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Unrolling Station BG01

The document provides operation and maintenance instructions for an unrolling station. It contains: 1. An overview of the unrolling station components and their functions, including a roll lifting device, web edge control unit, and unwinding controller. 2. Technical specifications for the maximum width and weight of rolls, as well as diameters that can be accommodated. 3. Descriptions of the operating elements and panels for web tension and edge control. Instructions are provided for starting up, shutting down, and responding to malfunctions. 4. Maintenance procedures including greasing points, recommended tests, and lists of fast-wearing parts. Care and safety practices are also outlined.
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0% found this document useful (0 votes)
119 views33 pages

Unrolling Station BG01

The document provides operation and maintenance instructions for an unrolling station. It contains: 1. An overview of the unrolling station components and their functions, including a roll lifting device, web edge control unit, and unwinding controller. 2. Technical specifications for the maximum width and weight of rolls, as well as diameters that can be accommodated. 3. Descriptions of the operating elements and panels for web tension and edge control. Instructions are provided for starting up, shutting down, and responding to malfunctions. 4. Maintenance procedures including greasing points, recommended tests, and lists of fast-wearing parts. Care and safety practices are also outlined.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 33

EM 260/340/410/510 Unrolling station BG 01

Contents:

BG 01 Unrolling ............................... 1 3.4 Starting up ..............................22

1. Safety ........................................ 2 3.5 Shutting down .........................23

2. Technical data ............................. 3 3.6 Malfunctioning .........................24

2.1 Additional units.......................... 4 4. Care and maintenance.................26

3. Operation .................................... 5 4.1 Care of machine .......................26

3.1 Operating elements ..................... 5 4.2 Greasing points on machine .......27

3.1.1 Operating panel for web tension 4.2.1 Chain drive and gearwheel drive27
control.................................... 5
4.2.2 Plain bearings, threaded spindles
3.1.2 Operating panel for web edge and sliding guides ...................28
control.................................... 7
4.2.3 Roller bearings.......................29
3.2 Insert web................................ 17
4.2.4 Compressed air lubrication ......30
3.2.1 Take over new web ................ 17
4.3 Tests to be done ......................31
3.2.2 Web run................................ 20
4.4 Fast wearing parts 32
3.3 Settings ................................... 21

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EM 260/340/410/510 Unrolling station BG 01

BG 01 Unrolling station

The unrolling station provides the material A splice table is provided for splicing the
supply to the downstream units. rolls at an angle. The clamping which is
Unrolling station BG 01 is fitted with a roll necessary for splicing is carried out via
lifting device, whereby rolls of material up expansion elements.
to a diameter of 1000 mm can be carried. The unrolling tension is generated via a
Control of the web edge is carried out by a electronic unwinding controller unit
unit of the Erhardt & Leimer company. operated by a dancer. The dancer force
This unit ensures the exact web inlet into and thus the unrolling tension can be set
the printing machine. It can be furnished via a fine control valve.
with three different scanners:

• Web edge scanner with infrared sensor


for control based on web edge and also
suitable for transparent material to be
printed

• Web edge scanner with ultrasonic


sensors for control based on the web
edge for crystal-clear , transparent
material to be printed

• Combined line/edge of printing for


control based on a printed line or edge
of a printed area.

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1. Safety

The general safety instructions must be


followed.
Please ensure that all safety equipment is
fitted and ready for operation before the
machine is switched on. Furthermore a
performance check of the safety
equipment should be carried out at the
start of each new shift. After splicing of a
new roll the clamping on the splicing table
must be loosened.
Care must be taken at open web edges
because there is risk of cutting injuries at
these places when the machine is running.

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2. Technical data

EM 260 EM 410 EM 510 EM 340


Width of material web max. 258 mm 413 mm 516 mm 343 mm
[10,125“] [16,25“] [20,25“] [16,25“]
Weight of rolls: max. 500 kg

Roll diameter EM 260 EM 410 EM 510 EM 340


Paper: max. 1000 mm
Aluminium: max. 700 mm
Core diameter: 3“ (76,2 mm)

