Form: MT3C-CVR5/04 © 2004 Alcoa CSI ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS -- Table of Contents -PAGE Table of Contents ................................ 1 PAGE Parts Cleaning and Inspection ......... 29 Scope ................................................... 3 • Scope ...................................................... 29 • Required Tools and Materials ................. 29 • Safety Precautions.................................. 29 • Cleaning .................................................. 29 • Inspection ............................................... 30 Tools and Materials .............................. 4 Headset Assembly ............................ 31 Safety ................................................... 2 Introduction ......................................... 3 Adjustment Procedures ..................... 5 • Top Load ................................................... 5 • Torque ....................................................... 7 • Torque Calibration .................................... 9 • Head Rise ...............................................11 • Scope ...................................................... 31 • Required Tools and Materials ................. 31 • Safety Precautions.................................. 32 • Headset Assembly .................................. 32 Illustrated Parts List ......................... 35 • Scope ...................................................... 13 • Required Tools and Materials ................. 13 • Safety Precautions .................................. 13 • Inspection Procedures ............................ 13 • Parts List (for 1-1/4" spindle size) .......... 35 • Recommended Spare Parts Kit List ....... 35 • Rebuild Kit Parts List ............................. 35 • Service Tools Parts List .......................... 35 • Headset Cross-Section Drawing ............ 36 • Headset Exploded View Drawing .......... 37 Lubrication ........................................ 16 Bearing Inspection ............................ 38 Inspection Procedures ..................... 13 • Scope ...................................................... 16 • Required Tools and Materials ................. 16 • Safety Precautions .................................. 16 • Lubrication Procedures .......................... 16 Parts Ordering Information .............. 39 Glossary of Terms ............................. 40 Index ................................................... 41 Maintenance Procedures .................. 18 • Introduction ............................................. 18 • Maintenance Schedules .......................... 18 • Daily (Eight-Hour) Maintenance ............ 18 • 4000-Hour* Maintenance ....................... 19 • Chuck Maintenance ................................ 22 Disassembly Procedures ................. 23 * NOTE: The 4000-hour headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. • Headset Removal ................................... 23 • Headset Disassembly ............................. 25 • Bearing Replacement ............................. 28 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 1 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Safety Precautions The following safety rules must apply (in addition to your local rules) while operating, maintaining or repairing this equipment. Refer to your capping machine manual for complete information. Proper use of lockout/tagout devices will insure that power can’t be switched on during maintenance or repair work. • Only qualified personnel who are fully trained in all safety and machine functions should be assigned to operate or service this machine. • Approved safety glasses and safety shoes must be worn at all times when operating or repairing an Alcoa capping machine. Remove all jewelry! • Always turn off, lock-out and tag-out both electrical and pneumatic power to the machine before any maintenance or repair work is started. • Read and obey all warning stickers on the machine. • All personnel must know where the Emergency Stop buttons are located. • Push the Emergency Stop button before clearing jams. Operator Control Box on Turret Main Electrical Box • Make sure all guards are in place and in good condition at all times before the machine is powered up. Never run this capping machine with missing guards! • Before starting the capper, make sure all personnel are a safe distance away, then yell “CLEAR” in a loud voice to alert everyone in the vicinity that you are about to start the machine. • NEVER tie down, wire back, or electrically jumper out any safety switch. IMPORTANT! All personnel must know where the E-stop buttons are located in case of emergency! • Follow the appropriate OSHA hearing protection guidelines.* DANGER WARNING CAUTION Warning labels similar to the examples at right are typically found on the machine to alert the operator to safety hazards. HIGH VOLTAGE ! DE-ENERGIZE BEFORE SERVICING ! Page 2 DO NOT OPERATE EQUIPMENT UNLESS ALL GUARDS ARE IN PLACE ! TO PREVENT EYE INJURY, WEAR SAFETY GLASSES AT ALL TIMES ! ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Introduction The Alcoa MT3 Calibrated headset is used to apply plastic closures at the desired torque to bottles. The heart of this system is a magnetic clutch that applies a preset amount of torque. The torque applied is consistent from closure to closure over the prescribed maintenance interval. Figure 1 Headset Function The plastic closure is first placed in the headset chuck (or on the bottle) and the rotating headset screws the closure onto the bottle until it reaches the preset torque. The magnetic clutch starts slipping to control how tightly the closure is applied. The headset then rises and disengages from the closure, ready to start the process over again. Scope The purpose of this manual is to explain how to safely maintain the MT3 headset so that it properly applies bottle closures in a safe and efficient manner. This manual also details how to use the correct tools and materials to help obtain maximum value from the MT3 headset. MT3 Headset Chuck Closure (Cap) The manual is divided into sections and arranged in the order of likelihood that the information would be needed by the operator, setup or maintenance person. Thus, the adjustment, inspection and lubrication procedures are at the front of the manual and the parts information towards the back. NOTE: "Magna Torq" is a registered trademark of Aloca. Bottle ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 3 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS ALCOA MT3 HEADSET SERVICE TOOLS Table 1. Tools Required** Hex Key (3/16") Headset Fixture Hex Key (1/8") Hex Key (1/16") Bearing Lock Ring Wrench Adapter MT Standard Assembly Fixture Adjustable Spanner Wrench These tables show the tools and materials required for a bottler to properly maintain Alcoa MT3 headsets. Tool Kit 9200230690 (MT3) - Purchased from Alcoa. Part Number Description 8490124101 8490125101 8490127501 5160306000 5160304000 5160310000 5160313000 5225291000 Wrench, Bearing Lock Ring Fixture, MT Standard Assembly Fixture, MT3 Headset Adjustable Spanner (1/4" pin) Hex Key, 3/16" Hex Key, 1/8" Hex Key, 1/16" Tool Bag Qty. 1 1 1 1 1 1 1 1 Torque Measuring Tools - Supplied by bottler. See ordering information in this manual. TORQUE MEASURING TOOLS Chuck Adapter Tool Description Torque Meter Torque Wrench Chuck Adapter Calibrated MRA torque meter. Alcoa CSI part no. 715703. A tool with 1/4 square socket on one end that fits the torque wrench and teeth/knurls on the other end that engages the teeth/knurls in the chuck. See the closure supplier's specs. Wear Measuring Tools - Optional. Contact your local machine shop for specified services. Torque Wrench Tool Description Bore Gauge/Inside Micrometer Dial Indicator Outside Micrometer 1"-2" range. To measure upper housing wear. To measure hub & housing wear. 1"-2" and 2"-3" range. To measure mounting hub wear. Torque Meter Other Tools - Supplied by Bottler. WEAR MEASURING TOOLS – OPTIONAL Bore Gauge Dial Indicator Tool Description Allen Wrench Pliers & Screwdriver 3mm. To remove spiral ring. * Chuck wrench is not included in headset tool kit. Refer to the chuck list in the parts catalog section of your capping machine manual. Table 2. Materials Required* Outside Micrometers Material Description Anti-Seize Compound Clean Towels/Rags Cleaning Solution Never-Seez® NSWT-14, Mfg. Phone: 978-777-0100. For wiping parts. Clean filtered petroleum base commercial parts cleaning solvent. To prevent contamination. Lubriplate® FGL-2 Food Grade, Lubriplate Division, Fiske Brothers Refining. Phone 973-589-9150. Dow Corning 111 Silicon Grease, Phone: 1-800-637-5377 ex. 5377. To collect metal filings. For cleaning parts. Over 120°F (to rinse the headsets.) OTHER TOOLS Clean Workbench Grease Pliers Screwdriver Allen Wrenches Figure 2. Headset Tools Required **NOTE: Always use tools and materials specified by Alcoa. Substandard materials will not perform satisfactorily. Page 4 Grease Masking Tape Water and Soap Water, Hot ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures NOTE: The numbers shown in parentheses in the text correspond to item numbers in the exploded view illustration in the back of this manual. Top Load Scope If the top load is greater than required, the result will be application problems such as closure thread damage, under-applied (high) closures, cocked closures, split closures, “poker chip” closures, “smiley” tamper bands, broken or split tamper bands and removal torque variation. Excessive top load can and will cause the above problems due to a “forced meshing” of the bottle and closure threads. The meshing of the closure and bottle threads should occur while the cam is lowering the headset and the headset top load spring is collapsing. If the top load is set above recommended levels, or if the turret height is too low, the closure threads will be forced against the bottle threads. A variety of application problems can result from this. Top load typically should be set between 20 and 40 pounds. The goal is to set the top load as small as possible without allowing bottle rotation to occur. For most application purposes, the closure only requires 10 to 15 pounds of top load. The remaining top load is there solely to assist in halting bottle rotation. Setting of the the top load will depend upon the package being run and the closure design. Exact set-up parameters can be found on the Alcoa CSI Technical Bulletin for the specific Alcoa closure design you are using. If you are not using Alcoa CSI closures, please refer to the Closure Supplier's information. If additional top load is required, always re-check the head rise and/or the condition of the anti-rotation parts. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 5 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) NOTE: All of the top load values given in Figure 3 are obtained when the head rise is 0.200 inches. Refer to the Head Rise Adjustment procedure shown on page 13. Required Tools and Materials • 3/16" Hex Key, part number 516-0304-000. Safety Precautions WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO sequence. Failure to do so could result in serious personal injury or death. DANGER Figure 3. TOP LOAD /ADJUSTMENT COLLAR SETTING 0.8 COLLAR SETTING (IN.) 0.7 0.6 0.5 0.4 2 3 0.3 0.2 0.1 1 0.0 21 26 31 35 40 45 50 TOP LOAD (LBS.) NOTE: The light orange band represents variations between headsets. Top Load Adjustment Procedure 1. Adjust the top load using the following procedure and the graph shown in Figure 3. The graph is used to determine the “Desired Setting” as follows: a. Find the desired top load on the horizontal axis at “1.” b. Read vertically to the angled line at “2.” c. Read horizontally left to the vertical axis at “3” to determine the actual top load collar setting. Interpolate between the numbers as necessary. Page 6 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) Collar Lock Screw (14) Mounting Hub (5) Adjusting Collar (1) Top Load Setting 2. Adjust the headset top load (Figure 4) as follows: Figure 4 Adjusting Headset Top Load a. Loosen the top load adjusting collar locking screw (14) using the 3/16" hex key supplied with the MT3 Toolkit. b. Turn the top load adjusting collar (1) until it is located below the top of the mounting hub (5) to a height difference equal to the “Desired Setting,” as determined from Step 1. 3. Tighten the adjusting collar locking screw (14). Do not overtighten. CAUTION: Overtightening the adjusting collar locking screw could damage the adjusting collar! 4. Repeat Steps 2 and 3 for each headset. a. All headsets should be set to the same amount of top load. If this is not possible, re-check the head rise, the condition of the anti-rotation parts and sources of set-up height variation 5. Unlock and restore power to the capping machine. Static Torque These procedures describe how to adjust the headset to a specific static torque. Torque adjustment may be done with a torque wrench or torque meter. Static torque values should be set to within ± 0.5 in-lb across all headsets on the capping machine. Exact set-up parameters can be found on the Alcoa CSI Technical Bulletin for the specific Alcoa closure design you are using. If you are not using Alcoa closures, please refer to the Closure Supplier's information. If the recommended removal and incremental torque is not obtained, investigate further for causes such as worn bearing, bottle rotation, coatings on the finish, bottle dimensions, etc. Always check the static torque with a torque wrench or torque meter. Confirm that the readings from the torque meter agrees with the torque wrench. Do this for all torque meters in the facility to establish the validity of the torque data. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 7 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) Static Torque (cont'd) Some bottling lines run different types of closures that may also require different torque values. For instance, it may be necessary to frequently switch a line back and forth from 28 mm to 38 mm closures. Since the application torque is a critical part of the package quality, it must be correct for each individual head. Using the MRA Torque Meter Method Scope This procedure requires removal of the headset(s) from the capping machine. A properly calibrated torque meter is required. Safety Precautions DANGER WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO sequence. Failure to do so could result in serious personal injury or death. Required Tools and Materials • • • • Page 8 MRA Torque Meter. Spanner Wrench (1-3/4" fixed face), part number 516-0309-000. 1/8" Hex Key, part number 516-0310-000. 1/16" Hex Key, part number 516-0313-000. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) Torque Adjustment Procedure 1. Turn off and lockout/tagout power to the capping machine, then loosen the set screw (item 12) in the headset's lower housing (9) with the 1/8" hex key before attempting to change the torque. Lower Magnet Carrier Assembly 3. Turn Chuck Calibration Ring 1. Mount Headset 4. Read Torque MRA Torque Meter 2. Clamp Headset 2. To increase the torque, rotate the lower magnet carrier assembly (16) to the right (up) until the notch in the calibration ring lines up with the desired torque setting stamped on the headset's lower housing (9). To decrease the torque, rotate the lower magnet carrier to the left (down) until the notch in the calibration ring lines up with the desired torque setting. 3. Tighten the set screw (item 12) to 40 inlbs. to secure the desired setting. 4. Repeat this procedure (per Steps 1-3 above) for each remaining headset. Adjusting Collar Figure 5. Checking Torque with the MRA Torque Meter Torque Calibration Procedure 1. Remove the Alcoa MT3 headsets from the capping machine, using the Headset Removal procedure described later in this manual. (NOTE: It may be necessary on some capping machines to raise the turret or remove the back guide(s) when removing the headsets.) 2. Thread a chuck into the quill and check the existing torque by slowly turning the chuck clockwise by hand and observing the maximum reading on the torque meter scale. (It is normal for the chuck to “jump” from one position to the next, due to the magnetic clutch.) 3. If the measured torque output is 15 in-lbs, proceed to Step 4 below. If the measured torque is not 15 in-lbs, loosen the SHCS (12) that clamps the torque ring and turn the torque ring clockwise to increase torque or counter clockwise to decrease torque. Tighten the SHCS to 40 in-lb and check the torque. Repeat as needed to achieve 15 in-lb. Figure 6. Calibration Ring Removal 4. Remove the three flat head screws (13) holding the calibration ring (11) in place and turn the calibration ring until the notch in the ring lines up with the 15 in-lbs. line on the headset housing. Reinstall the three flat head screws. (NOTE: You may have to move the calibration ring slightly to install the screws; this will not greatly affect the calibrated torque setting.) ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 9 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) DANGER WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO sequence. Failure to do so could result in serious personal injury or death. Checking Headset Calibration with a Torque Wrench Adjusting Collar (1) This section describes how to check the torque calibration while the headsets are on the capping machine. A properly calibrated torque wrench is required. Top Load Spring (2) Lower Magnet Carrier Assy. (16) Required Tools and Materials • Torque Wrench, Alcoa PN #715703 • Chuck Adapter Chuck Chuck Adapter Check Procedure Torque Wrench 1. Jog the capping machine until the headset is in a position where the torque wrench (with the proper chuck adapter attached) can be firmly inserted into the chuck, and where the wrench may be turned far enough to check the torque. 