Professional Documents
Culture Documents
9405425
Marquip, Inc.
1300 North Airport Road
Phillips, Wisconsin 54555-0028
715/339-2191
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PURPOSE OF MANUAL
Because the manual contains machine assembly and start-up information, every
attempt has been made to get the manual delivered at an early date. Changes to the
manual will be issued to the customer as revision pages.
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TABLE OF CONTENTS
INTRODUCTION - 9404727
SAFETY - 9404728
Safety ..............................................................................S-1
Safety Guidelines ............................................................S-2
Warnings In Manual ........................................................S-3
Signs And Their Locations ..............................................S-6
OPERATION - 9404729
Cleaning ..........................................................................Pm-1
Lubrication ......................................................................Pm-2
Knife Lubrication Chart ...................................................Pm-2
Tachometer Maintenance ...............................................Pm-4
Preventive Maintenance Checklist ..................................Pm-5
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COMPONENT REPLACEMENT - 9404737
Introduction .....................................................................Pt-1
Machine Records ............................................................Pt-2
Operator Training - Knife ..........................................Pt-2
Maintenance Training - Knife ....................................Pt-3
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Operator And Maintenance Quiz ....................................Pt-4
Maintenance Quiz .....................................................Pt-8
Operator And Maintenance Answer Key ........................Pt-14
SUPPLEMENT - 9432201
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OPERATIONAL DESCRIPTION
A continuous web of corrugated enters the knife system from the upstream slitter/
scorer. This web may be diverged into two or three levels by means of knife
lead-in forks (provided by others).
The web first engages a series of web detect photoeyes which provide input for
first sheet cut accuracy. Another set of photoeyes sense the tips of the knife
lead-in forks. These determine at which level the web is being directed. Just
downstream of the web detection area, the web enters the pull roll. The pull roll
runs slightly faster to maintain tension on the web and provides positive control of
the web during a cut.
A short distance further, the web is directed between the cutoff mechanism. 1/2"
to 1-1/2" of the leading edge of the web may be trimmed off at this time to create
a clean edge for the first sheet to be cut. The knife is pre-programmed to cut sheets
to a specific length. Immediately downstream of the knife mechanism is an exit
roll assembly which runs slightly faster than the upstream pull roll assembly. This
overspeed allows the web to be tensioned prior to the cut, plus serves to accelerate
the sheet away from the knife. The cut sheet is then powered into the downstream
stacking system. The knife system may be programmed to change the length of
the cut within one cycle of the knife mechanism. The trailing edge cut of the last
sheet is made at the same time as the leading edge cut of the first sheet. In the case
of a slitter/scorer setup change, a gap is created between the old and new setup by
means of speed changes (no gap type) or by chopping out some portion of the web
(gap type). In these cases, one short sheet at the end of the old setup will be
generated. During a no gap setup change at full line speed, the knife will maintain
full speed. At slower speeds, the corrugator may maintain speed while the slitter/
scorer and knife speed up to generate slitter/scorer change time. In most cases, the
corrugator slows down first, then a shear chop is made, and then the slitter/scorer
and knife speed up to pull the necessary gap. After the setup change is complete,
the corrugator is accelerated back up to full speed.
2. Exit Roll - Urethane covered roller which powers sheets into stacker.
Exit Roll Drive Motor - Variable speed motor which directly powers exit
roll.
3. Exit Roll Nip Wheels - These 2" wide wheels are directly over the exit
roll. They hold the sheets against the exit roll and provide the drive force.
Also called holddown wheels.
Knife Drive Motors - Variable speed motors which provide the power to
rotate the knife cylinders.
8. Lower Knife Cylinder - The lower knife cylinder of the pair on either
level. It has a nonadjustable blade and has no backlash adjustment.
Lubrication Tank - This system consists of a reservoir for oil for the
knife cylinder gears and bearings. It is fitted with a float level switch to
automatically stop the knife in case of low oil.
10. Motor Enclosure - Located on both sides of the knife. It houses motors,
blowers, and pneumatic valves.
Nip - Any pair of rollers running together to drive material between them.
11. Pull Roll - A urethane roll immediately upstream from the knife cylinders
which pulls the web through the knife.
12. Pull Roll Nip Wheels - These 2" wide wheels are directly over the pull
roll. They hold the web against the pull roll to provide the drive force.
Also called holddown wheels.
13. Roll Out Infeed Section - A roll out drawer which houses the pull roll
nip wheels. It rolls out to provide access to the knife cylinders.
14. Top Cover - A guard covering the knife cylinders and exit roll on the
upper level. It can be folded back to access the knife cylinders.
15. Upper Knife Cylinder - The upper knife cylinder of the pair on either
level. It has an adjustable blade and backlash adjustment on the ends.
1. The safety precautions given in this manual provide guides for the
protection of personnel and are specifically related to the system. In
addition to these precautions, observe all appropriate general rules of
safety and good judgement for your own protection and for protection of
fellow workers.
NOTE: When pneumatic power is turned off, some lines may still hold
pressure. The complete system must be drained of air.
3. Stay clear of all gear and direct coupled drives unless certain that power
has been locked out for the machine.
5. Check inside and around the machine for operator and maintenance
personnel before applying power to the machine.
Report any accident or near miss which occurs on any Marquip equipment to
Marquip immediately so that it can be analyzed and any necessary corrective
action can be taken to reduce the hazard.
The following warnings are contained in this manual. They warn maintenance
personnel of special hazards present while performing maintenance procedures
described in this manual. Follow their instructions exactly.
Marquip has provided caution and danger signs on the knife to warn operator and
maintenance personnel of hazards. Should a sign be removed, Marquip will
replace such signs. Figures 1, 2, 3, 4, 5, and 6 show the locations of all safety signs
on the Marquip Knife.
The functions of the knife operator controls on the machine are listed below.
Shown are buttons for a single level knife. A double or triple level knife will
require additional buttons for each additional level.
The Marquip Knife has several automatic functions with which the operator
should be familiar.
1. There are safety switches on all easily opened guards and doors that will
produce an emergency stop on the corrugator if tripped. These switches
are on the top cover, the roll out infeed sections, motor enclosure doors,
and the outfeed barrier guards.
2. A normal stop will occur if the oil flow or oil level in the gear lubrication
system falls below a preset oil level or if motor cooling airflow falls too
low.
3. Movement of the jam detect pan, located between the knife cylinders and
exit roll, due to a jam or wrap-up will trigger an emergency stop on the
corrugator.
5. If AUTO is enabled without a web in the machine, the knife cylinders will
go to a cocked position and will not rotate further until a web enters the
machine.
6. Located on the bus detector enclosure are five LED indicators. If any
LED turns off during normal operations, contact maintenance. If any LED
remains on for 30 seconds after turning off main disconnect switch,
contact maintenance.
CLEANING
1. Small pieces of scrap and trim will often hang up in the knife. These
should be periodically removed for two reasons. Scrap pieces rubbing
against rotating shafts and rolls can build up heat and be a potential fire
hazard. Long pieces of trim can wrap around rotating parts, generate
enormous forces, and bend or break shafts and bearings.
2. Dust and scrap will build up directly under the exit roll. Blow the dust
from this area on a daily basis. Excessive build-up will cause roll wear,
undue strain on drive components, or jams.
3. Coatings that are applied to the web may build up on the rolls and wheels
of the knife. It is important to keep all rolls and wheels clean.
4. Blowers provide cooling air for the knife cylinder drive motors. There is a
filter on the inlet of the blower to keep dust out of the motors. Keep this
filter clean and replace as required. When replaced, the air filter should
have an efficiency of 45-55% and an average arrestance exceeding 95X.
An airflow switch will shut off the knife if inadequate airflow exists. This
could indicate that the filter needs cleaning or replacing. Do not bypass
the shutdown switch. Operating the machine without cooling air can
result in sudden, total failure of the drive motors.
5. There is one compressed air filter per level. It should be purged of oil and
water periodically. The element should be replaced as required.
