Use and Maintenance: Code Revision

Model
TSI - EURO VA IES LIGHT

Serial number
17579
Pitch diameter
288 mm.
Nr of heads
6
Manufacturing year
2019
USE AND MAINTENANCE

TRANSLATION OF THE
ORIGINAL INSTRUCTIONS
Code
Z17579ABSEN001
Revision
0
BEFORE START UP THE PARTLY COMPLETED MACHINERY, READ
THE TECHNICAL INSTRUCTIONS IN THIS MANUAL AND FOLLOW
THE INDICATIONS SHOWN.
KEEP THE USE AND MAINTENANCE MANUAL IN PLACE
KNOWN AND ACCESSIBLE TO OPERATORS AND THE SERVICE
PERSONNEL.
1 PURPOSE OF THE MANUAL - EDITION - UPDATING METHOD......................1
2 IDENTIFICATION OF THE CLOSING MACHINE.................................................4
3 DECLARATION OF INCORPORATION...............................................................5
4 CLOSING MACHINE DESCRIPTION...................................................................6
4.1 MAIN UNITS OF THE CLOSING MACHINE.........................................................6
4.2 DESCRIPTION OF THE PRODUCTION CYCLE..................................................8
4.3 CLOSING MACHINE TECHNICAL DATA............................................................10
4.4 USE RESTRICTIONS.........................................................................................11
4.4.1 PRESCRIBED USE AND FORBIDDEN USES...................................................11
4.4.2 OPERATING MODES.........................................................................................11
4.4.3 NUMBER OF OPERATORS................................................................................12
4.4.4 PROFESSIONAL ROLES OF USERS................................................................12
4.4.4.1 OPERATOR.........................................................................................................12
4.4.4.2 MAINTENANCE MAN.........................................................................................13
4.4.5 EMPLOYER'S OBLIGATIONS............................................................................13
4.4.6 INFORMATION - JOB INSTRUCTIONS - TRAINING.........................................14
4.4.6.1 INFORMATION - JOB INSTRUCTIONS.............................................................14
4.4.6.2 TRAINING...........................................................................................................14
4.4.7 ARRANGEMENTS BY THE CUSTOMER...........................................................14
4.4.8 SIGNS FOR WARNING, OBLIGATION, PROHIBITION AND DANGER.............15
4.5 ENVIRONMENTAL LIMITS.................................................................................18
4.5.1 ENVIRONMENTAL OPERATING RISKS............................................................18
4.5.2 RESIDUES AND ENVIRONMENTAL CONTAMINATION....................................18
5 SECURITY AND ACCIDENT PREVENTION......................................................19
5.1 GENERAL INFORMATION..................................................................................19
5.2 RISKS - PROTECTIONS - CAUTIONS AND PRECAUTIONS...........................20
5.2.1 SAFETY DEVICES OF THE CLOSING MACHINE.............................................20
5.2.1.1 POSITION OF THE SAFETIES...........................................................................20
5.3 SAFETY PROCEDURES FOR THE OPERATION..............................................21
5.4 SAFETY PROCEDURES FOR THE MAINTENANCE........................................22
5.4.1 GENERAL SAFETY WARNINGS........................................................................23
5.5 RESIDUAL RISKS...............................................................................................23
6 HOW TO ASK FOR INTERVENTIONS...............................................................24
7 HOW TO ORDER SPARE PARTS......................................................................24
8 INSTALLATION AND CONNECTIONS...............................................................25
8.1 INSTALLATION OF THE CAPS CHUTE
WITH “PICK-OFF” CAP DISTRIBUTION.............................................................25
8.2 INSTALLATION OF THE "FLAT" CENTRIFUGAL CAPS SORTER....................28
8.3 PNEUMATIC CONNECTION...............................................................................33
I
THIS MANUAL IS PROPERTY OF AROL S.p.A.. ANY REPRODUCTION OR MODIFICATION, EVEN IN PART, IS PROHIBITED.
9 CLOSING MACHINE USE..................................................................................35
9.1 SETTING UP, CHECKS AND TEST FOR THE FIRST START UP......................35
9.1.1 CHECKS BEFORE THE START UP...................................................................35
9.2 PRELIMINARY CHECKS BEFORE STARTING..................................................36
9.3 PREPARATION FOR STARTING........................................................................37
9.3.1 CLOSING MACHINE HEIGHT ADJUSTMENT
FOR "PICK OFF" DISTRIBUTION CAPS............................................................37
9.3.2 CAPS SORTER LOADING..................................................................................41
9.4 EMPTYING OF THE CAPS DISTRIBUTION SYSTEM.......................................43
9.4.1 CAPS SORTER EMPTYING...............................................................................43
9.4.2 CAPS CHUTE DISCHARGE...............................................................................44
9.5 DISCONNECTION OF THE MOTION TRASMISSION.......................................45
9.6 CLOSING MACHINE CLEANING.......................................................................47
9.6.1 CLOSING MACHINE CLEANING INTERVALS...................................................47
9.6.2 EXTERNAL WASHING OF THE CLOSING MACHINE.......................................48
9.6.2.1 AUTOCLAVE CLOSURE HEADS STERILIZATION............................................50
9.6.2.2 CLOSURE HEADS STERILIZATION PROCEDURE..........................................50
10 SIZE CHANGE....................................................................................................51
10.6.1 CENTRAL STAR-WHEEL....................................................................................52
10.6.1.1 REMOVAL...........................................................................................................52
10.6.1.2 INSTALLATION....................................................................................................53
10.7 CAP SIZE CHANGE............................................................................................55
10.7.1 REMOVAL AND INSTALLATION OF THE CLOSURE HEADS...........................56
10.7.1.1 REMOVAL OF SSD HEAD..................................................................................56
10.7.1.2 INSTALLATION OF SSD HEAD..........................................................................58
10.7.2 "PICK OFF" CAPS CHUTE.................................................................................60
10.7.2.1 REMOVAL OF THE CAPS CHUTE WITH “PICK-OFF” CAP DISTRIBUTION....60
10.7.2.2 INSTALLATION OF THE CAPS CHUTE
WITH “PICK-OFF” CAP DISTRIBUTION............................................................62
10.7.3 CAPS SELECTION EQUIPMENT FOR CENTRIFUGAL CAPS SORTER.........65
10.7.3.1 CAPS EXIT MOUTH............................................................................................65
10.7.3.1.1 REMOVAL...........................................................................................................65
10.7.3.1.2 INSTALLATION....................................................................................................66
10.7.3.2 ADJUSTMENT OF THE CAPS SORTER FOR SIZE CHANGE..........................67
10.8 ADJUSTMENTS OF THE CLOSURE HEAD.......................................................69
10.8.1 "SSD" CLOSURE HEAD.....................................................................................69
10.8.1.1 CLOSURE HEAD PREPARATION......................................................................69
10.8.1.2 ADJUSTING THE THREADING ROLLER...........................................................76
10.8.1.3 ADJUSTING THE SKIRTING ROLLER...............................................................82
II
11 MAINTENANCE OF THE CLOSING MACHINE.................................................88
11.1 MAINTENANCE GENERAL INFORMATION......................................................88
11.1.1 MAINTENANCE SCHEDULE..............................................................................88
11.1.2 MAINTENANCE INTERVALS..............................................................................88
11.1.3 GENERAL INDICATIONS ON THE SCHEDULED MAINTENANCE PLAN........89
11.2 MAINTENANCE AND LUBRICATION PLANNING..............................................89
11.3 SCHEDULED MAINTENANCE...........................................................................90
11.3.1 ROUTINE MAINTENANCE.................................................................................90
11.3.1.1 EVERY 40 WORKING HOURS...........................................................................90
11.3.1.2 EVERY 120 WORKING HOURS.........................................................................90
11.3.1.3 EVERY 1000 WORKING HOURS.......................................................................91
11.3.1.4 EVERY 6000 WORKING HOURS.......................................................................92
11.3.1.5 EVERY 12000 WORKING HOURS.....................................................................92
11.3.2 HEADS CONTROL SPINDLES MAINTENANCE................................................93
11.3.2.1 SPINDLE PADS CLEARANCE ADJUSTMENT...................................................93
11.3.3 MAINTENANCE OF THE CLOSURE HEAD.......................................................95
11.3.3.1 "SSD" CLOSURE HEAD.....................................................................................95
11.3.3.1.1 REMOVAL OF THE ROLLER HOLDER ARMS...................................................95
11.3.3.1.2 BOTTLE MOUTH-HOLDER REPLACEMENT....................................................99
11.3.3.1.3 REPLACING THE SPRINGS............................................................................101
11.3.3.1.3.1 COMPENSATING SPRINGS....................................................................................... 101
11.3.3.1.3.2 SIDE LOADING SPRINGS........................................................................................... 104
11.3.3.1.3.3 THREADING ROLLER SPRINGS................................................................................ 106
11.3.3.1.3.4 SKIRTING ROLLER SPRINGS.................................................................................... 108
11.3.3.1.3.5 MOUTH-PRESSER SPRING........................................................................................110
11.3.4 MAINTENANCE OF THE "FLAT" CENTRIFUGAL CAPS SORTER.................113
11.4 LUBRICATION...................................................................................................115
11.4.1 GENERAL INFORMATION................................................................................115
11.4.2 LUBRICANT TYPE-APPROVAL ACCORDING TO NSF...................................115
11.4.3 TYPES OF LUBRICANTS.................................................................................116
11.4.3.1 LUBRICANT RE-ORDERING............................................................................118
11.4.4 LEGEND FOR LUBRICATION SCHEMES.......................................................118
11.4.5 POINTS TO BE LUBRICATED..........................................................................119
11.4.5.1 INSTRUCTIONS FOR READING THE "LUBRICATION POINT LIST" TABLE........119
11.4.5.2 LUBRICATION POINT LIST AND SCHEMES...................................................120
11.4.6 LUBRICANT CARTRIDGE................................................................................122
11.4.6.1 LUBRICATOR DESCRIPTION..........................................................................122
III
11.4.6.2 CARTRIDGE REPLACEMENT..........................................................................123
11.4.7 LUBRICATION OF THE CLOSURE HEAD.......................................................124
11.4.7.1 "SSD" CLOSURE HEAD...................................................................................124
11.4.8 BONFIGLIOLI REDUCER LUBRICATION........................................................126
11.4.8.1 INTRODUCTION...............................................................................................126
11.4.8.2 LUBRICATION...................................................................................................126
11.4.8.2.1 OIL REPLACEMENT.........................................................................................127
11.5 EXTRAORDINARY MAINTENANCE.................................................................128
11.5.1 SPINDLES CONTROL CAM WEAR CHECK....................................................128
11.5.2 REPLACEMENT OF THE BOTTLE SUPPORTING PLATES...........................129
11.5.3 TRANSPORT EQUIPMENT TIMING.................................................................131
11.5.3.1 ALIGNMENT BETWEEN BOTTLE CENTERING DEVICE
AND CENTRAL STAR-WHEEL.........................................................................131
12 FAULTS AND REMEDIES................................................................................132
13 SCRAPPING AND DISPOSING........................................................................135
IV
1 PURPOSE OF THE MANUAL - EDITION - UPDATING METHOD
The manual is integral to the partly completed machinery TSI - EURO VA IES LIGHT model, 17579 serial
number; it should be kept all the life of partly completed machinery; it must follow the same machinery when
it is moved to other premises or if it sold.
It is in Italian and translated in target language whenever required.
In case of doubts about the interpretation of the text, always refer to the original language and contact
Customer Service in case of need:
AROL S.p.A.
Viale Italia, n° 193
14053 CANELLI (Asti) - ITALY
ph. +39 0141 820 500 - Fax +39 0141 820 555
http://www.arol.com
Contact the international headquarters:
AROL HEXAGONE AROL NORTH AMERICA
Rue de l'Artisanat ZA Saint-Vincent (USA, Canada)
73190 CHALLES LES EAUX - FRANCE 2390 Satellite Blvd. (Suite D)
ph. +33 4 67 98 93 53 BUFORD, GEORGIA 30518 - U.S.A.
ph. +1 678 318 1290
AROL GERMANY GMBH AROL LATIN AMERICA
Wasserstr. 67 Bosque de Cidros # 18, Oficina 501 y 502
68519 VIERNHEIM - DEUTSCHLAND Col. Bosques de las Lomas, Cuajimalpa
ph. +49 6204 79073 C.P.05120, México, D.F., México
+52 (55) 1327-8618/8817
AROL ESPAÑA AROL BRAZIL
C/Llull, 321-329-Edificio CINC (Brasil, South America)
08019 BARCELONA - ESPAÑA Avenida Netuno, 19 - 2º andar/ sala 4 Alphaville
ph. +34 933 091 646 - Fax +34 935 579 974 Santana do Parnaíba
São Paulo (SP) - CEP 06541 015 - BRAZIL
ph. +55 11 4156-2176
AROL UK AROL CHINA
(UK & Ireland) Nanle Rd 1276/115 Bld. 5/102
Clifton , United Kingdom. Songjiang District
ph. +44 (0)7 931 336 177 201600 SHANGHAI - CHINA
ph. +86 021 57771952 - Fax +86 021 57771952
AROL INDIA
Pune IT Park, C 102/11, 34 Aundh Road
Bhau Patil Marg Pune 411 020 - INDIEN
ph. 020 - 30226105
Refer to http://www.arol.com for the update of the addresses of the headquarters.
1
The text of the manual will refer to the "closing machine" as an abbreviation of the standard name
"Closing machine which uses a closure" as stated in the UNI EN 415-1 standard (Terminology
and classification of packaging machines).
The manual contains information and instruction about all the operating cycle of the closing machine:
• Installation.
• Start up.
• Use.
• Size change.
• Maintenance.
• Dismantling and disposal.
The manual should be kept so that:
• avoid any damage.
• Arrange for its availability to the professional operators working on the closing machine.
• Prevent it from being modified or damaged during the use.
• Make it available in case of need (training, changed ownership of the closing machine, etc.)
Ask for a replacing copy if damaged.
This manual was written with care; if some of the sections needs to be reviewed to add information or
instructions, or simply for clarity reasons, AROL S.p.A. will proceed as follows:
• should the modification involve only a few pages: the replacement pages will be sent.
• should the modifications involve more pages of different chapters: all the chapters involving modification
will be sent again.
• should the modification involve many chapters : the whole replacement manual will be sent.
Should the manual be supplied in electronic form, the supplied manual will always be the complete and
updated one.
The consultation of this manual is made easier by the addition of the initial pages of the general table of
contents, for an immediate tracking of the topic concerned.
The chapters are organised a hierarchy structure for a fast tracking of the info required.
2
The manual shows graphic symbols that are used to distinguish:
• Informations and prescriptions.
• Obligations.
• Warning about residual risks.
The following documents are attached to this manual:
• Pneumatic diagram.
• Closing machine installation diagram.
• Identification tables for size change.
• Closure head calibration tables.
• Instructions manuals for accessories and/or equipment installed on the closing machine and not
integrated in this manual.
Before any operation with or on the closing machine read the procedures and warnings herein
carefully.
IMAGES OF ANY GENERAL KIND ARE NOT USED IF THE DETECTION OF SPECIFIC
STRUCTURE OF CLOSING MACHINE IS ESSENTIAL IN THE CONTEXT TO THE SUBJECT
MATTER. The reported instructions and use modes for all described components anyway remain
valid.
3
2 IDENTIFICATION OF THE CLOSING MACHINE
The upper part of the closing machine is provided with an identification plate. (See Figure).
On the plate are reported:
• Closing machine model (MODEL)
• Type of closing machine (TYPE)
• Pitch diameter (P.D. in mm)
• Number of closure elements (HEADS)
• Serial number (SERIAL N.)
• Manufacturing year (YEAR)
Fig. 1
The data plate is applied using 2 rivets at the opposite corners and should not be removed for whatever
reason.
In case of damage, ask for a spare copy to AROL S.p.A..
Clean with neutral detergents paying attention in order not to damage the warning instructions.
4
3 DECLARATION OF INCORPORATION
The closing machine of this manual is defined as "partly completed machinery" (according to the European
Directive 2006/42/EC art. 2 point g), and comes with the DECLARATION OF INCORPORATION.
The original copy of the DECLARATION OF INCORPORATION is kept at AROL S.p.A..
A compliant copy of the DECLARATION OF INCORPORATION is delivered together with the partly
completed machinery documents and must be kept till the machine is scrapped.
AROL S.p.A. points out that this statement only and exclusively concerns the above-described
partly completed machinery, in the conditions and utilisation processes it was placed on the
market, thus excluding any added components and/or operations carried out later on without any
authorisation by the manufacturer.
In particular, any possible modification or replacement of parts of the closing machine, like as,
for example modification to the software of programmable components, made without asking the
permission of AROL S.p.A., releases the manufacturer from any responsibility and may cancel the
validity of the Declaration of Conformity for the machine where this partly completed machinery is
integrated.
5
4 CLOSING MACHINE DESCRIPTION
The closing machine model EURO VA IES LIGHT has been designed and built for the application of:
• aluminium caps to threading and/or skirting on bottles/containers.
4.1 MAIN UNITS OF THE CLOSING MACHINE
Fig. 2
Legend:
• 1 Upper closure carousel.
• 2 Lower closure carousel.
• 3 Closure heads.
• 4 Chute for closure systems.
• 5 Closure system sorter.
6
The components forming the closing machine are located inside the main assemblies:
• Closure heads.
Fig. 3
• Closure heads driving spindle.
Fig. 4
• Height electrical adjustment of the closure
carousel.
Fig. 5
7
4.2 DESCRIPTION OF THE PRODUCTION CYCLE
The application and sealing of closure systems on the containers is the following:
• An orientation device selects the caps inside the

