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Industria Elettromeccanica Commerciale Italiana

Milanese S.r.l.
Via Muoni N16, 20064 Gorgonzola MILAN, ITALY
Tel: (+39) 02.951.5551 Fax: (+39) 02.951.5784
E-mail: iecim@iecim.191.it

SKIVER CUTTING UNIT

TYRE 800 TRUCK

SAFETY AT WORK AND FUNCTIONAL


DESCRIPTION MANUAL

SANTO ANDRE

Skiver Cutting Unit TYRE 800 Truck

Contents:

Page:

1.

GENERAL SAFETY ADVICE

1.1

Warnings and safety instructions Explanation of symbols

1.2

Intended use

1.2.1

Improper use

1.2.2

Inadmissible use

1.3

Safety at work advice

1.3.1

General instructions

1.3.2

Work carried out whilst the line is in operation

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1.3.3

RESIDUAL RISK __________________________________________

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1.4

List of most important safety signs

2.

FUNCTIONAL DESCRIPTION

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2.1

SKIVER CUTTER

26

2.2

Dancer Roll

40

2.3

Tread Centering Unit

2.4

15

____________________

41

Pressing Roller

_____________________

42

2.5

Measuring Unit

_____________________

43

2.6

Pressing Fingers Group

____________________

44

3.

TABLES OF LUBRICANTS

___________________

45

4.

DRAWINGS LIST

______________________

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Skiver Cutting Unit TYRE 800 Truck

1.

GENERAL SAFETY ADVICE

1.1

Warnings and safety instructions Explanation of symbols


Important operating and safety instructions that are to be strictly observed to avoid
personal injury or damage to the machine are set off as follows:

NOTE This term is used to identify important information on the machine and its subassemblies as well as safety instructions and other
Note !

important information to be strictly observed to ensure correct and safe


use and operation to the machine.

ATTENTION Failure to observe safety instructions and procedures


(precautionary measures in accordance with the regulations for the
Attention !

prevention of accidents or as specified in these operating instructions)


preceded by the term Attention! may cause minor injury and/or
damage to the machine.
WARNING Failure to observe safety instructions and procedures
(precautionary measures in accordance with the regulations for the
prevention of accidents or as specified in these operating instructions)
identified by the warning symbol may cause severe injury and/or
damage to the machine.
DANGER Failure to observe safety instructions and procedures
(precautionary measures in accordance with the regulations for the
prevention of accidents or as specified in these operating instructions)
identified by the danger symbol will inevitably cause severe injury, fatal
accidents and/or severe damage to the machine.

SANTO ANDRE

Skiver Cutting Unit TYRE 800 Truck

1.2

Intended use
The Skiver Cutting Unit TYRE 800 is designed for the cutting of un-vulcanized semifinished rubber products (treads).

1.2.1

Improper use
Any use of the Cutting Unit not in accordance with the definition in section 1.2
or with technical data specified in this manual or in other machine documentation
is improper. The user of the equipment is fully responsible for any damage to persons, to the machine or to the other equipment. The user is also responsible for
inadequate operating results arising from improper use of the equipment.
Failure to observe EU, UVV (Regulations for the prevention of accidents) regulations, occupational safety and disposal requirements or operating and safety
instructions is equally considered improper use.

1.2.2

Inadmissible use
Any use of the equipment not in accordance with the safety or operating instructions or with the intended use is inadmissible.

Note !

The manufacturer declines any responsibility for damage resulting from


use not in accordance with the operating instructions or from incorrect
use or operation of the machine.

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Skiver Cutting Unit TYRE 800 Truck

1.3

Safety at work advice

1.3.1

General instructions
Every person who is concerned with a operation of the machine must have read
and understood the operating instructions, or have been familiar with them in the
course of a training session.

Attention !

Safety, monitoring and guarding devices must neither be removed


nor their function in any way reduced or by-passed!

Note !

The safety instructions included in the individual sections of these


operating instructions warn against specific dangers and must be
strictly observed.

1.3.1.1

Safety equipment
Do not start the Skiver Cutting Unit if safety equipment is not in perfect working
order.
Do not change, disconnect or by-pass the safety equipment. The user of the
plant will be held fully responsible for damage arising from failure to observe
these instructions.
Detailed specifications must be provided for the following equipment where
included in the scope of supply (Product Liability Act; in the case of damage, any
proven manipulation of safety equipment will at least result in the user of the
plant being subject to secondary liability):

emergency switchgear

main switch, power switch

mode selector or repair switch

mechanical safety equipment, covers, protection hood, grids etc.

mechanical/electrical safety equipment, limit switches etc.

pneumatic safety equipment


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electrical safety equipment

danger and warning signs, type plate

additional safety equipment in accordance with local and internal regulations


and safety equipment to be provided and installed by the user prior to
commissioning
optional safety equipment, where necessary, which is available but not

included in the scope of supply.