6. On integral drive knives, there are filters located on top of the integral
drive cabinets. On external drive knives and triple level integral drive
knives, there are filters located on the right-hand side of the external drive
cabinets. Keep these filters clean and replace as required. When replaced,
the air filter should have an efficiency of 45-55% and an average
arrestance exceeding 95%. This prevents catastrophic control equipment
failure.
2. Lubrication of the knife's pull roll, exit roll, and pull roll holddown wheel
shaft bearings is by grease fittings. There is a fitting on the bearing on
each end of the two rolls and on each end of the holddown wheel shaft.
The location of these six bearings is shown in Figure 1. Do not grease
bearings while knife is running.
Blade Lubricator Mobil Gear #630 (From Per Flow Control Continuous
Cylinder Reservoir) Setting
Pull and Exit Roll Bearings (Figure Texaco Multifak #2, 3 Pumps * 4-8 Weeks
1) Mobil Mobilux #2 or Depending on Duty
Equivalent Cycle
* For duty cycles above 400 FPM and 18 hours per day, this interval should be
weekly.
The knife cylinder tachometer should be periodically inspected for brush and
commutator wear. Brushes and/or commutators should be replaced as required.
To inspect the knife cylinder tachometer, open the left side doors (looking
downstream). The tachometer is enclosed in an aluminum housing near the knife
drive motors. Remove the cover on the conduit fitting to expose the tachometer
leads. Remove the tachometer cover and carefully thread wire through the cover
while pulling the cover away from the tachometer housing. The amount of brush
dust inside the cover will give a general indication of wear. If more than a
thimbleful of dust is present, the brushes will most likely need to be replaced.
Remove the four screws holding the brushes in place. The brushes can then be
pulled out. The brushes are 5/16" long when new. If the brushes are worn down to
1/8", they must be replaced. (See Component Replacement section.)
Inspect the commutator. If a groove more than .010" deep is present, replace the
commutator. (See Component Replacement section.)
Inspect the inside of the tachometer housing. If any oil is present, it will be
necessary to replace the housing. Oil in the tachometer will cause rough and
erratic operation of the knife cylinders.
? CAUTION: When replacing the cover, pull all excess wire into the
conduit fitting to prevent wire from rubbing on rotating
shaft.
Step 2 Turn off CONTROL POWER for each level of the knife.
Step 4 Check that LEDs on bus bleeddown cards are all functional.
Step 2 Infeed section - lift the upstream edge of the infeed skid plate to its
upper resting position (upper levels) to allow clearance for the roll out
infeed section. Release both infeed section latches and roll out the
infeed section (all levels).
Step 3 Standing platform - the catwalk is stored under the lower knife
cylinder and is slid into position.
Procedure:
Step 2 Remove the cover plate on the knife cylinder gear case.
Step 3 Insert the socket on the end of the rotation shaft through the gear case
hole and engage the exposed nut.
Step 4 Place the other end of the rotation shaft in the rest provided and slide
a pin through the rest to secure the rotation shaft in place.
Step 5 Wrap a clean rag around the end of the shaft and push into the gear
case hole to prevent dirt and debris from entering the knife cylinder
gear case.
Step 6 Use the ratchet handle provided to manually rotate the knife
cylinders.
For added safety, the person tuning the knife should rotate the knife with one hand
on the handle and one hand behind his back, or with both hands on the handle.
Final Tune - The result of completely severing all of the wet 90-lb. liner fibers.
Gear Backlash - The finite distance between meshed gear teeth that must be
removed to prevent unwanted gear play.
Gear Preload - The force needed to bring meshed gear teeth together in order to
remove gear backlash.
Lapping - The process of applying an oil-based abrasive between the two knife
blade surfaces to eliminate unevenness between them and to create a sharpened
edge on the tip of each.
Minimum Surface Wear - The predetermined distance needed before the lapping
procedure is complete; 0.015" measured from the tip of the knife blade, down.
Rough Tune - The result of incompletely severing all of the wet 90-lb. liner paper
fibers.
Spot Tune - The procedure used to temporarily improve the cut quality of a small
portion of the knife blade when time does not permit a complete tune.
Springback - The tendency for gear teeth contact to relax when gear preload is
removed.
Tune - The procedure of advancing the upper knife blade with the knife blade
holder jackscrews.
Spot tuning knife blades should only be considered if the cut quality becomes
unacceptable on a portion of the knife blades and production schedules limit the
amount of time in such a way that a complete knife blade tuning procedure cannot
be accomplished immediately. You must, for certain, do a complete tune as soon
as possible after a spot tune.
Tool List:
NOTE: The tools listed above are available as part of the Knife
Maintenance Tool Kit available from Marquip. See Recommended Spare
Parts List.
Use this outline only as a guide when you are completely familiar with the
procedure.
Step 3 Verify poor cut quality area with wet 90-lb. test cuts.
Step 4 Remove wick lubricator and mask over knife blade bolts.
Step 5 Apply medium grit lapping compound to upper blade poor cut area
and oil to remainder of blades.
Step 6 Close knife and lap once with medium grit for five minutes.
Step 7 Inspect for sharp tip on both the upper and lower blades, repeat
lapping if necessary.
Step 8 Break loose and retorque to 150 in.-lbs. knife blade bolts.
Step 9 Final tune with minimum turning on jack bolts for clean cut (hot
knife) with wet 90-lb. liner in marked areas.
Step 10 Retorque knife blade bolts to 220 in.-lbs. and apply oil to both blades.
NOTE: Always keep a stock of soaking 90-lb. liner so you are not caught empty
handed. Change the soaking 90-lb. liner every two weeks.
Step 1 Before entering the knife, note the approximate area of the poor cut
quality by viewing previously run stacks of corrugated board.
Step 3 Upon entering the knife, verify poor cut quality areas by using wet
90-lb. liner and testing the cut across the entire width of the blade.
Mark the areas of concern with a magic marker.
Step 4 Remove the wick lubricator assembly and mask over the blade bolt
holes with 2" masking tape (both upper and lower blades).
Step 5 Apply medium grit lapping compound (220 grit) to the areas of the
upper knife blade you previously had marked and for additional five
bolts on each side of the marked area. Apply a film of oil to the rest of
the blade area (upper and lower) to avoid galling the blades.
Step 6 Close the knife and lap one time for five minutes.
Step 7 Using the graduated microscope, inspect both the upper and lower
blade lapping areas for a sharp tip.
If you do not see a sharp tip, you must relap with the medium grit
again in the marked areas. Be sure to apply a film of oil to rest of the
blade area (upper and lower) to avoid galling the blades.
If, after lapping with medium grit for three times and you still have
not obtained a sharp tip, rough tune the blades to cut wet 90-lb. liner
paper in the marked areas. (Loosen and retorque blade bolts to 150
in.-lbs. before adjusting blade. DO NOT CUT EVERY FIBER.) Do
not advance the knife blade by more than 1/12 of a turn on the
adjusting screw at a time. Retorque blade bolts to 220 in.-lbs. Lap
again with medium grit lapping compound until a sharp tip is
obtained.
Step 8 Remove the masking tape. Loosen and retorque the knife blade bolts
in the marked area to 150 in.-lbs., one at a time. Loosen five
additional knife blade bolts on each side of the marked area and
retorque to 150 in.-lbs.
Step 9 Starting from the right and working to the left (looking downstream),
final tune the knife blades in the marked areas to cut wet 90-lb. liner.
Do not advance the knife blade by more than 1/12 of a turn on the
adjusting screw at a time. Since the knife has just come out of
production and is still hot, tune the blades to cut the wet 90-lb. liner
cleanly across the entire width of the blade.
Step 10 Retorque all loosened knife blade bolts to 220 in.-lbs. Check all upper
knife blade bolts for 220 in.-lbs. of torque. Tighten adjusting screw
locknuts. Apply a film of oil to both blades.
Step 11 Check the wick lubricator for blade contact and good oil permeation,
then reinstall.
Step 13 Check the knife for tools and other debris. Close the knife up.
