tem-9007_en

Machine type:

Machine number:

20Tetra Alex®

5856819007

Operation Manual:

Technical Manual: TeM - 3011562-01

OM - 1235757-01

TeM - 3011562-35

OM - 1235757-35

RomanianEnglish

19/02/2009Issue date:

Tetra Pak Processing Systems Division

DRAWING SPECIFICATIONThe Drawing Specification is the key identification for the process equipment.

It is to be filed separately under safe conditions.

CONTENTS TAG

Technical ManualT

EM

_TO

C_E

U_E

N.f

m

Tetra Pak Processing Components AB

SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 2

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

DATATechnical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Test record . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Preventive maintenance recommendations . . . . . . . 8Service media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

CERTIFICATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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1 Safety precautions

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Safety precautionsTo ensure maximum safety for the operator, always read this section carefully before carrying out any work on the equipment.

Use of hazard informationHazard information in this documentation is defined as follows:

Failure to observe this information results in immediate danger to life.

Failure to observe this information can result in major personal injury or loss of life

Caution! Failure to observe this information can result in minor personal injury or damage to the equipment.

DANGER!

WARNING!

1 Tetra Pak

Safety precautions

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GeneralOnly trained personnel are allowed to operate the machine. The machine may only be used in accordance with the instructions given in the manuals delivered with the equipment.

If the Safety precautions are not followed, there is risk of personal injury.

The machine is normally started by an external signal, therefore:

• always keep all covers closed during operation, rotating wheels and moving pistons may cause severe injuries

• make sure the mains power is turned off and secured before the service covers are opened/removed

• regard all electrical equipment as live, make sure the doors for the starter panel are closed

During operation:

• stay outside the safety area (approximately 1m (3 feet) around the machine)

• regard all pipes including pulsation dampers as hot

• watch out for leakage/blasts from hot media at pipe connections and from pressurized parts of the machine

• always use hearing protection

• never throttle down the product flow to or from the machine

Risk of explosion - Immediate danger to lifeMake sure that the product outlet pipes not are blocked in any way. Due to high pressure, this will make a high risk of exploded pipes and dampers.

Risk of scaldsThis machine works under pressurised conditions and high temperatures. To avoid jets of hot liquid, steam or cleaning solution, make sure that any operation sequence is finalised, the machine is cooled down and without pressure before disassembling any parts.

Before carrying out maintenance and repair:

• turn off the external mains power switch and lock it in position OFF

• allow the machine to cool down

• inform the operator and other relevant personnel about the work you intend to do

• post warning signs in prominent places

• when handling heavy parts; carry ou the lift in a safe way and use only with safe lifting equipment

DANGER!

WARNING!

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Cleaning solution

Handling of cleaning solutionCleaning solutions normally contain caustic soda (NaOH) or nitric acid (HNO3). These chemicals may cause burning to skin and eyes. Follow the instructions given by the supplier.

Whenever there is a risk of exposure to these chemicals, always wear:

• safety glasses

• protective gloves

• shoes made of PVC or PE plastic, or rubber

• apron.

In the case of an accident involving cleaning solution, the basic rule is to rinse the affected area as soon as possible with as much water as possible.

For this reason, always make sure that the showers work, that there are additional washing facilities, and that an eyewash device is available at or near each machine site.

Emergency precautionsIf swallowedIf you happen to swallow cleaning solution:

• drink large amounts of lukewarm water (in order to dilute the cleaning solution); then seek medical attention immediately.

Contact with eyesIf cleaning solution is splashed into your eyes:

• wash the eyes thoroughly with lukewarm water for 15 minutes (keep eyelids widely apart); then seek medical attention immediately.

Contact with skin or clothesIf cleaning solution comes into contact with skin or clothes:

• rinse immediately with plenty of water

• thoroughly wash the clothes before they are worn again. If skin burns appear, seek medical advice immediately.

If inhaledIf you experience irritation or pain due to having inhaled vaporized cleaning solution:

• leave the affected area to get fresh air. If the symptoms become worse, seek medical advice.

3 Tetra Pak

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2 General information

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General information

Machine introduction

To ensure maximum safety for the technicians, always read the“Safety precautions” pages before doing any work on the machine ormaking any adjustments.

Intended use of this Tetra Pak equipmentThis unit is intended for use according to the specifications in Technicaldata (see Technical Manual) and related documents.

Tetra Pak will not be held responsible for injury or damage if the equipmentis used for any other purpose.

ServiceIn case of problems when operating the machine, contact the nearest TetraPak service station.

ManufacturerThis Tetra Pak equipment was produced by:

Tetra Pak Processing Components ABRuben Rausings gataS-221 86 LUNDSweden

Machine identificationAll units carry a machine plate stating:

– unit identification

– data unique to the unit

Have this information available before contacting Tetra Pak concerning thisparticular unit.

WARNING!

Mach ine Type

Draw ing Spec .

Mach ine No .

Manu fac tu re r

Year o f manufacture

Tetra Pak

1Doc No. TeM-1244110-01Tetra Pak

General information

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Document information

Product DocumentationThe documentation for this equipment consists of the following parts:

• Operation Manual

• Technical Manual

It is important that you:

• keep the manuals for the life of the equipment,

• pass the manuals on to any subsequent holder or user of the equipment.

Design modificationsThe directives in this document are in accordance with the design andconstruction of the machine at the time it was released by the Tetra Pakmachine production facility.

Document producerThis document has been produced by:

Tetra Pak Processing Components ABRuben Rausings gataS-221 86 LUNDSweden

Further copiesAdditional copies can be ordered from nearest Tetra Pak service station.When ordering technical publications, always quote the document number.

Copyright � 2002Tetra Pak Processing Systems DivisionAll rights reserved. No part of this document may be reproduced or copied inany form or by any means without the written permission ofTetra Pak Processing Systems Division.

Tetra Pak2 Doc No. TeM-1244110-01

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3 Installation data

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Tetra Pak

Table of contents2.

2358

53-0

1.to

c

Installation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Prior to operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preparatory work. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

General dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Service area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Product supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Water supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Electrical supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . 13

Requirements on personnel . . . . . . . . . . . . . . . . . . . . . 13

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Unloading and transportation . . . . . . . . . . . . . . . . . . . . 14

Unpacking and inspection. . . . . . . . . . . . . . . . . . . . . . . 14

Positioning and erection . . . . . . . . . . . . . . . . . . . . . . . . 15

Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Oil amount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Check after installation. . . . . . . . . . . . . . . . . . . . . . . . . 25

iDoc No. TeM-1235853-01Tetra Pak

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Tetra Pakii Doc No. TeM-1235853-01

IntroductionInstallation2.

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Introduction

Prior to operationPrepare the site according to the information given in Preparatory work and Technical data.

When installing the machine, follow the instructions in Installation instructions.

Before starting up, make the checks according to Check after installation.

Technical dataSome pages refer to the following machine unique information:

• Mass and centre of gravity

• Piston diametre

• Consumption data

This information is found in Technical data.

Example of Technical data

Tetra Pak Processing Systemsver. 1.1

Technical Data for homogeniserModel: Machine No.: Customer:

Tetra Alex 30 T584553xxxx NN

General:Capacity: Working pressure: Inlet pressure: Sound effect level (acc. to ISO 3746):

4000 / 8000 l/h 250 bar 3-10 bar Noise reduction: B(A)

Altitude: Ambient temperature: Total mass: Centre of gravity (a=): Sound pressure level (distance=1m):

<1000 m <40 °C 3480 kg 1354 mm dB(A)

Wetend design:Valve design: Piston diameter: Piston design: Piston packing:

Cone 50 mm Stainless steel Grooved Remote ind. of product pressure:

Mushroom X Chromium plated X V-packing X

Ball Ceramic coated

Ceramic solid

Homogenising device design:Size of 1st stage: Size of 2nd stage Remote indication of hydraulic pressure: Remote continuous setting:

33/43 33/43 1st stage 2nd stage 1st stage 2nd stage

Drive Motor:Manufacture: Model: Revolution: Protection:

ABB M2BA280SMB 4 1481 rpm IP55

Power: Voltage: Frequency: Full load current: Starting current:

90 kW 415 V 50 Hz 165 Amp. 1106 Amp.

Hydraulic Unit:Manufacture: Model:

Bosch 4722-5471-80

Hydraulic Motor:Manufacture: Model: Revolution: Protection:

ABB M2AA71B 6 920 rpm IP55

Power: Voltage: Frequency: Rated current:

0,25 kW 415 V 50 Hz 0,9 Amp.

Drive Unit:V-belt type: Number of tracks: Motor pulley diameter: Gearbox pulley diameter: V-belt length

SPC 4 250 mm 500 mm 2650 mm

Reduction Gear:Manufacture: Model: Reduction:

Benzler TV151 5,890 Crankshaft speed sensor:

Valves:Cooling water valve: Steam valve: Press. relief valve:

Solenoid X Pneumatic Solenoid X Pneumatic 1st Stage X 2nd Stage X

Voltage: Compressed air supply: Voltage: Compressed air supply: Voltage: Voltage:

V AC 4-7 bar V AC 4-7 bar 24 V DC 24 V DC

Cooling water supply:Pressure: Consumption: Temperature: Hardness:

2-4 bar 1260 l/h <25 °C <10 °dH

Steam supply: Condensate:Pressure: Consumption: Temperature:

2-4 bar 45 kg/h 110-115 °C

Date: Sign: Revision:

1997-09-04 AM 0

Tetra Pak Processing SystemsBox 64S-221 00 Lund


Introduction Installation

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Preparatory workInstallation2.

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Preparatory work

General dimensionsMeasures: mm (inch)

1300

(51

.2")

GF201979

1160

(45

.7")

1250 (49.2")

125-

150

(4.9

2"-

5.91

")


Preparatory work Installation

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Service areaMeasures: mm (inch)

1000 (39.4") 1000 (39.4")

1000

(39

.4")

1300 (51.2")

600

(23.

6")

1250

(49

.2")

GF201462

1800

(70

.9")

125-

150

(4.9

2-5.

91")

SERVICE AREA

SE

RV

ICE

AR

EA



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FloorWeight of machine, see Technical data.

Measures: mm (inch)

125-

150

(4.9

2"-

5.91

")

786 (30.9")

934

(36.

8")

165

(6.

5")

190 (7.5")

GF201978120(4.72")



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Product supplyThe machine connections have to be welded to the product inlet- / outlet pipes.

The pipe line, inlet and outlet, shall contain as few elbows as possible.

Quality of piping and weldingPiping: Local regulations as to pressure vessel codes and material quality vs. product properties have to be met

Welding: Methods according to standards that are acceptable for the transport of liquid food.

A “Testweld” should always be carried out and the sample piece examined by qualified persons and particularly to establish that there are no “pockets”, “cracks”, “pinholes” or “crevices” that could not be thoroughly cleaned under practical conditions.

Recommended inlet pressures

Caution! Risk of machine damage

• The machine should never be allowed to run without product.

• Make sure that the machine is always fed with cleaning solution during CIP.

Risk of explosion - Immediate danger to life

• Do not install a shut off valve

• Make sure that the outlet pipes not are blocked in any way. Due to high pressure, this will make a high risk of exploded pipes and dampers.

Product P1 bar (psi)

Low viscous products e.g. milk, juice

3 - 10 (45 - 150)

High viscous products e.g. sauces, ketchups

4 - 10 (60 - 150)

Outlet pressure P2 3 - 20 bar (45 - 300 psi)

P1P2

GF200226

DANGER!

GF200225



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Product inlet - outlet

GF201932

F G

DE

CA B

Piston diameter

Ø = 32 mm Ø = 36 mm Ø = 40, 45, 50 mm

mm inch mm inch mm inch

A 861 33.9” 863 34.0” 863 34.0”

B 705 27.7” 701 27.6” 701 27.6”

C 125-150 4.9”-5.9” 125-150 4.9”-5.9” 125-150 4.9”-5.9”

D 149 5.9” 149 5.9” 149 5.9”

E 271 10.7” 271 10.7” 271 10.7”

F 185 7.3” 204 8.0” 204 8.0”

G 140 5.5” 140 5.5” 204 8.0”

Product inlet - outlet

GF200355

Customer piping

Product pipes Product inlet Product outlet

Piston diameter mm (Ø) 32 (Ø) 36 (Ø) 40 - 50 (Ø) 32 (Ø) 36 (Ø) 40 - 50

Outer diameter mm inch

38.1 1.5”

50.8 2”

50.8 2”

25.4 1”

25.4 1”

38.1 1,5”

Pipe material thicknessmm inch

1.8 0.07”

1.8 0.07”

1.8 0.07”

1.2 0.05”

1.2 0.05”

1.8 0.07”

See Technical data for piston diameter (Ø)


Preparatory work


Installation

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Water supplyFor dimensioning pipes and drainage, see Technical data for consumptions.

Requirements on service media, see Service media.

GF201870

1850

(72

.8")

min

1 2 3

1 Cooling water inlet2 Cooling water outlet from cooler in gearbox 3 Cooling water outlet

Note!Open drainage at outlets 2 and 3

GF200100

12 mm (0.47") Stainless steel pipe, not connected at delivery

Preparatory workInstallation

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Tetra Pak

Electrical supplyPower consumption, see Technical data.

Electrical hazardWork to be done by authorized personnel only!

Install a mains power switch before the external starter panel.

Before starting the machine, make sure that:

• all cables are undamaged

• the cables are correctly connected

WARNING!

DANGER!

GF201980Connection box


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Wiring diagram

(Cont'd)

6-4722936200_AA

PO

WE

RS

IGN

AL



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(Cont'd)

W01 M801 Motor - Main

W02 M802S802

Motor - Hydraulic Unit Switch - Hydraulic Unit

W05 S8051S8052P805S805

StopStartHour meterEmergency Stop

W10 Y810 (V55) Cooling Water - Standard(Pneumatic = Option 11)

W11 Y811 (V48) Steam (Standard - Aseptic(Pneumatic = Option 11)

W18 R818 Thermistor in Main Motor

W20 Y820 Cooling Water Circuit - CIP 1(Option 36)


W22 Y822 Remote On/Off Setting Hydraulic Pressure Stage 1(Option 17)

W23 Y823 Remote On/Off Setting Hydraulic Pressure Stage 2(Option 17/18)

W24 Y824 Remote Continuous Setting Stage 1(Option 19)

W25 Y825 Remote Continuous Setting Stage 2(Option 19/20)

W26 B826 Speed Sensor (Extra)

W27 B827 Remote Ind. Product Pressure(Option 14)

W272 B8272 Remote Ind. Product Pressure(Extra)

W28 B828 Remote Ind. Hydraulic Pressure Stage 1 (Option 15)

W29 B829 Remote Ind. Hydraulic Pressure Stage 2 (Option 15/16)

W30 B830 Steam Temperature(Aseptic, Option 12))

W35 B835 Oil Level Guard - High LevelOil Level Guard - Low Level (Option 28)

W45 B845 Oil Temperature Crankcase(Option 28)

W46 B846 Flow/Pressure Guard(Option 28)

W47 B847 Inlet Pressure Guard(Option 28)



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Installation instructionsInstallation

13Doc No. TeM-1235853-01

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Tetra Pak

Installation instructions

Requirements on personnel• Certified according to local regulations

Caution! Unauthorized personnelOperation by unauthorized personnel may endanger personnel and property



Installation

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StorageTemperatures: +10°C - +40°C (+50°F - +104°F)Humidity: 20% - 85%

Avoid storage in the same facilities as open drums with cleaning solutions due to risk for corrosion.

Caution! Noncompliance with requirements may damage the equipment!

Unloading and transportationObserve the signs ‘centre of gravity’. The weight is marked on the crate.

Unpacking and inspection• Check the equipment against the packing lists attached to the crates.

• Report any damage to Tetra Pak immediately.

Note! If a mobile crane must be used to position the machine, position the crate before unpacking.

Centre of gravityGF200353

GF200352

1

2

2

2

Packing list

Installation instructionsInstallation

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Tetra Pak

Positioning and erectionCaution! Lifting with fork lift truck

Observe the centre of gravity, see Technical data for a.

• Put the machine on the floor plates(Included in delivery)

GF201981

a

Fork lift

Fork lift

GF200349



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Level the machineMeasure the level of the machine both ways with a machinists level placed on the pump block.

Adjust the level by turning the ball feet.

Note! In order to minimize vibrations:

• keep distance between machine and floor as low as possible

• tighten all ball feet equally against the floor

Installation instructionsInstallation2.

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Pulsation dampers (Used to level out pressure variations).

Adjust to vertical position.

Put oil in the crankcase

Caution! Running the machine without oil will cause damage to the crankshaft.

The crankcase is at delivery empty of oil. Top up to the Max. level marked on the sight glass.

(The gearbox and the hydraulic unit are at delivery filled with oil).

For oil type and oil amount, see Lubrication.

Connect• product supply

• service media supply

• electric power

according to Preparatory work

GF201447

90

GF200341

MaxMin


Installation instructions Installation

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LubricationInstallation2.

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Lubrication

Recommended oil

* Viscosity in mm2/sec (cSt) at 40°C (104°F)

** A synthetic oil for the crank case must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.

*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.

Note! Green oils is for the time beeing not availabe, but for some viscosities, and their lubricacion performance is not yet good enough for use in our type of heavy duty machines.

(Cont'd)

Crankcase

Recommended oil: Cirkulation/gearbox oils with EP additives which do not harm slidebearings (yellow metals)

Mineral Type

Producer Type Viscosity*BP/Castrol Energol GR-XP 220Exxon/Mobil Mobilgear 600 XP 220Shell Omala Oil 220

Synthetic Type**

Producer Type Viscosity*BP/Castrol Alphasyn EP 220Exxon/Mobil SHC 630 220Shell Omala RL 220

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb GT 220Exxon/Mobil DTE FM 220Shell Cassida GL 220


Lubrication Installation

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(Cont'd)

* Viscosity in mm2/sec (cSt) at 40°C (104°F)If the gear box temperatur is kept to max. 70 °C ( 158°F), 220 cSt is sufficient.

** A synthetic oil for the gear box must be of PAO ( poly alfa olefine) type, like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.

(Cont'd)

Gearbox

Recommended oil: Gearbox oil

Mineral Type


Synthetic Type**

Producer Type Viscosity*BP/Castrol Enersyn HTX 220-320Exxon/Mobil SHC 630-632 220-320Shell Omala RL 220-320

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb GT 220-320Exxon/Mobil DTE FM 220-320Shell Cassida GL 220-320


LubricationInstallation2.

