Citrus finisher 100 series maintenance manual (5 29-12)

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Citrus finisher 100 series maintenance manual (5 29-12)

  1. 1. Citrus Finisher – 100 Series Service Manual for Screw and Paddle Finishers
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  3. 3. This page is intentionally left blank.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 3
  4. 4. John Bean Technologies Corporation © 2012, All rights reserved The information contained herein is proprietary and shall not be copied, in whole or in part, adapted, modified, or disseminated without the express written consent of JBT Corporation. Glossary – Terms Acronyms and Abbreviations used in this Manual ACUS Automatic Cleanup System TSR Automated Spray Ring GPM Gallons Per Minute °C Degrees Celsius HMI CIP Cleaning In Place MSR Manual Spray Ring °F Degrees Fahrenheit SSR Single Spray Ring Human Machine Interface Programmable Logic Controller Personal Protective PPE Equipment PLC NOTICE CAREFULLY READ THE INFORMATION IN THIS MANUAL BEFORE WORKING ON THE FINISHER. FOLLOW THE INSTRUCTIONS FOR EACH STEP THOROUGHLY. PLEASE KEEP THIS MANUAL AND ALL ENCLOSED DOCUMENTATION IN AN ACCESSIBLE LOCATION KNOWN TO ALL OPERATORS, INSTALLATION, AND MAINTENANCE PERSONNEL. EMAIL ANY NEEDED REVISIONS, OMISSIONS, ADDITIONS OR COMMENTS ABOUT THIS MANUAL TO citrus.Info@jbtc.com. Latin America www.jbtfoodtech.com Europe South Africa JBT de México S de RL de CV Calle Oceanía #102 Fracc. Industrial Unidad Nacional II 66350 Santa Catarina, NL México Tel.: +52.81.8123.7055 Fax: +52.81.8123.7054 citrus.info@jbtc.com John Bean Technologies SpA Via Mantova 63/A 43122 Parma Italy Phone: +39.0521.908.411 Fax: +39.0521.460.897 sales.parma@jbtc.com John Bean Technologies (Pty) Ltd. Koper Street Brackenfell Cape Town, South Africa 7560 Phone: +27.21.982.1130 Fax: +27.21.982.1136 citrus.info@jbtc.com North America 4 South America John Bean Technologies Corporation 400 Fairway Avenue Lakeland, FL 33801 USA Phone: +1.863.683.5411 Fax: +1.863.680.3672 citrus.info@jbtc.com John Bean Technologies Màq. e Equip. Ind. Ltda. Av. Eng Camilo Dinucci 4605, 14808-900 Araraquara, São Paulo Brazil Phone: +55.16.3301.2000 Fax: +55.16.3332.0565 latinamerica.info@jbtc.com MAN# 04904600/4800.05292012 JBT FoodTech, S.L. Julián Camarillo 26, 4º 28037 Madrid Spain Phone: +34.91.304.0045 Fax: +34.91.327.5003 foodtech.spain@jbtc.com Asia Pacific John Bean Technologies (Shanghai) Co. Ltd. Haitong Security Building room 3002-3003 No. 689 Guangdong Road Shanghai 200001 China Phone: +86.21.6341.1616 Fax: +86.21.6341.0708 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  5. 5. Preface This manual will assist trained personnel with installation, operation, maintenance, cleaning and ordering spare parts for JBT FoodTech citrus processing equipment. Contact JBT FoodTech to purchase additional manuals and replacement parts by using the following information: JBT FoodTech 400 Fairway Avenue Lakeland, FL 33801 TEL: +1.863.683.5411 FAX: +1.863.680.3672 Be sure that orders for replacement parts include: 1. 2. 3. 4. 5. 6. Name of machine Quantity of parts required JBT part number (from the manual) Description of part Purchase order number Shipping instructions Be sure that orders for manuals include: 1. 2. 3. 4. Name of machine JBT assembly number (from manual, if known) Purchase order number Shipping instructions Continuous product improvement is the JBT FoodTech corporate policy and we reserve the right to discontinue or change specifications, models, or designs without notice and without incurring obligation. Please note that depending on the application of the actual equipment, our design may deviate slightly from the equipment description in this manual. Specifically, equipment integration into larger citrus plant control systems may display a different control panel than shown in this manual. All principles of operation remain the same. Please refer to this manual’s appendix section for any specific configuration changes to your equipment. Related documentation Other technical manuals may contain additional information concerning the operation of JBT FoodTech equipment. Their respective manufacturers provide these manuals. For current or additional copies, direct those requests toward the corresponding manufacturer. JBT FoodTech does not update or maintain these documents.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 5
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  7. 7. Contents Preface.......................................................................................................................................... 5 Related documentation ............................................................................................................. 5 Contents........................................................................................................................................ 7 Figures ........................................................................................................................................ 11 Safety Information ....................................................................................................................... 13 Points of Contact ..................................................................................................................... 13 Safety Precautions .................................................................................................................. 13 Signal Words and Symbols ..................................................................................................... 14 Hazard Zones on the 100 Series Finishers ............................................................................. 14 Mechanical Hazards ............................................................................................................ 14 Electrical Hazards ............................................................................................................... 15 Noise Hazards ..................................................................................................................... 15 Thermal Hazards ................................................................................................................ 15 Substance Hazards............................................................................................................ 15 Wastes and Environmental Pollution ....................................................................................... 15 Risks, Protections, Warnings and Precautions ....................................................................... 15 Intended, Non-Intended and Incorrect Uses ........................................................................... 16 Limits in usage of the machinery ...................................................................................... 16 Reasonably foreseeable misuse ......................................................................................... 16 Safety Label Locations ............................................................................................................ 17 Equipment Description ................................................................................................................ 19 Applications ............................................................................................................................. 19 Performance ............................................................................................................................ 20 Quick Fiber Value (See Appendix A on page 81) ................................................................ 20 Juice Quality Parameters ..................................................................................................... 20 Variables affecting finisher performance ............................................................................. 20 UCF110 Description ................................................................................................................ 20 UCF110 Identification .......................................................................................................... 22 UPF100 Description ................................................................................................................ 23     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 7
  8. 8. UPF100 Identification ........................................................................................................... 24 Installation ................................................................................................................................... 25 Site Planning ........................................................................................................................... 25 Site Preparation....................................................................................................................... 25 Installation Procedures ............................................................................................................ 27 Post Installation Inspection ...................................................................................................... 32 Operation .................................................................................................................................... 35 Pre-operational Inspection ...................................................................................................... 35 Quick Fiber Controls ................................................................................................................ 36 Daily Inspections for Proper Mechanical Operation ............................................................. 36 Weekly Inspections for Proper Controls Operation .............................................................. 36 Operating Procedures ............................................................................................................. 37 Manual (Short Term) Shutdown Procedures ........................................................................... 38 Season End (Long Term) Shutdown Procedures .................................................................... 38 Maintenance Procedures ............................................................................................................ 39 High Pressure Cleaning .......................................................................................................... 41 Single and Dual Spray Ring Removal ................................................................................. 42 Single and Dual Spray Ring Installation .............................................................................. 43 Screen Frame Removal ....................................................................................................... 44 Screen Removal .................................................................................................................. 45 Screen and Frame Inspection.............................................................................................. 46 Screen Installation ............................................................................................................... 47 Screw-to-Screen Alignment – UCF110 ................................................................................... 50 Paddle-to-Screen Alignment – UPF100 .................................................................................. 