Operating, Maintenance And Service Manual Spare Parts List IS
Contents
1. wniono uuruonO ding WNJOND YUlg WNJOND Jeajg UWNJOND uuruonO ding Seg 19 S oeg J9 S L6 YUL WNIJOND HUI WNIOND SJUEJOSJUISIG pue SJUS V 151 149 ANV TSI 0 SI 4 MUA BAADER 4 BAADER SLAND ehf Henkel Sales Partners European Operation Henkel Ecolab GmbH amp Co OHG Reisholzer Werftstr 34 42 Tel 49 211 98 93 203 Food amp Beverage P3 Division Austria Henkel Ecolab Gmbh Erdbergstra e 29 A 1031 Wien sterreich Attn Gerald H rmann Tel 43 171 52 55 08 12 Fax 43 171 52 55 08 54 Belgium Henkel Ecolab n v Doornveld Industrie Asse 3 Nr 11 B 1731 Zellik Asse Belgium Attn Stefan Naten Tel 32 24 67 51 62 Fax 32 24 67 51 13 Brazil Ecolab Quimira Ltda Brazil Av Brigadeiro Luiz Antonio 3767 3779 Sao Paolo SP1401 001 Brazil Attn Gustavo Miranda Tel 55 113886 2503 Fax 55 113885 8479 Bulgarien Henkel Ecolab Bulgaria Food Prof Dr g Pavlov Str 35 BG 1111 Sofia Bulgaria Attn Martin Cheytanov Tel 359 2 971 22 35 359 2 971 36 97 Fax 359 2 971 26 50 Canada Henkel Ecolab Ltd 5105 Tomken Road Mississauga Ontario L4W 2X5 Canada Attn Lew Chester Bruce Hamilton Tel 1 905 238 0171 Fax 1 905 238 0375 C2. 1637 Machine Applications and Features The fish is placed belly to operator head first into the machine The fish head is held and the entire fish is transported to the knife section where a high yield head cut is performed The main body of the fish with collarbone attached discharges to the front of the machine The head is transported via a chute to the rear Thanks to its construction the operator has a clear view of the working area Adjustments e g for adaptations or service operation including knife replacement are easily performed Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 10 7 BAADER 4 15 033 BAADER ISLAND ehf Power Connection The machine is supplied with approximately 5m of Olflex 191 5 G 2 5 cable terminating in a type 416P6 plug which is IP44 splash proof and conforms to IEC 60 309 2 To comply with the legal safety regulations the machine has to be connected to the mains electrical supply in accordance with the circuit diagram taking into account the regulations of the local electrical authorities and the rules EN 60204 and VDE 0100 Seal the cable bushes and screw so they are watertight An electrician must read and understand the electrical drawings suppli
3. bBujees LOOELOGE oe WW8 8 I 20109009 89661676 62 ssejuleys Duueeg eg 9098188 82 x ud asogee 22 LZ06 UIQ OLAJeuseM SOLOOBLE 92 _ LZO6 SW JEUSeM 78000815 9 1406 JeuseM X 78000815 va 82 9 82990818 ET X M S de pedH jexoos 6 0 lt jeg 194908 uoDexeH LOHESOE LT OG X ZLW 109 peeHxeH 05611808 oZ GE X OLIN peeHxeH SEOLL80E GBL _ GE X BIN 1108 peeH 980 808 BL _ O BW X H OE80L80E 21 _ OZ X 81N PEPH O780L80E OL eG UI OLW JN 00000 SL NU OAL 92700091617 L Meddns 9007060 EL AOD 90510550 al My LL E06KOLEO LL Aamdyequoor 20670 50 OL A endyequool 1069010 6 ___ 8 100 2 _ _______ 1057000 9 29905 9000 80 S abueq buueeg 70070150 v eDue j buueeg 50070150 PU 9NUM 2000 80 z Hoddnsemu 00v0160 b uonduoseg ON Hed wey Army sBuljeas yeus yo uono uid NV 3AIUY LO 4 V 3 Electrical equipment AN W 5 4 N 3 2 Electrical equipment 6 103103205 Bar 8 03104903 Brakemotortikw 9 033015144 45 169308202 5 4 7X 3 2 AN Suweibeig E91199 3 S007 875 snn p 20
4. BANDER BAADER ISLAND ehf Operating Maintenance And Service Manual Spare Parts List IS 033 Round Cut Heading Machine BAADER SLAND ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 7 BAADER 4 15 033 BAADER ISLAND ehf Preface This manual is dedicated to the personnel responsible for the operation maintenance and service of a Baader IS 033 Heading Machine Carefully read the instructions and safety precautions given in this manual Do not attempt to operate maintain or service this machine until you have thoroughly read and understood the information contained in this manual It is the responsibility of the owner to ensure training is given to all personnel involved on the operation of these machines Baader Island ehf Will not assume any liability for damages due to the non observance of this manual inadequately trained personnel improper handling of the machine nor its application in fields other than those specified in this manual In case of arbitrary modifications by removing or mounting parts or any modification of the machine without our written approval our conformity declaration EC directive will become invalid Use only Baader genuine spare parts It is imperative to comply with the legal safety regulations for food processing machinery which are in force in your country This manual is the intellectual property of Baader Isl
