signode stteel band operation_manual

OPERATION, PARTS AND SAFETY MANUAL

M410-W-114-3P

SPOT WELD JOINT POWER STRAPPING MACHINE HEAD

READ ALL INSTRUCTIONS BEFORE OPERATING THIS SIGNODE RPODUCT

SIGNODE KABUSHIKI KAISHA

M410-W-114-3P 1

This manual gives you information on how to operate and maintain your Signode Power Strapping Machine.

ONLY TRAINED PERSONNEL SHOULD OPERATE OR

SERVICE MACHINE. Read these safety instructions

before operating or servicing your machine.

OPERATING MACHINE

BEFORE

SERVICING MACHINE

1. Read the operating instructions. 2. Wear eye or face, and hand protection. 3. Inspect the machine for unsafe conditions －DAILY－ and replace any worn or broken parts.

4. Check that all guards are in place and all safety devices are working properly. Do not operate machine with any safety devices removed.

5. Make sure machine is clear of all tools, debris, and other objects not related to machine function.

DURING 1. Do not wear loose clothing or jewelry. 2. Never put any part of your body into, under or

near moving machinery. 3. Keep hands out of the strap chute area. AFTER 1. Shut off all electric an air power. 2. Remove all tools, debris, and other objects

from machine area.

1. Shut off and lock out electric and air power. 2. Remove packages from machine. 3. Do not stand or walk on conveyor service

machine. 4. Follow the maintenance instructions in your

manual. 5. Use the correct tools to repair machine. 6. Never adjust, repair or oil moving machinery.

ADDITIONAL CONSIDERATIONS

To insure proper operation of machine, use the specified electric and/or air power sources.

Do not overload machine by exceeding Signode's recommended performance limitations.

Do not attempt to after machine design unless written approval is received from Signode Corporation.

Keep your Operation, Service and Safety Manual at your machine. Refer to it － often.

SIGNS Read all of the signs on machine.

Do not remove any signs from machine

Replace all missing or damaged signs.

ADDITIONAL SAFETY INSTRUCTIONS ARE LOCATED THROUGHOUT THIS MANUAL. THEY SERVE TO WARN THE OPERATOR AND SERVICEMAN

ABOUT POTENTIALLY HAZARDOUS SITUATIONS.

GENERAL SAFETY

INSTRUCTIONS FOR SIGNODE POWER STRAPPING MACHINES

M410-W-114-3P

TABLE OF CONTENS Page

MACHINE MODEL 1

SPECIFICATIONS 2

CYCLE OPERATION 3

ADJUSTMENT 4

PARTS REMOVAL AND REPLACEMENT 5

CHECK POINTS AT ASSEMBLY 6

TROUBLE SHOOTING 7-8

LUBRICATION 9

SPARE PARTS 11-12

PARTS LIST, JAW STACK 13

PARTS LIST, UPPER WELDMENT & LINKAGE 15

PARTS LIST, FACE GATE ASSEMBLY 17

PARTS LIST, MID-LEVEL CYLINDER & LINKAGE 19-22

PARTS LIST, TOP FRAME ASSEMBLY 23

PARTS LIST, TRANSFORMER ASSEMBLY 25

PARTS LIST, FEED & TENSION FRAME 27

PARTS LIST, TRANSFER CASE & FEED / TENSION 29

PARTS LIST, BACK-UP WHEEL COMPONENT 31

PARTS LIST, STRAP GUIDE SYSTEM 33

PARTS LIST, STRAP STRAIGHTENER 35

PARTS LIST, GRIP & CUT AIR CYLINDER 37

PARTS LIST, AIR MOTOR / TRANSMISSION 39

AIR MOTOR / TRANSMISSION MANUAL 42-49

M410-W-114-3P Spot Weld PSM HEAD

1. MACHINE MODEL

(MODEL) (STRAP SIZE) (PART NO.)

M410-W-114-3P-RH 1-1/4” E-567670

M410-W-114-3P-LH 1-1/4” E-567671

2. SETTING OF AIR MOTOR/TRANSMISSION

RIGHT HAND (RH): The air motor is set from your right side standing behind the head. LEFT HAND (LH): The air motor is set from your left side standing behind the head.

3. SETTTING OF FACE GATE

RIGHT HAND (RH): The face gate is set from your right side standing behind the head. LEFT HAND (LH): The face gate is set from your left side standing behind the head.

(Note) Standard head is the right hand. In respond a necessity,

the left hand is assembled.

R.H. L.H.

1 M410-W-114-3P

MAJOR COMPONENTS

4. SPECIFICATIONS

(1) Strap Size : Width 32mm X Thick, 0.6 to 1.0 mm (2) Type of Strap : Apex grade (unpainted) (3) Feed Speed : 1400 to 2000 mm/sec. (4) Take-Up Speed : 1400 to 2000 mm/sec. (5) Final Tension Force : 600 to 2000 Kgf (6) High and Low Speed Ratio : 1/25.7 (7) Joint Strength : Mini. 75% (8) Head Weight : 235 Kgf (9) Weld Transformer (Type) : RT353-446 : RT303-405 (Rated Capacity) : 35KVA : 30KVA (Primary Voltage) : 440V : 400V (Secondary Voltage) : 6.8V : 5.4V (Freq.) : 60Hz : 50Hz

2 M410-W-114-3P

5. CYCLE OF OPERATION

(Operation) (Sequence Flow)

Shift High Speed

High Speed Feed

Face Gate Close

(Middle Speed Feed）

(Low Speed Feed)

Grip Strap

Back Bar Close

Face Gate Open

High Speed Take-Up

(Middle Speed Take-Up)

Shift Low Speed

Low Speed Tension

1st Spot Weld

Weld Tip Pivot

2nd Spot Weld

Strap Cut-Off

3rd Spot Weld

Weld Tip Return

Back-Bar Open

Jaws Retract

Face Gate Close

Home Position

(NOTES) 1. Just before starting strap feed, shift the transmission high-speed mode from

low speed mode, and then supply air into the motor.

2. In case of stopping the traction wheel suddenly, supply air into “A” and “B” port the same time.

3. When shifting the transmission low speed mode from high speed mode,

the air motor must be set “0” speed to start.