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(Cont'd)


** A synthetic oil for the hydraulic unit must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.


(Cont'd)

Hydraulic unit

Recommended oil: Hydraulic oil

Mineral Type

Producer Type Viscosity*BP/Castrol Bartran 68Exxon/Mobil Mobil DTE Excel 68Shell Tellus 68

Synthetic Type**

Producer Type Viscosity*BP/Castrol - -Exxon/Mobil Mobil SHC 526 68Shell Tellus 68

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb HY 68Exxon/Mobil Mobil DTE FM 68Shell Cassida HF 68


Lubrication Installation

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(Cont'd)

* Viscosity in mm2/sec (c.st) at 40°C (104°F)


Main drive motor

Recommended grease

Producer Type Viscosity*BP/Castrol Energrease LS EP 1 115Exxon/Mobil Mobilith SHC 100Shell Alvania grease RL3 100

Food GradeType***

Producer Type Viscosity*BP/Castrol -Exxon/Mobil Mobil grease FM 101 100Shell Cassida RLS 2 150


Installation instructionsInstallation2.

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Oil amount

Crankcase Gearbox Hydraulic unit

Approx. 20 litres (5.3 U.S. gallons)



GF200326 GF202053 GF200601


Installation instructions Installation

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Check after installationInstallation2.

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Check after installation

SafetyCheck:• All cables for damage

• That all cables are connected correctly

• That all covers are correctly installed

• That the product outlet pipes are not blocked in any way

Failure to make these checks will cause immediate danger to life!

Check:• Oil level in the:

– crankcase

– hydraulic unit

– gearbox

• Direction of rotation for the:

– crankcase shaft (as illustrated)

– hydraulic pump (marked on the pump unit)

• That product with correct feed pressure is available

• Cooling water circulation; check the drainage outlet

• That the covers are closed

• That the power consumption corresponds to the test protocol

Caution! Failure to make these checks may cause damage to the machine

DANGER!

GF200340


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fro

Doc No. TeM-1235897-01

GF201889

Tetra Alex® 20

Maintenance Instructions

Maintenance Instructions

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fro

Tetra Alex® 20

Issue 2009-01


Doc No. TeM-1235897-01

Table of contents 3

0 INTRODUCTION

Service preparations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1 FRAME

1.1 Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1-1 Covers - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1.1-1 Gas springs - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1.2-1 Insulation (optional) - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

1.2 Vibration elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2-1 Vibration elements - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 DRIVE UNIT

2.1 Drive motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1-1 Drive motor - clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.1-2 Drive motor - lubricate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.2 V-belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2.1-1 V-belts - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52.2.1-2 V-belts - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2.2-1 Belt pulleys - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2.3 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3-1 Gearbox - remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.3-2 Gearbox - fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92.3.1-1 Oil - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3.1-2 Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102.3.2-1 Seal rings - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.3.2-2 Seal rings - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112.3.3-1 Vibration elements - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3 CRANK CASE

3.1 Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.1-1 Oil - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.1-2 Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2 Oil level switch (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.2-1 Oil level switch - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.3 Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.3-1 Thermometer - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4 Crankshaft bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163.4-1 Crankshaft bearings - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

iTetra Alex® 20 Doc No. TeM-1235897-01

Table of contents

3

3.5 Cross head/Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233.5-1 Cross head/Connecting rod - check. . . . . . . . . . . . . . . . . . . . . . . . . 23

3.6 Piston area. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.6.1-1 Connections - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.6.1-2 Connections - set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243.6.2-1 Bellows - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253.6.2-2 Bellows - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

3.7 Speed sensor (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263.7-1 Speed sensor - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.8 Oil cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273.8-1 Oil cooler - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

4 WET END

4.1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284.1-1 Valves - disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294.1-2 Valves - assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304.1-3 Valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314.1.1-1 Valve seals - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

4.2 Piston unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334.2-1 Piston unit - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334.2-2 Piston unit - remove. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.2-3 Piston unit - disassemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354.2-4 Piston unit - assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.2.1-1 Piston - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364.2.2-1 Piston packing - change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

4.3 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374.3-1 Pressure gauge - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374.3-2 Pressure gauge - change O-ring . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

5 HOMOGENISATION HEAD

5-1 Homogenisation head - check . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5-2 Homogenisation head - remove. . . . . . . . . . . . . . . . . . . . . . . . . 40

5-3 Homogenisation head- assemble . . . . . . . . . . . . . . . . . . . . . . . 40

5.1 Homogenisation device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415.1-1 Homogenisation device - disassemble . . . . . . . . . . . . . . . . . . . . . . 415.1-2 Homogenisation device - assemble . . . . . . . . . . . . . . . . . . . . . . . . . 425.1.1-1 Seat - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.1.1-2 Seat - turn/change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435.1.2-1 Forcer - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445.1.2.1-1 Forcer disc - turn/change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ii Tetra Alex® 20Doc No. TeM-1235897-01

Table of contents 3

5.2 Hydraulic end . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455.2.1-1 Seals - change. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.3 Product connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465.3-1 Product connections - change gaskets . . . . . . . . . . . . . . . . . . . . . . 46

6 HYDRAULIC SYSTEM

6-1 Hydraulic system - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.1 Hydraulic unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486.1-1 Hydraulic unit - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486.1-2 Oil - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486.1-3 Hydraulic unit - disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496.1-4 Hydraulic unit - change parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 506.1.1-1 Safety valve - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

6.2 Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526.2-1 Pressure gauge - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

6.3 Pressure relief valve (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 536.3-1 Pressure relief valve - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

6.4 Remote setting valve (optional) . . . . . . . . . . . . . . . . . . . . . . . . . 546.4-1 Remote setting valve - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6.5 Sensor, hydraulic pressure (optional) . . . . . . . . . . . . . . . . . . . . 546.5-1 Sensor, hydraulic pressure - check . . . . . . . . . . . . . . . . . . . . . . . . . 54

7 COOLING WATER SYSTEM

7.1 Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567.1-1 Piping - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

7.3 Regulating valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577.3-1 Regulating valves - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.4 Water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587.4-1 Water valve - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

7.7 Cooling water regulator (optional) . . . . . . . . . . . . . . . . . . . . . . . 597.7-1 Cooling water regulator - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.8 Flow meter (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607.8-1 Flow meter - check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

iiiTetra Alex® 20 Doc No. TeM-1235897-01

Table of contents

3

8 ELECTRICAL SYSTEM

8-1 Wiring diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.1 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 638.1-1 Cables - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

8.2 Electrical cabinet (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 648.2.1-1 Cooling fan filter - change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

8.3 Temperature transmitter (optional). . . . . . . . . . . . . . . . . . . . . . . 658.3-1 Temperature transmitter - check . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

8.4 Emergency stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 668.4-1 Emergency stop - check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

9 MISCELLANEOUS

9.1 Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.2 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Recommended oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Oil amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

9.3 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

9.4 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

iv Tetra Alex® 20Doc No. TeM-1235897-01

Service preparations0 Introduction

1Doc No. TeM-1235897-01

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0 Introduction

Service preparationsBefore starting any maintenance work do as follows:

• Turn off main power and lock the main power switch in off position.

• Depressurize the hydraulic system

– Open the pressure adjusting valve in the hydraulic control device (in the two-stage version - open both valves)

• Close the shut-off devices in the product inlet pipes

• Close the cooling water inlet

• Remove the cladding

Note! When working with parts in contact with product, rinse and clean all parts before dismantling.

Risk of personal injuryAfter each service, always make sure that all covers are installed

WARNING!

1.1 Covers


1 Frame

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1 Frame1.1 Covers

1.1-1 Covers - checkCheck that the covers are undamaged and fit properly.

Check that the lock nuts for the hinges are tightened.

1.1.1-1 Gas springs - checkCheck the function of the gas springs.

Check that the lock nuts for the gas springs are tightened.

1.1.2-1 Insulation (optional) - checkCheck that the insulation material in the covers are not damaged and properly fitted.

GF201875

1

2

1 Gas spring2 Hinge

1.2 Vibration elements1 Frame

3Doc No. TeM-1235897-01

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1.2 Vibration elements

1.2-1 Vibration elements - checkCheck all vibration elements for wear, replace any defective.

GF201985

2.1 Drive motor


2 Drive unit

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2 Drive unit2.1 Drive motor

2.1-1 Drive motor - cleanCheck and if necessary clean the drive motor cooling fan (1) with compressed air.

2.1-2 Drive motor - lubricateUse an alemite gun to lubricate the nipples (2) for the bearings.

Note! Lubricating should be done during running; otherwise grease may penetrate into the motor through the sealing.

Risk of jamMake sure to stay clear from V-belts and belt pulleys

If lubrication is done at standstill, do not fill all at one time. Run the motor at least once between the fillings.

See Lubriction for recommended type of grease.

WARNING!

GF200409

2 1

2

1 Cooling fan2 Nipple

2.1 Drive motor2 Drive unit2.

2tf2

0159

4.en

2.2 V-belts

2.2.1-1 V-belts - checkCheck if the belts are worn. Replace any worn belt, see 2.2.1-2

Check the belt tension as follows:

• measure the distance Lf.

• apply a force of 75 N at one of the belts and measure the deflection te.

Adjust the belt tension until te = 2.8 x Lf /100.

Note! An incorrectly tensioned V-belt will wear out quickly.

GF200536

te = 2.8 x Lf /100

75 N

te Lf


2.1 Drive motor 2 Drive unit

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2.2.1-2 V-belts - changeAlways replace all belts at the same time

Loosen the nuts (1) for the adjusting bolt and remove the V-belts. Fit new V-belts by hand.

Caution! Do not use tools that can damage the V-belts

Adjust the belt tension.

2.2.2-1 Belt pulleys - checkCheck with a ruler that the belt pulleys on the drive motor and gearbox are aligned.

GF200635

1 Nut1

GF200633


2.3 Gearbox2 Drive unit2.

2TF

2023

57.e

n

2.3 Gearbox

2.3-1 Gearbox - removeDisconnect the cooling water hoses from the gear box.

Attach a sling to the gear box and hook it up to the lifting device. Undo the nuts (1), lower the gear box until the adjusting bolt (2) is free from the torque arm (3).

Remove the V-belts according to 2.2.1-2.

(Cont'd)

GF200637

1 Nut2 Adjusting bolt3 Torque arm

2

1

3


2.3 Gearbox 2 Drive unit

2.2T

F20

2357

.en

(Cont'd)

Depending on the dimension for the belt pulley (6), it may be necessary to remove it in order to remove the lid (4).

If needed, expand the slot (5) in the belt pulleys bushing in order to remove it from the shaft/key.

Remove the lid (4).

Position the lifting device above the gearbox and remove the slack from the sling.

Push/pull out the gearbox.

• Hydraulic tool to press out the gear box may be needed.

Caution! Risk of jam.

Remove the spacer sleeve from the crank shaft.

GF200665

6

5

4

4 Lid5 Slot6 Belt pulley



2TF

2023

57.e

n

2.3-2 Gearbox - fitInstall the sleeve to the crank shaft.

Apply some Molycote (grey) on the shaft and the key before installing the gearbox.

Install the lid, apply some Locktite 242 on the screw.

Install (if removed) the belt pulley.

Align the belt pulley to the drive motors belt pulley.

Lock the bushing with the correct torque. See Torque specifications.

Install the V-belts, the belt tensioner and set the belt tension, see V-belts.

Fit the cooling water hoses to the gearbox.

Install the cladding.

GF200666



2.2T

F20

2357

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2.3.1-1 Oil - checkUnscrew the drain plug (2) and check for water in the oil. Drain until all water is drain from the gear box.

Top up with oil. Type of oil, see Lubrication.

2.3.1-2 Oil - changeRemove the filler cap (1). Unscrew the drain plug (2) and drain the oil. Refit the plug.

Remove the venting plug (3) and fill up with oil.

Refit the venting plug.

Type of oil, see Lubrication.

GF200636

1 Filler cap2 Drain plug3 Venting plug4 Dipstick

2

3

1

4



2TF

2023

57.e

n

2.3.2-1 Seal rings - checkCheck for oil leakage at the seal rings (11, 13, 14) for the in- and out going shafts.

Change as required according to 2.3.2-2.

2.3.2-2 Seal rings - changeRemove the gearbox according to 2.3-1.

Remove and replace the seal rings (11, 13, 14) for the in- and out going shafts.

Install the gearbox according to 2.3-2.

GF202404

14 13

11



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2.3.3-1 Vibration elements - changeAttach a sling to the gear box and hook it up to the lifting device. Undo the nuts (1), lower the gear box until the adjusting bolt (2) is free from the torque arm (3).

Replace the vibration elements (4).

Adjust the belt tension, see V-belts.

GF202049

4

2

1

3

1 Nut2 Adjusting bolt3 Torque arm4 Vibration element


3.1 Oil3 Crankcase2.

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3 Crank case3.1 Oil

3.1-1 Oil - checkCheck if there is any water in the oil. Drain off any water through the drain hose.

Check that the oil level is between the min and max marks. Top up if necessary. Type and amount of oil, see Lubrication.

3.1-2 Oil - changeOpen the drain valve (1) and drain all oil from the housing.

Before filling with oil, check the oil level switch (optional) according issue 3.2-1

Close the drain valve and fill up with new oil.

– Check that the oil gauge glass (3) indicates correct level.(Valid for TA 25, TA 30 and TA S40 only)If fault, check oil pipe for blockage or damage.

Note! Bleed the drain hose.

Type and amount of oil, see Lubrication.

GF201437

1

MaxMin

2

3

1 Drain valve2 Thermometer 3 Oil gauge glass

(Valid for TA 25, TA 30 and TA S40 only)


3.2 Oil level switch (optional) 3 Crankcase

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3.2 Oil level switch (optional)

3.2-1 Oil level switch - checkWhen filling the crank case with oil, check that signals for low- and high level are achieved.

See 8-1 Wiring diagram for connections.

GF201481


3.3 Thermometer3 Crankcase2.

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3.3 Thermometer

3.3-1 Thermometer - checkCheck function of thermometer (1).

Temperature transmitter (optional), see issue 8.3.

Note! Max oil temperature at running: 55 ºC

GF201480

1


3.4 Crankshaft bearings 3 Crankcase

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3.4 Crankshaft bearings

3.4-1 Crankshaft bearings - changeRemove:

• the bellows,

• the drive motor; if necessary,

• the V-belts,

• the gearbox.

Drain the crankcase oil and remove the sight glass (1).

Remove the lock nuts (8) and the bolts (3) from the connecting rod (4). Push the cross head (2) forward and lock it in this position by help of the grub screw.

Remove the plane bearing cap (7) and the plane bearings (5) and (6).

(Cont'd)

GF200416

1

1 Sight glass

GF200417

34

5

6 7 8

22 Cross head3 Bolt4 Connecting rod5 Plane bearing6 Plane bearing7 Plane bearing cap8 Lock nut


3.4 Crankshaft bearings3 Crankcase2.

2tf2

0191

8.en

(Cont'd)

Support the crankshaft by a piece of wood (8) and remove:

a) the bearing flange (11); put two bolts in the threaded holes and press out the bearing flange,

b) the lid (10),

c) the ring (9) for the roller bearing,

d) the torque arm (1),

e) the bearing flange (4); the seal (2) and the outer ring of the roller bearing (3) comes out with the bearing flange,

f) the key (5) by help of a screw,

g) the spacing ring (6).

(Cont'd)

GF201426

1: TA25 & TA30

23

45

6

8

910

11

7

1 Bracket2 Seal3 Outer ring, roller bearing4 Bearing flange5 Key6 Spacing ring7 Inner ring, roller bearing8 Support (wood)9 Ring, roller bearing

10 Lid11 Bearing flange

1: TA20



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(Cont'd)

Fit the right sleeve (14) in the lifting tool (13).

Apply some grease, Molycote (grey), to the shaft before fitting the lifting tool (13).

Use the outer hole (12) for the lifting device when fitting the lifting tool to the crankshaft.

(Cont'd)

GF200419

13

12

14

12 Outer hole, lifting tool13 Lifting tool14 Sleeve, lifting tool



2tf2

0191

8.en

(Cont'd)

Remove the slack from the sling and remove the crankshaft.

Note! Take care not to damage the sensors (18, 19, 20).

Note! Make sure the crankshaft freely passes:

• the connecting rod (15),

• the oil distributer (16); If needed, lock the oil distributer in its top position,

• the cooler (17).

Replacing roller bearingsPut the crankshaft on a suitable support and heat the roller bearings inner ring evenly by help of a welding torch and pull them of the shaft. If required, knock lightly with a hammer to loosen the rings.

Caution! Wear heat protective gauntlets. .

(Cont'd)

15 Connecting rod16 Oil distributer17 Cooler18 Temperature transmitter

(optional)19 Sensor for cooling water

regulator (optional)20 Sensor for thermometer

GF201482

1516

1817

1920

GF200421



2.2t

f201

918.

en

(Cont'd)

Clean the ring seat. If required, smooth the ring seat surface with oil stone and rub sparingly with Molycote (grey).

Heat the new inner rings in oil bath to approximately 80°C, slip them up to their seats and let them cool down.

Caution! Wear heat protective gauntlets.

Note! Before installing the crankshaft:

• check the cross head and the connecting rod, activity 3.5-1

Fitting, crankshaftFabricate and install a support for the roller bearing before installing thecrankshaft.

Replace:

• the seal for the bearing flange,

• the O-rings.

Rub parts with Molycote (grey) and install in reverse order.

(Cont'd)

GF200422

GF200423



2tf2

0191

8.en

(Cont'd)

Fitting, plane bearingsClean and oil the plane bearings. Fit the plane bearing (5) to the connecting rod (4).

Fit the plane bearing cap (7) and the plane bearing (6) to the crankshaft and push back the connecting rod.

Note! Oil shuffle (18) turned as illustrated; oil-groove opposite the oil inlet hole.

Fit the bolts (3) and install new lock nuts (8). Tighten them evenly before applying the right torque. See Torque specifications.

Check that the crankshaft can be turned smoothly and without any un-normal noise.

(Cont'd)

GF200424

53 4

67

18

8

3 Bolt4 Connecting rod5 Plane bearing 6 Plane bearing7 Plane bearing cap8 Lock nut

18 Oil shuffle



2.2t

f201

918.

en

(Cont'd)

Set/clean the oil distributer

Note! In order to ensure proper lubrication for the cross heads, cross head pins and connecting rods, the oil distributer (16) must be free from deposits and be correctly set.

Clean the oil distributer. Make sure that the distributer pipes not are clogged.

