GERBER S91 Users Manual PDF

S-91 GERBERcutter
OPERATOR AND MAINTENANCE MANUAL

Copyright  1998 by Gerber Garment Technology, Inc. All rights reserved.
This document may not be reproduced by any means, in whole or in part, without the
written permission of the copyright owner.
This document is part of the proprietary articles furnished to document Gerber Garment
Technology’s S91 GERBERcutter®.
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1. The information contained herein is given in confidence and any part thereof shall not
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COMMAND, G (stylized logo), GGT, GERBER BRISTLE SQUARE, GERBERcutter,
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24 Industrial Park Road West
Tolland, CT 06084 USA
Printed in USA 2/98

Document Number 083878000
i
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What’s Inside ............................................................................................................................................. ix
Conventions .............................................................................................................................................x
Product Support ..................................................................................................................................... xi
Safety Precautions.................................................................................................................................... xiii
1 S91 GERBERcutters
Available Models ........................................................................................................................................ 1
Traveling Conveyorized (TCW) ............................................................................................................. 1
Static ....................................................................................................................................................... 2
Zoned Valve Conveyor (ZVC)................................................................................................................ 2
Major Subsystems ....................................................................................................................................... 3
C200 Controller ...................................................................................................................................... 3
Cutting Table .......................................................................................................................................... 3
Cutter Head and Beam Assembly........................................................................................................ 4
Work Surface ...................................................................................................................................... 5
Vacuum Assembly .............................................................................................................................. 6
Limit Switches .................................................................................................................................... 7
Operator Controls ................................................................................................................................... 7
Emergency Stop .................................................................................................................................. 8
Circuit Breakers ................................................................................................................................ 10
Platform and Conveyor Controls....................................................................................................... 11
Beam Control Panel .......................................................................................................................... 13
Operator Workstation............................................................................................................................ 15
Options.................................................................................................................................................. 16
Spare Cutter Head (Without Covers) ................................................................................................ 16
Spare Sharpener Assembly................................................................................................................ 16
Right Side Option.............................................................................................................................. 17
Electric Drills .................................................................................................................................... 17
CTOT................................................................................................................................................ 17
Cutter Info Database (CIDB) ............................................................................................................ 18
POWER Processor ............................................................................................................................ 18
2 Basic Concepts
Direction and Location.............................................................................................................................. 19
Ends and Sides ...................................................................................................................................... 19
X, Y, and C–Axes ................................................................................................................................. 20
Origin ........................................................................................................................................................ 21
Bite Feeding.............................................................................................................................................. 23
Software and Files..................................................................................................................................... 25
Software ................................................................................................................................................ 25
Cut File ................................................................................................................................................. 25
Setup ..................................................................................................................................................... 25
3 Cutting Markers
Spreading Material.................................................................................................................................... 28
Basic Cutting............................................................................................................................................. 29
Turning on the Cutter............................................................................................................................ 30
Enabling Servo Power........................................................................................................................... 31
Initializing the Cutter ............................................................................................................................ 32
Positioning the First Bite....................................................................................................................... 33
On TCW and ZVC Systems .............................................................................................................. 33
iii
On Static Systems.............................................................................................................................. 33
Selecting a Setup ................................................................................................................................... 35
Opening a Marker.................................................................................................................................. 36
Turning on the Vacuum......................................................................................................................... 37
Turning on the Laser Light.................................................................................................................... 37
Setting the Marker Origin...................................................................................................................... 38
Selecting Cutting Speed ........................................................................................................................ 39
Turning on the Knife Motor .................................................................................................................. 39
Processing a Marker .............................................................................................................................. 40
Exiting the Program............................................................................................................................... 41
Beyond the Basics ..................................................................................................................................... 42
Using Fabric Alignment ........................................................................................................................ 42
Using Pause Between Bites ................................................................................................................... 43
Using Check Origin............................................................................................................................... 43
Using X Data Scale Factor, Y Data Scale Factor .................................................................................. 44
Using Move To Origin .......................................................................................................................... 44
Using Trim Cut...................................................................................................................................... 45
Recovery from Interrupted Cutting ........................................................................................................... 46
Before Using Recovery Commands .................................................................................................. 46
Using Restore State ............................................................................................................................... 47
Restoring State Manually .................................................................................................................. 48
Using Piece Search................................................................................................................................ 49
Using Piece Recut ................................................................................................................................. 49
Using Restore Origin............................................................................................................................. 50
Using Bite Search.................................................................................................................................. 50
4 Utilities
Parameter Manager ................................................................................................................................... 52
Access Levels by Password................................................................................................................... 52
Parameters and Categories .................................................................................................................... 52
Run Time Biting........................................................................................................................................ 54
Static Length Biting............................................................................................................................... 54
Variable Length Biting.......................................................................................................................... 54
PreProcessor.............................................................................................................................................. 55
Reorder.................................................................................................................................................. 55
Common Line........................................................................................................................................ 55
Path Optimization.................................................................................................................................. 55
View Marker ............................................................................................................................................. 56
Selecting Pieces..................................................................................................................................... 56
Tool Code Reference......................................................................................................................... 56
Playing Back a Marker .......................................................................................................................... 56
Animate ............................................................................................................................................. 56
Piece by Piece ................................................................................................................................... 56
Segment by Segment ......................................................................................................................... 56
Queue Manager ......................................................................................................................................... 57
Job Queues ............................................................................................................................................ 57
Defaults for Queue Manager ................................................................................................................. 57
File Manager ............................................................................................................................................. 58
Directories and Files.............................................................................................................................. 58
Using Paths to Locate Files ............................................................................................................... 58
Using Wild Cards to Locate Files ..................................................................................................... 59
Locking File Manager ........................................................................................................................... 59
Cutter Information Database (CIDB) ........................................................................................................ 60
iv
Marker Report Types ............................................................................................................................ 60
Partial Marker Report ....................................................................................................................... 60
Marker Reports ................................................................................................................................. 61
Shift Reports ..................................................................................................................................... 61
5 Optimizing Cutter Performance
Sharpening and Replacing the Knife......................................................................................................... 63
Automatic Sharpening........................................................................................................................... 64
Sharpening When the Cutter is Idle ...................................................................................................... 64
Resetting for New Knife ....................................................................................................................... 65
Setting Knife Speeds............................................................................................................................. 66
Using Knife Intelligence ........................................................................................................................... 67
KI Settings ............................................................................................................................................ 67
Nulling Knife Intelligence Sensor......................................................................................................... 67
Using Path Intelligence ............................................................................................................................. 69
Path Intelligence Diagnostics ................................................................................................................ 69
Controlling Vacuum Levels ...................................................................................................................... 70
Energy Savings Mode ........................................................................................................................... 70
6 Maintenance
Safety Precautions............................................................................................................................. 72
Maintenance Procedures ........................................................................................................................... 73
Basics ................................................................................................................................................ 73
Advanced .......................................................................................................................................... 73
Electrical ........................................................................................................................................... 73
General Maintenance ............................................................................................................................ 74
Cleaning ............................................................................................................................................ 74
Lubrication........................................................................................................................................ 74
Ordering Spare Parts ............................................................................................................................. 74
Tools Available from GGT ................................................................................................................... 75
Additional Tools ............................................................................................................................... 75
S91 TCW Illustrations .......................................................................................................................... 76
S91 Static Illustrations .......................................................................................................................... 77
S91 ZVC Illustrations ........................................................................................................................... 77
Maintenance Summary and Schedule........................................................................................................ 79
8 Hour Maintenance Schedule .............................................................................................................. 79
40 Hour Maintenance Schedule ............................................................................................................ 85
160 Hour Maintenance Schedule .......................................................................................................... 91
960 Hour Maintenance Schedule .......................................................................................................... 97
Cutter Head ............................................................................................................................................. 103
Cover................................................................................................................................................... 103
Knife Drive Train................................................................................................................................ 104
Knife ................................................................................................................................................... 106
Sharpener Assembly............................................................................................................................ 107
Knife Guides and Offset...................................................................................................................... 109
Knife Guides ................................................................................................................................... 109
Knife Offset..................................................................................................................................... 110
Elevator............................................................................................................................................... 112
Elevator Guide Rods ....................................................................................................................... 112
Air Cylinder Rod............................................................................................................................. 112
Head Stops ...................................................................................................................................... 112
C–axis Drive ....................................................................................................................................... 113

Servo Gear ...................................................................................................................................... 113
Drive Belt........................................................................................................................................ 113
v
Knife Drive.......................................................................................................................................... 113
Tension and Pivot Arm Oil Cups .................................................................................................... 113
Knife Drive Gearing and Belts ........................................................................................................ 114
Knife Drive Motor........................................................................................................................... 115
Knife Speed..................................................................................................................................... 115
Electric Drill............................................................................................................................................ 116
Drill Bit ............................................................................................................................................... 116
Drill Assembly .................................................................................................................................... 118
Air Cylinder..................................................................................................................................... 118
Drive Belt ........................................................................................................................................ 118
Drive Motor..................................................................................................................................... 119
Drill Speed ...................................................................................................................................... 119
Beam ....................................................................................................................................................... 121
Roundway and Squareway .................................................................................................................. 121
Covers ................................................................................................................................................. 122
Basic X–axis and Y–axis..................................................................................................................... 122
Servo Motor Gearing....................................................................................................................... 123
Servo Pinion Gearing and Torque Tube Belts................................................................................. 123
Y–axis Countershaft Gear ............................................................................................................... 124
Wheel Housing Cam Rollers ........................................................................................................... 125
Wheel Assemblies ........................................................................................................................... 125
Bite Encoder.................................................................................................................................... 125
Advanced X–axis and Y–axis ............................................................................................................. 126
Roundway Bearings......................................................................................................................... 126
Squareway Bearings ........................................................................................................................ 126
Spring Scale Tests ........................................................................................................................... 127
Y–axis Drive Belt Tension .............................................................................................................. 128
Squaring the Beam .......................................................................................................................... 129
Table ....................................................................................................................................................... 130
Work Surface ...................................................................................................................................... 130
Work Surface Cleaner ......................................................................................................................... 132
Gear Box ......................................................................................................................................... 132
Pillow Block Bearings..................................................................................................................... 132
Roundways and Racks......................................................................................................................... 133
Roundways ...................................................................................................................................... 133
Racks ............................................................................................................................................... 133
Filters .................................................................................................................................................. 134
Vacuum Filter.................................................................................................................................. 134
Stack Filter ...................................................................................................................................... 134
Air/Reducer Filter ........................................................................................................................... 135
Vacuum Assembly............................................................................................................................... 135
Cover............................................................................................................................................... 135
Motor and Generator ....................................................................................................................... 136
Drive Belt Tensioning ..................................................................................................................... 136
Coupling Alignment ........................................................................................................................ 137
Material Handling Systems ................................................................................................................. 138
Clamp Bar ....................................................................................................................................... 138
Resealer ........................................................................................................................................... 138
Conveyor Drive Gear Box............................................................................................................... 139
Conveyor Drive ............................................................................................................................... 139
Lay Puller Gear Box........................................................................................................................ 139
Lay Puller Drive .............................................................................................................................. 140
Platform............................................................................................................................................... 141
vi
7 Troubleshooting
Product Support .............................................................................................................................. 143
Error Messages ....................................................................................................................................... 144
Class 1 FEP Errors.............................................................................................................................. 145
Class 1 MCC Errors ............................................................................................................................ 146
Class 2 Errors...................................................................................................................................... 147
Class 3 Errors...................................................................................................................................... 148
Class 4 Errors...................................................................................................................................... 148
Diagnostics.............................................................................................................................................. 149
Selecting Diagnostics ...................................................................................................................... 151
Input Output Test (DG 23).................................................................................................................. 151
KI Calibration (DG 20)....................................................................................................................... 152
C Home to System Zero Diagnostic.................................................................................................... 154
Cut Tests ............................................................................................................................................. 155
Beam Square Test ............................................................................................................................... 156
Heel to Heel Test ................................................................................................................................ 157
Knife Offset Setup .............................................................................................................................. 158
Training (CBT) ....................................................................................................................................... 159
Service Parts ........................................................................................................................................... 159
CAM Applications .................................................................................................................................. 160
Automated Cutting Concepts .............................................................................................................. 160
Data Preparation ............................................................................................................................. 161
Vacuum Hold Down ....................................................................................................................... 162
Knife Sharpening ............................................................................................................................ 162
Motion Control................................................................................................................................ 162
Glossary ............................................................................................................163
Appendix ...........................................................................................................169
vii
viii
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This manual contains information on using the S91 GERBERcutter. It includes
the following chapters:
Safety Precautions
This introductory chapter details safety precautions you must follow when
operating the S91 GERBERcutter. Read this section before you start cutting.
Chapter 1 S91 GERBERcutters

This chapter provides an overview of the three models of S91 GERBERcutters,
including major components and optional equipment.
Chapter 2 Basic Concepts

This chapter discusses basic ideas you need to understand in order to use this
automated cutting system.
Chapter 3 Cutting Markers

This chapter describes the basic steps required to start up the system, cut a marker
or cut file, and shut down the system. Recovery procedures are also covered.
Chapter 4 Utilities
This chapter introduces utilities in the C200MT program that help you manage cut
files and utilize the multitasking capabilities of the program.
Chapter 5 Optimizing Cutter Performance

This chapter covers how to quickly access settings in the C200MT program that
optimize GERBERcutter performance for the current cut file.
Chapter 6 Maintenance
This chapter covers preventative and corrective maintenance procedures for S91
GERBERcutters. Included are maintenance schedules of procedures that GGT
recommends be performed regularly after 8, 40, 160, and 960 hours of operation.
What’s Inside ix
Chapter 7 Troubleshooting
This chapter suggests several ways to obtain help if you ever experience
GERBERcutter performance that is less than expected. Error messages,
diagnostics, and other support and application information are covered briefly.
Glossary
The Glossary lists terms you need to know.
Index
The Index provides an alphabetical listing of topics of interest in this manual.
Conventions
The following conventions are used throughout this manual:
Bold type highlights important information in the text.
Italic type highlights titles of other manuals.
Note: Notes contain important or helpful information.
CAUTION: Cautions appear before procedures that could cause damage to

equipment or material if you do not do them correctly.
WARNING! Warnings tell you when you must follow a specific

procedure or practice to avoid personal injury or death.
x What’s Inside
Product Support
As a part of our commitment to excellence, GGT provides complete product
support for GERBERcutters, worldwide.
Inside the United States and Canada
For product support within the United States or Canada, call:
1-800-999-1448
For information about training or other products, call the GGT Sales and Service
Office in your area.
Have the following information ready when you call:
• Identify what equipment you are using.

• Identify any special equipment or software you are using, such as the drill
option.
• Identify what software packages you are using. Include the software
version numbers.
Outside the United States and Canada
For software/hardware support, training, or information about products outside of

the United States and Canada, call your local GGT Sales and Service office.
What’s Inside xi
xii What’s Inside
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About This Section
This section details safety precautions you must follow when operating the
S91 GERBERcutter.
WARNING! Failure to follow these safety precautions could result in

injury or death.
Dangerous Procedure Warnings

Warnings precede potentially dangerous procedures throughout this manual.
Instructions contained in warnings must be followed. You also should employ
all other safety precautions that you deem necessary for safe operation of the
equipment in your operating environment.
Do Not Perform Maintenance Alone

Do not perform any maintenance on the equipment unless another person that
can render first aid and resuscitation is present.
Live Circuits
High voltages exist inside the C200 controller/vacuum electronics enclosure.
Never perform any work inside the vacuum electronics enclosure. There are no
operator–serviceable parts. Two power cables enter this enclosure: a three–
phase cable for the vacuum generator system and a single–phase power cable for
the C200 controller. Both power cables must be disconnected before it is safe to
work within the enclosure. There must be a main disconnect that meets local
electrical codes for each power supply.
Safety Precautions xiii

Turn Off Power Before Maintenance
To prevent accidental start–up, always turn off all power by shutting off circuit
breaker 1 before doing any maintenance.
Circuit
Breaker 1
Laser Origin Light

The origin light in the cutter head uses a laser light that points toward the cutting
surface. When viewed as intended (by looking at the dot projected on the
material to be cut), the laser should pose no hazard to operators. However, the
origin light is a Class IIIa laser product, with a peak power of 5 mW at a
wavelength of 670 nm. Never look straight into the light source of this laser
beam; doing so may cause temporary, or even permanent, damage to your eyes.
Direct, bright reflections from the laser may also be harmful. Remove all
highly–reflective material (such as jewelry and mirrors) from the cutting surface
before turning on the origin light. Turn off the origin light before performing any
maintenance on the GERBERcutter.
WARNING! Use of controls or adjustments or performance

of procedures other than those specified herein may
result in hazardous radiation exposure.
xiv Safety Precautions

Moving Machinery
Keep hands away from the Resealer and other moving machine parts to avoid
personal injury. Make sure there is no one else near the table when you are
operating the GERBERcutter.
Replacing Parts
Report any broken or missing parts to your Field Service representative. Because
of the danger of introducing additional hazards, do not install substitute parts or
perform any unauthorized modification of the equipment.
Knife Blade
The knife blade is very sharp. Be extremely careful when working near the knife
blade.
Clothing
Loose–fitting clothing, dangling neck chains and ties, loose jewelry, and long
hair can be a hazard when working around machinery.
Compressed Air
Always use caution when using compressed air. Never use compressed air to
blow lint and dust off clothing or skin.
Lint
Avoid breathing in lint when changing the table and stack filters. Wear a mask
suitable for this purpose.
Safety Precautions xv
Equipment Training
Never attempt to operate this machinery unless you have received formal
training to do so.
Do Not Operate in an Explosive Atmosphere

Use extreme caution when handling flammable liquids such as cleaning
solvents. Do not operate the equipment in the presence of flammable gases or
fumes.
Use Caution When Handling the Monitor

The monitor on the operator workstation is a cathode–ray tube (CRT). Breaking
a CRT could cause it to implode and scatter glass fragments at a high velocity.
To prevent CRT implosion, avoid rough handling or jarring of the equipment.
xvi Safety Precautions

16*(5%(5FXWWHUV
The S91 GERBERcutter is a computer–controlled cutting system that cuts
spreads with a compressed ply height up to 7.6 cm (3.0 in.). It automates the
entire cutting process, replacing hand–held cutters, templates, and patterns.
Instead of patterns, the GERBERcutter uses computer data files called cut files
to guide its knife. These cut files are made on Gerber marker making systems
such as AccuMark or MicroMark. Computer–aided accuracy means
accurate notches and pieces so sewing operators waste little time matching parts.
Available Models
The S91 is available in static, traveling conveyorized (TCW), and zoned valve
conveyor (ZVC) models. Although these models share the same cutter control
software, each is meant for specific applications, such as high ply, denim, or
foam. These models also have some mechanical differences.
Traveling Conveyorized (TCW)

TCW systems have a moveable work surface (conveyor) and the entire cutter
moves laterally across the factory floor on metal rails to service several
spreading tables. The conveyor lets this system cut spreads much longer than the
cutting table. TCW systems have a material clamp and a built–in vacuum
generator.
Conveyor
Material
Clamp
Platform and
Conveyor
Controls
Chapter 1 S91 GERBERcutters Page 1

Static
The Static system has a stationary work surface and is fixed in place on the
factory floor. The base system has a single cutting table with a motorized lay
puller (not shown) and external vacuum generator (not shown). Mechanically
controlled vacuum zoning applies vacuum only to the area of the table surface
where the spread is being cut. This feature improves cut quality and lowers
power usage.
Stationary
Work Surface
Zoned Valve Conveyor (ZVC)

The ZVC system has a moveable work surface (conveyor) which is fixed in
place on the factory floor. The conveyor lets this system cut spreads much
longer than the cutting table itself. The ZVC has an external vacuum generator
(not shown). Software controlled vacuum zoning applies vacuum only to the
area of the table surface where the spread is being cut. This feature improves cut
quality and lowers power usage.
Conveyor
Page 2 Chapter 1 S91 GERBERcutters

Note: Unless otherwise noted, information in this chapter applies to all S91
models.
Major Subsystems
The S91 GERBERcutter has two major subsystems that work together to cut
material. These subsystems are the C200 controller and the cutting table.
C200 Controller
The C200 controller is the command center of the GERBERcutter. Using
C200MT software, the controller tells the cutting table how to cut material. The
C200 has two components that work together: the Front End Processor (FEP) or
PC and the motion control computer (MCC). Located in the operator
workstation, the PC lets you communicate with the GERBERcutter. It sends
your instructions and cut file data to the MCC. The MCC then uses these
instructions to run the cutting table.
Cutting Table
The cutting table cuts material according to instructions from the C200
controller. All S91 models have these major parts:
• Cutter head and beam assembly.
• Beam control panel.
• Work surface.
• Vacuum generator.
• Mast (exhaust stack).
Other major parts depending on the model include:
• Conveyor.
• Lay puller.
• Limit switches.
• Platform controls.

Cutter Head and Beam Assembly
The cutter head and beam assembly cuts material by moving a reciprocating
knife across the work surface. The assembly moves in response to commands
from the C200 controller. The cutter head holds the knife which both
reciprocates and turns to cut corners, curves, and notches. The cutter head
moves across the width of the cutting table on a beam. The beam also travels the
length of the cutting table. By combining these movements, the GERBERcutter
accurately cuts complex patterns.
A laser origin light on the cutter head lets you position the knife to start cutting
at the right place. To do this, the origin light shines a point onto the material.
The beam control panel is a terminal that lets you control the GERBERcutter
from the cutting table. For details on the types of beam control panels for S91
cutters, see the Beam Control Panel section later in this chapter.
Cutter Head
Beam Control
Panel
Beam Assembly
Work
Surface
Laser Light
Operator
Workstation

Work Surface
The work surface holds material for cutting. It is made of GERBER BRISTLE
SQUARES that fit into plastic grids on Static systems or into aluminum slats
on conveyorized (TCW and ZVC) systems. BRISTLE SQUARES are squares of
molded bristle that plug into the plastic grids or slats. Each bristle square has
small holes in its base. When you apply vacuum to the cutting table, air passes
through these holes to hold down the material.
BRISTLE
SQUARES
with Grids
BRISTLE
SQUARES
with Slats

Vacuum Assembly
To supply vacuum, the GERBERcutter uses either an external or built–in
vacuum generator. The vacuum generated is used to hold the material firmly on
the work surface during cutting. An external vacuum generator is connected to
the cutting table by a long duct; the built–in vacuum generator on a TCW is
located under the take–on end.
BRISTLE SQUARES
Vacuum
Valve Duct
The figure above shows air flow in a static or ZVC with an external vacuum
generator. The vacuum generator draws air through the BRISTLE SQUARES.
From there, the air travels through vacuum vents into a plenum in the cutting
table, and through a duct to the external air filter and vacuum generator. The air
finally exits through a remote exhaust stack, possibly located outside of the
building.
Stack
BRISTLE SQUARES
and Slats
Vacuum
Air Filter
Generator
The figure above shows air flow in TCW systems with a built–in vacuum
generator. In this case, air flows through the BRISTLE SQUARES and into the
slats. From there it flows through the frame of the cutting table to the air filter
and vacuum generator. The air finally exits through an exhaust stack (mast)
located on the cutter.

Limit Switches
Limit switches set limits for how far the cutter head and beam can move on the
cutting table in the +X, -X, +Y, and -Y directions. The limit switches also tell
the C200 controller when the cutter head reaches the X0,Y0 coordinate when
you initialize the system. Each limit switch is activated by a specifically placed
magnet or small metal plate.
Example: A limit switch located on the operator side of the work surface limits
cutter head movement by sensing when it has reached the home position.
Further cutter head movement in this direction would not be allowed by the
C200 controller.
Operator Controls
Operator controls let you give commands to your GERBERcutter and respond to
system messages. These controls are the:
• Emergency stop (EStops) switches and plungers.
• Circuit breakers.
• Table motion controls.
• Beam control panel.
• Operator workstation.

Emergency Stop
Emergency Stop (EStop) is a safety feature. You must know how to use EStops
before operating the GERBERcutter. An EStop halts all table motion in case of
danger to people, the GERBERcutter, or the material being cut.
Pressing an EStop switch or plunger immediately shuts off all power to the
conveyor, vacuum generator, cutter head, and beam. All motion stops. Only the
operator workstation stays on. You must perform a recovery procedure before
you can use the GERBERcutter again. The figure below shows typical EStop
locations.
EStop
Switches
EStop
Plungers
EStop
Switches
EStop Switches — EStop switches are large red buttons. An EStop switch is
located on the operator workstation and the beam control panel. Additional
button locations depend on the model.
To stop the system:
1. Press one of the red EStop switches.
All table motion stops.
2. For error recovery procedures, see chapter 3 or refer to the C200MT

Software User’s Guide.
CAUTION: Do not move the spread or jog the conveyor after an

EStop. If you do, it will be very difficult for the cutter to
start cutting in the right place.

EStop Plungers — EStop plungers (sometimes called paddles) are large yellow
buttons strategically located on the beam. They depress automatically whenever
interference is encountered, such as someone leaning against the table when the
beam is moving in that direction.
EStop
Plungers

Circuit Breakers
The GERBERcutter has two main circuit breakers located on the electrical
panel. The electrical panel may be located on the side of the cutting table or on a
separate table along side the cutting table. Both circuit breakers must be turned
on for the system to run properly.
High Voltage
Symbol
Circuit
Breaker 1
Circuit Breaker 2
(behind door)
Hazard
Symbol
Circuit breaker 1 provides power to the C200 controller, servo motors, and
conveyor. It is in the upper left corner. You use this circuit breaker to turn on the
GERBERcutter.
Circuit breaker 2 provides power for the vacuum generator. It is located in the
vacuum electrical enclosure. This circuit breaker is always left on.
WARNING! Do not turn circuit breaker 2 on or off. High

voltages exist within the vacuum electrical enclosure and
inside the C200 controller. Never perform any work inside the
vacuum electrical enclosure. There are no operator–serviceable
parts inside.

