MR 15plct Frevtfeb12

CG-76
MR-15 PLC-T
MR-15 PLCT-F
Braidmatic
Instruction Manual
and
Parts Catalog
18, 24 AND 36 CARRIERS
LIGHTWEIGHT
MII
MAYER INDUSTRIES INC.

February, 2012 MR-15 PLC-T Manual
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INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.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 April, 2006
Rev A Changes made to the following pages: 2-2, 2-13,
2-16, 2-26, 2-33, 2-37, 2-39, 2-43, 2-47 4-26,
thru 4-38, 5-3 thru 5-6, 7-1, 7-3, 7-11 thru 7-25,
7-30, 7-31, 7-35, 7-36, 7-71, 7-84 thru 7-97,
7-133 thru 7-145, 9-1;
Chapter 8: added safety information;
Added Italian and Dutch Safety Information to
this section
June, 2006
Rev B Changes made to the following pages: 7-117,
7-142 thru 7-145
August, 2006
Rev C Changes made to the following pages: 2-14,
2-15, 6-1, 7-31, 7-96, 7-97, 7-135, 7-146, 8-43
September, 2006
Rev D Changes made to the following pages: 7-55,
7-73, 7-97, 7-108, 7-110, 9-1
Added sections to Chapter 4
December, 2006
Rev E Changes made to the following pages: 4-40, 5-5,
7-9, 7-90, 7-91, 7-102
August, 2007
Rev F Changes made to the following pages: 7-12 thru
7-21, 7-55, 7-142 thru 7-145, 7-97, 9-1 thru
9-6
December, 2007
Rev G Dutch translations added to Sections 4.6, 4.9,
4.10, and 4.11
January, 2008
Rev H Changes made to the following chapters for the
Optional Braid Material Runout System:
Chapters 4, 6, and 10
March, 2008
Rev J Added Dual Drive Information; Changes also
made to the following pages: 1-6, 5-4, 5-5, 6-20,
7-12 thru 7-21, 7-77, 7-96, 7-114 thru 7-119,
8-37 thru 8-42, 9-7
October, 2008
LIST OF EFFECTIVE PAGES
INSERT LATEST CHANGED PAGES, DESTROY SUPERSEDED PAGES.
Date of Issue for original and changes pages are:
Revision Pages Changed Date
Rev K Changes made to the following pages: 6-24,
6-25, 6-31 thru 6-41, 7-9, 7-12, 7-21, 7-40, 7-41,
7-84, 7-85, 7-91, 7-116 thru 7-119, 8-38
February, 2009
Rev L Added 18 Carrier information. Changes also
made to the following pages: Table of Contents,
2-8, 3-3, 3A-3, 4-37, 4-39 thru 4-42, 5-5, 6-7
6-23, 6-34, 6-35, 7-5, 7-104, 7-105
November, 2009
Rev M Added Safety Cautions, 36 Carrier Parts, and
new Jog Box
March/April,
2010
Rev N Replaced Inverter Parameter List in Chapter 4 to
show Dual Drive
November, 2010
Rev P Changes made to the following pages: 6-24, 6-
28, 6-29, 6-31, 6-33, 6-35, 6-40, 6-41, 7-15,
7-21, 7-34, 7-35, 7-48 thru 7-51, 7-54, 7-55,
7-103, 7-105, 9-7
December, 2010
Rev R Added Color Touchscreen information Chapter
4A; Changes made to the following pages: 3-3,
3A-2, 3A-3, 6-42 thru 6-58 (Stand Alone),
7-112, 7-113, 7-116 thru 7-119, 7-143
May, 2011
Rev S Changes made to the following pages: 1-4, 6-19
thru 6-21, 6-27 thru 6-31, 6-53, 7-3, 7-9, 7-38
thru 7-43, 7-49, 7-142 thru 7-145, 9-7
October, 2011
Rev T Changes made to the following pages: 1-4, 1-5,
1-32, 2-10, 5-2, 6-46 thru 6-57, 7-13, 7-17 thru
7-21, 7-36 thru 7-41, 7-71, 8-29, 8-47
February, 2012
FOREWORD
This is the operating and parts manual for the Braidmatic MR-15 PLC-T and MR15 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 numbers
wherein they are located.

SAFETY FOR MR-15 PLC-T AND MR-15 PLCT-F BRAIDMATIC
Braiding machines are designed to produce quality braided structures by transferring shuttles via
cam tracks. Producing the braided structures requires high speed, high horsepower, and moving
elements. This in turn requires that operators and maintenance personnel of this equipment be
safety 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 this
equipment, 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 dont understand the instructions, please
contact Mayer Industries Inc.
An operator or maintenance personnel should become completely familiar with all machine
controls and corresponding moving elements before setting up, operating, or working on the
machine.
We suggest snug fitting clothing and safety glasses be worn. No ties and no attempt made to
operate the machine while fatigued or ill. Do not operate the machine if it is malfunctioning in any
way.
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
Do not store wrenches or other items on machine surfaces.
Maintain a clean and safe work area. Keep oil from floor to prevent slipping.
Be sure that all guards and covers are properly in place and doors are closed and fastened while
operating the machine.
CAUTION
The movement of the deck, gear, and transfer areas can create pinch points and the operator must
avoid these points.
During maintenance work, the control must be turned OFF, as an accidental control actuation can
cause 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 an
electrical component failure. Other maintenance must be performed by authorized personnel.
In conclusion, operators and maintenance personnel must be properly trained before being
allowed to operate or work on this equipment. Operators and Maintenance Personnel must treat
this 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 to
others without Mayer Industries' previous consent nor its contents exploited in any other way by
the user or any third party. Reprints, whether complete or partial, require the express authorization
of 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 the
important features of the design. However, dimensional accuracy and design details are not
guaranteed 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 the
standard 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 using
genuine MII or MII-approved components or replacement parts.
Before and while operating the machine, all general and special safety rules must be observed and
necessary 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 PROPERLY
TRAINED
English: DANGER
ONLY TRAINED AND EXPERIENCED
MAINTENANCE PERSONNEL OR
RIGGERS SHOULD BE ALLOWED TO
MOVE AND SETUP THIS EQUIPMENT.
NOTE: MACHINE WEIGHT AND
STABILITY ARE MAJOR CONCERNS IN
LIFTING AND MOVING THE EQUIPMENT.
SYMBOL TRANSLATIONS
English: DANGER
DO NOT OPEN WHILE MACHINE IS IN
OPERATION
English: WARNING
SICHERHEITSREGELN FR MR-15 PLC-T/MR-15 PLCT-F BRAIDMATIC
Braiding Maschinen sind entwickeld um hohe Qualitts braided structur produkte zu produzieren
bei transfer shuttles ber cam tracks. Beim Produktstionsvorgang wird mit hoher geschwindigkeit
und mit viel Kraftaufwand gearbeitet. Um unflle zu vermeiden soll nur geschultes Personal zur
Bedienung der Maschine verwendet werden.
Wir Knnen nicht alle mglichkeiten aufzhlen die einen Unfall verursachen Knnen, aber wir
fhren hier in generell einige Sicherheitsvorschriften auf.
Wenn dieses Zeichen im Buch erscheint, die instruktionen mssen 100% erfllt werden
um Unflle zu vermeiden. Wenn sie irgend etwas nicht verstehen, fragen sie uns bitte.
Bedienungspersonal und Betriebsmechaniker mssen 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 fhlen, oder krank sind. Niemals die
Maschine 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 wenn
die Maschine Luft.
Die sich bewegenden elemente Transferposition und Ritzel Knnen Leicht zu einer Falle werden,
so sei vorsichtig und trete zurck.
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 mchten wir daraufhinweisen das, das Personal die Maschine immer mit Respekt
behandelt, und immer alle Sicherheitsvorschriften beachtet.
Mayer Industrie behlt sich alle rechte fr die Betriebsanleitung vor. Es drfen Keine copien
gemacht werden, ohne das Wissen von Mayer Industrie.
Die Betriebsanleitung ist gemacht worden um zu helfen die Maschine in Produktion zu geben und
zu halten. Die Zeichnungen in Buch sind gemacht um zu erklren und zu helfen wie alles
zusammen geht. Die Zeichnungen sind aber nicht Masstab gerecht gezeichnet.
WARNUNG
TABLE OF CONTENTS
PAGE
CHAPTER 1 INSTALLATION
SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
SECTION II MACHINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION III INSTALLATION AND SET-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SECTION IV PRE-OPERATION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
SECTION V DECK WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
CHAPTER 2 SYSTEMS, ADJUSTMENTS, SETTINGS, AND MAINTENANCE
SECTION I GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION II SHUTTLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SECTION III SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
SECTION IV CARRIER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
SECTION V WIRE BRAIDING BOBBIN PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . 2-15
YARN BRAIDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
SECTION VI BOBBIN RUN OUT DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
SECTION VII BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
SECTION VIII DRIVE CARTRIDGE AND CHANGE GEAR DRIVE . . . . . . . . . . . . . . . . . . 2-23
SPEED LEAD CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
SECTION IX DRIVE SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33
SECTION X ROTOR AXLE ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
SECTION XI ROTOR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
CHAPTER 3 CONTROLS
SECTION I INTRODUCTION (EINFHRUNG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SECTION II OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
CHAPTER 3A PLCT-F CONTROLS
SECTION I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
SECTION II OPERATOR INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-2
CHAPTER 4A ELECTRICAL SYSTEM - COLOR TOUCHSCREEN
SECTION I GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
SECTION II SYSTEM DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
SECTION III INVERTER PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-13
SECTION IV ELECTRICAL CABLE INSTALLATION LOCATIONS . . . . . . . . . . . . . . . . . 4A-14
CHAPTER 4 ELECTRICAL SYSTEM
SECTION I GENERAL DESCRIPTION (GENERELLE BESCHREIBUNG) . . . . . . . . . . . . 4-1
SECTION II SYSTEM DESCRIPTION (SYSTEM BESCHREIBUNG) . . . . . . . . . . . . . . . . 4-2
SECTION III INVERTER PARAMETER LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
SECTION IV ELECTRICAL CABLE INSTALLATION LOCATIONS . . . . . . . . . . . . . . . . . 4-34
CHAPTER 5 LUBRICATION SYSTEM
SECTION I GENERAL DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION II SERVICE INSTRUCTIONS FOR BIJUR CENTRAL LUBRICATION SYSTEM. 5-4
CHAPTER 6 OPTIONS
SECTION I SUPER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
SECTION II TRUMPET AND BRAIDRING (SLO OPTION) . . . . . . . . . . . . . . . . . . . . . . 6-3
SECTION III BROKEN BRAID DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
SECTION IV BRAIDER STEEL MOUNTING PLATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
SECTION V BRAIDING NOSE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
SECTION VI BRAID MATERIAL RUNOUT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
SECTION VII DUAL DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
CHAPTER 7 PARTS
BREAKDOWN AND ORDERING PROCEDURE. . . . . . . . . . . . . . . . . . . . . . 7-5
SEE PARTS INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHAPTER 8 MAINTENANCE AND OVERHAUL
SECTION I MR-15+ BRAIDMATIC OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
SECTION II ROTOR INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
SECTION III SHUTTLE INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
SECTION IV PRELIMINARY SHUTTLE ADJUSTMENT AND INSTALLATION . . . . . . . . . 8-26
SECTION V INSTALLATION OF ROTOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 8-26
SECTION VI ROTOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
SECTION VII SHUTTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
SECTION VIII OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
SECTION IX INSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE . . . . . . . . . . . . 8-35
SECTION X INSTRUCTIONS FOR THE USE OF THE 240-1075
ROTOR GEAR TIMING GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
SECTION XI INSTRUCTIONS FOR THE USE OF THE 240-1076
CAM SET GAUGE WITH MASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
SECTION XII DISASSEMBLING, REASSEMBLING, ADJUSTING, AND
MAINTENANCE OF CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
CHAPTER 9 SPECIAL TOOLS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHAPTER 10 ELECTRICAL SCHEMATICS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
MR-15 PLC-T Manual February, 2012
1-INSTALLATION
February, 2012 MR-15 PLC-T Manual 1-1
CHAPTER 1
INSTALLATION
SECTION I. INTRODUCTION
UNLESS 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-15 PLC-T
Braidmatic is todays most advanced means
for 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 a
maximum 75 dBA ambient noise level)
Automatic lubrication
This manual is intended to provide the user
with the necessary information to obtain the
maximum benefits from the MR-15 PLC-T
Braidmatic.
A thorough understanding of this manual will
assure that the braider will be productive for
many years.
1.3. BENEFITS. The braider provides the user
the expected benefits of modern-day braiders.
Modular construction
Compatibility with existing equipment
Safety of operation
Change gear lead control (PLC-T)
Recirculating automatic lubrication
Modern electrical controls
Optional Inverter Drive (PLCT-F)
1.4. TRANSFER PRINCIPLE. The MR-15 PLC-
T Braider is a special variation of Maypole
Braiders. As with all Maypole decks, the
rotors are arranged in an endless circle. The
rotors consist of six pairs of pockets at 60 to
one another, and the rotors are in timed
relation to one another in that each drives the
other 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 one
direction, and the others in the opposite
direction. Their respective paths being
sinusoidal causes the shuttles to pass one
another. Each shuttle is equipped with a
carrier to provide strand storage and let-off
means. The strands from each are braided
together to form a structure by the fact that the
shuttles were "passed by" in 3 over 3 under
plait formation.
The braider does all of these, yet does them
differently, efficiently, and with a goal of
productivity and quality.
The MR-15 PLC-T Braidmatic transfer will be
described in such a manner that the sections of
this manual explaining instructional and
maintenance information are more readily
understood.
On the braider, the function of the planetary
gear system is to provide a programmed
positive, independent rotation of the axis of
any shuttle from that of the rotors direction of
rotation.
1-INSTALLATION
1-2 MR-15 PLC-T Manual February, 2012
The rotor and axle assemblies of the MR-15
PLC-T Braidmatic are identical to one another.
One peculiarity is that each of the identical
rotors is assembled with alternate rotors
positioned 60 (1/6 turn) from that of its
adjacent or neighboring rotor.
With this assembly pattern, and knowing that
every rotor has six pairs of shuttle pockets as
on a clock dial at 12 o'clock and 6 o'clock, and
8 oclock and mate in rotation with pockets at
2 o'clock and 6 o'clock and 10 oclock pockets
on adjacent rotors, the transfer principle of the
MR-15 PLC-T braider should begin to
emerge.
Every pair of opposite rotor pockets (12
o'clock, 4 oclock and 8 o'clock) includes three
front cam follower assemblies on the outer
flange of the rotor while the rotor pockets (2
o'clock, 6 oclock and 10 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, 4 oclock and 8 o'clock have a
pair of planetary gears which mesh with one of
two gears on each rotor axle.
Pockets at 2 o'clock, 6 oclock, and 10 o'clock
of the same rotor have different planetary
gears which mesh with the other gear teeth of
the same rotor axle.
All shuttle assemblies are of identical design
and manufacture and are equipped with a cam
track having two semi-circular segments.
These segments are passed behind the
appropriate 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 assemblies
are also loaded into rotor assemblies in a
specific 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 cam
follower having positive rolling engagement
with the cam track. The meshing of the shuttle
gear, rotor planetary gear and the rotor axle
assembly control the orientation of the shuttle
axis.
At a point in time the shuttle assembly
advances by rotation of the rotor to mate with
the next rotor (seen earlier to be at 60). Now
control of the shuttle is smoothly shifted from
one rotor to the next by the rear segment of the
cam track picking up the rear cam follower: at
the same time, the front segment of the cam
track 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 way
causes the shuttle axis to rotate as planetary
gearing cancels out the reversed directional
influence of the rotors. The planetary gear
train results in the shuttle completing a 360
rotation for every revolution of the shuttle
about the complete deck.
Successive transfers are made in the same way.
The entire sequence takes place between the
rotor and shuttles without any need for guides
or tracks.
Figure 1.4.1 illustrates a step by step operation
together with the unique control of rotation
between the rotor and shuttle axis. The
advantages of the patented MR-15 PLC-T
principle are:
Constant velocity of shuttle
Eliminated all "deck plates"
Anti-friction bearings at every friction
source
Constant angular rotation of shuttle axis
1-INSTALLATION
FIGURE 1.4.1: THE MR-15 PLC-T BRAIDMATIC DIFFERENCE
STEP 3
TRANSFER
STEP 2
AT TRANSFER
STEP 1
APPROACHING
TRANSFER
COMPLETED
REAR CAM
TRACK
FRONT CAM
TRACK ROTOR
SHUTTLE GEAR
PLANETARY
GEAR
FIXED GEARS
CAM
FOLLOWER
CAM
FOLLOWER
1-INSTALLATION
SECTION II. MACHINE SPECIFICATIONS
1.5. MACHINE SPECIFICATIONS.
TABLE 1.5.1: MACHINE SPECIFICATIONS
DECK
Number of carriers 18 24 36
RPM of rotors
a. Wire 225 225 225
b. Yarn 235 235 235
c. Super Pak 225 225 225
RPM of carriers
a. Wire 75 56.25 37.5
b. Yarn 78.3 58.75 39
c. Super Pak 75 56.25 37.5
Approx. weight per model (includes bobbins, carriers, and 20
lbs of wire per bobbin)
6500 lbs 7585 lbs 15034 lbs
2954.5 Kg 3447.7 Kg 6834 Kg
Floor space requirements See Figures 1.10.1 through 1.10.14
Braider principle Maypole
Braid pattern 3 over 3
Product orientation Horizontal
Construction Modular
Speed and braid angle control (PLC-T) Change gears (24 & 36 Car. Only)
Speed and braid angle control (PLCT-F) Inverter Drive
Rotor diameter 15 inch (381 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 inches above floor (24 carrier)
62 inches above floor (36 carrier
(includes 1 inch mounting plate)
Power Usage (PLC-T) 1 Deck 2 Deck 3 Deck
for 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)
Power Usage (PLCT-F)
18 and 24 Carrier Decks
7.5Hp (5.6Kw) Inverter Drive/Dk
7.5Hp (5.6Kw) Inverter Drive/HO
36 Carrier Decks
15Hp (11Kw) Inverter Drive/Dk
7.5Hp (5.6Kw) Inverter Drive/HO
POWER (PLCT-F)
Machine Type:
Max
Power Voltage Current Main Fuse
PLCT-F MR-11 & MR-15, all types except 36 Carrier
Single Deck 2 x 7.5 Hp Motors 6 Kw 380-480V 12-15A 25A
6 Kw 200-220V 27-30A 50A
1-INSTALLATION
POWER (PLCT-F) (CONTINUED)
Machine Type:
Max
Power Voltage Current Main Fuse
Double 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.
6 - 25 lbs
2.7 - 11.3 Kg
26.5 N - 110.8 N
Compensation Patented rotary
Let-off Wrapped spring
BOBBINS
Single 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)
Super pack yarn
Volume of cardboard tube 302 cubic inches (4947 cu cm)
Total package weight/tube and yarn Not to exceed 10 lbs (4.5 Kg)
Weight of yarn on flange bobbin 7.39 lbs (3.35 Kg)
Total package weight/bobbin and yarn Not to exceed 10 lbs (4.5 Kg)
TABLE 1.5.1: MACHINE SPECIFICATIONS
1-INSTALLATION
FIGURE 1.5.1: MR-15 PLC-T BRAIDMATIC
24 CARRIER
28.35 IN
720 mm
13.78 IN
350 mm
63 IN
1600 mm
27.56 IN
700 mm
40.7 IN
1035 mm
1
9
.
6
9

I
N
5
0
0

m
m
4
9
.
7
6

I
N
1
2
6
4

m
m
1
1
.
0
2

I
N
2
8
0

m
m
1
.
3
4

I
N
3
4

m
m
64.17 IN
1630 mm
8
6
.
4
6

I
N
2
1
9
6

m
m
5
1
.
1

I
N
1
2
9
8

m
m
1
2
3
4
5
6
7
8
8
1
.
8
9

I
N
2
0
8
0

m
m
8
1
.
1

I
N
2
0
6
0

m
m
5
.
3
5

I
N
1
3
6

m
m
** TOTAL HEIGHT DIMENSIONS CAN VARY 10MM
1-INSTALLATION
36 CARRIER
1
2
3
4
5
6
7
8
9
10
11
12
28.3 IN
720 mm
12.6 IN
320 mm
12.6 IN
320 mm
25.2 IN
640 mm
25.2 IN
640 mm
84.3 IN
2140 mm
33.5 IN
850 mm
1
1
2
.
5

I
N
2
8
5
7
.
8

m
m
85.3 IN
2166.1 mm
6
2

I
N
1
5
7
4
.
8

m
m
1
.
4

I
N
3
4
.
8

m
m
1
1
.
0
2

I
N
2
8
0

m
m
1-INSTALLATION
18 CARRIER
28.35 IN
720 mm
13.78 IN
350 mm
63 IN
1600 mm
27.56 IN
700 mm
40.7 IN
1035 mm
7
.
8
7

I
N
2
0
0

m
m
4
9
.
7
6

I
N
1
2
6
4

m
m
1
1
.
0
2

I
N
2
8
0

m
m
1
.
3
4

I
N
3
4

m
m
58.85 IN
1495 mm
8
2
.
3

I
N
2
0
9
0

m
m
5
1
.
1

I
N
1
2
9
8

m
m
1
2
3
4
5
6
1-INSTALLATION
1.6. FLOOR CONSTRUCTION. The MR-15
PLC-T Braidmatic is like other generally
heavy, high speed machinery in that proper
installation will enhance and extend the useful
life.
The nature of the braider floor loadings
(weight) and expected motion (vibration) will
involve concern for the proper specifications
of the floor in the vicinity of the braiders 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 MI approval
should be used; see Figure 1.6.1. The
foundation pockets to accommodate this
should be sized as shown by the forms on
Figure 1.10.15. Form 1 is preferred.
GROUT. MI has two types of grout that can
be used on the MR-15 PLC-T, MC-2 and MC-
3. The standard grout is Unisorb.
The requirements for use with the MR-15
PLC-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
18
Carrier
24
Carrier
36
Carrier
1 deck+1 Haul-Off 4 4 5
CHOCK FAST GRAY
Kits Required
18
Carrier
24
Carrier
36
Carrier
1-INSTALLATION
The floor is to be of steel rod reinforced
concrete 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. These
may be used individually or in combination to
accommodate various machine arrangements.
For 24 carrier braiders, no more than six decks
should be mounted on a pad: this may be two
three-deck machines abreast as shown in
Figures 1.10.3 and 1.10.8, or three two-deck
machines abreast as shown in Figures 1.10.4
and 1.10.9. Single-deck machines should be
limited to four abreast as shown 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
2647 Nm)
LOCK WASHER
FLAT WASHER
THREADED
NUT
PLATE
FOOT
COVER THIS END OF FOOT
TO KEEP GROUT OFF OF
BOLT THREADS
BUSHING
THREADS
1955 FT-LB
6

I
N
(
1
5
2

m
m
)
FLOOR
330 MM
13 IN MIN.
PAD THICKNESS
1-INSTALLATION
SECTION III. INSTALLATION AND SET-UP
1.7. MACHINE ERECTION AND MOUNTING.
Every MR-15 PLC-T Braider Deck has been
completely assembled and operated at the
factory, prior to package and shipment.
1.8. MOVING AND LOCATING THE
MACHINE.
CAUTION
Only trained Maintenance
Personnel or Riggers should be
allowed to move and set up this
equipment.
Each braider deck is fitted with a lifting eye
installed at the factory. This eye is intended
for up-righting the deck from its shipping
position, and can be used for in-plant
transporting of the deck to its intended location
within 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 the
deck bottom is hollow. It is
important, therefore, to use forks
that extend the complete length
and somewhat past the base of
the machine. It is also important
that caution must be used in
securing the deck to prevent it
from tipping.
The Hauloff should be transported as far as
practical on its shipping skid by forklift truck.
It can be lifted by overhead means, by using 12
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 and
located 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 shown
in Figure 1.6.1 and Figure 7.5.3.
2. Level module(s), using the outer face
of the rotor within 0.010 in, per foot
(0.8 mm/m), "B" on Figure 7.5.2. (An
alternate leveling surface is the
protruding shuttle spindle shaft, "C" on
Figure 7.5.2.) The base of the lower
deck frame should be leveled within
0.015 per foot (1.2 mm/m). A
machined surface has been provided
for this adjustment, "A" on Figure
7.5.2.
3. (Not required for dual drive.)
Assemble the connecting drive shaft,
part number 240-2084, (for the 24
carrier) or number 536-2084 (36
carrier) between haul-off and MR-15
PLC-T deck module and 240-2083,
(for the 24 carrier) or 536-2085 (36
carrier) between other decks (it is
important that a total lengthwise gap of
1/8 in.-3/16 in. (3.2 mm - 4.76 mm)
exists between the shafts to be
connected; see Figures 7.5.26 and
7.5.27) using set screws and keys at
each end of line shafts to be connected.
4. (Not required for dual drive.) Adjust
the center line height of the deck
module drive shaft to the identical
height of the drive shaft of the haul-off
unit. Align the shaft of the deck module
with the haul-off shaft within .005 in.
per foot (0.4 mm/m). This alignment is
made with the use of a precision level
and by attaching a dial indicator to the
deck end of the connecting drive shaft
and with the indicator probe contacting
1-INSTALLATION
the face of the MR-15 PLC-T drive
shaft flange. The shaft is turned by
hand 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, drive
shaft alignment (standard drive), and
that the floor mounting hardware is
imbedded in the floor per Figure 1.6.1.
Check each foot (Figure 1.6.1) on
deck(s) and hauloff. Make sure that the
foot is not touching the sides of the
foundation pocket at any place. Turn
the hex head bolt (Figure 1.6.1) until
the spacer sleeve is flat against the
plate. Do not over tighten as this may
distort the spacer sleeve, allowing
grout to get onto the hex head threads.
Only first quality, high head threads
and first quality, high strength, non-
shrinking grouting should be used. The
grouting must be of a type formulated
to withstand vibration and impact from
dynamic and repetitive loading.
6. Following "set-up" of floor (step 5), a
final check is made for alignment of all
components, and mounting hardware is
locked down. Apply permatex to
threads of all floor bolts. See torque
value for hold down bolts, Figure
1.6.1. Re-torque bolts after the first 500
hours 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 (24 carrier) or Figure
7.5.36 (36 carrier) and connect
lubrication lines. Level line shaft
covers. Position remote oil settling
tank and connect flexible lines, as
shown, to Bijur pump filters, and lower
deck frame.
8. Install sensor stand assembly to front
tunnel cover, as shown in Figure
7.5.30, for standard drive and to the
floor for dual drive, as shown in Figure
6.12.1.1.
9. Construct acoustical enclosure accord-
ing to separate instructions provided
with each enclosure. Locate enclosure
per Figure 1.10.10 or 1.10.14.
10. Install electrical panels, door switches,
blower fan and related electricals. See
Chapter 10, Schematics.
1.9. MACHINE STORAGE PRIOR TO
INSTALLATION. If the braider is to be stored
for 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 MI if in
doubt.
2. The braider and all of its sealed
components must remain sealed while
in storage.
3. The shipping crates must be stored in a
dry 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 than
30 days, contact the MI SERVICE
DEPARTMENT for instructions.
1.10. FINAL ASSEMBLY. The following com-
ponents must be installed prior to operating the
machine:
Shuttles - See Chapter 2, Section II
Sensors - See Chapter 2, Section III
Carriers - See Chapter 2, Section IV
Bobbins - See Chapter 2, Section V
Broken Braid Detector - See Chapter 2,
Section VII
Options - See option sections for those
options provided on your machine.
1-INSTALLATION
FIGURE 1.10.1: TYPE 1 FOUNDATION
18 & 24 CARRIER
1
0

I
N
2
5
4

m
m
12 IN O.C. @ 90
305 mm
FLOOR LINE INSULATION SEALANT
CONTINUOUS BEAD
ADJACENT
PLANT
FLOOR
WELD (TYP)
.75 IN
20 mm
REINFORCING ROD (TYP)
1 IN
25 mm
STYROFOAM
17 FT - 2 IN
5232 mm
SINGLE DECK
4 FT - 2 IN
1270 mm
2 FT - 2 IN
673 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
FIGURE 1.10.2: TYPE 1 FOUNDATION - SINGLE DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
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
)
4

F
T

-

0

I
N
1
2
2
0

m
m
4 FT - 2 IN
1270 mm
17 FT - 2 IN
5232 mm
1-INSTALLATION
FIGURE 1.10.3: TYPE 1 FOUNDATION - THREE DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
9 FT - 4 IN
2845 mm
22 FT - 7 IN
6884 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 IN
1220 mm
3 FT - 0 IN
915 mm
4 FT - 0 IN
1220 mm
1-INSTALLATION
FIGURE 1.10.4: TYPE 1 FOUNDATION - TWO DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
23 FT - 9 IN
7239 mm
4 FT - 2 IN
1270 mm
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
4

F
T

-

0

I
N
1
2
2
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
18 & 24 CARRIER
4

F
T

-

8

I
N
4 FT-0 IN
1220 mm
4 FT-3.57 IN
1310 mm
5 FT-5 IN
1650 mm
2 FT-10 3/8 IN
874 mm
2 FT-3 IN
700 mm
2 FT-3 IN
700 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.@90
305 mm
1
0

I
N
2
5
4

m
m
STYROFOAM
1 IN
25 mm
REINFORCING ROD
.75 IN
20 mm (TYP)
WELD (TYP)
FLOOR LINE
INSULATION SEALANT
CONTINUOUS BEAD
ADJACENT
PLANT
FLOOR
1-INSTALLATION
18 & 24 CARRIER
VIEW A-A
FLOOR ONLY
.75 IN (20 mm)
12 IN
305 mm
ADJACENT
FLOOR
INSULATION
SEALANT
FLOOR
LINE
12 IN O.C. @ 90
305 mm
STYROFOAM
1 IN (25 mm)
WELD(TYP)
15 FT-2 IN
4622 mm
8 FT-6.8 IN
2610 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 IN
305 mm
2 FT-2 IN
673 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
REINFORCING ROD (TYP)
1-INSTALLATION
FIGURE 1.10.7: TYPE 2 FOUNDATION - SINGLE DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
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
)
2

F
T

3
.
5

I
N
6
9
9

m
m
12 IN
305 mm
8 FT - 6.8 IN
2610 mm
15 FT - 2 IN
4622 mm
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
FIGURE 1.10.8: TYPE 2 FOUNDATION - THREE DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
9 FT - 4 IN
2845 mm
12 IN
305 mm
12 IN
305 mm
18 FT - 7 IN
5664 mm
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
FIGURE 1.10.9: TYPE 2 FOUNDATION - TWO DECK MACHINE ARRANGEMENT
18 & 24 CARRIER
21 FT - 8 IN
6605 mm
15 FT - 1.8 IN
4620 mm
2 FT - 2 IN
673 mm
1
2

I
N
3
0
5

m
m
12 IN
305 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
2

F
T

-

3
.
5

I
N
6
9
9

m
m
2 FT - 1.5 IN
648 mm
1
2

I
N
3
0
5

m
m
1-INSTALLATION
FIGURE 1.10.10: FLOOR SPACE REQUIREMENTS
18 & 24 CARRIER (SEE FIGURE 1.10.16 FOR DOOR LOCATIONS)
2 FT - 8.8 IN
832 mm
1 FT - 4.4 IN
416 mm
2

F
T

1
0
.
4

I
N
8
7
4

m
m
1 FT - 4 IN
314 mm
1

F
T

-
6

I
N
4
5
7
.
8

m
m
4

I
N
1
0
2

m
m
2

F
T

-
9

I
N
8
3
8
.
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
m
2 FT - 4.4 IN
720 mm
4 FT - 7.9 IN
1420 mm
4 FT - 3.1 IN
1298 mm
8 FT - 4 IN
2540 mm
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
36 CARRIER
MC-3 HAUL-OFF
2 FT - 5 IN
749 mm
18 FT - 11 IN
5755 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
14 IN
355.6 mm
12 IN O.C. @ 90
305 mm
1
3

I
N
3
3
0
.
2

m
m
STYROFOAM
1 IN
25 mm
REINFORCING ROD
.75 IN
20 mm (TYP)
FLOOR LINE
INSULATION SEALANT
CONTINUOUS BEAD
ADJACENT
MACHINE
FOUNDATION
A
A
(
M
I
N
)
WELD (TYP)
VIEW A-A
FLOOR ONLY
11 FT
3353 mm
1-INSTALLATION
FIGURE 1.10.12: DOUBLE DECK ARRANGEMENT
36 CARRIER
MC-3 HAUL-OFF
11 FT - 6 IN
3505 mm
6
.
1

I
N
1
5
7

m
m
2
0

F
T

-

1
0

I
N
6
3
4
3

m
m
2
7

F
T

-

5

I
N
8
3
5
5

m
m
1 FT - 2 IN
355.6 mm
2

F
T

-

5

I
N
7
4
9

m
m
2 FT - 8 IN
813 mm
1 FT - 5 IN
444 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
8
F
T

-

6

I
N
2
2
8
0

m
m
1-INSTALLATION
FIGURE 1.10.13: TRIPLE DECK ARRANGEMENT
36 CARRIER
MC-3 HAUL-OFF
2

F
T

-

1
0

I
N
11 FT - 6 IN
3505 mm
1 FT - 5.5 IN
444 mm
6
.
2

I
N
1
5
7

m
m
2
3

F
T

-

1
1

I
N
7
2
9
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
813 mm
1 FT - 2 IN
357 mm
2

F
T

-

5
.
5

I
N
7
4
9

m
m
1-INSTALLATION
FIGURE 1.10.14: FLOOR SPACE REQUIREMENTS
36 CARRIER (SEE FIGURE 1.10.17 FOR DOOR LOCATIONS)
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 mm
11 FT - 9 IN
3581 mm
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

F
T

-

3
.
7
5

I
N
4
0
0

m
m
1-INSTALLATION
FIGURE 1.10.15: ANCHOR POCKET FORMS
(EUROPEAN PROJECTION)
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
6

I
N
1
5
2

m
m
6 IN
152 mm
1-INSTALLATION
FIGURE 1.10.16: ENCLOSURE DOOR LOCATIONS
18 & 24 CARRIER
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
FIGURE 1.10.17: ENCLOSURE DOOR LOCATIONS
36 CARRIER
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
6

F
T

-

4

I
N
4
9
7
6

M
M
10 FT 7 IN
3226 mm
1
5
.
7
5

I
N
4
0
0

m
m
1-INSTALLATION
1-INSTALLATION
SECTION IV. PRE-OPERATION ADJUSTMENTS
EINSTELLUNGEN VOR INBETRIEBNAHME
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 in
safety 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. Shuttle sensor clearance.
i. All safety stops operating.
j. Insure that all carriers are securely locked
to shuttle spindle.
k. Insure 1 mm play in axial direction on all
bobbins.
l. All installed options adjusted.
m. Broken braid detector.
n. Silent Chain tensioned for standard drive.
Gear bolts for dual drive.
o. Rotor frame axial play.
p. Bobbin runout detector adjusted
1.11 MECHANISCH: Folgende Teile mssen
geprft und richtig eingestellt werden bevor
die Maschine in Produktion genommen
werden Kann
a. Maschine und Abzugsraupe in die Waage
stellen und ausrichten.
b. Antriebswelle ausrichten und fest
schrauben.
c. Befestiegungsschrauben im Fussboden gut
anziehen.
d. Spannung an den Klppeln Kontrollieren
und einstellen.
e. Alle Spindel schmieren bevor die Bobinen
installiert werden.
f. Klppelachse zur Rotoranlage Keil im
Transfer.
g. Spiel zwischen Transferlager und
Transferschiene.
h. Spiel zwischen Klppelachse und
Absteller sensor.
i. Kontrollieren das alle Sicherheitsabsteller
funktionieren.
j. Versichern das alle Klppel auf der
Klppelachse gut eingerastet sind.
k. Versichern 1mm Spiel in axialer Richtung
an allen Bobinen.
l. Alle installierten mglichkeiten eingestellt.
m. Draht-Fadenbruch absteller.
n. Ketten spannung.
o. Axial Spiel der Rotoranlage.
p. Auslaufende Bobinen Absteller eingestellt.
1.12. LUBRICATION. The following items
must 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-INSTALLATION
1.12 SCHMIERUNG: Folgende Teile mssen
Kontrolliert oder eingestellt werden bevor die
Maschine in Produktion genommen werden
Kann.
a. lpumpen druck.
b. ltank gefllt.
c. Hintere Deck tank gefllt.
d. Alle Rotorenachsen gefllt mit l.
e. Alle Klemmen und Verbindungsteile fest.
f. Keine Lecks.
1.13. ELECTRICAL. See Chapter 3 or 3A for
use of the controls, and for set-up procedures.
1.13 ELEKTRISCH: Siehe Chapter 3/3A fr
das Elektrische System, und ber die
verschiedenen Einstellungsfunktionen.
1.14. SETTING THE MOTOR SPEED. For
standard (PLC-T) drive only.
CAUTION
All electrical circuits are
energized. 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 the
decks to create minimum load condition.
2. Unplug the user panel on the inverter, plug
in the extension cable that comes with the
inverter and run the other end out of the
hauloff through the slit above the main
motor doors. Plug the user panel into the
other end of the extension cable. This will
allow one to close all of the safety
interlocks (gearbox doors) while still
having access to the inverter controls/
parameter unit.
See the Mitsubishi manual for exact
descriptions on how to change the parame-
ters; the parameters that are used for speed
control are described below.
Parameter 4 Multi-speed setting, high
speed this frequency should be set to the
standard run speed of the machine. Check
the drive-shaft speed and increase/decrease
the hertz setting to get the correct speed.
Parameter 5 Multi-speed setting,
medium speed this frequency should be
set to approximately 2/3 of the driveshaft
speed set in Parameter 4. Pressing the
slowstart button on the main cabinet will
engage this speed for one hour before auto-
matically changing the machine speed to
that which is set in Parameter 4. This is
useful for running in carriers slowly after
the braider has been sitting for a while.
Parameter 6 Multi-speed setting, slow
speed This frequency should be set for
the Jog speed of the machine.
Two other parameters that a user might
want to change are:
Parameter 7 Acceleration time
Parameter 8 Deceleration time.
1.14 MOTOR GESCHWINDIGKEIT EINSTEL-
LUNG.
WARNUNG
Folgende Regeln mssen
beachtet werden um elektrischen
Schock zu verhindern.
2 Personen werden gebraucht.
1-INSTALLATION
Bevor der Motor gestarted werden Kann:
1. Antriebswelle verbinden mit einem
tachometer, die Antriebsritzel entfernen so
das die Decks nur eine minimale
Kraftaufwand brauchen.
2. Entferne den Deckel am Inverter, steck das
Velngerungskabel vom Inverter durch die
Abzugsraupe und verbinde es mit deiner
Inverter controls parameter einheit.
Schlag nach im Mitsubishi.
Betriebsanleitungsbuch, die genaue param-
eter Einstellung fr die unten genannten
Punkte.
Parameter 4 Mehrfache geschwindig-
keitseinstellung. Hohe geschwindigkeit,
diese Frequenz sollte fr die Standard
geschwindigkeit der Maschine eingestellt
werden. Kontrollier geschwindigkeit der
Antriebswelle bei zu hoher, oder zu niedri-
ger geschwindigkeit. Einstellung mit der
hertzzahl.
keitseinstellung. Mittlere geschwindigkeit,
diese Frequenz sollte ungefhr 2/3 der
Standard geschwindigkeit von Parameter 4
eingestellt werden. Drcken den Knopf
Langsam slowstart am Schaltschrank
Lsst die Maschine eine Stunde Langsam
Laufen, und schaltet dann automatisch um
auf die normale Produktionsgeschwindig-
keit. Der Grund ist um die Klppel Kpfe
Langsam einlaufen zu Lassen.
keitseinstellung. Langsame geschwindig-
keit, diese Frequenz ist fr die Tip
geschwindigkeit der Maschine.
Zwei weitere Parameter die man
gebrauchen Knnte:
Parameter 7 Geschwindigkeitsbeschle-
unigung.
Parameter 8 Geschwindigkeitsreduz-
ierung.
SECTION V. DECK WIRING
1.15. CONNECTING THE DECK TO THE ELEC-
TRICAL SYSTEM. The following table shows
all of the wiring that leads from a deck to the
Braider electrical system. Twenty-four carrier
decks are wired identically with one cable
containing all of the main connections from
the deck. Thirty-six carrier decks have an extra
cable containing the extra twelve shuttle
sensors. Facing the back of the deck, the cable
containing shuttle sensors 1-24 is on the left
and the cable containing shuttle sensors 25-36
is on the right.
The wiring is always connected into the
terminal strip inside the primary operator box
located on the side of the enclosure. Terminal
numbers 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 main
cable. 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 on
the table below.
On the 36-carrier, there is a terminal strip
mounted on the back of the deck, these wires
can optionally be wired into this strip instead.
The last is the green-yellow ground wire
coming from the deck. Note that this must be
connected for proper operation since most of
the sensors on the deck itself are tripped by a
connection to ground.
1-INSTALLATION
TABLE 1.15.1: DECK WIRING MR-15 PLC-T CONTROLLER
CONNECTION BETWEEN DECK AND PRIMARY OPERATOR BOX
WIRE COLOR
FROM DECK CABLE TO
PRIMARY OPERATOR
BOX (3000412)
Blk X1/3
Brn X1/3
Red X1/4
Org X1/4
Yel X1/5
Grn X1/5
Blu X1/6
Vio X1/6
Gry X1/7
Wht X1/7
Tan X1/8
Pnk X1/8
Blk/Wht X1/9
Brn/Wht X1/9
Red/Wht X1/10
Org/Wht X1/10
Yel/Wht X1/11
Grn/Wht X1/11
Blu/Wht X1/12
Vio/Wht X1/12
Gry/Wht X1/13
Brn/Blk/Wht X1/13
Red/Blk/Wht X1/14
Org/Blk/Wht X1/14
Red/Yel X1/23
Yel/Blk/Wht X1/27
Red/Blk X1/30
Blu/Blk/Wht X1/31
Red/Grn X1/1
Grn/Blk/Wht X1/1
2-ADJUSTMENTS AND MAINTENANCE
CHAPTER 2
ADJUSTMENTS AND MAINTENANCE
SECTION I. GENERAL
2.1. GENERAL. This section delineates the
various systems utilized and all normal
adjustments, settings and maintenance
required to maintain and operate the MR-15
PLC-T Braidmatic. Special requirements may
be discussed with the Mayer Industries Service
Department.
All components, sub-assemblies and
assemblies have been thoroughly checked,
adjusted and set for average normal operating
conditions. Re-adjustments may be required to
suit particular conditions and requirements.
When a malfunction of the machine causes
undue strain, wear, or damage to any part or
assembly, the machine should be checked
immediately to see that the affected part and
associated 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 on
all shuttles. Failure to follow these
instructions can result in smashing
the braider.
SECTION II. SHUTTLE ASSEMBLY (FIGURE 7.5.17)
2.2. SHUTTLE ASSEMBLY. The shuttle
assembly serves two major functions. First, it
is the element which contributes to the transfer
from one rotor to the adjacent rotor and
secondly, it is the structure onto which the
carrier is affixed, together with the strand
material to be braided.
Every shuttle assembly is interchangeable with
that of another of the same design for the same
quantity of rotors per deck.
The MR-15 PLC-T and MR-15 PLCT-F
braider concept produces "three over three"
braid structures only, and this pattern is
dependent upon the shuttle assemblies being
loaded into rotors in six transfer pockets.
The basic shuttle assembly may be converted
from wire braiding, using MR-15 PLC-T
bobbins, to yarn wound on paper tubes or
bobbins. The conversion is accomplished by
the addition of a shuttle spindle adapter with
shuttles loaded into the deck. (see Figure
2.2.1)
The correct MR-15 PLC-T transfer requires
accurate axial and radial control of the shuttle
assembly, rotor cam followers, and the rotor
pockets.
FIGURE 2.2.1: SHUTTLE SPINDLE ADAPTER, YARN
STRAND SHOWN
OVER CENTER
ROLLERS
2.3. REMOVAL AND RELOADING OF SHUTTLE
ASSEMBLIES. Theoretically, all shuttles may
be removed and loaded into the deck by
removal 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, 1.5.2 and 1.5.3 for rotor
numbers):
Rotor numbers 5 and 6 of 12 rotor decks
The designated rotors include a prepinned
location for the front cam followers
assemblies. This feature eliminates the need
for adjustment of cam followers in the same
six pockets of the same rotor assemblies.
2.4. REMOVAL OF SHUTTLE ASSEMBLIES
FROM BRAIDER.
CAUTION
Moving elements/pinch points in
the shuttle assembly area.
Personal injury to hands and arms
could occur.
Only trained personnel/mechanics
are allowed to install and remove
shuttles and/or work in this area.
Personal safety equipment is to
be worn.
Work area to be clean and free of
oil to prevent slipping.
Cut power off at the main
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 on
PLCT-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 two
trained mechanics using special
tool #2000302, which mounts to
the face of the rotor frame using
the (4) M6 holes that are used to
mount the rotor cap. Mount this
tool to the rotor frame closest to
the 8:00/9:00 deck position.
The two mechanics must be able
to communicate.
The mechanic turning the deck
must be strong enough to control
the movement of the rotors.
Installing the shuttles will cause
uneven loading until they have all
been installed. This uneven
loading will result in unwanted
movement of the rotors that must
be controlled by the mechanic
using the special tool.
Note: Tool #2000302 is available
from MI (Figure 9.1.8).
CAUTION
Moving elements.
Personal injury could result.
Use only special tool #2000302
which gives the second person
control of the rotor/shuttle
movement.
3. Position rotors as shown in Figure 2.4.1.
4. Removal of one front cartridge numbered
transfer #1 will permit one sixth of the
deck shuttles to be removed. Remove four
M6 screws from face of rotor cam follower
cap, Figure 7.5.19. The removal of the
cartridge is made without removing the
cartridge cap. Care must be exercised to
reach behind rotor front face to push
cartridge and not on extended shaft to
remove entire cartridge assembly as one
unit. Place removed cam follower
assembly on clean surface with cap down.
5. Rotate rotor with removed cartridge in
clockwise direction and reach into rotor to
lift the first shuttle from the rotor pocket
without the cartridge.
6. Repeat step 5 to lift one sixth of shuttles
from the same rotor pocket. Do not drop
shuttles. Keep these shuttles together. See
Chapter 8, Section I, paragraph 8.2.
7. Replace cam follower cartridge and
assembly with one or two M6 screws.
8. Repeat steps 1-7 by removing cam
follower assembly #2 and continue to
rotate rotor clockwise to remove second
transfer shuttles. Replace the cartridge. Do
not mix any shuttles from one transfer with
shuttles from another transfer.
9. Repeat steps 1-7 to complete the removal
of all shuttles from adjacent rotor.
CAUTION
Release of shuttle assemblies.
Do not attempt to remove cam
follower assemblies when a
shuttle is engaged with the
cartridge.
10. The removal of all shuttles from rotors will
give 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.
c. General operating condition.
With all the shuttles removed, clean the
inside of the deck of any foreign matter.
FIGURE 2.4.1: SHUTTLE UNLOADING
FRONT CAM
FOLLOWER
REMOVED
2.5. RELOADING OF SHUTTLES INTO DECK.
Loading of the shuttles, as with unloading,
requires two people in the same positions as
for unloading.
CAUTION
Follow all Safety Precautions
documented in Paragraph 2.4.
All shuttles are alike for a given deck. Be sure
that all the shuttles go back into the transfer
they came out of.
1. Remove #4 transfer cam follower cartridge
from rotor as before.
2. Hold shuttle in two hands and direct person
in rear using a special tool on upper change
gear shaft to turn the lower of the two
rotors in a counterclockwise direction to
the approximate position shown in Figure
2.5.1.
3. Rotate rotor counterclockwise until the
shuttle is in transfer position at which time
the shuttle gear and cam track should be in
the correct timed engagement with the
upper rotor rear cam follower. Continue to
rotate in the same direction slowly until the
shuttle engages the upper rotor in transfer.
If the shuttle gear teeth were oriented
correctly in mesh with the rotor planetary
gears, the two transfers should be smooth
and positive.
4. Repeat steps 2-4 for the remaining shuttles
in transfer #4. Replace timed cartridge in
transfer #4. Repeat identical procedure for
the other five transfers until the deck is
full.
5. Rotate upper change gear shaft by hand
slowly, using special adapter tool 240-
3040, to insure correct loading. Person in
front should inspect each transfer by feel
for proper shuttle cam track to rotor cam
follower radial clearance. Check also for
axial play in transfer. See paragraph 2.69.
NOTE
The braider includes an electrical
sensor device to monitor the path
of a shuttle cam track under load
at high speed. Frequently, the
sensor probe may become
dislocated during unloading or
loading of shuttles into rotors. The
position of the sensor probes will
require checking prior to operation
of the deck. See instructions in
Chapter 4, Electrical System.
FIGURE 2.5.1: SHUTTLE LOADING INTO
ROTORS
SHUTTLE
FRONT CAM
FOLLOWER REMOVED
2.6. SHUTTLE DISASSEMBLY AND
ASSEMBLY. Every part of a shuttle assembly is
interchangeable with another within decks
having the same number of shuttles. See
Chapter 8, Section III and Section IV, for
disassembly and assembly instructions.
CAUTION
Be aware of possible sharp edges
on parts.
2.7. NOT APPLICABLE.
2.8. NOT APPLICABLE.
SECTION III. SENSORS
2.9. SENSOR STAND ASSEMBLY. (Figure
7.5.30) 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 carriers
during threading, Figure 7.5.29.
Mounting provision for the operator "JOG"
button to jog the deck from within the
enclosure, Figure 7.5.29.
CAUTION
Moving elements in deck.
Inside safety switch should always
be in the "ON" position when
working on deck. When the safety
switch inside the enclosure is
"ON" the braider cannot be run
from any location and can be
jogged only from the safety switch
that is "ON".
CAUTION
Only one trained operator to be
allowed 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 to
hands and arms.
"Always" switch the inside safety
switch to the "ON" position
immediately upon entering the
safety enclosure. This prevents
the braider from being run from
any other position and allows the
braider to be jogged from this
location.
The following safety equipment is
recommended:
Safety glasses
Safety shoes
Noise protection
Leather gloves
2.10. TYING IN OF BRAIDING STRANDS. The
braider provides a means to reduce the time
and effort required to attach plaits of yarn or
wire to a mandrel, hose or other object to
which strand materials are attached. The object
is to reduce operator reaching and lifting of
carriers and strand packages during the loading
and threading operation.
The braider carriers are most conveniently
loaded at rotors number 4 and 5 on one side or
rotors 8 and 9 on the opposite side. These
positions require less reaching and for this
reason, provide faster reloading, threading and
tying-in. Place the eye bolt assembly (3,
Figure 7.5.29) in the position shown. Be sure
the sensor pin (5, Figure 7.5.29) goes thru both
sides of the swinging arm assembly (4).
After loading 3 to 6 bobbins at these locations
and locking the carriers on, the operator
threads the plaits from the bobbins, through the
carriers and ties them onto the hook (3, Figure
7.5.29). Now with the pole, mandrel, etc. in
place, and carrier latches locked, the operator
may "JOG" the deck to bring other carriers
requiring service to within operator's
convenient reach. These next 3-6 carriers may
be loaded, threaded and plaits once again tied
in to the hook.
NOTE
Be Aware: Uneven loading of
bobbins can result in gravity
causing an unintended movement
of the carriers.
The sequence is continued until all carriers are
prepared for production.
The additional benefits of this approach are:
Cutting of wires or yarns is performed at a
location where stray ends are prevented
from getting inside the deck.
NOTE
Use eye protection and leather
gloves.
The tension on the plaits when tying to the
hook eliminates reaching to "back-wind"
threaded carriers to keep strands tight.
The sequential threading and tying-in can
avoid lumps in hose which would other-
wise necessitate readjustment of the haul-
off unit.
Once all threading and tying-in is
accomplished, the operator removes the pivot
hardware, and the hook is lowered into
position for braider production.
Double check to insure all carriers are in the
latched position.
CAUTION
Always lock latches on carrier
assembly.
Severe machine damage will
occur.
2.11. JOG BUTTON.
NOTE
When the safety switch inside the
enclosure is "ON" the braider
cannot be run from any location
and 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 plait
let-off. The sensor operates on the principle
that when any one or all strands from any
carrier plait becomes tangled, or when the
carrier clutch fails to release, the additional
tension in that plait will dislocate the braided
structure and jerk the braided member from its
usual position.
The dislocation of braided product will trigger
the broken briad detector and electrically shut
off the machine drive. The device has both
electrical and mechanical adjustments for
sensitivity.
While other "grounding" sensors can be used
in combination with the MR-15 PLC-T braid
sensor to detect broken wires, etc., the
objective here is to continuously monitor the
braid at each deck and to detect abnormal
strand behavior before the wires or plaits
rupture which can cause damage to braided
product or the braider deck.
The MR-15 PLC-T braid sensor functions with
yarn or wire braid strands.
A braid failure will shut off the machine and
will show a message on the touch screen for
the deck in question.
The operator may re-set the deck by clearing
the 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 close
to the braid point as possible.
2. See Section VII of this chapter (Figure
7.5.31).
2.12.2. ELECTRICAL. The sensitivity of the
sensor to respond to movement of the inner
ring, Figure 7.5.31, is made at each individual
deck. Experience with use for a particular
application will be the basis for the correct
setting.
NOTE
The ring halves must have a
clearance between the O.D. of the
hose and the I.D. of the ring
halves. The clearance is
recommended to be 2 to 5 mm per
side. Ring halves with different
I.D. are available from Mayer
Industries. Please contact the
sales department for any
additional information.
Ring halves are available in the following
sizes:
NOTE
Generally, the closer the sensor is
to the braid point, the quicker the
defect 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-15
PLC-T carrier is a compact assembly
containing a torsion spring tensioning device,
ball bearing compensator, and one way clutch.
MR-15 carriers are inter-changeable.
The braider carrier is readily adapted to
satisfy a wide range of applications includ-
ing:
Strand Materials
Need for preforming
Strand release tensions
See Chapter 8, Section XII for additional
details.
2.14. CARRIER COMPENSATIONS. The
function of the compensator is to store the
excess plait length produced by the carrier
being propelled from "outside" to "inside" of a
rotor during the usual Maypole cycle.
The MR-15 PLC-T carrier eliminates many
problems experienced on earlier Maypole
carriers by the use of a rotary ball bearing in
the compensator.
The compensator, working together with the
torsion spring, is capable of producing a
unique tension cycle suitable for a wide range
of braiding applications.
2.14.1. CARRIER CYCLE. To obtain an
adequate amount of strand compensation, the
MR-15 PLC-T carrier requires eight (8) strand
rollers - six (6) mounterd to the compensator
plate and two (2) mounted to the stationary
cap. The strand threading path is shown in
Figure 2.19.2.
2.14.2. COMPENSATION AND ADJUSTMENT.
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/yarn
slips or breaks, damage can occur
to the fingers.
RING
I.D. MM
RECOMMENDED
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 .984-1.220
40 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
(Reference Section 2.14.3).
.
To obtain an adequate amount of strand length
compensation, each carrier must "release" or
"payout" at the same position of compensator
rotation as other carriers on the same deck. The
setting for "A" (Figure 2.14.2.2) should be 0-8
mm (0-5/16"). These settings may vary from
product to product. Experimenting with
different settings will determine the best
setting for the product you are making.
2.14.3. COMPENSATION ADJUSTMENTS. It is
important that each carrier "release" or
"payout" at the same position of compensator
rotation as other carriers on the same deck.
Adjustment to this factory setting is
accomplished by first recognizing that the
torsion spring (20, 21, or 22, Figure 7.5.4), is
attached to the actuator block which is
mounted onto the compensator (Figure 7.5.5).
The rotation of the compensator clockwise
continues until the end of the actuator block
contacts the clutch sleeve member. Further
clockwise motion will rotate the sleeve and
release the clutch for strand payout.
The adjustment to the payout position is made
by positioning the tang of clutch spring into a
different slot within the plastic sleeve (Figure
2.14.2.1).
You must understand that the release position
is independent of the release tension.
2.15. CARRIER CLUTCH. (Figure 7.5.4) The
MR-15 PLC-T carrier clutch operates on the
one-directional wrapped spring principle. It
has been developed for long, trouble-free
performance.
The clutch function is to prevent the strand
supply wire bobbin or yarn package from
rotating until the plait has attained a
predetermined tension, at which time the
compensators clockwise rotation will actuate
the plastic clutch sleeve (13) which will open
the wrapped spring (11) or (12), and allow the
moveable hub (9) to rotate with the strand
supply package.
The stationary hub (6) of the clutch assembly
is timed to the carrier housing (1) with pin
(25). This fixed relationship insures that every
MR-15 PLC-T carrier will relate to any shuttle
assembly.
The movable hub (9) uses grease for
lubrication. Manually apply grease. See
lubrication, Chapter 5.
FIGURE 2.14.2.1: PAYOUT POSITION
ADJUSTMENT
FIGURE 2.14.2.2:
DECREASE
INCREASE
A
2.16. CARRIER PAY-OFF TENSIONS.
NOTE
Pay-off tensions indicated are
approximate. The actual release
tension will vary somewhat with:
strand diameter, strand material,
number of ends of strand/plait,
and to what extent (if any) the pre-
form pin is involved.
NOTE
When the desired pay-off tension
can 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 rotational
adjustment to the carrier adjusting ring (3,
Figure 7.5.4).
CAUTION
to the fingers.
When viewed from the front of the carrier, a
counter clockwise adjustment "increases" pay-
out tension while a clockwise rotation
"reduces" pay-out tension.
Radial holes have been provided in ring (3) to
make tension adjustment more convenient.
When the desired tension has been attained,
the socket head screw (32) is tightened in the
adjusting clamp (7) to secure the adjusting ring
to the carrier housing.
2.16.2. SUBSTITUTION OF ONE SPRING FOR
ANOTHER (SAME CARRIER). (Figures 7.5.4
and 7.5.5)
CAUTION
to the fingers.
1. Remove carrier from deck.
2. Loosen M8 screw (32, Figure 7.5.4) to
allow disassembly of adjusting ring (3).
PAY-OFF TENSION
LBS KILOGRAMS
TORSION
SPRING
6 - 9 2.7 - 4.1 Light
12 - 18 5.4 - 8.2 Medium
19 - 25 8.6 - 11.3 Heavy
3. Loosen spring clamp (14, Figure 7.5.4) by
loosening 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 the
spring that is bent radially outward against
the spring clamp (14) and the portion of the
coil adjacent to the tang should lay on the
surface of actuator block (5). See Figures
7.5.4 and 7.5.5, assembled outline of
spring. Tighten screw (28) which will
draw 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
radially inward against the raised lip, see
Figure 2.16.2.1. The curve of the spring is
such that it will not slip under the edge of
the raised lip easily. On the bottom spring
coil opposite the spring tang push radially
outward and twist the spring clockwise.
This will allow the edge of the spring to
slip over the lip and be pulled under the
rest of the lip by the twisting motion. If this
does not seat the spring or the spring goes
under the lip opposite the spring tang but
won't rotate, use a wide blade screwdriver
to force the inside edge of the spring up to
and 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 be
to force it up to the lip. The spring tang
must be up against the edge of the lip on
the tension ring as shown in Figure
2.16.2.1, section A-A. If it is not, the pay-
off tension can be set with a gap at section
A-A and then when the carrier goes into
production the working of the spring will
FIGURE 2.16.2.1: TENSION SPRING INSTALLATION
A
A
SECTION A-A
SPRING
ADJUSTING RING
TORSION SPRING
pull the spring tang against the lip, but this
will change the payoff tension. If this
tension is critical, hose problems could
develop.
6. Replace the adjusting ring (3) into
adjusting clamp (7) and back into the
carrier housing (1) as shown in Figure
7.5.4.
7. Adjust pay-off tension for plait material.
Tighten the screw (32) to secure the
adjusting ring in place. Use an allen
wrench and hand tighten. The ring (3)
should not move.
2.17. CARRIER LATCH. Every MR-15 PLC-T
carrier incorporates a simple, yet positive,
latch to secure the carrier assembly to the
shuttle shaft, or the shuttle extension.
The latch involves a 90 rotation to engage and
latch to the spindle. See Figure 2.17.1. It also
entails a slight pushing force to release the
latch for rotation.
MI's latch tool, part number S-5503, is
recommended for this purpose.
All carriers, when viewed from the front and
mounted to the shuttle assemblies in safe,
operating latched position, will be observed to
have the latch bars form a circle when they are
all in the latched position.
Double check to insure all carriers are in the
latched position.
CAUTION
"Always" switch the inside safety
switch to the "ON" position
immediately upon entering the
safety 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-15 PLC-T carrier is
interchangeable with another carrier and any
carrier may be latched to any shuttle assembly
on the same deck.
With this in mind, and assuming all or the
majority of all carriers will be changed at one
time, experience will indicate a preferred
sequence of package change.
1. Remove any one carrier assembly from the
shuttle using the latch tool. Place this
carrier aside. (This will be the last carrier
replaced when all others are loaded.)
2. Remove the empty bobbin or yarn tube
from the same shuttle spindle and replace it
with a full package or bobbin.
3. Remove an adjacent carrier from the
FIGURE 2.17.1: CARRIER LATCH
UNLATCHED POSITION
LATCHED POSITION
HOLE
LATCH BAR
LATCH BAR
HOLE
shuttle spindle and place this carrier onto
the first shuttle having the full package.
Lock the carrier.
4. Repeat sequence until the full deck is
reloaded.
2.19. PREFORMING OF WIRE. Preforming is
the practice of producing a set or curl in an
otherwise straight strand. The curl is
accomplished by drawing the strand over a
stationary or rolling surface under tension to
introduce compressive stress to one side of a
strand.
Preforming serves a very useful purpose in
producing certain wire braided structures.
NOTE
Using the stationary preform pin
on the L-support is the preferred
method for the MR-15 braiders.
See Figure 7.5.13.1.
For other braid applications, the ability of a
carrier to provide "rolling contact" between the
strand and carrier surfaces is the primary goal
for minimizing friction. This then allows the
strand to retain its usefulness as a
reinforcement member without disturbance to
the strand surface.
The MR-15 PLC-T braider has one carrier for
all conditions and materials, and offers pre-
forming as an elective capability.
A minor change in threading path can
introduce a preform pin. See Figure 2.19.1.
The variables for pre-form will include:
Wire strand diameter
Carrier release tension
Preform pin diameter
Number of ends per bobbin
In the majority of hose applications, the
standard braider pre-form components will
suffice.
FIGURE 2.19.1: OVER CENTER ROLLERS AND
PREFORM PIN
FIGURE 2.19.2: OVER CENTER ROLLERS
TO
HOSE
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 the
Mayer 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
details on winding adapters.
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 adequate
axial force is maintained so that the bobbin is
securely held by the winder.
2.20.2. WINDING QUALITY. Winding quality
is important to all braiding results.
Proper let-off tension control, suitable traverse
"stop" adjustments and guide beak condition
will benefit the quality of braider performance
and resulting braid product quality. Catenary
tests should be run as required.
2.20.3. BOBBIN CARE. Proper care of the MR-
15 PLC-T bobbin will provide the user with
long trouble-free service. The user is
cautioned against:
NOTE
1. Tensions in excess of 2.25 lbs./bobbin
from winder supply spool let-off can
exceed bobbin flange strength and
shorten the bobbins useful life.
2. Improper traverse setting at winder.
3. Rough handling of aluminum bobbins
when full or empty. Do not drop.
2.21. YARN BRAIDING. The MR-15 PLC-T
Braidmatic features the capability to convert to
a deck from braiding wire on 20 lbs. capacity
aluminum bobbins to yarn braiding with large
capacity packages wound on a paper tube or
fabricated bobbin.
The changeover from wire to yarn or yarn to
wire 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-15 PLC-T yarn package is prepared
according to Figure 2.21.1.1, and is wound on
yarn tube #240-4016, Figure 2.21.1.2. Names
and addresses of both tube and yarn suppliers
are available by contacting MI.
FIGURE 2.21.1.1: S.L.O.Y. PACKAGE
MAX. BULGE IN
6.4 mm
8 IN TRAVERSE
203 mm
6 IN (MAX)
165 mm
7/16 IN
11.1 mm
DIRECTION OF WIND
MUST BE AS SHOWN NOTE:
YARN MUST BE
BELOW ENDS OF
TUBE.
TOTAL PACKAGE WEIGHT
MUST NOT EXCEED 7 POUNDS
(3.8Kg)
FIGURE 2.21.1.2: S.L.O.Y. TUBE (240-4016)
1.75 IN
44.5 mm
+.01
-.00
+.25
-.00
VIEW A-A
LAY OF
PAPER
8.86 IN
225 mm
+.00
-.062
+.00
-1.5
.02
5
.
0
1
.
2
5
.44 IN
11.2 mm
.
2
5