5. 6j LS RIS N 3 62 62 5 1 2 3 4 5 6 T 8 9 AB6064675 AMP1 25 AB6063040 SALZX RT4A4L24 BLOK PSR230 24 2 5 AB6071685 AB6061773 AMP1 25 BLOK STU250 2x115 Fuse Fuse Time relay Relay Transformer Main switch Relay Fuse Transformer
6. 354 520 6911 lager baader is www baader is 34 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the trigger Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death It is important to verify that the proximity switch is correctly located in the holder fig 23 item 2 prior to adjustment Loosen the gland nut fig 25 item 5 push the cable sheath towards the holder whilst maintaining pressure re tighten the gland nut Loosen do not remove the 2 hexagon head bolts fig 25 item 1 Adjust the clearance of the proximity switch holder fig 25 item 2 to 1mm 0 040 fig 25 item 4 Re tighten the 2 hexagon head bolts fig 25 item 1 The trigger weight can be adjusted by loosening the hexagon head nut and bolt fig 25 item 3 and moving its position along the slot When complete re tighten the hexagon head nut and bolt A Warning It is possible a piece of fish can keep the trigger depressed allowing the machine to continuously cycle It is important to keep the area around the cycle start trigger clear see fig 26 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 35 7 BAADER 4 15 033 BAADER ISLAND ehf Tension of the knife drive belt Prior to working on the machine switch the main electrical switch to the
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8. comply with the USDA H1 requirements and is of the GRAS type semi synthetic and extremely seawater resistant Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 45 W 3 2 1 O Es Frame and Covers 2 NN AZ Q B B 9 m 1 00106005 03301051 03301052 A 20600240 Nut M24 Din 934 7 195030002 Adjusting spindle 2 1 6 T _8_ _9_ 3 4 at 2 Cover and Shutes V _6 103301612 Fishshue 19 30835533 Socket Head Cap Screw M8 x 20 Din 912 7 03303020 Fishshue 2030835533 SocketHeadCapScrewM8x20 I 8 03303202 Infeed Table 1 1 21 38004 WasherM8 Din9021B 9 03303303 Infeed pate 2231800084 WasherM8 Din9021B ___ 13 20600080 Nut M8 Din934 PH o o NV 4 Fish back pressure N m ite sp of z i NV Item 0 2 Q O N 9 NO 0 1 22 2 2 N N NO 5 NO 6 27 28 5 4 N 3 2 Fish back pressure Back plate holder 30 Hex Head Bolt M8 x 50 Distance shaft 32 Hex Head Bolt M10 x 25 Stoper Lifter Hex Head Bolt M10 x 60 38 Socket Head Cap Screw M10 x 25 Din 912 39 Socket Head Cap Screw M10 x 30 Din 912 Adjusting
9. 0 position and lock it Failure to comply may result in serious personal injury or death Loosen do not remove four hexagon head bolts fig 27 item 1 Adjust the tension off the toothed belt fig 27 item 2 by lifting the motor plate fig 27 item 3 up or down in the slots The correct tension of the toothed belt should allow approximately 20mm 3 4 of movement in the middle of the belt When complete re tighten the four hexagon head bolts Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 36 7 BAADER 4 IS 033 BAADER SLAND ehf Knifes To achieve the best possible results knife edges should be sharp The knife is to be verified at regular intervals and be re sharpened if required It is necessary to remove the knife from the machine for sharpening Knife Replacement Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Danger wear protective gloves when handling knifes Part no 52100196 1 off 2 are included in the tool set Ms Knife nuts with left handed threads are marked with notches on the hexagon Using two 41mm spanners one on the knife shaft and the other on the knife nut slacken the M20 LEFT HAND THREAD knife nut Remove the knife nut It is now possible to remove the rotary knife Ba
10. 5 30 9 JNBOnEd QM 202 GZ 1991 518945 1010 UO DIO UO JUN 010 7 se j9vd INOX 404 EON SHS EL NA Subs ey JNDVIA SNIQY 3H Fit HIH 19945 zn NWN 109 39 Vd LOVINOO AV Tad 8404 JONVHdddH 55049 39Vl11OA IVNSH3LX3 39NVHO UG AO IPA ALIHM UD IPA GAY ug A 98 Arc 31dMfd uv N 9 AvC AVYD N TVHLNIN 3018 LHOIT J NNWN109 39Vd NO 3ANNILNOO JdH 55080 3NIT id L LG INVN UY JOVLIOA TOHLNOD Ld 21 411 ONIMIM HIMOd 00 MOVIE ONDISVIN ANIL I O0L AV 138 Li lt YSEWAN LN3NOdWOO IVOINLOATA 0017 NOLLONN4 ZNN dOOM9 W3LSAS LV LV NOILONNH YIENAN SNIGOO 9NDISVIN LNAWdINOA NOILYNV 1dX3 Y3IAEWNNN LN3NOdWOO NOILVOOT NOILONN4 YIENAN 38lM 318V92 CL uw Ze KA T TVNINS3L eue1j Bulmeip dNOYUD TYNINYIL woJ Jequnu aye JUsUOdWOD UMOYS Jou uoijeoo JO pue uoijounj 9199 9522 NOILVNV 14X3 1Vd3N39 i Se VU dE 660 51 HSISSLIHM ANIHOVW 3H 1801 1994