hopper.
Fig. 6
• The cap placed at about 45°, is taken, by a

system calle "pick off", from the container that is
coming during the rotation.
Fig. 7
8
• The closure head follows the profile of a cam and
will thread and seal the cap on the container by
the rotation of the threading and skirting rollers.
• After the closure, the exiting container is released,
then there is a reset for the following closure.
Fig. 8
9
4.3 CLOSING MACHINE TECHNICAL DATA
TECHNICAL SPECIFICATIONS
Model EURO VA IES LIGHT
Serial number 17579
Pitch diameter 288 mm.
Nr of heads 6
Direction of rotation counter-clockwise
Manufacturing year 2019
NOMINAL PRODUCTION
Pieces/hour 6000 bph
CLOSING MACHINE WEIGHT
Weight 680 kg.
ELECTRICAL DATA
POWER SUPPLY VOLTAGE:
220 V~
main
50 Hz
auxiliary 24 V=
Installed power:
closing machine lifting motor 0,37 kW
caps sorter motor 0,37 kW
Total installed power: 0,74 kW

PNEUMATIC DATA
Sterile air capacity 400 ca l/min (1 bar 20°C)
Sterile air min. pressure 6 bar
Sterile air max. pressure 8 bar
10
4.4 USE RESTRICTIONS
4.4.1 PRESCRIBED USE AND FORBIDDEN USES

The closing machine has been designed and made to apply closure systems (caps/corks) on preformed rigid
containers with production limits indicated in chapter 4.3 CLOSING MACHINE TECHNICAL DATA page
10.
The closing machine must be used to apply closure systems (caps/corks) on preshaped rigid container
already produced according to the order, planning and building stages, as described in the tables attached
to this manual.
The closing machine receives the closure systems correctly orientated by its orientation system.
Besides the conduction of the closing machine out of what underlined in the chapter 4.3 C L O S I N G
MACHINE TECHNICAL DATA page 10, just as an example and not limited to, the following uses are
forbidden and not expected:
• use of closure systems (caps/corks) and/or preshaped rigid containers whose specifications are different
to the ones described in the expected use.
• supply to the closure systems (caps/corks) and/or preshaped rigid hand containers or other means.
• revert the rotation direction of motors.
• tamper guards and/or protection devices.
• overlook the protection means using means to rise on the top or climb on parts of the closing machine.
• perform maintenance operations without insulating and locking all the energy sources and dissipating
the residual energies.
• do not comply with the specifications of power sources listed in the table page 10.
• Treat products with characteristics other than those communicated at the order, changing the
environmental conditions here the closing machine must be fitted (example: temperature of the treated
product; with environmental characteristics other than those communicated at the order).
4.4.2 OPERATING MODES

The closing machine cannot work autonomously.
The installation technician must thus install the closing machine under his own responsibility and according
to the European Community directives and take care that all requirements and specifications of the laws in
force are complied with.
11
4.4.3 NUMBER OF OPERATORS
The operations described in this manual, referring the cycle of life of the closing machine, have been
analysed by AROL S.p.A.. Therefore, the number of phases and operators indicated is the one most suitable
to carry out the functions in a optimal way.
4.4.4 PROFESSIONAL ROLES OF USERS

The closing machine User shall check that the operators have the following requierements:
• had red and understood the indications that are in the manual.
• had received job instruction and training appropriate to their tasks;
• have been properly trained about the correct use of the closing machine, about the residual risks, on the
closing machine controls and on the PPM.
Only the operators and the person charged with the maintenance with a suitable training can use the closing
machine.
The professional terms used are specified here below to understand the manual fully:
TERM DESCRIPTION
EMPLOYER Person legally responsible for the use of the closing machine described
herein.
OPERATOR Person charged with the standard closing machine operation.
MECHANICAL MAINTENANCE Person charged with the routine and extraordinary mechanical
OPERATORS maintenance of the closing machine.
ELECTRICAL MAINTENANCE Person charged with the routine and extraordinary electrical
OPERATORS maintenance of the closing machine.
4.4.4.1 OPERATOR
The Operator must have:
• familiarity with the use of the check system (operator interface), with capacity of checking the correlation
between the set data and the effect of these on the production;
• knowledge of the technology and specific experience in operating the closing machine acquired through
the basic training of this manual;
• base general knowledge and sufficient technical knowledge to read and understand the manual content
and the annexes, included the correct interpretation of the drawings.
• Sufficient technical knowledge to carry out intervention specified in the manual, in safe operation
condition.
• Knowledge of the accident-preventing norms.
▫▫ General Health and safety, prevention of the accidents on the work place.
▫▫ specification (for the type of product processed by the closing machine, according the laws in force
of the country in which the machine is installed).
12
Besides the conduction of the closing machine from the productive point of view the operator must:
• Know the operation of all the safety devices (for the operator and for the closing machine) so as to be
able to check their efficiency and signal any possible fault to the personnel in charge according to the
procedures described herein.
When the operator locates a failure that might compromise safety, he must stop the closing machine using
the emergency stop controls.
it is forbidden to esecute any intervention on the electic and/or pneumatic equipement.
4.4.4.2 MAINTENANCE MAN

The Maintenance Man (mechanical/electrical), besides the above characteristics, must also have a good
technical preparation and a suitable working experience in the relevant field. Further, he must have specific
and special (mechanical and electrical) technical knowledge needed for the operations described in this
manual.
4.4.5 EMPLOYER'S OBLIGATIONS

the employer shall guarantee appropriate training and information of all the professional roles of the closing
machine on the following topics:
• Instruction and specific procedures for use and maintenance of the closing machine.
• The user of the closing machine should comply with the safety and health prescriptions on the workplace,
in force in the premises where the closing machine is started; all the specific risk conditions should be
taken into account.
He must have acquired a good knowledge of the contents of this manual so that he can correctly process
the training procedures of the professional roles of the closing machine.
At the end of the training, the employer must make sure that operators and maintenance technicians have
understood the above points.
Assess the risks resulting from installing the closing machine in the workplace.
The employer must supply the PP (Personal Protection Means) required for all operations linked to the
useful life of the closing machine.
13
4.4.6 INFORMATION - JOB INSTRUCTIONS - TRAINING
4.4.6.1 INFORMATION - JOB INSTRUCTIONS

The employer shall inform and train the personnel charged to use the closing machine and make sure that:
• On the work place there are suitable information concerning dangers, risks and prevention and protection
solutions including the use of P.P.M., if provided.
• the workers the task of using of work equipment receive a suitable training accordingly.
• The workers the task of using of equipment requiring special knowledge and responsibility receive a
suitable and specific training, so that they can use such equipment safely and suitably, also as far as
risks caused to other people are concerned.
4.4.6.2 TRAINING
Training serves to explain the correct use of the closing machine, in compliance with the obligations
prescribed by national laws transposing 2009/104/EC directive concerning minimum safety and health
requirements for the use of working tools by the operators while working.
4.4.7 ARRANGEMENTS BY THE CUSTOMER

Excluding special contract conditions, the user must arrange the following:
• The closing machine must be electrically supplied by the electric board of the machine to which the
partly completed machinery is to be installed. The protection against indirect contact must be envisaged
during installation, according to point 6.3 of EN 60204-1.
• Compressed air mains connection.
• Generic tools for the closing machine maintenance and consumables.
• Lifting means suitable for the closing machine handling.
14
4.4.8 SIGNS FOR WARNING, OBLIGATION, PROHIBITION AND DANGER
SYMBOLS CONTAINED IN THE MANUAL
The graphic symbols inside the manual are described and shown here below.
GRAPHIC SYMBOL DESCRIPTION
It indicates a generic warning.
Pay utmost care to the text blocks marked by this symbol.
Indicates the danger of hot surfaces.
It refers to a warning about key function or useful information.
Notes, usage tips, or additional information
Part of the manual dedicated to the OPERATOR.
Part of the manual dedicated to the MECHANICAL MAINTENANCE OPERATOR.
Part of the manual dedicated to the ELECTRICAL MAINTENANCE OPERATOR.
Obligation to insulate all energy sources.