53 Finisher Intake ......................................................................................................................... 54 7.5 HP Gear motor............................................................................................................... 54 Removal............................................................................................................................... 54 Installation............................................................................................................................ 54 Finisher Discharge .................................................................................................................. 56 Servicing Plug Valve Air Cylinder ........................................................................................ 59 8 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  9. 9. Troubleshooting........................................................................................................................... 61 Lubrication .................................................................................................................................. 63 Cleanup procedures.................................................................................................................... 65 Cleanup After Repair ............................................................................................................... 65 High Pressure Cleanup Operation .......................................................................................... 66 Recommended Spare Parts ........................................................................................................ 69 Appendix A.................................................................................................................................. 79 Quality Control – Quick Fiber Device ...................................................................................... 79 Quick Fiber Test ...................................................................................................................... 79 Equipment Needed .............................................................................................................. 80 Perform Procedure .............................................................................................................. 80 Data Interpretation ............................................................................................................... 80 Table 5: Quick Fiber Correction Factor ................................................................................ 81 Appendix B.................................................................................................................................. 83 Timed Spray Ring .................................................................................................................... 83 Appendix C ................................................................................................................................. 95 Fastener Torque Specifications ............................................................................................... 95 Standard Fasteners ............................................................................................................. 96 Torque Units Conversion Table ........................................................................................... 96 Manual Revision Log .................................................................................................................. 97     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 9
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  11. 11. Figures Figure 1 – Typical Safety Label Locations for UCF110 and UPF100 Finishers ......................... 17  Figure 2 – Separating Solids and Liquids ................................................................................... 19  Figure 3 – Quality and Yield Performance.................................................................................. 20  Figure 4 – Operation of the UCF110 Finisher ............................................................................ 21  Figure 5 – UCF110 Finisher Identification Plate ......................................................................... 22  Figure 6 – Operation of the UPF100 Finisher............................................................................. 23  Figure 7 – UPF100 Finisher Identification Plate ......................................................................... 24  Figure 8 – Finisher Maintenance Areas ...................................................................................... 26  Figure 9 – UCF110 Installation Dimensions ............................................................................... 28  Figure 10 – UCF110 Installation Instructions .............................................................................. 28  Figure 11 – UPF100 Installation Dimensions ............................................................................. 30  Figure 12 – UPF100 Installation Instructions .............................................................................. 30  Figure 13 – Manual Spray Ring (MSR) System (with optional casters) ...................................... 40  Figure 14 – Automatic Spray Ring (TSR) with Quick Fiber Controls (with optional casters) ...... 40  Figure 15 – 100 Series Finisher High-pressure Spray Ring Systems ......................................... 41  Figure 16 – High Pressure Spray Rings (UCF110 Shown, UPF100 Similar).............................. 42  Figure 17 – Disconnecting Vertical Actuator Arm ....................................................................... 43  Figure 18 – Screen Frame .......................................................................................................... 44  Figure 19 – Screen Removal ...................................................................................................... 45  Figure 20 – Screen Inspection .................................................................................................... 46  Figure 21 – JBT Specialty Tool ................................................................................................... 47  Figure 22 – JBT Specialty Tool Alignment .................................................................................. 48  Figure 23 – Installed Tool Bolted to Frame and Screen Flanges ................................................ 48  Figure 24 – Screen Flange to Frame Flange Contact ................................................................. 49  Figure 25 – Securing Screen to Frame ....................................................................................... 49  Figure 26 – Screen & Frame Assembly ...................................................................................... 50  Figure 27 – Indicator Gauge Mounting ....................................................................................... 51  Figure 28 – Dial Indicator Gauge Mounting ................................................................................ 53  Figure 29 – Adjusting Paddle Gap .............................................................................................. 53  Figure 30 – Intake End of 100 Series Finishers .......................................................................... 55  Figure 31 – Removing the Top Frame and Screen from the Finisher ......................................... 56  Figure 32 – UPF100 Finisher Discharge End ............................................................................. 57      Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 11
  12. 12. Figure 33 – UCF110 Finisher Discharge End ............................................................................. 58  Figure 34 – Disassembled Plug Valve Assembly for UCF110 and UPF100 with TSR ............... 59  Figure 35 – Manually Cleaning Screens using Single Spray Ring (SSR) ................................... 66  Figure 36 – Inspecting Screen for Cleanliness (TSR Shown with Dual Spray Ring) .................. 67  Figure 37 – Discharge End Spare Parts ..................................................................................... 69  Figure 38 – Intake End Spare Parts ............................................................................................ 70  Figure 41 – Screen and Frame Spare Parts ............................................................................... 72  Figure 42 – UCF110 Screw Spare Parts .................................................................................... 73  Figure 43 – UPF100 Paddle Spare Parts ................................................................................... 74  Figure 44 – Single Spray Ring Conversion to a Dual TSR for New 100 Series Finishers .......... 76  Figure 43 – TSR Electrical Enclosure Exploded View ................................................................ 84  Figure 45 – TSR Quick Fiber Electrical and HMI Enclosures – Parts Locator (P/N 04905310).. 91  Figure 45 – Cleaning-in-Place (CIP) ........................................................................................... 94  12 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  13. 13. Safety Information This manual contains important information on how to safely, efficiently and correctly operate and maintain JBT FoodTech equipment. Following these instructions will help keep personnel safe, reduce downtime, and increase the reliability and life of the equipment, its components, and related systems. This manual must always be available to operators whenever the equipment is operational and when the citrus processing season has ended. If you do not understand the 100 Series Finisher after reading this manual, please obtain the proper training before working with JBT FoodTech equipment to ensure your own safety and well as your co-worker’s safety. Do not attempt to operate any equipment or system until you completely understand why, when and how it operates. If you are uncertain after studying this manual, please contact your JBT FoodTech local technical service representative. Points of Contact Contact your JBT FoodTech Account Manager for the following: • • • Sales and order support Product technical training Support service agreements Safety Precautions This manual contains essential information regarding safe and appropriate operation of JBT FoodTech equipment. Operators performing any type of activity relating to the 100 Series Finishers must read and understand the instructions and warnings.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 13
