10).
3. Check the dimension B.
with the next step.
Standard
B 37.01.0 mm
M144- 7294 Issue 01 9- 25

9 Top former
9.6.5 Top heater temperature - Adjust
WARNING

screen.
(1)

(2) screen.
9- 26 M144- 7294 Issue 01

9 Top former
3. Push set temperature (3) from the ADJUST

HEATERS (1/3) screen. The numeric keypad is
displayed.
(3)
4. Input the set temperature for the drying heater,

and push Enter (4) to complete the setting.
5. Click the cross mark [X] (5) in the top right cor-
ner to close the numeric keypad.
(5)
Standard
Top preheater 200 - 500 _C
(4) Top heater 300 - 500 _C
M144- 7294 Issue 01 9- 27

9 Top former
9.6.6 Air filter - Check
(1)
(3)
(2)
(13)
(12)
(13) (1) (10) (11) (8) (6) (9) (7) (3)
View X (14)
(3)
(16)
(2)
(1)
(15) (15)
(10) (11) (16)
(2)
Detail Y
X (12)
(8) (6) (9) (7)

(4) (5)
9- 28 M144- 7294 Issue 01

9 Top former
Air flows through the pre- filter (1), the heater blow- The pressure sensors (6) (7) monitor the air pres-
er (2) and the HEPA filter (3). Air is cleaned by sure of the top pre- heaters. The pressure sensors
passing through the pre- filter and HEPA filter. (8) (9) monitor the air pressure of the top heaters.
Clean air is separately supplied to the top heater The pressure sensors (10) (11) monitor HEPA filter
(4) and the hydrogen peroxide drying heater (5). blockage. Air pressure can be checked on the
graphic panel.
No. Parts No. Parts

(1) Pre- filter (9) Pressure sensor (Top heater for R- side)
(2) Heater blower (10) Pressure sensor (HEPA filter differential

pressure for L- side)
(3) HEPA filter (11) Pressure sensor (HEPA filter differential
pressure for R- side)
(4) Top heater (12) Pre- filter element
(5) Hydrogen peroxide drying heater (13) Wing bolt
(6) Pressure sensor (Top preheater for L- side) (14) Nut
(7) Pressure sensor (Top preheater for R- side) (15) Locknut
(8) Pressure sensor (Top heater for L- side) (16) HEPA filter
9.6.6.1 Pre- filter element for top heater

blower - Clean & Replace

Check the pre- filter element (12) for heater
blower (2) every two weeks.
2. If the pre- filter element is blocked, loosen the
wing bolt (13), pull out the pre- filter in the direc-
tion of the arrow, and wash it with water.
After washing, let pre- filter element (12) dry
sufficiently.
4. If it is damaged, replace with a new one.
M144- 7294 Issue 01 9- 29

9 Top former
9.6.6.2 Top heater blower pressure - Check
The pressure sensors for the top preheater are

attached at the positions (6) (7) in Fig. 9-22.
The pressure sensors for the top heater are at-
tached at the positions (8) (9).
1. Push the top heater section (1) on the PRO-

The TOP HEATER SECTION STATUS window
appears.
(1)
2. Air pressure values for the top preheater and

top heater are shown in (2).
3. Check top preheater and top heater air pres-
(2) sure values.
Standard
(Top preheater)
(3)
(Top heater)
Fig. 9-24. TOP HEATER SECTION STATUS win-

If pressure values (2) (3) are not within the stan-
dow
dard value, check the filter for blockage.
9- 30 M144- 7294 Issue 01

9 Top former
9.6.6.3 HEPA filter element for top heater air -

Check & Replace
Refer to Fig. 9-22.

Check that the HEPA filter (3) is not blocked and
that the differential pressure values of the pressure
sensors (10) (11) indicate less than the standard
value on the graphic panel.
Standard
< 300 Pa
(10) (11)

screen.
(1)

screen.
(2)
sary.
M144- 7294 Issue 01 9- 31

9 Top former
3. Push TOP SEAL SECTION (3) on the VIEW

CONDITION screen. The TOP SEAL SECTION
(1/3) screen appears.
(3)
4. Check the differential pressure values (4) on the

TOP SEAL SECTION (1/3) screen. If the differ-
ential pressure values exceed the standard val-
ue, continue with the next step to replace HEPA
filter.
(4)
Fig. 9-28. TOP SEAL SECTION (1/3) screen
5. Loosen the nut (14) and locknut (15), and pull

out the HEPA filter element (16) in the direction
of the arrow. (Refer to Fig. 9-22. )
DANGER
HEPA FILTER IN A HIGH PLACE, PREPARE
THE LADDER AND PLATFORM WITH
HANDRAIL FOR SAFETY.
6. Install new HEPA filter element in reverse order.
CAUTION !
Do not wash the HEPA filter element.
9- 32 M144- 7294 Issue 01

9 Top former
9.6.7 Cooled guide position - Check & Adjust
(3)
A3 A2 A1
(3)
(4)
(1)
B3 B2 B1 C
(2)
Fig. 9-29. Cooled guide position

1. Check the dimensions A1~A3 between the Standard
cooled guides (1) under the top heaters.
A1 69.01.0 mm
2. Check the dimensions B1~B3 from the bottom
rail (2). A2 69.01.0 mm
A3 67.01.0 mm
3. Loosen the nuts (3) and adjust the dimensions. B1 (1,000 ml) 238.01.0 mm
4. After adjustment, tighten the nuts. B2 (1,000 ml) 238.01.0 mm

B3 (1,000 ml) 238.01.0 mm
No. Parts
C 251.0 mm
(1) Cooled guide
(2) Bottom rail
(3) Nut
(4) Opener
M144- 7294 Issue 01 9- 33

9 Top former
9.7 Top sealing section
(10) (3) (4) X (10)

(1)
(7)
(7)
Y X Y
(8)
(9)
(8)
(2)
(6) (5) View X- X
Fig. 9-30. Top sealing section (1 of 2)
9- 34 M144- 7294 Issue 01

9 Top former
(3) (4)
View Y- Y
Fig. 9-31. Top sealing section (2 of 2)
Carton top is sealed twice in the 1st. top sealing No. Parts
section (1) and the 2nd. top sealing section (2).
The 1st. top sealing section consists of the mov- (1) 1st. top sealing section
able sealer jaws (3) (4). The 2nd. top sealing sec- (2) 2nd. top sealing section
tion consists of the fixed sealer jaw (5) and the
movable sealer jaw (6). At first, the carton top (3) Movable sealer jaw
heated by the top heater is sealed in the 1st. top (4) Movable sealer jaw
sealing section. Next, the top sealed carton is
(5) Fixed sealer jaw
cooled in the 2nd. top sealing section for stable top
seal. (6) Movable sealer jaw
When there is no carton in the sealing section, the (7) Pin
1st. and 2nd. sealer jaws are in a standby position (8) Bushing
while keeping a preset distance between them.
(9) Bushing
(10) Pin
Replacement of pins (7), (10)

Every 4800 hours
Replacement of bushings (8), (9)

Every 2400 hours
M144- 7294 Issue 01 9- 35

9 Top former
9.7.1 1st. top sealer
(1) (4)
(2)
X X
Y Y
Fig. 9-32. 1st. top sealer (1 of 2)
9- 36 M144- 7294 Issue 01

9 Top former
(5) (5)
(6) (6)
(3) (3)
View X- X
(7)
(7)
(8) (10) (9) (8)

View Y- Y
Fig. 9-33. 1st. top sealer (2 of 2)
M144- 7294 Issue 01 9- 37

9 Top former
Function: To seal the carton top.
In the 1st. top sealing section, the movable sealer

jaw (1) is moved with the spring case (2). The
spring case is installed on the tie- rod driven by the
lever (3). The movable sealer jaw (4) is moved with
WARNING
the tie- rod driven by the lever (5). The lever (3) is
connected to the lever (5) with the link (6). The le- SOON AFTER THE HEATERS STOP RUN-
ver keeps moving forward after the sealer jaw has NING, HEATERS AND THEIR SUR-
contacted with the carton top. The movable sealer ROUNDS ARE VERY HOT.
jaw can seal correctly by spring pressure. BE CAREFUL WHEN ADJUSTING.
As the sealer jaws contact with the heated carton
top panels, temperature- controlled water is consis-
tently supplied to them to avoid excessive temper- CAUTION !
ature rise. Check that cartons are correctly folded by the
When there is no carton in the 1st. top sealing sec- 1st. top breaker and 2nd. top breaker. Then ad-
tion, the air cylinder (7) extends to separate the just the top sealer.
cam follower (9), which is attached to the tip of the
lever (8), from the cam (10). This causes the mov- CAUTION !
able sealer jaws (1) (4) to wait in a standby posi-
Inadequate clearance of the top sealer jaws will
tion while keeping a preset distance between them.
cause poor sealing of carton top fin.
No. Parts
(1) Movable sealer jaw
(2) Spring case
(3) Lever
(5) Lever
(6) Link
(7) Air cylinder
(8) Lever
(9) Cam follower
(10) Cam
9- 38 M144- 7294 Issue 01

9 Top former
9.7.1.1 Sealer jaw clearance - Check & Adjust

2. Check that the guarding doors and the covers
under the bed are closed.
Note ! If the doors are open, air is not sup-

plied to the air cylinder for safety.
Close the doors, and set up the servo
motor to reset the alarm. (Refer to 1.4)

(1)

(2)
5. Push TOP HEATERS/TOP SEAL (3) on the

MANUAL screen. The TOP HEATERS/TOP
SEAL window appears.
(3)
M144- 7294 Issue 01 9- 39

9 Top former
6. Push 1st. TOP SEALER CLUTCH MANUAL (4)

to check and adjust.
(4)
Fig. 9-37. TOP HEATERS/TOP SEAL window
7. Hand crank the main motor until the machine

timing becomes 195_ to 267_.
8. Open the guarding doors and check the dimen-

sion A.
next step.
Standard
A 0 mm

(6) (9) 10.Loosen the nuts (6) and adjust the clearance
(7) A (8) (5) between the movable sealer jaws (7) (8) by
manually rotating the bolts (9).
11.After adjustment, tighten the nuts (6) and the
bolts (5).
12.After adjustment, close the guarding doors.
No. Parts
(5) Bolt
(6) Nut
Fig. 9-38. Sealer jaw
(9) Bolt
9- 40 M144- 7294 Issue 01

9 Top former
13.Push 1st. TOP SEALER CLUTCH AUTOMATIC

(10).
(10) Note ! When the guarding doors and the cov-

ers under the bed are open, the non-
contact sensors are enabled. At this
time, the TOP HEATERS/TOP SEAL
window cannot appear on the graphic
panel to operate the 1st. TOP SEALER
CLUTCH.
M144- 7294 Issue 01 9- 41

9 Top former
9.7.1.2 Top fin - Adjust
9.7.1.2.1 Pattern 1
(See the top fin in the lower part of the Fig.)

(1) (1)
(4) 1. Loosen the bolts (1) and the nuts (2).
2. Move the sealer jaw (4) in the direction of the
arrow by manually rotating the bolts (3) to ad-
just.
3. After adjustment, tighten the bolts and the nuts.
(3) (2) (2) (3)
Fig. 9-40. Pattern 1
9.7.1.2.2 Pattern 2
(See the top fin in the lower part of the Fig.)

(1) (1)
(4) 1. Loosen the bolts (1) and the nuts (2).
2. Move the sealer jaw (4) in the direction of the
arrow by manually rotating the bolts (3) to ad-
just.
(3) (2) (2) (3)
9- 42 M144- 7294 Issue 01

9 Top former
9.7.1.2.3 Pattern 3
(1) (1)
(4) (See the top fin in the lower part of the Fig.)
1. Loosen the bolts (1) and the nuts (2).
2. Move the sealer jaws (4) clockwise by rotating
the bolts (3).
3. Aft
4. er adjustment, tighten the bolts and the nuts.
(3) (2) (2) (3)
9.7.1.2.4 Pattern 4
(1) (1)
(4) (See the top fin in the lower part of the Fig.)
1. Loosen the bolts (1) and the nuts (2).
2. Move the sealer jaws (4) counter- clockwise by
rotating the bolts (3).
(3) (2) (2) (3)
M144- 7294 Issue 01 9- 43

9 Top former
9.7.1.2.5 Pattern 5
1. Move the carriage conveyor to align the top

fins.
Note ! The direction of the arrow shows the

carton flow.
9.7.1.3 Sealing pressure - Adjust

3. Rotate the tie- rod (2), and adjust the dimension
A.
5. Refer to 9.7.1.1 and check the sealer jaw clear-
ance.
Standard
A 16.0 mm
(1) (2)
A
Fig. 9-45. Sealing pressure
9- 44 M144- 7294 Issue 01

9 Top former
9.7.1.4 Spring - Replace
(2)
(1)
(5)
(3) (9) (5)
A B
(8)
(4)
(7) (6)
(6)
Fig. 9-46. Spring

1. Loosen the bolt (1) and remove the cover (2). No. Parts
2. Pull out the pin (3) at the standby position by (1) Bolt
inserting a long bolt (M6) from the hole (5) on
the side surface of the frame (4) into the pin. (2) Cover
The pin has a tapped hole inside. (3) Pin
3. Next remove the nut (6) and cover (7) and pull (4) Frame
out the unit (A) from the upper hole.
(5) Hole
4. Loosen the rod (8) and replace the spring (9). (6) Nut
(7) Cover
Note ! Apply food grade grease to the sur-
face of new spring. (8) Rod
(9) Spring
Standard
B ≧0.5 mm
M144- 7294 Issue 01 9- 45

9 Top former
9.7.1.5 Toggle joint angle - Check & Adjust
(3) (7) (6) (5) (6) (7) (4)
(3) (5) (5) (4)

(1) (2)
A B
(11)
(9) (10)
(8)
Fig. 9-47. Toggle joint angle
9- 46 M144- 7294 Issue 01

9 Top former
1. Check the toggle angle using the jigs (3) (4).
Standard
A 61.0_
B 0_

next step.
3. Loosen the bolts (5), nuts (6) and bolts (7).
Move the sealer jaws (1) (2) backward on both
sides to keep enough clearance for adjustment.
4. Loosen the nut (8), turn the rod (9), and adjust
the toggle angle A using the jig (3). After adjust-
ment, tighten the nut (8).
5. Loosen the nut (10), turn the rod (11), and ad-
just the toggle angle B using the jig (4). After
adjustment, tighten the nut (10).
6. Adjust the sealer jaws position by turning the
bolts (7). Tighten the nuts (6) and bolts (5).
Refer to 9.7.1.1 and 9.7.1.2.
No. Parts
(3) Jig (angle 6_)
(4) Jig (angle 0_)
(5) Bolt
(6) Nut
(7) Bolt
(8) Nut
(9) Tie- rod
(10) Nut
(11) Tie- rod
9.7.1.6 Sealer jaw timing - Check


1,2 Y163L
20
3,4 Y163R
M144- 7294 Issue 01 9- 47

9 Top former
9.7.1.7 Top sealer jaw position - Check
(1)
(3)
A
(4)
(6) (5)
(2)
Fig. 9-48. Top sealer jaw position
1. Check the dimension A between the movable No. Parts

sealer jaw (1) and the carton top 5th panel (3).
If it is not within the standard value, continue (1) Movable sealer jaw
with the next step. (2) Movable sealer jaw
Standard (3) Carton top 5th panel
A 0~1.0 mm (4) Bolt

(5) Nut
2. Loosen the bolts (4) and the nut (5). (6) Bolt
3. Adjust the dimension by rotating the bolt (6).
4. After adjustment, tighten the bolts (4) and the
nut (5).
9- 48 M144- 7294 Issue 01

9 Top former
9.7.2 2nd. top sealer
(2) (1) (3)

B A
(4)
Fig. 9-49. 2nd. top sealer
In the 2nd. top sealing section, the movable sealer

jaw (1) is attached to the air cylinder (2).
When the carton comes, the air cylinder extends to
press the movable sealer jaw (1) against the fixed
WARNING
sealer jaw (3), allowing carton top to cool.
When there is no carton in the 2nd. top sealing NING, HEATERS AND THEIR SUR-
section, the air cylinder (2) retracts to keep a dis- ROUNDS ARE VERY HOT.
tance between the movable sealer jaw and the BE CAREFUL WHEN ADJUSTING.
fixed sealer jaw.
The air cylinder (4) lifts the movable sealer jaw unit
(A) using B as a pivot point. No. Parts
(2) Air cylinder
(4) Air cylinder
M144- 7294 Issue 01 9- 49

9 Top former
9.7.2.1 Sealer jaw clearance - Check & Adjust


plied to the air cylinder for driving top
seal for safety. Close the doors, and
set up the servo motor to reset the
alarm. (Refer to 1.4)

(1)

(2)
9- 50 M144- 7294 Issue 01

9 Top former
5. Push TOP HEATERS/TOP SEAL (3) on the

MANUAL screen.
The TOP HEATERS/TOP SEAL window ap-
pears.
(3)
6. Push and hold 2nd. TOP SEAL ON (4) to check

and adjust.
(4)

(5)
(6) sion A.
with the next step.
(9)
Standard
A 0 mm
(9)
(6)
(5) 9. Loosen the nuts (6).
10.Adjust the clearance between the movable
sealer jaw (7) and the fixed sealer jaw (8) by
(5) (7) (5) (8) manually rotating the bolts (9).
No. Parts
(5) Bolt
(9) (6) Nut
(6)
A
(9) Bolt
Fig. 9-54. Sealer jaw
M144- 7294 Issue 01 9- 51

9 Top former
11.After adjustment, tighten the nuts (6) and the

bolts (5).
Refer to Fig. 9-54.
12.Close the guarding doors.
13.Push and hold 2nd. TOP SEAL OFF (10).
Note ! When the guarding doors and the cov-

ers under the bed are open, the non-
(10) time, the TOP HEATERS/TOP SEAL
window cannot appear on the graphic
panel to operate the 2nd. TOP SEAL.
Fig. 9-55. TOP HEATERS/TOP SEAL
9.7.2.2 Sealer jaw position to carton top -

Check & Adjust
(3) 1. Check the dimension A between the carton top

5th panel (1) and the movable sealer jaw (2).
(2) (1) If it is not within the standard value, continue
with the next step.
Standard
A
A 0 ~ 1.0 mm

A.
No. Parts
(1) Carton top 5th panel
(4) (2) Movable sealer jaw

(3) Bolt
Fig. 9-56. Sealer jaw position
9- 52 M144- 7294 Issue 01

9 Top former
9.7.2.3 Sealer jaw timing - Check


1,2 Y165L
21
3,4 Y165R
M144- 7294 Issue 01 9- 53

9 Top former
9.7.2.4 2nd. top sealer jaw escape
B A
(1)
Fig. 9-57. 2nd. top sealer jaw escape

When the CARTON FEED (ON) button is pushed, Magazine No. Mode No. Solenoid No.
the air cylinder (1) lowers the unit (A) using B as a
pivot point. 1,2 Y143L, 144L
-
After all cartons have been discharged from the 3,4 Y143R, 144R
machine, the air cylinder lifts the unit (A) again us-
ing B as a pivot point.
No. Parts
(1) Air cylinder
9- 54 M144- 7294 Issue 01

10 Cap applicator
10 CAP APPLICATOR
M144- 7294 Issue 01
M144- 7294 Issue 01 10- 1

10 Cap applicator
10 CAP APPLICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 1
10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 3

10.1.1 Cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.2 Cap separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.3 Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.1.4 Cap detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 6
10.2 Cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 8
10.2.1 Cap track position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 9
10.2.2 Photoelectric switch - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 9
10.2.3 Photoelectric switch sensitivity for detecting caps - Check & Adjust/Replace . . . . . . . . . . 10- 10
10.3 Cap separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 12
10.3.2 Cap pusher timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 13
10.4 Cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 14
10.4.1 Escaped position of anvil - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 18
10.4.2 Horn position - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 20
10.4.3 Anvil and horn position check with jig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 22
10.4.4 Seal position - Clearance check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 24
10.4.5 Parallel contact between anvil and horn - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . 10- 28
10.4.6 Anvil and horn position relative to carton flow - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 29
10.4.8 Fibre sensor sensitivity for detecting timing belt cut - Check . . . . . . . . . . . . . . . . . . . . . . . . 10- 31
10.4.9 Servo manual operation of cap sealer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 32
10.4.10 Horn timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 32
10.4.11 Installing horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 33
10.5 Cap detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 34
10.5.1 Cap detected position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 35
10.5.2 Detecting timing - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 35
10.5.3 Fibre sensors sensitivity for detecting caps - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 36
10- 2 M144- 7294 Issue 01

10 Cap applicator
10.1 Description
The cap applicator consists of the following ele-
ments:
Chapter Elements
10.1.1 Cap track
10.1.2 Cap separator
10.1.3 Cap sealer
10.1.4 Cap detection
Refer to Fig. 10-1.

Caps are fed by the cap feeder through the cap
track (1) to the cap separator.
The caps are separated one by one from the chute
and come down to the anvil (11). Then the cap is
inserted into a hole on the carton from inside and is
sealed by ultrasonic.
The cap detection detects if a cap is attached on
the carton or not.
M144- 7294 Issue 01 10- 3

10 Cap applicator
(1) (1)
(2)
(2)
(15) (4)
(11)
Y
(10)
X X
(14)
(9)
(6)
(13) (12)
(9)
(8)
(5)
(7)
Fig. 10-1. Cap applicator (1 of 2)
10- 4 M144- 7294 Issue 01

10 Cap applicator
(10)
Z Y
(14) (13)
(10)
(17) (12)
(9)
(16)
View Z View X- X
Y
(3) (3)
(17)
(11)
(16) (16)
View Y- Y
Fig. 10-2. Cap applicator (2 of 2)
M144- 7294 Issue 01 10- 5

10 Cap applicator
10.1.1 Cap track

The cap track consists of the following components:
No. Parts No. Parts

(1) Cap track (2) Photoelectric switch (to detect no caps in-
side the track)
10.1.2 Cap separator

The cap separator consists of the following components:
No. Parts No. Parts

(3) Chute (4) Cap pusher
10.1.3 Cap sealer

The cap sealer consists of two main parts, the welding unit and the anvil unit, both are driven by a cam under
the bed.
No. Parts No. Parts

(5) Cam (11) Anvil
(6) Cam follower (12) Horn
(7) Lever (13) Booster
(8) Air cylinder (14) Converter
(9) Tie- rod (15) Servo motor
(10) Lever
10.1.4 Cap detection

The cap detection consists of the following components:
No. Parts No. Parts

(16) Fibre sensor (to detect no caps / no caps on (17) Bracket
cartons)
10- 6 M144- 7294 Issue 01

10 Cap applicator
M144- 7294 Issue 01 10- 7

10 Cap applicator
10.2 Cap track
A
X
(1) (1)
(2)
Y Y
Z
Section Y- Y
(2)
(5)
(6)
View Z
(3) (3)
(4) (4)
(3) (3)
View X Detail A
Fig. 10-3. Cap track
10- 8 M144- 7294 Issue 01

10 Cap applicator
Function: To transfer caps from the cap feeder

to the cap separator.
Caps are fed to the top of the machine from the

cap feeder. When the caps pass through the cap
track (1), they are detected by a pair of photoelec-
tric switches (2). When the photoelectric switches
do not detect caps, the carton feeder stops.
No. Parts
(1) Cap track
(3) Bolt
(4) Bolt
(5) Screw
(6) Screw
10.2.1 Cap track position - Check &

Adjust
1. Check the position of the cap track (1).

2. If the position is not correct, continue with the
next step.
3. Loosen the bolts (3) (4) and adjust the position.
10.2.2 Photoelectric switch - Check
1. Check that the photoelectric switches (2) are

correctly positioned in pairs.
2. If not, continue with the next step.
3. Loosen the screws (5) (6) and adjust the posi-
tion.
M144- 7294 Issue 01 10- 9

10 Cap applicator
10.2.3 Photoelectric switch sensitivity

for detecting caps - Check &
Adjust/Replace
 Check
Push and hold the teach button (1) for more than 2
seconds when no object is in the light beam. The
orange lamp (2) flashes. Upon releasing the but-
ton, the lamp turns on. When a cap is set in the
detecting position, the orange lamp turns on. The
lamp turns off when there is no cap.
 Adjust
(2) (3)
vals.
(1)  Replace
If malfunction is found during the above check, re-
Fig. 10-4. Photoelectric switch place the photoelectric switch with a new one.
No. Parts
(1) Teach button
(2) Orange lamp
(3) Green lamp
10- 10 M144- 7294 Issue 01

10 Cap applicator
M144- 7294 Issue 01 10- 11

10 Cap applicator
10.3 Cap separator
(4)
(1) (1)
(5)
(2) (2)
(7) (3)
(6)
(9)
(8)
(10)
(3)
Fig. 10-5. Cap pusher position

Caps, which pass through the cap track (1), come
down to the chute (2). When the anvil (3) rotates
and is set in the required position, the caps in the
chute are pushed into the anvil by the cap pusher
(6) which is on the top of the air cylinders (4) (5).
The anvil turns 180 and seals the cap (7) to the
carton hole from inside.
10- 12 M144- 7294 Issue 01

10 Cap applicator
10.3.1 Pusher position - Check &

Adjust
1. Check the dimension A between the cap pusher

(6) and the anvil (3).
with the next step.
Standard
A 62.01.0 mm
2. Loosen the nut (9) and rotate the joint (10) to

adjust the cap pusher (6).
No. Parts
(1) Cap track
(2) Chute
(3) Anvil
(4) Air cylinder
(5) Air cylinder
(6) Cap pusher
(7) Cap
(8) Carton
(9) Nut
(10) Joint
10.3.2 Cap pusher timing - Check

Magazine No. Parts No. Mode No. Solenoid No.

1 (4) (Left line) 43 Y149L
2 (5) (Left line) 43 Y151L
3 (4) (Right line) 43 Y149R
4 (5) (Right line) 43 Y151R
M144- 7294 Issue 01 10- 13

10 Cap applicator
10.4 Cap sealer
(14) (6) (22) (6) (5) (7) (1)
Y (9)
(8)
X X
Z Z
(12)
Y (19)
(4) (3) (10) (2)
View Y- Y
(11) (16) (13) (15)
(17) (12)
Fig. 10-6. Cap sealer (1 of 2)
10- 14 M144- 7294 Issue 01

10 Cap applicator
(14) (14) (18)
A
(21) (1) (2)
View A
View X- X
(4) (20) (3) (9) (8)
(22)
View Z- Z
Fig. 10-7. Cap sealer (2 of 2)
M144- 7294 Issue 01 10- 15

10 Cap applicator
No. Parts No. Parts

(1) Anvil (12) Air cylinder (Horn & Anvil escape)
(2) Horn (13) Main shaft
(3) Booster (14) Lever
(4) Converter (15) Cam
(5) Servo motor (16) Lever
(6) Timing belt (17) Lever
(7) Cap pusher (18) Shaft
(8) Stopper (19) Lever
(9) Nut (20) Air cylinder (Horn escape)
(10) Bolt (21) Air cylinder (Horn escape)
(11) Air cylinder (Horn & Anvil escape) (22) Fibre sensor
Function: To seal the caps on the cartons by ul- Rotary motion of the anvil is driven by the servo
trasonic. motor (5). Reciprocating motion is driven by the
cam.
The cap, which is carried by the cap track, is in- If the timing belt (6) for the servo motor is cut, the
serted into the anvil (1) by the cap pusher (7). fibre sensor (22) detects it, and the carriage con-
Then the anvil rotates, and the cap goes into the veyor on the line where the timing belt has been
carton. cut stops.
When the line is normal, it operates until all cartons
The driving force of the anvil and horn (2) is trans- have been discharged. Then, the main motor
mitted to the shaft (18) through the levers (14) (16) stops.
(17) by driving the cam (15). And finally, the anvil
and horn run in synchronisation with rotation of the When no- cap cartons are produced, the air cylin-
lever (19). ders (11) (12) (20) (21) are extended.
When the rods of the air cylinders (11) (12) (20) When the horn stroke or the anvil stroke exceeds
(21) retract, the cap is sealed to the carton. each set value due to some factors, the horn is
The air cylinders (11) (12) retract as the carton is prevented from touching the anvil by touching the
approaching. The air cylinders (20) (21) retract as stopper (8) to the anvil.
the carton comes just in front of them. The anvil and horn are cooled by air.
The anvil and horn move closer to each other by
the cam. The horn pushes the anvil until the cap is
sealed to the carton.
When the rods of the air cylinders (11) (12) (20)
(21) are extended, the cap is not sealed to the car-
ton.
Sealing pressure can be adjusted by adjusting air
pressure of the air cylinders (20) (21).
The horn, booster (3) and converter (4) are driven
by the cam.
10- 16 M144- 7294 Issue 01

10 Cap applicator
M144- 7294 Issue 01 10- 17

10 Cap applicator
10.4.1 Escaped position of anvil - Check & Adjust
(9) (3)
(1)
(4)
B
(1)
View X
(8) (2) (7)
(6) (6) (5) (5)
(6)
X (10)
(10)
(6) (10)
(10)
Fig. 10-8. Escaped position of anvil
10- 18 M144- 7294 Issue 01

10 Cap applicator
1. Stop the main motor. 8. Loosen the bolts (5) and nuts (6).
2. Check that the guarding doors and covers un- 9. Adjust the dimension B between the upper sur-
der the bed are closed. face of the bottom rail (7) and the centre of the
spigot (8) or the centre of the horn (9) to be the
Note ! If the doors are open, air is not sup- standard value by the bolts (10).
plied to the air cylinder for driving 10.After adjustment, tighten the bolts (5) and nuts
horn for safety. Close the doors and (6).
No. Parts
3. Hand crank the main motor until the machine (5) Bolt
timing becomes 298 to 110.
(6) Nut
sions A and B. (7) Bottom rail
If they are not within the standard values, con- (8) Spigot
(9) Horn
Standard
(10) Bolt
A 21.0 mm1.0 mm
B 213.0 mm2.0 mm 11.After adjustment, close the guarding doors.
5. Loosen the nuts (1).

