OPERATIONS MANUAL AUTOMATIC SPINDLE CAPPER (Shown above in one of several configurations.) 3999 East Hupp Road, Bldg. R-43 Phone: 219-393-3600 La Porte, IN 46350 Fax: 219-393-5260 www.liquidpackagingsolution.com
AUTOMATIC SPINDLE CAPPER Record the information below for servicing and maintenance throughout the life of the machine. SERIAL NUMBER: ORDER NUMBER: INSTALLED: Page 2 of 40
TABLE OF CONTENTS TOPIC PAGE List of Illustrations 4 Safety Precautions and Warning Summary 5 Machine Specifications and Facility Power Requirements 6 Glossary of Terms 7 Uncrating the Machine 8 Introduction and Theory of Operation 9 Operator Controls 10 Set-Up, Change-Over, and Machine Adjustments 14 Operating Instructions and Sequence of Operation 22 Routine Maintenance 23 Gripper Belt Maintenance and Replacement 24 Spindle Wheel Replacement 30 Troubleshooting 32 Assembly Drawings 34 Spare Parts Kit 40 Page 3 of 40
LIST OF ILLUSTRATIONS FIGURE NUMBER TITLE PAGE 1 Operator Control Panel 10 2 Emergency Stop (E-STOP) Button 11 3 Capper Power Switch 11 4 Power Height Control 11 5 Spindle Power and Speed Controls 12 6 Gripper Belt Power and Speed Controls 12 7 Elevator Power and Speed Controls 13 8 Conveyor Belt Power and Speed Controls 13 9 Cap Present Sensor 14 10 Level the Conveyor Belt 15 11 Level the Capper Housing from Side to Side 15 12 Level the Capper Housing from Front to Back 16 13 Level the Gripper Belts from Side to Side 16 14 Level the Gripper Belts from Front to Back 17 15 Solid Spacers and Drive Spacers 17 16 Stomper Activation Sensor 18 17 Proper Stabilizer Height Position 18 18 Spindle Width Adjustment Controls 19 19 Level Spindle Alignment 19 20 Proper Spindle Wheel Contact with Cap 19 21 Clutch Torque Nut 20 22 Gripper Belt Height Control 20 23 Gripper Belt Width Control 20 24 Proper Gripper Belt Contact with Bottle 21 25 Place Wood on Conveyor Belt 25 26 Removal of Spacer Bolts 25 27 Idler Pulley Tension Bolt 26 28 Bottom Idler Pulley Bolt 26 29 Spacer Block Bolts 27 30 Spindle without Clutch 30 31 Spindle with Clutch 30 Page 4 of 40
SAFETY PRECAUTIONS AND WARNING SUMMARY Listed below are general safety precautions, as well as a summary of Warnings found throughout this Manual. READ AND UNDERSTAND ALL OF THEM PRIOR TO DOING ANYTHING WITH THIS EQUIPMENT. Failure to read and understand all safety precautions and Warnings may risk injury to personnel or damage to the equipment. Only individuals trained and qualified to work on this equipment may perform maintenance, troubleshooting, diagnostic, or repair work on it. Never insert fingers into any part of machine. Note the location of the EMERGENCY STOP (E-STOP) button on the top of the Operator Control Panel and advise all personnel as to its location. It is used to instantly stop the machine. Never bypass any safety devices specifically designed for and built into the machine. Do not operate or perform work on this machine with clothing that is too loose or hair that is too long. Always perform all maintenance or repair work in accordance with your facility s Lock-Out / Tag-Out Procedures and in compliance with all applicable industry and government codes and guidelines. Make sure all electrical equipment is properly grounded prior to operation. Make sure machine power is off before opening the electrical box. Make sure that any replacement parts installed in this machine meet all applicable industry and government standards and that they have been designed to meet the specific load and function for the intended application. Always follow all established facility guidelines and applicable codes concerning the use of lifting and moving devices. Improper lifting or moving of equipment could cause injury to personnel or damage to the equipment. Following any lubrication procedure, always clean off and remove all excess lubricant before returning machine to production. Failure to do so may compromise product integrity or machine performance. Make sure all tasks are performed with enough personnel to safely perform them. Page 5 of 40
MACHINE SPECIFICATIONS AND FACILITY POWER REQUIREMENTS Machine specifications for the 3-station automatic spindle capper are listed below. Because not all applications are the same, it is always best to refer to the electrical schematic diagram that came with the machine. It can be found inside the electrical box. Always make sure machine power is off before opening the electrical box. Also refer to the information labels located on the machine itself. SPECIFICATION ENGLISH UNITS METRIC UNITS Power input 110 VAC single phase 50 / 60Hz Power consumption 20 AMP Air pressure 70 / 100 psi 5-7 bar Air volume 3-5 f 3 / minute 0.1-0.14 m 3 / minute Machine dimensions:* Length 96 in 2,438mm Width 48 in 1,220mm Height 75 in 1,900mm * some customer installations may vary from these numbers Machine weight (without the crate) ~ 1,200 pounds ~ 545kg Page 6 of 40
