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MR-11 PLC-TMR-11 PLCT-F

BRAIDMATIC

Instruction Manualand

Parts Catalog16, 20, 24 AND 36 CARRIERS

LIGHTWEIGHT

MII



LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.

Date of Issue for original and changes pages are:

Revision Pages Changed Date

Original August, 2004

Rev A Changes made to the following pages: 1-3, 1-5,1-12 thru 1-25, 1-31, 3-2, 4-10 thru 4-13, 7-37thru 7-41, 7-104 thru 7-111, 7-114, 7-118, 7-119,7-138 thru 7-141

January, 2005

Rev B Changes made to the following pages: 4-7 thru

4-24, Chapter 7, Electrical Schematics

February, 2005

Rev C Added German translation to Safety, Chapter 1,Chapter 3, Chapter 4, and Chapter 8,Change made to the following pages: 1-4, 7-24,7-26, 7-30, 7-32

March, 2005

Rev D Changes made to the following pages: 4-12thru 4-18, 8-3

March, 2005

Rev E Rearranged 4.2 thru 4.18 in Chapter 4, pages 4-1thru 4-18

April, 2005

Rev F Added Dutch translation to Safety, Chapter 1,Chapter 3, Chapter 4 and Chapter 8

June, 2005

Rev G Changes made to the following pages: 2-35,6-4, 6-10, 7-37, 7-57, 7-61, 7-86, 7-88, 7-92,

7-93, 7-99, 7-100 thru 7-111, 9-4

February, 2006

Rev H Changes made to the following pages: 1-1, 1-4,Chapter 4

March, 2006

Rev J Changes made to the following pages: 1-6, 1-7,1-29, 1-30, 2-2, 2-5 thru 2-18, 2-33 thru 2-50,7 13 7 15 7 73 7 75 7 88 7 89 7 94 7 95

May, 2006







Rev K Changes made to the following pages: 4-26 thru4-38, 7-138 thru 7-146

July, 2006

Rev L Changes made to the following pages: 7-146thru 7-149;Chapter 8: added Italian safety information;Added Italian Safety Information to this section

July, 2006

Rev M Changes made to the following pages: 7-146thru 7-149

August, 2006

Rev N Changes made to the following pages: 2-16, 6-5,7-3, 7-12, 7-20, 7-35, 7-100, 7-101, 7-139,7-150, 8-38, 8-39, 8-43

September, 2006

Rev P Changes made to the following pages: 7-21,7-25, 7-101, 9-1;

Added sections to Chapter 4

November, 2006

Rev R Changes made to the following pages: 4-40, 7-9,7-13 thru 7-27, 7-94, 7-95, 7-106

July, 2007

Rev S Added Dutch translations to Sections 4.6, 4.9,4.10, and 4.11; Changes made to the following pages: 7-20 thru 7-27, 7-77, 7-101, 7-146 thru7-149, 9-2 thru 9-6

January, 2008

Rev T Added Dual Drive Information; Changes alsomade to the following pages: 1-6, 3-3, 4-35 thru4-40, 5-5, 5-7, 6-22 thru 6-25, 7-12, 7-13, 7-20thru 7-25, 7-44, 7-45, 7-49, 7-81 thru 7-86,7-100, 7-104 thru 7-112, 7-118 thru 7-123, 8-38,9-7

June, 2009







Rev W Changes made to the following pages: 1-5, 6-28,6-31, 6-33, 6-35, 6-37, 6-39, 6-44, 6-45, 7-29,7-38, 7-39, 7-52 thru 7-54, 7-107, 7-109

December, 2010

Rev X Changes made to the following pages: AddedChapter 4A for color touchscreen; Added BraidMaterial Runout information to Chapter 4;Added Stand Alone Main Control Box informa-tion to Chapter 6 (6-46 thru 6-61); 3-4, 3A-2,3A-3, 6-23, 7-116 thru 7-123, 7-147, 8-6, 8-7,8-15, 8-28, 8-29, 8-48

June, 2011

Rev Y Changes made to the following pages: 1-5, 1-22,2-23, 2-35, 5-6, 5-7, 6-25, 6-31, 7-3, 7-15, 7-17,7-31, 7-40, 7-41, 7-1017-150, 8-33, 8-43, 9-7

November, 2011

Rev Z Changes made to the following pages: 1-4, 1-5,

6-50 thru 6-61, 7-9, 7-13, 7-17, 7-21, 7-42 thru7-45, 7-75

February, 2012



FOREWORD

This is the operating and parts manual for the Braidmatic MR-11 PLC-T and MR-11 PLCT-F.The furnishing of this document does not constitute or imply a grant of any license under any patents, patent applications, trademarks, copyrights or any other rights of seller or any third party.Machines made prior or subsequent to the publication date of this manual may have parts,systems, or configurations that are not covered herein. Please contact Customer Service.

NOTE: The Figure numbers in this manual correspond with the Chapter and Paragraph numberswherein they are located.



SAFETY FOR MR-11 PLC-T AND MR-11 PLCT-F BRAIDMATIC

Braiding machines are designed to produce quality braided structures by transferring shuttles viacam tracks. Producing the braided structures requires high speed, high horsepower, and movingelements. This in turn requires that operators and maintenance personnel of this equipment besafety conscious to avoid an accident which could be crippling or fatal to the operator or maintenance personnel.

Setup of this equipment should be done by trained mechanics and/or riggers.

We cannot anticipate all possible factors that could cause an accident to occur with thisequipment, but are listing general safety considerations as an aid to the operator or maintenance personnel becoming safety oriented.

When this symbol is shown in the manual, the written instructions must be followed 100 percent to prevent personal injury. If you don’t understand the instructions, pleasecontact Mayer Industries Inc.

An operator or maintenance personnel should become completely familiar with all machinecontrols and corresponding moving elements before setting up, operating, or working on themachine.

We suggest snug fitting clothing and safety glasses be worn. No ties and no attempt made tooperate the machine while fatigued or ill. Do not operate the machine if it is malfunctioning in anyway.

The following safety equipment and precautions should be utilized by all personnel operating and/or working on this equipment.

• Safety shoes with steel toes.

• Safety glasses with side shields.• Hearing protection

• Leather gloves when handling steel reinforcement materials.

• Only trained personnel should set up, operate, or work on this equipment

CAUTION



The movement of the deck, gear, and transfer areas can create pinch points and the operator mustavoid these points.

During maintenance work, the control must be turned OFF, as an accidental control actuation cancause an unexpected machine movement which could cause as accident. Utilize your plants lock out/tag out procedures.

High voltage is used to power this machine. Only authorized electricians should correct anelectrical component failure. Other maintenance must be performed by authorized personnel.

In conclusion, operators and maintenance personnel “must” be properly trained before beingallowed to operate or work on this equipment. Operators and Maintenance Personnel must treatthis equipment with the utmost respect and observe all safety precautions.

All rights are reserved for this instruction manual. It must not be copied nor made available toothers without Mayer Industries' previous consent nor its contents exploited in any other way bythe user or any third party. Reprints, whether complete or partial, require the express authorizationof Mayer Industries.

These operating instructions have been formulated to give you information on the construction,operation and maintenance of the machine. The enclosed diagrams and drawings illustrate theimportant features of the design. However, dimensional accuracy and design details are notguaranteed and we reserve the right to make any changes or amendments at any time.

The operating instructions also describe devices, spares or other parts which do not belong to thestandard version of the machine and which are only available to order as an extra. No right to

equip the machine with such parts or devices may be derived from these operating instructions.

Please consult Chapter 7 when ordering spares. The machine warranty is valid only if usinggenuine MII or MII-approved components or replacement parts.

Before and while operating the machine, all general and special safety rules must be observed andnecessary safety protections taken. No protective or safety devices must be put out of action.



TRANSLATIONS FOR LABELS AND CONTROL BUTTONS

SYMBOL TRANSLATIONS

English: CAUTION

English: NOTE

English: STOP

English: JOG / RUN

English: SAFETY OFF / ON

English: JOG / FORWARD

CAUTION

NOTE




SYMBOL TRANSLATIONS

English: STOP

English: DANGER / HIGH VOLTAGE

English: LASER LIGHT:

Do not stare into beam

English: DANGER TOXIC FUMES

English: DANGER:

Do Not Operate Without Guards In Place

STOP




SYMBOL TRANSLATIONS

English: HIGH VOLTAGE

English: PINCH POINT

English: DANGER PINCH POINT

English: DANGER

DO NOT OPERATE UNLESS PROPERLYTRAINED

English: DANGER

ONLY TRAINED AND EXPERIENCED

MAINTENANCE PERSONNEL OR RIG-GERS SHOULD BE ALLOWED TO MOVEAND SETUP THIS EQUIPMENT.

NOTE: MACHINE WEIGHT AND STABIL-ITY ARE MAJOR CONCERNS IN LIFTINGAND MOVING THE EQUIPMENT




SYMBOL TRANSLATIONS

English: DANGER

DO NOT OPEN WHILE MACHINE IS INOPERATION

English: WARNING



SICHERHEITSREGELN FÜR MR-11 PLC-T/MR-11 PLCT-F BRAIDMATIC

Braiding Maschinen sind entwickeld um hohe Qualitäts braided structur produkte zu produzieren bei transfer shuttles über cam tracks. Beim Produktstionsvorgang wird mit hoher geschwindigkeitund mit viel Kraftaufwand gearbeitet. Um unfälle zu vermeiden soll nur geschultes Personal zur Bedienung der Maschine verwendet werden.

Wir Können nicht alle möglichkeiten aufzählen die einen Unfall verursachen Können, aber wir führen hier in generell einige Sicherheitsvorschriften auf.

Wenn dieses Zeichen im Buch erscheint, die instruktionen müssen 100% erfüllt werdenum Unfälle zu vermeiden. Wenn sie irgend etwas nicht verstehen, fragen sie uns bitte.

Bedienungspersonal und Betriebsmechaniker müssen sich vorhehr mit der Funktion der Maschine

bestens vertraut machen. Elektrisch und mechanisch.Wir schlagen vor eng anliegende kleidung. Keine Krawatte, aber eine Schutzbrille zu tragen.Bleiben sie weg von der Maschine wenn sie sich nicht wohl fühlen, oder krank sind. Niemals dieMaschine laufen lassen mit einem eventuellen defekt.

Lasse niemals Werkzeug irgendwo in der Maschine Liegen.

Mach sicher das alle Abdeckungen immer in richtiger position sind und fest angeschraubt wenndie Maschine Läuft.

Die sich bewegenden elemente Transferposition und Ritzel Können Leicht zu einer Falle werden,so sei vorsichtig und trete zurück.

Bei Reperaturarbeiten mach sicher das die Maschine ausgeschaltet ist. “AUS” da wir mit hoher Spannung arbeiten.

Mach sicher das nur geschulte Elektriker an der Maschine arbeiten.

Am ende möchten wir daraufhinweisen das, das Personal die Maschine immer mit Respekt behandelt, und immer alle Sicherheitsvorschriften beachtet.

WARNUNG



Im Buch sind auch Teile aufgeführt die nicht in einer Standard Maschine verwendet werden.Diese Teile müssen seperat bestellt werden.

Wenn sie ersatzteile bestellen, nur original MII Teile verwenden. Im Buch Chapter 7.Andernfalls Können wir Keine grantie übernehmen.

Bevor die Maschine in Production genommen wird, müssen alle Sicherheitsvorkehrungen beachtet werden. Alle Abdeckungen am richtigen Platz und angeschraubt.



VEILIGHEID VOOR MR-11 PLC-T/MR-11 PLCT-F BRAIDMATIC

Vlechtmachines zijn ontworpen om hoogwaardige gevlochten strukturen te maken door middelvan langs geleidingen rondlopende spoelen. Om deze gevlochten stukturen te maken is er hogesnelheid, hoog vemogen en bewegende delen vereist. Daarom moeten operatoren en

onderhoudspersoneel veiligheidsbewust zijn om ongevallen met letsel of zelfs blijvend letsel tevemijden.

Wij kunnen niet alle mogelijke factoren welke tot een ongeval kunnen leiden voorzien, maar eenaantal algemene veiligheidsfactoren worden gelijst als hulpmiddel voor operatoren enonderhoudspersoneel.

Wanneer dit symbool aangegeven wordt in het handboek, dan moeten de geschreven

instrukties absoluut gevolg worden om het risiko op letsels te vermijden. Indien deinstruktie onduidelijk is, moet Mayer Industries Inc. geraadpleegd worden.

Vooraleer met de vlechter te werken moeten operatoren en onderhoudsmensen opgeleid wordenin de werking en de sturing van de machine.

Het dragen van aansluitende kleding en een veiligheidsbril wordt sterk aanbevolen. Het is ook aanbevolen om de machine niet te bedienen indien men ziek is of oververmoeid. Laat de machine

niet draaien indien er ergens een defect opgetreden is.

Bewaar geen stelsleutels of andere zaken op de machine.

Stel zeker dat alle beschermingen en afdekkingen op hun plaats zitten en goed vastgemaakt zijnvooraleer de machine te starten

Het verdraaien van de deck, tandwielen of andere bewegende delen kan knellen veroorzaken en

operatoren moeten hiervoor oppassen.

Bij onderhoud van de machine moet de sturing steeds in de positie “UIT” staan teneinde bij eeneventuele ongewilde activering van de startknop onverwachte start van de machine te vermijden;

De machine start onder electrische hogespanning. Enkel getrainde elektriekers en



Alle rechten zijn voorbehouden voor dit instruktieboek. Niets mag gecopieerd worden of aanderden terbeshikking gesteld zonder de uitdrukkelijke toelating van Mayer Ind. Herdrukken of

kopiëren, hetzij geheel of gedeeltelijk, vereist de uitdrukkelijke goedkeuring van Mayer Indindustries.

Dit handboek werd opgesteld om informatie te geven over de constructie , werkmethode enonderhoud van de machine. De meegeleverde tekeningen en schema’s tonen de belangrijkstevoordelen van het ontwerp. De nauwkeurigheid van de afmetingen en van de ontwerp details zijnniet verzekerd daar Mayer zich het recht voorbehoud deze ten aller tijden te wijzigen

De bedieningsinstrukties beschrijven ook reserve- en vervangingsonderdelen welke niet tot de basisuitrusting van de machine behoren maar beschikbaar zijn als optie. Het vermelden van dezeonderdelen in het handboek betekent niet dat deze ook automatisch op de machine mogengeplaatst worden.

Gelieve Hoofdstuk 7 te raadplegen voor reserve onderdelen. De machine garantie is enkel geldigals originele of door MII goedgekeurde onderdelen gebruikt worden.

Voor en tijdens het gebruik moeten alle algemene en specifieke veiligheidsvoorschiften envoorzorgsmaatregelingen in achtgenomen worden. Afschermingen of veiligheidsonderdelenmogen nooit uitgeschakeld worden



MISURE DI SICUREZZA PER LA BRAIDMATIC PLC-T MR-11/PLCT-F MR-11

Le intrecciatrici sono progettate per produrre strutture intrecciate di qualità trasferendo spoleseguendo il profilo di eccentrici. La produzione di strutture intrecciate richiede alta velocità,grande potenza e movimento di componenti. A propria volta, tutto questo richiede che l’operatoree il personale addetto alla manutenzione di questa apparecchiatura siano consci delle esigenze disicurezza per evitare infortuni che possono comportare lesioni personali invalidanti o mortali.

Non è possibile prevedere tutti i fattori che possono verificarsi o causare incidenti con questaapparecchiatura, ma si possono elencare alcune misure di sicurezza di carattere generale in gradodi indirizzare l’operatore e il personale addetto alla manutenzione a comportarsi in modo sicuro.

Quando questo simbolo appare nel manuale, seguire scrupolosamente le istruzioni iviriportate per evitare infortuni. Se le istruzioni non sono comprensibili, contattare leMayer Industries, Inc.

L’operatore e il personale addetto alla manutenzione devono acquisire la massima familiarità contutti i comandi della macchina ed i relativi componenti mobili prima di usare la macchina stessa olavorare su di essa.

Si consiglia di indossare indumenti attillati e occhiali di sicurezza; niente cravatte. Non usare lamacchina in caso di stanchezza o malattia/indisposizione. Non usare la macchina in caso dimalfunzionamenti di qualsiasi genere.

Non lasciare chiavi inglesi o altri oggetti sulle superfici della macchina.

Durante il funzionamento della macchina accertarsi che tutte le protezioni ed i coperchi sianomontati correttamente e che gli sportelli siano chiusi e fissati.

Il movimento del piano di lavoro, degli ingranaggi e delle aree di trasferimento può creare punti dischiacciamento che l’operatore deve evitare.

Durante le operazioni di manutenzione i comandi devono essere disattivati, poiché un loroazionamento accidentale può causare un movimento imprevisto della macchina con pericolo diinfortuni.

Questa macchina è alimentata ad alta tensione I guasti elettrici devono essere riparati solo da

ATTENZION



Tutti i diritti di questo manuale di istruzioni sono riservati. Non può essere copiato o resodisponibile a terzi senza previo consenso delle Mayer Industries; il suo contenuto non può essere

utilizzato in alcun modo dall’utente o da terzi. Eventuali ristampe, parziali o totali, dovrannoessere autorizzate dalle Mayer Industries.

Queste istruzioni operative sono state formulate per fornire informazioni su costruzione, uso emanutenzione della macchina. I diagrammi e i disegni allegati illustrano caratteristiche importantidella progettazione. Tuttavia, non si garantisce la precisione delle dimensioni e dei dettagli dellefigure e la Mayer Industries si riserva il diritto di apportare modifiche o cambiamenti in qualsiasimomento.

Le istruzioni operative descrivono anche dispositivi, ricambi o altre parti che non fanno partedella versione standard della macchina e che sono disponibili solo su ordinazione come partisupplementari. Nessun diritto di dotare la macchina di tali parti o dispositivi può essere dedotto daqueste istruzioni operative.

Quando si ordinano i ricambi, vedere il capitolo 7. La garanzia della macchina è valida solo se siusano componenti o ricambi originali della MII o omologati dalla MII.

Prima e durante l’uso della macchina, osservare scrupolosamente tutte le misure di sicurezzagenerali e particolari e adottare tutte le precauzioni necessarie. Non disattivare nessun dispositivodi protezione o sicurezza.



TABLE OF CONTENTS

PAGECHAPTER 1 INSTALLATIONSECTION I I NTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1SECTION II MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4SECTION III I NSTALLATION AND SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10SECTION IV PRE-OPERATION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29SECTION V DECK WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33

CHAPTER 2 SYSTEMS, ADJUSTMENTS, SETTINGS, AND MAINTENANCESECTION I GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1SECTION II SHUTTLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1SECTION III SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6SECTION IV CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9SECTION V WIRE BRAIDING BOBBIN PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 2-16

YARN BRAIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17SECTION VI BOBBIN R UN OUT DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20

SECTION VII BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23SECTION VIII DRIVE CARTRIDGE AND CHANGE GEAR DRIVE . . . . . . . . . . . . . . . . . . 2-24

SPEED LEAD CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-27SECTION IX DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35SECTION X R OTOR AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36SECTION XI R OTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40SECTION XII R OTATING PREFORM PIN (OPTION). . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54

CHAPTER 3 CONTROLSSECTION I I NTRODUCTION (EINFÜHRUNG) (I NTRODUCTIE) . . . . . . . . . . . . . . . . . . 3-1SECTION II OPERATOR I NTERFACE (OPERATOR BEDIENINGSVOORZIENINGEN) . . . 3-3

CHAPTER 3A CONTROLSSECTION I I NTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1SECTION II OPERATOR I NTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2

CHAPTER 4A ELECTRICAL SYSTEM - COLOR TOUCHSCREENSECTION I GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1SECTION II SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1SECTION III I NVERTER PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13S IV E C I L 4A 14



CHAPTER 5 LUBRICATION SYSTEMSECTION I GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

SECTION II SERVICE I NSTRUCTIONS FOR BIJUR CENTRAL LUBRICATION SYSTEM . 5-4

CHAPTER 6 OPTIONSSECTION I DOUBLE LET-OFF SYSTEM (DLOW) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

SUPER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5SECTION II TRUMPET AND BRAIDRING (SLO OPTION) . . . . . . . . . . . . . . . . . . . . . . 6-7SECTION III BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8SECTION IV BRAIDER STEEL MOUNTING PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

SECTION V BRAIDING NOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15SECTION VI BRAID MATERIAL R UNOUT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22SECTION VII DUAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

CHAPTER 7 PARTSBREAKDOWN AND ORDERING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . 7-5SEE PARTS I NDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

CHAPTER 8 MAINTENANCE AND OVERHAULSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

SECTION VIII MR-11PLC-T BRAIDMATIC OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 8-11SECTION IX R OTOR I NSPECTION AND R EPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20SECTION X SHUTTLE I NSPECTION AND R EPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23SECTION XI PRELIMINARY SHUTTLE ADJUSTMENT AND I NSTALLATION . . . . . . . . . 8-25SECTION XII I NSTALLATION OF R OTOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 8-26

SECTION XIII R OTOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28SECTION XIV SHUTTLE I NSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29SECTION XV OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33SECTION XVI I NSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE . . . . . . . . . . . . 8-35SECTION XVII I NSTRUCTIONS FOR THE USE OF THE 240-1075

R OTOR GEAR TIMING GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39SECTION XVIII I NSTRUCTIONS FOR THE USE OF THE 240-1076

CAM SET GAUGE WITH MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40SECTION XIX DISASSEMBLING, R EASSEMBLING, ADJUSTING, AND

MAINTENANCE OF CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

CHAPTER 9 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1



1-INSTALLATION



CHAPTER 1INSTALLATION

INSTALLATIE

SECTION I. INTRODUCTION

U NLESS NOTED IN THE TEXT , THE INFORMATION GIVEN FOR THE PLC-T IS

STANDARD FOR THE PLCT-F ELECTRONIC VERSION .

1.1. SCOPE.

1.2. FEATURES. The MR-11 PLC-TBraidmatic is today’s most advanced meansfor producing quality braidmatic structures.

The revolutionary concept of the braider features:

• Increased package capacity• Improved braid quality through patented

strand control• One carrier for both yarn and wire• High speed• Low operating cost• Sound level-85 dBA (with complete

enclosure and in an environment with amaximum 75 dBA ambient noise level)• Automatic lubrication

This manual is intended to provide the user with the necessary information to obtain themaximum benefits from the MR-11 PLC-TBraidmatic.

A thorough understanding of this manual willassure that the braider will be productive for many years.

1.3. BENEFITS. The braider provides the user the expected benefits of modern day braiders

1.4. TRANSFER PRINCIPLE. The MR-11 PLC-T Braider is a special variation of MaypoleBraiders. As with all Maypole decks, therotors are arranged in an endless circle. Therotors consist of four pairs of pockets at 90° toone another, and the rotors are in timedrelation to one another in that each drives theother by a rotor gear: thus, when one turns

clockwise, its neighbor turns counter-clockwise.

The rotors are intended to simultaneously propel one-half the number of shuttles in onedirection, and the others in the oppositedirection. Their respective paths beingsinusoidal causes the shuttles to pass one

another. Each shuttle is equipped with acarrier to provide strand storage and let-off means. The strands from each are braidedtogether to form a structure by the fact that theshuttles were "passed by" in 2 over 2 under plait formation.

The braider does all of these, yet does themdifferently, efficiently, and with a goal of

productivity and quality.The MR-11 PLC-T Braidmatic transfer will bedescribed in such a manner that the sections of this manual explaining instructional andmaintenance information are more readily

1-INSTALLATION



The rotor and axle assemblies of the MR-11PLC-T Braidmatic are identical to one another.One peculiarity is that each of the identicalrotors is assembled with alternate rotors positioned 90° (1/4 turn) from that of itsadjacent or neighboring rotor.

With this assembly pattern, and knowing thatevery rotor has four pairs of shuttle pockets ason a clock dial at 12 o'clock and 6 o'clock, andmate in rotation with pockets at 3 o'clock and 9

o'clock pockets on adjacent rotors, the transfer principle of the MR-11 PLC-T braider should begin to emerge.

Every pair of opposite rotor pockets (12o'clock and 6 o'clock) includes two front camfollower assemblies on the outer flange of therotor while the pair of rotor pockets (3 o'clock and 9 o'clock) on the same rotor have rear cam

follower units affixed to the inner rotor frame.In like manner, pockets at 12 o'clock and 6o'clock have a pair of planetary gears whichmesh with one of two gears on each rotor axle.

Pockets at 3 o'clock and 9 o'clock of the samerotor have different planetary gears whichmesh with the other gear teeth of the same

rotor axle.All shuttle assemblies are of identical designand manufacture and are equipped with a camtrack having two semi-circular segments.These segments are passed behind theappropriate cam follower assembly (front or rear) and retain the shuttle in the given rotor during its travel. Each shuttle assembly has a

gear to keep the timed relation to the semi-circular cam track. These shuttle assembliesare also loaded into rotor assemblies in aspecific timed relationship.

Now it can be seen that a shuttle traveling in its programmed path "outside" the rotor (see Figure. 1.4.1, step 1) is retained by a front camfollower having positive rolling engagementwith the cam track. The meshing of the shuttlegear, rotor planetary gear and the rotor axleassembly control the orientation of the shuttleaxis.

At a point in time the shuttle assemblyadvances by rotation of the rotor to mate with

the next rotor (seen earlier to be at 90°). Nowcontrol of the shuttle is smoothly shifted fromone rotor to the next by the rear segment of thecam track picking up the rear cam follower: atthe same time, the front segment of the camtrack disengages from the front cam track follower. This is done at a constant velocity.The shuttle has now moved from one rotor

frame to the next.It should be noted that the transfer in no waycauses the shuttle axis to rotate as planetarygearing cancels out the reversed directionalinfluence of the rotors. The planetary gear train results in the shuttle completing a 360°rotation for every revolution of the shuttleabout the complete deck.

Successive transfers are made in the same way.The entire sequence takes place between therotor and shuttles without any need for guidesor tracks.

Figure 1.4.1 illustrates a step by step operationtogether with the unique control of rotation between the rotor and shuttle axis. The

advantages of the patented MR-11 PLC-T principle are:

• Constant velocity of shuttle• Eliminated all "deck plates"• Anti-friction bearings at every friction

1-INSTALLATION



STEP 3TRANSFER

STEP 2

AT TRANSFER

STEP 1APPROACHING

A B A B

BABA

BABA

TRANSFER

COMPLETED

R EAR CAM

TRACK R EAR CAM

FOLLOWER

SHUTTLE AXIS

FRONT CAM

TRACK R OTOR

SHUTTLE GEAR

PLANETARY

GEAR

FIXED GEARS

FRONT CAMFOLLOWER

CAM

FOLLOWER

1-INSTALLATION



SECTION II. MACHINE SPECIFICATIONS

1.5. MACHINE SPECIFICATIONS.TABLE 1.5.1: MACHINE SPECIFICATIONS

DECK

Number of carriers 16 20 24 36

RPM of rotors

a. Wire 225 225 225 225

b. Yarn 235 235 235 235

c. Double Let Off Wire 165 165 165 165

d. Super Pak 225 225 225 225

RPM of carriers

a. Wire 56.3 45.0 37.5 25.0

b. Yarn 58.8 47.0 39.2 26.1

c. Double Let Off Wire 41.3 33.0 27.5 18.3

d. Super Pak 56.3 45.0 37.5 25.0

Approx. weight per model (includes bobbins, carriers,

and 20 lbs of wire per bobbin)

4900 lbs 5100 lbs 5300 lbs 11000 lbs

2227 Kg 2318 Kg 2409 Kg 5000 Kg Floor space requirements See Figures 1.10.1 through 1.10.14

Braider principle Maypole

Braid pattern 2 over 2

Product orientation Horizontal

Construction Modular

Speed and braid angle control (PLC-T) Computer/change gears

Speed and braid angle control (PLCT-F) Inverter Drive

Rotor diameter 11 inch (280 mm)Sound level (with complete machine enclosure and in an

environment with a maximum 75 dBA ambient noise level)85 dBA

Lubrication Automatic-metered

Product height 51-1/8 inch above floor (24 carrier)(includes 1 inch mounting plate)

Power Usage 1 Deck 2 Deck 3 Deck

for 16, 20, and 24 carrier decks (including haul-off) 15Hp/

11.5Kw

15Hp/

11.5Kw

20Hp/15Kw

for 36 carrier (including MC-3 haul-off) 20Hp/15Kw 20Hp/15Kw —

Free Braiding (no braidring required) EXCEPT FOR DLOW

Power Usage (PLCT-F)

16 20 d 24 C i D k7.5Hp (5.6Kw) Inverter Drive/Dk

1-INSTALLATION



POWER (PLCT-F) (CONTINUED)

Machine Type:

Max

Power Voltage Current Main FuseDouble Deck 3 x 7.5 Hp Motors 10 Kw 380-480V 16-25A 25A

10 Kw 200-220V 35-50A 50A

PLCT-F MR-11 & MR-15, 36 Carrier

Single Deck 1 x 7.5 Hp Motor 8 Kw 380-480V 16-21A 50A

Single Deck 1 x 15 Hp Motor 8 Kw 380-480V 16-21A 50A

Double Deck 1 x 7.5 Hp Motor 12 Kw 380-480V 25-32A 50A

Double Deck 2 x 15 Hp Motors 12 Kw 380-480V 25-32A 50A

CARRIERS (the same for wire and yarn)

Type of carrier Torsion spring

Release tension variable (by changing springs)

*See Chapter 2, Section 2.16 for the spring ranges.

4.4 - 30 lbs1.6 Kg - 13.6 Kg19.6 N - 133.4 N

Compensation Patented rotary

Let-off Wrapped spring

BOBBINSSingle let-off wire

Weight of wire-approximate 20 lbs (9.1 Kg)

Weight of bobbin-approximate 3.5 lbs (1.6 Kg)

Total package Not to exceed 23.5 lbs(10.66 Kg)

Volume of flange bobbins 98 cubic inches (1600 cu cm)

Single let-off yarn-cardboard tube

Volume of yarn 229 cubic inches (3747 cu cm)

Total package weight Not to exceed 7 lbs (3.18 Kg)Single let-off yarn bobbins

Weight of yarn-approximate 4.75 lbs (2.15 Kg)


Total package weight (one bobbin) Not to exceed 7.0 lbs (3.2 Kg)

Volume of flange bobbins 223 cubic inches (3800 cu cm)

Double let-off wire

Weight of wire per bobbin-approximate 18 lbs (8.2 Kg)


Total package weight (two bobbins) Not to exceed 43.2 lbs (19.6 Kg)

Super pack yarn

Volume of cardboard tube 302 cubic inches (4947 cu cm)

T t l k i ht/t b d N t t d 10 lb (4 5 K )

TABLE 1.5.1: MACHINE SPECIFICATIONS

1-INSTALLATION



4 0 . 7 I N

1 0 3 5 m m

2 7 . 5 6 I N

7 0 0 m m

24 CARRIER Ø19.69 INØ500 mm

Ø10.24 INØ260 mm

24 CARRIER 79.41 IN

2017 mm

82.80 IN2103 mm

16 AND 20 CARRIER

6 4 . 2 0 I N

1 6 3 0 m m

2 8 . 3 5 I N

7 2 0 m m

1 3 . 7 8 I N

3 5 0 m m

6 3 I N

1 6 0 0 m m

2 8 . 3

5 I N

7 2 0

m m

1 3 . 7 8 I N

3 5 0

m m

3 5 I N

0 m m

. 7 8 I N

0 m m

6 3

I N

1 6 0 0

m m

5 8 . 7 I N

1 4 9 0

m m

3 I N 0 m m

8 . 7 I N

9 0 m m

11.02 IN

280 mm

1.34 IN34 mm49.76 IN

1264 mm

C A R R I E R

2 0 C A R R I E R

2 4 C A R R I E R

1

2 3 4

5

6

7

8 9 1 0 1

1

1 2

1

2

3 4

5

6

7 8

9

1 0

1

2 3

4

16 AND 20 CARRIER

51.1 IN1298 mm

1-INSTALLATION



12

3

4

5

6

7

8

91011

12

13

14

15

16

1718

28.3 IN720 mm

12.6 IN320 mm

12.6 IN320 mm

25.2 IN640 mm

25.2 IN640 mm

84.3 IN2140 mm

33.5 IN850 mm

44.5 IN

1130 mm

1 1 2 . 5 I N

2 8 5 7 . 8 m m

85.3 IN2166.1 mm

36 CARRIER

1 1 . 0 2 I N

2 8 0 m m

1-INSTALLATION



1.6. FLOOR CONSTRUCTION. The MR-11PLC-T Braidmatic is like other generally

heavy, high speed machinery in that proper installation will enhance and extend the usefullife.

The nature of the braider floor loadings(weight) and expected motion (vibration) willinvolve concern for the proper specificationsof the floor in the vicinity of the braider’s site.

CAUTION

Overload and vibration hazard.Only ground floor locations may be used. Personal injury or

product or property damage could result.

Only mounting hardware of MII approvalshould be used; see Figure 1.6.1. Thefoundation pockets to accommodate thisshould be sized as shown by the forms on Figure 1.10.15. Form 1 is preferred.

GROUT. MII has two types of grout that can be used on the MR-11 PLC-T, MC-2 and MC-3. The standard grout is Unisorb.

The requirements for use with the MR-11PLC-T, MC-2 and MC-3 are as follows:

The part number for the Unisorb is S-3708(ONE KIT).

The part number for the Chock Fast Gray is S-4984 (ONE KIT).

UNISORB

Kits Required

16, 20 & 24Carrier

36Carrier

1 deck + 1 Haul-Off 4 5



CHOCK FAST GRAY

Kits Required

16, 20, & 24

Carrier

36

Carrier 1 deck + 1 Haul-Off 4 5



1-INSTALLATION



The floor is to be of steel rod reinforcedconcrete of first quality and minimum 3,500 psi compression strength. Two types of foundation pads are recommended as shown in Figures 1.10.1, 1.10.6, and 1.10.11. Thesemay be used individually or in combination toaccommodate various machine arrangements.For 16, 20, & 24 carrier braiders, no more thansix decks should be mounted on a pad: this

may be two three-deck machines abreast asshown in Figures 1.10.3 and 1.10.8, or threetwo-deck machines abreast as shown in Figures 1.10.4 and 1.10.9. Single-deck machines should be limited to four abreast asshown in Figures 1.10.2 and 1.10.7 . See Figures 1.10.11 thru 1.10.13 for 36 carrier braiders.

FIGURE 1.6.1: MOUNTING HARDWARE

(See Figure 7.5.3 for part numbers)

MACHINE BASE FRAME

SPACER SLEEVE INCLUDED IN

PACKING. DO NOT THROW AWAY.

PERMATEX FLOOR LINE

FOUNDATION

HEX HEAD BOLT (TORQUE VALUE

264±7 Nm)

LOCK WASHER

FLAT WASHER

THREADED

NUT

PLATE

FOOT

COVER THIS END OF FOOT

TO KEEP GROUT OFF OF

BOLT THREADS

BUSHING

THREADS

195±5 FT-LB

1-INSTALLATION



SECTION III. INSTALLATION AND SET-UP

1.7. MACHINE ERECTION AND MOUNTING.Every MR-11 PLC-T Braider Deck has beencompletely assembled and operated at thefactory, prior to package and shipment.

1.8. MOVING AND LOCATING THE MACHINE.

CAUTION

Only trained MaintenancePersonnel or Riggers should beallowed to move and set up thisequipment.

Each braider deck is fitted with a lifting eyeinstalled at the factory. This eye is intendedfor up-righting the deck from its shipping position, and can be used for in-planttransporting of the deck to its intended locationwithin the plant. General handling of the deck should be by forklift truck. The deck should

be carried by forklift in its shipping position,i.e. laying over on its side or upright.

CAUTION

When carrying in the upright

position, it must be noted that thedeck bottom is hollow. It isimportant, therefore, to use forksthat extend the complete lengthand somewhat past the base of

mm eye bolts in the angle brackets on each end

of the machine. A sling or lifting bar can then be used. Generally the hauloff is moved andlocated by fork lift truck.

1. Position the Braider(s) and haul-off unit according to Figure 1.10.10 or 1.10.14. Mounting hardware is shownin Figure 1.6.1 and Figure 7.5.3.

2. Level module(s), using the outer faceof the rotor within 0.010 in, per foot(0.8 mm/m), "B" on Figure 7.5.2. (Analternate leveling surface is the protruding shuttle spindle shaft, "C" on Figure 7.5.2.) The base of the lower deck frame should be leveled within0.015 per foot (1.2 mm/m). A

machined surface has been providedfor this adjustment, "A" on Figure7.5.2.

3. (Not required for dual drive.)Assemble the connecting drive shaft, part number 240-2084, (16, 20, 24carriers) or number 536-2084 (36carrier) between haul-off and MR-11PLC-T deck module and 240-2083,(16, 20, 24 carrier) or 536-2083 (36carrier) between other decks (it isimportant that a total lengthwise gap of 1/8 in.-3/16 in. (3.2 mm - 4.76 mm)exists between the shafts to beconnected; see Figures 7.5.26 and7.5.27 ) using set screws and keys at

each end of line shafts to be connected.

4. (Not required for dual drive.) Adjustthe center line height of the deck module drive shaft to the identicalheight of the drive shaft of the haul off

1-INSTALLATION



the face of the MR-11 PLC-T driveshaft flange. The shaft is turned byhand to read the accuracy of alignment.Recheck step 2. Note, Figures 7.5.26 and 7.5.27 .

5. After all the units are in proper location, check again for spacing, driveshaft alignment (standard drive), andthat the floor mounting hardware isimbedded in the floor per Figure 1.6.1.

Check each foot (Figure 1.6.1) ondeck(s) and hauloff. Make sure that thefoot is not touching the sides of thefoundation pocket at any place. Turnthe hex head bolt (Figure 1.6.1) untilthe spacer sleeve is flat against the plate. Do not over tighten as this maydistort the spacer sleeve, allowinggrout to get onto the hex head threads.Only first quality, high head threadsand first quality, high strength, non-shrinking grouting should be used. Thegrouting must be of a type formulatedto withstand vibration and impact fromdynamic and repetitive loading.

6. Following "set-up" of floor (step 5), a

final check is made for alignment of allcomponents, and mounting hardware islocked down. Apply permatex tothreads of all floor bolts. See torquevalue for hold down bolts, Figure1.6.1. Re-torque bolts after the first 500hours of operation. Check and re-torque as required thereafter.

7. Assemble line shaft covers (standard drive) and deck drain pans according to Figure 7.5.33 (16, 20 & 24 carrier) or Figure 7.5.36 (36 carrier) and connectlubrication lines. Level line shaft

floor for dual drive, as shown in Figure6.12.1.1.

9. Construct acoustical enclosure accord-ing to separate instructions providedwith each enclosure. Locate enclosure per Figure 1.10.10 or 1.10.14.

10. Install electrical panels, door switches, blower fan and related electricals. SeeChapter 10, Schematics.

1.9. MACHINE STORAGE PRIOR TO INSTALLATION. If the braider is to be storedfor up to 30 days before installation, certain precautions must be taken.

1. Check the shipping crates for damage.If there is damage, report it to the proper personnel. Contact MII if in

doubt.

2. The braider and all of its sealedcomponents must remain sealed whilein storage.

3. The shipping crates must be stored in adry location.

4. Wind must not be able to force rain or moisture into the crates.

5. Keep all the crates together.

If the braiders must be stored for longer than30 days, contact the MII SERVICE

DEPARTMENT for instructions.

1.10. FINAL ASSEMBLY. The following components must be installed prior to operating themachine:

• Shuttles - See Chapter 2, Section II

1-INSTALLATION



1

0 I N

2 5

4 m m

12 IN O.C. @ 90°305 mm

FLOOR LINE I NSULATION SEALANTCONTINUOUS BEAD

ADJACENT

PLANT

FLOOR

1 IN25 mmSTYROFOAM

17 FT - 2 IN5232 mm

SINGLE DECK

4 FT - 2 IN1270 mm 2 FT - 2 IN673 mm

1 3 F T - 3 I N

4 0 3 8 m m

4 F T - 0 I N

1 2 2 0 m m

4 F T - 0 I N

1 2 2 0 m m

1-INSTALLATION



2 FT - 2 IN

673 mm

4 1 F T - 6 I N

1 2 6 4 9 m m

9 F T - 4 I N ( M I N )

2 8 4 5 m m

9 F T - 4 I N ( M I N )

2 8 4 5 m m

9 F T - 4 I N ( M I N )

2 8 4 5 m m

4 F

T - 0 I N

1 2 2 0 m m

3 F T - 0 I N

9

1 5 m m

( M I N )

3

F T - 0 I N

9 1 5 m m

( M I N )

3

F T - 0 I N

9 1 5 m m

( M I N )

1-INSTALLATION



9 FT - 4 IN

2845 mm

2 F T - 2 I N

6 7 3 m m

3 0 F T - 4 I N

9 2 4 9 m m

4 F T - 2 I N

1 2 7 0 m m

4 FT - 0 IN1220 mm

3 FT - 0 IN915 mm

4 FT - 0 IN1220 mm

1-INSTALLATION



4 FT - 2 IN1270

9 F

T - 4 I N

2 8

4 5 m m

3 1 F T - 1 1 I N

9 7 3 4 m m

- 0 I N

0 m m

3 F T - 0 I N

9 1 5 m m

3 F T 0 I

N

9 1 5 m m

9 F T - 4 I N

2 8 4 5 m m

2 FT - 2 IN

673 mm

4 F T - 0 I N

1 2 2 0

m m

1-INSTALLATION



4 F T - 8 I N

4 FT-0 IN

1220 mm4 FT-3.57 IN

1310 mm5 FT-5 IN1650 mm

2 FT-10 3/8 IN874 mm

2 FT-3 IN700 mm

2 FT-3 IN700 mm

4 F T - 3 I N

1 3 0 9 m m

1 4 2 0 m m

2 F T - 4 I N

7 2 0 m m

2 F T - 8 3 / 4 I N

8 3 2 m m 1

3 F T - 3 I N

4 0 3 9 m m

23 FT - 9 IN

7239 mm

12 IN O.C.@90º305 mm

1 0 I N

2 5 4 m m

STYROFOAM1 IN25 mm

R EINFORCING R OD75 IN

WELD (TYP)


ADJACENTPLANTFLOOR

1-INSTALLATION



ADJACENTFLOOR

INSULATIONSEALANT

FLOOR LINE

12 IN O.C. @ 90°

305 mm

STYROFOAM1 IN (25 mm)

WELD(TYP)

15 FT-2 IN4622 mm

8 FT-6.8 IN2610 mm

2 FT-1.5 IN

648 mm

A

A

1 2 I N

3 0 5 m m

1 2 I N

3 0 5 m m

12 IN305 mm

2 FT-2 IN673 mm

9 F T - 3 I N

2 8 1

9 m m

2 F T - 3 . 5 I N

6 9 9 m m

1 0 I N

2 5 4 m m

1-INSTALLATION



2 FT - 2 IN

673 mm

2 FT 1.5 IN

648 mm

2 F T 3 . 5 I N

6 9 9 m m

1 2 I N

3 0 5 m m

3 F T - 0 I N

9 1 5 m m

( M I N )

1 2 I N

3 0 5 m m

3 F T - 0 I N

9 1 5 m m

( M I N )

3 F T - 0 I N

9 1 5 m m

( M I N )

F T 3 . 5 I N

6 9 9 m m 12 IN

305 mm

8 FT 6 8 IN

9 F T - 4 I N

2 8 4 5 m m

( M I N )

9 F T - 4

I N

2 8 4 5 m m

( M I N )

9 F T - 4 I N

2 8 4 5 m m

( M I N )

3 7 F T - 3

I N

1 1 3 5 5 m

m

( M I N )

1-INSTALLATION



9 FT - 4 IN2845 mm

12 IN305

12 IN 2 F T - 2 I N

6 7 3 m m

2 1 F T - 9 I N

6 6 3 0 m m

2 8 F T - 1 I N

8 5 6 0 m m

1 2 I N

3 0 5 m m

2 FT - 3.5 IN

699 mm

3 FT - 0 IN

915 mm

2 FT - 3.5 IN

699 mm

2 F T - 1 . 5 I N

6 4 8 m m

1-INSTALLATION



21 FT - 8 IN

6605 mm15 FT - 1.8 IN

4620 mm

2 FT - 2 IN673 mm

1 2 I N

3 0 5 m

m

12 IN305 mm

2 F T - 3 . 5 I N

6 9 9 m m

3 F T - 0 I N

9 1 5 m m

9 F T

- 4 I N

2 8 4

5 m m

9 F T - 4 I N

2 8 4 5 m m

2 7 F T - 1 1 I N

8 5 1 0 m m

3 F T - 0 I N

9 1 5 m m

N

1 2 I N

3 0 5 m m

1-INSTALLATION



2 FT - 8.8 IN832 mm

1 FT - 4.4 IN416 mm

2 F T 1 0 . 4 I N

8 7 4 m m 1 FT - 4 IN

314 mm

1 F T - 5 I N

4 3 1 m m

4 I N

1 0

2 m m

4 F T

- 8 I N

1 4 7 6 m m 7

F T - 0 I N

" L " S I N G L E

2 1 3 5 m m

1 3 F T - 5 . 5 I N

" L " D O U B L E

4 1 0 3 m m

2 0 F T

- 5 . 5 I N

" L " T R I P L E

6 2 3 6

m m

2 F T - 3 . 6 I N

7 0 0 m m

M = 6 F T - 7 I N

2 0 1 0 m m

M = 6 F T

- 7 I N

2 0 1 0

m m

7 F T - 8 . 5 I N

2 3 5 0 m m

2 F T - 3 . 6 I N

7 0 0 m m

2 F T - 3 . 6 I N

7 0 0 m m2 FT - 4.4 IN

720 mm

4 FT - 7.9 IN1420 mm

4 FT - 3.1 IN

6 F T -

4 I N

1 9 2 9

m m

F L O O R

L

I N E

F A N

5 F T 5 . 6 I N

1 6 6 6 m m

1-INSTALLATION



2 FT - 5 IN

749 mm

17 FT - 11 IN

5455 mm

4 F T - 4 . 5 I N

1 3 3 6 . 5 m

m

1 1 F T - 6 I N

3 5 0 5 m m

12 IN O.C. @ 90º

305 mm

1 3 I N

3 3 0 . 2 m mSTYROFOAM

1 IN25 mm


ADJACENT

MACHINE

FOUNDATION

A

A

( M I N )

11 FT

3353 mm

TO BE EVEN OR

BELOW THE

BOTTOM EDGE

OF EXISTING

FLOOR

1-INSTALLATION



11 FT - 6 IN3505 mm

6 . 1 I N

1 5 7 m m

1 8 F T - 1 0 I N

5 7 4 3 m m

2 5 F T - 5 I N

7 7 5 5 m m

1 FT - 2 IN355.6 mm

- 5 I N

9 m m

2 FT - 8 IN

813 mm 2 F T - 1 0 I N

8 7 3 m m

7 F T - 2 I N

2 1 8 1 m m

7 F T - 6 I N

2 2 8 0 m m

1-INSTALLATION



2 F T - 1 0 I N

11 FT - 6 IN

3505 mm1 FT - 5.5 IN

444 mm

6 . 2 I N

1 5 7 m m

2 5 F

T - 2 I N

7 7 6 0 m m

7 F T - 6 I N

2 2 8 0 m m

7 F T - 6 I N

2 2 8 0 m m

7 F T

- 2 I N

2 1 8

1 m m

2 6 F

T - 5 I N

8 0 4 3 m m

3 3 F T - 0 I N

1 0 0 5 5 m m

8 7 3 m m

2 FT - 8 IN

1 FT - 2 IN357 mm

- 5 . 5 I N

m m

1-INSTALLATION

12 25 IN



8 F T - 7 I N

2 6 1 6 m m

12.25 IN

311 mm

10 FT - 0 IN

3048 mm

4 I N

1 0 1 . 6 m m

5 FT - 2 IN

1571

2 3 F T - 1 1

I N

7 2 9 0 m m

T R I P L E

1 6 F T - 4 I N

4 9 7 8 m m

D O U B L E

8 F T - 1 0 I N

2 6 9 2 m m

S I N G L E

6 F T - 1 I N

1 8 5 5

m m

1-INSTALLATION



FORM 3

FORM 2

6 IN

152 mm

FORM 1

8.6 IN

218 mm

8 . 6

I N

2 1 8

m m

5 . 7

I N

1 4 5

m m

6 IN

152 mm

5 IN

127 mm

5 I

N

1 2 7 m m

N m m

6 IN152 mm

1-INSTALLATION



T O H A U L O F F

2 4 I N

6 1 0 m m ( T Y P . )

1 0 I N

8 7 . 5 I N

1 7

1 . 5 I N

4 3 5

6 . 1 m m

2 2 2 2 . 5 m m

2 5 3 . 8 m m

1-INSTALLATION



T O H A U L O F F

3 1 . 2 I N

7 9 2 m m

2 4 I N

1 2 1 . 4 I N

6 1 0 m m ( T y p . )

3 0 8 3 m m

1-INSTALLATION

SECTION IV. PRE-OPERATION ADJUSTMENTS



EINSTELLUNGEN VOR INBETRIEBNAHME

VOORALLEER TE STARTEN

1.11. MECHANICAL. The following items must be checked, properly adjusted, installed or set before operating the braider.

CAUTION

Be aware moving elements/pinch points. Personal injury could result.Personnel performing this work must be familiar with this

equipment and properly trained insafety procedures. Always lock out/tag out braider when possible.

a. Braiders and Haul-Off leveled and aligned b. Drive shafts aligned properly and

tightened. (Not for dual drive.)c. Bolts into floor torqued properly.d. Pay-off position and tension correct on

carriers.e. Lube spindles before installing bobbins.f. Shuttle to rotor frame key in transfer.g. Cam follower to cam track clearance.h. All safety stops operating.i. Insure that all carriers are securely locked

to shuttle spindle. j. Insure 1 mm play in axial direction on all

bobbins.k. All installed options adjusted.l. Broken braid detector.m. Silent Chain tensioned for standard drive.

Gear bolts for dual drive.

a. Maschine und Abzugsraupe in die Waagestellen und ausrichten.

b. Antriebswelle ausrichten und festschrauben.

c. Befestiegungsschrauben im Fussboden gutanziehen.

d. Spannung an den Klöppeln Kontrollierenund einstellen.

e. Alle Spindel schmieren bevor die Bobineninstalliert werden.

f. Klöppelachse zur Rotoranlage Keil imTransfer.

g. Spiel zwischen Transferlager undTransferschiene.

h. Spiel zwischen Klöppelachse undAbsteller sensor.i. Kontrollieren das alle Sicherheitsabsteller

funktionieren. j. Versichern das alle Klöppel auf der

Klöppelachse gut eingerastet sind.k. Versichern 1mm Spiel in axialer Richtung

an allen Bobinen.l. Alle installierten möglichkeiten eingestellt.m. Draht-Fadenbruch absteller.n. Ketten spannung.o. Axial Spiel der Rotoranlage. p. Auslaufende Bobinen Absteller eingestellt.

1.11 MECHANISCH. Vooraleer de machine ingebruik te nemen moet het volgende zakengekontroleerd worden:

a. Uitlijning vlechter en trekband. Machinesmoeten waterpas staan

b. aandrijfassen uitgelijnd en aangeschroefdc. bouten voor bevestiging op de vloer

1-INSTALLATION

g. speling tussen meeneemvinger (camroller) en cam plaat (cam track) 1.13. ELECTRICAL. See chapter 3 for use of



) p ( )h. speling van de shuttle sensor

i. kontrole van alle noodstoppen j. kontroleer of alle spoelhouders (carriers)vast zitten op de shuttels

k. 1 mm speling in as-richting op alle bobijnen

l. alle optionele onderdelen afgeregeldm. draadbreuk detectorn. ketingspanner opgespannen

o. axiale speling van de Rotor p. de spoel leegloop detector is bijgesteld

1.12. LUBRICATION. The following itemsmust be checked, properly adjusted, or set before operating the braider.

a. Oil pump pressure. b. Settling tank filled.c. Rear deck sump filled. (Not on dual drive.)d. All rotor axles filled with oil.e. All clamps and fittings are tight.f. No leaks.

1.12 SCHMIERUNG: Folgende Teile müssenKontrolliert oder eingestellt werden bevor dieMaschine in Produktion genommen werdenKann.

a. Ölpumpen druck. b. Öltank gefüllt.c. Hintere Deck tank gefüllt.d. Alle Rotorenachsen gefüllt mit Öl.e. Alle Klemmen und Verbindungsteile fest.f. Keine Lecks.

1.12 SMERING. De volgende zaken moetegecontroleerd en eventueel afgesteld wordenvooraleer de vlechter te starten:

pthe controls, and for set-up procedures.

1.13 ELEKTRISCH: Siehe Chapter 3 für dasElektrische System, und über dieverschiedenen Einstellungsfunktionen.

1.13 ELECTRISCH. Zie hoofstuk 3 voor hetgebruik van de sturingen en voor opstart procedures.

1.14. SETTING THE MOTOR SPEED. For standard (PLC-T) drive only.

CAUTION

All electrical circuits areenergized. Electrical shock may occur if these directions are not followed.

Personnel required: two (2).

Before turning on the motor:

1. Drive line is to be fitted with a tachometer and drive gears are to be removed from thedecks to create minimum load condition.

2. Unplug the user panel on the inverter, plugin the extension cable that comes with theinverter and run the other end out of thehauloff through the slit above the mainmotor doors. Plug the user panel into theother end of the extension cable. This willallow one to close all of the safetyi t l k ( b d ) hil till

1-INSTALLATION

Parameter 4 – Multi-speed setting, highspeed – this frequency should be set to the

das die Decks nur eine minimaleKraftaufwand brauchen.



p q ystandard run speed of the machine. Check

the drive-shaft speed and increase/decreasethe hertz setting to get the correct speed.

Parameter 5 – Multi-speed setting,medium speed – this frequency should beset to approximately 2/3 of the driveshaftspeed set in Parameter 4. Pressing theslowstart button on the main cabinet willengage this speed for one hour before auto-matically changing the machine speed tothat which is set in Parameter 4. This isuseful for running in carriers slowly after the braider has been sitting for a while.

Parameter 6 – Multi-speed setting, slowspeed – This frequency should be set for the Jog speed of the machine.

Two other parameters that a user mightwant to change are:

Parameter 7 – Acceleration time

Parameter 8 – Deceleration time.

1.14 MOTOR GESCHWINDIGKEIT EINSTEL-

LUNG.

WARNUNG

Folgende Regeln müssen

beachtet werden um elektrischenSchock zu verhindern.

2 Personen werden gebraucht.

2. Entferne den Deckel am Inverter, steck dasVelängerungskabel vom Inverter durch dieAbzugsraupe und verbinde es mit deiner Inverter controls parameter einheit.

Schlag nach im Mitsubishi.

Betriebsanleitungsbuch, die genaue param-eter Einstellung für die unten genannten

Punkte.