6. Adjust the dimension A between the carton
holder (2) and the anvil (3) to be the standard
value by rotating the tie- rod (4).
No. Parts
(1) Nut
(2) Carton holder
(3) Anvil
(4) Tie- rod
M144- 7294 Issue 01 10- 19

10 Cap applicator
10.4.2 Horn position - Adjust
(3)
(5)
View X- X
Y
(6)
(1)
(3) (3)
(5)
X X
(4)
(2) (5) (2)
Y
View Y- Y
Fig. 10-9. Horn position
1. Adjust the horn (1) inclination with the bolts (2). No. Parts
2. The vertical position can be adjusted with the (1) Horn
bolts (2).
(2) Bolt
3. Loosen the bolts (3) and nuts (4).
(3) Bolt
4. Adjust the direction of the carton flow with the
bolt (5). (4) Nut
(5) Bolt
5. Check the parallel between the anvil and horn
according to 10.4.5. (6) Anvil
6. After adjustment, tighten the bolts (3) and nuts
(4).
10- 20 M144- 7294 Issue 01

10 Cap applicator
M144- 7294 Issue 01 10- 21

10 Cap applicator
10.4.3 Anvil and horn position check with jig
(2)
(3)
(1) (3) (4) (2) (2)
(3)
(1) (4) (3)
Fig. 10-10. Anvil and horn position check with jig
10- 22 M144- 7294 Issue 01

10 Cap applicator
Note ! Use jig (3) to check the horn position

after anvil alignment (10.4.1).
1. Hand crank the main motor and stop when the

horn (1) and anvil (2) have come to escaped
position (298_ to 110_).
2. Put the jig (3) at the horn tip and pass it
through.
3. Hand crank the main motor and stop at the seal
position (140_ to 268_).
4. Slide the jig until it comes to the horn tip. Slide
the jig with A down as shown in Fig. 10-10. un-
til the jig touches the anvil lower surface.
5. Overlap the inside of A with the anvil end sur-
face, and turn it 45_ clockwise and counter-
clockwise alternately. If the jig turns smoothly,
the horn centre is correctly aligned with the
spigot (4). If the jig does not turn smoothly, ad-
just the horn centre position again.
No. Parts
(1) Horn
(2) Anvil
(3) Jig
(4) Spigot
M144- 7294 Issue 01 10- 23

10 Cap applicator
10.4.4 Seal position - Clearance check


plied to the air cylinder for driving
horn for safety. Close the doors and

(1)

ting.
(2) The MANUAL screen appears.

5. Push CAP SEAL (3) on the MANUAL screen.

The CAP SEAL window appears.
(3)
10- 24 M144- 7294 Issue 01

10 Cap applicator
6. Push ANVIL, HORN FORWARD ON (4) and

HORN FORWARD ON (5) on the CAP SEAL
window.
(4)
(5)
Fig. 10-14. CAP SEAL window
7. Hand crank the main motor until the machine

timing becomes 140_ to 268_.
8. Open the guarding doors and measure the di-

mensions A and B.
with the next step.
Standard
A 0 mm
B 0.1~0.2 mm
Fig. 10-15. Cap sealer
M144- 7294 Issue 01 10- 25

10 Cap applicator

(8)
10.Rotate the stopper (7) until it attaches to the
(6) (7) anvil (8).
11.After adjustment, tighten the nut.
No. Parts
(6) Nut
(7) Stopper
(8) Anvil
Fig. 10-16. Cap sealer
12.Loosen the nuts (9).

(8) 13.Adjust by tie- rod (10) so that the horn (11) con-
tacts the anvil (8) lightly.
(6)
14.Tighten the nuts (9).
(9) (7) 15.Loosen the nut (6).
16.Adjust the stopper (7) so that the horn (11) is
pushed back 0.1mm.
17.After adjustment, tighten the nut (6).
18.Check that the collar (12) moves lightly by rotat-
ing. If not, sealing pressure is not be adjusted
correctly.
Start from step 6 again.
No. Parts
(9) Nut
(10) (12) (11)
(10) Tie- rod
(11) Horn
(12) Collar
Fig. 10-17. Horn and anvil
19.After adjustment, close the guarding doors.
10- 26 M144- 7294 Issue 01

10 Cap applicator
20.Push ANVIL, HORN FORWARD OFF (13) and

HORN FORWARD OFF (14) on the CAP SEAL
window.
(13)
Note ! When the guarding doors and the cov-
(14) ers under the bed are open, the non-
time, the CAP SEAL window cannot
appear on the graphic panel to oper-
ate ANVIL, HORN FORWARD and
HORN FORWARD.
Fig. 10-18. CAP SEAL window
M144- 7294 Issue 01 10- 27

10 Cap applicator
10.4.5 Parallel contact between anvil

(1) and horn - Check & Adjust
(2)
1. Disassemble the spigot (1) on the anvil (2).
2. Push HORN FORWARD ON (5) and ANVIL,
HORN FORWARD ON (4) on the CAP SEAL
window. (Refer to Fig. 10-14. )
Fig. 10-19. Disassemble a spigot
3. Manually place the pressure sensitive paper (3)

and carton (4) in front of the anvil.
(2) 4. Manually set the machine timing between 140_
and 268_. (Set the anvil and horn to the seal
(5) position referring to 10.4.4.)
5. Check the sensitive paper for parallel contact.
6. If it is not parallel, refer to 10.4.2.
7. If cap hole on carton is not aligned with the an-
vil and horn position, perform the steps of
10.4.6.
No. Parts
(1) Spigot
(2) Anvil
(3) Sensitive paper
(4) Carton
(5) Horn
(4)
(3)
(4)
Fig. 10-20. Parallel contact between anvil and

horn
10- 28 M144- 7294 Issue 01

10 Cap applicator
10.4.6 Anvil and horn position relative

to carton flow - Adjust
1. Check that the anvil (1) and the horn (2) are
positioned correctly relative to the carton flow.
2. Loosen the bolts (3) and nuts (5).
3. Adjust the anvil and the horn positions with the
(3) (5) bolt (4).
(4) No. Parts

(1) Anvil
View X- X
(2) Horn
(3) Bolt
(4) Bolt
(1) (5) Nut
(2)
(5)
X (3) X
(4)
Fig. 10-21. Anvil and horn position
M144- 7294 Issue 01 10- 29

10 Cap applicator
(2)
(1)
(4)
(5)
View X- X (3)
View Z
(4) (1) (5) (3)

Y
(1)
X X
Z
View Y- Y
10- 30 M144- 7294 Issue 01

10 Cap applicator
1. Check the dimension A when pushing the tim-

ing belt centre (1) with a force of 16.2N ~
20.5N.
next step.
Standard
A 4.1 mm

4. Adjust the timing belt tension with the bolt (4).
5. After adjustment, tighten the nut and bolt (2).
No. Parts
(1) Timing belt
(2) Bolt
(3) Nut
(4) Bolt
(5) Fibre sensor (to detect timing belt cut)
Note ! Using push / pull scale with 16.2N

~20.5N force.
10.4.8 Fibre sensor sensitivity for

(1) (3)
detecting timing belt cut -
Check

the joint box 28, 29. Refer to Fig. 2-34.
(2) (4)
Manual.
1. Check for the illuminations of the red (1) and

green (2) indicator lamps.
2. If the red indicator lights up and the green indi-
cator does not, check for the illumination of the
green indicator by rotating the sensitivity adjust-
er (3).
No. Parts
(1) Input indicator (Red)
Fig. 10-23. Fibre sensor amplifier
(4) Mode selector
M144- 7294 Issue 01 10- 31

10 Cap applicator
10.4.9 Servo manual operation of cap

sealer
CAUTION
MANUAL OPERATION.

cal Manual, and set the cap sealer to the home
position.
D- 7 Left Anvil (13 axes)
S D- 7- 1 Jog
10.4.10 Horn timing - Check

noid valve purpose list (11.4)

1 44 Y171L
2 44 Y173L
3 44 Y171R
4 44 Y173R
10- 32 M144- 7294 Issue 01

10 Cap applicator
10.4.11 Installing horn
(2)
(3) (1)
Fig. 10-24. Installing horn

1. Screw the converter (1) to the booster (2). No. Parts
2. Screw the converter with booster to the horn (1) Converter
(3).
(2) Booster
(3) Horn
Note ! Use one or two open end wrenches.
When using a torque wrench, apply
the torque specified in Table 10-1.
Operating frequency Torque Converter - Booster Torque Booster - Horn

20 kHz 50 Nm 50 Nm
Table 10-1. Torque specified Part 1 of 1
M144- 7294 Issue 01 10- 33

10 Cap applicator
10.5 Cap detection
(3) (2) (1) (6)

Y
(1)
(1)
View Y
View X- X
X X
(6) (5) (2)
(1) (1) (4)
Fig. 10-25. Cap detection
10- 34 M144- 7294 Issue 01

10 Cap applicator
Function: To detect caps attached by the cap

applicator with fibre sensors (1).
(No cap - no filling)
No. Parts
(1) Fibre sensor
(2) Bolt
(3) Bolt
(4) Cap
(5) Bracket
(6) Bracket
10.5.1 Cap detected position - Check

& Adjust
1. Check that the fibre sensors (1) are correctly

positioned in pairs.
2. Loosen the bolts (2) and adjust the direction of
the carton flow.
Refer to Fig. 10-25.
10.5.2 Detecting timing - Check


1,2,3,4 40 -
M144- 7294 Issue 01 10- 35

10 Cap applicator
10.5.3 Fibre sensors sensitivity for

(5) (7) (1) (2) detecting caps - Check

the joint box 28, 29. Refer to Fig. 2-34.
(6) (8) (3) (4) For more details, refer to the Electrical
Manual.
1. If the actual value (7) does not exceed the set

value when light is received, check the wiring
and correctly position the fibre sensors in pairs.
2. The sensitivity (set value) (8) of the fibre sen-
sors can be adjusted with the adjust button (1)
(2). However, if you cannot, replace the pair of
fibre sensors with a new one.
Note ! For the preset value, refer to the Set-

ting Lists of Equipment Photo Sensor
Set Value in the Inspection Report.
Fig. 10-26. Fibre sensor amplifier No. Parts

(1) Adjust button (Up)
(2) Adjust button (Down)
(3) Mode button
(4) Teaching button
(7) Actual value (Displayed in red)
(8) Set value (Displayed in green)
10- 36 M144- 7294 Issue 01

11 Pneumatic System
11 PNEUMATIC SYSTEM
M144- 7294 Issue 01
M144- 7294 Issue 01 11- 1

11 Pneumatic System
11 PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1
11.1 Pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

11.1.1 Details A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 4
11.1.2 Details B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 7
11.1.3 Details C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
11.1.4 Details D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 8
11.1.5 Details E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 9
11.1.6 Details F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 9
11.1.7 Details G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 10
11.1.8 Details H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 11
11.2 Graphic symbols for pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 12
11.2.1 Standard graphic symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 12
11.2.2 Shikoku’s in- company symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 14
11.3 Pneumatic diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 15
11.3.1 Pneumatic diagram A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 15
11.3.2 Pneumatic diagram B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 16
11.3.3 Pneumatic diagram C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 18
11.3.4 Pneumatic diagram D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 20
11.3.5 Pneumatic diagram E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 22
11.3.6 Pneumatic diagram F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 23
11.3.7 Pneumatic diagram G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 24
11.3.8 Pneumatic diagram H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 25
11.3.9 Pneumatic diagram J . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 26
11.3.10 Pneumatic diagram K . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 27
11.3.11 Pneumatic diagram L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 28
11.3.12 Pneumatic diagram M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 29
11.3.13 Pneumatic diagram N . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 30
11.3.14 Pneumatic diagram P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 31
11.3.15 Pneumatic diagram Q . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 32
11.3.16 Pneumatic diagram R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 33
11.3.17 Pneumatic diagram S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 34
11.4 Solenoid valve purpose list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 35
11.5 Solenoid valve ON- OFF list - Related to carton size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 42
11.6 Standard pressure list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 44
11.7 Pressure switch & float switch & flow sensor list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 46
11.7.1 Air cylinder manual operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 47
11.8 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 48
11- 2 M144- 7294 Issue 01

11 Pneumatic System
11.1 Pneumatic parts arrangement
B A
E, F G C, D H
Fig. 11-1. Pneumatic parts arrangement

Air control units are located at the sections A~H. Note ! For details regarding pneumatic dia-
gram, refer to 11.3.
Section Item For details regarding solenoid valve
A for control box purpose list, refer to 11.4.
B for general lower part of bed
C for cap applicator (L- side)
D for cap applicator (R- side)
E for broken diaphragm detection and
top sealer (L- side)
F for broken diaphragm detection and
top sealer (R- side)
G for filler nozzle suck back
H for carton holder
M144- 7294 Issue 01 11- 3

11 Pneumatic System
11.1.1 Details A
Y1L Y2L Y3L Y4L Y208L Y209L
G2 G3 G30 B G18
H H1
K
G17 G31 G19 B1P
J J1 L
Y209R
Y208R
Y1R
Y5R Y2R Y4R G16
Y5L Y3R G1
Y6L Y6R Y7 Y10 A B5P B10P
Y91
Y10
View B
Y8L Y9L Y8R Y9R
Detail A
Fig. 11-2. Section A in Fig. 11- 1. (for control box)
11- 4 M144- 7294 Issue 01

11 Pneumatic System
11.1.1.1 Details H 11.1.1.2 Details J
Y27L Y13R Y17R Y23R Y27R

Y13L Y17L Y21L Y29R
Y11L Y15L Y19 Y29L Y11R Y15R Y21R Y25
Y23L
Fig. 11-3. Section H in Fig. 11- 2. Fig. 11-4. Section J in Fig. 11- 2.
11.1.1.3 Details H1 11.1.1.4 Details J1
Y33R Y37R Y41R Y45R

Y33L Y37L Y41L Y45L
Y43L Y47L Y31R Y35R Y39R Y43R Y47R
Y31L Y35L Y39L
Y34L Y38L Y42L Y46L

Y32L Y40L Y44L Y34R Y38R Y42R Y44R Y48R
Y36L Y48L
Y32R Y36R Y40R Y46R
Fig. 11-5. Section H1 in Fig. 11- 2. Fig. 11-6. Section J1 in Fig 11- 2.
M144- 7294 Issue 01 11- 5

11 Pneumatic System
11.1.1.5 Details K 11.1.1.6 Details L
Y53L Y57L Y61L Y65L Y73L Y53R Y57R Y61R Y65R Y73R
Y51L Y55L Y59L Y63L Y71L Y51R Y55R Y59R Y63R Y71R
Fig. 11-7. Section K in Fig.11- 2. Fig. 11-8. Section L in Fig. 11- 2.
11- 6 M144- 7294 Issue 01

11 Pneumatic System
11.1.2 Details B
G20
G5
C
D
E
F
Y125R
Y127R
Y129R
Y131R
Y127L
Y131L
Y125L
Y129L
Fig. 11-9. Section B in Fig. 11- 1. (for general lower part of bed)
M144- 7294 Issue 01 11- 7

11 Pneumatic System
11.1.3 Details C
Y171L Y175L Y181L

G28
Y173L Y179L
Y183L
G25
G11
Y253 G23
Y141L Y151L
Y251 Y161L
Y149L G32
Y147L,Y148L
Y145L,Y146L G24
Y143L,Y144L Y161R
Fig. 11-10. Section C in Fig 11- 9. & 11- 1. (for cap applicator, L- side)
11.1.4 Details D
Y173R
Y181R Y179R Y171R Y175R
G12
Y183R
Y141R Y151R
Y143R,Y144R Y149R
G27
Y145R,Y146R
Y147R,Y148R
Fig. 11-11. Section D in Fig 11- 9. & 11- 1. (for cap applicator, R- side)
11- 8 M144- 7294 Issue 01

11 Pneumatic System
11.1.5 Details E
Y165L Y163L Y109L Y107L B11LF B12LF
Y133
Y1S B1SP
G26 G15
Y189L G21 B13LP B14LP
Y105L
Fig. 11-12. Section E in Fig 11- 9. & 11- 1. (for broken diaphragm detection and top sealer, L- side)
11.1.6 Details F
B12RF B11RF Y107R Y109R Y163R Y165R
B71LF
B71RF
G22
Y192 Y193 G29 Y189R
B14RP B13RP
Y105R
Fig. 11-13. Section F in Fig 11- 9. & 11- 1. (for broken diaphragm detection and top sealer, R- side)
M144- 7294 Issue 01 11- 9

11 Pneumatic System
11.1.7 Details G
Y195L, Y195R Y197L, Y197R
G13(L), G14(R) G39(L), G40(R)
Fig. 11-14. Section G in Fig. 11- 1. (for filler nozzle suck back)
11- 10 M144- 7294 Issue 01

11 Pneumatic System
11.1.8 Details H
Y85R Y87R
Y85L Y87L
View X
Fig. 11-15. Section H in Fig.11- 1. (for carton holder)
M144- 7294 Issue 01 11- 11

11 Pneumatic System
11.2 Graphic symbols for pneumatic diagram
11.2.1 Standard graphic symbols
Symbol Description Symbol Description
Accumulator Lubricator
Air dryer Mechanical control by spring
Combined control by
solenoid and pilot Mist- separator
directional valve
Compressor, Pump Manual control by lever
A B Manual control by
Directional control valve 5/2 push button
R1 P R2
A B
Non- return valve with
Directional control valve 4/2
throttle valve
P R
Directional control valve 3/2 Oscillating motor

P R
Pilot actuated by release of
Double acting cylinder pressure
Pneumatic motor with two

Electrical control by solenoid directions of flow
Electrical control by twin Limit switch for detecting

solenoid solenoid valve position
Fig. 11-16. Standard graphic symbols
11- 12 M144- 7294 Issue 01

11 Pneumatic System
Filter Pressure switch
Pressure gauge Restriction
Pressure regulator Shut- off valve
Pressure source Silencer
Single acting cylinder

Rapid exhaust valve returned by spring
Fig. 11-17. Standard graphic symbols
M144- 7294 Issue 01 11- 13

11 Pneumatic System
11.2.2 Shikoku’s in- company symbols

Double diaphragm piston
cylinder Manifold vacuum pad
Float switch Pneumatic cylinder
Grease pump Vacuum pump
Float switch
(Level switch)
Fig. 11-18. In- company symbols
11- 14 M144- 7294 Issue 01

11 Pneumatic System
11.3 Pneumatic diagram

Note ! For details regarding solenoid valve (Y**) purpose list, refer to 11.4.
For details regarding standard pressure (G**) list, refer to 11.6.
For details regarding pressure switch & float switch & flow sensor (B**) list, refer to 11.7.
11.3.1 Pneumatic diagram A
(4) (3)
Y5R Y5L Y209L Y208L Y4L Y3L Y2L Y1L
Y209R Y208R Y4R Y3R Y2R Y1R
Y7 Y6L
Y6R
(2)
G3 G2
B5P
B1P
G1
G30
G31
(1)
Y10
B10P
Fig. 11-19. Pneumatic diagram A
No. Item No. Item

(1) Compressed air (3) Picker vacuum
(2) Vacuum pump (4) Unloader vacuum
M144- 7294 Issue 01 11- 15

11 Pneumatic System
11.3.2 Pneumatic diagram B
(2)
B14RP B13RP B14LP B13LP
B12RF B11RF B12LF B11LF
Y9R Y8R Y9L Y8L
(1)
Fig. 11-20. Pneumatic diagram B
No. Item
(1) Vacuum pump
(2) Diaphragm vacuum
11- 16 M144- 7294 Issue 01

11 Pneumatic System
M144- 7294 Issue 01 11- 17

11 Pneumatic System
11.3.3 Pneumatic diagram C
(5)
(4)
(3)
G28
(2)
Y40L Y39L Y38L Y37L Y36L Y35L Y34L Y33L Y32L Y31L
Y40R Y39R Y38R Y37R Y36R Y35R Y34R Y33R Y32R Y31R
Y48L Y47L Y46L Y45L Y44L Y43L Y42L Y41L

Y48R Y47R Y46R Y45R Y44R Y43R Y42R Y41R
(8)
(7) (6)
(1)
G18
G19
Fig. 11-21. Pneumatic diagram C
11- 18 M144- 7294 Issue 01

11 Pneumatic System
No. Item
(1) Compressed air
(2) Picker drive engage
(3) Bottom rail size change
(500 ml, 330/250 ml)
(4) Bottom rail size change (750 ml)
(5) Bottom rail UP- DOWN
(6) Loader shutter
(7) Carton basket size change
(8) Carton basket size change (Stopper)
M144- 7294 Issue 01 11- 19

11 Pneumatic System
11.3.4 Pneumatic diagram D
(2)
(5) (4) (3)

P P
Y19 Y17L Y15L Y13L Y11L

Y17R Y15R Y13R Y11R (1)
Y29L Y27L Y23L Y21L

Y29R Y27R Y25 Y23R Y21R
(9) (8) (7)

(6)
Fig. 11-22. Pneumatic diagram D
11- 20 M144- 7294 Issue 01

11 Pneumatic System
No. Item
(1) Compressed air
(2) H2O2 spray
(3) H2O2 pump
(4) H2O2 filter air vent
(5) Ethanol pump
(6) Carton pusher
(7) Bottom heater escape
(8) Top heater escape
(9) Unloader vacuum head movement
M144- 7294 Issue 01 11- 21

11 Pneumatic System
11.3.5 Pneumatic diagram E
(3)
(2)
Y87R Y87L Y85R Y85L
(1)
Fig. 11-23. Pneumatic diagram E

No. Item
(1) Compressed air
(2) Carton holder
(3) Bottom breaker wing
11- 22 M144- 7294 Issue 01

11 Pneumatic System
11.3.6 Pneumatic diagram F
(2)
B1P G1
G30
G31 (1)
Y10
B10P
G5 G20
(4) (3)
Fig. 11-24. Pneumatic diagram F

No. Item
(1) Compressed air
(2) Carriage conveyor tension
(3) 2nd. bottom heater (Damper)
(4) Unloader helper
M144- 7294 Issue 01 11- 23

11 Pneumatic System
11.3.7 Pneumatic diagram G
(6) (5) (4) (3) (2)
Y59L Y57L Y55L Y53L Y51L

Y59R Y57R Y55R Y53R Y51R
(1)
Y73L Y71L Y65L Y63L Y61L

Y73R Y71R Y65R Y63R Y61R
(11) (10) (9) (8) (7)
Fig. 11-25. Pneumatic diagram G
No. Item No. Item

(1) Compressed air (7) Tank drain valve (AV50, AV52)
(2) Potable water inlet valve (R- side:Spare) (8) Carton lifter size change (Air gripper)
(3) CIP recovery pump (R- side:Spare) (9) Tank drain valve (AV51, AV53)
(4) Empty carton blow (10) CIP divert valve (AV40, AV41)
(5) Unloader guide (11) UV- lamp shutter open/close
(6) Carton lifter size change (Pin)
11- 24 M144- 7294 Issue 01

11 Pneumatic System
11.3.8 Pneumatic diagram H
(2)
G16
Y91
(3)
Refer to Fig. 2-27.

G17
(1)
G32 (4)
Refer to Fig. 7-2.
Y251 Y253
(5)
Fig. 11-26. Pneumatic diagram H

No. Item
(1) Compressed air
(2) Bottom heater air shutter
(3) Positive pressure
(4) Bottom breaker air shutter
(5) Carton dust remover
M144- 7294 Issue 01 11- 25

11 Pneumatic System
11.3.9 Pneumatic diagram J
(1)
Y105L Y107L G15

Y105R Y107R
G21 Y133
G22
(2) (3) (4)

(5)
Fig. 11-27. Pneumatic diagram J

No. Item
(1) Compressed air
(2) Product inlet auto valve
(3) 2nd. top breaker (fork)
(4) 2nd. top breaker (wing)
(5) Grease pump
11- 26 M144- 7294 Issue 01

11 Pneumatic System
11.3.10 Pneumatic diagram K
G13
G14

Y197L Y195L G39
Y197R Y195R G40
(1)
Fig. 11-28. Pneumatic diagram K

No. Item
(1) Filler nozzle suck back device
M144- 7294 Issue 01 11- 27

11 Pneumatic System
11.3.11 Pneumatic diagram L
Y141L Y144L Y143L Y146L Y145L Y148L Y147L Y149L Y151L

G11
Y141R Y144R Y143R Y146R Y145R Y148R Y147R Y149R Y151R G12
(1)
(3) (2)
(7) (6) (5) (4)
Fig. 11-29. Pneumatic diagram L

No. Item
(1) Compressed air
(2) Cap pusher (Magazine No.2 and 4)
(3) Cap pusher (Magazine No.1 and 3)
(4) Reject gate
(5) Filling section shutter
(6) 2nd. top sealer jaw escape
(7) Control valve for cooling water jacket
11- 28 M144- 7294 Issue 01

11 Pneumatic System
11.3.12 Pneumatic diagram M
G26
G29
Y165L Y163L
Y165R Y163R
Y189L
Y189R
(5) (4)
G25
G27
Y175L Y173L Y171L

Y175R Y173R Y171R
B1SP
Y183L Y181L Y1S

Y183R Y181R
Y179L
Y179R
(3) (2)
(1)
Fig. 11-30. Pneumatic diagram M
No. Item
(1) Compressed air
(2) Horn escape
(3) Anvil
(4) 1st. top sealer jaw escape
(5) 2nd. top sealer
M144- 7294 Issue 01 11- 29

11 Pneumatic System
11.3.13 Pneumatic diagram N
G24 G23
Y161R Y161L
(4) (3) (2) (1)
Fig. 11-31. Pneumatic diagram N

No. Item
(1) Anvil cooling (L)
(2) Horn cooling (L)
(3) Anvil cooling (R)
(4) Horn cooling (R)
11- 30 M144- 7294 Issue 01

11 Pneumatic System
11.3.14 Pneumatic diagram P
B71RF FS FS B71LF
Y193 Y192
(1)
Fig. 11-32. Pneumatic diagram P

No. Item
(1) UV- lamp glass breakage detector
M144- 7294 Issue 01 11- 31

11 Pneumatic System
11.3.15 Pneumatic diagram Q
(1)
(6) (5) (4) (3) (2)
Fig. 11-33. Pneumatic diagram Q

No. Item
(1) Compressed air
(2) Product recovery valve (AV4, AV9)
(3) CIP recovery valve (AV5, AV10)
(4) CIP divert valve for spray ball (AV1, AV6)
(5) CIP divert valve for breathing pipe
(AV11, AV16)
(6) CIP divert valve (AV20, AV21)
11- 32 M144- 7294 Issue 01

11 Pneumatic System
11.3.16 Pneumatic diagram R
(1)
Y131L Y129L Y127L Y125L

Y131R Y129R Y127R Y125R
(5) (4) (3) (2)
Fig. 11-34. Pneumatic diagram R

No. Item
(1) Compressed air
(2) ELOFOAM (Bottom forming section)
(3) ELOFOAM (Carton decontamination sec-
tion)
(4) ELOFOAM (Filling section)
(5) ELOFOAM (Top sealing section)
M144- 7294 Issue 01 11- 33

11 Pneumatic System
11.3.17 Pneumatic diagram S
(1)
Y109L
Y109R
Fig. 11-35. Pneumatic diagram S

No. Item
(1) Empty carton pusher (Discharge section)
11- 34 M144- 7294 Issue 01

11 Pneumatic System
11.4 Solenoid valve purpose list
Solenoid valve No. Purpose Pneumatic Pneumatic

diagram arrangement
Y1L Picker vacuum open- close (Magazine No.1) A A
Y1R Picker vacuum open- close (Magazine No.3) A A
Y5L Unloader vacuum open- close (L- side) A A
Y5R Unloader vacuum open- close (R- side) A A
Y6L Picker vacuum (L- side) A A
Y6R Picker vacuum (R- side) A A
Y7 Unloader vacuum A A
Y8L Diaphragm vacuum (Magazine No.1) B A
Y8R Diaphragm vacuum (Magazine No.3) B A
Y9L Diaphragm vacuum (Magazine No.2) B A
Y9R Diaphragm vacuum (Magazine No.4) B A
Y31L Picker drive engage (L- side) C H1
Y31R Picker drive engage (R- side) C J1
Y32L Picker drive engage (L- side) C H1
Y32R Picker drive engage (R- side) C J1
Y33L Bottom rail size change (330/250 ml)(L- side) C H1
Y33R Bottom rail size change (330/250 ml)(R- side) C J1
Y34L Bottom rail size change (330/250 ml)(L- side) C H1
Y34R Bottom rail size change (330/250 ml)(R- side) C J1
Y35L Bottom rail size change (500 ml)(L- side) C H1
Y35R Bottom rail size change (500 ml)(R- side) C J1
M144- 7294 Issue 01 11- 35

11 Pneumatic System

diagram arrangement
Y39L Bottom rail up- down (L- side) C H1
Y39R Bottom rail up- down (R- side) C J1
Y40L Bottom rail up- down (L- side) C H1
Y40R Bottom rail up- down (R- side) C J1
Y41L Loader shutter (L- side) C H1
Y41R Loader shutter (R- side) C J1
Y42L Loader shutter (L- side) C H1
Y42R Loader shutter (R- side) C J1
Y43L Carton basket size change (L- side) C H1
Y43R Carton basket size change (R- side) C J1
Y47L Carton basket size change (Stopper)(L- side) C H1
Y47R Carton basket size change (Stopper)(R- side) C J1
Y48L Carton basket size change (Stopper)(L- side) C H1
Y48R Carton basket size change (Stopper)(R- side) C J1
Y11L Air operated valve for hydrogen peroxide spray D H
(L- side)
Y11R Air operated valve for hydrogen peroxide spray D J
(R- side)
Y13L Pump for hydrogen peroxide D H
Y13R Spare D J
Y15L Air operated valve for hydrogen peroxide filter air vent D H
Y15R Spare D J
11- 36 M144- 7294 Issue 01