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2. Technical data

2.1 Additional Equipment

• Web edge control

• Splicing table

• Adhesive tape for the unrolling unit

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3. Operation

3.1 Operating elements


1 unwinding arms 13 web edge control

2 roll securing and spindle clutch unit 14 photo electric cell for end of roll

3 pneumatic expansion spindle 15 knurled screw for photo electric cell

4 pressure valve at spindle end 16 dancer pressure controller

5 switch¸ lift unwinding arm, 17 pressure gauge (dancer pressure)


lower unwinding arm
18 operating panel for web edge control
6 operating panel for web tension
control 19 photo electric cell for web edge
control
7 splicing table
20 lever for roll securing
8 left hand pressure beam
21 roll of material
9 right hand pressure beam

10 switch for left hand pressure beam

11 switch for right hand pressure beam

12 dancer

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3.1.1 Operating panel for web


tension control 28 potentiometer (dancer position)
positioning of dancer arm
22 tumbler switch
control unit ON/OFF Caution!
This adjustment should only be
23 tumbler switch carried out in an exeptional case. The
brake ON/OFF setting of the dancer "0" position has
already been carried out at the
24 control lamp factory.
lights up when mains voltage is
applied

25 control lamp
lights up when brake has been
switched on and is ready for use

26 control lamp
lights up when dancer is ready for
use

27 trimming potentiometer (gain)


optimising controlling behaviour of
the dancer arm or amplification factor
for brake

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3.1.2 Operating panel for web edge


control

The web edge control ensure that the web


edge always keeps at the same place
when the machine is running. After the
web has been inserted, attention must be
paid that the turning frame of the web
edge control is set at mid-position.This is
necessary to ensure that the web edge is
controlled or aligned towards both sides
when the machine is running.

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3.1.2.1 Keys and displays


.

Operating voltage display " + 5 V DC "


This indicator lights up when this voltage is applied at
the electronic control.

Digital display
The digital display shows the set values of the various
parameters of the digital web run control. As set in the factory
it displays the shift of web.

"decrease value" key


With the key "decrease value" the parameter value displayed
can be reduced.

"increase value" key


With the key "increase value" the parameter value displayed can
be increased.

Display " web run direction"


Web run direction and the web run direction displayed must
correspond. If this is not the case the display must be inverted.
Either loosen the four fastening screws at the operating unit RT and switch over the switch on

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back side of the operating unit or change the web run direction
in the set up-mode:

⇒ set the unit no. and group no for the operating unit in the set
up mode.

⇒ change the displayed value ("0" or "1") in parameter ..6.


"display web run direction " . If "1" is shown set "0" and
vice-versa.

⇒ set unit no. and group no for the controller and leave set up
mode.

"Sensor" keys sensor comp-


These keys are used for setting the web guiding method letely covered
(red)

− left hand edge (left hand sensor)


− right hand edge (right hand sensor) sensor selected sensor free
− mid-web (both sensors) (green) (red)

When a sensor has been selected the green indicator "sensor


selected" lights up. sensor comp-
letely covered
When there is no web in the sensor sight area the red (red)
indicator "sensor free" lights up.

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When the sensor area is completely covered the red


indicator "sensor completely covered" lights up.

In automatic mode, if one of the red indicators "sensor


free" or "sensor completely covered" lights up, the
corresponding sensor must be newly positioned.

"line sensor" key sensor rage limit


(red)
This key is used for setting the guiding criterion:
- light coloured line
− light coloured line
-dark line
− dark line
− contrast edge -contrast edge

When one of the red indicators "sensor range limit" lights up the guiding sensor rage limit
(red)
criterion has reached the left hand or right hand range
limit (depending on the web run direction). The line sensor
must be newly positioned.

"web position adjustment/ manual adjustment" key


This key is used to pilot the web run control to the right
hand or left hand side in the operating mode "manual".
actuating drive end position
When the web run control has reached its end position, the (red)
indicator lights up in the respective key. The indicator
blinks shortly before the end position is reached.

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In the operating mode "automatic" the keys are used for web position adjustment. When
two keys are pressed simultaneously a web position adjustment setting will be deleted.

The web position adjustment is an electronic shifting of the sensor neutral position and the
desired position of the web is being shifted during automatic operation.