4. At the home position, keep the transmission low speed mode.

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6. ADJUSTMENT

4 M410-W-114-3P

(1) JAW STACK

When a proper number of shims are in place beneath the brim of jaw pins and upper guide block, there will be a jaw stack clearance of 0.08mm. This measurement must be taken when the jaw pin mounting screws are fully tightened. In addition to the clearance, the jaw stack must be exert a slight resistance when operated by hand.

(2) FACE GATE A clearance between the gate and the strap guide must be maintained and should fall within 0.8mm. If an adjustment is needed, adjust a clearance by turning the screw of the face gate air cylinder’s rod end.

(3) STRAP STRAIGHTENER

Adjust a strap curl with the straightener adjust bolt. To lower the adjust bolt allows forward curl, and upper the adjust bolt allows a backward curl.

(4) ENERGIZING SPRING

The energizing spring should be adjusted so that a smooth feed and tension of the strap an be acquired. When there is a slippage

or a deep wheel marks on the strap, adjust the coil spring’s extension.

WARNING

(5) STRAP TENSION Adjust machine’s pressure control so that the strap tension is suited for the application. Do not increase tension where by the strap results in breaking off. During low speed take-up and tensioning, air regulation must not exceed 4 Kgf/cm2.

(6) ADJUSTMENT OF SPOT GUN PRESS

FORCE Adjust the spot gun press force by adjusting the air pressure of the spot gun air cylinder so that a good spot welding condition (no spark welding) can be obtained. A recommended air pressure is around 4 Kgf/cm2

(7) ADJUSTMENT OF SPOT WELD CURRENT According to the electric control manual.

7. PARTS REMOVAL AND

REPLACEMENT (1) REPLACEMENT OF SPOT WELD TIP

Insert the weld tip exchanging tool hrough the window of the spot gun upper frame into the hole on the spot gun tip holder portion facing the tool’s inclined face to the weld tip, then pat the tool with a hammer until moving out of the tip. Push a new weld tip or a cleaned up weld tip into the hole on the tip holder by hand.

Electric and air power must be disconnected and locked out before adjusting the machine. However, if an adjustment requires power, only authorized and qualified personnel should make those adjustments.

(2) REPLACEMENT OF BACK BAR (LOWER ELECTRODE) From the front of the head, the back-bar can be replaced by removing four bolts fixing it on the back bar holder.

5 M410-W-114-3P

(3) JAW STACK

Remove the face plates (320), lower strap guide (319) and cap plate (154). Draw out the connecting rod pin (150), then remove the jaw stack. In this time, set a strap piece between jaws to keep the jaws their retract position and make easy to remove the jaw stack.

(4) TRACTION WHEEL

Remove the bearing cap and the bearing housing assembly by using two bolts as a draw-out tool, if necessary. In case of tight to draw the bearing housing, pat the side face of traction wheel with a brass bar and a hammer outward. Loosen the set bolt (708) of the spring housing(52), and make free the compression spring(821). Remove the traction wheel after lifting the release handle (18) to keep the back-up wheel’s collar away from the traction wheel (17).

(5) UPPER STRAP GUIDE

Remove the shoulder bolt (725), washer (773), spacer (64), nut(751), and adjust screw (61) of the strap straightener. Remove the long pin (55), then remove the upper strap guide assembly.

(6) LOWER STRAP GUIDE Remove long pin (55), then remove the lower strap guide assembly.

(7) AIR MOTOR / TRANSMISSION Disconnect all air hoses. Loosen the set bolt (708),. Make the compression spring (821) free. Remove four bolts (738), then remove the air motor/transmission.

(8) BACK-UP WHEEL Remove the bearing cap (612) by using two bolts (708) as a draw out tool, if necessary. Remove the self-link pin (49). Disconnect the self-link (20) from the self-lever (19) to expose the end face of the back-up wheel shaft (15). Loosen set bolt (787) and nut (750). Drive out the back-up wheel shaft by patting the end ace with a brass bar and a hammer until the shaft comes loose. Then remove the back-up wheel assembly and the shaft by hand through the name plate window on the head housing.

(9) TWO IN ONE AIR CYLINDER Move the air cylinder piston rod to the up-stroke end. Loosen nut (751) through the hole of the transformer bracket with a box-wrench, and loosen set screw (768). Return the air cylinder piston rod to home position. Then remove the piston pin (153). Disconnect all hoses. Remove four bolts (928). and remove the air cylinder.

WARNING Electric and air power must be disconnected and locked out before adjusting the machine. However, if an adjustment requires power, only authorized and qualified personnel should make those adjustments.

8. CHECK POINT AT ASSEMBLY

WARNING For proper operation, the air supply to the air motor must be set to deliver a minimum of 70 psig and a maximum of 90 psig. However, when the transmission is in low speed, air pressure to the air motor not exceed 70 psig.

(1) Eccentricity of Back Up Wheel Shaft

Check that the set-screw (767) of self-lever (19) fit into the follow position of back-up wheel shaft end, and the self lever fixed firmly

(2) Position of Piston Pin

Check that line mark on the end face of piston pin (153) keeps right angle against the piston rod (299-06).

(3) Guide Block for Long Toggle Pin Check that the grease nipple (930) of long toggle pin (132) can be seen through the hole of the guide block (131) at home position of the two-on-one air cylinder.

(4) Air Port of Two-in-One Air Cylinder Port direction of the small dia, air cylinder can be changed every 22.5°by changing the setting direction of the cylinder cover (299-04) according to an air piping application.

(5) Recommended Tightening Torque for Each Bolt size

(Size) Max. Torque (Kgf-cm)M16 S.H.C. Screw 3,000M14 S.H.C. Screw 2,000M12 S.H.C. Screw 1,300M10 S.H.C. Screw 800M8 S.H.C. Screw 400M6 S.H.C. Screw 160M4 S.H.C. Screw 40

.

6 M410-W-114-3P

9. TROUBLE SHOOTING

The causes and remedies listed in this section relate to the M410-W-114-3P Spot Weld Strapping Head only. Refer to the application manual for causes and remedies that relate specifically to the machine in which this head is mounted.

