AKR 550 CUSHION GUM EXTRUDER WITH TREAD BUILDER 1 PREFACE READ THIS USER MANUAL THROUGHLY BEFORE UTULIZING THE MACHINE. ALWAYS KEEP THIS MANUAL AVAILABLE AS REFERENCE. ALL THE INFORMATIONS IN THIS MANUAL ARE DESIGNED FOR EFFICIENT, SAFE AND LONG-TERM USE OF THE MACHINE. . This “User and Service Manual” is an inseparable part of the machine. User must act in reference to the instructions set out herein. 2 Picture 1 AKR550 Project : Type : Serial No : Project No : CUSHION GUM RETREADING MACHINE AKR550 B151013 000637 Year of Manufacture : 2015 Commissioning Date : 2016 Rev Modification Date Name, Surname 001 002 First publication before commissioning 15.02.2016 Abdullah AŞÇI Mechanical data update 23.03.2016 Serkan UYAR THIS MANUAL MUST BE READ THROUGHLY BEFORE USING THE MACHINE AND KEPT AS A REFERENCE GUIDE THROUGHOUT THE LIFE CYCLE 3 TABLE OF CONTENTS 1- GENERAL STANDARDS AND WARNINGS 1.1 WARNINGS 1.2 SECTIONS 2- GENERAL INFORMATION 2.1 2.2 2.3 2.4 2.5 INTENDED USE OF THE MACHINE MACHINE MANUFACTURER INFORMATION WARRANTY DISCLAIMER TECHNICAL SERVICE COMPLIANCE PART REPLACEMENT 3- GENERAL SAFETY WARNINGS and SYMBOLS 4- TRANSPORTATION & STORAGE AND ASSEMBLY 4.1 4.2 4.3 4.4 4.5 TRANSPORTATION STORAGE ASSEMBLY & DISASSEMBLY POWER CONNECTION AIR CONNECTION 5-TECHNICAL INFORMATION 5.1 5.2 MASTER GROUPS OF THE MACHINE TECHNICAL INFORMATION ON THE MACHINE Capacity and Mechanical Properties Equipment Properties Electrical Properties 6-CONTROL COMPONENTS OF THE MACHINE 6.1 CONTROL COMPONENTS OF MAIN CONTROL PANEL 7-PRE-OPERATION CONTROL and ADJUSTMENTS 7.1 7.2 PRE-OPERATION CONTROLS ADJUSTMENTS 8-OPERATIONAL PROCESSES 9-MAINTENANCE AND REPAIR 9.1 9.2 9.3 CONTROL OPERATIONS CLEANING OPERATIONS LUBRICATING POINTS 10-MECHANICAL PARTS, SHAPE and SPARE PART LIST 11-PNEUMATIC CIRCUIT DIAGRAM 12-ELECTRIC WIRING DIAGRAM 4 1. GENERAL STANDARDS & WARNINGS 1.1 Warnings This operation and maintenance hand book comprises AKR 550 Cushion Gum Retreading Machine and is a requisite part for technical documentation. All the information, instructions and recommendations provided in this manual are intended to ensure the health and safety of the operator primarily; and then the proper, efficient and extenden use of the machine. 1.2 Sections The whole hand book is composed of eleven sections. 1. General Standards ve Uyarılar 2. General Information 3. General Safety Warnings and Symbols 4. Transportation, Storage and Assembly 5. Technical Information 6. Control Components of the Machine 7. Pre-operation Controls and Adjustments 8. Operational Processes 9. Maintenance and Repair 10.Spare Part List 11.Pneumatic Circuit Diagram 12.Electric Wiring Diagram 5 2. GENERAL INFORMATION 2.1 Intended Use of the Machine Manufacturing purpose of the machine; is to provide implementation of the source material between the tread rubber and casing to surface of the casing. All the equipment and tools on the machine are designed in accordance with the intended use and quality and safety standards are at the top level. 2.2 Manufacturer Information Company Title Address Tel Fax Mail Web : AKAR MAKİNA SAN. TİC. A.S. : Organize Sanayi Bölgesi 14.Cad. No: 8 26110 Eskişehir / TURKIYE : +90 222 236 17 00 : +90 222 236 17 02 : [email protected] : www.akarmak.com.tr www.autoclave.com.t r Akar Makine carries operates at its facilities of 19,000 m² in total at Eskisehir Organized Industrial Site in machine manufacturing sector. We carry on business in two separate factories close to each othe within the following core business and sector: - Pressure Vessel / Autoclave Tire Retreading Machines Medical Waste Sterilisation Systems Project-based Manufactures Within the manufacturing of pressure vessel and autoclave; we make production of the glass using autoclave technology, composite material, rubber coating/gum, construction material, sterilization, etc.. We produce customer-specific pressure vessels other than standart manufactures. Thanks to our Tire Retreading Machines portfolio, we perform turn-key installation of retreading plants for truck and OTR groups. All the machine and ancillary equipment of truck and OTR group facilities are included in our portfolio. In the recent period, we started manufacturing Medical Waste Systems as an extension of autoclave products and successfully completed various facilities and commissioning recently. The said product groups can be offered to our customers as “Pre-Autoclave Shredding” and “Post-Autoclave Shredding” systems. Other than standard products, Akar Makine offers project-based manufacturing within the sectors of iron and steel, energy, mine and transportation. Akar Makina realizes projects requiring high level of project management and organizational skills and obtains the part of its sales figures from export sales. Our manufactures are performed in our facilities operating at cutting-edge technological infrastructure and at the top-level quality that meets 100% of our customers’ requirements. Our company is able to make all the manufacturing in compliance with ASME, 97/23/EC (CE), GOST standards. We meet expectations of our customers within the scope of optimum quality and price by creating best solutions. Our company considers long-term relationships and internationally accepted companies take an important place among our customers. 