  14. 14. Signal Words and Symbols JBT FoodTech equipment contains several signal words and symbols warning all personnel about certain hazardous or potentially unsafe conditions that may exist while operating and maintaining citrus processing equipment. The signal words used for product safety signs are: symbol indicates a hazardous situation, which if not avoided, will result The in death or serious injury. This signal word is limited to extreme situations. symbol indicates a hazardous situation, which if not avoided, could The result in death or serious injury. NOTE: DANGER or WARNING signal words are not used for property damage accidents unless personal injury risk appropriate to these levels is also involved. symbol indicates a hazardous situation, which if not avoided, could The result in minor or moderate injury. This signal word is usable with the safety alert symbol as an alternative to NOTICE. NOTE: For the great majority of hazards, the signal word “WARNING” is the best indicator of the hazard. As a rule, JBT does not use the signal word “CAUTION.” is the preferred signal word to address practices not related to personal The injury. The safety symbol are not be used with this signal world. Hazard Zones on the 100 Series Finishers Please read, understand, and daily remember the hazard zones of the 100 Series Finisher to help prevent personally injury and/or property damage: • Machine surroundings: One (1) meter from Finisher • Hot surfaces potentially above 170°F (76.7°C) Mechanical Hazards • • 14 Crushing or head injury from: o Falling components like nuts, bolts or clamps o Tank lids Hand injury from: o Pinching or cutting from finisher lids o Cutting from sharp corners MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  15. 15. o Cutting from sharp edges • Sprains or broken bones from: o Slipping caused by water spill o Wet surfaces • Eye injury from: o Loose air line o Lack of Proper Protective Equipment (PPE) o High pressure water o Chemicals used for cleaning Electrical Hazards • Receiving a shock from: o Electrical box o Gear motors • Burning from arcing: o Electrical box o Gear motors Noise Hazards  NA Thermal Hazards  Burning from hot caustic cleaning solution Substance Hazards • Skin and nasal irritation from: o Caustic cleaning solutions spilling on body from overflowing tanks Wastes and Environmental Pollution Please note that lubricants must comply with the regulations in force in the country of application. Risks, Protections, Warnings and Precautions THE CLOTHING OF THOSE WORKING OR PERFORMING MAINTENANCE OPERATIONS ON THE MACHINE MUST COMPLY WITH THE SAFETY REQUIREMENTS CONCERNING THE USE OF PERSONAL PROTECTIVE EQUIPMENT (PPE).     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 15
  16. 16. To ensure the health and safety of exposed people, JBT equipment is fitted with passive safety devices like guards and lids to help prevent the operator from making physical contact with hot surfaces and moving parts (motors, tanks, pipes, valves, steam, etc.) Intended, Non-Intended and Incorrect Uses Limits in usage of the machinery  The system operates automatically in the plant control room  An operator using proper safety equipment as defined by plant management operates the system  Qualified personnel maintain the machine  Qualified personnel operate the machine following the instructions given in the operating section of this manual  The machine is for professional use only  A person without limitations in physical abilities or visual impairment operates the machine if there is no danger in the person’s surroundings Reasonably foreseeable misuse  Processing liquids or materials other than those for which the finisher was designed (solid particles, juice, fermentation products)  Operating at temperatures/pressures higher than designed  Personnel in proximity of the system during CIP  The use of the machine by non-qualified personnel  The use of unsuitable tools or replacing components or spare parts with ones other than those specified in this manual  Removing standard safety devices  Blocking or disabling the air pressure system  Operation of system with Quick Fiber Control Panel cover removed on finishers with Timed Spray Ring (TSR). 16 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  17. 17. Safety Label Locations The machine has been designed in accordance with the most recent criteria in terms of safety and ergonomics. However, keep in mind that any moving part implies a certain danger level, and not touching any moving part is highly recommended. As an additional precaution, warning labels installed on areas implying potential or residual hazard constantly call the operator’s attention to said hazard (See Figure 1). See the ISO/ANSI Safety Labels form to order new labels at the back of this manual. TO CHANGE OR REMOVE GUARDS, SWITCHES, AND SAFETY LABELS WILL CATAGORICALLY VOID MACHINE SAFETY GUARANTEES AND WARRANTY AGREEMENTS. JBT FOODTECH IS NOT RESPONSIBLE FOR MACHINE SAFETY WHEN IGNORING OUR SAFETY DIRECTIVES IN THE DESIGN AND USE OF THE MACHINE. AS TIME GOES BY, LABELS MAY BECOME ILLEGIBLE OR OBSCURE. THE CUSTOMER IS RESPONSIBLE FOR KEEPING THEM IN GOOD CONDITION AND ORDERING REPLACEMENTS FROM JBT FOODTECH. Figure 1 – Typical Safety Label Locations for UCF110 and UPF100 Finishers Model UPF100 Model UCF110 Item No. U.S. Part No. Brazil Part No. Qty Description 1 2 Decal, WARNING, Read Operators Manual 2 09450009 2 Decal, DANGER, Automatic Start, ISO/ANSI,6″X2″ 3 09450013 2 Decal, WARNING, Rotating Shaft, ISO/ANSI,4″X2″ 4 09450065 2 Decal, WARNING, Rotating Parts, ISO/ANSI,4″X2″ 5 09450012 2 Decal, WARNING, UPF100 side discharge cover 6   09450020 09450012 1 Decal, WARNING, UPF100 front discharge cover   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 17
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  19. 19. Equipment Description A Finisher is a device that uses a screen to separate solids and liquids (See Figure 2). Examples include:  Juice and pulp  Frit and peel oil emulsion Figure 2 – Separating Solids and Liquids Applications  Juice (Primary): separates pulp from the extractor juice stream  Pulp Wash: separates soluble solids from pulp discharge coming from primary finisher  Oil Recovery: separates peel oil from the extractor frit stream  Core Wash: separates soluble solids from the membrane material stream  Classifying: separates core material and large defects from pulp juice stream in premium pulp recovery applications in the premium pulp system  Packaging/Drying: extracts excess juice from pulpy juice stream before or after pasteurization in pulp recovery applications     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 19
  20. 20. Performance Quality and yield parameters determine finisher performance. One measure of performance is the dryness of the solids discharged from the finisher (See Figure 3). Quick Fiber Value (See Appendix A on page 78)  Actual measurement of the relative dryness of finisher discharge through Quick Fiber test  Indicator of quality and yield performance  Control for optimum yield within quality parameters  Varies with fruit variety, maturity, and condition  Influenced by pressure and flow Juice Quality Parameters  Suspended (bottom) pulp  Juice viscosity  Product gelation Variables affecting finisher performance  Low Air Pressure: high Quick Fiber, juice loss  Excess Air Pressure: low Quick Fiber, pulp extrusion  Low Flow Rate: low Quick Fiber, pulp extrusion  High Flow Rate: high Quick Fiber, finisher backup, overflow Figure 3 – Quality and Yield Performance Plug Valve Function 1 Pulp In 2 Discharge Flange 3 Air Cylinder 4 Piston 5 Pulp Out 20 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  21. 21. UCF110 Description The UCF110 Finisher receives pulpy juice from inline juice extractors ❶ (See Figure 4). The solid liquid separation occurs by means of centrifugal force. The UCF110 Finisher can process any variety of citrus fruit (oranges, tangerines, lemons, limes, and grapefruit). The finisher can be used for both primary and secondary solids recovery. The screw finisher induces pulp separation from the juice ❸ and unloads the pulp pomace ❷ with uniform dryness. The finisher runs continuously with minimal operator intervention except when performing preventive maintenance prior to finisher operation. The only action required during the finisher’s operation is high-pressure water cleaning. Unfinished juice or other preprocessed citrus products enter the UCF110 Finisher through one intake opening ❶ only. Figure 4 – Operation of the UCF110 Finisher Product Flow 1 Juice + Pulp IN 2 Finished Juice OUT 3 Pulp OUT The screw conveys the product through a cylindrical screen cavity.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 21
  22. 22. Maintaining a uniform and constant pressure on the product pressed between the finisher screw and the screen produces a uniform dryness of the discharge pomace. Regulated air controls the pressure, which controls the plug valve assembly on the discharge end. The size of the screen perforations and the regulated air pressure on the finisher’s discharge end controls the degree of juice and pulp separation. All surfaces that contact the product are made of stainless steel. This type of corrosionresistant construction eliminates unsanitary conditions and allows high-pressure water cleaning. The finisher contains a ring with spray nozzles installed around the screen support. The ring moves (manually or with automation) along the length of the screen and applies high-pressure water spray on the screen. THE PROCESSING PLANT MUST PLAN FOR AN AUXILIARY PUMP CAPABLE OF SUPPLYING 75 GALLONS (284 LITERS) OF WATER PER MINUTE AT 450 (PSIG) POUNDS PER SQUARE INCH GAUGE (31.64 KG/CM2) FOR THE CLEANING SYSTEM. The high pressure cleaning system is used with the UCF110 while shut down or in operation. JBT FoodTech recommends using the cleaning system when the machine is operating without product flowing through the finisher. UCF110 Identification For all requests or orders always refer to the identification plate positioned on the machine (See Figure 5). Figure 5 – UCF110 Finisher Identification Plate 22 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  23. 23. UPF100 Description The UPF100 Finisher receives pulpy juice from inline juice extractors. The solid liquid separation occurs by means of centrifugal force. The UPF100 Finisher can process any variety of citrus fruit (oranges, tangerines, lemons, limes, and grapefruit). The finisher can be used for both primary and secondary solids recovery. The paddle finisher induces juice separation from the pulp and unloads pulp with even dryness. The finisher runs continuously with minimal operator intervention except when performing preventive maintenance prior to finisher operation. The only action required during the finisher’s operation is high-pressure water cleaning. Juice or other preprocessed citrus products enter the UPF100 Universal Pulping Finisher through inlet in one of its extremities (See Figure 6). Figure 6 – Operation of the UPF100 Finisher The product travels through a screw to the paddles and filtered by a cylindrical screen. The paddles force the product through the screen in order to filter the liquid and separate the evenly dried pulp before entering the pulp discharge head. Even and constant pressure on the processed product between the paddles and the screen maintains the even dryness of the pulp. Weights previously set on the finisher’s discharge head provide the pressure. The size of the screen perforations and the pressure on the discharge head controls the degree of juice and pulp separation.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 23
