ERTURK MAKINE SAN. TIC. LTD. STI.

19LT PET BOTTLE FILLING MACHINE

USER MANUAL

ADDRESS: AKCABURGAZ MH. 3132. SK. NO:7 K:3-4

ESENYURT/ISTANBUL/TURKEY

[Link] erturk@[Link]
Table of Contents
1. SAFETY WARNINGS.................................................................................................................................. 3
1.1. SAFETY WARNINGS EFFECTS ....................................................................................................................... 3
1.2. SAFETY INSTRUCTIONS ............................................................................................................................... 3
1.2.1. USER'S RESPONSIBILITIES .................................................................................................................... 3
1.2.2. ELECTRIC SHOCK RISKS ........................................................................................................................ 4
1.2.3. FIRE AND BURN RISK............................................................................................................................ 4
1.2.4. PRODUCT CHECK ................................................................................................................................. 4
1.3. WARNINGS ................................................................................................................................................. 4
2. FILLING MACHINE GENERAL INFORMATION ............................................................................................. 5
2.1 FILLING MACHINE DESCRIPTION .................................................................................................................. 5
2.2. FILLING MACHINE OPERATING PRINCIPLE .................................................................................................. 6
3. FILLING MACHINE TECHNICAL FEATURES ................................................................................................ 10
4. FILLING MACHINE GROUPS .................................................................................................................... 11
4.1. RINSING GROUP ....................................................................................................................................... 12
4.2. FILLING GROUP ......................................................................................................................................... 14
4.2.A. FILLING SECTION NOZZLE GROUP...................................................................................................... 17
4.3. CAPPING GROUP ...................................................................................................................................... 20
4.4. SLEEVE GROUP ......................................................................................................................................... 26
4.4.A. SLEEVE REEL HOLDER GROUP ............................................................................................................ 34
4.5. HEAT TUNNEL ........................................................................................................................................... 35
4.6. CAP ELEVATOR .......................................................................................................................................... 36
5. FILLING MACHINE STANDARD EQUIPMENT ............................................................................................ 38
5.1. REDUCER LIST ........................................................................................................................................... 38
5.2. PUMP LIST ................................................................................................................................................ 39
5.2. CYLINDER LIST ........................................................................................................................................... 39
6. FILLING MACHINE MAINTENANCE INSTRUCTION .................................................................................... 40
6.1. FILLING MACHINE GENERAL INFORMATION............................................................................................. 40
6.1.1. DAILY MAINTENANCE ............................................................................................................................ 40
6.1.2. MONTHLY MAINTENANCE ..................................................................................................................... 40
6.1.3. ANNUAL MAINTENANCE........................................................................................................................ 41
6.2. FILLING MACHINE MAINTENANCE CHART ................................................................................................ 42
6.3. FILLING MACHINE MAINTENANCE CHART DESCRIPTIONS ........................................................................ 43
6.3.1. CHECK OF MOTOR CABLE CONNECTIONS .......................................................................................... 43
6.3.2. CHECK OF MOTOR NOISE AND TEMPERATURE ................................................................................. 43

Page | 1
 6.3.3. CHECK OF MOTOR CONNECTING SPECIFICATION PARTS ................................................................... 43
6.3.4. CHECK OF FILLING NOZZLE FILTERS ................................................................................................... 43
6.3.5. CHECK OF FILLING NOZZLE O-RINGS .................................................................................................. 43
6.3.6. CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC. .......................................................... 43
6.3.7. CHECK OF FILLING FLOWMETERS ...................................................................................................... 43
6.3.8. CHECK OF ELECTRONIC EQUIPMENT AGAINST OXIDATION ............................................................... 44
6.3.9. CHECK OF CONTROL PANEL ............................................................................................................... 44
6.3.10. DEAIRING WATER PUMP BEFORE OPERATION ................................................................................ 44
6.3.11. CHECK OF MACHINE AIR BEFORE OPERATION ................................................................................. 44
6.3.12. CHECK OF WATER TANK .................................................................................................................. 44
6.3.13. CHECK OF SEALINGS ........................................................................................................................ 44
6.3.14. CHECK OF PNEUMATIC EQUIPMENT................................................................................................ 44
6.3.15. CHECK FOR DUST AND DIRT ............................................................................................................. 44
6.3.16. LUBRICATION OF ALL BEARINGS ...................................................................................................... 45
6.3.17. OTHER GENERAL CHECKS................................................................................................................. 45
6.3.18. GENERAL CLEANING – GENERAL CHECK .......................................................................................... 45
6.4. PROBLEMS AND SOLUTIONS THAT MAY CAUSE THE FILLING MACHINE TO STOP .................................... 46

Page | 2
1. SAFETY WARNINGS
1.1. SAFETY WARNINGS EFFECTS

The signs shown below indicate the risks that may lead to serious injuries. Please read these
signs carefully. If one of the labels is lost or becomes unreadable, please provide a new one.
RISK
Do not enter the machine while it is operating, do not put your hand between the operating
components. Do not perform any operation without turning off the main switch of the machine in
case of failure.
CAUTION
Open the air valve and water valve before operating the machine. Turn on the power switch
of the machine.
WARNING
Do not spill water on the electronics of the machine, prevent water from spilling.
Note: In case of any failure or danger, switch off the machine and report it to the authorized people.