11. Attn Michael McKenna Tel 35 31 28 68 225 Fax 35 31 28 69 298 Italy Henkel Ecolab S p A Centro Direzionale Colleoni Via Paracelso 6 Palazzo Liocomo 20041 Agrate Branza Milano Italy Attn Anette Dransfeld Tel 39 39 60 50 588 Fax 39 39 60 50 573 Japan Ecolab K K Takadanobaba Center Building 31 18 Takadanaobaba 1 chome Shinjuku ku Tokyo 169 8631 Japan Attn Hideo Oishi Tel 81 3 5285 2671 Fax 81 3 5285 2680 Netherlands Henkel Ecolab B gt V gt Edisonbaan 9 11 NL 3439 MN Nieuwegein Netherlands Attn Ari de Groot Tel 31 30 60 82 470 Fax 31 30 60 82 479 Norway Henkel Ecolab a s Stalverksveien 1 Postboks 6440 Etterstad N 0605 Oslo Norway Attn Vagn Andersen Denmark based Tel 47 22 681 800 Fax 47 22 682 050 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 sale baader is www baader is 43 MMA BAADER BAADER ISLAND ehf Poland Henkel Ecolab 5 2 0 0 Ul Kalwaryjska 69 PL 30504 Krakow Poland Attn Piotr Kubas Tel 48 12 2616 100 Fax 48 12 2616 101 Portugal Henkel Ecolab S A Estrada Outeiro de Polima Monte Trigo Lote C2 Aboboda 2775 S Domingos de Rana Portugal Attn Anette Dransfeld Italy based Tel 35 12 14 480 750 Fax 35 12 14 480 788 Romania Henkel Ecolab srl lasi office 3 Sos Nicolina Street BI 928 parter Lasi R 6600 Romania Attn Ciprian Petcu Tel 40 32 221 859
12. and the proximity switch fig 4 item 2 to 1mm Re tighten the 2 hexagon nuts fig 4 item 1 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 19 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the locking arm stop Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Loosen the hexagon locknut fig 5 item 2 The machine can be manually rotated as described on page 13 to aid the setting of the locking arm The rest position of the locking arm should be 8mm below the level of the cam Adjust the rest position by turning the hexagon head bolt fig 5 item 1 Re tighten the hexagon locknut fig 5 item 2 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 20 MMA BAADER 4 IS 033 BAADER SLAND ehf Adjustment of cycle start position Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Note The setting of the locking arm stop must be completed prior to adjusting the cycle start position Loosen do not remove the 3 hexagon head bolts fig 6 item 1 Turn the cam fig 6 item 2 as far possible anti clock wise Re ti
13. every 2000 hrs or 1 year Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 41 CV SI MMM 5 LL69 OZS 735 Xe3 0069 OZS 792 puejeo jua pue s Jopeeg Seg 191S 6 L6 xedo d oeg J91S L6 xedo d L6 xedo d dv enbu Seg 191S 6 YUL WNJOND uid WNIJOND WNJONT aiding Bissni 1s Juu z d 66 xedo d 9G WII d CL xedo d 89 9g4 eq parun 66 89 JL UWNJOND uinionp Bissni 1s Juu z d Mulq WNIJOND Mui q WNIJOND 66 xedor ed 9g xedor ed itd ZI Xedored 66xedored 89 xedored LI xedored Z xedol d Jeajg UWNJOND YUL WNIJOND HUI WNIJOND 6 66 89 JL Bissni 1s Juu z d L6 66 xedoi ed 9g xedoi ed 4
14. fig 15 item 1 amp 2 continued on next page Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 28 7 BAADER 4 15 033 BAADER ISLAND ehf The distance between the middle of the transport fork to the knife should be between 2 to 3mm in the middle and 10mm at the end See fig 16 amp 17 2 to 3mm 10mm Re tighten the hexagon bolts fig 15 item 1 and 2 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 29 MUA BAADER 4 15 033 Adjustment of the in feed plate Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as described on page 13 to move the transport fork to the in feed plate To adjust the in feed plate fig 18 item 2 slacken the 3 hexagon bolts fig 19 item 1 2 and 3 The in feed plate fig 18 item 2 should be adjusted as close to the transport fork fig 18 item 1 as possible 5 important that the in feed plate and the transport fork do not touch during the complete cycle Re tighten the 3 hexagon bolts fig 19 item 1 2 and 3 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 30 MUA BAAD
15. range and throughput rate However the proportions and the quality of the fish season fishing ground degree of freshness etc have an influence on the figures indicated these may vary in practice Live fish and fish in the state of rigor mortis cannot be processed Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 7 BAADER 4 15 033 BAADER ISLAND ehf Machine Set up The machine shall be readily accessible from all sides for ease of operation and maintenance Place the machine on the base plates fig 1 item 1 using the adjusting spindles fig 1 item 2 level and adjust the working height of the machine When complete lock the adjusting spindles using the lock nut fig 1 item 3 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is MMA BAADER 4 IS 033 BAADER SLAND ehf Dimensions 1777 1098 875
