BATTERY - POWERED PLASTIC STRAPPING TOOL MODEL P Manual for authorized dealers and service points

Transcription

1 SERVICE MANUAL BATTERY - POWERED PLASTIC STRAPPING TOOL MODEL P Manual for authorized dealers and service points P sen/MAS/

2 INDEX PAGE 1 SERVICE MANUAL P CHART OF TYPES ACCESSORIES Battery Battery chargers Battery tester Charger for car batteries Battery light TECHNICAL DETAILS Electric schematic Connecting plan Strap tension CONVERSION PARTS Conversion parts: strap width Conversion parts: strap thickness PERIODIC MAINTENANCE AND CONTROL Procedure Troubleshooting Battery test Checklist Glueing rules Lubrication rules Assembly informations RECOMMENDED SPARE PARTS ACCESSORY TOOLS USE OF ACCESSORY TOOLS ORDERING SPARE PARTS Ordering manuals Ordering address Finding out of the tool type (item number), the serial number and the version number: SERVICE ADDRESS

3 1 SERVICE MANUAL P CHART OF TYPES Item no. Model Strap width Strap thickness P321/12.7/ mm / 1/2" mm / " P321/13/ mm mm / " P321/16/ mm / 5/8" mm / " P321/19/ mm / 3/4" mm / " P321/19/ mm / 3/4" mm / " 1.2 ACCESSORIES Battery Use only original Fromm batteries N V / 2.4Ah for the P321 tool. In case of a damaged battery housing, it can be ordered separately under item no. N Battery chargers The battery charger must be separately ordered according to the table mentioned below. Item-No. Voltage / frequency Admitted for country N V / 50-60Hz A, B, BG, BIH, BOL, BR, BY, CH, CL, CZ, D, DK, DZ, E, EAS, EST, ET, F, FIN, GE, GR, H, HK, HR, I, IL, IND, IR, IRQ, IS, JOR, KSA, KWT, L, LAR, LT, LV, MA, MC, MK, MOC, N, NL, P, PK, PE, PL, PRC, PY, RA, RCH, RI, RL, RO, ROK, ROU, RP, RUS, S, SK, SLO, SYR, THA, TN, TR, UA, UAE, YU, YV, (Z), (ZA), (ZW) N V / 50-60Hz BRN, BRU, CY, EAK, EAT, GB, IRL, M, MAL, OM, SGP, Y N V / 50Hz GB N V / 50-60Hz AUS, NZ N V / 50-60Hz BR, C, CDN, CO, CR, DOM, EC, GCA, J, JA, KSA, LB, MEX, NIC, PA, Puerto Rico, RC, RP, USA, YV Battery tester For testing the batteries order battery tester N Charger for car batteries The charger N must be ordered for connection to a car battery with 12 or 24V Battery light For completely discharging of the battery the battery light N can be used. 1-3

4 1.3 TECHNICAL DETAILS Electric schematic Connecting plan red point red point Tensioning motor red red point red black white red white black Welding motor Strap tension The tension force values mentioned in the P321 operation manual ( N) are not achievable with each strap. They depend on following factors: Hardness of the package, the maximum tension force values are achievable with hard packages. Elongation and creep properties of the plastic strap, the maximum tension force values are achievable by using plastic straps with a low elongation. Surface quality of the plastic strap, the maximum tension force values are achievable with waxed and embossed straps. Strap width, strap thickness, the maximum tension force values are achievable with the thick and the wide straps. 1-4

5 1.4 CONVERSION PARTS When changing strap thickness or strap width following parts must be exchanged Conversion parts: strap width 12.7mm 13mm 16mm 19mm Guide pin P P P P Guide pin P P P P Strap stop P P P P Strap guide P P P P Guide case P P P P Conversion parts: strap thickness mm mm Steel insert P P Tensioning wheel P P Gripper P P Gripper P P Gripper P P Attention! When converting tools always change the item number on the type label Replace following parts: Type label N x hammer head bolts N Enclose the suitable operation manual with the tool after each conversion (see paragraph Ordering manuals) 1-5

