AirCooled KnifeMaint

MAINTENANCE MANUAL9405425

MARQUIP DIRECT DRIVE CUTOFF KNIFE (MODEL III)

DRY END CELL CONTROLLER

COPYRIGHT APRIL 1991 MARQUIP, INC.

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This document contains designs and constructions developed and engineered by Marquip Inc., which are its property, and all use or copying thereof shall be subject to authorization from Marquip Inc. upon terms to be established by it. All such designs and constructions are confidential, and any unauthorized manufacture or use of the same will be a violation of the rights of Marquip Inc. thereto. Any use you make of this document will constitute your agreement to the foregoing.

Marquip, Inc.1300 North Airport RoadPhillips, Wisconsin 54555-0028715/339-2191

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PURPOSE OF MANUAL

The Marquip automatic materials handling equipment described in this manual has been designed to normally operate with only supervisory human interface. Sections of this manual describing machine assembly, start-up, adjustment, and general maintenance, however, all require customer personnel to be in the area of potentially dangerous, automatically moved, mechanical parts and electric circuitry. At the outset of this manual, therefore, Marquip provides a reminder that extreme caution must be exercised whenever working near the equipment. CAUTION signs have been prominently mounted on the machine, warning installation and servicing personnel to stand clear whenever equipment is operating, and whenever air, electrical, or hydraulic power is being applied to or removed from the equipment.

The intent of this manual is to:

• Provide a functional description in enough depth that personnel unfamiliar with the machine will be able to control the material handling process after reading the manual.

• Provide information on safety aspects of the installation, start-up, operation, maintenance, and servicing of the machine.

• Provide information on the operational controls of the machine.

• Provide a machine start-up procedure.

• Define mechanical, pneumatic, and electrical adjustments required to keep the machine running properly.

• Define general maintenance procedures which, if followed, will keep the equipment running smoothly.

• Provide a recommended spare parts list so that, as parts wear out, they can be quickly replaced to minimize downtime.

The following sections of this manual discuss each of these items in detail.

Because the manual contains machine assembly and start-up information, every attempt has been made to get the manual delivered at an early date. Changes to the manual will be issued to the customer as revision pages.

In order to minimize the opportunity of damage to machinery resulting in costly downtime, checklists have been provided for installation, start-up, and maintenance. Close attention to these items will minimize machine downtime. A spare parts list has also been provided. Stocking key components allows quick replacement of items that need changing and also prevents costly downtime. Preventive maintenance is always cost-effective and should be started during the installation and start-up period.

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TABLE OF CONTENTS

INTRODUCTION - 9404727

Operational Description ..................................................I-1Glossary ..........................................................................I-2

SAFETY - 9404728

Safety ..............................................................................S-1Safety Guidelines ............................................................S-2Warnings In Manual ........................................................S-3Signs And Their Locations ..............................................S-6

OPERATION - 9404729

Operator Controls ...........................................................O-1Automatic Functions .......................................................O-6

PREVENTIVE MAINTENANCE - 9405423

Cleaning ..........................................................................Pm-1Lubrication ......................................................................Pm-2Knife Lubrication Chart ...................................................Pm-2Tachometer Maintenance ...............................................Pm-4Preventive Maintenance Checklist ..................................Pm-5

MAINTENANCE ADJUSTMENTS - 9405426

Safety Lockout And Gaining Knife Access .....................Ma-1Manual Rotation ..............................................................Ma-4Glossary Of Blade Tuning Terminology ..........................Ma-6Spot Tuning ....................................................................Ma-7Tuning Used Blades .......................................................Ma-13How To Loosen Tight Blades: New And Used ................Ma-19How To Check For Loss Of Gear Preload ......................Ma-20Holddown Wheel Downstops ..........................................Ma-21Air System Pressure Settings .........................................Ma-21Electrical Sensor Setups .................................................Ma-22Board Sense/fork Sense Photoeye Setup Procedure .....Ma-23

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COMPONENT REPLACEMENT - 9404737

Removal And Installation Of Knife Blades ......................Cr-1Broken Blade Bolt Removal ............................................Cr-4Threaded Insert Removal And Replacement ..................Cr-5Knife Cylinder Gear Backlash Removal And

Gear Preload ................................................................Cr-7Tuning New Blades .........................................................Cr-13Roll Replacement - Pull Roll ...........................................Cr-18Roll Replacement - Exit Roll ...........................................Cr-20Holddown Wheel Replacement ......................................Cr-22Resolver Replacement - Knife Cylinder Resolver ...........Cr-23Tachometer Brush/commutator Replacement -

Knife Cylinder ...............................................................Cr-25High-t Motor Resolver Replacement ...............................Cr-26Torque Teaser Setup Procedure ....................................Cr-27

SPARE PARTS - 9405427

Infeed Section Assembly ................................................Sp-2Exit Section Assembly ....................................................Sp-3Knife Cylinder Assembly .................................................Sp-3Knife Cylindfr Resolver Assembly ...................................Sp-4Knife Cylinder Tachometer Assembly .............................Sp-4Pull/exit Roll Motor And Accessories ..............................Sp-4Pneumatics .....................................................................Sp-5Tools ...............................................................................Sp-5Lubrication ......................................................................Sp-5Measuring Wheel Assembly ...........................................Sp-6Motor Cooling Accessories .............................................Sp-6Miscellaneous .................................................................Sp-7Machine Components .....................................................Sp-8Knife Drive Components Located In Knife

End Enclosures (Integral) Or Control Cabinets (External) .......................................................Sp-8

Decc Console .................................................................Sp-9Interface Enclosure On External Control/power

Panel On Integral Control .............................................Sp-10Ctm (Option) ...................................................................Sp-10Machine Wiring ...............................................................Sp-11Cable With Connectors ...................................................Sp-11

PERSONNEL TESTING - 9404740

Introduction .....................................................................Pt-1Machine Records ............................................................Pt-2

Operator Training - Knife ..........................................Pt-2Maintenance Training - Knife ....................................Pt-3

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Operator And Maintenance Quiz ....................................Pt-4Maintenance Quiz .....................................................Pt-8

Operator And Maintenance Answer Key ........................Pt-14

SUPPLEMENT - 9432201

Adjusting Electrical Sensor .............................................Su-1Limit Switches ...........................................................Su-1

Miscellaneous Spare Parts .............................................Su-2

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INTRODUCTION - 9404727 I-1

OPERATIONAL DESCRIPTION

A continuous web of corrugated enters the knife system from the upstream slitter/scorer. This web may be diverged into two or three levels by means of knife lead-in forks (provided by others).

The web first engages a series of web detect photoeyes which provide input for first sheet cut accuracy. Another set of photoeyes sense the tips of the knife lead-in forks. These determine at which level the web is being directed. Just downstream of the web detection area, the web enters the pull roll. The pull roll runs slightly faster to maintain tension on the web and provides positive control of the web during a cut.

A short distance further, the web is directed between the cutoff mechanism. 1/2" to 1-1/2" of the leading edge of the web may be trimmed off at this time to create a clean edge for the first sheet to be cut. The knife is pre-programmed to cut sheets to a specific length. Immediately downstream of the knife mechanism is an exit roll assembly which runs slightly faster than the upstream pull roll assembly. This overspeed allows the web to be tensioned prior to the cut, plus serves to accelerate the sheet away from the knife. The cut sheet is then powered into the downstream stacking system. The knife system may be programmed to change the length of the cut within one cycle of the knife mechanism. The trailing edge cut of the last sheet is made at the same time as the leading edge cut of the first sheet. In the case of a slitter/scorer setup change, a gap is created between the old and new setup by means of speed changes (no gap type) or by chopping out some portion of the web (gap type). In these cases, one short sheet at the end of the old setup will be generated. During a no gap setup change at full line speed, the knife will maintain full speed. At slower speeds, the corrugator may maintain speed while the slitter/scorer and knife speed up to generate slitter/scorer change time. In most cases, the corrugator slows down first, then a shear chop is made, and then the slitter/scorer and knife speed up to pull the necessary gap. After the setup change is complete, the corrugator is accelerated back up to full speed.

I-2 9404727 - INTRODUCTION

GLOSSARY

The numbers below are keyed to numbers in figures 1 & 2.

1. Control Cabinet - 60" x 39" rectangular, freestanding operator control station.

E-Stop - Emergency stop control command which brings all components of the line to a stop as quickly as possible. Used only to prevent injury to personnel or damage to machinery.

2. Exit Roll - Urethane covered roller which powers sheets into stacker.

Exit Roll Drive Motor - Variable speed motor which directly powers exit roll.

3. Exit Roll Nip Wheels - These 2" wide wheels are directly over the exit roll. They hold the sheets against the exit roll and provide the drive force. Also called holddown wheels.

4. External Drive Cabinet - The larger of two electrical enclosures. On external drive models they house all motor drives and starters. One enclosure per level. On triple level integral drive models there is one external drive cabinet and it houses all motor drives and starters for the middle level.

5. Integral Drive Cabinet - On double and triple level knives, if integral drive model, located on both sides of knife on the upstream end of the knife. On double level knives it houses all motor drives and starters. On triple level knives it houses motor drives and starters for the lower and top levels.

6. Interface Enclosure - External control only enclosure contains input and outputs from control computer control cards that help run and monitor the machine.

Knife Drive Motors - Variable speed motors which provide the power to rotate the knife cylinders.

Left Side - The left side of the knife looking downstream.


7. Level Disconnect - Main power disconnect, located on operator side on an integral control machine, on remote cabinet for an external control machine. Shuts off 460 volt power to a level's drive cabinet. Does not remove power from control cabinet .

8. Lower Knife Cylinder - The lower knife cylinder of the pair on either level. It has a nonadjustable blade and has no backlash adjustment.

Lubrication Tank - This system consists of a reservoir for oil for the knife cylinder gears and bearings. It is fitted with a float level switch to automatically stop the knife in case of low oil.

9. Main Disconnect - Main power disconnect, located on operator side on an integral control machine, on remote cabinet for an external control machine. Shuts off 460 volt power to drive cabinet(s). Does not remove power from control cabinet .

Measuring Wheel - A 6" diameter x 3" wide wheel mounted just downstream of the shear used to accurately measure sheets.

Motor Cooling Blower(s) - The blower(s) forces a low pressure airflow through the knife drive motor(s) to keep them cool.

10. Motor Enclosure - Located on both sides of the knife. It houses motors, blowers, and pneumatic valves.

Nip - Any pair of rollers running together to drive material between them.

Normal stop - A gradual coast to a stop by the corrugator. Used in non-emergency cases.

Photoeye - An electrical device which provides an output signal when a light beam emitted by it is broken.

11. Pull Roll - A urethane roll immediately upstream from the knife cylinders which pulls the web through the knife.

Pull Roll Drive Motor - A variable speed motor which is directly coupled to the drive roll.

12. Pull Roll Nip Wheels - These 2" wide wheels are directly over the pull roll. They hold the web against the pull roll to provide the drive force. Also called holddown wheels.


Right Side - The right side of the knife looking downstream.

13. Roll Out Infeed Section - A roll out drawer which houses the pull roll nip wheels. It rolls out to provide access to the knife cylinders.

14. Top Cover - A guard covering the knife cylinders and exit roll on the upper level. It can be folded back to access the knife cylinders.

15. Upper Knife Cylinder - The upper knife cylinder of the pair on either level. It has an adjustable blade and backlash adjustment on the ends.


Figure 1. Marquip Direct Drive Knife


Figure 2. Marquip Knife - Section View

SAFETY - 9404728 S-1

SAFETY

The Marquip Knife is designed to minimize the operator's functions. However, during installation and maintenance, there is a requirement for personnel to be in the proximity of potentially dangerous mechanical and electrical devices. EXTREME CAUTION must, therefore, be exercised while servicing or installing the machine. The nature of automatic equipment is such that false external inputs may cause the equipment to operate in an abnormal sequence. Manual actuation of a limit switch, for example, may create an unanticipated machine response. The only safe policy to follow when servicing machines is to shut off all pneumatic and electric power and bleed the pneumatic system. CAUTION and DANGER signs have been prominently mounted on the machines, warning personnel of existing and potential hazards.

S-2 9404728 - SAFETY

SAFETY GUIDELINES

1. The safety precautions given in this manual provide guides for the protection of personnel and are specifically related to the system. In addition to these precautions, observe all appropriate general rules of safety and good judgement for your own protection and for protection of fellow workers.

2. Observe all safety precautions. Keep disconnect handle on main control panel and pneumatic power locked out at all times while performing maintenance duties, except when operations must be performed with equipment operating.

NOTE: When pneumatic power is turned off, some lines may still hold pressure. The complete system must be drained of air.

3. Stay clear of all gear and direct coupled drives unless certain that power has been locked out for the machine.

4. Replace safety guards securely whenever finished with maintenance duties in that area.

5. Check inside and around the machine for operator and maintenance personnel before applying power to the machine.

6. Do not bypass the provided safety switches. Repair immediately any nonfunctional safety switches.

7. Check for a high voltage on and around electrical components before servicing. There are several separate power sources running into the electrical enclosures.

Report any accident or near miss which occurs on any Marquip equipment to Marquip immediately so that it can be analyzed and any necessary corrective action can be taken to reduce the hazard.

SAFETY - 9404728 S-3

WARNINGS IN MANUAL

The following warnings are contained in this manual. They warn maintenance personnel of special hazards present while performing maintenance procedures described in this manual. Follow their instructions exactly.

? CAUTION: THE FOLLOWING PROCEDURE IS PERFORMED WITH COMPRESSED AIR CONNECTED TO THE MACHINE.

? CAUTION: DO NOT STEP ON ROLLS OR WHEELS SINCE THEY ARE FREE TO TURN AND MAY CAUSE YOU TO LOSE YOUR BALANCE.

? DANGER: DO NOT PERFORM ANY MAINTENANCE ADJUSTMENTS WITHOUT FIRST DISCONNECTING AND LOCKING OUT POWER TO ALL KNIFE LEVELS.

? WARNING: TO AVOID DAMAGE TO THE BLADE EDGES, NEVER ROTATE THE CYLINDERS BACKWARDS OR FORCE THE BLADES TO PASS WITH INTERFERENCE.

? CAUTION: USE CARE WHEN TUNING NEW, COLD BLADES WITH WET 90-LB.; DO NOT TRY TO CUT EVERY FIBER CLEAN OR YOUR BLADES WILL BE TOO TIGHT. WHEN IN DOUBT, TUNE LOOSE. IT IS ALWAYS BETTER TO RETUNE THAN TO TUNE TOO TIGHT AND DESTROY A SET OF BLADES.