1.3.1.2

Safety instructions concerning electrical equipment


For detailed information, please refer to the vendor documentation supplied for
electrical equipment.
The machines have to be connected in accordance with the following standards
and regulations: EN 60204-1, EN 292, EN 563, EN 50082, UVV 1.0 (VBG 1),
UVV 7.0 (VBG 4), UVV 10.0 (VBG 5) or any other standard and regulation
notified in the electical equipment supply.
The control system must only be used by trained personnel and checked at
intervals.

As specified in UVV 7.0, section 2, para. 3, repair and maintence work is


only to be carried out by a trained electrician after the mains voltage has
been switched off.

1.3.1.3

Fire protection
Fire fighting and fire protection must involve all personnel employed at the
production site.
Employers and managers are required to:

take all technical and organizational mesures that are necessary to prevent
fires;
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provide all necessary fire fighting equipment and arrange for their personnel

to be trained in the use of such equipment;


inform all personnel of the fire hazards involved and provide instructions on

how to avoid such hazards.


In-plant occupational safety experts and safety officers are required to
support the employer and employees in implementation of the above
measures.
Staff members are required to observe all fire prevention instructions and
to conduct themselves in such a way as to help implement of all measures
for the prevention of fires and explosions.

1.3.1.4

Labour protection
Country of origin: European Union (EU).
The equipment complies with the following regulations and directives:

Machinery Directive 98/37/EG

Electromagnetic compatibility directive 89/336/EEC

Low Voltage Directive 73/23/CEE 93/68/EEC

Simple Pressure Vessels Directive 97/23/EC

The following harmonized standards apply in particular:

Safety of Machinery IECT/TS 62046

Safety Distances ISO 13857:2008

Electrical Equipment of Machinery EN 60204 - 1

The regulations governing labour protection and the prevention of accidents in


force at the installation site or at the users facilities and all measures specified
in these operating instructions must be observed during the transport, installation
and operation of the machine. The user of equipment is fully responsible for any
failure to observe these regulations.

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Skiver Cutting Unit TYRE 800 Truck

1.3.1.5

Fundamental safety information


General observations:
The Cutting Machine has been designed and built according to the state of art
(see IECT/TS 62046 ). It is safe if employed in accordance with its intended use
and provided that the agreed technical data and operating conditions are
observed.

WARNING!
The machine may cause danger to life, personal injury or damage
to the machine and other equipment if installation, operation and
maintenanance are not carried out by suitably qualified personnel
or if the machine is not employed for its inteded use or used in an
improper manner!

Unspecified risks of personal injury and damage to the equipment may be


caused within the installation area of the machine and by the material to be
processed. Such risks are beyond the manufacturers responsibility and cannot
be excluded even when the machine is operated in a proper manner. The user
of the machine is required to take all necessary measures to prevent injury or
damage resulting from such risks.

1.3.1.6

Users responsibility
In case of damage, the user of the plant is fully responsible for the safe
execution of any work carried out on the TYRE 800 machine by the users
personnel authorized by user to perform such work.
Safety measures to be taken by the user:

Immediate action is required in case of danger.

The machine must be checked to make sure it is safe and fully operative.

Damage and faults must be eliminated immediately.

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The users operators and maintenance personnel and any third parties
instructed to carry out work on the machine must be informed about the
risks involved.

The user must provide recommended / prescribed personal safety


equipment and make sure it is used.

Work on the machine must be carried out by qualified personnel only.

Spheres of responsibility for the operation and maintenance of the machine


must be clearly specified.

The regulations for the prevention of accidents and the Material Safety
Data Sheet must be available to the personnel.

1.3.1.7

Waste must be disposed of in the correct manner.

Operators duties
Every person who is concerned with the operation of the machine must have
read and understood the operating instructions before the first commissioning
of the machine!
Before taking up work on the machine, all operators must inform themselves about the following factors:

potential risks / residual risks at the machine

personal safety equipment

danger zones at the machine and at the workplace during operation

risks caused by emissions

external risks (at the place of installation)

safety equipment

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Skiver Cutting Unit TYRE 800 Truck

mode of operation and controls of the machine, in particular emergency


switches

controls and emergency stop switches, as well as escape route have to be


accessible at all times.

fire extinguishers.

