Filler Maintenance

Technical Documentation
Maintenance Procedures Manual
FILLER
COMBI MATRIX
SF300 FM 144/24
(SRMB0119)
Original instructions
© Sidel S.p.A.
All figures and photographs are for information only
Publication Date: 25/06/2013
SIDEL S.p.A. - Via La Spezia, 241/A - (43100), Parma ITALY

Tel.: +39 0521 9991 - Fax: +39 0521 959009
NON CONTRACTUAL DOCUMENT: if any constructive or commercial requirement should

occur, the supplier society reserves the right to modify
the machine, under no obligation to timely update this
manual.
© Sidel S.p.A.
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SERVICE CATALOGUE PRESENTATION PART A
MAINTENANCE PLAN PART B
MECHANICAL INTERVENTION PROCEDURES PART C
ELECTRICAL MAINTENANCE PROCEDURES PART D
TABLE OF CONTENTS
SERVICE CATALOGUE PRESENTATION..................................................................................................................... Part A
General presentation .........................................................................................................................................................A-1
MAINTENANCE PLAN ................................................................................................................................................... Part B

Maintenance plan...............................................................................................................................................................B-1
MECHANICAL INTERVENTION PROCEDURES ......................................................................................................... .Part C

Cleaning/control procedures list.........................................................................................................................................C-1
Removal/replacement procedures list................................................................................................................................C-2
Lubrication/greasing procedures list ..................................................................................................................................C-3
ELECTRICAL MAINTENANCE PROCEDURES............................................................................................................ Part D

List of cleaning/control procedures ....................................................................................................................................D-1
List of removal/replacement procedures............................................................................................................................D-2
© Sidel S.p.A.
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Parte A Maintenance Procedures Manual
ASSISTANCE CATALOGUE PRESENTATION PART A
MECHANICAL MAINTENANCE PROCEDURES PART C
TABLE OF CONTENTS
MAIN PRESENTATION ............................................................................................................................................................ A-1
Foreword .......................................................................................................................................................................... A-1-1
General safety information................................................................................................................................................ A-1-2
Using the assistance card catalogue ................................................................................................................................ A-1-3
Tightness values ............................................................................................................................................................... A-1-4
Lubricant/grease specification .......................................................................................................................................... A-1-5
© Sidel S.p.A.
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Maintenance Procedures Manual Parte A
A-1 MAIN PRESENTATION
A-1-1 Foreword
Prerequisites: You must carefully read the “User Manual” before starting any maintenance
procedures.
A-1-2 General safety information

The Maintenance Procedure Manual includes all preventive maintenance procedures.
General safety conditions during maintenance:
1. Machine maintenance must only be performed by qualified and authorised personnel.
2. Always wear the personal protection equipment required for each maintenance operation.
3. Always inform other operators of your intentions before making repairs or performing maintenance
on the machine.
4. All operations performed inside the perimeter marked by the safety doors must be undertaken with
the machine switched OFF, empty of bottles and in one of the following operating conditions:
- Mains power supply disconnected
- JOG control ON
5. Use ORIGINAL SPARE PARTS only.
6. Before starting the machine, make sure that:
- Any guards removed during maintenance are refitted and operating correctly.
- All spare parts are fitted correctly and locked in position.
- All foreign objects (cloths, tools, etc.) are removed from the machine.
Machine parts reach very high temperatures during sterilisation and CIP: burn hazard.
Operators must NOT access the inside of the machine until the temperature indicated
on the operator panel is less than 40°C.
Do NOT perform maintenance inside the perimeter marked by the safety doors during
sterilisation and/or CIP operations.
During sanitisation the machine hoses transfer toxic liquids which are a health hazard
in the event of contact.
WARNING: In the event of checks running programmable logic (PLC) installed

directly on the control panel (or inside the electrical cabinet which does not have a
front door – e.g. in the control room), the person assigned to electrical maintenance
must be sure to discharge any static electricity build-up before approaching the PLC to
perform maintenance operations or even simple tests. To do this, a portable
maintenance kit for static electricity discharge must be utilized. This kit is comprised of
a metal band to be applied around the wrist and a pad made of conductive material.
This kit must be connected to the same reference potential (earth) that the PLC body is
connected to.”
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WARNING: During maintenance involving the machine base, take care of the surface
which may be slippery.
WARNING: Tampering with or removing safety devices is strictly prohibited. The

manufacturer cannot be held responsible for the consequences of tampering with or
removal of safety devices.
In ”JOG” mode, the operator must be careful to the position of the cord to the portable pushbutton panel in
order to prevent crushing it.
Conduct that does not conform to the safety instructions given for the use of this machine could be fatal or
cause serious injury or damage to persons and or property.
A-1-3 Using the assistance card catalogue

How are the procedures classified?
• Maintenance procedures are classified into two areas:
- mechanical procedures (F_M)
- electrical procedures (F_E)
• Information included on the control bar:
Minimum operator level

required for the
procedure Name Number
procedure pages
Symbol Procedure
procedure classification and
progressive number
• Control bar list::
1 Mechanical checking / cleaning procedures from 001 to 999 FNM - xxx 1/1
1 Mechanical removal / substitution procedures from 001 to 999 FDM - xxx 1/1
1 Mechanical greasing / lubrication procedures from 001 to 999 FGM – xxx 1/1
1 Electrical checking / cleaning procedures from 001 to 999 FNE - xxx 1/1
© Sidel S.p.A.
1 Electrical removal / substitution procedures from 001 to 999 FDE - xxx 1/1
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• Operator levels
- level 1: generic operator:
- level 2: maintenance mechanic/electrician
- level 3: customer maintenance supervisor
- level 5: Sidel S.p.A. technician
What do the maintenance procedures describe?

- The exact position where the operation is required
- Reference to general safety precautions to be taken
- Reference to safety precautions specific to the procedure
- Specific operating instructions (machine emptying, rinsing, etc.)
- Specific tools to use
- Lubricant/s to use
- Standard operating procedure
How are the maintenance procedures used?

The procedures in this manual assume the machine is fully installed and connected correctly to services
(air, water, mains power and process liquids).
The following are described below:
- general safety precautions;
- operator level required of personnel performing maintenance;
- correct tools and equipment to be used for the operation;
- correct lubricants to use (for lubrication procedures).
Before starting the operation, read the entire procedure to:
- identify the exact position on the machine where the operation is to be performed;
- obtain the correct standard equipment (e.g. rags, brushes, gauges, etc.);
- be aware of all specific instructions;
- refer to all other procedures which may be required.
Always complete each step of the operation in the order listed in the procedure:
At the end of the procedure, clean the area carefully making sure the machine can restart production as
normal, no tools or size parts have been left inside the machine and the machine does not represent a
hazard for personnel. Make sure of compliance with all machine hygiene conditions.
Terminology used
The meaning of some specific terms is given below to clarify the terminology used in the procedures:
Overhaul total dismantling of a component and if necessary substitution of worn or damaged parts.
visual inspection and/or checks using equipment of a component and dismantling if
Check
necessary.
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A-1-4 Tightness values
Tri-clamp setting
Clamp 1” e 1 ½” Clamp ½” e ¾” Clamp 4”
Clamp 3” Clamp 2 ½” Clamp 2”
Clamp 6” © Sidel S.p.A.
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Screw torque wrench settings

Class of resistance
12.9 10.9 8.8
Area Starting Starting Starting
Threading Yield Tightening Yield Tightening Yield Tightening
mm2 clamping clamping clamping
point torque point torque point torque
strenght strenght strenght
kfg kfg kfg - cm kfg kfg kfg - cm kfg kfg kfg - cm
M 3x0.5 5.03 563 394 17 482 338 15 328 230 10
M 4x0.7 8.78 983 688 40 842 589 34 573 401 23
M 5x0.8 14.2 1590 1113 81 1362 953 69 927 649 47
M 6x1 20.1 2251 1576 138 1928 1349 118 1313 919 80
M 8x1.25 36.6 4099 2869 334 3510 2457 286 2390 1673 195
M 10x1.5 58 6496 4547 663 5562 3894 567 3787 2651 386
M 12x1.75 84.3 9442 6609 1160 8084 5659 990 5505 3853 674
M 14x2 115 12880 9016 1840 11029 7720 1580 7510 5257 1070
M 16x2 157 17584 12039 2870 15056 10539 2460 10252 7176 1670
M 18x2.5 192 21504 15053 3950 18413 12889 3380 12922 9045 2370
M 20x2.5 245 27440 19208 5600 23496 16447 4790 16489 11542 3360
M22x2.5 303 33936 23755 7620 29058 20340 6520 20392 14274 4580
M24x3 353 39536 27675 9680 33853 23697 8290 23757 16630 5820
The values in the table are approximate and for reference only.
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A-1-5 Lubricant/grease specifications