S-4 9404728 - SAFETY

? DANGER: DO NOT USE MARQUIP-SUPPLIED CONTACTS TO ACTIVATE AUTOMATIC EQUIPMENT BEFORE SAFETY PRECAUTIONS HAVE BEEN TAKEN TO GUARD AND INTERLOCK THAT EQUIPMENT PROPERLY. FAILURE TO DO SO MAY RESULT IN LOSS OF LIFE OR LIMB.

? CAUTION: CHECK THAT PATH IS CLEAR. THIS ROLLING INFEED ASSEMBLY COULD CAUSE INJURY IF CLOSED ON SOMEONE.

? CAUTION: KEEP HANDS AND FINGERS CLEAR OF ALL STOPS AND SUPPORT ROLLERS TO PREVENT INJURY WHEN MOVING THE INFEED ASSEMBLY.

? SAFETY: REVIEW THE SAFETY LOCKOUT AND GAINING KNIFE ACCESS PROCEDURES BEFORE ATTEMPTING TO WORK ON THE KNIFE.

? CAUTION: BLADES ARE VERY SHARP. USE CUT-RESISTANT GLOVES TO PROTECT YOUR HANDS.

SAFETY - 9404728 S-5

? CAUTION: ALWAYS LOOSEN BLADE BOLT TORQUE BEFORE ADJUSTING JACKSCREWS. IF YOU DON’T, STRESS IN ADJUSTING SCREWS MAY CAUSE BLADE TO ADVANCE WHILE RUNNING, CAUSING TOO TIGHT OF A TUNE.

? CAUTION: NEVER ROTATE CYLINDERS FORWARD THROUGH A CUT WITH BLADE LAPPING COMPOUND ON THE BLADES

? CAUTION: REMOVAL OF OLD BLADES AND INSTALLATION OF NEW BLADES CAN BE DANGEROUS SINCE TWO PEOPLE MAY BE IN THE KNIFE. BEFORE MANUALLY ROTATING THE KNIFE, CHECK THAT ALL HANDS AND FINGERS ARE CLEAR. DO ALL PROCEDURES HERE WITH ONE PERSON IF POSSIBLE.

? CAUTION: REMOVE KNIFE BLADES BY REMOVING BOLTS PROGRESSIVELY FROM ONE END TO THE OTHER TO PREVENT A SUDDEN, DANGEROUS RELEASE OF BLADE STRESS.

? CAUTION: KNIFE POWER MUST BE TURNED OFF AND DISCONNECT LOCKED OUT BEFORE PROCEEDING.

S-6 9404728 - SAFETY

SIGNS AND THEIR LOCATIONS

Marquip has provided caution and danger signs on the knife to warn operator and maintenance personnel of hazards. Should a sign be removed, Marquip will replace such signs. Figures 1, 2, 3, 4, 5, and 6 show the locations of all safety signs on the Marquip Knife.

ITEM COLOR/SIZE MARQUIP PART #

1. Black & Yellow 69918435" x 3-1/2"

2. Black, Red & White 69917935" x 3-1/2"

SAFETY - 9404728 S-7


3. Black & Yellow 69917925" x 3-1/2"

4. Black & Yellow 69917965" x 3-1/2"

5. Black & Yellow 69917945" x 3-1/2"

S-8 9404728 - SAFETY


6. Black & Yellow 69918585" x 2-1/4"

7. Black & Yellow 69919525" x 3-1/2"

8. White & Black 94038073" x 3"

SAFETY - 9404728 S-9


9. Black, Red & White 69917975" x 3-1/2"

10. Black & Yellow 94012625" x 3-1/2"

11. Black & Yellow 69918745" x 3-1/2"

S-10 9404728 - SAFETY


12. Black & Yellow 69918285" x 3-1/2"

13. Black & Yellow 69919145" x 3-1/2"

14. Black & Yellow 69920125" x 3-1/2"

SAFETY - 9404728 S-11


15. Black & Yellow 69922725" x 3-1/2"

16. Black & Red 6960007Don’t Touch Symbol

17. Black, Red & White 69750065-1/2" x 3"

S-12 9404728 - SAFETY


18. Black, Red & White 69918442-1/4" x 1-1/4"

19. Black & Yellow 6960016Caution Power Symbol

20. Black & Yellow 94019845" x 3-1/2"

SAFETY - 9404728 S-13


21. Red & White 94131707" x 3"

22. Black & Yellow 94014375" x 3"

S-14 9404728 - SAFETY

Figure 1. Stacker Door

Figure 2. Power Input Enclosure

SAFETY - 9404728 S-15

Figure 3. External Drive Cabinet

S-16 9404728 - SAFETY

Figure 4. Exit View

SAFETY - 9404728 S-17

Figure 5. Integral Drive Knife

S-18 9404728 - SAFETY

Figure 6. Knife Warning Signs

OPERATION - 9404729 O-1

OPERATOR CONTROLS

The functions of the knife operator controls on the machine are listed below. Shown are buttons for a single level knife. A double or triple level knife will require additional buttons for each additional level.

AUTO: White Illuminated Push Button

FUNCTION: This push on, push off button enables its respective machine to run automatically. When AUTO is turned on for every machine (and the slitter/scorer and backstops have been referenced), the dry end is ready to run and change setups. A white pilot light indicates AUTO is on. Pushing the button while running results in a normal stop. If a machine has more than one level, there will be one of these buttons for each level.

LOCATION: Dry End Cell Controller Console (Knife Section)

BLADE LAP UPPER: Two-Position Keyswitch (1 - 0)

FUNCTION: Allows the operator to rotate the knife at a preset speed in reverse for the purpose of blade lapping. It can only be used with AUTO off and CONTROL POWER on.

LOCATION: Manual Operator Station

O-2 9404729 - OPERATION

CONTROL POWER: Two-Position Keyswitch (Lockout-Enable)

FUNCTION: This keyswitch control provides a means of locking control power off of a machine. It should be used whenever an operator is clearing a jam or whenever it is necessary to work near a machine's moving parts. The key can and should be removed from the switch whenever it is in the LOCKOUT position.


CONTROL POWER: White Illuminated Mushroom Head

FUNCTION: This pull on, push off button activates all drives, valves, sensors, and hydraulic pumps for its respective machine. CONTROL POWER must be on to enable any manual functions a machine may have. It must also be on before the machine can be put in the AUTO mode. The white pilot light is lit when power is latched on. Pushing the button while running causes a normal stop. If a machine has more than one level, there will be one of these buttons for each level.



EMERGENCY STOP: Red Push - Twist to Release

FUNCTION: Allows the operator to bring the machine to the fastest stop possible to prevent or limit injury to persons and machinery. When the button is pressed, the knife cylinders, pull roll(s), and exit roll(s) stop immediately. The motor cooling blower(s) coast to a stop. CONTROL POWER and AUTO drop out. The controller also provides a contact opening for the corrugator E-stop circuit. In the event of a computer crash, there will be a two-second delay and the knife will coast to a stop. During this time, the E-stop will not function on the knife, but it will function on the corrugator.


JOG CYLINDERS FORWARD UPPER: Two- Position Selector Switch (0 - 1)

FUNCTION: Allows the operator to rotate the knife at a preset speed forward. It can only be used with AUTO off and CONTROL POWER on.



JOG ROLLS UPPER: Three-position Selector Switch, Spring Centered (Reverse-Stop-Forward)

FUNCTION: Allows the operator to jog the exit roll, pull roll, and drive roll at a preset speed forward or reverse. It can only be used with AUTO off and CONTROL POWER on.


KNIFE CONTROL: Two-Position Keyswitch (Lockout-Enable)

FUNCTION: Provides a key lockout of control power. It should be used by the operator when clearing jams or anytime it is necessary to work around the knife's moving parts. m e key can and should be removed when in the LOCKOUT position.


NOTE: The operator must also lockout the machine using the following procedure before clearing jams or working around the knife's moving parts: repeat "Safety Lockout" and "Gaining Knife Access" procedures found in the "Safety Lockout and Gaining Knife Access" portion of the Maintenance Adjustment section of this manual .


RAISE ROLLS UPPER: Two-Position Selector Switch (Down-Up)

FUNCTION: Allows the operator to raise the holddown nips over the exit roll, pull roll, and drive roll. It will retain either the UP or DOWN position with power off as long as compressed air is connected to the machine. m e nips can only be raised with AUTO off and CONTROL POWER on.


RUN-SERVICE: Two-Position Keyswitch

FUNCTION: This keyswitch is for maintenance purposes only. Turning the switch for a specific machine will open a contact in the E-stop circuit of that machine, allowing that machine to be powered down for maintenance. Yet, at the same time, the switch jumps around the machine E-stop string (cable switches, door switches, etc.) from that machine to the DECC. In this mode, maintenance may be performed on a machine without disturbing any of the others in the line. The wet end SERVICE switch jumps around the E-stop contact from the double backer to the dry end and opens the E-stop contact from the dry end to the wet end, not allowing the double backer to start. This allows dry end testing to be done without the need for the double backer to be powered up.



AUTOMATIC FUNCTIONS

The Marquip Knife has several automatic functions with which the operator should be familiar.

1. There are safety switches on all easily opened guards and doors that will produce an emergency stop on the corrugator if tripped. These switches are on the top cover, the roll out infeed sections, motor enclosure doors, and the outfeed barrier guards.

2. A normal stop will occur if the oil flow or oil level in the gear lubrication system falls below a preset oil level or if motor cooling airflow falls too low.

3. Movement of the jam detect pan, located between the knife cylinders and exit roll, due to a jam or wrap-up will trigger an emergency stop on the corrugator.

4. If the corrugator is running at a speed which overloads the knife's drive motors, the Dry End Cell Controller will send a slower signal to the corrugator to reduce its speed. If the corrugator does not respond and excess speed is maintained for a period of 10 seconds, a normal stop will occur.

5. If AUTO is enabled without a web in the machine, the knife cylinders will go to a cocked position and will not rotate further until a web enters the machine.

6. Located on the bus detector enclosure are five LED indicators. If any LED turns off during normal operations, contact maintenance. If any LED remains on for 30 seconds after turning off main disconnect switch, contact maintenance.

PREVENTIVE MAINTENANCE - 9405423 PM-1

The reliability of your knife will be optimized if a proper schedule of preventive maintenance is followed. Preventive maintenance involves the two major functions of cleaning and lubricating. Regular removal of dust, scrap, and coatings will keep the knife running safely and smoothly. Proper lubrication will greatly prolong the life of all components and prevent costly breakdowns. Items listed below should be performed periodically according to the "Preventive Maintenance Checklist" chart.

CLEANING

1. Small pieces of scrap and trim will often hang up in the knife. These should be periodically removed for two reasons. Scrap pieces rubbing against rotating shafts and rolls can build up heat and be a potential fire hazard. Long pieces of trim can wrap around rotating parts, generate enormous forces, and bend or break shafts and bearings.

2. Dust and scrap will build up directly under the exit roll. Blow the dust from this area on a daily basis. Excessive build-up will cause roll wear, undue strain on drive components, or jams.

3. Coatings that are applied to the web may build up on the rolls and wheels of the knife. It is important to keep all rolls and wheels clean.

4. Blowers provide cooling air for the knife cylinder drive motors. There is a filter on the inlet of the blower to keep dust out of the motors. Keep this filter clean and replace as required. When replaced, the air filter should have an efficiency of 45-55% and an average arrestance exceeding 95X. An airflow switch will shut off the knife if inadequate airflow exists. This could indicate that the filter needs cleaning or replacing. Do not bypass the shutdown switch. Operating the machine without cooling air can result in sudden, total failure of the drive motors.

5. There is one compressed air filter per level. It should be purged of oil and water periodically. The element should be replaced as required.

6. On integral drive knives, there are filters located on top of the integral drive cabinets. On external drive knives and triple level integral drive knives, there are filters located on the right-hand side of the external drive cabinets. Keep these filters clean and replace as required. When replaced, the air filter should have an efficiency of 45-55% and an average arrestance exceeding 95%. This prevents catastrophic control equipment failure.

PM-2 9405423 - PREVENTIVE MAINTENANCE

LUBRICATION

1. Lubrication of the knife cylinder gears and bearings is completely handled by an oil bath. Check the oil level on the left side of the machine. The oil level should be between the two marks on the sight gauge. m e distance between the marks corresponds to two gallons of oil. Completely drain the oil once every six months and replace with Mobil Gear 630. A safety float switch is provided to stop the knife if the oil level drops below the minimum level.

2. Lubrication of the knife's pull roll, exit roll, and pull roll holddown wheel shaft bearings is by grease fittings. There is a fitting on the bearing on each end of the two rolls and on each end of the holddown wheel shaft. The location of these six bearings is shown in Figure 1. Do not grease bearings while knife is running.

3. A wick lubricator is provided to lubricate the knife blades. This wick is mounted such that the lower blade rubs the wick. This wick is automatically oiled from the gear case through a flow control valve.


KNIFE LUBRICATION CHART

* For duty cycles above 400 FPM and 18 hours per day, this interval should be weekly.

LOCATION LUBE TYPE QUANTITY LUBE INTERVAL

Knife Cylinder Reservoir Mobil Gear #630 To Full Mark Weekly

Blade Lubricator Mobil Gear #630 (From Cylinder Reservoir)

Per Flow Control Setting

Continuous

Pull and Exit Roll Bearings (Figure 1)

Texaco Multifak #2, Mobil Mobilux #2 or Equivalent

3 Pumps * 4-8 WeeksDepending on Duty Cycle


Figure 1. Grease Fitting Locations

DO NOT Grease Bearings while Knife is Running!!!



TACHOMETER MAINTENANCE

The knife cylinder tachometer should be periodically inspected for brush and commutator wear. Brushes and/or commutators should be replaced as required.

To inspect the knife cylinder tachometer, open the left side doors (looking downstream). The tachometer is enclosed in an aluminum housing near the knife drive motors. Remove the cover on the conduit fitting to expose the tachometer leads. Remove the tachometer cover and carefully thread wire through the cover while pulling the cover away from the tachometer housing. The amount of brush dust inside the cover will give a general indication of wear. If more than a thimbleful of dust is present, the brushes will most likely need to be replaced. Remove the four screws holding the brushes in place. The brushes can then be pulled out. The brushes are 5/16" long when new. If the brushes are worn down to 1/8", they must be replaced. (See Component Replacement section.)

Inspect the commutator. If a groove more than .010" deep is present, replace the commutator. (See Component Replacement section.)

