0 0100 - Service Manual - EvoTape1600 - TDD31813 - EN - 2020 - 07 - 15

Service Manual
EvoTape1600
Film Tape Line
Document no.: TDD 31813 / 01.20 STC Spinnzwirn GmbH

Order no.: 11701 0 0100 Zwickauer Straße 247
Customer: Asia Dragon Cord & Twine Company Lt 09116 Chemnitz
Germany
Telephone +49 371 2388 240
Fax +49 371 85 21 42
www.stc-spinnzwirn.com
info@stc-spinnzwirn.com
STC Spinnzwirn GmbH
Zwickauer Straße 247
09116 Chemnitz
Germany
Telephone +49 371 2388 240
Fax +49 371 85 21 42
www.stc-spinnzwirn.com
info@stc-spinnzwirn.com
Book Version
11701 0 0100_V1.0
Copyright
The copyright remains with the company STC Spinnzwirn GmbH.
The information contained herein must not be duplicated or disseminated, in whole or in part
or used for competitive purposes or communicated to others without authorisation.
Copyright © 2020 by STC Spinnzwirn GmbH
All rights reserved
Table of Contents
Table of Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Safety instructions for tasks on electrical systems,

machines, and equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Safety Instructions for Tasks on Mechanical Systems,

Machines, and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.4 Safety Instructions for Maintenance Tasks . . . . . . . . . . . . . . . . . . 8
2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 How to Behave in Case of Malfunctions . . . . . . . . . . . . . . . . . . . . 13
3.2 Structure of the Malfunction Tables . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Malfunctions – Film Tape Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.4 Malfunction – Electric Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Malfunctions – Control Desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Malfunctions – Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.7 Malfunction – Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.8 Malfunction – Extruder Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.9 Malfunction – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.10 Malfunction – Adapter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.11 Malfunction – Melt Pump with Drive . . . . . . . . . . . . . . . . . . . . . . 21
3.12 Malfunction – Slot Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.13 Malfunction – Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.14 Malfunction – Take-off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.15 Malfunction – Thickness Measuring Device . . . . . . . . . . . . . . . . 25
3.16 Malfunctions – Cutting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.17 Malfunction – Draw Stand I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.18 Malfunction – Waste Strip Feedback Device . . . . . . . . . . . . . . . . 30
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3.19 Malfunctions – Draw Stand II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.20 Malfunction – Hot-Air Passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.21 Malfunctions – Draw Stand III/IV. . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.22 Malfunction – Fibrillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
3.23 Malfunctions – Draw Stand V/VI/VII . . . . . . . . . . . . . . . . . . . . . . . 40
3.24 Malfunctions – Cutting Device Baler Twine . . . . . . . . . . . . . . . . . 44
3.25 Malfunctions – Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.26 Malfunction – Ionization Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.27 Malfunction – Heating Devices/Cooling Devices . . . . . . . . . . . . 45
3.28 Malfunction – Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.1 Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.2 Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.3 Preparation - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.3.1 Cleaning Agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.3.2 Work Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.4 General Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.5 Replacing the Measuring Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.5.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.5.2 Replacing the Heating Temperature Sensor with Thread . . . . . . . . 55
4.5.3 Replacing the Heating Temperature Sensor with Bayonet Catch . 56
4.5.4 Replacing the Melt Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 56
4.5.5 Replacing the Melt Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . 58
4.5.6 Cleaning Methods for Line Parts that Come into Contact
with Melt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.6 Screw Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.7 Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.7.1 Pneumatic Plug Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
4.7.2 Pneumatic hose couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
4.7.3 Pneumatic Screw Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
4.7.4 Argus Hoses with OWA Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
4.7.5 Hose Clamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
4.8 Replacing Inverters, Temperature Controllers, Drives, etc. . . 67

4.8.1 Executing Motor Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4.9 Instructions concerning the maintenance schedules

of the line components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
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4.10 Maintenance – Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
4.11 Maintenance – Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.11.1 Maintenance Schedule – Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
4.11.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
4.11.3 Checking Oil Level of the Gear Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
4.11.4 Checking the V-Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.11.5 Checking the V-Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
4.11.6 Tensioning V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.11.7 Cleaning V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
4.11.8 Changing V-belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
4.11.9 Checking the Water Cooling on the Feed Housing, Gear Unit
and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
4.11.10 Checking Devices for Temperature and Pressure Regulation . . . . . 75
4.11.11 Checking the Air Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
4.11.12 Checking the Direction of Rotation of the Gear Unit . . . . . . . . . . . . 78
4.11.13 Running the Extruder Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.11.14 Disassembling the Extruder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
4.11.15 Cleaning the Extruder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.11.16 Cleaning the Extruder Barrel Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.11.17 Assembling the Extruder Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.11.18 Replacing the Feed Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.11.19 Replacing Stuffing Box Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.11.20 Replacing Feather Keys in the Driven Shaft of the Gear Unit . . . . . 92
4.11.21 Replacing Heating Band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
4.11.22 Replacing the Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
4.11.23 Assembling / Disassembling the V-Belt Pulley without Taper
Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.11.24 Assembling / Disassembling the V-belt Pulley with Taper Bushes . 96
4.11.25 Instructions for Replacing the Drive Motor . . . . . . . . . . . . . . . . . . . . 98
4.11.26 Adjusting the Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.12 Maintenance – Melt Pump with Drive . . . . . . . . . . . . . . . . . . . . . 100

4.12.1 Maintenance schedule – Melt Pump with Drive . . . . . . . . . . . . . . .100
4.12.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
4.12.3 Preparing Melt Pump for Disassembly from the Line . . . . . . . . . .102
4.12.4 Disassembling the Melt Pump from the Line. . . . . . . . . . . . . . . . . . 103
4.12.5 Disassembly of The Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
4.12.6 Installing the Melt Pump in the Line . . . . . . . . . . . . . . . . . . . . . . . . .106
4.12.7 Assembling the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
4.13 Maintenance – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.14 Maintenance – Adapter System . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.14.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.14.2 Replacing Heating Bands on the Adapter . . . . . . . . . . . . . . . . . . . . 110
4.14.3 Disassembling the Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
4.14.4 Assembling the Deflection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
01.20 11701 0 0100 Asia Dragon Cord & Twine Company Lt iii
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4.15 Maintenance − Slot Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.15.1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.15.2 Preparing Slot Die for Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . .114
4.15.3 Disassembling the Slot Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.15.4 Assembling the Slot Die. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.16 Maintenance – Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4.16.1 Maintenance Schedule – Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . 118
4.16.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.16.3 Cleaning the Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
4.16.4 Cleaning the Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
4.16.5 Checking the Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
4.16.6 Replacing the Chain for the Height Adjustment . . . . . . . . . . . . . . .120
4.16.7 Checking the Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 121
4.17 Maintenance – Take-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.17.1 Maintenance Schedule – Take-Off Device. . . . . . . . . . . . . . . . . . . . . 124
4.17.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.17.3 Adjusting Contact Pressure of the Pressure Roll . . . . . . . . . . . . . . . 125
4.17.4 Setting the Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
4.17.5 Checking the Function of the Drives . . . . . . . . . . . . . . . . . . . . . . . . .125
4.17.6 Checking the Direction of Rotation of the Rolls . . . . . . . . . . . . . . . . 126
4.17.7 Checking the Function of the Pneumatic System . . . . . . . . . . . . . .126
4.17.8 Checking the Function of the Air Knives . . . . . . . . . . . . . . . . . . . . . . 127
4.17.9 Checking the Function of the Residual Moisture Nozzles . . . . . . . 127
4.17.10 Replacing the Pressure Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
4.18 Maintenance – Thickness Measuring Device . . . . . . . . . . . . . . . 129
4.19 Maintenance – Cutting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.19.1 Maintenance Schedule – Cutting Device . . . . . . . . . . . . . . . . . . . . . . 130
4.19.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
4.19.3 Adjust the knife holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
4.19.4 Turning or Replacing the Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
4.19.5 Calculating the Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.19.6 Setting the Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
4.19.7 Setting the Cutting Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.19.8 Setting the Stop for the Cutting Depth . . . . . . . . . . . . . . . . . . . . . . . 137
4.20 Maintenance – Draw Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.20.1 Maintenance Schedule – Draw Stand I . . . . . . . . . . . . . . . . . . . . . . . 138
4.20.2 Maintenance Schedule – Draw Stand II . . . . . . . . . . . . . . . . . . . . . . 140
4.20.3 Maintenance Schedule – Draw Stand III/IV . . . . . . . . . . . . . . . . . . . 142
4.20.4 Maintenance Schedule – Draw Stand V/VI/VII . . . . . . . . . . . . . . . . . 144
4.20.5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.20.6 Function Check of the Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
4.20.8 Checking the Direction of Rotation of the Drive Motor . . . . . . . . .148
4.20.9 Replacing a Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
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4.20.10 Overview – Draw Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

4.20.11 Disassembling Godet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
4.20.12 Assembling the Godet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.20.13 Disassembling the Godet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . .158
4.20.14 Assembling the Godet Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
4.20.15 Relubricating the Godet Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
4.20.16 Checking and Replacing the Heating Liquid Hoses . . . . . . . . . . . .161
4.20.17 Checking and Replacing the Cooling Fluid Hoses . . . . . . . . . . . . . . 162
4.20.18 Replacing the Pressure Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
4.20.19 Checking and Adjusting the Pressure Roll . . . . . . . . . . . . . . . . . . . . 163
4.20.20 Checking and Adjusting the Position Switch and Actuator . . . . . . 164
4.21 Maintenance – Cutting Device Baler Twine . . . . . . . . . . . . . . . . 166

4.21.1 Maintenance Schedule – Cutting Device Baler Twine . . . . . . . . . . . 167
4.21.2 Replacing Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.21.3 Replacing the Knife Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
4.22 Maintenance – Hot-air Passage . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.23 Maintenance – Ionization unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.24 Maintenance – Heating Devices / Cooling Devices . . . . . . . . . . 169
4.25 Maintenance – Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.25.1 Maintenance Schedule – Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
4.26 Maintenance – Waste Strip Feedback Device . . . . . . . . . . . . . . 171

4.26.1 Maintenance Schedule – Waste Strip Feedback Device . . . . . . . . .172
4.26.2 Replacing Gear Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
4.26.3 Checking and Adjusting the Tension of the Toothed Belt . . . . . . . 174
4.26.4 Replacing a Toothed Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
4.27 Maintenance – Fibrillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.27.1 Maintenance Schedule – Fibrillator . . . . . . . . . . . . . . . . . . . . . . . . . .182
4.27.2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.27.3 Preparing the Fibrillator for Maintenance . . . . . . . . . . . . . . . . . . . . 183
4.27.4 Preparing the Fibrillator for Production . . . . . . . . . . . . . . . . . . . . . . 185
4.27.5 Cleaning and Lubricating the Guides . . . . . . . . . . . . . . . . . . . . . . . . 189
4.27.6 Checking the Seat of the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . 190
4.27.7 Checking and Adjusting the Position of the Safety Switches . . . . .191
4.27.8 Checking and Adjusting the Position of the Position Switches
of the Traverse Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.27.9 Cleaning the Needle Strips and Needle Roller . . . . . . . . . . . . . . . . . 194
4.27.10 Replacing the Needle Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
4.27.11 Replacing the Needle Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
4.27.12 Checking the Functioning of the Drive . . . . . . . . . . . . . . . . . . . . . . . 201
4.27.13 Checking the Direction of Rotation of the Drive Motor . . . . . . . . .203
4.27.14 Adjusting the Vertical Carriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.28 Maintenance – Electric Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 206
01.20 11701 0 0100 Asia Dragon Cord & Twine Company Lt v

Table of Contents
4.29 Maintenance – Control Desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.30 Maintenance – Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

4.30.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
4.30.2 Checking Pneumatic Lines and Connections . . . . . . . . . . . . . . . . . . 207
4.30.3 Checking Liquid-Conducting Lines . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.30.4 Checking the Electrical Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
4.31 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.31.1 Ordering Original Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
4.31.2 Ordering Spare Parts for Equipment from Suppliers . . . . . . . . . . . 208
5 Drawings, Forms and Customer Service. . . . . . . . . . . . . . . . . 209

5.1 Installation Plan PFB1-0-958 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
5.2 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
5.3 Return Shipping Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5.4 Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.5 Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
6 Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.1.1 Screw Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
6.1.2 Lubricating Screw Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
6.2 Comparison List of Lubricants, WN912 . . . . . . . . . . . . . . . . . . . . 227
6.3 Comparison List, Heat Transfer Oils . . . . . . . . . . . . . . . . . . . . . . 229
6.4 Third-Party Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
vi Asia Dragon Cord & Twine Company Lt 11701 0 0100 01.20

Foreword
Foreword
The documentation is only valid together with the operating instructions and the
service manuals.
• Instructions for Use

The documentation is part of the product. The documentation is an essential aid for
successful operation.
– Read all product documentation before starting any work.
– Comply with the documentation.
This is the only way to:

• Initiate the necessary measures for accident prevention
• Maintain the product at a high capacity level over a long service life
– Supplement the documentation with instructions from existing national acci-

dent prevention and environmental protection regulations.
• Text Layout
In this documentation you will find defined writing styles that make it easier to han-
dle the documentation and to find particular information faster.
Instruction for Action
– Text with instructions for actions lists the sequence of required actions for oper-
ation.
– Indented instructions for action describe the higher-level instruction for

action in more detail.
Listing
• Lists give pieces of information being logically connected; however, they are
not required to be listed in a particular sequence.
Enumeration
1. Enumerations are pieces of information being logically connected and that
have to be enumerated in correct sequence.
2. The sequence of enumerations can focus on the chronological sequence, the

action, or on the position.
01.20 11701 0 0100 Asia Dragon Cord & Twine Company Lt 1

Foreword
Typographic Conventions
Text Element Example
Pushbutton Press pushbutton [F1]
Button • Click the button [OK]

• Click the button
Indicator light ”Start”
Directories Start C:\Program.exe
Menu «File»
Menu commands «File > Save as»
• Warning Instructions
Warning Instructions in the Documentation
Warning instructions are used in the documentation. Comply with these warning in-
structions to avoid accidents, injury and material damage.
Warning instructions have a uniform structure.
! WARNING
Type and Source of Danger!

Possible consequences if the instructions are not complied with
► Measure for averting the danger.
⦸ Prohibited action
The following signal words are used to warn of injury or damage.

• Warning – Personal Injury
Imminent danger leading to death or serious injury.

! DANGER
Dangerous situation that could result in death or serious

! WARNING injury
Dangerous situation that could result in slight injury

! CAUTION
2 Asia Dragon Cord & Twine Company Lt 11701 0 0100 01.20

Foreword
• Warning – Material Damage
Damage to the product or its environment

NOTICE
• Important Information
Note: Indicates important information.

Warning Symbols in the Documentation
Warning symbols indicate danger zones. Warning symbols are used to illustrate the
hazards as pictogram in warning instructions. There are different warning symbols
for different danger sources.
• Original Version and Translation

The original language version of the documentation is German. Versions of any oth-
er language are translations of the original documentation.
• Validity
The document no. on the title page gives the identification number and the date of
delivery / amendment of these documentation. Previous versions shall lose their va-
lidity.
• Technical Alterations
If technical alterations are made by STC Spinnzwirn the documentation will be
adapted and versioned accordingly.
The version is specified on the back of the title page.
– Replace the out-of-date version with the current version.
– Ensure that only the current version is available.

Foreword
Note: The technical changes and the current version are documented in the ta-
ble below.
Technical Alterations
Date Order number Alterations Issue / version
• Disclaimer of Liability
The liability for any damage or error arising from the following shall be excluded:
• Operation outside of the intended use.
• Non-compliance with the documentation including the safety and warning in-
structions.
• Alterations and modifications by the operating company or its personnel

without the prior consent of STC Spinnzwirn.
• Use of non-original spare parts and accessories.

1 Safety
1 Safety
1.1 General Safety Instructions

Note: Comply with the safety and warning information provided in the Operat-
ing Instructions in the Safety chapter.
Maintenance tasks must only be performed by STC Spinnzwirn Customer Service or
by the owner's service technicians who have been trained by STC Spinnzwirn.
Note: Training courses for the owner's service technicians can be conducted at
STC Spinnzwirn or in the owner's facilities.
– Inform your operating personnel ahead of time of any repair tasks that should
be carried out on the line.
– Appoint a supervisory person.
– Ensure that all safety devices are serviced at regular intervals and checked for
proper function.
– Use appropriate hoists and transport aids and ensure sure that they are in good
working condition. Ensure proper transport (see the chapter dealing with trans-
portation in the Operating Instructions).
– When handling oil, grease, and other chemical substances, comply with the safe-
ty regulations prescribed for the specific product.
– Properly dispose of consumables, cleaning agents, production materials, and

line components, see Operating Instructions, chapter Disposal.

1 Safety
1.2 Safety instructions for tasks on electrical systems,

machines, and equipment
Note: Only service technicians with electro-technical training (qualified elec-
tricians) are allowed to work on electrical equipment, machines and operating
equipment, see Operating Instructions, section Qualified Electrician.
– Prior to starting the tasks ensure for yourself that all safety regulations have
been complied with.
– Comply with the applicable national regulations as amended for tasks on electri-
cal systems, machines, and equipment!
– For tasks on electrical equipment, comply with the 5 safety rules:
3. De-energise!
4. Safeguard against being switched back on!
5. Ensure de-energised status!
6. Ground and short-circuit!
7. Cover or shield live adjacent parts!
– Energising is executed in the reverse sequence!
Voltage
Even in switched off status some electrical devices can be energised (e.g. service
outlets, lights, humidity sensors, locking mechanism power circuits, parts of the ki-
netic buffering, external power supplies, uninterruptible power supply systems,
batteries, accumulators, capacitors, etc.)
– Pay attention to voltages that can be generated by parts that are still rotating.
– Use suitable devices to discharge those capacitors, for which automatic dis-
charge cannot be ensured!
– Take the discharge time of capacitors into account. Be aware of the hazards
posed by batteries and accumulators!
– Do not plug in or disconnect any energised plug connectors.
Protective earth conductor

– Do not disconnect the protective earth conductor.
– Do not remove the protective earth conductor.
– Do not use the protective earth conductor for other purposes.
– After each task, check to ensure the proper continuity of the protective earth
conductor.

1 Safety
Checking
– Check prior to commissioning whether all screws on electrical connection points
have been tightened with the correct tightening torque.
Humidity
– Protect energised parts of electrical equipment from wet conditions, moisture,
and condensation.
Cleaning
– For cleaning of electrical equipment: De-energise the equipment.
1.3 Safety Instructions for Tasks on Mechanical Systems,

Machines, and Components
– Comply with the applicable national regulations for working on hydraulic and
pneumatic systems, machines and components.
Pressurized systems must always be depressurized prior to repair and maintenance

work.
– Close the gate valves prior to the commencement of work.
Hydraulics (if existent)

– Drain hydraulic systems, machines and lines.
Pneumatic system
– Vent pneumatic systems, machines and lines.
Note: For some maintenance and repair work, the line must be connected hy-
draulically and pneumatically. Keep in mind that residual risks can occur with
regard to the line during operation and maintenance, see operating instruc-
tions.

1 Safety
1.4 Safety Instructions for Maintenance Tasks
! DANGER
Life-threatening High Voltage!

Electric shock, third degree burns or death.
After switching off the line, some electrical equipment in electric cabinets and
switch boxes can still be energised.
► Only have service technicians with electrical engineering training (quali-

fied electrician) perform tasks on electrical equipment.
► For tasks on electrical equipment, machines and devices always comply
with the "five safety rules", see chapter 1.1 General Safety Instructions,
page 5.
► Comply with warning instructions on the electrical equipment.
► Pay attention to the wiring diagram.
⦸ Never reach around covers in the electric cabinet or on electrical compo-

nents.
! WARNING
Rotating parts, entanglement, entrapment

Hand Injuries.
► Start tasks only after all rotating parts have come to a complete standstill.
! WARNING
Unexpected Start-Up!
Serious injuries, fractures, bruises.
► Switch off the line before servicing and maintenance tasks.

► Use a padlock to safeguard the main switch against being switched on
again.
► Wait until the entire line is de-energised.
► Wait until all drives have come to a standstill.

1 Safety
! WARNING
Line under pressure

Danger of Injury
► Execute maintenance tasks only when the equipment is depressurised

and de-energised.
► Ensure that systems under pressure (e.g. melt pipes, heat-transfer
medium pipes, pneumatic lines, or hydraulic hoses and tanks) are depres-
surised before opening.
► Shut the gate valves prior to starting tasks.
► Pay attention to the pressure monitoring devices.
► Set the pressure regulators to value 0 unless they are strictly required for
testing purposes.
! CAUTION
Hot surfaces, hot operating materials and auxiliary materials!

Burns, scalding
► Wear heat-resistant gloves, heat-resistant clothing, and a protective visor

or protective goggles.
⦸ Do not touch line parts without protective equipment.
Note: The specific safety instructions are provided in the Maintenance chap-
ters of the specific components.

1 Safety

2 Description
2 Description
19
3
4
5
6
7
8
10
11
12
13
14
15
16
17
18

2 Description
Component Maintenance chapter
1 Dosing System 4.10 Maintenance – Dosing System, page 68
2 Extruder 4.11 Maintenance – Extruder, page 68
3 Adapter system 4.14 Maintenance – Adapter System, page 109
4 Melt pump with drive 4.12 Maintenance – Melt Pump with Drive,
page 100
5 Slot die 4.15 Maintenance − Slot Die, page 113
6 Cooling bath 4.16 Maintenance – Cooling Bath, page 117
7 Take-off device 4.17 Maintenance – Take-Off Device, page 122
8 Thickness measuring device 4.18 Maintenance – Thickness Measuring Device,

page 129
9 Cutting device 4.19 Maintenance – Cutting Device, page 130
10 Draw stand I with heating device 4.20 Maintenance – Draw Stands, page 138
11 Waste strip feedback device 4.26 Maintenance – Waste Strip Feedback Device,
page 171
12 Draw stand II with cooling device 4.20 Maintenance – Draw Stands, page 138
13 Hot-air passage I 4.21 Maintenance – Cutting Device Baler Twine,

page 166
14 Hot-air passage II 4.21 Maintenance – Cutting Device Baler Twine,

page 166
15 Draw stand III/IV with heating 4.20 Maintenance – Draw Stands, page 138
device
16 Fibrillator with ionization device 4.27 Maintenance – Fibrillator, page 180
17 Draw stand V/VI/VII with heating 4.20 Maintenance – Draw Stands, page 138
device and cooling device
18 Suction 4.25 Maintenance – Suction, page 170
19 Control desk 4.29 Maintenance – Control Desk, page 206
20 Electric cabinet (not shown) 4.28 Maintenance – Electric Cabinet, page 206

3 Troubleshooting
3 Troubleshooting
Operators, process technologists, service technicians, or the STC Spinnzwirn Cus-

tomer Service can rectify malfunctions.
In the following tables the responsibilities are assigned according to personnel
groups.
STC Spinnzwirn Customer service offers training courses.
Note: For additional information, contact STC Spinnzwirn Customer Service,
see chapter 5.5 Customer Service, page 218.
3.1 How to Behave in Case of Malfunctions

– Comply with all safety instructions, warning instructions, and protective meas-
ures, see chapter 1 Safety, page 5.
– Comply with the following items depending on the type of malfunction:
– Switch off or de-energise components of the line, areas of the line, or the
entire line,
– Comply with the ramp-down times.
– Comply with the cooling times.
– Safeguard components of the line, areas of the line, or the entire line from being
switched back on.
– Rectify malfunctions or have them rectified as described in the following tables

of malfunctions.
– If there are malfunctions that pose a hazard for personnel or the line, proceed
as follows:
– Activate the emergency-stop device.
– Safeguard components of the line, areas of the line, or the entire line
from being switched back on.
– Notify the process technologist, service technician or STC Spinnzwirn Cus-

tomer Service.
– Rectify malfunctions or have them rectified as described in the following

tables of malfunctions.
– Start the line.