WARNING

Wear eye and protection when inspecting themachine. While locating causes for the following symptoms on the M410-W-114-3P head, it may be necessary to leave the machine’s electrical and pneumatic systems ON. Only qualified people with knowledge of electrically and pneumatics should inspect the machine when the power is ON.

A. Symptom: Air motor fail to start

(Cause) (Remedy) 1. No electrical power or signal

from associated equipment. 2. Insufficient air pressure.

1. Check electrical circuit refer to electrical schematic in application manual.

2. Check pneumatic circuit looking for stuck or closed valves refer to pneumatic diagram.

3. Internal wear or damage to Air Motor.

3. Replace Air Motor/Transmission or worn/damaged parts.

B. Symptom: Air motor is running slow. As result, the feed and take-up portion of the cycle are slow.

(Cause) (Remedy) 1. Insufficient lubrication to the air

motor. 2. Insufficient air pressure

1. Check and fill or re-adjust the lubricator if needed.

2. Check the air supply. Look for a closed valve or an inoperative regulator.

C. Symptom: Traction wheel rotates in the feed direction but does not feed strap

(Cause) (Remedy) 1. Insufficient expansion of the spring. 2. Grip and cut mechanism not fully

retracted, blocking strap path.

1. Adjust the nuts and spring post screw. 2. Remove any obstruction in the grip jaws.

Inspect the jaw stack and replace any damaged parts.

D. Symptom: Strap unthreads from the head during take-up or tensioning. (Cause) (Remedy) 1. Worn or damaged grip jaws or

stationary cutter. 2. The stationary cutter is not suitable to

the strap thickness.

1. Replace the grip jaws and/or the stationary cutter.

2. Replace the stationary cutter according to the part list.

E. Symptom: Strap breaks at the grip jaws during tension. 7 M410-W-114-3P

8 M410-W-114-3P

(Cause) (Remedy) 1. Gripping edge of jaws and/or

stationary cutter are too sharp.

1. Very lightly stone the sharp edge of the jaws and/or the stationary cutter. Excessive stoning may result in Symptom-D

F. Symptom: The traction wheel mills the strap, occasionally causing the strap

to brake. (Cause) (Remedy) 1. Tension set too high. 2. Take-Up speed at high-speed

tension set too high.

1. Reduce the low-tension air pressure. 2. Reduce the take-up speed air pressure,

or use middle speed circuit at a high speed mode.

G. Symptom: Welding spark brake out. (Cause) (Remedy) 1. Soiled welding tip. 2. Worm weld tip. 3. Improper welding current. 4. Worn the brake-bar. 5. Improper spot gun press force.

1. Clean up the tip by buffing. 2. Replace the weld rip. 3. Adjust welding current according to

electrical control manual. 4. Replace the back-bar. 5. Adjust the pressure of the air cylinder.

H. Symptom: Back-bar fails to retract. (Cause) (Remedy) 1. Insufficient air pressure for back-bar

air cylinder. 2. Obstruction between head and

the work face.

1. Check the air supply. 2. Remove any obstruction.

I. Symptom: Incomplete spot welding. (Cause) (Remedy) 1. No welding current.

1. Check a welding current timing on the PLC.

10. LUBRICATION CHART

9 M410-W-114-3P

1. GREASE LUBRICATION

(1) TRANSMISSION It is no necessary to lubricate usually. At a annual maintenance service, fill grease, 220gr. equivalent to the following:

(2) TOGGLE LINK AND PINS.

Fill up grease monthly equivalent to the follows:

(3) GEAR TRAIN ASS’Y

It is no necessary to lubricate usually. At a annual maintenance service, Fill grease, 120gp. equivalent the following:

Shell-Alvania EP-0 Esso-Lithtan EP-0 Mobil-Mobilux EP-0

2. OIL

(1) AIR MOTOR A mist type lubricator must be installed in the line to the air motor. Lubricator must be set at 2 to 3 drops per one cycle strapping. Type of lubricant is equivalent to the following:

(2) AIR CYLINDER Lubricator must be set at 2 to 3 drops per minute. Type of lubricant is equivalent to the following:

WARNING Disconnect and lock out all power before proceeding.

Shell-Alvania EP-0 Esso-Lithtan EP-0 Shell-Turb Oil T32 Mobil-Mobilux EP-0 Esso-Tersso 32

Mobil-Dte Oil Light

Shell-Alvania EP-2 Esso-Lithtan EP-2 Mobil-Mobilux EP-2 Shell-Turb Oil T32

Esso-Tersso 32 Mobil-Dte Oil Light

(3) JAW STACK

Lubricate a machine oil equivalent to ISO VG-10 as required.

PARTS LIST

10 M410-W-114-3P

11 M410-W-114-3P

RECOMMENDED SPARE PARTS LIST, M410-W-114-3P HEAD

KEY QTY PART NO. DESCRIPTION

17 1 567517 TRACTION WHEEL 109* 1 568009 STATIONARY CUTTER, 1.1 110* 2 568010 STATIONARY CUTTER, 0.8 114 2 568014 JAW LINK 123 12 568023 SHIM, LH 125 12 568025 SHIM, RH 126 2 568026 WASHER 180 1 568080 SCREW, MOV. CUTTER 305 2 568505 LEFT JAW 306 2 568506 RIGHT JAW 316 2 568516 MOVING CUTTER 318 1 568518 UPPER GUDIE BLOCK 323 1 568523 BACK BAR SUPPORTER 343 1 568543 LONG TOGGLE PIN 346 2 568546 STOPPER BLOCK 350 2 568550 BUSHING (A) 351 2 568551 BUSHING (B) 352 2 568552 BUSHING (C) 353 2 568553 BUSHING (D) 368 1 568568 JAW PIN, LH 369 1 568569 JAW PIN, RH 370 2 568570 LINK & JAW PIN 379 2 568579 SCREW, ST. CUTTET 384 1 568584 FACE GATE 455 1 568655 STRAP GUIDE 463 1 568663 SPOT GUN TIP HOLDER 467 1 568667 BACK BAR 4 7 569513 VANE, AIT MOTOR 16 3 569525 PLANET GEAR 755 2 569755 NYLOK BOLT M6X12 856 2 569856 OILESS BUSH 858 100 569858 ELECTRODE TIP 888 2 569888 BUSHING, BACK-UP WHEEL SHAFT 891 4 569891 SMALL BALL BERING 903 12 569903 BEARING #620ZZ 911 12 569911 NEEDLE BEARING HK1412 940 2 569940 O-RING, P-30, VITON 941 2 569941 O-RING, P-40, VITON 943 1 569943 O-RING, P-100, VITON 944 1 569944 O-RING, P-105, VITON 945 1 569945 O-RING, P-120, VITON 946 1 569946 O-RING, P-130, VITON 952 2 569952 O-RING, G-130, VITON 977 4 569977 SHOULDER BOLT

*Head Application will determine appropriate part to be used.