Adjust the gap A between the oil distributer (16) and the cam (20) according figure. Same gap at both sides.

Check the oil distribution while running.Remove the three plugs (19) to inspect.

Install:• the bellows,

• the drive motor, if removed,

• the gearbox,

• the V-belts.

Clean and install the sight glass. Refill the crankcase oil.

A = 1.5 ± 0.5 mm 19

16

A

A

20

GF202047

16 Oil distributer19 Plug20 Cam


3.5 Cross head/Connecting rod3 Crankcase

23Doc No. TeM-1235897-01

2.2t

f201

598.

en

Tetra Pak

3.5 Cross head/Connecting rod

3.5-1 Cross head/Connecting rod - checkRemove the crankshaft.

Check for play between the pin (8), cross head (3) and the bushing (9).

If the bushing is worn, replace the connecting rod (5) and base bearing cap (6). The new connecting rod is delivered with the bushing installed.

Check for the cross head:

• that the groove (2) for the bellows is intact,

• that the threads in the three holes (1) not are damaged.If needed, replace with Helicoil.

Caution! When installing, make sure that:

• the oil holes (4) in crosshead and connecting rod are turned upwards

• the base bearing cap (6) is fitted to the correct connecting rod (5)(they are fabricated in pair)

• there is free passage for the oil when fitting the base bearing to the base bearing cap

• the base bearing cap is turned with the oil shuffle (7) heading upwards, as illustrated

GF201894

1

2

3

4

5

8

9

67

10

1 Threaded hole2 Groove3 Cross head4 Oil hole5 Connecting rod6 Base bearing cap7 Oil shuffle8 Pin9 Bushing

10 Base bearing surface

3.6 Piston area 3 Crankcase

2.2t

f202

041.

en

3.6 Piston area

3.6.1-1 Connections - checkClean the area and check that there is no gap between the piston (1) and the crosshead (10):

• during production:

– a gap results in a hammering noise,

• during stand-still:

– check by jerking the piston back and forth by hand.

3.6.1-2 Connections - setRemovalCover the drain hole in the bottom of the crank case.

Inch the machine by hand until the piston (1) is in its back end position.

Remove the three screws (2) and slide the piston connection ring (7) over the piston.

SettingEliminate the gap by adding shims (5) between the plate (4) and the cross head.

1 Piston 2 Screw3 Hose clamp4 Plate5 Shims6 Hose clamp7 Piston connection ring8 Bellow ring, front9 Bellows

10 Crosshead11 O-ring12 Bellow ring, rear

1 2 3 4 5 6

7 8 10 11 129GF202142


3.6 Piston area3 Crankcase2.

2tf2

0204

1.en

3.6.2-1 Bellows - checkCheck the bellows (9) for leaks and damage.

3.6.2-2 Bellows - change RemovalRemove the piston connection according to activity 3.6.1-2.

Remove the hose clamps (3, 6) and remove the bellows (9).

FittingReassemble in reverse order.

1 2 3 4 5 6

7 8 10 11 129GF202142

1 Piston 2 Screw3 Hose clamp4 Plate5 Shims6 Hose clamp7 Piston connection ring8 Bellow ring, front9 Bellows

10 Crosshead11 O-ring12 Bellow ring, rear


3.7 Speed sensor (optional)


3 Crankcase

2.2t

f202

360.

en

3.7 Speed sensor (optional)

3.7-1 Speed sensor - checkCheck that the screws and nuts for the speed sensor assembly are tightened.

Check, and if needed, adjust distance A.

GF202407

A A = 4 mm

3.8 Oil cooler3 Crankcase

27Doc No. TeM-1235897-01

2.2t

f202

361.

en

Tetra Pak

3.8 Oil cooler

3.8-1 Oil cooler - checkPressurize the cooling water system and check the oil cooler for leakage.

Note! Max. pressure 3 bar (45 psi).

GF202408

4.1 Valves 4 Wet end

2.2t

f201

600.

en

4 Wet end4.1 Valves

Tools used for disassembly and assembly

Consumables Silicon greaseTP No. 90296-9

GF201428


4.1 Valves4 Wet end2.

2tf2

0160

0.en

4.1-1 Valves - disassembleRemove the valve cover (1) and lift up the valve parts. Use the tools, see previous page, when removing the valve cages (5), the valve spring (6), the valves (7) and the valve seats (10). Take care not to drop parts when removing in order to avoid damages on critical surfaces as valve seats e t c.

Note! Keep the parts from each valve together. Do not mix the valve and valve seats from different valves!

GF201516

1 Valve cover2 Support ring3 Valve seal4 Cylinder5 Valve cage6 Valve spring7 Valve8 Valve seal9 Support ring

10 Valve seat11 Support ring12 Valve seal13 Distance

1

2

3

4

5

6

7

8

9

10

11

12

13



2.2t

f201

600.

en

4.1-2 Valves - assembleApply silicon grease on the seals before assembling the valves.

Note! Keep the parts from each valve together. Do not mix the valve and valve seats from different valves!

Use the tool (1) to fit the two pre-assembled units, each containing valve cage (2), valve spring (3), valve (4) and valve seat (5) (fig.2).

Note! Make sure that the spring is correctly fitted to valve cage and valve as illustrated in fig. 2

Assemble the parts in reverse order to disassembly.

– Take care not to drop parts when assembling in order to avoid damages on critical surfaces as valve seats e t c.

Tighten the nuts (6) for the valve covers with a torque wrench. See Torque specifications.

GF201430

Fig. 2

Fig. 1

1 Tool2 Valve cage3 Valve spring4 Valve5 Valve seat6 Nut

1

6

2

3

4

5


4.1 Valves4 Wet end2.

2tf2

0160

0.en

4.1-3 Valves - checkThe valves must be disassembled, see activity 4.1-1.

Check the wear pattern on the contact surfaces for the valve and the seat.

Normal wear pattern, fig 1No action is required.

The normal wear pattern on valve contact surfaces shows a dull metallic finish. After approximately 100 hours of operation the contact surface will show a slight wear mark on its entire circumreference. This polished impression is quite normal.

Pitting formation, fig 2Replace valve and seat. The seat can be turned once.

Pittings are hammered by solids contained in the product to be homogenised. They are the cause of “blow through marks”in the valve and the seat.

Blow through marks in valve and seat, fig 3Replace valve and seat. The seat can be turned once.

Product deposits on sporadic spots of the valve contact surface have prevented the valve from seating properly. The product has “blown through” and eroded the valve and seat across the entire width of the contact surfaces.

Note! Failure of carrying out regular checks and maintenance will cause damage of this nature.

The spheric valve contact surface deformated, fig 4Replace the valve and seat. The seat can be turned once.

GF200528

Fig 1 Fig 2 Fig 3 Fig 4



2.2t

f201

600.

en

4.1.1-1 Valve seals - changeThe valves must be disassembled, see activity 4.1-1.

Clean the grooves in the valve seat (3) before putting on the new support rings (2) and valve seals (1).

Note! Direction of valve seals as illustrated.

1 Valve seal2 Support ring3 Valve seat

GF201426

1

2

3


4.2 Piston unit4 Wet end2.

2tf2

0229

7.en

DR

AFT

4.2 Piston unit

4.2-1 Piston unit - checkCheck:

• that no product leaks through piston packing (12); check cooling water outlet for product in water

• that the piston packing (9) is not leaking water,

• that the piston (3) is not worn.

10 11 4 5 12 1314 15 6 7 8 9

16 1 2 3

GF202743

1 Pressure nut2 Lid3 Piston4 O-ring5 Split support ring6 O-ring7 Piston bushing8 Guide band9 Piston packing

10 Spring11 Support ring12 Piston packing13 Compression ring14 Guide band15 Spacer ring16 Crankcase housing


4.2 Piston unit 4 Wet end

2.2t

f202

297.

en

DR

AFT

4.2-2 Piston unit - removeRemove the piston connection according activity 3.6.1-2.

Unscrew the pressure nut by help of the sickle spanner (17). In this way, the piston bushing is extracted from the cylinder bushing.

Remove the piston seal cartridge..

GF201918

17

18

17 Sickle spannerTool

18 Extracting deviceTool

10 11 4 5 12 1314 15 6 7 8 9

16 1 2 3

GF202743




4.2 Piston unit4 Wet end2.

2tf2

0229

7.en

DR

AFT

4.2-3 Piston unit - disassemble

Remove:

a) the piston (3)

b) the lid (2)

c) the pressure nut (1)

d) the spring (10)

e) the support ring (11)

f) the piston packing (12)

g) the compression ring (13)

h) the guide band (14)

i) the spacer ring (15)

j) the piston packing (9)

k) the guide band (8)

l) the O-ring (4)

m) the split support ring (5)

n) the O-ring (6)

GF202744

1314

15

10

1

5

4

6

7

3

98

2

11

12


10 Spring11 Support ring12 Piston packing13 Compression ring14 Guide band15 Spacer ring


4.2 Piston unit 4 Wet end

2.2t

f202

297.

en

DR

AFT

4.2-4 Piston unit - assembleApply silicon grease on the seal and on the surface between the guide bands and the piston before assembling.

Assemble the parts in reverse order.

4.2.1-1 Piston - changeReplace the piston and assemble the piston unit according activity 4.2-4.

4.2.2-1 Piston packing - changeReplace:

• the piston packings (9) and (12)

• the guide bands (8) and (14).

• the O-rings (4) and (6)

Assemble the piston unit according activity 4.2-4.

10 11 4 5 12 1314 15 6 7 8 9

16 1 2 3

GF202743




4.3 Pressure gauge4 Wet end2.

2tf2

0239

3.en

4.3 Pressure gauge

4.3-1 Pressure gauge - checkCheck that the relation between the homogenising pressure and the hydraulic pressure corresponds to the test protocol.

GF202429

2

1

1 Homogenising pressure gauge2 Sensor, homogenising pressure


4.3 Pressure gauge 4 Wet end

2.2t

f202

393.

en

4.3-2 Pressure gauge - change O-ringRemove the screws (1) and change the O-ring (2).

Tighten the screws with a torque wrench. See Torque specifications.

GF202428

1

2

1 Screw2 O-ring


5-1 Homogenisation head - check5 Homogenisation head2.

2tf2

0160

7.en

5 Homogenisation head5-1 Homogenisation head - check

Check that the homogenizing pressure is achieved; if not, loosen the vent plug (1) and vent the hydraulic system.

Check that no product leaks through the product drain hole (2). If leakage, the seat and forcer have to be checked, see activities 5.1.1-1 and 5.1.2-1.

Check that no oil leaks through the oil drain hole (3). If leakage, see activity 5-2.

GF201882

1

23

1 Vent plug2 Product drain hole3 Oil drain hole


5-2 Homogenisation head - remove 5 Homogenisation head

2.2t

f201

607.

en

5-2 Homogenisation head - removeRemove the:

• product pipe

• pipe connection (1)

• hydraulic end (2)

• housing (3)

• hydraulic end (4)

• housing (5)

5-3 Homogenisation head- assemble

Replace all O-rings and support rings. Rub the parts with silicon grease before assembly. Fit the parts in reverse order to dissasembly.

Note! Vent plugs (6) heading upwards.

Tighten the nuts (7) with a torque wrench. See Torque specifications.


GF201865

76

71

36

27

5

4

1 Pipe connection2 Hydraulic end3 Housing4 Hydraulic end5 Housing6 Vent plug7 Nut


5.1 Homogenisation device5 Homogenisation head2.

2tf2

0181

7.en

5.1 Homogenisation device

5.1-1 Homogenisation device - disassembleRemove:

• O-ring (3) and support ring (4)

• seat (5)

• forcer shaft (9)

• O-ring (6)

• guide band (12)

• O-ring (14)

• guide band (15)

Remove the O-ring (10) and support ring (11) from the forcer.

Forcer, see item 5.1.2-1.

GF201785

1

2

34

5 6

4 3

7 8 9 10 11 12 13 1514

1 Screw2 O-ring3 O-ring4 Support ring5 Seat6 O-ring7 Forcer disc8 O-ring9 Forcer shaft

10 O-ring11 Support ring12 Guide band13 Product drain hole14 O-ring15 Guide band


5.1 Homogenisation device 5 Homogenisation head

2.2t

f201

817.

en

5.1-2 Homogenisation device - assembleRub the parts with silicon grease before assembly.

Replace O-rings, support rings and guide bands.

Apply some locking fluid (16) of medium strength on the threads of screw (1). Tighten the screw hard enough to get metallic contact between the forcer disc (7) and the forcer shaft (9).

Assemble in reverse order to activity 5.1-1.

Install the homogenisation device according activity 5-3.

GF202016

1

2

34

5 6

4 3

7 8 9 10 11 12 13 1514

16

1 Screw2 O-ring3 O-ring4 Support ring5 Seat6 O-ring7 Forcer disc8 O-ring9 Forcer shaft

10 O-ring11 Support ring12 Guide band13 Product drain hole14 O-ring15 Guide band16 Locking compound

TP No. 90157-16

Locking compound• Force to open: 3 N/mm2

• Temperature: -20 to +150 ºC-4 to + 302 ºF


5.1 Homogenisation device5 Homogenisation head2.

2tf2

0181

7.en

5.1.1-1 Seat - checkCheck the condition of the seat.

Assemble according to activity 5.1-2.

5.1.1-2 Seat - turn/changeThe seat is symmetrical and its life time can be doubled by turning it.

Turn or replace the seat.


GF201788

Seat

Deep caviation

GF201787

Seat


5.1 Homogenisation device 5 Homogenisation head

2.2t

f201

817.

en

5.1.2-1 Forcer - checkCheck the condition of the forcer.


5.1.2.1-1 Forcer disc - turn/changeThe forcer disc (3) is symmetrical and its life time can be doubled byturning it.

Turn or replace the forcer disc (3).

Apply some locking fluid (6) of medium strength on the threads of screw (1). Tighten the screw hard enough to get metallic contact between the forcer disc (3) and the forcer shaft (5).


GF201790

Forcer disc

Deep caviation

GF202017

12

34

5

6

1 Screw2 O-ring3 Forcer disc4 O-ring5 Forcer shaft6 Locking compound

TP No. 90157-16

Locking compound• Force to open: 3 N/mm2

• Temperature: -20 to +150 ºC-4 to + 302 ºF


5.2 Hydraulic end5 Homogenisation head

45Doc No. TeM-1235897-01

2.2t

f201

610.

en

Tetra Pak

5.2 Hydraulic end

5.2.1-1 Seals - changeUndo the nuts (6) and remove the hydraulic ends (7) and (8).

Replace guide bands (1) and (4), the O-ring (3) and the support ring (2).

Apply some silicon grease to the parts, and fit the guide bands and the O-ring by hand.

Tighten the nuts (6) with a torque wrench. See Torque specifications.

Vent the hydraulic system by help of the vent plug (5).


GF201885

65

7

8

6

5 Vent plug6 Nut7 Hydraulic end8 Hydraulic end

2 3 4 5 61

GF201786

1 Guide band2 Support ring3 O-ring4 Guide band5 Vent plug6 Nut

5.3 Product connections


6 Hydraulic system

2.2t

f202

363.

en

5.3 Product connections

5.3-1 Product connections - change gasketsChange the gaskets (3), (5) and (9) for the inlet product connection.

Change the gaskets (17), (19) and (23) for the outlet product connection.

Note! Make sure to install the dampers (4) and (18) in vertical position.

19

18

17

23

GF202410

90

5

4

3

9

Inlet3 Gasket4 Damper5 Gasket9 Gasket

Outlet17 Gasket18 Damper19 Gasket23 Gasket

6-1 Hydraulic system - check6 Hydraulic system

47Doc No. TeM-1235897-01

2.2t

f201

612.

en

Tetra Pak

6 Hydraulic system6-1 Hydraulic system - check

Check:

• all connections for leakage

• the function of the hydraulic system.

GF201888

28

1

4

3

6

5

5

6

79

79

1st stage2nd stage

return pipe

1 Hydraulic unit2 Safety valve3 Pressure adjusting valve4 Hydraulic pressure gauge5 Hydraulic end6 Vent plug7 Pressure relief valve (optional)8 Sensor, hydraulic pressure (optional)9 Remote setting valve (optional)

6.1 Hydraulic unit 6 Hydraulic system

2.2t

f202

404.

en

6.1 Hydraulic unit

6.1-1 Hydraulic unit - checkCheck:

• all connections for leakage

• the oil level (if needed top up with oil according to recommendations in Lubrication.)

6.1-2 Oil - changeUnscrew the drain plug and drain all oil from the tank.

Fill oil according to recommendations in Lubrication.

GF444

1 Filler cap2 Drain plug3 Level glass

1

2

3


6.1 Hydraulic unit6 Hydraulic system2.

2tf2

0240

4.en

6.1-3 Hydraulic unit - disassembleRemove:

• the tank fastening screws (1), disconnect the oil pipes (2) and lift out the pump unit

• the screws (3) and lift up the motor /pump

• the oil pipes (4) from pump (5)

• the screws (6) and take out the pump

• the lock ring (7) and remove the suction strainer (8)

• the connection (9)

• the angel connection (10)

• the carrier (11)

Assemble in reverse order:

Install a new packing (12). Refill with new oil, see Lubrications for specifications. Bleed the hydraulic system.

22

GF201949

11

9610

78 5

12

1

3

13 4

1 Screw2 Pipe3 Screw4 Pipe5 Pump6 Screw7 Lock ring8 Strainer9 Connection

10 Connection11 Carrier12 Packing13 Filler cap


6.1 Hydraulic unit 6 Hydraulic system

2.2t

f202

404.

en

6.1-4 Hydraulic unit - change partsDisassemble the hydraulic unit according to 6.1-3.

Clean the suction strainers (8).

Check:

• the shaft coupling parts (14) and (15) for wear

• condition of the rubber cross (16)

• condition of the pump (5)

Change parts as required.

22

GF202445

11

9610

78 5

12

1

3

13

14

16

15

4

1 Screw2 Pipe3 Screw4 Pipe5 Pump6 Screw7 Lock ring8 Strainer9 Connection

10 Connection11 Carrier12 Packing13 Filler cap14 Shaft cupling15 Shaft coupling16 Rubber cross


6.1 Hydraulic unit6 Hydraulic system

51Doc No. TeM-1235897-01

2.2t

f202

405.

en

Tetra Pak

6.1.1-1 Safety valve - checkCheck:

• the safety valves (1)

– increase the homogenising pressure 5 bar (75 psi) and check that the safety valve opens.

If fault, set or change the safety valve(s).

