MOHR

Posttach 1220 - D-65702 Hofheim/Ts. 1

Telefon {061e2) so‹o
Teletex (2627) 61928 polar
Telefax (D6192) 22193

INFORMA

This SERVICE-INFORMATIONS is valid for all POLAR EMC machines

Reproduction in print, photo copy or any other method Is strictly prohibited. This manual
should not be handed over or lent out to persons outside the POLAR-organization.
(§ 15 d. Ges. vom 19. Jull 1901 und § 18 d. Ges. vom 7. Juni 1906)
C0NTENT 1. Checking of Plugs and other connections .... .. 5
S
2. Supply volages ....... ..... 5
2.1 Check poinu + 9 V keyboard and display BT S
2.2 Check points * 5 V keyboard computer ... S
2.3 Check points + 5 Vcard PS5 (CU) . . 5
2.4 Check ooints + 24 V card PS24 (CU) 5
2.5 Check points +42 V plug 1.pin 8 (CUI 5
2.6 Check points-J2 V card El (CU) 5
2.7 Check points—30 V card El (CUI 6
2.8 Checkpoints-J2V B card El (CUI 6
2.9 Check ooints—30 V B card El ICU) ................. 6
3. Initial-basic condition light diodes aHer machine is turned on 7
3.1 Cold key buard computer On ............. ........... 7
3.2 Card PS5 (CU) ...... ....“........................................7
3.3 CardSPE (CU) 7
3.4 CardEl (CU) 7
3.5 CardPS24 ICU) ..... .. . . .... ........ 7
3.6 CardTAM (CU) .. .. ..... .. . ............. 7
3.7 Card IHR (CUI ........ .. ...... . . .... 7
3fI Card IAR ICU) .. ........ .... .. ... 8
3.9 Card KK (CU) ........... ........... .. 8
3.J0 Card HK (CU) .............................. 8
3.1 I Gard ML (MCI ........... .. ........ 8

4. After control voltage is turned on

all machine functions will be blocked 9
4.1 No read out at backgauge position and keyboard displays......................9
4.2 Erroneous figures on all displays after control voltage Is urned on 9
4.3 Read out of Cl on last digit of keyboard display but no decimal point 9
4.3.1 LED V1 (SPEI will not come on after marhiru• i.t hmm nn
LEDs VI and V2 (KK) are lit up ........ 9
4.3.2 LED V (SPE I does not come after machine is turned on ... 9
4.3.3 LED V1 (SPE) does not come on and w ii stay on
aher machine is turned on 9
4.3.4 LED V 1 (SPEI will come on after machine is turnpd on
but will go off approx. 1 sec. thereafter 9
4.3.5 Control diagram: Fixomat ..... . 10
5. No backgauge movement. 11
5.1 Conditions ........ 11
5.2 Optional equipment to be switched off 11
5.3 LED V7 (ML) off .... 11
5.4 LED V6 (ML) oft i1
5.5 LEDs V7 resp. V8 tIAR) will not come on 12
5.6 LEDc VG resp. VB (ML) will not come on 12
5.7 LEDs V2, V5, V8 (MLI will not come on
if contact ,forward’ S10 is activated...........................................12
5.8 Checking functions ot ML and IAH witn the test positioning computer f2
5.8.1 Control diagram 1or backgauge motor and brake . 13
5.6 If handwheel adjustment (S18) is operated LED VS (ML)
does come up, backgauge motor brake does not release 12
g
5.10 After activatin ,forward’ (S10) or ,reverse’ (S14) LED V8 CML)
will light up, backgauge motor does not start 2

s. No reference point .........

7. Difference between displayed measurement
and actual backgauge posiGon .... . tu
8. Problems of clamp functions during use as cutting line indicator 15
8.1 Clamp will not move downward despite of activating pedal.................15
8.1.1 LED V6 I IAR) does not come on
wben pedal is operated (pedal switch) . 15
8. \.2 LED V12 (IAR) does not come on
wl›on potJal is operated (locking velvc)........................................1S
8.2 After releasing pedal clamp will not return to upper resting position 15
8.3 After clamp returned to uooer resting position
the locking valve is not switched off........................................... ›s

9. Prublsms uii function cycle clamping aod ctztt'^9 1C

9,1 Checking contacts of both cut buttons ...... .. 16
9.2
LED VG (HK) does not light up mo release of cutl . 16
9.3
After activating cut buttons LEDs V14 and V15 will light up,
LED V4 or VS (KK) remain off ...... . ..... . 16
9.3.1 Control diagram for cutting and clamping circuiwy....................17
9.4
Magnetic valve for clamping (Y27) will not close.................................16
9 5 Magnetic valve for cutting TY33l will not close...................................16
9.6 Checking functions of IAR, HK and KK with test positioning computer 16
 0. Problems on light berries.........................................................2o
J0.1 Both conool LEDs V8 aud V10 (LS•boardl are off.
LED V16 TLS-board) oN......................................................20
10.2 Control LED V8 (LS-board) is lit up, LED V13or Vt6 (LS-board) is off 20
JO.3 Interruption of individual light beams.......................................................20
11. Ezrnr Jetectien signals..............................................................................21
1I.1 Dashes at program and storage plaoe display (EM, EMC II)....................21
11.2 Number -02- (EM, EMG II)..............................................................2t
1J.3 Number —03— (EM, LMC II).................................................................21
11.4 NumLor -04- (EIyI, EMC II).....................................................21
I i.s numba‹ —os— ‹su, suc u) . . . . . . . . . . . . . . . . 21
1J.6 Number — , —09, —10- (EM, EMC 11) ....... 21
IN.7 Number - (only 76 EM, SD)..........................................................21
IN.8 Number —49- (only 76 EM, SDK.....................................................21
11.9 Number -57- (only 76 EM, SDI......................................................21
11.10 Number —68, 6B (only 76 EM, SD)..........................................................21
11.1I Numbet •-•G7- (only EMC II)..............................................................21
11.12 Number -68- (only 76 EMI.............................................................21
11.13 Number -6W OEM, EMC III...............................................................22
11.14 Number (EM, EMC III .................. 22
11.15Number —81— ............ .......................
1J.16 Number -82—....................................................................................22
11.17 Number —83— ................. 22
11.)8 Number............................................................................................. 22

11.22 Number —88— 23

11.23 Number —89— ......... 23
11.24 Number -9A . 23
12. Summary of Setting- and Measuring \ ilues, Mechanical ...... 24
12.1 Clutch gap ..................... ................. 24
12.2 Backgauge brake (Backgauge drive) 24
12.3 Play of teeth at the gear (for proper 24
tg, § A IIM I Ult Uf thC { dCkgowgg ................. .• • .. • • • • • • 2•9'
12.5 Tension of V-belu ......... ........ - -- - -- - - - //
j3. Summary of Setting and Measuring Values, Hydraulics . ...... 24
13.1 Loweringspeedofclamp .. ... . ... . . ... . . . 24
13.2 CIut1i picssuie ............. ...................... 24
13.3 Clamping pressure ........... ........... ..... ...... 24
13.4 SafetY orcoure Ifor cutting line indication) ................ 24
)3.5 Change over preuure .. .. ... .. .. .. . . . ... . - - -- - 2*
$ 3.{j il tgjytpgrgttjr$ ...... ....... .... .. ................ 25
13.7 Oil capacity of the pills ............................. 25
13.8 Adjusting of clamping preuure ......................... 25

]4. Clamp opening (cutting capability) .. . .... ... .. 2S

14.1 Guiding gibs ..................................... 25
14.2 Knife carrier ........ ............................. 25
J4.3 Gapbetweenkniteanoclamp . ... .. .... .. 25
14.4 Clamp pedal 2ñ

is. Installation of proximity switches at safety bolt ............ 26

J7. Adjusonent of limit switches for &ckgauge travel.....................27

19. Cutting and clamping POLAR 76.92,115, 137, 15g (mechanical) . 29

19.1 Machine does not cut through pile (i. e. knite get stuck in pile)...........29
19.2 Overcut or undercut...................................................................................32
19.4 Oblique cut........................................................................................35
19.5 Stepped cut......................................................................................................36
19.6 Warped cutting line ................................ 37
19.7 Notched cutting line . .. .................. ........... 37
19.8 Rough cutting line with sheets stuck together .... ..... ...... 3/
t9.9 Cutting line glitters and becomes darker ........ ..... ...... 37
19.10 Knife pulls out sheets from under the clamp ..... ..... 37
......

20. Knife carrier and cbmp ..... ... ... 39

20.1 Knrte carrier runs against guiding gibs at the top .. ..... ...... 39
20.2 Clamp does not touch the table when pedal is activated ........ 40
JOE Clamp is lowered too slow during cutting . . .. . 41
20.4 Clamp is returning too slow ......... ....... ..... 42
......
20.S Clamp pedal moves roughly ................ ..... ...... 42
20.6 Clamp does not move down .......... ..... .......... 42

21. Hydraulics ... . .. .. ... ...... ............. 43

2f.1 Hydraulic unit is kaking ............................. 43
21J Air in hydraulic systemm ............. . ............. 44
21.3 Inching mode for knrfe ineffectual ................ ...... 45

Gearandcluteh ...... . . . .... . 46

22.1 Gcarisleakingoil...................................................................................... 46
w 7 Gear and/or clutch noisy....................................................................57

23. Rake, backgauge and dedge...........................................................62

23.1 Bottom sheet clides under the backgauge rakes..........................................62
23.2 The cutting material is not square............................................................63
23.3 Difference between actual backgauge position and display......................64
fr Ċheckiug of plNgs
and other connections
1.7 uninecs6j2
εystem-vpe ae n uou 7.7.7 ts uumœr ou piu πousiug pjug tπe same as ou tπe matiug pjug4
t.7.s oe piu pJug aud m˙˙atiug pjug correctJy seatedc rπe suap ou procisious ou
tπe nemaJe pJug πousiug πaue to suap ocer tπe oues at tπe piu πousiug.
t.7.s ore
pjugtπe iudiciduaj pius aud matiug πardware secucejy suapped iuto tπe
πousiug?
tıπe 6ywires,
cπauœtπeusome tπe otjitrje
πemc6tcπcau sπoujd
be punjed out, usiugopeued
œ c6renujjy sjigπt pujjiug
a jittJetorœmore.
ou
rπereatter pius aud temaje matiug coutact sπoujd 6e pusπed 6acı arj tπe way
iuto tπe πou~ siug to assure correct seatiug.
1,3 the
eıugpjug*in
couuecions
&c&s on t.s.t &enoгe a macπiue is to go iu opratiou (anter iusajJatiou is compJetedµ remoce
aıJ pJug*iu cards aud termiuar pJug couuectors ou tπem iudiuiduarIy. Veiusert
a u d c o u ecrtetmπoemce
apaguoayiuiupot iusssaaud
ibcjearbeutuiJJdmupauounecr.oтrгoisiowuijor
rπoeJxpidtaoticojeuanuroamjr cocuetrasecat sπipmeut or projouged storage ot tπe
2r Spp)y YołtageS macπiue¸
3,t ley~board aud
dispjay Br: t6 vojt H.C.
rojerauz=
Cπecı Uoiut: 8,o − e,6 vojt H.C.
rest(UIcy
jacıs ou (&r·boardy jen (&rj·sy
cuse: cs

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c vojt H,C.
&ley:6oard c,o8 - c,7s vojt H.C.
2.2

тojerauce: resr jacıs ou &26oard computer top (BP1sy

Cπecı Uoiut: tc vojt H.C¸
2cC
Cu·uui: c,o8 - c,7s vojt H.C.
rojerauce: rest jacıs card Us (Usc; 7 aud sy
Cπecı Uoiut c1 (UIcy
cvse:
2.Q u ta voıt H.C.
Cu uuit: ts,8 - sa,t vont H.C.
тojerauce= rest(UIcy
jacıs card
Cπecı c1 aud Usso (Usso; t aud sy
c1 (essoy
Uoiut
3.c cuse:  os voıt H.C.
Cu-uuit: os - c8 vort Dr’.
тojerauce;
cCuπeec=ı Uoiuts: cUoug(9,CIucyUiu 8 B vojt, piu
9 9

t os v
6
3.6 Cu-uuit: -7s vojt H.C. (sIC, Iy
ojerauœ= − 77¸o
Cπecı rest jacıstocard
− 7s,6
sj (svojt
cdaud
C.7y
Uoiuts: c6, c8 (UIcy
cuse:
 <

2.7 CU-Unit: — 30 Volt D.C. EMC.

EM Tulwai› : - 28d ‹u - 31,5 Volt
D.C. Check Polnu: Test jecks card El (EIS
and 21 Fuze: F6, FB (PMF)

2.8 CU-Unit: - JR Volt D.C. B (EMC, EM)

Tohrance: - t1,4 to — 12,6 Volt
Check Poinu: Test i•cks card El (EI5 and 3I
Fuse: F6, FB IPMF)
- 30 'Vbh D.C. 8 IEMC, EM) B- Buffered
— 30 to - 34 Volt D.C.
Test jacks *card El lEl5 and 41
F6, F8 (PMF)

gJng capectzors and voltage stabilizing conzpouents.