12 M410-W-114-3P

EXPANDED SPARE PARTS LIST KEY QTY PART NO. DESCRIPTION

- 1 567482 BACK-UP WHEEL ASSEMBLY - 1 569505 AIR MOTOR / TARNSMISSION

23 1 567523 UPPER GUIDE UNIT, NO. 2 OUTER 44 1 567544 LIMIT FINGER 16 1 567602 DRIVE SHAFT 15 1 567603 BACK-UP WHEEL SHAFT 117 1 568017 ROLLER 118 1 568018 BAFFLE PLATE 120 1 568020 CUTTER HOIDER 142 1 568042 AIR CYLINDERROD END 371 1 568571 YOKE PIN 374 1 568574 PINION 384 1 568584 FACE GATE 889 6 569889 THRUST WASHER 892 1 569892 ANGULAR BALL BEARING SET, 7009DB 893 1 569893 BEARING NUT, AN09 969 1 569969 LOCK WASHER, AW09 971 1 569971 ENERGIZING SPRING

13 M410-W-114-3P

PARTS LIST JAW STACK ASSEMBLY KEY QTY PART NO. DESCRIPTION

109 1 568009 STATIONARY CUTTER (0.044”) 110 1 568010 STATIONARY CUTTER (0.031”-0.035”) 114 1 568014 JAW LINK 117 1 568017 ROLLER 118 1 568018 BAFFLE PLATE 120 1 568020 CUTTER HOLDER 123 A/R 568023 SHIM, LEFT 125 A/R 568025 SHIM, RIGHT 126 2 568026 WASHER 180 1 568080 SCREW, MOVING CUTTER 304 1 568504 LOWER GUIDE BLOCK 305 1 568505 LEFT GIRP JAW 306 1 568506 RIGHT GRIP JAW 316 1 568516 MOVING CUTTER 318 1 568518 UPPER GUIDE BLOCK 368 1 568568 LEFT GRIP JAW 369 1 568569 RIGHT GRIP JAW 370 2 568570 JAW AND LINK PIN 371 1 568571 YOKE PIN 379 2 568579 SCREW, STATIONARY CUTTER 380 1 568580 YOKE 381 1 568581 PLUNGER, SPRING 382 1 568582 SPRING COVER 383 1 568592 SPRING, SWB 18-20 384 1 568593 SPRING SHEET, SSWA19-1.0 701 4 569701 S.H.C. SCREW, M4X12 744 1 569744 B.H.C. SCREW, M8X16 755 2 569755 S.H.C. SCREW, NYLOK, M6X12 937 1 569937 SPRING PIN, 5X45

FIG-1 JAW STACK ASSEMBLY

WARNING All parts must be periodically inspected and replaced if worn or broken. Failure to do this can affect a machine’s operation and present a safety hazard.

14 M410-W-114-3P

15 M410-W-114-3P

PARTS LIST, UPPER WELDMENT AND LINKAGE KEY QTY PART NO. DESCRIPTION

55 1 566685 GUIDE HOLDER PIN 150 1 568050 CONNECTING ROD PIN 154 1 568054 CAP PLATE 155 1 568055 CAP PLATE 156 1 568056 CPNNECTING ROD GUIDE 175 3 568075 SENSOR BRACKET 300 1 568500 GRIP & CUT MACHANISM HOUSING 312 2 568512 GUIDE BLOCK, LONG TOGGLE PIN 313 2 568513 LONG TOGGLE LINK 314 2 568514 SHORT TOGGLE LINK 315 1 568515 CONNECTIONG ROD 319 1 568519 LOWER STRAP GUIDE 320 2 568520 FACE PLATE 340 1 568540 CENTER PIN 341 1 568541 PISTON ROD PIN 342 2 568542 SIDE PIN 343 1 568543 LONG TOGGLE PIN 344 1 568544 ROD END GUIDE 708 22 569708 S.H.C. SCREW, M6X12 709 12 569709 S.H.C. SCREW, M6X20X18 716 4 569716 S.H.C. SCREW, M8X20 729 4 569729 S.H.C. SCREW, M12X25 737 2 569737 S.H.C. SCREW, M14X30 766 4 569766 SET SCREW, DOG POINT, M6X6 817 3 569817 PROXIMITY SWITCH 917 2 569916 PLUG, 1/4 930 4 569930 GREASE NIPPLE 989 2 569989 RETAINING RING

WARNING All parts must be periodically inspected and replaced if worn or broken. Failure to do this can affect a machine’s operation and present a safety hazard.