Inspect the inside of the tachometer housing. If any oil is present, it will be necessary to replace the housing. Oil in the tachometer will cause rough and erratic operation of the knife cylinders.

? CAUTION: When replacing the cover, pull all excess wire into the conduit fitting to prevent wire from rubbing on rotating shaft.

Some knives utilize a speed signal generated by a tachometer driven by a shaft which turns when the slitter/scorer runs. The brushes in this tachometer should be checked on a periodic basis to insure that a smooth and linear voltage signal will be generated. Brushes are accessible through the covers located near the rear of the tachometer.


PREVENTIVE MAINTENANCE CHECKLIST

Refer to the following Preventive Maintenance Checklist for a guide to frequency of preventive maintenance checks.

Preventive Maintenance Checklist - Operator Personnel

RESPONSIBILITY CHECK LOCATION FREQUENCY

Operator Remove Scrap, Trim, and Dust Around Knife Cylinders and Under Exit Roll

Figure 2 in Introduction Section

Daily

Operator Clean Rolls and Wheels of Coatings

Figure 2 in Introduction Section

Weekly

Operator Clean Air Filters, Monitors, and Drive Cabinets

Weekly


Preventive Maintenance Checklist - Maintenance Personnel

RESPONSIBILITY CHECK LOCATION FREQUENCY

Maintenance Check Oil Level 1/Level Weekly

Maintenance Check Blade Lubricator 1/Level Weekly

Maintenance Check/Scope Power Supplies

External Controlled - Interface Enclosure; Integral Controlled - Upper Power Panel

Monthly

Maintenance Check Photoeyes 2 Pair/Level Monthly

Maintenance Verify All Drives Functioning/Current Sense Cards LEDs

10/Level Monthly

Maintenance Check Surface Under Web Resolver

1 Monthly

Maintenance Check/Clean Tachometers

3/Level Monthly

Maintenance Check/Adjust Pull/Exit Speeds

1/Level 6 Months

Maintenance Grease Bearings Figure 1 in Preventive Maintenance Section

6 Months

MAINTENANCE ADJUSTMENTS - 9405426 MA-1

SAFETY LOCKOUT AND GAINING KNIFE ACCESS

? DANGER: DO NOT PERFORM MAINTENANCE ADJUSTMENTS WITHOUT FIRST DISCONNECTING AND LOCKING OUT POWER TO ALL KNIFE LEVELS.

? CAUTION: CONTACT MAINTENANCE IF ANY LED IS OFF DURING NORMAL RUNNING. CONTACT MAINTENANCE IF ANY LED REMAINS LIT 30 SECONDS AFTER TURNING OFF MAIN DISCONNECT.

Safety Lockout Procedure:

Step 1 Lower pull/exit rolls.

Step 2 Turn off CONTROL POWER for each level of the knife.

Step 3 Turn CONTROL POWER keyswitch to LOCKOUT and remove key.

Step 4 Check that LEDs on bus bleeddown cards are all functional.

Step 5 Turn off main disconnect for each drive cabinet.

Step 6 Wait for all LEDs to turn off.

Step 7 Lock out main disconnects.

Step 8 Shut off compressed air.

Gaining Knife Access Procedure:

? CAUTION: CHECK THAT PATH IS CLEAR. THE ROLLING INFEED SECTION COULD CAUSE INJURY IF CLOSED ON SOMEONE.

? CAUTION: KEEP HANDS AND FINGERS CLEAR OF ALL STOPS AND SUPPORT ROLLERS TO PREVENT INJURY WHEN MOVING THE INFEED ASSEMBLY.

MA-2 9405426 - MAINTENANCE ADJUSTMENTS

Step 1 Open top covers - pull out plungers on limit switches and swing open covers. Covers must be opened in sequence starting with covers having safety switches.

Step 2 Infeed section - lift the upstream edge of the infeed skid plate to its upper resting position (upper levels) to allow clearance for the roll out infeed section. Release both infeed section latches and roll out the infeed section (all levels).

Step 3 Standing platform - the catwalk is stored under the lower knife cylinder and is slid into position.

? CAUTION: DO NOT STEP ON ROLLS OR WHEELS SINCE THEY ARE FREE TO TURN AND MAY CAUSE YOU TO LOSE YOUR BALANCE.

Step 4 Use the steps provided to climb into the knife.


Figure 1. Knife Access


MANUAL ROTATION

? CAUTION: KNIFE MAINTENANCE PROCEDURES SHOULD BE PERFORMED WITH ONLY ONE PERSON IN THE KNIFE.

Procedure:

Step 1 Slide the ratchet handle onto the rotation shaft.

Step 2 Remove the cover plate on the knife cylinder gear case.

Step 3 Insert the socket on the end of the rotation shaft through the gear case hole and engage the exposed nut.

Step 4 Place the other end of the rotation shaft in the rest provided and slide a pin through the rest to secure the rotation shaft in place.

Step 5 Wrap a clean rag around the end of the shaft and push into the gear case hole to prevent dirt and debris from entering the knife cylinder gear case.

Step 6 Use the ratchet handle provided to manually rotate the knife cylinders.


Figure 2. Manual Rotation of Knife Cylinders

For added safety, the person tuning the knife should rotate the knife with one hand on the handle and one hand behind his back, or with both hands on the handle.


GLOSSARY OF BLADE TUNING TERMINOLOGY

Final Tune - The result of completely severing all of the wet 90-lb. liner fibers.

Gear Backlash - The finite distance between meshed gear teeth that must be removed to prevent unwanted gear play.

Gear Preload - The force needed to bring meshed gear teeth together in order to remove gear backlash.

Lapped Surface - The result of lapping when knife blades seat.

Lapping - The process of applying an oil-based abrasive between the two knife blade surfaces to eliminate unevenness between them and to create a sharpened edge on the tip of each.

Minimum Surface Wear - The predetermined distance needed before the lapping procedure is complete; 0.015" measured from the tip of the knife blade, down.

Rough Tune - The result of incompletely severing all of the wet 90-lb. liner paper fibers.

Spot Tune - The procedure used to temporarily improve the cut quality of a small portion of the knife blade when time does not permit a complete tune.

Springback - The tendency for gear teeth contact to relax when gear preload is removed.

Tune - The procedure of advancing the upper knife blade with the knife blade holder jackscrews.


SPOT TUNING


? DANGER: DO NOT PERFORM MAINTENANCE ADJUSTMENTS, WITHOUT FIRST DISCONNECTING AND LOCKING OUT POWER TO ALL KNIFE LEVELS.


Criteria for Spot Tuning:

Spot tuning knife blades should only be considered if the cut quality becomes unacceptable on a portion of the knife blades and production schedules limit the amount of time in such a way that a complete knife blade tuning procedure cannot be accomplished immediately. You must, for certain, do a complete tune as soon as possible after a spot tune.

Tool List:

Pair of Cut-Resistant Gloves

0-600 in.-lbs. Torque Wrench

Ratchet Handle - 3/8" Drive

5/16" 8-point Socket - 3/8" Drive

Lapping Compound (C-220 Grit)

1/2" Hex Head Socket - 3/8" Drive

NOTE: The tools listed above are available as part of the Knife Maintenance Tool Kit available from Marquip. See Recommended Spare Parts List.

Open End Wrench Set

Masking Tape - 2"

90-lb. Liner Paper - 20" wide strips soaked for a minimum of 24 hours.


Spot Tuning Procedure Outline:

Use this outline only as a guide when you are completely familiar with the procedure.

Step 1 Locate poor cut quality area.

Step 2 Safety lockout and gaining knife access.

Step 3 Verify poor cut quality area with wet 90-lb. test cuts.

Step 4 Remove wick lubricator and mask over knife blade bolts.

Step 5 Apply medium grit lapping compound to upper blade poor cut area and oil to remainder of blades.

Step 6 Close knife and lap once with medium grit for five minutes.

Step 7 Inspect for sharp tip on both the upper and lower blades, repeat lapping if necessary.

Step 8 Break loose and retorque to 150 in.-lbs. knife blade bolts.

Step 9 Final tune with minimum turning on jack bolts for clean cut (hot knife) with wet 90-lb. liner in marked areas.

Step 10 Retorque knife blade bolts to 220 in.-lbs. and apply oil to both blades.

Step 11 Check and reinstall wick lubricator.

Step 12 Check blade pass for no extra torque through cut.

Step 13 Close knife.

Step 14 Schedule downtime to completely retune knife blades.

NOTE: Always keep a stock of soaking 90-lb. liner so you are not caught empty handed. Change the soaking 90-lb. liner every two weeks.

? CAUTION: NEVER ROTATE CYLINDERS FORWARD THROUGH A CUT WITH BLADE LAPPING COMPOUND ON THE BLADES.


Spot Tuning Expanded Procedure:

Step 1 Before entering the knife, note the approximate area of the poor cut quality by viewing previously run stacks of corrugated board.


Step 3 Upon entering the knife, verify poor cut quality areas by using wet 90-lb. liner and testing the cut across the entire width of the blade. Mark the areas of concern with a magic marker.

Step 4 Remove the wick lubricator assembly and mask over the blade bolt holes with 2" masking tape (both upper and lower blades).

Step 5 Apply medium grit lapping compound (220 grit) to the areas of the upper knife blade you previously had marked and for additional five bolts on each side of the marked area. Apply a film of oil to the rest of the blade area (upper and lower) to avoid galling the blades.

Step 6 Close the knife and lap one time for five minutes.

Step 7 Using the graduated microscope, inspect both the upper and lower blade lapping areas for a sharp tip.



If a sharp tip is obtained, proceed to Step 8.

If you do not see a sharp tip, you must relap with the medium grit again in the marked areas. Be sure to apply a film of oil to rest of the blade area (upper and lower) to avoid galling the blades.

Repeat this medium grit lapping procedure up to three times to achieve a sharp tip.

If, after lapping with medium grit for three times and you still have not obtained a sharp tip, rough tune the blades to cut wet 90-lb. liner paper in the marked areas. (Loosen and retorque blade bolts to 150 in.-lbs. before adjusting blade. DO NOT CUT EVERY FIBER.) Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. Retorque blade bolts to 220 in.-lbs. Lap again with medium grit lapping compound until a sharp tip is obtained.

? CAUTION: ALWAYS LOOSEN BLADE BOLT TORQUE BEFORE ADJUSTING JACKSCREWS. IF YOU DON’T STRESS IN ADJUSTING SCREWS MAY CAUSE BLADE TO ADVANCE WHILE RUNNING, CAUSING TOO TIGHT OF A TUNE.

Step 8 Remove the masking tape. Loosen and retorque the knife blade bolts in the marked area to 150 in.-lbs., one at a time. Loosen five additional knife blade bolts on each side of the marked area and retorque to 150 in.-lbs.

Step 9 Starting from the right and working to the left (looking downstream), final tune the knife blades in the marked areas to cut wet 90-lb. liner. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. Since the knife has just come out of production and is still hot, tune the blades to cut the wet 90-lb. liner cleanly across the entire width of the blade.

Step 10 Retorque all loosened knife blade bolts to 220 in.-lbs. Check all upper knife blade bolts for 220 in.-lbs. of torque. Tighten adjusting screw locknuts. Apply a film of oil to both blades.

Step 11 Check the wick lubricator for blade contact and good oil permeation, then reinstall.


Step 12 Manually rotate the blades forward through the cut. Torque on the ratchet handle needed to pass the blades through a cut may be slightly higher than the torque to rotate the cylinders when not in the cut. This torque difference should not be more than 75 in.-lbs. If the torque increase is greater than 75 in.-lbs. or the blades will not pass through the cut (NEVER FORCE THE BLADES THROUGH THE CUT), you have adjusted the blades too tightly together. See "How To Loosen Tight Blades" in the Maintenance Adjustments section of this manual.

Step 13 Check the knife for tools and other debris. Close the knife up.

Step 14 Schedule downtime to completely retune the knife blades.

? CAUTION: DO NOT SPOT TUNE MORE THAN TWO TIMES WITHOUT A COMPLETE RETUNE.


TUNING USED BLADES


? DANGER: DO NOT PERFORM MAINTENANCE ADJUSTMENT WITHOUT FIRST DISCONNECTING AND LOCKING OUT POWER TO ALL KNIFE LEVELS.


MARQUIP RECOMMENDS TUNING USED BLADES IMMEDIATELY AFTER THE KNIFE IS TAKEN OUT OF PRODUCTION AND IS STILL AT OPERATING TEMPERATURES.

NOTE ON BACKLASH: Normally you will not have to reset the gear backlash when tuning used blades, unless you have noticed a sudden loss of cut quality over a wide area of the knife blades. This sudden loss of cut quality may indicate that the gear backlash has changed and will need to be reset. To check gear preload before tuning used blades, see "How To Check for Loss of Gear Preload't in the Maintenance Adjustments section of this manual.

Tool List:


1/2" Socket - 3/8" Drive



1/4" F to 3/8" M Drive Adaptor

5/16" Hex Key - 3/8" Drive

7/16" x 1/2" Open End Wrench




Lapping Compound (C-220 Grit, 1A-320 Grit)

Microscope - Mitutoyo Series No. 183



Magnetic Base Dial Indicator

Magic Marker

Masking Tape - 2"

26-lb. Medium Paper - 20" wide strips

90-lb. Liner Paper - 20" wide strips soaked for a minimum of 24 hours

Turning Used Blades Procedure Outline:

Use this outline as a guide only when you are completely familiar with the procedure.


Step 2 Prepare the knife for lapping.

Step 3 Restore blade tips, apply medium grit lapping compound to the upper knife blade. Close the knife and lap for five minutes. Repeat medium grit lapping procedure two more times.

Step 4 Check for sharp tip.

A. Sharp tip, go to Step 5.

B. Dull tip.

1. Retorque bolts to 150 in.-lbs. Advance blade by 1/12 turn on adjusting screws in dull areas.

2. Relap with medium grit three times.

Step 5 Break loose and retorque to 150 in.-lbs. knife blade bolts. Rough tune with minimum turning on jack bolts to cut wet 90-lb. liner across the entire width of the knife blade.

Step 6 Retorque the blade bolts to 220 in.-lbs. for lapping. Apply fine grit lapping compound to the upper knife blade, close the knife and lap for five minutes. Repeat fine grit lapping procedure two more times.

Step 7 Retorque the blade bolts to 150 in.-lbs. for tuning. Final tune with minimum turning on jack bolts to cut wet 90-lb. liner. Tune to cut every fiber if the knife is still hot; i.e., if the final tune is made within two hours after shutdown.


Step 8 Retorque bolts to 220 in.-lbs. and end socket head bolts to 300 in.-lbs.

