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M20 Starpak
Multi-Functional Rotary Indexer

Serial No. 51667E

Operation
&
Technical Manual

Ref. "51667E", Release 1.0, D.R.H. 19-11-98

BWI KP Aerofill 33-35 Clayton Road Hayes, Middlesex UB3 1RU England. Telephone: 0181-848 4501 Fax: 0181-561 3308 Telex: 935502 Aerfil G
Barry Wehmiller International PLC. Registered in England. Number 490893. Registered Office: PO Box 95, Atlantic Street, Altrincham, Cheshire WA14 5EW
M20 STARPAK

MULTI-FUNCTIONAL ROTARY INDEXER

OPERATION
&
TECHNICAL MANUAL

Contents
Chapter 1 - General Information............................ 2

1. Introduction................................................... 3
2. General Description...................................... 4
3. Machine Specifications................................. 5
4. Safety............................................................ 6
5. Installation..................................................... 7
6. General Maintenance.................................... 9
7. Operation...................................................... 12
8. Changeparts & Changeover Procedure........ 18

Chapter 2 - Common Equipment........................... 22

1. Machine Base Unit........................................ 23


2. Machine Guard Assembly............................. 24
3. Index Mechanism.......................................... 26
4. Conveyor Queue Sensor Assemblies........... 30

Chapter 3 - Machine Tooling.................................. 31

3.1. Preliminary Equipment.................................. 33


3.2. Liquid Product Fillers..................................... 37
3.3. Valve Crimping.............................................. 63
3.4. Liquid Propellent Fillers................................. 93

Chapter 4 - Spare Parts & Service......................... 128

1. Spare Parts................................................... 129


2. Service.......................................................... 141

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CHAPTER 1

GENERAL INFORMATION

Contents

1. Introduction................................................... 3

2. General Description...................................... 4

3. Machine Specifications................................. 5

4. Safety............................................................ 6

5. Installation..................................................... 7

6. General Maintenance.................................... 9

7. Operation...................................................... 12

8. Changeparts & Changeover Procedure........ 18

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Chapter 1 SECTION 1
General Information INTRODUCTION

This manual has been written for the guidance of users of BWI KP Aerofill M20 Starpak
rotary indexer. Before the machine is installed and put into service, it is recommended that
all relevant staff read this manual thoroughly to familiarise themselves with the operations
and procedures required to run and maintain this machine in a safe efficient manner.
BWI KP Aerofill operate a process of continual development of our range of machinery,
therefore it is possible that minor differences may occur between the descriptions in this
manual and the actual machine delivered. If the information required does not appear in
this manual, or if you require technical assistance or spare parts, please contact your
agent, or...

BWI KP Aerofill,
33-35 Clayton Road,
Hayes, Middlesex,
UB3 1RU
England.

Telephone: 0181-848 4501 (International: 0044 181 848 4501)


Fax: 0181-561 3308 (International: 0044 181 561 3308)

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Chapter 1 SECTION 2
General Information GENERAL DESCRIPTION

The BWI KP Aerofill M20 Starpak is an all pneumatic multi-functional rotary indexing
machine, capable of processing a wide range of aerosol containers at speeds of up to 55
units per minute, subject to can size and fill volumes.

Empty containers on the infeed conveyor form a queue at the entrance to the machine, and
are guided into a starwheel assembly by an infeed guide rail arrangement. Once in the
starwheel pockets, the containers are indexed round under each of the machine's working
heads in turn. These are explained further in the sections within Chapter 3 - Machine
Tooling.

Once the container has been processed by each of the heads, it is indexed back onto the
conveyor through an outfeed guide rail assembly, and is transported away to the next
process.

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Chapter 1 SECTION 3
General Information MACHINE SPECIFICATION

3.1 MACHINE OUTPUT

Up to 55 c.p.m.

3.2 CONTAINER SIZE RANGE

Cans: Dia. 35-80mm / Height 50-320mm


Valves: 1" tinplate / aluminium cup, diptubes 0-325mm

3.3 PNEUMATIC REQUIREMENT

Supply: 8 bar (120 psi)


Connection: 1" BSP female
Consumption: Dependent on Application

3.4 PROPELLENT REQUIREMENT

Supply: 8 bar (120 psi)


Connection: 1" BSP female
Consumption: Dependent on Application

3.5 LUBRICATION

General Purpose: Shell "Alvania" or Rocol "MTS 1000" grease


Air Service Unit: Shell "Tellus 22"
Crimper: Molykote "165LT"

3.6 DIMENSIONS

Length: 911mm
Width: 705mm
Height : 1730mm

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Chapter 1 SECTION 4
General Information SAFETY

4.1 CLOTHING
w It is strongly recommended that eye protection and suitable protective clothing is
worn whilst operating and maintaining the machine. Be sure that any loose clothing, cuffs
and / or long hair is made safe.

4.2 MACHINE ISOLATION

w Always ensure that the machine is turned OFF, and is isolated from the pneumatic
mains before any work is carried out. Where isolation is required, the following warning will
appear in the descriptive sections of this manual:

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

w Some maintenance and set-up operations, however, may require the supplies to be
turned ON. If this is the case, it is essential that these operations are only performed by
authorised, trained personnel in strict accordance with procedures given. Where this is
required, the following warning will appear in the descriptive sections of this manual:

WARNING!
!
THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE LIVE, AND
SHOULD THEREFORE ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

w These warnings and procedures are given in the interests of operator safety and
good working practices, and as such they should be noted and followed.

FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY AND / OR DAMAGE TO


THE MACHINE.

4.3 CRIMPERS

w The crimp unit's internal seals will bed-in after a period of use. The reduced friction
between the seals and cylinder bores may allow the head to drop unexpectedly after the air
supply is cut. This is normal and does not indicate any malfunction, but does call for
vigilance on behalf of operators and service personnel.

 DO NOT PUT YOUR HANDS UNDER THE CRIMP HEAD IF IT REMAINS IN THE
UP POSITION WHEN THE PNEUMATIC SUPPLY IS CUT.

4.4 GENERAL

w This machine has been designed in accordance with the European Community
legislation affecting the sale and construction of process and packaging machinery, and as
such incorporates many features for the safety of it's operators. However, a degree of
responsibility still rests with the operator to adopt and follow safe working practices.

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BWI KP Aerofill can accept no liability for damage to the machine and / or personal
injury arising from any incident where any safety features have been tampered with
or disconnected.
Chapter 1 SECTION 5
General Information INSTALLATION

5.1 SITE REQUIREMENTS

5.1.1 Pneumatic Supply

w The machine needs a pneumatic supply of at least 8 bar (120 psi). It is important to
ensure that the air supply is clean and dry, and has sufficient flow available.

5.2 TRANSPORTATION

w During the installation procedure the machine will have to be positioned correctly in
order to connect it to the adjoining equipment. This is best done using a fork lift truck.

w It is highly important that the machine is only lifted by positioning the forks under the
base of the machine between the feet of the base unit.

 THE MACHINE IS NOT DESIGNED TO BE LIFTED IN ANY OTHER WAY. ANY


ATTEMPT TO LIFT THE MACHINE OTHER THAN AS STATED WILL ALMOST
CERTAINLY CAUSE DAMAGE TO THE MACHINE.

5.4 INSTALLATION PROCEDURE

w In some cases the machine will be installed by BWI KP Aerofill service engineers.
However, should the machine be supplied for the user to install, or if it has been moved to
an alternate production site, then the following should be observed:

(i) Unpack the machine: w Remove all packing materials and ties,
and check for transit damage. If any is
found, contact your agent and / or BWI KP
Aerofill immediately.

(ii) Position the machine: w Position the machine according to the


layout plan, and level the machine by
adjusting the support feet on the base
unit.

(iii) Connect the conveyors: w Connect the machine conveyor to the


infeed and outfeed conveyors. (See
conveyor manual), and assemble any
loose items.

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(iv) Connect the air supply: w Connect the 8 bar (120 psi) mains air
supply to the 3/4" BSP female fitting on the
air service unit. This is located on the
infeed end of the machine base unit under
the infeed conveyor.

continued...
(v) Check Air Service Unit: w Check the oil level in the air lubricator of
the air service unit and top up as required.
Also drain off any fluid present in the
moisture filter.

(vi) Run in machine: w Finally, referring to Section 7 - Operation,


start the machine and allow it to run for
around one hour, as a running in period.

w After this period a thorough inspection of


the machine should be made to ensure
that the machine is still set correctly and
all assemblies are secure.

NOTES:

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Chapter 1 SECTION 6
General Information GENERAL MAINTENANCE

w Details of maintenance requirements can be found in the later sections of this


manual covering the machine tooling.

w The following are guidelines for basic machine maintenance. It is important that the
machine is regularly cleaned and lubricated. The recommended lubricants to be used are
given in Section 3.3.

w Keep a record of any abnormal occurrences, noises, or vibration during operation.


Also, keep a record of any stoppages and / or incidents. This information could be useful in
diagnosing any problems that might occur.

w The instructions given throughout this manual are based on the machine performing
a single eight hour operating shift per day. If the machine is being operated for longer
periods, then the stated maintenance intervals should be adjusted accordingly.

w BWI KP AEROFILL CAN ACCEPT NO LIABILITY FOR ANY MACHINE


PROBLEMS ARISING FROM FAILURE TO FOLLOW THESE INSTRUCTIONS.

6.1 MAINTENANCE PROCEDURES

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

6.1.1 Daily

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(i) Clean the machine regularly, preferably w If solvent cleaners are used, ensure that
after each shift: they are of a high flashpoint nature, and
that they are not corrosive to machine
components. For cleaning the machine's
plastic components and guard panels, use
a damp cloth with a mild detergent. Make
sure that no rags or other cleaning
materials are left on or in the machine.

(ii) Regularly check the air service unit: w The moisture filter section of the A.S.U. is
fitted with a level sensor linked to an
automatic dump valve. This will
automatically drain the filter bowl when the
water reaches a certain level. Top up the
air lubricators if required, and drain off any
fluid present in the moisture filters.

(iii) Lubricate the index mechanism as stated


later in this manual.

continued...

6.1.2 Weekly

w As daily, plus...

(i) Inspect the machines pipework and w Check that all pipework, cables and fittings
fittings: are secure and, in the case of pneumatic
pipes, leak free. Any pipework or cables
that are damaged should either be
repaired if practicable, or preferably
replaced.

(ii) Check that the guard and general w Check that the guard structure is sound
structure of the machine are sound and that all panels are securely in place.
and in good working order:
The safety guard of the machine is
designed so that it is not possible to open
the access doors while the machine is
running and, vice-versa, that the machine
cannot be started with any of the doors
open. If either of these conditions can be
breached then there is a defect with the
guard security system and the machine
should not be operated until a satisfactory
repair has been made.

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(iii) Check all working heads: w Check that the working heads are all
functioning correctly, as described in the
later sections of this manual.

(iv) Inspect the index mechanism: w Inspect the index mechanism as stated
later in this manual.

6.1.3 Monthly

w As weekly, plus...

(i) Perform a thorough inspection of the w Thoroughly inspect the machine, including
machine: all previous points, noting and rectifying
any defects found.

(ii) Run the machine and listen for any w While the machine is running, watch each
noise or uneven running: of the machines main assemblies in turn
to determine whether they are operating
smoothly.

w Similarly, listen for any unusual knocking,


graunching or whining which could
indicate impending component failure.

continued...

NOTES:

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Chapter 1 SECTION 7
General Information OPERATION

7.1 MACHINE CONTROLS & THEIR FUNCTION

7.1.1 General Machine Controls

w The machine control console is mounted on the front of the machine base unit. The
controls and their function are described below.

(i) The "START" button: w Press this green button to start the
machine.

(ii) The "STOP / EMERGENCY STOP" w Press to stop the machine in both normal
button: use and emergency situations. It is
designed to lock down on activation, and
is released by twisting the button.

w Note that this button will not stop the


machine instantly, but will allow the
machine to complete current cycle. It is
required that all working heads complete
their cycle and return to their rest positions
for reasons of safety.

(iii) The "RESET" or "TABLE RELEASE" w Press to reset the machine and working
button: heads after a machine fault condition or
emergency stop. This button will only
function if all guard doors are closed, and
the emergency stop button has been
pressed then released. This prevents a
reset while the machine is cycling.

(iv) The "SINGLE INDEX" key switch: w This key operated switch allows the
machine to operated in individual single
index cycles. For use only by authorised
personnel during setting procedures.

(v) The "SPEED ADJUSTMENT" knob: w This large red hand wheel operates a
variable flow restrictor used to increase or
decrease the forward stroke speed of the
index mechanism. Turn clockwise to
decrease the operating speed, or anti-
clockwise to increase.

(vi) The "PNEUMATIC PRESSURE w This dial gauge displays the air pressure
INDICATOR": in the pneumatic circuit. Additional gauges
may be fitted showing the different
pressures in the operating cylinders of the
crimper unit, depending on specification.

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(v) The "EMERGENCY STOP" button: w Press to stop the machine instantly.

continued...

7.1.2 Working Head Controls

Also located on the console are a series of toggle switches which are used to
individually select the required working heads. Note that the crimper / sensor is permanently
engaged.

(i) The "PRODUCT FILLER 1" selector w Flick up to select the corresponding
switch: product filler, or down to de-select.

(ii) The "PRODUCT FILLER 2" selector w Flick up to select the corresponding
switch: product filler, or down to de-select.

(iii) The "PRODUCT FILLER 3" selector w Flick up to select the corresponding
switch: product filler, or down to de-select.

(iv) The "PRODUCT FILLER 4" selector w Flick up to select the corresponding
switch: product filler, or down to de-select.

(v) The "VALVE INSERTER / SENSOR " w Flick up to select the valve inserter /
switch: sensor head, or down to de-select.

(vi) The "GASSER 3" selector switch: w Flick up to select the corresponding
propellent filler, or down to de-select.

ƒ Note that the crimper is permanently engaged.

NOTES:

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continued...

7.2 PRE-OPERATIONAL REQUIREMENTS

w Before the machine is run, ensure that the following requirements are achieved:

(i) Close all guard doors: w Check all guard doors are securely closed.

(ii) Turn on the pneumatic supply: w Turn the handle on the air service unit
through 90° so that it is in line with the
unit. Check that pressure gauge reads 8
bar (120 psi). Check the oil level in the air
lubricator and top up if required. Drain off
any fluid present in the moisture filter.

(iii) Check and engage the product supply: w Check that the required product supply is
connected, then open the shut-off valve(s)
by turning the handle on each valve
through 90° so that it is in line with the
pipework.

(iv) Check and engage the propellent supply: w Check that the required propellent supply
is connected, then open the shut-off
valve(s) by turning the handle on each
valve through 90° so that it is in line with
the pipework.

(v) Engage the required working heads: w Select the required working heads using
the head selector switches.

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(vi) Check "EMERGENCY STOP " buttons: w Check that all "EMERGENCY STOP"
buttons are released. These are designed
to lock down when pressed, and are
released by twisting the button clockwise.

(vii) Check for obstructions: w Look around the machine and check that
nothing is out of place, or causing an
obstruction.

(viii) Start the conveyors: w Press the relevant "START" buttons on


the line control panel (if applicable) to start
the infeed and outfeed conveyors.

(ix) Check maximum queue switch: w Check that the maximum queue sensor on
the outfeed side of the machine has not
been activated.

NOTES:

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continued...

7.3 OPERATION PROCEDURE

7.3.1 To Run The Machine

(i) Press the "START" button: w Providing all the requirements of 7.2 - Pre-
Operation Requirements are met, the
machine will start cycling.

(ii) Press the "STOP / E/STOP" button when w When required press the "STOP" button to
required: decelerate and stop the machine.

w If the machine should stall, refer to 7.4 - Machine Stoppages During Operation.

7.3.2 Emergencies

! If an emergency situation arises:

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(i) Press the "EMERGENCY STOP " w Pressing the "EMERGENCY STOP"
button will stop the machine instantly.

button IMMEDIATELY :

(ii) Call your line technician: w IF THE NATURE OF THE EMERGENCY


THREATENS YOURSELF OR OTHERS
AROUND YOU, FOLLOW YOUR
COMPANY'S OWN EMERGENCY
PROCEDURES IMMEDIATELY.

NOTES:

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continued...
7.4 MACHINE STOPPAGES DURING OPERATION

w There are several conditions that may arise during normal operation which may
cause the machine to stall. The following lists these conditions and the required action to
restore operational status.

7.4.1 Minimum Can Queue

A closely formed queue of containers is required at the infeed to the machine to ensure
consistent feed into the starwheel and continuous running of the machine. A sensor
assembly is fitted to the infeed conveyor of the machine to maintain this, operating on the
principle that when a sufficient queue of containers has formed, the sensor will register that
containers are present and allow the machine to run. If the queue falls below the required
minimum, the sensor will not register and the machine will stop.

If the machine fails to start, or stops during production:

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(i) Check container supply: w Check that there is no problem with either
the conveyors or the machine up-stream
from the leak detector. A container may
have fallen and / or jammed in the
conveyors, or the up-stream machine, or
the up-stream machine may have stopped
for a separate reason. Either way, the
Starpak will be starved of containers.