The symbol placed close to this description means that all the energy sources
must be insulated, dissipating the residual energies by the user, because this
involves the risk of an accident.
Mandatory use of PROTECTIVE GLOVES.
The presence of the symbol close to the descriptions informs that the operator
must wear safety gloves due to the risk of injury.
INSPECTION AND OPERATION
Visual inspection.

Inspection hearing.

Intervention with tools

Manual intervention.

Intervention of lubrication.
15
SYMBOLS ON THE CLOSING MACHINE
A set of pictograms describing procedures, obligations, cautions and prohibitions are arranged on the
closing machine to attract the operator's attention.
The warning and/or prohibition pictograms on the closing machine have an extremely important
safety function; the operators must follow the warning indications.
The pictograms of the closing machine cannot be removed.
Should the pictograms wear out occasionally and become illegible, or if they are removed, they
must be restored with new ones that must be asked to AROL S.p.A..
The pictograms on the closing machine are described and shown here below.
PICTOGRAM DESCRIPTION
Indicates the duty to see instruction manual before to operate on the
machine.
It indicates a generic warning.

Pay attention to the specific pictogram that accompanies it.
Instructs to unlock the handles holding the anti-torsion columns and

the central column fastening screw.
Means that the lubricant cartridge must be activated before starting

the machine.
16
The following figures indicate the pictograms on the closing machine and their position.
Fig. 9 Re-ordering code: GETIC0000061
Fig. 10 Re-ordering code: GETIC0000021
17
4.5 ENVIRONMENTAL LIMITS
4.5.1 ENVIRONMENTAL OPERATING RISKS

USE ENVIRONMENTAL CONDITIONS
The closing machine must work in premises protected by weather agents, with a temperature ranging
between 5°C and 40°C, a maximum relative humidity of 80% and height above sea level not over 2000 m.
LIGHTING
The closing machine can work with the standard lighting of the workplace (about 250 lux); local lighting of
areas concerned with maintenance is not required very often and must be performed with low voltage lights.
EXPLOSIVE ATMOSPHERE
It is strictly forbidden to operate the closing machine in an area with potentially explosive atmosphere, even
if only momentarily.
4.5.2 RESIDUES AND ENVIRONMENTAL CONTAMINATION

No toxic substance is released if the closing machine is used and maintained according to the instructions
herein.
The disposal of spent lubricants must respect the norms in force for environment protection in the country
of use.
18
5 SECURITY AND ACCIDENT PREVENTION
5.1 GENERAL INFORMATION
The employer will must provide for the training of the staff about dangers caused by accidents, about
equipments arranged for the operator safety, about dangers of noise emission and about the general
accident rules provided by international directives and by legislation of the country of designation of the
closing machine.
Anyway the behaviour of staff, maintenance operator, cleaning, control, etc. will must scrupulously respect
the accident norms of the country of designation of the closing machine.
Before starting the work, the operator must be thoroughly familiar with the location and
operation of all controls and characteristics of the closing machine must also have fully
read this manual.
The closing machine must be used only from operators that had received a training and understand
totally the instructions of this manual.
It is necessary to respect totally instructions, cautions, general accident rules that are in this
manual.
Before any maintenance and/or size change operation, the closing machine must be safety
conditions:
• insulate the closing machine from all energy sources dissipating residual energies.
• divide and lock all the cutting off devices;
• P
revent access to the closing machine to unskilled staff, not charged with maintenance
operations, using suitable signs.
19
5.2 RISKS - PROTECTIONS - CAUTIONS AND PRECAUTIONS
5.2.1 SAFETY DEVICES OF THE CLOSING MACHINE

To guarantee health and safety of the people exposed, the closing machine is provided with this safeties:
FIXED GUARDS
All the fixed guards installed on the closing machine are connected to the structure by means of fastening
devices which do not allow manual removal, since they necessarily require the use of specific tools.
It is forbidden to use the closing machine after having disassembled the fixed guards; operation can resume
after the reassembly of guards.
The housing of the fixed guards in vertical position in the structure of the closing machine has been designed
so that the guards, once the fastening devices have been removed, do not remain in closed position, falling
by gravity.
To access the area protected by the guard, the closing machine must be insulated from all
power sources. (See sub-chapter 5.4 SAFETY PROCEDURES FOR THE MAINTENANCE
page 22).
5.2.1.1 POSITION OF THE SAFETIES

FIXED GUARDS
• Head protection guard.
Fig. 11
20
5.3 SAFETY PROCEDURES FOR THE OPERATION
Wrenches and tools used for the maintenance or the access to closing machine hazardous
sections must not be left at the disposal of operators not suitably trained for the size change
or the maintenance.
All check, adjustment, maintenance and lubrication steps must be carried out by staff previously
trained and instructed.
All check, adjustment and maintenance steps of the electric system must be carried out by staff
previously trained and instructed.
People on drugs, alcohol or drowsiness-causing medicines are not allowed to use or maintain the
machine.
All check, adjustment, maintenance and lubrication steps must be carried out with the closing
machine stopped and separated and split electric power supply.
The cap/cork feeding system has been designed and manufactured to be loaded by an automatic
elevator with ground loading.
If the cork/cap loading is manual, it should be performed leaving the closing machine at a standstill,
with separated and split electric power supply.
Before accessing the top of the machine, separate and split the energy sources and
dissipate the residual energies.
Access at any height must occur using certified means according to the norm UNI EN ISO 14122.
21
5.4 SAFETY PROCEDURES FOR THE MAINTENANCE
BEFORE CARRYING OUT ANY MAINTENANCE OPERATIONS, the closing machine must be
in safety conditions to avoid untimely screwing and/or electrocution.
It is therefore compulsory to insulate all energy sources dissipating residual energies.
The insulation for power sources must be charged to qualified technicians and be performed as follows:
• PNEUMATIC ENERGY - the pneumatic disconnecting switch must be set to discharge position, then
locked in this position by a lock - not supplied - to be fit in the suitable slots of the disconnecting switch.
The lock key must be removed and kept by the responsible maintenance technician who is
performing maintenance, for the whole intervention.
Wrenches and tools used for the maintenance or the access to closing machine hazardous
sections must not be left at the disposal of operators not suitably trained for the size change
or the maintenance.
After the maintenance works and before starting the closing machine again it is always necessary to:
• check that the possibly replaced parts and/or used tools have been removed from the closing machine.
• check that all guards, protections and safety devices possibly removed during the intervention have
been re-installed correctly and are operating.
Replace the electrical safety components within their life cycle, approximately 20 years.
The standard operating conditions will be restored only after the intervention and the checks.
22
5.4.1 GENERAL SAFETY WARNINGS
The safety for the closing machine and the operators also depends on a regular maintenance according to
the manufacturer's indications.
The routine and extraordinary maintenance interventions must be exclusively charged to skilled staff, that
is to technicians qualified according to the specifications in this manual.
If outsourced operators intervene, they must ensure the same performance of the inhouse qualified
technicians and must work in safe operating conditions.
The access to high levels is allowed only after separating and disconnecting any residual energy and using
means certified according to UNI EN ISO 14122 standard.
The qualified technicians must:
• respects the limits of their tasks (mechanical, electrical, etc.).
• Follow the procedures and warnings in the manual, within their tasks.
• Follow the times and intervals indicated in the manual for scheduled maintenance interventions.
The following general warnings must be noted:
• Electrocution hazard due to direct contact with the closing machine power supply terminal boards and
in the electrical system connector blocks (the hazard is signalled by plates with the suitable triangle with
yellow bottom).
• Be extremely careful during the interventions on the electrical system, if the system must be left live.
Such interventions must be carried out by staff skilled in this type of maintenance only, trained and
correctly equipped for the steps to be made. The intervention with live system must always be authorized
in advance by the employer who must oversee its operations by assessing the specific risk situations.
• Carry out maintenance operations on pneumatic systems and components only after cutting off and
separating the electric power and pneumatic sources and checking that the residual pressures have
been relieved.
• It is forbidden to carry out maintenance and lubrication interventions on moving components.
• While working on heated parts, the operator must always wait until they cool to a temperature below
55°C to prevent serious burns.
5.5 RESIDUAL RISKS

The residual risks are shown in Annex VII B of the European Directive 2006/42/EC about "Technical
documentation for partly completed machinery".
23
6 HOW TO ASK FOR INTERVENTIONS
AROL S.p.A. puts its own Technical Service at the disposal of its customers to solve any problem regarding
the machine use and maintenance.
The interventions must be required after carefully evaluating the faults and their reasons, and stating:
• The details on the occurred faults.
• The performed checks.
• The performed adjustments and resulting effects.
• Any further information deemed useful.
7 HOW TO ORDER SPARE PARTS

All orders for spare parts must be sent to AROL S.p.A..
The installation of not original spare parts will invalidate the warranty.
To order spare parts, fill in the suitable form in the “SPARE PART CATALOGUE” for the machine.
The replacement of safety devices must be performed with the same components. The 2006/42/
EC directive provides that the components supplied by the machine genuine manufacturer do not
need the Declaration of Conformity. Vice versa for all components purchased on the market, the
Declaration of Conformity is required, along with the control that the replacement component has
the same features and performance of the replaced one. Unsuitable components might cause
the decay of the safety performance expected by AROL S.p.A.. It is therefore recommended to
contact AROL S.p.A..
24
8 INSTALLATION AND CONNECTIONS
8.1 INSTALLATION OF THE CAPS CHUTE WITH “PICK-OFF” CAP
DISTRIBUTION
To install the caps chute on the machine it is necessary:

• Loosen the threaded fasteners located on the
support chute.
Fig. 12
Fig. 13
25
• Insert the head height adjustment pin into the
hole of the chute support and lift the complete
caps chute.
Fig. 14
• Place the caps chute so that the fixing brackets

are positioned on threaded fasteners.
• Lock threaded fasteners located on the support
chute.
Fig. 15
• Lock the threaded fixing system of the caps

distribution head.
Fig. 16
26
• Connect the electrical connection of the caps
presence photocell (one or more).
Fig. 17
27
8.2 INSTALLATION OF THE "FLAT" CENTRIFUGAL CAPS SORTER
For the installation of the centrifugal caps sorter see the listed below operations:
• Lift and extract the hopper lid.
Fig. 18
• Unscrew and remove the central screw locking

cone.
Fig. 19
28
• Slide out the central cone.
Fig. 20
• Screw at the center of the rotating disc an M8

eyebolt
Fig. 21
• Hook with a belt or a chain with hooks to the M8

eyebolt.
Fig. 22
29
• Unscrew the bolts that fasten the caps sorter to
the transport platform.
• Lift the caps sorter with adequate lifting means.