Parameter 4 – Mehrfache geschwindig-keitseinstellung. Hohe geschwindigkeit,diese Frequenz sollte für die Standardgeschwindigkeit der Maschine eingestelltwerden. Kontrollier geschwindigkeit der Antriebswelle bei zu hoher, oder zu niedri-

ger geschwindigkeit. Einstellung mit der hertzzahl.

Parameter 5 – Mehrfache geschwindig-keitseinstellung. Mittlere geschwindigkeit,diese Frequenz sollte ungefähr 2/3 der Standard geschwindigkeit von Parameter 4eingestellt werden. Drücken den Knopf Langsam – “slowstart” am Schaltschrank

Lässt die Maschine eine Stunde LangsamLaufen, und schaltet dann automatisch umauf die normale Produktionsgeschwindig-keit. Der Grund ist um die Klöppel KöpfeLangsam einlaufen zu Lassen.

Parameter 6 – Mehrfache geschwindig-keitseinstellung. Langsame geschwindig-

keit, diese Frequenz ist für die Tipgeschwindigkeit der Maschine.

Zwei weitere Parameter die mangebrauchen Könnte:

1-INSTALLATION

1.14 INSTELLING VAN DE MOTOR SNELHEID. Voor de juiste beschrijving/instrukties om parameters te wijzigen, raadpleeg het



OPGEPAST Alle electrische leidingen staanonder stroom. Gevaar voor electrische schokken indien de

instrukties niet gevolgd worden.

Nota: Afregeling moet gebeuren met 2 personen!

Vooraleer de motor te starten:

1. Koppel een tachometer aan de motor as;

verwijder de (drijvende) tandwielen uit dedecks om minimale belasting te bekomen.

2. Ontkoppel het gebruikerspaneel op defrequentie sturing en verbind nu het eneuiteinde van de meegeleverdeverlengskabel met de frequentie controller; breng het andere uiteinde naar buiten viade opening in de deur boven dehoofdmotor en sluit nu hetgebruikerspaneel aan op het andereuiteinde van deze verlengkabel. Op dezemanier heeft men toch toegang tot centralesturing met alle deuren gesloten en alleveiligheidsvoorziening in werking.

meegeleverd handboek van Mitsubishi.

Enkel de parameters om de snelheid tekontroleren worden hierna beschreven:

Parameter 4: Snelheidsinstelling – hogesnelheid. Deze frequentie moet op de stan-dard loopsnelheid van de vlechter ingesteldworden. Controleer de snelheid van de cen-trale aandrijfas en pas de frequentie (Hertz)aan tot juiste snelheid.

Parameter 5: Snelheidsinstellinggematigde snelheid - De frequentiehiervoor moet op ongeveer 2/3 van de hogesnelheid (ingesteld met parameter 4)ingesteld worden. Wanner op de tragestartknop geduwd wordt zal de vlechter ongeveer gedurende een uur op deze

snelheid lopen en daarna automatischomschakelen naar de hoge snelheid. Detragestart knop wordt gebruik voor hetinlopen van de carriers na een langeremachinestilstand.

Parameter 6 : snelheidsinstelling tragesnelheid. Deze frequency is de instellingvoor de Jog snelheid van de vlechter

Nog twee andere instelling die eventueeldoor de gebruiker kunnen veranderdworden zijn:

Parameter 7 : - acceleratie tijd

Parameter 8 : - deceleratie (uitloop-) tijd

1-INSTALLATION

SECTION V. DECK WIRING



1.15. CONNECTING THE DECK TO THE ELEC-TRICAL SYSTEM. The following table showsall of the wiring that leads from a deck to theBraider electrical system. Sixteen, twenty andtwenty-four carrier decks are wired identicallywith one cable containing all of the mainconnections from the deck. Thirty-six carrier decks have an extra cable containing the extra

twelve shuttle sensors. Facing the back of thedeck, the cable containing shuttle sensors 1-24is on the left and the cable containing shuttlesensors 25-36 is on the right.

The wiring is always connected into theterminal strip inside the primary operator boxlocated on the side of the enclosure. Terminalnumbers refer to terminals on the terminal

strips inside that operator box.

All decks have three sets of wires that are

wired in separately, in addition to the maincable. One is the proximity sensor for the hour meter, which consists of three wires; the other is the bobbin run-out sensor, which consists of one wire. These connections are also shown onthe table below.

On the 36-carrier, there is a terminal stripmounted on the back of the deck, these wirescan optionally be wired into this strip instead.

The last is the green-yellow ground wirecoming from the deck. Note that this must beconnected for proper operation since most of the sensors on the deck itself are tripped by aconnection to ground.

1-INSTALLATION

TABLE 1.15.1: DECK WIRING MR-11 PLC-T CONTROLLER

CONNECTION BETWEEN DECK AND PRIMARY OPERATOR BOX



CONNECTION BETWEEN DECK AND PRIMARY OPERATOR BOX

WIRE COLOR FROM DECK CABLE TO PRIMARY OPERATOR BOX (3000412)

Blk X1/3Brn X1/3Red X1/4Org X1/4

Yel X1/5Grn X1/5Blu X1/6Vio X1/6Gry X1/7Wht X1/7Tan X1/8Pnk X1/8

Blk/Wht X1/9Brn/Wht X1/9Red/Wht X1/10Org/Wht X1/10Yel/Wht X1/11Grn/Wht X1/11Blu/Wht X1/12Vio/Wht X1/12Gry/Wht X1/13Brn/Blk/Wht X1/13Red/Blk/Wht X1/14Org/Blk/Wht X1/14Red/Yel X1/23Yel/Blk/Wht X1/27Red/Blk X1/30

Blu/Blk/Wht X1/31Red/Grn X1/1Grn/Blk/Wht X1/1

2-ADJUSTMENTS AND MAINTENANCE

CHAPTER 2ADJUSTMENTS AND MAINTENANCE



SECTION I. GENERAL

U NLESS NOTED IN THE TEXT , THE INFORMATION GIVEN FOR THE PLC-T IS

STANDARD FOR THE PLCT-F ELECTRONIC VERSION .

2.1. GENERAL. This section delineates thevarious systems utilized and all normaladjustments, settings and maintenancerequired to maintain and operate the MR-11PLC-T Braidmatic. Special requirements may be discussed with the Mayer Industries ServiceDepartment.

All components, sub-assemblies andassemblies have been thoroughly checked,

adjusted and set for average normal operatingconditions. Re-adjustments may be required tosuit particular conditions and requirements.

When a malfunction of the machine causesundue strain, wear, or damage to any part or assembly, the machine should be checked

immediately to see that the affected part andassociated parts are operable, are not broken,or moved out of proper adjustment or setting.

NOTE

Do not operate the braider faster

than 100 RPM and for a time not to exceed 5 minutes without carriers and bobbins installed onall shuttles. Failure to follow theseinstructions can result in smashing the braider.

SECTION II. SHUTTLE ASSEMBLY (FIGURE 7.5.17)

2.2. SHUTTLE ASSEMBLY. The shuttleassembly serves two major functions. First, itis the element which contributes to the transfer from one rotor to the adjacent rotor andsecondly, it is the structure onto which the

carrier is affixed, together with the strandmaterial to be braided.

Every shuttle assembly is interchangeable withthat of another of the same design for the same

upon the shuttle assemblies being loaded intorotors in four transfer pockets.

The basic shuttle assembly may be convertedfrom wire braiding, using MR-11 PLC-T bobbins, to yarn wound on paper tubes or

bobbins. The conversion is accomplished bythe addition of a shuttle spindle adapter withshuttles loaded into the deck. (see Figure2.2.1)




STRAND SHOWN

IN DOUBLE

THREADING CYCLE


2.3. R EMOVAL AND R ELOADING OF SHUTTLE ASSEMBLIES. Theoretically, all shuttles may

disconnect and remove the upper change gear on PLC-T models.Follow plant lock out/tag out



ASSEMBLIES. Theoretically, all shuttles may

be removed and loaded into the deck byremoval of front cam follower assemblies of two rotors. The manufacturer has provided a preferred pair of adjacent rotors as below (see Figures 1.5.1 and 1.5.2 for rotor numbers):

• Rotor numbers 6 and 7 of 18 rotor decks




The designated rotors include a prepinnedlocation for the front cam followersassemblies. This feature eliminates the needfor adjustment of cam followers in the samefour pockets of the same rotor assemblies.

2.4. R EMOVAL OF SHUTTLE ASSEMBLIES FROM BRAIDER .

CAUTION

Moving elements/pinch points inthe shuttle assembly area.Personal injury to hands and armscould occur.

Only trained personnel/mechanicsare allowed to install and removeshuttles and/or work in this area.Personal safety equipment is tobe worn.

Follow plant lock out/tag out

procedureCut power off at main disconnect and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.

Read and follow manual instructions.

1. Remove all carriers and strand packages or bobbins from shuttles.

2. Remove outer shields, Figure 7.5.2.

NOTE

Removal of shuttles requires twotrained mechanics using special tool #2000302, which mounts tothe face of the rotor frame using the (4) M6 holes that are used tomount the rotor cap. Mount this

tool to the rotor frame closest tothe 8:00/9:00 deck position.

The two mechanics must be ableto communicate.

The mechanic turning the deck must be strong enough to control the movement of the rotors.

Installing the shuttles will causeuneven loading until they have all been installed. This unevenloading will result in unwanted movement of the rotors that must




CAUTION

Moving elements.

Personal injury could result.

Use only special tool #2000302 which gives the second personcontrol of the rotor/shuttle

movement.

3. Position rotors as shown in Figure 2.4.1.

4. Removal of one front cartridge numberedtransfer #1 will permit one fourth of thedeck shuttles to be removed. Remove four M6 screws from face of rotor cam follower

cap, Figure 7.5.19. The removal of thecartridge is made without removing thecartridge cap. Care must be exercised toreach behind rotor front face to pushcartridge and not on extended shaft toremove entire cartridge assembly as oneunit. Place removed cam follower assembly on clean surface with cap down.

5. Rotate rotor with removed cartridge inclockwise direction and reach into rotor tolift the first shuttle from the rotor pocketwithout the cartridge.

6. Repeat step 5 to lift one fourth of shuttlesfrom the same rotor pocket. Do not dropshuttles. Keep these shuttles together. See

Chapter 8, Section I, paragraph 8.2.

7. Replace cam follower cartridge andassembly with one or two M6 screws.

8 R t t 1 7 b i

9. Repeat steps 1-7 to complete the removalof all shuttles from adjacent rotor.

CAUTION

Release of shuttle assemblies.

Do not attempt to remove cam

follower assemblies when ashuttle is engaged with thecartridge.


10. The removal of all shuttles from rotors willgive opportunity to check the rotors for:

a. Axial thrust bearing clearance. b. Check all rotor cam follower cartridges

by rotating by hand to insure proper function.

FIGURE 2.4.1: SHUTTLE UNLOADING

FRONT CAM

FOLLOWER

"OUT"


2.5. R ELOADING OF SHUTTLES INTO DECK .Loading of the shuttles, as with unloading,

5. Rotate upper change gear shaft by handslowly, using special adapter tool 240-3040, to insure correct loading. Person in



g , g,

requires two people in the same positions asfor unloading.

CAUTION

Follow all Safety Precautions

documented in Paragraph 2.4.

All shuttles are alike for a given deck. Be surethat all the shuttles go back into the transfer they came out of.

1. Remove #4 transfer cam follower cartridgefrom rotor as before.

2. Hold shuttle in two hands and direct personin rear using a special tool on upper changegear shaft to turn the lower of the tworotors in a counterclockwise direction tothe approximate position shown in Figure2.5.1.

3. Rotate rotor counterclockwise until the

shuttle is in transfer position at which timethe shuttle gear and cam track should be inthe correct timed engagement with theupper rotor rear cam follower. Continue torotate in the same direction slowly until theshuttle engages the upper rotor in transfer.If the shuttle gear teeth were orientedcorrectly in mesh with the rotor planetary

gears, the two transfers should be smoothand positive.

4. Repeat steps 2-4 for the remaining shuttlesin transfer #4. Replace timed cartridge in

, g

front should inspect each transfer by feelfor proper shuttle cam track to rotor camfollower radial clearance. Check also for axial play in transfer. See paragraph 2.69.

NOTE

The braider includes an electrical

sensor device to monitor the pathof a shuttle cam track under load at high speed. Frequently, thesensor probe may becomedislocated during unloading or

FIGURE 2.5.1: SHUTTLE LOADING INTO

R OTORS

SHUTTLE

FRONT CAMFOLLOWER R EMOVED


2.6. SHUTTLE DISASSEMBLY AND ASSEMBLY. Every part of a shuttle assembly is

2.7. DISASSEMBLY OF SHUTTLE ASSEMBLY.See Chapter 8, Section III for disassembly of



interchangeable with another within deckshaving the same number of shuttles. SeeChapter 8, Section III and Section IV , for disassembly and assembly instructions.

CAUTION

Be aware of possible sharp edgeson parts.

shuttle assembly.

2.8. ASSEMBLY OF SHUTTLE ASSEMBLY. SeeChapter 8, Section IV for assembly of shuttleassembly.

SECTION III. SENSORS

2.9. SENSOR STAND ASSEMBLY. (Figure7.5.30) The sensor stand assembly provides

the braider system with a combination of functions, including:

• Mounting and adjustment of braid detector shown in detail in Figure 7.5.31.

• Means for "tying in" plaits from carriersduring threading, Figure 7.5.29.

• Mounting provision for the operator "JOG" button to jog the deck from within theenclosure, Figure 7.5.29.

CAUTION

Moving elements in deck.Inside safety switch should alwaysbe in the "ON" position whenworking on deck. When the safety

CAUTION

Only one trained operator to beallowed inside the enclosure to

perform this task. Reason: to prevent the braider from being started by a second operator.

Moving elements causing pinch points that could result in injury tohands and arms.

"Always" switch the inside safety switch to the "ON" positionimmediately upon entering thesafety enclosure. This prevents

the braider from being run fromany other position and allows thebraider to be jogged from thislocation.


2.10. TYING IN OF BRAIDING STRANDS. The braider provides a means to reduce the time

The sequence is continued until all carriers are prepared for production.

Th dditi l b fit f thi h



and effort required to attach plaits of yarn or wire to a mandrel, hose or other object towhich strand materials are attached.

The object is to reduce operator reaching andlifting of carriers and strand packages duringthe loading and threading operation.

The braider carriers are most conveniently

loaded at rotors number 2, 3 and 4 on one sideor rotors 7, 8, and 9 on the opposite side. These positions require less reaching and for thisreason, provide faster reloading, threading andtying-in. Place the eye bolt assembly (3, Figure 7.5.29) in the position shown. Be surethe sensor pin (5, Figure 7.5.29) goes thru bothsides of the swinging arm assembly (4).

After loading 3 to 6 bobbins at these locationsand locking the carriers on, the operator threads the plaits from the bobbins, through thecarriers and ties them onto the hook ( 3, Figure7.5.29). Now with the pole, mandrel, etc. in place, and carrier latches locked, the operator may "JOG" the deck after putting inside safetyswitch in the "ON" position, and bring other

carriers requiring service to within operator'sconvenient reach. These next 3-6 carriers may be loaded, threaded and plaits once again tiedin to the hook.

NOTE

Be Aware: Uneven loading of bobbins can result in gravity causing an unintended movement

The additional benefits of this approach are:

• Cutting of wires or yarns is performed at alocation where stray ends are preventedfrom getting inside the deck.

NOTE

Use eye protection and leather gloves.

• The tension on the plaits when tying to thehook eliminates reaching to "back-wind"threaded carriers to keep strands tight.

• The sequential threading and tying-in canavoid lumps in hose which would other-wise necessitate readjustment of the haul-off unit.

Once all threading and tying-in isaccomplished, the operator removes the pivothardware, and the hook is lowered into

position for braider production.Double check to insure all carriers are in thelatched position.

CAUTION

Moving elements in deck.

Always lock latches on carrier assembly.

P l i j ld lt


2.11. JOG BUTTON.The MR-11 PLC-T braid sensor functions withyarn or wire braid strands.



NOTE

When the safety switch inside theenclosure is "ON" the braider cannot be run from any locationand can be jogged only from the

safety switch that is "ON".

2.12. BRAID SENSOR ASSEMBLY INSTRUCTIONS. (Figure 7.5.31). Each deck of the braider is equipped with a device whose purpose is to detect a failure in the carrier plaitlet-off. The sensor operates on the principle

that when any one or all strands from anycarrier plait becomes tangled, or when thecarrier clutch fails to release, the additionaltension in that plait will dislocate the braidedstructure and jerk the braided member from itsusual position.

The dislocation of braided product will trigger

limit switches and electrically shut off themachine drive. The device has both electricaland mechanical adjustments for sensitivity.

While other "grounding" sensors can be usedin combination with the MR-11 PLC-T braidsensor to detect broken wires, etc., theobjective here is to continuously monitor the braid at each deck and to detect abnormalstrand behavior before the wires or plaitsrupture which can cause damage to braided product or the braider deck.

A braid failure will shut off the machine andwill show a light on the alarm panel for thedeck in question.

The operator may re-set the deck by clearingthe sensor and pushing the Reset button.

2.12.1. ADJUSTMENTS. (MECHANICAL).

1. The braid sensor is located in a direction parallel to the hose, but should be as closeto the braid point as possible.

2. See Section VII of this chapter.

2.12.2. ELECTRICAL. The sensitivity of thesensor to respond to movement of the inner

ring, Figure 7.5.31, is made at each individualdeck. Experience with use for a particular application will be the basis for the correctsetting.

NOTE

The ring halves must have aclearance between the O.D. of thehose and the I.D. of the ring halves. The clearance isrecommended to be 2 to 5 mm per side. Ring halves with different

I.D. are available from Mayer Industries. Please contact thesales department for any additional information.


Ring halves are available in the followingsizes: NOTE



Generally, the closer the sensor isto the braid point, the quicker thedefect will be detected.Experience with the sensor will determine the best location for the

products being used.

SECTION IV. CARRIER ASSEMBLY

2.13. GENERAL DESCRIPTION. The MR-11PLC-T carrier is a compact assemblycontaining a torsion spring tensioning device, ball bearing compensator, and one way clutch.

• Lightweight carriers are inter-changeableonly with other lightweight carriers of thesame design.

• The braider carrier is readily adapted tosatisfy a wide range of applicationsincluding:

• Strand Materials

• Need for preforming• Strand release tensions

See Chapter 8, Section XII for additionaldetails.

excess plait length produced by the carrier being propelled from "outside" to "inside" of arotor during the usual Maypole cycle.

The MR-11 PLC-T carrier eliminates many problems experienced on earlier Maypolecarriers by the use of a rotary ball bearing inthe compensator.

The compensator, working together with thetorsion spring, is capable of producing aunique tension cycle suitable for a wide rangeof braiding applications.

2.14.1. STANDARD CYCLE. The majority of wire braid applications can be satisifed withthe cycle which includes six compensator strand rollers affixed to the compensator asshown in Figure 2.14.1.1. The strand path is ash Fi 2 14 1 1

R ING I.D. MM

R ECOMMENDED HOSE SIZES MM

(DIA. OVER THE BRAID)INCH

15 5-11 .197-.433

20 10-16 .394-.630

25 15-21 .591-.827

30 20-26 .787-1.024

35 25-31 .984-1.22040 30-36 1.181-1.417

45 35-41 1.378-1.614

50 40-46 1.575-1.811

55 45-51 1.772-2.008


STRAND SHOWNIN STANDARD

STRAND SHOWNIN DOUBLE



NOTE

This threading path must be used

when setting the payoff dimensionfor wire or yarn.

2.14.2. DOUBLE CYCLE (OPTIONAL). Theadditional two strand rollers are affixed to thestationary cap (Figure 2.14.2.1).

The essential difference or benefit is thecapability to reduce release (pay-off) tensionsfor a given torsion spring setting and to reducethe angular motion of the compensator byabout 30%.

(The majority of yarn braiding applicationswill benefit from this optional feature.)

2.14.3. COMPENSATION ADJUSTMENTS.

CAUTION

Keep fingers clear of the pinch point between the carrier housing and compensator plate (relaxed

position) when checking or setting

FIGURE 2.14.1.1: STANDARD CYCLE STRAND

PATTERN

TO

HOSE

THREADING CYCLE

FIGURE 2.14.2.1: DOUBLE CYCLE STRAND

PATH

TO

HOSE

THREADING CYCLE


Adjustment to this factory setting isaccomplished by first recognizing that thetorsion spring (20, 21, or 22, Figure 7.5.4), is

The clutch function is to prevent the strandsupply wire bobbin or yarn package fromrotating until the plait has attained a



attached to the actuator block which ismounted onto the compensator ( Figure 7.5.5).The rotation of the compensator clockwisecontinues until the end of the actuator block contacts the clutch sleeve member. Further clockwise motion will rotate the sleeve andrelease the clutch for strand payout.

The adjustment to the payout position is made by positioning the tang of clutch spring into adifferent slot within the plastic sleeve (Figure2.14.3.1). When adjusting the payoff, thecarrier should be threaded in the standard cycle pattern. Reference Figure 2.14.1.1. SeeChapter 8, Section XIII .

You must understand that the release position

is independent of the release tension.

2.15. CARRIER CLUTCH. (Figure 7.5.4) The

predetermined tension, at which time thecompensators clockwise rotation will actuatethe plastic clutch sleeve (13) which will openthe wrapped spring (11) or (12), and allow themoveable hub (9) to rotate with the strandsupply package.

The stationary hub (6) of the clutch assemblyis timed to the carrier housing (1) with pin(25). This fixed relationship insures that everyMR-11 PLC-T carrier will relate to any shuttleassembly.

The movable hub (9) is supplied with felt padsfor lubrication. Manually oil the felt pads. Seelubrication, Chapter 5.

2.16. CARRIER PAY-OFF TENSIONS. Standardtorsion springs with corresponding releasetension are:

FIGURE 2.14.3.1: PAYOUT POSITION ADJUSTMENT

DECREASE

INCREASE

STANDARD CYCLE PAY-OFF TENSION

LBS K ILOGRAMSTORSION

SPRING

5-11 2.3-5.0 Light

11-22 5.0-10.0 Medium

20-30 9.07-13.6 Heavy

DOUBLE CYCLE PAY-OFF TENSION

LBS K ILOGRAMSTORSION SPRING

4.5-8 2.0-3.64 Light


NOTEout tension while a clockwise rotation"reduces" pay-out tension.



Pay-off tensions indicated areapproximate. The actual releasetension will vary somewhat with:strand diameter, strand material,number of ends of strand/plait,and to what extent the preform pin

is involved.

NOTE

When the desired pay-off tensioncan be satisfied with any two

springs, the practice should always be to use the spring having the higher tension capability.

2.16.1. ADJUSTMENT OF PAY-OFF TENSION (SAME SPRING). Adjustment of the pay-off tension is accomplished by the rotationaladjustment to the carrier adjusting ring (3,

Figure 7.5.4).

When viewed from the front of the carrier, acounter clockwise adjustment "increases" pay-

Radial holes have been provided in ring (3) tomake tension adjustment more convenient.When the desired tension has been attained,the socket head screw (32) is tightened in theadjusting clamp (7) to secure the adjusting ringto the carrier housing.

2.16.2. SUBSTITUTION OF ONE SPRING FOR

ANOTHER

(SAME

CARRIER

). (Figures 7.5.4and 7.5.5)

CAUTION

Keep fingers clear of the pinch

point between the carrier housing and compensator plate (relaxed position) when checking or setting the carrier tension and/or the

payout position. If the wire/yarnslips or breaks, damage can occur to the fingers.

1. Remove carrier from deck.2. Loosen M8 screw (32, Figure 7.5.4) to

allow disassembly of adjusting ring (3).




3. Loosen spring clamp (14, Figure 7.5.4) byloosening screw assembly (29) and screws(28). Remove the spring from the actuator block (5) and spring clamp (14).

4. To install a spring place, the end of thespring that is bent radially outward againstthe spring clamp (14) and the portion of thecoil adjacent to the tang should lay on thesurface of actuator block (5). See Figures7.5.4 and 7.5.5, assembled outline of spring. Tighten screw (28) which willdraw spring clamp (14) in toward actuator block (5). Note that screws (29) and (28)should be snug while this is being done.Tighten all three screws to 10.3 ft-lbs (14

Nm). All parts should be tight and appear as in Figure 7.5.4, assembled view.

5. To install the tension ring on the spring,place the end of the spring that is bent

slip over the lip and be pulled under therest of the lip by the twisting motion. If thisdoes not seat the spring or the spring goesunder the lip opposite the spring tang butwon't rotate, use a wide blade screwdriver to force the inside edge of the spring up toand under the lip.

CAUTION

Do not let the screwdriver being used to push the spring, gouge or nick the spring. This will cause a

stress riser and results in the premature failure of the spring.

The thinner the spring the easier it will beto force it up to the lip. The spring tang

FIGURE 2.16.2.1: TENSION SPRING INSTALLATION

A A

SECTION

A-A

SPRING

ADJUSTING R ING

TORSION SPRING


tension is critical, hose problems coulddevelop.

6. Replace the adjusting ring (3) into

The latch involves a 90° rotation to engage andlatch to the spindle. See Figure 2.17.1. It alsoentails a slight pushing force to release the



adjusting clamp (7) and back into thecarrier housing (1) as shown in Figure7.5.4.

7. Adjust pay-off tension for plait material.Tighten the screw (32) to secure theadjusting ring in place. Use an allenwrench and hand tighten. The ring (3)

should not move.

2.17. CARRIER LATCH. Every MR-11 PLC-Tcarrier incorporates a simple, yet positive,latch to secure the carrier assembly to theshuttle shaft, or the shuttle extension.

CAUTION




latch for rotation.MII's latch tool, part number S-5503, isrecommended for this purpose.

All carriers, when viewed from the front andmounted to the shuttle assemblies in safe,operating latched position, will be observed tohave the latch bars form a circle when they are

all in the latched position.Double check to insure all carriers are in thelatched position.

CAUTION

"Always" switch the inside safety switch to the "ON" positionimmediately upon entering thesafety enclosure.

Follow all instructions and safety precautions listed in Paragraph

2.10 for tying in of braiding strands.

2.18. CARRIER BOBBIN OR YARN PACKAGE CHANGE. Every MR-11 PLC-T lightweightcarrier is interchangeable with another lightweight carrier and any lightweight carrier may be latched to any lightweight shuttleassembly on the same deck.

With this in mind, and assuming all or themajority of all carriers will be changed at one

UNLATCHED POSITION

LATCHED POSITION

HOLE

LATCH BAR


2. Remove the empty bobbin or yarn tubefrom the same shuttle spindle and replace itwith a full package or bobbin.

A minor change in threading path canintroduce a preform pin. See Figures 2.19.1,2.19.3, and 2.19.4.



3. Remove an adjacent carrier from theshuttle spindle and place this carrier ontothe first shuttle having the full package.Lock the carrier.

4. Repeat sequence until the full deck isreloaded.

NOTE

Procedure for threading of strandsfrom carriers to braided structure(hose) is described under Tying in

of Braiding Strands, paragraph2.10.

2.19. PREFORMING OF WIRE. Preforming isthe practice of producing a set or curl in anotherwise straight strand. The curl isaccomplished by drawing the strand over astationary or rolling surface under tension to

introduce compressive stress to one side of astrand.

Preforming serves a very useful purpose in producing certain wire braided structures.

For other braid applications, the ability of acarrier to provide "rolling contact" between the

strand and carrier surfaces is the primary goalfor minimizing friction. This then allows thestrand to retain its usefulness as areinforcement member without disturbance tothe strand surface

The variables for pre-form will include:

• Wire strand diameter

• Carrier release tension

• Preform pin diameter

• Number of ends per bobbinIn the majority of hose applications, thestandard braider pre-form components willsuffice. Where special requirements exist, the pre-form pin diameter may be varied as well asintroducing a change to the angle at which the pin intersects the strand. See Section XII of thisChapter for rotating preform pin option and

Figure 7.5.13.1 for the support assembly preform pin.

TO

HOSE




SECTION V. WIRE BRAIDING BOBBIN PREPARATION

2.20. BOBBIN WINDING. See Figure 7.5.63.

NOTE

For superior high speed winding quality, MI recommends using theMayer MCW-LT series high speed winder.

2.20.1. ADAPTING BOBBINS. The Mayer

Carrier works exclusively with Mayer aluminum bobbins. Bobbin winders of other manufacturers may be readily converted to parallel wind the Mayer braider bobbin.Contact the MI SERVICE DEPARTMENT for

Since the length of the Mayer aluminum bobbin is different, the tailstock of the winder is readjusted to suit the shorter length.

Care should be taken to insure that adequateaxial force is maintained so that the bobbin is

securely held by the winder.2.20.2. WINDING QUALITY. Winding qualityis important to all braiding results.

Proper let-off tension control, suitable traverse"stop" adjustments and guide beak conditionwill benefit the quality of braider performanceand resulting braid product quality. Catenarytests should be run as required.

2.20.3. BOBBIN CARE. Proper care of the MR-11 PLC-T bobbin will provide the user with

FIGURE 2.19.2: OVER CENTER R OLLERS

TO

HOSE

FIGURE 2.19.3: OVER PREFORM PIN

TO

HOSE


NOTE 2.21. YARN BRAIDING. The MR-11 PLC-TBraidmatic features the capability to convert toa deck from braiding wire on 20 lbs. capacityl i b bbi t b idi ith l



1. Tensions in excess of 2.25 lbs./bobbinfrom winder supply spool let-off. Morethan 2.25 lbs./bobbin can exceed bobbinflange strength and shorten the bobbinsuseful life.

2. Improper traverse setting at winder.

3. Rough handling of aluminum bobbinswhen full or empty. Do not drop.

aluminum bobbins to yarn braiding with largecapacity packages wound on a paper tube or fabricated bobbin.

The changeover from wire to yarn or yarn towire braiding utilizes the same basic carrier and shuttle assembly for both strand options.The conversion may be made with shuttle

assemblies remaining in the deck.

2.21.1. YARN PACKAGE. The single let-off MR-11 PLC-T yarn package is preparedaccording to Figure 2.21.1.1, and is wound onyarn tube #240-4016, Figure 2.21.1.2. Namesand addresses of both tube and yarn suppliersare available by contacting MII.

MAX. BULGE ¼ IN6.4 mm

8 IN TRAVERSE

203 mmø 6 ½ IN (MAX)ø 165 mm

7/16 IN

DIRECTION OF WINDMUST BE AS SHOWN NOTE:

YARN MUST BEBELOW ENDS OFTUBE.

TOTAL PACKAGE WEIGHT


VIEW A-A 8.86 IN

225 mm

+.00-.062

+ 001 5

A



2.21.2. ADDITIONAL PARTS FOR CONVERSION TO YARN PACKAGES. Theconversion from an MR-11 PLC-T deck braiding wire on an aluminum flanged bobbin

to large capacity yarn on paper tube or reusable fabricated bobbins will require theaddition of shuttle spindle extensions. SeeChapter 7, Figure 7.5.11, and Figure 7.5.12.

All parts are interchangeable with any MR-11PLC-T lightweight shuttle assembly.

2.21.3. PROCEDURE FOR FIELD CONVERSION OF WIRE TO YARN.

are allowed to install and removeshuttles and/or work in this area.Personal safety equipment is tobe worn.

Work area to be clean and free of oil to prevent slipping.

Cut power off at the maindisconnect and remove the upper change gear on PLC-T models.Follow plant lock out/tag out

procedure

Cut power off at main disconnect and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.

FIGURE 2.21.1.2: S.L.O.Y. TUBE (240-4016)

ø 1.75 IN

ø 44.5 mm

+.01-.00

+.25-.00

LAY OF

PAPER

225 mm +.00-1.5±.02

±5

± . 0 1

± . 2 5

.44 IN11.2 mm

. 2 5 I N

6 . 4 m m

A

ø 2.4 INø 61 mm

1.

2. CONSTRUCTION:SONOCO PRODUCTS CO’S SPIRAL DUROLENE

WITH SEAMLESS LOW MARK OUTSIDE PLY.

NOTCHES TO BE AT 180º ±2º.


7.5.8) by removing four M6 screws andwashers. Pull "L" support from shuttle.

3. Grease shaft with anti-seize compound.

Push shuttle extension (2 Figure 7 5 11)

The remaining hole is used to inject oil or any anti-seize lubricant. It is tapped for anM4 thread and is used if the shuttleextension should be difficult to remove.Force a suitable penetrating oil through the



Push shuttle extension (2, Figure 7.5.11)onto shuttle shaft making sure that theorientation between the new shuttleextension and shuttle spindle is correct.The shuttle extension must have the carrier latch tip in the same alignment as that of the shuttle being converted.

4. Install "L" support assembly (3, Figure7.5.11) onto adapter and orient to mateslots over shuttle part (1).

5. Assemble four M6 screws and washers andtighten with M5 allen wrench. Torque to14Nm (10.3 ft-lbs). Permatex all screws atassembly.

6. INSTRUCTIONS FOR INSTALLATION OFTHE MODIFIED SHUTTLE EXTENSION

240-5140. The shuttle extension isinstalled per the instructions in the MR-11PLC-T or MR-11S/2 manuals. When this iscomplete, install an M6 x 6 DIN 916 setscrew at each location shown, usingLoctite 222 on the threads.

Force a suitable penetrating oil through thehole. (See Figure 2.21.3.1)

CAUTION

Gap between plastic tip on the L-bar and wear screw (15, Figure7.5.5) on the carrier assembly should never exceed 2 mm.

CAUTION

Replace the wear screw (15,Figure 7.5.5) before 2 mm isexceeded. Quality of the hosecould be affected.

NOTE

Check to see that the timing of all assemblies on each shuttle

provides for the mounting of eachcarrier in the same orientation aswith wire braiding. The conversionis now ready for loading prepared yarn packages for braiding.

NOTE

SPINDLE

M6 X 6 DIN 916

4 PLACES


2.21.4. YARN BRAIDING CARRIER OPTIONS.

1. Usually yarn requires less strand pay-off tension than wire and the light torsionspring (Figure 7 5 4) will be used See

7.5.11) without the 4 set screws,must be removed after every 150 hours of operation and its interior treated with an anti-seizecompound Failure to do this will



spring (Figure 7.5.4) will be used. See previous pages in this section, for explanation. Reference Paragraph 2.16.2.

2. The pre-form pin is not used and mayeither be removed or bypassed in thethreading.

3. The double threading cycle is employedfor most yarn braiding applications. Theaddition of the two strand rollers shown in Figure 2.14.2.1, is required for this.

NOTE

The shuttle extension (2, Figure

compound. Failure to do this will allow the adapter to freeze ontothe spindle. This will makeremoval extremely difficult.

NOTE

Contact MII field service for information concerning anoptional spindle that does not require a shuttle extension.

Reference Part #:240-5231 - Superpack

240-5230 - Single Let-Off Yarn

SECTION VI. BOBBIN RUN-OUT DETECTOR

CAUTION


Only trained personnel/mechanics

are allowed to install and removeshuttles and/or work in this area.Personal safety equipment is tobe worn.

change gear on PLC-T models.Follow plant lock out/tag out

procedureCut power off at main disconnect and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.


2.22. BOBBIN R UNOUT DETECTOR . The bobbin runout detector will stop the MR-11PLC-T braider when a bobbin has run out of


When a bobbin becomes empty, there is nolonger any tension on the compensator plate sothe plate moves to its fully relaxed position,which allows the extension to strike the spring,

grounding the control circuit and stopping the braider. See the following instructions toinstall the unit.



FIGURE 2.22.1: LEFT HAND SENSOR

#18 R OTOR FOR 36 SHUTTLE BRAIDERS



# 8 R OTOR FOR 16 SHUTTLE BRAIDERS

LEVEL TOP EMPTY POCKET OF

#1 R OTOR FOR 16, 20, 24 & 36CARRIER BRAIDERS

COMPENSATOR SHOWN INRELAXED POSITION

SIMULATING AN

EMPTY BOBBIN

SENSOR ASM.

BAR

JUMPER TO R IGHT HAND SENSOR LEFT SIDE SENSOR LOCATION

CL DECK

PROBE HOLDER

3 TO 6 mm

PROBE

0 TO 5 mm

CL

SPACER WASHER

HEX BOLT

SECTION A-A

TRIP R OLLER

A

A


JUMPER TO LEFT HAND SENSOR WIRE TO OPERATORS BOX







LEVEL TOP EMPTY POCKET OF#18 R OTOR FOR 36 SHUTTLE BRAIDERS

#12 R OTOR AS SHOWN

COMPENSATOR SHOWN INRELAXED POSITION

SIMULATING AN

EMPTY BOBBIN

SENSOR ASM.

BAR

R IGHT SIDE SENSOR LOCATION

CL DECK

PROBE

3 TO 6 mm

PROBE

0 TO 3 mm

CL

SPACER WASHER

HEX BOLT

SECTION A-A

TRIP R OLLER

A

A

HOLDER

SHIELD

16, 20, 24, 36 SHUTTLE BRAIDERS




SECTION VII. BROKEN BRAID DETECTOR

2.23. ASSEMBLY INSTRUCTIONS. (Figures7.5.29, thru 7.5.32).

6. Turn the main power back on. Verify that

the sensor is working properly by pushingthe ring in the direction of hose travel.



CAUTION

1. Turn electrical power off at the main power control.

2. Place the assembly (Figure 7.5.31) on thestand slide assembly (Figure 7.5.29).Using the 2 M6 screws (2, Figure 7.5.30)and B6.4 washers (3, Figure 7.5.30) securethe bracket assembly to the slide assemblyin the approximate position desired in

relation to the braid point.

3. Insert the two ring halves (18) in the braiddetector holder (14, Figure 7.5.31). Thering halves should snap in or out withoutexcessive force. No tools should berequired to install or remove the ringhalves. All adjustments have been set at the

factory. A few minutes practice installingand removing the ring halves will allow theoperator to develop the speed desired.

4. Insert the holder (14) containing the ringhalves into the spring assembly. The ringcan be inserted from the front or rear of thespring assembly. No tools are needed.Excessive force will damage the springs,

causing the sensor to operate improperly.

5. Adjust the 4 spring plungers (5) to clear thesprings about ½ mm. This adjustment

t l th iti it f th A

g p p y y p gg

NOTE

DO NOT RUN THE MACHINE AT

THIS TIME. An alarm messageshould show on the Alarm Box Display.

Reset the ring and then press the Reset button. The light should go out. Now pushon the springs individually and verify thateach spring will cause the light to come on.

7. Using extreme caution, run the machineand test by tripping any one of the springsor pulling the ring in the directions of hosetravel. The braider must shut down and notrestart. It is not necessary to have hosethreaded through the sensor for this test.

NOTE

If the sensor is too sensitive, the½ mm gap can be increased.However, if the gap is increased too much, it is possible for the

holder to move out of the springswithout tripping the braider off. If anew gap is set, the tests should berepeated. In some cases, the

t b


8. After completing the test in steps 6 and 7successfully, the sensor is ready to use. Thering halves should be removed whentheading the braider. After threading the braider, including braid detector holder ( ) i ll h i h l h

e. Slide the ring "upstream" of the defectand then reinstall the ring halves.



(14), reinstall the ring halves. The sensor operates by moving in the direction of hosetravel whenever any of the pins engage aloop or snarl on the hose.

This movement closes the gap between thespring and the spring plunger which

electrically grounds out the circuits thatcontrol the running of the braider. Thisgrounding stops the machine.

9. A suggested procedure for restarting themachine after a defect has moved holder (14) enough to turn off the braider is asfollows:

a. Turn the inside safety switch "ON".

b. Remove the holder (14) completely outof the spring holders, if it isn't alreadyout.

c. Remove the ring halves.

d. Jog the braider until the defect is 50 to100 mm "downstream" of the springassembly.

CAUTION

Do not push the reset button until the sensor is completely reset, thecause of the defect has beencorrected, and the braider is ready to be run. Failure to follow thisand all other machine safety

procedures can result in seriousinjury to personnel working on thebraider through inadvertent start-up of the braider.

f. Now push the ring, with ring halves, back into the spring assembly. Thesprings must engage the "V" groove.

g. Correct the cause of the defect.

h. Press the "Reset" button.

i. Turn the safety switch "OFF". The

braider is now ready to resumeoperations.

SECTION VIII. DRIVE CARTRIDGE AND CHANGE GEAR DRIVE (FIGURE 7.5.22, & FIGURE 7.5.23)

T HE INFORMATION IN S ECTION VIII IS FOR THE PLC-T STANDARD DRIVE ONLY .

S EE F IGURE 6.12.2.1 FOR DUAL DRIVE PINION ASSEMBLY .

Only trained personnel/mechanicsare allowed to install and remove


Cut power off at the maindisconnect and remove the upper change gear on PLC-T models.

Follow plant lock out/tag out procedure

Carrier] ) by adjusting the thickness of thespacer (2) at assembly. The desired axial playor clearance with all parts locked together,should be 0.15 mm. Reducing the thickness of this spacer will increase the axial clearance.



p

Cut power off at main disconnect and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.

Read and follow manual

instructions.

2.24. FUNCTION. Two cartridge units supportthe deck drive assemblies.

• Pinion Cartridge Assembly

• Driven change gear shaft

• Drive pinion to one rotor assemblygear

• Sprocket Cartridge Assembly

• Driven shaft for deck silent chain drivefrom deck drive shaft

• Driver change gear shaft

2.25. R EMOVAL OF CARTRIDGES. Bothcartridges can be removed through the changegear door. Figure 7.5.22 shows location of mounting screws for the 16, 20, & 24 Carrier braiders. Figure 7.5.23 shows the location of the mounting screws for the 36 Carrier.

2.26. SERVICE OF CARTRIDGES.

2.26.1. PINION CARTRIDGE ASSEMBLY. All

The sealed ball bearings (18 and 19) are a press fit to shaft and a slide fit to the cartridgehousing.

It is important to torque the nut (15) to 45-50ft-lb. (61-68 Nm) to insure a positive lock to

contain the rotor pinion gear (9). The safetywasher (16) must be engaged.

2.26.2. SPROCKET CARTRIDGE ASSEMBLY.The same instructions for the pinion cartridgealso apply to the sprocket cartridge assembly.

In addition, the sprocket cartridge has an

additional custom fit utilizing shims to alignthe upper driven silent chain sprocket with thatof driver silent chain sprocket (8, Figure7.5.22 & 7.23). The shims (2, Figure 7.5.22 &7.5.20) will serve to axially position upper sprocket within a tolerance of 0.2 mm. Astraight edge will serve to determine this axial position.

It can be seen from Figure 7.5.22 & 7.5.23 (36Carrier), that when the axial position of sprocket (8) is changed to suit sprocket (2, Figure 7.5.24) shims (2, Figure 7.5.22 &7.5.23) will be required to align the outer faceof upper change gears (23) within 0.2 mm of lower change gear.

2.27. CHANGE GEARS DRIVE. The MR-11PLC-T change gear drive is common to other braiders in that the rotor RPM may be varied




THE PINION CARTRIDGE AND

SPROCKET CARTRIDGE ARER EVERSED IN LOCATION FOR



THE 16 CARRIER

NOTE: AS VIEWED FROM REAR OF MR-11 PLC-T DECK DECK DRIVE SHAFT

DRIVE CHAIN STD 50 HERTZ

DRIVEN CHAIN SPROCKET

GEAR 21 T

CHAIN ADJUSTMENT

NOTE: SLIDER SHOULD BE

LIGHTLY PRESSED AGAINST

SILENT CHAIN TO TAKE UP

SLACK . THIS SHOULD BE CHECKED EVERY 200 HOURS.

R OTOR

GEAR 94 T

R OTOR DRIVE

PINION 32 TDECK CHANGE GEARS

136 T I N PAIRS


2.30. CHANGE GEAR TABLES (SPEED LEAD CHARTS). The tables are shown here to allowthe user to make setups.

2.30.1. DESCRIPTION OF TABLES. Tables are

3. At right of this row find "take-up" changegear combination.

4. Find production at far right of row, using

the same combination of take-up gears.



2.30.1. DESCRIPTION OF TABLES. Tables arearranged according to high, medium, and lowrotor speeds in combination with high,medium and low production rates. Therefore 9charts are required for each type of MR-11PLC-T braider with a given take-up. For theMR-11 PLC-T take-up only 29 change gears

are required because range gears permit use of these gears for 3 separate ranges of productionrate.

Numbers across the top of table represent thenumber of gear teeth for MR-11 PLC-T deck change gear combination (driven and driver).

Numbers in table body are leads in inches or millimeters produced by a given deck andtake-up change gear combination.

Numbers in second and third columns from theright present the number of teeth for possibletake-up change gear combination.

Numbers in far right hand column representthe theoretical rate of production in inches or meters per minute.

Information in the upper center gives driveshaft RPM information.

2.30.2. EXAMPLE.

Braider: 2 Model MR-11 PLC-T, 24 carrier decks braiding ("S.L.O.W.") wire.

1 Calculate "lead" for each reinforcement

5. Rotor RPM and carrier central RPM areshown at the base of column for respectivedeck change gears.

2.30.3. EXAMPLE.

Braider: 2 Model MR-11 PLC-T, 24 carrier decks braiding wire with a maximumrecommended rotor RPM = 225.

HOSE CONSTRUCTION:

2 wire braid at 54° 44’ braid angleLead of first braid = 1.045 inchesLead of second braid = 1.150 inches

Step 1: Select deck gears for first braid based on 223.7 rotor RPM

Step 2: Closest lead shown is 1.050 inchesusing 61 teeth driven and 75 teethdriver deck gears.

Step 3: Take-up change gears are 75 teethdriven and 61 teeth driver. Rangegears are 42 driver and 65 driven.Production is 39.15 inches per minute.

Step 4: Using 39.15 inches per minute production, the closest lead to thedescribed 1.150 inches is 1.147inches.

Step 5: Deck change gears for 1.147 lead are

72 teeth driver and 64 teeth driven.

NOTE


SUMMARY:

1st Wire Deck

Lead 1.050 inches

223

2nd Wire Deck

Lead 1.147 inches

Rotor RPM = 204.7Deck Change Gears = 64 teeth driven



Rotor RPM = 223.7

Deck Change Gears = 61 teeth driven75 teeth driver

g72 teeth driver

Take-Up

Production Rate = 39.15 inches per minute

Change gears = 75 driven, 61 driver

Range gears = 65 driven, 42 driver




O R

M ’ S

S N G E G E A R

I V E N

N G E G

E A R

V E R

- O F F

GEAR BOX



L E A D :

E A D :

m m

m m

C H A N G

E G E A R S

A R S

D R I V E

N :

D R I V E

R :

R O T O R R P M ’ S :

C A R R I E R R P M

’ S :

E R C H A

N G E G E A R S

D R I V E N

:

D R I V E R :

D E

C K

#

1

D E C K

# 2

M O T O

1 4 0 0 R P M

H A U L - O F F C H A

N G E G E A R S

R A N

D R I

R A N

D R I V

H / O C H A N G E G E A R

D R

I V E R

H / O C H A N G E G E A R

D R I V E N

H A U L -





SECTION IX. DRIVE SHAFT ASSEMBLY (FIGURES 7.5.24 AND 7.5.25)

(SECTION IX IS NOT USED FOR THE PLCT-F DUAL DRIVE)

2.31. FUNCTIONS.

• Provide a through drive shaft, so that the

drive shaft. Remove couplings and key

(12, Figure 7.5.24 or 7.5.25 (36 Carrier)).Care should be taken to remove burrs fromd i h ft t t d i il l



Provide a through drive shaft, so that thedecks may be driven in series.

• Provide a silent chain sprocket on the driveshaft for reducing speed and transmitting power to the sprocket cartridge assembly(8, Figure 7.5.22, & 7.5.23).

• Provide shear-pin overload protection between drive shaft and silent chainsprocket. The drive shaft is mountedwithin the lower base frame and is self-lubricated by splash lubrication. (Refer to paragraphs 2.33 and 2.34.)

2.32. R EMOVAL OF DRIVE SHAFT ASSEMBLY. The shaft unit is mounted into thelower deck frame with flanged ball bearingunits at either end. The shaft can be removedonly from rear of the deck. (Servicing thedrive shaft shear pin coupling can be donewithout removing the shaft.)

CAUTION

Moving elements in drive shaft area.

Disconnect power source fromdeck.

Minor personal injury to handsand arms could result.

drive shaft to prevent damaging oil seals.

4. Remove screws (5) from flange (4) at therear of the deck and the drive shaftassembly can now be removed from thedeck by pushing or driving from surface A,

Figure 7.5.22. It is not necessary to removescrews (5) from flange (4) at front of deck.

2.33. SHEAR PIN OVERLOAD. The object of this unit is to place two shear pins betweenspaced flanges. The shear pins have beendesigned to operate under all normal loadsassociated with the drive functions, but willfail if an overload occurs.

The purpose is to provide overload protectionto other deck members.

Figures 7.5.24 and 7.5.25 (36 Carrier), showthe design of the coupling shear pins, the bushing (7) shear pin ring (6) and the shear member (9) (two per deck retained to shear pinring with M6 set screws (13)).

2.34. SHEAR PIN ASSEMBLY INSTRUCTIONS.Several points are critical to the proper serviceof this coupling:

CAUTION


between shear pin flanges. Adjustment tothis gap is by changing the length of the brass bushing (8).

NOTE

The deck should be rotated by hand andsubsequently "jogged" to insure thatcontinued operation is safe and practical.

Refill oil sump if it was drained.



Correct the source of overload prior to replacement of shear pins.

SECTION X. ROTOR AXLE ASSEMBLY (FIGURE 7.5.21)

CAUTION

Only skilled/trained mechanics

should be allowed to work in thisarea of the braider because of themoving elements and numerous

pinch points.

Mechanics should adhere to all safety rules including the use of

personal safety equipment.

"Always" disconnect the power source. Follow your plant instructions for lock out/tag out.

Ensure that work area is clean (nooil on floor) and safe.

Beware of sharp edges on parts.

Beware of the weight of parts.Read and study manual instructions prior to work.

I l i M h i

and observe all safety precautions. Contact Mayer’sService Department if there arequestions.

2.35. FUNCTION. The rotor axle assemblyserves the basic function of bearing support for a rotor assembly.

Additionally, the rotor axle is the basis for timing the sun gears on each axle, and themajor and minor planetary gears on each rotor assembly (Figure 7.5.21).

The axle unit is fastened to the MR-11 PLC-Tupper deck frame and the automatic oillubrication supply for each rotor assembly isconnected to the rear of each axle.

All rotor axles are identical for each deck.Each rotor axle assembly is a "matchedassembly" to a given rotor assembly.

2.36. MATCHED ASSEMBLY-DEFINED (R OTOR TO AXLE). It is important tounderstand the minor yet significant reasons


2.36.1. BEARINGS - R ADIALLY MATCHED.(Refer to Figure 7.5.21). The front and rear roller bearings (3 and 4), which support therotor assembly have matched inner and outer

races. The bearings were purchased as anintegral bearing unit and must functiontogether Replacement of any one part of each

CAUTION

Heavy parts (90 lbs., 41 Kg.)



together. Replacement of any one part of eachfront or rear bearing must include replacementof matching parts for that particular bearings.

2.36.2. AXIAL MATCHED ASSEMBLY (R OTOR TO AXLE). (Refer to Figure 7.5.21). Each

rotor assembly and each rotor axle assemblyare identical in design and are manufactured toclose tolerances. However, to achieve thedesired axial play of any one rotor to itsadjacent rotor it is essential to provide acustom fit at assembly of one bearing ring (12, Figure 7.5.21).

Instructions will follow for field match-up of arotor assembly with a different rotor axleassembly.

It should be understood that the steps will bethe same regardless of which or how many parts will be changed.

2.37. R EMOVAL OF R OTOR AXLE ASSEMBLY.

1. Remove shuttles from deck.

NOTE

Mark the transfers the shuttles areremoved from so you can reinstall the shuttles at these locations

Do not attempt to remove without help.

Minor personal injury could result.

2. Remove the rotor assembly from the rotor

axle; see Section X I of this chapter.

3. Disconnect the Bijur lubrication fittingsfrom the rear of the rotor axle assembly.

4. Remove six M12 socket screws from therear of the deck upper frame.

5. Push the rotor axle assembly from theupper deck frame. The rotor axle timing pin may remain in the frame.

2.38. ASSEMBLY OF R OTOR AXLE TO DECK UPPER FRAME.

1. Check to see that:

a. The upper deck frame mounting holeand surface is free from burrs and dirt.

b. The rotor axle to be installed isequipped with proper bearing inner races for matched assembly with therotor components. The races are to beseated to the rotor axle, with their oil

holes oriented to the Bijur meter units.

c. The rear NAO 80 x 110 x 30 bearing isequipped with the cage assembly (3,


threads to prevent loosening due tovibration. For 36 carrier axles the keymust fit properly.

e. Bijur meter unit items 6, 7, and 27 arecorrect size and seated fully into tappedholes (Figure 7.5.21).

6. Check for axle to deck location usinggauge 240-1078 (Refer to Chapter 8).

Rotor axle is now ready to receive the rotor

assembly



NOTE

When installing axles onto decks,the timing hole will orient the axleto the deck. However, the 3 Bijur units, items 6, 7, and 27, must always be on the bottom side of the axle or below a horizontal center line thru the axle. In somecases it may be necessary to

remove the plug, (item 28, Figure7.5.21), install the Bijur unit, item7, where the plug was and put the

plug where the Bijur unit, item 7,was to be sure the Bijur unit will beat the proper location.

f. Oil passages through rotor axle are freefrom foreign matter.

g. "O" Ring (8) Figure 7.5.21, is installed.

2. With the axle assembly fully prepared for rotor assembly, orient the rotor axleassembly to timed engagement with theM10 locating pin (11). Verify that theBijur meter units are in the same position.

3. Assemble six M12 x 60 DIN 6912 socketscrews (16) together with six M12 DIN127 lockwashers (20) from rear of deck frame and torque screws to 65-70 ft-lbs

2.39. FIELD MATCHING OF R OTOR ASSEMBLY TO NEW OR DIFFERENT R OTOR AXLE.

CAUTION

See all Safety Notes from Section X: Rotor Axle Assembly.

NOTE

Rotor assembly to be installed must be equipped with outer racesfrom "matched" front and rear rotor axle bearings of the axle therotor frame is being installed on.

CAUTION

Heavy parts, 90 lbs (41Kg).



1. Assemble rotor assembly to rotor axlebl di t i t ti d


mount onto the outer face of the rotor assembly with the indicator tip to the outer end of the rotor axle. See Chapter 8 for additional details.

4. With nut tightened, read and record axial play. The desired axial play of 0.02 to 0.05

1. Remove the M5 screw (19) for the 16, 20,& 24 Carrier. Remove the M5 screw (19)and (22) washer for the 36 Carrier.

2. Push or tap the gear with a brass or plastic punch until it moves off the mounting flatand axle diameter.



mm is obtained by use of shims (23, 24, 25,and 26) between bearing ring (12) andthrust race (13). To remove thrust race(13) from bearing ring (12), rap bearingring (12) wide flange face onto a piece of

wood until thrust race (13) separates from bearing ring.

