RM 3093011 0102

RM
Rebuilding Manual
OK HeliCap2 23 Speed
3093009-0100
CAP30 Speed
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WARNING
Read and follow all safety precaution instructions throughout this
manual and on safety signs attached to this equipment. 
Failure to follow all safety precaution instructions could result in death or
serious injury.
The rebuilding must only be performed by personnel mandated by Tetra Pak.
Doc. No. RM-3093011-0102

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Copyright © 2012 Tetra Pak Group
All rights reserved. No part of this document may be reproduced or copied in any form or by any means
without written permission from Tetra Pak Packaging Solutions.
and all Tetra Pak products are trademarks belonging to the Tetra Pak Group.
The content of this manual is in accordance with the design and construction of the machine or
equipment at the time of publishing. Tetra Pak reserves the right to introduce design modifications
without prior notice.
The English language version of this document contains the original instructions. All other language
versions are translations of the original instructions.
This document was produced by:
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy
Additional copies can be ordered from Tetra Pak. When ordering additional copies, always provide the
document number.
Doc. No. RM-3093011-0102
Issue 2012-08
1 Introduction
2 Rebuilding Information
3 Rebuilding Instructions
RM
Rebuilding Manual
4 Enclosed
Documentation
OK HeliCap2 23 Speed
3093009-0100
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Machine or equipment configurations that

this manual is valid for are described on
the next page.
Doc. No. RM-3093011-0102
Issue 2012-08
Tetra Pak Packaging Solutions

Valid for:
Name Drawing Specification Additional Information
and Development Step
CAP30/Speed 662850-0100 Valid for the following volumes, Package Types and
Caps:
TBA 1000 S SlimCap 1000
Valid for all the T-Orders
CAP30/Speed 662850-0200 Valid for the following volumes, Package Types and
Caps:
TBA 1000 S SlimCap 1000
Valid for all the T-Orders
Mandatory Rebuilding Kit Requirements:

RK No. RK Name Notes
OK 2930224-0100 OK Positioning Device Speed
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UK 3117855-0100 UK Mach. Adapt. for HeliCap2 23 Speed
MKC 3132890-0100 MKC Hardware&Software Upgrade Jan11
1 Introduction
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Doc. No. RM-3093011-0102 1 - 1 (12)

1 Introduction
About the Introduction Chapter

The Introduction chapter contains basic information about this manual and
the corresponding Tetra Pak rebuilding kit.
1 - 2 (12) Doc. No. RM-3093011-0102

1 Introduction Table of Contents
Personnel Requirement . . . . . . . . . . . . . . . . . . . 1 - 5
Abbreviations and Terminology . . . . . . . . . . . . . 1 - 7

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Safety Messages Description . . . . . . . . . . . . . . . . 1 - 8
Reference Documents. . . . . . . . . . . . . . . . . . . . . 1 - 9
Information About this Manual. . . . . . . . . . . . . 1 - 10

How to Use the Rebuilding Manual . . . . . . . . . . 1 - 10
Layout and Numbering . . . . . . . . . . . . . . . . . . . . 1 - 10
Information About the Rebuilding Kit . . . . . . . . 1 - 11

Intended Use of the Rebuilding Kit . . . . . . . . . . 1 - 11
Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Support and Feedback . . . . . . . . . . . . . . . . . . . . 1 - 11
Doc. No. RM-3093011-0102 1 - 3 (12)

1 Introduction
This page intentionally left blank
1 - 4 (12) Doc. No. RM-3093011-0102

1 Introduction Personnel Requirement
Personnel Requirement
The sentences below are translations of the text “The rebuilding must only be
performed by personnel mandated by Tetra Pak” located on the front page of
this manual.
BG
Реконструкцията трябва да се извършва само от персонал,
упълномощен от Tetra Pak.
CS
Rekonstrukce musí být prováděna pouze pracovníky pověřenými firmou
Tetra Pak.
DA
Ombygningen må kun udføres af personale bemyndiget af Tetra Pak.
NL
Het reviseren mag uitsluitend door Tetra Pak erkend personeel worden
uitgevoerd.
ET
Ümberehitust tohivad teostada ainult Tetra Paki poolt volitatud töötajad.
FI
Muunnostyön saa tehdä vain valtuutettu Tetra Pak -asentaja.
FR
La conversion ne doit être effectuée que par du personnel agréé par
Tetra Pak.
DE
Die Wiedererrichtung darf nur von Personal ausgeführt werden, dass von
Tetra Pak beauftragt wurde.
EL
Η ανακατασκευή πρέπει να πραγματοποιείται μόνον από άτομα που είναι
εξουσιοδοτημένα από την Tetra Pak.
HU
A felújítást kizárólag a Tetra Pak által megbízott személyzet végezheti.
IT
La modifica deve essere effettuata solo da personale autorizzato da
Tetra Pak.
LV
Pārbūvi jāveic Tetra Pak pilnvarotam personālam.
LT
Atstatymą gali atlikti tik Tetra Pak paskirtas personalas.
PL
Przebudowę może wykonać tylko personel upoważniony przez Tetra Pak.
(Cont'd)
Doc. No. RM-3093011-0102 1 - 5 (12)

Personnel Requirement 1 Introduction
(Cont'd)
PT
A remodelação só deve ser feita por pessoal mandado pela Tetra Pak.
RO
Reconstrucţia trebuie realizată numai de către personal mandatat de
Tetra Pak.
SL
Predelavo lahko izvede le osebje, ki je v Tetra Pak-u odgovorno za
vzdrževanje.
SK
Prestavba musí byť vykonávaná iba pracovníkmi poverenými firmou
Tetra Pak.
ES
Solamente personal con mandato de Tetra Pak debe llevar a cabo la
reconstrucción.
SV
Ombyggnaden får endast utföras av personal som bemyndigats av Tetra Pak.
IS
Endursmíð má aðeins vera í höndum starfsmanna sem Tetra Pak hefur
viðurkennt.
NO (Bokmål)
Ombyggingen skal kun utføres av personer som er oppnevnt av Tetra Pak.
NO (Nynorsk)
Ombyggingen skal kun utføres av personer som er oppnevnt av Tetra Pak.
1 - 6 (12) Doc. No. RM-3093011-0102

1 Introduction Abbreviations and Terminology
Abbreviations and Terminology

Abbreviation/ Meaning Translation
Terminology
ASU Automatic Splicing Unit
B Base (package shape)
CIP Cleaning In Place
DE Distribution Equipment
DIMC Direct Injection Moulded
Concept
EM Electrical Manual
FSE Field Service Engineer
HI Headspace by gas Injection
ICU Integrated Cleaning Unit
IH Induction Heating
LED Light Emitting Diode
LH Left Hand
LS Longitudinal Seal(ing)
MB Master Batch
min Minimum
max Maximum
MKC Mandatory Kit Corrective
MKS Mandatory Kit Human and
Product Safety
MM Maintenance Manual
OK Optional Kit
OE Optional Equipment
OM Operation Manual
PE Polyethylene
PM Packaging Material
PT PullTab
RH Right Hand
RK Rebuilding Kit
RM Rebuilding Manual
S Slim (package shape)
SA Strip Applicator
SPC Spare Parts Catalogue
Sq Square (package shape)
TBA Tetra Brik Aseptic
TMCC Tetra Pak Multi-purpose
Compact Controller
TPOP Tetra Pak Operator Panel
TS Transversal Sealing
UK Upgrade Kit
UP Update Pages
Doc. No. RM-3093011-0102 1 - 7 (12)

Safety Precautions 1 Introduction
Safety Precautions
Before starting any work on the machine, it is compulsory to read the Safety
Precautions chapter in any of the existing manuals of the machine.
Safety Messages Description

A safety message is always accompanied by a safety alert symbol and a
signal word.
The safety alert symbol is used to alert about potential personal injury
hazards. To avoid hazards, obey all safety messages that follow this symbol.
The following safety alert symbols and signal words are used in this manual
to inform the user of hazards.
Danger indicates an imminently hazardous situation

DANGER which, if not avoided, will result in death or serious injury.
Warning indicates a potentially hazardous situation

which, if not avoided, could result in death or serious
WARNING
injury.
Caution indicates a potentially hazardous situation
which, if not avoided, may result in minor or moderate
CAUTION injury. It may also be used to alert against unsafe
practices.
CAUTION Caution without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided,
may result in property damage.
1 - 8 (12) Doc. No. RM-3093011-0102

1 Introduction Reference Documents
Reference Documents
• UP-3260217-0101
Doc. No. RM-3093011-0102 1 - 9 (12)

Information About this Manual 1 Introduction
Information About this Manual

Tetra Pak recommends reading all delivered manuals carefully. Make sure
that the delivered manuals are available to the personnel responsible for
installing the rebuilding kit onto the machine.
Tetra Pak will not be held responsible for any damage to the delivered
rebuilding kit or to the machine caused by not following the instructions in
this manual.
The Rebuilding Manual is used only for the installation of the rebuilding kit
and for updating the machine's existing delivered manuals. The Rebuilding
Manual is not intended to form part of the machine’s existing delivered
manuals.
If a Declaration of Incorporation is delivered with the rebuilding kit, the
Rebuilding Manual must be archived as part of the Technical File for the
machine.
How to Use the Rebuilding Manual

The content of the Rebuilding Manual is divided into the following chapters:
• The Rebuilding Information chapter provides information and
instructions necessary prior to the installation of the rebuilding kit.
• The Rebuilding Instructions chapter provides the instructions for
installing the rebuilding kit and updating the machine manuals.
• The Enclosed Documentation chapter contains individual documents
needed during and after the installation of the rebuilding kit. Instructions
for these documents are described in the Rebuilding Instructions chapter.
After the rebuilding has been completed, recycle the Rebuilding Manual
according to local practices and regulations. If there is an UP associated with
the Rebuilding Manual containing update pages, recycle the UP according to
local practices and regulations after updating the machine manuals.
Layout and Numbering

For information about page layout and numbering, consult the Introduction
chapter of the machine’s existing Maintenance Manual.
1 - 10 (12) Doc. No. RM-3093011-0102

1 Introduction Information About the Rebuilding Kit
Information About the Rebuilding Kit

Intended Use of the Rebuilding Kit
The intended use of this Tetra Pak rebuilding kit is to upgrade CAP 30 Speed
machines to run with HeliCap2 23.
All other use is prohibited. Tetra Pak will not be held responsible for injury
or damage if the rebuilding kit is used for any other purpose.
Manufacturer
This Tetra Pak rebuilding kit has been manufactured by:
Tetra Pak Packaging Solutions
Via Delfini 1
41123 Modena
Italy
Support and Feedback

For assistance when operating this equipment, or other inquiries, comments,
or suggestions, pose the questions or give feedback on the E-Liaison home
page at http://e-liaison.tetrapak.com. If access to the Tetra Pak intranet is not
available, contact the nearest Tetra Pak representative.
Doc. No. RM-3093011-0102 1 - 11 (12)

