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Highlight MAGNUM 4500 SD-R Operation Manual

Side drive random case sealer
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OPERATION MANUAL
MAGNUM 4500 SD-R
SIDE DRIVE RANDOM CASE SEALER
INCLUDES UNIFORM MODE OPTION
SERIAL NUMBER
Please refer to the serial number in all correspondence with Highlight or any Highlight
Distributor. This identifies your machine and will help in our ability to quickly and
efficiently respond to your needs.
Revision 1.4 – Feb, 2013

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Summary of Contents for Highlight MAGNUM 4500 SD-R

  • Page 1 SIDE DRIVE RANDOM CASE SEALER INCLUDES UNIFORM MODE OPTION SERIAL NUMBER Please refer to the serial number in all correspondence with Highlight or any Highlight Distributor. This identifies your machine and will help in our ability to quickly and efficiently respond to your needs.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. General System Information 1. System Specifications ……………………………………………………………………... I-1 System Overview Prints.…..……………………………………………………………… I-2 System Descriptions…..……………………..…………………………….………………. I-3 Tape Head and Tape Overview Prints……………………………………………..……. I-4 Tape Head Descriptions………………………………………………………………..…. I-5 Tape Threading Diagram……………………………………………………………….… I-6 Limited Warranty.…………………………………………………………………………. I-7 2. Installation Instructions Safety Precautions…………...……………………………………………………………..

  • Page 3: General System Information

    Chapter Chapter 1 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® General System Information...

  • Page 4: Electrical Data

    MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL SYSTEM SPECIFICATIONS Highlight’s Magnum® 4500 SD-R is a side belt drive case sealer designed to provide accurate, consistent tape application to random size cases. Highlight’s 200 series tape head will accept any 2-inch case tape and provide optimum case sealing to the top and bottom of the case.

  • Page 5: System Overview Prints

    MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL SYSTEM OVERVIEW PRINTS OFF ON Figure 1-1: Magnum® 4500 SD-R Views HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 6: System Descriptions

    Lower Tape Head Emergency Stop Button Tower Sensor Plate Electrical Control Panel Machine Body Electrical Control Box Main Power Switch Adjustable Leg Figure 1-3: Magnum® 4500 SD-R, Parts Description HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 7: Tape Head And Tape Overview Prints

    2”W Tape 3”W Tape 2” Tape Legs / 15.25”L Frame – REGULAR DUTY ***Tape heads w/ 2” tape legs are suited for general duty applications *** 2" or 3” HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 8: Tape Head Descriptions

    MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL TAPE HEAD DESCRIPTIONS HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 9: Tape Threading Diagram

    MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL TAPE THREADING DIAGRAM NOTE: Be sure EMERGENCY STOP button is pushed in before threading the tape and pulled out when tape is threaded. HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 10: Limited Warranty

    Highlight’s instructions. In no event regardless of the cause, shall Highlight be liable for penalties or penalty clauses of any description or any damages resulting from loss of profits, use of products or for any incidental indirect or consequential damages, even if advised of the possibility of such damages.

  • Page 11: Installation Instructions

    Chapter Chapter 2 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Installation Instructions...

  • Page 12: Safety Precautions

    Know the knife’s location BEFORE attempting to load and thread tape, or to make any tape head adjustments. NOTE: SEVERE INJURY AND/OR EQUIPMENT DAMAGE could result from failure to comply with the above. II-1 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 13: Positioning Of The Machine

    Inspections Before installation, inspect the entire machine for visual damage. If found, please report this damage to the truck line. Highlight Industries has taken every precaution during the packaging and loading of this equipment. However, it is YOUR RESPONSIBILITY to inspect for damage before installation.

  • Page 14: Machine Set-Up

    6. Select the desired mode (R1 or R2), then press STOP button. Wait a few seconds then press the START button. 7. While the machine is running, check if all the functions are working properly. II-3 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 15: Operation Instructions

    Chapter III. Chapter 3 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Operation Instructions...