6 1.5 PERIODIC MAINTENANCE AND CONTROL (Carry out 12- months cycles doing one shift work. Doing more shift work respectively often.) Procedure Before using check tool for following possible faults: Visual test of the tool for loose, lost or damaged parts Clean all dirty parts of the tool, especially strap abrasion in the tensioning or the welding unit by using compressed air. (Never use any hard tools like a wire brush or a screw driver for cleaning) Carry out a test strapping and check following: Strap feed and strap tensioning Tensioning force adjustment (see operation manual P321) Cutting of the upper strap Welding time adjustment (see operation manual P321) Welding pressure adjustment (see operation manual P321) Seal quality (see operation manual P321) Function of the LED - display Insertion of the strap Proceed according to paragraph after a fault appears. Attention! Remove battery from tool before each maintenance work. For exchange of wearing parts see operation Manual P321. Never use water or solvents for cleaning the tool s surface. 1-6

7 1.5.2 Troubleshooting Ensure before each tool repair that the battery is charged and the tool s specific strap is used SYMPTOM CAUSE REMEDY Tool doesn t work at all Battery is empty or defective Charge or replace battery Contact problems caused by a broken battery housing N Contact problems caused by a damaged connecting plate P or damaged motor housing P and P Defective busbar P /14 Contact problem of the internal wires Defective circuit board Replace battery housing Replace connecting plate or motor housing Replace busbar Check contacts and fix them if required or change defective parts Replace circuit board Tool doesn t tension Tensioning wheel is dirty or worn Clean tensioning wheel with compressed air or replace it Tensioning wheel turns back immediately after the tensioning cycle Faulty tensioning wheel or tensioning wheel is assembled reversed Grippers are dirty, worn or faulty assembled Gearing parts from the tensioning gear are defective Loose pinion on P Loose pinion on tensioning motor Defective tensioning motor Defective circuit board Micro switch N for tensioning motor is defective Contact problem of the internal wires Defective gear bearings Defective tensioning body Needle free wheeling assembled reversed Shaft P in lever P is loose Defective needle free wheeling N Wheel P is defective or not meshing with P Correct assembling Replace grippers, clean them with compressed air or assemble correct Check tensioning gear and replace defect parts Replace tensioning motor Replace circuit board Replace micro switch Check contacts and fix them if required or change defective parts Replace bearings Replace tensioning body Correct assembling Check parts and replace as required 1-7

8 SYMPTOM CAUSE REMEDY Tool doesn t weld Tool badly cuts the strap or doesn t cut at all Tool switches off after a few strappings (Displaying empty battery) Faulty adjustment of the welding pressure Welding gripper is dirty or worn Welding stop gripper P is dirty or worn Damaged housing parts Defective circuit board Defective welding motor Defective cup springs N Loose pinion P on welding motor Gearing parts of the welding gear are defective Micro switch N for welding motor is defective Defective busbar P Contact problem of the internal wires Defective gear bearing Cutter is worn or damaged Faulty adjustment of the coupler P Welding gripper is worn Welding time too short Defective pressure spring N Faulty adjustment of the welding pressure or battery is defective Correct adjusting (see Operation Manual P321) Replace or clean welding gripper by using compressed air Replace or clean welding stop gripper by using compressed air Replace housing parts Replace circuit board Replace welding motor Replace cup springs Replace pinion Check welding gear and replace defect parts Replace micro switch Replace busbar Check contacts and fix them if required or change defective parts Replace bearing Replace cutter Check adjustment and readjust if necessary (see operation manual P321) Replace welding gripper Change adjustment (see operation manual P321) Replace pressure spring Correct adjusting (see Operation Manual P321) Check battery and replace as required Gear noise Tensioning or welding gear is worn Check component parts and replace defect one s Battery test The battery should be checked while each maintenance by using the battery tester N The use is described in the instruction manual of the battery tester. Replace batteries (2.4Ah) with a capacity lower than 80% (1,9 Ah). 1-8

9 1.5.4 Checklist Carry out some test strappings and check following tool components. Insert battery in the tool and check function of the LED-display (see operation manual P321) Strap feed and strap tension Tension force adjustment (see operation manual P321) Cutting of the upper strap Welding time adjustment (see operation manual P321) Welding pressure adjustment (see operation manual P321) Seal quality (see operation manual P321) Function of the LED-display (see operation manual P321) Inserting of the strap Correct type label Glueing rules Following parts have to be glued with LOCTITE 603: Planet shaft P with the parallel pins N Tensioning body P with the parallel pins N Body P with swivel shaft P and parallel pins N