GLOSSARY OF TERMS Spindles Wheels Change-Over Chute Clutch Fingers Gripper Belts Spindles Stabilizer the rubber wheels located on the spindles that contact the caps during machine operation the process of changing from one product, bottle, or cap to another the pathway through which caps are fed to the line the final set of spindles which tighten the caps to final torque based on customer specification small guides located at the end of the cap chute that properly position in-feeding caps just before placement on the bottle the looped belts which guide the bottles through the capper the long cylinders to which are attached either the bearings or the clutches a metal bar that runs above the bottle travel path to help guide the capped bottles in place through the capper Page 7 of 40
UNCRATING THE MACHINE WARNING Make sure all tasks are performed with enough personnel to safely perform them. 1. Remove top and sides of crate, but leave the machine attached to crate base. 2. Carefully lift crate base with machine still attached to it using a forklift and carefully move machine into desired position. Make sure forklift forks extend through the entire crate base or skid. WARNING Always follow all established facility guidelines and applicable codes concerning the use of lifting and moving devices. Improper lifting or moving of equipment could cause injury to personnel or damage to the equipment. 3. Once machine is in desired position, remove the banding straps and bolts securing the machine to the crate base or skid. 4. Carefully lift the machine again and remove the crate base or skid from under it. 5. Once the machine itself is on the floor in the desired position, complete the uncrating process by removing any tie wraps or guards securing moving machine parts during shipment. Page 8 of 40
INTRODUCTION AND THEORY OF OPERATION The spindle capper receives bottles with caps and automatically tightens the caps. Gripper side belts and cap stabilizer hold caps and bottles in place while rubberized tightening discs (spindle wheels) contact the cap on opposite sides and spin the cap down. Clutches allow just the right torque on caps. Bottles do not stop during the continuous operation of tightening. Standard unit can take 1 to 4 tightening stations, and cap sorter can be vibrating bowl, centrifugal bowl, or sorting elevator for cap sizes of from 8mm to 120mm. Bottle sizes of from 1/2 an ounce to 2.5 gallons can be run. Key machine features include: 1 to 4 cap tightening stations stainless steel spill area exceptionally heavy-duty universal chute with cap range from 8mm to 120mm full chute sorter pause sensor power height adjustment clutches individual spindle adjustments crank gripper belt height adjustment can accommodate a huge range of cap types, including flat, tall, sport, Yorker, CRC, flip-top, pump sprayer, and trigger sprayer heavy-duty portable frame Based on specific applications, machine options include: single or double gripper belts F-style cap spacer a bottle separator hazardous (NEMA 1) electrical NEMA 4 electrical Suitable applications for this machine are pharmaceuticals cleaners bottled water juices foods chemicals Page 9 of 40
OPERATOR CONTROLS Operator controls are explained below. Refer to Figures 1 through 8. The Operator Control Panel is located on the right side of the machine. Refer to Figure 1. Figure 1. OPERATOR CONTROL PANEL. Page 10 of 40
OPERATOR CONTROLS (continued) An Emergency Stop (E-STOP) button is located on the front of the machine. To activate it, press it in and the machine will shut down immediately. To release it and resume operations, pull it out. Refer to Figure 2. Figure 2. EMERGENCY STOP (E-STOP) BUTTON. The capper is turned on or off using the Capper Power Switch. Refer to Figure 3. Figure 3. CAPPER POWER SWITCH. The Power Height control adjusts the height of the capper housing. Refer to Figure 4. To raise or lower the capper power box, move the selector switch to the desired function (up or down), hold the selector switch until the capper power box is positioned as desired, then release the selector switch. Figure 4. POWER HEIGHT CONTROL. Page 11 of 40
OPERATOR CONTROLS (continued) Capper spindle power and speed are controlled using the Spindle Power Switch and Spindle Speed Control. Refer to Figure 5. To increase the speed of the spindles, rotate the speed control dial clockwise. To decrease spindle speed, rotate the speed control dial counterclockwise. Figure 5. SPINDLE POWER AND SPEED CONTROLS. Gripper belt power and speed are controlled using the Belts Power Switch and Belts Speed Control. Refer to Figure 6. To increase the speed of the gripper belts, rotate the speed control dial clockwise. To decrease belt speed, rotate the speed control dial counterclockwise. Figure 6. GRIPPER BELT POWER AND SPEED CONTROLS. Page 12 of 40