6

3. Iniaal-Basic Condition of Pension of machine all operational devices inactive

light diodes after machine Elements knife in upper deadend position
is turned on clamp in upper resting position
^«*9*ugenot in range of limit switches
t›ackgauge movement h‹$ not been started yet

LED Basic Signal Function with LED ,on’

LZD V4 ON + 5,1 V oxistiiig fur koybuard computer

LED V7 CIN + fi. 1 V existing fnr main comp‹ilar, pnsitinning rwmpiItpr

3JOaMSPE
LED VI OFF Main computer in initial phase (is lit up for approx. 1 sec. after
control voltage is turnad on)
LED V2 OFF error signal in main computer
3.4 Card El
LED VI OFF write or erasing access to the memory bank (is lit up for approx.
0.2 sec. after control voltage is turned on)
LED V6 OFF - J2 Volt or — 30 Volt missing
Z.5 Gard PS 24
LLU V / ON + 24 Voit existing
3.B fiard TAM
LED V1 ON or Flashing during backgauge movement
OFF
LED V2 ON or OFF Counting forward
LEDV3 OFF will light up for approx. 0,5 sec. while passinq reference point
3.7 Card IHR LED V2 OFF Air valve front table Y94a ,ON’

@|TAM
 LED Basic Signal Function wrth LED ‘ON’
3.8 Card IAR LED V1 OFF CuI buttui›a activated with in O,D sec.
LED VG OFF Lightbarrier monitor test completed
LED V3 ON Safety bolt r›ot activated
LED V4 ON Gear limit switch S22b tripped
LEDVS ON Clamp upper position b29 tripped
LED V6 OFF rootpedeI SD09 activated
LEDV7 OFF Forward switch SJ 0 engaged
LEDV8 OFF Reverse switch S14 engaged
LEDV9 OFF Handwheel adjustment SJ8 engaged
LEDV10 OFF Air switch 589 ens•9ed
LED Vt2 OFF Locl<ing valve Y3t6 activated
LEDVt9 OFF + 24 Volt on transformer CU.T2 — clamping —
LEDV23 OFF + 24 Volt on transformer CU.TI — cut -
LEDV27 OFF Air vslvc Y94 aCtivated

3.P Card KK LED V 1 ON 4 12 Volt supply voltage ex isting

LED V2 OFF Logic error cutting circuit - logic disagreement -
LED V3 OFF Logic error cutting circuit - logic disagreement -
LED V4 OFF Magnetic valve clamping T?/ activated
LED VS OFF Ma9netic valve cutting Y33 activated

3.10 Card HK LEDVJ ON - 12 Volt supply voltage existing

LEDV2 OFF Retarding of cutting cycle oompleted
LkUVJ UN ‹I backgauge position has been displayed
(Cut cycle release) OFF if no backgauge position visible at the display
Lrnvx c› Safa•ty b•oIt in lmrk ing pntitimn - fi IRF —
LEDVS OFF Safety bolt disengaged — S.SBA —
LEDV6 ON Cut burton right — S28a — contact normally closed
LED V7 ON Cut burton left — 5 28b - contact nor rriall y cluscd
LED V8 OFF Cut button r ight — S28a - contact normally open
LED V9 OFF Cut button left — S28b - contact normaltv open
LED V10 OFF Automatic knife
LED VU OfF activated Knife upstroke
522a
LED V12 ON Light barrier beam3 clcor of obstructions
LEDV13 OFF Knife inching mode S340
LEDV14 OFF Cutting buttons activated within 0,5 sec.
LEDV15 OFF Signal for transformer CU.T2 - clamping —
LEDV16 OFF Safety bolt activated
LED V17 OFF Signal for transformer CU.TI — cutting —
LED V18 OFF Light barrier monitor test completed
3.11 Card ML
LEU V1 UI-I- backgauge motor slow - E11 disenergized
LEDV2 OFF Backgauge motor forward — K 15M disenergized
LFDV3 OFF Falso clamp plate I I - S218 activated
LEDV4 OFF False clamp plate I - S6 activated
LED VS OFF Lifting solenoid for motorbrake on — Y 17 - no brake action
LED V6 ON Table limit switch front - OF F, if tripped
LEDV7 ON Table limit switch rear S13 — OF F, if tripped
I ED VR OFF Rar*e• ‹ • ntnr IN

IAR
4. After control voltage is turned on, No measurerrent displayed at the ,backgauge position display’ positioning of
all machine functions a kgauge toward the reference point not possible (on EMC, EM)
will be blocked
4.1 No read out at backgauge position Control voltage 9 Volt at the BT-board
and keyboard dizplayz. No decimal missing (Plug BT 602)
pgint at backgauge position display.

4.2 Erroneousfiguresand symboles on all Control voltage + 5 V on computer

displayc immediately after conool vok should be checked.
tags is turned on or 0 missing on Check connection BT — BR (Flat wire
last digit of keyboard display. harness)
Decimal puixit UI L›•zukguugv Ex l›aii BR
lzosition display is visible. Exchange BT

4C Read out of Oon last digit of keyboard

display. No decimal point at keyboard

4.3.\ LED VI (SPE) wit I not come on eftcr Supply voltage -› 5 V (POSI Miscin9
machine is turned ,on‘, LED V1 and V2 No reset signal. exchange PSS
(KKI are lit up.

4.3.2 LED VI ISPE) does nol come on af- Exchange card

ter machine Is urned ,on’. HR Exchange card
SPE
Bus connection of the computer cards
blocked
Exchan9t AR
Excha^9< *!
CU-unit base plate
4.3.3 LCD V 1 \SPE) will come on sfter ma-
chine is turned ,on’ and will stay on Check connection II ft - I f i I3
Exchange card TAM
No return acknowledge signal from
the fixomat limit switches S341,
S342, S343, S344. Check switches
and con- nections according to wiring
4.3.ñ LED V1 (SPEI will corns on after diagram
ma- chine is turned ,on’ but will go off
approx. 1 sec. thereafter Chact‹ connection CU16 — BRSOO
Exchange carol HR
Check connection HR — IHR
Exchange card BR
Exchange card IHR
PN
5. No Backgauge Movement 5.1 Conditions: Decimal point in keyboard display is
lit up
No error number read out within the
keyboard display
Machine is not within a cut cycle(the
decimal point in the keyboaro a
lpiny is not flashing)
Turn nff hac.kgaiign aci†nmatic and au-
tomatic knife
Check overload switch 006 for back-
g»uyg motor

5.2 In case optional equipment is installed Turn oN transomat 3BL

Fixomat in rest position (limit switch
5341 and 5343 activated)
Autotrim tobk closed llimit switch
S364 activatedl
On rriachines equipped with backgau-
ge locking devise:
Turn oN special hydraulic

1 1 I i 1 1

I I I I I

5.3 LED V7 (ML) OFF Table limit switch rear TS13l tripped
check limit switch and connections
according to wiring diagram
5.4 LED V6 (ML) OFF Table limit switch front tripped
IS9 without false clamp plate)
Iñ6 with standard type false ctampl
¿ IS217a withspecial false clamp plate I)
t’. fS217h with special false rlamp plate II I
Check switches and connections ac-

sz If handwheel for 1orward motion -
S10 - or push button - 514 - for
vatad, the LED V7 rea›ecd•ely VB
LIAR) does not come on
5.6 If push button - S14 — for reverse
is pushad. the light diodes on card ML
1ED V5 (lifting soknoid for motor
brske on) LED VB (bau‹saune motor
on) do not come on
5.7 In engaging handwheel S10 for for-
ward motion, the light diodes on
card ML
LED V2 (forward)
LED V6 (lifting solenoid for motor
5.8
card IAR with the help of the test pa-
5.9 If the handwheel sdjustmnt (518) is
operated. the LED V5 (ML) will light
up, but tke zable motor brake does
not release
11
Machine size recognition on card INR
falsely adjusted
connection CU 26 - MC 109 should
be checked (flat wire harnessl
Check connection CU 2 — MC 108
Exchange card IAR
Check connection CU 26 — MC 100
(fI8t wire harness)
Ckeck connection CU 2 - DC 1fa
Exchange card IAR
Check connection table motor brake
(Y17) — plug MC T04
Brake coil open wire
Brake sVstem mechanically hlnrkerl
Exchange card ML
6 8.1 Control diagram to’ backgauge motor arz brake
 5.8.1 Control circuit for backgauge mot6r.and”braLe

AR Pnsrtioning Comptitnr
IAR ”Positioning computer Interface
IgC Control unit f•r backgauge m”otor
uiL M0tO¥ COFTl 1OglG
K11M
K15M Relay: Backg”auge motor ,express — 9lOw'
/d17 ReJa¿: Backgauge motor .lDrWard - backward'
Backgauge motor
Q98 Overland twitch fpr backgauge rñ r”
Coiitaot'fur falgs clamp
Limit switch: forward witty false clamp
Limit witch- forward
Contact ,forward ON‘
Limit switch- backward
st8” Contact: bacLward
Contact: backgauge' brake OF F (-”Y17 ON !)
S217a Limit switch fa ard with 1. additional fabe
ctamp S217b Limit switch forward uzith 2.
additional false clamp
S2.1B Corrtact for additional fa\se clamp
V1/J Dol“xd stetc reloy'for bacLgoupc motor
v2Id Solid state relay for backgauge motar
V3M Solid state reIay”for bacLgauge motor
Y17 Baclsgauge motot- lifting solenoid for brake
[motor bIc›cIted by spring tension, if solenoid is
deenergi¥ocl)

I4
6. No Reference Point
7. Difference between displayed
meaurement and actual
backg-dtJ9* /O5itiO63
8. Problems of clamp functions
6.1 Conditions: While scanning for reference point,
backgauge wi(I travel full length of
ta- ble without mopping ot the
reference point
The LEG V3 (TAM) does not flash Cock connections and cable between
when backgauge Wavels within the length measuring system and CU-un‹t
middle third of travol length Exchange card TAM
Exchange cpu length measuring syste
c.s The LED VS (TAM) is flashing when Cxchangc card TAM
backgauge moves within the middle Exchange card AR
thirs of travellength. But backgauge
does not stop
Connect counter monitor to card TAM plug ABC
7.1 Measurement displayed at counter Check connections between Icngt h•
monitor differs from actual backgauge measuring system and CU-unit
position Exchange length measuring
system
Exchange card TAM
7.2 Difference between display Exchongo card TAM
ter monitor and backgauge position Exchange card AR
display is more than * 0,1 mm
Conditions: Machine is not in cutting cycle ldeci-
mal point in the keybo8£d displey
does not flash)
8.1 The clamp will not move downward
despite of activating pedal
8. .1 LED V6 (lARl — S309 — does Check switch S300 and
connection not come on when gedal is operated accordina to wirinq
diagram
8.1.2 LED V12 (lA R) — locking valve Check connection AR — IAR (flat
— does not come on when pedal is wire harness)
operated Exchange card
IAR
Exchange card AR
8.2 After releasing pedal, the clamp will Check switch b29 and its
connection not return to the upper resting positi- according to wiring diagram
(LED V5 on IAR)
B.3 After the clamg ha returned to the Switch S309 still in closed position
upper resting position, the locking Switch b29 does not acknowledge
the vatve is not switched off (LED resting position of the
clamp
V12 IAR remains on)
 J5

9. Problems on function Backgauge position at the digital dis-

cycle clamping and Conditions:
play
cutting Autom. beckgeugc svvitchcd off
All special functions switched off
Light barrier not interrupted
Backgauge motor off

If co equipped' Retractnhle side qni iga in resting pin-

sition
Special hydraulic units nor turned on

Iln case of an error message at the display, see chapter 11 — error detection
sig- nals)
9.1 Check contacts of both cut buttons Check cut burtom and connections
seconding to w iring diagram

Cut burton right — normally closed contact - S28a - LED V6 HK

Cut button left - normally closed conzact — S28b - LED V7 HK
Cut button •*9* — normally openedcontact - S28a — LED V8 HK
Cut hcifsnn left - normally opened contact - S28b — LED V9 HK

,_¿ • • • 87b

9.2 LED V3 HK does not light up (no re- Exchange card AR

leese of cut) Exchange card HR
Exchange card SPE

9.3 After activating cut buttons the LED's Cutting circuit transformer CU.TJ or
V14 - V15 HK are lit up but LED V4 CU T2 are defect
or VS KK do not light up Exchange CU-unit
Exchange card KK

9.4 After activating cut buttons the LED Check magnetic valve Y27 —
and V4 KK will light up,but the magnetic related
connexions according to the valve Y27 — clamping — will not close
wiring diagram

9.5 After activating cut buttons the LED Check magnetic valve — Y33 -
and V5 KK will light up, but the magnetic related connection accordingto
wiring valve Y33 — cutting - will nut closediagram
Only on machines with elemro-magnetic clutch:
Relais M1a and K21b are not energi- Check connection SCU6 -
SCU30 zed Exchange card KUP
No contact between carbon
brushes and conductor rings
9.6 Check functions of cards IAH, HK and replace card AR by test
poslzionln9 KK using the test positioning oompu- computer
tw Test display to be connected to plue
CU 8
Arrenzlon ! All operational functions are now similar tu tito gQmiaciiii›e, dc nut r utt
backgauge into the range of front or rear limit switch.