10 Additional the screws N have to be glued with the planet shaft P using LOCTITE 222. Don t clamp the planet shaft on the pinion while loosening or tightening the screws N Clamp here Lubrication rules All gear parts have to be lubricated with MOLYKOTE BR 2 PLUS grease. Lubrication interval: While each maintenance or after 12 months at the latest. All bearing parts of the welding unit have to be cleaned and lubricated with Klüber Isoflex Alltime SL2 grease while each maintenance. Lubrication interval: While each maintenance or after 12 months at the latest. Bearing welding unit All other parts have to be greased due to the explosion drawing. Lubrication interval: While each maintenance 1-10

11 1.5.7 Assembly informations Pay attention to the correct position of the torsional stops while fitting the welding motor (see illustration). Torsional stops Welding motor Motor support Pay attention to the assembling direction of the needle free wheeling N The sense of rotation is stamped in the front of the free wheeling. N Pay attention to the direction of the teeths while assembling the grippers into the tensioning body. (look at the picture) P Grippers 1-11

12 1.6 RECOMMENDED SPARE PARTS Following spare parts are recommended for stock keeping: Item-No. Description Pieces per tool N Screw 2 N Flat head screw 4 N Flat head screw 2 N Flat head screw 1 N Flat head screw 1 N Flat head screw 6 N Washer 5 N Washer 10 N Washer 4 N PT-screw 4 N PT-screw 4 N Circlip 1 N Circlip 1 N Circlip 5 N Spring ring 1 N Tensioning ring 1 N Ball 6 N Ball 1 N Micro switch 2 N Housing 1 P Welding motor 1 P Tensioning motor 1 P Motor housing 1 P Lever 1 P Motor housing 1 P Connecting plate 1 P Motor cover 1 P Body 1 P Circuit board 1 P End cover 1 Besides schould be stocked the wearing parts of the different Types. Stock only parts from tools that are in sale. 1-12

13 1.7 ACCESSORY TOOLS Item number Description N Press in and press out pressure pad N3.3189/P (already included in the P300 tool set) N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * N * Press in and press out arbor for N3.4509/P Press in and press out pressure pad for N3.4509/P Press in and press out arbor for N3.1159/P Press in and press out pressure pad for N3.1159/P Press in arbor for N3.2347/P Press out arbor for N3.2347/P Press in and press out pressure pad for N3.2347/P Press in arbor for N3.1134, P /P Press out arbor N3.1134, P /P ; N5.1129/P Pressure pad for N3.1134, P /P ; N3.2350/P Press in arbor for N3.3150/P Press in arbor for N3.3189/P Press in and press out arbor for N3.3173/P ; P , N3.1158, P /N Press out arbor for N3.3173/P Distance sleeve for N3.1158, P , P /N5.1129; P /N Press in and press out pressure pad for N3.1158, P , P /N Press out pressure pad for P /N5.1129; P /N Press in arbor for P /N Press in and press out pressure pad for P /N Press out arbor for N3.1158, P , P /N Distance sleeve for N3.1158, P , P /N N Press in and press out arbor for N3.1157/P N Press in and press out pressure pad for N3.1157/P N Press in and press out arbor for N3.2350/P N Press in and press out arbor N3.3172/P ; N3.3150/P ; N3.3189/P N Press in and press out pressure pad for N3.3173/P ; N3.3150/P * These accessory tools are alredy included in the tool set for the Battery Plastic Strapping Tool P

14 1.8 USE OF ACCESSORY TOOLS Accessory tools should only be used with the suitable arbor press N to prevent a jam of the parts have to be pressed in. Additional a retainer (N7.3215) is necessary. N N Part Disassembly Assembly N3.1157/ P N N P N N3.1159/ P N N P N

15 Part Disassembly Assembly N3.2350/ P N N N P N3.2347/ P N N N P N N3.3189/ P N N N P N

16 Part Disassembly Assembly N3.3172/ P N N P N3.3150/ P N N N N P N3.3173/ P N N N P N

17 Part Disassembly Assembly N3.4509/ P N N3.4509* P N *Pay attention to the assembling direction see paragraph N5.1129/ P / N3.1158/ P N N N N P N P N N N N N5.1129/ P N N N P N N N