(ii) Rectify any problems found. w If no problems found, simply wait until the
queue length builds back past the sensor
and the machine will automatically re-start.

7.4.2 Maximum Can Queue

w If there is a problem with the down-stream machine and it stops, the queue of
containers waiting to enter that machine will start to queue back towards the Starpak. If un-
checked this queue could extend right into the Starpak causing the machine to lock-up,
resulting in extensive damage. To prevent this and to ensure continuous running of the
machine, a sensor assembly is fitted to the outfeed conveyor, operating on the principle
that if a queue of containers from the down-stream machine reaches this point, the sensor
will register that containers are present and stop the machine until the down-stream
machine is operational and has caught up with the Starpak.

If the machine fails to start, or stops during production:

(i) Check down-stream machine w Check that there is no problem with either
& conveyors: the conveyors or the machine down-
stream from the Starpak. A container may
have fallen and / or jammed in the
conveyors, or the down-stream machine,
or the down-stream machine may have
stopped for a separate reason. Either way,
containers will queue back towards the
Starpak.

(ii) Rectify any problems found. w If no problems found, simply wait until the
queue length decreases and the machine
will automatically re-start.

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Chapter 1 SECTION 8
General Information CHANGEPARTS & CHANGEOVER PROCEDURE

w The following is a list of operations that may be required to configure the machine to
suit a different diameter and / or height of can, and valve type, from that which the machine
is currently set for.

WARNING!
! UNLESS OTHERWISE STATED, ALWAYS ENSURE THAT THE MACHINE IS
ISOLATED FROM THE PNEUMATIC MAINS SUPPLY BEFORE PROCEEDING
WITH ANY SETTING OR CHANGEOVER OPERATIONS.

IMPORTANT:
i It is essential that all changeparts fitted are the correct size for the container to
be processed. For ease of recognition, all changeparts are marked with the diameter
of the can they are designed for.

8.1 INFEED & OUTFEED FLIGHT RAILS

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w If the can diameter has changed, the appropriate infeed and outfeed flight rail
changeparts will need to be fitted as follows:

(i) Remove the existing infeed flightrail w Unscrew the two locking thimbles on the
assembly: top of the lower flight rail blade, and lift the
assembly clear.

(ii) Position the replacement infeed flightrail w Position the appropriate replacement flight
assembly: rail assembly on the location dowels, and
secure with the locking thimbles.

(iii) Repeat steps (i) and (ii) for the outfeed


flight
rail assembly.

8.2 INFEED & OUTFEED GUIDE RAILS

w If the can diameter has changed, the infeed and outfeed guide rails will need to be
adjusted as follows:

(i) Slacken the guide rail: w Slacken the two lock nuts on the guide rail
adjustment screws.

(ii) Position a sample container: w If the diameter of the container to be


processed is greater than the current
setting, back off the two lock nuts and
slide the rail out sufficiently for a sample
container to be positioned in the infeed.

(iii) Adjust the guide rail position: w Adjust the guide rail position to give 2-
3mm clearance either side of the
container, then secure with the adjuster
and lock nuts, ensuring that the rail is
parallel.
continued...
(iv) Repeat steps (i) to (iii) for the outfeed
guide rail.

8.3 CENTRE STARWHEEL

w If the can diameter has changed, the appropriate centre starwheel changeparts will
need to be fitted as follows:

(i) Remove the existing starwheel assembly: w Unscrew the four locknuts on the top of
the lower starwheel, and lift the starwheel
assembly off the location dowels.

(ii) Fit the replacement starwheel assembly: w Position the appropriate replacement
starwheel assembly on the location
dowels, and secure with the locking
thimbles.

8.4 OUTER FLIGHT RAIL

w If the can diameter has changed, the appropriate outer flight rail changepart will
need to be fitted as follows:

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(i) Remove the existing outer flightrail w Unscrew the four locking thimbles on the
top of the lower flight rail blade, and lift the
assembly clear.

assembly:

(ii) Fit the replacement outer flightrail w Position the appropriate replacement flight
assembly: rail assembly on the location dowels, and
secure with the locking thimbles.

NOTES:

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continued...

8.5 PRODUCT NOZZLE HEIGHT

 If the can height has changed, the height setting of the product nozzle will need to
be adjusted. Refer to Chapter 3.1, Section 2.2.1 - Nozzle Height Adjustment for the correct
procedure.

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8.6 PRODUCT CHANGE

 If a change in product type is required, the product rams will need to be flushed
through and primed accordingly. Refer to Chapter 3.1, Section 1.2.2 - Nozzle Height
Adjustment for the correct procedure.

8.7 PRODUCT FILL VOLUME

 If a change in product fill volume is required, the product rams will need to be
adjusted accordingly. Refer to Chapter 3.1, Section 1.2.1 - Fill Volume Adjustment for the
correct procedure.

8.8 VALVE SENSOR HEIGHT

 If the can height has changed, the height setting of the valve inserter will need to be
adjusted. Refer to Chapter 3.2, Sections 2.2.1 - Height Adjustment & 2.2.2 - Valve Sensing
Probe Height Adjustment for the correct procedure.

8.9 CRIMPER HEIGHT

 If the can height has changed, the operating height of the crimpers will need to be
adjusted. Refer to Chapter 3.3, Section 1.2.1 - Height Adjustment for the correct procedure.

8.10 CRIMP DIAMETER & DEPTH

 If the valve type has changed, the crimp diameter will need to be checked and, if
necessary, adjusted. Refer to Chapter 3.3, Section 1.2.2 - Crimp Diameter and Depth
Adjustment for the correct procedure.

8.11 PROPELLENT NOZZLE CHANGEOVER

 If a different aerosol valve is to be used, the nozzle adaptor assembly will most likely
need to be changed to suit. Refer to Chapter 4.2, Section 4.2.1 - Nozzle Changeover for
the correct procedure.

 THIS IS ESSENTIAL FOR SAFE, EFFICIENT FILLING.

8.12 PROPELLENT NOZZLE HEIGHT

 If the can height has changed, the height setting of the propellent nozzle will need to
be adjusted. Refer to Chapter 3.2, Section 4.2.2 - Nozzle Height Adjustment for the correct
procedure.

8.14 PROPELLENT CHANGE

 If a change in propellent type is required, the propellent ram will need to be flushed
through and primed accordingly. Refer to Chapter 3.4, Section 1.2.2 - Nozzle Height
Adjustment for the correct procedure.

continued...
8.15 PROPELLENT FILL VOLUME

 If a change in propellent fill volume is required, the propellent ram will need to be
adjusted accordingly. Refer to Chapter 3.4, Section 1.2.1 - Fill Volume Adjustment for the
correct procedure.

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NOTES:

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CHAPTER 2

COMMON EQUIPMENT

Contents

1. Machine Base Unit........................................ 23

2. Machine Guard Assembly............................. 24

3. Index Mechanism.......................................... 26

4. Conveyor Queue Sensor Assemblies........... 30

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Chapter 2 SECTION 1
Common Equipment MACHINE BASE UNIT

1.1 GENERAL DESCRIPTION

1.2 The machine stands on a base frame constructed steel angle section and houses the index
and conveyor drive mechanisms mounted on the underside of the machine baseplate, and
the pneumatic control valves for the working heads. The base frame is clad with stainless
steel panelling, and is fitted with adjustable feet to compensate for uneven flooring. The
base unit also carries the machine control panel, mounted on the rear face of the unit.

SETTING AND ADJUSTMENT

w The base assembly requires no specific setting or adjustment.

1.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

1.3.1 Daily

(i) Clean the base unit exterior: w Machine cleanliness is highly important. A
build up of dirt or debris may impair the
efficiency of equipment housed in the
machine base. This could cause an
unsafe operating condition within the
machine, and as such the base assembly
and cover plate should be cleaned in
accordance with Chapter 1, Section 6.1.

1.3.2 Weekly

w As daily, plus...

(i) Inspect the base unit: w Check that the general structure of the
base is sound, and that all pipework and
fittings are secure and, in the case of
pneumatic pipes, leak free. Pipes that are
damaged should either be repaired if
practicable, or preferably replaced.

NOTES:

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Chapter 2 SECTION 2
Common Equipment MACHINE GUARD ASSEMBLY

2.1 GENERAL DESCRIPTION

The machine is fitted with a safety guard, mounted off the baseplate. This is of stainless
steel box-section tube construction, with either laminated glass or "Makrolon" panelling.
The access doors of the guard are equipped with automatic door bolts to prevent access
into the machine while it is in motion.

Additionally, the infeed and outfeed to the machine are guarded by tunnels mounted on the
side of the main guard structure around the conveyors to prevent access to the machines
moving mechanisms whilst the machine is operating.

These features are incorporated for the safety of the machine's operators in accordance
with the European Community legislation affecting the sale and construction of process and
packaging machinery.
BWI KP Aerofill can accept no liability for damage to the machine and / or personal
injury arising from any incident where these safety features have been tampered with
or disconnected.

2.2 SETTING AND ADJUSTMENT

w The guard assembly requires no specific setting or adjustment.

2.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

2.3.1 Daily

(i) Clean the machine guard: w Cleanliness is highly important. A build up


of dirt on the guard panelling will impair
visibility into the machine. This could hide
an unsafe operating condition within the
machine, and as such the guard assembly
should be cleaned regularly in accordance
with Chapter 1, Section 6.1.

2.3.2 Weekly

(i) Inspect the machine guard: w Check that the guard structure is sound
and that all panels are securely in place.
The safety guard is designed so that it is
not possible to open the access doors
while the machine is running and, vice-

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versa, that the machine cannot be started
with any of the doors open. If either of
these conditions can be breached then
there is a defect with the guard security
system and the machine should not be
operated until a satisfactory repair has
been made.
continued...
NOTES:

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Chapter 2 SECTION 3
Common Equipment INDEX MECHANISM

Ref. Dwg. No. Z418-03-00

3.1 GENERAL DESCRIPTION

The index mechanism is mounted centrally under the machine base plate, and provides the
controlled rotary indexing motion of the starwheel assembly above.

The mechanism is constructed around a central shaft, which runs in a pair of needle
bearings carried in a bearing housing, which is mounted on a sub-plate suspended from the
base plate. At the bottom of this shaft is the index hub assembly, which is basically a pair of
discs carrying 12, 16 or 20 vertical dowel pins (depending on machine type i.e. M20 = 20
pins, etc.) to provide the equivalent number of index positions per starwheel revolution.

Rotary motion is provided by an air/oil cylinder which is fitted with a two-armed, hinged
lever assembly. The whole mechanism is mounted on a sub-plate bolted to the underside
of the machine base plate. When the forward stroke of the cylinder is initiated, the hinged
lever assembly moves forward, engaging the front arm with the nearest dowel pin, so
causing the hub to rotate. As the forward stroke nears it's completion, the side arm is
brought into position to act as a stop, which halts the rotation of the hub.

At the end of the cylinder's forward stroke, a striker plate activates a pilot valve which
initiates the return stroke, withdrawing the hinged lever assembly. As the lever assembly is
withdrawn, it pivots against spring pressure to disengage from the dowel pins, with the
spring returning the lever to it's rest position. To provide some resistance for the air cylinder
to work against, and to prevent the hub rotating backwards during the return stroke of the
index mechanism, an adjustable friction brake assembly is fitted to act on the disc on the
lower surface of the hub. On completion of the return stroke, another striker plate activates
a second pilot valve to signal the start of the next forward stroke.

In order to produce a smooth action from the indexing mechanism, the cylinder used to
provide the indexing motion is hydraulically powered on it's forward stroke, and
pneumatically powered on the return stroke. The incompressible nature of the hydraulic oil
eliminates the jerking that can arise with all-pneumatic cylinders under load. The hydraulic
pressure is supplied by an air / oil dash-pot mounted on the machine base plate, and is
basically an oil reservoir piped to the cylinder through the index forward stroke control valve
(on the control panel). When the forward stroke of the air cylinder is initiated, the pneumatic
circuit applies air at mains supply pressure to the reservoir, forcing the oil through the
pipework and activating the cylinder. On completion of the forward stroke the air to the
reservoir is cut, and the pneumatic return stroke of the cylinder returns the oil to the
reservoir.

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continued...

3.2SETTING & ADJUSTMENT

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

3.2.1 Index Stroke Speed

w A speed valve on the machine control panel regulates the forward stroke of the
indexing cylinder. The pneumatic circuit of the machine is so arranged that the starwheel
will index forward as soon as the heads have retracted clear of the cans. However, the next
filling cycle will not commence until all the metering rams have fully returned. Therefore, the
forward indexing speed of the machine should be tuned so that the index stroke ends at
the same time as the filling rams complete their return stroke. This will give maximum
output with minimum wear.

3.2.2 Return Stroke Speed

A pre-set air flow restrictor is mounted inside the machine base and should not be
tampered with. A faster return stroke will make machine operation noisy, accelerate wear,
and will produce no gain in output, possibly even upsetting the pneumatic sequences.

NOTES:

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continued...

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3.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

3.3.1 Weekly

(i) Clean the index mechanism: w Machine cleanliness is highly important. A


build up of dirt or debris on the index
mechanism may impair the efficiency of
the assembly. This could cause an unsafe
operating condition within the machine,
and as such the index assembly should be
cleaned regularly in accordance with
Chapter 1, Section 6.1, then fully re-
lubricated as stated below.

(ii) Inspect the index mechanism: w Ensure that the general structure is sound
and that all fasteners are secure.

w Check that all pipework and fittings are


secure and leak free.

w Check the dowel pins in the hub assembly


for signs of wear, and ensure that they
rotate freely in their bearings.

w Check the main shaft for slop around the


keyways and/or irregular movement about
the needle bearings.

(iii) Lubricate the index mechanism: w Grease the mechanism through the
grease nipples on the control panel.

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w Grease the shaft bearings through the
grease nipple at the top of the main shaft.

w With the indexing mechanism in it's rest


position, i.e. fully retracted, and the air
supply to the machine turned off, check
the oil level in the air/oil dashpot and, if
required, top up to the mark on the dip
stick.

continued...

NOTES:

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Chapter 2 SECTION 4
Common Equipment CONVEYOR QUEUE SENSOR ASSEMBLIES

w Ref. ass'y. No. 452-21-0c

4.1 GENERAL DESCRIPTION

4.1.1 Minimum Can Queue

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A closely formed queue of containers is required at the infeed to the machine to ensure
consistent feed into the starwheel. A sensor assembly is fitted to the infeed conveyor of the
machine to maintain this, operating on the principle that when a sufficient queue of
containers has formed, the containers will pivot the sensor arm and hold it back, tripping
the valve. This registers that containers are present and allow the machine to run. If the
queue falls below the required minimum, the arm will not be activated and the machine will
stop.
To prevent the machine starting when the first container activates the assembly on it's way
to the machine, a flow restrictor is fitted to the valve, set so that it takes a short time for the
pressure to build up to activate the receiving valve in the machine. This acts as a time
delay to give the containers enough time to reach the machine and form a static queue
before the machine starts. The machine will only run while the sensor arm is held back by a
queue, not when tripped by individual containers.

4.1.2 Maximum Can Queue

If there is a problem with the down-stream machine and it stops, the queue of containers
waiting to enter that machine will start to queue back towards the Starpak. If un-checked
this queue could extend right into the Starpak causing the machine to lock-up, resulting in
extensive damage. To prevent this a sensor assembly is fitted to the outfeed conveyor,
operating on the principle that if a queue of containers from the down-stream machine
reaches this point, a special flightrail section will allow them will bunch up and activate the
sensor arm. This will stop the Starpak until the down-stream machine is operational and
has caught up.

4.2 SETTING AND ADJUSTMENT

The assemblies are pre-set prior to despatch, and should not need to be adjusted.

continued...

4.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

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4.3.1 Daily

(i) Clean the assembly: w Cleanliness is highly important. as a build


up for dirt or debris may impair the ability
of the sensors to detect the container
queue. As such the sensor assembly
should be cleaned regularly in accordance
with Chapter 1, Section 6.1.

4.3.2 Weekly

w As weekly, plus...

(iii) Inspect the assembly: w The assembly should be inspected


regularly to ensure that all fittings and
pipework are secure and leak free, and
that they are correctly set for the current
application.

NOTES:

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CHAPTER 3

MACHINE TOOLING

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Contents

3.1. Preliminary Equipment............................... 33

1. Can Cleaner.................................................. 34

3.2. Liquid Product Fillers................................. 37

1. 250ml Product Ram...................................... 38


1
2. /2" Streamflow Nozzle..................................57

3.3. Valve Crimping............................................ 63

1. Tandem Crimper & Double Acting


Vacuum Crimp Head..................................... 64

3.4. Liquid Propellent Fillers............................. 93

1. 90ml Propellent Ram.................................... 94

2. Nozzle Air Cylinder........................................ 110

3. Propellent Nozzle Body................................. 115

4. Nozzle Adaptor.............................................. 121

CHAPTER 3.1

PRELIMINARY EQUIPMENT
Ref. "51667E", Page
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Contents

1. Can Cleaner.................................................. 34

Chapter 3.1 SECTION 3


Preliminary Equipment CAN CLEANER

w Ref. Dwg. No’s. X420-33-00 / 0V

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3.1 GENERAL DESCRIPTION

w The
Sequence
can cleaner
of Operation
assembly is a simple device to pneumatically blast dust and dirt particles
from containers before they are filled. The assembly consists of a double-acting air cylinder,
with a hollow piston rod, mounted vertically on the machine head plate, with a probe tube
mounted on the end of the cylinder rod. The probe runs down through a shroud mounted
on the underside of the head mounting bracket. The shroud acts as a collector for the dust
and dirt expelled from the containers, being connected to an external vacuum pump
through a port in its side.