11 Pneumatic System

diagram arrangement
Y17L Pump for ethanol D H
Y17R Spare D J
Y19 Spare D H
Y21L Carton pusher (L- side) D H
Y21R Carton pusher (R- side) D J
Y23L Spare D H
Y23R Spare D J
Y25 Bottom heater escape D J
Y27L Top heater escape (L- side) D H
Y27R Top heater escape (R- side) D J
Y29L Unloader vacuum head movement (L- side) D H
Y29R Unloader vacuum head movement (R- side) D J
Y85L Carton holder (L- side) E H
Y85R Carton holder (R- side) E H
Y87L Bottom breaker wing (L- side) E H
Y87R Bottom breaker wing (R- side) E H
Y88L Bottom breaker wing (L- side) E H
Y88R Bottom breaker wing (R- side) E H
Y10 Main air F A
Y51L Potable water inlet G K
Y51R Spare G L
Y53L CIP recovery pump drain G K
Y53R Spare G L
Y55L Empty carton blow G K
Y55R Empty carton blow G L
Y57L Unloader guide (L- side) G K
Y57R Unloader guide (R- side) G L
Y59L Carton lifter size change (for pin)(L- side) G K
Y59R Carton lifter size change (for pin)(R- side) G L
Y61L Tank drain valve (AV50)(L- side) G K
Y61R Tank drain valve (AV52)(R- side) G L
Y63L Carton lifter size change (for air gripper)(L- side) G K
Y63R Carton lifter size change (for air gripper)(R- side) G L
M144- 7294 Issue 01 11- 37

11 Pneumatic System

diagram arrangement
Y65L Tank drain valve (AV51)(L- side) G K
Y65R Tank drain valve (AV53)(R- side) G L
Y71L CIP divert valve (AV40)(L- side) G K
Y71R CIP divert valve (AV41)(R- side) G L
Y73L UV- lamp shutter open/close (L- side) G K
Y73R UV- lamp shutter open/close (R- side) G L
Y91 Bottom heater air shutter H A
Y251 Carton dust remover (L- side) H C
Y253 Carton dust remover (R- side) H C
Y105L 2nd. top breaker (Fork)(L- side) J E
Y105R 2nd. top breaker (Fork)(R- side) J F
Y107L 2nd. top breaker (Wing)(L- side) J E
Y107R 2nd. top breaker (Wing)(R- side) J F
Y133 Grease pump J E
Y195L Filler nozzle suck back device (L- side) K G
Y195R Filler nozzle suck back device (R- side) K G
Y197L Filler nozzle suck back device (L- side) K G
Y197R Filler nozzle suck back device (R- side) K G
Y141L Control valve for cooling water jacket (L- side) L C
Y141R Control valve for cooling water jacket (R- side) L D
Y143L 2nd. top sealer jaw escape (L- side) L C
Y143R 2nd. top sealer jaw escape (R- side) L D
Y144L 2nd. top sealer jaw escape (L- side) L C
Y144R 2nd. top sealer jaw escape (R- side) L D
Y145L Filling section shutter (L- side) L C
Y145R Filling section shutter (R- side) L D
Y146L Filling section shutter (L- side) L C
Y146R Filling section shutter (R- side) L D
Y147L Reject gate (L- side) L C
Y147R Reject gate (R- side) L D
Y148L Reject gate (L- side) L C
Y148R Reject gate (R- side) L D
Y149L Cap pusher (Magazine No.1) L C
11- 38 M144- 7294 Issue 01

11 Pneumatic System

diagram arrangement
Y149R Cap pusher (Magazine No.3) L D
Y151L Cap pusher (Magazine No.2) L C
Y151R Cap pusher (Magazine No.4) L D
Y1S Quick exhaust valve M E
Y163L 1st. top sealer jaw escape (L- side) M E
Y163R 1st. top sealer jaw escape (R- side) M F
Y165L 2nd. top sealer (L- side) M E
Y165R 2nd. top sealer (R- side) M F
Y171L Horn escape (Magazine No.1) M C
Y171R Horn escape (Magazine No.3) M D
Y173L Horn escape (Magazine No.2) M C
Y173R Horn escape (Magazine No.4) M D
Y175L Anvil (L- side) M C
Y175R Anvil (R- side) M D
Y179L Cap horn port block (Magazine No.1) M C
Y179R Cap horn port block (Magazine No.3) M D
Y181L Cap horn port block (Magazine No.2) M C
Y181R Cap horn port block (Magazine No.4) M D
Y183L Anvil port block (L- side) M C
Y183R Anvil port block (R- side) M D
Y189L 2nd. top sealer port block (L- side) M E
Y189R 2nd. top sealer port block (R- side) M F
Y161L Anvil, horn cooling (L- side) N C
Y161R Anvil, horn cooling (R- side) N C
Y192 UV- lamp glass breakage detector (L- side) P F
Y193 UV- lamp glass breakage detector (R- side) P F
Y125L ELOFOAM (Bottom forming section)(L- side) R B
Y125R ELOFOAM (Bottom forming section)(R- side) R B
Y127L ELOFOAM (Carton decontamination section)(L- side) R B
Y127R ELOFOAM (Carton decontamination section)(R- side) R B
Y129L ELOFOAM (Filling section)(L- side) R B
Y129R ELOFOAM (Filling section)(R- side) R B
Y131L ELOFOAM (Top sealing section)(L- side) R B
M144- 7294 Issue 01 11- 39

11 Pneumatic System

diagram arrangement
Y131R ELOFOAM (Top sealing section)(R- side) R B
Y109L Empty carton pusher (Discharge section) S E
Y109R Empty carton pusher (Discharge section) S F
11- 40 M144- 7294 Issue 01

11 Pneumatic System
M144- 7294 Issue 01 11- 41

11 Pneumatic System
11.5 Solenoid valve ON- OFF list - Related to carton size

The following parameters show ON/OFF status of the solenoid valves related to carton size.
Solenoid valve 1,000 ml 750 ml 500 ml 330/250 ml

No.
Y1L ON ON ON ON
Y1R ON ON ON ON
Y2L ON ON ON ON
Y2R ON ON ON ON
Y3L ON ON OFF OFF
Y3R ON ON OFF OFF
Y4L ON ON OFF OFF
Y4R ON ON OFF OFF
Y208L ON OFF OFF OFF
Y208R ON OFF OFF OFF
Y209L ON OFF OFF OFF
Y209R ON OFF OFF OFF
Y33L OFF OFF OFF ON
Y33R OFF OFF OFF ON
Y34L ON ON ON OFF
Y34R ON ON ON OFF
Y35L OFF OFF ON OFF
Y35R OFF OFF ON OFF
Y36L ON ON OFF ON
Y36R ON ON OFF ON
Y37L OFF ON OFF OFF
Y37R OFF ON OFF OFF
Y38L ON OFF ON ON
Y38R ON OFF ON ON
Y39L OFF ON  OFF ON  OFF ON  OFF
Y39R OFF ON  OFF ON  OFF ON  OFF
Y40L ON OFF  ON OFF  ON OFF  ON
Y40R ON OFF  ON OFF  ON OFF  ON
Y43L ON OFF OFF OFF
Y43R ON OFF OFF OFF
Table 11-2. Solenoid valve ON- OFF list Part 1 of 2
11- 42 M144- 7294 Issue 01

11 Pneumatic System
Solenoid valve 1,000 ml 750 ml 500 ml 330/250 ml

No.
Y44L OFF ON ON ON
Y44R OFF ON ON ON
Y45L ON ON OFF OFF
Y45R ON ON OFF OFF
Y46L OFF OFF ON ON
Y46R OFF OFF ON ON
Y47L OFF OFF ON OFF
Y47R OFF OFF ON OFF
Y48L ON ON OFF ON
Y48R ON ON OFF ON
Table 11-2. Solenoid valve ON- OFF list Part 2 of 2
M144- 7294 Issue 01 11- 43

11 Pneumatic System
11.6 Standard pressure list

The following list shows the standard values for pressure gauges.
Gauge no. Section Standard Pneumatic Pneumatic

diagram arrangement
G1 Compressed air for main air 0.6 MPa A,F A
G2 Compressed air for picker and unloader 0.1 ~ 0.15 MPa A A
G3 Pilot air for picker and unloader 0.4 MPa A A
G5 Unloader helper 0.3 ~ 0.5 MPa F B
G11 Reject gate (L- side) 0.2 MPa L C
G12 Reject gate (R- side) 0.2 MPa L D
G13 Supply pressure control for G39 (L- side) 0.2 MPa K G
G14 Supply pressure control for G40 (R- side) 0.2 MPa K G
G15 Grease pump 0.3 MPa J E
G16 Bottom heater air shutter 0.1 ~ 0.2 MPa H A
G17 Bottom breaker air shutter 0.1 ~ 0.2 MPa H A
G18 Carton basket size change 0.2 MPa C A
G19 Carton basket size change (Stopper) 0.2 MPa C A
G20 2nd. bottom heater (Damper) 0.1 ~ 0.2 MPa F B
G21 Product inlet auto valve (AV2)(L- side) 0.4 MPa J E
G22 Product inlet auto valve (AV7)(R- side) 0.4 MPa J F
G23 Anvil, horn cooling air (L- side) 0.05 ~ 0.1 MPa N C
G24 Anvil, horn cooling air (R- side) 0.05 ~ 0.1 MPa N C
G25 Horn escape (L- side) 0.35 MPa M C
G26 1st. top sealer jaw escape, 2nd. top seal- 0.4 MPa M E
er (L- side)
G27 Horn escape (R- side) 0.35 MPa M D
G28 Bottom rail size change 0.3 MPa C C
G29 1st. top sealer jaw escape, 2nd. top seal- 0.4 MPa M F
er (R- side)
G30 Carriage conveyor tension (L- side) 0.3 MPa A,F A
G31 Carriage conveyor tension (R- side) 0.3 MPa A,F A
G32 Carton dust remover 0.3 Mpa H C
G34 Ethanol spray nozzle 0.1 ~ 0.2 MPa Fig. 2-27. Fig. 2-28.
G35 Ethanol tank 0.1 ~ 0.2 MPa Fig. 2-27. Fig. 2-28.
G36 Hydrogen peroxide air curtain (L- side) 0.1 ~ 0.2 MPa Fig. 7-2. Fig. 7-3.
Table 11-3. Standard pressure Part 1 of 2
11- 44 M144- 7294 Issue 01

11 Pneumatic System
Gauge no. Section Standard Pneumatic Pneumatic

diagram arrangement
G37 Hydrogen peroxide air curtain (R- side) 0.1 ~ 0.2 MPa Fig. 7-2. Fig. 7-3.
G38 Hydrogen peroxide tank 0.07 ~ 0.14 MPa Fig. 7-2. Fig. 7-3.
G39 Filler nozzle suck back device (L- side) 20 ~ 40 kPa K G
G40 Filler nozzle suck back device (R- side) 20 ~ 40 kPa K G
Table 11-3. Standard pressure Part 2 of 2
M144- 7294 Issue 01 11- 45

11 Pneumatic System
11.7 Pressure switch & float switch & flow sensor list
The following list shows switch No, purpose, and diagram area.
Switch No. Purpose Pneumatic Pneumatic

diagram arrangement
B1P Pressure switch for main air A,F A
B5P Pressure switch for main vacuum A A
B10P Pressure switch for supply air A,F A
B11LF Floating switch for broken diaphragm detection B E
(L- side, No.1 piston cylinder)
B11RF Floating switch for broken diaphragm detection B F
(R- side, No.1 piston cylinder)
B12LF Floating switch for broken diaphragm detection B E
B12RF Floating switch for broken diaphragm detection B F
B13LP Pressure switch for broken diaphragm detection B E
B13RP Pressure switch for broken diaphragm detection B F
B14LP Pressure switch for broken diaphragm detection B E
B14RP Pressure switch for broken diaphragm detection B F
B1SP Pressure switch for quick exhaust valve M E
B71LF Flow sensor for UV- lamp glass breakage detector (L- side) P F
B71RF Flow sensor for UV- lamp glass breakage detector (R- side) P F
B81LF Flow sensor for Hydrogen peroxide flow (Mandrel No.2) Fig. 7-2. Fig. 7-3.
B81RF Flow sensor for Hydrogen peroxide flow (Mandrel No.4) Fig. 7-2. Fig. 7-3.
B82LF Flow sensor for Hydrogen peroxide flow (Mandrel No.1) Fig. 7-2. Fig. 7-3.
B82RF Flow sensor for Hydrogen peroxide flow (Mandrel No.3) Fig. 7-2. Fig. 7-3.
B84LP Pressure switch for hydrogen peroxide spray (L- side) Fig. 7-2. Fig. 7-3.
B84RP Pressure switch for hydrogen peroxide spray (R- side) Fig. 7-2. Fig. 7-3.
Table 11-4. Pressure switch & float switch & flow sensor list Part 1 of 1
11- 46 M144- 7294 Issue 01

11 Pneumatic System
11.7.1 Air cylinder manual operation

(1)
WARNING
(2)
BE AWARE THAT THE AIR CYLINDER
ROD WILL MOVE WHEN THE SOLENOID
VALVES ARE MANUALLY OPERATED.
YOUR HAND CAN BE CAUGHT BY THE
SIZE CHANGE BLOCK WHICH AU-
TOMATICALLY MOVES.
1. Set OPERATION POWER to OFF.

Fig. 11-36. Air cylinder manual operation
2. Set the main circuit breaker to OFF.
(1) 3. The air cylinder rod will move when pushing the
manual switch (2) of the solenoid valve (1).
4. The air cylinder rod will move back to the origi-
nal position when releasing the manual switch.
(2) No. Parts

(1) Solenoid valve
(2)
(2) Manual switch
(2)
(1)
M144- 7294 Issue 01 11- 47

11 Pneumatic System
11.8 Personal notes
11- 48 M144- 7294 Issue 01

12 Cooling water system
12 COOLING WATER SYSTEM
M144- 7294 Issue 01
M144- 7294 Issue 01 12- 1

12 COOLING WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 1
12.1 Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 4

12.2 UV- lamp for decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 6
12.2.1 Quartz sleeve of UV- lamp unit - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 8
12.2.2 Alarm Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 12
12.2.4 UV- lamp - Clean . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 15
12.2.5 UV- lamp after cleaning - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 17
12.3 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 18
12- 2 M144- 7294 Issue 01

M144- 7294 Issue 01 12- 3

12.1 Cooling water diagram
b a a b
(27)
(32)
(30) (31)
(28) (29)
(34)
(53)
(33)
(35) (36)
(38) (40) (42)
(37) (39) (41)
(44)
(43)
(52)
(51)
(49)
(50)
(48)
(47)
(45) (46)
(4) (16)
(3)
(9) (17)
(1) (2)
(8) (10)
(6)
(15)
(5) (7)
(12) (14)
(11) (13)
(26)
(25)
(24)
(23)
(22)
(18) (20)
(21)
(19) a
b
Fig. 12-1. Cooling water diagram
12- 4 M144- 7294 Issue 01

Function: To supply water for cooling and lu- Note ! a: Upper part of the bed
brication. b: Lower part of the bed
Chilled water (1) and potable water (27) are supplied The temperature controlled water tank (18) is installed
to this machine from the customer as cooling water. in the machine, and temperature controlled water (35)
Inside the machine, water is used for cooling or lu- is circulated as cooling water by the pump (20).
brication.
No. Parts No. Parts

(1) Chilled water supply (28) UV- lamp
(2) Flow switch (29) Flow switch
(3) Bottom rail for carton decontamination sec- (30) Rotary valve
tion (L- side)
(4) Bottom rail for carton decontamination sec- (31) Carton lifter rod (L- side)
tion (R- side)
(5) Chain rail (L- side, Lower) (32) Carton lifter rod (R- side)
(6) Chain rail (L- side, Upper) (33) Rear bottom rail (L- side)
(7) Bottom rail (L- side) (34) Rear bottom rail (R- side)
(8) Chain rail (R- side, Lower) (35) Temperature controlled water supply
(9) Chain rail (R- side, Upper) (36) Flow switch
(10) Bottom rail (R- side) (37) Tension rod (L- side)
(11) 2nd. top sealer jaw (L- side) (38) Tension rod (R- side)
(12) 2nd. top sealer jaw (R- side) (39) Bottom sealer pressure pad (L- side)
(13) Cooled guide (L- side) (40) Bottom sealer pressure pad (R- side)
(14) Cooled guide (R- side) (41) Folding rail (L- side)
(15) Resistance temperature detector (42) Folding rail (R- side)
(16) Pump (43) 1st. top sealer jaw (L- side)
(17) Chilled water return (44) 1st. top sealer jaw (R- side)
(18) Temperature controlled water tank (45) Flow switch
(19) Resistance temperature detector (46) Solenoid valve
(20) Pump (47) UV- lamp for carton (L- side)
(21) Mandrel (L- side) (48) Chain rail for carton decontamination section
(L- side)
(22) Mandrel (R- side) (49) Flow switch
(23) Flow switch (50) Solenoid valve
(24) Heat exchanger (51) UV- lamp for carton (R- side)
(25) Solenoid valve (52) Chain rail for carton decontamination section
(R- side)
(26) Hydrogen peroxide tank (53) Temperature controlled water recovery
(27) Potable water
M144- 7294 Issue 01 12- 5

12.2 UV- lamp for decontamination
(2)
(1)
Fig. 12-2. UV- lamp
12- 6 M144- 7294 Issue 01

Function: To decontaminate potable water by

ultraviolet irradiation.
Supplied water is decontaminated with the quartz

sleeve (2) for the UV- lamp (1).
The expected lifetime of the UV- lamp is approximate-
ly 9,000 hours.
Note ! For handling details of the UV- lamp,

refer to the ”Document No.:
M214- 055- 109, WEDECO Aquada
Installation and Maintenance Instruc-
tions, Xylem Inc.” included in the
Chapter 17 APPENDIX.
No. Parts
(1) UV- lamp
(2) Quartz sleeve
CAUTION
SKIN.
RUBBER GLOVES, RUBBER APRON
AND RUBBER BOOTS, ETC.) WHILE
HANDLING UV- LAMP.
NEVER LOOK DIRECTLY AT AN ILLUMI-
NATED UV- LAMP.
THE UV- LAMP, ALWAYS UNPLUG THE
UV- LAMP UNIT FIRST.
NEVER OPERATE THE UV SYSTEM
M144- 7294 Issue 01 12- 7

12.2.1 Quartz sleeve of UV- lamp unit -

Clean
Standard
Cleaning cycle Every 600 hours
Note ! Dirt may accumulate on the quartz

sleeve decreasing UV output.
1. Stop the main motor by pushing the MAIN MO-

TOR OFF button after all cartons have been
MAIN MOTOR discharged from the machine.
Fig. 12-3. MAIN MOTOR buttons

(1)
12- 8 M144- 7294 Issue 01

3. Push END (2) for both R- and L- sides on the

SET MODE window. The green lamps flash at
2- second intervals. Push and hold CONFIRM
(3), and END lamps flash at 1- second intervals.
(3)
a) The green lamp turns on.
b) UV- lamp for potable water turns off.
(2)
4. Push and hold the OPERATION POWER OFF

button.
OPERATION POWER The lamp turns off.
CAUTION !
Before turning off the OPERATION POWER, be
sure to stop product supply.
Fig. 12-6. OPERATION POWER buttons
5. Turn off the main circuit breaker to the machine

and drain the water from the UV- lamp and
plastic container.
6. Disassemble the UV- lamp unit.

Refer to the ”Document No.: M214- 055- 109,
WEDECO Aquada Installation and Maintenance
Instructions, Xylem Inc., 2.1.2.1. Cleaning and
Replacement of Quartz Sleeve” included in the
7. Clean the outside of the quartz sleeve with a

cloth soaked in a commercial scale remover
(CLR), vinegar or some other mild acid, and
rinse it.
8. Assemble the UV- lamp unit.

Instructions, Xylem Inc., Assembling manual
(page 9 )” included in the Chapter 17 APPEN-
DIX.
M144- 7294 Issue 01 12- 9

9. Turn on the main circuit breaker.
10.Push the OPERATION POWER ON button.

OPERATION POWER
11.Push SET MODE on the SETUP screen.

12.Push PRODUCTION (1) for both RIGHT LANE

The green lamps flash at 2- second intervals.
Push and hold CONFIRM (2), and PRODUC-
(2) TION lamps flash at 1- second intervals.
(1) a) The green lamp turns on.
b) UV- lamp for potable water turns on.
12- 10 M144- 7294 Issue 01

M144- 7294 Issue 01 12- 11

12.2.2 Alarm Message

(2)
No. Parts
(1) UV- lamp controller
(1) (2) Day counter

Fig. 12-9. UV- lamp controller tions” included in the Chapter 17 AP-
PENDIX.
The following alarm messages can occur on the day counter (2) during operation :
Display Explanation
AL 1 UV- lamp failed.
 UV- lamp has not ignited.

 UV- lamp is defect.
 Lamp failure LED is lit up.
 Check plug connection of UV lamp.

 Remove transparent cap as described and fit it once more.
 Insert new UV- lamp.
 Have ballast checked by authorised service technician.
Display Explanation
AL 2 UV intensity less than 55 % of set value.
 Quartz sleeve is dirty.

 Sensor is dirty.
 End of UV- lamp life (due to frequent switching on and off).
 Unit has been operated too long without flowing water (reactor is heated up).
 Lamp filament wiring is in front of the sensor window.
 Disassemble quartz sleeve as described in section 2.1.2.1.in ”Document No.: M214- 055- 109, WEDECO
Aquada Installation and Maintenance Instructions” and clean with a cleaner.
 Disassemble sensor and clean sensor window.
 Avoid frequent switching on and off, as the unit has been designed for continuous operation.
 Switch unit off and let it cool down.
 Turn transparent lamp connector by 45_.
12- 12 M144- 7294 Issue 01

Display Explanation
AL 3 End of lamp life (days of use = 0).
 End of UV- lamp life.
 Replace with a new lamp (Use only original WEDECO spare parts).
Display Explanation
AL 4 UV intensity between 55 % and 70 % of set value.
 Normal UV- lamp ageing (disinfection is still given).

 Cleaning could be required soon.
 Lamp filament wiring is in front of the sensor window.
 Normal operating conditions can be restored by cleaning the unit.

 In the display ”HI” is replaced by ”LO” (only Maxima).
 Turn transparent lamp connector by 45_.
Display Explanation
AL 5 UV- lamp life < 30 days of use.
 End of lamp life in 30 days.
 Order new UV- lamp.
Note ! All alarm messages are also given acoustical. The acoustical signal can be reset by press-
ing the RESET button.
M144- 7294 Issue 01 12- 13

12.2.3 UV- lamp lifetime - Check
Note ! When the time to replace the UV-

lamps comes, the ”CONFIRM RUN-
Check for total hours of the UV- lamp
according to the following proce-
dures.
(1) (2)
screen.

screen.
(3) The RUNNING HOURS (1/4) screen appears.
Note ! Total hours of the UV- lamps can be

checked with UV LAMP for POTABLE
WATER HOURS (4) on the RUNNING
HOURS (1/4) screen.
3. When the time to replace the UV- lamp comes,

replace the lamps with new ones.
(5) 4. After replacement, push and hold RST (5) to
reset the total hours of UV- lamp.
(4) Refer to the Main Touch Panel Operation Manu-
Standard

Fig. 12-12. RUNNING HOURS (1/4) screen sary.
Note ! Refer to 14.16.1.2 for replacement of

the UV- lamp.
12- 14 M144- 7294 Issue 01

12.2.4 UV- lamp - Clean


(1)
3. Push END (2) for both RIGHT LANE and LEFT

LANE on the SET MODE window. The green
lamps flash at 2- second intervals. Push and
hold CONFIRM (3), and END lamps flash at
(3) 1- second intervals.
a) The green lamp turns on.
(2) b) UV- lamp for potable water turns off.
M144- 7294 Issue 01 12- 15


button.
CAUTION !

plastic container.

Note ! Be very careful when handling the

UV- lamps as they are extremely fra-
gile.
Do not twist the lamp from the con-
nector.
7. Clean glass surface of the UV- lamp with a lint

free cloth.
Note ! After cleaning, hold both ends of the

UV- lamp so as not to directly touch
the glass. If you must touch the lamp
glass, please use gloves or a soft
cloth.

DIX.
12- 16 M144- 7294 Issue 01

12.2.5 UV- lamp after cleaning - Check

2. Push the OPERATION POWER ON button.

OPERATION POWER
3. Push SET MODE on the SETUP screen.

(1)
4. Push PRODUCTION (1) for both RIGHT LANE

The green lamps flash at 2- second intervals.
Push and hold CONFIRM (2), and PRODUC-
(2) TION lamps flash at 1- second intervals.
(1) a) The green lamp turns on.
b) UV- lamp for potable water turns on.
M144- 7294 Issue 01 12- 17

12.3 Personal notes
12- 18 M144- 7294 Issue 01

13 Lubrication
13 LUBRICATION
M144- 7294 Issue 01
M144- 7294 Issue 01 13- 1

13 Lubrication
13 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 1
13.1 Manual greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3

13.1.1 Manual greasing - Check & Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3
13.1.2 Grease terminals for bottom heater, carton loader, bottom breaker and bottom sealer . . 13- 6
13.1.3 Grease terminals for cap applicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 8
13.1.4 Grease terminals for encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 9
13.1.5 Manual greasing with grease brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 10
13.2 Manual operation for automatic greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11
13.2.1 Grease manual supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 11
13.2.2 Grease clogged alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 12
13.3 Automatic greasing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 14
13.3.1 Examples of discharge amount from distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 17
13.3.2 Lubrication parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 18
13.3.3 Automatic greasing diagram (from master distributor to secondary distributors) . . . . . . . 13- 24
13.4 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 30
13.5 Oil - Check/ Refill/ Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 31
13.5.1 Oil for speed reducer (for main drive) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35
13.5.2 Oil for mandrel index unit - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35
13.5.3 Oil for bottom sealer gearbox - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
13.5.4 Oil for cooling water rotary joint - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 36
13.5.5 Oil for vacuum pumps - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 37
13.5.6 Oil filter for vacuum pump - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 38
13- 2 M144- 7294 Issue 01

13 Lubrication
13.1 Manual greasing
13.1.1 Manual greasing - Check &

Refill
1. Main motor hours are displayed on the No.1

panel (1) and on the RUNNING HOURS
screen.
Refer to Table 13-1.
(1)
Fig. 13-1. Main motor hours

screen.
(2)

screen. The RUNNING HOURS screen ap-
pears.
(3)
M144- 7294 Issue 01 13- 3

13 Lubrication
4. Check the displayed total hours and supply

grease manually.
13- 4 M144- 7294 Issue 01

13 Lubrication
Refer to Section Check and refill

Fig. 13-8. (1) Bottom heater and carton loader bearing unit Monthly
Fig. 13-8. (2) Bottom breaker / bottom sealer grease terminal Monthly
Fig. 13-9. (1), (2) Cap applicator Monthly
Fig. 13-10. (1) Encoder Yearly
Fig. 13-11. (1) Cams, gears, chain and sprocket under the ma- Weekly
chine bed
Fig. 13-12. (2) (Every 50 hours)
Fig. 13-13. (3), (4)
Table 13-1. Grease supply Part 1 of 1
5. Use the recommended greases or the equal specifications.
Petro - Canada
Grease pot, grease gun and grease brush
PURITY FG 00 GREASE
Heat- resistant grease
Table 13-2. Recommended food grade grease Part 1 of 1
DANGER
FOLLOW THE MANUFACTURER’S
AND DISCARDING GREASE.
CAUTION !
Check the recommended grease list before re-
fill or replacement.
CAUTION !
Discard the used grease in accordance with the
local regulation.
CAUTION !
Clean the grease nipples before greasing.
M144- 7294 Issue 01 13- 5

13 Lubrication
13.1.2 Grease terminals for bottom heater, carton loader, bottom breaker and
bottom sealer
(2) View X (2) (1) View Y (1)
X Y
(1)
(2)
Fig. 13-8. Grease terminals for bottom heater, carton loader, bottom breaker and bottom sealer
13- 6 M144- 7294 Issue 01

13 Lubrication
1. Supply grease to the grease nipples on the

grease terminals (1) for the bottom heater and
carton loader with the grease gun.
2. Supply grease to the grease nipples on the
grease terminals (2) for the bottom breaker and
the bottom sealer with the grease gun.
CAUTION !
Use the heat- resistant grease.
Section Grease type Cycle

Bearing unit for the As recom- Monthly
bottom heater and mended
carton loader
Bearing unit for the
bottom breaker and
bottom sealer
M144- 7294 Issue 01 13- 7

13 Lubrication
13.1.3 Grease terminals for cap applicator
(1)
View X View Y
X Y
A A
(1)
(1)
Fig. 13-9. Grease terminals for cap applicator
1. Supply grease to the grease nipples on the Note ! If grease leaks from the spline shafts
grease terminals (1) for the cap applicator and (Fig. 13-9. A), wipe off grease with a
the spline shaft with the grease gun. clean cloth.
Section Grease type Cycle

Grease terminals for As recom-
Monthly
the cap applicator mended
13- 8 M144- 7294 Issue 01

13 Lubrication
13.1.4 Grease terminals for encoder
(1)
(2)
Fig. 13-10. Grease terminals for encoder
1. Remove the plug (2). Section Grease type Cycle

2. Supply grease to the grease nipples on the Grease terminals for As recom- Yearly
grease terminals (1) for the encoder with the the encoder mended
grease gun.
3. Install the plug (2).
M144- 7294 Issue 01 13- 9

13 Lubrication
13.1.5 Manual greasing with grease

brush
1. Apply grease to the cams (1), gears (2), chain

(3) and sprocket (4) of the drive sections under
the machine bed with the grease brush.
(1) Section Grease type Cycle

Cams, gears, As recom- Every
chain, sprocket mended 50hours
under the ma- (Weekly)
Fig. 13-11. Manual greasing for cams chine bed
(2)
Fig. 13-12. Manual greasing for gears
(3)
(4)
Fig. 13-13. Manual greasing for chain and

sprocket
13- 10 M144- 7294 Issue 01

13 Lubrication
13.2 Manual operation for

automatic greasing system
The grease pump supplies grease to the predeter-
mined sections regularly through the distribution
valves.
13.2.1 Grease manual supply
1. Push GREASE (1) on the MANUAL screen. The

GREASE window appears.
(1)
2. Push MANUAL GREASE SUPPLY ON (2) on

the GREASE window.
The grease pump starts operating.
3. Grease pump automatically stops after one cir-
culation of grease.
(2)
Fig. 13-15. GREASE window
M144- 7294 Issue 01 13- 11

