Machine type: Machine number: 20 Tetra Alex ® 5856819007 Operation Manual: Technical Manual: TeM - 3011562-01 OM - 1235757-01 TeM - 3011562-35 OM - 1235757-35 Romanian English 19/02/2009 Issue date: Tetra Pak Processing Systems Division DRAWING SPECIFICATION The Drawing Specification is the key identification for the process equipment. It is to be filed separately under safe conditions.
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Transcript
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.
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!
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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.
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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.
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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Preparatory workInstallation2.
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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”
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
Installation instructions
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Installation
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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
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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
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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
Producer Type Viscosity*BP/Castrol Energol GR-XP 320Exxon/Mobil Mobilgear 600 XP 320Shell Omala Oil 320
Producer Type Viscosity*BP/Castrol Optileb GT 220-320Exxon/Mobil DTE FM 220-320Shell Cassida GL 220-320
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LubricationInstallation2.
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(Cont'd)
* Viscosity in mm2/sec (cSt) at 40°C (104°F)
** 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.
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
(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
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(Cont'd)
* Viscosity in mm2/sec (c.st) at 40°C (104°F)
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
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
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Installation instructionsInstallation2.
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Oil amount
Crankcase Gearbox Hydraulic unit
Approx. 20 litres (5.3 U.S. gallons)
Approx. 3 litres (0.8 U.S. gallons)
Approx. 6 litres (1.6 U.S. gallons)
GF200326 GF202053 GF200601
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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
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
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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
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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
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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.
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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
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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
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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
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(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
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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
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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
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57.e
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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
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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)
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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
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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
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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).
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
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(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
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(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.
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
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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
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
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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
Tetra Pak28 Doc No. TeM-1235897-01
4.1 Valves4 Wet end2.
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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
29Doc No. TeM-1235897-01Tetra Pak
4.1 Valves 4 Wet end
2.2t
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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.
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
31Doc No. TeM-1235897-01Tetra Pak
4.1 Valves 4 Wet end
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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
Tetra Pak32 Doc No. TeM-1235897-01
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,
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
Tetra Pak38 Doc No. TeM-1235897-01
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
39Doc No. TeM-1235897-01Tetra Pak
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.
10 O-ring11 Support ring12 Guide band13 Product drain hole14 O-ring15 Guide band
41Doc No. TeM-1235897-01Tetra Pak
5.1 Homogenisation device 5 Homogenisation head
2.2t
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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.
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.
Assemble according to activity 5.1-2.
GF201788
Seat
Deep caviation
GF201787
Seat
43Doc No. TeM-1235897-01Tetra Pak
5.1 Homogenisation device 5 Homogenisation head
2.2t
f201
817.
en
5.1.2-1 Forcer - checkCheck the condition of the forcer.
Assemble according to activity 5.1-2.
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).
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
55Doc No. TeM-1235897-01Tetra Pak
7.1 Piping 7 Cooling water system
2.2t
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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
Tetra Pak56 Doc No. TeM-1235897-01
7.3 Regulating valves7 Cooling water system
57Doc No. TeM-1235897-01
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en
Tetra Pak
7.3 Regulating valves
7.3-1 Regulating valves - checkCheck:
• function of regulating valves.
GF201430
7.4 Water valve
Tetra Pak58 Doc No. TeM-1235897-01
7 Cooling water system
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
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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)
Tetra Pak60 Doc No. TeM-1235897-01
7 Cooling water system
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
61Doc No. TeM-1235897-01Tetra Pak
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)
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!