Refer to specific maintenance cards for the specifications of lubricants and greases.
WARNING: Do NOT use lubricants/greases with viscosity index other than those
indicated as this may cause overheating and early wear of components.
- When topping up/substituting lubricants, make sure the new lubricant has the same composition and
viscosity characteristics. Mixing lubricants with different basic compositions can cause irreparable
damage to reduction gears and/or machine components.
- Do NOT use grease with a consistency value greater then 2 for automatic lubrication control units.
Failure to do this may result in ungreased parts requiring lubrication and damage to the grease
dosing and distribution pump.
Terminology
Contact SIDEL or the machine supplier if you have any doubts concerning the type of lubricant to use.
Resistance that the molecules of a liquid apply when sliding against each other.
Viscosity
This resistance is also known as internal friction.
Derives from the contact friction of the sliding surfaces when the lubricating film is
Wear
missing.
Mineral oil Oil obtained through processing of crude oil.
Oil obtained by synthesising chemical substances with low molecular weight –
Synthetic oil
hydrocarbon or silicon composites.
Unit of measure to assess grease consistency. The depth of penetration into the
Grease penetration
grease of a normalised cone is measured on a scale of 10-1 mm.
NLGI consistency The NLGI number indicates the depth of penetration of a grease measured using
class the penetration meter after a fixed processing cycle.
The temperature at which the external soapy structure of the grease releases the oil
Drop point
contained therein.
H1 is the code for Food grade lubricants, i.e. lubricants which can be used on all
H1 approval friction points on machines used in food processing where occasional contact
between the food and lubricant is possible.
It is recommended the Safety Cards provided by the supplier are to hand to identify:
- hazards;
- protection devices;
- first aid requirements;
- fire prevention measures;
- action in the event of accidental leaks;
- physical and chemical properties;
- stability and reactivity;
- toxicological information;
- ecological information;
- disposal information;
- shipping information.
© Sidel S.p.A.
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Part B Maintenance Procedures Manual
TABLE OF CONTENTS
MAINTENANCE PLAN ............................................................................................................................................................. B-1
© Sidel S.p.A.
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Maintenance Procedures Manual Part B
B-1 MAINTENANCE PLAN
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CodMacchina Location Position CodID ID Component Operation Period Hours Cycle Level Time ProcSheet Comments
SRMB0119 All modules 0 - MAINT2559 Services CT - Control 0 1 FNE059 Preliminary operations
SRMB0119 Ele - Electrical main group 0 - MAINT6042 Emergency stop button CT - Control Weekly 125 2 1 3 min FNE030
SRMB0119 Ele - Electrical main group 0 - MAINT6043 Electrical connections CT - Control Quarterly 1500 20 3 30 min FNE031
SRMB0119 V - Filler valve 1000 - MAINT1163 Body valve CT - Control Daily 24 0 2 2 min FNM240 Time for single component
SRMB0119 V - Filler valve 1000 - MAINT1165 Body valve CT - Control Weekly 125 2 2 1,5 min FNM244 Time for single component
SRMB0119 V - Filler valve 1000 - MAINT1166 Body valve CT - Control Weekly 125 2 2 3 min FNM245
SRMB0119 V - Filler valve 1000 - MAINT1172 Filling valves RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1005 - MAINT1163 Filling valve inlet part CT - Control Daily 24 0 2 2 min FNM240 Time for single component
SRMB0119 V - Filler valve 1005 - MAINT1172 Filling valve inlet part RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1010 - MAINT1163 Filling valve distributor group CT - Control Daily 24 0 2 2 min FNM240 Time for single component
SRMB0119 V - Filler valve 1010 - MAINT1165 Filling valve distributor group CT - Control Weekly 125 2 2 1,5 min FNM244 Time for single component
SRMB0119 V - Filler valve 1010 - MAINT1172 Filling valve distributor group RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1020 - MAINT1165 Group bell CT - Control Weekly 125 2 2 1,5 min FNM244 Time for single component
SRMB0119 V - Filler valve 1020 - MAINT1172 Group bell RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1025 - MAINT1172 Dummy bottle group RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1060 - MAINT1172 Filling valve grip RP - Replacement Annual 6000 60 5 7 min FDM380 Time for single component
SRMB0119 V - Filler valve 1075 - MAINT1181 Pilot valve RP - Replacement Conditional 0 0 3 5 min FDM395 Time for single component
SRMB0119 A - Filler 2020 - MAINT2269 Slewing ring CT - Control Quarterly 1500 20 3 10 min FNM252
SRMB0119 A - Filler 2020 - MAINT2273 Slewing ring CT - Control Annual 6000 80 5 30 min FNM253
SRMB0119 A - Filler 2035 - MAINT1178 Carousel control RP - Replacement Two years 12000 160 5 480 min FDM391
SRMB0119 A - Filler 2035 - MAINT1182 Filler control pinion RP - Replacement Conditional 0 0 5 60 min FDM396
SRMB0119 A - Filler 2035 - MAINT2266 Engine CT - Control Monthly 500 7 3 5 min FNM249
SRMB0119 A - Filler 2035 - MAINT2273 Pinion gear CT - Control Annual 6000 80 5 30 min FNM253
SRMB0119 A - Filler 2035 - MAINT2274 Filler gearbox oil level GR - Greasing Two years 12000 160 2 20 min FGM034
SRMB0119 A - Filler 2035 - MAINT2278 Engine RP - Replacement Conditional 0 0 5 60 min FDM394
SRMB0119 A - Filler 2500 - MAINT1171 Upper manifold 1 W. RP - Replacement Six months 3000 40 5 120 FDM378
SRMB0119 A - Filler 2500 - MAINT1183 Electric manifold rotating RP - Replacement Conditional 0 0 3 60 min FDM397
SRMB0119 A - Filler 2502 - MAINT1170 Lower manifold RP - Replacement Annual 6000 40 5 480 min FDM377
SRMB0119 A - Filler 2510 AVF201 MAINT1175 Tank blow-off valve RP - Replacement Annual 6000 80 3 60 min FDM385
SRMB0119 A - Filler 2510 AVF254 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 A - Filler 2510 LSF203H MAINT7004 Level probe CL - Cleaning Annual 6000 80 2 5 min FNM119 Time for single component
SRMB0119 A - Filler 2510 TTF201 MAINT7016 Temperature probe CT - Control Four years 24000 3 10 min FNM042
SRMB0119 A - Filler 2510 PTF204 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 A - Filler 2512 - MAINT1170 Feeding piping RP - Replacement Annual 6000 40 5 480 min FDM377
SRMB0119 A - Filler 2518 - MAINT1173 Flowmeter RP - Replacement Annual 6000 80 3 5 min FDM383 Time for single component
SRMB0119 A - Filler 2518 - MAINT6044 Flowmeter RP - Replacement Conditional 0 0 3 5 min FDE044 Time for single component
SRMB0119 A - Filler 2522 - MAINT1170 Product distribution RP - Replacement Annual 6000 40 5 480 min FDM377
SRMB0119 A - Filler 2525 - MAINT2271 Coupling product feeding RP - Replacement Six months 3000 40 3 30 min FDM379
SRMB0119 A - Filler 2525 PTF203 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 A - Filler 2575 - MAINT1168 Valve pneumatic connections CT - Control Monthly 500 7 2 5 min FNM251
SRMB0119 B - Base 3000 - MAINT2260 Capper base CL - Cleaning Daily 24 0 1 5 min FNM238
SRMB0119 B - Base 3020 - MAINT2578 Output tape OVERHEAD (belt drive) RP - Replacement Two years 12000 3 180 min FDM749
SRMB0119 B - Base 3023 - MAINT2272 Output tape RP - Replacement Annual 6000 80 3 60 min FDM382
SRMB0119 B - Base 3032 - MAINT1492 Starwheel control RP - Replacement Two years 12000 160 5 30 min FDM750 Time for single component
SRMB0119 B - Base 3063 - MAINT1177 Devices in the bottle body (output SOCKET NECK) RP - Replacement Annual 6000 80 3 5 min FDM387
SRMB0119 B - Base 3063 - MAINT1483 Output SOCKET NECK guide CT - Control Weekly 125 2 5 min FNM475
SRMB0119 B - Base 3065 - MAINT1167 Output starwheel (phasing) CT - Control Weekly 125 2 2 12,5 min FNM247
SRMB0119 B - Base 3065 - MAINT1177 Devices in the bottle body (output SOCKET NECK) RP - Replacement Annual 6000 80 3 5 min FDM387
SRMB0119 B - Base 4000 - MAINT2260 Filler base CL - Cleaning Daily 24 0 1 5 min FNM238
SRMB0119 B - Base 4016 - MAINT1492 Starwheel control 720 RP - Replacement Two years 12000 160 5 30 min FDM750 Time for single component
SRMB0119 B - Base 4033 - MAINT1179 Dummy bottle RP - Replacement Two years 12000 160 3 15 min FDM393
SRMB0119 B - Base 4034 - MAINT1185 Starwheel control pinion RP - Replacement Conditional 0 0 5 60 FDM411
SRMB0119 B - Base 4034 - MAINT2266 Starwheel engine CT - Control Monthly 500 7 3 5 min FNM249
SRMB0119 B - Base 4034 - MAINT2274 Starwheel control gearbox oil level GR - Greasing Two years 12000 160 2 20 min FGM034
SRMB0119 B - Base 4034 - MAINT2278 Starwheel engine RP - Replacement Conditional 0 0 5 60 min FDM394
SRMB0119 B - Base 4034 - MAINT2585 Base gear box RP - Replacement Two years 12000 160 3 480 min FDM753
SRMB0119 B - Base 4035 - MAINT2583 Phase sensor CT - Control Weekly 125 1 15 min FNE067
SRMB0119 B - Base 4036 - MAINT2584 Photocell CL - Cleaning Weekly 125 2 15 min FNE068
SRMB0119 B - Base 4037 - MAINT2265 Bottle ejector piston CT - Control Monthly 500 7 2 2 min FNM248
SRMB0119 B - Base 4037 - MAINT2277 Bottle ejector piston RP - Replacement Two years 12000 160 3 15 min FDM392
SRMB0119 B - Base 4039 - MAINT2281 Cooling bottle nozzles CL - Cleaning Monthly 500 7 2 5 min FNM261
SRMB0119 B - Base 4044 - MAINT2579 Belt - COMBI transmission unit RP - Replacement Two years 12000 160 3 60 min FDM751
SRMB0119 B - Base 4044 - MAINT2580 Belt - COMBI transmission unit CT - Control Quarterly 1500 20 3 15 min FNM477
SRMB0119 B - Base 4061 - MAINT1162 Neck handling tweezers CT - Control Daily 24 0 2 5 min FNM239 Time for single component
SRMB0119 B - Base 4061 - MAINT1167 Grip assembly (phasing) CT - Control Weekly 125 2 2 12,5 min FNM247
SRMB0119 B - Base 4061 - MAINT1176 Neck handling tweezers RP - Replacement Annual 6000 80 3 15 min FDM386 Time for single component
SRMB0119 C - Safeguard 5000 - MAINT6041 Doors sensor (COMBI base) CT - Control Daily 24 0 1 3 min FNE029
SRMB0119 C - Safeguard 5000 - MAINT6045 Doors sensor (COMBI base) RP - Replacement Conditional 0 0 3 5 min FDE045 Time for single component
SRMB0119 C - Safeguard 5004 - MAINT6041 Doors sensor (outlet base) CT - Control Daily 24 0 1 3 min FNE029
SRMB0119 C - Safeguard 5004 - MAINT6045 Doors sensor (outlet base) RP - Replacement Conditional 0 0 3 5 min FDE045 Time for single component
SRMB0119 C - Safeguard 5005 - MAINT6041 Doors sensor (filler) CT - Control Daily 24 0 1 3 min FNE029
SRMB0119 C - Safeguard 5005 - MAINT6045 Doors sensor (filler) RP - Replacement Conditional 0 0 3 5 min FDE045 Time for single component
SRMB0119 C - Safeguard 5020 - MAINT2581 GALVANI Filter RP - Replacement Annual 6000 80 2 10 min FDM752 Time for single component
SRMB0119 C - Safeguard 5020 - MAINT2582 GALVANI Filter CL - Cleaning Quarterly 1500 20 2 15 min FNM478
SRMB0119 C - Safeguard 5040 - MAINT2262 Safety plates CT - Control Daily 24 0 1 3 min FNM241
SRMB0119 C - Safeguard 5040 - MAINT2263 Doors safety plates CT - Control Daily 24 0 1 3 min FNM242
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7000 TRI-clamp gaskets RP - Replacement Annual 6000 2 5 min FDM088 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7001 DIN gaskets RP - Replacement Annual 6000 2 5 min FDM089 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 AVB223 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVE234 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVS219 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVF212 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 HVF209 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVG217 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVB284 MAINT7003 Diaphragm valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 RVG205 MAINT7003 Diaphragm valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 RVF201 MAINT7003 Modulating valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 RVG202 MAINT7003 Modulating valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 RVG203 MAINT7003 Modulating valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVF298 MAINT7003 MIXPROOF valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVF241 MAINT7003 MIXPROOF valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 AVS225 MAINT7003 MIXPROOF valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 OG212 MAINT7003 Non-return valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 OS201 MAINT7003 Non-return valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 OE201 MAINT7003 Non-return valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 OB201 MAINT7003 Non-return valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 Y - CIP/SIP Unit 6000 LSF206L MAINT7004 Level probe CL - Cleaning Annual 6000 80 2 5 min FNM119 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 PTF208 MAINT7005 Tank level probe CL - Cleaning Annual 6000 80 2 40 min FNM145 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7008 CO2 steriel filter RP - Replacement Annual 6000 80 2 15 min FDM183
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7009 Valve position controller CT - Control Annual 6000 80 1 2 min FNM112 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 FF200 MAINT7010 Filter cartridge RP - Replacement Annual 6000 2 30 min FDM174
SRMB0119 Y - CIP/SIP Unit 6000 PPF201 MAINT7011 Pump gasket RP - Replacement Annual 6000 80 2 60 min FDM173
SRMB0119 Y - CIP/SIP Unit 6000 PPS200 MAINT7011 Pump gasket RP - Replacement Annual 6000 80 2 60 min FDM173
SRMB0119 Y - CIP/SIP Unit 6000 OF220 MAINT7012 Speculum gaskets RP - Replacement Annual 6000 80 2 10 min FDM092
SRMB0119 Y - CIP/SIP Unit 6000 OF228 MAINT7012 Speculum gaskets RP - Replacement Annual 6000 80 2 10 min FDM092
SRMB0119 Y - CIP/SIP Unit 6000 EB200 MAINT7014 Heat exchanger RP - Replacement Conditional 0 0 3 30 min FDM176 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 TTB206 MAINT7016 Temperature probe CT - Control Four years 24000 3 10 min FNM042
SRMB0119 Y - CIP/SIP Unit 6000 TTS201 MAINT7016 Temperature probe CT - Control Four years 24000 3 10 min FNM042
SRMB0119 Y - CIP/SIP Unit 6000 FG202 MAINT7018 Y filter gaskets RP - Replacement Annual 6000 80 2 10 min FDM175
SRMB0119 Y - CIP/SIP Unit 6000 FG207 MAINT7018 Y filter gaskets RP - Replacement Annual 6000 80 2 10 min FDM175
SRMB0119 Y - CIP/SIP Unit 6000 FF207 MAINT7020 Outlet filter RP - Replacement Annual 6000 80 2 5 min FDM095 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 FG201 MAINT7022 Y filter CL - Cleaning Monthly 500 7 2 5 min FNM055
SRMB0119 Y - CIP/SIP Unit 6000 FG207 MAINT7022 Y filter CL - Cleaning Monthly 500 7 2 5 min FNM055
SRMB0119 Y - CIP/SIP Unit 6000 FF207 MAINT7024 Outlet filter CL - Cleaning Weekly 125 2 5 min FNM111 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 PCG203 MAINT7028 Pressure reducer gaskets RP - Replacement Annual 6000 80 2 10 min FDM098
SRMB0119 Y - CIP/SIP Unit 6000 PSG204 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 Y - CIP/SIP Unit 6000 PTF200 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 Y - CIP/SIP Unit 6000 PTF209 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 Y - CIP/SIP Unit 6000 PTS201 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 Y - CIP/SIP Unit 6000 PTE201 MAINT7049 Pressure switch gaskets RP - Replacement Annual 6000 80 2 10 min FDM448
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7068 Inlet air pressions CT - Control Daily 24 0 1 1 min FNM106
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7069 Pneumatic system connections CT - Control Monthly 500 7 2 10 min FNM107
SRMB0119 Y - CIP/SIP Unit 6000 FB200 MAINT7070 Washing solution filter CL - Cleaning Monthly 500 7 2 10 min FNM108
SRMB0119 Y - CIP/SIP Unit 6000 FB200 MAINT7077 Washing solution filter RP - Replacement Conditional 0 0 2 15 min FDM178
SRMB0119 Y - CIP/SIP Unit 6000 FSS200 MAINT7080 Flowmeter gaskets RP - Replacement Annual 6000 80 2 10 min FDM184
SRMB0119 Y - CIP/SIP Unit 6000 FTB209 MAINT7080 Flowmeter gaskets RP - Replacement Annual 6000 80 2 10 min FDM184
SRMB0119 Y - CIP/SIP Unit 6000 FSE201 MAINT7080 Flowmeter gaskets RP - Replacement Annual 6000 80 2 10 min FDM184
SRMB0119 Y - CIP/SIP Unit 6000 OF210 MAINT7082 Air stream trap CL - Cleaning Annual 6000 80 2 15 min FNM118
SRMB0119 Y - CIP/SIP Unit 6000 - MAINT7091 Solenoid RP - Replacement Conditional 0 0 2 3 min FDE028 Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 AVF298 MAINT7098 MIXPROOF valve CT - Control Six months 3000 40 2 3 min Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 AVS225 MAINT7098 MIXPROOF valve CT - Control Six months 3000 40 2 3 min Time for single component
SRMB0119 Y - CIP/SIP Unit 6000 AVF241 MAINT7098 MIXPROOF valve CT - Control Six months 3000 40 2 3 min Time for single component
SRMB0119 Y - CIP/SIP Unit 6010 LSB221H MAINT7004 Level probe CL - Cleaning Annual 6000 80 2 5 min FNM119 Time for single component
SRMB0119 Y - CIP/SIP Unit 6010 LSB222L MAINT7004 Level probe CL - Cleaning Annual 6000 80 2 5 min FNM119 Time for single component
SRMB0119 Y - CIP/SIP Unit 6010 PPB220 MAINT7011 Pump gasket RP - Replacement Annual 6000 80 2 60 min FDM173
SRMB0119 A - Filler 7000 - MAINT2269 Automatic centralised lubrication CT - Control Quarterly 1500 20 3 10 min FNM252
SRMB0119 A - Filler 7000 - MAINT2279 Lubrication automatic pump RP - Replacement Conditional 0 0 3 30 min FDM410
SRMB0119 A - Filler 7000 - MAINT2280 Lubircation automatic distributor CL - Cleaning Conditional 0 0 3 20 min FNM260
SRMB0119 A - Filler 7022 AVE213 MAINT7003 Diaphragm valve gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 A - Filler 7022 AVB208 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 A - Filler 7022 AVE201 MAINT7003 Throttle gaskets RP - Replacement Annual 6000 2 15 min FDM185
SRMB0119 A - Filler 7075 - MAINT2267 Pneumatic system CT - Control Monthly 500 7 2 5 min FNM250
Part C Maintenance Procedures Manual
TABLE OF CONTENTS
CONTROL/CLEANING PROCEDURES LIST.......................................................................................................................... C-1
REMOVAL/REPLACEMENT PROCEDURES LIST ................................................................................................................. C-2
LUBRICATION/GREASING PROCEDURES LIST .................................................................................................................. C-3
© Sidel S.p.A.
1/4
Maintenance Procedures Manual Part C
C-1 CONTROL/CLEANING PROCEDURES LIST
Control/cleaning procedures Number
Check the calibration of the temperature sensor FNM – 042