I
N
6
.
4

m
m
A
A
2.4 IN
61 mm
1.
2. CONSTRUCTION:
SONOCO PRODUCTS COS SPIRAL DUROLENE
WITH SEAMLESS LOW MARK OUTSIDE PLY.
NOTCHES TO BE AT 180 2.
2.21.2. ADDITIONAL PARTS FOR
CONVERSION TO YARN PACKAGES. The
conversion from an MR-15 PLC-T deck
braiding wire on an aluminum flanged bobbin
to large capacity yarn on paper tube or
reusable fabricated bobbins will require the
addition of shuttle spindle extensions. See
Chapter 7, Figure 7.5.11, and Figure 7.5.12.
All parts are interchangeable with any MR-15
PLC-T lightweight shuttle assembly.
2.21.3. PROCEDURE FOR FIELD CONVERSION
OF WIRE TO YARN.
CAUTION
could occur.
be worn.
procedure
instructions.
1. Remove carrier and wire bobbin from
shuttle for each assembly.
2. Remove carrier "L" support (2, Figure
7.5.8) by removing four M6 screws and
washers. Pull "L" support from shuttle.
3. Grease shaft with anti-seize compound.
Push shuttle extension (2, Figure 7.5.11)
onto shuttle shaft making sure that the
orientation between the new shuttle
extension 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, Figure
7.5.11) onto adapter and orient to mate
slots over shuttle part (1).
5. Assemble four M6 screws and washers and
tighten with M5 allen wrench. Torque to
14Nm (10.3 ft-lbs). Permatex all screws at
assembly.
6. INSTRUCTIONS FOR INSTALLATION OF
THE MODIFIED SHUTTLE EXTENSION
240-5140. The shuttle extension is
installed per the instructions in the MR-15
PLC-T manual. When this is complete,
install an M6 x 6 DIN 916 set screw at
each location shown, using Loctite 222 on
the threads.
FIGURE 2.21.3.1: SHUTTLE EXTENSION
SPINDLE
M6 X 6 DIN 916
4 PLACES
240-5140
SHUTTLE
EXTENSION
The remaining hole is used to inject oil or
any anti-seize lubricant. It is tapped for an
M4 thread and is used if the shuttle
extension should be difficult to remove.
Force a suitable penetrating oil through the
hole. (See Figure 2.21.3.1)
CAUTION
Gap between plastic tip on the L-
bar and wear screw (15, Figure
7.5.5) on the carrier assembly
should never exceed 2 mm.
CAUTION
Replace the wear screw (15,
Figure 7.5.5) before 2 mm is
exceeded. Quality of the hose
could be affected.
NOTE
Check to see that the timing of all
assemblies on each shuttle
provides for the mounting of each
carrier in the same orientation as
with wire braiding. The conversion
is now ready for loading prepared
yarn packages for braiding.
NOTE
Loctite 222 all screws at
assembly.
2.21.4. YARN BRAIDING CARRIER OPTIONS.
1. Usually yarn requires less strand pay-off
tension than wire and the light torsion
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 may
either be removed or bypassed in the
threading.
NOTE
If a stationary preform pin is
being used on the L-support,
it has to be replaced with a
strand roller.
NOTE
The shuttle extension (2, Figure
7.5.11) without the 4 set screws,
must be removed after every 150
hours of operation and its interior
treated with an anti-seize
compound. Failure to do this will
allow the adapter to freeze onto
the spindle. This will make
removal extremely difficult.
SECTION VI. BOBBIN RUN-OUT DETECTOR
CAUTION
could occur.
be worn.
procedure
instructions.
2.22. BOBBIN RUNOUT DETECTOR. The
bobbin runout detector will stop the MR-15
PLC-T braider when a bobbin has run out of
material. Each carrier has an extension on a
particular strand roller. During normal
operation of the braider, this extension is held
in a position so it will not strike the small
spring-like device that is hanging from the top
of the shield.
When a bobbin becomes empty, there is no
longer any tension on the compensator plate so
the 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 to
install the unit.
FIGURE 2.22.1: LEFT HAND SENSOR
#12 ROTOR FOR 36 SHUTTLE BRAIDERS
# 8 ROTOR FOR 24 SHUTTLE BRAIDERS
LEVEL TOP EMPTY POCKET OF
#1 ROTOR FOR 24 & 36
CARRIER BRAIDERS
COMPENSATOR SHOWN IN
RELAXED POSITION
SIMULATING AN
EMPTY BOBBIN
SENSOR ASM.
BAR
JUMPER TO RIGHT HAND SENSOR LEFT SIDE SENSOR LOCATION
C
L
DECK
PROBE HOLDER
3 TO 6 mm
PROBE
0 TO 5 mm
C
L
SPACER WASHER
HEX BOLT
SECTION A-A
TRIP ROLLER
A
A
FIGURE 2.22.2: RIGHT HAND SENSOR
LEVEL TOP EMPTY POCKET OF
#12 ROTOR FOR 36 SHUTTLE BRAIDERS
COMPENSATOR SHOWN IN
RELAXED POSITION
SIMULATING AN
EMPTY BOBBIN
SENSOR ASM.
BAR
JUMPER TO LEFT HAND SENSOR
RIGHT SIDE SENSOR LOCATION
C
L
DECK
PROBE
3 TO 6 mm
PROBE
0 TO 3 mm
C
L
SPACER WASHER
HEX BOLT
SECTION A-A
TRIP ROLLER
A
A
HOLDER
WIRE TO OPERATORS BOX
SHIELD
24 & 36 SHUTTLE BRAIDERS
# 8 ROTOR FOR 24 SHUTTLE BRAIDERS
ATTACH TO X1/21 TERMINAL
SECTION VII. BROKEN BRAID DETECTOR
2.23. ASSEMBLY INSTRUCTIONS. (Figures
7.5.29, thru 7.5.32).
CAUTION
1. Turn electrical power off at the main power
control.
2. Place the assembly (Figure 7.5.31) on the
stand 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) secure
the bracket assembly to the slide assembly
in the approximate position desired in
relation to the braid point.
3. Insert the two ring halves (18) in the braid
detector holder (14, Figure 7.5.31). The
ring halves should snap in or out without
excessive force. No tools should be
required to install or remove the ring
halves. All adjustments have been set at the
factory. A few minutes practice installing
and removing the ring halves will allow the
operator to develop the speed desired.
4. Insert the holder (14) containing the ring
halves into the spring assembly. The ring
can be inserted from the front or rear of the
spring 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 the
springs about mm. This adjustment
controls the sensitivity of the sensor. A
larger gap decreases the sensitivity, a
smaller gap increases the sensitivity. All
four gaps must be set identically. Too
great a gap will let the ring move without
shutting off the braider.
6. Turn the main power back on. Verify that
the sensor is working properly by pushing
the ring in the direction of hose travel.
NOTE
DO NOT RUN THE MACHINE AT
THIS TIME. An alarm message
should show on the Alarm Box
Display.
Reset the ring and then press the Reset
button. The alarm should go out. Now push
on the springs individually and verify that
each spring will cause the alarm to come
on.
7. Using extreme caution, run the machine
and test by tripping any one of the springs
or pulling the ring in the directions of hose
travel. The braider must shut down and not
restart. It is not necessary to have hose
threaded through the sensor for this test.
NOTE
If the sensor is too sensitive, the
mm gap can be increased.
However, if the gap is increased
too much, it is possible for the
holder to move out of the springs
without tripping the braider off. If a
new gap is set, the tests should be
repeated. In some cases, the
sensor may operate because a
compensator is not working
properly. This will allow the hose
to pull very hard against the side
of the ring (18) and can trip the
sensor. The proper procedure is to
correct the compensator.
8. After completing the test in steps 6 and 7
successfully, the sensor is ready to use. The
ring halves should be removed when
theading the braider. After threading the
braider, including braid detector holder
(14), reinstall the ring halves. The sensor
operates by moving in the direction of hose
travel whenever any of the pins engage a
loop or snarl on the hose.
This movement closes the gap between the
spring and the spring plunger which
electrically grounds out the circuits that
control the running of the braider. This
grounding stops the machine.
9. A suggested procedure for restarting the
machine after a defect has moved holder
(14) enough to turn off the braider is as
follows:
a. Turn the inside safety switch "ON".
b. Remove the holder (14) completely out
of the spring holders, if it isn't already
out.
c. Remove the ring halves.
d. Jog the braider until the defect is 50 to
100 mm "downstream" of the spring
assembly.
e. Slide the ring "upstream" of the defect
and then reinstall the ring halves.
CAUTION
Do not push the reset button until
the sensor is completely reset, the
cause of the defect has been
corrected, and the braider is ready
to be run. Failure to follow this
and all other machine safety
procedures can result in serious
injury to personnel working on the
braider through inadvertent start-
up of the braider.
f. Now push the ring, with ring halves,
back into the spring assembly. The
springs 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 resume
operations.
SECTION VIII. DRIVE CARTRIDGE AND CHANGE GEAR DRIVE (FIGURE 7.5.22, &
FIGURE 7.5.23)
THE INFORMATION IN SECTION VIII IS FOR THE PLC-T STANDARD DRIVE ONLY.
SEE FIGURE 6.12.2.1 FOR DUAL DRIVE PINION ASSEMBLY.
CAUTION
could occur.
be worn.
procedure
instructions.
2.24. FUNCTION. Two cartridge units support
the deck drive assemblies.
Pinion Cartridge Assembly
Driven change gear shaft
Drive pinion to one rotor assembly
gear
Sprocket Cartridge Assembly
Driven shaft for deck silent chain drive
from deck drive shaft
Driver change gear shaft
2.25. REMOVAL OF CARTRIDGES. Both
cartridges can be removed through the change
gear door. Figure 7.5.22 shows location of
mounting screws for the 24 Carrier braider.
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
parts are interchangeable as received from the
manufacturer. For reasons of tolerance
accumulation, it is necessary to custom fit the
axial position of the shaft (5, Figure 7.5.22 [24
Carrier], 5, Figure 7.5.23 [36 Carrier] ) by
adjusting the thickness of the spacer (2) at
assembly. The desired axial play or clearance
with all parts locked together, should be 0.15
mm. Reducing the thickness of this spacer will
increase the axial clearance.
The sealed ball bearings (18 and 19) are a
press fit to shaft and a slide fit to the cartridge
housing.
It is important to torque the nut (15) to 45-50
ft-lb. (61-68 Nm) to insure a positive lock to
contain the rotor pinion gear (9). The safety
washer (16) must be engaged.
2.26.2. SPROCKET CARTRIDGE ASSEMBLY.
The same instructions for the pinion cartridge
also apply to the sprocket cartridge assembly.
In addition, the sprocket cartridge has an
additional custom fit utilizing shims to align
the upper driven silent chain sprocket with that
of driver silent chain sprocket (8, Figure
7.5.22 & 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. A
straight edge will serve to determine this axial
position.
It can be seen from Figure 7.5.22 & 7.5.23 (36
Carrier), 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 face
of upper change gears (23) within 0.2 mm of
lower change gear.
2.27. CHANGE GEARS DRIVE. The MR-15
PLC-T change gear drive is common to other
braiders in that the rotor RPM may be varied
with respect to the drive shaft input speed. See
Figure 2.29.1.
The access to the change gear of MR-15 PLC-
T deck is through a latched door at the rear of
the braider.
CAUTION
Moving elements in gear drive
enclosure.
Do not circumvent interlock or run
machine with change gear door
open.
2.28. REMOVAL OF CHANGE GEARS. Each
change gear cartridge shaft includes a cap (7,
Figure 7.5.22) together with an M8 screw and
washer to retain the change gear to cartridge
shafts. Removal of screw, washer and cap will
free the respective gear to be pulled from the
shaft. A key provides the gear positive timed
rotation with the shaft.
If a change gear resists being pulled from the
shaft, a gear or wheel puller will aid in
removal. Note the location of the shoulder on
the gear and reinstall it in the same position.
2.29. MR-15 PLC-T CHANGE GEARS. Deck
change gears are available from MI in sizes
shown in Section 7 (Parts List).
FIGURE 2.29.1: CHANGE GEAR DRIVE FOR 24 AND 36 CARRIER DECKS
PLC-T STANDARD DRIVE ONLY
NOTE: AS VIEWED FROM REAR OF MR-15 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.
ROTOR
GEAR 94 T
ROTOR DRIVE
PINION 32 T
DECK CHANGE GEARS
136 T IN PAIRS
55 T STD. 240-2023.00 CHAIN SPROCKET
54 T OPT. 240-2024.00 MR-15 PLC-T 24 CARRIER
55 T STD. 536-2023.00 CHAIN SPROCKET
50 CYCLE
2.30. CHANGE GEAR TABLES (SPEED LEAD
CHARTS). The tables are shown here to allow
the user to make setups.
2.30.1. DESCRIPTION OF TABLES. Tables are
arranged according to high, medium, and low
rotor speeds in combination with high,
medium and low production rates. Therefore 9
charts are required for each type of MR-15
PLC-T braider with a given take-up. For the
MR-15 PLC-T take-up only 29 change gears
are required because range gears permit use of
these gears for 3 separate ranges of production
rate.
Numbers across the top of table represent the
number of gear teeth for MR-15 PLC-T deck
change gear combination (driven and driver).
Numbers in table body are leads in inches or
millimeters produced by a given deck and
take-up change gear combination.
Numbers in second and third columns from the
right present the number of teeth for possible
take-up change gear combination.
Numbers in far right hand column represent
the theoretical rate of production in inches or
meters per minute.
Information in the upper center gives drive
shaft RPM information.
2.30.2. EXAMPLE.
Braider: 2 Model MR-15 PLC-T, 24 carrier
decks braiding ("S.L.O.W.") wire.
1. Calculate "lead" for each reinforcement
layer.
2. Find desired lead in table body in column
beneath the deck change gear
combinations which will produce the
maximum rotor RPM recommended by
MI.
3. At right of this row find "take-up" change
gear combination.
4. Find production at far right of row, using
the same combination of take-up gears.
5. Rotor RPM and carrier central RPM are
shown at the base of column for respective
deck change gears.
2.30.3. EXAMPLE.
Braider: 2 Model MR-15 PLC-T, 24 carrier
decks braiding wire with a maximum
recommended rotor RPM = 225.
HOSE CONSTRUCTION:
2 wire braid at 54 44 braid angle
Lead of first braid = 26.54 mm
Lead of second braid = 29.21 mm
Step 1: Select deck gears for first braid
based on 225.1 rotor RPM
Step 2: Closest lead shown is 26.5 mm using
54 teeth driven and 82 teeth driver
deck gears.
Step 3: Take-up change gears are 65 teeth
driven and 71 teeth driver. Range
gears are 42 driver and 65 driven.
Production is 1.494 meters per
minute.
Step 4: Using 1.494 meters per minute
production, the closest lead to the
described 29.21 mm is 29.1 mm.
Step 5: Deck change gears for 29.1 lead are
79 teeth driver and 57 teeth driven.
NOTE
If more than 2 braiding decks
would be used, the same steps
would be continued.
SUMMARY:
1st Wire Deck
Lead 26.5 mm
Rotor RPM = 225.1
Deck Change Gears = 54 teeth driven
82 teeth driver
2nd Wire Deck
Lead 29.1 mm
Rotor RPM = 205.4
Deck Change Gears = 57 teeth driven
79 teeth driver
Take-Up
Production Rate = 1.494 meters per minute
Change gears = 65 driven, 71 driver
Range gears = 65 driven, 42 driver
MR-15 PLC-T BRAIDMATIC
SPEED LEAD CHARTS
(NOT USED FOR THE PLCT-F DUAL DRIVE)
(MR-15 / 18 CARRIER IS NOT OFFERED WITH CHANGE GEARS)