Information About the Rebuilding Kit 1 Introduction
1 - 12 (12) Doc. No. RM-3093011-0102

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Doc. No. RM-3093011-0102 2 - 1 (14)

About the Rebuilding Information Chapter

The Rebuilding Information chapter contains information necessary prior to
the installation of the rebuilding kit.
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2 - 2 (14) Doc. No. RM-3093011-0102

2 Rebuilding Information Table of Contents
2.1 Functional Description . . . . . . . . . . . . . . . . . . . . 2 - 5
2.2 Installation Skills and Time. . . . . . . . . . . . . . . . 2 - 12

2.3 Preparations. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
2.3.1 Site Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 13
2.3.2 Rebuilding Kit Inspection . . . . . . . . . . . . . . . . . . 2 - 13
2.3.3 Special Tools and Auxiliary Equipment . . . . . . . 2 - 13
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2 Rebuilding Information 2.1 Functional Description
2.1 Functional Description

This rebuilding kit has been introduced to upgrade CAP 30 Speed machines
to run with HeliCap2 23.
The rebuilding kit consists of the following new components:
Push Down
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(Cont'd)
Doc. No. RM-3093011-0102 2 - 5 (14)

2.1 Functional Description 2 Rebuilding Information
(Cont'd)
Hotmelt Applicator
• Nozzle (1)
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1
1 1 Nozzle
(Cont'd)
2 - 6 (14) Doc. No. RM-3093011-0102

(Cont'd)
Cap Sorter
• Sections (1)
• Brush holder (2)
• Shute (3)
1
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1 Section
2 Brush holder
3 Shute
(Cont'd)
Doc. No. RM-3093011-0102 2 - 7 (14)

(Cont'd)
Machine Body
• Heating chamber (1)
• Flange seal (2)
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1 Heating chamber
2 Flange seal
(Cont'd)
2 - 8 (14) Doc. No. RM-3093011-0102

(Cont'd)
Cap Holder
• Cap holder (1)
1 Cap holder
(Cont'd)
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(Cont'd)
Cap Sequencer
• Guide (1)
• Guide rail (2)
• Clamp (3)
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3
1 Guide
2 Guide rail
3 Clamp
(Cont'd)
2 - 10 (14) Doc. No. RM-3093011-0102

(Cont'd)
Cap Conveyor
• Guide rail (1)
1
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1 Guide rail
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2.2 Installation Skills and Time 2 Rebuilding Information
2.2 Installation Skills and Time

The installation skills (types and levels) and installation time (in man hours)
are specified in the Technical Bulletin for this rebuilding kit.
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2 - 12 (14) Doc. No. RM-3093011-0102

2 Rebuilding Information 2.3 Preparations
2.3 Preparations
2.3.1 Site Preparation
Before starting any rebuilding work on the machine:
• Make sure that the machine is available and that the rebuilding work can
be completed without interruption.
• Establish an adequate safe working area around the machine. Make sure
that no items stand in the installation area.
2.3.2 Rebuilding Kit Inspection

Before starting any rebuilding work on the machine:
• Make sure that the rebuilding kit is correct for the specific machine.
• Make sure that all the parts listed in the SPC included with this
Rebuilding Kit have been delivered.
If any part of the rebuilding kit is not present, create a claim notification in
SAP/R3 using transaction code IW51 (Create Service Notification).
If any damage to the crate contents has occurred during transportation,
create a discrepancy notification in SAP/R3 using the same transaction code,
TechPub_2614345_0110 - 01_RM3093011_01en.fm
IW51.
Take photographs of the damage and enclose the photographs with the
discrepancy notification.
2.3.3 Special Tools and Auxiliary Equipment

Before starting any rebuilding work on the machine, make sure that the
following special tools or equipment are available.
Tool/Equipment Notes
Setting tool Lens TP No. 90459-4931
valid for TBA 1000 S HeliCap2 23
Setting tool Template TP No. 3047353-0000
valid for TBA 1000 S HeliCap2 23
Setting tool TP No. 3077734-0000
Setting tool (Digital) Caliper
Doc. No. RM-3093011-0102 2 - 13 (14)

2.3 Preparations 2 Rebuilding Information
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2 - 14 (14) Doc. No. RM-3093011-0102

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Doc. No. RM-3093011-0102 3 - 1 (96)

About the Rebuilding Instructions Chapter

This chapter describes how to install this rebuilding kit and how to update
the documentation.
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3 - 2 (96) Doc. No. RM-3093011-0102

3 Rebuilding Instructions Table of Contents
3.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . 3 - 5

3.1.1 Push Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
3.1.1-1 Pressure Finger and Spring- Change . . . . . . . . . . 3 - 5
3.1.2 Hotmelt Applicator . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
3.1.2-1 Hotmelt Unit - Piston Pump Conversion . . . . . . . 3 - 6
3.1.2-2 Nozzle - Change . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 12
3.1.2-3 Hotmelt Gun - Set . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
3.1.3 Cap Sorter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
3.1.3-1 Section - Change . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
3.1.3-2 Cap Sorter - Change Discharger . . . . . . . . . . . . . 3 - 25
3.1.3-3 Air Injectors - Installation . . . . . . . . . . . . . . . . . 3 - 31
3.1.3-4 Air Injector - Add New Position . . . . . . . . . . . . 3 - 38
3.1.3-5 Feeder - Set Cam Positions . . . . . . . . . . . . . . . . 3 - 39
3.1.3-6 Feeder - Set Sorter Speeds . . . . . . . . . . . . . . . . . 3 - 40
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3.1.3-7 Cap Sorter - Set X Position . . . . . . . . . . . . . . . . 3 - 42

3.1.3-8 Feeder - Set Cap Level . . . . . . . . . . . . . . . . . . . . 3 - 44
3.1.3-9 Cap Sorter - Remove the Sensor . . . . . . . . . . . . 3 - 45
3.1.4 Machine Body. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 46
3.1.4-1 . . . . Heating Chamber and Flange seal - Change 3 - 46
3.1.5 Applicator Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 48
3.1.5-1 Cap Holder - Change . . . . . . . . . . . . . . . . . . . . . 3 - 48
3.1.6 Cap Sequencer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 49
3.1.6-1 Guide Rail - Change . . . . . . . . . . . . . . . . . . . . . . 3 - 49
3.1.6-2 Cap Line - Set Spring Gap . . . . . . . . . . . . . . . . . 3 - 51
3.1.6-3 Clamp Unit - Set Spring and Sensor . . . . . . . . . 3 - 52
3.1.7 Cap Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 55
3.1.7-1 Guide Rail - Change . . . . . . . . . . . . . . . . . . . . . 3 - 55
3.1.8 Special Setting for HeliCap . . . . . . . . . . . . . . . . . 3 - 57
3.1.8-1 Push Down - Set X, Y, Z and Zero . . . . . . . . . . . 3 - 57
3.1.8-2 Cams - Set Picking and Gripper Cams . . . . . . . . 3 - 66
3.1.8-3 Cams - Set Applicator and Release Cams . . . . . 3 - 69
3.1.9 Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . 3 - 76
Doc. No. RM-3093011-0102 3 - 3 (96)

3.1.9-1 Sensor Positioning . . . . . . . . . . . . . . . . . . . . . . . 3 - 76
3.2 Electrical Installation . . . . . . . . . . . . . . . . . . . . . 3 - 77

3.2.1 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
3.3 Final Installation Checks . . . . . . . . . . . . . . . . . . 3 - 78

3.3.1 Machine Checks and Settings . . . . . . . . . . . . . . 3 - 78
3.3.1-1 Check Cap Position - Opening Performance . . . 3 - 78
3.3.1-2 Hotmelt Gun - Check . . . . . . . . . . . . . . . . . . . . . 3 - 85
3.3.2 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 88
3.3.2-1 Touch Screen - Login As Service Technician . . 3 - 88
3.3.2-2 Touch Screen - Saving Recipe Settings . . . . . . . 3 - 92
3.4 Updating the Machine Documentation. . . . . . . 3 - 93

3.4.1 Schemes and Diagrams . . . . . . . . . . . . . . . . . . . 3 - 93
3.4.2 Delivered Design Label. . . . . . . . . . . . . . . . . . . . 3 - 93
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3.4.3 Declaration for Machinery Part(s) . . . . . . . . . . . 3 - 93
3.4.4 Obsolete and Recommended Spare Parts . . . . 3 - 93
3.5 Updating the Manuals . . . . . . . . . . . . . . . . . . . . 3 - 94

3.5.1 Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . 3 - 94
3.5.2 Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94
3.5.3 Electrical Manual . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94
3.5.4 Spare Parts Catalogue . . . . . . . . . . . . . . . . . . . . 3 - 95
3.5.5 Technical Manual. . . . . . . . . . . . . . . . . . . . . . . . . 3 - 95
3.5.6 Update Log Pages . . . . . . . . . . . . . . . . . . . . . . . . 3 - 95
3.5.7 Recycling of Replaced Manuals. . . . . . . . . . . . . 3 - 95
3 - 4 (96) Doc. No. RM-3093011-0102

3 Rebuilding Instructions 3.1 Mechanical Installation
3.1 Mechanical Installation

3.1.1 Push Down
3.1.1-1 Pressure Finger and Spring- Change
Machine Status Mains Power OFF
SPC Reference 2751667-0100
WARNING
Risk of burns.
Nearby components may be hot.
a) Remove the screw (1), the washer (2) and the arm (3), collecting the
sleeve (4) and the spring (5).
b) Change the arm (3) and spring (5) the bushings (6).
c) Assemble in the reverse order with the new parts.
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1
6 1 Screw
2 Washer
2
3 Arm
5 4 6
4 Sleeve
5 Spring
6 Bushing
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3.1 Mechanical Installation 3 Rebuilding Instructions
3.1.2 Hotmelt Applicator

3.1.2-1 Hotmelt Unit - Piston Pump Conversion

Air OFF
Disassembly
a) Step the machine to PREHEATING.
b) Set the temperature of the hotmelt unit at 90÷100°C, see the MM 6.5.1-5
Set Tank, Hose and Gun Temperatures on page 6-46.
c) Remove the screws (1) and the cover (2).
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2 1
1 Screw
2 Cover
(Cont'd)
3 - 6 (96) Doc. No. RM-3093011-0102

(Cont'd)
d) Disconnect the hose (3) from the pump (4).
e) Loosen and remove the screw (5).
f) Loosen the screws (6) and remove the cylinder head (7).
g) Remove the cylinder (8).
6
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4
8
3 Hose
4 Pump
3 5 Screw
6 Screw
7 Cylinder head
8 Cylinder
(Cont'd)
Doc. No. RM-3093011-0102 3 - 7 (96)