6 2.3 Warranty Disclaimer Global warranty of the machine is 12 months against labor and parts. AKAR Makina purchases guaranteed ancillary equipment for the use of manufacturing of the machines. We reflect such warranty period and conditions to the end-users. Defetcs arising from failing to observe the following clauses, machine damage as a result of occupational accidents and services and part replacements thereof shall not be covered by the guarantee. 1- Failing to follow the operator and safety warnings mentioned in this user manual. 2- Electrical faults arise from the electric supply system to which the facility of of the machine is connected and part replacements thereof. 3- Faults and damages arise from the modifications made beyond the original design of the machine. 4- Faults and damages arise from the modifications made on electical, pneumatic, hydrolic projects of the machine assembly. 5- Replacement of any part of the machine by unauthorized person. 6- Faults and damages arise from failing to follow the lubricating period given in this manual for the machine. 7- Defects from faulty maintenance and equipment installed and used other than the lubricant properties and spare part list mentioned in this manual. 8- Damages arise from acts of god such as fire, lighting, flood, flow, landslip, earthquake, etc.. 9- Problems arise from technical intervention performed beyond the authorized service personnel of AKAR Makina. 10- Damages occurred as a result of drops due to the improper connections, forklifts or ropes during the transportation/handling of the machine. 11- Damages occurred as a result of impacts arise from improper environment conditions during the storage. 12- Damages arise from electric and air connections incompatible with the instructions given for the assembly process. (absence of grounding or faulty grounding, voltage fluctuation, improper compressor, insufficient air, etc.) 2.4 Technical Service Compliance Machine operator must inform Maintenance-Repair service of the company if any fault occurs within the machine. Maintenance-Repair service of the company must contact the manufacturer company. User may encounter different problems during the use and operation of the machine. This manual is important to minimize the potential problems. User must contact with the manufacturer if he considers the solution is troublesome. Technical Service Contact Info Telephone Fax E-mail Address : :+90 222 236 1700 / +90 535 106 6267 +90 535 106 6268 / +90 535 106 6269 :+90 222 236 1702 :[email protected] :Organize San. Böl. 14. Cad. No:8 26110 Eskişehir / Türkiye 2.5 Part Replacement The machine is under warranty for part replacement against problems arising from manufacturer beyond its warranty. 7 3. GENERAL SAFETY WARNINGS and SYMBOLS Symbol Desctiption THIS SYMBOL REFLECTS SAFETY WARNING. WARNINGS UNDER THIS SYMBOL MUST BE CAREFULLY READ AND INSTRUCTIONS MUST BE FOLLOWED. NONCOMPLIANCE WITH THE INSTRUCTIONS MAY POSE OCCURRENCE OF HAZARDOUS SITUATIONS FOR THE USER AND ALL LIVING CREATURES AROUND. THIS SYMBOL REFLECTS INFORMATION FOR THE USER AND ALL PERSONS RELATED TO THE MACHINE. USEFUL INFORMATIONS ARE PROVIDED FOR ALL PHASES CONCERNING THE MACHINE. THIS SYMBOL REFLECTS TECHNICAL INFORMATION FOR THE OPERATOR USING THE MACHINE. THE OPERATOR MUST CONSIDER SUCH TECHNICAL INFORMATION. ACTING UPON SUCH INFORMATIONS WILL EXTEND THE QUALITY OF USE, SAFETY AND LYFE CYCLE OF THE MACHINE. INSTRUCTIONS MUST BE FOLLOWED IN THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED. IT MAY POSE AN ELECTRIC SHOCK RISK IF SUCH INSTRUCTIONS ARE NOT FOLLOWED. THE MACHINE MUST BE LIFTED FROM THE POINTS ON WHICH THIS SYMBOL APPEARS IN ORDER TO PERFORM PROPER TRANSPORTATION. OPERATOR MUST WEAR SAFETY HELMET IN THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED. OPERATOR MUST PERFORM HIS OPERATIONS VIA PROTECTIVE GLOVES IN THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED. OPERATOR MUST PERFORM HIS OPERATIONS VIA SAFETY FOOTWEARS IN THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED. Symbol Description SIGNALIZES THAT THE MACHINE MUST BE SHUT DOWN BEFORE MAKING ANY ADJUSTMENT. SIGNALIZES THAT THE MACHINE MUST BE DISCONNECTED BEFORE PERFORMING ANY MAINTENANCE OR CLEANING. THE USER MANUAL MUST BE READ BEFORE USING AND OPERATING THE MACHINE. 