MM-80249-0104 TBA3

MM
Maintenance Manual
TBA/3 600V
Doc No MM-80249-0104
This page intentionally left blank
Intruduction and Safety 000
This document is valid for:
precaution
Series No/ Machine No Sign.
Superstructure 100
MM
Maintenance Manual
Machine Body
200
TBA/3 Drive Unit 300

Tetra Brik Aseptic
640016-600V
Jaw System 400
Equipment included:
Final Folder 500
600
700
800
Doc No MM-80249-0104
Issue 9906 Setting Data Lubricants 900
Tetra Brik Packaging Systems Induction Heating/ Elec- 1000

trical Equipment
Intruduction and Safety precaution
Name Issue Page
Introduction
Machine introduction 9508 001
Document information 9508 001
Safety Precautions
Handling of Sterilisation Liquid 9508 002-1
Hydrogen Peroxide Storage 9508 002-1
Example of Warning Text on

Hydrogen Peroxide Can 9508 002-1
Hydraulic Oil, Lubricants, Acids,

Alkalis, And Cleaning Solutions 9508 002-1
Hearing protection 9508 002-1
Doc No MM-80249-0104 Issue

TBA/3 600V 9509 MM 000 1(1)
Introduction
Machine introduction
WARNING!
To ensure maximum safety for the technicians,
always read the “Safety precautions” pages
before doing any work on the machine or making
any adjustments.
Purpose usage
The purpose usage of this Tetra Pak equipment is
to pack pumpable food products.
Service
In case of problems when operating the machine,
contact the nearest Tetra Pak service station
Manufacturer
This Tetra Pak equipment is produced by:
Tetra Brik Packaging Systems AB.
Ruben Rausings gata
S- 221 86 Lund
Sweden
Machine identification
Tetra Pak
The machine plate to the right is an example of the
type of machine plate attached to the machine Machine Type TBA/3 - 540V 1000ml
frame. The plate carries data needed when Drawing Spec. 642016 - 540V
contacting Tetra Pak concerning this particular Machine No. XXXXX/XXXX
machine.This machine complies with the basic Manufacturer Tetra Brik Packaging Systems
health and safety regulations of the European Lund Sweden
Econimic Area (EEA) Year of manufacture 199X

TBA/3 600V 9906 MM 001 1(2)
Introduction
Document information
Purpose of Maintenance Manual (MM)
The purpose of the Maintenance Manual is to
provide technicians with information on how to
perform service and maintenance to the Tetra Pak
equipment.
Design modifications
The directives in this document are in accordance
with the design and construction of the machine at
the time it was delivered from Tetra Pak machine
production facility.
Document producer
The document has been produced by:
Tetra Brik Packaging Systems AB.
Technical Publications
Ruben Rausings gata
S- 221 86 Lund
Sweden
Example of manual
Document number
Further copies
Additional copies can be ordered from nearest
Tetra Pak service station.
When ordering technical publications, always
quote the document number printed on the front
cover of the document concerned.
Number of pages
This document contains totally 407 pages .
Copyright  1999
Tetra Brik Packaging Systems AB
All rights reserved. No parts of this document may
be reproduced or copied in any form or by any
means without written permission from Tetra Brik
Packaging Systems AB/Inc.
Issue Doc No MM-80249-

MM 001 2(2) 9906 TBA/3 600V
SAFETY PRECAUTIONS
9508
HANDLING OF STERILISATION LIQUID

The sterilisation liquid used for sterilising the
packaging material consists of 35% hydrogen
peroxide (H202).
WARNING!
In both liquid and gas form, hydrogen peroxide
may cause irritation or damage if in contact with 1
skin, mucous membranes, eyes, or clothes. GBAAOA04
2
Whenever there is risk of contact with sterilisation
liquid, always wear safety glasses TP No 779130-
102 (1), protective gloves TP No 90303-4 (2),
apron TP No 90303-5 (3), and shoes made of PE
or PVC plastic, or rubber.
In case of accidents, involving hydrogen peroxide,
the basic rule is to rinse as soon as possible with as GBAAOA05
much water as possible. For this reason, always

make sure that the showers (4) work, that there are 3
additional washing facilities, and that an eyewash
device (5) TP No 90303-6 is available at or near
each machine site.
Remember:
– If you get splashes or vapour in your eyes,
wash the eyes thoroughly with lukewarm
water for 15 minutes; keep eyelids wide
apart; then seek medical advice 4
immediately. GBAAOA06
GBAAOA02
1 Safety glasses (TP No 779130-102)

2 Protective gloves (TP No 90303-4)
3 Apron (TP No 90303-5)
4 Shower
5 Eyewash device (TP No 90303-6)
5
GBAAOA03

TBA/3 600V 9508 MM 002-1 1(5)
SAFETY PRECAUTIONS
HANDLING OF STERILISATION LIQUID
– If you happen to swallow hydrogen
peroxide, drink large amounts of lukewarm
water in order to dilute the peroxide; then
seek medical advice immediately.
– If you experience irritation or pain due to
having inhaled peroxide vapour, leave the
affected area and get some fresh air. If the
symptoms get worse, seek medical advice.
– If hydrogen peroxide gets in contact with /
skin or clothes, immediately rinse with
plenty of water. Thoroughly wash the clothes GBAAOA07
before they are worn again- If skin burns

appear, seek medical advice immediately.
– If peroxide is spilt on the floor or a table,
dilute it with large amounts of water and
flush it into the drain.
WARNING!
Never wipe with combustible material, such as
rags or paper, as these may self-ignite.
GBAAOA08
WARNING!
Do not allow hydrogen peroxide to get in contact
with live electrical parts. Risk of short-circuit.
– Make sure that areas or rooms for handling

or storing hydrogen peroxide are well
ventilated.
– In case of fire, cool the peroxide containers
by hosing with large quantities of water.
GBAAOA09
GBAAOA10
10

MM 002-1 2(5) 9508 TBA/3 600V
SAFETY PRECAUTIONS
HYDROGEN PEROXIDE STORAGE
The hydrogen peroxide has been stabilised, but
may nevertheless decompose into oxygen and
water if exposed to heat, pollution, or strong
sunlight. For this reason, it must be stored in a
cool, clean, and well ventilated area or room,
where it should be shielded from direct sunlight.
Keep the room free from combustible materials as
well.
WARNING!
Avoid contamination of hydrogen peroxide. It may
react with or form explosive products with many
organic substances (for instance acetone,
cellulose, and ethanol).
Hydrogen peroxide must be stored in the original

container as delivered by the supplier.
Always make sure that the container is properly
closed. Pumps or other facilities, used for
hydrogen peroxide, must be used for this purpose
only.
WARNING! GBAAOA01
Do not pour surplus hydrogen peroxide back into
the original container. The container must be kept
upright and must only be closed with a ventilation
cap, which allows oxygen to escape. Containers
that are not provided with ventilation caps may
explode if decomposition of the product occurs
violently.
DISPOSAL OF HYDROGEN
PEROXIDE
The hydrogen peroxide should be sent for
destruction, or be diluted with water to a
concentration below 1% and poured into drainage.
Hydrogen peroxide with a concentration below 1%
is considered to be harmless when poured into the
drain.
Never put used hydrogen peroxide back into
storage.
11

TBA/3 600V 9508 MM 002-1 3(5)
SAFETY PRECAUTIONS
EXAMPLE OF WARNING TEXT ON HYDROGEN PEROXIDE
CAN
35% w/w Aqueous Solution UN No 2014
Corrosive
Oxidising
Causes burns. Contact with combustible materials

may cause fire.
Keep in a cool place away from sources of heat.
Avoid contamination.
Wear suitable protective clothing, gloves, and eye/

face protection.
After contact with skin, wash immediately with

plenty of water.
In case of contact with eyes, rinse immediately

with plenty of water and seek medical advice.
In case of spillage or fire, drench with water.
Reference:
TP document No M 1751.80
12

MM 002-14(5) 9508 TBA/3 600V
SAFETY PRECAUTIONS
HYDRAULIC OIL, LUBRICANTS, ACIDS, ALKALIS, AND
CLEANING SOLUTIONS
When handling hydraulic oils, lubricants, acids,
alkalis, and cleaning solutions, carefully follow the
information in the material safety data sheets and
warning texts on the container labels.
Always use the recommended personal protective
equipment when handling the agents.
For disposal of agents follow the instructions in the
material safety data sheets.
WARNING!
The agents can be flammable, oxidising, irritating,
or otherwise hazardous to health. Always read the
warning texts before handling the agents.
Hearing protection
WARNING!
Risk of impaired hearing! Use Hearing protection
to minimise the risk of impaired hearing.
Always wear ear protectors when the machine is

running.
13

TBA/3 600V 9508 MM 002-1 5(5)
Superstructure
Name Issue Page
SA, Rollers and Bearings 9510
Checking 9510 101-12
SA, Pressure and Counter Rollers 9508

Replacing the Teflon Sleeve 9508 103-31
SA, Guards and Brake 9510 105-12

Supply Guard 9510 105-12
Broken Strip Guard 9510 105-12
Finger Brake 9510 105-12
Roller Brake 9510 105-12
SA/LS Cylinder 51
Setting 9508 107-51
SA, Strip Guide 9508

SA Element 9508
SA 9508
Setting with the aid of a string 9508 112-51
LS element 9508
Overhaul 9508 115-32
LS 9508
Setting by means of template 9508 116-53
SA/LS Heating 9510

Setting 9510 121-52
SA/LS element 9508

Removal 9508 124-21
Reassemble 9508 124-21

15

TBA/3 600V 9906 MM 100 1(5)
Superstructure
Name Issue Page
Overhaul 9508
Clear all air holes. 9508 124-31
Support plate on LS element 9508 124-31
Product(AP) Valve 9508

Replacement of seals and membranes

(1-4, 6-8, fig 1) in the valves 9508 127-31
Graph for the cylinders and the drive motor 9508 127-31
Filling tube 9508

Setting 9508 133-51
Lower filling tube 9508
Assembly 9508 134-12

Filling tube, pressure roller 9508
Distance A 9508 136-11
Alignment 9508 136-11
Pressure roller force, tool 74767-102 9508 136-11
Adjustment 9508 136-11
Lower forming ring 9508

Lower forming ring, support roller 9508

Checking (1000, 500ml) 9508 138-11
LS overlap 9808
Tube supports and upper forming ring 9508
16

MM 100 2(5) 9906 TBA/3 600V
Superstructure
Name Issue Page
Upper bending roller 9510
Splice detector 9510

Check 9510 142-52
Function 9510 142-52
Check 9510 142-52
Set 9510 142-52
Printed design correction system 9510

Bar code photocells, filters 9510 155-52
Bar code photocells 9510 155-52
Basic setting of the driven bending roller 9510 155-52
Photocells position - Basic setting 9608 155-52
Photocells - Sensitivity setting 9510 155-52
Photocells - Horizontal setting 9510 155-52
Suction filter 9508

Replacement 9508 159-22
Compressor of water ring type 9508

Checking and fault finding 9508 160-12
Basic setting 9508 160-53
Sterile air pressure 9508

Setting 9508 161-52
Water separator 9508 162-21
Dismantling, Cleaning, Checking float 9508 162-21
Fitting 9508 162-21
17

TBA/3 600V 9906 MM 100 3(5)
Superstructure
Name Issue Page
Overflow valve 9508
Cleaning, checking 9508 163-11
Air superheater 9508

Cleaning, Checking 9508 164-21
Checking the element 9508 164-21
Dismantling, cleaning 9508 164-21
Reassemble and fitting 9508 164-41
Sterile air cooler 9508

Checking tightness 9508 165-11

Sequence chart, water flow rate 9510 165-13
Sterile Air 9510

Checking the pressure guard 9510 167-12
Check pressure guard (monitor) MB 18 9510 167-12
Jet deflector valve 9508

Air knife 9508

Cleaning the slot and checking the rollers 9508 171-11
Sterile air system 9510

Checking, tightness 9510 175-12
Tube flushing 9508

Peroxide pump 9508

Checking; Piston type 9508 180-12
Overhaul; Piston type 9508 180-32
Peroxide consumption 9508

Peroxide consumption 9508 183-15
18

MM 100 4(5) 9906 TBA/3 600V
Superstructure
Name Issue Page
Peroxide bath 9508
Checking Squee-gee roller pressure 9508 184-11
Replacing the squee-gee roller sleeve 9508 184-61
Handling of the hose 9508 184-61
Peroxide bath 9510

Checking gap between
wetting and counter rollers 9510 185-12
Peroxide bath, level guard 9508

Setting 9508 186-51
Peroxide bath 9508

Checking position of
packaging material on wetting roller 9508 187-11
Wetting Monitor 9508

Checking/setting With through-flow
electrode and guard TP201 9508 189-12
During operation 9609 189-12
Fault finding 9609 189-61
Zone heater 9510

Checking the heated zone 9510 194-12
Checking the heated zone 9510 194-12

Checking during production 9510 194-12
19

TBA/3 600V 9906 MM 100 5(5)
SA, Rollers and Bearings
Checking
All rollers must rotate freely and be undamaged.
The radial play of the rollers (1-5) max 1 mm.
Also roller (2) must not have an axial play of more
than 0.5 mm.
Bearing (6) max radial play 0.5 mm.
Bearing (7) max radial play 1.5mm.
Clean and check the bushings (9) of the strip
guide.
Check the eyelet (8).
If required, clean or replace worn parts.
1 Roller
2 Roller
3 Roller
4 Roller
5 Roller
6 Bearing
7 Bearing
8 Eyelet
9 Bushing
21

TBA/3 600V 9510 MM 101-12 1(1)
SA, Pressure and Counter Rollers
Checking
Check that the rollers rotate freely and are
undamaged.
Bearing play must not be more than 0.5 mm.
Replacement of the teflon sleeve, see page 103-31
2(2).
Check the pressure between the rollers by applying
a force as shown by the arrow,
15-25 N (1.5-2.5 kp).
If required, clean or replace parts
1 Counter roller
2 Pressureroller
3 Spring
23

TBA/3 600V 9508 MM 103-11 1(2)
SA, Pressure and Counter Rollers
.
Replacing the Teflon Sleeve

Use a hot air gun (or an oven). Temperature
260-400oC.
Clean off any grease or other deposits, and sand
the surface by hand so it becomes rough.
Put the roller on an axle so that it can revolve. a
lathe will do fine.
Cut off the required length of teflon hose for the
sleeve; width of roller plus 5 mm. Teflon hose
TP No 90166-56.
If required, clean the inside of the sleeve with a
cloth that does not leave any fluff.
Slip the sleeve over the roller and rotate the roller
and the sleeve at a reasonably even speed.
Aim the hot air gun at the middle of the roller at a
range of 50-80 mm. Heat this area until the sleeve
shrinks evenly around the roller (fig. 1). When the
sleeve has shrunk so it hugs the closely, the range
should be reduced to 25 mm. Then move the hot
air gun sideways to first one and then the other
edge and make sure the protruding free bit of the
sleeve shrinks down to as small a size as it can get
(fig. 2)
After the sleeve has been shrunk on, cut off excess
material leaving appr 1 mm protruding outside the
edge of the roller.
24

MM 103-31 2(2) 9508 TBA/3 600V
SA, Guards and Brake
9508
Checking
Supply Guard
Check that the proximity switch of the supply guard
(M.B 032) triggers an alarm when the thickness of
the layers of remaining strip has gone down to 15
mm.
Broken Strip Guard

Check that the guard for broken strip (M.B 033)
triggers an alarm and the machine is stopped, if the
plastic strip is pulled out of the finger brake.
Finger Brake
Check that the surface of finger brake against
which the strip runs are not scratched or deformed.
Roller Brake
Check the brake spring of the roller brake (5).
Replace it if worn.
1 proximity switch M.B 033

2 proximity switch M.B 032
3 Finger guard
4 Finger brake
5 Roller brake
25

TBA/3 600V 9510 MM 105-12 1(1)
SA/LS Cylinder
9508
Setting
a) Detach the rigging screw (1) at one of its joints.
b) The SA element must be correctly set, page
112-51 1(1).
c) The LS element must be correctly set, page
116-53 1(1)
d) Turn on compressed air.
e) Adjust the length of the piston rod (2) until the
LS element bars lightly against the limit screws.
f) Attach the rigging screw.
g) Adjust the length of the rigging screw until the
SA element bears lightly against the limit
screws.
h) Turn off compressed air.
i) Shorten the piston rod by 1.5 turn. Lock with
the nut.
j) Check that the element carry well against the
limit screws.
k) Set end damping, by means of screws (3). So
that the element movement is smooth in both
directions.
1 Rigging screw
2 Piston rod
3 Screws
27

TBA/3 600V 9508 MM 107-51 1(1)
SA, Strip Guide
Checking
– That the roller (6) is parallel with the
packaging material and at right angles to its
edges.
– That the LS strip (7) is parallel with the
machine frame. Adjust by shimming under
the finger brake housing.
– That the link (2) hangs perpendicularly
viewed from the side of the machine
according to fig 1, and that the 15 mm
sideways measurement is obtained. Adjust at
the clamp holder (8). Adjust the guide hoop
(5) so that it bears against the packaging
material.
– That the LS strip is positioned 3-4 mm from
the edge of the guide roller (6)
Fig 1
12 Link
5 Guide hoop
6 Guide roller
7 LS strip
8 Clamp holder
29

TBA/3 600V 9508 MM 109-11 1(1)
SA Element
Checking
a) Check that the SA element is clean and that air
holes are not blocked
b) Check that the element is parallel with the
packaging material web and overlaps it by 8
mm.
In case of fault:
Check that the packaging material runs correctly
over the bending roller and through the guides. If
the element still is incorrectly adjusted and the
deviation is considerable, reset it in accordance
with page 112-51 1(1). If deviation is minor,
adjustment may be done by means of the limit
screws (3).
c) Check that the LS and SA elements hit the limit
screws simultaneously. If not, reset in
accordance with page 107-51 1(1)
1 Element
2 Packaging material
3 Limit screw
4 SA frame
31

TBA/3 600V 9508 MM 111-11 1(1)
SA
9508
Setting with the aid of a string

Fig 1 Fig 2
Apply loads to two strings between the bending The strings is to touch (as a tangent) the counter
rollers (1). roller (6), the rollers of the element (7), and the
lower part of the runner (4).
Move the pressure roller (2) out of the way and
move the element (3) against the limit screws.
Fig 3
One of the strings is to run parallel with and 51
mm from the mounting plate (distance B). The gap between the guide rails (8) is to be 1.5
mm.
Set the element so that it rests against the limit
screws and overlaps the string by 8 mm
(distance C) Fig 4
The support grill (5) is to touch (as a tangent) the
A = width of packaging material.
string between the bending rollers.
B = 51 mm
C = 8 mm
Fig 2 Fig 3
1 Bending roller
2 Pressure roller
3 Element
4 Runner
5 Support grill
6 Counter roller
7 Element roller
8 Guide rail
Fig 1 Fig 4
33

TBA/3 600V 9508 MM 112-51 1(1)
LS element
Checking
a) Check that the LS element is clean and that the
air holes are not clogged.
b) Check that the inner row of holes is parallel
with and positioned exactly underneath the
edge of the packaging material web (arrows).
In case of fault:
Make sure the jaws and volume flaps are
correctly aligned, page 442-52 1(1). Also the
LS overlap is to be correctly set and centred,
page 139-11 1(2) 139-51 2(2).
If the element setting still is not right and the
fault is considerable, reset with the aid of a
template, page 116-53 1(1)
Lesser faults can be eliminated with the screw
(1).
Check that the LS and SA elements hit the limit
screws simultaneously. If not, reset, page 107-
51 1(1).
1) Limit screw
35

TBA/3 600V 9508 MM 115-12 1(2)
LS element
Overhaul
Clean the element.
Check that the support plate (6) is not worn. If
required, replace it.
Check that the rollers (1) are not worn and rotate
freely. If required, replace them.
Note!
The guide plate (2) can be removed by unscrewing
the rollers (1).
The blow nozzle (49 can be removed by

unscrewing the screws (3).
1 Roller
2 Guide plate
3 Screw
4 Blow nozzle
5 Gasket
6 Support plate
36

MM 115-32 2(2) 9508 TBA/3 600V
LS
9508
Setting by means of template

Set the lower forming ring in relation to the
pressure roller, according to page 136-11 1(1)
Remove the rollers (1) and the guide plate (2) from
the LS element. Do not forget the washer behind
the rollers.
Remove two cap nuts and the roller (3) from the
upper forming ring.
Remove an Allen screw (4) and its washer from
the lower forming ring
Attach the template (5) as shown in A-A and B-B.
Fix it at the lower end with the Allen screw (4).
Set the distance between the forming rings by
shifting the upper forming ring.
Move the element up against the limit screw and
set it as shown in C-C and D-D.
Detach the template and refit removed parts.
LS element template
Volume ml No
1000 - 500 552525-101
250 - 200 552525-102
1 Roller in LS element
2 Guide plate
3 Roller in upper forming ring
4 Allen screw in lower forming ring
5 LS element template
37

TBA/3 600V 9508 MM 116-53 1(1)
SA/LS Heating
Setting
a) Check the SA element acc to page 111-11 1(1)
and the LS element to page 115-12 1(2).
b) The air pressure for LS and SA are to be set acc
to table on page 901-3 1(4).
c) If the heat setting is incorrect, check the
elements. check voltage with a universal
instrument, on the output terminals. Check the
current with a clip-on ampmeter inside the
electrical cabinet. If the heating is too low with
correct elements, the reason is air leakage
Volume SA (220 V) LS (220 V)

ml
W A W A
1000-500 1670 7.5 1500 6.8
250, 200 1500 6.8 1500 6.8
1 SA throttle valve
2 SA element
3 SA pressure gauge
4 LS throttle valve
5 LS element
6 LS pressure gauge
39

TBA/3 600V 9510 MM 121-52 1(1)
SA/LS element
Removal
Undo the screw (1) and remove the elements.
1 Screw
2 SA element
3 LS element
Reassemble
Check gaskets and pins.
Reassemble in the reverse order.
41

TBA/3 600V 9508 MM 124-21 1(2)
SA/LS element
Overhaul
Clear all air holes.
Check that the glass fibre strip of the LS element is
not worn. If required replace it. Clean it while it is
hot.
Check that the support roller are not worn, that
they rotate freely, and that the clearance to the hot
air nozzle is 4 mm (fig 1).
Check that the elements are straght (not bent due
to heat). If required straighten them.
Replace the gaskets behind the elements.
Support plate on LS element

250 - 200 ml (fig 2)
TP No 294110-2:
the edge of the support plate is to be in line with
the rear edge of the element.
1000 - 500 ml (fig 3)
TP No 294110-1:
Adjust to obtain the measurements illustrated. The
three hot air slits are to be edge-to edge with the
support plate. 1 mm shims are to be placed under
the support plate.
42

MM 124-31 2(2) 9508 TBA/3 600V
Product(AP) Valve
Overhaul WARNING!
Risk of personal injury.
If the valve is dismantled in wrong way, the spring
(25) may eject with considerable force. The tool
(11) must always be used.
Replacement of seals and membranes

(1-4, 6-8, fig 1) in the valves
a) Close the steam supply valve.
CAUTION!
Remember that steam under pressure may remain
in the steam line - release any such steam, for
instance by operating the steam valve by means of
the solenoid valve. Also, remember that the steam
valve might be hot.
b) Disconnect the steam and airlines, and

monitors.
(Cont’d)
1 Teflon seal (4 pcs)

2 O-ring
3 Rubber gasket
4 Membrane
5 Clamp ring
6 O-ring
7 Rubber gasket
8 Rubber gasket
9 O-ring
10 Seal ring
11 Tool 449969-0101(see fig 2 next page)
16 O-ring
18 Screw
25 Spring
43

TBA/3 600V 9508 MM 127-31 1(4)
Product(AP) Valve
(Cont’d)
In case work is done to the A, B or C valve

pneumatic cylinders, replace the O-rings (9) and
seal rings (10). In this case, tool 449969-0101 (11)
is used to unload the spring. Grease all seals and
O-rings with silicone, code L page 940-2 2(2)
c) Fit the tool (11) by means of the outer handle.
Compress the valve spring to take the load off
the inner clamp ring.
d) Loosen the inner clamp rings (pos 5, fig 1) and
take off the valves
e) Product valve (A)
Place the valve in a vice (use soft metal jaws)
(fig 2). Loosen the valve cone (12) and remove
it. Loosen the seal ring holder (13) and remove
it. Loosen the stop screw (14) in the end piece
of the valve.
f) Fasten softly the end piece in the vice (use soft
metal jaws) (fig 3). Turn the cylinder
anticlockwise until stop. Loosen the tool until
the spring pressure is released.
g) Disassemble the valve.
h) Replace the teflon seal (1) and the membrane
(4).
i) Fit the valve in the vice (use soft metal jaws)
(fig 4).
Note!
See to the hole (20) for the stop screw is aligned
with the hole (19) in the cylinder and that the square
hole on the tool fits on the end of the piston rod.
Compress the spring with tool. Turn clockwise

until the bayonet grips. Fasten the stop screw.
(Cont’d)
11 Tool 449969-0101
12 Valve cone
13 Ring holder
14 Stop screw
19 Hole in cylinder
20 Hole for stop screw
44

MM 127-31 2(4) 9508 TBA/3 600V
Product(AP) Valve
(Cont’d)
j) Screw in the valve cone slowly with a torque

wrench until a torque of 50 Nm is reached
(fig 5). Repeat this after 10-20 seconds. It is
recommended that this is done several times
because of the relatively low elasticity of the
teflon membrane. This will enable the teflon
membrane to penetrate into the grooves of the
parts.
k) Sterile air valve (B)
It is not possible to use the hand tool to
compress the spring due to insufficient space.
Therefore, compress the valve spring with
compressed air (operated from the panel).
Loosen the proximity switch on the end piece of
the valve and remove it. Loosen the clamp ring
and remove the valve.
CAUTION!
The valve cone will be pushed out when the
compressed air is turned off.
l) Loosen the pipe (15) for the proximity switch

and remove the sensor.
m)Loosen the valve cone and remove it.
n) Assemble and grease the new O-ring (16).
Grease the thread on the piston rod with silicon
compound.
Reassemble in reverse order.
o) Steam Valve (C).
Overhaul according to the instructions for valve
B. When fitting the holder to the teflon seal (1),
centre it on the shaft before tightening the
screws (18).
45

TBA/3 600V 9508 MM 127-31 3(4)
Product(AP) Valve
Graph for the cylinders and the drive motor
The synchronization of the cylinders must follow
the graph.
The closing time of the C valve varies, depending
on product viscosity. The higher the viscosity, the
longer time.
A) Product
B) Hot air or cleaning
C) Steam
21Open position
22 Close position
23 Exhaust with throttle
24 Air in
All valves are shown in closed

position. the cylinders are vented
and springs are closing them.
46

TBA/3 600V 9508 MM 127-31 4(4)
Filling tube
Setting
When setting the filling tube you must make sure
that the LS pressure roller is correctly positioned.
Moving the filling tube by removing the locking
pins (3) and (4) should only be done as a last
resort. If done new pins must be inserted.
1 Setting screw, turning in/out

