Table Of Contents. Introduction 3. Features and Specs 3-4. Standard Operating Guide 5-6. External Layout Internal Layout 36-46

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1 REV: 000 Freedom

2 Table Of Contents Introduction 3 Features and Specs 3-4 Standard Operating Guide 5-6 External Layout 7-35 Internal Layout Wiring/ Plumbing Diagrams F.A.Q Comprehensive Parts List

3 Introduction: The Freedom is the epitome of simple as it relates to screen printing. It s simple to set up, simple to operate, and simple to maintain. That said, The Freedom does not limit you to simple designs or small jobs. This machine turns any manual press operator into a mass producing printer. Freedom s fast indexing speed, simple to use controls and precise micro registration ensure that setups are as fast and easy as with your manual press. Add our patented Flashback to the Freedom and Workhorse has re-written the book on affordable high production while keeping it simple. Automating your manual shop gives you freedom from: long hours at the press, aching elbows and wrists, late deliveries, high labor costs, and the list goes on. Features and Specs: Power Options: 110v Single Phase, 50-60hz, 10 amps Air Requirements: 6-8: 120psi Construction: All steel construction. Polyurethane Airline Standard Print Size: 16 x 18 (41 x 46cm) Features: Fast squeegee and flood angle, pressure adjustment Double print stroke per screen for more opacity on dark garments Independent head control for easy job setup and registration Non-warping solid aluminum platen Double index, run two jobs simultaneously Adjustable print stroke Micro registration front & back for fast setups One knob quick change squeegee Precision milled Registration fork on every print head for exact registration Easy release platens Fast production rate - 60 doz./hr. Two year limited warranty 3

4 Dimensions: Freedom 6-8: 10.5ft (4m) Weight: Freedom 6-8: 2900lbs built 4

5 Standard Operating Guide: Print Head Selector Switch: Each print head has its own selection switch that is independent of all others and may be set in any one of the following positions; OFF - Single, Print Stroke & Double Stroke. During a print cycle those heads in the OFF position will remain at rest. The remaining head(s) will print after the pallet table has raised up, then upon completion the pallet table will lower and rotate to the next station while the flood stroke is occurring. If a double print stroke is required for any head(s), the pallet table will not rotate after lowering but will rise again in the same position for the second print cycle before continuing to the next station. 2. Manual Print Buttons: Each print head has its own numbered button, when one is depressed the pallet table will raise and the corresponding print head will print. The table will then lower but no table rotation will occur (used primarily to check registration). 3. Emergency Stop Button: When activated the air pump valve will cycle and release all air from the printer and cut power to all systems. (Note It is very important that the table be in alignment before reenergizing the emergency stop). 4. In Position Indicator: Before the press can begin any cycle or command the press must be in position meaning the correct sensors are reading for the command to begin. 5. Front/ Rear: Front Position; The squeegees will remain in the printed-rear position to leave the screen flooded for air dry inks. Rear Position; The squeegees will remain in the flood-front position to leave the screen opened and not flooded, used for most non air-dry inks such as plastisol. 6. Table Up/Down: In manual mode this will manually raise the table or lower the table, generally used during setup or registration. 7. Print On/ Off: If a squeegee requires service, the activation of this switch will release the air to the print cylinders so that the squeegee may be removed for cleaning, revised, replaced or to be able to adjust the squeegee angle and pressure adjustment. Flipping the switch to the original position will again supply air to the heads allowing operations to continue. 8. Sample: After registering a job it may be necessary to run a single sample to verify proper registration. Load test canvas, turn the sample on and the machine will print once on ever head that is turned on. 5

6 9. Begin/ End Production: Begin Production is used when first starting a production run. Engage Auto Start, then push Production Begin/End Button within 3 seconds. The pallet table will rotate and activate each head in turn as it proceeds around. When all heads have begun printing Auto Mode automatically begins. End Production: When finishing with a run, load your last shirt at Load On Station and push Production Begin/End Button. As the machine indexes, each head will deactivate in turn after printing and the machine will stop when the last shirt is completed. 10. Auto On/ Off: ON; Will start the printer into production run (flood, rotate and print). The table will begin rotation within 3 seconds of switching to Auto/On. Speed is controlled by the delay timer or the foot switch. OFF; In the manual stop position the table may be raised and lowered using the Table Up/Down Switch. The table can be rotated manually by hand. To print a desired head, select the number of the appropriate head and push that number switch. The table must be in the down position when printing a head. 11. Fuse: Used for circuit/ equipment protection if a fault occurs. For trouble shooting see question #1 in the FAQ section. 12. Power Indicator: Inline with the fuse above it, if a fault occurs blowing the fuse this light will be off. Under normal conditions this light will be on for the entire duration the press is on. 13. Main Power Switch: On Position: 110 Volt is supplied to the DC converter, computer and main air valve supplying air to the system. Off Position: Power is cut to main controls and air is released through main dump valve. (Note it is very important the table be in the proper alignment before energizing the main power switch). 14. Counter: Reset before each production run to keep track of the number of shirts printed. 15. Foot Pedal On/ Off: On position: To begin the production cycle, push the foot pedal down. When each print cycle is completed, the foot pedal must again be depressed in order for the cycle to start. Off Position: The delay Timer will energize and control the start of the next cycle. 16. Print Timer: This timer controls the time the pallets will remain in the up position while printing. Set the knob to the number that allows the slowest squeegee to complete its print stroke before the table lowers. 17. Delay Timer: After the print cycle is completed, the pallet table will lower and delay timer will be energized. Adjust the knob to the desired time for loading and unloading between print cycles. After the preset time is reached the table will rotate and begin the next print cycle. The delay timer is calculated in 1=1 sec. 18. Flood Timer: This timer controls the time the pallets will remain in the up position while printing. Set the knob to the number that allows the slowest squeegee to complete its print stroke before the table lowers. 6