  • Page 16: Safety Precautions

    Know the knife’s location BEFORE attempting to load and thread tape, or to make any tape head adjustments. NOTE: SEVERE INJURY AND/OR EQUIPMENT DAMAGE could result from failure to comply with the above. III-1 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 17: Belt Adjustment

    TIMES! Failure to comply could result in SERIOUS PERSONAL INJURY! A. Centering the tape on rollers: 1. Make sure the tape is pushed fully against the backstop fingers (see figure below). III-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 18 (which will also turn the spindle) clockwise or counter- clockwise until there is about ¼” gap between the support plate and the backstop fingers (see figure below). ¼” 4. Tighten the retaining nuts. III-3 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 19 Too much braking force applied to the tape will cause poor tape application and may lead to tape tabbing on the trailing tape leg. III-4 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 20: Spring Adjustment

    Highest possible tension setting shown above. -Inner screw position on rear roller arm -Outer screw position on rear roller arm -Loosened threaded rod position -Tightened threaded rod position III-5 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 21 BEFORE PUTTING THE TAPE HEAD BACK INTO SERVICE, ALWAYS CHECK THAT THE BLADE GUARD PROTECTS THE BLADE AND ALSO ALLOWS THE BLADE GUARD TO RETRACT WITHOUT INTERFERENCE ** III-6 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 22 Move blade arm extension “B” outward to increase the rear tape leg length and move “B” inward to shorten the rear tape leg length. Blade Arm Blade Arm Extension(B) Extension(B) TAPE TAPE Front Back Front Back III-7 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 23: Force Adjustment

    This should be set to 30-40 PSI for most case types. Too little belt squeezing pressure and the cases will stall and slip on the belts, causing premature wear. III-8 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 24: Operator Panel

    Select the desired operation. When MODE. (See changing modes, explanation below press STOP first; for the mode then press START to pattern) continue operation in the new mode. III-9 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 25 1/16” away from the top surface of the case before tightening the height locking knob. This will prevent case jams or difficulty passing cases through the machine when in Uniform mode. III-10 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 26: Machine Operations

    If the head does not easily slide horizontally in the holding slots, check for this retaining screw and loosen as necessary. III-11 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 27 11. At the rear of the machine a cycle complete sensor is triggered when the rear of carton passes by. Once signaled the machine side drives open and the top carriage returns to the position determined by the mode selector switch. III-12 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 28: Maintenance

    Chapter Chapter 4 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Maintenance...

  • Page 29: Preventive Maintenance

    It is important to understand that these maintenance schedules are minimum recommendations. Highlight Industries cannot possibly know, evaluate or advise the various trades in all schedules of periodic maintenance. Because of this, Highlight Industries has not undertaken such tasks. Accordingly, anyone who maintains or services a stretch wrap machine must first satisfy himself/herself as to the schedules of preventive maintenance based on cycling operation and environmental locations.
  • Page 30 Excess oil and grease attract dust, which can cause premature mechanical jamming and/or failure. Make sure oil and grease are not left on roller surfaces around which tape is threaded, as adhesive contamination will result. IV-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 31: Drive Belt Replacement

    It is recommended replacing both drive belts when one is sufficiently worn to impair proper production. After replacement, adjust belt tension by referring to instructions in Chapter 3. IV-3 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 32: Troubleshooting

    Chapter Chapter Five HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Uniform Case Sealer Operation Manual ® Troubleshooting...

  • Page 33: Machine Trouble

    Bent or hung-up air line. SELF DIAGNOSTICS: Press the START Button. START button flashes 1 Machine is set at Random 1 time mode. HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 34 Press overload RESET button on the overload after cause addressed to resume operation. START button flashes 6 E-STOP button is on. Or the times wiring may be disconnected. HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 35 Tape curling: Adjust the tape head roller limit stops to ensure the rollers remain in contact with the top & bottom of the box during taping. See next page. HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 36 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL Roller Limit Stop Adjustment HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 37: Brake Adjustment

    Clearance on the brake should be adjusted to 0.008” or 0.2mm. 0.008” or 0.2mm HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 38: Electrical References

    Chapter Chapter 6 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Electrical References...