Platform and Conveyor Controls
Depending on the model of your S91 cutter, platform controls (for TCW) and
conveyor controls (for TCW and ZVC) are provided on the operator side of the
cutter at the take–on end of the table.
Platform Controls
EStop
Conveyor Controls
Power Button
Vacuum Readout
TCW systems have table motion control switches similar to those shown above
to move the conveyor and the cutter. Table motion controls on your cutter can
include:
Vacuum Readout — Use to monitor vacuum pressure; your cutter may have a
digital readout instead of the pneumatic readout (shown).
Platform Controls — Use to control movement of the cutter along rails

positioned between two or more spreading tables.
• Forward — Moves the table forward laterally to align it with a spreading
table or take–off table.
• Reverse — Reverses table movement laterally for alignment purposes.
• Brake — Locks the table in place after positioning; ON sets the brakes
and OFF releases the brakes.
Power — Use to turn on power to the platform drive motors, as well as the
vacuum generator and conveyor. On RSO TCW systems, this one control is
located as shown; however, platform and conveyor controls are located on a
panel near the stack. See page 17.
Some units have power buttons (shown) while others have key switches. To turn
power on with a key switch, insert the key and turn it to the left; to turn off
power, turn the key to the right and remove it.

EStop — See earlier section in this chapter.
Conveyor Controls — Use to move spreads onto the conveyor and along the
cutting table.
• Mode — Switches between Manual, Auto, and Reverse modes. In
Manual mode the conveyor moves forward toward the take–off end
when you jog a spread. In Auto mode, the conveyor moves in response
to commands from the C200MT program. In Reverse mode, the
conveyor moves backward toward the take–on end when you jog.
• Jog Control — Moves the conveyor backward or forward depending on
how the Mode switch is set. Do not use this switch while the cutter is
processing a cut file.
• Blower — Controls whether or not air is blown up through the
BRISTLE SQUARES to assist in moving a spread. If Manual is
selected, the vacuum generator must be turned ON and OFF manually to
blow air when you jog. If Auto is selected, the vacuum generator blows
air automatically when you jog.
• Vacuum — Controls the level of table vacuum by opening and closing
the dump valve on the table. Select Dump to open the dump valve,
dropping table vacuum immediately. Select Auto to allow the C200MT
program to control vacuum level by automatically opening and closing
the dump valve.

Beam Control Panel
The beam control panel (BCP) lets you control the cutter head, beam, and
certain table functions from the cutting table. Two examples of beam control
panels are shown below.
Typical Panel
Flat Panel
on Static Cutter
Note: Certain controls on the beam control panel correspond to certain icon
keys on the operator workstation. Refer to the C200MT Software
User's Guide for further details.
The table on the following page explains how to use the switches and other
components on the beam control panel.

Component Description
EStop — Immediately stops all table motion.
Knife — Turns the knife motor on or off.
Manual Mode Light — Checks for head and beam movement; lights up
when the head and beam are both stopped.
Feedrate Dial —Sets the feed rate at which the cutter head and beam
move across the table. The range is from 1 (minimum) to 15
(maximum); 0 is no movement. Cutting speed is the same as feed rate.
Joystick — Moves (slews) the cutter head and beam in the direction of
the arrows. (-X, +X, -Y, or +Y); the Slew Enable switch must first be
depressed.
Slew Enable — Allows movement of the cutter head and beam; depress
and hold before using joystick.
Error Warning Light — Checks joystick functions; lights up when the
cutter is in Manual Bite or Trim Cut mode or when a controller error
occurs.
Stop — Stops the current operation of the cutter.
Vacuum — Turns cutting table vacuum ON or OFF.
KI Null — Resets Knife Intelligence.
Fabric Alignment — Sets fabric alignment when pressed twice.
Manual Bite — Switches between Manual Bite mode and Auto mode.
Initialize — Moves the cutter head to the home X0,Y0 position on the
table.
Trim Cut — Manually trims the edges of a spread.
Origin — Sets the current position of the origin light as the origin of
your marker. Marker origin is the X,Y coordinate where the marker
starts.
Note: The C200MT program takes into consideration the mechanical
offset between the knife and the origin light.
Start — Starts the GERBERcutter.
Sharpen Knife — Manually sharpens the knife blade one cycle.

Operator Workstation
You use the operator workstation and the beam control panel to run the
GERBERcutter. The operator workstation on your cutter looks similar to the
figure shown below. The operator workstation may also be called front end
processor (FEP) or PC.
Monitor
Speakers
EStop
Icon Keys
Servo Power
Enable
CD–ROM Drive
Keyboard 3.5 in. Disk Drive
Pointing Device
Hard Drive
Monitor — Receives computer video signals from the PC and displays

information on the screen.
Speakers — For use with Computer Based Training.
Keyboard — Device with keys, like those on a typewriter, that lets you enter
data and communicate with the C200MT program.
Icon (function) keys — Each key performs a C200MT command to operate the
cutter. The icon (picture) and color of the key tells you which key performs each
function. Refer to the C200MT Software User's Guide.
Pointing device — Moves the cursor around the screen to select cut files,
setups, or pieces and enter menu commands and information in dialog boxes.
Your pointing device may differ from the one shown above; refer to the
C200MT Software User’s Guide.

Servo power enable — Pushing this button turns on power to the servo motors.
These are motors that move the cutter head and beam as the GERBERcutter cuts
material.
Emergency stop — See section earlier in this chapter.
3.5 inch disk drive — C200MT software and cut files are stored on disks
before being copied into the hard drive of the operator workstation PC. Disks
come in two sizes: 3.5 and 5.25 inches.
CD–ROM drive — Use for accessing Computer Based Training and Service
Parts; see chapter 7 and check availability with your local GGT Sales and
Service office.
Hard disk drive — The hard disk drive holds the C200MT software that runs
the GERBERcutter. A hard disk drive uses rigid metal disks so it can store much
more data than a 3.5 inch disk.
You need to manage your hard disk so it does not become too full and
disorganized. Refer to Windows NT documentation and the C200MT Software
User’s Guide for information on managing files on the hard disk.
Options
There are many options for tailoring the S91 to the material you cut and your
way of doing business. Here is a partial list of hardware and software that may
be useful as you become more familiar with your system. For more information,
call your local GGT Sales and Service office.
Spare Cutter Head (Without Covers)

This cutter head replaces the cutter head running on the system to ensure
minimum downtime during maintenance and repairs.
Spare Sharpener Assembly

This sharpener assembly replaces the sharpener assembly running on the system
to ensure minimum downtime during maintenance.

Right Side Option
The right side option lets you run the GERBERcutter from the right side of the
cutting table. This lets you spread material with its straight edge on the right
side, which is more practical for some applications. Operator controls are moved
to the right side where appropriate. Shown below is a TCW system with the
RSO option.
Conveyor and
Platform Controls
Beam Control
Panel
Electric Drills
Electric drills are available as single, dual, and heavy duty units. GGT also
provides drill bits in a wide variety of sizes and types.
CTOT
A Conveyorized Take Off Table is available for use with the TCW and ZVC
models. The CTOT AUTO Enable control is located on the operator’s side of
the CTOT.

Cutter Info Database (CIDB)
CIDB is an optional time reporting software that helps you judge how well you
are using your GERBERcutter. CIDB records how long various cutting activities
take and provides reports that can help you decide how you can do things better.
For example, CIDB may show that a certain cut file keeps the knife out of the
material too long, increasing cutting time. These are some of the data CIDB
records:
• Marker being cut.
• Cutting speed.
• Cutting time (blade in the material).
• Dry haul time (blade out of the material).
• Cutter stop time while cutting a cut file.
• Time used to prepare and align next spread.
POWER Processor
The POWER Processor lets you change cut files so that the GERBERcutter
works more efficiently. Input to the POWER Processor is a cut file produced on
a marking and grading system such as GGT’s AccuMark or MicroMark. Output
is a modified cut file. Altering a cut file can improve cut quality, cut speed,
material use, and cut file efficiency. The POWER Processor lets you:
• Change piece cutting sequence.
• Change the start point of a piece.
• Add or remove knife lift and plunge points.
• Add or remove Optional Stop points for plaid/stripe matching.
Note: Some features of the POWER Processor are now included in the
PreProcessor utility of the C200MT program. See chapter 4.

2%DVLF&RQFHSWV
Note: Information in this chapter applies to all S91 models unless otherwise noted.
Direction and Location

GGT uses specific terms to describe direction and location on the cutting table.
Learning these words will make it easier for you to find your way around
the GERBERcutter.
Ends and Sides

Each side of the cutting table is named so you can identify it easily. The take–on
end is where material comes onto the work surface for cutting. The take–off end
is where material leaves the work surface after cutting. The right and left sides
are as they would appear to someone standing at the take–on end.
Right Side
(Far Side)
Take–on End
Take–off End (ZVC / TCW) (Right End on Static)
Left End (Static)
Left Side
Beam Control
Panel
Chapter 2 Basic Concepts Page 19

X, Y, and C–axes
The GERBERcutter uses three imaginary lines or axes to tell direction and
location on the cutting table. They are the X, Y, and C–axes, as shown below.
If you stand at the operator workstation, the Y–axis runs across the table, the
X–axis goes from left to right, and the C–axis is in the cutter head. The beam
moves along the X–axis, the cutter head travels the Y–axis, and the knife turns
around the C–axis in the cutter head.
Movement is always in a plus (+) or minus (-) direction on the X and Y–axes.
If you stand at the operator workstation:
• +X is to your right.
• +Y is away from you.
• -X is to your left.
• -Y is toward you.
Location is also given in terms of the X and Y–axes, as shown below.
Page 20 Chapter 2 Basic Concepts

If you stand at the operator workstation, the point X0, Y0 is at the lower left
corner of the work surface, as shown below.
X0, Y0
All locations on the work surface are relative to this position. Unlike direction,
location is always stated in positive numbers. To find the point (X=24 in., Y=36
in.), start at X0, Y0. Measure 24 in. to the right along the X–axis. From there,
measure 36 in. away from you on the Y–axis . You are now at the point
X24, Y36.
Origin
Just as the table has a X0, Y0 position marking its lower left corner, so does
each marker. The X0, Y0 position of the marker is called the origin. All data
points (locations) of the marker are relative to the origin.
Before the GERBERcutter can cut a marker, you must set the location of the
origin. The cutter then cuts each piece relative to this point. The origin is set
from the beam control panel or at the operator workstation (see chapter 3). The
origin light is a red laser light located in the cutter head that shines on the cutting
table (see the Safety chapter at the beginning of this manual).
WARNING! The origin light uses a Class IIIa laser. Do not look
directly into the laser beam without protective glasses. Do not
place any reflective (shiny) material on the cutting table.
Remove watches, rings, and other jewelry. Reflected laser light
may cause eye injury.

The origin must be close enough to the lower left corner of the table so that the
marker can fit on the table. For example, the origin shown below is at X25, Y50.
With that origin, the marker extends off the table in the Y direction. You can
correct this situation by moving the origin to X25, Y25.
If the cutter cannot cut the marker because it will go off the table, you will
receive an off table message, such as one of the following:
Off table in +Y
Off table in -X

Using the Check Origin feature, the system automatically verifies that the
marker will fit on the cutting table with the current origin. It does this before
cutting the marker. If the origin will not work for your marker, the system
displays an error message like this:
Bad Origin: X too high (x.xxx)

acceptable range: x.xxx - x.xxx
where x.xxx is a table location in the X direction. You get a similar message if
the origin needs to be corrected in the Y direction.
Bite Feeding
TCW and ZVC systems use a conveyor for bite feeding. Bite feeding is a feature
that matches cutter head movement with conveyor movement, permitting
automatic cutting of a long spread. The GERBERcutter does this by cutting the
spread in sections. The marking system sets the length of each section in inches
or centimeters as one bite. After the cutter pulls the bite onto the cutting table
and cuts it, the conveyor automatically advances, positioning the next bite on the
cutting surface.
An example of how the conveyor and bite feeding work is shown on the next
page.
Diagram 1 shows a 48.8 m (160 ft.) spread of material that the marker maker
has divided into 20 bites, each 2.4 m (8 ft.).
To begin automatic cutting, the conveyor pulls the leading edge of the spread
onto the cutting surface with the aid of underlay paper. The conveyor moves
until it pulls the first bite onto the cutting table as shown in Diagram 2.
The GERBERcutter cuts the first bite, including pieces that extend into the
second bite As shown in Diagram 3. The knife cuts a slit in the selvage of the
material to mark the origin of the second bite. The slit (or edge clip) made by the
marking system is a reference point in case you stop cutting during the second
bite.

Next, the conveyor automatically moves the first bite down the cutting table and
brings the second bite in position to be cut as shown in Diagram 4. While the
bundle handlers are removing the pieces from the first bite, the GERBERcutter
begins cutting the second bite.
After the system completes the second bite, the conveyor moves the third bite
onto the cutting surface. It brings the second bite down to the bundle handlers,
and moves the first bite scrap from the cutting surface to the take–off table,
where you can collect or discard it as shown in Diagram 5.
The GERBERcutter keeps feeding bite after bite until it cuts the whole spread.

Software and Files
Software
Software is the set of computer programs that the C200 controller uses to run the
GERBERcutter and communicate with you. These programs include:
• C200MT — Cutter control software that reads cut files and setups to tell
the cutting table how to cut material; this program starts up
automatically when you power on the GERBERcutter.
• Windows NT — Operating system for the PC at the operator
workstation.
For more information about C200MT software and Windows NT, refer to the
C200MT Software User's Guide.
Cut File
A cut file is a computer data file that tells the GERBERcutter how to cut a set of
patterns (a marker) out of a spread of material. The cut file is generated by a
GGT marker making system such as the AccuMark or MicroMark.
Setup
A setup is a computer data file that sets up the system for the materials being
cut. For example, you may have one setup for cutting denim and another for
flannel. The C200MT software comes with several default setup files. See
chapter 4.
Note: Setups were previously called Configuration or Config files.

3&XWWLQJ0DUNHUV
Sections in this chapter explain:
• Spreading material.
• Basic cutting on your GERBERcutter.
• Beyond the basics.
• Recovery after an EStop or system power down.
For additional information on how to use C200MT program features, refer to the
Chapter 3 Cutting Markers Page 27

Spreading Material
CAUTION: Different materials require specific spreading methods for the best
cutting results. Also, Static systems have different spreading
requirements than TCW and ZVC systems which have conveyorized
tables. The following procedures are general guidelines only.
To spread material on the spreading table
1. Place an underlay of perforated or air–porous paper (25 to 60 lbs.) on

the spreading table. Be sure the paper is straight on the table and
extends at least 0.3 m (1 ft.) beyond the leading edge of the spread. For
Static systems this should extend approximately 1 m (or 3 ft.) beyond.
The underlay lets you move the spread without pulling or disturbing
the material. When vacuum is applied, the underlay keeps the material
clean and in place. It also provides extra support for stretchy and
lightweight material.
2. Using the method appropriate for your site, spread the material on top
of the perforated paper. Normally the straight edge is on the operator’s
side of the cutting table.
CAUTION: Do not exceed your GERBERcutter’s maximum

compressed material ply height — 7.6 cm (3.0 in.).
Exceeding the maximum material ply height will lower
cut quality, shorten knife life, and may damage your
GERBERcutter.
3. If you use full–size plots to identify individual pieces after they are cut,
put the correct one on top of the spread.
Page 28 Chapter 3 Cutting Markers

Basic Cutting
The following sections explain the basic steps, shown in the diagram below,
required to a cut a marker on a GERBERcutter.
At Cutter
At Operator
Workstation
1. Turn on cutter
2. Enable
servo power
3. Initialize cutter
4. Position first bite
5. Select setup
6. Open marker
7. Turn on vacuum
8. Turn on laser
9. Position
laser light
10.Set marker origin
11. Select
cutting speed
12. Turn on
knife motor
13. Start processing
marker
14. Recovery
(if needed)

WARNING! Read the safety precautions at the beginning of this manual
before performing any operation at the cutter.
Turning on the Cutter

Turning on, or powering up, the cutter automatically opens Windows NT and
runs the C200MT program at the operator workstation.
To turn on the cutter
1. Make sure that no limit switch is parked on its magnet (see chapter 1).
If necessary, manually move the cutter head or beam toward the center
of the work surface.
2. At the beam control panel, set:
a) Knife button to OFF.
b) Feed rate to a low speed, such as 2 or 3.

3. For TCW systems, turn on the table power circuit breaker
(approximate location shown below). For Static and ZVC systems, turn
on circuit breakers at the panels for the external vacuum and for table
power or the lay puller.
C200 Controller
Table Power
(not shown)

4. Turn on circuit breaker 1 for the C200 controller. The control panel is
located on the right side of TCW systems; for other S91 cutters, the
C200 control panel may be located on a nearby table.
Circuit Breaker 1
Enabling Servo Power

Pressing the Servo Power Enable button turns on power to the servo motors.
These motors control movement of the cutter head and beam during cut
processing.
To enable servo power
1. Make sure that cutter power is turned on and the C200MT program is
running.
2. At the operator workstation, press the Servo Power Enable

button.
The servo motors are turned on and gauges display across the top of the
C200MT Main Cutter Control screen.
3. If nothing happens when you press the Servo Power Enable button, do
all of the following:
− Make sure that no limit switch is parked on a magnet.
If necessary, manually move the cutter head or beam toward the
center of the work surface.
− Make sure all EStop switches are up; if not, twist clockwise.
− Make sure no EStop plunger is activated.

Initializing the Cutter
Initializing the cutter identifies the zero position for the table in X and Y. This is
also called the home position and is written as (0,0). Limit switches (see chapter
1) tell the C200MT program when the cutter head reaches the (0,0) position.
Note: You must initialize the cutter before processing markers. Otherwise,
an error message displays.
To initialize the cutter
1. Make sure that the cutter power is turned on and the servo power is
enabled.
2. Do one of the following:
− Press the Initialize button on the beam control panel.

− Press the Initialize key on the keyboard.
The cutter head and beam moves to the (0,0) position on the table. A
new origin is reported in the System Messages box.
Note: If the cutter is set up for the Right Side Option, the cutter
head and beam moves to the right side of the table.

Positioning the First Bite
After the cutter is initialized, use the jog switch at the take–on end of the cutter
to advance the spread (material) into cutting position.
On TCW and ZVC Systems

These systems use a conveyor to jog, or move, the spread into position on the
cutting table. TCW systems also use the clamp bar to help the conveyor move
the spread.
To position the first bite
1. Manually pull about 1 m (3 ft.) of the spread onto the cutting table.
2. Use the jog control switch to advance the conveyor until the spread is
about 25 cm (10 in.) from the take–off end of the cutting table.
CAUTION: Do not advance the conveyor too far. You can not
reverse the conveyor without disturbing the spread.
3. Manually pull the plastic film overlay (polyethylene) from the film
dispenser to cover the entire bristle surface. This allows proper vacuum
compression.
CAUTION: If not positioned carefully, the plastic film can get

caught in the racks along which the beam travels. To
avoid damage to material and your GERBERcutter, keep
the plastic film away from the racks.
On Static Systems
Static systems use a motorized lay puller to move the spread into position on the
cutting table.
To position the first bite
1. The tow bar assembly of the motorized lay puller must be located at the
spreading table. If not, return it to this position.
2. Wrap the 1 m (3 ft.) extended end of underlay paper up over the

spread. See the Spreading Material section in this chapter.

3. Manually pull the spread and underlay paper onto the lower portion of
the tow bar assembly. Initiate clamping to lower the upper portion of
the tow bar assembly.
4. At the cutting table, turn on the motorized lay puller. The tow bar is
pulled along the cutting table.
5. When the spread covers the length of the cutting table, turn off the
motorized lay puller. Raise the upper portion of the tow bar assembly
and position the end of the spread flat on the table.
The tow bar waits at this end of the table until all pieces are cut and
removed from the table.
8. Manually pull the plastic film overlay (polyethylene) from the film
dispenser to cover the entire bristle surface. This allows proper vacuum
compression.
CAUTION: If not positioned carefully, the plastic film can get

caught in the racks along which the beam travels. To
avoid damage to material and your GERBERcutter, keep
the plastic film away from the racks.

Selecting a Setup
The C200MT program includes default, or preset setups, that configure the
system for most cutting applications. A setup is a file containing parameters
which enable or disable various features, options, and modes. Preset setups are
based on characteristics of the spread. For information on customizing setups,
refer to the C200MT Software User’s Guide.
To select a setup
− Press the Settings key on the keyboard.

− From the Setup menu, select Settings.
2. If some other page is selected, click the Setup List tab.
3. Use the pointing device to select the Name of the setup you want.
Note: To enter or edit a description for the setup you just selected,
click in the field at the bottom of the page and type a new
description.
4. To select this setup as the current setup, click the Apply or the OK
button.
5. When prompted to Activate the selected Setup, check your changes

and then click the Yes button.
6. When satisfied with the changes, press Enter or click the OK button.
Your system is now configured.

Opening a Marker
Use the Marker Open feature to select a marker, or cut file, and open it for
processing. The default directory for markers is C:\USER. To change the default
directory, refer to the C200MT Software User’s Guide.
To open a marker
− Press the Open Marker key on the keyboard.

− From the Marker menu, select Open.
2. If you know the name of the marker you want to open, type the name in
the Marker Select dialog box. Press Enter or click the OK button. Go
to step 6.
OR
To view a list of available markers on the hard disk, network, or disk

drive(s), press Enter or click the OK button. The Marker Open screen
displays.
Note: For a Right Side Option cutter, you will be prompted to enter
a new marker width. Press Enter to accept the marker width
or type a new marker width and then press Enter.
3. To change drives and directories, use the pointing device, Tab key, or
Arrow keys to select a drive and then a directory.
Note: To view files on a different 3.5 inch or 5.25 inch disk, insert
the new disk and click the Rescan Drives button.
4. Select the marker you want to process.
5. Press Enter or click the OK button to return to the C200MT Main

Cutter Control screen.
6. The first bite of the selected marker is processed and displays in the
Marker Plot screen. Verify that this is the marker you want to cut.

Turning on the Vacuum
Use the Vacuum feature to turn on the table vacuum in order to process markers.
When finished cutting, you can repeat the following procedure to turn off the
table vacuum. For information about setting vacuum features, refer to the
To turn the vacuum on in order to cut
1. Make sure that the first bite is positioned on the table and the correct
marker is open.
− Press the Vacuum On/Off button on the beam control panel.

− Press the Vacuum key on the keyboard.
Turning on the Laser Light

The laser origin light is turned on by pressing a button located on the cutter
head. This light is used to visually locate the marker origin on the cutting table.
WARNING! The origin light uses a Class IIIa laser product. To avoid injury to
your eyes, do not look at the laser at any time. Also, do not place any
reflective material, such as mirrors, polished steel, or jewelry on the
cutting table.

Setting the Marker Origin
Use the Origin feature to establish the origin, or X,Y position, for a marker.
To set the marker origin
1. At the beam control panel, make sure the Feedrate dial is set to 1
or 2.
2. Press and hold the Slew Enable button.
3. Use the joystick and then press the Arrow buttons to move the cutter
head until the laser origin light falls on the lower left corner of the
spread.
4. Release the Slew Enable button.
− Press the Origin button on the beam control panel.

− Press the Origin key on the keyboard.
The origin is reported in the System Messages box, where x.xxx and
y.yyy are the absolute table coordinates (origin) for the lower left
corner of the marker.
Note: If you use Fabric Alignment to adjust for a spread that is not
straight on the cutting table, do so now. See the Beyond
Basics section later in this chapter.

Selecting Cutting Speed
To select cutting speed
1. At the beam control panel, use the Feedrate dial to select the
appropriate cutting speed for processing the open marker.
This speed depends on the material being cut; 5 is a good starting

speed.
2. To manually adjust cutting speed, use the Feedrate dial, as needed,

throughout the marker.
OR
Cutting speed can be automatically adjusted, for example when cutting

corners, by parameter settings in the Setup file. Refer the C200MT
Turning on the Knife Motor
WARNING! The knife blade is very sharp. Be extremely careful when

working near the knife blade. See the Safety Precautions
chapter at the front of this manual.
To turn on the knife motor
At the beam control panel, use the Knife switch to turn on the
knife motor.
The knife reciprocates (moves up and down).

Processing a Marker
Use the Start feature to begin processing, or cutting, a marker.
To start processing a marker:
1. Make sure you have completed all the procedures previously explained
in this chapter.
WARNING! Check that it is safe to begin cutting! Make sure

nobody is near the cutter head, beam, and conveyor.
− Press the Start button on the beam control panel.

− Press the Start key on the keyboard.
The piece being cut is outlined in the Marker Plot screen and the
current piece and bite number display in the System Status window.
3. When prompted that processing is complete, press Enter or click the

OK button.

Exiting the Program
This section gives the steps necessary to close the C200MT program and shut
down the cutter.
CAUTION: To avoid losing data, always quit the C200MT program before
shutting down Windows NT. Also, shutdown Windows NT
before turning off the main circuit breaker for the cutter.
To quit the C200MT program
1. Make sure that the cutter is idle (not processing data).
2. From the Quit menu, select Confirm.
To shut down the cutter
1. From Windows NT, do one of the following:

− From the File menu, select Shutdown. Or, press ALT + F4.
− Click the Start button and then click Shutdown.
2. In the Shutdown dialog box, click the radio button next to Shutdown.
Then press Enter or click the OK button.
3. When prompted that it is safe to turn off your computer, turn off the
circuit breaker for the C200 controller.
4. For TCW systems, turn off Table power. For Static and ZVC systems,
turn off power at the panels for the external vacuum and for table
power or the lay puller.

Beyond the Basics
Besides allowing you to cut a marker using the basic steps, the C200MT
program provides commands and parameters for specific cutting applications.
This section explains how to use:
• Fabric Alignment.
• Pause Between Bites.
• Data Scale Factor.
• Trim Cut.
• Move to Origin.
For more information on parameters, refer to the C200MT Software User’s
Guide.
Using Fabric Alignment

Fabric Alignment can be used to cut a spread that is skewed relative to the
cutting table. This is done by selecting two points along the length of the spread
to define an adjustment angle. Use with Pause Between Bites (see next section).
To cut a skewed spread
1. Make sure that the Check Origin parameter in the Options and Modes
category is turned off.
2. Set the origin for the marker.
3. To define a new angle:
WARNING! Check that it is safe to move the cutter head and

beam! Make sure nobody is near the cutter head, beam,
and conveyor.
a) At the beam control panel, press and hold the Slew Enable button.
b) Use the joystick and Arrow keys to slew the laser origin light to a
point along the spread that is the same distance in Y from the edge
of the marker as the origin.
c) Release the Slew Enable button.
d) Press the F2 button twice.