1.2. SAFETY INSTRUCTIONS

The machine is safe when used in accordance with the instructions described in this book.
Read this book carefully before operating the machine. You need to learn how to use the machine
and follow safe operating procedures in order to prevent accidents.

1.2.1. USER'S RESPONSIBILITIES

1. In case of an emergency, learn how to stop the machine as soon as possible.

2. Learn the electronic parts of the machine, its controls, input-output sockets and connections.
3. Inform the people who will use the machine. Do not allow children to use the machine.
4. Do not allow children and pets to approach, enter and use the machine.
5. Place the machine on a solid and flat surface. Make sure there are no objects under the legs of
the machine.
6. Do not approach the machine with any object that may damage it.
7. Do not put your hand in mechanically operated systems.

Page | 3
 1.2.2. ELECTRIC SHOCK RISK

1. Pay attention to the electrical components of the machine. Unconscious use of parts such as
cables, buttons, switches, sockets, fuses, etc. may cause injuries or death.
2. The machine should not be used in the rain or snow, when working near pools and sprinklers,
or when your hands are wet. Otherwise, there is a risk of electric shock. The machine must
not get wet.
3. If moisture or ice has accumulated in the electrical panel of the machine, a failure or short
circuit may occur and as a result, there is a risk of electric shock.
4. Have the electrical operations carried out by authorized persons.

1.2.3. FIRE AND BURN RISK

1. There must not be flammable materials near the machine.

2. If overheating is observed during operation of the machine, stop the machine. And notify the
authorized people.
3. Do not clean the machine with flammable chemicals.
4. The machine must not be operated if a flammable material is spilled around the machine.
Spilled ground must be cleaned from flammable material.

1.2.4. PRODUCT CHECK

1. Filling nozzles must be cleaned and maintained on the days determined periodically.
2. Machine cleaning and maintenance must be performed periodically.
3. The amount of iron in the water must be considered.
4. Attention must be paid to filter cleaning.
5. Check that no foreign matter enters the system from outside by air or in any other way.
6. The operator who will use the machine must wear a bonnet, gloves and mask.

1.3. WARNINGS

1. PERFORM PERIODIC LUBRICATION.

2. MAKE SURE THE AIR PRESSURE OF THE MACHINE IS AT 6 BAR.
3. DO NOT ENTER THE MACHINE WHILE IT IS OPERATING.
4. DO NOT POUR WATER OR FLUID INTO THE MACHINE'S CONTROL PANEL AND PREVENT
SPILLING WATER OR FLUID ON THE CONTROL PANEL.
5. DO NOT STEP ON THE CONVEYORS OF THE MACHINE.
6. FOLLOW THE WARNING SIGNS.

Page | 4
2. FILLING MACHINE GENERAL INFORMATION
2.1 FILLING MACHINE DESCRIPTION

MACHINE DIMENSIONS 1 2

WIDTH (W) 2285mm 4255mm

LENGTH (L) 9275mm

HEIGHT (H) 1890mm 2655mm

Table 2.1. Filling Machine Measurements

Figure 2.1. Filling Machine Measurements Image

1. The whole machine is made of 304 grade stainless steel.

2. Places in contact with water are made of 316 grade stainless materials.
3. The total length with the filling machine inlet-outlet conveyors is 9275mm.
4. The total weight of the filling machine is 1700kg.
5. There are 4 nozzles in the filling machine linear filling system.
6. 4 digital flowmeters are used.
7. The filling double valve system has 2 stages with pump control.
8. Pneumatic Y-type valve is used in the water supply system in the filling and CIP tank.
9. Filling tank drainage system has a manual valve.
10. The filling level system is fluid level controlled.

Page | 5
 2.2. FILLING MACHINE OPERATING PRINCIPLE

Figure 2.2. Overview of the Filling Machine

 Empty bottles coming out of the blow molding machine are transferred to the filling machine
with the help of conveyor. There are 2 mechanically connected sensors at the entrance of the
machine as shown in Figure 2.2. When the 1st mechanical sensor (Counting Mechanical
Sensor) detects 4 bottles, it opens the inlet stop cylinder. The 2nd mechanically connected
sensor closes the inlet stop cylinder when it detects 4 bottles.