Always use the recommended / prescribed personal protection equipment,


such as heat-resistant gloves (protection against risk of burns in case of contact
with hot surfaces), safety goggles, ear protection etc.

Operators must respect the following rules:

The machine must only be switched on by authorized personnel.

The machine must only be switched on when danger to persons is excluded


(after machine switch off) and provided that faults have been rectified and
maintenance work has been completed.

The machine must be checked for external damage once a day or once per
shift. Any faults identified during these checks must be reported immediately
to the person / office appointed by the user of the machine.

In case of malfunctions, the machine must be switched off immediately.

Maintenance or repair work must only be carried out when the machine is
switched off and secured in such a way that it cannot be switched on by
unauthorized persons.

Any work carried out on the machine must be performed in proper manner
and observing all relevant safety regulations. Any tool or equipment used must
be in perfect working order.

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Work on the electrical equipment must only be carried out by a qualified


electrician.

Warning signs, pictographs and type plates must be kept legible at all times.

No unauthorized modifications or changes have to be carried out on the


machine. Safety equipment must not be modified, switched off or by-passed.

1.3.1.8

The place of installation must be kept clean and clear at all times.

Personnel qualification
Qualified personnel must be familiar with installation, connection, operation and
maintenance of rubber processing machinery and must have acquired such
knowledge and expertise in the course of technical training sessions.
The term qualified personnel refers to:

qualified mechanical engineers and technicians or personnel that must


have acquired special knowledge and expertise in this field in the course of an
in-house training sessions;

qualified electrical engineers and technicians or personnel that must have


acquired special knowledge and expertise in this field in the course of inhouse training sessions. Such personnel must meet the requirements of EN
60204 and any other standard, law or regulation in force at the installation site
and must be authorized to switch on/off, connect or ground electric circuits,
units and systems in accordance with safety standards.

The required qualification includes:

familiarity with the contents of these operating instructions and with machine,
its mode of operation, control system and equipment;

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completed training in the installation and operation of rubber processing


machinery and in the use and maintenance of labour protection and safety
equipment;

completed first aid course.

It is entirely the users responsibility to ensure that its staff members possess the
qualifications specified above, that they are trained on the machine and familiar
with all potential risks involved in the use of the machine.
Staff that have not completed the training specified above may only carry out
work on machine if supervised by experienced qualified personnel.

1.3.1.9

Potential risks and residual dangers


The following safety advice given in accordance with the requirements of the
Product Liability Act warns against danger zones and potential risk and residual
dangers. This safety advice must be observed in order to ensure safe operation
and maintenance of the machine

WARNING!
Failure to observe the warnings and instructions may cause danger
to life, personal injury and / or damage to the machine and other
equipment. The user is fully responsible for any failure to comply
with such warnings and instructions.

The warnings and instructions given below cannot provide exhaustive


information on all measures to be taken to ensure safe operation and maintenance of the machine.
These warnings and instructions do not relive the user of the plant of its obligation to initiate, implement and supervise additional safety and health protection measures required by special conditions for the installation and connection
of the machine and by special material properties.
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1.3.2

Work carried out whilst the machine is in operation:

The machine must only be operated by suitably trained personnel!

Access to the Cutting Machine is only allowed to the operating personnel.

Attention !

Work on the machine must only be carried out after the main
switch has been set to OFF (electrical equipment switched off and
pneumatic system depressurized).
This is of major importance when the protection hoods have to be
opened to allow maintenance work to be carried out!

The main switch must be locked in such a way that it cannot be


set to ON.

Work on the electric control system must only be carried out by suitably
qualified personnel!

The operation and maintenance instructions must be strictly observed.

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1.3.3

RESIDUAL RISK

Attention !

After the voluntary or unvoluntary stop of the machine the


blade continous to rotate per inertia.
DO NOT do a maintance work in the blade area until the FULL
STOP of the blade rotation!

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1.4

List of most important safety signs


I.E.C.I.M uses on its machines and in its operating instructions warning,
prohibiting and order signs according to EN 61310-1 / ICE 1310-1.
Added to these signs are safety signs that have proved useful in practice.

Warning signs (black and yellow)

DANGER

RISK OF ELECTRIC CURRENT

MACHINE IN OPERATION

RISK OF HAND INJURY

STUMBLING-BLOCK

BEWARE OF TRANSPORTATION VEHICLES

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Prohibition signs (red and white)

DONT TOUCH

NO SMOKING, MATCHES OR OPEN LIGHTS

NO TRESPASSING

TRANSPORTATION VEHICLES PROHIBITED

WATER MAY NOT BE USED TO EXTINGUISH


FIRE

Signs in case of fire-extinguishing (red and white)


ROUTE INDICATOR
( mostly in combination with other signs )

FIRE EXTINGUISHER

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Order signs (blue and white)


GENERAL SIGN
( mostly in combination with other signs )

SAFETY BOOTS COMPULSORY

EYE PROTECTION COMPULSORY

EAR PROTECTION COMPULSORY

SAFETY GLOVES COMPULSORY

SAFETY HELMET COMPULSORY

SAFETY SUIT COMPULSORY

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2.