16 M410-W-114-3P

17 M410-W-114-3P

PARTS LIST, FACE GATE ASSEMBLY KEY QTY PART NO. DESCRIPTION

142 1 568042 AIR CYLINDER ROD END 309 1 568509 GATE LEVER 384 1 568584 GATE, 3P 331 1 568531 PINION SHAFT 332 1 568532 AIR CYLINDER MOUNT 347 2 568547 GATE LEVER PLATE 367 2 568567 GATE BRACKET 374 1 568574 PINION GEAR 713 4 569713 S.H.C. SCREW, M6X120 715 7 569715 S.H.C. SCREW,M8X16 716 4 569716 S.H.C. SCREW,M8X20 717 1 569717 S.H.C. SCREW,M8X25 721 4 569721 S.H.C. SCREW,M8X65 805 1 569805 AIR CYLINDER, CDQ2B50-55DM-A71HS 853 1 569853 KEY, 8X7X20 856 2 569856 OILLES BUSH 923 2 569923 RETAINING RING

18 M410-W-114-3P

19 M410-W-114-3P

PARTS LIST, MID-LEVEL CYLINDERS & LINKAGE KEY QTY PART NO. DESCRIPTION

321 1 568521 BACK BAR PIVOT PIN

322 2 568522 BACK BAR LINK 323 1 568523 BACK BAR SUPPORTER 336 1 568536 LEFT BRACKET 337 1 568537 RIGHT BRACKET 346 2 568546 STOPPER BLOCK, MC NYLON 348 2 568548 STOPPER BLOCK 350 2 568550 BUSHING 351 2 568551 BUSHING 352 2 568552 BUSHING 353 2 568553 BUSHING 355 4 568555 LINK PIN 356 1 568556 END PLATE 357 1 568557 ROD END 360 2 568560 PIVOT PIN 361 1 568594 ROD END 373 11 568573 KEY PLATE 452 1 568652 SLIDE PLATE (1) 458 1 568501 SPOT GUN LOWER FRAME 459 1 568503 PIVOT BRACKET 461 1 568508 SPOT GUN 462 1 568511 BACK BAR HOLDER 463 1 568663 TIP HOLDER 467 1 568667 BACK BAR 701 6 569701 S.H.C.SCREW, M4X12 706 11 569706 S.H.C.SCREW, M6X8 715 3 569715 S.H.C.SCREW, M8X16 716 4 569716 S.H.C.SCREW, M8X20 722 4 569722 S.H.C.SCREW, M10X80 723 4 569723 S.H.C.SCREW, M10X85 724 3 569724 S.H.C.SCREW, M10X20 737 4 569737 S.H.C.SCREW, M14X30 765 1 569765 SET SCREW, M4X10 781 8 569781 S.H.C.SCREW, M6X25 782 8 569782 S.H.C.SCREW, M6X35 784 4 569784 S.H.C.SCREW, M10X25 785 1 569785 S.H.C.SCREW, M10X30 786 1 569786 JAM NUT, M16 787 1 569787 JAM NUT, M20 788 8 569788 SUS NUT, M6, CLASS 1 789 8 569789 HELL-COIL INSERT, M6X15 790 1 569790 HELL-COIL INSERT, M10X25 791 8 569791 FLAT WASHER, M6 792 8 569792 LOCK WASHER, M6 803 1 569803 AIR CYLIMDER 804 1 569804 AIR CYLINDER 812 2 569812 SHANT 814 2 569814 BOLT, END PLATE 854 5 569854 DU BUSHING 855 1 569855 SUS WIRE, φ1.6 858 1 569858 ELECTRODE TIP 938 1 569938 SPRING PIN, φ6X20

WARNINGAll parts must be periodically inspeand replaced if worn or broken. Failudo this can affect a machine’s operatioand present a safety hazard

20 M410-W-114-3P


21 M410-W-114-3P


22 M410-W-114-3P

23 M410-W-114-3P

PARTS LIST, TOP FRAME ASSEMBLY KEY

QTY

PART NO.

DESCRIPTION

453 4 568762 SLIDE TABLE (2) 455 1 568655 STRAP GUIDE, 3P 459 1 568590 SPOT GUN UPPER FRAME 708 4 569708 S.H.C. SCREW, M6X12 714 5 569714 S.H.C. SCREW, M6X140X20 715 4 569716 S.H.C. SCREW, M8X20 730 1 569730 S.H.C. SCREW, M14X30 806 1 569870 AIR CYLINDER, CDQ2B50-J1286-Xc11 851 1 569851 FLOATING JOINT

WARNING All parts must be periodically inspected and replaced if worn or broken. Failure todo this can affect a machine’s operation and present a safety hazard.

24 M410-W-114-3P

25 M410-W-114-3P

PARTS LIST, TRANSFORMER KEY

QTY

PART NO.

DESCRIPTION

333 1 568533 TRANSFORMER BRACKET 334 1 568534 COVER PLATE 706 4 569706 S.H.C. SCREW, M6X8 715 8 569715 S.H.C. SCREW, M6X16 781 8 569781 S.H.C. SCREW, M6X25 791 8 569791 FLAT WASHER, M6 792 8 569792 LOCK WASHER, M6 810* 1 569810 TRANSFORMER, RT353-446, 440V, 60Hz 810* 1 569810-1 TRANSFORMER, RT353-405, 400V, 50Hz 811 1 569811 TROIDAL COIL, MB-60E-3M 812 2 569812 SHUNT


26 M410-W-114-3P

27 M410-W-114-3P

PARTS LIST, FEED AND TENSION FRAME KEY

QTY

PART NO.

DESCRIPTION

00 1 567600 FRAME 40 1 567540 COTTER PLATE 41 2 567541 KEY 53 1 567553 AIR BLOW PIPE 72 2 567572 COVER PLATE 707 2 569707 S.H.C.SCREW, M6X10 708 4 569708 S.H.C.SCREW, M6X12 889 6 569889 TRUST WASHER 898 1 569898 MACHINE NAME PLATE 912 4 569912 SETTING RIVET, #2X4.8 928 4 569928 LOCK BOLT, M12X35 975 3 569975 SHIM RING 976 3 569976 SHOULDER BOLT

