#j2000-j3000 maintenance front pg july 2016 · incl. some j2000/j2000-600 maintenance issues....

Javelinthe leading edge in converting technology for the Paper Film and Foil industries

Javelin Machinery (Australia)A.C.N. 005 543 411 ABN 18 005 543 411

Email: [email protected]: www.javelinmachinery.com.au

HEAD OFFICEPO Box 805, Glen Waverley Vic 3150 Australia

Phone: +61 3 8786 3614

Model: J3000 series(up to & incl S/N188)

AUTOMATIC SINGLE KNIFESLITTER

JULY 2016

MAINTENANCE MANUALINCL. TROUBLESHOOTING

MACHINE PROBLEMS

Incl. some J2000/J2000-600 Maintenance Issues

JAVELIN MACHINERY (AUSTRALIA) J3000/J4000 MAINTENANCE MANUAL(Incl Troubleshooting Machine Problems)

________________________________________________________________________________________________________________________________________________________________

1JULY 2016

1. SPECIFICATION AND EQUIPMENT

JAVELIN series J3000 - Automatic Tape Slitting Machine

1.1 SPECIFICATION (J3000 up to & incl. SN188)

DESCRIPTION STANDARDMACHINE:

LENGTH:DEPTH:

HEIGHT:WEIGHT:

3400 mm (134”)1285 mm (51”)1700 mm (67”)1050 kg (2310 lb)

LOG ROLL:WIDTH:

OUTSIDE DIAMETER:CORE INSIDE DIAMETER:

1600 mm (63’”)Ø457 mm (18”)∅76.2 mm (∅3” )

MACHINE DRIVE MOTORS:CHUCK SPINDLE DRIVE: 3 kw (4 HP)-700 rpm Motor (Leroy Somer

LS132M)4 kw (5.3 HP) Inverter (Mitsubishi)

BALLSCREW DRIVE: 0.55 kw (0.75HP)-1000 rpm Motor (Leroy SomerLS80L)Warner-EM4 Clutch Brake∅25 x 5 mm Ballscrew

KNIFE DRIVE: 3 kw (4 HP)-1500 rpm Motor (Leroy SomerLS100L)4 kw (5.3 HP) Inverter (Mitsubishi)Single Speed Gearbox (Genat & Wood)

GRINDER DRIVE: 0.55 kw (.75HP) -3000 rpm Motor (Leroy SomerLS71)

KNIFE:DIAMETER (max):DIAMETER (min):

BORE:

Ø500 mm (20”)∅300 mm (∅12”)∅25.4 mm (∅1”)

MANDREL:EXPANDING (rotating): ∅76.2 mm (∅3”)

CRATE:DIMENSION: 3700 x 1600 x 1875 mm

(146” x 63” x 74”)

JAVELIN MACHINERY (AUSTRALIA) J3000/J4000 MAINTENANCE MANUAL(Incl Troubleshooting Machine Problems)

________________________________________________________________________________________________________________________________________________________________

2JULY 2016

2 MOVING AND/OR LEVELLING MACHINE

1. With a forklift, remove machine from floor of packing case.2. Position machine carriage in approximate centre of rails.3. Place an engineer's level across front and rear guide rails at the left hand end of

the machine and adjust the feet at left end of machine until level.4. Place engineer's level at right hand end and adjust the four adjustable feet until

right hand end is level.(To enable the level to clear the ballscrew cover, small packing of equal thicknesswill need to be placed on each rail.)

5. Check for level lengthwise and adjust left hand end as required.6. Recheck level across the rails at left hand end.

Ensure that all feet have approximately the same load on them.

JAVELIN MACHINERY (AUSTRALIA) J2000/J3000 MAINTENANCE SCHEDULE

__________________________________________________________________________J:\Local Disk\##Javelin Machine Old Series\#Maintenance\J3000 up to SN188\#J2000 - J3000 Maintenance July 2016.doc

3. LUBRICATION & MAINTENANCE

3.1 LUBRICATION

DAILY MAINTENANCE

Lubrication & Preventative Maintenance Chart Daily Maintenance~ always use cut resistant gloves when handling knives ~

Ref Part Method No. ofPlaces

Lubricant Check/Adjust

D1 Runner Blocks (LinearBearings), Linear rails

Clean off grit and moisture with clean dry cloth and wipe with oil impregnated cloth 3 Lightmachine oil

D2 Knife Spindle locatingsurface

Clean off all grit and moisture with clean dry cloth then wipe over with oil impregnatedcloth

1 Lightmachine oil

D3 Knife, Backing Plates,washer and locking nut

Clean off all grit and moisture with clean dry cloth then wipe over with oil impregnatedcloth

Lightmachine oil

D4 Knife Carriage Assembly ..including Knife Grindingmechanism, DiamondDresser & DeburrerMandrel Support Assemb.Chuck Face & Rack SlidesAll unpainted surfaces

Clean off all grit and moisture with clean dry cloth then spray with lubricant using aplastic container with pump action trigger.

AllOver

50/50Kero/Oil

* wipe off grinding grit from knife carriage assembly each time a knife is reground.

D5 Air ServiceRegulator Unit

Drain water manually in machines fitted with Bosch/Compare units. Rexroth Regulator drainswater automatically

1

D6Lexan Cover Clean with soft lint free cloth 1 Water based

windowcleaner

DO NOT USE ANY SOLVENT BASED CLEANER AS IT WILL DAMAGE LEXAN

*

*

*

*



WEEKLY MAINTANCE

Lubrication & Preventative Maintenance ChartWeekly Maintenance

~ always use cut resistant gloves when handling knives ~



W1 Slides on knifegrinder

Blow slide ways clean with airgun. Wipe slide way with cleancloth.

4Spray withkero/oil.