The caps sorter mass is not
symmetrically distributed so it
overturns when lifted up. Do not stand
or walk under the caps sorter when it is
hoisted!
• Position the caps sorter complete with the support

in such way that the references on the support
and the references of the flange are aligned and
that the exit mouth is aligned with the caps chute.
• Fix the caps sorter by bolts.
Fig. 23
• Unhook the belt or the chain with hooks from the

eyebolt.
Fig. 24
30
• Remove the eyebolt.
Fig. 25
• Remount the central cone and fix it with the

screw.
Fig. 26
• Place and fasten the caps cover on the caps

sorter proceeding as described below:
▫▫ Lean the complete caps sorter cover on the
support pins set on the hopper in such way
the hole for the caps level device is in the
opposite of the caps exit mouth.
Fig. 27
31
chute.
Fig. 28
• Place the caps level device on the caps sorter

proceeding as described below:
▫▫ Place the level blade in the hole of the cover
and the rod fixing bush on the hopper.
Fig. 29
▫▫ Fasten all things locking the screw against

the hopper.
Fig. 30
32
8.3 PNEUMATIC CONNECTION
Before operating on the closing machine, insulate all the energy sources and dissipate the
residual energies.
The air used in the pneumatic installation must be filtered, so without impurities, and dried.
For pneumatic data see the table page 10.

Connect with the mains as follows:
• install the air treatment unit on the machine
that incorporates the closing machine, in an
accessible area.
Fig. 31
33
• Connect the flow rate pipe coming from the
air treatment unit to the pneumatic unit main
coupling on the closisng machine.
Fig. 32
• Connect the flow rate pipe coming from the air

treatment unit to the caps sorter unit.
• Enable the sectioning device to allow air to flow
in.
Fig. 33
34
9 CLOSING MACHINE USE
9.1 SETTING UP, CHECKS AND TEST FOR THE FIRST START UP
The setting up operations of the closing machine for the first start up must be carried out
by qualified technicians.
The closing machine has been tested by AROL S.p.A. premises before the shipping; all the calibration and
required adjustments have been carried out during the test.
Before carry out operations on the closing machine, it is necessary to install and activate the lubricant
cartridge, proceeding as described in sub-chapter 11.4.6.2 CARTRIDGE REPLACEMENT
page 123.
9.1.1 CHECKS BEFORE THE START UP
In order to prevent errors and/or accidents, before the start up of the closing machine it is necessary
to carry out some checks:
• Check the sequence of the motor supply phases.

• Check that there are no leaks from the pneumatic circuit.
35
9.2 PRELIMINARY CHECKS BEFORE STARTING
Before starting the closing machine up, check the following:

• Check that all other safety devices installed on the closing machine are operating properly. (See also
sub-chapter 5.2.1 SAFETY DEVICES OF THE CLOSING MACHINE page 20.
• Check all closing machine components are lubricated (See Chapter 11.4 LUBRICATION page
115).
• Make sure the specific installed equipment are suitable for the size to be processed.
• Check the correspondence between container and cork to be treated.
Each set of equipment is marked as indicated in the relevant tables enclosed in this manual.
Each mark corresponds to a size to be processed.
• Check the height of the closure carousel according to the container height.
• Check the caps sorter is sufficiently full.
• Check that the working pressure is correct (the pressure is indicated on the pressure gauges).
36
9.3 PREPARATION FOR STARTING
9.3.1 CLOSING MACHINE HEIGHT ADJUSTMENT FOR "PICK OFF"

DISTRIBUTION CAPS
The height must be adjusted exclusively by lowering the closure carousel. Before operating, take
the closure carousel at a height higher than the one of the bottle to be processed.
For the adjustment and check, operate as described here below:

• Release the handles fastening the anti-torsion
columns.
Fig. 34
Fig. 35
37
• Release the screw locking the central column.
Fig. 36
• Loosen the fixing knob and lower the reference

bracket.
Fig. 37
Fig. 38
38
• Lift the closure carousel using the control till
passing the height of the bottle to be processed.
• Insert a bottle to be closed under the caps
distribution head.
Fig. 39
• Lower the closure carousel until the reference

bracket lays on the bottle neck.
Fig. 40
39
• Loosen the fixing knob and turn upwards the
reference bracket in such way it is not causing
obstruction.
Fig. 41
• Lock the handles of the anti-torsion columns.
Fig. 42
• Lock the fixing screw of the central column.

• Close interlocked mobile guards and restore the
operation of the safety circuit.
Fig. 43
40
9.3.2 CAPS SORTER LOADING
On the caps sorter is installed a caps level sensor

having the task to signal to the automatic elevator
when it is necessary to put a new quantity of caps.
Fig. 44
For correct operation, the device levelling rod must
be adjusted so that it is about 5 mm above the height
of an only layer of caps.
Fig. 45
For this adjustment, loosen the grub screw on the
levelling rod bush.
Fig. 46
41
The levelling rod must be positioned so that there
is a distance of one cap between it and the hopper
ring.
Fig. 47
For this adjustment, loosen the fixing screw on the

rod fixing bush.
Fig. 48
For correct operation of the device, with

empty orientator the sensor must be
oriented so as to be in the center of the
levelling rod.
Fig. 49
42
9.4 EMPTYING OF THE CAPS DISTRIBUTION SYSTEM
9.4.1 CAPS SORTER EMPTYING
To discharge the caps sorter it is necessary to rotate it till totally empty.
43
9.4.2 CAPS CHUTE DISCHARGE
To discharge the caps chute, operate as follows:

• Insert a collection container under the caps
distribution head.
• Remove the cap taking head spring.
Fig. 50
Fig. 51
• Rotate externally the caps stopping hammers so
as to allow the discharge of the caps.
• If necessary, empty the cap sorter.
• Empty the cap chute.
• Restore the position of the caps stopping
hammers.
• Mount the head taking cap springs on the spring
hooking pins.
Fig. 52
44
9.5 DISCONNECTION OF THE MOTION TRASMISSION

Before operating on the closing
machine, insulate all the energy sources
and dissipate the residual energies.
A manual device is installed on the closing machine

to engage/release the rotating motion transmission
to the same machine.
Fig. 53
To disconnect the closing machine from the work
cycle, proceed as follows:
• Lower the disconnection joint pin until to let it go
out from the seat of the disconnection joint bush
Fig. 54
• Turn the disconnection joint pin of 180° in such
way it enters into the rest seat of the disconnection
joint bush.
Fig. 55
45
To connect the closing machine to the work cycle,
proceed as follows:
• Lower the disconnection joint pin until to let it go
out from the rest seat of the disconnection joint
bush
Fig. 56
• Turn the disconnection joint pin of 180° in such

way it enters into the dragging seat of the
disconnection joint bush
Fig. 57
• Operate the closing machine in manual jog

by pressing the external JOG button until the
disconnection pin is inserted in the gear holder
bush.
Fig. 58
46
9.6 CLOSING MACHINE CLEANING
The determination of the frequency of cleaning operations during the closing machine continuous
use is to be checked by the user, depending on the environment is being operated.

The following subchapter describes the cleaning intervals of the closing machine and its
components, when considering their use in a clean industrial production area.
9.6.1 CLOSING MACHINE CLEANING INTERVALS

The following table shows the cleaning intervals of the closing machine, expressed in hours.
Cleaning Work shift (hours)
1 shift 2 shifts 3 shifts
Closing machine external washing. 8 16 40
See sub-chapter 9.6.2 EXTERNAL WASHING OF
THE CLOSING MACHINE page 48.
Closure head washing. 8 16 40
After having washed the closure heads,

proceed with lubrication as shown in the sub-chapter
11.4.7 LUBRICATION OF THE CLOSURE HEAD on
page 124.
Cork/cap sorter cleaning. 120 120 120
47
9.6.2 EXTERNAL WASHING OF THE CLOSING MACHINE
The description below concerns: cleaning areas, cleaning systems and specifications, products allowed for
cleaning the closing machine and its components.
Legend:
• 1 Closure system direction area
• 2 Upper area of the closure carousel
The direction of the jet coming

from cleaning system must be
directed downwards. Do not
direct air jet towards area "1".
• 3 Closure area
• 4 Bottle-guide and conveying area
Fig. 59
CLEANING SYMBOL MAX PRESSURE OF DISTANCE FROM WASHING SYSTEM
THE CLEANING THE SURFACE TILTING
[bar] [mm] [°]
fixed squirting nozzles ≤ 5 ≥ 250
or spray balls
cloth - - -
washing lance ≤ 20 ≥ 500
48
PRODUCT ZONE 3 - 4 CONCENTRATION MAX. TEMP. (°C) pH
Alkaline solutions of hydroxide sodium 1 ÷ 2 [%] 35 12 ÷ 13

(NaOH) and/or potassium (KOH)
Acid detergents containing nitric acid 1 ÷ 2 [%] 35 1÷2
(HNO3)
Acid detergents containing phosphoric 1 ÷ 2 [%] 35 1÷2
acid (H3PO4)
Disinfectant non chlorinated (Aldehyde, 1 ÷ 2 [%] 35 2÷6
quaternary ammonium)
PRODUCT ZONE 1 - 2 MAX. TEMP. (°C) pH

Water 35
Neutral detergents 35 5÷9
Before starting production, the closing machine should be suitably rinsed, to remove all the
detergents used, then dried up.
Make sure the the upper flange of the closure carousel is correctly dried.
It is absolutely forbidden to clean the closing machine with:

• steam.
Before carrying out cleaning, you should refer to the product data sheets relating to detergents.
IMPORTANT : AROL S.p.A. supplies instructions for washing in order to clean the parts are
remove coarse grease stains, powder and scale. On the other hand, it does not guarantee the
hygiene of the surfaces, which must be checked by the user depending on the type of treated
products, pollutants and disinfection, sanitisation or sterilisation procedures.
Detergents residuals or residuals of liquids used for the cleaning of the closing machine
must be disposed according the laws in force of the country in which it is used.
49
9.6.2.1 AUTOCLAVE CLOSURE HEADS STERILIZATION
The closure heads thanks to their specific materials, following the instructions listed below, can be subjected
to a sterilization process in autoclave.
The frequency of the sterilization in autoclave depends on the specifications and needs of the bottling
process and must be determined by the user according to his target and experiences. AROL S.p.A. suggests,
anyway, that closure heads in bottling lines of sensitive products must be subjected to a sterilization process
at least every time one proceeds to their maintenance, manipulation or after a long inactivity period.
AROL S.p.A. suggest that these procedures must be stricter by the increasing the frequency of the
sterilization cycles, considering some conditions linked to the context and specific needs or targets that only
the costumer can define.
9.6.2.2 CLOSURE HEADS STERILIZATION PROCEDURE

To carry out a sterilization cycle, it is necessary:
• Carry out the ordinary maintenance and closure heads components lubrication.
• Insert the closure heads previously cleaned, into the fitting sacks.
• Close and hermetically seal the sack containing the cleaned closure head.
• Position the closure head into the autoclave.
• Close the autoclave door.
• Carry out a 20 minutes duration sterilization cycle having a pressure of 1 bar and a temperature of 121
°C.
• After the sterilization cycle, remove the closure head from the autoclave.
The closure head must be removed from the sack ONLY in a sterile environment.
Remove the envelope bag. Install the closure head on the closing machine.
50
10 SIZE CHANGE
residual energies.
The closing machine has been designed to handle containers and caps / corks as indicated in the
relevant tables enclosed in this manual.
Every container and/or cap must be processed exclusively with the equipment there indicated.
Each series of equipment is marked according to the size to be processed:

• The cap guide equipment, in case of multiple sizes, are marked with an identification initials.
In order to run properly and without obstructions the format change operations, it is necessary to
raise the closing turntable at its maximum height.
51
10.6.1 CENTRAL STAR-WHEEL
10.6.1.1 REMOVAL
To remove proceed in the following way:
• Make the closing machine rotate in manual jog
until a semi star-wheel is totally in the the closure
carousel rear part.
Fig. 60
• Unscrew and remove the fixing bolt.
Fig. 61
• Slide the star-wheel out removing it from the
centering pins
Fig. 62
52
• Make the closing machine rotate in manual jog
until the second semi star-wheel is totally in the
the closure carousel rear part
• Unscrew and remove the fixing bolt.
• Slide the star-wheel out removing it from the
centering pins
Fig. 63
10.6.1.2 INSTALLATION
For installation proceed as follows:
• Position the half star-wheel on the centering pins.
Fig. 64
• Fasten the half star-wheel by fixing bolt.
Fig. 65
53
If it is necessary to adjust the height of
the star-wheel, loosen the locking grub
screw and adjust the height of the star-
wheel holder ring. When the adjustment is
completed, lock the locking grub screw
Fig. 66
54
10.7 CAP SIZE CHANGE
Having to change the format of the caps to be

treated, you must:
• replace the closure heads. (See sub-chapter
10.7.1 REMOVAL AND INSTALLATION OF
THE CLOSURE HEADS page 56).
Fig. 67
• Replace the caps distribution group, if provided.
(See sub-chapter 10.7.2 "PICK OFF" CAPS
CHUTE page 60).
Fig. 68
• Replace the caps selection units, if provided.
(See sub-chapter 10.7.3 CAPS SELECTION
EQUIPMENT FOR CENTRIFUGAL CAPS
SORTER page 65).
Fig. 69
55
10.7.1 REMOVAL AND INSTALLATION OF THE CLOSURE HEADS
The table below shows the dedicated tools for disassembly and assembly of the closure head.
TOOLS
Head mounting wrench
Removing threaded ring wrench
Installation threaded ring wrench
Do not use tools that transfer shocks to the closure head.
10.7.1.1 REMOVAL OF SSD HEAD