1 2

Figure 2.2. Filling Machine 1 and 2. Inlet Mechanical Connected Sensor

 After the bottles enter, the conveyor stops, the tipping cylinder moves and the bottles are
tipped. After the tipping cylinder returns, the lifting cylinder starts moving. Bottles in the 45°
position reach the 90° position. There are 2 sensors in the rinsing group as water spray sensor
and centering sensor as shown in Figure 2.3.

Page | 6
 1 2

Figure 2.3. Filling Machine Rinsing Group 1. (Water Spray) and 2. (Centering) Sensor

 The bottles enter the rinsing bottle holders and the rinsing group rotates until they see the
water spray sensor. Water with high flow rate hits the bottle after seeing the water spray
sensor. The rinsing mechanism rotates until the centering sensor detects. The bottles are left
in the outlet plate after the centering sensor detects.
 The outlet lifting cylinder moves and stays up until the bottles in front of it pass. The bottles
are lifted with the help of the outlet lifting cylinder. There is a cross sensor between the
rinsing and the filling group as shown in Figure 2.4 and a reflector accordingly. The bottles in
the rinsing group move, they move to the rinsing outlet conveyor and come under the nozzles
in the filling group when the cross sensor detects the reflector.

Cross sensor

Reflector

Figure 2.4. Filling Machine Cross-Mechanical Sensor and Reflector

Page | 7
 There are 2 mechanically connected sensors in the filling group as shown in Figure 2.5. The
conveyor stops and filling begins when the 1st mechanical sensor (start sensor) sees the 4th
bottle. The conveyor starts moving after the filling process is finished. The filling stop cylinder
blocks the route when the 2nd mechanical sensor (counting sensor) detects the 4th full
bottle.

1 2

Figure 2.5. Filling Machine Start and Counting Mechanical Sensor

 The filled bottles are placed on the conveyor on the capping section. The caps previously filled
into the reservoir of the cap elevator are transported to the cap sorting group with the help of
the belt. The caps are sorted sequentially in the cap sorting section and transmitted to the cap
route. The caps wait at the exit of the cap route. The caps are placed on the bottles and the
caps are closed with the conveyor pressure.

2
5

Figure 2.6. Filling Machine Capping Group Sensors

Page | 8
 There are 5 sensors in the capping group as shown in Figure 2.6. The 1st sensor sprays water
into the cap before the cap is placed on the bottle. The 2nd sensor does not work if there is
no cap on the cap route, the machine only works if there is a cap. The 3rd sensor signals to
cap carrying if there is no cap in cap sorting and the caps in the cap chamber are transferred
to the cap sorting chamber with the help of the belt, it stops carrying when it detects the cap.
The 4th and 5th sensors are used in the capping vertical setting.

2
1

Figure 2.7. Filling Machine Sleeve Group Sensors

 There are 4 sensors in the sleeve group as shown in Figure 2.7. When the 1st sensor detects
the bottle, it activates the sleeve receiving, sleeve stopping and sleeve inserting cylinders. The
2nd and 3rd sensors adjust the sleeve vertically. The 4th sensor is the bifurcated socket. The
bottle receiving the sleeve closes the sleeve thanks to the tunnel heat and the bottle leaves
the heat tunnel.

Page | 9
 3. FILLING MACHINE TECHNICAL FEATURES
19LT PET BOTTLE FILLING MACHINE TECHNICAL
SPECIFICATIONS

MODEL BOSS GDS

SERIAL NUMBER [Link]/600/DW/23002

CAPACITY 600 PCS/HOUR

BODY STRUCTURE 304 Cr-Ni STAINLESS STEEL

PRODUCT MEASURES 19LT PET BOTTLE

BOTTLE TRANSFER SYSTEM CONVEYOR SYSTEM FROM BOTTOM OF BOTTLE

CONTROL UNIT PLC WITH TOUCH DISPLAY

CONTROL STYLE FULLY AUTOMATIC

OPERATOR PANEL TURKISH-ENGLISH-FRENCH CONTROL PANEL

ELECTRONIC DEVICE TECHNOLOGY YES

FILLING MACHINE LINEAR SYSTEM 4 NOZZLES

DIGITAL FLOWMETER 4 PIECES

SLEEVE GROUP VERTICAL

HEAT TUNNEL HEAT CONTROL STANDARD

INLET-OUTLET CONVEYOR SYSTEM CONVEYOR BELT

TRANSFER BETWEEN STATIONS CONVEYOR BELT

POWER TYPE ELECTRICAL POWER

Table 3.1. Technical Features of Filling Machine

Page | 10
4. FILLING MACHINE GROUPS

5
1 2 3 4

4.1. RINSING GROUP

4.2. FILLING GROUP
4.3. CAPPING GROUP
4.4. SLEEVE GROUP
4.5. HEAT TUNNEL
4.6. CAP ELEVATOR
4.1. RINSING GROUP

2
4
5
7

Figure 4.1. Rinsing Group

Figure 4.1.1. Rinsing Group Bottle Holder

Figure 4.1.2. Rinsing Group Pipe Plastic Bearing Part

Page | 12
 Figure 4.1.3. Rinsing Group Motor Shaft Bearing

Figure 4.1.4. Rinsing Group Nozzle End Figure 4.1.5. Rinsing Group Nozzle End Connecting Part

