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The following is a procedure for disassembling the entire cutting unit(Figure27).Note that individual spindles and related parts can be removed without disassembling the entire cutting unit(for example,the circular knife spindle and stripper plate can be removed without disassembling any other part of the cutting unit).
Figure 27-----Cutting unit. (1)circular support assembly, (2)impeller (3)crosscut knife spindle, (4)slice gate , (5)stripper plate, (6)slicing knife (7)slice adjustment knob, (8)adjustment nut
1.Ower source must connected to machine and turned on.Turn the power disconnect/lockout switch to the “O”(OFF)position and lock out.Allow machine to come to a complete stop,then press the “I”(start)button and hold for two seconds to verify that the machine will not start.After the green guard locking switch status lights illuminate(when all rotating machine parts are idle)unfasten the draw latch connecting the feed cover door and support housing.Open the feed cover door.
2 .Slide protective sleeve provided with the machine over the crosscut spindle(see “Crosscut Knife Spindle Assembly”,page 80).
CAUTION:The following step in this maintenance procedure repuires that the cutting parts be rotated.Use the impeller to rotate the parts.The impeller should only be grasped near the bottom to avoid contact with slicing knife!
3 .Remove the circular support assembly which contains the circular spindle assembly .Rotate the impeller by hand (grasp near the bottom) until the line etched on the circular support assembly aligns with the line on the end of the circular spindle(Figure 28).The open side of the drive coupler must face out(Figure 39,page 45).This can be viewed by looking in the space between the circular support and the support housing.Remove the two locking nuts and pull the circualar support assembly straight out and off of the machine (Figure 29).Place the support assembly on a work surface in a safe palce.
Figuar 28----Aligning circular knife spindle. (1)Circular knife spindle, (2)Side,circular support assembly, (3)Alignment marks, (4)Lock nut
Figuar 29----Removing circular support assembly. (1)Cricular support assembly
CAUTION: Always carry and store the circual support assembly containing the circular spindle so that exposed knife edges do not present a safety hazard.
The crosscut knife spindle should be removed from the machine if replacing more than two crosscut knives and if removing the slicing knife holder.Proceed to step #4 to remove crosscut spindle.
Replacement of crosscut knives:To replace just one or two knives ,back off screws approximately two turns and pull retaining ring out .Carefully lift knife from slot(Figure 30).Replace knife making sure knife is seated in clean knife slot,with all knives is facing the same direction.Use the torque wrench provided with machine and tighten retaining ring screws to 20 inch/pounds(2:2 newton-meters).To replace more than two knives ,remove crosscut spindle from the machine as outlined below.See page 48 for maintenance information.
Figure 30----Replacing crosscut knives. (1)Retaining ring
CAUTION:The crosscut spindle is heavy ,weighing approximately 60 pounds(27 kg).Use appropriate lifting techniques.
4 .Use the “L” handle wrench provided with the machine and remove two of the three screws that hold the spindle to the machine.Loose the third screw but to not remove.
5 .Install the shaft extension tool provided with the machine .Guide the shaft extension tool in place over the stud in the crosscut shaft and tighten until it stops against the shaft (Figure 31).
Figure 31----Loosening crosscut knife spindle fasteners. (1)Protective sleeve, (2)shaft extension tool ,(3)”L” handle wrench
6 .Remove the remaining fastener that holds the spindle .Slide the spindle over shaft extension tool to remove from the machine (Figure 32).Carefully set the spindle aside on a surface that will not damage the knives.
Figure 32----Removing crosscut knife spindle. (1)Shaft extension tool, (2)Crosscut knife spindle
7 .Remove the stripper plate and stripper plate spacer.Three bolts hold the stripper plate to the stripper plate spacer on the slice gate.Three screws hold the spacer to the case(Figure 33).If the spacer is difficult to remove,use the stripper plate fasteners as jacking screws in the holes on the spacer used to attach the stripper plate.
Figure 33—Using stripper plate screws to remove stripper plate spacer. (1)Stripper plate spacer. (2)stripper plate fastener(used as jacking screw)
8 .Remove the slicing knife insert by using a screwdriver or similar tool that will fit in the hole in the exposed handle end of the slicing knife (Figure 34).Carefully pull the knife from the slicing knife holder.Note that some cutting applications may use the slicing knife that is integrated with the knife holder(no replaceable insert).That knife is removed in the same manner as the slicing knife holder as described below.