(Cont'd)
Pump Disassembly
a) Loosen the nut (1) and remove the piston cups (2) the piston cup
washers (3) and the piston seal washer (4).
b) Change the o-rings (5) and (6).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
2
6 1 Nut
2 Piston cup
3 Piston cup washer
4 Piston seal washer
5 O-ring
6 O-ring
(Cont'd)
3 - 8 (96) Doc. No. RM-3093011-0102

(Cont'd)
Piston Assembly
a) Install the cylinder (1).
b) On the workbench, put in shape the new piston cups (2) and (3) into the
6:1 ratio piston cup sleeve (4) by means of the new piston cup
washers (5) and (6).
Note! Insert the piston cup (2) and the piston cup washer (5) from the
bottom and the piston cup (3) and the piston cup washer (6) from the top of
the piston cup sleeve (4).
3
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1 Cylinder
2 Piston cup
1 3 Piston cup
4 Sleeve
5 Piston cup washer
6 Piston cup washer
(Cont'd)
Doc. No. RM-3093011-0102 3 - 9 (96)

(Cont'd)
Pump Assembly
a) Install the o-rings (1) and (2) onto the piston cup sleeve (3).
b) Install the piston cups (4) and (5), the piston seal washer (6) and the
piston cup washers (7) and (8) into the 6:1 ratio piston cup sleeve (3).
c) Install the 6:1 ratio piston cup sleeve (3) and tighten the nut (9).
d) Install the cylinder head (10) and tighten the screws (11).
e) Install the o-rings (12) and (13).
11
10
12
9
8
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
5
2
6
3 1 O-ring
2 O-ring
3 Piston cup sleeve
4 Piston cup
4
5 Piston cup
6 Piston seal washer
7 7 Piston cup washer
8 Piston cup washer
9 Nut
13 10 Cylinder head
11 Screw
12 O-ring
13 O-ring
3 - 10 (96) Doc. No. RM-3093011-0102

Assembly Cover
a) Install the cover (1) and tighten the screws (2).
b) Attach the sign (3) on the cover.
1 2 3
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Cover
2 Screw
Doc. No. RM-3093011-0102 3 - 11 (96)

3.1.2-2 Nozzle - Change

Air OFF
a) Loosen the two levers (1) and the cover (2).

b) Remove the three nozzles (3) and replace with the nozzles in the cap size
kit.
c) Assemble in the reverse order with the new parts.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
2
1 Lever
2 Cover
3 Nozzle
3
3
3 - 12 (96) Doc. No. RM-3093011-0102

3.1.2-3 Hotmelt Gun - Set

Machine Status PREPARATION
Set Nozzle Height

Note! Valid for machines from T Order: T75722/00001 to 75722/00010.
WARNING
Risk of burns
These parts and others close by may be hot.
a) Remove the cover, see the MM 4.3.1-2 Hotmelt Gun - Remove and
Install Cover.
b) Release the four screws (1) and add spacers (2) until within 2 mm of the
distance A. For distance A see, 13.1-1 Pressures/Adhesive/Temperature/
Nozzle.
c) Peel off the layers from the shim (3) until distance A is obtained between
the nozzle (4) and the cap (5).
d) Tighten the screws (1).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
2
4
5
A
1 Screw
2 Spacer
3 Shim
4 Nozzle
5 Cap
(Cont'd)
Doc. No. RM-3093011-0102 3 - 13 (96)

(Cont'd)
Hotmelt Gun Applicator Setting
Note! Valid for machines from T Order:T75722/00011.
Note! The hotmelt equipment must be at operating temperature. Check the
MM for the temperature of different glues.
Note! Do not let adhesive go on the machine parts.
WARNING
Risk of burns.
Hot adhesive. Wear safety glasses, protective gloves and other protective
clothing to avoid injuries from hot adhesive.
a) Remove the cap sequencer guides see, 8.1.1-1 Guide - Removal and
Installation.
b) Remove the cover, see the MM 4.3.1-2 Hotmelt Gun - Remove and
Install Cover.
CAUTION
The nozzles are delicate.
Handle the nozzles (1) with care to avoid any damage to their top (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
c) Loosen and remove the nozzles (1).
1
1
1 Nozzle
2 Top
(Cont'd)
3 - 14 (96) Doc. No. RM-3093011-0102

(Cont'd)
d) Check the guns (3) are touching their two reference pins (4).
e) Install the template (5) onto the inner cap guide mounting.
3 5
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 Gun
4 Pin
5 Template
(Cont'd)
Doc. No. RM-3093011-0102 3 - 15 (96)

(Cont'd)
f) Using the template set the guns Z alignment to the distance A.
Cap Type Distance A mm

Streamcap TBD
Slimcap TBD
Helicap2 23 TBD
Helicap27 12, mm
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A
(Cont'd)
3 - 16 (96) Doc. No. RM-3093011-0102

(Cont'd)
g) If the distance is not correct adjust it by loosening the two fixing
screws (6) and adjusting the two Z regulating screws (7).
h) Tighten the screws (6) when the correct distance is achieved.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
7 6 7
6 Screw
7 Screw
(Cont'd)
Doc. No. RM-3093011-0102 3 - 17 (96)

(Cont'd)
i) Loosen the two fixing screws (8) just a little in the outer guns only.
j) Move the guns (3) into the “Y setting slots” (9) of the template (5).
k) Let the loosened guns adjust them selves inside the template slot.
l) Tighten the fixing screws (8) of the guns.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 3
5 8
9
3 Gun
5 Template
8 Screw
9 Slots
(Cont'd)
3 - 18 (96) Doc. No. RM-3093011-0102

(Cont'd)
m) Loosen the screws (10)
n) Move the guns inside the templates “X setting slots”.
o) Let the gun module adjust itself in reference to the template (5).
p) Tighten the four screws (10).
Note! Check that the gun group can move freely inside the template (5).
q) Remove the template (5).
10 10
TechPub_2614345_0110 - 02_RM3093011_01en.fm
10
5 Template
10 Screw
(Cont'd)
Doc. No. RM-3093011-0102 3 - 19 (96)

(Cont'd)
Note! Do Not adjust the centre gun (11) when fine setting.
r) To move the left hand gun:
– to the left, release the lock nuts (12) and turn the screws (13) until
they touch the gun, then lock the nut (12). Loosen the screws (8) and
place your feeler gauge with the distance required between the
screw (13) and the gun. Tighten the screws (8) making sure that the
gun is touching the feeler gauge.
– to the right, loosen the screws (13) and place your feeler gauge with
the distance required between the screw (13) and the gun. Move the
screw (13) until it touches the feeler gauge and lock the nut (12).
Release the screw (8) and move the gun to the screw (13), tighten the
screws (8).
s) To move the right hand gun:
– to the left, loosen the screws (13) and place your feeler gauge with the
distance required between the screw (13) and the gun, then lock the
nut (12). Release the screws (8) and move the gun until it touches the
screw (13).
– to the right, loosen the screws (8) and place your feeler gauge with the
TechPub_2614345_0110 - 02_RM3093011_01en.fm
distance required between the screw (13) and the gun. Tighten the
screws (8) making sure that the gun is touching the feeler gauge.
Note! .Move the screws (13) away from the gun before going to production.
.
11
8 8
8 Screw
12 13 12 11 Gun
12 Nut
13 Screw
(Cont'd)
3 - 20 (96) Doc. No. RM-3093011-0102

(Cont'd)
t) Install the three nozzles (1).
u) Install the cap guides see, 8.1.1-1 Guide - Removal and Installation.
v) Install the cover, see the MM 4.3.1-2 Hotmelt Gun - Remove and Install
Cover.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Nozzle
Doc. No. RM-3093011-0102 3 - 21 (96)

3.1.3 Cap Sorter

SPC Reference 662804-0100; 662804-0200
3.1.3-1 Section - Change

Air OFF
SPC Reference 662804-0100; 662804-0200
WARNING
The cap sorter is high.
These components are in a high position, be sure to use suitable equipment
to reach them.
a) Remove the protection (1).
b) Loosen the nut (2) to manually rotate the cap sorter.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
2
1 Protection
2 Nut
(Cont'd)
3 - 22 (96) Doc. No. RM-3093011-0102

(Cont'd)
c) Remove the eight screws (3) and the four sections (4).
Note! Rotate the feeder (5) to access to the sections (4).
d) Assemble in the reverse order with the new sections (4).
4
3
5
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 Screw
4 Section
5 Feeder
(Cont'd)
Doc. No. RM-3093011-0102 3 - 23 (96)

(Cont'd)
e) Tighten the nut (2).
f) Install the protection (1).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
2
1
1 Protection
2 Nut
3 - 24 (96) Doc. No. RM-3093011-0102

3.1.3-2 Cap Sorter - Change Discharger

Air OFF
SPC Reference 662804-0100; 662804-0200
Cap Sorter Discharger Remove

a) Loosen the screws (1) and remove the discharger (2).
b) Remove the pins (3), if present.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3
1
2
1 Screw
2 Discharger
3 Pin
(Cont'd)
Doc. No. RM-3093011-0102 3 - 25 (96)

(Cont'd)
Change Guide
a) Remove the screws (1) and the guide (2).
b) Assemble in the reverse order with the new guide (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
2 1 1 Screw
2 Guide
(Cont'd)
3 - 26 (96) Doc. No. RM-3093011-0102

(Cont'd)
Cap Sorter Discharger Installation
a) Loosen without remove the screws (1) and (2).
b) Put in position the discharger (3).
c) Push downward the discharger (3) and tighten the screws (4).
d) Tighten the screws (1) and (2).
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 4
2
2
1 Screw
2 Screw
3 Discharger
4 Screw
(Cont'd)
Doc. No. RM-3093011-0102 3 - 27 (96)

(Cont'd)
Note! The procedure is correct if the discharger (3) is the closest to the
reference surface (5).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
5
3 Discharger
5 Surface
(Cont'd)
3 - 28 (96) Doc. No. RM-3093011-0102

(Cont'd)
Cap Sorter Discharger Lock
a) Lift the locking handles (1) and (2) up to lock the discharger (3) in the
correct position.
Note! Check that the locking handles keep pushed the discharger (3) in the
correct position. If the discharger (3) changes its position after the
handles (1) and (2) have been locked, proceed with the instruction b).
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Handle
2 Handle
3 Discharger
(Cont'd)
Doc. No. RM-3093011-0102 3 - 29 (96)

(Cont'd)
b) For each of the locking handles, remove the cap (4), if present.
c) Tighten the screw (5) (one rotation can be enough) to increase the
distance A.
d) Adjust the position of the screw (6).
e) Repeat from point a) on page 3-29.
5 4
A 6
4 Cap
5 Screw
TechPub_2614345_0110 - 02_RM3093011_01en.fm
6 Screw
3 - 30 (96) Doc. No. RM-3093011-0102