2 Setting screw, turning sideways
3 Locking pin, movement sideways
4 Locking pin, movement in/out
47

TBA/3 600V 9508 MM 133-51 1(1)
Lower filling tube
Checking
Check that the mechanism is not seized and that
the axles and the links are not worn.
Check that the butterfly valve is closed when the
float is its upper position and that it is open with
the float in the lower position.
Check by shaking the float that no liquid has
leaked into it. (on newer machines the weight of
the float is engraved for checkweighing).
Check that there isno visible mechanical damage
on the float.
49

TBA/3 600V 9508 MM 134-11 1(2)
Lower filling tube
Assembly
1) Identify the parts on the picture.
2) Arrange the parts in numerical order on the
table.
3) Pick up the flanged sleeve (1) and the linkage
(2). Insert the pin with looking collar on (2)
into the bracket on (1). Lock it so that the U-
shaped lever is on the opposite side of the
sleeve to the straight lever. Leave the assembly
standing up on the table.
4) Pick up the filling pipe (3) and the float (4).
slide (4) onto (3) with the welded bracket
towards the narrow end of (3).
5) Slide (1) slit first onto (3). Position (1) so that
its slit is over the larger longitudinal slot in (3).
6) Pick up the throttle (5). Insert the disk in the
slot and connect the hook to the straight lever.
7) Lock (1) with lock pin (6) under the flange.
8) Connect the U-shaped lever (2) to bracket on
(4) and lock with hinged pin (7).
9) Test the function of throttle by moving (4)
back and forth.
10) Assembly completed.
1 Flanged sleeve
2 Linkage
3 Filling pipe
4 Float
5 Throttle
6 Lock pin
7 Hinged pin
50

MM 134-12 2(2) 9508 TBA/3 600V
Filling tube, pressure roller
Checking
Check that the pressure roller rotates freely, that
the bearing play is no more than 0.5 mm, and that
its surface is not worn. If required, replace the
roller.
Distance A
check distance A. If require, rest buy raising or
lowering the lower forming ring.
Volume ml Distance A (axle pin Gap B

centre - top of
forming ring)
1000-500 Cyl.roller 48±1 appr 2
250-200 Cyl.roller 48±1 appr 1
Convex roller 41+1-0
Alignment
Check that the filling pipe is centred in the lower
forming ring, and pressure roller centred on the
counter roller. Check that there is a gap (B)
between the pressure roller spring and the bow,
and gap (C) between the fork and the filling pipe.
The check is made with a piece of double
packaging material between the pressure and
counter rollers.
Pressure roller force, tool 74767-102

Measure the pressure roller force, without any
packaging material inserted, by pressing against
the fork joint with the tool, unit the roller just lifts
off the counter roller.
Volume ml Force F Force F Stainless

Spring spring 544894 or
old vers. 544895
1000- 500 50-60 N 55-65 N
250-200 30-40 N 35-45 N
Adjustment
Replace or bend the spring until correct force is
obtained.
1 Spring 4 Counter roller
2 Cover 5 Lower forming ring
3 Pressure roller 6 Tool 74767-102
51

TBA/3 600V 9508 MM 136-11 1(1)
Lower forming ring
Checking
check that the play between the rollers does not
exceed 0.5 mm. In case of fault replace worn
rollers and axles.
The play between the rollers is to be the same all
around. Adjust with washer 2033-7 and 2033-8
1 Roller
2 Axle
3 Adjustment washer
53

TBA/3 600V 9508 MM 137-11 1(1)
Lower forming ring, support roller
Checking (1000, 500ml)
The roller is to be set in the middle between the
edge of the packaging material web when the
element is in operating position.
Note!
The purpose of the roller is to keep the edge of the
web apart when the element withdraws, so that the
edge cannot fuse or get stuck together at stand-still.
If the edge are stuck together, the element cannot
enter on restarting.
Especially on TBA machines, the roller is

important.
1 support roller
2 Counter roller
55

TBA/3 600V 9508 MM 138-11 1(1)
LS overlap
Checking
a) Pick out two packages and check the LS
overlap. If required, set the LS overlap as
follows: Note!
One trimming roller gives about 0.5 mm difference
– Replace one to three regular rollers in the
in overlap.
lower forming ring with minus trimming
Trimming rollers must always be fitted
rollers to increase the overlap A. See table.
symmetrically with respect to the pressure roller.
– Replace one to three regular rollers with plus Plus and minus trimming rollers must never be
trimming rollers to decrease the overlap A. fitted at the same time in the forming ring.
See table
Package Nominal width Overlap Regular roller Plus trimming Minus trimming
material web A (mm) roller roller
(mm) TP No TP No TP No
1000 B 322 -6 / +8 257825-1 257825-2 257825-3
500 B 322 -6 / +8 257825-1 257825-2 257825-3
250 B 214 -7 / +9 257825-7 257825-8 257825-9
200 B 214 -7 / +9 257825-7 257825-8 257825-9
A
A
57

TBA/3 600V 9808 MM 139-12 1(2)
LS overlap
Checking
During production, pick out two consecutive
packages. Place them bottom-to-bottom, or top-to-
top. The LS overlaps are to be located opposite one
another.
Adjust by means of the wing nut (2) behind the

tube support/paper guide.:
58

MM 139-51 2(2) 9508 TBA/3 600V
Tube supports and upper forming ring
Checking
check that all rollers rotate freely and are
undamaged.
Check that the play between the rollers in the tube
supportsn and the upper forming ring does not
exceed 1mm (fig 2).
Distribute the play between the rollers all around
by means of adjustment washers.
Check that the rollers of the guide (3) rotate freely
and have no play.
Check the distance between the upper and lower
forming rings (A). adjust by moving the upper
forming ring.
Volume ml A mm
250, 200 594.5±0.5
1000, 500 542.5±0.5
1 Upper bending roller

2 Tube support
3 Guide
4 Upper forming ring
59

TBA/3 600V 9508 MM 140-11 1(1)
Upper bending roller
Checking
Make sure there is no bearing play. If required
replace faulty parts.
Driven bending roller (see picture)

Check gear wheels and gear play. If required adjust
the gear play or replace worn parts. Adjust by
moving the mounting plate with the motor up or
down.
Check the function of the free-wheel hub.
Check the function of the motor.
Check the carbon brushes of the motor. Replace
any brush shorter than 5 mm.
Check that the LED on the proximity switch (5)
flash one time/revolution. if not adjust the switch
or replace.
1 Ball bearing
2 Free-wheel hub
3 Hole for adjusting gear play
4 Drive assembly
5 Proximity switch M.B 115
61

TBA/3 600V 9510 MM 141-12 1(1)
Splice detector
Check
Function Set
• Tape a piece of packaging material to the • Set the screw (7) so it touches the inductive
material web before the splice detector. switch and the LED (6) light up.
• Step up the Machne to step Production • Place a piece of double packaging material
• Check that the taped-on piece passes the ball between the ball bearings (4)
bearing. • screw in the screw (7) until the LED goes out.
• The machine discards three packages. Check • check with a single piece of packaging material
that the package with the taped-on piece of that the LED (6) lights up and with a double
material is one of these. piece of packaging material the LED goes out.
• If not go on to check
Check
• Check that the ball bearings (4) rotate easily,
change if required.
• Check that the spring (1) is intact, change if
required.
• Check that the bracket (3) is easy to turn. If not
, remove the circlip (5) and the bracket. Clean
or change the two bushings (2) if required.
1 Spring
2 Bushing
3 Bracket
4 Ball bearing
5 Circlip
6 LED
7 Screw
8 Nut
10 Taped-on piece of material
11 Proximity switch M.B 35
63

TBA/3 600V 9510 MM 142-52 1(1)
Printed design correction system
Checking
Bar code photocells, filters
When the filter (1) is coloured red, it must be
replaced.
When the filter (2) is coloured pink, it must be
replaced.
Bar code photocells

Check that the seals (3) are intact. If not replace
them.
Check that the screws (4) are tightened.
Check that the lenses of the photocells are intact. If
not replace the
photocell.
1 Filter
2 Filter
3 Seal
4 Screw
5 Photocell
65

TBA/3 600V 9510 MM 155-52 1(6)
Basic setting of the driven bending roller
Positions on the multi switch (1):
Position 1 = Min. speed
Position 4 = Max speed
Position 8 = Run
Position F = Autosetting
a) Loosen the packaging material web over the
driven bending roller.
b) Turn the potentiometer (5) fully counter
clockwise
c) Activate MANUAL OPERATING BENDING
ROLLER (S44) at the front panel. LED (4)
lights up. The driven bending roller starts
rotating.
d) Set the multi switch (1) in position “F”.
e) One of the LEDs S1-S8 will get a fixed light
and the rest will start to flash. Now the program
make an autosetting of the speeds 80 rpm and
120 rpm. When correct speeds are obtained the
LEDs S1-S8 stops flashing.
1 Multi switch
2 Light emitting diode (LED) power On
3 Light emitting diode (LED) Overload trip
4 Light emitting diode (LED) External Speed Setting
5 Potentiometer Acc.ramp
6 Potentiometer IxR
66

MM 155-52 2(6) 9510 TBA/3 600V
(Cont’d)
f) Set the multi switch (1) in position “1”.

Note!
The LED (3) have a very weak light. Try to have as
dark as possible in the electrical cabinet.
g) Turn the potentiometer (6) clockwise until the

motor starts to oscillate and the LED (3) starts
to flash, then turn it counter clockwise until the
motor speed becomes stable again and LED (3)
get a fixed light.
h) Set the multi switch (1) in position “F”.
i) New reference setting:
One of the LEDs S1-S8 will have a fixed light
and the rest will start to flash. Now the program
make an autosetting of speeds 80 rpm and
120 rpm. When correct speeds are obtained the
LEDs S1-S8 stops to flash.
j) Set the multi switch (1) in position “1”. Use a
tachometer to measure at the driven bending
roller. Verify the speed 80rpm. If the speed is
not correct set the potentiometer (1) at “0” and
repeat from item e)
k) Set the multi switch (1) in position “4”. Use a
tachometer to measure at the driven bending
roller. Verify the speed 120 rpm. If the speed is
not correct set the potentiometer at “0” and
repeat from item e).
l) Set the multi switch (1) in position “8”
1 Multi switch
2 Light emitting diode (LED) power On
3 Light emitting diode (LED) Overload trip
4 Light emitting diode (LED) External Speed Setting
5 Potentiometer Acc.ramp
6 Potentiometer lxR
67

TBA/3 600V 9510 MM 155-52 3(6)
Photocells position - Basic setting
Inch to SEALED TUBE.
With retracted arm, eliminate any play with the
screw (1).
Crank the machine to 0o and set distance A,
between the outer carrier and the centre of the
photocells, according to fig and table.
Set potentiometer at “0”.
0
-1 1
-2 2
-3 3
-4 4
-5 5
GBABBA47
Distance
Volume ml A mm
1000 653
500 608
250 605
200 625
68

MM 155-52 4(6) 9608 TBA/3 600V
1Screw
Photocells - Sensitivity setting

a) The photocells are equipped with double light
sources. For a new photocell, set the selector (4)
in position (16) shown in the picture and carry g) If the light-emitting diodes (3) are out, turn the
out setting according to items c) -i). setting knobs (5) counter-clockwise as far, but
no further, as to make the diodes light up
When the first light source has been used up,
set the selector in the opposite position and
carry out the corresponding settings. h) Still against the black tape:
– If a white only printed design background is
b) Set the 9±1 mm gaps, between the photocells used at the bar code, turn the setting knobs
and the “sealed tube”, by means of the screws under the covers clockwise until the
(6), fig 6. (Use for example a 9 mm drill). photocells go out but no further.
– If a white and unbleached printed design
c) Set the light images to coincide with the middle background is used at the bar code, make the
of the tube bar codes, by means of the screws photocells go out as described above, but
(7), fig 6. (Crank the machine to this position.) there after turn the setting knobs one full
turn counter-clockwise.
d) Remove the covers (8), fig 6. Set the selector Set the selector (4) at a black point (18) and refit
(4) at a white point (17). the cover.
e) Crank the machine until the photocell beams hit

white packaging material.
f) Set the selectors (4) at position J (16). The

signal values obtained at item e) are now stored
in the photocell unit. Put a piece of black tape
on the tube and carry out the corresponding
setting against the tape.
3 Light-emitting diode 16 Adjustment

4 Selector 17 Memorize
5 Setting knob 18 Run
69

TBA/3 600V 9510 MM 155-52 5(6)
Photocells - Horizontal setting
Cut the tube as the figure shows.Attach very
accurately a piece of black tape to the tube along
one of the horizontal crease lines. When the light
beam passes across the edge of the tape, both 19
photocells should light up or go out exactly at the
same time. Adjust in/out after loosening the screw
(6). Adjust the light images vertically by means of
shims or (on old model machines) by means of the
screws (13) and (14).
23
20
21
6 Screw
7 Screw
8 Cover
13 Screw
14 Screw 22
19 Lower forming ring
20 Photocells
21 Tube support roller
22 Jaws
23 Black tape
GBAABB65
70

MM 155-52 6(6) 9510 TBA/3 600V
Suction filter
Replacement
Loosen the quick release couplings (1) and remove
the filter unit.
Unscrew the three wing nuts (2) and lift the cover.
Replace the filter element (3).
Check the flange packings of the quick release
couplings.
Refit.
1 Quick release coupling

2 Wing nut
3 Filter element 90277-316
71

TBA/3 600V 9508 MM 159-22 1(1)
Compressor of water ring type
Checking and fault finding
1) Check that the pump is running without any
abnormal sounds.
2) Check that the axial seal of the compressor
does not leak. Any leakage can be seen on the
underside at the joint between the motor and
the compressor housing (1).
3) Check that the pressure indicated by the
separator pressure gauge is 45 kPa (0.45 kp/
cm2) in production position.
a) Too high pressure may be due to blocking
of the overflow valve or that separator float
has got stuck in closed position. In the latter
case water will be spurting out of the
overflow valve.
b) Too low pressure may be due to leakage in
the air system or too low compressor
capacity. The reason for the latter may be
inadequate water supply, faulty solenoid
valve, or faulty constant flow valve.
4) the motor and compressor will not start when
the Preheating On button is pushed.
a) The motor overload protection has been
tripped.
b) If the motor is running while the button is
kept depressed but stops when the operator
lets go of the button, see item 3, Low
Pressure
c) The D18 sterile air pressure guard is out of
action.
5) If checks as per items 1-4 have been done and
the prescribed pressure of 45 kPa (0.45 kp/
cm2) cannot be obtained, do as follows:
a) replace the pressure gauge.
b) Overhaul the compressor, see page 160-32
2(5)
73

TBA/3 600V 9508 MM 160-12 1(5)
Overhaul
Dismantling play A at the four screw with nuts 816)
a) remove the hexagonal screw (20) and the seal loosened. Add 0.1-0.2 mm to the average value
(19) of play A.
b) Remove the locking nut (7), washer (8), and i) Tighten the nuts (16).
rotor (11). there are two holes in the rotor for j) Check that the gap between the rotor (11) and
extractor No V3-74305-0101 the end cover (21) is appr. 0.1 mm by inserting
c) Remove the rotor key (9). a feeler gauge through the inlet or outlet pipe.
d) remove the four nuts (16) and separate the k) Lossen the screw (20) again. Position the cover
pump housing (12) from the motor (14). The (21) in the centre. Tighten the screws (20).
mechanical shaft seal 813) will then come away l) Check that the rotor does not scrape against the
with the pump housing when it is detached. cover when turned (turn by motor fan).
Take care not to damage the ceramic sealing m)Fit the inlet and out let flanges (5) and the
surface when removing the pump housing. gasket (6) with the screws (4).
e) Remove the fixed sealing section (1) from the n) Check once more that the rotor rotates freely.
pump housing by applying an even pressure
from the motor side.
Reassemble
a) Fit the mechanical seal (1) in the pump housing
(12) aided by a thin film of oil on the rubber
sleeve.
CAUTION!
No grease on the sealing surface. Fit the water
deflector ring (17) on the motor shaft.
b) Mount the pump housing (12) loosely against

the motor with the nuts (16).
c) Fit the rotating section (2) of the mechanical
seal on the motor shaft. Fit the coil spring (3).
d) Place the key (9) in its keyway in the shaft.
e) Fit the rotor (11).
f) Fit the washer (8) and locking nut (7) on the
shaft and tighten properly.
g) Put the pump housing seal (19) in place. Then
fit the end cover (21), and attach it with the
hexagonal screws (2). Undo the mounting nuts
(16) of the pump housing before tightening the
end cover screws.
h) fit shims (18) at the four screws between the
pump housing and the mounting flange of the
motor. Shi´m thickness as follows: Measure the
74

MM 160-32 2(5) 9508 TBA/3 600V
Overhaul
1 Fixed seal 8 Washer, locking nut 15 Stud screw, pump housing

2 Rotating seal 9 Key, rotor 16 Nut, pump housing
3 Spring 10 Drain plug 17 deflector ring
4 Screw, flange 11 Rotor 18 Shim
5 Flange 12 Pump housing 19 Gasket, end cover
6 Gasket, flange 13 Shaft seal, complete 20 Screw, end cover
7 Locking nut, rotor 14 Motor 21 End cover
75

TBA/3 600V 9508 MM 160-32 3(5)
Overhaul
1 Shaft
2 Motor
3 Pump housing
4 rotor
76

MM 160-32 4(5) 9508 TBA/3 600V
Basic setting
a) Screw in the LS/SA setting screws fully; then
unscrew them 1.5 turn.
b) Remove the cover and check that the
compressor rotor can be turned by hand, that it
“sounds smooth2, and that the rotor does not
catch or bind during its rotation. Jarring or
grating sounds may be caused by dirt in the
pump housing - clean out by removing the drain
plug and rinsing with water.
c) open the water cock. Push Preheating On
and keep the button depressed for about 15 s;
provided the compressor rotates in the right
direction the sterile air pressure indicated on the
pressure will now rise.
d) Keep Preheating ON depressed for about
30 s. Within this time, working pressure should
be reached. If the pressure is below appr 25 kPa
(.25 kp/cm2) when the button is released, the
machine reverts to Mains On status.
If working pressure is not reached

within 30 s, check
– that water is delivered to the compressor
– Check constant flow valve (1gallon/min) for
limestone deposits.
– that the float of water separator trap has not
jammed, see page 162-21 1(1)
– that the spring of the over-flow valve is
under tension
– that there is no leakage in the air system
(check the seals in the air heater)
– the MD18 pressure guard (monitor) (fixed
setting, replace if required)
– the compressor (overhauled)
Note!
For setting of working pressure, see page 161-52
1(1). If there is any danger of the compressor being
subject to temperatures below freezing, the
compressor and water separator must be drained.
77

TBA/3 600V 9508 MM 160-53 5(5)
Sterile air pressure
Setting
a) When the sterile air temperature (350o) has
been reached, do a basic setting of the pressure
at appr. 45 kPa by altering the spring tension of
the overflow valve by means of the nut (1)
b) During production, do a fine setting of the
pressure by means of the nut at 45±5 kPa.
79

TBA/3 600V 9508 MM 161-52 1(1)
Water separator
Dismantling, Cleaning, Checking float
a) Detach the entire water separator from the
machine.
b) Remove the flanges (2) and (3).
c) Check that float mechanism (4), the container
and the piping. If necessary use a deliming
agent.
Fitting
a) Check the O-ring (5,6) of the flanges and the
pipe-union seals.
b) Fit the water separator.
c) After starting the compressor, check that no
water comes of the overflow pipe (7). If so, the
water separator must be removed again and the
function of the float checked.
Note!
Water may also come out of the overflow pipe if the
sterile air cooler is blocked, see page 165-13 3(3)
1 Pressure gauge 5 O-ring

2 Upper flange 6 O-ring flow
3 Lower flange 7 Overflow pipe
4 Float mechanism
81

TBA/3 600V 9508 MM 162-21 1(1)
Overflow valve
Cleaning, checking
a) Detach the overflow valve.
b) Take off the cover and the mechanism.
c) clean the mechanism, container and piping. If
necessary use a deliming agent.
d) Check the seal (1).
e) Reassemble and refit the unit.
1 Seal
83

TBA/3 600V 9508 MM 163-11 1(1)
Air superheater
Cleaning, Checking
Checking the element
The temperature of the air from the superheater is
to reach 350o c. if not check:
a) Instrument S8
b) The six elements, effect 1900W each, amperage
8 -9 A in each. tong ammeter is suitable for
measuring in the electrical cabinet
Dismantling, cleaning
a) Undo the screw (1). Lift the element unit (2)
and tie it to the superstructure.
b) Disconnect the pipe connections and pull the
container down/forward from the element unit.
c) Clean the element and the container. Flush
through the outer cavity (4) of the container and
make sure there are no deposits in it.
1 Screw
2 Element unit
3 Container
4 Outer cavity
85

TBA/3 600V 9508 MM 164-21 1(2)
Air superheater
Reassemble and fitting
Check the pipe connection seal (1).
The pipe attachments (2) and (3) are to be
loosened.
Tighten the pipe connection, but make sure that the
seals do not get into an oblique angel (the new
asbestos-free types do not withstand uneven
loads).
Tighten the pipe attachments.
Fit the air superheater.
1 Seal
2 Pipe attachments
3 Pipe attachments
86

MM 164-41 2(2) 9508 TBA/3 600V
Sterile air cooler
Checking tightness
Loosen the connections (1) and (2) on the cooler
and the connections (3) and (4) on the cylinder.
Connect a pipe (nipple TP No 90030-115) (5) to a
hose (9) put into a tank of water (6).
Plug the upper connection with a nipple
(TP No 90030-115) and a plugged pipe (7). Plug
the lower pipe (1) with a welded-up coupling
(TP No 90330-064). Plug the lower connection of
the cylinder with a welded-up plug (TP No 90224-
097) (8).
Remove the fuses to the air superheater and step up
the machine to Preheating. Check that
there is no bubbling in the tank (6). Replace the
fuses and once again check that there is no
bubbling.
When the machine has reached the Ready for
sterilization state, disconnect the
sterile air going to the tube by removing the quick
coupling on the B-valve.
Turn the jet deflector valve by pushing the cylinder
to the outer position. Once again check that there is
no bubbling. Step down the machine to
Cooling and check that water is sucked up
into the hose (9).
1 Connection
2 Connection
3 Connection
4 Connection
5 Pipe
6 Tank of water
7 Plugged pipe
8 Welded-up plug
9 Hose
87

TBA/3 600V 9508 MM 165-11 1(3)
Sterile air cooler
Checking
a) Check that the gaskets (2) do not leak. If so,
replace them. Tighten the screws.
b) If the temperature of the cooled sterile air is
above 80o C during production, the water flow
of the cooling system is to be checked
according to the sequence chart overleaf. If the
flow rate is too low, clean by pumping 20%
acetic acid or some other deliming agent
through the sterile air cooler.
c) Check tightness according to page 165-11 1(3).
Lossen the connections (7-10). Use nipples
TP No. 90030-096 (2 pcs.).
1 Thermometer
2 Gasket
4 Valve
5 Valve
6 Outlet
7 Connection
8 Connection
9 Connection
10 Connection
88

MM 165-13 2(3) 9510 TBA/3 600V
Sterile air cooler
Sequence chart, water flow rate
Step MB16 Valve 5 Valve 4 MB33 Water flow

Movement rate l/min
Preheating not - + Closed 3.5
sterilizer actuat
Cooling not - + Open 11.5
ready for actuat.
production
(boosted
cooling)
Production actuated + - Closed 3.5
on
Production not - + Open 11.5
off actuat.
(boosted
cooling)
Production actuated + - Closed 3.5
finished
Mains not - + Closed 0
power off actuat.
Mains on actuated + - Closed 0
89

TBA/3 600V 9510 MM 165-13 3(3)
Sterile Air
Checking the pressure guard
a) Loosen a dairy union pipe connection upstream
of the pressure gauge so that the pressure drops.
b) Read on the pressure gauge at what pressure the
machine stops.
c) The machine is to stop at a pressure of 30 kPa
(0.3 kp/cm2).
d) If required adjust with the screw on MB 18.
Check pressure guard (monitor) MB 18

a) Machine in Preheating On status.
b) Turn off the water.
c) Check on the pressure gauge that the machine
reverts to Mains On status at appr. 25 kPa.
d) In case of fault, replace the pressure guard
(monitor).
91

TBA/3 600V 9510 MM 167-12 1(1)
Jet deflector valve
Checking
Check that the jet deflector valve functions on
stopping and starting
The air cylinder is to be in plus position during
production and in minus position during
production and in minus position during stand-
still.
The position of the jet deflector valve can be
checked by feeling whether the air pressure
changes in the air knife.
93

TBA/3 600V 9508 MM 170-11 1(1)
Air knife
Cleaning the slot and checking the rollers
Clean air slot (2) with an 0.4 mm feeler gauge. Do
it while the machine is hot.
Check during operation the setting of the air knife
according to the picture. The slot is to be located
2-3 mm outside the strip.
Check wear of the rollers (3).
1 Air knife
2 Air slot
3 Roller
95

TBA/3 600V 9508 MM 171-11 1(1)
Sterile air system
Checking, tightness
Check that the pipe connections and unions are
tight.
1 Compressor 12 Air superheater 21 Product valve “A” 29 Edge dryer
2 Water separator temperature 22 Sterile air valve “B” 30 Peroxide bath
3 Valve, drainage 13 SA heater 23 Sterile air temperature 31 Peroxide bath cooling
4 Valve, boosted cooling 14 SA heater 24 Proximity switch 32 Tube heater
5 Valve, sealing water temperature sterile air valve (B) 33 Float
for compressor 15 LS heater 25 Steam barrier valve 34 Valve, sprinkler
6 Valve, boosted cooling 16 LS heater (C) 35 Steam trap
7 Diversion valve temperature 26 Steam temerature
8 Ejector 17 Sterile air cooler 27 Proximity switch
9 Overflow valve 18 Sterile air temperature steam barrier valve
19 Jet diverter valve (C)
10 Pressure guard
20 Suction filter 28 Air knife
11 Air superheater
30
28 29
27
26
25 31
21
13
35
23
22 14
20 24
15
16
1
11
32
5
19
18
2
33
3 4
34
10 17
7
9
8 6
12
GBAABB77
97

TBA/3 600V 9510 MM 175-12 1(1)
Tube flushing
Checking
Check that the holes are not blocked on the three
tube flushings. Check the flow.
Upper tube flushing: highest possible flow without
water splashing from the tube. Intermediate tube
flushing: maximum flow without it reaching lower
forming ring and without water splashing into the
tube.
Lower tube flushing: least possible flow.
1
1 Ring sprinkler 2
2 Upper sprinkler
3 Sprinkler on tube support roller
4 Lower sprinkler
GBAABB68
99

TBA/3 600V 9508 MM 178-11 1(1)
Peroxide pump
Checking; Piston type
CAUTION!
Follow safety precaution according to page 002-1
1(5)
a) Check during operation if peroxide is leaking

from the hole in the bottom of the pump
housing. If so, replace the piston seal. Take care
not to scratch the piston.
b) Check that the pump piston moves easily.
c) Grease the component of the connection rod
head. Only silicon grease 90296-0009 must be
used on the piston, bearings and seals.
d) Before starting the pump after replacing the
seal, the pressure pipe (2) is to be disconnected
and the pump filled with distilled water or
sterilization liquid.
e) the spring on the connection rod is an overload
protection device. If the spring is working, there
is a blockage in the pipe-line or valves. Clear
the obstruction.
1 Connection rod head