7 Front Screen Hanger Micro Front Plate Part A Screen Clamp Part B Rear Screen Hanger Rear Screen Hanger Part C Screen Clamp Part B 7

8 Micro Adjustments (Left Side) Large Lever Part D Fitting Elbow Part E Fender Washer Part F Flange Nut Part I Micro Lock Cap Part J Knurled Knob Part G Micro Target Label Part H Micro Adjustments (Right Side) Large Lever Part D Flange Nut Part I Fitting Elbow Part E Fender Washer Part F Micro Lock Cap Part J Knurled Knob Part G Knurled Knob Part G Micro Target Label Part H 8

9 Micro Adjustments Disassembled (Front Screen Hanger Left Side) Hex Bolt Part K Flange Nut Part I Nylon Lock Nut Part L Micro Lock Cap Part J Close Up View (Picture Above) Micro Adjustments Disassembled (Front Screen Hanger Right Side) Flange Nut Part H Nylon Lock Nut Part L Flat Washer Part M Wave Washer Part N Micro Lock Cap Part J 9

10 Micro Adjustments (Front Screen Hanger Left Side) Jam Nut Spring Part O Part P Rod End (RH) Part Q Jam Nut Part O Wave Washer Part U Rod End (LH) Part T Hex Bolt Part R Knurled Knob Part G Hex Bolt Part S Micro Adjustments (Front Screen Hanger Right Side) Jam Nut Part O Wave Washer Part U Rod End (LH) Part T Jam Nut Spring Part O Part P Rod End (RH) Part Q Hex Bolt Part S Knurled Knob Part G Hex Bolt Part R 10

11 Micro Adjustments (Front Screen Hanger Left Side) Rod End (LH) Part T Hex Bolt Part S Micro Bottom Plate Part W Knurled Knob Part G Rod End (RH) Part Q Hex Bolt Part R Micro Top Plate Part V Hex Bolt Part X Micro Adjustments (Front Screen Hanger Right Side) Hex Bolt Part S Rod End (LH) Part T Hex Bolt Part S Rod End (LH) Part T Knurled Knob Part G Rod End (RH) Part Q Micro Bottom Plate Part W Hex Bolt Part X Micro Top Plate Part V Hex Bolt Part R 11

12 Micro Adjustments (Rear Screen Hanger Right Side) Flange Nut Part I Hex Bolt Part X Flange Nut Part Y U-Bracket Hex Bolt Part Z Part AA 4 Prong Knob Part AB Micro Adjustments (Front Screen Hanger Right Side) Bottom View U-Bracket Part Z Jam Nut Part AC Hex Bolt Part AA Spring Part AD 12

13 Micro Adjustments (Rear Screen Hanger Left Side) Lever Rear Screen Hanger Part AE Part C U-Bracket Stopper Part AF Flange Nut Flange Nut Hex Bolt Flange Nut Part I Part I Part X Part Y Part AG Micro Adjustments (Rear Screen Hanger, Left Side, Front View) Flange Nut Part I Hex Bolt Part X Flange Nut Part Y Shoulder Bolt Part AH Female Rod End Part AI 13

14 Print Head Control Panel (Top Half) Flow Plate Part AJ Plastic Snap Bushing Part AK Toggle Valve Part AL Toggle Valve Part AL 14

15 Print Head Control Panel (Bottom Half) Flow Plate Part AJ Flow Control Part AM Flow Control Part AM 15

16 Print Head Control Panel (Internal Top Half) Flow Plate Part AJ Branch Tee Part AN Fitting Elbow Part AP Toggle Valve Part AL Black Poly Air Line 1/4 Part AO Fitting Elbow Part AP Part AN Toggle Valve Part AL Print Head Control Panel (Internal Bottom Half) Flow Control Part AM Male Tube Fitting Part AQ Male Tube Fitting Part AQ 16