3.1.3-3 Air Injectors - Installation

Air OFF
SPC Reference 662804-0100; 662804-0200
a) Remove the nuts (1) and the air injectors (2).

b) Check the distances A, H for all the air injectors, see the drawing on the
next page.
1
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Nut
2 Air injector
(Cont'd)
Doc. No. RM-3093011-0102 3 - 31 (96)

Nozzles Position and Orientation Table
Air Metal Straight Upwards Downwards Inclined
Nozzle
Plastic Pressure
Code
Hose Hose Hose
3 - 32 (96)
(Cont'd)
Inverter Frequency: 50Hz
Hole ø5.5 mm
Quotes starting point

3.1 Mechanical Installation
Quote “H”
Pneumatic Panel
Doc. No. RM-3093011-0102

Cap Level Positioning
Tighten L-Connection code

TechPub_2614345_0110 - 02_RM3093011_01en.fm
(Cont'd)
c) In the installation of the air injector 1 (3), if the distance H is less than 53
mm install the air injector 1 (3) in the lower hole (4) and put a plug in the
upper hole (5).
d) In the installation of the air injector 1 (3), if the distance H is more or
equal than 53 mm install the air injector in the higher hole (4) and put a
plug in the lower hole (3).
e) In the installation of the air injector 4 (6), if the distance H is less than 57
mm install the air injector 1 (3) in the lower hole (4) and put a plug in the
upper hole (5).
f) In the installation of the air injector 4 (6), if the distance H is more or
equal than 57 mm install the air injector in the higher hole (4) and put a
plug in the lower hole (3).
Note! The air injectors 4 (5) have to be installed in the higher hole (4).
6 3
2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1
5
4
1 Nut
2 Air injector
3 Lower hole
4 Upper hole
5 Air injector 1
6 Air injector 4
(Cont'd)
Doc. No. RM-3093011-0102 3 - 33 (96)

(Cont'd)
Check the Air Injectors
Note! Check all the air injectors.
a) Check the drawing on page 3-32 if the air injector (1) has to be mounted
straight, upwards or downwards.
b) Check that the hole (2) is angled and aligned with the air injector (1).
c) If the hole (2) is not aligned with the air injector (1), adjust the
inclination of the hole (2) by means of a drilling machine (3).
2 2
1
1
Upward air injector Straight air injector
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 2
1 Air injector
2 Hole
3 Drilling machine
(Cont'd)
3 - 34 (96) Doc. No. RM-3093011-0102

(Cont'd)
Install the Air Injectors
a) Install the air injector (1) and tighten the nut (2).
Note! Check that there are no gaps between the air injector (1) and the
frame (3).
Upward air injector Straight air injector
2 2
1
1
3 3
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1
3
3
1 Air injector
2 Nut
3 Frame
(Cont'd)
Doc. No. RM-3093011-0102 3 - 35 (96)

(Cont'd)
Perform Air Connections
a) Install an L-connection (1) or a plug (2) according to the modification
drawings, see the drawing on page 3-32.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 2 1 Plug
2 L-Connection
(Cont'd)
3 - 36 (96) Doc. No. RM-3093011-0102

(Cont'd)
b) Check that the air injectors are connected to the correct pressure
regulator, see the drawing on page 3-32.
c) Check that the pressure regulator (1) is set to 2 bars, the pressure
regulator (2) is set to 4 bars, the pressure regulator (3) is set to 1-2 bars,
see the drawing on page 3-32.
d) At the start-up of the machine, check that the air coming from the air
injectors allows the passage of the caps.
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
2 5
3
7
6
1 Pressure regulator
4 Nozzle 50WI65
5 Nozzle 50WI67
6 Nozzle 50WI68
7 Nozzle 50WI66
8 Nozzle 50WI64x
9 Nozzle 50WI64
Doc. No. RM-3093011-0102 3 - 37 (96)

3.1.3-4 Air Injector - Add New Position

Air OFF
SPC Reference 662804-0100; 662804-0200
a) Install the new air injector (1) using the screw (2).
b) Connect the air pipe (3) to the air injector (1).
2
1
3
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Injector
2 Screw
3 Air Pipe
3 - 38 (96) Doc. No. RM-3093011-0102

3.1.3-5 Feeder - Set Cam Positions

Machine Status STEP 3
SPC Reference 662804-0100; 662804-0200
a) Remove the cams (1), (2) and (3) if present.

b) Install the new cam (3) in the correct position and combination using the
screw (4), see the drawing on page 3-32.
.
3 4 2 1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Cam
2 Cam
3 Cam
4 Screw
Doc. No. RM-3093011-0102 3 - 39 (96)

3.1.3-6 Feeder - Set Sorter Speeds

Machine Status Mains Power ON
Air ON
SPC Reference 662804-0100; 662804-0200
a) Log on as a user see 3.3.2-1 Touch Screen - Login As Service Technician

on page 3-88.
b) Touch the PRODUCTION CONTROL (1) and then the Cap Sorter
Icon (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1 PRODUCTION CONTROL
2 Cap Sorter Icon
3 - 40 (96) Doc. No. RM-3093011-0102

(Cont'd)
c) Select any of the buttons (3), (4), (5), (6) or (7) to adjust the value.
d) Touch the OK button (8) twice to confirm the setting.
e) When all the settings are correct touch the recipe button (9) and save, see
3.3.2-2 Touch Screen - Saving Recipe Settings on page 3-92.
Setting Value
Slim Cap Stream Cap HeliCap2 23
Time to Start Load TBD 0.25Sec 0.2Sec
Time to Stop Load TBD 0.45Sec 0.5Sec
Time to Start Elevator TBD 0.55Sec 0.2Sec
Time to Stop Elevator TBD 0.55Sec 0.5Sec
5
3
6
7
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
8
9
3 Time to start load button

4 Time to stop load button
5 Time to start elevator Button
6 Time to stop elevator button
7 Disk Speed button
8 OK button
9 Recipe button
Doc. No. RM-3093011-0102 3 - 41 (96)

3.1.3-7 Cap Sorter - Set X Position

Air OFF
SPC Reference 662804-0100; 662804-0200
X Position
a) Loosen the four screws (1) to free the plate (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Screw
2 Plate
(Cont'd)
3 - 42 (96) Doc. No. RM-3093011-0102

(Cont'd)
b) Measure the distance A between the beam (3) and the cap conveyor (4).
c) Make the distance B between the beam (5) and the cap conveyor (4) the
same as the distance A, by means of the screws (6).
B 5
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3
A
3 Beam
4 Cap conveyor
5 Beam
6 Screw
Doc. No. RM-3093011-0102 3 - 43 (96)

3.1.3-8 Feeder - Set Cap Level

Air ON
SPC Reference 662804-0100; 662804-0200
a) Release the screw (1) and adjust the bracket (2) to set the distance A.
b) Release the screw (3) and adjust the bracket (2) until the distance B is
reached between the lever (4) and the disc (5), tighten the screws (1)
and (3).
c) Adjust the sensor (6) until the distance C is reached between the
lever (4) and the sensor (6).
Note! The distances A, B and C are reported in the drawings on page 3-32.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
6
4
5
1 Screw
3
2 Bracket
2 3 Screw
4 Lever
5 Disc
1 B 6 Sensor
3 - 44 (96) Doc. No. RM-3093011-0102

3.1.3-9 Cap Sorter - Remove the Sensor

Air ON
SPC Reference 662804-0100; 662804-0200
a) Release the screw (1) and remove the sensor (2).
2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
D
C
A
E
B
1
1 Screw
2 Sensor
Doc. No. RM-3093011-0102 3 - 45 (96)

3.1.4 Machine Body

3.1.4-1 Heating Chamber and Flange seal - Change
Air OFF
SPC Reference 2758510-0100; 2873862-0100
WARNING
Risk of burns.
The preheating equipment is very hot. Failure to observe this information
could result in severe burns.
a) Loosen the screws (1) and remove the heat guard (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1 Screw
2 Heat guard
(Cont'd)
3 - 46 (96) Doc. No. RM-3093011-0102

(Cont'd)
a) Loosen the screws (3) and remove the flange seal (4) and the heating
chamber (5).
b) Assemble in the reverse order with the new parts.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 Screw
4 Flange seal
5 Heating chamber
Doc. No. RM-3093011-0102 3 - 47 (96)

3.1.5 Applicator Unit

3.1.5-1 Cap Holder - Change
Air OFF
SPC Reference 662806-0100; 662806-0200
a) Loosen the screws (4) and remove the cam module (3)
b) Loosen the screws (1) and remove the cap holder (2).
c) Install the new cap holder (2) and tighten the screws (1).
d) Install the cam module (3) and tighten the screws (4).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3
1 Screw
2 Cap holder
4 3 Cam module
4 Screw
3 - 48 (96) Doc. No. RM-3093011-0102

3.1.6 Cap Sequencer

3.1.6-1 Guide Rail - Change

Air OFF
Change Guide Rail

a) Release the screws (1) and slide the guides (2) out.
b) Remove the screws (3) and the guide rail (4).
c) Remove the screws (5) and the clamps (6).
d) Assemble in the reverse order with the new parts.
2
3
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1 Screw
2 Guide
1 3 Screw
4 Guide rail
5 Screw
6 Clamp
(Cont'd)
Doc. No. RM-3093011-0102 3 - 49 (96)

(Cont'd)
Set Roof
a) Remove the screws (1) and the bracket assembly (2).
b) Remove the screws (3) and the roof (4).
c) Insert shims (5) until the distance A is reached.
Note! The bracket assembly (2) is cap dependent, see latest SPC.
Cap Distance A
Slim Cap 1000 12.8 mm +0 / -0.2 mm
Stream Cap 1000 18 mm +0 / -0.2 mm
HeliCap2 23 16 mm +0 / -0.1 mm
HeliCap 27 18.4 mm +0 / -0.1 mm
HeliCap2 23 StreamCap 1000 SlimCap 1000

HeliCap 27
A
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3
2
1
1 Screw
2 Bracket assembly
3 Screw
4 Roof
5 5 Shim
3 - 50 (96) Doc. No. RM-3093011-0102

3.1.6-2 Cap Line - Set Spring Gap

a) Adjust the nuts (1) to set the distance A between the guides (2) making
sure that the distance A is equal at both ends.
Note! The steering guides (2) are cap dependent, see latest SPC.
Theoretical Cap Neck Size

Streamcap 1000 26.4 mm
Slimcap 1000 21.4 mm
HeliCap2 23 21.7 mm
HeliCap27 25. mm
A A = Cap Neck -0.2 mm
A
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Nut
2 Guide
Doc. No. RM-3093011-0102 3 - 51 (96)

3.1.6-3 Clamp Unit - Set Spring and Sensor

a) Set the distance A on the sensor (1) by adjusting the nuts (2).
Note! When the fingers (3) are open the LED on the sensor (1) should
be on.
A = 1.0 mm
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A
1
2
1 Sensor
2 Nut
3 Finger
(Cont'd)
3 - 52 (96) Doc. No. RM-3093011-0102