3 Troubleshooting
3.2 Structure of the Malfunction Tables

The malfunction tables contain the following information:
Assembly
No. Malfunction Cause of Malfunction Troubleshooting
1 Type and • Listing of possible Responsible group of persons, such as:

description of causes for the mal- • Operator
the malfunction / function
• Process Technologist
malfunction
• Service technician
message
• STC Spinnzwirn-Customer Service
– Instruction for troubleshooting
No. ... consecutive error numbering

Note: All malfunctions detected by the line itself are displayed on the visualisation.
In addition, the horn sounds and the indicator light on the control desk is flashing,
see Operating Instructions.
Other malfunctions that occur are listed in the tables below.
If malfunctions occur that are not listed in this documentation, contact STC
Spinnzwirn Customer Service. For third-party devices, the separate third-party
documentation is authoritative, see chapter 6.4 Third-Party Documentation,
page 231.

3 Troubleshooting
3.3 Malfunctions – Film Tape Line
Film tape line
1 Line component • No setpoint entered Operator / Process Technologist

does not start on the visualisation – On the visualisation enter a setpoint that does not equal
after switch on zero for the component, see Service Book for the PC of
the line.
– Depending on the component, enter a setpoint for pres-
sure, temperature, or speed.
2 Film shows • Contamination in the Operator

impurities extrusion system – Switch off the line.
Service technician
– Clean the adapter system and the filter.
– Clean the slot die.
Operator
– Switch on the line.
3 Film shows holes • Wet granulate Operator

and bubbles – Switch off the line.
– Remove the granulate from the material container of the
dosing system, see third-party documentation.
– Top up with new, dry granulate
• Feed housing is Process technologist / service technician

steamed up – Reduce cooling water flow, see third-party documenta-
tion.
3.4 Malfunction – Electric Cabinet

Note: The components of the electric cabinet and the control system are de-
scribed in the Service Book for the electrical system. The visualisation is docu-
mented in the on-line help or in the Service Book for the PC of the line.

3 Troubleshooting
3.5 Malfunctions – Control Desk

Note: The components of the control desk and the control system are de-
scribed in the Service Book for the electrical system. The visualisation is docu-
mented in the on-line help or in the Service Book for the PC of the line.
– If there are malfunctions on the heating systems, check the temperature con-
trollers, heating bands and heating cartridges.
All malfunctions detected by the line itself are displayed on the visualisation.
In addition, the horn sounds and the red indicator light on the control desk is flash-
ing.
– Notify the process technologist/service technician.
– After rectifying each malfunction, activate the pushbutton [Acknowledgement]

on operating panel +P01.
3.6 Malfunctions – Dosing System

Note: For detailed information see chapter 6.4 Third-Party Documentation,
page 231.

3 Troubleshooting
3.7 Malfunction – Extruder
Extruder
1 Extruder motor • Enable temperature Operator:

does not start of the heating system – Wait until enable temperature is reached or enable time
not reached or enable has expired, see Service Book for the PC of the line.
time has not yet – Switch on the extruder drive.
elapsed.
• Pressure setpoint P2 Process Technologist:
not specified – Enter the pressure setpoint P2.
2 Extruder motor • See malfunction mes- Process technologist / operator:

stops during sage on the visualis- – Pay attention to the malfunction message on the visualis-
production ation ation, see the Operating Instructions and Service Book
for the PC of the line.
• Filter extremely con- Operator:

taminated – Switch off the line.
Service technician:
– Clean the filter.
– Check the screen fineness.
– Replace the screen.
– Ensure the material supply.
Operator:
• Pressure P1 has ex- Operator:

ceeded the pressure – Switch off the line.
tolerance limits Service technician:
– Check the filters.
– Check the process material.
Operator:

3 Troubleshooting
3.8 Malfunction – Extruder Drive

Note: The table of malfunctions below is a general information by the belt
manufacturer. Comply with the instructions provided by the belt manufactur-
er.
Note: For all tasks on the extruder drive, the line must be switched off, and
must only be restarted after conclusion of the tasks.
Extruder Drive
1 Broken belt after • Force applied during Service technician:

short service life assembly, which dam- – Make it possible to put on the belt without force.
(belt torn) aged the tension train – Check the tension of the v-belt.
• Effect of foreign ob- Service technician:

jects during operation – Attach the protective device.
• Drive blocked Service technician:

– Eliminate the cause.
• Belt is oily due to Service technician:

leaky gear unit – Clean the gear unit.
– Check the oil level of the gear unit.
– Clean the belt.
2 Breaks and • Excessive heat expo- Service technician:

cracks in the belt sure – Eliminate the heat source and improve air circulation.
substructure STC Spinnzwirn Customer Service
– Use the special version (extra heat-resistant).
• Excessive exposure to Service technician:

cold temperatures – Warm the belt before start-up.
STC Spinnzwirn Customer Service
– Use the special version (extra cold-resistant).
• Increased belt slip Service technician:

– Re-tension the belt as specified in the assembly instruc-
tions.
– Check the drive ratio and re-dimension the ratio if neces-
sary.
• Chemical influences Service technician:

– Cover the drive.
– Use the special version.

3 Troubleshooting
3 V-belts are • Pulleys are not Service technician:

skewed aligned – Align the pulleys.
• Pulley grooves are se- Service technician:

verely worn – Replace the pulleys.
• Insufficient preten- Service technician:

sion – Check the pretension.
– Re-tension the drive.
• Foreign objects in the Service technician:

pulley grooves – Remove the foreign objects.
– Cover the drive.
4 Unusual flank • Worn pulley grooves Service technician:

wear. – Replace the pulleys.
• Pulleys are not Service technician:

aligned – Align the pulleys.

5 Excessive oper- • Pulleys are not Service technician:

ating noise aligned – Align the pulleys.

6 Belt is spongy • Influence of oil, Service technician:

and sticky grease, chemicals – Protect the drive from the external influences.
– Clean the pulleys with petrol and benzene before using a
new belt, see chapter 6.4, page 231.
– Use the special version (extra oil-resistant).

3 Troubleshooting
7 Non-uniform • Worn belts combined Service technician:

belt elongation with new belts to form – Completely replace the belt set.
a set.
• Several makes of belts Service technician:
combined as one set. – Only use belts from one manufacturer in the set.
3.9 Malfunction – Filter

page 231.
3.10 Malfunction – Adapter System
Adapter system
1 Filter leaks at the • Filter not installed Operator

flange connec- parallel between the – Switch off the line.
tion adaptor flanges Service technician:
– Clean the filter connection.
– Re-align the filter.
– Check the distance to the flanges with a feeler gauge.
Operator

page 231.

3 Troubleshooting
3.11 Malfuntion – Melt Pump with Drive
Melt pump
1 Pump motor • Enable temperature Operator

does not start of the heating system – Wait until enable temperature is reached or enable time
not reached or enable has expired, see Operating Instructions and the Service
time has not yet Book for the PC of the line.
elapsed. – Switch on the extruder drive.
2 Pump motor • Pay attention to the Process technologist / operator

stops during malfunction messag- – Pay attention to the malfunction message on the visualis-
production es on the visualisation ation, see the Operating Instructions and Service Book
• Pressure P3 has ex- Operator

ceeded the pressure – Switch off the line.
tolerance limits Process technologist / operator
– Check the extrusion die.
– Check the process material.
– Check the adapter system for clogging and failure of the
heating bands.
Operator
3.12 Malfunction – Slot Die

page 231.

3 Troubleshooting
3.13 Malfunction – Cooling Bath
Cooling bath
1 Temperature of • Water circuit is inter- Operator

the cooling bath rupted, water drain is – Switch off the line.
does not corre- clogged Service technician
spond to set- – Clean the screen in the overflow trough.
point Operator
• Water circuit is inter- Operator

rupted, water flow is – Switch off the line.
clogged Service technician
– Check the cooling device.
Operator
• Defective heat ex- Operator

changer – Switch off the line.
Service technician
Operator
• Water circuit is inter- Operator

rupted, water inlet is – Switch off the line.
clogged. Service technician
Operator
• Temperature sensor Operator

does not send a signal – Switch off the line.
Service technician
– Check the temperature sensor in the cooling bath,.
Operator

3 Troubleshooting
2 Cooling bath • Reference to a drive Process technologist / operator

cannot be malfunction – Pay attention to the malfunction message on the visualis-
adjusted in ation, see the Operating Instructions and Service Book
height for the PC of the line.
Operator
– Switch off the line.
Service technician
– Check the drive.
Operator
• Chain of the height- Operator

adjustment element – Switch off the line.
is defective, broken Service technician
– Replace the chain.
Operator

3 Troubleshooting
3.14 Malfunction – Take-off Device
Take-off device
1 Take-off rolls do • Pneumatic or electri- Operator

not swivel cal malfunction – Switch off the line.
Service technician
– Check the functionality of the pneumatic cylinder.
– Check the seals.
– Check the electrical activation.
Operator
2 Insufficient suc- • Defective radial fan Operator

tion capacity of – Switch off the line.
the air knive Service technician
– Repair or replace the radial fan.
Operator
• Air knife clogged Operator

– Clean the air knives.
– Switch on the radial fan for air knives.
– Check the blowing capacity.
– Switch off the radial fan for air knives.
• Filter – radial fan for Operator

air knives (side chan- – Switch off the line.
nel compressor) is Service technician
clogged – Clean the filter or replace it if necessary, see third-party
documentation.
Operator

3 Troubleshooting
3 No suction • Defective radial fan Operator

power of the – Switch off the line.
residual mois- Service technician
ture nozzles – Repair or replace the radial fan.
Operator
• Slot of the residual Operator

moisture nozzles is – Switch off the line.
clogged – Use a brush to remove contamination and lime scale.
– Switch on the radial fan for residual moisture nozzles.
– Check the suction capacity.
– Switch off the radial fan for residual moisture nozzles.
• Material abrasion – Operator

contaminants in the – Switch off the line.
water separator Service technician
– Clean the radial fan, see third-party documentation.
– Clean the water separator, see third-party documenta-
tion.
Operator
• Water column not Operator

present – Switch off the line.
– Fill the compensating tank (hose) of the water separator
with water.
3.15 Malfunction – Thickness Measuring Device

page 231.

3 Troubleshooting
3.16 Malfunctions – Cutting Device
Cutting device
1 Film wrinkles • Stretcher roller incor- Process technologist / operator

downstream of rectly adjusted – Adjust stretcher roller, so that the film runs without wrin-
the cutting kles over the stretcher roller I, see Operating Instruc-
device at start- tions.
up or
– Increase brake tension of the film brake, see Operating
Instructions
2 Cut edges of the • Blades are blunt Operator

film tapes are – Change the cutting depth of the blades.
not clean Note: If a change in the cutting depth is no longer
possible, turn or replace the blades.
Service technician
– Turn or replace the blades/knife set of the cutting device
Operator
• Insufficient cutting Process Technologist

tension of the film – Change the speed between take-off device and draw
tapes stand I.

3 Troubleshooting
3.17 Malfunction – Draw Stand I
1 Wrap on godet • Film tape break Operator:

or pressure rolls – Switch off the line.
– Remove the wrap.
2 Specific godets • Toothed belt torn Operator

or all godets are – Switch off the line.
not driven Service technician
– Replace the toothed belt.
Operator
• Insufficient toothed Operator

belt tension – Switch off the line.
Service technician
– Tension the toothed belt.
Operator
• Reference to a drive Process technologist / Operator

malfunction – Pay attention to the malfunction message on the line PC,
see the Operating Instructions and Service Book for the
PC of the line.
Operator
Service technician
Operator
• Safety limit switch/po- Operator

sition switch of safety – Switch off the line.
hood not approached Service technician
– Check safety limit switch/position switch and re-align
Operator

3 Troubleshooting
3 Pressure roll • Pressure roll has not Operator

does not turn moved down onto the – Press the pushbutton [Pressure roll down/up] on the op-
godet erating panel to lower the pressure roll.
NOTICE Malfunctions of the line!
► If you cannot rectify the malfunction, switch off
the line.
Service technician
– Check the functionality of the pressure roll.
Operator
• Material residues Operator

wrapped up – Switch off the line.
– Remove material residues.
• Defective bearing Operator

– Replace the bearing.
Operator
4 Pressure roll • Pneumatic malfunc- Operator

does not lift off tion – Switch off the line.
Service technician
– Check the pneumatic system and compressed air connec-
tions.
Operator

3 Troubleshooting
5 Heating capacity • Rotating leading-ins Operator:

of the godets (seals or parts of the – Switch off the line.
does not meet sealing heads) leak Service technician:
the process – Replace the seals.
requirements – Replace the leaky parts on the rotating leading-ins.
(heating device) Operator:
• Conduits to the go- Operator:

dets are leaking – Switch off the line.
Service technician:
– Replace the seals.
– Replace defective lines.
Operator:
• Heating elements or Process technologist / operator:

temperature sensors – Pay attention to the malfunction message on the line PC,
have failed see the Operating Instructions and Service Book for the
PC of the line.
Operator:
Service technician:
– Check the heating elements and temperature sensors.
Operator:
• Fuse of the electrical Operator:

system has failed – Switch off the line.
Service technician:
– Check the electrical system.
Operator:
• Godets calcified or Operator:

rusted in the interior – Switch off the line.
Service technician:
– Check the filters of the heating devices.
– Replace the godet.
Operator:

3 Troubleshooting
3.18 Malfunction – Waste Strip Feedback Device
Waste strip feedback device
1 Waste strips are • Waste strip feedback Operator

not pulled in device not switched – Switch on the waste strip feedback device.
on
• Radial fan of the Operator
waste strip feedback – Switch off the line.
device defective Service technician
Operator
• Waste strip too wide Operator

or too thick – Switch off the line.
Service technician
– On the cutting device insert additional blades for an addi-
tional division of the waste strips.
Operator
2 Waste strips are • Knife distances in the Operator

not sufficiently cutting mill are not – Switch off the line.
shredded. correctly set Service technician
– Check the cutting mill, see chapter 6.4 Third-Party Docu-
mentation, page 231.
Operator

3 Troubleshooting
Waste Strip Conveyor
3 Waste strips are • Gear wheels are worn Operator

not pulled in – Switch off the line.
Service technician
– Replace the gear wheels
Operator
• Toothed belt torn Operator

Service technician
Operator

Service technician
Operator
• Reference to a drive Process technologist / operator

malfunction – Pay attention to the malfunction message on the visualis-
ation, see the Operating Instructions and Service Book
Operator
Service technician
Operator
• Safety switches are Operator

not approached – Switch off the line.
Service technician
– Check the safety switch.
– Re-align the safety switch.
– Check the seating of the housing in the conveyor.
Operator

3 Troubleshooting
3.19 Malfunctions – Draw Stand II


Operator

Service technician
Operator

PC of the line.
Operator
Service technician
Operator

Operator

3 Troubleshooting

the line.
Service technician
Operator


Operator

Service technician
tions.
Operator

3 Troubleshooting
5 Cooling capacity • Rotating leading-ins Operator:

of godets does (seals or parts of the – Switch off the line.
not meet the sealing heads) leak Service technician:
process require- – Replace the seals.
ments (cooling – Replace the leaky parts on the rotating leading-ins.
device) Operator:

Service technician:
Operator:
• Cooling elements or Process technologist / operator:

PC of the line.
Operator:
Service technician:
– Check the cooling elements and temperature sensors.
Operator:

Service technician:
Operator:

Service technician:
– Check the filters of the cooling devices.
– Replace the godets.
Operator:

3 Troubleshooting
3.20 Malfunction – Hot-Air Passage
Hot-air passage
1 Film tape break • Temperature too high Process Technologist:

– Check the temperature value.
Operator
– Remove the film tape break, and the wraps that have oc-
curred
• Material residues in Operator

the hot-air passage – Switch off the line.
– Remove the film tape break, and the wraps that have oc-
curred.
2 Hot-air passage • Pneumatic or electri- Operator

does not open cal malfunction – Switch off the line.
Service technician:
– Check the functionality of the pneumatic and electrical
devices.
– Check the sensors of the lifting cylinders
Operator

3 Troubleshooting
3.21 Malfunctions – Draw Stand III/IV


Operator

Service technician
Operator

PC of the line.
Operator
Service technician
Operator

Operator

3 Troubleshooting


Service technician:
Operator:

PC of the line.
Operator:
Service technician:
Operator:

Service technician:
Operator:
• Godets clogged inside Operator:

with oil carbon – Switch off the line.
Service technician:
Operator:

3 Troubleshooting
3.22 Malfunction – Fibrillator
Fibrillator
1 Wrap on the • Film tape break Operator:

fibrillator – Switch off the line.
2 Needle roll • Reference to a drive Process technologist / operator:

is not driven malfunction – Pay attention to the malfunction messages on the line PC.
Operator:
CAUTION Cutting injury!
► Do not touch the needles of the needle roll.
Service technician:
– Check drives.
Operator:
• Safety switches are Operator:

not free – Switch off the line.
Service technician:
– Check the position of the safety switches on the horizon-
tal trolley and on the vertical carriage.
– Realign the safety switch via the slotted holes of the
plates.
Operator:
• Coupling not en- Operator:

gaged – Switch off the line.
Service technician:
– Check the seat of the coupling in the fibrillator.
– Bring the coupling into engagement.
Operator:

3 Troubleshooting
3 Traverse unit is • Reference to a drive Process technologist / operator:

not driven malfunction – Pay attention to the malfunction messages on the line PC.
Operator:
Service technician:
– Check drives.
Operator:
• Safety switches are Operator:

not free – Switch off the line.
Service technician:
– Check the position of the safety switches on the horizon-
tal trolley and on the vertical carriage.
– Realign the safety switch via the slotted holes of the
plates.
Operator:
• Position of the posi- Operator:

tion switch is not cor- – Switch off the line.
rect
Service technician:
– Check the position of the position switch of the traverse
unit.
Operator:

3 Troubleshooting
3.23 Malfunctions – Draw Stand V/VI/VII


Operator

Service technician
Operator

PC of the line.
Operator
Service technician
Operator

Operator

3 Troubleshooting

the line.
Service technician
Operator


Operator

Service technician
tions.
Operator

3 Troubleshooting


Service technician:
Operator:

PC of the line.
Operator:
Service technician:
Operator:

Service technician:
Operator:
• Godets clogged inside Operator:

with oil carbon – Switch off the line.
Service technician:
Operator:

3 Troubleshooting
6 Cooling capacity • Rotating leading-ins Operator:

of godets does (seals or parts of the – Switch off the line.
not meet the sealing heads) leak Service technician:
process require- – Replace the seals.
ments (cooling – Replace the leaky parts on the rotating leading-ins.
device) Operator:

Service technician:
Operator:
• Cooling elements or Process technologist / operator:

PC of the line.
Operator:
Service technician:
– Check the cooling elements and temperature sensors.
Operator:

Service technician:
Operator:

Service technician:
– Check the filters of the cooling devices.
– Replace the godets.
Operator:

3 Troubleshooting
3.24 Malfunctions – Cutting Device Baler Twine
Cutting Device Baler Twine
1 Blade does not • Blade is blunt Operator

cut – Interrupt the production of the line.
Service technician
– Replace the blade.
Operator
– Start up production.
2 Cutting device • Pneumatic malfunc- Operator

does not extend/ tion – Switch off the line.
retract Service technician
tions.
Operator
• Joint of the cutting de- Operator

vice has been moved – Switch off the line.
beyond dead centre Service technician
of the mechanical de- – Check
k the limit stop.
vice – Contact the STC Spinnzwirn customer service
3.25 Malfunctions – Suction
Suction
1 Insufficient suc- • Suction nozzles or Operator

tion capacity pipe system clogged – Switch off the line.
– Clean the suction nozzles and/or the pipe system.
– Remove foreign objects and material residues.
• Defective radial fan Operator

– Switch off the suction.
Service technician
Operator
– Switch on the suction.
NOTICEFormation of wraps!
► With suction switched off, wraps can occur on
godets and pressure rolls.

3 Troubleshooting
3.26 Malfunction – Ionization Unit

page 231.
3.27 Malfunction – Heating Devices/Cooling Devices

page 231.
3.28 Malfunction – Lines

Malfunctions of individual or several line components can be due to leaking or dis-
connected conduits or due to a malfunction in the conduit system.
During continuous operation of the line and as part of maintenance, the conduit
systems must be inspected regularly for damage. If damage or malfunctions occur,
the service technician must be informed immediately.

3 Troubleshooting

4 Maintenance
4 Maintenance
Regular maintenance of the line increases safety for operating personnel and the
functionality of the line.
The maintenance schedules are provided in the following sub-chapters. The regular
inspection, service and maintenance tasks and their prescribed times are described
in the maintenance schedules.
4.1 Instructions for maintenance

Service tasks in this context, should be understood as:
• Inspection: Overall visual inspection and diagnosis
• Maintenance: Maintenance intervals, lubrication intervals, cleaning, re-

adjustment
• Repair: Removal, dismantling, checking, maintenance / replacement, re-

assembly, settings, function checks, and installation
• Preventive and careful maintenance is the prerequisite for protecting the

health and safety of personnel in the line area. Moreover, maintenance is nec-
essary to preserve the functionality of the line.
• Bear in mind that the machine manufacturer cannot have any experience for
long-term operation under the operating conditions prevailing at your plant.
Consequently, supplement the information in this Service Manual with your
own experiences.
• Service and maintenance tasks must only be performed by a service techni-

cian and/or a qualified electrician.
• Enter into a maintenance contract. Information in this regard is available from

STC Spinnzwirn Customer Service.
• Ensure that inspection, maintenance, and service intervals are complied with.
• Document inspection, maintenance, and repair tasks by entering the execut-

ed inspections and tasks in the maintenance log.

4 Maintenance
Maintenance Log Order no.:
Machine type
Workplace Inspections and tasks that have been Name

Date Signature
Component executed Function

4 Maintenance
4.2 Regular Checks

For avoidance of damage or hazards regular visual and acoustic checks are neces-
sary.
Inspection
Inspection activity
interval
Daily • Check the legibility of the warning symbols.

• Check motors for abnormal noises, vibration and changes.
Weekly • Check connections for leaks and correct seat.

• Check the conduits and tubes for leaks.
Monthly • Test the emergency-stop devices.

• Check the indicating devices.
• Check the oil level of the motors.
Yearly • Check the screw connections for firm seat.
Process-dependent • Check the cleanliness of the components.

• Check the operating elements for operability.
Extruder
Inspection
Inspection activity
interval
Daily • Check the cooling water supply.
Weekly • Check the V-belts for wear.