8 4. TRANSPORTATION, STORAGE AND ASSEMBLY 4.1 Transportation Picture 2 Transportation Process The machine must be handled via being connected from the points mentioned considering the transportation pictures above. The haulage rope, chain or cable must be selected in compliance with the machine weight mentioned in the capacity and mechanical properties. Pay attention to fix the moving parts of the machine before transportation. Always ensure holding the handles shown. Do not stay under the machine during the transportation. Do not perform loading or discharging with fast movements. Min. 10 tons crane must be used for handling of the machine to the transportation vehicle. User is responsible for the risks arise from drops or impacts as a result of using improper haulage vehicles during the transportation of the machine. 4.2 Storage The machine is packaged by taking the measures after being tested in the factory. When performing the storage of the machine, a proper storage area must be determined according to the dimensions of the machine and impacts from narrow spaces must be avoided. The storage area must be moisture-free. Room temperature is recommended for storage. Long-term storage at 1000 m above the sea level is not recommended. 4.3 Assembly & Disassembly Storage and transportation must be performed via following the instructions at the work site of the machine. Initial installation processes of the machine must be performed by Akar staff. Providing required air and electric connections to operate the machine is sufficient for assemblies after transportation following the initial assembly. 9 The power must be turned off from panelboard of the facility before disconnecting. Installation valves must be open and main feed valves must be close when air connection is disconnected. The floor on which the machine is assembled must not be uneven as it may unbalance the machine. Sufficient space must be arranged around the machine for operation, maintenance and repair. No connection is needed for positioning the machine. The machine must be placed on the floor as it stands. 4.4 Power Connection Power connection is in the electric panel of the machine. The connection must be performed as it is shown in the electric circuit diagram. Electric connection must be performed by an authorized electrician. Cable amount to be connected to the panel must comply with the section mentioned in the electrical properties of the machine. The cable must not be powered-up when the connection is being performed. The energy source must comply with the operating voltage and frequency of themachine. We recommend taking the power compensation from a panelboard of the facility. When the distance of the energi cable exceeds 50 m from the panelboard, the section must be increased at one level. 4.5 Air Connection Air connection is in the equipment group of the machine. The connection must be performed in accordance with the equipment circuit diagram. Do not aerate the machine when the connection is being performed. Air pressure compressor must be avoided from air leakage. The compressor must be opened first and then the air inlet valve must be opened after the air connection is performed. 10 5. TECHNICAL INFORMATION 5.1 Machine Master Groups Picture 3 Master Groups Master groups of AKR 550 are divided into 9 main groups. 1 2 3 4 5 6 7 8 9 FRAME GROUP EXTRUDER GROUP MOLD TIRE ROTATING GROUP THRUST GROUP ROLLING GROUP HORIZONTAL MOVEMENT GROUP VERTICAL MOVEMENT GROUP ENCODER GRUOP 11 5.2 Technical Information of the machine Capacity & Mechanic Properties Model AKR550 Max. Tyre Diameter Ø 1450 mm Min. Tyre Diameter Ø 750 mm Dimensions 2685 mm (H), 4400 mm (L), 2040 (W) Weihgt 3,5 ton Capacity 1,5~2 min / tire Equipment Properties Connection Type Connection Operating Pressure Air 1” Max. 6 bar Electrical Properties Gross Power 30 KW Operating Voltage 400 V (3 faz) Frequency 50-60 Hz 12 6. CONTROL COMPONENTS OF THE MACHINE 6.1 Main Control Panel Control Components Picture 4 Main Control Panel Image ITEM NO COMPONENT DESCRIPTION 1 Inflation / Deflation 2 Cushion gum / Apply Tread / Stitching 3 Man / Auto Provides manual or automatic operation of the machine. 4 Auto Start Starts automatic process. 5 Auto Stop Stops automatic process. 6 Pause 7 System Start 8 Pressure 9 10 11 Pressure Adjusting Low / Medium / High Tire Rotating Backward / Forward Tire Rotating Slow / Fast 12 Laser On / Off 13 Lighting On / Off Provides inflation and deflation of tire. Determines operation mode of the machine. Cushion gum winding / Apply Tread / Stitching Pauses the system during the stitching process. Functions for recommissioning on initial start-up of the machine and after pressing the emergency stop. Decompresses and boosts cylinder pressure. Adjusts the cylinder pressure at the values entered in the adjustment page Moves forward – backward the tire rotation motor. Provides slow – fast circulation of the tire rotation motor. Turns the laser on/off. Controls the lighting. 