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BOX

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
decks may be driven in series.
Provide a silent chain sprocket on the drive
shaft 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 chain
sprocket. The drive shaft is mounted
within the lower base frame and is self-
lubricated by splash lubrication. (Refer to
paragraphs 2.33 and 2.34.)
2.32. REMOVAL OF DRIVE SHAFT
ASSEMBLY. The shaft unit is mounted into the
lower deck frame with flanged ball bearing
units at either end. The shaft can be removed
only from rear of the deck. (Servicing the
drive shaft shear pin coupling can be done
without removing the shaft.)
CAUTION
Moving elements in drive shaft
area.
Disconnect power source from
deck.
Minor personal injury to hands
and arms could result.
1. Drain oil as required.
2. Disconnect silent chain at connecting link
and remove.
3. Remove tunnel covers where necessary to
expose drive couplings and key at front of
drive shaft. Remove couplings and key
(12, Figure 7.5.24 or 7.5.25 (36 Carrier)).
Care should be taken to remove burrs from
drive shaft to prevent damaging oil seals.
4. Remove screws (5) from flange (4) at the
rear of the deck and the drive shaft
assembly can now be removed from the
deck by pushing or driving from surface A,
Figure 7.5.22. It is not necessary to remove
screws (5) from flange (4) at front of deck.
2.33. SHEAR PIN OVERLOAD. The object of
this unit is to place two shear pins between
spaced flanges. The shear pins have been
designed to operate under all normal loads
associated with the drive functions, but will
fail if an overload occurs.
The purpose is to provide overload protection
to other deck members.
Figures 7.5.24 and 7.5.25 (36 Carrier), show
the design of the coupling shear pins, the
bushing (7) shear pin ring (6) and the shear
member (9) (two per deck retained to shear pin
ring with M6 set screws (13)).
2.34. SHEAR PIN ASSEMBLY INSTRUCTIONS.
Several points are critical to the proper service
of this coupling:
CAUTION
1. With shear pins removed, the silent chain
drive sprocket (2) must be free to rotate on
the brass distance bushing (8, Figure
7.5.24 or 7.5.25 (36 Carrier)).
2. The gap shown in Figure 7.5.24 or 7.5.25
is the minimum and maximum axial play
between shear pin flanges. Adjustment to
this gap is by changing the length of the
brass bushing (8).
NOTE
Correct the source of overload
prior to replacement of shear pins.
The deck should be rotated by hand and
subsequently "jogged" to insure that
continued operation is safe and practical.
Refill oil sump if it was drained.
SECTION X. ROTOR AXLE ASSEMBLY (FIGURE 7.5.21)
CAUTION
Only skilled/trained mechanics
should be allowed to work in this
area of the braider because of the
moving 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 (no
oil on floor) and safe.
Beware of sharp edges on parts.
Beware of the weight of parts.
Read and study manual
instructions prior to work.
In conclusion: Mechanics
performing maintenance in these
areas must be highly skilled and
trained on this equipment.
Mechanics must treat this
equipment with the utmost respect
and observe all safety
precautions. Contact Mayers
Service Department if there are
questions.
2.35. FUNCTION. The rotor axle assembly
serves 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 the
major and minor planetary gears on each rotor
assembly (Figure 7.5.21).
The axle unit is fastened to the MR-15 PLC-T
upper deck frame and the automatic oil
lubrication supply for each rotor assembly is
connected to the rear of each axle.
All rotor axles are identical for each deck.
Each rotor axle assembly is a "matched
assembly" to a given rotor assembly.
2.36. MATCHED ASSEMBLY-DEFINED
(ROTOR TO AXLE). It is important to
understand the minor, yet significant reasons
for one rotor axle not having complete
interchangeability with other rotor assemblies.
The lack of interchangeability is based on the
following differences.
2.36.1. BEARINGS - RADIALLY MATCHED.
(Refer to Figure 7.5.21). The front and rear
roller bearings (3 and 4), which support the
rotor assembly have matched inner and outer
races. The bearings were purchased as an
integral bearing unit and must function
together. Replacement of any one part of each
front or rear bearing must include replacement
of matching parts for that particular bearings.
2.36.2. AXIAL MATCHED ASSEMBLY (ROTOR
TO AXLE). (Refer to Figure 7.5.21). Each
rotor assembly and each rotor axle assembly
are identical in design and are manufactured to
close tolerances. However, to achieve the
desired axial play of any one rotor to its
adjacent rotor it is essential to provide a
custom fit at assembly of one bearing ring (12,
Figure 7.5.21).
Instructions will follow for field match-up of a
rotor assembly with a different rotor axle
assembly.
It should be understood that the steps will be
the same regardless of which or how many
parts will be changed.
2.37. REMOVAL OF ROTOR AXLE
ASSEMBLY.
1. Remove shuttles from deck.
NOTE
Mark or tag the transfers the
shuttles are removed from so you
can reinstall the shuttles at these
locations.
CAUTION
Heavy parts (190 lbs., 86 Kg.)
Do not attempt to remove without
help.
Minor personal injury could result.
2. Remove the rotor assembly from the rotor
axle; see Section XI of this chapter.
3. Disconnect the Bijur lubrication fittings
from the rear of the rotor axle assembly.
4. Remove six M12 socket screws from the
rear of the deck upper frame.
5. Push the rotor axle assembly from the
upper deck frame. The rotor axle timing
pin may remain in the frame.
2.38. ASSEMBLY OF ROTOR AXLE TO DECK
UPPER FRAME.
1. Check to see that:
a. The upper deck frame mounting hole
and surface is free from burrs and dirt.
b. The rotor axle to be installed is
equipped with proper bearing inner
races for matched assembly with the
rotor components. The races are to be
seated to the rotor axle, with their oil
holes oriented to the Bijur meter units.
c. The rear NA 135 x 165 x 35 bearing is
equipped with the cage assembly (3,
Figure 7.5.21). (Caged rollers must be
kept clean until rotor is assembled over
axle.)
d. The major sun gear is properly fitted to
the rotor axle with (4) M5 screws and
lock washers. Permatex is to be applied
to the screw threads to prevent
loosening caused by vibration. The key
in the rotor axle must be properly
fitted.
e. Bijur meter unit items 6, 7, and 27 are
correct size and seated fully into tapped
holes (Figure 7.5.21).
NOTE
When installing axles onto decks,
the timing hole will orient the axle
to the deck.
f. Oil passages through rotor axle are free
from 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 axle
assembly to timed engagement with the
M10 locating pin (11). Verify that the
Bijur meter units are in the same position.
3. Assemble six M12 x 60 DIN 6912 socket
screws (16) together with six M12 DIN
127 lockwashers (20) from rear of deck
frame and torque screws to 65-70 ft-lbs
torque. Use Permatex on screw threads.
4. Check that screws and timing pin do not
protrude past face D, Figure 7.5.21.
5. Check for axle to axle location and
squareness using gauge 240-1078 (Refer to
Chapter 8).
6. Check for axle to deck location using
gauge 240-1078 (Refer to Chapter 8). Use
set master 524-1079 to set the 240-1078
gage.
Rotor axle is now ready to receive the rotor
assembly.
2.39. FIELD MATCHING OF ROTOR
ASSEMBLY TO NEW OR DIFFERENT ROTOR
AXLE.
CAUTION
See all Safety Notes from Section
X: Rotor Axle Assembly.
NOTE
Rotor assembly to be installed
must be equipped with outer races
from "matched" front and rear
rotor axle bearings of the axle the
rotor frame is being installed on.
1. Assemble rotor assembly to rotor axle
assembly according to instruction under
Rotor Assembly Section XI.
2. Assemble three-part thrust race together
with bearing ring (12, Figure 7.5.21).
3. Install the rotor axle nut (18) part number
KM8. Place a magnetic dial indicator
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.
CAUTION
Heavy parts (190 lbs., 86 Kg).
help.
4. With nut tightened, read and record axial
play. The desired axial play of 0.02 to 0.05
mm is obtained by use of shims (23, 24, 25,
and 26) between bearing ring (12) and
thrust race (13). To remove thrust race
(13) from bearing ring (12), rap bearing
ring (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, and
26) to obtain correct axial play. Removal
of spacer parts is done by removing the
KM8 nut (18) and carefully "pulling" the
rotor about 3/4 inch (20 mm) to the front
and "pushing" the rotor back to enable the
grasping of the four-part outer race
assembly.
5. Reassemble the thrust race (13) onto the
bearing ring (12) and install it back onto
the rotor axle (1). Install safety washer (17)
and locknut (18) and tighten to a torque
specification of 20-35 ft.-lbs./27-47 Nm.
Set the magnetic base onto the rotor frame
and 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 a
light push fit and is held in location by a key
and (4) M5 x 16 DIN 6912 socket screws (19).
2.41. REMOVAL OF SUN GEAR FROM ROTOR
AXLE. (Figure 7.5.21) The rotor axle assembly
is removed from the upper deck frame. (See
separate instructions, paragraph 2.37.
1. Remove outer race (3-3) and needle
bearing assembly, if attached.
2. Remove the four M5 screws (19) holding
the sun gear onto the axle. With the aid of
three 6 mm diameter holes through the rear
of the rotor axle, tap the inner ring (3-1) off
its seat. This will also move the sun gear
(2) far enough so it can be removed by
hand or allow a bearing puller to be used
on the sun gear.
To use a bearing puller, move the inner
race (3-1) and sun gear (2) about 6 mm
from their initial position. This should
leave enough gap between the sun gear (2)
and inner race (3-1) to insert a bearing
puller and remove the sun gear.
2.42. ASSEMBLY OF SUN GEAR TO ROTOR
AXLE. It is important that the matchup of the
sun gear with the rotor axle provide proper
timing.
1. Place the key (31) into the slot on the axle
(1).
2. Slide the major sun gear (2) onto the rotor
axle (1). The slot in the gear must line up
with key (31).
3. Apply Permatex (from the 3M company)
to the threads of the M5 screws (19) and
torque to 5 ft.-lbs. (7 N-m) to securely lock
the gear in place. Tighten the first screw,
then go to the screw on the opposite side of
the gear and tighten it. Then go to the
screw on the opposite side of the axle and
tighten it. Continue this until all screws are
tight.
2.43. REMOVAL OF REAR BEARING INNER
RACE . (3, Figure 7.5.21). Rotor axle
assembly is first removed from the upper deck
frame. (See separate instructions, paragraph
2.37.)
1. Remove major sun gear (2), paragraph
2.41.
2. Remove needle bearing assembly (3).
3. With the aid of three 6 mm diameter holes
through the rear of the rotor axle, tap the
inner race off its seat. MI bearing puller
#524-1074 may be used.
2.44. ASSEMBLY OF REAR BEARING INNER
RACE. (Note criteria for matched bearing
components).
1. Be sure that the inner race oil hole is
aligned with the Bijur meter unit.
2. Press oiled inner race onto the rotor axle so
that the race is seated squarely against
shoulder.
3. Replace needle bearing assembly (3,
Figure 7.5.21).
2.45. REMOVAL OF FRONT INNER BEARING
RACE. (4, Figure 7.5.21). This can be done
with the rotor axle attached to the deck frame.
1. Using a brass pin, tap the rear of the race
toward the outer end of the rotor axle.
When the race has moved forward about 5
mm, use a wheel or modified gear puller to
remove the race from the axle. MI bearing
puller #240-1073 may be used.
See Chapter 8 for additional details.
2.46. ASSEMBLY OF INNER BEARING RACE.
This operation may be performed with the axle
in 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 to
squarely seat the race against the shoulder.
NOTE
A new race assembled to a rotor
axle will require a check of the
axial clearance. Refer to separate
instructions, 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
performed by the MR-15 PLC-T rotor
assembly are explained in Chapter 1, Section I
of this manual.
It is the object of these instructions to provide
information for the removal, disassembly,
reassembly, care and maintenance of the rotor
assembly.
See Chapter 8 for additional details.
2.48. GENERAL. Each MR-15 PLC-T rotor
assembly is the same design as any other rotor
assembly. Each rotor assembly is numbered
and is a matched set to the rotor axle assembly
to which it is attached.
Each rotor assembly has been factory
assembled and adjusted for proper operation.
Rotors are stamped with numbers on the front
face of each rotor frame beneath the cap (16,
Figure 7.5.19), and each pocket transfer is
marked.
2.49. REMOVAL OF ROTOR ASSEMBLY.
Removal of the rotor assembly should only be
done after all shuttles have been removed from
the deck. (See shuttle removal instructions,
Chapter 2, Section II).
CAUTION
Moving elements in rotor
assembly area.
Disconnect power and remove
upper change gear.
Minor personal injury to hands
and arms could result.
1. Remove four M6 screws (15, Figure
7.5.19), four ST M6 washers (23, Figure
7.5.19), and remove rotor cap (16), and O-
ring (20).
2. Bend tang of MB8 safety washer (17) from
KM8 nut (18) and remove KM8 nut from
the rotor axle, Figure 7.5.21.
CAUTION
Heavy parts (190 lbs., 86 Kg)
help.
a. Rotor Frame Lift Kits are available.
See Figure 9.1.13 in Chapter 9,
Special Tools.
3. Removal involves two steps: Use nylon
adapter 240-3047 (Figure 9.1.9) to protect
the threads on the rotor axle. Screw the
adapter onto the threads on the end of the
axle.
a. Carefully pull the outer face of the
rotor assembly 3/4 inch (20 mm)
forward and then push the rotor face
back to its original position.
This should expose the four-part thrust
race unit, (12, 13, 14, 15 and the shims
23 through 26 of Figure 7.5.21).
Slide this four-part group off of the
rotor axle and place them in a clean
place for reassembly to the same axle.
These are a matched set. DO NOT
SEPARATE.
b. Rotate the rotor to place the front cam
follower cartridges vertically in (12
and 6 o'clock orientation) for removal.
CAUTION
Heavy parts (190 lbs., 86 Kg)
help.
c. Carefully remove the rotor assembly.
NOTE
Care should be taken when
tipping 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
have not been removed.
4. Replace all thrust race parts in their proper
location for later use, unless they are
damaged and must be replaced.
2.50. REASSEMBLY OF ROTOR ASSEMBLY TO
ROTOR AXLE. Use nylon adapter (240-3047)
to protect the threads on rotor axle. Note:
Rotor Frame Lift Kits are available. See
Figure 9.1.13 in Chapter 9, Special Tools.
1. With the rotor assembly setting vertically
on the front face, the three-part thrust race
(13, 14, and 15, Figure 7.5.21) is
assembled into the rotor housing. It is
important to place the thrust races as
shown. A light smear of grease on the
races will prevent them from moving in the
rotor bore when the rotor is tipped
horizontally for mounting to the axle.
2. Lift the rotor assembly to the rotor axle
with the front face tipped downward.
3. Slide the rotor assembly onto the rotor axle
taking care to see that the thrust races (step
1) remain in the proper position for correct
seating. If the rotor assembly was on the
machine be sure that the pocket transfer
marks align in the same position they were
in before removal.
4. Rotate the minor planetary gears to allow
the rotor to be pushed onto rotor axle.
5. Orient the rotor gear to mesh with adjacent
rotor gears for proper pocket alignment.
6. The rotor assembly is now able to be
pushed into final position with the outer
face flush with adjacent rotor.
7. Reassemble matched set of four-part front
thrust race unit. (Figure 7.5.21)
8. Reinstall the safety washer (17) and nut
(18, Figure 7.5.21). See paragraph 2.39,
and Chapter 8 for additional details.
9. Check to see that the rotor assembly is free
to rotate and for the proper 0.02 - 0.05 mm
(axial) clearance. This can be checked with
dial indicator attached to outer face of
adjacent rotor.
10. Before assembly of cap to rotor face with
four M6 screws, it is advised that the deck
rotors be run to insure that the lubrication
system is delivering oil through the rotor
axle. This can be seen by oil leaking from
rotor axle bore at front of rotor.
11. Prior to reloading shuttles into deck,
transfer one shuttle from each of the six
transfers through the newly assembled
rotor to check the axial clearance, 0.05 mm
min. in transfer to 0.45 mm max. out of
transfer, of the guide key to shuttle
assembly.
12. The final check of the reassembled rotor is
to see that the cam track sensor units are in
the correct location as explained in
paragraph 4.12.
2.51. ROTOR CAM FOLLOWER ASSEMBLIES.
The function of both front and rear cam
follower assemblies is to react the centrifugal
load of the shuttle between rotor transfers and
to contribute to the smooth transfer of the
shuttle from one rotor to the next.
The basic precision roller bearings used in
both locations (front and rear) are the same and
have been engineered to share both radial and
thrust (axial) loads from a cantilevered shaft
mating with the shuttle cam tracks. The
bearing units are automatically lubricated from
oil being forced into the rotor axle assembly
and then through the holes in the rotor frame to
the individual cam followers.
These roller bearing units have been
manufactured with special care to insure that
the assemblies are free from dirt, water, and
other potentially harmful substances. Any
reason for field service must include this care.
2.52. CAM FOLLOWER ECCENTRIC
ADJUSTMENT. Both front and rear cam
follower assemblies have been designed to
allow precise adjustment to set the desired
clearance between the cam track and the
mating cam follower extended shaft. Both
cam follower cartridges have been
manufactured with 0.7 mm eccentricity
between the inside bore and outer 45 mm
diameter of the cartridge. Rotation of the
cartridge will permit radial adjustment without
movement from the center line of the rotor
pocket. Slots have been machined in both
front and rear cam follower cartridges to be
used 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 bearings
have been engineered to provide long service
life for the MR-15 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.
A failure of the roller bearing will likely cause
wear to the rollers and their mating surfaces.
This wear, when allowed to continue, will
logically show up as an increase in the bearing
clearances. This wear will allow the shuttle
cam track outer diameter to contact the sensor
and turn off the motor.
The Touch Screen Alarm Box Panel will assist
the braider operator in locating the damaged or
worn cam follower cartridge.
It is important to check a bearing by "feel" to
determine the nature of the reported failure.
Usually, a defective roller bearing will show
one or more of the following symptoms:
1. Hot to the touch (over 120F, 49C)
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 cam
follower (9, Figure 7.5.19), should be replaced
if the area which is in contact with the cam
track shows indentations which are deeper
than 0.02 mm. If a cam follower has
indentations less than 0.02 mm and if you
desire to have this cam follower reworked,
contact MI for pricing. To avoid import duty,
mark all documents clearly stating that these
parts are being returned to the USA, and they
were originally made in the USA.
The following is a recommended method and
value to use when making a decision as to
whether or not to replace a cam follower. Use
gauge 240-1076 (Figure 9.1.4) or a dial
indicator on a magnetic base to measure the
movement of the cam follower. (See Chapter
8, Section XI) Rotate the rotor frame so the
cam follower you are checking is at the top, or
12 o'clock position. Lock the rotor so it can not
turn. Place the tip of the dial indicator on the
top of the cam roller about 2 mm back from the
front edge of the roller, as shown in Figure
2.56.2, Method A, in the braider manual. Set
the dial at 0.0. Push upward on the BOTTOM
of the roller. Replacement of the cam follower
is recommended if the reading for cam
follower movement is greater that 0.045 mm.
2.55. REMOVAL OF UNIT FROM ROTOR. The
front cam follower cartridges are basically all
alike. It is important, however, to note that
only 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 removed
from the deck. The special provision consists
of a "timed relationship", using a pin to permit
reassembly without eccentric adjustment. All
other 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 from
cartridge (9).
2. Care should be taken to reach to the rear of
the rotor face and press or push on the
cartridge (not shaft) to force the cartridge
from 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 by
inserting one of four M6 screws (2) and
placing two ST M6 washers (3) and an M6
nut (4) to secure the assembly, see Figure
2.56.1. Keep the unit clean and dry while
out of the rotor.
NOTE
See separate instructions for
inspection and assembly of rotor
cam follower units, Figure 2.55.1.
2.56. REASSEMBLY OF FRONT CAM
FOLLOWER CARTRIDGE TO ROTOR FRAME.
1. If a unit has been removed from a rotor, it
is advisable to check the assembly in the
following manner:
a. With the cartridge assembly held in
your hand, rotate the shaft within the
cartridge. It should turn freely and
smoothly without abnormal radial or
axial play. The protruding 25 mm
diameter shaft should be smooth, pit
free and not discolored by heat.
FIGURE 2.55.1: CAM FOLLOWER ASSEMBLY
INSTRUCTIONS
STEP 1
STEP 2
STEP 3
RUBBER BAND FOR
ASSEMBLY ONLY
2. Holding the cap onto the cartridge, remove
the assembly M6 nut (4, Figure 2.56.1) and
place the cartridge into the rotor frame
mounting hole. Care must be taken to
assemble the cap and housing with the 3
mm diameter hole in the cap face and the
timing notch on the cartridge, adjacent to
the "X" stamped on the rotor face to the
casting. (See Figure 7.5.19.)
3. Place four M6 screws (14) and ribbed
washers (23) in cap and thread into rotor
frame. Tighten fasteners lightly.
FIGURE 2.56.1:
FIGURE 2.56.2: METHOD A
(REAR CAM FOLLOWER SHOWN, SAME FOR FRONT CAM FOLLOWER)
GAGE (240-1076)
REAR POCKET
REAR CAM
FOLLOWER
SLOTS
SCREWS
SEE CHAPTER 8,
SECTION XI
NOTE
Use Permatex on screw threads.
4. Using the slots at the shaft end of the
cartridge and MI tool # 240-3037 (Figure
9.1.2) rotate the housing to the desired
radial adjustment of .02-.05 mm. The
proper clearance is set as follows.
Reference: (Figure 2.56.2) Preset cam
followers using set fixture 240-1077, base
plate, and 240-1076 setting gauge,
processed as follows:
NOTE
The set master (240-1076, Figure
9.1.4) was designed to be used
with a diameter 72 mm outer race
and a standard cam track with a
80 mm radius. If an undersized
outer race or a reworked cam
track is being used, the set
dimension on the set master has
to be adjusted accordingly.
Contact MI Service for additional
information.
NOTE
When checking the clearance
between 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 condition
exists, replace all the outer races.
NOTE
Be sure to identify and remove the
shuttles from each individual
transfer and keep the transfers
separated from each other. Also,
identify on the face of the rotor
frames of each transfer, so only
the correct shuttles from this
transfer will be used to perform
the 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 the
cap.
Place the dial indicator in the front hole of
the 240-1076 setting gage, the hole closest
to the handle. This is the position for the
front cam follower. For the rear cam
follower use the hold farthest from the
handle. Lightly tighten the indicator set
screw. Rotate the handle back and forth
clockwise and counter clockwise, making
sure that the indicator tip is touching the
set block with 0.1 to 0.15 mm movement
of the indicator needle. When rotating the
gage, hold the gage against the pins on the
left side of the set master gage. Do not let
the gage roll from one side to the other
between the pins on the set master because
this will cause an error in the gage setting.
Turn the indicator glass cover until the
indicator is reading "0" at the highest point
of the needle movement and tighten the
indicator set screw. Take precautions not to
over tighten the setscrew because this will
cause the indicator stem to bind. After
tightening, check to see that the stem and
needle movement are free. Recheck the "0"
reading on the gage. The gage is now ready
to preset the front cam followers.
Loosen the screws that hold the adjustment
for the front cam follower. Reference
Figure 2.56.2.
NOTE
Make sure that the rotor pockets
are free of burrs, oil and all foreign
material before using this gage.
NOTE
On the face of the rotor frames
(Figure 7.5.19) at the front cam
follower 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 the
cam follower cap assembly (9,
Figure 7.5.19) are both turned to
the "X' side. This is a must for
front and rear cam followers.
Place the setting gauge 240-1076 in the
rotor pockets as shown in Figure 2.56.2.
The dial indicator ball will be resting on
the front cam follower.
NOTE
Figure 2.56.2, shows the dial
indicator ball resting on the rear
cam follower.
Push up on the bottom of the front cam
follower similar to what is shown in Figure
2.56.2, and use the 240-3037 cartridge
wrench in the slots of the front cam
follower to rotate the cartridge until the
dial 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 the
dial indicator to the rear hole of the 240-
1076 setting gauge, place the gauge in the
240-1077 base plate and set it to 0 mm.
Repeat the above procedure to preset the
rear cam followers.
After the front and rear cam followers have
been preset to plus 0.015 mm using the
gage, the cam follower clearances "must"
be checked with 0.02 and 0.05 mm shim
stock. It is suggested that these settings be
done with the rotor frames on a
workbench. Make sure that the following
areas on the shuttle assemblies are very
clean 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 the six
transfers has to be selected and identified.
These shuttle assemblies are used as the
master to make the final cam follower
adjustments for the pockets in its transfer.
This procedure is repeated for the other
five transfers.
The following steps are used to set the cam
follower clearance with the shim stock:
Install the shuttle into the top, front and
rear pockets of the rotor frame. Rotate the
shuttle assembly 2 or 3 times to be sure it is
seated 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 cartridge
are loose so you can adjust the cam
follower using a screw driver blade or
cartridge wrench 240-3037. When the
screws are tightened in the cartridge,
recheck the setting with the .02 mm shim
to ensure a free movement of the shim.
Then check it using a .05 mm piece of shim
stock. The .05 mm shim should drag hard
or even lock up the cam follower so it can
not turn. Repeat this procedure 30 mm in
from the other end of the cam track.
Sequentially tighten the four M6 cap
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 cam
followers.
When all shuttles have been installed on
the deck, recheck with the .02 and .05
shim, correcting as required.
5. With screws torqued from previous step 5,
check again that: (See Figure 2.61.1, for
torque requirements).
a. The radial adjustment to shuttle cam
track is correct (0.02 to 0.05 mm).
b. The bearing shaft of the cam follower
can be turned freely by hand.
c. The shaft has axial play of .1-.4 mm.
FIGURE 2.56.3: METHOD B
CAMTRACK
SHUTTLE ASSEMBLY
NOT SHOWN
FOR CLARITY
1.18
30 mm
CAM FOLLOWER
TYPICAL FRONT
OR REAR
SHIM STOCK
d. The cap and bearing cartridge are in
correct position according to "X" on
rotor face (See step 2, paragraph 2.56).
2.57. REAR CAM FOLLOWER ASSEMBLY.
After five (5) years the rear cam followers
should be replaced.
The following is a recommended method to
use when making a decision as to whether or
not to replace a cam follower. Use gauge 240-
1076 or a dial indicator on a magnetic base to
measure the movement of the cam follower.
Rotate the rotor frame so the cam follower you
are checking is at the top, or 12:00 o'clock
position. Lock the rotor so it can not turn.
Place the tip of the dial indicator on the top of
the cam roller about 2 mm back from the front
edge of the roller, as shown in Figure 2.56.2,
Method A. Set the dial at 0.0. Push upward on
the BOTTOM of the roller. Replacement of the
cam follower is recommended if the reading
for cam follower movement is greater than
0.045 mm.
2.58. REMOVAL OF UNIT FROM ROTOR. The
rear cam follower assemblies for all rotors are
alike. Attachment of a rear cam follower
assembly is different from the front cam
follower cartridge in that each rear cartridge is
mounted within a pillow block, then fixed with
locating pins and screws to the rotor frame.
Each rear cam follower assembly is provided
with the same eccentric adjusting feature as the
front units and is adjusted in the same way. See
preceding instructions. The adjustment of the
rear cartridge position relative to a shuttle cam
track can be made without disturbing the
pillow block. Instruction for the adjustment of
the rear cartridges is the same as the front
cartridges and is explained in Chapter 2,
Section XI, paragraph 2.56.
Replacement of a rear cam follower assembly
will first require disassembly of the pillow
block from the rotor frame. One may elect to
do this either while the rotor assembly is on the
deck, or by removal of the rotor assembly to a
remote location.
Each pillow block is factory numbered as
shown in Figure 7.5.20. A corresponding
number for the individual pillow block is on
the rotor frame. It is important that the same
pillow block be replaced at the same location
on a given rotor.
1. Loosen and remove four M10 socket head
screws, (21) Figure 7.5.19, and lockwash-
ers (22).
2. Lift the pillow block vertically from the
rotor frame to disengage it from the M6
locating pins (9, Figure 7.5.20).
3. With pillow block and rear cam follower
cartridge assembly removed from the rotor
assembly, loosen and remove the four M6
screws (7) and washers (8). (Figure
7.5.20).
4. Push cartridge (not extended shaft), from
the pillow block (10).
2.59. ASSEMBLY OF REAR CAM FOLLOWER
ASSSEMBLY TO ROTOR. Put the same pillow
block on the same rotor frame pad with a
replaced cartridge bearing assembly (Figure
7.5.19).
NOTE
It is the manufacturers policy that
a failure to any part of a cam
follower assembly is cause to
replace the complete bearing
assembly.
1. Carefully remove the cap from the cam
follower assembly and place the housing
with 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
assembly, 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) and
thread into cap (1). Do not torque screws
at this time.
NOTE
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 screws
to 55-60 ft-lbs (75-81 Nm) torque.
NOTE
6. Adjust the radial clearance to the shuttle
cam track following the same procedure as
the front cam followers assembly (Figures
2.56.2 and 2.56.3). Torque the four M6
screws 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, paragraph
2.56, of the front cartridge units.
2.60. ROTOR GEAR. (Figure 7.5.19) The rotor
gear (2) is attached to rotor frame (1) with M8
socket head screws (17) and is timed at
manufacture with the dowel pin (12). Rotor
gears are numbered to the rotor frame. Every
rotor gear is identical to another, but
necessitates a custom timing when affixed to
another or new rotor frame.
2.61. REMOVAL OF ROTOR GEAR FROM
ROTOR FRAME. Remove eight M8 (17) socket
head screws from the rear of the rotor and tap
the rotor gear off the rotor frame and the M10
dowel pin. The dowel pin may or may not
come out with the gear.
FIGURE 2.61.1: CAM FOLLOWER TORQUE REQUIREMENTS
0.02
0.05
0.45 MAX
0.05 MIN
TORQUE
45 - 50 FT. LB.
61 - 68 Nm
TORQUE
20 - 35 FT. LB.
27 - 47 Nm
TORQUE
25 - 30 FT. LB.
34 - 41 Nm
TORQUE
65 - 70 FT. LB.
88 - 95 Nm
0.45 MAX
0.05 MIN
TORQUE
22 - 24 FT. LB.
30 - 32 Nm
TORQUE
22 - 24 FT. LB.
30 - 32 Nm
TORQUE
55 - 60 FT. LB.
75 - 81 Nm
ALL DIMENSIONS IN mm UNLESS NOTED
VIEW A-A
SECTION B-B
A
A
B
B
0
.
0
2
0
.
0
5
2.62. ASSEMBLY OF ROTOR GEAR TO SAME
ROTOR FRAME. Position the rotor gear onto
the rotor frame with the counterbored side of
the M8 screw hole exposed. Align it with the
timing pin, install and torque the M8 (17,
Figure 7.5.19) screws to 25-30 ft-lbs. (34-41
Nm). Stake the end of the timing dowel pin
with the pin flush or below the gear face. Use
Permatex on screw threads.
2.63. ASSEMBLY OF ROTOR GEAR TO NEW
ROTOR FRAME. (Figure 7.5.19) Two
alternatives exist to arrive at the proper timing
pin location for field replacement.
Case 1-With the rotor gear mounted to a new
rotor frame, and the timing hole of the gear in
the position shown in Figure 7.5.19, assemble
four M8 (17) screws loosely torqued (every
second hole) such that the rotor, together with
the gear, may be lifted onto the rotor axle
between two rotor assemblies having correct
timing and pinned and torqued screws.
The object is to allow the unpinned new rotor
to be "set" in the correct position mating with
matching pockets of neighboring rotor
assemblies. A shuttle must be passed into
transfer to force the best possible location for
all six pockets.
After passing the shuttle through all six
pockets, the rotor with its unpinned rotor gear
is carefully removed from the rotor axle and all
screws torqued to 25-30 ft-lbs. (34-41 Nm).
Recheck the timing by installing the rotor in
position (step 3, paragraph 2.50) and passing a
shuttle assembly through all six transfers. A
smooth transfer must be made at all locations.
When the transfer is smooth, drill a 9.8 mm
diameter hole to a 46 mm depth from the outer
gear face, then drill a 5 mm diameter hole thru,
to allow air to escape, and follow by reaming
to 10 mm diameter +0.00/-0.019 by 44 mm
deep.
Drive dowel pin (12) thru gear into rotor to
time the new rotor frame. Stake the pin.
Case 2-The rotor gear may be timed to a new
rotor frame with aid of timing fixture part
#240-1075 available from MI, (Figure 9.1.5).
The fixture enables the accurate orientation
between a rotor pocket and a space between
two rotor gear teeth. Figure 2.63.1 shows the
use of this method. (See Chapter 8, Section X,
paragraph 8.22). When the location of gear to
rotor has been accomplished, the identical
steps as in Case 1 are followed to drill, ream,
torque screws, install, and check.
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
Removal of either major or minor planetary
gears is accomplished with the rotor removed
from the rotor axle.
1. Rotor gear (2, Figure 7.5.19) is removed
from the rotor frame (1).
2. The needle bearing outer race (3-3, Figure
7.5.21) is removed from the rotor frame.
3. The roll pin (11, Figure 7.5.19) is driven
from planetary shaft (4).
4. Remove the planetary shaft.
5. Remove planetary gear (6 or 7) together
with its ball bearings (18), spacer (5) and
snap 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 replaced
also.
Assembly of a new planetary gear, new ball
bearings, and new planetary shaft within the
same rotor frame:
1. Insert two retaining rings (19) into the
grooves within the bore of the gear (7) or
(6). Press and seat ball bearings within the
bore and against the retaining rings by
pressing on outer race only of the ball
bearings. The bearing inner race must turn
smoothly by hand.
2. Hold the gear by hand in the correct
position shown in Figure 7.5.19. Note the
gear shoulder orientation. Install the
planetary shaft through the rotor frame and
bearings. Then slide spacer (5) over shaft
and continue to slide shaft into hole in
rotor flange per Figure 7.5.19.
3. With the shaft fully seated into the bearings
FIGURE 2.63.1:
REAR
POCKET
DIAL
INDICATOR
and against the shoulder, check for free
turning of the bearings, then drill a 6 mm
diameter hole for the roll pin (11, Figure
7.5.19).
4. Drive the roll pin (11) into the rotor frame
(1) and through the planetary shaft (4) as
shown in Figure 7.5.19.
5. Check, by turning the planetary gear by
hand, to see that the bearings are free and
smooth in rotation and that the axial play is
less than .3 mm. If tight or with no axial
play, remove the pin and face the shoulder
of the planetary shaft to attain axial
clearance and repin to the same hole.
6. Reassemble the rotor gear and press the
outer race of the needle bearing (3-3,
Figure 7.5.21) into its original position. If
the outer race is loose remove it, stake the
edges of the rotor frame adjacent to the
hole, sparingly apply Loctite #442 to the
outside diameter of the outer race and tap
gently into place using a plastic tool.
2.66. ROTOR BEARINGS. The bore of the rotor
housing contains two radial type roller
bearings for mounting to the rotor axle
assembly.
2.67. REAR ROTOR BEARINGS. The type 130
ID x 165 OD x 35 mm wide two-part bearing
is the basic bearing for rear rotational guidance
of the rotor assembly to the rotor axle
assembly. This bearing is automatically
lubricated through the rotor axle bore. The
inner race is to be assembled to the rotor axle
with the oil hole aligned with the Bijur unit,
Figure 7.5.21.
The bearing consists of an inner ring (3-1) and
outer race. The outer race and caged rollers of
this bearing are installed in the rotor frame.
Replacement of any one of the two
components will be cause to replace all two
parts. This bearing is to be treated as a
matched set. This is one reason for a rotor
assembly being paired with a specific rotor
axle assembly.
2.68. FRONT ROTOR BEARING. The front
radial roller bearing is of a two-part design.
The inner ring (4) is shown on rotor axle
assembly (Figure 7.5.21). The outer portion
consists of an outer race (4-1) with integral
rollers (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 race
is cause for the replacement of both races.
2.69. GUIDE KEY. The function of a guide key
is to engage with the shuttle assembly to retain
the shuttles in proper axial location.
While direct interchangeability of parts exists,
three concerns will require care in
replacement:
M6 screws (13, Figure 7.5.19) are securely
torqued and Permatex applied to the
threads to prevent loosening due to vibra-
tion upon assembly.
A check must be made to assure that the
rotor guide key allows the shuttle a mini-
mum of .05 mm axial play or movement
during transfer between adjacent rotors and
a maximum of .45 mm axial play when not
in transfer.
Special off-set keys are available from MI
to obtain these clearances. These special
keys are marked with an "X" to the off-set
side.
3-CONTROLS
May, 2011 MR-15 PLC-T Manual 3-1
CHAPTER 3
CONTROLS
EINFHRUNG
3.1. GENERAL. This section deals with the
general function of the electrical system and
describes its major parts.
3.1. GENERELL: Hier wird generell das
Elektrische System beschrieben, mit den
Hauptteilen.
3.2. EMERGENCY STOP CIRCUIT: This
circuit takes away all power from the Inverter
and Main Motor. Please note that the blowers
and oil pump are not included in this circuit,
only the main disconnect will disable those.
The main components of the E-Stop circuit are
all 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
are in place and no E-stop button is currently
active then the green light will come on,
Inverter will power up and the Run/Jog buttons
will be enabled. If the E-stop circuit ever drops
out, the green button will have to be pressed
again.
3.2. STROMKREIS AUSFALL IN EINEM
NOTFALL ROTER STOPKNOPF: Der
Stromkreis fllt aus vom Inverter und dem
Hauptmotor. Das Geblse und die lpumpe
sind in dem kreis nicht angeschlossen, und
mssen extra ausgeschaltet werden. Beim
auslsen des Notschalter Roter Stopknopf
sind folgende sicherheitsvorkehrungen im
Stromkreis mit eingeschlossen. Alle roten
Notschalter, Getriebekastentren,
Hauptmotortren, Starter fr Hauptmotor und
lpumpe, grner Knopf am Hauptschaltkasten
und Notschalter Sicherheits Relais.
Um die Maschine wieder zu starten, der grne
Knopf muss eingedrckt werden. Wenn alle
roten Notschalter nicht eingedrckt sind, wird
das grne Licht Leuchten. Der Inverter ist
wieder unter Strom, und die Tip und Start
Knpfe wieder frei zum Laufen lassen. Sollte
der Stromkreis grundlos ausfallen, den grnen
Knopf nochmals eindrcken.
3.3. STOP CIRCUIT. This circuit is responsible
for normal stops on the machine. The main
parts of this circuit are the stop buttons, Run/
Jog contacts, enable relay for all other stops
and 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 close
and the inverter enable signal will be turned
on. One of 3 speed enable signals will also be
sent to the inverter (see Section 1.14). Please
note that all of these stop functions except the
stop buttons themselves and the door
interlocks can be bypassed by actuating the jog
switch. As soon as the switch is released those
stop motions become active again.
3.3. STOP STROMKREIS: Dieser Stromkreis ist
verantwortlich fr die normalen Stops der
Maschine Die Hauptteile von diesem
Stromkreis sind Stop, Start und Tip Kontakte.
Relais ausschalten fr alle andern stops und
Sicherheitsschalter der Gehusetren. Der
Kreis Kann wieder geschlossen werden mit
Knopfdruck auf Start oder Tipknopf. Wenn
alle andern Stops O.K. sind schliessen die
3-CONTROLS
3-2 MR-15 PLC-T Manual May, 2011
Relais und geben das OK Signal zum Inverter.
Eins von den 3 Geschwindigkeitssignalen wird
zum Inverter gesandt. Bitte beachte das all
diese stopfunktionen ausser den Stopknpfen
und den Sicherheitsschaltern an den
Gehusetren berbrckt werden Knnen
durch aktievieren des Tipknopfes. Sobald der
Tipknopf Losgelassen wird sind alle
Stopfunktionen wieder aktiv.
SECTION II. OPERATOR INTERFACE
3.4. CONTROL LOCATIONS. The controls are
the same for each deck so a single or triple
deck would be similar. Figures 3.5.1, 3.6.1 and
3.7.1 show the face of each control box.
3.4. STAND DER KONTROLLANLAGE: . Die
Kontrollanlage ist gleich fr alle Decks, so das
sie gleich aussieht fr eine Anlage 1 - 2 - oder
3 Decks.
3.5. TERMINAL BOX. Figure 3.5.1 shows the
face of the Terminal Box..
The selector switch allows the operator to jog
or run the deck/s. The red Stop button is
normally used to stop the machine. See section
3.3 for information on the stop circuit.
The red mushroom pushbutton is the
Emergency stop button. See section 3.2 for a
description of what this circuit does.
3.5. ERSTER SCHALTKASTEN: . Die
Abbildung 3.5.1. zeigt die Vorderansicht des
Schaltkastens.
Der Wahlschalter Tip Start erlaubt dem
Arbeiter die Maschine auf Tip. Oder auf Start
Laufen zu Lassen. Der Rote Stop Schalter ist
normal dazu da um die Maschine zu stoppen.
Stromkreis fr Stop information: Artikel 3.3.
Der dicke rote Pilzkopfschalter ist der
Notschalter. Stromkreis information: Artikel
3.2.
3.6. REMOTE OPERATOR BOX. Figure 3.6.1
shows the face of the Remote Operator Box. It
is functionally identical to the Primary
Operator Box.
FIGURE 3.5.1: TERMINAL BOX
Erster Schaltkasten
3-CONTROLS
3.6. REMOTE SCHALTKASTEN: . Abbildung
3.6.1. zeigt die Vorderansicht des Remote
Schaltkastens. Von der Funktion her, ist er
identisch mit dem ersten Schaltkasten.
3.7. MAIN CONTROL BOX. The main control
box contains the entire electrical system for the
machine. All active electrical components
except for the display and digital stop circuit
are located here. The following switches are
also located here:
1. MAIN POWER SWITCH - This switch will
disable all electrical power within the
machine EXCEPT: 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.
3.7. HAUPTSCHALTKASTEN: Im
Hauptschaltkasten Kommt das gesammte
elektrische system fr die Maschine
zusammen. Alle elektrischen aktiven
Komponenten, ausser der Anzeige und des
Degitalen Stop Stromkreises sind hier
vorhanden.
1. Hauptschalter Der Hauptschalter legt
das ganze elektrische system der Maschine
lahm, ausser am unteren Ende wo das
Hauptkabel zur Maschine Kommt.
WARNUNG
ffne niemals den
Hauptschaltschrank ohne das der
Strom abgeschaltet ist. 3.7.1.
Hauptschaltschrank.
FIGURE 3.6.1: REMOTE OPERATOR BOX
Remote Schaltkaste
3-CONTROLS

3.8. INSIDE JOG STATION. This station allows
the machine to be JOGGED (run at a reduced
speed) from within a deck. It contains 3
buttons:
1. SAFETY SWITCH. In order to run the
machine from inside a deck, the safety
switch within that deck must be switched
on (the lit position). If this switch is on, the
machine can be jogged, but only from this
station. The door locks for that deck are
also disabled.
2. JOG BUTTONS. There are two buttons
that must be pushed to jog the braider from
the internal control station. They are
labelled buttons 1 and 2 in FIgure 3.8.1. In
order to prevent short circuits or bypassing
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. Pressing
this button will disable all switches that
can start the machine. Twist to release this
button.
CAUTION
When working in a deck always
turn the switch to ON. This will
prevent someone who does not
know there are personnel in the
enclosure 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 die
Maschine von Innen Laufen zu Lassen,
muss der Sicherheitsschalter auf ein
gelegt werden. Jetzt Kann die Maschine
von Innen Langsam auf Tip Laufen
gelassen werden. Die Sicherheitsschalter
fr die Tren sind berbrckt.
2. TIP SCHALTER. Bei drcken des
Tipschalters setz sich die Maschine in
bewegung wenn der Sicherheitsschalter
auf ein gelegt ist.
3. NOTSCHALTER. Bei drcken des
Notschalters sind alle anderen schalter
ausser Betrieb. Erst beim Zrcklassen
des Notschalters Kann die Maschine
wieder gestarted werden.
FIGURE 3.7.1: MAIN CONTROL BOX
Hauptschaltkasten
3-CONTROLS
WARNUNG
Wenn am Deck gearbeitet wird,
immer den Sicherheitsschalter auf
ein Legen in diesem fall Kann
Keiner von aussen die Maschine
Laufen Lassen. Nur so Kann ein
unfall verhindert werden.
FIGURE 3.8.1: INSIDE JOG STATION
Tip Schaltknopf in der Maschine
2 1
3-CONTROLS

3A - PLCT-F CONTROLS
May, 2011 MR-15 PLC-T Manual 3A-1
CHAPTER 3A
PLCT-F CONTROLS
3A.1. GENERAL. This section deals with the
general function of the electrical system and
describes its major parts.
3A.2. EMERGENCY STOP CIRCUIT: This
circuit takes away power from the inverters
and drive motors. Please note that the blowers
and oil pump are not part of this circuit, only
the main disconnect will disable those. The
main components of the Emergency Stop
circuit are the Red Mushroom buttons, the
PLC located in the enclosure with the display,
the safety relay and the motor starters for the
drive motors and oil pump.
Note that if the emergency-stop button is used
to stop the machine, power is immediately
removed from the inverters and motors so the
machine will not come to a synchronized stop.
The braid at that point will be defective.In
order to engage the Emergency stop circuit, the
green button must be pushed. If all safeties are
in place and no E-stop button is currently
active then the green light will come on,
Inverter will power up and the Run/Jog buttons
will be enabled. If the E-stop circuit ever drops
out, the green button will have to be pressed
again.
3A.3. STOP CIRCUIT. This circuit is
responsible for normal stops on the machine.
The main parts of this circuit are the stop
buttons, Run/Jog contacts, enable relay for all
other stops and 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 close and the inverter enable
signal will be turned on. Please note that all of
these stop functions except the stop buttons
themselves and the door interlocks can be
bypassed by actuating the jog switch. As soon
as the switch is released those stop motions
become active again.
3A-2 MR-15 PLC-T Manual May, 2011
SECTION II. OPERATOR INTERFACE
3A.4. CONTROL LOCATIONS. The controls are
the same for each deck so a single or triple
deck would be similar. Figures 3A.5.1, 3A.6.1
and 3A.7.1 show the face of each control box.
3A.5. TERMINAL BOX. Figure 3A.5.1 shows
the face of the Terminal Box.
The selector switch allows the operator to jog
or run the deck/s. The red Stop button is
normally used to stop the machine. See section
3A.3 for information on the stop circuit.
The red mushroom pushbutton is the
Emergency stop button. See section 3A.2 for a
description of what this circuit does.
3A.6. REMOTE OPERATOR BOX. Figure
3A.6.1 shows the face of the Remote Operator
Box. It is functionally identical to the Primary
Operator Box.
FIGURE 3A.5.1: TERMINAL BOX
FIGURE 3A.6.1: REMOTE OPERATOR BOX
May, 2011 MR-15 PLC-T Manual 3A-3
3A.7. MAIN CONTROL BOX. The main control
box contains the primary power systems,
hauloff motor and the inverter drives for the
machine. All active electrical components
except for the display and the Programmable
Logic Controllers (PLCs) responsible for the
deck IO are located here.
1. MAIN POWER SWITCH - This switch will
disable all electrical power within the
machine EXCEPT: 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 the
main control box. These can be used to turn off
each individual motor.

CAUTION
Be sure to follow proper lock out /
tag out procedures if these
switches are used to turn off a
motor.
CAUTION
These switches do NOT power
down the individual inverters, just
the speed reference, and cannot
be used as a safety lockout.
FIGURE 3A.7.1: MAIN CONTROL BOX
FIGURE 3A.7.2: MAIN CONTROL BOX
STAND ALONE
3A-4 MR-15 PLC-T Manual May, 2011
3A.8. INSIDE JOG STATION. This station
allows the machine to be JOGGED (run at a
reduced speed) from within a deck. It contains
3 buttons:
1. SAFETY SWITCH. In order to run the
machine from inside a deck, the safety
switch within that deck must be switched
on (the lit position). If this switch is on, the
machine can be jogged, but only from this
station. The door locks for that deck are
also disabled.
2. JOG BUTTONS. There are two buttons
that must be pushed to jog the braider from
the internal control station. They are
labelled buttons 1 and 2 in Figure 3A.8.1.
In order to prevent short circuits or
bypassing 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. Pressing
this button will disable all switches that
can start the machine. Twist to release this
button.
CAUTION
When working in a deck always
turn the switch to ON. This will
prevent someone who does not
know there are personnel in the
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
May, 2011 MR-11/MR-15 PLCT-F 4A-1
CHAPTER 4A
ELECTRICAL SYSTEM - COLOR TOUCHSCREEN
SECTION I. GENERAL DESCRIPTIONS
4A.1. GENERAL. The MR-11/MR-15 PLCT-F
electrical system provides safe and convenient
control of the Braidmatic Machine for the
operators, as well as devices to monitor the
quality of the braided product.
The MR-11/MR-15 PLCT-F electrical system
includes prewired enclosures, switches, alarm
panels, pushbutton stations, etc. The units are
factory assembled, adjusted and installed
together with harnesses for convenient
assembly.
The system is designed as a modular system
for the control and operation of one or more
decks and one haul-off unit. Each is an
independent unit that can be attached to any
hauloff. Also included is a main control
cabinet that can be attached to the outside of
the braider enclosure.
The system includes all electrical components
and 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 light
switch.
See Chapter 10, Electrical schematics for the
schematic diagram of the PLCT-F electrical
system for one or two decks. Schematics for a
3-deck version are provided as needed.
SECTION II. SYSTEM DESCRIPTIONS
4A.2. MAIN SCREEN. This is the default
startup and main run screen for the braiding
machine. The current speeds for the hauloff
and each deck are displayed when the machine
is running. In case of a stop motion, the reason
for the stop is shown. Below is a breakdown of
the information that is shown on this screen.
FIGURE 4A.2.1: MAIN DISPLAY SCREEN
1
2
3
4
2 2 2
4A-2 MR-11/MR-15 PLCT-F May, 2011
1) This is the operation information area.
When creating a recipe, if data was entered
into the 3 information strings for the
recipe, these are shown here.
2) These buttons are used to access different
screens
3) Reverse button and Hauloff Speed - Press
this button to enable reverse mode. In this
mode, 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 production
rate cannot be shown so the number that is
displayed 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 machine
operator can access a screen to set the
speed and pitch here. See section 4.7.
1) Error display area Any currently active
errors are displayed here. A maximum of
two errors can be displayed at a time. Most
errors warnings will disappear once the
corresponding PLC input returns to its
normal state but some errors such as the
bobbin runout are static and will be
displayed until the braider is run again.
2) The red circle indicates that a motor has
been turned off with the key switches. If
both decks are disabled, the hauloff will
run and jog at a default speed.
3) PLC warning This triangle appears if the
main PLC is not in its normal operating
mode. When rebooting the system, it may
take several minutes before the PLC is
ready to run.
4A.3. ERRORS AND WARNINGS. In case of
error, error messages are shown at the top of
the main screen. Some errors will also show
blinking icons to help with their identification.
Error messages have priority and will
overwrite information on any of the screens.
FIGURE 4A.2.2: MAIN DISPLAY SCREEN WITH ERRORS
1
2
3
May, 2011 MR-11/MR-15 PLCT-F 4A-3
Under View Data, one can access the Alarm
History and Warnings screens. Here, one
can see a list of the last 500 errors and
warnings. For each entry, you will see an error
number, the time and date that the error
occurred, the status, and a text string
describing the error.
Note that each error and warning is displayed
twice. Status -C shows when the error occurs.
Status CD shows when the error was
canceled.
Most errors will be cancelled as soon as the
PLC input for that error changes back to its
normal state. There are however several
exceptions to this. For example, the Bobbin
Runout error and some of the customer
options are static errors. These are
automatically reset the next time the machine
is run.
Alarm History
Warnings
This screen will show a log of several inputs
that are not considered stop motions. The main
use for this screen would be for
troubleshooting. For example, the stop buttons
are normally closed contacts so a loose wire on
one of the stop buttons may cause random
stops of the braider. This screen can be used to
track 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. This
screen is accessed through View Data-
>Production Log
On a dual drive system, the information shown
is the production rate of the machine. On a
drive shaft version, the data shown is an
aggregate of motor RPM. The buttons at the
bottom of the screen can be used to browse and
zoom through the production data. If no line is
shown, the braider was powered off.
FIGURE 4A.3.1: ALARM HISTORY
FIGURE 4A.3.2: WARNINGS
4A-4 MR-11/MR-15 PLCT-F May, 2011
The data itself is stored in a memory card
plugged into the display. The data file can be
found under My Computer->Storage Card
MMC->Logs->Run Time0 The data is stored
in a generic CSV format that can be read into
any spreadsheet or database. Data is stored
once per minute and the following information
is saved:
ProductionRate is the production rate of the
hauloff or the motor speed in a drive-shaft
version. P_Counter1 and P_Counter2 are the
two production counters shown on the left side
of the main screen.
The data file will hold approximately one
month worth of data, and the system will
automatically save the last 12 data files. So, if
applicable, the memory card contains data for
the previous year.
4A.5. CREATING AND LOADING RECIPES.
4A.5.1. CREATING RECIPES.
This screen is accessed through the main menu
and 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 the
hauloff. In case only one deck is used for a
recipe, set the pitch of the unused deck to
be the same as the other one. This will
enable the recipe to be run with either deck
active.
2. Maximum allowed speed This is the
maximum speed that a deck is allowed to
run for a given recipe. The minimum deck
speed is always 100 Rotor RPM and the
machine operator may select any speed
between 100 and maximum speed set in
the recipe.
3. Information strings These entries are
purely for information purposes, the text is
displayed at the top of the main screen.
4. Maximum Adjust This number is a
percentage that allows the machine
operator to vary the actual pitch for a deck.
For example: an adjust of zero means that
the operator cannot vary the pitch at all. An
adjust of 10 means that the operator can
vary the pitch by +/- 10 percent.
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 RECIPES
May, 2011 MR-11/MR-15 PLCT-F 4A-5
Note that if one wishes to run without using
recipes, simply create a recipe with the
maximum speed, a lead of 100 and an adjust of
100%. This will allow the entry of any pitch
between the minimum and 200 millimeters and
the setting of any speed between 100 and the
maximum.
4A.5.2. LOADING RECIPES.
The following screen is accessed through the
Load Recipe button on the main screen. Note
that the braider will stop automatically when
you enter or exit this screen. Only recipes that
have already been created through the recipe
editor can be loaded.
There are two ways to access a recipe. The ten
buttons on the left will show the currently
active recipes. The name of the recipe is shown
in 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 buttons
will switch between different sets of ten
recipes. The other way to load a recipe is to
enter the number of the recipe directly in the
field on the top right.
The Current Selection box will show the
information for the currently active recipe.
.
4A.6. TROUBLESHOOTING.
The 5 troubleshooting screens can be accessed
through the main menu.
4A.6.1. IO STATUS. This screen displays the
status of all of the inputs and outputs in the
system. Note that this information is from the
perspective of the main PLC located in the
display. If there is a communications problem
between it and the remote IO, its possible that
these screens would not match the actual status
of the remote IO. Inputs are shown in green
and outputs are shown in red.
The question mark beside each PLC will show
a list of all the inputs and outputs for that PLC.
4A.6.2. PROFIBUS STATUS.
This screen shows the status of the
communications with the different
components on the profibus. The status of the
Multi Panel must be green for communications
to take place. A red circle indicates that the
FIGURE 4A.5.2.1: LOADING RECIPES
FIGURE 4A.6.1.1: IO STATUS
4A-6 MR-11/MR-15 PLCT-F May, 2011
profibus address for that component was not
found. Note that all braiders do not necessarily
have all of these components.
4A.6.3. PLC STATUS.
This screen shows the status of the PLC that is
integrated into the touch panel. No changes
should ever be made here. Note that on a single
deck braider, it is normal for the fault LEDs to
blink red since the profibus components for the
second deck are not active in the system. This
has no affect on the operation of the braider.
4A.6.4. DRIVE STATUS.
This screen shows information about the
drives/inverters in the braider. The status word
displays the current status information of the
drive.
The speed is the current drive speed in Hertz.
The torque is the current torque of the drive.
These two numbers are approximations that
are dependent on the motor configuration
parameters.
4A.6.5. TORQUE SETTINGS. This screen is
accessed through the Drive status screen. One
can 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 a
motor stall is ignored. The minimum torque
setting can be used to check for something
such as a broken belt on the motor. If the
minimum torque is set to 0, this parameter is
ignored.
FIGURE 4A.6.2.1: PROFIBUS STATUS
FIGURE 4A.6.3.1: PLC STATUS
FIGURE 4A.6.4.1: DRIVE STATUS
May, 2011 MR-11/MR-15 PLCT-F 4A-7
The torque limits are ignored while the braider
is jogging and while it is accelerating to its
operating speed.
4A.7. SPEED AND LEAD ADJUST SCREEN.
This screen is accessed through the main run
screen and is used to make adjustments to the
information in a recipe. The pitch from a
recipe can be adjusted by the machine operator
up to the limit that was set in the maximum
adjust 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 the
recipe. If two decks are running at different
speeds, the set speed is determined by the
fastest deck.
4A.8. COUNTERS AND OPTIONS.
Customer options are inputs reserved for
customer-specific stop motions.
The screen is accessed from the main screen
through the button shown below.
FIGURE 4A.6.5.1: TORQUE SETTINGS
FIGURE 4A.7.1: SPEED AND LEAD ADJUST
4A-8 MR-11/MR-15 PLCT-F May, 2011
If the color of the button is Orange, it indicates
that one or more of the customer options have
been disabled.
The two reset buttons at the top of the screen
are used to set the production counters back to
zero. The buttons at the bottom of the screen
are used to enable or disable specific stop
motions. A red button indicates that the stop
motion will be ignored and a green button
indicates that the stop motion is active. For all
stop motions, current must be flowing for the
stop to be recognized so it is not necessary to
disable stop motions that are not wired on a
specific braider.
4A.9. SYSTEM FUNCTIONS.
The system functions are accessed through the
main menu. From here you can calibrate the
touch screen or exit the main program to the
windows CE desktop. Most of the standard
system functions from the desktop versions of
Windows are available for setup and
configuration of the basic system.
4A.10. OTHER SCREENS.
Two other screens of note are available
through 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 are
set in the main PLC program (DB2). This
screen 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 the
main menu. If you forget a password, the
default 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
May, 2011 MR-11/MR-15 PLCT-F 4A-9
4A.10.2. BLOWER.
This screen configures when the blowers,
located at the top of the main enclosure, will
turn on. There are three possible settings.
I= always on.
Auto = Blower turns on when the braider is
running
O = always off.
4A.11. BLOWER ASSEMBLY. The blower
assembly is located on top of the Accoustical
Enclosure. It is intended to provide ventilation
for the interior of the Accoustical Enclosure. If
the blower is not running while the braider is
in operation, temperatures inside the enclosure
will rise to levels that are dangerous to
personnel and detrimental to the performance
of the braiders.
CAUTION
Before attempting any repair work,
be certain that all power to the
motor and electrical accessories
are turned off and locked in the
"off" position.
4A-10 MR-11/MR-15 PLCT-F May, 2011
4A.11.1. BLOWER ASSEMBLY
INSTALLATION.
FIGURE 4A.11.1.1: BLOWER ASSEMBLY
STEP NO. 6
STEP NO. 4
STEP NO. 5
STEP NO. 2
STEP NO. 3
STEP NO. 1
MOUNT FAN INSIDE HOOD
USING M6X12mm HEX HEAD
CAP SCREWS W/ FLAT AND
LOCK WASHERS
RUN FAN WIRES
THRU 7/8"
DIA. HOLE
MOUNT INLET BELL COLLAR
AND BRACKET TO HOOD
CAP SCREWS W/FLAT AND
LOCK WASHERS
IMPELLER FAN
MOUNT INLET BELL
COLLAR TO BRACKET
W/M8X20mm HEX HEAD
LOCK WASHERS AND
HEX NUTS
INLET BELL COLLAR
SECURE BRACKET
TO FILTER BOX
M6X20mm HEX HEAD
CAP SCREWS W/FLAT
AND LOCK WASHERS
SLIDE FILTER BOX
ONTO COLLAR MOUNT
BRACKET
MOUNT LIGHT FIXTURE
MOUNTING BRACKETS W/
M6X20MM HEX HEAD CAP
SCREWS W/LOCK AND FLAT
WASHERS AND HEX NUT
May, 2011 MR-11/MR-15 PLCT-F 4A-11
FIGURE 4A.11.1.2: BLOWER ASSEMBLY
FILTER SLIDES IN
FROM END
2
5
6
1
7 4
3
FIG. &
INDEX
NO.
PART NO. DESCRIPTION
UNITS
PER ASM.
4A.11.1.2 BLOWER
1 S-5707 HOOD 1
2 S-5708 INLET 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 INLET RING 1
7 S-4891 16" X 20" X 2" MESH FILTER 1
TABLE 4A.11.1.1: TROUBLE SHOOTING CHART FOR BLOWER
SYMPTON POSSIBLE CAUSE(S) CORRECTIVE ACTION
Noise 1. Foreign objects in housing.
2. Incorrect wheel rotation.
1. Remove.
2. Reverse rotation.
Motor bearing noise Lack of bearing lubrication. Lubricate.
Excessive vibration 1. Loose mounting bolts.
2. Motor out of balance.
3. Accumulation of material on wheel.
4. Tighten.
5. Replace.
6. Clean.
Motor overloaded System static pressure less than 1" water column. Increase system static pressure.
Impeller not turning 1. Broken bolt.
2. Bearing sized.
1. Replace.
2. Replace.
4A-12 MR-11/MR-15 PLCT-F May, 2011
4A.11.2. OPERATION.
1. Before connecting the blower motor to the
junction box cable, check the electrical
characteristics 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 is
correct as indicated by directional arrows
on the unit. If rotation is correct, apply full
electrical power.
3. With the air system in full operation and all
ducts attached, measure current input to the
motor and compare with the nameplate
rating to determine if the motor is
operating 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.
4. Relubricate the motor per the
manufacturers instructions. Remove any
excess lubricants from the housing and
blower assembly.
CAUTION
A ground wire must run from the
blower motor housing to a suitable
electrical ground such as a
properly grounded metallic
raceway or ground wire system.
5. Do not operate the fan with the shield
removed.
CAUTION
are turned off and locked in the off
position.
May, 2011 MR-11/MR-15 PLCT-F 4A-13
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.
Parameter 100, set this using the dip
switch on the Inverter, not through the
parameter list.
Parameter 1800 sets the carrier fre-
quency for the motor. You can modify
this 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.
PARAMETER HAULOFF DECK
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 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
4A-14 MR-11/MR-15 PLCT-F May, 2011
SECTION IV. ELECTRICAL CABLE INSTALLATION LOCATIONS
4A.13. TERMINAL BOX PANEL TO REMOTE
OPERATOR STATION. Reference Figure
7.5.48.
FIGURE 4A.13.1: TERMINAL BOX PANEL TO REMOTE OPERATOR STATION
T
e
r
m
in
a
l
B
o
x
Remote Operator Box
Remote Operator
Station Cable
Run the cable up the inside wall of the Enclosure to the ceiling. [Clamp one (1) time.]
Run the cable along the inside ceiling to the opposite wall. [Clamp three (3) times.]
Run the cable down the inside wall of the Enclosure to the Remote Operator Station.
[Clamp one (1) time.]
May, 2011 MR-11/MR-15 PLCT-F 4A-15
4A.14. TERMINAL BOX PANEL TO INSIDE
JOG BOX. Reference Figure 7.5.40.
FIGURE 4A.14.1: TERMINAL BOX PANEL TO INSIDE JOG BOX
T
e
r
m
in
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.
Run cable up on the outside of the tunnel and up to the Inside Jog Station.
[Clamp or attach as needed.]
Station Cable
4A-16 MR-11/MR-15 PLCT-F May, 2011
4A.15. TERMINAL BOX PANEL TO BOBBIN
RUNOUT DETECTORS.
FIGURE 4A.15.1: TERMINAL BOX PANEL TO BOBBIN RUNOUT DETECTORS
T
e
r
m
in
a
l
B
o
x
Run small black wire assembly (240-9065) from Terminal Box Panel to
Bobbin Runout Detectors (240-9075). [No clamps needed.]
Bobbin Runout
Detector Wire
May, 2011 MR-11/MR-15 PLCT-F 4A-17
4A.16. TERMINAL BOX PANEL TO MAIN
CONTROL BOX. Reference Figure 6.12.2.9.
FIGURE 4A.16.1: TERMINAL BOX PANEL TO MAIN CONTROL PANEL
Cables to Main
Control Box
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,
then down the outside enclosure wall to the main control box (3000886).
T
e
r
m
in
a
l
B
o
x
M
a
i
n
C
o
n
t
r
o
l B
o
x
4A-18 MR-11/MR-15 PLCT-F May, 2011
4A.17. MAIN CONTROL BOX TO INSIDE
LIGHT FIXTURE. Reference Figure 7.5.62.
FIGURE 4A.17.1: MAIN CONTROL BOX TO INSIDE LIGHT FIXTURE
Run cable through the enclosure wall.
Run wire up the inside front of the enclosure wall, in conduit assembly,
Light Cable
L
i
g
h
t

F
i
x
t
u
r
e
to the ceiling, then run along ceiling to light fixture.
[Clamp as needed. See Figure 7.5.62.]
May, 2011 MR-11/MR-15 PLCT-F 4A-19
4A.18. BLOWER CABLES.
FIGURE 4A.18.1: BLOWER CABLES
BLOWER
BLOWER
PANDUIT
CONDUIT
1
2
1
3
FIG. &
INDEX
NO.
UNITS
PER
ASM.
4A.18.1 BLOWER CABLES
1 3000528 BLOWER CONDUIT CABLE ASSEMBLY 2
2 240-8870 BLOWER JUNCTION BOX ASSEMBLY 1
3 240-8883 BLOWER CABLE ASSEMBLY 1
4A-20 MR-11/MR-15 PLCT-F May, 2011
4A.19. MOTOR CABLE ROUTING.
FIGURE 4A.19.1: MOTOR CABLE ROUTING
Run cable from Main Control Box up outside of enclosure wall, across
the top, down the wall and under the deck to the motor.
M
a
i
n
C
o
n
t
r
o
l B
o
x
May, 2011 MR-11/MR-15 PLCT-F 4A-21
APPENDIX 1:
List of Alarms and warnings that are logged by
the system
DISCRETE ALARMS
TEXT
ALARM
NUMBER
ALARM CLASS TRIGGER TAG
TRIGGER
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 12
Motor 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
4A-22 MR-11/MR-15 PLCT-F May, 2011
Hauloff Motor-Torque
Limit Exceeded
25 Basic Alarms MainErrors2 8
Hauloff Motor-Minimum
Torque Error
Front Deck Motor-Torque
Limit Exceeded
Front Deck
Motor-Minimum Torque
Error
Back Deck Motor-Torque
Limit Exceeded
Back Deck
Motor-Minimum Torque
Error
DISCRETE ALARMS
TEXT
ALARM
NUMBER
ALARM CLASS TRIGGER TAG
TRIGGER
BIT
NUMBER
May, 2011 MR-11/MR-15 PLCT-F 4A-23
APPENDIX 2: REMOTE ACCESS
Port settings for accessing the Multipanel
through a router.
Server IP Address is the TCP/IP address of
the Multipanel.

