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EASTMAN MPC 5000 Service Manual

Multi-ply automatic cutting system
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THE EASTMAN
Multi-Ply
Automatic Cutting System
Model: MPC 5000
WARNING
This machine is equipped with a very sharp
knife. Keep hands, arms, and hair away from
the knife area at all times.
Misuse of this machine or failure to follow all
safety instructions on this machine and in the
instruction manual may result in serious
personal injuries.
779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • (716)856-2200 • Fax (716)856-1140 or (716)856-2068
Form E-551
®
Service Manual
Manufacturers of Eastman Cloth Cutting and Cloth Spreading Machines
Website: www.EastmanCuts.com
Technical Support:
1-800-872-5595

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Summary of Contents for EASTMAN MPC 5000

  • Page 1 779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • (716)856-2200 • Fax (716)856-1140 or (716)856-2068 Manufacturers of Eastman Cloth Cutting and Cloth Spreading Machines Website: www.EastmanCuts.com Form E-551...
  • Page 2 Eastman determines that the goods or parts are defective in materials or workmanship, Eastman’s sole obligation under this warranty shall be, at Eastman’s sole option, to repair or replace the defective goods or parts or to provide the buyer credit equal to the portion of the purchase price allocable to the defective goods or parts. This warranty should not apply if defects are caused by product misuse or neglect, if the machine has been altered or modified by the buyer or if other than genuine Eastman parts are used in the machine.

  • Page 3: Table Of Contents

    Table of Contents Instruction for Aligning, Cleaning and Replacing Consumable Parts ..........4 Replacement of Knife ......................4 Replacement of Sharpening Wheels ................... 7 Replacement of Drill Rod ....................9 Replacement of Guide Bushing ..................11 Replacement of Vacuum Filter ..................13 Replacement of Bristle Block ...................

  • Page 4: Instruction For Aligning, Cleaning And Replacing Consumable Parts

    Instruction for Aligning, Cleaning and Replacing Consumable Parts Replacement of Knife Removing the Knife Remove the thumb screw found on the front portion of tool head cover which secures the cover to the tool head. Carefully swing the tool head cover and move it upwards to ensure it is in upper position. Ensure that the reciprocating housing is in upper position.
  • Page 5 Pull the knife away from the coupler being careful to keep hands away from the sharp knife edge. Ensure that the removed knife is placed in a safe area because it contains sharp edges that pose hazards. Form E-551...
  • Page 6 Tighten the clamping bolt. Lightly grease the outside diameter of the coupling assembly using Eastman No. 67-26324. Insert the knife along with the coupler and blade link from the top into the reciprocating housing. The below picture shows the knife and coupler assembly installed in the upper, middle and lower knife guide assemblies.

  • Page 7: Replacement Of Sharpening Wheels

    After aligning the upper portion of blade link return the two socket head cap screws and secure it using allen key. Replacement of Sharpening Wheels Removing the Sharpening Wheels Remove the thumb screw found on the font portion of tool head cover which secures the cover to the tool head.
  • Page 8 Replacing the Sharpening Wheels Using a clean dry cloth saturated with alcohol clean the mounting surfaces of the sharpening housing. Apply a few drops of “loctite 222 MS” on the end of screws which hold the sharpening wheels. Install the new sharpening wheels. Return the screws to hold the grinding wheels.

  • Page 9: Replacement Of Drill Rod

    Replacement of Drill Rod Removing the Drill Rod Remove the thumb screw found on the font portion of tool head cover which secures the cover to the tool head. Carefully swing the tool head cover and move it upwards to ensure it is in upper position. Using the supplied chuck key turn counter clockwise to loosen the drill chuck.
  • Page 10 Replacing the Drill Rod Lift the drill pressure foot high enough to install the new drill rod. Insert the new drill rod through the drill bushing into the drill chuck. Hold the drill rod in one hand and tighten the drill chuck using the chuck key as required. Form E-551...

  • Page 11: Replacement Of Guide Bushing

    Replacement of Guide Bushing Removing the Guide Bushing Remove the thumb screw found on the font portion of tool head cover which secures the cover to the tool head. Carefully swing the tool head cover and move it upwards to ensure it is in upper position. Using the supplied chuck key turn counter clockwise to loosen the drill chuck.
  • Page 12 Replacing the Guide Bushing Install the new guide bushing into the hole of the drill pressure foot. Since the guide bushing has (4) different size holes align the correct size hole which matches the drill rod. Rotate the guide bushing until the drill rod is aligned with the hole of the drill chuck. Tighten the set screw on the drill pressure foot and ensure that the drill rod is aligned with the hole in the guide bushing.