Figure 4.1.6. Rinsing Motor Shaft Figure 4.1.7. Rinsing Pipe Bearing Shaft

Page | 13
4.2. FILLING GROUP

Figure 4.2. Filling Group

2 3

Figure 4.2.1. Filling Group Side View

Page | 14
 Figure [Link]. Filling Upper Group

Figure [Link]. CIP Collector Group Figure [Link]. Filling Alignment

Page | 16
4.2.A. FILLING SECTION NOZZLE GROUP

3 2

Figure 4.2.A. Nozzle Group

Figure 4.2.A.1. Nozzle Group Exploded View

Page | 17
 Figure 4.2.A.1.1. Nozzle Group Nozzle Flange Figure 4.2.A.1.2. Flowmeter

Figure 4.2.A.1.3. Nozzle Group Flowmeter Connecting Part Figure 4.2.A.1.4. Pneumatic Cylinder Valve

Page | 18
 Figure 4.2.A.1.5. Nozzle End Upper Part Figure 4.2.A.1.7. Nozzle End

Figure 4.2.A.1.6. Nozzle Glass Group

Figure 4.2.A.1.8. Nozzle End CIP Wash End-1 Figure 4.2.A.1.9. Nozzle End CIP Wash End-2

Page | 19
4.3. CAPPING GROUP

Figure 4.3. Capping Group

Figure 4.3.1. Capping Group Front View

Page | 20
3
1

2
4

Figure 4.3.A. Capping Group Capping Upper Connection Assembly

2 3

Figure 4.3.B. Capping Sorter-Capping Conveyor Assembly

Page | 21
 Figure 4.3.A.1. Capping Group Adjustment Mechanism Motor Shaft

Figure 4.3.A.2. Capping Group Adjustment Mechanism Shaft

Figure 4.3.A.3. Capping Group Adjustment Mechanism Chain Gear

Figure 4.3.A.4. Capping Group Adjustment Mechanism LMEF_30_LUU Housing

Page | 22
 1

Figure 4.3.B.1. Capping Cap Route-Cap Supplier Assembly

1 2 4

2 3

Figure 4.3.B.2. Capping Conveyor Body Group Figure 4.3.B.3. Capping Conveyor Assembly

Page | 23
 Figure 4.3.B.1.1. Capping Group Cap Sorter

Figure 4.3.B.1.2. Capping Group UV Lamp Group Figure 4.3.B.1.3. Capping Group Cap Route

Page | 24
 Figure 4.3.B.2.1. Capping Adjustment Mechanism Housing Shaft Figure 4.3.B.2.2
Adjustment Mechanism
Housing Nut

Figure 4.3.B.3.1. Capping Conveyor Chassis Connecting Shaft-1

Figure 4.3.B.3.2. Capping Conveyor Chassis Connecting Shaft-2

Figure 4.3.B.3.3. Capping Conveyor Spacer Plastic Figure 4.3.B.3.4. Capping Conveyor Motor Flange

Page | 25
4.4. SLEEVE GROUP

1
7

5 2

Figure 4.4. Sleeve Group

4.4.1. SLEEVE UPPER PLATE GROUP ASSEMBLY

4.4.2. SLEEVE LOWER TABLE ASSEMBLY
4.4.3. SLEEVE ROLLER GROUP ASSEMBLY
4.4.4. SLEEVE VACUUM CYLINDER GROUP ASSEMBLY
4.4.5. SLEEVE INSERTING GROUP ASSEMBLY
4.4.6. SLEEVE ALIGNMENT ASSEMBLY
4.4.7. SLEEVE BAND ALIGNMENT AND OPENING GROUP