W2 Knife grinder motor twoadjusting screws

Oil can 2Multi-gradeoil

Check dust cover in place

W3 Deburring assembly Oil can 2Multi-gradeoil

W3

where machines are being used to slit products such as foam tape or textiles and regular sharpening of the knife is occuring itwill be necessary to clean items marked with asterisk daily to remove build-up of grit.

*

*

*



MONTHLY MAINTENANCE

Lubrication & Preventative Maintenance ChartMonthly Maintenance

~ always use cut resistant gloves when handling knives ~



M1Diamond Dresser for GrindingWheel

Grease Gun 1MultiPurposegrease

Check diamond tip – replace if necessary

M2Runner Blocks (LinearBearings) located on:Knife carriage (traversingassembly)Mandrel support assembly

Grease Gun

442

Multi-purposegrease

MANDRELS

M3 Non rotating MandrelsSmear the end of mandrel whichlocates through chuck withgrease in order to lubricatebearing bush in chuck spindle

1Multipurposegrease

Replace Fibre Strip if necessary

M4 Mandrel with Expansionsection 76mm (3”) I/D cores

1 Adjust to give 1mm clearance betweenlocking collar and mandrel Replace rubbermandrel sleeve before it becomesexcessively worn.



SIX MONTHLY MAINTENANCE

Lubrication & Preventative Maintenance Chart - Six Monthly Maintenance

Ref Part MethodNo. ofPlaces


Six Monthly:

S1 3”(76mm) Mandrel withExpansion section.

Smear the end of mandrelwhich locates through chuckwith grease.

1Multi purposegrease

Replace rubber mandrel sleeve before it becomesexcessively worn.

Check Grub screw in retaining collar.

S2 Gearbox on knife drive (onlyfor machines fitted with twospeed gear box)

Top up with oil can ifrequired

1BP GR-XP 220

S3 Ball Screw & Nut Grease gun 1Multi-purposegrease

To adjust see manual/DVD.

S4 Ball Screw Drive Bearing Grease gun 1Multi-purposegrease

S5 Knife Spindle Bearings Grease gun 2Multi-purposegrease

Check knife spindle for run out with dial vernier.To adjust see manual/DVD.

Check knife drive belt for correct tension.

S6 Machine Level Check machine is level. If machine has beenmoved at any time it must be levelled (seemanual/DVD)

S7 Proximity & Limit SwitchesCheck all are operational

S8 Forward Stop Mechanism Wipe on. 1Grease

Remove front cover & tighten mechanism ifnecessary



SIX MONTHLY (CONT.)

Lubrication & Preventative Maintenance Chart - Six Monthly MaintenanceRef Part Method No. of

Places


S9 Mandrel Support Assembly Grease gun 3Grease

Tighten if necessary and align mandrel sothat the knife touches the mandrel evenlyin the centre and at either end of themachine.

CHUCK DRIVE ASSEMBLY

(A) For Machines fitted with Motor Slide Mehanism:S10 Motor Slide Base:

BushingsThrust bearing in adjust screwSlide BarsSpindleStop screw

Lubricate/OilLubricate/OilLubricate/OilLubricate/Oil

Adjust to prevent belt becoming looseS11 Intermediate Chuck Drive Shaft

BearingsGrease gun 2 Grease Check grub screw in bearings for

tightness.S12 Chuck Drive Chain & tensioner Spray can 1 Chain lubricant

(B) For Machines fitted with Electric Variable Speed Drive to Chuck/Mandrel::S13

Poly Chain Belt Check & Adjust Polychain belt if required.

PNEUMATIC SYSTEM

S14 Oil Reservoirs (Air/Oil System) Check seals OK / Check oil levelS15 Air Service Unit 1 Shell Morlina 32 Add oil when necessary as per manual.S16 Oil lines (tubing) Replace when clear tubing becomes

discoloured or loses flexability.S17 Solonoid valves, seals & fittings Apply soap and water solution with a

brush and check for air leaks and replacewhere necessary.

S18 Venturi Spray System Check Snaplock fittings & Spray Nozzles

JAVELIN MACHINERY (AUSTRALIA)J2000/J3000 MAINTENANCE SCHEDULE

8

3.2 MAINTENANCE

3.2.1 AIR OVER OIL SYSTEM – J3000

CHECKING OIL LEVELS IN RESERVOIRS

• Remove knife.• Move the carriage forward and adjust the FORWARD CARRIAGE STOP to give

maximum travel in the forward direction.• Adjust the REAR KNIFE STOP to give maximum travel to the rear.• With the ram stroke now adjusted for maximum travel move the carriage to the

fully forward position.• The oil should rise and fall in opposite reservoirs.• Check the reservoir with the higher level of oil, which should be approximately

50mm below the air inlet port at the top of the reservoir. If the oil level is lower addoil as required.

• To add oil:1. Turn off air supply to the J3000.2. Remove reservoir fill plugs. With an oil can,

filled with the specified oil, fill the reservoir.Avoid squirting oil in the quick exhaust valveslocated opposite the fill holes. (If the quickexhaust valves do become filled with oil theymay take 5 minutes to clear once you havestarted running the machine.)

3. Push by hand the carriage forward and backto check the levels again.

Fig. 5-2-1 Oil Reservoir

• Move the carriage to the rear position and againcheck the level in the other reservoir and fill ifrequired.

• Replace the fill plugs and connect air.• Replace knife.• Remember – re-adjust forward and rear carriage

stops.

BLEED AIR FROM SYSTEM

• Remove knife.• Adjust forward and rear carriage stops to give maximum travel.• Start the machine with the mode switch in the semi-position.• Leave to cycle back and forth for approximately three minutes. The air will bleed

from the system automatically.• After switching off, re-check oil levels as per previous instructions.

If the system constantly requires bleeding, check the tightness of all connections thatmay be causing an oil or air leak.

TYPE OF OIL

FILL PLUGS

RESERVOIRS

OIL LEVEL


9

Shell Tellus S32 .. Air Over Oil System.