28 M410-W-114-3P

FRAME ASSEMBLY


29 M410-W-114-3P

PARTS LIST, FEED AND TENSION、Continued FEED/TENSION COMPONENTS KEY QTY PART NO. DESCRIPTION

17 1 567517 TRACTION WHEEL 30 1 567530 BEARING CASE 33 1 567533 WASHER (2) 37 1 567537 DISTANCE RING (4) 38 1 567538 DISTANCE RING (5) 42 1 568418 COVER PLATE 505 1 569505 AIR MOTOR/TRANSMISSION 601 1 567601 ADAPTER PLATE 602 1 567602 DRIVE SHAFT 606 1 567606 SPACER, DRIVE SHAFT 607 1 567607 SPACER, TRACTION WHEEL 608 1 567608 DISTANCE RING, DRIVE SHAFT 610 1 567610 BEARING CAP (1), DRIVE SHAFT 700 2 569700 S.H.C. SCREW, M3X8 706 2 569706 S.H.C. SCREW, M6X8 711 2 569711 S.H.C. SCREW, M6X50X18 730 4 569730 S.H.C. SCREW, M12X30 809 1 569809 BEARING NUT, AN09 MODIFIED 818 1 569818 PROZIMITY SWITCH 824 2 569824 NILOS RING, #16010AV 825 1 569825 NILOS RING, #22209AV 826 2 569826 NILOS RING, #22207AV 835 2 569835 BEARING, NJ209 836 1 569836 BEARING, 22207H 840 1 569840 SOUNDPROOF CAP 844 1 569844 SILENCER 892 1 569892 ANGULAR BALL BEARING UNIT, 7009DB 893 1 569893 BEARING NUT, AN09 925 2 569925 RETAINING RING, C-85 969 1 569969 LOCK WASHER, AW09 973 1 569973 RETAINING RING, C-75

30 M410-W-114-3P

31 M410-W-114-3P

PARTS LIST, FEED AND TENSION、Continued FEED/TENSION COMPONENTS KEY QTY PART NO. DESCRIPTION

8 1 567508 BACK UP WHEEL 36 2 567536 DISTANCE RING (3) 37 1 567537 DISTANCE RING (4) 69 2 567569 FELT RING, BACK UP WHEEL 82 1 567482 BACK UP WHEEL ASSEMBLY 85 1 567585 RELEASE HANDLE 603 1 567622 ECCENTRIC SHAFT 604 1 567604 SELF LEVER 605 1 567605 SELF LINK 609 2 567609 SLEEVE, METAL BEARING 611 1 567611 BEARING CAP (2) 612 1 567612 BEARING CAP (3) 617 1 567617 SPRING BRACKET 708 4 569708 S.H.C. SCREW, M6X12 715 2 569715 S.H.C. SCREW, M8X16 750 1 569750 HEX NUT, M6 753 2 569753 HEX NUT, M12 756 2 569756 NYLOK BOLT, M6X20 767 1 569767 SET SCREW, M6X16 830 2 569830 V-RING, V-55A 832 3 569832 DU-BUSH, MB1212 837 1 569837 BEARING, 22209H 888 2 569888 METAL BEARING 920 2 569920 RETAINING RING, C-55 925 2 569925 RETAINING RING, C-85 971 1 569971 ENERGIZING SPRING 972 1 569972 SPRING POST 981 1 569981 LINK PIN 982 1 569982 LEVER PIN 989 2 569989 RETAINING RING


32 M410-W-114-3P

33 M410-W-114-3P

PARTS LIST, FEED AND TENSION STRAP GUIDE SYSTEM ASSEMBLY KEY QTY PART NO. DESCRIPTION

23 1 567523 UPPER GUIDE UNIT #2, OUTER 43 1 567543 LOWER STRAP GUIDE 44 1 568544 LIMIT FINGER 45 1 568545 STRIKER 46 1 568546 BRACKET, COMPLETE FEED 47 1 568547 TENSION BOLT 71 1 568571 SENSOR BRACKET, FEEDING 613 1 567613 UPPER GUIDE UNIT, INNER 614 1 567614 UPPER GUIDE UNIT, #1 OUTER 615 1 567615 LOWER GUIDE UNIT, INNER 616 1 567616 LOWER GUIDE UNIT, OUTER 706 2 569706 S.H.C. SCREW, M6X8 708 2 569708 S.H.C. SCREW, M6X12 709 2 569709 S.H.C. SCREW, M6X20X18 715 12 569715 S.H.C. SCREW, M8X16 750 2 569750 HEX. NUT, M6 772 8 569772 WASHER, M8 774 2 569774 WASHER, M12 817 1 569817 PROXIMITY SENSOR 820 1 569820 EXTENSION SPRING, H05-13 891 4 569891 SMALL BALL BEARING, B608ZZ 903 9 569903 BALL BEARING, 6201ZZ 913 3 569913 BALL BEARING, B6903ZZ

933 1 569933 SPRING PIN, 3X16 949 1 569949 SPACER, CLBS17-28 975 4 569975 SHIM RING 977 4 569977 SHOULDER BOLT 980 3 569980 SET SCREW 983 2 569983 ROLLER PIN 984 1 569984 ROLLER PIN 985 1 569985 GUIDE HOLDER PIN 989 2 569989 RETAINING RING, STWN12

WARNING

All parts must be periodically inspected and replaced if worn or broken. Failure todo this can affect a machine’s operation and present a safety hazard.

34 M410-W-114-3P

35 M410-W-114-3P

PARTS LIST, FEED AND TENSION STRAP STRAIGHTENER KEY QTY PART NO. DESCRIPTION

27 1 567527 STRAIGHTENER BRACKET 61 1 567561 ADJUST SCREW 618 1 567618 CONNECTOR 619 1 567619 LEVER 620 1 567620 LEVER MOUNT 715 2 569715 S.H.C. SCREW, M8X16 751 2 569751 HEX. NUT, M8 756 2 569756 NYLOC BOLT, M6X20 759 2 569759 U-NUT, M8 772 8 569772 WASHER, M8 774 2 569774 WASHER, M12 894 2 569894 LINK PLATE 903 3 569903 BALL BEARING, 6201ZZ 974 2 569974 SHIM RING 978 1 569978 SHOULDER BOLT 979 1 569979 SHOULDER BOLT 986 1 569986 STRAIGTENER SHAFT 987 1 569987 STRAIGTENER PIN 989 2 569989 RETAINING RING, STWN12