17 Front Screen Hanger Plate (View From Underneath) Socket Head Screw Part AR Micro Bottom Plate Part W Rear Stroke Stops, Squeegee Rail Lever Part AE Rear Screen Hanger Part C Lever Part AE Alum. Squeegee Track Part AT Squeegee Stop Part AS 17

18 Rear Screen Hanger Lever Part AE Rear Screen Hanger Part C Lever Part AE Rear Stroke Stop Lever Part AE Spring Part AU Squeegee Stop Part AS Spring Part AU Vinyl Cap Part AV Swivel Pad Part AW Lever Part AE 18

19 Squeegee Carriage Carriage Wheels Part AX Squeegee Carriage Part AY Stroke Cylinder (Mounted) Hex Bolt Part AZ Stroke Cyl. Mount Bracket Part BD Stroke Cyl. 20 Part BA Hose Clamp Part BB Fitting Elbow Compact Part BC 19

20 Stroke Cylinder to Squeegee, Shoulder Bolt Assy. Flat Washer Part M Female Rod End Part AI Spring Part BE Nylon Lock Nut Part BF Stroke Cylinder to Squeegee Carriage Mounting Shoulder Bolt Part EP Flat Washer Part M Female Rod End Part AI Spring Part BE 20

21 Assembled Squeegee carriage (Front View) Male Rod End Part BJ Flipper Block Part BG Squeegee Pin Part BH Angle Stop Barrel Part BI Flip Cylinder, Clevis and Spade Bolt Hex Nut Part BK Clevis Kit Part BL Spade Bolt Part BM Jam Nut Part BN 21

22 Flip Cylinder (View from Below) Fitting Elbow Compact Part BC Flip Cylinder Part BO Fitting Elbow Compact Part BC Flange Nut Part BP Hex Bolt Part BQ 22

23 Flipper Frame Assembled (Right View) 4 Prong Knob Part BU X-Large Lever Part BV Bronze Bushing Flanged Part BR Shoulder Bolt Part BS Squeegee Adj. Weldment Part BT Flipper Frame Assembled (Left View) Bronze Bushing Flanged Part BR Shoulder Bolt Part BS Squeegee Adj. Weldment Part BT Shoulder Bolt Part BS 23

24 Squeegee Pressure Assy. (Installed) 4 Prong Knob Part BU Male Rode End Part BJ X-Large Lever Part BV Sq. Pressure Adj. Assy. Part BW Squeegee Pressure Assy. 4 Prong Knob Part BU Male Rod End Part BJ Jam Nut Part BX Shoulder Bolt Part BY Sq. Pressure Adj. Assy. Part BW 24

25 Complete Control Box Lamp Part CD Control Panel Part CE Control Box (empty) Part CF 25

26 Complete Control Box (Left Half) Toggle Switch Part CI Button Switch Part CJ Button Switch Part CJ E-Stop Switch Part CG Lamp Part CH Toggle Switch Part CI Complete Control Box (Right Half) Potentiometer Part CK Toggle Switch Part CL Digital Counter Part CM Part CN Toggle Switch Part CL Lamp Part CH Fuse Holder Part CO 26

27 Complete Control Box (Rear View) Flange Bolt Part BZ Flat Washer Part CB Pan Head Screw Part CA Control Arm (Inner) Part CC 27

28 Table Up Switch Flat Washer Part CB Pan Head Screw Part CA Snap Action Switch Part CP Main Shaft Bushings Socket Head Screw Part CQ Hex Bolt Jam Nut Hex Nut Part CR Part BX Part CS Bearing Set (3) Part CT Socket Head Screw Part CQ 28

29 Wheel, and Print Arm Assembly Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU Flange Bolt Part CU 29

30 Registration Fork Flat Washer Part CV Flange Bolt Part CW Registration Fork Part CX Flat Washer Part CV Flange Bolt Part CW 30

31 Registration Fork, Cam Bearing (Rear View) Flange Bolt Part CW Flange Nut Part BP Flat Washer Part CV Flange Bolt Part CW Flat Washer Part CV Flange Nut Part BP Hex Nut Part CY Flat Washer Part CZ 31

32 Cam Bearing Assy. Square Head Bolt Part DA Square Head Bolt Part DA Jam Nut Part BX Jam Nut Part BX Registration Bearing Part DC Number Label (1-12) Part DB 32

33 Cam Bearing Assy. (To View of Arm) Square Head Bolt Part DA Square Head Bolt Part DA Jam Nut Part BX Jam Nut Part BX Vertical Mylar Ruler Part DD 33

34 Platen Bracket Hex Nut Part DE Hex Nut Part DE Hex Bolt Part DF Hex Bolt Part DF Flat Washer Part M Flat Washer Part M Hex Bolt Part DG Hex Bolt Part DG Cam Lever Left Part DH Cam Lever Right Part DI Flat Washer Part M Flat Washer Part M Hex Bolt Part DG Hex Bolt Part DG Cam Lever Left Part DH Cam Lever Right Part DI Flange Nut Part BP 34