13 14 Send To Park 15 Extruder Forward 16 17 18 Tire Move Backward / Forward Mold 1 Motor Backward / Forward Mold 2 Motor Backward / Forward Provides the moving parts of the machine to turn the home position and recipe value when the power is on. Moves extruder motor forward. Moves forward – backward the tire rolling motor. Moves forward – backward the mold 1 motor. Moves forward – backward the mold 2 motor. 19 Heater On / Off Starts the heater system on. 20 Emergency Stop Provides emergency stop (shutdown). Table 1 Main Control Panel Description of Controls START PAGE Picture 5 Start Page İmage When the main switch of the machine is turned on, the start page appears first. This page enables to proceed language selection page and other sub-pages. Proceeding to sub-pages can be administered via touching the desired page on the touch panel or pressing the function buttons on the touch panel. 14 CUSHION GUM PAGE Picture 6 Cushion Gum Page İmage Cushion gum page displays whether the conditions required for cushion gum process are provided or not. Also this page provides proceeding to the recipe page. COMPONENT DESCTIPTION Displays the actual level and position of the tire. Displays whether the extruder, upper and lower mold reach or not to the temperature rating specified at the temperature page. When it reaches to the desired temperature the sign turns into , otherwise . Displays whether the rubber is supplied or not at extruder rubber input. Displays the tire inflation or deflation. 15 Displays the position of tires and molds. Also enables to transfer the desired tire and mold positions to PLC. This can be made through touching the sign. The sign turns into . Displays the distance between shoulder molds. Displays whether the shoulder molds are reached the desired level or not. will turn into when reaches the desired level. Displays the active recipe loaded in the machine and provides proceeding to the recipe page after pressing the recipe button. Table 2 Cushion Gum Page Description of Controls 16 APPLY TREAD - STITCHING PAGE Picture 7 Apply Tread – Stitching Page İmage This page enables to enter required values for Apply tread - Stitching processes. Such as speed, position and pressure. COMPONENT DESCRIPTION Displays the actual position of the tire. Displays the actual cylinder pressure. Enables entering the moving down and up speeds of Apply tread - Stitching group in percentages. Enables entering the starting position of Apply tread - Stitching group. 17 Enables entering the thickness of the tread in mm. Pressure rate; Cylinder pressure value. Pressure level low; this value is entered in percentages and is the gap of the cylinder pressure by percentages. Pressure level high; this value is entered in percentages and is the excess of the cylinder pressure by percentages. These three values are activated via Pressure Adjusting Low / Medium / High buttons. Tire speed at the apply tread process. Displays the actual distance between rollers. Enables entering ranges of the zones in stitching process and the speed values of the motor in these zones. Also enables tire speed values in stitching process. Enables entering the number of rotating cycle of the tire and the speed value of the tire when the cylinder pressures the tire in the stitching process. Table 3 Apply Tread - Stitching Description of Controls 18 MANUEL CONTROL PAGE Picture 8 Manuel Control Page İmage In the manual control page, buttons on this page enable to control the outlets of the machine independent of each other after positioning the Man/Auto button to manual in control panel. Also it displays the actual values of the moving parts. COMPONENT DESCRIPTION Displays the actual values of the moving parts. Displays the position and agle of the tire. 19 Displays the actual positions of reelings and Apply tread – Stitching group. Enables to turn on/off the valves of the extruder valve group via buttons. Enables to heat the S,A and P group shoulder molds via buttons. Enables to operate the heater and chiller devices via buttons. Speed values of extruder and tire position motors on the manual mode. Enables to inflate/deflate the tire and rim expand/collapse via buttons. Enables to move up/down the Tread apply roller via the pressure value entered in manual process. Enables to move up/down the Apply tread - Stitching group via entering the speed value on manual process. Enable to operate the pressure valve of the reelings by the number of stitch area entered and to operate the roller motor forward/backward by the speed value entered. Table 4 Manuel Page Description of Controls 21 FAULT PAGE Picture 9 Fault Page İmage Faults and alarms occurred within the machine are followed on this page and the page enables to reset these faults and alarma via buttons. COMPONENT DESCRIPTION Pressing this button means that the operator displays the faults and alarms occurred. (Acknowledge Buton) This button restarts the process after the faults and alarms having been removed. Table 5 Fault Page Description of Controls 22 SYSTEM SETTING PAGE Picture 10 System Setting Page - 1 System setting-1 page enables to make shoulder mold and mold offset settings, certain settings required for winding process and settings related to tire inflation. COMPONENT DESCRIPTION Enables to enter offset values of molds. 