Clean the Y filter FNM – 055
Check the air supply pressure FNM – 106
Check the pneumatic system connections FNM – 107
Clean the washing solution filter FNM – 108
Clean the delivery side filter FNM – 111
Check the valve position controller FNM – 112
Clean the air condensate discharge valve FNM – 118
Clean the level sensor FNM – 119
Clean and check the level sensor Product tank FNM – 145
Cleaning the outside of the base FNM – 238
Checking the bottle neck gripper FNM – 239
Checking for leaks from membranes, actuators and seals FNM – 240
Checking the presence and condition of safety signage FNM – 241
Checking the presence of safety signage on doors FNM – 242
Checking the filling valve seal FNM – 244
Checking filling valves are secure FNM – 245
Checking equipment timing - Conveyor unit FNM – 247
Checking the bottle ejector pneumatic piston unit FNM – 248
Check the noise levels and inspect the drive FNM – 249
Cleaning and checking the pneumatic system for leaks FNM – 250
Checking filling valve pneumatic connections FNM – 251
Checking automatic greasing systems FNM – 252
Cleaning the automatic greasing distributors FNM – 260
Checking and cleaning the bottle cooling nozzles FNM – 261
Checking the bottle infeed neck guide FNM – 475
Belt wear – COMBI transmission unit FNM – 477
Clean the GALVANI laminar flow powered ventilation unit filters FNM – 478
© Sidel S.p.A.
Refer to the clearing procedures depicted in the “User Manual”.
2/4
Part C Maintenance Procedures Manual
C-2 REMOVAL/REPLACEMENT PROCEDURES LIST
Removal/replacement procedures Number
Substituting the TRI-clamp seals FDM – 088

Substituting the DIN seals FDM – 089
Substitute the inspection window seals FDM – 092
Substitute the delivery side filter FDM – 095
Substitute the pressure reducer seals FDM – 098
Substitute the centrifugal pump seal FDM – 173
Substitute the filter cartridge FDM – 174
Substitute the Y filter seals FDM – 175
Substitute the heat exchanger FDM – 176
Substitute the washing solution filter FDM – 178
Substitute the CO2 sterile filter FDM – 183
Substitute the flow switch seal FDM – 184
Substitute the valve seals FDM – 185
Substituting product infeed seal FDM – 379
Overhauling the outfeed belt FDM – 382
Substituting the filling valve FLOWMETER seals FDM – 383
Tank breather valve overhaul FDM – 385
Bottle body equipment overhaul FDM – 387
Bottle ejector pneumatic piston overhaul FDM – 392
Dummy bottle extractor overhaul FDM – 393
Substituting the pilot valve FDM – 395
Substitute the electric rotary manifold FDM – 397
Substituting worn components on the automatic greasing pump FDM – 410
Substitute the pressure switch seal FDM – 448
Overhauling the tilting outfeed belt (chain drive) FDM – 749
Substituting the COMBI transmission unit belts FDM – 751
Overhaul of GALVANI laminar flow powered ventilation unit filters FDM – 752
Overhauling the base gear motor FDM – 753
© Sidel S.p.A.
3/4
Maintenance Procedures Manual Part C
C-3 LUBRIFICATION/GREASING PROCEDURES’ LIST
Lubrication/Greasing procedures’ list Number
Changing the reduction gear oil FGM – 034

© Sidel S.p.A.
4/4
Part D Maintenance Procedures Manual
TABLE OF CONTENTS
CONTROL/CLEANING PROCEDURES LIST.......................................................................................................................... D-1
REMOVAL/REPLACEMENT PROCEDURES LIST ................................................................................................................. D-2
© Sidel S.p.A.
1/4
Maintenance Procedures Manual Part D
D-1 CONTROL/CLEANING PROCEDURES’ LIST
Control/Cleaning procedures’ list Number
Checking the front door sensors FNE – 029

Checking the emergency stop buttons FNE – 030
Checking the filling valve and carousel connections FNE – 031
Switching off the power supplies FNE – 059
Checking the timing sensors FNE – 067
Checking the photocells FNE – 068
© Sidel S.p.A.
Refer to the clearing procedures described in the “User Manual”.
2/4
Parte D Maintenance Procedures Manual
D-2 REMOVAL/REPLACEMENT PROCEDURES LIST
Removal/Replacement procedures list Number
Substitute a solenoid valve FDE – 028

Substituting the filling valve FLOWMETER FDE – 044
Substituting the front/rear door sensors FDE – 045
© Sidel S.p.A.
3/4
Maintenance Procedures Manual Part D
© Sidel S.p.A.
Page voluntarily left white
4/4
2 Check the calibration of the temperature sensor FNM - 042 1/2
Follow health and safety guidelines (see

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:
- Machine with the following power and product

supplies switched OFF:
air
mains power
process liquids
- Product filling system drained.
MATERIAL REQUIRED:
Consumables:
- Clean and dry rags.
Equipment:
- Thermometer
2 Check the calibration of the temperature sensor FNM - 042 2/2
DESCRIPTION OF OPERATIONS:
Preliminary operations
1) Drain the system by selecting the DRAINING mode

on the operator panel (see User manual).
A
2) Disable the compressed air supply:
Switch off the compressed air supply at

the knob (A).
3) Remove the guards preventing access to the

operating area. (Open the doors or detach the
panels fixed with screws).
Before you start this operation, read the

instructions in the component
manufacturer's use and maintenance
manual.
Checking calibration
4) Unscrew and remove the temperature sensor (B)
from its seat.
5) To check that the temperature sensor is measuring

correctly, proceed as follows:
- Measure the temperature of the test fluid with a
master thermometer. Note this temperature.
Immerse the temperature probe in the test fluid
and note its temperature reading.
- Check that the two readings are the same.
B
If the readings are not the same,

substitute the sensor.
Final operations
8) When you have finished, refit the temperature
sensor and screw it into its seat.
9) Close the guard doors and refit the guard panels
10) Return the filler to service.
2 Clean the Y filter FNM - 055 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:

2) Disable the services:

A
You must switch off the power and
product supplies before you start work:
Hazard. Components under pressure.
Chemical products may be present.
Switch OFF the mains electrical power

supply by moving the main switch lever
to 0 “OFF” (A).
Padlock the main ON-OFF switch in the OFF

(0) position.
Keep the key on your person or keep it in
place where access is restricted to
authorised persons. This is safety precaution
designed to prevent accidental start-up.
Switch OFF the compressed air supply

using the knob (B). B

Cleaning the filter

4) Unscrew the clamping Allen screw (C).
D C
5) Remove the filter (D) inside.

6) Wash the filter with running water and products
certified as safe for use with food products.
Final operations
7) When you have washed the filter (D), refit it to its
seat.
During dismantling and fitting, ensure

that the seal is not removed from its seat.
8) Tighten the Allen screw (C).
9) Close the guards removed previously. (Close the

doors or refit the fixed panels).
1 Check the air supply pressure FNM - 106 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:
Check (1)
- Machine rotating.
Check (2)
- machine stopped in STANDBY status with access
doors open;
services OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Equipment:
- Access ladder.
DESCRIPTION OF OPERATION:
(1) Checking pressures
1) Check the supply operating pressure of the A
pneumatic system on the pressure gauges (A): A
- Minimum pressure = 6 bar
- Maximum pressure = 8 bar
If you obtain other pressure readings,

substitute the filter cartridges.
2) Check the general pressure of the filler on the

pressure gauge (B):
- Pressure = 6 bar
If you obtain other pressure readings, adjust

the general pressure by turning the reducer
regulator knob.
B
3) Check the jack pressure (where fitted) from the

operator panel.
- Pressure = 1 bar higher than the filler
pressure measured on the filler tank.
Ensure that there are containers on the

carousel when you are checking the
values.
(2) Checking the pressures of the filler carousel

(where present)
4) Stop filling machine rotation from the control panel.
5) Enable opening of the mobile guard doors (see User
Manual).
6) Open the rear doors to access the operation area.
On systems fitted with a safety lockout or a
safety keylock. Before you start work,
remove the key and keep it on your person
for the entire period when you are inside the
guards.
This is a safety precaution to prevent
someone from inadvertently closing a guard
door and starting the machine.
7) Switch OFF the electrical power supply: C

Move the main ON-OFF switch lever to 0
“OFF” (C).

(0) position.
8) Climb on to the carousel using the ladder supplied.

9) Check the filling valve (D) pressures inside the D
pneumatic panel:
- Pressure = 5.5 bar
If you obtain other pressure readings,

substitute the filter cartridges.
Final operations
10) When you have finished the checks, close the doors
and return the keys to their storage position.
2 Check the pneumatic system connections FNM - 107 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
2 Check the pneumatic system connections FNM - 107 2/2

on the operator panel (see User manual). A
2) On the battery limit valves, shutdown the process

liquid supply.
To check the pneumatic system for leaks the

electrical and compressed air supplies must
be ON.
3) Remove the machine guards to enable access to the

working area (open the mobile doors and release
the fixed panels by removing the their screws).
Checking for leaks
4) Check the entire pneumatic system for leaks. Check

at the following points:
A. Pneumatic system piping and connections. B
B. Pressure reducers.
C. Pneumatic valve control stations.
Check the pneumatic system as follows:

- Wet the pneumatic connections with
soapy water. The formation of bubbles
indicates the presence of leaks.
- Listen for whistling sounds which may
indicate air leaks.
If you find any faults, substitute the faulty

parts.
Final operations
5) Close the guards removed previously. (Close the C

C
2 Clean the washing solution filter FNM - 108 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
- Machine stopped with power and product supplies

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


liquid supply.

be ON.

operating area. (Open the doors or detach the panels
fixed with screws).
Cleaning the filter

4) Close the manual infeed valve (A).
5) Open the drain valve (B) and drain off any remaining
liquid into the container (C).
Before you start to use chemical products,

obtain the relevant “Safety Data Sheets” A
provided by the supplier. The SDS indicate
the following:
- hazards;
- action in the event of accidental leaks; B
Chemicals and dirty rags must be

disposed of by specialist
companies in accordance with
current legislation in the country C
of use.
6) Release the locking collar (D) and remove the

filter (E) from inside.
certified as safe for use with chemical products.
Final operations
8) When you have washed the filter (E), refit it to its
seat.

that the seals remain in place.
9) Tighten the locking collar (D).