PORT SETTINGS
4A-24 MR-11/MR-15 PLCT-F May, 2011

4-ELECTRICAL SYSTEM
November, 2010 MR-15 PLC-T Manual 4-1
CHAPTER 4
ELECTRICAL SYSTEM
ELECTRISCH SYSTEEM
SECTION I. GENERAL DESCRIPTIONS
GENERELLE BESCHREIBUNG
ALGEMENE BESCHRIJVING
4.1. GENERAL. The MR-15 PLC-T electrical
system provides safe and convenient control of
the Braidmatic Machine for the operators, as
well as devices to monitor the quality of the
braided product.
The MR-15 PLC-T electrical system includes
prewired enclosures, switches, alarm panels,
pushbutton stations, etc. The units are factory
assembled, adjusted and installed together with
harnesses for convenient assembly.
The system is designed as a modular system
for the control and operation of one or more
decks and one haul-off unit. Each is an
independent unit that can be attached to any
hauloff. However, the control box with the
touch screen display must always be set up on
the deck closest to the hauloff.
The system includes all electrical components
and wiring to install and operate the MR-15
PLC-T. The system does not provide for
wiring the plant electrical power to the
machine or for running the power to the
fluorescent light switch.
See Chapter 10, Electrical schematics for the
schematic diagram of the MR-15 PLC-T
electrical system for one or two decks.
Schematics for a 3-deck version are provided
as needed.
Where applicable, the error graphics shown
below will also include the number of the deck
where the error occurred. In the case when
multiple error signals are active at the same
time, the order that the error messages are
displayed is undefined.
4.1. GENERELL. Das MR-15 PLC-T
elektrische system ist sicher und
bedienungsfreundlich fr die Braidmatic
Maschine. Es berwacht und garantiert das
beste Qualittsprodukt der Maschine. Das
Elektrische system ist in der Firma bestens
vormontiert, eingestellt, kontrolliert und
installiert um eine leichte aufstellung der
Maschine zu versichern. Das System ist
entwickelt fr 1 2 oder 3 Decks und eine
Abzugsraupe zu Kontrollieren. Jedes System
ist unabhngig, und Kann an jede Abzugsraupe
verwendet werden. Aber der Schaltkasten mit
dem Touch screen display muss immer am
Deck angebracht werden dicht zur
Abzugsraupe.
Dieses System hat alle Komponenten und
elektrische verkabelung installiert fr die MR-
15 PLC-T. Das System hat nicht die
Verkabelung fr das Hauptkabel oder die
Innenbeleuchtung im Gehuse.
Artikel 10: Elektrische diagramme fr MR-15
PLC-T 1 2 oder 3 Decks vorhanden.
Wenn ein Fehler auftritt die anzeige Touch-
screen zeigt an, in welchem Deck der Fehler
erscheint.
4-ELECTRICAL SYSTEM
4-2 MR-15 PLC-T Manual November, 2010
4.1. ALGEMEEN. Het MR-15 PLC-T
electronisch systeem van de Braidmatic
vlechter voorziet voor de operatoren een
veilige en gemakkelijke bediening, alsook de
middelen om de kwaliteit van het gevlochten
product te controleren.
Het MR-15 PLC-T electrisch systeem bevat
voorbekabelde behuizing, schakelaars, alarm
panelen, drukknop stations, enz. Deze
onderdelen zijn in de fabriek voor-
geassembleerd, afgesteld en voorzien van
hulpmiddelen voor gemakkelijke montage.
De vlechter is ontworpen als een modulair
systeem voor de besturing en werking met n
of meerdere decks en n trekband . De decks
zijn ontworpen als onafhankelijke eenheden en
kunnen aan elke trekband gekoppeld worden.
Echter, de bedieningskast met de touch screen
display moet altijd gemonteerd worden aan de
deck het dichtste bij de trekband.
Het systeem bevat alle electrische
componenten en bedrading om de MR-15
PLC-T te installeren en in werking te stellen.
Het systeem voorziet niet in de electrische
toevoerleiding(voedingskabel) van de
fabrieksstroomvoorzieningen naar de vlechter
noch voor de bedrading naar de
lichtschakelaar.
Zie hoofdstuk 10, electrische schemas van de
bedrading van het MR-15 PLC-T - n of
twee decks- worden meegeleverd. (Schemas
voor een drie-deck versie kunnen geleverd
worden wanneer nodig).
Indien van toepassing, zal de
foutmeldingsmodule (scherm) ook het
nummer van het deck opgeven waar de fout
zich voordoet. In geval van meerdere
foutmeldingen op het zelfde moment, is de
volgorde waarin de foutmeldingen afgebeeld
worden niet bepaald.
SECTION II. SYSTEM DESCRIPTIONS
SYSTEM BESCHREIBUNG
SYSTEEM BESCHRIJVING
4.2. MAIN DISPLAY. The screen below is
displayed both when the braider is running and
when it is stopped but there are no active
errors. The top row of numbers on this screen
shows the current production speed in meters
per minute. The bottom two sets of numbers
are 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 and
measure the production rate of the hauloff
itself. These counters do not take into account
any potential slippage between the hauloff and
the hose.
Located at the bottom of this screen are two
buttons for selecting further operator interface
screens. The button labeled Config will call
up the main configuration screen while the one
labeled Counters will allow the operator to
reset either of the production counters.
If the braider includes an integrated Braid
Material Runout System, you will see a line
near the top of the screen:
Bobbin runout in: xxx.x xxx.x
These numbers show the difference for each
deck between the settings for the Braid
Material Runout Sensor (see section 4.6) and
the actual distance being measured. The
braider will stop if that number reaches 0 or
becomes negative.
4-ELECTRICAL SYSTEM
NOTE
NOTE: To prevent accidental
stops in case the laser sensors
are not calibrated, the cutoff
distance must be within 2
millimeters of set distance for the
runout laser sensors to trigger a
machine stop.
On a PLCT-F version of the machine, the
Rotor Speed display at the top of the screen is
replaced with 2 input fields for lead length.
Simply press the field on the display and a
window will open that allows the user to
change the lead length for each deck. Simply
enter the desired lead in millimeters and press
enter. If the two leads on a double deck are not
equal, the deck with the shortest lead will run
at 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 Luft, und wenn
sie steht. Aber nicht wenn keine Fehler
aktiviert sind. Die obere Reihe zeigt die
Produktionsgeschwindigkeit in meter pro
minute an. Die untere Reihe hat zwei
unabhngige Zhler die in meter zhlen. Jeder
Zhler Kann seperat auf null zurckgestellt
werden. All diese Zhler sind mit einem
Induktiv Geber verbunden, die sich in der
Abzugsraupe befinden. Diese messen die
Produktivitt der Abzugsraupe.
Sie zhlen aber nicht, fr ein eventuelles
rutschen, das zwischen dem Schlauch und der
Abzugsraupe entstehen Kann. Am unteren
Ende der Anzeige sind zwei Knpfe fr
weitere funktionen. Ein Knopf Konfig ruft
die haupt konfiguration der Anzeige ab. Der
zweite Knopf Zaehler erlaubt dem Arbeiter
die Produktionszhler einzeln zurck zu
stellen.
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
(Figure 4.2.1) wordt getoond wanneer de
vlechtmachine inwerking is of wanneer de
vlechter gestopt wordt zonder dat er een
foutmelding was.
Het bovenste veld met nummers toont de
huidige productie snelheid in meters per
minuut. De onderste twee velden met nummers
zijn twee onafhankelijke productie tellers,
welke tellen in meters en welke elk apart
gereset kunnen worden. Al deze tellers zijn
verbonden met sensor in de trekband en meten
de loopsnelheid van de trekband. Deze tellers
houden geen rekening met potentile slip
tussen de trekband en de slang.
Onderaan het scherm zijn er twee
drukknoppen om verdere interface schermen te
selecteren. De drukknop met de label config
zal het hoofd configuratiescherm oproepen
terwijl de drukknop met de label teller
(counters) de operator de tellers terug op nul
zal zetten.
4.3. MAIN CONFIGURATION SCREEN. This
screen is selected by pressing the Config
button on the main display (20). Various
options 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" will
access a troubleshooting screen that
shows the active connections between
the PLCs.
The button labeled Slow Speed will
reduce the speed of the machine for a
time, after which it will automatically
resume running at full speed, screen
23.
The button labeled Setup is used to
configure the software for units of
measurement and machine type.
The button labeled Error Logs is used
to display the total number of times
that any given error message has been
displayed.
The buttons labeled Contrast- and
Contrast+ are used to set the contrast
for the display.
The button labeled Return will return
the operator to the main run screen
(20).
This screen also shows the current soft-
ware version.
FIGURE 4.2.1: HAUPT ANZEIGE FIGURE 4.2.1: START SCHERM
4-ELECTRICAL SYSTEM
The button labeled Language will
switch between the different languages
that are programmed into the display.
The actual languages programmed into
the touch screen may vary from one
display to the next.
4.3. HAUPT KONFIGURATION ANZEIGE: Bei
eindrcken des Konfig Knopfes an der
Hauptanzeige knnen viele mglichkeiten
eingestellt werden.
Der Knopf Geblaese erlaubt die Ein-
stellung fr die Produktionsfunktion
des Geblsemotors. Anzeige 25.
Der Knopf "Netzwerk" erffnet eine
Strungsanzeige, die anzeigt die
aktiven Verbindungen zwischen den
SPS.
Der Knopf Langsamlauf wird die
Geschwindigkeit fr eine gewisse Zeit
reduzieren, und danach wieder auf die
normale Geschwindigkeit zurck zu
gehen. Anzeige 23.
Der Knopf Einstellung wird benutzt
um den Maschinetyp so initialisieren.
Der Knopf Fehler zeigt die Fehler-
zaehler an. Diese Zaeler werden inkre-
mentiert wenn ein Fehler angezeigt
wird.
Die Knpfe Kontrast- und Kon-
trast+ sind dazu da, um den Kontrast
der Anzeige einzustellen.
Der Knopf O erlaubt dem Arbeiter
zurck zu gehen zur Hauptanzeige
(20).
Die Anzeige zeigt die Software version
an.
4.3. HOOFD CONFIGURATIESCHERM. Dit
scherm wordt geselecteerd door de drukknop
config in te drukken op het startscherm (20).
Verschillende opties kunnen hier gekozen
worden.
De drukknop blower (ventilator) laat
toe om de werking van de ventilator in
te stellen- (scherm 25)
De drukknop netwerk (network)geeft
toegang tot een troubleshooting scherm
welk de actieve connecties tussen de
PLCs weergeeft.
De drukknop slow speed(trage snel-
heid) zal de snelheid van de machine
voor een bepaalde tijd vertragen om
daarna automatisch terug op volle
snelheid te draaien (scherm 23).
De drukknop transfer wordt gebruikt
om de software van het beeldscherm te
updaten. Het electrische systeem moet
uitgeschakeld worden en gereset
worden na deze aktie.
De drukknop contrast- en contrast+
worden gebruikt om het contrast van
het beeldscherm te regelen.
FIGURE 4.3.1: MAIN CONFIGURATION SCREEN
FIGURE 4.3.1: HAUPT KONFIGURATION
ANZEIGE
4-ELECTRICAL SYSTEM
De drukknop return(terug) laat toe
om terug te gaan naar het startscherm
(20).
Op dit scherm wordt ook de huidige
software versie weergegeven.
4.4. BLOWER OPERATING MODE. This screen
is selected by pressing the Blower button on
screen 22. One of 3 operating modes for the
blower can be selected here.
OFF turns off the blower.
Manual turns on the blower when-
ever the machine is powered up.
Automatic turns on the blower only
when the machine is running.
4.4. GEBLSEFUNKTIONVORGANG: Die
Anzeige wird gewhlt bei drcken des
Geblaese Knopfes an Anzeige 22. Eine von
den drei funktionsvorgngen kann hier gewhlt
werden.
Aus Schaltet den Motor ab.
Manuel Schaltet den Motor an, wenn
die Maschine unter strom steht.
Automatik Schaltet den Motor an
aber nur wenn die Maschine Luft.
4.4. OPERATIONELE STATUS VAN DE
VENTILATOR. Dit scherm wordt geselecteerd
wanneer de drukknop ventilator (blower)
wordt ingedrukt op scherm 22. En van de 3
operationele statussen kunnen hier
geselecteerd worden.
UIT (OFF) zet de ventilator af.
Manueel (Manual) zet de ventilator
aan van zodra de stroom aangesloten
wordt.
Automatic zet de ventilator enkel aan
wanneer de vlechter in werking is.
FIGURE 4.3.1: HOOFD CONFIGURATIESCHERM
FIGURE 4.4.1: BLOWER SETUP SCREEN
FIGURE 4.4.1: GEBLSEFUNKTION
4-ELECTRICAL SYSTEM
4.5. SLOW SPEED. This screen is selected by
pressing the Slow Speed button on screen
22. This will allow the machine operator to
run the machine at a slower speed for a
predetermined time, after which it will
automatically return to the normal operating
speed. The time is set in minutes and must be
within a range of 1-32000 minutes.
Pressing the number field will allow
the operator to set the time.
Pressing the I button will enable this
function.
Pressing the 0 button will exit the
screen without enabling this function
or disable the function if has previously
been enabled.
4.5. LANGSAME GESCHWINDIGKEIT: Die
Anzeige wird gewhlt bei drcken des
Knopfes Langsamlauf an der Anzeige 22.
Dieses erlaubt das die Maschine fr eine
gewisse Zeit langsam Luft, und dann wieder
auf die normale Geschwindigkeit umschalted.
Diese Zeit ist gesetzt in minuten, und muss
Zwischen 1 und 32000 gewhlt werden.
Bei drcken des Nummern feldes
erlaubt dem Arbeiter die Zeit einzuge-
ben.
Bei drcken des I Knopfes wird
diese funktion ermglicht.
Bei drcken des 0 Knopfes verlassen
sie die Anzeige ohne das etwas von der
letzten funktion zerstrt wird.
4.5. TRAGE SNELHEID. (Figure 4.5.1 - sherm
23) Dit scherm wordt geselecteerd door de
drukknop trage snelheid (slow speed) in te
drukken op scherm 22. Dit laat de operator toe
om 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 ingesteld
in minuten en binnen een bereik van 1 - 32000
minuten.
De tijd kan ingesteld worden door op
het nummeriek veld te drukken.
Door op de I drukknop te drukken
wordt deze functie geaktiveerd.
FIGURE 4.4.1: VENTILATOR SCHERM
FIGURE 4.5.1: SLOW SPEED SCREEN
FIGURE 4.5.1: LANGSAME
GESCHWINDIGKEIT
4-ELECTRICAL SYSTEM
Door op de O drukknop te drukken
verlaat je het scherm zonder de functie
te activeren of uit te schakelen indien
ze eerder geactiveerd werd.
4.6. MACHINE TYPE. This screen is used to
configure whether the braider is an MR-11 or
MR-15. This affects the speed display on the
main screen.
The units of measurements that are displayed
on the main screen are configured here. Units
can either be meters or feet. To accept all of
the display changes, the braider must be
powered down after this screen is exited.
MR-15 Max Spd : xxx allows the operator
to set a maximum speed for the MR-15.
Depending on the material type, the maximum
allowed speed is either 225 or 235 RPM. The
allowed maximum RPMs is set in the factory
before the braider is shipped.
If a Bobbin Runout Sensor is installed in the
braider, the following line will appear on the
display:
Bobbin Runout: D1 On/Off D2 On/Off
Config
The D1 and D2 switches allow the user to
toggle the Laser Sensors on and off for Decks
1 and 2. The button labeled Config accesses
the configuration screen for the Bobbin
Runout Sensors (Screen 31).
4.6. MASCHINEN TYP. Die Anzeige zeigt an
den Maschinentyp MR-11 oder MR-15. Dies
entscheidet die Geschwindigkeitsanzeige an
der Hauptanzeige.
Die Masseinheiten auf der Hauptanzeige die
hier angezeigt werden Knnen in meter oder
fuss eingestellt werden. Um nderungen zu
akzeptieten muss die Maschine nach neu
eingabe Kurz ausgenschaltet werden.
FIGURE 4.5.1: TRAGE SNELHEID
FIGURE 4.6.1: MACHINE TYPE
FIGURE 4.6.1: MASCHINEN TYP
4-ELECTRICAL SYSTEM
4.6. MACHINE TYPE. Dit scherm wordt
gebruikt om de vlechter als MR11 danwel als
MR15 te configureren en bepaald de
snelheidsaanduiding op het hoofdscherm.
De meeteenheden welke op het hoofdscherm
getoond worden , worden hier geconfigureerd.
Eenheden kunnen ofwel in meters of in feet
uitgedrukt worden. Om veranderingen in dit
scherm te activeren moet, na verlaten van dit
scherm, de vlechter uitgeschakeld worden en
terug opgestart.
4.7. NETWORK STATUS. This screen displays
all of the PLC communications that are
currently active for the main PLC (U8). The
communications that should be active is
dependent on the type of braider, i.e: Single or
double deck, 24 or 36 carrier. In case a PLC is
not found on the network, this status page will
display a 1 for that connection.
NOTE
On a 36C double deck, U21 (on
the 2nd deck) is not checked on
this status page.
4.7. NETZWERK STATUS. Die Anzeige zeigt
alle SPS Nachrichten und Verbindungen die
aktiv mit der haupt SPS sind. Die Nachrichten
und Verbindungen die aktiv sein sollten,
hngen von dem Type der Flechtmaschine ab 1
oder 2 Decks, 24 oder 36 Klppel. Im Falle das
eine SPS im Netzwerk nicht gefunden werden
Kann, diese Abbildung wird eine 1 anzeigen
fr die Verbindung.
Notierung
An einem 36 Klppel dopple deck
U21 (andem zweiten deck) ist
nicht angezeigt auf dieser
Abbildung.
FIGURE 4.6.1:
FIGURE 4.7.1: NETWORK STATUS
FIGURE 4.7.1: NETZWERK STATUS
4-ELECTRICAL SYSTEM
4.7. NETWERK STATUS. Dit scherm geeft de
aktieve communicatie met de hoofd PLC (U8)
weer. Welke communicaties actief zijn is
afhankelijk 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 die
verbinding.
4.8. COUNTER RESET. This screen is accessed
by pressing the counters button on the main
screen (20). Reset counter 1 will set the
counter C1 on the main display to 0 while
Reset counter 2 will do the same for the C2
counter. Please note that the actual counters
cannot be updated until a new counter pulse is
received from the hauloff so the numbers on
the main screen (20) are only updated when
the machine is running.
4.8. ZHLER ZURCK STELLEN: Die
Anzeige wird aktiviert beim drcken des
Knopfes Zaehler an der Hauptanzeige (20)
Zurckstell Zhler 1 setzt den Zhler C1 auf
der Hauptanzeige zurck auf 0. Zurckstell
Zhler 2 hat dieselbe funktion fr den C2
Zhler. Die Zhler knnen nur gestarted
werden wenn sie einen Puls von der Laufenden
Maschine erhalten. So das die Rpm- Umin.
Auf der Hauptanzeige erscheint.
4.8. TELLER RESET. Door de drukknop teller
(counters) op het hoofdmenu (scherm 20) in
te drukken krijgt men toegang toe dit scherm .
Reset teller 1 (counter 1) zal de teller C1 op
nul zetten op de hoofddisplay terwijl reset
teller 2 (counter 2)hetzelfde zal doen voor de
teller C2.
Let op: de actuele tellerstanden worden maar
aangepast op het moment dat er een nieuw
teller signaal ontvangen wordt van de
trekband. Dit betekent dat de meterstand op het
hoofdscherm (20) zich enkel kan aanpassen als
de machine in werking is.
FIGURE 4.7.1: NETWERK STATUS
FIGURE 4.8.1: COUNTER RESET SCREEN
FIGURE 4.8.1: ZHLER ZURCK STELLEN
4-ELECTRICAL SYSTEM
4.9. OPTIONAL OPTICAL BRAID MATERIAL
RUNOUT SENSORS. This screen is used to
calibrate the Bobbin Runout Sensors. The
column on the left shows the actual measured
distance for each sensor. Note that this distance
is a maximum so the distance shown is for the
smallest bobbin diameter being read by that
sensor.
The column on the right allows the user to
enter the cutoff distance for that sensor. This
number will usually be 0.5 - 2mm smaller than
the measured distance to an empty bobbin. See
the setup section for more detailed instructions
on how to set up the sensors.
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 screen
described in section 4.11.
Shuttle Errors selects the screen
described in section 4.12
Entering the correct four-digit pass-
word beside reset will reset all of the
error counters to zero.
4.10.
Die Taste Standard Fehler selektiert den
Bildshirm der im absatz 4.11 beschrieben ist.
Die Taste Kloepel Fehler selektiert den
Bildshirm der im absatz 4.12 beschrieben ist.
Alle Fehlerzaehler werden zurueckgesetzt
wenn man das richige 4-stellige Passwort
eingibt in dem eingabefeld neben Reset.
FIGURE 4.8.1: TELLER RESET SCHERM
FIGURE 4.9.1: OPTIONAL OPTICAL BRAID
MATERIAL RUNOUT SENSORS
FIGURE 4.10.1: ERROR COUNTERS
4-ELECTRICAL SYSTEM
4.10. ALARMEN AANGAVE.
Dit scherm wordt gebruikt om de verschillende
alarmtellers te selecteren en om de alarmtellers
terug op nul te zetten
Standard alarmen kiest het scherm
beschreven in sectie 4.11
Shuttle alarmen kiest het scherm
beschreven in sectie 4.12
Het inbrengen van het 4-cijfer
paswoord + reset zal alle alarm tellers
terug op nul plaatsen.
4.11. This screen displays the counters for all
error-counters except shuttle sensors.
4.11. Alle Fehlerzaehler auser den
Kloepelsensoren werden hier angezeigt.
FIGURE 4.10.1:
FIGURE 4.10.1: ALARMEN AANGAVE
FIGURE 4.11.1:
FIGURE 4.11.1:
4-ELECTRICAL SYSTEM
4.11. Dit scherm toont de teller voor alle
alarmen behalve de shuttle alarmen.
4.12. The error counters for the shuttle sensors
are displayed here.
4.12. Die Fehlerzaehler fuer die
Kloepelsensoren werden hier angezeigt.
4.12. De alarmen voor shuttle fouten worden
hier getoond.
4.13. ENCLOSURE DOOR INTERLOCK SAFETY
SWITCHES. MR-15 PLC-T decks are designed
for operation within a sound and safety
enclosure. The enclosures are available for
single, double and triple deck operation. A
hinged door is provided on either side of the
deck module for access to the braid decks.
Each door is equipped with a door lock. As
soon as a Run or outside Jog switch is
activated, the doors are locked and cannot be
opened.
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 is
inoperative, with one exception. With the
inside safety switch in the ON position, the
braider may be jogged from within that, and
only that, enclosure, even with the doors open.
The door locks on any other deck will still
operate as described above and prevent the
operation 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:
4.13. SICHERHEITSSCHALTER AN DEN
GEHUSETREN. Die Decks sind entwickelt
in einem sicheren und schall gedmpften
Gehuse zu operieren. Die Gehuse sind
verfgbahr fr 1 2 und 3 Deck arbeiten.
Eine Tr ist von beiden seiten vom Gehuse
angebracht zum zugang zur Maschine. Jede
Tr hat einen Sicherheitsschalter. Sobald der
Tip oder Start Knopf aktiviert ist, die Tren
Knnen nicht geffnet werden.
Wenn eine Tr geffnet ist, Kann die Maschine
nicht gestartet werden, nur mit einer
aussnahme.
Ein Sicherheitsschalter im Gehuse muss auf
"Ein gelegt werden.
Dann Kann man die Maschine mit dem Tip
Knopf bei offener Tr nur von diesem
Gehuse, Langsam Laufen Lassen. Die
Sicherheitsschalter an den anderen Tren
behalten ihre beschriebene funktionen bei.
Wenn ein Sicherheitsschalter an einem
anderen Deck aktiviert ist Kann der Motor
nicht gestarted werden.
Die folgende Graphic erscheint auf der
Anzeige bei offener Gehusetr.
4.13. VLECHTKABINE
DEURBEVEILINGSSCHAKELAARS. MR-15
PLC-T decks zijn ontworpen om te werken
binnen een geluidsdichte en veilige cabine. De
cabines zijn beschikbaar voor enkel, dubbel en
triple deck vlechters. Er is een deur aan beide
zijden van elke deck welke toegang geef tot de
decks. Elke deur is voorzien van een
veiligheidsslot. Van zodra een AAN(Run)
of Jog schakelaar actief is zijn de deuren
vergrendeld en kunnen ze niet geopend
worden.
Zolang de deur geopend is, is de vlechter non-
actief, met n uitzondering: wanneer de
Veiligheidsschakelaar binnen in de kabine op
AAN ( ON) positie staat kan er van binnen (
en enkel van binnen) in die deck gejogged
worden, zelfs met de deuren open.
FIGURE 4.13.1: ENCLOSURE DOOR OPEN
SCREEN
FIGURE 4.13.1: ANZEIGE BEI OFFENER
GEHUSET
4-ELECTRICAL SYSTEM
De deursloten op de andere deck zullen in
werking blijven zoals hierboven bescheven en
de werking van de machine stoppen indien
deze geopend zijn/worden. Als de inside
safety schakelaar geactiveerd wordt op de
twee decks, kan de aandrijving niet gestart
worden.
De volgende afbeelding (Figure 4.13.1) wordt
op het scherm getoond wanneer een
cabinedeur geopend is:
4.14. CHANGE GEAR ACCESS DOORS. There
are safety switches installed on the change-
gear access doors for both the deck(s) and the
haul-off. In addition, the haul-off also has
safety switches for the doors that allow access
to the main motor.
When the change gear door is opened, the
activation of the switch will simultaneously:
1. Stop the main motor (if running) and
prevent the motor from being started while
the switch is actuated.
2. Display the follow graphic on the main
display:
4.14. ZUGANG ZUR GEHUSE TR FR
WECHSELRDER: Es sind Sicherheitsschalter
an den Tren angebracht am Deck und
Abzugsraupe. Der Sicherheitsschalter von der
Abzugsraupe hat zustzlich eine verbindung
zum Hauptmotor.
Wenn die Tr geffnet wird aktiviert der
Sicherheitsschalter folgendes.
1. Hauptmotor stoppt sofort und verhinderd
den Start des Motors.
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:
4.14. TOEGANGSDEUR TOT TANDWIELEN. Er
zijn veiligheidsschakelaars geinstalleerd op
deze toegangsdeuren voor zowel de deck(s) als
voor de trekband. Daarnaast heeft de trekband
ook nog veiligheidsschakelaars op de deuren
welke toegang geven tot de hoofdmotor.
Wanneer de toegangsdeur tot de tandwielen
geopend is dan zal de schakelaar tegelijkertijd:
1. De hoofdmotor stoppen (indien in
werking) en ervoor zorgen dat de motor
niet gestart kan worden zolang de
schakelaar geactiveerd is.
2. Een afbeelding van een open tandkastdeur
(deck of trekband) weergeven op het
hoofdscherm (Figure 4.13.1 of 4.13.2).
4.15. ELECTRICAL SYSTEM FOR
LUBRICATION: The Bijur automatic
lubrication system is a self-contained system.
The MR-15 PLC-T continuously monitors the
operation of the Bijur system and provides the
following controls and safety features. An
over-pressure valve is located by the oil pump
and prevents the oil pressure from reaching
more than 60 PSIG. If for any reason the Oil
Pressure in a deck should fall below the 455
PSIG minimum operating pressure, the
following will occur.
1. Stop the main motor.
FIGURE 4.14.1: DECK WECHSELRDER
TR OFFEN
FIGURE 4.14.2: ABZUGSRAUPE
WECHSELRDER TR 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 the
Oil pressure is once again above the
required minimum.
4.15. ELEKTRISCHES SCHMIERSYSTEM. Das
automatische Bijur Schmiersystem ist in sich
ein geschlossenes System fr jedes
Deckmodul. Das MR-15 PLC-T berwacht
fortlaufend den Bijur Systembetrieb und hat
die folgenden Kontrollen und
Sicherheitsmerkmale der Maschine. Ein
berdruckventil ist angebracht an der
lpumpe um einen berdruck von 60 PSIG zu
verhindern.
Wenn der ldruck an ein em Deck unter 455
PSIG fallen wrde, passiert folgendes.
1. Hauptmotor stoppt.
Anzeige:
4.15. ELECTRISCHE STURING VOOR HET
SMEREN. Het Bijur automatisch
smeringssysteem is een onafhankelijk systeem.
De MR-15 PLC-T verifieert voordurend de
werking van het Bijur systeem en voorziet in
de volgende bedienings- en
veiligheidsvoorzieningen. Er is een
overdrukklep voorzien aan de oliepomp en
deze zorgt ervoor dat de oliedruk niet meer dan
60 PSIG bereikt. Als er voor welke reden dan
ook de oliedruk in een deck terugvalt beneden
de minimum toegestane werkingsdruk van
455 PSIG zal het volgende gebeuren:
1. De hoofdmotor stopt.
2. De volgende foutmelding zal afgebeeld
worden totdat de oliedruk terug boven het
minimum vereiste niveau is.
FIGURE 4.15.1: LOW OIL PRESSURE SCREEN
FIGURE 4.15.1: LDRUCK ZU NIEDRIG.
FIGURE 4.15.1: OLIE DRUK TE LAAG.
4-ELECTRICAL SYSTEM
4.16. OPERATORS WORK LIGHT. A
fluorescent light kit has been provided above
or ahead of each MR-15 PLC-T deck module
to illuminate the inside of the sound enclosure.
This light is intended to be connected to the
customer's plant lighting so the light inside the
enclosure will be on as long as the lights in
your plant are on. This allows all power to the
MR-15 PLC-T to be turned off but the light
will remain on. Check your electrical
schematic for proper voltages.
4.16. LICHT IM GEHUSE FR DEN
ARBEITER. Ein licht ist im oberen Teil des
Gehuse angebracht um die Bedienung der
Maschine zu ermglichen.
Die Stromzufuhr ist direckt mit dem
Firmenstrom verbunden, unabhngig von der
Maschine, und bleibt immer an solange die
Firma den Strom nicht abschaltet.
4.16. WERK VERLICHTING. Een TL licht is
voorzien bovenaan elke MR-15 PLC-T deck
om de geluidsdichte cabine vanbinnen te
verlichten.
Het is de bedoeling deze lichtbron te koppelen
aan de verlichting van de fabriek. Dit laat toe
om alle stroom naar de MR-15 PLC-T uit te
schakelen zonder dat de verlichting in de
cabine uitgaat.
Raadpleeg het electrisch schema voor het
juiste voltage.
4.17. SHUTTLE SENSOR. (Figure 4.17.2) The
MR-15 PLC-T Braidmatic shuttle transfer
system has incorporated a means to detect any
cam track operating the intended limits of
operation. The purpose of the shuttle sensors is
to 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. Each
is radially set to produce a clearance of .55-.60
mm between the outside diameter of the cam
track and the probe.
Any malfunction to the rotor frame, rotor cam
followers or shuttle cam track relationship will
bring the probe into contact with the cam track.
The contact will simultaneously:
1. Stop the main drive motor.
2. Display the error screen below:
Do not place the deck back into service until
the cause of the sensor signal has been found
and corrected.
CAUTION
Moving elements in shuttle
assembly area.
Disconnect power and remove
upper change gear.
could result.
The steps for checkout are as follows:
FIGURE 4.17.1: SHUTTLE SENSOR SCREEN
4-ELECTRICAL SYSTEM
1. Remove the upper change gear and move
the shuttles around one complete
revolution on the deck.
2. Using a rotor that does not have a shuttle
sensor "on", move a shuttle onto, around
and off of the rotor. Notice how the shuttle
feels when doing this. This should be an
indication of a "good" shuttle and cam
follower.
3. Repeat step 2 on the rotor having the
identified sensor. A different feel can be
an indication of a problem.
4. Check the rotor cam follower for excessive
tightness or radial clearance to the shuttles.
5. Check that the probe location is .55-.60
mm from the track.
6. Check for anything on the end of the probe
that could trigger the sensor.
7. Replace the change gear and "JOG" the
deck slowly after having "reset" the shuttle
sensor by pressing the reset button on the
Alarm Panel Display.
4.17. KLPPELFHLGERT SENSOREN.
Das MR-15 PLC-T Braidmatic
Klppelbertragungssystem hat ein Gert um
jeglichen Transferschienenbetrieb ausserhalb
der gewnschten Bereichsgrenzen
festzustellen. Es ist der Zweck des
Klppelfhlers, das abnormales Verhalten
frhzeitig erkannt wird, und dadurch ernste
Transferprobleme vermieden werden.
Erdungssonden mit niedriger Spannung 24
Vdc werden von der Fabrik eingestellt und auf
der Innen-und Aussenseite eines jeden
Deckrotors verkabelt. Jede Sonde hat
Radialeinstellung, um einen Zwischenraum
von 0.55 0.60 mm zwischen dem
Aussendurchmesser der Transferschiene und
der Sonde zu schaffen. Jede Strung der
Rotorablesung, Rotorstssel oder Beziehung
der Transferschiene bringt die Sonde mit der
Transferschiene in Kontakt.
Der Kontakt wird gleichzeitig.
1. Den Antriebsmotor der Maschine stoppen.
Anzeige.
Starte nicht die Maschine bevor der Grund
gefunden ist, und der Fehler behoben ist.
WARNUNG
Bewegende Teile an den
Klppelkpfen.
Hauptschalter ausschalten und
das obere Wechselgetriebe
entfernen.
Leichte verletzungen an Hnden
und Armen knnten sonst der Fall
sein.
Die Prfung wird in den folgenden Schritten
ausgefhrt.
1. Oberes Wechselgetriebe entfernen und
Klppel in einer ganzen Deckumdrehung
verdrehen.
FIGURE 4.17.1: KLPPELFHLGERT
SENSOREN
4-ELECTRICAL SYSTEM
2. Wenn jeder Klppel an der identifizierten
Sonde vorbeigeht, durch Fhlen prfen,
das die Klppel vom Rotor Nr. 4 richtig
gefhrt werden, wenn sie sich zur
Aussenseite dieses Rotors bewegen.
3. Den Rotor Nr. 4 durch Fhlen prfen,
wenn er in der Umdrehung als eine Basis
fr die Radiallager vorbeigeht.
4. Vordere Transferlager auf bermssige
Straffheit oder Radialzwischenraum zu den
Klppelschienen prfen.
5. Die 0.55 0.60 mm Sondeneinstellung zur
Spur prfen.
6. Wechselgetriebe auswechseln und das
Deck Langsam stossweise vorrcken
zuerst aber den Klppelfhler wie auf der
Anzeige steht wieder einstellen.
4.17. SHUTTLE SENSOR. (Figure 4.17.2) De
MR-15 PLC-T heeft een ingebouwde sensor
om de speling bij de overname van de shuttles
te detecteren. Het doel van de shuttle sensor is
om preventief abnormaal gedrag te
detecteren en zo ernstige shuttle
beschadigingen te vermijden (braider crashes).
De laag voltage (24Vdc) voelers werden in de
fabriek gepositioneerd en gekoppeld naar de
binnenkant en buitenkant van elke deckrotor.
Deze zijn elk straalsgewijs ingesteld om een
speling 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 cam
track. HELP !!
Het contact zal tegelijkertijd :
1. De hoofd aandrijfmotor stoppen.
2. Het foutmeldings op het scherm tonen
(Figure 4.17.1):
3. Schakel de deck niet terug in werking
totdat de oorzaak van het sensor signaal is
gevonden is en de fout hersteld is. .
GEVAAR!
WAARSCHUWING!!
Bewegende delen in de shuttle
montage area.
Leg de stroom af en verwijder het
bovenste tandwiel.
Opgelet voor hand- en
armverwondingen.
Hier volgen de stappen voor de checkout:
1. Verwijder het bovenste tandwiel en laat de
shuttles een volledige deckomwenteling
doen.
2. Gebruik makend van een rotor die geen
shuttle sensor alarm op AAN heeft; breng
daar een shuttle naar toe, er rond en dan
terug weg van de rotor; beoordeel hoe de
shuttle aanvoelt terwijl je dit doet. Dit is
dan de referentie voor hoe een goede
shuttle en cam volger (meenemer)
aanvoelt.
FIGURE 4.17.1: SCHERM SHUTTLE VOELER
4-ELECTRICAL SYSTEM
3. Herhaal nu vorige stap op de rotor met de
sensor alarm. Een verschillend aanvoelen
kan reeds een aanduiding zijn dat er iets
mis is
4. Kijk de rotor volger (meenemer) na voor te
hoge 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 iets
anders dat het signaal zou kunnen
veroorzaken.
Plaats het tandwiel terug. Druk de sensor
reset knop en laat de deck langzaam
rondraaien met de JOG funktie.
4-ELECTRICAL SYSTEM
FIGURE 4.17.2: SHUTTLE SENSOR
KLPPELFHLGERT
SENSOR PROBE SETTING
C
L OF DECK
C
L
ROTOR
GAP
0.55 - 0.6 mm
SHUTTLE
SENSOR
PROBE
M4 SET SCREW
FOR
240-8055.01
240-8051
M10 HEX NUT
ST-M10
ADJUSTING GAP
4-ELECTRICAL SYSTEM
4.18. BROKEN BRAID/BOBBIN RUNOUT
SENSOR. (Figure 7.5.31) The function and
operation 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 is
likely to actuate the braid sensor.
The sensor, having been pulled from its
normal position, will dislodge the sensor ring
and actuate one of the 3 electronic limit
switches. This signal will:
1. Stop the braider.
2. Display the following error message:
The operator should:
1. Visually inspect the braided product and
carrier strands for broken wires, loose
wires, etc.
2. Using the "JOG" button on the Inside Jog
Station, jog the deck and observe the slow
speed release of strands. Any strands that
pull the product to one side probably have
a sticking carrier clutch. Correct all
conditions before restarting.
4.18. FLECHTFHLGERT SENSOR: Die
Funktion und der Betrieb dieses Gertes
werden in Abschnitt 2, Section 3 beschrieben.
Gebrochene oder verwickelte Fasern, Litzen
oder Drahtflechten reissen das gflochtene
Produkt heraus und schalten wahrscheinlich
das Flechtfhlergert ab.
Wenn der Fhler aus seiner normalen oder
geplanten Stelle herausgerissen worden ist,
wird er wahrscheinlich den Fhlerring
verschieben und einen der drei elektrischen
Begrenzungs schalter anschalten.
Das signal bewirkt elektrisch folgendes:
1. Motor der Maschine stopped.
Anzeige
Der Arbeiter sollte:
1. Mit dem Auge das Flechtprodukt und die
Fadenfhrerfasern und Litzen berprfen.
2. Den stossweisen Vorrckknopf unter dem
Fhler benutzen und unter Langsamer
Geschwindigkeit die Faser-und
Litzenauslsung beobachten.
FIGURE 4.18.1: BROKEN BRAID/BOBBIN
RUNOUT SENSOR SCREEN
FIGURE 4.18.1: FLECHTFHLGERT
SENSOREN
4-ELECTRICAL SYSTEM
4.18. VLECHTBREUK SENSOR. (Fig 7.5.31) De
functie 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 zal
de vlecht sensor aktiveren.
Een sensor, welke van zijn normale plaats
wordt getrokken, zal de sensor ring lostrekken
en n van de 3 electronische
eindloopschakelaars aktiveren. Dit signaal zal:
1. de vlechter stoppen
2. De volgende foutmelding afbeelden:
De operator moet dan:
1. het gevlochten product visueel nakijken
voor losse draden, gebroken draden van de
carrier, enz...
2. Door gebruikt te maken van de JOG
drukknop in de vlechter, het deck
ronddraaien en de afloop spanning van de
bobbijnen kontroleren. Spoelen welke de
vlecht naar een bepaalde richting trekken
hebben waarschijnlijk een slechte carrier.
Verbeter vooraleer opnieuw te starten.
4.19. OPTIONAL OPTICAL BRAID MATERIAL
RUNOUT SENSOR. This screen is displayed
when an optional Braid Material Runout
Sensor is installed and this sensor stops the
machine. These sensors are only active when
the braider is in Run mode. Press the O
button at the bottom to cancel the error screen.:
4.20. FRICTION LAYER OR HOSE RUNOUT
SENSORS. One input per deck and an error
graphic have been reserved for customer
specific sensors which can be used to detect a
missing friction layer or hose feed. This signal
must be shorted to ground to stop the machine.
If one of these sensors is tripped, the following
will occur:
1. Stop the braider.
FIGURE 4.18.1: VLECHT SENSOR
FIGURE 4.19.1: OPTIONAL OPTICAL BRAID
MATERIAL RUNOUT SENSOR SCREEN
4-ELECTRICAL SYSTEM
2. Display the following error graphic:
4.20. SPANNUNGSABFALL ODER
SCHLAUCHAUSLAUF ABSTELLER SENSOR:
Ein Absteller ist reserviert pro Deck fr
speziellen Kundenwunsch, welchen der Kunde
fr Spannung und Schlauchabsteller
verwenden Kann. Das Signal muss zum
geerdeten Kabel gegeben werden um die
Maschine zu stoppen.
Durch das Signal passiert folgendes:
Anzeige:
4.20. GEEN FRIKTIE OF GEEN SLANG
AANDUIDING. En input per deck en een
foutmeldingsafbeelding zijn gereseveerd voor
klanten eigen sensoren welke kunnen gebruikt
worden om geen frictie of geen slang te
detecteren.
Wanner n van deze sensoren afgaat , zal :
1. de vlechter zal stoppen.
2. afbeelding met volgende foutmelding
verschijnen (Figure 4.20.1):
4.21. CUSTOMER SPECIFIC STOP MOTIONS.
Six inputs have been made available for
customer needs. All 6 can be configured to
either switch to ground or 24Vdc, depending
on what the common input is tied to. Factory
setting is short to ground for these 6 inputs.
To reverse this, the common input on the PLC
for the inputs would have to be changed from
24Vdc to 0Vdc.
Triggering any of these inputs will cause:
1. The braider to stop.
2. Display the following error graphic, with
the number of the customer option (1 thru
6) displayed at the bottom:
3. Options 1, 2 and 3 are configured to stop
the machine and display the error message
FIGURE 4.20.1: HOSE RUNOUT SENSOR
SCREEN
FIGURE 4.20.1:
SCHLAUCHAUSLAUFABSTELLER SENSOR
FIGURE 4.20.1: GEEN SLANG
4-ELECTRICAL SYSTEM
for as long as the error signal is active.
Options 4, 5 and 6 are configured to
display an error message until the cancel
button is pressed.
4.21. KUNDENWUNSCH ZUSTZLICHE
ABSTELLER SENSOR. 6 mgliche Absteller
sind vorhanden fr den Kunden selbst zu
entscheiden. Alle 6 Knnen entweder geerdet
oder an die 24Vdc angeschlossen werden.
Firmen einstellung ist Kurz geerdet fr diese
6 mglichkeiten. Um das Rckgngig zu
machen muss die Eingabe an der PLC fr die 6
mglichkeiten von 24Vdc zu 0Vdc gendert
werden.
Bei Auslsung jeder dieser Absteller passiert
folgendes:
2. Anzeige wird anzeigen welcher von diesen
6 Abstellern ist ausgelst worden.
3. Mglichkeiten 1 - 2 und 3 stoppen die
Maschine, und die Anzeige Zeigt solange
den Fehler an, bis er behoben ist.
Mglichkeiten 4 - 5 und 6 zeigt solange
den Fehler an, bis der Knopf Cancel
Rckgngig gedrckt wird.
4.21. KLANTSPECIFIEK STOP ALARMEN. Zes
toegangen zijn beschikbaar gemaakt voor klant
eigen wensen. Alle 6 kunnen ze
geconfigureerd worden tot ofwel switch to
ground (nulgeleider) of 24Vdc, afhankelijk
aan wat de gemeenschappelijke input
verbonden is. De fabrieksinstelling voor deze 6
inputs is nul geleiding. Om dit om te keren
moet de gemeenschappelijke input op de PLC
voor deze inputs veranderd worden van 24Vdc
naar 0Vdc.
Het doen afgaan van n van deze inputs zal
als gevolg hebben :
1. het stoppen van de vlechter
2. De volgende foutmelding zal afgebeeld
worden met de nummers van de klants
optie (1 tot 6), afgebeeld onderaan :
Opties 1, 2 en 3 zijn geconfigureerd om de
machine te stoppen en de foutmelding af te
beelden voor zover het
foutmeldingssignaal actief is. Opties 4, 5
FIGURE 4.21.1: STOP MOTIONS SCREEN
FIGURE 4.21.1: ABSTELLER
4-ELECTRICAL SYSTEM
en 6 zijn geconfigureerd om de
foutmelding af te beelden tot de annuleer
drukknop wordt ingedrukt.
4.22. MOTOR OVERLOADS. The status of the
motor starter/overload relay is monitored by
the electrical system. Each of the three motors:
main drive, blower motor and lube pump has a
separate motor starter for monitoring the
current (in Amps) that is flowing to the motor.
In case of an over-current, these will trip and
send an error signal to the control.
Triggering any of these will cause the
following to occur:
1. The braider is stopped.
2. The error graphic shown below is
displayed. Note that the error graphic does
not distinguish between the 3 motor
starters. To verify which one actually
tripped and to reset this, qualified
maintenance personnel will have to reset
the components within the main electrical
enclosure.
4.22. MOTOR BERLASTUNG. Die
berlastung des Motores wird durch ein Relai
im elektrischen system berwacht. Alle drei
Motoren, Haupt-Geblse und
lpumpenmotor haben eine unabhngige
berwachung der Amperzahlen die zum Motor
fliessen. Im Falle einer berspannung fllt der
Motor ber einen Schalter aus, und gibt ein
Signal zur Anzeige.
Bei ausfall einer der drei Motoren passiert
folgendes:
2. Die Anzeige zeigt an Motor berlastung
Aber sie zeigt nicht an welcher von der 3
Motoren. 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 Maschine
wieder gestarted werden Kann.
4.22. MOTOR OVERBELASTING. De status van
de motor starter/overbelastingsrelais wordt
gecontroleerd door het electrisch systeem. Elk
van de 3 motoren : hoofdaandrijving,
ventilatormotor en de lube pomp heeft een
aparte starter relais voor het controleren van de
stroom (in Amps) die naar de motor gaat. In
geval van een over-stroom zal deze
verklikker en een foutsignaal zenden naar de
sturing.
Het doen afgaan van n van deze verklikkers
zal het volgende laten gebeuren:
1. De vlechter wordt gestopt
2. De foutmelding, hieronder afgebeeld,
wordt getoont. Let er op dat de
foutmelding geen onderscheid zal maken
tussen de 3 motor stroom verklikkers. Om
na te gaan welke juist een signaal heeft
doorgestuurd en hem te kunnen resetten,
zal gekwalificeerd onderhoudspersoneel
deze componenten moeten resetten in de
centrale electrische kast..
4.23. BLOWER ASSEMBLY. The blower
assembly is located on top of the Acoustical
Enclosure. It is intended to provide ventilation
for the interior of the Acoustical Enclosure. If
the blower is not running while the braider is
in operation, temperatures inside the enclosure
will rise to levels that are dangerous to
personnel and detrimental to the performance
of the braiders.
CAUTION
are turned off and locked in the
"off" position.
4.23. GEBLSE MONTAGE: Das Geblse ist
befestigt auf dem Gehuse der Maschine. Das
Geblse hat die Aufgabe um das Gehuse mit
luft zu versorgen, und gleichfalls zu Khlen.
Ohne das Geblse wrde der Innenraum zu
warm werden und wrde die Bedienung der
Maschie fast unmglich machen.
FIGURE 4.22.1: MOTOR BERLASTUNG FIGURE 4.22.1: MOTOR OVERBELAST
4-ELECTRICAL SYSTEM
WARNUNG
Bevor irgendwelcne Reperaturen
vorgenommen werden, mach sicher
das alle elektrischen schalter auf
Aus gelegt werden.
4.23. VENTILATOR EENHEID. De Ventilatie
eenheid bevindt zich bovenop de
geluidskabine. Deze is bedoeld om ventilatie te
geven in de ganse kabine. Als de ventilator niet
draait terwijl de vlechter in werking is zal de
temperatuur in de kabine stijgen naar een
niveau gevaarlijk voor het personeel en
schadelijk voor de werking van de vlechters.
!!Vooraleer herstellingswerken uit
te voeren moet men er zeker van
zijn dat alle stroom naar de motor
en de electrische onderdelen
uitgeschakeld is en vergrendeld in
de UIT positie.
4-ELECTRICAL SYSTEM
4.23.1. BLOWER ASSEMBLY INSTALLATION.
FIGURE 4.23.1.1: BLOWER ASSEMBLY
STEP NO. 6
STEP NO. 4
STEP NO. 5
STEP NO. 2
STEP NO. 3
STEP NO. 1
MOUNT FAN INSIDE HOOD
CAP SCREWS W/ FLAT AND
LOCK WASHERS
RUN FAN WIRES
THRU 7/8"
DIA. HOLE
MOUNT INLET BELL COLLAR
AND BRACKET TO HOOD
LOCK WASHERS
IMPELLER FAN
MOUNT INLET BELL
COLLAR TO BRACKET
W/M8X20mm HEX HEAD
LOCK WASHERS AND
HEX NUTS
INLET BELL COLLAR
SECURE BRACKET
TO FILTER BOX
M6X20mm HEX HEAD
CAP SCREWS W/FLAT
AND LOCK WASHERS
SLIDE FILTER BOX
ONTO COLLAR MOUNT
BRACKET
MOUNT LIGHT FIXTURE
MOUNTING BRACKETS W/
M6X20MM HEX HEAD CAP
SCREWS W/LOCK AND FLAT
WASHERS AND HEX NUT
4-ELECTRICAL SYSTEM
FIGURE 4.23.1.2: BLOWER ASSEMBLY
FILTER SLIDES IN
FROM END
2
5
6
1
7 4
3
FIG. &
INDEX
NO.
UNITS
PER
ASM.
4.23.1.2 BLOWER
1 S-5707 HOOD 1
7 S-4891 16" X 20" X 2" MESH FILTER 1
TABLE 4.23.1.1: TROUBLE SHOOTING CHART FOR BLOWER
SYMPTON POSSIBLE CAUSE(S) CORRECTIVE ACTION
Noise 1. Foreign objects in housing.
2. Incorrect wheel rotation.
1. Remove.
2. Reverse rotation.
Motor bearing noise Lack of bearing lubrication. Lubricate.
Excessive vibration 1. Loose mounting bolts.
2. Motor out of balance.
3. Accumulation of material on wheel.
4. Tighten.
5. Replace.
6. Clean.
Motor overloaded System static pressure less than 1" water column. Increase system static pressure.
Impeller not turning 1. Broken bolt.
2. Bearing sized.
1. Replace.
2. Replace.
4-ELECTRICAL SYSTEM
4.23.2. OPERATION.
1. Before connecting the blower motor to the
junction box cable, check the electrical
characteristics 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 is
correct as indicated by directional arrows
on the unit. If rotation is correct, apply full
electrical power.
3. With the air system in full operation and all
ducts attached, measure current input to the
motor and compare with the nameplate
rating to determine if the motor is
operating 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 is
damaged or frayed.
4. Relubricate the motor per the
manufacturers instructions. Remove any
excess lubricants from the housing and
blower assembly.
CAUTION
A ground wire must run from the
blower motor housing to a suitable
electrical ground such as a
properly grounded metallic
raceway or ground wire system.
5. Do not operate the fan with the shield
removed.
CAUTION
are turned off and locked in the off
position.
4-ELECTRICAL SYSTEM
SECTION III. INVERTER PARAMETER LIST
4.24. PARAMETER LIST FOR DUAL DRIVE.
Parameter 3 (access level) must be set to 3 in
order to see some of the parameters on this list.
Parameter 100, set this using the dip
switch on the Inverter, not through the
parameter list.
Parameter 1800 sets the carrier
frequency for the motor. You can
modify this if the motor is making a
high pitch noise when running. There is
no standard setting so you have to try
different values if you want to change
it.
PARAMETER HAULOFF DECK
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 notes
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.
4.25.1. TERMINAL BOX PANEL TO DECK
CONNECTOR AND OPTIONAL OPTICAL
BRAID MATERIAL RUNOUT CABLES.
Reference Connector in Figure 7.5.52.
FIGURE 4.25.1.1: TERMINAL BOX PANEL TO DECK CONNECTOR
T
e
r
m
in
a
l
B
o
x
Deck cable is clamped to inside wall of enclosure, above Terminal Box Panel.
Place one (1) clamp level with top of Braider Deck. The cable is then allowed to
rest on top of the deck and attached to the connector.
DECK
CABLE
BRAID MATERIAL
Optional Optical Braid Material Runout Cables should be tie wrapped to Deck Cable.
OPTIONAL OPTICAL
RUNOUT CABLES
4-ELECTRICAL SYSTEM
4.25.2. OPTIONAL OPTICAL BRAID
MATERIAL RUNOUT CABLES ON DOUBLE
DECK. .
FIGURE 4.25.2.1: BRAID MATERIAL RUNOUT CABLES
CLAMP
Clamp Optional Optical Braid Material Runout Cables to inside of Enclosure wall above door
and then tie wrap to second Deck Cable.
OPTIONAL OPTICAL
BRAID MATERIAL
RUNOUT CABLES
4-ELECTRICAL SYSTEM
4.26. TERMINAL BOX PANEL TO REMOTE
OPERATOR STATION. Reference Figure
7.5.48.
FIGURE 4.26.1: TERMINAL BOX PANEL TO REMOTE OPERATOR STATION
T
e
r
m
in
a
l
B
o
x
Remote Operator Box
Remote Operator
Station Cable
Run the cable up the inside wall of the Enclosure to the ceiling. [Clamp one (1) time.]
Run the cable along the inside ceiling to the opposite wall. [Clamp three (3) times.]
Run the cable down the inside wall of the Enclosure to the Remote Operator Station.
[Clamp one (1) time.]
4-ELECTRICAL SYSTEM
4.27. TERMINAL BOX PANEL TO INSIDE JOG
STATION. Reference Figure 7.5.40
FIGURE 4.27.1: TERMINAL BOX PANEL TO INSIDE JOG STATION
T
e
r
m
in
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.
Run cable up on the outside of the tunnel and up to the Inside Jog Station.
[Clamp or attach as needed.]
Station Cable
4-ELECTRICAL SYSTEM
4.28. TERMINAL BOX PANEL TO BOBBIN
RUNOUT DETECTORS.
FIGURE 4.28.1: TERMINAL BOX PANEL TO BOBBIN RUNOUT DETECTORS
T
e
r
m
in
a
l
B
o
x
Run small black wire assembly (240-9065) from Terminal Box Panel to
Braid Material Runout Detectors (240-9075). [No clamps needed.]
Braid Material
Runout
Detector Wire
4-ELECTRICAL SYSTEM
4.29. TERMINAL BOX PANEL TO MAIN
CONTROL PANEL. Reference Figure 7.5.43.
FIGURE 4.29.1: TERMINAL BOX PANEL TO MAIN CONTROL PANEL
Cables to Main
Control 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,
then down the outside enclosure wall to the main control panel (3000137).
T
e
r
m
in
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.
FIGURE 4.30.1: OUTSIDE LIGHT SWITCH TO INSIDE LIGHT FIXTURE
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
L
i
g
h
t