First, a container is indexed into position under the head by the index mechanism. Once in
position, a pneumatic signal activates the probe air cylinder and the probe is lowered into
the container. Once fully extended, a timed air blast is delivered through the probe to
agitate any dust and dirt which is then sucked out through the shroud by the vacuum pump.
The air cylinder then retracts the probe and the container is indexed away to the next
process.

3.2 SETTING & ADJUSTMENT

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WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

3.2.1 Height Adjustment

w If there is a change in container height, the height setting of the can cleaner will
need adjusting as follows:

(i) Slacken the locking handle on the side of


the head mounting bracket.

(ii) Position an empty sample container under w Place an empty sample container in the
the head: starwheel pocket under the nozzle to be
set.

w If the height of the new container is


greater than the current container, turn the
handwheel at the top of the support
assembly clockwise to raise the nozzle
sufficiently to allow a sample container to
be positioned.

(iii) Adjust the head height setting: w With the sample container in place, turn
the adjustment wheel anticlockwise to
lower the nozzle, and set the height to
give 2-3mm clearance between the top of
the can bead and the lowest point of the
nozzle spout.

(iv) Tighten the locking handle to clamp the


assembly in position, then remove the
sample container.

NOTES:

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continued...

3.3MAINTENANCE

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

1.3.1 Weekly

(i) Clean the exterior of the assembly: w Cleanliness is highly important. A build up
of dirt or debris may impair the efficiency
of the assembly, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.
Make sure that no rags or tools are left on
or in the machine.

(ii) Inspect the assembly: w The assembly will require periodic visual
inspection. Attention should be paid to the
following:

w Inspect the air cylinder to identify any


possible leaking of seals.

w All pipework should be regularly checked


for leaks

w Check that all fittings and unions are


secure.

NOTES:

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CHAPTER 3.2

LIQUID PRODUCT FILLERS

Contents

1. 250ml Product Ram...................................... 38


1
2. /2" Streamflow Nozzle..................................57

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Chapter 3.2 SECTION 1
Liquid Product Fillers 250ml PRODUCT RAM

w Ref. Dwg. No's. Y167-74-MEB, X175-53-0MA & 175-55-0P

1.1 GENERAL DESCRIPTION

w The machine is equipped with a 250ml product ram assembly, mounted on the side of the
machine, to measure and dispense a set volume of up to 250ml of product to the product
filling nozzle. Each product ram assembly consists of a 2 1/8" air cylinder (Y167-74-MEB), a
250ml metering ram (X175-53-0MA), and a bottom cap and master valve assembly (W175-
55-0P).

The air cylinder is the large diameter cylindrical unit forming the upper half of the ram
assembly, and provides stroke adjustment and pneumatic power for the metering ram
assembly mounted below. The metering ram receives it’s product supply from an external
source, and delivers a pre-set dose of product into the aerosol container through the
bottom cap and then the filling nozzle. The bottom cap contains the master valve assembly,
which is basically a non-return valve to prevent product being sucked back into the ram
during the return stroke.

The air cylinder contains an upper piston and a lower piston. The upper piston is mounted
on the hollow helical screw shaft at the top of the assembly, and provides fill volume
adjustment by means of the thimble mounted on the top of the screw, with the piston acting
as a stroke back-stop for the lower piston.

The lower piston is connected to a rod that runs down into the metering ram. At the lower
end of this piston rod, inside the metering ram, there is a third piston assembly. The
product continually feeds into the metering ram from an external supply through the inlet
port in its upper flange.

The lower piston is constructed using a ported floating piston which slides open when
retracted to allow the product above it in the metering ram to flow through the piston,
priming
Sequence the ram, then when the piston rod is extended by the downstroke of the air cylinder,
of Operation

Ref. "51667E", Page


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First a container is positioned under the product nozzle. A pneumatic signal then initiates
the downstroke of the ram air cylinder lower piston, and consequently the metering ram
piston. The metering ram piston head closes, forcing the product out of the metering ram
and through the pipework to the filling nozzle, through which the product is discharged into
the container. As the air cylinder piston nears the end of it’s downstroke, the underside of
the piston strikes a pilot valve assembly which switches the pneumatic signal to the
underside of the lower piston to return the piston to it’s rest position. This action retracts the
metering ram piston, which slides open to allow the product above to pass through to prime
the ram, resetting the whole assembly for the next cycle.

continued...
1.2 SETTING & ADJUSTMENT

1.2.1 Fill Volume Adjustment

WARNING!
!
THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE LIVE, AND
SHOULD THEREFORE ONLY BE CARRIED OUT BY AUTHORISED TRAINED
PERSONNEL.

w The product ram assembly is adjustable to provide fill volumes of up to 250ml. The
upper outer sleeve of the assembly provides this adjustment as described below.

NOTE:
i There is a scale mounted vertically on the side of the ram air cylinder, running
up under the sleeve. This is a calibrated scale in increments of 2ml to provide a
simple visual reference for setting the propellent fill volume.

(i) Cut air supply to the ram air cylinder: w The air supply to the ram air cylinder must
first be cut by operating the sliding dump
valve located on the pipework next to the
pump housing. This dumps the air on the
air cylinder lower piston.

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(ii) Adjust the fill volume setting as required: w To increase the fill volume, turn the
sleeve anti-clockwise. This raises the
upper piston in the air cylinder, allowing
the lower piston a longer stroke, giving a
higher fill volume.
w
To decrease the fill volume, turn the
sleeve clockwise. This lowers the upper
piston in the air cylinder, limiting the lower
piston to a shorter stroke, giving a lower fill
w volume.

Set the sleeve so that its bottom edge


lines up with the required scale increment.

(iii) Re-engage the air supply to the ram air w Slide the dump valve back to it's original
cylinder: position to re-engage the air supply to the
ram air cylinder.

(iv) Perform a single fill cycle: w Refer to Chapter 1, Section 7 - Operation,


and perform a single fill cycle on a sample
container.

w Ensure all working heads other than the


product ram being set are de-selected.

(v) Check that the actual volume delivered w If for any reason there is a discrepency
is correct: between the set volume and the actual
volume delivered, repeat steps (ii) or (iii)
and (iv) and (v) to trim the unit to the
required setting.

continued...
1.2.2 Product Change

w If the product type is to be changed, the filling heads must first be flushed through to
remove all traces of the previous product type, as follows.

WARNING!
!
THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE LIVE, AND
SHOULD THEREFORE ONLY BE CARRIED OUT BY AUTHORISED TRAINED
PERSONNEL.

(i) Turn on the air supply: w Engage the pneumatic mains supply as if
for normal operation.

(ii) Disconnect the external product supply: w Shut off the external product supply to the
heads, then close the inlet shut-off valves
and disconnect the supply.

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(iii) Connect the required flushing agent: w Connect a suitable supply of the required
flushing agent to the inlet. Note that the
system is designed to operate with a
gravity fed supply.

(iv) Place empty containers in the starwheel: w Place a sufficient number of empty, un-
valved containers in the infeed conveyor
and starwheel pockets leading up to the
product heads, to allow the heads to
perform 5-6 cycles each.

(v) Run the machine for 5 - 6 cycles on each w Referring to Chapter 1, Section 7 -
product ram: Operation, engage the selector switches
of the product heads to be flushed, then
run the machine for 5 - 6 cycles, or until
the discharge from the nozzles is clean.

w Ensure all working heads other than the


product ram being set are de-selected.

(vi) Disconnect the flushing agent supply: w When flushing is complete close the inlet
valves and disconnect the flushing agent
supply.

(vii) Connect the required product supply: w Connect the required product supply and
open the shut-off valves.

(viii) Repeat steps (iv) and (v): w Repeat steps (iv) and (v) to prime the
product rams with the new product type.

(ix) Isolate the machine: w De-select the product fillers and isolate the
machine.

continued...

NOTES:

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continued...

1.3MAINTENANCE

Ref. "51667E", Page


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WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

1.3.1 Weekly

(i) Clean the exterior of the product w Cleanliness is highly important. A build up
ram(s): of dirt or debris may impair the efficiency
of the product ram assembly. This could
cause an unsafe operating condition
within the machine, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the product ram(s): w The product rams should be inspected,
paying attention to the following:

w All pipework should be regularly checked


for leaks, and check that all fittings and
unions are secure.

w Inspect all structural joints to identify any


possible leaking of seals, particularly the
gland seal where the lower piston rod
enters the metering ram. Should product
be found escaping from this point, simply
tighten the gland nut with the spanner
provided (this brass nut is visible in the
aperture in the lower flange of the pump
housing). Do not over-tighten this nut, as
the seal will be crushed.

NOTES:

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Ref. "51667E", Page


48
Release 1.0
continued...

1.4 SEAL REPLACEMENT

~ Seal Replacement Intervals: 6 months

The reciprocating action of the piston assemblies will eventually cause the piston seals to
wear. This would cause a drop in efficiency in the unit as the air used to power the unit will
leak past the seals and cause inconsistencies in the air pressure, and variations in fill
volume will occur due to propellent bleeding past the ram piston. Also, the 'O' rings will
become compressed over a period of time which could cause air / propellent leaks.

 Spares Required:

w K167-74MEB 21/8" Product Air Cylinder

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K167-74-ME 21/8" Product Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - W167-20-01 Buffer 1
- - V592-06-15 Valve Op. Lever 1
- - 940-25-05 'O' Ring 1
- - 940-25-09 'O' Ring 1
- - 940-25-19 'O' Ring 1
- - 940-25-66 'O' Ring 1
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-84 Oil Seal 1
- - 940-46-050 Spring 1
- - 940-70-22 'O' Ring 1
- - 943-40-95 3 Way Valve Cam Op. 1

w K175-53-0MA 250ml Product Ram

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-53-0MA 250ml Product Ram - - -


- - W168-09-02 Cup Seal 1
- - W168-10-02 Back Seal 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1
- - 946-26-58 Ball Valve 1

continued...

Ref. "51667E", Page


49
Release 1.0
K175-55-0P Product Master Valve

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-55-0P Product Master Valve - - -


- - W002-23-02 Master Valve Seal 1
- - W175-55-05 Master Valve Spring 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1

NOTES:

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continued...
1.4.1 Product Ram Removal

w To replace the seals and 'O' rings in the product ram assembly, the assembly will
first need to be removed from the machine a follows:

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Disconnect the product ram assembly: w Disconnect all pipework leading to and
from the product ram assembly, and blank
off all ports to prevent ingestion of any
foreign matter.

(ii) Remove the product ram from the w Support the assembly, slacken and
machine: remove the mounting bolts, then carefully
withdraw the ram assembly from is
mounting.

Ref. "51667E", Page


50
Release 1.0
CAUTION!
!
THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly
while the retaining bolts are being removed, and to help when removing the
assembly from the machine.

NOTES:

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continued...
1.4.2 Bottom Cap (Ref. Dwg. No. Y169-18-0M)

~ Replacement Interval: 6 months

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-55-0P Product Master Valve - - -


- - W002-23-02 Master Valve Seal 1
- - W175-55-05 Master Valve Spring 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1

(i) Remove the bottom cap assembly: w Slacken and remove the four cap head
screws that secure the bottom cap
assembly to the metering ram barrel,
withdraw the assembly from the barrel,
and remove the old 'O' ring.

(ii) Remove the master valve assembly: w Remove the three cap head screws that
retain the master valve housing, extract
the housing and valve assembly, then
remove the old 'O' ring from the cap body.

Ref. "51667E", Page


51
Release 1.0
w Withdraw the valve stem from the housing
and discard the old spring.

(iii) Remove the old master valve seal: w Place the valve stem in a vice fitted with
protective soft-jaws, unscrew the seal
retaining nut, and remove the old master
valve seal.

(iv) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(v) Fit the new seal and spring: w Fit the new seal (W002-23-02) to the valve
stem and secure with the retaining nut.

w Fit the new spring (W002-22-07) to the


valve stem and seat the stem in the valve
housing.

(vi) Re-assemble the valve assembly: w Install the new 'O' ring (940-33-11) in the
counterbore in the cap body, then fit the
seal housing and valve assembly and
secure with the three cap head screws.

continued...
 If the metering ram piston is to be
serviced, go to 1.4.5 now.

(vii) Re-fit the bottom cap assembly: w Re-fit the bottom cap assembly to the
metering ram barrel, not forgetting the new
'O' ring (940-33-08), and secure with the
four cap head screws.

NOTES:

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continued...
1.4.3 Air Cylinder Upper Piston (Ref. Dwg. No. Y167-74-ME)

Ref. "51667E", Page


52
Release 1.0
~ Replacement Interval: 6 months

 Spares Required:

From Spares Ass'y. Description Component Component Description Qty.


Kit Part No.

K167-74-ME 21/8" Product Air Cylinder - - -


- - 940-25-66 'O' Ring 1
- - 940-34-84 Oil Seal 1

(i) Slide the adjustment thimble down to w Unscrew the four countersunk screws that
access the air cylinder top cap: retain the adjustment thimble, and slide
the thimble sleeve down to expose the air
cylinder top cap.

(ii) Remove the upper assembly and screw w Unscrew the four tie rod nuts that retain
shaft to expose the upper piston: the top cap of the assembly. Hold the
cylinder barrel and carefully withdraw the
upper assembly and screw-shaft. This will
expose the upper piston assembly on the
end of the piston rod.

(iii) Remove the upper piston head, and w Slacken and remove the piston retaining
discard the old seals: nut from the underside of the piston head,
and slide the two piston halves off the
screw-shaft.

w Remove the old lip seal and 'O' ring.

(iv) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(v) Fit the new seals: w Carefully fit the new lip seal (940-34-84)
and 'O' ring (940-25-66) to the upper
piston half.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the
reverse order of step (iii) above.

NOTES:

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continued...

Ref. "51667E", Page


53
Release 1.0
1.4.4 Air Cylinder Lower Piston (Ref. Dwg. No. Y167-74-ME)

~ Replacement Interval: 6 months

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares Kit: Part No.

K167-88ME 41/2" Air Cylinder - - -


- - 940-25-08 'O' Ring 1
- - 940-70-20 'O' Ring 1
- - 992-11-19 Cup Washer 2

w With the air cylinder upper piston removed:

(i) Remove the cylinder barrel and sealing w Carefully pull the cylinder barrel from the
washer: pump housing to expose the lower piston
assembly, and remove the sealing washer
from the barrel location groove in the
housing.

(ii) Refer to 1.4.5 steps (i) to (iii) and remove


the metering ram barrel.

(iii) Remove the lower piston assembly w Insert a tommy bar in the hole at the
retaining nut: bottom end of the lower piston rod, and
remove the lower piston retaining nut.

(iv) Disassemble the lower piston assembly: w Remove each component of the lower
piston assembly from the piston rod - i.e.
the washer, buffer, piston body, and
actuator plate.

w Discard the old seals.

(v) Clean the components: w Clean the other components using a high
flashpoint solvent, ensuring that there is
no foreign matter present where the new
seals are to be fitted.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the
reverse order of step (iii) and (iv) above,
fitting the new lip seals (940-34-84 x2).

(vii) Clean the pump housing as above.

(viii) Refit the cylinder barrel: w Fit the new 'O' ring (940-70-22) to the
groove in the pump housing, then refit the
cylinder barrel, taking care that the new 'O'
ring is seated correctly.

continued...
 If the metering ram piston is to be
serviced, go to 1.4.5 now.

Ref. "51667E", Page


54
Release 1.0
(ix) Refer to 1.4.5 step (ix) and refit the
metering ram barrel.

(x) Re-assemble the upper assembly: w Re-assemble the upper assembly in the
reverse order of 1.4.3, steps (i) to (ii).

(xi) Refit the product ram to the machine: w Refit the product ram to the mounting
plate in the reverse order of steps (i) to (iii)
at the start of this chapter.

NOTES:

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continued...
1.4.5 250ml Ram Piston (Ref. Dwg. No. X175-53-0MA)

~ Replacement Interval: 6 months

 Spares Required:

From Spares Ass'y. Description Component Component Description Qty.


Kit Part No.

K175-53-0MA 250ml Product Ram - - -


- - W168-09-02 Cup Seal 1
- - W168-10-02 Back Seal 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1

Ref. "51667E", Page


55
Release 1.0
(i) Disconnect the metering ram barrel and w If not already done, disconnect all
bottom cap assembly: pipework leading to and from the metering
ram barrel and bottom cap assembly, and
blank off all ports to prevent ingestion of
any foreign matter.