Tetra Pak66 Doc No. TeM-1235897-01
9.1 Tools9 Miscellaneous2.
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0161
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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
67Doc No. TeM-1235897-01Tetra Pak
9.1 Tools 9 Miscellaneous
2.2t
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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
Tetra Pak68 Doc No. TeM-1235897-01
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9.2 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
69Doc No. TeM-1235897-01Tetra Pak
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2.2t
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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
Producer Type Viscosity*BP/Castrol Energol GR-XP 320Exxon/Mobil Mobilgear 600 XP 320Shell Omala Oil 320
Producer Type Viscosity*BP/Castrol Optileb GT 220-320Exxon/Mobil DTE FM 220-320Shell Cassida GL 220-320
Tetra Pak70 Doc No. TeM-1235897-01
9.2 Lubrication9 Miscellaneous2.
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0872
9.en
(Cont'd)
* Viscosity in mm2/sec (cSt) at 40°C (104°F)
** 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.
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
(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
71Doc No. TeM-1235897-01Tetra Pak
9.2 Lubrication 9 Miscellaneous
2.2t
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729.
en
(Cont'd)
* Viscosity in mm2/sec (c.st) at 40°C (104°F)
*** Conform with FDA 21 CFR 178.3570 and classified in NSF H1.
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
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)
6 mm 50 Nm (37 ft lbf)
8 mm 90 Nm (66 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
75Doc No. TeM-1235897-01Tetra Pak
9.4 Trouble shooting 9 Miscellaneous
2.2t
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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
Tetra Pak76 Doc No. TeM-1235897-01
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77Doc No. TeM-1235897-01Tetra Pak
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5 Technical data
Tetra Pak
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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.
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
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
Machine No. Group Description
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
Pos Part No SPSP h UN Qty Description Page No
-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
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
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
Assembly DrawiIssue: 2006-11-09
Group Number Page No
6-4722 6977 80 7-13
h UN Qty Description Page NoPos Part No
Group number: 6
1 6-4722 842 6-4722 843 6-4722 844 6-4722 84
Machine No. Group Description
TA20 - 5856819007 Cooling Circuit Tetra Pak
ng: 6-472269770_1_AD
Pos Part No SPSP h UN Qty Description Page No
-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 Tetra Pak
ng: 6-4722845000_1_AC
Pos Part No SPSP h UN Qty Description Page No
-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
6-4722845100_1_AB 7-16Assembly drawingT
TA20 - 5856819007 Cooling System Gearbox Outlet
Machine No.etra Pak
Assembly DrawiIssue: 2009-03-11
Group Number Page No
6-4722 8451 80 7-17
h UN Qty Description Page NoPos Part No
Group number: 6
29 342991-051 6-4722 51
Machine No. Group Description
TA20 - 5856819007 Cooling System Gearbox Outlet Tetra Pak
ng: 6-4722845100_1_AB
Pos Part No SPSP h UN Qty Description Page No
-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
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
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
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
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
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
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)
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
6-4722796400 7-40Assembly drawingT
TA20 - 5856819007 M-Type Body
Machine No.etra Pak
Assembly DrawiIssue: 2009-03-11
Group Number Page No
6-4722 7964 80 7-41
h UN Qty Description Page NoPos Part No
Group number: 6
10 6-4722 8315 6-4722 8320 6-4722 8325 6-4722 83
Machine No. Group Description
TA20 - 5856819007 M-Type Body Tetra Pak
ng: 6-4722796400
Pos Part No SPSP h UN Qty Description Page No
-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
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
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
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
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
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
Pos Part No SPSP h UN Qty Description Page No
-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
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
Machine No. Group Description
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:
Pos Part No SPSP h UN Qty Description Page No
-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
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
6-47228025 7-70Assembly drawingT
4722-8025
8 9
8
TA20 - 5856819007 Standard ToolsMachine No.etra Pak
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
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:
Pos Part No SPSP h UN Qty Description Page No
-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
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8 Preventive maintenancerecommendations
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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.
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.
Tetra Pak2 Doc No. TeM-1235600-01
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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
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
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
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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
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
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
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
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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
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
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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
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
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
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)
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
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
Tetra Pak2 Doc No. TeM-1245067-01
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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!
1Doc No. TeM-1245069-01Tetra Pak
Cleaning Data
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Tetra Pak2 Doc No. TeM-1245069-01
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11 Certificates
Tetra Pak
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Tetra Pak
Tetra Pak Processing Components AB
98/37/EC Machinery
Tetra Pak Processing Components AB
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) -