Install or remove shim(s) (23, 24, 25, and26) to obtain correct axial play. Removalof spacer parts is done by removing theKM8 nut (18) and carefully "pulling" therotor about 3/4 inch (20 mm) to the frontand "pushing" the rotor back to enable thegrasping of the four-part outer raceassembly.

5. Reassemble the thrust race (13) onto the bearing ring (12) and install it back ontothe rotor axle (1). Install safety washer (17)and locknut (18) and tighten to a torquespecification of 20-35 ft.-lbs./27-47 Nm.

Set the magnetic base onto the rotor frameand recheck the axial play.

2.40. MAJOR SUN GEAR . (2, Figure 7.5.21).(Refer to parts list for part number.) The major sun gear is assembled to the rotor axle with alight push fit and is held in location by a timed

flat and an M5 x 16 DIN 6912 socket screw(19), for 16, 20, & 24 carrier decks. The 36carrier sun gear has a key and an M5 x 16 DIN6912 socket head screw, with an A5 DIN 127

h

3. On the 36 Carrier, remove the key (9).

2.42. ASSEMBLY OF SUN GEAR TO R OTOR AXLE. It is important that the matchup of thesun gear with the rotor axle provide proper timing.

1. Slide the major sun gear (2) onto the rotor axle with care to locate the flat on the axlewith the flat on the major sun gear. Acorrect fit will allow the gear to be pushedonto the flat, yet not have rotational

clearance. If the fit allows slop or wobbleof the gear to the axle, provide shim stock to make the assembly tight on the rotor axle.

2. Apply Permatex to the M5 screw (19) andtorque to 5 ft.-lbs. (7 Nm.) to securely lock it in place.

For the 36 Carrier axles, install the washer,item # (22).

2.43. R EMOVAL OF R EAR BEARING INNER R ACE . (3, Figure 7.5.21). Rotor axleassembly is first removed from the upper deck

frame.

1. Remove major sun gear (2).

2 Remove bearing spacer (10)


2.44. ASSEMBLY OF R EAR BEARING INNER R ACE. (Note criteria for matched bearingcomponents).

1. Be sure that the inner race oil hole isaligned with the Bijur meter unit.

toward the outer end of the rotor axle.When the race has moved forward about 5mm, use a wheel or modified gear puller toremove the race from the axle.

See Chapter 8 for additional details.



2. Press oiled inner race onto the rotor axle sothat the race is seated squarely againstshoulder.

3. Replace needle bearing assembly (3, Figure 7.5.21) and bearing spacer (10).

NOTE

The 36 Carrier does not use a

bearing spacer (10).

2.45. R EMOVAL OF FRONT INNER BEARING R ACE. (4, Figure 7.5.21). This can be donewith the rotor axle attached to the deck frame.

1. Using a brass pin, tap the rear of the race

2.46. ASSEMBLY OF INNER BEARING R ACE.This operation may be performed with the axlein or out of the deck (4-1, Figure 7.5.21).

1. Check the Bijur meter unit (27) for proper

installation, etc.

2. Oil the race before driving it onto the axle,using a brass or soft steel sleeve tosquarely seat the race against the shoulder.

NOTE

A new race assembled to a rotor axle will require a check of theaxial clearance. Refer to separateinstructions, paragraph 2.39.

SECTION XI. ROTOR ASSEMBLY (FIGURE 7.5.19)

CAUTION

See all Safety Notes from Section X: Rotor Axle Assembly.

2 47 FUNCTION The basic functions

assembly.

See Chapter 8 for additional details.

2.48. GENERAL. Each MR-11 PLC-T rotor

assembly is the same design as any other rotor assembly. Each rotor assembly is numberedand is a matched set to the rotor axle assemblyto which it is attached.


2.49. R EMOVAL OF R OTOR ASSEMBLY.Removal of the rotor assembly should only bedone after all shuttles have been removed from

the deck. (See shuttle removal instructions,Chapter 2, Section II ).

a. Carefully pull the outer face of therotor assembly 3/4 inch (20 mm)forward and then push the rotor face back to its original position.

This should expose the four-part thrustrace unit, (12, 13, 14, 15 and the shims23 th h 26 f Fi 7 5 21)



CAUTION

Moving elements in rotor assembly area.

Disconnect power and removeupper change gear.

Minor personal injury to handsand arms could result.

1. Remove four M6 screws (15, Figure7.5.19), four ST M6 washers (23, Figure7.5.19), and remove rotor cap (16), and O-ring (20).

2. Bend tang of MB8 safety washer (17) fromKM8 nut (18) and remove KM8 nut fromthe rotor axle, Figure 7.5.21.

CAUTION

Heavy parts (90 lbs., 41 Kg)



a. Rotor Frame Lift Kits are available.S Fi 9 1 13 i Ch t 9

23 through 26 of Figure 7.5.21).

Slide this four-part group off of therotor axle and place them in a clean place for reassembly to the same axle.These are a matched set. DO NOTSEPARATE.

b. Rotate the rotor to place the front camfollower cartridges vertically in (12and 6 o'clock orientation) for removal.

CAUTION

Heavy parts (90 lbs., 41 Kg)



c. Carefully remove the rotor assembly.

NOTE

Care should be taken whentipping the rotor front downward to

prevent the three parts 13, 14, and 15 of the thrust race from dropping out of the rotor frame bore if they


2.50. R EASSEMBLY OF R OTOR ASSEMBLY TO R OTOR AXLE. Use nylon adapter (240-3047)to protect the threads on rotor axle. Note:

Rotor Frame Lift Kits are available. SeeFigure 9.1.13 in Chapter 9, Special Tools.

1 With th t bl tti ti ll

bearing units are automatically lubricated fromoil being forced into the rotor axle assemblyand then through the holes in the rotor frame tothe individual cam followers.

These roller bearing units have beenmanufactured with special care to insure thath bli f f di d



1. With the rotor assembly setting verticallyon the front face, the three-part thrust race(13, 14, and 15, Figure 7.5.21) isassembled into the rotor housing. It isimportant to place the thrust races as

shown. A light smear of grease on theraces will prevent them from moving in therotor bore when the rotor is tippedhorizontally for mounting to the axle.

2. Lift the rotor assembly to the rotor axlewith the front face tipped downward andwith front cartridges in vertical position(12 and 6 o'clock).

3. Slide the rotor assembly onto the rotor axletaking care to see that the thrust races (step1) remain in the proper position for correctseating. If the rotor assembly was on themachine be sure that the pocket transfer marks align in the same position they werein before removal.

4. Reinstall all bearings and shims.

5. Reinstall the safety washer (17) and nut(18, Figure 7.5.21). See paragraph 2.39,and Chapter 8 for additional details.

2.51. R OTOR CAM FOLLOWER ASSEMBLIES.

The function of both front and rear camfollower assemblies is to react the centrifugalload of the shuttle between rotor transfers andto contribute to the smooth transfer of the

the assemblies are free from dirt, water, andother potentially harmful substances. Anyreason for field service must include this care.

2.52. CAM FOLLOWER ECCENTRIC ADJUSTMENT. Both front and rear camfollower assemblies have been designed toallow precise adjustment to set the desiredclearance between the cam track and themating cam follower extended shaft. Bothcam follower cartridges have beenmanufactured with 0.7 mm eccentricity between the inside bore and outer 45 mmdiameter of the cartridge. Rotation of thecartridge will permit radial adjustment withoutmovement from the center line of the rotor pocket. Slots have been machined in bothfront and rear cam follower cartridges to beused for rotational adjustment. See tool 240-3037 (Figure 9.1.2). When the desired radial position has been attained, four M6 screws are

tightened to lock-in the adjusted position.

2.53. CAM FOLLOWER BEARING FAILURE.The cam follower cartridge roller bearingshave been engineered to provide long servicelife for the MR-11 PLC-T braider decks.

The critical part these bearings play in the braider has required the use of an electrical"sensor" to monitor their correct location.


The Alarm Box Panel will assist the braider operator in locating the damaged or worn camfollower cartridge by turning on a light on theoperator's control panel, and on the inside of

the panel, showing which shuttle sensor has been tripped. See Chapter 4 for Shuttle Sensor information.

12 o'clock position. Lock the rotor so it can notturn. Place the tip of the dial indicator on thetop of the cam roller about 2 mm back from thefront edge of the roller, as shown in Figure

2.56.2, Method A, in the braider manual. Setthe dial at 0.0. Push upward on the BOTTOMof the roller. Replacement of the cam follower is recommended if the reading for cam



It is important to check a bearing by "feel" todetermine the nature of the reported failure.Usually, a defective roller bearing will showone or more of the following symptoms:

1. Hot to the touch (over 120°F, 49°C)

2. Discoloration of parts

3. Frozen-will not turn freely by hand

4. Too much radial or axial clearance

5. Bumpy-shaft, feels tight in certain places

when rotated by hand

2.54. FRONT CAM FOLLOWER CARTRIDGE ASSEMBLY. After five (5) years the front camfollower (9, Figure 7.5.19), should be replacedif the area which is in contact with the camtrack shows indentations which are deeper

than 0.02 mm. If a cam follower hasindentations less than 0.02 mm and if youdesire to have this cam follower reworked,contact MII for pricing. To avoid import duty,mark all documents clearly stating that these parts are being returned to the USA, and theywere originally made in the USA.

The following is a recommended method andvalue to use when making a decision as towhether or not to replace a cam follower. Usegauge 240-1076 (Figure 9.1.4) or a diali di t ti b t th

is recommended if the reading for camfollower movement is greater that 0.045 mm.

2.55. R EMOVAL OF UNIT FROM R OTOR . The

front cam follower cartridges are basically allalike. It is important, however, to note thatonly two rotor assemblies of each braider deck are provided with a special provision for removal of front cam follower cartridges used primarily when shuttles are to be removedfrom the deck. The special provision consistsof a "timed relationship", using a pin to permitreassembly without eccentric adjustment. Allother rotors have cartridges without timing pins and will require eccentric readjustment.

The technique for removal and replacement of front cam follower assemblies follows:

1. Loosen and remove four M6 screws (14, Figure 7.5.19) holding cap to rotor frame

outer face. Do not remove cap fromcartridge (9).

2. Care should be taken to reach to the rear of the rotor face and press or push on thecartridge (not shaft) to force the cartridgefrom rotor.

3. The cartridge is to be removed as one unit,

together with the cap. The cap (1) should be kept together with the same cartridge byinserting one of four M6 screws (2) and placing two ST M6 washers (3) and an M6


NOTE

See separate instructions for inspection and assembly of rotor

f ll it Fi 2 55 1

a. With the cartridge assembly held inyour hand, rotate the shaft within thecartridge. It should turn freely andsmoothly without abnormal radial or

axial play. The protruding 25 mmdiameter shaft should be smooth, pitfree and not discolored by heat.



cam follower units, Figure 2.55.1.

2.56. R EASSEMBLY OF FRONT CAM FOLLOWER CARTRIDGE TO R OTOR FRAME.

2. Holding the cap onto the cartridge, removethe assembly M6 nut (4, Figure 2.56.1) and place the cartridge into the rotor framemounting hole. Care must be taken toassemble the cap and housing with the 3mm diameter hole in the cap face and thetiming notch on the cartridge, adjacent tothe "X" stamped on the rotor face to thecasting. (See Figure 7.5.19.)

3. Place four M6 screws (14) and ribbedwashers (23) in cap and thread into rotor frame. Tighten fasteners lightly.

FIGURE 2.55.1: CAM FOLLOWER ASSEMBLY INSTRUCTIONS

STEP 1

STEP 2

STEP 3

R UBBER BAND FOR ASSEMBLY O NLY

FIGURE 2.56.1:


GAGE (240-1076)

R EAR POCKET



NOTE

Use Permatex on screw threads.

4. Using the slots at the shaft end of thecartridge and MI tool # 240-3037 (Figure

9.1.2) rotate the housing to the desiredradial adjustment of .02-.05 mm. The proper clearance is set as follows.

f

NOTE

The set master (240-1076, Figure9.1.4 ) was designed to be used with a diameter 72 mm outer raceand a standard cam track with a

80 mm radius. If an undersized outer race or a reworked camtrack is being used, the set dimension on the set master has

FIGURE 2.56.2: METHOD A(R EAR CAM FOLLOWER SHOWN, SAME FOR FRONT CAM FOLLOWER )

R EAR CAM

FOLLOWER

SLOTS

SCREWS

S EE C HAPTER 8,S ECTION XI


NOTE

When checking the clearancebetween the cam followers and cam tracks the front outer race (4

this will cause an error in the gage setting.Turn the indicator glass cover until theindicator is reading "0" at the highest pointof the needle movement and tighten the

indicator set screw. Take precautions not toover tighten the setscrew because this willcause the indicator stem to bind. After tightening, check to see that the stem and



cam tracks, the front outer race (4,Figure 7.5.17 ) should be checked for being out of round or undersized. If either conditionexists, replace all the outer races.

NOTE

Be sure to identify and remove theshuttles from each individual transfer and keep the transfersseparated from each other. Also,identify on the face of the rotor frames of each transfer, so only the correct shuttles from thistransfer will be used to performthe final check and adjustment (if needed) between the cam follower and cam track. Make sure

Permatex and washers (ST-M6)are on the screws that fit in thecap.

Place the dial indicator in the front hole of the 240-1076 setting gage, the hole closestto the handle. This is the position for thefront cam follower. For the rear cam

follower use the hold farthest from thehandle. Lightly tighten the indicator setscrew. Rotate the handle back and forthclockwise and counter clockwise, making

tightening, check to see that the stem andneedle movement are free. Recheck the "0"reading on the gage. The gage is now readyto preset the front cam followers.

Loosen the screws that hold the adjustmentfor the front cam follower. Reference Figure 2.56.2.

NOTE

Make sure that the rotor pocketsare free of burrs, oil and all foreignmaterial before using this gage.

NOTE

On the face of the rotor frames( Figure 7.5.19 ) at the front camfollower holes, there will be an "X" stamped onto the frame, this will also be found on the back side of the pillow blocks ( Figure 7.5.20 ).Be sure that the slot in the

cartridge and the timing hole in thecam follower cap assembly (9,Figure 7.5.19 ) are both turned tothe "X' side. This is a must for front and rear cam follo ers


NOTE

Figure 2.56.2, shows the dial indicator ball resting on the rear cam follower

After the front and rear cam followers have been preset to plus 0.015 mm using thegage, the cam follower clearances "must" be checked with 0.02 and 0.05 mm shim

stock. It is suggested that these settings bedone with the rotor frames on aworkbench. Make sure that the followingareas on the shuttle assemblies are very



cam follower.

Push up on the bottom of the front camfollower similar to what is shown in Figure2.56.2, and use the 240-3037 cartridge

wrench in the slots of the front camfollower to rotate the cartridge until thedial indicator reads plus 0.015 mm.

Lightly tighten the (4) M6 cam follower screws.

Recheck that the 0.015 mm reading has not

changed while pushing up on the bottom of the from cam follower.

To preset the rear cam follower move thedial indicator to the rear hole of the 240-1076 setting gauge, place the gauge in the240-1077 base plate and set it to 0 mm.

Repeat the above procedure to preset therear cam followers.

yclean and contain no oil or trash.

• Rotor Pockets, front and rear• Planetary Gears

• Cam Follower Shaft• Front and rear bearings of the

shuttle assembly• Both inner races of the cam track

The tightest shuttle from each of thetransfers has to be selected and identified.These shuttle assemblies are used as themaster to make the final cam follower adjustments for the pockets in its transfer.Repeat this procedure for the other transfers.

The following steps are used to set the camfollower clearance with the shim stock:


CAMTRACK SHUTTLE ASSEMBLY

NOT SHOWN

FOR CLARITY



Install the shuttle into the top, front andrear pockets of the rotor frame. Rotate the

shuttle assembly 2 or 3 times to be sure it isseated properly.

See Figure 2.56.3 for correct location to place a piece of .02 mm thick shim stock.Be sure the screws locking the cartridgeare loose so you can adjust the camfollower using a screw driver blade or

cartridge wrench 240-3037. When thescrews are tightened in the cartridge,recheck the setting with the .02 mm shimto ensure a free movement of the shim.

screws to securely lock the cap in place.Do this in at least four steps so as not to

skew or misalign cap.

Repeat this procedure for all camfollowers.

When all shuttles have been installed onthe deck, recheck with the .02 and .05shim, correcting as required.

5. With screws torqued from previous step 5,check again that: (See Figure 2.61.1, for torque requirements).

FIGURE 2.56.3: METHOD B

1.1830 mm

CAM FOLLOWER

TYPICAL FRONT

OR R EAR

SHIM STOCK




1. Carefully remove the cap from the camfollower assembly and place the housingwith the integral shaft and rollers into the pillow block. It is critical that the hole "A"

be on same side of the pillow block denoted by "X" on the pillow block face.(Figure 7.5.20).

2 Assemble cap (1) to installed cartridge

NOTE

Use Loctite 222 on screw threads.

6. Adjust the radial clearance to the shuttle



2. Assemble cap (1) to installed cartridgeassembly, taking care that thrust washer (6), is in the proper position.

3. Assemble four M6 screws (7) and ribbed

washers (8) through pillow block (10) andthread into cap (1). Do not torque screwsat this time.

NOTE

Use Loctite 222 on screw threads.

4. Clean mounting faces of both pillow block and rotor pad. Check that the two locating pins (9, Figure 7.5.20) are in place.Assemble pillow block (10) to rotor pad,making sure that the oil hole in both rotor and pillow block is free of dirt and grease.

5. Assemble four M10 socket screws (21, Figure 7.5.19) together with lockwashers(22) and sequentially tighten these screwsto 55-60 ft-lbs (75-81 Nm) torque.

cam track following the same procedure asthe front cam followers assembly (Figures2.56.2 and 2.56.3). Torque the four M6screws to 22-24 ft-lbs (30-33 Nm) to clamp

the cap to the cartridge.7. Check for proper function of the bearing

assembly following step 6, paragraph2.56 , of the front cartridge units.

2.60. R OTOR GEAR . (Figure 7.5.19) The rotor gear (2) is attached to rotor frame (1) with M8

socket head screws (17) and is timed atmanufacture with the dowel pin (12). Rotor gears are numbered to the rotor frame. Everyrotor gear is identical to another, butnecessitates a custom timing when affixed toanother or new rotor frame.

2.61. R EMOVAL OF R OTOR GEAR FROM R OTOR FRAME. Remove eight M8 (17) sockethead screws from the rear of the rotor and tapthe rotor gear off the rotor frame and the M10dowel pin. The dowel pin may or may notcome out with the gear.


0.020.050.45 MAX

0.05 MINTORQUE

45 - 50 FT. LB.61 - 68 Nm



TORQUE20 - 35 FT. LB.27 - 47 Nm

TORQUE

25 - 30 FT. LB.34 - 41 Nm

TORQUE65 - 70 FT. LB.88 - 95 Nm

0.45 MAX0.05 MIN

TORQUE11 - 12 FT. LB.15 16 N

TORQUE11 - 12 FT. LB.15 16 Nm

TORQUE

55 - 60 FT. LB.75 - 81 Nm

A

A

B

B

SHIM A/R TO OBTAIN.01 TI .05 E ND PLAY

0.020.05




2.64. PLANETARY GEARS. (Figure 7.5.19)

• Major Planetary Gear Index No. 7

• Minor Planetary Gear Index No. 6

• Planetary Shaft Index No. 4

R l f ith j i l t

bearings. Then slide spacer (5) over shaftand continue to slide shaft into hole inrotor flange per Figure 7.5.19.

3. With the shaft fully seated into the bearingsand against the shoulder, check for freeturning of the bearings, then drill a 6 mmdiameter hole for the roll pin (11, Figure7.5.19).



Removal of either major or minor planetarygears is accomplished with the rotor removedfrom the rotor axle.

1. Rotor gear (2, Figure 7.5.19) is removedfrom the rotor frame (1).

2. The needle bearing outer race (3-3, Figure7.5.21) is removed from the rotor frame.

3. The roll pin (11, Figure 7.5.19) is drivenfrom planetary shaft (4).

4. Remove the planetary shaft.

5. Remove planetary gear (6 or 7) together with its ball bearings (18), spacer (5) andsnap rings (19) from the rotor frame.

2.65. ASSEMBLY OF PLANETARY GEARS.

(Figure 7.5.19) If a new gear is required, the bearings and planetary shaft must be replacedalso.

Assembly of a new planetary gear, new ball bearings, and new planetary shaft within thesame rotor frame:

1. Insert two retaining rings (19) into thegrooves within the bore of the gear (7) or (6). Press and seat ball bearings within the bore and against the retaining rings by

i l f h b ll

7.5.19).

4. Drive the roll pin (11) into the rotor frame(1) and through the planetary shaft (4) asshown in Figure 7.5.19.

5. Check, by turning the planetary gear byhand, to see that the bearings are free andsmooth in rotation and that the axial play isless than .3 mm. If tight or with no axial play, remove the pin and face the shoulder of the planetary shaft to attain axialclearance and repin to the same hole.

6. Reassemble the rotor gear and press theouter race of the needle bearing (3-3, Figure 7.5.21) into its original position. If the outer race is loose remove it, stake theedges of the rotor frame adjacent to thehole, sparingly apply Loctite #442 to theoutside diameter of the outer race and tapgently into place using a plastic tool.

2.66. R OTOR BEARINGS. The bore of the rotor housing contains two radial type roller bearings for mounting to the rotor axleassembly.

2.67. R EAR R OTOR BEARINGS. The type NAO 80 x 110 x 30 mm three-part bearing isthe basic bearing for rear rotational guidanceof the rotor assembly to the rotor axle


caged rollers (3-2) which are held to the rotor axle by a ring (10) (Figure 7.5.21). The outer race of this bearing is (3-3), Figure 7.5.21, andis installed in the rotor frame.

Replacement of any one of the threecomponents will be cause to replace all three parts. This bearing is to be treated as amatched set This is one reason for a rotor

2.69. GUIDE K EY. The function of a guide keyis to engage with the shuttle assembly to retainthe shuttles in proper axial location.

While direct interchangeability of parts exists,three concerns will require care inreplacement:



matched set. This is one reason for a rotor assembly being paired with a specific rotor axle assembly.

2.68. FRONT R OTOR BEARING. The frontradial roller bearing is of a two-part design.The inner ring (4) is shown on rotor axleassembly (Figure 7.5.21). The outer portionconsists of an outer race (4-1) with integralrollers (4-2) installed in the rotor frame.

This bearing is automatically lubricated from

the rotor axle lubrication system.

Replacement of either inner race or outer raceis cause for the replacement of both races.

• M6 screws (13, Figure 7.5.19) are securelytorqued and Permatex applied to thethreads to prevent loosening due to vibra-tion upon assembly.

• A check must be made to assure that therotor guide key allows the shuttle a mini-mum of .05 mm axial play or movementduring transfer between adjacent rotors anda maximum of .45 mm axial play when notin transfer.

• Special off-set keys are available from MIIto obtain these clearances. These specialkeys are marked with an "X" to the off-setside.

SECTION XII. ROTATING PREFORM PIN (OPTION)

2.70. R OTATING PREFORM PIN. The purposeof the rotating preform pin is to put a curl inthe wire being braided with a minimum of coldworking of the wire and its coating. The actual

amount of curl will vary, depending on the

number of ends, tension and type of wire beingused.

Different threading paths will producedifferent amounts of curl in the wire.

3-CONTROLS

CHAPTER 3CONTROLS

STURING


EINFÜHRUNG



INTRODUCTIE

3.1. GENERAL. This section deals with thegeneral function of the electrical system anddescribes its major parts.

3.1. GENERELL: Hier wird generell dasElektrische System beschrieben, mit denHauptteilen.

3.1. ALGEMEEN. Dit gedeelte behandelt dealgemene functies van het electrische systeemen beschrijft de voornaamste onderdelenhiervan.

3.2. EMERGENCY STOP CIRCUIT: Thiscircuit takes away all power from the Inverter

and Main Motor. Please note that the blowersand oil pump are not included in this circuit,only the main disconnect will disable those.The main components of the E-Stop circuit areall of the Emergency Stop Mushroom buttons,all gearbox doors, the main motor doors, motor starters for the main motor and oil pump, green backlit pushbutton on the main control cabinet

and the Emergency Stop Safety Relay.In order to engage the Emergency stop circuit,the green button must be pushed. If all safeties

3.2. STROMKREIS AUSFALL IN EINEM NOTFALL R OTER STOPKNOPF: Der Stromkreis fällt aus vom Inverter und demHauptmotor. Das Gebläse und die Ölpumpesind in dem kreis nicht angeschlossen, undmüssen extra ausgeschaltet werden. Beimauslösen des Notschalter Roter Stopknopf – sind folgende sicherheitsvorkehrungen imStromkreis mit eingeschlossen. Alle roten

Notschalter, Getriebekastentüren,Hauptmotortüren, Starter für Hauptmotor undÖlpumpe, grüner Knopf am Hauptschaltkastenund Notschalter Sicherheits Relais.

Um die Maschine wieder zu starten, der grüneKnopf muss eingedrückt werden. Wenn alleroten Notschalter nicht eingedrückt sind, wird

das grüne Licht Leuchten. Der Inverter istwieder unter Strom, und die Tip und StartKnöpfe wieder frei zum Laufen lassen. Sollteder Stromkreis grundlos ausfallen, den grünenKnopf nochmals eindrücken.

3.2. NOODSTOP CIRCUIT. Dit circuit shakeltde stroom naar de frequentieregelaar en

hoofdmotor uit. De ventilators en oliepompzijn niet opgenomen in dit circuit en kunnenalleen met de hoofdschakelaar afgezetworden.

3-CONTROLS

De hoofdcomponenten van het Nood-stopcircuit bestaan uit : de noodstop ‘paddestoelvormige noodstop drukknoppen, dedeurenbeveiligingen van de tandwielkasten en

van hoofdmotor, de startknop van dehoofdmotor en de oliepomp, de groenedrukknop op het centrale sturings kast en denoodstop veiligheidsrelais.

Stromkreis sind Stop, Start und Tip Kontakte.Relais ausschalten für alle andern stops undSicherheitsschalter der Gehäusetüren. Der Kreis Kann wieder geschlossen werden mit

Knopfdruck auf Start oder Tipknopf. Wennalle andern Stops O.K. sind schliessen dieRelais und geben das OK Signal zum Inverter.Eins von den 3 Geschwindigkeitssignalen wirdzum Inverter gesandt. Bitte beachte das all



Om het noodstop circuit in te schakelen moetde groene drukknop ingedrukt worden.

Als de veiligheid in orde is en er is geen Noodstop drukknop ingedrukt dan zal er eengroen licht oplichten, de frequentieregelaar zaldan stroom nemen en de Run/Jog drukknoppenzullen ingeschakeld worden. Als het Noodstopcircuit uitvalt, zal de groene drukknop terugingedrukt moeten worden.

3.3. STOP CIRCUIT. This circuit is responsiblefor normal stops on the machine. The main parts of this circuit are the stop buttons, Run/Jog contacts, enable relay for all other stopsand the enclosure locks. This circuit is engaged by actuating the run or jog switch. If all other stop motions are OK then the relay will closeand the inverter enable signal will be turned

on. One of 3 speed-enable signals will also besent to the inverter (see Section 1.14). Pleasenote that all of these stop functions except thestop buttons themselves and the door interlocks can be bypassed by actuating the jogswitch. As soon as the switch is released thosestop motions become active again.

3.3. STOP STROMKREIS: Dieser Stromkreis istverantwortlich für die normalen Stops der Maschine Die Hauptteile von diesem

gdiese stopfunktionen ausser den Stopknöpfenund den Sicherheitsschaltern an denGehäusetüren überbrückt werden Könnendurch aktievieren des Tipknopfes. Sobald der Tipknopf Losgelassen wird sind alleStopfunktionen wieder aktiv.

3.3. STOPCIRCUIT. Dit circuit isverantwoordelijk voor de normale stops van demachine. De voornaamste onderdelen van ditcircuit zijn: de stop drukknoppen, Run/Jogschakelaars, de inschakelingsrelais voor alle

andere stop signalen en het vergrendelen vande vlechtcabine. Dit circuit zal ingeschakeldworden door het activeren van de run of jogschakelaar. Als alle andere veiligheidssignalenOK zijn kan de relais zich sluiten en hetinschakelsignaal van de frequentieregelaar zaloplichten. Eén van de 3 snelheidsschakelingssignalen zal dan naar de frequentieregelaar

gestuurd worden (zie section 1.14).

Notea: Al deze stop functies uitgezonderd destop drukknoppen zelf en dedeurvergrendelingen kunnen “omzeild”worden door de jog schakelaar te activeren.Van zodra de Jog knop gelost wordt, wordenalle stop (veiligheids-)mechanismen terug

actief worden.

3-CONTROLS

SECTION II. OPERATOR INTERFACE

OPERATOR BEDIENINGSVOORZIENINGEN (INTERFACE)

3.4. CONTROL LOCATIONS. The controls arethe same for each deck so a single or tripledeck would be similar. Figures 3.5.1, 3.6.1 and3.7.1 show the face of each control box.

3.5. OPERATOR HOOFDBEDIENINGSKAST.Fig. 3.5.1 laat de voorzijde van de centralesturingskast zien. De selectieschakelaar laat deoperator toe te schakelen tussen “jog” of “run”van het deck



3.4. STAND DER K ONTROLLANLAGE: DieKontrollanlage ist gleich für alle Decks, so das

sie gleich aussieht für eine Anlage 1 - 2 - oder 3 Decks.

3.4. BEDIENINGSLOCATIES: De bediening ishetzelfde voor elk van de decks. Tekening3.5.1, 3.6.1 en 3.7.1 laten het uitzicht zien vande verschillende bedieningskasten.

3.5. TERMINAL BOX. Figure 3.5.1 shows theface of the Terminal Box.

The selector switch allows the operator to jogor run the deck/s. The red Stop button isnormally used to stop the machine. See section3.3 for information on the stop circuit.

The red mushroom pushbutton is theEmergency stop button. See section 3.2 for adescription of what this circuit does.

3.5. ERSTER SCHALTKASTEN: Die Abbildung3.5.1. zeigt die Vorderansicht desSchaltkasten’s.

Der Wahlschalter Tip – Start erlaubt demArbeiter die Maschine auf Tip. Oder auf StartLaufen zu Lassen. Der Rote Stop Schalter istnormal dazu da um die Maschine zu stoppen

van het deck.

De rode stopknop wordt gebruikt om demachine op normale manier te stoppen. Zie

sectie 3.3 voor meer informatie betreffende hetstop circuit.

De rode ‘paddestoel’ drukknop is de noodstop.Zie sectie 3.2 voor de beschrijving van dewerking van dit circuit.

3.6. R EMOTE OPERATOR BOX. Figure 3.6.1

FIGURE 3.5.1: TERMINAL BOX

Erster Schaltkasten

hoofd bedieningskast

3-CONTROLS

3.6. OPERATOR SATELIETBEDIENINGSKAST.Fig. 3.6.1 laat de voorzijde van desatelitebesturingskast zien. Deze is functioneelidentiek aan de centrale bedieningskast.

CAUTION

Never open the main control box without turning off the main power disconnect



3.7. MAIN CONTROL BOX. The main control box contains the entire electrical system for themachine. All active electrical componentsexcept for the display and digital stop circuitare located here. The following switches are

also located here:1. MAIN POWER SWITCH - This switch will

disable all electrical power within the

3.7. HAUPTSCHALTKASTEN: ImHauptschaltkasten Kommt das gesammteelektrische system für die Maschine

zusammen. Alle elektrischen aktivenKomponenten, ausser der Anzeige und desDegitalen Stop Stromkreises sind hier vorhanden.

1. Hauptschalter – Der Hauptschalter legtdas ganze elektrische system der Maschinelahm, ausser am unteren Ende wo das

Hauptkabel zur Maschine Kommt.

WARNUNG

Öffne niemals den

Hauptschaltschrank ohne das der Strom abgeschaltet ist. 3.7.1.Hauptschaltschrank.

3.7. HOOFDSTURINGSKAST. Dehoofdsturingskast bevat het ganse electrischesysteem voor de vlechter. Alle electrischecomponenten, behalve de display en het

digitale stop circuit, bevinden zich hier.

Ook de volgende schakelaars bevinden zichhier:

FIGURE 3.6.1: R EMOTE OPERATOR BOX

Remote Schaltkaste

sateliet bediengskast

3-CONTROLS

!! De hoofdsturingskast nooit openen zonder dehoofdschakelaar op “uit” te zetten.

of the safety system, button 1 must be pressed followed by button 2 while the first button is still engaged. Releasing either button will stop the machine. Both buttons

must be released before the procedure can be repeated to jog again.

3. EMERGENCY STOP BUTTON. Pressingthis button will disable all switches thatcan start the machine Twist to release this



3.8. INSIDE JOG STATION. This station allowsthe machine to be JOGGED (run at a reducedspeed) from within a deck. It contains 3 buttons:

1. SAFETY SWITCH. In order to run themachine from inside a deck, the safety

switch within that deck must be switchedon (the lit position). If this switch is on, themachine can be jogged, but only from thisstation The door locks for that deck are

can start the machine. Twist to release this button.

CAUTION

When working in a deck alwaysturn the switch to “ON”. This will

prevent someone who does not know there are personnel in theenclosure working on the braider from accidentally jogging or running it. Failure to follow this

procedure can lead to personnel injury.

3.8. TIP SCHALTKNOPF IN DER MASCHINE:

1. SICHERHEITSSCHALTER. Um dieMaschine von Innen Laufen zu Lassen,muss der Sicherheitsschalter auf “ein”gelegt werden. Jetzt Kann die Maschinevon Innen Langsam auf Tip Laufengelassen werden. Die Sicherheitsschalter für die Türen sind überbrückt.

2. TIP SCHALTER. Bei drücken desTipschalters setz sich die Maschine in bewegung wenn der Sicherheitsschalter auf “ein” gelegt ist.

FIGURE 3.7.1: MAIN CONTROL BOX

Hauptschaltkastencentrale sturingskast

3-CONTROLS

WARNUNG

Wenn am Deck gearbeitet wird,immer den Sicherheitsschalter auf ein Legen – in diesem fall Kann

AANDACHT!

!!!Om ‘te werken in een deck’ zet de schakelaar altijd op “Aan” zetten Dit zal vermijden dat



Keiner von aussen die MaschineLaufen Lassen. Nur so Kann einunfall verhindert werden.

3.8. JOG STATION IN DE VLECHTER . Dit laatde machine toe om te joggen van in de deck (werkt aan lage snelheid) en heeft 3drukknoppen:

1. Veiligheidsschakelaar. Om de machine telaten werken van binnen de cabine moet de

veiligheidsschakelaar in die deck ingeschakeld worden . Als deze schakelaar aan staat kan de machine joggen, maar enkel vanaf dit station. Ook dedeurvergrendeling voor betreffende deck isdan uitgeschakeld

2. Jog drukknop. Door deze drukknop in tedrukken zal de machine joggen als deveiligheidsschakelaar voor die deck is in positie “aan” staat.

3. Noodstop drukknop. Door deze drukknopin te drukken worden alle schakelaars diede machine kunnen starten uitgeschakeld.Draai aan deze drukknop om hem terugvrij te maken.

zetten. Dit zal vermijden dat iemand anders per ongeluk zal

joggen of de machine in werking stellen terwijl er een ander

persoon ‘binnen in de machine’ zit. Door deze procedure niet tevolgen kunnen er ongelukkengebeuren.

FIGURE 3.8.1: INSIDE JOG STATION

2 1

3A - PLCT-F CONTROLS

CHAPTER 3APLCT-F CONTROLS


3A.1. GENERAL. This section deals with thegeneral function of the electrical system anddescribes its major parts.

in place and no E-stop button is currentlyactive then the green light will come on,Inverter will power up and the Run/Jog buttonswill be enabled. If the E-stop circuit ever drops



3A.2. EMERGENCY STOP CIRCUIT: This

circuit takes away power from the invertersand drive motors. Please note that the blowersand oil pump are not part of this circuit, onlythe main disconnect will disable those. Themain components of the Emergency Stopcircuit are the Red Mushroom buttons, thePLC located in the enclosure with the display,the safety relay and the motor starters for thedrive motors and oil pump.

Note that if the emergency-stop button is usedto stop the machine, power is immediatelyremoved from the inverters and motors so themachine will not come to a synchronized stop.The braid at that point will be defective.Inorder to engage the Emergency stop circuit, thegreen button must be pushed. If all safeties are

p pout, the green button will have to be pressedagain.

3A.3. STOP CIRCUIT. This circuit isresponsible for normal stops on the machine.The main parts of this circuit are the stop buttons, Run/Jog contacts, enable relay for allother stops and the enclosure locks. Thiscircuit is engaged by actuating the run or jogswitch. If all other stop motions are OK thenthe relay will close and the inverter enablesignal will be turned on. Please note that all of these stop functions except the stop buttonsthemselves and the door interlocks can be bypassed by actuating the jog switch. As soonas the switch is released those stop motions become active again.


SECTION II. OPERATOR INTERFACE

3A.4. CONTROL LOCATIONS. The controls arethe same for each deck so a single or tripledeck would be similar. Figures 3A.5.1, 3A.6.1and 3A.7.1 show the face of each control box.

3A.5. TERMINAL BOX. Figure 3.5.1 shows the

3A.6. R EMOTE OPERATOR BOX. Figure3A.6.1 shows the face of the Remote Operator Box. It is functionally identical to the PrimaryOperator Box.



3 .5. N O . igu e 3.5. s ows t eface of the Terminal Box.

The selector switch allows the operator to jog

or run the deck/s. The red Stop button isnormally used to stop the machine. See section3A.3 for information on the stop circuit.

The red mushroom pushbutton is theEmergency stop button. See section 3A.2 for adescription of what this circuit does.

FIGURE 3A.5.1: TERMINAL BOX

FIGURE 3A.6.1: R EMOTE OPERATOR BOX


3A.7. MAIN CONTROL BOX. The main control box contains the primary power systems,hauloff motor and the inverter drives for themachine. All active electrical componentsexcept for the display and the ProgrammableLogic Controllers (PLCs) responsible for thedeck IO are located here.

1. MAIN POWER SWITCH - This switch will



disable all electrical power within themachine E XCEPT : the input wires leading to the main power switch and the bottom

terminals on this switch.

CAUTION

Never open the main control box without turning off the main power

disconnect.

There are 3 switches that are located on themain control box These can be used to turn off

CAUTION

Be sure to follow proper lock out / tag out procedures if theseswitches are used to turn off amotor.

CAUTION

These switches do NOT power down the individual inverters just

FIGURE 3A.7.1: MAIN CONTROL BOX

FIGURE 3A.7.2: MAIN CONTROL BOX

STAND ALONE


3A.8. INSIDE JOG STATION. This stationallows the machine to be JOGGED (run at areduced speed) from within a deck. It contains3 buttons:

1. SAFETY SWITCH. In order to run themachine from inside a deck, the safetyswitch within that deck must be switchedon (the lit position). If this switch is on, the

CAUTION

When working in a deck alwaysturn the switch to “ON”. This will

prevent someone who does not know there are personnel in theenclosure working on the braider



machine can be jogged, but only from thisstation. The door locks for that deck arealso disabled.

2. JOG BUTTONS. There are two buttonsthat must be pushed to jog the braider fromthe internal control station. They arelabelled buttons 1 and 2 in FIgure 3.8.1. Inorder to prevent short circuits or bypassingof the safety system, button 1 must be pressed followed by button 2 while the first

button is still engaged. Releasing either button will stop the machine. Both buttonsmust be released before the procedure can be repeated to jog again.

3. EMERGENCY STOP BUTTON. Pressingthis button will disable all switches thatcan start the machine. Twist to release this button.

enclosure working on the braider from accidentally jogging or running it. Failure to follow this

procedure can lead to personnel injury.

FIGURE 3A.8.1: INSIDE JOG STATION

2 1

4A-ELECTRICAL SYSTEM - COLOR TOUCHSCREEN

CHAPTER 4AELECTRICAL SYSTEM - COLOR TOUCHSCREEN

SECTION I. GENERAL DESCRIPTIONS

4A.1. GENERAL. The MR-11/MR-15 PLCT-Felectrical system provides safe and convenientcontrol of the Braidmatic Machine for theoperators as well as devices to monitor the

independent unit that can be attached to anyhauloff. Also included is a main controlcabinet that can be attached to the outside of the braider enclosure.



operators, as well as devices to monitor thequality of the braided product.

The MR-11/MR-15 PLCT-F electrical systemincludes prewired enclosures, switches, alarm panels, pushbutton stations, etc. The units arefactory assembled, adjusted and installedtogether with harnesses for convenientassembly.

The system is designed as a modular systemfor the control and operation of one or more

decks and one haul-off unit. Each is an

The system includes all electrical componentsand wiring to install and operate the PLCT-F.

The system does not provide for wiring the plant electrical power to the machine or for running the power to the fluorescent lightswitch.

See Chapter 10, Electrical schematics for theschematic diagram of the PLCT-F electricalsystem for one or two decks. Schematics for a3-deck version are provided as needed.

SECTION II. SYSTEM DESCRIPTIONS

4A.2. MAIN SCREEN. This is the defaultstartup and main run screen for the braidingmachine. The current speeds for the hauloff

and each deck are displayed when the machineis running. In case of a stop motion, the reasonfor the stop is shown. Below is a breakdown of the information that is shown on this screen.

1

2


1) This is the operation information area.When creating a recipe, if data was enteredinto the 3 information strings for therecipe, these are shown here.

2) These buttons are used to access differentscreens

3) Reverse button and Hauloff Speed - Pressthis button to enable ‘reverse’ mode. In thismode the braider will run in reverse Only

Jog is enabled in this mode. If the hauloff is running, the speed will be shown here.On a drive shaft system, the productionrate cannot be shown so the number that isdisplayed is an aggregate of motor speed.On a dual drive system, the actual production rate of the hauloff is shown.

4) Speed and Pitch control – The machineoperator can access a screen to set the

d d it h h S ti 4 7



mode, the braider will run in reverse. Only speed and pitch here. See section 4.7.

1) Error display area – Any currently activeerrors are displayed here. A maximum of two errors can be displayed at a time. Mosterrors warnings will disappear once the

3) PLC warning – This triangle appears if themain PLC is not in it’s normal operatingmode. When rebooting the system, it maytake several minutes before the PLC is

FIGURE 4A.2.2: MAIN DISPLAY SCREEN WITH ERRORS

1

2

3


Under ‘View Data’, one can access the ‘AlarmHistory’ and ‘Warnings’ screens. Here, onecan see a list of the last 500 errors andwarnings. For each entry, you will see an error number, the time and date that the error occurred, the status, and a text stringdescribing the error.

Note that each error and warning is displayedtwice. Status -C shows when the error occurs.S C h h h

Warnings



Status –CD shows when the error wascanceled.

Most errors will be cancelled as soon as thePLC input for that error changes back to it’snormal state. There are however severalexceptions to this. For example, the ‘BobbinRunout’ error and some of the customer options are static errors. These areautomatically reset the next time the machineis run.

Alarm History

This screen will show a log of several inputsthat are not considered stop motions. The mainuse for this screen would be for troubleshooting. For example, the stop buttonsare normally closed contacts so a loose wire onone of the stop buttons may cause randomstops of the braider. This screen can be used totrack such random signal interrupts.

See appendix 1 for a list of all Alarms and Warnings that are logged by the system.

4A.4. PRODUCTION LOG AND GRAPH. Thisscreen is accessed through ‘View Data’->’Production Log’

On a dual drive system, the information shownis the production rate of the machine. On a

drive shaft version, the data shown is anaggregate of motor RPM. The buttons at the bottom of the screen can be used to browse and

th h th d ti d t If li i

FIGURE 4A.3.1: ALARM HISTORY

FIGURE 4A.3.2: WARNINGS


4A.5.1. CREATING R ECIPES.



The data itself is stored in a memory card plugged into the display. The data file can befound under ‘My Computer->Storage CardMMC->Logs->Run Time0’ The data is stored

in a generic CSV format that can be read intoany spreadsheet or database. Data is storedonce per minute and the following informationis saved:

ProductionRate is the production rate of thehauloff or the motor speed in a drive-shaftversion. P_Counter1 and P_Counter2 are thetwo production counters shown on the left sideof the main screen.

The data file will hold approximately one

month worth of data, and the system willautomatically save the last 12 data files. So, if applicable, the memory card contains data for the previous year.

This screen is accessed through the main menuand is used to define recipes for the braider.

Recipes include the following information:1. Pitch /Lead for each deck. - The back deck

is defined as the deck furthest from thehauloff. In case only one deck is used for arecipe, set the pitch of the unused deck to be the same as the other one. This willenable the recipe to be run with either deck active.

2. Maximum allowed speed – This is themaximum speed that a deck is allowed torun for a given recipe. The minimum deck speed is always 100 Rotor RPM and themachine operator may select any speed between 100 and maximum speed set inthe recipe.

3. Information strings – These entries are purely for information purposes, the text isdisplayed at the top of the main screen

FIGURE 4A.4.1: PRODUCTION GRAPH

ProductionRate 10/9/2010 2:08 0.244011 1

P_Counter2 10/9/2010 2:09 2071.276 1

P_Counter1 10/9/2010 2:09 40.8735 1

FIGURE 4A.5.1.1: CREATING R ECIPES


Note that if one wishes to run without usingrecipes, simply create a recipe with themaximum speed, a lead of 100 and an adjust of 100%. This will allow the entry of any pitch between the minimum and 200 millimeters andthe setting of any speed between 100 and themaximum.

4A.5.2. LOADING R ECIPES.

Th f ll i i d th h th

4A.6. TROUBLESHOOTING.

The 5 troubleshooting screens can be accessedthrough the main menu.

4A.6.1. IO STATUS. This screen displays thestatus of all of the inputs and outputs in thesystem. Note that this information is from the perspective of the main PLC located in thedisplay If there is a communications problem



The following screen is accessed through the‘Load Recipe’ button on the main screen. Notethat the braider will stop automatically whenyou enter or exit this screen. Only recipes thathave already been created through the recipeeditor can be loaded.

There are two ways to access a recipe. The ten buttons on the left will show the currentlyactive recipes. The name of the recipe is shownin the button text. Pressing one of these will

load the recipe. The user can browse a total of 100 recipes, the ‘Pg Up’ and Pg Down’ buttonswill switch between different sets of tenrecipes. The other way to load a recipe is toenter the number of the recipe directly in thefield on the top right.

The “Current Selection’ box will show the

information for the currently active recipe.

.

display. If there is a communications problem between it and the remote IO, it’s possible thatthese screens would not match the actual status

of the remote IO. Inputs are shown in greenand outputs are shown in red.

The question mark beside each PLC will showa list of all the inputs and outputs for that PLC.

4A.6.2. PROFIBUS STATUS.

This screen shows the status of thecommunications with the different

FIGURE 4A.6.1.1: IO STATUS


profibus address for that component was notfound. Note that all braiders do not necessarilyhave all of these components.

4A.6.4. DRIVE STATUS.

This screen shows information about thedrives/inverters in the braider. The status worddisplays the current status information of thedrive.

The speed is the current drive speed in Hertz.The torque is the current torque of the drive.These two numbers are approximations thatare dependent on the motor configuration



4A.6.3. PLC STATUS.

This screen shows the status of the PLC that isintegrated into the touch panel. No changesshould ever be made here. Note that on a singledeck braider, it is normal for the fault LEDs to blink red since the profibus components for thesecond deck are not active in the system. Thishas no affect on the operation of the braider.

are dependent on the motor configuration parameters.

4A.6.5. TORQUE SETTINGS. This screen isaccessed through the Drive status screen. Onecan set a maximum and minimum torque for each motor. If these limits are exceeded, the braider will stop with an error.

Maximum torque can be set to approximately

150%, any number higher than that and amotor stall is ignored. The minimum torquesetting can be used to check for something

h b k b lt th t If th

FIGURE 4A.6.2.1: PROFIBUS STATUS

FIGURE 4A.6.4.1: DRIVE STATUS


The torque limits are ignored while the braider is jogging and while it is accelerating to it’soperating speed.



4A.7. SPEED AND LEAD ADJUST SCREEN.This screen is accessed through the main runscreen and is used to make adjustments to theinformation in a recipe. The pitch from arecipe can be adjusted by the machine operator up to the limit that was set in the ‘maximumadjust’ of the recipe. In the screen shown below, the recipe allows a 10% variation to the base pitch of 25mm.

The speed of the braider can also be set here,limited by the maximum speed set in therecipe. If two decks are running at differentspeeds, the set speed is determined by thefastest deck.

4A.8. COUNTERS AND OPTIONS.

Customer options are inputs reserved for

customer-specific stop motions.

The screen is accessed from the main screenthrough the button shown below.

FIGURE 4A.6.5.1: TORQUE SETTINGS

FIGURE 4A.7.1: SPEED AND LEAD ADJUST


If the color of the button is Orange, it indicatesthat one or more of the customer options have been disabled.

Windows are available for setup andconfiguration of the basic system.



The two reset buttons at the top of the screenare used to set the production counters back tozero. The buttons at the bottom of the screenare used to enable or disable specific stopmotions. A ‘red’ button indicates that the stopmotion will be ignored and a ‘green’ buttonindicates that the stop motion is active. For allstop motions, current must be flowing for thestop to be recognized so it is not necessary todisable stop motions that are not wired on aspecific braider.

4A.9. SYSTEM FUNCTIONS.

The system functions are accessed through themain menu. From here you can calibrate the

touch screen or exit the main program to thewindows CE desktop. Most of the standardsystem functions from the desktop versions of

4A.10. OTHER SCREENS.

Two other screens of note are availablethrough the main menu.

4A.10.1. SETUP SCREEN.

This screen shows the basic machine

parameters; type of machine (MR11 or MR15)and number of carriers. These parameters areset in the main PLC program (DB2). Thisscreen also allows you to set a password. If the password is set to any number other than 0,that password must be entered to access themain menu. If you forget a password, thedefault password of 2112 will always allow

access to the main menu.

The time and date can also be set in this screen.

FIGURE 4A.8.1: COUNTERS AND OPTIONS FIGURE 4A.9.1: SYSTEM FUNCTIONS


4A.10.2. BLOWER .

This screen configures when the blowers,located at the top of the main enclosure, willturn on. There are three possible settings.

I= always on.

Auto = Blower turns on when the braider isrunning

4A.11. BLOWER ASSEMBLY. The blower assembly is located on top of the AccousticalEnclosure. It is intended to provide ventilationfor the interior of the Accoustical Enclosure. If

the blower is not running while the braider isin operation, temperatures inside the enclosurewill rise to levels that are dangerous to personnel and detrimental to the performanceof the braiders.



O = always off.

CAUTION

Before attempting any repair work,be certain that all power to themotor and electrical accessoriesare turned off and locked in the"off" position.


4A.11.1. BLOWER ASSEMBLY INSTALLATION.

STEP NO. 1

MOUNT FAN I NSIDE HOODUSING M6X12mm HEX HEAD

CAP SCREWS W/ FLAT AND

LOCK WASHERS

R UN FAN WIRESTHRU 7/8"DIA. HOLE



STEP NO. 4

STEP NO. 5

STEP NO. 2

STEP NO. 3MOUNT I NLET BELL COLLAR

AND BRACKET TO HOOD

USING M6X20mm HEX HEAD

CAP SCREWS W/FLAT AND

LOCK WASHERS

IMPELLER FAN

MOUNT I NLET BELL

COLLAR TO BRACKET

W/M8X20mm HEX HEAD


LOCK WASHERS AND

HEX NUTSI NLET BELL COLLAR

SECURE BRACKET

TO FILTER BOX

M6X20mm HEX HEAD

CAP SCREWS W/FLAT

AND LOCK WASHERS

SLIDE FILTER BOX

O NTO COLLAR MOUNT

BRACKET


2 5 6 1



FIGURE 4A.11.1.2: BLOWER ASSEMBLY

FILTER SLIDES INFROM END

74

3

FIG. &

INDEXNO.

PART NO. DESCRIPTIONUNITSPER ASM.

4A.11.1.2 BLOWER

1 S-5707 HOOD 1

2 S-5708 I NLET BELL MOUNTING BRACKET 1

3 S-5709 FILTER BOX 1

4 S-5710 LIGHT FIXTURE MOUNTING BRACKET 2

5 S-5705 EXHAUST FAN 1

6 S-5706 I NLET R ING 1

7 S-4891 16" X 20" X 2" MESH FILTER 1

TABLE 4A.11.1.1: TROUBLE SHOOTING CHART FOR BLOWER

S YMPTON P OSSIBLE C AUSE ( S ) C ORRECTIVE ACTION

Noise 1. Foreign objects in housing.2. Incorrect wheel rotation.

1. Remove.2. Reverse rotation.


4A.11.2. OPERATION.

1. Before connecting the blower motor to the junction box cable, check the electricalcharacteristics as indicated on the motor nameplate to insure proper voltage and phase.

2. After electrical connections are completed,apply just enough power to start the unit.Be sure that the rotation of the wheel iscorrect as indicated by directional arrows

4. Relubricate the motor per themanufacturer’s instructions. Remove anyexcess lubricants from the housing and blower assembly.

CAUTION

A ground wire must run from theblower motor housing to a suitable



correct as indicated by directional arrowson the unit. If rotation is correct, apply full

electrical power.

3. With the air system in full operation and allducts attached, measure current input to themotor and compare with the nameplaterating to determine if the motor isoperating under safe load conditions.

4A.11.3. MAINTENANCE

.1. Periodically remove dirt from the blower

wheel, housing and ducts.

2. Check tightness of all set screws.

3. After disconnecting the power source,check the wiring to see if insulation is

damaged or frayed.

electrical ground such as a properly grounded metallic raceway or ground wire system.

5. Do not operate the fan with the shieldremoved.

CAUTION

Before attempting any repair work,be certain that all power to themotor and electrical accessoriesare turned off and locked in the off

position.


SECTION III. INVERTER PARAMETER LIST

4A.12. PARAMETER LIST. Parameter 3(access level) must be set to 3 in order to see

some of the parameters on this list.

P ARAMETER H AULOFF D ECK

100 0-50Hz; * 0-50Hz * 50/ 60 Hz – See Notes

1101.0 0 0 Starting Hz

1237 0 2 Brake enable



• Parameter 100, set this using the dipswitch on the Inverter, not through the parameter list.

• Parameter 1800 sets the carrier fre-quency for the motor. You can modifythis if the motor is making a high pitch

noise when running. There is no ‘stan-dard’ setting so you have to try differ-ent values if you want to change it.

1470.0 Do not modify 6.0 Feedback loop

1472.0 Do not modify 100 Feedback loop1800 2-16 (default 4) * 2-16 (default 4) * Carrier Freq. - See notes

2106 2829 2829 Motor Overload, bug fix


2801.9 1 1 Motor Overload, bug fix

2828 2198.6 2198.6 Motor Overload, bug fix


SECTION IV. ELECTRICAL CABLE INSTALLATION LOCATIONS

4A.13. TERMINAL BOX PANEL TO R EMOTE OPERATOR STATION. Reference Figure

7.5.48.