2. Attach the chuck adapter to the torque wrench and firmly seat the adapter into the chuck. Measure the static torque by slowly turning the wrench counterclockwise (right hand threads) to simulate the movement of the chuck during the capping operation. Turn Figure 7. Checking Calibration with a Torque Wrench Turn the torque wrench as shown above and observe the needle value as the chuck jumps to the next position. (It's nomal for the headset's magnetic clutch to jump between positions as it reaches the pre-set torque.) Page 10 4. Watch the needle of the torque wrench and record the maximum value it reaches before the chuck jumps to the next position. If the reading does not match the current setting, the headset must be recalibrated per the calibration procedure covered earlier in this manual. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) Head Rise Scope This procedure, in conjunction with the top load adjustment procedure, sets the proper head rise in order to: Figure 8. Positioning the Headset to Adjust Head Rise. • Compensate for bottle height variations. • Apply adequate force to prevent the bottle from rotating. • Provide the proper thread engagement. Required Tools and Materials • Hand Tools used on capping machine. • Timing Plug and Closure. Adjustment Procedure 1. Raise the capping machine turret high enough to clear the timing plug. NOTE: The timing plug, not a bottle, must always be used for this procedure. 2. Place the timing plug, with a closure on top, into a pocket of the bottle control parts. 3. Rotate the capping machine turret into position so that the headset is in the full down position of the cam profile and resting on top of the closure and timing plug. (IMPORTANT! The proper timing plug and closure must always be used for this procedure. Never use a bottle!) ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 11 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Adjustment Procedures (cont'd) DANGER WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO sequence. Failure to do so could result in serious personal injury or death. 4. Adjust the turret down (or up) until the top edge of the upper housing (4) lines up with the scribe line on the mounting hub (5). See photo below. NOTE: The lockout procedure still applies for this procedure! 5. Lock the turret and clear the capping machine according to the operating instructions in your capping machine manual. Mounting Hub (5) Top Load Spring (2) Scribe Line on Mounting Hub Upper Housing (4) Spindle Shaft Adjusting Collar (1) Head Rise Note: The headset will be compressed between the timing plug and turret when the turret is lowered. The total movement is called the head rise. Figure 9. Head Rise Page 12 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Inspection Procedures Scope This section describes how to inspect the critical parts necessary to ensure the proper functioning of the headset. Safety Precautions DANGER WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO process. Failure to do so could result in serious personal injury or death. Knockout Sleeve Spindle Shaft Knockout Sleeve Pin Required Tools and Materials Pull Down and Release • Bore Gauge or Inside Micrometer, 1 to 2 inch range. • Dial Indicator to measure hub and housing wear. Inspection Procedures Bearing The bearing (8) must be replaced at each 4000-hr.* maintenance interval. Should you wish to inspect the bearing between rebuilds, the procedure can be found at the back of this manual. Knockout Spring For Series 200 capping machines: Figure 10. Inspecting the Knockout Sleeve 1.Remove the rear turret cover. 2.Grasp the knockout sleeve, pull down until the pin reaches the bottom of the slot in the spindle and release. If it doesn‘t return to the top of the slot, the spring is broken and must be replaced. * NOTE: The 4000-hour headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 13 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Inspection Procedures (cont'd) Chuck Assembly 1. Check the chuck detents, chuck teeth and rubber o-ring to make sure they are clean and in good condition. The chuck teeth must be closely examined for excessive wear and the o-ring checked carefully for stress cracks at the chuck detent locations. Replace the o-ring if any stress cracks are found. O-Ring Chuck Detent Chuck Teeth Figure 11. Chuck Inspection 2.010” Min Mounting Hub (1) 2. Check to be sure the chuck detents move freely. Mounting Hub 1. M in 74 6” Drive Pin (20) Figure 12. Inspecting for Mounting Hub Wear 1.757" Max. Upper Housing (6) Figure 13. Inspecting for Upper Housing Wear Spindle Shaft Push and Hold (10 lbs. of force) Turret Center Line Lower Housing (9) Measure 0.060″ Max. 1. Measure the outside diameter of the mounting hub (1). If the OD of the mounting hub is less than 1.746 inches, it must be replaced. 2. Place two new drive pins (3) in position on the mounting hub (5), and measure across the two pins. If the dimension is less than 2.010 inches, replace the mounting hub. Upper Housing 1. Measure the bore diameter. If it is greater than 1.757 inches, replace the upper housing (4). Mounting Hub and Upper Housing Check for wear between the mounting hub (5) and the upper housing (4) while the headset is still on the capping machine by moving the headset side to side as described in the three step method below: 1. Place a dial indicator on the capping machine and secure it in a way to measure in/out play of the headset at the bottom end of the lower housing (9). 2. Remove play in the spindle by grasping it just above the headset and pushing in with approx. 10 pounds of force. Push Pull Figure 14. Inspecting for Wear Between Mounting Hub and Upper Housing Page 14 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Inspection Procedures (cont'd) Adjusting Collar (1) Retaining Clip (15) Collar Locking Screw (14) Mounting Hub (5) Upper Housing (4) Scribe Mark on Mounting Hub (5) Top Load Spring (2) Lower Housing (9) Spanner Wrench Slot Set Screw (12) 3. Push the bottom of the headset in and out in the direction of the indicator point while pushing on the spindle. Note the movement of the headset at the bottom of the lower housing (9). Total movement must not exceed .060"; if it does, check the upper housing and mounting hub for wear and replace if wear specifications are exceeded. Upper and Lower Housing 1. Check and see if the upper housing (4) and lower housing (9) are tight and flush with each other. They should be tightened to at least 20 ft-lb. Adjusting Collar 1. Check to be sure the collar locking screw (14) is tight, but not overly tight. Lower Magnet Carrier (16) Notch in Calibration Ring (11) Figure 15. Inspecting the MT3 Headset ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 15 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Lubrication Requirements Scope This section defines and describes each point that requires lubrication. It also specifies what type of lubricants to use and describes how to apply them. The procedure should be done with the headset removed from the capping machine. Required Tools and Materials • Lubrication Points Diagram, see Figure 16. • Anti-Seize Compound and Grease; see Glossary for grease information. Safety Precautions CAUTION: When performing these procedures, always follow your established plant safety processes. Safety glasses are required! Lubrication Procedure NOTE: The step numbers below refer to the item numbers on the Lubrication Points Diagram (Figure 16). The numbers in parentheses refer to the exploded view drawing that can be found in the Parts List section of this manual. Applying Anti-Seize Compound A1. Apply anti-seize compound to the collar locking screw (14) threads. A2. Apply anti-seize compound to the mounting hub inside bore and threads (5). A3. Apply anti-seize compound to the set screw (12), chuck threads and the three flat head screws (13) that fasten the calibration ring (11). Applying Grease G4. Apply a light coat of FGL-2 grease to the upper housing (4) drive pin pockets. G5. Pack the grease reservoir groove full of FGL-2 grease on the inside bore of the upper housing (4). G6. Apply a light coat of FGL-2 grease to the mounting hub drive pin pockets (5). G7. Place the quad-ring (10) into its retaining groove on the inside diameter of the upper housing. Don't pack the seal with grease; it needs room to move. G8. Coat the adjusting collar (1) threads and mating threads with FGL-2 grease. G9. Apply a light coat of FGL-2 grease to the outside diameter of the mounting hub (5) and the inside diameter of the upper housing (4). G10. Apply a light coat of Dow Corning 111 grease to all inside surfaces, including threads, of the lower housing (9). G11. Apply a light coat of Dow Corning 111 silicone grease to the upper and lower seals (items 6 & 21) and ball bearing (8) outside surfaces. G12. Apply a coat of FGL-2 grease to both diameters where the quill (19) matches up with the magnet carrier assembly (16). Page 16 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Lubrication Requirements (cont'd) Refer to the lubrication procedure on page 17 for a step-by-step description. Figure 16. MT3 Headset Lubrication Points Diagram ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 17 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Maintenance Procedures Introduction The Alcoa MT3 Calibrated headset is engineered with advanced