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EASTMAN MPC 5000 Service Manual

Manual is about: Multi-Ply Automatic Cutting System

Summary of 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 technical support: 1-800-872-5595 warning this machine is equipped with a very sharp kn...

  • Page 2

    2 form e-551 congratulations congratulations in selecting anmulti-ply cutter. With over 100 years of experience in the cutting room, eastman is a world leader in cutting equipment. Every eastman employee takes pride in each machine we build and back it with unprecedented support. Our technical servi...

  • Page 3: Table of Contents

    3 form e-551 table of contents instruction for aligning, cleaning and replacing consumable parts ................................................. 4 replacement of knife ......................................................................................................... 4 replacement of sharpen...

  • Page 4: Parts

    4 form e-551 instruction for aligning, cleaning and replacing consumable parts replacement of knife removing the knife 1. Remove the thumb screw found on the front portion of tool head cover which secures the cover to the tool head. 2. Carefully swing the tool head cover and move it upwards to ensur...

  • Page 5

    5 form e-551 7. Pull the knife away from the coupler being careful to keep hands away from the sharp knife edge. 8. Ensure that the removed knife is placed in a safe area because it contains sharp edges that pose hazards..

  • Page 6

    6 form e-551 replacing the knife 1. Insert the new knife into the coupler. 2. Ensure that the sharp edge of knife should face the direction of the spring plunger. 3. Push the knife into the coupler until it stops. Make certain the knife is pushed past the ball plunger detent. 4. Tighten the clamping...

  • Page 7

    7 form e-551 7. 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 1. Remove the thumb screw found on the font portion of tool head cover which secures the cover to the to...

  • Page 8

    8 form e-551 replacing the sharpening wheels 1. Using a clean dry cloth saturated with alcohol clean the mounting surfaces of the sharpening housing. 2. Apply a few drops of “loctite 222 ms” on the end of screws which hold the sharpening wheels. 3. Install the new sharpening wheels. 4. Return the sc...

  • Page 9

    9 form e-551 replacement of drill rod removing the drill rod 1. Remove the thumb screw found on the font portion of tool head cover which secures the cover to the tool head. 2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position. 3. Using the supplied chuck key ...

  • Page 10

    10 form e-551 replacing the drill rod 6. Lift the drill pressure foot high enough to install the new drill rod. 7. Insert the new drill rod through the drill bushing into the drill chuck. 8. Hold the drill rod in one hand and tighten the drill chuck using the chuck key as required..

  • Page 11

    11 form e-551 replacement of guide bushing removing the guide bushing 1. Remove the thumb screw found on the font portion of tool head cover which secures the cover to the tool head. 2. Carefully swing the tool head cover and move it upwards to ensure it is in upper position. 3. Using the supplied c...

  • Page 12

    12 form e-551 replacing the guide bushing 1. Install the new guide bushing into the hole of the drill pressure foot. 2. Since the guide bushing has (4) different size holes align the correct size hole which matches the drill rod. 3. Rotate the guide bushing until the drill rod is aligned with the ho...

  • Page 13

    13 form e-551 replacement of vacuum filter removing the vacuum filter 1. Using flat head screw driver remove the screws which hold the filter box cover plate. 2. Remove the wing nut which holds the filter cover on filter housing. 3. Remove the filter cover from mounting stud..

  • Page 14

    14 form e-551 4. Slide filter cartridge from the filter housing. 5. Shake the cartridge over an open garbage can. 6. Using clean dry compressed air blow out filter until clean. 7. Replace with new filter if required based on inspection. Replacing the vacuum filter 1. Install a new filter. 2. Using v...

  • Page 15

    15 form e-551 replacement of bristle block removing the bristle block 1. Advance the conveyor to expose damaged bristle. 2. Apply e-stop to prevent the conveyor and gantry movement for safely. 3. Using a pair of pliers grab the bristle of the bristle block to be removed and pull from its aluminum sl...

  • Page 16

    16 form e-551 replacement of polythene rolls instructions 1. Two persons are required one on either side of the machine. 2. Lift up the bar which holds the plastic overlay tube and set it on flat surface. 3. Pull out the bar from tube and insert into a new roll. 4. Replace the bar on tower and threa...

  • Page 17: Service

    17 form e-551 disassembly and assembly instructions for parts requiring service replacement of x motor belts removing the x motor belts 1. Power down the machine using proper shut down / lock out procedures. 2. Remove the (6) screws using hexagonal wrench found on the left and right side of covers f...