"Sensor signal" display


This display shows the output signal of the sensor selected (left hand, right hand or buzzer
signal.) The further the signal of the light emitting diode tube swings out, the further away
the web edge is from the middle of the sensor optic system.

sensor selected
web run direction

„Sensor signal“ display

„Sensor signal“ display web run direction display

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"Controller stop" display


When the indicator "controller stop" is flashing, voltage is
applied to input "controller stop", and the operating mode
"automatic" is disabled. The web run controller now only
works in the operating modes "manual operation" or
"middle setting".

select set up mode


"Set up" key
By pressing the "set up" key and also the "increase value" +
key, one gets into the set up mode (always press the "set
up" key first) and the green light emitting diode on the "set
up-mode" key flashes.

In the set up mode, one can: Setup (green)


− change various parameters
− reset the middle setting of the web run controller system

See description "set up editor".


Automatic (green)

"Automatic" key
When the "automatic" key is pressed, the web run control
system controls in accordance with the signals of the
sensors, and the green indicator on the key lights up. It is
possible to undertake a web shift adjustment via the keys
web shift/manual
"web shift/manual setting"

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If the indicator flashes the signal "controller stop" is


applied, the automatic operating mode is blocked.

"Middle setting" key


When the key "middle setting" is pressed, the web run Middle setting
controller is positioned on the middle setting stored. The
indicator on the key lights up.

Trimming middle setting Trimming middle setting


By pressing the keys "set up" and "middle setting"
simultaneously the present position of the web run
+
controller is the new middle setting.

"Manual operation" key Manual operation (green)


When the "manual operation" key is pressed, the web run
controller can be adjusted to the left hand side or the right
hand side via the keys "web shift/manual setting".

When the key "manual operation" is pressed the indicator


on the key lights up. The indicator flashes while the keys
"web adjusting/manual setting" are pressed.

Before the end position is reached the indicator in the


button "web shift/manual setting" flashes.

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3.1.2.2 Operation

From feeding the web to the control operating mode.

⇒ Middle setting - web run controller off.


Before inserting the new web always set the web run
controller to operating mode "middle setting" first.

⇒ Setting web shift to "0"


Set web shift on operating unit RE.. to "0"
Set web shift on operating unit RT.. to "0"
(simultaneously pressing both buttons web shift/manual
setting).

⇒ Insert web

⇒ Select sensor - set web guiding type

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⇒ Sensor positioning
Position the sensors at the web (with a motor driven
setting support VS.. see description RT 4021, if the
setting support is manually adjusted, see sensor
description).
Caution !
The sensors must be positioned manually only when the
machine is not running. Danger of injury

⇒ Setting operating mode


Set the operating mode desired ("automatic", "middle
setting" or "manual operation").

− Automatic operation
The web run controller operates according to the
signals of the sensor. In the automatic operating mode
a web shift can be carried out via the operating unit
RE.. or via the buttons "web shift/manual setting".

− Middle setting
If the "middle setting" key is pressed, the web run
controller is positioned to the middle setting stored.

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− Manual operation
In the manual operating mode the
web run controller can be adjusted to
the left hand side or right hand side
via the buttons "web shift/ manual
setting".

For further information see the operating


instructions of the Erhardt & Leimer
company in the appendix.

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3.2 Insert a new web

3.2.1 Feeding in a new web

The following working steps apply both to • Actuate the valve at the front (4). This
the first take-over of a material roll and for releases the expansion spindle. Pull out
a change of material roll. the spindle (3) from the core of the
Working steps which must be only be empty material roll.
carried out for the first take-over or for
changing are specially marked.
• Push the spindle (3) into the core of a
After the scanning of the roll has stopped new material roll (21)
the main drive of the machine:

• Clamp (11) web at the exit side of the • Lower the unwinding arms (1) , turn
splicing table (7). switch (5) anticlockwise to the "down"
position.

• Cut off the old web


• Roll the new material roll (21) over the
location support of the unwinding arms
• Open spindle coupling and roll safety (1) .
device (2) by pulling the lever back
(20). Take empty material roll (21)
together with spindle (3) out of the
unwinding arms (1).