36 M410-W-114-3P

37 M410-W-114-3P

PARTS LIST

AIR CYLINDER, 150mm, E569450


1

1

569461

FRONT HEAD COVER

2 1 569462 REAR HEAD COVER 3 1 569463 DIA. 50 SHAFT 4 1 569464 PISTON (A) 5 1 569465 SEAL CASE (A) 6 1 569466 SPACER 7 1 569411 SEAL CASE (B) 8 1 569467 DIA. 150 CYLINDER PIPE 9 1 569468 DIA. 125 CYLINDER PIPE 10 1 569414 PISTON (B) 11 1 569415 DIA. 30 SHAFT 12 1 569416 BACK COVER 13 4 569718 S.H.C.SCREW, M8X30X22 14 4 569761 SP. WASHER, M8 15 1 569470 DUST SEAL, SDR40, NBR 16 1 569471 OILLESS BUSH, LFF4040 17 1 569472 PACKING, PNY40, NBR 18 2 569473 O-RING, G-145, NBR 19 1 569474 O-RING, P135, NBR 20 2 569475 BEARING NUT, AN-06 21 1 569476 BEARING NUT WASHER, AW-06 22 4 569477 HEX HEAD BOLT, M16X160X1.5P 23 4 569478 SPRING WASHER, M16 24 1 569433 OILLESS BUSH, IFF3020 25 1 569435 PACKING, PNY30, NBR 26 1 569436 O-RING, G-120, NBR 27 1 569447 O-RING, P-110, NBR 28 2 569440 BEARING NUT, AN-04 29 1 569441 BEARING NUT WASHER, AW-04 30 4 569709 S.H.C.SCREW, M6X20X18 31 4 569760 SP. WASHER, M6 32 4 569479 HEX HEAD BOLT, M12X125X1.25P 33 4 569763 SP. WASHER, M12 34 4 569774 WASHER, M12 35 1 569443 O-RING, G-65, NBR 36 1 569625 AIR VENT 37 1 569768 SET SCREW, LONG, DOG POINT, M8X22 38 1 569751 HEX NUT, M8

38 M410-W-114-3P

39 M410-W-114-3P

AIR MOTOR AND TRANSMISSION ASSEMBLY, 569505

AIR MOTOR ASSEMBLY, 567484


1 1 569510 MOTOR HOUSING 2 1 569511 CYLINDER 3 1 569512 ROTOR 4 7 569513 VANE 5 1 569514 CYLINDER HEAD 6 1 569515 COVER 7 1 569516 SPACER (A) 8 1 569517 ADAPTER HOUSING 9 1 569518 SPACER (B) 10 1 569519 OIL SEAL CASE 11 1 569520 DOWEL PIN (A) 12 2 569521 DOWEL PIN (B) 13 1 569522 END CAP 14 1 569523 END CAP PACKING 25 2 569534 NAME PLATE 703 12 569703 S.H.C. SCREW, M 5 X 12 716 14 569716 S.H.C. SCREW, M 8 X 20 904 1 569904 BALL BEARING, #6204ZZ 905 1 569905 BALL BEARING, #6205ZZ 912 4 569912 RIVET, #2X4.8 943 1 569943 O-RING, P100, VITON (NOK) 952 1 569952 O-RING, G130, VITON (NOK) 960 1 569960 OIL SEAL, SB25408, VITON (NOK) TRANSMISSION ASSEMBLY, 569507 KEY QTY PART NO. DESCRIPTION

15 1 569540 GEAR HOUSING 16 3 569525 PLANET GEAR 17 1 569526 CARRIER PLATE 18 3 569575 PLANET GEAR SHAFT 19 1 569528 DISTANCE PIECE (A) 20 1 569529 RING GEAR 21 1 569530 CLUTCH PISTON 22 1 569531 SEAL RETAINER 23 1 569532 DISTANCE PIECE (B) 24 1 569541 OUTPUT SHAFT 25 2 569534 NAME PLATE 901 1 569901 BALL BEARING, #6004 907 2 569907 BALL BEARING, #6821 908 1 569908 BALL BEARING, #16005 909 1 569909 BALL BEARING, #16012 911 12 569911 NEEDLE BEARING, HK1412 912 4 569912 RIVET, #2X4.8 (SUS) 927 1 569927 SNAP RING, C-100 930 1 569930 GREASE NIPPLE, A-MT6X1 944 1 569944 O-RING, P105, VITON (NOK) 945 1 569945 O-RING, P120, VITON (NOK) 952 1 569952 O-RING, G130, VITON (NOK) 961 1 569961 OIL SEAL, SB40588

40 M410-W-114-3P

41 M410-W-114-3P

AIR MOTOR TRANSMISSION

MAINTENANCE MANUAL

SIGNODE KABUSHIKI KAISHA

42 M410-W-114-3P

43 M410-W-114-3P

1. SPECIFICATIONS

High Speed Feed / Take-up Low Speed Tension

Air Pressure (kgf/cm2) 4.0 (3.5) 5.0 (4.3) 6.0 (5.0) 4.0 (3.5) 5.0 (4.3) 6.0 (5.0)

Gear Ratio 1/5.928 1/152.38

Output (RPM) 440 510 550 20 22 DO NOT USE

Torque Output (kgf / m) 2.14 2.40 2.63 42 43 DO NOT USE

Torque Stall (kgf / m) －－－ 80 92 DO NOT USE

Air Consumption (Nm3/min) 1.5 2.0 2.6 1.4 1.8 DO NOT USE

NOTE: Figures shown in parenthesis ( ) represent dynamic pressure; other figures represent static pressure.

2. AIR SUPPLY The air pressure supplied to the air motor is controlled by a regulator which is

installed in the line of each airport of the motor. For proper operation, the air

supply must be set between a minimum of 4 kgf/cm2 and a maximum of 6 kgf/cm2 .

Please note when operating low speed tension, do not use over 5 kgf/cm2 in order

to maintain the average life expectancy of the air motor. A minimum air supply of

3 kgf/cm2 is required to shift the transmission.

3. AIR PIPE PLUMPNG

The recommended diameter of the air line should be the same size or slightly larger as the diameter of the air ports.

To prevent moisture or dust build-up, always install a water leg with drain cock at the lowest point of the airlines.

A sufficient capacity silencer is required. If an insufficient silencer is used, the air motor's power output may be required from increased exhaust air pressure.

4. PLUMPNG CONNECTIONS

The air ports for the motor are ports “A” & “B”. One is used as the air inlet port

and the other is used as the air outlet port. Install a silencer at the exhaust port.