35 Platen Bracket (Side View) Flat Washer Part M Nylon Lock Nut Part DC Flange Nut Part BP Flat Washer Part M Flange Nut Part BP Flange Nut Part BP Flat Washer Part M Hex Bolt Part DF Hex Bolt Part DF 35

36 Communication Switch, Dummy Plug (Installed) Flat Washer Part CB Pan Head Screw Part CA Communicator Bracket Part DK Communicator Plug Part DJ Snap Action Switch Part CP Communicator Plug Part DJ 36

37 Table Up Switch Flat Washer Part CB Pan Head Screw Part CA Snap Action Switch Part CP In Location Switch (Installed) Snap Action Switch Part CP Pan Head Screw Part CA Flat Washer Part CB 37

38 Index Cylinder, Clevis (Installed) Index Cylinder Flow Controls (Installed) Black Air Line 3/8 Part DO Red Air Line 3/8 Part DP Fitting Elbow Part DL Index Cylinder Part DM Clevis Kit Part DN Male Connector Part DQ Index Cylinder Rear Mount, Fork, and All thread (Installed) Flow Control Part AM Male Connector Part DQ Part DM All Thread Part DR Hex Nut Part CY Rear Index Clevis Part DS Index Cyl. Rear Mount Part DT Fitting Elbow Part DL 38

39 Index Block (Installed) Socket Head Screw Part DU Socket Head Screw Part DU Index Fork Part DV Index Block Mount Plate/ Hardware (Installed) Nylon Lock Nut Part DW Nylon Lock Nut Part DW 39

40 Index Shock (Installed) Lift Cylinder (Installed) Index Shock Part DX Fitting Elbow Part DL Lift Cylinder Part DY Connect- Part DZ 40

41 Index Block Cylinder, Clevis (Installed) Index Cylinder Part DM Fitting Elbow Part DL Clevis Kit Part BL Fitting Elbow Part E Flip Cylinder Part BO Fitting Elbow Part E Red Air line 1/4 Part EA Black Air Line 1/4 Part EB 41

42 Index Block Cylinder, (Lower Mounting Hardware, Installed) Fitting Elbow Part E Flange Bolt Part CU Flange Nut Part CU Hex Bolt Part EC 42

43 Male Connector Part DQ Muffler Part EE Valve Single Part ED Muffler Part EE Male Connector Part DQ Muffler Part EE Flow Control 1/4 Part EF Flow Control 3/8 Part EG 43

44 Dump Valve (Installed) Dump Valve Part EH Male Connector Part DZ Male Connector Part DZ Muffler Part EI Power Supply (Installed) Power Supply Part EJ 44

45 PLC (BNR Box, Installed) Complete PLC Part EK Prog. Memory Card Part EA 45

46 Main Air Assy. (Installed) Fitting Elbow Part BC Male Connector Part DQ LockOut Valve Part EM Filter/ Regulator Part EN Secondary Filter Part EO 46

47 WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. All service should be done by or under the supervision of a trained technician Javelin Control Box, Non Touch Screen: 47

48 48

49 50 Wire Cable, Wiring: 49

50 50

51 51

52 7/10 Stack Wiring: 52

53 Head Plumbing/ Wiring: 53

54 Screen Clamp Plumbing: 54

55 Flip Cylinder Plumbing: 55

56 Print Arm Plumbing: 56

57 FAQ: WARNING! RISK OF ELECTRICAL SHOCK! Turn ALL power to unit OFF before service. All service should be done by or under the supervision of a trained technician 1. My Freedom will not turn on. If there is no air, the press will give the appearance that there is no power, but actually there is no air. Turn the Main Power switch on. The emergency stop button should be in the out position, on newer machines the light should be off when it is set correctly Make sure the safety cable is plugged in correctly Make sure the power cable is plugged in, you can check that the machine has power by turning the registration lamp on Image 1 Check the fuse to the left of the power switch Check the Fuse at the power supply on earlier models, Located in the base, attached to the frame. If all of these things are good we can begin to trouble shoot. Start with bypassing the safety cable for the first test. On newer machines you will need to pull the flow plate off the top of the print arm and find the connection point for the cables. Use wire nuts and connect the wires together this will close the circuit. If this fixes the problem you will need to figure out what is wrong with the cables, on older machines the safety cable makes the main connection near the center of the machine. You will need to pull the hole plugs off the top of the print arms and pull the wires through, remove the blue wire nuts and twist the wires together. Early Style Power Supply Output Image 3 Current Style Power Supply Input Input output If this does not correct the problem will need to get a digital volt meter. Using a digital Volt/Ohm meter in the ACV setting ( ) verify there is 110 volts AC going to into the power supply. If the power supply is getting the correct input voltage next check for 24VDC coming on the out of the power supply. If the correct voltage is coming from the power supply we need to go the PLC where the connections are and see if we have 24vdc there, On older Javelins the -24vdc is connected direct to the PLC and the +24 vdc goes through safety circuit. On javelin pro the +24vdc is connected direct to PLC and the -24 vdc goes through safety circuit. 57