10) Close the drain valve (B) and open the manual
infeed valve (A).

12) Return the machine to service.
2 Clean the delivery side filter FNM - 111 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.

2) Switch off the services:

A

to 0 “OFF” (A).

(0) position.


Cleaning the filter

4) Release the 2 locking collars (C) and dismantle the
filter body.
5) Remove filter (D) from inside the body.
certified as safe for use with chemical products.
Final operations
7) When you have washed the filter (D), refit it to its
seat.
Substitute and fit the seals ensuring that

they are correctly seated.
8) Tighten the locking collars (C).

1 Check the valve position controller FNM - 112 1/1

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:
- Machine operating.
Checking procedure
1) Check the condition of the valve position indicator A
(A) of the electrical connections.
If the indicator (A) does not operate, check

the electrical connections and the
configuration of the electrical connections
(see the Use and Maintenance manual for
this item).
If the problem persists, substitute the
component at the first opportunity when
the machine is out of service.
2 Clean the air condensate discharge valve FNM - 118 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


A

to 0 “OFF” (A).

(0) position.



manual.
Cleaning the discharge valve

4) Unscrew the air condensate discharge valve (C) and
detach it from the filter unit.
5) Clean the discharge valve with the recommended
products.
Substitute faulty discharge valves.
Final operations
6) When you have finished cleaning the air condensate
discharge valve, refit this item by following the
procedures described above in reverse order.
7) Close the guards (close the mobile doors and screw
up the fixed panels).
2 Clean the level sensor FNM - 119 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.



manual.
Cleaning
4) Unscrew and remove the level sensor (C).
5) Using a damp cloth, carefully clean the sensor.

Check the condition of the level sensor: If
the external sheath of the sensor is
damaged, substitute the sensor.
Final operations
6) When you have finished cleaning, refit the level D
sensor following the procedure described above in
reverse order.
Align the sensor with the piping: The
marking (D) must be facing in the
direction of flow.
Substitute the seal. Fit the new seal in its

seat.
Example picture

Clean and check the level sensor

2 FNM - 145 1/4
Product tank

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
Template
MACHINE CONDITIONS:
Cleaning the sensor

air
mains power
process liquids
Checking the sensor

- Machine stopped in stand-by condition with
the following power and product supplies OFF:
air
mains power
process liquids

2 FNM - 145 2/4
Product tank
MATERIAL REQUIRED:
Consumables:
- Cleaning cloth.
Equipment:
- New seals.
- Ladder.


A

to 0 “OFF” (A).

(0) position.



2 FNM - 145 3/4
Product tank
Cleaning the level sensor

Ensure that the product tank is empty
and depressurised before performing the
operations described below.
E E
4) Using the ladder, go to the level sensor.
5) Disconnect the level sensor connector (C).
6) Detach the sensor from its mounting (flange, Tri-
clamp, DIN). Example: Clamp (D). F C
7) Remove the complete sensor from the tank.
8) Unscrew and remove the screws (E).
9) Remove the upper body (F) of the probe from its H
lower body (G).
10) Substitute the seals (H) and (I).
G
11) Using a damp cloth, carefully clean the sensor.
Check the condition of the level sensor: If

the external sheath of the sensor is
damaged, substitute the sensor. D
12) When you have finished cleaning, refit the level

sensor following the operations described above in I
reverse order.
When tightening the clamp (D), use

adjustable pliers (p) to keep the two ends
close together.
By hand, tighten the trigger (J) as indicated
on the card “Torque wrench settings” (Part A-
1-4).
Do NOT force the hold of the pliers on the
collar to prevent damage to the new seal.
J D
p

2 FNM - 145 4/4
Product tank
Checking the level sensor

13) Switch on the electrical power supply to the
machine.
14) Check the efficiency of the sensor as follows:
Check that the level value (expressed as a
percentage) measured by the sensor and displayed
on the operator panel matches the actual level of the
liquid in the tank as indicated on the inspection
window.
If this is not the case, substitute the

sensor.
Final operations
1 Cleaning the outside of the base FNM - 238 1/2
Follow health and safety guidelines

(see “USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
Electrical power supply OFF
Compressed air supply OFF
(see “Switching off power supplies” operation sheet)
PERSONS INVOLVED
- One maintenance technician (mechanical)
MATERIAL REQUIRED:
Consumables:
1 Cleaning the outside of the base FNM - 238 2/2
1) Remove any crushed or fallen bottles from along the

bottle path.
Before you start cleaning, check there

are no people inside the maintenance
area of the machine.
2) Clean the base using compressed air.
Set the compressed air pressure to the

maximum (6 to 8 bar).
3) Rinse the base to remove any product residues.
Final operations
4) Close the guard doors.
3 Checking the bottle neck gripper FNM - 239 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped with the JOG MODE enabled:

System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
3 Checking the bottle neck gripper FNM - 239 2/2
Checking the grippers

1) Check that there are no bent grippers (A).
2) Check the state of the rollers (B) and springs (C).
3) Check that the distance between the upper and
lower gripper is:
B A
In the event of inconsistency or

components worn / damaged, to restore
the optimal conditions (adjustments or
replacements).
To check the less accessible grippers,

rotate the transfer starwheels.
For this operation, use the MAINTENANCE
CONTROL PANEL in the JOG mode.
Before you move the carousel, make

sure there are no physical obstructions
preventing rotation.
Final operations
1) When you have finished the check, close the guard
doors.
2 Checking for leaks from membranes, actuators and seals FNM - 240 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:

System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
2 Checking for leaks from membranes, actuators and seals FNM - 240 2/2
Checking for leaks
1) Check for leaks of air or process gas from the filling

valve by running your hand under, above and
around the valve.
Perform this operation for the valves

accessible from the area of intervention.
2) Move your hands away from the filling valves and

rotate the machine using the JOG control until there
is a new set of valves in front of you ready for
checking.
Before rotating the carousel make sure

there are no physical obstructions
Use the MAINTENANCE CONTROL
PANEL in the JOG mode.
3) Repeat the procedure until the check has been

performed for the entire carousel.
If you find any leaks, note the number of

the valve and the fault so the problem
can be rectified during the next
maintenance stop.
Final operations
4) When you have finished the checks, close the
mobile guard doors.
1 Checking the presence and condition of safety signage FNM - 241 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
MACHINE CONDITIONS:
- machine rotating.
DESCRIPTION OF OPERATION:
Check that the safety signage is present at the points
indicated. Refit missing signage. Substitute any signage
which has become illegible. The following mandatory and
warning signs must be present:
Wear safety gloves
Wear safety footwear
Wear safety eyewear
Hazard warning: Live electrical

components
Hazard warning: Corrosive substances
Hazard warning: Do not walk on roof.
Hazard warning: Hot surfaces
Warning: No unauthorised access.
Warning: Do not remove safety devices
Warning: Do not clean, lubricate or repair

moving components.
1 Checking the presence of safety signage on doors FNM - 242 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
MACHINE CONDITIONS:
- machine rotating.
PERSONS INVOLVED
- One maintenance technician (general)
LEGEND:
Rear doors
Front doors
1 Checking the presence of safety signage on doors FNM - 242 2/2
Checking the door signs

1) Check the the safety signage (A) is present on all
machine access doors.
Wear safety eyewear
Wear safety footwear
Wear safety gloves
Change any safety signs (A) which are

damaged or have become illegible.
Replace missing signs.
A
2 Checking the filling valve seal FNM - 244 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine rotating and in CIP mode

System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
2 Checking the filling valve seal FNM - 244 2/2
Valve seal check
1) Check for any leaks during hot washing. Check that

the tank is at the correct pressure and that the
filling valves are open in the recirculating mode on
the dummy bottle.
Perform the check FROM OUTSIDE THE

FRONT SAFETY DOORS.
2) Under these operating conditions, watch the

rotation of the filling carousel and check for leaks of
liquid from the valve in the areas (A).
If you find any leaks, note the valves

involved. When CIP has been
completed, drain the machine and
switch it to the STANDBY state. Perform
the maintenance necessary to return the
components to full operating efficiency. A
A
2 Checking filling valves are secure FNM - 245 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:

System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
2 Checking filling valves are secure FNM - 245 2/2
Checking for leaks

1) Check the valve securing screws (A) are tightened
correctly.
Tighten any loose screws.
Perform this operation for the valves

accessible from the area of intervention.
2) Move your hands away from the filling valves and

rotate the machine using the JOG control until there
is a new set of valves in front of you ready for
checking.

PANEL in the JOG mode. A
3) Repeat the procedure until the check has been

performed for the entire carousel.
A
If you find any leaks, note the number of
the valve and the fault so the problem
can be rectified during the next
maintenance stop.
Final operations
mobile guard doors.
A
2 Checking equipment timing - Conveyor unit FNM - 247 1/13

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
- Machine stopped with the JOG MODE enabled:

System drained
Guard doors open

PERSONS INVOLVED:
1 maintenance technician
MATERIAL REQUIRED:
Consumables:
- clean and dry rags.
Equipment:
- test bottle.
The machine is timed correctly when:

- the bottles are conveyed
perpendicularly to the transfer surface;
- the bottles are free to rotate on their
own axis in the starwheel to starwheel
and starwheel to carousel transfer
points;
-
Checking the timing

C
1) Stop filling machine rotation from the control panel. B
2) In the manual mode from the operator panel, open
D
the bottle block so that the first bottle is loaded on to
A
the machine infeed starwheel and then close the E
bottle block. F
3) Enable opening of the guard doors and then open
the guard doors to access the maintenance area
(see “Switching off power supplies” operation
sheet”).
4) Enable carousel rotation using the JOG control and
check the timing in the transfer areas by watching
the movement of the bottle loaded on the machine. C A A
Before you move the carousel make sure
there are no physical obstructions D
preventing rotation. Use the
MAINTENANCE CONTROL PANEL in JOG E
mode. F
Setting the timing

If timing is not as described above, proceed
to set machine timing in the areas indicated
with the starting point being the area of
transfer between the capper infeed
starwheel (D) and the capper starwheel (E)
then working backwards towards the
machine infeed.
E
D C A
F
Areas for checking/maintenance
A. Machine infeed starwheel
B. Rinser infeed starwheel
C. Filler infeed starwheel E
D. Filler outfeed starwheel.
E. Capper starwheel C
D
F. Capper outfeed starwheel F C
B
D
A
A F E
A
1. Capper infeed starwheel timing

7) Working from the control panel, release the
motor brake (see the User Manual).
8) Working by hand, rotate the capper infeed

starwheel unti the grippers on the starwheel are
concentric with the capper compartments and the
fixed grippers on the filling valve.
9) Working from the control panel, obtain the

starwheel offset position (see the User Manual) and
lock the brake.
2. Filler carousel timing
10) In the JOG mode rotate the carousel until the fixed
grippers of the filling valves are concentric with the
filler infeed starwheel grippers. A
11) Working from the control panel, obtain the offset

position (see the User Manual) and lock the brake.
3. Filler infeed starwheel timing

13) Working by hand, rotate the filler infeed starwheel

until the grippers on the starwheel are concentric
with the filling valve fixed grippers.
14) Working from the control panel, obtain the

starwheel offset position (see the User Manual) and
lock the brake.
4. Rinser timing (only for BLOCKRINSER bases)
15) In the JOG mode, rotate the carousel until the fixed
grippers of the rinser carousel are concentric with
the grippers of the rinser infeed starwheel.

position (see the User Manual) and lock the brake.
5. Rinser infeed starwheel timing (only for

BLOCKRINSER bases)

18) Working by hand, rotate the rinser infeed

starwheel until the grippers on the starwheel are
concentric with the fixed grippers of the rinser.

position (see the User Manual) and lock the
brake.
6. Transfer starwheel timing (only COMBI bases)

21) Working by hand, rotate the transfer starwheels

until the grippers on the starwheels are concentric
with the grippers on the filler infeed starwheel.

brake.
7. Machine infeed starwheel timing (only for

BLOCKRINSER and STANDALONE)
Filler / Rinser infeed starwheel
Transfer infeed starwheel
24) Working by hand, rotate the machine infeed

starwheel until the compartments and grippers are
concentric with the bottle.

brake.
8. Capper outfeed starwheel timing

The capper unit can be fitted with four
different types of starwheel:
- BODY PICKUP
- MULTIBODY
- STANDARD NECK PICKUP
- GRIPPER NECK PICKUP
BODY PICKUP
26) Loosen the 6 securing screws of the capper outfeed

starwheel.
27) Rotate the capper outfeed starwheel until the
compartment is concentric with the bottle and the
capper compartment on the straight line between
the starwheel centre and the capper centre.
2
1 3
6 4
5
28) When the capper outfeed starwheel timing is

correct, block the position by tightening the 6
securing screws.
MULTIBODY

starwheel.
Adjust the play between the starwheel

compartment and the bottle to 1 mm.
2
1 3
6 4
5
31) Turn the knob (K) to set the mobile guide (L) of the
bottle descender guide.

securing screws.