BLEED OIL FROM SYSTEM

In the event of oil exhausting from the carriage forward - retract pneumatic valvecheck the following:

1. If either of the oil reservoirs are over filled oil will exhaust from the pneumaticvalue - refer to “checking oil levels in reservoirs”.

2. The simplest way to remove the oil from the pneumatic lines once they arecontaminated with oil is to remove the silencers, adjust the forward and rearcarriage stops to give maximum travel and cycle the carriage in and out in semimode until the air exhausting out of the valve is clear of oil (10 - 20 minutesapproximately).

3. In the event that the oil levels are adjusted correctly and yet after a period of timeone oil reservoir over-fills and the other empties .... this is a sign that the seals inthe carriage cylinder are leaking and must be replaced.

4. Another possible cause of oil exhausting from the silencers is that air is atomisingthe oil in the reservoirs. If this is the problem a baffle plate or “tee” fitting must befitted to the inside of the oil reservoirs - top and bottom.


10

3.2.1 AIR OVER OIL SYSTEM – J2000

CHECKING OIL LEVELS IN RESERVOIRS


11

BLEED AIR FROM SYSTEM


12

3.2.2. MANDREL SLEEVE REPLACEMENT – EXPANDING MANDREL

TAN SLEEVE 400m (15¾”) WIDTHRetaining Collar

The worn area is cut out using a strong sharp knife and the good sections pushedup the mandrel. A retaining collar (see Figure 2) is secured to the mandrel bytightening two grub screws. This collar prevents the sleeves from separating.

The sleeves may appear to be a loose fit but when the retaining collar is pushedagainst sleeve at load end of machine and grub screws are tightened the sleeveswill not move. Ensure that there is no clearance between collar and sleeve.

NOTE: To maximize longevity of mandrel sleeves ensure knife is set approximately 2– 3mm away from OD of sleeve. When operator pulls the cutting handle down theknife should then fractionally penetrate the sleeve.

RED POLYURETHANE 100mm (4”) Sleeve (Expansion Sleeve)

The 4” wide red polyurethane sleeve (see Figure 1) is a new accessory which fits onthe section of the mandrel where the expansion jaws are located. Because it issofter you will find that it expands more evenly and therefore grips the I/D of the tapecore more securely. As there is a lot of wear on this part of the rubber sleeve it mayalso extend the life of the tan coloured rubber sleeve. You can easily replace justthe red section on its own:

Mandrel Sleeve (Tan)JPN154 2048 000These sleeves cover steelmandrel. The sleeves are easyto slide on and remove enablingsmall sections of worn sleeve tobe easily replaced.

Red Polyurethane SleeveJPN153 2048 000Fits on the section of the mandrelwhere the expansion jaws arelocated. Because it is softer thejaws will expand more fully andtherefore grip the I/D of the tape

Retaining CollarJPN154 2048 001Collar is secured to themandrel by tighteningtwo grub screws

Figure 2


13

Replacement of Red Polyurethane Sleeve

• Remove the mandrel from the machine.

• Use plastic hammer and a wide bladed screwdriver or wedge to drive redsleeve towards the right hand end of the mandrel until internal jaws areexposed.

• Wrap adhesive tape around jaws.

• Remove red sleeve.

• Push on new sleeve to hold jaws in position.

• Remove tape and tap sleeve home to correct position.

IMPORTANT NOTE (RED SLEEVE):

Over an extended period the (red) expanding sleeve may develop a bulgeand make it difficult to slide log rolls over the red sleeve. To prevent this werecommend that you occasionally loosen the grub screw in the retaining collar(Fig. 2) and slide the sleeves down the mandrel as show in Fig. 1 to relievethe pressure on the expanding sleeve. Then just move the sleeves back intoposition and slide the retaining collar against the tan sleeve and tighten thegrub screw. Do not push the collar hard against the sleeve, as you will onlycause the problem with the red sleeve to re-occur more quickly.

3.2.3 FIBRE STRIP REPLACEMENT NON-ROTATING MANDREL -

To replace fibre strip:

• Remove old fibre strip with sharp chisel or knife.• Clean the ‘FLAT’ on the mandrel with solvent.• Glue on new fibre strip with 2 pack - 24 hours araldite or similar high strength

adhesive.• Hold in position with PVC - Vinyl tape until dry.• Use emery paper or file to remove excess adhesive.

3.2.4. ROTATING MANDREL - EXPANDING

ALIGNING COUPLING HALVES ON EXPANDING MANDREL

• Turn release grip switch to grip position.• Fit mandrel into machine.• Align pop marks (if fitted) on left hand end of mandrel with pop marks on the

outside face of the chuck.• Locate cap screw in chuck spindle into dimple holes in mandrel and tighten.• Turn grip release switch to release position.• Adjust male half of coupling on threaded rod protruding from mandrel so that the

M6 cap screw joining the two halves of the coupling will fit freely.• Tighten lock nut up to coupling.


14

4. TROUBLE SHOOTING

4.1 SLITTING TOLERANCESTo achieve tolerances within .1mm or ± 4 thou you need to check the following:

1. Use the smallest diameter knife possible … the bigger the knife diameter themore chance of run-out. Check our knife selection chart for a knife bevel to suitthe width you wish to cut. As an example, you cannot hope to hold tolerancesslitting narrow widths with a knife with a back bevel.

2. Check the knife spindle, knife and backing plate for run-out using a dial indicator,as described below, where accuracy to .1mm (+/- 4 thou) is required.

3. With some products such as film tapes, you can use the knife brake so that theknife is locked and will not turn. By this method you eliminate any possibility ofknife run-out. However, you will need to stop slitting occasionally and rotate theknife so as to prevent a flat spot occurring on one section of the knife-edge.