23 Enables to enter offset values of shoulder molds. Extruder Stop Angle; extruder motor stops at this degree angle of the tire. Tire Stop Angle; tire rotating motor stops at this degree angle of the tire. Tire move back angle; tire move motoru proceeds to home position at this degree angle of the tire. Tire rotate Offset; tire rotating motor starts late turning by this value when the cushion gum process is started. Tire Approach Offset; Offset value of the tire move motor. Cushion gum Idle Waiting; extruder motor operates by Cushion gum Operate After Idle time if the cushion gum process is not started by this period. Tire Inflation Time; The value which determines the start of tire inflation after how many seconds from the rim expand. Tire Inflation Rotate Time; The value which determines that how long (seconds) the tire rotates when the tire inflation is started. Tire Deflation Time; The value that determines when the rim collapse is occurred after the tire deflation. The distance between twin rollers. Enable to proceed system setting - 2 page. Table 6 System page-1 Description of Controls 24 Picture 11 System Setting Page - 2 System setting-2 page enables to enter the speed and factors used by extruder and tire motor in the cushion gum process. Values entered in this page are critical. They have direct influence on cushion gum process. Therefore Akar Makinanın is not responsible for modifications made beyond Akar Makina‘s knowledge. COMPONENT DESCRIPTION Speed and pressure values in accordance with the buffed tread width. 25 Factors entered for synchronous operation of extruder and tire motor. Speed factor by cushion gum thickness. Enables to go back to system setting - 1 page. Table 7 System Page-2 Description of Controls 26 RECIPE Picture 12 Recipe İmage Enables to proceed recipe page from cushion gum page. Shoulder mold and tire are positioned at the desired position manually when creating the recipe and by pressing symbol located at section in which tire and shoulder mold positions at Cushion gum page, symbol turns into . Then the operator presses the NEW button. Recipe name must be entered in Data Record Name section. By pressing RECEIVE FROM PLC button and completing the empty areas and by pressing the SENT TO PLC button, the recipe is sent to the machine. Then the recipe can be saved by pressing the SAVE button. For the tires with similar properties, you just need to press SENT TO PLC button to send the tire values to the machine. 27 COMPONENT DESCRIPTION SENT TO PLC; Sends tire values of the recipe to the machine. RECIVE FROM PLC; Brings the tire values of the machine to the recipe. Enables to proceed Cushion gum page. Table 8 Recipe Description of Controls 28 WORKING TIME PAGE Picture 13 Working Time Page İmage This page displays working times of the machine, heater and processes. 29 HEATING SETTING PAGE - 1 Picture 14 Heating Setting Page – 1 İmage This page displays the set and actual values of the extruderin, lower – upper mold, heater and chiller. The page also displays the average temperatures of shoulder mold groups. By pressing "Waiting Activation" symbol, it turns into and all the temperature set values of the machine turns into the stand-by temperature values. The reason for this is to prevent the cushion gum (rubber) material in the extruder from decomposition if the machine stands by for a long time for any reason. 30 HEATING SETTING PAGE - 1 Picture 15 Heating Setting Page – 1 This page displays set, actual, + - tolerance and waiting values of extruder, lower – upper mold, heater, chiller and shoulder mold. + - tolerance values shows the proximity to set values and also shows that the extruder areas, heater, chiller and shoulder mold devices between such + - tolerance values are at the desired temperature levels for cushion gum winding. When the standby mode is activated, waiting set values of the machine substitutes the set values. 31 7. PRE-OPERATION CONTROLS and ADJUSTMENTS 7.1 Pre-operation Controls The following controls must be performed before the operation: Input Regulator Pressure Gauge (6 Bar) Valve Air Installation Lubricator Scraper Blades Cooling Water Control Package switch on the panelboard must be closed or locked if required before operation. The machine must not be operated if the main air inlet regulator displays a value over 8 bar. Main air intake regulator must be at 6 bar max.. Other regulators must be adjusted by the operator properly in accordance with the tire size during the running-in-period. The nuts to which the scraping blades are connected must be tightened. Cooling water tank must be filled with clean water. 