2 Pressure pipe
3 Suction pipe
4 Hole in bottom of pump housing
5 Arrow pointing up
101

TBA/3 600V 9508 MM 180-12 1(2)
Peroxide pump
Overhaul; Piston type
CAUTION!
1 Piston
1(5)
2 Bearing
a) Dismantle the pump. 3 Seal
4 Seat, non-return valve, pressure pipe
b) Inspect the piston (1) and bearing (2).
5 Ball
c) Dismantle the two non-return valves 6 Pin
(components 4-6) and (7). 7 Non-return valve, suction pipe
d) Replace seals and O-rings. 8 Connection rod
e) Reassemble. Grease the components of the
connecting piston rod. Only silicon grease
90296-0009 must be used on piston, bearings
and seals.
f) Before starting the pump, the pressure pipe is to
be disconnected and the pump filled up with
distilled water or sterilization liquid.
102

MM 180-32 2(2) 9508 TBA/3 600V
Peroxide consumption
Checking
CAUTION!
1(5)
At all times the peroxide consumption should be

checked every day, by means of two graduated
glass cylinders.
a) Insert the hoses into one of the graduated
cylinders (1) and let the peroxide circulate
through it.
b) Make sure the system is completely filled with
peroxide. Top up with peroxide to the top scale
division, level C.
c) top up peroxide to the top scale division of the
other graduated cylinder (2).
d) Let the level in the first cylinder (1) drop during
a predetermined period of time.
e) Top up to level C once more from the cylinder
(2).
f) Read the amount of peroxide consumed in the
cylinder (2).
If consumption deviates from the values listed 1 Grauated cylinder

below, check whether the squee-gee roller is worn 2 Grauated cylinder
or damaged; also check the roller force of the
squee-gee roller Acc to page 183-15 1(1) and the
play between the wetting and counter rollers.Acc
to page 185-12 1(1)
Peroxide consumption
Pkg vol. Consumption
ml ml/h
3720 pkg/h
1000 250-400
500 200-230
250, 200 120-150
4500 pkg/h
250, 200 130-190
103

TBA/3 600V 9508 MM 183-15 1(1)
Peroxide bath
Checking Squee-gee roller pressure
CAUTION!
1(5)
The tabulated force F refers to one spring only (of

two) in position.
Apply tool 74767-101, i e 74767-102 with pin
74912 removed, at right angles to the arm.
The force is to be measured at right angles to the
arm just as the squee-gee roller lifts off the counter
roller.
Volume ml Force F
1000, 500 40 N (4 kp)
250, 200 25 N (2.5 kp)
Adjust the setting nuts (3) until the correct force is

obtained. Repeat the procedure with the other
spring.
Note!
This only a basic setting . 1 Tool 74767-101
Fine adjustments should be done by means of 2 Squee-gee roller
checking H2O2 consumption. acc to page 183-15 3 Setting nut
1(1)
105

TBA/3 600V 9508 MM 184-11 1(2)
Peroxide bath
Replacing the squee-gee roller sleeve
CAUTION!
1(5). No lubricants what so ever should be
used!
Note!
The outer surface of the sleeve must be turned
outward during fitting.
a) Clamp the roller shaft in a vice (3).

b) Push the sleeve (1) 10 -15 mm on to the roller
(2).
c) Insert the air nozzle (4) between the roller and
the hose.
d) When compressed air blows in between the
roller and sleeve, an air cushion is created and
the sleeve can be slid over the shaft.
Handling of the hose

Be extremely careful not to damage the surface of
the sleeve. Any indentation, however small, will
increase the risk for excessive amounts of residual
H202 in packaged product.
1 Sleeve
Component No 2 Roller
1000, 500 ml 284891-2 3 Vice
4 Air nozzle
250, 200 ml 284891-1
106

MM 184-61 2(2) 9508 TBA/3 600V
Peroxide bath
Checking gap between wetting and counter rollers
CAUTION!
1(5)
Measure the gap without packaging material

between the rollers.
Be observant that the distance is the same at point
A and B
B
A
GBAABB69
1 Nut
2 Direction of rotation
Volume ml Gap B
1000, 500 0.9
250, 200 0.7
Adjust by means of the nuts (1). Tighten the nuts

after adjustment.
107

TBA/3 600V 9510 MM 185-12 1(1)
Peroxide bath, level guard
Setting
CAUTION!
1(5)
Set the level monitor during sterilization, when the

peroxide pump is running.
Make sure the liquid level is at the overflow of the
peroxide bath.
Undo the clamp (1) and move the level guard (2)
slowly upwards until the warning beacon and the
signal lamp on the panel begin to flash.
Reset by pushing alarm Stop on the control
panel. The warning then stops flashing and the
signal lamp changes over to fixed light.
Move the level guard slowly downwards, until the
lamp on the supervision panel goes out. Then
lower the level guard another 10 mm.
tighten the clamp.
1 Clamp
2 Level guard
109

TBA/3 600V 9508 MM 186-51 1(1)
Peroxide bath
Checking position of packaging material on wetting roller
CAUTION!
1(5)
To avoid absorption of H2O2 into the packaging

material, 1.0 - 1.5 mm of the web, on the opposite
side from the LS, must protrude beyond the
wetting roller.
if this is not the case:
a) Check that the packaging material runs
correctly through the SA element, upper
bending roller, and web guide, and that the
overlap is correctly centred. Check all bearings
in the H2O2-bath for wear.
b) Loosen the Allen screws of the stop rings (5)
and shift the bath. Position the stop rings so that
the bath is held firmly, and tighten the Allen
screws.
1 LS strip
2 Wetting roller
3 Counter roller
5 Stop rings
111

TBA/3 600V 9508 MM 187-11 1(1)
Wetting Monitor
Checking/setting With through-flow electrode and guard TP201
CAUTION!
1(5)
a) Set the gap between the wetting roller and the

counter roller, page 185-12 1(1)
b) The sliding electrode is to touch the packaging
material 5 - 10 mm from the squee-gee roller
(fig 1).
c) Do a basic setting of the gap between the metal
parts of the reference electrode, A = 5 mm (fig
2).
d) The tube to the lower part of the reference
electrode must ascend without dips.
e) Preheating On
Wait until the peroxide bath is completely full.
Then check that liquid is flowing through the
return loop (6) (fig 2). If required, adjust by
raising the mounting plate until peroxide starts
flowing through the return tube.
1 Reference electrode, upper part

2 Plastic hose
3 Min liquid level
4 Reference electrode, lower part
5 Vent
6 Return tube
113

TBA/3 600V 9508 MM 189-12 1(3)
Wetting Monitor
During operation
CAUTION!
1(5)
WARNING!
Risk of peroxide leakage. Fit the cover (7). Lock
with the screw M4 (8).
a) Check that the packaging material web is being

wetted evenly.
b) Check that liquid is flowing through the return
tube. The liquid level can be checked by rapidly
turning the drain tap on and off when the pump
is working. Liquid will then be pushed out of
the vent (5).
c) Connect a high-resistance voltmeter (input
resistance at least 10 M¾) between the poles of
the reference electrode. Adjust gap A until the
voltmeter indicates approximately 6 V
AC voltage (min 3 V, max 7.5 V)
d) Alternatively, raising (with the aid of an
insulated object) and short-circuiting the sliding
electrode, for a minimum of 2 seconds, should
make the signal lamp flash.
Short-circuiting or raising the electrode for a

longer time than that set on PLC timer R406- 15
s -should stop the machine synchronously.
1 Reference electrode, upper part

2 Plastic hose
3 Min liquid level
4 Reference electrode, lower part
5 Vent
6 Return tube
7 Cover 556670 (Tube Ø 10 mm)
Cover 556671 (Tube Ø 12 mm)
8 Screw M4 Note!
Fault-finding, see page 189-61 3(3)
114

MM 189-12 2(3) 9609 TBA/3 600V
Wetting Monitor
Fault finding
CAUTION!
1(5)
a) Checking/setting acc. to page 189-12 1(3).

Note!
The machine is to be running and producing filled
packages - step 8- for the measuring relay to be able
to function and the signal lamp to flash.
b) Substitute a resistor of 18 - 22 k¾ (nominally

20 k¾) for the reference electrode of the
wetting monitor, and a resistor of 75 - 100 k¾
(nominally 80 k¾) for the sliding electrode, fig
1, and check the voltages.
If the voltages given in the diagram of fig 1 are
not obtained, the wiring and connections to the
measuring relay must be checked. If the
voltages are obtained, the fault is in the sliding
electrode or in the reference electrode.
Remove the resistor and reconnect the
electrodes.
Check once again acc. to page 189-12 1(3).
c) Substitute the 20 k¾ resistor for the reference
electrode and the 80 k¾ resistor for the sliding
electrode (wiring acc to fig 2). With these
resistors the measuring relay is to work, i.e.
PLC timer R406 does not start.
Check that the time relay does start (perhaps
indicated by a buzzer wired in) if one of the
resistors is short-circuited or disconnected.
If the time relay does not start if one of the
resistors is short-circuited or disconnected, the
fault is in the measuring relay or in its circuit.
115

TBA/3 600V 9609 MM 189-61 3(3)
Zone heater
Checking the heated zone
The zone can be visualized by means of the
zonoscope and is then seen distinctly in dark blue
or brown.
The Zonoscope can be used for:
– Checking the position of the zone. The heat
pattern (5) should cover the opening device
but it must not reach the transversal seal (4).
– If required, adjust with the hand wheel (7).
Align the heat pattern sideways by loosening
the screws (6) and moving the zone heater.
– Checking the pulse time by examining the
width of the heated zone.
– Checking the intensity of the heating.
Fig 1 shows correctly positioned and
homogeneously heated zone.
A dark blue or brown zone means that the power is
correct.
3 Zonoscope
4 Transversal seal
5 Heat image
6 Screw
7 Hand wheel
117

TBA/3 600V 9510 MM 194-12 1(5)
Zone heater
Checking the heated zone
This picture shows a heated zone (10) when the
pulse time is too long. The surface of the treated
zone is a function of the pulse time. Measure:
reduce the pulse time with potentiometer (2).
This picture shows an inadequately heated zone

due to low power setting. The appearance will be
light brown and the edges of the zone ragged.
Measure: check the roller setting according to page
194-52 5(5). Increase the voltage with the control
(1).
This picture shows the result of excessive power. A

lighter colour will then be present in the heated
zone. If the power is much too high, the alufoil is
completely burnt-out. Measure: check that there is
no coating on the roller. Check the roller setting
according to page 194-52 5(5). Reduce the voltage
with the control (1).
This picture shows a ragged edge of the zone

caused by the pulse starting at the wrong time.
Measure: check once again the setting according to
page 194-52 5(5).
8 Transversal seal
9 Longitudinal seal
10 Heated zone
118

MM 194-12 2(6) 9510 TBA/3 600V
Zone heater
Checking during production
Check that the heat pattern (13) is clearly
defined. If not, adjust the setting according to
"Fine setting during production"
The heat image should cover the opening
device, but not reach the transversal seal (12).
If required, adjust with the hand wheel (14).
12 Transversal seal
13 Heat image
14 Hand wheel
119

TBA/3 600V 9510 MM 194-12 3(5)
Zone heater
Basic setting
a) Set distance A by means of the screws (1) acc. Crank the hand wheel (2) to a position where gaps
to the table E are the same
Volume A
ml mm Machine degree Machine degree scale,
scale, fixed reel vertically adjustable reel
(WI/PH)
1000 0 180° 140°
500 3 160°
250 85 180o
200
1 Screw
2 Hand wheel
120

MM 194-52 4(5) 9510 TBA/3 600V
Zone heater
Basic setting
b) Check that the gap between the inductor (5) and
the counter roller (4) is 1 mm along the whole
length of the roller.
If the gap is incorrectly set, adjust by means of
the screw (3). If the setting is at an angle,
straighten the axle mount of the roller.
c) Carry out a test run and check in accordance
with page 194-12 2(6).
3 Adjustment screw
4 Counter roller
5 Inductor
121

TBA/3 600V 9510 MM 194-52 5(5)
Machine Body
Name Issue Page
Central lubrication 9510
Pressure guard 9510 202-11
Oil feed 9510 202-11
Impure Oil 9510 202-11
Cleaning, Oil tank 9510 202-11
Removal 9510 202-11
Oil tank 9510 202-11
Bleeding 9510 202-21
Central Lubrication Diagram 9510

Central Lubrication Diagram 9510 203-11
Air Filter 9508

Cleaning 9508 211-32
Removal 9508 211-32
Fitting 9508 211-32
Cooling water system 9510

Cooling Water Diagram 9510 215-12
Cooling water temperature 9510 215-12
Water flow 9510 215-12
Pressure Guard 9510 215-12
Water Filter 9510

Water filter for deliming 9510

123

TBA/3 600V 9906 MM 200 1(3)
Machine Body
Name Issue Page
Paper supply monitor 9803
Photocell adjustment 9803 219-32
Photocell 9803 219-32
Cassette 9508
Checking / Installation 9508 222-11
Setting 9508 222-52
Paper Reel Holder 9508

Splicing device 9508

Check/Setting 9508 230-11
Breaking Device 9508
Rotation Monitor 177

Pneumatic Connection Diagram 9510
TBA/3 9510 261-15
Dating Unit 9508

Setting 9609 272-53
Printing Wheel Shaft 9508

Setting 9508 273-51
Setting 9508 274-51
Setting 9508 274-51
Setting 9508 274-51
Transfer Roller/Inking Roller 9508

Setting 9508 275-53
Setting 9508 275-53
124

MM 200 2(3) 9906 TBA/3 600V
Machine Body
Name Issue Page
Crease Wheel 9508
Basic Setting 9508 276-51
Jumbo Reel Holder 9906

Jumbo reel frame 9906
Check 9906 277-51
Packaging material reel holder 9906

Check 9906 277-51
Packaging-material Guard 9906
Check 9906 277-51
Hinge Assembly 9906
Check / Lubrication 9906 277-52
Drive Brake 9906
Low Speed setting: 9906 277-53

Frequency control 9906
Frequency control - basic setting 9906 277-54
CONFIGURATION/SETTING
OF FREQUENCY INVERTER: 9906 277-54
Frequency control - basic setting 9906 277-55
CONFIGURATION/SETTING
OF FREQUENCY INVERTER: 9906 277-55
125

TBA/3 600V 9906 MM 200 3(3)
Central lubrication
Checking
WARNING!
Risk of skin irritation.
Before handling oil, read the Safety Precautions in
section 000
Pressure guard
Check the mechanism when pushing Manual
lubrication
1 Pressure guard
Oil feed
Push Manual lubrication and check that oil
reaches:
• Guides jaw system
(loosen the nipple)
• Shaft rear on pressure arm
(loosen the nipple)
• Rollers on cams
(use your finger)
Make sure that oil reaches these parts.
When checking these parts also look for air
bubbles in the oil hoses, this could mean that the
lubrication pump is leaking.
(Cont’d)
127

TBA/3 600V 9510 MM 202-11 1(5)
Central lubrication
(Cont’d)
Impure Oil
Open the drain valve (13) and drain any impure oil
into a container placed under the machine. Close
the valve when clean oil comes out of the hose.
Top up with new oil through the nipple (9). See
lubricant code H acc to page MM 940-2 1(2)
Bleed acc to page MM 202-615(5)
Check the oil pressure according to page MM 202-
11 1(5)
Cleaning, Oil tank

a) Disconnect the electrical connection (10)
b) Undo the screws (12).
c) Remove the cover (11)
d) Clean the tank with lint-free cloths.
Be sure that there is no lint after cleaning.
e) Reassemble in reverse order and fill with new
oil through the nipple (9)
See lubricant code H acc to page MM 940-2
1(2)

11 1(5)
9 Nipple
10 Electrical connection
11 Cover
12 Screw
13 Drain valve
128

MM 202-11 2(5) 9510 TBA/3 600V
Central lubrication
Removal
WARNING!
section 000
Oil tank
Open the drain valve (1) in order to empty the oil
tank.
Disconnect the following details:
• OIl connection (2)
• Hose (3)
• Electrical connection (4)
• Screws (5) in the bracket.
• Air hose (6) and, after removing the oil tank
unit the pump (7)
Reassemble in reverse order
Close drain valve (1) and fill with new oil through
the nipple.
See lubricant code H acc to page MM 940-2 1(2)
11 1(5)
1 Drain valve
2 Oil connection
3 Hose
4 Electrical connection
5 Screw
6 Air hose
7 Pump
8 Solenoid valve
129

TBA/3 600V 9510 MM 202-113(5)
Central lubrication
Bleeding
WARNING!
section 000
Loosen the hose nipples and bleed

After loosening the nipple, push the Manual
lubrication button. repeat until air-free oil is
discharged. Then retighten the nipple.
Bleed in this order:
a) The distribution block on the right side of the
final folder
b) The distribution block on the left side of the

final folder
c) The pressure switch hose nipple.

(located at the back of the frame)
(Cont’d)
130

MM 202-214(5) 9510 TBA/3 600V
Central lubrication
(Cont’d)
d) The distribution block for the left jaw volume

cam section (1)
e) The distribution block for the right jaw volume

cam section (2)
f) The distribution block for the left printed design

correction device (3)
g) The distribution block for the right printed

design correction device (4)
131

TBA/3 600V 9510 MM 202-615(5)
Central Lubrication Diagram
GBAAOA69
a
f
b
RH
h
g
e
m
i
l
j
i
k
e
h
LH
b
f
RH
LH
n
133

TBA/3 600V 9510 MM 203-11 1(3)
LH = left hand
RH = right hand
Pos Function Pos Function

1 Ball bearing, folding flap cam 42 Pressure device guide, lower rear
2 Ball bearing, eccentric axle 43 Pressure device guide, in front
3 Volume cam curve section 44 Cam roller, pressure device
4 Catch, pressure 45 Pressure device guide, upper rear
5 Bearing housing, pressure jaw 46 Pressure device guide, upper front
6 Bearing housing, pressure jaw 47 Arm, pressure device
7 link, folding flap mechanism 48 Chain tensioner, left
8 Bracket, folding flap mechanism 49 Front shaft
9 Cam roller, folding flap mechanism 50 Guide, lower station chain
10 Carrier, cutting jaw 51 Cam roller, drive delivery unit
11 Cam roller, folding flap mechanism 52 Toothed rock delivery unit
12 Holding catch, pressure 53 Guide cam roller delivery unit
13 Link, pressure 54 Guide steering delivery unit
14 Guide bearing, lower 55 Chain tensioner, right
15 Guide bearing, upper yoke 56 Package damper
16 Mounting, yoke 57 Drive shaft
17 Yoke link, follower arm 58 Pressure device guide, upper front
18 Ball bearing arm with axle pressure 59 Pressure device guide, lower front
19 Spring housing 60 Pressure device guide, upper rear
20 Block 61 Pressure device guide, lower rear
21 Ball bearing arm with axle cut 62 Gear drive
22 Toothed segment 63 Gear drive
23 Bearing clamp 64 Carrier, cutting jaw side plate
24 Bushing bracket, front 65 Volume flap axle
25 Bearing bracket, front 66 Oil brush, barrier right
26 Bushing joint 67 Oil brush, front right
27 Bushing bracket, rear 68 Axle, link outer right
28 Bushing arm 69 Axle, guide plate upper right
29 Bushing link, pressure, upper 70 Axle, link inner right
30 Axle pin 71 Axle, link inner left
31 Bushing link, pressure, lower 72 Axle, guide plate upper left
32 Bearing, follower arm 73 Axle, link outer left
33 Link 74 Oil brush, front left
34 Cam roller
35 Ball bearing bracket
36 Cam roller arm
37 link bearing
38 Cylinder damper
39 Retriever
40 package damper
41 Guide group
134

MM 203-11 2(3) 9510 TBA/3 600V
LH = left hand
RH = right hand
Pos Function Pos Function

a Register retention AK Banjo connection
b Volume cam curve section AL Oil brush
d Pressure jaw housing
e Pressure arm with axle
f Cutting arm with axle
g Yoke
h Link system
i Follower arm
j Pressure arm
k Oil connection
l Tank
m Oil pump
n Final folder
A Distribution block 3-Ways

B Distribution block 4-Ways
C Distribution block 6-Ways
D Dosing block 3-Ways
E Dosing block 4-Ways
F Dosing block 6-Ways
H Metering valve 10mm3
I Metering valve 30mm3
J Metering valve 50mm3
K Pipe 3/32”
L Hose Ø6/3
M Hose Ø4/2
N Pressure guard
O Pump
P Tank
Q Oil filter
R Connection
S Suction pipe Ø6x1
AA Banjo connection
AB Pressure guard
AC Tube Ø2.5/1.5
AD Tube Ø6/4
AE Hose Ø6/4
AF Hose Ø4/2.5
AH Hose Ø2.5/1.6§
135

TBA/3 600V 9510 MM 203-11 3(3)
Air Filter
Cleaning
Unscrew the tank (15). The float (10) is loose
inside it and will drop out if the tank is turned.
By unscrewing the nut (16) the automatic drain
mechanism (11) can be removed.
Unscrew the divider screen (9) and remove the
filter insert (6) with the filter cover (8) and seal-
rings (5) and (7). Discard the filter insert.
Unscrew the filter guide (4) and remove the
turbine disc (3).
Clean the parts with soap and water.
CAUTION!
Solvent must not be used.
Grease the seal-rings and O-rings with silicon

grease.
Reassemble the filter unit with a new filter insert,
TP No 90277-0314. Take care to put the seal-rings
in place.
Replacement
Removal
Turn off the compressed air. Undo the nut (17) and
pull down the unit from the bracket.
Fitting
The arrows on the bracket (18) and those on the
unit (19) are to point the same way. Put the two O-
rings (1) in place and push up the unit. Tighten the
nut (17).
1 O-ring 17 Nut
3 Turbine disc 18 Arrow
4 Filter guide 19 Arrow
6 Filter insert
9 Divider screen
10 Float
15 Transparent tank
16 Nut
137

TBA/3 600V 9508 MM 211-32 1(1)
Cooling water system
Cooling Water Diagram
1-580
Note Function Note Function

A Cold water in J Sprinkler final folder
B Cold water out K Shower device
C Cold water in (RCW in) L Cooling water folding bar F.F
D Blank (RCW out) M1 Sealing Inductor left
M2 Sealing Inductor right
E Air in
N Cooling water peroxide bath
F Air out
O Spare
G Spray nozzle upper/lower sprinkler
H Compressor water
I Sterile air, cooling water
139

TBA/3 600V 9510 MM 215-12 1(2)
Cooling water system
Checking
Cooling water temperature
The temperature of the incoming cooling water is
to be below 20o C
Water flow
Check the water flow, as per the table.
In case of fault, blow the piping clear.
minimum flow
Unit l/min
IH Inductor 0.4
Sterile air cooler 4
Tube flushing 2
Final folding unit 1.3
Pressure Guard
Check that the pressure guard M.B3 cuts out if the
incoming water pressure drops below
200kPa (2 kp/cm2).
140

MM 215-12 2(2) 9510 TBA/3 600V
Water Filter
Cleaning
a) Close the water valve (arrow)
b) Remove the plug (1) and the seal-ring (2).
Remove the filter insert (3).
c) Replace or clean the filter insert
TP No 90415-0314.
d) Check if the seal-ring is damaged.
e) Refit the insert.
f) Open the water valve and check that there is no
leakage.
1 Plug
2 Seal-ring
3 Filter insert
141

TBA/3 600V 9510 MM 216-33 1(1)
Water filter for deliming
Cleaning
a) Close the water valve (arrow)
b) Remove the plug (1) and the seal-ring (2).
Remove the filter insert (3).
c) Clean the filter insert.
d) Check if the seal-ring is damaged.
e) Refit the insert.
f) Open the water valve and check that there is no
leakage.
1 Plug
2 Seal-ring
3 Filter insert
143

TBA/3 600V 9510 MM 217-32 1(1)
Paper supply monitor
Photocell adjustment
Adjust the photocell (2) position up or down.
Photocell
a) Unscrew the screw (3) and remove the cover.
b) Set the switch (4) in position PNP and the
switch (5) in position D-ON.
c) Turn the potentiometer (6) to mid - position (the
LEDs (7) and (8) lights up). 2
d) Put in a packaging material reel and make sure 1
that the LED (8) go out. The LED (7) should
remain lit up.
e) Fit back the cover and tighten the screw (3).
1 Screw
2 Photocell
3 Screw
4 Switch NPN/PNP
7 5 Switch L-ON/D-ON
10 6 Potentiometer
7 LED (green)
11 8LED (red)
8
9
GBAACA55
.
145

TBA/3 600V 9803 MM 219-32 1(1)
Cassette
Checking / Installation
Check that all screw unions in the cassette are
tightened.
Check that no oil leaks into the cassette.
Check measurement A:
A min
10 mm
1 Screw 90287-0083
2 Copper washer 90005-0052
3 Drip tray
4 Machine frame
5 Cassette top
6 Paper reel holder bearing bracket
147

TBA/3 600V 9508 MM 222-11 1(2)
Cassette
Setting
a) Put a round steel bar (1) in place of the reel
holder.
b) Check that the distance A is the same on both
sides. Adjust by shifting the brackets (2).
c) Shim under the brackets (2) so that the roller (3)
is horizontal.
d) Check by means of a spirit level that the bar (1)
has the same inclination as the roller (3). Adjust
by means of shims (4) under the bearing blocks.
e) Check that distance B is the same on both sides.
Adjust by means of shims (5) behind the
bearing blocks.
f) Position the reel holder in the trolley. Push the
trolley towards the cassette and check that the
shaft ends of the reel holder are located 3 mm
above the lugs (6). If required, adjust the
positions of the trolley brackets.
148

MM 222-52 2(2) 9508 TBA/3 600V
Paper Reel Holder
Checking
Check that the paper reel holder locks the paper
reel and that the thread does not bind.
Check that the paper reel holder shaft is straight,
and that those parts that rotate in the bearings, are
intact.
Measurements A is to be as follows:
Volume ml Measurement A mm
1000, 500 0 (edge to edge)
250, 200 52
149

TBA/3 600V 9508 MM 225-11 1(1)
Splicing device
Check/Setting
Replace the teflon cloth (4) if it has charred
deposits or has broken
Set the knife (1) so that the edge is level with the
underside of the sealing arm.
Check by means of a pyrometer that the
temperature of the outer section of the sealing arm
is appr. 200oC. The temperature can be checked on
the side surface (2) of the heating element as close
to the clamp bar as possible. If the temperature is
incorrect, remove the cover and adjust by means of
the screw (3). The on and off of the thermostat can
be checked by means of a voltmeter.
1 Knife
2 Side surface of heating element
3 Setting screw
4 Teflon cloth.
151

TBA/3 600V 9508 MM 230-11 1(1)
Breaking Device
Checking
Check that the rollers and shafts rotate freely.
Clean. Replace worn or damaged bearings. Check
that the brake roller is intact.
Set the 5 mm gap between the bending roller (1)
and the support (2).
153