F
i
x
t
u
r
e
to the ceiling, then run along ceiling to light fixture.
[Secure as needed. See Figure 7.5.62.]
4-ELECTRICAL SYSTEM
4.31. BLOWER CABLES.
FIGURE 4.31.1: BLOWER CABLES
BLOWER
BLOWER
PANDUIT
CONDUIT
1
2
1
3
FIG. &
INDEX
NO.
UNITS
PER
ASM.
4.31.1 BLOWER CABLES
1 3000528 BLOWER CONDUIT CABLE ASSEMBLY 2
2 240-8870 BLOWER JUNCTION BOX ASSEMBLY 1
3 240-8883 BLOWER CABLE ASSEMBLY 1
4-ELECTRICAL SYSTEM
4.32. MOTOR CABLE ROUTING. Dual Drive
(PLCT-F) only.
FIGURE 4.32.1: MOTOR CABLE ROUTING
Run cable from Haul-Off up outside of enclosure wall, across
the top, down the wall and under the deck to the motor.
M
a
i
n
C
o
n
t
r
o
l
B
o
x
Tamer Blower Motor Wiring
5-LUBRICATION SYSTEM
CHAPTER 5
LUBRICATION SYSTEM
SECTION I. GENERAL DESCRIPTION
5.1. GENERAL. Each MR-15 PLC-T deck
module has been engineered to provide proper
lubrication. The total system for lubrication
consists of both automatic and manually
controlled components.
This section will provide the user with
instruction for operation, maintenance, and
troubleshooting.
5.2. AUTOMATIC OIL LUBRICATION. A Bijur
Model V5W electric motor driven gear pump
provides a constant volume discharge of oil to
each 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 two
filtering 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 filters
and through nylon tubing to the rear of the
upper deck frame.
Oil from this closed circuit is diverted to feed
oil to these MR-15 PLC-T components.
5.3. ROTOR AXLE AND ROTOR ASSEMBLY.
(Figure 7.5.21) A continuous supply of oil
enters the rear of each rotor axle. Each axle
within 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
rotor axle bearing.
Control Unit (7) Directs oil to the rear
cam follower cartridges.
Control Unit (27) Directs oil to both the
front rotor axle bearing
as well as the front cam
follower cartridge
assemblies.
5.4. EXTERNAL LUBRICATION TO ROTORS.
A Bijur meter unit from the same supply
circuit 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 REGULATION. A pressure
gauge and pressure sensing switch (Figure
5.5.1) are mounted within the closed loop of
Bijur oil system located in the lower rear of
each upper deck frame (Figure 5.6.1), or on
the tank.
The gauge displays the oil pressure within the
Bijur system at that deck.
The pressure sensing switch is in series with
the pressure gauge and continuously monitors
the oil pressure. For whatever reason, should
the pressure fall below 45 PSIG 5 PSIG (310
KPa 34 KPa), the switch will automatically
shut off the drive motor, an "AMBER" light
will appear on the Enclosure, and a low oil
pressure screen will be displayed.
Common causes for inadequate pressure
include:
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 at
all times. A pressure relief valve located in the
settling 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 preset
for 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 to
level 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
5.7. RECYCLING OF REUSABLE OIL. The
MR-15 PLC-T system has been designed to
collect, strain, and filter the oil for reuse within
the system.
The oil from within each upper deck frame is
allowed to gravitate to the sump within the
lower deck base. The heavy foreign matter
will settle to the bottom. Oil is fed by gravity
through tubing to the settling tank. At this
point, the suction filter within the Bijur pump
strains the oil and the pump feeds oil to the two
filters.
5.8. UNUSABLE OIL. Oil which is not reusable
is collected from the following locations:
1. Small amounts of oil from carriers which
can become mixed with foreign matter is
allowed to gravitate to a remote drain pan
shown in (1, Figure 7.5.33) and is
collected in the removable catch pan (19).
FIGURE 5.6.1: LAYOUT FOR LUBRICATION SYSTEM
36 CARRIER DECK
ROTOR PINION GEAR
PRESSURE
SENSING
SWITCH
GAGE
VIEWED FROM REAR
OF DECK
Dump this oil container as required but DO
NOT put this oil back into the system. It
must be discarded.
2. Oil which is mixed with dirt will be
cleansed through filters as described
earlier.
3. Badly contaminated oil must be
periodically drained or pumped from all
three settling locations. (See Maintenance
of Lubrication)
5.9. CHANGE GEAR LUBRICATION. (Not
required on PLCT-F dual drive.) The
lubrication of the change gears and the deck
drive chain components is by a sump located
in the lower frame.
This sump is filled with about 2 U.S. gallons
(7.6 liters) of oil which is fed to the drive chain
and the two change gears by the churning and
the splashing of the oil.
Since the area is sealed, the oil can be used for
a long period before replacement. (See Table
5.13.1, Lubrication Schedule).
Oil level in this sump is to be to the center of
the drive shaft.
5.10. CARRIER LUBRICATION. The carrier
wrapped clutch is lubricated at recommended
intervals with grease within the moveable hub.
Recommended: Gleitmo 585M grease.
5.11. CAM TRACK LUBRICATION. The cam
track and cam follower rolling surfaces are
lubricated by oil flow out of the cam followers
and by slinging of oil from the gears.
SECTION II. SERVICE INSTRUCTIONS FOR BIJUR CENTRAL LUBRICATING
SYSTEM
5.12. GENERAL. Your machine is protected by
a built-in Bijur central lubricating system. By
correct lubrication of all bearings served, it
assures smooth operation of your machine for
years, if properly maintained.
The Bijur system consist of three basic
elements:
1. A LUBRICATOR which forces a constant
flow of oil into the system.
2. A single line of DISTRIBUTION
TUBING branched to supply oil to the
bearing surfaces throughout the braider.
3. CONTROL UNITS which proportion the
correct oil film to each bearing.
5.13. OIL. See Table 5.13.1.
** Approved oil list:
Mobilgear 629
Shell Omala 150
ESS0 Spartan EP 150
NOTE: Do not use any oils that contain
synthetics or animal fats. They will cause the
lubrication system to fail.
Selected oils must be formulated with high
quality mineral oils.
TABLE 5.13.1: LUBRICATION SCHEDULE
ITEM FUNCTION LOCATION SOURCE & MEANS LUBRICANT INTERVAL
1 Deck Drive
Shaft (Not
required on
PLCT-F dual
drive.)
Base of Deck Splash and Bath **EXXON - Spartan
EP 150 or New
Formulation Spartan
EP 150
After the 1st 1000 hrs.,
then at 2000 hr. intervals
2 Rotor Gears
and Pinion
Drive
Front of Deck Continuously
recirculated by
Bijur Pump
**EXXON - Spartan
EP 150
2000 hrs. NOTE: The
braiding of certain type
materials may
necessitate more
frequent oil changes. The
condition of the filters
will indicate this.
3 Carrier Clutch Clutch Hub Manually - Grease Gleitmo 585M 600 hours
4 Shuttle Shaft
and Bobbin
Shuttle Spindle Manually - Grease
Lithium 2
FINA - All Purpose 200 hours
5 Shuttle and
Cam Tracks
Front of Deck Continuously
recirculated by
Bijur Pump
**EXXON - Spartan
EP 150
2000 hours NOTE: The
braiding 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 each
Rotor
Continuously
recirculated by
Bijur Pump
**EXXON - Spartan
EP 150
7 Rotor Cam
Follower
Assemblies
Rotor Frame Continuously
recirculated by
Bijur Pump
**EXXON - Spartan
EP 150
10 Blower Motor Top of Sound
Enclosure
Manual See instructions with
Blower Motor
See instructions with
Blower Motor
11 Drive Motor
"Leeson"
(PLCT-F)
Back of Deck Manual Polyrex EM 2 Years
1 to 2 full strokes on
Grease Gun
5.14. STARTING A NEW MACHINE. Fill the
reservoirs with the correct amount of oil. The
settling tank holds 13 gallons, and the base
frame sump holds 6 gallons. Put 54/82 change
gears on the deck. Remove all rotor caps (16,
Figure 7.5.19), and axle plug (5, Figure
7.5.21). Start the machine and verify that oil is
flowing out the end of all axles. This may take
several hours. Replace the plugs and caps and
continue running until you verify that oil is
flowing to all bearings on all axles. Note: the
PLCT-F dual drive version does not use
change gears or require oil in the back sump.
5.15. MAINTENANCE. Check oil levels daily
and refill reservoir when required. Check the
system periodically for loose or broken tubing,
worn hoses, loose fittings and connections.
Replace filters as needed.
5.16. OPERATION. This fully automatic
lubricating system is preset by the machine
manufacturer for best operation. The lubricator
is a motor driven gear pump with a constant
volume discharge. Discharge volume may be
adjusted by turning the bypass valve
counterclockwise to reduce the pressure or by
closing valve to increase pressure. This must
be set at maximum pressure.
5.17. FILTER REPLACEMENT.
5.17.1. INLET FILTER. An inlet filter protects
the lubricating system. The filter should be
inspected every six months. If clogged, clean
it or replace it.
To remove the pump filter (7, Figure 7.5.34).
1. Turn off the MR-15 PLC-T. Verify that the
pump is not running.
2. Raise the settling tank cover and rest its
legs on the baffles in the settling tank.
3. Unscrew the filter from the adapter.
5.17.2. SETTLING TANK FILTER SCREEN.
The settling tank filter (3, Figure 7.5.35) is
made up of two different sizes of mesh wire.
Because of the different sizes of mesh wire,
this filter is one-directional and must be
installed so that the oil flows through the fine
mesh wire first.
If the filter is installed the other way, the filter
cannot be cleaned properly. Wire pieces and
other contamination will get stuck between the
coarse and the fine mesh wire, making it
difficult to remove.
5.17.3. BASE SUMP FILTER. The base sump
filter (14 and 18, Figure 7.5.33 for the 18 & 24
carrier) (5 and 6, Figure 7.5.36 for the 36
carrier) located in the base, is made up of two
different sizes of mesh wire. It must be
installed so that the oil flows through the fine
mesh wire first.
5.18. MOTOR REPLACEMENT.
1. Turn off the MR-15 PLC-T. Verify that the
pump is not running.
2. Turn off the main power at the Main
Control Box.
3. Disconnect the electric supply at the pump
motor.
CAUTION
Do not turn the main power on.
The ends of these wires will
become energized if you do.
4. Disconnect the pump from the output line
at the adapter (28) as shown in Figure
7.5.34.
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 screws
and O-rings. The pump and cover plate
should now lift off the motor.
8. Put the replacement motor down on the
work table, put the cover plate onto the
locating hub on the motor and rotate the
cover plate until its holes in the plate line
up with the motor mounting holes. Make
sure the motor electrical connection is
pointing in the desired direction.
9. Put the large O-ring into the groove in the
face of the pump body, put the four
mounting screws thru the pump body holes
and carefully put the small O-ring onto
each screw putting it well down into the
countersink.
10. Turn the tongue on the motor shaft to face
the same direction as the slot in the pump
shaft.
11. Carefully put the pump onto the motor hub.
The pump should drop into place if the
shafts line up.
12. Tighten the motor mounting screws evenly
using 20 in.-lbs. (2.2 Nm) of torque.
13. Replace the U-shaped outlet tube, put the
lubricator unit into the reservoir, connect
the system tubing and the motor electrical
supply.
14. Turn on the main power at the Main
Control Box.
15. Turn on the oil pump switch.
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 on
the back of the deck reads 45 PSIG 5
PSIG (310 KPa 34 KPa).
6-OPTIONS
CHAPTER 6
OPTIONS
SECTION I. SUPERPACK YARN PACKAGE
6.1. SUPERPACK. Superpack is a single let-off
yarn package (Figure 6.1.1) wound on a yarn
tube (Figure 6.1.2) or a flanged bobbin
(Figure 7.5.12). A special L-bar assembly,
(Figure 7.5.15) is required.
FIGURE 6.1.1: SUPERPACK
MAX. BULGE IN
6.4 mm
10 IN
266.7 mm
6 IN (MAX)
165 mm
7/16 IN
11.1 mm
DIRECTION OF WIND
MUST BE AS SHOWN
NOTE:
YARN MUST BE
BELOW ENDS OF
TUBE.
TOTAL PACKAGE WEIGHT MUST NOT EXCEED 10 LBS (4.5 Kg)
6-OPTIONS
NOTE
1. Notches to be at 180.
2. Contruction:
Sonoco Products Co.s Spiral
Durolene with seamless low
mark outside ply.
6.2. USE OF TRUMPET AND BRAIDRING. The
braidring and trumpet are intended for use with
wire only. The braidring and trumpet were
designed to increase wire coverage on the
hose. The MR-15 PLC-T will run up to about
86% coverage. Above this percentage, cross
overs and loose wires start to become a
problem. The braidring and trumpet
combination work together to keep cross overs
per foot to an acceptable level. They will work
up to about 93% coverage before they lose
their effectiveness. These numbers may vary
because they depend on the wire product being
used.
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 the
trumpet is too small, there is the danger that a
bulge in the extruded hose will not be able to
go through the trumpet and will tear the
trumpet stand off the tunnel cover. Proper
placement of the braidring and trumpet in
relation to each other is a must. Keep in mind,
however, that there are products that will run
better with the system set-up slightly different,
so users should experiment a bit.
In operation, when the braider is started there
will be loops and cross overs at the trumpet.
This is normal as the system seems to gather
all the loose wire it can at the start of the run
and pack it onto the hose. After running about
FIGURE 6.1.2: SUPERPACK YARN CONVERTER TUBE SPECIFICATIONS
1.592 IN
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 IN
294 mm
+.00
-.062
+.00
-1.5
.02
5
.
0
1
.
2
5
.44 IN
11.2 mm
.
2
5

I
N
6
.
4

m
m
A
A
.325 IN
8.25 mm
6-OPTIONS
6 inches (152 mm) of hose, the system will
have removed all the slack and very few cross
overs 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 slightly
loose wire and the occasional cross over.
SECTION II. TRUMPET AND BRAIDRING (SLOW OPTIONS)
6.3. INSTALLATION AND OPERATION OF
TRUMPET AND BRAIDRING (SLOW -
OPTIONAL). (Refer to Figure 7.5.28)
1. Before threading wire onto liner, loosen
Kipp handle (24, Figure 7.5.28) and move
braidring (1, Figure 7.5.28) all the way to
the right and retighten Kipp handle.
Loosen screws (4) and move trumpet (2)
all the way to the left and retighten all
screws (4).
CAUTION
With the braidring all the way in,
the carriers have no protection
from snagging strands passing too
close. Be sure this cannot happen
before running the braider. Move
the braidring out, if necessary, to
prevent this.
2. Thread the machine and attach all wires to
the liner. Operate the braider enough to
allow braid point to reach the position it
will remain in. Be sure that the tie-in point
for the wires on the liner will pass through
the trumpet (2) without jamming.
3. Jog the deck until any shuttle reaches a
position where it is as far from the center
of the hose as it can go. Leave it in this
position. Loosen the Kipp handle and
move the braidring (1) until it touches the
plait of wires that comes from this shuttle.
Now move the braidring inch (13 mm)
more. Retighten Kipp handle securely.
4. Loosen all screws (4) and slide the trumpet
(2) left until it touches the wires coming
from the braidring (1). Now run the deck
while moving the trumpet 1 inch (25 mm)
in from the point it touched the stationary
wires. When this point is reached, tighten
all screws (4). Use a 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
the trumpets.
7. The trumpet and braidring are now ready
for production operation.
8. To detect broken wires, a ground ring
should be used.
9. To aid in cleaning jams, remove the screws
holding split trumpet halves together.
10. The stand slide assembly and inside jog
station must be installed as shown (Figure
7.5.28). The box must be facing the haul-
off. Failure to do this can result in severe
damage to the braider.
11. The sensor stand assembly must be
installed as shown in order to place the
trumpet in the correct position (Figure
7.5.28).
12. On older braiders M6 screws are installed
at the 8 locations shown in Figure 7.5.28,
Item 20. Remove these screws (20), drill
the holes to 8.1 mm diameter and install
the M8 screws (20) and washers (21 and
23) and nuts (22) as shown in Figure
7.5.28. Newer braiders have the M8 screws
installed at these locations.
6-OPTIONS
SECTION III. BROKEN BRAID DETECTOR
6.4. INSTALLATION AND OPERATION OF
BROKEN BRAID DETECTOR. (Refer to Figure
7.5.31) The sensor operates by moving in the
direction of hose travel whenever any of the
pins engage a loop or snarl on the hose. This
movement closes the gap between the braid
detector spring (13, Figure 7.5.31) and the
spring plunger (5, Figure 7.5.31), which
electrically grounds out the circuits that
control the running of the braider, and stops
the braider. Proceed as follows to install and
operate the sensor.
1. Turn the electrical power switch to the
"Off" position at the main control box on
the haul-off to prevent the braider from
moving while you are installing the broken
braid detector.
2. Place the braid sensor assembly (Figure
7.5.31) on the stand slide assembly (2,
Figure 7.5.31) using the two M6 screws
and B6.4 washers. Secure the bracket
assembly to the slide assembly in the
approximate position desired in relation to
the braid point.
3. Insert the two ring halves as required by
the hose size (18, Figure 7.5.31) in the
holder (14, Figure 7.5.31). The ring halves
should snap in or out with out excessive
force. No tools should be required to
install or remove the ring halves. All
adjustments have been set at the factory. A
few minutes practice installing and
removing the ring halves will allow the
operator to develop the speed desired.
4. Insert the holder (14) containing the ring
halves into the spring assembly. The holder
can be inserted from the front or rear of the
spring assembly. No tools are needed.
Excessive force will damage the springs,
causing the sensor to operate improperly.
5. Adjust the four spring plungers (5, Figure
7.5.31); clear the springs about mm.
This adjustment controls the sensitivity of
the sensor. A larger gap decreases the
sensitivity, a smaller gap increases the
sensitivity. All four gaps must be set
identically. Too great a gap will let the
holder move out without shutting off the
braider.
6. Turn the power switch to the "On" position
at the main control box. Verify that the
sensor is working by moving the braid
detector holder so the braid detector
springs are no longer in the grooves of
braid detector holder, then close the
enclosure door and try to run the braider.
The braider should not start.
NOTE
The broken braid detector and the
bobbin runout detector will not
work when the inside safety
switch is in the "ON" position.
Now verify that each spring will trip the
sensor by pushing the braid detector holder
in the direction to trip one spring and then
try to run the braider. Reset the braider by
pushing the stop button before testing the
next spring. The braider must not start.
7. After completing the above test, the sensor
is ready to use. The ring halves should be
removed when threading the sensor.
8. In normal operation, a suggested procedure
for restarting the braider after a defect has
moved the braid detector holder enough to
turn off the braider, is as follows:
6-OPTIONS
NOTE
To prevent injury to the operator,
use the inside jog switch only.
a. Remove the braid detector holder (14)
completely out of the spring holders, if
it is not already out.
b. Remove the half assembly rings (18) if
they are still in place.
c. Use the inside jog button to jog the
braider until the defect is 50 to 100 mm
"down stream" of the spring assembly.
d. After taking care of the defect, slide the
braid detector holder (14) "upstream"
of the defect and then reinstall the ring
halves.
e. Now push the holder, with ring halves,
back into the spring assembly. The
springs must engage the "V" groove.
f. Return the inside safety switch to the
"Off" position. Push the "STOP"
button to reset the controls. The
braider is now ready to resume
operation.
Note that the ring halves must have
between 2 and 5 mm of clearance per side
between the OD of the hose and the ID of
the ring halves. Ring halves with different
inside diameters are available from Mayer
Industries Inc.. Please contact the Service
Department for any additional information.
Generally, the closer the sensor is to the
braid point, the quicker the defect will be
detected. Experience with the sensor will
determine the best location for the products
being used.
If the sensor is too sensitive, the mm gap
can be increased. However, if the gap is
too much, it is possible for the holder to
move out of the springs without stopping
the braider. If a new gap is set, the tests in
steps 1 thru 6 must be repeated. In some
cases the sensor may operate because a
compensator is not working properly. This
will allow the hose to pull very hard
against the side of the ring halves and trip
the sensor. The proper procedure is to
correct the compensator.
TABLE 6.4.1: AVAILABLE RING HALVES
(SIZES)
RING I.D.
RECOMMENDED HOSE SIZES
(DIAMETER OVER THE BRAID)
mm mm 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 - 1.220
40 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
6-OPTIONS
SECTION IV. BRAIDER STEEL PLATE MOUNTING
6.5. MOUNTING OF A BRAIDER ON A STEEL
PLATE. In some situations it is impractical to
mount the braider in the standard manner
shown in Chapter 1. In these cases a steel plate
can be secured to the floor and the braider
attached to it. See Figures 6.9.2 and 6.9.3 for
details of the plate.
NOTE: Before using this type of installation
review the details with your Plant Engineering
personnel and be sure you are in compliance
with all local building codes. The floor
beneath the steel plate/braider must have a
minimum thickness of 250 mm of high
grade concrete.
The steel plate is fastened to the floor using
standard industrial attachments. Contact your
local Industrial Supplier for details of these
attachments. The braider is fastened to the
steel plate using the hardware that is normally
used to secure the braider to the concrete floor,
except items 1, 2, 3 are replaced by their
metric equivalents, and which should be
purchased locally or through Mayer Industries.
See Figures 6.9.2 and 6.9.3. The diameter of
the holes that need to be drilled for the
hardware are as follows: Item 8 is to be 28 mm
and Item 9 will be 5/8 inches. All leveling and
alignment adjustments must be completed
before attempting to operate the braider.
The steel plate must be purchased from a local
supplier. Any good grade steel can be used.
FIGURE 6.5.1: SECURING HARDWARE (24 CARRIER DECK SHOWN)
1
2
3
4
5
6
7
8
9
HAUL-OFF
4
5
10
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.5.1 SECURING HARDWARE
1 M20 X 150 DIN 931
HEX HEAD BOLT (83291) (24 CAR.)
HEX HEAD BOLT (83291) (36 CARRIER)
8
12
2 A20 DIN 127
LOCKWASHER (84124) (24 CARRIER)
LOCKWASHER (84124) (36 CARRIER)
8
12
3 B21 DIN 125
WASHER (84055) (24 CARRIER)
WASHER (84055) (36 CARRIER)
8
12
4 240-0013
THREADED BUSHING (24 CARRIER)
12
16
5 240-0014
NUT (24 CARRIER)
NUT (36 CARRIER)
12
16
6 240-0001 BASE FRAME 1
7
240-0106
360-0106
DECK MOUNTING PLATE (24 CAR.)
DECK MOUNTING PLATE (36 CARRIER)
1
1
8 S-5573
ANCHOR (24 CARRIER)
ANCHOR (36 CARRIER)
12
16
9 S-5574 HAUL-OFF ANCHOR 4
10 240-0012 BASE PLATE 4
6-OPTIONS
FIGURE 6.5.2: STEEL MOUNTING PLATE DETAILS
MR-15 PLC-T 24 CARRIER ONLY
38.1
940
860
7000.2
80
(
1
2
)

3
0

T
H
R
U
(
8
)

M
2
0

T
H
R
U
120
1
0
0
5
0
2
5
0
3
5
0
0
.
2
3
5
0
0
.
2
7
2
0
0
.
2
2
5
0
5
2
0
1
6
2
0
2
5
0
2
5
0
+
1
0
-
0
+10
-0
6-OPTIONS
FIGURE 6.5.3: STEEL MOUNTING PLATE DETAILS
MR-15 PLC-T 36 CARRIER ONLY
1090
1010
120 8500.2
38.1
80
1
0
0
5
0
3
5
0
3
2
0
0
.
2
2
5
0
2
5
0
3
2
0
0
.
2
4
0
0
7
2
0
0
.
2
2
2
0
0
+
1
0
-
0
2
5
0
2
5
0
3
5
0
3
2
0
0
.
2
3
2
0
0
.
2
(
1
2
)

M
2
0

T
H
R
U
(
1
6
)

3
0

T
H
R
U
+10
-0
6-OPTIONS

6-OPTIONS
SECTION V. BRAIDING NOSE ASSSEMBLY
6.6. The Braid Nose Assembly, when
correctly positioned, prevents the wire tension
from being transferred directly to the hose
inner tube. This allows for better control of the
inner tube diameter. In some Hose
Constructions, the Braid Nose may eliminate
the need for freezing or using air in the inner
tube.
When selecting a Braid Nose for a Hose
Construction, the inside diameter of the Braid
Nose should be as close as possible to the
largest diameter of the inner tube.
Since each Hose Construction application is
different, the Braid Nose Assembly is designed
to be adjustable. This gives the operator the
ability to adjust the position of the Braid Nose
until the desired results are achieved. The
position of the Braid Nose setup can be
repeated by documenting the location from the
scales on each of the assembly components.
6-OPTIONS
FIGURE 6.6.1: BRAIDING NOSE ASSEMBLY
I.D. 4 THRU I.D. 41
SEE FIGURE 6.6.2
FOR BRAID NOSES
5
4
3
2
1
10
6
12
11
13
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.6.1 240-9257 ETC BRAIDING NOSE ASSEMBLY (I.D. 4 - 41)
5000233 GUIDE FLANGE ASSEMBLY KIT
1 240-9244 BRAIDING TUBE 1
2 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
7 S-5549 SQUARE DRIVE SOCKET (TOOL - NOT SHOWN) 1
8 S-5550 EXTENSION (TOOL - NOT SHOWN) 1
9 S-5551 SLIDING T (TOOL - NOT SHOWN) 1
5000235
5000236
5000237
5000238
5000239
5000240
5000241
CONE SET KIT 4MM THRU 12MM
CONE SET KIT 34MM
CONE 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
240-9246
240-9248
240-9249
240-9250
240-9251
240-9252
240-9253
BRAIDING CONE 4MM - 12MM (5000235)
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
FIGURE 6.6.2: BRAIDING NOSES
I.D. 4 THRU I.D. 41
1 THRU 35
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.6.2 240-9257 ETC BRAIDING NOSES (I.D. 4 - 41)
1 240-9236 BRAIDING NOSE (I.D. 4) 1 A/R
6-OPTIONS
FIGURE 6.6.3: BRAIDING NOSE ASSEMBLY
I.D. 63
4
3
2 1
5
6
11
10
14
12
13
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.6.3 2000016 BRAIDING NOSE ASSEMBLY (I.D. 63)
5000234 GUIDE FLANGE ASSEMBLY KIT
1 1000019 BRAIDING TUBE 1
3 1000156 HUB 1
4 240-9256 SLEEVE ASSEMBLY 1
7 S-5552 SQUARE DRIVE SOCKET (TOOL - NOT SHOWN) 1
8 S-5553 EXTENSION (TOOL - NOT SHOWN) 1
9 S-5554 SLIDING T (TOOL - NOT SHOWN) 1
5000242 CONE SET KIT 63MM
10 1000015 BRAIDING CONE 1
11 1000018 SPUR GEAR 1
12 S-5569 SOCKET SET SCREW (M6 X 10 BRASS TIP) 2
13 S-5546 SHOULDER SCREW 1
14 1000013 BRAIDING NOSE (SIZE 63) 1
6-OPTIONS
SECTION VI. BRAID MATERIAL RUNOUT SENSOR
6.7. Mayer Industries offers an optional Braid
Material Runout Sensor that will stop the
braider before a bobbin runs empty and creates
a defect in the hose. This is done through the
use of 2 laser sensors (per deck) that measure
the distance to the bobbin each time a bobbin
passes in front of the sensor. The smallest
diameter bobbin measured by each sensor is
recorded by the PLC. The system is calibrated
by measuring the distance to an empty bobbin.
The customer can then configure the PLC to
shut off the braider at a certain distance before
the bobbin is completely empty. Depending on
the type of material being used, this cutoff
distance is usually in the range of 0.5 - 2 mm.
6.8. SETUP.
1. Mount the two optical laser sensor
assemblies in the predrilled holes on the
top 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 6.11.1.
3. Plug the connection cables to the laser
sensors per Figure 6.11.1.
NOTE: Take care not to
damage the plug on the laser
sensor unit. The plug on the
laser 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 each
window of the enclosure.
6-OPTIONS
6.9. CALIBRATION.
1. Install one empty bobbin onto the shuttle at
counter-clockwise position; and one empty
bobbin at the clockwise position.
2. Install the rest of bobbins onto the shuttle
with 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 to
calibrate (NOT braiding).
6. At the main MENU, touch SETTINGS;
at the next menu pop-up, touch the
CONFIG button next to the bobbin run
out setting.
7. At the next menu, there will be displays of
the distance to the empty bobbin on each
sensor; run the machine for at least 5 to 10
minutes and watch the distance to bobbin
run out. When the readings of the distance
get steady, enter the desired bobbin run out
cutoff distances for the sensors at the right
hand side column.
8. Subtract 1.0 mm minimum for yarn and
0.5mm minimum for wire to the actual
readings on the left column. NOTE: For
yarn with a diameter larger than 1mm,
the cut off distance will have to be
modified according to the diameter.
EXAMPLE: If the reading on the left side
is 194mm, set the cut off distance at
193mm minimum for yarn and 193.5mm
minimum for wire.
9. Additional calibration is needed only if
bobbins with a different barrel diameter are
used.
6.10. BRAID MATERIAL RUNOUT
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
the lenses.
2. Depending on materials being braided, the
frequency of cleaning may vary - adjust as
required.
3. Erratic bobbin size readings are an
indication that the laser lenses need to be
cleaned.
6-OPTIONS
6.11. BRAID MATERIAL RUNOUT LASER
SENSOR DATA DRAWING.
FIGURE 6.11.1: BRAID MATERIAL RUNOUT LASER SENSOR DATA DRAWING
5
6
7
SHIELD
4
3
2
1
8
9
6
7
8
3
1
2
MAIN
CONTROL BOX
HAUL-OFF
DECK 1 SHIELD DECK 2 SHIELD
PRIMARY CONTROL BOX
ENCLOSURE
1
2
3
4
LASER
LASER
LASER
LASER
10
11
11
12
13
13
13 13
1
4
4
4
4
4
MAIN CONTROL BOX
STAND ALONE
6-OPTIONS
Tie wrap laser sensor cables to the
deck cables.
Sensor cables from Laser Sensors 3
and 4 are to be fastened to the inner wall of
the enclosure with cable clamps.
Take care not to damage the plug on
the 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 on
each window of the enclosure.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.11.1 BRAID MATERIAL RUNOUT SENSOR
1 3000651 SENSOR CABLE 4
2 S-5751 LASER SENSOR 4
3 1000639 SENSOR HOLDER 4
4
1000641
1000747
MOUNTING BASE (24 CARRIER)
MOUNTING BASE (18 CARRIER)
4
4
6 A8 DIN 127 LOCK WASHER (84105) 12
7 B8.4 DIN 125 FLAT WASHER (84025) 12
10 1000648 SENSOR BREAKING PROTECTOR BRACKET 4
12 1000647 SENSOR BREAKING PROTECTOR 4
13 S-5756 LASER LIGHT WARNING DECAL 4
1
2
3
4
6-OPTIONS
6-OPTIONS
SECTION VII. DUAL DRIVE SYSTEM
6.12. DUAL DRIVE SYSTEM. Mayer Industries
offers an optional Dual Drive System to
replace the drive shaft/change gear system.
This system has individual inverter drives and
motors on each deck and on the Haul Off.
Technical Description:
Hardware: Siemens S7-300 and
S7-200 PLCs
Profibus Network
Operator Interface:Siemans 6 inch Touch
Screen
Drives:7.5 Hp (Braider) (5.6 Kw) and
10 Hp (7.5 Kw) (Haul Off) Inverter
Drives;
1 per Braider and 1 per Haul Off
Motors: Leeson 7.5 Hp (5.6Kw) Inverter
Duty
Drive Train:Gear Belts
Lead/Pitch Range:6-200 mm
**Longer Pitches can be obtained with
software and/or gear pulley change.
ADVANTAGES:
Less wear parts: No change gears, drive
shafts or chains
Easier Installation: No drive shafts to line
up / no covers to install
Flexible Installation: No set distance
between the Braider and Haul Off
Less oil consumption: No lubrication
needed 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-
tions
POWER CONSUMPTION: (Ball Park)
Single Deck: 5 KVA
Double Deck: 9 KVA
INSTALLATION: See Chapter 1
ADJUSTMENTS AND MAINTENANCE: See
Chapter 2 (Excluding the drive train - all
adjustments 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
PARTS / DUAL DRIVE: See layouts in this
section
ELECTRICAL SCHEMATICS: See Chapter 10
6-OPTIONS
6.12.1. SENSOR STAND ASSEMBLY.
FIGURE 6.12.1.1: DUAL DRIVE SENSOR STAND ASSEMBLY
1
22
23
26
8,9
11,12
5
13
4
3,10
6/14
7/15
2
3
21
20
8,9
24
25
36 CARRIER
3
10 4
10
16
17,18,19
27
HIDDEN
FROM VIEW
6-OPTIONS
*Not part of Sensor Stand Assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.1.1
2000669
2000765
DUAL DRIVE SENSOR STAND ASM (18 & 24 CAR)
DUAL DRIVE SENSOR STAND ASM (36 CARRIER)
1
2000628
2000839
STAND BASE ASSEMBLY (18 & 24 CARRIER)
STAND BASE ASSEMBLY (36 CARRIER)
1 A/R
1 A/R
2 2000787 STAND SLIDE ASSEMBLY 1
3 240-6079
EYE BOLT ASSEMBLY (18 & 24 CARRIER)
EYE BOLT ASSEMBLY (36 CARRIER)
1 A/R
3 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) 2 A/R
7 B6.4 DIN 125 FLAT WASHER (051040.0) (84015) 2 A/R
8 M16 X 35 DIN 6912 SOCKET HEAD SCREW (050753.0) (83200) 4
9 B17 DIN 125 FLAT WASHER (84045) 4
10 M10 DIN 934
NUT (050945.0) (83580) (18 & 24 CARRIER)
NUT (050945.0) (83580) (36 CARRIER)
1 A/R
3 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) 3
20 2000786 SLIDE ASSEMBLY 1
21 1000788 CLAMPING PLATE 1
22* 1000744 OIL LINE PROTECTOR CONDUIT 1
23* S-4716 HEX HEAD ANCHOR BOLT (3/8 X 2 ) 6
24* A10 DIN 127 LOCK WASHER (051221.0) (84110) 6
25* B10.5 DIN 125 FLAT WASHER (051043.0) (84030) 6
26 2000837 PUSHBUTTON HOLDER ASSEMBLY 1
27 83450 KIPP HANDLE 1
6-OPTIONS
6.12.2. DUAL DRIVE ASSEMBLY.
FIGURE 6.12.2.1: DUAL DRIVE MOTOR DRIVE ASSEMBLY
12
11
10
13
14
15
4
5
16
6
22
3
1
21
19
2
23,24
8
7
9
20
16
6
18
17,25
SEE FIGURES 6.12.2.2
AND 6.12.2.3
26
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.1 MOTOR DRIVE ASSEMBLY
1
S-5739
S-5805
MOTOR, 7 1/2 HP FLANGED MOUNTED
MOTOR, 15 HP 60/50 HZ (36 CARRIER)
1
1
2
1000624
1000945
MOTOR ADJUSTING PLATE
MOTOR ADJUSTING PLATE (BRIDGESTONE)
1
1
3 1000623 MOTOR MOUNTING PLATE 1
4
S-5778
S-5728
S-5796
GEAR BELT TIMING BELT (18 CARRIER)
1
1
1
5
1000586
1000821
1000944
MOTOR PULLEY
MOTOR PULLEY (36 CARRIER)
MOTOR PULLEY (BRIDGESTONE)
1
1
1
6 1000627 BASE PLUG 2
7 S-5746 GEAR BELT BUSHING 1
8 S-5764 GEAR BELT PULLEY, 36 TEETH 1
9
2000675
2000664
2000831
GEAR BOX COVER ASSEMBLY (18 CARRIER)
1
1
1
10 M12 X 30 DIN 933 HEX HEAD SCREW (83020) 4
11 A12 DIN 127 LOCK WASHER (84115) 4
12 B13 DIN 125 FLAT WASHER (84035) 4
14 A10 DIN 127 LOCK WASHER (84110) 7
15 A10.5 DIN 9021-ST WASHER (84187) 7
17 M6 X 16 DIN 916 SOCKET HEAD SET SCREW (82357) 1
18 1000626 DECK PLUG (24 CARRIER) 1
19 S-5748 FLAT HEAD SOCKET SCREW (1/2 -13X1 1/4" LNG) 4
20 M6 X 10 DIN 9427 BUTTON HEAD SOCKET SCREW (82236) 4
21
5/16"X5/16"X60 mm
3/8"X3/8"X60mm
KEY (PART OF ITEM 1) (18 & 24 CARRIER)
KEY (PART OF ITEM 1) (36 CARRIER)
1
1
22 1/4" X 3/8" LNG PART OF ITEM 7 1
23 5/16" 2" LNG HEX HEAD SCREW (PART OF ITEM 7) 3
24 5/16" LOCK WASHER (PART OF ITEM 7) 3
25 M6 X 10 DIN 916 SOC HD SET SCREW (82220) (OVER KEYWAY) 1
26 240-6094 MACHINE I.D. PLATE (NOT SERVICED) 1
6-OPTIONS
FIGURE 6.12.2.2: DUAL DRIVE ASSEMBLY
24 CARRIER
1
.15 mm
AXIAL PLAY
7
2
8
5
4 9 3
10
UPPER DECK FRAME
6
6-OPTIONS
*Not part of Shaft Assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.2 240-2093
DUAL DRIVE PINION SHAFT ASSEMBLY
(24 CARRIER)
1 240-2011 BEARING HOUSING 2
2
30 X 42 X 0.1 DIN 988
30 X 42 X 0.2 DIN 988
30 X 42 X 0.3 DIN 988
30 X 42 X 0.5 DIN 988
30 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)
1 A/R
1 A/R
1 A/R
1 A/R
1 A/R
3 240-2016 PINION SHAFT 1
4 240-2025 PINION GEAR 32 T 1
5 A8 X 7 X 32 DIN 6885 KEY (050317.0) (81220) 1
6* M10 X 40 DIN 6912 SOCKET HEAD SCREW (050725.0) (82925) 8
7 KM 6 DIN 981 LOCK NUT (050986.0) (83840) 2
8 MB 6 DIN 5406 SAFETY WASHER (051248.0) (84160) 2
9 6306-2RS DIN 625 BALL BEARING (051362.0) (86625) 2
6-OPTIONS
FIGURE 6.12.2.3: DUAL DRIVE ASSEMBLY
36 CARRIER
1
.15 mm
AXIAL PLAY
7
2
8
5
4
9
3
10
UPPER DECK FRAME
6
6-OPTIONS
*Not part of Shaft Assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.3 2000760
DUAL DRIVE PINION SHAFT ASSEMBLY
(36 CARRIER)
2
30 X 42 X 0.1 DIN 988
30 X 42 X 0.2 DIN 988
30 X 42 X 0.3 DIN 988
30 X 42 X 0.5 DIN 988
30 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)
1 A/R
1 A/R
1 A/R
1 A/R
1 A/R
3 1000746 PINION SHAFT 1
4 240-2025 PINION GEAR 32 T 1
5 A8 X 7 X 32 DIN 6885 KEY (050317.0) (81220) 1
7 KM 6 DIN 981 LOCK NUT (050986.0) (83840) 2
6-OPTIONS
FIGURE 6.12.2.4: MAIN CONTROL BOX ASSEMBLY
SHEET 1 OF 2
11 10
12
9
2
1
5 3 8 4
6 7
A
A
SECTION A-A
13,14
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.4 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
6-OPTIONS
FIGURE 6.12.2.5: MAIN CONTROL BOX ASSEMBLY, OPEN DOOR
SHEET 2 OF 2
6,7 1
18 8 9
4,5
10,11,12
13,14,4,
2
2(FIG. 6.12.2.4)
BACK VIEW
EMERGENCY
STOP MAIN
POWER
PILOT
LIGHT
S3
S1
17
19
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.5 3000617 MAIN CONTROL BOX ASSEMBLY (SHEET 2)
1 3000610 MAIN CNTRL. BOX PANEL ASM. (FIGURE 6.12.2.6) 1
2 100-0718 MOUNTING RAIL 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 RED SWITCH 1
19 3000829 DOOR SWITCH CABLE 1
6-OPTIONS
FIGURE 6.12.2.6: MAIN CONTROL BOX PANEL ASSEMBLY
SHEET 1 OF 2
12
15
20
9,10
18
16
7
13,14
9,10
11
1
12
19
2
13,14
8
17
3
4
5
29 21
22
8
12
13,14
28
13,14
6 6
6
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.6 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 RELAY (K1) 1
4 S-5686 RELAY, 24V DC (K2) 1
5 S-5018 TERMINAL BLOCK (PE) 3
6 S-5083 AUXILLARY STARTER CONTACT BLOCK 3
7 S-5683 RELAY, 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 RAIL 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
29 S-3883 PART OF 3000418
6-OPTIONS
FIGURE 6.12.2.7: MAIN CONTROL BOX PANEL ASSEMBLY
SHEET 2 OF 2
1
4
13,14(FIG6.12.2.6)
12(FIG 6.12.2.6)
2 3
9,10(FIG 6.12.2.6)
5
6
7 8 18(FIG 6.12.2.6))
13,14(FIG6.12.2.6)
9,10(FIG 6.12.2.6)
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.7 3000610 MAIN CONTROL BOX PANEL ASM. (SHEET 2)
1 S-5736 DIN MOUNTING RAIL 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
FIGURE 6.12.2.8: INVERTER PLATE ASSEMBLY
7,8
2
4
3
5 16
6
9
2,10
15 11 17 12 13 14
1
18
19,20,21
6-OPTIONS
*Not included in plate assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.8
3000601
3000604
3000606
3000605
3000823
3000822
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 INVERTER PLATE ASSEMBLY 1
2
M5 DIN 934
M5 DIN 934
HEX NT (050937.0) (3000601, 3000606, 3000823)
HEX NT (050937.0) (3000604, 3000605, 3000822)
19
15
3
S-5758
S-5758
S-5762
S-5762
S-5804
S-5804
7.5 HP HIGH VOLT INVERTER (3000601)
7.5 HP HIGH VOLT INVERTER (3000604)
7.5 HP LOW VOLT INVERTER (3000606)
7.5 HP LOW VOLT INVERTER (3000605)
15 HP HIGH VOLT. INVERTER (3000823)
15 HP HIGH VOLT. INVERTER (3000822)
2
1
2
1
2
1
4
S-5760
S-5760
PROF. OPT. CARD (3000601, 3000606, 3000823)
PROF. OPT. CARD (3000604, 3000605, 3000822)
3
2
5 81889 SELF-TAPPING SCREW 6
6
S-5759
S-5759
S-5763
S-5763
10 HP HIGH VOLT INVERTER (3000601) (3000823)
10 HP HIGH VOLT INVERTER (3000604) (3000822)
10 HP LOW VOLT INVERTER (3000606)
10 HP LOW VOLT INVERTER (3000605)
1
1
1
1
7 S-2859 WIRE, BLACK 12 AWG 2000 mm
8 S-5305 WIRE FERRULE 18
10 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 6
11 S-5588 3 CONDUCTOR TERMINAL, GREEN 4
12 S-5586 2 CONDUCTOR TERMINAL, GRAY 9
13 S-5120 STRIP MARKER 1
14 S-5743 JUMPER, GRAY 6
15 1000655 SWITCH BRACKET 1
16
S-5671
S-5671
OPER. INT. FOR INV. (3000601, 3000606, 3000823)
OPER. INT. FOR INV. (3000604, 3000605, 3000822)
3
2
18 S-5589 TERMINAL BLOCK 9
19* 1000877 INVERTER COVER 1
20* 1000878 COVER 1
21* 81888 SELF-TAPPING SCREW 9
6-OPTIONS
FIGURE 6.12.2.9: MAIN CONTROL BOX ASSEMBLY (STAND ALONE)
SHEET 1 OF 2
5
7
8
3
3
7
6
8
4 2
7
5
8
9
1
SECTION A-A
(See Sheet 2)
SECTION B-B
(See Sheet 2)
10
11
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.9 3000886
MAIN CONTROL BOX ASSEMBLY
(STAND ALONE) (SHEET 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) 12
9 S-5829 FAN FILTER 1
10 S-5723 BLANK (BLACK) LEGEND 3
11 S-4047 EMERGENCY STOP LEGEND 1
6-OPTIONS
FIGURE 6.12.2.10: MAIN CONTROL BOX ASSEMBLY (STAND ALONE)
SHEET 2 OF 2
1
8
2,3
6,7
4,5
9,10
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.10 3000886
MAIN CONTROL BOX ASSEMBLY
1 3000885 MAIN CONTROL BOX PANEL ASSEMBLY 1
2 S-5788 2 POSITION KEYED SWITCH 3
3 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 1
6-OPTIONS
FIGURE 6.12.2.11: MAIN CONTROL BOX PANEL ASSEMBLY (STAND ALONE)
SHEET 1 OF 3
2,3,13,22
11
9
15
10
15
21
7
20
1
17
13
2,3,22
17
8,22
15
12
5
4
6
23 24
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.11 3000885
MAIN CONTROL BOX PANEL ASSEMBLY
2 M4X16 DIN 84 SLOTTED CHEESE HEAD SCREW (81850) 28
3 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 28
4 S-5590 JUMPER 10
5 S-5589 4 CONDUCTOR TERMINAL 50
7 S-5583 PLC 1
8 S-5499 NYLON CHEESE HEAD SCREW ( M4 X 12) 34
9 S-5582 E-STOP RELAY 1
10 S-5686 24 V DC RELAY 1
11 S-5681 POWER SUPPLY 1
13 S-3697 STANDARD RAIL 3@310mm
14
15 97340 WIRING DUCT WITH COVER 6@330mm
16
18
19
20 S-5744 PROFIBUS MODULE 1
21 S-5680 PROFIBUS CONNECTOR 4
22 S-5485 M4 INSERT 54
23 S-5845 2 POSITION CONNECTOR 1
24 S-5849 4 POSITION CONNECTOR 1
6-OPTIONS
SHEET 2 OF 3
3
15 (Sheet 1)
6
7
5
9
10
16
15
2,3,13,22
(Sheet 1)
11
13
1
2
12 8
15 (Sheet 1)
3
14
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.12 3000885
1 S-3697 STANDARD RAIL 200mm
3
5 S-5683 9 AMP RELAY 1
9 S-5381 CIRCUIT BREAKER (F2/F4) 2
14 S-4034 TRANSFORMER (540-220V) 1
16 S-5083 AUXILIARY STARTER CONTACT BLOCK 3
6-OPTIONS
SHEET 3 OF 3
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 (Sheet 1)
20
7
8
11
21 (Sheet 1)
18 (Sheet 1)
17,18
6
8
11
21 (Sheet 1)
18 (Sheet 1)
17,18
5 (Sheet 1)
12 (Sheet 1)
9
21
10
19
16
HAUL
OFF
DECK
1
DECK
2
LUBE BLOWER
2,3,22 (Sheet 1)
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.13 3000885
1
2
3 S-3697 STANDARD RAIL 2@70mm
4
5 97340 WIRING DUCT WITH COVER 890mm
6 S-5759 INVERTER, 10 HP HIGH VOLT 1
7 S-5758 INVERTER, 7.5 HP HIGH VOLT 1/Deck A/R
8 S-5761 OPERATOR INVERTER INTERFACE 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 INVERTER, 10 HP LOW VOLT A/R
13 S-5762 INVERTER, 7 HP LOW VOLT A/R
17 M5 DIN 934 HEX NUT (83520) 12
18 S-4082 SELF CLINCHING STUD (M5) 12
6-OPTIONS
FIGURE 6.12.2.14: TERMINAL BOX
SHEET 1 OF 3
2
3
1
10
5,6
7,8,9
11,12,13
4
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.14 3000900
TERMINAL BOX ASSEMBLY
(WITHOUT TOUCHSCREEN) (SHEET 1)
1 1000899 TERMINAL BOX 1
2 S-3505 RED PUSHBUTTON SWITCH 1
3 ZB2-BD5 SELECTOR SWITCH (97382) 1
4 1000638 TERMINAL BOX ANGLE 2
6 ZB2-BS54 OPERATOR PUSHBUTTON (97384) 1
8 M6 DIN 934 HEX NUT (050939.0) (83530) 4
9 A8 DIN 127 RIBBED 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 (050935.0) (83510) 4
13 A4 DIN 127 LOCK WASHER (051217.0) (84095) 4
6-OPTIONS
SHEET 2 OF 3
10,11,12
22
15,16
2,3,17
5
9
12,13,14
21
1
4
12,13,14
5
2,3,17
18
6
2,3,17
10,11,12
12,13,14
12,13,14
7
8
6-OPTIONS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.15 3000900
1 1000616 TERMINAL BOX PANEL 1
2 M5 X 8 DIN 84 CHEESE HEAD SCREW (050638.0) (81930) 9
3 S-3697 MOUNTING RAIL 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 1
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) 4
17 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 9
19 S-5290 STRAIN RELIEF CONNECTOR (NOT SHOWN) 1
20 S-5328 NUT (NOT SHOWN) 1
22 S-5591 MARKER 1-50 1
6-OPTIONS
SHEET 3 OF 3
4
2 1
3
5
6
7
9
8,14(Sheet 2)
6-OPTIONS