  • Page 18

    18 form e-551 4. Remove the (4) screws found on either side of the electronics tray and swing the electronics tray outwards. 5. Loosen the (4) screws of the motor and now the motor will drop down to loosen the tension on the belt..

  • Page 19

    19 form e-551 6. Cut the (2) zip ties found on the shaft support plate. 7. Remove the (6) screws found on the shaft support plate. 8. Rotate the shaft support plate to convenient orientation to get access to the belt..

  • Page 20

    20 form e-551 9. Loosen the belt guide and push it outwards so that so that it will help relieve the tension on belt. 10. Remove the worn out belt. Replacing the x motor belts 1. Take a new belt. 2. Put it on the big pulley and roll it on the motor pulley a couple of times until it seats itself..

  • Page 21

    21 form e-551 3. 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. 4. Tighten the (4) screws of the motor to get the tension on the belt. 5. Return the (6) screws back on the shaft support plate. 6. Return the (2) zip ties found...

  • Page 22

    22 form e-551 replacement of y motor belt removing the y motor belt 1. Power down the machine using proper shut down / lock out procedures. 2. Remove the thumb screw found on the front portion of tool head cover which secure the cover to the tool head. 3. Carefully swing the tool head cover and move...

  • Page 23

    23 form e-551 5. Remove the (3) screws on the operator side of the y car and slowly open the electronics tray and ensure that no wires interfere..

  • Page 24

    24 form e-551 6. Remove the (2) screws found on the operator side on the y pulley plate. 7. Remove the (2) screws found on the t of the y pulley plate..

  • Page 25

    25 form e-551 8. Remove the screws found on the non-operator side of y pulley plate. 9. Remove the pulley plate..

  • Page 26

    26 form e-551 10. Loosen the (4) screws which hold the y-motor mounting screws to take off the tension. 11. Loosen the belt and remove the worn out belt. Replacing the y motor belt 1. Take a new belt. 2. Put it on the big pulley and roll it on the motor pulley a couple of times until it seats itself...

  • Page 27

    27 form e-551 6. Return the screws found on the non-operator side of y pulley plate. 7. Return the (2) screws found on the t of the y pulley plate. 8. Return the (2) screws found on the operator side on the y pulley plate. 9. Return the (3) screws on the operator side of the y car and slowly close t...

  • Page 28

    28 form e-551 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, increas...

  • Page 29

    29 form e-551 5. Remove the (4) screws which hold the linear bearing block to the side plate. Repeat this step for all the (4) bearing blocks. 6. Unscrew the backlash adjusting screw from the backlash adjusting block until the gantry is resting on the 2" x 4" wooden blocks. 7. Remove the (4) screws ...

  • Page 30

    30 form e-551 installing new bearings: 1. 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. 2. Mount the bearing to the bearing bloc...

  • Page 31

    31 form e-551 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, inc...

  • Page 32

    32 form e-551 5. Slide the (2) bearings out towards the operator side. 6. Slide the (2) bearings out towards the operator side plate and remove them through the access relief / cutout. Installing new bearings: 1. Remove new bearings from package and press the zerk grease fitting provided into the be...

  • Page 33

    33 form e-551 2. Slide the new bearings unto the linear rail and ensure that bearing adjustment screws are accessible from the back of gantry. 3. Be careful not to damage the bearing seals while mounting on the linear rail. 4. Slide the bearings under the y-car ad align with the mounting holes and s...

  • Page 34

    34 form e-551 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, i...

  • Page 35

    35 form e-551 4. Disconnect all air lines by depressing the red color buttons and slightly pulling on the air lines. 5. Disconnect the theta motor cable and theta feedback cable. 6. Remove the (6) screws which secure the tool head to the y-car assembly. 7. Disconnect the laser pointer wiring from th...

  • Page 36

    36 form e-551 8. Disconnect the positional sensor from the back of y-car assembly. 9. Remove the (8) screws which secure the linear bearings to the tool head interface plate. 10. Lift the y car slightly. 11. Slide the (2) bearings out towards the operator side..

  • Page 37

    37 form e-551 12. Slide the (2) bearings out towards the operator side plate and remove them through the access relief / cutout. Installing new bearings: 1. Remove new bearings from package and press the zerk grease fitting provided into the bearings. Using a grease gun and the grease gun adapter pr...