(ii) Remove the metering ram barrel: w Support the ram barrel and remove the
four socket head screws that secure the
barrel to the air cylinder pump housing,
and carefully withdraw the ram barrel to
expose the metering ram piston assembly.

(iii) Unscrew the piston assembly: w Insert a tommy bar in the hole in the
tapered piston head, and another in the
hole in the piston rod, and unscrew the
piston assembly.

(iv) Remove the piston from the piston head: w Insert a tommy bar in the hole in the
tapered piston head, remove the locknut
inside the seal retaining nut, and remove
the lower piston head assembly and back
seal.

(v) Unscrew the seal retainer and discard w Slacken and remove the cup seal retaining
the old cup seal: nut from the lower piston head, and
remove the old cup seal.

(vi) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

 If the pump housing assembly is to be


serviced, go to 1.4.5 now.

continued...
(vii) Fit the new seals and re-assemble the w Re-assemble the piston assembly in the
piston assembly: reverse order of steps (iv) to (vi) above,
fitting the new back seal and the new cup
seal (W168-10-02 & W168-09-02).

(viii) Re-assemble the metering ram assembly: w Re-assemble the metering ram in the
reverse order of steps (i) to (iii) above,
fitting the new 'O' ring (940-33-10). When
refitting the barrel, use the tapered lead at
the top of the barrel to form the cup seal
as shown on the drawing.

(ix) Re-fit the bottom cap: w Re-fit the bottom cap, not forgetting the
new 'O' ring (940-33-08).

Ref. "51667E", Page


56
Release 1.0
NOTES:

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continued...
1.4.6 Pump Housing, Pilot Valve and Gland Housing (Ref. Dwg. No. Y167-88-ME)

~ Replacement Interval: 6 months

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares kit: Part No.

K167-88ME 41/2" Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - 940-25-05 'O' Ring 1
- - 940-25-09 'O' Ring 1
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-86 Oil Seal 1

(i) Gain access to the gland housing: w Push the piston rod down through the
pump housing to expose the gland
housing.

(ii) Remove the gland housing from the w Insert a tommy bar in the hole in the side
piston rod: of the gland housing, slacken the gland
nut, then slide the gland housing down off
the rod and set aside.

(iii) Remove the piston rod from the pump w Carefully withdraw the piston rod from the
housing: top of the pump housing.

Ref. "51667E", Page


57
Release 1.0
(iv) Remove the cover plate in the top face of w Remove the four countersunk screws that
the pump housing: retain the central cover plate in the top
face of the pump housing, and lift out the
plate.

(v) Remove the valve operating pin and w Carefully lift out the valve operating pin
discard the old 'O' rings: complete with the seal holder and spring,
and remove the old 'O' rings from the seal
holder.

(vi) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(vii) Re-assemble the operating pin assembly: w Re-assemble the operating pin assembly
in the reverse order of steps (iv) and (v)
above, fitting the new 'O' rings (940-25-05
& 940-25-09) to the seal holder.

(viii) Remove the external pilot valve assembly


from the side of the pump housing.

continued...
(ix) Remove the seal retainer plate in the w Remove the four screws that hold the seal
pump housing aperture and discard the retainer plate in the top face of the pump
old lip seal: housing aperture, remove the plate, and
extract the lip seal that is now exposed.

(x) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(xi) Re-assemble the seal and valve w Re-assemble the seal and valve assembly
assembly: in the reverse order of steps (viii) and (ix)
above, fitting the new lip seal (940-34-61)
to the seal holder.

(xii) Remove the gland nut and lip seal, and the
outer 'O' ring from the gland housing.

(xiii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

Ref. "51667E", Page


58
Release 1.0
(xiv Re-assemble the gland housing assembly: w Re-assemble the gland housing assembly
) in the reverse order of step (xi) above,
carefully fitting the new gland seals
(W167-01-12 x3) and the new 'O' rings
(940-25-19 & 940-33-10). Gently tighten
the gland nut - this should be checked and
adjusted as required once the unit is back
on the machine.

(xv) Re-install the pump housing on the piston w Clean the piston rod as above and slide
rod: the lower end of the rod down through the
gland housing, then slide the upper end of
the rod up through the pump housing.

 Refer back through the procedures and re-


assemble the product ram assembly, and
refit the assembly to the machine.

NOTES:

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continued...

1.5 FAULT FINDING

Fault Remedy

Metering ram fails to fill: „ Check propellent supply is available.

„ Check propellent ram inlet valve is open.

„ Check all air couplings are engaged.

„ Check air supply to ram air cylinder.

„ Check propellent nozzle opens.

„ Ensure gland seal nut is not too tight.

Ref. "51667E", Page


59
Release 1.0
„ Check NCNF lever is not being actuated
due to nozzle being set too high.

„ Check propellent piston head is not


jammed.

„ Check air cylinder master valve assembly.

„ Ensure air cylinder piston seals are not


leaking.

Fill volume not consistent: „ Check propellent supply.

„ Vent propellent metering ram.

„ Ensure air cylinder piston returns fast


enough.

„ Check propellent nozzle closes at end of


fill.

„ Check propellent piston slides freely.

„ Check propellent piston seals.

continued...

NOTES

Ref. "51667E", Page


60
Release 1.0
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Ref. "51667E", Page


61
Release 1.0
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Chapter 3.2 SECTION 2


1
Liquid Product Fillers /2" STREAMFLOW PRODUCT NOZZLE

Ref. Dwg. No. X175-46-0D

2.1 GENERAL DESCRIPTION

This machine is equipped with ‘Streamflow’ product filling nozzles mounted on the height
adjustable mounting plate. Each nozzle consists of a lower body section, a cylinder body
and a cylinder barrel, which are screwed into each other, and house a spring loaded
piston / spool assembly, with the spring being fitted to hold the spool closed when the
pneumatic supply is shut off. The lower body section is also fitted with a product inlet tube,
which is connected to the product supply pipework from the metering ram assembly.

SEQUENCE OF OPERATION:

When a container is indexed into position under the filling nozzle, pneumatic signal to the
cylinder body forces the piston / spool upwards against the spring pressure to open the
nozzle. Simultaneously, another signal activates the filling cycle of the product ram
assembly. The product is then discharged into the container through the nozzle and
connecting pipework. Once the product dose has been discharged, the signal to the
cylinder body is cut and another is applied to the top of the barrel to force the spool down
onto the seal, thus shutting off the nozzle to prevent any dripping. The nozzle is now ready
to repeat the cycle.

Ref. "51667E", Page


62
Release 1.0
continued...

2.2 SETTING & ADJUSTMENT

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

2.2.1 Nozzle Height Adjustment

w If there is a change in container height, the height setting of the nozzle will need adjusting
as follows:

(i) Slacken the locking handle on the side of


the nozzle mounting bracket.

(ii) Position a sample container under the w Place an empty sample container in the
head: starwheel pocket under the nozzle to be
set.
w
If the height of the new container is
greater than the current container, turn the
handwheel at the top of the support
assembly anti-clockwise to raise the
nozzle sufficiently to allow a sample
container to be positioned.

Ref. "51667E", Page


63
Release 1.0
(iii) Adjust the head height setting: w With the sample container in place, turn
the adjustment wheel clockwise to lower
the nozzle, and set the height to give 4mm
clearance between the top of the can
bead and the lowest point of the nozzle
spout.

(iv) Tighten the locking handle to clamp the


assembly in position, then remove the
sample container.

NOTES:

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continued...

2.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

2.3.1 Weekly

Ref. "51667E", Page


64
Release 1.0
(i) Clean the exterior of the assembly: Cleanliness is highly important. A build up
of dirt or congealed product may impair
the efficiency of the shut-off mechanism in
the nozzle. This could cause splashing
and inconsistent fills, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle: The nozzle should be inspected, paying


attention to the following:

All pipework should be regularly checked


for leaks, and check that all fittings and
unions are secure.

Inspect the structural joints of the air


cylinder to identify any possible leaking of
seals.

Inspect the tip of the nozzle to ensure that


the mechanism is shutting off correctly

NOTES:

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continued...

Ref. "51667E", Page


65
Release 1.0
2.4 SEAL REPLACEMENT PROCEDURE

~ Replacement Interval: 6 months

The reciprocating action of the air cylinder piston will eventually cause the internal seals to
wear and / or deform. This will reduce the efficiency of the unit as air will bleed past the
seals and reduce the working pressure of the unit, and also product splashing and
inconsistent fills may be experienced.

 Parts Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-46-0J 1
/2" Streamflow Nozzle - - -
- - W120-54-04 P.T.F.E. Seal 1
- - V120-54-08 Seal Washer 1
- - 940-25-08 'O' Ring 1
940-25-66 'O' Ring 1
940-34-46 Lip Seal 1
940-34-81 Lip Seal 2

2.4.1 Nozzle Removal

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

w The nozzle must first be removed from the machine, as follows:

(i) Disconnect all pipework: w Disconnect the pipework leading to and


from the nozzle assembly, then blank off
all ports using clean, dry, lint-free rag to
prevent ingestion of any foreign matter.

(ii) Remove the nozzle assembly: w Remove the nozzle assembly by undoing
the bracket clamp which holds it in place.
The nozzle assembly should be supported
until it can be lowered from the clamp.
Note that the clamp bolts do not have to
be removed for the assembly to be
removed.

NOTES:

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Ref. "51667E", Page


66
Release 1.0
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continued...

2.4.2 Seal Replacement

With the assembly on a workbench:

(i) Gain access to the spool piston sub- w Unscrew the cylinder barrel from the
assembly: cylinder body to reveal the spool piston
sub-assembly.

w Remove the return spring.

(ii) Disassemble the piston sub-assembly: w Unscrew the piston locknut, and remove
the clamp washer, lip seals and retainer,
and support washer.

(iii) Remove the old seals: w Remove the old lip seals from retainer,
and the old 'O' ring from the cylinder body.

(iv) Remove the spool: w Unscrew cylinder body from the lower
body section and extract the spool.

(v) Remove the old seals: w Remove the old 'O' ring from the cylinder
body and the lip seal from the lower body.

(vi) Remove the lower clamp and the old seal: w Unscrew the three retaining screws from
the lower clamp, and remove the clamp
and the old PTFE seal.

(vii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals and 'O' rings are to be fitted.

(viii) Re-assemble the product nozzle assembly w Re-assemble the product nozzle assembly
fitting the new seals: in reverse order of steps (i) to (ix) above,
fitting the new PTFE seal (W120-54-04),
seal washer (V120-54-08), the new lip
seals (940-34-46 & 940-34-81 x2) and 'O'
rings (940-25-08 & 940-25-66), taking care
not to damage any of these.

(ix) Refit the nozzle assembly pipework in


reverse order of steps as above.

NOTES:

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continued...

2.5 FAULT FINDING

Fault Remedy

Zero, low or inconsistent product fill: „ Check product supply.

„ Check pipework and connections.

„ Check spool operation.

„ Check seals are not leaking.

NOTES:

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Ref. "51667E", Page


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CHAPTER 3.3

VALVE CRIMPING

Contents

1. Tandem Crimper & Double Acting


Vacuum Crimp Head..................................... 64

Ref. "51667E", Page


69
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Chapter 3.2 SECTION 1
Valve Crimping TANDEM CRIMPER & D/A VACUUM CRIMP HEAD

w Ref. Diagrams on following pages & Dwg. No's. Y404-62-0A & Y404-47-0E

1.1 GENERAL DESCRIPTION

w The tandem crimper and double acting vacuum head assembly is a unit designed for
drawing a vacuum in containers which have had valves inserted, then crimping the valve in
place.

Each crimper unit consists of primary cylinder and a secondary cylinder. The primary
cylinder is mounted on the crimper plate and forms the basis for the crimper assembly.
Through the primary cylinder runs the hollow primary shaft, which carries the crimp head at
it’s lower end, and is connected to the secondary cylinder at it’s top end. Mid-way down this
shaft is a piston, which operates within the primary cylinder. The action of this piston lowers
and raises the crimp head. The secondary shaft runs through the hollow primary shaft, and
is attached to the crimp wedge of the head assembly at it’s lower end. At the top end, the
secondary shaft is connected to a tandem piston assembly, consisting of the upper and
lower secondary pistons, which reciprocates within the secondary cylinder to operate the
crimp wedge. Another piston, the primary piston, is located within the lower bore of the
secondary piston and slides on the primary shaft. This piston acts as a stop when the head
is lowered, allowing the vacuum phase of the crimping process to be performed before the
crimp head itself is lowered fully to crimp.
Sequence of operation:

1.1 Stage 1 - Crimper at rest

 The crimp head, vacuum shroud and primary and secondary assemblies all held in
their retracted positions. The vacuum pump constantly running.

Ref. "51667E", Page


70
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1.1. Air applied to port 'C' to hold vacuum
1 shroud retracted (up).

1.1. Air applied to port 'E' to hold up secondary


2 cylinder.

1.1. Air applied to port 'B' to hold up primary w Port 'B' is indirectly powered by the air
3 shaft and crimp head. applied to port 'E' passing through the
upper secondary cylinder and out of port
'E1', then through pipework from 'E1' to
port 'B'.

1.2 Stage 2 - down stroke & vacuum

ƒ The vacuum shroud is extended, as are the internal stop piston, primary shaft and
crimp head. Once these are extended, the vacuum phase is performed.

1.2. Air applied to port 'S' to extend the internal


1 stop piston.

1.2. Air applied to 'H' to extend the vacuum


2 shroud.
continued...
1.2. Air to port 'E' cut and applied to port 'A' to w The air under the primary piston from
3 power down the primary shaft and crimp Stage 1.1.3 exhausts through a flow
head. restrictor on port 'B', through in the
connecting pipework, back into port 'E1'
then out of port 'E'. This air finally
exhausts through a valve in the crimper
circuit. The flow restrictor is incorporated
to control the flow of the exhausting air,
providing a means of controlling the speed
of the downstroke.

w To enable the vacuum phase to take


place, the primary shaft is prevented from
descending fully by the internal stop piston
contacting the top of the primary cylinder.
This holds the crimp head clear of the
aerosol valve, allowing the vacuum seal to
contact the neck of the can. Once the seal
makes contact the air in the can is
evacuated around the valve and out
through port 'F'.

1.3 Stage 3 - crimp

1.3. Vacuum phase times out.


1

Ref. "51667E", Page


71
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1.3. Air to ports 'H' & 'S' cut, air to port 'A' w With air removed from port 'H' the vacuum
2 maintained. shroud, while still in contact with the can,
is free to 'float'. When the air to port 'S' is
cut, the air still applied to port 'A' powers
the primary shaft and crimp head down to
complete the downstroke, with the crimp
head sliding down through the vacuum
shroud. This brings the crimp head down
on the aerosol valve, which locates in the
can location ring in the crimp head, and
presses down on the valve to compress
the valve gasket. The air previously
holding down the vacuum shroud and the
internal stop piston passes out through
ports 'H' and 'S' and exhausts through the
circuit.

1.3. Pilot valve activated, air applied to ports w At the end of the downstroke, an external
3 'C', 'D' and 'D1'. pilot valve mounted on the secondary
cylinder is activated. This signals air to be
applied to port 'C' to retract the vacuum
shroud, and to ports 'D' and 'D1' to power
down the secondary shaft and crimp
wedge to crimp the valve. The vacuum is
maintained in the can by the crimp head
pressing down on the valve. The air under
the upper secondary piston passes out
through port 'E' and exhausts through the
circuit.

continued...
1.3. Air applied to port 'G' signals end of crimp. w Some of the air applied to port 'D' in 1.3.3
4 is allowed to escape through the bleed
hole in the secondary cylinder top cap,
under the crimp diameter adjustment nut.
When the secondary shaft completes its
downstroke, the buffer on the underside of
the adjustment nut seals the bleed hole,
causing a pulse of air to pass through port
'G'. This pulse activates a valve to signal
that the crimp is complete and initiates the
crimper return stroke.

1.4 Stage 4 - return stroke

1.4. Air to ports 'D' & 'D1' cut, air applied to w Air is first applied to port 'E' to retract the
1 port 'E' to retract secondary shaft secondary shaft and crimp wedge,
assembly. consequently allowing the crimp jaws to
close. This has to be first movement of the
return stroke since if the crimp head is
retracted while the jaws are still open, the
jaws will pick up the can.

Ref. "51667E", Page


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1.4. Air applied to port 'B' to retract primary w Port 'B' is indirectly powered by the air
2 shaft and crimp head. applied to port 'E' in 1.4.1 passing through
the upper secondary cylinder and out of
port 'E1', then through a flow restrictor in
the pipework connecting 'E1' to port 'B'.
The flow restrictor is incorporated to
ensure that the primary cylinder takes
longer to pressurise than the secondary
cylinder. This results in a delay between
the two cylinders operating, preventing the
can from being picked up as 1.4.1. The air
above the tandem secondary pistons
exhausts through ports 'D' and 'D1', then
the air above the primary piston exhausts
through port 'A'.

w The crimper is now ready to repeat the


cycle.