3
33) Turn the knob (M) to set the height of the bottle
descender chute (N).
Adjust the distance between the chute and

the bottle bottom to approx. 5-6 mm.
M N
STANDARD NECK PICKUP

starwheel.
1 2
3
6
4
5

3

securing screws.
GRIPPER NECK PICKUP

starwheel.
1 2
3
6
4
5

securing screws.

3
Checking the bottle rotation and the passage play

40) Using a plug gauge with the same diameter as the
bottle neck, check the play between the
compartment and the guide (O).
41) Unscrew the stop screws on the guides (P) and

precision adjust the distance between the cavity
and the guide.
Checking the bottle rotation height.

42) Go to the carousel infeed/outfeed starwheels.
The next check must be performed with air

in the filling valves.
43) The filler outfeed starwheel must be 0.5 – 1 mm

lower than the filling valve bracket.
44) The filler infeed starwheel must be 0.5 - 1 mm
higher than the filling valve bracket.

3
The next check must be performed without

air in the filling valves.
45) Check that the radial play between the filling valve
bracket and the guide is approx. 1 mm.
46) Check that the play between the roller and the cam
is 1-2mm.
To facilitate the infeed and outfeed of the

bottles to and from the filler carousel, adjust
as follows:
- At the infeed: align the lowest point of
the starwheel with the filling valve
bracket; this means that the bottles will
always travel downwards to the other
points.
- At the outfeed: align the highest point
of the starwheel with the filling valve
bracket; this means that the bottle will
always drop downwards towards the
other points.
Final operations
47) When you have finished timing, close the guard
doors.
1 Checking the bottle ejector pneumatic piston unit FNM - 248 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
1 Checking the bottle ejector pneumatic piston unit FNM - 248 2/2
Check
1) Check the following ejector unit components:
- Check the sliding surface of the roller on the
cam (A).
- By hand, check that the pneumatic piston (B)
can slide freely.
- Check that the play between the sliding bushes
(C) and pins is no greater than 0.4 mm.
Substitute worn or damaged

components.
Final operations
2) When you have finished, close the mobile guard
doors.
3 Check the noise levels and inspect the drive FNM - 249 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Checking noise levels:

- Machine stopped:
System drained
Guard doors open
Visual inspection of critical points:

- Machine stopped with the JOG MODE enabled:
System drained
Guard doors open
PERSONS INVOLVED

3 Check the noise levels and inspect the drive FNM - 249 2/2
The procedure consists of 2 steps:

- Checking operating noise level.
- Visual inspection of critical points on B
the drive.
Checking operating noise level

1) Start filler rotation at production speed.
2) Go to zone A and stop the filler with an
emergency stop at the same time checking for A
any unusual noise. C
3) Repeat this operation at zones B and C checking
for unusual noises during the emergency stop.
Perform this check two or three times to
check for any faults and then proceed to B
the next step.
Visual inspection of critical points on the drive A

4) Operate the machine using the JOG control. C
Listen for excessive noise at the points
indicated. Excessive noise may indicate the
presence of the following faults:
- loose bolts;
- excessive play or wear.
C
Before you move the carousel make
sure there are no physical
obstructions preventing rotation. Use
the MAINTENANCE CONTROL PANEL
in the JOG mode.
5) Restore the correct operating conditions in the A B

event of any anomalies:
- tighten any loose bolts;
- substitute worn components. B B
Final operations
guard doors.
A C
3 Cleaning and checking the pneumatic system for leaks FNM - 250 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Ladder
Pneumatic system
3 Cleaning and checking the pneumatic system for leaks FNM - 250 2/2
Checking the pneumatic system for leaks
1) Check the entire pneumatic system for leaks or

deposits of condensate or oil in the following
areas:
A. Carousel shaft
B. Filler outfeed starwheel bottle ejector
C. Capper D
D. Bottle block A
B
C
If you identify any functioning faults,
restore the correct functioning
conditions by substituting any non-
conforming parts in accordance with
the relevant maintenance cards or by
draining/cleaning the parts with any
fluid inside.
Before you start to use oils, greases and A

lubricants, obtain the relevant “Safety
B
Data Sheets” provided by the supplier.
The SDS indicate the following:
C
- Hazards.
- Protection devices.
- First aid requirements.
- Fire prevention measures.
- Action in the event of accidental
spillage and leaks.
- Physical and chemical properties.
- Stability and reactivity. A
- Toxicological information.
- Ecological information. C B
- Disposal information.
- Shipping information. D
Oil, lubricants and dirty rags

must be disposed of by
specialist companies in
accordance with current B A
A
legislation in the country of use.
B
Final operations
2) When you have finished all checks and
cleaning, close the mobile guard doors.
C D C
2 Checking filling valve pneumatic connections FNM - 251 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Ladder
2 Checking filling valve pneumatic connections FNM - 251 2/2
Checking the connections
1) Climb on to the carousel using the ladder supplied.

Identify the pneumatic connections to be checked.
B
A
2) Check for leaks of valve control air from the

connectors (A) and from the connection hoses (B).
In the event of any leaks, note the

damaged components and substitute any
non-conforming parts in accordance with
that stated on the relevant maintenance
cards.
Final operations
3) When you have finished the check, close the guard
doors.
3 Checking automatic greasing systems FNM - 252 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Step A:
- Machine stopped in STANDBY state:
System drained
Guard doors open

Step B:
- Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
LEGEND:
Filler greasing area
(filler rack – capper – rinser)
Position of the main greasing pump (1)
3 Checking automatic greasing systems FNM - 252 2/2
The procedure for the general greasing

system consists of the following steps:
A. Check the automatic operation of the
greasing system
B. Visual inspection for leaks of grease at
critical points
Step A: B B
Check that there is grease inside the A B

general greasing pump (A).
1) Press the automatic greasing button on the

operator panel. B
2) Wait for the end of the automatic greasing cycle.
3) Check for any alarms at the end of the greasing
cycle and, if necessary, restore correct
functioning conditions to clear the alarms.
4) Repeat the procedure for each automatic
greasing system.
A B
Step B: A B
5) Go inside the machine to the filler / rinser (where

present) / capper rack.
6) Check for the presence of new, wet grease in the
areas (B) indicated. B
A B B
Final operations
mobile guard doors.
B A
Greasing circuit
3 Cleaning the automatic greasing distributors FNM - 260 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
LEGEND:
3 Cleaning the automatic greasing distributors FNM - 260 2/2
Substituting the pump components
Clean the distributors as instructed in the

relevant operation and maintenance
manual.
Before you start to use oils, greases and

lubricants, obtain the relevant “Safety Data
Sheets” provided by the supplier. The SDS
indicate the following:
- Hazards.
spillage and leaks.
- Stability and reactivity.
- Ecological information.
- Shipping information.
Oil, lubricants and dirty rags must

be disposed of by specialist
current legislation in the country
of use.
Final operations
1) When you have finished the maintenance work,
close the guard doors.
Greasing circuit
Maintenance Procedure Manual
2 Checking and cleaning the bottle cooling nozzles FNM - 261 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Check
- Machine rotating.
Cleaning
- Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
2 Checking and cleaning the bottle cooling nozzles FNM - 261 2/2
Checking the nozzles

1) Activate the "bottle bottom cooling system" in
MANUAL mode from the operator panel.
2) Visually check the spray from all the nozzles (A).
If a nozzle is blocked, make a note of its
position and clean it at the first
opportunity when the machine is
STOPPED AND POWERED DOWN (see
section below.
Cleaning the nozzles

3) Go to the bottle cooling unit and unscrew the
blocked nozzle (A).
4) Clean the nozzle using compressed air.

5) Clean the nozzle (A) then screw it back in to the

bottle cooling manifold.
Substitute damaged nozzles.
Final operations
doors.
2 Checking the bottle infeed neck guide FNM - 475 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
2 Checking the bottle infeed neck guide FNM - 475 2/2
Check the outfeed guide
1) Visually inspect the machine outfeed neck guide (A).

Check for wear.
Substitute any guides which are cut,

damaged or bent. (see the “Bottle body
equipment overhaul” maintenance sheet). A
Final operations
doors.
3 Belt wear – COMBI transmission unit FNM - 477 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Equipment:
- Binder frequency meter
Checking the belts
Checking of the belts is divided into two

steps:
a. Visual inspection to check for belt wear
b. Belt tensioning check
a. Visual inspection to check for belt wear

1) Check the side (A) and the teeth (B) of the belt for
cuts, fraying or any other signs of a possible belt
breakage.
Substitute the belt if damaged.

B A
b. Belt tensioning check

2) Position the Binder frequency meter (C) at a
distance of 5 mm under the belt.
3) Vibrate the belt and press the red button until a
value is displayed on the meter display.
The correct tension value is:

approximately 30 Hz
C
4) If the belt is not tensioned correctly, adjust the nuts

on the tensioner (D) until the correct tension is
obtained.
Make sure the tension is not too high.

Excessive tension will cause rapid belt
wear.
Final operations
2 Clean the GALVANI laminar flow powered ventilation unit FNM - 478 1/6
filters

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Ladder conforming to current accident
prevention regulations.
filters
Cleaning the standard filter

The filter consists of two parts:
- Pre-filter (on fan inlet)
- Fine filter (on fan outlet)
Cleaning the pre-filter
1) Using a ladder which complies with accident

prevention regulations, go to the powered
ventilation unit.
DO NOT climb onto the roof to
substitute the pre-filter. The roof is not
designed to support the weight of
persons.
2) Raise the pre-filter (A) and remove it from its seat.
3) Clean with compressed air taking care not to

damage the component.

4) Refit the pre-filter to its seat.

Take care not to crush the filter during
positioning. Slowly and carefully guide
the filter into position until it reaches
its final position.
filters
Cleaning the fine filter
5) Disconnect the electrical connections (B) of the

powered ventilation unit.
B
B
6) Unscrew the countersunk screws (C) on both

sides of the powered ventilation unit.
7) Using the handles (D) provided, lift the tilting
powered ventilation unit until it reaches the end
of its travel.
C
filters
8) Raise the filter (E) and remove it from its seat.
9) Clean with compressed air taking care not to

damage the component.

10) Refit the filter making sure that it is positioned in

the direction of the arrow (fr).
its final position.
fr
11) Grip the handles (D) and slowly guide the tilting
element into its closed position.
Take care not to crush the filter. Slowly

guide the tilting element into position.
12) Tighten the screws (C) to secure the tilting

element in its seat.
13) Reconnect the electrical connections (B).
filters
Cleaning the vertical filter (RFA only)
14) Go to the powered ventilation unit.

15) Remove the guard cover (F) by lifting it and
pulling it outwards in the direction of the arrow
as shown in the figure.
16) Raise the pre-filter (G) and remove it from its
seat.
F
G
17) Remove the metal frame by unscrewing the

retaining screws (H) on the sides of the
framework.
18) Loosen the four screws (I) securing the fan (J).
H
I
J
filters
19) Remove the fan unit (K) and the fine filter (L)
outwards.
20) Clean the pre-filter (G) and the filter (L) with
compressed air. Take care not to damage the
elements.

21) Refit the filters following the instructions given

above in reverse order.
Take care not to crush the filter
elements during positioning. Slowly
and carefully guide the filter into
position until it reaches its final
position.
22) Refit the guard cover (F) slowly guiding it back

into its closed position.
Crushing hazard. Slowly guide the

guard cover (F) back into position.
Final operations
23) When you have completed the operations
described above, return the filler to service.
2 Substituting the TRI-clamp seals FDM - 088 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.
1) Drain the system by selecting the DRAINING

mode on the operator panel (see User manual).

A

to 0 “OFF” (A).
Padlock the main ON-OFF switch in the

OFF (0) position.
authorised persons. This is safety
precaution designed to prevent accidental
start-up.
Switch OFF the compressed air supply B

using the knob (B).

