Polychem PWT Operation Manual And Spare Parts List

PWT

OPERATION MANUAL | SPARE PARTS LIST

PNEUMATIC PLASTIC STRAPPING TOOL

READ ALL INSTRUCTIONS BEFORE OPERATING THE TOOL

6277 HEISLEY ROAD, MENTOR, OHIO 44060

POLYCHEM CORPORATION

PHONE: [phone], FAX: [phone]

WWW.POLYCHEM.COM

ED. 08/11

TABLE OF CONTENTS

1)

Safety instructions

2)

Technical data

3)

Warranty and liability

4)

Installation

5)

Operating elements

6)

Operation

7)

Servicing and cleaning

8)

Troubleshooting

9)

Layout – spare parts list

READ THE OPERATING INSTRUCTION CAREFULLY

WHEN OPERATING THE TOOL, WEAR EYE, FACE AND HAND SAFETY
PROTECTION

GENERAL SAFETY INSTRUCTIONS :

The tool must be used by properly trained people. Failure to follow the operating instructions or
improper use could cause strap breakage, injuries, or package damages.
Check tool daily, do not use tool with worn or damaged parts. Use original spare parts for
replacement. Never modify any tool part.
Do not put fingers, hands or other body parts between the strap and package during the cycle.
It is your responsibility to check the seal joints made by your tool. Training about the weld time
adjustment will be useful to check the seal quality in order to avoid severe injury. Never move goods
with bad quality seals. Only use specific strap dispenser to dispense the strap. Keep your working
area clean and always use the tool in good balance and safety conditions. Never use straps as a
means of pulling or lifting goods.
Always use a proper safety strap cutter and keep other people and yourself at a safe distance from
strap, always stand to side of strap, away from direction of strap trajectory once cut. Hold the upper
strap portion and pay attention that the lower strap will snap forward away from you.
Improper operation, excessive tensioning, use of non-recommended strap, or sharp corners on the
package could cause a loss of strap tension and/or strap breakage that could lead to packaging
failure or injury. The following is recommended; use edge protectors if package has sharp corners,
place the strap correctly around a properly positioned package, stand in safety position (on one side
of strap) during strapping cycle, and use the correct strap quality, width, thickness, and break
strength as recommended in this manual.
Please save this manual, as it is a part of the tool. This tool is manufactured without any substances
which could be dangerous to health. National instructions must be observed for disposal of all the
parts.

GENERAL SAFETY INSTRUCTIONS FOR COMPRESSED AIR:

Never operate this tool using bottled air or other gas source. Do not exceed the air pressure range as
shown in this operation manual. For all adjustments, repairs or cleaning of the tool, always
disconnect air supply. Always use dry, clean and lubricated compressed air.

1) SAFETY INSTRUCTIONS

TOOL SIZE

Length:

250 mm – 9.8”

Width:

130 mm – 5.1”

Height:

120mm – 4.7”

Weight:

2.6 kgs – 5.7 lbs

REQUIRED AIR

Pressure range:

4.5-7 bar / 64-99 psi

PERFORMANCE

Sealing:

Friction seal

Joint strength:

80% plastic strap
strength*

• depends on strap quality

CHART OF TYPES

ITEM

MODEL STRAP

THICKNESS

T189901
T182501

PWT

PP-PET 16-19mm / 5/8”- 3/4”

PET 25mm – 1”

>0.016” –

0.055”<

Polychem Corporation warrants all its tools and battery chargers during a period of 6 months from the
shipping date document. Wear parts are warranted for 45 days, otherwise wear parts are excluded from
regular warranty, wear parts are shown on spare parts list (in tool manual).

Warranty includes free replacement parts. The warranty is not valid in case of improper use, lack of
maintenance, tampering, arbitrary modifications and reparations, use of non-original parts, disregard of
instructions of the operation manual, or missing serial number. No compensation can be claimed for
production shutdowns and for damages to people and objects due to tool defects. Polychem Corporation
reserves the right to modify the tools and documentation without any obligation to update previous ones.

Polychem warrants all its batteries during a period of 120 days from the shipping date document. The
manufacturer is committed to replace it with a free battery only when there are manufacturing defects that
make it unfit for use.