Ref. "51667E", Page


73
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Tandem Crimper

Guide to Main Assemblies & Pneumatic Ports

1. Crimp Diameter Adjustment Nut


2. Secondary Cylinder
1
3. Secondary Shaft & Tandem
Piston Assembly
4. Internal Stop Piston
5. Primary Shaft 2
6. Primary Cylinder
7. Primary Piston
8. Crimp Head
'G' 'D' 3
9. Vacuum Shroud

'E'
'D1'
'E1'

'S'
4

5
6

7
'A'

'B'

8
9

'C'

'H'
'F'

Ref. "51667E", Page


74
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Stage 1 Stage 2 Stage 3 Stage 4
Crimper at Rest Downstroke Crimp Return Stroke
& Vacuum

'D'

'G' 'D'
'E' 'E'
'E1' 'E1'
'E'
'D1' 'E'
'E1'
'E1'

'S'
'S'

'A' 'A' 'A'

'B' 'B' 'B' 'B'

'C'
'C'

'C' 'C'

'H' 'H'

'F'

Ref. "51667E",
Page 75
1.2 SETTING & ADJUSTMENT

w Valves of different types and specifications may possess varying crimp properties by
nature of differing materials, dimensions etc. Consequently, if an alternate valve is to be
processed the crimper may need to be adjusted using the following procedures to achieve
the valve manufacturers’ recommended crimp dimensions. Note that the crimp head must
be in it’s down position, and also that the crimp diameter should be set before the crimp
depth.

1.2.1 Height Adjustment

w If the overall container height has changed, the height setting of the crimper will
need to be adjusted as follows.

WARNING!
! PARTS OF THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE
LIVE, AND SHOULD ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

(i) Gain access to the crimper: w Open the guard door to gain access to the
crimper unit and height adjustment
column.

(ii) Pull the crimp head down: w With the pneumatic supply turned OFF, it
will be possible to manually pull the crimp
head down to it's lower position. The crimp
head may slide down under it's own
weight when the pneumatic supply is cut.
If not, grasp the crimp head and gently
pull downward until a pronounced stop is
felt.

WARNING!
! The crimp unit's internal seals will bed in after a period of use, and as a
consequence the head may drop unexpectedly after the air supply is cut. This
does not indicate any malfunction, but does call for vigilance on behalf of
operators and service personnel.
ƒ If the crimp head should remain in the UP position when the air is cut:
w DO NOT put your hands under the crimp head;
w DO NOT use any tools or excessive force to lower the head;

(iii) Release the mounting bracket: w Slacken the locking handle on the side of
the column mounting bracket to allow the
height to be adjusted.

Ref. "51667E", Page


76
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(iv) Position a sample container with valve: w If the overall height of the container to be
processed is greater than that which the
machine is currently set for, turn the
handwheel at the top of the support
assembly clockwise to raise the crimper
sufficiently to allow a sample container,
complete with a seated valve, to be placed
in the starwheel pocket under the crimper.

continued...
(v) Adjust the crimper height setting: w With the sample container in position, turn
the handle anti-clockwise to lower the
crimper until the can location ring in the
crimp head touches the lip of the sample
valve.

w Lower the head by a further two turns of


the handle to ensure that the valve gasket
is sufficiently compressed when the crimp
process takes place, and to prevent the
crimper bottoming-out in operation.

(vi) Remove the sample container / valve: w Manually lift the crimp head sufficiently to
remove the sample container / valve, then
lower the head back to the down position.

(vii) Secure the mounting bracket: w Tighten the locking handle and close the
guard door.

NOTES:

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continued...

Ref. "51667E", Page


77
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1.2.2 Crimp Diameter and Depth Adjustment

WARNING!
! PARTS OF THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE
LIVE, AND SHOULD ONLY BE CARRIED OUT BY TRAINED PERSONNEL.

(i) Refer to Chapter 1, Section 7 - Operation,


and prepare the machine for operation.

(ii) Position a sample container with valve: w Place a sample can, complete with valve,
in the starwheel under the crimp head to
be set.

(iii) Perform a single crimp cycle: w There is a "SINGLE CRIMP" key switch
mounted on the control console next to
each crimp head. Insert the correct key in
the switch on the corresponding console
and turn then return to perform a single
crimp cycle on the sample valve in the
can.

 It is important that the key is returned


immediately since if the crimp head is left
down for longer than during a normal
crimp cycle, the resultant crimp diameter
will be larger due to the prolonged force
applied.

(iv) Measure the crimp diameter: w Remove the sample can and measure the
crimp diameter using the appropriate dial
gauge.

(v) Adjust the crimp diameter as required: w Refer to the valve manufacturers'
recommended dimensions for crimp
diameter and adjust as required.

w Adjustment is by means of the knurled


thumb nut at the top of the crimper
assembly. This contains a spring loaded
ball mechanism which provides click-stop
adjustment of the crimp diameter in
increments of 0.05mm. To adjust, rotate
the adjustment nut anti-clockwise to
increase the crimp diameter, or clockwise
to decrease.

Ref. "51667E", Page


78
Release 1.0
w Repeat steps (ii) to (v) until the required
crimp diameter is achieved, then proceed
to step (vi).

(vi) Repeat steps (ii) and (iii), then measure w Once the crimp diameter has been set,
the crimp depth: repeat steps (ii) and (iii), then remove the
sample can and measure the crimp depth
using the appropriate dial gauge.

continued...
(vii) Adjust the crimp depth as required: w Refer to the valve manufacturers'
recommended dimensions for crimp depth
and adjust as required.

w Adjustment is by means of the crimp depth


adjustment ring at the top of the vacuum
shroud assembly. This is fitted with a
spring loaded locking pin which provides
adjustment of the crimp depth in
increments of 0.01mm. Pull out the locking
pin on the adjustment ring, and rotate the
ring anti-clockwise to increase the crimp
depth, or clockwise to decrease. Ensure
that the pin is returned to it’s locked
position.

w Repeat steps (vi) and (vii) until the


required crimp depth is achieved.

(vii) Repeat for all crimp heads: w Repeat steps (i) to (vii) as required until
each of the crimper units are correctly set.

(viii) Close the guard door and isolate the


machine.

NOTES:

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continued...

Ref. "51667E", Page


79
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1.2.3 Vacuum To Non-Vacuum Changeover

w If required, the crimper can be made to operate as both the standard vacuum crimper, and
also as a conventional non-vacuum crimper.

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Remove the vacuum seal retainer: w Unscrew the vacuum seal retainer from
the bottom of the vacuum shroud.

(ii) Extract the vacuum shroud.

(iii) Replace the seal retainer.

(iv) Disable or turn off the vacuum generator.

(v) Check the crimper settings: w Check that the crimp depth and diameter
settings are still correct for the valve type
to be crimped.

(vi) To revert to vacuum crimping, reverse


steps (i) to (iv) above, then repeat step (v).

NOTES:

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continued...

1.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

1.3.1 Per Shift

w The lubrication of crimp jaws and wedge cannot be emphasised too highly. This will
minimise wear to both the jaw set and the crimp wedge, and also greatly reduce the risk of
breakage, helping to maximise the operating life of costly replacement items.

IMPORTANT!
! There are several areas within the crimper assemblies where sliding
components are subject to metal-to-metal contact under high loading. As a
consequence, regular and frequent lubrication is essential to prevent the rapid
wear of components contained in this assembly.

Ref. "51667E", Page


81
Release 1.0
(i) Lubricate the crimp jaws: w The inside of the crimp collet should be
smeared with Molykote 165LT grease or
equivalent at the start of, and half way
through, each shift. This should be applied
all round the outer face of the crimp collet,
ensuring that the whole surface is
covered.

w If long shifts are in operation, or if the units are being used at high cycle rates,
then the time between applications should be reduced accordingly. Lubrication twice
per shift, or even three times in extreme conditions, should be considered.

1.3.2 Daily

(i) Lubricate the crimper: w General lubrication of the head is


facilitated by the grease nipple fitted to the
body of the assembly, and should be
performed at least once a day.

(ii) Clean the exterior of the crimper: w The exterior of the crimper should be
cleaned daily in accordance with Chapter
1, Section 6.1.

1.3.3 Weekly

As daily, plus...

(i) Inspect the crimper unit: w The crimp wedge and jaws should be
regularly inspected for wear and / or
damage in the form of scoring, cracks etc.

w Attention should be paid to structural joints


to identify any possible leaking of seals.
All pipework should be checked for leaks,
ensuring that all fittings and unions are
secure.
continued...
NOTES:

Ref. "51667E", Page


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1.4 SEAL REPLACEMENT PROCEDURE

~ Replacement Interval: 6 Months

Ref. "51667E", Page


83
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w The reciprocating action of the crimper will eventually cause the primary and secondary
cylinder piston seals to wear. This would cause a drop in efficiency in the unit as the air
used to power the unit will leak past the seals and cause inconsistencies in the air
pressure. Also, the 'O' rings will become compressed over a period of time which could
cause air leaks. Consequently, the seals and 'O' rings in the crimper assembly should be
changed every 6 months.

 Parts Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-47-0P Vacuum Crimp Head - - -


- - V404-40-13 Buffer 1
- - V404-47-20 Vacuum Seal - 45 / 50mm 1
- - V404-47-21 Vacuum Seal - 53mm 1
- - V404-47-22 Jaw Spring Mod. 1
- - 940-37-80 External Seal - 70mm 1
- - 940-37-81 Rod Wear Ring - 65mm 1
- - 940-37-82 Internal Seal - 65mm 1
- - 940-37-83 Rod Wear Ring - 56mm 1
- - 940-37-84 Internal Seal - 56mm 1
- - 940-70-33 'O' Ring 1
- -
K404-62-0A Tandem Crimper - - -
- - V404-62-03 Adjusting Nut Buffer 1
- - V404-62-07 Internal Buffer 2
- - V404-62-27 Internal Buffer 1
- - 940-25-32 'O' Ring 1
- - 940-37-69 Internal Seal 2
- - 940-37-70 Rod Wear Ring - 18mm 4
- - 940-37-71 External Seal - 75mm 3
- - 940-37-72 Pstn Wear Ring - 75mm 4
- - 940-37-73 External Seal - 48mm 1
- - 940-37-74 Pstn Wear Ring - 48mm 2
- - 940-37-75 Internal Seal - 28mm 1
- - 940-37-76 Rod Wear Ring - 28mm 2
- - 940-37-77 Internal Seal - 30mm 2
- - 940-37-78 Rod Wear Ring - 30mm 4
- - 940-70-25 'O' Ring 1
- - 940-70-26 'O' Ring 2
- - 940-70-27 'O' Ring 1
- - 940-70-32 'O' Ring 1

1.4.1 Crimper Removal

Ref. "51667E", Page


84
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The vacuum seal and vacuum shroud seals can be replaced with the crimper 'in situ'.
However, to replace the seals and 'O' rings in the main crimper assemblies, the unit will
first need to be removed from the machine a follows:

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Disconnect the crimper: w Disconnect all pipework leading to and


from the crimper unit, and blank off all
ports using pieces of clean, dry, lint-free
rag to prevent ingestion of any foreign
matter.

(ii) Remove the crimper from the machine: w If not already done, remove the crimp
head as stated in 1.4.2 steps (i) to (iii).

w Insert a tommy bar in one of the holes in


the crimp head body, grip the secondary
cylinder, then unscrew and remove the
crimp head and 'O' ring from the end of
the primary shaft.

w Have an assistant support the unit, then


slacken and remove the clamp collar and
shim from the secondary cylinder under
the head plate support block.

w Carefully withdraw the crimper from the


machine, taking care not to knock the
assembly against the guard or other
heads.

(iii) Place on a suitable work bench.

CAUTION!
! THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly
while the clamp collar is being removed, and to assist when removing the
assembly from the machine.

NOTES:

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continued...
1.4.2 Vacuum Seal

w If difficulties have been encountered when attempting to draw off high vacuums, try
replacing the vacuum seal, as follows, before investigating the problem any further.

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Remove the vacuum seal retainer: w Using a suitable 'C' spanner, slacken and
remove the vacuum seal retainer from the
bottom of the vacuum shroud.

(ii) Extract the vacuum seal and inspect for


wear and / or damage.

(iii) Fit a new vacuum seal if required: w Fit a new vacuum seal if required,
ensuring that it is of the correct type for
the container being processed.

(iv) Re-fit the seal retaining ring.

(v) Test the new seal: w Perform some trial crimp cycles to see
whether this has cured the problem. If it
has not, suspect seal failure within the
vacuum shroud assembly.

IMPORTANT!
i
Where the use of a 'C' spanner is stipulated, it is important that this tool is
used. Other methods, especially the use of punches, will damage the
components and eventually render them useless.

NOTES:

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Ref. "51667E", Page


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continued...

1.4.3 Vacuum Shroud

If difficulties have been encountered when attempting to draw off high vacuums, first try
replacing the vacuum seal, as stated previously in 1.4.1 - Vacuum Seal. If replacing the
vacuum seal fails to cure the problem, replace the seals in the vacuum shroud.

The crimp head will first have to be removed from the main unit.

IMPORTANT!
i
Where the use of a 'C' spanner is stipulated, it is important that this tool is
used. Other methods, especially the use of punches, will damage the
components and eventually render them useless.

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares Kit: Part No.

K404-47-0P Vacuum Crimp Head - - -


- - 940-37-81 Rod wear Ring - 65mm 1
- - 940-37-82 Internal Seal - 65mm 1
- - 940-37-83 Rod Wear Ring - 56mm 1
- - 940-37-84 Internal Seal - 56mm 1
- - 940-70-33 'O' Ring 1
K404-62-0A Tandem Crimper - - -
- - 940-25-32 'O' Ring 1

(i) Disconnect the vacuum shroud: w Disconnect all pipework leading to and
from the vacuum shroud assembly, and
blank off all ports using pieces of clean,
dry, lint-free rag to prevent ingestion of
any foreign matter.

(ii) Remove the single cap head screw that


retains the crimp wedge.

Ref. "51667E", Page


87
Release 1.0
(iii) Remove t he crimp head: w Using a suitable 'C' spanner applied to the
body of the assembly, unscrew the crimp
head from the primary shaft, and place on
a suitable work bench.

(iv) Remove the vacuum shroud assembly w Using a suitable 'C' spanner, unscrew the
from the crimp head: shroud retaining ring, then carefully pull
the vacuum shroud assembly from the
crimp head.

(v) Remove the adjustment pin: w Carefully remove the adjustment pin
retaining spring then extract the
adjustment pin.

continued...
(vi) Unscrew the adjustment sleeve from the
body.

(vii) Remove the adjustment ring and the w Slacken and remove the four cap head
shroud retainer: screws from the adjustment ring, remove
the ring, then slide off the shroud retainer.

(viii) Remove the vacuum seal: w Using a suitable 'C' spanner, slacken and
remove the vacuum seal retainer from the
bottom of the vacuum shroud, and extract
the vacuum seal. If this has recently been
replaced, set it aside to be re-fitted on
assembly.

(ix) Remove all old seals: w Remove all the old 'O' rings, seals and
wear rings from the shroud retaining ring,
the shroud body, and the adjustment
sleeve.

w If desired, the components contained within the crimp housing can now be extracted for
inspection. If this is the case, check the components for wear and / or damage, noting that
a certain amount of light wear is normal. However, if any components bear heavy wear
marks, scoring and / or cracks, they should be replaced.

IMPORTANT!
i It is critical that crimp jaws are replaced as a matched set. Jaw sets are marked
as such to aid identification. Under no circumstances whatsoever should
individual jaws from different sets be mixed.

(x) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
'O' rings, seals and wear rings are to be
fitted.

Ref. "51667E", Page


88
Release 1.0
(xi) Fit the new seals to the shroud retainer: w Fit the new internal seal (940-37-82) and
wear ring (940-37-81) to the groove in the
shroud retainer.

(xii) Fit the new seals to the shroud: w Fit the new 'O' ring (940-70-33), internal
seal (940-37-84) and wear ring (940-37-
83) to the shroud.

(xiii) Fit the new seal to the adjustment sleeve: w Fit the new external seal (940-70-80) to
the groove in the adjustment sleeve.

(xiv Re-assemble the vacuum shroud w Re-assemble the vacuum shroud


) assembly: assembly in reverse order of steps (iii) to
(viii) above taking, care not to damage any
of the new seals, etc.

 If the main crimper unit is to be serviced, go to 1.4.4 now.


continued...
(xv) Refit the crimp head: w Refit the crimp head to the crimper unit in
the reverse order of steps (i) to (iii) above,
not forgetting to fit the new 'O' ring (940-
25-32) to the end of the primary shaft.

NOTES:

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continued...
w Main Crimper Unit

Ref. "51667E", Page


89
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IMPORTANT!
i
Where the use of a 'C' spanner is stipulated, it is important that this tool is
used. Other methods, especially the use of punches, will damage the
components and eventually render them useless.

1.4.5 Secondary Cylinder Top Cap

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares Kit: Part No.