  24. 24. All surfaces that contact the product are made of stainless steel. This type of corrosionresistant construction eliminates unsanitary conditions and allows high-pressure water cleaning (See Figure 1). The finisher contains a ring with spray nozzles installed around the screen support. The ring moves (manually or with automation) along the length of the screen and applies high-pressure water on it. THE PROCESSING PLANT MUST PLAN FOR AN AUXILIARY PUMP CAPABLE OF SUPPLYING 75 GALLONS (284 LITERS) OF WATER PER MINUTE AT 450 (PSIG) POUNDS PER SQUARE INCH GAUGE (31.64 KG/CM2) FOR THE CLEANING SYSTEM. The high pressure cleaning system is used with the UPF100 while at idle or in operation. JBT FoodTech recommends using the cleaning system when the machine is moving, but not processing. UPF100 Identification For all requests or orders always refer to the identification plate positioned on the machine (See Figure 7). Figure 7 – UPF100 Finisher Identification Plate 24 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  25. 25. Installation Site Planning The 100 Series Finishers operate in a citrus processing plant. These machines are normally a part of a new extraction room or added to an existing system. The terms and conditions of the sales contract, agreed upon by the processor and JBT FoodTech, determines specific data for each installation of the UCF110 and UPF100 Finishers. The following items are priority considerations when placing and installing the UCF110 and UPF100 Finishers: 1. Proximity to the source of the product feed. If necessary, consider modifying the piping or structure for product supply 2. Proximity to the final processing area of the finisher’s output liquor. If necessary, consider modifying the piping or structure for product supply 3. Removal of discharged pulp from the finisher 4. Evaluate the location of pumps, carriers, or spouts for removal of the discharged pulp, and the availability of services such as electric power, portable water, industrial water, compressed air for instruments, etc. 5. JBT recommends gravity feed of the water supply. Install vents if the water supply travels through a pumping system. Site Preparation JBT FOODTECH HAS SPECIALIZED PROFESSIONALS THAT PROVIDE ASSISTANCE FOR THE INSTALLATION SITE OF ANY JBT EQUIPMENT. CONTACT JBT FOODTECH TO TAKE ADVANTAGE OF OUR EXPERIENCE. In the next few pages, Figure 8 outlines the spaces needed for the maintenance of the UCF110 and UPF100 Finishers while Figure 9 and Figure 11 displays the finisher’s external dimensions. 1. Plan for cleaning and maintenance space: a. At least 31-1/2˝ (800 mm) around the inlet head. b. At least 47-1/4˝ (1250 mm) around the outlet head to allow for removal of the finisher’s screw or paddle. c. At least 31-1/2˝ (800 mm) on the opposite side of the finisher.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 25
  26. 26. 2. The floor or base where you are installing the UCF110 or UPF100 Finisher must be level. If not, use shims during installation. 3. The floor must have the structural strength to support a minimum weight of 1,014 lbs. (460 kg) per finisher, not operating, plus the weight of any other attached equipment to the finisher. 4. Fasten the finisher to the floor according to the design or use the optional casters. 5. The floor must have an angled non-skid surface sloped towards the drainage gutter in order to allow for removal of water and cleaning solution. 6. Plan for the supply of electric power, water, etc., as close to the finisher as possible. 7. Electric panels must have waterproof gaskets. 8. Water lines must have manual lock out valves. Figure 8 – Finisher Maintenance Areas 26 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  27. 27. Installation Procedures THE UPF100 AND UCF110 FINISHERS WEIGH APPROXIMATELY 1,014 POUNDS (460 KILOGRAMS) WHEN NOT IN USE. TRANSPORT AND MOVE THESE MACHINES WITH CARE. TWO OR MORE SAFETY PERSONNEL MUST BE PRESENT DURING INSTALLATION. KEEP THE FINISHER AWAY FROM OTHER EQUIPMENT DURING MOVES. KEEP YOUR BODY AND HANDS AWAY FROM THE FINISHER WHEN LOWERING THE MACHINE TO THE GROUND. NON-COMPLIANCE WITH THESE INSTRUCTIONS MAY RESULT IN SERIOUS INJURIES OR DEATH! 1. Unload the finisher with a forklift or other moving equipment. 2. Transport the finisher as close as possible to the installation site. 3. Remove all packing and other materials, if any, from the inside and outside of the machine. 4. Inspect and measure the floor or base level. Place the level on the floor or between the fastening screws on the base and level the finisher. 5. Inspect the level of the finisher after installation and adjust as needed. 6. Anchor the finisher firmly on the floor or base, according to the design, or use the optional casters. 7. Clean the finisher’s product supply lines with high-pressure water before connecting them to the finisher. Foreign objects may damage the finisher. 8. Connect the water supply tubes to the finisher. 9. Connect the output liquor tubing to the finisher’s 3″ sanitary fitting with a tri-clamp. 10. Install the pulp discharge spout or plug valve assembly. TURN OFF AND LOCK OUT THE MAIN PANEL’S ELECTRIC POWER SUPPLY BEFORE CONNECTING THE ELECTRIC POWER TO THE 100 SERIES FINISHER. INSTALL THE ELECTRIC WIRING ACCORDING TO ESTABLISHED STANDARDS AND LAWS IN THE CUSTOMER’S GEOGRAPHIC LOCATION. DEFECTIVE WIRING MAY RESULT IN SERIOUS INJURY OR DEATH! 11. Inspect the electric motor power supply wiring. 12. Connect the high-pressure water line to the cleaning system. (For UCF110, see Figure 9 and Figure 10. For UPF100, see Figure 11 and Figure 12.)     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 27
  28. 28. Figure 9 – UCF110 Installation Dimensions 28 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  29. 29. Figure 10 – UCF110 Installation Instructions Item No. 1 09210015 2 N/A 3 N/A 4 N/A Spray Ring Inlet (Supplied with Finisher) 5 N/A Air Supply to Cylinder (Included in Optional TSR) 6 04050043 Clamp, High Pressure 7 07195012 Hose, High Pressure - 3/4″ ID X 13/16″ OD 8 10405827 Barb, Hose, 3/4″ ID Hose, 3″ LG 9 07136153 Reducer - CONC, 1-1/4″ X 1/2″ SCH10, Butt Weld, 304 SS 10 07740909 Valve, Actuated Ball – 1-1/2″ Tri-clamp 11 N/A Cleaning Water - 450 PSI Recommended for Citrus - 70-150 PSI may be Sufficient for Other Products 12 N/A 1-1/2″ Ferrule, 1-1/2″ Gasket, 1-1/2″ Clamp 13   U.S. Part No. Brazil Part No. Description N/A Bolt to Floor or use Optional Casters Screen - 0.020″ or (04904061 - Optional 0.020″ Screen w/Spiral) or (04904828 - Screen, Half - 0.020″) Product Outlet - 3″ Tri-clamp Cleanup Overflow - (Optional) 3″ Tri-clamp; Drain to Floor or to Drain   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 29
  30. 30. Figure 11 – UPF100 Installation Dimensions 30 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  31. 31. Figure 12 – UPF100 Installation Instructions Item No. 1 09210015 2 N/A 3 N/A 4 N/A Spray Ring Inlet (Supplied with Finisher) 5 N/A Air Supply to Cylinder (Included in Optional TSR) 6 04050043 Clamp, High Pressure 7 07195012 Hose, High Pressure - 3/4″ ID X 13/16″ OD 8 10405827 Barb, Hose, 3/4″ ID Hose, 3″ LG 9 07136153 Reducer - CONC, 1-1/4″ X 1/2″ SCH10, Butt Weld, 304 SS 10 07740909 Valve, Actuated Ball – 1-1/2″ Tri-clamp 11 N/A Cleaning Water - 450 PSI Recommended for Citrus - 70-150 PSI may be Sufficient for Other Products 12 N/A 1-1/2″ Ferrule, 1-1/2″ Gasket, 1-1/2″ Clamp 13   U.S. Part No. Brazil Part No. Description N/A Bolt to Floor or use Optional Casters Screen - 0.020″ or (04904061 - Optional 0.020″ Screen w/Spiral) or (04904828 - Screen, Half - 0.020″) Product Outlet - 3″ Tri-clamp Cleanup Overflow - (Optional) 3″ Tri-clamp; Drain to Floor or to Drain   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 31
  32. 32. Post Installation Inspection After the installation and before starting the machine, perform the following procedures: 1. Verify the tightness of all fasteners including screws, bolts, and nuts. DO NOT TIGHTEN FASTENERS MANUALLY. MANUAL FASTENER TIGHTENING FOR LATER TOOL TIGHTENING HAS RESULTED IN PERSONAL INJURIES AND A WASTE OF TIME AND MATERIALS. ALWAYS USE A TORQUE WRENCH WHEN TIGHTENING FASTENERS THE FIRST TIME. 2. Visually inspect the lubrication points in the intake and discharge ends for proper lubrication. 3. Remove the top screen support and check the alignment between the screw or paddle and the inlet and outlet heads using a dial indicator or caliper adjusted to the desired gap. 4. Manually rotate the finisher screw or paddle while inspecting for obstructions between the screw or paddle and the screen. Readjust the screen clearance, if necessary. (See Screw-to-Screen Alignment – UCF110 on page 50 or Paddleto-Screen Alignment – UPF100 on page 53). SCREENS AND OTHER PARTS CAN BE DAMAGED OR DESTROYED BY MISALIGNED OR BROKEN PARTS, OR BY FOREIGN OBJECTS IN THE FINISHER. 5. Power up the finisher for brief intervals (one-half to one second) to operate the finisher paddles. 6. Open the top cover and observe the finisher paddles through the screen. 7. The screw or paddle must rotate clockwise when viewed from the drive side. 8. The brief operation of the screw or paddle should also loosen any foreign objects, if any, that may damage the screen. 9. If you hear strange noises (squeaks, clanks, etc.) stop and lock out the machine, remove the screen support and screen, remove the foreign object, replace the screen support and screen. NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! 32 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  33. 33. 10. Inspect the high-pressure water supply fitting for tightness and leakage and repair as needed. 11. Open the manual water supply valve. 12. Move the spray ring along the entire length of the screen or use the automated spray ring system, if equipped. 13. Open the top cover. 14. Note where the water from the spray ring hits the screen. 15. Compare both sides. 16. Determine if the screen support needs to be rotated and in which direction. Perform any correction needed. 17. Position and tighten the spray nozzles so that the jet coming out of a nozzle overlaps the jets from the adjacent nozzles without interfering with each other. 18. Remove and clean the spray nozzles if needed. They can be unscrewed from the spray ring without removing the ring.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 33
  34. 34. This page is intentionally left blank. 34 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  35. 35. Operation Pre-operational Inspection SCREENS AND OTHER PARTS CAN BE DAMAGED OR DESTROYED BY MISALIGNED OR BROKEN PARTS, OR BY FOREIGN OBJECTS IN THE FINISHER. 1. Perform a machine inspection prior to every startup to prevent damage to the equipment. BEFORE ATTEMPTING TO OPERATE THIS EQUIPMENT, FAMILIARIZE YOURSELF WITH THE LOCATIONS OF ALL SAFETY SHOWERS AND EYEWASH STATIONS. DISCONNECT MACHINE USING PROPER LOCKOUT / TAGOUT PROCEDURES BEFORE PERFORMING ANY OF THE FOLLOWING INSPECTIONS. a. Inspect for leaks at water and air supply connections to the Air/ Water Control Panel and at the high-pressure cleanup system. Clean water filter, if equipped. b. Tighten loose connections. c. Clean work area of trash, rags, tools, and other foreign items. d. Open cover and inspect screen openings. e. Clean screen openings of any pulp and fibers, if needed. FINISHER EFFICIENCY, YIELD AND QUALITY OF THE PRODUCT ARE AFFECT BY PLUGGED SCREENS 2. Fasten drive guards and motor covers securely in place, if needed. 3. Open the cover and energize the finisher power switch for one-half second to one second at a time. 4. Inspect for clockwise rotation of the finisher screw or paddle when viewed from the drive end. 5. Jogging the motor indicates the rotation and dislodges loose objects. 6. Remove any loose objects from the finisher to prevent damage to the screens. NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH!     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 35
