CUSTOMER: SRI MANJUNATHA SPINNING MILLS PVT LTD DATE OF VISIT: 28.10.2020 TO 29.10.

2020

PLACE: THIMMAPURAM

Machine History

Machine Manufacturer: Schlafhorst

Machine No: 148-0200-1302

Age of the Machine: 20 years old

Total No of winding units: 60

Overhead travelling cleaner: with-ELGI Make

Automatic Doffer: with

Package Cradle: 5’ 57’’

Yarn Guide Drum: 2.5ggas

Displacement Drive: With

Propack: with out

Cradle Taper Acceleration Device: With

Waxing: With & Without (Mix-up)

Electronic Yarn Clearer: Uster

Ecopack: Without

Yarn Tension Device: With

Splicer: Standard & Wet (Mix-up)

Prism: DZ3

Retainer Tube: M & Saw tooth (Mix-up)

Front Plate: Normal & Ceramic (Mix-up)

Yarn Tension Device: with Disc pressure

Precleaner: With

Round Magazine: With 5 Bobbins Type

Snarl brake (Loop Gate): With

Section Dust Collection Chamber: With

Empty Tube Conveyor (DHT): With DHT

Package Conveyor: With Belt

Power Supply: GZK Old Type

Informator: Color Informator

Observations

Machine
 The machine conditions found good

Points need to be taken care for improvements are as follows

OHTC
 The blowing air force not sufficient. Which is a result poor machine cleaning? To be check and
correct earlier possible

 Sometimes the OHTC crossing the energy unit side parking point due to wrong sensing of sensor or
settings. To be correct immediately and avoid accident.

Doffer
 Doffer found idle condition which is results operator work load slightly increasing and efficiency loss.
Doffer idles due to following Electrical and Mechanical parts missing.

Pos Part No Part Name Dim Qty

110 148-018.448 Covering plate 1
109 148-018.447 Covering plate 1
111 900-912.273 Cheese head screw M5X12 2
128 148-004.201 Rotary head 1
129 842-410.044 Angular connecting 4/M5 1
127 836-460.001 O-ring 8X2 1
126 148-000.750 Banjo bolt 1
208 148-014.832 Limit stop 1
118 900-933.312 Hexagon head cap screw M5X25 1
119 900-934.064 Hexagon nut M5 1
133 148-005.278 Bushing 1
135 842-410.044 Angular connecting 4/M5 1
134 148-003.243 Cylinder 1
138 901-850.012 Bushing T6X8X4 1
137 148-006.267 Guide lever 1
139 901-850.056 Bushing 6X8X10 1
153 148-005.300 Rocker shaft 1
140 148-013.481 Leaf spring 1
141 148-006.270 Support 1
144 832-805.067 Starting disc 6X15X1 1
145 906-799.004 Retaining washer DM 5 1
142 900-125.052 Washer DM 5,3 1
143 900-912.273 Cheese head screw M5X12 1
147 901-850.036 Bushing 6X8X10 1
148 900-912.273 Cheese head screw M5X12 1
146 148-023.289 Scissors support 1
152 900-912.273 Cheese head screw M5X12 1
151 148-001.245 Clamping plate 1
149 148-014.684 Yarn catch plate 1
150 900-933.171 Hexagon head cap screw M5X10 1
215 900-125.052 Washer DM 5,3 1
156 832-805.065 Starting disc 5X12X1 1
155 906-799.003 Retaining washer DM 4 1
159 900-965.013 Countersunk head screw M4X16 1
157 148-005.303 Scissors support 1
158 901-850.036 Bushing 6X8X10 1
160 138-006.032 Bearing bush 2
161 148-022.772 Clamping plate 1
162 148-022.773 Clamping plate 1
163 148-005.306 Half of cutter 1
169 148-005.312 Actuating rod 1
171 148-005.317 Locking lever 1
173 901-850.034 Bushing T4X5,5X3 1
172 900-912.273 Cheese head screw M5X12 1
170 906-799.002 Retaining washer DM 3,2 1
164 148-000.761 Half of cutter 1
165 148-000.762 Leaf spring 1
166 107-020.304 Pressure spring 1
167 148-005.307 Covering plate 1
168 900-934.063 Hexagon nut M4 2
104 834-310.186 Toothed belt HTD 665 1
72 148-005.182 Magnet holder 1
4 148-004.837 Contact spring LINKS 1
6 900-125.053 Washer DM 6,4 2
5 900-912.255 Cheese head screw M6X12 2
7 148-009.388 Retaining bolt 2
10 117-005.676 Distance washer 2
11 836-201.003 Pressure spring 2
12 906-799.007 Retaining washer DM 8 2
13 830-365.005 Contact disc 6 2
14 900-912.255 Cheese head screw M6X12 2
1 148-004.838 Contact spring RECHTS 1
15 147-010.353 Cylinder 1
18 842-410.033 G-Connection 4-G1/8 1
7 148-006.439 Cam shaft 1
11 906-885.262 Fitting key A6X6X263 1
27 146-009.954 Magnet holder 1
17 148-021.823 Cam disk SPF2-2 1
20 148-021.830 Cam disk 1
29 138-012.254 Cylinder 12X10HUB 1
6 148-010.600 Drive gear 1
2 148-022.533 Step motor 1
28 148-656.035 Connecting cable 1
43 155-006.263 Cylinder 1
80 148-006.223 Holding plate 1
57 148-022.747 Spherical washer 1
 62 148-011.110 Finger 1
44 842-410.044 Angular connecting 4/M5 2
46 148-004.805 Guide lever 1
31 148-003.346 Magnet holder 1
1 148-021.000 Cam follower SPF2 1
1 148-670.096 Adapter card 1
2 148-670.172 Control system 1
9 148-002.159 Chain link 10