TBA/3 600V 9508 MM 231-12 1(1)
Rotation Monitor
Checking
Start the machine. Unscrew the screws (2) and pull
the proximity transmitter (1) away from the
magnets (4). The machine should now stop.
If not, check the following:
a) whether the contacts of the rotation monitor are
fouled.
b) PLC input I57 timer R680, R664
Check that the gap between the sensor (3) and the
magnets (4) is 1±0,5 mm. Adjust by shimming
with washer (5) between the transmitter and its
holder.
1 Proximity transmitter
2 Screw
3 Sensor
4 Magnet
5 Washer
155

TBA/3 600V 9909 MM 234-12 1(1)
157
TBA/3
TBA/3 600V
500
205 501 502 503 210
Doc No MM-80249-0104
102
104 105 106
U1:3 U1:1 U1:2 U31 101 103
T1:3 T1:1 T1:2 T31
Issue
9510
T3
D
U3
U2
T2
T40
U40
A2
206
203 402 401 208 202 209 404 403
207
GBAACA42
Pneumatic Connection Diagram
MM 261-15 1(2)
Pneumatic Connection Diagram
TBA/3
1-580896 No Function
No Function
100 SUPERSTRUCTURE 900 VALVE PANEL
101 Steam barrier
102 Product valve A Shut off valve
103 Sterile air C Cylinder
104 Separator, heat exchanger D Pressure guard M.B2
105 Jet diverter valve Y Cylinder
106 LS/SA hot air element U Gauge
movement
T Pressure regulator
200 MACHINE BODY

202 Drop chute
203 Paper brake
204 Air jet
205 Air jet pistol
206 Air blowing drop chute
207 Air blowing photocell
208 Air injection in cooling water
209 Central lubrication
210 Photocell design correction
400 JAW SYSTEM

401 Cut, left
402 Cut, right
403 Design correction, left
404 Design correction, right
500 FINAL FOLDER

501 Flap sealing element, top flap
502 Flap sealing element, bottom
flap
503 Flap sealing element, top flap
158

MM 261-15 1(2) 9510 TBA/3 600V
Dating Unit
Checking
Check
– the O-rings of the printing wheel (4) and – the lock stud (2).
transfer roller (11).
– that the hose (6) does not kink when the
– that the ink roller (10), transfer roller, crease bottle is raised or lowered.
wheel (19, printing wheel, and carrier shaft
– that the cannular tube (5) is intact.
(13) rotate easily.
– that the bottle holder (3) stays in position
– the chain tensioner and chain (14).
when raised.
– the carrier stud (12).
– that there is no ink in the spillage bottle (8);
– the gasket of ink unit cover (9). ink in the spillage bottle indicates that the
– the locking springs (7) holding the ink unit system is not tight.
cover.
1 Crease wheel
2 Lock stud
3 Bottle holder
4 Printing wheel
5 Cannular tube
6 Hose
7 Locking spring
8 Spillage bottle
9 ink unit cover
10 Ink roller
11 Transfer roller
12 Carrier stud
13 Carrier shaft
14 Chain
159

TBA/3 600V 9508 MM 272-13 1(2)
Dating Unit
Setting
Distance H on machines without
crease wheel
a) Check that the distance between the lower edge
of the platform and the top edge of the dating
unit is H mm.
b) The bottom crease (2) is to be at the volume
flap.
c) Check that shift register in block 11 and PLC
timer in block 5 are correctly set. acc to Volume
Adaption doc 47921-90:XX
H
Narrow Bath o
Z 2
Volume H Z°
ml mm
1000 565 98
500 98
250 440 85
200 85
GBAABA76
2 Bottom crease
Wide Bath
Volume H Z°
ml mm
1000 461 102
500 407 102
250 410 85
200 354 85
160

MM 272-53 2(2) 9609 TBA/3 600V
Printing Wheel Shaft
Setting
a) The printing wheel shaft (1) is to be in line with
the carrier shaft (2). Check with the aid of
template 533460. If not, first make sure that the
ring nuts (5) and (6) are tightened so that there
is no shaft play. Thereafter, adjust by means of
the limit screws (3) and (4).
b) Check that measurement F is at least 6 mm,
clearance H at least 0.6 mm, and clearance G at
least 5 mm. If not, adjust or replace parts as
required.
c) There must be packaging material inserted. The
gap between the printing wheel shaft (both shaft
ends) and the packaging material is to be
checked and set by means of gauge 434841 (7).
Adjust by means of the ring nuts (5) and (6). To
turn the ring nuts, use tool 458492. 1 Printing wheel shaft
2 Carrier shaft
3 Stop screw
4 Stop screw
5 Ring nut
6 Ring nut
7 Gauge 434841
8 Eccentric shaft
161

TBA/3 600V 9508 MM 273-51 1(1)
Transfer Roller/Inking Roller
Setting
Transfer roller (sideways, setting 1)
The transfer roller (1) is to be set sideways to
obtain the 72.5 mm distance, as illustrated. Adjust
by means of shimming washers (3) according to
the table below.
Inking roller (sideways)

The sideways setting of the inking roller (2) must
not deviate from that of the transfer roller by more
than 0.3 mm. If required, adjust by means of
shimming washers (3) according to the table
below.
Thickness TP part No
2.0 293669-1
2.3 293669-2
1.7 293669-3
2.6 293669-4
1 Transfer roller
2 Inking roller
3 Shimming washer
163

TBA/3 600V 9508 MM 274-51 1(3)
Setting
Transfer roller (vertical)
Check and set the gap between the printing wheel
shaft (2) and the transfer roller (4) by means of
gauge 434841 (3). Set the gap with the screws (7)
and (5).
Transfer roller (sideways, setting 2)

The O-rings (8) of the printing wheel are to be
positioned symmetrically on either side of the O-
ring (9) of the transfer roller. (This setting can also
be made by means of template 466397; there must
be no gap at points F and G, shown in the picture.)
If required, adjust by putting shims 466500
underneath the bracket (6) of the ink unit and
shims 466499 under the block (1) of the revolver
device.
Note!
When this setting has been completed, the ink unit
has been given a standard setting and becomes
interchangeable in the dating unit with other
exchange ink units according to the established unit
rotation system.
1 Revolver device block
2 Printing wheel shaft
3 Gauge 434841
4 Transfer roller
5 Screw
6 Ink unit bracket
7 Screw
8 O-ring
9 O-ring
10 Gauge 466397
164

MM 274-51 2(3) 9508 TBA/3 600V
Setting
Inking roller (vertically)
The inking and transfer rollers are to be set so
close to each other that no gap between them is
visible. To adjust, loosen the nut (2) and turn the
eccentric shaft (5) by means of tool 434448 (4).
Close up the rollers by turning in the direction of
arrow in fig 2 or 3.
Checking during production:

If the rollers are correctly set against each other,
the surface of the transfer roller (3) is to have a
dull-looking coating of ink. If required, readjust
the rollers.
Fig 1
Ink trough
Check the vertical difference between the inking
roller (1) and the connection (7) by means of
gauge 440094 (6).
1 Ink roller 5 Eccentric shaft

2 Nut 6 Gauge 440094 Fig 2. Ink unit located on the LS strip side. Close
3 Transfer roller 7 Connection up by turning in the direction of the arrow.
4 Tool 434448
Fig 3. Ink unit located on the side opposite to the

LS strip side. Close up by turning in the direction
of the arrow.
165

TBA/3 600V 9508 MM 274-51 3(3)
Checking
Check the vertical position of the printing insert
holder by means of template 293692 (3) and a Ø
15 mm rod (4). Alternatively, key 434448 may be
used instead of the rod.
The gaps are to be as follows:
A = 0.6 mm
B = 0.95 mm
C = 0.35 mm
Width D of the tracks in the insert holder is to be
1.6+ 0.6-0.1 mm, gauge 522023.
the insert holders may be fitted in different ways as
illustrated in fig 3 and 4.
1 O-ring
2 Contact surface of the insert holder
3 Gauge 293692
4 Rod or key 434448
Normal position Normal position

stamping on LS stamping on
strip side non-strip side
167

TBA/3 600V 9508 MM 275-13 1(3)
Setting
Insert gauge 434841 (3) into the setting hole (4).
Loosen the screw (6). Turn the crease wheel (1) in
its direction of rotation to angle A as illustrated
and according to the table below. Lock the screw
Note!
Incorrect stamping position on every other package
may be due to the fact that the printing wheel shaft
is out of alignment with the carrier shaft. Setting,
see page 273-51 1(1)
Volume Angle A
1000 40o
1000HiFin
500 130o
250 144o
200 115o
1 Crease wheel
2 Horizontal plane
3 Gauge 434841
4 setting hole
5 Carrier
6 Screw
168

MM 275-53 2(3) 9508 TBA/3 600V
Setting
put in printing insert for one of the areas marked
(1) or (2), so that stamping is done within the
whole of the stamping area. Check that the stamp
is clear within this area.
Volume Dimensions in mm
ml A B C D E F G H
1000, 500 9 30 13 26
250a 4 30 11.5 16.5
a. With opening arrangement
Package seen from above
1 Pull tab side

2 LS strip side
169

TBA/3 600V 9508 MM 275-53 3(3)
Crease Wheel
Basic Setting
First Check that the rulers are straight, parallel,
and intact.
Shimming washers (1)
Distances A and B are to be according to the table
overleaf. If not, adjust by adding or removing Volume ml Thickness
shimming washers (1) according to the table to the 0.2 mm 0.3 mm 0.4 mm
right and fig 1 or fig 2.
1000, 500 458193-1 458193-3 458193-2
1 Shimming washer
250, 200 458194-1 458194-3 458194-2
171

TBA/3 600V 9508 MM 276-51 1(4)
Crease Wheel
Basic Setting
Distance at different location and type of crease wheel edge
T = Crease wheel for printed design correction
U = Crease wheel in dating unit
Volume Crease wheel Sharp edge mm Round edge mm

position A B A B
1000 T 79 165.6 78.5 166.6
U 78 165 78.5 164
500 T 79 87.6 78.5 88.3
U 78 87 78.5 85.2
250 T 57.6 105.4 57.3 106.2
U 57 104.8 57.3 104.2
200 T 57.6 82.1 57.3 82.9
U 57 82.1 57.3 80.7
172

MM 276-51 2(4) 9508 TBA/3 600V
Crease Wheel
Basic Setting
First Check that the rulers are straight, parallel,
and intact.
Distances A and B are to be according to the table
overleaf. If not, adjust by adding or removing
shimming washers (1) see below.
Volume Thickness
ml
0.2 mm 0.3 mm 0.4 mm
1000, 500 458193-1 458193-3 458193-2
250, 200 458194-1 458194-3 458194-2
1 Shimming washer
Fig.1 Crease wheel, type D, with sharp edge. Fig. 2Crease wheel, type E, with rounded edge.
173

TBA/3 600V 9508 MM 276-52 3(4)
Crease Wheel
Basic Setting
Distance at different locations and type of crease wheel.
F = Dating unit
G = Design correction
Volume F Crease wheel with sharp edge, type D Crease wheel with rounded edge, type
/ E
G
A mm B mm Template No A mm B mm Template No
1000 F 78 165 279886-2 78.5 164 527862-3
G 79 165.6 279886-1 78.5 166 527863-3
500 F 78 87 279886-6 78.5 85.7 527862-7
G 79 87.6 279886-5 78.5 88.1 527863-7
250 F 57 104.8 279886-12 57.3 104.2 527862-13
G 57.6 105.4 279886-11 57.3 105.9 527863-13
200 F 57 81.5 279886-16 57.3 80.7 527862-15
G 57.6 82.1 279886-15 57.3 82.6 527863-15
174

MM 276-52 4(4) 9508 TBA/3 600V
Jumbo Reel Holder
Jumbo reel frame
Check
• Check the wear plates (1) and the nylon block
(2) for excessive wear. If necessary, replace
them.
• When the jumbo reel frame is in the closed
position, the wear plates must align with the (2)
nylon block both vertically and horizontally.
• If necessary, loosen the bolts holding the hinge
bracket (3) and adjust as required.
• Examine the springs in the detent pin assembly
(4) for any damage. If necessary, replace the
springs.
1 Wear plates
2 Nylon block
3 Hinge bracket
4 Detent pin
175

TBA/3 600V 9906 MM 277-51 1(9)
Jumbo Reel Holder
PACKAGING MATERIAL REEL HOLDER
Packaging material reel holder

Check
• Examine the movement of the lift cylinder (1).
If necessary, adjust the flow control valves on
the cylinder to achieve a slow and smooth
motion.
• Examine the rollers (2) on the bottom plate for
wear. If necessary, replace the rollers.
1 Lift cylinder
2 Roller
176

MM 277-51 2(9) 9906 TBA/3 600V
Jumbo Reel Holder
PACKAGING-MATERIAL GUARD
Check
• Examine the packaging material guard (1) for
any damage. Check that the packaging material
cage (2) slides in and out unobstructed. If
necessary, replace the packaging material
guard.
• Examine the wear strips (3) on the inner bottom
surface of the packaging material guard for any
wear. If necessary, replace the wear strips.
1 Guard
2 Cage
3 Wear strip
177

TBA/3 600V 9906 MM 277-51 3(9)
Jumbo Reel Holder
HINGE ASSEMBLY
Check / Lubrication
• Examine the lower bearing (1) for excessive
wear. If necessary, replace the bearing.
See lubrication specifications. ‘
1 Lower bearing
178

MM 277-52 4(9) 9906 TBA/3 600V
Jumbo Reel Holder
Drive Brake
The function of the Drive brake is to reduce the High Speed setting:
paper speed. This is obtained by using 2 different
The High speed shall be set to 52 rpm for 1000 ml
speed settings of the Drum motor compared by the
and 38 for 250 ml and 33 for 200 ml.(See D) If the
nominal speed of the paper.
speed is checked by tachometer 90243-105,
equipped with standard wheel the tachometer will
Basic Setting show High speed 190 for 1000 ml, and 140 for
1) Set the gap between the switch (7)and the 250ml and 120 for 200 ml. (See B) The wheel
pendulum arm (4) is less than1 mm. should be pressed against the Rubber mantle on
the Motor when this reading is done.
2) The screws (3) and (5)should be adjusted so
that the pendulum arm (4) moves within the
stroke of the cylinder (2)
Low Speed setting:

The low speed shall be set to 33 rpm for 1000 ml
1 2
and 30 for 250 ml and 25 for 200 ml.(See C). If the
speed is checked by tachometer 90243-105,
equipped with standard wheel the tachometer will 3
show low speed 120 for 1000 ml, and 110 for
250ml and 90 for 200 ml.(See A) The wheel
should be pressed against the Rubber mantle on 4
the Motor when this reading is done.
< 1 mm
5
6
1 Joki roller 5 Screw
2 Cylinder 6 Paper web
7 3 Screw 7 Switch
4 4 Pendulum arm
Machine A B C (rpm), D (rpm),
TBA/3- 1000ml 120 190 33 52
TBA/3-500ml Not yet Evaluated
TBA/3- 250ml 110 140 30 38
TBA/3- 200ml 90 120 25 33
179

TBA/3 600V 9906 MM 277-53 5(9)
Jumbo Reel Holder
Frequency control
Frequency control - basic setting
SPC reference 90430-50
WARNING!
There is high voltage in the electrical cabinet.
Follow the Safety precautions.
CONFIGURATION/SETTING OF
FREQUENCY INVERTER: e) Press the increase value button (1) or the
a) Switch On Power. decrease value button (2) to change the value of
the parameter.
b) Press the parameter button (3). The display (6)
shows P000. f) Set the inverter values for all the parameters,
see the table below.
c) Select the parameter to set (see table below f)
by means of the increase value button (1) and g) When the setting is finished, go to P000
the decrease value button (2). position and then press the parameter button
(3). once more
d) Press the parameter button (3) to view the value
of the parameter currently selected. h) The display will now show present frequency
Note!
The selector switch inside the inverter may be in
any position
1
6 Jog
P 2
5
3
4
1 Up button
SW1
2 Down button
3 Parameter button
4 Screw I V
5 Switch SW1
6 Display
(Cont’d)
180

MM 277-54 6(9) 9906 TBA/3 600V
Jumbo Reel Holder
(Cont’d)
Note!
To increase the resolution to 0.01, keep the parameter button (3) pressed until the display changes to “--
.n0” (n = the current tenths value, for example if the parameter value = 055.8 then n=8). Press the buttons
(1) or (2) to change the value and then press (3) twice to return to the parameter display.
Note!
Relay K003 (PLC Output Q16) must be energised. K003 is energised in all Steps, except Step "0".
For parameters not included in the table, choose the default value. See chapter 6 of the enclosed “Siemens”
manual for details
Parameter Value Default Function

P002 1 10 Ramp up time in seconds
P003 1 10 Ramp down time in seconds
P006 2 0 Fixed frequency
P007 0 1 Front panel buttons disabled. Control is via digital
inputs
P009 1 0 Parameter protection setting. 1= Parameters from
P001 to P009 can be set, and
all other parameters can only be read. During first
setting at TP change to 2= All parameters can
be set, butP009 resets to 0 the next time power
is removed from the inverter and only parame-
ters P001 - P009 can be set and read. At del.
change back to 0.
P013 52.00 50.00 Maximum motor frequency in Hz
P015 1 0 Automatic restart after a mains break. 1 = Enabled,
0 = Disabled
P041 30 5.00 1st fixed frequency. (Low Speed) Valid if P055 = 6
(Terminal 12)
P042 38 10 2nd fixed frequency. (High Speed) Valid if P056 = 6
(Terminal 11)
P082 1400 (***) Nominal speed in r.p.m for the motor
See rating plate on the Joki-motor Pos. M. M500
P083 0.4 (***) Nominal current in Amp.for motor at 230V
P084 230 (***) Nominal Voltage, V for the motor
P085 0.11 (***) Nominal power in kW for the motor
P089 7.0 (***) Stator resistance in Ω
Note!
The motor shall after setting run clockwise (Direction of the motor when looking from the cable end) with
2 different speeds.
Note!
The setting of these 2 parameters depends on the volume, see table page 277-53 5(9)
181

TBA/3 600V 9906 MM 277-54 7(9)
Jumbo Reel Holder
Frequency control - basic setting

SPC reference 90430-70
WARNING!
There is high voltage in the electrical cabinet.
Follow the Safety precautions.
CONFIGURATION/SETTING OF
FREQUENCY INVERTER:
a) Press the parameter button (3). The display (5) d) Press the increase value button (1) or the
shows P000. decrease value button (2) to change the value of
b) Select the parameter to set (see table below f) the parameter.
by means of the increase value button (1) and e) Set the inverter values for all the parameters,
the decrease value button (2). see the table below.
c) Press the parameter button (3) to view the value f) When the setting is finished, go to P000
of the parameter currently selected. position and then press the parameter button
(3), once more.
g) The display will now show present frequency
Note!
The selector dip-switch may be in any position
1
5 Jog
P 2
3
4
1 Up button
2 Down button On
3 Parameter button
4 Switch Dip
5 Display 12 3
Off
(Cont’d)
182

MM 277-55 8(9) 9906 TBA/3 600V
Jumbo Reel Holder
(Cont’d)
Note!
Relay K003 (PLC Output Q16) must be energised. K003 is energised in all Steps, except Step "0".
For parameters not included in the table, choose the default value.
See chapter 6 of the enclosed “Siemens” manual for details.
Parameter Value Default Function

P002 1,0 10.0 Ramp up time in seconds
P003 1,0 10-0 Ramp down time in seconds
P006 2 0 Fixed frequency
P007 0 1 Front panel buttons disabled. Control is via dig-
ital inputs
P009 1 0 Parameter protection setting. 1= Parameters
from P001 to P009 can be set, and
all other parameters can only be read. During
first setting at TP change to 2= All parame-
ters can be set, butP009 resets to 0 the next
time power is removed from the inverter and
only parameters P001 - P009 can be set and
read. At del. change back to 0.
P013 52.00 50.00 Maximum motor frequency in Hz
P041 30 5.00 1st fixed frequency. (Low Speed)
P042 38 10 2nd fixed frequency. (High Speed)
P074 0 1 I2 t motor derating (0 = no derating)
P080 (0,72) (***) Factor cos
P082 1400 (***) Nominal speed in r.p.m for the motor
P083 0.4 (***) Nominal current in Amp.for motor at 230V
P084 230 (***) Nominal Voltage, V for the motor
P085 0.11 (***) Nominal power in kW for the motor
P089 7.0 (***) Stator resistance in Ω
Note!
The motor shall after setting run clockwise (Direction of the motor when looking from the Cable end) with
2 different speeds.
183

TBA/3 600V 9906 MM 277-55 9(9)
Drive Unit
Name Issue Page
Follower Arm Return segment Roller 9508
Removal/Replacement 9508 301-21
Fitting 9508 301-41
Follower Arm Return segment Roller 9508


Follower Arm 9508
Pressure Arm Mounting 9508

Follower Arm 9508

Jaw Pressure, Damper Unit 9510

Machine without holes for checking 9510 313-12
Link System 9508

Wear Checking 9508 320-11
Link Rod Measurements 219

Setting adjustable rear rod 9510 321-53
Link Arm 9508

Main Shaft/Intermediary Shaft 9508

Lubrication 9508 330-11
Gear Play Adjustment 9508 330-51
185

TBA/3 600V 9906 MM 300 1(2)
Drive Unit
Name Issue Page
Main Cam 9510
Replacing Cam 9510 331-23
Cam position 9510 331-23
Timing Belt 9508

Motor Brake 9508

Checking (with disc brake) 9508 340-12
Replacing the brake disc. 9508 340-12
Worm Gear 9508

Oil Change 9508 345-11
186

MM 300 2(2) 9906 TBA/3 600V
Follower Arm Return segment Roller
Checking
Unscrew the nut (1) so far that the return segment
roller (2) lifts off the cam. Check that the roller
rotates freely and that there is no play. Replace the
roller if worn acc. to page 301-21 2(3). Tighten the
nut, and make sure the spring guides function
correctly.
1 Nut
2 Return segment roller
187

TBA/3 600V 9508 MM 301-11 1(3)
Removal/Replacement
Remove the rear cover above the cassette. Crank
the machine to appr. 315°, RH side, appr. 135°, LH
side. Loosen the lubrication pipe (1).
Remove the circlip and axle pin (3).Loosen the nut
and undo the screw (4)
Remove the yoke (5) with the two springs.
Remove the gate piece (6) from the cam (10). Now
the arm (7) can be removed.
Replace the roller (8).
Check the bushings.
Check that the rod (11) is straight and does not
bind.
Replace defective parts.
Check that oil is supplied acc. to page 301-11 1(3).
Fit acc. to page 301-41 3(3)
1 Lubrication pipe
3 Axle pin
4 Screw
5 Yoke with springs
6 Gate piece
7 Arm
8 Roller
9 Spacer ring
10 Cam
11 Rod
12 Washer
188

MM 301-21 2(3) 9508 TBA/3 600V
Fitting
Set the machine at appr. 315°, RH side, appr. 135°,
LH side.
Put the yoke (1) with its spring guide rods, spacers
and springs in place.
Push up the axle rod (4) and tighten the Allen
screw (2) and the nut (3).
Check that the spring guide rods enter their holes
(distance between the axle stud/holder and the
yoke 92 - 93 mm after assembly).
Insert the axle pin (5) and fit the circlip.
Check that there is a clearance of appr. 0.5 mm
between the return segment roller and the cam
side.
Connect the lubrication pipe (6) and fit the gate
piece (8).
1 Yoke
2 Screw
3 Nut
4 Axle rod
5 Axle pin with circlip
6 Lubrication pipe
7 Roller
8 Gate piece
189

TBA/3 600V 9508 MM 301-41 3(3)
Checking
Place a block of wood (7) under the yoke (RH side
appr 315°, LH side appr 135°) and crank until the
cam roller lifts 1-2 mm off the main cam.Make
sure there are no depressions caused by the needle
rollers of the needle bearing, by turning the roller
while at the same time pushing it axially. If worn,
replace the roller.
Note!
Remove the block of wood.
Disconnect the oil pipes (6) at the roller end. Push

LUBRICATION ON, and check that oil is
delivered. Reconnect the oil pipes.
1 Screw
2 Lock plate, disposable, 90062-0016
3 Circlip
4 Cam roller
5 Bracket
6 Oil pipe
7 Block of wood
191

TBA/3 600V 9508 MM 302-11 1(2)
Replacement
The circlip (3) of the axle pin on the RH side must If the screws have worked loose, a new
be removed at appr. 160°. At the same time remove (disposable) lock plate 90062-0016 is to be fitted.
the circlip on the LH side.
Put a block of wood (7) under the yoke (RH side
appr 315°, LH side appr 135°) and crank the By shining a torch from behind the roller, you can
machine until the cam roller (4) lifts 1-2 mm off check that the roller engages the cam correctly.
the main cam. Note!
Engage the brake. Remove the block of wood.
Replace the roller and, if required, the axle pin and

the bracket (5). make sure the screws (1) are
tightened.
1 Screw
2 Lock plate, disposable, 90062-0016
3 Circlip
4 Cam roller
5 Bracket
6 Oil pipe
7 Block of wood
192

MM 302-21 2(2) 9508 TBA/3 600V
Follower Arm
Removal/Replacement
First remove the link arm acc. to page 322-31 1(1) Undo the five screws in the bracket (5).
and return segment roller acc to page 301-21 2(3).
Lift out the big follower arm.
Disconnect the lubrication connections (1).
Undo the screws (2) of the clamp union.
Remove the lubrication connections and the upper
and lower axle pins of the link (3). 1 Lubrication connections
Disconnect the lubrication connections. 2 Screws
3 Link
4 Lubrication connections
5 Bracket
193

TBA/3 600V 9508 MM 303-31 1(1)
Pressure Arm Mounting
Checking
Put the jaws in open position.
Remove the axle pin (2).
Play at the pivot point (4) is measured by moving
the pressure arm sideways - the movement must
not exceed 3 mm at the arrow.
If the play is greater, remove the bracket (6) from
the machine body (5) and slide the pressure arm
(3) forward far enough for the bracket and axle pin
to be replaced.