58 2. The Press tables up but will not print. The normal sequence for this process is the table raises then just sits there waiting to print and nothing happens until you turn the power off. Then you start all over and it still just sits there again. The machine will not print if the table up sensor (Image 4) is not making a connection to the PLC, on older javelins and on Freedoms this sensor will register under green lights #1 This is in the first bank of Green lights in the E16A The input is #1 to the PLC (Image 5) showing it has made Contact and it is ok to begin the print stroke. Image 4 Image 5 On either PLC if the connections are not being made, the table up switch will need to be adjusted or replaced. With machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (omega symbol Ω) to test the switch for continuity place one probe on COM terminal of the switch and the other probe on the NO terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. 3. Table will not lower after printing This normally only on older Javelins and Freedoms, After the Press has made the print stroke the PLC is looking for the print timer to finish, once this happens it sends a input to the input labeled 0 in the E16A (Image 6) if the #2 yellow light is on under the A12C this is output to the print timer. If that light is still on your print timer has not cycled. Image 6 58

59 3. (Continued) You should open the control box and make sure the connections are secure at the timer and the speed pot. If all the connections look good will need to get a VOM and check for the 24vdc going to the timer and through the timer back to base. On the orange power lamp, there are 2 purple wires one is the -24vdc leg this is normally connected with a White blue red wire. Expose this connection by removing the blue wire nut. Then with the machine still in the middle of the cycle we can to see if there is +24vdc going to the delay timer and coming out of the timer. If this all test good then we need to test the wire that comes from the timer and runs to the input #0 under the E16A If it test bad we can switch the timer around with one of the other timers in the control box, I would use the delay timer so we are able to get past the flood time with a manual stroke. If this still does not correct your problem or at least move it the it is most likely a bad wire 4. My Freedom will not table up Depending on the command we give the machine will direct us on where to start trouble shooting. Say we hit manual print and the squeegee does not move it just sits there and the press does nothing, then we should check that the press is in location and that the PLC is showing location light is on. Freedom s and older Javelin will have Green light #2 on under the E16A. If the sensor is not made the machine will not perform. Image 7 Say we hit the manual print and the squeegee moves forward and then the table just sits there, then we should then check if we turn the machine off and back on will it table up? If so, then we need to check on the PLC is the orange light #1 on and the flood timer not timing out? This will be on older javelins and Freedoms. If the light is on then the flood timer has not cycled, and we need to diagnose the flood timer and see if we have a loose connection. You should open the control box and make sure the connections are secure at the timer and the speed pot. If all the connections look good will need to get a VOM and check for the 24vdc going to the timer and through the timer back to base. On the orange power lamp, there are 2 purple wires one is the -24vdc leg this is normally connected with a White blue red wire. Expose this connection by removing the blue wire nut. Then with the machine still in the middle of the cycle we can to see if there is +24vdc going to the Flood timer and coming out of the timer. If this all test good then we need to test the wire that comes from the timer and runs to the input #0 under the E16A Another Scenario is you just hit table up and nothing happens machine will do other functions but just will not table up, Then we start looking at other items for example Flashbacks on the machine interfering with the output, first step is to check the simplest thing. Are the air supplies turned on to the flashbacks, if not turn them on as this allows the element tray to drift forward. 59

60 Are all the Flashback cables plugged in and Dummy plug in the last Flashback? If this is correct is the #5 orange light on? If yes at this point put the dummy plug in to the base of the machine and then try to table up again if this corrects the problem then we know it is somewhere in the flashbacks if not then we need to go directly to the valve and check it for 24vdc. If the valve has 24vdc then we have a bad valve. If the Dummy plug in the base solved the problem we need to go to the Flashback trouble shooting for more in depth testing of the Flashbacks. Refer to the Flashback Tech Guide for further testing. 5. The press will not print. Press tables up then just sits there until you turn the power off. When the machine raises it hits a switch that then sends a signal to a PLC that the table is up. If the switch is not making contact, the machine will not finish it needs the switch to continue on. Normally just lowering the switch or fixing a loose connection will cure the problem however you may need to change the switch if it is damaged or covered in spray adhesive. On some machines it is in between the #3 and #4 print heads on others it is in front of the on Load and un-load stations. With the machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (Upside down omega symbol) to test the switch for continuity place one probe on COM terminal of the switch and the other probe on the NO terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. 6. My machine spins before I am ready for it to. This requires you to add more Delay time, turn the delay time up for longer flash times especially if your using Flashback. You can also turn the foot pedal on and step on the pedal when ready for the machine to turn 7. The Press tables down before completing the print. Adjust the print timer on the control box to a higher number to increase print dwell time. Pull the base panel off the press an locate the PLC. With the press powered on, and the pallet table down check the PLC for green light 1.1 If the 1.1 light is on the table up switch is stuck in the on position. Check the condition of the switch and replace if required. With machine off locate the table up switch, note the location of the current position of the black and white wires, remove the wires. Next using a digital Volt/Ohm meter in the resistance setting (omega symbol Ω) to test the switch for continuity place one probe on COM terminal of the switch and the other probe on the NO terminal. With the probes in place depress the switch, the meter should have a low reading or produce a beep, if the meter reads zero or does not produce a beep the switch will need to be replaced. 60