OPERATOR CONTROLS (continued) Cap elevator power and speed are controlled using the Elevator Power Switch and Elevator Speed Control. Refer to Figure 7. To increase the speed of the elevator, rotate the speed control dial clockwise. To decrease elevator speed, rotate the speed control dial counterclockwise. Figure 7. ELEVATOR POWER AND SPEED CONTROLS. Conveyor belt power and speed are controlled using the Conveyor Power Switch and Conveyor Speed Control. Refer to Figure 8. To increase the speed of the conveyor belt, rotate the speed control dial clockwise. To decrease conveyor belt speed, rotate the speed control dial counterclockwise. Figure 8. CONVEYOR BELT POWER AND SPEED CONTROLS. Page 13 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS The information in this section is a guide for proper machine function. In general, there are several good practice set-up and adjustment tips that should be followed for reliable operation. These are listed below. It may also be useful to refer to the Troubleshooting section of this Manual, as the information in these 2 sections complement each other and both contribute to proper machine function. When changing from one bottle or cap to another, requiring a change to the settings of the adjustment control knobs based on those new requirements, see your Supervisor or a facility Maintenance representative. 1. Make sure the speed of the conveyor belt is the same as the speed of the gripper belts. 2. Capper machine operation is facilitated by two photoelectric sensor eyes. The first is located up inside the cap feed chute and senses the presence of caps in the chute, triggering the chute elevator to stop when a cap is detected. The second of the two sensors will be addressed later in this section. Make sure the Cap Present Sensor is properly set to read or sense the presence of caps in the chute. Refer to Figure 9. Sensor eye Figure 9. CAP PRESENT SENSOR. 3. Set the cap chute to be properly in line with the bottle. Make sure it isn t off from side-to-side, too high, or too low. Page 14 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 4. To ensure proper line performance during production, the conveyor belt must be level, the capper must be level with the conveyor belt, and the gripper belts must be level with the conveyor belt. Refer to the figures below for detailed views of machine leveling points. 4a. Place a level on the conveyor belt and verify that it is level. Refer to Figure 10. Level on conveyor belt Figure 10. LEVEL THE CONVEYOR BELT. 4b. Place a level across the front of the capper housing and verify that it is level from side to side. Refer to Figure 11. Level under capper housing Figure 11. LEVEL THE CAPPER HOUSING FROM SIDE TO SIDE. Page 15 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 4c. Place a level from front to back under the capper housing to verify that the capper housing is level from front to back. Refer to Figure 12. Level under capper housing Figure 12. LEVEL THE CAPPER HOUSING FROM FRONT TO BACK. 4d. Make sure the gripper belts are level from side to side by placing a level across the top of the gripper belt assembly. Refer to Figure 13. Level on gripper belts Figure 13. LEVEL THE GRIPPER BELTS FROM SIDE TO SIDE. Page 16 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 4e. Make sure the gripper belts are level from front to back by placing a level across the in-feed side of both sets of belts. Refer to Figure 14. Level on gripper belts Figure 14. LEVEL THE GRIPPER BELTS FROM FRONT TO BACK. 5. Make sure the 2 solid spacers are tight. Refer to Figure 15. 6. Make sure the final or drive spacers have approximately 1/16-inch of play in them for proper bottle travel flow. Refer to Figure 15. Solid Spacers (2 pairs) Drive Spacers (1 pair) Figure 15. SOLID SPACERS AND DRIVE SPACERS. Page 17 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 7. The second of the two photoelectric sensor eyes, referenced in Step 2 of this section, triggers the stomper assembly to activate when a capped bottle is present in the stomper assembly position. The stomper assembly is factory-set to be a 1-shot operation, activating the stomper assembly one time whenever a capped bottle is detected. Make sure the Stomper Activation Sensor is properly set to read or sense the presence of a capped bottle. Refer to Figure 16. Sensor eye Figure 16. STOMPER ACTIVATION SENSOR. 8. Make sure the stabilizer bar is set to the proper height to meet up with the capped bottle prior to tightening. Refer to Figure 17. Stabilizer bar height Figure 17. PROPER STABILIZER HEIGHT POSITION. 