4. To use the previous angle:
a) From the Cutter menu, select Fabric Alignment.
b) Click the Recall button on–screen.
5. Between each bite, repeat step 3 or 4 as needed.
Using Pause Between Bites

It is possible to stop the cutter between bites in order to perform a procedure,
such as setting origin or fabric alignment.
To use pause between bites
1. Edit the setup using Parameter Manager and the Bite Parameters
category. Refer to the C200MT Software User’s Guide.
The cutter will pause automatically between each bite.
2. When cutting stops, complete any necessary procedure.
3. Process the next bite.
Using Check Origin

Check Origin can be used to check whether or not the entire marker will fit on
the usable table surface based on the current origin. For example, if the X value
of the origin is too great, pieces at the take–on end of the current bite might not
cut properly.
To check the origin
1. Edit the setup using Parameter Manager and the Options and Modes
category. Refer to the C200MT Software User’s Guide.
2. Open and set the origin for a marker as usual.
3. If pressing the Start button results in a system prompt of Bad Origin:
a) Reposition the cutter head within the acceptable range, as

prompted.
b) Set the Origin and press the Start button again.

Using X Data Scale Factor, Y Data Scale Factor
On occasion you may need to adjust scaling for cut file data so that a marker will
fit on the available material. Scaling can be adjusted in either X, Y, or both X
and Y directions.
To use a data scale factor
1. Calculate the X data scale factor by dividing the usable material length
by the marker length.
2. Calculate the Y data scale factor by dividing the usable material width
by the marker width.
3. Edit the setup using Parameter Manager and the Data Format/Scaling
and RSO category.
4. Open and process the marker.
CAUTION: To avoid cutting the next marker incorrectly, return each data
scale factor to 100% after cutting the current marker.
Using Move To Origin

Use the Move to Origin feature to move the cutter head to the last established
origin. You can use this command whenever you want to verify the origin; for
example, use after Fabric Alignment.
To move to the last established origin
− Press the Move to Origin key on the keyboard.

− From the Cutter menu, select Move to Origin.
The cutter head and beam moves to the last established origin which is
reported in the System Messages box.

Using Trim Cut
Use the Trim Cut feature to trim away excess material and plastic after cutting a
marker.
To trim
− Press the Trim Cut button on the beam control panel.

− From the Cutter menu, select Trim Cut.
2. At the beam control panel, use the slew keys to make required cut(s).
3. To exit Trim Cut mode, do one of the following:
− At the beam control panel, press the Stop button.

− At the operator workstation, press Esc.

Recovery from Interrupted Cutting
Recovery procedures allow the cutter to resume cutting after a power loss,
EStop, or a system power down interrupts cut processing. An EStop occurs
whenever cutter motion is stopped by pressing one of the emergency stop
(EStop) switches or plungers located on the cutter.
Note: The reason for the power down displays as an on–screen error
message.
Recovery procedures include:

• Restore State — Return to the last piece and bite being cut.
• Restore Origin — Restore origin for the current marker.
• Bite Search — Find and cut a specific bite.
• Piece Search — Find and cut a specific piece.
• Piece Recut — Recut a specific piece.
Before Using Recovery Commands

Before using any of the recovery commands you need to perform the following
procedures.
To correct the condition before recovery
1. If the operator workstation lost power, turn on the main power supply
and start up the C200MT program. Then enable servo power and
initialize the cutter.
OR
If an EStop occurred, press Enter to clear the message from the screen.
Enable servo power.
OR
If accidental system power down occurred, press Enter to clear any

error message from the screen. Restart Windows NT, if necessary, and
restart the C200MT program. Then enable servo power and initialize
the cutter.

Using Restore State
Use the Restore State feature to return to the last piece and bite that was being
cut before a power loss, EStop, or system power down. This feature
automatically restores all of the following:
• Reopens the cut file.
• Restores the setup.
• Restores Fabric Alignment.
• Restores the origin.
• Restores the bite (TCW or ZVC systems).
• Searches for the piece being cut before the cutter stopped.
• Restores a Job Queue (see chapter 4).
To restore state of last marker
1. Make sure that the condition which stopped cutting is corrected.
− Press the Restore State key on the keyboard.

− From the Recover menu, select Restore State.
3. If the marker and piece information displayed in the Restore State
dialog box is correct, press Enter or click the OK button.
Note: If this information is not correct, you can use the procedure
for restoring state manually. See the next section.
The marker is opened and the System Message box prompts that the
State is restored.
4. Verify that the correct piece and bite number display in the System
Status window. If correct, start processing.

Restoring State Manually
Instead of using the Restore State feature, you can manually restore state using
the following steps.
To restore state manually
1. To set the origin, do one of the following:

− Position the origin light at the top of the bite clip for the last bite
cut. Set a new origin.
− If restoring the first bite (TCW or ZVC), use the origin or set
origin as normal.
2. Choose the correct setup to configure your cutter.
3. Open the marker.
4. Use Piece Search explained in the next section.

Using Piece Search
Use the Piece Search feature to find and cut a specific piece in a marker. This is
useful after an EStop or system power down, especially if the Restore State
command does not find the correct piece to cut.
To find and cut a specific piece
1. If cutting was interrupted, make sure that the condition is corrected and
the marker you want to cut is open.
− Press the Piece Search key on the keyboard.

− From the Recover menu, select Piece Search.
3. In the Piece Search dialog box, type to enter the Piece to Search to.
Then press Enter or click the OK button.
The Marker Plot screen shows the piece in the marker. The System
Messages box reports that the requested piece was found and gives the
bite number it was found in (TCW and ZVC systems).
Note: When the piece being searched for is split across two bites, a
dialog box displays. If you want to begin cutting the part of
the piece located in the first of these two bites, click the Yes
button. If not, click the No button.
Using Piece Recut

Use the Piece Recut feature to recut a specific piece in a marker that might not
have been cut properly.
To recut a specific piece
1. Make sure the marker you want to cut is open.
2. From the Recover menu, select Piece Recut.

3. In the Piece Recut dialog box, type the piece number to recut. Then
press Enter or click the OK button.
The piece you want to recut displays alone in the Marker Plot screen.
The System Status window reports that the requested piece was found
and gives the bite number it was found in (TCW and ZVC systems).
4. Position material on the table.
5. Position the cutter head near the lower left corner of the area to be cut.
6. Set the origin.
7. Start processing.
Using Restore Origin

Use the Restore Origin feature to restore the origin point.
To restore the last origin
1. Make sure that the condition which stopped cutting is corrected.
2. From the Recover menu, select Restore Origin.
The origin is reported in the System Messages box, where x.xxx and
y.yyy are the absolute table coordinates for the restored origin point.
Using Bite Search

For TCW and ZVC systems, use the Bite Search feature to find and cut a
specific bite in a marker.
To find and cut a specific bite
1. If cutting was interrupted, make sure that the condition is corrected and
the marker you want to cut is open.
2. From the Recover menu, select Bite Search.
3. In the Bite Search dialog box, type to enter the Bite to Search to. Press
Enter or click the OK button.
The System Messages box reports that the requested bite is found and
gives the piece number of the first piece in that bite.

48WLOLWLHV
This chapter presents a brief overview of the following C200MT utilities:
• Parameter Manager — Customizes setups by editing parameter settings.
• Run Time Biting — Bites markers for cutting.
• PreProcessor — Preprocesses cut file data to reduce cutting time and
material waste when cutting the marker.
• View Marker — Displays pieces and bites in a marker and plays back
how the marker will cut.
• Queue Manager — Creates and edits job queues for processing a select
batch of markers.
• File Manager — Manages marker files, performing such tasks as
copying, moving, renaming, and deleting.
• CIDB — Generates reports about markers processed on a
GERBERcutter.
Chapter 4 Utilities Page 51

Parameter Manager
The Parameter Manager allows you to:
• Change parameters for one or all setups, temporarily, or permanently.
• Create a new setup.
• Change the current setup.
• Print the current setup.
• Search for a specific parameter.
• Assign access levels to parameters.
• Customize the Frequently Used Parameters category for your needs.
For information on using the Parameter Manager, refer to the C200MT Software
User’s Guide.
Access Levels by Password

Access to specific parameters can be restricted in order to prevent accidental
changes. The C200MT program allows for four levels of access to the Parameter
Manager.
• User.
• Supervisor (password required).
• Field Service (password required).
• Software (password required).
Parameters and Categories

Parameters are settings that are included in the setup for your cutter. Some
parameters turn a feature on or off. Other parameters define a value within an
allowable range.
Categories group parameters that relate to a cutter feature. See the table on the
following page.
Page 52 Chapter 4 Utilities

Categories that can be accessed at the user level are listed in the table below. For
Field Service level parameters and information about individual parameters,
refer to the C200MT Software User’s Guide.
Category Parameters Used To
Frequently Used Parameters Provide quick access to frequently used parameters; this category can
be customized.
Knife and Drill Speeds Control knife and drill speed for specific cutting conditions.
Sharpen Parameters Control how and when the knife is sharpened.
Define how the cutter determines wear on the knife blade and when the
knife should be replaced.
Cutting Parameters Control advance and overcut distances and limits.
Control cut angle and slowdown percentage for cutting operations.
Vacuum System Control the vacuum options.
Ignore Codes Tell the cutter to ignore or respond to certain marker data codes.
Bristle Cleaner Control times and number of sweeps for automatic cleaning.
Knife and Path Intelligence Control how Knife Intelligence compensates for cutting forces on
the knife.
Set up Path Intelligence to automatically adjust feed rate for the best
cut quality and throughput.
Data Format/Scaling and RSO Define the format of cut file data or AAMA data conversion.
Define X and Y–axis scaling.
Define marker size.
Initialize RSO cutters.
Bite Parameters Define how the cutter handles bites. Define end park position.
(TCW and ZVC systems)
Options and Modes Turn on/off various GERBERcutter features.
Mirror Image and Clipping Turn on the mirroring options which rotate the marker before cutting.
Window Turn on the clipping window feature and define boundaries.
OPSTOP and Report Options Control how the cutter responds to Opstop codes.
Define Cutter Info Database (CIDB) reporting.
Selvage Cut/Contiguous Cut Control Selvage/Web cutting for vertical line cuts through the selvage
or the selvage and web.
Control processing of consecutive markers.
System Setup Parameters Set maximum beam velocities for dry haul and cutting.
Check system setup parameters set by field service.
Queue Manager Set preferences for handling cut files and job queues in Queue
Manager.
Cut File Preprocessor Set parameters for the Preprocess utility.

Run Time Biting
For TCW and ZVC systems, the Run Time Biting utility bites the marker,
designating sections of the marker for automatic cutting. Each bite fits on the
cutter table and can be cut at one time. Run Time Biting can take place either
while:
• Cutting a marker.
• Preprocessing a marker with Bite Generation (see PreProcessor section
in this chapter).
Settings for Bite Parameters determine the length of the bites and whether they
are equal (static length biting) or variable in length (variable length biting).
For diagrams showing biting, see chapter 2. Also, refer to the C200MT Software
User’s Guide.
Static Length Biting

Static length biting divides the marker into bites of equal lengths. If a piece
extends beyond the bite, the cutter splits the piece and only cuts the portion of
the piece that fits within the bite. When the cutter has finished cutting all pieces
or parts of pieces for that bite, the conveyor advances the next bite. The cutter
then cuts the second portion of the piece.
Variable Length Biting

When Variable Length Biting is turned on, the cutter only splits those pieces too
large to fit on the cutting table. This feature is useful to:
• Eliminate split pieces in a marker requiring pieces not be split.
• When matching plaids and stripes in split pieces.
Using Variable Length Biting, the cutter cuts all pieces in a given bite that
completely fit on the table. The conveyor then advances to the uncut piece
farthest to the left. It cuts that piece and any other whole pieces on the cutting
table. The conveyor again advances to the uncut piece farthest to the left. This
step is repeated until all pieces are cut. Variable length bites usually are shorter
and occur more often than static length bites.

PreProcessor
Use the PreProcessor utility to process and organize cut file data in order to
reduce cutting time and material waste when cutting the marker. Without
preprocessing, all lines for each piece in a marker are cut before the next piece is
cut. The PreProcessor utility optimizes on the normal cutting strategy by using
bite generation and features from the GGT POWER Processor™ program:
• Bite Generation — Generates bite data before preprocessing (see the
Run Time Biting section on the previous page).
• Reorder — Resequences the order in which pieces will be cut in a
marker.
• Common Line — Cuts common lines only once.
• Path Optimization — Cuts pieces more efficiently.
For information on using PreProcessor, refer to the C200MT Software User’s
Guide.
Reorder
Reorder allows the system to automatically determine the sequence in which
marker pieces are cut based on parameters that you can define or change.
Common Line
Common Line analyzes and reorganizes cut files so that all common lines are
cut once. A common line is a line that is shared by two neighboring pieces in a
marker or cut file. This feature can save cutting time and improve cut quality in
common line regions when cutting markers with block–shaped pieces.
Path Optimization
Path Optimization analyzes pieces in a cut file and looks for more efficient ways
to cut them. For example, four neighboring pieces, semicircular in shape, might
be cut as a “figure 8.”

View Marker
Use the View Marker utility to access the GGT Cutview screen. Features in the
Cutview screen allow you to:
• View a marker.
• Change the view scale.
• Overlay a grid.
• Display dry haul lines, bite lines, drill points, and data points.
• Change default colors.
• Playback on–screen how the cutter is going to cut the marker, piece by
piece.
For information on using View Marker, refer to the C200MT Software User’s
Guide.
Selecting Pieces
To select a piece, first click the Piece Select button and then click inside the
piece that you want to playback or get information about. Information about the
cut data for the piece displays on–screen in the Piece Data window.
Tool Code Reference

Use the Tool Code Reference command in the Cutview Help menu to find a
description and example of the tool codes that may display in the Piece Data
window.
Playing Back a Marker

Cutview provides three options for playing back cut data in a marker.
Animate
Use to playback a marker, cutting pieces according to piece number sequence.
Piece by Piece
Use to switch playback modes so that cut data displays one piece at a time,
beginning with a selected piece.
Segment by Segment
Use to switch playback modes so that cut data for a selected piece is displayed
one line segment at a time.

Queue Manager
When processing a batch of markers, use the Queue Manager utility to:
• Create a job queue.
• Run a job queue.
• Close a job queue.
• Select the next job in a queue.
• Edit a job queue.
Queue Manager runs minimized (an icon or task bar button displays at the
bottom of the screen) while the C200MT is running a queue.
For information on using the Queue Manager, refer to the C200MT Software
User’s Guide.
Job Queues
A job queue contains multiple markers to be cut sequentially. Each marker and
the corresponding setup file are called a job. Each job is opened, processed, and
closed automatically until all jobs have been processed.
Using job queues can increase throughput because queues can be created while
other markers are being processed and then run automatically. More than one
job queue window can be open at a time in the Queue Manager screen.
Defaults for Queue Manager

To simplify creating and editing a job queue, the Queue Manager uses the
following default files and directories:
• Location of available markers — C:\USER
• Setup to use when adding a job — DEFAULT.CNF
Queue Manager defaults can be changed using the Change Defaults command in
the Tools menu of the Queue Manager screen.

File Manager
Managing cut files is an important task. You can use the File Manager utility to
perform the following routine data management tasks:
• Copy files from a disk or a network drive to the hard drive of the cutter.
• Move files to another directory on the hard drive.
• Rename files from a previous season.
• Delete files after backing them up to disk or to the network.
• Manage directories.
Note: If you are familiar with Windows NT 3.51 or Windows 3.1

File Manager, you already know how to use features in the
C200MT File Manager. For those learning how to use
Windows, refer to the C200MT Software User’s Guide or
refer to your Windows documentation for additional
information.
Directories and Files

Directories and sub–directories help organize cut files, for example by style or
season. Use the File Manager utility to create or delete directories.
File Manager uses a window to display information about the directories and
files for each drive. More than one drive window can be open at a time. At the
left of the drive window is a directory tree showing all directories on that drive.
Click on a directory to display all files for that directory.
Using Paths to Locate Files

When managing marker files, you may find it easier to type the path to locate a
file rather than making selections with the pointing device. A path is all the
information (drive, directory, and any sub–directory) the system requires to
locate a directory or file. Items in the path are separated by the backslash (\).
For example, to select files in the sub-directory SLACKS in the WINTER

directory on the network H drive, type H:\WINTER\SLACKS.

Using Wild Cards to Locate Files
Using a wild card can simplify managing multiple files. Wild cards replace
similar character(s) in a file name, so that the system considers them the same
file. The “?” wild card replaces one character in a file name; the “*” wild card
replaces several characters.
For example, to move files named SUIT123, SUIT456, and SUITABC,

type SUIT*
Locking File Manager

The File Manager is password protected. The first time the File Manager
command is selected during a C200MT session, the supervisor password must
be entered. File Manager can then be used for the remainder of the C200MT
session or until it is locked again.
Refer to the C200MT Software User’s Guide for more information and the
default passwords.

Cutter Information Database (CIDB)
CIDB is an optional database utility which can be used to generate reports for
the C200MT program. When this option is enabled, the system automatically
inserts information about the marker currently being processed into the Cutter
Info database. Reports based on this data can:
• Be viewed and printed from the C200MT program.
• Be output automatically to a text file in the C:\REPORT directory.
• Be accessed using a database program.
• Include operator comments.
CIDB reports can be viewed on–screen using the Report Generator. For
information on using CIDB, refer to the C200MT Software User’s Guide.
Marker Report Types

The following types of Marker reports are available:
• Partial Marker reports.
• Marker reports.
• Shift reports.
Partial Marker Report

Partial Marker reports are permanent entries in the CIDB database which can be
made before a marker is completely cut. A partial marker report can be:
• Used to obtain CIDB statistics for cutting that has occurred up to the
present, for example, when a shift ends.
• Requested for any marker that is currently being processed, as long as
cutting has not finished.

Marker Reports
For each cut file processed on a GERBERcutter with the CIDB option, marker
reports are automatically entered in the CIDB database. These reports can be
viewed and printed using the Report Generator. Marker reports can also be sent
to a text file, MARKERS.RPT. Marker reports include:
• Prep time (for example, time spent setting the marker origin or opening a
cut file).
• Interrupt time (when the cutter is stopped using the Stop button).
• Sharpen time.
• Bite time.
• Downtime (when the C200MT program is not running).
Shift Reports
Shift reports are summary reports derived from individual marker report times
for the shift. These reports can be viewed and printed using the Report
Generator. A Shift report includes:
• Interrupt time (when the cutter is stopped using the Stop button).
• Downtime (when the C200MT program is not running).
• Percent of operating time and percent of total time for all times reported.
• Distance totals for the shift as well as their percentage of total distance.
• Average cut speed and throughput for the shift.
• Miscellaneous statistics (for example, knife wear and free disk space).
• Operator comments.
• System comments (includes all cutter error messages).

52SWLPL]LQJ&XWWHU3HUIRUPDQFH
Differences in fabric and spreads require that adjustments be made to the cutter.
This chapter covers procedures that help keep your GERBERcutter running at
peak performance. These include:
• Sharpening and replacing the knife.
• Setting defaults for knife speeds.
• Using Knife Intelligence to compensate for lateral force on the knife.
• Using Path Intelligence to automatically control cutter speed based on
knife sharpness, vacuum level, and XY force.
• Controlling vacuum levels.
Note: Setups allow you to set adjustments specifically for differences in

fabrics and spreads. For more information about available
parameters, refer to the C200MT Software User’s Guide.
Sharpening and Replacing the Knife

The knife blade must be sharp and within wear limits to cut properly. C200MT
features provide:
• Automatic sharpening cycles while cutting.
• Sharpening when the cutter is idle.
• Sharpening when installing a new knife.
• Resetting default knife speeds.
WARNING! The knife blade is very sharp. See chapter 6 for specific
procedures to inspect, adjust, remove, and install a knife blade.
Chapter 5 Optimizing Cutter Performance Page 63

Automatic Sharpening
The GERBERcutter provides automatic sharpening cycles which occur while a
marker is being cut. Automatic sharpening is controlled by Sharpen parameter
settings in the setup. For example, how often a sharpen cycle occurs can be
based on cutting distance or piece count.
For specific information, refer to the C200MT Software User’s Guide.
Sharpening When the Cutter is Idle

When the cutter is idle, a sharpen cycle can be initiated manually for the current
knife or a newly–installed knife.
Note: If you are sharpening a newly–installed knife, first use the New
Knife command.
To sharpen when cutter is idle
1. Make sure the knife motor is running.
WARNING! The knife blade is very sharp. See chapter 6 of

this manual for specific procedures to inspect, adjust,
remove, and install a knife blade.
− Press the Sharpen key on the keyboard.

− Press the SHARP button on the beam control panel.
3. In the Sharpen Knife dialog box that displays on–screen, press Enter
or click the OK button to accept the defaults for sharpening the current
or a new knife. Or you can enter a different number of sharpens.
When sharpening is finished, the Knife Wear gauge is reset.
Page 64 Chapter 5 Optimizing Cutter Performance

Resetting for New Knife
Your cutter uses knife wear logic to track sharpening cycles for the current
knife. This logic, which prompts when the knife wear limit is reached, must be
updated whenever a new or partially–used knife is installed. For information
about setting Sharpen parameters which affect knife wear logic, refer to the
To reset for a new knife
1. Carefully install a new or partially–used knife blade.

2. Turn on the knife motor .
3. From the Cutter menu, select New Knife.
4. In the New Knife dialog box, check the appropriate radio button for a
Brand New or Used knife. If Used is selected, type the number of times
this knife was previously sharpened.
5. Press Enter or click the OK button to reset the Knife Wear gauge.
Note: After installing a new knife, perform a sharpening cycle (as

described on the previous page) before beginning to cut.

Setting Knife Speeds
The table below briefly explains knife speeds that can be adjusted for the current
session or set as defaults in the setup.
Knife Speed Type Use to
Idle Set reciprocating speed when the cutter is idle.

Dry Haul/Maximum Set reciprocating speed during dry haul.
Set minimum reciprocating speed when cutting.
Cut/Maximum Set maximum reciprocating speed when cutting.
Sharpen Set reciprocating speed during sharpen cycle.
Cut Speed=Maximum Define the relationship between maximum cutting speed and
the cutting speed dial on the beam control panel.
To set knife speed defaults, use the Set Knife Speed feature in C200MT. Refer
to the C200MT Software User’s Guide.
Note: Make sure that the cutter is in the mode for which you want to set
knife speed. For example, the cutter must be at idle to set Idle Knife
speed.

Using Knife Intelligence
Knife Intelligence (KI) optimizes cutting performance by:
• Sensing deflection of the knife (lateral force) caused by cutting difficult
materials or high ply spreads.
• Changing knife angle to compensate for this deflection.
Setup parameters in the Knife and Path Intelligence category define Knife
Intelligence for GERBERcutters. Refer to the C200MT Software User’s Guide.
Knife Intelligence features available in the C200MT program are briefly

described below and on the next page.
KI Settings
Use the Knife Settings command in the Cutter menu to quickly adjust the
following parameter settings used to compensate for knife deflection:
• KI: Gain — Controls the amount of force which can be used.
• KI: Deflection Angle — Sets the greatest angle allowable for KI to turn
the C–axis.
Nulling Knife Intelligence Sensor

Use the Null KI command in the Cutter menu to reset (to zero) Knife
Intelligence sensor. This command should be used:
• When KI is first turned on.
• Daily after the cutter is initialized (when using KI).
• For each new spread (when using KI).
To null Knife Intelligence
1. Use the slew buttons on the beam control panel to move the cutter head
until the knife blade is just off the edge of the spread.
2. Turn on the knife motor .
3. Turn on the vacuum .

− From the Cutter menu, select Null KI. In the KI Warning box,
press Enter or click the OK button.
− Press the button on the beam control panel twice.

The knife plunges and then rises. The System Messages box prompts
when the Null procedure is completed.
5. As needed the KI Calibration diagnostic (see chapter 7) should be used

at the beginning of each shift to calibrate the Knife Intelligence
deflection voltage sensor.

Using Path Intelligence
Path Intelligence completely or partially controls cut speed using built–in
application knowledge and by measuring one or more of the following:
• Knife sharpness.
• Vacuum level.
• XY force.
Setup parameters in the Knife and Path Intelligence category define the Path
Intelligence (PI) feature. Settings can only be changed when the cutter is idle.
Refer to the C200MT Software User’s Guide.
Path Intelligence Diagnostics

The following diagnostics are available to calibrate for Path:
Calibration — Use to set up PI and test the current draw of the cutter head and
beam. This diagnostic should be used at least once daily and for each new
spread.
Watch Forces — Use to determine the maximum speed setting and number of
plies to cut.

Controlling Vacuum Levels
Your GERBERcutter uses vacuum to hold material firmly on the table work
surface during cutting. Setup parameters in the Vacuum System category (refer
to the C200MT Software User’s Guide) define how the cutter:
• Uses vacuum zoning.
• Displays vacuum error warnings.
• Controls vacuum levels and ensures quality cutting; only for cutters
equipped with Vacuum Level Control system.
• Uses the energy savings mode when the cutter is idle.
• Reports low vacuum levels.
Energy Savings Mode
Note: The Energy Savings Mode (ESM) parameter must be enabled. Refer
To turn on Energy Savings Mode
1. Make sure the vacuum is turned on.
2. From the Cutter menu, select Energy Savings Mode.
In the main C200MT control screen, the Vacuum Level gauge label is
changed to Energy Savings Mode.
3. Select again to turn off ESM.