18 Part Disassembly Assembly P / N3.1134/ P N N P N N P

19 1.9 ORDERING SPARE PARTS On principle spare part numbers should be taken from the drawings or spare parts lists. Check if the version number of the tool and the spare parts list are the same. Type dependent spare parts should be ordered as follows: Ordering example Ordering a tensioning wheel: Take item numbers of the tensioning wheel from drawing (P /29) Find out the tool type in which the tensioning wheel should be assembled (e.g ) Find out the item number of the needed tensioning wheel by using the type dependent spare parts lists (for type it is tensioning wheel P ). Order as follows if 10 tensioning wheels are needed: P Tensioning wheel 10 pcs Ordering manuals When converting tools make sure that the used manual has still validity. If tools change their item number because of the conversion (see chart of types) the adequate manual must be ordered as follows. Ordering example: Tool item number: Version number: 02 Language of the manual: de The manual order for this tool must look as follows: de If the manual is needed in another language replace the shorthand expression "de" (see table) Ordering address Spare parts and manuals can be ordered at: de en fr it nl po se sf sp ru German English French Italian Dutch Portuguese Swedish Finnish Spanish Russian Fromm Holding AG Tel.: +41(0) Hinterbergstrasse 26 Fax: +41(0) CH-6330 Cham hold.ch@fromm-pack.com Switzerland Finding out of the tool type (item number), the serial number and the version number: Type label P321 Item number Serial number Version number {

20 1.10 SERVICE ADDRESS You will get further assistance and information at: Post address Physical address: Fromm System GmbH Fromm System GmbH Technical customer support Technical customer support Postfach Neulandstr. 10 D Achern D Achern Germany Germany Phone: +49(0)7841 / Fax: +49(0)7841 / de@fromm-pack.com 1-20

21 2 DRAWING P A N P N P P P N (N5.4318) P P N P N P N N N N N N P P P P P P P B P P P N P N N (P ) P P N P P N Œ N N N P C N D P N P N N N P P N N P P P N P P P P N N P P P N P N Œ N N P P N P Ž P Ž P Ž N N N x N Ž P N Œ N Ž P N N N N N P Ž P P N N Ž N3.1703Ž N P N P P P P N N Ž (N3.3174) N N P N P Ž P Ž P N N N P /58/61* P P (N5.2322) (N1.7206) N P P N (P ) P /33/35* P /64/67* N N (N5.2322) (N1.7206) P P P P P N N P N P N P N N N P P N P P N P N E P P /06* P en.za4 P N N P Ž P Ž Œ P P N N P N N N N P P P Œ N N2.2189Œ N N P /21* P /20* P /19* N N P N P /23/34/36* P /29* N N N N N P /43/46/1724* N P N P N N N N N N N Œ Loctite 603 Loctite 222 Ž ESSO Beacon 2 Molykote BR 2 plus Klueber Isoflex Alltime SL2 Klueber Isoflex NBU 15 * see 1.9 Ordering spare parts 2-1