K404-62-0A Tandem Crimper - - -


- - 940-37-69 Internal Seal 1
- - 940-37-70 Rod Wear Ring - 18mm 2

(i) Remove the crimp diameter adjustment w Unscrew the crimp diameter adjustment
nut: nut from the top of the assembly.

(ii) Remove the top cap from the secondary w Remove the six cap head screws from the
cylinder body: top of the secondary cylinder top cap, and
remove the top cap from the secondary
cylinder body, exposing the upper
secondary piston.

(iii) Remove the old seal and wear rings from


within the top cap.

(iv) Clean the top cap: w Clean the top cap using a high flashpoint
solvent, and ensure that there is no
foreign matter present where the new
seals are to be fitted.

(v) Fit the new seals: w Carefully fit the new seal (940-37-69) and
wear rings (940-37-70 x 2) to the piston
assembly.

NOTES:

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Ref. "51667E", Page


90
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continued...
1.4.6 Upper Secondary Piston

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - V404-62-27 Internal Buffer 1
- - 940-37-71 External Seal - 75mm 1
- - 940-37-72 Pstn Wear Ring - 75mm 1
- - 940-70-25 'O' Ring 1

(i) Remove the upper secondary piston w Insert a tommy bar in the through hole in
assembly: the crimp diameter adjustment shaft,
unscrew the shaft, and remove the upper
secondary piston assembly.

(ii) Split the piston and remopve the old seals: w Remove the four cap head screws from
the piston, and split the piston into it’s two
halves.

w Remove the old seal, wear ring, and buffer


from the piston, and the shaft 'O' ring.

(iii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(iv) Inspect the buffer: w Inspect the buffer. If worn or damaged,


replace the buffer with a new item (W404-
62-27). If not, refit the buffer.

(v) Fit the new seals: w Carefully fit the new seal (940-37-71) to
the piston, the new wear ring (940-37-72)
to the piston cap, and the new 'O' ring
(940-70-25) to the shaft.

(vi) Re-assemble the piston in the reverse


order of step (ii) above.

Ref. "51667E", Page


91
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continued...
1.4.7 Secondary Cylinder Manifold

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - 940-70-26 'O' Ring 2
- - 940-37-69 Seal 1
- - 940-37-70 Wear Ring 2

(i) Remove the secondary cylinder manifold: w Pull the secondary cylinder manifold from
the lower secondary piston spigot and
cylinder body.

(ii) Remove the old seals: w Remove the two 'O' rings from the outer
edges of the manifold, and the two wear
rings and seal from the central bore.

(iii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(iv) Fit the new seals: w Carefully fit the new outer 'O' rings (940-
70-26 x 2), the new seal (940-37-69) and
the new wear rings (940-37-70 x 2) to the
manifold.

NOTES:

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Ref. "51667E", Page


92
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continued...
1.4.8 Lower Secondary Piston

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - 940-37-71 Seal 1
- - 940-37-72 Wear Ring 1

(i) Remove the lower secondary piston and w Withdraw the lower secondary piston and
secondary shaft: secondary shaft from the cylinder body
and primary shaft assembly.

(ii) Split the piston and remove the old seals: w Remove the four cap head screws from
the piston assembly, and split the piston
into it’s two halves.

Remove the old seal, wear ring, and buffer


from the piston, and the 'O' ring from the
shaft.

(iv) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(v) Inspect the buffer: w Inspect the buffer for wear and / or
damage. If any is found, replace the buffer
with a new item. If not, refit the buffer to
the piston.

(vi) Fit the new seals: w Carefully fit the new seal (940-37-71) to
the piston, and the new wear ring (940-37-
72) to the piston cap.

(vii) Re-assemble the piston in the reverse


order of step (ii) above.

NOTES:

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Ref. "51667E", Page


93
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continued...
1.4.9 Primary Piston

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - W404-62-07 Buffer 1
- - 940-37-71 Seal 1
- - 940-37-72 Wear Ring 2
- - 940-37-75 Seal 1
- - 940-37-76 Wear Ring 1

(i) Remove the primary shaft locknut: w Slacken and remove the locknut.

(ii) Remove the secondary cylinder body: w Pull the secondary cylinder body away
from the primary shaft. Note the primary
piston may be withdrawn with the body.

(iii) Remove the primary piston: w Remove the primary piston from the
primary shaft or the secondary cylinder
body, whichever is applicable.

(iv) Remove the buffer and old seals: w Remove the buffer, the old seal and wear
rings from the skirt of the piston, and the
seal and wear ring from the central bore.

(v) Clean the piston: w Clean the piston using a high flashpoint
solvent, ensuring that no foreign matter is
present where the new seals are to be
fitted.

(vi) Inspect the buffer: w Inspect the buffer for wear and / or
damage. If any is found, replace the buffer
with a new item (W404-62-07). If not, refit
the buffer.

(vii) Fit the new seals: w Carefully fit the new seal (940-37-71) and
wear rings (940-37-72 x 2) to the skirt of
the piston, and the new seal (940-37-75)
and wear ring (940-37-76) in the central
bore.

NOTES:

Ref. "51667E", Page


94
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continued...
1.4.10 Primary Cylinder Top Cap

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - W404-62-07 Buffer 1
- - 940-37-77 Seal 1
- - 940-37-78 Wear Ring 2
- - 940-70-32 'O' Ring 1

(i) Remove the fixed shield: w Remove the three countersunk screws
from the fixed shield, and slide the shield
off the primary cylinder top cap.

(ii) Remove the primary shaft clamp ring: w Unscrew the two screws from the primary
shaft clamp ring on the primary shaft, and
remove the two clamp ring halves.

(iii) Remove the top cap: w Remove the six cap head screws from the
top cap, and slide the cap off the primary
shaft.

(iv) Remove the buffer and the old seals: w Remove the buffer, the 'O' ring from the
outer boss of the cap, and the two wear
rings and seal from the central bore.

(v) Clean the top cap: w Clean the top cap using a high flashpoint
solvent, and ensure that there is no
foreign matter present where the new
seals are to be fitted.

(vi) Inspect the buffer: w Inspect the buffer for wear and / or
damage. If any is found, replace the buffer
with a new item (W404-62-07). If not, refit
the buffer to the piston.

(vii) Fit the seals: w Carefully fit the new outer 'O' ring (940-70-
32), and the new seal (940-37-77) and
wear rings (940-37-78 x 2) to the central
bore.

NOTES:

Ref. "51667E", Page


95
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continued...
1.4.11 Primary Shaft

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - 940-37-73 Seal 1
- - 940-37-74 Wear Ring 2
- - 940-70-27 'O' Ring 1

(i) Remove the primary shaft: w Grasp the primary shaft and withdraw the
shaft from the primary cylinder body.
(ii) Remove the old seals: w Remove the old seal and wear rings from
the shaft piston, and the 'O' ring from the
top end of the shaft.
(iii) Clean the shaft: w Clean the shaft using a high flashpoint
solvent, and ensure that there is no
foreign matter present where the new
seals are to be fitted.
(iv) Fit the new seals: w Carefully fit the new seal (940-37-73) and
wear rings (940-37-74 x 2) to the shaft
piston, and the new 'O' ring (940-70-27) to
the top end of the shaft.

NOTES:

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Ref. "51667E", Page


96
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continued...
1.4.12 Primary Cylinder Body

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-62-0A Tandem Crimper - - -


- - 940-37-77 Seal 1
- - 940-37-78 Wear Ring 2

(i) Remove the old seals: w Remove the old seal and wear rings from
the lower bore of the cylinder body.

(ii) Clean the cylinder body: w Clean the cylinder body using a high
flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(iii) Carefully fit the new seals: w Carefully fit the new seal (940-37-77) and
wear rings (940-37-78 x 2) in the lower
bore of the cylinder body.

NOTES:

Ref. "51667E", Page


97
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continued...
1.4.13 Re-assembly

w To re-assemble the crimper unit, reverse the dis-assembly procedures given in 1.4.1
to 1.4.12.

NOTES:

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continued...

Ref. "51667E", Page


98
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1.5 FAULT FINDING

Fault Remedy

w Crimp head fails to descend: „ Check air speed control valve is not
closed.

„ Check pilot valve operation.

„ Check pressure regulator is operational.

w Crimper fails to crimp valve onto „ Check air speed control is open.
container:
„ Check air supply pressure.

„ Check height setting of crimp head.

„ Check crimp depth.

„ Check crimp diameter.

„ Check valve is not displaced during


positioning.

„ Check for broken crimp jaw.

„ Check centre starwheel alignment to


crimper.

„ Check crimper seals are not leaking.

w Poor Crimp: „ Check air supply pressure.

„ Check height setting of crimp head.

„ Check crimp depth.

„ Check crimp diameter.

„ Check for broken crimp jaw.

„ Check pneumatic connectors are secure.

„ Check for wear on crimp jaws.

w Poor vacuum: „ Check vacuum pump operation.

„ Check height setting of crimp head.

continued...

Ref. "51667E", Page


99
Release 1.0
„ Check crimp head vacuum seal.

„ Check crimp head vacuum shroud seals.

w Crimp head fails to return: „ Check speed control valve is open.

„ Check pilot valve operation.

NOTES:

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CHAPTER 3.3

LIQUID PROPELLENT FILLERS

Contents

1. 90ml Propellent Ram.................................... 94

2. Nozzle Air Cylinder........................................ 110

3. Propellent Nozzle Body................................. 115

4. Nozzle Adaptor.............................................. 121

Ref. "51667E", Page


100
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Chapter 3.3 SECTION 1
Liquid Propellent Fillers 90ml PROPELLENT RAM

w Ref. Dwg. No's. Y167-88-ME & X169-25-0C

1.1 GENERAL DESCRIPTION

Ref. "51667E", Page


101
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The machine is equipped with a 90ml propellent ram assembly, mounted on the side of the
base unit, to measure and dispense a set volume of up to 90ml of propellent to the
propellent filling nozzle.

The propellent ram consists of two main assemblies, namely a 4 1/2" air cylinder (Y167-88-
ME) and a 90ml metering ram (X169-25-0C). The air cylinder is the large diameter
cylindrical unit forming the upper half of the ram assembly, and provides stroke adjustment
and pneumatic power for the metering ram assembly mounted below. The metering ram
receives it’s propellent supply from an external source, and delivers a pre-set dose of
propellent into the aerosol container through the filling nozzle.

The metering ram receives it’s propellent supply from an external source, and delivers a
pre-set dose of propellent into the aerosol container through the filling nozzle. The air
cylinder contains an upper piston and a lower piston. The air cylinder contains an upper
piston and a lower piston. The upper piston is mounted on the hollow helical screw shaft at
the top of the assembly, and provides fill volume adjustment by means of the sleeve
mounted on the top of the screw, with the piston acting as a stroke back-stop for the lower
piston. The lower piston is connected to a rod that runs down into the metering ram.

At the lower end of this piston rod, inside the metering ram, there is a third piston assembly.
The propellent feeds into the metering ram from an external supply through the port in its
upper flange. The lower piston is constructed using a ported floating piston which slides
open when retracted to allow the propellent above it in the metering ram to flow through the
piston, then when the piston rod is extended by the downstroke of the air cylinder, the
piston is closed and the propellent is forced out of the exhaust port in the bottom cap,
w Sequence of Operation

First a container is positioned under the propellent nozzle. Then, a pneumatic signal
initiates the downstroke of the nozzle air cylinder, which forces the nozzle assembly down
onto the valve of the container below, opening the shut off piston inside the nozzle
assembly. The filling stroke of the ram air cylinder is then initiated, forcing the metering ram
piston rod down, discharging the propellent into the can via the nozzle. When the air
cylinder lower piston reaches the bottom of it’s stroke, the underside of the piston strikes a
pilot valve assembly which switches the pneumatic signal to the underside of the lower
piston to return the piston to it’s rest position. This action retracts the metering ram piston,
which slides open to allow the product above to pass through to prime the ram, resetting
the whole assembly for the next cycle. Simultaneously, a signal activates the nozzle air
cylinder’s return stroke, raising the nozzle assembly to reset the whole assembly ready for
the next cycle.

continued...

1.2SETTING & ADJUSTMENT

1.2.1 Fill Volume Adjustment

WARNING!
!
Ref. "51667E", Page
102
Release 1.0
THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE LIVE, AND
SHOULD THEREFORE ONLY BE CARRIED OUT BY AUTHORISED TRAINED
PERSONNEL.

w The propellent ram assembly is adjustable to provide fill volumes of up to 90ml. The
upper outer sleeve of the assembly provides this adjustment as described below.

NOTE:
i There is a scale mounted vertically on the side of the ram air cylinder, running
up under the sleeve. This is a calibrated scale in increments of 5ml to provide a
simple visual reference for setting the propellent fill volume.

(i) Cut air supply to the ram air cylinder: w The air supply to the ram air cylinder must
first be cut by operating the sliding dump
valve located on the pipework next to the
pump housing. This dumps the air on the
air cylinder lower piston.

(ii) Adjust the fill volume setting as required: w To increase the fill volume, turn the
sleeve anti-clockwise. This raises the
upper piston in the air cylinder, allowing
the lower piston a longer stroke, giving a
higher fill volume.
w
To decrease the fill volume, turn the
sleeve clockwise. This lowers the upper
piston in the air cylinder, limiting the lower
piston to a shorter stroke, giving a lower fill
w volume.

Set the sleeve so that its bottom edge


lines up with the required scale increment.

(iii) Re-engage the air supply to the ram air w Slide the dump valve back to it's original
cylinder: position to re-engage the air supply to the
ram air cylinder.

(iv) Perform a single fill cycle: w Refer to Chapter 1, Section 7 - Operation,


and perform a single fill cycle on a sample
container.

w Ensure all working heads other than the


product ram being set are de-selected.

(v) Check that the actual volume delivered w If for any reason there is a discrepency
is correct: between the set volume and the actual
volume delivered, repeat steps (ii) or (iii)
and (iv) and (v) to trim the unit to the
required setting.

continued...

1.2.2 Propellent Change

Ref. "51667E", Page


103
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w If the propellent type is to be changed, the propellent fillers must first be flushed
through to remove all traces of the previous propellent type, then primed with the new type,
as follows.

WARNING!
! THE FOLLOWING PROCEDURE REQUIRES THE MACHINE  TO  BE LIVE, AND
SHOULD THEREFORE ONLY BE CARRIED OUT BY AUTHORISED TRAINED
PERSONNEL.

(i) Turn on the air supply: w Engage the pneumatic mains supply as if
for normal operation.

(ii) Disconnect the external propellent supply: w Shut off the external propellent supply to
the heads, then close the inlet shut-off
valves and disconnect the supply.

(iii) Disconnect the new propellent supply: w Connect the required replacement
propellent supply and open the shut-off
valves.

(iv) Place valved containers in the starwheel: w Place a sufficient number of valved,
crimped containers in the starwheel
leading up to the propellent heads, to
allow the heads to perform 2 -3 cycles
each.

(v) Run the machine for 2 - 3 cycles on each w Referring to Chapter 1, Section 7 -
propellent ram: Operation, engage the selector switches
of the propellent heads to be flushed, then
run the machine for 2 - 3 cycles. This is
sufficient to both flush and prime the
heads.
w
Ensure all working heads other than the
product ram being set are de-selected.

(vi) De-select the propellent heads and


remove the containers.

NOTES:

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Ref. "51667E", Page


104
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continued...

1.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

1.3.1 Weekly

(i) Clean the exterior of the propellent w Cleanliness is highly important. A build up
ram(s): of dirt or debris may impair the efficiency
of the propellent ram assembly. This could
cause an unsafe operating condition
within the machine, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the propellent ram(s): w The propellent rams should be inspected,
paying attention to the following:

w All pipework should be regularly checked


for leaks, and check that all fittings and
unions are secure.

w Inspect all structural joints to identify any


possible leaking of seals, particularly the
gland seal where the lower piston rod
enters the metering ram. Should
propellent be found escaping from this
point, simply tighten the gland nut with the
spanner provided (this brass nut is visible
in the aperture in the lower flange of the
pump housing). Do not over-tighten this
nut, as the seal will be crushed.

NOTES:

Ref. "51667E", Page


105
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continued...

1.4 SEAL REPLACEMENT

~ Seal Replacement Intervals: 6 months

w The reciprocating action of the piston assemblies will eventually cause the piston seals to
wear. This would cause a drop in efficiency in the unit as the air used to power the unit will
leak past the seals and cause inconsistencies in the air pressure, and variations in fill
volume will occur due to propellent bleeding past the ram piston. Also, the 'O' rings will
become compressed over a period of time which could cause air / propellent leaks.

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K167-88ME 41/2" Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - W167-20-01 Buffer 1
- - V592-06-15 Valve Op. Lever 1
- - 940-25-05 'O' Ring 1
- - 940-25-08 'O' Ring 1
- - 940-25-09 'O' Ring 1
- - 940-25-19 'O' Ring 1
- - 940-25-66 'O' Ring 1
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-86 Oil Seal 1
- - 940-46-050 Spring 1
- - 940-70-20 'O' Ring 1
- - 943-40-95 3 Way Valve Cam Op. 1
- - 992-11-19 Cup Washer 2
K169-25-0C 90ml Prop. Ram - - -
- - W169-12-02 Piston Back Seal 1
- - 940-25-11 ‘O’ Ring 1
- - 940-33-08 P.T.F.E ‘O’ Ring 1
- - 940-33-10 P.T.F.E ‘O’ Ring 1
- - 940-37-34 Slydring 1
- - 940-37-39 Disc Seal 1

Ref. "51667E", Page


106
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continued...