Other factors that can affect tolerance are the index counter and encoder and in veryrare cases the clutch brake. An encoder problem is usually indicated by significiantvariations in width from roll to roll although the index counter will still read correctly.Always check for any loose wires to the encoder or index counter. A clutch brakeproblem is usually indicated by erratic tolerances displayed on the P1. Whenchecking for a problem with the unit always first check the correct voltage is going tothe clutch brake.

Remember that any burrs on the knife, backing plate, washer and even the lockingnut are enough to prevent tight tolerances being held.

Knives should always be fitted on the machine so that the engraved parallel linesface the mandrel and the engraved word “top” is uppermost. The knife must alwaysbe sharpened on the integrated knife sharpener mounted on the machine. Javelinknives are bevelled at 11º and any alteration to that angle will cause problems. Westrongly advise against sending knives out for sharpening. Even when you receivenew knives from Javelin they must be finally sharpened true on your machine.

Remember also that the mandrel must be aligned properly (see section 6.2 KnifePedestal alignment in this manual) and the fit of the rubber sleeve to the I/D of thecore of your material must be a close fit.

The material must be gripped firmly on the expanding mandrel and up against theface of the chuck so there can be no sideways movement. If you are using a spacerroll between the chuck and material to be cut make sure it has straight edges andthat it is approximately the same diameter as the material to be cut.

When measuring slit rolls with a dial vernier do not allow the jaws of the vernier toclose against the cardboard or plastic core as this can give you a false reading.

If you follow the above points closely you will be able to slit tape to close tolerances.


15

a. CHECKING FOR KNIFE SPINDLE RUN OUT:

Place dial indicator on clamping face of knife spindle and rotate spindle slowly,check for run out 0.03 - 0.05 mm (0.001" - 0.002") permissible.

To remove burrs or score marks from spindle face:i) run the spindle at medium speedii) hold a strip of emery cloth on a flat file and place it flat on the spindle face.

CARE MUST BE TAKEN NOT TO ROUND THE FACE OF THE SPINDLE.

b. CHECKING FOR BACKING PLATE RUNOUT:

The backing plate face should beconcave This can be checked byplacing a straight edge or steel ruleacross the face of the backingplate and checking if a gap of.1mm (.004”) exists.Backing plates that have beendropped onto a hard surface maybe out of specification and willneed to be replaced.

i) Run a smooth flat file across the face of the backing plate and washer toensure there are no burrs.

ii) Check spindle face for burrs or grit.iii) Fit backing plate and washer and check for runout with dial indicator.iv) Runout should not be more than .08mm (.003”). If runout exceeds

tolerance, mark backing plate in 4 positions and one position on spindlewith marking pen.

1

2

3

4

backing plate

spindle

.

Check runout in each position. If a position is found which is within tolerancepermanently mark backing plate and spindle. Ensure that the marks are alignedwhenever the backing plate is being placed back on the spindle

NOTE: Checkbacking plate oninside by fittinglarge backingplate/smallbacking plateand nut, thenplacing dialvernier on edgeof backing plateas shown inpicture.


16

c. CHECKING FOR KNIFE RUNOUT

Place dial indicator on knife face and rotate knife. A runout of not more than.08mm (.003”) is permissible.

d. HOW TO TIGHTEN KNIFE SPINDLE BEARINGS:

Tighten loose knife spindle bearings as follows:

• Fit largest diameter knife.• Grasp knife on either side and try to move knife in, out, backwards and

forwards.• If movement is detected in spindle locate knife lock in knife backing plate to

prevent knife spindle from turning.• Remove cover from left-hand end of spindle.• Tighten nylon nut 1/6th of a turn to preload spindle bearings and check knife

again (see Point 3) for movement. Again tighten the nylon nut 1/6th of a turnand continue this process until there is no movement of the knife. This isexactly the same process as tightening the front wheel bearings on a car. Seefollowing note.

• Replace cover and remove knife lock.

Note: It is important not to tighten the nylon nut in one continuous turn of thespanner as this could put excessive load on the bearings and can cause damagewithin the pedestal.

e. PEDESTAL ALIGNMENT

If the knife has been jammed or forced at some time, the knife spindle could be bentor the pedestal could be out of square. The knife should be checked to see that it isparallel to the chuck face.

A B


17

f. ALIGN KNIFE PARALLEL TO CHUCK

• Remove the knife guard• Fit large diameter knife• Check the knife and spindle are running true• Remove mandrel• Adjust forward knife stop fully forward• Traverse knife close to chuck• Move knife forward• Measure distance between face of knife and chuck at the front and rear of the

knife• Loosen pedestal retaining screws• Adjust as required to bring both faces parallel


18

4.3 BALLSCREW DRIVE

4.3.1 BALLSCREW AND NUT

Position and holds carriage accurately with no sideways play of carriage

BALLSCREW NOISY OR VIBRATING

• Grease ballscrew nut• Check alignment of ballscrew nut mounting bracket• Check preload on ballscrew taper bearings

VARIATION IN WIDTH OR DOUBLE CUTTING

• Check preload on ballscrew taper bearings• Adjust ballscrew nut retaining bolts

TO CHECK FOR ENDPLAY IN BALLSCREW

Sideways freeplay in knife carriage. Traverse carriage to left hand end of machine,stand at end of the machine and grasp carriage, try to pull forward and backwards. Ifmovement is felt, adjust taper bearings on ballscrew.

ADJUSTMENT OF BALLSCREW END PLAY

Turn off the machine at main ON / OFF switch on the electrical cabinet, this dis-engaged electrical clutch / brake unit allowing the ballscrew to be rotated.

Remove rear cover to expose ballscrew adjusting nuts. Loosen the two grub screwsin the alloy timing pulley. loosen outer nut and adjust inner locknut to lightly preloadtaper bearings. Tighten outer nut, a grub screw in pulley, check for end play inballscrew, check ballscrew rotates smoothly.


