Contiform

Mechanical Adjustments

7.1. Blowing Wheel, Infeed/Discharge Starwheel

Clamp Transfer to the Blow Mould

To adjust the blowing wheel at the infeed/discharge
starwheel, remove the clamp from one arm and replace it
using the adjusting device (3).
The mould, to which this arm transferred, and the blowing
nozzle of this station must be removed as well. Instead of the
blowing nozzle, the adjusting tip (2) must be screwed into
the blowing piston. Then, jog the starwheel to the transfer
position.
As a rule, the zero reference arm according to the test record

n
should be used here. Usually, arm number 1 is the zero
reference arm (1).

kap4-09010.eps

o p
Einstell12-001_1/2.eps
Marks At the transfer position, the adjusting tip (2) should be set to
allow for an admission at the mark (3) of one graduation
(approx. 1 mm) up to Contiform S 16 and two graduations
(approx. 2 mm) as of Contiform S 20, to compensate for the
belt backlash at maximum machine speed.

Firstly loosen the 6 hexagon head screws (4) and turn the
starwheel manually in machine operating direction past the
correct position. The starwheel must then be turned back in
the opposite direction until the correct position is reached.
This is necessary to exclude any possible play from the
transfer arm.
If the position is correct, retighten the screws (4) with a
q torque of 45 Nm and check the position again.
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Training Manual 7-1

 Contiform

Mechanical Adjustments

Height Adjustment, Infeed/Discharge

Starwheel
First, loosen the hexagon head screws on the tightener (1).

kap4-09012.eps
Then loosen the hexagon socket screw (2). By turning the
brass disk (3), you can move the complete infeed/discharge
o starwheel up or down, thus enabling the height to be
adjusted precisely.
p Please make sure that, after height adjustment, the brass disk
will be turned back 1/2 revolution, so that it does not closely
fit the starwheel.
09-14050.eps

The topmost mould carrier is the zero reference mould, and

the arm identified with position 1 is the reference arm
(measured in the factory) used for adjustment. Move the
reference arm above the reference mould. Make sure that the
preform is in the clamp. It should be adjusted in such a way
that the distance between the lower edge of the preform
neck ring and the upper edge of the mould shell amounts to
0.3 mm (using a feeler gauge) for the infeed starwheel and
0 mm for the discharge starwheel.

Infeed/discharge starwheel: lowest arm, highest mould

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Training Manual 7-2

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Mechanical Adjustments

7.2. Adjustment of the Heating Chain in Relation to the Infeed

Starwheel of the Blowing Wheel
The heating chain must be adjusted at the transfer position
to the infeed starwheel of the blowing wheel as follows.

kap4-09005.eps

Check whether the position of the heating mandrel is centred

to the clamp.
If the heating mandrel is not positioned above the centre of
the clamp, the position of the heating chain must be
readjusted.

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Training Manual 7-3

 Contiform

Mechanical Adjustments

kap4-09007.eps
First, remove the cover plate (1) above the belt drive to allow
for access to the oven drive unit.

Then, loosen all inner screws (2) at the pulley. This will
disengage the heating chain from the rest of the machine.
Turn the main drive using the handwheel to exactly centre
the clamp of the infeed starwheel above the heating mandrel
of the oven.
Then, lock the hexagon socket screws (2) with a torque of
42 Nm and check the optimum state of the oven in relation
to the machine.
To test, jog some preforms through the machine.

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Training Manual 7-4

 Contiform

Mechanical Adjustments

7.3. Infeed Starwheel

The infeed starwheel (otherwise known as the starwheel
with chamfered pockets) must be readjusted if the heating
mandrel fails to meet the centre of the preform neck finish.
p q
They are readjusted by means of the clamping set (6)
provided in the centre of the infeed starwheel. To do so, a
preform is jogged through the starwheel as far as the transfer
position. If this position is not correct, this unit will need to
be readjusted.

s
kap4-09001.eps

To do so, loosen all hexagon socket screws (1) and unscrew

them a little. Now, completely remove three of the screws
and screw them into the forcing-off thread (2), until there is a
resistance. Now, turn these screws, one after the other, half a
rotation each and repeat this procedure until the clamping
o n set springs apart. Then return the screws to the position
shown in (1).
kap4-09002.eps