FIG. &
INDEX
NO.
UNITS
PER
ASM.
6.12.2.16 3000900
1 S-3506 CONTACT BLOCK SWITCH W/MTG. BASE 1
2 S-5800 CONTACT BLOCK 1
3 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" 1
9 S-4700 STRIP, RUBBER SPONGE 1400mm
6-OPTIONS

7-PARTS
CHAPTER 7
PARTS
TABLE OF CONTENTS
DESCRIPTION FIGURE # PAGE
PICTORIAL INDEX 7.5.1 7-6
MACHINE 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 ROLLERS 7.5.6 7-18
SINGLE LET-OFF WIRE SHUTTLE ASSEMBLY 7.5.8 7-24
SHUTTLE EXTENSION 7.5.10 7-28
SINGLE LET-OFF YARN SHUTTLE 7.5.11 7-30
SUPER PACKAGE YARN SHUTTLE 7.5.12 7-32
L-SUPPORT SINGLE LET-OFF WIRE 7.5.13 7-34
L-SUPPORT ASSEMBLY WITH PREFORM PIN 7.5.13.1 7-36
L-SUPPORT SINGLE LET-OFF YARN (LONG) 7.5.14 7-38
L-SUPPORT SUPER PACK 7.5.15 7-40
SHUTTLE ASSEMBLY 7.5.17 7-44
ROTOR ASSEMBLY 7.5.19 7-48
CAM FOLLOWER ASSEMBLY, REAR 7.5.20 7-52
ROTOR AXLE ASSEMBLY 7.5.21 7-54
CARTRIDGE, DRIVE AND CHANGE GEAR (24 CARRIER) 7.5.22 7-56
CARTRIDGE, DRIVE AND CHANGE GEAR (36 CARRIER) 7.5.23 7-60
DRIVE SHAFT ASSEMBLY (24 CARRIER) 7.5.24 7-64
DRIVE SHAFT ASSEMBLY (36 CARRIER) 7.5.25 7-66
DRIVE SHAFT CONNECTING HARDWARE (CARRIER) 7.5.26 7-68
DRIVE SHAFT CONNECTING HARDWARE (36 CARRIER) 7.5.27 7-70
TRUMPET AND BRAIDRING S.L.O.W. 7.5.28 7-72
STAND SLIDE ASSEMBLY 7.5.29 7-76
SENSOR STAND ASSEMBLY 7.5.30 7-78
7-PARTS

7-PARTS
TABLE OF CONTENTS
DESCRIPTION FIGURE # PAGE
BRAID SENSOR ASSEMBLY 7.5.31 7-80
TUNNEL ASSEMBLY (24 CARRIER) 7.5.33 7-84
LUBRICATION SYSTEM ASSEMBLY 7.5.34 7-86
TUNNEL ASSEMBLY (36 CARRIER) 7.5.36 7-90
LUBRICATION, BIJUR PUMP 7.5.37 7-92
LUBRICATION ASSEMBLY, BACK OF DECK 7.5.38 7-94
ELECTRICAL, PROXIMITY SENSOR 7.5.39 7-96
ELECTRICAL, INSIDE JOG BOX ASSEMBLY 7.5.40 7-98
ELECTRICAL, MAIN CONTROL BOX ASSEMBLY 7.5.42 7-102
ELECTRICAL, MAIN CONTROL BOX ASSEMBLY (DOOR OPEN) 7.5.43 7-104
ELECTRICAL, REMOTE OPERATOR STATION 7.5.47 7-112
ELECTRICAL, PRIMARY OPERATOR BOX 7.5.48 7-114
ELECTRICAL, PRIMARY OPERATOR BOX OPEN 7.5.49 7-116
BOBBIN RUNOUT DETECTOR (36 CARRIER) 7.5.52 7-122
ELECTRICAL SYSTEM, BACK OF DECK 7.5.53 7-124
ELECTRICAL, GEAR BOX DOOR SWITCH 7.5.54 7-126
ELECTRICAL, WIRING DUCT 7.5.55 7-128
ELECTRICAL, WIRING DUCT, MOUNTING BRACKET 7.5.56 7-130
ELECTRICAL, WIRING DUCT, DETAILS 7.5.57 7-132
ELECTRICAL, DOOR LOCK 7.5.58 7-134
SLIDING DOOR LOCK 7.5.59 7-136
BLOWER 7.5.60 7-138
ELECTRICAL, DECK LIGHTS 7.5.62 7-142
BOBBIN WINDING OPTIONS (ROCKWELL WINDER) 7.5.63 7-146
7-PARTS

7-PARTS
PARTS
PARTS BREAKDOWN AND ORDERING PROCEDURE
7.1. SCOPE. This chapter includes the procedure
to 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 and
rapidly if the following information is
specified.
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
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.
Address all orders and inquiries on parts to:
MAYER INDUSTRIES, INC.
MII Headquarters and Plant
P.O. Drawer 1466
Orangeburg, South Carolina 29116
TELEPHONE: (803) 536-3500
FAX: (803) 536-2545
TOLL FREE: 1-800-845-4816
7.4. INSTRUCTIONS FOR RETURNING 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 Service
Department for a Return Material Authorization
(RMA) number. To avoid unnecessary delays and
to speed up the return of parts to you, please use the
assigned RMA number to identify your return
shipment.
7.5. PARTS LIST.
NOTE
Note: Some Figures show parts not
included in purchased assembly.
These parts are shown to aid in
assembly.
The life expectancy of use-up parts depends on proper set-up and alignment of the parts,
quality of the lubricants and proper maintenance of the equipment, including cleaning.
7-PARTS
FIGURE 7.5.1: INDEX
PARTS LIST MR-15 PLC-T 24 & 36 CARRIER (SHEET 1)
FIGURES 7.5.3 THRU 7.5.27
7-PARTS
FIGURE 7.5.1: INDEX
PARTS LIST MR-15 PLC-T 24 & 36 CARRIER (SHEET 2)
LUBRICATION SYSTEM
ELECTRICAL SYSTEM
BOBBINS
FIGURE 7.5.65
7-PARTS
FIGURE 7.5.2: MACHINE ASSEMBLY
SEE PARAGRAPH 1.8 FOR A, B, & C
A
C
B
10,11
12
13 7,8
9
1
15,16,17,
18,19,20
3
2
14
4
5*
6
This picture shows all parts that make up a
standard new machine assembly.
This does not indicate special machine
configuration.
7-PARTS
*Mayer Industries Inc. recommends the use of a thin coat of grease or lubricant on the inside
diameter of the Guide Assembly to help prevent rust.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.2
MACHINE ASSEMBLY (24 CARRIER)
MACHINE ASSEMBLY (36 CARRIER)
1
240-0001
524-0001
536-0001
BASE FRAME (18 CARRIER)
1
1
1
2
518-0002
524-0002
536-0002
UPPER DECK (18 CARRIER)
1
1
1
4 14 X 60 DIN 7978 TAPERED PIN (80858) 2
5*
518-0093
524-0093
536-0093
524-6315
ADJUSTABLE GUIDE ASSEMBLY (18 CARRIER)
ADJUSTABLE GUIDE ASSEMBLY (BRIDGESTONE)
1
1
1
1
6
2000731
524-6130
536-6130
2000937
SHIELD SUPPORT ASSEMBLY (18 CARRIER)
SHIELD SUPPORT ASSEMBLY (BRIDGESTONE)
1
1
1
1
8 B6.4 DIN 125 FLAT WASHER (84015) 13
9
2000482
2000451
2000522
DOOR ASSEMBLY (18 CARRIER)
1
1
1
10 240-6094 MACHINE I.D. PLATE (NOT SERVICED) 1
11 3 X 6 DIN 1476 GROOVED PIN (80145) 4
12
2000485
2000452
2000521
RIGHT PLATE ASSEMBLY (18 CARRIER)
GEARBOX PLATE (24 CARRIER)
GEARBOX PLATE (36 CARRIER)
1
1
1
13
1000484
2000450
2000518
DOOR SPACER (24 CARRIER)
1
1
1
14
240-9191
360-9191
EYE LIFT (18 & 24 CARRIER)
EYE LIFT (36 CARRIER)
1
1
16 B17 DIN 125 FLAT WASHER (84045) 4
17 S-4961 WASHER 12
18 S-4962 SPHERICAL WASHER 4
19 A16 DIN 127 LOCK WASHER (84120) 4
20 M16 DIN 934 NUT (83620) 4
7-PARTS
FIGURE 7.5.3: FLOOR MOUNTING HARDWARE
3
2
9
6
8
7
4
5
1
7-PARTS
* 4 EACH OF THESE PARTS ARE IN KIT 240-0010.
TWO KITS ARE REQUIRED FOR 18 AND 24 CARRIER BRAIDERS.
THREE KITS ARE REQUIRED FOR 36 CARRIER BRAIDER.
.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.3 240-0010 FLOOR MOUNTING HARDWARE
1* 83400 (-10-2AX8")
HEX HEAD BOLT GRADE 2 (18 & 24 CARRIER)
HEX HEAD BOLT GRADE 2 (36 CARRIER)
8
12
2* 240-0015
SPACER SLEEVE (18 & 24 CARRIER)
SPACER SLEEVE (36 CARRIER)
8
12
3* 240-0011
FOOT (18 & 24 CARRIER)
FOOT (36 CARRIER)
8
12
4* 84073
STD WASHER " I.D. (18 & 24 CARRIER)
STD WASHER " I.D. (36 CARRIER)
8
12
5* 84130
LOCK WASHER " I.D. (18 & 24 CARRIER)
LOCK WASHER " I.D. (36 CARRIER)
8
12
THE FOLLOWING PARTS ARE NOT INCLUDED IN THE FLOOR MOUNTING HARDWARE KITS
6
240-0001
524-0001
536-0001
1
1
1
7 240-0013
8
12
8 240-0014
NUT (24 CARRIER)
NUT (36 CARRIER)
8
12
9
240-0107
360-0107
LONG BASE PLATE (24 CARRIER)
LONG BASE PLATE (36 CARRIER)
4
6
7-PARTS
FIGURE 7.5.4: CARRIER ASSEMBLY (STANDARD)
(SHEET 1 OF 2)
1
39
17
34
35
34
23
4
10
31
41
10
53
10
29
46
14
5
28
SEE FIGURE 7.5.5
2
27
33
16
10
53
30
53 10
43
53
10
54
54
10
53
54
54
10
53
54
54
54
11
40
44
54
53
10
54
53
18
11
5
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.4 536-5143 CARRIER ASSEMBLY (STANDARD) (SHEET 1)
1 536-5127 HOUSING 1
2 2000572 THERMAL PLASTIC COMPENSATOR 1
3 240-5178 ADJUSTING RING 1
4 536-5130 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) 1
9 240-5013 MOVEABLE HUB ASSEMBLY 1
10 240-5061 STRAND ROLLER 9
11 536-5191 RUBBER ROD 2
12 240-5019 CLUTCH SPRING 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
18 240-5194 RUBBER ROD (PART OF ITEM 5) 1
19
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 10 DIN 7343 SPIROL PIN (80162) (050207) (PART OF ITEM 6) 1
26
27 M5 X 12 DIN 7991 FLAT SOCKET HEAD SCREW (82025) 3
29 240-5188 ACTUATOR SCREW ASSEMBLY 2
30 M6 X 20 DIN 7991 FLAT HEAD SCREW (82435) 2
7-PARTS
FIGURE 7.5.4: CARRIER ASSEMBLY (STANDARD)
(SHEET 2 OF 2)
9
36
20,21,22
3
15
24
12
13
38
37
1
8
6
45
7
32
25
42
47
51
50
49
7-PARTS

FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.4 536-5143 CARRIER ASSEMBLY (STANDARD) (SHEET 2)
33 V5.3 DIN 6798 SERRATED LOCK WASHER (84195) 3
34 WI351-015 ASSOC. SPRING WASHER (84405) 3
35 AS2035 INA WASHER (84410) 1
36 1000127.0 SNAP RING - EXTERNAL 1
37 BR 40 INA RETAINING RING (85135) (PART OF ITEM 6) 1
38 WR 50 INA RETAINING RING (85140) 1
39 KP37B-FS 160 BALL BEARING-FAFNIR (86373) 1
40 536-5042 STRAND ROLLER BUSHING 1
42 240-5132 HUB CLUTCH (PART OF ITEM 6) 1
43 2000564 TRIP STRAND ROLLER ASSEMBLY 1
44 M6 X 20 DIN 915 SOC. DOG PT. SET SCREW (82410) (050557.0) 1
45 240-5201 SHIM WASHER 1
46 240-5190 WEAR PLATE 1
47 ST-M8 RIBBED WASHER (84210) 1
48
49 1000540 RUBBER BLOCK 1
51 B5.3 DIN 125 WASHER (84010) 4
52
53 M8 X 1 X 20 DIN 961 HEX HEAD CAP SCREW (82455) 9
54 1000560 SPACER 9
7-PARTS
FIGURE 7.5.5: CARRIER ASSEMBLY DETAIL (REFERENCE ONLY)
7
2,3,4
8
9
10
6
1
1
5
7-PARTS
.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.5 CARRIER ASSEMBLY DETAIL (REFERENCE)
7 240-5188 ACTUATOR SCREW 2
8 240-5190 WEAR PLATE 1
7-PARTS
FIGURE 7.5.6: CARRIER ASSEMBLY WITH CHROME ROLLERS
(SHEET 1 OF 2)
1
39
17
34
35
34
23
4
10
31
41
10
53
10
29
46
14
5
28
SEE FIGURE 7.5.5
2
27
33
16
10
53
30
53 10
43
53
10
54
54
10
53
54
54
10
53
54
54
54
11
40
44
54
53
10
54
53
18
11
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.6
2000571
2000667
2000932
2001021
CARRIER ASM. W/ CHROME ROLLERS (SHT. 1)
CARRIER ASM. W/ 12 MM CHROME (SHEET 1)
CARRIER ASM. W/ CERAMIC ROLLERS (SHT. 1)
CARRIER ASM. W/ 12MM CER. ROLLERS (SHT. 1)
1
536-5127
1000649
HOUSING (2000571 AND 2000932)
HOUSING (2000667 AND 2001021)
1 A/R
1 A/R
3 240-5178 ADJUSTING RING 1
4 536-5130 CAP 1
6 240-5184 STATIONARY CLUTCH HUB ASSEMBLY 1
7 240-5164 ADJUSTING CLAMP 1
8 240-5134 NYLATRON BUSHING (PART OF ITEM 6) 1
9 240-5013 MOVEABLE HUB ASSEMBLY 1
10
240-5440
240-5245
2000806
2000962
CHROME STRAND ROLLER (2000571 ONLY)
CHROME STRAND ROLLER (2000667 ONLY)
CERAMIC STRAND ROLLER ASM. (2000932 ONLY)
12 MM CER. STRND ROLLER ASM. (2001021 ONLY)
9 A/R
9 A/R
9 A/R
9 A/R
11 536-5191 RUBBER ROD 2
12 240-5019 CLUTCH SPRING 1
13 240-5020 CLUTCH SLEEVE 1
15 240-5024 WEAR SCREW (PART OF ITEM 1) 2
16 240-5025 BEARING CLAMP 3
17 240-5027 LATCH 1
18 240-5194 RUBBER ROD (PART OF ITEM 5) 1
19
23 240-5041 ACTUATOR 1
24 240-5055 STEM BUMPER (PART OF ITEM 1) 3
25 3 X 10 DIN 7343 SPIROL PIN (80162) (050207) (PART OF ITEM 6) 1
26
27 M5 X 12 DIN 7991 FLAT SOCKET HEAD SCREW (82025) 3
29 240-5188 ACTUATOR SCREW ASSEMBLY 2
7-PARTS
FIGURE 7.5.6: CARRIER ASSEMBLY WITH CHROME ROLLERS
(SHEET 2 OF 2)
9
36
20,21,22
3
15
24
12
13
38
37
1
8
6
45
7
32
25
42
47
51
50
49
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.6
2000571
2000667
2000932
2001021
CARRIER ASM. W/ CHROME ROLLERS (SHT. 2)
CARRIER ASM. W/ 12 MM CHROME (SHEET 2
CARRIER ASM. W/ CERAMIC ROLLERS (SHT. 2)
CARRIER ASM. W/ 12MM CER. ROLLERS (SHT. 2)
33 V5.3 DIN 6798 SERRATED LOCK WASHER (84195) 3
34 WI351-015 ASSOC. SPRING WASHER (84405) 3
35 AS2035 INA
WASHER (84410) (2000571, 2000667, & 2000932
ONLY)
1
36 1000127.0 SNAP RING - EXTERNAL 1
37 BR 40 INA RETAINING RING (85135) (PART OF ITEM 6) 1
38 WR 50 INA RETAINING RING (85140) 1
39 KP37B-FS 160 BALL BEARING-FAFNIR (86373) 1
40
536-5042
1000753
STRAND ROLLER BUSHING (2000571 & 2000932)
STRAND ROLLER BUSHING (2000667 & 2001021)
1
1
41
M6 X 45 DIN 6912
M6 X 50 DIN 6912
SOCKET HD SCREW (82519) (2000571 & 2000932)
SOCKET HD SCREW (82522) (050701.0) (2000667
& 2001021)
1
1
42 240-5132 HUB CLUTCH (PART OF ITEM 6) 1
43
2000563
2000562
2000931
2001019
CHROME TRIP STRAND ROLLER ASM. (2000571)
12MM CHROME TRIP STRAND ROLLER (2000667)
CERAMIC TRIP STRAND ROLLER ASM. (2000932)
12MM CER. TRIP STRAND ROLLER ASM (2001021)
1
1
1
1
44 M6 X 20 DIN 915
SOC. DOG PT. SET SCREW (82410) (050557.0)
(2000571 & 2000667 ONLY)
1
45 240-5201 SHIM WASHER 1
46 240-5190 WEAR PLATE 1
47 ST-M8 RIBBED WASHER (84210) 1
48
49 1000540 RUBBER BLOCK 1
50 M5 X 16DIN 912 SOCKET HEAD SCREW (055147.0) (82046) 2
51 B5.3 DIN 125 WASHER (84010) 4
52
53
M8 X 1 X 20 DIN 961
M8 X 1 X 25 DIN 961
HEX HEAD BOLT (82455) (055706.0) (2000571 &
200932)
HEX HEAD BOLT (82456) (2000667 & 2001021)
9
9
54
1000560
1000560
SPACER (2000571 & 2000932)
SPACER (2000667 & 2001021)
9 A/R
18 A/R
7-PARTS

THIS PAGE INTENTIONALLY LEFT BLANK

7-PARTS

7-PARTS
FIGURE 7.5.8: SINGLE LET-OFF WIRE SHUTTLE SUPPORT ASSEMBLY (SLOW)
WITH PREFORM PIN ON THE SUPPORT ASSEMBLY
1
2
4
3
5
(SEE FIGURE 7.5.13.1)
(SEE FIGURE 7.5.17)
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 an
assembly aid only.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.8 2000507 SR
2000506 SR
SINGLE LET-OFF WIRE SHUTTLE SUPPORT ASM.
SLOW (24 CARRIER)
SLOW (36 CARRIER)
1
2000728
2000507
2000506
SHUTTLE ASSEMBLY (18 CARRIER)
1
1
1
2 2000216 SUPPORT ASSEMBLY 1
3 S-4903 SOCKET HEAD SCREW 4
4 ST M6 RIBBED WASHER (051238.0) 4
5* 2000366.0 SINGLE LET-OFF WIRE BOBBIN ASSEMBLY 1 A/R
7-PARTS
7-PARTS

7-PARTS
FIGURE 7.5.10: SHUTTLE EXTENSION
1
3
2
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.10 SHUTTLE EXTENSION LIGHTWEIGHT YARN
1 1000454 SPINDLE 1
2 M6 X 6 DIN 916 SET SCREW (050523.0) (82185) 4
3 240-5140 SHUTTLE EXTENSION 1
7-PARTS
FIGURE 7.5.11: SINGLE LET-OFF YARN SHUTTLE EXTENSION ASSEMBLY (SLOY)
1
6
2
5
4
3
7
8
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.11
SINGLE LET-OFF YARN SHUTTLE EXTENSION
ASSEMBLY
SLOY (24 CARRIER)
SLOY (36 CARRIER)
1*
2000728
2000507
2000506
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
5 ST M6 RIBBED 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
FIGURE 7.5.12: SINGLE LET-OFF SUPER PACKAGE YARN ADAPTER
PAYOFF
DIRECTION
1
2
5
4
3
6
8
7
7-PARTS
* Not included in standard assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.12 SINGLE LET-OFF SUPER PKG. YARN ADAPTER
1*
2000728
2000507
2000506
1
1
1
2 1000354 SHUTTLE EXTENSION 1
3 240-5169 "L" SUPPORT ASSEMBLY 1
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 - SUPERPACK 1 A/R
7-PARTS
FIGURE 7.5.13: "L" SUPPORT ASSEMBLY (SLOW)
8
9
4
12
5
11
7
10
1
3
6
2
6
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.13 2000873 SUPPORT ASSEMBLY (OPTION)
1 240-5222 ROLLER PIN L-SUPPORT 1
2 240-5006 BALER ROLL 1
3 240-5005 BALER SPINDLE 1
4 240-5135 CARRIER BUMPER 1
5 240-5061 STRAND ROLLER 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 ROLL PIN (050223.0) (80380) 1
12 S-5449 SPACER 1
7-PARTS
FIGURE 7.5.13.1 SUPPORT ASSEMBLY WITH PREFORM PIN
8
9
4
5
7
10
1
3
6
2
6
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.13.1 2000216 SUPPORT ASSEMBLY WITH PREFORM PIN
1 240-5222 LIGHTWEIGHT L-SUPPORT (STD.) 1
2 240-5006 BALER ROLL 1
4 240-5135 CARRIER BUMPER BRACKET ASSEMBLY 1
5 2000214 PREFORM PIN ASSEMBLY 1
8 M8 X 20 DIN 912 SOCKET HEAD SCREW (054683.0) 1
10 4 X 24 DIN 7343 ROLL PIN (050223.0) 1
7-PARTS
FIGURE 7.5.14: SUPPORT ASSEMBLY (SLOY)
12
5
13
1
10
6
7
9
8
6
2
3
15
16
14
4
17
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.14
240-5232
240-5242
240-5251
SUPPORT ASSEMBLY (SLOY)
SUPPORT ASM. (SLOY) W/CHROME ROLLER
SUPPORT ASM. (SLOY) W/12MM CHROME
1 240-5233 L-SUPPORT (LONG) 1
2 240-5234 BALER ROLL (LONG) 1
3 240-5235 BALER SPINDLE (LONG) 1
4 2000260 CARRIER BUMPER BRACKET ASSEMBLY 1
5
240-5061
240-5440
240-5245
STRAND ROLLER ASSEMBLY (240-5232 ONLY)
CHROME STRAND ROLLER ASSEMBLY (240-5242)
12MM CHROME STRAND ROLLER ASM. (240-5251)
1 A/R
1 A/R
1 A/R
6 240-5165 BAILER ROLLER BUSHING 2
7 S-3679 SOCKET SET SCREW (M6 X 10) 1
10 A10 X 6 DIN 6321 REST BUTTON (99780) 1
11
13
S-5449
S-5449
SPACER
SPACER (240-5251)
1
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
17 1000941 PIN SCREW 1
7-PARTS
FIGURE 7.5.15: "L" SUPPORT ASSEMBLY (SINGLE LET-OFF SUPER PACK)
6
2
6
3
7
8
9
4
13
5
12
1
10
14
15
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.15
240-5169
240-5442
240-5249
2000933
2001015
SUPPORT ASM (SINGLE LET-OFF SUPER PK)
SUPPORT ASM. WITH CHROME ROLLER
SUPPORT ASM. WITH 12MM CHROME ROLLER
SUPPORT ASM. WITH CERAMIC ROLLER
SUPPORT ASM. WITH 12MM CERAMIC ROLLER
1 240-5168 L-SUPPORT 1
2 240-5166 BALER ROLL 1
4 1000259 CARRIER BUMPER 1
5
240-5061
240-5440
240-5245
2000806
2000962
STRAND ROLLER ASSEMBLY (240-5169 ONLY)
CHROME STRAND ROLLER ASM. (240-5442 ONLY)
12MM CHROME ROLLER ASM. (240-5249 ONLY)
CERAMIC ROLLER ASM. (2000933 ONLY)
12MM CERAMIC ROLLER ASM. (2001015 ONLY)
1 A/R
1 A/R
1 A/R
1 A/R
1 A/R
6 240-5165 BALER ROLLER BUSHING 2
7 S-3679 SOCKET SET SCREW (M6 X 10) 1
10 A10 X 6 DIN 6321 REST BUTTON (99780) 1
11
12
M8 X 1 X 20 DIN 961
M8 X 1 X 25 DIN 961
HEX HEAD CAP SCREW (82455)
HEX HD CAP SCREW (82456) (240-5249, 2001015)
1 A/R
1 A/R
13
S-5449
S-5449
SPACER
SPACER (240-5249, 2001015)
1
2
14 240-5055 STEM BUMPER 1
15 1000941 PIN SCREW 1
7-PARTS
FIGURE 7.5.16: SUPPORT ASSEMBLY WITH GROOVE ROLLER
8
9
4
5 (2000783)
7
10
1
3
6
2
6
12
11
13
5 (2000946)
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.16
2000783
2000946
SUPPORT ASSEMBLY WITH GROOVE ROLLER
SUPPORT ASSEMBLY WITH STATIONARY
PRE-FORM PIN
1 240-5222 LIGHTWEIGHT L-SUPPORT 1
2 240-5006 BALER ROLL 1
4 240-5135 CARRIER BUMPER BRACKET ASSEMBLY 1
5
2000720
2000214
GROOVE ROLLER (2000783)
PRE-FORM PIN (2000946)
1
1
10 4 X 24 DIN 7343 ROLL PIN (050223.0) (80380) 1
11 240-5061 STRAND ROLLER ASSEMBLY 1
12 S-5449 SPACER 1
13 M8X1X20 DIN 961 HEX HEAD BOLT (055706.0) (82455) 1
7-PARTS
FIGURE 7.5.17: SHUTTLE ASSEMBLY
12
11
10
9
8
7
5
4
3
1
6
2
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.17
2000728
2000507
2000506
1 1000454 SHUTTLE SPINDLE 1
2 4 X 24 DIN 7343 ROLL PIN (050223.0) (80380) 1
3 240-4002 MOUNTING SPACER 1
4 240-4007 OUTER RING 1
5 240-4008 INNER RING 1
6 240-4004 KEY 1
7
1000650
524-4003
1000505
CAM TRACK (18 CARRIER)
1 A/R
1 A/R
1 A/R
8 524-4005 SHUTTLE GEAR 1 A/R
9 240-4009 RING 1
10 S-4095 CAM YOKE BEARING 1
12 KM 6 DIN 981 SLOTTED SHAFT NUT (050986.0) (83840) 1
7-PARTS
7-PARTS

7-PARTS
FIGURE 7.5.19: ROTOR ASSEMBLY
17
12
11 (24 & 36 CARRIER)
4 (24 & 36 CARRIER)
18
19
7
19
18
5
13
3
20
16
24
15
11
4
18
19
6
19
18
5 (24 & 36 CARRIER)
22
21
8
10
1
9
23
14
REAR CAM FOLLOWER ASSEMBLY
FRONT CAM FOLLOWER ASSEMBLY
NUMBERS
PUSH HERE
2
(SEE FIGURE 7.5.20)
25 (18 CARRIER)
26 (18 CARRIER)
27 (18 CARRIER)
28
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.19 ROTOR ASSEMBLY (18, 24 AND 36 CARRIER)
1
518-3001
524-3001
ROTOR FRAME (18 CARRIER)
ROTOR FRAME (24 & 36 CARRIER)
1
1
2 524-3002 ROTOR GEAR 1
3 240-3004 GUIDE KEY 3
4
518-3005
524-3005
PLANETARY SHAFT (18 CARRIER)
PLANETARY SHAFT (24 & 36 CARRIER)
3
6
5
240-3006
240-3006
PLANETARY SPACER (18 CARRIER)
PLANETARY SPACER (24 & 36 CARRIER)
3
6
6
518-3008
524-3008
PLANETARY MINOR GEAR (18 CARRIER)
PLANETARY MINOR GEAR (24 & 36 CARRIER)
3
3
7
518-3007
524-3007
PLANETARY MAJOR GEAR (18 CARRIER)
PLANETARY MAJOR GEAR (24 & 36 CARRIER)
3
3
8 240-3017 PILLOW BLOCK 3
9
240-3025/518-3025
240-3014/518-3014
FRONT CAM FOLLOWER ASM (SEE NOTES 1 & 2)
FRONT CAM FOLLOWER ASM (SEE NOTES 1 & 2)
3 A/R
3 A/R
10 240-3030 REAR CAM FOLLOWER ASSEMBLY (FIG. 7.5.20) 3
11
6 X 24 DIN 7343
6 X 24 DIN 7343
ROLL PIN (050241.0) (80700) (18 CARRIER)
ROLL PIN (050241.0) (80700) (24 & 36 CARRIER)
3
6
12 10 M6 X 40 DIN 7 DOWEL PIN (80910) 1
13
M6 X 25 DIN 6912
M6 X 25 DIN 912
SOC. HD. SCREW (82460) (050697.0) (18 CAR.)
SOCKET HEAD SCREW (82445) (24 & 36 CAR.)
6
6
16* 240-3022 CAP 1
18 6001-2RS DIN 625 BALL BEARING (86438) 12
19 28 X 1.2 DIN 472 INTERNAL SNAP RING (84675) 12
20* OR 72 X 2.5 O-RING (86030) 1
21
M10 X 50 DIN 6912
M10 X 45 DIN 912
SOCKET HEAD SCREW (82930) (18 CARRIER)
SOC. HD. SCREW (GRADE 12.9) (82928) (24 & 36)
12
12
22
A10 DIN 127
B10 DIN 127
LOCK WASHER (84110) (051221.0) (18 CARRIER)
STAINLESS LOCK WASHER (84111)
12
12
24* ST M6 RIBBED WASHER (051238.0) (84200) 4
25 518-3006 PLANETARY SPACER (18 CARRIER) 3
26 518-3016 PLANETARY SHAFT (18 CARRIER) 3
27 M8X16 DIN 933 HEX HEAD SCREW (050846.0) (82640) 3
28 050064.0
SOFT DOWEL PIN (24 CARRIER) [POS 3 & 4]
SOFT DOWEL PIN (36 CARRIER) [POS 5 & 6]
6
6
7-PARTS
FIGURE 7.5.19: ROTOR ASSEMBLY
17
12
11
4
18
19
7
19
18
5
13
3
20
16
24
15
11
4
18
19
6
19
18
5
22
21
8
10
1
9
23
14
REAR CAM FOLLOWER ASSEMBLY
FRONT CAM FOLLOWER ASSEMBLY
NUMBERS
PUSH HERE
2
(SEE FIGURE 7.5.20)
28
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. Cartridges 240-3014 and 518-3014 have four timing holes while standard cartridges 240-
3025 and 518-3025 have only one timing 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 cartridges 240-
3014 and 518-3014 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
FIGURE 7.5.20: REAR CAM FOLLOWER ASSEMBLY
HOLE
THIS
SIDE
HOLE "A"
"X" ON BACK
FACE OF
PILLOW BLOCK
NUMBERS STAMPED
AT EITHER END IN
THIS LOCATION
9
2
10
8
7
3
1
6
4
5
7-PARTS

FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.20 240-3030 REAR CAM FOLLOWER ASSEMBLY
1 240-3032 REAR CAP 1
2 240-3033 REAR CARTRIDGE 1
3 240-3031 CAM FOLLOWER 1
4 7 X 10RB INA ROLLER (SHORT) (86235) 13
5 7 X 14ZRB INA ROLLER (LONG) (86240) 13
6 240-3036 THRUST WASHER 1
ADDITIONAL PARTS SHOWN FOR ASSEMBLY INSTRUCTIONS
9 6 X 24 DIN 7343 ROLL PIN (050241.0) 2
10 240-3017 PILLOW BLOCK 1
7-PARTS
FIGURE 7.5.21: ROTOR AXLE ASSEMBLY
15
13
23
24
25
26
12
17
18
5
3 3-3
3-2
3-1
2
13
15
4
14
4-1
4-2
14
11
16
20
19
1
27
7
6
27
7
6
FACE
"D"
9
8
22
10
7-PARTS
** Not included in standard assembly; part of Rotor Frame Assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.21
2000884
2000554
2000883
ROTOR AXLE ASSEMBLY (18 CARRIER)
1
518-3010
524-3010
536-3010
ROTOR AXLE (18 CARRIER)
1 A/R
1 A/R
1 A/R
2
518-3012
524-3012
536-3012
MAJOR SUN GEAR (18 CARRIER)
1 A/R
1 A/R
1 A/R
3
518-3024
524-3024
NEEDLE BEARING ASSEMBLY (18 CARRIER)
NEEDLE BEARING ASSEMBLY
1 A/R
1 A/R
4 NA6908 (INA) NEEDLE BEARING ASSEMBLY (2 PART) (86710) 1
5 " - 18 NPT PRESSURE PLUG (BENSON) (87860) 1
6 S-5539 METER UNIT (BIJUR) (A) CKA-00-B7 125 1
7 S-5541 METER UNIT (BIJUR) (B) CKA-2 B7 128 1
8 86060 105 X 3 O-RING 1
9 524-3014 KEY 1
10** 1000752 BEARING CUP (518 ONLY) 1
11* 240-3023 LOCATION PIN 1
12* 240-3021 BEARING RING (FIT AT ASSEMBLY) 1
13* WS 81110 THRUST RACE (86305) 2
14* GS 81110 THRUST RACE (86300) 2
15* AXK 5070 NEEDLE RACE (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) 1
20* A12 DIN 127 LOCK WASHER (051222.0) (84115) 6
21
22 A5 DIN 127 LOCK WASHER (051218.0) (84097) 4
23* S-3688 .001 INCH STEEL SHIM A/R
27 S-5540 METER UNIT (BIJUR) (C) CKA-1-B7127 1
7-PARTS
FIGURE 7.5.22: DRIVE CARTRIDGE AND CHANGE GEAR DRIVE
24 CARRIER
10
20,21
8
14
19
2
4
1
18
.15 mm
AXIAL PLAY
23
12
2
.15 mm
AXIAL PLAY
15
17
SPROCKET
CARTRIDGE
PINION
CARTRIDGE
2
SPROCKETS MUST
BE IN LINE WITHIN
0.2 mm
16
11
9 18 5 19 2
3
6
23
7
13
UPPER DECK FRAME
NOTE: STAMP THAT INDICATES
NUMBER OF TEETH ON
CHANGE GEAR SHOULD
FACE OUTWARD.
22
17
7
13
22
16
15
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.22
DRIVE CARTRIDGE AND CHANGE GEAR DRIVE
(24 CARRIER)
2
30 X 42 X 0.1 DIN 988
30 X 42 X 0.2 DIN 988
30 X 42 X 0.3 DIN 988
30 X 42 X 0.5 DIN 988
30 X 42 X 1 DIN 988
SHIM WASHER (051128.0)
SHIM WASHER (84248)
A/R
A/R
A/R
A/R
A/R
3 240-2014 BRASS SHEAR KEY 1
4 240-2015 GEAR SHAFT 1
6 240-2017 ADAPTER 1
7 240-2019 CAP 2
8 240-2023 SILENT CHAIN SPROCKET (55T) 50 CY 1565 RPM 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 KEY (050317.0) 1
12 240-2013 KEY (A8 X 7 X 70 DIN 6885) 1
15 KM 6 DIN 981 LOCK NUT (050986.0) 2
16 MB 6 DIN 5406 SAFETY WASHER (051248.0) 2
17 4M6 X 12 DIN 7 DOWEL PIN (050089.0) 2
18 6306-2RS DIN 625 BALL BEARING (051362.0) 2
20
99507
RAMSEY SILENT CHAIN
24 CARRIER SC406-118 LINKS 1 A/R
21 SC406
RAMSEY SILENT CHAIN CONNECTOR PARTS
24 CARRIER
1
7-PARTS
24 CARRIER
10
20,21
8
14
19
2
4
1
18
.15 mm
AXIAL PLAY
23
12
2
.15 mm
AXIAL PLAY
15
17
SPROCKET
CARTRIDGE
PINION
CARTRIDGE
2
SPROCKETS MUST
BE IN LINE WITHIN
0.2 mm
16
11
9 18 5 19 2
3
6
23
7
13
UPPER DECK FRAME
NOTE: STAMP THAT INDICATES
NUMBER OF TEETH ON
CHANGE GEAR SHOULD
FACE OUTWARD.
22
17
7
13
22
16
15
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.22
(24 CARRIER)
23
240-2054 THRU
240-2082
CHANGE GEARS (SEE CHART) 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 72
240-2058 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
36 CARRIER
10
0.15 mm
AXIAL PLAY
SPROCKETS MUST BE
IN LINE WITHIN 0.2 mm
16
UPPER DECK FRAME
0.15 mm
AXIAL PLAY
6
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
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.23
(36 CARRIER)
2
30 X 42 X 0.1 DIN 988
30 X 42 X 0.2 DIN 988
30 X 42 X 0.3 DIN 988
30 X 42 X 0.5 DIN 988
30 X 42 X 1 DIN 988
SHIM WASHER (84248)
A/R
A/R
A/R
A/R
A/R
3 240-2014 BRASS SHEAR KEY 1
4 536-2015 GEAR SHAFT 1
6 536-2039 SILENT CHAIN WEAR BLOCK 1
7 536-2019 CAP 2
8 536-2023 SILENT CHAIN SPKT (55T) 60/50 CY 1400 RPM 1 A/R
9 240-2025 PINION GEAR 32 T 1
10 A8 X 7 X 32 DIN 6885 KEY (050317.0) 1
11 240-2013 KEY (A8 X 7 X 70 DIN 6885) 1
14
536-2095
536-2096
536-2097
536-2098
SHIM
SHIM
SHIM
SHIM
A/R
A/R
A/R
A/R
15 KM 6 DIN 981 LOCKNUT (050986.0) 2
17 S-4907
RAMSEY SILENT CHAIN 60/50 CY DRIVES (120
LINKS)
1 A/R
20 SC410 CP RAMSEY SILENT CHAIN CONNECTOR PARTS 1
22 ST M12 RIBBED WASHER (84225) 4
24 240-2085 WASHER WITH GRIP DOTS 2
25 10.5 DIN 7349 WASHER (055383.0) 2
7-PARTS
36 CARRIER
10
0.15 mm
AXIAL PLAY
SPROCKETS MUST BE
IN LINE WITHIN 0.2 mm
16
UPPER DECK FRAME
0.15 mm
AXIAL PLAY
6
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
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.23
(36 CARRIER)
27
240-2054 THRU
240-2082
CHANGE 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 72
240-2058 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
FIGURE 7.5.24: DRIVE SHAFT ASSEMBLY (THROUGH BASE)
24 CARRIER
.05 - .30 mm (.002 - .012 IN.) GAP
BEFORE INSTALLING THE SHEAR PIN.
WHEN THE SHEAR PIN IS INSTALLED,
POSITION SHEAR PIN RING (6) TO HAVE
.00 CLEARANCE AND THEN SECURE
IN PLACE WITH SET SCREW (13).
OIL LEVEL
SURFACE "A"
FRONT OF BRAIDER REAR OF BRAIDER
23
27
26
25
29
5
28
12 7 9 14 13 8 2 10 15 21
20
1
18
17
4
19 16 11
3
6
24
5
5
22
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.24 240-2090 DRIVE SHAFT ASSEMBLY (24 CARRIER)
1 240-2001 DRIVE SHAFT 1
2 240-2002 DRIVE SPROCKET 1
3* S-3924 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 RING 1
7 240-2007 BUSHING 1
8 240-2008 DISTANCE BUSHING 1
9 240-2009 SHEAR PIN 2
10 240-2010 RETAINING NUT 1
11 6m6 X 16 DIN 6325 DOWEL PIN (80670) 2
12 A12 X 8 X 40 DIN 6885 KEY (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 SNAP RING (050380.0) 1
19 80 X 2.5 DIN 472 INTERNAL SNAP RING (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" RING (86045) (051636.0) 1
23* A10 X 8 X 40 DIN 6885 KEY (050327.0) (81300) 1
24* 240-2091 FRONT FLANGE ASM. (INCLUDES ITEMS 25-29)
28 1307 DIN 630 BALL BEARING (86390) 1
29 OR 86 X 2.5 "O" RING (86045) (051636.0) 1
7-PARTS
FIGURE 7.5.25: DRIVE SHAFT ASSEMBLY (THROUGH BASE)
36 CARRIER
.05 - .30 mm (.002 - .012 IN.) GAP
BEFORE INSTALLING THE SHEAR PIN.
WHEN THE SHEAR PIN IS INSTALLED,
POSITION SHEAR PIN RING (6) TO HAVE
.00 CLEARANCE AND THEN SECURE
IN PLACE WITH SET SCREW (13).
OIL LEVEL
SURFACE "A"
FRONT OF BRAIDER REAR OF BRAIDER
17
19
2 8
6
14 16
15
18
3
28
26
10
24
25
27
1
20
21
4
11
13
9
12
7
22
5
5
5
23
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
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 NPT PLUG 4
5* M8 X 20 DIN 6912 SOCKET HEAD SCREW (050709.0) 8
6 536-2006 SHEAR PIN RING 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 KEY (050327.0) 1
11 6m6 X 16 DIN 6325 DOWEL PIN (050168.0) 2
12 A12 X 8 X 40 DIN 6885 KEY (053771.0) 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 SNAP RING (050380.0) 1
22 OR 86 X 2.5 "O" RING (86045) (051636.0) 1
23* 240-2091 FRONT FLANGE ASM. (INCLUDES ITEMS 24-28)
27 1307 DIN 630 BALL BEARING (86390) 1
28 OR 86 X 2.5 "O" RING (86045) (051636.0) 1
7-PARTS
FIGURE 7.5.26: INSTALLATION CONNECTION HARDWARE
24 CARRIER
27.56 IN
700 mm
27.56 IN
700 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
UNIT
SEE FIGURE 7.5.24
1 3 2 4
1
1
MR-15 MR-15
1
ALIGN SHAFT (2) TO
MR-15 PLC-T SHAFT
W/MAGNETIC BASE
INDICATOR AS SHOWN
8*
8*
S-5008 HUB PLC-T PLC-T
7-PARTS
* All drive shaft assemblies (Items 1 and 2) require a S-5006 Flex Pack for each end when
assembling to a machine.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.26
INSTALLATION CONNECTION HARDWARE
(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 KEY (050327.0) A/R
4 3/8 X 3/8 X 1 KEY, ROUNDED ENDS (99916) 1
5 240-6011 COVER ASSEMBLY 1
6 2000503 DRIVE SHAFT COVER ASSEMBLY 1
7 240-6023 DRIVE SHAFT COVER A/R
8* S-5006 REPAIR KIT FOR FLEXIBLE COUPLING A/R
7-PARTS
FIGURE 7.5.27: INSTALLATION CONNECTION HARDWARE
36 CARRIER
33.5 IN
850 mm
33.5 IN
850 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
UNIT
SEE FIGURE 7.5.25
1 3 2 4
1
1
MR-15 MR-15
1
ALIGN SHAFT (2) TO
MR-15 PLC-T SHAFT
W/MAGNETIC BASE
INDICATOR AS SHOWN
PLC-T PLC-T
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.27
INSTALLATION 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 KEY (050327.0) A/R
4 3/8 X 3/8 X 1 KEY, ROUND ENDS (99916) 1
6 2000525 FRONT COVER ASSEMBLY (TAMER) 1
7 536-6009 DRIVE SHAFT COVER A/R
7-PARTS
FIGURE 7.5.28: INSTALLATION OF TRUMPET AND BRAIDRING (SINGLE LET-OFF WIRE)
20
21
23
22
12
17
18
19
28
27
17
18
19
12
13
14
16
15
14
6
5
4
7
8
3
9
10
11
2
1**
10 23,24,25
29
ALTERNATE MOUNTING
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.28 DA-1527
INSTALLATION OF TRUMPET AND BRAIDRING
(SINGLE LET-OFF WIRE)
1**
240-9120
240-9226
240-9231
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
240-9091
240-9100
240-9094
240-9093
240-9101
240-9082
240-9102
240-9092
240-9103
240-9099
240-9095
240-9127
240-9128
240-9129
240-9130
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 mm
15 mm
19 mm
25 mm
28 mm
31 mm
35 mm
38 mm
42 mm
44 mm
50 mm
59 mm
71.3 mm
84.5 mm
110 mm
26 mm
29 mm
33 mm
39 mm
42 mm
45 mm
49 mm
52 mm
56 mm
58 mm
64 mm
73 mm
85.3 mm
98.5 mm
124 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. (INCLUDES ITEMS 4-19) 1
6 240-9096 TRUMPET HOLDER PLATE 1
11 240-9087 RACK 1
12 240-9097 TRUMPET HOLDER 1
13 240-9084 DRIVE SHAFT 1
14 S-3471 FLANGED BUSHING 2
15 6 X 30 DIN 7343 ROLL PIN (80746) 1
16 240-9083 GEAR 1
17 B13 DIN 125 FLAT WASHER (051044.0) 2
7-PARTS
FIGURE 7.5.28: INSTALLATION OF TRUMPET AND BRAIDRING (SINGLE LET-OFF WIRE)
20
21
23
22
12
17
18
19
28
27
17
18
19
12
13
14
16
15
14
6
5
4
7
8
3
9
10
11
2
1**
10 23,24,25
29
ALTERNATE MOUNTING
7-PARTS
** Mayer Industries Inc. recommends the use of a thin coat of grease or lubricant on the
outside diameter of the Braidring Assembly to help prevent rust.
*** Not included in standard assembly.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.28 DA-1527
INSTALLATION OF TRUMPET AND BRAIDRING
(SINGLE LET-OFF WIRE)
20*** M8 X 25 DIN 6912 SOCKET HEAD SCREW (050710.0) (82680) 8
21*** ST M8 RIBBED WASHER (051239.0) 8
22*** M8 DIN 934 HEXAGON NUT (050941.0) 8
23*** B8.4 DIN 125 FLAT WASHER (051042.0) 9
24*** 83450 KIPP HANDLE 1
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) 4
29*** 240-6034 JUNCTION BOX PAD ASM. (ALTERNATE MTG.) 1
7-PARTS
FIGURE 7.5.29: STAND SLIDE ASSEMBLY
MANDREL, LINER
POLE, ETC.
1
8
9
6
7
9
8
11
12
5
13
4
10
3
6/14
7/15
2
36 CARRIER
3
10
4
10
3
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.29
240-6064
536-6064
SENSOR STAND ASM. (24 CAR.) (STANDARD DR.)
SENSOR STAND ASM. (36 CAR.) (STANDARD DR.)
1
240-6127
536-6127
1 A/R
1 A/R
2 240-6072 STAND SLIDE ASSEMBLY 1
3 240-6079
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) (83580) (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
7-PARTS
FIGURE 7.5.30: SENSOR STAND ASSEMBLY
1
2,3
7-PARTS
* Insert not included.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.30 SENSOR STAND ASSEMBLY
1* 240-9050
BRAID SENSOR ASSEMBLY
(SEE FIGURE 7.5.31 FOR COMPONENT PARTS)
1
3 B6.4 DIN 125 FLAT WASHER (051040.0) 2
7-PARTS
FIGURE 7.5.31: BRAID SENSOR ASSEMBLY
24 CARRIER
GAP
13
16
17 12
15
19
10
9
15
10
9
7
11
18
2
6
5
8
3
4
1
14
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.31 240-9050 BRAID SENSOR ASSEMBLY (24 CARRIER)
1 240-9049 BRACKET - WELDMENT 1
2 3000383 WIRE ASSEMBLY 1
3 M8 X 8 DIN 916 SOCKET SET SCREW (82585) 2
5 240-9026 SPRING PLUNGER 4
6 M6 DIN 934 NUT (050939.0) 4
8 S-3699 BALL PLUNGER 2
11* 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 RING 1
17 240-9029 SPACER 4
18*
240-9031
240-9033
240-9035
240-9037
240-9039
240-9041
240-9043
240-9045
240-9047
HALF RING 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
1 A/R
19 S-3225 SHRINKABLE TUBING (INSULATOR) 8
7-PARTS
FIGURE 7.5.32: BRAID SENSOR ASSMEBLY
36 CARRIER
1
5
6
7
2
14
4
3
GAP
11
18
8
13
16
17
12
15
19
10
9
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
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
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 RING 1
17 240-9029 SPACER 4
18*
360-9054
360-9052
1 A/R
1 A/R
19 S-3225 SHRINKABLE TUBING (INSULATOR) 8
7-PARTS
FIGURE 7.5.33: TUNNEL ASSEMBLY
24 CARRIER
18
14
16,17
6
19
2
5
1
15
5
13
12
9
3
8
4
7
11
10
13
12
20
21
22
23
13
24
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.33 TUNNEL ASSEMBLY (24 CARRIER)
1 524-6025 FLOOR PAN 1
3 2000503 FRONT COVER ASSEMBLY (TAMER) 1
4 240-6001 COVER SUPPORT 1
7 S-4716 HEX HEAD ANCHOR BOLT (3/8 X 2 ) 4
8 240-6305 ANCHOR 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) 4
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) 2
18 240-6052 BASE SUMP FILTER 1
19 240-6031 CATCH PAN ASSEMBLY 1
21 M8 DIN 934 HEX NUT (83570) (050941.0) 4
23 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 6
24 1000504 ANTISLIP PLATE 1
7-PARTS
FIGURE 7.5.34: LUBRICATION SYSTEM ASSEMBLY
SHEET 1 OF 2
4
14
5
6
7
9
8
15
16
20
18
17
10
1
11
24
22
21
25
13
23
12
28
19
2
26
29
27
3
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
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
3
S-5543
S-5544
PALL FILTER ASSEMBLY
REPLACEMENT FILTER
1
4 S-3776 PUMP 1
5 99731 BUSHING 1
6 99744 PIPE THREAD REDUCER ( X PTR-B) 1
7 99760 PUMP FILTER ( SEH 8) 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) 2
11 S-3768 MALE ADAPTER ( X 3/8 BRASS) 1
12 99751 MALE " NPT ELBOW ( TUBE X ) 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) 10
18 A6 DIN 127 LOCK WASHER (051219.0) 17
20 M6 DIN 934 HEX NUT (050939.0) 7
21 99718 STRAIGHT ADAPTER ASSEMBLY 1
22 S-4715 RESERVOIR FILLER 1
23 S-4674 NYLON TUBING (" - B-8599) 1200 mm
24 S-4675 INSERT 4
26 S-103-M SOCKET HEAD SCREW (5/16-18 X 3/4) 2
27 B8.4 DIN 125 FLAT WASHER (051042.0) 2
28 1000209 1" SAE TO " REDUCER 2
29 A8 DIN 125 FLAT WASHER (84105) 2
7-PARTS
FIGURE 7.5.35: LUBRICATION SYSTEM ASSEMBLY
SHEET 2 OF 2
3
5
4
6
1
2
7
8
9
1
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
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 1
6 S-5481 FLUID LEVEL GAUGE 1
7 M8 DIN 934 HEX NUT (050941.0) 4
9 M12 X 1.5 DIN 908 SCREW PLUG WITH GASKET (050893.0) 3
7-PARTS
FIGURE 7.5.36: TUNNEL ASSEMBLY
36 CARRIER
5
6
7,8
31
27,
28
26
30
29
9
15,16
14
1
10,11
17
3
8
18
2
11,12,13
4
19,20
21
22
10
34
18,8
23
25
32
33
24
27
24
27
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.36 TUNNEL ASSEMBLY(36 CARRIER)
1 536-6025 PAN ASSEMBLY 1
2 536-6011 TUNNEL ASSEMBLY COVER (SMALL) 1
3
2000525
536-6009
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 ANCHOR BOLT (3/8 X 2 1/4) 4
22 536-6305 ANCHOR COVER PLATE ASSEMBLY 1
23 1000526 ANGLE 2
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
29 87800 OIL SIGHT GLASS (051705.0) 1
30 S-5508 BALL VALVE 1
31 360-6162 OIL COLLECTOR PANEL ASSEMBLY 1
32 360-6359 ANTISLIP PLATE 2
33 360-6360 ANTISLIP PLATE 1
34 S-4709 BIT-TIP SCREW 6
7-PARTS
FIGURE 7.5.37: BIJUR LUBRICATION SYSTEM
TO
PRESSURE
FILTERS
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. &
INDEX
NO.
UNITS
PER
ASM.
7.5.37 BIJUR LUBRICATION SYSTEM
1 S-3776 PUMP 1
2 99752 " TUBE X 1/8" ELBOW 1
3 99747 CHECK VALVE B-9557 1
4 B-7659 OIL OUTLET 1
5 B-6903 GASKET 1
6 HO-442 O-RING (LARGE) 1
7 B-6898 RELIEF VALVE 1
8 B-6479 OUTLET TUBING 1
9 C-2972 PUMP AND FILTER ASSEMBLY 1
10 99744 " - " PIPE REDUCER 1
11 B-8480 OUTLET TUBING 1
12 99731 4541K11 BUSHING 1
13 99760 PUMP FILTER UC-SE 1320 NPT 1
14 B-8471 MOUNTING SCREW 4
NOT
SHOWN
HO-418 O-RING (SMALL) 1
15 B-7726 BY-PASS VALVE 1
7-PARTS
FIGURE 7.5.38: LUBRICATION ASSEMBLY - BACK OF DECK
36 CARRIER SHOWN
1
7
8
SEE
20
19
18
DETAIL B
17
16
9
15
28
29
25
DETIAL A
DETAIL B
DETAIL C
SEE
DETAIL A
ROTOR
AXLE
24
26
24
30
1
6
11
2
27
3
2
4
5
SEE
DETAIL C
4,11,12,
13,14
10
15
21,22,23
31
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.38 LUBRICATION ASSEMBLY - BACK OF DECK CARRIERS
36 24 18
1 240-7019 NYLON TUBING (") 15 9 6
2 B-8272 SLEEVE (99722) 36 24 18
3 B-1371 BUSHING (99725) 18 12 9
4 A-2835 STRAIGHT ADAPTER (99720) 19 13 10
5 4541 K11 BRASS BUSHING (99731) 18 12 9
6 240-7020 NYLON TUBING (5/32") 1 1 1
7 240-7021 BRASS TUBING (5/32") 1 1 1
8 240-7022 NYLON TUBING (") 1 1 1
9 240-7025 COPPER TUBING (") 1 1 1
10 B-7688 5-WAY JUNCTION (99716) 1 1 1
11 B-1095 NUT (99721) 19 13 10
12 S-5537 BIJUR CONTROL UNIT (CJB-1) 1 1 1
13 A-4019 STRAIGHT CONNECTOR 1 1 1
14 B-1061 SLEEVE (99723) 1 1 1
15 240-7023 NYLON TUBING (") 1 1 1
16 240-7024 NYLON TUBING (") 1 1 1
17 240-7026 COPPER TUBING 1 1 1
18 S-4087 PRESSURE SWITCH 1 1 1
19 B-7694 4-WAY JUNCTION (99714) 1 1 1
20 S-4088 PRESSURE GAUGE 1 1 1
21 B6.4 DIN 125 FLAT WASHER (84105) (051040.0) 57 38 27
22 M5 X 30 DIN 6912 SOCKET HEAD SCREW (82125) 19 13 10
23 S-4066 PIPE CLIP 16 10 7
24 B-6534 STRAIGHT ADAPTER ASSEMBLY (99718) 41 27 20
25 B-7692 3-WAY JUNCTION (99712) 17 11 8
26 A-3080 ELBOW ADAPTER (99715) 18 12 10
27 S-5537 BIJUR CONTROL UNIT (CJB-1) 18 12 9
28 SR-338 IDLER ARM SPACER 1 1 1
29 M5 X 40 DIN 6912 SOCKET HEAD SCREW (82130) 1 1 1
30 S-4675 INSERT 38 26 20
31 99752 ELBOW (" TUBE) 1 1 1
7-PARTS
FIGURE 7.5.39: PROXIMITY SENSOR
3
2
1
9
5
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 in
the 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 proximity
sensor to 0.40 mm -0.05 mm. Lock the sensor in position with the lock nut. Recheck to insure
the correct setting.
Manually rotate several more shuttle assemblies into position and check them for the correct
setting.
After verifying the correct setting, manually rotate the deck/shuttles for one full revolution.
Check to insure that each shuttle triggers the sensor; a yellow light located at the back of the
sensor should come on each time a shuttle passes by. If the sensor doesnt trigger for each
shuttle, recheck the setting of the Proximity Sensor.
When verification of the correct setting is complete, replace the top shield and the upper change
gear. The braider is now ready for normal operations.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.39 SWITCH
1
1000745
1000576
1000575
PROXIMITY SWITCH BRACKET (18 CARRIER)
1 A/R
1 A/R
1 A/R
2 1000492 CLAMP 1
3 3000574 PROXIMITY SENSOR SWITCH ASSEMBLY 1
4 M6 X 10 DIN 916 SOCKET SET HEX CUP POINT SCREW (82220) 1
5
240-8051
1000985
SENSOR SCREW
SENSOR SCREW (BRIDGESTONE ONLY)
1
1
7 ST-M6 RIBBED WASHER (84200) (051238.0) 2
8 M10 DIN 934 HEX NUT (050945.0) 1
9 ST-M10 RIBBED WASHER (84220) (051240.0) 1
CAUTION
7-PARTS
FIGURE 7.5.40: INSIDE JOG BOX ASSEMBLY
SHEET 1 OF 2
1
2,3
6,7
4,6
5,6
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.40 3000841 INSIDE JOG BOX ASSEMBLY (SHEET 1)
1 1000840 INSIDE JOG BOX 1
3 3000569 YELLOW LEGEND 1
4 ZB2-BA2 OPERATOR PUSHBUTTON (97176) 1
5 S-5806 OPERATOR PUSHBUTTON (YELLOW) 1
6 S-5723 LEGEND 3
7 S-5153 ILLUMINATED SWITCH 1
7-PARTS
FIGURE 7.5.41: INSIDE JOG BOX ASSEMBLY
SHEET 2 OF 2
3
1
16,2
4,5
10,11
12,13
14 7 8 6 10,11,12
9
15
1
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.41 3000841 INSIDE JOG BOX ASSEMBLY (SHEET 2)
2 S-5799 AMBER SWITCH 1
4 S-5290 STRAIN RELIEF CONNECTOR 1
5 S-5328 NUT 1
12 M5 DIN 934 HEX NUT (83520) 3
13 S-2875-4 LUG RING, 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
FIGURE 7.5.42: MAIN CONTROL BOX ASSEMBLY
SHEET 1 OF 2
11 10
12
9
2
1
5 3 8 4 6 7
A
A
SECTION A-A
13,14,15,10
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.42 3000418 MAIN CONTROL BOX ASSEMBLY (SHEET 1)
3 S-5816 PUSHBUTTON, FLUSH, CLEAR 1
4 S-4047 EMERGENCY STOP 1
6 240-8656 ELECTRICAL LABEL 1
7 M3 X 6 DIN 84 CHEESE HEAD SCREW (81580) (050608.0) 4
10 A8 DIN 127 LOCK WASHER (84105) (051220.0) 14
11 M8 DIN 557 SQUARE NUT (83565) (050979.0) 6
12 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
FIGURE 7.5.43: MAIN CONTROL BOX ASSEMBLY, OPEN DOOR
SHEET 2 OF 2
6,7 1 3
15 8 9
4,5
10,11,12
13,14,4,
2
2(FIG. 7.5.42)
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.43 3000418 MAIN CONTROL BOX ASSEMBLY (SHEET 2)
1 3000390 MAIN CNTRL. BOX PANEL ASM. (FIGURE 7.5.44) 1
2 100-0718 MOUNTING RAIL 2
3 1000417 SHIELD 1
4 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 8
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
13 A4 DIN 127 LOCK WASHER (84095) (051217.0) 4
14 M4 DIN 935 HEX NUT (83510) (050935.0) 4
7-PARTS
FIGURE 7.5.44: MAIN CONTROL BOX PANEL ASSEMBLY
SHEET 1 OF 3
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
23
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
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 RELAY (K1) 1
5 S-5686 RELAY, 24V DC (K2) 1
6 S-5018 TERMINAL BLOCK (PE) 3
7
8 S-5683 RELAY, 9AMP (KM3) 1
11 B4.3 DIN 125 FLAT WASHER (84005) (051037.0) 11
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 3000418
19 S-5588 3 CONDUCTOR TERMINAL (AWG 24-6 PE) 4
20 S-5590 JUMPER 9
22 S-3883 PART OF 3000418
23 S-5704 ANALOG OUTPUT MODULE 1
7-PARTS
SHEET 2 OF 3
1
4
14,15(FIG7.5.44)
13(FIG 7.5.44)
9(FIG 7.5.44)
2 3
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.
UNITS
PER
ASM.
7-PARTS
SHEET 3 OF 3
1
14,15(FIG 7.5.44)
13(FIG 7.5.44)
3
18(FIG 7.5.44)
A A
SECTION A-A
6
5
8
8
4 7
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.
UNITS
PER
ASM.
1 S-5490 INVERTER DRIVE (400-480V) 1
2
5 M8 DIN 934 HEX NUT (83570) (050941.0) 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 (AWG-24-6 BLUE) 1
7-PARTS
FIGURE 7.5.47: REMOTE OPERATOR STATION ASSEMBLY
19
19
2
3
4
1
19
7
5
6
13,14,
15,16
18
10
17
11
10
9
13,14,15
12
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.47 3000146 REMOTE OPERATOR STATION ASSEMBLY
1 240-8773 REMOTE 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
14 A5 DIN 127 LOCK WASHER (84097) (051218.0) 4
15 M5 DIN 934 HEX NUT (83520) (050937.0) 4
16 S-2875-4 RING LUG 16-14 AWG. 2
17 S-3798 WIRE, 14 AWG, GREEN/YELLOW 100mm
19 S-5723 BLANK LEGEND 3
7-PARTS
SHEET 1 OF 3
2 3 4 1 5,6 7,8,9
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.48
3000618
3000684
TERMINAL BOX ASSEMBLY (SHEET 1)
1
1000573
1000683
TERMINAL BOX (FOR 3000618)
TERMINAL BOX (FOR 3000684)
1
1
2 S-3505 RED PUSHBUTTON SWITCH 1
3 ZB2-BD5 SELECTOR SWITCH (97382) 1
4 1000638 TERMINAL BOX ANGLE 2
8 M6 DIN 934 HEX NUT (050939.0) (83530) 4
9 A8 DIN 127 RIBBED WASHER (84105) 4
10* S-5750 TOUCHSCREEN PROTECTIVE COVER (NOT SHOWN) 10/PK
7-PARTS
SHEET 2 OF 3
10,11,12 22
15,16
2,3,17
5
9
12,13,14
21
1
4
12,13,14 5 2,3,17 18
6
2,3,17
10,11,12
12,13,14
12,13,14
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.49
3000618
3000684
1 1000616 TERMINAL BOX PANEL 1
2 M5 X 8 DIN 84 CHEESE HD SCREW (050638.0) (81930) 9
3 S-3697 MOUNTING RAIL (3000618) 275mm ea.
4 S-5590 JUMPER 6
6 S-5744 EXPANSION MODULE 1
7 S-5753 (DUAL DRIVE) EXPANSION CABLE 1 A/R
8 S-5754 (DUAL DRIVE) INPUT ANALOG MODULE 1 A/R
9 S-5583 PLC 1
12 S-5499 NYLON CHEESE HEAD SCREW 20
17 B5.3 DIN 125 FLAT WASHER (84010) (051038.0) 9
20 S-5328 NUT (NOT SHOWN) 1
22 S-5591 MARKER 1-50 1
7-PARTS
SHEET 3 OF 3
1
5
3
2 4
6 7
8
9
11
10, 15 (Fig7.5.49)
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.50
3000618
3000684
1 S-5749 TOUCH SCREEN (3000618 ONLY) 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 ONLY) 1
8 S-5261 HOUR METER 1
9 3000428 HOUR METER CABLE 1
10 S-244-C NUT, HEX 1/4-20 X 3/16" 1
11 S-4700 STRIP, RUBBER SPONGE 1400mm
7-PARTS
7-PARTS