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23 SPARE PARTS LIST P SPARE PARTS LIST P Type independent spare parts [ ] = Group * = Wearing part P Item-No. in group Pcs. Description Dimension Field N SCREW M4 X 7.8 D3 N P SCREW M3 X 10 C4 N P HEXAGON SCREW M4 X 8 C5 N FLAT HEAD SCREW M5 X 20 D7+ N FLAT HEAD SCREW M3 X 5 E3+ N P FLAT HEAD SCREW M4 X 8 D5 N FLAT HEAD SCREW M4 X 20 E6 N FLAT HEAD SCREW M5 X 50 D7 N P FLAT HEAD SCREW M4 X 50 A4+ N P COUNTERSUNK SCREW M4 X 10 C1 N COUNTERSUNK SCREW M3 X 8 E4+ N P WASHER 12 X 16 X 2 C5 N P SPRING LOCK WASHER M4 D5 N P SPACER WASHER 10 X 16 X 0.5 B5 N P SUPPORTING DISK 8 X 14 X 1.2 C2 N P SPACER WASHER 6 X 12 X 0.5 B6+ N SAFETY WASHER M5 D6+ N SAFETY WASHER M4 D3+ N P SAFETY WASHER M4 B3+ N P SAFETY WASHER M4 C5 N SAFETY WASHER M3 E3 N P SAFETY WASHER M3 C4 N P PT-SCREW 2.2 X 10 C5+ N P PT-SCREW 3 X 40 A1+ N P PT-SCREW 3 X 14 A4+ N P PARALLEL PIN 5 h6 X 40 D3 N P PARALLEL PIN 3 m6 X 8 E5 N P SECURITY RING E8 C2 N SECURITY RING E6 C7 N SECURITY RING E5 C5 N P SECURITY RING E5 C5+ N SPRING RING SW6 A3 N P SPRING RING C1 N P TENSIONING RING 4 MM C1 N P PARALLEL PIN 4 m6 X 10 D3 N P PARALLEL PIN 4 h6 X 18 C2 N P PARALLEL PIN 3 m6 X 6 D4 N P PARALLEL PIN 3 m6 X 5 E3+ N P PARALLEL PIN 6 h6 X 18 B7 N PARALLEL PIN 3 m6 X 32 C5 N P DOWEL PIN 4 X 15 MM B3 N P DOWEL PIN 2.5 X 16 B1 N P FEATHER KEY 2 X 2 X 10 E2 N HAMMER HEAD BOLT 1.85 X 4.76 B3+ N P PRESSURE SPRING 0.5 X 4 X 16 D4 N P PRESSURE SPRING 0,6 X 4,8 X 20 C3 N PRESSURE SPRING 0.32X2.82X20.5 D5 N P PRESSURE SPRING 0.5 X 4.50 X / 28.5 C3 3-1

24 SPARE PARTS LIST P P Item-No. in group Pcs. Description Dimension Field N P PRESSURE SPRING 0.9 X 15 X 59.7 / 7.5 C5 N PRESSURE SPRING 0.8 X 4.8 X 25 / 18.5 D5 N P CUP SPRING 15 X 8.2 X 0.7 C3 N P TORSION SPRING 1,25/11 D1 N TORSION SPRING 2,8/59 E4 N P BALL BEARING C6 N P BALL BEARING C7 N P BALL BEARING D2 N P BALL BEARING B6 N P BALL BEARING B7 N P BALL BEARING C1 N BALL BEARING E4+ N P BALL BEARING C1 N P BALL 4 MM C4 N P BALL 5 MM D4 N P NEEDLE CAGE C2 N NEEDLE CAGE 5 X 9 X 13 D4 N P NEEDLE BUSH C6 N P NEEDLE CASE 6 X 10 X 9 D5 N P INNER RACEWAY D4 N P SLIDE-BEARING E3 N P SLIDE-BEARING E2 N P SLIDE-BEARING D4 N P SLIDE-BEARING C5 N P SLIDE-BEARING C2 N P NEEDLE FREE WHEELING D1 N ADHESIVE LABEL D6 N TYPE PLATE <<P321>> B4 N P ADHESIVE LABEL 14.4 VOLT A5+ N ADHESIVE LABEL 54 X 12 X 0.1 A5 N LABEL <<CE>> E6 N P ELECTRIC MOTOR B7 N P ELECTRIC MOTOR A2 N P MICRO SWITCH C5+ N COVER B3 [N5.4309] 1 BATTERY A6 N N HOUSING A6 N P O-RING B7 N P O-RING A3 [P ] P ENERGY TRANSMISSION A7 [P ] P WELDING MOTOR A7 [P ] P SPRING PACKAGE B3 [P ] P WHEEL B1 [P ] 1 TENSIONING BODY E3 [P ] 1 END COVER D6 [P ] 1 BASE MODEL A5 [P ] P TENSIONING MOTOR A3 [P ] P SPUR WHEEL B1 [P ] P IDLER STEP C2 P P FELT C3+ P P COUPLER D2 P P SHAFT D2 [ ] = Group * = Wearing part 3-2