Page | 26
 2
3

Figure 4.4.1. Sleeve Upper Plate Group Assembly

Figure [Link]. Sleeve Table

Figure [Link]. Sleeve Intermediate Vertical Shaft

Page | 27
 Figure [Link]. Sleeve Main Table Power Screw Shaft

Figure [Link]. Sleeve Main Table Power Screw Shaft Housing

1
3

4
2
7

6
8 9 5

Figure 4.4.2. Sleeve Lower Table Assembly

Page | 28
 Figure [Link]. Sleeve Lower Plate

Figure [Link]. Sleeve Cylinder and Blade Connecting Metal Bar Carrier

Figure [Link]. Sleeve Bottom U-Blade

Page | 29
 Figure [Link]. Sleeve Knife Metal Bar

Figure [Link] Sleeve Bearing Housing Metal Bar Interconnecting Shaft

Figure [Link]. Sleeve Blade Connecting Metal Bar

Figure [Link]. Sleeve Sensor Connecting Shaft

Page | 30
Figure [Link]. Sleeve Sensor Connecting Metal Bar

Figure [Link]. Sleeve Sensor Connecting Shaft-2

Figure 4.4.3. Sleeve Roller Group Assembly

Figure [Link]. Sleeve Rubber Coated Barrel

Page | 31
 Figure [Link]. Sleeve Bearing Housing

Figure [Link]. Rubber Coated Barrel Connecting Metal Bar

Figure 4.4.4. Sleeve Vacuum Cylinder Group Assembly

Figure [Link]. Sleeve Flanged Shaft

Page | 32
 Figure [Link]. Sleeve Flanged Shaft Support Bearing Housing Shaft

Figure [Link]. Sleeve Sucker

Figure 4.4.5. Sleeve Inserting Group Assembly

Figure 4.4.6. Sleeve Alignment Assembly Figure 4.4.7. Sleeve Alignment and Opening Group

Page | 33
4.4.A. SLEEVE REEL HOLDER GROUP

Figure 4.4.A. Sleeve Reel Holder Group

Figure 4.4.A.1. Sleeve Reel

Figure 4.4.A.2. Sleeve Reel Power Screw Shaft

Page | 34
 Figure 4.4.A.3. Sleeve Bearing Housing

4.5. HEAT TUNNEL

Figure 4.5. Heat Tunnel

 Snail fan no. 1 in the heat tunnel and resistance no. 2 are shown in Figure 4.5.

Page | 35
4.6. CAP ELEVATOR

Figure 4.6. Cap Elevator

Figure 4.6.1. Cap Elevator Chassis

Page | 36
 1

3
2

Figure 4.6.2. Cap Elevator Conveyor Group

Figure [Link]. Cap Elevator Conveyor Belt

Figure [Link]. Cap Elevator Conveyor Reel Figure [Link]. Cap Elevator Conveyor Motor Flange

Page | 37
5. FILLING MACHINE STANDARD EQUIPMENT

5.1. REDUCER LIST

 Reducers used in 19LT Pet Bottle Filling Machine are of BONFIGLIOLI brand.

SEQUENCE REDUCER DESCRIPTION AMOUNT

1. RINSING REDUCER 1 PIECE

2. RINSING INLET CONVEYOR REDUCER 1 PIECE

3. CAP SORTING REDUCER 1 PIECE

4. CAPPING REDUCER 1 PIECE

5. SLEEVE REDUCER 1 PIECE

6. CAP CARRYING REDUCER 1 PIECE

7. CAPPING ADJUSTMENT REDUCER 1 PIECE

8. FILLING CONVEYOR REDUCER 1 PIECE

9. FILLING OUTLET CONVEYOR REDUCER 2 PIECES

10. FILLING INLET CONVEYOR REDUCER 1 PIECE

Table 5.1. 19L Pet Bottle Filling Machine Reducer List

Page | 38
5.2. PUMP LIST

 Pumps used in 19LT Pet Bottle Filling Machine are of EBARA brand.

SEQUENCE PUMP DESCRIPTION AMOUNT

1. RINSING PUMP 1 PIECE

2. FILLING PUMP 1 PIECE

3. CIP PUMP 1 PIECE

Table 5.2. 19L Pet Bottle Filling Machine Pump List

5.2. CYLINDER LIST

 Cylinders used in 19LT Pet Bottle Filling Machine are of SMS brand.

SEQUENCE CYLINDER DESCRIPTION AMOUNT

1. INLET STOP CYLINDER 1 PIECE

2. RINSING TIPPING CYLINDER 1 PIECE

3. RINSING INLET LIFTING CYLINDER 1 PIECE

4. RINSING OUTLET LIFTING CYLINDER 1 PIECE

5. FILLING STOP CYLINDER 1 PIECE

6. SLEEVE INSERTING CYLINDER 1 PIECE

7. SLEEVE ATTACHING CYLINDER 1 PIECE

8. SLEEVE STOP CYLINDER 1 PIECE

9. RINSING WATER SPRAY CYLINDER 1 PIECE

Table 5.3. 19L Pet Bottle Filling Machine Cylinder List

Page | 39
 6. FILLING MACHINE MAINTENANCE INSTRUCTION
6.1. FILLING MACHINE GENERAL INFORMATION
Read these maintenance instructions carefully so that the 19-liter pet bottle filling machine can
operate healthier and longer.
The filling machine must be able to perform its task in production without disruption. The
machine may not be able to perform its task as a result of a failure in the machine during production.
This leads to a disruption of production and causes production, time and financial loss. Maintenance
must be performed at certain intervals in accordance with the instructions specified in the user
manuals in order to achieve the maximum production performance expected from the machine. It has
been determined in this maintenance method at which time intervals the machine will be stopped and
taken into maintenance. Periodic maintenance is planned and performed as Daily Maintenance,
Monthly Maintenance and Annual Maintenance.