Bring backgauge to scan reference

point
If it i3 now possible, in this position,
to operate clamp and knife cycle
pro perIy, then a new positioning
comput ter card (AR) should be
replacing the
” test positioning computer
 17

9.3.1 Control cimuit for Muxing and Fleming EMC, EM, SD. SD-P

CU : Control unit
CU,T1 : Transformer 1o/ cutting circuit
CU.T2 : Transformer for clamping circuit
AR : Positioning computer
IAR : Positioni”ng computer i”nterface
KK : Monito channel
MHS : Hardware channel
LS : Light barrier
PSV . Llght jgarri9r emitter diso'ibutor plate.
V35 : Light barrier emitter diodes
V'36 • Light harrier rnrsiver dudes
B20 . Proximiw switch for upper gositan of clamp
BSB.A • I\/IonitDring sensar :safe bolt retracted’
BSB.E : MonnorlnB sensor ,safely boh in b.Iocki po>itJon'
K22a” • Auxiliary relay ,cutting and clâmping'
EZ2b : Auxiliary relay cutting Bnd ctarfiping’
S22a : Limit switch .cuning And Carñpin9‘
USB : Pushburton .?uzting and clamping'
Z26”b : Push buruan uEting arid clornp'ir@
SZ0s : Switch at pedal for”clamp
5340 : Switch for knife changing (inching mode)
Y27 : Magnetic valve for clamping
Y33 . Magnetic velve for cutting
Y315 . Ma”giiutiu cac iiii g valve for c\aropiñg
Y8B : Safety bolt alenoid
1B

3.3.I Control diagram far curt n j and clarag 'zg ci cuitry EMC, EM, SD•P, SD
10. Problems on Ii$tt bo«ar to.1 s»a«aeu uo vsa++4v1oaeoff.
LED V16 off
10J Co«rznnl LED VB is lh up. LEO V13
or V16 off
10J lmamzption of izzdlvMualB ztbeams,
eaxasa by the LED1VZ- V7 (V17
- V20 in addition if zoadsina is
aguippMwith’Bzhwszzd tightbarrlez!
Light diode ,ERROR’ on
Supply voltage + 24 V D.C. on PIu9
LS 600 - CU 4to be ched‹ed
Imerruptinn wtthin sha respective
Check connections according to wi-
ring di rem
Emitter LED's:
If tbe voltage on any emfttsr-Led is
exceeding 3 V D.C., then the LED is
Check adjustment of light barrier (we
servks mwsuat 4)
Skort circuit of any emitter LED:
If the vohaqe on anV emitter LED is
ka tkan 0,5 V D.C. it is to acsume
that this LED hss s short
Exchanya card LS
Ct›eck oonr›ection LS 60a - CU 4
Exchaz›ge cmd LS
20

11. Error detection signals Meaning: Remedy:

11.1 Dashes in tfie digital dupiay
program number and storage space
(ER, EMC)
The computer control system is recoq-
ni2inq an error with the program me-
mory bank as soon as machine is
turned on. The complete data of the
memory bank can be erased by acti-
varir+g the key ,Elu>iiig’. If howevei
the same error will appear again, the
following should be done:
Cr›eck supply voltages on cara El
(see chapter 2)
Chack connection card El — CU bas-
plate (flat wire harness)
Exchange interchangeable memory
bank (WSP)
Exchange card El

In program no. @ a special size false See error no. —68—

Only on 76 EM: clamp plate has been ctored, either
being smaller than 1,8 cm or larger
thsn 35 cm

Error in data exchange between main Check connection plug BR 500 —

IU Number —02- (EM, EMC) computer and kevboard computer CU16
Main computer signals more than 3 Exchange card BR
repeat demands Exchange card HR
Exchange card SPE

Error in data exchange between maip Check connection plug BR 500 —

11.3 Number —03— (EM, EMC) computer and keyboard computer CU16
Keyboard computer receives more Exchange card
than 3 erroneous snals HR Fxchange rrl
OF Exchange card
BR
Keyboard computer does not receive
11.4 Number -04— (EM, EMC) acknowledgement from main compu- Check connection plug BR 500 —
ter CU16
Excharxle card HR
Exchange card SPE
Exchange card BR
Error within analog-digital converter
11.s NumHr —as— lEu, Euc› of card BR Exchange card BR

Error in data exchange between key-

11.6 Number —OF, —08—,
—0g—, —IO— (GM, EMC)
11.7 Number —39— (only 76 EM. SD)
J1.8 Number —49— (only 76 8l¥l, SO)
board computer and main compute'r Check connection plug BR 500 —
CU16
Exchange card BR
Exchange card HR
Exchange card SPE
Preset measurement of reference
point is larger than 76 cm or smaler Set reference point measurement cor-
than 7 cm. The erroneous measure- rectly on the card TAM
ment will be shown f Icshing in the Exchange card AR
backgauge position display Exchange oard TOM
Exchange CU-unit
brror in the cross total of all Eprom
data Check and compare the Lprom-versi-
ons of cards AR and KDI for confor-

Exchange card KDI

Exchange cerd AR
Error in memory component of card
11.9 Number -57— (only 76 EM, SD) Exchange card KDI

Error in memory components of card

It.10Number -58—, —59— (only 76 EM. SD) AR Exchange card AR

Fixomat limit switch S341 and S342

11.11Number -67— (only EMC)
11.12 2 Number —68— (only 76 EM)
or Sñ4J and d44 are activated simul
taneously
In program no. @ the measurement
for a special size false clamp plate
has been stomd, either being smaller
than 1,8 cm or larger than 35 cm
Check switches and connectionsaccor-
ding to wiring diagram
Exchange card FIX
Check connection CM-unit —
MC•unit (flat wire harness)
Check connection MC-unit — SE-unit
(Olaf wire liar ness)
Exchange card IHR
Turn oH machine. Put to rest special
false clamp plate on switch S6. Attach
service jumper to card IAR. Turn on
machine. Erase complete memory sto-
rage by using key ,Program erasing’
and key ,Erase’ insert correct size of
special false clamp plate into program
no 6 of memory bank (see service-
 manual 4›.

21

Meaning: Remedy:

11.13 Nuiylbei —69- (EM, EMC) Dul-ing a read — write — or erase-func- If dashes ai r visible within time p‹wg‹ an
tion within the program memory bank number and storage space displays
af- a data error was discovered ter the machine was turned ,oH’
and
.on’ again see chapter 11.1
If the same problem comes back:
CheoL supply voltage on card El (see
chapter 2)
Check connection between card El —
CU baseplate (flat wire harneul
Exchange interchangeable memory
hank (WSPI
Exchange card El
11. t4Number —80— iEM, EMC)
Er rur in data excftange Uctw etc maiii Excliangc card AR
computer and positioning computer Exchange card HR
11.15 Number —81—
The monitor switch of safety bolt is Check switch S.SB
acknowkedging both endstops at the Check connection S.SB — CU 9
same t ime On machines with proximity switohcs
monitoring the safety bolt:
Check supply voltage for the switches
\pIug 44)
Check connection IAR — AR. (flat
wire harness)
Exchange card IAR
Exchange card AR

11.16 Number -52-

Dui iiig au£ivaLirig uf luck iiiy valve — CIink uunrlection IAR - AR (flat wi•
Y315 — the control transistor on card re harness)
IAR does not function Exchange card IAR
Exchnage card AR

11.17 Number 83 — The light barrier doe• not ream to the Check adjustment of light bcrr icr (sec
test signal before cutting cycle service manual 4)
starts with the output Check connection CU 4 — LS 600
condition ,interrup- ted‘ Check connection IAR — AR (tlat wi-
re harness)
Protem receiver side ef light barrier
against excessive may light
Exchange card LS
Exchange card IAR
Exchange card AR
11.18Number —84- While locking valve — Y3t 5 — is Check supply voltage + 42 V D.C. on
swit- ched oN, the voltage of + 42 V lockingvave
D.C. ie missing on the Control line' for Check connection CU 6 — lock in9 val-
the tt ve — Y315
5
lockin9 •aIve(plug 6.81 Check resistance of coil — Y315 — for
open circuit
Check connection IAR — AR
Exchange card IAR
Exchange card AR

11.19 Number —BE Check basic condition of all light dio-

During a cutting cycle the control
channel (card K K) will register discre-
pancies more than 3 times at the logic
outputs between the 2 cutting circuit
channels (hardware channel
posi- tioning computer)
des on card HK and IAR
Check adjustment of limit switches
.dia and S?2b nt thp gear box |see
service manual 41
and Check adjustment of light barrier(see
service manual 4)
Exchange card HK
Exchange card IAR
 Exchange card AR
Exchange card K
K
Meaning:
11 JONumber —86 A static diccrepancy doas exict bet-
— ween the output of lath cutting
circuit channels (hardware channel
and positioning computer )LLU V"z
and V3 KK are lit up permanently
Normally open ano normally closed
11.21Number —87— of a cut button are simul-
tenem isly rlwsnrJ
The safety bolt, without being
11.22 Number —88- activa- ted. has leh the locking
position or is not returning to the
locking position within 2 sec. after
cutting cycle com- pletion. Knife is
not in the uppermost position. PS24.
The normally open contact of one of
1113 Number —89- the cut buttons is in closed position
when the control voltage is turned
The normally closed contact of one
11J4Number -90— of the cut buttons is not in the
closed position
After safety bolt is activated, the un-
l1J5Number —92— locked position is not
acknowledged within y seconds
Remedy:
Check voltage + 42 V on plug CU 9.2
(safety bolt)
Check basic conditions of LED‘s V14
- V18 HK \see chapter J. IO). If one
of these LED‘s is lit up:
Exchange card HK
Cbeck basic condition of LED's V1 —
V3, V19 and V23 IAR (see chapter
3.8). If the basic condition is not in
agreement as per chapter 3.8:
Exchange card IAR
Check connection AR — IAR Iflat wi-
re harneu)
Exchange card AR
Exchange card KK
Check bunons S28a and S28b and
connections according to wiring dia-
gram
Exchange card IAR
Cbeck connection AR — IAR (flat wi-
re harness)
Exchange card AR
Check safety bolt for mechanical stiff-
ness in its movement
Check monitor switch S.SB and con-
nection according to wiring diagram
chapter 11.15)
Exchange card ion. cher ri
Check cut buoons and connections
according to wiring diagram
(see chapter 9.1I
Check cut buttons and connections
according to wiring diagram
\see chapter 9.1)
Check safety bolt for mechanical
stiff- ness in its moverñent
Check monitor switch S.SB and con-
nections according to wiring diagram
(see chapter 11.15)
 23

12. Summary af Adjustment 12.1 Clutch sir gap Hydraulic clutch fB2/115/T37/165f
0,4 - 0,8 mm
Mechanical Ei•ktro.-mognciic olusch (76)
0J “d,4 mm
Inside ait gap between drive
whaef And br8ke disc during
engaged positi• on 0,2 - 0,4 mm
12a Motor btwke (tsble drived Machine models 7b/B2/t15/197/155
should have inside air Izrake dkk.and
magnetic coil carrier during engaged
position. In the disengaged position
the air gap between brake dice and
clutch lining is O,2 mm
Brake on model 92/115/1S7/OSS EMC
= \ b Nm. EM = 1b Nm. SD = 6 hjm,
brakeimputeo• model 78 End = 8 Nm.
SD = 4 him
UJ Gear pity on geer unit The most max. admissible tooth pJay
”Sta assure”totai cutting) 1or model 76 - 65 mm, 92” = 70 mm”,
115 = 100 mm, J37 - 120 mm, 155
= 14D mm measured on the outside
dimmest o't W drive wheel.
32.4 &ackgañg« aftuzruri Generally from 0,3 - O,6 mm

Correct v-butt tension is present if

the tmitcan lxpw ddo- App ox.
\O mm. using modest finger pressure.