Package Conveyor
 Package conveyor found idle condition due to drive belt missing. Which results collection of
packages more difficulty? To be correct immediately.

 Package conveyor drive motor inverter PCB found missing. To be purchased immediately

 Package conveyor limit stop switch found damaged condition. To be purchased immediately.

 Customer requested to the package collected to change suction units side to energy unit side how to
changing the direction and procedure method to explained to electrical technician.

 Conveyor idle parts list bellow

Pos Part no Part name Dim Qty

40 148-670.107 P. c. board 1
115 148-346.744 Conveyor belt 1
36 883-431.215 Selector switch 1
Limit Switch 1

Package cradle

 Package cradle assembly area servicing does not started because of the special tools are not
available from customer end. To be purchase earlier possible and start servicing for better
performance.

 The package cradle open arm found damaged due to handling of unloading. To be replace
immediately.

 The package cradle open arm found more play and vibration due to supporting bushes found
missing and worn out. Which are results subsequent mother board failures? To replace immediately
in all the machines for reducing mother board failures.

 The RH adaptor parts like brake lining and brake rings are in worn out condition resulting poor
functioning of package brake, delayed upper end pickup and doffer blockage during doffing. To
replace immediately.
  The RH adaptor parts like pressure spring found missing during running which is result winding unit
idle. To be replace immediately.

 LH adaptor part like Round cord ring found worn-out which result higher vibrations is. To be replace
immediately.

Waxing

 Waxing units Wax shaft found missing which result yarn breaks and package problems.to be
replace immediately.

 Waxing unit yarn trap tube Seal found missing which result suction leakage and subsequently
higher power consumption and also waste accumulation in this area. To replace immediately.

 Yarn trap tube clamp found in damaged condition which results improper sucking-off of the bit yarn
and may lead to package complaint. To be replace immediately.
  Few waxing unit Housing found damaged which result lead to package complaint. To be replace
immediately.

EYC

 Many winding unit’s yarn clearer multi jet air hose found missing and clearer sensing area is not
getting cleaned which causes unnecessary clearer cuts / clearer blockages and subsequent drop in
efficiency. To be replace urgently.

Splicer
 The splicers shear blade and leaf spring to be replaced as it has completed its life. This will lead to weak
splice and more breaks in the subsequent process. This will reduce the repeater cycle and improve the splice
quality.