S91 Maintenance
60DLQWHQDQFH
This chapter covers preventive maintenance and corrective maintenance
procedures for the S91 GERBERcutter. Preventive, or scheduled, maintenance
is important because it improves cut quality and extends machine life. Highly
technical procedures or those requiring special skills, such as adjusting
alignments for the knife and motors, should only be performed by maintenance
personnel who have received GERBERcutter training. Otherwise, call your
GGT Service Representative.
Use the table below or the index for this manual to quickly find maintenance
procedures. Illustrations on pages 76 and 77 show assembly locations.
Assembly Subassembly Page Number
Head cover 103

knife drive train 80, 104
knife 106, 170
sharpener 81, 107
guides and rollers 110
elevator 80, 86, 112
C–axis 85, 113
yaw alignment 79
knife drive 80, 86, 97, 113
alignment/speed adjustment 79, 91, 109, 115
Drill drill bit 116, 171
assembly 81, 87, 92, 97, 118
Beam covers 122
X–axis
gearing and belts 87, 123
scale test 89, 127
Y–axis
roundway and squareway 82, 92, 121, 126
gearing and belt 93, 124, 128
scale test 89, 127
Table work surface 130
cleaner 99, 132
roundways and racks 82, 133
vacuum
filters 82, 94, 134
motor and cover 93, 98, 135
Spencer turbine 93, 98, 136
Hoffman blower 94, 98, 136
conveyor and clamp bar 89, 95, 99, 138
lay puller 95, 99, 140
resealer 89, 138
platform and overhead cable 100, 102, 141
Chapter 6 Maintenance Page 71

Safety Precautions
In addition to the safety warnings below, refer to the Safety Precautions chapter
at the beginning of this manual.
WARNING! High voltages exist inside the C200 controller,

vacuum and platform electrical enclosure and the cutting table.
There are no operator–serviceable parts inside. Only qualified
personnel should perform maintenance on these assemblies.
Contact your Service Technician in case of a problem. Failure
to follow these instructions could cause injury or death.
WARNING! To avoid serious injury, turn off the C200 controller when
instructed. With the main circuit breaker of the C200 controller
turned on, power is applied to the cutting table and vacuum
generator. Parts could move suddenly.
WARNING! The origin light on the cutter head uses a Class IIIa laser
product which points toward the cutting surface. Never look
directly into the laser light source; doing so may cause
temporary, or even permanent, damage to your eyes. To avoid
potentially harmful reflections, remove all highly–reflective
material (such as jewelry) from the cutting surface before
turning on the origin light. Turn off the origin light before
performing any maintenance on the GERBERcutter.
Page 72 Chapter 6 Maintenance

S91 Maintenance
Maintenance Procedures
Basics
The following sections cover basic procedures that need to be performed while
maintaining a GERBERcutter. These include:
• Removing covers for the head, beam control panel, and end cap.
• Replacing a knife blade.
• Inspecting, cleaning, and lubricating head, beam, and table components.
• Maintaining the table.
• Cleaning filters for vacuum and stack.
WARNING! To prevent injury, turn off the main circuit breaker for the cutter
before performing maintenance procedures, unless instructed
otherwise.
Advanced
CAUTION: To prevent damage to the cutter and/or fabric, only qualified operators
or maintenance personnel who have received GERBERcutter training
should perform the following procedures.
In addition, there are advanced procedures that should only be performed by

operators or maintenance personnel who have received GERBERcutter training.
These procedures are indicated by the above caution and include:
• Performing sharpener assembly and presser foot maintenance.
• Checking mechanical alignments, such as heel to heel knife alignment
and that the beam is squared.
• Belt tensioning.
Electrical
Procedures requiring electrical drawings are not covered in this manual.
Personnel who have received GERBERcutter training should refer to the
appropriate Service Manual or Reference drawings for the cutter.
WARNING! High voltages exist within the vacuum and platform

electrical enclosure and inside the C200 controller. Only qualified
personnel should perform electrical maintenance procedures. There
are no operator–serviceable parts inside.

General Maintenance
This section provides hints on performing general cleaning and lubrication for
your GERBERcutter.
Cleaning
• In general, use a clean rag to wipe old grease, dirt, and lint away.
• Denatured alcohol can be applied sparingly with a rag to remove
stubborn dirt accumulations. To prevent damage to components made of
rubber or to BRISTLE SQUARES, do not use regular alcohol.
Lubrication
• Apply lubricants sparingly with a clean rag.
• Use a stiff paint brush to apply multipurpose grease sparingly.
• Use a grease gun with the appropriate adapter for zerk fittings or a
needle tip where indicated. Fill and then wipe away any excess grease.
CAUTION: Apply all lubricants sparingly. Excess oil or grease can

damage fabric. It is better to lubricate lightly and more
frequently than it is to apply one heavy coat.
Lubricant/Cleaner Uses GGT Part No.
GSG–44 Belt pulley, knife guides, knife blade 072395000

Loctite Safety Solvent Sharpener stones 308010101
Petro–Lon Mulitpurpose 596500005
Shell Alvania EP2 Swivel assembly 596500006
Fiske Lubriplate Lithium–based grease 596002003
Chevron SRI–2 Spencer vacuum turbine 596041001
Ordering Spare Parts

If you find a broken or worn part while performing preventive maintenance, you
can order replacement parts through Product Support. For those inside the
United States and Canada, call GGT Product Support at 800-999-1448. For
those outside the United States and Canada, please call your local Sales and
Service office.
Note: The Service Parts CD–ROM is a useful tool for identifying parts and
part numbers. Ask your local Sales and Service office about
availability.

S91 Maintenance
Tools Available from GGT

The table below lists tools available from GGT for general maintenance
procedures for the S91 GERBERcutter. Specific GGT parts or tools required for
a procedure are listed at the beginning of that procedure.
Tool Description GGT Part No.
screwdriver set 944211601

socket drive 3/8 in. with 6 in. extension 944582805
crowfoot attachment 3/8 in. x 7/16 in opening 945500000
socket set 1/4 in. and 3/8 in. 944212801
snap ring pliers 90 deg. 944003901
pliers 944003903
wrench 1/4 in. 945500005
wrench 1/2 in. opening 3/16 in. thick 944012502
open end wrench 5/8 in. to 9/16 in. 944012503
hex wrench 1/4 in. 020945000
T-handle hex key set 945500051
right angle handle hex key set 944022402
9-piece open-end combination wrenches 944002401
spanner wrench 021513000
spring scale 945500034
marker pen 608042001
Note: This tool list may vary slightly depending on your system
configuration.
Additional Tools
Additional tools required for basic procedures in this chapter:
• Clamping pliers.
• Industrial shop vacuum.
• Ruler.
• Step ladder.
For advanced procedures by personnel with GERBERcutter training:
• Tachometer or strobe light.
• Feeler gauges.

S91 TCW
Cutter
Head
Resealer
Beam Clamp
Bar
Take–off End Operator Side Beam

Control
Panel
Surface Cleaner Operator

Access Door Workstation
Front
Ramp
(Take–on
Cover)
Vacuum
Filter Platform
Drum Control
Panel
Traveling
Stack
Light
(Mast)
Conveyor
Work
Surface
Front Beam
Ramp
(Take–on
Cover)
End Cap
Cover
C200
Controller Clamp
Panel Bar
Take–on End Remote Side
RSO
Platform
Panel
Platform Drive
Wheel
Assembly

S91 Maintenance
S91 Static
Flat
Panel
Operator Side
Cutter
Head Operator
Workstation
Stationary
Work
Surface
End
Cap
Cover
Beam Left End
Remote Side
S91 ZVC
Beam Cutter
Operator
Head
Workstation
End
Conveyor Cap
Work Cover
Surface
Beam
Take–off End Control
Panel
Operator Side

8 Hour Maintenance Schedule
Maintenance Summary and Schedule

The next sections summarize by assembly the preventive and corrective
maintenance procedures recommended for your GERBERcutter. Checklists for
each maintenance schedule are included in the appendix.

In general, eight hour (per shift) maintenance procedures include:
• Removing lint buildup from and lubricating components.
• Cleaning filters.
• Checking knife alignment.
• Performing knife sharpener maintenance.
WARNING! To avoid serious injury, turn off the C200 controller when
instructed. With the main circuit breaker for the C200 controller turned
on, power is applied to the vacuum and platform control enclosure and
cutting table. Parts could move suddenly.
CAUTION: Excess oil or grease can damage fabric. Apply sparingly.
Head
Check knife yaw alignment
Use the C Home to System Zero diagnostic. See Chapter 7.
Check knife offset alignment

Use the Knife Offset Setup diagnostic. See Chapter 7.
Check knife intelligence alignment

1. Use KI Null. See Chapter 5.
2. Then use KI Calibration diagnostic to calibrate the KI sensor.
See Chapter 7.

Fill the tension arm oil cups (a)

1. Turn off power at the C200 controller and open the head cover.
(a)
2. Fill each cup with 10 weight synthetic oil.
(b)
3. Wipe clean. Lightly apply 10 weight synthetic oil.
(c)
Fill the pivot arm oil cup (near b)
Same as above.
Clean and film coat the air cylinder rod (c) for the elevator
Clean and film coat the two elevator guide rods (d)
Same as above. (f)
(g)
Head — Knife Drive Train
2. Follow the procedures for removing and inspecting the knife drive
train beginning on page 104.
(d)
Clean and lubricate swivel assembly
1. Use the swivel lube kit to fill the lubrication hole (e) in the swivel
assembly with grease. Wipe away any excess. (e)
2. Lightly apply multipurpose grease to the outside of the swivel
assembly before installing in the cutter tube.
Clean and lubricate knife articulating arm (f)

Wipe away old grease. Lightly apply multipurpose grease.
Clean and lubricate cutter tube (g)

1. Wipe out old grease.
2. Lightly apply multipurpose grease to the inside of the cutter tube.
Reassemble
1. Follow the assembly procedures on page 104.
2. Then check bristle penetration on page 112.

(a) (b)
Head — Sharpener Assembly
Turn off power at the C200 controller and open the head cover.
Perform sharpener assembly maintenance and knife blade

alignment, as necessary
Follow the procedure on page 107.
Clean and film coat the knife presser foot slide rod (a) and rod
guide (b)
Wipe clean. Lightly apply 10 weight synthetic oil.
(c)
Clean and film coat the air cylinder rod for the knife presser foot
1. Reduce air pressure to the head. Lower the air cylinder (c).
Perform knife guide alignment, as required

Follow the procedure on page 110.
Drill
Turn off power at the C200 controller.
Clean and film coat the up/down air cylinders (a) for each drill
unit
1. Reduce air pressure to the head. Lower the drill unit to access the
two air cylinder rods.
(a)
3. Repeat for the auxiliary drill, if available.
Clean and film coat the air cylinder rods (b) for the drill presser
foot
(b)
1. Reduce air pressure to the head. Lower the presser foot.

Beam
Inspect, clean, and film coat the Y–axis roundway (a)
1. Turn off power at the C200 controller.
2. Check for scratches, nicks, and gouges which can damage
bearings. If found, contact Field Service.
3. Check for debris. Wipe clean. Lightly apply 10 weight synthetic
oil.
Clean and film coat the Y–axis squareway (b) (b)

Table
(a)
Inspect, clean, and film coat the X–axis roundways (c)
2. Check for abrasions or scoring. If found, contact Field Service.
3. Check for debris. Wipe clean. Lightly apply 10 weight synthetic
oil. (c)
Inspect the X–axis racks (d)

2. Check for damaged teeth, scoring or abrasion. If found, contact
Field Service. (d)
3. Check for excess debris and wipe away.
Table — Vacuum
Clean the vacuum intake filter
1. Turn off power at the C200 controller. For Static and ZVC
systems, turn off power at the external vacuum assembly.
2. Remove the nut and bolt and then the retaining ring. Remove the
cover (indicated).
3. Remove the wing nut and then remove the screens and filter.
Vacuum the filter, screens, and inside of the drum. Soak the filter,
if necessary.
4. Reinstall the filter and cover.

(a)
Table — Vacuum (contd.)

Check for fluid in air/reducer filters
systems, turn off power at the external vacuum assembly.
2. Take note of the air pressure setting. For each of two filters, turn
the top cap (a) to reduce air pressure before proceeding. (b)
3. Loosen the drain plug (b) at the bottom of the filter.
4. Allow any fluid to drain out.
5. Retighten the drain plug and reset the air pressure.



Depending on the number of shifts required by your production schedule, the
following maintenance procedures need to be performed at least once and
possibly three times per week. These procedures include:
• Cleaning, lubricating, and checking X, Y, and C–axis gears.
• Checking drive belt tension.
• Checking head stops.
WARNING! To prevent injury, turn off the main circuit breaker for the C200
controller before performing maintenance procedures, unless
instructed otherwise.
Head — C–axis Drive

Check C–axis drive belt (a)
2. Check for wear or damage. To prevent slippage, the belt must be
wiped free of any grease.
3. Check belt tension. There should be approx. 6 or 7 mm (1/4 in.)
deflection at the center of the belt. Replace the belt, if needed.
See page 113.
(b)
Clean, lubricate, and check C–axis servo gearing (b)
(a)
2. Wipe away old grease. Check for wear and damaged teeth.
3. Lightly apply multipurpose grease.

Head — Knife Drive

Check tension of knife drive belts
2. Check for belt wear or damage. To prevent slippage, the belt must
be wiped free of any grease. Replace the belt, if needed.
3. Check belt tension. Adjust, if needed. See page 114.
Check mechanical alignment of the knife

1. Use the Heel to Heel Cut Test diagnostic along with the knife
alignment box. See chapter 7.
2. Adjust mechanical knife offset, if needed. See page 111.
Check head upper stop

(a)
2. With the head assembly up (as shown), set the flywheel (a) at the
top of its stroke (TDC).
(b)
3. Adjust the upper stop (b) until the corner edge of the knife blade is
in the middle of the lower grinding wheel (shown).
Check head lower stop (c)
1. Remove air pressure from the head. With the head assembly down
(not shown), set the flywheel (a) at TDC.
2. Adjust the lower stop (c) until the tip of the knife blade penetrates
the bristle to proper depth. See below.
Flywheel Stroke Depth
Grinding
13/16 in. 1/8 in. (3.2 mm) Wheel
1 in. 1/16 in. (1.6 mm)
Chopping 3/8 in. (9.3 mm)
set @ BDC
Corner
Edge
Table
Surface

Drill
Check the drill belt(s)
1. Turn off power at the C200 controller and remove the drill motor
cover (indicated).
2. Check for belt wear or damage. To prevent slippage, the belt must
be wiped free of any grease. Replace the belt, if needed.
(b)
Beam X and Y–axes Gearing
Clean, lubricate, and check first X–axis pinion gearing (a)
1. Turn off power at the C200 controller. Remove the beam control
panel cover.
2. Wipe clean and check gears for nicks. Check for a slight amount
of backlash between gearing. (a)
Note: Check in several places in case there are any high spots in (g)
the gears or racks. (c)
Clean, lubricate, and check first X–axis servo gearing (b)

Same as above.
Clean, lubricate, and check Y–axis countershaft gearing (c)

(d)
Same as above.
Clean, lubricate, and check Y–axis servo gearing (d)

(g)
Same as above.
Clean, lubricate, and check second X–axis pinion gearing (e in

both views)
(e)
1. Turn off power at the C200 controller. Remove the end cap cover.
2. Wipe clean and check gears for nicks. Check for a slight amount
of backlash between gearing.
Note: Check in several places in case there are any high spots in
the gears or racks.
Clean, lubricate, and check second X–axis servo gearing (f) (f)
(e)
Same as above.

Beam — X and Y–axes Gearing (contd.)

Check the torque tube drive belts (g on previous page)
panel and end cap covers.
2. At both sides of the beam, check for wear or damage. To prevent
slippage, the belts must be wiped free of any grease. Replace the
belt(s), if needed.
Clean, lubricate, and check wheel housing cam rollers

panel cover as needed to access zerk fittings.
(a)
2. Find four cam rollers (a) on the beam control side of the cutter
(two shown; two on the squareway side of the beam).
3. Check for any binding against the roundway when moving the
beam along the full length of the table. Adjust cam rollers, if (a)
(b)
needed. See page 125.
4. Fill zerk fittings on each cam roller with multipurpose grease.
Clean and lubricate first X–axis wheel assembly

panel cover cover as needed to access zerk fittings.
2. Find zerk fittings on two wheel assemblies (b), one shown. Fill
with multipurpose grease.
Clean and lubricate second X–axis wheel assembly

1. Turn off power at the C200 controller. Remove the end cap cover
as needed to access zerk fittings.
2. Find zerk fittings for two wheel assemblies (c), one shown from
the back. Fill with multipurpose grease. (c)

Beam — X and Y–axes Gearing (contd.)

Perform X–axis spring scale test Bite Encoder for TCW
See procedure on page 127.
Perform Y–axis spring scale test

See procedure on page 127.
Beam — Bite Encoder

Clean and inspect bite encoder wheel (TCW and ZVC) Bite Encoder for ZVC
2. Check that the grit on the encoder wheel is not worn away.
3. Remove any plastic that might be wrapped around the wheel.
4. Tighten the set screw on the collar, as needed. Check that the
wheel remains positioned directly over the bite indicator strip(s)
along the edge of the cutting table.
Table — Clamp Bar (TCW)

Clean and film coat the clamp bar air cylinders
1. With power on, lower the clamp (shown in up position).
2. Wipe away debris from two air cylinder rods. Lightly apply 10
weight synthetic oil.
Table — Resealer Option (TCW)

Clean and film coat the resealer air cylinder rods
1. With power on, run the Input Output Test (DG 23) diagnostic.
See chapter 7.
(a)
2. Raise the resealer bar (a).
3. Wipe away debris from the air cylinder rods, one located in each
end post (b). Lightly apply 10 weight synthetic oil.
(c)
Check resealer bar up/down air flow adjustment
1. Raise and lower the resealer bar, checking for even motion.
2. If up or down motion is uneven, adjust air flow by turning the
adjustment screw (c) on the hose connector for each air cylinder.
(b)



following maintenance procedures need to be performed three to six times
yearly. These procedures include:
• Running diagnostics to check knife or drill speed and that the beam is
square.
• Checking beam bearings.
• Checking table and vacuum components.
Head
Check knife speed adjustment
(should be OK for one year)
1. With the power on, use the Parameter Manager to set a low knife
speed.
2. Run the Input Output Test (DG23) diagnostic to enable the knife
drive. See chapter 7. Use a tachometer or strobe light to verify the
low speed setting.
3. If necessary, adjust the Zero and Max potentiometers on the knife
drive board.
4. See adjustment procedure and warnings on

page 115.
5. Repeat steps 1 through 4, setting and verifying a high knife speed
setting.

Drill
Check drill speed adjustment for each drill unit
(should be OK for one year)
1. With the power on, use the Parameter Manager to set a low drill
speed.
2. Run the Input Output Test (DG23) diagnostic to enable the drill
drive. See chapter 7. Use a tachometer or strobe light to verify the
low speed setting.
3. If necessary, adjust the Zero and Max potentiometers on the drill
drive board.
4. See adjustment procedure and warnings on

page 119.
5. Repeat steps 1 through 4, setting and verifying a high drill speed
setting.
6. Repeat for the auxiliary drill, if available.
Beam — Y–axis
Check Y–axis roundway bearings
2. Attempt to physically move the cutter head from side to side. If
you notice movement, adjust the roundway bearings (a). (b)
See page 126.
3. Note: There should be no binding on the Y–axis. (a)
Check Y–axis squareway bearings

2. Attempt to move the cutter head up and down. If you notice
movement, adjust the squareway bearings (b). See page 126.
3. Note: There should be no binding on the Y–axis.

Beam — Y–axis (contd.)

Check Y–axis belt
2. Push the cutter head toward the operator workstation.
3. Check the belt for signs of wear or fraying. Replace if damaged.
4. Check belt tension by inserting several fingers under the belt at a
location approx. 60 cm (2 ft.) from the end cap cover. You should
be able to raise the belt 2.5 to 3.8 cm (1 to 1 1/2 in.) only.
5. Adjust the tension, if needed. See page 128.
Check if beam is square

1. Run the Beam Square Test diagnostic. See chapter 7.
2. Square the beam, if needed. See page 129.
Table — Vacuum
Check vacuum generator belts (Spencer turbine)
systems, turn off power at the external vacuum assembly and at
the table control or lay puller panel.
2. For TCW systems, remove front ramp. For Static and ZVC
systems, remove the jack shaft cover.
3. Check the belt(s) for wear or fraying. Replace all belts, even if
only one is damaged.
4. Check belt tension by depressing the center of the belt(s) between
the vacuum motor and vacuum turbine. Compare the deflection
amount with manufacturing specs.
5. To adjust or replace the belt(s), see page 136.


Check vacuum generator belts (Hoffman blower with pillow block
assembly)
1. Turn off power at the C200 controller. Turn off power at the
external vacuum assembly and at the table control or lay puller
panel.
2. Check the belt(s) for wear or fraying. Replace if damaged.
3. Check belt tension by depressing the center of the belt between the
vacuum motor and the pillow blocks. Compare the deflection
amount with manufacturing specs.
4. To adjust or replace the belt(s), see page 136.
Clean vacuum stack filter

systems, turn off power at the external
vacuum assembly and at the table control
or lay puller panel.
2. Use a step ladder to reach the stack.
3. Remove the wing nut and then the filter
and screens from the top of the vacuum
stack filter.
4. Clean the filter by soaking.
5. Reinstall or replace, if needed.

Table — Material Handling (TCW and ZVC)

Check conveyor drive alignment
1. Place a typical production spread on the spreading table.
2. At the Platform control panel (TCW shown), set the Conveyor
Mode to Manual.
3. Jog the conveyor.
4. If the conveyor movement is not satisfactory or the motor
“growls” for too long before the conveyor begins moving, adjust
potentiometers on the drive board.
5. See warnings and procedure on page 139. See

also the documentation for the conveyor drive.
Table — Material Handling (Static)

Check lay puller drive alignment
1. Position a typical production spread in the lay puller.
2. Jog the lay puller.
3. If the lay puller movement is not satisfactory or the motor
“growls” for too long before the lay puller begins moving, adjust
potentiometers on the drive board.
4. See warnings and procedure on page 140.



following maintenance procedures need to be performed two to three times
yearly. These procedures include:
• Checking knife and drill motor bushings.
• Checking fluid levels of gear boxes for conveyor and surface cleaner.
• Cleaning and lubricating platform components.
• Lubricating vacuum motor and turbine/blower.
• Checking overhead cable trolley.
Head
Check knife drive motor brushes
1. Turn power off at the C200 controller.
2. Remove two bushing caps (one shown) to gain access to the motor
brushes.
3. Check for excessive wear. Replace the brushes and caps, as
Drill
Check drill motor brushes
1. Turn power off at the C200 controller. Remove the drill drive
motor cover (indicated).
2. Remove two caps to gain access to the motor brushes.
3. Check for excessive wear. Replace the brushes and caps, as

Table — Vacuum Motor

Lubricate Baldor vacuum motor
1. Turn power off at the C200 controller. For Static and ZVC
systems, also turn off power at the external vacuum assembly and
at the table control or lay puller panel.
2. Remove the front ramp for TCW only. Find two zerk fittings on
the vacuum motor (indicated).
3. Fill with lithium–based grease.
Lubricate Spencer vacuum turbine
(Required more often for extreme ambient temperatures, bearing Turbine

temperatures of 120 to 170 deg F, and in very dirty operating
conditions; required less often for intermittent operation.)
1. With the front ramp removed (TCW only), find two fill cups on
the vacuum turbine (indicated).
2. Insert a clean, metal probe into each cup several times to a depth
of 35 mm (1 1/2 in.).
3. Remove the probe and fill with Chevron SRI #2 grease.
4. Repeat insertion of probe and filling with grease three or four
times.
Lubricate Hoffman blower (a)

(should be OK for 1800 to 2000 hours) External Vacuum
System with Blower
1. Turn power off at the C200 controller. Also, turn off power at the
external vacuum assembly and at the table control or lay puller (b)
panel.
2. At the end of the blower, open the top and bottom plugs (not
shown).
3. Insert a metal rod through the top plug opening and push old
grease out of the bottom plug opening.
4. Fill from the top with Chevron SRI #2 grease until clean grease
comes out of the bottom plug. Replace the plugs.
(a)
Lubricate pillow blocks (not shown)
1. Depending on the setup of the external system, find zerk fittings
on two pillow blocks.
2. Fill with lithium–based grease.


Check Hoffman coupling alignment
1. Turn power off at the C200 controller. Also, turn off power at the
external vacuum assembly and at the table control or lay puller
panel.
2. Remove the coupling guard (b on previous page).
3. Use hot system method to check coupling alignment.
See page 137.
4. Use cold system method to adjust alignment. See page 137.
Table — Material Handling (TCW and ZVC)

Check fluid level of conveyor gear box
(change every third time)
2. For TCW systems, remove the front ramp and several slats to gain
access to the gear box. For ZVC systems, remove the take–on
cover.
3. Remove the fill screw from the gear box. Check the oil level.
4. As required, add SAE 600 weight oil to the center line of the shaft.
Table — Material Handling (Static)

Check fluid level of lay puller gear box
2. Remove the oil level plug at the side of the gear box. Check the oil
level.
3. As needed, add SAE 600 weight oil through the vent fitting up to
the oil level fitting.

Table — Surface Cleaner (TCW)

Check fluid level of surface cleaner gear box (c)
2. Remove the cover (a) for the gear box.
3. Remove the fill screw on top of the gear box and check the fluid
level.
4. As required, add SAE 600 weight oil to the level indicated on the (a)
side of the gear box.
(b)
Lubricate surface cleaner pillow block bearings
2. Open each access door (b in both views) at the take–off end of the
cutter.
3. Using a flashlight, locate each of two pillow block bearings, one
on opposite sides of the cutter (c in both views indicates general
location).
4. Each bearing has a zerk fitting. Fill with multipurpose grease.
(c)
(b)
Table — Platform Drive (TCW)

Clean and lubricate platform drive chain
1. Turn power off at the C200 controller. Also, turn off power to the
table control panel.
2. Remove round black plates, two located on the remote side
(d – one shown) and one located on the operator side of the cutter
behind the GERBERcutter name panel. (d)
3. Lighly apply multipurpose grease to the chain.

4. Manually reposition the chain, as needed to complete the job.
Lubricate platform drive sprocket bearings

1. Turn power off at the C200 controller. Also, turn off power to the Location of drive
table control panel. sprocket zerk fittings
on cutter
2. Locate four zerk fittings on the sides of the cutter as shown at
right.
3. Fill with multipurpose grease.

Table — Platform Drive (contd.)

Lubricate platform drive cam roller bearings
2. Remove the front ramp and several slats to gain access to two cam
roller bearings, each with one zerk fitting.
3. Fill with multipurpose grease.
Check fluid level of platform drive gear box

2. On each side of the cutter, remove covers over the platform drive
wheel assemblies (a).
3. Remove the fill screw from the gear box. Check the level.
4. As required, add SAE 600 weight oil to the center of the shaft.
Lubricate platform drive shaft bearings

(a)
2. On the remote side of the cutter, remove the cover from the
platform drive wheel assembly. On the operator side of the cutter,
find the access holes.
3. Fill zerk fittings on each drive shaft with multipurpose grease
(four fittings total).
Lubricate platform wheel cam roller bearings

1. Turn power off at the C200 controller. Also, turn off power to the (b)
2. Find the access holes (b) in the covers for the platform drive
wheel assemblies, one assembly on each side of the cutter at the
take–off end.
3. Fill zerk fittings on each wheel cam roller bearing with
multipurpose grease (four fittings total).