The infeed starwheel can now be turned manually until the

transfer position is correct. It may be better to remove the
centre guide (3). To do so, loosen the clip (4) and lift off the
guide. In this way, the transfer position (5) is better visible.
Slightly tighten the screws of the clamping set, check the
transfer by jogging some preforms through the passage and
readjust if necessary. If the transfer position is correct, evenly
retighten the screws of the clamping set (1) in a diagonal
p order using a torque of 17 Nm. Refit the centre guide (3), if it
has been removed, and lock with the clip (4).
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r
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Training Manual 7-5

 Contiform

Mechanical Adjustments

7.4. Pyrometer Adjustment

1 Pyrometer

kap4-09009.eps

As shown on the drawing, the pyrometer should measure

the temperature profile of at least 3 preforms!

Mandrel chain The laser beam should be directed to the central preform of
5 preforms (A) in the heating zone, and should be set at such
A an angle that it meets all of the 3 preforms. If a preform is
missing, it should not detect any gap with this setting.
Laser beam The 3rd layer of the heating tubes is the optimum height
adjustment position for the pyrometer .
pyrometer.dsf
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Training Manual 7-6

 Contiform

Mechanical Adjustments

7.5. Stretching Module to the Stretching Cam

Adjust the joint head (1) at the piston rod to set a gap (2) of
0.1-0.2 mm between the cam roller and the highest point of

n the stretching cam, which is provided with a mark HP

(highest point). To do so, check with the feeler gauge and
readjust if required.

o
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Training Manual 7-7

 Contiform

Mechanical Adjustments

7.6. Blowing Nozzle

The blowing nozzle must be adjusted as follows: there must
be a distance of 0.7 mm between the blowing nozzle (1) and
the blow mould.
kap4-09014.eps

Adjusting the Height of the Blowing Nozzle

First remove the castle nut (1). Raise the blowing nozzle slide
by hand (bottom picture) (2) and place a spacer (approx. 50

n mm) underneath it (3) so that the setscrew (4) can be

accessed. Then loosen the setscrew and, as shown in the
bottom picture on the right, the blowing nozzle piston can be
moved upwards or downwards by turning it using the
spanner (5). When doing so, please make sure that the
wrench stays in position to prevent the sleeve from also
being turned, as can be seen in the picture.

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p
o
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q
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Training Manual 7-8

 Contiform

Mechanical Adjustments

7.7. Stretching Rod

kap4-09017.eps

To check or adjust the stretching rod, use the adjustment

device (1) for base moulds.
p At first, the appropriate base mould must be jogged to the
adjustment device. Loosen the two threaded pins with
q hexagon socket at the side of the device (2), it is then
possible to shift toward the inside. Exactly position the base
mould roller (3) above the value (4) indicated on the hori-
zontal part of the adjusting device and insert a feeler gauge
between roller and adjusting device. The mould can now be
n opened and the base mould will remain exactly in the
production position.

Machines of more recent design are adjusted using another

adjusting device (1). It must be removed again after each
checking or adjustment. The principle, however, is the same
as in the illustration shown above.

n
kap4-09032.eps
kap4-09018.eps

Then, insert a preform (5) and manually pull the stretching

rod downwards until the stretching stopper completely butts
against the counterpart (6). (See the picture on the next
page).
The stretching rod height is correctly adjusted if the preform
cannot be moved upwards or downwards but can easily be
rotated. Otherwise, the height of the stretching rod must be
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readjusted, as shown in the following illustration.

Training Manual 7-9

 Contiform

Mechanical Adjustments
kap4-09019.eps

Adjusting the Height of the Stretching Rod in

Relation to the Base Mould

Loosen the lock nut (8) at the stretching rod and turn the
stretching rod upwards or downwards, by means of an
open-end wrench applied to the wrench side (9) of the
stretching rod. Then, retighten the lock nut (8).
Check this preset adjustment and repeat until the above-
mentioned criteria are met.
u
v
t
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Training Manual 7-10