7-PARTS
FIGURE 7.5.52: BOBBIN RUNOUT DETECTOR ASSEMBLY
7
8
15
14
9
10
12
13
5
1
3
11
10
9
8
6
4
16
TO DECK MONITOR
2
2
(36 CARRIER)
17
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.52
240-9075 (DA-1463)
536-9076
BOBBIN RUNOUT DETECTOR ASM. (24 CARRIER)
BOBBIN RUNOUT DETECTOR ASM. (36 CARRIER)
1 240-9058 BOBBIN RUNOUT BAR 2
2
240-9059
536-9059
MOUNTING CLAMP (24 CARRIER)
MOUNTING CLAMP (36 CARRIER)
2 A/R
2 A/R
3 240-9078 PROBE SPRING SLIDER 2
4 M5 X 10 DIN 916 SET SCREW (050521.0) 4
5
240-9067
536-9067
INSULATOR SPACER (24 CARRIER) 4.7 mm THICK
INSULATOR SPACER (36 CARRIER) 36.7 mm THICK
2 A/R
2 A/R
6
M8 X 20 DIN 6912
M8 X 55 DIN 6912
SOCKET HEAD SCREW (050709.0) (24 CARRIER)
2 A/R
2 A/R
7
M8 X 45 DIN 6912
M8 X 80 DIN 6912
SOCKET HEAD SCREW (053881.0) (24 CARRIER)
2 A/R
2 A/R
9 B8.4 DIN 125 FLAT WASHER (051042.0) 4
10 84235 NYLON WASHER 4
11 240-9064 INSULATOR BUSHING 2
12 240-9062 CLAMP INSULATOR 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
FIGURE 7.5.53: ELECTRICAL SYSTEM, BACK OF DECK
1,2,3,16
16
14
11,12,13
4,
7,8
9
10
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.53 ELECTRICAL SYSTEM- BACK OF DECK CARRIERS
36 24
1 3000478 DECK TO SENSOR WIRE ASSEMBLY 1
2 M3 X 16 DIN 84 SLOTTED CHEESE HEAD SCREW (050614.0) 4 4
3 B3.2 DIN 125 FLAT WASHER (84000) 4 4
4 S-5295 SAFETY POSITION SWITCH (SEE FIG. 7.5.54) 1 1
5
6
7 M5 X 20 DIN 6912 SOCKET HEAD SCREW (81200) 2 2
8 B5.3 DIN 125 FLAT WASHER (051038.0) 2 2
9 S-3172 WIRE CONNECTOR 2 2
10 S-2080 CABLE TIE 1 1
11 99729 TUBE CLIP 17 11
12 M5 X 10 DIN 6912 SOCKET HEAD SCREW (050680.0) 18 12
13 B6.4 DIN 125 FLAT WASHER (051040.0) 50 38
14 87280 TERMINAL BLOCK 12 POLE (SMALL) 1
15
16 S-5310 STRAIN RELIEF CONNECTOR 2 1
7-PARTS
FIGURE 7.5.54: GEAR BOX DOOR SWITCH
3,4 1 2
9
8
7
5
6
7-PARTS
INSTRUCTIONS FOR KLOCKNER MOELLER SWITCH
The safety switch installed on the gear box door on the rear of the braider locks the door closed
while the braider is in operation or, if the door is open, it will prevent the braider from being
started.
An alarm message 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) to insure easy and unrestricted operation of the switch.
NOTE: Do not attempt to bypass the switch or modify it in any way.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.54 GEAR BOX DOOR SWITCH
1
2000451
2000522
GEAR BOX DOOR (24 CARRIER)
GEAR BOX DOOR (36 CARRIER)
1
1
2
1000447
1000523
DOOR FINGER (24 CARRIER)
DOOR FINGER (36 CARRIER)
1
1
5 S-5295 SAFETY POSITION SWITCH 1
6 SEE ITEM 5 KEY (PART OF SWITCH) N/A
9 M4 X 10 DIN 7991 FLAT HEAD SOCKET SCREW (81808) 2
7-PARTS
FIGURE 7.5.55: WIRING DUCT AND LIGHT
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
152mm
6" REF
3
8
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.55 WIRING DUCT AND LIGHT
1
240-8867
536-8867
WIRING DUCT 45 (18 & 24 CARRIER)
WIRING DUCT 45 (36 CARRIER)
2
2
2 S-5267 WIRING DUCT 2
3 2000441
LIGHT MOUNTING BRACKET ASSEMBLY
(INCLUDES ITEMS 4 - 7)
1
4 2000421 LIGHT MOUNTING BRACKET 1
5 M4 X 8 DIN 84 CHEESE HEAD SCREW (81760) 2
6 174723 INDICATOR LAMP ASSEMBLY 1
8 97363 SLOTTED HEAD SELF TAPPING SCREW 2
7-PARTS
FIGURE 7.5.56: MOUNTING BRACKET
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.
UNITS
PER
ASM.
7.5.56 MOUNTING BRACKET
1 S-5286 WIRING DUCT COVER 4
2* S-5267 WIRING DUCT 2
3* 240-8867 WIRING DUCT 45 2
5 S-5266 MOUNTING BRACKET 15
7-PARTS
FIGURE 7.5.57: WIRING DUCT DETAILS
8
9
10
11
12
6
7
3
4
5
2
1
7-PARTS
* CUT TO FIT
FIG. &
INDEX
NO.
UNITS
PER
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
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
FIGURE 7.5.58: DOOR LOCK
4
11
7
5
9
10
3
7
6
2
7
6
1
8
DOOR OF
ENCLOSURE
INSIDE WALL OF
ENCLOSURE
7-PARTS
NOTE: Quantities shown are per door.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.58 DOOR LOCK
1 S-5721 DOOR LOCK 1
2
S-5717
S-5718
SWITCH MOUNT BRACKET - RIGHT
SWITCH MOUNT BRACKET - LEFT
1 A/R
1 A/R
3 S-5716 SWITCH KEY MOUNTING BRACKET 1
4 S-5715 FLEXIBLE ACTUATOR 1
5 A6 DIN 127 SPRING WASHER (051219.0) (84100) 2
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
FIGURE 7.5.59: SLIDING DOOR LOCK
1
7
3
4
2
10
2
13
14
15
12
8
9
5
11
6
7-PARTS
NOTE: Quantities shown are per door.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
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 SNAP BUSHING 2
7-PARTS
FIGURE 7.5.60: BLOWER
FILTER SLIDES IN
FROM END
2
5
6
1
7 4
3
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.60 BLOWER
1 S-5707 HOOD 1
7 S-4891 16" X 20" X 2" MESH FILTER 1
7-PARTS
7-PARTS

7-PARTS
FIGURE 7.5.62: DECK LIGHTS (SHEET 1)
1
4,5,6
7,8,11,12
2
9,10
3
9,10 (4000919)
(DA-1615,
DA-1706)
2 (4000919)
(DA-1615,
DA-1706)
7-PARTS
*Not used with Stand Alone Main Control Box.
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.62
DA-1615
DA-1706
4000919
DECK LIGHTS (24 CARRIER) (SHEET 1)
DECK LIGHTS (STAND ALONE) (SHEET 1)
1
ATE-457 (16, 20, 24)/
ATE-473 (36)
ENCLOSURE LIGHT CONDUIT ASSEMBLY
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
0
1
2
2
ATE-458 (16, 20, 24)/
ATE-472 (36)
3000920
SWITCH TO LIGHT CONDUIT ASM. (DA-1615
& DA-1706 ONLY)
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
SWITCH TO LIGHT CONDUIT ASSEMBLY (4000919)
1
1
1
1/Deck
3*
240-8005 (16, 20, 24)/
360-8005 (36)
LIGHT SWITCH BOX ASSEMBLY (DA-1615
& DA-1706 ONLY)
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
1 A/R
1 A/R
1 A/R
4 99953
D-LOOP SIZE #5 CHAIN
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
0.45 m
0.9 m
1.35 m
5 99952
OPEN STYLE S-HOOK
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
4
8
12
6 99950
WIRE SCREW EYE
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
2
4
6
7 99951
WIRE EYE BOLT
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
2
4
6
8
S-5724 LIGHT FIXTURE
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
1
2
3
9 97264
CONDUIT CLAMP, 1/2 INCH
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
2
6
10
7-PARTS
FIGURE 7.5.62: DECK LIGHTS (SHEET 2)
1
4,5,6
7,8,11,12
2
9,10
3
9,10 (4000919)
(DA-1615,
DA-1706)
2 (4000919)
(DA-1615,
DA-1706)
7-PARTS
FIG. &
INDEX
NO.
UNITS
PER
ASM.
7.5.62
DA-1615
DA-1706
4000919
DECK LIGHTS (STAND ALONE) (SHEET 1)
10 97363
SELF TAPPING SCREW
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
4
12
20
11 S-2076
WIRE NUT
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
3
9
15
12 S-5725
LIGHT BULB
(SINGLE DECK)
(DOUBLE DECK)
(TRIPLE DECK)
2
4
6
7-PARTS
FIGURE 7.5.63: BOBBINS
SINGLE LET-OFF WIRE BOBBIN (#2000366)
APPROXIMATE WIRE WEIGHT: 20 LBS (9.1 KG)
MAXIMUM BOBBIN & MATERIAL WEIGHT: 23.5 LBS (10.66 KG)
SINGLE LET-OFF YARN - CARDBOARD TUBE (#240-4016)
**TUBES TO BE PURCHASED FROM YARN CONVERTER
PER THIS DRAWING - REFERENCE PAGE 2-14 FOR TUBE
AND PACKAGE DIMENSIONS
MAXIMUM TUBE AND MATERIAL WEIGHT: 7 LBS (3.18 KG)
YARN VOLUME: 229 CUBIC INCHES (3747 CU CM)
SINGLE LET-OFF FABRICATED YARN BOBBIN (#240-5160)
APPROXIMATE MATERIAL WEIGHT: 4.75 LBS (2.15 KG)
MAXIMUM BOBBIN & MATERIAL WEIGHT: 7 LBS (3.2 KG)
VOLUME: 223 CUBIC INCHES (3800 CU CM)
SUPER PACK FABRICATED YARN
APPROXIMATE MATERIAL WEIGHT:
7.36 LBS (3.35 KG)
MAXIMUM BOBBIN & MATERIAL WEIGHT:
10 LBS (4.5 KG)
SUPER PACK YARN - CARDBOARD
**TUBES TO BE PURCHASED FROM
PER THIS DRAWING - REFERENCE
FOR TUBE AND PACKAGE DIMENSIONS
MAXIMUM TUBE AND MATERIAL
YARN VOLUME: 302 CUBIC INCHES (4947 CU CM)
WEIGHT: 10 LBS (4.5 KG)
PART NUMBER 240-5162
DRAWING NUMBER 240-4018
PART NUMBER 240-5160
DRAWING NUMBER 240-4016
PART
NUMBER
2000366
BOBBIN (#240-5162)
TUBE (#240-4018)
YARN CONVERTER
PAGES 6-1 AND 6-2
7-PARTS

WINDING OPTIONS FOR USE WITH ROCKWELL WINDER
ADAPTER PINS 240-5105
BORE CONVERSION KITS 240-5107 SINGLE LET-OFF
240-5126 DOUBLE LET-OFF
7-PARTS

8-MAINTENANCE AND OVERHAUL
CHAPTER 8
MAINTENANCE AND OVERHAUL
SECTION # SECTION TITLE PAGE
SAFETY (SICHERHEITSREGELN) (VEILIGHEID) . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
SECTION I MR-15 PLC-T AND MR-15 PLCT-F BRAIDMATIC OVERHAUL . . . . . . 8-12
SECTION II ROTOR INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
CAM FOLLOWER LIFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
SECTION III SHUTTLE INSPECTION AND REPAIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-23
SECTION IV PRELIMINARY SHUTTLE ADJUSTMENT AND INSTALLATION . . . . . . . . . 8-26
SECTION V INSTALLATION OF ROTOR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . 8-26
SECTION VI ROTOR CHECKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
SECTION VII SHUTTLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
SECTION VIII OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-33
SECTION IX INSTRUCTIONS FOR THE USE OF THE 240-1078 GAUGE . . . . . . . . . . . . 8-35
CHECKING TIR (TOTAL INDICATOR RUNOUT) SQUARENESS OF AXLES
TO DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
CHECKING DISTANCE BETWEEN ROTOR AXLES . . . . . . . . . . . . . . . . . . 8-36
SECTION X INSTRUCTIONS FOR THE USE OF THE 240-1075 (ROTOR GEAR TIMING
GAUGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
SECTION XI INSTRUCTIONS FOR THE USE OF THE 240-1076 (CAM SET GAUGE WITH
MASTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
SECTION XII DISASSEMBLING, REASSEMBLING, ADJUSTING, AND MAINTENANCE OF
CARRIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
REASSEMBLY OF CARRIER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
CARRIER MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48

CHAPTER 8
MAINTENANCE AND OVERHAUL
SAFETY
Braiding machines are designed to produce
quality braided structures by transferring
shuttles via cam tracks. Producing the braided
structures requires high speed, high
horsepower, and moving elements. This in turn
requires that operators and maintenance
personnel of this equipment be safety
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 this
equipment, 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 dont
understand the instructions, please contact
Mayer Industries Inc.
An operator or maintenance personnel should
become completely familiar with all machine
controls and corresponding moving elements
before setting up, operating, or working on the
machine.
We suggest snug fitting clothing and safety
glasses be worn. No ties and no attempt made
to operate the machine while fatigued or ill. Do
not operate the machine if it is malfunctioning
in any way.
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
Do not store wrenches or other items on
machine surfaces.
Maintain a clean and safe work area. Keep oil
from floor to prevent slipping.
Be sure that all guards and covers are properly
in place and doors are closed and fastened
while operating the machine.
The movement of the deck, gear, and transfer
areas can create pinch points and the operator
must avoid these points.
During maintenance work, the control must be
turned OFF, as an accidental control actuation
can cause 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 an
electrical component failure. Other
maintenance must be performed by authorized
personnel.
CAUTION
In conclusion, operators and maintenance
personnel must be properly trained before
being allowed to operate or work on this
equipment. Operators and Maintenance
Personnel must treat this 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 to others without Mayer Industries'
previous consent nor its contents exploited in
any other way by the user or any third party.
Reprints, whether complete or partial, require
the express authorization of 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 the important features of the design.
However, dimensional accuracy and design
details are not guaranteed 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 the standard 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 using
genuine MII or MII-approved components or
replacement parts.
Before and while operating the machine, all
general and special safety rules must be
observed and necessary safety protections
taken. 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
RIGGERS SHOULD BE ALLOWED TO
MOVE AND SETUP THIS EQUIPMENT.
NOTE: MACHINE WEIGHT AND
STABILITY ARE MAJOR CONCERNS IN
LIFTING AND MOVING THE EQUIPMENT.
SYMBOL TRANSLATIONS
English: DANGER
DO NOT OPEN WHILE MACHINE IS IN
OPERATION
English: WARNING
SYMBOL TRANSLATIONS
SICHERHEITSREGELN
Braiding Maschinen sind entwickeld um hohe
Qualitts braided structur produkte zu
produzieren bei transfer shuttles ber cam
tracks. Beim Produktstionsvorgang wird mit
hoher geschwindigkeit und mit viel
Kraftaufwand gearbeitet. Um unflle zu
vermeiden soll nur geschultes Personal zur
Bedienung der Maschine verwendet werden.
Wir Knnen nicht alle mglichkeiten
aufzhlen die einen Unfall verursachen
Knnen, aber wir fhren hier in generell einige
Sicherheitsvorschriften auf.
Wenn dieses Zeichen im Buch
erscheint, die instruktionen mssen
100% erfllt werden um Unflle zu
vermeiden. Wenn sie irgend etwas nicht
verstehen, fragen sie uns bitte.
Bedienungspersonal und Betriebsmechaniker
mssen 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 fhlen, oder krank
sind. Niemals die Maschine 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
wenn die Maschine Luft.
Die sich bewegenden elemente
Transferposition und Ritzel Knnen Leicht zu
einer Falle werden, so sei vorsichtig und trete
zurck.
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 mchten wir daraufhinweisen das,
das Personal die Maschine immer mit Respekt
behandelt, und immer alle
Sicherheitsvorschriften beachtet.
VEILIGHEID VOOR MR-15 PLC-T/MR-15 PLCT-F BRAIDMATIC
Vlechtmachines zijn ontworpen om
hoogwaardige gevlochten strukturen te maken
door middel van langs geleidingen
rondlopende spoelen. Om deze gevlochten
stukturen te maken is er hoge snelheid, hoog
vemogen en bewegende delen vereist. Daarom
moeten operatoren en onderhoudspersoneel
veiligheidsbewust zijn om ongevallen met
letsel of zelfs blijvend letsel te vemijden.
Wij kunnen niet alle mogelijke factoren welke
tot een ongeval kunnen leiden voorzien, maar
een aantal algemene veiligheidsfactoren
worden gelijst als hulpmiddel voor operatoren
en onderhoudspersoneel.
WARNUNG
Wanneer dit symbool aangegeven
wordt in het handboek, dan moeten
de geschreven instrukties absoluut
gevolg worden om het risiko op letsels te
vermijden. Indien de instruktie onduidelijk is,
moet Mayer Industries Inc. geraadpleegd
worden.
Vooraleer met de vlechter te werken moeten
operatoren en onderhoudsmensen opgeleid
worden in 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 zijn vooraleer 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
een eventuele ongewilde activering van de
startknop onverwachte start van de machine te
vermijden;
De machine start onder electrische
hogespanning. Enkel getrainde elektriekers en
onderhoudspersoneel mogen aan de machine
werken
OPERATOREN EN ONDERHOUDSMENSEN
MOETEN MET DE NODIGE OMZICHTHEID
WERKEN EN ALLE
VEILIGHEIDSVOORSCHRIFTEN
RESPEKTEREN!
MISURE DI SICUREZZA PER LA BRAIDMATIC PLC-T/PLCT-F MR-15
Le intrecciatrici sono progettate per produrre
strutture intrecciate di qualit trasferendo spole
seguendo il profilo di eccentrici. La
produzione di strutture intrecciate richiede alta
velocit, grande potenza e movimento di
componenti. A propria volta, tutto questo
richiede che loperatore e il personale addetto
alla manutenzione di questa apparecchiatura
siano consci delle esigenze di sicurezza per
evitare infortuni che possono comportare
lesioni personali invalidanti o mortali.
Non possibile prevedere tutti i fattori che
possono verificarsi o causare incidenti con
questa apparecchiatura, ma si possono elencare
alcune misure di sicurezza di carattere
generale in grado di indirizzare loperatore e il
personale addetto alla manutenzione a
comportarsi in modo sicuro.
Quando questo simbolo appare nel
manuale, seguire scrupolosamente le
istruzioni ivi riportate per evitare
infortuni. Se le istruzioni non sono
comprensibili, contattare le Mayer Industries,
Inc.
ATTENZION
Loperatore e il personale addetto alla
manutenzione devono acquisire la massima
familiarit con tutti i comandi della macchina
ed i relativi componenti mobili prima di usare
la macchina stessa o lavorare su di essa.
Si consiglia di indossare indumenti attillati e
occhiali di sicurezza; niente cravatte. Non
usare la macchina in caso di stanchezza o
malattia/indisposizione. Non usare la
macchina in caso di malfunzionamenti 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
siano montati correttamente e che gli sportelli
siano chiusi e fissati.
Il movimento del piano di lavoro, degli
ingranaggi e delle aree di trasferimento pu
creare punti di schiacciamento che loperatore
deve evitare.
Durante le operazioni di manutenzione i
comandi devono essere disattivati, poich un
loro azionamento accidentale pu causare un
movimento imprevisto della macchina con
pericolo di infortuni.
Questa macchina alimentata ad alta tensione.
I guasti elettrici devono essere riparati solo da
elettricisti qualificati. Le altre operazioni di
manutenzione devono essere eseguite da
personale autorizzato.
In conclusione, loperatore e il personale
addetto alla manutenzione devono trattare la
macchina con il massimo rispetto ed osservare
tutte le misure di sicurezza.
Tutti i diritti di questo manuale di istruzioni
sono riservati. Non pu essere copiato o reso
disponibile a terzi senza previo consenso delle
Mayer Industries; il suo contenuto non pu
essere utilizzato in alcun modo dallutente o da
terzi. Eventuali ristampe, parziali o totali,
dovranno essere autorizzate dalle Mayer
Industries.
Queste istruzioni operative sono state
formulate per fornire informazioni su
costruzione, uso e manutenzione della
macchina. I diagrammi e i disegni allegati
illustrano caratteristiche importanti della
progettazione. Tuttavia, non si garantisce la
precisione delle dimensioni e dei dettagli delle
figure e la Mayer Industries si riserva il diritto
di apportare modifiche o cambiamenti in
qualsiasi momento.
Le istruzioni operative descrivono anche
dispositivi, ricambi o altre parti che non fanno
parte della versione standard della macchina e
che sono disponibili solo su ordinazione come
parti supplementari. Nessun diritto di dotare la
macchina di tali parti o dispositivi pu essere
dedotto da queste istruzioni operative.
Quando si ordinano i ricambi, vedere il
capitolo 7. La garanzia della macchina valida
solo se si usano componenti o ricambi originali
della MII o omologati dalla MII.
Prima e durante luso della macchina,
osservare scrupolosamente tutte le misure di
sicurezza generali e particolari e adottare tutte
le precauzioni necessarie. Non disattivare
nessun dispositivo di protezione o sicurezza.
SECTION I. MR-15 PLC-T AND MR-15 PLCT-F BRAIDMATIC OVERHAUL
CAUTION
the shuttle/rotor assembly area.
could occur.
be worn.
procedure
instructions.
8.1. Turn all power OFF to the machine.
Remove all carriers and bobbins. Remove the
top change gear on the deck, then remove the
inner and outer shields.
CAUTION
Release of shuttle assemblies.
Do not attempt to remove cam
follower assemblies when a
shuttle is engaged with the
cartridge.
8.2. Remove shuttles from machine at their
proper places. On a 36 carrier machine,
shuttles are removed at rotor frames 4 & 5. On
a 24 carrier machine, shuttles are removed at
rotor frame numbers 3 and 4.
NOTE
to communicate.
from MI (Figure 9.1.8)
NOTE
Before removing shuttles from
their transfers, it is best to put
each set of shuttles into its
transfer position and identify on
the rotor face. Tag or mark each
transfer number onto every
shuttle. This enables a correct
shuttle from each transfer to be
used in checking the clearance
between the front and rear cam
followers and cam track.
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 #1
transfer shuttles into transfer and with a
marker that will not rub off, mark all the front
and rear cam followers in this transfer #1 on
the face of the rotor frame. The same should be
done on #2, #3, and #4 transfers.
Be sure to keep each transfer separated. In
other words, on a 24 carrier machine, keep all
shuttles removed from #1 transfer together, but
separated from transfers #2, #3, and #4, etc.
Each transfer is marked by its respective
number on the front cam follower cap. By
doing this, you are assured that the shuttles
removed from each transfer will return to its
original transfer.
NOTE
This information is for a deck
being overhauled and rotors
returned to original locations on
the same deck.
8.3.
1. Install the front pocket polishing tool (240-
1001) on to a hand drill motor. See Figure
8.3.1.
2. Wrap a piece of 320 grit (very fine) emery
cloth around the polishing roll. BE SURE
THE ENDS OF THE CLOTH (PAPER)
DO NOT OVERLAP.
3. Place the polishing tool into a pocket and
rotate the rotor to the transfer position.
4. Let the drill motor rotate the polishing tool
a few revolutions. The object is to polish
out rough or high places, removing a
minimal 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, 5
and 6, 7 and 8, 9 and 10, 11 and 12, 13 and
14, 15 and 16, 17 and 18.
After the polishing tool has been run in all
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 a
rotor and with a finger lightly holding the
outer race into position, slowly rotate the
rotor through a transfer position. The outer
race should pass through the transfer
without any restrictions. If there are any
restrictions, the cause must be found and
corrected.
CAUTION
Moving elements in this assembly
area.
could result.
NOTE
If there are restrictions in all
pockets of a rotor, then the timing
of the rotor gear to pockets is off
and must be corrected. See
Section X, Instructions for the use
of the Rotor Gear Timing Gauge
(240-1075).
If only 1 or 2 pockets have restrictions, it is
usually a high or rough place in the
pocket(s) and should be corrected as
follows:
Using marking ink, paint the mating
pockets that show restriction. Place the
outer race (4, Figure 7.5.17) into one of the
pockets and very lightly holding the race in
the pocket with a finger, slowly rotate the
rotor through the transfer position. This
should cause the outer race to try to rotate,
thus marking the high or rough place(s) in
the pocket. Using a scraping tool, scrape
the marked place(s). Check the outer race
through transfer after each scraping until
there is no restriction of the outer race
through the transfer position.
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
72.0 mm
INCLUDING
#320 EMERY CLOTH
1 1 IT MAY BE NECESSARY TO WRAP THE
POLISHING HUB WITH A PIECE OF
MASKING TAPE TO COMPENSATE FOR
POCKET WEAR.
NOTE
The rear pockets should be
checked for restrictions using a
new S-4095 bearing (10, Figure
7.5.17), a rear polishing tool 240-
1002 (Figure 8.3.2) and the same
method as the front pockets.
7. After all the pockets have been checked
proceed as follows:
a. Obtain shim stock 7 mm wide and in
varying thickness from .01 mm (.0039
inch) up to .30 mm (.0118 inch). Note
that .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 bottom
of the pocket, then place the new outer
race (4, Figure 7.5.17) into the pocket
and hold it there. Very slowly rotate the
rotor into the transfer position. The
thinnest shim should pass through the
transfer without any resistance. If any
resistance is felt, stop. If no resistance
is felt, repeat this procedure using
thicker shims until you reach a shim
thickness that produces resistance
when the transfer point is approached.
The shim thickness between the outer
race and the pocket is an approximate
indication of the wear between mating
pockets.
NOTE
If this reading exceeds 0.30 mm
(.0118 inch), one (1) of the rotor
frames will have to be replaced.
FIGURE 8.3.2: REAR 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
62.0mm
INCLUDING
#320 EMERY CLOTH
1
1
IT MAY BE NECESSARY TO WRAP THE
POLISHING HUB WITH A PIECE OF
MASKING TAPE TO COMPENSATE FOR
POCKET WEAR.
NOTE
Rotor frames can be returned to
MI for rework
8. After all the pockets have been checked,
set up a magnetic base with an indicator
and mount it onto the face of the rotor,
letting the point (tip) of the indicator touch
onto the face of the opposite rotor.
Grasping the sides of this rotor, push in as
far 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 reading
should be recorded for future reference
when rotors are reinstalled onto the deck.
See Figure 8.3.3.
NOTE
After the rotors are reinstalled on
the deck, they must be adjusted
so the axial movement is between
0.01 mm to 0.05 mm after the
KM8 nut is tightened (18, Figure
7.5.21).
End play adjustment is obtained by the use
of shims as described in METHOD 1 or by
machining as described in METHOD 2.
See Section V, Paragraph 8.16.
FIGURE 8.3.3: ROTOR AXIAL MOVEMENT
AXIAL MOVEMENT
ROTOR FRAME
DIAL GAUGE
AXIAL MOVEMENT
.01 mm MINIMUM
.05 mm MAXIMUM
8.4.
Remove the rotor assembly from each rotor
axle. See Chapter 2, Section XI, Paragraph
2.49. Be sure to keep the bearing ring (12,
Figure 7.5.21) with its correct rotor assembly.
The bearing ring determines the amount of
axial end-play of the rotor assembly.
8.5.
CAUTION
help.
After the rotor assemblies are removed, turn
the oil pump on manual and without increasing
or decreasing oil pump pressure, check and be
sure that the oil is flowing freely from the
Bijur 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 axle
will have to be removed from the deck and
the major sun gear (2) and rear bearing
inner race (3-1, Figure 7.5.21) removed
from the rotor axle.
NOTE
Use MII tool 524-1074 (Figure
8.5.1) unless a race puller is
available.
2. The middle and front Bijur units (7 and 27,
Figure 7.5.21) can be extracted without
removing the rotor axle from the deck. If
the front metering unit has to be replaced,
the front inner race can be removed by use
of 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 524-1074
AXLE
REAR BEARING 524-1074
8.6.
After checking the metering units in the rotor
axles, check the rear bearing (3, Figure
7.5.21), major sun gear (2) and the front
bearing (4).
NOTE
Use MII rear bearing puller 524-
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 set
on rear or front. If the rear bearing has to be
replaced, the following steps should be
followed: Note: MII tool 524-1074 is
available. See Figure 8.5.1.
1. Disconnect the oil lines from the rotor axle.
2. Remove the (6) M12x60 DIN 6912 screws
(16, Figure 7.5.21).
NOTE
Rotor axles are sealed into the
deck with Permatex; therefore, the
axle 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 (4) M5 DIN 912 (19, Figure
7.5.21) screw from the major sun gear (2)
and remove the sun gear from the axle. The
sun gear may have to be lightly pried or
tapped with a hammer and aluminum or
soft brass rod. Remove the key from the
rotor axle.
4. Using the (3) 6 mm holes through the rear
of the rotor axle, tap the inner race from the
rotor axle.
NOTE
The inner race is a press fit onto
the axle. Parts can be driven on
by carefully using a fitted bearing
driver or plastic mallet.
FIGURE 8.5.2: FRONT BEARING PULLER 240-1073
AXLE
FRONT BEARING
240-1073
5. When installing the new inner race, be sure
the oil hole is aligned with the metering
unit before pressing or driving onto the
axle.
6. Install the new needle bearing onto the
inner race.
7. Install the major sun gear after checking it
for cracks or defective areas. If at all
possible, MAGNAFLUX all the sun gears
on the machine. If this is not possible and
there is some question about a sun gear,
replace it. On installing the sun gear, be
sure to align the keyway to the key in the
rotor axle and lightly tap it down until it
bottoms out.
8. Install lock washers on the (4) M5 DIN
912 screws, apply permatex to the screw
threads and install them into the sun gear to
secure the sun gear to the rotor axle.
9. Clean the Permatex from the rotor axle and
deck hole and apply a moderate, fresh coat
of Permatex, Aviation Form-A-Gasket,
Liquid Type, #3H to the axle shaft and the
hole.
10. The rotor axle is now ready for
reinstallation.
11. Slip the axle into the hole, aligning the
timing pin in the deck with the dowel hole
in the rotor axle.
12. Assemble the (6) M12x60 DIN 912 screws
together with the (6) A12 lock washers.
Apply Permatex to all the screw threads
and torque the screws to 65-70 ft.-lbs. See
Figure 7.5.21, items 16 & 20.
13. Check and be sure that the screws and
timing pin do not protrude past the face of
the axle flange.
14. With the use of gauge 240-1078.01,
(Figure 8.20.1) the squareness of the axles
to deck face and the distance between axles
can be checked. A distance of (+) or (-) .07
mm is allowable from the master setting on
the indicator and a squareness of 0.03 mm
TIR. Any distance or out of squareness
over this should be corrected.
NOTE
In case the axle has to be
shimmed, the flatness cannot be
held.
NOTE
The gauge for setting distances
between axles consists of a
bearing hub, extension rods,
indicator, and master gauge. See
Figure 8.21.1.
When using this gauge for checking
squareness, be sure to screw the KM8 nut
finger tight against the bearing hub. This
eliminates false readings from backward
and forward movements.
15. If the squareness measurement is too great,
it is sometimes possible to loosen the (6)
M12x60 DIN 6912 screws in the axle, tap
the axle loose, and retighten in a different
pattern; or a brass shim may have to be
installed at the proper location for
correction. Normally, these two procedures
are not necessary.
16. Also, there is a possibility that the rotor
axle may be bent, especially if it is in the
area where a smash-up has occurred.
Before shimming, install a new rotor axle
and check the center distance and flatness
to insure that a bent rotor axle is not the
problem.
17. Remove the old outer race (3-3, Figure
7.5.21) from the mating rotor assembly and
tap the new outer race into place in the
rotor 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 and
rear cam followers for pitted or galled shafts,
free rotation (clockwise and counterclock-
wise), too much radial end-play (cap end and
shaft end), and too much axial end-play. An
indicator mounted on a magnetic base can be
attached to the rotor frame to check the radial
and axial end-play. Refer to Figure 8.3.3.
The following dimensions are the tolerances
for the radial and axial end-play of the front
and rear cam followers. Also, if the cam
followers have 10,000 hours or 5 years running
time, the cam follower shafts should be
removed and magnafluxed. Replace shafts that
show any signs of cracks or wear. Refer to
Chapter 2, Paragraphs 2.54, and 2.57.
If the dimensions are more than the maximum
allowable tolerance, the cam follower
assembly must be replaced. DO NOT TRY TO
REPAIR IT.
8.8. CAM FOLLOWER LIFE. Based on the cam
followers returned to us from machines which
have been in operation a minimum of five
years, we make the following recommenda-
tions for preventative maintenance purposes.
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 the
area which is in contact with the cam track
shows indentations which are deeper than
0.02mm. If a cam follower has
indentations less than 0.02 mm and if you
desire 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 they were originally made in the
USA.
Be sure when replacing front or rear cam
followers, that the slot in the cartridge and the
indentation 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 threads
and be torqued to 55-60 ft.-lbs.
The adjustment of the cam followers to the
cam track will follow in SECTION XI. Also
reference the Adjustment and Maintenance
Section, 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 any
obstructions found. There are two oil holes for
the front cam followers and two oil holes for
the rear cam followers.
Axial end-play
.1 mm - .4 mm, front and rear
cam follower
Radial play of
shaft
.01 mm Minimum Play
.045 mm Maximum Play
8.9. Inspect the planetary gears (6 or 7, Figure
7.5.19) (major and minor) for free turning. If
any tightness or roughness is noticed, remove
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 are
found in a rotor that was removed
from a deck and this rotor is to go
back in the same location, on the
same deck, the timing should be
checked and recorded, before
removing the rotor gear so that the
gear may be timed to the same
reading as recorded. Use gauge
240-1075, 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 35
DIN 6912 screws (17, Figure 7.5.19) from
the rotor gear (2, Figure 7.5.19).
2. With a plastic or rubber hammer or a
hammer and a soft material rod (soft brass
or aluminum), tap the rotor gear off the
rotor 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 shaft
should now protrude through the back of
the rotor frame.
5. The planetary shafts must be identified so
they can go back into the holes from which
they were removed, unless they are being
replaced. This will insure correct location
and dowel hole alignment when
reinstalling.
6. Pull the shaft (4, Figure 7.5.19) out of the
rotor frame.
7. Inspect the shaft for bends or bearing
grooves.
8. Inspect the (2) 6001-2RS bearings (18,
Figure 7.5.19) for roughness.
NOTE
If shaft is bent or worn, it must be
replaced. DO NOT TRY TO REPAIR.
8.10. Replacement of a shaft is as follows:
1. Insert the new shaft into the hole, making
sure the planetary gear (6 or 7, Figure
7.5.19) and planetary spacer (5, Figure
7.5.19) are in proper position.
2. Secure the top of the planetary shaft so that
it 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 inch
thick under the front rotor pocket. Using a
6 mm drill and the previously drilled holes
as a guide, drill completely through the
new 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
bad, just tap out the gear and
install a new bearing. It is best to
replace both bearings in the
planetary gear if one is bad. The
same planetary shaft can go back
into the rotor frame if it is not
damaged; however, be sure that
the roll pin hole is properly
aligned.
8.11. On reinstalling the rotor gear (2), inspect
the 10m6 x 40 DIN 7 dowel pin (12, Figure
7.5.19) for defects. If any defective signs are
seen, replace the pin. If the dowel hole in the
rotor frame is out of round, or if installing a
new rotor gear:
CAUTION
help.
NOTE
The procedure as follows is to be
used only if the dowel hole in the
rotor frame is out of round, too
large for the 10 mm dowel pin, or if
installing a new rotor gear. If
nothing appears wrong with the
dowel pin or the hole in the rotor
frame, the rotor gear should be
reinstalled, the dowel pin hole
properly aligned, and the dowel
pin lightly tapped back into the
rotor gear and the rotor frame.
There should be no problems with
the timing of the pockets, but to be
sure, 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 the
fastest and best means of timing the rotor gear
to the pockets. Proceed as follows:
1. Mount the rotor gear onto the rotor frame
with the timing hole in the rotor gear in
line with the existing timing pin hole
location in the rotor frame. Use (8) M8x35
DIN 6912 screws (17, Figure 7.5.19) to
mount the rotor gear. Note: Use Permatex
on the screw threads.
2. Lightly tighten (4) screws (every other
one).
3. Lay the rotor frame down on its side with
the machined guide key slot facing up.
4. Set the rear pocket of one of the machined
key slots, key side up, on a block thick
enough so that rotor frame is sitting level
and the rotor gear is clear of the working
surface.
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 side
and take the reading.
8. With a soft piece of material (soft brass,
aluminum, etc.), and hammer, tap lightly
on 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 the
reading on the indicator.
10. Rotate the rotor frame 120 and set it back
up on the block.
11. Lay the gauge in this set of pockets and
using the same indicator setting as on the
previous pockets, but 120 from the last
reading, take a reading. Then repeat step 8.
12. Rotate the rotor frame 120 and set it back
up on the blocks. Lay the gage in this set of
pockets. Using the indicator setting from
the previous pockets, take a reading.
Repeat Step #8. When this adjustment is
completed, tighten the (8) M8x35 DIN
6912 screws (17, Figure 7.5.19) to a torque
of 25-30 ft-lbs. (33.9-40.7 Nm).
13. Recheck the timing of the rotor gear to
pockets to be sure the timing did not
change on tightening of the M8 screws.
14. Lay out a hole position on the face of the
rotor gear that is 180 from the existing
timing pin location. This hole is to be
centered between and on the same center
line as the M8 rotor gear mounting holes.
Note: Rotor Gears shipped after 1/1/12
will have a pre-marked hole location.
Stand the rotor frame up on it face and:
a. Install a 5 mm drill (long shank) and
drill down through the rotor frame until
the drill comes through the underside.
(This is a knock-out air hole.)
b. Install a 9.8 mm drill and drill into the
rotor frame a depth of 46mm from the
top face of the rotor gear.
c. Install a 10 mm N7 reamer and ream to
a depth of 44 mm from the top face of
the rotor gear.
15. Drive in the 10m6x40 DIN 7 (12, Figure
7.5.19) 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 the
staking end.
16. Use a center punch to identify/deform the
old timing hole so that it will not be used
again by mistake
NOTE
If a new rotor gear (2, Figure
7.5.19) is being installed, the
dowel hole will be 9.8 mm, so
therefore, a 9.8 mm drill must be
used for spot drilling.
SECTION III. SHUTTLE INSPECTION AND REPAIR
8.12. The shuttles are to be inspected for the
following:
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 bearing
races. Cam Tracks that show any of the
above should be replaced.
NOTE
Mayer Industries Inc. offers a one
(1) time rework program for cam
tracks. Contact the Mayer
Industries Inc. Spare Parts
Department for pricing/cost.
Reworked Cam Tracks can only be
installed in transfer sets. EXAMPLE: A 24
Carrier has four (4) transfers of six (6) cam
tracks. If reworked cam tracks are used, all
cam tracks in a given transfer must be
reworked cam tracks. Also, adjustments to
the cam followers in that transfer will have
to be made to obtain the correct running
clearances.
Reasons to have cam tracks reworked:
Cost savings.
To improve the surface finish of the
track bearing race.
NOTE
Only cam tracks that have
bearing races that can be
reground to new condition
with 0.025 mm stock
removal can be reworked.
2. Outer Races: The front outer race (4,
Figure 7.5.17) is to be checked for proper
diameter using gauge 240-1003 (Figure
9.1.3). If the diameter of the outer race is
71.85 or less anywhere on the surface, it is
to be replaced. There are certain problems
that undersized bearings can cause, such as
carriers hitting each other or a hooking
sensation. (The cam track strikes the cam
follower during transfer, preventing a
smooth transfer) Also insure that the
diameters 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 IN
A TRANSFER, ALL OUTER RACES
MUST BE REPLACED IN THE
TRANSFER IF ONE IS UNDERSIZE.
NOTE
This hooking sensation can also
occur if cam followers are
improperly 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 THAT
ON A 20 CARRIER SHUTTLE GEAR,
THE TIMING HOLE OF THE SHUTTLE
GEAR ALIGNS WITH THE TIMING
HOLE 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 be
removed, the following procedure should
be followed:
a. Straighten the locking tang of the MB6
safety washer (11, Figure 7.5.17).
b. Remove the KM6 lock nut (12).
c. Using a puller, grasp the key groove of
the shuttle gear and pull off the spindle.
This will remove the bearing (10),
spacer (9), and shuttle gear (8).
d. The cam track can now be slipped off
the spindle.
e. The outer race can now be slipped off
the inner ring.
5. Inner Ring: The inner ring (5, Figure
7.5.17) is pressed onto the spindle, so care
must be taken if it has to be removed. The
cam track key (6) has to be removed by
means of the 5 mm threaded holes in it.
Then, using a hollow shaft fitted down
over the front end of the shuttle spindle and
resting onto the protruding ears of the
mounting spacer (3), the inner ring can be
removed by tapping with a hammer. BE
SURE TO PAY CLOSE ATTENTION OR
MARK THE SLOTS IN THE SHUTTLE
SPINDLE THAT THE MOUNTING
SPACER EARS ARE PROTRUDING
THROUGH, BECAUSE IT MUST GO
BACK ON THE SAME PLACE OR THE
"L" BRACKET WILL NOT ALIGN TO
THE LEFT OF THE TIMING HOLE IN
THE CAM TRACK. WITH THE KEY
SLOT FACING UP, THE LONG EAR OF
THE MOUNTING SPACER WHEN IT IS
BEING MOUNTED ONTO THE
SPINDLE SHOULD BE TO THE LEFT
OF 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 to
side play between it and the outer race, the
diameter 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, Figure
7.5.17) is installed correctly.
2. Inner ring (5) is pressed onto the spindle
(1) after oiling or moly-coating the spindle.
NOTE
Use a stone to deburr the inner
edges if necessary.
3. The outer race (4) must be oiled on the
inside and slipped onto the inner ring (5).
4. A little loctite is dropped into the key slot
and the key (6) is mounted with a good fit.
No looseness between key and slot is
allowable. 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. Make
sure it is a good, snug fit. Grasping the cam
track with both hands, try rotating it
clockwise and counterclockwise. If any
movement occurs between the key and the
cam 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 clockwise
and counterclockwise. If there is any
movement, try rotating the shuttle gear
180. This can be done on a 24 carrier
machine but not on a 36 carrier because the
timing holes must align with the shuttle
gear and cam track. If any movement
occurs on this one side on a 36 carrier, try a
different shuttle gear. On a 24 carrier, if
any movement occurs after the 180
rotation, try a different shuttle gear. If the
cam track and shuttle gear are the same
ones that were removed from 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 not
to damage the bearing. After driving it onto
the spindle, rotate the bearing by hand
making sure it turns freely. If there are any
tight 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 it
turns freely and has back and forth
movement between the mounting spacer
(3) and the cam track (7). THERE MUST
BE BACK AND FORTH MOVEMENT
HERE.
13. With a .02 mm piece of shim stock, try
inserting it between the flat surfaces of the
cam track (7) and the shuttle gear (8). If the
shim goes between them, then the cam
track has to be removed, more chamfer put
onto the slot edges of the cam track, and
then 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 be
installed, making sure that it mounts to the
left of the timing hole. If it mounts to the
right, then the mounting spacer (3, Figure
7.5.17) is installed wrong. See Figures
7.5.8, thru 7.5.12.
SECTION IV. PRELIMINARY SHUTTLE ADJUSTMENT AND INSTALLATION
8.14. Using the transfer number of the pocket
and cam follower to be checked and adjusted if
necessary, the following steps should be
followed:
1. If the pocket is marked #1 (all the pockets
should have been marked before the
shuttles and rotors were removed from the
machine as stated previously), take a
shuttle from the #1 transfer group, making
sure that the following places are cleaned
thoroughly (no oil or trash is allowable):
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 being
used, make sure that they are used in
groups of 6 for the 36 Carrier braider and 4
for the 24 Carrier braider. These cam
tracks must be in the same places in the
same transfer and the cam followers
adjusted accordingly.
3. Check the diameter of the outer race (4,
Figure 7.5.17). If the diameter is below
71.85 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 be
replaced.
NOTE
The outer race for all shuttle
assemblies in a given transfer
must be within 0.03 mm.
4. Also, select the shuttle assembly from each
transfer that is the tightest to a given cam
follower setting. Use this shuttle assembly
as the master for setting the cam followers
in that transfer.
5. Install the shuttle into the proper pockets
and rotate the shuttle a few turns to be sure
of proper seating.
6. Adjust clearance between the cam track
and the cam follower until a shim of
.02mm thickness goes freely between them
and 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 on
every rotor frame.
SECTION V. INSTALLATION OF ROTOR ASSEMBLIES
CAUTION
the shuttle/rotor assembly area.
could occur.
be worn.
procedure
instructions.
8.15. Installation of the rotor assemblies onto
the rotor axles is as follows: (Note: Rotor
Frame Lift Kits are available. See Figure
9.1.13 in Chapter 9, Special Tools.)
CAUTION
help.
1. The thrust races (13 and 14, Figure 7.5.21)
and the needle bearing (15) should be
removed from the rotor frame and
thoroughly inspected. If the needle bearing
is warped or bearings fall out, replace it. It
is best when replacing this bearing to
replace the two thrust races, also. There are
two sets of these bearings and races in each
rotor assembly; one at the front and one
inside the rotor frame that has to be
removed from the rotor gear end of the
rotor frame.
NOTE
When removing a rotor, the
needle bearing (15) inside the
rotor assembly usually gets
warped 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 bearing
to hold it in place. The thrust races (13 and
14, Figure 7.5.21) and the needle race (15)
should be installed inside the rotor
assembly, before the rotor is installed onto
the axle.
The front set will come out when the rotor
assembly is removed from the rotor axle,
and the thrust race (13, Figure 7.5.21) will
most likely be seated down onto the
bearing ring (12). If the thrust race (13) is
to be removed, hold the front flange of the
bearing ring in the palm of your hand and
tap down onto a semi-hard surface (not
metal). Several taps may be required to
break it loose.
2. After the bearings have been checked and
fitted back properly, the rotor frame is now
ready 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 it
was removed. It must be put back at its
original location. Also, the pockets should
be located properly to have the transfers in
correct orientation.
4. With a thread protector 240-3047 (Figure
9.1.9) screwed onto the rotor axle, slip the
rotor frame onto the axle and mesh the
planetary gears with the rotor axle until the
rotor frame slips freely to its stopping
point.
5. Install the thrust race (14, Figure 7.5.21)
and the correct bearing ring with the thrust
race (13) and needle bearing (15) installed
onto 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, aligning
any slot on the lock with a tang of the
safety 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 the
indicator point touch the rotor face next to
it.
8. With both hands, grasp this rotor frame and
pull and push to check axial end-play. See
Figure 8.3.3.
9. There must be at least .01 mm movement
and not more than .10 mm movement.
Anything above or below these tolerances
must be corrected. It is advisable if there is
a .10 mm reading that this be taken down
to .01 mm - 0.05 mm reading, and this is
done by the use of a bearing ring. See this
Section, Paragraph 8.16, methods 1 or 2.
8.16. To increase or decrease the axial end-
play of the rotor frame, the following steps
should be followed:
METHOD #1
1. Install shims (23 thru 26, Figure 7.5.21) to
obtain the .01 mm/0.05 mm end-play.
NOTE
Shims are installed between the
bearing 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. leaving
enough of the inward flange protruding
out, so as not to strike the chuck jaws with
the cutting tool.
4. Indicate the inward flange to within .03
mm or .001 inch.
5. If the axial end-play is to be decreased,
then the length of the bearing ring barrel
has to be decreased.
6. Get a dimension reading of the distance
from the end of the barrel to the edge of the
inward flange. Remember or write this
dimension down because this dimension
has to be decreased by the amount of the
desired 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 inward
flange face, just to clean it up.
9. Take a dimension reading of the distance
from the end of the barrel to the inward
flange.
10. Take light cuts across the end of the barrel
until 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 the
rotor assembly along with the safety
washer (17) and lock nut (18). Tighten to
25-35 ft.-lbs. (33.8-40.7 Nm).
13. Set the indicator point onto the rotor face
and, again, grasp the rotor frame and push
and 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, then
the length of the barrel must be increased;
therefore, removal of material must come
off the inward flange
SECTION VI. ROTOR CHECKOUT
8.17.
1. Leaving the rotor frame caps (16, Figure
7.5.19) off, switch the oil pump on and let
it pump for approximately 30 minutes.
NOTE
On decks with a pressure relief
valve the gauge will read 65 lbs/
in. Do not set any lower.
2. Install the upper change gear back onto the
deck and run the rotors for approximately
45 minutes. Rotor speed should not exceed
100 RPMs.
3. Listen for any loud or unusual noises. If
everything has been checked and
assembled correctly, there should be no
clunks, thumps, or pounding.
4. Check for oil coming from the rotor axles
through the rotor frames. There should be a
good flow, and all axles should have the
same 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 the
O-rings if broken or deteriorated.
7. Install the caps (16) onto the rotor frames.
Be sure to Permatex threads of the cap
screws. Tighten to 11-12 ft.-lbs, (14.9-16
Nm).
8. Ground out each shuttle sensor
individually and check to make sure it is
operating correctly. Also check for proper
setting of sensors. Check for proper
operation of the other safety devices such
as change gear door, enclosure doors,
broken braid detectors, and bobbin run-out
detector, if so equipped.
9. Install all the inner shields and outer shield
except the two at the locations shuttles are
loaded onto rotor frames.
SECTION VII. SHUTTLE INSTALLATION
8.18.
1. Remove the top change gear and install a
driving socket (240-3040, Figure 9.1.8)
onto the shaft.
CAUTION
could occur.
be worn.
procedure
instructions.
CAUTION
Use a break-over bar or speed
wrench to drive the socket.
UNDER NO CONDITIONS
SHOULD A RATCHET OF ANY
TYPE BE USED.
NOTE
to communicate.
from MI (Figure 9.1.8)
2. Before installing the shuttles into the deck,
take one shuttle at a time from each of the
transfers and pass it through each of its
transfers. At each transfer, check for a
grabbing or hooking sensation. If there are
no problems, a magnetic base with the
indicator attached onto the rotor face or
adjacent surface and check axial end-play
(Figure 8.18.1). There should be a
minimum .05 mm end-play of the shuttle in
transfer. Now, rotate the shuttle out of
transfer and there should be a maximum
axial movement of .45 mm. These
dimensions are determined by the keys in
the rotor frame and pillow block and
should be corrected only by working with
the guide key (Figure 8.18.2, and 3, Figure
7.5.19). Never work with a pillow block
key to get shuttle axial play. After each of
the transfers have been checked, then a
complete transfer of shuttles can be
installed.
3. It does not matter which transfer is loaded
first, just be sure to put the proper shuttles
in the transfer from which they were
removed.
4. When a transfer is loaded, reinstall the
timed cam follower assembly making sure
each screw has a ST M6 ribbed washer on
it. Permatex the threads of the screws and
install it into the cam follower caps and
tighten screws securely. Torque to 11-12
ft.-lbs. (14.9-16 Nm).
5. Grasp the shaft of the cam follower and
make sure it turns both ways freely and has
axial end-play of .1 mm-.4 mm.
6. Grasp a shuttle and turn the machine by
hand to put the shuttles into transfer
position.
7. In transfer position, grasp each shuttle and
check the axial end-play. Be sure there is
axial end-play of at least 0.05 mm in each
shuttle. See Figure 8.18.1.
8. Check every shuttle in every transfer.
9. When all transfers are loaded, install the
rest of the outer shields, use 54 driver and
82 driven change gears on the braider and
run the machine for approximately 30
minutes at low speed. Rotor RPM will be
97.6 RPM.
FIGURE 8.18.1: SHUTTLE AXIAL MOVEMENT
AXIAL MOVEMENT
SHUTTLE
AXIAL MOVEMENT
IN TRANSFER .05 mm MINIMUM
OUT OF TRANSFER .45 mm MAXIMUM
FIGURE 8.18.2: GUIDE KEY CLEARANCE
(REFERENCE FIGURE 8.18.1)
KEY CLEARANCE
GUIDE KEY
SHUTTLE
.
0
5