13.1 Hotion speed of clamp B2 = ”1J - I.3 sec.

1 i5 = 1.7 xc.
135 = 1.7 see

92 - 65 ua
1 \.5 • 70 bar
137 = ?5 bar
Iss - w ur
13a Cksmp pr ure am axbariometer'gauge• 7G = min. 1B bar - méx. 125 bar
B2 = min. 3D-34 bar - maX. 1 IO
LBr 115 = min. 30-34 bar - max.
1.00 b0r
137 = min. 30-34 bar - max. 105 bar
158 = min, 30-34 bar - max. t2O bar
76 - 150 - 22D0 daN
82 - 150 - 3000 deN
1tg• = 300 - 4ooO daN
137 = 2IXl - 40D0 deN
155 = 2IXl - 56BD daN

13.4 6afecy pressure On manometer gauge: On clamp'

92= 17 bar 30 daN
115=. T7 bar 30 daI\I
aZ7 = 16 bar SO del
155.= 2O W 3O dsN
13a gwitch over pressure Y6 - 5 bai

T 15 = 35 ba”r
137 = 35 bsr
155 - 35 bar
 13.6 TemperaNre All pressures should be set and
correc- ted with the operating
temperature L<tw«ei i 40 - DO” C.
13.7 Oil capacity within the pillar frame 55/58 9 liter
tank 76 10 liter
92 = 21 liter
115, 137, 155 = 2g liter
with lift = 35
liter 137 and 155
w. retr. side gauge = 5 liter
w. lift and retr.
side gauge = 38 liter

Set min. pressure approx. 2 bar

t3.8 Adjustment of clamp pressure
lower on the hydr. control block. After
thi9 adjust the minimum pressure
accor- ding to the pre-tension of the
return
SgfiFf9

14. Capacity (pile height) Capacity according to pile height Knife bevel 2@ gray card board 2 mm
thickness
with models 76 = 110 mm
92 - 110 mm
115 = 165 mm
137 = 165 mm
J55 = 165 mm

14.1 Guiding gibs Max play 0.05 mm

14.2 Knife nrriet Max. play 0.05 mm, to be checked

between knife cérrier and frame and
between knite carrier and front plate.

14.3 Space between kntfe amrl rIamp lip 115/1'27/155 = 0.3 — D.35 mm 1 0.05
76/92 = 0.25 — 0.3 mm 0.05
to be checked under full clamp pres-

14.4 Foot pedal for clamp movement Model 92/115/137/155

Upper top position 0.0 - 0.1 mm
between ad•
justing cem
and plunger
Lower bottom position plunger
pushed indmm
 e+g!nkq wia wrks ›/az mo4ei ›e me«h.-no. ua1a1 ail +af»ty bolo iee
been fumbled with 2 approach switches The full trasaI wey of tbe eppromh
switsh is roocbsd, it the z vitoh cylinder is oovering half of the zeepeotime ewboh.

7he distant swñch cylinder - zwltch should be adjusted to 0.8 mm.

Tie zazu arrangement is fumidwd to zrzodcl 116 EââC II tie inning wia mach.-
no 5232530
Approach switdas replacing switcMs AT t1d 1-i AT

137/155

76

I'ñoñe in mm
Measurements in
millimeters

16. Adjusonent Spañfications Adjuamem of referent meuurement

Before the reference point is adjusted it k eo«ntiaI a›et ttn over-under cut as
wall as the oaralbl cut foe men ancuretslY eztabliztnd. The adjustment of the
reference point will bring the display maarufsment of tha .is* dispby in
ooordñ nstion to the axsct rraanzrement between tnck of knife (wtting line)
and from port of the bookgougn rokes.
For th purpose of prezcenning tbe referent point a middle value of th
totsl backgauge traveldzstance is Being inserted to the oodier switches on tha
kit side of csd TAB.
On the model 155 EMC this mnasurerzent value is approx.77.5
cm. On thz model 115 EMC this measurement value is approx.
57.5 cm.

In case that thiz meaazrertent velue had been already inerted previously
and onlv a che«k or correction should take pt then the basic adjustment
is not needed ezymorc.
The final and exest adjustment should be dons as follows:
A xnall pile of min. 3 cm haight Is to be cut on one side. The backgauge b
now to be moved forward to an emn memurement, e.g. 10 cm. Th second
side is tten wt tin pile wat sm›zd If and carefully allipad alamat the
back- auo. The pik is now meaaxed with a pa&a cslliper for size. Tie
reauh tar in«zanco, let cay is 8.358 cm, which meens th etrip is smaller then
the ra-
ay.Now the difference between these two values bave
'» bli '°' ‘•'
 67 6
5
1
3 2
dm cm mm / l0mm /100 m m

1.615*m
Sinoe this measurement vaiu”e of 1.616 Cjyj represents a smal ler strip
ogainit”the exirtir›g display •eadiñ g the correction has to be made by
sobstraction of this amount Jrom the se”tting of the alipn switches (in cess the
cutted strip was larger
1han the display read out. this difterenct then has to be addad o the align
switches setti sJ.
77.50a (value cutting)
— 1.616
75.885 inew value to be set at tke codier suzitches {see ppm rn)
The align switches have to ba corremed in suCh a way that the new value reeds
75685.

After the co£f9Chon has been made bring backgaug6 beyond the midway travel
distance in order to read out the naw reference ooim and establish the *i•
veneo of the correction adjustrñ ent..
in additions I chalking of the measurement by cutting 5 eqMal strips”as sugges-
ted in the @i vice IiarxJkuck 2 s!›uuJd be followed.
During the adjustment end correction of the reference measurement point it is
advisible to us0 only the standard fBBtLlDB to operate the backqauge.

Cheating mecfsell BI p”}By of tBble spindle

Press in handwheel until clutch cngagcrTiñ m takfie p/aco. Turn left at igl t aixl
absene digital display indication of 0.0t mm.

17. Table limit switches Checking table and farts elarzzp plato limit itekns"(Bafaty désnonneozion)
(Basic measurement hss to t›e set accurately)
Limft switch aud oead stop acfjustrnent on table:
I n order to correct[y position the limit switches on the table as we/J u
Irving the o”rooer measurement for the dead end stop bolrs nn zh+ backgauge
sindgs for the various models the following chart con be used for this puro‹sse.
The re- SPeGtive measuCement in metric Bnd iD'Ch. coukJ be re8d Off from po$ition
display'.

* lix iit tWitch rE¥sr

• I imi7 sWizch for faige. clamp p I”ata.

57.E7I. 1#T,S'
18. Electrical adjustment
instruction for tilting After the backgauge has been mounted to the table, the electrical adjustment
f›eckgauge of tilting device aan be started. Between backgauge and table an angle of
9CP should exist and to be verified using a precise square. In cace the angle is
over, W then the backgauge can be moved with switch S5, which is located
on the
BTF part and motor M358 to bring the back9augeto a position toward the
table. If the angle is uncter , then the switch S3 ana motor M3hd rs to be
used to establish 9@ position between backgauge and table. After the 9@
pasi-
tion is mechanica!!v assured.the electrically adjustment procericire can be smarten

Connect a digital test meter (e. g. model Normatest D 1210) with a range of
20 V— between ckeu-kpoint M3 I*) ar<I MW (-) oi i the DNS-ui›it. U>< tl ie putcii-
tiometer RN, located on the backgauge (unlock same for adjustment
purpose) until the test meter shows a reading of 2.15 V. After this volo9e
reading is esta- blished, secure the potentiomeler again and make sure during
the lock ing that a value of 2.90 V 0.02 is retained. Remove test lead trom
check point M5 (—) and connect came to check point MW. The voltage range on
the digital mctcr should be set to 2 V—. By means of turning potentiometer
R44 the equalization between these 2 points should be found. In other words
the potentiometer should be turned as long as necessary to get a readift9 * **-
***^* I* 0.OI7i) on the
digital test meter. The switching cam for limit switch S351 is now to be turned
i i mil thp switoh is tr iggr•rprI. The rJisp(ay in the BTF unit having .shown before a
value of 0.0 will go out and the light diode V4 will come on. Before the full
range of the tilting of the backgauge both ways is adjusted and set an indicator
should be attached to the oenter rake of the backgauge and being adjusted o a
medium value of approx. 3.0 mm.

In case of turn and tilting backgauge equipment it is essential to select the til-
ting mode, i. e. the switch SI should be engaged in order to have the upper par
tion of the display P1 lit up.

The motor M358 is now to be enqa9*d via the switch 53 until the
indicator instrument shows a reading of 0.5 mm * 0.02. The light diode V3
will come on after the limit switch 5351 for the zero position is not engaged
any more.

The display on the BTF unit is bein9 adjusted by the potentiometer R42,
which is located on the DNS-unit, to a value of 0.5. After this adjustment a
mechani- cal limitation of zhe backgau movement is necessary and analned by
turning the cam until limit switch S349 is engaged. Now the motor M358 can
not be started up any more with switch S3 After the adjustment for one
direction is finished the other direction adjustment for tilting can proceed.

The motor M3b8 is being controlled by switch S6 bringing the backgauge

away from the cam for limit switch S349 via the zero position into the opposite
direction. The light diodes will light up in the sequence V3, then V4 and at the
end VS. The Dackgauge is now moved into tilting motion with switch 5b and
motor M358 to a position where the indicator instrument on the backgauge
rake will show a reading of 1.7 mm * 0.02. Using the potentiometer R43 loca-
ted on DNS-unit this value off.7 mm is now transfered to the display on the
BTF unit.

After this adjustment the mechanical movement of the backgauge has to be

li- mited. This will be accomplished by turning the cam until the limit switch
S350 is engaged. Now the motor M358 can not be started up any more with
switch SS. It becomes necessary to bring the backgauge from one end limit
position
to the zero position, i. e. bctween backgauge and table was a OOO position, then
the switch S4 should be touched only once and the backgauge will
automatical- ly return to the zero position. The indication display for the
individual range position (VG or Vb) will go out and the light diode V4 to
come on.

Altar these art)tistmr•nts have I•u•en yrop•Pr Iy ppr4ormed. the ti ltinq backgauge
will now be operational.
19. Cutting and clamping It is essential to check first the condition of knife, knife carrier and clamp be-
76, 92, 115. 117, fnr/• soarrhing fmr thz• snoroe nf ri irting prohk•ms (see i Ill ‹stratinn)
155
cutting faults (mechanicallyl

76 92 115/137/J55

76G2 • 0,25 - 0,3 mm 1 0.05

19/37/199 - O,3 - O3fl 1 O.OO

19.1 Machine does nnt but thrz¥tegh pile i. e. the knifz• keezsmoc ctueh in the pile.

Neaning:
a) Knife is blunt
b) Knife has wrong bevel
c) V-delis tiave not enough tension
d) V-belts are wprn or frayed
e) V-be frs are oliy
I) Brake and clutch linir›g> url oily
g) Clutch and brake linings to far worn
Remedy:
a) Regr ind knife (see IP 5/76 and „Cutting in Practise”)
bl Use knife with correct bevel (see chart in „Cutting in Practice”l
c) Loosen mounting screws of main motor and reaoiust V belts with the tension
bolts. On model 76 no tension bolts are provided. On this model reposition main
motor for Drooer V- belt tension. The tension is correct if the V-belt can be de-
pressed approx. J0 - 15 mm, modest finger pressure. Make sure that the
pulleys are still in allignrrent after adjustment is made. Secure motor
mounting screws aga in and back up tension bolu slightly.
d) Before fitting new V-belts check allignment of pulleys Imost often not align-
ed pulleys are the cause for exoessive belt wear). Fit new V-belts and adjust for
proper tension (V-belts: see spare parts catalog group 10.01).
e) It is usually not easy to determine whether V•belts are too oily since the oil
is seeping into the belu. However, it is a good practice to replace the V-belts
if there is a reason to believe that they are oily. clean pulleys and search for oil
leakage. A possibility is that the gear unit looses oil and if this is the case the
clutch and hrake linings will aIsa be oily C‘wutinn during nil «hange. cover V•
belu. Another possibility is a leaking pump contributing to oily V-belts.
I) Clean clutch and Drake linings. Dy\ermine cause of oil »uDstanm. Pussiblv
oil leakage on gear unit (for repair see chapter 22.I).
g) The gap on machines with hydraulic clutch for model 92/115/137/155 should
be 0.4 — 0.8 mm and on mc<lels with electro-magnetic clutch (76) the air
gap
,Z* in 0.2 — 0.4 mm between drive wheel end brake disc in energized condition
of the clutch.
Clutch air gap shoy!d ie measured and if needed restored using alu foils
under clutch and brake shoes. It is important to keep the total thickness
(shoe and lining) according to the specifikation whenever foils sre added.
Domineering in
any event is t < required air gep. ollowing is a cAort of shoe and lining thick-
ness for clutch and brake rings in new condition:

Models 76 92 115 ' f37 155

Clvtch ring 13 mm 12 mm 14 mm 15 mm 18,5 mm

Brake ring 13 mm 12 mm 14 mm 15 mm 18.5 mm

In case of very excessive worn linings where the lining thickness is down tolmm
it will be necessary to repbce the complete rings (for parts see spare part cata-
log group 3o.IXP)
 29

»ctAs e2

POLAR 76
h) Tbs cutting nwmrial ie too hard r› gu••o nx«w›a›n«.e. hw eve wt b«‹>›t i• tw ww auh«id›t xz x
Is pozsibb with normsl writing paper. Or card txzard of 1 mm tfñckress can be
cut even wben the alloneble pik M ht is used, but the z¥ms cmd boazl with
a thianao of a -+mmcan not b«w‹in a hl$h pi«.