Make sure the roller runs along the centre line of
the cam, and that the arm does not bear against the
cam.
Check lubrication (7).
1 Pressure cam
2 Axle pin
3 Pressure arm
4 Pivot point
5 Machine body
6 Bracket
7 Lubrication pipe
195

TBA/3 600V 9508 MM 310-11 1(1)
Follower Arm
Replacement
Crank the machine until the dismantling hole of
the cam opposite the cam roller of the pressure
arm.
Lock the motor brake.
Detach the cam roller (1) from the pressure arm
through the hole in the cam.
1 Cam roller
2 Pressure cam
3 Pressure arm
4 Fork
197

TBA/3 600V 9508 MM 311-31 1(1)
Jaw Pressure, Damper Unit
°
Checking
Machine without holes for checking Machine with holes for checking (3):
Measure distance A (fig 1) with the machine at Make sure there is a clearance of at least 2 mm at
following degree positions: max movement.
155°/335°
CAUTION!
Stop cranking the machine if the upwards
Crank the machine forward another 180° and movement of the sleeve exceeds 35 mm and
measure distance B (fig 2). the difference between reduce distance A by screwing up rod (2).
distance A and B, in other words the vertical
movement upwards of the sleeve (1) should be 34 - After adjustment, crank to make sure the damper
35 mm, and must not exceed 35 mm. unit does not hit any other machine parts.
199

TBA/3 600V 9510 MM 313-12 1(2)
Jaw Pressure, Damper Unit
Basic Setting
When assembling the damper unit the
measurements shown in fig 1 and 2 must be set.
Max vertical movement must be checked to
page 313-12 1(2).
the hole (2) for the oil pipe at the top of the axle is
to be directed towards the centre line of the damper
unit.
The dampening effect can be varied by altering the
spring pressure within the given range
(275±10 mm).
200

MM 313-51 2(2) 9510 TBA/3 600V
Link System
Wear Checking
.The play at the pivot points of the arms (1) and (2) If required replace worn or deformed parts.
and the joints (3) must not exceed 0.3 mm.
a) When checking the rear pivot point (1) of the
follower arm, place a pinch bar between the
bracket (4) and the follower arm (5). Put a strain
on the follower arm in different directions.
b) When checking the front pivot points (2) of the
link arm between the follower arm and the yoke
the pinch bar is to be placed between the yoke 1 Rear pivot of follower arm
and the machine body. Lift the yoke and 2 Pivot points of link arm between
determine the play at the upper and lower pivot follower arm and yoke.
points. 3 Joints
c) Check the pivot points of the joints (3). 4 Bracket
5 Follower arm
d) Remove the link (8) by detaching the pivot
6 Link arm
points (9) and disconnecting the lubrication 7 Cam roller
pipes. Check the cam roller and the cam.
8 Link
9 Pivot points
201

TBA/3 600V 9508 MM 320-11 1(1)
Link Rod Measurements
Setting adjustable rear rod
Front rod 358±1 mm(216±1)
Rear rod
Basic setting B 508±1
Gap 237.5 mm
Set the gap between the pressure (1) and cutting
jaws (2) at 237.5±1 mm, using gauge 74282, at the
following degree positions:
155°/335°
Do the setting by means of the screw (3) and nut

(4).
1 Pressure jaw
2 Cutting jaw
3 Screw
4 Nut
203

TBA/3 600V 9510 MM 321-53 1(2)
Link Rod Measurements
Setting adjustable rear rod
If required, adjust the overtravel to appr. 5 mm by
turning the threaded rear rod and then once more
set the 237.5 gap.
Large overtravel results a clanking sound each
time the jaw pressure is relieved.
Small overtravel causes the jaw to grip the tube
less firmly when shifting from one to the other jaw
pair. And maybe blocked TS-seal.
Too small an overtravel due to machine wear can
be compensated for by shortening the rear rod.
Turning the rod one turn changes the overtravel by
appr. 1 mm after the 237.5 gap has been adjusted.
When rod length b has to be reduced to 498 mm or
less, the jaw system components are too worn and
must be replaced, see page 461-13 1(1)
204

MM 321-53 2(2) 9510 TBA/3 600V
Link Arm
Removal/Replacement
Crank the machine to the lower turning position of
the yoke.
Disconnect the lubrication pipe (1) from the rear
angle arm.
Undo the screw and remove the axle pin (2) in the
rear angle arm.
Remove the splash guard brackets (3).
Lift out the link arm.
1 Lubrication pipe connection

2 Axle pin
3 Splash guard bracket
4 Front joint
5 Link arm
205

TBA/3 600V 9508 MM 322-31 1(1)
Main Shaft/Intermediary Shaft
Lubrication
Set the machine so that both grease nipples on the

main shaft are accessible from the rear of the
machine.
Grease the three grease nipples (3) and (4). Use
lubricant according to code F page 940-2 1(2)
1 Main shaft
2 Intermediary shaft
3 Lubrication point on main shaft
4 Lubrication point on intermediary
shaft
207

TBA/3 600V 9508 MM 330-11 1(2)
Main Shaft/Intermediary Shaft
Gear Play Adjustment
Adjust by loosening four screw (1) and shifting the
eccentric bearing holder around until correct gear
play is obtained.
1 Adjustment screw
208

MM 330-51 2(2) 9508 TBA/3 600V
Main Cam
Replacing Cam
Before commencing work turn off the main
switch, the air and water supplies.
Crank the machine to 0°.
Loosen the screws, slide the emitter aside and
tighten it.
Remove the crease breaking device and the plates.
If the machine is fitted with a dampener unit, this
is now removed.
Remove the return segment rollers, (page 301-21
2(3)).
Remove the pressure arm cam roller and the rod on
the same side, (page311-31 1(1)).
Crank the machine slowly and open the jaws by
hand in order to remove the roller and the rod on
the other side.
Loosen the link arms on both sides and tie them
up, (page 322-31 1(1)).
Lift the yoke until the follower arm cam rollers are
free of the cams and place blocks (3) under the
yokes. Tie the blocks so they will not fall off.
209

TBA/3 600V 9510 MM 331-23 1(4)
Main Cam
Replacing Cam
Tap the axles out from the middle towards the
outside of the machine to remove the follower arm
link (4).
Insert a smaller rod (5) to support the follower arm
in the upper position.
Mount the hoist support and the hoist 74956-0101

(6) and the cradle 74514-0101 (7).
Loosen the bearing housings on both sides.
Using the cradle as a lever, lift the cam pack over
the drive pinion.
Roll out the cam pack to the first set of stops (8).
Secure the nylon slings.
Move the stops to the second position (9).
With the aid of the hoist, lower the cam pack on to
two pallets.
Again using the hoist, turn the cam pack on its
side, drive wheel downwards and with the axle
between the pallets.
Remove the inner screws (10).
210

MM 331-23 2(4) 9510 TBA/3 600V
Main Cam
Replacing Cam
Lift off the upper pair of cams.
Remove the screws (11) and lift off the cam (12).
Remove the screws (13) and lift off the cam (14).
Position the new main cam next to the drive wheel.
The minimum radius on the main cam is to be
positioned at the same side as the flat section of the
drum (1)) (see figure page 331-23 4(4)).
The hole (15) on the cam which does not receive a
bolt shall correspond with the largest hole (16) on
the drive wheel.
Assemble the other cams and use the Alignment rod
27627 (17) to synchronize the cam pack. The cams
are to be off set 180° from one another.
Fit the protractor to the new cam in such way that
0o is towards the side where the gate piece (18) is.
crank the machine to 0°. Set the impulse emitter to
its noted down position and secure it.
When the cams have been changed the following
checks must be carried out:
Stroke length, (page 455-63 1(1))
Jaw-over-jaw, (page 458-11 1(1))
Link rod measurement, (page 321-53 1(2))
Jaw gap, (page 446-12 1(1))
Folding flaps, (page 429-51 1(1))
Synchronize the final folder with the machine,
(page 574-51 1(1))
Set over travel, (page 461-13 1(1))
211

TBA/3 600V 9510 MM 331-23 3(4)
Main Cam
Cam position
15 Hole in the cam which does not receive a bolt.

17 Alignment rod 27627.
19 The main cam is to be positioned with its minimum radius facing the same way as the
flat section of the drum.
212

MM 331-23 4(4) 9510 TBA/3 600V
Timing Belt
Checking
Shine a torch to the right of the cassette to check
the widths and the teeth of the belts look alright.
Check the belt tension acc to the figure. The spring
balance is to be applied at right angles to the belts,
in the middle.
Adjust belt tension by shifting the motor shelf or
by shimming under the motor shelf (old model
machines also by shifting the bearing housing).
make sure the teeth of the belts have not worn
down to expose the card, which means a wear of
appr 2 mm.
Make sure the belts are free from grease and
lubricating oil. If required, clean them.
Check that the edge of the belts have not worn
more than 5 mm. If required, replace them.
Make sure the belts do not foul the guide flanges
(fig 3). Adjust, starting from the intermediate shaft
(1), by shifting/turning the motor shelf and
thereafter the worm gear.
Belt Nominal Minimum

(as per fig) width width
5 38 33
6 19 14
7 19 14
8 38 33
9 19 14
1-3 Belt pulley

4 Crank shaft
5-9 Timing belt
10 Guide flange
11 Timing belt
213

TBA/3 600V 9508 MM 335-11 1(1)
Motor Brake
Checking (with disc brake)
Crank the machine to 40° or 220°. Release the
brake lever so that the brake engages. Apply a
spring balance to crank handle. The spring balance
is to indicate at least 60 N (6 kp) (corresponding to
a torque of 25 Nm (2.5 kpm)). If required adjust or
replace the brake disc.
Adjustment
a) Remove the cover.
b) Pull off the fan impellor (fig 1).
c) Adjust by means of the setting ring (preferably
using the dairy union spanner) (fig 2). Turning
the adjustment ring 1/4 turn alters the torque by
appr. 0.25 kpm.
Replacing the brake disc.

Dismantle according to fig 1-4.
Take care not to damage the electrical cable.
On reassembly make sure the rubber sleeve is
correctly positioned.
After adjustment or replacement of parts, check
the brake torque again.
1 Brake lever
2 Brake disc
3 Setting ring
4 Pressure plate
215

TBA/3 600V 9508 MM 340-12 1(1)
Worm Gear
Oil Change
Change oil in the worm gear, oil E according to
page 940-2 1(2)
Oil volume 2 - 2.5 l.9508
1 Worm gear
2 Oil drain plug
3 Oil level tube
4 Oil filling plug
5 Level plug
217

TBA/3 600V 9508 MM 345-11 1(1)
Jaw System
Name Issue Page
Setting sequence 9510
Cutting Jaw Unit 9510

Removal 9510 402-21
Fitting 9510 402-42
Cutting Jaw 9508

Oil Change 9508 403-11
Cutting Knife IH 9508

Check/Cleaning 9508 404-11
Pressure Jaw Unit 9510

Removal 9510 407-22
Fitting 9510 407-22
Dismantle the pressure jaw unit. 9510 407-31
Assembly 9510 407-31
Inductor 9508
Check/Cleaning 9508 409-11
Yoke 9508
Removal 9508 412-21
Fitting 9508 412-41
Yoke and Arms 9508

Checking version With Sleeve Bearings 9508 413-11
Replacing Bearings 9508 413-11
Checking version
With Conical Roller Bearings 9508 413-12
Replacing Bearings 9508 413-12

219

TBA/3 600V 9906 MM 400 1(4)
Jaw System
Name Issue Page
Yoke Guide 9508
Replace Bushings 9508 414-11
Volume Flaps 9508

Replacing The Volume Flap Bushings 9508 417-11
Checking The Buffer Unit 9508 417-11
Checking the Stop Lug 9508 417-11
Volume Cam Curve section 9510

Volume Cam 9508

Centring 9508 421-51
Package Weight 9508

Setting 9508 422-51
Design Correction Mechanism 9510

Checking of Easy Movement 9510 423-11
Removal 9510 423-21

Fitting 9510 423-21
Setting 9804 423-52
Folding Flaps 9508

Checking Cam and Support Rollers 9508 426-11
Checking the Chain Link 9508 426-11
Folding Flaps Mechanism 9508

Checking Bearing Play 9508 428-11
220

MM 400 2(4) 9906 TBA/3 600V
Jaw System
Name Issue Page
Folding Flap Mechanism 9508
Setting 9508 429-51
Fine Setting 9508 429-51
Pressure Header 9508

Removal 9508 432-22
Fitting 9508 432-22
Pressure Header 9508

Vertical Jaw Position 9508
Volume Flaps 9508

Tube Support Rollers 9508

Setting During Production 9508 443-62
Tube Roller 9508

Jaw Gap 9508
221

TBA/3 600V 9906 MM 400 3(4)
Jaw System
Name Issue Page
Stroke 9508
Final Adjustment 9508 455-53
Stroke 9508 455-53
Clearance T 9508 455-53
Setting During Operation 9508 455-63
During operation 9508 455-63
Jaw-Above-Jaw Height 9508

Setting 9508 458-12
Overtravel 9508
Checking: Adjustable Rear Link Rod 9508 461-13
Jaw Pressure 9508 461-13
Fault-Finding 9508 461-13
Jaw Pressure With Springs 9508

Jaw Pressure Tool 75152-0101 9508 464-11
Lifting Force with Spring Balance 9508 464-11
Catch Position 9508

Catch Position And Booms 9508

Catch Detachable 9510

Replacing 9510 470-11
Catch Guards 9508

222

MM 400 4(4) 9906 TBA/3 600V
Setting sequence
Basic setting
Gap distance (237.5 mm) Gap distance (237.5 mm)

page MM 321-53 1(2) page MM 321-53 1(2)
Volume flaps alignment T-measurment

(pressure jaw) page MM 455-53 1(1)
page MM 442-52 1(1)
Tube support rollers alignment Jaw gap

page MM 443-52 1(2) page MM 446-12 1(1)
Filling tube page Overtravel

MM 136-11 1(1) /443-52 1(2) page MM 461-13 1(1)
Stroke Catch position

page MM 455-53 1(1) page MM 467-11 1(1)
Gap distance (237.5 mm) Catch guards

page MM 321-53 1(2) page MM 472-11 1(1)
Vertical Jaw position Pressure header

page MM 441-11 1(1) (Venting)
page MM 432-22 1(2)
Volume flaps alignment

(cutting jaw) Cutting Jaws
page MM 417-11 1(2)/ 420-12 (Oil fill)
1(1)/ 421-51 1(1)/ 442-52 1(1) page MM 403-11 1(1)
Jaw above Jaw

page MM 458-11 1(1)
223

TBA/3 600V 9510 MM 401-52 1(1)
Cutting Jaw Unit
Removal
Place the jaws in open position.
Undo the clamp union (1) and the connection (2).
Detach the buffer unit (3) from the carrier (4).
Unscrew the screws (5) and (6); now the cutting
jaw unit can be removed.
Loosen the screws (8) and pull out the rod (7).
Check the rod and the O-ring.
Replace the spring at the time of the 3000-3600 H
service.
1 Clamp union
2 Connection
3 Buffer unit
4 Carrier
5 Screw
6 Screw
7 Pull rod
8 Washer
225

TBA/3 600V 9510 MM 402-21 1(3)
Cutting Jaw Unit
Overhaul
Check the volume flaps, see page 417-11 1(2). Grease the knife holder.
Remove the knife (6) and cutting jaw (5). Make sure the folding flap can complete its full
stroke - the screw (9) must not hit the bearing
Detach and inspect the carrier bar (1). Replace it,
housing.
If worn.
Remove the locking screws (9) from the carrier
(8).
Check the bushings, axles and folding flaps. Check 1 Carrier bar
the roller (7) of the carrier. Replace worn parts. 2 Bearing housing
3 Piston
Make sure the knife holder is straight. Straighten it
4 Axle pin
or replace it, if required.
5 Cutting jaw
Check the axle pin (4) of the cutting jaw. Replace 6 Knife
it, If worn. Blow the pistons (3) carefully out of the 7 Roller
bearing housing. 8 Carrier
9 Locking screw
Replace the O-ring (10). 10 O-ring
Re assemble in reverse order.
226

MM 402-32 2(3) 9510 TBA/3 600V
Cutting Jaw Unit
Fitting
Place the carriers in open position. Fit the buffer unit (3).
Fit a new gasket (7) between the bearing housing Fit the connection (5) and the clamp union (8).
and the carrier. Check that the volume flap axle grub screw is
The gap between the carrier bar and the vbearing tightened.
housing should basically be set at distance (A). Fit the pull rod.
Fit the cutting jaw unit with two screws (1) on top Fill up with oil to the level plugs (4); oil code B,
of the carrier and with two screws (2) underneath page 940-2 1(2).
the cutting jaw housing.
Vent the cutting jaw system in accordance with
Make sure that the distance between the spacer page 432-31 2(2)
screw (10) and the bearing housing is distance (B)
when tighteening the screw (1).
1 Screw
2 Screw
3 Buffer unit
4 Level plug
5 Connection
6 Pull rod
7 Gasket
8 Clamp union A = 5 mm
9 Washer B = 0.05mm
10 Screw
227

TBA/3 600V 9510 MM 402-42 3(3)
Cutting Jaw
Oil Change
Drain the oil from the bearing housing (1) by
opening the drain plugs (5) and level plugs (4) and
(6) Then refit the plugs.
Disconnect the oil pipe (3), push LUBRICATION
ON and check that oil is delivered to oil pipe
connection. Reconnect the oil pipe.
Fill with oil up to the plug with an oil can equipped
with 1/8” nipple (7). Oil according to code H page
940-2 1(2). Fill up until oil comes out of the hole
for the plug (6). Refit the plugs.
1 Bearing housing
2 Carrier
4 Level plug
5 Drain plug
6 Drain plug
7 Oil can with 1/8” nipple
229

TBA/3 600V 9508 MM 403-11 1(1)
Cutting Knife IH
Check/Cleaning
Dismantle acc. to fig A, B and C.
Clean the knife and knife holder with a brass wire
brush.
If required replace the knife.
The length of the spring is to be 75 +0.5 -1.0 mm.
231

TBA/3 600V 9508 MM 404-11 1(1)
Pressure Jaw Unit
Removal
Disconnect the flex cable(1) and the three
lubrication pipes.
Undo the screw (6) in the link (3).
Disconnect the lubrication lines (2), (7) and (8).
Unscrew the screws (4) and remove the pressure
unit
Fitting 1 Flex cable

Place the arms in open position.
2 Lubrication pipe
Fit the pressure jaw unit by means of the screws 3 Link
(4). 4 Screw
5 Carrier
Thereafter, connect the three lubrication lines (2) 6 Screw
and the flex cable (1). Fit the link (3). 7 Lubrication line
8 Lubrication line
Note!
that there are two O-rings underneath the carrier. 9 IH-transformer
233

TBA/3 600V 9510 MM 407-22 1(3)
Pressure Jaw Unit
Overhaul
Dismantle the pressure jaw unit.
Remove the carrier (21).
Remove the locking ring (19), the wear ring (8),
and the locking ring (7).
Pull out the eccentric shaft (6) with the fixed catch
(4).
Remove the link (3) by removing the circlip (1)
and washer (2) and pulling off the link by means of
a puller.
Remove the key (11) and the fixed catch (4).
Remove the bearings (9) and (12) from the
catches.
Remove the pressure spring (18) with its spring
guide.
Remove the seal rings (13) and(16).
1 Circlip 9 Bearing 17 Cylindrical pin

2 Washer 10 Adjustable catch 18 Pressure spring with spring
3 Link 11 Key guide
4 Fixed catch 12 Bearing 19 Locking ring
5 ring 13Seal ring 20 Pressure jaw
6 Eccentric shaft 14 Bearing 21 Carrier
7 Locking ring 15 Bearing 22 Cylindrical pin
8 Wear ring 16 Seal ring 23 Bearing
234

MM 407-31 2(3) 9510 TBA/3 600V
Pressure Jaw Unit
Overhaul
Remove the bearings by means of tool
75023-0101
Place the inserts (26) in the bearing housing above
the bushing.
Position the punch (24) and the guide collar (25) in
the bearing housing as illustrated.
Put the bearing housing into the die (27).
Punch out the bearings (14) and (15).
Checking
check that the needle bearings and bearing
surfaces do not show wear or corrosion.
Replace seals and bearings.
Check that the spring and spring guide are not
worn or deformed.
Check that the cylindrical pins (17) and (22) are
not worn or deformed.
Check the bearing (23).
Replace worn or deformed parts as required.
Assembly
Assemble in reverse order.
Make sure that the straight side of the locking ring
(7) is parallel with the lower edge of the bearing
housing, and that the ring (5) is not forgotten when
the eccentric shaft is fitted.
14 Bearing
15 Bearing
24 Punch
25 Guide collar
26 Insert
27 Die
235

TBA/3 600V 9510 MM 407-31 3(3)
Inductor
Check/Cleaning
Check that the knife notch (2) in the inductor (1) is
not clogged and that the edges are not deformed.
Check that the electric conductors (3) are not
oxidized, clean them with a brass wire brush if
needed.
Check that the isolators are not damaged.
after fitting, check that the cutting jaw (4) is
correctly positioned compared to the inductor.
Flush through and check that the cooling water
lines are not clogged (lime deposits).
Check that there is no damage on the inductor
surface.
1 Inductor
2 Knife notch
3 Electric conductor
4 Cutting jaw
237

TBA/3 600V 9508 MM 409-11 1(1)
Yoke
Removal
Remove: Catch guards pipe
Pressure header pipe (12)
Lubrication piping (10)
Electrical cables
Cooling water piping
Flush guard holder
Undo four screws (1) in the square column and
carefully knock out the lower pin (2).
Pull out and turn the column - in doing so catch the
two guide plungers (3) in your hand.
Remove the axle pin (7).
Mark the blocks (11) and remove them by undoing
the screws (4) and knocking out the pins (5).
Remove the guide (6) and the flush guard holder
(9).
Remove the split pin in the axle pin (8)
Ease the yoke and knock out the axle pin. Remove
the yoke.
Guide Pistons, Guide Blocks and

Springs
Check the guide pistons (3) and springs at the yoke
guide bar
The guide blocks (11) must not be worn more than
0.5 mm and the guide pistons not more than 1 mm.
1 Screw
2 Pin
3 Guide plunger
4 Screw
5 Pin
6 Guide
7 Axle pin
8 Axle pin with split pin
9 Flush guard holder
11 Guide block
12 Pressure header pipe
239

TBA/3 600V 9508 MM 412-21 1(2)
Yoke
Fitting
Check that the hole in the fork for the axle pin (8)
is not worn. If it is replace the fork.
Lift up the yoke and insert the axle pin and then
put in a split pin.
Fit the guide.
Fit the marked blocks and pin them.
Fit the guide pistons and grease the spring.
Attach the square column with the screws and pin
it.
Connect the piping to the design correction
cylinder.
Insert the axle pin (7).
Fit: Flush guard holder
Cooling water piping
Electrical cables
Lubrication piping
Pressure header pipe
Catch guards
1 Screw
2 Pin
3 Guide plunger
4 Screw
5 Pin
6 Guide
7 Axle pin
8 Axle pin with split pin
9 Flush guard holder
11 Guide block
12 Pressure header pipe
240

MM 412-41 2(2) 9508 TBA/3 600V
Yoke and Arms
Checking version With Sleeve Bearings
Check whether there is bearing play between the
yoke and the arms.
If there is, replace the bearings.
Replacing Bearings
Remove the blocks (1) and the bearing cover (2).
Remove the bearing (3) by means of an extractor
tool. Replace one bearing at a time.
Note!
There is a spacer ring (5) on the rear arms only.

Secure the screws with locking liquid.
Check after assembly:
1) That the central lubrication supplies oil to the
lubrication points.
2) The vertical position of the jaws (boom
position).
3) The jaw support/inclination.
4) The jaw gap.
1 Block
2 Bearing cover
3 Bearing
4 Seal ring
5 Spacer ring
241

TBA/3 600V 9508 MM 413-11 1(2)
Yoke and Arms
Checking version With Conical Roller Bearings
Check whether there is bearing play between the
yoke and the arms.
If there is, replace the bearings.
Replacing Bearings
Remove the blocks (1) and the bearing cover (2)
and spacer (5) on both sides.
Undo the shaft in one direction to force out one
bearing, and then in the other one.
Fit new bearings. Force the bearing into position
with the aid of the bearing cover; then remove the
cover.
Make sure the dividable spacer (5) is on the same
plane as the outer bearing ring. If required the
spacer may be divided. Tighten the cover with the
four screws. Check that the bearings rotate freely.
Tighten the two screws (6) fixing the shaft.
Secure the screws (3) with locking liquid.
1 Block
2 Lubrication pipe
connection
3 Screw
4 Bearing cover
5 Spacer
242

MM 413-12 2(2) 9508 TBA/3 600V
Yoke Guide
Checking
Make sure that the bearing of the guides rotate
freely and without play (fig 1).
In case of play replace the bushings.
Replace Bushings
Remove the yoke.
Remove the collar (1) and the circlip (2).
Knock out the two bushings (3) from the opposite
by means of a punch.
1 Collar
2 Circlip
3 Bushing
243

TBA/3 600V 9508 MM 414-11 1(1)
Volume Flaps
Checking
Check that there are no cracks or other damage to
the volume flaps.
Make sure that the cam rollers (8) have not been
worn out of true round and that the roller bearing
play does not exceed 0.5 mm
Check that the volume flap bearing play does not
exceed 0.5 mm.
Replacing The Volume Flap Bushings

Crank the machine so that the volume flap shaft
can be removed without the catches preventing
this.
Disconnect the cooling water (4).
Remove the cutting jaw knife holder.
Loosen the grub screw (3) of the shaft or the shaft
nut.
Remove the buffer unit from the volume flap.
Replace the volume flap bushings.
Checking The Buffer Unit

1) Machine with rubber damper buffers: Check
the bonding between the steel plate and the
rubber buffer block (fig. 2).
2) Machine with wire spring: Check the
condition of the spring (fig. 3).
1 Buffer unit
2 Bearing housing
3 Grub screw
4 Cooling water connection
5 Buffer unit screw
6 Volume flap
7 Grub screw
8 Roller
9 Rolleraxle pin
245

TBA/3 600V 9508 MM 417-11 1(2)
Volume Flaps
Checking the Stop Lug
Crank the machine and check that the stop lug
does not catch the hoop at the top or bottom when
the volume flap rollers enter the cams or are in the
cams, as the case may be.
If there is no clearance, move, file down, or bend
the lug or the hoop.
1 Volume cam
2 Cam roller
3 Stop lug
246

MM 417-11 2(2) 9508 TBA/3 600V
Volume Cam Curve section
Checking
Check that the play between the cam rollers (2)
and bottom of the cam is 0.8-1.5 mm (fig. 1).
Check that the volume cams are not worn,
especially the section that determines the volume
(3). Maximum wear allowed is 0.5 mm.
Check that the rubber cams (4) are not worn.
Check that there is no bearing play and that the
volume adjustment knob moves freely.
After replacing volume cams, bearings or cam
rollers, carry out basic volume setting.
(The volume adjustment device is only intended
for fine adjustment during operation.)
1 Volume cam
2 Cam roller
3 Section of cam that determines volume
4 Rubber cam
5 Pivot/bearing points
6 Volume adjustment knob
247

TBA/3 600V 9510 MM 420-12 1(1)
Volume Cam
Centring
After replacing the volume adjustment device, for
instance after a machine break-down, the device
has to be centred.
set distance c between the underside of the cam
mount (3) and the Q-level (2) as per the table
below:
Volume ml C mm
1000 539.0±0.5
500 480.0±0.5
250 483.5±0.5
200 461.5±0.5
Screw in the volume adjustment device

completely. Check that there is play in the stop
hoop.
Check that the volume cams are parallel.
Set the complete volume adjustment device so that
it is parallel with the guide.
Force the volume flaps first inwards and then
outwards. Play D should be the same in both cases.
Thighten the screws and pin.
1 Volume cam
2 Q-level
3 Cam mount
249

TBA/3 600V 9508 MM 421-51 1(1)
Package Weight
Setting
a) Set the initial gap B by means of the volume
setting knob.
Initial gaps Max

gap
Volume ml A mm B mm B
mm
1000 44.6 3 6
500 34.7 2.5 5
250, 200 33.2 1.0 2
b) Set the weight shims under the volume bolges.