Step 9 Oil blades.


Step 11 Check wick lubricator and reinstall.

Step 12 Check for tools and close knife.


? CAUTION: NEVER ROTATE CYLINDERS FORWARD THROUGH A CUT WITH BLADE LAPPING COMPOUND ON BLADES.

Tuning Used Blades Expanded Procedure:


Step 2 Remove the wick lubricator assembly and mask over the blade bolt holes with 2" masking tape (both upper and lower blades).

Step 3 To restore the blade tips, apply medium grit lapping compound (220 grit) to the upper blade, close the knife and lap for five minutes. Repeat the medium grit lapping two more times for five minutes each.

Step 4 Using the graduated microscope, inspect both the upper and lower blade lapping areas for sharp tips.



If you see a sharp tip, continue with Step 5.

? CAUTION: ALWAYS LOOSEN BLADE BOLT TORQUE BEFORE ADJUSTING JACKSCREWS. IF YOU DON’T, STRESS IN ADJUSTING SCREWS MAY CAUSE BLADE TO ADVANCE WHILE RUNNING, CAUSING TOO TIGHT OF A TUNE.

If you do not see a sharp tip, you must: 1) Loosen and retorque all the upper knife blade bolts to 150 in.-lbs. 2) In areas where tip is not sharp, advance blade by 1/12 turn on the adjusting screw. 3) Retorque blade bolts to 220 in.-lbs. 4) Reapply medium grit (220 grit) lapping compound to the upper knife blade. 5) Close the knife and relap the knife blades for five minutes. 6) Reapply medium grit compound and lap (five minutes) two more times.

Step 5 After restoring the knife blade tips, clean the medium grit lapping compound off the knife blades. Loosen and retorque all of the upper blade bolts to 150 in.-lbs. Starting from the right and working to the left (looking downstream), rough tune the knife blades to cut wet 90-lb. liner across the entire width of the knife blade. IMPORTANT: Do not try to cut every fiber of the wet 90-lb. liner . Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. Retorque blade bolts to 220 in.-lbs.

Step 6 Apply fine grit (320 grit) lapping compound to the upper knife blade, close the knife and lap for five minutes; reapply fine grit compound and lap (five minutes) two more times.


Step 7 Clean the fine grit lapping compound off the knife blades and remove the masking tape covering the bolt holes. Loosen and retorque all of the upper blade bolts to 150 in.-lbs. Starting from the right and working to the left (looking downstream), FINAL TUNE the knife blades to cut wet 90-lb. liner across the entire width of the knife blade. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. If the final tune is being done within two hours after the knife was taken out of production, tune the knife blades to cut every fiber of the wet 90-lb. liner. If the final tune is being made after the knife has cooled down (approximately two hours), DO NOT TUNE THE KNIFE BLADES TO CUT EVERY FIBER OF THE WET 90-LB. LINER SINCE THE BLADES WILL BECOME TOO TIGHT ONCE THE KNIFE AGAIN REACHES OPERATING TEMPERATURE. IT IS ALWAYS BETTER TO RETUNE THAN TO TUNE TOO TIGHT AND DESTROY A SET OF KNIFE BLADES.

Step 8 Retorque the knife blade bolts to 220 in.-lbs. and the outer socket head bolts to 300 in.-lbs. Tighten adjusting screw locknuts.

Step 9 Apply a film of oil over both knife blades to prevent galling the knife blades.

Step 10 Manually rotate the blades forward through the cut. Torque on the ratchet handle needed to pass the blades through a cut may be slightly higher than the torque to rotate the cylinders when not in the cut. This torque difference should not be more than 75 in.-lbs. If the torque increase is greater than 75 in.-lbs. or the blades will not pass through the cut (NEVER FORCE THE BLADES THROUGH THE CUT), you have adjusted the blades too tightly together. See "How To Loosen Tight Blades" in the Maintenance Adjustments section of this manual.

Step 11 Check that the wick lubricator is oil soaked and has been making contact with the knife blade. Reassemble wick lubricator and adjust wick height if necessary.

Step 12 Check to be sure all tools are cleared from the knife, roll in the infeed section (all levels), reposition the infeed skid pan to the run position, and close up the top covers of the knife.


HOW TO LOOSEN TIGHT BLADES: NEW AND USED

If at any time during a tuning procedure, either the blades refuse to pass or the differential torque needed to rotate the blades through the cut exceeds 75 in.-lbs., you must loosen the blades.

Step 1 Inspect the blades. Back the blades back out of the cut. Examine the blades and smooth over any rough spots with the honing stone.

Step 2 Loosen the adjusting screws near the tight spot. This will release the tension and may allow the blade to retract slightly.

Step 3 Recheck blade pass. If the blades pass, continue with the tuning procedure.

Step 4 If the blades do not pass, locate and mark the high resistance spot.

Step 5 Back off five adjusting screws to the left and right of the tight spot.

Step 6 Loosen and retorque one at a time; five blade bolts to the left and right of the tight spot to 75 in.-lbs.

Step 7 Place a clean piece of wood 2 x 4 or larger on the tight area of the blade and with a 3-4 lb. hammer force the blade back against the holder.

Step 8 Recheck the blade pass. If the blades do not pass, repeat this procedure from Step 4.

Step 9 Retorque the knife blade bolts one at a time to 150 in.-lbs. of torque for tuning purposes.

Step 10 Resume the tuning procedure.


HOW TO CHECK FOR LOSS OF GEAR PRELOAD


Step 2 Loosen eight hub locking studs on the right end of cylinder.

Step 3 Prepare the hub lock stud. Completely remove both of the nuts and brackets from the two hub lock studs below screw D. See figure 1 in the Component Replacement section of this manual. Using the two free nuts, turn them both back onto the hub lock stud located to the lower left of screw D. Jam the two nuts together at least 1/4" above the knife cylinder, making sure the top nut has a face perpendicular to the knife cylinder.

Step 4 Mount dial indicator on the right end of cylinder, indicating off of lock stud near screw D.

Step 5 Back off screw D until loose, then 1/2 turn additional. Note indicator movement.

Step 6 Advance screw C until .015" of additional indicator movement is observed.

Step 7 Back off screw C one full turn.

Step 8 Advance screw D in .005" increments, backing off each time and watching for springback. At the first sign of springback, continue backing off screw D until springback stops. This is the gear contact point. Indicator should show .008" movement from the original position (Step 5).

Step 9 Set gear preload. Zero the indicator. Advance screw D for .008" of movement. Torque to obtain .008" advancement should not exceed 75 in.-lbs.

Step 10 Retorque the loosened bolts as follows:

A. Torque all eight hub lock bolts to 340 in.-lbs.B. Increase the eight hub lock bolts torque to the final torque of

680 in.-lbs.C. Hand tighten screw C against the push stud.D. Confirm that screw D meets or exceeds 50 in.-lbs. of torque.E. Torque screw C to 50 in.-lbs. torque.F. Torque screw D to 100 in.-lbs. torque.G. Torque screw C to 100 in.-lbs. torque.H. Torque screw D to 150 in.-lbs. torque.I. Torque screw C to 150 in.-lbs. torque.


HOLDDOWN WHEEL DOWNSTOPS

Use the following procedure to set the height of the holddown wheels over the pull roll and exit roll.

Exit Roll Holddown Wheels:

Use this procedure to set the holddown wheel shock absorbers over the exit roll.

Step 1 Apply air pressure to the rod end of the air cylinder to bottom out the cylinder.

Step 2 Rotate the shock absorber body until it comes against the wheel pivot arm and raises the wheel to just miss the roll. Back the shock body out one turn to provide good contact.

Step 3 Set the shock absorber speed as fast as possible, but not so fast that the shock absorber is not functioning at all. & sure the shock absorber settings are consistent across the width of the machine.

Infeed Roll Holddown Wheels:

Step 1 Turn bottom stop jackscrews until they touch the cross tube.

Step 2 Back off 1/2 turn.

AIR SYSTEM PRESSURE SETTINGS

Set all regulators at 80 psi.


ELECTRICAL SENSOR SETUPS

Limit Switches:

There are plunger type limit switches at several locations on the knife. All have a similar function--they indicate open doors or guards that should be closed before starting the knife. At each of the following locations, check that it actuates with greater than 1/16" over travel and does not bottom out.

Airflow:

Each knife is supplied with a diaphragm style pressure switch. The switch is located in the left-hand motor enclosure on the upstream side of the air tube. The switch will be normally open and will close as air pressure reaches approximately 8.0" of water. The switch will be set so that contacts open at a decreasing pressure of 8.0" of water.

Step 1 Attach an appropriate pressure gauge to an outlet on the left side of the plenum (air tube).

Step 2 Observe all safety rules while applying power to the blower.

Step 3 Read the plenum pressure. It should be greater than 8.0" of water with the air filter in place. If the pressure is low, check:

A. Is blower rotation correct?

B. Is filter clogged?

C. Is there a major leak?

Step 4 Monitor the pressure switch output with a DMV, it should read approximately 0 VDC. Gradually block the blower inlet until the DMV just switches to +15 VDC. This is the pressure switch set point. The pressure gauge should read 8.0" of water. If this value is incorrect, the pressure switch point needs adjustment.


Step 5 Block the blower inlet until the pressure gauge reads 8.0" of water. Remove the snap-on cover from the conduit enclosure by loosening its retaining screw and pulling firmly at its bottom end. Turn the slotted adjustment screw at the top of the range spring housing clockwise to raise the set point pressure and counterclockwise to lower the set point. Make final approach to set point slowly. Be certain the switch is checked in the position it will assume in use, i.e. with diaphragm in a vertical plane and switch lettering and nameplate in an upright position. Once correct setting is achieved, repeat step 5 and verify that switch opens at a decreasing pressure of 8.0" of water.

BOARD SENSE/FORK SENSE PHOTOEYE SETUP PROCEDURE

Step 1 Block photoeye.

Step 2 Turn sensitivity adjustment counterclockwise until photoeye LED goes off.

Step 3 Turn sensitivity adjustment clockwise until photoeye LED goes on.

Step 4 Turn sensitivity five turns clockwise. Photoeye is now set.

COMPONENT REPLACEMENT - 9404737 CR-1

REMOVAL AND INSTALLATION OF KNIFE BLADES

? CAUTION: REMOVAL OF OLD BLADES AND INSTALLATION OF NEW BLADES CAN BE DANGEROUS SINCE TWO PEOPLE MAY BE IN THE KNIFE. BEFORE MANUALLY ROTATING THE KNIFE, CHECK THAT ALL HANDS AND FINGERS ARE CLEAR. DO ALL PROCEDURES HERE WITH ONE PERSON IF POSSIBLE.


? CAUTION: REMOVE KNIFE BLADES BY REMOVING BOLTS PROGRESSIVELY FROM ONE END TO THE OTHER TO PREVENT A SUDDEN, DANGEROUS RELEASE OF BLADE STRESS.

Tool List:






1/2" Hex Nut Driver


Feeler Gauge:

Before installing new blades, several steps should be followed:

Step 1 Gain access to the knife blades by following the "Safety Lockout and Gaining Knife Access". procedure in the Maintenance Adjustments section of this manual.

Step 2 Remove the old blades, starting at either end and progressing to the other.

CR-2 9404737 - COMPONENT REPLACEMENT

Step 3 On upper cylinder, back off the blade holder adjustment screws so they do not extend beyond the knife blade holder.

Step 4 Clean off the blade holder. Inspect all threaded inserts for damaged or stripped out threads. Replace as required. See "Threaded Insert Removal and Replacement" in the Component Replacement section of this manual.

Step 5 For safety, install the lower blade first. There is an upper and lower blade. The lower blade is designated the "fixed" blade and is bolted in place with the blade's back against the holder. The upper blade has slotted mounting holes and is adjustable. The two end bolts are 3/8" NC socket head cap screws while the remaining bolts are 5/16" NF x 1/2" hex head screws. Always use new bolts when installing new blades.

Knife Blade Installation Procedure:

NOTE: For safety, install the lower blade first.

Step 1 Lay new blade on holder. Position the blade laterally until holes in the center of the blade are directly centered over the threaded holes in the holder.

Step 2 Install blade bolts starting in the center and working alternately outward toward the ends of the knife blade. Finger start as many bolts as possible, being careful to get the bolts threaded straight! When bolts can no longer be started, begin torquing the bolts down from the center bolt and working alternately toward the ends of the blade. Progress along the blade in this manner until all the bolts are started.

Step 3 Torque all bolts to 75 in.-lbs., again starting at the center bolt and working alternately outward toward the ends of the knife blade.

Step 4 The blade must be forced tightly against the blade holder. Place a piece of clean wood (2 x 4 or larger) against the blade and strike with a hammer (3 to 4 lbs.) to force the blade against the back of the holder. Repeat at 2"-4" intervals while working from right to left (looking downstream). The knife blade must seat no greater than 0.002" from the holder. Check the gap with a feeler gauge.

Step 5 For lower blade, torque blade bolts to 220 in.-lbs. Double check the final knife blade bolt torque. Upper blade bolts torque to 150 in.-lbs. for tuning.


Step 6 For lower level, torque the socket head bolt at each end of the knife blade to 300 in.-lbs. On upper level, torque the socket head bolts to 150 in.-lbs.

Repeat this procedure starting at Step 1 for the upper blade.

Proceed to "Knife Cylinder Gear Backlash Removal and Gear Preload" in the Component Replacement section of this manual.


BROKEN BLADE BOLT REMOVAL



Tool List:

Drill Centering Jig

1/8" Cobalt Left-Hand Drill Bit

E-Z Out


Masking Tape

Drill Motor

Open End Wrench Set

Procedure:

Step 1 Use masking tape and mark the drill bit to drill to a depth of 3/8" beyond the drill alignment jig.

Step 2 Center the drill alignment jig over the broken bolt. You may have to shim the jig up over the broken bolt using washers.

Step 3 The cobalt drill cuts very fast. Use cutting oil and a low RPM drill motor to avoid heat. To avoid drilling through the bolt and into the knife cylinder, use masking tape and mark the drill bit to drill to a depth of 3/8" beyond the drill alignment jig. Carefully drill down the center of the broken bolt.

Step 4 Remove the drill alignment jig.

Step 5 Use an E-Z Out to remove the broken bolt.

Step 6 Inspect the insert for damaged threads and replace if necessary.