Reset the homogenising pressure.

Caution! It is important that the safety valves are set to release the hydraulic pressure within 5 bar over the homogenising working pressure

GF200979

1 Safety valve1

6.2 Pressure gauge


6 Hydraulic system

2.2t

f201

627.

en

6.2 Pressure gauge

6.2-1 Pressure gauge - checkCheck:

• pressure gauge,

(pressure gauge value - homogenising pressure, see the test protocol).

GF201893

6.3 Pressure relief valve (optional)6 Hydraulic system

53Doc No. TeM-1235897-01

2.2t

f201

012.

en

Tetra Pak

6.3 Pressure relief valve (optional)

6.3-1 Pressure relief valve - checkCheck that the hydraulic pressure goes on/off when the pressure relief valve (1) is activated/deactivated.

GF200980

1

6.4 Remote setting valve (optional)


6 Hydraulic system

2.2t

f202

362.

en

6.4 Remote setting valve (optional)

6.4-1 Remote setting valve - checkCheck function of the remote setting valve (1).

6.5 Sensor, hydraulic pressure (optional)

6.5-1 Sensor, hydraulic pressure - checkCheck function of the hydraulic pressure sensor (2).

GF202409

2 1

1 Remote setting valve2 Sensor, hydraulic pressure

7 Cooling water system2.

2tf2

0126

1.en

7 Cooling water system

GF20161112345

3

4

1

2

5

Description Function

1 Cooling water valve Shut of valve

2 Cooling water flow meter (optional) Indicates flow rate and accumulated valueFlow rate, see Technical Data

3 Cooling water regulating valve Regulation of crank case oil temperatureMax. 55 °C (131 °F)

4 Cooling water regulator (optional) Automatic control of crank case oil temperature

5 Cooling water regulating valve Regulation of gear box oil temperature


7.1 Piping 7 Cooling water system

2.2t

f201

261.

en

7.1 Piping

7.1-1 Piping - checkCheck:

• all connections for leakage.

1 Cooling water shut off valve2 Cooling water flow meter (optional)3 Cooling water regulating valve 4 Cooling water regulator (optional)5 Cooling water regulating valve

GF20161112345

3

4

1

2

5


7.3 Regulating valves7 Cooling water system

57Doc No. TeM-1235897-01

2.2t

f201

266.

en

Tetra Pak

7.3 Regulating valves

7.3-1 Regulating valves - checkCheck:

• function of regulating valves.

GF201430

7.4 Water valve



2.2t

f201

267.

en

7.4 Water valve

7.4-1 Water valve - checkActivate and de-activate the cooling water shut off valve and check its function.

GF201431

1 Cooling water shut off valve, solenoid (standard)2 Cooling water shut off valve, pneumatic

(optional)

1 2

7.7 Cooling water regulator (optional)7 Cooling water system

59Doc No. TeM-1235897-01

2.2t

f201

269.

en

Tetra Pak

7.7 Cooling water regulator (optional)Controls the crank case oil temperature.

7.7-1 Cooling water regulator - checkCheck function.

GF201434

12345

Flow direction

7.8 Flow meter (optional)



2.2t

f201

270.

en

7.8 Flow meter (optional)Indicates the flow rate and the accumulated value.

7.8-1 Flow meter - checkCheck function.

GF201435

0 0 0 5 7 6 5 2

Flow direction

0 - 999 litres

8-1 Wiring diagram8 Electrical system2.

2TF

2086

80.e

n

8 Electrical system8-1 Wiring diagram

(Cont'd)

6-4722936200_AA

PO

WE

RS

IGN

AL


8-1 Wiring diagram 8 Electrical system

2.2T

F20

8680

.en

(Cont'd)

W01 M801 Motor - Main

W02 M802S802

Motor - Hydraulic Unit Switch - Hydraulic Unit

W05 S8051S8052P805S805

StopStartHour meterEmergency Stop

W10 Y810 (V55) Cooling Water - Standard(Pneumatic = Option 11)

W11 Y811 (V48) Steam (Standard - Aseptic(Pneumatic = Option 11)

W18 R818 Thermistor in Main Motor



W22 Y822 Remote On/Off Setting Hydraulic Pressure Stage 1(Option 17)

W23 Y823 Remote On/Off Setting Hydraulic Pressure Stage 2(Option 17/18)

W24 Y824 Remote Continuous Setting Stage 1(Option 19)

W25 Y825 Remote Continuous Setting Stage 2(Option 19/20)

W26 B826 Speed Sensor (Extra)

W27 B827 Remote Ind. Product Pressure(Option 14)

W272 B8272 Remote Ind. Product Pressure(Extra)

W28 B828 Remote Ind. Hydraulic Pressure Stage 1 (Option 15)

W29 B829 Remote Ind. Hydraulic Pressure Stage 2 (Option 15/16)

W30 B830 Steam Temperature(Aseptic, Option 12))

W35 B835 Oil Level Guard - High LevelOil Level Guard - Low Level (Option 28)

W45 B845 Oil Temperature Crankcase(Option 28)

W46 B846 Flow/Pressure Guard(Option 28)

W47 B847 Inlet Pressure Guard(Option 28)


8.1 Cables8 Electrical system2.

2TF

2086

80.e

n

8.1 Cables

8.1-1 Cables - check

Electrical hazardMake sure the power supply to the homogeniser is shut of and prevented from accidentally being turned on.

Check all cables and cable connections.

Failure to make these checks will cause immediate danger to life!

WARNING!

DANGER!


8.2 Electrical cabinet (optional) 8 Electrical system

2.2T

F20

8680

.en

8.2 Electrical cabinet (optional)

8.2.1-1 Cooling fan filter - changeChange the in- and outlet filters.

GF200449


8.3 Temperature transmitter (optional)8 Electrical system2.

2TF

2086

80.e

n

8.3 Temperature transmitter (optional)

8.3-1 Temperature transmitter - checkAs optional equipment, there are temperature transmitters for:

• crank case oil temperature, placed in the crank case

• condensate temperature, placed below the condensate thermometer (valid only for aseptic machines)

Check function of the temperature transmitter(s) (Pt100).

If malfunction suspected, check the resistance.

°C Pt100 - Resistance diagram

140120100

806040

+ 200

- 2090 95 10 105 110 115 120 125 130 135 140 145 150 Ohm

GF202414


8.4 Emergency stop 8 Electrical system

2.2T

F20

8680

.en

8.4 Emergency stop

8.4-1 Emergency stop - checkCheck the function of the emergency stop button.

Press the emergency stop button and check:

• that the machine stops immediately

Release the emergency stop button and check:

• that the machine does not start when the button is pulled out

Failure to make these checks can result in major personal injury or damage to the machine

WARNING!


9.1 Tools9 Miscellaneous2.

2tf2

0161

5.en

9 Miscellaneous

9.1 ToolsTools included in tool kit

Note! Only the variants of tools used for the machine described in this manual are listed below.

(Cont'd)

Usage: Valves

See activities: 4.1-1, 4.1-2

Usage: Valves

See activity: 4.1-2

Usage: Valves

See activity: 4.1-1

Usage: Piston seal cartridge

See activity: 4.2-2, 4.2-4

Usage: Piston seal cartridge

See activity: 4.2-2

GF202226GF200454

GF200453

GF200457

GF200456


9.1 Tools 9 Miscellaneous

2.2t

f201

615.

en

(Cont'd)

Tool not included in tool kitDrawings for local fabrication can be ordered

Usage: Removal / fitting of crankshaft

See activity: 3.4-1

Drawing No:a: 4722-6377b: 4722-6378

GF200458a

b


9.2 Lubrication9 Miscellaneous2.

2tf2

0872

9.en

9.2 Lubrication

Recommended oil


** A synthetic oil for the crank case must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.


Note! Green oils is for the time beeing not availabe, but for some viscosities, and their lubricacion performance is not yet good enough for use in our type of heavy duty machines.

(Cont'd)

Crankcase

Recommended oil: Cirkulation/gearbox oils with EP additives which do not harm slidebearings (yellow metals)

Mineral Type


Synthetic Type**

Producer Type Viscosity*BP/Castrol Alphasyn EP 220Exxon/Mobil SHC 630 220Shell Omala RL 220

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb GT 220Exxon/Mobil DTE FM 220Shell Cassida GL 220


9.2 Lubrication 9 Miscellaneous

2.2t

f208

729.

en

(Cont'd)

* Viscosity in mm2/sec (cSt) at 40°C (104°F)If the gear box temperatur is kept to max. 70 °C ( 158°F), 220 cSt is sufficient.

** A synthetic oil for the gear box must be of PAO ( poly alfa olefine) type, like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.

(Cont'd)

Gearbox

Recommended oil: Gearbox oil

Mineral Type


Synthetic Type**

Producer Type Viscosity*BP/Castrol Enersyn HTX 220-320Exxon/Mobil SHC 630-632 220-320Shell Omala RL 220-320

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb GT 220-320Exxon/Mobil DTE FM 220-320Shell Cassida GL 220-320


9.2 Lubrication9 Miscellaneous2.

2tf2

0872

9.en

(Cont'd)


** A synthetic oil for the hydraulic unit must be of PAO ( poly alfa olefine) type , like the Omala, that is mixable with mineral oils and does not affect rubber, sealings and paint.


(Cont'd)

Hydraulic unit

Recommended oil: Hydraulic oil

Mineral Type

Producer Type Viscosity*BP/Castrol Bartran 68Exxon/Mobil Mobil DTE Excel 68Shell Tellus 68

Synthetic Type**

Producer Type Viscosity*BP/Castrol - -Exxon/Mobil Mobil SHC 526 68Shell Tellus 68

Food GradeType***

Producer Type Viscosity*BP/Castrol Optileb HY 68Exxon/Mobil Mobil DET FM 68Shell Cassida HF 68


9.2 Lubrication 9 Miscellaneous

2.2t

f208

729.

en

(Cont'd)

* Viscosity in mm2/sec (c.st) at 40°C (104°F)


Main drive motor

Recommended grease

Producer Type Viscosity*BP/Castrol Energrease LS EP 1 115Exxon/Mobil Mobilith SHC 100Shell Alvania grease RL3 100

Food GradeType***

Producer Type Viscosity*BP/Castrol -Exxon/Mobil Mobil grease FM 101 100Shell Cassida RLS 2 150


9 Miscellaneous

73Doc No. TeM-1235897-01

2.2t

f208

730.

en

Tetra Pak

Oil amount

Crankcase Gearbox Hydraulic unit




GF200326 GF202053 GF200601

9.3 Torque specifications


9 Miscellaneous

2.2t

f201

622.

en

9.3 Torque specifications1 Valve cover / Pump block 180 Nm (133 ft lbf)

2 Homogenisation head 140 Nm (103 ft lbf)

3 Product inlet / Pump block 140 Nm (103 ft lbf)

4 Pressure gauge flange 140 Nm (103 ft lbf)

5 Pump block / Crankcase 360 Nm (265 ft lbf)

6 Piston connection 44 Nm (32 ft lbf)

7 Plane bearing cap / Connecting rod 50 Nm (37 ft lbf)

8 Belt pulley bushing Allen key size

Torque

3 mm 6 Nm (4.4 ft lbf)

5 mm 20 Nm (15 ft lbf)



10 mm 115 Nm (85 ft lbf)

12 mm 170 Nm (125 ft lbf)

14 mm 190 Nm (140 ft lbf)

17 mm 270 Nm (199 ft lbf)

GF201890

6

GF201897

2

3

2

15

7

4

9.4 Trouble shooting9 Miscellaneous2.

2tf2

0162

1.en

9.4 Trouble shooting

(Cont'd)

Fault Possible cause Action

No throughput No voltage in the drive motorMotor not workingCrank shaft not turningSuction or discharge pipes closedNo feed pressureGas / air in wetend or pipingValves stucked

Check fuses and leadsRepair or replace motorCheck the driveOpen shut-off devicesSwitch on feed pumpVent wetend and pipingDisassemble the wetend and check for damages or obstacles

Troughput to small or decreasing

Suction and discharge valves dirty or damagedSpeed drop due to slipping V-beltGas / air in wetend or pipingGas / air in productCapacaty of feed pump to smallPiston packing damagedValves stucked

Clean / change valves

Adjust belt tensionVent wetend or pipingDeaerate productIncrease capacity of feed pumpReplace piston packingDisassemble the wetend and check for damages or obstacles

Homogenisation pressure dropping or fluctuating

Suction and discharge valves dirty or damaged Gas / air in cylinder block, possibly in only one or two cylindersHydraulic end seal leakingPressure fluctuations or pressure drop in the hydraulic systemPressure gauge for homogenisation pressure not working

Clean / change valves

Vent the wetend

Replace sealCheck pressure adjusting valveVent the hydraulic systemCheck, and if necessary, replace pressure gauge

Homogenisation pressure not reached

Insufficient hydraulic pressure at homogenisation headHomogenisation head worn

Pressure adjusting valve in hydraulic system is leakingHydraulic pump wornHydraulic pump not rotating

Check pressure valveVent the hydraulic systemCheck forcer and seat

Clean the pressure adjusting valveNote! The maximum set pressure must not be changedReplace the pumpCheck electrical connections


9.4 Trouble shooting 9 Miscellaneous

2.2t

f201

621.

en

(Cont'd)

Fault Possible cause Action

Vibration in piping Pulsation dampers fullValves wornPiston packing damagedTo low inlet pressureTo high inlet pressure

DrainReplace valvesCheck for product in cooling waterIncrease pressureDecrease pressure

Hammering noise during production

To low inlet pressurePulsation damper fullFeed system empty while changing balance tank

Increase pressureDrainShut off the hydraulic pressure while switching tank


9.4 Trouble shooting9 Miscellaneous2.

2tf2

0162

1.en



2.25

_.en

5 Technical data

Tetra Pak

2.25

_.en


Tetra Pak

Tetra Pak Processing Components ABTechnical Data for homogenizerModel: Machine No.: Customer:Tetra Alex 20 5856819007 Logos Group , Republic of Moldovia

General:Capacity: Working pressure: Inlet pressure: Sound effect level (acc. to ISO 3746):5000 l/h 160 bar 3-10 bar Noise reduction: B(A)Altitude: Ambient temperature: Total mass: Centre of gravity (a=): Sound pressure level (distance=1m):<1000 m <40 °C 1355 kg mm dB(A)

Wetend design:Valve design: Piston diameter: Piston design: Piston packing:Cone 50 mm Stainless steel Grooved X Remote ind. of product pressure:Mushroom X Chromium plated X V-packingBall Tungsten carbide Feed: Signal:

Ceramic solid V DC mA

Homogenising device design:Size of 1st stage: Size of 2nd stage Remote indication of hydraulic pressure: Remote continuous setting:53/62 53/62 1st stage 2nd stage 1st stage 2nd stage

Feed: Signal: Feed: Control signal: V DC mA V DC mA

Amp.

Drive Motor:Manufacture: Model: Revolution: Protection: Thermistor:ABB M3AA200MLB 4 H 1470 rpm IP55 <7.5 V DCPower: Voltage: Frequency: Full load current: Starting current:30 kW 380 V 50 Hz 58 Amp. 395 Amp.

Hydraulic Unit:Manufacture: Model:Bosch 6-4722 5471 81

Hydraulic Motor:Manufacture: Model: Revolution: Protection:ABB M2VA71A 4 1375 rpm IP55Power: Voltage: Frequency: Rated current:0.25 kW 380 V 50 Hz 0.95 Amp.

Pressure Lubrication Motor:Manufacture: Model: Revolution: Protection: rpmPower: Voltage: Frequency: Rated current: kW V Hz Amp.

Drive Unit:V-belt type: Number of tracks: Motor pulley diameter: Gearbox pulley diameter: V-belt lengthSPB 3 280 mm 315 mm 2000 mm

Reduction Gear:Manufacture: Model: Reduction:Benzlers BT-51 5,760

Valves:Cooling water valve: Steam valve: Press. relief valve:Solenoid X Pneumatic Solenoid Pneumatic 1st Stage X 2nd Stage X

Voltage: Compressed air supply: Voltage: Compressed air supply: Voltage: Voltage:24 V DC bar V DC bar 24 V DC 24 V DC16 VA VA 0.75 Amp. 0.75 Amp.

Cooling water supply:Pressure: Consumption: Temperature: Hardness:2-4 bar 130 l/h <25 °C <10 °dH

Steam supply: Condensate:Pressure: Consumption: Temperature: bar kg/h °C

Other:Fluorescent tube: Door safety lock: Crankshaft speed sensor:Voltage: Voltage: Feed:

V AC V DC V DC W mA

Date: Sign: Revision:2009-03-17 TC 1

BL0081EN:3

Tetra Pak

2.25

_.en


2.26

_.en

6 Test record

Tetra Pak

Tetra Pak

2.26

_.en



Test Record for homogenizerModel: Machine No.:

Tetra Alex 20 5856819007Customer:

Republic of Moldovia

Performance dataInlet pressure: Test liquid: Test voltage:

2,0 bar Water 40-70°C 380 V

Testing time Homogenizing Capacity Crankshaft Current Frequencypressure Hydraulic Signal Hydraulic Signal revolution consumption

pressure pressure(h) (bar) (bar) (mA) (bar) (mA) (l/h) (rpm) (Amp) (Hz)

1 50 - - 33 - 5200 231 15 50100 42 - 33 - 5140 230 25 50150 78 - 33 - 5080 229 37 50

6 160 87 - 33 - 5050 229 41 50

Manufacturing No.