19

4.3.2 CLUTCH BRAKE UNIT

Machines manufactured after December 1993 are fitted with a Warner Electricclutch brake unit which is “self adjusting”.

Machines manufactured up to December 1993 are fitted with a Lenze clutch brakewhich is adjusted as follows:

ADJUSTING THE AIRGAP - LENZE

Value in (P1) should be no greater than 2.2 mm, if so turn power off at main isolatorand adjust airgap in clutch brake. The four screws (1) in the output cover must beloosened until the underlying pressure springs are released (1-2 turns). They mustnot be completely removed.

The small cover in the casing slot has to be removed. You will see a radial hole intowhich you can insert a cylindrical rod and can now rotate the cam ring, the cam ringhas to be rotated to its stop in the arrow direction. There after rotate the ring backapprox. 0.1 mm (0.004"). Retighten the airgap screws rotate clutch brake pulley toensure brake is not binding. If it is increase airgap fractionally. Turn power on andcheck (P1) for over run.

ENCODER PLUG

ENCODER BALLSCREW TIMINGPULLEY

GRUB SCREWS

LOCK NUTS

CLUTCH BRAKEFig. 6.3.2 Warner Electric clutch brake


20

4.4 INDEX COUNTERPROBLEM/EFFECT CAUSE REMEDIES

Digits not changing onindex counter whentraversing.

Incorrect programming. Compare programming inindex counter withprogramming sheet. If incorrectturn off power, removeretaining screws in controlpanel and swing hinged paneldown carefully.Remove program disconnectlink and reposition controlpanel. Turn machine on andmake necessary changes,check counter is workingcorrectly.Turn off power replace disablelink and control panel screws.

Loose terminals. Turn off machine and checkterminal rails and wires areconnected on back of counter.

Faulty plug. Check plug on encoder, forbroken wires or wires shortingout.

Encoder faulty. Replace encoder, note whichend of the encoder is fitted intoballscrew. If incorrect indexcounter will count backwards.

Index counter faulty Replace

4.5 KNIFE GRINDING

PROBLEM/EFFECT CAUSE REMEDIESKnife vibrates when beingground leaving scallopededge on knife. Usuallyoccurs with large diameterknives.

• Loose knife spindlebearings

• Slightly raise or lowerknife RPM

• backing plate bent or nolonger concave

• Tighten knife spindlebearings

• loose grinding wheel ongrinder motor shaft

• replace backing plate

• tighten grinding wheel


21

4.6 PNEUMATIC CHUCK

4.6.1 PNEUMATIC CHUCK MK II

(see Fig. 7-7)

PROBLEM/EFFECT CAUSE REMEDIESPin holders not gripping orreleasing

• Low Air Pressure • Gripping pressure regulatormust be set to at least 2bar (30lbs/13.5kg)pressure.

One slide bar (pin holder)not moving.

• Low Air Pressure• Pin holder not fitted

correctly into slide bar.• No lubrication between

slide bar and wear strip.• Grit or rust between slide

bar and wear strip.

• As above.• Rectify

• See Lubrication Chart.

• Remove, clean andlubricate.

Pins disengaging frommaterial when machine isoperating.

• Air leading frompneumatic system

• Pressurise system andpaint all fitting in chuckpneumatic system withsoapy water and check forair bubble.


22

4.6.2 PNEUMATIC CHUCK MK I

PROBLEM/EFFECT CAUSE REMEDIESPin holders fail to operate inany direction

• Pneumatic coupling (24)not engaged

• No air supply topneumatic couplingports (24A)

• Air leakage in system• Main air supply pressure

setting too low• External pin holder

pressure regulatorsetting too low

• Operate pneumaticcoupling

• Check air supply

• Rectify leaks• Check and adjust

compressor switched on• Check and adjust supply

pressure

External pin holders do notdisengage

• Push rod bracket loosecylinder barrel

• Push rod disengagedfrom either push rodbracket or cam lockrelease ring

• Both cams are not beingdisengaged

• Adjust and tight

• Refit push rod

• Check push rod brackets(30) adjusted correctlyadjust cam screws. *Low air pressure

Pneumatic coupling doesnot disengage

• No air supply topneumatic couplingclamping cylinders

• Supply pressure toclamping cylinder portstoo low

• Air leakage in system

• Check air supply

• Check and adjust thecompressor switched on

• Rectify leaksChuck will not rotate • Pneumatic coupling

engaged• Disengage pneumatic

coupling. * Low airpressure

Pins do not engage with φ1.25" mandrel with pinholders on lowestadjustment hole

• Long sliding barsinstalled

• Shoulder screws locatedin incorrect holes at rearof sliding bars

• Fit short sliding bars

• Fit shoulder screws tocorrect holes

Pins do not accommodatelargest roll φ 16" 406 mmwith dogs at highestadjustment hole

• Short sliding barsinstalled

• Shoulder screw locatedin incorrect holes at rearof sliding bars

• Fit long sliding bars

• Fit shoulder screws tocorrect holes

Pins do not engagesimultaneously

• Pin holders not installedin common hole position

• Shoulder screws notinstalled in common holepositions

• Fit pin holders tocommon hole position

• Fit shoulder screws incorrect holes positions

Cause: L.E.D. switch on coupling cylinder incorrectly position *(L.E.D. light must be off).


23

4.7 MANDREL SUPPORT ARM

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibrates. • Worn pivot bush/pivot

shaft in mandrel supportarm.

• Replace shaft bushes.

Sideways movementbetween mandrel supportarm and mandrel supportarm bracket.

• Mis-adjustment ofcollars

• Adjust locking collars onpivot shaft against mandrelsupport arm bracket.

Knife not slitting throughcore and/or knife cuttinginto mandrel at one end ofmachine.

• Mandrel support notaligned parallel to knifecarriage.