NOTE ON BACKLASH: Normally you will not have to reset the gear backlash
when tuning used blades, unless you have noticed a sudden loss of cut quality
over a wide area of the knife blades. This sudden loss of cut quality may indicate
that the gear backlash has changed and will need to be reset. To check gear
preload before tuning used blades, see "How To Check for Loss of Gear Preload't
in the Maintenance Adjustments section of this manual.
Tool List:
Use this outline as a guide only when you are completely familiar with the
procedure.
Step 3 Restore blade tips, apply medium grit lapping compound to the upper
knife blade. Close the knife and lap for five minutes. Repeat medium
grit lapping procedure two more times.
Step 5 Break loose and retorque to 150 in.-lbs. knife blade bolts. Rough tune
with minimum turning on jack bolts to cut wet 90-lb. liner across the
entire width of the knife blade.
Step 6 Retorque the blade bolts to 220 in.-lbs. for lapping. Apply fine grit
lapping compound to the upper knife blade, close the knife and lap for
five minutes. Repeat fine grit lapping procedure two more times.
Step 7 Retorque the blade bolts to 150 in.-lbs. for tuning. Final tune with
minimum turning on jack bolts to cut wet 90-lb. liner. Tune to cut
every fiber if the knife is still hot; i.e., if the final tune is made within
two hours after shutdown.
NOTE: Always keep a stock of soaking 90-lb. liner so you are not caught empty
handed. Change the soaking 90-lb. liner every two weeks.
Step 2 Remove the wick lubricator assembly and mask over the blade bolt
holes with 2" masking tape (both upper and lower blades).
Step 3 To restore the blade tips, apply medium grit lapping compound (220
grit) to the upper blade, close the knife and lap for five minutes.
Repeat the medium grit lapping two more times for five minutes each.
Step 4 Using the graduated microscope, inspect both the upper and lower
blade lapping areas for sharp tips.
If you do not see a sharp tip, you must: 1) Loosen and retorque all the
upper knife blade bolts to 150 in.-lbs. 2) In areas where tip is not
sharp, advance blade by 1/12 turn on the adjusting screw. 3) Retorque
blade bolts to 220 in.-lbs. 4) Reapply medium grit (220 grit) lapping
compound to the upper knife blade. 5) Close the knife and relap the
knife blades for five minutes. 6) Reapply medium grit compound and
lap (five minutes) two more times.
Step 5 After restoring the knife blade tips, clean the medium grit lapping
compound off the knife blades. Loosen and retorque all of the upper
blade bolts to 150 in.-lbs. Starting from the right and working to the
left (looking downstream), rough tune the knife blades to cut wet
90-lb. liner across the entire width of the knife blade. IMPORTANT:
Do not try to cut every fiber of the wet 90-lb. liner. Do not advance
the knife blade by more than 1/12 of a turn on the adjusting screw at a
time. Retorque blade bolts to 220 in.-lbs.
Step 6 Apply fine grit (320 grit) lapping compound to the upper knife blade,
close the knife and lap for five minutes; reapply fine grit compound
and lap (five minutes) two more times.
Step 8 Retorque the knife blade bolts to 220 in.-lbs. and the outer socket
head bolts to 300 in.-lbs. Tighten adjusting screw locknuts.
Step 9 Apply a film of oil over both knife blades to prevent galling the knife
blades.
Step 10 Manually rotate the blades forward through the cut. Torque on the
ratchet handle needed to pass the blades through a cut may be slightly
higher than the torque to rotate the cylinders when not in the cut. This
torque difference should not be more than 75 in.-lbs. If the torque
increase is greater than 75 in.-lbs. or the blades will not pass through
the cut (NEVER FORCE THE BLADES THROUGH THE CUT),
you have adjusted the blades too tightly together. See "How To
Loosen Tight Blades" in the Maintenance Adjustments section of this
manual.
Step 11 Check that the wick lubricator is oil soaked and has been making
contact with the knife blade. Reassemble wick lubricator and adjust
wick height if necessary.
Step 12 Check to be sure all tools are cleared from the knife, roll in the infeed
section (all levels), reposition the infeed skid pan to the run position,
and close up the top covers of the knife.
If at any time during a tuning procedure, either the blades refuse to pass or the
differential torque needed to rotate the blades through the cut exceeds 75 in.-lbs.,
you must loosen the blades.
Step 1 Inspect the blades. Back the blades back out of the cut. Examine the
blades and smooth over any rough spots with the honing stone.
Step 2 Loosen the adjusting screws near the tight spot. This will release the
tension and may allow the blade to retract slightly.
Step 3 Recheck blade pass. If the blades pass, continue with the tuning
procedure.
Step 4 If the blades do not pass, locate and mark the high resistance spot.
Step 5 Back off five adjusting screws to the left and right of the tight spot.
Step 6 Loosen and retorque one at a time; five blade bolts to the left and
right of the tight spot to 75 in.-lbs.
Step 7 Place a clean piece of wood 2 x 4 or larger on the tight area of the
blade and with a 3-4 lb. hammer force the blade back against the
holder.
Step 8 Recheck the blade pass. If the blades do not pass, repeat this
procedure from Step 4.
Step 9 Retorque the knife blade bolts one at a time to 150 in.-lbs. of torque
for tuning purposes.
Step 2 Loosen eight hub locking studs on the right end of cylinder.
Step 3 Prepare the hub lock stud. Completely remove both of the nuts and
brackets from the two hub lock studs below screw D. See figure 1 in
the Component Replacement section of this manual. Using the two
free nuts, turn them both back onto the hub lock stud located to the
lower left of screw D. Jam the two nuts together at least 1/4" above
the knife cylinder, making sure the top nut has a face perpendicular to
the knife cylinder.
Step 4 Mount dial indicator on the right end of cylinder, indicating off of
lock stud near screw D.
Step 5 Back off screw D until loose, then 1/2 turn additional. Note indicator
movement.
Step 8 Advance screw D in .005" increments, backing off each time and
watching for springback. At the first sign of springback, continue
backing off screw D until springback stops. This is the gear contact
point. Indicator should show .008" movement from the original
position (Step 5).
Step 9 Set gear preload. Zero the indicator. Advance screw D for .008" of
movement. Torque to obtain .008" advancement should not exceed 75
in.-lbs.
Use the following procedure to set the height of the holddown wheels over the
pull roll and exit roll.
Use this procedure to set the holddown wheel shock absorbers over the exit roll.
Step 1 Apply air pressure to the rod end of the air cylinder to bottom out the
cylinder.
Step 2 Rotate the shock absorber body until it comes against the wheel pivot
arm and raises the wheel to just miss the roll. Back the shock body out
one turn to provide good contact.
Step 3 Set the shock absorber speed as fast as possible, but not so fast that
the shock absorber is not functioning at all. & sure the shock absorber
settings are consistent across the width of the machine.
Step 1 Turn bottom stop jackscrews until they touch the cross tube.
Limit Switches:
There are plunger type limit switches at several locations on the knife. All have a
similar function--they indicate open doors or guards that should be closed before
starting the knife. At each of the following locations, check that it actuates with
greater than 1/16" over travel and does not bottom out.
Airflow:
Each knife is supplied with a diaphragm style pressure switch. The switch is
located in the left-hand motor enclosure on the upstream side of the air tube. The
switch will be normally open and will close as air pressure reaches approximately
8.0" of water. The switch will be set so that contacts open at a decreasing pressure
of 8.0" of water.
Step 2 Observe all safety rules while applying power to the blower.
Step 3 Read the plenum pressure. It should be greater than 8.0" of water with
the air filter in place. If the pressure is low, check:
A. Is blower rotation correct?
B. Is filter clogged?
C. Is there a major leak?
Step 4 Monitor the pressure switch output with a DMV, it should read
approximately 0 VDC. Gradually block the blower inlet until the
DMV just switches to +15 VDC. This is the pressure switch set point.
The pressure gauge should read 8.0" of water. If this value is
incorrect, the pressure switch point needs adjustment.
Step 3 Turn sensitivity adjustment clockwise until photoeye LED goes on.