FUNCTIONAL DESCRIPTION

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General Assembly drawing PK/SA2.M.01

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The function of this Skiver Cutting Unit is cutting of tread in start/stop mode.

EXTRUSION LINE DATA


Mechanical speed

[m/min.]

3,0 to 30

Production speed

[m/min.]

14,0 to 27,0

Working width

[mm]

800

Operator side

Left to flow direction

LENGTH TOLERANCE OF THE CUT


Accuracy of tread cut length

[mm]

+/- 4,0

Mechanical length tolerance w/o material

[mm]

+/- 0,5

CUTTING ANGLE
Cutting angle, side view / to the surface

[deg]

17,5 to 32,5

Cutting angle, top view / to flow direction

[deg]

90

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OPERATING CONDITIONS

LOCATION

Santo Andr - BRAZIL

POWER SUPPLY
VOLTAGE

3 X 440 V AC, + / - 10%


60 Hz, + / - 2%

CONTROL VOLTAGE

110 V AC, + / - 10%


60 Hz, + / - 2%
24 V DC (solenoids, limit switches, sensors, etc.)

AMBIENT
TEMPERATURE

Geared motors: from 15C to 45C


Electric equipment: from 15C to 40C

HUMIDITY STRESS

MAX. 60% relative humidity

COMPRESSED AIR

6 bar

AMBIENT AIR

Free from harmful influences

OPERATING HOURS

24 h / day

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After passing through the cooling process, treads are cut to the correct length on
the Skiver Cutting Unit which alternates between Stop/Go operations.
During the cutting process rubber profiles form a loop which is scanned with a
Dancer Roll and used for control and regulation purposes, such as for the
calculation of the starting speed.
A programmable logic control system regulates the process and the positioning of
the profiles to accord with the pre-selected length of the cut.
Profiles in-feed is via specially designed drive (with brushless motor) with the
capacity to accelerate the product rapidly.
During the cutting rubber profiles are held in position on a cutting bar arranged on a
level with a conveyor, by means of pneumatically controlled hold-down clamps
(Pressing Fingers).
The cut is carried out by a rotating circular knife lubricated by a very fine water
spray.
The advance / return transversing travel of the cutter ball-bearing supported
carriage is by means of an AC brushless motor.
The travel of the knife carriage is adjustable within limits.
After the completed cut, the rubber profiles are transported on a friction roller
conveyor which is driven by its own geared motor.

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SKIVER CUTTING UNIT TYRE 800 TRUCK

Rubber profiles length

[mm]

from 2300 to 3350

Rubber profiles maximum thickness

[mm]

60

Cutting angle, top view / to flow direction

[deg]

90

Cutting angle, side view / to the surface

[deg]

Rubber profiles maximum width

[mm]

550

Cutting disc diameter

[mm]

500

[nCUTS /min.]

20

Number of cuts

Cutting discs cooling and cut lubrication

Material temperature after cutting

Noise level

from 17,5 to 32,5

H2O spray

[C]

from 30 to 50C

< 80 Db

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TREAD MAIN GEOMETRY, TOLERANCES AND COMPOUND CHARACTERISTICS

TREAD

min. [mm]

MAX. [mm]

Length

2300

3350

LT (total width)

200

550

LS (shoulder width)

160

450

EM (thickness)

16

60

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SKIVER CUTTING UNIT is composed of:

Skiver Cutter 800 Truck


Dancer Roll
Tread Centering Unit
Pressing Roller
Measuring Unit
Pressing Fingers Group

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2.1

SKIVER CUTTER Dwg.s PK/SA2.M.100A, PK/SA2.M.100B, PK/SA2.M.100C

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TECHNICAL FEATURES:

Belt Type: AMMERAAL type ULTRASYNC T10 590 FG, code UC5900,
Colour BLUE, Width = 850 mm, Development = 7760 mm.

Conveyors Motor: Brushless ALLAN-BRADLEY type MPM-B1302T, P = 1,65 kW,


Output shaft 24X50 mm.

Conveyors Gearbox: SEW EURODRIVE type KH57/R/TAQA115/3,


Red. ratio: 1/15,22, Output shaft: hollow 40 mm
Mounting position: M1A.