• Check the extruder for leaks.
• Check the oil level of the gear unit.
Process-dependent • Check the material feed
Extruder Electric Cabinet
Inspection
Inspection activity
interval
Monthly • Check the electric cabinets and production equipment for damage and irregularities.
Half-yearly • Test the protective circuit breaker.

4 Maintenance
Adapter system
Inspection
Inspection activity
interval
Weekly • Check the adapter system for leaks.
Slot die
Inspection
Inspection activity
interval
Weekly • Check the slot die for leaks.
Process-dependent • Check the lips for deposits
Cooling bath
Inspection
Inspection activity
interval
Daily • Check the water level in the cooling bath.

• Check the connections for leaks.
• Check the lighting in the cooling bath.
• Check the water temperature on the cooling unit or line PC.
Process-depend- • Check the cleanliness of the screens in the overflow gutters and of the discharge pipe.
ent
Take-off device
Inspection
Inspection activity
interval
Process-dependent • Check the cleanliness of the nozzels.

• Check the tape on the discharge side for residual moisture.
Draw stand
Inspection
Inspection activity
interval
Weekly • Check the draw stands for leaks.
Process-dependent • Check the godets for deposit.

4 Maintenance
Fibrillator
Inspection
Inspection activity
interval
Daily • Check the production results.
Monthly • Execute lamp test.
Process-dependent • Check the direction of rotation of the motor of the needle roller at switch-on.
• Check the speed of the needle roll.
• Check the needle roll for wraps.
• Check the guides for contamination.
Electric Cabinet
Inspection
Inspection activity
interval
Monthly • Check the electric cabinets and production equipment for damage and irregularities.
Half-yearly • Test the protective circuit breaker.
Process-dependent • Check and clean the filter fan.

• Replace the filter after approx. 2000 operating hours.
4.3 Preparation - Maintenance

– Comply with the information in the maintenance schedule.
– Check the parts cited for wear or damage.
– Comply with all safety instructions and warning instructions for maintenance
tasks, see chapter 1 Safety, page 5.
– Inform operating personnel prior to performing maintenance tasks.
– Appoint a supervisory person.
– Switch off the line / component.
– Safeguard the line / component against being restarted.
Note: For additional information, contact STC Spinnzwirn Customer Service,

see chapter 5.5 Customer Service, page 218.

4 Maintenance
4.3.1 Cleaning Agents
NOTICE
The wrong cleaning fluids corrode the assemblies and components of

machines.
► Only use cleaning fluids that have a pH value > 5.50.
► Do not use cleaning fluids that attack nickel.
► Used cleaning fluids with a silicon content in the water proportion of the
emulsion under 00.05 ppm (mg/litre) or SiO2 content under 00.10 ppm
(mg/litre) to prevent the coating.
► Check each cleaning fluid before using it.
The pH value can drop due to longer storage of the cleaning fluid and the effect of
bacteria.
An excessive silicic acid (silicon) content of the water results in a glassy coating
(SiO2) on the yarn guiding components and increases the yarn friction.
– Check the cleaning fluid for pH value and proportion of silicic acid.
Note: STC Spinnzwirn offers a test set for measuring the silicon content: Article
no. A-585-1421. The test set is not included in the STC Spinnzwirn scope of de-
livery.

4 Maintenance
4.3.2 Work Equipment

For all service tasks, please use the equipment mentioned in this chapter, i.e.:
• Fixtures:
• Hoist with appropriate load-bearing capacity
• Sling gear
• Screw push-out device (depending on the extruder type)
• Tools:
• Brass wire brush, brass-aluminium scraper, mesh-wire pads made of

brass, wooden spatula
• Scissors
• Yarn suction gun
• 1 set ring spanners
• 1 set of hex socket spanners
• Lubricants
• See the following chapter in the maintenance schedule for the compo-
nents
• Auxiliary materials
4.4 General Maintenance Tasks

– Check the following parts for wear or damage and replace damaged parts:
• Surfaces of rollers and shafts
• Parts that guide material
• Guide rods
• Belts
• Bearing
• Coupling
• Gear unit and drive
• Blowers, fans
• Operating and display elements

4 Maintenance
– Prior to shutting down the line, walk around the line and check all ball bearings
for noise emission, as well as temperature, i.e. through vibration measurement.
– For proper disassembly and assembly, use STC Spinnzwirn auxiliary fixtures and
tools. Request a list of this auxiliary equipment from STC Spinnzwirn.
– We do recommend for all maintenance tasks, to disassemble the component

parts of a unit only to the extent that is strictly required, and to mark the associ-
ation of the disassembled parts.
NOTICE
► Comply with the information for handling electronic components and
assemblies, see chapter 5.3 Return Shipping Advice, page 213.
– As part of preventive maintenance, replace line components based on operating

hours.
– Use the respective drawings and parts lists when replacing line components (see
separate original parts catalogue).
NOTICE
► Do not reuse replaced bearings and rubber elements.
► Only use original spare parts from STC Spinnzwirn, to achieve the operat-
ing hours specified in the lubrication and maintenance schedules, as these
original spare parts are designed especially for the operating load (see the
title page overleaf for the Customer Service address).
► Regularly clean the entire line. Remove material residues immediately and
properly dispose of them.
– Grease lubrication must be executed only when the machine is running.
– Use a high-temperature compound (e.g. Unimoly HTC METALLIC paste from

Klüber) to lubricate screws and nuts that will be subjected to high temperature,
before screwing them back in.
– Check the threaded fittings for firm seat after maintenance tasks and replace-
ment of original spare parts (for tightening torques see chapter 6.1 Tightening
Torques, page 219).
– After maintenance tasks, execute a trial run with all checks and settings.

4 Maintenance
4.5 Replacing the Measuring Sensor

Note: You can order fixtures, tools, and auxiliary materials that are not includ-
ed in the scope of delivery from STC Spinnzwirn.
4.5.1 Safety
Note: Comply with all safety instructions and warning instructions, see chap-
ter 1 Safety, page 5.
4.5.2 Replacing the Heating Temperature Sensor with Thread
NOTICE
► Disassemble a threaded heating temperature sensor only when the line
has been heated up.
CAUTION Hot Surfaces! Burn injuries!

– Disconnect the heating temperature sensor.
– Carefully unscrew the heating temperature sensor.
– Check the thread turns of the screw-in thread for damage.
– If you detect damage, recur the thread.
NOTICE Only use grease in accordance with WN912-BG18, see 6.2 Comparison
List of Lubricants, WN912, page 227.
– Apply grease to the thread on the new heating temperature sensor.
– Carefully screw in the heating temperature sensor.
– Firmly screw in the heating temperature sensor with a torque of 20 Nm.
– Connect the heating temperature sensor.

4 Maintenance
4.5.3 Replacing the Heating Temperature Sensor with Bayonet

Catch
– Release the bayonet catch (2).
– Pull out the bayonet catch together

with the measuring sensor (1) 1 2
– Unscrew the screw-in nipple.
– Thinly lubricate the thread of the

screw-in nipple with high-temperature
metal paste "Unimoly HTC Metallic
from Klüber, see 6.2 Comparison List X
of Lubricants, WN912, page 227.
– Screw in the screw-in nipple.
– Tighten the screw-in nipple hand-tight.
– Apply heat-conducting paste to the tip of the temperature sensor (1) to ensure
optimal heat transfer.
NOTICE The measuring sensor must be assembled with pretension. In order

to increase the pretension, move the bayonet catch (2) by turning it in direc-
tion "X".
– Insert the measuring sensor (1).
– Secure the measuring sensor with the bayonet catch (2).
4.5.4 Replacing the Melt Temperature Sensor
NOTICE
► Disassemble / assemble a melt pressure sensor only when the line is
heated up.
► Reduce the line pressure to "zero".


4 Maintenance
– Disconnect the melt pressure sensor.
– Unscrew the sleeve on the melt pres-

sure sensor with a wrench (AF19). 1
– Remove the melt pressure sensor.
– Screw in the check bolt (4). 2

Note: If greater resistance occurs when 3
screwing it in, you must clean the
thread.
– Use a tap wrench (1) to screw a thread
cleaner (2) in and out
– Use a cleaning tap (3) to clean the con- 5

ical seat and the through-bore
4
– With the channel cleaner (5) provide
free space in the melt for the tip of the
sensor.
– Insert the melt temperature sensor

with the engraved arrow on the upper
hexagon in the flow direction.
NOTICE When fastening, ensure that

the engraved arrow points in the flow
direction.
– Firmly screw in the sleeve with a
wrench (AF19), (max. torque 20 Nm).
– Connect the melt pressure sensor.
Note: If the cleaning tool is not included

in the scope of delivery, you can order it
under article no. A-088-4765 for bores 1/
2" - 20 UNF. For other thread, please
contact STC Spinnzwirn Customer Ser-
vice.

4 Maintenance
4.5.5 Replacing the Melt Temperature Sensor
NOTICE
► Disassemble / assemble a melt pressure sensor only when the line is
heated up. Removal of the melt pressure sensor when the melt is solidi-
fied can damage the diaphragm through adhesion of the melt. This can
cause deformation of the membrane or it can even come off.
► Reduce the line pressure to "zero".

– Disconnect the melt pressure sensor.
– Carefully unscrew the melt pressure

sensor. 1
– Screw in the check bolt (4).
Note: If greater resistance occurs when 2

screwing it in, you must clean the
3
thread.

4 Maintenance
– Use a tap wrench (1) to screw a thread cleaner (2) in and out
– Use a cleaning tap (3) to clean the conical seat and the through-bore
– Carefully screw in the melt pressure sensor.
– Firmly screw in the melt pressure sensor with a torque of 20 Nm.
– Connect the melt pressure sensor.
Note: If the cleaning tool is not included

in the scope of delivery, you can order it
under article no. A-088-4765 for bores 1/
2" - 20 UNF. For other thread, please
contact STC Spinnzwirn Customer Ser-
vice.

4 Maintenance
4.5.6 Cleaning Methods for Line Parts that Come into Contact with
Melt
Note: The operating company is responsible for selection and application of
the appropriate cleaning method. Applicable guidelines and regulations of the
operating company must be complied with.
Note: Request binding information concerning the raw material from the raw
material manufacturer.
Note: Specialized engineers and STC Spinnzwirn Customer Service are available
within the framework of service consultation.
The cleaning method depends on the material processed (melt), as well as on the
conditions prevailing at the operating company or local directives and regulations.
There are a number of cleaning methods, e.g.:
• Manual cleaning with tools made of copper or brass
• Cleaning in a burnout oven
• Cleaning in a cleaning bath
• Cleaning in a hydrolysis oven
• Cleaning in a pyrolysis oven
4.6 Screw Connections

Note: Information concerning the tightening torques is provided in the techni-
cal drawings or tables, see 6.1 Tightening Torques, page 219.

4 Maintenance
4.7 Pneumatic Connections
4.7.1 Pneumatic Plug Connections
NOTICE
► Proper sealing of the plug connections depends on proper handling.
► Only use calibrated Rilsan hoses (PA11).
► The hoses and connections must be free of contamination.
► For cutting, only use the hose cutter offered by STC Spinnzwirn (article no.
A-093-7134).
► Cut off the hoses clean and straight before sliding them into the hose con-
nection.
► Do not press the hoses.
► For handling the hoses, the use of the pliers (article no. BM_30206) is rec-
ommended.
Note: Hose cutter and pliers are not included in the scope of delivery of STC
Spinnzwirn.

4 Maintenance
A-093-7134
Fig.. 4–1: Hose cutter
• Connect
– Slide in the hose.
Note: When reaching the retaining

edge of the clamping tool (1), you can
feel a slight resistance.
– Slide the hose in further through the O-
ring (2).
Note: A slight resistance is tangible. The

seal will be effective. 1
2
• Detach
– With an extraction tool, press on the
clamping ring (3) and simultaneously
pull on the hose.
Note: The extraction tool is not included 3

in the STC Spinnzwirn scope of delivery.
A set of extraction tools can be ordered
from STC Spinnzwirn: Article no. 1-025-
3820

4 Maintenance
4.7.2 Pneumatic hose couplings
• Connect
– Fit the hose coupling together.
• Detach
– Slide the ring (1) back.
1

4 Maintenance
4.7.3 Pneumatic Screw Connection
• Connect
– Insert the insert sleeve (4) into the end
of the hose (1). 1
2
– Slide the socket union (2) and the ta-
pered ring (3) onto the end of the hose.
4 3
– Guide the end of the hose into the de-

pression to the stop.
2
– Firmly tighten the socket union (2).
• Detach
– Remove the socket union (2).
– Pull the end of the hose (1) out of the

depression.
– Pull the socket union and the tapered

ring (3) off of the end of the hose.
– Pull the insert sleeve (4) out of the end

of the hose (1).

4 Maintenance
4.7.4 Argus Hoses with OWA Fittings

Note: Hose diameter øi = 10 mm with hose clamp.
• Connect
– Cut off hose straight or at a right angle
with a metal saw or cut-off wheel.
– Screw the end of the hose into the

OWA socket left rotation.
Note: Provide for a small gap between

the socket end and the hose end

4 Maintenance
– Lubricate the screw-in nipple and the

inside of the hose with oil.
– With a wrench, screw the screw-in nip-

ple into the OWA socket to the stop.
• Detach
– With a wrench, unscrew the screw-in nipple.
– Unscrew the hose end out of the OWA socket.
4.7.5 Hose Clamps

– Cut off the end of the hose straight.
– Slide the hose clamp over the end of the hose.
– Slide the end of the hose over the joining piece.
– Fasten the hose by screwing down the hose clamp on the connection.

4 Maintenance
4.8 Replacing Inverters, Temperature Controllers, Drives,

etc.
4.8.1 Executing Motor Identification
NOTICE
► After installing a motor that is not identical, execute motor identification.
► Assemblies can be damaged through the motor identification procedure.
► Prior to starting motor identification, disconnect the motor from the gear
unit.
CAUTION Automatic Start-up of the Drive! Entanglement! Danger of crushing

injuries on the hands!
► Prior to starting, designate a supervising person who provides security for
the danger area.
– Execute motor identification via the visualisation (see On-Line Help or the Service
Book for the PC of the line chapter, Service, Fig. 0432)
4.9 Instructions concerning the maintenance schedules of

the line components
The schedules in table form provide the following information on lubrication, main-
tenance and repair of the individual line components as prescribed by STC Spinn-
zwirn:
• Name of the part or the assembly
• Lubricants, auxiliary materials, and cleaning agents to be used
• Prescribed time intervals
• Activities to be executed and special comments
• References to additional explanations concerning the specific points (chapter

references)
Note: For third-party devices, the separate third-party documentation is au-

thoritative, see 6.4 Third-Party Documentation, page 231.
Note: All data is based on an assumed operating time of 7200 hours/year. The
recommendations given for preventive maintenance of the line components
are based on continuous 3-shift operation of the line.

4 Maintenance
4.10 Maintenance – Dosing System

page 231.
4.11 Maintenance – Extruder
1 3 5 6
7
10
12 11
Fig.. 4–2: Extruder 12E10
1 Barrel connection flange 7 V-belt, safety device: Cover of belt drive
2 Terminal box (without illustration) 8 Internal screw cooling (optional)
3 Safety device: Barrel enclosure 9 Radial fan
4 Barrel with heating elements and safety 10 Frame

device: Temperature monitoring
through temperature sensor (without il-
lustration)
5 Feed housing with safety device: Grat- 11 Drive motor

ing cover
6 Gear unit 12 Safety device: [Emergency-stop] push-

button

4 Maintenance
4.11.1 Maintenance Schedule – Extruder
Maintenance
Assembly Maintenance instruction
interval
Drive motor See third-party Service technician

documentation – Execute inspection and maintenance as specified in the third-party
documentation.
V-belt Monthly Service technician

– Check the V-belts for wear, damage and contamination, see chapter
4.11.4, page 72.
– Check the V-belt tension with the pretension measurement device,
see chapter 4.11.5, page 72.
– Replace damaged worn V-belts, see chapter 4.11.8, page 74.
– Clean the V-belts with a glycerine / spirit mixture in the ratio of 1:10,
see chapter 4.11.7, page 73.
– Tension the V-belts, see chapter 4.11.6, page 73.
Gear unit See third-party Service technician

documentation – Check the oil level of the gear unit, see chapter 4.11.3, page 71 and
third-party documentation.
– Top up gear oil or replace the gear oil.
Gear unit Monthly Service technician

Rotary shaft seals – Check the gear unit shaft seals on the driving shaft and driven shaft
on the driving for wear and damage, see third-party documentation.
shaft and – Replace the gear unit shaft seals on the driving shaft and driven shaft,
see third-party documentation.
driven shaft
Extruder screw when screw is Service technician

removed – Clean the extruder screw and the extruder barrel with brass wire
brush, brass, aluminium, copper scraper, wire-mesh pads of copper,
polishing wheel and polishing paste (not included in the STC Spinn-
zwirn scope of delivery), see chapter 4.11.15, page 84.
– Grease the shank of the extruder screw with high-temperature com-
pound, e.g. Unimoly HTC Metallic Paste from Klüber, see chapter
Each time before 4.11.17 Assembling the Extruder Screw, page 85.
installing the – Lubricant quantity: 5g
screw
Cylinder bore when screw is Service technician

removed – Clean the extruder barrel bore, see chapter 4.11.16, page 84.
– After cleaning, lightly spray the barrel bore with silicone oil M200, see
chapter 4.11.16, page 84.
– Lubricant quantity: 8g
Barrel connection Before installing Service technician

flange the screw – Before insertion, grease the connecting screws with high-tempera-
ture compound, e.g. Unimoly HTC Metallic Paste from Klüber, see
chapter • Connection on the Barrel Outlet, page 86.

4 Maintenance
Maintenance
interval
Heating zones / after 2200 operat- Service technician

cooling zones of ing hours – Clean the heating / cooling sleeves.
the barrel: – Check the heating bands.
Heating / cooling – Replace the heating bands, see chapter 4.11.21 Replacing Heating
Band, page 92.
sleeves
Heating zones / See chapter 6.4 Service technician

cooling zones of Third-Party Docu- – Execute inspection and maintenance as specified in the third-party
the barrel: mentation, documentation, see chapter 6.4, page 231.
Radial fan page 231.
Stuffing box pack- after 4000 operat- Service technician

ing ing hours – Replace the stuffing box packing, see chapter 4.11.19 Replacing
Stuffing Box Packing, page 90.
– Before insertion, grease the connecting screws with high-tempera-
ture compound, e.g. Unimoly HTC Metallic Paste from Klüber, see
chapter • Connection on the Barrel Outlet, page 86.
4.11.2 Safety
! DANGER
Overheating, explosion of the extruder!

Death
► Never check the heating zones without temperature sensor.

► Never check the heating zones for longer that 2 minutes.
! WARNING
Wrong direction of rotation of the gear unit, pressing hot melt and gases
out of the funnel housing!
Danger of Injury, Scalding.
⦸ Never let the extruder run in the wrong direction of rotation!

► Check the direction of rotation.

4 Maintenance
! CAUTION
Outflow of hot air at the air slots of the barrel enclosure

Burn injuries

! CAUTION
Entanglement
Hand injuries
► Seal the feed opening.
⦸ When assembling the extruder screw, do not reach into the feed opening.
! CAUTION
Entanglement
Hand injuries
⦸ When turning the V-belt ensure that fingers are not pinched.
4.11.3 Checking Oil Level of the Gear Unit

Prerequisite: The line must be switched
off and safeguarded against being
switched back on.
– At gear unit standstill, on the oil-level
glass (1) check whether the gear oil is
up to the upper edge of the oil-level
glass.
Note: For detailed information see

1
chapter 6.4 Third-Party Documenta-
tion, page 231.

4 Maintenance
4.11.4 Checking the V-Belts

Prerequisite: The line must be switched off and safeguarded against being
switched back on.
– Disassemble the cover of the belt drive.
– Check the V-belt tension, see chapter 4.11.5 Checking the V-Belt Tension,
page 72.
– Check the V-belts for contamination.
– Clean the V-belts, see chapter 4.11.7 Cleaning V-belt, page 73.
– Check the V-belts for wear.
– Replace the V-belts, see chapter 4.11.8 Changing V-belt, page 74.
– Assemble the cover of the belt drive.
4.11.5 Checking the V-Belt Tension

switched back on.
– Check the V-belt tension with the pretension measurement device.

page 231.
– Re-tension the V-belts, see chapter 4.11.6 Tensioning V-belt, page 73..

4 Maintenance
4.11.6 Tensioning V-belt

switched back on.
– Remove the hexagon nuts (3) under

the motor base plate (2).
– By tightening the top hexagon nuts (1)

adjust the motor so that the V-belts
reach the specified tension
NOTICE Adjust the hexagon nuts uni- 1

2
formly. The belt pulleys of motor and
3
gear unit must be in exact alignment af-
ter tensioning of the V-belts.
– Check the parallelity of the belt pulleys

of motor and gear unit:
– Place the steel ruler (4) on the 4

facing sides of the belt pulleys
of motor and gear unit.
– Adjust the parallelity by moving

the motor.
– Firmly screw the bottom hexagon nuts

(1) against the motor base plate.
4.11.7 Cleaning V-belt

switched back on.
NOTICENever use petrol, benzene, turpentine or the like, nor sharp-edged

objects, wire brushes, emery paper, etc. for cleaning, as these items cause me-
chanical damage of the V-belts!
– Clean contaminated V-belts with a glycerine / spirit mixture in the ratio of 1:10.

4 Maintenance
4.11.8 Changing V-belt

switched back on.
NOTICE
► Always replace all belts with new ones.
► Ensure the same belt quality.
► The relative deviation of the belts must not exceed 1.5°∕∞.
► Only put on belts of identical length, selected in pairs.
– Unscrew the hexagon nuts (1) above

the motor plate (2) far enough that the
old V-belts can be taken off.
1
– Take off the old V-belts. 2
3
– Put on the new V-belts.
CAUTION Danger of Injury through

Entanglement, Entrapment.
► When turning the belt, ensure that fingers are not pinched.
– Turn the drive through several rotations.
– Tension the new V-belts with the maximum deflection force.

page 231.
– Press the extruder screw approx 30 cm out of the screw receptacle of the gear
unit.
Note: This allows the V-belts to run in at idle and maximum pretension, and
thus they can take on equal lengths.
– Firmly screw the bottom hexagon nuts (3) against the motor base plate.
– Regularly observe the drive during the first operating hours.
– Re-tension the V-belts in idle, for the first time after the run-in time (24 hours);
this enables the initial elongation to be taken on.
Note: After the run-in time the inspection or maintenance intervals for belt
pretension can be extended. Checks and possible re-tensioning are required
only once per month. For detailed information see chapter 6.4 Third-Party Doc-
umentation, page 231.