  • Page 13: Replacement Of Vacuum Filter

    Replacement of Vacuum Filter Removing the Vacuum Filter Using flat head screw driver remove the screws which hold the filter box cover plate. Remove the wing nut which holds the filter cover on filter housing. Remove the filter cover from mounting stud. Form E-551...
  • Page 14 Slide filter cartridge from the filter housing. Shake the cartridge over an open garbage can. Using clean dry compressed air blow out filter until clean. Replace with new filter if required based on inspection. Replacing the Vacuum Filter Install a new filter. Using vacuum cleaner remove all debris found inside the filter chamber.

  • Page 15: Replacement Of Bristle Block

    Replacement of Bristle Block Removing the Bristle Block Advance the conveyor to expose damaged bristle. Apply E-stop to prevent the conveyor and gantry movement for safely. Using a pair of pliers grab the bristle of the bristle block to be removed and pull from its aluminum slot. Replacing the Bristle Block Install the new bristle block by ensuring that the tab alignment is proper according to the slat arrangement on the aluminum slat.

  • Page 16: Replacement Of Polythene Rolls

    Replacement of Polythene Rolls Instructions Two persons are required one on either side of the machine. Lift up the bar which holds the plastic overlay tube and set it on flat surface. Pull out the bar from tube and insert into a new roll. Replace the bar on tower and thread under the elevation bar as required.

  • Page 17: Disassembly And Assembly Instructions For Parts Requiring Service

    Disassembly and Assembly Instructions for Parts requiring Service Replacement of X Motor Belts Removing the X Motor Belts Power down the machine using proper shut down / lock out procedures. Remove the (6) screws using hexagonal wrench found on the left and right side of covers from both the operator and non-operator side of the gantry.
  • Page 18 Remove the (4) screws found on either side of the electronics tray and swing the electronics tray outwards. Loosen the (4) screws of the motor and now the motor will drop down to loosen the tension on the belt. Form E-551...
  • Page 19 Cut the (2) zip ties found on the shaft support plate. Remove the (6) screws found on the shaft support plate. Rotate the shaft support plate to convenient orientation to get access to the belt. Form E-551...
  • Page 20 Loosen the belt guide and push it outwards so that so that it will help relieve the tension on belt. Remove the worn out belt. Replacing the X Motor Belts Take a new belt. Put it on the big pulley and roll it on the motor pulley a couple of times until it seats itself. Form E-551...
  • Page 21 Pick up the motor and put a screw driver under the motor housing and pick up the screw driver to get tension to the belt. Tighten the (4) screws of the motor to get the tension on the belt. Return the (6) screws back on the shaft support plate. Return the (2) zip ties found back on the shaft support plate.

  • Page 22: Replacement Of Y Motor Belt

    Replacement of Y Motor Belt Removing the Y Motor Belt Power down the machine using proper shut down / lock out procedures. Remove the thumb screw found on the front portion of tool head cover which secure the cover to the tool head.
  • Page 23 Remove the (3) screws on the operator side of the Y car and slowly open the electronics tray and ensure that no wires interfere. Form E-551...
  • Page 24 Remove the (2) screws found on the operator side on the Y pulley plate. Remove the (2) screws found on the T of the Y pulley plate. Form E-551...
  • Page 25 Remove the screws found on the non-operator side of Y pulley plate. Remove the pulley plate. Form E-551...
  • Page 26 Loosen the (4) screws which hold the Y-motor mounting screws to take off the tension. Loosen the belt and remove the worn out belt. Replacing the Y Motor Belt Take a new belt. Put it on the big pulley and roll it on the motor pulley a couple of times until it seats itself. Pick up the motor and put a screw driver under the motor housing and pick up the screw driver to get tension to the belt.

  • Page 27: Replacement Of Theta Motor Belt

    Return the screws found on the non-operator side of Y pulley plate. Return the (2) screws found on the T of the Y pulley plate. Return the (2) screws found on the operator side on the Y pulley plate. Return the (3) screws on the operator side of the Y car and slowly close the electronics tray and ensure that no wires interfere.

  • Page 28: Replacing The X-Axis Linear Bearings

    Replacing the X-axis Linear Bearings It is important to regularly inspect and replace the linear bearings on the Multi-Ply cutter. Properly maintaining your linear bearings with grease and regular replacement will prevent damage to the linear rails, increase life of spur gears, increase cutting performance and accuracy.
  • Page 29 Remove the (4) screws which hold the linear bearing block to the side plate. Repeat this step for all the (4) bearing blocks. Unscrew the backlash adjusting screw from the backlash adjusting block until the gantry is resting on the 2"...
  • Page 30 Installing New Bearings: Remove new bearings from package and press the Zerk grease fitting provided into the bearings. Using a grease gun and the grease gun adapter provided with machine, fill the bearings with white or clear lithium grease. Mount the bearing to the bearing block by securing it with (4) screws. Ensure the grease fitting is pointing to the outside of gantry for easy access.