To remove the closure head from the spindle, proceed as follows:
• Insert the removing threaded ring wrench in the
head fixing threaded ring seats.
• Unscrew the head fastening threaded ring with
the removing threaded ring wrench till releasing
the closure head.
Fig. 70
56
• Insert the head mounting wrench in the seats of
the closure head.
• Untighten the closure head with the head
mounting wrench and remove it.
Fig. 71
Fig. 72
57
10.7.1.2 INSTALLATION OF SSD HEAD
To install the closure head on the spindle, proceed
as follows:
• Insert the closure head on the spindle.
Fig. 73
• Screw the head on the spindle, manually as far
as possible.
Fig. 74
58
• Insert the head mounting wrench in the seats of
the closure head.
• With the head mounting wrench complete the
screw to the bottom of the thread.
Fig. 75
• Insert the installation threaded ring wrench in the

head fixing threaded ring seats.
• Tighten the head fixing threaded ring with the
threaded ring installation wrench.
Fig. 76
59
10.7.2 "PICK OFF" CAPS CHUTE
10.7.2.1 REMOVAL OF THE CAPS
CHUTE WITH “PICK-OFF” CAP
DISTRIBUTION
Remove the caps chute in the following way:
• Disconnect the electrical connection from the
caps presence photocell (one or more).
Fig. 77
support chute.
Fig. 78
Fig. 79
60
• Loosen the threaded fastening placed on the
caps sorter
Fig. 80
• Lift the complete caps chute, so as to extract it

from fixing systems.
• Successively lower the caps chute so that the
head height adjustment pin come out from the
hole of the chute support, then remove the chute.
Fig. 81
61
10.7.2.2 INSTALLATION OF THE CAPS CHUTE WITH “PICK-OFF” CAP
DISTRIBUTION
To install the caps chute on the machine it is
necessary:
support chute.
Fig. 82
Fig. 83
• Insert the head height adjustment pin into the
hole of the chute support and lift the complete
caps chute.
Fig. 84
62
• Place the caps chute so that the fixing brackets
are positioned on threaded fasteners.
chute.
Fig. 85

distribution head.
Fig. 86

distribution head.
Fig. 87
63
• Connect the electrical connection of the caps
presence photocell (one or more).
Fig. 88
• If necessary, adjust the height of the caps upper

guide:
▫▫ loosen the screw of the clamp.
▫▫ Align the caps upper guide with the guide of
the caps distribution head.
▫▫ Lock the screw of the clamp.
When necessary, the height relative to the

size of cap to be treated, is engraved on
the rod of the guide itself. The engrave
should be aligned with the upper side of
the clamp.
Fig. 89
64
10.7.3 CAPS SELECTION EQUIPMENT FOR CENTRIFUGAL CAPS SORTER
residual energies.
10.7.3.1 CAPS EXIT MOUTH
10.7.3.1.1 REMOVAL
To remove proceed as follows:
• disconnect the pneumatic connections from the
caps exit-mouth.
Fig. 90
• Unscrew and remove the fixing systems of the

caps exit mouth.
Fig. 91
65
• Remove the whole caps exit-mouth.
Fig. 92
10.7.3.1.2 INSTALLATION
To install proceed as follows:
• Position the exit mouth and fasten it into the
holes by the suitable fastening systems
Fig. 93
• Connect the pneumatic connections to the caps

exit-mouth.
Fig. 94
66
10.7.3.2 ADJUSTMENT OF THE CAPS SORTER FOR SIZE CHANGE
• If varies the height of the cap to be treated must

be adjust the height of the inner hopper ring in
the following way:
▫▫ loosen the screws located on the outer
perimeter of the hopper.
Fig. 95
▫▫ Adjust the height of the hopper ring in such a
way between the new cap to be treated and
the ring there is a clearance of about 3 mm.
• Tighten the screws previously loosened.
Fig. 96
• On the caps sorter there is a door that allows,
thanks to the centrifugal force, the ejection of
caps without seaming and seaming on them.
• If varies the height of the cap to be treated must
adjust the height of the adjustable door in the
following way:
▫▫ loosen the fixing knobs.
Fig. 97
67
▫▫ Adjust the height of the adjustable door
so that they can be expelled only the caps
without seal.
▫▫ After adjustment, tighten the fixing knobs.
Fig. 98
If the cap is not correctly shifted by the nozzles it is

sufficient to increase or decrease the air pressure by
the fitting pressure reducers.
Fig. 99
68
10.8 ADJUSTMENTS OF THE CLOSURE HEAD
10.8.1 "SSD" CLOSURE HEAD

The table below shows the necessary tools for adjustment of the closure head.
TOOLS
Springs adjustment wrench
Rollers height adjustment wrench
Adjustment pad
10.8.1.1 CLOSURE HEAD PREPARATION

Proceed as follows:
• Insert the the closure head supporting equipment

into a jaw.
Fig. 100
69
Before working, measure and make a note
of the distance between the adjustment
bush and the head holder flange.
Fig. 101
• Loosen the bush fixing nuts with the spring

adjustment hexagonal wrench.
Fig. 102
70
• Completely unscrew the adjustment bushes with
the spring adjustment hexagonal wrench.
Fig. 103
Fig. 104
71
• Hold the spring guide tie-rods with a 10 mm
hexagonal wrench and loosen the tie-rod
fastening nuts with a springs adjustment wrench.
Fig. 105
• Completely unscrew the spring guide tie-rods

with a 10 mm hexagonal wrench.
Fig. 106
• Slide out the spring guide tie-rods and tie-rod

locking nuts.
Fig. 107
72
• Remove the compensating springs, tie rod
locking nuts and springs supporting washers.
Fig. 108
• Screw the closure head on the sleeve of the

supporting equipment.
Fig. 109
73
• Unscrew the centering device fixing screws with
a 3 mm Allen wrench.
Fig. 110
Fig. 111
• Remove the centering device.
Fig. 112
74
• Unscrew the centering device's support columns
with a 10 mm exagonal wrench, and remove the
centering device's support columns.
Fig. 113
75
10.8.1.2 ADJUSTING THE THREADING ROLLER
For the adjustment of the threading roller, proceed in the following way:
• Insert the specific adjuster pad, indicated in
the "CLOSURE HEAD CALIBRATION TABLE"
enclosed in this manual, on the bottle mouth-
presser.
Fig. 114
• Loosen the fixing grub screws with a 3 mm Allen

wrench, in order to free the threading roller bush.
Fig. 115
76
• Screw or unscrew the threading roller bush with
the rollers height adjustment wrench, in order
to bring the threading roller to the height of the
adjuster pad surface.
• For a further delicate adjustment, when provided,
it is necessary to screw or unscrew the threading
roller bush of n°/6 of angle as described in
"CLOSURE HEAD CALIBRATION TABLE"
enclosed in this manual.
EXAMPLE:
Towards pressure block Towards centering
device
1/6 3/6
▫▫ Towards pressure block: screw the threading

roller bush in such way to move the roller
Fig. 116
towards the mouth-presser.
▫▫ Towards centering device: unscrew the
threading roller bush in such way to move the
roller towards the centering device.
▫▫ Each 1/6 equals to 60° of rotation. To make
easy the operation use as reference of rotation
the 6 faces of the nut into the threading roller
bush.
f in the table the movement towards the

mouth-presser and centering device are
not indicated, it means that the adjustment
must be carried out with the adjustmend
pad.
• After adjustment, secure the fixing grub screws

with a 3 mm Allen wrench.
Fig. 117
• Insert a 3 mm Allen screw wrench in the seat of

the fixing grub screw.
Fig. 118
77
• Insert the 10 mm hexagonal wrench on the
locking nut.
• Holding a 3 mm Allen wrench, loosen the locking
nut with a 10 mm hexagonal wrench.
Fig. 119
• Move the roller support arms in a closed position

by pushing the head downward.
Fig. 120
• Screw or unscrew the locking grub screw with

a 3 mm Allen wrench, until the threading roller
touches the pad diameter.
• Repeat the above steps also for all the threading
rollers.
Fig. 121
78
• Make the pad rotate on the mouth-presser,
during the pad rotation the threading rollers must
turn freely too.
Fig. 122
• Fasten the blocking nut with a 10 mm exagonal

wrench, making sure that the grub screw does
not move.
Fig. 123
• Repeat the same operation for the remaining

threading arms.
• Remove the pad used for the adjustmnent.
• Free the arms driving cam putting it in rest
position (the rollers holder arms widen).
Fig. 124
79
• Insert a 3 mm Allen screw wrench into the seat of
the spring holder bush
Fig. 125

locking nut.
• Holding a 3 mm Allen screw, loosen the locking
nut with a 19 mm hexagonal screw.
Fig. 126
• Using a dynamometer measure the side

pressure strenght of the threading rollers. The
measurement must takes place when threading
arm moves.
Fig. 127
80
If the carried out measurement is different
from the one indicated in "CLOSURE
HEAD CALIBRATION TABLE" enclosed in
this manual, it is necessary to carry out as
follows:
• Screw the spring holder bush with a 3 mm Allen

wrench to increase the side pressure.
• Unscrew the spring holder bush with a 3 mm
Allen wrench to decrease the side pressure.
Fig. 128
• Keeping a 3 mm Allen wrench still, screw the

locking nut with the 19 mm hexagonal wrench.
threading arms.
Fig. 129
81
10.8.1.3 ADJUSTING THE SKIRTING ROLLER
For the adjustment of the skirting roller, proceed in the following way:
• Insert the specific adjuster pad, indicated in
the "CLOSURE HEAD CALIBRATION TABLE"
enclosed in this manual, on the bottle mouth-
presser.
Fig. 130
• Loosen the fixing grub screws with a 3 mm Allen

wrench, in order to free the skirting roller bush.
Fig. 131
82
• Screw or unscrew the skirting roller bush with
the rollers height adjustment wrench, in order
to bring the skirting roller to the height of the
adjuster pad surface.
• For a further delicate adjustment, when provided,
it is necessary to screw or unscrew the skirting
roller bush of n°/6 of angle as described in
"CLOSURE HEAD CALIBRATION TABLE"
enclosed in this manual.
EXAMPLE:
Towards pressure block Towards centering
device
1/6 3/6
▫▫ Towards pressure block: screw the skirting

roller bush in such way to move the roller
Fig. 132
towards the mouth-presser.
▫▫ Towards centering device: unscrew the
skirting roller bush in such way to move the
roller towards the centering device.
▫▫ Each 1/6 equals to 60° of rotation. To make
easy the operation use as reference of
rotation the 6 faces of the nut into the skirting
roller bush.
f in the table the movement towards the

mouth-presser and centering device are
not indicated, it means that the adjustment
must be carried out with the adjustmend
pad.
• After adjustment, secure the fixing grub screws

with a 3 mm Allen wrench.
Fig. 133
• Insert a 3 mm Allen screw wrench in the seat of

the fixing grub screw.
Fig. 134
83
locking nut.
• Holding a 3 mm Allen wrench, loosen the locking
nut with a 10 mm hexagonal wrench.
Fig. 135
• Move the roller support arms in a closed position

by pushing the head downward.
Fig. 136
• Screw or unscrew the locking grub screw with a 3

mm Allen wrench, until the skirting roller touches
the pad diameter.
• Repeat the above steps also for all the skirting
rollers.
Fig. 137
84
• Make the pad rotate on the mouth holder, during
the pad rotation the skirting rollers must turn
freely too.
Fig. 138
• Fasten the blocking nut with a 10 mm exagonal

wrench, making sure that the grub screw does
not move.
Fig. 139

skirting arms.
• Free the arms driving cam putting it in rest
position (the rollers holder arms widen).
Fig. 140
85
Fig. 141

locking nut.
Fig. 142
• Using a dynamometer measure the side pressure

strenght of the skirting rollers. The measurement
must takes place when threading arm moves.
Fig. 143
86
If the carried out measurement is different
from the one indicated in "CLOSURE
HEAD CALIBRATION TABLE" enclosed in
this manual, it is necessary to carry out as
follows:
• Screw the spring holder bush with a 3 mm Allen

wrench to increase the side pressure.
• Unscrew the spring holder bush with a 3 mm
Allen wrench to decrease the side pressure.
Fig. 144

skirting arms.
Fig. 145
87
11 MAINTENANCE OF THE CLOSING MACHINE
11.1 MAINTENANCE GENERAL INFORMATION
11.1.1 MAINTENANCE SCHEDULE