61 7. (Continued) If the switch is functioning properly a simple adjustment may be needed. To adjust the switch, with your thumb on the base of the tab where it connects to the switch body, bend the tab down towards the floor just enough that it makes adequate contact with surface of the carousel when the press tables up. Adjust as needed until press functions properly. (Older Javelins) If the switch is working properly, you may have a defective print timer. Locate the print timer inside the control box by following the two wires from the print timer control to the print timer. Replace the print timer. The print timer may be timing out early also from static discharge and it may need to be grounded out with a resistor to drain any left over power in the line. See wiring diagrams section for resistor wiring specs. 8. The Squeegee s Flip to hard or not fast enough When the squeegee flips it is controlled by the flip valve it the valve is set to fast it can cause the squeegee to snap over to fast slinging the ink forward (make sure print head is not running to fast forward causing the ink to fly forward) Adjust the flow controls on the flip valve to make squeegee flip at a controlled speed, by turning clockwise it will slow the flip. Counter clock wise will speed it up To test the flipping motion put the machine in automatic with 2 strokes and make sure the flip is fast enough on the table down after the first print stroke and when the table raises for second print stroke. Remember though that the motion does not need to be super fast, nice and controlled motion is ideal. 61

62 9. The Squeegee s lose pressure before completing the print stroke. This condition is usually a defective flip cylinder. It is usually worse on one head, but can affect other heads as well. You may hear an unusual flow of air. The head with a defective flip cylinder may not even be one of the heads you are using, but it can still affect other heads ability to hold pressure. If you can hear air leaking when you have the print toggle switch in the on position we will need to find what is causing the leak. A weak cylinder can cause loss of pressure on a print stroke excessive pressure can cause it and ink that is really thick will give the same result as well. Printing with white ink is usually the biggest culprit for loss of pressure if this is the case we need to make sure the ink has been mixed really well before adding it to the screen. If a leak has been heard we need to check the flip cylinders to see if one or two are causing a exhaust of air. The reason for this is all the flip cylinders are branched together off the same valve and one being bad can cause issues at all the others. The best way to test is to raise the tables with the print on and if you have excessive air loss turn the print off and see if that stops the leak of air. If it does, turn the print back on and see if it continues to leak. If it does not, lower the tables and then raise the tables again. At this point if it begins to leak air start by kinking the red and black airlines that come out of the top of the flow plates and wrap with masking tape. Until you stop the leak, then open the airlines one at a time and see which one causes the leak keeping in mind more than one could be bad. Once you have found the bad cylinder it will need to be replaced. You could have a weak cylinder also and you can test for a weak one by just putting a ¾ wrench on the flip block and rotate the block back and forth and compare the weak ones with heads that are printing well you may see some variance in the pressure from head to head using your best judgment on which one is stronger you will want to change the weaker cylinder. It is not a bad idea to change out all flip cylinders at one time when pressure problems arise. If you had a leak with the print on and table up and you kinked all the airlines at every head and left them taped and the leak continued you may have a bad air valve that needs replacing. Locate the flip valve and kink the red and black coming off the top of it and see if that does not stop the leak before deciding to replace the valve. 10. The heads flood but will not print. This condition usually indicates a defective stroke cylinder. While this head is hung in the flooded position, after other heads have completed there print stroke. You will usually here air leaking. If you hear air leaking, turn both flow controls on top of the print head all the way clockwise. if this stops the air leak you more than likely have a defective stroke cylinder and will need to replace it. But you may also have a valve that is causing it and the easiest method to test that is move airlines blue and green from valve with bad head to valve with good head remembering to open the flow controls that we had closed previously if the problem stays on the effected head it is a bad cylinder, but if the problem then moves to a different head it is a bad valve. If you do not hear any airflow when the print head is hung in the flooded position after all other heads have finished printing and table has come down. You may have a stuck valve and you can test this also by moving the airlines from known working head and the bad one and if you do move the problem you will know for sure the valve is bad. You may also be able to add to tool oil into the valve and get it to function, this may loosen the valve up and keep it running to get through a job. But this is not a permanent fix the valve will need to be replaced 62