• Raise mandrel support.• Traverse carriage to

extreme right.• Adjust forward knife stop

so that the knife justtouches mandrel.

• Traverse knife to theextreme left and moveknife forward to mandrel.

• Loosen grub screwslocking mandrel supportarm to pivot shaft andmove arm sideways so thatknife touches the mandrelfractionally harder than atthe other end of machine(0.1 mm or 0.004").

• Lock grub screws and re-check.

Air operated mandrelsupport in-operative

• Lack of air • Check air supply.

Air operated mandrelsupport operates too slowor too fast at end ofstroke.

• Cushion flow valveincorrectly adjusted.

• Adjust flow valves locatedon either end of aircylinder, turn clockwise toslow down, anti-clockwiseto increase speed. Valvescontrol air exhausting fromcylinder.


24

4.8 MANDRELS

4.8.1 NON ROTATING MANDREL

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibrates • ∅25.4 mm (∅1")

adaptor not fitted tomandrel support.

• Core I/D diameteroversize.

• Log roll tear dropped orbowed.

• Incorrect cutting speed.

• Incorrect knife fitted.

• Mandrel flexing.

• Sprays not working

• Fit nylon adaptor block.

• Use correct size cores.

• Rewind log

• Check operator referencesheet.


• Move mandrel support upthe bed of the machinetowards the chuck as far aspossible.

• See Lubricant spray troubleshooting

Rolls sticking on mandrel • Worn or rough fibrestrip.

• Poor quality cores.

• Replace fibre strip.

Rolls sticking together • Lubrication of knifeineffective.

• Incorrect knife.

• Increase flow of lubricantand/or add extra detergentto water.


Chuck spindle becomingwarm

• Lack of lubricationbetween mandrel andchuck spindle.

• Grease mandrel throughchuck.

• Remove mandrel andlubricate.

Knife not cutting throughcore towards centre partof log

• Knife Dull or mandrelFlexing or bowed

• Not enough dwell time

• Sharpen Knife to ensure itslits through the corecleanly. A knife with a dulledge can tend to push thecore away rather than slitthrough as the mandrelflexes at its centre point

Check Mandrel for straightness• Increase knife dwell time

Move mandrel support upthe bed of the machine asfar as possible.Slow mandrel speed


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4.8.2 ROTATING MANDREL

PROBLEM/EFFECT CAUSE REMEDIESMandrel vibration. • Worn mandrel sleeve.

• Core ID oversize.• Log roll out of round.• Knife forward stop not

set correctly.• Mandrel flexing.

• Replace sleeve.• Use correct core size.• Slow mandrel speed.• Set knife close to mandrel.

• Move mandrel support upthe bed of the machinetowards the chuck asmuch as possible.

Mandrel overheats orgrinding noises omits frombearings.

• Insufficient clearancebetween mandrelretaining locking collarand mandrel.

• Bearings dry.• Bearings worn.

• Adjust to give 1 mmclearance.

• Grease bearings.• Replace bearings.

Strands protruding frommandrel.

• Knife cutting too deep. • Adjust forward knife stop..

4.9 POLYCARBONITE GUARD

Machine will not operate unless the key mounted on the POLYCARBONITE GUARDis fully engaged into the switch (see Fig. 6-8).

If key fails to fully engage into switch when safety hood is lowered, loosen the switchmounting screws and move the switch up until the key is fully engaged.

Fig. 6-8 Polycarbonite Guard Key Switch

SAFETYSWITCH

POLYCARBONITEGUARD

GAS STRUT


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4.10 SPRAY SYSTEM

PROBLEM/EFFECT CAUSE REMEDIESSpray not working. • No air pressureor low

air pressure.• Knife must be moving

forward in a semi or automode.

• Flow valve (air control)closed off, open in an anti-clockwise direction.

Air but no water fromnozzle or intermittentspray.

• Water pick up tube notpushed into bottle.

• Water bottle empty.• Flow valve closed off.• Loose fitting or split

tubes.• Capillary tube blocked.

• Air pressure too highwill cause backpressure forcing waterout of system

• Filter missing or blockedin spray system waterbottle

• Push tube fully home.

• Fill bottle.• Open anti-clockwise.• Tighten fitting, check

tubing.• Remove tube from inlet

side of water supply flowvalve. Turn machine on.Block both spray nozzleswith your fingers. Airpressure will force anyobstruction out of thesystem. Replace watersupply tube and operateuntil spray works.

• Turn air pressure flow valveclockwise to reducepressure (air volume)

• Replace filterClean filter usingcompressed air.Clean water bottle

NOTE: Low grade detergents cause rust & can congeal and block tubes.Javelin has sourced a good quality lubricant which is now available

in 1 Litre containers from Javelin


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4.11 PNEUMATIC SYSTEM

PROBLEM/EFFECT CAUSE REMEDIESKnife jumps forward orknife cutting actionspongy

• Low oil level.• Air in system.• Loose Fittings/air or oil

line not sealing – checkfor air/oil leak (see notebelow).

• Check oil level.• Bleed system.• Tighten fitting.

Knife moves rapidly tomandrel

• Cutting speed flow valveopened too far.

• Low oil level• Air in system

• Turn flow valve clockwise toslow speed.

• Check oil level.• Bleed system.

Knife jumps forward whenslitting mode switch isturned from semi or autoposition to manualposition

• Solonoid valve 23opening bypass valve 17too quickly

• Fully close flow valve andthen adjust the valveapproximately 0.8 mm(1/32") on the circumferenceof the screw.

Knife and other aircontrolled functions slowor cease to operate.

• Low air pressure. • Check air pressure (700kpa).

Knife does not moveforward.

• Knob controlling forwardspeed of knife closed off.

• Faulty solenoid valve orelectrical fault.

• Turn anti-clockwise to open.

• Check.