16. the machine and secured to the hose tail by means of a hose clip Water pressure should be a between 1 to 5 bar 15 to 75 psi IS 033 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 12 IS 033 BAADER ISLAND ehf A Warning Ensure the machine is isolated from the electrical supply before attempting to rotate the machine by hand Failure to observe this instruction may result in serious personal injury or death Use a suitable tool to manually rotate the machine fig 3 item 1 Start reset button fig 3 item 2 Note Pressing the start reset button for more than 1 second when released the machine will run for 1 complete cycle Stop button fig 3 item 3 Safety lever Emergency Stop fig 3 item 4 Baader sland ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 13 7 BAADER 4 15 033 BAADER ISLAND ehf Initial Start up Procedure Prior to starting the machine remove the preservative from all areas in contact with the product Wash the machine from bottom to top using a low pressure wash max 30 bar with drinking water heated to 60 C After cleaning run the machine briefly grease to remove any cleaning fluid that may have penetrated the bearings Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 14 7 BAAD
17. 9945 _ E m S 3aus 1010 110110201 zuo JUNH 0 5002 85 JLET 9100 3af 0g YIMOd WVY9VIC 1X1 ZW U l lt C 5 DS LXL jd z O O O LX c 0 SI 30 4903 SE EE dd SI Japeeq 1 3 LL690ZS X84 0069 029 191 ZOZ SZ ju GNVISI FEIIET vor ZHOS AOOPXE AlddNS H3MOd LX ET L1 ET 1 SUR Vins EE E 4 SE ____ ___ we 5 C Jays JX N LJ LV 00 8S oJopeeq ew LL69029 X84 0069 OZS 191 518805 100 11011020 110112404 9100 0 5 30 inBonedoy ZOZ sz ONIHIM 1081NO 3 404 349 ONVIS LET NYHDVIO 11170 JNIDYW 33US BUIMDUG 3af 0g NES e NET Be MEUSE b Y gt 7 ER rue w LYVLS cd 4015 19 gt N ___ op ma 2s X9 N Cc 5 oi J0A Z AOEZ SS LS a 1 ta N N X Eh FE Og GE 9t Ey Li L ty N NR SS W X X R gt 4015 AONIDYINS ss Z 72 E gt C3 3 E LE M dOLS
18. ER 4 15 033 Adjustment of the back plate maximum travel stop screw Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as described on page 13 until the back plate reaches its maximum travel Slacken the lock nut fig 20 item 1 and adjust the stop screw fig 20 item 2 toa clearance distance of 16mm 5 8 Re tighten the lock nut Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 31 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the angular position of the back plate Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death STOP Loosen do not remove the 2 hexagon head bolts fig 21 item 1 in the slots Adjust the back plate angle to accommodate different species of fish Adjustment in the direction of the BREBISSN fig 21 closer to neck bone more yield Adjustment in the direction of the fig 21 away from neck bone less yield Baader island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 32 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the back plate minimum travel stop screw Prior t
19. ER 4 IS 033 BAADER SLAND ehf Cleaning Clean the complete machine at regular intervals 8 operating hours When using low pressure cleaning devices do not direct the jet into bearings Rest periods oet the main switch unto position O Remove product remainders and wash the machine from all sides with a powerful water jet Pre cleaning otart and clean the machine observing the appropriate safety distance from the moving machine parts e With low pressure max 30 bar e with 60 C drinking water e from bottom to top Keep the safety distance Make sure that clothing hoses cleaning devices do not get caught by the moving components of the machine danger of serious bodily injuries and damage to the machine Do not run the machine unattended After pre cleaning stop the machine set the main switch to position 0 and secure it Baader island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 15 BAADER ISLAND ehf BAADER 4 15 033 Main cleaning The main electrical switch shall be at the 0 position and lock it Observe the safety instructions at the beginning of this manual Wear protective clothing during cleaning and sanitation operations Observe the specific national regulations for the cleaning agents and disinfectants used Cleaning Agent Device Method Foam with low From bottom to top 2 5 P3 topax 17 pressure foaming react