THREADED INSERT REMOVAL AND REPLACEMENT



Tool List:

13/32" Diameter Left-Hand Drill Bit

Insert Installation Tool

TRK 5/16" Insert Impact Tool

E-Z Out Tool

Replacement Inserts


Light Hammer

Small Cold Chisel

Drill Motor

Masking Tape

Procedure:

Step 1 Using masking tape, mark the drill depth for 3/16". This will remove the insert material between the keys and internal threads.

Step 2 Drill to the marked depth.

Step 3 Deflect the four keys inward and break them off using a small cold chisel.

Step 4 Remove the insert using an E-Z Out tool.

Step 5 Screw the new insert onto the insert installation tool, being sure to line up the extended insert keys with the holes on the insert installation tool.


Step 6 Put a drop of oil on the new insert and screw the insert into the blade holder. The depth to which the insert is screwed into the blade holder is controlled by the insert installation tool and is typically between 0.010" - 0.015" recess.

Step 7 Back out the insert installation tool and check to be sure that the insert is recessed between 0.010" - 0.015" below the knife blade holder.

Step 8 Using the TRK 5/16" impact tool, drive down the insert keys with several light taps from a hammer.

Step 9 Check to be sure that the insert keys have been driven down flush with the insert.


KNIFE CYLINDER GEAR BACKLASH REMOVAL AND GEAR PRELOAD




Tool List:













26-lb. Medium Paper - 20" wide strip.

Manual Rotation Shaft and Ratchet



Knife Cylinder Gear Backlash Removal and Gear Preload Procedure Outline:


Step 1 Loosen hub lock bolts.

Step 2 Back off C and D.

Step 3 Check blade pass.

Step 4 Test cuts with 26-lb. medium paper.

Step 5 Prepare hub lock stud for dial indicator.

Step 6 Mount dial indicator.

Step 7 Remove gear preload and make reverse gear teeth contact in opposite direction of gear preload.

Step 8 Remove gear backlash.

Step 9 Set gear preload.

Step 10 Check for forward blade pass clearance.

Step 11 Set initial position.

Step 12 Recheck and reset the gear preload.

Step 13 Check blade pass. If blades pass, proceed to "Tuning New Blades" section of this manual. If blades do not pass, return to Step 11.

Step 14 Hub lock stud retorquing procedure.


Knife Cylinder Gear Backlash Removal and Gear Preload Expanded Procedure:

Step 1 Loosen all 16 hub locking bolts.

Step 2 Back off adjustment screws C and D (see figure 1)

Figure 1. Backlash Adjustment Screws

Step 3 Carefully check to see if the blades will pass forward through the cut. If not, back off screw A and advance B in 1/4 turn increments. Repeat until blades pass.

Step 4 Using the 26-lb. medium paper, proceed to make test cuts along the blade working from right to left.

CAUTION: Never force the blades through the cut or damage to the blades may occur.

When making your test, if the 26-lb. paper is cut anywhere along the blade, proceed to Step 5. If not, back off B by 1/8 turn and advance screw A by 1/8 turn increment and repeat Step 4. Continue backing off B and advancing screw A in 1/8 turn increments and repeating Step 4 until the 26-lb. paper is cut somewhere along the blade.


Step 5 Completely remove the nut and bracket from the lock stud located to the lower left of screw D. Also remove the nut from the lower right lock stud.

Using the two nuts, turn them both back onto the lower left stud, jamming them together at least 1/4" above the knife cylinder. Making sure that the top nut has a face perpendicular (cross-machine direction) to the knife cylinder will provide a point of reference for the dial indicator.

Step 6 Mount the dial indicator on the knife cylinder in such a way as to bring the dial indicator shaft in contact with the prepared stud (Step 5). Make sure that the dial indicator shaft is at right angles (perpendicular) to the prepared stud.

NOTE: Dial indicator must be mounted on the knife cylinder, NOT on the machine frame, gear case, or exit roll assembly.

Step 7 Make sure screw D is backed out far enough so as not to make contact with the push stud when screw C is advanced.

Advance screw C until you feel tightening. At this point, release screw C while watching the dial indicator for springback. If you do not see springback, continue to advance screw C further and release. As soon as the dial indicator measures springback, you have made gear teeth contact.

Step 8 Remove gear backlash.

A. Back off screw C at least three full turns.

B. Alternately advance and release screw D, advancing 0.005" further each time until springback is obtained.

C. At the first sign of springback, continue backing off screw D until springback stops. This is the gear contact point from which .008" gear preload is put in.

NOTE: Do Not jump back to Step 8, Item B to recheck the gear contact point. To recheck the gear contact point, return to Step 7.


Step 9 Set gear preload. Zero the dial indicator and advance screw D until the dial indicator shows 0.008" movement. You now have set the gear preload.

NOTE: Once the gear backlash has been removed and the gear preload has been set, this should not be changed. To retain the gear preload, you will be advancing/backing off screws A and D equal amounts; i.e., if you advance screw A, you will back off screw D an equal amount. This will allow you to set the initial position of knife cylinders without changing the gear preload .

CAUTION: NEVER FORCE THE BLADES THROUGH A CUT, AS DAMAGE TO THE KNIFE BLADES MAY OCCUR. ALWAYS SLOWLY ROTATE THE BLADES FORWARD THROUGH THE CUT.

Step 10 Remove the dial indicator and back off screw B at least three full turns. Pass the blades forward through the cut to check for any blade binding that may have been caused when the gear preload was set. If the blades pass, go to Step 11.

A. If the blades bind during the cut, you will have to open the knife blades. Back off screw A by 1/8 turn and advance screw D by an equal 1/8 turn. Pass the blades through the cut. If they bind together, again continue to back off screw A by 1/8 turn and advance screw D by equal 1/8 turn, checking each time to see if the blades will pass.

Step 11 Set the initial position. Using the 26-lb. medium paper, proceed to make test cuts along the blade working from right to left. If the 26-lb. paper was cut anywhere across the knife blades, proceed to Step 11, Item B.

A. If the paper was not cut, you will have to bring the knife blades closer together. Back off screw D by 1/8 turn and advance screw A by an equal 1/8 turn. Make the 26-lb. paper test cut again. Repeat the blade closing until the 26-lb. paper is cut somewhere along the knife blades.

B. Open blades by backing off screw A 1/8 turn and advance screw D 1/8 turn. Initial position is now set.


Step 12 Recheck and reset the gear preload.

A. Mount the dial indicator (see Step 6).

B. Zero the dial indicator.C. Back off screw D.D. Advance screw C for .015" of movement.

E. Back off screw C.F. Alternately advance and release screw D, advancing .005"

further each time until springback is obtained.G. At the first sign of Springback, continue backing off screw D

until springback stops.This is the gear contact point. Dial indicator should show .008" movement from zero. If not, gear preload was altered during blade movement.

H. Zero the dial indicator.

I. Advance screw D for .008" of gear preload.

Step 13 Test for blades passing. If blades pass, proceed with Step 14. If the blades do not pass, return to Step 10, Item A.

Step 14 Retorque the gear preload studs as follows:

A. Torque all 16 hub lock studs to 340 in.-lbs. (300 in.-lbs. - Model I).

B. Torque all 16 hub lock studs to their final torque of 680 in.-lbs. (600 in.-lbs. - Model I).

C. Hand tighten screw B against the push stud.D. Set torque wrench to 50 in.-lbs. and confirm that screw A meets

or exceeds 50 in.-lbs.E. Torque screw B to 50 in.-lbs.F. Torque screw A to 100 in.-lbs.

G. Torque screw B to 100 in.-lbs.H. Torque screw A to 150 in.-lbs. final torque.I. Torque screw B to 150 in.-lbs. final torque.

J. Hand tighten screw C against the push stud.K. Set torque wrench to 50 in.-lbs. and confirm that screw D meets

or exceeds 50 in.-lbs.L. Torque screw C to 50 in.-lbs.M. Torque screw D to 100 in.-lbs.

N. Torque screw C to 100 in.-lbs.O. Torque screw D to 150 in.-lbs. final torque.P. Torque screw C to 150 in.-lbs. final torque.

You are now ready to proceed with tuning blades. See "Tuning New Blades" in the Component Replacement section of this manual.


TUNING NEW BLADES




Tool List:












Lapping Compound (C-220 Grit, 1A-320 Grit)

Microscope - Mitutoyo Series No. 183


26-lb. Medium Paper - 20" wide strips

Manual Rotation Shaft and Ratchet


Magic Marker

90-lb. Liner Paper - 20" wide strips soaked for a minimum of 24 hours.


Tuning New Blades Procedure Outline:


Step 1 Gear preload and initial position must be set. Confirm that all blade bolts are properly torqued for tuning.

Step 2 Remove wick lubricator.

Step 3 Rough tune blades with minimum turning on jack bolts to cut wet 90-lb. liner.


Step 5 Retorque knife blade bolts to 220 in.-lbs. for lapping. Apply medium grit lapping compound to the upper knife blade. Close the knife and lap for five minutes. Repeat medium grit lapping procedure two more times.

Step 6 Check for minimum wear surface.

A. Correct wear surface, go to Step 7.

B. Incorrect wear surface.

1. Rough tune blades with minimum turning on jack bolts to cut wet 90-lb. paper (DO NOT CUT EVERY FIBER) across entire width of the knife blade.

2. Repeat Step 5.

Step 7 Retorque knife blade bolts to 150 in.-lbs. for tuning. Rough tune blades with minimum turning on jack bolts to cut wet 90-lb. (DO NOT CUT EVERY FIBER) across the entire width of the knife blade.

Step 8 Retorque knife blade bolts to 220 in.-lbs. for lapping. Apply fine grit lapping compound to the upper knife blade. Close the knife and lap for five minutes. Repeat fine grit lapping procedure two more times.

Step 9 Clean blades. Retorque knife blade bolts to 150 in.-lbs. for lapping. Final tune blades with minimum turning on jack bolts to cut wet 90-lb. liner paper (DO NOT CUT EVERY FIBER).

Step 10 Torque all bolts to final torque.

Step 11 Oil blades and check blade pass for no extra torque through cut.


Step 12 Check and reinstall wick lubricator.

Step 13 Close knife.


? CAUTION: NEVER ROTATE CYLINDERS FORWARD THROUGH A CUT WITH BLADE LAPPING COMPOUND ON THE BLADES.

? CAUTION: USE CARE WHEN TUNING NEW, COLD BLADES WITH WET 90-LB. DO NOT TRY TO CUT EVERY FIBER CLEAN OR YOUR BLADES WILL BE TOO TIGHT. WHEN IN DOUBT, TUNE LOOSE. IT IS ALWAYS BETTER TO RETUNE THAN TO TUNE TOO TIGHT AND DESTROY A SET OF BLADES.

NOTE: As this is an initial tune, you must expect to retune the knife within two weeks, allowing the blades to "seat in".


Tuning New Blades Expanded Procedure:

See "Knife Cylinder Gear Backlash Removal and Gear Preload" in Component Replacement section of this manual.

Step 1 Before proceeding, gear preload and initial position must be set. Confirm that all upper blade bolts are torqued to 150 in.-lbs. and all lower blade bolts are torqued to 220 in.-lbs.

Step 2 Make sure you have removed the wick lubricator.

Step 3 Rough tune blades to cut wet 90-lb. liner across entire width of the blade, but not 100% of fibers. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time.

Step 4 Manually rotate the blades forward through the cut. If the torque required to rotate the blades through the cut has increased or the blades will not pass through the cut (NEVER FORCE THE BLADES THROUGH THE CUT), you have adjusted the blades too tightly together. See "How To Loosen Tight Blades" in the Maintenance Adjustments section of this manual.

Step 5 Torque the upper blade bolts to 220 in.-lbs. Apply medium grit lapping compound (220 grit) to the upper knife blade, close the knife, and lap for five minutes. Reapply the medium grit lapping compound and lap (five minutes) two more times.

Step 6 Using the graduated microscope, inspect both the upper and lower blade lapping areas for a minimum .015" surface wear measured from the tip of the blade down.


If you see the minimum surface wear, continue with Step 7. If you do not see the minimum surface wear, you must: 1) Loosen and retorque the blade bolts to 150 in.-lbs. 2) Rough tune the knife blades to cut 90-lb. liner in areas where there is not .015" wear surface. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. IMPORTANT: Do not try to cut every fiber of the wet 90-lb. liner. 3) Retorque blade bolts to 220 in.-lbs. 4) Reapply medium grit (220 grit) lapping compound, close the knife, and relap the knife blades for five minutes. Reapply medium grit compound and lap (five minutes) two more times.

Step 7 Loosen and retorque the blade bolts to 150 in.-lbs. Rough tune the knife to cut (not every fiber) wet 90-lb. liner paper across the entire width of the knife blade. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time. You want to slowly bring the knife blades in together and allow the lapping procedures to "seat in" the knife blades.

Step 8 Retorque blade bolts to 220 in.-lbs. Apply fine grit lapping compound (320 grit) to the upper knife blade, close the knife, and lap for five minutes. Reapply the fine grit lapping compound and lap (five minutes) two more times.

Step 9 Loosen and retorque the blade bolts to 150 in.-lbs. Final tune the knife to cut (not every fiber) wet 90-lb. liner paper across the entire width of the blade. Do not advance the knife blade by more than 1/12 of a turn on the adjusting screw at a time.

Step 10 Torque the blade bolts to 220 in.-lbs. and torque the two socket head bolts to 300 in.-lbs.

Step 11 Apply a film of oil to both blades and manually rotate the blades forward through the cut. If the torque required to rotate the blades through the cut has increased or the blades will not pass through the cut (NEVER FORCE THE BLADES THROUGH THE CUT), you have adjusted the blades too tightly together. See "How To Loosen Tight Blades t' in the Maintenance Adjustments section of this manual.

Step 12 Check that the wick lubricator is oil soaked and has been making contact with the knife blade. Reassemble wick lubricator and adjust wick height if necessary.

Step 13 Check to be sure all tools are cleared from the knife, roll in the infeed section (all levels), reposition the infeed skid pan to the run position, and close up the knife.


ROLL REPLACEMENT - PULL ROLL

The pull roll will require occasional replacement due to wear on its urethane cover. Use the following procedure to remove it with minimum effort.

Step 1 Turn off main disconnect on the drive cabinet for all levels of the knife and lock them out. Leave the compressed air on.

Step 2 Fold back the four top covers.

Step 3 Lift the upstream edge of the infeed skid plate to its upper resting position to allow clearance for the upper roll out infeed section to pass.

Step 4 Release the two latches retaining the upper roll out infeed section.

Step 5 Roll out the infeed section.

Step 6 Release the two latches retaining the lower infeed section.

Step 7 Roll out the lower infeed section.