Remote Operator



T e r m

i n a l

B o x

Remote Operator BoxRemote Operator

Station Cable


4A.14. TERMINAL BOX PANEL TO INSIDE JOG BOX. Reference Figure 7.5.40.



T e r m

i n a l

B o x

Inside Jog Box

Inside Jog

Run cable from Terminal Box Panel to floor. [Clamp two (2) times.]Run cable along front of Braider, under the drip pans to tunnel.Run cable under tunnel to bottom of sensor stand.

Station Cable


4A.15. TERMINAL BOX PANEL TO BOBBIN R UNOUT DETECTORS.

Bobbin RunoutD t t Wi



T e r m

i n a l

B o x

Run small black wire assembly (240-9065) from Terminal Box Panel to

Detector Wire


4A.16. TERMINAL BOX PANEL TO MAIN CONTROL BOX. Reference Figure 6.12.2.9.

Cables to MainC t l B



Control Box

Run two (2) cables from the Terminal Box Panel, up the inside of the enclosurell th h th ll i i th l ili

T e r m i n a

l

B o x

M a i n C o n t r o l B o x




4A.18. BLOWER CABLES.

BLOWER

1



FIGURE 4A.18.1: BLOWER CABLES

BLOWER

PANDUIT

CONDUIT

1

21

3

FIG. &INDEX PART NO DESCRIPTION

UNITSPER


4A.19. MOTOR CABLE R OUTING.



Run cable from Main Control Box up outside of enclosure wall, across

M a i n C o n t r o l B o x


APPENDIX 1:List of Alarms and warnings that are logged bythe system

DISCRETE ALARMS

T EXT A LARM

NUMBER A LARM CLASS T RIGGER TAG

T RIGGER

BIT

NUMBER

Drive Error: Hauloff 1 Basic Alarms MainErrors 0

Drive Error: Front Deck 2 Basic Alarms MainErrors 1



Drive Error: Back Deck 3 Basic Alarms MainErrors 2

Low Oil 4 Basic Alarms MainErrors 3

Safety Cover Hauloff 5 Basic Alarms MainErrors 4

Broken Braid: Front Deck 6 Basic Alarms MainErrors 5

Broken Braid: Back Deck 7 Basic Alarms MainErrors 6

Bobbin Runout: Front Deck 8 Basic Alarms MainErrors 7

Bobbin Runout: Back Deck 9 Basic Alarms MainErrors 8

Enclosure Door-Front Deck 10 Warnings MainErrors 9

Enclosure Door-Back Deck 11 Warnings MainErrors 10

Motor Overload: Lube Pump(Q2)

12 Basic Alarms MainErrors 11

Motor Overload: Blower (Q3) 13 Basic Alarms MainErrors 12Motor Overload: Main Drives(Q1)

14 Basic Alarms MainErrors 13

Emergency Stop 15 Basic Alarms MainErrors 14

Inside Jog Override 16 Warnings MainErrors 15

Bus Error 17 Basic Alarms MainErrors2 0

Stop Button 18 Warnings MainErrors2 1

Option 1 19 Basic Alarms MainErrors2 2


Hauloff Motor-TorqueLimit Exceeded

25 Basic Alarms MainErrors2 8

Hauloff Motor-MinimumTorque Error


Front Deck Motor-TorqueLimit Exceeded


DISCRETE ALARMS

T EXT A LARM

NUMBER A LARM CLASS T RIGGER TAG

T RIGGER

BIT

NUMBER



Limit Exceeded

Front Deck Motor-Minimum TorqueError


Back Deck Motor-TorqueLimit Exceeded


Back Deck Motor-Minimum Torque

Error







APPENDIX 2: R EMOTE ACCESS

Port settings for accessing the Multipanelthrough a router.

‘Server IP Address’ is the TCP/IP address of the Multipanel.



PORT SETTINGS




4-ELECTRICAL SYSTEM

CHAPTER 4ELECTRICAL SYSTEM

ELECTRISCH SYSTEEM

SECTION I. GENERAL DESCRIPTIONS

GENERELLE BESCHREIBUNG

ALGEMENE BESCHRIJVING

Where applicable, the error graphics shown



4.1. GENERAL. The MR-11 PLC-T electricalsystem provides safe and convenient control of the Braidmatic Machine for the operators, aswell as devices to monitor the quality of the braided product.

The MR-11 PLC-T electrical system includes prewired enclosures, switches, alarm panels, pushbutton stations, etc. The units are factory

assembled, adjusted and installed together withharnesses for convenient assembly.

The system is designed as a modular systemfor the control and operation of one or moredecks and one haul-off unit. Each is anindependent unit that can be attached to anyhauloff. However, the control box with the

touch screen display must always be set up onthe deck closest to the hauloff.

The system includes all electrical componentsand wiring to install and operate the MR-11PLC-T. The system does not provide for wiring the plant electrical power to themachine or for running the power to thefluorescent light switch.

See Chapter 10, Electrical schematics for theschematic diagram of the MR-11 PLC-T

pp , g p

below will also include the number of the deck where the error occurred. In the case whenmultiple error signals are active at the sametime, the order that the error messages aredisplayed is undefined.

4.1. GENERELL. Das MR-11 PLC-Telektrische system ist sicher und

bedienungsfreundlich für die BraidmaticMaschine. Es überwacht und garantiert das beste Qualitätsprodukt der Maschine. DasElektrische system ist in der Firma bestensvormontiert, eingestellt, kontrolliert undinstalliert um eine leichte aufstellung der Maschine zu versichern. Das System istentwickelt für 1 – 2 oder 3 Decks und eineAbzugsraupe zu Kontrollieren. Jedes Systemist unabhängig, und Kann an jede Abzugsraupeverwendet werden. Aber der Schaltkasten mitdem Touch screen display muss immer amDeck angebracht werden dicht zur Abzugsraupe.

Dieses System hat alle Komponenten undelektrische verkabelung installiert für die MR-

11 PLC-T. Das System hat nicht dieVerkabelung für das Hauptkabel oder dieInnenbeleuchtung im Gehäuse.

4-ELECTRICAL SYSTEM

4.1. ALGEMEEN. Het MR-11 PLC-Telectronisch systeem van de “Braidmatic”vlechter voorziet voor de operatoren eenveilige en gemakkelijke bediening, alsook demiddelen om de kwaliteit van het gevlochten

product te controleren.

Het MR-11 PLC-T electrisch systeem bevatvoorbekabelde behuizing, schakelaars, alarm panelen, drukknop stations, enz. Dezeonderdelen zijn in de fabriek voor-geassembleerd, afgesteld en voorzien vanhulpmiddelen voor gemakkelijke montage.

Het systeem bevat alle electrischecomponenten en bedrading om de MR-11PLC-T te installeren en in werking te stellen.Het systeem voorziet niet in de electrischetoevoerleiding(voedingskabel) van de

fabrieksstroomvoorzieningen naar de vlechter noch voor de bedrading naar delichtschakelaar.

Zie hoofdstuk 10, electrische schema’s van de bedrading van het MR-11 PLC-T - één of twee decks- worden meegeleverd. (Schema’svoor een drie-deck versie kunnen geleverd

d di )



De vlechter is ontworpen als een modulair systeem voor de besturing en werking met éénof meerdere decks en één trekband . De deckszijn ontworpen als onafhankelijke eenheden enkunnen aan elke trekband gekoppeld worden.Echter, de bedieningskast met de ‘touch screendisplay’ moet altijd gemonteerd worden aan dedeck het dichtste bij de trekband.

worden wanneer nodig).

Indien van toepassing, zal defoutmeldingsmodule (scherm) ook hetnummer van het deck opgeven waar de foutzich voordoet. In geval van meerderefoutmeldingen op het zelfde moment, is devolgorde waarin de foutmeldingen afgebeeldworden niet bepaald.

SECTION II. SYSTEM DESCRIPTIONS

SYSTEM BESCHREIBUNG

SYSTEEM BESCHRIJVING

4.2. MAIN DISPLAY. The screen below isdisplayed both when the braider is running andwhen it is stopped but no there are no activeerrors. The top row of numbers on this screenshows the current production speed in meters per minute. The bottom two sets of numbersare two independent production counters,counting in meters, each of which can be reset

separately. All of these counters are tied to the proximity sensor located in the hauloff andmeasure the production rate of the hauloff

Located at the bottom of this screen are two

buttons for selecting further operator interfacescreens. The button labeled ‘Config’ will callup the main configuration screen while the onelabeled ‘Counters’ will allow the operator toreset either of the production counters.

If the braider includes an integrated BraidMaterial Runout System, you will see a line

near the top of the screen:‘Bobbin runout in: xxx.x xxx.x’

4-ELECTRICAL SYSTEM

NOTE

NOTE: To prevent accidental stops in case the laser sensorsare not calibrated, the cutoff distance must be within 2 millimeters of set distance for therunout laser sensors to trigger amachine stop.



On a PLCT-F version of the machine, theRotor Speed display at the top of the screen isreplaced with 2 input fields for lead length.Simply press the field on the display and awindow will open that allows the user tochange the lead length for each deck. Simplyenter the desired lead in millimeters and pressenter. If the two leads on a double deck are notequal, the deck with the shortest lead will runat the speed set in section 4.6. The deck with

the longer lead will always run slower.

4.2. HAUPT ANZEIGE: Die Anzeige zeigt beides an, wenn die Maschine Läuft, und wennsie steht. Aber nicht wenn keine Fehler aktiviert sind. Die obere Reihe zeigt dieProduktionsgeschwindigkeit in meter pro

minute an. Die untere Reihe hat zweiunabhängige Zähler die in meter zählen. Jeder Zähler Kann seperat auf null zurückgestelltwerden. All diese Zähler sind mit einemInduktiv Geber verbunden, die sich in der Abzugsraupe befinden. Diese messen dieProduktivität der Abzugsraupe.

Sie zählen aber nicht, für ein eventuelles

rutschen, das zwischen dem Schlauch und der Abzugsraupe entstehen Kann. Am unterenEnde der Anzeige sind zwei Knöpfe für weitere funktionen. Ein Knopf “Konfig” ruftdie haupt konfiguration der Anzeige ab. Der zweite Knopf “Zaehler” erlaubt dem Arbeiter die Produktionszähler einzeln zurück zustellen.

FIGURE 4.2.1: MAIN DISPLAY SCREEN

FIGURE 4.2.1.1: MAIN DISPLAY SCREEN PLCT-F VERSION

4-ELECTRICAL SYSTEM



4.2. START SCHERM. Het scherm hieronder (fig 4.2.1) wordt getoond wanneer devlechtmachine inwerking is of wanneer devlechter gestopt wordt zonder dat er eenfoutmelding was.

Het bovenste veld met nummers toont dehuidige productie snelheid in meters per minuut. De onderste twee velden met nummerszijn twee onafhankelijke productie tellers,welke tellen in meters en welke elk apartgereset kunnen worden. Al deze tellers zijnverbonden met sensor in de trekband en metende loopsnelheid van de trekband. Deze tellershouden geen rekening met potentiële slip

tussen de trekband en de slang.

Onderaan het scherm zijn er tweedrukknoppen om verdere interface schermen teselecteren. De drukknop met de label ‘config’zal het hoofd configuratiescherm oproepenterwijl de drukknop met de label “teller”(counters) de operator de tellers terug op nul

zal zetten.

4.3. MAIN CONFIGURATION SCREEN. Thisscreen is selected by pressing the ‘Config’ button on the main display (20). Variousoptions can be set from here.

• The button labeled “Blower” will allow

one to set the operating mode of the blower, screen 25.

• The button labeled "Network" willaccess a troubleshooting screen thatshows the active connections betweenthe PLCs.

• The button labeled “Slow Speed” willreduce the speed of the machine for atime, after which it will automaticallyresume running at full speed, screen23.

• The button labeled “Setup” is used toconfigure the software for units of measurement and machine type.

• The button labeled ‘Error Logs’ is used

to display the total number of timesthat any given error message has beendisplayed.

FIGURE 4.2.1: HAUPT ANZEIGE FIGURE 4.2.1: START SCHERM

4-ELECTRICAL SYSTEM

• The button labeled ‘Language’ willswitch between the different languagesthat are programmed into the display.The actual languages programmed intothe touch screen may vary from one

display to the next.

• Der Knopf ‘Fehler’ zeigt die Fehler-zaehler an. Diese Zaeler werden inkre-mentiert wenn ein Fehler angezeigtwird.

• Die Knöpfe “Kontrast-” und “Kon-

trast+” sind dazu da, um den Kontrastder Anzeige einzustellen.

• Der Knopf “O” erlaubt dem Arbeiter zurück zu gehen zur Hauptanzeige(20).

• Die Anzeige zeigt die Software versionan.



4.3. HAUPT K ONFIGURATION ANZEIGE: Beieindrücken des “Konfig” Knopfes an der Hauptanzeige können viele möglichkeiteneingestellt werden.

• Der Knopf “Geblaese” erlaubt die Ein-stellung für die Produktionsfunktiondes Gebläsemotors. Anzeige 25.

• Der Knopf "Netzwerk" eröffnet eineStörungsanzeige, die anzeigt dieaktiven Verbindungen zwischen denSPS.

• Der Knopf “Langsamlauf” wird dieGeschwindigkeit für eine gewisse Zeitreduzieren, und danach wieder auf dienormale Geschwindigkeit zurück zugehen. Anzeige 23.

• Der Knopf “Einstellung” wird benutztum den Maschinetyp so initialisieren.

4.3. HOOFD CONFIGURATIESCHERM. Dit

scherm wordt geselecteerd door de drukknop‘config’ in te drukken op het startscherm (20).Verschillende opties kunnen hier gekozenworden.

• De drukknop ‘blower’ (ventilator) laattoe om de werking van de ventilator inte stellen- (scherm 25)

• De drukknop ‘netwerk’ (network)geefttoegang tot een troubleshooting schermwelk de actieve connecties tussen de

FIGURE 4.3.1: MAIN CONFIGURATION SCREEN

FIGURE 4.3.1: HAUPT K ONFIGURATION ANZEIGE

4-ELECTRICAL SYSTEM

• De drukknop ‘slow speed’(trage snel-heid) zal de snelheid van de machinevoor een bepaalde tijd vertragen omdaarna automatisch terug op vollesnelheid te draaien (scherm 23).

• De drukknop ‘transfer’ wordt gebruiktom de software van het beeldscherm teupdaten. Het electrische systeem moetuitgeschakeld worden en geresetworden na deze aktie.

• De drukknop ‘contrast-‘ en ‘contrast+’worden gebruikt om het contrast vanhet beeldscherm te regelen.

• “Automatic” turns on the blower onlywhen the machine is running.



• De drukknop ‘return’(terug) laat toeom terug te gaan naar het startscherm(20).

• Op dit scherm wordt ook de huidigesoftware versie weergegeven.

4.4. BLOWER OPERATING MODE. This screenis selected by pressing the “Blower” button onscreen 22. One of 3 operating modes for the

blower can be selected here.• “OFF” turns off the blower.

4.4. GEBLÄSEFUNKTIONVORGANG: DieAnzeige wird gewählt bei drücken des“Geblaese” Knopfes an Anzeige 22. Eine vonden drei funktionsvorgängen kann hier gewählt

werden.• “Aus” Schaltet den Motor ab.

• “Manuel” Schaltet den Motor an, wenndie Maschine unter strom steht.

• “Automatik” Schaltet den Motor anaber nur wenn die Maschine Läuft.

FIGURE 4.3.1: HOOFD CONFIGURATIESCHERM

FIGURE 4.4.1: BLOWER SETUP SCREEN

4-ELECTRICAL SYSTEM

4.4. OPERATIONELE STATUS VAN DE VENTILATOR . Dit scherm wordt geselecteerdwanneer de drukknop ‘ventilator’ (blower)wordt ingedrukt op scherm 22. Eén van de 3operationele statussen kunnen hier

geselecteerd worden.

• ‘UIT ’(‘OFF’) zet de ventilator af.

• ‘Manueel’ (‘Manual’) zet de ventilator aan van zodra de stroom aangeslotenwordt.

• ‘Automatic’ zet de ventilator enkel aanwanneer de vlechter in werking is.



4.5. SLOW SPEED. This screen is selected by pressing the “Slow Speed” button on screen22. This will allow the machine operator torun the machine at a slower speed for a predetermined time, after which it willautomatically return to the normal operatingspeed. The time is set in minutes and must bewithin a range of 1-32000 minutes.

• Pressing the number field will allowthe operator to set the time.

• Pressing the “I” button will enable this

4.5. LANGSAME GESCHWINDIGKEIT: DieAnzeige wird gewählt bei drücken desKnopfes “Langsamlauf” an der Anzeige 22.Dieses erlaubt das die Maschine für einegewisse Zeit langsam Läuft, und dann wieder auf die normale Geschwindigkeit umschalted.

Diese Zeit ist gesetzt in minuten, und mussZwischen 1 und 32000 gewählt werden.

• Bei drücken des Nummern feldeserlaubt dem Arbeiter die Zeit einzuge- ben.

• Bei drücken des “I” Knopfes wirddiese funktion ermöglicht.

• Bei drücken des “0” Knopfes verlassensie die Anzeige ohne das etwas von der letzten funktion zerstört wird.

FIGURE 4.4.1: VENTILATOR SCHERM

FIGURE 4.5.1: SLOW SPEED SCREEN

4-ELECTRICAL SYSTEM

4.5. TRAGE SNELHEID. (Fig 4.5.1 - sherm 23)Dit scherm wordt geselecteerd door dedrukknop ‘trage snelheid’ (‘slow speed’) in tedrukken op scherm 22. Dit laat de operator toeom de machine aan een trage snelheid te laten

werken gedurende een vooraf ingestelde tijd,om daarna automatisch om te schakelen naar de standard snelheid. Deze tijd wordt ingesteldin minuten en binnen een bereik van 1 - 32000minuten.

• De tijd kan ingesteld worden door ophet nummeriek veld te drukken.

The units of measurements that are displayedon the main screen are configured here. Unitscan either be meters or feet. To accept all of the display changes, the braider must be powered down after this screen is exited.



• Door op de “I” drukknop te drukkenwordt deze functie geaktiveerd.

• Door op de “O” drukknop te drukkenverlaat je het scherm zonder de functiete activeren of uit te schakelen indienze eerder geactiveerd werd.

4.6. MACHINE TYPE. This screen is used toconfigure whether the braider is an MR-11 or MR-15. This affects the speed display on the

main screen.

If a Bobbin Runout Sensor is installed in the

4.6. MASCHINEN TYP. Die Anzeige zeigt an

den Maschinentyp MR-11 oder MR-15. Diesentscheidet die Geschwindigkeitsanzeige ander Hauptanzeige.

Die Masseinheiten auf der Hauptanzeige diehier angezeigt werden Können in meter oder fuss eingestellt werden. Um änderungen zuakzeptieten muss die Maschine nach neueingabe Kurz ausgenschaltet werden.

FIGURE 4.5.1: TRAGE SNELHEID

FIGURE 4.6.1: MACHINE TYPE

4-ELECTRICAL SYSTEM

4.6. MACHINE TYPE. Dit scherm wordtgebruikt om de vlechter als MR11 danwel alsMR15 te configureren en bepaald desnelheidsaanduiding op het hoofdscherm.

De meeteenheden welke op het hoofdschermgetoond worden , worden hier geconfigureerd.Eenheden kunnen ofwel in meters of in “feet”uitgedrukt worden. Om veranderingen in ditscherm te activeren moet, na verlaten van ditscherm, de vlechter uitgeschakeld worden enterug opgestart.



4.7. NETWORK STATUS. This screen displaysall of the PLC communications that are

currently active for the main PLC (U8). Thecommunications that should be active isdependent on the type of braider, i.e: Single or double deck, 24 or 36 carrier. In case a PLC isnot found on the network, this status page willdisplay a 1 for that connection.

NOTE

4.7. NETZWERK STATUS. Die Anzeige zeigtalle SPS Nachrichten und Verbindungen dieaktiv mit der haupt SPS sind. Die Nachrichtenund Verbindungen die aktiv sein sollten,hängen von dem Type der Flechtmaschine ab 1oder 2 Decks, 24 oder 36 Klöppel. Im Falle daseine SPS im Netzwerk nicht gefunden werdenKann, diese Abbildung wird eine 1 anzeigenfür die Verbindung.

Notierung

An einem 36 Klöppel dopple deck U21 (andem zweiten deck) ist nicht angezeigt auf dieser

Abbildung.

FIGURE 4.6.1: MACHINE TYPE

FIGURE 4.7.1: NETWORK STATUS

4-ELECTRICAL SYSTEM

4.7. NETWERK STATUS. Dit scherm geeft deaktieve communicatie met de hoofd PLC (U8)weer. Welke communicaties actief zijn isafhankelijk van het type van vlechter, d.w.z.enkel of dubbeldeck, 24 carrier. In geval dat

een PLC niet gevonden wordt op het netwerk,zal de status pagina een ‘1‘ afbeelden voor dieverbinding.

4.8. ZÄHLER ZURÜCK STELLEN: DieAnzeige wird aktiviert beim drücken desKnopfes “Zaehler” an der Hauptanzeige (20)Zurückstell Zähler 1 setzt den Zähler C1 auf der Hauptanzeige zurück auf 0. Zurückstell

Zähler 2 hat dieselbe funktion für den C2Zähler. Die Zähler können nur gestartedwerden wenn sie einen Puls von der LaufendenMaschine erhalten. So das die “Rpm- Umin.”Auf der Hauptanzeige erscheint.



4.8. COUNTER R ESET. This screen is accessed by pressing the ‘counters’ button on the mainscreen (20). ‘Reset counter 1’ will set thecounter C1 on the main display to 0 while‘Reset counter 2’ will do the same for the C2counter. Please note that the actual counters

cannot be updated until a new counter pulse isreceived from the hauloff so the numbers onthe main screen (20) are only updated whenthe machine is running.

4.8. TELLER RESET. Door de drukknop ‘teller’(‘counters)’ op het hoofdmenu (scherm 20) inte drukken krijgt men toegang toe dit scherm .‘Reset teller 1’ (counter 1) zal de teller C1 opnul zetten op de hoofddisplay terwijl ‘resetteller 2’ (counter 2)hetzelfde zal doen voor deteller C2.

Let op: de actuele tellerstanden worden maar aangepast op het moment dat er een nieuwteller signaal ontvangen wordt van detrekband. Dit betekent dat de meterstand op hethoofdscherm (20) zich enkel kan aanpassen als

de machine in werking is.

FIGURE

4.7.1: NETWERK

STATUS

FIGURE 4.8.1: ZÄHLER ZURÜCK STELLEN

4-ELECTRICAL SYSTEM

4.10. ERROR COUNTERS.

This screen is used to select the different error counters and to reset the counters to zero.

• ‘Standard Errors’ selects the screendescribed in section 4.10.

• ‘Shuttle Errors’ selects the screendescribed in section 4.11

• Entering the correct four-digit pass-word beside ‘reset’ will reset all of theerror counters to zero.



4.9. OPTIONAL OPTICAL BRAID MATERIAL R UNOUT SENSORS. This screen is used tocalibrate the Bobbin Runout Sensors. Thecolumn on the left shows the actual measureddistance for each sensor. Note that this distanceis a maximum so the distance shown is for thesmallest bobbin diameter being read by thatsensor.

The column on the right allows the user toenter the cutoff distance for that sensor. Thisnumber will usually be 0.5 - 2mm smaller thanthe measured distance to an empty bobbin. Seethe setup section for more detailed instructions

on how to set up the sensors.

4.10.

Die Taste ‘Standard Fehler’ selektiert denBildshirm der im absatz 4.10 beschrieben ist.

Die Taste ‘Kloepel Fehler’ selektiert denBildshirm der im absatz 4.11 beschrieben ist.

Alle Fehlerzaehler werden zurueckgesetztwenn man das richige 4-stellige Passworteingibt in dem eingabefeld neben ‘Reset’.

FIGURE 4.8.1: TELLER R ESET SCHERM

FIGURE 4.10.1: ERROR COUNTERS

4-ELECTRICAL SYSTEM

4.11. This screen displays the counters for allerror-counters except shuttle sensors.

IGURE 4 10 1



4.10. ALARMEN AANGAVE.

Dit scherm wordt gebruikt om de verschillendealarmtellers te selecteren en om de alarmtellersterug op nul te zetten

• ‘Standard alarmen’ kiest het scherm beschreven in sectie 4.10

• ‘Shuttle alarmen’ kiest het scherm beschreven in sectie 4.11

• Het inbrengen van het 4-cijfer paswoord + ‘reset’ zal alle alarm tellersterug op nul plaatsen.

4.11. Alle Fehlerzaehler auser denKloepelsensoren werden hier angezeigt.

FIGURE 4.10.1:

FIGURE 4.11.1:

FIGURE 4.11.1:

4-ELECTRICAL SYSTEM

4.11. Dit scherm toont de teller voor allealarmen behalve de shuttle alarmen.

4.12. Die Fehlerzaehler fuer dieKloepelsensoren werden hier angezeigt.



4.12. The error counters for the shuttle sensorsare displayed here.

4.12. De alarmen voor shuttle fouten wordenhier getoond.

4.13. ENCLOSURE DOOR INTERLOCK SAFETY SWITCHES. MR-11 PLC-T decks are designed

for operation within a sound and safetyenclosure. The enclosures are available for single, double and triple deck operation. A

FIGURE 4.11.1:

FIGURE 4.12.1:

FIGURE 4.12.1:

FIGURE 4.12.1:

4-ELECTRICAL SYSTEM

As long as the door is open, the braider isinoperative, with one exception. With the‘inside safety’ switch in the ON position, the braider may be jogged from within that, andonly that, enclosure, even with the doors open.

The door locks on any other deck will stilloperate as described above and prevent theoperation of the machine if they are open. If the ’inside safety’ switch is activated on two or more decks, the motor cannot be started.

The following graphic is displayed whenever an enclosure door is open:

Dann Kann man die Maschine mit dem TipKnopf bei offener Tür nur von diesemGehäuse, Langsam Laufen Lassen. DieSicherheitsschalter an den anderen Türen behalten ihre beschriebene funktionen bei.

Wenn ein Sicherheitsschalter an einemanderen Deck aktiviert ist Kann der Motor nicht gestarted werden.

Die folgende Graphic erscheint auf der Anzeige bei offener Gehäusetür.



4.13. SICHERHEITSSCHALTER AN DEN

GEHÄUSETÜREN. Die Decks sind entwickeltin einem sicheren und schall gedämpftenGehäuse zu operieren. Die Gehäuse sindverfügbahr für 1 – 2 und 3 Deck arbeiten.Eine Tür ist von beiden seiten vom Gehäuseangebracht zum zugang zur Maschine. JedeTür hat einen Sicherheitsschalter. Sobald der Tip oder Start Knopf aktiviert ist, die Türen

Können nicht geöffnet werden.Wenn eine Tür geöffnet ist, Kann die Maschine

4.13. VLECHTKABINE DEURBEVEILINGSSCHAKELAARS. MR-11PLC-T decks zijn ontworpen om te werken

binnen een geluidsdichte en veilige cabine. Decabines zijn beschikbaar voor enkel, dubbel entriple deck vlechters. Er is een deur aan beidezijden van elke deck welke toegang geef tot dedecks. Elke deur is voorzien van eenveiligheidsslot. Van zodra een ‘AAN’(“Run”)of “Jog” schakelaar actief is zijn de deurenvergrendeld en kunnen ze niet geopend

worden.Zolang de deur geopend is, is de vlechter non-

FIGURE 4.13.1: ENCLOSURE DOOR OPEN SCREEN

FIGURE 4.13.1: ANZEIGE BEI OFFENER GEHÄUSETÜ

4-ELECTRICAL SYSTEM

De deursloten op de andere deck zullen inwerking blijven zoals hierboven bescheven ende werking van de machine stoppen indiendeze geopend zijn/worden. Als de ‘insidesafety’ schakelaar geactiveerd wordt op de

twee decks, kan de aandrijving niet gestartworden.

De volgende afbeelding (fig 4.8.1) wordt ophet scherm getoond wanneer een cabinedeur geopend is:

2. Display the follow graphic on the maindisplay:



4.14. CHANGE GEAR ACCESS DOORS. Thereare safety switches installed on the change-gear access doors for both the deck(s) and the

haul-off. In addition, the haul-off also hassafety switches for the doors that allow accessto the main motor.

When the change gear door is opened, theactivation of the switch will simultaneously:

1. Stop the main motor (if running) and prevent the motor from being started while

the switch is actuated.

4.14. ZUGANG ZUR GEHÄUSE TÜR FÜR WECHSELRÄDER : Es sind Sicherheitsschalter an den Türen angebracht am Deck undAbzugsraupe. Der Sicherheitsschalter von der Abzugsraupe hat zusätzlich eine verbindungzum Hauptmotor.

FIGURE 4.13.1: CABINE DEUR OPEN

FIGURE 4.14.1: DECK GEAR DOOR OPEN SCREEN

FIGURE 4.14.2: HAUL-OFF DOOR OPEN

SCREEN

4-ELECTRICAL SYSTEM

2. Die folgende Graphic erscheint auf der Anzeige:

3. Een afbeelding van een open tandkastdeur (deck of trekband) weergeven op hethoofdscherm (fig 4.9.1 of 4.9.2).



4.14. TOEGANGSDEUR TOT TANDWIELEN. Er zijn veiligheidsschakelaars geinstalleerd opdeze toegangsdeuren voor zowel de deck(s) alsvoor de trekband. Daarnaast heeft de trekbandook nog veiligheidsschakelaars op de deurenwelke toegang geven tot de hoofdmotor.

4.15. ELECTRICAL SYSTEM FOR LUBRICATION: The Bijur automaticlubrication system is a self-contained system.The MR-11 PLC-T continuously monitors the

operation of the Bijur system and provides thefollowing controls and safety features. Anover-pressure valve is located by the oil pump

FIGURE 4.14.1: DECK WECHSELRÄDER

TÜR OFFEN

FIGURE 4.14.2: ABZUGSRAUPE WECHSELRÄDER TÜR OFFEN

FIGURE 4.14.1: TANDKAST DECK OPEN

FIGURE 4.14.2: DEUR TREKBAND OPEN

4-ELECTRICAL SYSTEM

2. Display the follow error graphic until theOil pressure is once again above therequired minimum.

4.15. ELECTRISCHE STURING VOOR HET SMEREN. Het Bijur automatischsmeringssysteem is een onafhankelijk systeem.De MR-11 PLC-T verifieert voordurend dewerking van het Bijur systeem en voorziet in

de volgende bedienings- enveiligheidsvoorzieningen . Er is eenoverdrukklep voorzien aan de oliepomp endeze zorgt ervoor dat de oliedruk niet meer dan60 PSIG bereikt. Als er voor welke reden danook de oliedruk in een deck terugvalt benedende minimum toegestane werkingsdruk van45”5 PSIG zal het volgende gebeuren:

1 De hoofdmotor stopt



4.15. ELEKTRISCHES SCHMIERSYSTEM. Dasautomatische Bijur Schmiersystem ist in sichein geschlossenes System für jedesDeckmodul. Das MR-11 PLC-T überwachtfortlaufend den Bijur Systembetrieb und hatdie folgenden Kontrollen undSicherheitsmerkmale der Maschine. EinÜberdruckventil ist angebracht an der Ölpumpe um einen Überdruck von 60 PSIG zuverhindern.

Wenn der Öldruck an ein em Deck unter 45±5

PSIG fallen würde, passiert folgendes.1. Hauptmotor stoppt.

2. Die folgende Graphic erscheint auf der Anzeige:

1. De hoofdmotor stopt.

2. De volgende foutmelding zal afgebeeldworden totdat de oliedruk terug boven hetminimum vereiste niveau is.

4.16. OPERATOR ’S WORK LIGHT. Afluorescent light kit has been provided aboveor ahead of each MR-11 PLC-T deck module

to illuminate the inside of the sound enclosure.

This light is intended to be connected to the

FIGURE 4.15.1: LOW OIL PRESSURE SCREEN

FIGURE 4.15.1: OLIE DRUK TE LAAG.

4-ELECTRICAL SYSTEM

4.16. LICHT IM GEHÄUSE FÜR DEN ARBEITER . Ein licht ist im oberen Teil desGehäuse angebracht um die Bedienung der Maschine zu ermöglichen.

Die Stromzufuhr ist direckt mit demFirmenstrom verbunden, unabhängig von der Maschine, und bleibt immer an solange dieFirma den Strom nicht abschaltet.

4.16. WERK VERLICHTING. Een TL licht isvoorzien bovenaan elke MR-11 PLC-T deck om de geluidsdichte cabine vanbinnen teverlichten.

H t i d b d li d li htb t k l

2. Display the error screen below:

FIGURE 4.17.1: SHUTTLE SENSOR SCREEN



Het is de bedoeling deze lichtbron te koppelenaan de verlichting van de fabriek. Dit laat toeom alle stroom naar de MR-11 PLC-T uit teschakelen zonder dat de verlichting in decabine uitgaat.

Raadpleeg het electrisch schema voor het

juiste voltage.

4.17. SHUTTLE SENSOR . (Figure 4.17.2) TheMR-11 PLC-T Braidmatic shuttle transfer system has incorporated a means to detect anycam track operating the intended limits of operation. The purpose of the shuttle sensors isto detect such abnormal behavior at an early

stage and thus avoid serious shuttle transfer problems.

Low voltage (24Vdc) grounding probes have been factory positioned and wired on the‘inside’ and ‘outside’ of each deck rotor. Eachis radially set to produce a clearance of .55-.60mm between the outside diameter of the cam

track and the probe.Any malfunction to the rotor frame, rotor cam

Do not place the deck back into service untilthe cause of the sensor signal has been foundand corrected.

CAUTION

Moving elements in shuttleassembly area.

Disconnect power and removeupper change gear.

Personal injury to hands and armscould result.

The steps for checkout are as follows:

1. Remove the upper change gear and movethe shuttles around one completerevolution on the deck.

2. Using a rotor that does not have a shuttlesensor "on", move a shuttle onto, around

F GU 4.17.1: S U S NSO SC N

4-ELECTRICAL SYSTEM

4. Check the rotor cam follower for excessivetightness or radial clearance to the shuttles.

5. Check that the probe location is .55-.60mm from the track.

6. Check for anything on the end of the probethat could trigger the sensor.

7. Replace the change gear and "JOG" thedeck slowly after having "reset" the shuttlesensor by pressing the reset button on theAlarm Panel Display.

4.17. K LÕPPELFÜHLGERÄT “SENSOREN”.D MR 11 PLC T B id ti

Anzeige.

FIGURE 4.17.1: K LÖPPELFÜHLGERÄT



Das MR-11 PLC-T BraidmaticKlöppelübertragungssystem hat ein Gerät um jeglichen Transferschienenbetrieb ausserhalbder gewünschten Bereichsgrenzenfestzustellen. Es ist der Zweck desKlöppelfühlers, das abnormales Verhaltenfrühzeitig erkannt wird, und dadurch ernste

Transferprobleme vermieden werden.Erdungssonden mit niedriger Spannung 24Vdc werden von der Fabrik eingestellt und auf der Innen-und Aussenseite eines jedenDeckrotors verkabelt. Jede Sonde hatRadialeinstellung, um einen Zwischenraumvon 0.55 – 0.60 mm zwischen demAussendurchmesser der Transferschiene undder Sonde zu schaffen. Jede Störung der Rotorablesung, Rotorstössel oder Beziehungder Transferschiene bringt die Sonde mit der Transferschiene in Kontakt.

Der Kontakt wird gleichzeitig.

1. Den Antriebsmotor der Maschine stoppen.

2. Die folgende Graphic erscheint auf der

Starte nicht die Maschine bevor der Grundgefunden ist, und der Fehler behoben ist.

WARNUNG

Bewegende Teile an denKlöppelköpfen.

Hauptschalter ausschalten und das obere Wechselgetriebe

entfernen.

Leichte verletzungen an Händenund Armen könnten sonst der Fall sein.

Die Prüfung wird in den folgenden Schrittenausgeführt.

1. Oberes Wechselgetriebe entfernen undKlöppel in einer ganzen Deckumdrehungverdrehen

“SENSOREN”

4-ELECTRICAL SYSTEM

wenn er in der Umdrehung als eine Basisfür die Radiallager vorbeigeht.

4. Vordere Transferlager auf übermässigeStraffheit oder Radialzwischenraum zu denKlöppelschienen prüfen.

5. Die 0.55 – 0.60 mm Sondeneinstellung zur Spur prüfen.

6. Wechselgetriebe auswechseln und dasDeck Langsam stossweise vorrückenzuerst aber den Klöppelfühler wie auf der Anzeige steht wieder einstellen.

4 17 SHUTTLE SENSOR (Fig 4 17 2) De MR-

3. Schakel de deck niet terug in werkingtotdat de oorzaak van het sensor signaal isgevonden is en de fout hersteld is. .



4.17. SHUTTLE SENSOR . ( Fig 4.17.2) De MR-11 PLC-T heeft een ingebouwde sensor om despeling bij de overname van de shuttles tedetecteren. Het doel van de shuttle sensor isom preventief ‘abnormaal gedrag’ tedetecteren en zo ernstige shuttle beschadigingen te vermijden (braider crashes).

De laag voltage (24Vdc) voelers werden in defabriek gepositioneerd en gekoppeld naar de binnenkant en buitenkant van elke deckrotor.Deze zijn elk straalsgewijs ingesteld om eenspeling van .55-.60 mm toe te laten tussen de buitendiameter van de cam track en de voeler.

Elk onderling slecht functioneren van het rotor

frame, rotor cam volger of shuttle cam track zal de probe in contact brengen met de camtrack. HELP !!

Het contact zal tegelijkertijd :

1. De hoofd aandrijfmotor stoppen.

2. Het foutmeldings op het scherm tonen (fig

4.12.1):

GEVAAR!

WAARSCHUWING!!

Bewegende delen in de shuttlemontage area.

Leg de stroom af en verwijder het bovenste tandwiel.

Opgelet voor hand- enarmverwondingen.

Hier volgen de stappen voor de ‘checkout’:

1. Verwijder het bovenste tandwiel en laat deshuttles een volledige deckomwentelingdoen.

2. Gebruik makend van een rotor die geenshuttle sensor alarm op ‘AAN’ heeft; breng

FIGURE 4.17.1: SCHERM SHUTTLE VOELER

4-ELECTRICAL SYSTEM

sensor alarm. Een verschillend aanvoelenkan reeds een aanduiding zijn dat er ietsmis is

4. Kijk de rotor volger (meenemer) na voor tehoge weerstand of radiale speling.

5. Kontroleer de plaatsing van de voeler,Moet .55 tot .60 mm tot het spoor (track)zijn

6. Kontroleer de voelerkop voor vuil of ietsanders dat het signaal zou kunnenveroorzaken.

Plaats het tandwiel terug. Druk de ‘sensor

reset’ knop en laat de deck langzaamrondraaien met de JOG funktie.



4-ELECTRICAL SYSTEM

SENSOR PROBE SETTING

CL OF DECK

CL R OTOR GAP

0.55 - 0.6 mm

SHUTTLE

SENSOR

PROBE

M4 SET SCREWFOR

240 8055 01

DJUSTING GAP



240-8055.01

240-8051

M10 HEX NUT

ST-M10

4-ELECTRICAL SYSTEM

4.18. BROKEN BRAID/BOBBIN R UNOUT SENSOR . (Figure 7.5.31) The function andoperation of this device is described in Chapter 2, Section III.

A broken or tangled strand or plait of wires or fibers will jerk the braided product and islikely to actuate the braid sensor.

The sensor, having been ’pulled’ from it’snormal position, will dislodge the sensor ringand actuate one of the 3 electronic limitswitches. This signal will:

1 St th b id

4.18. FLECHTFÜHLGERÄT “SENSOR ”: DieFunktion und der Betrieb dieses Geräteswerden in Abschnitt 2, Section 3 beschrieben.

Gebrochene oder verwickelte Fasern, Litzen

oder Drahtflechten reissen das gflochteneProdukt heraus und schalten wahrscheinlichdas Flechtfühlergerät ab.

Wenn der Fühler aus seiner normalen oder geplanten Stelle herausgerissen worden ist,wird er wahrscheinlich den Fühlerringverschieben und einen der drei elektrischenBegrenzungs – schalter anschalten.

D i l b i kt l kt i h f l d



1. Stop the braider.

2. Display the following error message:

The operator should:

1. Visually inspect the braided product andcarrier strands for broken wires, loose

wires, etc.2. Using the "JOG" button on the Inside Jog

Das signal bewirkt elektrisch folgendes:

1. Motor der Maschine stopped.

2. Die folgende Graphic erscheint auf der Anzeige

Der Arbeiter sollte:

1. Mit dem Auge das Flechtprodukt und dieFadenführerfasern und Litzen überprüfen

FIGURE 4.18.1: BROKEN BRAID/BOBBIN

R UNOUT SENSOR SCREEN

FIGURE 4.18.1: FLECHTFÜHLGERÄT “SENSOREN”

4-ELECTRICAL SYSTEM

4.18. VLECHTBREUK SENSOR . (Fig 7.5.31) Defunctie en werking van dit apparaat wordt beschreven in hoofdstuk 2, sectie III.

Een gebroken of gedraaide draadbundel zal de

slang waarschijnlijk uit center trekken en zalde vlecht sensor aktiveren.

Een sensor, welke van zijn normale plaatswordt getrokken, zal de sensor ring lostrekkenen één van de 3 electronischeeindloopschakelaars aktiveren. Dit signaal zal:

1. de vlechter stoppen

2 De volgende foutmelding afbeelden:

4.19. OPTIONAL OPTICAL BRAID MATERIAL R UNOUT SENSOR . This screen is displayedwhen an optional Braid Material RunoutSensor is installed and this sensor stops themachine. These sensors are only active whenthe braider is in ‘Run’ mode. Press the “O” button at the bottom to cancel the error screen.:



2. De volgende foutmelding afbeelden:

De operator moet dan:

1. het gevlochten product visueel nakijkenvoor losse draden, gebroken draden van decarrier, enz...

2. Door gebruikt te maken van de JOGdrukknop in de vlechter, het deck

ronddraaien en de afloop spanning van de bobbijnen kontroleren. Spoelen welke de

l ht b ld i hti t kk

4.20. FRICTION LAYER OR HOSE R UNOUT SENSORS. One input per deck and an error graphic have been reserved for customer specific sensors which can be used to detect amissing friction layer or hose feed. This signal

must be shorted to ground to stop the machine.

If one of these sensors is tripped, the followingwill occur:

1. Stop the braider.

2. Display the following error graphic:

FIGURE 4.18.1: VLECHT SENSOR

FIGURE 4.19.1: OPTIONAL OPTICAL BRAID MATERIAL R UNOUT SENSOR SCREEN



4-ELECTRICAL SYSTEM

Options 4, 5 and 6 are configured todisplay an error message until the cancel button is pressed.

Möglichkeiten 4 - 5 und 6 zeigt solangeden Fehler an, bis der Knopf “Cancel”“Ròckgängig” gedrückt wird.



4.21. K UNDENWUNSCH ZUSÄTZLICHE ABSTELLER “SENSOR ”. 6 mögliche Absteller sind vorhanden für den Kunden selbst zuentscheiden. Alle 6 Können entweder geerdet

oder an die 24Vdc angeschlossen werden.Firmen einstellung ist Kurz – geerdet für diese6 möglichkeiten. Um das Rückgängig zumachen muss die Eingabe an der PLC für die 6möglichkeiten von 24Vdc zu 0Vdc geändertwerden.

Bei Auslösung jeder dieser Absteller passiert

folgendes:1. Motor der Maschine stopped.

2. Anzeige wird anzeigen welcher von diesen6 Abstellern ist ausgelöst worden.

3. Möglichkeiten 1 - 2 und 3 stoppen dieMaschine, und die Anzeige Zeigt solange

den Fehler an, bis er behoben ist.

4.21. K LANTSPECIFIEK STOP ALARMEN. Zestoegangen zijn beschikbaar gemaakt voor klanteigen wensen. Alle 6 kunnen zegeconfigureerd worden tot ofwel “switch to

ground’ (nulgeleider) of 24Vdc, afhankelijk aan wat de gemeenschappelijke inputverbonden is. De fabrieksinstelling voor deze 6inputs is “nul geleiding”. Om dit om te kerenmoet de gemeenschappelijke input op de PLCvoor deze inputs veranderd worden van 24Vdcnaar 0Vdc.

Het doen afgaan van één van deze inputs zalals gevolg hebben :

1. het stoppen van de vlechter

2. De volgende foutmelding zal afgebeeldworden met de nummers van de klant’soptie (1 tot 6), afgebeeld onderaan :

Opties 1, 2 en 3 zijn geconfigureerd om demachine te stoppen en de foutmelding af teb ld h t

FIGURE 4.21.1: STOP MOTIONS SCREEN FIGURE 4.21.1: ABSTELLER

4-ELECTRICAL SYSTEM

en 6 zijn geconfigureerd om defoutmelding af te beelden tot de annuleer drukknop wordt ingedrukt.

maintenance personnel will have to resetthe components within the main electricalenclosure.



4.22. MOTOR OVERLOADS. The status of themotor starter/overload relay is monitored bythe electrical system. Each of the three motors:

main drive, blower motor and lube pump has aseparate motor starter for monitoring thecurrent (in Amps) that is flowing to the motor.In case of an over-current, these will trip andsend an error signal to the control.

Triggering any of these will cause thefollowing to occur:

1. The braider is stopped.

2. The error graphic shown below isdisplayed. Note that the error graphic doesnot distinguish between the 3 motor starters. To verify which one actuallytripped and to reset this, qualified

4.22. MOTOR ÜBERLASTUNG. DieÜberlastung des Motores wird durch ein Relaiim elektrischen system überwacht. Alle dreiMotoren, Haupt-Gebläse – und

Ölpumpenmotor haben eine unabhängigeüberwachung der Amperzahlen die zum Motor fliessen. Im Falle einer Überspannung fällt der Motor über einen Schalter aus, und gibt einSignal zur Anzeige.

Bei ausfall einer der drei Motoren passiertfolgendes:

1. Motor der Maschine stopped.

2. Die Anzeige zeigt an Motor ÜberlastungAber sie zeigt nicht an welcher von der 3Motoren. So es muss vom geschulten personal Kontrolliert werden welcher

FIGURE 4.21.1: STOP ALARMEN FIGURE 4.22.1: MOTOR OVERLOAD SCREEN

4-ELECTRICAL SYSTEM

Motor, und vor allendingen warum,repariert, ersetzt bevor die Maschinewieder gestarted werden Kann.

zal gekwalificeerd onderhoudspersoneeldeze componenten moeten resetten in decentrale electrische kast..



4.22. MOTOR OVERBELASTING. De status vande motor starter/overbelastingsrelais wordtgecontroleerd door het electrisch systeem. Elk van de 3 motoren : hoofdaandrijving,

ventilatormotor en de lube pomp heeft eenaparte starter relais voor het controleren van destroom (in Amps) die naar de motor gaat. Ingeval van een ‘over’-stroom zal deze‘verklikker’ en een foutsignaal zenden naar desturing.

Het doen afgaan van één van deze verklikkers

zal het volgende laten gebeuren:1. De vlechter wordt gestopt

2. De foutmelding, hieronder afgebeeld,wordt getoont. Let er op dat defoutmelding geen onderscheid zal makentussen de 3 motor stroom verklikkers. Omna te gaan welke juist een signaal heeft

doorgestuurd en hem te kunnen resetten,

4.23. BLOWER ASSEMBLY. The blower assembly is located on top of the AccousticalEnclosure. It is intended to provide ventilation

for the interior of the Accoustical Enclosure. If the blower is not running while the braider isin operation, temperatures inside the enclosurewill rise to levels that are dangerous to personnel and detrimental to the performanceof the braiders.

CAUTION

Before attempting any repair work,be certain that all power to themotor and electrical accessoriesare turned off and locked in the

"off" position.

4 23 GEBLÄSE MONTAGE: Das Gebläse ist

FIGURE 4.22.1: MOTOR ÜBERLASTUNG FIGURE 4.22.1: MOTOR OVERBELAST



4-ELECTRICAL SYSTEM

4.23.1. BLOWER ASSEMBLY INSTALLATION.

STEP NO 3

STEP NO. 1MOUNT FAN I NSIDE HOOD


CAP SCREWS W/ FLAT AND

LOCK WASHERS

R UN FAN WIRESTHRU 7/8"DIA. HOLE



STEP NO. 4

STEP NO. 5

STEP NO. 2

STEP NO. 3MOUNT I NLET BELL COLLAR

AND BRACKET TO HOOD



LOCK WASHERSIMPELLER FAN

MOUNT I NLET BELLCOLLAR TO BRACKET

W/M8X20mm HEX HEAD


LOCK WASHERS AND

HEX NUTSI NLET BELL COLLAR

SECURE BRACKET

TO FILTER BOX

M6X20mm HEX HEAD

CAP SCREWS W/FLAT

AND LOCK WASHERS

SLIDE FILTER BOXO NTO COLLAR MOUNT

BRACKET

4-ELECTRICAL SYSTEM

FILTER SLIDES IN

FROM END

2 5 6 1

74

3



FIGURE 4.23.1.2: BLOWER ASSEMBLY

7

FIG. &INDEX

NO.


4.23.1.2 BLOWER

1 S-5707 HOOD 1




5 S-5705 EXHAUST

FAN


7 S-4891 16" X 20" X 2" MESH FILTER 1

TABLE 4.23.1.1: TROUBLE SHOOTING CHART FOR BLOWER

S YMPTON P OSSIBLE C AUSE ( S ) C ORRECTIVE ACTION

Noise 1. Foreign objects in housing.2. Incorrect wheel rotation. 1. Remove.2. Reverse rotation.

4-ELECTRICAL SYSTEM

4.23.2. OPERATION.

1. Before connecting the blower motor to the junction box cable, check the electricalcharacteristics as indicated on the motor nameplate to insure proper voltage and

phase.

2. After electrical connections are completed,apply just enough power to start the unit.Be sure that the rotation of the wheel iscorrect as indicated by directional arrowson the unit. If rotation is correct, apply fullelectrical power.

3. With the air system in full operation and allducts attached, measure current input to the

4. Relubricate the motor per themanufacturer’s instructions. Remove anyexcess lubricants from the housing and blower assembly.

CAUTION

A ground wire must run from theblower motor housing to a suitableelectrical ground such as a

properly grounded metallic

raceway or ground wire system.5. Do not operate the fan with the shield



motor and compare with the nameplaterating to determine if the motor isoperating under safe load conditions.

4.23.3. MAINTENANCE.

1. Periodically remove dirt from the blower wheel, housing and ducts.

2. Check tightness of all set screws.

3. After disconnecting the power source,check the wiring to see if insulation isdamaged or frayed.

removed.

CAUTION

Before attempting any repair work,be certain that all power to themotor and electrical accessoriesare turned off and locked in the off

position.

4-ELECTRICAL SYSTEM

SECTION III. INVERTER PARAMETER LIST

4.24. PARAMETER LIST. Parameter 3 (accesslevel) must be set to 3 in order to see some of

the parameters on this list.

P ARAMETER H AULOFF D ECK

100 0-50Hz; * 0-50Hz * 50/ 60 Hz – See Notes

1101.0 0 0 Starting Hz

1237 0 2 Brake enable

1470.0 Do not modify 6.0 Feedback loop

1472.0 Do not modify 100 Feedback loop

1800 2-16 (default 4) * 2-16 (default 4) * Carrier Freq. - See notes2106 2829 2829 Motor Overload, bug fix

2800 1 1 Motor Overload bug fix



• Parameter 100, set this using the dipswitch on the Inverter, not through the parameter list.

• Parameter 1800 sets the carrier fre-quency for the motor. You can modifythis if the motor is making a high pitch

noise when running. There is no ‘stan-dard’ setting so you have to try differ-ent values if you want to change it.


2801.9 1 1 Motor Overload, bug fix

2828 2198.6 2198.6 Motor Overload, bug fix

4-ELECTRICAL SYSTEM

SECTION IV. ELECTRICAL CABLE INSTALLATION LOCATIONS

4.25. TERMINAL BOX PANEL TO DECK CONNECTOR . Reference Connector in Figure7.5.53.

BRAID MATERIAL

OPTIONAL OPTICAL

R UNOUT CABLES



T e r m

i n a l

Deck cable is clamped to inside wall of enclosure above Terminal

DECK

CABLE

B o x

4-ELECTRICAL SYSTEM

4.26. TERMINAL BOX PANEL TO R EMOTE OPERATOR STATION. Reference Figure7.5.48.

Remote Operator BoxRemote Operator

Station Cable



T e r m

i n a l

B o x

Run the cable up the inside wall of the Enclosure to the ceiling. [Clamp one (1) time.]

4-ELECTRICAL SYSTEM

4.27. TERMINAL BOX PANEL TO INSIDE JOG STATION. Reference Figure 7.5.40



T e r m

i n a l

B o x

Inside Jog Station

Inside Jog

Run cable from Terminal Box Panel to floor. [Clamp two (2) times.]

Run cable along front of Braider, under the drip pans to tunnel.Run cable under tunnel to bottom of sensor stand.R bl th t id f th t l d t th I id J St ti

Station Cable

4-ELECTRICAL SYSTEM

4.28. TERMINAL BOX PANEL TO BOBBIN R UNOUT DETECTORS.

Bobbin RunoutDetector Wire



T e r m i n a l

B o x

Run small black wire assembly (240-9065) from Terminal Box Panel to

4-ELECTRICAL SYSTEM

4.29. TERMINAL BOX PANEL TO MAIN CONTROL PANEL. Reference Figure 7.5.43.

Cables to MainControl Panel



Run two (2) cables from the Terminal Box Panel, up the inside of the enclosure

wall, through the small opening in the enclosure ceiling.Run cables inside wire duct (240-8067) on top of enclosure to front of enclosure,

T e r m i n

a l

B o x

M a i n

C o n t r

o l

B o x

4-ELECTRICAL SYSTEM

4.30. OUTSIDE LIGHT SWITCH TO INSIDE LIGHT FIXTURE. Reference Figure 7.5.62.

L i g h t F i x tu



Run cable from outside light switch through the enclosure wall.

Run wire up the inside front of the enclosure wall, in conduit assembly,

Light Switch Cable

xt u r e

to the ceiling, then run along ceiling to light fixture.



Tamer Blower Motor Wiring



5-LUBRICATION SYSTEM

CHAPTER 5LUBRICATION SYSTEM

SECTION I. GENERAL DESCRIPTION

U NLESS NOTED IN THE TEXT , THE INFORMATION GIVEN FOR THE PLC-T IS STANDARD FOR THE PLCT-F ELECTRONIC VERSION .