63 Freedom indexer is jumping out of capture block: When the machine cycles its stopping point is the index shock. If the press is jumping past the stopping point the vertical cylinder that holds the capture block to the bottom of the pallet arm may have come loose or the speed of the indexer is set to fast. When the vertical cylinder is mounted to the angle iron of the capture arm assembly it will normally cut in to the powder and you will see a gap in between the bottom bolt and the mounting bolt of the cylinder. This needs to be adjusted so the cylinder can pull the capture block to the pallet arm where the block has a good hold on it. Once this has been adjusted cycle the machine a couple of times to test If the speed has been set to fast adjust the flow control on the red airline of the horizontal cylinder by screwing it in and then test the machine by cycling it 63

64 Freedom index adjustments: The speed of the index is controlled by adjusting the flow control with red air lines located under the index cylinder. The flow control with black air lines controls the speed at which the indexer retracts to start position. The shock absorber catches the indexer and brings it to a stop. The shock absorber should be set to #2. If the shock absorber is in good working order this setting will work. Adjust the flow control with the red air lines, located under the index cylinder. Clockwise to slow the index down, and counter clockwise to speed it up. Let the press run a few indexes then re-adjust so that the pallet table comes to nice stop. If you cannot get the pallet table to stop correctly after the above steps, make a slight adjustment to the index shock setting. Going below a setting of #2 will make the shock stiffer, and going above #2 will make to shock softer. 64

65 Index Shock Adjustment: The type 1 shock has a scale engraved on the ring at the end of the shock. This ring butts against the threaded body of the shock where there is a dimple indicating the setting of the shock. When the table indexes the shock should be adjusted to bring the table to a stop, bottoming out all the way without shaking. If the shock is to stiff it will not compress enough on impact causing registration problems the same issues can occur if the shock is set to soft as well as damage to the press. The shock is very sensitive to change, adjust with caution moving is fractions between the numbers. The lower the number the stiffer the shock gets. Note: the number indicated in the picture above does NOT reflect what the shock setting is on each press. Always consult a trained Workhorse products technician before any adjustments are made. 65

66 Comprehensive Parts List. Description P/N Description P/N A. Front Micro Assembly SA-0060 AG. Kep Nut (1/4-20) 42-KEPS B. Screen Clamp I-0003 C. Rear Screen Clamp Hanger T-0210 D. Large Lever (5/16-18 THD) K-0006 E. Fitting Elbow 5/32T X 1/8 NPT F. Fender Washer 43-FND G. Knurled Knob SA-0103 H. Micro Target Label I. Flange Nut 42-FLG J. Micro Lock Cap I-0514 K. Hex Bolt (5/16-18 x 2) 41-HTB L. Nylon Lock Nut 42-NYL M. Flat Washer 43-FLT N. Wave Washer 43-WAV-M8-10 O. Jam Nut 42-JAM P. Spring Q. Rod End (RH) I-0265 R. Hex Bolt (3/8-16 x 1.5) 41-HB S. Shoulder Bolt T-1977 T. Rod End, (LH) I-0266 U. Wave Washer 43-WAV V. Screen Clamp Cylinder A-0119 W. Screen Clamp Cylinder Foot F-0106Z X. Hex Bolt (1/2-13 x 3") 41-HTB Y. Flange Nut 42-FLG Z. U-Bracket Weldment WA-0128 AA. Hex Bolt (1/4-20 x 1) 41-HTB AB. 4 Prong Knob (5/16-24 THD) K-0002 AC. Jam Nut 42-JAM AD. Spring M-0319 AE Lever ( 5/16-18 x 1-9/16 STD) K-0005 AF. U-Bracket, Stopper I-0302 AH. Shoulder Bolt (5/16 x 1.75 ) 41-SB AI. Female Rod End (5/16-24) B-0004 AJ. Flow Plate I-0139-SCR AK. Plastic Snap Bushing 1" F-0154 AL. Toggle Valve AM. Flow Control A-0971 AN. Branch Tee (5/32 T x 10-32) A-0003 AO. Black Poly Air Line (5/32) PER FT A-0301 AP. Fitting Elbow (10-32 NPT x 5/32TUBE ) AQ. Male Tube Fitting (1/4 x 1/4) A-0032 AR. Button Head Screw (5/16-18 X 1) 41-BHCS AS. Squeegee Stop Assy. SA-0025 AT. Aluminum Squeegee Track T-0167 AU. Spring, Squeegee Stop M-0045 AV. Vinyl Cap F-0904 AW. Swivel Pad F-0902 AX. Squeegee Carriage Wheel B-0101 AY. Squeegee Carriage WA-0153 AZ. Hex Bolt (1/4-20 x 1/2 ) 41-HB BA. Stroke Cylinder 20" A-0140 BB. Hose Clamp A-0910 BC. Fitting Elbow Compact (1/4 T x 1/8) A-0015 BD. Stroke Cylinder Mount I-0294 BE. Spring, Stroke Cylinder M-0402 BF. Nylon Lock Nut 42-NYL BG. Flipper Block T-0201 BH. Squeegee Pin SA-0004 BI. Squeegee Angle Stop Barrel T-0095 BJ. Male Rod End (1/2-20) B-0006 BK. Hex Nut 42-HEX BL. Clevis Kit A