  36. 36. Quick Fiber Controls (Applies to Finishers using TSR with Quick Fiber Controls only) Calibrate the current-to-pressure transducers at the start of every fruit season. Replace gauges and regulator as needed. Repair poly tubing as needed. This is also the time of year to verify Quick Fiber Controls and automated spray ring (TSR) operation. BEFORE STARTUP, INSPECT THE FINISHER FOR PROPER LUBRICATION THAT DISPLAYS NO SIGNS OF CONTAMINATION. 1. Immediately after startup, monitor Quick Fiber readings. Adjust bias numbers to achieve the correct Quick Fiber values (See Appendix A on page 78). 2. Take one Quick Fiber reading per finisher every 24 hours. Open the cover on the finisher to inspect for blinding due to excessive spray intervals or plugged nozzles. 3. Perform a mechanical inspection of the plug valve and air supply when any Quick Fiber reading is not adjustable with the bias. 4. In the event that Quick Fiber Control continues to function improperly, please contact your authorized JBT FoodTech representative. Daily Inspections for Proper Mechanical Operation Spray nozzles are open Plug valve operational (TSR only) Spray ring travel TSR Interval (automated systems only) Quick Fiber values are on target (set by customer) Discharge gate air supply (at the correct psi) Hoses for damage Bushings and retainers Finisher screens Water/ Air leaks Cover latches Weekly Inspections for Proper Controls Operation Daily Inspections Bias numbers in range (not under 0.5 not over 2) Transducer air gauges operational (supply and output) Flow meters Any issues reported by finisher operators (Cleanup, bottom pulp, etc.) 36 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  37. 37. Operating Procedures THE DISCHARGE BEARING HOUSING MAY BECOME HOT AT 230°F [110°C] OR GREATER DURING OPERATION. THIS IS NORMAL. BEARING FRICTION CAUSES HEAT BUILDUP. AS AIR PRESSURE INCREASES, HEAT INCREASES. DO NOT TOUCH THE DISCHARGE BEARING HOUSING OF THE FINISHER DURING OPERATION OR BURNS MAY RESULT. MAKE SURE THE FINISHER HAS THE PROPER LUBRICATION WITH NO SIGNS OF CONTAMINATION BEFORE START-UP. 1. Open the air pressure valve to the Air Control Panel. 2. Adjust the pressure regulator to obtain a 0-15 PSI reading on the gauge. 3. Start the finisher and start the product flow as quickly as possible. 4. Listen for scraping or unusual noises. 5. STOP THE FINISHER IMMEDIATELY IF YOU HEAR ANY UNUSUAL NOISES. 6. Determine the cause of the noise and make the proper correction (See the Troubleshooting section on page 61 for assistance). 7. If you have to eliminate any noises, repeat the above steps. 8. When pulp begins discharging from the plug valve, inspect the dryness of the pulp by performing a Quick Fiber Test (See Appendix A on page 78). 9. Test Quick Fiber regularly to make certain it is consistent with the quality standards established by the customer. 10. A rise in Quick Fiber can mean three things:  The air pressure on the discharge has decreased  The screens have blinded with pulp  An increase in the juice flow rate of the finisher MAINTAINING CONSISTENT QUICK FIBER VALUES IS VERY DIFFICULT WHEN THE SCREEN CLEANING PROCEDURE IS NOT DONE ON A REGULAR OR AS NEEDED BASIS.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 37
  38. 38. Manual (Short Term) Shutdown Procedures Shut off electrical power to the finisher if the flow of unfinished product is interrupted for two minutes or longer. If the finisher will be shutdown longer than ten minutes: 1. Rotate the control panel air valve to the OFF position (Plug valve will open) 2. Flush the finisher for approximately one minute with the high-pressure spray ring. Slowly move (MSR only) the ring back and forth the full length of the screens or activate the automated cleanup system (TSR with Quick Fiber Controls only). 3. Shut off electrical power to the finisher. Season End (Long Term) Shutdown Procedures A CUSTOMER’S CLEANUP PROCEDURES ARE USUALLY A PART OF THE SYSTEM SHUTDOWN PROCEDURE. THE FINISHER’S CORROSION RESISTANT CONSTRUCTION PERMITS CLEANING WITH CAUSTIC CLEANING SOLUTIONS. WHERE A PROPER PROVISION EXISTS, INTERNAL CLEANING OF THE FINISHER CONTINUES WITH THE CLEANUP SOLUTION FROM THE EXTRACTORS. CAUSTIC CLEANING SOLUTION CAN CAUSE SERIOUS BURNS OR EYE INJURY. IF CAUSTIC CONTACTS SKIN OR EYES, IMMEDIATELY RINSE AND APPLY FIRST AID. 1. Allow the finisher to complete the processing cycle. Observe the finished pulp discharge chute to verify a completed processing cycle before performing step 2. 2. Rotate the air valve to the OFF position on the air control panel. 3. Clean the finisher with water. Use the high-pressure spray ring to flush out pulp and fibers remaining in the finisher. 4. Turn off and lockout power at the main control panel. 5. Wash the finisher’s exterior surfaces. 6. Close the manual water valve to the high-pressure spray ring. Call JBT FoodTech at +1.863.683.5411 and ask for “Finisher Service” if there are any questions concerning the operation of this finisher. 38 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  39. 39. Maintenance Procedures NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! This section contains instructions for removal, disassembly, assembly, and replacement of the 100 Series Finisher parts (See Figure 13Error! Reference source not found. and Figure 14). The spare parts list section identifies all replacement parts. Use the troubleshooting section to investigate part failures. DISASSEMBLY AND ASSEMBLY OF THE 100 SERIES FINISHER REQUIRES THE SUPPORT OF HEAVY PARTS AND ASSEMBLIES. DO NOT ATTEMPT TO REMOVE THESE ITEMS WITHOUT HELP. USE BLOCKS AND SLINGS TO SUPPORT THE WEIGHT WHENEVER POSSIBLE. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE PERSONAL INJURY OR DAMAGE THE EQUIPMENT. OPERATION OF THE 100 SERIES FINISHER USES A HIGH PRESSURE WATER SUPPLY AND ALL CONNECTIONS SHOULD BE TIGHT. CLOSE OFF THE MAIN INPUT VALVE WHEN PERFORMING MAINTENANCE OR DURING SHUTDOWN. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE PERSONAL INJURY.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 39
  40. 40. Figure 13 – Manual Spray Ring (MSR) System (with optional casters) UCF110 Screw Finisher (PN 04904600-01) UPF100 Paddle Finisher (PN 04904800-01) Figure 14 – Automatic Spray Ring (TSR) with Quick Fiber Controls (with optional casters) UCF110 Screw Finisher (PN 04904600-02) 40 MAN# 04904600/4800.05292012 UPF100 Paddle Finisher (PN 04904800-02) Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  41. 41. High Pressure Cleaning NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! The top half of the spray ring is normally the only part of the high-pressure clean-in-place (CIP) system that needs removal; usually to remove the screen and screen frame. The spray nozzles can be unscrewed from the spray ring without removing the spray ring. It should not be necessary to remove the bottom half of the spray ring even for major repairs (See Figure 15). Figure 15 – 100 Series Finisher High-pressure Spray Ring Systems     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 41
  42. 42. Single and Dual Spray Ring Removal CLOSE, LOCKOUT AND TAGOUT THE MAIN HIGH PRESSURE WATER SUPPLY VALVE BEFORE DISCONNECTING THE WATER SUPPLY HOSE FROM THE SPRAY RING PIPE. FAILURE TO DO THIS MAY RESULT IN POSSIBLE INJURY TO PERSONNEL OR DAMAGE TO THE EQUIPMENT To remove the cleanup system from the finisher, proceed as follows (See Figure 16): 1. Close off and lock the main high-pressure water supply valve. 2. Disconnect water supply hose from the pipe end of the spray ring ①. 3. Open the finisher cover. 4. Loosen the hex coupling nuts ② on each side of the screen frame to separate the two ring halves. The coupling nuts are part of the upper half of the spray ring. Figure 16 – High Pressure Spray Rings (UCF110 Shown, UPF100 Similar) Timed Spray Ring (TSR) System 42 MAN# 04904600/4800.05292012 Single Spray Ring (SSR) System Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  43. 43. 5. Lift the top half of the spray ring ③ from the finisher (See Figure 16). 5a. For TSR Systems only: Remove the cotter pin ⑦ and clevis pin ⑧ securing the vertical actuator arm ⑨ to the clevis on the drive cylinder ⑩. Figure 17 – Disconnecting Vertical Actuator Arm 6. Unscrew the pipe ① from the spray ring ③. 7. Pull the pipe ① out through the bushing ④. 8. Remove the self-locking nut ⑤from the guide rail ⑥ at the finisher intake end. 9. Pull the spray ring guide rail ⑥ out of the spray ring and out through the discharge end of the finisher. Work the bottom half of the spray ring around the screen frame and remove. 10. Remove nozzles threaded into the spray ring ③ by rotating nozzles counter-clockwise. 11. Inspect the condition of one wear block ⑪ for SSR and two wear blocks ⑫ for TSR cleaning-in-place (CIP) systems. 12. If wear block is worn, rotate it 90° so an unworn surface will slide on the finisher sidewall. Replace any wear block if worn on both sides. Single and Dual Spray Ring Installation 1. Replace the SSR or DSR in reverse order of removal (Review Figure 16). 2. After reassembly, open the high-pressure water valve. 3. Manually or automatically, move or activate the spray ring the length of the screen. 4. Observe where the water spray strikes the screens and compare the spray patterns. 5. Determine if the spray ring nozzles should be rotated, and in what direction. 6. Tighten and position nozzles so adjacent spray patterns overlap without interference.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 43
  44. 44. Screen Frame Removal DO NOT PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! 1. Unlatch and open the finisher cover. 2. Remove the top half of the spray ring (Review the Single and Dual Spray Ring Removal procedure, Figure 16 for TSR and SSR). 3. Remove the twelve (12) hex-head cap screws and nuts (six on each side) that secures the two halves of the screen frame together (See Figure 18). 4. Lift the top screen frame and screen straight up and out of the finisher. 5. Gently set down the top screen frame and screen. Do not damage it. 6. Grasp the bottom screen frame. 7. Rotate the bottom screen frame 180-degrees. 8. Lift the frame up and out of the finisher. DO NOT DROP THE FRAME HARDWARE INTO THE FINISHER. NEVER WELD THIS HARDWARE TO THE FRAME. SOME FRAMES MAY HAVE STUDS RATHER THAN HEX-HEAD SCREWS. Figure 18 – Screen Frame Item No. Part Numbers U.S. Brazil QTY Description 1 12 Nut, Hex, Heavy, 3/8-16, SS 2 44 04111049 04501152 12 Screw, Cap, Hex. 3/8-16 X 2″, SS MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  45. 45. Screen Removal 1. Place both frame halves on a non-marring surface with the screen facing upward. Remove five (5) screws on each side of the frame and lift the screens out of the frame halves (See Figure 19).  DO NOT SWITCH ENDS OR POSITION of the screens.  DO NOT FORCE the screens as they might bend, puncture, or tear.  Larger openings in screen frame are toward the intake end of the finisher.  Smaller openings are toward the discharge end of the finisher. Figure 19 – Screen Removal Item No. Part Numbers U.S. QTY Brazil Description RSP 1 0490618:1 1 Support Frame, Screen  2 0490618:2 1 Support Frame, Screen  3 09210015 2 Screen, Flat, 0.020″ Etched  4 39200314 20 Screw, Machine, 1/4-20 SS RSP=Recommended Spare Part     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 45