There should be roughly the same number of
shims on the cutting side as on the pressure
side.
c) After setting as per item b, the available
adjustment range by means of the knobs is as
follows:.
Volume ml g/package
(with water)
1000 ±12
500 ±8
250, 200 ±4
251

TBA/3 600V 9508 MM 422-51 1(1)
Design Correction Mechanism
Checking of Easy Movement
The supply of compressed air to the cylinder is to
be turned off and the cylinder depressurized.
Lift the cylinder rod and check that it drops back to
its bottom position by its own weight. If not, adjust
the locking rings at the eccentric axle pins(4) to
achieve easy movement.
In case of bearing play, overhaul according to page
423-31 3(4)
.
1 Bearing housing
2 Folding flap cam
3 Stop lug
4 Eccentric axle pin
253

TBA/3 600V 9510 MM 423-11 1(4)
Removal
Set the machine so that the folding flap roller is out
of the cam.
Disconnect the four lubrication pipes (1). Unscrew
the piston rod (4) from the fork. Undo the two
screws (2).Remove the design correction
mechanism.
Disconnect the compressed air pipes to the design
correction cylinder and the locking ring (5) and
remove the design correction cylinder.
Fitting
Fit the folding flap cam with the bearing housing.
Fix it with the screws (2). Connect the four
lubrication pipes (1). Fit the design correction
cylinder and put in the locking ring (5). Screw the
piston rod to the fork (3).
Connect the compressed air pipes (6).

2 Screw
3 Fork
4 Piston rod
5 Design correction cylinder locking ring
6 Compressed air connection
254

MM 423-21 2(4) 9510 TBA/3 600V
Overhaul
In case there is play in the bearings in the design
correction bearing housing, or if they bind, these
bearings are to be replaced.
The bearings and bushings of the links are to be
replaced if the bearing play exceeds 0.5 mm.
Check that the cam is not worn. If required replace
it.
Check the contact surface of the stop lug (3). If
required turn the lug 180o or replace it.
Check/overhaul the cylinder, renewal
set 90239-0365.
1 Design correction bearing housing

2 Folding flap cam
3 Stop lug
255

TBA/3 600V 9510 MM 423-31 3(4)
Setting
Attach fixed template 72374-0101 to the bearing
housing. At the same time, move the link angle
blocks with clamp unions (1) to non-activated
correction position and lock them there. In this
position, tighten the limit screw (2) against its stop
lug. After replacing the bearing housing, adjust the
housing (non-activated correction position and
template) so that it is aligned with the square-
section column. set height C of the folding flap
cam (8). Tighten the limit screw (2). Then repin
the bearing housing.
Remove the template.
Turn on air and push Preheating Off.
With the 12 mm measurement already set, undo
the air connection (3), and the cylinder ends up in
correction position.
Set measurement A by means of the screw (5), the
screws (4) loosened. Tighten loosened screws and
lock nuts.
Check the 0.05 mm clearance between the cam and
the pins (6). If required, adjust by means of the
screw (7).
Make sure the mechanism functions easily. If it
binds, one of the clamp unions may be loosened
and shifted in or out on the shaft.
Volume ml A mm C + 1 mm
1000 5 629
500 5 616
250, 200 4.5 610
1 Clamp union 7 Screw

2 Limit screw 8 Folding flap cam
3 Air connection 9 Q-level
4 Screw
5 Screw
6 Pin
256

MM 423-52 4(4) 9804 TBA/3 600V
Folding Flaps
Checking Cam and Support Rollers
Check that the cylindrical surface of the cam and
support rollers have not been worn out of true
round and that bearing play does not exceed 0.3
mm.
The support roller (2) is to bear against the support
cam (3) lightly 8it should be possible to turn the
roller by hand when it is in the cam). Adjust with
shims (4).
Checking the Chain Link

Check that play in the chain link does exceed 0.5
mm.
1 cam roller
2 Support
3 Support cam
4 Shim
257

TBA/3 600V 9508 MM 426-11 1(1)
Folding Flaps Mechanism
Checking Bearing Play
Check that the play in the folding flap bearing in
the cutting jaw does not exceed 0.5 mm.
Pull out the link (1) as long as possible. Both
folding flaps is to be in close contact with the
cutting jaw. if there is play in the mechanism, only
one of the folding flaps is in close contact with the
cutting jaw, while the other folding flap is allowed
to have a play of 0.25±0.1 mm to the cutting jaw.
Replace rollers, bearings or bar as required.
1 Link
259

TBA/3 600V 9508 MM 428-11 1(1)
Folding Flap Mechanism
Setting
Basic setting
Adjust the gap (4) so that it is even all the way by
means of the screws (8) and (9).
Crank the machine to a position where the roller is
completely in on the cam. Move the cylinder into
its top position and check the play between folding
flaps and cutting jaw and between folding flaps
and inductor. None of the four distances may be
below distance A according to the table.
(Measurement will become easier if the volume
flaps on the cutting side is removed.) adjust by
means of shims (4) between the square column and
the bearing housing.
Fine Setting
Place twice the packaging material in the jaws.
Crank to a position where the roller is completely
in on the cam. Place the feeler gauge A under the
folding flaps.
Move the cylinder and check that the distance in
correct on both the cutting and the pressing side.
Adjust with the screws (8) and (9).
Note!
Remove the feeler gauge.
Volume ml Pack. Double A mm

material thickness
1 Shim
G/m2 of mat.
2 Cam roller
mm
3 Chain link
1000-500 220-255 0.7-0.8 0.7 4 Gap
1000-500 280-300 0.9-1.0 0.9 5 Folding flap
6 Folding flap
250, 200 220-250 0.7-0.8 0.7 7 Link
8 Screw
9 Screw
261

TBA/3 600V 9508 MM 429-51 1(1)
Pressure Header
Removal
Disconnect the oil hose (7) and the compressed air
pipe.
Disconnect the vent pipe (2).
Detach the pressure header by unscrewing the nut
(3) on the strap.
Fitting
Fit: Pressure header with strap (4). and nuts.
Compressed air pipe (1)
Oil hose (7)
Vent pipe (2)
Connection (9) and clamp bracket (8).
Oil acc to code K page 940-2 1(2). fill oil into the
filling hole (5) or vent the pipe of the pressure
header.
Loosen the venting plug (10) appr 15°. The cutting
solenoid valve can be operated at the same time.
Tighten the plug as soon as the oil, emerging by
the venting plug, is free from air.
Note!
The gasket is to be positioned correctly on the plug
guide.
Check that the amount of oil in the pressure header

is correct.
1 Compressed air connection

2 Vent pipe
3 Nut
4 Strap
5 Filling hole
6 Level glass
7 Oil hose
8 Clamp bracket
9 Connection
10 Venting screw
11 Level plug of bearing housing (78 —>)
263

TBA/3 600V 9508 MM 432-22 1(2)
Pressure Header
Overhaul
Undo the screw (5). Pull out the piston and the
spring. Detach the connection (1).
Check that the piston seal (4) is not worn or
damaged.
Replace the spring if it has been permanently
compressed or otherwise deformed - min length
240 mm.
Make sure the cylinder and guide are not scratched
or otherwise damaged.
Check that the piston (2) is not scratched or
damaged.
Check that the O-rings are intact.
Check that the stop/buffer (9) is not worn.
When fitting a buffer, secure the screw with thread
locking liquid (TP No 90157-0016).
Tighten the screw (5) with a torque of 10 Nm (1
kpm9.
Note!
Remember the spacer (3).
1 Connection
2 Piston
3 Spacer
4 Piston seal
5 Screw
6 Spring
7 Guide
8 O-ring
9 Stop/buffer
264

MM 432-31 2(2) 9508 TBA/3 600V
Pressure Header
Checking
Undo four screws (1).
Check the piston seal (2).
Clean the housing.
Fit.
1 Screw
2 Piston
3 Spring
265

TBA/3 600V 9508 MM 433-11 1(1)
Vertical Jaw Position
Checking
Stick a piece of adhesive tape over the inductor.
Crank the jaws closed.
Turn on the air.Push the knife forward by
manipulating the valves (5) and (6). Alternatively,
tap the screw (3) lightly with a plastic mallet so
that the knife cuts through the strip of tape.
Crank the jaws open and remove the piece of tape.
It is to be cut through in the middle between the
impressions by the inductor (4).
Adjust the vertical position by increasing, or
decreasing, the thickness of the shimming under
the carrier on the cutting side (1). Adjust so that
the knife is as nearly in the middle as possible.
The knife may also be worn, so that it is slightly
inclined. Such an inclination cannot be eliminated
by adjustment (if the knife is excessively worn,
replace it).
Note!
It is very important that that the thicknes of the two
shims in point (1) is exactly the same. If not, could
result in bad TS-sealing.
1 Shim
2 Carrier
3 Screw
4 Impression by inductor
5 Manipulating valve L11 (RH)
6 Manipulating valve L12 (LH)
267

TBA/3 600V 9508 MM 441-11 1(1)
Volume Flaps
Alignment
Crank the machine until the left hand volume flaps
just close, but no further. attach the fixture to the
guides. always start by tightening the left hand Gauge block
wing nut (3), then the right hand one. Volume ml Fixtur incl in
fixture
Align the volume flaps sideways in the middle
with the aid of the fixture by shifting the carriers. 1000, 500 74972-0101 74971-0001
250, 200 74972-0103 74971-0002
Note!
The cutting side is pinned.
The machine must not be cranked with the Note!

fixture fitted. Remove the fixture before cranking Complete fixture set for all volumes:
the right hand volume flaps volume flaps in S-74972-0104. the tube supports are to be aligned
position for alignment. with the aid of the same fixture, page 443-62 2(2)
1 Electrical contact
2 Gauge block
3 Wing nut
269

TBA/3 600V 9508 MM 442-52 1(1)
Tube Support Rollers
Alignment
Crank the machine until the left hand volume flaps
just close, but no further. Attach the fixture to the
guides. always start by tightening the left hand Volume ml Template Template
wing nut (2), then the right hand one. incl. in
Fixture
Note!
the machine must not be cranked with the fixture 1000, 500 S74972-0101 74967
fitted. 250, 200 S74972-0103 74969
Align the support rollers and set the distance
between them with the aid of the fixture and
template as listed below: (Complete fixture set for all volumes S74972-
0104)
Setting the filling tube and pressure roller, page
133-51 1(1) and 136-11 1(1).
The tube supports are to be aligned with the aid of
the same fixture, page 442-52 1(1)
271

TBA/3 600V 9508 MM 443-52 1(2)
Tube Support Rollers
Setting During Production
Check that the forming of the four corners of the
package is equal and uniform.
Fig 1 and 2 show sections through packages.
Fig 1 shows a package, where the support rollers
have displaced the tube to one side, with rounded
corners on the other side as result. The mounting
plate of the support rollers then has to be shifted in
the direction of the arrow.
Fig 2 shows a package after correct setting of the
support rollers.
Set the rollers during production with the setting
screw (1) using key 74387.
Note!
After basic setting acc. to page 443-62 2(2),
adjustment during production should not normally
be required, and if it is, only by turning the setting
screw (1) one or two turns. If major resetting is
required, begin by carrying out basic setting.
272

MM 443-62 2(2) 9508 TBA/3 600V
Tube Roller
Checking
Check that the gap between the roller and the
filling tube is 6-7 mm
Carry out fine adjustment during operation so that
the packaging material is correctly positioned.
273

TBA/3 600V 9508 MM 444-11 1(1)
Jaw Gap
Checking
Before checking the jaw gap the 237.5 mm
measure is to be set, page 321-53 1(2)/321-53 2(2).
Crank the machine so that the distance of
116.7±0.2 mm (gauge 72847) is obtained when the
jaws are closing.
Put a load pointing downwards by means of tool
72889-0101, and a load on the carriers of
150 N = 15 kp in the direction of the arrow
(tool 72846-0101).
Check from above with a feeler gauge that the gap
between the pressure jaw and the cutting jaw is
1.5±0.1 mm.
Adjustment
Loosen the grub screws (5) and the locking nut (6)
Adjust by means of the two screws (7). when the
upper screw is screwed out (upwards) the jaw gap
increases and vice versa.
Tighten the locking nut and grub screws after the
adjustment.
Note!
There should allways be the same pressure between
the two screws.
1 Lug
2 Follower cam
3 Yoke
4 Feeler gauge
5 Grub screw
6 Locking nut
7 Screw
275

TBA/3 600V 9508 MM 446-12 1(1)
Stroke
Basic Setting
Set gap E at 44mm.
Final Adjustment
Stroke
Attach measuring point clamps 74652-0101 to
guides. Maximum permitted difference between A
measured on the two sides is 0.4 mm. Adjust by
shifting the link head (1). After alteration, do not
inch the machine until clearance T and the 237.5
distance have been checked (page 321-53 1(2)/
321-53 2(2)
Clearance T
Set the volume adjustment gap B, page 422-51
1(1), at its max plus position with the volume
setting knob. Crank and check that the clearance
between the volume flap and jaw at no time is less
than T mm. To check, force the volume cam rollers
apart. Check both sides. Reset gap B.
Volume Aa mm T mm A
mm
min
ml gap
1000 0.25 1.0 284

500 0.15 0.8 168
250 0.17 0.7 194
200 0.14 0.7 160
a. Shifting link head 1 mm alters stroke A
mm.
277

TBA/3 600V 9508 MM 455-53 1(1)
Stroke
Setting During Operation
a) Before setting the stroke, the sensor, the crease
breaking device/brake and the folding flap
system are to be set. These settings should not
subsequently be altered.
b) The recommended speed of the free shaft (1) of
the bending roller motor is 90-100 rpm. If the
shaft speed is too low, the stroke is to be
reduced.
If the speed is to high, the stroke is to be
increased.
Alter equally much on both sides. After
adjustment, check gap T (page 455-53 1(1)) and
the 237.5 measurement (page 321-53 2(2)).
c) If the machine is operated with several different
types of packaging material, the motor shaft
speed has to be set somewhat slower than
recommended for some materials and 1 Piece of tape four counting revolutions
somewhat faster for others. 2 Alternatively, a tachometer may be used
Design correction frequency is to be appr 60%
(i.e. correction of 6 packages out of 10), which
is obtained at speeds between 55 and 130 rmp.
d) If the speed is constant at 50 rpm, the correction
frequency is higher than 60%. If the speed is
constant 135 rpm, the frequency is lower than
60%. These two extreme frequencies may occur
if the machine is operated with widely different
materials, but should, if possible, be avoided.
Note!
The speed of the bending roller motor is affected by
the stroke, the crease braking roller/brake, the
folding flap mechanism, the sensor, and any seizing
or jamming of roller bearings.
Machines without driven bending roller or with

driven, not speedcontrolled bending roller
During operation
Design correction frequency 50-80% (5-8 A Stroke
packages corrected out of 10).
If the frequency is too high, reduce the stroke and
increase it if the frequency is too low. Alter equally
much on both sides. After alteration, check gap T
and measurement 237.5 mm.
278

MM 455-63 1(1) 9508 TBA/3 600V
Jaw-Above-Jaw Height
Checking
Set the machine at 70o and measure height B. Set
the machine at 250o and measure height B again.
the difference between the two heights must not
exceed 0.3 mm.
In case of deviation, adjust by means of the right,
hand yoke link.
One turn of the screw (1) alters the link length by
1.75 mm, which corresponds to an alteration of the
difference between the two D lengths by 3.5 mm
(1/2 turn gives an 0.3 mm alteration).
Note!
That the 237.5 distance must always be checked
after adjusting the jaw-above-jaw height (see page
321-53 2(2)).
Basic setting D
Aluminium 210
1 Screw
279

TBA/3 600V 9508 MM 458-11 1(1)
Jaw-Above-Jaw Height
Setting
Undo the screws (1) to the damper unit. detach the
cutting flaps.
At 70° measure height J between the pressure
jaws. repeat at 250°. calculate the average value of
the two heights values. Maximum deviation
allowed between allowed between the jaws is 0.1
mm. In the case of deviation, adjust by means of
the right, hand yoke link (3).
1 Screws
3 Yoke link
280

MM 458-12 1(1) 9508 TBA/3 600V
Overtravel
Checking: Adjustable Rear Link Rod
Compensation of overtravel
If the overtravel is too small, it can be increased by
reducing the length of the rear rod, acc. to page
321-53 2(2). If the minimum recommended
overtravel cannot be obtained with this adjustment,
worn parts must be replaced acc. to the table below
Jaw Pressure
Crank the machine to pressure position with a 60
mm wide, double piece of packaging material
between the jaws.
Measure, or estimate, the gap between the limit
screw and the link (fig 2).
Adjust the gap (overtravel) to appr. 5 mm acc to
page 321-53 2(2)
Fault-Finding
Part Wear of part mm Alteration of
overtravel mm
Pressure jaw 0.1 0.9
Catch position, cutting jaw 0.1 0.9
Catch bearings 0.1 0.9
Catches 0.1 0.9
Eccentric shaft 0.1 0.9
Pressure cam 0.1 0.2
Cam roller 0.1 0.2
Bearing, pressure arm 0.1 0.1
Keyway in pressure link, 0.1 0.9
fixed catch
281

TBA/3 600V 9508 MM 461-13 1(1)
Jaw Pressure With Springs
Checking
Set the machine to 0o/180owith double packaging
material between the jaws.
a) Measure gap A.
b) Set the machine to 130-140°RH/310-320°
c) Detach the fork (3) from the link (2).
Machine with damper:
Remove the spring and spring rod.
d) Fit the measuring lever (4) at the pivot point (8).
Clamp the feeler gauge (thickness A mm as
measured) between the limit screw (1) and the
link. alter the length of the rigging screw (5)
until the feeler gauge drops. Read the spring
balance (6). If the value does not agree with the
value listed on the table below, proceed to next
item.
e) Increase or decrease the pre-tension of the jaw
pressure spring by means of the adjustment
sleeve (7). Clamp the feeler gauge between the
link and the limit screw once more. Alter the
rigging screw until the gauge drops. read the
spring balance. Repeat the procedure until
correct value acc. to the table is obtained.
f) Attach the fork to the link.
Machine with damper:
Fit the spring and spring rod.
Lifting Force with Spring Balance

Volume ml N (kp)
1000, 500 120 (12)
250, 200 120 (12)
Jaw Pressure Tool 75152-0101

The tool includes lever (74710), attachment, chain,
spring balance and rigging screw.
The tool can be used for machines both with and
without damper units.
283

TBA/3 600V 9508 MM 464-11 1(1)
Catch Position
Checking
Make sure there is no play in the catch bushing. If
required replace the bushing.
Crank the machine with air turned on so that the
fixed catch (5) is point-to-point with the cutting
jaw when the jaws are beginning their outward
movement.
In this machine position the adjustable catch (1)
should also be point-to-point position.
If this is not the case, set the adjustable catch in
correct point-to-point position by means of the
adjustment screw (3). Tighten the locking nut (4)
after adjustment.
1 Adjustable catch
2 Cutting jaw
3 Adjustment screw
4 Locking nut
5 Fixed catch
285

TBA/3 600V 9508 MM 467-11 1(1)
Catch Position And Booms
Checking
Check that the booms (1) of the cutting jaw are not
corroded (which might cause corner leakage).
Check that the catch positions of the cutting jaw
are not worn. Max permitted wear 0.5 mm (fig. 2).
1 Boom
2 Metal strip
3 Feeler gauge
287

TBA/3 600V 9508 MM 469-11 1(1)
Catch Detachable
Replacing
a) Check link rod measurement acc. to page 321-
51/52
b) Check pressure arm acc to page 310-11
c) Dismantle old cutting jaw.
d) Assemble cutting jaw (4) and catch (1) with
shim (2)
e) Check link rod measurement acc to page 321/-
51/52
f) Check jaw pressure acc. to page 464-11. Adjust
with shim under catch.
g) Secure shim to catch with screw (5).
Note!
Equal shim left/right hand side.
1 Catch
2 Shim
3 Screw
4 Cutting jaw
5 Screw
6 Washer
3 4
6
5
2 1
GBAAEA001
289

TBA/3 600V 9510 MM 470-11 1(1)
Catch Guards
Checking
Check that distance D is set in accordance with the
table below:
Volume ml D mm
200 47
250 26
500 43
1000 15
Check gaps A and B when the machine is cranked.

A 1.5 - 2.0 mm
B min 1.5 mm
The gaps are adjusted by screwing out or in the
catch guard trigger rod (2).
Tighten the locking nut (4) after adjustment.
1 Cutting jaw
2 Catch guard trigger rod
3 Catch
4 Locking nut
5 Fender
291

TBA/3 600V 9508 MM 472-11 1(1)
Final Folder
Name Issue Page
Disc Coupling 9508
Clamp Ring Coupling 9508 502-11
Flap Sealing Element 9508

Removal 9508 504-21
Fitting 9508 504-21
Setting: with nozzles for

offset packaging material 9508 504-53
FS-element with setting washers: 9508 504-53

Pressure Unit 9508
Check/Removal 9508 520-22
Check 9508 520-22
Removal 9508 520-22
Fitting 9508 520-42
Pressure Unit Links and Lever 9508

Replacing the bearings 9508 521-11
Setting 9508 521-51
Pressure Unit Cam Roller 9508

Check/Replacement 9508 522-11
Replacing the cam roller 9508 522-11
Pressure Unit Cam 9508

Check/Replacement 9508 523-11
Replacing the cam 9508 523-11
Pressure Unit, Pressure Plate 9508

Setting 9508 524-51
Position the yoke in top position. 9508 524-51
293

TBA/3 600V 9906 MM 500 1(4)
Final Folder
Name Issue Page
Pressure Unit, Pressure Side 9508
Setting 9508 525-52
Pressure Block 9508

.Overtravel 9508 526-12
Setting 9508 526-52
Pressure Block 9508

Wear 9508 530-11
Cup springs 9508 530-11
Chain with centre drive 9508 530-11
Removal 9508 530-21
Fitting 9508 530-21

Upper Guides 9508
Checking (after removing the chain) 9508 531-11
Sprocket 9508
Checking (after removing the chain) 9508 532-11
Setting 9508 532-51
Discharger Arm 9508

Removal 9508 535-21
Overhaul 9508 535- 31
Fitting 9508 535-41
Setting 9508 535-51
Discharger Arm Roller 9508

294

MM 500 2(4) 9906 TBA/3 600V
Final Folder
Name Issue Page
Discharge Slide 9508
Removal 9508 539-21
Fitting 9508 539-21
Setting 9508 539-51
Discharge Slide Carrier 9508

Indexing Unit 9508

Check/Oil change 9508 543-12
Removal/Fitting 9508 543-22
Bevel Gear 9508

Check/Oil Change 9508 546-11
Side Discharger 9508

Checking bushings/axles (fig. 1) 9508 549-11
Checking synchronization (fig 2) 9508 549-11
Flap Folding Pipe 9508

Setting 9508 552-51
Flap Folding Bars, Top Flaps 9508

Setting 9508 553-52
Flap Folding Bars with Support Bar 9508 553-52
Flap Folding Bars without Support Bar 9508 553-52
Push-Down Device, Slite Plate 9508

Setting 9508 556-51
Push-Down Device 9508

Setting 9508 557-52
Cup Spring Pile 9508 557-52
295

TBA/3 600V 9906 MM 500 3(4)
Final Folder
Name Issue Page
Drop Chute 9508
Piston rod extension seal. 9508 559-11
Gap A 9508 559-11
Roof 9508
Damper 9508
Checking/Setting 9508 565-12
Congestion Monitor 9608

During Production 9608 566-12
Pressure Hoop 9508

Folding Arms 9508

Setting 9508 571-51
Synchronization
Main Machine - Final Folding Unit 9508
Safety Coupling 9508

Fitting 9508 577-41
296

MM 500 4(4) 9906 TBA/3 600V
Disc Coupling
Clamp Ring Coupling
Undo the four screws (1) according to page 574-51
1(1) and tap them in with a punch so that the clamp
ring comes off. the final folding unit can now be
turned manually by means of the bar of disc
coupling.
1 Screw
297

TBA/3 600V 9508 MM 502-11 1(1)
Disc Coupling
Checking
Check that all the discs are intact. If required
replace them.
Make sure there is a pre-tension of 1 mm on
reassembly (see fig.).
the thickness of the disc pack is to be 4 mm, either
10 x 0.4 mm discs or 8 x 0.5 mm discs.
298

MM 502-12 1(1) 9508 TBA/3 600V
Flap Sealing Element
Removal
Undo the two cable connections (3).
Undo the nut of one of the air nozzles (2) and turn
the nozzle so that it does not catch when the unit is
lifted out.
Undo the four screws (4) and remove the element.
Attach the elements units so that they cannot drop
out if the flap sealing element is turned upside
down.
Fitting
Fit the element with the four screws (4).
Attach the cables (3).
Before fitting the element cover set up the air
nozzles in accordance with
”Flap Sealing Element - Setting Up”.
2 Air nozzle
3 Cable connection
4 Screw
299

TBA/3 600V 9508 MM 504-21 1(4)
Overhaul
Remove and clean the air nozzle (4) and the
insulation sleeve (2).
Lift up the three element units (1).
Detach the ceramic collars (3) that enclose the
heating coils (5). Replace discoloured or damaged
parts.
Make sure the insulation sleeves (2) are not
damaged. If they are, replace them.
Check that all seals are intact.
Re assemble in reverse order.
1 Element unit
2 Insulation sleeve
3 Ceramic collar
4 Air nozzle
5 Heating coil.
300

MM 504-31 2(4) 9508 TBA/3 600V
Setting: with nozzles for offset packaging material
Put the pressure sides of the folding unit in closed
position.
Check the positions of the air nozzles (1) in
relation to the package station by means of the
templates according to the table (the holes by the
scribe marks).
Adjust by loosening the nut (3) and turning the air
nozzle. The entire Flap Sealing element can be
moved along the chain after undoing the four
mounting screws. After adjustment tighten the nuts
and screws.
Vertical adjustment can
be made by loosening
the air nozzle and
adding or removing
copper shimming
washers (2).
Fit the element cover.
For fitting the flap folding
guide (8), see page 552-51 1(1)
Air nozzle Volume Template

Bottom flaps 1000, 500 544738
250, 200 544739
Top flaps 1000, 500 72802-2
250, 200 72802-4
1 Air nozzle
2 Copper shimming washer
3 Nut
4 Insulation sleeve
5 Template for bottom flaps
(Cont’d) 6 Package station
7 Template for the top flaps
8 Flap folding guide
301

TBA/3 600V 9508 MM 504-53 3(4)
(Cont’d)
FS-element with setting washers:

Adjust lengthwise by means of the setting washers
(9).
Adjusting sideways by means of the setting screws
(10).
Note!
When removing the FS-element, do not loosen (do
not alter) the setting washers (9) and setting screws
(10). Remove the removal washers (11).
9 Setting washer
10 Setting screw
11 Removal washer
302

MM 504-53 4(4) 9508 TBA/3 600V
Pressure Unit
Check/Removal
Check 1 Nut
2 Screw
If there is play in the pressure sides remove the
3 Screw
pressure unit for overhaul.
4 Cooling water hose
5 Screw
6 Screw
Removal 7 Arm
8 Lubrication hose
Remove: Four nuts (1) on the pressure plate
9 Spacer washer
Two screws (2) per guide, then tap
down all four guides.
Four screws (3) holding the guide plate.
The cooling water hoses (4).
The bracket with its screw (5).
Two screws (6) holding the flap folding
bar guide.
Two arms (7).
Four lubrication hoses (8).
Remove the four spacer washers (9) from the
guides.
Lift up the pressure unit.
303

TBA/3 600V 9508 MM 520-22 1(1)
Pressure Unit
Fitting
Put the pressure unit in position. 1 Nut
2 Screw
Put in the spacer washers (9) and tap up the four
3 Screw
guides.
4 Cooling water hose
Fit: Four lubrication pipes (8). 5 Screw
Two arms (7). 6 Screw
Two screws (6) holding the flap folding 7 Arm
pipe. 8 Lubrication hose
The bracket with its screw (5). 9 Spacer washer
Cooling water hoses (4).
Four screws (3) holding the pressure
plate.
Four nuts (1) on the pressure plate.
Do not tighten the two screws (2) per guide until
the pressure plate of the pressure unit has been set,
acc. to page 524-51 1(1).
304

MM 520-42 1(1) 9508 TBA/3 600V
Pressure Unit Links and Lever
Checking
Check that the axle pins (1) show no play in the
links (2). If there is play replace the links, and if
necessary also bushings and axle pins.
At the same time check that there is no play in the
yoke (4). Incase of play replace the bushings.
Set the yoke in its top position and check that there
is no play in the ball bearings (5) by levering
upwards with a screwdriver pushed through the
lever. In case of play replace the bearings.
Replacing the bearings

Disconnect the lubrication pipes (7).
Detach the links by removing the locking plates
and pulling out the axle pins.
Undo one screw (6) on the outside and one on the
inside of each bracket and detach the lever.
Remove the axle and replace the bearings.
1 Axle pin
2 Link
3 Bearing in lever
4 Bearing in yoke
5 Ball bearing
6 Screw
305

TBA/3 600V 9508 MM 521-11 1(2)
Pressure Unit Links and Lever
Setting
Set the yoke (5) in its bottom position.
Check with the aid of a feeler gauge that there is a
free play between the lever (4) and the side frame
(1) of at least 0.5 mm.
Adjust by loosening the four screws (3) holding
the two bearing brackets (2) and moving the
brackets.
1 Side frame
2 Bearing bracket
3 Screw
4 Lever
5 Yoke
306

MM 521-51 2(2) 9508 TBA/3 600V
Pressure Unit Cam Roller
Check/Replacement
Check whether there is any play in the cam roller
bearing. If there is play, replace the cam roller.
Replacing the cam roller

Turn the cam so that the hole in it lines up with the
cam roller.
disconnect the lubrication pipe connection (1) and
undo the nut (3) holding the cam roller.
Tap out the cam roller.
Fit a new cam roller.