Date: Test performed by:

20090317 Mikael LindholmDate: Test approved by:

20090317 Thomas Carlsson

Stage 1 Stage 2

A3873

Pump block Pressure lubrication Motor Crankcase, (TA 400)0939921510001

Main motor

Hydraulic motor

3GVA072001-BSD

Gearbox

990400-001

BL0106EN:2

2.26

_.en


Tetra Pak

2.27

_.en

7 Parts list

Tetra Pak

2.27

_.en


Tetra Pak

Page No

7-1T

7 SPCSpare Parts Catalogue

Machine No. Group Description

TA20 - 5856819007 Tetra Alex 20 etra Pak

7-2Assembly drawingT
TA20 - 5856819007
Machine No.etra Pak


Assembly DrawiIssue: 2009-03-11

Group Number Page No

7-3Tetra P

Part NoPart No Description Page No

6-47226-4722

6-4726-4722

6-47226-47226-47226-47226-4722

6-47226-47226-4722

6-47226-4722

6-47226-4722

6-47226-47226-4722

6-4726-4726-4726-472

6-47226-47226-4722

6-47226-47226-4722

6-4722

LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

COMMISSIONING KIT . . . . . . . . . . . . . . . .66Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Standard Tools. . . . . . . . . . . . . . . . . . . . . . . 70

SPARE PARTS KIT . . . . . . . . . . . . . . . . . .72

Version:PL-0OF-0


TA20 - 5856819007 ak

8163 80 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 8166 80 Drive Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

6835 80 PRODUCT CONNECTIONS . . . . . . . . . . . 56 8122 80 Inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 8123 80 Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

6671 80 ELECTRICAL PARTS . . . . . . . . . . . . . . . . 62

ng:

Description Page No Description Page No Part No

7516 80 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . 4 1982 80 Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 1991 80 Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . . 8 8155 80 Oil System . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6977 80 COOLING CIRCUIT . . . . . . . . . . . . . . . . . . 12 8450 80 Cooling System Water Inlet . . . . . . . . . . . . . 14 8451 80 Cooling System Gearbox Outlet. . . . . . . . . . 16 8452 80 Cooling System Crankcase Circuit. . . . . . . . 18 8453 80 Cooling System Piston Circuit . . . . . . . . . . . 20

8132 80 WETEND . . . . . . . . . . . . . . . . . . . . . . . . . . 22 8144 50 Piston Cartridge . . . . . . . . . . . . . . . . . . . . . . 24 8161 80 Valve Cartridge . . . . . . . . . . . . . . . . . . . . . . 26

7040 80 HOMOGENIZING HEAD . . . . . . . . . . . . . . 28 8763 80 Flange Manometer . . . . . . . . . . . . . . . . . . . . 30

7563 80 HYDRAULIC UNIT . . . . . . . . . . . . . . . . . . . 32 5471 81 Hydraulic Unit. . . . . . . . . . . . . . . . . . . . . . . . 34

7963 80 FRAME WITH BODY . . . . . . . . . . . . . . . . . 36 7966 80 Frame Complete . . . . . . . . . . . . . . . . . . . . . 38 7964 80 M-Type Body . . . . . . . . . . . . . . . . . . . . . . . . 402 8360 80 Cladding Middle Complete . . . . . . . . . . . . . . . . 422 8361 80 Cladding Front Complete . . . . . . . . . . . . . . . . . 442 8362 80 Cladding Rear Complete . . . . . . . . . . . . . . . . . 462 8363 80 Lid Complete . . . . . . . . . . . . . . . . . . . . . . . . . . 48

6580 80 DRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . 50

6-4722 6575 80

6-4722 6660 806-4722 6681 806-4722 8025 82

6-4722 6676 80

751600_1_AA 7-4Assembly drawingT
TA20 - 5856819007 Crankcase
Machine No.etra Pak



6-4722 7516 80 7-5

h UN Qty Description Page NoPos Part No

Group number: 6

1 6-4722 1925 312105-036 6-4722 6948 6-4722 9449 6-4018 0056 312105-057 315105-058 312601-063 6-4722 5578 6-4722 6779 6-4722 8080 6-4722 5281 6-4722 74150 6-4722 81


TA20 - 5856819007 Crankcase Tetra Pak

ng: 751600_1_AA

Pos Part No SPSP h UN Qty Description Page No

-4722 7516 80

82 80 PC 1 CRANKCASE COMPLETE ALEX 20495 PC 9 Screw M6S ISO 4017 M10x30 A48043 01 PC 1 NIPPLE PIPE 3/4”69 01 M 1 Hose 25 x 4.540 12 PC 1 HOSE CLIP 26-38 /12633 PC 4 Screw M6S ISO 4014 M16x65 A480186 PC 4 Washer BRB 17X30 RFR324 PC 4 Hexagon Nut, DIN 934 M16 8 FZB38 02 PC 3 Hose clamp 64-7590 01 PC 3 Bellow ring front TA2082 01 PC 3 Piston connection ring ALEX 2051 01 PC 9 Screw MLC6S 6 x 16 FZB 8.8 DIN 798445 01 ML 25 Flange sealing55 80 PC 1 OIL SYSTEM ALEX 20

198280_1_AA 7-6Assembly drawingT
TA20 - 5856819007 Crankcase
Machine No.etra Pak



6-4722 1982 80 7-7


Group number: 6

1 6-4722 092 6-4722 204 6-4722 095 6-4722 096 6-4722 097 6-4722 098 6-4722 0911 6-4722 6713 6-4931 8014 6-4722 0915 6-4722 0916 6-4722 5117 90030-018 90459-019 312105-020 312101-022 312101-023 6-4300 0024 312105-026 315401-030 6-4301 5031 6-4722 5132 315202-033 6-4302 0434 6-4302 0435 6-4302 0040 6-4016 0341 6-4016 0342 6-4241 2243 6-4241 0044 6-4305 0051 6-4648 0054 312104-0

PC 3 Plain bearing ALEX 20PC 6 Hexagon Nut, Ny-Lock M12 fzbPC 3 Screw MLC6S 6 x 16 FZB 8.8 DIN 7984PC 1 Spacer tubePC 1 Screw M6S M8x45H FZB


TA20 - 5856819007 Crankcase Tetra Pak

55 312601-0320 PC 4 Hexagon Nut, M10 8 FZB, ISO 403259 342718-0107 PC 2 Support sleeve VH10MSX60 315105-0165 PC 14 Washer BRB 8,4x16 RFR61 6-4722 8055 01 PC 1 Frame62 6-4722 1987 01 PC 3 Bellows TA2064 6-4722 5538 04 PC 3 Hose clamp 109-12067 6-4722 2455 02 PC 3 Plate82 6-4722 1991 80 PC 3 Connecting rod complete ALEX 2083 6-4722 2021 02 PC 3 Cross head ALEX 2084 6-4722 2453 03 PC 3 Cross head bolt TA20

ng: 198280_1_AA


-4722 1982 80

68 02 PC 1 CRANK HOUSING TA2000 02 PC 1 Crank shaft SHL 2035 01 PC 1 LEVEL WINDOW TA20/2570 02 PC 1 Bearing cover TA2071 01 PC 1 Washer Bearing SHL 2072 02 PC 1 Bearing flange TA2073 01 PC 1 Spacer ring SHL 20 (SZO 140)92 01 PC 3 Bellow ring rear TA2090 09 PC 1 Filler cap 1.5”78 80 PC 1 OIL SCRAPER ALEX 2075 01 PC 1 Oil cooler TA20/2574 01 PC 3 Screw

030 PC 2 Conn. Bulkhead SV12L71276 PC 3 Screw Hex.Sock.Set Conept.MS6SS M6x25 A2455 PC 14 Screw M6S ISO 4017 M8x30 A480538 PC 6 Screw M6S M12x35 fzb534 PC 3 Screw M6S M12x25 fzb18 04 PC 2 Sealing ring 18 x 22 DIN 7603543 PC 6 Screw M6S ISO 4014 M12x55 A480178 PC 6 Washer FBH12,2FZB00 11 PC 1 Housing gasket TA20/2581 01 PC 3 Seal 21 x 26 x 1.5237 PC 3 O-ring 99,1x5,7 mm90 72 PC 1 O-ring 172 x 490 40 PC 1 O-ring 242 x 475 05 PC 1 O-ring 75 x 402 15 PC 1 Circlip 215x5 DIN 47201 80 PC 1 Circlip 180 x 4 DIN 47200 02 PC 1 Roller bearing right ALEX 20 NUP22010 57 PC 1 Roller bearing left ALEX 20 NU22412 50 PC 1 SEALING BOX 125 x 150 x 12 DIN 376000 05 PC 3 Plug 10.7506 PC 2 Screw M6S M10x75H FZB

85 6-4722 2161 0186 312810-032287 6-4722 5251 01142 6-4722 7129 01143 312104-0460

6-4722199100_1_AC 7-8Assembly drawingT
TA20 - 5856819007 Connecting Rod
Machine No.etra Pak



6-4722 1991 80 7-9


Group number: 6

1 6-4722 203 6-4722 194 6-4722 205 312810-06 6-4002 64


TA20 - 5856819007 Connecting Rod Tetra Pak

ng: 6-4722199100_1_AC


-4722 1991 80

04 02 PC 3 Connecting rod ALEX 2095 01 PC 3 Bearing bushing ALEX 2008 01 PC 6 Connecting rod bolt322 PC 6 Hexagon Nut, Ny-Lock M12 fzb00 06 PC 3 Stop screw M6x10 DIN 551

6-4722815500_1_AB 7-10Assembly drawingT
TA20 - 5856819007 Oil System
Machine No.etra Pak



6-4722 8155 80 7-11


Group number: 6

49 6-4018 0050 6-4722 5698 6-4722 69105 6-4722 69118 6-4722 69119 6-4722 69120 6-4722 69133 6-4722 94138 6-1995 10


TA20 - 5856819007 Oil System Tetra Pak

ng: 6-4722815500_1_AB


-4722 8155 80

40 12 PC 3 HOSE CLIP 26-38 /1275 01 PC 1 BALL VALVE45 01 PC 1 PLUG RSK 2451 OUT 1/2”28 01 PC 1 Thermometer43 01 PC 2 NIPPLE PIPE 3/4”35 01 PC 2 CLAW CONNECTION OUT 3/4”44 01 PC 1 PLUG RSK 2451 OUT 3/4”69 01 M 16 Hose 25 x 4.56 510 PC 2 Stripes black TY 5232MX 200X2,4mm

6-472269770_1_AD 7-12Assembly drawingT
TA20 - 5856819007 Cooling Circuit
Machine No.etra Pak



6-4722 6977 80 7-13


Group number: 6

1 6-4722 842 6-4722 843 6-4722 844 6-4722 84


TA20 - 5856819007 Cooling Circuit Tetra Pak

ng: 6-472269770_1_AD


-4722 6977 80

50 80 PC 1 COOLING SYSTEM WATER INLET ALEX 2051 80 PC 1 Cooling system Gear box outlet ALEX 2052 80 PC 1 COOLING SYSTEM CRANKCASE CIRCUIT ALEX 2053 80 PC 1 COOLING SYSTEM PISTON CIRCUIT ALEX 20

TA20 - 5856819007 Cooling System Water Inlet
Machine No.etra Pak



6-4722 8450 80 7-15


Group number: 6

6 6-4722 607 6-4722 6013 90030-017 90030-026 6-4722 6027 6-4722 5228 6-4722 5129 342991-033 312115-035 312115-053 6-4722 8454 6-4722 8455 6-4722 8458 6-4722 8463 6-4722 84120 6-4350 84Y810 6-4722 73


TA20 - 5856819007 Cooling System Water Inlet Tetra Pak

ng: 6-4722845000_1_AC


-4722 8450 80

93 01 PC 1 Trim valve R 3/8”94 01 PC 2 Screw connection 12 R10

058 PC 1 Conn. T-Pipe T-12106 PC 1 Conn. Pipe G-1295 01 PC 2 Spacer 12 x 8.2 x 1513 01 PC 2 PIPE HOLDER RAP112X86 01 PC 1 Hose 10 x 16101 PC 2 Hose Clip,Worm Drive Type (13)-16372 PC 2 Screw ISO4762 M6x25 A4 80376 PC 2 Screw ISO4762 M6x35 A4 8026 15 PC 1 Cooling pipe ø1226 13 PC 1 Cooling pipe ø1226 16 PC 1 Cooling pipe ø1226 08 PC 1 Cooling pipe ø1226 13 PC 1 Cooling pipe ø1200 78 PC 2 Straight connection GE 12 L/R3/8”12 03 PC 1 Water valve 3/8” 24V DC

TA20 - 5856819007 Cooling System Gearbox Outlet
Machine No.etra Pak



6-4722 8451 80 7-17


Group number: 6

29 342991-051 6-4722 51


TA20 - 5856819007 Cooling System Gearbox Outlet Tetra Pak

ng: 6-4722845100_1_AB


-4722 8451 80

101 PC 2 Hose Clip,Worm Drive Type (13)-1686 01 PC 1 Hose 10 x 16

6-6-4722845200_1_AB 7-18Assembly drawingT
TA20 - 5856819007 Cooling System Crankcase Circuit
Machine No.etra Pak



6-4722 8452 80 7-19


Group number: 6

6 6-4722 607 6-4722 6017 90030-026 6-4722 6027 6-4722 5233 312115-035 312115-037 312115-043 6-4722 6359 6-4722 8475 6-4722 8477 6-4722 84


TA20 - 5856819007 Cooling System Crankcase CircuitTetra Pak

ng: 6-6-4722845200_1_AB


-4722 8452 80

93 01 PC 1 Trim valve R 3/8”94 01 PC 2 Screw connection 12 R10

106 PC 2 Conn. Pipe G-1295 01 PC 4 Spacer 12 x 8.2 x 1513 01 PC 5 PIPE HOLDER RAP112X372 PC 2 Screw ISO4762 M6x25 A4 80376 PC 4 Screw ISO4762 M6x35 A4 80382 PC 2 Screw ISO4762 M6x60 A4 8010 01 PC 2 JOINT NUT M6 x 1426 14 PC 1 Cooling pipe ø1226 25 PC 1 Cooling pipe ø1226 27 PC 1 Cooling pipe ø12

TA20 - 5856819007 Cooling System Piston Circuit
Machine No.etra Pak



6-4722 8453 80 7-21


Group number: 6

14 6-4350 8417 90030-024 90030-026 6-4722 6027 6-4722 5233 312115-035 312115-052 6-4722 8457 6-4722 8460 6-4722 8461 6-4722 8462 6-4722 84


TA20 - 5856819007 Cooling System Piston Circuit Tetra Pak

ng: 6-4722845300_1_AB


-4722 8453 80

00 78 PC 6 Straight connection GE 12 L/R3/8”106 PC 2 Conn. Pipe G-12096 PC 2 Conn. Elbow W12L7195 01 PC 2 Spacer 12 x 8.2 x 1513 01 PC 2 PIPE HOLDER RAP112X372 PC 2 Screw ISO4762 M6x25 A4 80376 PC 2 Screw ISO4762 M6x35 A4 8026 02 PC 1 Cooling pipe ø1226 07 PC 1 Cooling pipe ø1226 10 PC 1 Cooling pipe ø1226 11 PC 2 Cooling pipe ø1226 12 PC 2 Cooling pipe ø12

TA20 - 5856819007 Wetend
Machine No.etra Pak



6-4722 8132 80 7-23


Group number: 6

20 6-4722 8121 6-4722 6828 6-4722 8129 6-4722 2932 6-4722 7433 6-4010 6234 6-4722 6835 6-4015 0088 6-4722 50


TA20 - 5856819007 Wetend Tetra Pak

ng: 6-4722813200_1_AB


-4722 8132 80

44 50 PC 3 Piston cartridge ALEX 20 ø50 BASIC44 01 PC 1 PUMP BLOCK ø65 US-3A61 80 PC 3 VALVE CARTRIDGE ø65 MUSHROOM11 01 PC 3 Valve cover Mushroom valve46 01 PC 12 Screw M6S 20 x 55, A2-7040 02 PC 8 Cap nut M2452 38 PC 8 Stud bolt M24 x 16825 05 PC 8 Washer BRB 25 DIN12584 02 PC 2 Guide pin CP m6 20 x 80 SMS 2374

6-4722814450_1_AD 7-24Assembly drawingT

314671

TA20 - 5856819007 Piston CartridgeMachine No.etra Pak



6-4722 8144 50 7-25


Group number: 6

1 6-4722 692 6-4722 613 6-4722 614 6-4722 685 311103-06 6-4722 587 312105-09 6-4722 6810 6-4722 0311 6-4722 9012 6-4722 9013 6-4722 2214 6-4722 1415 6-4722 1516 6-4722 9017 6-4722 9018 6-4722 9056 6-4722 1157 6-4722 11


TA20 - 5856819007 Piston Cartridge Tetra Pak

ng: 6-4722814450_1_AD


-4722 8144 50

12 02 PC 3 Cylinder bushing 50 US-3A29 02 PC 3 Piston bushing 50 US-3A22 13 PC 3 Cover ø5097 01 PC 3 Pressure nut 50306 PC 3 Parallel pin ISO 2338 5m6x12 A143 02 PC 3 Spring 7.0 x 65 x 80 x 6 US-3A287 PC 12 Screw M6S ISO 4017 M4x8 A47007 01 PC 3 Piston 50-CR86 12 PC 3 Support ring 50 Basic26 08 PC 3 Piston seal 50 PSB226 08 PC 3 Piston seal 50 PSB264 12 PC 3 Compression ring 5018 10 PC 6 Guide band 50x9.552 49 PC 3 Spacer ring 50 US-3A42 49 PC 3 O-ring 75 x 5 EPDM 80 E850242 41 PC 3 O-ring 62 x 4 EPDM 80 E850242 49 PC 3 O-ring 75 x 5 EPDM 80 E850278 17 PC 3 Support ring 8578 23 PC 3 Support ring 74

TA20 - 5856819007 Valve Cartridge
Machine No.etra Pak



6-4722 8161 80 7-27


Group number: 6

23 6-4722 6624 6-4722 6625 6-4722 6626 6-4722 6627 6-4722 0958 6-4722 1159 6-4722 66


TA20 - 5856819007 Valve Cartridge Tetra Pak

ng: 6-4722816100_1_AB


-4722 8161 80

48 02 PC 6 Mushroom valve 6549 03 PC 6 Valve seat 6552 01 PC 6 Valve spring 6557 01 PC 6 Valve cage ø6542 02 PC 15 Valve sealing 55 x 65 x 878 18 PC 15 Support ring 6551 01 PC 3 Spacer 65

6-4722704000_2_AG 7-28Assembly drawingT
TA20 - 5856819007 Homogenizing Head
Machine No.etra Pak



6-4722 7040 80 7-29


Group number: 6

1 6-4722 702 6-4722 903 6-4722 704 6-4010 625 6-4722 686 6-4722 657 6-31353 08 6-4306 009 6-4722 9010 312115-011 6-4722 5213 6-4722 9017 6-4722 9018 6-4722 7019 6-4722 6821 6-4722 9022 6-4722 9024 6-4722 7126 6-4722 1427 6-4722 9028 6-4722 7129 6-4722 7130 6-4722 7032 90087-033 6-4722 9034 6-4722 7035 6-4722 7040 6-4722 8743 6-4722 9094 6-4722 93