Step 8 Remove all locknuts that connect the roll coupling hub to the disc pak. While loosening hardware, turn the locknut only. Disconnect resolver connector from housing on motor. Support the roll drive motor and unbolt motor mounting bracket from motor mount bearing plate. This will allow removal of an assembly consisting of motor, motor mounting bracket, coupling hub, and coupling center member assembly. Support assembly or set on floor until installation, saving all hardware.

Step 9 Sling the roll at its center and remove the slack from the sling. Loosen the bearing on the left side of the machine and increase the strap's lift on the roll until it supports the roll's weight. Remove the bearing's bolts. Remove the bolts from the bearing on the other end of the roll. Remove the roll by allowing the right side to lift first, until the shaft and hub on left end can be pulled through the hole in the bearing mounting plate and frame. Do not remove the bearing mounting plate from the side frame because it is shimmed to side plate for close tolerance. With roll removed, loosen coupling hub setscrews. Apply heat to coupling hub and remove with puller because hub was mounted using Loctite (heat hub uniformly and do not overheat). Remove both bearings.


Step 10 Put bearings on new pull roll and install so that edge of urethane is 7.97" from left side frame. Tighten bearing bolts. Apply Loctite to roll journal, hub I.D., and key. Make sure bolts and spacers are on hub before installing. Install key in shaft, slide hub onto roll journal until it comes against shoulder, and tighten setscrews. Wipe off excess Loctite. Fasten motor assembly to bearing mounting plate. Torque bolts to 900 in.-lbs. for 1/2" diameter or 384 in.-lbs. for 3/8" diameter. Unlock bearing collars on roll. Using coupling spacer #9413777 (located in tool kit), move roll until gap between hub flanges is correct. Lock down bearing collars on roll. Install remaining hardware to center member assembly and roll hub bolts. Tighten all locknuts on coupling assembly to 156 in.-lbs. While tightening hardware, turn the locknut only. Turning the bolt will score its body and destroy its tolerance fit with disc pak.


ROLL REPLACEMENT - EXIT ROLL

The exit roll will require occasional replacement due to wear on its urethane cover. Use the following procedure to remove it with minimum effort.

Before turning power off, raise the holddown nips to provide better access to the exit roll. Turn electrical power off but leave the compressed air connected.

? CAUTION: THE FOLLOWING PROCEDURE IS PERFORMED WITH COMPRESSED AIR CONNECTED TO THE MACHINE.

Step 1 Remove all locknuts that connect the roll coupling hub to the disc pak. While loosening hardware, turn the locknut only. Disconnect resolver connector from housing on motor. Support the roll drive motor and unbolt motor mounting bracket from motor mount bearing plate. This will allow removal of an assembly consisting of motor, motor mounting bracket, coupling hub, and coupling center member assembly. Support assembly or set on floor until installation, saving all hardware.

Step 2 Remove the stripper plate and its mounting bracket just downstream of the roll. Remove bearing mounting screws and remove jam detect pan. Sling the roll at its center and remove the slack from the sling. Loosen the bearing on the right side of the machine and increase the strap's lift on the roll until it supports the roll's weight. Remove the bearing's bolts. Remove the bolts from the bearing on the other end of the roll. Remove the roll by allowing the left side to lift first, until the shaft and hub on right end can be pulled through the hole in the bearing mounting plate and frame. Do not remove the bearing mounting plate from the side frame because it is shimmed to side plate for close tolerance. With roll removed, loosen coupling hub setscrews. Apply heat to coupling hub and remove with puller because hub was mounted using Loctite (heat hub uniformly and do not overheat). Remove both bearings.


Step 3 Put bearings on new pull roll and install so that edge of urethane is 8.44" from right side frame. Tighten bearing bolts. Apply Loctite to roll journal, hub I.D., and key. Make sure bolts and spacers are on hub before installing. Install key in shaft, slide hub onto roll journal until it comes against shoulder, and tighten setscrews. Wipe off excess Loctite. Fasten motor assembly to bearing mounting plate. Torque bolts to 900 in.-lbs. for 1/2" diameter or 384 in.-lbs. for 3/8" diameter. Unlock bearing collars on roll. Using coupling spacer #9413777 (located in tool kit), move roll until gap between hub flanges is correct. Lock down bearing collars on roll. Install remaining hardware to center member assembly and roll hub bolts. Tighten all locknuts on coupling assembly to 156 in.-lbs. While tightening hardware, turn the locknut only. Turning the bolt will score its body and destroy its tolerance fit with disc pak.

Step 4 Reinstall jam detect pan. Reinstall stripper plate and its mounting bracket.


HOLDDOWN WHEEL REPLACEMENT

Step 1 Remove the holddown wheel pivot tube from the infeed section as follows: disconnect air cylinder rod end and socket head shoulder bolts supporting the infeed holddown pan. Next, unbolt the 2-bolt flange bearings from the pivot tube mounting pad. Do not remove the bolts attaching the pad to the infeed section since they are pre-adjusted at Marquip. Remove assembly from machine.

Step 2 Remove the 2-bolt flange bearings on each end of the holddown wheel shaft.

Step 3 Loosen lock collars at the ends and center of the holddown wheel shaft.

Step 4 Using a hammer and a block of wood, drive the holddown wheel shaft out far enough to remove the holddown wheels.

Step 5 Install new holddown wheels on bushings. The wheels should be installed on the shaft so that a washer is always on the outside of the bushing. There should be one washer between each wheel.

Step 6 Repeat Steps 4 and 5 for the other side of the pivot tube.

Step 7 Center infeed roll in pivot tube assembly, tighten all lock collars, and install the 2-bolt flange bearings on both ends of the holddown wheel shaft.

Step 8 Reinstall the pivot tube assembly in the infeed section.

Step 9 Adjust holddown wheels as described in "Holddown Wheel Downstops" in the Maintenance Adjustments section of this manual.


RESOLVER REPLACEMENT - KNIFE CYLINDER RESOLVER

To replace the resolver, first turn off the main disconnect and lock it out. Manually rotate the knife cylinders until the blade tips separate enough to pass a C-flute board between them on the left side of the knife. (Refer to Maintenance Adjustments section for the proper procedure for manual rotation of the knife cylinders.) Remove the manual rotation shaft, roll in the infeed section, and replace all guards.

Loosen the two clamp screws on the end of the coupling nearest the side frame. Remove the four resolver mounting bolts and remove the resolver and coupling assembly. Disconnect the shaft coupling and the power cord connector. Before bolting the new resolver in place, it is necessary to properly position its shaft. This is accomplished with power on, so be very careful. Connect the power cord to the new resolver.

Clear the knife area of all people. Turn on the main disconnect. Turn on CONTROL POWER.

The resolver shaft position is indicated by three small lights on the junction box shown in figure 2. When the resolver shaft is correctly positioned, only the center light is on. When either of the other two lights flash, the resolver is incorrectly positioned. The faster they flash, the closer the resolver is to the correct position.

Hold the resolver in your hand with its mounting holes in line with the mating holes on the mounting flange. Rotate the shaft near the correct position and slide the coupling on the shaft in a position that will allow access to the clamp screws when the coupling is in the mounting flange. Clamp the coupling to the resolver shaft.


Figure 2. Cylinder Resolver Replacement

Slide the resolver and coupling into the mounting flange while carefully guiding the coupling over the drive shaft. Bolt the resolver in place. Position the resolver shaft by rotating the coupling, using the three lights as a guide. Then clamp the coupling to the drive shaft. If the clamping causes the resolver to lose position, the resolver mount may be rotated to correct it by loosening the clamp on the mounting flange.


TACHOMETER BRUSH/COMMUTATOR REPLACEMENT - KNIFE CYLINDER

To replace the knife cylinder tachometer brushes and/or commutator:

Step 1 Turn off the main disconnects for all knife levels and lock them out.

Step 2 Open the left side doors (looking downstream). The tachometer is enclosed in an aluminum housing near the knife drive motors. Remove the cover on the conduit fitting to expose the tachometer leads. Remove the tachometer cover and carefully thread wire through the cover while pulling the cover away from the tachometer housing.

Step 3 Remove the four screws holding the brushes in place. Remove the worn brushes and insert new ones. Replace the retaining screws.

Step 4 The brush holder ring must be removed if the commutator is to be replaced. Remove the setscrew in the end of the shaft. Push in on the commutator and remove the retaining pin. Pull out the worn commutator. Avoid handling the new commutator in the brush running area. Slide in the new commutator, insert retaining pin, and tighten setscrew against pin. CAUTION: Commutator must not rock on the shaft. The commutator must be preloaded on the shaft by at least 15 lbs. If 15 lbs. cannot be achieved after tightening the setscrew, insert an additional wave spring behind the commutator.

Step 5 Carefully replace the brush ring assembly so as not to damage the brushes.

CAUTION: When replacing the cover, pull all excess wire into the conduit fitting to prevent wire from rubbing on rotating shaft.


HIGH-T MOTOR RESOLVER REPLACEMENT

Step 1 Ensure main breaker is off and capacitors are bled down.

Step 2 Align the scribe marks on the motor rotor shaft with the scribe marks on the motor tail bell.

Step 3 Loosen the flex coupling at both the resolver and the motor. Disconnect the resolver cable.

Step 4 Remove the four 10-32 bolts securing the resolver to the resolver mount and remove the resolver. There is no need to remove the aluminum resolver mount.

Step 5 Install the new resolver and coupling (make sure cable connector is facing down and to the right). Do not tighten the coupling. Connect the resolver cable.

Step 6 Turn on CONTROL POWER. One or more LEDs on the sine/cosine card should be lit.

Step 7 Two people are required to set up the resolver position. With one person watching the LEDs on the sine/cosine card, the other person can rotate the resolver coupling until ALL LEDs on the sine/cosine card are on or off.

Step 8 With the coupling still loose, turn the coupling until most of the LEDs are on or off. The setscrews in the coupling should be facing the same way as the resolver connector. This is to provide clearance to tighten the connector. Tighten the coupling on the resolver side.

Step 9 Rotate the coupling on the motor side until ALL LEDs are on or off.

Step 10 Keeping all LEDs on or off, tighten the coupling on the motor side.


TORQUE TEASER SETUP PROCEDURE

Step 1 Set toggle SW2 in down position to disable torque teaser function (default mode).

Step 2 Jumper J2 pin 1 to pin 2 on torque teaser cards, if torque teasers are being used with a 0-10 volt line speed signal.

Step 3 Jumper J2 pin 3 and pin 4 and remove jumper J2 pin 5 and pin 6 on torque teaser cards, if torque teasers are being used with a Marquip Slitter/Scorer.

Step 4 Jumper J2 pin 5 and pin 6 and remove jumper J2 pin 2 and pin 3 on torque teaser cards, if torque teasers are not being used with a Marquip Slitter/Scorer.

NOTE: There are two existing pull/exit roll options on the Marquip Knife. The correct DIP switch and jumper configuration is dependent on the type of knife. The following is a summary of pull/exit roll options and the configurations for each type:

Option 1 Direct drive pull/exit rolls with square, brown brushless motor.

Option 2 Direct drive pull/exit rolls with round, black brushless motor.

DIP Switch Settings SW1 on Torque Teaser (Default Torque Limit):

Option 1 Close SW1-2, SW1-4, and SW1-6 (1.66 volts at test point B)

Option 2 Close SW1-3, SW1-5, and SW1-6 (2.12 volts at test point B)

Jumper Configuration J3 and J4 of Torque Teaser:


Step 5 Determine type of knife and set DIP switches and jumpers accordingly.

Step 6 Set slip detect DIP switches all open.

Slip Detect Card Flat Cable Connections:

NOTE: Attach flat cable from appropriate header on the slip detect card to J1 on the torque teaser card of that level.

Torque Teaser Card Setup:

UPPER KNIFE

Step 1 Turn on power.

Step 2 Monitor test point B with a digital voltmeter. Voltage should be default torque limit as set by DIP switches on torque teaser card.

Step 3 Run double backer without board at 200 FPM.

Step 4 Monitor test point A with a digital voltmeter. Adjust P1 for 1.8 volts at test point A.

FROM TO

Slip Detect J1 (10 Pin) Torque Teaser (upper) J1

Slip Detect J2 (10 Pin) Torque Teaser (middle) J1

Slip Detect J3 (10 Pin) Torque Teaser (lower) J1


Step 5 Monitor pull roll speed with a hand tachometer. Adjust P2 for a pull roll speed of 225 FPM.

Step 6 Monitor exit roll speed. Adjust P3 for an exit roll speed of 240 FPM.

Step 7 Stop corrugator.

REPEAT THIS PROCEDURE FOR MIDDLE AND LOWER TEASER CARDS

Upper Slip Detect Card Setup Procedure:

NOTE: You may want to put the torque teaser card on an extender board during the slip detect card setup so you will not have to turn off power and remove the torque teaser when torque teaser DIP switches are changed.

Step 1 Set DIP switches on upper torque teaser card as follows: DIP Switch SW1-5 closed and all others open. NOTE: SW2 should be in down position (disabled) to put the torque teaser in default mode.

Step 2 Run corrugator with board at approximately 400 PPM.

Step 3 Observe LED 1-10 on the slip detect card. (LED 1 corresponds with the upper knife, LED 2 with the middle knife, and LED 3 with the lower knife.) If the LED is on or flashes frequently, close DIP switch SW1-8 on the slip detect card.

Step 4 If LED 1-10 is still on or flashes frequently, close DIP switch SW1-7 on slip detect card and open DIP switch SW1-8 on the slip detect card. Continue closing DIP switches on the slip detect card in a binary sequence (DIP switch SW1-8=LSB, SW1-1=MSB) until LED 1-10 goes off and stays off.


Switch Sequence Example:

Close SW1-8

Open SW1-8, Close SW1-7

Close SW1-8

Open SW1-8, Open SW1-7, Close SW1-6

Close SW1-8


Close SW1-8

Open SW1-8, Open SW1-7, Open SW1-6, Close SW1-5

Close SW1-8


Step 5 Stop corrugator.

Step 6 Return DIP switches on the torque teaser card to the default torque limit setting.

Step 7 Close SW2 on torque teaser card (up position). This enables the torque teaser. To disable the torque teaser and go to default torque limit, SW2 can be opened at any time.

REPEAT THIS PROCEDURE FOR THE MIDDLE AND LOWER LEVELS. DIP SWITCH SW2 ON THE SLIP DETECT CARD CORRESPONDS WITH THE MIDDLE LEVEL AND DIP SWITCH SW3 ON THE SLIP DETECT CARD CORRESPONDS WITH THE LOWER LEVEL. MAKE DIP SWITCH CHANGES ON RESPECTIVE TORQUE TEASER CARDS.