Carriage translation Motor: Brushless ALLAN-BRADLEY type MPM-B1304M,


P = 2,2 kW, Output shaft 24X50 mm.

Cutting blades Motor: WEG type W22, Cast iron frame IE3, P = 3 kW,
Frame type L100L, IP55.

All components of the Cutting Machine: supporting structure, tanks, etc. are made of
stainless steel.

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Attention!

ADJUSTING CUTTING ANGLE

In order to cut various types of product profiles, we can change a cutting angle
within range from 17,5 to 32,5.

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Note!

Instructions for adjustment of the cutting blades angle

Tools: Wrench 36 mm (for M24 bolt)

Be sure that the cutting blade is in UPPER (No-Cutting) position and that
Transversal Carriage is in RIGHT (out-off center) position.

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Loose Nr 2 screws M24.

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Turn a Screw Jacks lever until you reach desired cutting angle.

Lock Nr 2 screws M24.

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Verify that the knifes edge is penetrating between two cutting bars as shown in
the picture.

Perform a cutting probe.

If necessary adjust positions of two cutting bars.

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KNIFE DISMOUNTING AND SHARPENING


After some period of time a disc blades edge will become dull and the edge is to be
re-sharpened.

First, dismount lower water jet and lower blade protection cover.

Loose Nr 3 M8 screws and with attention dismount a blade.

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Attention!

During operations of blades dismounting / mounting wear safety


anti-cut gloves.

ADJUSTMENTS OF THE BLADES POSITION

For the best cutting result the blades edge during cutting must be always in
position shown in the picture.

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We can adjust that position moving forward / backward blades carriage starting
position.

Loose Nr 8 M10 screws shown in the picture above.

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Put a blade in best cutting position with loosing / closing nuts.

Lock all nuts and bolts.

If necessary adjust a position of two cutting bars.

Perform a cutting probe.

If necessary repeat all operations until you find a perfect cut.

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2.2

DANCER ROLL Dwg. PK/SA2.M.600

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2.3

TREAD CENTERING UNIT Dwg. PK/SA2.M.400

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2.4

PRESSING ROLLER Dwg. PK/SA2.M.300

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2.5

MEASURING UNIT Dwg. PK/SA2.M.500

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2.6

PRESSING FINGERS GROUP PK/SA2.M.200

The function of this pneumatically driven group is to hold down a product during
cutting.
Because profiles to cut are not flat, it is composed of 44 pressing springed fingers
which follow products profiles.

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3.

TABLES OF LUBRICANTS

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LUBRICATION

Components

Lubrication
system

Lubricant
type

Producer

Instruction

Geared
Motors
SEW
EURODRIVE

Permanent
lubrication
with
synthetic oil

See
producers
manual

See
producers
manual

See
producers
manual

Grease

Bearing
supports

Greasing

Sliding
guides

Greasing

Air treatment
systems

To fill up every
ESSO

BEACON EP2

four months

Grease

Filling up

To grease every
ESSO

BEACON EP2

four months

Oil
TERESSO
320

To control weekly
ESSO
oil level

Grease

Chains and
gears

Greasing

Lubricators

Greasing

To grease every
ESSO

BEACON EP2

four months

Grease

To fill up every
ESSO

BEACON EP2

four months

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Transversal Carriages Runner Blocks are lubricated from central lubrication unit.

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4.

DRAWINGS LIST

ITEM DESCRIPTION

DRAWING

SKIVER CUTTING UNIT


2.1

PK/SA2.M.01

NOTE
General Assembly

SKIVER CUTTER

PK/SA2.M.100A

Assembly

SKIVER CUTTER

PK/SA2.M.100B

Assembly

SKIVER CUTTER

PK/SA2.M.100C

Cutting Carriage

2.2

DANCER ROLL

PK/SA2.M.600

Assembly

2.3

TREAD CENTERING UNIT

PK/SA2.M.400

Assembly

2.4

PRESSING ROLLER

PK/SA2.M.300

Assembly

2.5

MEASURING UNIT

PK/SA2.M.500

Assembly

2.6

PRESSING FINGERS GROUP

PK/SA2.M.200

Assembly

Copyright
All rights reserved. No part of this manual may be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopying, recording, or any
information storage and retrieval system, without our explicit permission.

Industria Elettromeccanica Commerciale Italiana Milanese S.r.l.


Via Muoni N16, 20064 Gorgonzola MILAN, ITALY
Tel: (+39) 02.951.5551 Fax: (+39) 02.951.5784
E-mail: iecim@iecim.191.it
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