(Cont'd)
b) Set the distance B between the fingers (3) by adjusting the distance C
using the nut (4) and the damper (5).
Note! Turning the damper (5) counter clockwise will increase the gap.
Note! If the stop fingers (6) trap the next cap (7) repeat step b) until
position (8) is achieved.
.
Cap Theoretical Value

SlimCap 1000 B = 11 mm
StreamCap 1000 B = 11 mm
HeliCap2 23 B = 5 mm
HeliCap27 B = 11 mm
B 6
3
6
TechPub_2614345_0110 - 02_RM3093011_01en.fm
7 8
5 4
3 Finger
4 Nut
5 Damper
6 Stop finger
7 Next cap
8 Position (8)
(Cont'd)
Doc. No. RM-3093011-0102 3 - 53 (96)

(Cont'd)
c) Set the tension of the spring (9) by adjusting the nuts (10) until the
distance D is obtained.
10 9
TechPub_2614345_0110 - 02_RM3093011_01en.fm
D = 20 mm D
9 Spring
10 Nut
3 - 54 (96) Doc. No. RM-3093011-0102

3.1.7 Cap Conveyor

SPC Reference 662908-0100; 662808-0200
3.1.7-1 Guide Rail - Change

Air OFF
SPC Reference 662908-0100; 662908-0200
Remove Guide Rail

a) Release the latches (1).
b) Remove the guide rail (2).
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Latch
2 Guide rail
(Cont'd)
Doc. No. RM-3093011-0102 3 - 55 (96)

(Cont'd)
Install new Guide Rail
a) Install the new guide rail (1).
b) Close the latches (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1 Guide rail
2 Latch
3 - 56 (96) Doc. No. RM-3093011-0102

3.1.8 Special Setting for HeliCap

3.1.8-1 Push Down - Set X, Y, Z and Zero

Air OFF
Set Y Cam
Note! Valid only for HeliCap2 23.
a) Inch the machine to 330 degrees.
b) Check that the distance A is correct between the pushdown (1) in the cap
holder and the pushdowns in the end stroke position (2).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 2 2
A
1 Pushdown
2 End stroke pushdown
(Cont'd)
Doc. No. RM-3093011-0102 3 - 57 (96)

(Cont'd)
c) Place a straight edge (3) under the pushdowns (2), release the screws (4)
and move the cam (5) until the distance A is obtained. Tighten the
screws (4).
Note! Removing the cap holder (6) will help during this setting.
6 5 2 3 2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A = 4 mm
A
2 Pushdown
3 Straight edge
4 Screw
5 Cam
6 Cap holder
3 - 58 (96) Doc. No. RM-3093011-0102

Set Z Cam
Air OFF
Note! This adjustment is for the pushdown fingers to the applicator only.
CAUTION
Application pressure
Do not adjust the pushdown pressure here, see the MM 6.1.1-1 Package
Conveying - Set Height.
(Cont'd)
TechPub_2614345_0110 - 02_RM3093011_01en.fm
Doc. No. RM-3093011-0102 3 - 59 (96)

(Cont'd)
a) Inch the machine to 330 degrees and check the distance A between the
pushdown finger (1) and the bottom of the cap holder claw (2).
b) Release the screws (3) and turn the screws (4) to raise or lower the
height of the push down (5).
Note! Keep the distance B equal at both ends of the pushdown.
5
1
2
4
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3
B
1 Pushdown finger
2 Cap holder claw
3 Screw
4 Screw
5 Pushdown
3 - 60 (96) Doc. No. RM-3093011-0102

Set X Cam
Air OFF
a) Release the screws (1).

Note! Verify that the push down is in the middle of the cap. If not adjust the
distance A, see next page.
Note! s setting.
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Screw
(Cont'd)
Doc. No. RM-3093011-0102 3 - 61 (96)

(Cont'd)
b) Turn the two screws (2) to move the pushdown (3) and set the distance A
so that the pushdown is centred on the cap. Tighten the screws (1).
c) Check that the distance B is equal between the cam (4) and the belt (5) at
both ends.
A B
2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
4
1 Screw
2 Screw
3 Pushdown
4 Cam
5 Belt
3 - 62 (96) Doc. No. RM-3093011-0102

Set Zero
Air OFF
a) Using a straight edge (1), align the leading edge of a pushdown

holder (2) with the front surface of the zero tool (3).
3
2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Straight edge
2 Pushdown holder
3 Zero tool
(Cont'd)
Doc. No. RM-3093011-0102 3 - 63 (96)

(Cont'd)
b) Turn the main power on.
c) Touch the SYSTEM SETUP button (4) and login see, 3.3.2-1 Touch
Screen - Login As Service Technician on page 3-88.
d) Touch the MAINTENANCE button (5).
e) Touch the APPLICATOR UNIT button (6).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
5 4
4 SYSTEM SETUP button

5 MAINTENANCE button
6 APPLICATOR UNIT button
(Cont'd)
3 - 64 (96) Doc. No. RM-3093011-0102

(Cont'd)
f) Touch the ZERO button (7)
g) Touch the ON button (8).
h) Touch the OK button (9) for three seconds. The background of the ON
button (8) should go green.
i) Touch the EXIT button (10).
10
8
TechPub_2614345_0110 - 02_RM3093011_01en.fm
7 ZERO button
8 ON button
9 OK button
10 EXIT button
Doc. No. RM-3093011-0102 3 - 65 (96)

3.1.8-2 Cams - Set Picking and Gripper Cams

Air OFF
Picking Cam - Z Adjustment

Note! Before setting the cams set the cap holder group see 7.3 Cap Carrier.
Coarse Setting
a) Release the two upper screws (1).
b) Using the screw (2), adjust the picking cam (3) to change the distance A.
c) Tighten the screws (1).
d) Check that the distance A is equal at each end of the picking cam.
3
1
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A
1 Screw
2 Screw
3 Picking cam
(Cont'd)
3 - 66 (96) Doc. No. RM-3093011-0102

(Cont'd)
Fine Setting
a) Inch the machine slowly around so that caps are collected by the cap
holders.
b) Make sure that the cap is not held by more than the distance B. This will
make sure that the cap holder lever does not touch the cap sequencer.
c) If the distance B is incorrect, repeat the Coarse Setting procedure and
steps a) and b) of this procedure.
StreamCap SlimCap HeliCap2 23 HeliCap27
Dimension B Dimension B Dimension B Dimension B
4.5 mm 5.5 mm 5. mm 6.5 mm
B
TechPub_2614345_0110 - 02_RM3093011_01en.fm
(Cont'd)
Doc. No. RM-3093011-0102 3 - 67 (96)

(Cont'd)
Gripper Cam - Z Adjustment
Note! Before setting the cams (1), set the cap holder group see 7.3.1-3
Guide Bracket - Set X Position (No Positioning Device Only).
a) Release the screws (2).
b) Using the screw (3), adjust the gripper cam (1) to change the distance A.
d) Check that the distance A is equal at each end of the cam (1).
Note! Check that the grippers (4) are holding the cap before the cap
completely leaves the guides (5).
2 A 3
TechPub_2614345_0110 - 02_RM3093011_01en.fm
4
1 Cam
2 Screw
3 Screw
A = 4.5 mm
4 Gripper
5 Guide
3 - 68 (96) Doc. No. RM-3093011-0102

3.1.8-3 Cams - Set Applicator and Release Cams

Air OFF
Release Cam
Note! Before setting the cams, set the cap holder group see 7.2.1-3 Cap
Holder - Set Y Position.
a) Release the screws (1) and then use the screw (2) to adjust the release
cam (3) to set the distance A making sure that the cap is still being
gripped.
b) Tighten the screws (1).
Note! Make sure that the distance A is equal at both ends of the cam (3).
A = 9 mm
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A 2
3
1
1 Screw
2 Screw
3 Release cam
(Cont'd)
Doc. No. RM-3093011-0102 3 - 69 (96)

(Cont'd)
Application Cam
a) Inch the machine to 360 degrees.
b) Release the screws (1) and then use the screw (2) to adjust the position
of the applicator cam (3) until the stroke at the spring is the distance A.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
A
A = 19.5 mm ±0.5
1 Screw
2 Screw
3 Applicator cam
3 - 70 (96) Doc. No. RM-3093011-0102

(Cont'd)
Release and Application Cam - with Vision System
a) The release and applicator cam (2) is moved into position by the
motor (3) and the vision system, see 12 Optional Equipment.
b) Position the pin (4) in the zero slot (5).
c) Close all doors and guards.
3
2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
4 5
1 Guide cams
2 Release and applicator cam
3 Motor
4 Pin
5 Zero slot
(Cont'd)
Doc. No. RM-3093011-0102 3 - 71 (96)

(Cont'd)
d) Touch the MAINTENANCE button (6).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
6 MAINTENANCE button
(Cont'd)
3 - 72 (96) Doc. No. RM-3093011-0102

(Cont'd)
e) Touch the VISION SYSTEM button (7).
f) Touch the ZERO button (8).
g) Touch the ON button (9).
h) Touch the OK button (10) for three seconds. The background of the ON
button (9) should go green.
i) Touch the EXIT button (11).
7
TechPub_2614345_0110 - 02_RM3093011_01en.fm
11
10
7 VISION SYSTEM button
9 8 ZERO button
9 ON button
10 OK button
11 EXIT button
(Cont'd)
Doc. No. RM-3093011-0102 3 - 73 (96)

(Cont'd)
Note! Set the machine to zero degrees.
j) Rotate the cam (12) checking that the roller (13) stays in contact with the
cam (2) during the total rotation on the cam (12).
2 13
TechPub_2614345_0110 - 02_RM3093011_01en.fm
12
2 Cam
12 Cam
13 Roller
(Cont'd)
3 - 74 (96) Doc. No. RM-3093011-0102

(Cont'd)
Set X Position
a) Inch the machine to 15 degrees and centre the cap (1) between the guides
(2) on the cap sequencer.
b) Loosen but not remove the screw (3).
c) Move the cap carrier (4) by means of the screw (5) until that the cap (1)
is centred between the guides (2).
d) Repeat for all cap carriers.
2 2
= =
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Cap
2 Guide
5 3 Screw
3 4 Cap carrier
5 Screw
Doc. No. RM-3093011-0102 3 - 75 (96)

3.1.9 Sensor Positioning

3.1.9-1 Sensor Positioning
The distance A, between the too long package queue sensor (1) and the DE
unit (2), must not exceed 15 m for Family packs and 20 m for Portion packs.
Distance B. This is the distance required to empty the cap applicator. The
distance is package dependent, see the table on the next page.
1 2 3 4 5 6 7 8 9 12 11
10
TechPub_2614345_0110 - 02_RM3093011_01en.fm
A B
1 Too long package queue sensor