Tool List:
NOTE: The tools listed above are available as part of the Knife Maintenance
Tool Kit available from Marquip. See Recommended Spare Parts List.
Feeler Gauge:
Step 1 Gain access to the knife blades by following the "Safety Lockout and
Gaining Knife Access". procedure in the Maintenance Adjustments
section of this manual.
Step 2 Remove the old blades, starting at either end and progressing to the
other.
Step 4 Clean off the blade holder. Inspect all threaded inserts for damaged or
stripped out threads. Replace as required. See "Threaded Insert
Removal and Replacement" in the Component Replacement section
of this manual.
Step 5 For safety, install the lower blade first. There is an upper and lower
blade. The lower blade is designated the "fixed" blade and is bolted in
place with the blade's back against the holder. The upper blade has
slotted mounting holes and is adjustable. The two end bolts are 3/8"
NC socket head cap screws while the remaining bolts are 5/16" NF x
1/2" hex head screws. Always use new bolts when installing new
blades.
Step 1 Lay new blade on holder. Position the blade laterally until holes in the
center of the blade are directly centered over the threaded holes in the
holder.
Step 2 Install blade bolts starting in the center and working alternately
outward toward the ends of the knife blade. Finger start as many bolts
as possible, being careful to get the bolts threaded straight! When
bolts can no longer be started, begin torquing the bolts down from the
center bolt and working alternately toward the ends of the blade.
Progress along the blade in this manner until all the bolts are started.
Step 3 Torque all bolts to 75 in.-lbs., again starting at the center bolt and
working alternately outward toward the ends of the knife blade.
Step 4 The blade must be forced tightly against the blade holder. Place a
piece of clean wood (2 x 4 or larger) against the blade and strike with
a hammer (3 to 4 lbs.) to force the blade against the back of the
holder. Repeat at 2"-4" intervals while working from right to left
(looking downstream). The knife blade must seat no greater than
0.002" from the holder. Check the gap with a feeler gauge.
Step 5 For lower blade, torque blade bolts to 220 in.-lbs. Double check the
final knife blade bolt torque. Upper blade bolts torque to 150 in.-lbs.
for tuning.
Proceed to "Knife Cylinder Gear Backlash Removal and Gear Preload" in the
Component Replacement section of this manual.
Tool List:
NOTE: The tools listed above are available as part of the Knife Maintenance
Tool Kit available from Marquip. See Recommended Spare Parts List.
Masking Tape
Drill Motor
Open End Wrench Set
Procedure:
Step 1 Use masking tape and mark the drill bit to drill to a depth of 3/8"
beyond the drill alignment jig.
Step 2 Center the drill alignment jig over the broken bolt. You may have to
shim the jig up over the broken bolt using washers.
Step 3 The cobalt drill cuts very fast. Use cutting oil and a low RPM drill
motor to avoid heat. To avoid drilling through the bolt and into the
knife cylinder, use masking tape and mark the drill bit to drill to a
depth of 3/8" beyond the drill alignment jig. Carefully drill down the
center of the broken bolt.
Step 6 Inspect the insert for damaged threads and replace if necessary.
Tool List:
NOTE: The tools listed above are available as part of the Knife Maintenance
Tool Kit available from Marquip. See Recommended Spare Parts List.
Light Hammer
Small Cold Chisel
Drill Motor
Masking Tape
Procedure:
Step 1 Using masking tape, mark the drill depth for 3/16". This will remove
the insert material between the keys and internal threads.
Step 3 Deflect the four keys inward and break them off using a small cold
chisel.
Step 5 Screw the new insert onto the insert installation tool, being sure to
line up the extended insert keys with the holes on the insert
installation tool.
Step 7 Back out the insert installation tool and check to be sure that the insert
is recessed between 0.010" - 0.015" below the knife blade holder.
Step 8 Using the TRK 5/16" impact tool, drive down the insert keys with
several light taps from a hammer.
Step 9 Check to be sure that the insert keys have been driven down flush
with the insert.
Tool List:
NOTE: The tools listed above are available as part of the Knife Maintenance
Tool Kit available from Marquip. See Recommended Spare Parts List.
Use this outline as a guide only when you are completely familiar with the
procedure.
Step 7 Remove gear preload and make reverse gear teeth contact in opposite
direction of gear preload.
Step 13 Check blade pass. If blades pass, proceed to "Tuning New Blades"
section of this manual. If blades do not pass, return to Step 11.
Step 3 Carefully check to see if the blades will pass forward through the cut.
If not, back off screw A and advance B in 1/4 turn increments. Repeat
until blades pass.
Step 4 Using the 26-lb. medium paper, proceed to make test cuts along the
blade working from right to left.
CAUTION: Never force the blades through the cut or damage to the
blades may occur.
When making your test, if the 26-lb. paper is cut anywhere along the
blade, proceed to Step 5. If not, back off B by 1/8 turn and advance
screw A by 1/8 turn increment and repeat Step 4. Continue backing
off B and advancing screw A in 1/8 turn increments and repeating
Step 4 until the 26-lb. paper is cut somewhere along the blade.
Using the two nuts, turn them both back onto the lower left stud,
jamming them together at least 1/4" above the knife cylinder. Making
sure that the top nut has a face perpendicular (cross-machine
direction) to the knife cylinder will provide a point of reference for
the dial indicator.
Step 6 Mount the dial indicator on the knife cylinder in such a way as to
bring the dial indicator shaft in contact with the prepared stud (Step
5). Make sure that the dial indicator shaft is at right angles
(perpendicular) to the prepared stud.
Step 7 Make sure screw D is backed out far enough so as not to make
contact with the push stud when screw C is advanced.
NOTE: Once the gear backlash has been removed and the gear
preload has been set, this should not be changed. To retain the gear
preload, you will be advancing/backing off screws A and D equal
amounts; i.e., if you advance screw A, you will back off screw D an
equal amount. This will allow you to set the initial position of knife
cylinders without changing the gear preload.
Step 10 Remove the dial indicator and back off screw B at least three full
turns. Pass the blades forward through the cut to check for any blade
binding that may have been caused when the gear preload was set. If
the blades pass, go to Step 11.
A. If the blades bind during the cut, you will have to open the knife
blades. Back off screw A by 1/8 turn and advance screw D by
an equal 1/8 turn. Pass the blades through the cut. If they bind
together, again continue to back off screw A by 1/8 turn and
advance screw D by equal 1/8 turn, checking each time to see if
the blades will pass.
Step 11 Set the initial position. Using the 26-lb. medium paper, proceed to
make test cuts along the blade working from right to left. If the 26-lb.
paper was cut anywhere across the knife blades, proceed to Step 11,
Item B.
A. If the paper was not cut, you will have to bring the knife blades
closer together. Back off screw D by 1/8 turn and advance
screw A by an equal 1/8 turn. Make the 26-lb. paper test cut
again. Repeat the blade closing until the 26-lb. paper is cut
somewhere along the knife blades.
B. Open blades by backing off screw A 1/8 turn and advance
screw D 1/8 turn. Initial position is now set.
Step 13 Test for blades passing. If blades pass, proceed with Step 14. If the
blades do not pass, return to Step 10, Item A.
Tool List:
NOTE: The tools listed above are available as part of the Knife Maintenance
Tool Kit available from Marquip. See Recommended Spare Parts List.
Use this outline as a guide only when you are completely familiar with the
procedure.
Step 1 Gear preload and initial position must be set. Confirm that all blade
bolts are properly torqued for tuning.
Step 3 Rough tune blades with minimum turning on jack bolts to cut wet
90-lb. liner.
Step 5 Retorque knife blade bolts to 220 in.-lbs. for lapping. Apply medium
grit lapping compound to the upper knife blade. Close the knife and
lap for five minutes. Repeat medium grit lapping procedure two more
times.
Step 7 Retorque knife blade bolts to 150 in.-lbs. for tuning. Rough tune
blades with minimum turning on jack bolts to cut wet 90-lb. (DO
NOT CUT EVERY FIBER) across the entire width of the knife blade.