TA20 - 5856819007 Homogenizing Head Tetra Pak

ng: 6-4722704000_2_AG


-4722 7040 80

41 01 PC 2 Hydraulic cylinder 7519 01 PC 2 Forcer shaft42 01 PC 2 Hydraulic piston 7540 09 PC 8 Cap nut M1652 43 PC 4 Stud bolt M16 x 29662 47 PC 2 O-ring 62.87 x 5.33362 1 PC 2 Screw ARC/SMO/SRC00 05 PC 4 Guide band 7542 35 PC 2 O-ring 16.3x2.4 EPDM 80 E8502364 PC 2 Screw ISO4762 M6x10 A4 8033 01 PC 2 Sealing ring 6 x 1042 08 PC 2 O-ring 40.87x3.53 EPDM 80 E850218 01 PC 1 Forcer disc 53/6344 01 PC 1 Seat 53/6252 44 PC 4 Stud bolt M16 x 22042 03 PC 2 O-ring 24.99x3.53 EPDM 80 E850242 15 PC 5 O-ring 69.44x3.53 EPDM 80 E850251 03 PC 2 Support ring axial 3.53 x 32.218 16 PC 4 Guide band 32x5.542 05 PC 2 O-ring 31.34x3.53 EPDM 80 E850252 03 PC 3 Support ring radial 3.53 x 79.853 03 PC 2 Support ring axial 5.33 x 7545 01 PC 1 Housing

015 PC 2 Plug, Ext. Thread Hex. Socket VSTI 1/4-E18 01 PC 1 Forcer disc 53/6344 01 PC 1 Seat 53/6245 01 PC 1 Housing63 80 PC 1 Pressure gauge flange42 08 PC 1 O-ring 40.87x3.53 EPDM 80 E850222 02 PC 1 Intermediate flange 86

6-4722876300_1_AA 7-30Assembly drawingT
TA20 - 5856819007 Flange Manometer
Machine No.etra Pak



6-4722 8763 80 7-31


Group number: 6

40 6-4722 8742 312105-049 6-4722 6352 6-4722 9053 6-4722 87


TA20 - 5856819007 Flange Manometer Tetra Pak

ng: 6-4722876300_1_AA


-4722 8763 80

52 01 PC 1 Pressure gauge flange631 PC 2 Screw M6S ISO 4014 M16x55 A48096 01 PC 1 Pressure gauge42 52 PC 1 O-ring 23.39x3.53 EPDM E850253 01 PC 1 Back-up Ring

6-4722756300_1_AE 7-32Assembly drawingT
TA20 - 5856819007 Hydraulic Unit
Machine No.etra Pak



6-4722 7563 80 7-33


Group number: 6

1 6-4722 542 6-4722 525 6-4722 927 6-4722 9215 6-4932 2018 6-4932 2019 6-4722 6523 342741-025 342741-026 342731-027 342731-028 342731-029 6-4350 8430 342731-032 342747-034 6-4350 8336 342741-037 90087-040 6-4722 6444 6-4722 6747 6-4722 6748 6-4722 6749 6-4722 6750 6-4722 6755 6-4722 8359 312115-061 312115-065 90458-067 312115-070 312105-078 315105-085 6-4722 55122 312812-0


TA20 - 5856819007 Hydraulic Unit Tetra Pak

ng: 6-4722756300_1_AE


-4722 7563 80

71 81 PC 1 Hydraulic unit Bosch65 01 PC 1 Motor 220/380V/50Hz 0,25kW47 01 PC 2 Pressure adjusting valve45 01 PC 2 Pressure relief valve 24V DC NO02 25 PC 1 Hydraulic pressure gauge 250bar02 26 PC 1 Hydraulic pressure gauge 60bar15 01 PC 8 O-ring 9,25x1,78 NBR103 PC 2 Conn. T-Pipe TA-8-R1/4103 PC 1 Conn. T-Pipe TA-8-R1/4103 PC 1 Conn. Elbow WE 8LRCF103 PC 1 Conn. Elbow WE 8LRCF103 PC 1 Conn. Elbow WE 8LRCF05 07 PC 2 CONNECTION LR/G 1/4”103 PC 1 Conn. Elbow WE 8LRCF103 PC 1 Conn. T-Pipe T-802 00 PC 1 Pipe coupling GE 8 LR/A3C103 PC 1 Conn. T-Pipe TA-8-R1/4

015 PC 2 Plug, Ext. Thread Hex. Socket VSTI 1/4-E87 03 PC 2 HYDRAULIC PIPE 8x1.546 11 PC 1 Hydraulic hose 110046 09 PC 1 Hydraulic hose 90046 13 PC 1 Hydraulic hose 130046 13 PC 1 Hydraulic hose 130046 13 PC 1 Hydraulic hose 130069 01 PC 1 PANEL PLATE ALEX 20366 PC 4 Screw ISO4762 M6x12 A4 80335 PC 8 Screw ISO4762 M5x30 A4 80072 PC 8 Screw ISO 7380 S M6x12 A2459 PC 1 Screw ISO4762 M8x40 A4 80451 PC 4 Screw M6S ISO 4017 M8x20 A480165 PC 4 Washer BRB 8,4x16 RFR39 01 PC 2 HOSE BRACKET318 PC 1 Hexagon Nut, Ny-Lock M8 A480

6-4722547100_1_AE 7-34Assembly drawingT
TA20 - 5856819007 Hydraulic Unit
Machine No.etra Pak



6-4722 5471 81 7-35


Group number: 6

5 6-4722 658 6-4722 659 6-4722 7510 6-4722 7511 6-4722 7524 90287-032 6-4722 7533 6-4722 7534 312318-035 6-4722 7536 90087-038 90087-039 312605-040 315701-041 6-4722 75


TA20 - 5856819007 Hydraulic Unit Tetra Pak

ng: 6-4722547100_1_AE


-4722 5471 81

42 01 PC 2 VALVE PRESSURE LIMIT41 02 PC 1 Pump two stages Bosch53 01 PC 1 Sight glass54 01 PC 1 Filter52 01 PC 2 Filter

049 PC 8 Screw MLC6S 5x12 10.950 01 PC 1 Shaft coupling51 01 PC 1 Rubber cross289 PC 1 Screw ISO4029 M4x10 A455 01 PC 1 Key 2 x 2 6 DIN 6888

015 PC 1 Plug, Ext. Thread Hex. Socket VSTI 1/4-E024 PC 1 Plug, Ext. Thread Hex. Socket VSTI 1/2-E316 PC 1 Hexagon Nut, M6M M6 A280203 PC 1 Parallel key w. round ends 5x5x25 mm49 01 PC 1 Gasket

6-47227963001 7-36Assembly drawingT
TA20 - 5856819007 Frame with Body
Machine No.etra Pak



6-4722 7963 80 7-37


Group number: 6

1 6-4722 792 6-4722 794 6-4722 855 6-4722 856 6-4722 858 6-1 64813


TA20 - 5856819007 Frame with Body Tetra Pak

ng: 6-47227963001


-4722 7963 80

66 80 PC 1 FRAME ALEX 20 COMPLETE64 80 PC 1 M-TYPE BODY ALEX 2005 01 PC 1 STRIPE BLUE B=70 MM, L=8.5 M03 01 PC 1 STRIPE “ Tetra Pak” WHITE H=4204 01 PC 1 STRIPE “ Tetra Alex” WHITE H=423 02 PC 4 Base plate (support leg)

TA20 - 5856819007 Frame Complete
Machine No.etra Pak



6-4722 7966 80 7-39


Group number: 6

1 6-4722 792 90458-23 6-31801 24 6-4722 795 6-4722 796 6-4722 877 6-4722 638 312605-09 312605-010 312105-030 6-4722 7931 6-4000 0032 315105-0


TA20 - 5856819007 Frame Complete Tetra Pak

ng: 6-4722796600


-4722 7966 80

68 01 PC 1 WELDED FRAME744 PC 4 Plug, VL 100X40X4329 1 PC 4 Plastic plug75 01 PC 1 Plate74 01 PC 1 Plate98 01 PC 4 Spindle85 01 PC 4 BARRIER NUT316 PC 4 Hexagon Nut, M6M M6 A280318 PC 8 Hexagon Nut, M6M M8 A280449 PC 2 Screw M6S ISO 4017 M8x16 A48070 01 PC 1 Belt shield06 01 PC 4 Screw M6S-h 6 x 10 DIN 933153 PC 4 Washer BRB 6,4X12 RFR

TA20 - 5856819007 M-Type Body
Machine No.etra Pak



6-4722 7964 80 7-41


Group number: 6

10 6-4722 8315 6-4722 8320 6-4722 8325 6-4722 83


TA20 - 5856819007 M-Type Body Tetra Pak

ng: 6-4722796400


-4722 7964 80

60 80 PC 1 CLADDING MIDDLE COMPLETE ALEX 2061 80 PC 1 CLADDING FRONT COMPLETE ALEX 2062 80 PC 1 CLADDING REAR COMPLETE ALEX 2063 80 PC 2 Lid complete ALEX 20

TA20 - 5856819007 Cladding Middle Complete
Machine No.etra Pak



6-4722 8360 80 7-43


Group number: 6

10 6-4722 8315 6-4722 8320 6-4722 8325 6-4722 8335 6-4722 9340 6-4722 22300 6-31801 2500 6-990471505 312311-0510 312105-0600 312812-0605 312715-0610 315105-0


TA20 - 5856819007 Cladding Middle Complete Tetra Pak

ng: 6-4722836000_1_AB


-4722 8360 80

64 01 PC 1 UPPER FRAME65 01 PC 1 Plate66 01 PC 1 Plate72 01 PC 2 BRACKET57 01 PC 1 Brace03 02 PC 5 RUBBER DAMPER 30 x 30 x M8329 1 PC 4 Plastic plug

29 PC 14 Screw K6S M6x10H A2-70455 PC 4 Screw ISO4028 M8x30 FZB447 PC 1 Screw M6S ISO 4017 M8x12 A480316 PC 10 Hexagon Nut, Ny-Lock M6 A480116 PC 4 Wing nut DIN 315 A2 MVM-K M6165 PC 1 Washer BRB 8,4x16 RFR

TA20 - 5856819007 Cladding Front Complete
Machine No.etra Pak



6-4722 8361 80 7-45


Group number: 6

10 6-4722 8315 6-4722 8320 6-4722 8325 6-4722 8330 6-4722 22500 6-990471505 312311-0510 90459-0600 312812-0605 312605-0


TA20 - 5856819007 Cladding Front Complete Tetra Pak

ng: 6-4722836100


-4722 8361 80

70 01 PC 1 UPPER FRAME67 01 PC 1 Plate72 01 PC 1 BRACKET71 01 PC 2 BRACKET03 02 PC 2 RUBBER DAMPER 30 x 30 x M8

29 PC 7 Screw K6S M6x10H A2-70455 PC 2 Screw ISO4028 M8x30 FZB325 PC 10 Blank Rivet 4,8x14316 PC 7 Hexagon Nut, Ny-Lock M6 A480318 PC 2 Hexagon Nut, M6M M8 A280

TA20 - 5856819007 Cladding Rear Complete
Machine No.etra Pak



6-4722 8362 80 7-47


Group number: 6

10 6-4722 8315 6-4722 8320 6-4722 8325 6-4722 8330 6-4722 22500 6-990471505 312311-0510 90459-0600 312812-0605 312605-0


TA20 - 5856819007 Cladding Rear Complete Tetra Pak

ng: 6-4722836200


-4722 8362 80

70 01 PC 1 UPPER FRAME68 01 PC 1 Plate72 01 PC 1 BRACKET71 01 PC 2 BRACKET03 02 PC 2 RUBBER DAMPER 30 x 30 x M8

29 PC 7 Screw K6S M6x10H A2-70455 PC 2 Screw ISO4028 M8x30 FZB325 PC 10 Blank Rivet 4,8x14316 PC 7 Hexagon Nut, Ny-Lock M6 A480318 PC 2 Hexagon Nut, M6M M8 A280

TA20 - 5856819007 Lid Complete
Machine No.etra Pak



6-4722 8363 80 7-49


Group number: 6

10 6-4722 8315 6-4722 7520 6-4722 8325 6-4722 82300 6-4722 75505 6-990471510 6-990471515 312105-0520 6-4722 52600 312605-0605 312812-0610 315105-0615 315105-0


TA20 - 5856819007 Lid Complete Tetra Pak

ng: 6-4722836300_1_AB


-4722 8363 80

74 01 PC 2 Lid08 01 PC 2 HANDLE73 01 PC 2 BRACKET50 01 PC 4 HINGE74 02 PC 2 Gas spring G19 - 150 - 400N

30 PC 4 Screw K6S M8x10H A2-70 31 PC 2 Screw K6S M6x20H A2-70463 PC 4 Screw M6S ISO 4014 M8x60 A48008 01 PC 4 Screw MC6S 5 x 10318 PC 10 Hexagon Nut, M6M M8 A280316 PC 8 Hexagon Nut, Ny-Lock M6 A480153 PC 2 Washer BRB 6,4X12 RFR165 PC 2 Washer BRB 8,4x16 RFR

TA20 - 5856819007 Drive Unit
Machine No.etra Pak



6-4722 6580 80 7-51


Group number: 6

1 6-4722 812 6-4722 8118 312601-019 315105-020 312105-026 6-4015 0527 315402-0


TA20 - 5856819007 Drive Unit Tetra Pak

ng: 6-4722658000_1_AB


-4722 6580 80

63 80 PC 1 DRIVE UNIT ALEX 2066 80 PC 1 DRIVE UNIT324 PC 4 Hexagon Nut, DIN 934 M16 8 FZB186 PC 4 Washer BRB 17X30 RFR633 PC 4 Screw M6S ISO 4014 M16x65 A48071 02 PC 4 Washer RBS 17 DIN 9021186 PC 4 Lock washer FBB 16,2

TA20 - 5856819007 Drive Unit
Machine No.etra Pak



6-4722 8163 80 7-53


Group number: 6

1 6-4722 642 6-4722 653 6-4722 104 311103-05 312101-06 6-4722 647 6-4722 548 6-4722 5411 315111-012 6-4016 0013 6-4722 5616 6-4722 5617 6-4722 6421 6-4722 6122 6-4722 6123 6-4722 6124 315751-025 315751-031 312115-032 315105-035 6-4722 6536 6-4722 6537 6-4722 6538 6-4722 6539 6-4722 6540 6-4722 6541 6-4722 6542 342701-043 6-4722 5144 342991-0



ng: 6-4722816300


-4722 8163 80

57 02 PC 1 Gear box BT51 TA20 SS73 01 PC 1 Wedge 20 x 12 x 16289 01 PC 1 Washer SHL 20353 PC 1 Parallel pin ISO 2338 6m6x20 A1672 PC 1 Screw M6S M20x40 fzb61 01 PC 1 TORQUE ARM TA2015 01 PC 1 Adjusting bolt TA2557 01 PC 1 Sleeve 30 x 60 x 55205 PC 1 Washer TBRB33x58FZB11 30 PC 1 Washer 21 DIN 43218 01 PC 2 NUT M6M 3021 01 PC 1 NUT ML6M 3064 01 PC 1 Spacer sleeve Benzler BT5134 01 PC 1 Spacer32 01 PC 2 Bushing31 01 PC 1 Joint119 PC 2 Retaining ring for Shaft DIN 471 25 SS122 PC 1 Retaining ring for Shaft DIN 471 30 SS366 PC 2 Screw ISO4762 M6x12 A4 80153 PC 2 Washer BRB 6,4X12 RFR74 01 PC 1 CANTILEVER91 01 PC 1 LEVEL TUBE WN 398 B 3/8” -13092 01 PC 1 BARRIER NUT 3/8”93 01 PC 1 HOSE CLAMP 3/8”94 01 PC 2 Washer 14 x 20 x 1.595 01 PC 1 Nipple 90 1/4”96 01 PC 1 BANJO SCREW 1/4”205 PC 1 Bushing,INT./EXT.G-THREAD G1/2”-G1/4”86 01 PC 1 Hose 10 x 16101 PC 2 Hose Clip,Worm Drive Type (13)-16

TA20 - 5856819007 Drive Unit
Machine No.etra Pak



6-4722 8166 80 7-55


Group number: 6

1 6-4722 592 6-4722 593 6-4722 594 6-4722 595 6-4722 596 6-4722 58



ng: 6-4722816600_1_AC


-4722 8166 80

96 23 PC 1 Motor M3AA200MLB 4H 30kW 380V/50Hz00 02 PC 1 Pulley 3 SPB 28065 09 PC 1 Bushing 3020 D5501 02 PC 1 Pulley 3 SPB 31565 03 PC 1 Bushing 3020 D3857 05 PC 3 V-Belt SPB 2000 MC

TA20 - 5856819007 Product Connections
Machine No.etra Pak



6-4722 6835 80 7-57


Group number: 6

30 6-4722 8140 6-4722 8162 312105-063 6-4722 9072 312105-0


TA20 - 5856819007 Product Connections Tetra Pak

ng: 6-4722683500


-4722 6835 80

22 80 PC 1 PRODUCT CONNECTIONS INLET ALEX 2023 80 PC 1 PRODUCT CONNECTIONS OUTLET ALEX 20622 PC 2 Screw M6S ISO 4017 M16x25 A48042 12 PC 1 O-ring 53.57x3.53 EPDM 80 E8502624 PC 4 Screw M6S ISO 4017 M16x30 A480

TA20 - 5856819007 Inlet
Machine No.etra Pak



6-4722 8122 80 7-59


Group number: 6

1 6-4722 682 6-2110 543 6-881 1714 6-4722 605 6-881 1716 6-2110 547 6-4722 608 6-2110 549 6-881 17110 6-9611 3425 6-4722 6527 312601-028 315105-0


TA20 - 5856819007 Inlet Tetra Pak

ng: 6-4722812200_1_AA


-4722 8122 80

16 01 PC 1 Inlet flange ø51PC 1 Clamp single hinge A13MHM-2-S

13 PC 1 Seal ring H-Line H40-X-2 Silicone85 01 PC 1 Damper basic Clamp ø5113 PC 1 Seal ring H-Line H40-X-2 Silicone

PC 1 Clamp single hinge A13MHM-2-S81 01 PC 1 Attachment pipe Clamp ø51

PC 1 Clamp single hinge A13MHM-2-S13 PC 1 Seal ring H-Line H40-X-2 Silicone 2051 PC 1 Ferrule 3A H-line-female 2” AISI316L25 04 PC 1 Support 100 D51x89320 PC 2 Hexagon Nut, M10 8 FZB, ISO 4032173 PC 2 Washer BRB 10,5X22 RFR