features and built with high quality materials held to close tolerances. The level of service and performance each MT3 headset will provide, however, is directly dependent upon the care and maintenance it receives from the end-user. This section gives a detailed maintenance schedule and step by step maintenance procedures. Carefully following the schedules and procedures will pay big dividends in terms of performance and life of the headset and its components. When performing maintenance and replacing worn parts, always use Alcoa parts and materials. Replacing components with non-Alcoa parts may not provide desirable results because they may not meet the required quality standards. Refer to the Parts Specification chart in the back of this manual for quality requirements. Maintenance Schedules Two types of maintenance schedules are recommended for the headset. As shown below, a daily, or eight-hour, schedule is recommended to clean the system, while a complete disassembly, inspection, and cleaning is recommended for every 4000 hours* of operation. Thus, the daily (eight-hour) maintenance procedure consists of flushing (not spraying) all headsets with water hotter than 120°F, but less than 200° F. The more extensive 4000-hour* maintenance procedure consists of a complete disassembly, cleaning and inspection for mounting hub and upper housing wear or damage. It also includes replacing the quad-ring, drive pins, bearing, o-ring, upper and lower seals and lubricating the proper areas with grease and anti-seize compound. Daily (Eight-Hour) Maintenance Scope A clean headset is the first step to proper closure application, trouble free operation, and longevity. For proper performance, the headset should be free of dust, dirt, oil, glass and plastic fragments, and other foreign materials. The product that is being packaged is also a source of contamination to the headset. Sugars, syrups, juices, and other types of products left on the headsets and the working parts can prevent proper closure application and cause excessive wear or sticking. Consistent application torque requires that the bearing rotate freely and not be hampered by foreign materials and other types of contamination or damage. The bearing, chuck pins and other working parts of the headset must be kept clean to ensure proper headset performance. * NOTE: The 4000-hour headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. Page 18 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Maintenance Procedures (cont'd) Daily cleaning of the headset with hot water MUST be performed in order to insure easy movement of the magnet carrier assembly (19). Daily cleaning of the headsets also influences the overall quality of the package, cost of operation and life of the headset. Flush the headsets at least once each day or each shift with hot water. IMPORTANT! Do not use pressurized spray equipment because MT3 headsets should not be sprayed with water under pressure. Required Tools and Materials • Hot Water, temperature between 120°F and 200°F Safety Precautions WARNING! Never attempt these procedures without proper training! Read and obey the Alcoa safety precautions in your capping machine manual, follow your established plant safety processes and wear safety glasses at all times. Failure to do so could result in serious personal injury up to and including death. Daily Maintenance Procedure This procedure assumes the headsets are mounted on the capping machine. Turning on the capping machine will facilitate flushing of all headsets from different angles. * NOTE: The 4000 hr. headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. 1. Clear the capping machine of all bottles. 2. Keep the capping machine running. 3. Flush all of the headsets with hot water (between 120°F and 200°F) while the turret is rotating. Pay particular attention to the mounting hub OD and inside the top load spring (2). Product build up in these areas can make the mounting hub (5) and magnet carrier (19) hard to move. Do not use pressurized spray equipment because the headsets should not be sprayed with water under pressure. 4. After flushing, inspect to make sure the chuck interior and chuck pins are clean. 4000-Hour* Maintenance Scope To make sure that a package is sealed securely, the capping machine must properly screw the closure onto the bottle and apply the precise amount of torque. The MT3 headset has been specially designed to perform this difficult and critical operation. The MT3 headset must do its job in a very hostile environment and continue to function efficiently after long production runs. Continuous exposure to water, cleaning solutions, splashed product, plastic fines, glass fragments and dirt will cause the headset's internal parts to wear down over time. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 19 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Maintenance Procedures (cont'd) To make sure that the MT3 headset continues to provide quality service, it must be cleaned, lubricated, assembled and adjusted properly. The specified replacement parts must be used when needed and certain inexpensive parts must be replaced each time the headset is serviced. NOTE: Alcoa approved bearings must be used as part of the 4000-hour maintenance procedure. The headset will provide a continuous quality performance with a maximum length of service only if the required maintenance procedures are strictly followed. Required Tools and Materials • • • • • • • • • • • • • • • • • • • • Adjustable Spanner Wrench, 2" x 4-3/4", 1/4" pin, part number 516-0306-000. Bearing Lock Ring Wrench, part number 849-0124-101. MT3Assembly Fixture, part number 849-0125-101. MT3 Headset Fixture, part number 849-0127-501. Hex Key, 3/16", part number 516-0304-000. Hex Key, 1/8", part number 516-0310-000. Spanner Wrench supplied with Chucks; see the machine manual chuck list. Pliers and small Screwdriver. Anti-Seize Compound, see Glossary. Grease, see Glossary. New Drive Pins (4 required). New Quad-ring (10) and Upper and Lower Seals (6 & 21). New Ball Bearing (8). Approved Cleaning Solvent. Top Load Adjustment Procedure. Dawn® Dishwashing Soap. Torque Adjustment Procedures. MRA Torque Meter or Torque Wrench, Alcoa CSI part number 715703. Outside Micrometers, 1 to 2 and 2 to 3 inch. Bore Gauge or Inside Micrometer, 1 to 2 inch range, or Dial Indicator to measure Hub and Housing wear. • Cleaning Rags or Towels. • Workbench area, clean and free of metal filings. Page 20 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Maintenance Procedures (cont'd) Safety Precautions DANGER WARNING! Before performing this procedure, turn off and lockout power to the capping machine and test the lockout per your established LOTO process. Failure to do so could result in serious personal injury or death. CAUTION: When performing these procedures, follow your established plant safety processes. Safety glasses are required! 4000-Hour* Maintenance Procedure 1. Use the Headset Removal procedure detailed later in this manual to remove the headset(s) from the capping machine spindle. 2. Use the Headset Disassembly procedure, also described later in this manual, to disassemble and inspect the headset(s) on the workbench. 3. Use the Inspection procedures in this manual to check for mounting hub and upper housing wear. 4. Install a new quad-ring (10), new drive pins (3), new bearing (8), new o-ring (25) and new upper and lower seals (6 & 21). 5. Lubricate points A-1, A-2 and A-3 with anti-seize compound. (See Figure 16.) 6. Lubricate points G-4 through G-12 with the recommended grease (Fig. 16). Refer to the Lubrication Procedures section of this manual for complete information.) 7. Use the Headset Assembly procedure in this manual to reassemble the headset. *NOTE: The 4000-hour MT3 headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure Figure 16a. Lubrication Points ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 21 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Maintenance Procedures (cont'd) Chuck Maintenance Scope This procedure describes the proper inspection, care, and maintenance specifically related to the chuck assembly. Required Tools and Materials • Plastic Closure to test chuck for wear. • Dawn® Dishwashing Soap and Hot Water. • Workbench area, clean and free of metal filings. Safety Precautions CAUTION: Before performing these procedures, read and follow your established plant safety precautions. Safety glasses are required! Chuck Inspection 1. Check to be sure the chuck detents are clean and move freely within the holes. 2. Inspect the rubber o-ring. It must be clean and free of all foreign material, plastic or product. It must not have cracks or any other obvious visual problems. Leave the chuck detents and o-rings off the chuck. O-Ring Chuck Detent Chuck Teeth 3. Check to be sure that the teeth inside the chuck are in good condition. Insert a closure into the chuck to see if it grips the closure adequately to torque a closure onto a bottle. 