4 Maintenance
4.11.9 Checking the Water Cooling on the Feed Housing, Gear Unit
and Filter
Feed housing, gear unit, as well as optional extruder motor and extruder screw are
cooled with water. The cooling water is supplied via the cooling water distributor as-
sembled on the extruder with central connection (see dimensioned drawing – cool-
ing water distributor chapter 5 Drawings, Forms and Customer Service, page 209)
Note: Special versions are possible, deviating designs are shown in the dimen-
sioned drawing. For the dimensions of the connections, see the dimensioned
drawing and the installation plan (see chapter 5 Drawings, Forms and Custom-
er Service, page 209), for water quality, see the Operating Instructions, chap-
ter Technical Data.
– Check the water flow on the outlet side with a transparent hose or with a flow
meter (not included in the STC Spinnzwirn scope of delivery).
– Open the valves and shut-off taps.
– Check whether water flows out of the discharge hose.
4.11.10 Checking Devices for Temperature and Pressure Regulation

Prerequisite: The line is switched on.
Note: A malfunction of the controller, the heating band, or the fan is indicated
on the visualisation.
• Checking Heating Zones and Temperature Sensors in Automatic

Mode
– On the control desk, set the temperature of the heating zones so that the tem-
perature for the heating zone to be tested can be achieved (heating/cooling).
Note: The actual values and the setpoints of the heating zone have to become
equalized.
– If the actual values and target values are not the same, for the individual heating
zones, measure the heating currents to determine whether the heating zone or
the temperature sensor is defective.
– Replace defective heating zones or defective temperature sensors on the extrud-

er.
– Check the temperature sensors for correct seat.
• Checking Heating Zones and Temperature Sensors in Manual

Mode
Note: See the Service Book for the PC of the line in chapter 2.9, main menu "Ser-
vice", sub-menu "Manual mode" for details.

4 Maintenance
DANGER Overheating, explosion of the extruder! Life-threatening danger!

► Never check the heating zones without temperature sensor.
► Never check the heating zones for longer that 2 minutes.
– Click [Manual mode].
– Set the output value to 100%.

4 Maintenance
4.11.11 Checking the Air Cooling

• Checking the Function of the Fans

– Reduce the temperature setpoints via the heating zone controllers of the visual-
isation to values significantly below the actual values (see on-line help or the Ser-
vice Book for the PC of the line)
Note: The fans must start up. If the blowers do not start up, replace the fans,
see chapter 4.11.22 Replacing the Fan, page 95.
CAUTION Burns due to out-flowing hot air on the vent slots of the cylinder
cover!
– Check the allocation of the fans to the heating zone.
– Check the direction of rotation of the fans.
• Checking Cooling Mode

CAUTION Burns due to out-flowing hot air on the vent slots of the cylinder
cover!
– Check the infeed air and exhaust air flow paths for free air flow.
– Remove contaminants.

4 Maintenance
4.11.12 Checking the Direction of Rotation of the Gear Unit

WARNING Danger of Injury Due to Wrong Direction of Rotation of the Gear
Unit!
Pressing hot melt and gases out of the funnel housing!
► Never let the extruder run in the wrong direction of rotation!
► Check the direction of rotation.
Note: You can check the direction of rotation with the extruder screw removed
or installed.
NOTICE
► If the extruder screw is installed, the extruder must be heated up before
switching it on (see Operating Instructions, chapter, Heating up the line).
► With an installed extruder screw, never operate the extruder without
material!
► Without an installed extruder screw, operate the extruder without mate-
rial only for a short time and at the lowest rotational speed level.
► Disconnect the motor from the gear unit if the extruder is to be operated
without an installed extruder screw for a longer period of time.
– Switch on the extruder drive on the op-

erating panel +P01.
– Check whether the driven shaft rotates 1

in the direction shown on the gear unit
(1).
Note: If the driven shaft does not rotate

in the indicated direction, you must re-
verse the motor polarity.
– Switch off the extruder drive on the op-
erating panel +P01.

4 Maintenance
4.11.13 Running the Extruder Empty
NOTICE
► Never operate the extruder without material for a longer period of time!
– Close the material feed on the feed

housing (1).
Note: With decreasing pressure (with

pressure control switched on) the ex-
truder is automatically ramped down to
a lower rotational speed. A short-term 1
increase of rotational speed can occur.
Should the extruder operate at the low
rotational speed for a longer period of
time, a warning message (material
shortage) will be displayed on the vis-
ualisation and the signal column output
an alarm (visual and acoustic).
– Check whether the draw-in area is completely emptied.
– If the draw-in area is not completely emptied, run the draw-in area empty in
manual mode (see online help or Service Book of the PC of the line).
Note: Draw-in areas that are not run empty can cause draw-in difficulties when
starting up again.
– Switch off the extruder drive on the operating panel +P01.

4 Maintenance
4.11.14 Disassembling the Extruder Screw

Prerequisite: The extruder must be run empty, see chapter 4.11.13 Running
the Extruder Empty, page 79.
NOTICE
► When the extruder has cooled, prior to pushing out the extruder screw,
switch on the heating on operating panel +P01 and heat up the extruder
to operating temperature.
► Wait approx. 2-3 hours until the barrel is heated up. Then you can start
disassembling the extruder screw.
► Use the provided screw push-out device to push-out the extruder screw.
The push-out device is designed in such a manner that disassembly of the
extruder screw can take place immediately after emptying of the extruder.
In this case the melt residues are viscous, so that the extruder screw can
be pushed out of the barrel with relative ease.
► Have a suitable hoist on hand to take up the extruder screw.
CAUTION Scalding, burn injuries due to hot surface!

► Never touch extruder components and emerging melt without protective
equipment!
– Disassemble the extrusion die, see chapter 4.15.3 Disassembling the Slot Die,
page 115.
– Disassemble the deflection, see chapter 4.14.3 Disassembling the Deflection,

page 111.
– Disassemble the melt pump, see chapter 4.12.4 Disassembling the Melt Pump
from the Line, page 103.
– Disassemble the adapter system and filter.
– Move the cooling bath downward and move it out of the production line.
Note: The extruder screw can be pushed out without disassembling the cover
of the belt drive.

4 Maintenance
– optional: Disassemble the internal

screw cooling (1).
– Ensure that in front and in back of the

extruder in the direction of the longitu-
2 3
dinal barrel axis, adequate space is
available for the push-out extruder
screw (2) and for the screw push-out
device (3).
Note: The required minimum values are

shown in the dimensioned drawing, see
chapter 5 Drawings, Forms and Custom-
er Service, page 209.
– Unscrew the bottom fastening screw

(6) of the covering plate on the belt cov-
er
4
– Swing the protective disc (4) on the belt
cover upward
Note: Now, you can freely access the

driven shaft and are able to push the
ejection device into the driven shaft. 5

4 Maintenance
– Remove the plug (5) on the driven shaft (vacuum seal)
– Fasten the receptacle element (7) with the bayonet catch on the extension of the
driven shaft (6).
– Slide the threaded spindle (9) with the first extension piece (4) into the opened
nut (10).
– Close the nut by swinging the lever (8) 180°.
– Slide the retaining bracket (11) upward.
– Press out the extruder screw by turning the retaining clip clockwise, segment by
segment.
– Through changeover, support the retaining bracket (11) against twisting on the
gear unit housing or on the frame.
– Turn the extruder screw by hand.
Note: The threaded spindle now moves into the barrel and pushes out the ex-
truder screw.
– Let the threaded spindle (9) run-in to the outer edge of the retaining bracket.
– Take off the retaining bracket (11).
– Open the nut (10) by turning back the lever (8).
– Pull out the threaded spindle (9).
– Slide in a second extension piece (5).
– Slide the threaded spindle back in.
– Close the nut (10).
– Slide the retaining bracket (11) upward and prop it up so that it cannot twist.
Note: Take up the extruder screw when pushing out after approx. 1/3 of the
length and 2/3 of the length with a suitable lifting tool and non-metallic rope.
– Proceed as previously described until all extension pieces are fitted on.
– Pull the threaded spindle (9) with extension piece out of the extruder.
– Pull out the extruder screw.

4 Maintenance
4 5 6 7
11 10 9
Fig.. 4–3: Push out the extruder screw (example)

4 Maintenance
4.11.15 Cleaning the Extruder Screw

Note: Clean the removed extruder screw in hot condition.
equipment!
– Clean the extruder screw with the following tools:
• Brass wire brush
• Scraper made of brass / aluminium / copper (not included in STC Spinnzwirn

scope of delivery)
• Mesh-wire pad made of copper (not included in STC Spinnzwirn scope of de-
livery)
• Polishing wheel and paste (not included in STC Spinnzwirn scope of delivery)
– Grease the shank of the extruder screw with solid grease (see chapter 4.11.1
Maintenance Schedule – Extruder, page 69 for the lubricant and quantity).
4.11.16 Cleaning the Extruder Barrel Bore

Note: Clean the extruder barrel bore in hot condition.
equipment!
– For cleaning, use a semicircular scraper made of aluminium or brass fastened on
a rod that matches the bore diameter (not included in the STC Spinnzwirn scope
of delivery).
– When introducing the scraper in the barrel, align it upward.
– Turn the scraper in the barrel downward and pull it out with the residual melt.
– Repeat this procedure several times.
– Brush out the barrel with a brass or copper brush that matches the bore.
– After cleaning, lubricate the barrel bore with silicone oil (see chapter 4.11.1
Maintenance Schedule – Extruder, page 69 for lubricant and quantity).

4 Maintenance
4.11.17 Assembling the Extruder Screw
NOTICE
► Lubricate the screws and fitting surfaces with temperature-resistant-
grease, see chapter 6.2 Comparison List of Lubricants, WN912, page 227.
► Comply with specified tightening torques, see chapter 5.2 Drawings,
page 211.
CAUTION Hand injuries due to entanglement!

► When assembling the extruder screw, do not reach into the feed opening.
► Seal the feed opening.
Note: The Assembly of the extruder screw occurs at ambient temperature
without heating up the extruder.
– Grease the shank of the extruder screw with high-temperature compound, e.g.
Unimoly HTC Metallic Paste from Klüber.
– Use a non-metallic rope and appropriate hoist.
– Slide the extruder screw into the barrel to the return thread.
– Check horizontal position of the extruder screw with a spirit level.
– Correct the position of the extruder screw.
NOTICE The extruder screw must not tilt inside the cylinder. The gap between
extruder screw and barrel must have a uniform gap dimension. Never use
force to drive in the extruder screw.
– Lightly moisten the lands of the extruder screw with silicone oil.
Note: To facilitate assembly there is a

1
marking (notch) (2) on the rear of the
driven shaft of the gear unit. This mark-
ing indicates the position of the feather
key (1) in the shaft.

4 Maintenance
– Move the gear unit so that the marking is pointing up.
– Carefully introduce the extruder screw into the gear unit driven shaft until the
tangible stop.
– Ensure that the feather key on the shank of the extruder screw points upward,
so that feather key and feather key groove are guided into each other.
– Check the correct position of the ex-

truder screw via the dimension X, see
extruder dimensioned drawing, chap-
ter 5 Drawings, Forms and Customer
Service, page 209.
– Grease the barrel connection flange

with solid grease (see chapter 4.11.1
Maintenance Schedule – Extruder,
page 69 for lubricant and quantity).
– Re-insert the plug in the driven shaft

(vacuum seal). X
– Assemble the adapter system and fil-
ter.
– Assemble the melt pump, see chapter 4.12.6 Installing the Melt Pump in the Line,
page 106.
– Assemble the deflection, see chapter 4.14.4 Assembling the Deflection,

page 112.
– Assemble the extrusion die, see chapter 4.15.4 Assembling the Slot Die,
page 116.
• Connection on the Barrel Outlet

Note: The connection on the barrel out-
let occurs with the assemblies intended
for the delivered line.

4 Maintenance
NOTICE Prior to connecting, ensure that the centring elements are free of
contamination and that the sealing surfaces are not damaged.
– Insert the connecting screws with high-temperature compound, e.g. Unimoly
HTC Metallic Paste, Klüber.
– After concluding the installation of the connection piece, assemble the measur-
ing devices.
– Use stud bolts with washers and nuts for the flange connection.
– Use a torque wrench to tighten the

nuts in three steps in a cross pattern
(see Fig.) at ambient temperature until
final torque is reached.
– After establishing all flange connec-

tions check the gap between the con-
nections for uniformity.
– Eliminate all deviations through a 10%

higher torque at the appropriate point.

4 Maintenance
4.11.18 Replacing the Feed Bushing

Prerequisite: Cooling water must be turned off.
– optional: Disassemble the internal screw cooling.
– Disassemble the cover (5) on the feed area.
– Disassemble the extruder screw (10), see chapter 4.11.14 Disassembling the Ex-
truder Screw, page 80).
– Disassemble the heating band on the feed housing (4), see chapter 4.11.21 Re-
placing Heating Band, page 92.
– Remove the threaded fittings from the water inflow and water outflow on the
feed housing.
– Remove the fastening screws (9).
– Remove flange (7) from the stuffing box housing (6).
– Slide the flange in the direction of the gear unit (8).
– Disassemble the stuffing box housing (6) with the stuffing box packing elements,
see chapter 4.11.19 Replacing Stuffing Box Packing, page 90.
– Remove the connecting screws (1) for the barrel.
– Use the push-off thread (2) to push the feed housing (4) out of the guide.
– Slide the feed housing (4) back in the direction of the gear unit.
– Lift the feed housing (4) upward and out.
– Disassemble the feed bush (11) by removing the screws (3).
– Replace the feed bush (11).
Note: Tighten the screws in a crosswise sequence in several steps until the re-
quired tightening torque is reached. For the tightening torques of the fasten-
ing screws, see chapter 6.1 Tightening Torques, page 219.

4 Maintenance
– Assemble the feed bush (11) with the screws (3) on the feed housing (4).
– Slide the feed housing (4) into the guide of the housing.
– Pull the feed housing (4) into the guide with the connecting screws (1).
– Assemble the stuffing box housing (6) and the flange (7), see chapter 4.11.19 Re-
placing Stuffing Box Packing, page 90.
– Assemble the extruder screw (10), see chapter 4.11.17 Assembling the Extruder
Screw, page 85).
– Establish the water connections.
– Screw the cover (5) onto the feed area.
– optional: Assemble the internal screw cooling.
3 4 5 6 7
1.2
11 10 9
Fig.. 4–4: Replacing the feed bush (example)

4 Maintenance
4.11.19 Replacing Stuffing Box Packing

– optional: Disassemble the internal screw cooling.
– Disassemble the cover plate (1) between the feed opening and gear unit (7).
– Slide the shank of the extruder screw forward to the feed opening.
– Remove the fastening screws (4).
– Slide the flange (5) in the direction of the gear unit (7).
– Unscrew the fastening screws (2), several turns.
Note: The stuffing box packings (6) slacken.

– Completely unscrew the fastening screws (2).
– Take the stuffing box housing (3) with stuffing box packing (6) and the cup
springs (8) upward and off.
– Replace the stuffing box packing (6).
Note: Each individual packing ring must be pressed in separately.

– Insert the stuffing box housing (3) with pre-assembled stuffing box packing (6)
and the cup springs (8) into the feed housing.
NOTICE Ensure that the cup springs are arranged properly.

– Lightly fasten the stuffing box housing with the screws (2).
– Slide the flange (5) back to the stuffing box housing (3).
– Lightly fasten the flange with the screws (4).
– Assemble the extruder screw, see chapter 4.11.17 Assembling the Extruder
Screw, page 85.
– Firmly tighten the flange connection (2 and 4).
Note: The stuffing box packing tenses.

– Screw on the cover (1).
– optional: Assemble the internal screw cooling.

4 Maintenance
1 2 3 4 5
Fig.. 4–5: Replacing the stuffing box packing (example)

4 Maintenance
4.11.20 Replacing Feather Keys in the Driven Shaft of the Gear Unit
Prerequisite: The feed housing must be disassembled (see chapter 4.11.18 Re-
placing the Feed Bushing, page 88) and the stuffing box packing must be disas-
sembled (see chapter 4.11.19 Replacing Stuffing Box Packing, page 90).
Note: There are two feather keys in the extruder to take the extruder screw
into the gear unit driven shaft.
– Disassemble the cover of the feed
housing.
– Unscrew the fastening screws (1).
– Replace the feather keys.
– Firmly tighten the fastening screws (1).

1
– Assemble the cover of the feed hous-
ing.
1
4.11.21 Replacing Heating Band

equipment!
Note: If a heating zone or a heating band fails, replace the band as described
below:
– Open the barrel enclosure (1).
– Check the individual heating bands of 1

the switched off zone.
– Remove the electrical supply cables in

the terminal box of the defective heat-
ing band

4 Maintenance
• Replacing the Heating-Cooling Combination With Fan

– Disassemble the heating temperature
sensor and the radial fan (4).
– Remove the clamp screws (2) of the in-

sulation.
– Unscrew the fastening screws of the

two heating half-shells (3). 2
– Removing the heating half-shells. 3

Note: Assembly of the new heating-
cooling combination is executed in the
reverse sequence. 4
– Use pan head cap screws to tighten the

cup springs (or spiral springs) between the heater half-shells, all the way.
– Check the heater blocks for firm and uniform seat.
• Replacing Heater Bands on the Barrel

– Provide space for replacing the heating
band by removing the barrel enclosure
and the inner cooling baffle.
– Disassemble the heating temperature 5

sensor.
– Remove the clamp screws (5) of the

heating band.
– Replace the heating band.
Note: Assembly of the new heater band

is executed in the reverse sequence.
– Use clamp screws to tighten the cup
springs (or spiral springs) between the heating band half-shells, all the way.
NOTICE When assembling, do not knock the heating bands.


4 Maintenance
• Replacing Heating Bands on the Adapter

– Disassemble the heating temperature
sensor.
– Remove the clamp screws (6) of the

heating band.
– Replace the heating band. 6

Note: Assembly of the new heater band 6
is executed in the reverse sequence.
– Use clamp screws to tighten the cup
springs (or spiral springs) between the
heating band half-shells, all the way.
NOTICE When assembling, do not

knock the heating bands.
– Assemble the barrel enclosure (1).

4 Maintenance
4.11.22 Replacing the Fan

equipment!
– Disassemble the barrel enclosure.
– Take off the upper cooling baffle in the

inner covering.
– Remove the front cooling baffle.
– Detach the rear cooling baffle and slide

it to the back wall.
– Lift the dummy sheet out of the an-

choring and slide it in the direction of
the rear wall.
1
– Take the dummy sheet and the fan out
to the free side between frame and
heater block.
– Unscrew the fastening screws (1) of the fan.
Note: Assembly of the new fan is executed in the reverse sequence.

– Assemble the barrel enclosure.
– Check the direction of rotation of the fan.

4 Maintenance
4.11.23 Assembling / Disassembling the V-Belt Pulley without Taper

Bushes
• Assembling the V-belt pulleys

– Clean the bare surfaces.
– Lightly grease the cleaned surfaces, ex-

cept for the wedge flanks.
– Slide the V-belt pulley onto the shaft to

the stop.
– Fasten the V-belt pulley with washer

and thread lock.
• Detach V-belt Pulleys

– Use a pull-off device to take off the V-
belt pulleys.
4.11.24 Assembling / Disassembling the V-belt Pulley with Taper

Bushes
• Assembling the V-belt pulleys

– Clean and grease all bare surfaces.
– Fit pulley and bush into each other.
– Line up the holes.
– Loosely screw in the screws.

4 Maintenance
– Slide the pulley with bush onto the

shaft.
– Align the pulley with bush on the shaft.
– Firmly tighten the screws uniformly.
• Disassembling the V-belt pulleys

– Unscrew the screws.

4 Maintenance
– Screw a screw as push-off screw with

half thread into the hole in the bush.
– Tighten the screw.
Note: This detaches the taper-lock

bush.
– Take off the pulley unit that has be-

come loose by hand, without impact
and without damaging the machine.
4.11.25 Instructions for Replacing the Drive Motor

page 231.
NOTICE Comply with the instructions on motor identification provided in
chapter 4.8 Replacing Inverters, Temperature Controllers, Drives, etc.,
page 67.

4 Maintenance
4.11.26 Adjusting the Extruder

Note: The connecting flange of the barrel, as well as the screw-on surface of the feed
opening, serve as the measuring basis for adjusting.
– Use an optical adjusting device.
– When adjusting ensure that the ex-

truder is positioned horizontally in the
barrel axial direction and at right an-
gles to the barrel axis.

4 Maintenance
4.12 Maintenance – Melt Pump with Drive
1 4
Fig.. 4–6: Melt pump with drive
1 Melt pump 4 Temperature sensor with safety device

for temperature monitoring
2 Cardan shaft with safety device: fixed 5 Pump insulation (not shown)
cover of the rotating drive parts (not
shown)
3 Gear motor behind cover
4.12.1 Maintenance schedule – Melt Pump with Drive
Maintenance
interval
Melt pump See third-party Service technician

documentation – Clean
– Service
Gear motor See third-party Service technician

documentation – Clean
– Service
Flexible shaft See third-party Service technician

documentation – Lubricate the flexible shaft with Berutox FH28KN (Bechem)
– Replace the entire quantity of the old grease.
Note: The different lubricants and their manufacturers are listed in the provid-
ed comparison list of lubricants, see chapter 6.3 Comparison List, Heat Trans-
fer Oils, page 229.
4 Maintenance
4.12.2 Safety
! WARNING
Pump parts and adapter parts tipping over or falling down.

Danger of Injury
► Secure pump parts and adapter parts with suitable hoists, for:
• Assembly
• Disassembly
• Transport
! WARNING
Hot melt spraying out under high pressure!

Severe injuries, scalding

► Have a metal collection container on hand for polymer drips.
! CAUTION
Hot Surfaces!
Burn injuries

⦸ Do not touch pump parts or melt without protective equipment.
4 Maintenance
4.12.3 Preparing Melt Pump for Disassembly from the Line

Note: For easier disassembly and more effective cleaning of the individual
pump parts (pinions, bearing bushings, etc.), the pump is disassembled in hot
condition. Because the adhering melt is highly viscous and solidifies if the
pump temperature is too low, to the extent possible, prevent cooling of the
pump during the disassembly process. Have all tools and hoists on hand, to en-
able fast disassembly.
WARNING Danger of Injury Due to Hot Melt Spraying Out!

► Prior to starting disassembly tasks, ensure that the interior of the pump is
depressurised.
► Prior to starting the disassembly tasks, shut the gate valves in the pres-
sure lines upstream and downstream of the melt pump.
► Pay attention to the pressure monitoring devices.
NOTICE
Protect the disassembled, hot pump parts against fast and one-sided cooling, in
particular, (e.g. by placing them in transport containers with hardwood floors), to
prevent the parts from being damaged through thermal tensions.
Comply with the instructions concerning storage of the pump and the pump
drive.
Note: Comply with the instructions on safety, transport, and disassembly pro-
vided by the manufacture, see chapter 6.4 Third-Party Documentation,
page 231.
– Remove the drive covers .
WARNING Injuries due to lateral tilt-

ing or falling of the flexible shaft.
1
► Attach a suitable hoist before
unscrewing screws and removing
the flexible shaft.
► Secure the flexible shaft to prevent
it from slipping apart.
4 Maintenance
– Loosen the screws .
– Disconnect the drive flange of the flexible shaft from the hub .
– Pull the temperature sensor out of the pump.
4.12.4 Disassembling the Melt Pump from the Line

Prerequisite: The flexible shaft must be disassembled, see chapter 4.12.3 Pre-
paring Melt Pump for Disassembly from the Line, page 102.
WARNING Danger of Injury Due to Hot Melt Spraying Out!
CAUTION Burn injuries due to hot surfaces!
► Do not touch the heating plates without protective equipment.
NOTICE
Support the deflection before removing the pump.
4 Maintenance
– Remove the connecting cable of the

heating plates.
WARNING Injuries due to lateral tilt-

ing or falling of the adapter or of the
die.
► Attach a suitable hoist before 1
unscrewing the screws.
– Remove the screws between the de-
flection flanges and the product flang-
es of the pump.
– Separate the flanges from each other.
– Slide the die unit with deflection away from the pump.
– Remove the nuts (1).
– Transport the pump with a suitable hoist.
4 Maintenance
4.12.5 Disassembly of The Drive

WARNING Danger of Injury Due to
Lateral Tilting or Falling of the Flexible
Shaft!
► Prior to removing the screws and
removing the flexible shaft, attach a
suitable hoist.
– Disassemble the flexible shaft 4.12.3
Preparing Melt Pump for Disassembly
from the Line, page 102.
1
– Remove the electrical connections of
the gear motor .
– Remove the screws . 2
– With a suitable hoist, lift the gear mo- 3

tor out of the extruder frame.
4 Maintenance
4.12.6 Installing the Melt Pump in the Line
NOTICE
page 211.
– Fasten the bracket (1) on the pump .
– Lift the pump with heating plates into

the line with a suitable hoist. 1
– Fasten the pump with the cup springs,
washers and nuts (2) on the sliding 2
plates and on the frame. 3
– Initially tighten the screws (2) tight

enough that the cup springs are com-
pletely pressed together.
– Loosen the nuts (2) 1/2 turn.
– Slide the die unit with deflection onto the pump.
– Fasten the deflection to the pump with flange screws.
– Carefully align the flanges of the pump to the mating flanges of the line via the
centring edge.
– Fasten the pump to the flange of the intermediate piece with screws.
– Tighten the screws crosswise and incrementally with controlled torque.
– Connect the connecting cable of the heating plates.
– Attach a contact safety device around the pump.
4 Maintenance
4.12.7 Assembling the Drive
NOTICE
• When installing the drive, ensure that the pinion shaft of the pump and the
driven shaft of the motor are axially parallel.
• The driven shaft of the motor and the pinion shaft of the pump must be off-
set in such a manner that the flexible shaft shows an angle of approx. 3°.
Note: Comply with the instructions in the chapter Transport, see Operating In-
structions, as well as the third-party documentation, see chapter 6.4 Third-
Party Documentation, page 231.
– With a suitable hoist, lift the gear mo-
tor into the extruder frame.
– Fasten the gear motor with the screws

.
DANGER Electrical shock due to life-

threatening high voltage!
► For tasks on electrical equipment,
comply with the 5 safety rules.
1
– Attach the electrical connections of the
gear motor .
– Insert the temperature sensor into the

2
pump.
WARNING Injuries due to lateral tilt- 3

ing or falling of the flexible shaft.
► Prior to assembling the flexible shaft, attach an appropriate hoist.
► Secure the flexible shaft to prevent it from slipping apart.
4 Maintenance
– Position the drive flange of the flexible

shaft (6) on the hub (4).
– Firmly tighten the screws (5). 7

– Assemble the drive cover (7).
4.13 Maintenance – Filter

page 231.
4 Maintenance
4.14 Maintenance – Adapter System
1 2 45 6 7 8 9
Fig.. 4–7: Adapter system
1 Extruder flange 6 Melt pump with temperature sensor
2 Spacer 1 with cylinder heater 7 Cylinder heater
3 Screen changer 8 Deflection
4 Temperature sensor / resistance ther- 9 Temperature sensor / resistance ther-

mometer / measuring sensor with safe- mometer / measuring sensor with safe-
ty device: Pressure monitoring, ty device: Pressure monitoring,
temperature monitoring temperature monitoring
Optional bursting disc Optional bursting disc
5 Spacer 2 with cylinder heater 10 Safety device: Adapter insulation (not

shown)
4.14.1 Safety
4 Maintenance
! WARNING
Line under pressure, ejection of hot melt and gases if pressure in con-
duits is not completely dissipated!
Danger of Injury
► Only remove flange connections when the line is depressurised and de-
energised.
► Only replace filters, pressure sensors and melt temperature sensors when
the line is depressurised and de-energised.
! CAUTION
Hot Surfaces!
Burn injuries

⦸ Do not touch filter and adapter without protective equipment.
4.14.2 Replacing Heating Bands on the Adapter

DANGER Life-threatening High Voltage!
► Only have service technicians with electrical engineering training perform
tasks on electrical equipment.
► Comply with the 5 safety rules.

► Do not touch filter and adapter without protective equipment.
– Disassemble the insulation.
– Disconnect the supply cable on the respective heating band.
– Unscrew the sensor, see chapter 4.5 Replacing the Measuring Sensor, page 55.
– Detach the heating band.
Note: For non-contiguous heating bands, remove the fastening screws.
4 Maintenance
– Remove the heating band.
– Fasten the new heating band
Note: For non-contiguous heating bands, assemble the fastening screws.

– Check whether heating bands are seated firmly and uniformly.
– Tighten the screws hand tight.
NOTICE Do not grasp or knock on the heating bands when installing them.
– Connect the supply cable of the respective heating band.
– Fasten the sensor, see chapter 4.5 Replacing the Measuring Sensor, page 55.
– Insulate the adapter.
4.14.3 Disassembling the Deflection

Note: To facilitate disassembly, the deflection must be disassembled while hot.
Because the adhering melt is highly viscous and solidifies if the temperature
istoo low, cooling of the deflection must be avoided during the disassembly
process.
1 2 3
Fig.. 4–8: Deflection example
– Remove the electrical connections for the pressure and temperature sensors as
well as the cylinder heaters (2).
– optional: Disassemble the pressure and temperature sensors, see chapter 4.5
Replacing the Measuring Sensor, page 55.
– Attach a suitable hoist to the deflection.
– Remove the fastening screws (3) from the deflection on the die side.
– Remove the fastening screws (1) from the deflection on the melt pump.
– Set the deflection down on a temperature-resistant surface.
4 Maintenance
4.14.4 Assembling the Deflection
NOTICE
page 211.
1 2 3
Fig.. 4–9: Deflection example
– Attach a suitable hoist to the deflection.
– Lift the deflection into the line.
– Clean the sealing surfaces of the deflection, die and melt pump.
– Align the deflection between the die and the melt pump.
– Assemble the deflection on the melt pump with the fastening screws (1). Comply
with the specified tightening torques, see chapter 5.2 Drawings, page 211.
– Assemble the deflection on the die side with the fastening screws (3). Comply-
with the specified tightening torques, see chapter 5.2 Drawings, page 211.
– optional: Assemble the pressure and temperature sensors, see chapter 4.5 Re-
placing the Measuring Sensor, page 55.
– Connect the electrical connections for the pressure and temperature sensors as
well as the cylinder heaters (2).
4 Maintenance
4.15 Maintenance − Slot Die

page 231.
4.15.1 Safety
! WARNING
Line under pressure, ejection of hot melt and gases if pressure in the slot
die is not completely dissipated!
Danger of Injury, Scalding
► Prior to starting disassembly tasks, ensure that the interior of the slot die
is depressurized
energised.
! CAUTION
Hot Surfaces!
Burn injuries

► To prevent burns due to slipping, only use tools that are in proper working
order.
⦸ Do not touch the slot die or emerging melt without protective equipment.
4 Maintenance
4.15.2 Preparing Slot Die for Disassembly

Note: In order to facilitate disassembly and render cleaning of the individual
die parts more efficient, the slot die must be disassembled in hot condition. Be-
cause the adhering melt is highly viscous or solidified if the die temperature is
too low, to the extent possible, prevent cooling of the slot die during the disas-
sembly process.
WARNING Danger of Injury Due to Ejection of Hot Melt and Gases if Pressure
in the Slot Die is Not Completely Dissipated!
► Prior to starting disassembly tasks, ensure that the interior of the slot die
is depressurized
WARNING Hand and arm injuries due to rotating components!

► Ensure that the drives of the extruder, melt pump, and heating system are
electrically switched off and are safeguarded from being switched on
again.
► Disassemble the slot die only after the rotating parts of the line have come
to complete standstill.
.
NOTICE
► Prior to disassembly, attach a suitable hoist to the slot die to prevent it
from falling down or tilting sideways.
► Protect the disassembled, hot slot die parts against fast and one-sided
cooling, in particular, (e.g. by placing them in transport containers with
hardwood floors), to prevent the parts from being damaged through ther-
mal tensions.
► Comply with the instructions concerning storage, see Operating Instruc-
tions.
– Have all tools and hoists on hand, to enable fast disassembly.
– Move the cooling bath downward.
– Release the arrest of the cooling bath.
– Push the cooling bath out of the production line.
– Arrest the cooling bath.
– Switch off the heating zones of the slot die.
4 Maintenance
4.15.3 Disassembling the Slot Die

Prerequisite: The slot die must be prepared for disassembly (see chapter 4.15.2
Preparing Slot Die for Disassembly, page 114).
WARNING Danger of Injury Due to Ejection of Hot Melt and Gases if Pressure
in the Slot Die is Not Completely Dissipated!
energised.
WARNING Burn injuries due to hot surfaces!
► To prevent burns due to slipping, only use tools that are in proper working
order.
– Remove the electrical connections of

4 5 5
the slot die (1).
– Fasten a suitable hoist on the slot die

or the crossbeam (3)
– Remove the screws of the slot die on

3
the adapter (2)
– Remove the screws (5) of the cross-

beam in the take-off frame (4) (Illustra-
2
tion similar).
1
NOTICE When lifting, lowering, trans-
porting or setting down the slot die, en-
sure that the edges of the nozzle lips, cables, and sealing surfaces are not
damaged.
– Lift the slot die upward and out of the take-off frame with a crane on the cross-
beam
CAUTION Hot escaping melt at disassembly and transport of the slot die!
Burns, scalding!
► Set down the slot die in such a manner that it cannot tip over, to prevent
melt from running out.
4 Maintenance
4.15.4 Assembling the Slot Die

NOTICE Clean all components that come into contact with melt upstream of
the slot die to remove contamination and metal particles (e.g. welding beads).
– Carefully clean the sealing surfaces between adapter (2) and slot die (1).
NOTICE When lifting, lowering, transporting or setting down the slot die, en-
sure that the edges of the nozzle lips, cables, and sealing surfaces are not dam-
aged.
– Lower the slot die (1) into the take-off
4 5 5
frame (4), from above with a crane
– Install the traverse (3) in the take-off

frame with the fixing screws (5).
– Remove the hoist.

3
2
1
– Use the adjusting nuts (7) to align the

sealing surface of the slot die with the 7
sealing surface of the adaptor (2) (sim-
7
ilar to the figure).
NOTICE Ensure uniform tension of the

crossbeam (3) and threaded rods (6). Do 6
not tilt. The fixing screws on the adap-
tor must be easy to install.
– Uniformly tighten the fastening screws 3
incrementally, for tightening torque
see chapter 6.1 Tightening Torques,
page 219.
– Install the electrical connections on the slot die, see circuit diagram/Service Book
for the electrical system.
– Move the cooling bath into the production line and arrest it in place.
4 Maintenance
4.16 Maintenance – Cooling Bath
1 2 3 4 5 6 7
16 15 14 13 12 11 10
Fig.. 4–10: Cooling bath
1 Drain pipe 9 Running wheels, safety device:

Protective covers of the running wheels
2 Residual moisture nozzle 10 Guide rail
3 Water scraper 11 Chain drive for height adjustment
4 Trough 12 Drive motor
5 Valve to drain water 13 Safety device: Arresting device
6 Scraper 14 Water inflow with hose nozzle
7 Overflow gutter with screen 15 Adjusting spindle
8 Guide tube 16 Overflow trough
4 Maintenance
4.16.1 Maintenance Schedule – Cooling Bath
Maintenance
interval
Cooling bath when required Service technician

– Check the cooling bath for leaks.
– Clean the cooling bath if there is silt formation, see chapter 4.16.3
Cleaning the Cooling Bath, page 119.
– Refill the cooling bath.
Temperature sen- Monthly Service technician

sor – Check the function of the temperature sensor, see chapter 4.16.7
Checking the Temperature Sensor, page 121.
– Replace the defective temperature sensor.
Water inflow and Monthly Service technician

outflow – Check the water connections for leaks.
Hose line Monthly Service technician

– Check the status of the hose lines.
– Replace defective hose lines.
Screens when required Service technician

– Clean the screens of the overflow channels, see chapter 4.16.4 Clean-
ing the Screens, page 119.
Drive motor See third-party Service technician

documentation – Execute cleaning and maintenance as specified in the third-party doc-
umentation.
Chain for height after 7200 hours Service technician

adjustment – Check the status of the chain.
– Replace the defective chain, see chapter 4.16.6 Replacing the Chain
for the Height Adjustment, page 120.
4.16.2 Safety
4 Maintenance
4.16.3 Cleaning the Cooling Bath

– Close the water supply from the cooling device.
– Use the water inflow line from the cooling device to the cooling bath to drain the
cooling water out of the cooling bath.
– Open the ball valve on the cooling bath and let the water drain out of the cooling
bath.
– Disassemble the covering of the cooling water distribution on the bottom of the
trough.
– Clean the cooling bath.
– Assemble the covering of the cooling water distribution on the bottom of the
trough.
– Close the ball valve on the cooling bath
– Open the water supply from the cooling device.
4.16.4 Cleaning the Screens

Note: You can clean the screens while the water is being filtered.
– Take the screens out of the overflow trough.
– Clean the screens.
– Insert the screens into the overflow trough.
4.16.5 Checking the Cooling Bath

– Fill the cooling bath with water.
– Check the cooling bath for leaks.
– Check the hose lines and water connections for leaks.
4 Maintenance
4.16.6 Replacing the Chain for the Height Adjustment

switched back on.
– Disassemble the side coverings on the cooling bath.
– Open the chain lock.
– Remove the defective chain.
– Loosen the lateral roller chain sprockets (1).
– Place a new chain over the corner roller chain sprockets (2) and lateral roller
chain sprockets (1).
– Close the chain lock.
– Tension the chain with the lateral roller chain sprockets (1).
– Assemble the side coverings.
1 2 1 1 2
1
3
2
Fig.. 4–11: Replace the chain for height adjustment - illustration similar
4 Maintenance
4.16.7 Checking the Temperature Sensor

– Change the setpoint specification for temperature on the visualisation, see Ser-
vice Book for the PC of the line.
Note: Regulation of the temperature must be recognisable.

– Enter the setpoint of the temperature of the cooling bath for the running process
on the visualisation.
4 Maintenance
4.17 Maintenance – Take-Off Device
2 6
7
7
3 7
7
4
4
5
8
Fig.. 4–12: Take-off device
1 Gear motor 5 Rod
2 Frame 6 Pneumatic cylinder
3 Drip tray 7 Residual moisture nozzle
4 Air knives 8 Deflector roll (behind frame)
4 Maintenance
9 10
11
11
12
13
14
Fig.. 4–13: Take-off device
9 Take-off roll and adjustment 12 Film brake
10 Pressure roll 13 Drain plate
11 Water drain channels and drain hose 14 Drip tray
4 Maintenance
4.17.1 Maintenance Schedule – Take-Off Device
Maintenance
interval
Slots of the Monthly Service technician

residual moisture – Clean the slots of the residual moisture nozzles with a brass brush.
nozzles
Radial fan for See third-party Service technician

residual moisture documentation – Execute cleaning and maintenance as specified in the third-party doc-
nozzles umentation.
Water separator See third-party Service technician

documentation – Execute cleaning as specified in the third-party documentation.
Air knives Monthly Service technician

– Clean the air knives.
Radial fan for air See third-party Service technician

knives documentation – Execute cleaning and maintenance as specified in the third-party doc-
umentation.
Pressure roll when required Service technician

– Clean the pressure roll with water/alcohol.
– Check the coating of the pressure roll for damage.
– Replace the pressure roll, see chapter 4.17.10 Replacing the Pressure
Roll, page 128.
Pneumatic cylin- after 7200 operat- Service technician

der ing hours – Check the seals.

documentation. – Execute cleaning and maintenance as specified in the third-party doc-
umentation.
– Check the oil level of the gear unit, see third-party documentation.
Film brake when required Service technician

– Clean the film brake.
– Maintain the film brake.
4 Maintenance
4.17.2 Safety
! WARNING
Entanglement, entrapment, crushing!

Hand injuries
⦸ Never reach between the rollers.
4.17.3 Adjusting Contact Pressure of the Pressure Roll

– Adjust the contact pressure of the rubberised pressure roll via pressure reducing
valve
4.17.4 Setting the Speed

– Set the speed via the visualisation (see online help or the Service Book for the PC
of the line).
4.17.5 Checking the Function of the Drives

– Switch on the drives on the operating panel +P01.
Note: The drives must audibly start-up.
Two methods to switch the drives off must be possible:

– Switch off the drives on the operating panel +P01.
or
– Switch off the drives on the operating panel +OP01.
Note: The drives must stop.
4 Maintenance
4.17.6 Checking the Direction of Rotation of the Rolls

WARNING Hand injuries due to entanglement, entrapment, crushing!
► Never reach between the roller pair
► Wear tight-fitting protective clothing.
– Switch on the drives on the operating panel +P01.
– Close the roller pair on the operating panel +OP01.
– Check whether the rollers turn in such

a manner that the film is pulled-off up-
ward
– If the film is not pulled-off upward re-

verse the polarity of the drive motor of
the take-off roller
– Check the track alignment of the roller

pair with a piece of paper placed be-
tween the rollers
4.17.7 Checking the Function of the Pneumatic System

WARNINGHand injuries due to entanglement, entrapment, crushing!
► Never reach between the roller pair
– Place the pressure roll against the take-off roll by pressing the button on the
+OP01 operating panel.
Note: Pressure roll must rest on the take-off roll.

– Swivel the pressure roll away from the take-off roll by pressing the button on the
+OP01 operating panel.
Note: Pressure roll must pivot away from the take-off roll.
4 Maintenance
4.17.8 Checking the Function of the Air Knives

– Switch on the air knives on operating panel +OP01.
– Check the direction of rotation of the motors.
Note: The air must be blown out.

– Change the polarity of the appropriate motor if the air knives do not function.
4.17.9 Checking the Function of the Residual Moisture Nozzles

– Switch on the residual moisture nozzles on the operating panel +OP01.
– Check the direction of rotation of the motors.
Note: The air must be suctioned in.

– Change the polarity of the appropriate motor if the residual moisture nozzles do
not function.
4 Maintenance
4.17.10 Replacing the Pressure Roll

.
NOTICE
► To prevent damage of the rubberised surface of the pressure roll, do not
use chains or steel wire ropes to transport the pressure roll.
– Fasten a suitable hoist to the pressure roll (1).
– Remove the screws (2) on the flanged bearings on both sides of the pressure roll.
– Lift the pressure roll out of the take-off frame.
– Use a suitable hoist to lift the new pressure roll into the take-off frame from
above.
– Firmly tighten the screws (2) on the flanged bearings.
– Remove the hoist.
1
2
2
Fig.. 4–14: Replacing the pressure roll (example)
4 Maintenance
4.18 Maintenance – Thickness Measuring Device

page 231.
4 Maintenance
4.19 Maintenance – Cutting Device
8
9
3 10
4
5 11
6
1
2 7
12
13
14
15
16
Fig.. 4–15: Cutting device
1 Knife holder 9 Handwheel for knife bar adjustment
2 Blade 10 Worm gear for knife bar adjustment
3 Safety device: 11 Clamping lever

Protective cover
4 Knife bar 12 Overflow rod
5 Handwheel for knife-set infeed 13 Overflow roll
6 Overflow rod 14 Overflow roll
7 Stretcher roller 15 Flap
8 Knife set 16 Overflow roll
4.19.1 Maintenance Schedule – Cutting Device
4 Maintenance
Maintenance
interval
Knife set/ when required Service technician

Blades – Turn the knife set, see chapter 4.19.4 Turning or Replacing the Blades,
page 133.
– Turn the blades, see chapter 4.19.4 Turning or Replacing the Blades,
page 133.
– Replace the blades with a flat-nose pliers, see chapter 4.19.4 Turning
or Replacing the Blades, page 133.

documentation – Execute inspection and maintenance as specified in the third-party
documentation.
4.19.2 Safety
! CAUTION
Sharp blades!
Cutting injuries.
► Wear protective gloves.

► Ensure that the protective hood covers the blades.
⦸ Do not touch the blades of the cutting device.
4 Maintenance
4.19.3 Adjust the knife holder

Note: Optimisation must be undertaken at commissioning or during produc-
tion.
2 2 4 3 2
Fig.. 4–16: Adjust the knife holder
The knife holders (1) of both axes (2) must be on one plane.
– Adjust the blades with the screws (3) and the knurled screws (4), in such a man-
ner that the film can be cut without tearing or warping
4 Maintenance
4.19.4 Turning or Replacing the Blades

Note: During production, turning or replacement of the blades can be under-
taken on the knife set that is not in use.
1 2 3 4 5 6 7 7
9 8
Fig.. 4–17: Turning or Replacing the Blades
CAUTIONSharp blades! Cutting injuries!

► Do not touch the blades of the cutting device.
► Wear protective gloves.
► Use flat-nose pliers to insert the blades.
– Open the protective cover.
CAUTION Falling of the protective cover! Crushing injuries to the hands,

breaking of the blades!
► Always arrest the flipped up protective cover.
4 Maintenance
– Release clamp lever (1 or 3) of the knife set that is not in use (8 or 9)
– Turn knife set that is not in use upward to the stop via the hand wheel (2 or 4)
– Lock the knife set with the appropriate clamping lever (1 or 3).
– Remove the screws (5 and 7).
– Turn or replace the blades (6).
Note: The thickness of the blades and the spacing of the blades determine the
cutting width of the film tapes, see chapter 4.19.5 Calculating the Cutting
Width, page 135.
– Firmly tighten the screws (5 and 7).
– Release the clamping lever (1 or 3).
– Use the hand wheel (2 or 4) to rotate the knife set (8 or 9) downward.
– Bring the knife set into use.
– Firmly tighten the clamping lever (1 or 3).
– Proceed in the same manner with the second knife set.
– Close the protective cover.
4 Maintenance
4.19.5 Calculating the Cutting Width

The cutting width is the dimension for the width of the cut, unstretched film tapes.
The cutting width results from
• the thickness of a blade
• and the distance between the blades at the knife set.
To maintain the desired end width of the drawn film tape at the winder, the cutting
width must be calculated.
The setting of the distance when assembling the blades determines the cutting
width.
The cutting width is determined using the following formula:
• A= Cutting width
• B= End width of the drawn film tape
• C= Draw ratio
A = B x C
The draw ratio is the ratio of the godet speed of draw stand I to the last draw unit.
Calculation example:
• End width of the drawn film tape: 2.5 mm
• Draw ratio: 1:6,35
• Blade thickness: 0.20 mm
• D= distance between the blades
• E= Blade thickness
A =  2, 5mm  6, 35 
A = 6, 30mm
D = A – E = 6, 30mm – 0, 20mm
= 6, 10mm
The distance between the blades must be 6.10 mm
4 Maintenance
4.19.6 Setting the Cutting Width
2 3 2
Fig.. 4–18: Setting the cutting width
– Remove the screw (3).
– Slide the knife holder (1on the axle (2).
– Firmly tighten the screw (3).
4 Maintenance
4.19.7 Setting the Cutting Depth
Fig.. 4–19: Setting the cutting depth
– Set the cutting depth through turning of the hand wheel (1) depending on the
process.
4.19.8 Setting the Stop for the Cutting Depth

Note: The stop adjustment for the cutting depth must be undertaken at com-
missioning or during production, see Operating Instructions.
4 Maintenance
4.20 Maintenance – Draw Stands
4.20.1 Maintenance Schedule – Draw Stand I
12
1 7
2
4 8 13
5 14
9 15
10
16
6 11
Fig.. 4–20: Draw stand I
1 Pneumatic cylinder 10 Screw (tensioner)
2 ambient godet 11 Lock nut (tensioner)
3 Toothed belt 12 Safety device: Safety hood
4 Rotating leading-in 13 Safety device: Protective cover of the ro-

tating leading-ins and conduits
5 Heated godet 14 Safety device: rotating cover
6 Three-phase gear motor 15 Operating panel with safety device:

Emergency-stop Pushbutton
7 Flat lubricating nipple, conical lubricat- 16 Position switch, safety hood

ing nipple
8 Pressure roll with safety device: Pneu- 17 Safety device: Emergency-stop ripcord
matic control (not shown)
9 Tensioner pulley
4 Maintenance
Maintenance
interval
Three-phase gear See third-party Service technician

motor documentation – Clean the motor.
– Service the motor.
Toothed belt See third-party Service technician

documentation – Check the toothed belt for wear and damage.
– If the toothed belt is worn, replace the toothed belt, see chapter
4.20.9 Replacing a Toothed Belt, page 149.
– Check the tension of the toothed belt and re-tension the toothed
belt if necessary, see chapter 4.20.9 Replacing a Toothed Belt,
page 149.
Tempered godet Monthly Service technician

– Clean the godet.
– Check the godet for damage.
– If the godet is damaged, replace or repair the godet.
Godet bearing (flat After 3600 Service technician

lubrication nipple) operating hours – Lubricate the godet bearing with Petamo GHY 441, from Klüber,
see chapter 4.20.15 Relubricating the Godet Bearing, page 160.
Ambient godets Monthly Service technician

Godet bearing After 3600 Service technician

(conical lubricating operating hours – Lubricate the godet bearing with Li-complex grease 2EP, see
nipple) chapter 4.20.15 Relubricating the Godet Bearing, page 160.
Rotating leading-in See third-party Service technician

documentation – Check the rotating leading-in for leaks.
– Clean the rotating leading-in.
– Service the rotating leading-in.
Pressure roll See third-party Service technician

documentation – Check the pressure roll for damage.
– If the pressure roll is damaged replace it, see chapter 4.20.18 Re-
placing the Pressure Roll, page 162.
– Clean the pressure roll.
– Service the pressure roll.
4 Maintenance
4.20.2 Maintenance Schedule – Draw Stand II
15
1 8
9
2
3
4
10
16
11
17
12
13
14
5 6 7
Fig.. 4–21: Draw stand II
1 Flat lubricating nipple 10 Safety device: Protective cover of the ro-

Conical lubricating nipple tating leading-ins and conduits
2 Rotating leading-in 11 Safety device: Scraper – wrap protection
3 cooled godets 12 Operating panel with safety device:

4 Toothed belt 13 Three-phase gear motor
5 Tensioner pulley 14 Position switch, safety hood
6 Screw (tensioner) 15 Safety device: Safety hood
7 Lock nut (tensioner) 16 Pressure roll with safety device: Pneu-

matic control
8 Pneumatic cylinder 17 Safety device: rotating cover
9 ambient godet 18 Safety device: Emergency-stop ripcord

(not shown)
4 Maintenance
Maintenance
interval


page 149.
cooled godets Monthly Service technician


Ambient godets Monthly Service technician

Godet bearing After 3600 Service technician

(conical lubricating operating hours – Lubricate the godet bearing with Li-complex grease 2EP, see
nipple) chapter 4.20.15 Relubricating the Godet Bearing, page 160.
Pressure roll See third-party Service technician

documentation – Check the pressure roll for damage.
– If the pressure roll is damaged replace it, see chapter 4.20.18 Re-
placing the Pressure Roll, page 162.
– Clean the pressure roll.
– Service the pressure roll.

4 Maintenance
4.20.3 Maintenance Schedule – Draw Stand III/IV
10
1
2
3
4 8
5
11
6
9 12
7
Fig.. 4–22: Draw stand III/IV
1 Flat lubricating nipple 8 Safety device: Protective cover of the ro-

2 Heated godet 9 Three-phase gear motor
3 Rotating leading-in 10 Safety device: Safety hood
4 Toothed belt 11 Safety device: rotating cover
6 Screw (tensioner) 13 Safety device: Emergency-stop ripcord

(not shown)
7 Lock nut (tensioner)
4 Maintenance
Maintenance
interval


page 149.
Heated godets Monthly Service technician



4 Maintenance
4.20.4 Maintenance Schedule – Draw Stand V/VI/VII
15
7
1 8
2 9
3
10
16
4 11 17
5 12
13
6
14
Fig.. 4–23: Draw stand V/VI/VII
1 Rotating leading-in 10 Safety device: Protective cover of the ro-

2 Heated godet 11 Cutting device baler twine (behind the

cover)
3 Toothed belt 12 Operating panel with safety device:

5 Screws (tensioner) 14 Three-phase gear motor
6 Lock nut (tensioner) 15 Safety device: Safety hood
7 Flat lubricating nipple 16 Pressure roll with safety device: Pneu-

matic control
8 Pneumatic cylinder 17 Safety device: rotating cover
9 cooled godets 18 Safety device: Emergency-stop ripcord

(not shown)
4 Maintenance
Maintenance
interval


page 149.
Heated godets Monthly Service technician



4 Maintenance
4.20.5 Safety
! WARNING
Danger of Entanglement Due to Rotating Roller!

Severe injuries

► Use a yarn suction gun.
⦸ Do not touch the film/film tapes with your hand.
⦸ Do not let long film/film tapes hang down.
! WARNING
Lower the pressure roll

Crushing injuries on the hands!
⦸ Never reach between the pressure roll and the godet.
! WARNING
Components running at high speed, entanglement, entrapment

Crushing injuries on arms and body, hand injuries
► After switch-off wait until the drives have come to a complete standstill
before starting the tasks.
► Secure the switched-off drive against unauthorized restart.
⦸ Never perform tasks while the drive is running.
4 Maintenance
! CAUTION
Hot Surfaces!
Burn injuries

► Prior to starting troubleshooting and maintenance tasks, let the line cool
down.
⦸ Do not touch heated godets without protective equipment.
4.20.6 Function Check of the Drives

Note: The drives of the draw stands are switched on via the draw fields on the
operating panel. In the draw stand overview the appropriate operating panels
and draw fields are allocated to the specific draw stands.
• Control Desk
– Specify a setpoint for all drives of the draw stands, see Service Book for the PC of
the line.
– Switch on the drives with the push button on operating panel +P01.
Note: Drives must audibly start-up.

Two methods to switch the drives off must be possible:
• Control Desk
– Switch off the drives with the push button on operating panel +P01.
• Operating Panel
– Switch off the drives with the pushbutton on operating panel.
Note: The drives must stop.
4 Maintenance

There are two possibilities to set the take-off godet speed:
• Control Desk
– Set the godet speed via the visualisation (see online help or the Service Book for
the PC of the line).
• Operating Panel
– Set a slightly higher or lower godet speed with the pushbuttons.
Note: In the draw stand overview the appropriate operating panels are allocat-
ed to the specific draw stands.
4.20.8 Checking the Direction of Rotation of the Drive Motor

Note: After replacing the drive motor, you must check its direction of rotation.
– Check whether the godets are rotating in the direction in which the material is
taken off.
Note: The directions of rotation of the godets are presented in the chapter
Maintenance Schedule of the appropriate draw stand.
– If the direction of rotation is not correct, reverse the polarity of the motor.
4 Maintenance
4.20.9 Replacing a Toothed Belt

switched back on.
• Installing a New Toothed Belt

Note: Detailed information concerning press-in depth and press-in force is pro-
vided in 6.4 Third-Party Documentation, page 231.
– Remove the belt covering.
– Shut-off the supply to the cooling or heating devices.
– Let the cooling medium or heating medium drain out of the hose lines.
– Remove the hose lines on the rotating leading-ins.
Note: The tensioner pulley is assembled either vertically or horizontally, see

maintenance chapter Draw Stands.
Fig.. 4–24: Toothed belt tensioning device – example
– Remove the screws of the tensioner pulley holder (1).
– Remove the lock nuts (2).
– De-tension the old toothed belt and take it off.
– Put on a new toothed belt.
– To tension the new toothed belt, tighten the lock nuts (2) and firmly tighten the
screws (1).
– Turn the belt drive through.
– For the measurement, knock the toothed belt on the measuring point (MP) with
your hand or a suitable tool
4 Maintenance
Note: Pay attention to the different measuring points depending on toothed

belt guide, see chapter 4.20.10 Overview – Draw Stands, page 151.
– Measure the pretension with the belt tension measurement device.
– Repeat measurement 3 times and find the average value.
– Between the measurements, turn the toothed belt through.
– Connect the hose lines on the rotating leading-ins and check for leaks.
– Assemble the belt covering.
– If the direction of rotation is not correct, reverse the polarity of the motor.
WARNING Hand injury due to fast-moving parts!

► After installing the toothed belt, re-assemble the belt cover.
• Installing Used Toothed Belt

– Mark the position of the tensioner pulley holder, before detaching the old
toothed belt.
– To retain the original pretension, install the toothed belt only at the point at
which it was removed.
Note: Always check the pretension of the toothed belt after placing it on.
– If the tensioner pulley holder has not been marked prior to disassembly of the
old toothed belt, use a new toothed belt, see page 149.
4 Maintenance
4.20.10 Overview – Draw Stands
Draw stand I Draw stand II Draw stand III/IV
MP
MP MP1 MP2
Belt type Toothed belt Toothed belt Toothed belt
drive power 7.5 kW 29 kW 2x22 kW
Measured value Toothed belt frequency at the MP: 45.5-48 Hz Toothed belt frequency at the MP: 83-87 Hz Toothed belt frequency at the MP1+MP2: 37-
41 Hz
Lubricating nipple Flat lubricating nipple Flat lubricating nipple Flat lubricating nipple
Lubrication Klüber Petamo GHY 441 Klüber Petamo GHY 441 Klüber Petamo GHY 441
Lubricating nipple Conical lubricating nipple Conical lubricating nipple
Lubrication Li-complex grease 2EP Li-complex grease 2EP
Operating Panel +OP02 +OP03 +OP04
4 Maintenance
Draw stand V/VI/VII
MP2
MP1 MP3
Belt type Toothed belt
drive power 3x22 kW
Measured value Toothed belt frequency at the MP: 37-41 Hz
Lubricating nipple Flat lubricating nipple
Lubrication Klüber Petamo GHY 441
Operating Panel +OP05
4 Maintenance
4.20.11 Disassembling Godet
• Disassembling the Rotating Leading-in of a Godet
NOTICE
Leak at the Rotating Leading-in

When replacing pay attention to the different types of rotating leading-ins
The type of the rotating leading-in depends on the temperature of the heat-
ing / cooling medium and the direction of rotation. For the article number
refer to the original parts catalogue.
– Use the drain srew of the rotating leading-in to let the cooling medium or heat-
ing medium drain out from the heating or cooling devices and of the hose lines.

► Prior to starting maintenance tasks, let the line cool down.
► Let the heating medium cool down.
– Remove the hose lines on the rotating leading-ins.
– Remove the fastening screws and nuts (2).
– Pull out the rotating leading-in and piping (1) in the arrow direction.
– Take out the support ring half shells (4) and remove the flange (3).
1 2 3
4
Fig.. 4–25: Rotating leading-in with draw stand (example)
4 Maintenance
• Disassembling Godet
– Secure the godet with a suitable hoist. 5 6
– Detension the toothed belt and take it
off.
– Disassemble the shaft locking ring .
– Pull off the belt pulley (6).
– Unscrew the threaded pin (8) out of the

ring.
– Remove the pan head cap screws (9)

and hex screws (7) and pull off the bearing cover (10).
– Remove the pan head cap screws (12).
– Take off the protective ring (11).
– Remove the pan heat cap screws (13).
– Pull the godet with complete bearing forward and out.
– Place the godet with bearing on a workbench.
7 89 10
13 12 11
4 Maintenance
4.20.12 Assembling the Godet

Prerequisite: The godet bearing is assembled (see chapter 4.20.14 Assembling
the Godet Bearings, page 159).
– Use a suitable hoist to slide the godet into the receptacle of the draw stand.
– Firmly tighten pan head cap screws (8).
– Slide on the protective ring (6).
– Secure the protective ring (6) with the pan head cap screws (7).
– Slide on the ring (4).
– Slide on the bearing cover (5).
– Secure the bearing cover (5) with the pan head cap screws (3) and the hex screws
(1).
– Insert the threaded pins (2) with a thread-lock compound (for example, Loctite
242).
– Secure the ring (4) with the threaded pins (2).
1 23 4 5
8 7 6
4 Maintenance
– Pull off the belt pulley (10).

9 10
– Assemble the shaft locking ring (9).
– Assemble and tension the toothed belt.
• Assembling the Rotating Leading-in of a Godet
NOTICE
Leak at the Rotating Leading-in

When replacing pay attention to the different types of rotating leading-ins
The type of the rotating leading-in depends on the temperature of the heat-
ing / cooling medium and the direction of rotation. For the article number
refer to the original parts catalogue.
– Slide the flange (13) onto the end of the godet.
– Slide the support ring half shells (14) onto the end of the godet.
– Fit on the rotating leading-in and piping (11).
– Firmly tighten the fastening screws and nuts (12).
– Assemble the hose lines on the rotating leading-ins.
– Fill the heating device or cooling device with heating or cooling medium.
– Check the concentricity of the rotating leading-in, see chapter 6.4 Third-Party
Documentation, page 231.
4 Maintenance
11 12 13
14
Fig.. 4–26: Rotating leading-in with draw stand (example)
• Checking the Concentricity of the Godet

– Check the concentricity of the godet.
– Adjust the concentricity via the fastening screws.
Note:Detailed information concerning concentricity specifications is provided

in chapter 6.4 Third-Party Documentation, page 231.
4 Maintenance
4.20.13 Disassembling the Godet Bearing

Prerequisite: The godet is disassembled (see chapter 4.20.11 Disassembling Godet,
page 153)
– Slide the bearing housing (3) over the bearing (2) to the rear.
– Use the puller to pull the bearing (2) off the godet.
– Remove the threaded pin (4) and pull off the sleeve (5).
– Remove the pan head cap screws (8) of the bearing cover (9)
– Pull the bearing housing (6) with the inner ring over the bearing (7) to the front.
– Use the puller to pull the bearing (7) off the godet.
– If the bearing (7) cannot be removed from the godet with a puller, disassemble
the outer bearing ring with the self-aligning rolls.
– Notch the inner ring with the angle grinder diagonally. (Do not cut all the way
through)
– Split the inner ring with a chisel and remove the inner ring.
1 2 3 4 5 6 7 8 9
Fig.. 4–27: Draw stand with godet bearing (example)
4 Maintenance
4.20.14 Assembling the Godet Bearings

– Clean the new bearing.
CAUTION Burn injuries due to hot bearings!

► Wear heat-resistant gloves when assembling the bearings.
– Inductively heat up the bearings (2) and (7) to approx. 120°C.
– Slide the bearing cover (9) onto the godet.
– Slide the bearing (7) onto the godet and lubricate it with grease.
– Slide the bearing housing (6) with the inner ring over the bearing (7) and onto
the godet.
– Fasten the bearing cover with the pan head cap screws (8).
– Slide the sleeve (5) onto the godet.
– Insert the threaded pin (4) with a thread-lock compound (for example, Loctite
242) and firmly tighten it.
– Slide the bearing housing (3) onto the godet.
– Slide the bearing (2) onto the godet and lubricate it with grease.
– After cool-down of the bearings, carefully knock the inner ring of the bearing (2)
with the ring (1) in the direction of the godet. This seats the individual compo-
nents on the godet without gaps.
Note: The outer diameter of the ring (1) must not exceed the outer diameter of
the inner bearing ring.
4 Maintenance
1 2 3 4 5 6 7 8 9
Fig.. 4–28: Draw stand with godet bearing (example)
4.20.15 Relubricating the Godet Bearing

WARNING Danger of Entanglement Due to Rotating Rollers!
► Never reach into the area of the rotating godets.
– Ramp up the draw stand to operating speed
– Top up the lubricant on the lubricating nipples with the grease gun.
– Add grease until the grease escapes on the relief opening of the bearing cover.
4 Maintenance
4.20.16 Checking and Replacing the Heating Liquid Hoses

Medium: Heat transfer oil or water
NOTICE
Only use heat transfer oil that has been approved by STC Spinnzwirn, see
chapter 6.3 Comparison List, Heat Transfer Oils, page 229.

► Do not touch hoses, heated godets, and heating device without protective
equipment.
► The operating company must provide sufficient insulation of the hoses
between heating device and heated godets.
• Check
– Check the connections
– Open the valves.
– Check the connections and the hose lines to the heated godets for leaks
• Replace
– Connect the hose lines of the heating device installed for the medium on the ro-
tating leading-ins of the heated godets.
– Lay out the hose lines in accordance with the hosing diagrams and connect the
hose lines.
4 Maintenance
4.20.17 Checking and Replacing the Cooling Fluid Hoses

Medium: Water
NOTICE
The cooling water must meet the requirements specified in the chapter
Technical Data, see Operating Instructions.
• Check
– Check the connections
– Open the valves.
– Check the connections and the hose lines to the cooled godets for leaks
• Replace
– Connect the hose lines of the cooling device installed for the medium on the ro-
tating leading-ins of the cooled godets.
– Lay out the hose lines in accordance with the hosing diagrams and connect the
hose lines.
4.20.18 Replacing the Pressure Roll
NOTICE
To prevent damage of the rubberised surface of the pressure roll, do not
use chains or steel wire ropes to transport the pressure roll.
• Disassembling the Pressure Roll

– Detach the pneumatic cylinder.
– Pivot the swivel device to the rear.
– Remove the covers (1) on both sides.
– Disassemble the screws (2) and remove the holder (3).
– Lift out the pressure roll with a suitable hoist.
4 Maintenance
2 2
1 1
• Assembling the Pressure Roll

– Place the pressure roll with a suitable hoist.
– Assemble the holder (3) and fasten the screws (2).
– Assemble the covering (1).
– Pivot the swivel device into the initial position.
– Assemble the pneumatic cylinder.
4.20.19 Checking and Adjusting the Pressure Roll

CAUTION Danger of crushing through lowering of the pressure roll!
► Never reach between the lowering pressure roll and the godet!
Note: The appropriate operating panels for the draw stands are allocated in
the draw stand overview, see chapter 4.20.10 Overview – Draw Stands,
page 151.
• Operating Panel
– To lift off the pressure roll, press the pushbutton (Up arrow).
Note: The pressure roll lifts off quickly.

– To set the pressure roll down, press the pushbutton (Down arrow).
Note: The swivel device with the pressure roll moves slowly toward the godet.
4 Maintenance
• Draw stand
Note: To prevent sudden lowering of
the pressure roll onto the godet, damp-
1
ing is provided for the last 20 cm.
– Adjust the damping via the screws (2)
on the pneumatic cylinder.
2
– Firmly tighten the screws so
that the pressure roll remains in
position above the godet.
2
– Unscrew the screws far enough
that the pressure roll slowly
lowers onto the godet.
Note: The pressure rolls must rest on

the godet.
– Adjust the distance of the pressure roll to the godet by turning the yoke end (1).
4.20.20 Checking and Adjusting the Position Switch and Actuator

Note: The drives of the draw stand are ready for operation as soon as the posi-
tion switch (3) is approached with the actuator (2) on the safety hood (1).
– Close the safety hood.
– Check the alignment of position switch and actuator.
4 Maintenance
• Adjust the position switch (3)

– Remove the hexagon screw (4).
– Adjust the holder of the position switch (7).
– Tighten the hexagon screw (4).
– Remove the hexagon screw (5).
– Adjust the stop of the safety hood (6).
– Firmly tighten the hexagon screw (5).
– Check the alignment of position switch (3) and actuator (2).
4
7
5
6
5
• Adjust the Actuator (2)

– Remove the pan head cap
screws (8).
– Adjust the adapter actuator (9).
– Tighten the pan head cap screw 8

(8).
9
– Check the alignment of position
switch (3) and actuator (2). 2
4 Maintenance
4.21 Maintenance – Cutting Device Baler Twine
Fig. 4–29: Cutting device in the lateral holder of the draw stand.
1
3
2
5 4
3
4 6
Fig. 4–30: Cutting device
1 Guides 4 Blade
2 Holder 5 Stop
3 Knurled screw 6 Pneumatic cylinder
4 Maintenance
4.21.1 Maintenance Schedule – Cutting Device Baler Twine
Maintenance
interval
Blade Process-dependent Service technician

– Check the blade for wear and damage.
– Replace a blunt blade.
4.21.2 Replacing Blade

For fast blade change on the cutting device, a second blade holder must be fitted
with a new blade beforehand.
CAUTION Cutting injury due to sharp
blades!
► When working with the blade
increased caution is required.
– Prepare the second knife holder with a
new blade.
1
– Remove the nuts.
2
– Remove the used blade.
3
– Clamp in the new blade be-
tween the dished washers. 4
– Firmly tighten the nuts.
4 Maintenance
4.21.3 Replacing the Knife Holder

– Prepare the second knife holder with a new blade, see chapter 4.21.2 Replacing
Blade, page 167
Prerequisite: Interrupt production of the line.

– Close all safety hoods.
– Press the white pushbutton [locking mechanism – safety hoods] on operating

panel +P01.
All safety hoods are closed and locked.

– With the hand wheel, crank cutting device to the front stop.
– Activate pushbutton [Retract/extend cutting device] on the operating panel of

the draw stand.
Cutting device is extended.

– Activate black pushbutton [unlocking mechanism – safety hoods] on operating
panel +P01.
All safety hoods are unlocked.

– Open the safety hood at the draw stand.
– Replace the knife holder in the cutting device.
CAUTION Cutting injury due to sharp blades!

► When working with the blade increased caution is required.
– Unscrew knurled screw.
– Disassemble the blade holder.
– Assemble the new blade holder.
– Firmly tighten the knurled

screw.
– Close the safety hood. 1
– Press the white pushbutton [locking 2

mechanism – safety hoods] on operat-
ing panel +P01.
All safety hoods are closed and locked.

– Activate pushbutton [Retract/extend cutting device] on the operating panel of
the draw stand.
Cutting device is retracted.
4 Maintenance
4.22 Maintenance – Hot-air Passage

page 231.
4.23 Maintenance – Ionization unit

page 231.
4.24 Maintenance – Heating Devices / Cooling Devices

page 231.
4 Maintenance
4.25 Maintenance – Suction
Fig.. 4–31: Suction
1 Pipeline 3 Fan with drive motor
2 Suction nozzle
4.25.1 Maintenance Schedule – Suction
Maintenance
interval
Drive motor fan See third-party Service technician

documentation – Clean the cooling fins.
– Check the motor for function.
4 Maintenance
4.26 Maintenance – Waste Strip Feedback Device
1 2 3 4 5 6
8
9
10
11
Fig.. 4–32: Waste strip feedback device
1 Cutting Mill 7 Bracket
2 Safety device: safety switch 8 Gear wheel
3 Safety device: Guide tube 9 Conveyor
4 Rubber gear wheel 10 Pushbutton
5 Guide plate 11 Gear motor
6 Safety device: Finger guard 12 Toothed belt (without illustration)
4 Maintenance
4.26.1 Maintenance Schedule – Waste Strip Feedback Device
Maintenance
interval
Cutting mill knife See third-party Service technician

documentation – Dismantle the knife.
– Sharpen the knife.
Cutting mill See third-party Service technician

exhaust fan documentation – Clean the cooling fins of the motor, see third-party documentation.
Ionization unit See third-party Service technician

(optional) documentation – Clean the ionization unit, see third-party documentation.
Drive motor con- See chapter 6.4 Service technician

veyor Third-Party Doc- – Execute inspection and maintenance as specified in the third-party
umentation, documentation, see chapter 6.4 Third-Party Documentation,
page 231 page 231.
Toothed belt See chapter 6.4 Service technician

Third-Party Doc- – Check the toothed belt for wear and damage.
umentation, – Replace worn or damaged toothed belts, see chapter 4.26.3 Checking
page 231 and Adjusting the Tension of the Toothed Belt, page 174.
– Check the toothed belt tension with the pretension measurement de-
vice, see chapter 4.26.3 Checking and Adjusting the Tension of the
Toothed Belt, page 174.
– Tension the toothed belts.
– Execute inspection and maintenance as specified in the third-party
documentation, see chapter 6.4 Third-Party Documentation,
page 231.
Gear wheels Weekly Service technician

– Check the gear wheels for wear and damage.
– Replace worn or damaged gear wheels, see chapter 4.26.2 Replacing
Gear Wheels, page 173.
safety switch Daily Service technician

– Check the safety switch for correct seat.
4 Maintenance
4.26.2 Replacing Gear Wheels
Fig.. 4–33: Replacing Gear Wheels
– Dismantle both finger guard covers (1).
– Remove the screws (2).
– Replace the gear wheels.
– Firmly tighten the screws (2).
– Reassemble both finger guard covers (1).
4 Maintenance
4.26.3 Checking and Adjusting the Tension of the Toothed Belt
3 4
6 5
Fig.. 4–34: Checking the Tension of the Toothed Belt
– Dismantle the side cover (1) of the conveyor.
• Checking the Tension of the Toothed Belt

– Strike the toothed belt at the measuring points (5 or 6) with your hand or a suit-
able tool.
– Measure the toothed belt tension with the belt tension measurement device.
Toothed Belt 1 (4) Toothed Belt 2 (3)
353–371 Hz (new toothed belt) 139-146 Hz (new toothed belt)
296–316 Hz (used toothed belt) 116-124 Hz (used toothed belt)
– Repeat measurement 3 times and find the average value.
Note: Between the measurements, turn the toothed belt through.
4 Maintenance
• Adjusting the Tension of the Toothed Belt
Fig.. 4–35: Tensioning toothed belt 2
Tensioning toothed belt 2 (3)

– Tension the toothed belt (3) by adjusting the tensioning roller via the slotted
holes.
– When the prescribed tension is reached, firmly tighten the screws (7).
4 Maintenance
Fig.. 4–36: Tensioning toothed belt 1
Tensioning toothed belt 1 (4)

– Tension the toothed belt (4) by adjusting the tensioning roller via the tensioning
device.
– Assemble the side cover (1) of the conveyor.
– Assemble both finger guard covers (2).
4 Maintenance
4.26.4 Replacing a Toothed Belt
4 5
3
2
Fig.. 4–37: Replace toothed belt
– Dismantle the side cover (2) of the conveyor.
4 Maintenance
• Replacing toothed belt 2 (4)
Fig.. 4–38: Replacing toothed belt 2
– Release the tension on toothed belt 2 (4) by removing the screws (6).
– Dismantle the motor (1).
– Remove the old toothed belt (4).
– Put the new toothed belt in place.
– Tension the new toothed belt appropriately, see chapter 4.26.3 Checking and Ad-
justing the Tension of the Toothed Belt, page 174.
4 Maintenance
• Replacing toothed belt 1 (5)
Fig.. 4–39: Replacing toothed belt 1
– Release the tension on the toothed belt 1 (5) by removing the screws (7) on the
tensioning device.
– Dismantle the motor (1).
– Remove the old toothed belt (5).
– Put the new toothed belt in place.
– Tension the new toothed belt appropriately, see chapter 4.26.3 Checking and Ad-
justing the Tension of the Toothed Belt, page 174.
– Assemble the side cover (2) of the conveyor.
– Assemble both finger guard covers (3).
– Assemble the motor (1).
4 Maintenance
4.27 Maintenance – Fibrillator
1 2 3 4
11 10 9 8 7 6 5
Fig.. 4–40: Fibrillator (side view)
1 Hand wheel 7 Drive motor needle roll
2 spindle-driven elevating element 8 Drive motor traverse unit
3 Vertical carriage 9 Safety device:

Safety switch of vertical carriage.
4 Vertical guides 10 Horizontal trolley
5 Horizontal guides 11 Safety device: Locking clamp of traverse

unit
6 Frame
4 Maintenance
17
18
16 19
15 20
14
21
13
Fig.. 4–41: Fibrillator (front view)
12 Safety device: Safety switch of the hori- 17 Operating panel with safety device:
zontal trolley (not illustrated) Emergency-stop Pushbutton
13 Position switch of the traverse unit 18 Position indicator
14 Needle roll with needle strips 19 Film-tape guide with deflector rolls
15 Safety device: Protective hood of the 20 Guide rod

needle roll
16 String-up pin 21 Drawer unit
4 Maintenance
4.27.1 Maintenance Schedule – Fibrillator
Maintenance
interval
Guides Yearly Service technician

– Clean the vertical and horizontal guides, see chapter 4.27.5 Cleaning
and Lubricating the Guides, page 189.
Guides when required Service technician

– Lubricate the vertical and horizontal guides with Li-complex grease 2
EP WN 912 No. 270 via the grease fitting, see chapter 4.27.5 Cleaning
and Lubricating the Guides, page 189.
Drive motor nee- See third-party Service technician

dle roll documentation – Execute cleaning and maintenance as specified in the third-party doc-
umentation.
spindle-driven ele- See third-party Service technician

vating element documentation – Execute cleaning and maintenance as specified in the third-party doc-
umentation.
Drive motor trav- See third-party Service technician

erse unit documentation – Execute cleaning and maintenance as specified in the third-party doc-
umentation, see third-party documentation.
Needle roll when required Service technician

with needle strips – Clean the needle roller and needle strips with a brush, see chapter
4.27.9 Cleaning the Needle Strips and Needle Roller, page 194.
– Replace the needle strip, see chapter 4.27.10 Replacing the Needle
Strips, page 195.
– Replace the needle roller, see chapter 4.27.11 Replacing the Needle
Roller, page 198.
Drawer unit when required Service technician

– Empty the drawer unit.
– Clean the drawer unit.
4.27.2 Safety
! CAUTION
Pointed, sharp needles!

Cuts and puncture wounds
► Wear tight-fitting protective clothing an protective gloves.

► Close protective hood of the needle roll, when the fibrillator is not in oper-
ation.
⦸ Do not touch the needles of the fibrillator.
4 Maintenance
4.27.3 Preparing the Fibrillator for Maintenance
1 2 3
4
Fig.. 4–42: Preparing the Fibrillator for Maintenance
WARNING Components running at high speed, entanglement, entrapment!

Crushing injuries on arms and body, hand injuries!
► Never perform tasks while the drive is running.
► Start tasks only after all rotating parts have come to a complete standstill.
► Secure the switched-off drive against unauthorized restart.
– With the hand wheel (1) move the vertical carriage (2) to the upper stop
Note: The vertical carriage must be positioned far enough above the horizontal
trolley (3), to avoid collisions when moving out the horizontal trolley.
– Switch off the traverse unit drive at the operating panel.
– Switch off the drive of the fibrillator at the operating panel.
– Unlock the traverse unit locking clamp (4).
– Pull the horizontal trolley (3) into the maintenance position.
CAUTION Pointed, sharp needles!

Cutting injuries, stab injuries!
► Do not touch the needles of the fibrillator.
– Close the protective hood of the needle roll (5).
4 Maintenance
Fig.. 4–43: Fibrillator in maintenance position
The service position for maintenance tasks is set.
4 Maintenance
4.27.4 Preparing the Fibrillator for Production

Prerequisite: The fibrillator must be in maintenance position (see chapter
4.27.3 Preparing the Fibrillator for Maintenance, page 183).
2
– Open the protective hood (1) of the needle roll.

4 Maintenance
– Push horizontal trolley (2) into working position to the stop
6 5
Fig.. 4–45: Position switch of the traverse unit
– Check the position of the traverse unit position switch (5 and 6).
NOTICE The position switch (3) has been turned too far.
The fibrillator is not ready for operation.
On the visualisation the message "Error – traverse unit limit switches implausible" is
output.
– If the position switch (3) has been turned too far, push the horizontal trolley until
the position switch snaps into the stop edge (4).
4 Maintenance
Fig.. 4–46: Safety switch of the horizontal trolley
– Check the safety switch of the horizontal trolley (7) in working position, see chap-
ter 4.27.7 Checking and Adjusting the Position of the Safety Switches, page 191.
The safety switch (7) must be approached.
4 Maintenance
9 10
12
11
Fig.. 4–47: Safety switch of vertical carriage.
– Move the vertical carriage (10) with the hand wheel (8) in the direction of the nee-
dle roll until the pushbutton [Fibrillator ON/OFF] on the operating panel (9) is
flashing.
– Check the safety switch of the vertical carriage (11) in working position, see chap-
ter 4.27.7 Checking and Adjusting the Position of the Safety Switches, page 191.
The safety switch (11) must be approached.

The drive of the fibrillator is released.
– With the hand wheel (8) move the vertical carriage (10) to the upper stop
– Lock the traverse unit locking clamp (12).
The fibrillator is ready for operation.
4 Maintenance
4.27.5 Cleaning and Lubricating the Guides

1
1
2 2
– Clean the vertical (1) and horizontal (2) guides.
– If required, lubricate the vertical (1) and horizontal (2) guides with Li-complex
grease 2 EP WN 912 No. 270.
– Restore the fibrillator to operational readiness, see chapter 4.27.4 Preparing the
Fibrillator for Production, page 185.
4 Maintenance
4.27.6 Checking the Seat of the Coupling

2 3 4
– Remove the knurled nuts (1) on the cover of the coupling.
– Slide the cover (4) aside.
– Check that the coupling (2) is properly seated – visual inspection.
Bring the coupling into engagement

– Undo the quick-release element (3) on the coupling.
– Correct the seating of the coupling (2).
– Close the quick-release element (3).
– Close the cover (4) of the coupling.
– Firmly tighten the knurled nuts (1).
4 Maintenance
4.27.7 Checking and Adjusting the Position of the Safety Switches

Note: The drive of the fibrillator is ready for operation when the safety switch-
es, horizontal trolley in working position and vertical carriage in working posi-
tion, are approached.
• Adjusting the safety switch of the horizontal trolley

Prerequisite: The vertical carriage of the fibrillator must be at the upper stop.
1 2 3
1 5 4
6
Fig.. 4–50: Safety switch of the horizontal trolley
– Dismantle the cover (6).
– Loosen the screws (1).
– Adjust the holder (5) horizontally.
– Set the distance of the safety switch (4) to the stop point (3)
The safety switch must be active in approached status.

– Check the position of the safety switch.
– Move the horizontal trolley into the working position.

4 Maintenance
• Adjusting the safety switch of the vertical carriage

8 9
7 10
10
7
11
Fig.. 4–51: Safety switch of vertical carriage.
– Dismantle the cover.
– Loosen the screws (10) of the switch cam (9).
– Adjust the switch cam (9) vertically.
– Set the safety switch (11) horizontally.
– Set the horizontal distance of the safety switch (11) to the switch cam (9).
4 Maintenance
– Check the position of the safety switch.
– Move the vertical carriage into working position with the hand wheel

– Assemble the covering.
4.27.8 Checking and Adjusting the Position of the Position Switches

of the Traverse Unit
3
4
2
5
Fig.. 4–52: Position switch of the traverse unit
– Dismantle the cover (5).
– Set the distance of the position switch (2) to the stop edge (1).
– Adjust the traversing distance of the position switch (2).
4 Maintenance
4.27.9 Cleaning the Needle Strips and Needle Roller

1
1 2

– Clean individual needle strips or the complete needle roller (2) with a brush.
– Close the protective hood (1) of the needle roller.
4 Maintenance
4.27.10 Replacing the Needle Strips

Prerequisite: The fibrillator must be in maintenance position, see chapter
4.27.3 Preparing the Fibrillator for Maintenance, page 183.
1
1
2
4 3

– Remove the cover (3).
The needle roller (4) is exposed.
4 Maintenance
5 6
Fig.. 4–55: Replacing the Needle Strips
– Remove the screws (7) of the grooved disc (6).
– Turn the grooved disc (6) so that the groove with the needle strip (7) is exposed.

– Remove each individual needle strip (7) from the grooves with a piece of wood
covered with fleece.
– Clean the grooves of the needle strip.
– Install the new needle strips.
NOTICE Damage to the needle strips!

► Comply with the following points when assembling the needle strips:
– Pay attention to the numbering.
The needle strips are marked with numbers.

– Install the needle strips with consecutive numbering (e.g. 1-2-1-2-1-2).
– Pay attention to the installation direction.
– Install the needle tips against the tape run.
4 Maintenance
8 9 10 11 12
Fig.. 4–56: Installation direction of needle strips
8 Needle roller 11 Film tape
9 Needle 12 Work direction of the line
10 Direction of rotation of the needle roll
– Pay attention to the smooth running of the needle strips.
The needle strips must run smoothly in the groove.

– Slide the needle strips into the groove without strong force.
– Slide the needle strips into the groove until the gap is closed.
– Use a fleece-covered piece of wood to slide the needle strips .
The needle strips are installed.

– Secure the grooved disc (6) with screws.
– Secure the cover (3) with screws.
4 Maintenance
4.27.11 Replacing the Needle Roller

1
1
2
4 3

– Remove the cover (3).
The needle roller (4) is exposed.
4 Maintenance
• Replace needle roller with a suitable hoist
7 6 4
10 9
8
Fig.. 4–58: Replace needle roller with a suitable hoist
– Screw the eye bolts for a sling gear firmly into the threaded holes (6) on both
sides of the needle roller (4) (not included in the STC Spinnzwirn scope of deliv-
ery)
– Secure the needle roller (4) with a suitable hoist.
Front axle
– Remove the screws (9) from the axle (10).
– Remove the axle (10).
– Use the jacking holes (5) to remove the axle (10).
Rear axle
– Remove the screws (8) from the sleeve (7).
– Carefully lift the needle roller (4) out of the fibrillator.
Assemble new needle roll

– Insert the new needle roller (4) into the fibrillator.
– Install the sleeve (7) on the rear axle.
– Install the axle (10) on the front of the needle roller (4).
– Remove the eye bolts from the needle roller (4).
The needle roll is assembled.
4 Maintenance
• Replacing the needle roller without hoist
7 6 4
10 9
8
Fig.. 4–59: Replacing the needle roller without hoist
– Remove all needle strips from the needle roller (4), see chapter 4.27.10 Replac-
ing the Needle Strips, page 195
– Secure the needle roller (4) against falling down (e.g., with tapes; not in the scope
of delivery of STC Spinnzwirn ).
Front axle
– Remove the screws (9) from the axle (10).
– Remove the axle (10).
– Use the jacking holes (5) to remove the axle (10).
Rear axle
– Remove the screws (8) from the sleeve (7).
– Carefully lift the needle roller (4) out of the fibrillator.
Assemble new needle roll

– Insert the new needle roller (4) into the fibrillator.
– Install the sleeve (7) on the rear axle.
– Install the axle (10) on the front of the needle roller (4).
– Insert all needle strips into the needle roller (4), see chapter 4.27.10 Replacing
the Needle Strips, page 195.
The needle roll is assembled.
4 Maintenance
4.27.12 Checking the Functioning of the Drive

Prerequisite: The fibrillator is ready for operation, see chapter 4.27.4 Prepar-
ing the Fibrillator for Production, page 185.
2
Fig.. 4–60: Checking the functioning of the drive
• Checking the fibrillator drive (1)

Note: The drive of the fibrillator is not released, until the horizontal carriage is
in working position and the vertical carriage has been moved with the hand
wheel far enough in the direction of the needle roll that the pushbutton [Fibril-
lator ON/OFF] on the operating panel is flashing.
– Move the vertical carriage with the hand wheel in the direction of the needle roll
until the pushbutton [Fibrillator ON/OFF] on the operating panel is flashing.
– Switch on the fibrillator at the operating panel.
The button [Fibrillator ON/OFF] is continuously illuminated.

Note: The drive must audibly start-up.
Note: The green indicator light “Fibrillator drive ON” on the +P01 operating
panel must light up.
– Set the set value speed for the fibrillator on the visualisation.
The needle roller is rotating.
4 Maintenance
Two methods of switching off the drive of the fibrillator must be possible:
1. At the operating panel +P01 with the pushbutton [draw field ON/OFF]
– Switch off the fibrillator at the operating panel +P01.
The button [Fibrillator ON/OFF] on the operating panel flashes.

2. At the operating panel at the fibrillator with the pushbutton [Stations OFF]
– Switch off the drive of the fibrillator at the operating panel.

Note: The drive must stop.
• Checking the traverse unit drive (2)

– Switch on the traverse unit at the operating panel.
Note: The drive must audibly start-up.

– Switch off the drive of the traverse unit on the operating panel +P01.
Note: The drive must stop.
4 Maintenance
4.27.13 Checking the Direction of Rotation of the Drive Motor

1 2
1 3 4 5 6
Fig.. 4–61: Checking the Direction of Rotation of the Drive Motor
1 Needle roll 4 Direction of rotation of the needle roll
2 Drive fibrillator 5 Film tape
3 Needle 6 Work direction of the line
Note: After maintenance tasks on the drive (2) and after a replacement of the
drive (2) the direction of rotation must be checked.
(1) until the pushbutton [Fibrillator ON/OFF] on the operating panel is flashing.

– Set the set value speed for the fibrillator on the visualisation.
The needle roller is rotating.

– Check whether the needle roll (1) rotates in the direction in which the film tapes
(5) are taken off.
NOTICE Destruction of the needles (3) on the needle strips!

► If the direction of rotation is wrong, change the polarity of the motor.
– Switch off the fibrillator at the operating panel.
4 Maintenance
4.27.14 Adjusting the Vertical Carriage

2
3
5
1
Fig.. 4–62: Adjusting the safety switch of the vertical carriage
Note: The distance of the film tape guide (5) to the needle roll (1) depends on
the material or process. The closer the film tape guide is to the needle roll, the
higher the degree of wrap of the film tapes on the needle roll.
– Use the handwheel (3) to move the vertical carriage (4) in the direction of the
needle roll (1) until the film-tape guide (5) is close to the needle roller.
The distance of the film tape guide determined for the particular production process
can be read-off and adjusted via the position indicator (2) and thus it can be repro-
duced at any time.
4 Maintenance

NOTICE Malfunction of the fibrillator!
The speed of the needle roll must be greater than the speed of the delivered
film tapes.
Note: The process parameters must be determined and specified by the oper-
ator depending on the process and material.
until the pushbutton [Fibrillator ON/OFF] on the operating panel is flashing.
There are two possibilities for setting the speed of the needle roll:
– Set the speed via the visualisation (see online help or the Service Book for the PC
of the line).

– Change the speed by pressing the [Fibrillator-speed] button on the operating
panel.
– Press the plus side.
The speed increases.

– Press the minus side.
The speed decreases.
4 Maintenance
4.28 Maintenance – Electric Cabinet

Note: See the Service Book for the electrical system for details.
4.29 Maintenance – Control Desk

Note: See the Service Book for the electrical system for details.
4.30 Maintenance – Lines
4.30.1 Maintenance Schedule
Maintenance
interval
Pneumatic lines and Monthly Service technician

connections – Check the lines for damage, see chapter 4.30.2, page 207.
Cooling circuits, Monthly Service technician

extruder feed area, – Check the lines for leaks and damage, see chapter 4.30.3,
extruder gear unit, fil- page 207.
ters, cooling devices
for cooling bath, cool-
ing bath, cooling
device for cooled
godets
Heating fluid circuits, Monthly Service technician

heating device for – Check the lines for leaks and damage, see chapter 4.30.3,
heated godets page 207.
Electrical connecting Monthly Service technician

cables – Check the lines for damage, see Service book for the electrical
system, chapter 4.30.4, page 207.
4 Maintenance
4.30.2 Checking Pneumatic Lines and Connections

Note: See the pneumatic circuit diagrams in chapter 5.2 Drawings, page 211
and the Operating Instructions, chapter Technical Data.
– Check whether the required compressed air is applied.
– Check the correct settings of operating pressure and contact pressure.
– Check the lines, connections, cylinders and valves for leaks.

CAUTION Danger of Injury Due to Pressurised Line!
► Execute maintenance tasks only when the equipment is depressurised and de-
energised.
4.30.3 Checking Liquid-Conducting Lines

– Check the connections in accordance with:
• Line Installation Plan
• Cooling water distributor on the extruder
• Dimensioned drawings
• Third-Party Documentation
– After opening the main valves, check all lines for cooling and heating fluids for
leaks.
4.30.4 Checking the Electrical Lines

DANGER Electrical shock and severe burn injuries due to life-threatening
high voltage!
► Comply with the safety instructions in the chapter Safety.
NOTICE
The electrical connecting lines must be laid out conduits, ducts or under
covers, to protect them against damage.
– Check whether the necessary supply voltage is applied, see Operating Instruc-
tions, chapter Technical Data.
– After service tasks, check the lines for damage.
4 Maintenance
4.31 Spare Parts

Note: Only use original STC Spinnzwirn spare parts, see the Original Parts Cat-
alogue on CD.
4.31.1 Ordering Original Spare Parts

– Use the Original Parts Catalogue to order spare parts.
– Specify the following data for fast and safe processing.
1. Lines / machine type
2. STC Spinnzwirn-Order number
3. Year of delivery
Note: The information for points 1 to 3 is provided on the title page of the Op-
erating Instructions.
4. Designation of the part
5. Article number (order number)
6. Quantity
7. Quantity unit
Note: The information for points 4-7 is provided in the Original Parts Catalogue
on CD.
4.31.2 Ordering Spare Parts for Equipment from Suppliers

For spare parts orders for equipment from suppliers, the data specified on the rat-
ing plate of the respective device must also be provided:
1. Device type
2. Serial number / order number
3. Precise designation of the spare part
4. Quantity
5. Quantity unit
6. Pump number when ordering spare parts for the pump
Note: Pump number and order number are specified in the pump housing or
on the aggregate.
5 Drawings, Forms and Customer Service
5.1 Installation Plan PFB1-0-958
5.2 Drawings
Assembly / Component Drawings, tables, diagrams Drawing number
Electric cabinet see Service Book for the electrical system
Extruder Extruder – dimensioned drawing FBA1-10-778Z

Distributor, cooling water – dimensioned drawing FBA1-10-96
Adapter system See third-party documentation for the filter
Melt pump with drive See third-party documentation for the melt pump
Slot die See third-party documentation for the slot die
Cooling bath Cooling bath – dimensioned drawing KBF1-0-1681Z

See third-party documentation for the cooling
device
Take-off device Take off device – dimensioned drawing KBF1-0-1748Z

Pneumatic circuit diagrams and associated parts KBF1-49S-11Z, KBF1-49-2P
lists
Thickness measuring See third-party documentation for the thickness

device measuring device
Cutting device Cutting device – dimensioned drawing LAS3-3-797Z
Draw stand I Draw stand I – dimensioned drawing STB9-0-360A

Pneumatic circuit diagrams and associated parts STB7-49S-8Z, STB7-49-8P and
lists STB21-49S-1Z, STB9-49-1P
See third-party documentation for the heating

device
Waste Strip Cutting Waste Strip Cutting Device – dimensioned drawing ABV2-0-157Z
Device
Draw stand II Draw stand II – dimensioned drawing STB9-0-390A

Pneumatic circuit diagrams and associated parts STB21-49S-1Z, STB9-49-1P
lists
device
Hot-air passage I+II See third-party documentation for the hot-air pas-
sage
Draw stand III/IV Draw stand III/IV – dimensioned drawing STB9-0-362A

Pneumatic circuit diagrams and associated parts STB21-49S-1Z, STB9-49-1P and
lists STB7-49S-10Z/ STB7-49-10P

device
Fibrillator Fibrillator – dimensioned drawing FIB9-0-5Z
Assembly / Component Drawings, tables, diagrams Drawing number
Ionization unit See third-party documentation for the ionization

unit
Draw stand V/VI/VII Draw stand V/VI/VII – see dimensioned drawing STB9-0-391A
device
device
Cutting Device Baler Retract the baler twine – dimensioned drawing STB9-3-151Z
Twine Pneumatic circuit diagrams and associated parts STB9-49S-4Z, STB9-49-5P
lists
Suction Suction – dimensioned drawing ABV2-7-553Z
5.3 Return Shipping Advice
NOTICE
► Pack the goods so that they are stable and safe.
Thus you avoid additional damage due to transport.
► If possible, use the original packaging of original STC Spinnzwirn spare
parts.
► If there are defective electronic modules and devices, inform STC Spinn-
zwirn Customer Service, see chapter 5.5 Customer Service, page 218.
► Avoid additional damage to electronic modules and devices through the
following influences:
• Mechanical impact and vibration
• Humidity
• Electrostatic discharge (ESD)
► Electronic modules and devices must be packed in ESD protective bags or
wrapped in corrugated cardboard.
► Cushion the packaging boxes of electronic modules and devices for trans-
port.
► Avoid direct contact of electronic modules and devices with:
• Polystyrene
• Foam material
• Plastic film
Note: During repair, such damage often goes unnoticed, because the compo-
nent is initially still functional.
However, these parts could fail again shortly after return.
– Contact STC Spinnzwirn Customer Service beforehand for smooth return ship-
ment of the goods, see chapter 5.5 Customer Service, page 218.
– Address return shipments of goods to the mailing address of STC Spinnzwirn,

see chapter 5.5 Customer Service, page 218
– Do not forget to include the return material authorisation and the packing list
with the return shipment.
Return material authorisation

Return shipping advice
Von:
From:
Auftrag:
Order no.:
Bezeichnung:
Designation:
Zeichnungs- oder Artikel-Nr.:

Drawing or article no.:
Bearbeiter Kundenservice:
Contact in Customer Service:
Grund der Rücksendung:

Reason for return:
5.4 Packing List
Packliste/Packing List
Kunde/Customer
Projekt/Project
Lieferschein-Nr./No of delivery note
Pos. / Menge Teile-Bezeichnung / Zeichn.-Nr. / Artikel-Nr. / * Bemerkung/Remark

Item / Qty Designation Drw. No. Article No. S
Bemerkung/
Remark
Aussteller/Issuer
Datum/Date Maß/Dimensions
Unterschrift/
Signature
5.5 Customer Service
• STC Spinnzwirn-Customer Service

Phone: + 49 371 2388 240
Fax: + 49 371 85 21 42
E-Mail: info@stc-spinnzwirn.com
Internet: www.stc-spinnzwirn.com
• Mailing Address
STC Spinnzwirn GmbH
Zwickauer Str. 247
09116 Chemnitz
Germany
6 Appendices
6 Appendices
6.1 Tightening Torques
NOTICE
► Only use the screws specified by the manufacturer.
► Tighten the screws, with the tightening torques specified in the engineer-
ing drawings (see chapter 5.2 Drawings, page 211) or the corresponding
third-party documentation (see chapter 6.4 Third-Party Documentation,
page 231).
► The specifications below apply to screws for which tightening torques are
not specified in the engineering drawings or the third-party documenta-
tion.
6.1.1 Screw Connection
• DIN Screws
Note: For tightening torques, see tables page 221 to page 223.
• Heat-resistant Screws
Note: Heat-resistant screws are marked with the code letters GA on the screw
head.
NOTICE
► Hand-tighten connections with heat-resistant screws in a crosswise
sequence.
► When the screw connections have reached the operating temperature,
tighten them in a crosswise sequence in three steps as follows to reach
the final tightening torque: Apply tightening torque of 50 %, 100 %, and
again 100 % of the final tightening torque!
• Components (except extruder and melt filter)

Note: For tightening torques, see Table page 224.
6 Appendices
• Extruder and Melt Filter
NOTICE
Tightening torques have been reduced to two thirds of the maximum
(value based on STC Spinnzwirnexperience). Do not reduce the specified
tightening torques under any circumstances!
Note: For tightening torques, see Table page 225.
6.1.2 Lubricating Screw Connections
NOTICE
Lubricant must not come into contact with the melt.
Note: Use a high-temperature compound, e.g. Unimoly HTC METALLIC paste

from Klüber (WN912-BG18), to obtain the smooth engagement of the screw
connections required under the specified temperatures.
– Clean the thread.
– Use a brush to apply lubricant on the thread base.
6 Appendices
Tightening torques for DIN screws for operation at room temperature.
Property class 8.8 10.9 12.9
Lubricant status Dry with HTC* Dry with HTC* Dry with HTC*
(μ = 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1)
Nm Nm Nm Nm Nm Nm
M4 3.1 2.4 4.3 3.4 5.2 4.1
M5 6.1 4.8 8.6 6.8 10.0 8.1
M6 11.0 8.3 15.0 12.0 18.0 14.0
M8 26.0 20.0 36.0 28.0 43.0 34.0
M10 51.8 40.0 72.0 56.0 86.0 67.0
M12 88.0 69.0 125.0 96.0 150.0 115.0
M14 140.0 110.0 195.0 155 235.0 185
M16 220.0 170.0 310.0 240.0 370.0 285.0
M18 305.0 235.0 425.0 330.0 510.0 395.0
M20 430.0 330.0 600.0 465.0 730.0 560.0
M22 590.0 455.0 830.0 640.0 990.0 770.0
M24 740.0 570.0 1050.0 800.0 1250.0 970.0
M27 1100.0 840.0 1550.0 1200.0 1850.0 1400.0
M30 1500.0 1150.0 2100.0 1600.0 2500.0 1950.0
M33 2000.0 1550.0 2850.0 2150.0 3400.0 2600.0
M36 2600.0 2000.0 3650.0 2800.0 4350.0 3350.0
M39 3350.0 2550.0 4750.0 3600.0 5700.0 4350.0
M42 4150.0 3200.0 5850.0 4450.0 7000.0 5350.0
M45 5200.0 3950.0 7300.0 5550.0 8750.0 6700.0
M48 6250.0 4800.0 8800.0 6750.0 10600.0 8100.0
M52 8100.0 6150.0 11350.0 8650.0 13650.0 10400.0
M56 10050.0 7650.0 14150.0 10800.0 16950.0 12950.0
M60 12500.0 9500.0 17600.0 13350.0 21100.0 16000.0
M64 15050.0 11450.0 21150.0 16100.0 25400.0 19300.0
M68 18200.0 13800.0 25600.0 19400.0 30750.0 23300.0

* = For example, high temperature compound, Unimoly HTC Metallic-Paste, from Klüber
6 Appendices
Tightening torques for DIN screws for operation at temperatures up to 200 °C.
(μ = 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1)
Nm Nm Nm Nm Nm Nm
M4 4.1 3.2 4.5 3.5
M5 8.1 6.4 8.9 7.0
M6 14.0 11.0 15.0 12.0
M8 34.0 27.0 37.0 29.0
M10 68.0 53.0 74.0 58.0
M12 115.0 91.0 130.0 100.0
M14 185.0 145.0 205.0 160.0
M16 290.0 225.0 320.0 245.0
M18 400.0 310.0 440.0 340.0
M20 570.0 440.0 630.0 485.0
M22 780.0 600.0 860.0 660.0
M24 980.0 760.0 1100.0 830.0
M27 1450.0 1000.0 1600.0 1200.0
M30 1950.0 1500.0 2150.0 1650.0
M33 2700.0 2050.0 2950.0 2250.0
M36 3450.0 2650.0 3750.0 2900.0
M39 4450.0 3400.0 4900.0 3750.0
M42 5500.0 4200.0 6050.0 4600.0
M45 6900.0 5250.0 7550.0 5750.0
M48 8350.0 6350.0 9100.0 6950.0
M52 10750.0 8150.0 11750.0 8950.0
M56 13350.0 10200.0 14600.0 11150.0
M60 16600.0 12600.0 18150.0 13800.0
M64 20000.0 15200.0 21850.0 16600.0
M68 24200.0 18350.0 26450.0 20050.0

6 Appendices
Tightening torques for DIN screws for operation at temperatures up to 300 °C.
(μ = 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1)
Nm Nm Nm Nm Nm Nm
M4 3.9 3.0 4.1 3.2
M5 7.7 6.0 8.1 6.4
M6 13.0 10.0 14.0 11.0
M8 32.0 25.0 34.0 27.0
M10 53.0 50.0 68.0 53.0
M12 110.0 86.0 115.0 91.0
M14 175.0 135.0 185.0 145.0
M16 275.0 210.0 290.0 225.0
M18 380.0 295.0 400.0 310.0
M20 540.0 415.0 570.0 440.0
M22 740.0 570.0 780.0 600.0
M24 920.0 720.0 980.0 760.0
M27 1350.0 1050.0 1450.0 1100.0
M30 1850.0 1450.0 1950.0 1500.0
M33 2550.0 1950.0 2700.0 2050.0
M36 3250.0 2500.0 3450.0 2650.0
M39 4200.0 3200.0 4450.0 3400.0
M42 5200.0 3950.0 5500.0 4200.0
M45 6500.0 4950.0 6900.0 5250.0
M48 7850.0 6000.0 8350.0 6350.0
M52 10100.0 7700.0 10750.0 8150.0
M56 12600.0 9550.0 13350.0 10200.0
M60 15650.0 11850.0 16600.0 12600.0
M64 18800.0 14300.0 20000.0 15200.0
M68 22750.0 17250.0 24200.0 18350.0

6 Appendices
Tightening torques for heat-resistant screws
Operating temperature up to 200°C 300°C 400°C
(μ = 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1) (μ= 0.15) (μ= 0.1)
Nm Nm Nm Nm Nm Nm
M4 2.4 1.9 2.2 1.7 2.0 1.5
M5 4.8 3.7 4.4 3.5 3.9 3.1
M6 8.3 6.5 7.6 6.0 6.8 5.3
M8 20.0 16.0 18.0 14.0 16.0 13.0
M10 40.0 31.0 36.0 29.0 33.0 25.0
M12 69.0 53.0 63.0 49.0 56.0 44.0
M14 110.0 85.0 100.0 78.0 90.0 70.0
M16 170.0 135.0 160.0 120.0 140.0 110.0
M18 235.0 185.0 220.0 170.0 195.0 150.0
M20 335.0 260.0 310.0 240.0 275.0 215.0
M22 460.0 355.0 425.0 325.0 380.0 290.0
M24 580.0 445.0 530.0 410.0 475.0 365.0
M27 860.0 660.0 790.0 600.0 700.0 540.0
M30 1150.0 890.0 1050.0 820.0 950.0 730.0
M33 1600.0 1200.0 1450.0 1100.0 1300.0 990.0
M36 2000.0 1550.0 1850.0 1450.0 1650.0 1250.0
M39 2650.0 2000.0 2400.0 1850.0 2150.0 1650.0
M42 3250.0 2500.0 3000.0 2300.0 2650.0 2050.0
M45 4050.0 3100.0 3750.0 2850.0 3300.0 2550.0
M48 4900.0 3750.0 4500.0 3450.0 4000.0 3050.0
M52 6300.0 4800.0 5800.0 4400.0 5200.0 3950.0
M56 7850.0 6000.0 7250.0 5500.0 6450.0 4900.0
M60 9750.0 7400.0 9000.0 6800.0 8000.0 6100.0
M64 11750.0 8950.0 10800.0 8200.0 9650.0 7350.0
M68 14250.0 10800.0 13100.0 9900.0 11650.0 8850.0

6 Appendices
Tightening torques for heat-resistant screws
The tightening torques are 2/3 of the maximum values resulting, according to the former VDI 2230,
for a minimum coefficient of friction of m=0.10.
Operating temperature 250–350°C
Lubricant status with HTC*

(μ= 0.1)
Nm
M3 0.51
M4 1.15
M5 2.3
M6 4.0
M8 9.7
M10 19
M12 33
M14 53
M16 81
M18 115
M20 160
M22 220
M24 270
M27 400
M30 550
M33 740
M36 950
M39 1250
M42 1500
M45 1900
M48 2300
M52 2900
M56 3700
M60 4600
M64 5500
The table applies for the material 21 Cr Mo V 57* = e. g. high-temperature compound, Unimoly HTC Metallic paste from Klüber
6 Appendices
6 Appendices
6.2 Comparison List of Lubricants, WN912
6 Appendices
6 Appendices
6.3 Comparison List, Heat Transfer Oils

The heat transfer oils cited below from different manufacturers have been evaluat-
ed by STC Spinnzwirn and have been approved for use in the heating devices.
Designation Manufac- Base oil max. Viscosity Viscosity at Pour point

turer film temper- < 5 mm²/s 20 °C
ature [mm²/s][cst]
Alaria 2 Agip mineral oil 340 °C 100-305 °C 16 12 °C
Alaria 3 Agip mineral oil 320 °C 100-305 °C 30 9 °C
Jarytherm DBT Total Synthetic oil 370 °C 80-300 °C 50 -24 °C
Marlotherm N Sasol Synthetic oil 340 °C 80-300 °C 34 -60 °C
Marlotherm SH Sasol Synthetic oil 380 °C 70-360 °C 47 -34 °C
Mobiltherm 603 Mobil mineral oil 330 °C 90-320°C 20 -15 °C
Mobiltherm 605 Mobil mineral oil 330 °C 100-300 °C 30 -12 °C
Farolin U Aral mineral oil 350 °C 100-320°C 50 -15 °C
Perfecto HT 5 Castrol mineral oil 345 °C 100-300 °C 63 -9 °C
Thermofluid B Avia mineral oil 320 °C 80-340 °C 54 -15 °C
Thermofluid Avia Synthetic oil 320 °C 80-320°C 49 -45 °C
Transcal N BP mineral oil 320 °C 10-300 °C 50 -12 °C
6 Appendices
6 Appendices
6.4 Third-Party Documentation
Assembly Component Manufacturer Article number
Dosing System Dosing system Doteco See Operating Instructions
Extrusion line Extruder BBE 1-030-2618

Filter Nordson See Operating Instructions
Cylinder heater Ihne & Tesch 1-030-4242
Resistance thermometer Gräff A-D11-3729
Melt pump Oerlikon Barmag See Operating Instructions
Resistance thermometer Gräff A-614-3485
Pressure gauge Dynisco A-D05-6700
Temperature sensor Gräff 1-017-5852
Motor (pump) Siemens 3-000-1581
Flexible shaft Welte 1-037-1526
Bimetal thermometer Wika 1-030-7239
Motor (Extruder) Siemens 3-000-1598
V-belt Gates 1-002-2505
Slot die Slot die Cloeren See Operating Instructions
Cooling bath Motor KEB 5001013183

Temperature sensor Pohltechnic 1-030-0315
Cooling device Kelviplast See Operating Instructions
Take-off device Pressure gauge Drumag A-529-0409

Motor Siemens 3-000-1583
Air knives Simco 1-023-5072
Air knives Simco 1-023-5071
Radial fan Gardner Denver A-E75-4408
Radial fan Reitz 1-012-3652
Radial fan Reitz 1-023-6772
Thickness measuring Thickness measuring device Scantech See Operating Instructions

device
Cutting device Stretcher roller Stowe Woodward A-426-9888
Draw stand I Rotating leading-in Maier 1-041-7402

Rotating leading-in Maier 1-041-7403
Filter controller Drumag A-401-2753
Pressure gauge Drumag A-401-2779
Toothed belt Flender 1-024-6109
Motor Siemens 3-000-1579
Heating device Kelviplast See Operating Instructions
6 Appendices
Assembly Component Manufacturer Article number
Draw stand II Rotating leading-in Maier 1-041-7402

Motor (22kW) Siemens 3-000-1580
Waste strip feedback Cutting Mill PCC See Operating Instructions

device Motor Siemens 3-000-2666
Hot-air passage Hot-air passage Lytzen See Operating Instructions

Hot-air passage Lytzen See Operating Instructions
Draw stand III/IV Rotating leading-in Maier 1-041-7402

2x Toothed belt Flender 5001003698
2x Motor Siemens 3-000-1578
Heating device SMK See Operating Instructions
Fibrillator Motor Siemens 1-023-8277

Coupling Stemin/Breitbach 1-023-8371
Spindle lifting gear Thomson Neff A-D05-3319
Flexible shaft Thomson Neff 1-023-8291
Motor (traverse unit) Dunkermotoren 1-023-8453
Draw stand V/VI/VII Rotating leading-in Maier 1-041-7402

Filter controller Drumag A-401-2753
Pressure gauge Drumag A-401-2779
3x Toothed belt Flender 5001003698
3x Motor Siemens 3-000-1578
Heating device SMK See Operating Instructions
Suction Radial fan Reitz A-E73-3651
Ionization unit Ionization device Simco See Operating Instructions

Ionization rod Simco See Operating Instructions
2x Ionization device Simco See Operating Instructions
Accessories Heat-transfer oil Agip 5001007493

Yarn suction gun Heberlein 5001008163
Belt tension measuring device Flender 5001003976
Lacquer repair kit Mankievicz 3-000-1911

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Service Manual

Document no.: TDD 31813 / 01.20 STC Spinnzwirn GmbH

1.2 Safety instructions for tasks on electrical systems,

1.3 Safety Instructions for Tasks on Mechanical Systems,

1.4 Safety Instructions for Maintenance Tasks . . . . . . . . . . . . . . . . . . 8

3.2 Structure of the Malfunction Tables . . . . . . . . . . . . . . . . . . . . . . . 14

3.3 Malfunctions – Film Tape Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.4 Malfunction – Electric Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.5 Malfunctions – Control Desk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.6 Malfunctions – Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

3.7 Malfunction – Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.8 Malfunction – Extruder Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.9 Malfunction – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.10 Malfunction – Adapter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.11 Malfunction – Melt Pump with Drive . . . . . . . . . . . . . . . . . . . . . . 21

3.12 Malfunction – Slot Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.13 Malfunction – Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.14 Malfunction – Take-off Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3.15 Malfunction – Thickness Measuring Device . . . . . . . . . . . . . . . . 25

3.16 Malfunctions – Cutting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

3.17 Malfunction – Draw Stand I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.18 Malfunction – Waste Strip Feedback Device . . . . . . . . . . . . . . . . 30

01.20 11701 0 0100 Asia Dragon Cord & Twine Company Lt i

3.19 Malfunctions – Draw Stand II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

3.20 Malfunction – Hot-Air Passage . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

3.21 Malfunctions – Draw Stand III/IV. . . . . . . . . . . . . . . . . . . . . . . . . . 36

3.22 Malfunction – Fibrillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

3.23 Malfunctions – Draw Stand V/VI/VII . . . . . . . . . . . . . . . . . . . . . . . 40

3.24 Malfunctions – Cutting Device Baler Twine . . . . . . . . . . . . . . . . . 44

3.25 Malfunctions – Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.26 Malfunction – Ionization Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

3.27 Malfunction – Heating Devices/Cooling Devices . . . . . . . . . . . . 45

3.28 Malfunction – Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

4.2 Regular Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

4.3 Preparation - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

4.4 General Maintenance Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.5 Replacing the Measuring Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 55

4.6 Screw Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

4.7 Pneumatic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

4.8 Replacing Inverters, Temperature Controllers, Drives, etc. . . 67

4.9 Instructions concerning the maintenance schedules

ii Asia Dragon Cord & Twine Company Lt 11701 0 0100 01.20

4.10 Maintenance – Dosing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.11 Maintenance – Extruder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

4.12 Maintenance – Melt Pump with Drive . . . . . . . . . . . . . . . . . . . . . 100

4.13 Maintenance – Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.14 Maintenance – Adapter System . . . . . . . . . . . . . . . . . . . . . . . . . . 109

4.15 Maintenance − Slot Die . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.16 Maintenance – Cooling Bath . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

4.17 Maintenance – Take-Off Device . . . . . . . . . . . . . . . . . . . . . . . . . . 122

4.18 Maintenance – Thickness Measuring Device . . . . . . . . . . . . . . . 129

4.19 Maintenance – Cutting Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.20 Maintenance – Draw Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

iv Asia Dragon Cord & Twine Company Lt 11701 0 0100 01.20

4.20.10 Overview – Draw Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

4.21 Maintenance – Cutting Device Baler Twine . . . . . . . . . . . . . . . . 166

4.22 Maintenance – Hot-air Passage . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.23 Maintenance – Ionization unit . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.24 Maintenance – Heating Devices / Cooling Devices . . . . . . . . . . 169

4.25 Maintenance – Suction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.26 Maintenance – Waste Strip Feedback Device . . . . . . . . . . . . . . 171

4.27 Maintenance – Fibrillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.28 Maintenance – Electric Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . 206