'¥ba u«t boctnm dsmz is eat only bus dos daft aide ar eat out dsru «I MI

a) Cutting stid‹ is cut on tno deep Reverse wtting ztick or exchange zsme (see operation manual)
b) Knife Is not adjusted paalbl
to cutting stick F non at besic podtion of the bft excentric handb for knifa carrier adjust-

Stmdlrig in tiodt of the machine and turning the asosntric handk clocXwisa will
more tfe knife cezier zortewhst up or down. Note the pozftion of th
f›andk whon the knifs eezrisr is in the uppermost position. Nrzw turn tha
handla box. 9@ the sazue way cIod‹wise. Lock the exmntric bolt raw in this
zero•positlorc
Remove oa ia ea Inch down ttw knife to the luwsr nxat deed point.
Ot›servs the zero-indicator (1). ft the knife is not paralkl to the table
zurfscs, unlock lock nut (5) of tfe ri9ht eszamric boh (7) on the rear of
the frame. Turn the kmdle (6) until the knife k paraibl to tke tabh surfaa
fcutting stick). Sacure lock nut (5). Now sdjust the knife carrier w"rth the
adjwtirtg nut (2) in such a wey that tha knife will cuta single skeet of paper
rtght I cu over the full width of the tabk. The adjusting rxit (2) d›ouId then be
secured by the lock nuts (3).

On model 76 the prozedura is as follows:

To pressure retarding all the wsy dsa stop. Innh knife downwards
ta the Iowa’ dead point. Remove lid and obseme markar (8). If the knife b
not allel to the table surface then lo‹uan up'lock mit{B) of tie oxcsmric bolt
f7) on o›e raar dde of the frame and twzi handk (6) until Uis knife is adjusted
pro-
perly. Secure IoM nut again.
c) If the knife still does not out tlxu, especially on tt›s left skh, ewn K the
ad- justment wss mazb oorrectly ttan it has to be assuzrud that the gibs
have ex• msai o ploy (usually the left guiding gib). Inert down the knifs rkr
urrtil the knife is approx. 6 mm sway frooi the table. Ramove freme oowr md
check the Up between guiding gib and slot groove by meens of a feeler
gaul. If the pby
exoeedc 0.N mm new guiding gibs wiii be required. Replaosmont riding gibs
can be furnished in a erdzes of OJ - 0.3 and 0.4 mm. 3t›s rapbwment gui-
diro lbs should be a erziwd of about &1 mm dxzve tfn measured plav.
Dkmantiing of the knik carrier:
The out the knife end brirg knife carrier to tin upper position. Place wooden
blocks left and right of the supporting the knlfo «erriet end here tksm
projecting about 50 cm In front of the cutting line Mow knife cerrhr down by
hend umil resting on tte wooden bIocIcz• Dismnruet power Ikie to tha
cuzter. Remove frarm cowr ar«i also on the right side the oo›er for msin
switch md lies.Loozsn up cdzle brackets• Pull up csbk for law clamp plao
limit switch and loom eabta to tha proximityswiteh. Remove cover frcm
both light barrier houdngs urfpltg cabk snd put ttwu opening of frame.
Compktely dismarnb balding block of the pressure regulating device.
Sheat metal ozvar on front frame and main zwitch to be takan off from
brsek«s prerrovs from frame.Ob- serve location end amount of spec foils
(maka sketch), sins tfay hses N get baek to tha aazna lozstion later on.
Open the from pbts from rat to left, but leave tbe left portion of front
ptata mating on tha Arsne. Suppmt tM right side of front plata to
present it from felling orsr.
Azwnzlon I Pleaze nuke
sure that thn wims and
cable still on the ktt sale are
not pinched during the front
ptate mrs. Removo eral
wssher from oank shaft.
Iroert a pipe or wooden
bsazi of approx. 1 m knqth
fmo the top opening of the
knife carrier. An assiztar<s
should ztand on tfo zear tB
e of the mashire to cugport
the upright standing knife
carrier with the wooden bem
or

19.2Overcut
a) Knife, table or backgauge
b) Knife is blunt
c) Knife has burrs and i< nn1 nrogerly
seated in knife carrier
clear of the guiding gibs. At this lime the knife carrier can be laid down for-
ward onto the wooden blocks. Clean guiding gibs and slots for parallelness,
using the old guiding gib and feeler gauges. If necessary file and scrape the
slots to
make them absolutely parallel. After this the new 9uidino gib has to be fitted.
A feeler gauge of 0.03 mm should not pass thru between gib and slot in
order to have a proper gib fitting. Before assembling the guiding gibs apply a
liberal arnoui it of Lub• al BS 21 or Lithium Multi Purpose Grease NLG I cless 2 to
these parts. The assembly of all parts has to be done in the reverse
procedure to the above dimantling. Do not forget the spacer foils arm its proper
location. After assembling front plate check the play of the knife carrier. First
in the upper pop sition then with the knife carrier in the lower position. In both
instances measure with a feeler g• 9^ Of 0.05 mm between gui€:ling 9'b and slot
wall ac well as kni- fe carrier and frame guiding surface. The feeler gauge
should just barely enter
the gap.
II necessary add or remove spacer foils to obtatn the proper ease of movement.
As a final test make a full turn o1 Ifie knife carrier by hand.
(The kn ife moves forward as i t ib guiiig IIii u II iu pile >u fliat LI ie luwvi bf›eutx u f
the pile are longer in size. This is especially true with hard and thin type
cutting materiall
a) Whether knife or table and backgauge is causing the overcut can easily be deter-
mined. Take a new cunlnq stick and make a cutting cycle without any paper to
be cut. The cutting stick will be marked by the knife edge. Now load the machi-
ne with a eile of art paper approx. 1£@ mm in height and make a cut. If the
cutting stick now receives a second line being in front of the first marking then
the knife is the reason for the overcut.
bl K nite to be sharpened (see IP 5/76 and brochure „Cutting in Practice“)
c) Remove burrs by means of a file and clean knife seating area on the knife
carrier
32
Meaning:
d) Knife has counter bevel
caused ba faulry honing
e) Rear of knife is bowed
f) Wrong knife bevel
ol Clampir›o pressure too hish
h) The table is not sauare to the knife
carrier
Remedy:
d) Regr ind knife until counter bevel disappears (see aIsa IP 5/67 and brochure
„Cutting in Practice”).
e) Replace with new knife.
f) Use knife wiEh correct bevel (see brochure „Cutting in Practice“).
a) Readjust pressure on pressure requlatin9 valve.
h) Inch the knife carrier down to the lower dead end position. Use a square or
frame water level (side length of 100 mm or 4“) against the rear side of the
knife carrier and onto the table surface for proper adjustment of the table.
Tur• ning the table support stands will move table up or down. Maximum
discrepan- cy on squareness is U.US mm.
Cleaning:
Remedy:
i) The baukgoug< is not square to the table
i) Place a scjuare on the table in front of the backgauge. Loosen one of the
side locking bolts on the rear of the backgauge as well as the rear top bolt. Turn
the adjusting knob until the backgauge is square to the table. Secure the bolts.

Kugelbolzen z‘
Haltebolzen

verstet I gri rf

k) Knife carriers play k) Bring knife carrier into upper position and lower position when checking
for possible pley. A teeler gauge of 0.OS mm should be used for the mcasurc
ment between knife carrier and frame guiding surface as well as front plate gui-
ding surface. The feeler gauge should just hardly go into these spaces. To
restore a correct spacing remove or add spacer foils as needed.

Undercut

a) Knife is blunt a) Reqrind knife (see IP 5/67 and brochure „Cutting in Practice”)
b) Kniffe has burrs and is not properly b) File down the burrs and clean surface where the knife is to be mounted against.
seated in knife corr icr
c) Wrong knife bevel c) Use knife with a correct bevel (see brochure „Cutting in Practice“)

I\Cleaning: Remedy:

a) Use knife with a wider bevei {see” brochure „Cutting in

b) Clamp pressure .”too low Practice") D} Readjust clamp pressure on regulating vaNe.
c”) Incorrect k'nife seating

1g.3 Bow or hollow cut

a)
The cutting malaria) is uneven”in a) Use of the flex. false. clamp plate required. This plate wifi.equalize diNeren.
height ces uo to 4 mm. If the diNe”re”nces. in height are very close to9eth9r it will be
ad• visable zo use stzips of felt unde”r neath the false clamp platé or to glue
felt”di• rectly underneath the clamp at the respective area.

b) The wavy paper i5. being pushed backwards st the time of clamping and
b› The cutting mstsrial”is wavy will eturn after tha cut. The resuIt will be a hollow cut. To prwer t this problem ••
feducz it to a rti\nimum only one salution is possible. Reduce the clamping
presume as far down es pozzibIe-and cart trimming the pile from the center.

19.4 Wanting cut

 Remedy:

e) Table is not squcre to the knife carrier a) On all modelc a readjustment for squareness of table to cutting line is provi•
ded with the 2 adjusting bolts on the frame.

bl Backgeugenotpa‹altel4o b) Readjust backgauge parallel to knffe.

knife

c) Cfwck on sidP of Ignr•.kgai›gn whether the backgauge has excessive Islay for-
c) Sledge 9uiding hac play ward or reverse. Adjust side ledge (1) by means of screws t2) to take out
play. Ako check oonact area of adjusting screws (2i for proeer seating. The
sledge uniz has to be adjusted for easy muvcingnt but wither play.
a) Clamp pressure too low a) Increase clamping pressure.
bl Unsuitable knife bevel b) Use knife with correct knife bevel \see brochure .,Cutting in Practice"l

Meaning: Remedy:
19.G Warped cutting surface

a) Difterences in pile ñeight al Flexible false clamp plate

causing unequal clamping

b) Knife has burrs or is seated improperly b) File away burrs and clean area where knife is to be
seated. in knife carrier

19.7 Notched cutting surface

al K i i ife buve I tu flciidei a) Replace willi k‹›ilu l›uvitig wider Liuvul (see brochure „Cutting in Pracll “).

b) Knife steel to hard (wben cutting hard bT Use normal type knife
material the knife made of hard steel
has the tendency to break out)

c) Foreign matter in cutting material c) Exchange knife and check cutting material.

19.8 Rouoh and fused together cutting surfaoe or cut thru of last sheets with a

banl al Knife blunt a) Exchange knife and cutting stick

19.9 Cut surface is shiny and derk on some spots

*) Knite blunt a) Exchange knife and cutting stick

b) Knife is ground crowned b) Replace with new knife.

c) Knife has burrs and is cl File away burrs on knife and clean knife area on the knife carrier.
improperly seated in knife
carrier
d) Regrind Level of knife until counter bevel has been removed (see also IP 5/67
d) Knife has counter bevel as a result and brochure „Cutting in Practice“) .
from wreng hPning

19.10 The knife is pulling sheets out from under the clamp

a) The cutting material is sort arm spongy a) Because of the high air volume of the soft material the clamping pressure has
to be set at the higher range, in order to get the air out of the pile and to pre-
vent the knife from pulling. To prevent the fingers of the clamp from leaving
impressions on the material it is advisable to use the false clamp plate.

c) Sr›aoe between knife carridr
37
However, zine 1alse clamp piazs reduces the surface pressure and i1”can hagpen
that tbe knife pulls very é›ftcutting material from under the clamp depitc of a
high c)arnqing pressure: If problems like this should oecur p/ue a 4.— 5 mm th
ch cardbaard rtrip under the”front third of the fate clamp plate slanting the
strip toward the rea”r thzcall the pres ure is actually at the vary area where
the cut tdksa pfaos. Thé' cardboard” shouJd protrude a little from the else
clamp place and will be cut”off a”ta very first cutting Tele.
For nwterial with a soft and soongy character the optional eouioement ..Clam-
ping without Cut” is of tremendotu help to press the eir out of tke pile.
L)M tWuhyd uicsy*mm(Cx apurf1.2)
c) Check space beMeen knife carrier and clamp durinl full clampiñe
pressure having a pile of paper under the cl8mp. Remo•e V-belts from drive
pujlgy and run ”machine with hydr. pump belt only. Bring knife carrie down
to height of olamp by means of the 2 clutch T-hanâfaz. I lave the assistant press. ttrc
cut£irrg buttons for the check procedure.
»eaao:ubi‹ eau. 7sac = ozis -o.smm Ao.as
115/1Z7/155 = D.3 — B.35 mm 0.05 Isee picture point JB)
20 Knife and clamp

20.1 Knife carrier is running against guiding gibs at the top

Meaning: Remedy:

a) The connecting rod has been a) It the connecting rod hsd been screwed out too far the possibility exists that
wrongly adjusted the knife barrier is running against the left 9uiding gib when coming to the top
position. The following damages can occur°
Bending of connecting rod, bending of crank shaft, burring of the left side gui-
ding gib or bending of the excentr ie bolt.
An exact investigation is absolutely necessarv t prevent further damage to vital
psrts. Check and measure alignment between crank arm (5) and gear lid at
posi- finn ..A“ (snz• pirhirn) in upjaer mnsf position of knife as well as knife
in lowest position.
If fthere is a difference of more than 0.1 mm the crank shaft is bent and the
gear has to be excnanged. The exchange of zne crank shaft (4) can be done by
quail- fied personnel of any POLAR agancy if a hydraulic press is available. In
all other cases the crank shaft has to be exchanged at our factors.
If a crank shaft is bend it also will be necessary to exchange the guiding gibs
since these parts most likely have becouw damaged and this may lead to a
seizing uf the giLzs. I f the sJ1eai pins are break ing for new apparent reason then it
can be auumed that a bent crank shaft ist the cause. Removal of guidiFtg 9'bs
and knife carrier see under point 19.1. The connecting rod can be removed
without dismant- ling of the front plate. The connecting rod bolts have inside
thread and can be removed after the safety plates are taken off.