Table — Overhead Cable Trolley (TCW)

Check roller and clamps for overhead cable trolley
1. Turn power off at the C200 controller. Also, turn off
power to the table control panel.
2. Wipe roller bearings clean.
3. Lubricate sparingly with multipurpose grease.

Cover Maintenance
Cover
Cutter Head
The cover encloses the cutter head. It is a
The cutter head contains the knife and two–piece unit that protects the cutter head
performs the actual cutting of material. components from damage and the operator
It moves across the cutting table on the beam. from injury.
Knife Open/Remove
Drive
Elevator
Assembly
WARNING! To prevent injury, turn off

the main circuit breaker for the
C200 controller before
performing maintenance
procedures, unless instructed
otherwise.
2. Lift to open (or raise) the front cover

Knife
Drive C–axis section.
Train Motor
Cutter
3. If it is necessary to remove the front and
Tube back sections of the cover:
Sharpener
Assembly a) Remove all screws that attach the
back cover section to the frame.
b) Slide the two cover pieces up and off
Cutter head assemblies covered in this section the cutter head.
are listed in the table below.
Assembly See Page WARNING! Do not routinely operate

the GERBERcutter without the
Cover 103 cutter head covers; this could
cause injury.
Knife Drive Train 104
Knife 106 Install/Close
Sharpener Assembly 107
1. If the front and rear sections of the cover
Knife Guides and Offset 109
were removed:
Elevator 112
a) Slide the two cover pieces over the
C–axis Drive 113
cutter head so that they rest in the
Knife Drive 113 groove of the cutter head.
b) Replace and tighten all screws that
attach the back cover section to the
frame.

Knife Drive Train Maintenance
2. Lower and close the front head cover.

Inspect
3. If you are through with maintenance,
Turn on power at the C200 controller. 1. Wipe away old grease from the:
− Articulating arm.
− Inside of the cutting tube.
Knife Drive Train
− Swivel assembly.
The knife drive train moves the knife and
2. Inspect the swivel assembly for gouges,
works with the C–axis gear to let the knife cut
cracks, and other damage. Rotate the stem
corners, notches, curves, and other complex
of the swivel assembly several times to
shapes. The drive train is comprised of a
check for binding. If there are any defects
flywheel, connecting rod, pivot block, swivel
or the stem binds, replace the assembly.
link, swivel assembly, and knife.
Maintenance procedures related to this Flywheel

part of the cutter are covered in the 8 hour
maintenance schedule. Screw 1
Connecting Rod
Pivot Block and Articulating Arm

WARNING! The knife is very sharp.
Screw 2
To prevent personal injury,
exercise care in handling the
knife during any maintenance
procedure.
Swivel Link
Remove
2. Open the cutter head cover. Swivel Assembly
3. Remove screw 2 which fastens the swivel

link to the pivot block and articulating
arm.
4. Lower the swivel link into the cutter tube

Knife
(see previous page).
5. Disconnect the connecting rod from the

flywheel by removing screw 1.
6. Pull the swivel link, swivel assembly, and

knife out of the cutter tube.

Knife Drive Train Maintenance
6. Check the knife penetration into the

Required Supplies GGT Part No. bristle. See page 112.
swivel lube kit 031154000 CAUTION: Always check bristle penetration

EP2 lubricant 596500006 when you install a new knife.
Failure to check the depth of
Lubricate bristle penetration can damage
the work surface.
1. Using the grease gun with the 0.050 in.
needle installed, inject grease into the 7. Check knife operation:
lubrication hole of the swivel until it
a) At the beam control panel, set the
starts to seep out around the stem. Wipe
knife switch to ON.
off excess grease.
Lubrication Hole
b) Check that the knife moves smoothly
with no unusual noise. If you notice
any problems, call your service
representative.
c) At the beam control panel, set the
CAUTION: Excess lubricants can damage knife switch to OFF.
fabric. Apply sparingly.
8. At the operator workstation, use the New
2. Using multipurpose grease, lightly coat Knife command in the Cutter menu to
the: reset the knife wear logic.
− Outside of the swivel assembly. 9. Execute several sharpening cycles by
− Inside of the cutter tube. pressing the SHARP button on the beam
control panel.
− Pivot block of the articulating arm
assembly.
Install To prevent personal injury,
1. Insert the swivel link, swivel assembly, knife during any maintenance
and knife into the cutter tube. procedure.
2. Fasten the connecting rod to the flywheel

with screw 1.
3. Reposition the articulating arm. Fasten

the swivel link to the pivot block and
bushing assembly with screw 2.
4. Lower and close the front head cover.
5. Turn on power at the C200 controller and

run the C200 program.

Knife Maintenance
Install
Knife
Note: Knife sizes and types are available for
The knife is the part of the cutter head that
different applications. See the table on
actually cuts the material. It is attached to the
page 170. If you are unsure about the
lower end of the knife drive train. Good cut
size or type of knife in your system,
quality depends on a properly sharpened,
contact Field Service.
undamaged knife.
1. Inspect the new knife for flaws before
installing it.
2. Slide the knife into the swivel assembly.
procedure. 3. Install screw 1, but do not tighten it.
Notice that the hole is offset to prevent
Inspect installing the knife backwards.
1. Turn off power at the C200 controller. 4. While holding the knife and swivel link,
place against a firm surface and push
2. Check the knife for excessive wear and down on the knife and swivel. Tighten
improper sharpening. screw 1.
Or, hold as shown below. While

maintaining the pressure, have an
assistant tighten screw 1. This seats the
back of the knife in the back of the swivel
assembly.
Good Unacceptable
3. If necessary, install a new knife.
Remove
5. Install the knife drive train.
6. Check bristle penetration. See page 112.
2. Open the cutter head cover.
CAUTION: Always check bristle penetration
3. Remove the knife drive train (see page when you install a new knife.
104). Failure to check the depth of
bristle penetration can damage
4. Remove screw 1 that fastens the knife to the work surface.
the swivel assembly.
7. If you are through with maintenance:
5. Slide the old knife out of the swivel
assembly. a) Lower and close the front head cover.

Sharpener Assembly Maintenance
b) Turn on power at the C200 controller. CAUTION: To prevent damage to the cutter
Sharpener Assembly and/or fabric, only qualified
operators or maintenance
Sharpener maintenance is critical to cutter personnel who have received
performance, because it keeps the knife sharp. GERBERcutter training should
A dull knife causes material fusing and poor perform the following
performance. Worn or dirty grinding wheels procedures.
can cause uneven sharpening.
Inspect
Procedures in this section are included in
the 8 hour maintenance schedule. 1. Use the checklist below as you remove
and disassemble the sharpener assembly.
Note: Grinding wheel mesh varies
according to application and size and 9 Part Check For
type of knife. Contact your Field
Service representative for more sharpener dirt and lint build–up
assembly
information.
KI connectors damaged cable or loose
Presser and cable connectors
Foot Bowl
Cutter Tube
Shaft Locations grinding wheel cracks, stretching, or oil
Location
pulley drive deposits
belts (O-rings)
Latch yoke arms excessive play on the

Spring pinion wheel shaft
Clamp
grinding wheels deterioration and particle
build–up
Upper
Pulley latch spring and bends, wear, or other
clamp damage
presser foot scratches, nicks, or gouges
bowl shafts
Yoke
Arms upper knife any damage
guide
lower knife scratches, nicks, or gouges
guide and rollers
Spring
Grinding Wheel
Assembly
2. If you see any of the conditions described
above, replace the appropriate part. If you
are unsure why the damage resulted, call
your Field Service representative before
replacing.

Sharpener Assembly Maintenance
Disassemble
Remove
1. Remove the foot spring (shown on
1. Turn off power at the C200 controller. previous page).
2. Open the cutter head cover. 2. Remove the presser foot bowl assembly.
3. Remove the knife drive train (see page 3. Remove the latch spring clamp.
104).
4. Stretch the grinding wheel pulley belts
4. Pull the swivel link, swivel assembly, and over each pulley. Then slide the pulleys
knife out of the cutter tube. out of the yoke arms.
5. Unplug the two connectors for the Knife

Clean and Lubricate
Intelligence (KI) transducer.
Required Supplies GGT Part No.
6. Loosen the mounting screw (shown
below) that holds the sharpener assembly Loctite Safety Solvent 308010101
on the cutter tube. grinding wheel (60 mesh) 036779000
grinding wheel (80 mesh) 020505000
7. Lower the sharpener assembly and
remove it from the cutter head. grinding wheel (100 mesh) 036779001
belt, pulley (O-ring) 496500215
CAUTION: Do not spray solvent near KI

connector.
1. Using a clean cloth and either denatured

Mounting alcohol or Loctite solvent, clean:
Screw
− Inside the cutter tube.
KI
Connector − Grinding wheels (replace if worn).
Wire
Air Cylinder − Grinding pulley belts.
Rod
− Upper knife guide.
− Presser foot bowl shafts.
− Air cylinder rod.
Presser
Foot 2. Using a clean rag dampened with SAE 10
Bowl
oil, lubricate the presser foot bowl shafts
and air cylinder rod.
CAUTION: Excess lubricants can damage

fabric. Apply sparingly.

Knife Guides and Offset Maintenance

Assemble
9. Remove the knife drive train.
1. Install the grinding wheels and grinding
pulley belts on the yoke arms. 10. Inspect the grinding pattern in the ink on
the knife. It should be equal on both sides
Note: You should keep a spare set of and extend from the cutting edge back. It
grinding wheels. When you need to also should extend from the heel of the
change the grinding wheels, replace blade to about 100 mm (4 in.) above the
them with the spare set and resume heel.
cutting.
− If the pattern is not acceptable, call
2. Install the latch spring clamp. your service representative.
3. Install the presser foot bowl assembly. − If the pattern is acceptable, install the
knife drive train.
4. Install the foot spring.
Install a) Lower and close the front head cover.
1. Place the sharpener assembly onto the b) Turn on power at the C200 controller.
cutter tube. Tighten screw 1 that holds the
sharpener assembly on this tube.
Knife Guides and Offset
2. Plug in the KI connectors.
Alignment of the upper and lower knife
3. Coat both sides of the knife with ink from guides must be done whenever you replace
a black marker with a broad tip. components in the sharpener assembly that
affect knife guide alignment. These include
the upper or lower knife guides and rollers in
WARNING! The knife is very sharp. the presser foot.
procedure. Lower
Guide
Rollers
4. Install the knife drive train. See page 106.
5. Turn on power at the C200 controller and Presser

Foot
run the C200MT program.
6. On the beam control panel, set the knife

switch to ON.
7. Execute 10 sharpening cycles by pressing

the SHARP button on the beam control
panel.

Back of blade must contact all 3 runners flatly.

3. Check the knife blade alignment as
follows:
a) Hold the sharpener assembly
Upper knife guide
Sharpener housing
horizontally in one hand and pull the
presser foot bowl away from the
Correct alignment is when the
Rear roller of back of the blade contacts roller. sharpener assembly approximately
lower guide
100 mm (4 in.).
b) Guide a knife through the upper
guide, making sure the back of the
knife fully contacts all three runners
Make sure all parts are in spec. in the upper guide (shown at top left).
Shimming may not be possible in this case.
Check that back of the knife blade just
contacts the rear roller of the lower
guide.
c) If the knife blade does not align
correctly, shims placed in the upper
Shim these points between the upper guide may correct the alignment.
guide and sharpener housing. The shim material used is a laminated
1/32 in. round washer made up of
Knife Guides numerous layers of brass shim stock
0.002 in. thick. To adjust shim
Align thickness, you can separate these
layers with a pocket knife.
Note: Appropriately placed shims
2. Remove the knife drive train and the should remain in place until
sharpener assembly. See pages 104 and either the upper or lower
108. guide is replaced.
4. Install the sharpener assembly and knife

WARNING! The knife is very sharp. drive train.
exercise care in handling the 5. Make sure that the knife blade moves
knife during any maintenance freely through the cutter tube and
procedure.
sharpener assembly.

a) Lower and close the front head cover.
b) Turn on power at the C200 controller.

− If the pattern looks like (b), loosen the

Knife Offset 270 degree screw and tighten the 90
The knife should produce a cut pattern that degree screw.
can be aligned heel–to–heel as shown below
4. To correct the heel–to–heel measurement,
with the correct distance measurement.
loosen the 90 degree and 270 degree
positioning screws. Then adjust the 0 and
Inspect
180 degree positioning screws as follows:
− If the measurement was greater than
knife alignment box 027014000 the spec, loosen the 180 degree screw
and tighten the 0 degree screw.
1. Place the knife alignment box on the table
and cover with plastic. Apply vacuum. − If the measurement was less than the
spec, loosen the 0 degree screw and
2. Run the Heel to Heel Test diagnostic. See tighten the 180 degree screw.
chapter 7.
5. When adjusted, tighten the top four cutter
3. If either the cut pattern is unacceptable or block locking screws and at least two of
the measurement is not within 12.7 to the bottom four cutter tube locking
14.3 mm (0.5 to 0.56 in.), align as screws.
explained below.
6. Turn on power at the C200 controller.
Measurement
7. Run the Heel to Heel Test diagnostic
(a) (b) again to check knife alignment. If
additional alignment is required, repeat
steps 3 through 6 as needed.
Good Unacceptable
8. When the knife has been adjusted

correctly, tighten the 90 and 270 degree
Alignment positioning screws and all locking screws.
1. Turn off power at the C200 controller and Note: Be careful not to over tighten the
open the cutter head cover. positioning screws. These are meant
to be used for adjustment only, and
2. Loosen the four cutter block locking not to secure the cutting block.
screws. Lower the presser foot bowl and
loosen the four cutter tube locking bolts.
3. To correct the cut pattern, loosen the

0 degree and 180 degree positioning
screws. Then adjust the 90 and 270 180 Cutter Block
degree positioning screws as follows: Degree Locking Screw
Screw
− If the pattern looks like (a) shown Location
90 Degree
above, loosen the 90 degree screw and Screw
Location
tighten the 270 degree screw.

Elevator Maintenance
Elevator Bristle penetration refers to how

far the knife goes into the bristle.
The elevator assembly is the frame that The correct distance is related to the
supports the knife drive gear, the knife drive flywheel stroke as shown in the
train, and the cutter tube. The elevator table below.
assembly rides up and down on two guide
rods. The air cylinder rod connects the CAUTION: To prevent damage to
elevator assembly to the air cylinder piston. the bristle work surface, always
As the piston moves through the air cylinder check the adjustment for bristle
it moves the rod. The rod in turn moves the penetration after installing a
elevator assembly. new knife.
The rods on which the elevator assembly Flywheel Stroke Depth

moves up and down must be kept free of dirt 13/16 in. 3.2 mm
and grit so that the elevator assembly rides (1/8 in.)
smoothly. 1 in. 1.6 mm
(1/16 in.)
Elevator Guide Rods Chopping 9.3 mm
set @BDC (3/8 in.)
Check the guide rods for scratches, nicks, and
gouges. These defects can damage the Maintenance procedures related to this
bearings in the elevator assembly. If you see part of the cutter are covered in the 40
any of these conditions, call Field Service hour maintenance schedule.
immediately.
Air Cylinder Rod

Knife
Check the two elevator guide rods for Drive
scratches, nicks, and gouges. These defects Head
can damage the bearings in the elevator Upper
assembly. If you see any of these conditions, Stop
call Field Service immediately.
Head
Maintenance procedures related to this Lower
part of the cutter are covered in the 8 hour Stop
maintenance schedule.
Head Stops
To prevent knife damage to the bristle work Elevator
Assembly
surface, elevator head stops limit the up and
down travel of the elevator. After checking
bristle penetration, the upper and lower head
stops are adjusted. Check and make all
adjustments with the flywheel at top dead
center (TDC). Exception is for the chopping
stroke, which is adjusted at BDC.

C–axis Drive Maintenance
C–axis Drive 6. If you are through with maintenance:
The C–axis drive belt links the knife drive a) Lower and close the front head cover.
servo gear to the knife drive train. The drive b) Turn on power at the C200 controller.
belts and gears must be in good condition for
the best cutting performance.
Servo Gear Knife Drive
Check for wear and damaged teeth. Look for Knife drive belts connect the knife drive
excessive oil or grease on the gear. Call your motor to the knife crankshaft through a series
Field Service representative if any of these of pulleys. As the knife drive motor turns, the
conditions exist. drive belts transfer motion to the knife
crankshaft. The circular crankshaft motion is
Drive Belt translated to up and down knife motion by the
articulating arm assembly.
Check for wear or damage. To prevent
slippage, wipe the belt free of any grease
or oil. Belt deflection should be 6 or 7 mm Tension and Pivot Arm Oil Cups
(1/4 in.) at the center of the belt. Replace, Fill the two tension arm oil cups and the pivot
if needed. arm oil cup.
Maintenance procedures related to this Maintenance procedures related to this

part of the cutter are covered in the 40 part of the cutter are covered in the 8 hour
hour maintenance schedule. maintenance schedule.
Adjust/Replace

Upper
belt, C–axis 180138037 Drive Belt

Upper
2. Open the cutter head cover. Tensioning
Bar
Mount
3. Loosen three mounting screws on the
C–axis motor. Sliding the knife motor Drive Motor
Lower
Mounting
away from the knife drive train tightens Plate Drive Belt
the drive belt. Sliding it towards the knife
drive train loosens the drive belt.
C–axis
4. If needed, replace the belt. Drive
5. Tighten the mounting screws and check C–axis

Drive Belt
the drive belt tension again. Repeat the
tensioning procedure, as needed.

Knife Drive Maintenance
Knife Drive Gearing and Belts Adjust/Replace
Check CAUTION: To prevent premature wear, do

not over tighten knife drive belts.
1. Turn off power at the C200 controller. If the drive belt makes excessive
noise when running, it may be
2. Open the cutter head cover.
tensioned too tightly.
3. Inspect all knife drive gears for excessive
1. The upper drive belt is tensioned with the
wear, damaged teeth, and presence of
elevator in the up position. Loosen the
excessive oil. Call your Field Service
two hex key bolts on the two piece upper
representative if any of these conditions
tensioning bar. Sliding the drive gear, on
exist.
the knife assembly side of the cutter head,
4. Wipe clean with denatured alcohol on a towards the knife will tighten the drive
rag. Use a stiff brush as required for belt. Sliding it towards the knife motor
built–up debris. will loosen the drive belt.
5. Inspect both knife drive belts for wear or 2. If needed, replace the upper belt.
damage to the teeth. Check for grease or
3. Tighten the two adjusting bolts and check
oil contamination. To prevent slippage,
the belts must be free of any lubricant.
tensioning procedure, as needed.
6. Check tension of the upper knife drive
4. The lower drive belt is tensioned with the
belt with the elevator in the up position.
elevator in the up position. Loosen four
Check tension of the lower knife drive
adjustable mounting bolts on the knife
belt with the elevator in the down
motor mounting bracket. Sliding the knife
position. The amount of deflection on
motor away from the gearing tightens the
each belt should be about 6 or 7 mm
drive belt. Sliding it towards the gearing
(1/4 in.).
loosens the drive belt.
5. If needed, replace the lower belt.

Required Supplies GGT Part No. 6. Tighten the four adjusting bolts and check
belt, knife drive to idler 180138036 drive belt tension again. Repeat the
28 tooth tensioning procedure, as needed.
belt, idler to fly wheel 180088001
22 tooth
belt, idler to fly wheel 180138036 a) Lower and close the front head cover.
28 tooth

Knife Drive Maintenance
Knife Drive Motor 5. Repeat steps 2 through 4, setting a high

knife speed of 5000 ± 100 rpm.
As part of normal maintenance, you should
inspect the motor brushes for the knife drive 6. To adjust knife speeds, if needed,
motor located on the flatway side of the qualified personnel can refer to the
beam. Replace as needed. jumper and potentiometer
settings/instructions on GGT technical
drawing, part number 078774000.
brush, 2.3 hp Dumore motor 238040201
brush cap 632500010
WARNING! High voltages
Maintenance procedures related to this exist inside the vacuum and
part of the cutter are covered in the 960 platform control enclosure, the
C200 controller, and the cutting
hour maintenance schedule. table. There are no operator–
serviceable parts inside these
Knife Speed electrical areas. Only qualified
personnel should perform
The knife drive motor is translated to the maintenance on these
knife drive train through two drive belts. The assemblies. Failure to follow
actual knife speed should be checked against these instructions could cause
C200MT parameter settings for knife speed. injury or death.
Verify with a tachometer or strobe light and
adjust as needed.
Maintenance procedures related to this

part of the cutter are covered in the 160
hour maintenance schedule.
Check
1. Run the C200MT program and open the

Parameter Manager.
2. In the Knife and Drill Speed category, set

a low knife speed of 1500 ± 100 rpm.
3. Run the Input Output Test (DG 23)

diagnostic. See chapter 7. Enable the
knife drive motor.
4. Check the knife speed using a tachometer

or strobe light.

Drill Bit Maintenance
Drill Bit
Electric Drill
The drill bit is the part of the drill that cuts
If your S91 GERBERcutter is equipped with holes in the material. Drill bits are available
the electric drill option, you will need to in a variety of sizes and types. See the table
perform the maintenance procedures on page 171.
explained in this section. The drill assembly
mounts to the subplate at the back of the CAUTION: When replacing the drill bit,
cutting head. If there are two electric drill remember to match the drill bit
units on a cutter, one mounts in front of the size to the appropriate size collets
other and is referred to as the auxiliary drill. and ejector rod (for hollow bit
drills).
Although one drive motor runs both drills,
parameters in the C200MT software allow for Remove
independent control of each drill. And, you
can run with drill bits of different sizes. 1. Turn off power at the C200 controller.
Assemblies covered in this section are listed 2. For hollow bit drills, remove the ejector
in the table below. rod:
Assembly See Page a) Remove the drill motor cover by

removing the two wing nuts.
Drill Bit 116
b) Using two wrenches, hold the chuck
Drill Assembly 118
nut in place while loosening the upper
collet.
Drill
Motor c) Slide the ejector rod up and out.
Cover
3. Remove the drill bit:
a) Press and hold the detent (shown on
next page) while manually turning the
Air drill pulley until the pulley locks in
Cylinder place.
Rod
Note: The pulley can be reached from
behind the drill motor cover.
Drill
Bit b) Hold down the safety spring. Then
depress the detent while loosening the
lower collet.
c) Remove the drill bit through the
presser foot.
Presser
Foot

Drill Bit Maintenance
4. For hollow drill bits, install the ejector

Detent rod:
a) Use the correct–sized ejector and slide
the ejector rod down through the
upper collet.
Drill
Bushing b) Align the ejector rod so that it is 1.5
to 3 mm (1/16 to 1/8 in.) lower than
the bottom of the drill when the drill
Set Screw
unit is up.
c) Tighten the upper collet finger tight.
4. Loosen the set screw that retains the drill Using a wrench, tighten 1/4 turn
bushing. Remove the bushing. more.
d) Tighten the chuck nut 1/4 turn more.
5. If installing a different–sized drill bit,
remove the upper and lower collets. 5. Check drill penetration into the bristle:
Install
a) Remove air pressure to the drill.
Manually, lower the drill to its lower
1. If you are installing a different–sized drill limit. Or, turn power on and use the
bit, install the appropriate collets for the Input Output Test (DG 23) to lower
drill bit size and leave them loose. See the the drill.
table on page 171. b) Mark the drill bit at the point it enters
the bristle. Measure the distance from
2. Insert the new drill bit. Install the drill the drill tip to this mark. The
bushing and tighten the set screw. measurement should be 6 or 7 mm
(1/4 inch).
3. The tip of the drill should be inside of the
lower bushing when the drill is in the
raised position. If not, loosen the two
collar clamps, one on each presser foot air
cylinder, and raise or lower the presser
foot assembly until the drill tip is inside
of the bushing. Tighten the collar clamps.
See step 5b.
6. If necessary, adjust by loosening the

lower collet and repositioning the drill bit.
7. Install the drill motor cover, if removed.
See step 4b. 8. If you are through with maintenance,

Turn on power at the C200 controller.

Drill Assembly Maintenance
Drill Assembly
Air Cylinder Required Supplies GGT Part No.

There are three air cylinder rods for each
belt, standard drill, 1.6 hp 180138003
electric drill unit. Two air cylinder rods raise belt, GM
and lower the drill presser foot. One air
cylinder rod raises and lowers the drill unit. belt, heavy duty drill, 2.3 hp 180078009
These rods must be kept free of dirt and grit belt, 1/4 in. dual drill 0.5 hp, 180138003
so that the drill assembly rides smoothly. inner drill
belt, 1/4 in. dual drill 0.5 hp, 180138001
Maintenance procedures related to this outer drill
part of the cutter are covered in the 8 hour belt, 1/4 in. dual drill 2.3 hp, 180078009
maintenance schedule. inner drill
belt, 1/2 in. dual drill 2.3 hp, 180500020
Drive Belt outer drill
Check the drive motor belt for wear or
damage. To prevent slippage, wipe free of Adjust/Replace
any grease or oil. Replace the belt, if needed.
CAUTION: To prevent premature wear, do
Maintenance procedures related to this not over tighten the drill drive
part of the cutter are covered in the 160 belt(s). If a drive belt makes
hour maintenance schedule. excessive noise when running,
it may be tensioned too tightly.
Check
2. Remove the drill motor cover.
2. Remove the drill motor cover.
3. Loosen four adjustable mounting bolts on
3. Inspect the belt for wear or damage to the the drill motor mounting bracket.
teeth. Check for grease or oil
4. Replace the belt(s), as needed.
contamination. To prevent slippage, the
belt must be free of any lubricant. 5. Adjust by sliding the drill motor away
Replace, the belt as needed. from the drill to tighten the drive belt.
Sliding it toward the drill loosens the
4. Check belt tension. The amount of belt
drive belt.
deflection midway between the drill
motor and pulley should be about 6 or 7
mm (1/4 in.).