  46. 46. Screen and Frame Inspection 1. Inspect screen frame surfaces.  Frames should be clean, smooth, and free of burrs, nicks, or gouges. 2. File screen frames if necessary to remove any burrs. Replace frame if unserviceable. 3. Inspect the upper and lower screens for damage and wear. Replace if necessary (See Figure 20.) Figure 20 – Screen Inspection Damaged Screen Worn Screen New Extended Life Screens 46 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  47. 47. Screen Installation IF HALF SCREENS ARE BEING INSTALLED FOR LOW FLOW CONDITIONS, INSTALL THE “CLOSED END” OF THE SCREEN TOWARDS THE INTAKE END (LARGER OPENINGS IN SCREEN FRAME) WITH THE “OPEN END” OF THE SCREEN TOWARDS THE DISCHARGE END (SMALLER OPENINGS IN SCREEN FRAME) OF THE FINISHER. 1. Place one screen in one frame half ① and make sure each screen edge is 1/8″ (3.175 mm) away from the frame edge (See Figure 19). Hold the screen in place by hand while installing the ten (10) machine screws. DO NOT TIGHTEN SCREWS AT THIS TIME. JBT Special Tool P/N 2033303 is required to locate, clamp, and hold the screen in place before and while tightening these screws (See Figure 21). CONTACT JBT FOODTECH TO PURCHASE ALL OF YOUR 100 SERIES FINISHER SPECIALTY TOOLS. PLEASE NOTE THAT THE TOOLS DISPLAYED IN THIS PROCEDURE MAY NOT LOOK EXACTLY LIKE THE TOOLS FOR YOUR FINISHER MODEL. HOWEVER, THE OVERALL PROCEDURE IS THE SAME; SECURING THE FINISHER SCREENS TIGHT AGAINST THE SCREEN FRAME HALVES. Figure 21 – JBT Specialty Tool 2. On the JBT special tool, rotate the six clamping screws counter-clockwise until the thread ends are flush with the bracket surface. 3. Place the JBT special tool on one frame and screen flange as illustrated in Figure 22. There are two possible ways of installing the special tool on each side. The tool is properly located when each end is about 1/8″ (3.175 mm) from the end of the frame and the screw heads fit in the holes provided. If the tool does not fit, rotate the tool end-to-end and recheck for proper tool location. 4. Install six 3/8″ (9.525 mm) cap screws ③ (The ones used to hold the screen frames together) through the frame flange holes, screen flange holes, tool holes and secure with six nuts ④ (See Figure 23).     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 47
  48. 48. Figure 22 – JBT Specialty Tool Alignment Improperly Placed Tool with gap Properly Placed Tool with no gap 5. Hand-tighten all six 3/8″ (9.525 mm) cap screws ③ and nuts ④ with a wrench and then loosen all six bolts one-quarter (1/4) turn (See Figure 23). 6. Hand-tighten three special tool clamping screws ❻ to hold the flange square edgewise. This will pull the screen ② against the inside diameter of the screen frame ① next to the flange. Figure 23 – Installed Tool Bolted to Frame and Screen Flanges 48 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  49. 49. 7. Visually verify screen flange to frame flange contact and retighten the six 3/8″ (9.525 mm) cap screws and nuts (See Figure 24 . Figure 24 – Screen Flange to Frame Flange Contact 8. Again, visually verify that the flange of the screen is in contact with the flange of the frame. If the flanges are not in contact, repeat steps three through eight. 9. Tighten the five machine screws with a screwdriver as shown in Figure 25. Figure 25 – Securing Screen to Frame 10. Remove the tool by taking out the six 3/8″ (9.525 mm) cap screws ③ and loosening three (3) clamp screws ❻. It is best to loosen the clamp screws one full turn to clear the frame (Refer back to Figure 23 if needed). 11. Repeat the same procedure on the other flange and then on the other half of the screen frame.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 49
  50. 50. Screw-to-Screen Alignment – UCF110 NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! Tools required to perform this procedure include:  Dial Indicator Gauge  End wrench  Hex wrench  Mirror, 4″ (104.6 mm) or 5″ (127 mm) 1. Remove top covers and gear motor guard if not already removed (See Figure 30). 2. Located on each side of the six 3/8″ (9.525 mm) hex-head cap screws ① are twelve 3/8″ (9.525 mm) socket head setscrews ②. Rotate these setscrews counter-clockwise to where the threaded end will not contact the frame (See Figure 26.) Figure 26 – Screen & Frame Assembly 3. Tighten the six 3/8″ (9.525 mm) hex-head cap screws ① until the flange flatly contacts the main frame. 4. Mount the indicator gauge on the screw (See Figure 29) so that the indicating point rests on the diameter that locates the screen and screen frame assembly. 50 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  51. 51. Figure 27 – Indicator Gauge Mounting 5. Rotate the screw in the direction of travel several times, noting the high and low indicator readings. 6. On the main frame, write a "+" where the reading is the greatest, and a "–" where the reading is the least. 7. Reset the indicator by unlocking the dial and rotating it or adjusting the mount, so that the + and – readings are the same at the two points previously marked. 8. Start with the hex-head cap screw nearest the + reading and mark with #1. Proceed to number them #2, #3, #4, #5 and #6 in a clockwise direction. 9. Loosen hex-head cap screw ① at the other positions two turns (See Figure 26.) 10. Tighten the socket head setscrews ② at the #1 position until the flange moves outward to contact the hex-head cap screw. DO NOT USE EXCESSIVE FORCE AT ANYTIME DURING THE ALIGNMENT PROCESS. Tightening the socket head setscrews causes the indicator to move in the plus (+) direction. Tightening the hex-head cap screws causes the indicator to move in the minus (–) direction. In all adjustments, be sure the hex-head cap screw is loose when tightening the setscrews. The setscrews must be loose before tightening the hex-head screw or the flange will distort and so will the diameter that the indicator is contacting. 11. Rotate the screw so that the indicator is at screw location #3. 12. Tighten the setscrew until the indicator reads near zero. 13. Tighten the hex-head cap screw until it holds the setscrew against the main frame. If the indicator changes, readjust the screws at this location until the reading is within ± 0.005″ (0.127 mm).     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 51
  52. 52. 14. Rotate the screw until the indicator is at the #5 position and repeat the above procedure. 15. Rotate the screw back to the #1 position and make adjustments using the socket head setscrews and hex-head cap screw to bring the indicator to zero. 16. Rotate the screw while watching the indicator and note the high and low readings. 17. Readjust the indicator to where the + and – readings are equal. 18. Start at position #1, using the socket head setscrews and hex- head cap screw; bring the indicator to zero. 19. Do the same at position #3 and #5, which should result in a rather uniform reading all the way around. 20. If the reading is within ± 0.003″ (0.0762 mm), GO TO THE OTHER END OF THE FINISHER. 21. Align the opposite end following the above procedures. After the second end is aligned within ± 0.003″ (0.0762 mm), go back to the first end and check the alignment there. Aligning the second end causes a change in the first end and needs readjustment. 22. Align the first end within ± 0.002″ (0.0508 mm) or less, following the above procedures. At this time, the socket head setscrews and hex-head cap screws should be tight at #1, #3 and #5 positions. If not, tighten the hex-head screws. Position the indicator at each location during the tightening operation to detect any change created by the tightening. If the indicator reading is less than zero, loosen the hex-head screw, tighten the setscrews, and then retighten the hexhead screw. Repeat this at each of the six positions on this end of the finisher. The indicator reading should not go beyond ± 0.002″ (0.0508 mm) on the indicator after this tightening. 23. Go back to the other end of the finisher and follow this same procedure until a reading of ± 0.002″ (0.0508 mm) or less is reached. 24. Go back and check the other end to see if it has changed. If it is still within the ± 0.002″ (0.0508 mm), the alignment is complete. If not, repeat the process until it is. WHILE THE ABOVE PROCEDURE IS RECOMMENDED, OTHER SEQUENCES WOULD NO DOUBT BE JUST AS EFFECTIVE. ANY PROCEDURE THAT GIVES THE ALIGNMENT REQUIRED, WITHOUT DISTORTING THE SCREEN SUPPORT DIAMETERS, CAN BE USED. 52 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  53. 53. Paddle-to-Screen Alignment – UPF100 NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! Tools required to perform this procedure include:  Dial Indicator  Caliper or ruler  Open/closed box end wrench  Hex wrench  Mirror, 4″ (104.6 mm) or 5″ (127 mm) 1. Open the finisher cover and remove all twelve 3/8″ (9.525 mm) cap screws ② and nuts ① from the screen frame. Lift the top screen frame and screen out of the finisher (Review Figure 18, if needed). 2. Mount the dial indicator ① on the paddle, using the appropriate device. Rotate the entire paddle assembly in 90° quadrants until you obtain “zero movement” on all four points (See Figure 28). Figure 28 – Dial Indicator Gauge Mounting 3. If you detect any misalignment, adjust paddle gap on each paddle, if needed (See Figure 29). Figure 29 – Adjusting Paddle Gap Finisher Type Paddle Gap ④ Primary Juice and Pulp Concentrating 1/8″ Pulp Wash and Pulp Packaging 3/16″ – 1/4″ Oil Finisher 3/4″ ① Screen Frame ② Paddle ③ Adjustment Screws and Nuts     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 53
  54. 54. Finisher Intake NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! 7.5 HP Gear motor The finisher drive system includes:   A 7.5 hp, 60 Hz, 1800 rpm gear motor, or A 7.5 hp, 50 Hz, 1500 rpm gear motor Removal RESET THE SCREW-TO-SCREEN ALIGNMENT AFTER REMOVING AND REINSTALLING THE INTAKE END (SEE PAGE 50 FOR PROCEDURE). To remove the intake (See Figure 30): 1. Remove the gear motor cover ① to access the greaseable flange bearing ⑨ (remove every three months and inspect bearing to make sure seals are not blown due to over greasing, which would mandate bearing replacement). Slowly inject grease into the flange bearing at the grease nipple every three months. 2. If the flange bearing seals look like they are damages, loosen and remove the bolt and washer from the end of the gear motor ⑩. THE MOTOR IS HEAVY. DO NOT ATTEMPT TO MOVE MOTOR WITHOUT HELP. KEEP YOUR BODY AND HANDS AWAY FROM THE MOTOR WHILE REMOVING AND LOWERING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD CAUSE SEVERE PERSONAL INJURY! 3. Remove the gear motor ⑩ with torque arm ⑪ from the screw shaft. 4. Remove intake cover ②, chute ③ and housing ④. 5. Inspect flange bearing for blown seals or dry bearings. Slowing inject grease into bearing without breaching the flange bearing seals with excess grease. Replace bearing if needed. Installation Reassemble the gear motor in reverse order of removal. Observe all safety notices (See Figure 30). 54 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  55. 55. Figure 30 – Intake End of 100 Series Finishers Part Numbers Finisher model Item UCF110 / UPF100 1 04904831 Cover, Shaft Top UCF110 / UPF100 2 04906374 Cover, Intake UCF110 / UPF100 3 04906373 Chute, Intake UCF110 / UPF100 4 04904820 Housing, Intake UCF110 / UPF100 5 07660101 Seal, Hydraulic Pressure UCF110 / UPF100 6 07486160 O-ring, Viton UCF110 / UPF100 7 04904642 Seal, Cartridge, Intake UCF110 / UPF100 8 04904641 UCF110 / UPF100 9 05074026 UCF110 / UPF100 10 05754086-1 Shim, Flange Bearing Bearing, Intake Flange Ball Motor, Gear (without torque arm) Arm, Torque U.S. Brazil UCF110 / UPF100 11 04905300 RSP=Recommended Spare Part   Description RSP         Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 55