6.1.1. DAILY MAINTENANCE

Maintenance of the machine at the end of one day of operation.

 GENERAL CLEANING AND GENERAL CHECKING OF THE SYSTEM MUST BE PERFORMED

 CHECK OF MOTOR CABLE CONNECTIONS
 CHECK OF MOTOR OPERATION NOISE AND TEMPERATURE
 CHECK OF MOTOR CONNECTING SPECIFICATION PARTS
 CHECK OF FILLING NOZZLE FILTERS
 CHECK OF FILLING NOZZLE O-RINGS
 DEAIRING WATER PUMP BEFORE OPERATION
 CHECK OF MACHINE AIR BEFORE OPERATION
 CHECK OF OPERATING PARTS AND MACHINERY AGAINST DUST AND DIRT

6.1.2. MONTHLY MAINTENANCE

Maintenance of the machine at the end of one month of operation.

 THE SYSTEM SHOULD BE FULLY CHECKED

 LUBRICATION OF RINSING GROUP HOUSINGS
 LUBRICATION OF RINSING OUTLET LIFTING HOUSINGS
 CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC.
 CHECK OF FILLING FLOWMETERS
 LUBRICATION OF CAPPING CONVEYOR HOUSINGS
 LUBRICATION OF CAPPING VERTICAL HOUSINGS
 LUBRICATION OF CAP CARRYING HOUSINGS
 LUBRICATION OF CAPPING CONVEYOR HOUSINGS
 CHECK OF SLEEVE SUCKERS
Page | 40
 CHECK OF VACUUM GENERATOR
 CHECK OF ELECTRONIC EQUIPMENT AGAINST OXIDATION
 CHECK OF WATER TANKS
 CHECK OF SEALINGS
 CHECK OF PNEUMATIC EQUIPMENT
 LUBRICATION OF ALL HOUSINGS
 CHECK FOR AIR LEAKS ON CYLINDER
 CHECK OF SENSORS ON THE MACHINE
 CHECK OF CONVEYOR PALLETS ON THE MACHINE
 CHECK OF HEAT TUNNEL RESISTANCES
 CHECK OF CONVEYOR GEARS AND IDLERS

6.1.3. ANNUAL MAINTENANCE

Maintenance of the machine at the end of one year of operation.

 CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC.

 LUBRICATION OF RINSING GROUP HOUSINGS
 LUBRICATION OF RINSING OUTLET LIFTING HOUSINGS
 CHECK OF FILLING FLOWMETERS
 LUBRICATION OF CAPPING CONVEYOR HOUSINGS
 LUBRICATION OF CAPPING VERTICAL HOUSINGS
 LUBRICATION OF CAP CARRYING HOUSINGS
 LUBRICATION OF CAPPING CONVEYOR HOUSINGS
 CHECK OF SLEEVE SUCKERS
 CHECK OF VACUUM GENERATOR
 CHECK OF ELECTRONIC EQUIPMENT AGAINST OXIDATION
 CHECK OF SLEEVE BLADES
 CHECK OF THE CONTROL PANEL
 CHECK OF CONVEYOR PALLETS ON THE MACHINE
 CHECK OF CONVEYOR GEARS AND IDLERS
 CHECK OF HEAT TUNNEL RESISTANCES
 LUBRICATION OF ALL HOUSINGS
 CHECK OF SEALINGS
 CHECK OF PNEUMATIC EQUIPMENT
 CHECK OF WATER TANKS
 THE SYSTEM SHOULD BE FULLY CHECKED