x 3
2

16 15

5
6

p) Ctamp guiding air
or not iubricstsa prowriy
b) Oamg guiding not sdJusted •o IY
c) Footpedal looze
d) Return spring he too mud› tension
Remedy:
During repair work it é neoscsary to bring the turnbuckk onto the lower
con• namingth part (axosption on 92) as wr specification
POALR 92 - 2 turns to ujgzer part
POLAR 115 - 4 turns to lower port
POLAR 137 - 4 turns to lower
pert POLAR 155 - 1.6tums to
lower part
After the adjusumm it will be rsceaary to bring tfe knife carriw up to the
upper dead point in order to check the free movement of the right excentrio
a) Clan guiding and grease (see operating manual)
b) Before adiusting the guides bring ckmp to the tebb end ct›sck for perellel-
ness For readjustment turn the eXztentric bolts in the clamp and secure same
after the adjustment is completed. If the guiding of the cb is still to stiff add
foils (2) to the guiding plots until theolemp moves freely without plsy. There-
after adjust the side ledge (3) with the adjusting screw t4). Pay attention to
drapzarks on the guiding ledge \3I after ti9htsn!n9 the sc•e s (5).
i› foil, i,a,s a w saa+a pey art«mion to t»s air gap between xn‹u ono cia p.
c) Redghten footpedal.
d) A return spring ñaving •xcezsi e tension is usually tha rsszon to Mlicve that
the cb skiing ie not adjuoed properly arxl holding back the descending
clamp and most often the condition is worstened by giving more tension to
the return spring in hope this will tet tfe clarr›p go down faster. !n caze
there is a somewhat slaw going etanqs movemcm check first the clamg
guiding bv relea- s"ing sha tenfino of th return spring and fras u# any stiffness
on the guiding k• self. After the elazzp riding bmecfankally in proper
condition and hydrauli• cgtly tbe zafcty pressure has been clocked out ur›
POLAR 92 - 17 bsr
 POLAR 137 = 17 bar
POLAR 1S5 = *0 bar

then the return spring tension has to be set in such a way that the clamp will
press down with b0 daN when the foot pedal is engaged.

Meaning: Remedy:

el Cam on foot pedal device is out of position e) With the foot pedal in its normal position. i. e. in the ups:er position. an air
gap of 0.0 — 0.1 mm should exist between plunger of the conool block and
the adjusting cam. If this is not the case, then the adjusting cam has to be
repositio- ncd. Pushing the foot pedal to iu lowest position should move the
plunger 12 mm into the control block (exception 76). If this plunger travel
distance is not reached, the readjustment of the foot pedal movement is
necessary. Adjustment is macfe with the endstop screw on the right pillar.
The foot pedal, in its upper most position, should not touch the metal conool
box.

I) Safety pressure set too low II Hemove clutch guard, covers and lid. lately pressure should be checked on
check point (J ) with the foot pedal pressed down completely. The oorrect safe
ty pressure on
POLAR 92 = 17 bar
POLAR 1 15 = J 7 bar
POLAR 137 — 1 7 ba‹
POLAR 155 = 20 bar
If necessary readjust safety pressure on the safety valve la). Take off cap nut,
loosen up lock nut (8) and adjust the pressure, using an allen wrench SW 6
(clock - ise turn will increase the pressure). After adjustment secure lock nut
and cap nut again. Observe proper seating of copper washers. Bleed
hydraulic system
(see chapter 2t .2)
1

8
20.9 Clamp is moving down too 3Iow during cutting cynic

a) Pipes or connections are leaking. Air in a) Check all pipes and retighten connections. Bleed hydraulic svstem. Distribu-
the hydraulic system. Distribution device tion device to be cleaned and readjust.
dip or out of adjustment
b) Pump delivery is insufficient despite b) Remove clutch guard, lid and cover plates as well as V-belts, take out hy-
pressure to be okay draulic oil and remove pump to be exchanged. Bleed hydraulic system (see
 c) Ctsmpirq juamxe build up ie retarzted. c) fs•a eheptec 19.10)
Switzfl›-ouer pbtan is delayed. Exohmp cylinder

a) ftettxn zpring does not bans
a) Remow lid (3) (exznpt 78) on the bft side of the frame talow the end of
the franw oowr. Adjust the tendon uzew (2) In such a wsy that the foot
psdsl actuetnd clamp is pressing down with 50 daN (safety regulation). It is
ezzerrtfsl thst the sefaty pressure is correct and dv clamp guiding W baen
sdjucted for easy moyeuent but without pky.

b) Slide veke moves with hesitation b) Loosen up dide Yalve shale

c\ Vatvs SZ/2 jammd or not energized c) Exchange valve S2/2 or cheek supply unltsge approx. 42 V D.C.

d) V lw M3 has not dropped off d) Supply volt should have been disoonrncted toe chapter 9.3.1)

b) Sliding valve in control block for
clempingcycls Is moving with hesitation
hydraulic systam Isee cbsptar 21J).
al Rerr›ove ohee'bnataI oovers and cheek m6tlng of the adjusting cam. If found
\oazs, ratightsn ume.Worm in adjusting cen bas to be excM d. Adjusting
zmzi has to be fitted as follows:
With tlw foot padel in its normal position, i.e. in the upper position, an air
gap of 0.0 - 0.1 mm should exist between plunger of the control bloci‹ and
the W juzting cam, K this ie not the caso,than the adjusting cam has to be
repocitionad. Bzin§ing the foot pedal to the lowast position shouM move the
plunger 12 mm into the conool block. If this travel dioanm is not reached,
tbe readjustment of me foot pedairtwvemem k nacescary. Tec end szop
screw on tne right pihar wi›l ‹ro«ia«tI›is«uju tmmt lcxcsptlon 76).
b) Remove sheetmetal cover and ao›ess opening lid. Gxcf›e control block.
Bleed

ZO.6 CIazzgz dnas not descend

a) Limit su/iteh k zaa or out of a) Reprettion lim"it sutiteh.' 3@i and adjwt.
42
21. Hydraulic
21.1 Hydraulic unrt ic loosing oil
Meaning:
a) Seal in the pump is leak ing
b) Seal between flange and pillar or
c) Copper washer under screws for pump
or nn hip flange arfi•. leak ing
Work on hydraulic skould only be performed by qualified personnel. It is
essen- tial to maimain the upmost cleanliness during work performance and
that no dirt is allowed to emer the hydraulic system.
Remedy:
a) Diasmantle pump and return to factory unopened. To do this job it will be
necessary to remove clutch ouard. V-belts and access hole cover. The oil can
be saved if it is pumped into an absolutely clean container. Remove pump
pulley with a gear puller. The filter has to be unscrewed. Looson connection P1
and P2 ui i the puiJip. Remove all screws ho lding the pump against the flange.
The pump can now be removed imide the pillar. One other possibility for
removal of the
pump is to dismantle the complete flan9e with the pump still attached to it. In
this instance take out all screws by which the flange is attached to the frame
A«scmblC new pump to flan9•. insert same into pillar and tighten up all screws.
Do not forget to put new gaskets between pump and 1lange and also
between f(ange and pillar. Also use new copper washer underneath all screws.
Connect again the pipes to PI and P2 as well as the filter to the pump. Fit
pulley to pump shaft and V-belts to pulley. Fill in oil again and bleed hydraulic
system. Mount accecs cover end clutch guard. Imrnediately after machine ic
turned on, apply load to hydr. pump to assure the immediate lubrication to all
pass of the pump. To accomplish this, move foot pedal for clamp a few
times or make a few knife cycles with clamp pressure set at half. Bleed
hydraulic system.
b) Remove clutch guard. V-belts and access hole couer. Pump oi I into clean con-
tainer. Pull of pulley. Unscrew the screws holding pump to flange as well as the
screws holding the flange against the pillar. Replace the gaskets and assemble all
parts in a reverse sequence. Hydraulic system should be bled thoroughly.
c) Remove pulley and retighten flange screws if the result is negative, pump hy
draw lie oil in†o clean container and replace all copper washers A 8 x 14 x 1DIN
7603 (200928). Fill in oil again and bleed hydraulic system (see chapter 21.2).
Meaning: Remedy:
d) 0-ring in end pletc of pi+ton d) Retighten holdin9 •••e\Al ( 10) on end plate (2). If this does not solve the pro -
housing blem, then replace the 0-ring (11). Dimension for:
is leaking
POLAFI U2' : H •40-2 {2O5Ob4)
POLAR 1t5,137,155 . R 55-2 (205057)
Check chamfered edge of cylinder housing (3) for burrs etc. Refinish if
necessa- ry. Fit the endplate again and secvre with equal torque to the screws.
Check tlghlness of screws again aflei tLtc nidulJirJe liar Uest i upur dtud Jul o 6liui \
tiltjc.

e) The noise produced bY the pump is a high pitched whine. If the preuure is
increased and the pump noise becomes higher and more intense during the cut-
ting cycle, then the pump has to be exchanged.

21.2 Air in hydraulic system Remove cover plates and lid. The bleeding is to be done with the machine run-
ning.

1. Bleedin9 on manometer check point P1 — clamp pressure

First, 3 cutting cycles should be made with full pressure setting. Now release
cap nut orJ rrtanunzc for vl ock pvint P1 and press back the inside ball. OiI should
flow out until it is not foamy any more. Retighten immediately cap nut. The
normal oil pressure produced by the machine running idle is suNicient for this
purpose.

2. Bleeding of work in9milder

Inorder to bleed the Ivor k ing cylinder the piston t6) has to be turned in such a
way that the bleeding screw (7) is positioned to the front, Loosen the bleeding
screw somewhat, not too much, as otr›erwise oil could get into the control pa-
nel and wires. Operate foot pedal. Attention: Piston will move out.
Let oil flow oi‹t of the hleerling .screw with the piston in the out position. until
it is free of air bubbles. Use drip pan to catch the oil, have the piston bar
move back to the normal position. and retighten bleeding screw.

3. Bleeding of clutch cylinder (only model 92. 1 15, 137, 155)

The bleedino screw (5) on the clutch cylinder (3) has to be loosened during the
downstroke of the knife and retightened as soon as the knife upstroke begins.
This sequence has to be repeated as long as needed to get all air out of the sy-
stem (air 6ublce free) .

4. Bleeding on manometer check point P2 clutch pressure (only model gz,

115, J37, 1551
The bleeding on this particular point is only necessary after removing of the
manometer gauge or in oil rhange had been done. Loosen cap nut during cut-
ting cycle and press ball inside away from seating, so that oil can flow out until
it is free of air bubbles. After the bleeding is completed, check with a trouble
light tne hydraulic oil inside the tank, wlietl tel it is hauling oi r›ot. Foaming oil
is an indication of leaking pipe lines and joints. Eventually search for these lea-
king oarts and retiohten connections as needed. Please remember that even the
smallest air pocket in the hydraulic system could lead to operational problems
and trouble.

E ntlJtunq
.uoolungszylinder

E ntliiftung
Arbeitszylindet
 Manometeranschlug Manometeranschluo
Pre&d ruck K ugplungsdruck

Meaning: Remedy:
21.5 No inchiryy etlwcle of knife

a) Valve open or out of adjustment a) Inching valve has to be adjusted as follows:

Connect manometer gau9e to check point P2. Bring clamp down to table
using foot pedal and pull out hand wheel. After loosening the clamping
devise, shift same to a position where On inching pressure of 36 - 40 bar is rcachniâ.
cure clamping devise again.
b) I Iutch pressure too low
bl connect manometer gauge to check point P2. The clutch pressure can
only be checked during an actual cutting cycle. Temperature of the hydr. oil
should be 40 — 5£P C for best result. The clutch pressure specifications am nn
mrx4r•l

POLAR 92 = 6S bar
POLAR 115 70 Uai
POLAR 137 = 75 bar
POLAR 155 = 90 bar

In case the clutch pressure is not as specified above. a readjustment of the clutch
valve (9) on the hydr. block is necessary. Proceed as follows:

Loosen up lock nut (9). Use an allen Wrench SW 6 to adiust the clutch
pressure
as specified. Secure lock nut again.
 45

Z2. and clutch

â&aniny
al Oil level is rising
a) if the oil lwsl in the ar Is constantly rising, the pools rinB (4) in the
piston housing (31 is mact likety demagad or has been fitted tha wroro wav.
The hvdr. oil can Sep into the gear unit. Everrtually it can rise to tbe point
where th oil wi‹ it„„ out of to ve‹ni aria. Take out tin gw oil finn and
than proceed
with th groove ring exchange as follows:
3 smove pipe connection (1) end uke off end plate (2). Obzsrva that the
end plate is undar a wrtain presszxs. Cetch any oil wmirtg out this time.
Locuen screws (6) on the piston houdng end pull off same ‹3f from paton
IB). it ‹s im- portant a hold to piston l9) in tl•• p‹e•ent o‹aitlon to prevem
tf›e presazrs bok displacing itceff from th fitting kay. Ehazdc pigton houdng f3)
for any da• mage and alzo piston for cracks at the csnm area .,Z". Replaog
groove King {4).
Dimensions of groovering for modal:
O L A R g 2 - ( * * )
P
e L a R i › s, i37, iss = *i m-s I z oum r
Psy attention to the correct groow ring podtion. The lip of the groove ring
has to face toward the oil inout line (Dec pictu‹a).