  56. 56. Finisher Discharge NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! RESET THE SCREW-TO-SCREEN ALIGNMENT AFTER REMOVING AND REINSTALLING THE DISCHARGE END. To remove the matched tapered roller bearing assembly and rotary seal from the bearing housing in the discharge end: 1. Open the finisher cover and remove all twelve 3/8″ (9.525 mm) cap screws ② and nuts ① (See Figure 31) from the screen frame. Lift the top screen frame and screen out of the finisher. MAKE NOTE OF EACH BEARING POSITION AS IT RELATES TO THE UNIQUE SPACER BETWEEN THEM. Figure 31 – Removing the Top Frame and Screen from the Finisher THERE IS NO EXTERNAL GREASE NIPPLE CONNECTED TO THE SELFALIGNING, TAPERED ROLLER BEARINGS. THE GREASE IN THE TWO BEARINGS ARE HAND-APPLIED ONCE THEY ARE REMOVED FROM THE DISCHARGE END AT THE BEGINNING OF EACH PROCESSING SEASON. 56 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  57. 57. BE CAREFUL WHEN REMOVING THE SELF-ALIGNING, TAPERED ROLLER BEARING (A MATCHED SET CONSISTING OF A BEARING-SLEEVEBEARING COMBINATION) AS SEEN IN Figure 32 AND Figure 33, ITEM ⑦. THIS TWO BEARING SET IS MARRIED FACE-TO-FACE WITH A UNIQUE MIDDLE SPACER AND ARE NOT INTERCHANGEABLE. THE MATCHED SET IS REPLACEABLE AS AN ASSEMBLY (BEARING-SLEEVE-BEARING COMBINATION) AND NOT AS THREE SEPARATE PARTS. ONLY GREASE ONE BEARING AT A TIME TO AVOID MISPOSITIONING THE BEARINGS. Figure 32 – UPF100 Finisher Discharge End Part Numbers Finisher model Item UPF100 1 04904715 Screw, Balanced Paddle UPF100 2 04906193 Head, Discharge UCF110 / UPF100 3 07660102 Seal, Hydraulic UCF110 / UPF100 4 07486162 O-Ring, Viton UCF110 / UPF100 5 04904614 Bearing, Housing UCF110 / UPF100 6 07660013 Seal, Grease UCF110 / UPF100 7 04904764 Bearings, Tapered Roller UCF110 / UPF100 8 07486162 O-Ring, Viton UCF110 / UPF100 9 04904615 Cap, Bearing Housing UPF100 10 04905157 Cover, Inspection UPF100 11 04905163 Chute, Pulp Discharge UPF100 12 04906198 Assembly, Retention U.S. Brazil UPF100 13 04904712 RSP=Recommended Spare Part   Description RSP      Support, Bearing   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 57
  58. 58. Figure 33 – UCF110 Finisher Discharge End Part Numbers Finisher model Item UCF110 1 04904605 Screw UCF110 2 04904612 Housing, Discharge UCF110 / UPF100 3 07660102 Seal, Hydraulic UCF110 / UPF100 4 0748616 O-Ring, Viton UCF110 / UPF100 5 04904614 Bearing, Housing UCF110 / UPF100 6 07660013 Seal, Grease UCF110 / UPF100 7 04904764 Bearings, Tapered Roller UCF110 / UPF100 8 07486162 O-Ring, Viton UCF110 / UPF100 9 04904615 Cap, Bearing Housing UCF110 10 04904722 Gasket, Plug Valve UCF110 11 04904810 Assembly, Plug Valve UCF110 12 04903374 Cylinder, Plug Valve UCF110 13 04903372 Piston, Plug Valve UCF110 14 04904812 Coupling, Piston UCF110 15 04903372 Cap, Cylinder U.S. UCF110 16 07055518 RSP=Recommended Spare Part 58 MAN# 04904600/4800.05292012 Description Brazil Cylinder, Pneumatic RSP      Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  59. 59. Servicing Plug Valve Air Cylinder Check with the juice room operator and be sure everyone knows you are going to shut down the 100 Series Finisher for repairs. NEVER PERFORM MAINTENANCE OR REPAIR WORK UNTIL YOU ARE SURE THE ELECTRICAL POWER IS OFF, LOCKED OUT AND CANNOT BE TURNED BACK ON WITHOUT YOUR KNOWLEDGE. ELECTRICAL SHOCK AND MOVING MACHINERY CAN CAUSE SERIOUS INJURY OR DEATH! 1. Locate and tag the air cylinder airlines for reconnection in the proper location. 2. Disconnect the airlines from the pneumatic cylinder ⑥ and the plug valve air cylinder ② (See Figure 34.) 3. Unscrew the cylinder cap ⑤, along with the pneumatic cylinder ⑥ in a counter-clockwise motion and pull them out of the cylinder ② (See Figure 34.) UCF110 FINISHERS WITH AND WITHOUT AUTOMATION HAVE A 1-1/2 INCH AIR CYLINDER BORE WITH TWO AIRLINES. THE UPF100 FINISHER DOES NOT USE AN AIR CYLINDER UNLESS IS HAS THE TSR OPTION. Figure 34 – Disassembled Plug Valve Assembly for UCF110 and UPF100 with TSR Part Numbers Finisher model Item UCF110 only 1 04904722 Gasket, Plug Valve UCF110 only 2 04903374 Cylinder, Plug Valve UCF110 only 3 04903372 Piston, Plug Valve UCF110 only 4 04904812 Coupling, Piston UCF110 only 5 04904811 Cap, Cylinder U.S. UCF110 only 6 07055518 RSP=Recommended Spare Part   Description Brazil Cylinder, Pneumatic RSP    Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 59
  60. 60. 4. Be very careful when pulling this assembly out. The piston ③ is a slip fit on the piston coupling ④, and it will fall off when it clears the housing. Hold your hand under the separated area of the plug valve to catch it as it exits the air cylinder ②. 5. Take the cylinder to a work table where there is a vise. Place the assembly in the vise by clamping the air cylinder on the milled end. Do not clamp the cylinder on the body, as damage will occur. 6. Hold the piston coupling ④ with pliers and loosen the jam nut. 7. Just below the jam nut on the cylinder shaft there is a milled off place for a wrench. Hold the shaft and unscrew the piston coupling ⑤ and the jam nut. 8. Unscrew the cylinder cap ②. Sometimes it is hard to break loose because of corrosion. 9. Remove the fittings from the cylinder. 10. Preparing parts for reassembly: a. Apply anti-seize to threads on the cylinder ⑥ to help prevent corrosion. b. Clean threads on the other parts and inspect the piston coupling ⑤ for burrs and correct as needed. 11. To reassemble, clamp the new cylinder in the vise in the same position as the old cylinder. 12. Rotate the cylinder cap ② clockwise onto the cylinder until it bottoms out. 13. Rotate the jam nut clockwise onto the cylinder shaft until it bottoms out. 14. Rotate the piston coupling ⑤ to the shaft clockwise until it bottoms out. 15. Tighten the jam nut against the piston coupling ⑤. 16. Slip the piston ④ onto the coupling ⑤. It must slide on freely and spring around on the coupling if necessary. 17. Reinstall the plug valve assembly. Be very careful not to drop the piston. Rotate the cylinder cap and piston assembly clockwise until it stops. Tighten until just snug. Do not over tighten. 18. Reinstall the fittings in the cylinder and rotate them to the proper position. 19. Reconnect the airlines in the proper location. Make sure the piston moves freely after assembly. If not, disassemble and check for burrs and rough surfaces. Carefully remove burrs and polish any rough surfaces. 60 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  61. 61. Troubleshooting Refer to Table 1 for diagnosis and corrective actions. Refer to chapters in the manual and the Spare Parts Section for assistance in disassembly and assembly of the finisher. Table 1: Troubleshooting Trouble Indication Cause Visual observation Corrective Action No power to motor  Check control box Faulty wiring Motor shaft does not rotate  Replace fuses  Repair wiring  Repair / replace motor Finisher screw does not turn Motor burned out No power Visual observation  Check fuses / wiring  Repair / replace motor No pulp discharge Finisher screw does not turn Faulty motor or broken screw  Replace screw. Return assembly to JBT. Finisher overflowing  Replace flange ball bearing assembly Leaking around shaft and flange bearing or in between Visual inspection shaft and intake housing  Replace hydraulic seal, O-ring, and cartridge intake seal Contamination Uneven or grinding sound Noisy intake bearing  Lubricate Foreign object in finisher  Replace bearings  Replace / Align screen Worn screen on intake end Deformed screen Improper fit to frame Screen wear  Refit and replace screen Misalignment of screw Visual inspection  Replace bearings Foreign object General wear Visual inspection   Unusual noises during operation Intake or discharge bearing wear Excessive pulp in product Screen puncture or tear Improperly fitted screen Foreign object in finisher  Replace screen  Check juice intake supply source   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 61
  62. 62. Trouble Indication Excessive build-up of pulp Pulp and fiber build-up starts plugs screen holes at discharge end and builds Excessive pressure on up toward intake end control gate Air regulator installed in reverse No air supply Faulty air control Corrective Action Insufficient large pulp—too many 0.040″ strainer tubes Visual Inspection Screens plugging Cause Wet discharge Defective air regulator Air valve set in wrong position  Clean with high pressure clean-up system  Check air supply at source  Check supply lines  Check air valve at control panel  Check action of chamber  Replace air regulator Sensing switch shorted out Unusual noises during operation Faulty intake or discharge bearings Worn bearings Worn screens Misaligned bearings Bearings not lubricated Misaligned finisher screw Over-greased bearings Worn and torn screens Misaligned finisher screw Worn or misaligned bearings Scraping noise 62 MAN# 04904600/4800.05292012  Replace bearing  Check bearing installation  Replace seals and Orings  Check bearings; replace if worn  Realign intake and discharge housing Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  63. 63. Lubrication THE 100 SERIES FINISHER IS OPERATED WITHOUT OPERATOR CONTROL FOR LONG TIME PERIODS; THEREFORE, LUBRICATION SCHEDULES AND PROCEDURES MUST BE FOLLOWED CAREFULLY! FAILURE TO LUBRICATE OR IMPROPER LUBRICATION CAN RESULT IN SERIOUS DAMAGE TO THE EQUIPMENT. Table 2: Lubrication Function and Type Lubrication Point Type of Lubricant Intake Motor Bearing  Grease Fitting (Flange bearing) (The UCF110 has one easily accessible point of lubrication located on the side of the side panel) Discharge Bearing (Self-aligning tapered roller, matched set married face-to-face with a noninterchangeable unique spacer between the bearings)    Hand-applied There is no external grease nipple connected to the self-aligning, tapered roller bearings. The grease in the two bearings are handapplied once they are removed from the discharge end at the beginning of each processing season.  SKF LGFP 2 Food Quality grease, 4/230°F (-20/110°C) Lubrication Schedule  Grease every 3 months. JBT FoodTech recommends not mixing SKF LGFP 2 with other greases. DO NOT hand install too much grease into the fitting, as the flange bearing seals will rupture requiring bearing replacement.   SKF LGFP 2 Food Quality grease, 4/230°F (-20/110°C) JBT FoodTech recommends not mixing SKF LGFP 2 with other greases. Grease every 12 months Manually hand-apply grease to bearings: Bearing cavity between the ball bearings and bearing cages only needs to be 25% full of grease.   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 63
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  65. 65. Cleanup procedures INCREASING AIR PRESSURE EXCESSIVELY CAN LOWER THE QUICK FIBER , PUTTING TOO MUCH PULP INTO THE PRODUCT. EXCESSIVE AIR PRESSURE WILL OVERLOAD THE MOTOR. MAKE SURE THE AIR PRESSURE SETTING IS CORRECT AT YOUR PLANT LOCATION. In a 24-hour period, check the finisher hourly or as scheduled by the customer for the following:  Proper Quick Fiber readings (TSR only) and pulp discharge.  Lift the finisher cover. Make sure the product flow is uniform and screens are unplugged.  Clean screens of any fine build-up during processing without interrupting the cycle.  If equipped with a single spray ring on the discharge end of the finisher, grasp the spray handle or hose and slowly push in and pull back the high pressure cleanup spray ring the entire length of the screens.  Times Spray Ring (TSR) cleanup systems operate by a set schedule written into the processing plant’s automatic cleanup system (ACUS) software program. Cleanup After Repair Clean the UCF110 and UPF100 finishers with the CIP system whenever pulp fibers build up in the screen perforations during operation. The chief factors in determining cleaning frequency are production volume, size of screen perforations, type of fruit, and temperature. Become familiar with cleaning requirements by occasionally opening the finisher cover and checking the screens for pulp and fiber build-up. Cleaning once an hour is sufficient for most operations. The actual cleaning operation seldom requires more than a minute. When the finished juice passes onto the evaporators for further processing, cleaning occurs during operation with no shutdown of the finisher. The potable cleaning water mixes with the juice and flows to the evaporators for processing. However, if the finished juice is to be single strength, the juice outlet diverts and the cleaning water exits the finisher. The high-pressure cleanup system requires the following: Pressure Flow rate Water purity Screen frame Spray ring and nozzles   90 psi minimum (450-500 psi preferred) 40 gallons per minute is ideal Potable (drinkable); free of impurities, scale, film or scale-forming chemicals Must be aligned to the spray ring Must be free of impurities or scale   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 65