Page | 41
6.2. FILLING MACHINE MAINTENANCE CHART

MAINTENANCE TIME PERIOD

FILLING MACHINE MAINTENANCE CHART
DAILY MONTHLY ANNUAL
1. CONTROL OF ALL MOTORS AND CONNECTING GROUPS
CHECK OF MOTOR CABLE CONNECTIONS X
CHECK OF MOTOR OPERATION NOISE AND TEMPERATURE X
CHECK OF MOTOR CONNECTING SPECIFICATION PARTS X
2. CHECK OF THE RINSING GROUP
CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC. X X
LUBRICATION OF RINSING GROUP HOUSINGS X X
LUBRICATION OF RINSING OUTLET LIFTING HOUSINGS X X
3. CHECK OF THE FILLING GROUP
CHECK OF FILLING NOZZLE FILTERS X
CHECK OF FILLING NOZZLE O-RINGS X
CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC. X X
CHECK OF FILLING FLOWMETERS X X
4. CHECK OF THE CAPPING GROUP
LUBRICATION OF CAPPING CONVEYOR HOUSINGS X X
LUBRICATION OF CAPPING VERTICAL HOUSINGS X X
LUBRICATION OF CAP CARRYING HOUSINGS X X
LUBRICATION OF CAPPING CONVEYOR HOUSINGS X X
5. CHECK OF THE SLEEVE GROUP
CHECK OF SLEEVE SUCKERS X X
CHECK OF SLEEVE BLADES X
CHECK OF VACUUM GENERATOR X X
6. CHECK OF ELECTRICAL-ELECTRONICS GROUP
CHECK OF ELECTRONIC EQUIPMENT AGAINST OXIDATION X X
CHECK OF THE CONTROL PANEL X
7. GENERAL OTHER CHECKS
DEAIRING WATER PUMP BEFORE OPERATION X
CHECK OF MACHINE AIR BEFORE OPERATION X
CHECK OF WATER TANKS X X
CHECK OF SEALINGS X X
CHECK FOR DUST AND DIRT X
CHECK OF PNEUMATIC EQUIPMENT X X
LUBRICATION OF ALL BEARINGS X X
OTHER GENERAL CHECKS X X
Table 6.1. Filling Machine Maintenance Chart

Page | 42
6.3. FILLING MACHINE MAINTENANCE CHART DESCRIPTIONS
6.3.1. CHECK OF MOTOR CABLE CONNECTIONS
The cables of the all motors on the machine should be checked against heating, crushing, cutting and
oxidation.

6.3.2. CHECK OF MOTOR NOISE AND TEMPERATURE

Motors can heat up for some reason and make disturbing noises. There could be many reasons for
this. The cause of heating in the motors may vary depending on the environment temperature,
operating conditions or operating times. The motors used in the filling machine are selected to bear
long-term operations and to work in most environments.
Periodically observe the sound of the motor used in the machine you receive and check for
overheating while the machine is operating every day. Contact technical service immediately if you
encounter any heat and noise that disturb you. Keep in mind that a malfunction in the motor will cause
your machine to stop.

6.3.3. CHECK OF MOTOR CONNECTING SPECIFICATION PARTS

Check against loosening of the equipment such as shafts, bolts, nuts etc. connected to the motor. A
gap in the connecting parts will cause uncomfortable vibrations in your machine. These vibrations will
also greatly damage your machine.

6.3.4. CHECK OF FILLING NOZZLE FILTERS

Filling nozzle group is of great importance in the operation of the filling line. The filters in the filling
nozzles make the filling more hygienic. You must clean 30 nozzles of the linear filling group in order to
have a more hygienic nozzle system.

6.3.5. CHECK OF FILLING NOZZLE O-RINGS

Filling nozzle o-rings may wear out after a certain period of time in the operation of the filling line.
O-rings should be checked and replaced. (You must check them in shorter intervals depending on the
use of ozone in the factory.)

6.3.6. CHECK OF EQUIPMENT SUCH AS SPRINGS, PIMS, BOLTS, ETC.

Ensure that the connecting and specification parts such as springs, pins, nuts, bolts, screws, etc.
are not damaged. Replace the damaged ones such as broken, cracked, inclined, etc. with new ones. If
the old or damaged connecting parts are not checked, it may cause great damage. It should be kept in
mind that many of these pars operate under heavy conditions.

6.3.7. CHECK OF FILLING FLOWMETERS

Empty bottles are filled in the filling line. The amount of water to be filled into a bottle and whether
the filling is completed are determined by the flowmeters here. Flowmeters should be checked to
avoid incomplete filling or overfilling. Uncontrolled flowmeters that perform excessive or incomplete
filling cause faulty filling.

Page | 43
6.3.8. CHECK OF ELECTRONIC EQUIPMENT AGAINST OXIDATION
Keep electronics away from fluids such as water, etc. Water may cause oxidation and malfunction in
electronic materials. Water can short-circuit the machine and cause burn in circuits and other
electronics.

6.3.9. CHECK OF CONTROL PANEL

The control panel to be used by the operator using the machine is touch panel. Avoid impacts on
the control panel. The impacts on control panel will cause the control panel to fail to operate and
lose its function.

6.3.10. DEAIRING WATER PUMP BEFORE OPERATION

If the water pumps are not deaired, they do not operate. First open the outlet valve on the tank and
wait until the water flows with pressure in order to get air out of the pumps. If the water coming out
of the water tank starts to flow with pressure, the water pumps are deaired. This ensures the water
going to the machine flows with more pressure and better.

6.3.11. CHECK OF MACHINE AIR BEFORE OPERATION

Note that the indicator on the machine chassis points to 6 BAR.