2 Cam
3 Nut
4 Cam roller
307

TBA/3 600V 9508 MM 522-11 1(1)
Pressure Unit Cam
Check/Replacement
Check with the aid of a feeler gauge that the cam
track has not been worn more than 0.3 mm in any
place.
Also check that the cam roller has not worn
depressions into the running track.
Faulty cam or cam roller must be replaced.
Replacing the cam

Remove the intermediary shaft.
Remove the lever (1).
Unscrew the two screws from the taper lock
bushing. Push out the cam with the aid of one of
these screws screwed into the third hole.
Replace the cam.
After replacing the cam, set the unit in accordance
with “Discharger Slide - Setting“, see page 539-51
3(3).
1 Lever
3 Screw bracket
4 Bracket
5 Screw
6 Taper lock bushing
7 Cam
309

TBA/3 600V 9508 MM 523-11 1(1)
Pressure Unit, Pressure Plate
Setting
Position the yoke in top position.
Distance A between the pressure plate (2) and the
guide plate (3) is to be as listed in the table.
Adjust by placing two gauges (gauge No as listed
in the table) diagonally so that a measurement is
obtained at all four guide columns.
Tighten the eight screws (7).
Remove the gauges.
.
Machine A mm B mm Gauge
No
cam with 20 68+0.30 - 74806
mm
movement
1 Gauge
2 Pressure plate
3 Guide plate
4 Yoke
5 Screw
6 Guide columns
7 Yoke screw
311

TBA/3 600V 9508 MM 524-51 1(1)
Pressure Unit, Pressure Side
Setting
a) Set the pressure plate (1) in its bottom position. 1 Pressure plate
2 Guide plate
b) Check that gap B (fig 1) is 30 mm. To adjust
3 Holder
loosen the screws (4) and shift the holder (3) on
4 Screw
the guides
5 Screw
c) Check that both pressure sides are parallel with 6 Holder
the station sides (fig 1) and in line with the edge 7 Screw
of the stations (fig 2). To adjust, loosen the 8 Screw
screws (5) and shift the holder (6). Continue to
adjust the pressure sides by turning them until
they are parallel; thereafter tighten the screws
(7).
d) Check that gap A (fig 2) are the same in front of
the pressure side as behind it. To adjust, loosen
the four screws (8) on either side and shift the
pressure unit forwards or backwards.
313

TBA/3 600V 9508 MM 525-52 1(1)
Pressure Block
Checking
Place a semi-finished package in the final folding
unit and inch it to the folding unit stations.
Check that there is overtravel, a and B in the table
below.
Adjust by screw up, or down, the pairs of twin nuts
(1). Then lock by tightening these nuts.
.Overtravel
1000, 500ml
Travel mm A B
2 0.5 - 1
250, 200ml
Travel mm 0.5 - 1
1 Nut
2 Pressure block
3 Direction of production
315

TBA/3 600V 9508 MM 526-12 1(2)
Pressure Block
Setting
Position the pressure plate in top or bottom
position.
Set gap C by screwing up, or down, the pairs of
adjustment nuts (1). Then lock by tightening the
nuts
1000, 500ml
Gap C mm Bottom pos Top pos
1st pressure 0 20
block
2nd pressure 2 22
block
250, 200 ml
Gap C mm Bottom pos Top pos
1 21
Check with a semi-finished package, page 526-12

1(2)
There must be a play between the pressure blocks
(2) and the guide plate (4).
1 Adjustment nut
2 Pressure block
3 Station chain
4 Guide plate
316

MM 526-52 2(2) 9508 TBA/3 600V
Pressure Block
Checking
Wear
Check wear of the chain and guides at the first
station of the pressure unit (most of the wear of
chain and guides takes place during the pressure
length passage).
If play B at the top edge of the station - from the
middle to one of the extreme positions - exceeds
the figure listed below, overhaul the chain and
guides.
Volume ml Play B mm
1000 3
500 2
250, 200 1.5
If play B is correct and the sideways adjustment

range of the pressure unit is insufficient, the
sprockets are worn and have to be exchanged.
Cup springs
Unscrew the nut (1). Remove the cover (2). Check
that all the 100 cup springs are intact. Replace as
required. Reassemble.
Chain with centre drive

Check that the Washer (3) in the lugs (4) are intact.
1 Nut
2 Cover
3 Washer
4 Lug
317

TBA/3 600V 9508 MM 530-11 1(3)
Pressure Block
Removal
Remove the leg (5) and side plate (6). Pull the chain and punch out the axle pin (8).
Disconnect the lubrication pipes (3) on both sides. Remove two stations, turn the disc coupling,
Screw in one tool 20990 (1) into each lubrication remove two more stations, etc.
hole.
Turn the disc coupling until one of the lugs (9) Fitting
(rollers on old model machines) is immediately in Fit in reverse order.
front of the side frame.
The pin (10) is to face the stop (7).
Tighten the nuts (2) of the tools to take the tension
off the chain on both sides. (do not tighten the nuts
so hard that the sprocket are held immovable.)
Remove the washer (10) from the lug (9).
1 Tool 20990
2 Nut
3 Lubrication pipe
4 Spring housing
5 Leg
6 Side plate
7 Stop
8 Axle pin
9 Lug
10 Washer
318

MM 530-21 2(3) 9508 TBA/3 600V
Pressure Block
Overhaul
Replace such axles (1) as have been worn down to
a diameter of less than 9.9 mm.
Replace such lugs (4) as have an outside
dimension smaller than 19.9 mm and an inside
diameter bigger than 10.1 mm.
1 Axle
4 Lug
5 Bushing
6 Wasker
319

TBA/3 600V 9508 MM 530-33 3(3)
Upper Guides
Checking (after removing the chain)
Check that the inside measurement of the guides
does not exceed 20.6 mm in any place (maximum
wear will occur in the indexing position of the
pressure unit).
In case considerable wear, replace the guides.
321

TBA/3 600V 9508 MM 531-11 1(1)
Sprocket
Checking (after removing the chain)
Check that there is no bearing play in any of the
two sprockets and that none of them is damaged.
In case of play, replace the bearing.
In case of play at the indexing device, the latter has
to be replaced/overhauled.
1 Drive shaft
2 Indexing device
3 Sprocket
323

TBA/3 600V 9508 MM 532-11 1(2)
Sprocket
Setting
Crank the input shaft of the indexing device until
the key is facing upwards as shown in fig 1.
Check the 1 mm measurement (34.5 o) shown in
fig 1. (Place a complete station unit on the sprocket
if the chain has been removed.)
Check that the outer screws (6) are tight. Setting
can be carried out after loosening the inner screws
(7).
1 Drive shaft
2 Indexing device
3 Sprocket
4 Input shaft
5 Complete station unit
6 Screw
7 Screw
8 Intermediary chute/
push-down device
324

MM 532-51 2(2) 9508 TBA/3 600V
Discharger Arm
Checking
Set the discharger arm in its middle position.
Check with the aid of feeler gauge that the
clearance between the tooth and seat is not less
than 0.1 mm.
Pull the discharger arm up and down and check
play. If the play exceeds 5 mm, the discharger arm
must be overhauled.
Lubricate with a grease gun.
1 Grease nipple
325

TBA/3 600V 9508 MM 535-12 1(6)
Discharger Arm
Removal
Crank the machine to 42o or 222o.
Take off the plate between the station chain and the
discharger arm (the plate may be lifted up after
removing the carrier).
Remove the sleeve (1).
Remove the screw (2) and disconnect the
lubrication pipes (3).
Loosen the four screws (4) at the back of the bevel
gear of the discharger arm and remove the
discharger arm.
1 Sleeve
2 Screw
4 Screw
326

MM 535-21 2(6) 9508 TBA/3 600V
Discharger Arm
Overhaul
Replace the tooth and its seat if required.
Replace the self-lubricating bushings (hole
diameter must not exceed nominal size more than
0.2 mm). The diameter of the bearings between the
rod (1), axle (2) and upper arm (4) must not
deviate by more than 0.2 mm from nominal
diameter.
Replace faulty bushings and washers (3).
Wear of the cam track in the upper arm (4) must
not be more than 0.3 mm, maximum measurement
26.3 mm.
Wear of the cam track in the lower arm (5) must
not be more than 0.3 mm, maximum measurement
35.3 mm.
In case of fault, replace the arm.
1 Rod
2 Axle
3 Wear washer
4 Upper arm
5 Lower arm
327

TBA/3 600V 9508 MM 535- 31 3(6)
Discharger Arm
Fitting
Crank the machine to 42o or 222o.
Fit: Discharger arm by means of four screws (1).
Lubrication pipe connections.
check the height of the cup spring column: 56 mm,
36 springs.
Fit: Sleeve (2)
Slide (4)
Screw (3)
Plate between station chain and discharger
arm.
1 Screw
2 Sleeve
3 Screw
4 Slide
328

MM 535-41 4(6) 9508 TBA/3 600V
Discharger Arm
Fitting
Check that the gap between the arm (5) and slide
(6) is 2 - 3 mm. to adjust, loosen the screws (2) and
clamp unions (3) and (4) and turn the gear
assembly (1). Also check that the arm clears the
bracket (7).
329

TBA/3 600V 9508 MM 535 41 5(6)
Discharger Arm
Setting
a) The slide (1) is to be in its extreme bottom
position. check that the plane of the carrier (2)
is appr. 2 mm below the bottom of the station
(3) (fig. 1). adjust by loosening the screws (7)
and turning the mounting plate (6). Tighten the
screws.
b) Check, when the slide (1) is in both its extreme
bottom and top positions that the gap between
the adjustment screws (10) of the rack and the
rubber buffer (8) is appr. 1 mm (fig. 3). Adjust
by loosening the locking nuts (9) and turning
the adjustment screws (10). Tighten the locking
nuts (9).
Special for volumes 500, 250, 200 ml

Check that the flap (4) is appr. 1 mm below the
station (3) when the station chain has completed
indexing (fig. 1).
Adjust with the adjustment screw (5).
1 Slide
2 Carrier plane
3 Bottom station
4 Flap
5 Adjustment screw
6 Mounting plate
7 Screw
8 Rubber buffer
9 Locking nut
10 Adjustment screw
330

MM 535-51 6(6) 9508 TBA/3 600V
Discharger Arm Roller
Checking
Check by pulling the discharger arm forth and
back that there is no play in the cam roller. If so,
replace the roller.
Replacement
Turn the disc coupling until the roller is in its
lower position, opposite the hole in the cam.
Unscrew the nuts (1) and (2). Disconnect the
lubrication connection (3). disconnect the
lubrication connection guide (4).
Replace the roller (5).
Check lubrication of the roller.
1 Nut
2 Nut
3 Lubrication connection
4 Guide
5 Roller
331

TBA/3 600V 9508 MM 536-11 1(1)
Discharge Slide
Removal
Unscrew the nuts on the locking pins (1) and tap in
the pins.
Remove the screws (2). Remove the hose clip and
disconnect the lubrication pipe (3).
Tap the bracket block (4) outwards. The guide bars
(5) will be pulled out and the discharge slide
comes off.
Inspect the rubber (6) and replace it if required.
Fitting
Fit the discharge slide with its guide bars and
bracket block (4).
Tighten the screws (2).
Connect the lubrication pipe (3) by means of the
hose clip.
Tighten the nuts on the locking pins (1).
1 Locking pint
2 Screw
3 Lubrication pipe
connection
4 Bracket block
5 Guide bar
333

TBA/3 600V 9508 MM 539-21 1(3)
Discharge Slide
Overhaul
Remove the screw (11), spring (12) and locking Check the cylindrical surface of the cam roller (6)
plunger (13). The plunger may be extracted with and make sure there is no play. In case of fault
the aid of an M6 screw. remove the roller and replace worn parts. Fit new
pressure discs (10). Check that the hole in the
Remove the cap (2).
screw (11) is not blocked. The four punch marks
Check that there is no play in the carrier (8) and on the axle (9), gear wheel (14) and rack (15) are
rack (15). Replace worn parts. to be lined up as shown in fig. 2.
Check the spring (12) - 38 N (3.9 kp) when
compressed to 33 mm. If faulty it is to be replaced.
Check that the diameter of the locking plunger
(13) is not smaller than 11.8 mm and that the 1.5
mm measurement as shown in fig. 3 is not
exceeded. If required replace the plunger.
Replace the self-lubricating bushing (16) if the
hole diameter exceeds 12.2 mm.
Check all bushings (1).
1 Self-lubr. bushing
2 Cap
3 Banjo coupling
4 Nut
5 Locking pin
6 Cam roller
7 Axle pin
8 Carrier
9 Axle
10 Pressure disc
11 Screw
12 Spring
13 Locking plunger
14 Gear wheel
15 Rack
16 Self-lubr. bushing
334

MM 539-31 2(3) 9508 TBA/3 600V
Discharge Slide
Setting
a) Put the final folding unit in indexing position
(when the chain begins its forward movement).
Volume ml Gap A mm
b) Undo the clamp ring coupling (1) of the
intermediary shaft by unscrewing the screws 1000 10
(2). 500 15
c) Turn the intermediary shaft (3) in its direction
250, 200 20
of rotation until the carrier (5) on the slide -
upward movement - is A mm above the upper
edge of the package station (4).
the carrier may be moved slightly from its basic
setting in order to change the direction in which
the packages drop. 1 Clamp ring coupling
2 Screw
d) Retighten the clamp ring coupling with the 3 Intermediary shaft
screws. 4 Package station
5 Carrier
335

TBA/3 600V 9508 MM 539-51 3(3)
Discharge Slide Carrier
Checking
Check if there is any play in the carrier (1) of the
discharge slide. If so, replace the locking plunger
(2).
1 Carrier
2 Locking plunger
337

TBA/3 600V 9508 MM 540-11 1(1)
Indexing Unit
Check/Oil change
Check that the seal (10) and (11) do not leak.
Drain the oil and take off the cover. Wipe off oil
and dirt from the cam and the cam rollers. Make
sure the nuts (6) and (8) are tightened.
Turn and check that the play between the cam and
the cam rollers does not exceed 0.1 mm. If there is
play replace/overhaul the indexing unit.
Check whether there is any play in the conical
roller bearings (9) by grabbing hold of the shaft
ends. In case of play the indexing unit is to be
replaced/overhauled.
Fill up with oil above the low-level mark (5)
according to code A, page 940-2 1(2)
1 Plug, oil filling

2 Plug, oil draining
4 Cover
5 Low-level mark
6 nut
7 Shaft
8 Round nut SKF
9 Bearing
10 Seal
11 Seal
12 Cam roller
339

TBA/3 600V 9508 MM 543-12 1(2)
Indexing Unit
Removal/Fitting
Remove the chain according to page 530-11 1(3)
Drain the oil according to page 543-12 1(2)
Remove the intermediary shaft, and undo the
clamp ring coupling (1).
Unscrew the two screws from the taper lock
bushing (12). Force out the cam (2) with one of
these screws inserted into the third screw hole.
Detach the push-down device bracket (5) (three
screws).
Detach the push-down device rod.
Undo the two screws (7) and bend the disc
coupling out of the way.
Undo the screws (6) of the clamp ring coupling.
Pull out the safety coupling and the eccentric of
the push-down device.
Remove the plate (4).
Unscrew the four inner screws (11) of the sprocket.
Put a support underneath the indexing unit and pull
out the latter.
Overhaul the unit.
Fill up with oil according to page 543-12 1(2)
1 Clamp ring coupling

2 Cam
4 Plate
5 Bracket
6 Screw
7 Screw
11 Screw
340

MM 543-22 2(2) 9508 TBA/3 600V
Bevel Gear
Check/Oil Change
Check the oil level, oil according to code A.
Check whether there is any play in the bevel gear
by pushing the arm (1) in different directions.
In case of play, replace the gear.
Note!
Change oil when doing the 3000 h service
1 Arm
2 Bevel gear
3 Oil filling plug
4 Drain plug
5 Level glass
341

TBA/3 600V 9508 MM 546-11 1(1)
Side Discharger
Checking
Checking bushings/axles (fig. 1)
If the bill (1) can be moved more than 4 mm, all
bushings and possibly also the axles are to be
replaced.
To replace the bushings, start by taking off the
front cover plate. Undo the locking screws to
replace the axles.
Checking synchronization (fig 2)

a) Volumes 1000, 500 ml:
Set the slide in its extreme top position (X- X).
Volumes 250, 200 ml:
Allow the slide to descend 70 mm (A) from its
extreme top position.
b) Loosen the screws (4) and turn the eccentric
disc so that the side discharger is in its end
position. Tighten the screws.
Note!
The eccentric disc is to be turned 180o when
changing over from left hand to right hand
discharge (or vice verse). In this the bill (1) and the
conveyor belt bracket (2) have to be changed over.
1 Bill
2 Bracket
3 Slide
4 Screw
5 Eccentric disc
6 Self-lubricating bushings
343

TBA/3 600V 9508 MM 549-11 1(1)
Flap Folding Pipe
Setting
Place the pressure sides of the pressure unit in their
outer positions. The station chain is to have
completed indexing.
Place a template for bottom flaps in accordance From 640005 220V—>
with the figure and table. The flap folding pipe (1) Air nozzle Volume Template
is to be located sideways between the two holes (3)
in the template. Bottom Flaps 1000, 500 544738
To adjust loosen the screws (4) and (5) (and (9) on Bottom Flaps 250, 200 544739
old machines) and move the flap folding pipe.
Tighten the screws.
Check that the gap between the straight part of the
flap folding pipe and the station chain (6) is in
accordance with the fig.
To adjust loosen the nuts (7) of the locking pins
and move the distributor (8) up or down.
1 Flap folding pipe

2 Air nozzle
3 Hole in template
4 Screw
5 Screw
6 Station chain
7 Nut
8 Distributor
9 Screw
345

TBA/3 600V 9508 MM 552-51 1(1)
Flap Folding Bars, Top Flaps
Setting
Flap Folding Bars with Support Bar Flap Folding Bars without Support Bar
The clearance between the support bar (1) and the The clearance between the flap folding bar (1) and
station chain (2) is to be as shown in fig 1. the station chain (2) is to be as shown in fig 2.
Adjust by means of the screws (3) Adjust by means of the screws (3)
1 Support bar 1 Flap folding bar

2 Station chain 2 Station chain
3 Screw 3 Screw
347

TBA/3 600V 9508 MM 553-52 1(1)
Push-Down Device, Slite Plate
Setting
Check that the slide plate of the pushdown device
(2) is located 1 mm in front of the station (3) when
the station chain has completed indexing (the key
(4) of the output shaft of the indexing unit facing
straight up).
Adjust by loosening the screws (1) and moving the
push-down device.
1 Screw
2 Slide plate
3 Station
4 Indexing unit output shaft key
349

TBA/3 600V 9508 MM 556-51 1(1)
Push-Down Device
Setting
a) Position the key (1) of the indexing unit shaft so
it points straight up (66o/246o).
b) Basic setting. Put the push-down device in its
bottom position. Check that not less than two
turns of thread (9) remain for link rod
adjustment. Adjust so that there is no play in the
ball joint by loosening the nut (11) and turning
the link head (12).
c) Check that the pressure plates (4) and (9) are at
the same height and that the push-down device
is centred above the station chain (gaps 2 - 4
mm). Adjust by means of the screws (2) and the
locking ring (3). Check clearance over the
pressure hoop pipes (13).
d) Check during production that there is a visible
play of appr. 0.1 mm. adjustment is possible
with the nut (8) without the lock nut (11) having
to be loosened. (The axle and spring pile will
then turn with the nut, remaining in position at
even half-turns.)
Cup Spring Pile

If faulty, remove the pile of cup springs. Check the
ball joint. Make Sure the 24 cup springs are intact,
correctly mounted, and greased. Set the spring pile
pre-tension at measurement A by turning the
setting nut (7).
Measurement A
Up to and incl. Ser. No. 1465 20 mm
From Ser. No. 1466 24 mm
1 Key 8 Adjustment nut

2 Screw 9 Thread
3 Locking ring 10 Lock nut
4 Pressure plate 11 Lock nut
5 Cross-stay 12 Link head
6 Pressure plate 13Pressure hoop pipe
7 Setting nut
351

TBA/3 600V 9508 MM 557-52 1(1)
Drop Chute
Checking
Piston rod extension seal.
Check that the seal (1) of the piston rod extension Note!
is intact. If not, replace the seal. If the drop chute touches the push-down device, the
chute may be raised by undoing the locking nut (2)
Gap A and turning the piston rod. The Gap A
measurement must be readjusted.
The chain must have completed its indexing
movement. Do the setting by loosening the locking Sideways adjustment of the drop chute can be
nuts (3) and turning the link rod until gap A is made after loosening the screws (6).
obtained.
Retighten the locking nuts.
1 Seal
2 Locking nut
Volume ml Gap A mm Gap B mm 3 Locking nut
1000, 500 ml 1-3 1-2 4 Chute
5 Slide plate
250, 200 1 0-2
6 Screw
353

TBA/3 600V 9508 MM 559-11 1(1)
Roof
Checking
Check that the roof (1) is located in the centre of
station chain the measures A are to be the same on
both sides.
Adjust by loosening the screws (2) or (3) and
moving the roof.
1 Roof
2 Screw
3 Screw
355

TBA/3 600V 9508 MM 562-11 1(1)
Damper
Checking/Setting
Make sure the rubber buffers are intact. If not,
replace them.
Volume ml Meas. A Meas. B
Check that there is no bearing play. If so, replace
the bearings. Check distance A. If required, adjust 250, 200 30±5 30
by shimming under the lower buffer (1). 500 40±5 30
Check that the damper arms move close to the 1000 60±5 100
bottom of the station chain, but without hitting it.
If they do, adjust by shimming under the upper
buffer (2).
Gaps C are to be the same on both sides of the
station. Straighten if required.
The arms are to release 100 mm before the
package reaches the bottom of the station chain.
Correct setting is obtained if the arms can clear a
5 x 5 mm square-section bar (4). Adjust by means
of the screw (3).
Special for 500ml:
The arms are to reach to within 2-3 mm of the
edge of the station bottom.
1 Rubber buffer
2 Rubber buffer
3 Adjustment screw
4 5 x 5 square-section bar
357

TBA/3 600V 9508 MM 565-12 1(1)
Congestion Monitor
Checking
When the damper arms (3) are in top position, the
activator must cover the sensing field of the
transmitter (2).
The clearance between activator and transmitter
must be 0.5+0.5/-0 mm
During Production
In case of package congestion, an impulse is
obtained and the drop chute discards the packages.
Check the function by inserting a feeler gauge,
thinner than 0.5 mm, between the activator and the
transmitter. After a time lag according to the table
below, the drop chute will go to discard position.
As long as the feeler gauge is held in position, the
drop chute is to move from discard to normal
production position and back again at intervals
according to the table. When the feeler gauge is
withdrawn, the drop chute is to remain in
production position.
1 Activator
2 Transmitter
3 Damper arm
359

TBA/3 600V 9608 MM 566-12 1(1)
Pressure Hoop
Checking
Check measurement B according to fig. and table.
Volumes 1000, 500 ml:
Check that the spring (1) is not bent or cracked. If
faulty, replace it.
1 Spring
Volume ml B
1000 79
500 26
250 51
200 35
361

TBA/3 600V 9508 MM 568-11 1(1)
Folding Arms
Setting
Put the pressure sides of the pressure unit in the
open, or out position.
Check that the folding arms (1) are 8 mm above
the station.
To adjust, undo the screw (3) in the lever (4) and
turn the folding arm (1). Retighten the screw.
1 Folding arm
2 Station
3 Screw
4 Lever
363

TBA/3 600V 9508 MM 571-51 1(1)
Synchronization Main Machine - Final Folding Unit
Checking
a) Crank the machine until the final folding unit
starts moving.Use a dial test indicator, measure
at station chain.
b) If the degree reading does not agree with the
table, loosen the screws of the clamp ring
coupling and tap them in with a punch.
c) Crank the machine to the degree reading given
in the table.
d) Tighten the screws of the clamp ring coupling
with a torque of Nm 48 (4.8 kpm).
Note!
If the synchronized position alters frequently, clean
the drive belts and the main shaft thoroughly to
remove oil.
1 Clamp ring coupling screw
Volume ml Degree setting

1000, 500, 250, 200 110 290
1000 Hifin 80 260
365

TBA/3 600V 9508 MM 574-51 1(1)
Safety Coupling
Checking
Lubricate the safety coupling with grease
according to code F, page 940-2 1(2)
Push Mains Power On.
Check that alarm is triggered by depressing the
microswitch (1).
Crank forward the safety coupling cam so that its
high sector opposes the microswitch. The gap
between the cam and the microswitch is then to be
1±0.2 mm
1 Microswitch
367

TBA/3 600V 9508 MM 577-11 1(2)
Safety Coupling
Fitting
Polish off any rust on the shaft (1) before fitting.
Grease the clamp rings (2) and make sure they are
fitted facing the right way illustrated.
Note!
Make sure inner ring (6) is fitted first.
Tighten the screws (3) alternately to a torque of 20