9. The four pairs of spindle wheels function in tandem with each other, front and back, and must be set in line and level to facilitate equal contact with, and to apply equal pressure on, the stable part of each capped bottle passing between them. Refer to Figures 18 through 21. Page 18 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 9a. Spindle width adjustments are made with individual controls. Refer to Figure 18. Figure 18. SPINDLE WIDTH ADJUSTMENT CONTROLS. 9b. All four pairs of spindles should be level along the line. Refer to Figure 19. When running taller caps, however, it may be necessary to raise the first pair of spindles. The second and final pair of spindles, though, should still be level with each other. Typical spindle wheel level alignment (First set of spindles may be higher if running taller caps.) Figure 19. LEVEL SPINDLE ALIGNMENT. 9c. Spindle wheels must support capped bottle. Refer to Figure 20. Spindle wheel contact points Figure 20. PROPER SPINDLE WHEEL CONTACT WITH CAP. Page 19 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 9d. On the last set of spindles, set the clutch torque nut by turning it clockwise (CW) to tighten (plus torque) or counterclockwise (CCW) for less torque (minus torque). Refer to Figure 21. Torque adjustment Figure 21. CLUTCH TORQUE NUT. 10. The gripper belts function together to contact and support the stable part of the bottles passing between them. Make sure the gripper belts are set to the proper height and width to contact and support the stable part of the bottle. Refer to Figures 22, 23, and 24. 10a. Gripper belts can be raised or lowered together. Refer to Figure 22. Figure 22. GRIPPER BELT HEIGHT CONTROL. Page 20 of 40
SET-UP, CHANGE-OVER, AND MACHINE ADJUSTMENTS (continued) 10b. The distance between the gripper belts can be adjusted as needed. Refer to Figure 23. Figure 23. GRIPPER BELT WIDTH CONTROL. 10c. Set the gripper belts to contact and support the stable part of the bottle. Refer to Figure 24. Gripper belt contact points Figure 24. PROPER GRIPPER BELT CONTACT WITH BOTTLE. NOTE When a change-over has been implemented to run different product, bottles, or caps, or when any change has been made to the machine settings, it is useful to restore power to the line and perform a test run prior to resuming production to verify proper line speed and operation. Performing a pre-production test run will help identify and eliminate any unresolved concerns which could negatively impact your production run. Page 21 of 40
OPERATING INSTRUCTIONS AND SEQUENCE OF OPERATION After setting up, adjusting, and testing the capper as described earlier in this Manual, perform the steps below to run production. Refer to the Operator Controls section of this Manual for photographs and descriptions of the operator control buttons. NOTE Make sure all settings have been made and verified as described in the Set-Up, Change-Over, and Machine Adjustments section of this Manual. If additional changes or adjustments are desired, see your Supervisor or facility Maintenance representative. NOTE Make sure the photoelectric sensor eyes are properly set as described in the Set-Up, Change-Over, and Machine Adjustments section of this Manual. 1. Release the red Emergency Stop (E-STOP) button by pulling it out. The E-STOP is located at the top of the Operator Control Panel. 2. The spindles, gripper belts, conveyor belt, and elevator all have their own individual power switches. Turn all of these power switches to the ON position. 3. Once all of the individual component power switches have been placed in the ON position, as described above, the spindles, gripper belts, conveyor belt, and cap elevator all begin to cycle. The capper is now ready to run production. 4. Capper machine operation is described below. a. b. c. d. e. 5. Upon receiving input from the Stomper Activation Sensor, the stomper assembly places the cap on the bottle. The capped bottle passes under the stabilizer bar to seat the cap. The first set of spindles (left-side) begins the cap threading process. The second set of spindles begins the cap tightening process. The last set of spindles, called clutches, completes the cap tightening process by achieving the desired cap torque or tightness in accordance with customer and product specification. Operator should monitor line operation during production, check for ample cap and bottle supply, as well as proper machine and line function. Page 22 of 40