7.2 Adjustments The following adjustments must be made before the operation. 1. 2. 3. Rim selection and assembly Pneumatic pressure level must be at optimum level Scraping data entry Selection of rim must be made in accordance with the tire size. Main air inlet must be closed when performing the adjustments. Fastening locks are ensured to be replaced in their housing when the rims are assembled. 7.3 Proper Rim Selection 7 types of rims manufactured in accordance with the tire sizes commonly used in the market are as follows. Rims to be used other than such tires can be manufactured upon the demand of the customer. Operator decides the proper rim for the tire to be scraped and the Hub is mounted on it. 1) 17-20x6,75'' 2) 17-20x8,25'' 3) 17-20x13,5'' 4) 20-22,5x9'' 5) 20-22,5x11,75'' 6) 22-24,5x9'' 7) 22-24,5x11,5'' Picture 16 Rim Selection 32 8. OPERATIONAL PROCESSES Main swith and air valve of the machine is opened. Heater device is opened through main control panel after starting the machine program and no actions are taken till the extruder and molds are conditioned (temperature). When the extruder and mold reach the desired temperature, cushion gum material is taken to be fed. Recommended cushion gum dimensions; Ideal size : Tape cushion gum 40 mm x 7 mm Max size : Tape cushion gum 50 mm x 7 mm After preparing the extruder and mold system, proper rim is attached to the machine which suits the tire to be retreaded. Right/left shoulder molds suitable for the tire shape are attached to the mold. Cushion gum winding mode is selected via the control panel. The tire is loaded and inflated (Average tire pressure must be 1,5). The tire is approached to the mold and pressed adequately and right/left shoulders are adjusted, then the recipe created is recorded for the tire size. Automatic mode of the machine is started via the control panel. After making all the settings, winding process is automatically started via the panel. After the machine completed the winding process, it goes to the starting point automatically. Tread apply mode is selected via the control panel. Then the thrust mode is selected according to the tread properties to be used via the control panel. By ordering the automatic start via the control panel, tread applying module is sent to the starting position. The operator pastes the rubber tread to the tire back surface. In the meantime the operator controls the tire via foot switch by rotating it step by step. Picture 17 Start of Tread Apply Process Center the tread by turning the laser on and continue rotating via foot switch. The tire automatically stops when the end of the tread is aligned with the tension cylinder. By pressing the automatic start button via the control panel, the tension cylinder is ensured to pressurize the tread surface completely. After the tire rotated at 2700 (3/4 lap), it stops automatically for the check by the operator and the operator provides kissing the back ends by adjusting the tension pressure via a joystick. Picture 18 Tread Apply Process Rotation of the tire and tread apply process are completed automatically. The system is restarted by pressing the automatic stop button more than 3 seconds. 33 The stitching mode is selected via the control panel. By selecting the automatic start via the control panel, the stitching module is sent to the starting position. Automatic start is selected via the control panel. Stitching cylinder goes down and then the stitching process is completed at the desired time period. Picture 19 Stitching Process 8. Twin rollers start stitching process by landing on the tire according to the desired parameters. After the machine complete the stitching process automatically, again goes to the starting position. MAINTENANCE and REPAIR 8.1 Control Operations Make manual and visial control before using the machine. Contact technical service if it has any broken or malfunctioned part. Keep the machine clean to use it long-term and reduce maintenance cost. Daily Maintenance General maintenance, cleaning of the working area and burrs must be performed. Operating noise and temperature of target motors must be chaecked. All the pneumatic system must be reviewed. Leakages from the joints of pneumatic system must be checked. Points required lubrication of the pneumatic system must be lubricated. Main air pressure which operates the machine must be checked whether it is at 6 bar or not. The water collected in the waterstop filter of the conditioner placed on the machine must be discharged. Cutting tools must be chacked. Blunt cutters must be replaced. Weekly Maintenance Regular maintenance of the whole machine must be made. The system must be checked throughly. Machine panel and electic control buttons and switches on the panel