20. Tel 40 32 222 597 Tel 40 32 226 459 Fax 40 32 226 448 Bucharest Office Str Horia Closca si Crisan Street 61 63 Otopeni lifov Bucharest R 6600 Romania Tel 40 1 203 00 52 53 54 56 Fax 40 32 226 448 Russia Henkel Ecolab Chaussee Entuziastov 14 111 024 Moscow Russia Attn Alexei V Latyshev Tel 7 095 785 27 26 Fax 7 095 785 27 25 Slovakia Henkel Ecolab Bratislava Spol s r o Zahradnicka 91 82009 Bratislava Slovakia Attn Robert Krutak Tel 421 7 5024 6391 92 Fax 421 7 5024 6388 Slovenia Henkel Ecolab d o o Vajngerlova 4 SLO 2001 Maribor Slovenia Attn Dejan Gorsek Tel 38 62 42 93 100 Fax 38 62 42 96 152 South Africa Namibia Klenzade South Africa Pty lotd Trading as Ecolab 1 Ampete Street Chloorkop Edenglen 1633 Tel 27 11393 5022 Fax 27 11393 1567 Spain Henkel Ecolab S A Edificio Conata Frucutos Gelabert 2 4 7 E 08790 San Joan Despi Barcelona Spain Attn Jose Fernandez Tel 34 93 475 8903 Fax 34 93 477 0539 Sweden Henkel Ecolab A B Box 61 03 Fruangsplan 10 5 12907 Hagersten Sweden Attn Vagn Andersen Denmark based Tel 46 8 60 32 200 Fax 46 8 60 32 228 Switzerland Henkel Ecolab AG Kriegackerstr 91 CH 4132 Muttenz Schweiz Attn Marco Moser Tel 41 61 46 69 408 Fex 41 61 46 69 455 Turkey Henkel Ecolab Temizleme Sistemleri A gt S gt Sahrayi Cedid Mah Halk Sok No 54 Nokta Is Merkezi Kozyatagi Is
21. ader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 37 7 BAADER 4 15 033 BAADER ISLAND ehf After removal of the rotary knife Clean the knife mounting face Replace the rotary knife ensuring the knife drive dogs are located in the rotary knife Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 38 7 BAADER 4 15 033 BAADER ISLAND ehf Use a suitable food quality anti seize lubricant when re placing the knife nut Using two 41mm spanners one on the knife shaft and the other on the knife nut tighten the M20 LEFT HAND THREAD knife nut Baader island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 39 7 BAADER 4 15 033 BAADER ISLAND ehf Grease Lubrication The machine has been lubricated with BAADER grease GLS 380 33 This grease is of the GRAS type semi synthetic and highly seawater resistant It complies with the German Food and Consumer Goods Acts LMBG 5 art 1 clause 1 and is authorized according to USDA H1 We recommend using this lubricant at all times When using other GRAS lubricants the trouble free functioning of the machine cannot be guaranteed Ensure only grease free from contaminants is used Do not blend with mineral lubricants Note that mineral lubrica
22. and ehf and may not be copied reproduced nor made available to third parties without our prior written approval Warning To clearly show details of this machine covers guards barriers or doors may have been removed or shown in an open position All such safety components must be replaced prior to the machine being used Failure to observe this instruction may result in serious personal injury or death Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 7 BAADER 4 15 033 BAADER ISLAND ehf Table of Contents Safety instructions PG Technical data __6 Machinesetup 1 1 1 1 1 1 9 8 Power connection PM 9 Water connection 12 Baader island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is BAADER ISLAND ehf 7 BAADER 4 15 033 Pictograms used this manual Important Note Caution In case of non compliance damage of the machine and or property cannot be ruled out Particular attention required Danger of personal injury Danger Unprotected electrical systems Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is A 7 BAADER 4 15 033 BAADER ISLAND ehf SAFETY PRECAUTIONS IMPORTANT FOR THE MACHINE OPERATORS Non specified use as well as improper ope
23. bolt 53 Tension spring Hex Head Bolt M8 x 35 Csk Head Screws M6 x 16 cO C2 oO O O C2 cO gt QD Wu NO Wu AN NV D Fish transport 6 AN Duude ZE X 94 Buiusng Duude 0 X ZE 24 Buiusng Buds uoisue 948 15 Joo 1206 CLIN 206 OLIN 206 OLIN J9SUSEM 1206 UIA BIN 206 9IN v 6889 Op X 8 X OL ZE X 8 x OL V 6889 04 X Z x 8 v 6889 9 x x 8 2 6 ZV Ob X OLIN de 184205 2 6 GE X 8IN M S deg peeH 184905 uonduoseg 70070996 90710 0 21020926 O CEVLC6 GOLOLO8E 60 008T OE LOO8 LE GOLO08 LE 90100815 780008 LE 790008 LE 07801515 CESOLELE 022808 LE 951808515 67986806 96966806 ON Hed LO N N CH st CN cO KI KI CH O ke LO v Wo AR ZL6 0 X 8N M S deg peeH 194908 xeH OG X ZLIN 09 x OLIN OG X OLIN GE x OLIN GZ X OLIN X SN xeH GE x SN Og xeH OZ X SIN peer xeH pueH 9