Step 8 Retorque knife blade bolts to 220 in.-lbs. for lapping. Apply fine grit
lapping compound to the upper knife blade. Close the knife and lap
for five minutes. Repeat fine grit lapping procedure two more times.
Step 9 Clean blades. Retorque knife blade bolts to 150 in.-lbs. for lapping.
Final tune blades with minimum turning on jack bolts to cut wet
90-lb. liner paper (DO NOT CUT EVERY FIBER).
Step 11 Oil blades and check blade pass for no extra torque through cut.
NOTE: Always keep a stock of soaking 90-lb. liner so you are not caught empty
handed. Change the soaking 90-lb. liner every two weeks.
NOTE: As this is an initial tune, you must expect to retune the knife within two
weeks, allowing the blades to "seat in".
See "Knife Cylinder Gear Backlash Removal and Gear Preload" in Component
Replacement section of this manual.
Step 1 Before proceeding, gear preload and initial position must be set.
Confirm that all upper blade bolts are torqued to 150 in.-lbs. and all
lower blade bolts are torqued to 220 in.-lbs.
Step 3 Rough tune blades to cut wet 90-lb. liner across entire width of the
blade, but not 100% of fibers. Do not advance the knife blade by
more than 1/12 of a turn on the adjusting screw at a time.
Step 4 Manually rotate the blades forward through the cut. If the torque
required to rotate the blades through the cut has increased or the
blades will not pass through the cut (NEVER FORCE THE BLADES
THROUGH THE CUT), you have adjusted the blades too tightly
together. See "How To Loosen Tight Blades" in the Maintenance
Adjustments section of this manual.
Step 5 Torque the upper blade bolts to 220 in.-lbs. Apply medium grit
lapping compound (220 grit) to the upper knife blade, close the knife,
and lap for five minutes. Reapply the medium grit lapping compound
and lap (five minutes) two more times.
Step 6 Using the graduated microscope, inspect both the upper and lower
blade lapping areas for a minimum .015" surface wear measured from
the tip of the blade down.
Step 7 Loosen and retorque the blade bolts to 150 in.-lbs. Rough tune the
knife to cut (not every fiber) wet 90-lb. liner paper across the entire
width of the knife blade. Do not advance the knife blade by more than
1/12 of a turn on the adjusting screw at a time. You want to slowly
bring the knife blades in together and allow the lapping procedures to
"seat in" the knife blades.
Step 8 Retorque blade bolts to 220 in.-lbs. Apply fine grit lapping compound
(320 grit) to the upper knife blade, close the knife, and lap for five
minutes. Reapply the fine grit lapping compound and lap (five
minutes) two more times.
Step 9 Loosen and retorque the blade bolts to 150 in.-lbs. Final tune the
knife to cut (not every fiber) wet 90-lb. liner paper across the entire
width of the blade. Do not advance the knife blade by more than 1/12
of a turn on the adjusting screw at a time.
Step 10 Torque the blade bolts to 220 in.-lbs. and torque the two socket head
bolts to 300 in.-lbs.
Step 11 Apply a film of oil to both blades and manually rotate the blades
forward through the cut. If the torque required to rotate the blades
through the cut has increased or the blades will not pass through the
cut (NEVER FORCE THE BLADES THROUGH THE CUT), you
have adjusted the blades too tightly together. See "How To Loosen
Tight Blades t' in the Maintenance Adjustments section of this
manual.
Step 12 Check that the wick lubricator is oil soaked and has been making
contact with the knife blade. Reassemble wick lubricator and adjust
wick height if necessary.
Step 13 Check to be sure all tools are cleared from the knife, roll in the infeed
section (all levels), reposition the infeed skid pan to the run position,
and close up the knife.
The pull roll will require occasional replacement due to wear on its urethane
cover. Use the following procedure to remove it with minimum effort.
Step 1 Turn off main disconnect on the drive cabinet for all levels of the
knife and lock them out. Leave the compressed air on.
Step 3 Lift the upstream edge of the infeed skid plate to its upper resting
position to allow clearance for the upper roll out infeed section to
pass.
Step 4 Release the two latches retaining the upper roll out infeed section.
Step 6 Release the two latches retaining the lower infeed section.
Step 8 Remove all locknuts that connect the roll coupling hub to the disc
pak. While loosening hardware, turn the locknut only. Disconnect
resolver connector from housing on motor. Support the roll drive
motor and unbolt motor mounting bracket from motor mount bearing
plate. This will allow removal of an assembly consisting of motor,
motor mounting bracket, coupling hub, and coupling center member
assembly. Support assembly or set on floor until installation, saving
all hardware.
Step 9 Sling the roll at its center and remove the slack from the sling. Loosen
the bearing on the left side of the machine and increase the strap's lift
on the roll until it supports the roll's weight. Remove the bearing's
bolts. Remove the bolts from the bearing on the other end of the roll.
Remove the roll by allowing the right side to lift first, until the shaft
and hub on left end can be pulled through the hole in the bearing
mounting plate and frame. Do not remove the bearing mounting plate
from the side frame because it is shimmed to side plate for close
tolerance. With roll removed, loosen coupling hub setscrews. Apply
heat to coupling hub and remove with puller because hub was
mounted using Loctite (heat hub uniformly and do not overheat).
Remove both bearings.
The exit roll will require occasional replacement due to wear on its urethane
cover. Use the following procedure to remove it with minimum effort.
Before turning power off, raise the holddown nips to provide better access to the
exit roll. Turn electrical power off but leave the compressed air connected.
Step 1 Remove all locknuts that connect the roll coupling hub to the disc
pak. While loosening hardware, turn the locknut only. Disconnect
resolver connector from housing on motor. Support the roll drive
motor and unbolt motor mounting bracket from motor mount bearing
plate. This will allow removal of an assembly consisting of motor,
motor mounting bracket, coupling hub, and coupling center member
assembly. Support assembly or set on floor until installation, saving
all hardware.
Step 2 Remove the stripper plate and its mounting bracket just downstream
of the roll. Remove bearing mounting screws and remove jam detect
pan. Sling the roll at its center and remove the slack from the sling.
Loosen the bearing on the right side of the machine and increase the
strap's lift on the roll until it supports the roll's weight. Remove the
bearing's bolts. Remove the bolts from the bearing on the other end of
the roll. Remove the roll by allowing the left side to lift first, until the
shaft and hub on right end can be pulled through the hole in the
bearing mounting plate and frame. Do not remove the bearing
mounting plate from the side frame because it is shimmed to side
plate for close tolerance. With roll removed, loosen coupling hub
setscrews. Apply heat to coupling hub and remove with puller
because hub was mounted using Loctite (heat hub uniformly and do
not overheat). Remove both bearings.
Step 4 Reinstall jam detect pan. Reinstall stripper plate and its mounting
bracket.
Step 1 Remove the holddown wheel pivot tube from the infeed section as
follows: disconnect air cylinder rod end and socket head shoulder
bolts supporting the infeed holddown pan. Next, unbolt the 2-bolt
flange bearings from the pivot tube mounting pad. Do not remove the
bolts attaching the pad to the infeed section since they are
pre-adjusted at Marquip. Remove assembly from machine.
Step 2 Remove the 2-bolt flange bearings on each end of the holddown
wheel shaft.
Step 3 Loosen lock collars at the ends and center of the holddown wheel
shaft.
Step 4 Using a hammer and a block of wood, drive the holddown wheel shaft
out far enough to remove the holddown wheels.
Step 6 Repeat Steps 4 and 5 for the other side of the pivot tube.
Step 7 Center infeed roll in pivot tube assembly, tighten all lock collars, and
install the 2-bolt flange bearings on both ends of the holddown wheel
shaft.
To replace the resolver, first turn off the main disconnect and lock it out.
Manually rotate the knife cylinders until the blade tips separate enough to pass a
C-flute board between them on the left side of the knife. (Refer to Maintenance
Adjustments section for the proper procedure for manual rotation of the knife
cylinders.) Remove the manual rotation shaft, roll in the infeed section, and
replace all guards.