13 Lubrication
13.2.2 Grease clogged alarm
1. The lamp (1) turns on, and VIEW ALARM (2)

starts flashing.
(1)
(2)
2. The red colour of alarm light (3) and buzzer (4)

(3) turns on. The buzzer will automatically turn off
after 3 seconds.
(4)

STATUS screen. (Refer to Fig. 13-16. )
(5) 4. Push GREASE LINE CLOGGED (5) on the

ALARM LIST screen.
13- 12 M144- 7294 Issue 01

13 Lubrication
5. Check the following on the Alarm help screen.

a) Low level in grease pot.
b) Grease pipe broken or loose.
c) Pneumatic or electrical fault.
6. Push RESET (6) on the Alarm help screen.
a) The related alarm on ALARM LIST is reset.
(8) (6) (Refer to Fig. 13-18. )
(7) b) The ALARM LIST screen is reset.
Fig. 13-19. Alarm help screen c) The lamp (7) turns off.
TION STATUS screen.
Note ! If other alarms remain, the ALARM

LIST screen appears again. (Refer to
Fig. 13-18. )
M144- 7294 Issue 01 13- 13

13 Lubrication
13.3 Automatic greasing system
(6)
(5)
(3)
(7)
(4)
(2) (1)
(8)
View X
(7) (6) (7)
Fig. 13-20. Automatic greasing system
Automatic greasing system is a one- way CAUTION !

lubrication system consisting of grease pump, dis- Do not block any discharge port of distributors
tributors, control device, attachments and piping.
with plug. The whole system will malfunction.
The pump (1) is operated by air cylinder (2) pres-
sure, and supplies grease from grease pot (3) con-
nected with the pump to master distributor (5) No. Parts
through discharge piping (4). Specified amounts of (1) Pump
grease are supplied to each lubrication point
through tertiary distributors (7) from secondary dis- (2) Air cylinder
tributors (6) linked to the master distributor (5). (3) Grease pot
The pump is automatically started by a counter in (4) Discharge piping
the PLC, and completes one greasing cycle every (5) Master distributor
4 hours. The pump is stopped by a feedback signal
from the cycle M switch (9) (refer to Fig. 13-21. ) (6) Secondary distributor
when the greasing cycle is completed which nor- (7) Tertiary distributor
mally takes approximately 3 minutes. The lubrica-
(8) Fill port hole
tion system can also be manually operated in
manual mode.
13- 14 M144- 7294 Issue 01

13 Lubrication
CAUTION !
When “GREASE LINE CLOGGED” alarm ap-
pears on the graphic panel, promptly take nec-
essary action to eliminate clogged grease.
If you continue to operate the machine with
grease clogged, the machine can be damaged
due to problems such as piping breakage.
(Refer to 13.2.2.)
The grease pump is located behind the fixed guard

on L- side of the machine below the carton dis-
charge section.
CAUTION !
Check list of recommended grease before refill.
Note ! To avoid contaminating the grease, do

not open or remove the grease pot lid
to refill.
The grease pot must be refilled with grease

through the fill port hole (8).
The master distributor (5) is attached with a cycle

M switch (9) and a block signal (10) as attach-
ments.
The piston motion inside of the master distributor
(5) can be checked by the indicator rod in the cycle
M switch. The motion of the indicator rod assures
the normal operation. In case the indicator rod
does not operate within 5 minutes after pump start,
cycle M switch (9) will give an alarm.
(9) Refer to Fig. 13-20. ~ Fig. 13-22.
No. Parts
Fig. 13-21. Cycle M switch (9) Cycle M switch
M144- 7294 Issue 01 13- 15

13 Lubrication
The block signal (10) operates when the discharge

line is clogged. When the pressure to any secon-
(11) dary or tertiary distributor increases higher than
specified pressure due to clogging, the indicator
pin (11) pops out to inform which system is clogge-
d.
No. Parts
(10) Block signal
(10) (11) Indicator pin
Fig. 13-22. Block signal
Refer to Fig. 13-24. for discharge volume from the

secondary distributors and tertiary distributors.
INLET Fig. 13-23. shows the detailed drawing of the mas-
ter distributor. The master distributor consists of 3
types of blocks A (12), M (13) and E (14). The first
letter after each number denotes the block type.
(12) The letter T (15) after the block type denotes that
there are 2 discharge ports.
(15) The number shows the piston size. The discharge
(13) volume (cc) per operation is calculated by dividing
the piston size by 100. For example; Block A is 60.
60 divided by 100 is 0.6 (60÷100=0.6). Each dis-
charge port of block A discharges 0.6cc, and block
A has 2 discharge ports.
The last letter R (16) of block E denotes the indica-
tor pin, which enables the cycle M switch to sense
how many times the master distributor has oper-
ated.
Greasing is performed every 4 hours. The cycle M
switch controls the master distributor to operate 4
times per greasing. So, each discharge port of the
(9) (14) (15) (16) (10) master distributor discharges 2.4cc (0.6 x 4) per
greasing, and discharged grease is supplied to the
secondary distributors (A,B,C,D,E,G,K,L). Then
grease is supplied to the tertiary distributors.
Fig. 13-23. Detail of master distributor Refer to Fig. 13-24. for discharge volume from the
secondary distributors and tertiary distributors.
Grease discharge is switched to the next discharge
port in sequence after 0.3 cc grease is discharged
from one discharge port of the secondary or the
tertiary distributor.
13- 16 M144- 7294 Issue 01

13 Lubrication
13.3.1 Examples of discharge amount from distributors
E3
E1
E4
E8
E5
E6 E7
Fig. 13-24. Secondary distributor and tertiary distributors
The above shows the grease discharge amount

supplied from the master distributor to the secon-
dary distributors (E) and the tertiary distributors
(E1, E3 ~ E8).
M144- 7294 Issue 01 13- 17

13 Lubrication
13.3.2 Lubrication parts arrangement
13.3.2.1 Lubrication parts arrangement
Refer to the arrangement figures for the detailed

installation positions of the distributors.
Fig. 13-25. Lubrication parts arrangement

(General)
Fig. 13-26. Lubrication parts arrangement A
(Lower part of the bed)
Fig. 13-27. Lubrication parts arrangement B
(Bottom sealing section)
Fig. 13-28. Lubrication parts arrangement C
(Filling section)
C B A
Fig. 13-25. Lubrication parts arrangement (General)
Grease distributors are arranged in 3 places (A~C).
13- 18 M144- 7294 Issue 01

13 Lubrication
Note ! The index numbers in Fig. 13-26. ~ Fig. 13-28. are as follows:
(1) Grease pump (19) Tertiary distributor E7
Lubrication point mainly for picker (Lower
(2) Pressure gauge K- 99
part of the bed)
(3) Master distributor
(20) Tertiary distributor E8
(4) Secondary distributor C Lubrication point mainly for mandrel (Lower
Lubrication point mainly for filler (R- side) part of the bed)
(21) Secondary distributor G
(5) Secondary distributor D
(22) Tertiary distributor G1
(6) Tertiary distributor D1 Lubrication point mainly for cap applicator
Lubrication point mainly for mandrel (Lower (Lower part of the bed)
part of the bed)
(23) Tertiary distributor G5
(7) Tertiary distributor D2 Lubrication point mainly for cap applicator
Lubrication point mainly for picker (Lower (Lower part of the bed)
part of the bed)
(24) Secondary distributor K
(8) Tertiary distributor D3
(25) Tertiary distributor K1
Lubrication point mainly for mandrel (Lower
Lubrication point mainly for filler (L- side)
part of the bed)
(Upper part of the bed)
Lubrication point mainly for cap applicator
part of the bed)
Lubrication point mainly for J- flap breaker
part of the bed)
Lubrication point mainly for bottom sealer
part of the bed)
(Upper part of the bed)
Lubrication point mainly for bottom sealer
part of the bed)
(13) Secondary distributor E
(14) Tertiary distributor E1 Lubrication point mainly for 1st. top breaker
Lubrication point mainly for mandrel (Lower (Lower part of the bed)
part of the bed)
(31) Secondary distributor L
(32) Tertiary distributor L1
Lubrication point mainly for top sealer (Low-
part of the bed)
er part of the bed)
part of the bed)
er part of the bed)
Lubrication point mainly for 2nd. top breaker
part of the bed)
part of the bed)
M144- 7294 Issue 01 13- 19

13 Lubrication
(35) Tertiary distributor L5 (37) Tertiary distributor L7

Lubrication point mainly for carriage convey- Lubrication point mainly for top heater (Low-
or (Lower part of the bed) er part of the bed)
er part of the bed)
13- 20 M144- 7294 Issue 01

13 Lubrication
13.3.2.2 Lubrication parts arrangement A

(14) (16)
(12)
(7)
(13)
(5) (6)
(20)
(29) (30) (9) (11) (10) (8)

(15) (19) (18) (17)
(26)
(23) (27)
(22)
(24)
(4)
(34)
(21)
(31) (37)
(32)
(3)
(35) (36) (33)

(2)
(1)
Fig. 13-26. Lubrication parts arrangement A (Lower part of the bed)
M144- 7294 Issue 01 13- 21

13 Lubrication
13.3.2.3 Lubrication parts arrangement B

(28)
Fig. 13-27. Lubrication parts arrangement B (Bottom sealing section)
13- 22 M144- 7294 Issue 01

13 Lubrication
13.3.2.4 Lubrication parts arrangement C

View X
(25)
Fig. 13-28. Lubrication parts arrangement C (Filling section)
M144- 7294 Issue 01 13- 23

13 Lubrication
13.3.3 Automatic greasing diagram

(from master distributor to
secondary distributors)

Specified amounts of grease are automatically
supplied from each port of master distributor (1)
through,
 Secondary distributor C to lubrication points
mainly for filling section.
 Secondary distributor D to lubrication points

mainly for mandrel section and picker section.
 Secondary distributor E to lubrication points

mainly for mandrel section and picker section.
 Secondary distributor G to lubrication points

mainly for cap applicator and top heater sec-
tion.
 Secondary distributor K to lubrication points

mainly for 1st. top breaking section, bottom
sealing section, J- flap breaker section and fill-
ing section.
 Secondary distributor L to lubrication points

mainly for 2nd. top breaking section, top heater
section, top sealing section and carriage con-
veyor.
In case the discharge line is clogged, the cycle M

switch (2) attached on the master distributor (1) will
give an alarm. The block signals (3) in each port of
the master distributor (1) can identify which dis-
charge line is clogged.
Note ! Check that tube piping between the

distributors and movable lubrication
points such as rod ends, cam follow-
ers, and needle bearings is not bent,
removed, or rubbed against other
parts by contacting.
13- 24 M144- 7294 Issue 01

13 Lubrication
2. Grease diagram Fig. 13-32. Secondary distributor D diagram.

Refer to the following grease diagrams for the de- Fig. 13-33. Secondary distributor E diagram.
tailed grease lubrication.
Fig. 13-34. Secondary distributor G diagram.
Fig. 13-30. Grease diagram (General).
Fig. 13-35. Secondary distributor K diagram.
Fig. 13-31. Secondary distributor C diagram.
Fig. 13-36. Secondary distributor L diagram.
(1)
(3)
(2)
Fig. 13-29. Automatic greasing diagram (Main diagram)
No. Parts No. Parts

(1) Master distributor (3) Block signal
(2) Cycle M switch
M144- 7294 Issue 01 13- 25

13 Lubrication
D
E
C
K
L
G
(3)
(2)
(1)
Fig. 13-30. Grease diagram (General)
The details of C~L are shown from 13.3.3.1 to 13.3.3.6.
13- 26 M144- 7294 Issue 01

13 Lubrication
Refer to Fig. 13-26. General diagram is shown in Fig. 13-30.

13.3.3.1 Secondary distributor C diagram
(4)
Fig. 13-31. Secondary distributor C diagram

13.3.3.2 Secondary distributor D diagram
(6) (7) (8) (9)
D1 D2 D3 D4
(5)
D5 D6
D7
(10) (11)
(12)
Fig. 13-32. Secondary distributor D diagram
M144- 7294 Issue 01 13- 27

13 Lubrication
Refer to Fig. 13-26. General diagram is shown in Fig. 13-30.

13.3.3.3 Secondary distributor E diagram
(14) (15) (16)

E1 E4
E3
(13)
E5 E6 E7 E8
(17) (18) (19)

(20)
Fig. 13-33. Secondary distributor E diagram

13.3.3.4 Secondary distributor G diagram
(22)
G1
(21)
G5
(23)
Fig. 13-34. Secondary distributor G diagram
13- 28 M144- 7294 Issue 01

13 Lubrication
Refer to Fig. 13-26. ~ Fig. 13-28. General diagram is shown in Fig. 13-30.
13.3.3.5 Secondary distributor K diagram
(25) (26)
K1 K2
(24)
K5
K6 K7 K8
(27)
(28) (29) (30)
Fig. 13-35. Secondary distributor K diagram

13.3.3.6 Secondary distributor L diagram
(32) (34)
(33)
L1 L4
L3
(31)
L5
L8
(35) L6
(37)
(36)
Fig. 13-36. Secondary distributor L diagram
M144- 7294 Issue 01 13- 29

13 Lubrication
13.4 Disposal
Dispose of the used grease according to local au-
thority regulations.
DANGER
AND DISCARDING GREASE.
13- 30 M144- 7294 Issue 01

13 Lubrication
13.5 Oil - Check/ Refill/ Replace
(1) (4) (5) (3) (2) (6)
Fig. 13-37. Lubrication arrangement
1. Oil refill and replacement are necessary for 6 places.
No. Section Check and refill Replace

(1) Speed reducer (for main drive) Weekly Every 1,200 hours
(2) Mandrel index unit Weekly Every 1,200 hours
(3) Bottom sealer gearbox Weekly Every 1,200 hours
(4) Vacuum pump (for picker and unloader) Weekly Every 500 hours
(5) Vacuum pump (for diaphragm) Weekly Every 500 hours
(6) Cooling water rotary joint Before production 
Table 13-3. Oil refill / replacement Part 1 of 1
M144- 7294 Issue 01 13- 31

13 Lubrication
CAUTION !
CAUTION Replace oil for all sections after the initial 100
hours of operation.
OIL IN THE SPEED REDUCERS, INDEX

UNIT, GEARBOX, VACUUM PUMPS ETC.
IS HOT AFTER OPERATION. LET OIL
COOL DOWN BEFORE REFILL OR
REPLACEMENT.
2. Main motor hours are displayed on the No.1

panel (1) and on the RUNNING HOURS
screen.
Check the displayed total hours and refill or re-
place oil manually.
(1)
Fig. 13-38. Main motor hours

screen.
(2)

(3) screen. The RUNNING HOURS screen ap-
pears.
13- 32 M144- 7294 Issue 01

13 Lubrication
5. Check the displayed total hours and refill or re-

place oil manually.
M144- 7294 Issue 01 13- 33

13 Lubrication
6. Use the recommended oils or equal specifications.
Oil supply section Shell ExxonMobil

Speed reducers  GLYGOYLE 220
(for main drive)
Vacuum pumps TELLUS OIL 100 MOBIL DTE OIL HEAVY
(for picker and unloader, for diaphragm)
Cooling water rotary joint TURBO OIL T 32 MOBIL DTE OIL LIGHT
Table 13-4. Recommended oils Part 1 of 1
Petro - Canada
Mandrel index unit PURITY FG EP GEAR FLUID 220
Bottom sealer gearbox PURITY FG EP GEAR FLUID 150
Table 13-5. Recommended food grade oils Part 1 of 1
DANGER
AND DISCARDING OIL.
CAUTION !
Check the recommended oil list before refill or
replacement.
CAUTION !
Discard the used oil in accordance with the lo-
cal regulation.
13- 34 M144- 7294 Issue 01

13 Lubrication
13.5.1 Oil for speed reducer (for main

drive) - Replace
(2) 1. Put a pan or something to collect oil under the
plug (1).
235mm 2. Remove the plug, and drain oil.

3. Check that oil has drained completely, and
(3) install the plug.
4. Supply new oil from the inlet (2).
(1)
5. Check the oil level on the level indicator (3).
Fig. 13-45. Oil replacement for speed reducer
(for main drive)
Cycle
Check and refill Weekly or when oil level is low
Replace Every 1,200 hours
(after the initial 100 hours of op-
eration)
Oil quantity 9.5 litres
13.5.2 Oil for mandrel index unit -

Replace
1. Put a pan or something to collect oil under the
plug (1).
2. Remove the plug.
3. Open the valve (2), and drain oil.
4. Make sure that oil has drained completely.
Then, supply new oil from the inlet (3) with a
suitable pump.
5. Check the oil level on the level indicator (4).
(4)
6. Close the valve (2) and install the plug.
(2)
Cycle
Replace Every 1200 hours
(1) (3) eration)
Oil quantity 4.0 litres
Fig. 13-46. Oil replacement for mandrel index
unit
M144- 7294 Issue 01 13- 35

13 Lubrication
13.5.3 Oil for bottom sealer gearbox -

(4) Replace

plug (1).
2. Remove the plug.
3. Open the valve (2) and drain oil.
(3)
(2)
4. Check that oil has drained completely.
(1) Then, supply new oil from the inlet (3) with a
suitable pump.
Fig. 13-47. Oil replacement for bottom sealer 5. Check the oil level on the level indicator (4).
gearbox
6. Close the valve, and install the plug.
Cycle
Replace Every 1,200 hours
eration)
Oil quantity 1.0 litre x 4
13.5.4 Oil for cooling water rotary joint

- Refill
(1)
Cycle
Check and refill Daily or when oil level is low
1. Check the oil level in the oil cup (1)

2. If the oil level is low, refill with oil.
Fig. 13-48. Oil refill for cooling water rotary

joint
13- 36 M144- 7294 Issue 01

13 Lubrication
13.5.5 Oil for vacuum pumps -

Replace
Note ! Refer to 16.11.
1. Remove the plug (1).

plug (2).
3. Remove the plug, and drain oil.
(1) 4. Check that oil has drained completely, and
install the plug (2).
5. Supply new oil from the inlet (1).
(3) 6. Check the oil level on the level indicator (3).
(2) 7. Install the plug (1).
Cycle
Replace Every 500 hours
Fig. 13-49. Oil replacement for vacuum pump eration)
(for picker and unloader)
Oil quantity 1.0 litre
(For picker and unloader)
0.5 litres
(For diaphragm)
(1)
(2) (3)
Fig. 13-50. Oil replacement for vacuum pump

(for diaphragm)
M144- 7294 Issue 01 13- 37

13 Lubrication
13.5.6 Oil filter for vacuum pump -

Replace
CAUTION !
Replace the oil filter once for every two times
of oil replacement (not exceeding 1,200 hours).
Note ! There is no oil filter for vacuum pump

for diaphragm.
1. Drain oil completely.

filter.
3. Turn the oil filter (1) counter- clockwise and re-
move it.
4. Apply a little oil to the filter packing.
5. Install the new filter by turning clockwise and
(1) tighten it by hand.
6. Refill oil (Refer to 13.5.5 Step 5- 7).
Fig. 13-51. Oil replacement for vacuum pump CAUTION !

(for picker and unloader) Tighten the oil filter only by hand.
13- 38 M144- 7294 Issue 01

14 Preventive maintenance
14 PREVENTIVE MAINTENANCE
M144- 7294 Issue 01
M144- 7294 Issue 01 14- 1

14 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 1
14.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 3

14.2 Daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 4
14.2.1 Lamp test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 4
14.2.2 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 5
14.3 Weekly check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 8
14.4 100 hours or 2 weeks check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 10
14.5 200 hours or monthly check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 11
14.7 500 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 12
14.9 1000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.10 1200 hours or 6 months check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.11 2400 hours or 1 year check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 14
14.12 2500 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 15
14.13.1 Accumulated grease in the mandrel gearbox - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 16
14.14 5000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 17
14.14.1 Carton decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 17
14.15 6000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 19
14.15.1 Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 19
14.16 9000 hours check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 22
14.16.1 Potable water decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 22
14.18 Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 28
14.19 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 38
14- 2 M144- 7294 Issue 01

14.1 Description
Maintenance schedule is classified as follows for
each item:
S Daily check
S Weekly check
S 100 hours or 2 weeks check
S 200 hours or monthly check
S 450 hours or 2 months check
S 500 hours check
S 1000 hours check
S 2400 hours or 1 year check
S 2500 hours check
S 4800 hours or 2 years check
S 5000 hours check
S 6000 hours check
S 9000 hours check
S 9600 hours or 4 years check
Periodical inspection must be required to maintain
stable machine operation for a long time.
M144- 7294 Issue 01 14- 3

14.2 Daily check

14.2.1 Lamp test
1. Push the LAMP TEST button on No.1 panel.

Check that all the lamps on the panel turn on.
LAMP TEST Refer to 2.3.2.1 in the Operator’s Manual.
2. Replace the lamp with a new one if it does not
turn on.
Push the LAMP TEST button again to complete
the test.
Fig. 14-1. LAMP TEST button
14- 4 M144- 7294 Issue 01

14.2.2 Check items

Section Check
1. General 1. All lamps turn on in the lamp test (Refer to 14.2.1.)
2. No unusual noises or abnormal vibration are found throughout the entire
machine
3. The carton forming and packaging sections are well cleaned and there are
no loose tools, machine parts, etc. left
4. Normal pressure gauge reading; air, vacuum, etc.
5. Proper amount of water is contained in the tank of cooling water for man-
drels
6. Sufficient ethanol level in the ethanol tank
7. No clogged nozzle of spray sanitising
8. Bolts and nuts fixing the device above the carriage conveyor are not loose
9. No crack or damage to the LED covers
10. No wear or damage on hoses of cooling water
11. No blocked HEPA filter (Check the differential pressure on the graphic
panel)
12. Normal operation of the safety system (Refer to 1.7)
13. No leaks from the piping for CIP and ELOFOAM
2. Picker and carton 1. Normal vacuum pressure gauge reading; vacuum pump
loader
2. No unusual noises or abnormal vibration
3. No clogging in the suction holes of vacuum cups
4. No abnormal wear or damage in the vacuum cups
5. No PE dust sticks to the surfaces of carton guides
6. Loader pushers are properly fixed
3. Mandrel 1. No cooling water leaks from the joints which connects mandrels to
mandrel boss
2. No dirt and foreign objects stick to the surfaces of the mandrel
3. No grease leaks from the gearbox that drives unloader turret
4. No cooling water leaks from the rotary joints
5. No oil leaks from the mandrel index unit
6. Proper oil level in the cooling water rotary joint
4. Bottom heater 1. Proper heater temperature
2. Proper air pressure has been secured
3. Heater nozzles move up and down smoothly
4. No paper and PE dust stick to heater nozzles
5. No deterioration or damage to the heater element (Refer to 14.15.2)
M144- 7294 Issue 01 14- 5

Section Check
5. Bottom breaker 1. Normal operation of the breaker
2. No PE dust sticks to the surfaces of breaker wings and arms
6. Bottom sealer 1. No cooling water leaks on connections of the pressure pad and folding rail
assembly
2. The surfaces of pressure pads are free from dirt and other contamination
3. No PE dust sticks to the surfaces of folding rails
4. No oil leaks from the gearbox
7. Unloader and tur- 1. No clogging in the suction holes of vacuum cups
ret
2. No abnormal wear or damage in the vacuum cups
3. No dirt and foreign objects stick to the surfaces of turret guides
4. Unloaders move up and down smoothly
8. Carriage conveyor 1. Lubrication water is supplied in proper quantity so that it does not splash in
all directions
9. Filler 1. No interference between filler nozzle and carton
2. Correct positioning between filler nozzles, carton guides and stripper
3. No creases on the diaphragm
4. Normal condition of the filler
5. Carton lifter works properly
6. Filler nozzles have been disassembled and cleaned before SIP
7. No excessive grease on the stripper stand
8. No heavy condensate on the filler nozzle surfaces
9. No crack in the glass for filler pump
10. 1st. top breaker 1. No interference between breaker wings and conveyor
2. No interference between breaker wings and anvils
3. No foreign objects stick to the anvils
4. No deformation or peeling of the stopper
11. 2nd. top breaker 1. No interference between breakers (wings) and conveyor
2. No foreign objects stick to the surfaces of breakers (fork and wings)
14- 6 M144- 7294 Issue 01

Section Check
12. Top heater 1. Proper heater temperature
2. No other contamination such as PE dust on the surface of the heater
nozzle
3. No cooling water leaks from connections of carton cooling guides
4. Proper air pressure has been kept
5. Heater nozzles move up and down smoothly and properly
6. No contact with cartons occurring when heater nozzles move up and down
7. No wear on the carton cooling guides
13. Top sealer 1. No cooling water leaks from connections of sealer jaws
2. Surfaces of carton guides are free of PE dust and other contamination
3. No dirt and foreign objects stick to the surfaces of the sealer jaws
14. Carton decontami- 1. No unusual noises heard from cooling fan for UV- lamp
nation
2. Check lighting of all UV- lamps
3. No scale sticks to the surface of quartz glass
4. Sufficient hydrogen peroxide level in the tank
5. No clogged nozzle of hydrogen peroxide spray
6. No unusual noises or abnormal vibration found in air pump
7. No leaks found from the joints of the piping for supplying sterilant
8. Proper heater temperature and air pressure have been secured
9. No deterioration or damage to the spray nozzle
10. No crack or damage to the quartz glass
15. Cap applicator 1. Surfaces of anvil and horn are free of PE dust and other contamination
2. No contamination found in the cooling nozzle of the horn
3. Wipe grease from the spline shaft surface of the anvil with a clean cloth
16. Empty carton 1. No other contamination such as PE dust on the surface of the empty car-
pusher ton pusher
17. CIP box 1. No damages, wears or cracks found in packings for sealing
2. No leaks found during CIP or SIP
18. ELOFOAM unit 1. Foam is sprayed correctly
2. No water or foam leaks from the joints of each piping
3. After ELOFOAM, the machine is rinsed and wiped well by hand
M144- 7294 Issue 01 14- 7

14.3 Weekly check
Section Check
1. General 1. Sufficient grease has been supplied to the following greasing points
¯ Under the bed: cams, cam followers, chains, drive gears, bearings, rod
ends
¯ Above the bed: bearings, rod ends
2. The air filter and mist- separator are drained
3. Proper oil level in the vacuum pump
4. Proper grease level in the grease pot
5. Grease pump operates properly
If you want to confirm that the grease pump is working properly with no
grease leaking, set the greasing pump in motion by pushing MANUAL
GREASE SUPPLY- ON on the GREASE window on the MANUAL screen
6. No clogging found in vacuum inlet filters
7. No clogging found in air filters, mist separator and exhaust cleaner
8. No play or slack occurring in cams and cam followers (Use feeler gauge)
9. No loosening found in the cam followers
10. No bolts, nuts and equipment are missing on the machine bed
11. Reading is correct in air pressure gauge and vacuum gauge
2. Main drive 1. Proper oil level in the speed reducer
3. Picker and carton 1. Normal operation of the carton detector
loader
Normal function : If there is no carton between the light emitter and light
receiver of the detector, the indication lamps of the emitter and receiver
turn on
2. No PE dust sticks to the surfaces of the carton guides
3. No damage to the belt of carton loader
4. Proper oil level in the vacuum pump
4. Mandrel 1. No oil leaks from the index unit. Proper oil level has been secured
2. Proper water level in cooling water tank
3. No grease leaks from the gearbox that drives unloader turret
5. Bottom heater 1. No deterioration found in electric wiring
2. No deterioration found in air hoses
14- 8 M144- 7294 Issue 01

Section Check
6. Bottom sealer 1. Firmly fixed folding rails
2. Proper clearance between pressure pad and mandrel top
3. No loose bolts and nuts
4. No oil leaks onto the surfaces of gearbox
Proper amount of oil has been supplied
5. Pressure pads moves properly and smoothly
6. No abnormal wear or damage to the oil seals in the gearbox
7. Unloader and tur- 1. No loose bolts and nuts
ret
2. Normal function of the photoelectric switch
Normal function : each indicator lamp turns on when there is no object be-
tween the photoelectric switches
3. No abnormal wear or damage to the oil seals in the turret unit
4. Normal operation of the sus pusher
8. Carriage conveyor 1. No misalignment of the conveyor pockets to any station on the conveyor
line
2. Proper tension has been given to the carriage conveyor chain
3. No damage or excessive wear is found in lower chain rail of top heater
4. No cooling water leaks
9. Filler 1. Accurate power transmission, no loose bolts and nuts
2. No damaged parts have been found during disassembly and inspection of
filling section
3. No dirt or smears are found on the punching plates of clean booth
4. Damage is not found on the suck back membrane
5. Proper oil level and proper oil colour in the vacuum pump
6. No excessive wear on the diaphragm
7. Disassemble the filling section to check O- rings, packing, etc.
8. No coating peeled off from the electrode rod of the resistance temperature
detector
10. 1st. top breaker 1. No loose bolts and nuts
2. No loose wing on the rotation shaft
3. Smooth vertical sliding
4. No PE dust sticks to the surfaces of the breaker
11. 2nd. top breaker 1. No loose wing bolts or bolts
12. Top heater 1. No deterioration in electric wires
2. No deterioration in air hoses
M144- 7294 Issue 01 14- 9

Section Check
13. Top sealer 1. Normal condition of cooling water hoses
2. No interference or chafing of hoses
3. Correct clearance between sealer jaws
4. No loose bolts and nuts
5. Sealer jaws are working properly and smoothly
14. Carton decontami- 1. No deterioration in electric wires
nation
2. No deterioration in tubes
3. Check the intensity of UV- lamp (Refer to 7.3.5)
4. Normal operation of the hydrogen peroxide flow decrease detector (flow
sensor)
5. No blockage found in the strainer at the outlet of the hydrogen peroxide
tank
6. No PE dust sticks to the surfaces of the plates of hydrogen peroxide dry-
ing heater (Refer to 7.4.2)
15. Cap applicator 1. Correct clearance between anvil and horn
2. Normal condition cooling air horses
3. No interference or chafing of horses
14.4 100 hours or 2 weeks check
Section Check
1. General 1. No wear or dirt on the Pre- filter
¯ For bottom heater (1 piece)
¯ For hydrogen peroxide drying heater and top heater (2 pieces)
¯ HEPA unit for filling section (2 pieces)
2. Differential pressure for HEPA filter indicates standard pressure (Refer to
2.4.3)
14- 10 M144- 7294 Issue 01