 Contiform

Mechanical Adjustments

7.8. Adjustment of the Opening and Closing Movement at the

Mould Carrier
Checking the Proximity Switch Adjustment
Pressurise the pneumatic cylinder with 8-10 bar of
compressed air. Use a filler gauge to adjust a distance of 2.2-
0.5 mm (1) between the proximity switch and switching
device.
p
2 Bottom cylinder: 9.5 bar pressure
o 3 Moveable cam segment

n
Einstell12-002.eps

0.2 -0.5 mm

Adjusting the Mould Carrier Control Lever

To loosen the tightener (1), turn out the 6 hexagon head
screws (2) and screw in each respective adjacent thread
again. Please note that three of these six screws are screwed
in more deeply than the others. The reason for this is that
this tightener is mounted on 2 rings which must be
separated by force independently from one another.
Please note that the longer screws must be separated first.
p This means that the longer three screws must be repeatedly

n
tightened one after another for approximately half a rotation
until the top clamping mechanism has been released. This
must then be repeated with the shorter screws until the
kap4-09021.eps

bottom clamping mechanism has been released. Now the

o control lever (3) has been released and can be readjusted.
The 7th screw is used for centring between the top and
bottom clamping mechanism.
09-14053/09-14051.eps

Adjust the Main Lever

Move the mould carrier to the start of the locking cam. Press
the mould-carrier side parts together slightly using a screw
clamp, as can be seen in the picture on the left.
Check with a feeler gauge whether the gap between locking
Gap measurement shaft and hammer is 0.1 mm. The edge of the locking shaft
should have plunged approx. 2 – 5 mm into the locking
hammer for checking.
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Training Manual 7-11

 Contiform

Mechanical Adjustments

Turn the machine in the direction of operation until the

gauge (1) starts jamming at 0.2mm between shaft and
hammer. This is the exact locking moment which should be
used for fixing the tightener.
n

Feeler gauge 0.2 mm

09-14052/09-14054.eps

Firstly remove 8-10 bar from the main cam and leave
0.1 mm between the fixed segment and the cam roller. Then
pressurise the main cam to 8-10 bar again.
09-14055/09-14056.eps

Place a 8 mm spacer (1) underneath and tighten the tighener

to the specified 27 Nm.
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Training Manual 7-12

 Contiform

Mechanical Adjustments

Remove the 8-10 bar pressure from the main cam. Remove
the feeler gauge (0.1mm), screw clamp and spacer. Pressurise
the main cam to 8-10 bar again and once again check the
o n 0.1 mm gap between the locking shaft (1) and the locking
hammer (2).
The mould must be able to be locked easily.

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Training Manual 7-13

 Contiform

Mechanical Adjustments

7.9. Adjusting the Mould Shells

Check the height difference with a dial gauge. When doing

so, place the dial gauge on the left (moveable) and right
(fixed) mould-carrier side part.
The left mould-carrier side part must be lower than the right
so that the pressure pad does not experience any friction.
Tolerance: -0.05 mm.
If necessary, place an adjustment plate (1) underneath.

kap4-09028.eps

Left Side of the Mould Carrier Right Side of the Mould Carrier
kap4-09027.eps

The right side of the mould carrier is the fixed side.

The left side is the side which can be moved. It should be 0-
0.5 mm lower than the right side. You must be able to close
the mould gap once the blowing nozzles have been sealed
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against the preform neck finish.

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Training Manual 7-14

 Contiform

Mechanical Adjustments

7.10. Adjusting the Mould Carriers

Adjusting the Mould Gap

n 1 Tighten the hexagon socket screws using a torque wrench
with 20 Nm.
2 Tighten the hexagon socket screws using a torque wrench

{ with 25 Nm.

o
{
n kap4-09024.eps

If repairs or other tasks must be performed at the mould

carrier, please make sure that the mould gap (3) is correctly
adjusted to 0.25-0.35 mm. It is very important to always
check this gap width at four points.
For small cavity machines, this mould gap should range
between 0.25 and 0.30 mm, in heatset machines, 0.15 mm.

p In "H" machines, measurements are always performed on hot

moulds.
The hexagonal socket screws (1, 2) are used to fix the
pressure pad (4). This so-called component will close the
q mould gap as soon as the blowing pressure is provided.

kap4-09029.eps

This mould gap can be changed and/or adjusted, when (5)

presses on (1). Afterwards, it is necessary to secure the

r s adjustment screw (5). To do so, lock (6) on (5).