Loosen the two clamp screws on the end of the coupling nearest the side frame.
Remove the four resolver mounting bolts and remove the resolver and coupling
assembly. Disconnect the shaft coupling and the power cord connector. Before
bolting the new resolver in place, it is necessary to properly position its shaft. This
is accomplished with power on, so be very careful. Connect the power cord to the
new resolver.
Clear the knife area of all people. Turn on the main disconnect. Turn on
CONTROL POWER.
The resolver shaft position is indicated by three small lights on the junction box
shown in figure 2. When the resolver shaft is correctly positioned, only the center
light is on. When either of the other two lights flash, the resolver is incorrectly
positioned. The faster they flash, the closer the resolver is to the correct position.
Hold the resolver in your hand with its mounting holes in line with the mating
holes on the mounting flange. Rotate the shaft near the correct position and slide
the coupling on the shaft in a position that will allow access to the clamp screws
when the coupling is in the mounting flange. Clamp the coupling to the resolver
shaft.
Slide the resolver and coupling into the mounting flange while carefully guiding
the coupling over the drive shaft. Bolt the resolver in place. Position the resolver
shaft by rotating the coupling, using the three lights as a guide. Then clamp the
coupling to the drive shaft. If the clamping causes the resolver to lose position, the
resolver mount may be rotated to correct it by loosening the clamp on the
mounting flange.
Step 1 Turn off the main disconnects for all knife levels and lock them out.
Step 2 Open the left side doors (looking downstream). The tachometer is
enclosed in an aluminum housing near the knife drive motors.
Remove the cover on the conduit fitting to expose the tachometer
leads. Remove the tachometer cover and carefully thread wire
through the cover while pulling the cover away from the tachometer
housing.
Step 3 Remove the four screws holding the brushes in place. Remove the
worn brushes and insert new ones. Replace the retaining screws.
Step 5 Carefully replace the brush ring assembly so as not to damage the
brushes.
CAUTION: When replacing the cover, pull all excess wire into the
conduit fitting to prevent wire from rubbing on rotating shaft.
Step 1 Ensure main breaker is off and capacitors are bled down.
Step 2 Align the scribe marks on the motor rotor shaft with the scribe marks
on the motor tail bell.
Step 3 Loosen the flex coupling at both the resolver and the motor.
Disconnect the resolver cable.
Step 4 Remove the four 10-32 bolts securing the resolver to the resolver
mount and remove the resolver. There is no need to remove the
aluminum resolver mount.
Step 5 Install the new resolver and coupling (make sure cable connector is
facing down and to the right). Do not tighten the coupling. Connect
the resolver cable.
Step 7 Two people are required to set up the resolver position. With one
person watching the LEDs on the sine/cosine card, the other person
can rotate the resolver coupling until ALL LEDs on the sine/cosine
card are on or off.
Step 8 With the coupling still loose, turn the coupling until most of the LEDs
are on or off. The setscrews in the coupling should be facing the same
way as the resolver connector. This is to provide clearance to tighten
the connector. Tighten the coupling on the resolver side.
Step 9 Rotate the coupling on the motor side until ALL LEDs are on or off.
Step 10 Keeping all LEDs on or off, tighten the coupling on the motor side.
Step 1 Set toggle SW2 in down position to disable torque teaser function
(default mode).
Step 2 Jumper J2 pin 1 to pin 2 on torque teaser cards, if torque teasers are
being used with a 0-10 volt line speed signal.
Step 3 Jumper J2 pin 3 and pin 4 and remove jumper J2 pin 5 and pin 6 on
torque teaser cards, if torque teasers are being used with a Marquip
Slitter/Scorer.
Step 4 Jumper J2 pin 5 and pin 6 and remove jumper J2 pin 2 and pin 3 on
torque teaser cards, if torque teasers are not being used with a
Marquip Slitter/Scorer.
NOTE: There are two existing pull/exit roll options on the Marquip Knife. The
correct DIP switch and jumper configuration is dependent on the type of knife.
The following is a summary of pull/exit roll options and the configurations for
each type:
Option 1 Direct drive pull/exit rolls with square, brown brushless motor.
Option 2 Direct drive pull/exit rolls with round, black brushless motor.
Option 1 Close SW1-2, SW1-4, and SW1-6 (1.66 volts at test point B)
Option 2 Close SW1-3, SW1-5, and SW1-6 (2.12 volts at test point B)
FROM TO
NOTE: Attach flat cable from appropriate header on the slip detect card to J1 on
the torque teaser card of that level.
UPPER KNIFE
Step 4 Monitor test point A with a digital voltmeter. Adjust P1 for 1.8 volts
at test point A.
Step 6 Monitor exit roll speed. Adjust P3 for an exit roll speed of 240 FPM.
NOTE: You may want to put the torque teaser card on an extender board during
the slip detect card setup so you will not have to turn off power and remove the
torque teaser when torque teaser DIP switches are changed.
Step 1 Set DIP switches on upper torque teaser card as follows: DIP Switch
SW1-5 closed and all others open. NOTE: SW2 should be in down
position (disabled) to put the torque teaser in default mode.
Step 3 Observe LED 1-10 on the slip detect card. (LED 1 corresponds with
the upper knife, LED 2 with the middle knife, and LED 3 with the
lower knife.) If the LED is on or flashes frequently, close DIP switch
SW1-8 on the slip detect card.
Step 4 If LED 1-10 is still on or flashes frequently, close DIP switch SW1-7
on slip detect card and open DIP switch SW1-8 on the slip detect
card. Continue closing DIP switches on the slip detect card in a binary
sequence (DIP switch SW1-8=LSB, SW1-1=MSB) until LED 1-10
goes off and stays off.
Close SW1-8
Open SW1-8, Close SW1-7
Close SW1-8
Open SW1-8, Open SW1-7, Close SW1-6
Close SW1-8
Open SW1-8, Close SW1-7
Close SW1-8
Open SW1-8, Open SW1-7, Open SW1-6, Close SW1-5
Close SW1-8
Open SW1-8, Close SW1-7
Step 6 Return DIP switches on the torque teaser card to the default torque
limit setting.
Step 7 Close SW2 on torque teaser card (up position). This enables the
torque teaser. To disable the torque teaser and go to default torque
limit, SW2 can be opened at any time.
Serial No.: 13817-1000 - 98" Double Integral Drive Model III Knife
Direct Drive Pull/Exit (Mechanical)
Level 3
Level 3
Level 1
Level 3
Level 1
Level 3
Level 1
Level 3
Level 3
PNEUMATICS
Level 3
5061030 Regulator 2
5046680 Valve 2
TOOLS
Level 3
LUBRICATION
Level 3
Level 1
Level 3
Level 2
Level 3
MISCELLANEOUS
Level 3
Serial No.: 13817-1000 - 98" Double Integral Drive Model III Knife
Direct Drive Pull/Exit (Electrical)
MACHINE COMPONENTS
Level 3
Level 1
Level 2
Level 3
DECC CONSOLE
Level 1
Level 1
Level 2
Level 3
CTM (OPTION)
Level 1
Level 3
MACHINE WIRING
Level 3
Level 3
For your safety, you will receive training on your new Marquip equipment. The
following section is an outline of training that you will receive at the time of
installation. Included in this section is a quiz. This quiz will be administered by
Marquip Field Service while on the job site. An attendance list will be taken at
that time and kept on file at Marquip. The quiz is broken down into two parts. Part
one is the operator section. Parts one and two is the maintenance section. It is our
opinion that maintenance should not only be able to maintain the machine, but
also must be able to operate the machine. These quizzes will reinforce the safe
operation and maintenance guidelines for your machine. It is recommended that
this section be kept on file for future use. This information should be passed on
and the quiz taken by any new operators and maintenance personnel.