6.3.12. CHECK OF WATER TANK

Check the water level in the water tank on the indicator. The lack of water will prevent the
operation of the machine.

6.3.13. CHECK OF SEALINGS

Check the parts where water and air inlet and outlet pipes and other oils are located in the machine
against leaking. The filling machine operates with 6 bar air. In case of any leakage, the machine will
display failure. Note that there is no oil reduction. Movement from gearboxes in the machines is
transmitted to the spindle through shafts. Bearings are used to support the shafts and to allow them
to rotate better. Sealing parts are used to prevent the oils inside the gearboxes from leaking out of the
places where the bearings are installed. In some cases, these sealing parts become incapable of
performing their task and the oils in the gearbox and other areas leak out. This area needs to be
checked out regularly.

6.3.14. CHECK OF PNEUMATIC EQUIPMENT

Pay attention to the seals of pneumatic equipment that enable the machine cylinders to operate. If
the seal is not checked, it may cause many problems.

6.3.15. CHECK FOR DUST AND DIRT

Keep the environment where the machine is located clean. Dust may damage the operating parts or
electric-electronic components of the machine.

Page | 44
6.3.16. LUBRICATION OF ALL BEARINGS
Lubrication is required at the end of long-term operation of all housings and moving parts of
the machine. Housings start to make disturbing noises if they are not lubricated. The housings will be
damaged after a while, which will cause the machine to stop or cause disruptions. Therefore, pay
attention to lubricating the housings of the machine. Below are the housings to be lubricated in the
machine.
1. Lubrication of inlet conveyor housings
2. Lubrication of inlet tipping housings
3. Lubrication of inlet lifting housings
4. Lubrication of rinsing group main housings
5. Lubrication of rinsing outlet lifting housings
6. Lubrication of filling outlet conveyor housings
7. Lubrication of capping conveyor housings
8. Lubrication of capping vertical housings
9. Lubrication of cap carrying housings
10. Lubrication of capping conveyor housings

6.3.17. OTHER GENERAL CHECKS

1. Check for air leaks on cylinder
2. Check of sensors on the machine
3. Check of conveyor pallets on the machine
4. Check of heat tunnel resistances
5. Check of sleeve suckers and vacuum generator
6. Check of conveyor gears and idlers

6.3.18. GENERAL CLEANING – GENERAL CHECK

Perform general cleaning of your machine. Do not leave any chemical substance, cutter or piercing
tool that may damage the machine around it. Do not attempt to enter the machine while it is operating.
Do not approximate fluid or volatile substances that may damage the components of the machine.

Page | 45
6.4. PROBLEMS AND SOLUTIONS THAT MAY CAUSE THE FILLING
MACHINE TO STOP
1. If there is a bottle at the entrance of the machine and the bottles do not enter the machine,
the second mechanical sensor does not detect.
2. If the stop cylinder does not block the road, the counting sensor does not detect.

3. If the cylinder does not tip the bottle or the bottle stays ahead, the sensor on the cylinder
should be checked. The sensor may be faulty or displaced.
4. If the lifting cylinder is not moving, the sensors on the cylinder may be faulty or displaced. If
the cylinder does not move although there is no problem with the sensor, if the water spray
and centering sensors in the rinsing group are faulty or not detecting, the rinsing group rotate
continuously. In this case, the cylinder does not make the first movement if the machine is
switched off and switched on again.
5. If the bottles do not enter the rinsing bottle holders, the centering sensor position has shifted.

6. If the water spray cylinder does not work or does not spray water in place, the water spray
sensor is faulty or shifted.
7. If the outlet lifting cylinder remains open, the sensor with the cross-facing reflector is faulty or
its position has shifted.
8. If the rinsing section does not rotate, the sensor at the outlet is faulty or its position has
shifted.
9. If the filling does not start or the conveyor does not stop, the start filling sensor is faulty or
does not detect.
10. If the filling nozzles fill the bottle partly, the filters inside the nozzle may be clogged or the
flowmeters may be faulty.
11. If the bottles in front of the filling stop cylinder pass and the filling stop cylinder does not
work, the mechanical sensor is faulty or does not detect.
12. If cap sorting does not work, the sensor in the cap route is faulty. If the sensor inside the cap
sorting chamber is faulty, it does not take the cap in or it is too full.

13. If the capping is performed but caps are not taken in, the capping conveyor may need to be
adjusted down.
14. If the sleeves do not give, the sensor that detects the bottle is faulty or does not detect. If it
detects continuously, it will stop endlessly. If the sleeve does not give even though there is no
problem in the sensor, the stepper motor or power supply may be broken.
15. If the sleeve blades do not cut, it is necessary to connect them to the cylinder inversely to the
blade attached to the cylinder, that is, to the counter to the cutting surface and if they do not
cut, the blades should be sharpened.

Page | 46