2 DE unit
3 Long package queue sensor
4 Fallen package sensor
5 Short package queue sensor
6 Rear of belt brake
7 End of bearing housing
8 Outfeed congestion package sensor
9 Cap detector photo-electric sensor
10 Queue Outfeed Left Line
11 DE unit
12 DE unit
3 - 76 (96) Doc. No. RM-3093011-0102

3 Rebuilding Instructions 3.2 Electrical Installation
3.2 Electrical Installation

3.2.1 Wiring
Always follow the electrical document supplied with the rebuilding manual,
all electrical modifications are marked with heavy dashed lines, see UP
Updates of Manuals. The electrical document is based upon the latest
released Electrical Manual and may not reflect exactly previous Electrical
Manual versions. It is important that at the end of the installation the
machine wiring corresponds to the electrical document supplied including all
modifications.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
Doc. No. RM-3093011-0102 3 - 77 (96)

3.3 Final Installation Checks 3 Rebuilding Instructions
3.3 Final Installation Checks

3.3.1 Machine Checks and Settings
The following machine checks or settings are required after the installation
of this rebuilding kit.
3.3.1-1 Check Cap Position - Opening Performance
Air ON
TEMPLATE TP No. 3047350-0100
TOOL (Digital) Caliper
a) Perform a package sample and collect six consecutive packages from the
conveyor after the machine, see the MM.
b) Open the caps (1) and empty the packages (2).
c) Cut the packages (2) and remove the grey area shown in the picture.
d) Number the samples from 1 to 12 (3) by means of a pen.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1
1
1 Cap
2 Package
3 Number
(Cont'd)
3 - 78 (96) Doc. No. RM-3093011-0102

3 Rebuilding Instructions 3.3 Final Installation Checks
(Cont'd)
e) Remove the aluminium layer (4) from the bottom of the cap (5).
5
TechPub_2614345_0110 - 02_RM3093011_01en.fm
4 Aluminium layer
5 Bottom of the cap
(Cont'd)
Doc. No. RM-3093011-0102 3 - 79 (96)

(Cont'd)
f) Insert the bottom of the cap (5) into the template (6) and check that it
doesn’t rotate.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
5 Bottom of the cap

6 Template
(Cont'd)
3 - 80 (96) Doc. No. RM-3093011-0102

(Cont'd)
Note! Use a (digital) caliper to check the position of the cap on package.
g) Measure the maximum distance Y between theY-reference (7) of the
template and the packaging material (8).
h) Measure the maximum distance X between the X-reference (9) of the
template and the packaging material (8).
Note! Be sure that the measure is taken between the template and the
board of the hole: the caliper shouldn’t touch the cap.
i) Put the measures in the tables of pages 3-82 and 3-82.
j) Repeat from g) to i) for all the 12 packages.
Y 9
X
TechPub_2614345_0110 - 02_RM3093011_01en.fm
7 Y-reference
8 Packaging material
9 X-reference
(Cont'd)
Doc. No. RM-3093011-0102 3 - 81 (96)

(Cont'd)
Position of the Cap on Package Table
a) Repeat from a) on page 3-78 to i) on page 3-81 other times.
b) Calculate the average values of columns X and Y between the 3 values
collected for every cap holder.
Package Number Distance X Distance Y

1(first sample)
1(second sample)
1(third sample)
Average 1

2(first sample)
2(second sample)
2(third sample)
Average 2
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3(first sample)
3(second sample)
3(third sample)
Average 3

4(first sample)
4(second sample)
4(third sample)
Average 4

5(first sample)
5(second sample)
5(third sample)
Average 5

6(first sample)
6(second sample)
6(third sample)
Average 6
3 - 82 (96) Doc. No. RM-3093011-0102

(Cont'd)

7(first sample)
7(second sample)
7(third sample)
Average 7

8(first sample)
8(second sample)
8(third sample)
Average 8

9(first sample)
9(second sample)
9(third sample)
Average 9
TechPub_2614345_0110 - 02_RM3093011_01en.fm

10(first sample)
10(second sample)
10(third sample)
Average 10

11(first sample)
11(second sample)
11(third sample)
Average 11

12(first sample)
12(second sample)
12(third sample)
Average 12
(Cont'd)
Doc. No. RM-3093011-0102 3 - 83 (96)

(Cont'd)
c) Subtract ‘5’ to every average and put these values in the following table:
Package Number Offset

1
2
3
4
5
6
7
8
9
10
11
12
d) Activate the vision system, see the MM 12.4.11.1-1 Turning On the

Vision System on page 12-138.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
e) Check the offsets:
• If the offsets are less than ±0.5 mm no further action is necessary

• If the offsets are more or less the same value, correct their position
according to the MM 12.4.11.1-3 Making Corrections to the General
Offset Values on page 12-149.
• In case of different offsets, perform a correction to the single cap holder,
MM 12.4.11.1-4 Making Corrections to the Delta Tolerance on page 12-
153.
3 - 84 (96) Doc. No. RM-3093011-0102

3.3.1-2 Hotmelt Gun - Check

Machine Status PREPARATION
Setting tool Template TP No. 3047353-0000
valid for TBA 1000 Sq HeliCap2
Setting tool Lens TP No. 90459-4931
valid for TBA 1000 Sq HeliCap2
Alignment
WARNING
Risk of burns
These parts and others close by may be hot.
Note! This procedure checks the alignment of the three nozzles relative to
the centre line of the cap sequencer.
This alignment can be checked using a test facility incorporated in the TPOP
program. To check the glue application proceed as follows.
a) Make sure that the machine is at PREPARATION.
b) At the control panel, touch the PRODUCTION CONTROL button (1).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
c) In the window that appears, touch the SERVICE button (2).
1
1 PRODUCTION CONTROL button
2 SERVICE button
(Cont'd)
Doc. No. RM-3093011-0102 3 - 85 (96)

(Cont'd)
d) In the SERVICE PARTS (3), touch the HOTMELT PATTERN TEST
button (4).
e) Touch the ON button (5) to active the function and press the STEP UP
button (6).
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 SERVICE PARTS
4 HOTMELT PATTERN TEST button
5 ON button
6 STEP UP button
(Cont'd)
3 - 86 (96) Doc. No. RM-3093011-0102

(Cont'd)
f) Perform a pattern test, see Alignment on page 3-85.
g) Use a calibration lens (1) TP90459-4931 to check that the distance from
the cap edge to the glue bead is centred in Y direction. In example: if the
distance Y1= 2 mm and the distance Y2=3 mm change the Y offset of
+0.5mm.
h) Repeat for the X direction.
Note! If the glue is not well positioned, set it correctly according to the MM,
4.3.1-9 Hotmelt Gun - Check.
y2 y1
x
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 Calibration lens
Doc. No. RM-3093011-0102 3 - 87 (96)

3.3.2 Appendix
3.3.2-1 Touch Screen - Login As Service Technician
a) On the TPOP, touch the SYSTEM SETUP button (1).

b) In the SYSTEM SETUP window, touch the USER MANAGEMENT
button (2).
c) In the USER MANAGEMENT window, touch the LOG ON button (4)
to display the LOGIN window (5).
1 2 3 4 5
TechPub_2614345_0110 - 02_RM3093011_01en.fm
1 System setup button
2 User management button
3 Log off button
4 Log on button
5 Login window
(Cont'd)
3 - 88 (96) Doc. No. RM-3093011-0102

(Cont'd)
d) Touch the USER button (6) to display the keyboard (7).
e) Use the keyboard (7) to type your user name, then touch the ENTER
button (8).
Note! Login as Service technician, see the table on page 3-90.
7
TechPub_2614345_0110 - 02_RM3093011_01en.fm
6 User button
7 Keyboard
8 Enter button
(Cont'd)
Doc. No. RM-3093011-0102 3 - 89 (96)

(Cont'd)
User Profile User Name Password Access Description

Supervisor supervisor shiftsup Access to:
- user administration
- production control settings and
functions
- maintenance control settings
and functions
- create and delete recipes
- software installation and
configuration
- shutdown
- diagnostic
- partial access to the
configuration window
Service technician custtech Access to:
technician - production control settings and
functions
- maintenance control settings
and functions
- create and delete recipes
- software installation and
configuration
TechPub_2614345_0110 - 02_RM3093011_01en.fm
- partial access to the
configuration window
Operator - - Access to:
(default user - production control settings and
with no log on) functions
- alarm management
- basic recipe management
(Cont'd)
3 - 90 (96) Doc. No. RM-3093011-0102

(Cont'd)
f) Touch the PASSWORD button (9) to display the keyboard (7).
g) Use the keyboard (7) to type your password, then touch the ENTER
button (8).
h) Touch the ENTER button (10) to confirm the data entry.
The user is now logged on to the TPOP with the corresponding level of
access.
10
9
TechPub_2614345_0110 - 02_RM3093011_01en.fm
7 Keyboard
8 Enter button
9 Password button
10 Enter button
Doc. No. RM-3093011-0102 3 - 91 (96)

3.3.2-2 Touch Screen - Saving Recipe Settings

a) Logon the TPOP as a Service Technician, see 3.3.2-1 Touch Screen -

Login As Service Technician on page 3-88.
b) Touch the RECIPE button (1) and the active RECIPE NAME (2) will
appear.
c) Touch the SAVE button (3).
d) Touch the OK button (4) to confirm. The changes will be saved as
default values in the recipe.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 1 4
1 RECIPE button
2 RECIPE NAME
3 SAVE button
4 OK button
3 - 92 (96) Doc. No. RM-3093011-0102

3.4 Updating the Machine
3 Rebuilding Instructions Documentation
3.4 Updating the Machine Documentation

3.4.1 Schemes and Diagrams
If included, place the plastic laminated schemes and diagrams delivered with
this rebuilding kit in the appropriate document holder on the machine. Make
sure any old schemes or diagrams that are no longer valid are discarded.
3.4.2 Delivered Design Label

Update the delivered design label inside the electrical cabinet. Complete the
fields with the information about this rebuilding kit.
3.4.3 Declaration for Machinery Part(s)

Store the Declaration for Machinery Part(s) for this rebuilding kit together
with the Declaration of Conformity for the machine. The Declaration for
Machinery Part(s) is included in Chapter 4 Enclosed Documentation.
3.4.4 Obsolete and Recommended Spare Parts

Make sure that the obsolete and recommended spare parts lists are given to
the person responsible for the spare parts for the machine. The obsolete and
recommended spare parts lists are included in Chapter 4 Enclosed
Documentation.
TechPub_2614345_0110 - 02_RM3093011_01en.fm
Doc. No. RM-3093011-0102 3 - 93 (96)

3.5 Updating the Manuals 3 Rebuilding Instructions
3.5 Updating the Manuals

A list of the manuals that must be replaced after the installation of this
rebuilding kit can be found in the Technical Bulletin. For manuals that only
require updating, the updated pages are included in UP-Manual.
3.5.1 Maintenance Manual