4. Install the chuck detents and o-ring. Insert a closure into the chuck to see if there is sufficient grip to prevent the closure from falling out. Figure 17. Chuck Inspection Page 22 Check for Good Serrations 5. Evaluate chuck wear by removing the chuck from the capping head and applying a fresh closure to a bottle that has been placed in the MRA torque meter. If the closure strips in the chuck under 25 in-lbs., the chuck is too worn to remain in service and should be replaced. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Disassembly Procedures Headset Removal Scope This procedure describes how to safely remove the headset from the capper. Required Tools and Materials • Hand Tools for servicing the capping machine. • Dial Indicator. • Adjustable Spanner Wrench, part number 516-0306-000. Safety Precautions CAUTION: When performing these procedures, follow your established plant safety processes. Safety glasses are required! Removal Procedure 1. Raise the turret to allow adequate clearance for removing the headset. DANGER WARNING! Before proceeding further, turn off and lockout power to the capper and test the lockout per your established LOTO process. Failure to do so could result in serious personal injury or death. 2. Remove any necessary guards to provide access to the headset(s). Figure 18. Inspecting for wear between mounting hub and upper housing Spindle Shaft 3. If the headset is being disassembled for inspection, note that wear between the mounting hub (5) and the upper housing (4) should be inspected while the headset is still on the capping machine. To do so, move the headset in and out as described in the following three step method: Push and Hold (10 lbs. of force) Turret Center Line Lower Housing (9) Measure 0.060″ Max. Push Pull a. Place a dial indicator on the capper and secure it to measure the in/out play of the headset at the bottom of the lower housing. b. Grasp the spindle shaft just above the headset and push in with approximately 10 pounds of force to remove spindle play. c. Push/pull the bottom of the headset in the direction of the indicator point while pushing on the spindle. Note the movement of the headset at the bottom of the torque ring/lower magnet carrier assembly (16). The total movement should not exceed .060 inches; if it does, check the upper housing (4) and mounting hub (5) for wear. Replace if the wear specification is exceeded. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 23 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Disassembly Procedures (cont'd) e 4. Unlock the headset from the spindle by inserting the spanner wrench pin into a slot in the upper housing (4) and turning the wrench clockwise (right-hand threads). It may be necessary to bump the wrench handle with your hand to loosen the headset. CAUTION ! Do NOT use the large spanner wrench and lower housing (9) slot to remove the headset from the spindle shaft. Doing so may loosen the joint between the upper housing (4) and the lower housing. Once loose, the lower housing could separate from the headset, causing machine damage or personal injury. 5. Place one hand under the end of the headset and support its weight to keep it from falling. (Failure to support the headset may result in hand injury or damage to the headset or the knives below it.) Unscrew the headset from the spindle. 6. If you are performing a repair or 4000-hour* headset maintenance, please proceed directly to the Headset Disassembly procedure. * NOTE: The 4000-hour headset maintenance cycle is applicable for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. Figure 19. Removing the Headset IMPORTANT! Place one hand under the headset for support before unscrewing to keep it from falling. Failure to properly support the headset could result in hand injury and/or damage to the headset or knives. Page 24 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Disassembly Procedures (cont'd) Headset Disassembly NOTE: The area where the headset will be disassembled and inspected must be clean and free of any metal shavings and filings that might be attracted to the magnets. It is recommended that clean paper or cloth be laid on the bench. Scope This procedure describes how to safely disassemble the headset. Disassembly is usually required for inspection or maintenance. Required Tools* and Materials • Bearing Lock Ring Wrench, part number 849-0124-101. • MT3 Assembly Fixture, part number 849-0125-101. • MT3 Headset Fixture, part number 849-0127-501. • Two Adjustable Spanner Wrenches (1/4" pin), part #516-0306-000. • 3/16" Hex Key, part number 516-0304-000. • 1/8" Hex Key, part number 516-0310-000. • Spanner Wrench supplied with Chucks, see the machine manual chuck list. • Pliers and small Screwdriver. • Workbench area, clean and free of metal filings. Safety Precautions CAUTION: When performing these procedures, always follow your established plant safety processes. Safety glasses are required! *Per Toolkit #9200230690 for Alcoa MT3 headsets. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 25 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Disassembly Procedures (cont'd) Disassembly Procedure Figure 20. Headset Assembly Fixture Retaining Clip (15) NOTE: The bearing/upper magnet carrier assembly is the most likely cause of torque problems. The headset must be disassembled as follows to get at these components for cleaning, inspection and lubrication. A spare bearing/upper magnet carrier assembly can then be substituted while the “problem” assembly is being repaired. 1. Clamp the headset assembly fixture (found in your MT standard tool kit) into a vise. Do not clamp the headset itself into the vise. To do so could damage the headset components. Mounting Hub (5) Adjusting Collar (1) Top Load Spring (2) Hex Key for Collar Locking Screw (14) Headset Assembly Fixture IMPORTANT! Check to be sure your work area is clean and free of metal filings before proceeding. Metal filings will impede performance and damage the headset by sticking to the magnetized components. 2. Removal of the adjusting collar (1) & top load spring (2). a. The retaining clip (15) must be removed first using a small screwdriver and/or pliers. b. Loosen the locking screw (14) and unscrew the collar. c. The top load spring (2) can now be removed by simply pulling it off over the upper housing (4) and mounting hub (5). 3. Place the headset into the assembly fixture by turning it upside down and seating it so the pins in the fixture engage the slots in the upper housing as shown in the photograph at right. A Lower Magnet Carrier (16) Lower Housing (9) Set Screw (12) Headset Assembly Fixture Pin Slot in Upper Housing (4) 4. Remove the chuck from the headset as follows. First, lock the upper magnet carrier in place by inserting a 1/8" pin through the hole (see "A" in Fig. 21) in the lower magnet carrier and up into the slot in the upper magnet carrier. The chuck can now be unscrewed with a wrench. (Some chucks require a special chuck spanner wrench, which is included in your capping machine tool kit.) Figure 21. Insert Headset into Fixture Page 26 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Figure 22. Lower Magnet Carrier Assembly Removal Lower Magnet Carrier Assembly (16) Disassembly Procedure (cont'd) Set Screw (12) 5. The lower magnet carrier assembly (16) can now be removed by first loosening the set screw (12) with the 1/8" hex key (supplied with your MT3 tool kit) and then unscrewing the assembly from the lower housing. Lower Housing (9) Headset Assembly Fixture CAUTION: This headset contains strong magnets which can pull together and mash or pinch your fingers! To prevent accidents, keep magnets separated and away from other metal parts! Hex Key 6. Unscrew the lower housing (9) with the adjustable spanner wrench (supplied with your MT3 tool kit) as shown in Figure 23 at left. Figure 23. Lower Housing Removal Upper Magnet Carrier Assembly (19) Note: Before turning the wrench, make sure you are holding the headset so it remains fully seated down into the assembly fixture. The assembly fixture pins must be fully engaged in the upper housing slots as the lower housing is being removed. Failure to do so could allow the headset to slip out of the fixture and cause personal injury or component damage. Lower Housing (9) Spanner Wrench 7. The mounting hub and drive pins can now be pulled out of the upper housing per Figure 24 below. Headset Assembly Fixture Figure 24. Mounting Hub Removal NOTE: The 4000-hour maintenance cycle applies for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. Mounting Hub (5) Drive Pin Upper Housing (4) ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 27 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS MT Std. Headset Fixture Figure 25. Headset Fixture Disassembly Procedure (cont'd) Vise 8. To remove the bearing lock ring (7), bearing (8), upper seal (6), upper magnet carrier assembly (19) and lower seal (21), place the second headset fixture from your MT3 headset tool kit into the vise (per Figure 25), then position the lower housing/upper magnet carrier/bearing assembly onto the fixture with the lock ring facing up. Unscrew the bearing lock ring with a wrench and the special bearing lock ring adapter (also provided with your tool kit) as shown in Figure 26 at left. Bearing Lock Ring Adapter Bearing Lock Ring (7) Bearing (8) Lower Housing (9) Figure 26. Bearing Lock Ring Removal * NOTE: The 4000 hour maintenance cycle applies for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. 