To shift the transmission between high & low speeds, use the “H” & “L” ports.

One is used as the air inlet port and the other is used as the air outlet port.

Please note that both side of the pipe mounts for ports “H” & “L” open

therefore, the unused side must be plugged.

The illustration below shows the direction of rotation for the transmission shaft

when supplying air through ports “A” or “B” and ports “H” or “L”.

NOTE: All end caps can be turned 180° on the air inlet & outlet ports. In this case,

the rotation directions illustrated above, are reversed.

5. LUBRICATION Air Motor:

A mist type lubricator, capable of dispersing micron sized particles of oil, must be installed in the

line of the air motor. The lubrication application must be set release 2 ～ 3 drops of oil per

strapping cycle. Prior to initial start-up & operation, pour 3 cc of lubricant into the air inlet port.

Transmission:

As required. During re-assembly, fill with 220 g of grease. Use grease listed in the following table

or its equivalent:

SHELL ESSO MOBIL

Air Motor Turb Oil T 32 Teresso 32 DTE Light Oil

Transmission ALVANIA LITIITAN MOBILUX

EP GREASE-0 EP-0 EP-0

44 M410-W-114-3P

45 M410-W-114-3P

6. CLEANING & INSPECTION The Air Motor & Transmission must be cleaned & inspected annually or every

2,000 hours of operation, whichever comes first. Operation of the Air Motor is

required at least once a month or more. In cases when the Air Motor is not

operated for any period more than one month, pour an evaporate rust preventive

type lubricant into the air inlet port before resuming operation.

7. TROUBLE SHOOTING SYMPTOMS: 7-1 Air Motor Fails to Start

CAUSE REMEDY insufficient air pressure check the pneumatic circuit

damage or wear to the vane replace the vane

seizure of air motor: caused by insufficient lubrication or blockage from foreign matter

replace the air motor

7-2 Transmission Fails to Shift

CAUSE REMEDY insufficient shifting pilot air pressure check the pneumatic circuit

damage or wear to the o-ring of clutch piston replace the o-ring

damage or wear to the meshing gears of the clutch piston and carrier plate replace clutch piston or carrier plate

7-3 Increased Temperature of the Air Motor

CAUSE REMEDY insufficient lubrication check the lubrication

7-4 Increased Temperature of the Transmission

CAUSE REMEDY insufficient grease level check grease level, add to adjust

wear of gear teeth or bearings replace gear or bearings

46 M410-W-114-3P

8. BREAKEDOWN NOTE: The Air Motor can be separated from the Transmission by removing bolts #716.

8-1 Air Motor

Remove bolts #716 and the end cap #13.

Remove cylinder head #5.

Remove rotor #3. If necessary, tap the end of the rotor shaft with a plastic hammer (only) to loosen.

Remove cylinder #2.

Remove adapter housing #8.

.NOTE: Bolts #703 are locked with “Locktite” adhesive. If required, DO NOT remove these bolts.

8-2 Transmission The inner components can be removed in bulk by tapping the end of the output

shaft #24, with a plastic hammer (only). 9. RE-ASSEMBLY

By simply reversing the breakdown order, the Air Motor and Transmission can be

re-assembled. Follow the recommendations below to insure proper operational functions after

re-assembly:

9-1 Transmission

Apply a coating of grease to all gears, bearings, oil seals & o-rings.

Only after applying a coat of grease, attach distance piece-A #19 onto the carrier plate #17.

Re-assemble the carrier plate #17, the ring gear #20 and the distance piece-B #23, onto the output shaft #24. Once this has been completed, install the output shaft assembly into the gear housing #15.

When installing the planet gears #16 onto the inner gears of the output shaft #24,

be sure to follow he proper tooth pattern as indicated in the following table:

As illustrated below, the planet gears #16 and the inner gears of the output shaft

47 M410-W-114-3P

1 #24, both have matching yellow markings.

2 Install the ring gear #20 onto the carrier plate #17 from the planet gear side.

Stand the output shaft assembly vertically, then install the plant gear assembly 3 into the inner gear, making sure to match the yellow markings.

4 Install distance piece-B #23.

5 Be careful not to drop distance piece-A.

install the output shaft assembly into the gear housing #15 by tapping the end of 6 the carrier plate flat to the surface of the bearing #907 until it is flush with the

inner step of the gear housing.

Apply grease inside the end of the small air ports of the gear housing to prevent 7 o-ring damage.

9-2 Air Motor

● once the cylinder head #5, adapter housing #8, ball bearing #904, and the rotor #3 have been re-assembled, adjust the clearance between the rotor #3 and the cylinder head #5 according to the following instructions:

A. Install ball bearings #904 into the cylinder head #5 and adapter housing #8, then install oil seal case #10 and cover #6 with bolts #703. Secure bolts #703 with “Locktite” adhesive, 3-M BOND1342 or an equivalent.

B. Put in spacer-A #7 and spacer-B #9. Using a depth micrometer, measure the protrusion of the spacers: i,e, this protrusion acts as the motor's clearance after assembly. A suitable measurement is between 0.04 ～ 0.06 mm. If the spacer protrusion is not within the suitable range, change the spacers and re-measure until a suitable measurement is acquired.

C. Four types of spacers are prepared as follows.

Insert dowel pin-A #11 into the hole of the 3 holes of the motor housing

#1 and then insert the dowel pins-B #12 into the left & right holes.

The outside diameter of the left & right sides of the cylinder #2 are different from each other by 1mm. Insert the cylinder toward the smaller diameter side.

The end cap #13 can be installed at a 180° reversal. The standard installation is illustrated below:

10. PARTS LIST AND REPLACEMENT SCHEDULE

48 M410-W-114-3P

PART NO. NOMENCLATURE DIMENSIONS REPLACEMENT SCHEDULE

49 M410-W-114-3P

When thickness is less than 4.5 mm.

When height is less than 28.0 mm. E569513 Vane

When length is less than 54.5 mm.

O-Rings As required & during re-assembly

E569526 Carrier Plate Gear tooth is served or worn

E569530 Clutch Piston Gear tooth is served or worn

E569525 Planet Gears Gear tooth is served or worn

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