24. ed with the machine before connecting to the electrical supply After connecting the machine the electrician should test correct function of the electrical equipment and ensure the machine is correctly grounded It is important to verify the correct rotation of the electrical motors Ensure that all exposed electrical equipment is properly covered Seal the cable bushes and tighten to make watertight The doors of the cabinet must be closed after the completion of the electrical connection Always lock the main electrical switch in the OFF position prior to performing any maintenance or service work Do Not bypass or wire around any safety equipment Removal of any cover or guard is prohibited Improper operation or insufficient maintenance can result in serious personal injury and severe material damages Employees who are responsible for safe working practices have to ensure that any maintenance or service work is only completed by qualified personnel Operating instructions and information required for procedures completed by operators to be available at all times Operators must strictly observe the contents of this information Baader island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 11 MMA BAADER BAADER ISLAND ehf Water Connection The water connection fig 2 item1 is configured for 3 8 hose ID 10mm The hose should be led from the top down to
25. eservation liquid MBF 360 ref no 51 10 0200 5 I container These preservatives meet the requirements according to USDA H1 Before resuming production remove the preservative from all areas in contact with the product e with low pressure max 30 bar e with 60 C drinking water e from bottom to top Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 17 7 BAADER 4 15 033 BAADER ISLAND ehf Back plate In feed plate Transport fork Trigger Fish chute Head chute Knife Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 18 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the cycle control proximity switch Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death It is important to verify that the proximity switch is correctly located in the holder fig 4 item 2 prior to adjustment Loosen the gland nut fig 4 item 3 Push the cable sheath towards the holder whilst maintaining pressure re tighten the gland nut Loosen the 2 hexagon nuts fig 4 item 1 Rotate the machine manually as described on page 13 so that the switch fane is at its closest position to the proximity switch holder fig 4 item 2 Adjust the distance between the switch fane
26. ghten the 3 hexagon bolts fig 6 item 1 continued on next page Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 21 7 BAADER 4 15 033 BAADER ISLAND ehf Rotate the machine manually as described on page 13 until the ball fig 7 item 1 touches the cam fig 7 item 2 Loosen hexagon bolt fig 8 item 1 Turn the activating fane fig 8 item 2 Align the centre line of the fane to the corner of the proximity switch housing Re tighten hexagon bolt fig 8 item 1 Cycle start position setting is now complete Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 22 7 BAADER 4 15 033 BAADER ISLAND ehf Cam alignment position Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death The upper 2 cams have a setting mark on the uppermost side of the cam The setting mark for the lowest cam is located on the underside of the of the cam support Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 23 MMA BAADER 4 IS 033 BAADER SLAND ehf Adjustment of the knife drive support bracket Prior to working on the machine switch the main electrical switch to the 0 posi
27. ion time 15 device minutes For removing calcareous deposits use 1 time From bottom to top per week cleaning foam 2 5 P3 topax 56 reaction time 15 instead of P3 topax 17 minutes 60 C pressure max 30 bar bottom isa From top to bottom reaction time about Low pressure 10 15 minutes since spraying max 30 bar contingent upon germ spectrum refer to product data sheet Rinsin Drinking water max Low pressure Binse E 9 20 C max 30 bar 9 avoid white deposits P3 topax 17 should not foamed on hot surfaces Main Cleaning Sanitation 1 P3 topax 91 e xe d 1 The cleaning agents P3 topax 17 and P3 topax 56 recommended the avoidance of painted areas of the machine due to aggressive cleaning properties of the products After cleaning run the machine briefly and grease to remove any cleaning fluid that may have penetrated the bearings et H WI A AT fang gd Correctly dispose of cleaning agents that are ecologically harmful s Baader sland ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 16 MMA BAADER 4 15 033 BAADER ISLAND ehf Preservation Prior to the machine not being used for long periods Protect the machine using food approved preservatives Recommended preservatives e Preservation spray MBF 370 ref 51 10 0201 400 ml can e Pr