9. The ball bearing (8) and upper seal (6) can now be removed by lifting them off the upper magnet carrier assembly. If the customer wishes to inspect the ball bearing (11) between 4000-hour* rebuilds, it should be wrapped in a clean rag or placed in a plastic bag to protect it from contamination. (NOTE: The bearing is a shielded-type bearing, designed to retain grease and prevent contamination from dirt and other foreign materials. It should not be washed or cleaned with solvents or other liquids.) IMPORTANT! The ball bearing must be replaced with an Alcoa-approved bearing at each 4000 hr.* maintenance cycle to assure optimum headset performance between rebuilds! 10. To get at the lower seal (21), simply lift the lower housing (9) off the fixture and upper magnet carrier assembly (19). The lower seal can now be removed. 11. The disassembly procedure for Alcoa MT3 pin-driven headsets used on Series 200/200E/125 cappers is now complete and no further disassembly is recommended. If you are performing 4000-hr. maintenance, turn to the Parts Cleaning & Inspection section in this manual. Page 28 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Parts Cleaning and Inspection Scope This procedure describes how to clean and inspect the disassembled parts of the Alcoa MT3 magnetic capping headset. Required Tools and Materials • • • • • • • • • Approved Bottling Plant Cleaning Solvent. Dawn® Dishwashing Soap and Hot Water. Bore Gauge or Inside Micrometer, 1 to 2 inch range, or: Dial Indicator to measure Hub and Housing wear. Cleaning Rags or Towels. Workbench area, clean and free of metal filings. Masking Tape. Clean Cloth or Cardboard to lay on the bench. Outside Micrometers 1 to 2 and 2 to 3 inch. Safety Precautions CAUTION: When performing these procedures, always follow your established plant safety processes. Safety glasses are required! Cleaning Thoroughly clean all headset parts (except the ball bearing*) of dust, dirt, oil, grease and/or product buildup as follows: 1. Clean all parts with the approved bottling plant petroleum based cleaning solvent, and then dry them. 2. Clean all parts with Dawn® dishwashing soap and hot water, and dry them. NOTE: This two-step process of cleaning is necessary to make sure that all types of contamination are removed. * The ball bearing is a shielded-type bearing, designed to retain grease and prevent contamination from dirt and other foreign materials. It should not be washed or cleaned with solvents or other liquids. Simply wipe off with a clean, dry cloth. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 29 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Parts Cleaning and Inspection (cont'd) 2.010" Min Mounting Hub (1) M in 1. 74 6" Drive Pin (20) Inspection/Additional Cleaning Figure 27. Mounting Hub Wear Check Apply tape here to remove filings 1. Check the drive pin pockets in the mounting hub (5) for excessive wear. Place two new drive pins (3) in position on the mounting hub (5) and measure across the two pins. If the dimension is less than 2.010 inches, replace the mounting hub. If using old drive pins, the measurement shown still applies. Do not use the pins if this measurement is less than shown. Be sure not to mix pins between different headsets. 2. Thoroughly clean the upper magnet carrier assembly (19) and lower magnet carrier assembly (16) including removal of all metal shavings or filings. The recommended method for removing metal filings from the magnet is to apply masking tape to the filings and peel off the tape along with the metal filings. 3. Inspect to make sure the ball bearing (8) is securely attached to the upper magnet carrier assembly (19). Figure 28. Cleaning the Lower Magnet Carrier Assembly 4. Inspect the lower magnet carrier assembly (16) to be sure it is clean and free of metal filings. Remove any metal filings with masking tape as described in Step 2. 5. Place a closure in the chuck with pins removed and check to see if the chuck serrations engage the closure knurls. Replace the chuck if the serrations are excessively worn. Evaluate chuck wear by removing the chuck from the capping head and applying a fresh closure to a bottle that has been placed in the MRA torque meter. If the closure strips in the chuck under 25 in-lbs., the chuck is too worn to remain in service and should be replaced. O-Ring Chuck Detent Chuck Teeth Install a new o-ring on the capping chuck at first sign of stress cracks and at each 4000-hour* maintenance interval. This is a chuck component, so it's not included in the headset rebuild kit. Refer to the parts catalog section of your capping machine manual for the correct part number or ask your Alcoa CSI Spare Parts Specialist to assist you. Figure 29. Inspecting the Chuck Check for Good Serrations 6. Proceed to the Headset Assembly section for instructions on how to reassemble the headset. * NOTE: The 4000-hour maintenance cycle applies for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. Page 30 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Headset Assembly NOTE: The area where the headset will be assembled must be clean and free of any metal shavings and filings that might be attracted to the magnets. (It is strongly recommended that clean paper or cloth be laid on the bench first.) Scope This procedure describes in detail how to properly assemble the Alcoa MT3 headset with pin drive housing. Required Tools and Materials • Bearing Lock Ring Wrench, part number 849-0124-101. • MT3 Assembly Fixture, part number 849-0125-101. • MT3 Headset Fixture, part number 849-0127-501. • Two Adjustable Spanner Wrenches (1/4" pin), part #516-0306-000. • 3/16" Hex Key, part number 516-0304-000. • 1/8" Hex Key, part number 516-0310-000. • Spanner Wrench supplied with Chucks; see the machine manual chuck list. • Pliers and small Screwdriver. • Workbench area, clean and free of metal filings. • Anti-Seize Compound, see Glossary. • Grease, see Glossary. • New Drive Pins (4 req'd.), part number 513-1343-000. • New Quad-ring, part number 534-0418-000. • New O-ring (1 req'd.), part number 534-0330-000. • New Bearing (1 req'd) part number 503-1189-000. • New Upper Seal (1 req'd), part number 535-0273-000. • New Lower Seal (1 req'd.), part number 535-0271-000. • New Retaining Clip (1 req'd) part number 522-5602-000. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 31 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Headset Assembly (cont'd) Safety Precautions CAUTION: When performing these procedures, always follow your established plant safety processes. Safety glasses and safety shoes are required at all times! Headset Assembly 1. Apply a uniform coat of food grade anti-seize compound to the inside bore and threads of the mounting hub (5) and set aside. Quad Ring (10) Upper Housing (4) O-ring (25) Drive Pin (3) Mounting Hub (5) Upper Seal (6) Figure 30. Upper Headset Sub-Assembly CAUTION: This headset contains strong magnets that can pull together and mash or pinch fingers. To prevent an accident, keep magnets separated and away from other metal parts! 2. Sub-assemble the upper housing, quad ring, mounting hub, drive pins, o-ring and upper seal as follows: a. Insert the new quad-ring (10) into the upper housing (4). Lightly coat the quad-ring (10) with FGL-2 grease and completely fill the grease reservoir groove just below the quad-ring with FGL-2 grease. NOTE: Do not use a standard quad-ring; this is a high wear item. It must withstand long, hard use in a harsh environment. Use only Alcoa approved quad-rings. b. Apply a light coat of FGL-2 grease to the largestdiameter, threads and pin pockets of the mounting hub (5); also coat four new drive pins (3) with the same grease. c. Coat the inside of the upper housing (4) with FGL-2 grease, insert the four new drive pins (3), into the pockets on the mounting hub (5) and insert the sub-assembly into the upper housing (4), taking care not to pinch or damage the quad-ring (10). d. Coat the upper seal (6) with a light film of Dow Corning 111 silicone grease and install it flange up in the upper housing (4). Page 32 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Headset Assembly (cont'd) Bearing Lock Ring (7) Bearing (8) Lower Housing (9) Set Screw (12) Lower Seal (21) Upper Magnet Carrier Assembly (19) Lower Magnet Carrier Assembly (16) Calibration Ring (11) Flat Head Cap Screw (13) Figure 31. Lower Headset Sub-assembly e. Coat the o-ring (25) with Dow Corning 111 silicone grease, insert it into the groove in the bottom of the upper housing (4) and set the completed sub-assembly aside. NOTE: Do not use standard o-rings; use only the Alcoa approved o-rings when re-assembling Alcoa MT3 headsets. 