5.1. GENERAL. Each MR-11 PLC-T deck module has been engineered to provide proper lubrication. The total system for lubricationconsists of both automatic and manually

controlled components.This section will provide the user withinstruction for operation, maintenance, and

5.3. R OTOR AXLE AND R OTOR ASSEMBLY.( Figure 7.5.21) A continuous supply of oilenters the rear of each rotor axle. Each axlewithin itself has three Bijur metering units

( Figure 7.5.21). These units distribute the proper discharge of oil as follows:

• Control Unit (6) Directs oil to the rear



troubleshooting.

5.2. AUTOMATIC OIL LUBRICATION. A Bijur Model V5W electric motor driven gear pump provides a constant volume discharge of oil toeach deck module.

The Bijur pump is affixed to the Settling Tank Assembly (See Figure 7.5.34). Oil under pressure is fed from the pump through twofiltering stations.

• Suction Filter Suction Filter for Bijur pump, Index No. 7, Figure 7.5.34.

• Cartridge Filter Figure 7.5.34.

The oil is passed in series through the filtersand through nylon tubing to the rear of theupper deck frame.

Oil from this closed circuit is diverted to feed

( )rotor axle bearing.

• Control Unit (7) Directs oil to the rear cam follower cartridges.

• Control Unit (27) Directs oil to both thefront rotor axle bearingas well as the front camfollower cartridgeassemblies.

5.4. EXTERNAL LUBRICATION TO R OTORS.

A Bijur meter unit from the same supplycircuit distributes oil from the rear of the upper deck frame through a meter unit to a dripper line positioned above the rotor pinion gear ( Figure 5.6.1) for 16, 20, 24 & 36 carrier braiders.

5.5. OIL PRESSURE R EGULATION. A pressuregauge and pressure sensing switch ( Figure5 5 1) are mounted within the closed loop of


The pressure sensing switch is in series withthe pressure gauge and continuously monitorsthe oil pressure. For whatever reason, shouldthe pressure fall below 45 PSIG ± 5 PSIG (310KPa ± 34 KPa), the switch will automaticallyshut off the drive motor and a "RED" light will

appear on the Alarm Box Display.

Common causes for inadequate pressureinclude:

1. Clogged filters: Check both filters.

2. Lubricator failure: Pump.

3. Leak in oil distribution circuit.

4. Low oil level within Bijur pump reservoir.

5.6. BIJUR SYSTEM SETTINGS. The Bijur pump is set to provide maximum pressure atall times. A pressure relief valve located in thesettling tank controls the pressure to the decks.This valve is set at 65 PSI (450 KPa) and is

nonadjustable.

The pressure sensing switch located near the pressure gauge at the rear of the deck is presetfor 45 PSIG ± 5 PSIG (310 KPa ± 34 KPa),minimum and is nonadjustable (Figure 5.5.1)

The capacity of the settling tank is 13 U.S.

gallons (49.2 liters) and should be filled tolevel of fluid level gauge using reservoir filler ( Figures 7.5.34 and 7.5.35).



CAUTION

Low oil level.

Do not run Bijur pump without oil.

Property damage could result.

FIGURE 5.5.1: PRESSURE SENSING SWITCH




2. Oil which is mixed with dirt will becleansed through filters as describedearlier.

3. Badly contaminated oil must be periodically drained or pumped from all

three settling locations. (See Maintenanceof Lubrication)

5.9. CHANGE GEAR LUBRICATION. (Not required on PLCT-F dual drive.) Thelubrication of the change gears and the deck drive chain components is by a sump locatedin the lower frame.

This sump is filled with about 2 U.S. gallons(7.6 liters) of oil which is fed to the drive chainand the two change gears by the churning and

5.10. CARRIER LUBRICATION. The carrier wrapped clutch is lubricated at recommendedintervals with oil by a felt pad within themoveable hub.

NOTE

MII offers a foam wick and largefelt wick as optional oiling methods. Contact MII Field

Service for additional information.Only one end of the felt pad must go thru a hole. The pad is trimmed to clear the hole. Do not allow the



and the two change gears by the churning andthe splashing of the oil.

Since the area is sealed, the oil can be used for a long period before replacement. (See Table5.13.1, Lubrication Schedule).

Oil level in this sump is to be to the center of the drive shaft.

pad to drag on the stationary hub.This will increase strand tension.The pad should just touch thestationary hub.

5.11. CAM TRACK LUBRICATION. The camtrack and cam follower rolling surfaces arelubricated by oil flow out of the cam followersand by slinging of oil from the gears.

SECTION II. SERVICE INSTRUCTIONS FOR BIJUR CENTRAL LUBRICATING

SYSTEM

5.12. GENERAL. Your machine is protected bya built-in Bijur central lubricating system. Bycorrect lubrication of all bearings served, itassures smooth operation of your machine for years, if properly maintained.

The Bijur system consist of three basicelements:

1. A LUBRICATOR which forces a constantflow of oil into

2. A single line of DISTRIBUTIONTUBING branched to supply oil to the bearing surfaces through

3. CONTROL UNITS which proportion thecorrect oil film to each bearing.


5.13. OIL. See Table 5.13.1.

TABLE 5.13.1: LUBRICATION SCHEDULE

I TEM F UNCTION LOCATION S OURCE & M EANS LUBRICANT I NTERVAL

1 Deck DriveShaft

*Not required

on PLCT-F

Dual Drive

Base of Deck Splash and Bath **EXXON - SpartanEP 150 or NewFormulation SpartanEP 150

After the 1st 1000 hrs.,then at 2000 hr. intervals

2 Rotor Gears and

Pinion Drive

Front of Deck Continuouslyrecirculated byBijur Pump

**EXXON - SpartanEP 150

2000 hrs. NOTE: The

braiding of certain type

materials may necessitate

more frequent oilchanges. The condition of

the filters will indicate

this.

3 C i Cl t h Cl t h H b M ll Oil EXXON S t EP 600 h



3 Carrier Clutch Clutch Hub Manually - Oil EXXON - Spartan EP150

600 hours

4 Shuttle Shaft

and Bobbin

Shuttle Spindle Manually - GreaseLithium 2

FINA - All Purpose 200 hours

5 Shuttle and CamTracks

Front of Deck Continuouslyrecirculated byBijur Pump


2000 hours NOTE: Thebraiding of certain type

materials may necessitate

more frequent oil

changes. The conditions

of the filters will indicate

this.

6 Rotor Axle

Bearings Front

& Rear

Within eachRotor

Continuouslyrecirculated byBijur Pump


7 Rotor Cam

Follower

Assemblies

Rotor Frame Continuouslyrecirculated byBijur Pump

**EXXON - SpartanEP

10 Blower Motor Top of SoundEnclosure

Manual See instructions withBlower Motor

See instructions withBlower Motor

11 Drive Motor

"Leeson" (PLCT-F)

Back of Deck Manual Polyrex EM 2 Years

1 to 2 full strokes onGrease Gun


5.14. STARTING A NEW MACHINE. Fill thereservoirs with the correct amount of oil. Thesettling tank holds 13 gallons, and the baseframe sump holds 6 gallons. Put 54/82 changegears on the deck. Remove all rotor caps (16,

Figure 7.5.19), and axle plug (5, Figure7.5.21). Start the machine and verify that oil isflowing out the end of all axles. This may takeseveral hours. Replace the plugs and caps andcontinue running until you verify that oil isflowing to all bearings on all axles. Note: the PLCT-F dual drive version does not usechange gears or require oil in the back sump.

5.15. MAINTENANCE. Check oil levels dailyand refill reservoir when required. Check thesystem periodically for loose or broken tubing,

3. Unscrew the filter from the adapter.

5.17.2. SETTLING TANK FILTER SCREEN.The settling tank filter (3, Figure 7.5.35) ismade up of two different sizes of mesh wire.Because of the different sizes of mesh wire,

this filter is one-directional and must beinstalled so that the oil flows through the finemesh wire first.

If the filter is installed the other way, the filter cannot be cleaned properly. Wire pieces andother contamination will get stuck between thecoarse and the fine mesh wire, making it

difficult to remove.

5.17.3. BASE SUMP FILTER . The base sumpfilter (14 and 18, Figure 7.5.33 for the 16, 20& 24 i ) (5 d 6 F 7 5 36 f h 36



system periodically for loose or broken tubing,worn hoses, loose fittings and connections.Replace filters as needed.

5.16. OPERATION. This fully automaticlubricating system is preset by the machinemanufacturer for best operation. The lubricator is a motor driven gear pump with a constantvolume discharge. Discharge volume may beadjusted by turning the bypass valvecounterclockwise to reduce the pressure or byclosing valve to increase pressure. This must

be set at maximum pressure.

5.17. FILTER R EPLACEMENT.

5.17.1. INLET FILTER . An inlet filter protectsthe lubricating system. The filter should beinspected every six months. If clogged, clean

it or replace it.T th filt (7 Fi 7 5 34)

& 24 carrier) (5 and 6, Figure 7.5.36 for the 36carrier) located in the base, is made up of twodifferent sizes of mesh wire. It must beinstalled so that the oil flows through the fine

mesh wire first.

5.18. MOTOR R EPLACEMENT.

1. Turn off the MR-11 PLC-T. Verify that the pump is not running.

2. Turn off the main power at the MainControl Box.

3. Disconnect the electric supply at the pumpmotor.

CAUTION

Do not turn the main power on.


5. Remove four socket head screws (14, Figure 7.4.34).

6. Carefully remove the pump from the tank.

7. Turn the lubricator unit upside down and

rest the motor end on a work table.Remove the U-shaped pump outlet tubing.Remove the four pump mounting screwsand O-rings. The pump and cover plateshould now lift off the motor.

8. Put the replacement motor down on thework table, put the cover plate onto thelocating hub on the motor and rotate thecover plate until its holes in the plate lineup with the motor mounting holes. Makesure the motor electrical connection is pointing in the desired direction.

shaft.

11. Carefully put the pump onto the motor hub.The pump should drop into place if theshafts line up.

12. Tighten the motor mounting screws evenlyusing 20 in.-lbs. (2.2 Nm) of torque.

13. Replace the U-shaped outlet tube, put thelubricator unit into the reservoir, connectthe system tubing and the motor electricalsupply.

14. Turn on the main power at the Main

Control Box.

15. Turn on the oil pump switch.

16 Set the pressure for maximum



9. Put the large O-ring into the groove in theface of the pump body; put the four mounting screws through the pump body

holes and carefully put the small O-ringonto each screw putting it well down intothe countersink.

10. Turn the tongue on the motor shaft to facethe same direction as the slot in the pump

16. Set the pressure for maximum.

17. Check for leaks.

18. Turn switch off.

19. Verify that pump operates when the braider is operating and that the pressure gage onthe back of the deck reads 45 PSIG ±5PSIG (310 KPa ±34 KPa).




6-OPTIONS

T R A N D

M U S T

P A Y

- O F F

HI S

S I D E

ø 6.10 INø 155 mm

3 74 IN

2 4 0 - 5 1

2 0



6.3. PROCEDURE FOR FIELD CONVERSION TO THE DLOW BRAIDING SYSTEM. (Refer to Figure 7.5.9)

CAUTION

Moving elements in shuttleassembly area. Disconnect power

and remove upper change gear.P l i j t h d d

1. Remove the carrier and wire or yarn bobbin from each shuttle assembly. Pleasenote the orientation of the "L" supports for reassembly.

2. Remove the "L" supports, (2, Figure 7.5.8or 3, Figure 7.5.11) by removing the M6screws (4, Figure 7.5.9). Pull the "L"support off the shuttle. Pull the shuttleextension to remove it from the shuttleshaft. Be sure the air hole is not plugged.

3. Apply a thin coat of a Molycoat lubricantor a Never-Seize compound to the shuttleshaft or to the inside of the shuttle

FIGURE 6.2.1: WIRE BOBBIN

S T T

H I

ø 1.96 INø 50 mm

ø 2.95 INø 75 mm

3.74 IN95 mm

4.84 IN

123 mm

6-OPTIONS

NOTE

The Molycoat lubricant or Never-Seize compound should bereapplied at six month intervals, or every 150 hours of operation,which ever comes first.

NOTE

The shuttle extension must havethe carrier latch up in the sameposition as the shuttle being

6. Install the sleeve (6, Figure 7.5.9) onto theshuttle extension (2) by pushing it by hand.Make sure that the O-rings remain in placeon the inside of the sleeve. The sleeve is toseat against the shoulder of the "L"support.

7. Assemble the sleeve socket (41, Figure7.5.5) to the moveable hub (9, Figure7.5.5) of the carrier assembly as follows:

a. Remove the two M4 slotted set screws(40) from the moveable hub (9).

b. Place the sleeve socket (41) in position

over the moveable hub (9) and securein place with two M4 x 10 socket headscrews (42). Apply Permatex to thescrew threads.



position as the shuttle being converted.

4. Install the "L" support assembly (3, Figure

7.5.9) onto the shuttle extension (2) andorient it to mate the slots over the shuttlemounting spacer (3, Figure 7.5.17 ). Notethe position of the "L" support to the fronttrack of the shuttle cam track (reference Figure 7.5.8). Also insure that the rest pin(10, Figure 7.5.16 ) is seated properly in theslot in the shuttle extension flange.

NOTE

The "L" support assembly (3,Figure 7.5.9), shuttle extension(2), and sleeve (6) are shipped as

an assembly. Therefore, steps 3,4 and 6 can be combined when

c. Check to insure that the clutch hubturns freely.

8. Turn the deck by hand to insure that all parts are properly located. All shuttlesmust move around the deck without hittingeach other.

9. Replace the standard adjustable strandguide sleeve with part - extended length -adjusting strand guide sleeve (1, Figure7.5.28) for DLOW. Position the face of the

flange approximately 50 mm in front of thecarrier pay-off roller and secure it in it place with the Kipp-lock-handle (24, Figure 7.5.28).

10. Choose the gears to produce the lead youwant. Remember that the rotor rpm cannotexceed 165 RPM for the 36 carrier & 185

RPM f or the 16, 20, & 24 carrier.

6-OPTIONS

same orientation as the wire or yarn braiding attachments that were removed.

The DLOW conversion is now ready for installing the prepared DLOW bobbins.

6.4. DECKING PROCEDURE FOR DLOW.

1. Put the first bobbin in place making surethat it is positioned for counterclockwise pay-off ( Figure 7.5.9).

2. Place the differential assembly in position.

Make sure that the key is properly seatedinto the key slot in the first bobbin.

3. Place the second bobbin on the differentialsleeve. Make sure that the bobbin is

best suited for the hose construction being run. The use of the center rollersor preform pins may be necessary as instandard braiding depending on wiretension, number of ends, and coveragerequired.

7. See use of trumpet and braidring ( Figure7.5.28), Paragraph 6.6 .

a. Before threading the wire onto theliner, loosen the Kipp handle (24) andmove the braidring (1, Figure 7.5.28)all the way in toward the deck andretighten the Kipp handle. Loosenscrews (4) and move the trumpet (2) allthe way away from the deck andretighten all screws (4).

b Thread the machine and attach the



positioned for counterclockwise pay-off and that the key is properly seated.

4. Install the carrier and latch in place.Repeat the procedure for all shuttles.

5. Check to insure that all carriers are in thelatched position.

6. Tying-in of the braiding strands.

a. Take the wire from the first bobbin, the

one farthest from the carrier, and goover the first bailer roller and aroundthe first strand roller.

b. Take the wire from the second bobbinand go over the second bailer roller andaround the second strand roller.

c. Pull the wire from the first bobbin even

with the end of wire from the second bobbin. Make sure that the wire from

b. Thread the machine and attach thewires to the liner.

CAUTION

With the braidring all the way tothe right, carriers have no

protection from snagging strands passing too close. Be sure this

cannot happen before jogging or running the braider.

Operate the braider enough to allow the braid point to reach the position it willremain in.

Be sure that the tie-in point for the

wires on the liner will pass through thetrumpet (2) without jamming.

6-OPTIONS

braidring ½ inch (13 mm) more.Retighten the Kipp handle securely.

d. Loosen all screws (4) and slide thetrumpet (2) right until it touches thewires coming from the braidring (1).

Now run the deck while moving thetrumpet 1 inch (25 mm) to the rightfrom the point it touched the stationarywires. When this point is reached,tighten all screws (4). Use a ½ inch (13mm) drive to operate the trumpetholder drive.

e. Use M12 socket screws (19) to adjustthe trumpet vertically and side to side.

f. Remove M8 socket screws (10) to

change the trumpets.

g. The trumpet and braidring are nowready for production operation.

h. To detect broken wires, a ground ring

should be used.i. To aid in clearing jams, remove the

screws holding the split trumpet halvestogether.

6.5. SUPERPACK . Superpack is a single let-off yarn package ( Figure 6.5.1) wound on a yarn

tube ( Figure 6.5.2) or a flanged bobbin( Figure 7.5.12). A special L-bar assembly,( Figure 7.5.15) is required.



MAX. BULGE ¼ IN6.4 mm

10 ½ IN

266.7 mmø 6 ½ IN (MAX)

ø 165 mm

DIRECTION OF WIND

MUST BE AS SHOWNNOTE:

YARN MUST BEBELOW ENDS OF

TUBE.

6-OPTIONS

ø 1.592 IN

ø 40.5 mm

+.01-.00+.25-.00 PART NO. 240-4018

VIEW A-A

P A Y O F F

D I R E

C T I O

N

LAY OF

PAPER

11.575 IN294 mm

+.00-.062

+.00-1.5

±.02

±5

± . 0 1

± . 2 5

.44 IN11.2 mm

. 2 5

I N

6 . 4 m m

A

A

.325 IN 8.25 mm



NOTE

1. Notches to be at 180°.

2. Contruction:Sonoco Products Co.’s Spiral Durolene with seamless low mark outside ply.

6.6. USE OF TRUMPET AND BRAIDRING. The braidring and trumpet are intended for use with

wire only. The braidring and trumpet weredesigned to increase wire coverage on the

per foot to an acceptable level. They will work up to about 93% coverage before they losetheir effectiveness. These numbers may vary because they depend on the wire product beingused.

Picking the correct size trumpet to match the

diameter of the hose is the key to proper operation of the system. If the trumpet is too big, more cross overs will be present. If thetrumpet is too small, there is the danger that a bulge in the extruded hose will not be able togo through the trumpet and will tear thetrumpet stand off the tunnel cover. Proper placement of the braidring and trumpet inrelation to each other is a must. Keep in mind,however, that there are products that will runbetter with the system set up slightly different

FIGURE 6.5.2: SUPERPACK YARN CONVERTER TUBE SPECIFICATIONS

6-OPTIONS

6 inches (152 mm) of hose, the system willhave removed all the slack and very few crossovers will appear. Slack wire between the braid point and the bobbin will be almost

eliminated. The system will take this wire and place it on the hose in the form of slightlyloose wire and the occasional cross over.

SECTION II. TRUMPET AND BRAIDRING (SLOW OPTIONS)

6.7. INSTALLATION AND OPERATION OF TRUMPET AND BRAIDRING (SLOW -OPTIONAL). (Refer to Figure 7.5.28)

1. Before threading wire onto liner, loosenKipp handle (24, Figure 7.5.28) and move

braidring (1, Figure 7.5.28) all the way tothe right and retighten Kipp handle.Loosen screws (4) and move trumpet (2)all the way to the left and retighten allscrews (4).

4. Loosen all screws (4) and slide the trumpet(2) left until it touches the wires comingfrom the braidring (1). Now run the deck while moving the trumpet 1 inch (25 mm)in from the point it touched the stationarywires. When this point is reached, tightenall screws (4). Use a ½ inch drive to

operate the trumpet holder.5. Use M12 socket screws (19) to adjust the

trumpet vertically and side by side.

6 Remove M8 socket screws (10) to change



CAUTION

With the braidring all the way in,the carriers have no protectionfrom snagging strands passing tooclose. Be sure this cannot happenbefore running the braider. Movethe braidring out, if necessary, to

prevent this.

2. Thread the machine and attach all wires tothe liner. Operate the braider enough toallow braid point to reach the position itwill remain in. Be sure that the tie-in pointfor the wires on the liner will pass throughthe trumpet (2) without jamming.

3. Jog the deck until any shuttle reaches ai i h i i f f h

6. Remove M8 socket screws (10) to changethe trumpets.

7. The trumpet and braidring are now ready

for production operation.

8. To detect broken wires, a ground ringshould be used.

9. To aid in cleaning jams, remove the screwsholding split trumpet halves together.

10. The stand slide assembly and inside jogstation must be installed as shown. The box must be facing the haul-off. Failure todo this can result in severe damage to the braider.

11. The sensor stand assembly must beinstalled as shown in order to place thetrumpet in the correct position.

12. On older braiders M6 screws are installed



6-OPTIONS

FIG. &INDEXNO.

PART NO. DESCRIPTIONUNITSPERASM.

6.9.1 SECURING HARDWARE

1 M20 X 150 DIN 931HEX HEAD BOLT (83291) (16, 20, 24 CAR.)

HEX HEAD BOLT (83291) (36 CARRIER)

8

12

2 A20 DIN 127LOCKWASHER (84124) (16, 20, 24 CARRIER)LOCKWASHER (84124) (36 CARRIER)

812

3 B21 DIN 125WASHER (84055) (16, 20, 24 CARRIER)WASHER (84055) (36 CARRIER)

812

4 240-0013THREADED BUSHING (16, 20, 24 CARRIER)THREADED BUSHING (36 CARRIER)

1216

5 240-0014 NUT (16, 20, 24 CARRIER) NUT (36 CARRIER)

1216

6 240-0001 BASE FRAME 1

7240-0106360-0106

DECK MOUNTING PLATE (16, 20, 24 CAR.)DECK MOUNTING PLATE (36 CARRIER)

11



360 0106 DECK MOUNTING PLATE (36 CARRIER) 1

8 S-5573ANCHOR (16, 20, 24 CARRIER)ANCHOR (36 CARRIER)

1216

9 S-5574 HAUL-OFF ANCHOR 4

10 240-0012 BASE PLATE 4

6-OPTIONS

38.1

940

860

700±0.280

120

1

0 0

5 0

2 5 0

3 5 0 ± 0 . 2

2 5 0

1 0 0

+10-0



( 1

2 ) ø

3

( 8 ) M

2 0

3 5 0 ± 0 . 2

7 2 0 ±

0 . 2

5 2

0 1 6 2 0

2 5 0

2 5 0

+ 1 - 0



6-OPTIONS



6-OPTIONS

SECTION V. BRAIDING NOSE ASSSEMBLY

6.10. The Braid Nose Assembly, whencorrectly positioned, prevents the wire tensionfrom being transferred directly to the hose

inner tube. This allows for better control of theinner tube diameter. In some HoseConstructions, the Braid Nose may eliminatethe need for freezing or using air in the inner tube.

When selecting a Braid Nose for a HoseConstruction, the inside diameter of the Braid Nose should be as close as possible to thelargest diameter of the inner tube.

Since each Hose Construction application isdifferent, the Braid Nose Assembly is designedto be adjustable. This gives the operator theability to adjust the position of the Braid Nose

until the desired results are achieved. The position of the Braid Nose setup can berepeated by documenting the location from thescales on each of the assembly components.



6-OPTIONS

5

4

32110

11

13



SEE FIGURE 6.10.2

FOR BRAID NOSES

612

6-OPTIONS

FIG. &INDEXNO.


6.10.1 240-9257 ETC BRAIDING NOSE ASSEMBLY (I.D. 4 - 41)

5000233 GUIDE FLANGE ASSEMBLY KIT

1 240-9244 BRAIDING TUBE 12 M5 X 8 DIN 915 SOCKET SET HEX SCREW (81942) 2

3 240-9254 BRAIDING HUB 1

4 M5 X 12 DIN 6912 SOCKET HEAD SCREW (82020) 6

5 240-9256 SLEEVE ASSEMBLY 1

6 M5 X 5 DIN 913 SOCKET SET HEX SCREW (81890) 2

7 S-5549 SQUARE DRIVE SOCKET (TOOL - NOTSHOWN) 1

8 S-5550 EXTENSION (TOOL - NOT SHOWN) 1

9 S-5551 SLIDING T (TOOL - NOT SHOWN) 1

50002355000236

CONE SET KIT 4MM THRU 12MMCONE SET KIT 13MM THRU 15MM



500023650002375000238500023950002405000241

CONE SET KIT 13MM THRU 15MMCONE SET KIT 16MM THRU 20MMCONE SET KIT 21MM THRU 23MMCONE SET KIT 24MM THRU 27MMCONE SET KIT 34MMCONE SET KIT 41MM

10 240-9255 SPUR GEAR 1

11 S-5644 SOC. HD. SHLDR. SCREW (1/4"X1/2"X10-24) 1

12 S-5569 SOCKET SET SCREW (M6 X 10 BRASS TIP) 2

13

240-9246240-9248240-9249240-9250240-9251240-9252240-9253

BRAIDING CONE 4MM - 12MM (5000235)BRAIDING CONE 13MM - 15MM (5000236)BRAIDING CONE 16MM - 20MM (5000237)BRAIDING CONE 21MM - 23MM (5000238)BRAIDING CONE 24MM - 27MM (5000239)BRAIDING CONE 34MM (5000240)BRAIDING CONE 41MM (5000241)

1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R

6-OPTIONS



1 THRU 35

6-OPTIONS

FIG. &INDEXNO.


6.10.2 240-9257 ETC BRAIDING NOSES (I.D. 4 - 41)

1 240-9236 BRAIDING NOSE (I.D. 4) 1 A/R

2 240-9237 BRAIDING NOSE (I.D. 5) 1 A/R 3 240-9238 BRAIDING NOSE (I.D. 6) 1 A/R











12 240 9286 BRAIDING NOSE (I.D. 15) 1 A/R












6-OPTIONS

43

2111

10

14

13



56

12



6-OPTIONS

SECTION VI. BRAID MATERIAL RUNOUT SENSOR

6.11. Mayer Industries offers an optionalBraid Material Runout Sensor that will stopthe braider before a bobbin runs empty andcreates a defect in the hose. This is donethrough the use of 2 laser sensors (per deck)that measure the distance to the bobbin eachtime a bobbin passes in front of the sensor. Thesmallest diameter bobbin measured by eachsensor is recorded by the PLC. The system iscalibrated by measuring the distance to anempty bobbin. The customer can thenconfigure the PLC to shut off the braider at a

certain distance before the bobbin iscompletely empty. Depending on the type of material being used, this cutoff distance isusually in the range of 0.5 - 2 mm.

6 12 SETUP

3. Plug the connection cables to the laser sensors per Figure 6.15.1.

NOTE: Take care not todamage the plug on the laser

sensor unit. The plug on thelaser sensor unit will pull out of the laser sensor if any force is applied to it.

4. Connect the ribbon and power cable to the primary control box.

5. Install the Laser warning stickers on eachwindow of the enclosure.



6.12. SETUP.

1. Mount the two optical laser sensor assemblies in the predrilled holes on thetop of the deck shield using two M8 x 25 bolts, two M8 flat washers and two lock washers at each location.

2. Mount auxiliary box and run the sensor cable per Figure 6.15.1.

6-OPTIONS

6.13. CALIBRATION.

1. Install one empty bobbin onto the shuttle atcounter-clockwise position; and one empty bobbin at the clockwise position.

2. Install the rest of bobbins onto the shuttlewith FULL wire or yarn bobbins.** Do not tie in for braiding. **

3. Install and lock all the carrier assemblies.

4. Turn on the power.

5. Run the braiding machine at slow speed tocalibrate (NOT braiding).

6. At the main MENU, touch “SETTINGS”;at the next menu pop-up, touch the“CONFIG” button next to the bobbin runout setting.

8. Subtract 1.0 mm minimum for yarn and0.5mm minimum for wire to the actualreadings on the left column. NOTE: For yarn with a diameter larger than 1mm,the cut off distance will have to bemodified according to the diameter.EXAMPLE: If the reading on the left sideis 194mm, set the cut off distance at193mm minimum for yarn and 193.5mmminimum for wire.

9. Additional calibration is needed only if bobbins with a different barrel diameter areused.

6.14. BRAID MATERIAL R UNOUT PREVENTIVE MAINTENANCE.

1. Wipe the lenses of the Lasers at each bobbin change with a "clean" cotton cloth -Do not use any material that will scratch



7. At the next menu, there will be displays of

the distance to the empty bobbin on eachsensor; run the machine for at least 5 to 10minutes and watch the distance to bobbinrun out. When the readings of the distanceget steady, enter the desired bobbin run outcutoff distances for the sensors at the righthand side column.

Do not use any material that will scratchthe lenses.

2. Depending on materials being braided, thefrequency of cleaning may vary - adjust asrequired.

3. Erratic bobbin size readings are anindication that the laser lenses need to becleaned.



6-OPTIONS

FIG. &INDEXNO.


6.15.1 BRAID MATERIAL R UNOUT SENSOR

1 3000651 SENSOR CABLE 4

2 S-5751 LASER SENSOR 43 1000639 SENSOR HOLDER 4

4 1000640 MOUNTING BASE 4


6 A8 DIN 127 LOCK WASHER (84105) 12

7 B8.4 DIN 125 FLAT WASHER (84025) 12

8 M4 X 24 DIN 6912 SOCKET HEAD SCREW (81866) 129 M8 X 30 DIN 6912 SOCKET HEAD SCREW (82700) 4

10 1000648 SENSOR BREAKING PROTECTOR BRACKET 4


12 1000647 SENSOR BREAKING PROTECTOR 4



Tie wrap laser sensor cables to thedeck cables.

Sensor cables from Laser Sensors 3and 4 are to be fastened to the inner wall of

the enclosure with cable clamps.

Take care not to damage the plug onthe laser sensor unit. The plug on the laser sensor will pull out of the laser sensor if any force is applied to it.

Install the Laser Warning Decal oneach window of the enclosure.

13 S-5756 LASER LIGHT WARNING DECAL 4

1

2

3

4

6-OPTIONS



6-OPTIONS

SECTION VII. DUAL DRIVE SYSTEM

Note: This manual does not include 16 Carrier Dual Drive at this time.

6.16. DUAL DRIVE SYSTEM. Mayer Industriesoffers an optional Dual Drive System toreplace the drive shaft/change gear system.This system has individual inverter drives andmotors on each deck and on the Haul Off.

Technical Description:

• Hardware: Siemens S7-300 andS7-200 PLC’sProfibus Network

• Operator Interface: Siemans 6 inch Touch Screen

• Drives:7.5 Hp (Braider) (5.6 Kw) and10 Hp (7.5 Kw) (Haul Off) Inverter

• Less oil consumption: No lubricationneeded for chains or change gears. This

results in cost savings and no clean up after change gear exchange

• Faster Hose construction: No change or range gears needed

• Absolute selection of pitch/leads

• Ability to store programs / hose construc-

tionsPOWER CONSUMPTION: (Ball Park)

• Single Deck: 5 KVA

• Double Deck: 9 KVA



10 Hp (7.5 Kw) (Haul Off) InverterDrives;

1 per Braider and 1 per Haul Off

• Motors: Leeson 7.5 Hp (5.6Kw) InverterDuty

• Drive Train:Gear Belts

• Lead/Pitch Range: 6-200 mm**Longer Pitches can be obtained withsoftware and/or gear pulley change.

ADVANTAGES:

• Less wear parts: No change gears, driveshafts or chains

• Easier Installation: No drive shafts to line

up / no covers to install

INSTALLATION: See Chapter 1

ADJUSTMENTS AND MAINTENANCE: SeeChapter 2 (Excluding the drive train - alladjustments are the same except):

• Check and adjust belt tension on Haul-Off and Braider drive belts after 100 hours of service and then at 500 hour intervals.

• See Lubrication chart in Chapter 5 for lubrication of the drive motor.

CONTROLS: See Chapter 3A

ELECTRICAL SYSTEM: See Chapter 4

LUBRICATION: See Chapter 5

P / D D S l i hi

6-OPTIONS

6.16.1. SENSOR STAND ASSEMBLY.

26

8,9

11,125

13

4

3,10

6/147/15

2

21

20

8,9

27

HIDDEN



1

22

23

3

24

25

3

10 4

10

16

17,18,19

HIDDEN

FROM VE

6-OPTIONS

FIG. &INDEXNO.


6.16.1.120006692000765

DUAL DR SENSOR STND ASM (20 & 24 CARRIER )DUAL DRIVE SENSOR STAND ASM (36 CARRIER )

1

2000628

NOT DESIGNED

STAND BASE ASSEMBLY (20 & 24 CARRIER )

STAND BASE ASSEMBLY (36 CARRIER )

1 A/R

1 A/R 2 240-6072 STAND SLIDE ASSEMBLY 1

3 240-6079EYE BOLT ASSEMBLY (20 & 24 CARRIER )EYE BOLT ASSEMBLY (36 CARRIER )

1 A/R 2 A/R

4 240-6080 SWING ARM ASSEMBLY 1

5 240-6061 SENSOR PIN 1

6 M6 X 16 DIN 912 SOCKET HEAD SCREW (053508.0) (82379) 6 A/R 7 B6.4 DIN 125 FLAT WASHER (051040.0) (84015) 6 A/R

8 M16 X 35 DIN 6912 SOCKET HEAD SCREW (050753.0) (83200) 2

9 B17 DIN 125 FLAT WASHER (84045) 2

10 M10 DIN 934 NUT (050945.0) (83580) (20 & 24 CARRIER ) NUT (050945.0) (83580) (36 CARRIER )

1 A/R 2 A/R



11 M8 X 80 DIN 931 HEX BOLT (82800) 1

12 M8 DIN 934 NUT (050941.0) (83570) 1

13 89020 SAFETY PEG (NR. 202055) 1

14 M8 X 16 DIN 6912 SOCKET HEAD SCREW (82650) 2 A/R

15 B8.4 DIN 125 FLAT WASHER (84025) 2 A/R

16 S-5783 PIPE STRAP 2



19 B8.4 DIN 7349 FLAT WASHER (84028) 2

20 2000786 SLIDE ASSEMBLY 1

21 1000788 CLAMPING PLATE 1

22* 1000744 OIL LINE PROTECTOR CONDUIT 1

23* S-4716 HEX HEAD A NCHOR BOLT (3/8 X 2 ¼) 6

24* A10 DIN 127 LOCK WASHER (051221 0) (84110) 6

6-OPTIONS

6.16.2. DUAL DRIVE ASSEMBLY.

23,248

7

920

166

18

SEE FIGURES 6.16.2.2AND 6.16.2.3



121110

13 14

15

4 5

16

622

3

1

21

2

18

17,25

26



6-OPTIONS

5

493

10

UPPER DECK FRAME



1 .15 mmAXIAL PLAY

7

2

8

6

6-OPTIONS

FIG. &INDEXNO.


6.16.2.2 DUAL DRIVE ASSEMBLY (16, 20 & 24 CARRIER )

1 240-2011 BEARING HOUSING 2

2

30 X 42 X 0.1 DIN 988

30 X 42 X 0.2 DIN 98830 X 42 X 0.3 DIN 98830 X 42 X 0.5 DIN 98830 X 42 X 1 DIN 988

SHIM WASHER (051128.0) (84249)

SHIM WASHER (84248)SHIM WASHER (051129.0) (84245)SHIM WASHER (051130.0) (84247)SHIM WASHER (051131.0) (84246)

A/R

A/R A/R A/R A/R

3 240-2016 PINION SHAFT 1

4 240-2025 PINION GEAR 32 T 1

5 A8 X 7 X 32 DIN 6885 K EY (050317.0) 1

6 M10 X 40 DIN 6912 SOCKET HEAD SCREW (050725.0) 8

7 KM 6 DIN 981 LOCK NUT (050986.0) 2

8 MB 6 DIN 5406 SAFETY WASHER (051248.0) 2

9 6306-2RS DIN 625 BALL BEARING (051362.0) 2




6-OPTIONS

8

549

3

10

UPPER DECK FRAME



1.15 mm

AXIAL PLAY

7

2

6



6-OPTIONS

2

53 8 4 6 7



1110

12

9

1

A

A

SECTION A-A

13,14

6-OPTIONS

FIG. &INDEXNO.


6.16.2.4 3000617 MAIN CONTROL BOX ASSEMBLY (SHEET 1)

1 1000411 MAIN CONTROL BOX 1

2 S-5360 MUFFIN FAN GUARD 2

3 S-5816 PUSHBUTTON, FLUSH, CLEAR 1

4 S-4047 EMERGENCY STOP 1

5 S-4773 PUSHBUTTON LENS 1

6 240-8656 ELECTRICAL LABEL 1

7 M3 X 6 DIN 84 CHEESE HEAD SCREW (81580) (050608.0) 4

8 S-3883 PRIMARY POWER SWITCH ASSEMBLY 1

9 M8 X 16 DIN 6912 SOCKET HEAD SCREW (82650) (050707.0) 6

10 A8 DIN 127 LOCK WASHER (84105) (051220.0) 10

11 M8 DIN 557 SQUARE NUT (83565) (050979.0) 6

12 B8.4 DIN 125 FLAT WASHER (84025) (051042.0) 6

13 S-5723 BLACK LEGEND 3

14 S-5788 2 POSITION KEYED SWITCH 3



14 S 5788 2 POSITION K EYED SWITCH 3

6-OPTIONS

18 89

10,11,1213,14,4,2(FIG. 6.16.2.4)

EMERGENCYSTOP MAIN

POWER

PILOTLIGHT

S3S1



6,7 1 4,5 217 19

6-OPTIONS

FIG. &INDEXNO.


6.16.2.5 3000617 MAIN CONTROL BOX ASSEMBLY (SHEET 2)

1 3000610 MAIN C NTRL. BOX PANEL ASM. (FIGURE 6.16.2.6) 1

2 100-0718 MOUNTING R AIL 2

3

4 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 8

5 M4 X 16 DIN 84 SLOTTED CHEESE HEAD SCREW (81850) 4

6 B10.5 DIN 125 WASHER (84030) (051043.0) 6

7 M10 DIN 934 HEX NUT (83580) (050945.0) 6

8 3000416 CONTROL BOX DOOR WIRE ASSEMBLY 1

9 S-5815 BLUE SWITCH 1

10 S-5359 MUFFIN FAN 1

11 S-5361 FAN POWER CABLE 1


13 A4 DIN 127 LOCK WASHER (84095) (051217.0) 4

14 M4 DIN 935 HEX NUT (83510) (050935.0) 4



( ) ( )

15 S-5738 MEMORY CARD (NOT SHOWN) 1

16 S-5784 BLUE HOOK -UP WIRE (NOT SHOWN) 10m

17 97390 CONTACT BLOCK 3

18 S-5798 R ED SWITCH 1

19 3000829 DOOR SWITCH CABLE 1

6-OPTIONS

12 15 20

9,10

18 167

11

12

19

13,14

8

17

29 21 2228

13,14

6

6



13,14

9,10

1

2

3 4

58

12

13,14

6-OPTIONS

FIG. &INDEXNO.


6.16.2.6 3000610 MAIN CONTROL BOX PANEL ASM. (SHEET 1)

1 1000410 MAIN CONTROL BOX PANEL 1

2 S-4034 TRANSFORMER (540-220V) (T1) 1

3 S-5582 E-STOP R ELAY (K1) 1

4 S-5686 R ELAY, 24V DC (K2) 1

5 S-5018 TERMINAL BLOCK (PE) 3

6 S-5083 AUXILLARY STARTER CONTACT BLOCK 3

7 S-5683 R ELAY, 9AMP (KM3) 1

8 S-5589 4 CONDUCTOR TERMINAL (AWG 28-12 GREY) 34


10 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 13

11 S-5591 TERMINAL MARKER 1-50 1

12 S-5499 NYLON CHEESE HEAD SCREW (M4 X 12) 19

13 97340 WIRING DUCT 3.2 M

14 97341 WIRING DUCT COVER 3.2 M



15 S-5681 POWER SUPPLY (U3) 1

16 S-5381 CIRCUIT BREAKER (F2) 1

17 S-3697 STANDARD R AIL 1510 mm

18 S-5588 3 CONDUCTOR TERMINAL (AWG 24-6 PE) 4

19 S-5590 JUMPER 9

20 S-5082 MANUAL STARTER (Q3) 1



23

24

25

26

27

6-OPTIONS

4

13,14(FIG6.16.2.6)

12(FIG 6.16.2.6)

5

6

7 8 18(FIG 6.16.2.6))

13,14(FIG 6.16.2.6)

9,10(FIG 6.16.2.6)



12 39,10(FIG 6.16.2.6)

6-OPTIONS

FIG. &INDEXNO.


6.16.2.7 3000610 MAIN CONTROL BOX PANEL ASM. (SHEET 2)

1 S-5736 DIN MOUNTING R AIL 1 A/R

2 S-5735 PLC 1

3 S-5737 FRONT CONNECTOR SCREW 1

4 S-5682 CONTACTOR (KM1) 1


6 S-5587 2 CONDUCTOR TERMINAL (AWG 24-6 BLUE) 1


8 S-5120 STRIP MARKER (L1 L2 L3 BIG) 2



6-OPTIONS

2

4

3

5 16

6

9

19,20,21



7,8

2,1015111712 1314

1

18

6-OPTIONS

FIG. &INDEXNO.


6.16.2.8

3000601300060430006063000605

30008233000822

INVERTER PLATE ASM. (HIGH VOLT. DOUBLE D)INVERTER PLATE ASM. (HIGH VOLT. SINGLE D)INVERTER PLATE ASM. (LOW VOLT. DOUBLE D)INVERTER PLATE ASM. (LOW VOLT. SINGLE D)

INVERTER PLT. ASM. (HV) (DBL D) (36 CAR .)INVERTER PLT. ASM. (HV SINGLE D) (36 CAR )

1 2000607 I NVERTER PLATE ASSEMBLY 1

2M5 DIN 934M5 DIN 934

HEX NT (050937.0) (3000601, 3000606, 3000823)HEX NT (050937.0) (3000604, 3000605, 3000822)

1915

3

S-5758S-5758S-5762S-5762S-5804S-5804

7.5 HP HIGH VOLT I NVERTER (3000601)7.5 HP HIGH VOLT I NVERTER (3000604)7.5 HP LOW VOLT I NVERTER (3000606)7.5 HP LOW VOLT I NVERTER (3000605)15 HP HIGH VOLT. I NVERTER (3000823)15 HP HIGH VOLT. I NVERTER (3000822)

212121

4S-5760S-5760

PROF. OPT. CARD (3000601, 3000606, 3000823)PROF. OPT. CARD (3000604, 3000605, 3000822)

32

5 81889 SELF-TAPPING SCREW 6

S-5759 10 HP HIGH VOLT I NVERTER (3000601) (3000823) 1



6 S-5759S-5763S-5763

10 HP HIGH VOLT I NVERTER (3000604) (3000822)10 HP LOW VOLT I NVERTER (3000606)10 HP LOW VOLT I NVERTER (3000605)

111

7 S-2859 WIRE, BLACK 12 AWG 2000 mm

8 S-5305 WIRE FERRULE 18

9 S-3697 STANDARD R AIL 450 mm

10 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 6

11 S-5588 3 CONDUCTOR TERMINAL, GREEN 412 S-5586 2 CONDUCTOR TERMINAL, GRAY 9

13 S-5120 STRIP MARKER 1

14 S-5743 JUMPER , GRAY 6

15 1000655 SWITCH BRACKET 1

16S-5671S-5671

OPER . I NT. FOR I NV. (3000601, 3000606, 3000823)OPER . I NT. FOR I NV. (3000604, 3000605, 3000822)

32

17 S 5121 STRIP MARKER 1

6-OPTIONS

5

7

8

33

7

6

8

42

SECTION A-A(See Sheet 2)

10



7

5

8

9

1

SECTION B-B(See Sheet 2)

11

6-OPTIONS

FIG. &INDEXNO.


6.16.2.9 3000886MAIN CONTROL BOX ASSEMBLY

(STAND ALONE) (SHEET 1)


2 S-5359 MUFFIN FAN 13 S-5360 MUFFIN FAN GUARD 2

4 S-5361 FAN POWER CABLE 1

5 M4 X 12 DIN 84 SLOTTED CHEESE HD. SCREW (81810) (052709.0) 8

6 M4 X 16 DIN 84 SLOTTED CHEESE HD. SCREW (81850) 4

7 M4 DIN 934 HEX NUT (83510) (050935.0) 12

8 A4 DIN 127 LOCK WASHER (84095) (051217.0) 129 S-5829 FAN FILTER 1

10 S-5723 BLANK (BLACK ) LEGEND 3

11 S-4047 EMERGENCY STOP LEGEND 1



6-OPTIONS

1

8

2,3

6,7

4,5



9,10

6-OPTIONS

FIG. &INDEXNO.


6.16.2.10 3000886MAIN CONTROL BOX ASSEMBLY


1 3000885 MAIN CONTROL BOX PANEL ASSEMBLY 1

2 S-5788 2 POSITION K EYED SWITCH 33 97390 CONTACT BLOCK WITH BASE 3


5 S-5816 CLEAR FLUSH PUSHBUTTON 1

6 97383 OPERATOR 2 POSITION SELECTOR SWITCH 1

7 97393 CONTACT BLOCK WITH BASE 1

8 S-5823 8" TOUCH SCREEN 19 S-5798 R ED SWITCH 1

10 S-4773 PUSHBUTTON LENS 1



6-OPTIONS

10

1

17

13

2,3,22

17

8,22

15

12

5

4

6

2324



2,3,13,22

11

15

7

20

6-OPTIONS

FIG. &INDEXNO.


6.16.2.11 3000885MAIN CONTROL BOX PANEL ASSEMBLY



2 M4X16 DIN 84 SLOTTED CHEESE HEAD SCREW (81850) 283 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 28

4 S-5590 JUMPER 10

5 S-5589 4 CONDUCTOR TERMINAL 50

6 S-5591 TERMINAL MARKER 1-50 1

7 S-5583 PLC 1

8 S-5499 NYLON CHEESE HEAD SCREW ( M4 X 12) 349 S-5582 E-STOP R ELAY 1

10 S-5686 24 V DC R ELAY 1

11 S-5681 POWER SUPPLY 1

12 S-5018 TERMINAL BLOCK 3

13 S-3697 STANDARD R AIL 3@310mm

14



1415 97340 WIRING DUCT WITH COVER 6@330mm

16

17 97340 WIRING DUCT WITH COVER 2@360mm

18

19

20 S-5744 PROFIBUS MODULE 1

21 S-5680 PROFIBUS CONNECTOR 4

22 S-5485 M4 I NSERT 54

23 S-5845 2 POSITION CONNECTOR 1

24 S-5849 4 POSITION CONNECTOR 1

6-OPTIONS

16

1511

13

1

2128 15 (Sheet 1)

3

14



3

15 (Sheet 1)

6 7

5

9

10

2,3,13,22(Sheet 1)

6-OPTIONS

FIG. &INDEXNO.




1 S-3697 STANDARD R AIL 200mm

2 S-5588 3 CONDUCTOR TERMINAL 53 97340 WIRING DUCT WITH COVER 2@400mm

4

5 S-5683 9 AMP R ELAY 1



8 S-5072 CIRCUIT BREAKER (F1) 19 S-5381 CIRCUIT BREAKER (F2/F4) 2





14 S-4034 TRANSFORMER (540-220V) 115 S 3883 PRIMARY POWER SWITCH ASSEMBLY 1



( )15 S-3883 PRIMARY POWER SWITCH ASSEMBLY 1

16 S-5083 AUXILIARY STARTER CONTACT BLOCK 3

6-OPTIONS

17,18

7

8

11

21 (Sheet 1)

18 (Sheet 1)

17, 18

5

16 (Sheet 2)

2,3,22 (Sheet 1)3

14

2,3,22 (Sheet 1)3

15

2 (Sheet 2)

2 3 22 (Sh 1)20

78

11

21 (Sheet 1)

18 (Sheet 1)



2,3,22 (Sheet 1) 17,18

6

8

11

21 (Sheet 1)

18 (Sheet 1)

9

21

10

19

16

HAULOFF

DECK 1

DECK 2

LUBE BLOWER

2,3,22 (Sheet 1)

6-OPTIONS

FIG. &INDEXNO.




1

23 S-3697 STANDARD R AIL 2@70mm

4

5 97340 WIRING DUCT WITH COVER 890mm

6 S-5759 I NVERTER , 10 HP HIGH VOLT 1

7 S-5758 I NVERTER , 7.5 HP HIGH VOLT 1/Deck A/R

8 S-5761 OPERATOR I NVERTER I NTERFACE 2/Deck A/R 9 S-5586 2 CONDUCTOR TERMINAL, GREY 9

10 S-5743 GREY JUMPER 6

11 S-5760 PROFIBUS OPTION CARD 2/Deck A/R

12 S-5763 I NVERTER , 10 HP LOW VOLT A/R

13 S-5762 I NVERTER , 7 HP LOW VOLT A/R





( )


17 M5 DIN 934 HEX NUT (83520) 12

18 S-4082 SELF CLINCHING STUD (M5) 12




6-OPTIONS

11,12,13



2 3

1

10

5,6 7,8,94

6-OPTIONS

FIG. &INDEXNO.


6.16.2.14 3000900TERMINAL BOX ASSEMBLY

(WITHOUT TOUCHSCREEN) (SHEET 1)

1 1000899 TERMINAL BOX 1

2 S-3505 R ED PUSHBUTTON SWITCH 13 ZB2-BD5 SELECTOR SWITCH (97382) 1

4 1000638 TERMINAL BOX A NGLE 2

5 S-4047 EMERGENCY STOP LEGEND 1

6 ZB2-BS54 OPERATOR PUSHBUTTON (97384) 1


8 M6 DIN 934 HEX NUT (050939.0) (83530) 49 A8 DIN 127 R IBBED WASHER (84105) 4

10 1000897 I.D. NAMEPLATE 1

11 M4 X 10 DIN 84 CHEESE HEAD SCREW (81790) 4

12 M4 DIN 934 HEX NUT 4

13 A4 DIN 127 LOCK WASHER 4



6-OPTIONS

10,11,1222

15,16

2,3,17

5

1

4

6

2,3,17

10,11,12

12,13,14

12,13,14

7



12,13,14

12,13,14

6-OPTIONS

FIG. &INDEXNO.




1 1000616 TERMINAL BOX PANEL 1

2 M5 X 8 DIN 84 CHEESE HEAD SCREW (050638.0) (81930) 93 S-3697 MOUNTING R AIL 275mm ea.

4 S-5590 JUMPER 10


6 S-5744 EXPANSION MODULE 1

7 S-5848 4 POSITION HEADER 1

8 S-5844 2 POSITION HEADER 19 S-5583 PLC 1

10 97340 WIRE DUCT 400mm ea.

11 97341 WIRE DUCT COVER 400mm ea.

12 S-5499 NYLON CHEESE HEAD SCREW 20






16 M8 X 40 DIN 7380 BUTTON HEAD SCREW (82752) 4

17 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 9


19 S-5290 STRAIN R ELIEF CONNECTOR (NOT SHOWN) 1

20 S-5328 NUT (NOT SHOWN) 1


22 S-5591 MARKER 1-50 1

6-OPTIONS

6

7

9

8,14(Sheet 2)



6-OPTIONS

FIG. &INDEXNO.




1 S-3506 CONTACT BLOCK SWITCH W/MTG. BASE 1

2 S-5800 CONTACT BLOCK 13 ZB2-BZ103 CONTACT BLOCK (97393) 1

4 S-2081 CABLE TIE 1

5 240-8875 TERMINAL BOX DOOR CABLE ASSEMBLY 1

6 S-5261 HOUR METER 1

7 3000428 HOUR METER CABLE 1

8 S-244-C NUT, HEX 1/4-20 X 3/16" 19 S-4700 STRIP, R UBBER SPONGE 1400mm



7-PARTS

CHAPTER 7PARTS

TABLE OF CONTENTS

DESCRIPTION FIGURE # PAGE

PICTORIAL INDEX 7.5.1 7-6MACHINE ASSEMBLY 7.5.2 7-8

FLOOR MOUNTING HARDWARE 7.5.3 7-10

CARRIER ASSEMBLY 7.5.4 7-12

CARRIER ASSEMBLY WITH CHROME R OLLER 7.5.7 7-20

CARRIER ASSEMBLY WITH 12mm WIDE CHROME R OLLER 7.5.7.1 7-24

SINGLE LET-OFF WIRE SHUTTLE ASSEMBLY 7.5.8 7-28

DOUBLE LET-OFF WIRE SUPPORT ASSEMBLY 7.5.9 7-30

SHUTTLE EXTENSION 7.5.10 7-32

SINGLE LET-OFF YARN SHUTTLE 7.5.11 7-34

SUPER PACKAGE YARN SHUTTLE 7.5.12 7-36

L-SUPPORT SINGLE LET-OFF WIRE 7.5.13 7-38L-SUPPORT ASSEMBLY WITH PREFORM PIN 7.5.13.1 7-40



L-SUPPORT SINGLE LET-OFF YARN (LONG) 7.5.14 7-42

L-SUPPORT SUPER PACK 7.5.15 7-44

L-SUPPORT DOUBLE LET-OFF WIRE 7.5.16 7-46

SHUTTLE ASSEMBLY 7.5.17 7-48

DOUBLE LET-OFF WIRE GEAR SLEEVE ASSEMBLY 7.5.18 7-50R OTOR ASSEMBLY 7.5.19 7-52

CAM FOLLOWER ASSEMBLY, R EAR 7.5.20 7-56

R OTOR AXLE ASSEMBLY 7.5.21 7-58

CARTRIDGE, DRIVE AND CHANGE GEAR (16, 20 & 24 CARRIER ) 7.5.22 7-60

CARTRIDGE, DRIVE AND CHANGE GEAR (36 CARRIER ) 7.5.23 7-64

7-PARTS



7-PARTS

TABLE OF CONTENTS

DESCRIPTION FIGURE # PAGE

SENSOR STAND ASSEMBLY 7.5.30 7-82

BRAID SENSOR ASSEMBLY 7.5.31 7-84

TUNNEL ASSEMBLY (16, 20, & 24 CARRIER ) 7.5.33 7-88LUBRICATION SYSTEM ASSEMBLY 7.5.34 7-90

TUNNEL ASSEMBLY (36 CARRIER ) 7.5.36 7-94

LUBRICATION, BIJUR PUMP 7.5.37 7-96

LUBRICATION ASSEMBLY, BACK OF DECK 7.5.38 7-98

ELECTRICAL, PROXIMITY SENSOR 7.5.39 7-100

ELECTRICAL, INSIDE JOG BOX ASSEMBLY 7.5.40 7-102

ELECTRICAL, MAIN CONTROL BOX ASSEMBLY 7.5.42 7-106

ELECTRICAL, MAIN CONTROL BOX ASSEMBLY (DOOR OPEN) 7.5.43 7-108

ELECTRICAL, R EMOTE OPERATOR STATION 7.5.47 7-116

ELECTRICAL, PRIMARY OPERATOR BOX 7.5.48 7-118

ELECTRICAL, PRIMARY OPERATOR BOX OPEN 7.5.49 7-120BOBBIN R UNOUT DETECTOR (16 CARRIER ) 7.5.51 7-124



( )

BOBBIN R UNOUT DETECTOR (20, 24 & 36 CARRIER ) 7.5.52 7-126

ELECTRICAL SYSTEM, BACK OF DECK 7.5.53 7-128

ELECTRICAL, GEAR BOX DOOR SWITCH 7.5.54 7-130

ELECTRICAL, WIRING DUCT 7.5.55 7-132ELECTRICAL, WIRING DUCT, MOUNTING BRACKET 7.5.56 7-134

ELECTRICAL, WIRING DUCT, DETAILS 7.5.57 7-136

ELECTRICAL, DOOR LOCK 7.5.58 7-138

ELECTRICAL, SLIDING DOOR LOCK 7.5.59 7-140

BLOWER 7.5.60 7-142

7-PARTS



7-PARTS

PARTS

PARTS BREAKDOWN AND ORDERING PROCEDURE

7.1. SCOPE. This chapter includes the procedureto order parts, a parts index, and individual parts

breakdown figures.