SPARE PARTS - 9405427 SP-1

SP-2 9405427 - SPARE PARTS

MARQUIPPART NO. DESCRIPTION QTY.

RECOMMENDED SPARE PARTS LIST (Prices Available On Request)

LEVEL 1 indicates recommended essential spare parts.

LEVEL 2 indicates recommended essential spare parts with high Meantime-Between-Failure (MTBF) or parts that are generally available locally.

LEVEL 3 indicates additional recommended spare parts.

Customer: Boise Cascade Corporation, Huntsville, AL

Serial No.: 13817-1000 - 98" Double Integral Drive Model III KnifeDirect Drive Pull/Exit (Mechanical)

INFEED SECTION ASSEMBLY

Level 3

9413781 Bearing, Machining, Direct Drive, Pull/Exit 2

3014910 Bearing, Tapped Base Pillow Block - 1-15/16 2

3069946 Bushing, Pull Roll Holddown Wheel 2-5/8 x 2-1/4 x 2 92

9413646 Hub Machining, Pull/Exit 2

9401435 Keystock, 5/16 x 5/16 x 1.25 2

9401328 Roll, Pull, Direct Drive 2

3222610 Wheel, Radius 6-1/2 x 2-9/16 x 2 2



EXIT SECTION ASSEMBLY

Level 3

3010015 Bearing, 2-Bolt Flange - 1-15/16 2

9413781 Bearing, Machining, Direct Drive, Pull/Exit 2

3039620 Bearing, Radius 17 mm 48


9401435 Keystock, 5/16 x 5/16 x 1.25 2

9413517 Roll, Exit Direct Drive w/Grooves 2

5012900 Shock Absorber - 1/4 x 1/2 24

9415320 Spacer, Holddown Wheel Exit 48

3222610 Wheel, Radius, 6-1/2 x 2-9/16 x 2 48

KNIFE CYLINDER ASSEMBLY

Level 1

9402042 Blade Kit, Sharp Tip 98" 2

Level 3

3172720 Gear, Knife Cylinder 4

3172721 Gear, Knife Cylinder 4

2994490 Insert, Threaded 3/8 - 16 x .50 w/Lock 8

2994520 Insert, Threaded, Stainless - .328 Lg. 200

9413030 Kit, Lower Holder, 98" 2

9413029 Kit, Upper Holder, 98" 2

3992150 Seal, Split 8

2022300 Screw, Socket Head Cap 3/8 x 1/2 8

2052587 Screw, Square Head Setscrew, Dog Point 5/16 x 1-1/2 8

2094410 Washer, Hardened 5/16 x 11/16 x 1/32 200



KNIFE CYLINDFR RESOLVER ASSEMBLY

Level 1

9401636 Resolver Housing Assembly 2

Level 3

3264151 Coupling, 3/8 x 3/8 2

3174108 Gear, Encoder Set 2

3174128 Gear, Encoder Pinion 2

9415682 Mount, Resolver w/Shaft 2

KNIFE CYLINDER TACHOMETER ASSEMBLY

Level 1

6411555 Rotor Tachometer 2

6411550 Stator, Tachometer 2

Level 3

3039990 Bearing, Radius - 3/4 4

6411552 Brush, Tachometer 8

3172738 Gear, Tachometer Set 2

PULL/EXIT ROLL MOTOR AND ACCESSORIES

Level 3

3264631 Coupling, Insert 4


9401049 Motor, Pull/Exit, Tested 4



PNEUMATICS

Level 3

5061030 Regulator 2

5046680 Valve 2

TOOLS

Level 3

3960131 Adhesive, Threadlock Remover 1

3951476 Comparator, Lens 1

3951475 Comparator, Pocket 10X 1

3959975 Compound, Lapping 1

3999995 Gloves, Wizard Large 2

9416525 Kit, Knife Blade Tool 1

9413777 Spacer, Coupling 1

3990766 Tool, Ratchet Handle - 1-1/4 1

LUBRICATION

Level 3

9401508 Felt, Wick Lubricator 2

6048215 Switch, Float 2



MEASURING WHEEL ASSEMBLY

Level 1

9401636 Resolver Housing Assembly 1

Level 3

3010020 Bearing, 2-Bolt Flange - 5/8 2

9403424 Measuring Wheel Assembly, 5/8 Bearing 1

3162093 Sheave, Timing - 3/8 1

3162091 Sheave, Timing - 1/2 1

9403423 Wheel Assembly, Measuring Wheel, 5/8 Bearing 1

MOTOR COOLING ACCESSORIES

Level 2

5066846 Filter, Air, 20 x 20 x 2 4

Level 3

5020567 Blower, Clockwise w/Base 1

9401147 Blower Gasket 1

9404035 Blower Gasket 1

5066146 Filter, Air, 16 x 20 x 2 2

6040013 Switch, Pressure 1



MISCELLANEOUS

Level 3

6142170 Handle/Latch, w/Key 1

9402023 Key Assembly, Switch 2

9413016 Program, NTSC Knife Blade Tuning VHS 1

6048062 Switch, Key 2

6014030 Switch, Limit 6



Customer: Boise Cascade Corporation , Huntsville, AL

Serial No.: 13817-1000 - 98" Double Integral Drive Model III KnifeDirect Drive Pull/Exit (Electrical)

MACHINE COMPONENTS

Level 3

6381030 Contactor, ASEA (For Blower Motor)

9402572 Enclosure, Cylinder Timing Indicator, DECC

6340014 LED, Green, 5 V "/Resistor Panel Mounted

6340012 LED, Red, 5 V "/Resistor Panel Mounted

6340013 LED, Yellow, 5 V "/Resistor Panel Mounted

6025368 Relay Overload, ASEA (For Blower Motor)

KNIFE DRIVE COMPONENTS LOCATED IN KNIFE END ENCLOSURES (INTEGRAL) OR CONTROL CABINETS (EXTERNAL)

Level 1

9402503 Card, Velocity Amp (Non-1000) 1

9406899 Drive, 3-Phase Knife 2

9420095 High I 50 Amp Knife Drive Blue 2

9406302 Power Supply Knife Blue (115 V AC Supply) 2(Separate from Rack)

6024350 Relay, 110 V Coil 3P3T Gold 3

6304250 Resistor, 50W 100 Ohm 2

Level 2

6317087 Capacitor, 6100mF 350 V 1

9406650 Card, Regeneration Bleeddown 2

6381080 Contactor, 45A DC ASEA (3 Pole) 1

6381060 Contactor, 56A 50/60 ASEA (2 Pole) 1



Level 3

6231680 Block, Terminal Fuse Clip

6233030 Block, Terminal 600 V 60A

6299990 Bracket, Resistor

9400133 Card, Current Sense

6254310 Fuse, FNM 20

6277005 Fuse Block

9405650 Mount, Capacitor (behind drive racks)

9406614 Rack, 3-Phase, 300 V DC

9400094 Rack, Drive, Dual, Blue

6300760 Resistor, 1/2W 332K

6290910 Resistor, 1/4W 150K Ohm

6022125 Socket, Relay

DECC CONSOLE

Level 1

9903608 Card, Computer VME Profiler Control 1

9901601 Card, VME, Resolver Interface 1

9905870 Card, VME, Toroid Interface 1



INTERFACE ENCLOSURE ON EXTERNAL CONTROL/POWER PANEL ON INTEGRAL CONTROL

Level 1

9400505 Card, Shaped Sine/Cosine Resolver (1 per Level) 1

6429693 Input, DC 10-30 V 32 (1 per Level) 1

6429710 Output, TTL (1 per Level) 1

6397520 Power Supply, 5 V 1

6397500 Power Supply, +/-15 V 1

6397876 Power Supply, PLC 1

Level 2

9406823 Card, Torque Teaser, without Speed Govenor 1(1 per Level)

Level 3

9403503 Card, Slip Detect (1 per Machine)

6254580 Fuse, FNM .5A

6254510 Fuse, FNM 1.6A

CTM (OPTION)

Level 1

9902043 Card, Computer VME CTM Control (1 per Level) 1

Level 3

9411607 Sensor, CTM w/cable (1 per Level) 1



MACHINE WIRING

Level 3

6186925 Cable, 3 pair shielded 22 Gauge (For Resolvers)

6340788 Connector, 12 Pin (For Resolvers: Pull and Exit Motors)

6411297 Connector, Encoder (For Resolvers: Wheel, Cyl., Motor 1)

CABLE WITH CONNECTORS

Level 3

9413039 Cable, Resolver, Upper Cylinder, 50' 1

PERSONNEL TESTING - 9404740 PT-1

INTRODUCTION

For your safety, you will receive training on your new Marquip equipment. The following section is an outline of training that you will receive at the time of installation. Included in this section is a quiz. This quiz will be administered by Marquip Field Service while on the job site. An attendance list will be taken at that time and kept on file at Marquip. The quiz is broken down into two parts. Part one is the operator section. Parts one and two is the maintenance section. It is our opinion that maintenance should not only be able to maintain the machine, but also must be able to operate the machine. These quizzes will reinforce the safe operation and maintenance guidelines for your machine. It is recommended that this section be kept on file for future use. This information should be passed on and the quiz taken by any new operators and maintenance personnel.

PT-2 9404740 - PERSONNEL TESTING

MACHINE RECORDS

OPERATOR TRAINING - KNIFE

F/S Name Serial Number

Customer Date

F/S INITIALS

1. Safety (have operators read the Safety section of the Operator manual).A. Show safety keyswitchesB. Show door (limit switches) and coversC. Show knife bladesD. Show infeed roll out sectionE. Show all safety signs and warnings

2. Operator controlsA. Disconnects (drive cabinets, operator console)B. Safety keyswitchC. Stop and E-stopD. Manual or jog controls

3. Preventive maintenance - cleaning!

OPERATOR PERSONNEL SIGNATURES:

Date

Date

Date

Date

Date


MAINTENANCE TRAINING - KNIFE

F/S Name Serial Number

Customer Date

F/S INITIALS

1. All items as described in Operator Training

2. Safety: Knife blades, power wiring and disconnection, capacitors and capacitor drain, and interface wiring.

3. Component location.

4. Print divisions and their layouts.

5. Blade tuning and lapping.

6. Diagnostics and indicator lights.

7. Changed out critical spare parts (cards, drives, resolvers, etc.).

8. Troubleshooting (prints).

9. Preventive maintenance.

MAINTENANCE PERSONNEL SIGNATURES:

Date

Date

Date

Date

Date


OPERATOR AND MAINTENANCE QUIZ

Name:

Circle the correct answer. There may be more than one correct answer for each question.

1. You turn on the one remaining control lockout keyswitch when starting the knife. What should you do if the key breaks off?a. Go ahead and run the knife.b. Notify the maintenance department when you get the chance.c. Stop immediately and notify maintenance and your supervisor.

2. Before you start running the knife, you find a safety sign laying on the floor. You then go ahead anda. run production - the sign does not affect production.b. throw the sign away.c. put the sign on the operator's console.d. notify your supervisor and maintenance before you do anything else.

3. Assume all of your safety switches are okay. It is safe to open the top covers of your knife while AUTO is turned on. T/F

4. When you turn off the keyswitch, it is then safe to enter the knife.T/F

5. When clearing a jam inside the knife, you must have the keyswitch off and in your pocket, plusa. the main disconnect off.b. B. all incoming power off and verified that it is off.c. C. the main disconnect off and capacitor banks verified to be at O

volts by observance of the warning LEDs mounted on the door.

6. Action of the keyswitch can best be described as a. removing power from the knife. b. removing only control power from operator's console. c. fixing the cylinders so they cannot move.

7. If the roll out section is out, before repositioning it correctly, you musta. find some help and roll it in.b. roll it in yourself if no help is available.c. make sure the path is clear for the rolling infeed assembly.


8. You open a top door on the knife and AUTO and CONTROL POWER drop off. It is now safe to clear a jam out of the knife. T/F

9. On Monday start-up you find this object that looks like a guard. To dispose of it properly, you would a. throw it in the junk barrel. b. use it for a seat. c. call maintenance to find out where it belongs.

10. You have turned AUTO off, CONTROL POWER off, and safety keyswitch off and the keys are in your pocket. Before you did this, you raised the rolls to clear a jam. It is now safe to reach in between the exit rolls to remove a scrap jam. T/F

11. The knife has CONTROL POWER and AUTO turned on with no line movement. Facing the knife as board would flow, you open the left side door. AUTO does not drop out. You would thena. ignore it, close the door, and run.b. leave the door open.c. check to see if there is a limit switch on the door.d. call maintenance and have them check the limit switch.

12. The knife is in a normal run at 350 FPM line speed. You depress the E-stop button anda. the knife gives out an E-stop to the line and follows the line to a

stop.b. does an E-stop.c. shuts off all power immediately.d. gives an E-stop to the line and stops all motion of cylinders and pull

exit rolls as fast as possible.

13. In a normal stop (stop button was pressed), the knife follows the corrugator to a stop. T/F

14. The pull/exit holddown wheels will not raise. AUTO is on and you have a jam in the knife. One reason for them not to raise could be thata. somebody turned off the air going to the knife.b. board is jammed over the top of them.c. the valve is jammed from the board.d. AUTO is on.


15. You have no board in the knife and when you turn AUTO on, the knife does not go to the cocked position. A reason could be thata. air is turned off going to the knife.b. AUTO is on.c. somebody forgot to turn on the main disconnect.d. the knife senses board.

16. The stacker operators complain about this short piece of scrap about 20" long that comes out at the start of a setup. One way you might get rid of it would bea. to shut the knife down and call maintenance.b. to check for jams following all safety rules.c. to make sure the pull/exit rolls are turning.d. you cannot get rid of it. You cannot avoid the trim cut that the knife

is programmed to cut at the start of each setup.

17. If the operator gets a random shutdown with a low airflow diagnostic, maintenance shoulda. ignore it. It only happens once a shift.b. jumper out pressure switch.c. check airflow, replace filter if necessary.

18. Your Model III Direct Drive Knife has identical upper and lower levels. However, there are certain items that are used by both levels in normal run to determine cut length and if the knife senses board. They area. knife profile computer.b. web measuring assembly and web entering photoeyes.c. web detect photoeye and web entering photoeyes.d. web measuring assembly, web detect photoeye, and web entering

photoeyes.e. none of the above.