TA20 - 5856819007 Outlet
Machine No.etra Pak



6-4722 8123 80 7-61


Group number: 6

26 6-4722 6527 312601-028 315105-015 6-4722 7016 6-2110 5317 6-881 17118 6-4722 6019 6-881 17120 6-2110 5321 6-4722 6022 6-2110 5323 6-881 17124 6-9611 34


TA20 - 5856819007 Outlet Tetra Pak

ng: 6-4722812300_1_AA


-4722 8123 80

25 02 PC 1 Support 260 D38x254320 PC 2 Hexagon Nut, M10 8 FZB, ISO 4032173 PC 2 Washer BRB 10,5X22 RFR49 06 PC 1 Outlet flange Clamp 38 2-ST

PC 1 Clamp single hinge A13MHM-1 1/5-S12 PC 1 Seal ring H-Line H40-X-1 1/286 01 PC 1 Damper basic Clamp 3812 PC 1 Seal ring H-Line H40-X-1 1/2

PC 1 Clamp single hinge A13MHM-1 1/5-S84 01 PC 1 Attachment pipe Clamp 38

PC 1 Clamp single hinge A13MHM-1 1/5-S12 PC 1 Seal ring H-Line H40-X-1 1/2 2050 PC 1 Ferrule 3A H-line-female 1.5” AISI316L

TA20 - 5856819007 Electrical Parts
Machine No.etra Pak



6-4722 6671 80 7-63


Group number: 6

6-4722 756-4722 916-4722 896-4722 70

6-4722 751 6-4722 9340 6-4722 9341 6-4722 9350 6-4722 9360 90459-370 6-99047571 90135-072 315105-073 312105-0

6-4722 911 6-4722 692 6-4722 693 6-4722 934 6-4722 915 6-4722 546 6-4722 698 6-4722 559 6-4722 5410 6-4722 6911 6-99047512 90099-013 90135-014 90135-015 90165-016 90165-017 352103-018 312115-0

PC 1 Wiring 22/23, Press reliefPC 1 Wiring 22/23, Press relief

PC 1 Wiring 02, Motor - Hydraulic unitM 225 Spiral Conduit Di=16 mmPC 2 Gland fitting PR 18,6PC 1 Gland fittingPC 1 Gland, Lock nut M20x1,5M 27 Cable Olflex 4Gx1,5 mm2 light/grey

PC 1 Wiring 05, Start - StopM 29 Spiral Conduit Di=16 mmPC 1 Gland fitting PR 18,6PC 1 Gland fitting M20x1.5PC 1 Gland, Lock nut M20x1,5M 345 Cable Olflex 7x0,75 mm2 light/grey


TA20 - 5856819007 Electrical Parts Tetra Pak

19 312812-0316 PC 4 Hexagon Nut, Ny-Lock M6 A48020 312125-0287 PC 9 Screw ISO 1207 M4x8 A421 312125-0323 PC 5 Screw ISO 1207 M5x8 A422 312605-0318 PC 2 Hexagon Nut, M6M M8 A28023 315105-0146 PC 4 Washer BRB 5,3x10 RFR24 315105-0153 PC 4 Washer BRB 6,4X12 RFR25 90005-0114 PC 1 Washer Plain Round 5,3(M5)/15, H=126 6-990475 08 PC 4 Lock washer 5,3x10x0,6 A4W02 6-4722 8938 19 PC 1 Wiring 02, Motor - Hydraulic unitW05 6-4722 8941 29 PC 1 Wiring 05, Start - StopW18 6-4722 9198 16 PC 1 Wiring 18, Thermistor

ng: 6-4722919500


-4722 6671 80

92 80 PC 1 COMMON ELECTRIC PARTS95 80 PC 1 CONNECTION BOX TA 20, 25, 3067 80 PC 1 CABLING TA 20, 25, 3022 80 PC 1 CABLING

92 80 PC 1 COMMON ELECTRIC PARTS54 01 PC 1 MANOEUVRE BOX55 01 PC 1 Hour Meter 24V DC56 01 PC 1 Gauge Anti Slip Ring77 01 PC 1 Reducing sleeve M20/15,2 (Pg9)

352 PC 3 Flat pin socket, 6,3x0,8 10 PC 4 Lock washer 8,2x14x0,8035 PC 1 Earth wire, L=250 mm 16 mm2165 PC 2 Washer BRB 8,4x16 RFR449 PC 1 Screw M6S ISO 4017 M8x16 A480

95 80 PC 1 CONNECTION BOX TA 20, 25, 3049 01 PC 1 CONNECTION BOX 280 x 38050 01 PC 1 Sheet71 01 PC 1 TERMINAL BLOCK POWER56 01 PC 1 TERMINAL BLOCK/SIGNAL29 01 PC 1 Flange 9x19+5x15,5/22,582 01 PC 1 FLANGE 4 x Pg11/21 + 7 x Pg1628 01 PC 2 Lock screws30 01 PC 2 Gasket42 01 PC 1 GROUNDING SCREW

10 PC 6 Lock washer 8,2x14x0,8003 PC 1 Nut Pr 22,5035 PC 1 Earth wire, L=250 mm 16 mm2040 PC 1 Earth wire, L=150 mm 16 mm2056 PC 2 Pipe Clip for Tube d=4 mm058 PC 7 Pipe Clip for Tube d=2,5 mm110 PC 1 Cable gland, STR 16, PR22,5/PG16368 PC 4 Screw ISO4762 M6x16 A4 80

W22 6-4722 8953 21W23 6-4722 8953 21

W02 6-4722 8938 191 352135-01062 352136-01273 352137-01304 353250-00205 351150-0413

W05 6-4722 8941 291 352135-01062 352136-01273 352136-01304 353250-00206 351150-0406

TA20 - 5856819007 Labels
Machine No.etra Pak

��



6-4722 6675 80 7-65


Group number: 6

9 6-4722 5610 6-4722 5615 359705-0


TA20 - 5856819007 Labels Tetra Pak

ng:


-4722 6675 80

86 01 PC 1 SIGN CLEANING OF PIPE SYSTEM ENG/GER96 01 PC 1 SIGN CHECK WATER IN OIL ENG/GER002 PC 2 Warning Sign ISO, Entanglement

TA20 - 5856819007 Commissioning Kit
Machine No.etra Pak




6-4722 6660 80 7-67


Group number: 6

6-4722 666-4722 666-4722 75 90458-0 90458-06-4722 636-4722 566-4722 566-4722 56

6-4722 666-4722 666-4722 816-4722 816-4722 706-4722 876-4722 68

6-4722 8111 6-4722 9012 6-4722 9014 6-4722 1416 6-4722 9018 6-4722 9056 6-4722 11

6-4722 8127 6-4722 0958 6-4722 11

6-4722 706 6-4722 659 6-4722 90

PC 1 COMM. KIT FLANGE MANOMETERPC 1 O-ring 23.39x3.53 EPDM E8502PC 1 Back-up Ring

PC 1 COMM. KIT PRODUCT CONNECTIONS ALEX 20PC 1 O-ring 53.57x3.53 EPDM 80 E8502


TA20 - 5856819007 Commissioning Kit Tetra Pak

13 6-4722 9042 08 PC 2 O-ring 40.87x3.53 EPDM 80 E850221 6-4722 9042 03 PC 2 O-ring 24.99x3.53 EPDM 80 E850222 6-4722 9042 15 PC 5 O-ring 69.44x3.53 EPDM 80 E850224 6-4722 7151 03 PC 2 Support ring axial 3.53 x 32.227 6-4722 9042 05 PC 2 O-ring 31.34x3.53 EPDM 80 E850228 6-4722 7152 03 PC 3 Support ring radial 3.53 x 79.843 6-4722 9042 08 PC 1 O-ring 40.87x3.53 EPDM 80 E8502

ng:


-4722 6660 80

60 80 PC 1 COMMISSIONING KIT63 80 PC 1 COMMISSIONING KIT ALEX 2069 01 L 20 Oil mineral 220 cSt

863 L 3 Oil mineral 320 cSt861 L 6 MOBIL DTE 26, 68 cSt32 01 PC 3 ATTACHMENT PIPE WATER/STEAM42 01 PC 3 Shim 0.142 02 PC 3 Shim 0.242 03 PC 3 Shim 0.3

63 80 PC 1 COMMISSIONING KIT ALEX 2081 80 PC 1 TOOLS ALEX 2044 91 PC 3 COMM. KIT PISTON CARTRIDGE ALEX 20 BASIC61 91 PC 3 COMM. KIT VALVE CARTRIDGE ø65 MUSHROOM40 89 PC 1 COMM. KIT HOMOGENISING HEAD63 91 PC 1 COMM. KIT FLANGE MANOMETER35 91 PC 1 COMM. KIT PRODUCT CONNECTIONS ALEX 20

44 91 PC 3 COMM. KIT PISTON CARTRIDGE ALEX 20 BASIC26 08 PC 3 Piston seal 50 PSB226 08 PC 3 Piston seal 50 PSB218 10 PC 6 Guide band 50x9.542 49 PC 3 O-ring 75 x 5 EPDM 80 E850242 49 PC 3 O-ring 75 x 5 EPDM 80 E850278 17 PC 3 Support ring 85

61 91 PC 3 COMM. KIT VALVE CARTRIDGE Ø65 MUSHROOM42 02 PC 15 Valve sealing 55 x 65 x 878 18 PC 15 Support ring 65

40 89 PC 1 COMM. KIT HOMOGENISING HEAD62 47 PC 2 O-ring 62.87 x 5.3342 35 PC 2 O-ring 16.3x2.4 EPDM 80 E8502

6-4722 8763 9152 6-4722 9042 5253 6-4722 8753 01

6-4722 6835 9163 6-4722 9042 12

TA20 - 5856819007 Tools
Machine No.etra Pak



6-4722 6681 80 7-69


Group number: 6

1 6-4722 8014 6-4722 9514 6-1995 1017 6-4722 6818 6-4690 0219 6-4722 6820 6-4722 8023 6-4722 8024 6-4722 1825 6-4722 7426 6-4722 82


TA20 - 5856819007 Tools Tetra Pak

ng: 6-4722668100_1_AA


-4722 6681 80

25 82 PC 1 Standard tools ALEX 20, 2508 01 PC 1 Assembly paste, tube 100 g9 012 PC 1 UNISILICONE00 01 PC 1 Extractor plate 16260 00 PC 1 Puller 21/5 30-3703 81 PC 1 Extractor extension26 01 PC 1 Tongs38 01 PC 1 VALVE MOUNTING TOOL 65/5539 01 PC 1 Hook spanner 11635 01 PC 1 Tool piston bushing87 03 PC 1 Puller ring ALEX 20


4722-8025

8 9

8

TA20 - 5856819007 Standard ToolsMachine No.etra Pak

-80

-81

-82

-83 2

1

3 4 5 6 7

6 7

2 3 4 5 6 7

2 3 4 5 6 7



6-4722 8025 82 7-71


Group number: 6

1 6-4722 802 6-4722 803 6-4722 804 6-4722 805 6-4722 805 6-4722 805 6-4722 805 6-4722 805 6-4722 806 6-4722 806 6-4722 806 6-4722 806 6-4722 807 6-4722 808 6-4722 80


TA20 - 5856819007 Standard Tools Tetra Pak

ng: 6-47228025


-4722 8025 82

24 01 PC 1 Tool box21 01 PC 1 CATCH HANDLE 3/4”22 01 PC 1 REDUCING ADAPTER 3/4” -1/2”23 01 PC 1 EXTENSION 125 x 1/2”16 18 PC 1 HEXAGON SOCKET 18 x 1/2”16 24 PC 1 HEXAGON SOCKET 24 x 1/2”16 27 PC 1 HEXAGON SOCKET 27 x 1/2”16 30 PC 1 HEXAGON SOCKET 30 x 1/2”16 36 PC 1 HEXAGON SOCKET 36 x 3/4”17 07 PC 1 BOX WRENCH 717 19 PC 1 BOX WRENCH 1917 22 PC 1 BOX WRENCH 2217 46 PC 1 BOX WRENCH 4618 01 PC 1 ALLEN KEY SET20 01 PC 1 OFFSET END WRENCH SET

TA20 - 5856819007 Spare Parts Kit
Machine No.etra Pak




6-4722 6660 80 7-73


Group number: 6

6-4722 66

6-4722 666-4722 196-4722 816-4722 816-4722 68

6-4722 1962 6-4722 1967 6-4722 2487 6-4722 52

6-4722 819 6-4722 6811 6-4722 9012 6-4722 9013 6-4722 2214 6-4722 1416 6-4722 9017 6-4722 9018 6-4722 9056 6-4722 1157 6-4722 11

6-4722 8125 6-4722 6627 6-4722 0958 6-4722 11

6-4722 683 6-881 1715 6-881 171


TA20 - 5856819007 Spare Parts Kit Tetra Pak

9 6-881 17113 PC 1 Seal ring H-Line H40-X-2 Silicone17 6-881 17112 PC 1 Seal ring H-Line H40-X-1 1/219 6-881 17112 PC 1 Seal ring H-Line H40-X-1 1/223 6-881 17112 PC 1 Seal ring H-Line H40-X-1 1/263 6-4722 9042 12 PC 1 O-ring 53.57x3.53 EPDM 80 E8502

ng:


-4722 6660 80

77 80 PC 1 SPARE PARTS STD

77 80 PC 1 SPARE PARTS STD82 85 PC 1 Spare parts Crankcase ALEX 2044 92 PC 1 SPARE PARTS PISTON CARTRIDGE ALEX 20 STD61 92 PC 3 SPARE PARTS VALVE CARTRIDGE ø65 MUSHROOM35 84 PC 1 SPARE PARTS PRODUCT CONNECTIONS ALEX 20

82 85 PC 1 Spare parts Crankcase ALEX 2087 01 PC 3 Bellows TA2055 02 PC 3 Plate51 01 PC 3 Screw MLC6S 6 x 16 FZB 8.8 DIN 7984

44 92 PC 1 SPARE PARTS PISTON CARTRIDGE ALEX 20 STD07 01 PC 3 Piston 50-CR26 08 PC 6 Piston seal 50 PSB226 08 PC 6 Piston seal 50 PSB264 12 PC 3 Compression ring 5018 10 PC 12 Guide band 50x9.542 49 PC 6 O-ring 75 x 5 EPDM 80 E850242 41 PC 3 O-ring 62 x 4 EPDM 80 E850242 49 PC 6 O-ring 75 x 5 EPDM 80 E850278 17 PC 6 Support ring 8578 23 PC 3 Support ring 74

61 92 PC 3 SPARE PARTS VALVE CARTRIDGE ø65 MUSHROOM52 01 PC 6 Valve spring 6542 02 PC 15 Valve sealing 55 x 65 x 878 18 PC 15 Support ring 65

35 84 PC 1 SPARE PARTS PRODUCT CONNECTIONS ALEX 2013 PC 1 Seal ring H-Line H40-X-2 Silicone13 PC 1 Seal ring H-Line H40-X-2 Silicone

2.2T

F20

2563

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8 Preventive maintenancerecommendations

Tetra Pak

2.2T

F20

2563

.en


Tetra Pak

8 Preventive maintenance recommendations2.

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63.e

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TPMS - DescriptionThe maintenance system used for equipment from Tetra Pak is called the Tetra Pak Maintenance System (TPMS). If you are using TPMS, the checklists will be delivered directly from your local Tetra Pak service station.

The TPMS checklists are designed to match and keep pace with the ongoing development of new and existing equipment from Tetra Pak, and to meet the demands set by our customers for even higher efficiency and better economy.

If you require further information regarding TPMS, please do not hesitate to contact your local Tetra Pak office

Preventive maintenance recommendations -DescriptionThis section of the TeM covers all the preventive maintenance activities for the specified machine, accompanied with the relevant spare parts.

If you have any questions regarding the maintenance of your Tetra Alex machine, please do not hesitate to contact your local Tetra Pak office.

! Important informationThe recommendations related to wear and tear parts are given general average figures for the product portfolio Tetra Alex. The data relates typically to white milk, homogenized at equal or less than 250 bar at 80% of the maximum crankshaft speed of the machine. The machine should be installed according to the installation instructions.

Please note, that for example abrasive products, higher crankshaft speed or increased pressure as well as unresolved dry matter or air in the product will reduce the life time of the parts in contact with the product. In the same way will optimum conditions increase the indicated life time of these parts.

The initially given data should be seen as starting point for the tool. Adjustments based on experience from the actual products will give correct intervals for each machine over time.