  • Page 31: Replacing The Y-Axis Top Linear Bearings

    Replacing the Y-axis Top Linear Bearings It is important to regularly inspect and replace the linear bearings on the Multi-Ply Cutter. Properly maintaining your linear bearings with grease and regular replacement will prevent damage to the linear rails, increase life of spur gears, increase cutting performance and accuracy.
  • Page 32 Slide the (2) bearings out towards the operator side. Slide the (2) bearings out towards the operator side plate and remove them through the access relief / cutout. Installing New Bearings: Remove new bearings from package and press the Zerk grease fitting provided into the bearings. Using a grease gun and the grease gun adapter provided with machine, fill the bearings with white or clear lithium grease.
  • Page 33 Slide the new bearings unto the linear rail and ensure that bearing adjustment screws are accessible from the back of gantry. Be careful not to damage the bearing seals while mounting on the linear rail. Slide the bearings under the Y-car ad align with the mounting holes and secure back the (8) screws. After the replacement of new bearings check for the Y car backlash and adjust as required.

  • Page 34: Replacing The Y-Axis Front Linear Bearings

    Replacing the Y-axis Front Linear Bearings It is important to regularly inspect and replace the linear bearings on the Multi-Ply Cutter. Properly maintaining your linear bearings with grease and regular replacement will prevent damage to the linear rails, increase life of spur gears, increase cutting performance and accuracy.
  • Page 35 Disconnect all air lines by depressing the red color buttons and slightly pulling on the air lines. Disconnect the theta motor cable and theta feedback cable. Remove the (6) screws which secure the tool head to the Y-car assembly. Disconnect the laser pointer wiring from the back of Y-car assembly. Form E-551...
  • Page 36 Disconnect the positional sensor from the back of Y-car assembly. Remove the (8) screws which secure the linear bearings to the tool head interface plate. Lift the Y car slightly. Slide the (2) bearings out towards the operator side. Form E-551...
  • Page 37 Slide the (2) bearings out towards the operator side plate and remove them through the access relief / cutout. Installing New Bearings: Remove new bearings from package and press the Zerk grease fitting provided into the bearings. Using a grease gun and the grease gun adapter provided with machine, fill the bearings with white or clear lithium grease.

  • Page 38: Replacing Of Take-Off Conveyor Drive Belt

    Replacing of Take-off Conveyor Drive Belt Removing the Take-off Conveyor Drive Belt Power down the machine using the proper lock out / tag lock out procedures. Remove the (3) allen screws which secure the cover to the assembly on the operator side. Carefully remove the cover without disturbing the electronics connection.
  • Page 39 Loosen the (4) screws found on the side support. Remove the allen screw found on the end cover for additional clearance. Form E-551...
  • Page 40 Slide the motor plate to the left and remove the belt. Replacing of Take-off Conveyor Drive Belt Install new belt by sliding the belt on to the motor pulley first and then to the drive pulley. Slide the motor mount plate to the right to tension the belt until a ¼” belt deflection is achieved. Install the allen screw which is removed for clearance.

  • Page 41: Replacing Of Take-Off Conveyor Belt

    Replacing of Take-off Conveyor Belt Removing the Take-off Conveyor Belt Advance the conveyor belt until the zipper seam is exposed. Power down the machine using the proper lock out / tag lock out procedures. Remove the (7) screws found on the take-off transfer plate. Form E-551...
  • Page 42 Remove the transfer plate exposing the take-off conveyor tension roller. Remove the (4) screws found on the tension assembly cover plate which is located at the front on the operator side. Loosen the (2) screws found on the side frame. Form E-551...
  • Page 43 Loosen the tension jack screw to release tension on the belt. Repeat steps 5 through 7 on non-operator side. Using a pry bar or screw driver pull up the belt exposing the edge where the zipper seam is exposed. Using pliers pull the seam wire from the zipper seam. When the seam wire is removed the belt will come apart.
  • Page 44 Remove the belt from conveyor. Clean the wear surfaces found under the belt with a clean dry cotton rag. Replacing of Take-off Conveyor Belt Install the new belt back on the conveyor surface in the same way as it was removed. Ensure that the belt is underneath the lip of the side frame except for 10"...