REFER TO MAINTENANCE MANUAL FOR INFORMATION ON :1. CHECKING OIL LEVELS IN RESERVOIRS2. BLEEDING AIR FROM SYSTEM3. BLEEDING OIL FROM SYSTEM

NOTE: When replacing any section of tubing for air or oil take care that tubing is cutsquare otherwise there will not be a positive seal which will cause problems asdescribed above.


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4.12 ELECTRICAL SYSTEM

ELECTRICAL CONTROL SYSTEM

In order for the main system to be enabled:

• The main electrical panel isolate must be ON.• The motor overloads must be set (the motor overload indicator must be OFF.• The control panel emergency stop push button must be pulled out (red lamp

must be OFF.• The safety hood guard must be down with key switch engaged. (see Fig. 6-8)• The mandrel support must be raised.• Safety cage door to be closed.

MOTOR OVERLOAD

The motors are protected by overload setting located in the main electrical cabinet,in the following order:

Carriage Motor M1Grinder Motor M2Knife Motor M3Chuck Spindle Motor M4

PLC OPERATION

The programming function for this machine are contained on a Eeprom moduleinside the PLC unit.

All electrical equipment is controlled from this point its operation can be checked byusing the LED display located on the front of the unit.

ROLL COUNTER

To check display is operating correctly press the two buttons on the left hand side ofthe counter together.Ensure the dip. switch settings are as shown below:

SW 1 2 3 4 5* UP position

* * * * * DOWN position

CUTS PER GRIND COUNTER

This counter is the same as the roll counter and all the functions are the same asabove.


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INDEX COUNTER

The input for this counter is 360 pulse/revolution encoder located on the end of theballscrew, this counter has two preset values, preset #2 ‘P2’ which is the indexingdistance and preset #1 ‘P1’ which is the stop signal to the clutch/brake unit. Thisstop signal is a constant time to allow for the de-acceleration of the ballscrew.The counter has the ability to disable programming by connecting the "PGM.DIS"terminal to common and this link has to be removed before attempting to re-programthe counter.

Ensure that the dip. switch setting are as shown below:

SW 1 2 3 4 5* * UP position* * * * * DOWN position

ROLL COUNTER

The counter is set up for a timed output of 2.0 seconds as the counter reaches zero,and is automatically reset to the preset value after the timed output.

KNIFE DWELL TIMER

The Knife Dwell Timer is to ensure there is a timed stage at fully advanced knifeposition. After the timed stage is complete the carriage will retract via the retractsolenoid, called for the Knife Dwell Timer. The timer is to be set at 0-10 seconds.

AUTO GRIND TIMER

The Auto Grind Timer is to ensure that the operation of the Auto Grind Solenoid isonly for a pre-determined time. The timer is to be set at 0-1 minutes.

WIRING

All connections are to be checked for loose connections due to transport vibration.The supply cable for this machine is to be of a size to carry a load of 25 amp.The connection terminals are located towards the bottom left hand corner of themain electrical cabinet.


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KNIFE CARRIAGE FAILS TO TRAVERSE

1. Check carriage motor overload is contacted (refer to motor section).2. In ‘MANUAL’ mode, check that the carriage left and right push buttons are alight.

If not alight, then retract knife until they are. The lamps indicate that all safetyconditions for traversing are intact.

3. Carriage motor contactor operates but carriage fails to traverse. Check that theclutch/brake unit is operating correctly, if clutch/brake is OK then it should bepossible to turn the carriage ballscrew by hand when the brake disengages. If theclutch/brake is satisfactory then check that all motor connections are tight.

4. Carriage motor contact fails to operate, check the following:

• Green start lamp is ON.• PLC is in "RUN" mode.• Safety hood is down, and switch contact is closed.• Mandrel support is raised and indicating lamp is OFF.• Carriage left and right over travel switches are OK.• Safety cage door closed and switch making contact.• Carriage left and right limit switches are OK.• Opposite direction auxiliary contact has been released.

If all these conditions are correct it will mean the carriage motor contactor will needto be replaced.

KNIFE FAILS TO OPERATE

If the knife fails to operate, check that the following conditions have been met:

• Check knife motor overload is intact (refer to overload section).• Green lamp is ON.• Safety hood is down and switch contact is closed.• Mandrel support is raised and indicating lamp is OFF.• In DC version, check that both the fuses on the speed controller are OK.• If invertor is used check power on lamp, and that no fault lamps are on.• If all these conditions are correct it will mean the knife motor contact will need to

be replaced.

KNIFE FAILS TO ADVANCE

• Safety hood is down, and switch contact is closed.• Check that the knife advance limit switch is operating correctly.• Check the knife advance solenoid is operating correctly.

KNIFE FAILS TO RETRACT

• Safety hood is down and switch contact is closed.• Check that the knife retract limit switch is operating correctly.• Check that the knife retract solenoid is operating correctly.


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INDEX COUNTER FAILS TO COUNT

• Check that the index counter is programmed correctly (refer to index countersection).

• Check connection to shaft encoder at ballscrew.• Check connection terminal at the rear of the counter.

GRINDER FAILS TO OPERATE

• Knife must be allowed to start before grinder can operate.• Grinder dwell timer set to zero (refer to cut/grind section).• Carriage traverse lights must be illuminated.•

CARRIAGE FAILS TO AUTOMATICALLY RETURN LEFT WHEN RIGHT HANDSTOP IS CONTACTED

• Check that the carriage RETURN selector is in AUTO.• Check that the retract limit switch is OK.• Check that the carriage left limit switch and carriage left proximity switch are

operating correctly.• If over travel proximity switch has sensed carriage will not return.

CHUCK FAILS TO ROTATE

• Check that the hood is down.• Check that the mandrel support is raised.• The pneumatic chuck limit switch is closed.• Check operation of the hood contactor and chuck contactor.• If contactors are operating check condition of the motor.