From the constructive point of view, interventions concern mechanical, electrical and pneumatic parts.
The envisaged operations are grouped according to work time intervals. Each intervention or group of
interventions can concern about mechanical, electrical and pneumatic aspects.
The ordinary maintenance is divided in two categories:
• scheduled ordinary maintenance (or preventive).
• Maintenance according to the conditions (caused by wear and tear).
The scheduled ordinary maintenance (so called periodical or preventive) includes inspections, checks and
interventions that, to prevent stops and faults, keep under control:
• the lubrication state of the closing machine.
• The state of parts that can be affected by wear and tear.
The maintenance according to special conditions recommends a regular inspection of components, to
check their conditions and perform the maintenance only if it is required.
11.1.2 MAINTENANCE INTERVALS
The following tables show the maintenance deadlines and the operations needed for a correct operation
and long life of the closing machine.
The interventions described below have been arranged at intervals of time expressed in hours.
Interval Working in Working in Working in
(hours) 1 shift 2 shifts 3 shifts
8 - - -
40 1 week - -
120 3 weeks - 1 week
250 6 weeks 3 weeks 2 weeks
500 3 months 6 weeks 1 month
1000 6 months 3 months 2 months
3000 12 months 9 months 6 months
6000* * * 12 months
(*) every 6000 hours or anyway once a year.
88
11.1.3 GENERAL INDICATIONS ON THE SCHEDULED MAINTENANCE PLAN
A logbook of the scheduled maintenance and lubrication interventions must be arranged according to the
maintenance indications in the sub-chapters below and to the closing machine working conditions.
Example:
MAINTENANCE SCHEDULED AT 1000 HOURS
INTERVENTION DATE MAINTENANCE SIGNATURE INTERVENTION NOTES
MAN RESULT
Check of the height sliding of XX/XX/XX Mario Rossi positive
the closure carousel.
Control gear lubrication XX/XX/XX Mario Rossi lubricated
11.2 MAINTENANCE AND LUBRICATION PLANNING
Interval Intervention type

40 hours Ordinary maintenance
120 hours lubrification
Ordinary maintenance
89
11.3 SCHEDULED MAINTENANCE
11.3.1 ROUTINE MAINTENANCE
11.3.1.1 EVERY 40 WORKING HOURS

OPERATION AIM NOTES
Pneumatic system check. Check the air supply pressure to the
various utilization points.
Check by the gauges, that the pressure
reducers are adjusted at the work
pressure (the pressure is indicated on the
pressure gauges)
Drain the possible condensate collected
under the discharge filter.
Checking the filter clogging. If necessary,
replace it.

OPERATION AIM NOTES
Heads rollers check. Check the perfect rotation of the skirting
and threading rolles (they must turn
freely).
Check of the closure head Check the efficiency of the springs in

rollers springs. general and replace them if necessary.
90
OPERATION AIM NOTES
Closure heads check. Check the state of wear of springs and if it See sub-chapter 11.3.3
is necessary, replace them. MAINTENANCE OF THE
CLOSURE HEAD page 95.
Check the state of wear of rollers and
mouth-presser and if it is necessary
replace them.
Check of the springs of the Check the state of wear of springs of pick
pick off device. off. If worn or damaged, replace them.
Check of the height sliding of Check the correct vertical sliding, making
the closure carousel. the closure carousel slide from the min. to
the max. value, so as to ensure a correct
component sliding in time.
Equipment timing check. Check the timing of the whole equipment See sub-chapter 11.5.3
and, if necessary, re-time it. TRANSPORT EQUIPMENT
TIMING page 131.
Electric connection check. Carefully check all the connectors and

connection cables and if necessary
replace all the damaged parts.
Sight and sound check of Check, starting and stopping the closing
possible noises, clearances machine several times without bottles, for
and unbalancing. possible noises, faults, clearances and
vibrations in the motor-drive components
(motors, reducers, gears, bearings).
Replace possible worn components.
Lubricate the new installed components.
Clean and lubricate the disassembled
components.
Report any anomalies you need to contact
Technical Support.
Pneumatic system check. Check the correct operation and possible
leaks (from fittings, lines, etc.):
▪ verify the air pressure at the
closing machine entry.
▪ Supplying the pneumatic system
with compressed air, check there is no
leak, broken or disconnected pipe.
▪ Check that the closing machine
pressure gauges indicate the applied
pressure on the suitable data plate.
91
OPERATION AIM NOTES
Check of the head control Check the clearance of the spindle pads. See sub-chapter 11.3.2.1
spindles. SPINDLE PADS CLEARANCE
ADJUSTMENT page 93.

OPERATION AIM NOTES
Overhaul of the cork inserting Complete overhaul of pistons, including For the overhaul of the piston,
pistons. replacement of: contact the Technical Service
▪ Bearings.
▪ Rotating and static sealing.
▪ Scraper.
▪ Snap rings.
▪ Upper pressure roller.
▪ Lower pressure roller.
▪ Bearing fixing nut.
▪ Piston-guide pads.
▪ Pad fixing plates.
▪ Hardened bush for lower roller.
▪ Main sealing.
▪ Spindle key.
▪ Head fixing threaded ring.
▪ Roller rotation pin.
▪ Spindle closing threaded ring.
▪ Spindle gear.
▪ Gear connection sleeve.
Check the wear of the cap/cork Visually check the wear of the roller See sub-chapter 11.5.1
driving punch unit cam race. sliding race. SPINDLES CONTROL CAM
WEAR CHECK page 128.
Closing machine general Check the correct operation of the closing

check. machine; if faults are found, contact the
Technical Service.
92
11.3.2 HEADS CONTROL SPINDLES MAINTENANCE
11.3.2.1 SPINDLE PADS CLEARANCE

ADJUSTMENT
To adjust the pad clearance, operate as follows:
• make the closing machine rotate in jog until the
spindle to be adjusted is in the flat (rear) section
of the cam.
• Lift the ends of the pads fixing safety plates so as
to release the bolts.
Fig. 146
• Loosen the fixing bolts of both pads.
Fig. 147
• Loosen nuts and adjustment grub screws for

both pads.
Fig. 148
93
• Fit a 0.1 mm shim between the two pads and the
spindles driving cam.
Fig. 149
• Push the pads against the shim.

• Register the position of the head driving piston
so that the distance between the pad and the
cam is the same for both pads.
• Verify the distances and lock the previously
loosened bolts.
• Screw the adjusting screws until they are in
contact with the pads.
• Screw all the grub screws locking nuts.
Fig. 150
A clearance between 0.1 and 0.2 mm must

be kept all along the race cam.
This condition must be checked on the cam

circumference in at least four diametrically
opposed points (e.g. rear and front parts,
left and right side).
• After adjustment, again bend the ends of the

pads fixing safety plates so as to prevent that
bolts may loosen.
Repeat the operation for the other possible spindles
to be adjusted.
94
11.3.3 MAINTENANCE OF THE CLOSURE HEAD
11.3.3.1 "SSD" CLOSURE HEAD

The table below shows the necessary tools for maintenance of the closure head.
TOOLS
Roller washer mounting wrench
Hook wrench 34-36 with ball
Mouth-presser wrench
11.3.3.1.1 REMOVAL OF THE ROLLER HOLDER ARMS

Remove the closure head from the closing machine as described in sub-chapter 10.7.1 REMOVAL AND
INSTALLATION OF THE CLOSURE HEADS page 56.
Proceed as follows:
• Insert the the closure head supporting equipment
into a jaw.
Fig. 151
95
• Screw the closure head on the sleeve of the
supporting equipment.
Fig. 152
• Unscrew the centering device fixing screws with

a 3 mm Allen wrench.
Fig. 153
Fig. 154
96
• Remove the centering device.
Fig. 155
• Unscrew the centering device's support columns

with a 10 mm exagonal wrench, and remove the
centering device's support columns.
Fig. 156
Fig. 157
97
• Unscrew the dowel fixing grub screw with a 3
mm Allen wrench.
Fig. 158
• Withdraw the arm movement pin.
Fig. 159
• Remove the roller support arm.

• Proceeding in the same way to remove the
remaining roller holder arms.
Before removing the roller holder arms, it is

necessary to mark the arms in such way so
to remount them in their original position.
Fig. 160
98
11.3.3.1.2 BOTTLE MOUTH-HOLDER REPLACEMENT
Proceed as follows:
Remove the roller holder arms operating as
described in subchapter 11.3.3.1.1 REMOVAL OF
THE ROLLER HOLDER ARMS page 95.
Fig. 161
• Fit the mouth-presser dismounting wrench in one
of the holes of the central shaft.
Fig. 163
• Fit the mouth-presser dismounting wrench in one
of the holes of the mouth-presser.
Fig. 164
99
• Unscrew the bottle mouth-presser with the
mouth-presser wrenches, and remove the bottle
mouth-presser.
Fig. 165

The mouth-presser threading is left
handed.
• Proceed in assembling the new mouth-presser.

• Reassemble the closure head, carrying out
what was previously described in the opposite
direction.
• Carry out the adjustment as described in sub-
chapter 10.8 ADJUSTMENTS OF THE
CLOSURE HEAD page 69.
100
11.3.3.1.3 REPLACING THE SPRINGS
11.3.3.1.3.1 COMPENSATING SPRINGS

Before working, measure and make a note
of the distance between the adjustment
bush and the head holder flange.
Fig. 166
Proceed as follows:
• Loosen the bush fixing nuts with the spring
adjustment hexagonal wrench.
Fig. 167
101
• Completely unscrew the adjustment bushes with
the spring adjustment hexagonal wrench.
Fig. 168
Fig. 169
• Unscrew the tie-rod fastening nuts with the

springs adjustment wrench using the 10 mm
hexagonal wrench to hold the spring guide tie-
rods.
Fig. 170
102
• Completely unscrew the spring guide tie-rods
with a 10 mm hexagonal wrench.
Fig. 171
• Slide out the spring guide tie-rods and tie-rod

locking nuts.
Fig. 172
• Remove the compensating springs, tie rod

locking nuts and springs supporting washers.
• Reassemble inversely to that described for
disassembly, taking care to restore the previously
measured distances.
Fig. 173
103
11.3.3.1.3.2 SIDE LOADING SPRINGS
Proceed as follows:
Fig. 174
locking nut.
Fig. 175
• Loosen the spring holder bush with a 3 mm Allen
wrench,and remove the bush.
Fig. 176
104
• Extract the lateral pressure spring and replace it
with a new one.
Lubricate the new spring proceeding as

described in sub-chapter 11.4.7
LUBRICATION OF THE CLOSURE HEAD
page 124.
Fig. 177
• Reassemble the spring holder bush.