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 Contiform

Mechanical Adjustments

At the interior of the mobile mould-carrier side part, the

gasket must be tightly pressed into the recess during
assembly. To do so, apply some silicone grease to the gasket.
Afterwards, make sure that the pressure compensation
remains mobile at a pressure of 0.5 bar, and the pressure is
allowed escape. This is to make sure that the pressure
compensation device does not jam and remains mobile.
Afterwards, apply a pressure of 2 bar to the pad. Now the
pressure must no longer escape (listen to check).

kap4-09031.eps

Set the shock absorber (7) to 6 mm with the mould-carrier

6 mm side parts being closed.
The mould-carrier side parts should also be closed for
adjusting the distance between the pressure component (8)
and the mould carrier stop to 0.15 mm using a feeler gauge.
t

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Training Manual 7-16

 Contiform

Mechanical Adjustments

7.11. Replacement of the Mandrel

The mandrel should be replaced at the rear of the oven.

kap4-09033.eps

This is the best possible assembly position. When doing so,

you must make sure that the two cylinders (1) which keep
the oven chain tight, are always held without pressure during
assembly.

n
09-14060/09-14059.eps

Remove the plastic bearings (1).

n
kap4-09035.eps

Loosen the screw (1) using a hexagon socket screw key.

o
Remove the lock washer (2) and pull off the pin.
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n
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Training Manual 7-17

 Contiform

Mechanical Adjustments

7.12. Belt Tension Frequencies

The belt tension frequencies must always be set at the side of
the belt without the tension roller. When a belt is
disassembled, it must be assembled again in the same
running direction! If the original direction of operation is not
known, a new belt must be used! If a used belt is fitted, the
belt must be adjusted according to the tension frequency
indicated in the "used" column (see below). Belts must not
be retightened! A 20% loss of tension is normal!

09-14061.eps

Belt tensioning frequencies, 8-10 mould

positions
New Used
Belt 1 17.3 -18.1Hz 14.5 -15.5Hz
Belt 2 30.1 -31.6Hz 25.2 -26.9Hz
Belt 3 42.1 -44.2Hz 35.2 -37.7Hz
Belt 4 19.3 -20.3Hz 16.2 -17.3Hz

2
09-14062/63.eps

3 1
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Training Manual 7-18

 Contiform

Mechanical Adjustments

Belt tensioning frequencies, 12-14 mould

positions
New used
Belt 1 15.8 -16.6Hz 13.2 -14.1Hz
Belt 2 49.3 -51.7Hz 41.3 -44.1Hz
Belt 3 37.7 -39.1Hz 31.2 -33.4Hz
Belt 4 20.3 -21.2Hz 17.0 -18.1Hz

4 3 09-14064/65.eps

1
2

Belt tensioning frequencies, 16-18 mould

positions
New used
Belt 1 14.4 -15.1Hz 12.0 -12.8Hz
Belt 2 35.6 -37.3Hz 29.8 -31.8Hz
Belt 3 30.6 -32.1Hz 25.6 -27.4Hz
Belt 4 20.7 -21.7Hz 17.3 -18.5Hz

1
09-14066/67.eps
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Mechanical Adjustments

Belt tensioning frequencies, 20-24 mould

positions
new used
Belt 1 13.8 -14.5 Hz 11.5 -12.3 Hz
Belt 2* 35.3 -37.0 Hz 29.5 -31.6 Hz
Belt 2** 37.4 -39.2 Hz 31.3 -33.4 Hz
Belt 3 23.2 -24.4 Hz 19.4 -20.8 Hz

3
2**
09-14068/69.eps

2* 1
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Training Manual 7-20

 Contiform

Mechanical Adjustments

7.13. Overview of the Torques

Oven Infeed Starwheel, Cone Tightener

17 Nm

Blowing Wheel Infeed/Discharge Starwheels

45 Nm: M10 hexagon head
41 Nm: tightener

Control Lever for Opening/Closing

27 Nm

Blowing Slide and Stretching Slide

30 Nm

Blowing Nozzle Block

50 Nm

n Mould Compensation in the Mould Carrier

1 4x20 Nm
2 8x25 Nm

o
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Flange for Stretching Rod

30 Nm

Training Manual 7-21

 Contiform

Mechanical Adjustments

n Securing the Base Mould

1 M6 = 7 Nm

Securing the Mould and Mould Holder

1 Mould secured at: M8 = 12 Nm
2 Mould holder secured at: M6 = 10 Nm

n
o
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Training Manual 7-22