67 Comprehensive Parts List. Description P/N Description P/N BO. Flip Cylinder A-0102 CU. Flange Bolt (3/8-16 x 3/4) 41-FLG BP. Flange Nut 42-FLG BQ. Hex Bolt (3/8-16 x 4) 42-HB BR. Bronze Bushing, Flanged (3/8) B-0022 BS. Shoulder Bolt (3/8 x 3/4) 41-SB BT. Squeegee Angle Adj. Weldment WA-0101 CV. Flat Washer 43-FLT CW. Flange Bolt (3/8-16 x 1 1/2) 41-FLG CX. Registration Fork T-0059 CY. Hex Nut 42-HEX CZ. Flat Washer 43-FLT BU. 4 Prong Knob (1/2-20 THD) K-0017 DA. Hex Bolt Square Head (5/16-18 x 2) 41-SQH BV. X-Large Lever (3/8-16 THD) K-0014 BW. Squeegee Pressure Adj. Assy. SA-0005 BX. Jam Nut 42-JAM BY. Shoulder Bolt T-0913 BZ. Flange Bolt (5/16-18 x 1) 41-FLG CA. Flat Washer 43-FLT-8-10 CB Pan Head Screw (#6-32 x 1-1/4) 41-PHMS-6-50 CC. Control Arm (Inner) WA-0129 CD. Lamp DB. Number Label (1-12) (1-12) DC. Registration Bearing B-0012 DD. Vertical Mylar Ruler DE. Hex Nut 42-HEX DF. Hex Bolt (3/8-16 x 2-1/2) 41-HTB DG. Hex Bolt (5/16-18 x 2) 41-HB DH. Cam Lever, Left DI. Cam Lever, Right DJ. Harness, Communicator Cable CE Control Panel (Empty) I-0017-SCR DK. Communicator Bracket CF. Control Box (Empty) WA-0089 CG. Illuminated E-stop Switch CH. Lamp E-0901 CI. Toggle Switch (sp/st) E-0106 CJ. Button Switch, Red E-0991 CK. Potentiometer (110k ohm) E CL. Toggle Switch (sp/dt) E-0901 CM. Digital Counter E-0903 CN. ON/OFF Switch Main E-0104 CO. Fuse Holder, Panel Mount E-0912 CP. Snap Action Switch E-0982 DL. Fitting, Elbow, Male (3/8t x 3/8 npt) DM. Index Cylinder A-0104 DN. Clevis Kit A-0905 DO. Black Poly Air Line (3/8) A-0056 DP. Red Poly Air Line (3/8) A-0306 DQ. Male Connector (3/8 x 1/4p) A-0022 DR. All Thread T-0904 DS. Rear Index Clevis A-0904 DT. Index Cylinder Rear Mount A-0902 DU. Socket Head Screw(3/8-16x1-1/4) 41-SHCS DV. Index Fork T-2035 CQ. Socket Head Screw (3/8-16 x 1-1/2) 41-SHCS DW. Nylon Lock Nut 42-NYL CR. Hex Bolt (5/16 x 2) 41-HTB CS. Hex Nut 42-hex CT. Bearing Set (3pcs) I-0523 DX. Index Shock A-0962 DY. Lift Cylinder A-0106 DZ. Connector Male(3/8t x 3/8npt) A

68 Comprehensive Parts List. Description P/N Description P/N EA. Red Poly Air line (1/4) A-0054 EB. Black Poly Air line (1/4) A-0055 EC. Hex Bolt (3/8-16 x 2) 41-HTB ED. Valve Single A EF. Flow Control Fitting (1/4) A-0042 EG. Flow Control Fitting (3/8) A-0043 EH. Dump Valve A-0210 EI. Muffler (3/8) A-0031 EJ. Power Supply EK. Complete PLC E-0241 EL. Programmed Memory Card E-0059-P EM. Lockout Valve A-0097 EN. Filter Regulator, 1/2 gauge A-0143 EO. Secondary Filter A-0142 EP. Knob K-0008 EQ. Hex Nut 42-HEX ER. All Thread T-0915 ES. All Thread T-0901 ET. Hex Nut 42-HEX EU. Flow Control (Old Style) A-0201 EV. Pem Stud 44-FH EW. Lock Washer 43-LOK EX. Hex Nut 43-HEX EY. E-Clip F-0957 EZ. Shoulder Bolt 41-SB FA. Disc Washer 43-DIS

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