1.4.1 Propellent Ram Removal

w To replace the seals and 'O' rings in the propellent ram assembly, the assembly will
first need to be removed from the machine a follows:

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Disconnect the propellent ram assembly: w Disconnect all pipework leading to and
from the propellent ram assembly, and
blank off all ports using pieces of clean,
dry, lint-free rag to prevent ingestion of
any foreign matter.

(ii) Remove the propellent ram from the w Support the assembly, slacken and
machine: remove the mounting bolts, then carefully
withdraw the ram assembly from the side
of the machine.

CAUTION!
! THIS ASSEMBLY IS HEAVY! Have an assistant ready to support the assembly
while the retaining bolts are being removed, and to help when removing the
assembly from the machine.

NOTES:

Ref. "51667E", Page


107
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continued...

1.4.2 Bottom Cap (Ref. Dwg. No. Y169-18-0M)

~ Replacement Interval: 6 months

 Spares Required:

From Description Component Component Description Qty.


Spares Kit: Part No.

K169-25-0C 90ml Prop. Ram - - -


- - 940-33-08 P.T.F.E. 'O' ring 1

(i) Remove the lower cap from the ram w Support the bottom cap and remove the
barrel: four socket head screws that secure the
cap to the lower flange of the metering
ram barrel.

w Withdraw the bottom cap and remove the


old 'O' ring from the boss.

(ii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(iii) Fit the new 'O' ring: w Carefully fit the new 'O' ring (940-33-08) to
the bottom cap boss.

Ref. "51667E", Page


108
Release 1.0
(iv) Re-fit the bottom cap: w Re-fit the bottom cap to the ram barrel in
the reverse order of steps (i) to (iv) above.

NOTES:

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continued...

1.4.3 Air Cylinder Upper Piston (Ref. Dwg. No. Y167-88-ME)

~ Replacement Interval: 6 months

 Spares Required:

from Ass'y. Description Component Component Description Qty.


spares kit: Part No.

K167-88ME 41/2" Air Cylinder - - -


- - 940-25-66 'O' Ring 1
- - 940-34-86 Oil Seal 1

(i) Slide the adjustment thimble down to w Unscrew the four countersunk screws that
access the air cylinder top cap: retain the adjustment thimble, and slide
the thimble sleeve down to expose the air
cylinder top cap.

Ref. "51667E", Page


109
Release 1.0
(ii) Remove the upper assembly and screw w Unscrew the four tie rod nuts that retain
shaft to expose the upper piston: the top cap of the assembly. Hold the
cylinder barrel and carefully withdraw the
upper assembly and screw-shaft. This will
expose the upper piston assembly on the
end of the piston rod.

(iii) Remove the upper piston head, and w Slacken and remove the piston retaining
discard the old seals: nut from the underside of the piston head,
and slide the piston off the screw-shaft.
Remove the old lip seal and 'O' ring.

(iv) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(v) Fit the new seals: w Carefully fit the new lip seal (940-34-86)
and the new 'O' ring (940-25-66) to the
piston.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the
reverse order of steps (iii) and (iv) above.

NOTES:

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continued...

1.4.4 Air Cylinder Lower Piston (Ref. Dwg. No. Y167-88-ME)

~ Replacement Interval: 6 months

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares Kit: Part No.

Ref. "51667E", Page


110
Release 1.0
K167-88ME 41/2" Air Cylinder - - -
- - 940-25-08 'O' Ring 1
- - 940-70-20 'O' Ring 1
- - 992-11-19 Cup Washer 2

w With the air cylinder upper piston removed:

(i) Remove the cylinder barrel and sealing w Carefully pull the cylinder barrel from the
washer: pump housing to expose the lower piston
assembly, and remove the sealing washer
from the barrel location groove in the
housing.

(ii) Refer to 1.4.4 steps (i) to (iii) and remove


the metering ram barrel.

(iii) Remove the lower piston assembly w Insert a tommy bar in the hole at the
retaining nut: bottom end of the lower piston rod, and
remove the nut that retains the lower
piston assembly.

(iv) Disassemble the lower piston assembly: w Remove each component of the lower
piston assembly from the piston rod - i.e.
the top buffer, upper seal back plate,
upper seal, middle buffer, lower seal,
lower seal back plate, and piston head
locator. Discard the old seals and 'O' ring.

(v) Clean the components: w Clean the other components using a high
flashpoint solvent, ensuring that there is
no foreign matter present where the new
seals are to be fitted.

(vi) Re-assemble the piston assembly: w Re-assemble the piston assembly in the
reverse order of step (iii) and (iv) above,
fitting the new seals (992-11-19 x2) and
'O' ring (940-25-08).

(vii) Clean the pump housing as above.

(viii) Refit the cylinder barrel: w Fit the new 'O' ring (940-70-20) to the
groove in the pump housing, then refit the
cylinder barrel, taking care that the new 'O'
ring is seated correctly.
continued...
 If the metering ram piston is to be
serviced, go to 1.4.5 now.

(ix) Refer to 1.4.5 step (ix) and refit the


metering ram barrel.

(x) Re-assemble the upper assembly: w Re-assemble the upper assembly in the
reverse order of 1.4.3, steps (i) to (ii).

Ref. "51667E", Page


111
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(xi) Refit the propellent ram to the machine: w Refit the propellent ram to the mounting
plate in the reverse order of steps (i) to (iii)
at the start of this chapter.

NOTES:

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continued...
1.4.5 90ml Ram Piston (Ref. Dwg. No. Y169-25-0C)

~ Replacement Interval: 6 months

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares Kit: Part No.

K169-25-0C 90ml Prop. Ram - - -


- - W169-12-02 Piston Back Seal 1
- - 940-25-11 ‘O’ Ring 1
- - 940-33-10 P.T.F.E ‘O’ Ring 1
- - 940-37-34 Slydring 1
- - 940-37-39 Disc Seal 1

(i) Disconnect the metering ram barrel and w If not already done, disconnect all
bottom cap assembly: pipework leading to and from the metering
ram barrel and bottom cap assembly, and
blank off all ports using pieces of clean,
dry, lint-free rag to prevent ingestion of
any foreign matter.

(ii) Remove the metering ram barrel: w Support the ram barrel and remove the
four socket head screws that secure the
barrel to the air cylinder pump housing,
and carefully withdraw the ram barrel to
w expose the metering ram piston assembly.

(iii) Unscrew the piston assembly: w Insert a tommy bar in the hole in the piston
head, and another in the hole in the piston
rod, then unscrew the piston assembly.

Ref. "51667E", Page


112
Release 1.0
(iv) Remove the piston from the piston head: w Insert a tommy bar in the hole in the piston
head, remove the piston retaining ring
inside the piston, slide the piston
assembly off the piston head, and remove
the old buffer ring.

(v) Unscrew the seal retainer and discard w Insert a tommy bar in both the piston and
The old cup seal: the seal retainer, unscrew the retainer and
remove the lip seal, slydring and ‘O’ ring.

(vi) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

 If the pump housing assembly is to be


serviced, go to 1.4.5 now.

continued...
(vii) Fit the new seals and re-assemble the w Re-assemble the piston assembly in the
piston assembly: reverse order of steps (iii) to (v) above,
fitting the new buffer seal (W169-12-02),
slydring (940-37-34), ‘O’ ring (940-25-11)
and the new lip seal (940-37-39).

(viii) Re-assemble the metering ram assembly: w Re-assemble the metering ram assembly
in the reverse order of steps (i) to (iii)
above fitting the new 'O' ring (940-33-10).

NOTES:

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continued...

Ref. "51667E", Page


113
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1.4.6 Pump Housing, Pilot Valve and Gland Housing (Ref. Dwg. No. Y167-88-ME)

~ Replacement Interval: 6 months

 Spares Required:

From Ass'y. Description Component Component Description Qty.


Spares kit: Part No.

K167-88ME 41/2" Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - 940-25-05 'O' Ring 1
- - 940-25-09 'O' Ring 1
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-86 Oil Seal 1

(i) Gain access to the gland housing: w Push the piston rod down through the
pump housing to expose the gland
housing.

(ii) Remove the gland housing from the w Insert a tommy bar in the hole in the side
piston rod: of the gland housing, slacken the gland
nut, then slide the gland housing down off
the rod and set aside.

(iii) Remove the piston rod from the pump w Carefully withdraw the piston rod from the
housing: top of the pump housing.

(iv) Remove the cover plate in the top face of w Remove the four countersunk screws that
the pump housing: retain the central cover plate in the top
face of the pump housing, and lift out the
plate.

Ref. "51667E", Page


114
Release 1.0
(v) Remove the valve operating pin and w Carefully lift out the valve operating pin
discard the old 'O' rings: complete with the seal holder and spring,
and remove the old 'O' rings from the seal
holder.

(vi) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(vii) Re-assemble the operating pin assembly: w Re-assemble the operating pin assembly
in the reverse order of steps (iv) and (v)
above, fitting the new 'O' rings (940-25-05
& 940-25-09) to the seal holder.

(viii) Remove the external pilot valve assembly


from the side of the pump housing.

continued...
(ix) Remove the seal retainer plate in the w Remove the four screws that hold the seal
pump housing aperture and discard the retainer plate in the top face of the pump
old lip seal: housing aperture, remove the plate, and
extract the lip seal that is now exposed.

(x) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(xi) Re-assemble the seal and valve w Re-assemble the seal and valve assembly
assembly: in the reverse order of steps (viii) and (ix)
above, fitting the new lip seal (940-34-61)
to the seal holder.

(xii) Remove the gland nut and lip seal, and the
outer 'O' ring from the gland housing.

(xiii) Clean the components: w Clean the components using a high


flashpoint solvent, and ensure that there is
no foreign matter present where the new
seals are to be fitted.

(xiv Re-assemble the gland housing assembly: w Re-assemble the gland housing assembly
) in the reverse order of step (xi) above,
carefully fitting the new gland seals
(W167-01-12 x3), and the new 'O' ring
(940-33-10). Gently tighten the gland nut -
this should be checked and adjusted once
the unit is back on the machine.

(xv) Re-install the pump housing on the piston w Clean the piston rod as above and slide
rod: the lower end of the rod down through the
gland housing, then slide the upper end of
the rod up through the pump housing.

Ref. "51667E", Page


115
Release 1.0
 Refer back through the procedures and re-
assemble the product ram assembly, and
refit the assembly to the machine.

NOTES:

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continued...

1.5 FAULT FINDING

Fault Remedy

Metering ram fails to fill: „ Check propellent supply is available.

„ Check propellent ram inlet valve is open.

„ Check all air couplings are engaged.

„ Check air supply to ram air cylinder.

„ Check propellent nozzle opens.

Ref. "51667E", Page


116
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„ Ensure gland seal nut is not too tight.

„ Check NCNF lever is not being actuated


due to nozzle being set too high.

„ Check propellent piston head is not


jammed.

„ Check air cylinder master valve assembly.

„ Ensure air cylinder piston seals are not


leaking.

Fill volume not consistent: „ Check propellent supply.

„ Vent propellent metering ram.

„ Ensure air cylinder piston returns fast


enough.

„ Check propellent nozzle closes at end of


fill.

„ Check propellent piston slides freely.

„ Check propellent piston seals.

continued...

Ref. "51667E", Page


117
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NOTES

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Ref. "51667E", Page


118
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Chapter 3.3 SECTION 2


Liquid Propellent Fillers NOZZLE AIR CYLINDER

Ref. Ass’y. No. 405-03-0P

2.1 GENERAL DESCRIPTION

2.2 The
SETTING
nozzle
& ADJUSTMENT
air cylinder is a pneumatically operated cylinder fitted to the machine to
automatically apply the propellent filling nozzle that it carries to the valve of the container
being processed. The assembly consists of a cylinder barrel which forms the main body of
the assembly, and the mounting point for the mounting plate bracket, a hollow through-
shaft piston rod which is connected to the propellent pipework from the propellent ram at
the top, and carries the piston assembly inside the barrel. A pneumatic signal to the top of
the piston forces the piston down, so lowering the nozzle onto the container. This signal is
maintained while the filling cycle is taking place, then a signal to the underside of the piston
retracts the nozzle assembly ready for the next cycle.

See the relevant section of this manual covering the nozzle adaptor(s).

2.3 MAINTENANCE

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

2.3.1 Weekly

Ref. "51667E", Page


119
Release 1.0
(i) Clean the exterior of the nozzle air w A build up of dirt or debris may impair the
cylinder(s): efficiency of the assembly. This could
cause an unsafe operating condition
within the machine, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle air cylinder(s): w All pipework should be checked for leaks,
and check that all fittings and unions are
secure.

w Also inspect all structural joints to identify


any possible leaking of seals.

NOTES:

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continued...

2.4 SEAL REPLACEMENT PROCEDURE

~ Replacement Interval: 6 months

The reciprocating action of the nozzle air cylinder will eventually cause the cylinder piston
seals to wear. This would cause a drop in efficiency in the unit as the air used to power the
unit will leak past the seals and cause inconsistencies in the air pressure. Also, the 'O'
rings will become compressed over a period of time which could cause air leaks.
Consequently, the seals and 'O' rings in the air cylinder assembly should be changed
every 12 months.

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K405-04-0B Nozzle Air Cylinder - - -


- - W011-43-04 Buffer 1
- - W011-50-06 Buffer 1
- - 940-25-29 'O' Ring 1
- - 940-25-66 'O' Ring 1
- - 940-34-88 Oil Seal 2

Ref. "51667E", Page


120
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NOTES:

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continued...

2.4.1 Nozzle Removal (Common to all types)

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Disconnect any nozzle pipework: w Disconnect any pipework leading to or


from the nozzle adaptor / body assembly
and blank off all ports using pieces of
clean, dry, lint-free rag to prevent
ingestion of any foreign matter.

Ref. "51667E", Page


121
Release 1.0
(ii) Remove the nozzle body / adaptor from w Insert a tommy bar in the hole in the side
the piston rod: of the nozzle body and another in the hole
in the bottom flange of the air cylinder
piston rod, and unscrew the body /
adaptor assembly from the piston rod.

2.4.2 Nozzle Air Cylinder (Ref. Dwg. No. W405-03-0B)

WARNING!
! ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Remove the assembly from the machine: w Support the assembly and remove the cap
head screws that retain the support
bracket clamp, remove the clamp, and
withdraw the assembly from the machine.

(ii) Remove the cylinder top cap and discard w Remove the three cap head screws from
the old seals: the cylinder top cap, lift the top cap from
the cylinder barrel, and remove the old 'O'
rings from the cap and the lip of the barrel.

(iii) Remove the piston retaining ring, then w Slide the barrel down the piston rod to
the piston: bring the piston assembly within reach,
then remove the piston retaining ring.

w Slide the piston assembly off the piston


rod, then withdraw the piston rod from the
base of the barrel.

(iv) Remove the piston and discard the old w Slide the piston assembly off the piston
seals: rod, then withdraw the piston rod from the
base of the barrel.

w Remove the old lip seals from the piston


head, the old 'O' ring from the barrel, and
the buffers from within the barrel and the
top of the setting ring on the piston rod.
Note that there is no need to remove the
setting ring from the piston rod.
continued...
(v) Clean the components: w Clean the components using a high
flashpoint solvent, and ensure that there is
no foreign matter present where the new
'O' rings are to be fitted.

(vi) Fit the new seals: w Fit the new 'O' rings (940-25-29 & 940-25-
66) to the top cap and barrel, the new lip
seals (940-34-88 x2) to the piston head,
and the new buffer (W011-43-04) to the
setting ring.

Ref. "51667E", Page


122
Release 1.0
(vii) Re-assemble the nozzle air cylinder: w Re-assemble the nozzle air cylinder in the
reverse order of steps (iii) to (v) above, not
forgetting to fit the new buffer (W011-50-
06) under the piston head.

(viii) Re-fit the assembly to the mounting plate


in the reverse order of steps (i) and (ii)
above.

(ix) Refer back through the procedures and


refit the propellent nozzle assembly.

NOTES:

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continued...

2.5 FAULT FINDING

Ref. "51667E", Page


123
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Fault Remedy

Air cylinder fails to descend: Check pneumatic supply.

Check pipework and connections.

Check pneumatic circuit.

Check seals are not leaking.

Air cylinder fails to return: Check pneumatic supply.

Check pipework and connections.

Check pneumatic circuit.

Check seals are not leaking.