  • Page 45: Replacing The Xmp Controller Card And Loading Configuration Files

    In the rare case that a Controller Card needs replacement, the loading of the proper Configuration Files should be done with the help of Eastman’s Technical Service Department. If the Multi-Ply Machine’s Computer is hooked up to the internet, Eastman’s Technical Service Department has the capability of remotely accessing your machine through the internet and loading the proper files for you.

  • Page 46: Adjustment Procedures And Specifications For Parts Requiring Service

    Adjustment Procedures and Specifications for parts requiring Service Checking and Adjusting Gantry Backlash This procedure ensures that the gantry drive gears are properly engaged to the gear racks so that pieces are accurately processed on the automated cutting machine. Performing this procedure also helps to minimize wear, repair, and replacement of gantry drive components.
  • Page 47 If no free movement in drive belt is found then backlash is okay. Replace cover assembly, ensure cable is reconnected. e) If free movement in drive belt is found then adjust the gantry backlash. Adjusting Gantry Backlash Remove all screws from gantry E-chain cover allen wrench & remove cover. (Although this step is not required, it allows for easier access &...
  • Page 48 Using an allen wrench, turn each of two (2) backlash adjusting screws ¼-turn clockwise into backlash adjuster block, raising gantry side plate, & raising gantry drive gear tighter into gear rack. Adjust screws so that gantry side plate remains level. Recheck gantry drive belt backlash.

  • Page 49: Checking And Adjusting Y-Car Backlash

    Checking and Adjusting Y-car Backlash Checking Y-car Backlash Power down the machine using proper shut down / lock out procedures. Hold the pulley and move the Y-car back and forth in Y direction and observe if there is any audible click or movement.
  • Page 50 Loosen the (4) screws of the pulley plate on either side of the Y-car. Tighten the (4) screws of the pulley plates on the non-operator side of Y-car. Pull the pulley plate towards the linear rack and tighten the (4) screws of the pulley plates found on the operator side.
  • Page 51 Using a screw driver or pry-bar apply pressure to motor belt to displace motor belt. Tighten the motor until there is no belt deflection. Tighten the motor mounting screws. Please note when ever the belt is replaced the backlash adjustment should follow. Form E-551...

  • Page 52: Checking And Adjusting Stop Discs

    Checking and Adjusting Stop Discs Checking Stop Discs Power up the machine. Move the stop discs to see if they are activated by a slight touch or vibration. If the stop discs are not activated by slight touch or movement are then adjust the stop discs. Adjusting Stop Discs Remove the operator side cover which will expose the stop disc mechanism.
  • Page 53 Tighten the set screw which in turn increases the force on the detent ball until sufficient tension is applied to the stop disc rod. Tighten the nut while holding the set screw in position. Return the cover. Check the operation of stop disc. Do the same check on non-operator side.

  • Page 54: Scheduled Maintenance Procedure

    30 minute weekly inspection and one hour monthly inspection. Time invested on these tasks will mini- mize downtime. Eastman Machine Company is not liable for damage as a result of poor maintenance and any resulting damage would be repaired at user’s expense. All maintenance should be performed by qualified personnel, following all safety procedures.
  • Page 55 • Lubricate table linear bearings with Eastman Lubricant 67-26324 (Mobil: NLG1 Grade 2 Moblith AW-2). • Lubricate knife coupling with Eastman Lubricant 67-26324. • Using compressed air, clean dust and debris from inside of Y-car. • Use clean cloth to wipe down Y-axis rails and lubricate.

  • Page 56: Lubrication Chart

    Lubrication Chart Below are the lubrication points for the Multi-Ply Cutter. Form E-551...

  • Page 57: Yearly Maintenance Checklist For Multi-Ply

    Yearly Maintenance Checklist for Multi-Ply Below is the recommended maintenance checklist for the Multi-Ply Cutter. It provides a good guideline for yearly maintenance and can be copied and kept as a maintenance log. Stop Discs are operational. y f i c t i &...
  • Page 58 T . I & i t s c t i & g i l & l l a t a l & t l e & l i o e l l c t i & c t i & e i l y f i &...
  • Page 59 t l e o i t & l i o l l u & i r i & i r i & l l u l l u & l l a o i t r t n r t n y r t i r i , r a...
  • Page 60 " 0 c t i c t i & e t l c t i n i l l l a & n i l l i a & l i o & & l l a Form E-551...
  • Page 61 t l e l l a & e l l e l l & l l a c t i c t i i f i l Form E-551...
  • Page 62 t l e n i l i t c & t f i l & l l i r t f i l y t i e l l n i l n i l y l l l e t c i l f t l &...
  • Page 63 t l i f l l a f i l e i l l l a & l l a Form E-551...
  • Page 64 l l a t l u l i f l l a t i n Form E-551...
  • Page 65 Additional Comments: Maintenance Signature: Date: Form E-551...