25 SPARE PARTS LIST P P Item-No. in group Pcs. Description Dimension Field P P CARTRIDGE C3 P P SWITCH ROCKER C2 P P MOTOR HOUSING C7 P P PINION C7 P P BALL CAGE C4 P P BOLT D4 P P THRUST PIECE C4 P P SPRING BOLT C3 P P SPRING SLIDE B3 P P DRIVING PIN C4 P P LEVER D5 P P DRIVER D4+ P P SPUR WHEEL B6 P P SHAFT B2 P P CAM B2 P P IDLER GEAR C2 P P COVER C1 P P WHEEL C1 P P FRONT TOGGLE LINK E2 P P LEVER D1 P P STANCHION C1 [P ] P MOTOR HOUSING A5 P P RETAINER C5 P P TURNING BUTTON B5 P P MOTOR SUPPORT A7 [P ] P BUSBAR A6 [P ] P BUSBAR A6 [P ] P BUSBAR A6 P P CONNECTING PLATE A7 P P PINION B6 P P FELT WASHER B7 P P TORSIONAL STOP B7 P P TORSIONAL STOP A3 P P RUBBER BUSHING A7 P P RUBBER BUSHING B2 P P INSERT A1 P P MOTOR COVER A1 P P PLUG SOCKET B6 P CENTERING SLEEVE D4 P COVER D6 [P ] 1 HANDLE LEVER B6 P HANDLE SHAFT A4 P PRESSURE ROLLER E2 P HOLDER E3 P HOLDER E3 P SEESAW LEVER D6 P SEESAW LEVER C5 P P COUPLER C5 P P SWIVEL SHAFT E3 P P ROCKER C6 P * P WELDING GRIPPER D4 P P ECCENTRIC SHAFT D5 [ ] = Group * = Wearing part 3-3

26 SPARE PARTS LIST P P Item-No. in group Pcs. Description Dimension Field P P COVER C4 [P ] P BODY D2 P P BODY D2 [P ] P PLANET SHAFT C2 [P ] P RATCHET WHEEL C1 P P SPUR WHEEL D1 P P SPUR WHEEL B1 P P PINION A3 [P ] P CIRCUIT BOARD B6 [P ] 1 COUPLER C5 P P THRUST PIECE C5 P P TENSIONING BODY E3 P * 1 WELDING STOP GRIPPER E1 P * 1 CUTTER D5 P CENTERING SLEEVE D6 P DOWEL E4 P P END COVER D6 P IDLER GEAR D3 [P ] P WELDING EXCENTRIC C7 P P WELDING EXCENTRIC C6 P P ROCKER C6 [ ] = Group * = Wearing part 3-4

27 SPARE PARTS LIST P Type dependent spare parts P Type P321/12.7/ P Item-No. in group Pcs. Description Dimension Field P GUIDE PIN D5 P STRAP GUIDE E5 P STEEL INSERT E1 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 TENSIONING WHEEL E5 P GUIDE CASE D5 P STRAP STOP E4 Type P321/13/ P Item-No. in group Pcs. Description Dimension Field P GUIDE PIN D5 P STRAP GUIDE E5 P STEEL INSERT E1 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 TENSIONING WHEEL E5 P GUIDE CASE D5 P STRAP STOP E4 Type P321/16/ P Item-No. in group Pcs. Description Dimension Field P GUIDE PIN D5 P GUIDE PIN D5 P STRAP GUIDE E5 P STEEL INSERT E1 P GUIDE CASE D5 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P STRAP STOP E4 P * 1 TENSIONING WHEEL E5 [ ] = Group * = Wearing part 3-5

28 SPARE PARTS LIST P Type P321/19/ P Item-No. in group Pcs. Description Dimension Field P GUIDE PIN D5 P GUIDE PIN D5 P STEEL INSERT E1 P GUIDE CASE D5 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P STRAP STOP E4 P STRAP GUIDE E5 P * 1 TENSIONING WHEEL E5 Type P321/19/ P Item-No. in group Pcs. Description Dimension Field P GUIDE PIN D5 P GUIDE PIN D5 P STEEL INSERT E1 P GUIDE CASE D5 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P * 1 GRIPPER E4 P STRAP STOP E4 P STRAP GUIDE E5 P * 1 TENSIONING WHEEL E5 [ ] = Group * = Wearing part 3-6