3. Sub-assemble the lower housing, magnet carrier assemblies, bearing, seals and lock ring as follows: a. Coat the whole interior of the lower housing (9) and the exterior threads with Dow Corning 111 silicone grease. b. Coat the lower seal (21) with a light film of Dow Corning 111 silicone grease, seat it flange up onto the upper magnet carrier and insert the assembly into the lower housing (9). c. Coat the inside and outside surfaces of the ball bearing (8) with Dow Corning 111 silicone grease, seat it black side (seal) down onto the upper magnet carrier (19) and secure with the bearing lock ring (7) to 75 ft. lbs. This is accomplished by placing the sub-assembled components onto the headset fixture (see Fig. 25 on page 29) and tightening with a torque wrench and the lock ring adapter from your tool kit. NOTE: The bearing is a "shielded" bearing, designed to retain grease and prevent contamination. It should not be washed or cleaned with solvents. Wiping it with a clean rag is the only recommended method of cleaning. d. Coat the lower magnet carrier assembly (16) threads with food grade anti-seize compound and screw it onto the lower housing (9). The set screw (12) threads should also be coated with anti-seize compound. A Lower Magnet Carrier (16) Lower Housing (9) Set Screw (12) Headset Assembly Fixture Pin Slot in Upper Housing (4) Figure 32. Headset Assembly Fixture 4. Assemble the upper and lower housings (along with the subassembled components from steps 2 & 3 above) as follows: a. Secure the headset assembly fixture in a vise and place the upper housing sub-assembly (from step 2) into the fixture by turning it upside down and seating it so the pins in the fixture fully engage the slots in the upper housing. Screw the lower housing sub-assembly (from step 3) onto the upper housing, hold the headset firmly down in the fixture and tighten the upper and lower housings together as hard as possible with the adjustable spanner wrench provided in your tool kit. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 33 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Headset Assembly (cont'd) b. IMPORTANT! If a headset assembly fixture is not available, the upper and lower housings must be tightened together as hard as possible with two opposing spanner wrenches as described in the note below. NOTE: To properly tighten the upper and lower housings without a heaset fixture, lay the headset on its side. Find the hole locations in the upper and lower housings that position the two opposing spanner wrench handles as far apart as possible. While holding one spanner wrench handle down against the work surface, push the other spanner wrench handle toward the work surface until it can support your upper body weight. Push on the wrench several times to ensure it is tight. This tightening effort should be 20 ft-lb., which you can get a feel for by applying arm force to a standard torque wrench when holding the wrench 7-1/2″ from the pivot end. WARNING! Failure to properly tighten the threaded joint between the upper and lower housings could result in separation of the lower housing from the headset, causing machine damage and/or serious injury! Retaining Clip (15) Locking Screw (14) Adjusting Collar (1) Top Load Spring (2) Mounting Hub (5) Upper Housing (4) Figure 33. Installing the Top Load Spring and Adjusting Collar Page 34 5. Assemble the top load spring, adjusting collar and retaining clip: a. Coat the collar locking screw (14) with food grade antiseize compound and install it loosely into the collar (1). b. Install the top load spring (2). Coat the adjusting collar (1) threads with anti-seize compound and screw it down about 1/2 inch from the top of the mounting hub (5). c. Using pliers and small screwdriver, install the retaining clip (15) by sliding one end of the clip into the groove above the threads and working the rest of the clip into the groove. 6. Install the chuck by applying a light coat of food grade anti-seize compound to the chuck threads and screwing the chuck into the upper magnet carrier assembly (19). Continue turning the chuck clockwise, slipping the clutch a few times to make sure the chuck is completely threaded into the upper magnet carrier. 7. Adjust the torque using the Torque Adjustment procedure as described in this manual. 8. Adjust the top load, using the Top Load Adjustment procedure in this manual. After adjustment, check to be sure the collar locking screw (13) and nut (12) are tight (but not overly tight). 9. Coat the spindle shaft threads and lower spindle shaft with food grade anti-seize compound. Screw the headset onto the spindle (R.H. threads) by hand, then place the spanner wrench into the slot on the upper housing (4) and tighten to 50 ft-lbs. 10. Refer to the calibration procedure in this manual for information on how to properly check and calibrate the torque. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Illustrated Parts Lists Alcoa Magna Torq MT3 Calibrated Headsets with Pin Drive Housings for use on Alcoa Series 200 Capping Machines with 1-1/4" Spindle Size The following Tables and Figures show the parts breakdown of the Alcoa MT3 headset for use on Series 200 1-1/4" spindle size capping machines. A cutaway illustration shows the assembled parts and an exploded view is provided to help isolate the individual headset components. Table 3. Components for MT3 Headset with Pin Drive Housing Table 4. MT3 Headset Spare Parts Kit NOTE: Always use only the parts and materials specified by Alcoa. Sub-standard components will not perform satisfactorily in Alcoa MT3 headsets. MT3 Headset Spare Parts Kit D200-24179-0 Item Parts List for MT3 Headset D200-24109-1 Spindle Size: 1-1/4" 4 5 -- Item Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Adjusting Collar Top Load Spring Drive Pin Upper Housing Mounting Hub Upper Seal Lock Ring Ball Bearing Lower Housing Quad Ring Calibration Ring SHSS, Cup Point, SS FHCS, #4-40, SS SHCS 1/4-20 x 1 SS Retaining Clip Lower Magnet Carrier Assembly Upper Magnet Carrier Assy., MT3 Lower Seal O-Ring 19 21 25 Part Number 1 1 4 1 1 1 1 1 1 1 1 1 3 1 1 1 300-0518-101 1 535-0271-000 534-0330-000 1 1 Associated Parts 1 1 1 1 *Item numbers in the above list refer to Alcoa assembly drawing #D200-241091. IMPORTANT! To obtain maximum headset service life and efficiency, it is recommended that adequate spare parts be available at all times. Headsets that are not functioning properly due to worn or damaged parts can cause downtime, inefficiencies and worst of all – bad packages. Keep one kit on hand for every 8 headsets. For example: order 3 kits for an 18 head capping machine. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Part Number Upper Housing Mounting Hub Rebuild Kit 300-0126-101 300-0343-101 D200241760 Qty. 1 1 1 Qty. 200-1015-202 533-1321-000 513-1343-000 300-0126-101 300-0343-101 535-0273-000 200-1023-206 503-1189-000 300-0796-101 534-0418-000 300-0795-101 97829350 97804003 97803204 522-5602-000 200-1028-226 Chuck Spindle Knock Out Knock Out Spring Description Table 5. MT3 Headset Rebuild Kit MT3 Headset Rebuild Kit D200-24176-0 Item 3 6 8 10 15 21 25 Description Drive Pin Upper Seal Ball Bearing Quad Ring Retaining Clip Lower Seal O-Ring Part Number Qty. 513-1343-000 535-0273-000 503-1189-000 534-0418-000 522-5602-000 535-0271-000 534-0330-000 4 1 1 1 1 1 1 NOTE: One rebuild kit is required per head to rebuild all headsets on a capping machine at the same time. The kit contains the minimum parts to rebuild one headset and has a special price based upon the whole package. Table 6. Headset Service Tools MT3 Headset Tool Kit No. 9200-23069-0 Item Description Part Number Qty. 1 2 3 6 9 26 32 34 Bearing Lock Ring Wrench MT3 Assembly Fixture MT3 Headset Fixture 1/8" Hex Key 1/16" Hex Key Adjustable Spanner Wrench 3/16" Hex Key Tool Bag 849-0124-101 849-0125-101 849-0127-501 516-0310-000 516-0313-000 516-0306-000 516-0304-000 522-5291-000 1 1 1 1 1 1 1 1 Table 6a. Additional Service Tools Item Description Part Number -- Spanner Wrench (Chuck) See Capping Machine Manual Chuck List Page 35 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Figure 34. Alcoa MT3 Headset Cutaway Drawing Page 36 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Figure 35 Alcoa MT3 Headset Exploded View (Refer to the tables on page 36 for descriptions, part numbers and rebuild kit information) ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 37 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Bearing Inspection Procedure Scope The headset bearing must be replaced at each 4000-hour* maintenance interval. This section describes how to inspect the bearing for wear between rebuilds, should you need to do so. Required Tools and Materials • Dial Indicator to measure headset ball bearing (8) for wear. Inspection Procedure There are two methods of checking headset bearing (8) wear. 1. Unscrew the adjusting collar (1) until it stops compressing the top load spring (2). 