must be checked. All the moving parts and systems (Skids and sash bars) must be lubricated, the areas directly in contact with the rubber burr must be cleaned with a dry cloth. The lubricants and equivalents are as follows. Petrol Ofisi MOBİL : SUPER GRES EP-0 : MOBİLUX EP-00 SHELL : ALVANIA EP-0 Mechanical systems of the machine subject to the abrasion must be supported with sufficient grease oil. The grease oils and and equivalents to be used are as follows. BP Petrol Ofisi MOBİL : ENERGREASE LS3 : SUPER GRES 3 : MOBİLUX 3 SHELL CASTROL : ALVANIA R-3, RL-3 : SPHEEROL AP-3 34 The lubricant level of the tube on the conditioner of the machine, which lubricates the pneumatic system must be checked, if the lubricant level is at the minimum, a suitable lubricant addition must be made. The lubricants and equivalents to be used are as follows. Petrol Ofisi Mobil : Regal Oil 68 (Turbine Oil) SHELL : DTE Oil Heavy Medium HM : Turbo T68 Anchorage bolts of the general mechanical assembly of the machine must be checked against loosening. Loosen bolts must be tightened according to the suitable torque level. Bearings of the moving parts of the machine must be chacked against loosening. Cleaning of the cutting tools cooling tank must be made. Moving parts of the pneumatic valves must be made. Cleaning and maintenance of pneumatic pistons must be made. All the manometers must be checked. Lubricants of all the pneumatic systems must be checked whether they are active or not. All pneumatic and lubricating hoses and joints thereof must be checked. Leakages and escapes on pneumatic pipes must be checked. Faulty and malfunctioned pneumatic circuit components must be replaced. Impurity indicator of pneumatic filter must be checked. Monthly Maintenance The system must be checked throughly. Machine parts such as tool-sets or tool handles must be checked. Linear skids and carriers, worm gear ball rods and fixed bearings must be visually and manually checked by removing the protective covers whether they are lubricated or not. Monthly maintenance of the filters must be made. Leakages must be checked. Seals and cushioning adjuster bolts of vertical and horizontal cylinders must be checked and if the cushioning setting is out of oreder, the adjustments must be made. The cylinder must be replaced if the seals do not function or the cushioning settings are out of order. The leakage of the pneumatic and lubricating system must be checked. In the same manner; the cental lubrication system must be checked visually and manually against any disconnexion, blockage in the direction of flow or if the hoses are repleted with oil. In case of any of such problems occur, plastic oil hoses must be replaced. The machine must be cleaned with a brush or a dry cloth without aerating by removing all the protection covers for the burrs occurred. The machine should not be operated before closing the protection covers. Monthly Maintenance Cooling liquid tank should be discharged, cleaned and reassembled. Tension of the spindle motor belt and deformation thereof should be checked. Proxmity switch detection surface should be cleaned. Coal and collectors of Electromotors should be checked and cleaned and replaced. Functions of the stopping switch and emergency stop button should be checked. Brakers on the control boards of protective relay contacts should be checked. All the hose joints on the machine (Water, air, hydrolic etc.) should be checked. 35 Annual Maintenance Abrasion and oil film occurrence on the starting skids must be checked and adjusted. All the powertrain parts on the machine must be checked. Abraded, worn equipment or equipment needs replacement must be replaced. Tension of the belt and pulley systems on the machine must be checked. The lubricant used in hydrolic systems must be replaced. Wearing parts must be replaced. Electric cable connections must be checked. Broken, disconnected and damaged cables must be replaced. Bushings and bearings of moving parts must be checked against abrasion replaced if required. Impaired sealing gaskets of pneumatic system must be replaced. Maintenance of the filters must be made. Sound absorbers must be checked and their filters must be replaced. Efficiency and power control of circuit elements must be followed. 8.2 Cleaning Operations Cleaning Schedule and Criteria Rubber burrs on the machine must be cleaned daily. Dust and burrs on the skids must be cleaned within the 6 monhts maintenance by removing the skid covers. By this means, skids will have ease of movement and abrasion on the surface is avoided. Electric and pneumatic tools and mechanical assembly must be protected from dust. Because dust deposit causes various malfunctions on the machine. Electric and pneumatic tools can be cleaned with a dry cloth. Mechanical assembly and the body of the machine may be cleaned with a damp cloth. Mechanical parts should be cleaned with an oil-soaked cloth to prevent dust accumulation. Inside and outside of the main control panel may be cleaned with a clean and dry cloth. Dirty surfaces of the panel can be cleaned with an alcohol-soaked cloth. Pacco swith and main air inlet valve of the machine must be closed during the cleaning process. When cleaning the inside of the main control panel, the power must be off. Do not use solvent, flammable and corrosive liquid materials for cleaning. Pressurized air must be used in a controlled manner for cleaning the electrical materials. 