If indicated in the Technical Bulletin, the Maintenance Manual for the
machine must be replaced with the latest released version which includes the
new instructions related to this rebuilding kit.
If the new manual is available, make sure that old manual is discarded. If the
latest released version of the Maintenance Manual is not available:
• use the MM pages located in UP-Manual to update the existing MM
• if possible, remove and discard MM pages containing obsolete
procedures. If pages containing obsolete procedures can not be removed,
use a red permanent pen to cross out the procedure and clearly mark the
pages with the words ‘No longer valid’
• inform the person responsible that the latest released version of the
Maintenance Manual must be ordered for the machine.
3.5.2 Operation Manual
TechPub_2614345_0110 - 02_RM3093011_01en.fm
If indicated in the Technical Bulletin, the Operation Manual for the machine
must be replaced with the latest released version which includes the new
instructions related to this rebuilding kit.
If the new manual is available, make sure that old manual is discarded. If the
latest released version of the Operation Manual is not available:
• use the OM pages located in UP-Manual to update the existing OM
• if possible, remove and discard OM pages containing obsolete
procedures. If pages containing obsolete procedures can not be removed,
use a red permanent pen to cross out the procedure and clearly mark the
pages with the words ‘No longer valid’
• inform the person responsible that the latest released version of the
Operation Manual must be ordered for the machine.
3.5.3 Electrical Manual

After the installation of the rebuilding kit, the Electrical Manual for the
machine must be updated with the new electrical information related to the
rebuilding kit. Use the EM pages located in UP-Manual to update the
existing EM.
3 - 94 (96) Doc. No. RM-3093011-0102

3 Rebuilding Instructions 3.5 Updating the Manuals
3.5.4 Spare Parts Catalogue

After the installation of the rebuilding kit, the Spare Parts Catalogue for the
machine must be updated with the new parts information related to the
rebuilding kit.
Insert the rebuilding kit SPC located in UP-Manual inside the existing SPC.
If possible, remove and discard SPC pages containing obsolete parts. If
pages containing obsolete parts can not be removed, use a red permanent pen
to cross out the obsolete parts and clearly mark the pages with the words ‘No
longer valid’.
3.5.5 Technical Manual

After the installation of the rebuilding kit, the Technical Manual for the
machine must be replaced with the latest released version which includes the
new instructions related to the rebuilding kit.
If the latest released version of the Technical Manual is not available, use the
TeM pages located in UP-Manual to update the existing TeM. If possible,
remove and discard TeM pages containing obsolete procedures. If pages
containing obsolete information can not be removed, use a red permanent
pen to cross out the information and clearly mark the pages with the words
TechPub_2614345_0110 - 02_RM3093011_01en.fm
“No longer valid”.
3.5.6 Update Log Pages

Note! The Update Log pages are located after page 4 in a manual. If a
machine manual does not include an Update Log page, use the update log
page located in UP-Manual.
The Update Log pages must be updated for each of the affected machine
manuals. Use a black permanent pen to write the following information on
the Update Log page:
• the date that the rebuilding kit was installed
• the name of the rebuilding kit
• the document number of the added pages
• the page numbers of the pages that have been removed from the manual
• the signature of the technician responsible for the installation
3.5.7 Recycling of Replaced Manuals

Recycle any manuals that have been replaced according to local regulations.
Doc. No. RM-3093011-0102 3 - 95 (96)

3.5 Updating the Manuals 3 Rebuilding Instructions
TechPub_2614345_0110 - 02_RM3093011_01en.fm
3 - 96 (96) Doc. No. RM-3093011-0102

4 Enclosed Documentation
TechPub_2614345_0110 - ed1_RM3093011_01en.fm
Doc. No. RM-3093011-0102 4 - 1 (22)

About the Enclosed Documentation Chapter

This chapter contains all the separate documents related to this rebuilding kit.
For instructions explaining how to update the documentation for the
machine, see Section 3.4 Updating the Machine Documentation.
4 - 2 (22) Doc. No. RM-3093011-0102

4 Enclosed Documentation Table of Contents
4.1 Obsolete and Recommended Spare Parts . . . . 4 - 5

4.1.1 Obsolete Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
4.1.2 Recommended Spare Parts. . . . . . . . . . . . . . . . . . 4 - 6
4.2 Modification Drawings . . . . . . . . . . . . . . . . . . . . 4 - 7

4.3 Schemes and Diagrams . . . . . . . . . . . . . . . . . . . 4 - 9
4.4 Declaration for Machinery Part(s) . . . . . . . . . . 4 - 15

Doc. No. RM-3093011-0102 4 - 3 (22)

I LIKE MY B BLANK
4 - 4 (22) Doc. No. RM-3093011-0102

4.1 Obsolete and Recommended
4 Enclosed Documentation Spare Parts
4.1 Obsolete and Recommended Spare Parts

4.1.1 Obsolete Parts
The table contains a list of parts to be removed and discarded from machines
equipped with OK HeliCap2 23 Speed 3093009-0100.
SPC Reference
Common Parts
Pos. Part No. Qty. Description
NO OBSOLETE PARTS
Doc. No. RM-3093011-0102 4 - 5 (22)

4.1 Obsolete and Recommended
Spare Parts 4 Enclosed Documentation
4.1.2 Recommended Spare Parts

The table contains a list of the recommended spare parts to be made available
for machines equipped with OK HeliCap2 23 Speed 3093009-0100.
SPC Reference
Common Parts
Pos. Part No. Qty. Description
NO RECOMMENDED SPARE PARTS
4 - 6 (22) Doc. No. RM-3093011-0102

4 Enclosed Documentation 4.2 Modification Drawings
4.2 Modification Drawings

The following modification drawings are needed during the installation of
the rebuilding kit.
Doc. No. RM-3093011-0102 4 - 7 (22)

4.2 Modification Drawings 4 Enclosed Documentation
I LIKE MY B BLANK
4 - 8 (22) Doc. No. RM-3093011-0102

4 Enclosed Documentation 4.3 Schemes and Diagrams
4.3 Schemes and Diagrams

The following schemes and diagrams are included as a reference for the
installation of the rebuilding kit.
Doc. No. RM-3093011-0102 4 - 9 (22)

4.3 Schemes and Diagrams 4 Enclosed Documentation
4 - 10 (22) Doc. No. RM-3093011-0102

4 Enclosed Documentation 4.4 Declaration for Machinery Part(s)
4.4 Declaration for Machinery Part(s)

The Declaration for Machinery Part(s) for the rebuilding kit must be stored
together with the Declaration of Conformity for the machine.
Doc. No. RM-3093011-0102 4 - 15 (22)

Tetra Pak Tetra Pak
Izjava za sestavni Konformitätserklärung
del (dele) stroja für Maschinenteile
Tetra Pak Packaging Solutions S.p.A. Tetra Pak Packaging Solutions S.p.A.
Via Delfini 1 Via Delfini 1
41123 Modena 41123 Modena
Italy Italy
izjavlja, da je (so) sestavni del (deli) stroja: erklärt hiermit, dass diese Maschinenteile
CAP30 Speed CAP30 Speed

OK 3093009-0100 Helicap2 23 Speed OK 3093009-0100 Helicap2 23 Speed
izdelan(i) v skladu z naslednjim standardom (standardi): konform sind mit folgenden harmonisierten Standards:
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Varnost sestavnega dela (sestavnih delov) stroja je preskuena pri namenski uporabi z Die Maschinenteile wurden untersucht und im Rahmen einer Risikoanalyse hinsichtlich ihrer
oceno tveganja. vorgesehenen Anwendung als sicher befunden.
Sestavni del (deli) stroja mora(jo) biti vgrajen(i) v stroj/opremo/sistem v skladu s priloenimi Die Maschinenteile sind gemäß beiliegender Anleitungen in Maschinen/Anlagen/komplexe
navodili. Einrichtungen einzubauen.
Modena 01/08/2012 Modena 01/08/2012
Andrea Tusini Andrea Tusini

Specification Owner Specification Owner
Slovenina/Slovenian Deutsch/German
FORM 5297 version 2011-10-27 FORM 5297 version 2011-10-27
Tetra Pak Tetra Pak

Erklæring Declaración sobre el (los) componente(s)
vedr. maskindele de las máquinas
Italy Italy
erklærer, at følgende maskindele: declara que este (estos) componente(s) de las máquinas:

følger nedenstående harmoniserede standarder: es (son) conforme(s) al (los) siguiente(s) estándar(es)
armonizado(s):
EN ISO 12100:2010 EN ISO 12100:2010
EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Det er blevet bekræftet ved hjælp af en risikovurdering, at maskindelene er sikre til den Se ha comprobado la seguridad del (de los) componente(s) de las máquinas en el uso para
tiltænkte anvendelse. el cual está(n) destinado(s) mediante una evaluación de riesgos.
Maskindelene skal inkorporeres i maskinen/udstyret/ El (los) componente(s) de las máquinas deberán integrarse en el conjunto de la instalación
det komplekse anlæg i overensstemmelse med de anvisninger, som følger med. de la máquina/equipo de acuerdo con las instrucciones adjuntas.
Modena 01/08/2012 Modena 01/08/2012

Dansk/Danish Español/Spanish
Tetra Pak Tetra Pak
Vakuutus koskien Déclaration concernant
koneiston osia la (les) pièce(s) de machine
Italy Italy
vakuuttaa, että tämän koneen osa(t): déclare que la (les) présente(s) pièce(s) de machine :

vastaavat seuraavia harmonisoituja standardeja: est (sont) conforme(s) aux normes harmonisées suivantes :
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Riskin arvioinnissa on varmistettu, että koneiston osa(t) ovat turvallisia, kun niitä käytetään Une évaluation des risques a établi que l'application prévue de la (des) pièce(s) de machine
niiden käyttötarkoituksen mukaisesti. est sûre.
Koneiston osa(t) tulee sisällyttää koneeseen/laitteistoon/laitekokonaisuuteen oheisten La (les) pièce(s) de machine doi(vent) être intégrée(s) à la machine / à l'équipement /
ohjeiden mukaisesti. à l'installation complexe conformément aux instructions jointes.
Modena 01/08/2012 Modena 01/08/2012

Suomi/Finnish Français / French

Tetra Pak Tetra Pak

( ) Verklaring
van machineonderdeel/machineonderdelen
Italy Italy
# & () () : verklaart dat dit/deze machineonderdeel/machineonderdelen:

! &% () & () () overeenstemt/overstemmen met de volgende geharmoniseerde norm(en):
& ():
EN ISO 12100:2010 EN ISO 12100:2010
EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
() () ( ) () Het machineonderdeel/de machineonderdelen is/zijn in een risicobeoordeling veilig
!" ( ) #$%. bevonden voor de bedoelde toepassing.
() () %%!( $) Het machineonderdeel/de machineonderdelen zal/zullen volgens de bijgaande instructies in
/ &/$ $% #! . de machine/apparatuur/installatie worden ingebouwd.
Modena 01/08/2012 Modena 01/08/2012