Operations to substitute the seals

C
Substitute ALL THE TRI-clamp seals on the
machine.
4) Unscrew the trigger (C) and release it from its seat

by tilting it as shown in the figure.
5) Open the collar and remove the TRI-clamp.
6) Remove and substitute the seal (D).
On units fitted with a DIAPHRAGM in

addition to the seals, you must also
substitute the diaphragm. Proceed as D
follows:
- Remove the diaphragm and measure
the diameter of the hole.
- New diaphragms are supplied blanked
off.Take a new diaphragm and make a
hole with the same diameter.
- Fit the new diaphragm.
Final operations
7) When you have finished refit the TRI-clamp by
securing the collar using adjustable pliers (p) to
keep the 2 ends (E) close together.

C
8) By hand, tighten the trigger (C) as indicated on the
card “Torque wrench settings” (Part A-1-4).
p E
2 Substituting the DIN seals FDM - 089 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.
Equipment:
- Universal ring nut spanner.


A

to 0 “OFF” (A).

(0) position.


Substitute ALL THE DIN seals on the

machine.
1) Remove the ring nut (C) by unscrewing it using the

special wrench (p). p

C
Make sure you insert the seal in the
correct direction (asymmetrical seal).
D
Final operations
3) When you have finished tighten the ring nut (C) using
the wrench (p).
2 Substitute the inspection window seals FDM - 092 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.


4) Detach the inspection window (C) and remove the

seals as follows:
a. For inspection windows with a flange fitting,
unscrew the screws (D).
b. For inspection windows with a clamp fixing,
detach the pin (E) and open the collar (F).
b E
a D
F
D C
5) Remove the inspection window (C) and substitute the

seal.
Substitute the seals on both inspection

windows following this procedure.
Substitute the seal ensuring that it is

correctly positioned in its seat.
Final operations
6) When you have finished, fit the new seals and refit
the inspection windows (E) following the
instructions given above in reverse order.
When you refit the inspection windows,
check that there are no obstructions in the
piping which might interfere with the
efficiency of the machine.
7) Close the guards (close the mobile doors and

screw up the fixed panels).
2 Substitute the delivery side filter FDM - 095 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


A

to 0 “OFF” (A).

(0) position.


Substituting the filter

4) Release the 2 locking collars (C) and dismantle the
filter body.
5) Remove filter (D) from inside the body.
Final operations
6) Fit a new filter (D) in the filter seat.
Substitute the seals taking care to
ensure that they fit correctly in their
seats.
7) Tighten the locking collars (C).

2 Substitute the pressure reducer seals FDM - 098 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.

using the knob (B).
B


manual.
4) Detach the pressure reducer (C) from the infeed and

outfeed piping by removing the fittings.
Substituting the seals
5) Take the pressure reducer to the workbench and

proceed to substitute the seals (see the instructions
in the related use and maintenance manual).
Final operations
6) When you have finished, refit the reducer following
the dismantling procedure in reverse order.
During reassembly, check that there are no

extraneous objects inside the unit which
might reduce the efficiency of reducer
operation.

2 Substitute the centrifugal pump seal FDM - 173 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.


Substituting the pump seal
4) Detach the centrifugal pump from the inlet (C) and

outlet (D) connections.
D
Remove and substitute the seals.


obtain the relevant “Safety Data Sheets”
the following:
- hazards;

of use.
Perform this maintenance operation following

the instructions given in the component
manufacturer's use and maintenance manual.
Final operations
5) When you have finished, refit the pump to the inlet
and outlet pipes.


2 Substitute the filter cartridge FDM - 174 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.
- New filter cartridge.

on the operator panel (see User Manual).

A
Switch off the mains electrical power

to 0 “OFF” (A).
When you have switched off the electrical

power supply, padlock the main ON-OFF
switch in the OFF (0) position.
Keep the key on your person or keep it in a
authorised persons. This is a safety
start-up.
B
using the knob (B).

Substituting the filter cartridges
4) Operate the drain valve (C) on each filter to

discharge any residues remaining in the housing.
5) Unscrew the clamp (D).
6) Remove the housing (E).
7) Remove and substitute the filter cartridge (F).

D
Substitute the seal (G) ensuring that it is
correctly positioned in its seat.
If the sterile water filter cartridge is F

changed (bottle and cap handling), run
the CIP sanitisation procedure on the
processing piping downstream of the
second filter and the housing of the filter
itself before the filter is refitted. E
The quality of the treatment water must
comply with specification CDC004.18 and
specifically the Silt Density Index must
be < 1.
C
Final operations
8) When you have finished, refit the filter following the
operations described above in reverse order.
9) Fix the clamp collar (H) using adjustable pliers (p) to
keep the two ends together.
I H
10) By hand, tighten the trigger (I) as per the instructions

given on the card “Tightening torque values” (Part A-
1-4).
p
2 Substitute the Y filter seals FDM - 175 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


A

to 0 “OFF” (A).

(0) position.



manual.

4) Unscrew the clamping Allen screw (C).
D C
5) Remove and substitute the seals (D) inside.
Final operations
6) Fit the new seal (D) in its seat.
During fitting of the new seal, check that
there are NO obstructions inside the filter
which might interfere with efficient
operation.
7) Tighten the Allen screw (C).

2 Substitute the heat exchanger FDM - 176 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


A

to 0 “OFF” (A).

(0) position.



manual.
Substituting the heat exchanger

D
4) Detach the plate heat exchanger (C) by unscrewing
the 4 couplings (D).
5) Remove and substitute the heat exchanger (C).
Final operations
6) When you have finished, refit the heat exchanger

following the dismantling procedure in reverse order.

might reduce the heat exchanger
efficiency.

2 Substitute the washing solution filter FDM - 178 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:


liquid supply.

be ON.

operating area. (Open the doors or detach the panels
fixed with screws).

4) Close the manual infeed valve (A).
5) Open the drain valve (B) and drain off any remaining
liquid into the container (C).

A
the following:
- hazards;
B

current legislation in the country C
of use.
6) Release the locking collar (D).

7) Remove and substitute the filter (E) inside.
Final operations
8) Fit the new filter (E) in its seat.

that the seals remain in place.
9) Tighten the locking collar (D).

10) Close the drain valve (B) and open the manual
infeed valve (A).

2 Substitute the CO2 sterile filter FDM - 183 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.
- New filter cartridge.
Equipment:
- Universal ring nut spanner.


A

to 0 “OFF” (A).

(0) position.



D
4) Operate the drain valve (C) on each filter to
discharge any residues remaining in the housing.
5) Disconnect the IN and OUT connections (D).
6) Remove the fixings (E). Substitute the filter.
E
When you substitute the filter also
substitute the filter seal. Ensure that the
seal is correctly seated.
Final operations
C
7) When you have finished, refit the filter following the
operations described above in reverse order.
8) Tighten the fixings (E) as per the instructions given

on the card “Tightening torque values (Part A-1-4).


2 Substitute the flow switch seal FDM - 184 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.



4) Unscrew the clamping nut (C) and remove the flow
switch from its seat.
Final operations
6) When you have finished, refit the flow switch
following the instructions given above in reverse
order.
2 Substitute the valve seals FDM - 185 1/3

“USER Manual”).
Example picture
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.



the following:
- hazards;

manual.
Perform this maintenance operation on one

valve at a time. This will ensure that you do
not inadvertently confuse the positions of
the valves.
4) Disconnect any compressed air connections to the

valve.
5) Detach the valve from the piping by removing any
fittings.
6) Take the valve to the workbench and proceed to

substitute the seals (see the instructions in the
related use and maintenance manual).
Final operations
7) When you have finished, refit the valve following the
dismantling procedure in reverse order.

might reduce the efficiency of reducer
operating efficiency.

3 Substituting product infeed seal FDM – 379 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:

1) Unscrew the screws (A) with an appropriate tool.
2) Lower the feed piping (B) using the feet (C) if
necessary.
3) Unscrew the screws (D) with an appropriate tool.

4) Remove the coupling (E). Dismantle the coupling
at the workbench.
E
5) Unscrew the M8 hex head screws (F) together with

their nuts (G).
6) Dismantle the flanges (H). Remove and substitute
the seal (I).
F H I H G
Final operations
7) Reassemble the unit following the instructions
given above in reverse order.
8) Close the guard doors. Refit any guards removed
earlier.
3 Overhauling the outfeed belt FDM – 382 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
3 Overhauling the outfeed belt FDM – 382 2/2
Overhauling the belt B D
Guide profile
1) Unscrew the 4 securing screws (A) (2 on each C
side) and remove the sprocket guard (B).
2) Remove a joint link from the chain. Remove the A
outfeed belt chain (C).
3) Unscrew the fixing screws (D) and substitute the
two guide profiles.
The new guide profiles must be cut

and drilled to ensure alignment with
the previous securing points.
F E
Outfeed belt idle sprocket

4) Rotate the idle sprocket (E) until the two securing
screws (F) are accessible.
5) Unscrew the screws (F) and substitute the two
halves of the sprocket (E).
J
UCF support bearings H
6) Unscrew the screws (I). G
7) Remove the plate (G) from the shaft (J).
8) Remove and substitute the bush (H).
I
Final operations
9) When you have finished, refit the outfeed belt
unit following the operations described above in
reverse order.
3 Substituting the filling valve FLOWMETER seals FDM – 383 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
3 Substituting the filling valve FLOWMETER seals FDM – 383 2/2
Substituting the flowmeter seals
1) Climb onto the carousel and identify the flowmeter

(A) requiring substitution.
2) Disconnect the connector (B).
3) Unscrew the tri-clamp (C).
4) Remove the flowmeter (A) with the hose (D) still
connected.
5) Place the flowmeter on the bench, remove the tri-
clamp (E) and remove the hose (D).
6) Substitute the 2 seals (F).
F
B
Final operations
7) Refit the flowmeter following the instructions given
The tightness of the tri-clamps must
match the reference given in the
“General Information” table.

doors.
3 Tank breather valve overhaul FDM – 385 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Tank breather valve overhaul
1) Go to the work area.

2) Identify the rotary tank breather valve (A).
3) Loosen and remove the screws (B).

4) Remove the breather valve (A).
B
5) Overhaul the breather valve by (A) substituting

the following components: G D E
C. spring
D. bush
E. stop ring
F. pin membrane
G. seal
H
H. O-Ring
C F
Final operations
6) When you have finished, refit the valve following
the operations described above in reverse order.
Grease the work side lip and fit the seal

(G).

2 Bottle body equipment overhaul FDM – 387 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Bottle body equipment overhaul
The bottle body equipment overhaul

procedure consists of checking and
substituting the following:
machine outfeed starwheel guides
machine outfeed starwheel body*
(* only on the version with the standard neck pickup)
A. Overhauling the guides
1) Check the state of wear on the bottle body guides.
Substitute any guides which are cut,

damaged or bent.
B A
2) Unscrew the nuts (A) and remove the damaged
bottle guides (B).
3) Substitute the guides (B).
4) Unscrew the nuts (A).

B. Overhaul the neck pickup starwheel body
5) Check the state of wear on the bottle body

starwheels.
Substitute starwheels which are cut or

otherwise damaged.
D
6) Unscrew the nuts (C) and remove the components

of the bottle body starwheel (D).
7) Substitute the damaged starwheel (D) parts.
8) Unscrew the nuts (C).

C
Final operations
doors.
3 Bottle ejector pneumatic piston overhaul FDM – 392 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Overhauling the ejector

The overhaul procedure is divided into 3
steps:
- ejector unit dismantling
- ejector unit overhaul on a bench
- refitting the ejector after overhaul
1) Disconnect the 3 pneumatic connections (A).
Mark the position of the bolts relative to the

support plate so as not to lose the timing.
2) Unscrew the 3 securing bolts (B).

A
3) Remove the bottle ejector unit upwards.
B
B
4) Unscrew the nut (C) and remove the piston (D).

5) Unscrew the 2 couplings (E). E
6) Substitute the piston (D).
Fit the couplings (E) on the new

piston (D) using LOCTITE thread
locker.
C D
7) Unscrew the 2 bolts (F) and remove the guide pins

(G).
8) Remove the bushes (H) sideways and
substitute them.
H G
Final operations
9) When you have finished re-assemble the bottle
ejector unit by following the operations described
above in reverse.
Make sure the timing of the bottle ejector
unit is correct by tightening the 3 bolts
securing the support plate in the positions
marked at the beginning of the operation.
10) Close the mobile guard doors.

3 Dummy bottle extractor overhaul FDM – 393 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Overhauling the extractor

1) Disconnect the pneumatic connections (A). A F
2) Unscrew the screws (B) securing the piston.

3) Remove and substitute the Rilsan tube (C).
4) Remove the cotter pins (D) and remove the pin
(E).
5) Remove the pneumatic cylinder (F).
D
6) Make sure that the cylinder (N) has the

measurements shown in the figure:
164 mm
197 mm (STROKE= 60 mm)

F
7) Unscrew the nut (G) and the screw (H).