28. nts do not comply with the provisions of Food and Consumer Goods Acts and may thus not be used The complete lubrication system jerk fitting mouth of grease gun hand lever press and the coupling should be free of any impurities The maximum lubricant pressure at the mouth of the grease gun should not exceed 190 bar Whenever cleaned the machine is to be lubricated to expel any cleaning fluids that may have penetrated the machine bearings Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 40 7 BAADER 4 15 033 BAADER ISLAND ehf Lubricant change of the gear motors Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death e Unscrew the drain and vent plugs e After draining the oil flush the gear box thoroughly using suitable flushing oil e Prior to filling the gear motor with new oil make sure that all flushing oil residue is removed Replace the drain plug e Checking the oil level With the gear at rest the oil must extend to the lower rim of the threaded bore when the oil level screw is removed Refit the vent plug e The roller bearings should to be cleaned and greased during the same period Make sure that only one third of the roller bearing space is filled with grease to prevent premature failure e Lubrication change
29. o working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as EA A described on page 13 until the back HH 1 Was A Slacken the lock nut fig 22 item 1 and TT adjust the stop screw fig 22 item 2 to E plate reaches its minimum travel maintain a clearance of approximately 10mm 3 8 Re tighten the lock nut Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 33 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of back plate travel position Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death STOP Manually rotate the machine as described on page 13 until the back plate is approximately in the middle of its travel Loosen do not remove the hexagon head bolt fig 23 item 1 Adjust the back plate fig 24 item 2 position by turning the excentric bushing fig 23 item 2 for the back plate cam roller fig 23 item 3 The clearance of the back plate to the transport should be approximately 10mm 3 8 fig 24 Re tighten the hexagon head bolt fig 23 item 1 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax
30. ration of the machine can result in serious bodily injuries and severe material damages It is essential that operators observe the following safety instructions Read the operating instructions prior to starting up the machine Unauthorised personnel must not operate maintain or service the machine Wear close fitting work clothing especially around arms Do not wear any finger rings Do not reach into running machine Do not place loose articles on the machine Do not run the machine unattended In case of failure of the functional sequence prior to cleaning maintenance and lubrication switch off the machine Put the machine switch to 0 position and secure It Only qualified personnel should maintain or service the machine strictly observing these operating instructions The safety devices installed by the manufacturer must not be bypassed modified or removed Spraying in electrical enclosures and controls gears is prohibited explosion hazard Never operate maintain or service this machine if affected by alcohol or other substances that may impair alertness or judgement Use safety protective equipment Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 7 BAADER 4 15 033 BAADER ISLAND ehf SAFETY INSTRUCTION Prior to starting up the machine Ensure all machine covers are fitted Verify the proper functioning of all safety devices D
31. roatia Henkel Ecolab Zagreb d 0 0 Kucerina 5 HR 10 000 Zagreb Croatia Attn Dejan Gorsek Slovenia based Tel 385 1365 1383 Fax 385 1365 1388 D 40589 Dusseldorf or P O Box 13 04 06 D 40554 Dusseldorf Germany Czech Republic Henkel Ecolab spol S r o Jakubske namesti 1 CZ 65686 Brno Czech Republic Attn Peter Slapal Tel 420 54 22 10 823 Fax 420 54 22 11 227 Denmark Henkel Ecolab A S Carl Jaocbsens Vej 29 37 DK 2500 Copenhagen Valby Denmark Attn Vagn Andersen Tel 45 36 15 85 85 Fax 45 36 15 85 99 Finland Oy Henkel Ecolab Ab Makelankatu 54 A FIN 00510 Helsinki Finland Attn Vagn Andersen Denmark based Tel 358 9 39 65 51 Fax 358 9 39 65 53 05 France Henkel Ecolab SNC 8 Rue Rouget de Lisle F 92441 Issy Les Mouineaux France Attn Bertrand Laroche Tel 33 140 93 93 06 Fax 33 140 93 94 60 Germany Henkel Ecolab Deutschland GmbH Reisholzer Werftstr 38 42 D 40589 Dusseldorf Germany Attn Walter Hamels Tel 49 211 98 93 551 Fax 49 211 98 93 386 Greece Henkel Ecolab A E 15 Flemingstr GR 15123 Maroussi Athens Greece Attn Diitri Valachis Tel 30 16 873 730 Fax 30 16 841 333 Fax 49 211 98 93 223 Hungary Henkel Ecolab Kft David Ferenc Utca t H 1113 Budapest Hungary Attn Pal Teglasy Tel 36 1 372 55 76 Fax 36 1 209 15 44 Ireland Henkel Ercolab Ltd Beechwood Close Boghall Road Bray Co Wicklow Ireland