 The splicers bearing bush and leaf spring to be replaced as it has completed its life. This will lead to weak
splice and more breaks in the subsequent process. This will reduce the repeater cycle and improve the splice
quality.
Tension Device
 Cut mark on RH tension disc in all of the spindles, which results tension breaks more than 10%. And yarn
surface damage to be replace immediately.

 LH tension device intermediate piece & starting washer found worn out in all the spindles.
Schlafhorst has developed a trouble free new intermediate piece with disc. to be replaced with
new ones to avoid above problems.

 The lower end scissors pivoting shear blade, leaf spring and the nylon washers found in
worn out condition. To replace immediately. This will reduce unnecessary bobbin rejection and
avoid package quality problems.
 The RH tension device drive motor toothed gear wheel found crack and damaged condition.
This will lead to more tension breaks and improper winding tension. This also is affecting the yarn
quality like hairiness and imperfections. To be replace immediately.

 The RH tension device Expansion bellows Found in lot of spindles are damaged. To be replace
immediately.

 The RH tension device tension disc worm found crack and damaged condition. This will lead to
more tension breaks and improper winding tension. This also is affecting the yarn quality like
hairiness and imperfections.
  The RH tension device Lever found crack and damaged condition. This will lead to more tension
breaks and improper winding tension. This also is affecting the yarn quality like hairiness and
imperfections.

Round Magazine

 Found most of the round magnets are powdered in creeling device.

Training given to the technicians for the followings and done in one Spindle,

 Splicer unit complete dismantling, serving and assembling s method shown to the mill technicians. To do the
work as per Schlafhorst standards.

 Tension unit complete dismantling, serving and assembling method shown to the mill technicians. To do the
work as per Schlafhorst standards.
 Suction arm drive and nozzle complete dismantling, serving and assembling method shown to the mill
technicians. To do the work as per Schlafhorst standards.

 Round magazine complete dismantling, serving and assembling method shown to the mill technicians. To do
the work as per Schlafhorst standards.

 Round Magazine Bobbin Chute complete dismantling, serving and assembling Chute method shown to the
mill technicians. To do the work as per Schlafhorst standards.

 Central housing cam assembly complete dismantling, serving and assembling Chute method shown to the
mill technicians. To do the work as per Schlafhorst standards.
  Unwinding accelerator complete dismantling, serving and assembling Chute method shown to the mill
technicians. To do the work as per Schlafhorst standards.

 Splicer basics setting method shown to the mill technicians. To do the work as per Schlafhorst standards.

 Suction arm basics settings method shown to the mill technicians. To do the work as per Schlafhorst
standards.

 Bobbin chute setting method shown to the mill technicians. To do the work as per Schlafhorst standards.

 Bobbin Magazine swivel lid setting method shown to the mill technicians. To do the work as per Schlafhorst
standards.

Idle Winding Units Required parts list

Total Three winding units found idle condition

Pos Part No Part Nam Dim Qty

1 148-013.953 Operation unit 3
4 148-006.553 Blind 3
6 147-005.946 Stopping element 12
6 148-004.813 Cover 3
4 148-006.852 Cradle carrier shaft 2
11 148-006.880 Toothed segment 2
9 832-805.015 Starting disc 25X36X2 3
12 900-934.064 Hexagon nut M5 6
13 900-965.050 Countersunk head screw M5X18 6
4 148-012.775 Cradle shock absorber 3
6 148-013.238 Compensating lever 3
4 148-000.500 Stator 3
9 148-011.009 Drum shaft 3
32 836-625.020 Dowel 3
5 836-480.030 Plug 36,5X15X18 3
22 148-013.596 Lever 3
28 900-985.012 Hexagon nut M6 3
29 147-032.329 Damping washer 3
 45 901-850.017 Bushing T10X12X6 6
34 148-005.043 Cover RECHTS 4" 3
6 830-171.011 Countersunk head screw 3
30 906-799.007 Retaining washer DM 8 3
17 148-003.449 Brake bush 2
6 146-001.757 Pressure spring 3
18 146-017.582 Fastening piece 3
35 885-910.109 Sensor 11MT BIP 3
5 148-006.771 Housing 3