8.3 Lubricating Points Adjust the pneumatic system lubricant control and oil adding lubricator to operate one drop per minute. Drop amount can be displayed on the glass indicator of the lubricator and adjusted via the screw on the upper part of it. 36 10. MECHANICAL PARTS, SHAPE and SPARE PART LİST ITEM NO STITCHING ROLLER PIECE PART NAME PICTURE / STANDARD NO 1 DEEP GROOVE BALL BEARING DIN 625 2 6004‐2RS 2 HOLE RING DIN 472 1 Ø42x1,75 3 SHAFT RING DIN 471 1 Ø20x1,2 DESCRIPTIONS 37 REEL UP GROUP ITEM NO PART NAME 1 LSUD2005 LH Kozanli 2 3 DEEP GROOVE BALL BEARING REDUCER PICTURE / STANDARD DIN 625 PIECE DESCRIPTIONS 1 LMT LSUD 2005 LH 2 6002‐2RS 1 YILMAZ EV030.03‐63/4b, 0,18 kW, 97 d/d 4 PNEUMATIC CYLINDER 2 PEMAKS PK‐A‐T 040‐125 (ERKEK MİLLİ) 5 LINEER RAY 2 HIWIN HGR15R840H E:30 6 8 HIWIN HGW 15CCH 7 RAIL CARRIER ENCODER 1 8 INDUCTIVE SENSOR 2 AUTONICS E5058‐1024‐3‐T‐24‐CS LEUZE IS 212MM/4NC‐4E0‐S12 9 WEDGE DIN 6885 2 A 5x5x25 10 WEDGE DIN 6885 1 A 5x5x56 11 BALL SCREW NUT 1 LMT LSUD 2005 LH 38 TIRE ROTATING GROUP ITEM NO PART NAME 1 2 RAIL CARRIER FLANGED BEARING 3 SAFETY WASHER DIN 5406 4 LOCK NUT 5 WEDGE 6 7 8 9 PICTURE / STANDARD NO PIECE DESCRIPTIONS 4 HIWIN HGW 30 CCH 2 1 FAG UCFC 212 MB 12 DIN 981 1 KM 12 DIN 6885 2 A 14 x 9 x 100 TIMING BELT 1 16 T5/840 z:168 REDUCER ROTATING ELEMENT DOUBLE LINE CONNECTION BEND 1 YILMAZ KN473.00 İ:51,22 ROTOTECH 3100‐011‐210 ROTOTECH R00042513041514 (Ø15,8 DELİKLİ) 1 1 10 LINEER RAY 2 HIWIN HG30R1640H E:20 11 INDUCTIVE SENSOR 2 LEUZE IS 212MM/4NC‐4E0‐S12 12 RUBBER WEDGE 2 Ø30x30 ‐ M8x25 SINGLE‐SIDED BOLTED 39 ITEM NO 1 2 3 HORIZONTAL MOVEMENT GROUP PART NAME PICTURE/STANDART NO PIECE DESCRIPTIONS 1 LMT LSUD 3205 550‐02.01.18 1 LMT LS 3205 BALL SCREW L:1035 KV_10_3_R_2G90S_B14_ML1 1 BALL SCREW NUT POWER SCREW REDUCER YILMAZ KV102.00, 1,5 kW, 462 d/d 4 ENCODER 1 AUTONICS E5058‐1024‐3‐T‐24‐CS 5 INDUCTIVE SENSOR 2 LEUZE IS 212MM/4NC‐4E0‐S12 6 RUBBER CUSHION 2 7 BEARING 1 Ø30x30 ‐ M8x25 SINGLE‐ SIDED BOLTED FK25 40 ITEM NO 1 2 3 4 ENCODER GROUP PART NAME RESİM/STANDART NO PIECE DESCRIPTIONS HOLE RING DIN 472 2 Ø47x1,75 1 AUTONICS E5058‐1024‐3‐T‐24‐CS DIN 625 2 6005‐2RS DIN 6885 1 A 6x6x20 ENCODER DEEP GROOVE BALL BEARING WEDGE 41 S. PART NO VERTICAL MOVE GROUP PART NAME PICTURE / STANDARD NO PIECE DESCRIPTIONS 1 REDUCER 1 YILMAZ KV102.03, 1,5 kW, 462 d/d 2 FLANGED BEARING 1 UCFC 206 3 RAIL CARRIAGE 4 HIWIN HGW30CCH 4 BALL SCREW NUT 1 LMT LSUD 4005 5 LINEER RAY 2 HIWIN HGR30R990H E:15 6 ENCODER 1 AUTONICS E50S8‐100‐3‐T‐1 7 RUBBER WEDGE 2 Ø30x30 ‐ M8x25 SINGLE‐ SIDED BOLTED 42 LASER GROUP PICTURE / STANDARD NO PIECE DESCRIPTIONS HAND WHEEL 1 WEDGE SK 7305‐101 VERTICAL BEARING RAIL CARRIAGE 1 UCPA 202 4 LASER 2 LASER‐T TE 056 5 LINEER RAY 1 HIWIN HGR15R560H E:10 ITEM NO PART NAME 1 2 3 2 HGR15R_560_H_1 HIWIN HGW 15CCH 43 IMPRESSION ROLLER ITEM NO PART NAME 1 SENSOR PNEUMATIC CYLINDER 2 PNEUMATIC CYLINDER 3 BEARING PICTURE / STANDARD NO PIECE 1 ISO 15552 1 2 DESCRIPTIONS LEUZE HRTR 25B/66‐S8 SMC CP96SDB80‐160 UCPA 205 LEUZE HRTR 25B/66‐ S8 44 11. PNOMATİK DEVRE ŞEMASI ITEM NO Reference Brand Piece 01 02 03 04 05 ‐ ‐ 175‐00.00.00 C ‐ VP742‐5YD1‐ 04FA PEMAKS PEMAKS AKAR Tire 2 1 1 1 06 07 08 09 10 11 SV3A00‐5FU‐X2 SV3100‐5FU SV3100‐5FU VHS40‐F04 AW40‐F04DE ARP40‐F04H SMC SMC SMC SMC SMC SMC SMC 2 2 1 1 1 1 1 12 ITV2050‐31F3L3‐ Q 13 14 15 16 17 18 19 IR2020‐F02BG AR20K‐F02BE AFM30‐F03D EVR1220‐F02 ASP430F‐02‐08S AS3201F‐03‐08S AKAR DEPO SMC SMC SMC SMC SMC SMC SMC PAKKENS 1 1 4 1 4 2 3 1 Description PK‐A‐T ø40‐125 Pneumatic Cylinder ISO‐M ø80‐160 Pneumatic Cylinder Wheel Rim Tightening HUB Tire Inflation Coil Valve, 3/2, 24 VDC, N.K.(N.A. Practicable), 1/2" Coil Valve, Dual 3/2, 24 VDC, N.K./N.K., LED, Shielded, 1/4" Coil Valve, 3/2, 24 VDC, N.A., 1/4" Coil Valve, 3/2, 24 VDC, N.K., 1/4" 3/2 Modular Open/Close Valve, 1/2" Filter Regulator, 1/2", Automatic Discharge, Manometer Precision Regulator, 0,05‐6 Bar, 1/2" Electropneymatic Digital Proportional Controller, 0,05‐9 Bar, 0‐10 VDC Kum., Socket, 3/8" Precision Regulator, 0,1‐8 Bar, 1/4", Bracket, Manometer Regulator, 10 Bar, 1/4" Gear Linkage, Manometer Oil Baffle Valve, 0,3 Micron, 3/8", Automatic Discharge 1/4"OR Valve Adjustable Speed, Pilot‐operated Check Valve, 1/4", ø 8 mm Bend‐Type Speed Adjuster Valve, 3/8" ‐ ø8 mm Pressure Relief Valve, Membrane, Male, 2,5 Bar, 1/2"