6 4 -9 3 7l !0

Tt›e ammbly f›as to be done k› the reverza sequence. Malce xire thst tha blee-
ding axew (6) on the piston housing roiiwiew on th top. Check th 0-rings
(t2) for any damege snd if ne‹aczsry replace same. Fill in gear oil to proper
level.
Chez I hydrau lic oil level. rsolenizh if need to be and blaad hydrsulk system
‹•••a•»er z ›.z›.
For checking the groove ring on modsl 92 It will be neceaary to remove tie
oompkts gear unit.

b) Oil is coming out on the b) Support knife carrier. Bring brake disk tightly to the drive Wh66l by
brake m8MtS of tin two clutsh handles, and cMck whether O•ring (18) on tin
worm shsft or tfe Simmering (20) rswecziwly the gaskets (Z2) on tha cemer
gesr lid Is dana- gad.
If the oil is earning
out on the 9lot of the
zm shaft. then the
O•ring f•1g) in tie
worm glwh (1) is
demsged and has to
be repkced (only on
‹z›odeIs 92, 116,
t37, 1bb).
Dimensions of the
O-ring on model:
 POLAR 92 - R 18-3 (205043)
POLAR 115 = R 22-3 t205046l
POLAR 137, 155 = R 25-3 (205047)
For replacement of this 0-ring remove the piston housing and in addition romo-
ve also piston (7) and pressure bolt (8). The 0-ring is now acoessible. On
model 92 it will be necessary to take off the complete gear.

A6

If tha oil is coming out On thn rs•n1r•r bearing cover (28a it is most likelY to have
a damaged Simmering 120) or the gasket 122) ›s defektive. Repbcement is neces-
s v. ‹» » to start this repair job h will be to take off drive
neoessaw wheel
and disrr›entlirrg
is done •s follows.
Model 92, I t5, 137.155
Teke out gear oil. Remova front bearing coyer
t81). Unscrew slot type nut (24l
wilh $afezy ptote. Take uu\ sll a1lenlwad scrvwa of the reBr
on the drive wheel. Dismantling tools for model:
POLAR g3 8 9
POLAR 115 4 8 1B 26 ' 37
POLAR 1:27 4 B B JO 2D
P 10 27
20 J7
POLAR t55 4 8 9 00 20 27

prepare FgBpgCt iU'0}'y' tDOl$ 8 §Mll dFI3f6 WhB€'l •

Mnolzina Mnriel 92
 47

Remedy:

/› d•u^aniIir•g or cssnmblir j of the drive wh•e.I an mojql j 1 , j $y, j §g g j

b• netassarv to use the spe al lih kit SKV 6B3. wing device is mctJrrtao
*° °^ "s* •^• •* '^ •°•'••. u›*ne ‹*• s''•4riile4 how la •»° hvd›. i fu. i
tho mach‹m is eQw J wart tFo hydr. lift, the the lifting device SK'v• N3
can Is mounted to the hydr, lift flange. In •.h”ic cee 2 cyJindr¿ so'rws ME x
DCs DIN 912 should be ml On machines wrtAut. the aydr lift unit.
stta& •l e Id ti @ device Jo th frarrs by using this time 2 cyiin«r c
screws M 16 x 3g 0lM Bi 2
T:sot• nee•1ed far: POLAR 72 6 8 ^ 17
POLAR 1 S 5 8 E 19 27
POLAI3 137 4 8 ? 21 28
POLAR 156 4 g /J /g

e the req>ec•.ive s>ols her bearing removd.

Tool» needed fer b•oks disk rsznoval "or model.

POLAR I l6 7 8 9 27
POLAR 137 7 8 8
POLAR 1b6 7 8 9
Reazedy:

25
20

Release tension of snaP ring (25) and uk• seme off. Dismantle spring counter
«nshcr, Springs, breke didt 110! and kay f9). ExcMnga Simmering (20) in cen-
ter terrine ‹x›vw f2s) ‹•sp. e-lwt (22).
Dimeaion of tha Stmnay\n s Dimendon of the O•rirgs
POLAR @8APg t6x Qx 101223830) R 76x 2 f2J 2781
P0LAR11bBA 4Sx62x12(2IWM8) R tNx3 f20b077)
POLAR 137 BA B0x 7Mx 10(Z24 ) OR 1‘I5x
2,5(23ZZ00I POLAR16bBA 60x86x13(207274) R 230x 4
(2fG083)
wie» i»nsiiipea fi«xrerim, paYm»uia tn ate coompo«tion ef i:e.
btzt the protection sleaus over eral of worm &W 35 model 116, 36 II 156
or on model S2 tins worm left has to be wrsppad with sootch or
ezBzsslvc tape to Prevent demage to the Simmeri 6lide owr oenlar
bearing afar (26) withsimzzaring(20)aIresdymoum«dtotsme.& i
shouldzze wbaPodzad afar uopiotemea slots, gzooaasoz ttaeads, as
ottzuwlm'¥se Ilp oftha ringaould
Alf otber pams nza now sz mbMd m fnitmust
BrAeandclutch must be broughttooorzact thickness and shimsaddsdasreeded:
POLAR 92 12 nirri + 0.0b
POLAR IIM 14 mm + 0.05
POLAR 137 16 mm +
0.05 POLAR 155 18a mm
+ 0.OB
Rezz›ow oaak morks er rust on the key (9) or en the krake disc, sz›oothen
out and polbh groove in tfa bake dix (10). Lulsisate worm d›eh and key
whh Lubral GLL9. RII greaa chazrzberz in brake disk with same and
lubricate
Us thsssnotoobto raeszcmbb be dice. snapping and zpring a›u«er
wssker as was ia¥ed far Jizmanding. Install zagr bearing oover f23) with
Simmering to the drive s aa\ (J2). Di«szeion of tfe Simmerinqs for
model:
POLAR 02 BA 3b x b2 x 7
(205tM2l POLAR 115 BA 45 x 6b x
10 (20btB6)
POLAR 137 BA bb x 75 x 10 (224830)
 POLAR J55 BA 60 x 85 x 13 (107274)
AttoCh {D£Ot€CtiOF¥ 3fCSvC (/ fT¥O€fCl 1 1 /, IT\Al ‘I ) IOgtlt,j U( Shaft fOF pyg-
mention of damege to Simmering. Use adhesive tape on model 92.
Push the drive wheel carefully onto the shaft end and secure same to the
brake disc (10) by slightly turning in the clutch handles. Remove
protection cover resp. adhesive tape and center the drive wheel now with
tookl8 26 or m‹xieI 92, 20 27 on model 11S, 137, g3 28 on model 166. Now
tighten the clutch handles to the full extend and remow the centering tools.

11D + 137 «oxa›o› ’

156 «oozzo

Fit snapring (on model 92) resp. support ring (on model 115, 137 and t55) to
the worm shah. Measure distanw „a“ and „b“ (see picture) with depth geuge.
Distance at „b“ should be larger by 0.4 mm than the distance at ,p”. If
necessary for adjustment add shims (see spare parts catalog 30.00).
Prepere tnols for bearing a mbfy for mr›deI:

POLAR 92 8 9 26 31
POLAR 1 15 8 9 13 27 32
POALR 137 8 9 42 43 4é 45
POLAR 155 8 9 15 28 33

Before bearings are fitted fill same with roller bearing grease.
 $1

On models ] 15, 137 and 1S5 steel shims (Xt 0,075 mm and fYt 0,05 mm have
to be put between the bearings.
If baacing6 are reptacad. then now etael chims hcve to bo uced a\so.

Reassemble support ring, safety plate and slotted nuts to worm shale
Drive wI›est i› still preyed againstthe brakedisc. Now measure with a depth
gauge the zhouoer of the front bearing oover I2J). This measuremenhtas to
be larper by 0.6 mm than tha maasurarnant between tho outer face of the
drive whael
and the outer ring Of the bearing. IN necessary this measurement has to be ad-
justed by adding shims.
After this has been completed, tit front bearing uaver. J•JIJ with gear oil and
if needed add hydraulic oil. Bleed hydraulic system Isee chepter 21C).

h0achine /¥Iodel 76
Remoye gear oil and tgke all carbon thrush holdur. Take OH front bsyr Ing cover
f21). Remova now visible slotted nut (24) with safety plate. Takg out support
washer and steel shims.
Remedy:

Get tools G, 0, 9, 30 ready for tJismandiflg of drivo wheel with beut ings. Since
the Simmering BA 35 x 52 x 7 (205052) always becomes damaged during the
above dismantling, it is necessary to replace the same. Please pay attention
to location and amount of support washers and spacer foils.

Remove brake dix as follows:

Prepare tool J and screw grooved nut (24) onto the worm shaft. Release tension
of snap ring (2S) and take off. Dismantle now cpring counter disc, gpring•, brake
disc (J0l and key from shaft.

Dismantle center hearing onver (76) aru4 rz•pIar•n shimmering BAFg 35 x 5S x 10

(205098) as weel as gasket (22). As mentioned f›etore at the instruction for
92, 1 JS, 137, f55 the Simmering has to be fitted very carefully.
Brake ring shuvs (13 * 0.05 mm thickness) and clulch ring shoes T13.2 + 0.05
mm thickness) should be brought to proper dimensions by adding foils accor-
dingly. Bring brake disc against the already mounted clutch segments of the
drive wheel and check air gap between brake disc and magllet coil body with a
feeler gauge. The air gap should be OF - 0.3 mm. If necessary adjust with
foils. Drive shaft (disc 0Coting orCa) and key should be lubricated with Lubral G
LLSt. They grease chambers in thee brake disc should also be filled with this type
grease.
 Grace owe, snap ring aria spr‹r›g retaining wastac snout be mounted wnn tns
sarru special tools as had been used for dismantling. Mount Simmwing into the
drive wheel. Get tool 11 and N ready. Center drive wlusl and acrew
tiyhtty agaksst take dix Ramoua oarrtaring tool t1. Mot›nt cnsp ring (28) and
support wacher (30) onto thesfoftaml preasnapring a9ainzt tu rear side of
tia groove, usire tt›e sleeve 34 for this purp‹ae. Mean›re»er‹t „c“ and ,p*

(see pictu‹a) ha to be establistwd with a depU› geugv. Meezu‹err rit on ,@"

free to be OF mm

Get toob 8, 9, 11, 30, 31, 38 ready and fit baerinqc Before mourning bearings
p'eeca same with rolbr bearing great.

Reessernbk support wacher, safaty catch and ntrts to worm shh.

Drive wheel is still prezzed ag0iret the braka disc Now rn6ssurs with a
depth gauge the shoulder of the front bearing oover t21). Wrfte dv this
maazure- m•na a”• This ant.x” h•• so b• 1J8 mm Ia•ger than tlwrno
cement
„f*’ WhiCh is th distance from wlWrg th front bearing cover is resting
against to the out rfrig of the beadng.
If this measure nt is r›ot m required, then it Us to be rrods up with «oel
ring tpaeers. Remo«e soews M and mount bearing oover. Rcfil gear oil.
c) Oil is seeping from sight glass or around
holding ring or oil drain plug
Meaning:
d) Oil is Icak ing be tween gear
Housing
and piston housing
cl Retighten glass respectively holding ring. If this will not solve the problem,
drain oil into clean container, remove oil level sight glass incl. holding ring.
Check seals and gaskets as well as the seal sealing area. If necessary replace seals
— gas- kets. Seal for oil level sight gla‹s: 25 B x 20.5 6 x 1.5 (205622).
al leer H ratra rel›ig A 16 x 22 x 1.5 DIN 7603 (200966).
For oil quantity and brand see operation manuel.
Remedy:
d) Drein gear oil, remove pipe (J I and also cnd plete (2). Attention: The end
plate (21 is under pressure by the inside spring. Catch any oil coming out.
Loo- sen up the screws (6) on the piston housing. Pull off the piston
housing (3) from the piston. Replace 0-ring (12l. Dimension of 0-rings on
model:
POLAR 92 R 80-3 (205072)
POLAR 115 R 100-3 (205077)
POLAR J37 OR 1 15-2.5 (232360)
POLAR J60 R !3O-4 f205083)
Reassemble all parts in reverse procedure. PaY attention to the bleedinq screw
Reasse
Reassemble all parts in reverse procedure. Pay attention to the bleeding screw
(51 position, which always has to be on the top of the housing.
Fill in gear oil and bleed hydraulic system (see chapter 21.2).
On POLAR model 92 the gear has to be removed from the frame.
Attention ! Every time a gear is to be removed from the machine, the knife
carrier has to be supported by wooden blocks or cardboard piles up to r›e
clamp opening on which the knife is
than rested.
Remedy:
Furthermore remove clutch guard and oil tank access cover. Remove oil. Take
off V-belts. Take off cover (15) and remove limit switches from cams l16I.
Take off end washer f17) from pulling arm and all pipes attached to gear.
Carefully remove gear holding screws 118) since the gear has a weight of 90
kg.