ROUTINE MAINTENANCE Listed below are some common components found in Liquid Packaging Solutions machines. Note that not all of these components are found in all machines. The purpose of this listing is to provide a general overview concerning good sense maintenance practices and some basic tips regarding how to prolong the useful life of the machine. In all cases, following any lubrication procedure, always clean off and remove excess lubricant before resuming production. ITEM TASK FREQUENCY COMMENTS Bearings lubricate semi-annually multi-purpose or food-grade grease Chains lubricate semi-annually 90-weight gear lube Gear reducers lubricate semi-annually 90-weight gear oil (fill only to lower plug as over-filling will cause the excess to leak out the vent) Guide shafts lubricate semi-annually silicone spray Following any lubrication procedure, remember to always clean off and remove all excess lubricant before resuming production. Failure to do so may compromise product integrity or machine performance. Page 23 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT To clean the gripper belts without damaging the texture of the belt, use a mild detergent with water for best results. A sponge or fine scotch-bright pad will also increase the cleaning effectiveness. Be sure belts are completely dry before resuming production. Never use any type of alcohol or other petroleum product to clean the urethane belts. Replacing the belts is best performed by breaking the task into smaller sections. It is good practice, as well, to replace all of the gripper belts at one time. This procedure is written to reflect that. It is recommended to read the entire procedure before starting work. NOTE This process is best performed by two people working together to better support the various components during disassembly and re-assembly. NOTE It is best to perform this process from front to back during disassembly, then from back to front during re-assembly to better access the various components during the process. NOTE If your machine has only one pair of gripper belts, proceed to page 28 and perform the steps listed there. Refer to the figures as referenced. If your machine has four gripper belts (an upper and a lower pair), perform the steps below as described below. 1. Remove the front and back lower gripper belt assemblies first. Perform Steps 1a through 1g below. Refer to Figures 25 and 26. 1a. Place two pieces of wood on the conveyor belt to coincide with the under side of the gripper belt assemblies above them. Refer to Figure 25. 1b. In preparation for lowering the capper housing, note the current height setting of the capper housing using the graduated rule on the side of the box. It is useful to write down that height setting for use at the end of this process. Page 24 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT (continued) 1c. After the wood has been placed on the conveyor belt under the gripper belt assemblies and noting the current height setting of the capper housing, carefully lower the capper housing all the way so that the lower gripper belt assemblies rest on the pieces of wood. Refer to Figure 25. Shut off machine power. Figure 25. PLACE WOOD ON CONVEYOR BELT. 1d. Remove the two spacer bolts (one on each side) from the top of the front gripper belt assembly. Refer to Figure 26. Repeat the process for the back top gripper belt assembly. Retain all mounting hardware for re-use. After removing these bolts, both the front and back lower gripper belt assemblies will be disconnected and should be resting on the wood. Spacer bolts (two per belt) Figure 26. REMOVAL OF SPACER BOLTS. Page 25 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT (continued) 1e. After removing all four of the spacer bolts from the upper front and back gripper belt assemblies and with both the lower front and back gripper belt assemblies resting on the wood, restore machine power and raise the capper housing to its highest position in order to create the maximum work space clearance possible. 1f. Once the capper housing is all the way up, shut off all machine power. 1g. At this time, remove and set aside the lower front and back gripper belt assemblies from the wood to get them out of the way. The belts in those two assemblies will be replaced later. 2. To remove the belts on the upper front and back gripper belt assemblies, perform Steps 2a through 2d below. Refer to Figures 27, 28, and 29. 2a. Loosen, but do not remove, the two idler pulley tension button head bolts. Refer to Figure 27. Loosen but do not remove top bolt. Figure 27. IDLER PULLEY TENSION BOLT. 2b. From the under side of both assemblies, remove the bottom idler pulley bolt. Refer to Figure 28. Retain mounting hardware. Remove and retain lower bolt. Figure 28. BOTTOM IDLER PULLEY BOLT. Page 26 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT (continued) 2c. Remove the four small bolts from the spacer blocks. Refer to Figure 29. Once these bolts are removed, the gripper belt assembly protective plate will come off. Retain all mounting hardware for re-use. Remove and retain spacer bolts. Figure 29. SPACER BLOCK BOLTS. 