6. Tighten the four adjusting bolts and check Check

tensioning procedure, as needed. 1. Run the C200MT program and open the
Parameter Manager.
2. In the Knife and Drill Speed category, set
a) Install the drill motor cover.
a low drill speed of 1500 ± 100 rpm.
3. Run the Input Output Test (DG 23)
Drive Motor diagnostic. See chapter 7. Enable the drill
As part of normal maintenance, you should drive.
inspect the motor brushes for the drill drive
4. Check the drill speed using a tachometer
motor located under the drive motor cover.
or strobe light.
Replace the brush and cap, as needed.
5. Repeat steps 2 through 4, setting a high
drill speed of 5000 ± 100 rpm.
brush, 2.3 hp Dumore 238040201
motor or 1.6 hp Boehm 6. To adjust drill speeds, if necessary,
motor qualified personnel can refer to the
brush cap, Dumore motor 632500010 jumper and potentiometer
settings/instructions on GGT technical
Maintenance procedures related to this drawing, part number 078774000.
WARNING! High voltages
Drill Speed exist inside the vacuum and
platform control enclosure, the
The drill motor runs the heavy duty electric C200 controller, and the cutting
drill(s). The actual drill speed of each drill table. There are no operator–
unit should be checked against C200MT serviceable parts inside these
parameter settings for drill speed. Check electrical areas. Only qualified
personnel should perform
speeds with a tachometer or strobe light and maintenance on these
adjust as needed. assemblies. Failure to follow
these instructions could cause
Maintenance procedures related to this injury or death.


Roundway and Squareway Maintenance
Roundway and Squareway

Beam The roundway supports and guides the cutter
The beam transports the cutter head. Electric head as it travels along the beam. It is a round
motors drive the beam along roundways and shaft that runs the length of the beam facing
racks on the cutting table and move the cutter toward the take–off end of the table. The
head along the beam. The cutter head travels squareway also supports and guides the cutter
on the beam along a roundway and a flatway. head as it travels along the beam. This is a flat
The combined motions of the beam and cutter plate that runs the length of the beam on the
head allow the knife to cut complex patterns. take–on end of the table. You must keep the
roundway and squareway clean, lightly
Beam assemblies covered in this section are lubricated, and free of scratches so the cutter
listed in the table below. head can move freely.
Assembly See Page Inspect the roundway and squareway for

scratches, nicks, and gouges. These defects
Roundway and Squareway 121
can damage the roundway or squareway
Covers 122 bearings in the cutter head subplate. Call your
Basic X and Y–axes 122 service representative immediately if you see
these conditions.
Advanced X and Y–axes 126
Inspect the beam roundway and squareway
for dirt and built–up lint. Clean and lubricate.

Squareway
Subplate
for Cutter
Head
Squareway
Wheel Bearings
Y–axis
Assembly
Drive
Roundway
Second X–axis
Drive
Roundway
Bearings
First X–axis
Drive
Cam
Rollers

Covers Maintenance
Covers
The beam control panel cover and end cap Beam

Control Panel
cover protect the motors, gearing, and belts Beam Cover
that move the beam along the length of the
table and move the cutting head across the EndCover
Cap
beam. These covers must be removed to

perform many beam maintenance procedures
explained in this section.
Remove

Basic X–axis and Y–axis
WARNING! To prevent injury, turn off
X–axis gearing allows the beam to move
the main circuit breaker for the
C200 controller before along the length of the cutting table. Y–axis
performing maintenance gearing allows the head to move on the beam
procedures, unless instructed across the width of the cutting table.
otherwise. The first X–axis gearing is located on the
beam under the beam control cover; second
2. Remove the mounting screws that hold X–axis gearing is located on the beam under
either the beam control panel cover or the the end cap cover.
end cap cover in place.
3. Slide the cover up over the panel and off

the beam.
CAUTION: Do not routinely operate the

GERBERcutter without the beam
control panel and end cap covers
in place; this could cause damage
to beam components.
Install
1. Slide the cover over the panel and cables

into position on the beam.
2. Install and tighten the mounting screws.
3. If you are through with maintenance, turn

power on at the C200 controller.

Basic X–axis and Y–axis Maintenance
Servo Pinion Gearing and Torque

Servo Motor Gearing Tube Belts
The first and second X–axis (see below) and The first and second X–axis pinion gears
Y–axis servo motor gears (see next page) should be lubricated regularly and must be
should be lubricated regularly and must be adjusted so that there is a slight amount of
adjusted so that there is a slight amount of backlash between the pinion and rack gears.
backlash between the servo motor gear and
the driven gear. Note: Check in several places in case there
are any high spots in the gears or
Note: Check in several places in case there racks.
are any high spots in the gears.
Maintenance procedures related to these
Maintenance procedures related to these parts of the cutter are covered in the 40
parts of the cutter are covered in the 40 hour maintenance schedule.
Adjust/Replace
Adjust
belt, X–axis 180138035
2. Remove the beam control panel and end
cap covers.
2. Remove the beam control panel and end
3. To adjust, loosen the three mounting
cap covers.
screws for each servo motor and position
the servo motor for a lesser amount of 3. Adjust gearing on each side of the beam:
backlash.
a) Loosen the idler pulley for the torque
4. Tighten the screws and check the amount tube belt so that the belt is loose.
f backlash again.
b) Disconnect the X–axis servo motor
5. If you are through with maintenance: connector.
c) Loosen the servo motor shoulder
a) Install the beam control panel and end
screw, remove the other two servo
cap covers.
motor mounting screws, and swing
b) Turn power on at the C200 controller. the servo motor out of the way.
d) Turn the X–axis rack drive gear so
that the three holes in the gear line up
with the three mounting screws for
the rack drive assembly.
e) Loosen the three mounting screws for
the rack drive assembly and
physically adjust the rack drive for a
X–axis slight amount of backlash. Check this.
First Axis Rack and Servo Motor
Torque Tube Belt Pinion Gears

4. Replace the torque tube belt, if needed.

Adjust
5. Tighten the torque tube belt and tighten
the idler pulley screws. 1. Turn off power at the C200 controller.
6. Reinstall the servo motor with a slight 2. Remove the beam control panel cover.
amount of backlash. Check this.
3. Adjust the gear:
7. Reconnect the X–axis servo motor a) Disconnect the Y–axis servo motor
connector. connector.
8. If you are through with maintenance, b) Loosen the servo motor shoulder
screw, remove the other two servo
a) Install the beam control panel and end motor mounting screws, and swing
cap covers. the servo motor out of the way.
b) Turn power on at the C200 controller. c) Loosen the three mounting screws on
Countershaft the Y–axis countershaft assembly and
Gear physically adjust for minimal
backlash.
d) Tighten the three mounting screws.
Y–axis
Servo 4. Check the amount of backlash again.
Gear
5. Reinstall the servo motor with a slight
amount of backlash. Check this.
6. Reconnect the Y–axis servo motor

connector.
Y–axis Countershaft Gear
The Y–axis countershaft gear should be
lubricated regularly and must be adjusted so a) Install the beam control panel cover.
that there is a minimal amount of backlash b) Turn power on at the C200 controller.
between it and the Y–axis pulley gear.
Note: Check in several places in case there

are any high spots in the gears.


Wheel Housing Cam Rollers Wheel Assemblies

The wheel housing cam rollers (four on the Check the four brass wheel assemblies (two
beam control panel side of the beam) should on each end of the beam) for wear or damage.
be lubricated regularly and must be adjusted Lubricate regularly.
so that there is no binding against the
roundway as the beam travels the full length Maintenance procedures related to this
of the table. part of the cutter are covered in the 40
part of the cutter are in the 40 hour
hex wrench, 1/4 in. 020945000
Adjust

Cam
Rollers Wheel
2. Remove the beam control panel cover. Assembly
3. Loosen the locking nut on the top of the

inside cam roller. Bite Encoder
The bite encoder tracks information about the
4. Adjust the cam roller until it barely current bite for use by the C200MT program.
touches the roundway at the tightest spot It is attached to the take–on side of the beam
on the table. near the beam control panel (TCW shown).
5. Tighten the locking nut. Check again for
any binding against the roundway as the
beam travels the full length of the table.

Bite Indicator
a) Install the beam control panel cover. Strips
Encoder
b) Turn power on at the C200 controller. Wheel
Check the encoder wheel for worn areas on

the grit surface, wobbling, and correct
positioning over the bite indicator strip(s)
along the edge of the table surface.


Advanced X–axis and Y–axis Maintenance
Advanced X–axis and Y–axis

Squareway Bearings
CAUTION: To prevent damage to the cutter
The Y–axis squareway bearings are located
and/or fabric, only qualified
on the subplate where the cutter head is
operators or maintenance
mounted. They should be adjusted so that the
personnel who have received
subplate and cutter head can not be physically
GERBERcutter training should
moved up and down when force is applied to
perform advanced X and
the back of the subplate, and with no binding
Y–axes procedures.
on the Y–axis.
Roundway Bearings Maintenance procedures related to this
The Y–axis roundway bearings are located on part of the cutter are covered in the 160
the subplate where the cutter head is hour maintenance schedule.
mounted. They should be adjusted so that the
cutter head and subplate can not be physically Adjust
twisted on the beam, and with no binding on
the Y–axis. 1. Turn off power at the C200 controller.
Maintenance procedures related to this 2. Loosen the locking nut on the lower
part of the cutter are covered in the 160 bearing.
3. Adjust the eccentric with a screwdriver
Required Supplies GGT Part No. until the lower bearing barely makes
contact with the squareway.
hex wrench, 1/4 in. 020945000
4. Tighten the locking nut.
Adjust
5. Check that:
a) The subplate and cutter head can not
2. Carefully tighten the bottom screws for be moved by lifting from the back.
the roundway bearings (two screws for
b) There is no binding on the Y–axis.
each of four bearings).
CAUTION: To prevent scoring of the power on at the C200 controller.
roundway, do not over tighten the
roundway bearing screws.
3. Check that:
a) The subplate and cutter head can not
be twisted.
b) There is no binding on the Y–axis. Squareway
Bearings
power on at the C200 controller. Roundway
Bearings

5. Verify that the spring scale does not

Spring Scale Tests exceed 6.8 Kg (15 lbs.). If it does:
The spring scale tests are used to evaluate the
− Check for any obstructions, worn
mechanical operation of the X and Y–axes.
bearings, or pulleys.
These tests can determine whether gearing, is
set too tightly, lacks lubrication, or is binding − Perform mechanical alignments
due to misalignment or obstructions. dealing with the Y–axis covered in
this section.
Note: The spring scale test can not
determine if gearing is set too loosely. 6. If you are through with maintenance, turn
Use other X and Y–axes alignment power on at the C200 controller.
procedures in this section to check
and adjust for loose gearing. Test X–axis
Maintenance procedures related to this 1. Turn off power at the C200 controller.
hour maintenance schedule. 2. Move the cutter head to the farthest -X
position on the table and to the center
CAUTION: To prevent damage to the cutter position on the beam.
operators or maintenance 3. Attach a spring scale to a support bracket
personnel who have received on the cutter head.
GERBERcutter training should
perform advanced X and 4. Keep the spring scale held parallel to the
Y–axes procedures. X–axis while pushing the cutter head
across the entire length of X–axis travel.
Required Supplies GGT Part No. The assistant should use the least amount
of force possible applied at a steady rate.
spring scale 945500034
5. Check that the spring scale does not
Test Y–axis exceed 11.3 Kg (25 lbs.). If it does:
1. Turn off power at the C200 controller. − Check for any obstructions, worn
bearings, or pulleys.
2. Move the cutter head to the farthest -Y
position on the beam. − Perform mechanical alignments
dealing with the X–axis covered in
3. Attach a spring scale to a support bracket this section.
on the cutter head.
4. Keep the spring scale held parallel to the power on at the C200 controller.
Y–axis while an assistant pulls the cutter
head across the entire length of Y–axis
travel. The assistant should use the least
amount of force possible applied at a
steady rate.

7. Tighten the two locking set screws.

Y–axis Drive Belt Tension
The Y–axis drive belt must be adjusted so 8. If you are through with maintenance,
that when the servo motors are locked up and a) Install the end cap cover.
the Y–axis is physically pushed or pulled, the
belt should not show signs of slack or contact b) Turn power on at the C200 controller.
the outer edge of the pulley on the remote
side of the cutter when the Y–axis is slewed Replace
from one end of the beam to the other.
CAUTION: To prevent damage to the cutter belt, Y–axis 041555006
operators or maintenance 1. Turn off power at the C200 controller.
GERBERcutter training should 2. Remove the beam control panel and end
perform the advanced X and cap covers.
Y–axes procedures.
3. On the remote side, loosen the two
locking set screws on the sides of the
Adjust adjusting screws for the Y–axis belt
pulley.
4. Remove the four screws that attach the
2. Remove the end cap cover.
Y–axis belt to the subplate to which the
3. Loosen the two locking set screws on the cutter head is mounted (indicated).
sides of the adjusting screws for the
Y–axis belt pulley.
5. Remove the belt from the adjustment

Adjusting Locking
Screw pulley and from the track that runs under
Set Screw
the beam.
4. Adjust the screws in to tighten the belt or
out to loosen the belt. 6. Install the new belt.
5. Slew the head back and forth to check the 7. Follow steps 4 through 7 of the procedure
belt skew. Repeat step 4 as needed. for adjusting the belt.
With the cutter head slewed toward the 8. If you are through with maintenance:
remote side, you should be able to insert a) Install the beam control panel and end
several fingers under the belt at a location cap covers.
60 cm (2 ft.) from the end cap cover and
raise it 2.5 to 3.8 cm (1 to 1.5 in.). b) Turn power on at the C200 controller.

Squaring the Beam

Adjust
In order to correctly cut pieces from a marker
the beam must be square to the table. 1. Position the cutter head at the first X–axis
side of the beam (nearest to the beam
Maintenance procedures related to this control panel).
hour maintenance schedule. 2. Press the EStop button on the beam
control panel to disable servos.
CAUTION: To prevent damage to the cutter
and/or fabric, only qualified 3. Position two C–clamps on the table rack,
operators or maintenance one on each side of the beam.
GERBERcutter training should 4. Turn power off at the C200 controller.
perform the advanced X and
Y–axes procedures. 5. Remove the end cap cover. Use a pencil
to scribe a mark for the current beam
Check position onto the roundway or rack.
1. Run the Beam Square Test diagnostic to 6. Loosen the collar clamp on the torque
make four cuts, one at each corner of an tube pulley.
imaginary square. See chapter 7.
7. Refer to step 2b of the Check procedure
2. The difference in the two measurements and physically move the second X–axis
taken diagonally across the imaginary side of the beam relative to the pencil
square determines: mark:
a) Whether the beam is square. − If the second X–axis side of the beam
leads, then move the beam in the -X
b) If it is not square, whether the first X direction an amount equal to the
or second X–axis leads and by how recorded measurement.
much. Record this value for use in
step 5 of the adjust procedure. − If the first X–axis side of the beam
leads, then move the beam in the +X
3. If the beam is not square within 1 mm direction an amount equal to the
(1/32 in.), adjust (square) the beam. recorded measurement.
8. Tighten the coupling clamp on the torque
tube pulley.
9. Enable servos and then run the Beam

Square Test diagnostic again to check the
adjustment.

a) Install the end cap cover.

Work Surface Maintenance
Table
The cutting table provides a work surface for Work Surface
cutting material. Major assemblies of the
table include the beam, bristle work surface, The BRISTLE SQUARES form the work
filtration, vacuum generator, and material surface of the cutter. They are small, plastic
handling. TCW systems also have assemblies squares with bristles on one side and a
related to the traveling platform. perforated base on the other. The BRISTLE
SQUARES fit into aluminum slats on TCW
Table assemblies covered in this section are and ZVC systems and in plastic grids on
listed in the table below. Static systems.
Assembly See Page BRISTLE SQUARES last longer if you clean

Work Surface 130
them regularly and move them to different
positions on the table to spread wear more
Work Surface Cleaner 132 evenly.
Roundways and Racks 133
Filters 134 Inspect
Vacuum Assembly 135 1. If your system is a TCW or ZVC do the

Material Handling Systems 138 following:
Platform 141 a) Turn power on at the table control
panel.
b) To access all portions of the work
surface, set the Conveyor Mode to
Manual.
c) Jog the conveyor to move unexposed
portions of the bristle work surface
into view.
2. Inspect the BRISTLE SQUARES for lint,
broken bristles, and other cutting debris.
Clean them if necessary.
3. Inspect the BRISTLE SQUARES for

uneven wear, scarring, or creasing.
Rearrange the BRISTLE SQUARES if
necessary. Sometimes the squares may be
damaged beyond repair; this could be a
sign of another problem. If you see such
damage, call your Field Service
representative.

Work Surface Maintenance
c) Remove the grid. You can remove the

Clean remaining grids by hand.
1. Vacuum the BRISTLE SQUARES to d) Position the grid on a portion of the
remove debris. cutting table that is less worn.
2. For TCW or ZVC systems, jog the Install

conveyor to reach unexposed portions of
the bristle work surface. Install the BRISTLE SQUARES in the
work surface of TCW and ZVC systems
Remove/Rearrange
by snapping them into place in the slats.
To rearrange BRISTLE SQUARES for Install the BRISTLE SQUARES in the

TCW or ZVC systems: work surface of Static systems:
a) Working on one slat at a time, set a a) Replace all but the last BRISTLE
clamping pliers deeply into the bristle SQUARE grid in the table.
and pull the square out of the slat. See b) Place the bristle locating over the
below. edges of the bristle surrounding the
b) Remove the other squares in this slat remaining grid.
by hand.
Locating
Guides
c) Move the square to a part of the slat

that is less worn. c) Snap the remaining grid into place
and remove the bristle locating
d) Jog the conveyor to reach unexposed
guides.
portions of the bristle work surface.
To rearrange BRISTLE SQUARES for
Static systems: Required Supplies GGT Part No.
a) Locate the first grid that you want to bristle locating guides 023678000
remove. bristle locating guides 023679000
b) Set one clamping pliers deeply into
one side of the grid. Set another
clamping pliers deeply into the bristle
on the opposite side of the grid.

Work Surface Cleaner Maintenance
Work Surface Cleaner Gear Box

TCW systems have a mechanical work The gear box for the work surface cleaner is
surface cleaner. This is an auger located on located on the remote side of the cutter at the
the take–off end of the table. The auger take–off end of the table. Periodically, check
rotates through the bristle work surface that is the fluid level in this gear box. The third time
not exposed. The lint and debris that falls you check the fluid level, drain and replace
from the auger collects in a basin at the take– with SAE 600 weight oil.
off end of the system. You must clean this
basin periodically. Maintenance procedures related to this
Inspect hour maintenance schedule.
2. Open the access doors at the take–off end

of the TCW table.
3. Check the basin for accumulated lint and

cutting debris. Clean the basin, if
necessary.
Gear
Box
WARNING! Avoid breathing in lint Cover
Access
collected in the basin of the Doors
work surface cleaner. Wear a
mask suitable for cleaning lint. Pillow Block Bearings
There are two pillow block bearings located
Clean inside of the work surface cleaner basin, one
on each side of the cutter. Open the access
1. Vacuum out the lint and debris that has
doors to lubricate these bearings.
collected in the basin.
2. Inspect the auger for damage of any kind.
If you notice any cracks, heavy scoring, or
other signs of damage, call Field Service
immediately.

power on at the C200 controller.

Roundways and Racks Maintenance
Roundways and Racks Racks

The beam travels the length of the cutting The racks are toothed tracks that run the
table on roundways and racks. The beam can length of the cutting table. Motors and gears
not travel smoothly if the roundways and in the beam drive the beam along the racks.
racks are excessively dirty or damaged. The beam can not travel smoothly if the teeth
of the racks are damaged or dirty.
Inspect
Roundway 1. Turn off power at the C200 controller.
2. Check the racks for damaged teeth,

scoring, or abrasions. If you see any of
these conditions, call your Field Service
representative.
3. Inspect the racks for built–up dirt and lint.
CAUTION: Use care not to damage the teeth

of the rack. Clean only when
absolutely needed.
Rack
Roundways
The roundways run the length of the cutting
table. Motors for the beam drive the beam
along the roundways. The beam can not travel
smoothly if the roundways are damaged or
dirty.
Inspect the roundways for abrasions and

scoring. Contact your Field Service
representative if you notice any. Inspect the
roundways for built–up dirt and lint. Clean, as
needed.


Filters Maintenance
Filters
WARNING! Avoid breathing in lint
The GERBERcutter uses filters as part of the from the filters. Wear a mask
vacuum system to trap lint and moisture from suitable for cleaning the filter.
the work environment.
CAUTION: Do not use compressed air to
Vacuum Filter blow out the drum as cutting
debris may work its way into the
The vacuum filter canister for S91 systems is turbine or blower and cause
a drum with a filter inside. The vacuum filter damage.
traps lint and other debris from the table top.
Keep the filter clean to prevent a decrease in Maintenance procedures related to this
vacuum. part of the cutter are covered in the 8 hour
Note: The on–screen gauge in the C200MT
program will alert you to decreased Stack Filter
vacuum pressure.
The stack filter is located in a canister on the
For a TCW system the drum is located at the exhaust stack. For TCW systems, the stack is
take–on end of the table under the front ramp. part of the mast at the take–on end of the
For ZVC and Static systems, the drum is table. For Static and ZVC systems, the stack
mounted in–line between the external is located at the external vacuum assembly.
vacuum assembly and the cutting table.
The stack filter traps debris which might
damage the vacuum generator. You must
Filter keep this filter clean to ensure the proper
working of the vacuum generator.

Cover Required Supplies GGT Part No.
filter element, stack 460500037

WARNING! Avoid breathing in lint
filter element, Static or ZVC 022810000 from the filters. Wear a mask
filter element, TCW 460500102 suitable for cleaning the filter.

Vacuum Assembly Maintenance
Air/Reducer Filter Cover

On TCW systems, there are one or more The vacuum generator assembly for TCW
air/reducer filters located on the exhaust stack systems is located under the front ramp or
and mast of the table. These filters improve (take–on cover). This ramp must be removed
air flow. If they get clogged, air pressure to perform maintenance procedures such as
drops. lubrication and tensioning of the belt(s).
CAUTION: Before opening the drain valve, External vacuum assemblies for Static and
reduce air pressure manually by ZVC systems have either a jack shaft cover or
turning the cap. Dirty liquid may a coupling guard that must be removed to
spray and stain material. perform maintenance procedures.
Cap Remove

For Static and ZVC systems, also turn off
power at the external vacuum assembly
and at the table control (or lay puller
control) panel.
Drain
Valve 2. Depending on your system:
− For TCW systems, remove mounting
screws and shims at both sides of the
front ramp. With the help of an
Maintenance procedures related to this assistant, lift off the cover.
maintenance schedule. − For Static or ZVC systems with a
Hoffman blower and coupling guard,
remove four screws from the coupling
guard. Lift off the coupling guard.
Vacuum Assembly − For Static or ZVC systems with a
The vacuum generator assembly includes the Spencer turbine, unlatch three
vacuum generator and the vacuum generator fasteners on the jack shaft cover.
motor. The motor drives the turbine Lower the cover and move aside.
generator.
Install
In all TCW systems and some ZVC and
1. Depending on your system:
Static systems, the motor drives a turbine or
blower by use of a single wide or multiple − For TCW systems, with the help of an
narrow drive belt(s). In most ZVC and Static assistant, lift the cover into place.
systems, a coupling connects the motor and a Reposition the shims. Install and
blower. tighten the mounting screws.

− For Static or ZVC systems with a

Drive Belt Tensioning
Hoffman blower and coupling guard,
reposition the coupling guard. Install Drive belt(s) between the motor and generator
and tighten four screws for the can stretch, fray, or wear. Adjust belt tension
coupling guard. or replace as needed.
− For Static or ZVC systems with a Maintenance procedures related to this
Spencer turbine, reposition the jack part of the cutter are covered in the 160
shaft cover. Latch the three fasteners. hour maintenance schedules.
Adjust/Replace
a) Turn power on at the external vacuum
assembly, if applicable. Required Supplies GGT Part No.
b) Turn power on at the C200 controller. belt, 50 Hz (4 per unit) 180078008

belt, 50 Hz (5 per unit) 180500038
Motor and Generator
belt, 60 Hz (5 per unit) 180500006
Lubricate the motor and generator regularly.
Check belt tension or coupling alignment 1. Turn off power at the C200 controller.
between the motor and generator. For Static and ZVC systems, also turn off
Maintenance procedures related to this and at the table control (or lay puller
part of the cutter are covered in the 960 control) panel.
hour maintenance schedules.
2. As required, remove the front ramp or
For systems with a Spencer turbine or an jack shaft cover to access the drive belt(s).
Hoffman blower with pillow block assembly,
you need to check belt tension regularly and 3. Adjust or replace as follows:
adjust belt tension as needed. For systems
a) Loosen the nuts on four bolts that
with a Hoffman blower coupled to the motor,
secure the generator motor.
you need to check coupling alignment.
b) If replacing a belt, remove all belt(s).
CAUTION: To prevent damage to the cutter Install new belt(s).
operators or maintenance Note: All belts must be replaced,
personnel who have received even if only one is worn or
GERBERcutter training should frayed.
perform the following c) With the help of an assistant,
procedures. reposition the motor and then tighten
the nuts.
d) Check belt tension again and compare
the deflection to the manufacturer’s
specs.

4. If required, replace the front ramp or the Align (cold system method)
jack shaft cover.
1. Make sure the C200 controller is turned
5. If you are through with maintenance, off. For Static and ZVC systems, also
a) Turn power on at the external vacuum make sure the power is off at the external
assembly. vacuum assembly and at the table control
(or lay puller control) panel.
b) Turn power on at the C200 controller.
2. Remove the coupling cover.
Coupling Alignment
3. Adjust alignment as follows:
For motors coupled to an Hoffman blower,
the coupling between the motor and Hoffman a) Loosen the nuts on four bolts that
blower must be checked for alignment secure the generator motor.
regularly. It is possible to check coupling
alignment when the assembly is cold. b) Place a straight edge across the hub
However, the hot alignment method, which and verify with a feeler gauge that the
checks after the unit has run for at least an centerline for the shaft of the motor is
hour, is more accurate. higher than the centerline for the shaft
of the blower by the specified amount.
Maintenance procedures related to this The spec for the cold system method
part of the cutter are covered in the 960 is printed on a plate affixed to the
hour maintenance schedules. blower.
c) Use shims as required. Then tighten
CAUTION: To prevent damage to the cutter the four bolts.
operators or maintenance 4. If you are through with maintenance,
GERBERcutter training should a) Turn power on at the external vacuum
perform the following assembly.
procedures. b) Turn power on at the C200 controller.
From Cutter
Align (hot system method)
Blower 1. Run the vacuum system for an hour or

Coupling
Guard more.
Motor
For Static and ZVC systems, also turn off
and at the table control (or lay puller
control) panel.
3. Remove the coupling cover.