  • Page 38

    38 form e-551 replacing of take-off conveyor drive belt removing the take-off conveyor drive belt 1. Power down the machine using the proper lock out / tag lock out procedures. 2. Remove the (3) allen screws which secure the cover to the assembly on the operator side. 3. Carefully remove the cover w...

  • Page 39

    39 form e-551 4. Loosen the (4) screws found on the side support. 5. Remove the allen screw found on the end cover for additional clearance..

  • Page 40

    40 form e-551 6. Slide the motor plate to the left and remove the belt. Replacing of take-off conveyor drive belt 1. Install new belt by sliding the belt on to the motor pulley first and then to the drive pulley. 2. Slide the motor mount plate to the right to tension the belt until a ¼” belt deflect...

  • Page 41

    41 form e-551 replacing of take-off conveyor belt removing the take-off conveyor belt 1. Advance the conveyor belt until the zipper seam is exposed. 2. Power down the machine using the proper lock out / tag lock out procedures. 3. Remove the (7) screws found on the take-off transfer plate..

  • Page 42

    42 form e-551 4. Remove the transfer plate exposing the take-off conveyor tension roller. 5. Remove the (4) screws found on the tension assembly cover plate which is located at the front on the operator side. 6. Loosen the (2) screws found on the side frame..

  • Page 43

    43 form e-551 7. Loosen the tension jack screw to release tension on the belt. 8. Repeat steps 5 through 7 on non-operator side. 9. Using a pry bar or screw driver pull up the belt exposing the edge where the zipper seam is exposed. 10. Using pliers pull the seam wire from the zipper seam. When the ...

  • Page 44

    44 form e-551 11. Remove the belt from conveyor. 12. Clean the wear surfaces found under the belt with a clean dry cotton rag. Replacing of take-off conveyor belt 1. 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...

  • Page 45

    45 form e-551 replacing the xmp controller card and loading configuration files the multi-ply cutter uses one xmp controller card located inside the computer. The xmp controller card commu- nicates over the purple network cables with all of the motor amplifiers and the slice input/output (io) cards....

  • Page 46: Service

    46 form e-551 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 thi...

  • Page 47

    47 form e-551 d) 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 1. Remove all screws from gantry e-chain cover allen wrench & ...

  • Page 48

    48 form e-551 4. 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. 5. Recheck gantry drive belt bac...

  • Page 49

    49 form e-551 checking and adjusting y-car backlash checking y-car backlash 1. Power down the machine using proper shut down / lock out procedures. 2. Hold the pulley and move the y-car back and forth in y direction and observe if there is any audible click or movement. 3. If there is any free side-...

  • Page 50

    50 form e-551 2. Loosen the (4) screws of the pulley plate on either side of the y-car. 3. Tighten the (4) screws of the pulley plates on the non-operator side of y-car. 4. Pull the pulley plate towards the linear rack and tighten the (4) screws of the pulley plates found on the operator side. 5. En...

  • Page 51

    51 form e-551 6. 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. 7. Tighten the motor mounting screws. 8. Please note when ever the belt is replaced the backlash adjustment should follow..

  • Page 52

    52 form e-551 checking and adjusting stop discs checking stop discs 1. Power up the machine. 2. Move the stop discs to see if they are activated by a slight touch or vibration. 3. If the stop discs are not activated by slight touch or movement are then adjust the stop discs. Adjusting stop discs 1. ...

  • Page 53

    53 form e-551 4. Tighten the set screw which in turn increases the force on the detent ball until sufficient tension is applied to the stop disc rod. 5. Tighten the nut while holding the set screw in position. 6. Return the cover. 7. Check the operation of stop disc. 8. Do the same check on non-oper...

  • Page 54

    54 form e-551 scheduled maintenance procedure caution it is important to perform regular maintenance on the equipment. A daily, weekly and monthly schedule should be maintained. Failure to do so can result in more frequent breakdowns damage to equipment and/or injury. Proper maintenance will help to...

  • Page 55

    55 form e-551 • 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 lubricat...

  • Page 56

    56 form e-551 lubrication chart below are the lubrication points for the multi-ply cutter..

  • Page 57

    57 form e-551 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. Y l b m e s s a r e v o c t n o r f s t n e m m o c f f o n g i s l a...

  • Page 58

    58 form e-551 y l b m e s s a e t a l p d n e t n o r f s t n e m m o c f f o n g i s ) n o i t a r a p e s d a e r h t , s k c a r c ( t l e b e v i r d t c e p s n i s g n i r a e b y e ll u p e g r a l l i o & k c e h c g n i r i w & h c t i w s e m o h 1 x k c e h c g n i r i w & h c t i w s t i...