2d. Once the four spacer bolts have been removed and the protective plate is off, remove the existing belt. 3. To replace the gripper belt on the upper front and back gripper belt assemblies, perform Steps 3a through 3e below. From this point, the process is basically the reverse of the process performed thus far. Remember to re-assemble the back assembly first and then the front for full access to the work area. 3a. Position the replacement belt as the old one had been. 3b. Re-assemble the gripper belt assembly with the protective plate in place. Align mounting holes. 3c. Re-install the four bolts through the spacers removed in Step 2c above. 3d. From the bottom of the assembly, re-install the idler pulley bolt that was removed in Step 2b above. 3e. From the top of the assembly, move the idler pulley tension bolt to the full out position and then tighten it. To prolong the life of the new belt, there should be approximately 1/2 an inch of slack in the belt so it isn t too tight. Page 27 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT (continued) 4. To change the belts on the lower gripper belt assemblies, repeat Steps 2a through 3e above. Remember that both the process and the construction are both the same, but that the orientation is backwards. In other words, on the lower gripper belt assemblies, it is the lower idler pulley tension bolt that is loosened and the upper idler pulley bolt that is removed. 5. Set the completed lower gripper belt assemblies back on the wood, positioned near where they were is Step 1a. 6. Restore machine power. 7. Lower the capper housing down to the level of the lower gripper belt assemblies on the wood. 8. Shut off machine power. 9. Re-install the lower gripper belt assemblies, the back one first, by re-installing the spacer bolts which were removed in Step 1d. 10. Restore machine power again. 11. Raise the capper housing back up to its original level as noted in Step 1b. 12. Shut off machine power. 13. With all machine components re-assembled, re-confirm at this time, as in Step 3e above, that there is approximately 1/2 an inch of slack in all four of the gripper belts. If not, verify re-assembly and the location of the idler pulley tension bolts. 14. Restore machine power again and perform a test run to ensure proper function and alignment before resuming production. If your machine has only one pair of gripper belts, perform the steps below. Refer to Figures 3, 4, and 5 on the previous pages. 1. Note and record the height of the capper housing using the graduated rule. 2. Raise the capper housing for better access to the work area, then shut off machine power. Page 28 of 40
GRIPPER BELT MAINTENANCE AND REPLACEMENT (continued) 3. Loosen, but do not remove, the two idler pulley tension button head bolts. 4. From the under side of both assemblies, remove the bottom idler pulley bolt. Retain mounting hardware. 5. Remove the small bolts securing the gripper belt assembly protective plate. Once these bolts are removed, the plate will come off. Retain all mounting hardware for re-use. 6. Once the protective plate is off, remove the existing belt. 7. To replace the gripper belts on the front and back gripper belt assemblies, perform Steps 8 through 13 below. Remember to re-assemble the back assembly first and then the front for full access to the work area. 8. Position the replacement belt as the old one had been. 9. Re-assemble the gripper belt assembly with the protective plate in place. Align mounting holes. 10. Re-install the small bolts through the plate that were removed in Step 5. 11. From the bottom, re-install the idler pulley bolt removed in Step 4 above. 12. Move the idler pulley tension bolt loosened in Step 3 to the full out position, then tighten it. To prolong the life of the new belt, there should be approximately 1/2 an inch of slack in the belt so it isn t too tight. Adjust idler pulley tensions bolt(s) as needed. 13. Restore machine power, lower capper housing to its original height as noted in Step 1 of this section. Perform a test run to ensure proper function and alignment before resuming production. Page 29 of 40
SPINDLE WHEEL REPLACEMENT Depending on production volume, it will be necessary to replace the spindle wheels located at the ends of each spindle. It is recommended to replace all of them at one time. The process is slightly different for the spindles with the clutch assemblies. Both are covered in this section. To replace the spindle wheels, perform the steps below. 1. Note the height of the capper housing using the graduated rule on the side of the housing assembly. 2. Raise the capper housing box to its full height to permit sufficient work clearance. 3. Turn off all machine power. 4. Raise and brace each spindle and remove the flathead screws securing the lower spindle plate to the bottom of the spindle shaft. Refer to Figures 30 and 31. Use an 1/8-inch Allen wrench. Retain the screws for re-use. With the screws removed, the lower plate will come off. Retain the plate for re-use. Remove four bolts and plate. Figure 30. SPINDLE WITHOUT CLUTCH. Remove three bolts and plate. Figure 31. SPINDLE WITH CLUTCH. Page 30 of 40