8) Remove the dummy bottle extractor cam (I). H
9) Remove and substitute the spacer (J). I
Final operations
10) When you have finished, refit the dummy bottle
extractor assembly following the instructions

3 Substituting the pilot valve FDM – 395 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:

System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
3 Substituting the pilot valve FDM – 395 2/2
Substituting the pilot valve

1) Go to the PILOT VALVE (A) to be substituted.
2) Disconnect the connectors (B) from the pilot valve.
3) Unscrew the screws (C) and substitute the pilot
valve (A) which is faulty.
If you need to substitute a pilot valve (A)

A
which you cannot reach from the
maintenance zone, proceed as follows:
Move your hands away from the filling B
valves and rotate the machine using the
JOG control until the pilot valve to be
substituted is in front of you in the
maintenance zone.

PANEL in the JOG mode.
C
Final operations
4) Refit the pilot valve (A) following the instructions
Make a note of the serial number marked
on the pilot valve. You will need this later
during initialisation (see “User Manual”).

doors.
3 Substitute the electric rotary manifold FDM – 397 1/3

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
1) Climb on to the filling carousel to access the

electric rotary manifold (A).
2) Disconnect the connections of the electric rotary
manifold (B).
3) Unscrew the three screws (C) securing the electric
rotary manifold.
4) Remove the electric rotary manifold assembly (A).
5) Unscrew the screws (D) and remove the flange (E). D

6) Substitute the ELECTRIC ROTARY MANIFOLD F
(F).
D
E
Final operations
7) When you have finished, refit the electric rotary
manifold by performing the operations described F
Position the electric rotary manifold (F), p

ensuring that the pin (p) is inserted in the
hole provided on the clamping bracket.
Reconnect the cabling by following the

indications given in the wiring diagram.

Substituting worn components on the

3 FDM – 410 1/2
automatic greasing pump

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
LEGEND:
Substituting worn components on the

3 FDM – 410 2/2
automatic greasing pump
Substituting the pump components
Substitute any worn components in the

automatic greasing pump (A) as instructed
in the relevant operation and maintenance
manual.

Sheets” provided by the supplier. The SDS A
- Hazards.
spillage and leaks.
- Shipping information. A
Oil, lubricants and dirty rags must

companies in accordance with A
of use.
Final operations A
1) When you have finished the maintenance work,
close the guard doors.
Greasing circuit
2 Substitute the pressure switch seal FDM - 448 1/3

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
Goggles
MACHINE CONDITIONS:

OFF:
air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New seals.


A

to 0 “OFF” (A).

(0) position.


Substituting the seal

manual.
4) Unscrew the clamping nut (C) and remove the

pressure switch from its seat.
Substitute the seal (D) and ensure that it

is correctly seated.
Final operations
6) When you have finished, refit the pressure switch
order.

might reduce the pressure switch efficiency.

3 Overhauling the tilting outfeed belt (chain drive) FDM – 749 1/6

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Safety eyewear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

(see “Switching off power supplies” operation sheet”)
PERSONS INVOLVED:
MATERIAL REQUIRED:
Consumables:
Equipment:
- Lifting equipment (min. capacity 500 kg).
- Trestle to support the belt.
Overhauling the belt

1) Position the trestle (A) under the tilting belt (B).
2) Unscrew the securing screws (C). Detach the tilting
belt (B) from the filler belt (D)
3) Detach and remove the chain from the belt.
C D
4) Unscrew the fixing screws (E) of the neck guide

support. By hand, remove the guide support (see the
maintenance card “Overhaul the bottle body fittings).
(example picture)
5) Before you remove the belt, position the forks of a

forklift truck or similar lifting equipment under the
belt.
To lift and transport the belt, use a fork

lift truck or similar equipment with a
minimum load bearing capacity of 500
Kg.
Exercise extreme caution during lifting

and handling. Take care not to damage
the belt components.
Keep all personnel away from the

operating area of the lifting device. Only
the operator trained to use the device
should be in the area.
6) Using an Allen key, unscrew the countersunk

screws (F).
7) With the aid of the lifting device positioned
previously, lift and remove the belt (D).
F
F
F
8) Turn the handwheel (G) to remove the feed

screw (H) from the lead nut (I).
9) Remove the belt support sleeve.
10) Change the scraper ring (K).
M L
11) Unscrew the screws (L).

12) Remove the bracket and the handwheel (M)
from the reduction gear drive shaft.
13) Remove a link from the chain (N) and remove

the chain.
Check chain (N) wear. Substitute worn

chains.
14) Remove the sprockets (P) from the two jacks

(O).
15) Unscrew the screws (Q) and slide the jack unit (O)
out and down to the floor.
Go to the work bench. Overhaul the jacks (O)

following the instructions in the
manufacturer’s manual.
S
Q
R
R
T
T
O P O
16) Unscrew the screws (R). Remove the flange (S). V V

17) Unscrew the screws (T). Remove the flange (U).
18) Unscrew the screws (V).

W
19) Lift and remove the hub (W).
20) Substitute the seal (X).
X
Final operations
21) When you have finished dismantling and
substituting wear parts, reassemble the unit by
performing the operations described above in
reverse order.
22) Close the guard doors. Close the guards.
3 Substituting the COMBI transmission unit belts FDM – 751 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Equipment:
- Binder frequency meter
3 Substituting the COMBI transmission unit belts FDM – 751 2/2
Substituting the belt
1) Loosen the belt using the nuts on the tensioner

(A).
2) When the belt is loose, slide the belt off the
pulleys.
3) Fit a new belt by wrapping it around the pulleys as

shown in the diagram.
4) Position the Binder frequency meter (B) at a
distance of 5 mm under the belt.
5) Vibrate the belt and press the red button until a
value is displayed on the meter display.
6) Adjust the nuts on the tensioner (A) until the
following value is shown on the meter:
approximately 30 Hz
Make sure the tension is not too high.

Excessive tension will cause rapid belt
wear.
Final operations
B
2 Overhaul of GALVANI laminar flow powered ventilation unit FDM – 752 1/6
filters

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Ladder conforming to current accident
prevention regulations.
filters
Overhauling the standard filter

The filter consists of two parts:
- Pre-filter (on fan inlet)
- Fine filter (on fan outlet)
Overhauling the pre-filter
1) Using a ladder which complies with accident

prevention regulations, go to the powered
ventilation unit.
DO NOT climb onto the roof to
substitute the pre-filter. The roof is not
designed to support the weight of
persons.
2) Raise the pre-filter (A) and remove it from its seat.
3) Substitute the pre-filter. Fit the new pre-filter in its

seat.
its final position.
filters
Overhauling the fine filter
4) Disconnect the electrical connections (B) of the

powered ventilation unit.
B
B
5) Unscrew the countersunk screws (C) on both

sides of the powered ventilation unit.
6) Using the handles (D) provided, lift the tilting
powered ventilation unit until it reaches the end
of its travel.
C
filters
7) Raise the filter (E) and remove it from its seat.
8) Substitute the filter. Fit the new filter making sure

that it is positioned in the direction of the arrow
(fr).
its final position.
fr
9) Grip the handles (D) and slowly guide the tilting
element into its closed position.
Take care not to crush the filter. Slowly

guide the tilting element into position.
10) Tighten the screws (C) to secure the tilting

element in its seat.
11) Reconnect the electrical connections (B).
filters
Overhauling the vertical filter (RFA only)
12) Go to the powered ventilation unit.

13) Remove the guard cover (F) by lifting it and
pulling it outwards in the direction of the arrow
as shown in the figure.
14) Raise the pre-filter (G) and remove it from its
seat.
F
G
15) Remove the metal frame by unscrewing the

retaining screws (H) on the sides of the
framework.
16) Loosen the four screws (I) fixing the fan (J).
H
I
J
filters
17) Remove the fan unit (K) and the fine filter (L)
outwards.
18) Substitute the pre-filter (G) and the filter (L) by

order.
Take care not to crush the filter elements
during positioning. Slowly and carefully
guide the filter into position until it
reaches its final position.
19) Refit the guard cover (F) slowly guiding it back

into its closed position.
Crushing hazard. Slowly guide the guard

cover (F) back into position.
Final operations
20) When you have completed the operations
described above, return the filler to service.
5 Overhauling the base gear motor FDM – 753 1/4

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Lifting device (minimum load capacity 500 kg).
1) To to the base drive unit.
Any piping obstructing movement should

be removed after you have drained the
pipes (see “USER Manual”).
2) Before you remove the drive unit, position the forks

of a transpallet or similar lifting equipment under the
unit.
To lift and transport the drive unit, use a

transpallet or lifting equipment with the
following characteristics:
- minimum load bearing capacity 500
Kg
- low enough to pass under the filler
base.
Take care not to damage the drive unit

components during lifting and moving.
Do not modify the machine stopped

position.
C
Overhauling the gear motor
3) Remove the motor guard by unscrewing its

retaining screws.
4) Disconnect the connectors (A) from the motor.
5) Unscrew the screws (B) from the 4 stud bolts (C)
holding the reduction gear mounting plate.
6) Using the lifting equipment positioned previously,

remove the base drive unit and take it to the
bench. B
7) Unscrew the screws (D).

8) Remove the brushless motor (E) from the reduction
gear.
F F
J
D E
K
M
9) Unscrew the screws (F) and their nuts (f).
10) Remove the gears (G).
11) Unscrew the screw (H) and remove the shaft (I).
12) Remove the tab (J) by unscrewing the screws.
Check the tab. Substitute if damaged.
13) Remove the flange (K). N
14) Remove and substitute: O

- the seal (L)
- the ring (M)
15) Unscrew the screws (N) and remove the plate (O). Q
P
16) Unscrew the screws (P) and remove the fixing
flange (Q). P
17) Remove the reduction gear (P) Q Q
Refer to the reduction gear manual provided

by the manufacturer and proceed as follows:
- check the play of the outfeed shaft;
- substitute the seal rings;
- change the oil.
P
H
Final operations
18) When you have finished, refit the drive unit
following the operations described above in reverse
order.
Check and carefully clean all the
components during re-assembly.
Substitute all the seals.
Make sure that the connection is as

specified on the electrical diagram.
The oil removed from the gears must be

collected in a container and forwarded to a
specialist disposal company in accordance
with current legislation in the country of use.
Reconnect any piping dismantled during

maintenance to improve access.
19) Close the doors. Refit the guards.

2 Changing the reduction gear oil FGM – 034 1/4

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
- Special oil for reduction gears (see table below).
Equipment:
- Oil filling pump.
Greasing the bearings

Sheets” provided by the supplier. The SDS
- Hazards.
- Action in the event of accidental spillage
and leaks.
- Shipping information.
Oil, lubricants and dirty rags must B

current legislation in the country of
use.
1) Align the used oil container with the oil drain plug
(A).
2) Remove the drain plug (A) and allow the oil to run
into the used oil container positioned previously.
3) Remove the filler cap (B) to facilitate draining.
4) When you have drained all the oil from the reduction
gear, refit and tighten the drain plug (A) complete
with a new seal.
Remove the used oil container and
dispose of the oil in accordance
with current legislation in the
country of use.
5) Fill the reduction gear with the oil specified. Fill at A

the filling point (B). Use the filling pump (see oil
table).
Gear motor type 80.81 100 125 140 160 180 200
Capacity
(litres) 2 3.8 7 8.3 13 15.3 24
6) After 30 seconds check the level using the level plug

(C). B
The CORRECT LEVEL (a) is between the

halfway point and the bottom point of the
level glass.
The minimum oil level must NOT fall below
the MINIMUM LEVEL (b).
7) Top up the oil in the reduction gear until the level is

correct (a).
8) When filling is complete, refit the filling cap (B) C
complete with a new seal.
a b
Final operations
Clean the reduction gear using a clean and

dry rag.
9) When you have finished changing the oil, close the

guard doors.
Oil table
ISO VG KINEMATIC FOOD SAFE
VISCOSITY VISCOSITY AT SAFETY
USE APPLICATION AREA SYMBOL MAKE NAME
CLASS 40° C (min-max) APPROVAL H1
(DIN 51519) mm2/s (USDA/NSF)
Klübersynth GH 6-220 220 -
Gears 220 Klüber
Klübersynth UH1 6-220 232 H1

Gears 320 Klüber
Reduction gears*
Gears 460 Klüber

Gears 680 Klüber
Pneumatic Pneumatic system

system lubricators, tank lifting air 32 Klüber Klüber Summit HYSYN FG 32 33 H1
lubrication motor
Pneumatic
Jack lubrication tank 15 Klüber Klüber Summit HYSYN FG 15 15 H1
systems
Pneumatic Bluestar and Newcanfill

32 Klüber Klüber Summit HYSYN FG 32 33 H1
systems filling valves
* The reduction gear specifications are given in the “Reduction gear lubrication specification table”
Reduction gear lubrication specification table