7.2. INSTRUCTIONS FOR ORDERING PARTS.When ordering parts by letter, fax or phone,your order can be filled more accurately andrapidly if the following information isspecified.

• Model or type of machine• Serial No. of machine (where Part No.

Unknown)• Catalog No. & Part No. (Where Shown)• Other remarks (special shipping instructions,

description of parts not shown in catalog,etc.)

NOTE

Address all orders and inquiries on parts to:

MAYER INDUSTRIES, INC.

MII Headquarters and PlantP.O. Drawer 1466Orangeburg, South Carolina 29116TELEPHONE: (803) 536-3500FAX: (803) 536-2545TOLL FREE: 1-800-845-4816

7.4. INSTRUCTIONS

FOR

R ETURNING

PARTS

.In the event that parts have to be returned to Mayer Industries, Inc. for rework or quality checking, please contact our Spare Parts or ServiceDepartment for a Return Material Authorization

(RMA) number. To avoid unnecessary delays andto speed up the return of parts to you, please use theassigned RMA number to identify your returnshipment.

7 5 PARTS LIST



All orders subject to minimum

charge.

7.3. TERMS. Net 30 days, F.O.B. Orangeburg,S.C. 29116 U.S.A. Claims for shortage or damaged parts should be placed with carrier immediately.

7.5. PARTS LIST.

NOTE

Note: Some Figures show parts not

included in purchased assembly.

These parts are shown to aid in

assembly. .

7-PARTS

FIGURES 7.5.3 THRU 7.5.27



7-PARTS




LUBRICATION SYSTEM


ELECTRICAL SYSTEM


BOBBINS

FIGURE 7.5.65

7-PARTS

C

B

10,11

12

137,8

9

15,16,17,18,19,20

3

214

4

5*

6



A

1

7-PARTS

FIG. &INDEXNO.


7.5.2MACHINE ASSEMBLY (16, 20, & 24 CARRIER )MACHINE ASSEMBLY (36 CARRIER )

1240-0001536-0001

BASE FRAME (16, 20, & 24 CARRIER )BASE FRAME (36 CARRIER )

11

2 160-0002240-0002360-0002

UPPER DECK (16 CARRIER )UPPER DECK (20 & 24 CARRIER )UPPER DECK (36 CARRIER )

111


4 14 X 60 DIN 7978 TAPERED PIN (80858) 2

5* 240-0092 ADJUSTABLE GUIDE ASSEMBLY 1

6

160-6130

200-6130240-6130360-61302001006

SHIELD SUPPORT ASSEMBLY (16 CARRIER )

SHIELD SUPPORT ASSEMBLY (20 CARRIER )SHIELD SUPPORT ASSEMBLY (24 CARRIER )SHIELD SUPPORT ASSEMBLY (36 CARRIER )SHIELD SUPPORT ASSEMBLY (24) (BRIDGESTONE)

1

1111


8 B6.4 DIN 125 FLAT WASHER (84015) 13

9

160-0105

240-0105360-0105

DOOR ASSEMBLY (16 & 20 CARRIER )

DOOR ASSEMBLY (24 CARRIER )DOOR ASSEMBLY (36 CARRIER )

1

11

10 240-6094 MACHINE I.D. PLATE (NOT SERVICED) 1



11 3 X 6 DIN 1476 GROOVED PIN (80145) 4

12200-0098240-0098360-0098

GEARBOX PLATE (16 & 20 CARRIER )GEARBOX PLATE (24 CARRIER )GEARBOX PLATE (36 CARRIER )

111

13160-0045200-0045240-0101360-0101

DOOR SPACER (16 CARRIER )DOOR SPACER (20 CARRIER )DOOR SPACER (24 CARRIER )DOOR SPACER (36 CARRIER )

1111

14240-9191360-9191

EYE LIFT (16, 20, & 24 CARRIER )EYE LIFT (36 CARRIER )

11


7-PARTS

9

6

8

7

4

5

1



3

2

7-PARTS

* 4 EACH OF THESE PARTS ARE IN K IT 240-0010 OR 360-0010.TWO KITS (240-0010) ARE REQUIRED FOR 16, 20 & 24 CARRIER BRAIDER .THREE KITS (360-0010) ARE REQUIRED FOR 36 CARRIER BRAIDER

FIG. &INDEXNO.


7.5.3240-0010360-0010

FLOOR MOUNTING HARDWARE (16, 20, 24 CAR .)FLOOR MOUNTING HARDWARE (36 CARRIER )

1* 83400 (¾-10-2AX8½")HEX HEAD BOLT GRADE 2 (16, 20 & 24 CAR .)HEX HEAD BOLT GRADE 2 (36 CAR .)

812

2* 240-0015 SPACER SLEEVE (16, 20 & 24 CARRIER )SPACER SLEEVE (36 CARRIER ) 812

3* 240-0011FOOT (16, 20 & 24 CARRIER )FOOT (36 CARRIER )

812

4* 84073STD WASHER ¾" I.D. (16, 20 & 24 CARRIER )STD WASHER ¾" I.D. (36 CARRIER )

812

5* 84130LOCK WASHER ¾" I.D. (16, 20 & 24 CARRIER )LOCK WASHER ¾" I.D. (36 CARRIER )

812

THE FOLLOWING PARTS ARE NOT INCLUDED IN THE FLOOR MOUNTING HARDWARE K ITS

6240-0001536-0001

BASE FRAME (16, 20, & 24 CARRIER )BASE FRAME (36 CARRIER )

11

7 240-0013THREADED BUSHING (16, 20 & 24 CARRIER )THREADED BUSHING (36 CARRIER)

812



THREADED BUSHING (36 CARRIER ) 12

8 240-0014 NUT (16, 20 & 24 CARRIER ) NUT (36 CARRIER )

812

9240-0107360-0107

LONG BASE PLATE (16, 20 & 24 CARRIER )LONG BASE PLATE (36 CARRIER )

46



7-PARTS

FIG. &INDEXNO.


7.5.4160-5143240-5143

CARRIER ASSEMBLY (16 CARRIER ) (SHEET 1)CARRIER ASSEMBLY (20, 24, & 36 CAR .) (SHT 1)

1240-5127160-5127

HOUSING (20, 24, & 36 CARRIER )HOUSING (16 CARRIER )

11

2 2000516 COMPENSATOR

13 240-5178 ADJUSTING R ING 1

4 240-5130 CAP 1

5 240-5187 ACTUATOR BLOCK 1

6 240-5184 STATIONARY CLUTCH HUB ASSEMBLY 1

7 240-5164 ADJUSTING CLAMP 1

8 240-5134 NYLATRON BUSHING (PART OF ITEM 6) 19 240-5013 MOVEABLE HUB ASSEMBLY 1

10 240-5061STRAND R OLLER (16 CARRIER )STRAND R OLLER (20, 24, & 36 CARRIER )

37

11 240-5194 R UBBER R OD (PART OF ITEM 5) 1

12 240-5019.12 CLUTCH SPRING (75 mm ID) 1

13 240-5020 CLUTCH SLEEVE 1

14 240-5189 SPRING CLAMP 1

15 240-5024 WEAR SCREW (PART OF ITEM 1) 2



16 240-5025 BEARING CLAMP 3

17 240-5027 LATCH 1

18 240-5030 PREFORM PIN, Ø 5 mm 2 A/R

19 242-4590 GROOVED R OTATING PREFORM PIN ASM. (8mm) 2 A/R

20 240-5035 TORSION SPRING (LIGHT) - BLUE 1 A/R

21 240-5036 TORSION SPRING (MEDIUM) - YELLOW 1 A/R

22 240-5037 TORSION SPRING (HEAVY) - GREEN 1 A/R

23 240-5041 ACTUATOR 1

24 240-5055 STEM BUMPER (PART OF ITEM 1) 3

25 3 X 8 DIN 7343 R OLL PIN (80159) (PART OF ITEM 6) 1

7-PARTS

42

12

13

38

37

50

24

1

6

25

45

747

32

51

52

15

26



36

20,21,22

3

41

7-PARTS

FIG. &INDEXNO.


7.5.4160-5143240-5143

CARRIER ASSEMBLY (16 CARRIER ) (SHEET 2)CARRIER ASSEMBLY (20, 24, & 36 CAR .) (SHT 2)



33 V5.3 DIN 6798 SERRATED LOCK WASHER (84195) 334 WI351-015 ASSOC.. SPRING WASHER (84405) 3

35 AS2035 INA WASHER (84410) 1

36 1000127 S NAP R ING - EXTERNAL 1

37 BR 40 INA R ETAINING R ING (85135) (PART OF ITEM 6) 1

38 WR 50 INA R ETAINING R ING (85140) 1

39 KP37B-FS 160 BALL BEARING-FAFNIR (86373) 140

41* 240-5116 SLEEVE SOCKET (DOUBLE LET-OFF) 1 A/R

42* M4 X 10 DIN 6912 SOCKET HEAD SCREW (81807) (050671.0) 2 A/R

43 2000564 TRIP STRAND R OLLER ASSEMBLY 1 A/R

44 240-5061 STRAND R OLLER ASSEMBLY 2 A/R

45 240-5201 SHIM WASHER 146 240-5190 WEAR PLATE 1

47 ST-M8 R IBBED WASHER (84210) 37



* Not included in standard assembly.

48 160-5066 STRAND R OLLER (16 CARRIER ) 3

49 160-5067 STRAND R OLLER (16 CARRIER ) 1

50 240-5072 R UBBER BLOCK 1

51 M5 X 16 DIN 912 SOCKET HEAD SCREW (82046) 252 B5.3 DIN 125 WASHER (84010) 4

53 M8 X 1 X 20 DIN 961 HEX HEAD CAP SCREW (82455) 9

54 1000560 SPACER 9

7-PARTS

7

2,3,4

8

9

10

6

1



1

7-PARTS

FIG. &INDEXNO.


7.5.5 CARRIER ASSEMBLY DETAIL (R EFERENCE)

1 2000516 COMPENSATOR 1




5 M6 X 20 DIN 7991 FLAT HEAD SCREW (82435) 2


7 240-5188 ACTUATOR SCREW 2

8 240-5190 WEAR PLATE 1





7-PARTS

THIS PAGE INTENTIONALLY LEFT BLANK



7-PARTS

THIS

PAGE

INTENTIONALLY

LEFT

BLANK



7-PARTS

10,49,53,54

1

20,21,22

39

10,53,54

29

46

145

28

SEE FIGURE 7.5.5

2

273316

10,48

53

30

54

10,48

53

53

54

54 10,48

10

5418



1734

3534

234

31

44

53

5310

43 54

54

53

7-PARTS

FIG. &INDEXNO.


7.5.720000972000099

CARRIER ASM., CHROME (16 CARRIER ) (SHT 1)CARRIER ASM., CHROME (20, 24, 36) (SHT 1)

1240-5127160-5127

HOUSING (20, 24, & 36 CARRIER )HOUSING (16 CARRIER )

11


3 240-5178 ADJUSTING R ING 1

4 240-5130 CAP 1


6 240-5184 CLUTCH HUB ASSEMBLY 1


8 240-5134 NYLATRON BUSHING (PART OF ITEM 6) 1

9 240-5013 MOVEABLE HUB ASSEMBLY 1

10 240-5440CHROME STRAND R OLLER (16 CARRIER )CHROME STRAND R OLLER (20, 24 & 36 CARRIER )

3 A/R 7 A/R





15 240-5024 WEAR SCREW (PART OF ITEM 1) 2

16 240-5025 BEARING CLAMP 3



17 240-5027 LATCH 1

18

19




23 240-5041 ACTUATOR 1





7-PARTS

FIG. &INDEXNO.


7.5.720000972000099

CARRIER ASM., CHROME (16 CARRIER ) (SHT 2)CARRIER ASM., CHROME (20, 24, 36) (SHT 2)



33 V5.3 DIN 6798 SERRATED LOCK WASHER (84195) 334 WI351-015 ASSOC. SPRING WASHER (84405) 3

35 AS2035 INA WASHER (84410) 1

36 78X2.5 DIN 471 S NAP R ING - EXTERNAL (85015) 1



39 KP37B-FS 160 BALL BEARING-FAFNIR (86373) 140

41* 240-5116 SLEEVE SOCKET (DOUBLE LET-OFF) 1 A/R

42* M4 X 10 DIN 6912 SOCKET HEAD SCREW (81807) (050671.0) 2 A/R

43 2000563 CHROME TRIP STRAND R OLLER ASSEMBLY 1 A/R

44 240-5440 CHROME STRAND R OLLER ASSEMBLY 2 A/R

45 240-5201 SHIM WASHER 146 240-5190 WEAR PLATE 1


48 160-5071 CHROME STRAND ROLLER (16 CARRIER) 3 A/R




48 160-5071 CHROME STRAND R OLLER (16 CARRIER ) 3 A/R

49 160-5070 CHROME STRAND R OLLER (16 CARRIER ) 1 A/R

50 240-5072 R UBBER BLOCK (16) 1

51 M5 X 16 DIN 912 SOCKET HEAD SCREW (82046) 252 B5.3 DIN 125 WASHER (84010) 4


54 1000560 SPACER 10

7-PARTS

10,53,54

1

20,21,22

39

40,53,54

29

46

145

28

SEE FIGURE 7.5.5

2

273316

40

53

30

54

10

53

53

54

5410

54

1054

SPECIAL

S P E C

I A L

11



1734

3534

23

431

44

53

5310

4354

54

53

7-PARTS

FIG. &INDEXNO.


7.5.7.1 240-5253CARRIER ASM., 12mm WIDE CHROME R OLLER

(24 AND 36 CARRIER ) (SHT 1)

1 1000427 HOUSING 1


3 240-5178 ADJUSTING R ING 14 240-5130 CAP 1


6 240-5184 CLUTCH HUB ASSEMBLY 1


8 240-5134 NYLATRON BUSHING (PART OF ITEM 6) 1

9 240-5013 MOVEABLE HUB ASSEMBLY 110 240-5245 CHROME STRAND R OLLER 5 A/R





15 240-5024 WEAR SCREW (PART OF ITEM 1) 216 240-5025 BEARING CLAMP 3

17 240-5027 LATCH 1

18



19


21 240-5036 TORSION SPRING (MEDIUM) - YELLOW 1 A/R 22 240-5037 TORSION SPRING (HEAVY) - GREEN 1 A/R

23 240-5041 ACTUATOR 1



26 240-5021 FELT PAD 8

7-PARTS

26

41

42

12

13

38

37

50

24

1

86

25

45

747

32

51

52

15



36

20,21,22

3

41

7-PARTS

FIG. &INDEXNO.

PART NO. DESCRIPTION UNITSPERASM.

7.5.7.1 240-5253CARRIER ASM., 12mm WIDE CHROME R OLLER

(24 AND 36 CARRIER ) (SHT 2)



33 V5.3 DIN 6798 SERRATED LOCK WASHER (84195) 334 WI351-015 ASSOC.. SPRING WASHER (84405) 3

35 AS2035 INA WASHER (84410) 1

36 1000127 S NAP R ING - EXTERNAL 1



39 KP37B-FS 160 BALL BEARING-FAFNIR (86373) 140 1000424 12mm WIDE CHROME R OLLER ASM. (SPECIAL) 2

41

42

43 200056212MM TRIP R OLLER ASSEMBLY (I NCLUDING TRIP BOLT & SPACERS)

1

44 240-5245 CHROME STRAND R OLLER ASSEMBLY 2 A/R

45 240-5201 SHIM WASHER 1

46 240-5190 WEAR PLATE 1


48



48

49

50 240-5072 R UBBER BLOCK (16) 1


52 B5.3 DIN 125 WASHER (84010) 4

53 M8 X 1 X 25 DIN 961 HEX HEAD BOLT (82456) 9

54 1000560 SPACER 18

7-PARTS

1

24

3



5

7-PARTS

*Not included in standard assembly.

Note: Items #1, #2, #3, #4 and #5 are sold as separate items. This figure is shown as anassembly aid only.

FIG. &INDEXNO.


7.5.8160-5150 SR 200-5150 SR 240-5150 SR

SINGLE LET-OFF WIRE SHUTTLE SUPPORT ASM.SLOW (16 CARRIER )SLOW (20 CARRIER )SLOW (24 CARRIER )

1

160-5146

200-5146240-5146360-5146

SHUTTLE ASSEMBLY (16 CARRIER )

SHUTTLE ASSEMBLY (20 CARRIER )SHUTTLE ASSEMBLY (24 CARRIER )SHUTTLE ASSEMBLY (36 CARRIER )

1

111

2 2000873 SUPPORT ASSEMBLY 1

3 S-4903 SOCKET HEAD SCREW 4

4 ST M6 R IBBED WASHER (051238.0) 4

5* 2000366.0 SINGLE LET-OFF WIRE BOBBIN ASSEMBLY 1 A/R



7-PARTS

P AY O F F D I R E C T I O N

6

2

5

3

4

1

9



K EY SLOTP AY O F F D I R E C T I O N

7

8

7-PARTS


FIG. &INDEXNO.


7.5.9 240-5144 DOUBLE LET-OFF WIRE SUPPORT ASSEMBLY

1*

160-5146200-5146240-5146360-5146

SHUTTLE ASSEMBLY (16 CARRIER )SHUTTLE ASSEMBLY (20 CARRIER )SHUTTLE ASSEMBLY (24 CARRIER )SHUTTLE ASSEMBLY (36 CARRIER )

16202436

2 240-5141 SHUTTLE EXTENSION 1/ASM

3 240-5149 "L" SUPPORT ASSEMBLY 1



6 240-5114 SLEEVE (WITH O-R INGS) 1/ASM

7 240-5153 SR GEAR SLEEVE ASSEMBLY (SEE FIGURE 7.5.18) 1/ASM

8* 240-5120 DOUBLE LET-OFF WIRE BOBBIN ASSEMBLY 1 A/R

9 M4 X 4 DIN 913 SOCKET SET HEX SCREW (050506.0) (81705) 1 A/R



7-PARTS

FIG. &INDEXNO.


7.5.10 SHUTTLE EXTENSION LIGHTWEIGHT YARN

1 240-5139 SPINDLE 1

2 M6 X 6 DIN 916 SET SCREW (050523.0) (82185) 4

3 240-5140 SHUTTLE EXTENSION 1



7-PARTS

1

6

2

5

4



3

7

7-PARTS


FIG. &INDEXNO.


7.5.11160-5236200-5236240-5236360-5236

SINGLE LET-OFF YARN SHUTTLE EXTENSION ASSEMBLY

SLOY (16 CARRIER )SLOY (20 CARRIER )SLOY (24 CARRIER )SLOY (36 CARRIER )

1*

160-5146200-5146240-5146360-5146


1 A/R 1 A/R 1 A/R 1 A/R

2 240-5140 SHUTTLE SPINDLE EXTENSION 1

3 240-5232 YARN SUPPORT ASM., LIGHTWEIGHT LONG 1

4 S-4903 SOCKET HEAD SCREW 45 ST M6 R IBBED WASHER (051238.0) (84200) 4

6 M6 X 6 DIN 916 SOCKET SET SCREW (050523.0) (82185) 4

7* 240-4016 YARN TUBE (PURCHASE FROM YARN CONVERTER ) 1 A/R

8* 240-5160 FLANGED SINGLE LET-OFF YARN BOBBIN 1 A/R



7-PARTS


FIG. &INDEXNO.


7.5.12 240-5161 SINGLE LET-OFF SUPER PKG. YARN ADAPTER

1*

160-5146200-5146240-5146360-5146


1111

2 1000354 SHUTTLE EXTENSION 13 240-5169 "L" SUPPORT ASSEMBLY 1


5 ST M6 R IBBED WASHER (051238.0) (84200) 4

6 M4 X 4 DIN 913 SOCKET SET SCREW (050506.0) (81705) 4

7* 240-5162 SINGLE LET-OFF YARN - SUPERPACK 1 A/R

8* 240-4018 YARN TUBE - SUPER PACK 1 A/R



7-PARTS

8

9

4

12

5

7

10

3

6

2

6



5

11

1

7-PARTS

FIG. &INDEXNO.


7.5.13 2000873 SUPPORT ASSEMBLY (SLOW)

1 240-5222 R OLLER PIN L-SUPPORT 1

2 240-5006 BALER R OLL 1

3 240-5005 BALER SPINDLE 1

4 240-5135 CARRIER BUMPER 15 240-5061 STRAND R OLLER ASSEMBLY 1

6 OILITE 8 X 12 X 12 BEARING (86205) 2

7 S-3679 SOCKET SET SCREW 1



10 4 X 24 DIN 7343 R OLL PIN (050223.0) (80380) 111 M8 X 1 X 20 DIN 961 HEX HEAD CAP SCREW (82455) 1

12 S-5449 SPACER 1



7-PARTS

8

9

4

7

10

3

6

2

6

12 (2000783)

11 (2000783)

5 (2000946)



1

11 (2000783)

13 (2000783)

7-PARTS

FIG. &INDEXNO.


7.5.13.120002162000783

SUPPORT ASSEMBLY WITH PREFORM PIN

SUPPORT ASSEMBLY WITH GROOVE R OLLER

1 240-5222 LIGHTWEIGHT L-SUPPORT 1

2 240-5006 BALER R OLL 1


4 240-5135 CARRIER BUMPER BRACKET ASSEMBLY 1

520002142000720

PREFORM PIN ASSEMBLY (2000216 O NLY)GROOVE R OLLER (2000783 O NLY)

11


7 S-3679 SOCKET SET SCREW 1



10 4 X 24 DIN 7343 R OLL PIN (050223.0) (80380) 1

11 240-5061 STRAND R OLLER ASSEMBLY (2000783 O NLY) 1

12 S-5449 SPACER (2000783 O NLY) 1

13 M8 X 1 X 20 DIN 961HEX HEAD BOLT (055706.0) (82455)(2000783 O NLY)

1



7-PARTS

125

13

1

6

7

9

8

6

2

3

15 16

14

4

17



10

7-PARTS

FIG. &INDEXNO.


7.5.14240-5232240-5242240-5251

SUPPORT ASSEMBLY (SLOY)SUPPORT ASM. (SLOY) W/CHROME R OLLER

SUPPORT ASM. (SLOY) (12mm, CHROME)

1 240-5233 L-SUPPORT (LONG) 1

2 240-5234 BALER R OLL (LONG) 1

3 240-5235 BALER SPINDLE (LONG) 1

4 2000260 CARRIER BUMPER BRACKET ASSEMBLY 1

5240-5061240-5440240-5245

STRAND R OLLER ASSEMBLY (240-5232 ONLY)CHROME STRAND R OLLER ASSEMBLY (240-5242)12mm CHROME STRAND R OLLER ASM. (240-5251)

1 A/R 1 A/R 1 A/R

6 240-5165 BAILER R OLLER BUSHING 2

7 S-3679 SOCKET

SET

SCREW

(M6X

10) 18 M8 X 20 DIN 912 SOCKET HEAD SCREW (054683.0) (82654) 1


10 A10 X 6 DIN 6321 R EST BUTTON (99780) 1

11

12M8 X 1 X 20 DIN 961M8 X 1 X 25 DIN 961

HEX HEAD CAP SCREW (82455) (240-5232/5242)HEX HEAD CAP SCREW (82456) (240-5251 ONLY)

1

13 S-5449 SPACER 1

14 1000258 CARRIER BRACKET (PART OF ITEM 4) 1

15 1000259 CARRIER BUMPER (PART OF ITEM 4) 1

16 M4 X 10 DIN 9427 BUTTON HD. SCREW (81809) (PART OF ITEM 4) 2

17 1000941 SCREW PIN 1



17 1000941 SCREW PIN 1

7-PARTS

6

2

6

3

7

8

94

135

12

14

15



1

10

7-PARTS

FIG. &INDEXNO.


7.5.15240-5169240-5442240-5249

SUPPORT ASM (SINGLE LET-OFF SUPER PK )SUPPORT ASM. WITH CHROME R OLLER

SUPPORT ASM. WITH 12mm CHROME R OLLER

1 240-5168 L-SUPPORT 1

2 240-5166 BALER R OLL 1


4 1000259 CARRIER BUMPER 1

5240-5061240-5440240-5245

STRAND R OLLER ASSEMBLY (240-5169 ONLY)CHROME STRAND R OLLER ASM. (240-5442 ONLY)12mm CHROME STRAND R OLLER ASM. (240-5249)

1 A/R 1 A/R 1 A/R

6 240-5165 BALER R OLLER BUSHING 2

7 S-3679 SOCKET SET SCREW (M6 X 10) 1



10 A10 X 6 DIN 6321 R EST BUTTON (99780) 1

11

12M8 X 1 X 20 DIN 961M8 X 1 X 25 DIN 961

HEX HEAD CAP SCREW (82455)HEX HEAD CAP SCREW (82456) (240-5249 ONLY)

1 A/R 1 A/R

13 S-5449 SPACER 1

14 240-5055 STEM BUMPER 1

15 1000941 PIN SCREW 1



7-PARTS

8

915

6

2

6

3

62

6

3

7

7

13

5

12

7

4

16

14



11

10

1

13

512

12

7-PARTS

FIG. &INDEXNO.


7.5.16 240-5149 SUPPORT ASSEMBLY (DLOW)

1 240-5138 L-SUPPORT 1

2 240-5006 BALER R OLL 2


4 2000260 CARRIER BUMPER BRACKET ASSEMBLY 15 240-5061 STRAND R OLLER ASSEMBLY 2


7 S-3679 SOCKET SET SCREW (M6 X 10) 3



10 A10 X 6 DIN 6321 R EST BUTTON (99780) 111 4 X 12 DIN 7343 R OLL PIN (050218.0) (80305) 1


13 S-5449 SPACER 2

14 1000258 CARRIER BRACKET (PART OF ITEM 4) 1

15 1000259 CARRIER BUMPER (PART OF ITEM 4) 1

16 M4 X 10 DIN 9427 BUTTON HD. SCREW (81809) (PART OF ITEM 4) 2



7-PARTS

8

7

5

4

3

1

6

2



12

11

10

7-PARTS

FIG. &INDEXNO.


7.5.17

160-5146200-5146240-5146360-5146


1 240-5139 SHUTTLE SPINDLE 1

2 4 X 24 DIN 7343 R OLL PIN (050223.0) (80380) 13 240-4002 MOUNTING SPACER 1

4 240-4007 OUTER R ING 1

5 240-4008 I NNER R ING 1

6 240-4004 K EY 1

7160-4003200-4003240-4003

CAM TRACK (16 CARRIER )CAM TRACK (20 CARRIER )CAM TRACK (24 & 36 CARRIER )

1 A/R 1 A/R 1 A/R

8240-4005200-4005360-4005

SHUTTLE GEAR (16 & 24 CARRIER )SHUTTLE GEAR (20 CARRIER )SHUTTLE GEAR (36 CARRIER )

1 A/R 1 A/R 1 A/R

9 240-4009 R ING 1

10 S-4095 CAM YOKE BEARING 1

11 MB 6 DIN 5406 SAFETY WASHER (051248.0) (84160) 112 KM 6 DIN 981 SLOTTED SHAFT NUT (050986.0) (83840) 1



7-PARTS

1

52

4

6

3



5

2

7-PARTS

* Note: Additional spring washers may be added to adjust tension.

FIG. &INDEXNO.


7.5.18 240-5153 SR BEVEL GEAR SLEEVE ASSEMBLY

1 240-5117 GEAR SLEEVE 1

2 240-5113 BEVEL GEAR 2

3 240-5115 BEVEL PINION GEAR 4

4 240-5123 SOCKET HEAD SHOULDER BOLT 4

5 WR50 INA R ETAINING R ING (85140) 2

6* WO618-008 SPRING WAVE WASHER (84407) 4 A/R



7-PARTS

17

12

11

4

1819

7

19

185

13

3

2016

24

15

11

4 18

19

6

1

NUMBERS

2



19

185

22

21

8

10

23

14

PUSH HERE

25

7-PARTS

FIG. &

INDEXNO.

PART NO. DESCRIPTION

UNITS

PERASM.

7.5.19

160-3000200-3000240-3000360-3000

R OTOR ASSEMBLY (16 CARRIER )R OTOR ASSEMBLY (20 CARRIER )R OTOR ASSEMBLY (24 CARRIER )R OTOR ASSEMBLY (36 CARRIER )

1 240-3001 R OTOR FRAME 1

2 240-3002 R OTOR GEAR 13 240-3004 GUIDE K EY 2

4240-3005524-3005

PLANETARY SHAFT (16, 20 & 24 CARRIER )PLANETARY SHAFT (36 CARRIER )

4 A/R 4 A/R

5 240-3006 PLANETARY SPACER 4 A/R

6240-3008360-3008

PLANETARY MINOR GEAR (16, 20 & 24 CARRIER )PLANETARY MINOR GEAR (36 CARRIER )

2 A/R 2 A/R

7160-3007240-3007360-3007

PLANETARY MAJOR GEAR (16 CARRIER )PLANETARY MAJOR GEAR (20 & 24 CARRIER )PLANETARY MAJOR GEAR (36 CARRIER )

2 A/R 2 A/R 2 A/R

8 240-3017 PILLOW BLOCK 2

9240-3025240-3014

FRONT CAM FOLLOWER ASM (SEE NOTES 1 & 2)FRONT CAM FOLLOWER ASM (SEE NOTES 1 & 2)

2 A/R 2 A/R

10 240-3030 R EAR CAM FOLLOWER ASSEMBLY (FIG. 7.5.20) 2

11 6 X 24 DIN 7343 R OLL PIN (050241.0) 8

12 10 M6 X 40 DIN 7 DOWEL PIN (80910) 1



15* M6 X 12 DIN 6912 SOCKET HEAD SCREW (050693.0) (82280) 4

16* 240 3022 CAP 1



16* 240-3022 CAP 1


18 6001-2RS DIN 625 BALL BEARING (86438) 8

19 28 X 1.2 DIN 472 I NTERNAL S NAP R ING (84675) 8

20* OR 72 X 2.5 O-R ING (86030) 1

21 M10 X 45 DIN 912 SOCKET HEAD SCREW (GRADE 12.9) (82928) 4

22 B10 DIN 127 STAINLESS LOCK WASHER (84111) 4

7-PARTS

17

12

11

4

1819

7

19

185

13

3

2016

24

15

11

4 18

19

619

1

NUMBERS

2



19

185

22

21

8

10

23

14

PUSH HERE

25

7-PARTS

NOTES:

1. Front and Rear Cam followers are serviced and sold as assemblies only. Components are not

available. These units are built with selected fit components, and components are not inter-

changeable from one to another.

These parts are sold as complete assemblies only.

2. Cartridge 240-3014 has four timing holes while standard cartridge 240-3025 has only onetiming hole. The advantage is that the same part can be used four times over in case the

original timing location can no longer be used. However, it is very important that the cam

follower cartridge and cap always remain in the original position even if new timing holes

have been drilled. The master slot on cam follower cartridge 240-3014 is marked with a 2 mm

I.D. mark. In order to drill new timing holes a special drilling cap is needed. The part number

of the drilling cap is 240-1011.



7-PARTS

HOLE

THIS

SIDE

HOLE "A"

"X" ON BACK

FACE OF

PILLOW BLOCK

2

10

8

7

3

1

6



NUMBERS STAMPED

AT EITHER END IN

THIS LOCATION

9

3

4

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.20 240-3030 R EAR CAM FOLLOWER ASSEMBLY

1 240-3032 R EAR CAP 1

2 240-3033 R EAR CARTRIDGE 1

3 240-3031 CAM FOLLOWER 1

4 7 X 10RB INA R OLLER (SHORT) (86235) 13

5 7 X 14ZRB INA R OLLER (LONG) (86240) 13

6 240-3036 THRUST WASHER 1

ADDITIONAL PARTS SHOWN FOR ASSEMBLY I NSTRUCTIONS



9 6 X 24 DIN 7343 R OLL PIN (050241.0) 110 240-3017 PILLOW BLOCK 1



7-PARTS

1513

2324

2526

1217

185

OR

3 3-3

3-2

3-1

1019

2

13

15

4

19

2221 914

4-1

4-214

11

1620

8

1

28

28



277

6

28

27 7 6

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.21

160-3010 SR 200-3010 SR 240-3010 SR 2000254

R OTOR AXLE ASSEMBLY (16 CARRIER )R OTOR AXLE ASSEMBLY (20 CARRIER )R OTOR AXLE ASSEMBLY (24 CARRIER )R OTOR AXLE ASSEMBLY (36 CARRIER )

1240-3010160-3010

360-3010

R OTOR AXLE (20 & 24 CARRIER )R OTOR AXLE (16 CARRIER )

R OTOR AXLE (36 CARRIER )

1 A/R 1 A/R

1 A/R

2240-3012160-3012

MAJOR SUN GEAR (24 CARRIER )MAJOR SUN GEAR (16 & 20 CARRIER )

1 A/R 1 A/R

3 NAO 80X 110X 30 IS1 NEEDLE BEARING ASSEMBLY (3 PART) (86715) 1

4 NA6908 (INA) NEEDLE BEARING ASSEMBLY (2 PART) (86710) 1

5 ¼" - 18 NPT PRESSURE PLUG (BENSON) (87860) 1

6 S-5539 METER U NIT (BIJUR ) (A) CKA-00-B7 125 17 S-5541 METER U NIT (BIJUR ) (B) CKA-2 B7 128 1

8 S-5055 O-R ING 1

9 360-3014 K EY (36 CARRIER O NLY) (A10X8X22 DIN 6885) 1

10 240-3020 BEARING SPACER (16, 20 & 24 CARRIER O NLY) 1

11* 240-3023 LOCATION PIN 12

12* 240-3021 BEARING R ING (FIT AT ASSEMBLY) 113* WS 81110 THRUST R ACE (86305) 2

14* GS 81110 THRUST R ACE (86300) 2

15* AXK 5070 NEEDLE R ACE (INA) (86175) 2

16* M12 X 60 DIN 6912 SOCKET HEAD SCREW (83065) 6

17* MB 8 DIN 5406 SAFETY WASHER (051250.0 (84168)) 1



18* KM 8 DIN 981 LOCK NUT (050988.0) (83860) 119 M5 X 16 DIN 912 SOCKET HEAD SCREW (055147.0) (82046) 1

20* A12 DIN 127 LOCK WASHER (051222.0) (84115) 6

21 360-3012 MAJOR SUN GEAR (36 CARRIER O NLY) 1

22 A5 DIN 127 LOCK WASHER (36 CARRIER ) (051218.0) (84097) 1

23* S-3688 .001 I NCH STEEL SHIM A/R

7-PARTS

14 2

4

1

18

.15 mmAXIAL PLAY

23

12

2

.15 mmAXIAL PLAY

1517

SPROCKETCARTRIDGE

PINIONCARTRIDGE

2SPROCKETS MUST

BE IN LINE WITHIN0.2 mm

16

1191851923 6

23

7

13

UPPER DECK FRAME

NOTE: STAMP THAT INDICATES

22

17

7

13

22

16

15



NOTE: THE SPROCKET AND

20,21

8

19NUMBER OF TEETH ONCHANGE GEAR SHOULD

FACE OUTWARD.

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.22DRIVE CARTRIDGE AND CHANGE GEAR DRIVE (16, 20, & 24 CARRIER )


2

30 X 42 X 0.1 DIN 98830 X 42 X 0.2 DIN 988

30X

42X

0.3 DIN 98830 X 42 X 0.5 DIN 98830 X 42 X 1 DIN 988

SHIM WASHER (051128.0)SHIM WASHER (84248)

SHIM

WASHER

(051129.0)SHIM WASHER (051130.0)SHIM WASHER (051131.0)

A/R A/R

A/R A/R A/R

3 240-2014 BRASS SHEAR K EY 1

4 240-2015 GEAR SHAFT 1


6 240-2017 ADAPTER 1

7 240-2019 CAP 2

8

240-2020240-2022240-2023240-2024

SILENT CHAIN SPROCKET (66T) 60 CY

SILENT CHAIN SPROCKET (65T) 60 CY

SILENT CHAIN SPROCKET (55T) 50 CY 1373 RPMSILENT CHAIN SPROCKET (54T) 50 CY 1373 RPM

1 A/R 1 A/R 1 A/R 1 A/R

9 240-2025 PINION GEAR 32 T 1

10 240-2039 SILENT CHAIN WEAR BLOCK 1

11 A8 X 7 X 32 DIN 6885 K EY (050317.0) 1

12 240-2013 K EY (A8 X 7 X 70 DIN 6885) 1



15 KM 6 DIN 981 LOCK NUT (050986.0) 2




( )

17 4M6 X 12 DIN 7 DOWEL PIN (050089.0) 2



209950399406

R AMSEY SILENT CHAIN 50/60 CY DRIVES

24 CARRIER SC406-108 LINKS20 CARRIER SC406-122 LINKS

1 A/R 1 A/R

7-PARTS

14 2

4

1

18

.15 mmAXIAL PLAY

23

12

2

.15 mmAXIAL PLAY

1517

SPROCKETCARTRIDGE

PINIONCARTRIDGE

2SPROCKETS MUST

BE IN LINE WITHIN0.2 mm

16

1191851923 6

23

7

13

UPPER DECK FRAME

NOTE: STAMP THAT INDICATES

NUMBER OF TEETH ON

22

17

7

13

22

16

15



NOTE: THE SPROCKET AND

20,21

8

19NUMBER

OF

TEETH

ON

CHANGE GEAR SHOULD

FACE OUTWARD.



7-PARTS

10

0.15 mmAXIAL PLAY

SPROCKETS MUST BE

IN LINE WITHIN 0.2 mm

16

UPPER DECK FRAME

0.15 mm

AXIAL PLAY

17,20

23,24,25,26

21,22

12

11

14

4

15

9 18

13 1 19 5 27

2

3

7

8

13

1618

13 19

7

12

15



6

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.23DRIVE CARTRIDGE AND CHANGE GEAR DRIVE (36 CARRIER )


2

30 X 42 X 0.1 DIN 98830 X 42 X 0.2 DIN 98830 X 42 X 0.3 DIN 98830 X 42 X 0.5 DIN 98830 X 42 X 1 DIN 988

SHIM WASHER (051128.0)SHIM WASHER (84248)SHIM WASHER (051129.0)SHIM WASHER (051130.0)SHIM WASHER (051131.0)

A/R A/R A/R A/R A/R

3 240-2014 BRASS SHEAR K EY 1

4 536-2015 GEAR SHAFT 1


6 360-2039 SILENT CHAIN WEAR BLOCK 1

7 536-2019 CAP 2

8536-2023536-2024

SILENT CHAIN SPKT (55T) 60/50 CY 1400 RPMSILENT CHAIN SPKT (54T) 60/50 CY 1400 RPM

1 A/R 1 A/R

9 240-2025 PINION GEAR 32 T 1

10 A8 X 7 X 32 DIN 6885 K EY (050317.0) 1

11 240-2013 K EY (A8 X 7 X 70 DIN 6885) 1

12 M8 X 25 DIN 6912 SOCKET HEAD SCREW (050710.0) 213 M10 X 40 DIN 6912 SOCKET HEAD SCREW (050725.0) 8

14

536-2095536-2096536-2097536-2098

SHIM

SHIM

SHIM

SHIM

A/R A/R A/R A/R

15 KM 6 DIN 981 LOCKNUT (050986.0) 2



16 MB 6 DIN 5406 SAFETY WASHER (051248.0) 217 S-5337 R AMSEY SILENT CHAIN (110 LINKS) 1 A/R



20 99509 R AMSEY SILENT CHAIN CONNECTING LINK 1


7-PARTS

10

0.15 mmAXIAL PLAY

SPROCKETS MUST BE

IN LINE WITHIN 0.2 mm

16

UPPER DECK FRAME

0.15 mm

AXIAL PLAY

17,20

23,24,25,26

21,22

12

11

14

4

15

9 18

13 1 19 5 27

2

3

7

8

13

16

18

13 19

7

12

15



6

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.23DRIVE CARTRIDGE AND CHANGE GEAR DRIVE (36 CARRIER )

27240-2054 THRU

240-2082CHANGE GEARS 2 A/R

PART NO. NO.TEETH

PART NO. NO.TEETH

240-2054 54 240-2069 69

240-2055 55 240-2070 70

240-2056 56 240-2071 71

240-2057 57 240-2072 72240-2058 58 240-2073 73

240-2059 59 240-2074 74

240-2060 60 240-2075 75

240-2061 61 240-2076 76

240-2062 62 240-2077 77

240-2063 63 240-2078 78

240-2064 64 240-2079 79

240-2065 65 240-2080 80

240-2066 66 240-2081 81

240-2067 67 240-2082 82



240-2068 68

7-PARTS

.05 - .30 mm (.002 - .012 IN.) GAP

BEFORE INSTALLING THE SHEAR PIN.WHEN THE SHEAR PIN IS INSTALLED,POSITION SHEAR PIN R ING (6) TO HAVE

.00 CLEARANCE AND THEN SECURE

IN PLACE WITH SET SCREW (13).

OIL LEVEL

23

27

26

2529

5

28

1279141382101521

20

1

18

17

4 19 16 11

3

65

5



SURFACE "A"

FRONT OF BRAIDER R EAR OF BRAIDER

324

22

7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.24 240-2090 DRIVE SHAFT ASSEMBLY (16, 20 & 24 CARRIER )

1 240-2001 DRIVE SHAFT 1

2 240-2002 DRIVE SPROCKET 1

3* S-3924 ½ NPT PLUG 4

4 240-2004 BEARING FLANGE 1

5* M8 X 20 DIN 912 SOCKET HEAD SCREW (050709.0) 8

6 240-2006 SHEAR PIN R ING 1

7 240-2007 BUSHING 1

8 240-2008 DISTANCE BUSHING 1

9 240-2009 SHEAR PIN 2

10 240-2010 R ETAINING NUT 1

11 6m6 X 16 DIN 6325 DOWEL PIN (80670) 2

12 A12 X 8 X 40 DIN 6885 K EY (053771.0) (81345) 1

13 M6 X 8 DIN 916 SOCKET SET SCREW (050524.0) 2


15 KM 8 DIN 981 SLOTTED SHAFT NUT (050988.0) 1


17 S35 X 45 X 2.5 DIN 988 SUPPORTING WASHER (84253) 2

18 35 X 1.5 DIN 471 EXTERNAL S NAP R ING (050380.0) 1

19 80 X 2.5 DIN 472 I NTERNAL S NAP R ING (050418.0) (85030) 2

20 S-5439 OIL SEAL 1

21 6307-2RS DIN 625 BALL BEARING (86630) 1

22 OR 86 X 2.5 "O" R ING (86045) (051636.0) 1



23* A10 X 8 X 40 DIN 6885 K EY (050327.0) (81300) 1

24* 240-2091 FRONT FLANGE ASM. (I NCLUDES ITEMS 25-29)




7-PARTS

.05 - .30 mm (.002 - .012 IN.) GAP

BEFORE INSTALLING THE SHEAR PIN.

WHEN THE SHEAR PIN IS INSTALLED,POSITION SHEAR PIN R ING (6) TO HAVE

.00 CLEARANCE AND THEN SECURE

IN PLACE WITH SET SCREW (13).OIL LEVEL

SURFACE "A"

FRONT OF BRAIDER R EAR OF BRAIDER

1719 2 8 6 14 16 15

18

328

26

10

24

2527

1

20

214 11

139

127

22

5

5 5

23



7-PARTS

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.25 536-2090 DRIVE SHAFT ASSEMBLY (36 CARRIER )

1 536-2001 DRIVE SHAFT (36 CARRIER ) 1

2 536-2002 DRIVE SPROCKET 1

3* S-3924 ½ NPT PLUG 4


5* M8 X 20 DIN 6912 SOCKET HEAD SCREW (050709.0) 8

6 536-2006 SHEAR PIN R ING 2

7 536-2007 BUSHING 1

8 240-2008 DISTANCE BUSHING 2

9 240-2009 SHEAR PIN 3

10* A10 X 8 X 40 DIN 6885 K EY (050327.0) 1

11 6m6 X 16 DIN 6325 DOWEL PIN (050168.0) 2

12 A12 X 8 X 40 DIN 6885 K EY (053771.0) 1



15 KM 8 DIN 981 SLOTTED SHAFT NUT (050988.0) 1


17 S35 X 45 X 2.5 DIN 988 SUPPORTING WASHER (84253) 2

18 35 X 1.5 DIN 471 EXTERNAL S NAP R ING (050380.0) 1




22 OR 86 X 2.5 "O" R ING (86045) (051636.0) 1

23* 240 2091 FRONT FLANGE ASM (INCLUDES ITEMS 24 28)



23* 240-2091 FRONT FLANGE ASM. (I NCLUDES ITEMS 24-28)




27 1307 DIN 630 BALL BEARING (86390) 1

7-PARTS

27.56 IN700 mm

27.56 IN700 mm

FLOOR

.12 IN - .18 IN GAP

3.18 mm - 4.76 mm

1 1 . 0 2 I N

2 8 0 m m

1 2 . 3 6 I N

3 1 4 m m

3 5 7 5 6

HAUL-OFF

U NIT

SEE FIGURE 7.5.24

1 3 2 4

1

1

MR-11 PLC-TMR-11 PLC-T

1 ALIGN SHAFT (2) TO

MR-11 PLC-T SHAFT

W/MAGNETIC BASE

INDICATOR AS SHOWN

8*8*

S-5008 HUB



I NDICATOR AS SHOWN

7-PARTS

* All drive shaft assemblies (Items 1 and 2) require a S-5006 Flex Pack for each end whenassembling to a machine.

FIG. &

INDEXNO.


UNITS

PERASM.

7.5.26INSTALLATION CONNECTION HARDWARE

(16, 20, & 24 CARRIER )

1 240-2083 BRAIDER TO BRAIDER SHAFT ASSEMBLY A/R

2 240-2084 HAUL-OFF TO BRAIDER SHAFT ASSEMBLY 1

3 A10 X 8 X 40 DIN 6885 K EY (050327.0) A/R

4 3/8 X 3/8 X 1½ K EY, R OUNDED E NDS (99916) 15 240-6011 COVER ASSEMBLY 1

6 2000503 FRONT COVER ASSEMBLY 1

7 240-6023 DRIVE SHAFT COVER A/R

8* S-5006 R EPAIR K IT FOR FLEXIBLE COUPLING A/R



7-PARTS

33.5 IN850 mm

33.5 IN850 mm

FLOOR

1 1 . 0 2 I N

2 8 0 m m

1 2 . 3 6 I N

3 1 4 m m

3 5 7 5 6

HAUL-OFF

U NIT

SEE FIGURE 7.5.25

1 3 2 4

1

1

MR-11 PLC-TMR-11 PLC-T

1 ALIGN SHAFT (2) TO

MR-11 PLC-T SHAFT

W/MAGNETIC BASE

I NDICATOR AS SHOWN



I S

7-PARTS

FIG. &

INDEXNO. PART NO. DESCRIPTION

UNITS

PERASM.

7.5.27INSTALLATION CONNECTION HARDWARE

(36 CARRIER )

1 536-2085 BRAIDER TO BRAIDER SHAFT ASSEMBLY A/R

2 536-2086 HAUL-OFF TO BRAIDER SHAFT ASSEMBLY 1

3 A10 X 8 X 40 DIN 6885 K EY (050327.0) A/R

4 3/8 X 3/8 X 1½ K EY, R OUND E NDS (99916) 15 536-6011 COVER ASSEMBLY 1

6 2000525 FRONT COVER ASSEMBLY 1

7 536-6009 DRIVE SHAFT COVER A/R



7-PARTS

23

22

12

1718

19

2827

1718

19

12

13

141615

14

6

5

4

7

8

3

9

1011

21**

10 23,24,25

29

ALTERNATE MOUNTING



20

21

7-PARTS

FIG. &


UNITS

PERASM.

7.5.28 DA-1527INSTALLATION OF TRUMPET AND BRAIDRING

(SINGLE LET-OFF WIRE)

1**240-9120240-9226240-9231

19" BRAIDRING ASSEMBLY

1028 mm BRAIDRING ASSEMBLY (36 CARRIER )800 mm BRAIDRING ASSEMBLY (36 CARRIER )

1 A/R 1 A/R 1 A/R

LINER O.D.

TRUMPET

SIZE

2

240-9091240-9100240-9094240-9093240-9101240-9082240-9102

240-9092240-9103240-9099240-9095240-9127240-9128240-9129240-9130

1/2"19/32"3/4"1"1-7/64"1-1/4"1-3/8"

1-1/2"1-21/32"1-3/4"2"2-1/3"2-3/4"3-1/3"4-1/3"

12 mm15 mm19 mm25 mm28 mm31 mm35 mm

38 mm42 mm44 mm50 mm59 mm

71.3 mm84.5 mm110 mm

26 mm29 mm33 mm39 mm42 mm45 mm49 mm

52 mm56 mm58 mm64 mm73 mm

85.3 mm98.5 mm124 mm

1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R

1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R

3 240-9098 TRUMPET HOLDER ASM. (I NCLUDES ITEMS 4-19) 14 M10 X 35 DIN 6912 SOCKET HEAD SCREW (82915) 4


6 240-9096 TRUMPET HOLDER PLATE 1







11 240-9087 R ACK 1

12 240-9097 TRUMPET HOLDER 1

13 240-9084 DRIVE SHAFT 1

7-PARTS

23

22

12

1718

19

2827

1718

19

12

13

141615

14

6

5

4

7

8

3

9

1011

21**

10 23,24,25

29

ALTERNATE MOUNTING



20

21

7-PARTS

* The Kipp Handle cannot be used on the 16 carrier braider deck. Use the M8 x 25 DIN6912 socket head screw instead.

** Mayer Industries Inc. recommends the use of a thin coat of grease or lubricant on theoutside diameter of the Braidring Assembly to help prevent rust.

*** Not included in standard assembly.

FIG. &


UNITS

PERASM.

7.5.28 DA-1527INSTALLATION OF TRUMPET AND BRAIDRING

(SINGLE LET-OFF WIRE)

20*** M8 X 25 DIN 6912 SOCKET HEAD SCREW (050710.0) (82680) 8

21*** ST M8 R IBBED WASHER (051239.0) 8

22*** M8 DIN 934 HEXAGON NUT (050941.0) 8

23*** B8.4 DIN 125 FLAT WASHER (051042.0) 9

24* ***83450M8 X 25 DIN 6912

K IPP HANDLE (20, 24 & 36 CARRIER O NLY)*SOC. HEAD SCREW (82680) (16 CARRIER O NLY)*

1 A/R 1 A/R

25*** NT-74 T-NUT 1

26***

27*** M16 X 35 DIN 6912 SOCKET HEAD SCREW (050753.0) 2

28*** B17 DIN 125 FLAT WASHER (84045) 429*** 240-6034 JUNCTION BOX PAD ASM. (ALTERNATE MTG.) 1



7-PARTS

MANDREL, LINER POLE, ETC.

1

8

9

67

9

8

11

12

5

13

4

10

3

6/14

7/15

2

3



10 4

10

3

7-PARTS

FIG. &


UNITS

PERASM.

7.5.29240-6064536-6064

SENSOR STAND ASSEMBLY (16, 20 & 24CARRIER ) (STANDARD DRIVE)SENSOR STAND ASSEMBLY (36 CAR .) (STD. DR .)

1240-6127536-6127

STAND BASE ASSEMBLY (16, 20 & 24 CARRIER )STAND BASE ASSEMBLY (36 CARRIER )

1 A/R 1 A/R

2 240-6072 STAND SLIDE ASSEMBLY 1

3 240-6079EYE BOLT ASSEMBLY (16, 20, 24 CARRIER )EYE BOLT ASSEMBLY (36 CARRIER )

1 A/R 2 A/R

4 240-6080 SWING ARM ASSEMBLY 1

5 240-6061 SENSOR PIN 1

6 M6 X 16 DIN 912 SOCKET HEAD SCREW (053508.0) (82379) 6 A/R

7 B6.4 DIN 125 FLAT WASHER (051040.0) (84015) 6 A/R


9 B17 DIN 125 FLAT WASHER (84045) 4

10 M10 DIN 934 NUT (050945.0) (16, 20, 24 CARRIER ) (83580) NUT (050945.0) (36 CARRIER ) (83580)

1 A/R 2 A/R

11 M8 X 80 DIN 931 HEX BOLT (82800) 1

12 M8 DIN 934 NUT (050941.0) (83570) 1

13 89020 SAFETY PEG (NR. 202055) 114 M8 X 16 DIN 6912 SOCKET HEAD SCREW (82650) 2 A/R

15 B8.4 DIN 125 FLAT WASHER (84025) 2 A/R



7-PARTS

1

2,3



7-PARTS

* Insert not included.

FIG. &


UNITS

PERASM.7.5.30 SENSOR STAND ASSEMBLY

1* 240-9050BRAID SENSOR ASSEMBLY

(SEE FIGURE 7.5.31 FOR COMPONENT PARTS)1


3 B6.4 DIN 125 FLAT WASHER (051040.0) 2



7-PARTS

GAP

13

16

1712

15

1910

9

15

10

97

11

18

26

5

814



1

7-PARTS

FIG. &


UNITS

PERASM.