Nm (2 kpm) and check that gap A does not exceed
6 mm after the screw have been tightened.
The cut-out torque is to be set with the unit
removed from the machine, by placing the
required number of shims (5) underneath the
pressure plate (4).
Torque setting:
150±15 Nm
(15±1.5 kpm)
1 Shaft
2 Clamp ring
3 Screw
4 Pressure plate
5 Shim
6 Inner ring
368

MM 577-41 2(2) 9508 TBA/3 600V
Setting Data Lubricants
Name Issue Page
Setting Data 9601
Common setting 9601 901-3
Tube heater 9601 901-3
LS sealing 9601 901-3
SA sealing 9601 901-3
Sterile air, air superheater 9601 901-3
Sterile air, sterilization 9601 901-3
Steam barrier 9601 901-3
Lubricant Recommendation 9510 940-2

Lubrication Chart 9510 940-2
Templates/Tools 9510 980-1
Templates/Tool 9510 981-1
369

TBA/3 600V 9906 MM 900-1 1(1)
Setting Data
PRESSURE GUARDS
M.B2 Incoming air 0.6 - 0.7 MPa (6.0 - 7.0 kp/cm2)
M.B3 Incoming cooling water 0.3 - 0.6 MPa (3.0 - 6.0 kp/cm2)
M.B18 Compressor, sterile air 30 kPa (0.30 kp/cm2)
COMPRESSED AIR SETTING
Compressor, in production 45 ± 5 kPa (0.45 ± 0.05 kp/cm2)
SA sealing, basic setting 2.0-2.2 kPa (200-220mm WC)
LS setting, basic setting 1.9-2.0 kPa (190-200mm WC)
M3 Cutting pressure 0.30-0.40 MPa (3.0 - 4.0 kp/cm2)
M4 Product valve 0.35 MPa (3.5 kp/cm2)
M5 Flap sealing
Bottom 120kPa (1.2 kp/cm2)
Top left 80kPa (0.8 kp/cm2)
Top right 80kPa (0.8 kp/cm2)
M8 brake device 0.10-0.30 MPa (1.0-3.0 kp/cm2)
Photocells (design correction), 0.40 MPa
air-blowing
PEROXIDE CONSUMPTION, See page 183-15 1(1)

COOLING WATER FLOW, See page 215-12 1(2)
371

TBA/3 600V 9601 MM 901-3 1(4)
Setting Data
Common setting
Configuration Parameter
Level
Con 1 Con 2 Pt2: HCA LOC:
Tube heater 0230 0000 0 min, ---- 1
LS sealing 0230 0000 0 min, ---- 1
SA sealing 0230 0000 0 min, ---- 1
Sterile air, air superheater 0230 0000 0 min, ---- 1
Sterile air, sterilization 0230 0000 0 min, ---- 1
Steam barrier 0230 0000 0 min, ---- 1
Tube heater
GBCK0068
Parameter Operating
Level
Volume ml SP2a LCL1 LCH1 LCL2 LCH SPL SPH SP1b

2
200 460o 30o 30o 30o 30o 230o 460o 230o
250 480o 30o 30o 30o 30o 240o 480o 240o
500 625o 30o 30o 30o 30o 312o 625° 312o
1000 660o 30o 30 30o 30o 330o 660o 330o
a. SP2 = Set point during production

b. SP1 = Set point during sterilizing, cooling and stop longer than 3 minutes
372

MM 901-3 2(4) 9601 TBA/3 600V
Setting Data
LS sealing
GBCKAA02
Parameter Operating
Level
Volume ml SP2 LCL1 LCH1 LCL2 LCH2 SPL SPH SP1
250, 200 ---- 20o 20o ---- ---- 200o 350o 220°
1000, 500 ---- 20o 20o ---- ---- 200o 350o 240°
SA sealing
GBCKAA03
Parameter Operating
Level
250, 200 ---- 20o 20o ---- ---- 200o 350o 270o-290°
500 ---- 20o 20o ---- ---- 200o 350o 280°-300o
1000 ---- 20o 20o ---- ---- 200o 350o 300o-320°
Sterile air, air superheater

GBCK0065
Parameter Operating
Level
1000 - 200 ---- 20o 20o ---- ---- 335o 365o 335o-365°
373

TBA/3 600V 9601 MM 901-3 3(4)
Setting Data
C
A Sterile air, sterilization
B
GBABAA56
Parameter Operating
Level
1000 - 200 ---- 1 30o ---- ---- 280o 281o 280°
Steam barrier
GBCK0064
Parameter Operating
Level
Volume ml SP2 LCL1 LCH LCL2 LCH2 SPL SPH SP1

1
1000 - 200 ---- 1o 20o ---- ---- 0o 135o 125°
374

MM 901-3 4(4) 9601 TBA/3 600V
Lubricant Recommendation
The table below lists only a selection of lubricants Lubricant specifications may be ordered from
with their respective designations. Comparable Technical Standardization, AB Tetra Pak,
lubricants from other suppliers may be selected Ruben Rausings gata
with the aid of the lubricant specifications S-221 86 Lund
(document No in the table). Sweden
Lubricant Document No Material No Part No (used Example
Code (internal TP when ordering
Supplier Product designation
designation for from
material type) Tetra Pak)
A
Motor Oil M 1251.122 51122-85 90 296-28 BP Energol HD 20W-30
ESSO Essolube XD-3
Statoil PowerWay D4/
DieselWay D2
Mobil HD 20W-30
Shell Shell X-100 20W-30
E
Compounded M 1254.922 54922-460 90 296-77 BP Energol AC-C460
cylinder oil 90 296-2 ESSO Cylesso TK 460
Statoil CylWay FZ 460
Mobil 600W super Cylinder Oil
Shell Valvata Oil J460
F
Lithium, grease EP M 1255.115 55115-20 90 296-68 BP Energrease LS EP 2 Grease
type XRB 2EP
ESSO Esso MP Grease/ Beacon
Statoil EP 2
Mobil UniWay EP 2N
Shell Mobillux EP 2
Calithia EP Grease T 2
Grease 1344 LiEP 2
H
Highpressure oil M 1254.322 54322-320 90 296-75 BP Energol GR-XP 320
ESSO Spartan EP 320
Statoil LoadWay EP 320
Mobil Mobilgear 632
Shell Omala oil 320
54322-220 90 296-73 BP Energol GR-XP 220
90 296-78 ESSO Spartan EP 220
For use in production plant Statoil LoadWay EP 220
with start temperature below Mobil Mobilgear 630
5oC Shell Omala oil 220
K
Circulation oil M 1254.942 54942-100 90 296-15 BP Energol CS 100
ESSO Teresso 100
Statoil TubeWay 100
Mobil DTE Oil Heavy
Shell Tellus OIl 100
L
Silicon grease M 1255.322 55322-30 90 296-9 Dow Dow Corning 7 Compound
Klüber Unisilikon L 250 L
Q
FTPE M 1255.622 55622-20 90 296-91 Sikema Fluolub 175
Lubricating grease
375

TBA/3 600V 9510 MM 940-2 1(2)
Lubricant Recommendation
Lubrication Chart
11
10
9
1
1 7
5 4 3
8 2 6 GBAAOA70
Lubrication code
Monthly
Weekly
Yearly
Daily
Pos Description
1 Hydraulic system K C E C Check

2 Lubrication system H C E E Change
3 Bevel gear A C E L Lubricate
4 Indexing device A C E
5 Worm gear E C E
6 Safety clutch F L
7 Distance shaft F L
8 Cutting knife spring F L
9 Main shaft F L
10 Sterile air valve Q L
11 Product valve Q L
376

MM 940-2 2(2) 9510 TBA/3 600V
Templates/Tools
Templates
Ordering N0.
Intended for MM ( Volume in brackets) Fig
LS 116-53 552525-0101
(1000-500)
552525-0103 (300)
552525-0102
(284-180)
Link rod 321-53 74282

measurement 237.5
Folding flap cam 423-52 72374-0101
Tube support rollers 443-52 74972-0101

(1000-500)
74972-0103
(250-200)
74972-0104
(1000-200)
377

TBA/3 600V 9510 MM 980-1 1(6)
Templates/Tools
Templates
Ordering N0.
Jaw gap 116.7 446-12 72847
Spring 446-12 72889-0101
Spring 446-12 72846-0101
Flap sealing
Top 504-53 72802-2 (1000-500)
72802-4 (250-200)
Bottom 504-53 544738 (1000-500)
544739 (250-200)
Pressure unit 524-51 72839 (88 mm)

pressure plate 74806 (68 mm)
378

MM 980-1 2(6) 9510 TBA/3 600V
Templates/Tools
Tools
Ordering N0.
AP valve, 127-31 449969-010V

pneumatic/cylinder
Filling tube, 136-11 74767-0102

pressure roller (74912+74767-0101)
Squee-gee roller, 184-11 74767-0101

force
Upper driven 155-52 90243-0105

bending roller,
tachometer
Rotor water ring 160-32 74305-0101

compressor, puller
Cam unit, cradle for 331-23 74514-0101

cam replacement
Cam unit, hoist 331-23 74956-0101

support and hoist
379

TBA/3 600V 9510 MM 980-1 3(6)
Templates/Tools
Tools
Ordering N0.
Cam unit, position
gauge 331-23 27627
Pressure jaw, 407-31 75023-0101

bushing
replacement
Stroke, measuring 455-53 74652-0101

point clamp
Jaw pressure, 464-11 75152-0101

complete tool
Tube support 475-62 74387

rollers, key
Station chain, 530-21 20990

tension rod
380

MM 980-1 4(6) 9404 TBA/3 600V
Templates/Tools
Tools
Ordering N0.
Station chain 530-31 73377

bushings, punch 530-32
Flow meter for B- 215-12 230665-0101

machines with
circulating cooling
water. Is to be
connected in the
valve panel.
Crease wheel 276 See order No on

page 276-52 4(4)
Shaft 273 533460

parallelling
Ink unit, 274 440094

level check
Ink unit 274 434448

275
381

TBA/3 600V 9404 MM 980-1 5(6)
Templates/Tools
Tools
Ordering N0.
Printing wheel 275 293692
Printing wheel 273 434841

274
275
Printing wheel, C- 275 458492

spanner
Printing wheel, 275 522023

printing insert
holder
382

MM 980-1 6(6) 9510 TBA/3 600V
Templates/Tool
Description/reference Part No Quantity
Pump 90278-0001 1
Oil can 90279-0001 1
Brass wire brush 776422-0101 2
Screwdriver 777100-0113 1
Screwdriver 777100-0184 1
Open spanner 777120-0215 2
Allen key N=2.5 777150-0100 2
Allen key N=3 777150-0101 2
Allen key N=4 777150-0104 2
Allen key N=5 777150-0106 2
Allen key N=6 777150-0108 2
Allen key N=8 777150-0110 2
Allen key N=10 777150-0112 2
Allen key N=12 777150-0114 2
Allen key N=1.3 777150-0491 2
Allen key N=1/16" 777150-0492 2
C-spanner 777200-0101 1
Scissors 777510-0101 1
Whisk 33634 1
Whisk 36430 1
Lifting block 25817 2
Tie rod 20990 2
Position gauge 27627 1
Gauge 70540 1
C-spanner 72947 1
Key 74387 1
Lifting eye bolt LTM30FZB 318301-0130 4
Bracket 449970 1
Spindle 449971 1
Stop screw P6SS12X70FZB 312306-0546 1
Flange bush 18F7X12 321101-0222 1
383

TBA/3 600V 9510 MM 981-1 1(1)
Induction Heating/ Electrical Equipment
Name Issue Page
Safety precautions 9510
Important information TPIH 9510 1001-71
General description 9510 1001-71
Instrument and tools 9510 1001-71
Trouble shooting 9510

LED display 9510 1003-71
TPIH pulse duration 9510

Checking 9510 1004-21
Setting 9510 1004-31
Cables 9510
Checking 9510 1005-11
Removal 9510 1005-21
TPIH test instrument 9510

General 9510 1006-71
Test instrument TP No 68466-0101 9510 1006-71
TPIH power 9510

Setting 9510 1007-51
Final setting 9510 1007-51
Generator 9510
Removal 9510 1008-21
Ge Fanuc 9510
Degree setting 9510 1009-11
Battery Checking /Replacement 9510 1009-21
Temperature regulators 9604

Installation and access to instrument levels 9604 1010-51
385

TBA/3 600V 9510 MM 1000 1(1)
Safety precautions
Important information TPIH
The pulse duration is controlled by the PLC
WARNING! (GeFanuc) program
High voltage!
three phase 400/220 V, one phase 220 V and 24 V
The TPIH generator must not be opened. May
cause shock, burns or even death. In case of DC are needed to the generator.
accident, immediately call for medical advice.
Instrument and tools
General description The TPIH Test Instrument (68462-0101) is
TPIH generators can be used for: described on page MM 1006-71
• TS (Transversal Sealing). If a generator is to be replaced, make sure that the

three phase 400/230 V and the 230 V voltage are
• ZH (Zone Heater, extra equipment).
switched off before removal of the TPIH
Each TPIH system contains: generator!
• one generator, Nobody, is allowed to open the TPIH generator.
• one impedance transformer (5),
• one inductor (4),
• one coaxial cable (6),
• one current rail (3),
• one potentiometer (1) for power adjustment.
1
Potentiometer for power adjustment
2
TPIH Generator
3
Current rail
4
Inductor
5
Impedance transformer
6
Coaxial cable
7
400/220 V and 220 V
8
24 V DC
9
Control signals to and from PLC
(GeFanuc))
10 LED Display
387

TBA/3 600V 9510 MM 1001-71 1(1)
Trouble shooting
LED display
(1) Control voltage on (green) (6) Output voltage low (red)
230V is connected - alarms are enabled. Note that If this is the only red LED that has lit up:
this does not check three phase 400/230V to the
• the potentiometer is broken or defective
power supply.
• the +10 V DC to the potentiometer is missing,
or
(2) Output on (green)
• the potentiometer setting is below the minimum
Lights up when a pulse is transmitted from the value of 350.
generator into a proper load - the entire generator
• the generator is faulty and must be replaced
system is operating perfectly.
Before replacing the generator, check the
potentiometer setting and the presence of 10 V DC
(3) Load error (red) across the potentiometer. Also establish that the
The generator is unable to transmit a pulse due to output voltage from the potentiometer follows the
faulty load caused by: movement of the slider via the knob.
• short circuit in coaxial cable, flexible cable,
inductor or impedance transformer,
• open circuit in coaxial cable, flexible cable,
inductor or impedance transformer,
• no pressure applied to the inductor,
• wrong type of impedance transformer, or
• wrong type of inductor installed.
(4) Temperature high (red)

• the cooling fan inside the generator is not
working,
• the ambient temperature is above 50°C.
Replace the generator if the fan does not operate.
(5) Mains voltage low (red)

at least one of the three phases is below 85% of
nominal value and as a consequence the generator
is not able to deliver the proper output power.
Check the mains supply for any possible open 1) Control voltage on
fuse. If all three fuses are intact, the problem will 2) Output on
disappear when the voltage rises above 85% again.
3) Load error
4) Temperature high
5) Mains voltage low
6) Output voltage low
389

TBA/3 600V 9510 MM 1003-71 1(1)
TPIH pulse duration
Checking
Since the pulse duration is determined by the PLC
(GeFanuc) program, the only necessary adjustment
is the power setting via the potentiometer.
If, however, there is a reason for checking the
actual pulse duration, this can be done with the
TPIH test instrument (68462-0101) or TP102
Pulse Time Counter.
391

TBA/3 600V 9510 MM 1004-21 1(2)
TPIH pulse duration
Setting
The output power level is not affected by mains
voltage fluctuation between 85% and 110%. Use
the TPIH Test Instrument (68462-0101) to check
the HF voltage as described on page MM 1006-71.
An external potentiometer is used to adjust the
power level. A DC voltage is applied to the
generator via the potentiometer. The IH voltage
from the generator directly follows the
potentiometer setting, e.g. a setting of 500
corresponds to 50% of maximum IH voltage, 900
to 90%, etc. Settings below 350 give the alarm
Output voltage low.
This is only adjustment for the IH generator
system.
392

MM 1004-31 2(2) 9510 TBA/3 600V
Cables
Checking
TPIH
Check the following details for wear and/or
damage:
• the contact rails (1); make sure that there are no
signs of moisture. Clean as required
• the coaxial cables (2); make sure that the cables
are flexible
• the coaxial connectors (3); make sure there is
no moisture
• the other connectors
• the rubber gasket (4) in the male connector;
make sure that it seals properly between the two
coupling halves (5) and (6) (it should not be
possible to turn the male connector easily). If
required, replace the impedance transformer
Replace as required.
1) Contact rail
2) coaxial cable
3) Coaxial connector
4) Rubber gasket
5) Male contact
6) Female contact
393

TBA/3 600V 9510 MM 1005-11 1(2)
Cables
Removal
a) Undo the screws (1) and remove the cramp.
b) Remove the coaxial cable from the impedance
transformer.
c) Undo the screws and remove the plate (2).
d) Remove the busbar (3).
e) Undo the screw (4) and remove the transformer.
f) Reassemble in reverse order.
1) Screw
2) Plate
3) Bus bar
4) Screw
394

MM 1005-21 2(2) 9510 TBA/3 600V
TPIH test instrument
General
The TPIH test instrument, TP No. 68462-0101 is The results of these measurements can be used to
used to check the available output power from the compute the available HF power.
TPIH generator as well as condition of the coaxial
The instrument should simplify the work, when
cable, the impedance transformer, the current rail
trying to locate the origin of a problem.
and the inductor.
One 9 V battery is used for the instrument and an
The instrument is connected in series with the
automatic power-off function is used to minimize
coaxial cable from the generator.
the battery consumption.
Note!
A test outlet permits connection of a printer, such
Stop the machine to prevent the generator from
as a Brush recorder. Print-outs of the HF voltage,
pulsing, when the instrument shall be connected or
HF-current and the phase shift as a function of
disconnected.
time are possible.
The instrument can be used for direct The instrument kit contains complete operating
measurement of the following parameters: instructions as well as a printer cable and battery
• HF voltage eliminator.
• HF current
• phase angle between voltage and current
• pulse duration
Test instrument TP No. 68462
395

TBA/3 600V 9510 MM 1006-71 1(2)
TPIH test instrument
Test instrument TP No 68466-0101
The test equipment is used at a service station to The test procedure includes:
check the performance of a sealed IH-unit to verify
• Low power test.
if the unit is operational or if it must be sent to a
service-shop for repair. It is also possible to verify • Test of “Output voltage low”-indication.
if an impedance transformer is operational or not. • Test of normal operation.
• Measurement of maximum available output
WARNING! power.
The test equipment must never be connected • Test of “Mains voltage low”--indication.
to an open TPIH generator. The incoming 400 V
• Test of “Load error”-indication.
leads are accessible inside the generator and
contact with them can be hazardous! • Test of the complete system.
Please observe that if an IH-generator is faulty, it

must be sent to an approved service-shop.
The test equipment can be used to:
• Verify that the maximum output power from the
generator is between 280 and 2000W at a
frequency of a 500 khz.
• Verify that the output power is unaffected by
mains voltage variations between 85% and
110% of the nominal value.
• Check that the generator detects an open or a
shorted load.
• Check if a problem is caused by the generator,
the impedance transformer, the inductor or the
interconnecting cables.
• Make operation tests.
• Show the operation of the IH-system
Test instrument TP No 68466-0101
396

MM 1006-71 2(2) 9510 TBA/3 600V
TPIH power
Setting
The power for the TS-sealing unit is set with the
potentiometer (1) in the electrical cabinet. The
power can be set in any machine step.
Basic setting
Set power for the sealing unit with the
potentiometer (1), see table below
Volume, ml Value
1000 810
500 810
250 810
200 810
Final setting 1) Potentiometer

Evaluate the TS sealing, see the OM-book. If
required, make futher adjustments on the
potentiometer.
397

TBA/3 600V 9510 MM 1007-51 1(2)
TPIH power
Basic setting
The power for the Zone heater unit is set with the
potentiometer in the electrical cabinet according to
the table below.
Volume, ml Value
1000 900
500 900
250 900
200 900
Final setting
Evaluate the zone use a Zonoscope. If required,
make further adjustments on the potentiometer
1 Potentiometer
3 Zonoscope TP No. 90243-0170
398

MM 1007-51 2(2) 9510 TBA/3 600V
Generator
Removal
a) Make sure that the main power switch of the
machine is in position off and that it has been
padlocked.
b) Undo connectors X1 and X2 (2)
c) Undo the coaxial connector (3).
d) Loosen the screw (1) and pull out the generator.
WARNING!
High voltage. do not open the generator.
Send the generator to the nearest service center
for cleaning or service.
1) Screw
2) Connectors X1 and X2
3) Coaxial connector
399

TBA/3 600V 9510 MM 1008-21 1(1)
Ge Fanuc
Degree setting
Crank the machine to degree setting 08. Check that
the display (3) display 0.
Crank to degree setting 2528 (octal degrees).
If required, adjust the angle encoder:
Loosen the screws (2) and turn the angle encoder.
2 Screw
3 Display
401

TBA/3 600V 9510 MM 1009-11 1(2)
Ge Fanuc
Battery Checking /Replacement
If the BATT LED on the power supply turns ON
and the battery alarm on the alarm panel lit up,
replace the battery. A battery may be removed and
new one installed with the baseplate powered on.
To replace a battery, use the following procedure:
• Remove the battery cover at the bottom of the
faceplate.
• Remove the battery from its mounting clip.
• Firmly insert the replacement battery into the
battery mounting clip.
• Remove the old battery cable connector from its
receptacle and discard the old battery.
• With the needle nose pliers, push the new
battery connector firmly into one of the
receptacles on the board. The new battery
must be replaced within 20 minutes of
removing the old battery to ensure that the
contents of RAM memory will be retained if
a loss-of-power should occur.
• Replace the module faceplate cover.
1 Battery
2 Battery cable connector
402

MM 1009-21 2(2) 9510 TBA/3 600V
Temperature regulators
1002-51
Installation and access to instrument levels

After TIME-OUT = Changes are effective
E = end of access
403

TBA/3 600V 9604 MM 1010-51 1(3)
Basic setting
Note! (Cont’d)
If any setting is not possible to achieve it is
probably due to limitations set by SPL and SPH in
the parameter level. This is remedied by changing
the limitations SPL/SPH. LOC must be set to 0.
(see instruction for parameter level.)
Setting
The temperature setting SP1 is carried out in the
operating level. The actual temperature is
displayed in process value (3). Set the correct
temperature value in set value SP1 (4) by pressing
increase value (6) or decrease value (7). See table
page 901-3 2(4).
Step up to the parameter level by pressing the

selector key (5) for three seconds. The parameter
symbols can be changed by pressing the selector
key. Step to parameter Loc and set the value to
“0”.
Step up to the configuration level by pressing the
selector key for five seconds. After transition to
configuration level, Con l and the configuration
code are displayed. For correct code, see table
page 901-3 2(4)
After checking/adjusting the configuration code,
and pressing the selector key once more, Con 2
and a new configuration code are displayed.
Check/adjust for correct code.
Press the selector key for transition to the
operating level. Step up to the parameter level, and
set the correct value. See table page 901-3 2(4).
Repeat the setting for all parameters, except the
parameter “LOC”. When all settings are correct,
wait for 30 seconds to return to the operating level.
In this mode the low temperature is programmed.
See table page 901-3 2(4).
• Step up the machine to Sterilizing when
selftuning the regulator for the tube heater.
• Remaining regulators for LS, SA and Air
superheater can be selftuned in step Preheating.
404

MM 1010-51 2(3) 9604 TBA/3 600V
(Cont’d)
SELFTUNING
Press the selector key and increase value button 1 Heating
simultaneously for self tuning start. Process value 2 Without function
and code AdA are displayed alternately in the 3 Process value
upper display line. After successful tuning, 4 1:st set point /W2 lit = 2:nd set point
maximum 10 minutes, code AdA disappears and 5 Selector key
the actual process value is displayed. 6 Increase value
7 Decrease value
If successful tuning is prevented due to faults in
8 Heating current alarm (red LED)
the control loop during start or tuning, the latter is
9 Temperature within limits (green LED)
cancelled and AdF is displayed (error signal), if
10 2:nd set point (W2)
error, repeat selftuning
Finally
Step up to the parameter level, and change the
value of parameter Loc to “1”. Return to the
operating level by pressing the selector key, or
wait for 30 seconds. Now the controller works
with the new parameter values.
Error signals
In case of an error, an error signal instead of the
process value is displayed in upper display line,
until an error is acknowledged, or until its cause is
eliminated. With range monitoring, the sensor
error is displayed until eliminated.
The following error signals can be displayed:
Display Cause
FbF Sensor break
POL Wrong sensor polarity
AdF Self-tuning error
Maintenance/action in case of problem

The temperature regulators do not require any
maintenance. In case of problems, check that all
connections are in correct conditions.
Replace the temperature regulator with a new one
if necessary and repeat the configuration.
405

TBA/3 600V 9604 MM 1010-51 3(3)

MM-80249-0104 TBA3

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MM

Series No/ Machine No Sign.

TBA/3 Drive Unit 300

Final Folder 500

Issue 9906 Setting Data Lubricants 900

Tetra Brik Packaging Systems Induction Heating/ Elec- 1000

Document information 9508 001

Hydrogen Peroxide Storage 9508 002-1

Example of Warning Text on

Hydraulic Oil, Lubricants, Acids,

Hearing protection 9508 002-1

Doc No MM-80249-0104 Issue

contacting Tetra Pak concerning this particular Machine No. XXXXX/XXXX

health and safety regulations of the European Lund Sweden

Econimic Area (EEA) Year of manufacture 199X

Doc No MM-80249-0104 Issue

Issue Doc No MM-80249-

HANDLING OF STERILISATION LIQUID

much water as possible. For this reason, always

1 Safety glasses (TP No 779130-102)

Doc No MM-80249-0104 Issue

before they are worn again- If skin burns

– Make sure that areas or rooms for handling

Issue Doc No MM-80249-

Hydrogen peroxide must be stored in the original

Doc No MM-80249-0104 Issue

Causes burns. Contact with combustible materials

Keep in a cool place away from sources of heat.

Wear suitable protective clothing, gloves, and eye/

After contact with skin, wash immediately with

In case of contact with eyes, rinse immediately

In case of spillage or fire, drench with water.

Issue Doc No MM-80249-

Always wear ear protectors when the machine is

Doc No MM-80249-0104 Issue

SA, Pressure and Counter Rollers 9508

Replacing the Teflon Sleeve 9508 103-31

SA, Guards and Brake 9510 105-12

Supply Guard 9510 105-12

Broken Strip Guard 9510 105-12

Finger Brake 9510 105-12

Roller Brake 9510 105-12

SA, Strip Guide 9508

Overhaul 9508 115-32

SA/LS Heating 9510

SA/LS element 9508

Reassemble 9508 124-21

Doc No MM-80249-0104 Issue

Support plate on LS element 9508 124-31

Product(AP) Valve 9508

Replacement of seals and membranes

Filling tube 9508

Assembly 9508 134-12

Distance A 9508 136-11

Alignment 9508 136-11

Pressure roller force, tool 74767-102 9508 136-11

Adjustment 9508 136-11

Lower forming ring 9508

Lower forming ring, support roller 9508