14.5 200 hours or monthly check
Section Check
1. General 1. No wear or damage to hoses and no leaks from hose joints
2. Smooth and quiet operation of the air cylinders
3. No damage found in cams and cam followers
4. Inner surfaces of guarding have been wiped clean with cloth soaked in
potable water
5. No clogging found in the spray sanitising piping and ethanol tank strainer
6. No loose cam follower
2. Picker and carton 1. No damaged or creased hoses
loader
2. Rollers in the carton loaders turn around smoothly
3. The belt of carton loader is under normal tension
3. Mandrel 1. No damage to mandrel surface
2. Mandrels are cooled properly
3. Index unit rotates properly and smoothly
4. Bottom heater 1. Normal condition of thermocouple cable
2. Normal vertical stroke motion of heater assembly
3. Supply grease to the grease nipples on the grease terminals with the
grease gun
5. Bottom breaker 1. Supply grease to the grease nipples on the grease terminals with the
grease gun
6. Bottom sealer 1. No wear on pressure pad emboss stakes
2. Supply grease to the grease nipples on the grease terminals with the
grease gun
7. Unloader and tur- 1. No damage to cam and cam follower
ret
2. No wear or damage on the vacuum hose
3. No excessive wear on the vacuum cups
4. Turret rotates properly and smoothly
5. No play or slack found in the turret
6. No play or slack found unloader rods and their bearings
7. No damage found in turret guides
8. Carriage conveyor 1. Smooth rotation of drive assembly
2. Conveyor chains are under proper tension
3. No damage found in carton holders
9. Filler 1. Timing belt in the filling section is under proper tension
2. No accumulated grease or dirt on the grease pan under the servo motor
for the filler piston
M144- 7294 Issue 01 14- 11

Section Check
10. Top heater 1. No damage to the thermocouple cable
2. Smooth vertical stroke motion of the heater assembly
11. Top sealer 1. No wear on sealer jaws
12. Carton decontami- 1. No clogging found in the sterilant piping
nation
13. Cap applicator 1. Supply grease to the grease nipples on the grease terminals with the
grease gun
2. No accumulated grease or dirt on the grease pan under the servo motor
for the cap applicator
14. CIP box 1. O- ring in the joints are in normal condition
14.6 450 hours or 2 months check
Section Check
1. Filler 1. Replacement of diaphragm (19) (Refer to Fig. 8-34. )
14.7 500 hours check
Section Check
1. Picker and carton 1. Oil replacement for the vacuum pump (Refer to 13.5.5)
loader
2. Filler 1. Oil replacement for the vacuum pump (Refer to 13.5.5)
14- 12 M144- 7294 Issue 01

Section Check
1. General 1. No loose bolts and nuts found on driving levers and tie- rods
2. Oil replacement for the vacuum pump
3. No loose set bolts of cams found
4. No damage to the grease piping
2. Mandrel 1. Refill the distilled water for cooling for mandrel
2. Drain water from the drain plugs (2) located in the lower part of the gear-
box (1) (Refer to Fig. 14-2. )
3. Replace cooling water (Always use distilled water)
3. Filler 1. Disassemble and clean the filler tank
4. UV- lamp for pota- 1. No contamination on the surfaces of UV- lamp and quartz sleeve
ble water
5. CIP box 1. Replace O- ring for CIP box
(1)
(2) (2)
Fig. 14-2. Drain water from the gearbox
M144- 7294 Issue 01 14- 13

Section Check
1. Picker and carton 1. Replacement of the oil filter for the vacuum pump
loader
2. Filler 1. Disassembly check of the rotary valve
2. Replacement of the shaft seals (11) (14) and O- rings (23) (26) of the
rotary valve (Refer to 8.2.11)
Section Check
1. General 1. No slack found in bearing units
2. No wear found in cams
2. Main drive 1. Oil replacement of the speed reducer
3. Picker and carton 1. Replacement of the vacuum cups
loader
2. Replacement of the loader belt
4. Mandrel 1. Oil replacement of the mandrel index unit
5. Bottom sealer 1. Oil replacement of the bottom sealer gearbox
6. Unloader and tur- 1. Replacement of the vacuum cups
ret
7. Carriage conveyor 1. No wear found in the sliding parts of carton holders
8. Filler 1. Replacement of packings in the carton lifter rod
2. Replacement of the diaphragm (23) (Refer to Fig. 8-34. )
14.11 2400 hours or 1 year check
Section Check
1. Picker and carton 1. Replacement of the pusher and roller
loader
2. Replacement of the inlet filter element for the vacuum pump
3. Replacement of the exhaust filter for the vacuum pump
2. Carton decontami- 1. Replacement of 0.2 micron filter
nation
3. Filler 1. Replacement of the inlet filter element for the vacuum pump
2. Replacement of the exhaust filter for the vacuum pump
3. Replacement of the ring of the rotary valve (Refer to 8.2.11)
4. Top sealer 1. Replacement of the bushings (8) (9) (Refer to Fig. 9-30. )
14- 14 M144- 7294 Issue 01

Section Check
1. Carton deconta- 1. Replacement of the UV- lamp
mination
Note ! For handling details of the UV- lamp, refer to the ”Document
No.: M214- 131- 459, High pressure mercury lamp surface sterilizer,
Instruction manual, Iwasaki Electric Co., Ltd.” included in the Chap-
ter 17 APPENDIX.
M144- 7294 Issue 01 14- 15

14.13 4800 hours or 2 years check
Section Check
1. General 1. Element replacement of the (Micro) Mist- Separator and Odor Removal
Filter (When replacing the element, replace the O- ring and gasket as well)
2. Mandrel 1. No excessive grease in the gearbox
3. Top sealer 1. Replacement of the pins (7) (10) (Refer to Fig. 9-30. )
14.13.1 Accumulated grease in the

(1) mandrel gearbox - Check
1. Loosen the bolts (1) and open the gearbox (2).
(2)
Fig. 14-3. Check excessive grease

3. Drain excessive grease and water from the
(3) drain plugs (4) located in the lower part of the
gearbox.
4. Wipe off the excessive grease and water, which
cannot be drained from the drain plug, with a
waste cloth.
5. Check that grease is not accumulated in the
gearbox.
6. Close the cover and tighten the bolts.
No. Parts
(1) Bolt
(2) Gearbox
(2) (4) (4) (5) (3) Cover

(4) Drain plug
(5) Bevel gear
Fig. 14-4. Grease removal
14- 16 M144- 7294 Issue 01

14.14.1 Carton decontamination
CAUTION
SKIN.
HANDLING UV- LAMP.
NATED UV- LAMP.

ry lamp surface sterilizer, Instruction
manual, Iwasaki Electric Co., Ltd.” in-
cluded in the Chapter 17 APPENDIX.
Note ! UV- lamps contain a minor quantity of

mercury.
M144- 7294 Issue 01 14- 17

14.14.1.1 UV- lamp and reflection board - Check
Note ! When the time to replace the UV- lamp 1. Lighting hours of the UV- lamp can be checked
comes, the ”CONFIRM RUNNING by looking at the UV LAMP for CARTON
HOURS (1/4)” message appears in the HOURS on the RUNNING HOURS (1/4)
message box on the PRODUCTION screen.
STATUS screen. Refer to 7.3.1.and 7.3.6.
2. Replace UV- lamps with new ones according to
Note ! Total hours of the UV- lamp can be the following procedures.
checked with UV LAMP for CARTON
HOURS on the RUNNING HOURS (1/4)
screen. Refer to 7.3.1.
14.14.1.2 UV- lamp and reflection board - Replace
(1)
(5)
(3) (6) (2)
(4)
(3)
(3)
Fig. 14-5. Replacement of UV- lamp (for cartons)
Note ! Before replacing the UV- lamps, re- (9) Replace the reflection board.
move the cable, hose and piping as (Lifetime : 5,000 hours).
needed. (Refer to 7.3.2) (10) Put back the cover after replacing UV- lamp.
(1) Check that the UV- lamp (1) has turned off. Note ! When removing dirt, wipe with an
ethanol- soaked- cloth, or wash with
(2) Remove the cable, hose and piping, and re- soap and water, and then wipe with a
move UV- lamp unit (2) from the filling ma- dried soft cloth.
chine.
(3) Loosen the catch clips (3). No. Parts
(4) Remove the cover (4) of UV- lamp unit. (1) UV- lamp
(2) UV- lamp unit
(5) Carefully pull out the UV- lamp from the
socket (5) (Lifetime : 2,500 hours). (3) Catch clip
(6) Carefully package the lamps. (4) Cover
(7) Contact waste management specialists to (5) Socket
collect the waste for recycling. (6) Reflection board
(8) Remove the reflection board (6).
14- 18 M144- 7294 Issue 01

Section Check
1. Bottom heater 1. Replacement of the heater element (Refer to 14.15.1)
2. Cap applicator 1. Replacement of the heater element (Refer to 14.15.1)
3. Top heater 1. Replacement of the heater element (Refer to 14.15.1)
14.15.1 Electric heater
* (2)
* (1)
Fig. 14-6. Electric heater
Air is heated by the electric heater. Heater air is Note ! Repair parts marked * can be ordered
directed to selected areas of the carton flaps, and as a kit. Cannot be ordered separately.
softens the polyethylene coating on the bottom and
top flaps of each carton.
No. Parts
(1)* Heater element
(2)* Packing
M144- 7294 Issue 01 14- 19

14.15.2 Heater assembly - Check
1. Check the heater element (1) for cracks in the

ceramic part. Check that there is no abnormality
(1)
when measuring with a resistor.
Standard
Heater element Daily
2. Replace with a new one if necessary.
Fig. 14-7. Heater element
Note ! Replace the heater element (1) after

6,000 hours even if it is operating cor-
rectly.
No. Parts
(1) Heater element
14- 20 M144- 7294 Issue 01

14.15.3 Heater element - Inspection
Note ! Check that there are no cracks on the surface of the ceramic parts.
Note ! Replace the heater element with a new one if it is not in normal condition.
Bottom preheater Bottom heater, Hydrogen peroxide

drying heater
Top heater
Part No. of the heater No. LUPHS10P408 No. LUPHS10P410 No. LUPHS05P804
element
No. LUPSH108 No. LUPHS10P41P1 No. LUPSH508
Rated output 400V 8.1kW 400V 10.95kW 400V 8.1kW
Connection diagram
Delta connection
u
Calculated resistance u v u v u v 37.5 

37.8  28.0 
in normal condition
u w 37.8  u w 28.0  u w 37.5 
v w 37.8  v w 28.0  v w 37.5 

Resistance in case of u v u v u v
connection u v 113.4  84.0  112.6 
broken down
u w 56.7  u w 42.0  u w 56.3 
v w 56.7  v w 42.0  v w 56.3 
Resistance in case of u v u v 1
connection u v
1 u v 1
and v w broken u w 56.7  42.0  u w 56.3 
u w
down
v w 1 v w 1 v w 1
Table 14-1. Resistance of the heater element in normal and damaged condi- Part 1 of 1
tion
M144- 7294 Issue 01 14- 21

14.16.1 Potable water decontamination
CAUTION
SKIN.
HANDLING UV- LAMP.
NATED UV- LAMP.

tions, Xylem Inc.” included in the
Note ! UV- lamps contain a minor quantity of

mercury.
14- 22 M144- 7294 Issue 01

14.16.1.1 UV- lamp - Check
Note ! When the time to replace the UV- lamp

comes, the ”CONFIRM RUNNING
(2) HOURS (1/4)” message appears in the
message box on the PRODUCTION
STATUS screen.
Note ! Total hours of the UV- lamp can be

checked with UV LAMP for POTABLE
WATER HOURS on the RUNNING
(1) HOURS (1/4) screen. Refer to 12.2.3
No. Parts
(1) UV- lamp
(2) Quartz sleeve
Fig. 14-8. UV- lamp
14.16.1.2 UV- lamp - Replace

M144- 7294 Issue 01 14- 23


(1)
3. Push END (2) for both R- and L- sides on the

SET MODE window. The green lamps flash at
2- second intervals. Push and hold CONFIRM
(3), and END lamps flash at 1- second intervals.
(3)
d) The green lamp turns on.
e) UV- lamp for potable water turns off.
(2)

button.
CAUTION !

plastic container.
14- 24 M144- 7294 Issue 01


Note ! Hold both ends of new UV- lamp so as

not to directly touch the glass. If you
must touch the lamp glass, please use
gloves or a soft cloth.
Note ! Be very careful when handling the

UV- lamps as they are very fragile.
8. Replace the UV- lamp with a new one.

DIX.
10.The quartz sleeve and sensor should be

cleaned after each replacement of the UV-
lamp. The reactor should be cleaned when ne-
cessary.
11.Remove the nuts (3), then remove the PC plate

(4) on the No.2 panel.
No. Parts
(3) Nut
(4) PC plate
(4)
(3)
Fig. 14-13. No.2 panel
M144- 7294 Issue 01 14- 25

12.Turn on the main circuit breaker.
13.Push PRODUCTION (5) on the SET MODE

(5) window.
14.For the new start of the system proceed in the

(7) same way as for first commissioning. When you
push and hold the RESET button (6) (Push and
hold for 10 sec.), directly after switching on, the
day counter (7) is reset to 365 and the unit is
newly initialised.
No. Parts
(6) (6) RESET button

(7) Day counter
Fig. 14-15. UV- lamp controller
tions” included in the Chapter 17 AP-
PENDIX.
15.After adjustment, put the PC plate (4) back, and

tighten it with the nuts (3).
14- 26 M144- 7294 Issue 01

14.17 9600 hours or 4 years check
Section Check
1. Carriage conveyor 1. Replacement of lower chain rail of top heater
2. Carton decontami- 1. Replacement of igniter for the UV- lamp unit.
nation
Note ! For handling details of the UV- lamp, refer to the ”Document
No.: M214- 131- 459, High pressure mercury lamp surface sterilizer,
Instruction Manual, Iwasaki Electric Co., Ltd.” included in the Chap-
ter 17 APPENDIX.
M144- 7294 Issue 01 14- 27

14.18 Measurements
C-Head Section Standard Measurement

Air pressure Compressed air for main air 0.6 MPa MPa
Compressed air for picker and unloader 0.1~0.15 MPa MPa
Pilot air for picker and unloader 0.4 MPa MPa
Bottom air shutter (Pre- heater) 0.1~0.2 MPa MPa
Bottom air shutter (Breaker) 0.1~0.2 MPa MPa
Product inlet auto valve (AV2) L 0.4 MPa MPa
Product inlet auto valve (AV7) R 0.4 MPa MPa
Grease pump 0.3 MPa MPa
Unloader helper 0.3~0.5 MPa MPa
Hydrogen peroxide air curtain L 0.1~0.2 MPa MPa
R 0.1~0.2 MPa MPa
Hydrogen peroxide spray L 0.2 MPa MPa
R 0.2 MPa MPa
Hydrogen peroxide tank pressure 0.07~0.14 MPa MPa
Bottom heater damper 0.1~0.2 MPa MPa
Ethanol spray nozzle for sanitising 0.1~0.2 MPa MPa
Ethanol tank for sanitising 0.1~0.2 MPa MPa
Cap applicator L 0.2 / 0.35 MPa MPa
R 0.2 / 0.35 MPa MPa
Cap drive clutch L 0.5 MPa MPa
R 0.5 MPa MPa
Anvil, horn cooling air L 0.05~0.1 MPa MPa
R 0.05~0.1 MPa MPa
Bottom rail size change 0.3 MPa MPa
Carton basket size change 0.2 MPa MPa
Carton basket size change (Stopper) 0.2 MPa MPa
Empty carton blow L 0.3 MPa MPa
R 0.3 MPa MPa
Carriage conveyor tension L 0.3 MPa MPa
R 0.3 MPa MPa
UV- lamp glass breakage detector 015~0.025 MPa MPa
Carton dust remover 0.3 MPa MPa
14- 28 M144- 7294 Issue 01


Air pressure 1st. top sealer jaw escape, 2nd. top sealer L 0.4 MPa MPa
R 0.4 MPa MPa
Filler nozzle suck back device L 0.1~0.2 MPa MPa
R 0.1~0.2 MPa MPa
Reject gate L 0.2 MPa MPa
R 0.2 MPa MPa
Temperature Bottom heat- 14,000 C/H L1 300~500 _C _C
er
(M/C speed 1) L2 300~500 _C _C
R1 300~500 _C _C
R2 300~500 _C _C
L1 300~500 _C _C
(M/C speed 2) L2 300~500 _C _C
R1 300~500 _C _C
R2 300~500 _C _C
12,000 C/H L1 300~500 _C _C
(M/C speed 3) L2 300~500 _C _C
R1 300~500 _C _C
R2 300~500 _C _C
L1 300~500 _C _C
(M/C speed 4) L2 300~500 _C _C
R1 300~500 _C _C
R2 300~500 _C _C
Alarm range (±) 10 _C Fixed
Bottom pre- 14,000 C/H L 200~500 _C _C
heater
(M/C speed 1) R 200~500 _C _C
L 200~500 _C _C
(M/C speed 2)
R 200~500 _C _C
12,000 C/H L 200~500 _C _C
(M/C speed 3) R 200~500 _C _C
L 200~500 _C _C
(M/C speed 4)
R 200~500 _C _C
M144- 7294 Issue 01 14- 29


Temperature Top heater 14,000 C/H L 300~500 _C _C
(M/C speed 1) R 300~500 _C _C
L 300~500 _C _C
(M/C speed 2)
R 300~500 _C _C
12,000 C/H L 300~500 _C _C
(M/C speed 3) R 300~500 _C _C
L 300~500 _C _C
(M/C speed 4)
R 300~500 _C _C
Top per- 14,000 C/H L 200~500 _C _C
heater
(M/C speed 1) R 200~500 _C _C
L 200~500 _C _C
(M/C speed 2)
R 200~500 _C _C
12,000 C/H L 200~500 _C _C
(M/C speed 3) R 200~500 _C _C
L 300~500 _C _C
(M/C speed 4)
R 300~500 _C _C
Hydrogen peroxide drying heater L 220~240 _C _C
R 220~240 _C _C
Mandrel wa- Set value 20 _C _C
ter
Upper limit 25 _C _C
Set value 15 _C _C
Chilled water Upper limit 15 _C _C
14- 30 M144- 7294 Issue 01


Blower Bottom heat- M/C speed 1 L1 800~1300 kPa kPa
er
14,000 C/H L2 800~1300 kPa kPa
R1 800~1300 kPa kPa
R2 800~1300 kPa kPa
M/C speed 2 L1 800~1300 kPa kPa
14,000 C/H L2 800~1300 kPa kPa
R1 800~1300 kPa kPa
R2 800~1300 kPa kPa
M/C speed 3 L 800~1300 kPa kPa
R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
Bottom pre- M/C speed 1 L 800~1300 kPa kPa
heater
14,000 C/H R 800~1300 kPa kPa
14,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
Top heater M/C speed 1 L 800~1300 kPa kPa
14,000 C/H R 800~1300 kPa kPa
14,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
M144- 7294 Issue 01 14- 31


Blower Top pre- M/C speed 1 L 800~1300 kPa kPa
heater
14,000 C/H R 800~1300 kPa kPa
14,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
12,000 C/H R 800~1300 kPa kPa
Hydrogen 14,000 C/H
peroxide dry- L 800~2800 kPa kPa
M/C speed 1, 2
ing heater
12,000 C/H
R 800~2800 kPa kPa
M/C speed 3, 4
Inverter Main motor M/C speed 1
Pr.4 52.2 Hz Hz
14,000 C/H
M/C speed 2
Pr.5 Hz Hz
M/C speed 3
Pr.6 Hz Hz
M/C speed 4
Pr.25 Hz Hz
Idle / Jog
Pr.26 22.00 Hz Hz
ELOFOAM
Bottom heat- Speed 1 Pr.4 Hz Hz
er blower
Speed 2 Pr.5 Hz Hz
L Speed 3 Pr.6 Hz Hz
Speed 4 Pr.25 Hz Hz
ELOFOAM Pr.26 40.0 Hz Hz
Speed 1 Pr.4 Hz Hz
Speed 2 Pr.5 Hz Hz
R Speed 3 Pr.6 Hz Hz
Speed 4 Pr.25 Hz Hz
14- 32 M144- 7294 Issue 01


Inverter Top heater Speed 1 Pr.4 Hz Hz
blower
Speed 2 Pr.5 Hz Hz
Speed 3 Pr.6 Hz Hz
L
Speed 4 Pr.24 Hz Hz
Stand by Pr.25 25.0 Hz Hz
Speed 1 Pr.4 Hz Hz
Speed 2 Pr.5 Hz Hz
Speed 3 Pr.6 Hz Hz
R
Speed 4 Pr.24 Hz Hz
Stand by Pr.25 25.0 Hz Hz
Discharge Speed 1 Pr.4 Hz Hz
conveyor
Speed 2 Pr.5 Hz Hz
L Speed 3 Pr.6 Hz Hz
Speed 4 Pr.25 Hz Hz
Idle Pr.26 30.0 Hz Hz
Speed 1 Pr.4 Hz Hz
Speed 2 Pr.5 Hz Hz
R Speed 3 Pr.6 Hz Hz
Speed 4 Pr.25 Hz Hz
Idle Pr.26 30.0 Hz Hz
Clean booth Filling sec- High Pr.4 Hz Hz
fan tion Low Pr.5 Hz Hz
CIP recovery Product line CIP Pr.4 50.0 Hz Hz
pump
Spray ball CIP Pr.5 42.0 Hz Hz
Breathing line CIP Pr.6 23.0 Hz Hz
CIP drain Pr.25 48.5 Hz Hz
Vacuum Filler piston L1 - 80~- 102 kPa kPa
L2 - 80~- 102 kPa kPa
R1 - 80~- 102 kPa kPa
R2 - 80~- 102 kPa kPa
Vacuum pump (Main) - 0.1 kPa kPa
Vacuum pump (Diaphragm) - 0.1 kPa kPa
M144- 7294 Issue 01 14- 33


Pressure Bottom heater Upper limit 1500 Pa Pa
Bottom preheater Lower limit 500 Pa Pa
Top heater Upper limit 3000 Pa Pa
Top preheater Lower limit 500 Pa Pa
Hydrogen peroxide drying Upper limit 3000 Pa Pa
heater
Lower limit 1150 Pa Pa
Filler vacuum (FIRST) N1 - 70 kPa kPa
H1 - 10 kPa kPa
L1
P2 - 75 kPa kPa
H2 - 10 kPa kPa
N1 - 70 kPa kPa
H1 - 10 kPa kPa
L2
P2 - 75 kPa kPa
H2 - 10 kPa kPa
N1 - 70 kPa kPa
H1 - 10 kPa kPa
R1
P2 - 75 kPa kPa
H2 - 10 kPa kPa
N1 - 70 kPa kPa
H1 - 10 kPa kPa
R2
P2 - 75 kPa kPa
H2 - 10 kPa kPa
14- 34 M144- 7294 Issue 01


Pressure Filler vacum (SECOND) ON N2 - 70 kPa kPa
OFF N1 - 60 kPa kPa
L1
ON P4 - 85 kPa kPa
OFF P3 - 75 kPa kPa
ON N2 - 70 kPa kPa
OFF N1 - 60 kPa kPa
L2
ON P4 - 85 kPa kPa
OFF P3 - 75 kPa kPa
ON N2 - 70 kPa kPa
OFF N1 - 60 kPa kPa
R1
ON P4 - 85 kPa kPa
OFF P3 - 75 kPa kPa
ON N2 - 70 kPa kPa
OFF N1 - 60 kPa kPa
R2
ON P4 - 85 kPa kPa
OFF P3 - 75 kPa kPa
Main air ON 0.5 MPa MPa
Main air ON 0.5 MPa MPa
OFF 0.4 MPa MPa
Supply air ON 0.5 MPa MPa
OFF 0.4 MPa MPa
Main vacuum Upper limit - 60 kPa kPa
Diaphragm vacuum Upper limit - 60 kPa kPa
Safety SV second pres- ON (P- 1) 0.5 MPa MPa
sure
OFF (P1 - H1) 0.4 MPa MPa
Differential Clean booth Filling section Pa Pa
pressure gau-
ge Top heater Pa Pa
L
Upper limit Pa Pa
Pa Pa
R
Upper limit Pa Pa
M144- 7294 Issue 01 14- 35


Ultrasonic os- Mode L1
cillator
L2
Energy mode
R1
R2
Amplitude L1 %
L2 %
100%
R1 %
R2 %
Energy setting L1 *Reference %
L2 110J (XE cap) %
R1 100J (UE cap) %
R2 %
Max window L1 % %
L2 % %
R1 % %
R2 % %
Min window L1 % %
L2 % %
R1 % %
R2 % %
Monitored power L1 % %
L2 % %
R1 % %
R2 % %
Others Orifice Bottom pre heater L mm mm
R mm mm
Top pre heater L 18 mm mm
R 18 mm mm
Top heater L 18.6 mm mm
R 18 mm mm
Hydrogen peroxide dry L mm mm
heater
R mm mm
14- 36 M144- 7294 Issue 01


Others Operation time Hr. Hr.
Hydrogen peroxide spray L1 10~11 ml/min ml/min
L2 10~11 ml/min ml/min
R1 10~11 ml/min ml/min
R2 10~11 ml/min ml/min
Water Potable L/min
Upper limit 40.0 L/min L/min
Lower limit 8.0 L/min L/min
Chilled L/min
Mandrel L/min
Tempera- L/min
ture con-
trolled Lower limit 5.0 L/min L/min
UV Lamp L/min
cooling
Lower limit (L) 5.0 L/min L/min
L/min
Lower limit (R) 5.0 L/min L/min
M144- 7294 Issue 01 14- 37

14.19 Personal notes
14- 38 M144- 7294 Issue 01

15 Troubleshooting
15 TROUBLESHOOTING
M144- 7294 Issue 01
M144- 7294 Issue 01 15- 1

15 Troubleshooting
15 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 1
15.1 Incorrect carton feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 3

15.1.1 Blanks are not fed from magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 3
15.1.2 Unopened blank in picker section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 4
15.1.3 Cartons are incorrectly loaded onto mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 4
15.2 Incorrect bottom forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.1 Bottom flap is folded in outward direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.2 Insert flap is folded outside of bottom flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 5
15.2.3 Bottom flap is not folded along the score lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 6
15.3 Poor bottom sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.3.1 Unevenly heated carton bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.3.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.3.3 Incorrect bottom forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7
15.4 Carton is retained by mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.4.1 Carton is not pulled out at all . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.4.2 Carton is not pulled out completely from mandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 8
15.5 Carton is jammed in loading cycle between turret and conveyor . . . . . . . . . . . . . . . . . . . . 15- 9
15.5.1 Carton bottom is jammed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 9
15.6 Abnormal filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.1 Fluctuations of filling amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.2 Filling into empty carton holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 10
15.6.3 Foaming causes poor top seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
15.6.4 Carton is jammed between carton guide and carton lifter . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 11
15.6.5 Product splashing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 12
15.6.6 Product dripping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 12
15.7 Incorrect top forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 13
15.7.1 Top flap is not folded along score lines correctly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 13
15.7.2 Top flap is folded in outward direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 14
15.7.3 Gap on top flap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 14
15.8 Poor carton top sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.1 Unevenly heated carton top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.8.3 Incorrect top forming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 15
15.9 Trouble in carton decontamination system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.9.1 Incorrect quantity of hydrogen peroxide flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.9.2 Incorrect intensity and cooling temperature of UV- lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 16
15.10 Trouble in cap applicator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.10.1 Caps are not fed from cap track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.10.2 Poor sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 17
15.11 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 18
15- 2 M144- 7294 Issue 01

15 Troubleshooting
15.1 Incorrect carton feeding

CAUTION !
Adjust after checking the dimension, if neces-
sary. Incorrect adjustment may cause trouble.
15.1.1 Blanks are not fed from magazine
Possible cause Remedy

1. Defective blank is placed in magazine 1. Remove the defective blank
2. Blanks are set in the wrong direction or incor- 2. Reset the blanks
rect position
3. Defective vacuum pump 3. Perform operational test of vacuum pump
4. Misaligned opening fingers and retainer plates 4. Check the standard dimension (Refer to 3.2.1)
on basket
5. Contact failure between the vacuum cup and on 5. Readjust the top position of the vacuum cup to
the surface of the blank pick the blank correctly (Refer to 3.3.3)
6. Incorrect picker vacuum head open- close tim- 6. Check the standard timing (Refer to 3.3.5)
ing
7. Worn or damaged vacuum cup 7. Replace vacuum cup (Refer to 3.3.6)
8. Clogging of the vacuum cup 8. Remove all dust (Refer to 3.3.7)
9. Blockage of the filter elements 9. Clean or replace the filter elements
10. Defective picker vacuum solenoid valve 10. Perform operational test of solenoid valve and
replace, if necessary
11. Leakage of vacuum 11. Locate the leakage point on the vacuum tubes
and fittings, then repair
M144- 7294 Issue 01 15- 3

15 Troubleshooting
15.1.2 Unopened blank in picker section

1. Incorrect picker vacuum switch timing 1. Readjust (Refer to 2.1.5, 3.3.4)
2. Incorrect picker vacuum head open- close ti- 2. Readjust (Refer to 3.3.5)
ming
3. Misaligned opening fingers and retainer plates 3. Reposition (Refer to 3.2.1)
on basket
4. Incorrect position of carton guides 4. Reposition (Refer to 3.4.1)
15.1.3 Cartons are incorrectly loaded onto mandrel

1. Incorrect position of the carton guide to the 1. Reposition (Refer to 3.4.1)
mandrel
2. Incorrect loader movement timing 2. Readjust (Refer to 2.1.4, 3.4)
3. Damage of loader belt 3. Replace (Refer to 3.4.4)
4. Defective carton 4. Remove
5. Servo motor malfunction 5. Replace
6. Misaligned loader pusher 6. Readjust (Refer to 3.4.5)
15- 4 M144- 7294 Issue 01