• Adjust the threading rollers side loading as
described in sub-chapter 10.8.1.2
ADJUSTING THE THREADING ROLLER page
76.
• Adjust the skirting rollers side loading as
described in sub-chapter 10.8.1.3
ADJUSTING THE SKIRTING ROLLER page 82.
Fig. 178
105
11.3.3.1.3.3 THREADING ROLLER SPRINGS
Proceed as follows:
• remove the threading arm as described in sub-
chapter 11.3.3.1.1 REMOVAL OF THE ROLLER
HOLDER ARMS page 95.
Fig. 179
• compress the threading roller spring.
Fig. 180
• Extract from the roller seat the threading roller
washer.
Fig. 181
106
• Extract the threading roller spring.
Fig. 182
• Insert the new spring on the threading roller and

keep it compressed.
• Reposition the threading roller washer in
threading washer seat.
107
11.3.3.1.3.4 SKIRTING ROLLER SPRINGS
Proceed as follows:
• remove the skirting arm as described in sub-
chapter 11.3.3.1.1 REMOVAL OF THE ROLLER
HOLDER ARMS page 95.
• Using a suitable tool (for example a screwdriver)
compress, pushing down, the skirting roller
spring.
Fig. 183
• Extract from the roller seat the skirting roller
washer.
Fig. 184
• Extract the skirting roller spring.
Fig. 185
108
• Insert the roller support arm complete with the
skirting roller into a vice with soft jaws.
• Insert the new spring on the skirting roller.
Fig. 186
• Keep compressed the skirting roller spring with

the roller washer mounting wrench.
Fig. 187
• Reposition the washer in skirting roller seat.
Fig. 188
109
11.3.3.1.3.5 MOUTH-PRESSER SPRING
Remove the mouth-presser from the closure head

as described in sub-chapter 11.3.3.1.2
BOTTLE MOUTH-HOLDER REPLACEMENT page
99.
Proceed as follows:
• Insert the mouth-presser wrench in a vice.
Fig. 189
• Insert the mouth-presser on the wrench.
Fig. 190
• Unscrew the GAS feeler pin bush with a 17 mm
exagonal wrench.
Fig. 191
110
• Unscrew the GAS feeler pin bush with a 17 mm
exagonal wrench.
Fig. 192
• Remove the GAS feeler pin bush and the plunger

mouth-presser from the mouth-presser
Fig. 193
• If present, remove the spacers from the mouth-

presser inside.
Fig. 194
111
• Extract the GAS mouth-presser spring and
replace it with a new one.
Lubricate the new spring proceeding as

described in sub-chapter 11.4.7
LUBRICATION OF THE CLOSURE HEAD
page 124.
• Remount the GAS feeler pin bush.
Fig. 195
112
11.3.4 MAINTENANCE OF THE "FLAT" CENTRIFUGAL CAPS SORTER
residual energies.
If there is an anomalous distribution, it is necessary

to carry out the following operations:
• check that the nozzles placed on the exit mouth
are not obstructed and are in the correct position
to push caps, not correctly orientated, into the
discharge tube.
Fig. 196
• Check that the nozzle or nozzles, if more than one,
placed on the circumference is not obstructed.
Fig. 197
113
• Check that the nozzle placed on the discharge
tube is not obstructed.
• Check that in the tube there are no caps; if there
are caps it is necessary to remove them.
Fig. 198
• For the removal of the caps from the discahrge
tube it is necessary:
▫▫ unscrew the fixing grub screw placed on the
holding clamp;
Fig. 199
▫▫ Pull down the lower discharge tube.
Fig. 200
114
11.4 LUBRICATION
11.4.1 GENERAL INFORMATION
residual energies.
Before starting the closing machine, check the lubrication of all components described in the
following subchapters.
If the closing machine is not used for a long time, lubricate it again.
Mineral oils, when not used for over six months, loose their properties and must be changed.
11.4.2 LUBRICANT TYPE-APPROVAL ACCORDING TO NSF

Due to the fact that the closing machine is used in food industry, AROL S.p.A. dedicated and special
lubricants should be used on the machines, to prevent possible contamination problems of the food/drink
in case of occasional or occidental contact between lubricant and food and drink. To this purpose, the
selection of the lubricant was made according to the lubricant approval standard, according to NFS, a
standard applied all over the world for food industry.
The type-approval according to NSF includes two categories: NSF - H1 and NSF - H2.
• H1 indicates Food grade lubricants, that can thus be used in all friction points of machines and systems
for the food and pharmaceutical industries, where occasional, and technically unavoidable, contacts can
occur between lubricant and food.
• H2 indicates lubricants that are recommended for the general use in the food and pharmaceutical
industries, supposing that a contact with the fool is totally to be excluded.
Due to the fact an accidental contact with the food/drink cannot be totally avoided, AROL S.p.A. decided to
use always lubricants of category H1 (Food grade lubricants).
The user company must use category H1 lubricants as described in the following tables.
115
11.4.3 TYPES OF LUBRICANTS
AROL S.p.A., after careful studies and functional tests, recommends to use only the lubricants indicated in
the table below to lubricate its machines:
The lubricants indicated in the table are classified NSF-H1.
SIGNS PRODUCT NLGI Base Thickener Base oil Worked T. T.

oil viscosity penetration Min Max
[Viscosity
Index] [cSt] [0.1mm] [°C] [°C]
A Klubersynth 2 S y n t h - Gel silica 60 265-295 -40 150
PAO
UH1 64-62
G4501 1 S i n t h - AlK 100 310-340 -40 150
PAO
B Kluberlub 2 MO AlK 220 265-295 -15 110
NH1-11-222
Klubersynth 2 S i n t h - AlK 220 265-295 -25 120
PAO
UH1-14-222
Kluberfood 1/2 Synth C o m p l e x 400 280-300 -30 160
calcium
NH1 94-402
C Paraliq Synth+MO 150 -15 100
P150
D Klubersummit S y n t h - [130] 46 -45 135
FG46 PAO
L0346FG MO [100] 46 -21
Purity AW 46 HT/MO [108] 46 -15
E Purity FG Synth 2 S i n t h - C o m p l e x 46 294 -45 200

PAO sulfonate
calcium
F Kluberpaste 1 S y n t h - PTFE 200
PAO
UH1 84-201
P1900 1 MO AlK 85 290-340 -30 300
G Barrierta L55 / 1 1 S y n t h - PTFE 400 -40 260

PFPE
Krytox GPL 226 2 S y n t h - PTFE 240 -30 288
PFPE
[155]
H Klubersynth 2 S i n t h - Gel silica 60 265-295
PAO
UH1 64-62
G4501 1 S i n t h - AlK 100 310-340 -40 150
PAO
I Purity MF Spray HT/MO [150] 151 -9 150
116
SIGNS PRODUCT NLGI Base Thickener Base oil Worked T. T.
oil viscosity penetration Min Max
[Viscosity
Index] [cSt] [0.1mm] [°C] [°C]
I Purity MF Spray HT/MO [150] 151 -9 150
J Klubersynth 2 S i n t h - Gel silica 60 265-295 -40 150

PAO
UH1 64-62
G4501 1 S i n t h - AlK 100 310-340 -40 150
PAO
K Paraliq GB 363 3 Synth+MO Bentonite 2400 215-245 -30 140
L Paraliq GB 363 3 Synth+MO Bentonite 2400 215-245 -30 140
M Kluberlub 2 MO AlK 220 265-295 -15 110

NH1-11-222
Klubersynth 2 S i n t h - AlK 220 265-295 -25 120
PAO
UH1-14-222
calcium
NH1 94-402
N Kluberoil S y n t h - [150] 220 -25 120
PAO
4 UH1-220N
L1122FG S i n t h - [142] 197 -33
PA O /
MO
Purity FG HT/MO [92] 206 -18
Gear Oil 220
O G4501 1 S i n t h - AlK 100 310-340 -40 150
PAO
P Klubersynth 2 Synth Silicate 1300 265-295 -10 150
UH1 64 1302
Q Purity FG EP MO [95] 144 -18 247
150
R Kluberfood S y n t h - [150] 220 -30 120
PAO
NH1 4-220N
Spray
S Klubersynth 2 Synth Silicate 1300 265-295 -10 150
UH1 64 1302
calcium
NH1 94-402
T Cassida Grease 2 S y n t h - C o m p l e x 46 265-295 -45 170
PAO sulfonate
GTS 2
calcium
U Kluberfood MO
NH1 1-17
117
11.4.3.1 LUBRICANT RE-ORDERING
The lubricants used for the machine can be directly ordered to AROL S.p.A. or to the local distributors.
See the table here below for the international addresses.
http://www.klueber.com
http://www.molykote.com
http://www.petro-canada.ca
http://www.krytox.com
http://www.fuchs-oil.com
11.4.4 LEGEND FOR LUBRICATION SCHEMES

SYMBOL DESCRIPTION
Lubricate with manual pump for grease
Lubricate with brush for grease
Lubrication glass with disposable cartridge
Lubricate with spray
Lubricate with manual pump for oil
Lubrication glass
118
11.4.5 POINTS TO BE LUBRICATED
To protect the closing machine from wear, seizure or other severe damage to the mechanisms, it
is necessary to lubricate and grease periodically all indicated points.
AROL S.p.A. guarantees the maintenance intervals indicated hereby and the correct operation of
the mechanisms exclusively with the recommended lubricants.
11.4.5.1 INSTRUCTIONS FOR READING THE "LUBRICATION POINT LIST" TABLE

The following pages show:
• the description table (Lubrication point table) relevant to time intervals, methods and used lubricants for
the maintenance interventions on the closing machine herein.
• the position of the lubricating points (Lubrication point scheme) described herein.
The table "Lubrication point list" is designed to find immediately the operations to be carried out for the
closing machine lubrication.
The "Lubrication point scheme" indicates the position of the points described in the table on the closing
machine.
The points marked by a double frame indicate that the lubrication is carried out in a centralized way. Thus,
the quantity of lubricant indicated in the table must be filled; then, the system will distribute the correct
quantities to the different components.
POINT CODE The column indicates the reference of the point to be lubricated,
indicated on the closing machine next to the greaser and in the
"Lubrication point scheme"
POINT DESCRIPTION This column briefly describes the greasing point.
LUBRICANT TYPE The reference letter for the lubricant to be used is indicated in this
column. See the table for the lubricant type to be used.
METHOD This column shows the tool by which the relevant greasing point must
be greased.
INLET NUMBER [NO.] It indicates the number of greasing points on the closing machine.
QUANTITY/POINT [gr.] It indicates the lubricant quantity to be fed in each greasing point.
TOTAL QUANTITY [gr.] It indicates the total lubricant quantity to be used.
INTERVAL [h] It indicates every how many hours the different lubrication points must
be greased.
After the lubrication of each points by grease, check that there are not leaks from seal gaskets or
from the ditribution pipes.
119
11.4.5.2 LUBRICATION POINT LIST AND SCHEMES
LUBRICATION POINTS LIST

Order Ack. S/N Version Reference Typ Model P.D. H.N.
19469700 17579 0 Progetto 417 Tajikistan T EURO VA IES LIGHT 288 6
Point Description Lubr. Lubr. Number Qty per Total qty Lubr. Int.
Type Method of points point [g] [g] [h]
6 Central bearings or central slewing bearing M 1 50 50 500
8A Piston upper roller A 6 6 36 500
8C Piston fork bearing A 6 6 36 500
8D Piston liner A 6 15 90 500
16A Lower central bearing or column slewing bearing. B 1 30 30 500
16B Upper central bearing or column slewing bearing. B 1 30 30 500
68 Cuscinetti giunto disinnesto B 1 40 40 500
4 Pistons controlling cam M 1000
7 Sliding bush M 1 5 5 1000
11 Heads rotation gearing M 1000
13 Heads rotation angular transmission M 1000
19 Turret rotation gearing B 1000
1 Lifting screw N 1 120 120 3000 *
17 Central column inner bearing N 1 120 120 3000 *
18 Lifting axial bearing N 1 120 120 3000 *
Rotating point
* Value that depends on environmetal conditions: check into use and maintenance manual
Fig. 201 Lubrication point table
120
Fig. 202 Lubrication point scheme
121
11.4.6 LUBRICANT CARTRIDGE
At the closing machine delivery, the lubricant cartridge is not fit, thus it is not active. Before starting
the closing machine, install and activate the cartridge.
11.4.6.1 LUBRICATOR DESCRIPTION

The cartridge of the lubricant is composed of:
• an adjustment screw (1).
• A body containing the lubricant (2).