T
O

.
4
5

m
m
SECTION VIII. OPERATIONAL CHECK
8.19.
1. Check the oil pressure cut-off setting (45
lbs./in) (Figure 5.5.1).
2. Set the oil pressure to the desired operating
pressure. On new braiders the pressure is
set automatically by the pressure relief
valve under the tunnel in deck #1. Set this
pressure after the machine and oil have
warmed up (approximately 3-4 hours).
3. Check the adjustment of the slider on the
silent chain (Figure 2.29.1). The slider
should be lightly pressed against the silent
chain. Check to be sure that there is
adjustment 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 worn
sprocket (2 and 9, Figure 7.5.25).
4. Inspect Flex Packs and replace any cracked
or 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 about
this schedule, please contact MAYER
INDUSTRIES INC.
FIGURE 8.19.1: FLEX PACK S-5006 FOR 24 CARRIER
HUB
FLEX PACK KITS 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
RUNOUT) SQUARENESS OF AXLES TO DECK.
NOTE
Assemble the gauge per Figure
8.20.1, for checking squareness of
axles to deck.
When checking the TIR (squareness of axles to
deck) install the 90 connector (2) into the
head piece (1). Be sure to keep the threaded
hole 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 and
indicator will be as parallel as possible to the
axle when checking TIR.
With a stone, deburr the teeth on the front end
of the rotor axle because a burr will give a
false reading. Mount the indicator (7) onto the
holder (5) and secure with the screw (9). Screw
the extension rod (3) onto the 90 connector
(2) and tighten. Install the holder with
indicator mounted into the extension rod and
lightly tighten with the screw (6). Mount the
headpiece (1) onto the rotor axle, screw on a
KM8 nut, tightening it up against the head
piece. DO NOT OVERTIGHTEN. Rotate the
headpiece making sure it turns freely. If it does
not rotate freely, the KM8 nut is probably too
tight, so loosen it a little, then recheck for free
rotation. Now loosen the screw (6) in the
extension rod (3) and slide the holder (5)
forward or backwards until there is
approximately .2-.3 mm movement of the
indicator dial needle. Set the ball of the
indicator stem so that it is about 3-4 mm away
from flange of rotor axle. Make sure the ball
touches the deck face completely around the
rotor 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 on
the flat surface of the deck, then retighten the
screw. The setting on the indicator dial may
have to be readjusted. With the indicator tip
located at the top of the rotor axle flange, set
the indicator dial on "0" by rotating the dial
face. Using a marking pencil mark "0" at this
position on rotor axle flange. Then slowly
rotating the head piece (1) to a 90 position
from "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), toward
the axle, as you rotate the head piece. This
eliminates any movement of the head piece
that could give an incorrect reading. Proceed
with 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 the
indicator needle moves. If it does, the KM8 nut
is 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 the
indicator reading at certain positions because it
is almost impossible to read the indicator. The
flatness of the rotor axle to the deck should not
be over 0.03 mm, unless the deck has had a
crash and the rotor axle had to be shimmed.
The above procedure should be done on each
rotor axle and it is advisable to make a chart
and record the axle location, axle number
(stamped of front end of axle) and the axle
TIR. When checking each axle, it is very
possible the indicator will have to be reset on
"0" each time because of axle tolerance.
8.21. CHECKING DISTANCE BETWEEN
ROTOR AXLES. After the TIR has been
checked and recorded, the next step is to check
the distance between the axles using the
following procedure:
Assemble the gauge per Figure 8.21.1, "For
Checking Center-Line to Center-Line of Rotor
Axles". Mount the assembled gauge onto the
set master. Now rotate the gauge and let the
ball tip touch the distance pin on the set
master. Be sure that you press against the
location gauge body toward the distance pin as
you rotate the gauge. This eliminates any
FIGURE 8.20.1: GAUGE 240-1078 FOR CHECKING SQUARENESS OF AXLES TO DECK
DECK
AXLE
7
9
5
6
3
2
1
NUT
movement of the body that could give an
incorrect reading. Set a reading of about .3-.4
mm on the indicator, and tighten the M6x 12
DIN 84 screw securely. Rotate the gauge back
and forth, finding the highest reading of the
indicator. At the highest indicator reading, set
the indicator dial to "0" reading. This is the
exact distance from axle to axle.
Once the "0" position has been determined, set
and secured, remove the complete gauge set up
from the set master and install it onto the #1
rotor axle (Figure 8.21.2), pushing it back
against the axle teeth. Grasp the gauge (1) and
rotate it so the indicator ball touches the inner
race of the rotor axle #2. Be sure that you press
against the gauge, toward the axle, as you
rotate 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 is
advisable to make a chart and record these
readings.
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 cause
false readings.
NOTE
It is advisable to put a (+) plus
sign on the left of the "0" and a (-)
minus sign on the right of the "0",
using a removable marker such as
a crayon pencil. By putting these
marks on the dial face, the
distance can be determined much
easier and with less confusion
because when the indicator is
reading on the (+) side this means
that the distance between the two
(2) axles is wider and the distance
is closer if it reads on the (-) side.
NOTE
Do not rotate the gauge to try and
take readings between axle #1
and #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 the
indicator.
Check the distance from axle to axle
completely around the deck and compare
readings between the axles. Any indicator
reading over (+) or (-) .07 mm is not good and
the axle will have to be shimmed or replaced to
get the dimension under .07 mm. Sometimes it
is possible to get rid of the .07 mm dimension
by loosening the six (6) M12x60 DIN 912
screws 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 that
will put the axle in the direction desired. If this
does not correct the misalignment, the axle
must be shimmed or replaced. The shim stock
has to be installed between the rotor axle and
the deck. It is advisable to use brass or soft
shim stock and not a hardened stock. The stock
should be cut with an angle on each end so that
it will fit down between two of the M12x60
DIN 912 screws with approximately 5 mm
sticking out beyond the rotor axle flange.
If there are any questions about the use of this
gauge, shimming or the axle or flatness of
axles to deck, please contact MAYER
INDUSTRIES INC.
FIGURE 8.21.1: AXLE LOCATION AND SET MASTER (524-1079) FOR
CENTERLINE TO CENTERLINE GAUGE 240-1078
DISTANCE PIN
BALL TIP
M6 X 12 DIN 84
LOCATION GAUGE ASSEMBLY
240-1078
SET MASTER
524-1079
FIGURE 8.21.2: GAUGE CHECKING AXLE TO AXLE DISTANCE
0.07 mm MAXIMUM
ROTOR AXLE #1 ROTOR AXLE #2
1
SECTION X. INSTRUCTIONS FOR THE USE OF THE 240-1075 ROTOR GEAR
TIMING GAUGE (SEE FIGURES 2.63.1, & 9.1.5)
8.22. This gauge comes with a handle,
indicator, and indicator extensions. The
indicator is divided into .01 mm increments.
The handle has a precision ground solid
surface on one end and a precision ground,
hard locating pin in the other end. There is a
hole with a screw going into its side for
mounting and securing the indicator. When
using this gauge, the extension stem of the
indicator will have to be installed onto the
indicator, then the indicator is installed into the
handle and lightly secured with the screw.
NOTE
The rotor gear dowel pin hole is
always 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 mm
diameter. At this diameter, there is
drilling and reaming stock left in
the dowel hole.
NOTE
When timing the rotor gear to the
rotor pockets, the timing is always
done at the removable guide key
pockets,(3, Figure 7.5.19) never
at the pillow block pockets.
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 pin
hole 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. Put
Permatex on the threads of the eight (8)
M8x35 DIN 912 screws (17, Figure 7.5.19)
and install. Tighten four (4) screws
approximately 90 apart. This will pull the
gear down onto the frame. Set the removable
key rear pockets on a piece of flat stock that is
thick enough so that the rotor gear (2, Figure
7.5.19) is not resting on anything. Set the
handle (with the indicator mounted), into the
removable key pockets with the ground
surface resting in the front pocket and the
hardened 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 set
about .4-.5 mm travel tension on the indicator.
Be sure and look at the mm needle (small
needle) on the indicator and get its reading.
This graduation is in mm. Tighten the securing
screw, check and be sure that the needle and
stem movement are free. Rest a piece of flat
stock, anything stiff and not too big, on the top
edge of the pocket and press down on it with
your thumb. This will hold the stock down
flatly on the edge and provides a stop for the
indicator stem. Turn the handle until the stem
of 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 side
of the pocket, get an indicator reading and
mark on the side of the pocket. Compare the
two (2) readings and which direction the rotor
gear will have to be rotated to get a "0" reading
on this pocket.
Loosen the four (4) tightened screws and with
a hammer and a piece of soft material such as
brass, aluminum or cold rolled steel, tap on the
rotor gear in the direction required. Tighten the
four (4) screws in the gear again. Swing the
indicator up to the top edge on the "0" side and
reset the indicator to "0" reading. Now swing
the indicator to the opposite side and get a
reading. 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 the
gauge from the rotor frame, trying not to move
the dial or jar the indicator. Set the gauge out
of the way. Rotate the rotor frame 180 and set
it on the flat stock again. Now set the tool into
these pockets and turn the gauges so that the
indicator stem is at the top edge of the pocket.
Take a reading on the indicator and mark the
reading on the side of the pocket. Now turn the
indicator up to the top edge of the opposite
side, take an indicator reading and mark it
down on the side of the pocket.
Now compare these pocket readings to the
pocket reading of the other pocket checked on
the rotor frame and see if there is any way that
the rotor gear could be rotated and get a closer
or equal reading between the two (2) pockets.
After the closest reading is obtained tighten all
eight (8) screws using the stagger line of
tightening. Torque the eight (8) M8x35 DIN
912 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.
Stand the rotor frame up on its face. If it is a
new gear, the predrilled hole will probably be
9.8 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 drill
in a drill press and bring it down through the
hole in the rotor gear until it touches the rotor
frame. If the hole is a 10 mm hole, then drill a
centering hole into the rotor frame. Without
moving the rotor frame, install a long 5 mm
drill 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 the
rotor gear face, then install a 10 mm N7 reamer
and ream the hole to a 44 mm depth from the
rotor gear face. If the hole is 9.8 mm diameter,
then drill down to the 46 mm depth with a 9.8
drill bit, then drill through with the 5 mm drill
bit and then ream hole to the 44 mm depth with
the 10 mm N7 reamer. If possible, install the
dowel pin in a lathe and with a 10 mm drill,
countersink the end of the dowel pin. Install
the dowel pin into the hole in the rotor gear
and drive it down until it is approximately 3-4
mm below the face of the rotor gear. Then with
a center punch, stake the pin at about three (3)
places to prevent it from working back out
again.
NOTE
Never use a hardened dowel pin.
If there are any questions or problems, contact
MAYER INDUSTRIES INC.
SECTION XI. INSTRUCTIONS FOR THE USE OF THE 240-1076 CAM SET GAUGE
WITH MASTER (SEE FIGURES 2.56.2 AND 9.1.4)
8.23. This gauge comes with the handle,
indicator and master. The handle has two holes
in it for the holding and setting of the indicator.
Also, note that there are two ground solid
surfaces on the handle. The smaller is for the
rear pocket (in front of the rotor gear) and the
larger (at the knurled handle) is for the front
pockets, so the handle can only be set in the
pockets one way. In the handle there are two
holes as stated previously. The front hole is for
setting of the front cam followers and the rear
hole is for setting of the rear cam followers (in
the pillow blocks). The master consists of two
precision ground gauge blocks, one thin block
for setting of the front cam followers and one
thick 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 the
rear cam follower is larger in diameter than the
front. 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 certain
distance apart. This insures that the handle can
be set into the master only one way.
It is best, when using this gauge, to either set
all 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 does
not have to be moved from hole to hole as
often. This is entirely up to the individual.
If the front cam followers are going to be
adjusted first, install the indicator in the first
hole in the handle and just lightly tighten on
the securing screw. Rotate the handle back and
forth (clockwise and counterclockwise)
making sure the stem of the indicator is
touching 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 the
gauge. Do not let the tool roll from one side to
the other, this will produce an error in the tool
setting. Turn the indicator glass cover until it is
reading "0" at the highest point of the needle
movement. When this is reached, tighten the
securing screw, but take precautions not to
overtighten, because overtightening could
cause binding of the indicator stem. After
tightening, check to see that the stem and
needle movement are free. Once the indicator
is set to "0" and free movement is checked and
obtained, then the front cam followers are
ready to be set.
NOTE
On the face of the rotor frames
(Figure 7.5.19) at the front cam
follower 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 the
cam follower cap assembly (9,
Figure 7.5.19) are both turned to
the "X' side. This is a must for
front and rear cam followers.
Make sure the rotor frame pockets are free
from burrs before using the gauge. Set the
gauge into the pockets and by rotating the
handle back and forth (clockwise and
counterclockwise) find the highest point of the
cam follower shaft front and rear. With the
four (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 rotate
the cartridge in a direction that causes the
needle to come up to "0". Lightly tighten the
four (4) M6 DIN 6912 screws (14, Figure
7.5.19, 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-play
there is on the cartridge end. After the front
and rear cam followers have been adjusted to
"0" by use of the gauge, the clearance still
must be checked between the cam follower
and the cam track by using .02 and .05 mm
shim stock. The tightest shuttle from each of
the four transfers is used for the final
adjustment of the proper clearance between the
cam follower and the cam track. A shuttle from
each transfer is first set into the rotor frame
and the clearance is checked between the cam
follower and the cam track. Adjustments are
made if needed, and the other remaining
shuttles are set into their respective transfer
and clearances checked. The tightest shuttle is
then identified and used as a master for
checking the clearance of this transfer in the
remaining rotor frames between the cam
follower and the cam tracks. This procedure is
used for each of the other three transfers.
NOTE
The set master (240-1076, Figure
9.1.4) was designed to be used
with a diameter 72 mm outer race
and a standard cam track with a
80 mm radius. If an undersized
outer race or a reworked cam
track is being used, the set
dimension on the set master has
to be adjusted accordingly.
Contact MII Service for additional
information.
NOTE
When checking the clearance
between 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 condition
exists, replace all the outer races.
If the outer race is to be replaced,
check the inner ring (5) for being
out of round. If so, replace the
inner ring on the shuttles before
checking the clearance. The
dimension at which the race
should be replaced is 71.85 mm
on the outer ring.
NOTE
Be sure to identify and remove the
shuttles from each individual
transfer and keep the transfers
separated from each other. Also,
identify on the face of the rotor
frames of each transfer, so only
the correct shuttles from this
transfer will be used to perform
the 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 the
cap.
SECTION XII. DISASSEMBLING, REASSEMBLING, ADJUSTING, AND
MAINTENANCE OF CARRIERS
CAUTION
to the fingers.
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 16 screw (32) and remove the
adjusting ring (3).
Remove the three screws (28 and 29) on the
actuator block (5) and from the spring clamp
(14). Remove the torsion spring (20, 21 or 22).
Remove the center strand rollers (44) from the
cap (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 the
spring washers (34) the washer (35) and the
latch (17).
Note the orientation of item 17 to 4.
Remove the housing (1) from the clutch
assembly (6, 8, and 9).
Remove the shim washer (45).
Remove the snap ring (36) and then remove
plastic clutch sleeve (13) from the clutch
assembly (6, 8, and 9).
Remove the clutch spring (11 or 12).
Remove the retaining ring (38) from the clutch
halves (6 and 9). Item 8 does not need to be
removed unless it is being replaced.
Remove the foam wicks or felt pads, (26) and
place in a pan of EP-150 braider oil and allow
about 15 minutes for soaking.
NOTE
MI recommends removing the felt
pads and lubricating the clutch
with Gleitmo 585m grease to
increase the lubrication intervals.
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
cause improper operation of the carrier.
FIGURE 8.24.1: CARRIER ASSEMBLY
1
39
17
34
35
34
23
4
10
31
41
10
53
10
29
46
14
5
28
SEE FIGURE 7.5.5
2
27
33
16
10
53
30
53 10
43
53
10
54
54
10
53
54
54
10
53
54
54
54
11
40
44
54
53
10
54
53
18
11
5
FIGURE 8.24.2: CARRIER ASSEMBLY
9
36
20,21,22
3
15
24
12
13
38
37
1
8
6
45
7
32
25
42
47
51
50
49
8.25. REASSEMBLY OF CARRIER HEAD.
(Figures 8.24.1 and 8.24.2)
Apply grease (Gleitmo 585m) in the moveable
hub assembly, (9).
Place the clutch hub (6) into the moveable hub
(9), and insert the retaining ring (38), onto the
clutch hub (6). This will lock the clutch halves
together. Make sure the clutch turns freely.
If any of the wear screws (15) or stem bumpers
(24) on the housing (1) need replacing, do it
now.
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 surface
on the shim (45).
Place the housing (1) onto the clutch hub (6).
Be sure that the shim washer (45) is placed
correctly and that the pin (25) lines up with the
hole in the housing (1).
Place the latch (17) into the clutch hub (6).
Verify that the orientation is correct. Place the
2 spring washers (34) on top of the latch. Place
the washer (35) on top of the 2 spring washers.
Install another spring washer (34) on top of the
washer (35). Install the actuator (23). Be sure it
is orientated correctly.
Install ball bearing (39), into the compensator
(2), if it was removed. Use bearing clamps
(16), with serrated washers (33) and flat socket
head screws (27) at 3 locations and actuator
block assembly (5) with two M6 x 20 DIN
7991 screws (30) at two locations. Be sure to
use Permatex Aviation Form-A-Gasket on the
threads.
Place the cap (4) through the ball bearing (39),
and onto the clutch hub (6). Be sure the shim
washer (45) is installed correctly. Place
Permatex Aviation Form-A-Gasket on three
M6 x 25 DIN 6912 screws (31) and insert them
into the holes in the cap (4). Tighten the three
screws using 101 inch-pounds of torque.
Install the clutch spring (11 or 12) onto the
clutch hub assembly, aligning the long
downward tang approximately 3/8 inch to the
right of the 3 mm roll pin in the stationary
clutch hub. (This allows easier assembly onto
the carrier housing.
Install the clutch sleeve (13) and place the
vertical tang of the clutch spring in the 5th or
6th tooth slot from the left side. Note if you
know which notch the end of the spring should
be placed in, put it there. Adjustments will
follow. Install snap ring (36).
Place two drops of Loctite #222 on the threads
of two strand rollers (44), and insert them into
the cap (4). Tighten them to 101 inch- pounds.
If the other strand rollers were removed, items
10, 43, 44, 48, 49, 53, or 54, reinstall them
now. Place two drops of Loctite #222 on the
threads and install them at the proper locations.
Note the location of the trip strand roller (43).
If this is not installed properly the bobbin
runout 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 the
actuator block (5) with the tang of the spring
fitting against the curved end of the spring
clamp (14) as shown in Figure 8.24.1. Place
the wear plate (46) onto the actuator block.
Install both screws (29), but do not tighten
them fully. Tighten (28), but be sure that the
edge of the spring clamp (14) pushes against
the outer diameter of the spring and forces the
spring against the actuator block (5). Now
tighten both screws (29).
Place the adjusting ring (3) onto the end of the
torsion spring (20, 21, or 22). The spring end
should snap into place and must be held
securely by the adjusting ring.
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.
Place the adjusting clamp (7) onto the
adjusting ring (3) and onto the housing (1).
Install the screw (32) and the washer (47).
Rotate the adjusting ring (3) so there is some
resistance to rotation felt when you try to move
the compensator plate (2). Tighten the screw
(32).
It is important that each carrier "release for
payout" at the same position of compensator
rotation as other carriers on the same deck.
To obtain an adequate amount of strand length
compensation, each carrier must release or
payout at the same position of compensator
rotation as other carriers on the same deck. The
setting for "A" (Figure 8.25.1) should be 0-8
mm (0-5/16"). These settings may vary from
product to product. Experimenting with
different settings will determine the best
setting for the product you are making.
Adjust the payout position by removing the
snap ring (36) and moving the tang of the
clutch spring (11 or 12) to the slot in the clutch
sleeve (13) that will allow the carrier to release
properly. Reference Figures 8.25.1 and 8.25.2.
Reinstall the snap ring, (36) when checking the
payoff position.
Adjust the carrier tension by loosening the
screw (32), rotating the adjusting ring (3),
retightening the screw and checking the
tension. Repeat this until the desired tension is
reached.
FIGURE 8.25.1:
FIGURE 8.25.2:
A
INCREASE
DECREASE
NOTE
Any time the carrier pay-off
tension or the torsion spring is
changed, the pay-out position
must be rechecked.
8.26. CARRIER MAINTENANCE. (Figures
8.24.1, and 8.24.2)
CAUTION
to the fingers.
Grease the latch parts every 300 hours with
multi-purpose grease.
Apply grease in the moveable hub every 600
hours. MI recommends using Gleitmo 585m
grease.
Clean and check carriers every 600 hours.
1. Braiding certain type materials may
necessitate more frequent cleaning.
2. Clean with varsol, diesel oil or other
suitable cleaner, and air.
NOTE
Do not submerge the carrier in the
cleaner or spray the cleaner on
the carrier, because this will
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 found
loose, disassemble as necessary and
tighten.
5. Check the torsion spring (20, 21, or 22) to
insure that it is properly seated in the
actuator block (5). Incorrect seating will
cause wear and carrier malfunctioning.
CAUTION
Always lock latches on carrier
assembly.
Checking the tension and pay-off position of
the carriers is necessary only when an erratic
movement of the hose is noticed at the braid
point.
Disassemble the moveable hub (9) from the
carrier every 600 hours. Check for wear on the
hub and clutch spring (11 or 12). Replace if
needed.
Possible cause of carrier malfunctioning:
1. Needs lubricating.
2. Needs cleaning.
3. Loose screws.
4. Improperly set pay-off tension or release
point.
5. Sticking clutch (6).
6. Improperly seated torsion spring (20, 21,
or 22).
7. Incorrect range torsion spring.
a. Braiding on the extreme low side of the
tension range of a particular spring.
b. Exceeding the high range of a
particular spring. This may cause the
I.D. of the torsion spring to hit the
clutch sleeve (13) before pay-off and
activate the clutch (6). It will also cause
excessive 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
October, 2011 MR-15 PLC-T Manual 9-1
CHAPTER 9
SPECIAL TOOLS
FIGURE 9.1.1: 2000527 AXLE AND DECK LOCATION GAUGE
AND SET MASTER
Reference Figures 8.20.1,
8.21.1 and 8.21.2
524-1079
for Instructions
SET MASTER
240-1078.02
FIGURE 9.1.2: 240-3037.00 CARTRIDGE WRENCH
9-SPECIAL TOOLS
9-2 MR-15 PLC-T Manual October, 2011
FIGURE 9.1.3: 240-1003.00 OUTER RACE FRONT POCKET GAUGE
FOR 72 mm OUTER RACE BEARING
1000219.0 OUTER RACE FRONT POCKET GAUGE FOR 74 mm OUTER RACE BEARING
FIGURE 9.1.4: 240-1076.00 CAM FOLLOWER SET GAUGE AND MASTER FOR 72
2000221.0 CAM FOLLOWER SET GAUGE AND MASTER FOR 74
MASTER
SET
GAUGE
240-1076.01 (72)
1000218.0 (74)
240-1077.00 (72)
1000220.0 (74)
9-SPECIAL TOOLS
FIGURE 9.1.5: 240-1075.00 ROTOR GEAR TIMING GAUGE FOR 72 POCKETS
2000138.0 ROTOR GEAR TIMING GAUGE FOR 74 POCKETS
FIGURE 9.1.6: 524-1074.00 REAR BEARING PULLER
9-SPECIAL TOOLS
FIGURE 9.1.7: S-5503 T-HANDLE HEX KEY
FIGURE 9.1.8: 2000302 SHUTTLE REMOVAL TOOL
9-SPECIAL TOOLS
FIGURE 9.1.9: 240-3047.00 THREAD PROTECTOR
FIGURE 9.1.10: 240-1073.00 FRONT INNER RACE BEARING PULLER
9-SPECIAL TOOLS
FIGURE 9.1.11: S-5099 TENSION GAUGE
FIGURE 9.1.12: 1000222 74 R/W ROTOR POCKET GAUGE
240-1017 72 STANDARD ROTOR POCKET GAUGE
REFERENCE DA-1661 FOR INSTRUCTIONS
9-SPECIAL TOOLS
FIGURE 9.1.13: ROTOR FRAME LIFT KITS
ENCLOSURE
5000283, *5000847 - 18 & 24 CARRIER
ROTOR FRAME LIFT KIT, 230V 50 HZ
5000285, *5000848 - 18 & 24 CARRIER
5000292, *5000845 - 36 CARRIER
5000293, *5000846 - 36 CARRIER
For Enclosures without built in dispersion plate
manufactured prior to 2003
For Enclosures
with built in
dispersion plate
manufactured
after April, 2003
**REQUEST DATA DRAWING #4000282.0
FOR INSTRUCTIONS ON LIFT KITS FOR
18 & 24 CARRIER AND #4000296.0
FOR 36 CARRIER
*USED IN ENCLOSURES SUPPLIED
AFTER JANUARY, 2009
9-SPECIAL TOOLS

10-ELECTRICAL SCHEMATICS
April, 2006 MR-15 PLC-T Manual 10-1
CHAPTER 10
ELECTRICAL SCHEMATICS
10-ELECTRICAL SCHEMATICS
10-2 MR-15 PLC-T Manual April, 2006

MR-11/MR-15 PLCT-F Schematics
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
DRAWN BY CHECKED Created Last Changed SHEET NO.
FE 4/13/10 12/7/11 1
Mayer Industries
PO Box 1466
Orangeburg SC
29116
Telephone: 803-536-3500
E-mail: franke@mayerind.com
Description: MR11/15 (Color)
Version: 1.08
Line Voltage: 380-480V 10%
220V 10%
Maximum Current: 25 Amp at 480V
50 Amp at 220V
Schematic Files: 3000908.1
Special Notes:
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 4/13/10 12/15/08 2
Page
Page Type
Description
Last
Modified
by:
1 Cover Sheet Overview 12/7/11 FE
2 Table ndex FE
3 Schematic FE
4 Schematic 12/7/11 FE
5 Schematic Emergency Stop 12/7/11 FE
6 Network Profibus Layout FE
7 Schematic FE
11 Schematic FE
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 3
Input Voltage
L1 L2 L3
S1
N
F1
Q1
Q2
Q3
M
M
Blower
Deck 1
Blower
Deck 2
M
Oil Pump
M
M
M
Inverters
Hauloff Motor
Double Deck only
U 31
U 32
U 33
L1
L2
L3
X2
X3 L1 L2 L3
X4
U1
V1
W1
M
Deck 1 Motor
U2
V2
W2
M
Deck 2 Motor
U3
V3
W3
X4 U4 V4 W4
X4 U5 V5 W5
K3M
page 7
K1M
page 5
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 4
L1
L2
L3
F2
N L1
0V DC
24V DC
X2 1 2
Cooling Fan, main enclosure
F3
U8
T1 220V
Transformer
N L1
U9
N L1
0V DC
24V DC
K 1
E-stop
Relay
Y 1 Y 2
S 4
Start
21
U6
N L1
U3
22
X 102 42 41
X 202 42 41
A4
A3
M L+
N L+
M L+
N L+
M L+
N L+
Profibus Modules
P6
2
P6
1
P7
2
P7
1
Note: See page 9 for
voltage distribution
and plugs
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 5
24V DC
S 3
1L
Q0.4
X1 5
Q1
34
33
Q2
34
33
K 1
A1
A2
0V DC
U6
34
33
H 3
23
24
KM1
H 1
41
42
X 102 30
S 104
2
1
X 102 32
S 106
1
2
X 102 33
X 102 31
S 105
1
2
X1 6
I 1.4
Single
Deck
U6
A1
A2
P4-3
P4-4
P8-3
P8-4
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 4/13/10 12/7/11 5a
24V DC
S 3
1L
Q0.4
X1 5
X1 7
Q1
34
33
Q2
34
33
K 1
A1
A2
0V DC
U6
34
33
H 3
23
24
KM1
H 1
41
42
X 102 30
S 104
2
1
X 102 32
S 106
1
2
X 102 33
X 102 34
S 105
1
2
X1 6
I 1.4
Single
Deck
U6
A1
A2
X 202 30
S 104
2
1
X 102 32
S 106
1
2
X 102 33
X 202 31
S 105
1
2
X 102 31
P4-3
P4-4
P9-3
P9-4 P8-3
P8-4
CIRCUIT DIAGRAM
MR11/15 PLCT-F
FE 5/26/11 5/26/11 6
U6 (S7-224)
U8 (S7-224)
Profibus
U31
Inverter
Siemens MM440
Profibus
Address
Part No.
Node
Description
2
(Master)
TD1 Multiplanel
3 U8
PLC Deck
S7-224
4 U9
PLC Deck
S7-224
5 U6
PLC-Hauloff
S7-224
31 U31
nverter
MM440
32 U32
nverter
MM440
33 U33
nverter
MM440
Profibus Addresses
TD1
Multipanel
Siemens MP277
U9 (S7-224)
U32
Inverter
Siemens MM440
U33
Inverter
Siemens MM440
U8
CIRCUIT DIAGRAM
MR11/15 PLCT-FC
FE 5/26/11 5/26/11 7
S111
24V DC
S121
I 0.0
Run
I 0.1
Jog
U9
S211
I 0.0
Run
I 0.1
Jog
Double Deck only
U6
K3M
page 3
O 0.1
Blower
O 0.0
K 2
I 0.3 I 0.4 I 0.5 I 0.6 I 0.7 I 1.0
0V DC
Enable
Deck 1
Enable
Deck 2
Enable
Hauloff
I 1.1 I 1.2 I 1.3
S 10 S 12
S 11
X 102 21 X 102 19
X 202 21
X 202 19
3
4 4
4 4
4 4
4 4
3
3 3
3 3
3
4 4
4
X1 23 24 25 26 27 28
Option: 1 2 3 4 5 6
S122 S112 S212 S221 S222
A1
A2
A1
A2
22
K 2
21
External
Stop
Light
CIRCUIT DIAGRAM
MR11/15 PLCT-F
FE 12/15/08 12/7/11 8
U8
I 0.4
Jog
Override
I 0.2
Inside Jog
O 0.1
Inside Jog
Light
I 0.6
Stop
Buttons
24V DC
0V DC
U9
I 0.4
Jog
Override
I 0.2
Inside Jog
O 0.1
Inside Jog
Light
I 0.6
Stop
Buttons
S 107
H 107
S 110
S 109
S 108
S 207
H 207
S 210
S 209
S 208
X 102 25
X 102 26 X 202 26
X 202 25
Double Deck only
U6
Q1 Q2 Q3
Motor
Starters
I 0.0
Proximity
Sensor
Hauloff
I 1.5
X 102 24
X 102 36
X 102 18 27
X 202 24
X 102 36
X 102 18 27
X 1 8
4
3
4
3
3
4
3
4
S 113
S 213
I 0.3
Inside Jog
I 0.3
Inside Jog
S 213
3
4
S 213
I 0.1 I 0.2
S 113
P5
1
CIRCUIT DIAGRAM
MR11/15 PLCT-F
FE 12/15/08 12/7/11 9
X 2 1 2
X 2 3 4
F4
To external 220V florescent lights
220V ac
Warning: This circuit is independent
of the main disconnect.
U6
1M 2M
1L
24V DC
0V DC
S 2
U8
1M 2M
1L
U9
1M 2M
1L
X 2 3 4
P4-1 P4-2
X 2 9 10
P5-2
P5-3
P8-1 P8-2
X 102 29 28
X 202 28 29
P9 1 2
Double Deck
Only
CIRCUIT DIAGRAM
MR11/15 PLCT-F
FE 12/15/08 12/7/11 10
U8
I 1.1 I 0.7
X 102 23 17
S 113
Broken Braid
Bobbin Runout
(Springs)
0V DC 0V DC
Low Oil
S 114
15
Q 0.4 2 L
Hour
Meter
U9
I 1.1 I 0.7
X 202 23 17
S 213
Broken Braid
Bobbin Runout
(Springs)
S 214
15
Q 0.4 2 L
Hour
Meter
Low Oil
I 1.0
I 1.0
X 102 16
X 102 16
P 10
3
P 10
1
P 10
2
P 11
3
P 11
1
P 11
2
CIRCUIT DIAGRAM
MR11/15 PLCT-F
FE 12/15/08 12/15/08 11
24V DC
U8
K 101 K 102
K 101 K 102
X 103 2
X 103 3
X 103 4
X 103 1
X 102 35
X 102 20
I 0.5 Q 0.0
U9
K 201 K 202
K 201 K 202
X 203 2
X 203 3
X 203 4
X 203 1
X 202 35
X 202 20
I 0.5 Q 0.0
Enclosure Door Interlocks
0V DC

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