  66. 66. Prior to any shutdown of over ten (10) minutes, thoroughly clean the finisher. Use the high-pressure cleanup system. Operate the spray ring back and forth over the screens until they are free of pulp and fibers. As cleaning water drains through the juice outlet, visually inspect the finisher screens to determine when the finisher is clean. Periodically clean the entire juice processing system with approved food processing cleaners. Flush the entire system. The stainless steel materials in the finisher allow this method of cleaning. The finisher requires a thorough rinsing to prevent any caustic solutions residue from mixing with the processed juice and pomace. CAUSTIC CAN CAUSE SERIOUS SKIN BURNS OR EYE INJURY. IF CAUSTIC CONTACTS THE SKIN OR EYE, IMMEDIATELY RINSE AND APPLY FIRST AID. High Pressure Cleanup Operation DURING OPERATION THE HIGH-PRESSURE WATER VALVE SHOULD BE IN THE OFF (CLOSED) POSITION; THE SPRAY RING SHOULD BE AT THE INTAKE END OF THE FINISHER. THE FINISHER CAN CONTINUE TO OPERATE DURING CLEANUP, OR SHUT DOWN. To operate the high-pressure cleanup system: 1. Open the high-pressure water valve. 2. Leave finisher covers closed. 3. Move the spray ring (SSR or TSR) slowly along the length of the finisher by means of the water pipe (with hose connected) at the discharge end (See Figure 35). Figure 35 – Manually Cleaning Screens using Single Spray Ring (SSR) 66 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  67. 67. 4. Push in the water pipe to return the spray ring to the finisher’s intake end. 5. Turn off water supply. 6. Open the cover and visually inspect the screen perforations (See Figure 36). Figure 36 – Inspecting Screen for Cleanliness (TSR Shown with Dual Spray Ring) 7. Repeat until the screens are free of pulp and fibers. 8. Push the water pipe into the finisher for SSR. This will place the spray ring at the intake end and the pipe will be out of the way inside the finisher except for the hose connection. 9. Close (shut-off) the high-pressure water valve. IF HOT CLEANING SOLUTIONS ARE USED, THE TEMPERATURE SHOULD NOT EXCEED 165°F (74°C) AT THE SOURCE. EXCESSIVE HEAT CAUSES UNEQUAL EXPANSION AND CONTRACTION OF SCREEN AND FRAMES RESULTING IN SCREEN TO SCREW INTERFERENCE.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 67
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  69. 69. Recommended Spare Parts JBT FoodTech recommends that the 100 Series Finisher customers keep a supply of spare parts in their plant stockroom. Listed on the next pages are the spare parts most likely to become unserviceable or damaged through normal use or disassembly. Use the following figures and spare parts tables to identify the part number and location of all spare parts for ordering. Figure 37 – Discharge End Spare Parts Recommended Spare Parts for Wear 100 Series Finishers Item No. UCF / UPF 3 007660102 2 Seal, Discharge Pressure  UCF / UPF 4 007486162 2 O-ring, Viton Discharge  UCF / UPF 6 007660013 2 Seal, Bearing Grease  UCF / UPF 7 04904764 1 Bearings, Tapered Roller  UCF / UPF 8 007486162 2 O-ring, Viton Discharge  16 007055518 1 Cylinder, Plug Valve Air, 1-1/2″ Air Cylinder Bore  Part Numbers U.S. Brazil QTY Description RSP UPF / UCF TSR with Quick Fiber Controls Recommended Spare Parts for Damage UPF / UCF TSR with 11 04904810 Quick Fiber Controls RSP = Recommended Spare Part   1 Valve, Plug, 1-1/2″ Bore    Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 69
  70. 70. Figure 38 – Intake End Spare Parts Finisher UCF110 UPF100 Recommended Spare Parts for Wear Item No. Part Numbers U.S. Brazil QTY Description RSP 1 55 Key  58 1 Seal, Cartridge, Intake  59 007486160 2 O-ring, Viton Intake, 3/16″ SEC x 2-1/2″ ID, 2-7/8″ OD  60 70 04904642 007660101 1 Seal, Intake Pressure 2-1/4″, 1.500″ Shaft  MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  71. 71. Finisher UCF110 UPF100 Recommended Spare Parts for Wear Item No. Part Numbers U.S. Brazil QTY Description RSP 62 005074026 1 Bearing, Intake Flange Ball, 4 bolt  90 009710021 1 Sleeve, Intake Speedi, 1.5″ Shaft Diameter  Recommended Spare Parts in Case of Damage 96 04904550 1 Base, Common  112 04904831 1 Cover, Shaft Top  157 04905300 1 Torque Arm, Used With Gearbox  165 005754086 1 Gear Motor (without torque arm), 7.5 Hp (5.5kw), 60 Hz  RSP = Recommended Spare Part     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 71
  72. 72. Figure 39 – Screen and Frame Spare Parts Item No. Part Numbers U.S. Brazil QTY Description RSP 1&2 04906180 2 Support Frame, Screen  3 009210015 2  N/A 04904828 2 4 039200314 20 Screen, Standard 0.020″ Etched Screen, Half, 0.020″ Etched, 0.12″ Thick (Item 1 and 2 substitute) Screw, Machine, 1/4-20 SS (Included in Item 1 Spare Parts Package)   RSP = Recommended Spare Part 72 MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  73. 73. Figure 40 – UCF110 Screw Spare Parts Preview Item No. Part Numbers U.S. Brazil QTY Description RSP 1 2 Plat, End, 3/8″, 30 SS 2 003240098 1 Bar, Red, 2-3/4″, 304 SS 3 04904607 1 Not Shown 4 04903392 1 Pipe, Welded, 6″, SCH40, 304 SS 5 04902161 2 Helix, Worm, BAR, FL, 304 SS, 1/4″ X 1-1/4″ 6 003309018 4 Bar, SQ, 3/16″, 303 SS (Not Shown) 7 009710021 1 Sleeve, Intake Speedi, 1.5″ Shaft Diameter  8 009710028 2 Sleeve, Discharge Speedi, 1.625″ Shaft Diameter  9 04904661 6 Weight, Balancing Screw, LG, ROD, THD, SS, 1/2-13 10 Only BOM 04902387 04904662 6 Plug, Balancing Screw, SHT, Rod, THD, SS, 1/2-13, 304 SS ½″ NC RSP = Recommended Spare Part     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 73
  74. 74. Figure 41 – UPF100 Paddle Spare Parts Preview Item No. Part Numbers U.S. Brazil QTY Description 1 2 Paddle Support Type 2 2 04905144 2 Paddle Plate, Bigger Shim, 5/8″, 304 SS 3 04905146 6 Paddle Limitor - 1/23, Bar, RD, 11/2", 303 SS 4 04906304 3 Paddle, Finisher 100, BAR, FL, 304 SS, 1/2″ X 1-1/2″ TRUE 5 04906305 3 Shim, Paddle, Plate, 5/8″, 304 SS 6 04906306 3 Shim, Paddle, Plate, 5/8″, 304 SS 7 004352413 3 Hex Cap Screw 8 004352407 3 Hex Cap Screw 9 74 04906302 004156072 6 RSP Nut, Hex, S/L, HVY, 3/8-16, SS MAN# 04904600/4800.05292012 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  75. 75. Preview Item No. Part Numbers U.S. Brazil QTY Description RSP 10 04905145 1 Shaft Key, Long, Mixed UPF100 (Not Shown) 11 004405030 2 Screw, Set, Hex SKT, CUP, 3 /8-16 X 3/8″ LG, SS" 12 04904711 1 Shaft, BAR, RD, 1-7/8″, 304 SS 13 009710021 2 Sleeve, Intake Speedi, 1.5″ Shaft Diameter  14 009710028 1 Sleeve, Discharge Speedi, 1.625″ Shaft Diameter  15 04905148 6 Paddle Limiter - 1/23, BAR, RD, 11/2″, 303 SS 16 04905141 1 Screw Hub, BAR, RD, 2-1/2″, 303 SS 17 04905142 6 Helix 18 004352312 2 Screw, Full Thread Hex Cap, 5/1618 X 5/8″ LG, 304 SS (Not Shown) RSP = Recommended Spare Part     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 75
  76. 76. Figure 42 – Single Spray Ring Conversion to a Dual TSR for New 100 Series Finishers Part Numbers U.S. Brazil 4903902 4903903 4903905 4903913 4903916 4903917 4903918 4903919 4903921 4903921 4904065 4903901 7005556 7661061 7055542 4541083 4506093 4406031 4903421 4206028 4116037 4111064 4156098 4231019 3925022 4901624 4231045 4901625 4156095 7135003 76 MAN# 04904600/4800.05292012 Description Adapter, Cylinder, Dbl TSR Sys Flange, Cylinder, Ext TSR Sys Bushing, Delrin, TSR Spray Ring Clevis, Drive Cylinder, Ext TSR Carrier & Arm, Weldment, Ext TSR Header, TSR Supply, Ext TSR Sys Bar, Link, Ext TSR Sys Guide, Delrin, Spray Ring, Ext Header,Conn, Piped and Union, Ext TSR Sys, UPF100 Finisher Header, Conn, Pipes and Union Ring, Spray, Complete, Dual TSR Pin, Small, Gate Closing Mechanism Flow Control, Pneumatic, 1/4″ NPT Wiper, Rod, Type P, 0.625″ Shaft Cylinder, Pneu, Dbl-Act, 2-1/2″ B Screw, Set, Cap, S/L, 1/4-20 x 3/8″ Screw, Cap, Soc S/L, 1/4-20 x 3/4″ Screw, St, Hex Skt, Nylon Tip, 5/1 Plug, End Plate (Non-Auto CIP) Pin, Cotter, 3/32″ x 1″ Lg, SS Nut, Hex, Jam, 1/2-20, SS Nut, Hex, 1/2-13, SS Nut, Hex, S/L, Thin, 1/2-13, SS Ring, Retain, Basic Ext Series Tubing, 1/4″ OD, Black Nylon Bushing, Spray Ring, Conn Pipe Ring, Retain External, 304 SS Rail, Guide-Spray Ring, CIP Sys Nut, Hex, S/L, Lt, 1/2-13, SS Nut, Hex, Union, 1″ OD, 304 SS Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle
  77. 77. ISO/ANSI Safety Labels – Order Form See Figure 1 for safety label locations on the 100 Series Finishers. ISO/ANSI Safety Labels Order Form JBT FoodTech | 400 Fairway Avenue | Lakeland, FL 33801 Fax completed order form to: +1.863.680.3672 Customer Name Street Address City, State, Country Zip Code ISO/ANSI Harmonized Labels Part No. 04904697 Part No. U.S.: 09450020 U.S.: 09450013 U.S.: 09450065 Size 2″ X 4″ 4″ x 2″ 4″ x 2″ Description Read and understand the operator’s manual before using this machine. Moving parts can crush and cut. Moving parts can crush and cut. (ROTATING SHAFT) (BLADES) 2 Quantity Label 2 Part Number U.S.: 09450009   2 Size 6″ x 2″ Description Equipment starts automatically; LOTO (AUTOMATIC START) QTY 2   Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 77
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  79. 79. Appendix A Quality Control – Quick Fiber Device NOTE: The “Quick Fiber ” test procedure was developed by the Minute Maid Corporation of Orlando, Florida.     Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle MAN# 04904600/4800.05292012 79
  80. 80. Quick Fiber Test Quick method for estimating the juice content retained in the pulp at the finisher’s discharge.   Equipment Needed  Forty (40) mesh sieve with approximately 5″ in diameter and 2-3/4″ deep, made of 0.015″ diameter stainless steel wire and containing 40 square openings of 0.015″ per inch.  Automatic Agitator   Perform Procedure 1. Collect a very homogeneous portion of pulp in the finisher. 2. Weigh 200 g in a 1-liter beaker. 3. Shake for 1 minute. 4. Let it rest for 3 minutes. 5. Transfer the mixture immediately to a 40 mesh sieve. 6. Shake for 3 minutes in the Quick Fiber device. 7. Collect the recovered liquid and read its volume in ml. Data Interpretation This method concentrates on the recovery of free liquid, as long as the recovered volume is exactly equal to the volume of water added.  Values above 200 ml indicate that there is free juice in the pulp.  Values below 200 ml indicate that the pulp absorbed part of the added water, as it was drier. The objective of the use of the screen is to recover the free liquid completely and uniformly from the water-pulp mixture. Based on the procedure and on the JBT shaking device, the condition of the pulp in the finisher is classified as follows: Quick Fiber Finisher Conditions Very tight: <130 80 MAN# 04904600/4800.05292012 Tight: 140 to 160 Moderate: 160 to 180 Loose: 180 to 200 Citrus Finisher Service Manual – UCF110 Screw | UPF100 Paddle

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