(Cont'd)


8 Preventive maintenance recommendations

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1 2 3 4 5 6 7 8 9 10

GF202589

1 LabelPos No. on Drawing and Bill of Material in TeM - 7 Parts list

2 Group No.Number of Bill of Material (Group Number) in TeM - 7 Parts list

3 Doc No. ReferenceActivity no. in TeM - 4 Maintenance Instructions where more information can be found

4 Work timeThe approx. time in minutes to perform the action

5 IntervalRecommended service interval in production hours during normal running conditions and with white milk as product

6 ActionDescription of action: Check, Change, Clean, Lubricate e.t.c.

7 DescriptionWhat to perform the action on

8 Spare Part No.Article number of the spare part, Part No. in TeM - 7 Parts list

9 QtyThe required number of spare parts

10 Filter ButtonsUse these to select type of maintenance, interval, etc.


1(6)

Tetra Pak Processing Components AB Preventive maintenance recommendations Tetra Alex 20 Machine No: 5856819007 Date: 15/01/2009Ver. AO

Item No. Label Class Group No. Denomination Type Doc No. Work time Interval Action Description Spare Part No. Denomination Qty Action performedReference (minutes) (h) Date / Result

PREVENTIVE MAINTENANCE CHECKS999 5 10 Check Leaks, noise and vibrations999 5 10 Check Product pipe - Leakage999 5 10 Check Drive - Noise and vibrations

FRAME AND BODY Tag 4, section 1TeM 1.1 1 50 Check Cover - Function

DRIVE UNIT Tag 4, section 2999 6-4722 8166 80 TeM 2.1-1 20 6000 Clean Drive motor - Cooling fan999 6-4722 8166 80 TeM 2.1-2 10 3000 Lubricate Drive motor

6 6-4722 8166 80 TeM 2.2.1-1 1 1500 Check V-belt - Tension / wear 6-4722 5857 05 36 6-4722 8166 80 TeM 2.2.1-2 20 6000 Change V-belt 6-4722 5857 05 3

999 6-4722 6660 80 TeM 2.3.1-1 5 250 Check Gear box - Oil - Level / Water 90458-0863 3999 6-4722 6660 80 TeM 2.3.1-2 20 6000 Change Gear box - Oil 90458-0863 3

7 6-4722 8163 80 TeM 2.3.2-2 1 1500 Check Gear box - Adjusting bolt - Vibration damper 6-4722 5415 01 18 6-4722 8163 80 TeM 2.3.2-2 30 12000 Change Gear box - Sleeve 6-4722 5457 01 1

11 6-4722 6457 02 TeM 2.3.2-1 1 1500 Check Gear box - Seal ring 90459-1278 113 6-4722 6457 02 TeM 2.3.2-1 1 1500 Check Gear box - Seal ring 90459-1282 114 6-4722 6457 02 TeM 2.3.2-1 1 1500 Check Gear box - Seal ring 90459-1283 111 6-4722 6457 02 TeM 2.3.2-2 180 12000 Change Gear box - Seal ring 90459-1278 113 6-4722 6457 02 TeM 2.3.2-2 1 12000 Change Gear box - Seal ring 90459-1282 114 6-4722 6457 02 TeM 2.3.2-2 1 6000 Change Gear box - Seal ring 90459-1283 1

2(6)



CRANKCASE Tag 4, section 3999 TeM 3.1-1 5 10 Check Crankcase - Oil - Level / Water100 TeM 3.1-2 30 3000 Change Crankcase - Oil 6-4722 7569 01 20107 6-4722 8155 80 TeM 3.2-1 5 1500 Check Oil level switch (Option)

TeM 3.6-1 10 500 Check Cross head - Piston - Play14 6-4722 1982 80 TeM 3.4-1 10 3000 Check Oil scraper14 6-4722 1982 80 TeM 3.4-1 10 12000 Clean Oil scraper42 6-4722 1982 80 TeM 3.4-1 240 12000 Check Roller bearing 6-4241 2200 02 143 6-4722 1982 80 TeM 3.4-1 240 12000 Check Roller bearing 6-4241 0010 57 130 6-4722 1982 80 TeM 3.4-1 5 24000 Change Gasket 6-4301 5000 11 132 6-4722 1982 80 TeM 3.4-1 5 24000 Change O-ring 315202-0237 333 6-4722 1982 80 TeM 3.4-1 5 24000 Change O-ring 6-4302 0490 72 134 6-4722 1982 80 TeM 3.4-1 5 24000 Change O-ring 6-4302 0490 40 135 6-4722 1982 80 TeM 3.4-1 5 24000 Change O-ring 6-4302 0075 05 142 6-4722 1982 80 TeM 3.4-1 240 24000 Change Roller bearing 6-4241 2200 02 143 6-4722 1982 80 TeM 3.4-1 240 24000 Change Roller bearing 6-4241 0010 57 144 6-4722 1982 80 TeM 3.4-1 5 24000 Change Sealing box 6-4305 0012 50 185 6-4722 1982 80 TeM 3.4-1 180 12000 Change Plain bearing 6-4722 2161 01 386 6-4722 1982 80 TeM 3.4-1 5 12000 Change Lock nut 312810-0322 683 6-4722 1982 80 TeM 3.5-1 5 12000 Check Cross head84 6-4722 1982 80 TeM 3.5-1 5 12000 Check Cross head - Bolt62 6-4722 1982 80 TeM 3.6-1 1 500 Check Bellows 6-4722 1987 01 362 6-4722 1982 80 TeM 3.6-1 60 6000 Change Bellows 6-4722 1987 01 367 6-4722 1982 80 TeM 3.6-1 1 500 Check Plate 6-4722 2455 02 367 6-4722 1982 80 TeM 3.6-1 5 24000 Change Plate 6-4722 2455 02 387 6-4722 1982 80 TeM 3.6-1 1 1500 Check Screw 6-4722 5251 01 387 6-4722 1982 80 TeM 3.6-1 5 6000 Change Screw 6-4722 5251 01 3

999 TeM 3.6 1 500 Check Connections - Leakage

3(6)



WETEND Tag 4, section 4Valves and seals

23 6-4722 8161 80 TeM 4.1-3 60 1500 Check Valve 6-4722 6648 02 624 6-4722 8161 80 TeM 4.1-1 1 1500 Check Valve seat 6-4722 6649 03 625 6-4722 8161 80 TeM 4.1-1 1 1500 Check Spring 6-4722 6652 01 626 6-4722 8161 80 TeM 4.1-1 1 1500 Check Valve cage 6-4722 6657 01 627 6-4722 8161 80 TeM 4.1-1 1 1500 Check Valve seal / O-ring 6-4722 0942 02 1558 6-4722 8161 80 TeM 4.1-1 1 1500 Check Support ring 6-4722 1178 18 1523 6-4722 8161 80 TeM 4.1-3 60 6000 Change Valve 6-4722 6648 02 624 6-4722 8161 80 TeM 4.1-1 1 6000 Turn Valve seat 6-4722 6649 03 625 6-4722 8161 80 TeM 4.1-1 1 12000 Change Spring 6-4722 6652 01 626 6-4722 8161 80 TeM 4.1-1 1 18000 Change Valve cage 6-4722 6657 01 627 6-4722 8161 80 TeM 4.1.1-1 1 3000 Change Valve seal / O-ring 6-4722 0942 02 1558 6-4722 8161 80 TeM 4.1.1-1 1 3000 Change Support ring 6-4722 1178 18 15

Piston cartridge9 6-4722 8144 50 TeM 4.2-1 1 500 Check Piston 6-4722 6807 01 3

11 6-4722 8144 50 TeM 4.2-1 1 500 Check Piston seal 6-4722 9026 08 312 6-4722 8144 50 TeM 4.2-1 1 500 Check Piston seal 6-4722 9026 08 313 6-4722 8144 50 TeM 4.2-1 1 500 Check Compression ring 6-4722 2264 12 314 6-4722 8144 50 TeM 4.2-1 1 500 Check Guide band 6-4722 1418 10 616 6-4722 8144 50 TeM 4.2-1 1 500 Check O-ring 6-4722 9042 49 317 6-4722 8144 50 TeM 4.2-1 1 500 Check O-ring 6-4722 9042 41 318 6-4722 8144 50 TeM 4.2-1 1 500 Check O-ring 6-4722 9042 49 356 6-4722 8144 50 TeM 4.2-1 1 500 Check Support ring 6-4722 1178 17 357 6-4722 8144 50 TeM 4.2-1 1 500 Check Support ring 6-4722 1178 23 39 6-4722 8144 50 TeM 4.2-3 150 4000 Change Piston 6-4722 6807 01 3

11 6-4722 8144 50 TeM 4.2-3 1 2000 Change Piston seal 6-4722 9026 08 312 6-4722 8144 50 TeM 4.2-3 1 2000 Change Piston seal 6-4722 9026 08 313 6-4722 8144 50 TeM 4.2-3 1 4000 Change Compression ring 6-4722 2264 12 314 6-4722 8144 50 TeM 4.2-3 1 2000 Change Guide band 6-4722 1418 10 616 6-4722 8144 50 TeM 4.2-3 1 2000 Change O-ring 6-4722 9042 49 317 6-4722 8144 50 TeM 4.2-3 1 12000 Change O-ring 6-4722 9042 41 318 6-4722 8144 50 TeM 4.2-3 1 2000 Change O-ring 6-4722 9042 49 356 6-4722 8144 50 TeM 4.2-3 1 2000 Change Support ring 6-4722 1178 17 357 6-4722 8144 50 TeM 4.2-3 1 12000 Change Support ring 6-4722 1178 23 3

4(6)



HOMOGENIZING HEAD Tag 4, section 59 6-4722 7040 80 TeM 5.1-2 90 6000 Change O-ring 6-4722 9042 35 2

11 6-4722 7040 80 TeM 5.2.1-1 1 6000 Check Sealing ring 6-4722 5233 01 213 6-4722 7040 80 TeM 5.1-2 1 6000 Change O-ring 6-4722 9042 08 217 6-4722 7040 80 TeM 5.1.2-1 1 1500 Check Forcer disc / Forcer 6-4722 9018 01 117 6-4722 7040 80 TeM 5.1.2-2 1 6000 Turn Forcer disc / Forcer 6-4722 9018 01 118 6-4722 7040 80 TeM 5.1.1-1 1 1500 Check Seat 6-4722 7044 01 118 6-4722 7040 80 TeM 5.1.1-1 1 6000 Turn Seat 6-4722 7044 01 121 6-4722 7040 80 TeM 5.1-1 1 6000 Change O-ring 6-4722 9042 03 222 6-4722 7040 80 TeM 5.1-2 1 6000 Change O-ring 6-4722 9042 15 524 6-4722 7040 80 TeM 5.1-2 1 6000 Change Support ring 6-4722 7151 03 226 6-4722 7040 80 TeM 5.1-2 1 6000 Change Guide band 6-4722 1418 16 427 6-4722 7040 80 TeM 5.1-2 1 6000 Change O-ring 6-4722 9042 05 228 6-4722 7040 80 TeM 5.1-2 1 6000 Change Support ring 6-4722 7152 03 333 6-4722 7040 80 TeM 5.1.2-1 1 1500 Check Forcer disc / Forcer 6-4722 9018 01 134 6-4722 7040 80 TeM 5.1.1-1 1 1500 Check Seat 6-4722 7044 01 143 6-4722 7040 80 TeM 5.2.1-1 1 6000 Change O-ring 6-4722 9042 08 1

Hydraulic end6 6-4722 7040 80 TeM 5.2.1-1 20 9000 Change O-ring 6-4722 6562 47 28 6-4722 7040 80 TeM 5.2.1-1 1 9000 Change Guide band 6-4306 0000 05 4

29 6-4722 7040 80 TeM 5.2.1-1 1 9000 Change Support ring 6-4722 7153 03 2Manometer flange

49 6-4722 8763 80 TeM 4.3-1 5 1500 Check Pressure gauge 6-4722 6396 01 152 6-4722 8763 80 TeM 4.3-2 5 6000 Change O-ring 6-4722 9042 52 153 6-4722 8763 80 TeM 4.3-2 5 6000 Change Support ring 6-4722 8753 01 1

5(6)



HYDRAULIC SYSTEM Tag 4, section 61 6-4722 7563 80 TeM 6.1-1 1 250 Check Hydraulic unit

95 6-4722 6660 80 TeM 6.1-1 1 250 Check Hydraulic unit - Oil level 90458-0861 695 6-4722 6660 80 TeM 6.1-2 20 9000 Change Hydraulic unit - Oil 90458-0861 65 6-4722 5471 81 TeM 6.1.1-1 1 1500 Check Safety valve8 6-4722 5471 81 TeM 6.1-4 5 9000 Check Hydraulic pump 6-4722 6541 02 18 6-4722 5471 81 TeM 6.1-4 60 18000 Change Hydraulic pump 6-4722 6541 02 1

10 6-4722 5471 81 TeM 6.1-3 10 9000 Clean Filter11 6-4722 5471 81 TeM 6.1-3 10 9000 Clean Filter32 6-4722 5471 81 TeM 6.1-4 1 9000 Check Coupling33 6-4722 5471 81 TeM 6.1-4 1 9000 Change Rubber cross 6-4722 7551 01 12 6-4722 7563 80 TeM 6-1 1 3000 Check Motor5 6-4722 7563 80 TeM 6-1 1 3000 Check Pressure adjusting valve

15 6-4722 7563 80 TeM 6.2-1 1 1500 Check Pressure gauge - Function 6-4932 2002 25 118 6-4722 7563 80 TeM 6.2-1 1 1500 Check Pressure gauge - Function 6-4932 2002 26 17 6-4722 7563 80 TeM 6.3-1 1 1500 Check Pressure relief valve (Option)9 6-4722 7563 80 TeM 6.4-1 1 1500 Check Proportional valve (Option)

17 6-4722 7563 80 TeM 6.4-1 1 1500 Check Proportional valve (Option)13 6-4722 7563 80 TeM 6.5-1 1 1500 Check Pressure transmitter (Option)

PRODUCT CONNECTIONS Tag 4, section 563 6-4722 6835 80 1 3000 Check O-ring 6-4722 9042 12 163 6-4722 6835 80 10 6000 Change O-ring 6-4722 9042 12 1

Inlet3 6-4722 8122 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17113 13 6-4722 8122 80 TeM 5.3-1 30 6000 Change Silicone gasket 6-881 17113 15 6-4722 8122 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17113 15 6-4722 8122 80 TeM 5.3-1 1 6000 Change Silicone gasket 6-881 17113 19 6-4722 8122 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17113 19 6-4722 8122 80 TeM 5.3-1 1 6000 Change Silicone gasket 6-881 17113 1

Outlet17 6-4722 8123 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17112 117 6-4722 8123 80 TeM 5.3-1 30 6000 Change Silicone gasket 6-881 17112 119 6-4722 8123 80 TeM 5.3-1 1 6000 Change Silicone gasket 6-881 17112 119 6-4722 8123 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17112 123 6-4722 8123 80 TeM 5.3-1 1 3000 Check Silicone gasket 6-881 17112 123 6-4722 8123 80 TeM 5.3-1 1 6000 Change Silicone gasket 6-881 17112 1

6(6)



COOLING CIRCUIT Tag 4, section 7999 TeM 7.1-1 5 250 Check Connections - Leakage

6 6-4722 8450 80 C S inlet TeM 7.3-1 5 1500 Check Trim valveF/Y810 6-4722 8450 80 C S inlet TeM 7.4-1 5 1500 Check Cooling water valve

91 6-4722 8450 80 C S inlet TeM 7.8-1 5 1500 Check Flow meter (Option)5 6-4722 8452 80 C S crankcase TeM 7.7-1 5 1500 Check Cooling water regulator (Option)6 6-4722 8452 80 C S crankcase TeM 7.3-1 5 1500 Check Trim valve

ELECTRICAL SYSTEM Tag 4, section 8999 TeM 8.2-1 5 1500 Clean Cooling fan - Filter999 TeM 8.2-1 5 12000 Change Cooling fan - Filter, AM 400P 216 x 216 6-990408 75999 TeM 8.2-1 5 12000 Change Cooling fan - Filter, AM 700P 283 x 283 6-990408 76108 6-4722 8155 80 TeM 8.3-1 1 1500 Check Temperature transmitter, PT-100 (Option)

1 6-4722 7592 80 TeM 8.4-1 1 1500 Check Emergency stop

2.29

_.en

9 Service media

Tetra Pak

9 Service media

2.29

_.en


Tetra Pak

Service mediaData2.

2tf2

0001

7.en

Service media

Water

General requirementsFor consumption and pressure data, see ‘Technical data’.

• The supply pressure must be constant.

Water hardnessIf the water is hard (high concentration of Calcium carbonate, CaCO3), the wear and tear of the piston and piston seals will be excessive.

CorrosionIn order to minimize corrosion:

AbrasivenessIf the water contains to much of solid particles, the pistons will rapidly wear down

Caution! Noncompliance with these requirements may endanger the equipment

(Cont'd)

Hardness: < 10° dHmax 180 mg/l CaCO3

Chlorine: max. 0.2 mg/l Cl2Chloride: max. 30 mg/l Cl-

pH: 7 - 8.5

Turbidity: max. 3 NTU


Service media Data

2.2t

f200

017.

en

(Cont'd)

Water used for cooling, product flushing, rinsing and cleaning should meet the WHO guidelines (stated below) or the European drinking water directive.

Characteristics

Taste none

Smell none

Turbidity max. 3 NTU

Colour max. 20 mg/l Pt

Oxygen demand max. 20 mg/l KMnO4

Tot. dissolved solids max. 500 mg/l

pH 7 - 8.5

Hardness <10° dH (max. 180 mg/l CaCO3)

Ammonium trace amounts

Ammonia max. 0.5 mg/l NH4

Iron none

Manganese none

Nitrate max. 30 mg/l NO3

Sulphate max. 100 mg/l SO4

Chlorine (M, S) max. 0.2 mg/l Cl2

Chloride (M, S) max. 30 mg/l Cl-

Aggressive carbon acid max. 0 mg/l CO2

Total amount of bacteria max. 100/ml

Total amount of 35°C coliform bacteria

max. 1/100 ml

Total amount of 44°C coliform bacteria

0/100 ml

Copper max. 0.05 mg/l Cu

Zinc max. 1.0 mg/l Zn


2.21

0_.e

n

10 Cleaning

Tetra Pak

2.21

0_.e

n


Tetra Pak

Data2.

2tf2

0002

1.en

CleaningChemical hazardCleaning solution contains Caustic soda (NaOH) or Nitric acid (HNO3).These chemicals may cause severe burning to skin and eyes. Use protective clothes, goggles and gloves during handling.If exposed - wash with water for at least 15 minutes. Seek medical assistance. Follow the instructions given by the supplier.

Risk of scaldsThis machine works under pressurised conditions and high temperatures. To avoid jets of hot liquid, steam or cleaning solution, make sure that any operation sequence is finalised, the machine is cooled down and without pressure before disassembling any parts.

CIPWhen Cleaning In Place observe following:

• Max 2 % at max 85°C (185 °F) Lye

• Max 1.5 % at max 85°C (185 °F) Acid

• Inlet pressure > 2 bar (30 psi)

Cleaning• Cleaning program as for the process equipment. The minimal required

cleaning flow is 100% of maximal requested production flow.

Sterilisation• Max 85°C (185 °F) at 30 minutes

WARNING!

WARNING!


Cleaning Data

2.2t

f200

021.

en



2.21

1_01

.en

11 Certificates

Tetra Pak

2.21

1_01

.en


Tetra Pak


98/37/EC Machinery


DECLARATION OF CONFORMITY

Anders Karlsson

2009-01-16

Ruben Rausings gataS-221 86 LundSweden

S-221 86 Lund

Manager, Homogenization and High Pressure Pumping

declare that this machine/ equipment/ complex installation:

HomogenizerMachine No

is in conformity with the following harmonized standards:EN ISO 12100-1:2003 EN ISO 12100-2:2003EN 294: 1992

5856819007Tetra Alex 20

EN ISO 13850: 2006 EN 61000-6-2:2001EN 61000-6-2:2001EN 61000-6-2:2001

EN 61000-6-4:2001EN 60204-1: 1997EN 1672-2: 2005

including amendments:

X

X

X

X

EnglishVer 2008-01

2004/108/EC Electromagnetic compatibility (EMC)

2006/95/EEC Low voltage

97/23/EC Pressure Equipment, § 3.3

and is in conformity with the provisions of the Directive(s) -

Tetra Pak

2.21

1_01

.en


tem-9007_en

Documents

intentionally

tetra pak

cleaning solution

technical

technical

safety precautions

tetra pak

affected area