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• Lift the unrolling arms (1), turn switch • Put the material web onto the splicing
(5) to the "raise" position. table (7) , align it according to the old
Caution! web and clamp it on the infeed side (10)
The ball bearings of the spindle must .
locate exactly in the location supports
of the unwinding arms. • Cut both web ends simutaneously with
a sharp knife ( this cut is diagonal due
to the integrated guidance in the
• Align material roll (21) in the transverse splicing table).
direction
• Remove waste material and glue the
• Expand spindle (3) with pneumatic tool web ends together
(...). Push the nozzle of the pneumatic
tool hard into the valve (4) of the • Loosen both clamping devices (8/9),
spindle (3) . After expanding, the (10/11).
nozzle should be pulled away quickly
from valve 4. If there is not any web left in the
machine take the following steps:

• Close spindle coupling and roll retainer • Put web onto the splicing table (7) and
(2) by pulling lever (20) forwards clamp it on the infeed side (10)

• Let the spindle coupling (2) snap in by • Begin to cut the the web diagonally (
turning the material roll (21) slowly this cut is diagonal due to the integrated
guidance in the splicing table).

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• Remove the waste material and loosen


the clamping device (8) at the infeed
side (10)

• Thread the web in accordance with the


web run indicated (see web run ....).

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3.2.2 Web run

Make sure that the web is threaded


according to the drawing shown above.
This is essential to ensure that the unit
fulfills ist function.

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3.3 Settings dancer arm via pressure control valve (16)


The air pressure is read on gauge (17) .

Web width

When feeding in a new web with a The max. set pressure should not exceed
different web width, the web run 2,5 bar.
controller must be changed to fit the new Dancer (12) should work with as little
web width as follows: hunting as possible in the vertical ideal
position or 0-position. Each adjustment of
• by loosening the knurled screw at the the unwinding tension to the material to be
holder of the photo electric cell the printed also requires an adjustment of the
holder can be reset on a guiding rail (see dancer pressure.
also operating instruction web edge It may be necessary to adjust the control
control of the Erhardt & Leimer according to the operating conditions.
company in the appendix) The control behaviour depends on the
following items:

Web tension • size of roll (diameter)


• speed (acceleration)
The basic requirement for an exactly • web tension setting
registered web transport is a constant web • material
tension at the inlet of the machine. The
web tension between unrolling and feeder The hunting behaviour of the dancer
station is produced by the the unwinding should be checked, if necessary the gain
brake and dancer (12) and set via the air factor has to be changed. Too strong
pressure in the pneumatic cylinder on the hunting of dancer (12) can be eliminated
via "gain" (27) .

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3.4 Starting up instruction web edge control of the


Erhardt & Leimer company).
After the first threading of a web the
components of station 01 must be
switched on individually. When a new web has been fed into the
This must be executed as follows: machine or connected with the unwound
• Set dancer pressure on pressure valve web the operation of station 01 or each
(16) (setting value about 1.5 bar) component is started by pressing the
Caution! starting button at the main operating panel
The max. value of 2.5 bar should not of drive station BG 09.
be exceeded.

• Set tumbler switch (22) to position


"ON" . Control lamp (24) must now
light up.

• Set tumbler switch (23) to position


"brake closed". Control lamp (25) must
now light up. Should the dancer be
situated at the front or back end
position the control light will not light
up. In this case the dancer should be
moved manually to the middle position.

• Select the operation mode "automatic"


on the operating panel of web edge
control (18) ( see also operating

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3.5 Shutting down


If it is necessary to switch off the unrolling At the beginning or end of a shift it is not
station BG 01 then this can be done in necessary to switch off the unit, but
two ways: functioning tests of the protection devices
should be done.

⇒ by pressing the "OFF" button at the


main control cabinet of drive station BG
09, this interrupts the total power
supply of the machine.

⇒ by pressing button (22) at the operating


panel of the web run control this
switches off the brake and the dancer
controlled web tension control.

With short stoppages, e.g. splicing of a


new web it is not necessary to switch the
unrolling station BG 01 off.
Should maintenance or cleaning jobs be
done on this station the "OFF" button at
the main control cabinet must be pressed
and in addition the main switch must be
switched off and secured against
unoutherized operation.