/Greek Nederlands/Dutch

Tetra Pak Tetra Pak
Erklæring Declaração para peça(s)
om maskindeler de máquinas
Italy Italy
erklærer at denne maskindelen / disse maskindelene: declaramos que a(s) peça(s) componente(s) desta máquina:

er i samsvar med følgende harmoniserte standarder: está(ão) em conformidade com
a(s) seguinte(s) norma(s) harmonizada(s):
EN ISO 12100:2010 EN ISO 12100:2010
EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Etter en risikovurdering er det fastslått at det er trygt å bruke maskindelen(e) i den tiltenkte A(s) peça(s) componente(s) desta máquina foi(ram) considerada(s) segura(s) no que se
anvendelsen. refere à sua aplicação de destino pela avaliação de riscos.
Maskindelen(e) skal monteres i maskinen/utstyret / den komplekse A(s) peça(s) componente(s) desta máquina deverá(ão) ser incorporada(s) no conjunto de
installasjonen i henhold til instruksjonene som følger med. instalação da máquina/equipamento/instalação complexa de acordo com as instruções
Modena 01/08/2012 Modena 01/08/2012

Norsk/Norwegian Português/Portuguese
Tetra Pak Tetra Pak

Yfirlýsing um vélhluti(-a) Dichiarazione
di parte/i di macchina
Italy Italy
lýsir yfir að þessi(r) vélhluti(-ar): dichiara questa/e parte/i di macchina

sé(u) í samræmi við eftirfarandi samræmda staðla: è/sono conforme/i con le seguenti norme armonizzate:
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Áhættumat hefur staðfest að vélhlutinn er öruggur fyrir áformuð not. La parte/i della macchina è stata verificata ed è risultata sicura nelle sue applicazioni
Vélhlutinn mun verða felldur inn í vél-/tækjabúnað og vélasamstæður og kerfi samkvæmt previste mediante una valutazione dei rischi.
meðfylgjandi leiðbeiningum. La parte/i della macchina verranno incorporate nella macchina/apparecchiatura/ installazione
complessa conformemente alle istruzioni in dotazione.
Modena 01/08/2012 Modena 01/08/2012

Íslenska/Icelandic Italiano/Italian
Tetra Pak Tetra Pak
Deklaration Vyhlásenie
av maskinkomponenter o strojárskom dielci (dielcoch)
Italy Italy
försäkrar att produkten (produkterna): vyhlasuje, e tento strojársky dielec (dielce):

är i överensstämmelse med följande harmoniserade standarder: zodpovedá poiadavkám nasledujúej harmonizovanej normy (noriem):
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Till följd av lämplig riskanalys har produkten (produkterna) ansetts säkra för avsedd Na základe hodnotenia rizík bolo overené, e strojársky dielec (dielce) sú bezpené
användning. pri jeho pouití na urený úel.
Produkten (produkterna) skall anslutas/monteras till maskinen/utrustningen/anläggningen i Strojársky dielec (dielce) bude zabudovaný do stroja/zariadenia/
enlighet med bifogade anvisningar. komplexnej intalácie v súlade s priloenými pokynmi.
Modena 01/08/2012 Modena 01/08/2012

Svenska/Swedish Slovensky/Slovak
Tetra Pak Tetra Pak

Prohláení Masinaosa(de)
o strojních souástech deklaratsioon
Italy Italy
prohlauje, e tyto strojní souásti: deklareerib, et see (need) masinaosa(d):

jsou v souladu s následujícími slad;nými normami: on vastavuses alljärgneva(te) ühtlustatud standardi(te)ga:
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Strojní souásti byly na základ; posouzení rizika schváleny jako bezpené pro Masinaosa(d) on riskihindamise abil tunnistatud nende eesmärgipärase kasutamise korral
zamýlené pouití. ohutuks.
Strojní souásti musí být zalen;ny do stroje/vybavení/komplexní instalace Masinaosa(d) ühendatakse masina, seadme või kompleksse paigaldisega vastavalt lisatud
podle p<iloených pokyn=. juhistele.
Modena 01/08/2012 Modena 01/08/2012

*etina/Czech Eesti/Estonian
Tetra Pak Tetra Pak
Nyilatkozat Apliecinjums
a gépalkatrészekrl par manas dau(m)
Italy Italy
Nyilatkozom, hogy ez a berendezés: apliecina, ka @s ma@nas daBa(as):

megfelel a következ> harmonizált szabványoknak: atbilst Jdam(iem) harmonizQtajam(iem) standartam(iem):
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
A gépalkatrészek biztonságát a rendeltetésszer? alkalmazás során kockázat értékeléssel Ma@nas daBas(u) dro@ba ir pJrbaud@ta no riska novQrtQjuma viedokBa tJm paredzQtJ
ellen>riztük. pielietojuma jomJ.
A gépalkatrészeket a kísér> utasításoknak megfelel>en kell a gépbe/berendezésbe/komplex Ma@nas daBa(as) ir paredzQta(as) iekBauanai ma@nJ/iekJrtJ/sareW@tJ instalJcijJ saskaXJ
installációba beépíteni. ar pievienotajJm pamJc@bJm.
Modena 01/08/2012 Modena 01/08/2012

Magyar/Hungarian Latviski/Latvian
Tetra Pak Tetra Pak

Pareikimas Deklaracja dotyczca
dl mechanizmo dalies(-i) czci maszyny
Italy Italy
pareikia, kad io mechanizmo dalis(-ys): deklaruje, |e poni|sze cz]^ci maszyny:

atitinka iuos darniuosius standartus: sZ zgodne z nast]pujZcymi normami zharmonizowanymi:
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
Mechanizmo dalies(-iY) sauga numatyto taikymo sZlygomis buvo patikrinta vertinant rizikos Cz]^ci maszyny zosta_y zbadane pod kZtem ryzyka i ocenione jako bezpieczne dla
veiksnius. zastosowa` zgodnych z przeznaczeniem.
Mechanizmo dalis(-ys) bus prijungta(-os) prie mainos/[renginio/kompleksin\s [rangos Cz]^ci maszyny winny zosta{ zamontowane w maszynie/wyposa|eniu/z_o|onej instalacji w
laikantis gautY instrukcijY. sposób zgodny z za_Zczonymi instrukcjami
Modena 01/08/2012 Modena 01/08/2012

LietuviY k./Lithuanian Polski/Polish

Tetra Pak Tetra Pak
!"#$%$&'* Declaraie
+$ ,$01(') 2$ 3$4'2$ privind componentele utilajului
Italy Italy
, ( ) : declar c aceste componente de utilaj:

~ ~ : sunt în conformitate cu urmtoarele standarde armonizate:
EN ISO 12100:2010 EN ISO 12100:2010

EN ISO 13857:2008 EN ISO 13857:2008
EN ISO 13850:2008 EN ISO 13850:2008
EN 61000-6-2:2005 EN 61000-6-2:2005
EN 61000-6-4:2007 EN 61000-6-4:2007
EN 60204-1:2006+A1:2009 EN 60204-1:2006+A1:2009
EN 1672-2:2005+A1:2009 EN 1672-2:2005+A1:2009
, ( ) ~ Componentele utilajului au fost verificate ca fiind sigure în aplicaiile
. pentru care au fost proiectate, printr-o evaluare a riscurilor.
( ) ~ / / Componentele utilajului trebuie încorporate în cadrul mainii/echipamentului/
, ~ ~ . instalaiei complexe în conformitate cu instruciunile însoitoare.
Modena 01/08/2012 Modena 01/08/2012

}~ / Bulgarian Român/Romania

Label for 40 mm binder Note! This page is generated automatically.
OK HeliCap2 23 Speed OK HeliCap2 23 Speed 1(2)

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Doc. No. RM-3093011-0102

Machine or equipment configurations that

Doc. No. RM-3093011-0102

Tetra Pak Packaging Solutions

TBA 1000 S SlimCap 1000

Valid for all the T-Orders

TBA 1000 S SlimCap 1000

Valid for all the T-Orders

Mandatory Rebuilding Kit Requirements:

Doc. No. RM-3093011-0102 1 - 1 (12)

About the Introduction Chapter

1 - 2 (12) Doc. No. RM-3093011-0102

Abbreviations and Terminology . . . . . . . . . . . . . 1 - 7

Information About this Manual. . . . . . . . . . . . . 1 - 10

Information About the Rebuilding Kit . . . . . . . . 1 - 11

Doc. No. RM-3093011-0102 1 - 3 (12)

1 - 4 (12) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 1 - 5 (12)

1 - 6 (12) Doc. No. RM-3093011-0102

Abbreviations and Terminology

Doc. No. RM-3093011-0102 1 - 7 (12)

Safety Messages Description

Danger indicates an imminently hazardous situation

Warning indicates a potentially hazardous situation

Caution indicates a potentially hazardous situation

CAUTION Caution without the safety alert symbol indicates a

1 - 8 (12) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 1 - 9 (12)

Information About this Manual

How to Use the Rebuilding Manual

Layout and Numbering

1 - 10 (12) Doc. No. RM-3093011-0102

Information About the Rebuilding Kit

Support and Feedback

Doc. No. RM-3093011-0102 1 - 11 (12)

1 - 12 (12) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 2 - 1 (14)

About the Rebuilding Information Chapter

2 - 2 (14) Doc. No. RM-3093011-0102

2.1 Functional Description . . . . . . . . . . . . . . . . . . . . 2 - 5

2.2 Installation Skills and Time. . . . . . . . . . . . . . . . 2 - 12

Doc. No. RM-3093011-0102 2 - 3 (14)

2 - 4 (14) Doc. No. RM-3093011-0102

2.1 Functional Description

Doc. No. RM-3093011-0102 2 - 5 (14)

2 - 6 (14) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 2 - 7 (14)

2 - 8 (14) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 2 - 9 (14)

2 - 10 (14) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 2 - 11 (14)

2.2 Installation Skills and Time

2 - 12 (14) Doc. No. RM-3093011-0102

2.3.2 Rebuilding Kit Inspection

2.3.3 Special Tools and Auxiliary Equipment

Doc. No. RM-3093011-0102 2 - 13 (14)

2 - 14 (14) Doc. No. RM-3093011-0102

Doc. No. RM-3093011-0102 3 - 1 (96)

About the Rebuilding Instructions Chapter

3 - 2 (96) Doc. No. RM-3093011-0102

3.1 Mechanical Installation . . . . . . . . . . . . . . . . . . . . 3 - 5

3.1.3-7 Cap Sorter - Set X Position . . . . . . . . . . . . . . . . 3 - 42