  • Page 59

    59 form e-551 y l b m e s s a e t a l p d n e k c a b s t n e m m o c f f o n g i s ) n o it a r a p e s d a e r h t , s k c a r c ( tl e b e v i r d t c e p s n i s g n i r a e b y e ll u p e g r a l li o & k c e h c g n i r i w & h c t i w s e m o h 2 x k c e h c g n i r i w & h c t i w s t i m i ...

  • Page 60

    60 form e-551 y l b m e s s a e b u t n i a m s t n e m m o c f f o n g i s n o i t a r e p o r e p o r p r o f m a c d n a h c t i w s e m o h - y k c e h c n o i t a r e p o r e p o r p r o f m a c & h c t i w s t i m il e v - y d n a e v + y k c e h c s e l b a c n i a h c - e y k c e h c d e r e...

  • Page 61

    61 form e-551 y l b m e s s a e g a i r r a c - y s t n e m m o c f f o n g i s ) n o i t a r a p e s d a e r h t , s k c a r c ( t l e b e v i r d r o t o m y t c e p s n i d n e t n o r f o t d e n e t s a f y l e r u c e s s i y a r t s c i n o r t c e l e e h t t a h t k c e h c s e d i s h t o ...

  • Page 62

    62 form e-551 y l b m e s s a d a e h l o o t s t n e m m o c f f o n g i s d a e r h t , s k c a r c ( t l e b e v i r d r o t o m a t e h t t c e p s n i ) n o i t a r a p e s s r e d n il y c r i a r o f ) 3 ( s g n i r a e b m m 6 1 e s a e r g e s a e r g e c n a m r o f r e p h g i h e t i t c...

  • Page 63

    63 form e-551 t e n i b a c l a c i r t c e l e s t n e m m o c f f o n g i s r e t u p m o c n o r e t l i f n a f n a e l c e d i s n i n a e l c o t r i a y r d e s u s l a n i m r e t w e r c s ll a n e t h g i t s n o i t c e n n o c d n a s g u l p ll a e r u c e s s w e r c s g n i t n u o m ...

  • Page 64

    64 form e-551 s e l b a c r e t u p m o c s t n e m m o c f f o n g i s t u o t e n q n y s n i t e n q n y s k r o w t e n e l b a c b u h b s u o e d i v l a n g i s o e d i v r e w o p r e t u p m o c r e w o p r o t i n o m e s u o m d r a o b y e k y r t n a g - t i u r e t u p m o c - t i u r ...

  • Page 65

    65 form e-551 additional comments: maintenance signature: date:.

  • Page 66

    66 form e-551 trouble shooting guides and aides uit error messages this has to be developed by software hence it is on hold as of now..

  • Page 67

    67 form e-551 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 preve...

  • Page 68

    68 form e-551 problem: machine stop during cut due to unintentional pause description of problem: the machine stops in middle of cut and displays message “machine paused, press zero, next or abort” on touch screen. When pressing next on the keypad, the machine will continue to cut where it left off....

  • Page 69

    69 form e-551 3. With finger is still on touch screen have a co-worker turn on machine power. 4. After the “power on setup” screen appears, remove your finger from the corner of touch screen. 5. After the power on setup screen appears, use the left and right arrows to navigate, and select to enter a...

  • Page 70

    70 form e-551 7. Follow the same procedure for the bottom right cross. 8. Navigate to page 3 and toggle down to save and exit and select it. 9. Your touch screen will restart in normal mode. It is ok to run the machineafter all proper startup procedures are followed..

  • Page 71

    71 form e-551 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. Troubles...

  • Page 72

    72 form e-551 a) hit the cut down button on the uit and verify the corresponding led lights for desired tool. B) try firing the tool manually by pressing gently with the end of a small paper clip into the small hole at the top front of desired air valve. Each solenoid can be manually fired by pressi...

  • Page 73

    73 form e-551 rf/emi interference some factory environments may have equipment that generates radio frequency (rf) or electro-magnetic 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. (...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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- out prior written consent of eastman. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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- out prior written consent of eastman. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • 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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • Page 86

    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. New release rev ecn heat treat by date changes finish material do not scale drawing - - - 779 washington street, buffa...

  • Page 87

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  • Page 88

    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 ©2012 eastman machine company printed in u.S.A. 3/12 technical data eastman mulyi-ply cutter form ...