Material Handling Systems Maintenance
Material Handling Systems
Material handling systems depend on the type

of cutter. These may include: the clamp bar,
resealer, conveyor, or motorized lay puller.
Clamp Bar
On TCW systems, the clamp bar works with
the conveyor to pull material onto the cutting
table. The air cylinders that raise and lower
4. Adjust alignment as follows: the clamp bar require cleaning and lubrication
to work smoothly.
a) Loosen the nuts on four bolts that
secure the generator motor. Maintenance procedures related to this
b) Place a straight edge across the hub. part of the cutter are covered in the 40
The straight edge should lay flat. hour maintenance schedules.
c) As shown above, measure the
Resealer
distance between the outside hubs at
four places, each 90 degrees from the If your cutter has the resealer option shown
previous location. If the distance below, routine maintenance procedures
between the four measurements is not include lubricating the air cylinder rods and
within 0.40 mm (1/64 in.), then go to checking that the bar moves up and down
step 5. evenly.
5. When the system is cold, use shims to

raise or lower the motor, as required. (See Resealer
the cold system method.) Bar
6. Tighten the four bolts.

a) Turn power on at the external vacuum
assembly.
b) Turn power on at the C200 controller.


Conveyor Drive Gear Box

The gear box for the conveyor drive is located
at the take–on end of the cutter. Periodically,
check the fluid level in this gear box. The
third time you check the fluid level, drain and
replace with SAE 600 weight oil.

part of the cutter are covered in the 960 3. Jog the conveyor to start moving the
hour maintenance schedule. spread onto the table.
Conveyor Drive 4. Adjust the potentiometers for the Baldor

drive as follows:
TCW and ZVC systems use a conveyor to
move material on and off the cutting table. a) Set an initial torque, T1, for ramp up
Potentiometers for the drive motor that jogs speed.
the conveyor can be aligned to accommodate b) Set a normal operation speed, T2
a variety of spreads. (Range for torque is 0 to 100%).
c) Set the time for ramp up, A, from 0 to
WARNING! High voltages T1 and from T1 to T2. (Range for A
exist inside the C200 controller, is 0 to 7 sec.)
vacuum and platform electrical
enclosure and the cutting table. These settings should result in the shortest
There are no operator– and smoothest acceleration capable of
serviceable parts inside. Only pulling a production spread onto the
qualified personnel should
cutting table.
perform maintenance on these
assemblies. Contact your
Service Technician in case of a
problem. Failure to follow these
instructions could cause injury
or death.

Align Note: Refer to the documentation that came

with the drive motor.
1. At the platform control panel, set the
Conveyor Mode to Manual. 5. Position a typical spread on the spreading
table. Check the alignment by jogging the
2. For ZVC systems, remove the take–on conveyor; repeat step 4 as required.
end cover. For TCW systems, open the
door to the vacuum and platform
electronics (shown below).

Lay Puller Gear Box

Align
The gear box for the lay puller drive is
located under the cutting table. Periodically, Note: Do not refer to the documentation for
check the fluid level in this gear box and the drive motor when setting
replace with SAE 600 weight oil. potentiometers. Use the following
procedure instead.
part of the cutter are covered in the 960 1. Initial settings for the Reuland drive are:
− Turn the torque potentiometer (pot)
Lay Puller Drive fully counter clockwise.
Static systems use a motorized lay puller to − Turn the time pot fully clockwise.
move a spread onto the take–on end and 2. Jog the lay puller to start moving the
along the length of the cutting table. spread onto the table. Adjust the torque
Potentiometers for the drive motor that jogs pot clockwise until the lay puller bar just
the lay puller can be aligned to accommodate begins to move.
a variety of spreads.
3. Again, jog the lay puller and readjust the
torque pot so the maximum delay before
WARNING! High voltages the bar begins to pull is 1 or 2 seconds.
exist inside the C200 controller,
vacuum and platform electrical
4. Position a typical spread in the lay puller.
enclosure and the cutting table.
There are no operator– Repeat steps 2 and 3.
serviceable parts inside. Only
qualified personnel should 5. Adjust the time pot counter clockwise
perform maintenance on these (decreasing) to attain the shortest and
assemblies. Contact your GGT smoothest acceleration acceptable for
Service Technician in case of a
pulling a production spread onto the
problem. Failure to follow these
instructions could cause injury cutting table.
or death.


Platform Maintenance
Platform
S91 TCW systems travel on rails between

spreading tables. Power is transferred through
an overhead cable trolley.
Platform drive maintenance includes:

• Lubricating the platform drive chain,
sprocket bearings, and cam roller
bearings.
• Checking fluid levels in the platform
drive gear boxes on two wheel
assemblies.
• Lubricating platform wheel cam roller
bearings and shaft bearings on four
wheel assemblies.
Overhead cable trolley maintenance includes
cleaning and lubricating the roller bearings.

Overhead
Cable
Trolley
Platform Drive
Wheel
Assembly
Wheel
Assembly

Platform Maintenance

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The C200MT cutter control software provides the following features to assist
you in troubleshooting your GERBERcutter.
• Error messages.
• Diagnostics.
These features are explained briefly in this chapter. For more information, refer
Additional troubleshooting tools available currently or in the near future include:

• Training (CBT) on CD–ROM.
• Service Parts on CD–ROM.
• Applications manual.
See sections later in this chapter. Contact GGT Product Support or your local
Field Service office for information on availability and how to obtain copies.
Product Support
If a condition still exists after troubleshooting, call your GGT Product Support
or local Field Service office for help. Within the United States and Canada, call
800-999-1448. Otherwise, call you local Field Service office. Have your service
contract number ready.
Chapter 7 Troubleshooting Page 143

Error Messages
The GERBERcutter displays an error message dialog box when it detects an
error condition. The system numbers these error messages for easy reference.
The first digit of the error number defines the error class. The error classes range
from 1 to 4, with class 1 being the least severe. PreProcessor error messages do
not have an error number.
Error Message Type Error Number Range
Class 1 FEP 1000-1999

Class 1 MCC 1000-1999
Class 2 2000-2999
Class 3 3000-3999
Class 4 4600
This section gives a brief overview of the types of error messages, samples of
messages, and recommended solutions. A complete list of errors and solutions is
included in the C200MT Software User’s Guide.
Page 144 Chapter 7 Troubleshooting

Class 1 FEP Errors
Class 1 FEP (workstation PC) errors relate to conditions with the cut file. When
a class 1 error occurs, the system stops cutting. To resume cutting, see the
recovery procedures in chapter 3.
The following table gives some keywords you might find in this type of error
message, actual samples of class 1 FEP error messages, and possible solutions.
Simple solutions, such as editing cut data or restarting the program, should be
tried before contacting Field Service.
Note: Before trying solutions that involve reloading software, refer to the
C200MT Software User’s Guide for a complete listing of messages
or call Field Service.
Message Keywords Possible Solutions Sample Messages
illegal; invalid; not found; Edit or regenerate cut data 1002 Illegal character in
max allowed; converting file. Change parameter logical block
settings. Reposition the
file; character; code; data; 1429 SBITE: Can’t bite
spread.
point; block; stops; SBITE without reorder
wrong number; too many; Quit the C200MT 1105 Wrong number of
out of range; overrun; not program, turn off the parameters: TR
responding; failed power, and restart. Call
1302 Overrun on serial 2
Field Service if condition
parameter; queue; serial line
persists.
line; buffers; PC controller
\SYSFILES\xxx.INT
offtable Move the origin. Check the 1017 Offtable -X
cut file format. Check that
the cutter head and beam
are not too close to the
limit switches.
timeout; not found Quit the C200MT program 1410 Timeout Error
and reload the C200MT requesting input status
\SYSFILES\ENGLISH\
software. Call Field
xxx.INT 1418 \SYSFILES\
Service if condition
ENGLISH\ DG23.INT
persists.
not found

Class 1 MCC Errors
Class 1 MCC errors relate to conditions with the commands that the Motion
Control Computer (MCC) sends to the cutting table. When a class 1 MCC error
occurs, the system stops cutting. To resume cutting, see the recovery procedures
in chapter 3.
message, actual samples of class 1 MCC error messages, and possible solutions.
Refer to the C200MT Software User’s Guide for a complete listing of messages.
Message Keywords Possible Solutions Examples
initialization not completed Check cable connections, 1006 Error occurred while
loose wiring, and fuses. homing (initializing)
limit switch; knife motor;
Check air pressure. Check
beam control panel 1008 C–axis could not get
limit switches.
off limit switch
Change parameters.
1423 Y limit switch active
Initialize the cutter. Turn
knife motor on. Slew
beam.
up; down; position; not on Use Input Output Test 1021 Bite Sensor not down
(DG23) diagnostic to
tool; bite sensor; knife; 1107 Drill not up
check for signal.
drill; auxiliary drill;
sharpener solenoid
failed; rejected; invalid; Quit the C200MT 1009 Encoder reset failure
logging; aborted; not program, turn off the
1315 Bad piece number
oriented power, and restart. Call
Field Service if condition 1619 Error setting X
number; memory block;
persists. Dynamic coefficients
coefficients; data; encoder;
C–axis

Class 2 Errors
Class 2 errors relate to conditions resulting from communication and data
processing. When a class 2 error occurs, the system displays an error message.
To resume cutting, see the recovery procedures in chapter 3.
message, actual samples of class 2 error messages, and possible solutions. Refer
to the C200MT Software User’s Guide for a complete listing of messages.
following error; level too Quit the C200MT 2000 X following error
high program. Check sensor or
2552 Vacuum level too
mechanical condition of
bite; conveyor; vacuum high to bite (ZVC)
the system. Call Field
persists.
overflow; invalid; too Quit the C200MT 2330 Non-numeric char in
many; no more; bad program, turn off the ASCII to integer
power, and restart. Call conversion
vacuum; parameter; BGL
ASCII 2357 Bad parameter table
persists.
failure Use the KI Calibration 2006 KI sensor failure
(DG20) diagnostic to
KI
calibrate the KI sensor.
Call Field Service if
condition persists.
knife down Edit cut file. Change 2350 Knife down move
parameter. length exceeds max

Class 3 Errors
A class 3 error is a serious hardware error. Cutting halts. To resume cutting, see
the recovery procedures in chapter 3.
message, actual samples of class 3 error messages, and possible solutions. Refer
to the C200MT Software User’s Guide for a complete listing of messages.
offscale Check data format and 3400 Offscale +X

regenerate cut file. Set
origin closer to the
initialization point of
the table.
unknown; failed Check cabling to BCC. 3010 Unknown BCC error
Check power to the servo detected by 68K
BCC; beam control panel;
drive.
servo; emergency stop 3237 C servo drive failed
Fix the EStop condition.
Press the Servo Power
button.
following error; invalid; Quit the C200MT 3000 X max following
unknown; excessive program. Check error
mechanical condition of
conveyor; knife 3810 Excessive Knife
the system. Call Field
Current
persists.
invalid; error sending Quit the C200MT
program, turn off the
sharpen; servo
power, and restart. Call
persists.
Class 4 Errors
A class 4 error is a serious non–recoverable C200 controller error caused by
either a hardware or software condition. Power down the system, then power up
again. If the error appears again, call Field Service. To resume cutting, see the
recovery procedures in chapter 3.

Diagnostics
Diagnostics included in the C200MT program provide tools which can be used
by the person in your company responsible for GERBERcutter maintenance or
by Field Service to ensure cutter performance. Diagnostics used for routine
maintenance and covered in this section include:
• Input Output Test (DG23).
• KI Calibration (DG 20).
• C Home to System Zero.
• Heel to Heel Cut Test.
• Beam Square Cut Test.
• Knife Offset Setup Cut Test.
Note: For detailed information about diagnostics that are not covered in
this section, refer to the C200MT Software User’s Guide.
Diagnostic Use To
Input Output Test (DG 23) Check MCC input and output signals.
Servo I/O Test (DG 16) Read and zero selected encoders; control output voltage of
digital–to–analog converters; display input voltage for analog–
to–digital converters.
KI Calibration (DG 20) Set Knife Intelligence deflection voltage.
C Axis Angle Rotate the C–axis to any angle.
Single Step Run in single step mode to check cut file data.
Continuous Run Run one cut file continuously in the same place.
Display Bite Adjust Values Display the difference (error) between how much the conveyor
and the beam move during a bite.
Position Info Calculate change in distance from current position to origin.
Conveyor/CTOT Speed Calibrate Calibrate conveyor and CTOT speeds.
C Home to System Adjust this knife setting and command the knife to plunge four
times in a straight line.
Stepsize Setup Calculate new stepsize settings for the X and Y–axes.
Zone Vacuum Exerciser Test, setup, or troubleshoot hardware for the vacuum zone
control.

Diagnostic Use To
Cut Tests
Multiple Horizontal Lines Check C–axis mechanical alignment

Multiple Vertical Lines Check C–axis mechanical alignment.
Multiple 45 Degree Lines Check X, Y, and C–axes electrical alignments.
50" Square Test Square the beam.
Concentric Circles Test cutting.
Beam Square Test Square the beam.
Heel to Heel Test Check knife mechanical alignment.
Yaw in X Test Check C–axis mechanical alignment in X–axis.
Yaw in Y Test Check C–axis mechanical alignment in Y–axis.
10" Square Center drill hole.
Check drill placement.
Geometric Shapes Test cutting.
5' Bite Test Test a conveyorized GERBERcutter.
Knife Offset Setup Check knife alignment.
Drill 1 Offset Setup Check main drill alignment.
Drill 2 Offset Setup Check auxiliary drill alignment.
Pen Offset Setup Check pen alignment.
Software Diagnostics (Used for software development only)
Path Intelligence
Calibration Calibrate PI.

Watch Forces Check XY forces on the knife blade.

Selecting Diagnostics
Choose the commands in the Diagnostics menu to access diagnostics.
Additional diagnostics are available in the Cut Tests, Software Diagnostics, and
Path Intelligence submenus.
Input Output Test (DG 23)

This diagnostic can be used to test individual motors, switches, lights, and other
components. Only use this diagnostic when told to by this manual or by Field
Service.
To run diagnostic
1. Turn on the GERBERcutter and run the C200MT program.
2. Optional — Enable servo power and then initialize the cutter.
3. From the Diagnostics menu, click Input Output Test (DG 23).
The system displays a test screen. On this screen, active shows as

green; inactive shows as red.
WARNING! Stand away from moving parts on your

GERBERcutter when using this diagnostic. Injury or
death may result if you are in the path of GERBERcutter
parts when they move. Depending on which control you
are testing, part of the GERBERcutter may move. This
can be, but is not limited to, the knife blade, drill,
conveyor, and other mechanical parts.

4. To test an output signal, use the arrow keys or pointing device to
highlight the signal that you want to test. Then hold down the Ctrl key
and press the Space bar.
5. To test an input signal, you will need to use a cutter component. For
example, press a button.
The listed signal changes either from 0 to 1 or 1 to 0. The actual

component on the cutter you are testing becomes active or inactive.
Note: On this screen, active shows as green; inactive shows as red.
6. After you finish testing components, press Esc or click the Exit I/O
Diagnostic button.
KI Calibration (DG 20)

Use this diagnostic at the beginning of each shift to calibrate the Knife
Intelligence deflection voltage sensor (if the cutter can utilize KI).
Note: To check if calibration is required, first use the Null KI command

(see chapter 5).
right angle handle hex key set 944022402

To run diagnostic
2. On the presser foot bowl assembly, loosen the clamping screw that
locks the transducer adjusting screw. See chapter 6.
Note: For this diagnostic, it is not necessary to remove the presser

foot bowl assembly (as shown below for clarity purposes
only).
Clamping
Screw
3. Enable servo power.
4. From the Diagnostics menu, select KI Calibration (DG 20).
5. Adjust the transducer screw until the output voltage is at, or near,
zero (0).
6. Tighten the clamping screw to lock the transducer adjusting screw.
7. When finished, press Esc or click the Exit DG20 button.
8. Use the Null KI command to null Knife Intelligence (see chapter 5).

C Home to System Zero Diagnostic
The C Home to System Zero diagnostic allows you to adjust knife yaw and
command the system to plunge the knife four times in a straight line.
To use C Home to System Zero
2. Open Parameter Manager and use the Advanced button to enter a

password and change access level to Supervisor or Field Service. Refer
3. Place a large square of paper on the cutting surface. Position the cutter
head over the paper.
4. From the Diagnostics menu, select C Home to System Zero.
5. In the dialog box, type the number of degrees to adjust the knife
setting.
6. Press the Plunge Knife 4 Times button.
7. After the knife has plunged four times, compare the cuts to the
example shown below and in the dialog box. Make any necessary
adjustments.
8. Reposition the head over the paper. Repeat steps 4 through 7 until
satisfied with results.
9. Initialize the cutter to make your changes effective.
10. When finished, press Enter or click the OK button.
11. When prompted, you can choose to save changes to all setups.
12. If you clicked Yes in step 11, the system prompts how many setups
were changed. Press Enter or click the OK button.

Running Cut Tests
A Cut Test is actually just a marker designed to check a specific cutter
operation. Run Cut Tests as you would any marker, replacing the spread with a
piece of paper. Specific steps required for a Cut Test diagnostic and the expected
results are explained in each topic.
To run Cut Tests
1. Run the C200MT program.
2. Enable servo power.
3. Initialize the cutter.
4. Position paper and plastic on the table. See each diagnostic for the
specific paper size to use.
5. Turn on the vacuum.
6. Slew the cutter head to the lower left corner of the paper.
7. On the beam control panel do all of the following:

− Press the ORIG button.
− Set CUTTING SPEED to 10, unless otherwise noted.
− Set KNIFE to ON.
8. From the Diagnostics menu, choose Cut Tests. Then select the
appropriate diagnostic.
9. Press the Start button to run the diagnostic. The GERBERcutter

displays the status screen while the diagnostic is running.
10. When processing is complete, at the beam control panel do all of the
following:
− Set KNIFE to OFF.
− Press the VAC ON/OFF button.
11. Slew the cutter head out of the way, unless otherwise noted.
12. Check the results as explained in the topic for each diagnostic.

Beam Square Test
Use this Cut Tests diagnostic to check that the beam is square with the cutting
table. In this diagnostic, the cutter plunges the knife at each corner of a square. If
the measurements from corner to corner are the same, neither end leads as the
beam travels along the table and the beam is square. If the one end leads,
perform the maintenance procedure on page 129.
To run the diagnostic
1. Run the Cut Tests diagnostic as (see page 155) except:
a) Place a piece of paper at least 1.5 m (60 in.) square and preferably
larger on the table. This diagnostic must be rerun after making any
adjustments.
b) Before initializing the cutter, turn Run Time Biting OFF.
2. To check results, first measure a diagonal line from top right tip to
bottom left tip of the knife plunges. Then repeat from top left tip to
lower right tip to get the second measurement. Each line should be 160
cm (63 in.).
First Measurement
Second Measurement
3. Compare the measurements with those in the following table.
Measurement Indication Action
Equal to within 1.0 mm The beam is square. None

(0.03 in.)
First is greater than second The beam is not square. Use the difference
The +Y end of the beam between these
leads the -Y end. measurements to adjust
beam alignment.
See page 129.
Second is greater than first The beam is not square. Same as above.
The -Y end of the beam
leads the +Y end.

Heel to Heel Test
Use this Cut Tests diagnostic to check the mechanical alignment of the knife in
the C–axis. The knife must be properly aligned for accurate cutting. In this
diagnostic, the system plunges the knife twice so that alignment can be checked.
1. Run the Cut Tests diagnostic as normal (see page 155) except:
a) Place a piece of paper 0.5 m (20 in.) square or larger on the table.
b) After initializing the cutter set Knife speed to 2,500 rpm for all S91
systems.
CAUTION: Knife speed must be set as indicated above to simulate

the knife load caused by cutting a spread and to ensure
that results of this diagnostic are accurate.
c) Set Cutting speed to 1.
2. To check results, compare your test knife cuts with the drawing shown
below.
Measurement
(a) (b)
Good Unacceptable
a) If results are good, go to step 3.
b) If the knife alignment is unacceptable, your trained GERBERcutter

maintenance person can adjust knife alignment using the procedure
on page 111. Otherwise, call Field Service.
Note: A slight negative offset is beneficial under certain cutting

applications. Contact Field Service for recommendations and
limitations.
3. When alignment is correct, measure the heel–to–heel distance. If this

measurement falls outside the 2.7 to 14.3 mm (0.5 to 0.56 in.) range,
your trained GERBERcutter maintenance person can adjust knife
alignment using the procedure on page 111. Or, call Field Service.

Knife Offset Setup
Use this Cut Tests diagnostic to check that the cutter is using the correct value
for knife offset. Knife offset is the location of the knife blade relative to the
origin light. If the system is using the wrong value for knife offset, cuts will not
be made in the correct location.
Note: This diagnostic should be used whenever the laser light or head is
changed.
1. Run the Cut Tests diagnostic as normal (see page 155) except place a
piece of paper 1.5 m (60 in.) square or larger on the table.
The cutter positions the knife at, or near, the origin and executes a
knife down cycle.
2. After cutting stops, the Systems Message box prompts that processing
is complete. Use the Move to Origin command.
3. To check results, make sure that the origin light shines exactly on the
intersection of the horizontal and vertical lines. If it does not, do one of
the following:
− Continue with steps 4 through 6.
− Call Field Service.
4. Use the Position Info diagnostic (refer to the C200MT Software User’s
Guide) to determine the exact location.
5. Make appropriate changes to the Offset in X - Knife and Offset in

Y- Knife parameters in the System Setup category.
6. Reorigin and repeat this diagnostic to check your changes.

Training (CBT)
GERBERcutter computer based training (CBT) is designed to work right on
your cutter. More than just training, the GERBERcutter Training CD includes:
• Basic operation modules.
• Maintenance modules.
• Application wizards.
• Navigator.
Video and animation, along with text, guides you step–by–step through basic
operations and complex maintenance procedures. Application wizards offer
suggestions to resolve conditions such as pushing or fusing. The Navigator
shows you at a glance the types of information available and jumps right to the
specific information you need. Ask your local Sales office about availability.
To run Training (CBT) at your cutter
1. Insert the CD–ROM in the disc drive.
2. From the Help menu, select Training (CBT).
The Training software must be installed on your cutter in order to access this
program. Refer to installation information in the CD–ROM insert.
Service Parts
The GGT Service Parts documentation on CD–ROM provides the latest parts
information for your GERBERcutter. Assembly drawings in exploded view are
provided with indexes that identify names and part numbers. Drawings are
grouped by the type of GERBERcutter. Categories within each type are Head,
Beam, Electrical, and Installation. There is also a listing for all GERBERcutters
of consumables (spare parts), such as drill bits, knife blades, and belts.
Information is stored in Adobe Acrobat PDF format for easy access. Features in
the Acrobat reader include:
• Zoom for enlarging drawings.
• Search for finding a part by name or number.
• Print for printing out assembly drawings or part number lists.
Refer to the installation instructions that come with the CD when installing the
Parts documentation and the Acrobat reader.

CAM Applications
Flexibility within the C200MT program allows you to set up your
GERBERcutter based on differences in patterns, materials, and types of
manufacture. When your GERBERcutter was first installed, your Field Service
representative or trainer customized setup files for your manufacturing needs at
that time. To achieve optimal cutting performance for a different application
you should:
• Prepare the cut file data for automated cutting. Consider fabric, size of
the pieces, and cutting sequence. See below.
• Select the most appropriate preset setup available in the C200MT
program. Your selection should be based on fabric hardness, porosity,
tendency to fuse, and ply height. Refer to the C200MT Software User’s
Guide.
• Customize vacuum settings, knife sharpening, and motion control
parameters for this setup. See the next page.
Automated cutting concepts are explained briefly below. For detailed
applications information, ask your Field Service representative about the
availability of the CAM Applications manual.
Automated Cutting Concepts

The GERBERcutter is an efficient, computer aided manufacturing (CAM)
system. Computer aided design (CAD) systems provide instructions in a cut file
to control the cutting system. The GERBERcutter executes those commands.
Parameters in the C200MT program determine exactly how those commands are
executed.
To improve cutting results consider the following concepts.

Data Preparation
Preparation of data for a GERBERcutter differs from hand cutting in that special
consideration must be given to the pattern pieces and the material being cut. An
operator cutting by hand intuitively compensates for a different fabric or tattered
corners on a pattern piece.
Because the GERBERcutter simply follows CAD instructions, the pattern

maker, digitizer, and marker maker must give consideration to some of the
things mentioned below. Remember, automated cut quality is directly related to
the CAD instructions.
Pattern Pieces — Before pattern pieces are digitized and stored, it is a good
idea to answer the following questions based on the cutting results desired.
− Are slit, V, or both notch types going to be used?
− Is it permissible to miter corners?
− Is there an added buffer on the pattern template to compensate
for hand cutting inaccuracy? If so, is it still needed?
If existing pattern pieces are torn, wrinkled, or frayed, redefine making sure
corners are accurate, crisp, and clean with straight lines and smooth curves.
Digitizing — Always define an accurate grain line. If the grain line is off in
rectangular pieces, the parts will not nest with true common lines.
Marker Making — The marker maker should consider the placement of large
and small pieces (see Vacuum Hold Down section).