  • Page 39: Electrical Parts List And Prints

    MICROSWITCH, SMALL BOX OPTION 404200 LOWER PHOTO EYE, SMALL BOX OPTION 504115 SENSOR BRACKET, SMALL BOX OPTION 403167 PHOTOELECTRIC SENSOR, 7360CD01 408326 TERMINAL BLOCK 408328 END BARRIER 408329 MARKING TAG VI-1 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 40 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VI-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 42 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VI-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 43 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VI-3 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 45 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VI-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 46: Mechanical References

    Chapter VII. Chapter 7 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Mechanical References...

  • Page 47: Mechanical Parts List And Prints

    MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL MECHANICAL PARTS LIST AND PRINTS PNEUMATIC PARTS Ref No. HLI Part No. Description Qty. 300894 AIR FILTER REGULATOR UNIT 300895 PRESSURE REGULATOR 300896 SOLENOID VALVE, DBL SOL, 24 VDC 300898 FLOW CONTROL VALVE 300899 REGULATOR SILENCER 209770...
  • Page 49 MACHINE FRAME & TOP FRAME ASSEMBLY Ref No. HLI Part No. Description Qty. 600293 UPPER TAPING FRAME 600294 SUPPORT BRACKET 501295 WIREWAY MOUNT BRACKET 503867 PROX TARGET BRACKET 500402 A-PLATE, UPPER TAPE HEAD HANGER 500403 B-PLATE, UPPER TAPE HEAD HANGER 501297 COVER PLATE 200807...
  • Page 50 501304 REAR ROLLER LOCK PLATE 500454 PNEUMATICS PANEL 600140 CONTROL BOX 600141 CONTROL BOX DOOR 500455 WIRING PLATE 504268 LOWER FILLER BLOCK 503869 SPUR GEAR, 44 TOOTH VII-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 52 SHCS, M8 x 20L & S.W & W 300875 ISO CYLINDER, MCQV-11-40-250M, RIGHT 300018 BEARING, 6004ZZ 503828 BUMPER 306145 KNOB, M12 MALE THREAD 503868 KNOB MOUNT SEAT 306146 NUT, AN∮25 VII-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 53 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VII-3 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 54 CHAIN, CENTERING, #40 * 75CM 300883 LINEAR MOTION BEARING, LM-20UU 300884 LINEAR MOTION BEARING BLOCK, B 300886 ISO CYLINDER, CENTERING, MCQV-11-32-250M 200804 SHCS, M8 x 20L & S.W & W VII-4 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 55 SHCS, M6 x 12L & S.W & W 501306 LINEAR SHAFT, CENTERING 200802 SHCS, M6 x 16L & S.W & W 500326 A-PLATE 500325 B-PLATE 600101 ENTRY GUIDE, LEFT 600103 ENTRY GUIDE, RIGHT VII-5 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 56 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VII-6 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 57 SAFETY DOOR SUPPORT, RIGHT 503830 SUPPORT BRACE 600347 SAFETY DOOR SUPPORT, LEFT 600344 ROLLER FRAME WELDMENT 304572 ROLLER 501865 REINFORCEMENT PLATE 501866 ACRYLIC PLATE 700410 ROLLER TABLE ASSEMBLY VII-7 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 58 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VII-8 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 59 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VII-9 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

  • Page 60: Notes

    Chapter VIII. Chapter 8 HIGHLIGHT INDUSTRIES, INC. Magnum 4500 SD-R Random Case Sealer Operation Manual ® Notes...
  • Page 61 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VIII-1 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...
  • Page 62 MAGNUM® 4500 SD-R RANDOM CASE SEALER OPERATION MANUAL VIII-2 HIGHLIGHT INDUSTRIES, INC. * 2694 PRAIRIE SW; WYOMING; MI 49519 * 1-800-531-2465...

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