Figure 34----Removing replaceable slicing knife insert. (1)Screwdriver, (2)Slicing knife insert, (3)Slicing knife holder, (4) Fastening post
9 .Remove the slicing knife holder.The fastening posts act as fasteners to secure the knife holder to the case.If the machine is being used as a strip cutter, the circular support assembly may not be in use, in which case the slicing knife holder is held by hex head cap screws.
10 .The slice gate generally dose not require removal unless changing between straight and crinkle slice gates.If removal is required ,proceed as follows.
11.Remove adjustment nut.(see Figure27,page 28.)From within the gear compartment, remove the tightening rod.Push back on the tightening rod from binding as it is removed(Figure 35).Remove the slice gate guard ,which is by the tightening rod.
Figure 35----Removing tightening rod for slice gate . (1)Adjustment block, (2)Tightening rod
12 .Remove four fasteners and washers on the lower portion of the plate(Figure 36).Remove the slice gate.
Figure 36----Removing slice gate .(1)Hinge plate, (2)Slice gate
The impeller generally dose not need removal .If removal is required:
CAUTION:The impeller is heavy ,weighing approximately 77 pound(35 kg).Use appropriate lifting technipuse.
13. Carefully slide impeller out of case after unfastening the eight screws that hold the impeller in place(Figure 37).
Figure 37----Removing impeller. (1)Impeller. (2)case
INSPECTION
All parts should be cleaned ,inspected for serviceability ,and repaired if necessary.
Stripper plate:Clean all product from slots.Replace if edges become rounded.
Stripper plate spacer:clean thoroughly .Check for nicks or burrs on the mating surface and hone if necessary.
Circular support assembly containing circular knife spindle assembly:Clean all product from slots.
Clean product from between knives and inspect for damage or wear .See”Disassembly”,page 46.
Circular knife spindle bearings:Rotate circular knife spindle shaft by hand and feel for any rough or tight spots that may indicate bearing wear .check for any side-to-side movement.End play should measure from .000 to .010”(.00 to .254 mm)total movement .Bearings should be replace if movement exceeds .010”(.254 mm).Replace if necessary.See “bearing replacement”,page 47.
Crosscut knife spindle :Inspect knife slots for burrs or foreign material ;clean slots thoroughly and hone burrs if necessary.
Slicing knife ,replaceable insert:Check for nicks and file or hone if necessary.For detailed information on knife care and sharpening ,see pages 57-59 and refer to the “SHARP” bulletin provided with the machine.
Slicing knife holder:check the knife slot for nicks and file or hone if necessary.Slot must hold slicing,knife securely with no gaps along mating edges.The edges of the knife holder opposite the knife acts as a shear edge for the crosscut knives .Check for nicks along the shear edge and file or hone if necessary.If shear edge is rounded from wear ,the knife holder should be replaced.
Slicing knife ,straight and crinkle(no replaceable insert knife):
The edge of the knife opposite the cutting edge acts as a shear edge for the crosscut knives .Check for nicks and file or hone if necessary.If shear edge is rounded from wear,the slicing knife should be replaced .For detailed information on knife care and sharpening ,see pages 57-59 and refer to the “SHARP” bulletin provided with the machine.
Slicing gate:check for nicks and file or hone if necessary.
Impeller:Check for worn or chipped paddles.Check for nicks or burrs on the mating surface.
REASSEMBLY
WARNING: Knife spindles are heavy and contain sharp knives!the crosscut spindle weights approximately 60 pounds(27 kg).Wear the protective gloves supplied with the machine when working with or knife spindles.
1. Install the impeller and slice gate.Lightly grease impeller hub and fasteners .Carefully side the impeller into the case and fasten with the eight screws.install the slice gate if it was removed.Replace the fasteners in the hinge plate but do not tighten.Install the slice gate guard,tightening rod and adjustment nut.The slice adjustment should be at the 0 or 1/8 “ position before tightening the fasteners in hinge plate(see “Adjustments”,next page).push the gate against the case as the fasteners are tightened.
2. Install the slicing knife holder.Two fastening posts hold the slicing knife holder to the case.Note that some cutting applications may use a slicing knife that is integrated with the knife holder(no replaceable insert).This knife is installed in the same manner as the slicing knife holder.
3.Install the replaceable slicing knife insert.Apply a small amount of grease to the slicing knife.Guide the knife into the slot in the slicing knife holder.Use a screwdriver or similar tool through the hole in the knife handle,and push the knife in until fully seated .The knife must be down to the bottom of the slot.