15 Troubleshooting
15.2 Incorrect bottom forming

CAUTION !
15.2.1 Bottom flap is folded in outward direction

1. Insufficient folding by bottom breaker 1. Check the standard dimension
(Refer to 4.4.1, 4.4.2, 4.4.3)
2. Misalignment of folding rail 2. Reposition folding rails (Refer to 4.5.1)
(1) (3)
No. Parts
(1) Bottom flap
(2) Insert flap
(3) Gusset
(2)
Fig. 15-1. Carton bottom
15.2.2 Insert flap is folded outside of bottom flap

1. Blanks set in wrong direction in magazine 1. Reset blanks
2. Misalignment of folding rail 2. Reposition folding rails (Refer to 4.6.1)
(1)
No. Parts
(1) Bottom flap
(2) Insert flap
(2)
Fig. 15-2. Carton bottom
M144- 7294 Issue 01 15- 5

15 Troubleshooting
15.2.3 Bottom flap is not folded along the score lines

1. Defective loading of carton onto the mandrel 1. Refer to 15.1.3
2. Incorrect carton positioning bolt in the bottom 2. Check the standard dimension (Refer to 4.3.9)
heater nozzle
15- 6 M144- 7294 Issue 01

15 Troubleshooting
15.3 Poor bottom sealing

CAUTION !
15.3.1 Unevenly heated carton bottom

1. Incorrect position of heater nozzle 1. Check the heating pattern on the carton, and
readjust the bottom heater (Refer to 4.3.5)
15.3.2 Poor sealing

1. Insufficient or excessive heating 1. Temperature adjustment (Refer to 4.3.13)
2. Incorrect clearance of bottom pressure pad 2. Check the standard dimension (Refer to 4.6.1)
3. Incorrect position of pressure pad 3. Check the standard dimension (Refer to 4.6.2)
15.3.3 Incorrect bottom forming

1. Incorrect bottom forming 1. Refer to 15.2
M144- 7294 Issue 01 15- 7

15 Troubleshooting
15.4 Carton is retained by mandrel

CAUTION !
15.4.1 Carton is not pulled out at all

1. Defective vacuum pump 1. Perform operational test of vacuum pump
2. Clogging of the vacuum cup 2. Remove all dust and chips (Refer to 5.2.5)
3. Worn unloader vacuum cup 3. Replace vacuum cup (Refer to 5.2.5)
4. Blockage of the filter elements 4. Clean or replace the filter elements
5. Defective unloader vacuum solenoid valve 5. Perform operational test of solenoid valve and
replace, if necessary
6. Leakage of vacuum piping 6. Find the leakage point on the vacuum tubes
and fittings, then repair
7. Contact failure between the vacuum cup and 7. Readjust (Refer to 5.2.4)
the surface of the carton
8. Incorrect horizontal movement timing of vac- 8. Check the standard timing (Refer to 5.2.1)
uum head
9. Incorrect unloader vacuum head open- close 9. Check the standard timing (Refer to 5.2.3)
timing
10. Misalignment of turret and mandrel 10. Readjust (Refer to 5.3)
11. Heat of mandrel beneath the bottom heater dur- 11. Idle the machine to cool it down before resum-
ing maintenance work ing production
12. Insufficient mandrel cooling 12. Check the flow of cooling water
15.4.2 Carton is not pulled out completely from mandrel

1. Incorrect horizontal movement timing of vac- 1. Check the standard timing (Refer to 5.2.1)
uum head
2. Incorrect unloader vacuum head open- close 2. Check the standard timing (Refer to 5.2.3)
timing
3. Worn unloader vacuum cup 3. Replace vacuum cup (Refer to 5.2.5)
4. Misalignment of turret and mandrel 4. Readjust (Refer to 5.3)
15- 8 M144- 7294 Issue 01

15 Troubleshooting
15.5 Carton is jammed in loading cycle between turret and conveyor

CAUTION !
15.5.1 Carton bottom is jammed

1. Misalignment of unloader pusher 1. Check the standard dimension (Refer to 5.2.8)
2. Turret guide too tight on turret 2. Check the standard dimension (Refer to 5.3.1)
3. Misalignment of conveyor carton holder and 3. Readjust (Refer to 5.3.2)
turret
4. Conveyor carton holder too tight 4. Check the standard dimension (Refer to 6.3.2)
M144- 7294 Issue 01 15- 9

15 Troubleshooting
15.6 Abnormal filling

CAUTION !
15.6.1 Fluctuations of filling amount

1. Loose clamp or nut 1. Retighten (Refer to 8.1)
2. Damaged packings 2. Replace
3. Damaged rotary valves 3. Replace
4. Product selection mistake 4. Check product No. and select the product
again (Refer to Operator’s Manual 4.5)
5. Crease on the diaphragm 5. Check the filler pump (Refer to 8.2.1.5)
6. Damaged rubber nozzle 6. Replace
7. Damaged suck back device 7. Replace
8. Damaged O- ring 8. Replace
9. Insufficient timing belt tension 9. Check the standard dimension (Refer to 8.2.5)
15.6.2 Filling into empty carton holder

1. Defective photoelectric switch for carton detec- 1. Check the photoelectric switch (Refer to 5.4.3)
tion in the unloader section
15- 10 M144- 7294 Issue 01

15 Troubleshooting
15.6.3 Foaming causes poor top seal

1. Loose clamp or nut 1. Retighten (Refer to 8.1)
3. Damaged rotary valves 3. Replace
4. Product selection mistake 4. Check product No. and select the product
again (Refer to Operator’s Manual 4.5)
5. Crease on the diaphragm 5. Check the filler pump (Refer to 8.2.1.5)
7. Damaged suck back device 7. Replace
9. Incorrect timing of filling and lifting 9. Check the standard timing (Refer to 2.1.4)
10. Product contains too much air in filler tank 10. Drain the product
15.6.4 Carton is jammed between carton guide and carton lifter

1. Misalignment of carton guide to conveyor car- 1. Check the standard dimension
ton holders (Refer to 8.2.9, 8.3.1.2)
2. Incorrect protrusion of carton lifter rod from bot- 2. Check the standard dimension
tom rail surface at bottom dead centre (Refer to 8.3.1.3)
3. Incorrect stripper height 3. Check the standard dimension
(Refer to 8.3.1.4)
4. Incorrect timing of conveyor indexing and lifting 4. Check the standard timing (Refer to 2.1.4)
M144- 7294 Issue 01 15- 11

15 Troubleshooting
15.6.5 Product splashing

1. Incorrect timing of filling 1. Check the standard timing (Refer to 2.1.4)
2. Product contains to much air in filler tank 2. Drain the product
3. Insufficient timing belt tension 3. Check the standard dimension
(Refer to 8.3.1.5)
4. Misalignment of conveyor carton holders to car- 4. Check the standard dimension
ton guide (Refer to 6.4.3.1, 8.3.1.2)
5. Incorrect stripper height 5. Check the standard dimension
(Refer to 8.3.1.4)
7. Incorrect carton lifter rod height 7. Check the standard dimension
(Refer to 8.3.1.3)
15.6.6 Product dripping

15- 12 M144- 7294 Issue 01

15 Troubleshooting
15.7 Incorrect top forming

CAUTION !
15.7.1 Top flap is not folded along score lines correctly

1. Insufficient conveyor chain tension 1. Readjust (Refer to 6.3.3)
2. Misalignment of a pair of conveyor carton hol- 2. Readjust (Refer to 6.4.3)
ders
3. Incorrect bottom rail height 3. Check the standard dimension (Refer to 6.4.1)
4. Misalignment of the following units to conveyor 4. Readjust the adjustment should be done after
carton holder caused by conveyor chain exten- the alignment of conveyor and unloader turret
sion
1st. top breaker (Refer to 9.2.1)
2nd. top breaker (Refer to 9.5.1)
Top heater (Refer to 9.6.1)
1st. top sealer (Refer to 9.7.1.7)
2nd. top sealer (Refer to 9.7.2.2)
5. Misalignment of anvil to score lines (1st. top 5. Check the standard dimension (Refer to 9.2.2)
breaker)
6. Incorrect position of wings (1st. top breaker) 6. Check the standard dimension (Refer to 9.2.1)
7. Incorrect angle of wings (1st. top breaker) 7. Check the standard dimension (Refer to 9.2.5)
8. Incorrect position of breaker (2nd. top breaker) 8. Check the standard dimension (Refer to 9.5.1)
M144- 7294 Issue 01 15- 13

15 Troubleshooting
15.7.2 Top flap is folded in outward direction

2. Misalignment of the following units to conveyor 2. Readjust the adjustment should be done after
carton holder caused by conveyor chain exten- the alignment of conveyor and unloader turret
sion
1st. top breaker (Refer to 9.2.1)
2nd. top breaker (Refer to 9.5.1)
Top heater (Refer to 9.6.1)
1st. top sealer (Refer to 9.7.1.7)
2nd. top sealer (Refer to 9.7.2.2)
15.7.3 Gap on top flap

2. Incorrect internal dimension of conveyor carton 2. Check the standard dimension (Refer to 6.3.2)
holder
3. Misalignment of a pair of conveyor carton hol- 3. Readjust (Refer to 6.4.3)
ders
5. Incorrect position of cooled guides (top sealer) 5. Check the standard dimension (Refer to 9.6.7)
15- 14 M144- 7294 Issue 01

15 Troubleshooting
15.8 Poor carton top sealing

CAUTION !
15.8.1 Unevenly heated carton top

1. Incorrect position of heater nozzle 1. Check the heating pattern on the carton, and
readjust the top heater (Refer to 9.6.1)
15.8.2 Poor sealing

1. Insufficient or excessive heating 1. Temperature adjustment (Refer to 9.6.5)
2. Excessive filling amount 2. Readjust
3. Excessive foam (during filling) 3. Refer to 15.6.3
4. Product splashing (during filling) 4. Refer to 15.6.5
5. Product dripping (during filling) 5. Refer to 15.6.6
6. Incorrect clearance of top sealer jaws 6. Check the standard dimension
(Refer to 9.7.1.1)
7. Incorrect position of sealer jaws 7. Check the standard dimension
(Refer to 9.7.1.7, 9.7.2.2)
8. Product shake during conveyor movement 8. Readjust (Refer to 6.3.3, 9.6.7)
15.8.3 Incorrect top forming

1. Incorrect forming 1. Refer to 15.7.3
2. Incorrect position of sealer jaws 2. Check the standard dimension
(Refer to 9.7.1.7, 9.7.2.2)
M144- 7294 Issue 01 15- 15

15 Troubleshooting
15.9 Trouble in carton decontamination system
15.9.1 Incorrect quantity of hydrogen peroxide flow

1. Damaged solenoid valve on the hydrogen per- 1. Replace of solenoid valve
oxide line
2. Clogged tube for suppling hydrogen peroxide 2. Clean or replace strainer
supply
3. Malfunction of sterilant air pump 3. Replace with a new pump
15.9.2 Incorrect intensity and cooling temperature of UV- lamps

1. Expired UV- lamp lifetime 1. Replace (Refer to 7.3.1, 14.14.1)
2. Dirty quartz glass 2. Clean (Refer to 7.3.5)
3. Defective actuation of cooling fan 3. Check the actuation of cooling fan
4. Temperature rise of UV- lamp 4. Increase wind quantity of cooling fan
15- 16 M144- 7294 Issue 01

15 Troubleshooting
15.10 Trouble in cap applicator system
15.10.1 Caps are not fed from cap track

1. Defective cap is placed in cap track 1. Remove the defective cap
2. Misaligned cap track 2. Readjust the position of the cap track
(Refer to 10.2.1)
3. Incorrect timing of cap pusher movement 3. Readjust (Refer to 2.1.5, 10.3.2)
15.10.2 Poor sealing

1. Incorrect clearance between horn and anvil 1. Check the standard dimension
(Refer to 10.4.4)
2. Incorrect position of the horn 2. Check the standard dimension
(Refer to 10.4.6)
M144- 7294 Issue 01 15- 17

15 Troubleshooting
15.11 Personal notes
15- 18 M144- 7294 Issue 01

16 Miscellaneous equipment
16 MISCELLANEOUS EQUIPMENT
M144- 7294 Issue 01
M144- 7294 Issue 01 16- 1

16 MISCELLANEOUS EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 1
16.1 Main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 4

16.1.1 Brake gap - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 6
16.1.2 Brake gap - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 6
16.2 Worm gear speed reducer (Main drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 8
16.3 Worm gear speed reducer (Carriage conveyor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 10
16.4 Mandrel index unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 11
16.5 Mecha lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 12
16.5.1 Mecha lock - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 13
16.5.2 Mecha lock - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 13
16.6 Pneumatic equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 14
16.6.1 Air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 14
16.6.2 Mist separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 16
16.6.3 Air pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 18
16.7 Air cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 22
16.7.1 Repair parts (CG1 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 23
16.7.2 Repair parts (CM2 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 26
16.7.3 Repair parts (CQ2 TYPE) - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 27
16.8 Air pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 28
16.8.1 Air pressure switch (ISE 40, ZSE40, ZSE50F TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 28
16.8.2 Air pressure sensor (PI 2095, PI 2098 TYPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 29
16.9 Heater blowers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 30
16.9.1 Cleaning and lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 32
16.10 Automatic grease pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 33
16.10.1 Grease level in grease pot - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
16.10.2 Grease pot - Refill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 34
16.10.3 Grease pot - Air purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 35
16.11 Vacuum line equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 36
16.11.1 Vacuum pump (for picker and unloader) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 36
16.11.2 Vacuum pump (for diaphragm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 38
16.12 Electric heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 40
16- 2 M144- 7294 Issue 01

CAUTION !
Do not attempt to adjust the equipment in this
chapter without consulting the factory because
one adjustment may involve other important
adjustments.
M144- 7294 Issue 01 16- 3

16.1 Main motor
(18) (9) (10)(13) (1)(6)(20)(11)(19)(7) (8) (24) (25) (26) (27)(28) (29)
(17)
(14)
(16)
(15)
(2) (3) (5) (4) (21)(22) (23) (30) (31)
Fig. 16-1. Main motor
The main motor is a standard and totally closed type with external fan, and it is used for the main drive.
When the motor power is turned on and supplied to the electromagnetic coil (7), the braking of brake disc (5)
shall be released.
When the motor power is turned off, the brake disc (5) is pressed to the braking plate (14) by the power of
spring (11), it can keep the braking.
If the handle (16) is removed from the handle holder (15) and moved it upward, the braking of brake disc
should constantly be released.
CAUTION !
Before operation, return the handle (16) to the handle holder (15).
If the handle (16) is not returned to the handle holder (15), the machine cannot be stopped at the
proper position.
16- 4 M144- 7294 Issue 01

No. Parts No. Parts No. Parts

(1) Cover (12) Sound- deadening insula- (23) Washer
tion
(2) Sound absorber (13) Washer (24) Stator coil
(3) Centre hub (14) Braking plate (25) Stator
(4) Pin (15) Handle holder (26) Rotor
(5) Brake disc (16) Handle (27) Frame
(6) Moving shaft (17) External fan (28) Shaft
(7) Electromagnetic coil (18) Fan cover (29) Shield
(8) Fixed shaft (19) Fan cover installing (30) Anti- operation side ball bear-
ing
(9) Stud bolt (20) Gap plug (31) Operation side ball bearing
(10) Nut (21) Collar
(11) Spring (22) Washer
Problem Possible cause Remedy

No rotation. 1. No power supply. 1. Check the electric circuit.
No buzzing. 2. Snapping of stator coil. 2. Check the stator coil and re-
place the motor assembly if
the stator coil is damaged.
Rumbling sound. 1. Ball bearing is damaged. 1. Replace the motor assembly.
Impossible to brake. 1. Brake setting lever is not set. 1. Set it on the holder.
Brake is weakened. 1. Oil or water adheres to brak- 1. Remove the liquid and dry
ing surface. the surface.
Abnormal sound 1. Impossible to release brake 1. Adjust brake gap.
because the brake gap is too
narrow.
2. Snapping of electromagnetic 2. Check the electromagnetic
coil. coil and replace the motor
assembly if the electro- mag-
netic coil is damaged.
3. Snapping the stator coil. 3. Check the electromagnetic
coil and replace the motor
assembly if the electro- mag-
netic coil is damaged.
4. Ball bearing is damaged. 4. Replace the motor assembly.
Table 16-1. Troubleshooting Part 1 of 1
M144- 7294 Issue 01 16- 5

16.1.1 Brake gap - Check
Note ! Check the brake gap. If it reaches the

limit value, adjust the gap.
1. Remove the gap plug (20).

2. Measure the gap with the gap gauge.
Initial gap. 0.3 mm

Limit gap. 1.3 mm
Table 16-2. Brake gap
16.1.2 Brake gap - Adjust
1. Loosen the handle (16) and remove from the

pin (4).
2. Take the pin out.
3. Remove the bolt and the fan cover (18).
4. Loosen the set screw and remove the external
fan (17).
6. Remove the nut (10) and the braking plate (14).
7. Remove the required number of the washers
(13). (The gap adjustment can be performed
twice.)
8. Assemble all parts in reverse order.
16- 6 M144- 7294 Issue 01

M144- 7294 Issue 01 16- 7

16.2 Worm gear speed reducer (Main drive)
(1) (9)
(4)
(14)
(13) (6)
(2) (19)
(3)
(11) (18)
(12)
(8)
(17)
(10) (7)
(15)
(5)
(16)
Fig. 16-2. Worm gear speed reducer
The speed reducer transmits power to the main drive shaft of the machine.
No. Parts No. Parts

(1) Case (11) Packing
(2) Input shaft (12) Shim plate
(3) Worm wheel (13) Cover
(4) Bearing (14) Cover
(5) Bearing (15) Cover
(6) Oil seal (16) Cover
(7) Oil seal (17) Output shaft
(8) Level indicator (18) Key
(9) Plug (19) Packing
(10) Plug

The speed reducer overheats. 1. Oil level exceeds the upper 1. Adjust the oil level.
and lower limits.
2. Oil quality is not suitable. 2. Drain the oil and refill with
recommended oil.
Oil leaks from drain plug. 1. Drain plug is not tightened. 1. Tighten.
16- 8 M144- 7294 Issue 01

16.2.1 Oil level - Check & Refill
Note ! Refer to 13.5.1.
M144- 7294 Issue 01 16- 9

16.3 Worm gear speed reducer (Carriage conveyor)
(1) (9)
(8)
(2)
(7)
(11)
(10)
(3)
(4) (6)
(5)
Fig. 16-3. Worm gear speed reducer
The speed reducer transmits power to the carriage conveyor drive shaft of the machine.
No. Parts No. Parts

(1) Fitting position (7) Input shaft coupling
(2) Output flange (8) Rubber cap
(3) Output oil seal (9) Bearing
(4) Bearing (10) Direction of input rotation
(5) Bolt hole (11) Direction of output rotation
(6) Motor installation flange
Note ! If damaged, replace it with a new one.
16- 10 M144- 7294 Issue 01

16.4 Mandrel index unit

The index unit roller gear cam mechanism is an
intermittent mechanism with a drum shaped cam
and 2 axes turret rollers placed radially at right
angles
Fig. 16-4. Mandrel index unit
Fig. 16-5. Roller gear cam mechanism

Abnormal noise and vibration 1. The movable part is loose. 1. After tightening, consult the
ELOPAK representative.
2. The connecting point is 2. After tightening, consult the
loose. ELOPAK representative.
The temperature of the indexing 1. Drain plug is not tightened. 1. After adjusting the amount of
unit rose oil, consult the ELOPAK re-
presentative.
16.4.1 Oil level - Check & Refill

Note ! Refer to 13.5.3.
M144- 7294 Issue 01 16- 11

(6)
16.5 Mecha lock
(4)
(7) The mecha lock consists of inside ring (1), outside
ring (2), and bolts (3). The inside and outside rings
are connected on the taper. The bolts, when fas-
tened, press the outside ring against the boss (4)
(2) and the inside ring, on the shaft (5), by the taper
effects. This presses the boss against the mecha
lock collar (6) while the mecha lock spigot (7)
(3) keeps the boss right angled to the shaft, and the
(1) (5)
shaft centred precisely. The outside ring has a slit
and the inside ring has several slits, for easy
Fig. 16-6. Working principles expansion and contraction.
No. Parts
(1) Inside ring
(2) Outside ring
(3) Bolt
(4) Boss
(5) Shaft
(6) Collar
(7) Spigot

Slip 1. Boss bore becomes too large 1. Check the boss bore and
or shaft diameter too small shaft diameter.
for clamping after the bore is
machined.
2. Molybdenum- disulfide- 2. Clean the shaft, the hub and
contained grease or oil con- the mecha lock.
taining extreme- pressure ad-
ditives are left on the shaft or
in the mecha lock.
3. Bolts are not perfectly fas- 3. Fasten bolts with a hexago-
tened. nal bar wrench, first lightly,
and then gradually tighter in
turn and evenly. When espe-
cially accurate torque is nec-
essary, use specifications
tables and a torque wrench.
16- 12 M144- 7294 Issue 01

Series Bolt Tightening torque (N⋅m)

MA30- 48 M5  18 8.8
MA35- 57 M6  20 15.7
MA50- 72 M6  20 15.7
MA60- 82 M6  20 15.7
MB45- 73 M8  25 39.2
MB60- 88 M8  25 39.2
SA55- 77 M6  20 11.8
Table 16-6. Bolt tightening torque Part 1 of 1
16.5.1 Mecha lock - Install 16.5.2 Mecha lock - Disassembly
CAUTION ! 1. Loosen all bolts until bolt head lifts about 3mm
Use only original bolts. Never use inferior above collar surface.
bolts, which are often broken and damage me- 2. Apply slight impact on bolt heads or boss if
cha lock. inside and outside rings are locked together
due to rust from long use or as they were
clamped at excessive torque.
1. Before installing the mecha lock, remove rust
and oil deposit from the shaft with a thinner 3. To loosen entire assembly, remove 2 or 3 bolts
soaked cloth, and lightly lubricate mecha lock and screw them into disassembling holes at
with machine oil or turbine oil. even torque.
CAUTION !
Never use molybdenum disulfide contained
grease or oil containing extreme pressure addi-
tives.
2. Insert a correctly machined boss over the shaft.

3. Insert the boss into mecha lock so that it may fit
the mecha lock collar tightly, tapping the boss
with a plastic hammer, if necessary.
4. Fasten bolts with a hexagonal bar wrench, first
lightly, and then gradually tighter in turn and
evenly.
Note ! When especially accurate torque is

necessary, use specifications tables
and a torque wrench.
M144- 7294 Issue 01 16- 13

16.6 Pneumatic equipment
CAUTION !
The case is made of plastics. Keep them away
from organic solutions such as thinner and car-
bon tetrachloride.
Clean the case with a mild detergent.
16.6.1 Air filter
Any contaminants from the air compressor, such

as moisture, dirt, grit or oil, will be automatically
(4) drained by an automatic drain valve built into the
unit.
(2) No. Parts
(3) (1) Case assembly
(2) O- ring
(5) (3) Filter element
(4) Deflector
(1) (5) Baffle

Air resistance is large. 1. Filter element is clogged. 1. Replace the element with a
new one.
(Flow rate decreases)
Air leaks from mounting part of 1. O- ring is damaged. 1. Replace the O- ring.
bowl.
2. Case is damaged. 2. Replace the case assembly.
Drain or air blown out of drain dis- 1. Orifice plate is clogged. 1. Replace the case assembly.
charge port.
2. Valve is damaged. 2. Replace the case assembly.
3. O- ring is damaged. 3. Replace the case assembly.
Drain is not discharged from drain 1. Small hole (nozzle) in case 1. Replace the case assembly.
discharge port. assembly is clogged.
16- 14 M144- 7294 Issue 01

16.6.1.1 Filter element- Replace
(6)
(7)
CAUTION
BEFORE REPLACING THE FILTER ELE-
MENT, CHECK THAT IT IS DEPRESSU-
RISED.
1. Lift the case (6) up and push locking button (7)

(8) down. Check that the arrow mark will appear.
2. Meet mark ’II’ of body (8) with that of the case.
After that, pull the case down and the case can
be disconnected.
No. Parts
(6) Case
(7) Locking button
(8) Body
Fig. 16-8. Replacing filter element
3. Remove the case. (Refer to Fig. 16-7. )

4. Replace the O- ring (2) and the deflector (4).
5. Rotate the baffle (5) counter- clockwise, and
remove the baffle with the element (3) from the
body. (Refer to Fig. 16-7. )
6. Attach the new element to the baffle (5).
7. Attach baffle (5) and the case to the body.
M144- 7294 Issue 01 16- 15

16.6.2 Mist separator
*(1) A mist separator works to remove tiny dust which

cannot be removed by the air filter.
*(2) No. Parts
(1)* O- ring
(2)* Filter element
Standard
Element replace- Once every 2 years
ment
CAUTION !
Discharge the drain from the drain valve before
it exceeds the upper limit mark.
Fig. 16-9. Mist separator

Air resistance is large. 1. Filter element is clogged. 1. Replace the element with a
new one.
(Flow rate decreases)
Air leaks from mounting part of 1. O- ring is damaged. 1. Replace the O- ring.
bowl.
Note ! Repair parts marked * can be ordered

as a kit. Cannot be ordered separately.
16- 16 M144- 7294 Issue 01

16.6.2.1 Filter Element and O- ring - Replace

(3)
1. Unscrew 4 bolts of the body (3) to remove the
housing (1).
(2) 2. Mount a new O- ring (2) to the body.
(4) 3. Mount a new packing (4) to the body.
View X 4. Insert a new filter element (5) facing the hous-
ing with the hole side up. The joint of the ele-
ment surface should be placed on rear side.
(5)
5. Fix the housing firmly with the 4 bolts.
No. Parts
(1) (1) Housing
(2) O- ring
(3) Body
(4) Packing
(5) Filter element
Fig. 16-10. Replacing the element and O- ring
M144- 7294 Issue 01 16- 17

16.6.3 Air pressure regulator
(10) The air pressure regulator is installed mid way in

(9)
the air pressure piping, and it can set up the air
pressure of the secondary side by a spring and a
diaphragm.
(1) No. Parts
(1) Bonnet
(2) (2) Body
*(3)
(3)* Diaphragm
(4) Valve guide
(5) O- ring
(6)* Valve assembly
(5) (7)* O- ring
(8)* Valve spring
(9) Pressure adjusting spring
*(6)
(10) Adjusting dial
*(7)
*(8)
(4)
Fig. 16-11. Air pressure regulator as a kit. Cannot be ordered separately.
Note ! When the adjusting dial (10) cannot be

turned, pull the adjusting dial once to
release its lock. When you push the
adjusting dial, it is locked.
16- 18 M144- 7294 Issue 01


Pressure is not regulated. 1. Broken pressure adjust 1. Replace the air pressure reg-
spring regulator assembly. ulator.
2. Broken valve spring. 2. Replace the valve spring.
3. Foreign objects caught be- 3. Remove the valve guide and
tween the valve and the clean the valve and the valve
valve seat. seat.
4. Damaged rubber lining on 4. Replace the valve.
valve.
5. Broken diaphragm. 5. Replace the diaphragm.
Set pressure does not return to 1. Foreign objects caught be- 1. Clean the valve and the
zero when pressure regulating tween the valve and the valve seat.
handle is loosened. valve seat.
2. Damaged rubber lining on 2. eplace the case assembly.
valve.
3. Broken valve spring. 3. Replace the valve spring.
4. Drainage adheres to valve. 4. Wash the sliding surface of
O- ring or the inside of valve
guide and grease up.
Air leaks out of small hole on bon- 1. Broken diaphragm. 1. Replace the diaphragm.
net.
2. Dust is lodged between the 2. Clean the sheet section.
stem end and the diaphragm
sheet surface.
Air leaks near bonnet. 1. Loose the bonnet. 1. Fasten the bonnet evenly.
2. Broken diaphragm. 2. Replace the diaphragm.
M144- 7294 Issue 01 16- 19

16.6.3.1 Valve spring - Replace
CAUTION
TAKE CARE BECAUSE THE SPRING
MAY JUMP OUT.
1. Remove the valve guide (4).

2. Replace the valve spring (8) with a new one.
3. Attach the valve guide.
16.6.3.2 Valve assembly - Replace
CAUTION
MAY JUMP OUT.
CAUTION !
Take care not to damage the O- ring.

2. Replace the valve assembly (6) with a new one.
3. Attach the valve guide.
16.6.3.3 Diaphragm - Replace

1. Loosen the bolts and remove the bonnet (1)
from the body.
2. Loosen the pressure adjusting spring (9).
3. Replace the diaphragm (3) with a new one.
16- 20 M144- 7294 Issue 01

16.6.3.4 Valve and valve seat - Clean
CAUTION
MAY JUMP OUT.
CAUTION !

2. Pull out the valve assembly (6).
3. Wash the valve and valve seat with oil.
4. Apply grease to the valve and valve seat after
washing.
5. Install the valve guide.
16.6.3.5 O- ring sliding surface of valve - Clean
CAUTION
MAY JUMP OUT.
CAUTION !
1. Pull out the valve assembly (6).

2. Wash the sliding surface of the O- ring (7) with
oil.
3. Apply grease to the sliding surface of the O-
ring after washing.
M144- 7294 Issue 01 16- 21

16.7 Air cylinders

Various types of air cylinders are used throughout
the machine. Each type requires dedicated disas-
sembly/assembly procedure. In general, air cylin-
ders must be handled as mentioned under the
CAUTION remark below.
Clean air is required for trouble free function of the
pneumatic equipment. Take care that the air treat-
ment equipment mounted on the machine is prop-
erly maintained.
Items marked (*) are replaceable items.