19. If you only wanted to work on the wick lubricator on the lower level and you were pressed for time, you could do this by disconnecting and locking out the lower level only. T/F

20. The knife will be down for the weekend and operators and maintenance will be working on it. Before total shutdown and lockout, per safety rules, additional accident prevention steps might be toa. jog knife to closed position to protect blades and personnel from

contact.b. shut off air to knife.c. clean knife and below knife thoroughly.d. do all of the above.


21. Turning off the main disconnecta. makes it safe to work on the operator's console.b. removes power from the drive enclosure.

22. If you turn off CONTROL POWER while running, youa. remove power from the drive cabinets.b. remove power from the capacitor banks.c. remove power from the auto control circuit after 12 seconds.

23. Checking for no voltage at the capacitor side of the Regen carda. can alert you to possible stored energy that could be accidentally

discharged through the drive amps.b. confirms that the knife is electrically powered down.

24. What would you do if the capacitor banks had not been discharged?a. Alert your supervisor to the problem.b. Call in a certified electrician to troubleshoot the problem.c. Both A and B.

25. The pull/exit rolls will turn if stepped on with the main disconnect locked out. T/F

26. Movement of the jam detect pan, located between the knife cylinders and exit roll, due to a jam or wrap-up will trigger an E-stop on the


MAINTENANCE QUIZ

27. The wick lubricator flow control on a Model III is located on the right-hand side of the knife. T/F

28. To save time when tuning blades, it is okay to have two men in the knife. T/F

29. Spot tuning should only be considered if you do not have the time to completely retune the knife blades because of a pressing production schedule. T/F

30. When inspecting the knife blades for a sharp tip after lapping, you only need to inspect the upper knife blade tip. T/F

31. You should never rotate the knife blades forward through the cut with lapping compound on the blades. T/F

32. A sharp knife blade tip is one where the lapping wear lines extend from the tip of the knife blade down the blade surface. T/F

33. You can spot tune without lapping first. T/F

34. The knife blades cut from the a. right to left. b. left to right.

35. You should always tune the knife blades working from the right to the left. T/F

36. Anytime you rough tune you should try to cut every fiber of the wet 90-lb. liner. T/F

37. To prevent galling blades, you must apply a film of oil to those blade areas which do not have lapping compound. T/F

38. Because blades are very sharp, you must wear cut-resistant gloves. T/F

39. You can spot tune more than two times without a complete retune of the knife blades. T/F

40. You should use the microscope with the graduated scale attached to inspect the knife blade tips. T/F


41. When final tuning HOT nonserrated knife blades, you should tune them to cut every fiber of the wet 90-lb. liner paper. T/F

42. For how long is a nonserrated knife blade considered to be still hot enough to final tune them to cut every fiber of the wet 90-lb. liner paper?a. 1 hour.b. 2 hours. c. 3 hours.

43. A sudden loss of cut quality over a wide area of the knife blades is one reason to check for loss of gear preload. T/F

44. You must always retorque the upper knife blade bolts one at a time to 150 in.-lbs. for tuning. T/F

45. When you rough tune the knife blades, you should never advance the blade by more than 1/12 of a turn on the adjusting screw at a time, and you should not try to cut every fiber of the wet 90-lb. liner paper. T/F

46. If you were to tune the knife blades to cleanly cut all the fibers of the wet 90-lb. liner paper when they were cold (i.e., after 2 hours of production shutdown), what would happen?a. When the knife was put back into production, the knife cylinder and

blade temperature would rise. This rise in temperature would cause the metal to expand, causing the blade tune to tighten, causing possible damage to the knife blades, and reduce knife blade tune life.

b. The knife blades would be tuned tight and the knife would cut very well at operating temperature.

47. You need to tape over the blade bolt holes to prevent the lapping compound from filling the recessed bolt holes. T/F

48. The maximum torque difference when checking blade pass should not exceed a. 150 in.-lbs. b. 75 in.-lbs. c. 220 in.-lbs. d. 25 in.-lbs.


49. With the hub locking bolts loose, will the gear preload be removed if screw D is backed off? a. Yes. b. No. c. Does not affect the gear preload.

50. After gear preload is set, which pair of jackscrews are in opposition with one another and are used to set initial position? a. Screws A and B. b. Screws C and D.c. Screws D and A.

51. It is important to torque down the hub lock bolts to their proper torque specifications to prevent the hubs from moving when all four jackscrews are torqued to their final torque specifications. T/F

52. It is important to loosen and retorque one knife blade bolt at a time.a. Yes, this is important.b. No, this does not matter at all.

53. You can jog the pull/exit rolls under which conditions? a. CONTROL POWER on and AUTO off. b. CONTROL POWER off and AUTO on. c. CONTROL POWER off and AUTO off. d. CONTROL POWER on and AUTO on.

54. When the photoeye at the web measuring assembly senses a gap in the web, you transfer the board position input to the pull roll. T/F

55. The knife profile computer on a Model III will shut down two drives if one drive is not producing armature current. T/F

56. On Model III Knives, board sense is enabled by first receiving a web entering signal and then a sense forks input. T/F

57. If you have a web entering photoeye failure, you can jumper it out of the circuit and continue to run normally. T/F

58. The web severed signal from the shear enables the knife to track the tail of the expiring web. T/F

59. At the time of shear cut plus 6", the knife transfers its measuring source from the web assembly to the pull roll. T/F


60. During tailout, the board bows and buckles between the slitter/scorer and knife infeed rolls on the upper level only. A logical check might bea. cylinder resolver. b. teaser card setup. c. board detect photoeye. d. holddown wheels are raised.

61. One reason for a knife not to cut during a tailout with a shear cut might be becausea. the pull roll motor resolver binary input to knife profile computer is

inoperative.b. board detect photoeye is defective.c. the number of cuts for the setup had not been reached. d. the web resolver is defective.

62. Check most of the DC power supplies at the a. power supply. b. DC terminal strip. c. supply bus. d. no need to check; auto adjustment.

63. The knife profile computer can correct a constant cut length error up to ±10%. T/F

64. The corrugator run signal causes the pull/exit roll drives to be enabled. T/F

65. You hear a growl in the knife that sounds like the gears are coming apart on one level only. One logical check may be the a. cylinder feedback tech. b. measuring roll jam detect proximity sensor. c. exit roll tech.

66. If the knife loses board sense at anytime in a run, it goes to the cocked position. T/F

67. The current sense card monitorsa. how fast the knife is going.b. to see if AUTO is turned on.c. each drive amp to see if it is feeding current to the associated

armature winding.


68. The current sense card gives its information to a. the operator. b. the circuit breakers supplying the rack. c. the knife profile computer.

69. The knife profile computer waits approximately how many seconds after being informed of a malfunction on one drive amplifier before it disables the entire rack? a. One second. b. Two and a half seconds. c. 20 seconds. d. Ten seconds.

70. The knife profile computer will keep a rack enabled if it sees the corresponding LEDs for that rack on the current sense card blink at least once every two seconds. T/F

71. To determine the speed of the knife cylinder, the knife profile computer must knowa. the exact position of the board by use of web resolver.b. where it is supposed to cut by use of a length input from the operator

interface computer (OIC).c. the velocity and position of the cylinder using cylinder tech and

cylinder resolver.d. all of the above.

72. The drive amp does no computing of its own outside of the self-monitor circuits/diagnostics. T/F

73. The knife cylinder drive amp gets its information in the form of a current command. This command comes from a. the current sense card. b. the pull roll tech feedback. c. the speed reference signal. d. the knife profile computer. e. all of the above working together.

74. If one motor or rack on the knife fails, the other motors and racks are working harder to maintain operation. T/F

75. If the pull and exit rolls never enable or pull in their contactors, you might be missing a. a speed reference signal. b. a speed command from the pull exit card.


c. a stop command to reset the card. d. a corrugator run signal.

76. In the knife drive racks, you have one power supply feeding or supplying two drive amps with a high voltage/ampere source and a low voltage logic supply. T/F

77. If you had lower voltage than recommended supplying the power supply in the drive rack, what would be a logical assumption? a. Motors would last longer. b. Drive amps would not have to work as hard. c. Speed specifications would remain the same. d. All of the above are wrong.


OPERATOR AND MAINTENANCE ANSWER KEY

1. C 26. True

2. D 27. False

3. False 28. False

4. False 29. True

5. C 30. False

6. B 31. True

7. C 32. True

8. False 33. False

9. C 34. A

10. False 35. True

11. D 36. False

12. D 37. True

13. True 38. True

14. D 39. False

15. D 40. True

16. D 41. True

17. C 42. B

18. A and D 43. True

19. False 44. True

20. D 45. True

21. B 46. A

22. C 47. True

23. A 48. B or D

24. C 49. A

25. True 50. C


51. True

52. A

53. A

54. True

55. True

56. False

57. False

58. True

59. True

60. B

61. A

62. C

63. True

64. True

65. A

66. True

67. C

68. C

69. C

70. True

71. D

72. True

73. D

74. True

75. D

76. True

77. D

P.O. Box 28 ?1300 North Airport Road Phillips, WI 54555 715-339-2191

Service Bulletin

1

DATE: January 25, 1984 SERVICE BULLETIN NO. 46REISSUED SEPTEMBER 26, 1988

MACHINERY TYPE: Direct Drive Knife SUBJECT: Exit Roll

MACHINERY MODEL: All

Field experience has shown a potential problem area on the Marquip Direct Drive Knife. The problem being a build up of dust, small pieces of scrap, etc., in a confined area directly under the exit roll.

If contaminant is allowed to build in this area, it will eventually start to interfere with the exit roll causing additional drag, and effect exit roll speed. This may result in Jam ups and/or leading edge sheet damage.

If the build up is not removed, it will result in additional wear and/or premature failure on the exit roll and drive components.

To prevent this problem, Marquip recommends this area to be cleaned on a tally basis with air pressure directed in below the exit roll from each end and also through slots between the exit roll and stripper plate. This area should also be visually inspected periodically by using a flashlight in one end and a mirror on the other.

As always wines performing this preventative maintenance:

POWER MUST BE TURNED OFF AND THE SAFETY SWITCH LOCKOUT KEY REMOVED FROM THE OPERATOR CONSOLE.

The first time this area is cleared you may also get a speed change in the exit roll. To correct this do a normal pull/exit roll card set up as described in your knife manual.

If you require further information or field service assistance, please call.

H. Dee WelchField Service Manager

/cb 9/26/88



Service Bulletin

2

DATE: January 20, 1989 BULLETIN NO.: 109MACHINERY TYPE: Knife SUBJECT: Cut Length AccuracyMACHINERY MODEL: All APPLICABLE CATEGORY: Informational

PROBLEM:When we have investigated reported cut length variation problems, we have frequently found that the measuring wheel was not properly installed.

Solution:

1. The structure to which the measuring wheel assembly is attached must be free from any vibration. This means that it should not be mechanically attached to the double backer or any other machine. Where possible the structure should be connected directly and securely to the floor.

2. The table under the measuring wheel must be of metal. If it is made of wood or a plastic laminate it will wear over time and not provide the necessary support for the web and thus the web wheel.

3. The table must be as level as possible in cross machine direction. Any out of levelness will cause the castored wheel to weave from side to side and not correctly measure board travel.

4. The height of the table at the point of contact of the measuring wheel must be such that no gap ever occurs between the table and the web. A slight bias upward of the table may be to your advantage.

5. The routing of the multi-conductor cable to the encoder shall be made in a way to give equal freedom of travel of the castored measuring wheel assembly -- right or left.

6. The table under the measuring wheel must be dimensionally stable as it undergoes wide temperature changes. Caution should be used in the fabrication of tables with a thin metal surface which could buckle and oil-can.

7. The table under the measuring wheel should be inspected frequently to assure that no welds or bolts have loosened or have broken due to thermal cycling or operators walking on table to remove scrap or do maintenance.

8. The height and weight of the measuring wheel must be kept adjusted per the knife mainte-nance manual.


HDW/cb1/20/89


Service Bulletin

3

DATE: October 26. 1990 BULLETIN NO.: 136MACHINERY TYPE: Knife SUBJECT: Increasing Life On Pull/Exit Rolls

by Regarding Roll SurfaceMACHINERY MODBL: All APPLICABLE CATEGORY: Maintenance

In order to reduce the cost of pull/exit roll replacement or recoating, the rolls can be reground to provide a smooth and uniform diameter. The reground roll. will perform like a new roll. Versus a glazed and non-uniformily worn roll, the reground roll will improve tailout accuracy and reduce board skew.

A standard machine lathe with roll grinding attachments is required to successfully grind the rolls. The L.R. Oliver and Co., Inc. of Anchorville, NI manufactures both roll grinding wheels (Rubber-hog) and grinding attachments. The roll grinding attachments are custom made to meet each cus-tomers specific centerline height and bolt pattern. To provide the correct surface finish, an 8 inch O.D. X 1 1/2 inch wide SSG 330 grinding wheel is recommended. In order to get the best overall performance during the roll grinding process, the following criteria must be met:

1. Lathe must be rigid and free of vibration.

2. Lathe centerline must be parallel to grinding spindle.

3. Grinding wheel must be dressed before grinding roll.

Please contact L.R. Oliver and Co., Inc. for more details on proper roll speed and transverse speed.

L.R. Oliver and Co., Inc.9974 Dixie Highway

Anchorville, MI 48004(313) 725-1230

The roll diameter must not be ground to below 5.750 inches or positive drive contact with the board may be lost. Take only as much material as needed off of the roll. After installing the rolls, insure both the infeed and outfeed holddown wheels are adjusted properly. Refer to your knife maintenance manual for further details. If your knife has a wrap around exit roll stripper, check to insure the stripper is at least 1/16 inch below the roll. Lastly, do a complete knife speed set-up.



Supplement

SUPPLEMENT - 9432201 1

Top Cover Limit Switch Upgrade

ADJUSTING ELECTRICAL SENSOR

LIMIT SWITCHES

Plunger-type limit switches indicate when open doors or guards should be closed before starting Knife. Proper setup of switches is shown in the Limit Switches figure.

Figure 6. Limit Switches

1 66 mm (2.61”) Free Position

4 54 mm +/- 2 mm (2.13” +/- .07”)

2 6 mm (.26”) Set Up Position

5 Roller must touch bottom of cam groove in the free position (while door is closed)

3 9 mm (.39”) Free Position



Supplement

2 SUPPLEMENT - 9432201

MISCELLANEOUS SPARE PARTS


Level 3

6142170 Handle/Latch, w/Key 1

9402023 Switch, Key Assembly 2

9413016 Program, NTSC Knife Blade Tuning VHS 1

6010002 Switch, Body 2

6010003 Switch, Side Roller Plunger Head 2

Documents

AirCooled KnifeMaint