Customer Date
F/S INITIALS
2. Operator controls
A. Disconnects (drive cabinets, operator console)
B. Safety keyswitch
C. Stop and E-stop
D. Manual or jog controls
Date
Date
Date
Date
Date
Customer Date
F/S INITIALS
3. Component location.
8. Troubleshooting (prints).
9. Preventive maintenance.
Date
Date
Date
Date
Date
Name:
Circle the correct answer. There may be more than one correct answer for each
question.
1. You turn on the one remaining control lockout keyswitch when starting
the knife. What should you do if the key breaks off?
a. Go ahead and run the knife.
b. Notify the maintenance department when you get the chance.
c. Stop immediately and notify maintenance and your supervisor.
2. Before you start running the knife, you find a safety sign laying on the
floor. You then go ahead and
a. run production - the sign does not affect production.
b. throw the sign away.
c. put the sign on the operator's console.
d. notify your supervisor and maintenance before you do anything else.
3. Assume all of your safety switches are okay. It is safe to open the top
covers of your knife while AUTO is turned on. T/F
4. When you turn off the keyswitch, it is then safe to enter the knife.
T/F
5. When clearing a jam inside the knife, you must have the keyswitch off
and in your pocket, plus
a. the main disconnect off.
b. B. all incoming power off and verified that it is off.
c. C. the main disconnect off and capacitor banks verified to be at O
volts by observance of the warning LEDs mounted on the door.
7. If the roll out section is out, before repositioning it correctly, you must
a. find some help and roll it in.
b. roll it in yourself if no help is available.
c. make sure the path is clear for the rolling infeed assembly.
9. On Monday start-up you find this object that looks like a guard. To
dispose of it properly, you would
a. throw it in the junk barrel.
b. use it for a seat.
c. call maintenance to find out where it belongs.
10. You have turned AUTO off, CONTROL POWER off, and safety
keyswitch off and the keys are in your pocket. Before you did this, you
raised the rolls to clear a jam. It is now safe to reach in between the exit
rolls to remove a scrap jam. T/F
11. The knife has CONTROL POWER and AUTO turned on with no line
movement. Facing the knife as board would flow, you open the left side
door. AUTO does not drop out. You would then
a. ignore it, close the door, and run.
b. leave the door open.
c. check to see if there is a limit switch on the door.
d. call maintenance and have them check the limit switch.
12. The knife is in a normal run at 350 FPM line speed. You depress the
E-stop button and
a. the knife gives out an E-stop to the line and follows the line to a
stop.
b. does an E-stop.
c. shuts off all power immediately.
d. gives an E-stop to the line and stops all motion of cylinders and pull
exit rolls as fast as possible.
13. In a normal stop (stop button was pressed), the knife follows the
corrugator to a stop. T/F
14. The pull/exit holddown wheels will not raise. AUTO is on and you have a
jam in the knife. One reason for them not to raise could be that
a. somebody turned off the air going to the knife.
b. board is jammed over the top of them.
c. the valve is jammed from the board.
d. AUTO is on.
16. The stacker operators complain about this short piece of scrap about 20"
long that comes out at the start of a setup. One way you might get rid of it
would be
a. to shut the knife down and call maintenance.
b. to check for jams following all safety rules.
c. to make sure the pull/exit rolls are turning.
d. you cannot get rid of it. You cannot avoid the trim cut that the knife
is programmed to cut at the start of each setup.
17. If the operator gets a random shutdown with a low airflow diagnostic,
maintenance should
a. ignore it. It only happens once a shift.
b. jumper out pressure switch.
c. check airflow, replace filter if necessary.
18. Your Model III Direct Drive Knife has identical upper and lower levels.
However, there are certain items that are used by both levels in normal
run to determine cut length and if the knife senses board. They are
a. knife profile computer.
b. web measuring assembly and web entering photoeyes.
c. web detect photoeye and web entering photoeyes.
d. web measuring assembly, web detect photoeye, and web entering
photoeyes.
e. none of the above.
19. If you only wanted to work on the wick lubricator on the lower level and
you were pressed for time, you could do this by disconnecting and
locking out the lower level only. T/F
20. The knife will be down for the weekend and operators and maintenance
will be working on it. Before total shutdown and lockout, per safety rules,
additional accident prevention steps might be to
a. jog knife to closed position to protect blades and personnel from
contact.
b. shut off air to knife.
c. clean knife and below knife thoroughly.
d. do all of the above.
23. Checking for no voltage at the capacitor side of the Regen card
a. can alert you to possible stored energy that could be accidentally
discharged through the drive amps.
b. confirms that the knife is electrically powered down.
24. What would you do if the capacitor banks had not been discharged?
a. Alert your supervisor to the problem.
b. Call in a certified electrician to troubleshoot the problem.
c. Both A and B.
25. The pull/exit rolls will turn if stepped on with the main disconnect locked
out. T/F
26. Movement of the jam detect pan, located between the knife cylinders and
exit roll, due to a jam or wrap-up will trigger an E-stop on the
27. The wick lubricator flow control on a Model III is located on the
right-hand side of the knife. T/F
28. To save time when tuning blades, it is okay to have two men in the knife.
T/F
29. Spot tuning should only be considered if you do not have the time to
completely retune the knife blades because of a pressing production
schedule. T/F
30. When inspecting the knife blades for a sharp tip after lapping, you only
need to inspect the upper knife blade tip. T/F
31. You should never rotate the knife blades forward through the cut with
lapping compound on the blades. T/F
32. A sharp knife blade tip is one where the lapping wear lines extend from
the tip of the knife blade down the blade surface. T/F
35. You should always tune the knife blades working from the right to the
left. T/F
36. Anytime you rough tune you should try to cut every fiber of the wet 90-lb.
liner. T/F
37. To prevent galling blades, you must apply a film of oil to those blade
areas which do not have lapping compound. T/F
38. Because blades are very sharp, you must wear cut-resistant gloves. T/F
39. You can spot tune more than two times without a complete retune of the
knife blades. T/F
40. You should use the microscope with the graduated scale attached to
inspect the knife blade tips. T/F
42. For how long is a nonserrated knife blade considered to be still hot
enough to final tune them to cut every fiber of the wet 90-lb. liner paper?
a. 1 hour.
b. 2 hours.
c. 3 hours.
43. A sudden loss of cut quality over a wide area of the knife blades is one
reason to check for loss of gear preload. T/F
44. You must always retorque the upper knife blade bolts one at a time to 150
in.-lbs. for tuning. T/F
45. When you rough tune the knife blades, you should never advance the
blade by more than 1/12 of a turn on the adjusting screw at a time, and
you should not try to cut every fiber of the wet 90-lb. liner paper. T/F
46. If you were to tune the knife blades to cleanly cut all the fibers of the wet
90-lb. liner paper when they were cold (i.e., after 2 hours of production
shutdown), what would happen?
a. When the knife was put back into production, the knife cylinder and
blade temperature would rise. This rise in temperature would cause
the metal to expand, causing the blade tune to tighten, causing
possible damage to the knife blades, and reduce knife blade tune
life.
b. The knife blades would be tuned tight and the knife would cut very
well at operating temperature.
47. You need to tape over the blade bolt holes to prevent the lapping
compound from filling the recessed bolt holes. T/F
48. The maximum torque difference when checking blade pass should not
exceed
a. 150 in.-lbs.
b. 75 in.-lbs.
c. 220 in.-lbs.
d. 25 in.-lbs.
50. After gear preload is set, which pair of jackscrews are in opposition with
one another and are used to set initial position?
a. Screws A and B.
b. Screws C and D.
c. Screws D and A.
51. It is important to torque down the hub lock bolts to their proper torque
specifications to prevent the hubs from moving when all four jackscrews
are torqued to their final torque specifications. T/F
52. It is important to loosen and retorque one knife blade bolt at a time.
a. Yes, this is important.
b. No, this does not matter at all.
53. You can jog the pull/exit rolls under which conditions?
a. CONTROL POWER on and AUTO off.
b. CONTROL POWER off and AUTO on.
c. CONTROL POWER off and AUTO off.
d. CONTROL POWER on and AUTO on.