  • Page 66: Trouble Shooting Guides And Aides

    Trouble Shooting Guides and Aides UIT Error Messages This has to be developed by software hence it is on hold as of now. Form E-551...

  • Page 67: Additional Trouble Shooting

    Additional Trouble Shooting Any troubleshooting or maintenance performed on the machine should be done by a qualified technician. Before performing any work follow proper electric lockout procedures at your facility. All power to the machine should be off and proper care taken to prevent damage to the machine and/or injury. WARNING Failure to remove power and take proper safety precautions when performing maintenance and/or troubleshooting can result in injury or death.
  • Page 68 Operator needs to push above, below, right or left of the button for the command to take effect. Troubleshooting: The following procedure outlines the steps required to calibrate a touch screen on the Eastman Multi-ply gantry. If you notice buttons are not lined up while you are pressing them a Touch Screen calibration may be needed.
  • Page 69 With finger is still on touch screen have a co-worker turn on machine power. After the “Power On Setup” screen appears, remove your finger from the corner of touch screen. After the Power On Setup screen appears, use the left and right arrows to navigate, and select to enter a sub-menu.
  • Page 70 Follow the same procedure for the bottom right cross. Navigate to page 3 and toggle down to Save and Exit and select it. Your Touch Screen will restart in normal mode. It is ok to run the machineafter all proper startup procedures are followed.
  • Page 71 Problem: The Cutting Tool does not come down Description of Problem: A tool does not come down when cutting a file or they are delayed coming down at the beginning of a cut. This can be caused by an electrical short, tool mapping in software or a problem with the power supply. Troubleshooting: Make sure that Tool power on gantry is turned on.
  • Page 72 Make sure all yellow wires are securely attached to the Y-car slice output card. If any wires are loose refer to schematic for proper location otherwise call Eastman technical support. The Tool delays coming down and misses beginning of marking or cut.

  • Page 73: Rf/Emi Interference

    Interference (EMI). These signals in close proximity to the Eastman Multi-Ply cutter can generate electrical noise and cause problems for the machine and computer. (Eastman does offer a shielded mouse.) It is recom- mended that any RF Welders or other equipment generating RF or EMI noise be a minimum of 75 feet (23 meter) from the cutter.
  • Page 74 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. 115 VAC Black Main Disconnect Main Circuit Breaker See Dwg. 31-26515 See Dwg.
  • Page 75 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. From Transformer HPI-35 See Dwg. 31-26523 230 VAC Black /1.E5...
  • Page 76 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. TSIO - 6006 ANALOG INPUT Blue White/Blue Red (Black) White (Black)
  • Page 77 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. Table Remote E-Stop Boxes DB15 Screw Terminal E-STOP E-STOP Interface Block...
  • Page 78 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. See Dwg. 31-26519 3 Phase Circuit Breaker Black Black Line Filter...
  • Page 79 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- White/Blue See Dwg. 31-26549-MS out prior written consent of Eastman. Blue See Dwg. 31-26549-MS 24 VDC Common Tie White/Blue /12.D5...
  • Page 80 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. Belden 9367 (1TRD14) 230 VAC LF - X Black See Dwg. 31-26545-MS /2.A5...
  • Page 81 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- /9.B1 Blue +24 VDC - Y-Car out prior written consent of Eastman. /10.B1 /11.A1 230 VAC Fan /9.B1...
  • Page 82 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. SynqNet In Theta Motor Gantry Amplifier THETA MOTOR B+ White/Blue...
  • Page 83 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. KNIFE MOTOR B+ /8.A2 See Dwg. 31-26556 KNIFE MOTOR B- Black /8.A2...
  • Page 84 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. Air Cylinder Solenoids REF: 27-26050 Black +24 VDC - Y-Car...
  • Page 85 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, copied, used or disclosed to any third party with- out prior written consent of Eastman. See Dwg. 31-26565 Pause PB +24 VDC - X Blue /6.A1...
  • Page 86 These drawings and specifications are the prop- erty of Eastman and shall not be reproduced, FNQ-R copied, used or disclosed to any third party with- out prior written consent of Eastman. Takeoff Table - 115 VAC Black /1.D6 Line Filter...
  • Page 88 " 8 " 1 " 2 779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • (716)856-2200 • Fax (716)856-1140 or (716)856-2068 Manufacturers of Eastman Cloth Cutting and Cloth Spreading Machines Website: www.EastmanCuts.com Form E-551 ©2012 Eastman Machine Company Printed in U.S.A. 3/12...

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