4.Install the stripper plate and stripper plate spacer.Different sizes of stripper plate spacers are available depending on size of cut desired (see “Circular Knife Spindle Assembly”,page 79).Use the three low head socket head cap screws to fasten the spacer to the slice gate.Fasten the stripper plate to the stripper plate spacer with the hex head cap screws.
5.Install the crosscut knife spindle assembly.Slide the protective sleeve provide with the machine over the crosscut spindle .Install shaft extension tool if it was removed .The mounting surface pictured in Figure 38 above shows the chamfered holes which mount against the crosscut shaft.Chamfered holes should not be visible when crosscut shaft or the spindle is installed incorrectly.
Figure 38----Chamfered holes on crosscut mounting surfaces must be placed against the crosscut shaft (not visible when spindle is installed on machine.). (1) Chamfered hole,(2)Mounting surface
6.Slide crosscut spindle over shaft extension tool to install on machine.
7.Install the three screws that hold the spindle to the shaft.Unscrew and remove the shaft extension tool.
8.Install the circular support assembly containing the knife spindle assembly.Rotate the impeller by hand (hold the impeller at the bottom and keep hands clear of the slicing knife)until the open side of the drive coupler faces out (Figure 39).Align the marks on the circular spindle shaft and the spindle housing.Guide the circular support assembly onto the fastening posts making sure the assembly is fully seated.Replace the two locking nuts and tighten securely.
Figure 39----Aligning drive coupler for circular support assembly. (1)Drive coupler,(2)Alignment marks (3)Fastening post
IMPORTANT!:The circular spindle support assembly and slicing knife holder must be fully seated !Remove any foreign material or nicks that may prevent parts from seating.Parts can be damaged if not installed properly.
9.Replace ,close and securely latch all covers and guards.
ADJUSTMENTS
Slice thickness is controlled the slice gate adjustment knob(Figure 40).To adjust slice thickness ,loosen the adjustment nut with a screwdriver or similar tool and turn the slice gate adjustment knob to desired setting ;tighten the adjustment nut .Each etched line on the chip guard represents a 1/8”(3 mm) increment in slice thickness ,with 1/4”(6 mm) increments marked with numbers(Figure 41).Use the marks as a reference.Product should be cut and measured to verify that desired slice is being produced.
Figuer 40----Slice adjustment. (1)Slice gate, (2)Slice gate adjustment knob, (3)Adjustment nut
Figure 41----(1)Slice thickness adjustment setting
DISASSEMBLY
WARNING:Cutting parts are sharp and can cause injury !Wear protective gloves when handing cutting parts.
1.Remove circular knife spindle support from the machine and set on work surface that will not damage the knives,see “Disassembly”,pages 38-39.
2.Check the bearings for wear.Bearings need to be replaced if any rough or tight spots are detected.Check the shaft for side-to-side and up-and-up-down movement.Total end play should not exceed .010”(.254 mm).To replace bearings,see “Bearing Replacement”,next page.
3.Remove circular knife spindle assembly from circular knife spindle support.Set the support upright on the end where the shaft is flush with the side.Side to the top.Lift up to the side and gently tap the end of the circular spindle to loosen the side from the top(figure 42).Remove the circular spindle.
Figure 42----Removing the side from circular knife spindle support. (1)Side ,(2)Top
4.Clamp the end of the spindle in a soft jaw vise.(Soft jaws are necessary to protect the precision parts.)
5.Remove spindle nut ,turning clockwise (the nut is a left hand thread) using the wrench supplied with the machine (figure 43).Remove knives and spacers.
Figure 43----Using spindle wrench to loosen and tighten spindle nut.
INSPECTION
All parts should be cleaned, inspected for serviceability, and repaired or replaced if necessary.
Spacers ,Spindle and spindle nut:Check for burrs and hone if necessary,but be careful to remove only the burr.
Knives:Replace any that are bent or have large nicks.For detailed information on knife care and sharpening,see pages 57-59 and refer to the “SHARP” bulletin provided with the machine.
Spindle support:Check for damage or scoring in the bearing areas.Check all mating surfaces for nicks or burrs;use a hone to remove any burrs that may prevent parts from seating properly.