7.5.31 240-9050BRAID SENSOR ASSEMBLY

(16, 20, & 24 CARRIER )

1 240-9049 BRACKET - WELDMENT 1

2 3000383 WIRE ASSEMBLY 1

3 M8 X 8 DIN 916 SOCKET SET SCREW (82585) 2

4 M8 X 12 DIN 915 SOCKET SET SCREW (82635) 25 240-9026 SPRING PLUNGER 4

6 M6 DIN 934 NUT (050939.0) 4


8 S-3699 BALL PLUNGER 2


10 ST M4 R IBBED WASHER (84189) 811* M5 X 10 DIN 9427 BUTTON HEAD SCREW (82005) 2

12 99794 SPRING 4

13 240-9025 BRAID DETECTOR SPRING 4

14 240-9024 BRAID DETECTOR HOLDER 1

15 240-9027 BLOCK 4

16 240-9028 SHORTING R ING 117 240-9029 SPACER 4

18*

240-9031240-9033240-9035240-9037240-9039240-9041240-9043240-9045

HALF R ING ASSEMBLY, 15 DIAMETER








1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R 1 A/R




240-9047 HALF R ING ASSEMBLY, 55 DIAMETER 1 A/R

19 S-3225 SHRINKABLE TUBING (I NSULATOR ) 8

7-PARTS

1

567

2

14

4

3

GAP

11 18

8

13

16

17

12

15

19

109



1

7-PARTS


FIG. &


UNITS

PERASM.7.5.32 360-9050 BRAID SENSOR ASSEMBLY (36 CARRIER )

1 360-9049 BRACKET - WELDMENT 1

2 3000383 WIRE ASSEMBLY 1



5 240-9026 SPRING PLUNGER 4

6 M6 DIN 934 NUT (050939.0) 4


8 S-3699 BALL PLUNGER 2


10 ST M4 R IBBED WASHER (84189) 8

11* M5 X 10 DIN 9427 BUTTON HEAD SCREW (82005) 2

12 99794 SPRING 4

13 240-9025 BRAID DETECTOR SPRING 4

14 360-9024 BRAID DETECTOR HOLDER 1

15 240-9027 BLOCK 4

16 360-9028 SHORTING R ING 1

17 240-9029 SPACER 4

18*360-9054360-9052



1 A/R 1 A/R

19 S-3225 SHRINKABLE TUBING (I NSULATOR ) 8



7-PARTS

18

14

16,17

6

192

5

1

15

5

138

7

11

10

1312

20

21

22

23

13

24



3

4

7-PARTS

FIG. &


UNITS

PERASM.7.5.33 TUNNEL ASSEMBLY (16, 20 & 24 CARRIER )

1 240-6025 FLOOR PAN 1

2 240-6011 COVER ASSEMBLY 1

3 2000503 FRONT COVER ASSEMBLY (TAMER ) 1

4 240-6001 COVER SUPPORT 1


7 S-4716 HEX HEAD BOLT (HD 3/8 X 2 ¼) 4

8 240-6305 A NCHOR COVER PLATE ASSEMBLY 1

9 240-6008 TANK LEG 2

10 M12 DIN 934 NUT (050946.0) 4

11 B13 DIN 125 FLAT WASHER (051044.0) 412 M8 X 35 DIN 6912 SOCKET HEAD SCREW (050712.0) 8

13 B8.4 DIN 125 FLAT WASHER (051042.0) (84025) 12

14 240-0018 OIL SHIELD SCREEN 1



17 B6.4 DIN 125 FLAT WASHER (051040.0) 218 240-6052 BASE SUMP FILTER 1

19 240-6031 CATCH PAN ASSEMBLY 1


21 M8 DIN 934 HEX NUT (83570) (050941.0) 4

22 M5 X 10 DIN 9427 BUTTON HEAD SOCKET SCREW (82005) 6

23 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 6

24 1000504 A NTISLIP PLATE 1



7-PARTS

4

145

20

18

1710

1

11

2422

21

25

13

23

12

2819

226

29

27

3



6

79

815

16

7-PARTS

FIG. &INDEXNO.


7.5.34 240-7028 LUBRICATION SYSTEM ASSEMBLY (SHEET 1)

1 240-6330 SETTLING TANK COVER 1

2 2000003 OIL FILTER HOLDER HANDLE ASSEMBLY 1

3S-5543S-5544

PALL FILTER ASSEMBLY

R EPLACEMENT FILTER

1

4 S-3776 PUMP 15 99731 BUSHING 1

6 99744 PIPE THREAD R EDUCER (¾ X ¼ PTR-B) 1

7 99760 PUMP FILTER ( SEH 8¾) 1

8 240-6338 FILTER LEG ASSEMBLY 4

9 S-3771 CHECK VALVE (3/8 IN.) 1

10 B17 DIN 125 FLAT WASHER (051046.0) 211 S-3768 MALE ADAPTER (¼ X 3/8 BRASS) 1

12 99751 MALE ¼" NPT ELBOW (¼ TUBE X ¼) 3

13 S-3901 MALE BRANCH TEE (BRASS) 1

14 M5 X 16 DIN 912 SOCKET HEAD CAP SCREW (055147.0) 4

15 M5 DIN 934 HEX NUT (050937.0) 10

16 A5 DIN 127 LOCK WASHER (051218.0) 1017 M6 X 20 DIN 912 SOCKET HEAD CAP SCREW (054251.0) 16

18 A6 DIN 127 LOCK WASHER (051219.0) 17

19 M6 X 12 DIN 912 SOCKET HEAD CAP SCREW (054682.0) 4

20 M6 DIN 934 HEX NUT (050939.0) 7

21 99718 STRAIGHT ADAPTER ASSEMBLY 1

22 S-4715 R ESERVOIR FILLER 123 S-4674 NYLON TUBING (¼" - B-8599) 1200 mm

24 S 4675 INSERT 4



24 S-4675 I NSERT 4


26 S-103-M SOCKET HEAD SCREW (5/16-18 X 3/4) 2

27 B8 4 DIN 125 F W (051042 0) 2

7-PARTS

3

5

4

6

1

2

7

8

9

1



2

7-PARTS

FIG. &INDEXNO.


7.5.35 240-7028 (CONT.) LUBRICATION SYSTEM ASSEMBLY (SHEET 2)

1 240-6040 SETTLING TANK ASSEMBLY 1

2 240-6347 OIL PAN 1

3 240-6051 SETTLING TANK FILTER 1

4 88008 ELBOW 1

5 97263 CONDUIT CLAMP 16 S-5481 FLUID LEVEL GAUGE 1

7 M8 DIN 934 HEX NUT (050941.0) 4

8 M8 X 45 DIN 933 HEX HEAD SCREW (82770) 4

9 M12 X 1.5 DIN 908 SCREW PLUG WITH GASKET (050893.0) 3



7-PARTS

5

6

7,8

31

27,28

26

30

29

9

15,16

14

1

10,11

17

3

818

2

11,12,13

4

19,20

2110

34

18,823

25

32

33

24

27

24

27



2118,8

7-PARTS

FIG. &INDEXNO.


7.5.36 TUNNEL ASSEMBLY (36 CARRIER )

1 536-6025 PAN ASSEMBLY 1

2 536-6011 TUNNEL ASSEMBLY COVER (SMALL) 1

32000525536-6009

FRONT COVER ASM. (H/O TO BRAIDER ) (TAMER )MIDDLE COVER ASM. (BRAIDER TO BRAIDER )

1 A/R 1 A/R

4 240-6001 COVER SUPPORT 1

5 240-6052 BASE SUMP FILTER 1

6 240-0018 OIL SHIELD SCREEN 1


8 B6.4 DIN 125 FLAT WASHER (84105) 12

9 536-6024 BRACKET WELDMENT 2


11 B8.4 DIN 125 FLAT WASHER (051042.0) 9


13 M8 DIN 934 HEX NUT (050941.0) 7

14 100-0887 SPACER 2


16 B10.5 DIN 125 FLAT WASHER (051043.0) 4


19 M12 DIN 934 HEX NUT (050946.0) 2

20 B13 DIN 125 FLAT WASHER (051044.0) 2

21 S-4716 HEX HEAD BOLT 4

22 536-6305 A NCHOR COVER PLATE ASSEMBLY 1

23 1000526 A NGLE 224 M5 X 10 DIN 9427 BUTTON HEAD SOCKET SCREW (82005) 16




26 M5 DIN 934 HEX NUT (050937.0) 4

27 B5.3 DIN 125 FLAT WASHER (051038.0) (84010) 20

28 A5 DIN 127 LOCK WASHER (051218 0) 4

7-PARTS

TO

PRESSUREFILTERS

15

NAMEPLATE

2

3

1

4

5

6

7

8

14

9

10

12

11

13



7-PARTS

NOTE: Order by part number and the names shown. Specify the complete lubricator part number

and the serial letters shown on the nameplate. Example: "S-181 Filter Group for Lubricator D-

2956, Serial Letters GF." For major repairs requiring parts not identified in the illustration,

return the lubricator to MII for factory rebuilding and adjustment. If a new lubricator is required

for replacement, order by the part number and serial letters shown on the nameplate.

FIG. &INDEXNO.


7.5.37 BIJUR LUBRICATION SYSTEM

1 S-3776 PUMP 1

2 99752 ¼" TUBE X 1/8" ELBOW 1

3 99747 CHECK VALVE B-9557 1

4 B-7659 OIL OUTLET 1

5 B-6903 GASKET 16 HO-442 O-R ING (LARGE) 1

7 B-6898 R ELIEF VALVE 1

8 B-6479 OUTLET TUBING 1

9 C-2972 PUMP AND FILTER ASSEMBLY 1

10 99744 ¼" - ¾" PIPE R EDUCER 1

11 B-8480 OUTLET TUBING 112 99731 4541K11 BUSHING 1

13 99760 PUMP FILTER UC-SE 1320 NPT 1

14 B-8471 MOUNTING SCREW 4

NOT SHOWN

HO-418 O-R ING (SMALL) 1

15 B-7726 BY-PASS VALVE 1



7-PARTS

1

7

8

SEE

20

19

18

DETAIL B

17

16

15

25

SEE DETAIL A

R OTOR AXLE

24 6112

3 5

SEE DETAIL C

4,11,12,13,14

21,22,23 31



28

29

2627

7-PARTS

FIG. &INDEXNO.


7.5.38 LUBRICATION ASSEMBLY - BACK OF DECK CARRIERS

36 24 20 16

1 240-7019 NYLON TUBING (¼") 15 9 7 5

2 B-8272 SLEEVE (99722) 36 24 20 16

3 B-1371 BUSHING (99725) 18 12 10 8

4 A-2835 STRAIGHT ADAPTER (99720) 19 13 11 95 4541 K11 BRASS BUSHING (99731) 18 12 10 8

6 240-7020 NYLON TUBING (5/32") 1 1 1 1

7 240-7021 BRASS TUBING (5/32") 1 1 1 1

8 240-7022 NYLON TUBING (¼") 1 1 1 1

9 240-7025 COPPER TUBING (¼") 1 1 1 1

10 B-7688 5-WAY JUNCTION (99716) 1 1 1 111 B-1095 NUT (99721) 19 13 11 9

12 S-5537 BIJUR CONTROL U NIT (CJB-1) 1 1 1 1

13 A-4019 STRAIGHT CONNECTOR 1 1 1 1

14 B-1061 SLEEVE (99723) 1 1 1 1

15 240-7023 NYLON TUBING (¼") 1 1 1 1

16 240-7024 NYLON TUBING (¼") 1 1 1 117 240-7026 COPPER TUBING 1 1 1 1

18 S-4087 PRESSURE SWITCH 1 1 1 1

19 B-7694 4-WAY JUNCTION (99714) 1 1 1 1

20 S-4088 PRESSURE GAUGE 1 1 1 1

21 B6.4 DIN 125 FLAT WASHER (84105) (051040.0) 57 38 32 26

22 M5 X 30 DIN 6912 SOCKET HEAD SCREW (82125) 19 13 11 923 S-4066 PIPE CLIP 16 10 8 6

24 B-6534 STRAIGHT ADAPTER ASSEMBLY (99718) 41 27 22 18



25 B-7692 3-WAY JUNCTION (99712) 17 11 9 7

26 A-3080 ELBOW ADAPTER (99715) 18 12 10 9

27 S 5537 B C U (CJB 1) 18 12 10 8

7-PARTS

32

1

95

8

4

6

NOTE: THE CLEARANCE BETWEEN THE O.D. OF THE CAM TRACK AND THE END OF THE PROXIMITY SENSOR SWITCH IS TO BE

SET AT 0.4 mm -.05 mm.

7



7-PARTS

ADJUSTING THE PROXIMITY SENSOR

Remove the upper change gear from the deck before starting this procedure. Moving elements inthe deck area could cause personal injury to hands and arms.

• Remove the top shield from the shield support.• Manually rotate a shuttle so that the O.D. of the cam track is at its closest position to the end

of the proximity switch. Adjust the clearance between the cam track O.D. and the proximitysensor to 0.40 mm -0.05 mm. Lock the sensor in position with the lock nut. Recheck to insurethe correct setting.

• Manually rotate several more shuttle assemblies into position and check them for the correct

FIG. &INDEXNO.


7.5.39 PROXIMITY SENSOR

1

1000582100057810005771000580

PROXIMITY SWITCH BRACKET (16 CARRIER )PROXIMITY SWITCH BRACKET (20 CARRIER )PROXIMITY SWITCH BRACKET (24 CARRIER )PROXIMITY SWITCH BRACKET (36 CARRIER )

1 A/R 1 A/R 1 A/R 1 A/R

2 1000492 CLAMP 1

3 3000574 PROXIMITY SENSOR SWITCH ASSEMBLY 14 M6 X 10 DIN 916 SOCKET SET HEX CUP POINT SCREW (82220) 1

5240-80511000985

SENSOR SCREW

SENSOR SCREW (BRIDGESTONE O NLY)11


7 ST-M6 R IBBED WASHER (84200) (051238.0) 2

8 M10 DIN 934 HEX NUT (050945.0) 19 ST-M10 R IBBED WASHER (84220) (051240.0) 1

CAUTION



• Manually rotate several more shuttle assemblies into position and check them for the correctsetting.

• After verifying the correct setting, manually rotate the deck/shuttles for one full revolution.Ch k i h h h l i h ll li h l d h b k f h

7-PARTS

1

2,3

6,7

4,6

5,6



7-PARTS

FIG. &INDEX

NO.

PART NO. DESCRIPTIONUNITSPER

ASM.7.5.40 3000841 INSIDE JOG BOX ASSEMBLY (SHEET 1)

1 1000840 I NSIDE JOG BOX 1


3 3000569 YELLOW LEGEND 1

4 ZB2-BA2 OPERATOR PUSHBUTTON (97176) 1

5 S-5806 OPERATOR PUSHBUTTON (YELLOW) 16 S-5723 LEGEND 3

7 S-5153 ILLUMINATED SWITCH 1



7-PARTS

3

1

16,2

4,5

10,1112,13

14 7 8 6 10,11,12

915

1



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.41 3000841 INSIDE JOG BOX ASSEMBLY (SHEET 2)

1 ZB2-BZ101 CONTACT BLOCK (97390) 2

2 S-5799 AMBER SWITCH 1


4 S-5290 STRAIN R ELIEF CONNECTOR 1

5 S-5328 NUT 16 S-3697 STANDARD R AIL 65mm





11 A5 DIN 127 LOCK WASHER (84097) 312 M5 DIN 934 HEX NUT (83520) 3

13 S-2875-4 LUG R ING, 16-14 AWG 1

14 S-3798 WIRE, GRN/YEL 14 AWG 250mm


16 97391 CONTACT BLOCK W/O BASE 1

17 3000386 WIRE ASM. (BROKEN BRAID DET.) (NOT SHOWN) 1



7-PARTS

12

2

1

53 8 4 6 7

A

A

13,14,15,10



9

7-PARTS

FIG. &INDEX

NO.


ASM.7.5.42 3000418 MAIN CONTROL BOX ASSEMBLY (SHEET 1)


2 S-5360 MUFFIN FAN GUARD 2

3 S-5816 PUSHBUTTON, FLUSH, CLEAR 1

4 S-4047 EMERGENCY STOP 1

5 S-4773 PUSHBUTTON LENS 16 240-8656 ELECTRICAL LABEL 1

7 M3 X 6 DIN 84 CHEESE HEAD SCREW (81580) (050608.0) 4

8 S-3883 PRIMARY POWER SWITCH ASSEMBLY 1


10 A8 DIN 127 LOCK WASHER (84105) (051220.0) 14

11 M8 DIN 557 SQUARE NUT (83565) (050979.0) 612 B8.4 DIN 125 FLAT WASHER (84025) (051042.0) 6

13 S-5420 EMI FILTER 1


15 M8 DIN 934 HEX NUT (83570) (050941.0) 8



7-PARTS

6,7 1 3

15 89

4,5

10,11,1213,14,4,

2

2(FIG. 7.5.42)



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.43 3000418 MAIN CONTROL BOX ASSEMBLY (SHEET 2)

1 3000390 MAIN C NTRL. BOX PANEL ASM. (FIGURE 7.5.44) 1

2 100-0718 MOUNTING R AIL 2

3 1000417 SHIELD 1

4 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 8

5 M4 X 16 DIN 84 SLOTTED CHEESE HEAD SCREW (81850) 46 B10.5 DIN 125 WASHER (84030) (051043.0) 6

7 M10 DIN 934 HEX NUT (83580) (050945.0) 6

8 3000416 CONTROL BOX DOOR WIRE ASSEMBLY 1


10 S-5359 MUFFIN FAN 1

11 S-5361 FAN POWER CABLE 112 M4 X 50 DIN 912 SOCKET HEAD SCREW (81884) 4

13 A4 DIN 127 LOCK WASHER (84095) (051217.0) 4

14 M4 DIN 935 HEX NUT (83510) (050935.0) 4

15 S-5798 R ED SWITCH 1



7-PARTS

13

16

21

10,11

19

17

8

14,15

10,11

12

1

13

20

3

22

2

14,15

9

18

4 5 6



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.44 3000390 MAIN CONTROL BOX PANEL ASM. (SHEET 1)


2 S-4034 TRANSFORMER (540-220V) (T1) 1

3 S-5583 PLC (U6) 1

4 S-5582 E-STOP R ELAY (K1) 1

5 S-5686 R ELAY, 24V DC (K2) 16 S-5018 TERMINAL BLOCK (PE) 3

7

8 S-5683 R ELAY, 9AMP (KM3) 1



11 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 1112 S-5591 TERMINAL MARKER 1-50 1

13 S-5499 NYLON CHEESE HEAD SCREW (M4 X 12) 19

14 97340 WIRING DUCT 3.2 M

15 97341 WIRING DUCT COVER 3.2 M

16 S-5681 POWER SUPPLY (U3) 1

17 S-3883 PART OF 300041818 S-3697 STANDARD R AIL 1510 mm

19 S-5588 3 CONDUCTOR TERMINAL (AWG 24-6 PE) 4

20 S-5590 JUMPER 9


22 S-3883 PART OF 3000418



7-PARTS

14

14,15(FIG7.5.44)

13(FIG 7.5.44)

9(FIG 7.5.44)

23

12(FIG 7.5.44)

18(FIG 7.5.44)

10,11(FIG7.5.44)

13(FIG7.5.44)

19(FIG7.5.44)

5



7-PARTS

FIG. &INDEX

NO.










7-PARTS

1

14,15(FIG 7.5.44)

13(FIG 7.5.44)

3

18(FIG 7.5.44)

A A

6

5

8

14,15(FIG 7.5.44)

14,15(FIG 7.5.44)

9

10

11

19(FIG 7.5.44)



7-PARTS

FIG. &INDEX

NO.



1 S-5702 I NVERTER DRIVE (400-480V) 1

2



5 M8 DIN 934 HEX NUT (83570) (050941.0) 46 A8 DIN 127 LOCK WASHER (84105) 4

7 M8 DIN 439 HEX JAM NUT (83550) (050957.0) 4

8 B8.4 DIN 125 FLAT WASHER (84025) (051042.0) 8

9 S-5120 STRIP MARKER (L1 L2 L3 BIG) 2


11 S-5587 2 CONDUCTOR TERMINAL (ARG-24-6 BLUE) 1



7-PARTS

19

19

2

3

4

1

19

7

5

6

13,14,15,16

18

9

13,14,15

12



10

7-PARTS

FIG. &INDEX

NO.


ASM.7.5.47 3000146 R EMOTE OPERATOR STATION ASSEMBLY

1 240-8773 R EMOTE OPERATOR STATION 1

2 ZB2-BS54 OPERATOR PUSH BUTTON (97384) 1

3 S-3505 OPERATOR SWITCH 1

4 ZB2-BD5 OPERATOR SELECTOR , 3 POS. (97382) 1

5 S-5800 CONTACT BLOCK (RB2-BZ1026)) 1






11 S-5074 TERMINAL

BLOCK



14 A5 DIN 127 LOCK WASHER (84097) (051218.0) 4

15 M5 DIN 934 HEX NUT (83520) (050937.0) 4

16 S-2875-4 R ING LUG 16-14 AWG. 2

17 S-3798 WIRE

, 14 AWG, GREEN

/YELLOW

100mm18 S-5109 WIRE FERRULE 2

19 S-5723 BLANK LEGEND 3



7-PARTS

2 3 415,6 7,8,9



7-PARTS


FIG. &INDEX

NO.


ASM.7.5.48

30006183000684

TERMINAL BOX ASSEMBLY (SHEET 1)TERMINAL BOX ASSEMBLY (SHEET 1)

110005731000683

TERMINAL BOX (FOR 3000618)TERMINAL BOX (FOR 3000684)

11

2 S-3505 R ED PUSHBUTTON SWITCH 1

3 ZB2-BD5 SELECTOR SWITCH (97382) 1

4 1000638 TERMINAL BOX A NGLE 25 S-4047 EMERGENCY STOP LEGEND 1



8 M6 DIN 934 HEX NUT (050939.0) (83530) 4

9 A8 DIN 127 R IBBED WASHER (84105) 4

10* S-5750 TOUCHSCREEN PROTECTIVE COVER (NOT SHOWN) 10/PK



7-PARTS

10,11,1222

15,16

2,3,17

5

12,13,14

1

4

12 13 14

6

2,3,17

10,11,12

12,13,14

12,13,14

23



92112,13,14 24

7-PARTS

FIG. &INDEX

NO.


ASM.7.5.49

30006183000684


1 1000616 TERMINAL BOX PANEL 1

2 M5 X 8 DIN 84 CHEESE HD SCREW (050638.0) (81930) 9

3 S-3697 MOUNTING R AIL 275mm ea.

4 S-5590 JUMPER 6

5S-5589S-5589

3 CONDUCTOR TERMINAL (3000618)3 CONDUCTOR TERMINAL (3000684)

3537

6 S-5744 EXPANSION MODULE 1

7 S-5753 (DUAL DRIVE) EXPANSION CABLE (NOT SHOWN) 1 A/R

8 S-5754 (DUAL DRIVE) I NPUT A NALOG MODULE (NOT SHOWN) 1 A/R

9 S-5583 PLC 1

10 97340 WIRE DUCT 400mm ea.11 97341 WIRE DUCT COVER 400mm ea.

12 S-5499 NYLON CHEESE HEAD SCREW 20




16 M8 X 40 DIN 7380 BUTTON HEAD SCREW (82752) 417 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 9



20 S-5328 NUT (NOT SHOWN) 1


22 S-5591 MARKER 1-50 123 S-5848 4 POSITION HEADER 1

24 S-5844 2 POSITION HEADER 1



7-PARTS

1

8

9

11

10, 15 (Fig7.5.49)



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.50

30006183000684


1 S-5749 TOUCH SCREEN (3000618 O NLY) 1


3 S-5800 CONTACT BLOCK 1


5 S-2081 CABLE TIE 1

6 240-8875 TERMINAL BOX DOOR CABLE ASSEMBLY 1

7 S-5687 DISPLAY CABLE (3000618 O NLY) 1

8 S-5261 HOUR METER 1

9 3000428 HOUR METER CABLE 1

10 S-244-C HEX NUT 1/4-20 X 3/16" 1

11 S-4700 R UBBER SPONGE STRIP 1400mm



7-PARTS

67

174

8

9

1011

12

2

14

3

1

13

11

10

15

16 9

8

5

TO DECK MONITOR

18



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.51 160-9075 (DA-1463) BOBBIN R UNOUT DETECTOR ASM. (16 CARRIER )

1 240-9058 BOBBIN R UNOUT BAR 2

2 240-9059 MOUNTING CLAMP 2

3 240-9078 PROBE SPRING SLIDER 2


5 160-9069 I NSULATOR SPACER , 16 CARRIER 2

6 160-9070 THREADED R OD 2

7 160-9071 THREADED R OD 2

8 M8 DIN 439 NUT (050957.0) 4


10 B8.4 DIN 125 FLAT WASHER (051042.0) 4

11 84235 NYLON WASHER 4

12 240-9064 I NSULATOR BUSHING 2

13 240-9062 I NSULATOR 2


15 240-9065 WIRE ASSEMBLY 1

16 240-9072 JUMPER WIRE 1

17 2000215 PROBE SPRING ASSEMBLY 2

18 M5 X 12 DIN 916 SET SCREW (82012) 2



7-PARTS

7

8

15

14

9

10

1213

5

1

311

10

9

8

64

16

TO DECK MONITOR

217



7-PARTS

FIG. &INDEX

NO.


ASM.

7.5.52200-9075 (DA-1463)240-9075 (DA-1463)536-9076

BOBBIN R UNOUT DETECTOR ASM. (20 CARRIER )BOBBIN R UNOUT DETECTOR ASM. (24 CARRIER )BOBBIN R UNOUT DETECTOR ASM. (36 CARRIER )

1 240-9058 BOBBIN R UNOUT BAR 2

2240-9059536-9059

MOUNTING CLAMP (20 & 24 CARRIER )MOUNTING CLAMP (36 CARRIER )

2 A/R 2 A/R

3 240-9078 PROBE

SPRING

SLIDER

24 M5 X 10 DIN 916 SET SCREW (050521.0) 4

5200-9068240-9067536-9067

I NSULATOR SPACER (20 CARRIER ) 16 mm THICK

I NSULATOR SPACER (24 CARRIER ) 4.7 mm THICK

I NSULATOR SPACER (36 CARRIER ) 36.7 mm THICK

2 A/R 2 A/R 2 A/R

6M8 X 30 DIN 6912M8 X 20 DIN 6912M8 X 55 DIN 6912

SOCKET HEAD SCREW (050711.0) (20 CARRIER )SOCKET HEAD SCREW (050709.0) (24 CARRIER )SOCKET HEAD SCREW (82777) (36 CARRIER )

2 A/R 2 A/R 2 A/R

7M8 X 55 DIN 6912M8 X 45 DIN 6912M8 X 80 DIN 6912

SOCKET HEAD SCREW (82777) (20 CARRIER )SOCKET HEAD SCREW (053881.0) (24 CARRIER )SOCKET HEAD SCREW (82801) (36 CARRIER )

2 A/R 2 A/R 2 A/R


9 B8.4 DIN 125 FLAT WASHER (051042.0) 4

10 84235 NYLON WASHER 4

11 240-9064 I NSULATOR BUSHING 212 240-9062 CLAMP I NSULATOR 2


14 240-9065 WIRE ASSEMBLY 1

15 240-9072 JUMPER WIRE 1

16 2000215 PROBE SPRING ASSEMBLY 2

17 M5 X 12 DIN 916 SET SCREW (82012) 2



7-PARTS

1,2,3,1615,1614

11,12,13

4,5,7,8

9

10



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.53 ELECTRICAL SYSTEM- BACK OF DECK CARRIERS

36 24 20 16

1

AWE-812AWE-682AWE-691AWE-750

DECK TO SENSOR WIRE ASSEMBLY

11

11

2 M3 X 16 DIN 84 SLOTTED CHEESE HEAD SCREW (050614.0) 4 4 4 4

3 B3.2 DIN 125 FLAT WASHER (84000) 4 4 4 4

4 S-5295 SAFETY POSITION SWITCH (SEE FIG. 7.5.54) 1 1 1 1

5 98808 SPACER PLATE (16 CARRIER O NLY) 1

6

7 M5 X 20 DIN 6912 SOCKET HEAD SCREW (81200) 2 2 2 2

8 B5.3 DIN 125 FLAT WASHER (051038.0) 2 2 2 2

9 S-3172 WIRE CONNECTOR 2 2 2 2

10 S-2080 CABLE TIE 1 1 1 1

11 99729 TUBE CLIP 17 11 9 7

12 M5 X 10 DIN 6912 SOCKET HEAD SCREW (050680.0) 18 12 10 8

13 B6.4 DIN 125 FLAT WASHER (051040.0) 50 38 34 30

14 87280 TERMINAL BLOCK 12 POLE (SMALL) 1

15 AWE-813 DECK TO SENSOR WIRE ASSEMBLY 1

16 S-5310 STRAIN R ELIEF CONNECTOR 2 1 1 1



7-PARTS

3,4 1 2

9

8

7

5

6



7-PARTS

INSTRUCTIONS FOR K LOCKNER MOELLER SWITCH

The safety switch installed on the gear box door on the rear of the braider locks the door closedwhile the braider is in operation or, if the door is open, it will prevent the braider from beingstarted.

A light on the Operator Panel will turn on when the gear box door is opened. The arm on the gear

box door is adjustable to provide a method of locating the key (6) in relation to the switch (5) toinsure easy and unrestricted operation of the switch.

NOTE: Do not attempt to bypass the switch or modify it in any way.

FIG. &INDEX

NO.


ASM.7.5.54 GEAR BOX DOOR SWITCH

1160-0040240-0104360-0104

GEAR BOX DOOR (16 & 20 CARRIER )GEAR BOX DOOR (24 CARRIER )GEAR BOX DOOR (36 CARRIER )

111

2 240-0103 DOOR FINGER (16, 20, 24 & 36 CARRIER ) 1


4 ST M6 R IBBED WASHER (051238.0) 25 S-5295 SAFETY POSITION SWITCH 1

6 SEE ITEM 5 K EY (PART OF SWITCH) N/A


8 ST M4 R IBBED WASHER (84189) 2

9 M4 X 10 DIN 7991 FLAT HEAD SOCKET SCREW (81808) 2



7-PARTS

MAIN CONTROL BOX

SEE FIGURE 7.5.57

2

1

MOUNTING BRACKETS (S-5266)15 PLACES

SEE FIGURE 7.5.56 FOR DETAILS

1

2

3

LIGHT DETAIL

152mm6" REF

3

8



7-PARTS

FIG. &INDEX

NO.


ASM.7.5.55 WIRING DUCT AND LIGHT

1240-8867536-8867

WIRING DUCT 45º (16, 20 & 24 CARRIER )WIRING DUCT 45º (36 CARRIER )

22

2 S-5267 WIRING DUCT 2

3 2000441LIGHT MOUNTING BRACKET ASSEMBLY

(I NCLUDES ITEMS 4 - 7)1

4 2000421 LIGHT MOUNTING BRACKET 1

5 M4 X 8 DIN 84 CHEESE HEAD SCREW (81760) 2

6 174723 I NDICATOR LAMP ASSEMBLY 1


8 97363 SLOTTED HEAD SELF TAPPING SCREW 2



7-PARTS

1

2,3

4

5



7-PARTS

* See Figure 7.5.57 for information on using either 2 or 3, depending on the location.

FIG. &INDEX

NO.


ASM.7.5.56 MOUNTING BRACKET

1 S-5286 WIRING DUCT COVER 4

2* S-5267 WIRING DUCT 2

3* 240-8867 WIRING DUCT 45º 2

4 S-4710 BIT-TIP SCREW 15

5 S-5266 MOUNTING BRACKET 15



7-PARTS

8

9

10

1112

6 7

3

4

5

2

1



7-PARTS

* CUT TO FIT

FIG. &INDEX

NO.


ASM.7.5.57 WIRING DUCT DETAILS

1* S-5286 WIRING DUCT COVER 1

2* S-5267 WIRING DUCT 1


4 S-5266 MOUTNING BRACKET 2

5 M4 X 8 DIN 9427 BUTTON HEAD SCREW (81779) 2

6 A4 DIN 127 LOCK WASHER (051217.0) 2

7 M4 DIN 934 HEX NUT (050935.0) 2

8 240-8868 SUPPORT BRACKET 2


10 B6.4 DIN 125 FLAT WASHER (051040.0) 2

11 A6 DIN 127 LOCK WASHER (051219.0) 2

12 M6 DIN 934 HEX NUT (050939.0) 2



7-PARTS

4

11

7

5

9

10

3

7

62

7

6

18

DOOR OFE NCLOSURE

I NSIDE WALL OFE NCLOSURE



7-PARTS

NOTE: Quantities shown are per door.

FIG. &INDEXNO.


7.5.58 DOOR LOCK

1 S-5721 DOOR LOCK 1

2S-5717S-5718

SWITCH MOUNT BRACKET - R IGHT

SWITCH MOUNT BRACKET - LEFT

1 A/R 1 A/R

3 S-5716 SWITCH K EY MOUNTING BRACKET 1

4 S-5715 FLEXIBLE ACTUATOR 1

5 A6 DIN 127 SPRING WASHER (051219.0) (84100) 26 M6 X 25 DIN 912 SOCKET HEAD SCREW (055160.0) (82445) 4

7 B6.4 DIN 9021 FLAT WASHER (84016) 6


9 M6 DIN 934 HEX NUT (050939.0) (83530) 2

10 6.4 DIN 7349 WASHER (051071.0) (84022) 2

11 M6 X 35 DIN 912-12.9 SOCKET HEAD SCREW (82499) 2



7-PARTS

1

7

3 4

2 10

2

13

14

15

12

89

511

6



7-PARTS

NOTE: Quantities shown are per door.

FIG. &INDEXNO.


7.5.59 SLIDING DOOR LOCK

1 2000026 SWITCH HINGE ASSEMBLY

2 MCT-187663.0 DOOR LOCK 1

3 M4 X 20DIN 6912 SOCKET HEAD SCREW (050675.0) (81862) 2

4 B4.3 DIN 125 FLAT WASHER (051037.0) (84005) 4

5 2000024 SWITCH HINGE ASSEMBLY 1

6 1000025 SWITCH HINGE BASE 1

7 4m6 X 40 DIN 6325 DOWEL PIN (80355) 1

8 M4 DIN 934 HEX NUT (050935.0) (83510) 2

9 A4 DIN 127 LOCK WASHER (051217.0) (84095) 2

10 S-5538 SHORT SPRING PLUNGER 2



13 240-6350 PLATE 1

14 S-5469 NYLON S NAP BUSHING 2




7-PARTS

FILTER SLIDES INFROM END

2 5 6 1

74

3



7-PARTS

FIG. &INDEXNO.


7.5.60 BLOWER

1 S-5707 HOOD 1




5 S-5705 EXHAUST FAN 1


7 S-4891 16" X 20" X 2" MESH FILTER 1



7-PARTS




7-PARTS

1

4,5,6

7,8,11,12

2

9,10

3



7-PARTS

FIG. &INDEXNO.


7.5.62DA-1615DA-1706

DECK LIGHTS (16, 20, 24 CARRIER ) (SHEET 1)DECK LIGHTS (36 CARRIER ) (SHEET 1)

1ATE-457 (16, 20, 24)/ATE-473 (36)

E NCLOSURE LIGHT CONDUIT ASSEMBLY

(SINGLE DECK )(DOUBLE DECK )(TRIPLE DECK )

012

2 ATE-458 (16, 20, 24)/ATE-472 (36)

SWITCH TO LIGHT CONDUIT ASSEMBLY


111

3*240-8005 (16, 20, 24)/360-8005 (36)

LIGHT SWITCH BOX ASSEMBLY


1 A/R 1 A/R 1 A/R

4 99953

D-LOOP SIZE #5 CHAIN


0.45 m0.9 m

1.35 m

5 99952

OPEN STYLE S-HOOK


4812

6 99950WIRE SCREW EYE(SINGLE DECK )(DOUBLE DECK )(TRIPLE DECK )

246

7 99951

WIRE EYE BOLT


246

8

S-5724 LIGHT FIXTURE


123

CONDUIT CLAMP, 1/2 I NCH



7-PARTS

1

4,5,6

7,8,11,12

2

9,10

3

7 PARTS



7-PARTS

FIG. &INDEXNO.


7.5.62 DA-1615DA-1706

DECK LIGHTS (16, 20, 24 CARRIER ) (SHEET 2)DECK LIGHTS (36 CARRIER ) (SHEET 2)

10 97363

SELF TAPPING SCREW


41220

11 S-2076

WIRE NUT


3915

12 S-5725

LIGHT BULB


246

7 PARTS



7-PARTS

SINGLE LET-OFF WIRE BOBBIN (#2000366)APPROXIMATE WIRE WEIGHT: 20 LBS (9.1 K G)MAXIMUM BOBBIN & MATERIAL WEIGHT: 23.5 LBS (10.66 K G)VOLUME: 98 CUBIC INCHES (1600 CU CM)

DOUBLE LET-OFF WIRE BOBBIN (#240-5120)APPROXIMATE WIRE WEIGHT: 18 LBS (8.2 K G)MAXIMUM BOBBIN & MATERIAL WEIGHT: 21.6 LBS (9.8 K G)**TOTAL PACKAGE WEIGHT (2 BOBBINS): NOT TO EXCEED 43.2 LBS (19.64 K G)

SINGLE LET-OFF YARN - CARDBOARD TUBE (#240-4016)**TUBES TO BE PURCHASED FROM YARN CONVERTER

PER THIS DRAWING - R EFERENCE PAGE 2-16 FOR TUBE

AND PACKAGE DIMENSIONS

MAXIMUM TUBE AND MATERIAL WEIGHT: 7 LBS (3.18 K G)YARN VOLUME: 229 CUBIC INCHES (3747 CU CM)

SINGLE LET-OFF FABRICATED YARN BOBBIN (#240-5160)APPROXIMATE MATERIAL WEIGHT: 4.75 LBS (2.15 K G) (#240-5160)MAXIMUM BOBBIN & MATERIAL WEIGHT: 7 LBS (3.2 K G) (#240-5160)VOLUME: 223 CUBIC INCHES (3800 CU CM) (#240-5160)

SUPER PACK FABRICATED YARN BOBBIN (#240-5162)APPROXIMATE MATERIAL WEIGHT:7.36 LBS (3.35 K G)MAXIMUM BOBBIN & MATERIAL WEIGHT:

SUPER PACK YARN - CARDBOARD TUBE (#240-4018)**TUBES TO BE PURCHASED FROM YARN CONVERTER

PER THIS DRAWING - R EFERENCE PAGES 6-5 AND 6-6FOR TUBE AND PACKAGE DIMENSIONS

MAXIMUM TUBE AND MATERIAL WEIGHT:

YARN VOLUME: 302 CUBIC INCHES (4947 CU CM)10 LBS (4.5 K G)

P ART N UMBER 240-5162

D RAWING N UMBER 240-4018

P ART N UMBER 240-5160

D RAWING N UMBER 240-4016

P ART

N UMBER

240-5120

P ART

N UMBER

2000366

P ART N UMBER 1000996

7-PARTS



7-PARTS

WINDING OPTIONS FOR USE WITH R OCKWELL WINDER

ADAPTER PINS 240-5105

BORE CONVERSION K ITS 240-5107 SINGLE LET-OFF

240-5126 DOUBLE LET-OFF

7 PARTS



7-PARTS

8-MAINTENANCE AND OVERHAUL



8 MAINTENANCE AND OVERHAUL

CHAPTER 8MAINTENANCE AND OVERHAUL

SECTION # SECTION TITLE PAGE

SAFETY (SICHERHEITSREGELN) (VEILIGHEID) . . . . . . . . . . . . . . . . . . . . . . . . . .8-3

SECTION I MR-11 PLC-T AND MR-11 PLCT-F BRAIDMATIC OVERHAUL . . . . . . 8-11

SECTION II R OTOR I NSPECTION AND R EPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20CAM FOLLOWER LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

SECTION III SHUTTLE I NSPECTION AND R EPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23

SECTION IV PRELIMINARY SHUTTLE ADJUSTMENT AND I NSTALLATION . . . . . . . . . 8-25

SECTION V I NSTALLATION OF R OTOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 8-26

SECTION VI R OTOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28

SECTION VII SHUTTLE I NSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

SECTION VIII OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33

SECTION IX I NSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE . . . . . . . . . . . . 8-35

CHECKING TIR (TOTAL I NDICATOR R UNOUT) SQUARENESS OF AXLES

TO DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35

CHECKING DISTANCE BETWEEN R OTOR AXLES . . . . . . . . . . . . . . . . . . 8-36

SECTION X I NSTRUCTIONS FOR THE USE OF THE 240-1075 (R OTOR GEAR TIMING GAUGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39

SECTION XI I NSTRUCTIONS FOR THE USE OF THE 240-1076 (CAM SET GAUGE WITH MASTER ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40

SECTION XII DISASSEMBLING, R EASSEMBLING, ADJUSTING, AND MAINTENANCE OF CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43

DISASSEMBLY 8 43




8 MAINTENANCE AND OVERHAUL




CHAPTER 8MAINTENANCE AND OVERHAUL

SAFETY

Braiding machines are designed to producequality braided structures by transferringshuttles via cam tracks. Producing the braided

structures requires high speeds, highhorsepower and moving elements. This in turnrequires that operators or maintenance personnel of this equipment be safetyconscious to avoid an accident which could becrippling or fatal to the operator or maintenance personnel.

Setup of this equipment should be done by

trained mechanics and/or riggers.

We cannot anticipate all possible factors thatcould cause an accident to occur with thisequipment, but are listing general safetyconsiderations as an aid to the operator or maintenance personnel becoming safetyoriented.

When this symbol is shown in themanual, the written instructions must be followed 100 percent to prevent

personal injury. If you don’t understand theinstructions, please contact Mayer IndustriesInc.

An operator or maintenance personnel should

become completely familiar with all machinecontrols and corresponding moving elements before setting up, operating, or working on themachine.

We suggest snug fitting clothing and safety

• Safety shoes with steel toes.

• Safety glasses with side shields.

• Hearing protection• Leather gloves when handling steelreinforcement materials.

• Only trained personnel should set up,operate, or work on this equipment

Do not store wrenches or other items onmachine surfaces.

Maintain a clean and safe work area. Keep oilfrom floor to prevent slipping.

Be sure that all guards and covers are properlyin place and doors are closed and fastenedwhile operating the machine.

The movement of the deck, gears, and transfer

areas can create pinch points and the operator must avoid these points.

During maintenance work, the control must beturned OFF, as an accidental control actuationcan cause an unexpected machine movementwhich could cause an accident. Utilize your plants lock out/tag out procedures.

High voltage is used to power this machine.Only authorized electricians should correctany electrical component failure. Other maintenance must be performed by authorized personnel.

CAUTION




All rights are reserved for this instructionmanual. It must not be copied nor made

available to others without Mayer Industries' previous consent nor its contents exploited inany other way by the user or any third party.Reprints, whether complete or partial, requirethe express authorization of Mayer Industries.

These operating instructions have beenformulated to give you information on theconstruction, operation and maintenance of themachine. The enclosed diagrams and drawingsillustrate the important features of the design.However, dimensional accuracy and designdetails are not guaranteed and we reserve theright to make any changes or amendments atany time.

The operating instructions also describedevices, spares or other parts which do not

belong to the standard version of the machineand which are only available to order as anextra. No right to equip the machine with such parts or devices may be derived from theseoperating instructions.

Please consult Chapter 7 when ordering spares.The machine warranty is valid only if usinggenuine MII or MII-approved components or replacement parts.

Before and while operating the machine, allgeneral and special safety rules must beobserved and necessary safety protectionstaken. No protective or safety devices must be put out of action





SYMBOL TRANSLATIONS

English: CAUTION

English: NOTE

English: STOP

English: JOG / RUN

English: SAFETY OFF / ON

English: JOG / FORWARD

CAUTION

NOTE




English: STOP

English: DANGER / HIGH VOLTAGE

English: LASER LIGHT:

Do not stare into beam

English: DANGER TOXIC FUMES

English: DANGER:Do Not Operate Without Guards In Place


SYMBOL TRANSLATIONS

STOP




English: HIGH VOLTAGE

English: PINCH POINT

English: DANGER PINCH POINT

English: DANGER

DO NOT OPERATE UNLESS PROPERLY

TRAINED

English: DANGER

ONLY TRAINED AND EXPERIENCED

MAINTENANCE PERSONNEL OR RIG-GERS SHOULD BE ALLOWED TO MOVEAND SETUP THIS EQUIPMENT.

NOTE: MACHINE WEIGHT AND STABIL-ITY ARE MAJOR CONCERNS IN LIFTINGAND MOVING THE EQUIPMENT


SYMBOL TRANSLATIONS




English: DANGER

DO NOT OPEN WHILE MACHINE IS INOPERATION

English: WARNING


SYMBOL TRANSLATIONS




SICHERHEITSREGELN

Braiding Maschinen sind entwickeld um hoheQualitäts braided structur produkte zu produzieren bei transfer shuttles über camtracks. Beim Produktstionsvorgang wird mithoher geschwindigkeit und mit vielKraftaufwand gearbeitet. Um unfälle zu

vermeiden soll nur geschultes Personal zur Bedienung der Maschine verwendet werden.

Wir Können nicht alle möglichkeitenaufzählen die einen Unfall verursachenKönnen, aber wir führen hier in generell einigeSicherheitsvorschriften auf.

Wenn dieses Zeichen im Bucherscheint, die instruktionen müssen100% erfüllt werden um Unfälle zu

vermeiden. Wenn sie irgend etwas nichtverstehen, fragen sie uns bitte.

Bedienungspersonal und Betriebsmechaniker müssen sich vorhehr mit der Funktion der Maschine bestens vertraut machen. Elektrischund mechanisch.

Wir schlagen vor eng anliegende kleidung.Keine Krawatte, aber eine Schutzbrille zutragen. Bleiben sie weg von der Maschine

wenn sie sich nicht wohl fühlen, oder krank sind. Niemals die Maschine laufen lassen miteinem eventuellen defekt.

Lasse niemals Werkzeug irgendwo in der Maschine Liegen.

Mach sicher das alle Abdeckungen immer inrichtiger position sind und fest angeschraubtwenn die Maschine Läuft.

Die sich bewegenden elementeTransferposition und Ritzel Können Leicht zueiner Falle werden, so sei vorsichtig und trete

zurück.

Bei Reperaturarbeiten mach sicher das dieMaschine ausgeschaltet ist. “AUS” da wir mithoher Spannung arbeiten.

Mach sicher das nur geschulte Elektriker ander Maschine arbeiten.

Am ende möchten wir daraufhinweisen das,das Personal die Maschine immer mit Respekt behandelt, und immer alleSicherheitsvorschriften beachtet.

VEILIGHEID VOOR MR-11 PLC-T/MR-11 PLCT-F BRAIDMATIC

Vlechtmachines zijn ontworpen om Wij kunnen niet alle mogelijke factoren welke

WARNUNG




gevolg worden om het risiko op letsels tevermijden. Indien de instruktie onduidelijk is,

moet Mayer Industries Inc. geraadpleegdworden.

Vooraleer met de vlechter te werken moetenoperatoren en onderhoudsmensen opgeleidworden in de werking en de sturing van demachine.

Het dragen van aansluitende kleding en eenveiligheidsbril wordt sterk aanbevolen. Het isook aanbevolen om de machine niet te bedienen indien men ziek is of oververmoeid.Laat de machine niet draaien indien er ergenseen defect opgetreden is.

Bewaar geen stelsleutels of andere zaken op demachine.

Stel zeker dat alle beschermingen enafdekkingen op hun plaats zitten en goedvastgemaakt zijn vooraleer de machine testarten

Het verdraaien van de deck, tandwielen of andere bewegende delen kan knellen

veroorzaken en operatoren moeten hiervoor oppassen.

Bij onderhoud van de machine moet de sturingsteeds in de positie “UIT” staan teneinde bijeen eventuele ongewilde activering van destartknop onverwachte start van de machine tevermijden;

De machine start onder electrischehogespanning. Enkel getrainde elektriekers enonderhoudspersoneel mogen aan de machinewerken

OPERATOREN EN ONDERHOUDSMENSENMOETEN MET DE NODIGE OMZICHTHEIDWERKEN EN ALLE

VEILIGHEIDSVOORSCHRIFTENRESPEKTEREN!

MISURE DI SICUREZZA PER LA BRAIDMATIC PLC-T/PLCT-F MR-11

Le intrecciatrici sono progettate per produrrestrutture intrecciate di qualità trasferendo spoleseguendo il profilo di eccentrici. La produzione di strutture intrecciate richiede alta

velocità, grande potenza e movimento dicomponenti. A propria volta, tutto questorichiede che l’operatore e il personale addettoalla manutenzione di questa apparecchiaturasiano consci delle esigenze di sicurezza per evitare infortuni che possono comportare

generale in grado di indirizzare l’operatore e il personale addetto alla manutenzione acomportarsi in modo sicuro.

Quando questo simbolo appare nelmanuale, seguire scrupolosamente leistruzioni ivi riportate per evitare

infortuni. Se le istruzioni non sonocomprensibili, contattare le Mayer Industries,Inc

ATTENZION




Si consiglia di indossare indumenti attillati eocchiali di sicurezza; niente cravatte. Non

usare la macchina in caso di stanchezza omalattia/indisposizione. Non usare lamacchina in caso di malfunzionamenti diqualsiasi genere.

Non lasciare chiavi inglesi o altri oggetti sullesuperfici della macchina.

Durante il funzionamento della macchinaaccertarsi che tutte le protezioni ed i coperchisiano montati correttamente e che gli sportellisiano chiusi e fissati.

Il movimento del piano di lavoro, degliingranaggi e delle aree di trasferimento puòcreare punti di schiacciamento che l’operatoredeve evitare.

Durante le operazioni di manutenzione icomandi devono essere disattivati, poiché unloro azionamento accidentale può causare unmovimento imprevisto della macchina con pericolo di infortuni.

Questa macchina è alimentata ad alta tensione.

I guasti elettrici devono essere riparati solo daelettricisti qualificati. Le altre operazioni dimanutenzione devono essere eseguite da personale autorizzato.

In conclusione, l’operatore e il personaleaddetto alla manutenzione devono trattare lamacchina con il massimo rispetto ed osservare

tutte le misure di sicurezza.

Tutti i diritti di questo manuale di istruzionisono riservati. Non può essere copiato o reso

disponibile a terzi senza previo consenso delleMayer Industries; il suo contenuto non puòessere utilizzato in alcun modo dall’utente o daterzi. Eventuali ristampe, parziali o totali,dovranno essere autorizzate dalle Mayer Industries.

Queste istruzioni operative sono stateformulate per fornire informazioni sucostruzione, uso e manutenzione dellamacchina. I diagrammi e i disegni allegatiillustrano caratteristiche importanti della progettazione. Tuttavia, non si garantisce la precisione delle dimensioni e dei dettagli dellefigure e la Mayer Industries si riserva il dirittodi apportare modifiche o cambiamenti inqualsiasi momento.

Le istruzioni operative descrivono anchedispositivi, ricambi o altre parti che non fanno parte della versione standard della macchina eche sono disponibili solo su ordinazione come parti supplementari. Nessun diritto di dotare lamacchina di tali parti o dispositivi può esserededotto da queste istruzioni operative.

Quando si ordinano i ricambi, vedere ilcapitolo 7. La garanzia della macchina è validasolo se si usano componenti o ricambi originalidella MII o omologati dalla MII.

Prima e durante l’uso della macchina,osservare scrupolosamente tutte le misure di

sicurezza generali e particolari e adottare tuttele precauzioni necessarie. Non disattivarenessun dispositivo di protezione o sicurezza.

SECTION I. MR-11 PLC-T/MR-11 PLCT-F BRAIDMATIC OVERHAUL




be worn.

Work area to be clean and free of

oil to prevent slipping.Cut power off at the maindisconnect and remove the upper change gear on PLC-T models.Follow plant lock out/tag out

procedure

Cut power off at main disconnect

and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.


8.1. Remove all carriers and bobbins. Turn all power "off" to the machine. Remove the topchange gear on the deck, then remove the inner and outer shields.

CAUTION

Release of shuttle assemblies.

Do not attempt to remove camfollower assemblies when ashuttle is engaged with thecartridge.


8.2. Remove shuttles from machine at their proper places. On a 36 carrier machine,shuttles are removed at rotor frames 6 & 7. Ona 24 carrier machine shuttles are removed at

NOTE

Removal of shuttles requires twotrained mechanics using special tool #2000302, which mounts tothe face of the rotor frame using the (4) M6 holes that are used to

mount the rotor cap. Mount thistool to the rotor frame closest tothe 8:00/9:00 deck position.


The mechanic turning the deck must be strong enough to control the movement of the rotors.Installing the shuttles will causeuneven loading until they have all been installed. This unevenloading will result in unwanted movement of the rotors that must be controlled by the mechanic using the special tool.

Note: Tool #2000302 is availablefrom MI (Figure 9.1.8)

NOTE

Before removing shuttles fromtheir transfers, it is best to put each set of shuttles into itstransfer position and identify onthe rotor face. This enables acorrect shuttle from each transfer t b d i h ki th




CAUTION

Moving elements.

Use only the special tool,2000302, which gives the second mechanic control of the rotor/ shuttle. Do not use a ratchet.


EXAMPLE:

On a 24 carrier machine, put all of the #1transfer shuttles into transfer and with amarker that will not rub off, mark all the front

and rear cam followers in this transfer #1 onthe face of the rotor frame. The same should bedone on #2, #3, and #4 transfers.

Be sure to keep each transfer separated. Inother words, on a 24 carrier machine, keep the(6) shuttles removed from #1 transfer together, but separated from transfers #2, #3, and #4.

Each transfer is marked by its respectivenumber on the front cam follower cap. Bydoing this, you are assured that the shuttlesremoved from each transfer will return to itsoriginal transfer.

NOTE

This information is for a deck being overhauled and rotorsreturned to original locations on

8.3.

1. Install the front pocket polishing tool (240-1001) on to a hand drill motor. See Figure8.3.1.

2. Wrap a piece of 320 grit (very fine) emerycloth around the polishing roll. BE SURETHE ENDS OF THE CLOTH (PAPER)DO NOT OVERLAP.

3. Place the polishing tool into a pocket androtate the rotor to the transfer position.

4. Let the drill motor rotate the polishing toola few revolutions. The object is to polishout rough or high places, removing aminimal amount of material from pockets.

NOTE

Pockets will not polish out completely.

5. Run polishing tool in transfer position between rotor frames 1 and 2, 3 and 4, 5and 6, 7 and 8, 9 and 10, 11 and 12, 13 and14, 15 and 16, 17 and 18.

After the polishing tool has been run in thefour (4) transfer positions between rotors#1 and #2, do not run it between rotors #2

and #3, but instead between rotors #3 and#4 in transfer position.




6. When this is complete, place a new outer race (4, Figure 7.5.17 ) in a pocket of arotor and with a finger lightly holding theouter race into position, slowly rotate therotor through a transfer position. The outer race should pass through the transfer

without any restrictions. If there are anyrestrictions, the cause must be found andcorrected.

CAUTION

Moving elements in this assembly area.

Personal injury to hands and armscould result.

(4) pockets of a rotor, then thetiming of the rotor gear to pocketsis off and must be corrected. SeeSection X, Instructions for the useof the Rotor Gear Timing Gauge(240-1075).

If only 1 or 2 pockets have restrictions, it isusually a high or rough place in the pocket(s) and should be corrected asfollows:

Using marking ink, paint the mating pockets that show restriction. Place theouter race (4, Figure 7.5.17 ) into one of the

pockets and very lightly holding the race inthe pocket with a finger, slowly rotate therotor through the transfer position. Thisshould cause the outer race to try to rotate,thus marking the high or rough place(s) inthe pocket Using a scraping tool scrape

FIGURE 8.3.1: FRONT POCKET POLISHING TOOL 240-1001

A

A

VIEW A-A

POLISHING HUB SLOT FOR HOLDING

#320 EMERY CLOTH

DO NOT ALLOW ENDS OF

CLOTH

TO

OVERLAP

Ø72.0 mmINCLUDING

#320 EMERY CLOTH 11 IT MAY BE NECESSARY TO WRAP THEPOLISHING HUB WITH A PIECE OFMASKING TAPE TO COMPENSATE FOR POCKET WEAR .