Life end & Worn out parts list

Pos Part No Part Name Dim Qty

6 148-004.813 Cover 60
19 832-667.006 Ball cage support 12,95 60
11 148-012.863 Cover 60
23 148-012.873 Piston 60
16 148-012.868 Tube 60
29 148-000.523 Supporting ring 60
28 148-004.719 Seal ring 60
27 148-000.521 Stop ring 60
26 148-004.717 Covering cap 60
19 885-910.074 Sensor 11MT BIP. 60
18 148-000.519 Cover plate 10
10 148-011.008 Drum shaft 10
4 148-000.500 Stator 10
32 836-625.020 Dowel 30
5 836-480.030 Plug 36,5X15X18 60
28 148-022.915 Rubber washer 60
29 147-032.329 Damping washer 60
45 901-850.017 Bushing T10X12X6 120
30 906-799.007 Retaining washer DM 8 60
34 148-005.043 Cover RECHTS 4" 40
6 830-171.011 Countersunk head screw 100
9 836-450.033 Grooved ring 25X19X3,25 120
14 138-010.197 Bearing shaft 15
35 885-910.109 Sensor 11MT BIP 30
20 148-014.829 Brake lining 60
36 148-014.846 BRAKE RING 60
23 836-460.238 Round cord ring 60
40 148-005.783 Directional control valve 5
59 148-011.605 Pilot motor 2
9 148-002.756 Magnet holder 10
65 147-022.600 Coupling half 120
38 901-850.024 Bushing 12X14X12 120
46 901-850.024 Bushing 12X14X12 120
20 901-850.042 Bushing T12X14X15 60
53 901-850.096 Bushing T12X14X6 60
 25 836-473.016 Retaining ring 10
5 148-011.851 Suction pipe 10
5 148-006.771 Housing 10
16 148-012.517 Spring-loaded latch 60
39 148-010.501 Seal 60
19 836-460.241 O-ring 30X2 60
74 148-012.893 Tension disc 60
16 148-005.512 Starting disc 60
137 830-173.024 Flat-head screw KB30X10 30
16 148-012.218 Stationary shear blade STEEL 60
20 138-015.744 Pivoting shear blade STEEL 60
21 148-013.131 Leaf spring 60
43 900-125.030 Washer DM 4,3 60
144 148-012.270 Wax shaft 60
22 148-001.853 Seal 60
21 117-001.335 Intermediate disc 10
13 146-001.641 Tube clamp 20
37 148-003.805 Housing 5

Chances of the Mother Board Failures

 Frequently power fluctuations and power fail. Which resulting short circuit and subsequent
mother board failures?

 The drive part applied high load (to check cam roller or bearing condition). Which resulting
short circuit and subsequent mother board failures?

 The winding unit tester (Game Boy) cable or connector found damaged. Which resulting short
circuit and subsequent mother board failures?

 Kindly follow after remove the winding units fuse then only carried electrical or mechanical
maintenance work.

 Don’t make any manual joint to sensor or CAN bus cable. Which resulting short circuit and
subsequent mother board failures?

 The package RPM sensor cable routing in case wrongly then damaged the sensor and short
circuit and subsequent mother board failures?

 Autoconer-338 machines drum motor housing encoder with cable in case found damage.
Which resulting short circuit and subsequent mother board failures?

 The winding unit’s mother board’s heat sing to housing fixed bolt loose and tight gently.

 Note: major issue found drum motor housing encoder cable damaged. To replace immediately
and avoid mother board failure

 In case of failure of mother board in any spindle, reason has to be analyzed before replacing
with new mother board. (Or mother board failure will increase).

 Stabilizer should be on stabilizing mode and strictly should not be in bypass mode.
  Stabilizer switch on has to be done manually after power failure.

 Stabilizer should be switched on after at least consuming 50 % of the load utilization.

 No work should be done in power on condition (Maintenance & Electrical). (Informed during last
visit)

Best Regards
P.Leproy Jeya Sundar
Saurer Textile Solutions P Ltd
Guntur-AP
Phone: +91 9393640510