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5 CONNECTING TO ELECTRICAL SUPPLY

Connect power to machine according to electrical diagrams supplied. (see Fig. 2-4)

DESCRIPTION STANDARD OPTIONALSupply voltage (Volts) 415 415 240 240Supply Current (Amps) 25 25 35 35

3 phase, Neutral Earth (5 wire) 3 phase, Neutral Earth (5 wire)Supply Frequency (Hz) 50 60 50 60

The supply cable for this machine is to be of a size to carry a load of 25 amp. Thevoltage required is 240/208 volt 3 phase or 415 volt 3 phase. Other voltages can besupplied by a transformer if required.

A supply connection is provided on the terminal strip in the main cabinet. Theterminals can be located by looking for the larger terminals at the left hand end ofthe terminal strip. These terminals are the only spare terminals and the out goingcables are red in colour and are not numbered.

The colour coding of the cables used within the machine is as follows :

COLOUR DESCRIPTIONRed, White, Blue L1, L2, L3 240/208 or 415 voltBlack 240 volt AC neutral (if required)Pink 24 volt DC activeGrey 24 volt DC neutralGreen/Yellow Earth conductor

All wires are to be checked for loose connections due to transport vibration.

Warning: Check rotation of all motors. Incorrect rotation can result in majordamage to this machine and void warranty.

Motor directions are as follows:

Chuck Spindle Motor: With the switch in the forward position, the chuck faceshould turn clockwise.

Grinder Motor: Looking at the grinding wheel, the motor should turn anti-clockwise.

Ballscrew Motor: The left and right push buttons determine the direction of themotor. If the left push button is pressed and the carriagemoves right, the motor needs to be reversed.


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Caution: At this point avoid contact between the carriage and the end of themachine. Major damage to the ballscrew can result if motor direction isincorrect.

Knife Motor: Looking at the knife, the knife should turn clockwise.

Check PLC unit has 24 volt DC power and that the unit is in the RUN mode. Theseoperations can be checked by looking at the LED display on the front of the PLCunit.

If any electrical problems occur consult the electrical trouble shooting section.

Fig. 5 Electrical Cabinet


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6 CONNECTING TO PNEUMATIC SUPPLY

The operating pressure of the system is approximately 700kpa (100lbs). This can bechecked at the gauge on the regulator at the end of the machine (see Fig. 2-5).Turning clockwise increases pressure.

The lubricator should be checked regularly and replenished with oil specified, whennecessary. see Section 5.1. The regulator should be drained of any water regularly.

Fig. 6 Air Service Unit


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Table of Contents

1. SPECIFICATION AND EQUIPMENT.............................................................................................................. 1

1.1 SPECIFICATION (J3000 UP TO & INCL. SN188) ............................................................................................. 1

2 MOVING AND/OR LEVELLING MACHINE .................................................................................................. 2

3. LUBRICATION & MAINTENANCE................................................................................................................ 3

3.1 LUBRICATION ................................................................................................................................................... 3DAILY MAINTENANCE ........................................................................................................................................ 3WEEKLY MAINTANCE ......................................................................................................................................... 4MONTHLY MAINTENANCE................................................................................................................................. 5SIX MONTHLY MAINTENANCE .......................................................................................................................... 6SIX MONTHLY (CONT.) ....................................................................................................................................... 7

3.2 MAINTENANCE ................................................................................................................................................. 83.2.1 AIR OVER OIL SYSTEM – J3000................................................................................................................. 83.2.1 AIR OVER OIL SYSTEM – J2000............................................................................................................... 103.2.2. MANDREL SLEEVE REPLACEMENT – EXPANDING MANDREL ........................................................ 123.2.3 FIBRE STRIP REPLACEMENT NON-ROTATING MANDREL - ............................................................. 133.2.4. ROTATING MANDREL - EXPANDING.................................................................................................... 13

4. TROUBLE SHOOTING .................................................................................................................................... 14

4.1 SLITTING TOLERANCES................................................................................................................................ 14a. CHECKING FOR KNIFE SPINDLE RUN OUT: ............................................................................................ 15b. CHECKING FOR BACKING PLATE RUNOUT:............................................................................................ 15c. CHECKING FOR KNIFE RUNOUT................................................................................................................ 16d. HOW TO TIGHTEN KNIFE SPINDLE BEARINGS:....................................................................................... 16e. PEDESTAL ALIGNMENT................................................................................................................................ 16f. ALIGN KNIFE PARALLEL TO CHUCK.......................................................................................................... 17

4.3 BALLSCREW DRIVE ....................................................................................................................................... 184.3.1 BALLSCREW AND NUT............................................................................................................................. 184.3.2 CLUTCH BRAKE UNIT.............................................................................................................................. 19

4.4 INDEX COUNTER ............................................................................................................................................ 204.5 KNIFE GRINDING ............................................................................................................................................ 204.6 PNEUMATIC CHUCK ...................................................................................................................................... 21

4.6.1 PNEUMATIC CHUCK MK II..................................................................................................................... 214.6.2 PNEUMATIC CHUCK MK I ...................................................................................................................... 22

4.7 MANDREL SUPPORT ARM............................................................................................................................. 234.8 MANDRELS ...................................................................................................................................................... 24

4.8.1 NON ROTATING MANDREL..................................................................................................................... 244.8.2 ROTATING MANDREL .............................................................................................................................. 25

4.9 POLYCARBONITE GUARD ............................................................................................................................ 254.10 SPRAY SYSTEM............................................................................................................................................. 264.11 PNEUMATIC SYSTEM................................................................................................................................... 274.12 ELECTRICAL SYSTEM.................................................................................................................................. 285 CONNECTING TO ELECTRICAL SUPPLY....................................................................................................... 326 CONNECTING TO PNEUMATIC SUPPLY........................................................................................................ 34

#j2000-j3000 maintenance front pg july 2016 · incl. some j2000/j2000-600 maintenance issues....

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