2. One method of checking is to measure axial play with the headset fully assembled. Rotate the chuck from one clutch position to another. Using the dial indicator, check to see that the bearing (8) axial play does not exceed .020 inches up or down. Dial Indicato Tilt 0.026" Max. 3. The second method of checking wear is to measure the tilt of the inner race with the bearing out of the headset. Using the dial indicator, measure the movement, or tilt, at one point on the inner race of the bearing (8). The total movement in the axial direction should not exceed .026 inches. 4. Make sure the bearing turns freely without any drag or rough spots. Figure 36. Measuring Bearing Axial Play 5. Check to see if the bearing has worn to the extent where it causes the outside diameter of the upper magnet carrier assembly (19) to rub the inside diameter of the lower magnet carrier assembly (16). Push the upper magnet carrier assembly (19) sideways while rotating it to see if it rubs the lower magnet carrier assembly (16). Upper Magnet Carrier (19) Push Sideways Chuck Push and Rotate Figure 37. Inspecting for Bearing Wear Page 38 Lower Magnet Carrier (16) Check for Rubbing Bearing Lubrication The bearing is a shielded-type bearing, designed to retain grease and prevent contamination from dirt and other foreign materials. This bearing should not be washed or cleaned with solvents or other liquid. Wiping the bearing with a clean rag or paper towel is the only recommended method of cleaning it. * NOTE: The 4000-hour maintenance cycle applies for the carbonated soft drink and water markets only if Alcoa approved bearings are used as replacements during the rebuild procedure. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS INFORMATION FOR ORDERING SPARE AND REPLACEMENT PARTS A spare parts inventory should be maintained to avoid prolonged downtime when replacements are needed. It is strongly recommended that you stock an entire Spare Parts Kit for each machine so you’ll have the appropriate parts on-site when you need them. HOW TO ORDER SPARE PARTS ................................................................................... Your order will be processed much more efficiently if you are ready to provide the following information before you call us: 1. 2. 4. 5. 6. Customer Purchase Order Number. How and Where to Ship the Parts. (Address/company contact/phone number/carrier.) Machine Model/Serial Number of the capping machine the parts are to be used on. Part Name/Description & Quantity Required. (Refer to your machine manual.) Part Number. (Refer to your machine manual.) To avoid confusion when ordering, always be prepared to specify each part by its number and description exactly as listed in your machine manual. For example, if you want only a single part of an assembly and you use the word “assembly” in your description, it raises a question as to whether you need a particular part or the entire assembled piece. (In some cases, due to the nature of the part, it may be necessary or less costly for us to supply the additional related pieces.) WHERE TO ORDER PARTS AND SERVICE ................................................................................... Three Easy Ways to Order Alcoa Capper Parts: (1) AlcoaDirect parts link. Order spare parts on-line though AlcoaDirect parts link, the fastest way possible! AlcoaDirect is a web-based service for sourcing of content and information with Alcoa Closure Systems International. With AlcoaDirect, you improve your ordering planning and efficiency. Order capper spare parts any time of day or night from a customized parts catalog for your capper. Then after placing your order, use AlcoaDirect to track your order until it arrives at your plant. Other features of AlcoaDirect offer field service requests, and keeping up to date with technical bulletins, manual changes and engineering updates. There is no cost for AlcoaDirect. Simply register for AlcoaDirect access by connecting to www.alcoacsi.com or contacting your Alcoa representative. ---------------------Alcoa CSI Customer Support Center; 6625 Network Way, Suite 200; Indianapolis, IN 46278. (2) Telephone orders. Parts: 1-800-311-2743. Service: 1-800-311-2740 or 317-390-5000. (3) Fax orders. Fax #: 317-390-5137. In Mexico: Alcoa CSI de Mexico; Calle Indiana No. 435; Frac. Industrial Valle de Saltillo; Saltillo Coahuila, Mexico CP 25217. Parts, Service & Sales: 011 52 844 411 1692. Emergencias, Dias Festivos o Domingos: 011 52 844 429 0530. New Machines and Upgrades: Alcoa CSI Customer Support Center; 6625 Network Way, Suite 200; Indianapolis, IN 46278. Phone: 317-390-5000. Fax: 317-390-5380 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 39 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Glossary of Terms ............................................................. Anti-Rotation Knives The knives (or teeth) that prevent plastic bottles from rotating during the capping process. Anti-Seize Compound Bostik® Never-Seez® White Food Grade with PTFE #NSWT-14 (www.bostikfindley.com) Phone: 978-777-0100. Capper The overall capping machine assembly. Chuck The device/tool attached to the headset quill that grips and screws the closure onto the bottle. Chuck Adapter A device/tool with a 1/4 square socket on one end that fits the Torque Wrench, and some teeth/knurls on the other end that engages the teeth/knurls in the chuck. See the closure supplier for specifications. Chuck Pins Small spring-loaded grippers positioned in the chuck wall that grips the closure. Cleaning Solution Clean, filtered, petroleum base commercial parts cleaning solvent Closure Bottle Cap, Bottle Top, Cap. Grease Lubriplate® FGL-2 Food Grade, Lubriplate Division, Fiske Brothers Refining. (www.lubriplate.com) Phone: 1-800-733-4755 for the nearest distributor. Dow Corning 111 Silicone Grease. (www.dowcorning.com) Phone: 1-800-637-5377 ext. 5377, for nearest distributor. Page 40 Head Rise The amount the lower portion of the headset moves up relative to the upper part of the headset when the closure is fully screwed onto a nominal height bottle. Headset The complete closure application unit. Incremental Torque The amount of torque required to rotate a sealed bottle closure an additional 6 degrees. MRA Maximum Removal and Application. MRA Torque Tester Secure Pak, Inc. P.O. Box 14499; Toledo, Ohio 43614 Telephone: (419) 893-9965 FAX: (419) 893-9940 Timing Plug A precision bottle set-up gauge. ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS -- Operating Manual Index -A M Adjustment Procedures ................................ 5-12 - Head Rise ................................................. 11-12 - Top Load ......................................................5-7 - Torque ....................................................... 7-11 Assembly Procedures ................................. 31-34 Maintenance Procedures ............................ 18-22 - 4000-Hour Maintenance ........................... 19-22 - Bearing Replacement .................................... 13 - Chuck Maintenance ...................................... 23 - Daily (Eight-Hour) Maintenance .............. 18-19 Maintenance Schedules ................................... 18 Materials Required ............................................. 4 B Bearing Replacement ...................................... 13 C Chuck Maintenance ......................................... 22 Cleaning Procedures ................................... 29-30 Cross-Section Drawing .................................... 36 D Daily (Eight-Hour) Maintenance ................ 18-19 Disassembly Procedures ............................ 23-28 Headset Disassembly ................................. 25-28 Headset Removal ...................................... 23-24 E Exploded View ................................................ 37 G P Parts Lists ........................................................ 35 - Cross-Section Drawing ................................. 36 - Exploded View .............................................. 37 - Parts List (1-1/4" Spindle Size) ..................... 35 - Rebuild Parts Kit List ................................... 35 - Spare Parts Kit List ....................................... 35 - Service Tools Parts List ............................... 35 R Rebuild Parts Kit Lists ..................................... 35 S Safety ................................................................. 2 Scope ................................................................. 3 Spare Parts Kit Parts List ................................ 35 Service Tools Parts List ................................... 35 Glossary ........................................................... 40 T H Head Rise Adjustment ................................ 11-12 Tools Required ................................................... 4 Top Load Adjustment ......................................5-7 Torque Adjustment ....................................... 7-11 I Inspection Procedures ......................... 13-15; 30 Introduction ....................................................... 3 Lubrication ................................................. 16-17 Lubrication Points Diagram ............................. 17 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06 Page 41 ALCOA MT3 CALIBRATED HEADSET OPERATING INSTRUCTIONS Page 42 ALCOA CLOSURE SYSTEMS INTERNATIONAL FORM NUMBER: MT3-C-5/04R4/06