Bad movement of the piston rod. 1. Piston packing is damaged. 1. Replace piston packing.
2. Worn packing. 2. Replace air cylinder.
Air leaking. 1. Packing is damaged. 1. Find the air leaking position,
replace the packing.
CAUTION !
Great care must be taken when an air cylinder
is disassembled. Do not hit the cylinder body
with tools or scratch the inside of the cylinder
or piston rod surface.
Even a slight damage deteriorates the function
of the cylinder and excessive wear of seals will
be the result.
Lubricant should be applied liberally to piston
rod, bushings, cylinder tube and seals when
the cylinder is assembled.
Note ! Adjusting the cushion valve. The

effect of the cushion becomes high
when the cushion valve is rotated
clockwise, it becomes low when the
valve is rotated counter- clockwise.
16- 22 M144- 7294 Issue 01

16.7.1 Repair parts (CG1 TYPE) -

Replace
Refer to Fig. 16-12. , Fig. 16-13. , Fig. 16-14.
Note ! Tube cover(6) and rod cover (5) of CG1

cylinder are fixed using correct tightening
torque.
1. When disassembling, hold the two chamfers of

the tube cover (6) with a vise, two chamfers of
rod cover (5) with a spanner or a monkey
wrench, and unscrew the rod cover.
Note ! Disassembly for those cylinders of

bore size 50mm or over is difficult
because they are assembled by big
tightening torque.
Note ! Consult Shikoku Kakoki when disas-

sembly is required.
2. When assembling the cylinder, check that parts

are free of dust or foreign objects.
3. Coat the sliding parts such as tube cover, piston
(8), piston rod (1), bushing (3) and packings (1)
(2) (9), with grease.
4. Assemble them without damaging the packing
etc. Then, tighten the rod and tube covers.
M144- 7294 Issue 01 16- 23

Note ! Repair parts marked * can be ordered as a kit. Cannot be ordered separately.
(1) *(2) (3) *(4) (5) (6) (7) (8) *(9) (10)
Fig. 16-12. Air cylinder (CG1 lN  26 ~ 63 Type)
No. Parts No. Parts

(1) Piston rod (6) Tube cover
(2)* Rod packing (7) Damper
(3) Bushing (8) Piston
(4)* Tube packing (9)* Piston packing
(5) Rod cover (10) Wearing
*(15) (12) (13) (1) *(2) (3) *(4) (5) (16) (6) (7) (8) *(9) (10)
(14)
*(11)
Fig. 16-13. Air cylinder (CG1 lA  20 ~ 63 Type)
No. Parts No. Parts

(1) Piston rod (9)* Piston packing
(2)* Rod packing (10) Wearing
(3) Bushing (11)* Valve packing
(4)* Tube packing (12) Cushion valve
(5) Rod cover (13) Nut
(6) Tube cover (14) Valve holder
(7) Damper (15)* Holder packing
(8) Piston (16) Cushion packing
16- 24 M144- 7294 Issue 01

*(15) (12) (13) (1) *(2) (3) *(4) (5) (16) (6) (8) *(9) (10)
(14)
*(11)
Fig. 16-14. Air cylinder (CG1 lA  80 ~ 100 Type)
No. Parts No. Parts

(1) Piston rod (10) Wearing
(2)* Rod packing (11)* Valve packing
(3) Bushing (12) Cushion valve
(4)* Tube packing (13) Nut
(5) Rod cover (14) Valve holder
(6) Tube cover (15)* Holder packing
(8) Piston (16) Cushion packing
(9)* Piston packing
M144- 7294 Issue 01 16- 25

16.7.2 Repair parts (CM2 TYPE) -

Replace
1. Remove the cylinder by removing the C-

shaped stop ring (2) for holes with a plier
(C- shaped stop ring fitting).
2. For the next procedures, refer to 16.7.1

(2) *(3) (4) (1) (5) (6) (7)
Fig. 16-15. Air cylinder (CM2 Type)
No. Parts No. Parts

(1) Piston rod (5) Tube cover
(2) C- shaped stop ring (6) Piston
(3)* Rod packing (7) Head cover
(4) Rod cover
16- 26 M144- 7294 Issue 01

16.7.3 Repair parts (CQ2 TYPE) -

Replace
1. Remove the cylinder by removing the C-

*(2) shaped stop ring (4) with a plier (C- shaped
*(1) stop ring fitting).
2. For the next procedures, refer to 16.7.1
*(3)
No. Parts
(1)* Tube packing
(2)* Piston packing
(3)* Rod packing
(4) (4)* C- shaped stop ring

Fig. 16-16. Air cylinder (CQ2 type)
M144- 7294 Issue 01 16- 27

16.8 Air pressure sensor

The air pressure sensor detects the air pressure
level in the system. If the pressure exceeds a pre-
determined range, the switch gives a signal to the
PLC.
16.8.1 Air pressure switch (ISE 40,

(1) kPa ZSE40, ZSE50F TYPE)
The air pressure switch detects pressure of gas

(2) (3) such as air and nitrogen, pressure of fluid such as
water and oil, and vacuum pressure.
Out 1 Out 2
(4) (5)
SET
(6)
Fig. 16-17. Air pressure switch - Setting
No. Name Function

(1) LED display (3 1/2- digit) Displays present pressure.
Displays each mode.
Displays error code.
(2) LED (Green) Displays OUT1 operation condition.
ON: When output is ON.
(3) LED (Red) Displays OUT2 operation condition.
ON: When output is ON.
(4) UP button Switching of the mode and set value.
(5) Down button Switching of the mode and set value.
(6) SET button Switching to each mode and fixing the set value.
16- 28 M144- 7294 Issue 01

16.8.2 Air pressure sensor (PI 2095, PI

(2)
2098 TYPE)
(1)
The air pressure sensor has 3A and FDA approv-
(3)
als which are granted for the machinery used in
food and pharmaceutical industries.
No. Name
(1) 4- digit display
(2) LED
(3) Setting button
(4) Sealing edge
(5) ifm special screw
(4) (5)
Fig. 16-18. Air pressure sensor
M144- 7294 Issue 01 16- 29

16.9 Heater blowers
(2)
(5- 2)
(5- 1)
(3)
(4)
(1)
Fig. 16-19. Heater blower
The heater blower blows high pressure air from air intake out the exhaust.
No. Parts No. Parts

(1) Silencer (4) Cover
(2) Fan (5- 1) Bearing
(3) Impeller (5- 2) Bearing
16- 30 M144- 7294 Issue 01


Motor does not start, no rotor At least two power supply con- Eliminate interruption by means
noise. ductors interrupted. of fuses, terminals or feeder
leads.
Motor does not start, humming Interruption in one power supply See ”Motor does not start, no ro-
noise. conductor; tor noise”.
impeller jammed. Open cover, remove foreign ob-
jects, and clean; if necessary
check impeller gap adjustment
and correct if necessary.
Impeller defective. Fit new impeller.
Motor bearing defective. Fit new bearing.
Motor protective circuit- breaker Short- circuit in the winding. Arrange for winding to be in-
trips again after motor is switched spected.
on, power consumption too high.
Motor overloaded. Reduce operating pressure, clean
filter, silencer, connecting pipes if
necessary.
Compressor jammed. See ”Motor does not start, hum-
ming noise”.
No vacuum or too weak vacuum Leak in the system, Make system air- tight;
is produced.
wrong direction of rotation. Change direction of rotation.
(changeover to electrical supply
leads):
Wrong frequency. Correct the frequency.
Compressor too small. Use larger compressor.
Shaft seal defective. Fit new shaft seal.
Varying density of delivery gas. Pay attention to conversion of
pressure values.
Change of blade profile due to Clean impeller, replace worn
fouling. impeller with a new one.
Abnormal squeaking noises. Too high flow rate; Clean.
Silencer dirty. Clean silencer inserts, fit new
ones if necessary.
Ball bearing lacks grease or is de- Grease ball bearing or fit new
fective. one.
Compressor not air- tight. Packing defective. Check packing.
M144- 7294 Issue 01 16- 31

16.9.1 Cleaning and lubrication
1. Check the outer and inner parts of the blower

once a year. If there is any dust, clean it with
compressed air.
Standard
Inner parts of the Once a year
blower
2. Remove grease residue from the rolling- con-

tact bearings (5- 1) and adjacent spaces.
3. Refill the recommended greases or the equal
specifications.
Brand Recommended food grade

grease
Petro - Canada PURITY FG 00 GREASE
CAUTION !
Closed rolling- contact bearing (5- 2) should be
replaced with a new one. Their adjacent grease
spaces are not filled with grease.
CAUTION !
Never mix different types of grease.
16- 32 M144- 7294 Issue 01

16.10 Automatic grease pump

The pneumatically operated plunger meters the
amount of grease in the hydraulic cylinder and
forces it into the supply line.
(1)
No. Parts
(2) (1) Grease pot

(2) Grease fill port
(3) Discharge port
(4) Discharge check valve
(3)
CAUTION !
Do not open the grease pot lid to avoid the
entry of any air and foreign object, which may
(3) cause incorrect operation of the pump or valve.
(4)
Fig. 16-20. Automatic grease pump

The pump works, but grease is not 1. The grease pot is empty. 1. Supply clean grease.
discharged.
2. Foreign objects such as dust, 2. Disassemble, wash in oil and
and the like are found in the assemble the discharge
discharge check valve of check valve unit of pump.
pump.
3. The pump sucks a large 3. While operating the pump,
amount of air. loosen the piping of dis-
charge port and purge air.
Pump does not work. 1. Air supply pressure to the 1. Investigate and repair the air
pump drops. source.
2. If pump discharge line is 2. Investigate and repair the
clogged, the pump stops. discharge line. (clogging of
distributor, main pipe, lubrica-
ting pipe)
M144- 7294 Issue 01 16- 33

16.10.1 Grease level in grease pot -

Check
1. You can see the grease pot (1) and piston (2)
(3) (2) through the window on the cover (3). Check the
grease level by the bottom line of the piston.
2. If the grease level is low, refill grease.
No. Parts
(1)
(1) Grease pot
(2) Piston
Fig. 16-21. Grease pump
(3) Cover
16.10.2 Grease pot - Refill
(2) 1. Remove the inlet plug (1) from the grease pot
(2).
2. Connect the hose of the grease filling unit (3) to
the grease pot.
3. Pump the handle (4) of the grease filling unit,
(4)
and supply grease.
4. Check the grease level. If it is OK, remove the
hose from the grease pot.
5. Wipe off excessive grease around the inlet.
6. Install the inlet plug.
Note ! Use the recommended greases or the

equal specifications.
No. Parts
(3) (1) (1) Inlet plug
(2) Grease pot
(3) Grease filling unit
Fig. 16-22. Grease pot
(4) Handle
DANGER Brand Recommended food grade

grease
Petro - Canada PURITY FG 00 GREASE
AND DISCARDING GREASE. CAUTION !
Discard the used grease in accordance with the
local regulation.
16- 34 M144- 7294 Issue 01

16.10.3 Grease pot - Air purge
CAUTION !
Observe the grease pump operation. If an
unusual noise or incorrect idling is observed,
purge entrapped air from the pump according
to the following procedures.
1. Loosen the yellow painted screw on the pump.

2. Manually operate the pump.
3. Check that grease appears in the yellow
painted screw hole.
4. Tighten the screw.
5. Operate the pump again, and note that the
guide rod on the selector grease valve moves
to press the microswitch, completing the
lubrication.
M144- 7294 Issue 01 16- 35

16.11 Vacuum line equipment
16.11.1 Vacuum pump (for picker and

unloader)
[Oil - Check & Replace]

Refer to 13.5.5
[Inlet filter - Check & Clean / Replace]

Check and clean the inlet filter element (1) every
week. Clean with air blow.
Replace the inlet filter element every 2,400 hours.
Open the cover (2), remove the inlet filter element,
and replace with a new filter element.
No. Parts
(1) Filter element
(1) (2) (2) Cover
Fig. 16-23. Inlet filter (for picker and unloader)
[Oil filter - Replace]

Refer to 13.5.5
[Exhaust filter - Replace]
Replace the exhaust filter every 2,400 hours.
Replacement instructions are as follows :
1. Loosen the bolts and remove the cover (1).
2. Remove the spring (2) and pull out the exhaust
filter (3).
3. Attach the new filter and O- ring (4).
4. Attach the spring.
5. Attach the cover and tighten the bolts.
16- 36 M144- 7294 Issue 01

(21)
(18)
(13)
(20)
(14) (19)
(1)
(12)
(2)
(7)
(8)
(3)
(15) (4)
(16)
(17) (5)
(6)
(9)
(11)
(10)
Fig. 16-24. Vacuum pump (for picker and unloader)
No. Parts No. Parts

(1) Cover (12) Baffle strainer
(2) Spring (13) O- ring
(3) Exhaust filter (14) O- ring
(4) O- ring (15) Coupling gear
(5) Oil level indicator (16) Coupling sleeve
(6) Packing (17) Coupling gear
(7) Oil fill plug (18) Pump fan
(8) O- ring (19) Locking ring
(9) Oil drain plug (20) Motor
(10) O- ring (21) Inlet filter
(11) Oil filter
M144- 7294 Issue 01 16- 37

16.11.2 Vacuum pump (for diaphragm)
[Oil - Replace]
Refer to 13.5.5
[Inlet filter - Check & Clean / Replace]

Check and clean the inlet filter element (1) every
week. Clean with air blow.
Replace the inlet filter element every 2,400 hours.
Open the cover (2), remove the inlet filter element,
and replace with a new filter element.
No. Parts
(1) Filter element
(1) (2) (2) Cover
Fig. 16-25. Inlet filter (for diaphragm)
[Exhaust filter - Replacement]

Replace the exhaust filter every 2,400 hours.
Replacement instructions are as follows :
1. Loosen the bolts and remove the cover (1).
2. Remove the spring (2) and pull out the exhaust
filter (3).
3. Attach the new filter and O- ring (4).
4. Attach the spring.
5. Attach the cover and tighten the bolts.
16- 38 M144- 7294 Issue 01

(1) (2) (3) (4)
(9) (10) (11) (12) Section Y- Y

View X
(5) (13)
(6)
Y
Y
(7)
(8)
Fig. 16-26. Vacuum pump (for diaphragm)
No. Parts No. Parts

(1) Cover (8) O- ring
(2) Spring (9) Coupling gear
(3) Exhaust filter (10) Coupling sleeve
(4) O- ring (11) Coupling gear
(5) Oil fill plug (12) Motor
(6) O- ring (13) Inlet filter
(7) Oil drain plug
M144- 7294 Issue 01 16- 39

16.12 Electric heater
* (2)
* (1)
Fig. 16-27. Electric heater
Air is heated by the electric heater. Heater air is Note ! Repair parts marked * can be ordered
directed to selected areas of the carton flaps, and as a kit. Cannot be ordered separately.
softens the polyethylene coating on the bottom and
top flaps of each carton.
No. Parts
(1)* Heater element
(2)* Packing

The temperature does not rise. 1. The heater element is crack- 1. Check the heater element.
ed. Replace it if there are cracks.
2. The nichrome wire is cut and 2. After measuring with a resis-
the functions have deterio- tor, if there are any abnorma-
rated. lities replace the heater ele-
ment.
16- 40 M144- 7294 Issue 01

16.12.1 Heater element - Inspection
Note ! Check that there are no cracks on the surface of the ceramic parts.
Note ! Replace the heater element with a new one if it is not in normal condition.
Bottom preheater Bottom heater, Hydrogen peroxide

drying heater
Top heater
Part No. of the heater No. LUPHS10P408 No. LUPHS10P410 No. LUPHS05P804
element
No. LUPSH108 No. LUPHS10P41P1 No. LUPSH508
Rated output 400V 8.1kW 400V 10.95kW 400V 8.1kW
Connection diagram
Delta connection
u
Calculated resistance u v u v u v 37.5 

37.8  28.0 
in normal condition
u w 37.8  u w 28.0  u w 37.5 
v w 37.8  v w 28.0  v w 37.5 

Resistance in case of u v u v u v
connection u v 113.4  84.0  112.6 
broken down
u w 56.7  u w 42.0  u w 56.3 
v w 56.7  v w 42.0  v w 56.3 
Resistance in case of u v u v 1
connection u v
1 u v 1
and v w broken u w 56.7  42.0  u w 56.3 
u w
down
v w 1 v w 1 v w 1
Table 16-14. Resistance of the heater element in normal and damaged Part 1 of 1
condition
M144- 7294 Issue 01 16- 41

16.12.2 Heater assembly - Check
1. Check the heater element (1) for cracks in the

ceramic part. Check that there is no abnormality
(1)
when measuring with a resistor.
Standard
Heater element Daily
2. Replace with a new one if necessary.
Fig. 16-28. Heater element Note ! Replace the heater element (1) after
6,000 hours even if it is operating cor-
rectly.
No. Parts
(1) Heater element
16- 42 M144- 7294 Issue 01

17 APPENDIX
17 APPENDIX
M144- 7294 Issue 01
M144- 7294 Issue 01 17- 1

17 APPENDIX
17 APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 1
17.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 3

17.2 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 4
17- 2 M144- 7294 Issue 01

17 APPENDIX
17.1 Contents
Refer to the attached documents.
1. Document No. : M214- 055- 109

WEDECO Aquada Installation and Maintenance Instructions Xylem.Inc
2. Document No. : M214- 131- 459
High pressure mercury lamp surface sterilizer Instruction manual Iwasaki Electric Co., Ltd.
M144- 7294 Issue 01 17- 3

17 APPENDIX
17.2 Personal notes
17- 4 M144- 7294 Issue 01

M214-055-109
WEDECO Aquada
GB Installation and Maintenance Instructions
DE Installations- und Wartungsanleitung
F Notice d’Installation et de Maintenance
I Istruzioni di Installazione e Manutenzione

Contents
1. General & Applications
2. Assembly & Installation
2.1. Reactor
2.1.1. Assembly of Reactor

2.1.2. Installation of Quartz Sleeve and of UV Lamp
2.1.2.1. Cleaning and Replacement of Quartz Sleeve
2.1.2.2. Fitting of UV Sensor (only for Maxima)
2.1.3. Connection to the Water Line Network
2.2. Control System
2.2.1. Assembly of Control Box

2.2.2. Electrical Connection
2.2.3. Connection of UV Lamp
3. Commissioning
3.1. Units with Solenoid Valve

3.1.1. Units without Solenoid Valve
3.2. Tightness Test
4. Software
4.1. Alarm Messages

4.2. New Start after Replacement of UV Lamp
5. Exploded Diagram
6. Spare Parts List
7. Declaration of conformity (page 82)
ATTENTION:
Please read this manual carefully and follow the instructions given in it.
Installation must be carried out only by authorized technicians.
2
1. General & Applications
Disinfection by means of ultraviolet light (UV) is an efficient, economic and particu-

larly environmentally friendly process.
UV light kills pathogene microorganisms within a few seconds without leaving any
residues, harmful by-products or affecting the sense of smell or of taste.
Thanks to this the operators‘ exposure to danger by handling harmful chemicals is
excluded.
The effect of the UV light is used by very effective UV-C radiation (254 Nm). Within
a few seconds this brings about a photochemical reaction in DNA (desoxyribonucle-
ic acid) which is vital for all microorganisms. By this microorganisms are either killed
GB
or their ability to increase is destroyed.
The rate of kill depends on minimum UV radiation (UV dose), i.e. the time that a mi-
croorganism is exposed to a certain intensity of UV radiation (W/m²). At a UV dose
of 400 J/m² the most important human pathogene bacteria and virus are reduced
by 4 logs (decimal exponents), which corresponds to international requirements
and ensures safe disinfection.
The disinfection performance of a UV system is essentially based on the fact that

each volume element obtains the necessary UV dose when it passes through the UV
reactor. To ensure this the radiation field and hydraulic properties in the UV system
have been optimally adapted to each other.
UV radiation of drinking water does not cause any undesired secondary reactions
based on the UV doses we use for disinfection.
As we do not add efficient disinfective substances to the water by UV radiation,
there are no deposit effects when the volume element has passed through the UV
reactor.
ATTENTION:
Correct function (disinfection performance) can only be guaran-

teed when original WEDECO spare parts (lamps, ballasts, etc.)
are used.
Should you have any questions please contact:
www.wedeco.com
Tel.: +49 (0)5221 930-777
Fax : +49 (0)5221 930-196
3
General Safety Instructions
ELECTRIC SHOCK!
Attention - dangerous electrical voltage. The non-observance of this
instruction can cause serious personal injuries.
ENSURE EYE PROTECTION IS WORN!
IMPORTANT!
Instruction regarding useful tips or other information.
CAUTION!
UV-C radiation is harmful to the eyes and skin! UV lamps should be used
only in the irradiation chamber if suitable protection caps have been fItted.
Persons should never be exposed to UV-C radiation.
• Make sure this disinfection unit is only used for the intended purpose as describ-
ed in the operating instructions. The use of additional apparatus, which have not
been recommended by and are not sold by Xylem can cause an
unsafe situation.
• This disinfection unit is to be installed properly before use according to the opera-
ting instructions
• Do not use a unit with damaged electrical lead or plug, or a unit with faulty func-
tions, or a unit, which has been dropped or has been damaged in some way
• Make sure the unit is unplugged when it is not being used before fitting, or remo-
ving any parts, or before cleaning the unit. Do not remove the plug from the
socket by pulling the electrical lead, but take the plug directly out of the socket.
4
• Ensure the disinfection unit is electrically isolated before:
A. Carrying out repairs
REMARK:
We recommend that any maintenance is carried out by qualified persons.
B. Cleaning
GB
C. Replacement of the UV lamp
• The unit is to be depressurized before maintenance
• Do not use the UV lamp outside of the UV disinfection reactor
WEDECO UV lamps have been designed for permanent operation

to reach their best disinfection capacity.
Frequent switching on and off reduces the life of the UV lamp!
Max. 200 switching operations!
UV systems, which have been equipped with a solenoid valve,

should not be used without flowing water for long periods
(max. 48 hours). In cases of longer absence the system is to be
put out of operation.
5
2. Assembly & Installation
Make sure the national standards and prescriptions for assem-

bly and installation are observed. Installation must be carried
out only by qualified technicians.
The following items must be checked prior to installation:
• A max. operating pressure of 1000 K Pa (10 bar) must not be exceeded
• The max. ambient temperature is 40° C
• The max. water temperature is 25° C
• The max. flow rate must not be exceeded (see section 2.1.)
• The installation site of the reactor must be frost-protected and dry
2.1. Reactor
The following reactor types are available in the Aquada series:
Type Length Diameter Connections Min. free space Max. flow rate*
„ above reactor m3/h
1 470 mm 70 mm R 1/2 370 mm 0,70
2 670 mm 70 mm R 3/4 570 mm 1,77
4 670 mm 101,6 mm R 3/4 570 mm 3,01
7 1030 mm 101,6 mm R1 920 mm 6,20
10 1030 mm 140 mm R1 1/2 920 mm 9,00
Flow rate: 400 J/m2, UV-Transmission: 94 %

*
6
2.1.1. Assembly of Reactor
• Before installation ensure you know which reactor type you are using.
(Information about the reactor type can be found on the type plate)
• Make sure that there is enough free space above the reactor (for dimensions see
section 2.1.), otherwise it will not be possible to install the UV lamp and to
maintain the system
• The reactor is to be fixed by means of the enclosed assembly clips either on the
wall or on a special holder
GB
• In units with a UV sensor the reactor can only be assembled in a vertical position
• The assembled reactor is to be protected from frost exposure
UV lamp
Outlet
UV sensor (optional)
Control box
Inlet
7
2.1.2. Installation of Quartz Sleeve and of UV Lamp
The reactor is supplied together with a built-in quartz sleeve. The black head piece
in which the UV lamp is to be inserted has been screwed to a tightness of 5 Nm
in our factory. Prior to commissioning all screw connections are to be checked for
tightness.
For installation of UV lamp see section 2.2.3.
2.1.2.1. Cleaning and Replacement of Quartz Sleeve
The transparent plug of the lamp connection is to be turned slightly to the left or
the right (up to the raised part in the head piece) and then removed.
Remove UV lamp from the reactor by pressing the two transparent catching tabs.
Unscrew head piece from reactor and then carefully remove it together with the
quartz sleeve.
The quartz sleeve and the head piece are two single parts.
In case of disassembly, hold both parts in order to avoid the
quartz sleeve slipping out of the head piece!
UV lamp Quartz sleeve Head piece Catching tabs

UV lamp
O-ring Lamp filament wiring

O-ring
Then remove any coating from the quartz sleeve and reassemble it after cleaning.
8
Assembling manual
The UV lamp is also to be

cleaned before assembly.
It is to be inserted into the
Transparent lamp
head piece from above until
connection
the two transparent catching
tabs of the connecting plug
lock into place in the head UV lamp
piece.
Head piece
GB
After the assembly of the UV
lamp the transparent lamp
connecting plug is to be fit-
ted on the head piece. Make
sure that it locks into place.
(See guide in the plug)
The transparent lamp con- This figure shows the trans-

nector must properly snap parent lamp connector
into the groove on the head pushed too far.
piece.
Transparent connecting plug
Put the connection plug onto The connection plug is

the head piece until it clicks properly installed. It does not
Head piece UV lamp in. seperate when pulled away
from the head piece.
9
2.1.2.2. Fitting of UV Sensor
In our factory the UV sensor has been fitted to the control (only for Maxima model).
It is only to be screwed to the reactor. Tightening should be carried out with a light
tool only. A starting torque of 5 Nm is sufficient. Make sure this torque is not excee-
ded, otherwise the quartz glass in the sensor may be damaged.
UV sensor
NOTE:
The sensor is to be cleaned in regular intervals depending on the water

quality. For this purpose unscrew sensor after it has been depressurized
and is free from water, and then clean the quartz glass with the cleaner.
To avoid breakage, do not remove the quartz glass plate (located in the sensor)
when cleaning it. The glass plate should only be cleaned with a soft, clean cloth.
2.1.3. Connection to the Water Line Network

• When carrying out the connection to the water line network make sure to fit stop
valves on the inlet and outlet of the reactor to make maintenance easier
• UV resistant material is to be used for the connections to the water line network.
For the connection sizes please refer to the table in section 2.1.
• The connection to water line network is to be carried out in accordance with the
national regulations
• A solenoid valve is offered as an optional (Proxima, Maxima). This prevents wa-

ter flowing through in the case of power failure or insufficient UV intensity in the
reactor
10
2.2. Control System
The following equipment variants can be supplied:
1. Altima
• Visual function control of UV lamp by transparent lamp connection
• Control box which can be fastened easily (assembly on the wall or reactor)
2. Proxima
GB
• As Altima variant
• Possibility of connecting a solenoid valve which allows water flow only in the case
of a shining UV lamp
• Control of the solenoid valve by a micro-controller
• Remaining life of UV lamp shown on the display
• Visual and acoustic alarm in the case of lamp failure
3. Maxima
• As Proxima variant
• A UV sensor which continuously monitors the intensity, switches off the solenoid
valve when the minimum intensity is not reached and emits a visual and acoustic
alarm. The intensity is shown on the display.
11
2.2.1. Assembly of the Control Box
The control box can be fitted directly to the reactor by means of the supplied faste-
ning bands.
Pull bands through the opening

of the housing and fasten them
to the reactor.
• Assembly on the wall is also possible. For this method drill two holes
(hole spacing 134 mm) and fit dowels and screws. Then the control
housing can be hung on the screws.
• In the case of wall mounting the lengths of the supplied cables are to be taken
into account
» Connecting line to the mains: 200 cm

» Sensor cable: 150 cm (only for Maxima)
» Lamp cable : 150 cm
» Solenoid valve cable: 150 cm (optional)
The supplied cables must not be shortened or lengthened!
2.2.2. Electrical Connection
When the control box is connected to the mains make sure to

observe the valid national regulations as well as the indications
on the type plate (supply voltage, frequency, etc). The unit shall
only be operated with power lines including a ground wire (PE).
Installation work is to be carried out only by qualified elec-
tricians. Make sure to remove mains plug from socket before
carrying out work at the unit.
The grounding cable (earth) is to be connected to the reactor!