Reduction Screw speed Design type
ISO VG
gear size rpm B3 B6 B7 B8 V5 V6
= 280 680
32, 40, 50,
63, 64, 80,
81 > 280 320
2800 - 1400 320

1400 - 710 320
100 710 - 355 460

355 - 180 680
Reduction Quantity of oil (litres)
< 180 680
gear size B3 B6, B7 B8 V5, V6
2800 - 1400 320/220* 32 0.2 0.25 0.2 0.2
1400 - 710 320 40 0.32 0.4 0.32 0.32
125, 126,
710 - 355 460 50 0.5 0.7 0.5 0.5
160, 161
355 - 180 680/460** 63, 64 1 1.3 1 1
< 180 680 80, 81 1.5 2.5 2 1.5
2800 - 1400 220 100 2.1 6.3 4.5 3.3
Rossi 1400 - 710 320/220* 125, 126 3.8 11.6 8.8 6.3
reduction
710 - 355 460/320*** 160, 161 6.5 20.8 16.5 11.2
gears
200, 250 355 - 180 460 200 10.4 38 31.5 21.2
< 180 320 250 18.3 67 53 35.7
* Use ISO 320 oil for reduction gears B3,V5, V6 and ISO 220 oil for B6, B7, B8.
** Use ISO 680 oil for reduction gears B3, V5, V6 and ISO 460 oil for B6, B7, B8.
*** Use ISO 460 oil for reduction gears B3, V5, V6 and ISO 320 oil for B6, B7, B8.
Right-angle gear-boxes Angular output speed rpm ISO VG
> 710
710 - 280 *
SIZE 80, 100, 125
280 - 90
< 90
> 710 150
710 - 280 220
SIZE 160, 200, 250, 320
280 - 90 320
< 90 460
* Right-angle gearboxes sizes 80 to 125 do not require lubrication because they are supplied complete with synthetic grease for lifetime greasing.
1 Checking the front door sensors FNE - 029 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Check 1
- Machine rotating.
Check 2
- Machine stopped in STANDBY state:
System drained
Guard doors open
PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
LEGEND:
Front doors fitted with interlocked sensors
and door lock
Rear doors fitted with interlocked sensors
and door lock
1 Checking the front door sensors FNE - 029 2/2
Check 1
1) During a production cycle, check on the operator

panel that the opening of all doors is DISABLED.
2) With the machine rotating, try to open the doors.

Check that the following condition is present:
- It must NOT be possible to open the doors when
the machine is operating.
If this is not the case, check the

alignment of the keys (A) with the A B
interlocked sensors (B).
Check 2
3) Stop filling machine rotation from the control panel.

Enable opening of the front mobile guard doors (see
the “Switching off power supplies” operation sheet).
4) Open ONE door and try to start the machine from

the operator panel. It should not be possible to start
the machine and an alarm message indicating that a
door is open will appear on the operator panel.
5) Close the door. Repeat the check on ALL the front
mobile guard doors.
If this is not the case, check the

alignment of the keys (A) with the
interlocked sensors (B).
If the alignment is correct but the fault

persists this indicates that the sensor is
damaged. Substitute the faulty sensor.
Final operations
guard doors.
1 Checking the emergency stop buttons FNE - 030 1/1

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
MACHINE CONDITIONS:
- Machine rotating without bottles.
1) During production, press the emergency stop button

and check the following conditions:
- Immediate machine stop (i.e. control voltage is
cut to the electric motor contactors; the PLC,
adjustment tools, the monitors and the main
compressed air solenoid valve and pressure
switch remain powered up).
- Red light on signal light column switched ON
flashing.
- Actuation of buzzer.
To restart the machine, release the

emergency stop button (rotate in a clockwise
direction) and press the reset button.
Check the functioning of all the

emergency stop buttons on the filler.
1 Checking the filling valve and carousel connections FNE - 031 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open
PERSONS INVOLVED
- One maintenance technician (electrical)
MATERIAL REQUIRED:
Consumables:
1 Checking the filling valve and carousel connections FNE - 031 2/2
O C M
Checking the electrical connections H
Routinely check the condition I

E
of the electrical connections
for burns, corrosion and the B D
condition of the insulation.
F A
1) Carefully check the electrical J K
connections indicated below:
G N L
- Front (A) and rear door (B) safety
sensor.
- Main motor (C).
O C M
- Valve 1 sensor (D). H
- Bottle presence sensors (E).
I
- Electric manifold (F). E
- Filling valve FLOWMETER (G). B D

- Pneumatic system stations (H). F A
- Modulating and pneumatic valves (I).
J K
- Pilot valve (J).
G N L
- Jog (K).
- HMI (L).
- Dummy bottle sensor (M).
- Outfeed belt bottle unloading safety B J G F H
sensor (N).
D I
- Main electric cabinet (O).
A O
N C
K M
Final operations
2) When you have finished, close the L E
mobile guard doors.
3) Return the filler to service. I H H I
B
O C B
D F
J
N O
G
M J
E G
K F
A C L N D
1 Switching off the power supplies FNE - 059 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Depending on the maintenance operation required,

perform the following operations in the order shown:
Drain the system.

Open the guard doors.
Switch off the mains power supply.

Switch off the compressed air supply.
Draining the system

on the operator panel (see User Manual).
1 Switching off the power supplies FNE - 059 2/2
Opening the guard doors.
2) With the machine stopped, enable opening of the

mobile guard doors (see User Manual).
3) Open the guard doors to access the maintenance
area.
On systems fitted with a safety lockout or a

safety keylock. Before you start work,
remove the key and keep it on your person
for the entire period when you are inside the
guards. This is a safety precaution to
prevent someone from inadvertently closing
a guard door and starting the machine.
Switching off the mains power supply.
Do NOT perform any work on the

machine until the services are switched
off and locked out. Crushing hazard in
the event of inadvertent start-up.
A
Switch off the mains electrical power
to 0 “OFF” (A).
When you have switched off the electrical

power supply, padlock the main ON-OFF
switch in the OFF (0) position.
Switching off the compressed air supply.

using the knob (B).
With the electrical power supply ON:

When you have switched off the
compressed air supply, padlock the knob in B
the OFF (0) position.
Keep the key on your person or keep it in a
authorised persons. This is safety a
start-up.
1 Checking the timing sensors FNE - 067 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
1 Checking the timing sensors FNE - 067 2/2
Checking the sensors

1) Clean the timing sensors (A).
2) Check that the timing sensors are correctly fixed.
Use the references (B) to align the timing

sensors.
Final operations
1 Checking the photocells FNE - 068 1/1

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Checking the photocells
1) Clean the projector (emitter) with a clean, dry cloth.
Final operations
2 Substitute a solenoid valve FDE - 028 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:

air
mains power
process liquids
MATERIAL REQUIRED:
Consumables:
Components:
- New solenoid valves.
2 Substitute a solenoid valve FDE - 028 2/2
1) Stop the machine and switch off the power and

product supplies. A


to 0 “OFF” (A).

(0) position.
Switch OFF the compressed air supply B

using the knob (B).

Substituting a solenoid valve
Substitute the solenoid valve following the

instructions in the related User and
Maintenance Manual.
Final operations
3) When you have completed maintenance, close the
guards removed previously. (Close the doors or refit
the fixed panels).
3 Substituting the filling valve FLOWMETER FDE - 044 1/2

OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Goggles
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open


PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
3 Substituting the filling valve FLOWMETER FDE - 044 2/2
Substituting the flowmeter seals
1) Climb onto the carousel and identify the flowmeter

(A) requiring substitution.
2) Disconnect the connector (B).
3) Unscrew the tri-clamp (C).
4) Remove the flowmeter (A) with the hose (D) still
connected.
5) Place the flowmeter on the bench, remove the tri-
clamp (E) and remove the hose (D).
6) Substitute the flowmeter (A).
Substitute the seals (F) before fitting the
flowmeter.
Mount the seals without using grease or
oil.
C
F
B
Final operations
7) Refit the flowmeter following the instructions given
The tightness of the tri-clamps must
match the reference given in the
“General Information” table.

doors.
3 Substituting the front/rear door sensors FDE - 045 1/2

“USER Manual”).
OPERATION SAFETY:
Compulsory PPE:
Gloves
Safety footwear
Helmet
Overalls
MACHINE CONDITIONS:
Machine stopped:
System drained
Guard doors open

PERSONS INVOLVED
MATERIAL REQUIRED:
Consumables:
Equipment:
- Ladder conforming to current accident prevention
regulations.
- Triangular socket spanner
LEGEND:
Front doors fitted with interlocked sensors
and door lock
Rear doors fitted with interlocked sensors
and door lock
3 Substituting the front/rear door sensors FDE - 045 2/2
Substituting the front door sensors
3) Open the operator door which has the faulty sensor.

C A
If the door remains locked you must release
it mechanically. To do this, use the triangular
socket spanner provided.
4) Unscrew the screws (A).

5) Disconnect the electric cable (B).
6) Substitute the sensor (C).
7) Fit the new sensor (C) following the instructions

A B
Substituting the rear door sensors
8) Using a ladder which conforms to applicable safety

standards, go to the sensors to be substituted.
9) Disconnect the electric cable (D).
10) Remove the two pins (E) securing the sensors in
place (one per sensor) using a thin punch.
11) Remove both the sensors (F), as shown in the
figure.
12) Substitute the sensors (F).
13) Fit the new sensors (F), reversing the steps

described above.
F1 F2
Final operations
14) Close the guard doors. F
E

Filler Maintenance

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Filler Maintenance

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Technical Documentation

Maintenance Procedures Manual

All figures and photographs are for information only

Publication Date: 25/06/2013

SIDEL S.p.A. - Via La Spezia, 241/A - (43100), Parma ITALY

NON CONTRACTUAL DOCUMENT: if any constructive or commercial requirement should

SERVICE CATALOGUE PRESENTATION PART A

MAINTENANCE PLAN PART B

MECHANICAL INTERVENTION PROCEDURES PART C

ELECTRICAL MAINTENANCE PROCEDURES PART D

MAINTENANCE PLAN ................................................................................................................................................... Part B

MECHANICAL INTERVENTION PROCEDURES ......................................................................................................... .Part C

ELECTRICAL MAINTENANCE PROCEDURES............................................................................................................ Part D

ASSISTANCE CATALOGUE PRESENTATION PART A

MAINTENANCE PLAN PART B

MECHANICAL MAINTENANCE PROCEDURES PART C

ELECTRICAL MAINTENANCE PROCEDURES PART D

A-1 MAIN PRESENTATION

A-1-2 General safety information

WARNING: In the event of checks running programmable logic (PLC) installed

WARNING: Tampering with or removing safety devices is strictly prohibited. The

A-1-3 Using the assistance card catalogue

• Information included on the control bar:

Minimum operator level

• Control bar list::

What do the maintenance procedures describe?

How are the maintenance procedures used?

A-1-4 Tightness values

Clamp 1” e 1 ½” Clamp ½” e ¾” Clamp 4”

Clamp 3” Clamp 2 ½” Clamp 2”

Clamp 6” © Sidel S.p.A.

Screw torque wrench settings

A-1-5 Lubricant/grease specifications

Page intentionally left blank

SERVICE CATALOGUE PRESENTATION PART A

MAINTENANCE PLAN PART B

MECHANICAL INTERVENTION PROCEDURES PART C

ELECTRICAL MAINTENANCE PROCEDURES PART D

B-1 MAINTENANCE PLAN

SERVICE CATALOGUE PRESENTATION PART A

MAINTENANCE PLAN PART B

MECHANICAL INTERVENTION PROCEDURES PART C

ELECTRICAL MAINTENANCE PROCEDURES PART D

REMOVAL/REPLACEMENT PROCEDURES LIST ................................................................................................................. C-2

LUBRICATION/GREASING PROCEDURES LIST .................................................................................................................. C-3

C-1 CONTROL/CLEANING PROCEDURES LIST

Control/cleaning procedures Number

Check the calibration of the temperature sensor FNM – 042

Refer to the clearing procedures depicted in the “User Manual”.

C-2 REMOVAL/REPLACEMENT PROCEDURES LIST

Removal/replacement procedures Number

Substituting the TRI-clamp seals FDM – 088

C-3 LUBRIFICATION/GREASING PROCEDURES’ LIST

Lubrication/Greasing procedures’ list Number

Changing the reduction gear oil FGM – 034

SERVICE CATALOGUE PRESENTATION PART A

MAINTENANCE PLAN PART B

MECHANICAL INTERVENTION PROCEDURES PART C

ELECTRICAL MAINTENANCE PROCEDURES PART D

REMOVAL/REPLACEMENT PROCEDURES LIST ................................................................................................................. D-2

D-1 CONTROL/CLEANING PROCEDURES’ LIST

Control/Cleaning procedures’ list Number

Checking the front door sensors FNE – 029

Refer to the clearing procedures described in the “User Manual”.