The lubricant cartridge may provide
lubrication intervals from 1 to 12 months.
The interval is defined according to the
alignment of the screw with the number on
the ring nut of the cartridge.
AROL S.p.A. suggests for the lubrication

of its machine to rotate the adjsutment
screw on number 6 of the ring nut on the
cartridge.
Fig. 203
Fig. 204
During the supply period, the lubricator must not be removed to maintain the pressure inside it.
122
11.4.6.2 CARTRIDGE REPLACEMENT
When the cartridge must be replaced, operate as
follows:
• Remove the plug from the discharge opening.
• Screw by hand the lubricating cartridge on the
suitable coupling.
Fig. 205
• Rotate the adjsutment screw on number 6 of the

ring nut on the cartridge.
Fig. 206
Fig. 207
123
11.4.7 LUBRICATION OF THE CLOSURE HEAD
11.4.7.1 "SSD" CLOSURE HEAD

Use lubricant "I" type.
• Lubricate the rollers of arms forks with a aerosol
spray oil. Lubricate every 8 hours.
Fig. 208
• Lubricate the springs and threading rollers with a
aerosol spray oil. Lubricate every 8 hours.
Fig. 209
• Lubricate the springs and skirting rollers with a
aerosol spray oil. Lubricate every 8 hours.
Fig. 210
124
Use lubricant "J" type.
• Lubricate the head central block with a grease
pressure syringe. Lubricate every 120 hours,
introducing 10 gr of lubricant.
Fig. 211
• In case you must lubricate the side load springs

and/or the GAS mouth-presser spring, after their
replacement, using a brush apply a layer of
lubricant on all the spring coils. Use a brush.
Since it is objectively difficult to express

an amount of lubricant to be laid with a
brush, with "stroke" refers to the amount
of grease that is retained, plunging up to
half the bristles of a brush number 8 off
about 10 mm high 18 mm bristle.
Fig. 212
Fig. 213
125
11.4.8 BONFIGLIOLI REDUCER LUBRICATION
11.4.8.1 INTRODUCTION
On the reducer is fitted with the nameplate on the
side shown. On this plate there are all the references
and all the indispensable indications for its correct
identification.
Fig. 214
11.4.8.2 LUBRICATION
VF30....VF49 AND W63....W86 REDUCERS
For reducers of this group, that are on a average at high power, the oil lubrication is adopted. These reducers
have not charge, discharge and level oil plugs and so do not need any maintenance having already the right
oil quantity.
VF130....VF150 AND W110 REDUCERS
For reducers of this group, that are on a average at low power, the permanent lubrication with synthetic oil
is adopted. Reducers have charge, discharge and level oil plugs
Reducers are supplied with a lubrication oil load TIVELA OIL S320 type.
It is recommended, if the lubricants is not of the recommended ones, that it has an equivalent
composition on synthetic nature and viscosity. Moreover it must have the suitable antifoam
additives.
OIL QUANTITY TABLE (LITRES)

B3 B6 B7 B8 V5
VF130 HS 3,90 2,50 2,50 2,30 3,30
P(IEC) 3,00 2,50 2,50 2,30 3,30
VFR130 0,40 0,50 0,50 0,70 0,40
W110 P80…P132 1,50 1,70 1,70 1,90 1,70
M2-M3 1,50 1,70 1,70 1,90 1,70
7 < i < 15 1,50 1,70 1,70 1,90 1,70
20 < i < 100 2,70 1,70 1,70 1,90 1,70
126
11.4.8.2.1 OIL REPLACEMENT
Do not mix oil with different trade marks and characteristics and check that the oil in use has high
anti-foam characteristics and EP.
If an identic lubricat is not available completely empty the reducer and clean it inside with a light solvent,
before the next filling.
• Place a container of adecuate capacity under the discharge plug.
• Remove the charge, discharge and level plug and let the oil freely flow.
To make easier the discharge operation, it is recommended to operate with hot oil.
• Wait some minutes so that all the oil is went out, then screw again the discharge plug, after the gasket
has been replaced.
• Pour new oil only after the reducer is its definitive position, until the half of the level plug is reached.
• Screw the charge plug, after the gasket has been replaced.
The exhausted oil must be disposed according to the environment protection norms.
If there are leaks, before to reset the lubricant quantity, it is necessary to find the cause of the
problem before startin up again the reducer.
127
11.5 EXTRAORDINARY MAINTENANCE
11.5.1 SPINDLES CONTROL CAM WEAR CHECK
To check the piston control cam race wear proceed as follows:
residual energies.
• Remove the safety guard.

• Check the conditions of the spindles control cam
in the cap application point. The worn part is
usually the roller sliding race; if the wear is such
to form a difference over 1 mm the cam must be
replaced.
• Check the wear along the whole sliding race and
above all in the area where the piston reaches its
bottom dead center.
Fig. 215
To replace the cam, contact the Technical Service.
128
11.5.2 REPLACEMENT OF THE BOTTLE SUPPORTING PLATES
To replace the bottle supporting plates, proceed as

follows:
• insert a flat head screwdriver or a similar tool
between the plate and its support.
Fig. 216
• Prise the plate out of the support using flat head
screwdriver or similar tool.
• Complete the plate removal from the support.
Fig. 217
• Position the new plate in the support seat.
Fig. 218
129
• Complete the plate insertion inside the support,
using a rubber hammer and beating on the plate
side
Fig. 219
130
11.5.3 TRANSPORT EQUIPMENT TIMING
11.5.3.1 ALIGNMENT BETWEEN
BOTTLE CENTERING DEVICE
AND CENTRAL STAR-WHEEL
The closure head must always be aligned with a
cavity of the central star-wheel
If the closure head must be axially aligned with the
star-wheel cavity, operate as follows:
• Fit a bottle in the central star-wheel cavity.
• Check the vertical alignment between capping
head axis and star-wheel axis.
Fig. 220
• If the alignment is not correct:

Before operating on the closing
machine, insulate all the energy sources
and dissipate the residual energies.
▫▫ loosen the fixing screws.
Fig. 221
▫▫ Manually rotate the star-wheel support
complete with star-wheel, till getting a correct
alignment between a closure head and a
star-wheel cavity.
• At the end, tighten the fixing screws strongly
again.
• Remove the bottle.
Fig. 222
131
12 FAULTS AND REMEDIES
The list of the faults in the following pages is useful to detect as fastest as possible their reasons and
possible solutions.
The research and the interventions must be carried out methodically (from the most probable to the less
probable reason) and in logical sequence.
Proceed by steps: a first intervention, a test on the obtained result, then passage to the next intervention.
The main closing machine units are:
• Closure unit
• Caps/corks distribution.
• Caps/corks feeding.
residual energies.
132
FAULT CAUSE REMEDY
Lifting or lowering the closure Interference with the container Identify the reason for the overload
carousel, the same does not conveying equipment, (interference with the container conveying
move vertically. foreign matters in the lifting equipment, foreign matters in the lifting
mechanism, other. mechanism, other).
The fastening screw of the Loosen the fastening screw.
sliding bush has not been
loosened.
Min. or max. limit of closing Make sure the closing machine has
carousel vertical range been preset for the container size to
reached. be processed. If so contact Technical
Assistance Service.
The containers break in the The closure carousel is too Position the closure carousel at the correct
closure step. low. height for the container to be processed.
Container transfer equipment Replace the equipment with the one
not suitable. suitable for the size to be processed.
Caps are not descending from The sorter exit-mouth is Remove possible caps, cap parts or
the sorter. clogged. foreign matters.
Check on the pressure gauges if the
pressure of the air jets is correct.
Caps are not correctly sized or Use caps with the suitable size and even
are strained. features.
The cap is too much little or not Insufficient pressure of the Adjust the pressure of the threading
at all threated. threading rollers. rollers.
Threading rollers are locked Manually check the rotation and the
(seized up). sliding of threading rollers. If they are
locked, dismount them, clean them and
lubricate them.
Spring of the threading roller is Replace the spring of the threading
broken. rollers.
Springs of the closure head Replace the springs with those parts.
are broken.
For the replacement see the relative sub-
chapter of the closure head.
Incorrect closure carousel Place the closure carousel at the correct
height. height for the bottle to handle.
The cap is too much little or not Incorrect height of the skirting Adjust the height of the rollers
at all skirted. rollers.
Insufficient pressure of the Adjust the pressure of the rollers
skirting rollers.
Spring of the skirting roller is Replace the spring of the skirting roller.
broken.
133
FAULT CAUSE REMEDY
The cap is cut on the thread. Too much pressure on the Adjust the pressure of the threading
threading rollers. rollers.
Threading rollers are locked Manually check the rotation and the
(seized up). sliding of threading rollers. If they are
locked, dismount them, clean them and
lubricate them.
Problems in the cap Incorrect cap gripping. Verify the height of the closure carousel.
distribution. Check the operating of springs Check that the caps positioning device is
of the caps positioning device. properly operating. If it does not contact
the Technical Service.
134
13 SCRAPPING AND DISPOSING
As there are in force different norms of observation, it is necessary to follow the prescriptions fixed by laws
and authorities of the states where the closing machine will be installed.
Proper precautions must be taken for out-of-order and scrapping of the closing machine in order to avoid
possible dangerous situations.
In particular, follow these general instructions:
• disconnect the closing machine from the electric network and check that no residual voltage exists.
• Empty all the lubrication points of oil paying attention in not dispersing and dispose it according the laws
in forces in the country where the closing machine has been used.
• Lock all the moving parts of the closing machine, making sure that there are no possibilities of movement,
also due to accidental collision during the transfer operation.
• With the help of qualified and authorized personnel proceed to the dismounting of components and the
differentiated collection of materials (steel, plastic, electrical components, wires, etc.) in order to dispose
everything according to the indications forseen by the laws in force.
Always use security clothes during the operations that require direct intervention on the
closing machine.
135

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Model

TSI - EURO VA IES LIGHT

USE AND MAINTENANCE

Refer to http://www.arol.com for the update of the addresses of the headquarters.

Ask for a replacing copy if damaged.

4.1 MAIN UNITS OF THE CLOSING MACHINE

• An orientation device selects the caps inside the

• The cap placed at about 45°, is taken, by a

closing machine lifting motor 0,37 kW

caps sorter motor 0,37 kW

Total installed power: 0,74 kW

4.4.1 PRESCRIBED USE AND FORBIDDEN USES

4.4.2 OPERATING MODES

4.4.4 PROFESSIONAL ROLES OF USERS

it is forbidden to esecute any intervention on the electic and/or pneumatic equipement.

4.4.4.2 MAINTENANCE MAN

4.4.5 EMPLOYER'S OBLIGATIONS

4.4.6.1 INFORMATION - JOB INSTRUCTIONS

4.4.7 ARRANGEMENTS BY THE CUSTOMER

Notes, usage tips, or additional information

Part of the manual dedicated to the OPERATOR.

Part of the manual dedicated to the MECHANICAL MAINTENANCE OPERATOR.

Part of the manual dedicated to the ELECTRICAL MAINTENANCE OPERATOR.

Obligation to insulate all energy sources.

INSPECTION AND OPERATION

INSPECTION AND OPERATION

INSPECTION AND OPERATION

INSPECTION AND OPERATION

The pictograms of the closing machine cannot be removed.

It indicates a generic warning.

Instructs to unlock the handles holding the anti-torsion columns and

Means that the lubricant cartridge must be activated before starting

Fig. 9 Re-ordering code: GETIC0000061

Fig. 10 Re-ordering code: GETIC0000021

4.5.1 ENVIRONMENTAL OPERATING RISKS

4.5.2 RESIDUES AND ENVIRONMENTAL CONTAMINATION

5.2.1 SAFETY DEVICES OF THE CLOSING MACHINE

5.2.1.1 POSITION OF THE SAFETIES

It is therefore compulsory to insulate all energy sources dissipating residual energies.

The following general warnings must be noted:

5.5 RESIDUAL RISKS

7 HOW TO ORDER SPARE PARTS

To install the caps chute on the machine it is necessary:

• Place the caps chute so that the fixing brackets

• Lock the threaded fixing system of the caps

• Unscrew and remove the central screw locking

• Screw at the center of the rotating disc an M8

• Hook with a belt or a chain with hooks to the M8

• Position the caps sorter complete with the support

• Unhook the belt or the chain with hooks from the

• Remount the central cone and fix it with the

• Place and fasten the caps cover on the caps

• Place the caps level device on the caps sorter

▫▫ Fasten all things locking the screw against

For pneumatic data see the table page 10.

• Connect the flow rate pipe coming from the air

9.1.1 CHECKS BEFORE THE START UP

• Check the sequence of the motor supply phases.

Before starting the closing machine up, check the following: