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AKR 550
CUSHION GUM
EXTRUDER WITH
TREAD BUILDER
1
PREFACE
READ THIS USER MANUAL THROUGHLY BEFORE UTULIZING THE MACHINE.
ALWAYS KEEP THIS MANUAL AVAILABLE AS REFERENCE. ALL THE INFORMATIONS
IN THIS MANUAL ARE DESIGNED FOR EFFICIENT, SAFE AND LONG-TERM USE OF THE
MACHINE.
.
This “User and Service Manual” is an inseparable part of the machine.
User must act in reference to the instructions set out herein.
2
Picture 1 AKR550
Project :
Type :
Serial No :
Project No :
CUSHION GUM RETREADING MACHINE
AKR550
B151013
000637
Year of Manufacture :
2015
Commissioning Date :
2016
Rev
Modification
Date
Name, Surname
001
002
First publication before commissioning
15.02.2016
Abdullah AŞÇI
Mechanical data update
23.03.2016
Serkan UYAR
THIS MANUAL MUST BE READ THROUGHLY BEFORE USING THE MACHINE AND KEPT AS A
REFERENCE GUIDE THROUGHOUT THE LIFE CYCLE
3
TABLE OF CONTENTS
1- GENERAL STANDARDS AND WARNINGS
1.1
WARNINGS
1.2
SECTIONS
2- GENERAL INFORMATION
2.1
2.2
2.3
2.4
2.5
INTENDED USE OF THE MACHINE
MACHINE MANUFACTURER INFORMATION
WARRANTY DISCLAIMER
TECHNICAL SERVICE COMPLIANCE
PART REPLACEMENT
3- GENERAL SAFETY WARNINGS and SYMBOLS
4- TRANSPORTATION & STORAGE AND ASSEMBLY
4.1
4.2
4.3
4.4
4.5
TRANSPORTATION
STORAGE
ASSEMBLY & DISASSEMBLY
POWER CONNECTION
AIR CONNECTION
5-TECHNICAL INFORMATION
5.1
5.2
MASTER GROUPS OF THE MACHINE
TECHNICAL INFORMATION ON THE MACHINE

Capacity and Mechanical Properties

Equipment Properties

Electrical Properties
6-CONTROL COMPONENTS OF THE MACHINE
6.1
CONTROL COMPONENTS OF MAIN CONTROL PANEL
7-PRE-OPERATION CONTROL and ADJUSTMENTS
7.1
7.2
PRE-OPERATION CONTROLS
ADJUSTMENTS
8-OPERATIONAL PROCESSES
9-MAINTENANCE AND REPAIR
9.1
9.2
9.3
CONTROL OPERATIONS
CLEANING OPERATIONS
LUBRICATING POINTS
10-MECHANICAL PARTS, SHAPE and SPARE PART LIST
11-PNEUMATIC CIRCUIT DIAGRAM
12-ELECTRIC WIRING DIAGRAM
4
1.
GENERAL STANDARDS & WARNINGS
1.1 Warnings
This operation and maintenance hand book comprises AKR 550 Cushion Gum Retreading Machine and is
a requisite part for technical documentation.
All the information, instructions and recommendations provided in this manual are intended to ensure
the health and safety of the operator primarily; and then the proper, efficient and extenden use of the
machine.
1.2 Sections
The whole hand book is composed of eleven sections.
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1. General Standards ve Uyarılar
2. General Information
3. General Safety Warnings and Symbols
4. Transportation, Storage and Assembly
5. Technical Information
6. Control Components of the Machine
7. Pre-operation Controls and Adjustments
8. Operational Processes
9. Maintenance and Repair
10.Spare Part List
11.Pneumatic Circuit Diagram
12.Electric Wiring Diagram
5
2.
GENERAL INFORMATION
2.1 Intended Use of the Machine
Manufacturing purpose of the machine; is to provide implementation of the source material between the
tread rubber and casing to surface of the casing.
All the equipment and tools on the machine are designed in accordance with the intended use and
quality and safety standards are at the top level.
2.2 Manufacturer Information
Company Title
Address
Tel
Fax
Mail
Web
: AKAR MAKİNA SAN. TİC. A.S.
: Organize Sanayi Bölgesi 14.Cad. No: 8
26110 Eskişehir / TURKIYE
: +90 222 236 17 00
: +90 222 236 17 02
: info@akarmak.com.tr
: www.akarmak.com.tr
www.autoclave.com.t
r
Akar Makine carries operates at its facilities of 19,000 m² in total at Eskisehir Organized Industrial Site
in machine manufacturing sector. We carry on business in two separate factories close to each othe
within the following core business and sector:
-
Pressure Vessel / Autoclave
Tire Retreading Machines
Medical Waste Sterilisation Systems
Project-based Manufactures
Within the manufacturing of pressure vessel and autoclave; we make production of the glass using
autoclave technology, composite material, rubber coating/gum, construction material, sterilization,
etc.. We produce customer-specific pressure vessels other than standart manufactures.
Thanks to our Tire Retreading Machines portfolio, we perform turn-key installation of retreading plants
for truck and OTR groups. All the machine and ancillary equipment of truck and OTR group facilities are
included in our portfolio.
In the recent period, we started manufacturing Medical Waste Systems as an extension of autoclave
products and successfully completed various facilities and commissioning recently. The said product
groups can be offered to our customers as “Pre-Autoclave Shredding” and “Post-Autoclave Shredding”
systems.
Other than standard products, Akar Makine offers project-based manufacturing within the sectors of
iron and steel, energy, mine and transportation.
Akar Makina realizes projects requiring high level of project management and organizational skills and
obtains the part of its sales figures from export sales. Our manufactures are performed in our facilities
operating at cutting-edge technological infrastructure and at the top-level quality that meets 100% of
our customers’ requirements. Our company is able to make all the manufacturing in compliance with
ASME, 97/23/EC (CE), GOST standards. We meet expectations of our customers within the scope of
optimum quality and price by creating best solutions.
Our company considers long-term relationships and internationally accepted companies take an
important place among our customers.
6
2.3 Warranty Disclaimer
Global warranty of the machine is 12 months against labor and parts.
AKAR Makina purchases guaranteed ancillary equipment for the use of manufacturing of the machines.
We reflect such warranty period and conditions to the end-users.
Defetcs arising from failing to observe the following clauses, machine damage as a result of occupational
accidents and services and part replacements thereof shall not be covered by the guarantee.
1- Failing to follow the operator and safety warnings mentioned in this user manual.
2- Electrical faults arise from the electric supply system to which the facility of of the machine is
connected and part replacements thereof.
3- Faults and damages arise from the modifications made beyond the original design of the machine.
4- Faults and damages arise from the modifications made on electical, pneumatic, hydrolic projects of
the machine assembly.
5- Replacement of any part of the machine by unauthorized person.
6- Faults and damages arise from failing to follow the lubricating period given in this manual for the machine.
7- Defects from faulty maintenance and equipment installed and used other than the lubricant
properties and spare part list mentioned in this manual.
8- Damages arise from acts of god such as fire, lighting, flood, flow, landslip, earthquake, etc..
9- Problems arise from technical intervention performed beyond the authorized service personnel of
AKAR Makina.
10- Damages occurred as a result of drops due to the improper connections, forklifts or ropes during the
transportation/handling of the machine.
11- Damages occurred as a result of impacts arise from improper environment conditions during the
storage.
12- Damages arise from electric and air connections incompatible with the instructions given for the
assembly process. (absence of grounding or faulty grounding, voltage fluctuation, improper
compressor, insufficient air, etc.)
2.4 Technical Service Compliance
Machine operator must inform Maintenance-Repair service of the company if any fault occurs within the
machine. Maintenance-Repair service of the company must contact the manufacturer company.
User may encounter different problems during the use and operation of the machine. This manual is
important to minimize the potential problems. User must contact with the manufacturer if he considers
the solution is troublesome.
Technical Service Contact Info
Telephone
Fax
E-mail
Address
:
:+90 222 236 1700 / +90 535 106 6267
+90 535 106 6268 / +90 535 106 6269
:+90 222 236 1702
:servis@akarmak.com.tr
:Organize San. Böl. 14. Cad. No:8 26110
Eskişehir / Türkiye
2.5 Part Replacement
The machine is under warranty for part replacement against problems arising from manufacturer beyond
its warranty.
7
3.
GENERAL SAFETY WARNINGS and SYMBOLS
Symbol
Desctiption
THIS SYMBOL REFLECTS SAFETY WARNING. WARNINGS UNDER THIS SYMBOL
MUST BE CAREFULLY READ AND INSTRUCTIONS MUST BE FOLLOWED.
NONCOMPLIANCE WITH THE INSTRUCTIONS MAY POSE OCCURRENCE OF
HAZARDOUS SITUATIONS FOR THE USER AND ALL LIVING CREATURES
AROUND.
THIS SYMBOL REFLECTS INFORMATION FOR THE USER AND ALL PERSONS
RELATED TO THE MACHINE. USEFUL INFORMATIONS ARE PROVIDED FOR
ALL PHASES CONCERNING THE MACHINE.
THIS SYMBOL REFLECTS TECHNICAL INFORMATION FOR THE OPERATOR
USING THE MACHINE. THE OPERATOR MUST CONSIDER SUCH TECHNICAL
INFORMATION. ACTING UPON SUCH INFORMATIONS WILL EXTEND THE
QUALITY OF USE, SAFETY AND LYFE CYCLE OF THE MACHINE.
INSTRUCTIONS MUST BE FOLLOWED IN THE SECTIONS IN WHICH THIS
SYMBOL IS APPEARED. IT MAY POSE AN ELECTRIC SHOCK RISK IF SUCH
INSTRUCTIONS ARE NOT FOLLOWED.
THE MACHINE MUST BE LIFTED FROM THE POINTS ON WHICH THIS
SYMBOL APPEARS IN ORDER TO PERFORM PROPER TRANSPORTATION.
OPERATOR MUST WEAR SAFETY HELMET IN THE SECTIONS IN WHICH THIS
SYMBOL IS APPEARED.
OPERATOR MUST PERFORM HIS OPERATIONS VIA PROTECTIVE GLOVES IN
THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED.
OPERATOR MUST PERFORM HIS OPERATIONS VIA SAFETY FOOTWEARS IN
THE SECTIONS IN WHICH THIS SYMBOL IS APPEARED.
Symbol
Description
SIGNALIZES THAT THE MACHINE MUST BE SHUT DOWN BEFORE
MAKING ANY ADJUSTMENT.
SIGNALIZES THAT THE MACHINE MUST BE DISCONNECTED BEFORE
PERFORMING ANY MAINTENANCE OR CLEANING.
THE USER MANUAL MUST BE READ BEFORE USING AND
OPERATING THE MACHINE.
8
4.
TRANSPORTATION, STORAGE AND ASSEMBLY
4.1 Transportation
Picture 2 Transportation Process
The machine must be handled via being connected from the points mentioned considering the
transportation pictures above. The haulage rope, chain or cable must be selected in compliance with the
machine weight mentioned in the capacity and mechanical properties.
Pay attention to fix the moving parts of the machine before transportation.
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
Always ensure holding the handles shown.
Do not stay under the machine during the transportation.
Do not perform loading or discharging with fast movements.
Min. 10 tons crane must be used for handling of the machine to the
transportation vehicle.
User is responsible for the risks arise from drops or impacts as a result of using
improper haulage vehicles during the transportation of the machine.
4.2 Storage
The machine is packaged by taking the measures after being tested in the factory. When performing the
storage of the machine, a proper storage area must be determined according to the dimensions of the
machine and impacts from narrow spaces must be avoided. The storage area must be moisture-free.


Room temperature is recommended for storage.
Long-term storage at 1000 m above the sea level is not recommended.
4.3 Assembly & Disassembly
Storage and transportation must be performed via following the instructions at the work site of the
machine. Initial installation processes of the machine must be performed by Akar staff. Providing
required air and electric connections to operate the machine is sufficient for assemblies after
transportation following the initial assembly.
9


The power must be turned off from panelboard of the facility before disconnecting.
Installation valves must be open and main feed valves must be close when air
connection is disconnected.

The floor on which the machine is assembled must not be uneven as it may
unbalance the machine.

Sufficient space must be arranged around the machine for operation,
maintenance and repair.
 No connection is needed for positioning the machine. The machine must be
placed on the floor as it stands.
4.4 Power Connection
Power connection is in the electric panel of the machine. The connection must be performed as it is
shown in the electric circuit diagram.
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Electric connection must be performed by an authorized electrician.
Cable amount to be connected to the panel must comply with the section
mentioned in the electrical properties of the machine.
The cable must not be powered-up when the connection is being performed.
The energy source must comply with the operating voltage and frequency of
themachine.
We recommend taking the power compensation from a panelboard of the facility.
When the distance of the energi cable exceeds 50 m from the panelboard, the
section must be increased at one level.
4.5 Air Connection
Air connection is in the equipment group of the machine. The connection must be performed in accordance
with the equipment circuit diagram.

Do not aerate the machine when the connection is being performed.

Air pressure compressor must be avoided from air leakage.

The compressor must be opened first and then the air inlet valve must be opened
after the air connection is performed.
10
5.
TECHNICAL INFORMATION
5.1 Machine Master Groups
Picture 3 Master Groups
Master groups of AKR 550 are divided into 9 main groups.
1
2
3
4
5
6
7
8
9
FRAME GROUP
EXTRUDER GROUP
MOLD
TIRE ROTATING GROUP
THRUST GROUP
ROLLING GROUP
HORIZONTAL MOVEMENT GROUP
VERTICAL MOVEMENT GROUP
ENCODER GRUOP
11
5.2 Technical Information of the machine

Capacity & Mechanic Properties
Model
AKR550
Max. Tyre Diameter
Ø 1450 mm
Min. Tyre Diameter
Ø 750 mm
Dimensions
2685 mm (H), 4400 mm (L), 2040 (W)
Weihgt
3,5 ton
Capacity
1,5~2 min / tire

Equipment Properties
Connection Type
Connection
Operating Pressure

Air
1”
Max. 6 bar
Electrical Properties
Gross Power
30 KW
Operating Voltage
400 V (3 faz)
Frequency
50-60 Hz
12
6.
CONTROL COMPONENTS OF THE MACHINE
6.1 Main Control Panel Control Components
Picture 4 Main Control Panel Image
ITEM
NO
COMPONENT
DESCRIPTION
1
Inflation / Deflation
2
Cushion gum /
Apply Tread /
Stitching
3
Man / Auto
Provides manual or automatic operation of the machine.
4
Auto Start
Starts automatic process.
5
Auto Stop
Stops automatic process.
6
Pause
7
System Start
8
Pressure
9
10
11
Pressure Adjusting
Low / Medium / High
Tire Rotating
Backward / Forward
Tire Rotating
Slow / Fast
12
Laser On / Off
13
Lighting On / Off
Provides inflation and deflation of tire.
Determines operation mode of the machine. Cushion gum winding /
Apply Tread / Stitching
Pauses the system during the stitching process.
Functions for recommissioning on initial start-up of the machine and
after pressing the emergency stop.
Decompresses and boosts cylinder pressure.
Adjusts the cylinder pressure at the values entered in the adjustment
page
Moves forward – backward the tire rotation motor.
Provides slow – fast circulation of the tire rotation motor.
Turns the laser on/off.
Controls the lighting.
13
14
Send To Park
15
Extruder Forward
16
17
18
Tire Move
Backward / Forward
Mold 1 Motor
Backward / Forward
Mold 2 Motor
Backward / Forward
Provides the moving parts of the machine to turn the home position
and recipe value when the power is on.
Moves extruder motor forward.
Moves forward – backward the tire rolling motor.
Moves forward – backward the mold 1 motor.
Moves forward – backward the mold 2 motor.
19
Heater On / Off
Starts the heater system on.
20
Emergency Stop
Provides emergency stop (shutdown).
Table 1 Main Control Panel Description of Controls
START PAGE
Picture 5 Start Page İmage
When the main switch of the machine is turned on, the start page appears first. This page enables to
proceed language selection page and other sub-pages. Proceeding to sub-pages can be administered via
touching the desired page on the touch panel or pressing the function buttons on the touch panel.
14
CUSHION GUM PAGE
Picture 6 Cushion Gum Page İmage
Cushion gum page displays whether the conditions required for cushion gum process are provided or
not. Also this page provides proceeding to the recipe page.
COMPONENT
DESCTIPTION
Displays the actual level and
position of the tire.
Displays whether the extruder,
upper and lower mold reach or
not to the temperature rating
specified at the temperature
page. When it reaches to the
desired temperature the sign
turns into
, otherwise
.
Displays whether the
rubber is supplied or not
at extruder rubber input.
Displays the tire inflation
or deflation.
15
Displays the position of tires
and molds. Also enables to
transfer the desired tire and
mold positions to PLC. This
can be made through
touching the
sign. The sign turns into
.
Displays the distance
between shoulder molds.
Displays whether the
shoulder molds are reached
the desired level or not.
will turn into
when reaches the desired level.
Displays the active recipe
loaded in the machine and
provides proceeding to the
recipe page after pressing
the recipe button.
Table 2 Cushion Gum Page Description of Controls
16
APPLY TREAD - STITCHING PAGE
Picture 7 Apply Tread – Stitching Page İmage
This page enables to enter required values for Apply tread - Stitching processes. Such as speed,
position and pressure.
COMPONENT
DESCRIPTION
Displays the actual position of the tire.
Displays the actual cylinder pressure.
Enables entering the moving down and up
speeds of Apply tread - Stitching group in
percentages.
Enables entering the starting position of
Apply tread - Stitching group.
17
Enables entering the thickness of the tread
in mm.
Pressure rate; Cylinder pressure value.
Pressure level low; this value is entered in
percentages and is the gap of the cylinder
pressure by percentages.
Pressure level high; this value is entered in
percentages and is the excess of the cylinder
pressure by percentages.
These three values are activated via
Pressure Adjusting
Low / Medium / High buttons.
Tire speed at the apply tread process.
Displays the actual distance between
rollers.
Enables entering ranges of the zones in
stitching process and the speed values of the
motor in these zones. Also enables tire speed
values in stitching process.
Enables entering the number of rotating cycle
of the tire and the speed value of the tire
when the cylinder pressures the tire in the
stitching process.
Table 3 Apply Tread - Stitching Description of Controls
18
MANUEL CONTROL PAGE
Picture 8 Manuel Control Page İmage
In the manual control page, buttons on this page enable to control the outlets of the machine
independent of each other after positioning the Man/Auto button to manual in control panel.
Also it displays the actual values of the moving parts.
COMPONENT
DESCRIPTION
Displays the actual values of the moving
parts.
Displays the position and agle of the tire.
19
Displays the actual positions of
reelings and Apply tread – Stitching
group.
Enables to turn on/off the valves of the
extruder valve group via buttons.
Enables to heat the S,A and P group
shoulder molds via buttons.
Enables to operate the heater and
chiller devices via buttons.
Speed values of extruder and tire
position motors on the manual mode.
Enables to inflate/deflate the tire and
rim expand/collapse via buttons.
Enables to move up/down the Tread
apply roller via the pressure value
entered in manual process.
Enables to move up/down the Apply
tread - Stitching group via entering the
speed value on manual process.
Enable to operate the pressure valve of
the reelings by the number of stitch area
entered and to operate the roller motor
forward/backward by the speed value
entered.
Table 4 Manuel Page Description of Controls
21
FAULT PAGE
Picture 9 Fault Page İmage
Faults and alarms occurred within the machine are followed on this page and the page enables to reset
these faults and alarma via buttons.
COMPONENT
DESCRIPTION
Pressing this button means that the
operator displays the faults and alarms
occurred. (Acknowledge Buton)
This button restarts the process
after the faults and alarms having
been removed.
Table 5 Fault Page Description of Controls
22
SYSTEM SETTING PAGE
Picture 10 System Setting Page - 1
System setting-1 page enables to make shoulder mold and mold offset settings, certain settings
required for winding process and settings related to tire inflation.
COMPONENT
DESCRIPTION
Enables to enter offset values of molds.
23
Enables to enter offset values of shoulder
molds.
Extruder Stop Angle; extruder
motor stops at this degree angle of
the tire.
Tire Stop Angle; tire rotating motor
stops at this degree angle of the tire.
Tire move back angle; tire move
motoru proceeds to home position
at this degree angle of the tire.
Tire rotate Offset; tire rotating motor
starts late turning by this value when
the cushion gum process is started.
Tire Approach Offset; Offset value of the
tire move motor.
Cushion gum Idle Waiting; extruder
motor operates by Cushion gum Operate
After Idle time if the cushion gum
process is not started by this period.
Tire Inflation Time; The value which
determines the start of tire inflation
after how many seconds from the rim
expand.
Tire Inflation Rotate Time; The value
which
determines
that
how
long
(seconds) the tire rotates when the tire
inflation is started.
Tire Deflation Time; The value that
determines when the rim collapse is
occurred after the tire deflation.
The distance between twin rollers.
Enable to proceed system setting - 2 page.
Table 6 System page-1 Description of Controls
24
Picture 11 System Setting Page - 2
System setting-2 page enables to enter the speed and factors used by extruder and tire motor in the
cushion gum process. Values entered in this page are critical. They have direct influence on cushion
gum process. Therefore Akar Makinanın is not responsible for modifications made beyond Akar Makina‘s
knowledge.
COMPONENT
DESCRIPTION
Speed and pressure values in
accordance with the buffed
tread width.
25
Factors entered for
synchronous operation of
extruder and tire motor.
Speed factor by cushion
gum thickness.
Enables to go back to
system setting - 1 page.
Table 7 System Page-2 Description of Controls
26
RECIPE
Picture 12 Recipe İmage
Enables to proceed recipe page from cushion gum page. Shoulder mold and tire are positioned at the
desired position manually when creating the recipe and by pressing
symbol located at section in
which tire and shoulder mold positions at Cushion gum page, symbol turns into .
Then the
operator presses the NEW button. Recipe name must be entered in Data Record Name section. By
pressing RECEIVE FROM PLC button and completing the empty areas and by pressing the SENT TO PLC
button, the recipe is sent to the machine. Then the recipe can be saved by pressing the SAVE button.
For the tires with similar properties, you just need to press SENT TO PLC button to send the tire values
to the machine.
27
COMPONENT
DESCRIPTION
SENT TO PLC; Sends tire values of the
recipe to the machine.
RECIVE FROM PLC; Brings the tire
values of the machine to the recipe.
Enables to proceed Cushion gum page.
Table 8 Recipe Description of Controls
28
WORKING TIME PAGE
Picture 13 Working Time Page İmage
This page displays working times of the machine, heater and processes.
29
HEATING SETTING PAGE - 1
Picture 14 Heating Setting Page – 1 İmage
This page displays the set and actual values of the extruderin, lower – upper mold, heater and
chiller. The page also displays the average temperatures of shoulder mold groups.
By pressing "Waiting Activation"
symbol, it turns into and all the temperature set values of the
machine turns into the stand-by temperature values. The reason for this is to prevent the cushion
gum (rubber) material in the extruder from decomposition if the machine stands by for a long time
for any reason.
30
HEATING SETTING PAGE - 1
Picture 15 Heating Setting Page – 1
This page displays set, actual, + - tolerance and waiting values of extruder, lower – upper mold,
heater, chiller and shoulder mold.
+ - tolerance values shows the proximity to set values and also shows that the extruder areas, heater,
chiller and shoulder mold devices between such + - tolerance values are at the desired temperature
levels for cushion gum winding.
When the standby mode is activated, waiting set values of the machine substitutes the set values.
31
7. PRE-OPERATION CONTROLS and ADJUSTMENTS
7.1 Pre-operation Controls
The following controls must be performed before the operation:




Input Regulator Pressure Gauge (6 Bar)
Valve Air Installation Lubricator
Scraper Blades
Cooling Water Control

Package switch on the panelboard must be closed or locked if required
before operation.
The machine must not be operated if the main air inlet regulator
displays a value over 8 bar.

Main air intake regulator must be at 6 bar max..
Other regulators must be adjusted by the operator properly in accordance
with the tire size during the running-in-period.
The nuts to which the scraping blades are connected must be tightened.
Cooling water tank must be filled with clean water.




7.2 Adjustments
The following adjustments must be made before the operation.
1.
2.
3.
Rim selection and assembly
Pneumatic pressure level must be at optimum level
Scraping data entry
Selection of rim must be made in accordance with the tire size.


Main air inlet must be closed when performing the adjustments.

Fastening locks are ensured to be replaced in their housing when the rims
are assembled.
7.3 Proper Rim Selection
7 types of rims manufactured in accordance with the tire sizes commonly used in the market are as
follows. Rims to be used other than such tires can be manufactured upon the demand of the customer.
Operator decides the proper rim for the tire to be scraped and the Hub is mounted on it.
1) 17-20x6,75''
2) 17-20x8,25''
3) 17-20x13,5''
4) 20-22,5x9''
5) 20-22,5x11,75''
6) 22-24,5x9''
7) 22-24,5x11,5''
Picture 16 Rim Selection
32
8. OPERATIONAL PROCESSES
















Main swith and air valve of the machine is opened.
Heater device is opened through main control panel after starting the machine program and no
actions are taken till the extruder and molds are conditioned (temperature).
When the extruder and mold reach the desired temperature, cushion gum material is taken to be fed.
Recommended cushion gum dimensions;
Ideal size : Tape cushion gum 40 mm x 7 mm
Max size
: Tape cushion gum 50 mm x 7 mm
After preparing the extruder and mold system, proper rim is attached to the machine which
suits the tire to be retreaded.
Right/left shoulder molds suitable for the tire shape are attached to the mold.
Cushion gum winding mode is selected via the control panel.
The tire is loaded and inflated (Average tire pressure must be 1,5).
The tire is approached to the mold and pressed adequately and right/left shoulders are
adjusted, then the recipe created is recorded for the tire size.
Automatic mode of the machine is started via the control panel.
After making all the settings, winding process is automatically started via the panel.
After the machine completed the winding process, it goes to the starting point
automatically.
Tread apply mode is selected via the control panel.
Then the thrust mode is selected according to the tread properties to be used via the control panel.
By ordering the automatic start via the control panel, tread applying module is sent to the
starting position.
The operator pastes the rubber tread to the tire back surface. In the meantime the operator
controls the tire via foot switch by rotating it step by step.
Picture 17 Start of Tread Apply Process




Center the tread by turning the laser on and continue rotating via foot switch.
The tire automatically stops when the end of the tread is aligned with the tension cylinder.
By pressing the automatic start button via the control panel, the tension cylinder is ensured to
pressurize the tread surface completely.
After the tire rotated at 2700 (3/4 lap), it stops automatically for the check by the operator and
the operator provides kissing the back ends by adjusting the tension pressure via a joystick.
Picture 18 Tread Apply Process


Rotation of the tire and tread apply process are completed automatically.
The system is restarted by pressing the automatic stop button more than 3 seconds.
33



The stitching mode is selected via the control panel.
By selecting the automatic start via the control panel, the stitching module is sent to the starting
position.
Automatic start is selected via the control panel. Stitching cylinder goes down and then the
stitching process is completed at the desired time period.
Picture 19 Stitching Process


8.
Twin rollers start stitching process by landing on the tire according to the desired parameters.
After the machine complete the stitching process automatically, again goes to the starting
position.
MAINTENANCE and REPAIR
8.1 Control Operations


Make manual and visial control before using the machine. Contact technical service if it
has any broken or malfunctioned part.
Keep the machine clean to use it long-term and reduce maintenance cost.
Daily Maintenance








General maintenance, cleaning of the working area and burrs must be performed.
Operating noise and temperature of target motors must be chaecked.
All the pneumatic system must be reviewed.
Leakages from the joints of pneumatic system must be checked.
Points required lubrication of the pneumatic system must be lubricated.
Main air pressure which operates the machine must be checked whether it is at 6 bar or not.
The water collected in the waterstop filter of the conditioner placed on the machine must be discharged.
Cutting tools must be chacked. Blunt cutters must be replaced.
Weekly Maintenance



Regular maintenance of the whole machine must be made. The system must be checked throughly.
Machine panel and electic control buttons and switches on the panel must be checked.
All the moving parts and systems (Skids and sash bars) must be lubricated, the areas directly in
contact with the rubber burr must be cleaned with a dry cloth. The lubricants and equivalents are as
follows.
Petrol Ofisi
MOBİL

: SUPER GRES EP-0
: MOBİLUX EP-00
SHELL
: ALVANIA EP-0
Mechanical systems of the machine subject to the abrasion must be supported with
sufficient grease oil. The grease oils and and equivalents to be used are as follows.
BP
Petrol Ofisi
MOBİL
: ENERGREASE LS3
: SUPER GRES 3
: MOBİLUX 3
SHELL
CASTROL
: ALVANIA R-3, RL-3
: SPHEEROL AP-3
34

The lubricant level of the tube on the conditioner of the machine, which lubricates the
pneumatic system must be checked, if the lubricant level is at the minimum, a suitable
lubricant addition must be made. The lubricants and equivalents to be used are as follows.
Petrol Ofisi
Mobil











: Regal Oil 68 (Turbine Oil) SHELL
: DTE Oil Heavy Medium HM
: Turbo T68
Anchorage bolts of the general mechanical assembly of the machine must be checked
against loosening. Loosen bolts must be tightened according to the suitable torque level.
Bearings of the moving parts of the machine must be chacked against
loosening.
Cleaning of the cutting tools cooling tank must be made.
Moving parts of the pneumatic valves must be made.
Cleaning and maintenance of pneumatic pistons must be made.
All the manometers must be checked.
Lubricants of all the pneumatic systems must be checked whether they are active or not.
All pneumatic and lubricating hoses and joints thereof must be checked.
Leakages and escapes on pneumatic pipes must be checked.
Faulty and malfunctioned pneumatic circuit components must be replaced.
Impurity indicator of pneumatic filter must be checked.
Monthly Maintenance








The system must be checked throughly.
Machine parts such as tool-sets or tool handles must be checked.
Linear skids and carriers, worm gear ball rods and fixed bearings must be visually and
manually checked by removing the protective covers whether they are lubricated or not.
Monthly maintenance of the filters must be made. Leakages must be checked.
Seals and cushioning adjuster bolts of vertical and horizontal cylinders must be
checked and if the cushioning setting is out of oreder, the adjustments must be made.
The cylinder must be replaced if the seals do not function or the cushioning settings
are out of order.
The leakage of the pneumatic and lubricating system must be checked.
In the same manner; the cental lubrication system must be checked visually and manually
against any disconnexion, blockage in the direction of flow or if the hoses are repleted with
oil. In case of any of such problems occur, plastic oil hoses must be replaced.
The machine must be cleaned with a brush or a dry cloth without aerating by removing all the
protection covers for the burrs occurred. The machine should not be operated before closing
the protection covers.
Monthly Maintenance







Cooling liquid tank should be discharged, cleaned and reassembled.
Tension of the spindle motor belt and deformation thereof should be checked.
Proxmity switch detection surface should be cleaned.
Coal and collectors of Electromotors should be checked and cleaned and
replaced.
Functions of the stopping switch and emergency stop button should be
checked.
Brakers on the control boards of protective relay contacts should be
checked.
All the hose joints on the machine (Water, air, hydrolic etc.) should be checked.
35
Annual Maintenance











Abrasion and oil film occurrence on the starting skids must be checked and adjusted.
All the powertrain parts on the machine must be checked. Abraded, worn equipment or
equipment needs replacement must be replaced.
Tension of the belt and pulley systems on the machine must be checked.
The lubricant used in hydrolic systems must be replaced.
Wearing parts must be replaced.
Electric cable connections must be checked. Broken, disconnected and damaged cables
must be replaced.
Bushings and bearings of moving parts must be checked against abrasion replaced if required.
Impaired sealing gaskets of pneumatic system must be replaced.
Maintenance of the filters must be made.
Sound absorbers must be checked and their filters must be replaced.
Efficiency and power control of circuit elements must be followed.
8.2 Cleaning Operations
Cleaning Schedule and
Criteria





Rubber burrs on the machine must be cleaned daily.
Dust and burrs on the skids must be cleaned within the 6 monhts maintenance by removing the skid
covers. By this means, skids will have ease of movement and abrasion on the surface is avoided.
Electric and pneumatic tools and mechanical assembly must be protected from dust. Because dust
deposit causes various malfunctions on the machine. Electric and pneumatic tools can be cleaned
with a dry cloth. Mechanical assembly and the body of the machine may be cleaned with a damp
cloth.
Mechanical parts should be cleaned with an oil-soaked cloth to prevent dust accumulation.
Inside and outside of the main control panel may be cleaned with a clean and dry cloth. Dirty
surfaces of the panel can be cleaned with an alcohol-soaked cloth.




Pacco swith and main air inlet valve of the machine must be
closed during the cleaning process.
When cleaning the inside of the main control panel, the
power must be off.
Do not use solvent, flammable and corrosive liquid materials
for cleaning.
Pressurized air must be used in a controlled manner for cleaning
the electrical materials.
8.3 Lubricating Points
Adjust the pneumatic system lubricant control and oil adding lubricator to operate one drop per minute.
Drop amount can be displayed on the glass indicator of the lubricator and adjusted via the screw on the
upper part of it.
36
10. MECHANICAL PARTS, SHAPE and SPARE PART LİST

ITEM
NO
STITCHING ROLLER
PIECE
PART NAME
PICTURE / STANDARD NO
1
DEEP GROOVE BALL BEARING
DIN 625
2
6004‐2RS
2
HOLE RING
DIN 472
1
Ø42x1,75
3
SHAFT RING
DIN 471
1
Ø20x1,2
DESCRIPTIONS
37

REEL UP GROUP
ITEM NO
PART NAME
1
LSUD2005 LH Kozanli
2
3
DEEP GROOVE
BALL BEARING
REDUCER
PICTURE /
STANDARD
DIN 625
PIECE
DESCRIPTIONS
1
LMT LSUD 2005 LH
2
6002‐2RS
1
YILMAZ EV030.03‐63/4b, 0,18 kW, 97 d/d
4
PNEUMATIC CYLINDER
2
PEMAKS PK‐A‐T 040‐125 (ERKEK MİLLİ)
5
LINEER RAY
2
HIWIN HGR15R840H E:30
6
8
HIWIN HGW 15CCH
7
RAIL CARRIER
ENCODER
1
8
INDUCTIVE SENSOR
2
AUTONICS E5058‐1024‐3‐T‐24‐CS
LEUZE IS 212MM/4NC‐4E0‐S12
9
WEDGE
DIN 6885
2
A 5x5x25
10
WEDGE
DIN 6885
1
A 5x5x56
11
BALL SCREW
NUT
1
LMT LSUD 2005 LH
38

TIRE ROTATING GROUP
ITEM NO
PART NAME
1
2
RAIL CARRIER
FLANGED BEARING
3
SAFETY WASHER
DIN 5406
4
LOCK NUT
5
WEDGE
6
7
8
9
PICTURE / STANDARD NO
PIECE
DESCRIPTIONS
4
HIWIN HGW 30 CCH
2
1
FAG UCFC 212
MB 12
DIN 981
1
KM 12
DIN 6885
2
A 14 x 9 x 100
TIMING BELT
1
16 T5/840 z:168
REDUCER
ROTATING ELEMENT
DOUBLE LINE
CONNECTION BEND
1
YILMAZ KN473.00 İ:51,22
ROTOTECH 3100‐011‐210
ROTOTECH R00042513041514 (Ø15,8
DELİKLİ)
1
1
10
LINEER RAY
2
HIWIN HG30R1640H E:20
11
INDUCTIVE SENSOR
2
LEUZE IS 212MM/4NC‐4E0‐S12
12
RUBBER WEDGE
2
Ø30x30 ‐ M8x25 SINGLE‐SIDED BOLTED
39

ITEM
NO
1
2
3
HORIZONTAL MOVEMENT GROUP
PART NAME
PICTURE/STANDART NO
PIECE
DESCRIPTIONS
1
LMT LSUD 3205
550‐02.01.18
1
LMT LS 3205 BALL SCREW L:1035
KV_10_3_R_2G90S_B14_ML1
1
BALL SCREW NUT
POWER SCREW
REDUCER
YILMAZ KV102.00, 1,5 kW, 462 d/d
4
ENCODER
1
AUTONICS E5058‐1024‐3‐T‐24‐CS
5
INDUCTIVE SENSOR
2
LEUZE IS 212MM/4NC‐4E0‐S12
6
RUBBER CUSHION
2
7
BEARING
1
Ø30x30 ‐ M8x25 SINGLE‐
SIDED BOLTED
FK25
40

ITEM
NO
1
2
3
4
ENCODER GROUP
PART NAME
RESİM/STANDART NO
PIECE
DESCRIPTIONS
HOLE RING
DIN 472
2
Ø47x1,75
1
AUTONICS E5058‐1024‐3‐T‐24‐CS
DIN 625
2
6005‐2RS
DIN 6885
1
A 6x6x20
ENCODER
DEEP GROOVE
BALL BEARING
WEDGE
41

S.
PART
NO
VERTICAL MOVE GROUP
PART NAME
PICTURE / STANDARD
NO
PIECE
DESCRIPTIONS
1
REDUCER
1
YILMAZ KV102.03, 1,5 kW, 462
d/d
2
FLANGED BEARING
1
UCFC 206
3
RAIL CARRIAGE
4
HIWIN HGW30CCH
4
BALL SCREW NUT
1
LMT LSUD 4005
5
LINEER RAY
2
HIWIN HGR30R990H E:15
6
ENCODER
1
AUTONICS E50S8‐100‐3‐T‐1
7
RUBBER WEDGE
2
Ø30x30 ‐ M8x25 SINGLE‐
SIDED BOLTED
42
 LASER GROUP
PICTURE /
STANDARD NO
PIECE
DESCRIPTIONS
HAND WHEEL
1
WEDGE SK 7305‐101
VERTICAL BEARING
RAIL
CARRIAGE
1
UCPA 202
4
LASER
2
LASER‐T TE 056
5
LINEER RAY
1
HIWIN HGR15R560H E:10
ITEM NO
PART NAME
1
2
3
2
HGR15R_560_H_1
HIWIN HGW 15CCH
43

IMPRESSION ROLLER
ITEM NO
PART NAME
1
SENSOR PNEUMATIC CYLINDER
2
PNEUMATIC CYLINDER
3
BEARING
PICTURE / STANDARD NO
PIECE
1
ISO 15552
1
2
DESCRIPTIONS
LEUZE HRTR 25B/66‐S8
SMC CP96SDB80‐160
UCPA 205 LEUZE HRTR 25B/66‐
S8
44
11. PNOMATİK DEVRE ŞEMASI
ITEM NO
Reference
Brand
Piece
01
02
03
04
05
‐
‐
175‐00.00.00 C
‐
VP742‐5YD1‐ 04FA
PEMAKS
PEMAKS
AKAR
Tire
2
1
1
1
06
07
08
09
10
11
SV3A00‐5FU‐X2
SV3100‐5FU
SV3100‐5FU
VHS40‐F04
AW40‐F04DE
ARP40‐F04H
SMC
SMC
SMC
SMC
SMC
SMC
SMC
2
2
1
1
1
1
1
12
ITV2050‐31F3L3‐ Q
13
14
15
16
17
18
19
IR2020‐F02BG
AR20K‐F02BE
AFM30‐F03D
EVR1220‐F02
ASP430F‐02‐08S
AS3201F‐03‐08S
AKAR DEPO
SMC
SMC
SMC
SMC
SMC
SMC
SMC
PAKKENS
1
1
4
1
4
2
3
1
Description
PK‐A‐T ø40‐125 Pneumatic Cylinder
ISO‐M ø80‐160 Pneumatic Cylinder
Wheel Rim Tightening HUB
Tire Inflation
Coil Valve, 3/2, 24 VDC, N.K.(N.A. Practicable), 1/2"
Coil Valve, Dual 3/2, 24 VDC, N.K./N.K., LED, Shielded, 1/4"
Coil Valve, 3/2, 24 VDC, N.A., 1/4"
Coil Valve, 3/2, 24 VDC, N.K., 1/4"
3/2 Modular Open/Close Valve, 1/2"
Filter Regulator, 1/2", Automatic Discharge, Manometer
Precision Regulator, 0,05‐6 Bar, 1/2"
Electropneymatic Digital Proportional Controller, 0,05‐9 Bar, 0‐10 VDC Kum., Socket, 3/8"
Precision Regulator, 0,1‐8 Bar, 1/4", Bracket, Manometer
Regulator, 10 Bar, 1/4" Gear Linkage, Manometer
Oil Baffle Valve, 0,3 Micron, 3/8", Automatic Discharge
1/4"OR Valve
Adjustable Speed, Pilot‐operated Check Valve, 1/4", ø 8 mm
Bend‐Type Speed Adjuster Valve, 3/8" ‐ ø8 mm
Pressure Relief Valve, Membrane, Male, 2,5 Bar, 1/2"
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