NOTES:

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Ref. "51667E", Page


124
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Chapter 3.3 SECTION 3
Liquid Propellent Fillers PROPELLENT NOZZLE BODY

w Ref. Dwg. No. V458-66-0C

3.1 GENERAL DESCRIPTION

The propellent nozzle body is the connecting piece between the nozzle air cylinder and the
nozzle adaptor, and contains the main shut-off valve of the propellent filling nozzle
assembly,

At the start of the filling cycle, the nozzle air cylinder lowers the nozzle assembly onto the
valve of the container below. The seals in the tip of the adaptor seals on the tip of the valve
nozzle, and the nozzle is depressed to open the valve. When the filling stroke of the ram is
performed, the propellent dose travels through the air cylinder piston rod to the nozzle
body, which contains a spring loaded piston. When the pressure of the propellent dose
exceeds that applied to the piston by the spring, the piston will lift away from the seal in the
top face of the nozzle adaptor, allowing the dose to pass into the can through the adaptor.
On completion of the filling stroke, the resultant pressure drop allows the body spring to
close the piston to prevent any leakage. The assembly is then retracted by the nozzle air
cylinder, ready to repeat the cycle.

3.2 SETTING & ADJUSTMENT

3.2.1 Height Adjustment

See the relevant section of this manual covering the propellent nozzle adaptor(s).

continued...

Ref. "51667E", Page


125
Release 1.0
3.3MAINTENANCE

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

3.3.1 Weekly

(i) Clean the exterior of the nozzle body: w Cleanliness is highly important. A build up
of dirt or debris may impair the efficiency
of the nozzle body assembly. This could
cause an unsafe operating condition
within the machine, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle body: w The nozzle body should be inspected,
paying attention to the following:

w All pipework should be regularly checked


for leaks, and check that all fittings and
unions are secure. Inspect all structural
joints to identify any possible leaking of
seals.

NOTES:

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Ref. "51667E", Page


126
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continued...

3.4 SEAL REPLACEMENT

~ Replacement Interval: 6 months

w The reciprocating action of the nozzle body will eventually cause the piston and spring to
wear. This would cause a drop in efficiency in the unit as the pressure required to open the
body will decrease, causing inconsistencies in propellent fills. Also, the 'O' rings will
become compressed over a period of time which could cause propellent leaks.
Consequently, the spring and 'O' rings in the body be changed every 6 months.

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K458-66-0C Nozzle Body - - -


- - V010-24-011 Spring 1
- - 940-33-11 'O' Ring 1
- - 940-35-12 Variseal 1

NOTES:

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Ref. "51667E", Page


127
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continued...

3.4.1 Nozzle Removal (Common to all types)

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Disconnect any nozzle pipework: w Disconnect any pipework leading to or


from the nozzle adaptor / body assembly
and blank off all ports using pieces of
clean, dry, lint-free rag to prevent
ingestion of any foreign matter.

(ii) Remove the nozzle body / adaptor from w Insert a tommy bar in the hole in the side
the piston rod: of the nozzle body and another in the hole
in the side of the nozzle adaptor, and
unscrew the body / adaptor assembly from
the piston rod.

3.4.2 Nozzle Body

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

Ref. "51667E", Page


128
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(i) Remove the nozzle adaptor: w Refer to the relevant section of this
manual for the nozzle adaptor type fitted
to the body, and remove the adaptor.

(ii) Unscrew the nozzle body from the nozzle w Insert a tommy bar in the hole in the side
air cylinder: of both the nozzle body and the bottom
flange of the nozzle air cylinder piston rod,
and unscrew the body from the cylinder.

(iii) Extract the piston components and old ‘O’ w Remove the old 'O' ring from the top face
ring: of the body, extract the piston, spring and
washer from the nozzle body.

w Discard the piston, spring and ‘O’ ring, but


retain the washer.

(iv) Clean the components: w Clean the body using a high flashpoint
solvent, and ensure that there is no
foreign matter present where the new
components are to be fitted.

(v) Re-assemble the nozzle body, fitting the w Fit the new 'O' rings (940-33-11) to the
new spring (V010-24-11). body, then fit the washer to the piston, the
spring over the washer, then install the
piston in the body.

(vii) Re-assemble the nozzle assembly: w Re-assemble the nozzle assembly in the
reverse order of steps (i) and (ii) above.

NOTES:

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Ref. "51667E", Page


129
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continued...
3.5 FAULT FINDING

Fault Remedy

w Zero, low or inconsistent fill: „ Check propellent supply.

„ Check height setting.

„ Check pipework and connections.

„ Check piston operation.

„ Check seals are not leaking.

Ref. "51667E", Page


130
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NOTES

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Chapter 3.3 SECTION 4


Liquid Propellent Fillers NOZZLE ADAPTOR - SUMMIT RAISED BOSS

Ref. "51667E", Page


131
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w Ref. Dwg. No. V458-28-0F

4.1 GENERAL DESCRIPTION

The propellent nozzle for "Summit raised boss" cup valves consists of three main sections,
namely the adaptor body, the stripper ring and the nozzle probe. In operation the nozzle is
mounted on a nozzle body assembly which is in turn mounted on the nozzle air cylinder.

When the air cylinder lowers the nozzle onto the aerosol valve of the container below, the
stripper ring comes into contact with the shoulder of the aerosol container, and the stripper
springs are compressed. The tip of the probe then enters the aerosol valve and contacts
the valve mechanism inside. As the nozzle continues to descend, the probe forces open
the valve mechanism, with the valve's internal seal forming a seal around the probe. Once
the underside of the body section the lip of the aerosol valve, the filling cycle of the
propellent ram is activated.
The propellent dose travels through the hollow piston rod of the nozzle air cylinder to the
nozzle body, which contains a spring loaded piston. When the pressure of the propellent
dose exceeds that applied to the piston by the spring, the piston will lift away from the seal
in the top face of the nozzle adaptor, allowing the dose to pass into the can through the
adaptor and into the container through the drillings in the probe tip.

On completion of the filling stroke, the resultant pressure drop allows the spring to close the
piston to prevent any leakage. The nozzle assembly is then withdraw by the nozzle air
cylinder, the aerosol valve is closed by it's internal spring, and the stripper ring ensures that
the container is not picked up by the probe. The assembly is now ready for the next cycle.

continued...
4.2 SETTING & ADJUSTMENT

Ref. "51667E", Page


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WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

4.2.1 Nozzle Adaptor Changeover

w If there is a change in valve type, the correct nozzle adaptor must be fitted.

 THIS IS ESSENTIAL FOR SAFE, EFFICIENT FILLING.

(i) Unscrew the nozzle adaptor from the w Insert a tommy bar or 'C' spanner in the
nozzle body: hole in the side of both the nozzle adaptor
and the nozzle body, and unscrew the
adaptor from the body.

(ii) Select the required replacement nozzle w Select the correct replacement adaptor
adaptor: and check that the 'O' rings in the top face
of the assembly are in good condition. If
they are damaged of have become
flattened, they must be replaced as in 4.4
- Seal Replacement.

(iii) Fit the replacement nozzle adaptor: w Carefully screw the replacement adaptor
onto the nozzle body and tighten the
adaptor using the tommy bar or 'C'
spanner.

NOTES:

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continued...

Ref. "51667E", Page


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4.2.2 Nozzle Height Adjustment

If there is a change in can height, the discharge height of the nozzle will need adjusting:

(i) Slacken the locking handle on the side of


the nozzle mounting bracket:

(ii) Position a sample container under the w If the overall height of the container to be
nozzle: processed is greater than that which the
machine is currently set for, turn the
handwheel at the top of the support
assembly clockwise to raise the nozzle
sufficiently to allow a sample container,
complete with crimped valve, to be placed
in the starwheel pocket under the nozzle.

(iii) Adjust the nozzle height setting: w With the sample container in place, turn
the adjustment wheel anti-clockwise to
lower the nozzle, and set the height to
give 3-4mm clearance between the top of
the aerosol valve stem and the lowest
point of the nozzle adaptor.

(iv) Tighten the locking handle to clamp the


nozzle in position.

NOTES:

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continued...

Ref. "51667E", Page


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4.3MAINTENANCE

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

4.3.1 Weekly

(i) Clean the exterior of the nozzle adaptor: w Cleanliness is highly important. A build up
of dirt or debris may impair the efficiency
of the nozzle adaptor assembly. This
could cause an unsafe operating condition
within the machine, and as such the
assembly should be cleaned regularly in
accordance with Chapter 1, Section 6.1.

(ii) Inspect the nozzle adaptor: w The nozzle adaptor should be inspected,
paying attention to the following:

w All pipework should be regularly checked


for leaks, and check that all fittings and
unions are secure. Inspect all structural
joints to identify any possible leaking of
seals.

NOTES:

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continued...

4.4SEAL REPLACEMENT

~ Replacement Interval: 6 months

The pressure at which the nozzle adaptor is applied to the aerosol valve will cause the
seas in the tip to deform. This would allow propellent to leak past the seal instead of
passing into the container, causing inconsistent fills and raising the gas levels in and
around the machine. Also, the 'O' rings will become compressed over a period of time
which could cause propellent leaks. Consequently, the seals and 'O' rings in the adaptor
should be changed every 6 months.

 Spares Required:

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K440-28-0F Nozzle Adaptor - - -


- - V010-28-05 Stripper Spring 2
- - 940-33-02 'O' Ring 1
- - 940-33-05 'O' Ring 1

NOTES:

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Ref. "51667E", Page


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continued...

WARNING!
!
ENSURE THAT THE MACHINE IS ISOLATED FROM THE PNEUMATIC MAINS
SUPPLY BEFORE PROCEEDING.

(i) Remove the nozzle adaptor from the w Insert a tommy bar in the hole in the side
nozzle body: of both the nozzle adaptor and the nozzle
body, and unscrew the adaptor from the
body. Note that there is no need to
remove the setting ring from the nozzle
adaptor.

(ii) Carefully extract the insert and remove the


two old 'O' rings.

(iii) Clean the components: w Clean the adaptor and insert using a high
flashpoint solvent, and ensure that there is
no foreign matter present where the new
'O' rings are to be fitted.

(iv) Fit the new 'O' rings: w Fit the new 'O' rings (940-33-02 & 940-33-
05) to the nozzle adaptor.

(v) Re-fit the assembly to the nozzle body


in the reverse order of step (i).

Ref. "51667E", Page


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4.5 FAULT FINDING

Fault Remedy

w Zero, low or inconsistent fill: „ Check propellent supply.

„ Check height setting.

„ Check pipework and connections.

„ Check piston operation.

„ Check seals are not leaking.

NOTES

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CHAPTER 4

SPARE PARTS & SERVICE

Contents

1. Spare Parts................................................... 129

Ref. "51667E", Page


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2. Service.......................................................... 141

Chapter 4 SECTION 1
Spare Parts & Service RECOMMENDED SPARE PARTS LIST

1.1 SPARE PARTS

The following tables list recommended spare parts and consumables for 6 months that
should be kept in stock.

When ordering spare parts or making technical enquiries, please be sure to quote the
machine serial number. This can be found on the machine identification plate, which will be
affixed to the machine's base unit.

Ref. "51667E", Page


140
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Also, spare parts should be ordered by part number, description and quantity required.

continued...

K167-74MEB 21/8" Product Air Cylinder

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K167-74-ME 21/8" Product Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - W167-20-01 Buffer 1
- - V592-06-15 Valve Op. Lever 1
- - 940-25-05 'O' Ring 1
- - 940-25-09 'O' Ring 1
- - 940-25-19 'O' Ring 1
- - 940-25-66 'O' Ring 1

Ref. "51667E", Page


141
Release 1.0
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-84 Oil Seal 1
- - 940-46-050 Spring 1
- - 940-70-22 'O' Ring 1
- - 943-40-95 3 Way Valve Cam Op. 1

K175-53-0MA 250ml Product Ram

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-53-0MA 250ml Product Ram - - -


- - W168-09-02 Cup Seal 1
- - W168-10-02 Back Seal 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1
- - 946-26-58 Ball Valve 1

K175-55-0P Product Master Valve

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-55-0P Product Master Valve - - -


- - W002-23-02 Master Valve Seal 1
- - W175-55-05 Master Valve Spring 1
- - 940-33-08 P.T.F.E. ‘O’ Ring 1
- - 940-33-10 P.T.F.E. ‘O’ Ring 1

K175-46-0J ½” Streamflow Nozzle

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K175-46-0J 1
/2" Streamflow Nozzle - - -
- - W120-54-04 P.T.F.E. Seal 1
- - V120-54-08 Seal Washer 1
- - 940-25-08 'O' Ring 1
- - 940-25-66 'O' Ring 1
- - 940-34-46 Lip Seal 1
- - 940-34-81 Lip Seal 2

Ref. "51667E", Page


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Release 1.0
K404-47-0P Vacuum Crimp Head

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K404-47-0P Vacuum Crimp Head - - -


- - V404-40-13 Buffer 1
- - V404-47-20 Vacuum Seal - 45 / 50mm 1
- - V404-47-21 Vacuum Seal - 53mm 1
- - V404-47-22 Jaw Spring Mod. 1
- - 940-37-80 External Seal - 70mm 1
- - 940-37-81 Rod Wear Ring - 65mm 1
- - 940-37-82 Internal Seal - 65mm 1
- - 940-37-83 Rod Wear Ring - 56mm 1
- - 940-37-84 Internal Seal - 56mm 1
- - 940-70-33 'O' Ring 1

K404-62-0A Tandem Crimper


Spares Kit Ass'y. Description Component Component Description Qty.
No. Part No.

K404-62-0A Tandem Crimper - - -


- - V404-62-03 Adjusting Nut Buffer 1
- - V404-62-07 Internal Buffer 2
- - V404-62-27 Internal Buffer 1
- - 940-25-32 'O' Ring 1
- - 940-37-69 Internal Seal 2
- - 940-37-70 Rod Wear Ring - 18mm 4
- - 940-37-71 External Seal - 75mm 3
- - 940-37-72 Pstn Wear Ring - 75mm 4
- - 940-37-73 External Seal - 48mm 1
- - 940-37-74 Pstn Wear Ring - 48mm 2
- - 940-37-75 Internal Seal - 28mm 1
- - 940-37-76 Rod Wear Ring - 28mm 2
- - 940-37-77 Internal Seal - 30mm 2
- - 940-37-78 Rod Wear Ring - 30mm 4
- - 940-70-25 'O' Ring 1
- - 940-70-26 'O' Ring 2
- - 940-70-27 'O' Ring 1
- - 940-70-32 'O' Ring 1
K167-88-ME 41/2” Air Cylinder

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K167-88-ME 41/2" Air Cylinder - - -


- - W167-01-12 Gland Seal 3
- - W167-20-01 Buffer 1
- - V592-06-15 Valve Op. Lever 1
- - 940-25-05 'O' Ring 1
- - 940-25-08 'O' Ring 1

Ref. "51667E", Page


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Release 1.0
- - 940-25-09 'O' Ring 1
- - 940-25-19 'O' Ring 1
- - 940-25-66 'O' Ring 1
- - 940-33-10 P.T.F.E. 'O' Ring 1
- - 940-34-61 Seal 1
- - 940-34-86 Oil Seal 1
- - 940-46-050 Spring 1
- - 940-70-20 'O' Ring 1
- - 943-40-95 3 Way Valve Cam Op. 1
- - 992-11-19 Cup Washer 2

K169-25-0C 90ml Propellent Ram

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K169-25-0C 90ml Prop. Ram - - -


- - W169-12-02 Piston Back Seal 1
- - 940-25-11 ‘O’ Ring 1
- - 940-33-08 P.T.F.E ‘O’ Ring 1
- - 940-33-10 P.T.F.E ‘O’ Ring 1
- - 940-37-34 Slydring 1
- - 940-37-39 Disc Seal 1

K405-04-0B Nozzle Air Cylinder

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K405-04-0B Nozzle Air Cylinder - - -


- - W011-43-04 Buffer 1
- - W011-50-06 Buffer 1
- - 940-25-29 'O' Ring 1

Ref. "51667E", Page


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- - 940-25-66 'O' Ring 1
- - 940-34-88 Oil Seal 2

K458-66-0C Nozzle Body

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K458-66-0C Nozzle Body - - -


- - V010-24-011 Spring 1
- - 940-33-11 'O' Ring 1
- - 940-35-12 Variseal 1

K440-29-0F Nozzle Adaptor

Spares Kit Ass'y. Description Component Component Description Qty.


No. Part No.

K440-28-0F Nozzle Adaptor - - -


- - V010-28-05 Stripper Spring 2
- - 940-33-02 'O' Ring 1
- - 940-33-05 'O' Ring 1

Chapter 4 SECTION 2
Spare Parts & Service SERVICE

If the information required does not appear in this manual, or if you require technical
assistance or advice, please contact us at the address below or through your agent. When
making technical enquiries, please be sure to quote the machine serial number. This can
be found on the machine identification plate, which will be affixed to the machine's base
unit.

Ref. "51667E", Page


145
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BWI KP Aerofill,
33-35 Clayton Road,
Hayes, Middlesex,
UB3 1RU
England.

Telephone: 0181-848 4501 (International: 0044 181 848 4501)


Fax: 0181-561 3308 (International: 0044 181 561 3308)

Ref. "51667E", Page


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