SPINDLE WHEEL REPLACEMENT (continued) 5. After the lower spindle plate is removed, work the wheel off the spindle shaft. 6. Insert the replacement disk up onto the spindle shaft, positioned as the original wheel had been. 7. Position the lower spindle plate onto the bottom of the spindle shaft and align mounting holes. 8. Reinstall the flathead screws removed in Step 4. 9. Return the spindles to their normal down position. 10. Restore machine power. 11. Lower the capper housing back down to its original height. 12. Perform a test run before resuming production. Make sure that when they are rotating, the spindle wheels all appear flat from all angles and not wobbling or wavy. It is important for all the spindle wheels to be level to ensure equal contact with and equal pressure on each capped bottle passing between them. Page 31 of 40
TROUBLESHOOTING Listed below are some common situations that may occur over the life of the capper. Each symptom is followed by some possible causes. It may also be useful to refer to the Set-Up, Change-Over, and Machine Adjustments section of this Manual, as the information in these 2 sections complement each other and contribute to proper machine function. SYMPTOM COMMENTS No cap on bottle. Check set-up for proper component alignment. Check cap chute finger function. Make sure there are caps in chute. Check cap chute width. Check stabilizer height. Crooked cap on bottle. Make sure bottle enters gripper straight and that gripper belts aren t squeezing bottle. Check cap chute mounting plate alignment. Check cap chute finger settings. Make sure stabilizer is low enough to push cap all the way down. Loose cap on bottle. Check all 3 spindle stages for proper function. Check spindle alignment. Check spindle clutch for proper function. Check for damaged or worn spindle wheels. Check that spindle wheels contact the stable part of the cap. Destroyed cap on bottle. Check spindles to ensure proper position for bottles and caps being run. Wheels could be too tight or too fast. Stomper assembly doesn t activate. Photoelectric sensor eye not properly set. Check distance from capped bottle. Stomper assembly stomps repeatedly. This is factory-set to be a 1-shot function. Return control to OSD (one-shot delay). Page 32 of 40
TROUBLESHOOTING (continued) SYMPTOM COMMENTS Bottle tipping. Make sure bottle enters gripper straight and that gripper belts aren t squeezing bottle. Check alignment of spindle wheels. Check bottle travel path through capper for obstructions. Check that gripper belts and conveyor belt are traveling at the same speed. Check tightness of gripper belts on bottle. Make sure the spindle wheels are centered on the cap and that both have the same amount of torque. Product overflows bottle during capping. Check gripper belts to make sure they re not too tight. Capped bottle looks squishy or appears to be soft, dented, or dimpled. Check that gripper belts aren t too tight. Lower gripper belt wobbling. Check torque on drive spacer and make sure there s approximately 1/16 inch of play in it. It should click. Gripper wheel is spinning oblong. Loosen, adjust, then retighten bottom spindle plate. Gripper belts break. Gripper belts are too tight. There should be about a ½ inch of slack in the belts. Bottles are being lifter off conveyor belt. Gripper belts are not level with conveyor belt. Capper is not level with conveyor belt. Sensor doesn t stop cap chute elevator. Eye is out of adjustment for cap. Eye is dirty. Cap color has changed. Page 33 of 40
ASSEMBLY DRAWINGS On the following pages are the assembly drawings for the 4-station automatic spindle capper. Use them to verify assembly and for confirmation of part numbers, spare parts ordering, and related information. Page 34 of 40
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SPARE PARTS KIT Spare parts are available from and should be purchased directly through Liquid Packaging Solutions to ensure proper form, fit, and function to satisfy customer-specific applications. Liquid Packaging Solutions cannot guarantee the usability or suitability of any spare parts not purchased directly from Liquid Packaging Solutions. To order a spare parts kit or to contact the Liquid Packaging Solutions Sales Department, call (219) 393-3600. Refer to the Assembly Drawings on the previous pages to determine Part Numbers for individual parts Page 40 of 40