Do not open the housing of the control unit, otherwise the gua-
rantee will become void!
12
2.2.3. Connection of UV Lamp
• Unpack UV lamp and wipe it with a clean cloth (do not touch the lamp with your
fingers)
• Insert the lamp into the head piece until the transparent catching tabs of the
lamp connecting plug lock into place in the head piece (when you insert the lamp,
slightly press in catching tabs with two fingers; see figure 1 page 8)
• When inserting the UV lamp, make sure that the lamp filament wirings (see fig. 1
page 8) do not attenuate the sensor signal. The wirings must not be in front of
the sensor window.
GB
3. Commissioning
Make sure to check all important items of the operating instructions

prior to commissioning.
3.1. Units with Solenoid Valve

• Loosen head piece by two turns
• Open stop valve of domestic water supply system
• Air escapes through the head piece. Leave the head piece open until water flows
out. After that relock the head piece. Be careful of splash water!
• Commission UV system. Insert plug into socket. The display shows:
Sample Proxima
13
• Press Reset button for approx. 10 seconds after having switched on the unit, until
you hear a signal
• The unit is now in the warm up phase. After 5 minutes the solenoid valve is
switched on and fully opened.
• Now open the stop valve slowly but completely. At the same time a water tap is
to be opened to ensure that the rest of the air escapes from the unit.
3.1.1. Units without Solenoid Valve

• Open a water tap
• Open slowly the main water tap of the domestic water supply plant until the air
has completely escaped from the unit
• Insert the mains plug into the socket. The display of the Proxima and Maxima unit
shows 365 days
The function control of the Alti-

ma units can be seen through the
blue shiny cap.
• Press the Reset button for approx. 10 sec. after switching on (Proxima, Maxima)
• Now the unit is in the warming up phase. After 5 minutes it has reached the
highest intensity and is ready for use.
All UV systems must only be switched on after the reactor has been filled
with water.
14
3.2. Tightness Test
After commissioning, all screw connections are to be checked

for tightness.
Xylem do not assume any responsibility for water damage(s)!
4. Software
The Aquada units (Proxima & Maxima) are equipped with a monitoring unit which
GB
is controlled by a micro-controller. The Aquada unit (Altima) is equipped with an
visual function control (section 3.1.1.)
• After first commissioning 365 is shown on the display and the LED „days of use“
is lit up (Proxima, Maxima)
• Press the RESET button for approx. 10 sec. (directly after switching on)
• The initialization time is 5 minutes
• After this the unit is ready for operation and the outlet solenoid valve is switched
on
• The display of the Maxima version now changes every 2 seconds from the display
of the days of use to the display of the UV intensity. The Proxima display remains
showing the days of use. In normal rating operation, the intensity is shown by HI
in the display.
• The display always shows the remaining number of days of use
15
4.1. Alarm Messages
The following alarm messages can occur during operation:
AL 1 » UV lamp failed
AL 2 » UV intensity less than 55 % of set value
AL 3 » End of lamp life (days of use = 0)
AL 4 » UV intensity between 55 % and 70 % of set value
AL 5 » UV lamp life < 30 days of use
Alarm 1
• UV lamp has not ignited

• UV lamp is defect
• Lamp failure LED is lit up
» Check plug connection of UV lamp

» Remove transparent cap as described and fit it once more
» Insert new UV lamp
» Have ballast checked by authorized service technician
Alarm 2
• Quartz sleeve is dirty

• Sensor is dirty
• End of UV lamp life (due to frequent switching on and off)
• Unit has been operated too long without flowing water (reactor is heated up)
• Lamp filament wiring is in front of the sensor window
» Disassemble quartz sleeve as described in section 2.1.2.1. and clean with a cleaner
» Disassemble sensor and clean sensor window
» Avoid frequent switching on and off, as the unit has been designed for
continuous operation
» Switch unit off and let it cool down
» Turn transparent lamp connector by 45°
Alarm 3
• End of UV lamp life
» Install new lamp (Use only original WEDECO spare parts)
16
Alarm 4
• Normal UV lamp ageing (disinfection is still given)

• Cleaning could be required soon
• Lamp filament wiring is in front of the sensor window
» Normal operating conditions can be restored by cleaning the unit

» In the display „HI“ is replaced by „LO“ (only Maxima)
» Turn transparent lamp connector by 45°
GB
Alarm 5
• End of lamp life in 30 days
» Order new UV lamp
All alarm messages are also given acoustical. The acoustical signal can be
reset by pressing the RESET button.
4.2. New Start after Replacement of UV Lamp

The quartz sleeve and sensor should be cleaned
after each replacement of the UV lamp. The reactor
should be cleaned when necessary.
For the new start of the system proceed in the same

way as for first commissioning. When you press the
RESET button (press for 10 sec.), directly after swit-
ching on, the day counter is reset to 365 and the
unit is newly initialized.
17
5. Exploded Diagram
1 » control box
2 » reactor
3 » quartz sleeve
4 » UV lamp
5 » head piece
6 » O-ring (head piece)
7 » lamp connection
8 » O-ring (quartz sleeve)
9 » UV sensor
10 » sensor connection
11 » control fastening band
12 » reactor fastening band
13 » reactor fastening band
18
6. Spare Parts List
Spare Part No. Description

760054 Control Box AQUA 1 Altima
760055 Control Box AQUA 2 & 4 Altima
760056 Control Box AQUA 7 & 10 Altima
760057 Control Box AQUA 1 Proxima
760058 Control Box AQUA 2 & 4 Proxima
760059 Control Box AQUA 7 & 10 Proxima
760060 Control Box AQUA 1 Maxima
760061 Control Box AQUA 2 & 4 Maxima
GB
760062 Control Box AQUA 7 & 10 Maxima
703321 Quartz sleeve 25 x 1,3 x 360 (inc. seal)
37085 UV Lamp NLR 1825 WS (Aquada 1)
37086 UV Lamp NLR 1845 WS (Aquada 2 & 4)
37087 UV Lamp NLR 1880 WS (Aquada 7 & 10 )
36538 Head piece Ø 48 x 40 PBT Crastin S 600
35492 O-Ring 24,77 x 5,33 FPM
37126 Assembly Lamp cable Ölflex 5 x 0,75 mm² 1,5 m
703324 Assembly Sensor window 18 x 2 (inc. Seal)
37250 Assembly UV Sensor (inc. Seal)
38127 power cord swiss
37155 power cord european
37156 power cord italian
36944 power cord british
36623 Reactor R1 (304)
36622 Reactor R2 (304)
36621 Reactor R4 (304)
36620 Reactor R7 (316 L)
36619 Reactor R10 (316 L)
36628 Reactor (Sensor) R1 (304)
36625 Reactor (Sensor) R7 (316 L)
36624 Reactor (Sensor) R10 (316 L)
37360 Face Spanner
37361 Torque-controlled Spanner „Slipper“ 2 - 10 Nm
19
M214-131-459
High pressure mercury lamp surface sterilizer
GSE1.6K01CN3(CE)-003
GSE2K01CN1(CE)
（Inverter type）
Instruction Manual
Before operating, checking, and preparing this product, be
sure to read this instruction manual to comprehend the
content.
The operator and administrator of this product should
comprehend the content.
(Sales/production) Iwasaki Electric Co., Ltd.

Change history
型式：1.6KW（GSE1.6K01CN3(CE)-003）
2KW（GSE2K01CN1(CE)）
Rev. Date of issue Changes Reason for revise Date of revise Notes
A 2014/04/23 －－ 2014/04/23 －
2KW lamp model change

B 2014/06/04 Revision 2014/06/04 －
(H02-L22→H02-L22XG)
Introduction
Thank you for purchasing the high pressure mercury lamp surface sterilizer.
☆ This document is the guide book for using this product safely.
☆ Before using this product, be sure to read this document and comprehend the operation,
inspection, and maintenance.
☆ If you operate this product differently from the description in this document, it may cause a
serious accident.
☆ If you modify this equipment without our permission, it may cause an unexpected accident.
Before modifying it, please be sure to consult us.
☆ In this document, the following precautions are written in each part.
These indications are the precautions for ensuring especially safety. Operate the product after
comprehend them.
WARNING
If you use this equipment without paying attention, heavy
injury, serious casualty or accident may be caused.
The operator and maintenance people should read this document before
operating or doing maintenance.
Keep this document near the equipment for easy reference.
Before comprehending this document completely, do not operate this
equipment or do maintenance.
If you lose or damage this document, order it to our distributor or us
immediately.
When you assign this product to someone, please assign it with this document
attached to next holder.
☆ Safety precautions ☆
[Classification of warning displays]

In order to comprehend this instruction manual and warning labels of this product well, the
warning displays are classified as shown below. Please comprehend these contents and follow
the instructions.
DANGER This word is the precaution used for precautions for safety and warning
label of the emergent dangerous part that may cause death or heavy injury
if the danger is not avoided.
These precautions for safety include preventive measure that should be
taken for avoiding danger.
WARNING This word is the precaution used for precautions for safety and warning
label of the potential dangerous part that may cause death or heavy
injury if the danger is not avoided.
CAUTION This word is the precaution used for precautions for safety and warning
label of the potential dangerous part that may cause light injury or medium
level damage if the danger is not avoided.
Be sure to bring these warning labels in clear view always. Furthermore, the positions of labels are
shown in equipment appearance drawing included with exhibit. When the label is removed, damaged,
or it cannot be read, please replace it with a new one.
[Warning label]
Warning label are described in the irradiator figure drawing, will be as follows.
Voltage note ：There is a risk of injury due to electric shock

Please do not remove the safety cover during operation.
High temperature：Doing so could cause burns

The maintenance and inspection work, please perform it after
sufficiently cooled.
Ultraviolet note ：Yes risk of inflammation of the eyes and face

The maintenance and inspection work, please wear protective
equipment.
Note engulfment：Risk of injury and caught the hand and clothing

The maintenance and inspection other than work, please do not
touch.
Content
1．Configuration and type ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 1
2．General description of equipment ・・・・・・・・・・・・・・・・・・・・・・・ 1
3．Installation / use condition ・・・・・・・・・・・・・・・・・・・・・・・ 4
4．Precautions for using this equipment ・・・・・・・・・・・・・・・・・・・ 5
5．Attaching and replacing the lamp, light reflector and quartz glass ・・・・・・・・・・・ 7
5.1 Lamp replacement procedure ・・・・・・・・・・・・・・・・・・・・・・ 7
5.2 Reflector replacement procedure ・・・・・・・・・・・・・・・・・・・・ 12
5.3 Procedure of replacement the quartz glass ・・・・・・・・・・・・・・・・・ 14
5.4 Replacement procedure of igniter ・・・・・・・・・・・・・・・・・・・ 16
6．List of I/O lines ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 18
7．Troubleshooting ・・・・・・・・・・・・・・・・・・・・・・・・・・・ 19
8．Consumable parts of irradiator ・・・・・・・・・・・・・・・・・・・・・・・ 20
9．Checklist of regular check ・・・・・・・・・・・・・・・・・・・・・・・ 23
10．Guarantee ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 23
11．Contact ・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 23
Attached diagrams：Appearance drawing of irradiator ・・・KC-AS-306991 (1.6KW)

KC-AS-306674 (2KW)
：Cables ・・・KC-CD-33228 (1.6KW)
KC-CD-33097 (2KW)
：Appearance drawing of electronic ballast ・・KG-AS-3234
：Electronic ballast connecting diagram ・・KG-CW-4186
：Electronic ballast specification ・・・KG-EX-4489 (1.6KW)
KG-EX-4490 (2KW)
：Operation time chart
(22,5)No.07-188A-E
Released on：2014/04/23
Revised on：2014/06/04
1 Configuration and type

Name of part Type, specification Quantity
H016-L22G
Lamp 1
（Ozone-less interference film）
1.6kW Irradiator GSE1.6K01CN3(CE)-003 1
Electronic ballast BE16HD2/2.4-01R 1
H02-L22XG
Lamp 1
（Ozone-less interference film）
2kW Irradiator GSE2K01CN1(CE) 1
Electronic ballast BE20HD2/2.4-01R 1
Cable － 1 set
UV monitor － 1
※Carry out installation and wiring of the electronic ballast referencing the electronic
ballast specification.
2 General description of equipment

2.1 Irradiator 1.6KW (GSE1.6K01CN3(CE)-003)
2KW (GSE2K01CN1(CE))
The external appearance of irradiator is shown below.
5
1
3
7
4
8
6
10
Photo 1 Irradiator(1.6KW)
1
(22,5)No.07-188A-E
5 1
3 7
4 8
6 10
Photo 2 Irradiator(2KW)
11
12
Photo 3 Under view of irradiator

The name of each part is shown below.
1. Irradiator main unit
2. Junction box
3. Air inlet (shutter open) (PT1/4)
4. Air inlet (shutter close) (PT1/4)
5. Inlet of cooling water(PT1/4)
6. Outlet of cooling water(PT1/4)
7. Piping port
8. Spring catch for removing front cover
9. Drive unit cover
10. Piping port for sensing broken glass
11. Front cover
12. Quartz glass
2
(22,5)No.07-188A-E
13
15
17
16
14
Photo 4 Irradiator body inside
19
18
Photo 5 Inside of the junction box
13. Shutter
14. Lamp(H016-L22G／H02-L22XG)
15. Light reflector
16. Limit switch for front cover
17. Circular truncated core insulator（×2）
18. Igniter unit
19. UV monitor
3
(22,5)No.07-188A-E
3 Installation / use condition

3.1 Installing the irradiator
Locate the irradiator in a horizontal position as a general rule.
3.2 Connecting with utility
3.2.1 Connecting with cooling water piping
Specifications of cooling water
Water quality：equivalent to water supply
Water temperature：15 to 25 ℃
Feed rate：2 to 3 L/min (1.6KW)
2.5 to 3.5 L/min (2KW)
Water pressure：0.1 to 0.3 MPa
Cooling water end connection：PT1/4 socket（×2）
3.2.2 Connecting the compressed air
Pressure：0.4 to 0.6 MPa
Connect the dried compressed air that does not build up condensation in piping.
※ Dry compressed air only. Do not use the lubricating oil.
With this irradiator, an air cylinder is used but no solenoid valve is included. Locate
this on the equipment side that uses this irradiator
3.2.3 Connecting the UV monitor
Connect with UV monitor referencing the Cables (KC-CD-33228／KC-CD-33097).
Shield cable is used for connecting the UV monitor（2 Meter）.
CAUTION
When the cooling water does not flow in irradiator, it may burn out.
3.2.4 Connecting the air for detecting the glass crack.

From the gas supply port on the front panel side, please supply the gas in the glass
breakage detection.
This irradiator doesn’t have a function to sense pressure. Set it up in customer’s
equipment.
CAUTION
Applying a pressure of more than necessary to quartz glass, there is
a risk of quartz glass may be damaged.
4
(22,5)No.07-188A-E
3.2.5 Grounding
This irradiator, be sure to do C type grounding work.
WARNING
Be sure to C type grounding work.
3.3 Use condition of irradiator

3.3.1 Use temperature ：5 to 35℃
3.3.2 Humidity ：Relative temperature 85 % or less
(No dew on power supply Equipment）
4 Precautions for using this equipment

4.1 Irradiator
4.1.1 When you replace lamps, be sure to hold the insulator of lamp end. Do not touch or
mess the glass part of lamp with bare hand. If the glass part is stained, damp the clean
cloth with alcohol and wipe it. When the water drop is attached on it, handle it in a
similar fashion.
4.1.2 Prevent the water or dust from going into irradiator from air supply /exhaust opening.
4.1.3 The water proof performance of this irradiator is IPX5, however, prevent the water
flow such as water radiation as much as possible.
4.1.4 The lamps which can be used for this irradiator are limited to the lamps shown in
“Configuration and type” of this document. Do not use other lamp.
4.1.5 Handle the damaged lamp with your hands protected with gloves etc.
4.1.6 The irradiator can become very hot During maintenance work, please go to cool
enough.
CAUTION
If you handle the damaged lamp with pare hands, your hands may
be poisoned or injured.
WARNING
When the equipment is operated in a harsh environment than
waterproof performance of the irradiator, there is a risk of a
serious accident occurs.
5
(22,5)No.07-188A-E
WARNING
If you touch the irradiator at high temperatures, serious accident
may be caused.
4.2 Note on cooling lamp

When the lamp starts lighting, start cooling of the lamp after the output of the lamp is
stabilized (lamp stabilization (STBY) signal of electronic ballast). Furthermore, immediately
after the lamp has been intentionally turned OFF or arc has accidentally quenched, be sure to
keep circulating cooling water for at least four minutes at flow rate specified in section 3.2.1.
No cooling water circulation is necessary when the lamp power has been turned OFF by
ignition failure.
4.3 Note on lamp lighting and operation of the shutter
Please control the dimmer and rating the lamp and the movement of the shutter with
remote control by customer’s external signal.
If you set the opening and closing speed of the shutter so fast, irradiator may be broken.
Using the speed controller, and set the shutter speed appropriately. (Please set the
opening or closing speed to more than 0.5 sec)
If the malfunction of operation of the shutter occurs, detach the drive unit cover and check the
movement of the drive gear.
4.4 Note on UV monitor
UV monitor measures light around the lamp electrode. There is not a correlation between the
UV monitor and the UV intensity meter.
Use the value of the UV monitor as an aim to the last.
Please measure the intensity with intensity meter for regularly.
4.5 Note on detecting the glass crack
It is structured to apply pressure to the space that is sandwiched between the quartz glass and
the front panel , it is possible to detect glass breakage due to pressure changes.
Because there is a risk that the quartz glass is damaged, please do not apply pressure more
than necessary in this space. In addition, please do not give a strong shock to the quartz
glass.
4.6 Operation flow
For the operation flow, refer to the attached operation time chart.
6
(22,5)No.07-188A-E
5 Attaching and replacing the lamp, reflector, glass.

5.1 Lamp replacement procedure
1) Detach the spring catches from the side of the irradiator, and then remove the front panel.
Photo 6 Lamp replacement (1)
2) Remove the knurl screws that fix shading plates and remove the shading plates.
Shading
plate
knurl screw
7
(22,5)No.07-188A-E
3) Unscrewed the hexagonal screw nut of circular truncated cone insulator that fixes the lead
lamp (be careful with the falling of washer etc.).
Circular truncated
cone insulator
4) Remove the lead line from circular truncated cone insulator completely.
Lamp lead
8
(22,5)No.07-188A-E
5) Hold up the insulator of lamp end and remove the lamp from the reflector unit.
Insulator
Reflector
unit
6) Attach it with the opposite procedure of attachment.

※After attaching the front panel, please fix the front panel to the irradiator using hex bolts.
※ Caution
When installing the lamp on the reflecting plate unit, please toward the front panel side
lamp sealing portion.
Then, fix the lamp lead line to circular truncated cone insulator.
Sealing portion
Photo 11 High pressure mercury lamp (H016-L22G／H02-L22XG)
9
(22,5)No.07-188A-E
When installing the lamp lead, install it between the upper and lower hexagon nuts and flat
washers on top of the conical stand insulator, and be sure to use a spanner to retain the lower
hexagon nut while tightening and fixing the upper hexagon nut to the specified torque(200 N･cm).
Tighten the hexagon nuts above and below the conical stand insulator by leaving a clearance
between the nuts to prevent contact.
※Please note that tightening the lower hexagon nut when in contact with the other hexagon nut
without retaining it with a spanner may damage the conical stand insulator.
Lamp lead
Hexagon nut,
Leave a clearance spring washer, and
here to prevent the flat washer(upper)
hexagon nuts from
getting into contact Hexagon nut,
and flat washer
(lower)
Lamp
Photo 12 Installing the lamp lead
Upper hexagon nut
Upper spanner (tightening side)
Lamp lead
Lower hexagon nut Lower spanner (fixing side)
Lamp line
(illuminator side)
Conical stand insulator
Figure 1 Installation diagram for lamp lead
10
(22,5)No.07-188A-E
Supplement of lamp replacement
When replacing lamps, be sure to hold the insulator of lamp end.

The configuration of lamp holders is shown in Figure 2.
※When attaching / replacing lamp, reference Figure 2. Be sure to tighten the hexagon nuts to the
specified torque (200 N･cm). Improper torque will result in loosen screw or damage to ceramic
insulators.
※Lamp after installation, please direct the proximity conductor and the sealing portion of the
lamp on the front panel side.
High pressure
Mercury lamp
Sealing portion
(Glass protrusion)
Hex nut
Spring washer
Frat washer
Please attach proximity
conductor to be the
front panel side Hex nut
Circular truncated
cone insulator
Lamp line
(Irradiator side)
Figure 2 Configuration of lamp (H016-L22G／H02-L22XG)holder
11
(22,5)No.07-188A-E
5.2 Reflector replacement procedure

※Please shut off the air of the shutter drive before removing the front panel.
1) Detach the spring catches from the side of the illuminator, and then remove the front panel.
There are a total of six spring catches.
2) Remove the socket head cap screw (special low head : M3×6) retaining each reflector-
retainer and reflector, and then detach the reflector-retainer and reflector. There are total of
eight socket head cap screws, four reflector-retainers and two reflectors.
reflector-retainer
socket head cap screw

(special low head)
reflector
Photo 13 Removing the reflector(1)

3) Place a new reflector on the extruded aluminum mold, press the groove of the
reflector-retainer against the reflector, and then fix it with socket head cap screw (special low
head : M3×6). At that time, pay attention to the orientation of the reflector.
With reference to the schematic diagram, I attach a reflector. Curvature of the reflector is a
ventilation port side the smaller, please on the front panel side towards the curvature is large.
Reflector-retainer
reflector
Extruded aluminum
mold
Photo 14 Removing the reflector (2)
12
(22,5)No.07-188A-E
Figure 3 Schematic diagram about

reflector orientation
Ventiration port side (upper) Small curvature
Large curvature
Front panel side (lower)
4) Install the front panel on the illuminator to complete the reflector replacement procedure.
※Front panel after installation, please fix hexagon socket head cap screw in the front panel
and the irradiator.
※When replacing the reflector with the lamp installed on it, take care not to damage to the
lamp. If there is a risk of lamp damage, remove the lamp and replace the reflector.
13
(22,5)No.07-188A-E
5.3 Procedure of replacement the quartz glass

※Before removing the front panel, please shut off the air off the shutter drive.
※Please work to put it on the air pack the front panel.
※It is dangerous if glass breaks. Please always wear the protective equipment such as gloves then
work.
1) Release all six spring latches which locate on the side of irradiator, and also remove a
hex-head cap screw on back of irradiator body to remove front panel.
2) Remove the spacer C that attached to the glass holding frame.
Spacer C
（Limit dog）
Glass holding frame
Photo 15 Replacement of the quartz glass (1)

3) Remove the cap bolt that hold the glass holding frame, and detach the glass holding frame.
And remove the O-ring(small) is attached to the frame.
Front panel
Glass holding frame

Cap bolt(SPW+W) O-ring(small)
Photo 16, 17 Replacement of the quartz glass (2)
4) Detach the quartz glass, and remove the O-ring from the front panel.
O-ring(small)
Quartz glass O-ring(large)
Photo 18, 19 Replacement of the quartz glass (3)
14
(22,5)No.07-188A-E
5) When installing the quartz glass, please reverse the steps above, paying attention to the
following.
After mounting the front panel, please fix it with the hexagon bolt the front panel fixed part
and illuminator body back.
・Please place the quartz glass clearance of the entire circumference of the quartz glass and so
that the front panel is evenly.
・If you are installing a glass holding frame to the front panel, please note O-ring so as not to
deviate from the O-ring groove. O-ring is not attached properly, it may cause and water
infiltration and pressure change.
・Please make sure that the gap of the entire circumference of the quartz glass and glass
pressing frame has become equally. Also, please make sure that the gap of the entire
circumference of the quartz glass and the front panel has also become equally.
・When installing the front panel to the irradiator, please set up the spacer C of the front panel
and the limit switch of the irradiator to fit the position.
15
(22,5)No.07-188A-E
5.4 Replacement procedure of igniter

※Before the replacement, be sure to turn OFF the power supply.
※And after 10 minutes or more after turning OFF, please perform the work irradiator has cooled
down sufficiently.
1) Remove screws (M4×8,8 pieces) that fix the junction box cover at the top of the
irradiator. Remove the junction box cover.
Junction box cover Screw (M4 × 8 ， 8 pieces) for

fixing the junction box cover.
Photo 20, 21 Igniter replacement ①
2) Remove four lead lines coming from the igniter inside the junction box.
・ Remove the primary lead lines (Line No.4 and Line number V1) that are
connected to the terminal block of the igniter board.
Igniter board
Primary lead line

(Line No.4) Primary lead line
(Line number V1)
Photo 22 Igniter replacement ②
16
(22,5)No.07-188A-E
・Remove the secondary lead lines (Line number L1 and L101) that are connected
to the terminal block attached to the side of the igniter.
Secondary lead line Igniter Secondary lead line

(Line number L1) (Line number L101)
Screw for fixing igniter

(M4×6，2 pieces)
Photo 23 Igniter replacement ③
3) Remove screws (M4×6，2 pieces) that fix the igniter inside the junction box.
Remove the igniter.
4) Place a new igniter. Implement the steps 1) to 3) reversely. This is the end of
replacement.
17
(22,5)No.07-188A-E
6 List of I/O lines

6.1 Irradiator 1.6KW (GSE1.6K01CN3(CE)-003)
6.1.1 Lamp lead
Pin No. Line No.
A L1
B V1
D E1
6.1.2 Control line of the irradiator

Item Pin No. Line No.
Temperature switch A THS1
Irradiator interlock B LTS1
24V C +24V1
0V E COM1
Shutter open F OP1
Shutter close G CL1
6.1.3 UV monitor
Pin No. Line No.
A +24V1
B 0V1
C OUT1
E 0V1
18
(22,5)No.07-188A-E
6.2 Irradiator 2KW (GSE2K01CN1(CE))

6.2.1 Lamp lead
Pin No. Line No.
A L1
B V1
D E1
6.2.2 Control line of the irradiator ･ UV monitor

Item Pin No. Line No.
Temperature switch A THS1
Irradiator interlock B LTS1
24V C +24V1
0V D COM1
Shutter open E OP1
Shutter close F CL1
N +24V1
P 0V1
UV monitor
R OUT1
S 0V1
7 Troubleshooting
Major Failures and Related Repair
Symptom Probable cause Repair
Unspecified power Check whether the specified
Electronic voltage. power is being supplied.
ballast Worn-out or faulty
Replace the electronic ballast.
operation electronic ballast.
The bactericidal error. Improper ambient Set the proper ambient
lamp remains off. temperature. temperature.
Improperly mounted Mount the bactericidal
bactericidal lamp. lamp properly.
Worn-out or faulty
Replace the bactericidal lamp.
bactericidal lamp.
19
(22,5)No.07-188A-E
8 Maintenance parts of irradiator

Quantity Service Recommendation
No. Name Type exchange time
Notes
used Life
There is a
Difference
2,500 hours depending
H016-L22G Service life setting to which on the use
1 Lamp 1
H02-L22XG general use condition of conditions
filling machine is added such as
blinking
frequency
2 Light reflector KT-P-37397 2 5,000 hours
Follow a stabilizer, but we

Assembly drawing recommend exchange of
3 KC-AP-34986 1
of igniter trance every two or three years in
－
the environment where an
irradiation device is affected
BE16/20HD by the humidity.
4 Igniter board 1
-IGN-01R
Without the stubborn stains or damage,
5 Quartz glass KC-P-357933 1
usually 7 to 8 years are available.
6 O ring(Small) KC-P-441254 2 Replacement when the waterproof ness of
the front panel deteriorates or the glass is
7 O ring(Large) KC-P-441255 1 replaced with new one
8 Waterproof packing KC-P-357932*1 1 Replacement is recommended when the

waterproof ness between the front panel and
the main body of the irradiator deteriorated,
Packing for or remarkable crazing and deterioration are
9 KC-P-362255 1 seen.
JB cover
Packing for （For the replacement, please Contact our
10 KC-P-443356 1 sales representative）
plumbing cover A
Packing for
11 KC-P-443357 1
drive unit cover
CDRB2BW40
12 Rotary actuator 1 3 years －
-270SZ-S7P
R12 No.4641
13 X-ring for rotation 8 5 years －
FKM D0280
Sealed miniature
14 D2VW-5L3-1HS 1 －
basic switch
3 ～5years
Conical stand
15 － 2 －
insulator
20
(22,5)No.07-188A-E
15 2 1
13 13
14
Photo 24 Inside of the Irradiator
6 5
7 8
Photo 25 Front panel ①
Photo 26 Front panel ②
21
(22,5)No.07-188A-E
Photo 27 Inside of the junction box
10
12
Photo 28 Plumbing cover A opened
11
Photo 29 Drive unit cover detached
22
(22,5)No.07-188A-E
9 Checklist of regular check

Place to be Point to be Content of Industrial Judgment
Cycle
checked checked operation tools used standard
Operation of Checked by Normal

-
When shutter control board operation
starting Irradiator
workday
Normal
Dimmer / rating Same as above -
operation
Cleaning(with
the surface with
External surface Gauze and
gauze dampened No stain
Per one of front glass alcohol etc.
Irradiator moderately
week
Lightly
Lamp lead line Securing
Spanner Not loosened
terminal area additionally
Replacing
Lamp Replacement Spanner lamp with a
New one
Per 2500H Irradiator No stain or
Gauze and Evaporated
Light reflector Check with eye
alcohol etc. film is not
deteriorated
10 Guarantee period
1) The Guarantee period of this equipment is one year after delivery. When the failure occurs
because of our fault, we will repair it or replace it with a new one without charge.
2) However, the following cases do not apply to the range of guarantee. We will repair it or
replace it with a new one with extra charge.
：Failure or damage after the warranty period.
：Failure caused by abnormal use or storage.
：Failure or damage caused by fire, natural disaster, casualty of earth shock, or accidental
force.
：Failure or damage caused by repair and remodeling.
11 Contact
Iwasaki Electric Co., Ltd Optical Application Sales Department
Sales Engineering Division
Address : Fukiage office, 3361, Shimooshi, Kounosu-shi, Saitama, Japan, 369-0113
Tel : +81-48-598-5884 / FAX : +81-48-598-5883
EB Application Sales Division
Address : Bakurocho first building, 1-4-16, Bakurocho, Nihonnbashi, Chuo-ku, Tokyo,
Japan, 103-0002
Tel : +81-3-6861-8920 / FAX : +81-3-5847-8644
23

(Reference) S-PS140UC #5016 Maintenance Manual M144-7294

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Copy No.

Original Maintenance Manual

Model No. . . . . . . . . . . . . . . . . . : S- PS140UC

Publisher . . . . . . . . . . . . . . . . . . : Shikoku Kakoki Co., LTD.

Copyright 2015 SHIKOKU KAKOKI CO., LTD.

0.1 EC DECLARATION OF CONFORMITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 3

1.1 Check items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 3

M144- 7294 Issue 01 III

1.2 Emergency stop system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 16

IV M144- 7294 Issue 01

2.4.1 Before check & replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 47

M144- 7294 Issue 01 V

3.4.5 Loader pusher position - Check & Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 38

VI M144- 7294 Issue 01

M144- 7294 Issue 01 VII

6.6 Discharge conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 32

VIII M144- 7294 Issue 01

8.2.8 Suck back membrane - Check & Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 43

M144- 7294 Issue 01 IX

10 CAP APPLICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 1

10.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10- 3

11 PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 1

11.1 Pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 3

X M144- 7294 Issue 01

11.3.5 Pneumatic diagram E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11- 22

12 COOLING WATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 1

12.1 Cooling water diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12- 4

13.1 Manual greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 3

M144- 7294 Issue 01 XI

13.5.2 Oil for mandrel index unit - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13- 35

14 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 1

14.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14- 3

15.1 Incorrect carton feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 3

XII M144- 7294 Issue 01

15.3.1 Unevenly heated carton bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15- 7

16 MISCELLANEOUS EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 1

16.1 Main motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 4

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16.7 Air cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16- 22

17.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17- 3

1. Document No. : M214- 055- 109

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Fig. 0-1. Cartons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0- 6

Fig. 1-1. Danger of fall hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 7

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Fig. 1-4. Warning of mechanical hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 8

XVI M144- 7294 Issue 01

Fig. 1-55. Fixed covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1- 38

Fig. 2-1. Noise emission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 15

M144- 7294 Issue 01 XVII

Fig. 2-28. Solenoid valves and pneumatic parts arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2- 56

Fig. 3-1. Carton feeder (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3- 4

Fig. 4-1. Bottom former . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 4

XVIII M144- 7294 Issue 01

Fig. 4-12. Carton positioning bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4- 20

Fig. 5-1. Unloader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5- 4

Fig. 6-1. Conveyor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 4

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Fig. 6-12. Adjustment for 250ml . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6- 20

Fig. 7-1. Carton decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 4

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Fig. 7-38. Hydrogen peroxide drying heater (2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7- 41

Fig. 8-1. Product filling (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8- 4

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