Bearing replacement:
1.Remove the bearings.Remove both sides of the support assembly.Support one side in an arbor press.Using the seal seating tool supplied with the machine,press the worn bearing out and discard(Figure 44).Repeat with the remaining side.
Figure 44----Removing the circular knife spindle bearings.(1)Side, (2)Bearing, (3)Bearing Seating Tool
NOTE:Replacement bearings should be purchased from Urschel Laboratories.The inner race of the bearings have a slight taper to mate with tapered areas on the circular knife spindle.
2.Apply a thin layer of grease(Royal Purple Ultra-Performance Clear FDATM )to the bearing areas of the circular support assembly sides.
3.Press new bearings into the sides with the bearing searing tool and an arbor press. One side of the outer race of the bearing has marking. The unmarked side of the bearing should be placed into the side,to be pressed against its seat,and the marked side should be against the side,to be pressed against its seat,and the marked side should be against the tool.with the bearings installed,the markings on the outer races should be visible.When the support is assembled, the marked outer race is facing in toward the circular spindle.With the bearings installed in this manner,the shaft of the circular spindle enters the inner race of the bearing at the wide end of the taper.
4.Attach one side to the top of the circular support assembly.Install the side with the alignment marks first.Replace the circular knife spindle,than install the remaining side of the support assembly.
REASSEMBLY
1.The circular knife spindle begins and ends with a knife. Alternate spacer and knives to obtain the size cut desired.See “Circular Knife Spindle Assembly”,page 79.
NOTE: Never start or end the assembly with a space.Feed discs may be substituted for circular knives for certain applications.
2.Lubricate spindle threads and replace the nut on the spindle.The end of the nut with the recessed surface should face the knife.Make sure the last knife is not in the threaded portion of the spindle before tightening the nut.
3.Place the spindle assembly in the circular support and replace and tighten the two fasteners on the support end.Install the support in the machine or store in a safe place. See “Reassembly”,page 45.
DISASSEMBLY
WARNING:Cutting parts are sharp and can cause injury! Wear protective gloves when handling cutting parts.
1.With protective sleeve over crosscut spindle,remove crosscut knife spindle from machine. See”Disassembly”,pages 38-40.place on a level work surface that will not damage the knife edges.Remove the protective sleeve.
2.Remove the retaining ring. Two retaining rings hold the knives in place on the spindle. rings hold the knives in place on the spindle. Generally, only the ring that faces away from the machine needs to be removed. This end can be determined by looking at the mounting holes inside the spindle. The mounting surface with the chamfered holes mounts against the crosscut shaft. Remove the retaining ring on the opposite end (Figure 45). If the attached ring has product build-up, remove it also and clean thoroughly.
Figure 45 ---- Crosscut knife spindle disassembly. (1)Knives, (2) Retaining Ring.
3. Remove knives.Carefully pull knives from slots
INSPECTION
All parts should be cleaned, inspected for serviceability, and repaired or replaced if necessary.
Crosscut spindle: Check for burrs on all mating surfaces,especially the knife seats and the ends of the hubs. Hone if necessary, but be careful to remove only the burr.
Retaining rings: Inspect for burrs and swelling；hone if necessary.
Knives: Replace any knives that have large nicks or are bent beyond straightening. For information on knife care and sharpening, see pages 57-59 or refer to the “SHARP”bulletin provided with machine.
REASSEMBLY
1.Check the retaining ring that remains attached to the spindle(the end of the spindle installed towards the machine). Screws should be fully tightened. If this retaining ring has been removed, grease the fasteners before installing.
2.Clean the knife slots and install the knives. Stand the spindle upright on the attached retaining ring (the mounting surface with the chamfered holes should not be visible).Carefully slide knives into slots. Install the knives with the sharpened edges pointing counterclockwise when looking down on the spindle(Figure 46).
Figure 46----Correct orientation of the crosscut knives when looking down on the spindle (the mounting suface with the chamfered holes should not be visible ) (1) Crosscut Knife, (2) Mounting Holes
NOTE: The knives must be installed correctly or poor quality cuts and machine jam will result.
3.Install the retaining ring.Grease the fastener. Gradually and alternately tighten the fasteners using the torque wrench provided with the machine(20 in-ibs,2.2 newton-meters).
NOTE:Bearings in accordance with the instructions (see”Lubrication”,page 37) will seldom need replacement. If water enters the bearings due to lack of lubrication, the bearings will rust and quickly fail. Contact Urschel Laboratories for repair information.