Vacuum Hold Down
The GERBERcutter relies upon a vacuum system to compress and stabilize the
material to be cut. The size of cut pieces, material porosity, and cutting sequence
affect the performance of the cutting system. You can customize a setup by
changing parameters in the Vacuum Systems category. Refer to the C200MT
Regularly scheduled maintenance of the vacuum system ensures optimum

mechanical performance of the GERBERcutter. See chapter 6.
Knife Sharpening
Material content (i.e. natural or synthetic fibers, coatings, etc.) and ply heights
determine knife sharpening requirements. You can customize a setup by
changing parameters in the Sharpen Parameters category. Refer to the C200MT
Regularly scheduled maintenance of the sharpener assembly ensures optimum

mechanical performance of the GERBERcutter. See chapter 6.
Motion Control
Quality requirements, material, and type of manufacture must be considered
when optimizing the performance of the GERBERcutter.
The C200MT program has a built–in knowledge base and is flexible enough to
meet the needs of Aerospace, Apparel, Automotive, Furniture and many other
industrial applications. For example, if cutting tubular goods you may want to
use the Clipping Window or Centerline Origin features. If cutting narrow
markers, Marker Stacking may speed throughput. Refer to the C200MT

*ORVVDU\
axis
An imaginary line used to describe movement and location on the cutting table.
The GERBERcutter has three axes: X (parallel to table length), Y (parallel to table width), and C
(knife direction).
backlash
The space between two gears or a gear and its rack.
beam control panel (BCP)
A terminal that lets you control the cutter head and beam assembly from the cutting table.
The computer that processes input from the beam control panel is called the BCC.
bite feeding
A feature on TCW and ZVC systems that matches cutter head movement with conveyor movement,
permitting automatic cutting of a long spread. The spread is cut in sections that fit on the cutting
table surface. Each section is called a bite.
BRISTLE SQUARE
Squares of molded bristle that plug into conveyor slats on TCW and ZVC systems or into grids on
Static systems. They form a work surface for cutting material.
C200 controller
The command center of the GERBERcutter.
C–axis
An imaginary straight line that the knife rotates about.
circuit breaker
A switch that automatically interrupts an electric circuit.
command
A request entered at a terminal, such as the operator workstation, to perform a function.
config
See setup.
conveyor
Moving work surface on TCW and ZVC systems made from aluminum slats and covered with
Gerber BRISTLE SQUARES.
cursor
A pointer that you see on the monitor screen of your operator workstation. Use the pointing device
to move the cursor.
Glossary Page 163

cut file
A computer data file that tells the GERBERcutter how to cut out pattern pieces in a marker from a
spread.
Cutter Info Database (CIDB)
An optional report generation package that helps you judge how well you are using your
GERBERcutter.
data
Information stored on a disk.
default
A setting that is programmed into the computer at the factory. This is used until you override it by
selecting another setting.
disk
A computer data storage medium made of plastic covered with a magnetic coating.
disk drive
A device that lets a computer read and write data on a 3.5 or a 5.25 inch disk.
downloading
Transmitting a file or program from a central computer to another computer (that is, from the
operator workstation PC to the MCC).
drill
An optional unit that attaches to the cutter head for making drill hole marks.
dry haul
The distance traveled with the knife out of the fabric.
dry run
Executing a cut file without plunging the knife or drill into the material.
emergency stop (ESTOP)
A red, push button that immediately stops all GERBERcutter motion.
Energy Saving Mode (ESM)
A vacuum feature that reduces vacuum to the cutting table when the cutter has been idle for a
certain period of time.
front end processor (FEP)
Another name for the operator workstation PC.
hard disk drive
A computer data storage device that holds the software that runs the GERBERcutter. A hard disk
drive uses rigid metal disks to store large amounts of data.
Page 164 Glossary

hardware
Physical elements of the computer, such as the monitor and keyboard.
heel cut
Cut made by the heel of the knife. The heel is the thickest edge (following edge) of the knife blade.
initialize
Setting the X0, Y0 coordinate for the cutting table after downloading the C200MT software. The
system uses this coordinate as a reference when processing a cut file.
keyboard
A device with keys, like those on a typewriter, that lets you enter data and communicate with the
C200MT.
lateral drive
A table option. The cutting table can travel from one spreading table to another.
lay puller
A material handling system for Static systems.
left side
The left side of the table as seen from the take–on end.
limit switch
A switch that sets boundaries (limits) for cutter head or beam travel on the work surface of the
cutting table. Limit switches also tell the C200MT when the cutter head reaches the X0, Y0
coordinate when you initialize the system.
marker
Another name for a cut file being processed on the cutter.
monitor
A device like a television that receives computer video signals and displays information on the
screen.
motion control computer (MCC)
A computer that responds to instructions sent from the operator workstation PC to control cutting
table motion.
network
A set of computers connected together.
network file server
A computer that provides a central database for other networked computers.
Glossary Page 165

operator workstation
The computer, monitor, and keyboard used to access the C200MT program and relay your
commands, cut file data, and setup data to the Motion Control Computer (MCC) for processing.
origin
A point that represents the X0,Y0 location for the cutting table (or a marker). Every other point on
the table (or on the marker) is relative to the origin point.
parameter
A setting defined in a setup file.
plenum
A sectioned chamber that is part of the vacuum system.
printer
A device for putting computer data onto paper.
program
A set of instructions for a computer to execute. The programs that direct a computer are called
software.
right side
The right side of the cutting table as seen from the take–on end.
Run Time Biting
A utility that bites the marker just before the GERBERcutter processes it.
servo motor
One of several electric motors used to move the beam along the X–axis, the cutter head along the
Y–axis of the cutting table, and control knife rotation on the C–axis.
setup
A computer data file that configures the system in a particular way, depending on what materials
you are cutting.
software
Set of computer programs used to run the GERBERcutter and communicate with you. These
include the C200MT program and Windows NT.
spread
One or more layers of material spread on a table for the purpose of cutting out pattern pieces.
static length biting
A method of biting in which each bite has the same length. In this method, some pieces are split
between bites.
Page 166 Glossary

take–off end
The end of the cutting table where material leaves after being cut.
take–on end
The end of the cutting table that receives material for cutting.
utility
A program that helps you operate the computer. Examples include Queue Manager and File
Manager.
vacuum gauge
Measures table vacuum. The vacuum pressure gauge in the Main Cutter Control screen displays the
current vacuum levels.
vacuum generator
The unit that makes a vacuum which is used to hold material firmly to the table work surface during
cutting.
vacuum level control
A vacuum feature that increases or reduces table vacuum depending on the current cutter mode
(idle, bite, or cut).
variable length biting
A method of biting a marker so that pieces are not split between bites.
X–axis
A horizontal reference line in a coordinate system. The X–axis is the length of the table, from the
take–on end to the take–off end.
Y–axis
A vertical reference line in a coordinate system. The Y–axis is the width of the table, from the left
(operator) side to the right (remote) side.
zoned vacuum
A vacuum feature that applies vacuum to a certain area of the cutting table. The cutting table is
divided into five more zones. Vacuum can be applied to one, two, or three zones at a time
depending on the pieces being cut. This feature is available only on Static and ZVC systems with
pneumatic zoning.
Glossary Page 167

Page 168 Glossary
$SSHQGL[
Knife and Drill Bit Part Lists
This appendix provides a list of knife blades and drill bits available from Gerber
at the time this manual was printed.
Note: For the most current information, refer to the Service Parts
CD–ROM. Ask your local Sales and Service office about the
availability of this useful tool.
Maintenance Checklists
For your convenience, checklists for 8, 40, 160, and 960 hour maintenance
schedules are included at the end of this appendix. See chapter 6 for detailed
procedures.
Note: To keep an electronic record of scheduled maintenance, use the

checklists available in the Training CBT feature. Ask your local
Sales and Service office about the availability of this CD–ROM.
Appendix Page 169

Knife Blades for S91 GERBERcutters
Various knife widths are available for your GERBERcutter. For example, 0.125
knives are recommended for cutting heavy duty materials, such as denim while
carbide knives are used for Aerospace applications. In addition to the knives
described below, there is an optional knife setup for lingerie.
Note: Changing to a different knife width may require changing additional

parts in the knife drive train and the sharpener assembly. Check with
your Field Service representative.
Knife GGT Part

Width Description Number
0.093 Knives 0.093 x 5/16 x 10 1/16, Hollow Ground, M2 Steel 021261008

0.093 x 5/16 x 10 1/16, Flat Ground, M2 Steel 021261009
0.093 x 5/16 x 10 1/16, Flat Ground, GKS 45 021261010
0.093 x 5/16 x 10 1/16, Hollow Ground 021261011
0.093 x 5/16 x 10 1/16, Flat Ground 021261012
0.093 x 5/16 x 10 1/16, Cryogenic Treated Knife 032426000
0.093 x 0.250 x 10 1/16, Flat Ground, M2 HS Steel, Silk Blade 078798003
0.093 x 0.250 x 10 1/16, Hollow Ground, M2 HS Steel, Silk 078798004
Blade
0.093 x 0.250 x 10 1/16, Flat Ground, GKS 45, Silk Blade 078798005
0.078 Knives 0.078 x 0.200 x 10.00, Flat Ground, M2 HS Steel 022217005
0.078 x 0.200 x 10.00, Hollow Ground, M2 HS Steel 022217006
0.078 x 0.200 x 10.00, Flat Ground, GKS 45 022217007
0.125 Knives 0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 032419010
0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel 032419011
0.385 x 0.125 x 10.00, Hollow Ground, M2 HS Steel 039536003
0.385 x 0.125 x 10.00, Flat Ground, M2 HS Steel, Service Only 039536004
Carbide Knives 0.0625 x 0.188 x 2.00, Carbide Grade K68 034325000
0.0625 x 0.188 x 2.00, Carbide Grade Ramet #1 Ultra Fine 044274000
Page 170 Appendix

Drill Bits, Ejectors, and Collets for S91 GERBERcutters
Note: Changing to a drill bit with a different diameter requires changing additional
parts in the drill assembly. Larger diameter drill bits also require an ejector.
Check with your Field Service representative.
GGT Part Number
Ejector Upper Lower Presser

Description & Diameter Drill Bushing Rod Collet Collet Foot
solid 3/64 (0.047)(1.19 mm) 044330000 021706013 945500274

groove 5/64 (0.078)(1.98 mm) 030595003 021706007 945500274
(1/2) rnd 3/32 (0.093) 030595002 021706002 945500274
(2.36 mm)
hollow 3/32 (0.093)(2.36 mm) 024351001 021706004 024348001 945500274 945500274
5/64
(1/2) rnd 1/8 (0.125)(3.17 mm) 030595001 021706001 945500274
hollow 1/8 (0.125)(3.17 mm) 024351002 021706003 024348002 945500274 945500274
7/64
hollow 5/32 (0.156)(3.96 mm) 024351003 021706005 024348003 945500274 945500274
9/64
hollow 3/16 (0.187)(4.75 mm) 024351004 021706006 024348004 945500274 945500274
11/64
hollow 0.197 (5 mm) 075782000 021706014 024348004 945500274 945500274
11/64
hollow 1/4 (0.250)(6.35 mm) 072490000 021706008 024348004 945500274 945500274
11/64
hollow 5/16 (0.313)(7.95 mm) 072490001 021706010 024348004 945500274 945500274
11/64
hollow 3/8 (0.375)(9.53 mm) 031199004 021706011 024348004 945500274 945500274
11/64
hollow1/2 (0.500)(12.7 mm) 031199003 021706009 060136000 945500274 945500274
hollow 19/32 (0.591) 031199005 060137000 060136000 945500274 945500274
(15.01 mm)
hollow 21/32 (0.666)(17 mm) 031199007 064356001 060136002 945500274 945500274 021746001
hollow 3/4 (0.787)(20 mm) 031199006 064356000 060136001 945500274 945500274 021746001
Appendix Page 171

8 Hour Maintenance Schedule Checklist
See pages 79 through 83 for procedures. To keep an electronic record of
scheduled maintenance, use the checklists available in the Training CBT feature.
Initials/Date
• Check knife yaw alignment _____________
• Check knife offset alignment _____________
• Check Knife Intelligence alignment _____________
• Fill the tension arm oil cups _____________
• Fill the pivot arm oil cup _____________
• Clean and film coat the air cylinder rod for the elevator _____________
• Clean and film coat the elevator guide rods _____________
• Clean and lubricate the swivel assembly _____________
• Clean and lubricate the cutter tube _____________
• Clean and lubricate the knife articulating arm _____________
• Perform sharpener assembly maintenance _____________
• Clean and film coat the knife presser foot guide rods _____________
• Clean and film coat the air cylinder rod for the knife presser foot _____________
• Clean and film coat the drill(s) up/down air cylinder _____________
• Clean and film coat the air cylinder rods for the drill presser foot _____________
• Clean and film coat the Y–axis roundway _____________
• Clean and film coat the Y–axis squareway _____________
• Clean and film coat the X–axis roundways _____________
• Check the X–axis racks _____________
• Clean the vacuum intake filter _____________
• Check for fluid in air/reducer filters _____________
Page 172 Appendix

Initials/Date
• Check the C–axis drive belt ______________
• Clean, lubricate, and check the C–axis servo gearing ______________
• Check tension of the knife drive belts ______________
• Check mechanical alignment of the knife ______________
• Check the head upper stop ______________
• Check the head lower stop ______________
• Check tension of the drill drive belt(s) ______________
• Clean, lubricate, and check the first X–axis pinion gearing ______________
• Clean, lubricate, and check the first X–axis servo gearing ______________
• Clean, lubricate, and check the Y–axis countershaft gearing ______________
• Clean, lubricate, and check the Y–axis servo gearing ______________
• Clean, lubricate, and check the second X–axis pinion gearing ______________
• Clean, lubricate, and check the second X–axis servo gearing ______________
• Check the torque tube drive belts ______________
• Clean, lubricate, and check the wheel housing cam rollers ______________
• Clean and lubricate the first X–axis wheel assembly ______________
• Clean and lubricate the second X–axis wheel assembly ______________
• Clean and inspect the bite encoder wheel ______________
• Perform X–axis spring scale test ______________
• Perform Y–axis spring scale test ______________
• Clean and film coat the clamp bar air cylinders (TCW) ______________
• Clean and film coat the resealer air cylinder rods (TCW) ______________
• Check resealer bar up/down air flow adjustment (TCW) ______________
Appendix Page 173

Initials/Date
• Check the knife speed adjustment (should be OK for one year) ______________
• Check the drill speed adjustment (should be OK for one year) ______________
• Check the Y–axis roundway bearings ______________
• Check the Y–axis squareway bearings ______________
• Check tension of the Y–axis belt ______________
• Check if the beam is square ______________
• Check the vacuum generator belts ______________
• Clean the vacuum stack filter ______________
• Check the conveyor drive alignment (TCW and ZVC) ______________

• Check the lay puller drive alignment (Static) ______________
Page 174 Appendix

Initials/Date
• Check the knife motor bushings ______________
• Check the drill motor bushings ______________
• Lubricate the vacuum motor ______________
• Lubricate the Spencer vacuum turbine ______________
• Lubricate the Hoffman vacuum blower ______________
• Check alignment of the coupling for Hoffman blower ______________
• Check fluid level of the conveyor gear box (TCW and ZVC) ______________
Change every third time ______________
• Check fluid level of the lay puller gear box (Static) ______________
• Check fluid level of the surface cleaner gear box (TCW) ______________
• Lubricate the surface cleaner pillow block bearing (TCW) _____________
• Lubricate the platform drive cam roller bearings (TCW) ______________
• Clean and lubricate the platform drive chain (TCW) ______________
• Lubricate the platform drive sprocket bearings (TCW) ______________
• Check fluid level of the platform drive gear box (TCW) ______________
• Lubricate the platform drive shaft bearings (TCW) ______________
• Lubricate the platform wheel cam roller bearings (TCW) ______________
• Check the roller and clamps for overhead cable trolley (TCW) ______________
Appendix Page 175

Page 176 Appendix
,QGH[
Bristle Penetration, 112
A BRISTLE SQUARES, 5, 130
rearranging, 131
Air/Reducer Filter, 83, 135
Alignment
coupling for vacuum assembly, 99, 137
C
conveyor drive, 95, 139 C Home to System Zero Diagnostic, 154
lay puller drive, 95, 140 C200 Controller, 3
See also Knife Alignment C200MT, 25
Applications, 159 accessing, 30
exiting, 41
B CAM Applications, 160
Categories
BCP, 13
parameter, 52
Beam, 4
C–axis, 20
maintenance, 82, 87, 92, 121
drive belt, 85, 113
square, 93, 129
servo gear, 85, 113
wheel assemblies, 125
yaw alignment, 79
wheel housing cam rollers, 125
Check Origin, 43
See also X–axis
CIDB, 18, 60
See also Y–axis
Circuit Breaker, 10
Beam Control Panel, 13
turn off, 41
cover, 122
Clamp Bar, 89, 138
Beam Square Test, 156
position first bite, 33
Bearings
Cleaner
platform drive, 101
solvents, 74
roundway, 126
work surface, 132
squareway, 126
Collet
surface cleaner pillow block, 132
part numbers, 171
Belt
Config. See Setup
C–axis drive, 85, 113
Conveyor
drill drive, 87, 118
controls, 11
knife drive, 86, 114
drive alignment, 95, 139
torque tube, 88, 123
gear box, 99, 139
vacuum drive, 93, 136
Y–axis drive, 93, 128
Coupling
Bite, 23
alignment, 99, 137
pause between, 43
vacuum blower, 135
run time, 54
Covers, 103, 122, 135
static length, 54
CTOT, 17
variable length, 54
Cut File, 25
Bite Encoder, 89, 125
opening, 36
Blower
Cutter Head, 4, 103
vacuum, 94, 98, 136
See also Head
Cutting
basic steps, 29
Bristle Locating Guides, 131
Index Page 177

speed, 39 FEP, 15
Cutview, 56 File Manager, 58
Filters, 134
D air/reducer, 83, 135
stack, 83, 134
Data Preparation, 160
vacuum, 82, 134
Data Scale Factor, 44
Flywheel Stroke, 86, 112
Diagnostics, 149
Beam Square Test, 156
C Home to System Zero, 154
G
Cut Tests, 155 Gear
Heel to Heel Test, 157 knife drive, 114
Input Output Test (DG 23), 151 X and Y–axis servo, 123
KI Calibration, 152 X–axis pinon, 123
Knife Offset Setup, 158 Y–axis countershaft, 124
Drill, 17 Gear Box
air cylinder rods, 81 conveyor drive, 139
belt, 87, 118 lay puller, 140
bit, 116, 171 work surface cleaner, 132
collet, 171
drive belt, 118 H
drive motor, 119
Head
ejector rod, 116, 171
cover, 103
motor brushes, 97, 119
lower stop, 86, 112
part numbers, 171
maintenance, 79, 85, 91, 97, 103
speed, 92, 119
upper stop, 86, 112
Heel to Heel Test, 86, 111, 157
E
Elevator, 112 I
air cylinder rod, 80
Initialize, 32
guide rods, 80, 112
Input Output Test (DG 23), 151
head stops, 86, 112
End Cap
cover, 122 J
Ejector Rod, 116 Jog
part numbers, 171 controls, 12
Error Messages, 144 position first bite, 33
EStop, 9 See also Conveyor
plungers, 9 See also Lay Puller
switches, 8
Exiting, 41
F
K
Fabric Alignment, 42
Feed Rate, 30 KI Calibration (DG 20), 152
Page 178 Index

Knife, 106 advanced X and Y–axis, 126
bristle penetration, 86, 112 basic X and Y–axis, 122
part numbers, 170 beam, 82, 87, 92, 121
reset for new, 65 C–axis, 85, 113
setting speeds, 66 cleaning, 74
sharpen, 63, 162 drill, 81, 87, 92, 97, 116
speed, 91, 115 electrical, 73
Knife Alignment elevator, 80, 86, 112
mechanical offset, 86, 111, 156 filters, 82, 83, 94, 134
offset, 79, 158 head, 79, 85, 91, 97, 103
yaw, 79, 154 knife, 106
Knife Drive knife drive, 80, 86, 114
belt, 86, 114 knife drive train, 80, 104
motor brushes, 97, 115 lubrication, 74
tension and pivot arms, 80, 113 material handling systems, 99, 138
Knife Drive Train platform, 100, 141
articulating arm, 80, 105 safety, 72
cutter tube, 80, 105 roundway and squareway, 82, 92, 121
swivel assembly, 80, 105 roundways and racks, 82, 133
Knife Guides, 110 sharpener assembly, 81, 107
Knife Presser Foot, 108 table, 82, 89, 93, 99
air cylinder rod, 81 tools, 75
Knife Intelligence, 67 vacuum, 82, 93, 98, 135
alignment, 79 work surface, 130
calibration, 152 Maintenance Schedule
null, 67 160 hour, 91, 174
Knife Motor 40 hour, 85, 173
turn on, 39 8 hour, 79, 172
Knife Offset Setup, 157 960 hour, 97, 175
Marker, 36
L Marker Report, 60
Material Handling Systems, 138
Laser Light
Motor
safety, xiv, 72
drill drive, 97, 119
turn on, 37
knife drive, 97, 115
Lay Puller
vacuum, 98, 136
drive alignment, 95, 140
gear box, 99, 140
O
tow bar, 33 Operator Workstation PC, 15
Limit Switches, 7, 32 Origin, 21
Lubricants, 74 check, 43
restore, 50
M set for cut file, 38
Maintenance, 71 Overhead Cable Trolley, 102
Index Page 179

Overlay, 33 Restore State, 47
manual, 48
P Right Side Option, 17
initialize, 32
Parameter
Roundway, 82, 122
categories, 52
bearings, 126
manager, 52
Roundways, 133
Parts
Run Time Biting, 54
numbers for drill, 171
numbers for knife, 170
order, 74
S
service CD, 159 S91
Path Intelligence, 69 models available, 1
Pause Between Bites, 43 Static, 2, 77
Piece Recut, 49 TCW, 1, 76
Piece Search, 49 ZVC, 2, 77
Platform Safety, xiii, 72
controls, 11 Service Parts, 159
drive maintenance, 101, 141 Servo Power Enable, 31
Ply Height Setup, 25
conveyor drive alignment, 139 change, 52
lay puller drive alignment, 140 selecting, 35
maximum, 28 Sharpener Assembly, 81, 107
POWER Processor, 18 knife presser foot, 81, 108
Power Up, 30 Shift Report, 61
PreProcessor, 55 Shut Down, 41
Processing Software, 25
cut file, 40 Squareway, 82, 121
Product Support, xi, 74, 143 Squaring the Beam, 129
Stack
Q filter, 94, 134
Spread, 28
Queue Manager, 57
Spring Scale Test, 89, 127
Static, 2, 77
R Support. See Product Support
Racks, 82, 133 Surface Cleaner
plastic film caution, 33 gear box, 100, 132
Recovery, 46 pillow block bearings, 98, 132
before, 46 Switches, 7
Bite Search, 50 EStop, 8
Piece Recut, 49 knife, 30
Piece Search, 49 limit, 30
T
Restore Origin, 50 Table, 130
Restore State, 47 maintenance, 82, 89, 93, 98, 130
Reports, 61 Take–off End, 19
Resealer, 89, 138 Take–on End, 19
Page 180 Index

TCW, 1, 76 platform drive, 101
Tool Codes, 56 Windows NT, 25
Tools, 75 Work Surface, 5, 130
Torque Tube, 88, 123 Work Surface Cleaner, 132
Training (CBT), 159 gear box, 99, 132
Trim Cut, 45
Troubleshooting X
diagnostics, 149
X–axis, 20
error messages, 144
cam rollers, 88, 125
Turbine. See Vacuum
pinion gear, 87, 123
Turn On, 30
racks, 82, 133
roundways, 82, 133
U servo gear, 87, 123
Underlay, 28 spring scale test, 89, 127
Utilities torque tube, 88, 123
C200MT, 51 wheel assemblies, 88, 125
V Y
Vacuum, 6 Y–axis, 20
energy savings mode, 70 bearings, 92, 126
hold down for application, 161 belt, 93, 128
readout, 11 countershaft gear, 87, 124
turn on, 37 servo gear, 87, 123
Vacuum Maintenance spring scale test, 89, 127
blower, 94, 136
blower lubrication, 98 Z
coupling alignment, 99, 137
ZVC, 2, 77
coupling guard, 135
belts, 93, 136
filter, 82, 94, 134
generator, 93, 136
jack shaft cover, 135
motor, 98, 136
take–on cover, 135
turbine, 98, 136
View Marker, 56
W
Wheel
assemblies, 88, 125
housing cam rollers, 88, 125
Index Page 181

Page 182 Index
U.S.A./CANADA INTERNATIONAL EUROPE
Gerber Garment Technology, Inc. Gerber Garment Technology, Inc. GGT Europe N.V./S.A.
WORLD HEADQUARTERS INTERNATIONAL DIVISION Excelsiorlaan 55
P.O. Box 769 P.O. Box 769 B-1930 Zaventem, BELGIUM
24 Industrial Park Road West 24 Industrial Park Road West TEL: (32) (2) 716 03 11
Tolland, Connecticut 06084 USA Tolland, Connecticut 06084 USA FAX: (32) (2) 716 03 22
TEL: (860) 871-8082 TEL: (860) 871-8082
FAX: (860) 871-6007 TLX: 192558 GGTIHQ
FAX: (860) 872-6742
P/N 083878000
Printed in USA 2/98

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S-91 GERBERcutter

OPERATOR AND MAINTENANCE MANUAL

The information contained in this document is subject to change without notice.

Gerber Garment Technology, Inc.

Printed in USA 2/98

C–axis Drive ....................................................................................................................................... 113

Chapter 1 S91 GERBERcutters

Chapter 2 Basic Concepts

Chapter 3 Cutting Markers

Chapter 5 Optimizing Cutter Performance

Bold type highlights important information in the text.

Italic type highlights titles of other manuals.

Note: Notes contain important or helpful information.

CAUTION: Cautions appear before procedures that could cause damage to

WARNING! Warnings tell you when you must follow a specific

Inside the United States and Canada

For product support within the United States or Canada, call:

Have the following information ready when you call:

• Identify what equipment you are using.

For software/hardware support, training, or information about products outside of

WARNING! Failure to follow these safety precautions could result in

Dangerous Procedure Warnings

Do Not Perform Maintenance Alone

Safety Precautions xiii

Laser Origin Light

WARNING! Use of controls or adjustments or performance

xiv Safety Precautions

Do Not Operate in an Explosive Atmosphere

Use Caution When Handling the Monitor

xvi Safety Precautions

Traveling Conveyorized (TCW)

Chapter 1 S91 GERBERcutters Page 1

Zoned Valve Conveyor (ZVC)

Page 2 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 3

Page 4 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 5

Page 6 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 7

To stop the system:

1. Press one of the red EStop switches.

All table motion stops.

2. For error recovery procedures, see chapter 3 or refer to the C200MT

CAUTION: Do not move the spread or jog the conveyor after an

Page 8 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 9

WARNING! Do not turn circuit breaker 2 on or off. High

Page 10 Chapter 1 S91 GERBERcutters

Platform Controls — Use to control movement of the cutter along rails

Chapter 1 S91 GERBERcutters Page 11

Page 12 Chapter 1 S91 GERBERcutters

Chapter 1 S91 GERBERcutters Page 13

EStop — Immediately stops all table motion.

Knife — Turns the knife motor on or off.

Vacuum — Turns cutting table vacuum ON or OFF.

KI Null — Resets Knife Intelligence.

Fabric Alignment — Sets fabric alignment when pressed twice.

Sharpen Knife — Manually sharpens the knife blade one cycle.