32. tanbul Turkey Attn Anette Dransfeld Italy based Tel 90 216 260 99 22 Fax 90 216 360 60 81 Ukraine Henkel Ecolab LLC Bulv Lichachova 1 27 Kiev 133 Ukraine Attn Anatoliy Kindybalyuk Tel 380 44 29 4 4441 Tel 380 44 29 6 6721 Fax 380 44 23 0 2873 IS 033 United Kingdom Henkel Ecolab UK Ltd David Murray John Building Swindon Wiltshire SN1 1ND United Kingdom Attn Alan Usher Tel 44 1 793 54 87 81 Fax 44 1 793 54 88 92 USA Ecolab Inc 840 Sibley Memorial Highway St Paul MN 55118 USA Attn Shaun Kennedy Tel 1 651 306 5857 Fax 1 651 552 4821 Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 44 7 BAADER 4 IS 033 BAADER SLAND ehf Lubrication and Preservative Recommendation The mineral oil companies listed maintain Technical Services whose engineers will always be available to our customers to give technical advice in lubricating matters viss 1 1 pf Company eg nevn pp Iesel Tribol ICI Molub Alloy Special Baader Baader Baader lubricants Baader Lubrication Grease Special Preservation Preservation and spray Spray Liquid preservatives 51 50 0103 51 50 0102 51 50 0109 51 10 0186 51 10 0201 51 10 0200 Available 400 g 25 kg 50 kg 5 Cartridge Hobbock Hobbock Sep som authorised by USDA H1 The lubricant is of GRAS type
33. tion and lock it Failure to comply may result in serious personal injury or death Loosen do not remove the 2 hexagon bolts fig 9A and 9B Items 1 and 2 continued on next page Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 24 7 BAADER 4 15 033 BAADER ISLAND ehf Adjust the inner edge to 184mm 7 1 4 as shown fig 10 Note The dimension is taken square to the side of the machine Adjust the outer edge to 34mm 1 5 16 as shown fig 11 EL UI rnm IHRER UH HIT RO ra po Note M dide 7 8 2 The dimension is taken square to the side of the machine Re tighten the 2 hexagon bolts Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 25 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the transport fork setting distance Prior to working on the machine switch the main electrical switch to the 0 STOP position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as described on page 13 to move the transport fork as close as possible to the knife The transport fork should be 15 to 20mm from the circular knife see fig 11 For adjustment see fig 13 Slacken the hexagon nut fig 13 item 1 and using the 2 adjusting bolts adjust fig 13 items 2 and 3 the posi
34. tion of the transport fork It is important to ensure that the bolts fig 13 items 2 and 3 are re tightened after adjustment When complete re tighten the hexagon nut Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 26 7 BAADER 4 15 033 BAADER ISLAND ehf Replacement of the transport fork cam roller Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as described on page 13 toa ligning the cam roller to the access hole machined in the cam support plate fig 14 Slacken the 2 hexagon head bolts fig 13 items 1 and 2 and remove the hexagon nut fig 13 item 1 The transport cam roller can now be removed through the access hole Reverse the procedure to re assemble Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 21 7 BAADER 4 15 033 BAADER ISLAND ehf Adjustment of the Transport Fork Prior to working on the machine switch the main electrical switch to the 0 position and lock it Failure to comply may result in serious personal injury or death Manually rotate the machine as described on page 13 to move the transport fork as close as possible to the knife Slacken do not remove the hexagon bolts
35. uring operation the machine should stop when setting the main switch 1 of the heading machine to position 0 When pressing the 0 button 2 red light When actuating the safety lever 3 in front off the in feeding section Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is 7 BAADER 4 15 033 BAADER ISLAND ehf General The machine is designed to remove the head of whitefish with throat cut It is recommended to wash the fish prior to beheading Note Live fish and fish in the state of rigor mortis cannot be processed Baader Island ehf Hafnarbraut 25 Kopavogur Iceland Tel 354 520 6900 Fax 354 520 6911 lager baader is www baader is MMA BAADER IS 033 BAADER ISLAND ehf Technical Data Fish Species Process Condition Size range Throughput rate Power Consumption Water supply Consumption Pressure Connection Dimensions Length Width Height Weight Operator requirements Noise measurement evaluation according to DIN 45635 Workplace level LpAeq Whitefish Throat cut 1 to 13 kg Up to 30 fish per minute 2 2 kW approx 10 litre per minute 1 to 5 bar 15 to 75 psi 3 8 hose ID 10mm 1673mm 65 9 930mm 36 6 1777mm 70 310kg 1 person 82dB A Wear Ear Protection The machine is configured for the above mentioned size
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