54. When the photoeye at the web measuring assembly senses a gap in the
web, you transfer the board position input to the pull roll. T/F
55. The knife profile computer on a Model III will shut down two drives if
one drive is not producing armature current. T/F
56. On Model III Knives, board sense is enabled by first receiving a web
entering signal and then a sense forks input. T/F
57. If you have a web entering photoeye failure, you can jumper it out of the
circuit and continue to run normally. T/F
58. The web severed signal from the shear enables the knife to track the tail of
the expiring web. T/F
59. At the time of shear cut plus 6", the knife transfers its measuring source
from the web assembly to the pull roll. T/F
61. One reason for a knife not to cut during a tailout with a shear cut might be
because
a. the pull roll motor resolver binary input to knife profile computer is
inoperative.
b. board detect photoeye is defective.
c. the number of cuts for the setup had not been reached.
d. the web resolver is defective.
63. The knife profile computer can correct a constant cut length error up to
±10%. T/F
64. The corrugator run signal causes the pull/exit roll drives to be enabled.
T/F
65. You hear a growl in the knife that sounds like the gears are coming apart
on one level only. One logical check may be the
a. cylinder feedback tech.
b. measuring roll jam detect proximity sensor.
c. exit roll tech.
66. If the knife loses board sense at anytime in a run, it goes to the cocked
position. T/F
69. The knife profile computer waits approximately how many seconds after
being informed of a malfunction on one drive amplifier before it disables
the entire rack?
a. One second.
b. Two and a half seconds.
c. 20 seconds.
d. Ten seconds.
70. The knife profile computer will keep a rack enabled if it sees the
corresponding LEDs for that rack on the current sense card blink at least
once every two seconds. T/F
71. To determine the speed of the knife cylinder, the knife profile computer
must know
a. the exact position of the board by use of web resolver.
b. where it is supposed to cut by use of a length input from the operator
interface computer (OIC).
c. the velocity and position of the cylinder using cylinder tech and
cylinder resolver.
d. all of the above.
72. The drive amp does no computing of its own outside of the self-monitor
circuits/diagnostics. T/F
73. The knife cylinder drive amp gets its information in the form of a current
command. This command comes from
a. the current sense card.
b. the pull roll tech feedback.
c. the speed reference signal.
d. the knife profile computer.
e. all of the above working together.
74. If one motor or rack on the knife fails, the other motors and racks are
working harder to maintain operation. T/F
75. If the pull and exit rolls never enable or pull in their contactors, you might
be missing
a. a speed reference signal.
b. a speed command from the pull exit card.
76. In the knife drive racks, you have one power supply feeding or supplying
two drive amps with a high voltage/ampere source and a low voltage logic
supply. T/F
77. If you had lower voltage than recommended supplying the power supply
in the drive rack, what would be a logical assumption?
a. Motors would last longer.
b. Drive amps would not have to work as hard.
c. Speed specifications would remain the same.
d. All of the above are wrong.
1. C 26. True
2. D 27. False
5. C 30. False
6. B 31. True
7. C 32. True
9. C 34. A
17. C 42. B
21. B 46. A
23. A 48. B or D
24. C 49. A
52. A
53. A
54. True
55. True
56. False
57. False
58. True
59. True
60. B
61. A
62. C
63. True
64. True
65. A
66. True
67. C
68. C
69. C
70. True
71. D
72. True
73. D
74. True
75. D
76. True
77. D
Field experience has shown a potential problem area on the Marquip Direct Drive Knife. The
problem being a build up of dust, small pieces of scrap, etc., in a confined area directly under the
exit roll.
If contaminant is allowed to build in this area, it will eventually start to interfere with the exit roll
causing additional drag, and effect exit roll speed. This may result in Jam ups and/or leading edge
sheet damage.
If the build up is not removed, it will result in additional wear and/or premature failure on the exit
roll and drive components.
To prevent this problem, Marquip recommends this area to be cleaned on a tally basis with air
pressure directed in below the exit roll from each end and also through slots between the exit roll
and stripper plate. This area should also be visually inspected periodically by using a flashlight in
one end and a mirror on the other.
The first time this area is cleared you may also get a speed change in the exit roll. To correct this
do a normal pull/exit roll card set up as described in your knife manual.
H. Dee Welch
Field Service Manager
/cb 9/26/88
1
P.O. Box 28 ?1300 North Airport Road Phillips, WI 54555 715-339-2191
Service Bulletin
DATE: January 20, 1989 BULLETIN NO.: 109
MACHINERY TYPE: Knife SUBJECT: Cut Length Accuracy
MACHINERY MODEL: All APPLICABLE CATEGORY: Informational
PROBLEM:
When we have investigated reported cut length variation problems, we have frequently found that
the measuring wheel was not properly installed.
Solution:
1. The structure to which the measuring wheel assembly is attached must be free from any
vibration. This means that it should not be mechanically attached to the double backer or
any other machine. Where possible the structure should be connected directly and securely
to the floor.
2. The table under the measuring wheel must be of metal. If it is made of wood or a plastic
laminate it will wear over time and not provide the necessary support for the web and thus
the web wheel.
3. The table must be as level as possible in cross machine direction. Any out of levelness will
cause the castored wheel to weave from side to side and not correctly measure board travel.
4. The height of the table at the point of contact of the measuring wheel must be such that no
gap ever occurs between the table and the web. A slight bias upward of the table may be to
your advantage.
5. The routing of the multi-conductor cable to the encoder shall be made in a way to give equal
freedom of travel of the castored measuring wheel assembly -- right or left.
6. The table under the measuring wheel must be dimensionally stable as it undergoes wide
temperature changes. Caution should be used in the fabrication of tables with a thin metal
surface which could buckle and oil-can.
7. The table under the measuring wheel should be inspected frequently to assure that no welds
or bolts have loosened or have broken due to thermal cycling or operators walking on table
to remove scrap or do maintenance.
8. The height and weight of the measuring wheel must be kept adjusted per the knife mainte-
nance manual.
H. Dee Welch
Field Service Manager
HDW/cb
1/20/89
In order to reduce the cost of pull/exit roll replacement or recoating, the rolls can be reground to
provide a smooth and uniform diameter. The reground roll. will perform like a new roll. Versus a
glazed and non-uniformily worn roll, the reground roll will improve tailout accuracy and reduce
board skew.
A standard machine lathe with roll grinding attachments is required to successfully grind the rolls.
The L.R. Oliver and Co., Inc. of Anchorville, NI manufactures both roll grinding wheels (Rubber-
hog) and grinding attachments. The roll grinding attachments are custom made to meet each cus-
tomers specific centerline height and bolt pattern. To provide the correct surface finish, an 8 inch
O.D. X 1 1/2 inch wide SSG 330 grinding wheel is recommended. In order to get the best overall
performance during the roll grinding process, the following criteria must be met:
Please contact L.R. Oliver and Co., Inc. for more details on proper roll speed and transverse
speed.
The roll diameter must not be ground to below 5.750 inches or positive drive contact with the
board may be lost. Take only as much material as needed off of the roll. After installing the rolls,
insure both the infeed and outfeed holddown wheels are adjusted properly. Refer to your knife
maintenance manual for further details. If your knife has a wrap around exit roll stripper, check to
insure the stripper is at least 1/16 inch below the roll. Lastly, do a complete knife speed set-up.
H. Dee Welch
Field Service Manager
3
P.O. Box 28 ?1300 North Airport Road Phillips, WI 54555 715-339-2191
Supplement
Top Cover Limit Switch Upgrade
LIMIT SWITCHES
Plunger-type limit switches indicate when open doors or guards should be closed
before starting Knife. Proper setup of switches is shown in the Limit Switches
figure.
SUPPLEMENT - 9432201 1
P.O. Box 28 ?1300 North Airport Road Phillips, WI 54555 715-339-2191
Supplement
MISCELLANEOUS SPARE PARTS
MARQUIP
PART NO. DESCRIPTION QTY.
Level 3
O-2
2 SUPPLEMENT
9635921 - OPERATION
- 9432201