2 3

15

J8 1
56

Meaning:

ZZ.z None on gear (and clutch)

a) Bearings indrive wheel are defective
al If there is a noise in the drive wheel during idle speed. which will disappear
as soon as tke clutch ic engaged, it has to be assumed that the drive wheel bea-
rings are defective end en exchange is inevitable.
It In to be emphasized again that only bearings supplied by our Parts Dept.
should be used for replacementsince they have special tolerances not found
on the regular bearings. Furthermore it is of upmost importance to pay
attemion to the required pretension (see picture) applied to the bearings on
model 115, J37 and 155. On model POLAR 76 this pretension for the
bearings has been in- aorporated without falls durin9 ac••mbIy at the
factory.

Q0t8-

When exchanging bearings, new shims heve to be used. On modell:

POLAR J 15 IY) - 40 x 50 x 0.05 (21fiO79)
(X) = 80 x 90 x 0.075 (2150B0)
POLAR 137 (Y) (224842)
(X) - (224843)
POLAR t55 (Y) = 55 x 65 x 0.05 (2J9525)
(X) = 1JO x 120 x 0.075 f219S26)

zz

2c
Meaning:
bl Worm shaft bear ing defective
c) Trust bearing defective
Remedy:
b) If only during cutting cycles bearing noise will be present, it has to be
assumed that the worm shaft bearings or the trust bearing are defective. In
every case work is performed on the gear it is essential to block the knifC
carr icr. During gear assembling it is equaly important to observe the
correct amount and location of spacer washers.
c) Removal of trust bearing:
Elismantling ot piston housing as ‹.inder chapter 22.1. Thereafter turn drive
wheel with the clutch handles to such a position that the key in the brake
disc is positioned horizontal. This cBn be observed by looking through the
gap bet- ween Drake rlng and Drake disc. Now remove piszon I9) including
pressure rod. Take off snap ring on piston and press back bearing by means
of screws. Take out carter pin and remove crown nut.’ Take oN washer and
pull off bearing from support bushing.
5 2
—12 ! C
4— 9 3 1\ —10
When a new bearing is fitted, pay attention that the inner shoulder of the
bea- ring is facing the support bushing. Reassemble by reversing the above
procedure. The following bearings are furnished to model:
POLAR 92 7305 B (205157)
POLAR 115 7307 B f205160)
POLAR 1J7 7308 BUO 1205162)
POLAR 155 7310 B (207284)
Bearing removal on model 76
Dismenlllng of drive wheel up zo the cenzer bearing cover. remove bearing cen-
ter cover 1261 incl. Simmering BAFg 35 x 55 x 10 (205093) carefully.
Unscrew rea bearing glate (33) and drive out bearing from thn rlrive sirlr'
{see arrow in picture). Dismantle worm gear and take out worm shaft incl.
bearing from the gear housing. Use reverse procedure for assembling. Insert
bearing and pay spe- cial attention to the pietet‹siui i uf the Dvoi ing. Tfjc larter
should be delerMlr¥gd at the nrne of assembly. To determine the amount of
pretension, the following measurement technique has to be followed.
Assemble bearing 134) and (35) (see picture) complete onto the worm shaft
and retighten center bearing cover (26). The bearing (3S) is resting against the
 - ° ° step the worm st Before the tear bearing cover 133) is ottac4 iotJ,
measure with a depth gauge (361 the distance from the gear housing outside sur-
face to the bearing (35) (see pictured. Thereafter measure tha shoulder height
at IM bearing cover (33) with the depth gauge. For pretension purpose add
now steel spacer shims (37) with the dimension 55 x 72 x 0.05 f222677) to
the latter measurement, so tfsat tke shoulder height will be incmaeed by 0.2 nans
against tf›e distance between bearing and gear housing outside surface.
Bearing end plate (33) should now be tightened with equal torque, Funher
assembly in- structions see 22.1.

26 34

35

35
 se

Remedy:

Dismantle the drive wheel up to the center bearing oover 126) and ihe nivton
housing. Pull out piston with pressure rod. Remove center bearing cover
(26) and snap ring (29). Carefully drive out the bearing from the side of the
piston.
worm gear ae›d worm shaft including bearing from tic gear housing.
Reverseprocedure for reassembling. Insert bearings. The pretension of the
bea- rings is very important and should be determined at the time of assembly.
Please proceed as follows: Measure the distance „X” from the ouoide
shoulder of the
gear houSiFtg (7). Us ofa depth gauge is required.
 u

Thereafter establishe the shoulderhight of the piston housing. This distance is

now adjusted to be 0.5 mm larger as the previously meaured distance „X” by
adding steel shims i8) with the dimensions of 63 x 80 x 0.2 (224332). Tqhten
screws for piston housing with IlAl ?OF€'j£7@. DLI PF assembly inctructicirjs See
chapter 22.) .

oi,mg,miiiq bna•e on the «»>aei ›1s, may a•a 1ss.

Dismantle tha driyo wheel (12\, tha brake disc (ION the center beaming cdyer
\26) \sé e *hapte 22.1) and the piston hciusing incl. pi•rhnn f7] and pregeute rod
(B} jeer chapter 22.11

Remo•• worm shaft nuts (3d] and drive out carefully the bearing from the
side ot the pi$ton. Th6 Worm goal d oes not have to be revved. Revvr w”
p‹ucecl-uis to e•ssembIe. Agsin it shou)d be pointed out that only bearings
supplied bv tha f»etory should be used ss these bearings have special close
tolerances.
c) Gear vibrates: CMt vfbrateC
c) Either the bearing4 of the era n?shafi (4\ are worn out”or be bushing (bea-
ring) of pu\lirzg a i \G), which is riding on 1hc clank dam,
Anothgr possibility is the excessive pJaY baton worm shaft and worm jar
and w.arm gear teeth. E9 Y' '{gf$ is sspecialTy notlceable during cutti Of
thick or”hard material.
 xc most petmi.sible play within tho teoth are model 76 = 65 mrrj, D2 = 70 mm.
115 = 1OD mm, 137 = 120 mm, 155 = 140 mm. The play is measured on
the outside diameter of the drive wheel.

Remedy in case of excessive play' Exchange gear.

?1

23. Rakes, backgauge and sledge

23.1 Bottom sheet slides uruJer rakes

Ro+cdy:

a) Table not correctly adjusted diagonally a) Check table diagonally with a long straight edge and readjust if necessary.
The adjustment is done by turning table support stands up or down, if necessary
additional spacers can be put under the table support bridge.

b) Rakc3 or back9•Us• ••ction s loose or b) FlemovC rakes and section. Clcan all mounting surfaces, rc move burrs and
dirt on mounting s‹ rface check backgauge position with an accurate square to be sure all parts are ad-
justed 90a to the table. Secure rakes end backgauge section to center sledge
as explained later on.

Fcgcrg melt@bis Arschl 3

einschfTtubeh
Z \/erste1lsrhroAe met /eder bis
6s lndeende enschouben
3 Rechen onset uA onschle- mud l›eru»teidi’ucken, Scheme vrJ orrehert

t0 the stop
2 free' ’n adjusting srrewith
 Q@If 0ff9FwQfdS ‘6QShe/’
is arrested. 1.

) 3.

02

Rmaiedr:
c) Adjustment of backgauge rakas model 92 T , Screw in spring assembly (A) until dead stop
2, Lift rake and push down again to have washer (bl wposltioned.

2Z.2 The cutting material i3”not parallel

a) The backgauge is not parallel to the knife.
a) Ad)ustme•t of the back9•u@ is done as follows:
Take a ream of papgr, approX, 5 cm in height. JD te 20 cm in width an”d prefer-
able as long aa. zhe zable IenBth. Make a cIeéni‹iq cuc on emir of ihe lurgj ‹ids.
Take a half of cot ream and turn it around 18a. Pleoe”thispile now on top
of the remaining half in the machine. Make sure both piles ar.e rezrin9
accuratziY against the backgauge. On this, side on which the lower haP et
the -m”iswider then the top half. The adjusting screw on 1hf3 side fias to be
turned clockwise. However the oppoqitc scrcw alwcys to be tumad bask
”bcforahend the semc amount. Make.cot on laoth sides again and repeat the
sdMe adjUsting procedure until both reams (upper and lower kaff) are of tha
same size. Only then the

b) Dirt between rakes and resung aree
on the backgauge
c) Backs mounting devlos becam9
lozzse
a) Backgauge guiding rails dirty or dry
b) TabM spindle rasp. spindk nus
d) Stedge guiding rallc we wom
baekgatge ts exactly pmalldto the knife. Secure adjusting crews (1 + 21
from tf›e top by inserting worm «at soeus (3). Kzxirled nut (4) with scale
should now be ezzashcd to th• edjustln9 snrew (1) on the l•ft dde and
positioned In ezoh e way thct the zéro «marking it in alignment with tha mark
„& ”on tbe baskgau$s. Saaxo knurkd nut 14) in this position with the two
worm set soews. a oampi‹g type urau ‹s› u t‹t u ‹be ngrit aajusti !
s‹rew. culling tf›s
handk out ef tbe tootfNd snap devies makes it pascible to ha«e the fzandk al•
wsys patnting in the up position.
b) It th bad‹ga‹zge is parallel adjusted as under cñafnsr a and cutur›g differen-
ces still ere emotmtered whm oming other P zer sizes, it b poalbk tfat thb
may be cmmmd fry foreign mactar bataean rakes and baekgatqja surfa«a.
Removerakesandbeckgau$ezemions for tfxzrouphly cleaning. Reazcemble pals
c l T bt itc n h e x. v ie w on
i« u a < il i
b a ll tv ne b ol t. In u s e t in
a n » o ne i,
b e l l t Y m A lt it m l f
e › u i* n o a e • o • ei • u i » • t • e «ip . t» o » n
tm p locking screw for the bolt (teemed on the stad9e) sql retighten bell
w tra
bolt. Se- cure agcit› with locking screw end assemble bach$auge pane
a) Backgauge guiding raib have to be ckaned on a regular scfeduk, more of-
tan if outer isexpoced to excessiw dust aocumulction. After cleaning with mi-
rnral spfrh lubricsteemire rsils by moving bankgau$e beck and forwa'd In
order u tw ml dist«autea •«<> ••• t*• ‹uli sw+i ••• e tf• gu«i•g
roia.
Check as wlwtfar dl oil linas are pumplg out oil.
a) Motor make too rfniCh wom
 rswh tfa abo«e air gap mesaxs-
b) Wtenencion
adjustable spindb nut
Beforehand rarrove tie
2 locksoswz of the
stationary spindle nut
and raUghten the
stationery nut. Thic will
reposi- tion the
bzckgzuge and she
sdjuszable spindle nut
will iw some more
ten- sion from the
cprig Rctightan the
stationary rnrt m far m
neoded to s«t tke play
redu d to a mininwm.
I'f with ttzrr rig of the
handwheel for fine
sdjust- ment no nxse
plsy b to be felt, the
the pby he been taken
all our Ttazssfter
zecure tho' ¥tBtionary nut 8gain
with 1t'sag
tha
spindle nus b too far advanced
arm any adjusaram is fruitless,
the excl
of both, zplrutts and spindk rarts
cpl. , b inevftabb.

cl Adiuct beckseuss sledge

guiding. Altar loosening of
eountar nus adltm tta
uzQ› ay maa a wjta«ng ’rta
«jummem hue &
ful in ardcr to mairrBin
an free and easy
mowment but without
play. Seoure counter
nuta e$ain and clock
performance of
besk$au$e in front end
rear ses• tion of tabs. If
the gu“xling ledges
are wom too fa, they
ttsn have to be ex-
changed as a complete
set.

d\ In saae tha stsd$a

guiding zails ore worn
more st the frorrt
portion of phs tabb than
at the raar, problems
with the automatic
performance will corre
up due to the
differences in
backgauge movemanh
(Front-rear) Tta cutting
accura- cy b effecBd.
If this is tt›e mass the
guxstng rails have to
be v x1‹ed on (Scza-
ping off higher areas).
Howevw the complete
exchsrqe of the guiding
rails is in-
waui+ x the ai«e›o» »stw••n
6om ana av i•too*rp a I•
h•<be«sad

el Adjtzst firstek on
the motor brake. The
gep zfwuld zezd OJ
mm ( pic• ture below).
It thizairgapof 0.2 mm
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