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EM 260/340/410/510 Unrolling station BG 01

3.6 Malfunctioning
Problem Cause Remedy

Dancer moves to the left • power failure check fuse, replace if


end position necessary

• loose contact on plug-in check plug-in connection on


connection sensor, at the magnetic
brake and on control unit

• there is no pneumatic check fine control valve,


pressure gauge and compressed air
hoses

Dancer is unstable or it • sensor is not trimmed increase amplification by


hunts with a large swing turning the trimming
potentiometer

web run control is not • power failure at the web check fuse, replace if
working run control necessary

web tears when starting • clamping device not open open clamping device on
(error message on operat- the splicing table
ting panel BG 09)

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EM 260/340/410/510 Unrolling station BG 01

Problem Cause Remedy

web is completely pulled off • photo electric cell for end put into proper position
the core of roll set wrongly using the knureled screw

• photo electric cell faulty check photelectric cell


or contaminated replace if necessary

web roll is controlled • web run control set too set web run control more
backwards and forewards sensitively damped
via web run control

unwinding arms stay in • there is no pneumatic check switching valve and


lower end position pressure lifting cylinder, replace if
necessary

Material roll is not braked • power failure at the brake check fuse, replace if
necessary

• brake is open
• spindle is not expanded

• core internal diameter is


too big

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EM 260/340/410/510 Unrolling station BG 01

4. Care and maintenance

4.1 Care of the machine The cleaning methods mentioned above do


not harm the paint.
To maintain the quality and functioning of
Under no cirmustances may cleaning rags
the machine for a long time it is important
soaked in solvent, solvent pools or solvent
to pay attention to the following notes for
splashes work on the paint over a longer
the care of the machine:
time period.
Avoid putting ink or solvent containers on
Daily care helps to discover possible wear
top of the machine.
, too low an oil level, dry sliding surfaces,
loose screws etc. And avoid greater After cleaning stainless steel parts (black
damage! burnished parts) should these be sprayed
with a thin layer of anticorrosive, e.g.
Painted areas should be treated carefully Caramba.
and ink splashes should be wiped off with
a cloth at once. The cleaning of operating panels and
To dissolve printing ink for inks containing operating elements and all synthetic parts
solvents, a light ink thinners is must only be done with a cleaner for
recommended, e.g. ethyl alcohol, or if synthetic materials, e.g.:
used carefully, paint restrainer e.g.
Lixtop from the company Dreusicke & Co.KG
ethoxypropanol. Rohdestraße 17,
12099 Berlin
For water soluble ink use abrasive-free, Telephone 030/7525081
soapy domestic cleaning fluids or ammonia or
diluted with water. CS-180 from the company Chemaco GmbH
Industriestraße 155
50999 Köln
The machine is painted with a two-pot DD- Telephone 02236/66015
lacquer which is resistant to nomal wear
and tear.

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4.2 Greasing points on the machine

4.2.1 Chain drive and gearwheel drive

• rear chain drive for dancer


potentiometer

Note:
Open gearwheels and chain drives must be
checked every 200 operating hours for
greasing and if necessary greased with
Nigrin chain grease.

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4.2.2 Plain bearings, threaded


spindles and sliding guides

• carrier on the brake flange

• locking device of the unrolling shaft

Note:
Check these lubricating points daily for
sufficient lubricant film and if necessary
lubricate with gear oil (oil can greasing)

• Esso Saprtan EP 320


• Mobil Mobilgear 632
• Shell Omala Oil 320

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4.2.3 Roller bearings

The closed ball bearings are self-lubricating


(life-long greased)

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4.2.4 Compressed air lubrication

At the rear side of drive station BG 09 is a


maintenance unit which performs the air
lubrication of this unit (see also operation
instruction drive station BG 09).

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4.3 Tests to be done

Before initial operation of the unrolling unit


the following tests should be carried out:

• functioning test of the safety devices

• functioning test of the brake

• functioning test of the dancer

• "zero position" of dancer

• functioning test of the web tension


control

• functioning test of web tension control

• functioning test of the pneumatic


expansion spindle

• functioning test of the splicing table

• functioning test of the roll safety device


and the spindle coupling

• functioning test of the unroller arms

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4.4 Fast wearing parts

Description arsoma code Qty.


carrier shaft 094 01 054 1
field 24 DC ATV - F 002 1
control device ATV - R 001 1
tractive force key HMCS 605 - E ATV - Z 001 1
with accessories HMCS -KIT 3
(ATV-K 001)
expansion hose ¾ x ½ " TID - E 005 1
cap ZG No. A 7495 TID - K 001 4
nut 3/8 TID - M 003 4
O-ring joining piece TID - O 001 2
hose end piece TID - S 002 2

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