NOTE

The rear pockets should be

checked for restrictions using anew S-4095 bearing (10, Figure7.5.17 ), a rear polishing tool 240-1002 (Figure 8.3.2) and the samemethod as the front pockets.

7. After all the pockets have been checked proceed as follows:

a. Obtain shim stock 7 mm wide and invarying thickness from .01 mm (.0039inch) up to .30 mm (.0118 inch). Notethat .30 mm is the MAXIMUM wear allowable for any pocket.

b. Starting with the thinnest shim, place a piece about 25 mm long in the bottomof the pocket, then place the new outer

(4 Fi 7 5 17) i t th k t

when the transfer point is approached.The shim thickness between the outer race and the pocket is an approximateindication of the wear between mating pockets.

NOTE

If this reading exceeds 0.30 mm

FIGURE 8.3.2: R EAR POCKET POLISHING TOOL 240-1002

A

A

VIEW A-A

POLISHING HUB

SLOT FOR HOLDING

#320 EMERY CLOTH

DO NOT ALLOW ENDS OF

CLOTH TO OVERLAP

Ø62.0mm

INCLUDING#320 EMERY CLOTH 1 1 IT MAY BE NECESSARY TO WRAP THE

POLISHING HUB WITH A PIECE OFMASKING TAPE TO COMPENSATE FOR POCKET WEAR .




Grasping the sides of this rotor, push in asfar as possible, "0" zero the indicator, then pull out as far as possible and release.Check the indicator reading, this is the

axial end-play of the rotor and this readingshould be recorded for future referencewhen rotors are reinstalled onto the deck.Slee Figure 8.3.3.

NOTE

After the rotors are reinstalled onthe deck, they must be adjusted so the axial movement is between0.01 mm to 0.05 mm after theKM8 t i ti ht d (18 Fi

End play adjustment is obtained by the useof shims as described in METHOD 1 or bymachining as described in METHOD 2.See Section V, Paragraph 8.16 .

8.4.

Remove the rotor assembly from each rotor axle. See Chapter 2, Section XI, Paragraph

FIGURE 8.3.3: R OTOR AXIAL MOVEMENT

AXIAL MOVEMENT

R OTOR FRAME

DIAL GAUGEAXIAL MOVEMENT

.01 mm MINIMUM

.05 mm MAXIMUM




8.5.

CAUTION

Heavy parts (90 lbs., 41 Kg).

Do not attempt to remove without

help.Minor personal injury could result.

After the rotor assemblies are removed, turnthe oil pump on manual and without increasingor decreasing oil pump pressure, check and besure that the oil is flowing freely from theBijur metering units in each axle. If there is

any doubt, replace the Bijur metering unit (6,7, and 27, Figure 7.5.21).

1. To replace the rear metering unit, CKA-00-B7125 (6, Figure 7.5.21), the rotor axlewill have to be removed from the deck and

the major sun gear (2) and rear bearinginner race (3-1, Figure 7.5.21) removedfrom the rotor axle.

NOTE

Use MII tool 240-1074 ( Figure8.5.1 ) unless a race puller is

available.

2. The middle and front Bijur units (7 and 27, Figure 7.5.21) can be extracted withoutremoving the rotor axle from the deck. If the front metering unit has to be replaced,the front inner race can be removed by useof a front bearing puller 240-1073 ( Figure

8.5.2).3. If no oil flows, check the metering unit (27,

Figure 7.5.38) at the input to the axle (if the machine is so equipped).

FIGURE 8 5 1: REAR BEARING PULLER 240-1074

AXLE

R EAR BEARING 240-1074




8.6.

After checking the metering units in the rotor axles, check the rear bearing (3, Figure7.5.21), major sun gear (2) and the front bearing (4).

NOTE

Use MII rear bearing puller 240-1074 ( Figure 8.5.1 ) unless a race

puller is available.

The rear bearing and the front bearing each

come as a matched set and should never be partially replaced. Install a new complete seton rear or front. If the rear bearing has to bereplaced, the following steps should befollowed: Note: MII tool 240-1074 is

il bl S Fi 8 5 1

NOTE

Rotor axles are sealed into thedeck with Permatex; therefore, theaxle may have to be tapped lightly from the rear, with a hammer and

punch, taking care not to strike the

oil fittings.

3. Remove the M5x16 DIN 912 (19, Figure7.5.21) screw from the major sun gear (2)and remove the sun gear from the axle. Thesun gear may have to be lightly pried or tapped with a hammer and aluminum or soft brass rod. 36 carrier braiders also have

a key in the sun gear.4. Using the (3) 6 mm holes through the rear

of the rotor axle, tap the inner race from therotor axle.

FIGURE 8.5.2: FRONT BEARING PULLER 240-1073

AXLE

FRONT BEARING

240-1073




5. When installing the new inner race, be surethe oil hole is aligned with the meteringunit before pressing or driving onto theaxle.

6. Install the new needle bearing onto theinner race.

7. Install the bearing spacer (10, Figure7.5.21).

8. Install the major sun gear after checking itfor cracks or defective areas. If at all possible, MAGNAFLUX all the sun gearson the machine. If this is not possible andthere is some question about a sun gear,replace it. On installing the sun gear, besure to align the flat of the extended lipwith the flat of the rotor axle and lightlytap it down until it bottoms out, on 16, 20

& 24 carrier braiders. The 36 carrier braiders have a key that must be installed before the sun gear goes on.

9. Permatex the M5x16 DIN 6912 screw (19, Figure 7.5.21) and install it in the sun gear.

10. Clean the Permatex from the rotor axle anddeck hole and apply a moderate, fresh coatof Permatex, Aviation Form-A-Gasket,Liquid Type, #3H to the axle shaft and thehole.

11. The rotor axle is now ready for reinstallation.

12. Slip the axle into the hole, aligning the

timing pin in the deck with the dowel holein the rotor axle.

13. Assemble the (6) M12x60 DIN 912 screwstogether with the (6) A12 lock washers.Apply Permatex to all the screw threads

15. With the use of gauge 240-1078.01,( Figure 8.20.1) the squareness of the axlesto deck face and the distance between axlescan be checked. A distance of (+) or (-) .07mm is allowable from the master setting onthe indicator and a squareness of 0.03 mmTIR. Any distance or out of squarenessover this should be corrected.

NOTE

In case the axle has to shimmed,the flatness cannot be held.

NOTE

The gauge for setting distancesbetween axles consists of abearing hub, extension rods,indicator, and master gauge. SeeFigure 8.21.1.

When using this gauge for checkingsquareness, be sure to screw the KM8 nutfinger tight against the bearing hub. Thiseliminates false readings from backwardand forward movements.

16. If the squareness measurement is too great,it is sometimes possible to loosen the (6)

M12x60 DIN 6912 screws in the axle, tapthe axle loose, and retighten in a different pattern; or a brass shim may have to beinstalled at the proper location for correction. Normally, these two proceduresare not necessary




Before shimming, install a new rotor axleand check the center distance and flatnessto insure that a bent rotor axle is not the problem.

18. Remove the old outer race (3-3, Figure7.5.21) from the mating rotor assembly andtap the new outer race into place in therotor assembly.

SECTION II. ROTOR INSPECTION AND REPAIR

8.7.

The inspection of the rotor assemblies ( Figure

7.5.19) is as follows:

In every rotor assembly, check the front andrear cam followers for pitted or galled shafts,free rotation (clockwise and counterclock-wise), too much radial end-play (cap end andshaft end), and too much axial end-play. Anindicator mounted on a magnetic base can be

attached to the rotor frame to check the radialand axial end-play. Refer to Figure 8.3.3.

The following dimensions are the tolerancesfor the radial and axial end-play of the frontand rear cam followers. Also, if the camfollowers have 10,000 hours or 5 years runningtime, the cam follower shafts should beremoved and magnafluxed. Replace shafts that

show any signs of cracks or wear. Refer toChapter 2, Paragraphs 2.54, and 2.57 .

If the dimensions are more than the maximumallowable tolerance, the cam follower assembly must be replaced. DO NOT TRY TO

R EPAIR IT.

1. After five (5) years the rear cam follower,(10, Figure 7.5.19), should be replaced.

2. After five (5) years the front cam follower

(9, Figure 7.5.19), should be replaced if thearea which is in contact with the cam track shows indentations which are deeper than0.02mm. If a cam follower hasindentations less than 0.02 mm and if youdesire to have this cam follower reworked,contact MII for pricing. To avoid importduty, mark all documents clearly stating

that these parts are being returned to theUSA, and they were originally made in theUSA.

Be sure when replacing front or rear camfollowers, that the slot in the cartridge and theindentation in the cap are both turned to the"X" side on the rotor face or pillow block. If the pillow block is removed from the rotor frame, the (4) M10 screws (21, Figure 7.5.19)should have Permatex reapplied to the threadsand be torqued to 55-60 ft.-lbs.

The adjustment of the cam followers to thecam track will follow in SECTION XI. Alsoreference the Adjustment and MaintenanceSection, Chapter 2, in the Braidmatic

Instructional Manual. See Figure 2.56.3(Method “B”).

Be sure and check the oil holes in the rotor frame for clear oil passage. Clean out anyobstructions found. There are two oil holes for

Axial end-play.1 mm - .4 mm, front and rearcam follower

Radial play of

shaft

.01 mm Minimum Play

.045 mm Maximum Play




and check for a bad bearing (18) or a bent shaft(4). The following are steps for removal of the planetary gear(s):

NOTE

If defective bearings or a shaft arefound in a rotor that was removed

from a deck and this rotor is to goback in the same location, on thesame deck, the timing should bechecked and recorded, beforeremoving the rotor gear so that thegear may be timed to the samereading as recorded. Use gauge240-1075, rotor gear time gauge

( Figure 9.1.5 ).1. Place the rotor frame on a working surface

with the gear up. Remove the (8) M8 x 35DIN 6912 screws (17, Figure 7.5.19) fromthe rotor gear (2, Figure 7.5.19).

2. With a plastic or rubber hammer or ahammer and a soft material rod (soft brass

or aluminum), tap the rotor gear off therotor frame. THE TIMING PIN MAY COME

OUT WITH THE GEAR OR IT MAY STAY IN

THE FRAME.

3. Tap out the 6x24 DIN 7343 roll pin (11, Figure 7.5.19).

4. With a soft object (plastic hammer, etc.),tap the planetary gear upward. The shaftshould now protrude through the back of the rotor frame.

5. The planetary shafts must be identified so

7. Inspect the shaft for bends or bearinggrooves.

8. Inspect the (2) 6001-2RS bearings (18, Figure 7.5.19) for roughness.

NOTE

If shaft is bent or worn, it must bereplaced. DO N OT T RY TO R EPAIR .

8.10. Replacement of a shaft is as follows:

1. Insert the new shaft into the hole, makingsure the planetary gear (6 or 7, Figure

7.5.19) and planetary spacer (5, Figure7.5.19) are in proper position.

2. Secure the top of the planetary shaft so thatit will not shift or turn during drilling.

3. Lay the rotor frame on its side. Place a piece of flat stock about 3 mm or 1/8 inchthick under the front rotor pocket. Using a

6 mm drill and the previously drilled holesas a guide, drill completely through thenew shaft.

4. Install a 6 x 24 DIN 7343 roll pin (11, Figure 7.5.19), making sure it does not protrude through, inside or outside.

NOTE

If a bearing (18 Figure 7.5.19) is




8.11. On reinstalling the rotor gear (2), inspectthe 10m6 x 40 DIN 7 dowel pin (12, Figure

7.5.19) for defects. If any defective signs areseen, replace the pin. If the dowel hole in therotor frame is out of round, then the rotor gear should be turned 180°, retimed, and secured.

CAUTION




NOTE

The above procedure is to befollowed only if the dowel hole inthe rotor frame is out of round or too large for the 10 mm dowel pin.

If nothing appears wrong with thedowel pin or the hole in the rotor frame, the rotor gear should bereinstalled, the dowel pin hole

properly aligned, and the dowel pin lightly tapped back into therotor gear and the rotor frame.There should be no problems withthe timing of the pockets, but to besure, it is best to check the timing.MII rotor gear timing gauge 240-1075 is available for this.

Using gauge 240-1075 ( Figure 9.1.5) is thef t t d b t f ti i th t

2. Lightly tighten (4) screws (every other one).

3. Lay the rotor frame down on its side withthe machined guide key slot facing up.

4. Set the rear pocket of one of the machinedkey slots, key side up, on a block thick enough so that rotor frame is sitting leveland the rotor gear is clear of the workingsurface.

5. Lay the timing gauge 240-1075 in the pocket above the key. DO NOT USE THE

PILLOW BLOCK POCKETS.

6. Zero "0" the indicator on one side of the pocket. Identify this side using a marking pen.

7. Swing the indicator 180° to the other sideand take the reading.

8. With a soft piece of material (soft brass,aluminum, etc.), and hammer, tap lightlyon the rotor gear teeth until both sides of the pocket are as close to "0" as possible.

9. With this completed, remove the gauge

from the pocket without disturbing thereading on the indicator.

10. Rotate the rotor frame 180° and set it back up on the block.

11. Lay the gauge in this set of pockets andusing the same indicator setting as on the previous pockets, but 180° opposite from

the last reading, take a reading. Thenrepeat step 8.

12. When this adjustment is completed, tightenthe (8) M8x35 DIN 6912 screws (17,Fi 7 5 19) t t f 25 30 ft lb




14.

a. Stand the rotor frame up on its face and

using a 10 mm drill, spot drill throughthe rotor gear dowel hole into the rotor frame.

b. Install a 5 mm drill (long shank) anddrill down through the rotor frame untilthe drill comes through the underside.(This is a knock-out air hole.)

c. Install a 9.8 mm drill and drill into therotor frame a depth of 46mm from thetop face of the rotor gear.

d. Install a 10 mm N7 reamer and ream toa depth of 44 mm from the top face of the rotor gear.

15. Drive in the 10m6x40 DIN 7 (12, Figure7.5.19) dowel pin and with a center punch,stake the dowel pin around the sides. It is best to use a 10 mm drill and concave one(1) end or grind one (1) end flat. This is thestaking end.

NOTE

If a new rotor gear (2, Figure7.5.19 ) is being installed, thedowel hole will be 9.8 mm, sotherefore, a 9.8 mm drill must beused for spot drilling.

SECTION III. SHUTTLE INSPECTION AND REPAIR

8.12. The shuttles are to be inspected for thefollowing:

1. Cam Tracks: Check for nicks, galled or chipped out places, indentations and/or indications of heat (bearing race will be brown or blue) on both cam track bearingraces. Cam Tracks that show any of theabove should be replaced.

NOTE

Mayer Industries Inc. offers a one(1) time rework program for camtracks. Contact the Mayer Industries Inc. Service

to be made to obtain the correct runningclearances.

Reasons to have cam tracks reworked:• Cost savings.

• To improve the surface finish of the

track bearing race.

NOTE

Only cam tracks that havebearing races that can bereground to new conditionwith 0.025 mm stock removal can be reworked.

2. Outer Races: The front outer race (4,1 ) i b h k d f




smooth transfer) Also insure that thediameters of the outer races are within 0-.03 mm for all shuttle assemblies that are

placed in any one transfer. NEVER REPLACE JUST ONE OUTER RACE INA TRANSFER, ALL OUTER RACESMUST BE REPLACED IN THETRANSFER IF ONE IS UNDERSIZE.

NOTE

This hooking sensation can alsooccur if cam followers areimproperly adjusted.

3. Shuttle Gear: Check shuttle gear (8,

Figure 7.5.17 ), for cracked, broken, or chipped teeth. If any defects are found,replace the shuttle gear. BE SURE THATON A 20 CARRIER SHUTTLE GEAR,THE TIMING HOLE OF THE SHUTTLEGEAR ALIGNS WITH THE TIMINGHOLE IN THE CAM TRACK.

4. Bearing: Check the bearing (10, Figure

7.5.17 ) for free turning. If defective,replace with a new bearing.

If the front bearing (4 and 5), cam track (7), gear (8), or bearing (10) has to beremoved, the following procedure should be followed:

a. Straighten the locking tang of the MB6safety washer (11, Figure 7.5.17 ).

b. Remove the KM6 lock nut (12).

c. Using a puller, grasp the key groove of

the inner ring.

5. Inner Ring: The inner ring (5, Figure

7.5.17 ) is pressed onto the spindle, so caremust be taken if it has to be removed. Thecam track key (6) has to be removed bymeans of the 5 mm threaded holes in it.Then, using a hollow shaft fitted downover the front end of the shuttle spindle andresting onto the protruding ears of themounting spacer (3), the inner ring can be

removed by tapping with a hammer. BESURE TO PAY CLOSE ATTENTION OR MARK THE SLOTS IN THE SHUTTLESPINDLE THAT THE MOUNTINGSPACER EARS ARE PROTRUDINGTHROUGH, BECAUSE IT MUST GOBACK ON THE SAME PLACE OR THE"L" BRACKET WILL NOT ALIGN TOTHE LEFT OF THE TIMING HOLE INTHE CAM TRACK. WITH THE KEYSLOT FACING UP, THE LONG EAR OFTHE MOUNTING SPACER WHEN IT ISBEING MOUNTED ONTO THESPINDLE SHOULD BE TO THE LEFTOF THE KEY SLOT.

The inner ring (5, Figure 7.5.17 ) should

not be removed unless there are signs of running hot, cracking, too much side toside play between it and the outer race, thediameter is oval or the race has a taper in it.

8.13. To assemble the spindle, the following procedure is followed:

1. Be sure the mounting spacer (3, Figure7.5.17 ) is installed correctly.

2. Inner ring (5) is pressed onto the spindle(1) after oiling or moly-coating the spindle.




3. The outer race (4) must be oiled on theinside and slipped onto the inner ring (5).

4. A little loctite is dropped into the key slotand the key (6) is mounted with a good fit. No looseness between key and slot isallowable. If the key is loose, replace it.

5. Oil or moly-coat the shuttle spindle (1) before installing the cam track (7).

6. Slide the cam track over the key. Makesure it is a good, snug fit. Grasping the camtrack with both hands, try rotating itclockwise and counterclockwise. If anymovement occurs between the key and thecam track, replace the key.

7. Slide the shuttle gear (8) onto the spindle.The ears of the shuttle gear should

interlock with the slots in the cam track with a snug fit. Grasping the shuttle gear with both hands, try rotating it clockwiseand counterclockwise. If there is anymovement, try rotating the shuttle gear 180°. This can be done on a 16 or 24carrier machine but not on a 20 or 36carrier because the timing holes must align

with the shuttle gear and cam track. If anymovement occurs on this one side on a 20or 36 carrier, try a different shuttle gear. Ona 16 or 24 carrier, if any movement occursafter the 180° rotation, try a differentshuttle gear. If the cam track and shuttlegear are the same ones that were removedfrom the spindle, there should be no

problems with them.

8. Install the ring (9) onto the spindle (1) after the shuttle gear (8) is properly installed.

9. Using a bearing driver, drive the bearing(10) onto the shuttle spindle taking care notto damage the bearing. After driving it ontothe spindle, rotate the bearing by handmaking sure it turns freely. If there are anytight spots or any doubt about the bearing,replace it.

10. Install the MB6 safety washer (11).11. Install the KM6 lock nut (12) and torque it

to 45-50 (MIN.) ft.-lbs (61-67.8 Nm).

12. Turn the front outer race (4) making sure itturns freely and has back and forthmovement between the mounting spacer (3) and the cam track (7). THERE MUST

BE BACK AND FORTH MOVEMENTHERE.

13. With a .02 mm piece of shim stock, tryinserting it between the flat surfaces of thecam track (7) and the shuttle gear (8). If theshim goes between them, then the camtrack has to be removed, more chamfer put

onto the slot edges of the cam track, andthen reassembled.

14. Bend down the tang of the safety washer that aligns with the slot of the locking nut.

15. The "L" bracket is now ready to beinstalled, making sure that it mounts to theleft of the timing hole. If it mounts to the

right, then the mounting spacer (3, Figure7.5.17 ) is installed wrong. See Figures7.5.8, thru 7.5.12.

SECTION IV. PRELIMINARY SHUTTLE ADJUSTMENT AND INSTALLATION


k f d



a. Pockets, front and rear.

b. Planetary gears.

c. Cam follower shaft.

d. Outer race and rear bearing of shuttle.

e. Both sides of the cam track.

2. Also, if reworked cam tracks are beingused, make sure that they are used in

groups of 9 for the 36 Carrier braiders, 6for the 24 Carrier braider, 5 for the 20Carrier braider and 4 for the 16 Carrier Braider. These cam tracks must be in thesame places in the same transfer and thecam followers adjusted accordingly.

3. Check the diameter of the outer race (4, Figure 7.5.17 ). If the diameter is below71.85 mm, it has to be replaced. NEVER

REPLACE ONE OR TWO OUTER RACES ON

SHUTTLE ASSEMBLIES FOR ANY GIVEN

TRANSFER . All in the transfer must bereplaced.

NOTE

The outer race for all shuttleassemblies in a given transfer must be within 0.03 mm.

4. Also, select the shuttle assembly from eachtransfer that is the tightest to a given camfollower setting. Use this shuttle assemblyas the master for setting the cam followersin that transfer.

5. Install the shuttle into the proper pocketsand rotate the shuttle a few turns to be sureof proper seating.

6. Adjust clearance between the cam track and the cam follower until a shim of .02mm thickness goes freely between themand a .05 mm shim will not pass freely,meaning that it has a hard drag or locks up.

7. This is to be repeated at each transfer onevery rotor frame.

SECTION V. INSTALLATION OF ROTOR ASSEMBLIES

CAUTION

Moving elements/pinch points inthe shuttle/rotor assembly area.Personal injury to hands and armscould occur.

Only trained personnel/mechanics

disconnect and remove the upper change gear on PLC-T models.Follow plant lock out/tag out

procedure

Cut power off at main disconnect

and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure.

Read and follow manual i t ti


b d h ld h f fl f h



CAUTION




1. The thrust races (13 and 14, Figure 7.5.21)and the needle bearing (15) should beremoved from the rotor frame andthoroughly inspected. If the needle bearingis warped or bearings fall out, replace it. Itis best when replacing this bearing toreplace the two thrust races, also. There aretwo sets of these bearings and races in each

rotor assembly; one at the front and oneinside the rotor frame that has to beremoved from the rotor gear end of therotor frame.

NOTE

When removing a rotor, theneedle bearing (15) inside therotor assembly usually getswarped and must be replaced.

Be sure when installing the thrust races

that they are installed correctly or the rotor assembly will not fit back onto the rotor axle. Also, put a little grease on the bearingto hold it in place. The thrust races (13 and14, Figure 7.5.21) and the needle race (15)should be installed inside the rotor

to be removed, hold the front flange of the bearing ring in the palm of your hand andtap down onto a semi-hard surface (not

metal). Several taps may be required to break it loose.

2. After the bearings have been checked andfitted back properly, the rotor frame is nowready to be installed onto the axle.

3. Each rotor frame is numbered 1, 2, 3, 4, 5,

etc., and this is the location from which itwas removed. It must be put back at itsoriginal location. Also, the pockets should be located properly to have the transfers incorrect orientation.

4. With a thread protector 240-3047 ( Figure9.1.9) screwed onto the rotor axle, slip therotor frame onto the axle and mesh the

planetary gears with the rotor axle until therotor frame slips freely to its stopping point.

5. Install the thrust race (14, Figure 7.5.21)and the correct bearing ring with the thrustrace (13) and needle bearing (15) installedonto it. Tap it onto the axle until it is fully

seated into the rotor frame.6. Install the MB8 safety washer (17) and the

KM8 lock nut (18) and tighten, aligningany slot on the lock with a tang of thesafety washer. DO NOT BEND TANG INTO

SLOT AT THIS STEP.

7. Using an indicator mounted onto a

magnetic base, mount the base onto a rotor face or other adjacent surface and let theindicator point touch the rotor face next toit.


to 01 mm 0 05 mm reading and this is 6 Get a dimension reading of the distance



to .01 mm - 0.05 mm reading, and this isdone by the use of a bearing ring. See thisSection, Paragraph 8.16 , methods 1 or 2.

8.16. To increase or decrease the axial end- play of the rotor frame, the following stepsshould be followed:

METHOD #1

1. Install shims (23 thru 26, Figure 7.5.21) toobtain the .01 mm/0.05 mm end-play.

NOTE

Shims are installed between thebearing ring (12) and the thrust race (13).

METHOD #2

1. Remove the thrust race (13, Figure 7.5.21)from the bearing ring (12). (This side will

be the inward flange.)2. Set the bearing ring up in a lathe with the

inward flange facing out.

3. Clamp onto the flange O.D. leavingenough of the inward flange protrudingout, so as not to strike the chuck jaws withthe cutting tool.

4. Indicate the inward flange to within .03mm or .001 inch.

5. If the axial end-play is to be decreased,then the length of the bearing ring barrel

6. Get a dimension reading of the distancefrom the end of the barrel to the edge of theinward flange. Remember or write this

dimension down because this dimensionhas to be decreased by the amount of thedesired axial end-play.

7. Using dye-kem or a marking pencil,completely paint the inward flange and barrel-end surfaces.

8. Take a very light cut across the inwardflange face, just to clean it up.

9. Take a dimension reading of the distancefrom the end of the barrel to the inwardflange.

10. Take light cuts across the end of the barreluntil the desired dimension length is

reached.11. Deburr the cut surfaces and reinstall the

thrust race and needle bearing onto the bearing ring.

12. Reinstall the bearing ring (12) into therotor assembly along with the safetywasher (17) and lock nut (18). Tighten to

25-35 ft.-lbs. (33.8-40.7 Nm).

13. Set the indicator point onto the rotor faceand, again, grasp the rotor frame and pushand pull to get the axial end-play reading.

14. When the rotor frame's axial end-play has been checked and corrected, if necessary,then bend the tang of the safety washer into

the slot of the lock nut that it aligns to.

15. If the axial end-play is to be increased, thenthe length of the barrel must be increased;therefore, removal of material must come


5 Stop the machine



NOTE

On decks with a pressure relief valve the gauge will read 65 lbs/ in². Do not set any lower.

2. Install the upper change gear back onto thedeck and run the rotors for approximately

45 minutes. Rotor speeds should notexceed 100 RPM’s.

3. Listen for any loud or unusual noises. If everything has been checked andassembled correctly, there should be noclunks, thumps, or pounding.

4. Check for oil coming from the rotor axlesthrough the rotor frames. There should be agood flow, and all axles should have thesame amount of oil coming out.

5. Stop the machine.

6. Check the rubber O-rings (20, Figure

7.5.19) in the rotor frame caps. Replace theO-rings if broken or deteriorated.

7. Install the caps (16) onto the rotor frames.Be sure to Permatex threads of the capscrews. Tighten to 11-12 ft.-lbs, (14.9-16 Nm).

8. Ground out each shuttle sensor (Chapter 4, Figure 4.16.1) individually and check tomake sure it is operating correctly. Alsocheck for proper setting of sensors ( Figure4.16.1). Check for proper operation of theother safety devices such as change gear door, enclosure doors, broken braiddetectors, and bobbin run-out detector, if so equipped.

9. Install all the inner shields and outer shieldexcept the two at the locations shuttles areloaded onto rotor frames.

SECTION VII. SHUTTLE INSTALLATION

8.18.

1. Remove the top change gear and install adriving socket (240-3040, Figure 9.1.8)onto the shaft.

CAUTION


Personal safety equipment is tobe worn.

Work area to be clean and free of oil to prevent slipping.

Cut power off at the maindisconnect and remove the upper change gear on PLC-T models.Follow plant lock out/tag out

procedureCut power off at main disconnect and remove the drive belt onPLCT-F models. Follow plant lock out/tag out procedure


(Figure 8 18 1) There should be a



CAUTION

Use a break-over bar or speed wrench to drive the socket.UNDER NO CONDITIONSSHOULD A RATCHET OF ANY TYPE BE USED.

NOTE

Removal of shuttles requires twotrained mechanics using special tool #2000302, which mounts to

the face of the rotor frame using the (4) M6 holes that are used tomount the rotor cap. Mount thistool to the rotor frame closest tothe 8:00/9:00 deck position.


The mechanic turning the deck must be strong enough to control the movement of the rotors.Installing the shuttles will causeuneven loading until they have all been installed. This unevenloading will result in unwanted movement of the rotors that must

be controlled by the mechanic using the special tool.

Note: Tool #2000302 is availablefrom MI (Figure 9.1.8)

2 B f i lli h h l i h d k

( Figure 8.18.1). There should be aminimum .05 mm end-play of the shuttle intransfer. Now, rotate the shuttle out of

transfer and there should be a maximumaxial movement of .45 mm. Thesedimensions are determined by the keys inthe rotor frame and pillow block andshould be corrected only by working withthe guide key ( Figure 8.18.2, and 3, Figure7.5.19). Never work with a pillow block key to get shuttle axial play. After each of

the four transfers have been checked, thena complete transfer of shuttles can beinstalled.

3. It does not matter which transfer is loadedfirst, just be sure to put the proper shuttlesin the transfer from which they wereremoved.

4. When a transfer is loaded, reinstall thetimed cam follower assembly making sureeach screw has a ST M6 ribbed washer onit. Permatex the threads of the screws andinstall it into the cam follower caps andtighten screws securely. Torque to 11-12ft.-lbs. (14.9-16 Nm).

5. Grasp the shaft of the cam follower andmake sure it turns both ways freely and hasaxial end-play of .1 mm-.4 mm.

6. Grasp a shuttle and turn the machine byhand to put the shuttles into transfer position.

7. In transfer position, grasp each shuttle andcheck the axial end-play. Be sure there isaxial end-play of at least 0.05 mm in eachshuttle. See Figure 8.18.1.

8. Check every shuttle in every transfer.




FIGURE 8.18.1: SHUTTLE AXIAL MOVEMENT

AXIAL MOVEMENT

SHUTTLE

AXIAL MOVEMENT

I N TRANSFER .05 mm MINIMUM

OUT OF TRANSFER .45 mm MAXIMUM




K EY CLEARANCE

GUIDE K EY

SHUTTLE

. 0 5 T O

. 4 5 m m


SECTION VIII. OPERATIONAL CHECK



8.19.

1. 1. Check the oil pressure cut-off setting (45lbs./in²) ( Figure 5.5.1).

2. Set the oil pressure to the desired operating pressure. On new braiders the pressure isset automatically by the pressure relief

valve under the tunnel in deck #1. Set this pressure after the machine and oil havewarmed up (approximately 3-4 hours).

3. Check the adjustment of the slider on thesilent chain ( Figure 2.29.1). The slider should be lightly pressed against the silentchain. Check to be sure that there isadjustment left in the slider. If all the

adjustment has been used, replace the

silent chain, because a slack silent chain

will result in broken shear pins and wornsprocket (2 and 9, Figure 7.5.25).

4. Inspect Flex Packs and replace any crackedor broken parts, MII part number S-5006( Figure 8.19.1).

5. Check over haul-off and grease in proper

places. (See the haul-off manual.)6. The braider should now be ready for

operation.

If there are any questions or comments aboutthis schedule, please contact MAYER

INDUSTRIES INC.




HUB

FLEX PACK K ITS CONSIST

OF FLEX ELEMENTS,WASHERS, NUTS, AND BOLTS.HUBS ARE NOT INCLUDED.

HUB


SECTION IX. INSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE



(FIGURE 8.20.1)

8.20. CHECKING TIR (TOTAL INDICATOR R UNOUT) SQUARENESS OF AXLES TO DECK .

NOTE

Assemble the gauge per Figure8.20.1, for checking squareness of axles to deck.

When checking the TIR (squareness of axles todeck) install the 90° connector (2) into thehead piece (1). Be sure to keep the threadedhole in the flat surface of the 90° connector

parallel with the big hole in the head piece.This should be done so that the extensions andindicator will be as parallel as possible to theaxle when checking TIR.

With a stone, deburr the teeth on the front endof the rotor axle because a burr will give afalse reading. Mount the indicator (7) onto the

holder (5) and secure with the screw (9). Screwthe extension rod (3) onto the 90° connector (2) and tighten. Install the holder withindicator mounted into the extension rod andlightly tighten with the screw (6). Mount theheadpiece (1) onto the rotor axle, screw on aKM8 nut, tightening it up against the head piece. DO NOT OVERTIGHTEN. Rotate the

headpiece making sure it turns freely. If it doesnot rotate freely, the KM8 nut is probably tootight, so loosen it a little, then recheck for freerotation. Now loosen the screw (6) in theextension rod (3) and slide the holder (5)f d b k d til th i

from flange of rotor axle. Make sure the balltouches the deck face completely around therotor axle flange. If the tip of the indicator drops off the deck face, loosen the screw (9)and adjust the indicator so that the tip stays onthe flat surface of the deck, then retighten thescrew. The setting on the indicator dial mayhave to be readjusted. With the indicator tip

located at the top of the rotor axle flange, setthe indicator dial on "0" by rotating the dialface. Using a marking pencil mark "0" at this position on rotor axle flange. Then slowlyrotating the head piece (1) to a 90° positionfrom "0", check the indicator reading and mark it on the rotor axle flange. Be sure that you press against the head piece, on the side

directly opposite the 90° connector (2), towardthe axle, as you rotate the head piece. Thiseliminates any movement of the head piecethat could give an incorrect reading. Proceedwith this step completely around the rotor axle.While the head piece is mounted on the rotor axle, try pushing and pulling on it to see if theindicator needle moves. If it does, the KM8 nutis too loose or there is a burr or a particle between the axle teeth and the head piece.Correct as required and recheck the reading.

It will be necessary to use a mirror to see theindicator reading at certain positions because itis almost impossible to read the indicator. Theflatness of the rotor axle to the deck should not be over 0.03 mm, unless the deck has had acrash and the rotor axle had to be shimmed.The above procedure should be done on eachrotor axle and it is advisable to make a chartand record the axle location, axle number (stamped of front end of axle) and the axle




FIGURE 8.20.1: GAUGE 240-1078 FOR CHECKING SQUARENESS OF AXLES TO DECK

DECK

AXLE

7

9

5

6

3

21

NUT


movement of the body that could give anincorrect reading Set a reading of about 3 4

because when the indicator isreading on the (+) side this means



incorrect reading. Set a reading of about .3-.4mm on the indicator, and tighten the M6x 12

DIN 84 screw securely. Rotate the gauge back and forth, finding the highest reading of theindicator. At the highest indicator reading, setthe indicator dial to "0" reading. This is theexact distance from axle to axle.

Once the "0" position has been determined, setand secured, remove the complete gauge set up

from the set master and install it onto the #1rotor axle ( Figure 8.21.2), pushing it back against the axle teeth. Grasp the gauge (1) androtate it so the indicator ball touches the inner race of the rotor axle #2. Be sure that you pressagainst the gauge, toward the axle, as yourotate the head piece. Get the distance reading between these two axles (+) or (-) and mark on

the deck face between the axles #1 and #2. It isadvisable to make a chart and record thesereadings.

NOTE

If the indicator gives different readings, on the master gauge,after "0" setting, check the small screws in the indicator base plate.If they are loose, this will causefalse readings.

NOTE

It is advisable to put a (+) plus

reading on the (+) side this meansthat the distance between the two

(2) axles is wider and the distanceis closer if it reads on the (-) side.

NOTE

Do not rotate the gauge to try and take readings between axle #1and #12. Only take readings going clockwise. Checking should be#1-2, #2-3, #3-4, etc.

After the reading between axles #1 and #2 has been taken, mount the gauge back onto the set

master and make sure the "0" position has not been changed. It is advisable to do this after checking between each axle because of the possibility of bumping or jarring of theindicator.

Check the distance from axle to axlecompletely around the deck and comparereadings between the axles. Any indicator reading over (+) or (-) .07 mm is not good andthe axle will have to shimmed or replaced toget the dimension under .07 mm. Sometimes itis possible to get rid of the .07 mm dimension by loosening the six (6) M12x60 DIN 912screws that hold the axle flange to the deck,loosening the rotor axle from its seated position and then retightening the six (6)

screws, starting with the three (3) screws thatwill put the axle in the direction desired. If thisdoes not correct the misalignment, the axlemust be shimmed or replaced. The shim stock has to be installed between the rotor axle and


If there are any questions about the use of thisgauge shimming or the axle or flatness of

axles to deck, please contact MAYER

INDUSTRIES INC



gauge, shimming or the axle or flatness of INDUSTRIES INC.

FIGURE 8.21.1: AXLE LOCATION AND SET MASTER FOR

CENTERLINE TO CENTERLINE GAUGE 240-1078

DISTANCE PIN

BALL TIP

M6 X 12 DIN 84

LOCATION GAUGE ASSEMBLY240-1078

SET MASTER 240-1079

±0.07 mm MAXIMUM

1


SECTION X. INSTRUCTIONS FOR THE USE OF THE 240-1075 ROTOR GEARTIMING GAUGE (SEE FIGURES 2 63 1 & 9 1 5)



TIMING GAUGE (SEE FIGURES 2.63.1, & 9.1.5)

8.22. This gauge comes with a handle,indicator, and indicator extensions. Theindicator is divided into .01 mm increments.The handle has a precision ground solidsurface on one end and a precision ground,hard locating pin in the other end. There is ahole with a screw going into its side for

mounting and securing the indicator. Whenusing this gauge, the extension stem of theindicator will have to be installed onto theindicator, then the indicator is installed into thehandle and lightly secured with the screw.

NOTE

The rotor gear dowel pin hole isalways aligned on the right side of the minor planetary gear (7,Figure 7.5.19 ). This is the small

planetary gear and its gear teeth

are closest to the rotor gear and mounted over the pillow blocks.On new rotor gears, the dowel hole is predrilled to 9.8 mmdiameter. At this diameter, there isdrilling and reaming stock left inthe dowel hole.

NOTE

When timing the rotor gear to the

After making sure that the bottom surface of the rotor gear is burr free, mount the rotor gear onto the rotor frame, positioning the dowel pinhole as instructed in Chapter 2, Figure 2.63.1,and aligning the screw holes in the rotor gear and the rotor frame as close as possible. PutPermatex on the threads of the eight (8)M8x35 DIN 912 screws (17, Figure 7.5.19)

and install. Tighten four (4) screwsapproximately 90° apart. This will pull thegear down onto the frame. Set the removablekey rear pockets on a piece of flat stock that isthick enough so that the rotor gear (2, Figure7.5.19) is not resting on anything. Set thehandle (with the indicator mounted), into theremovable key pockets with the ground

surface resting in the front pocket and thehardened pin resting between two (2) rotor gear teeth. Turn the handle so that the indicator stem is resting at the top edge of the pocket.Loosen the securing screw on the side and setabout .4-.5 mm travel tension on the indicator.Be sure and look at the mm needle (smallneedle) on the indicator and get its reading.This graduation is in mm. Tighten the securingscrew, check and be sure that the needle andstem movement are free. Rest a piece of flatstock, anything stiff and not too big, on the topedge of the pocket and press down on it withyour thumb. This will hold the stock downflatly on the edge and provides a stop for theindicator stem. Turn the handle until the stemof the indicator lightly touches the underside

of the flat stock. Turn the indicator dial to "0"and mark "0" reading on the side of the pocket;now swing the indicator gauge to the other sideof the pocket, get an indicator reading andmark on the side of the pocket. Compare the


Loosen the four (4) tightened screws and witha hammer and a piece of soft material such as

Stand the rotor frame up on its face. If it is anew gear, the predrilled hole will probably be



p brass, aluminum or cold rolled steel, tap on the

rotor gear in the direction required. Tighten thefour (4) screws in the gear again. Swing theindicator up to the top edge on the "0" side andreset the indicator to "0" reading. Now swingthe indicator to the opposite side and get areading. Repeat the gear adjustment step until"0" readings are obtained on both sides. BE

SURE TO TIGHTEN THE FOUR (4) SCREWS

AFTER EACH ADJUSTMENT. Now remove thegauge from the rotor frame, trying not to movethe dial or jar the indicator. Set the gauge outof the way. Rotate the rotor frame 180° and setit on the flat stock again. Now set the tool intothese pockets and turn the gauges so that theindicator stem is at the top edge of the pocket.Take a reading on the indicator and mark thereading on the side of the pocket. Now turn theindicator up to the top edge of the oppositeside, take an indicator reading and mark itdown on the side of the pocket.

Now compare these pocket readings to the pocket reading of the other pocket checked onthe rotor frame and see if there is any way thatthe rotor gear could be rotated and get a closer

or equal reading between the two (2) pockets.After the closest reading is obtained tighten alleight (8) screws using the stagger line of tightening. Torque the eight (8) M8x35 DIN912 screws to 25-30 ft.-lbs. (33.8-40.7 Nm).Recheck the timing after torquing the screws,making sure there has been no gear movement.

g , p p y9.8 mm, if it is not, then it will be a 10 mm

hole. Use the following on either of the predrilled holes. Install the hole diameter drillin a drill press and bring it down through thehole in the rotor gear until it touches the rotor frame. If the hole is a 10 mm hole, then drill acentering hole into the rotor frame. Withoutmoving the rotor frame, install a long 5 mmdrill and drill down until the drill bit comes

through the bottom side. Install a 9.8 mm drill bit and drill the hole to a 46 mm depth from therotor gear face, then install a 10 mm N7 reamer and ream the hole to a 44 mm depth from therotor gear face. If the hole is 9.8 mm diameter,then drill down to the 46 mm depth with a 9.8drill bit, then drill through with the 5 mm drill bit and then ream hole to the 44 mm depth withthe 10 mm N7 reamer. If possible, install thedowel pin in a lathe and with a 10 mm drill,countersink the end of the dowel pin. Installthe dowel pin into the hole in the rotor gear and drive it down until it is approximately 3-4mm below the face of the rotor gear. Then witha center punch, stake the pin at about three (3) places to prevent it from working back outagain.

NOTE

Never use a hardened dowel pin.

If there are any questions or problems, contactMAYER INDUSTRIES INC.

SECTION XI. INSTRUCTIONS FOR THE USE OF THE 240-1076 CAM SET GAUGEWITH MASTER (SEE FIGURES 2.56.2 AND 9.1.4)


precision ground gauge blocks, one thin block for setting of the front cam followers and one

( Figure 7.5.19 ) at the front camfollower holes, there will be an "X"



gthick block for setting of the rear cam

followers. If you will look at the front and rear cam followers, you will see that the shaft of therear cam follower is larger in diameter than thefront. This is the reason for the different gauge block thickness. On each end of the master there is a set of pins that are set a certaindistance apart. This insures that the handle can be set into the master only one way.

It is best, when using this gauge, to either setall the front cam followers first or all the rear first. It does not matter, but in setting all of either, the front or the rear, the indicator doesnot have to be moved from hole to hole asoften. This is entirely up to the individual.

If the front cam followers are going to beadjusted first, install the indicator in the firsthole in the handle and just lightly tighten onthe securing screw. Rotate the handle back andforth (clockwise and counterclockwise)making sure the stem of the indicator istouching the thin block (front cam followers)with approximately .10-.15 mm movement of the indicator needle. When rotating the tool,hold the tool against the pins on one side of thegauge. Do not let the tool roll from one side tothe other, this will produce an error in the toolsetting. Turn the indicator glass cover until it isreading "0" at the highest point of the needlemovement. When this is reached, tighten thesecuring screw, but take precautions not toovertighten, because overtightening could

cause binding of the indicator stem. After tightening, check to see that the stem andneedle movement are free. Once the indicator is set to "0" and free movement is checked andobtained, then the front cam followers are

,stamped onto the frame, this will

also be found on the back side of the pillow blocks ( Figure 7.5.20 ).Be sure that the slot in thecartridge and the timing hole in thecam follower cap assembly (9,Figure 7.5.19 ) are both turned tothe "X' side. This is a must for front and rear cam followers.

Make sure the rotor frame pockets are freefrom burrs before using the gauge. Set thegauge into the pockets and by rotating thehandle back and forth (clockwise andcounterclockwise) find the highest point of thecam follower shaft front and rear. With thefour (4) M6x30 DIN 6912 screws loosened,insert a cartridge wrench (240-3037, Figure

9.1.2) or a tool, such as an offset screwdriver,that will fit into the cartridge slots and rotatethe cartridge in a direction that causes theneedle to come up to "0". Lightly tighten thefour (4) M6 DIN 6912 screws (14, Figure7.5.19, or 1, Figure 7.5.20).

While the indicator is still reading "0", push up

from the underside of the cam follower shaft,checking to see how much radial end-playthere is on the cartridge end. After the frontand rear cam followers have been adjusted to"0" by use of the gauge, the clearance stillmust be checked between the cam follower and the cam track by using .02 and .05 mmshim stock. The tightest shuttle from each of the four transfers is used for the finaladjustment of the proper clearance between thecam follower and the cam track. A shuttle fromeach transfer is first set into the rotor frameand the clearance is checked between the camfollower and the cam track Adjustments are


NOTE

If the outer race is to be replaced,check the inner ring (5) for being



NOTE

The set master (240-1076, Figure9.1.4 ) was designed to be used with a diameter 72 mm outer raceand a standard cam track with a80 mm radius. If an undersized outer race or a reworked cam

track is being used, the set dimension on the set master hasto be adjusted accordingly.Contact MII Service for additional information.

NOTE

When checking the clearancebetween the cam followers and cam tracks, the front outer race (4,Figure 7.5.17 ) should be checked for being out of round or

undersized. If either conditionexists, replace all the outer races.

out of round. If so, replace the

inner ring on the shuttles beforechecking the clearance. Thedimension at which the raceshould be replaced is ø71.85 mmon the outer ring.

NOTE

Be sure to identify and remove theshuttles from each individual transfer and keep the transfersseparated from each other. Also,identify on the face of the rotor frames of each transfer, so only the correct shuttles from thistransfer will be used to performthe final check and adjustment (if needed) between the cam follower and cam track. Make surePermatex and washers (ST-M6)are on the screws that fit in thecap.


SECTION XII. DISASSEMBLING, REASSEMBLING, ADJUSTING, ANDMAINTENANCE OF CARRIERS



CAUTION


position) when checking or setting the carrier tension and/or the


8.24. DISASSEMBLY. ( Figures 8.24.1 and 8.24.2; for part numbers see Figures 7.5.4 and 7.5.5.)

Loosen the M8 x 20 screw (32) and remove theadjusting ring (3).

Remove the three screws (28 and 29) on theactuator block (5) and from the spring clamp

(14). Remove the torsion spring (20, 21 or 22).

Remove the center strand rollers (44) from thecap (4).

Remove all three M6 x 25 DIN 6912 screws(31) from the cap. Remove the compensator (2) and the cap (4).

Remove the actuator (23). Remove all thespring washers (34) the washer (35) and thelatch (17).

Note the orientation of item 17 to 4.

Remove the housing (1) from the clutchassembly (6, 8, and 9).

Remove the shim washer (45).

Remove the snap ring (36) and then remove

plastic clutch sleeve (13) from the clutchassembly (6, 8, and 9).

Remove the clutch spring (11 or 12).

Remove the retaining ring (38) from the clutchhalves (6 and 9). Item 8 does not need to beremoved unless it is being replaced.

Remove the foam wicks or felt pads, (26) and place in a pan of EP-150 braider oil and allowabout 15 minutes for soaking.

NOTE

Never submerge an assembled carrier, strand rollers or center bearing in a degreaser solvent such as kerosene, varsol,gasoline or any solvent that would damage the bearing. Wipe them

clean.

Clean the carrier parts, except items 10, 39, 43,44, 48, 49, 53, and 54, in a cleaning solvent.Inspect and replace all worn parts that may




53

44

31

17

34

3534

23

4

53 10

43

28

5

2

30

53

18,19

20,21,22

10,53,54

29

46

14

1

10,49,53,54

39

2733

16

10,4854

54

5453 10

54

54

5410,48

10,48

53

53

19

11


8



8

6

257

4732

53

52

1

15

24

50

45

11,12

13

38

19

42

41

3

20,21,22

26


8.25. R EASSEMBLY OF CARRIER HEAD.(Figures 8 24 1 and 8 24 2)

M6 x 25 DIN 6912 screws (31) and insert theminto the holes in the cap (4). Tighten the threescrews using 101 inch pounds of torque



( Figures 8.24.1 and 8.24.2)

Insert the foam wicks or felt pads, (26), in themoveable hub assembly, (9).

Place the clutch hub (6) into the moveable hub(9), and insert the retaining ring (38), onto theclutch hub (6). This will lock the clutch halvestogether. Make sure the clutch turns freely.

If any of the wear screws (15) or stem bumpers(24) on the housing (1) need replacing, do itnow.

Place the shim washer (45), on the clutch hub(6) and align the hole in the washer with the pin (25). Note the location of the flat surfaceon the shim (45).

Place the housing (1) onto the clutch hub (6).Be sure that the shim washer (45) is placedcorrectly and that the pin (25) lines up with thehole in the housing (1).

Place the latch (17) into the clutch hub (6).Verify that the orientation is correct. Place the2 spring washers (34) on top of the latch. Placethe washer (35) on top of the 2 spring washers.Install another spring washer (34) on top of thewasher (35). Install the actuator (23). Be sure itis orientated correctly.

Install ball bearing (39), into the compensator (2), if it was removed. Use bearing clamps

(16), with serrated washers (33) and flat sockethead screws (27) at 3 locations and actuator block assembly (5) with two M6 x 20 DIN7991 screws (30) at two locations. Be sure touse Permatex Aviation Form-A-Gasket on the

screws using 101 inch-pounds of torque.

Install the clutch spring (11 or 12) onto theclutch hub assembly, aligning the longdownward tang approximately 3/8 inch to theright of the 3 mm roll pin in the stationaryclutch hub. (This allows easier assembly ontothe carrier housing.

Install the clutch sleeve (13) and place thevertical tang of the clutch spring in the 5th or 6th tooth slot from the left side. Note if youknow which notch the end of the spring should be placed in, put it there. Adjustments willfollow. Install snap ring (36).

Place two drops of Loctite #222 on the threadsof two strand rollers (44), and insert them intothe cap (4). Tighten them to 101 inch- pounds.

If the other strand rollers were removed, items10, 43, 44, 48, 49, 53, or 54, reinstall themnow. Place two drops of Loctite #222 on thethreads and install them at the proper locations. Note the location of the trip strand roller (43).If this is not installed properly the bobbinrunout detector will not operate.

Place spring clamp (14) onto the actuator block, and install the socket head screw (28), but do not tighten the screw. Place the tang of the torsion spring (20, 21, or 22) into theactuator block (5) with the tang of the springfitting against the curved end of the spring

clamp (14) as shown in Figure 8.24.1. Placethe wear plate (46) onto the actuator block.Install both screws (29), but do not tightenthem fully. Tighten (28), but be sure that theedge of the spring clamp (14) pushes against




NOTE

cleaner or spray the cleaner onthe carrier, because this will remove the grease from the



Any time the carrier pay-off tension or the torsion spring ischanged, the pay-out positionmust be rechecked.

8.26. CARRIER MAINTENANCE. ( Figures8.24.1, and 8.24.2)

CAUTION


position) when checking or setting the carrier tension and/or the


Grease the latch parts every 300 hours withmulti-purpose grease.

Oil the moveable hub every 600 hours with braider oil (EP-150).

Clean and check carriers every 600 hours.

1. Braiding certain type materials maynecessitate more frequent cleaning.

2 Clean with varsol diesel oil or other

remove the grease from the

strand rollers and center compensator bearing.

3. Check all screws, including strandrollers,to insure tightness.

4. Inspect the bearing clamps (16) on the bottom side of compensator. If foundloose, disassemble as necessary and

tighten.

5. Check the torsion spring (20, 21, or 22) toinsure that it is properly seated in theactuator block (5). Incorrect seating willcause wear and carrier malfunctioning.

CAUTION




Checking the tension and pay-off position of the carriers is necessary only when an erraticmovement of the hose is noticed at the braid point.

Disassemble the moveable hub (9) from thecarrier every 600 hours. Check for wear on the

hub and clutch spring (11 or 12). Replace if needed.

Possible cause of carrier malfunctioning:


5. Sticking clutch (6).

6. Improperly seated torsion spring (20, 21,

b. Exceeding the high range of a particular spring. This may cause theI.D. of the torsion spring to hit the



or 22).7. Incorrect range torsion spring.

a. Braiding on the extreme low side of thetension range of a particular spring.

p g

clutch sleeve (13) before pay-off andactivate the clutch (6). It will also causeexcessive spring breakage.

8. Jammed strand rollers (10, 43, 44, 48, 49,53, and 54).

9. Wires coming from bobbin out-of-wrap.

10. Poorly wound bobbins.




9-SPECIAL TOOLS

CHAPTER 9SPECIAL TOOLS



FIGURE 9.1.1: 240-1078.02 AXLE AND DECK LOCATION GAUGE

9-SPECIAL TOOLS



FIGURE 9.1.3: 240-1003.00 OUTER R ACE FRONT POCKET GAUGE

FOR Ø72 mm OUTER R ACE BEARING

1000219.0 OUTER R ACE FRONT POCKET GAUGE FOR Ø74 mm OUTER R ACE BEARING

MASTER

SET

GAUGE

240-1076.01 (Ø72)

1000218.0 (Ø74)

240-1077.00 (Ø72)1000220.0 (Ø74)

9-SPECIAL TOOLS



FIGURE 9.1.5: 240-1075.00 R OTOR GEAR TIMING GAUGE FOR Ø72 POCKETS2000138.0 R OTOR GEAR TIMING GAUGE FOR Ø74 POCKETS

9-SPECIAL TOOLS



FIGURE 9.1.7: S-5503 T-HANDLE HEX K EY

9-SPECIAL TOOLS



FIGURE 9.1.9: 240-3047.00 THREAD PROTECTOR

9-SPECIAL TOOLS



FIGURE 9.1.11: S-5099 TENSION GAUGE

9-SPECIAL TOOLS

For Enclosures without built in dispersion plate



E NCLOSURE

5000283, *5000847 - 16, 20, 24 CARRIER R OTOR FRAME LIFT K IT, 230V 50 HZ

5000285, *5000848 - 16, 20, 24 CARRIER R OTOR FRAME LIFT K IT, 110V 60 HZ

5000292, *5000845 - 36 CARRIER R OTOR FRAME LIFT K IT, 230V 50 HZ

5000293, *5000846 - 36 CARRIER

R OTOR FRAME LIFT K IT, 110V 60 HZ

p p

manufactured prior to 2003

For Enclosures

with built in

dispersion platemanufactured

after April, 2003

**R EQUEST DATA DRAWING #4000282.0

*USED IN E NCLOSURES SUPPLIED

AFTER JANUARY, 2009

9-SPECIAL TOOLS



10-ELECTRICAL SCHEMATICS

CHAPTER 10ELECTRICAL SCHEMATICS



10-ELECTRICAL SCHEMATICS



MR-11/MR-15 PLCT-F Schematics

mr 11plct frevzfeb12

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