It is recommended to always use a dryer unit near the compressor and a filter-regulator-lubricator
unit with pressure gauge (Polychem part # 200-0025) close to the tool air connection to avoid water
and dirt in the valves or in the pneumatic motors. Connect the tool to air with quick connector ¼” and
use minimum 8mm or 3/8” internal diameter pipe; max length for flexible pipe 10 m between tool and
regulator group. Check that your compressor / air distribution plant is able to supply the right air
quantity as shown in the operation manual without losing pressure.

TOOL AIR CONNECTION

200-0025

4) INSTALLATION

3) WARRANTY

• DO NOT OPERATE THE TOOL WITHOUT STRAP, YOU COULD DAMAGE THE WELDING / CUTTING GROUP

Handle rotation

It is possible to change the handle position 90°.To change the position you unscrew the handle and move it as pictured.

Welding time adjustment

The welding time can be adjusted with a screwdriver as shown in picture A; turning clockwise will increase the time, and
counter clockwise will decrease the time.

(A)

Strap size conversion

( B1 ) ( B2 )

To set the tool for 16mm 5/8” and 19mm ¾” strap sizes follow the instructions below:

HANDLE

19 > 16

3/4”>5/8”

16 > 19

5/8”>3/4”

Turn the strap guides 1 and 2 in 16mm5/8” position (pic.B1-B2)

Turn the strap guides 1 and 2 in 19mm 3/4” position (pic.B1-B2)

LEVER 1 – CUTTING /
WELDING

WELDING
MOTOR

Front strap guide (1)

Rear strap guide (2)

Wrap the parcel to be bound with the strap, as shown in (pic.C1), (make sure that the strap is clean, and oil and grease
free); align the two straps and insert them between the body and bottom plate, against the front / rear strap guides

(pic.C2), push lever 1 one time to cut and weld the strap. (pic.C3). Remove the tool.

( C1 ) ( C2 ) ( C3 )

WARNING : Wait 2-3 seconds after the welding cycle to cool the strap before releasing it

Seal check

A regular seal quality control is very important and it can be checked visually as follows:

(D1) (D2) (D3)

DISCONNECT TOOL FROM COMMPRESSED AIR LINE BEFORE PERFORMING ANY SERVICE

Periodically clean the tool from strap dust, particularly the gripper plates and the cutter using compressed air.

(Do not use other tools or keys) (pic. E)

(E)

6) OPERATION

NO – seal strength insufficient
YES -- right

NO – seal strength affected

Weld time too short

Weld time too long

Cutter replacement

Disconnect the air pipe from welding motor (pic.F1), remove the 2 locking motor screws (pic.F2), remove the motor
(pic.F3).Pull out the cutter spring with pliers (pic.F4), remove the cutter by inserting air into the disconnected pipe to push

the piston down to free the cutter and then remove it from its seat with pliers (pic.F5). Replace it and reassemble in
reverse order putting grease on spring and cutter seat.

( F1 ) ( F2 ) ( F3 )

( F4 ) ( F5 )

Grippers replacement

( G1 ) ( G2 ) ( G3 )

Remove the 4 bottom plate screws (pic.G1), unscrew the gripper screw (pic.G2), replace the parts (pic.G3), and
reassemble in reverse order.

Welding gripper replacement

Remove the cutter as shown in F1 to F5 sequence, remove the bottom plate as point G1, remove the safety circlip from
welding gripper pin (pic.H1), remove the pin from welding gripper (pic.H2), and replace the worn out part(pic.H3) .
Reassemble all parts in reverse order. It is advised to replace the safety circlip with a new one.

( H1 ) ( H2 ) ( H3 )

PROBLEM

REMEDY

Air leaking

Check the air connection. May need to replace the gaskets ( contact the after sale service)

The seal is weak; the upper strap isn’t completely cut; the cutting is inconsistent

Improper weld time adjustment set it properly. Check if the sealing foot and the cutter are damaged or worn out. Check

if the sealing foot is dirty or slides on strap. Check the air pressure value. Check if the strap qualities are right for the

strapping tool and application. Check if the sealing motor or the pneumatic valve is locked or dirty (contact the after

sale service), try to clean the timer valve, check the air circuit.

The strap is breaking while sealing

Improper weld time adjustment, may be too long, set it properly.

Both straps are cut while sealing

Check if the gripper plate is dirty or damaged (clean or replace it). Improper weld time adjustment, may be too long.

The sealing time is inconsistent

Timer valve problem, try to clean, lubricate or replace it ( contact the after sale service)

POLYCHEM

PART #

ITEM

DESCRIPTION

QNTY

189825

A000107

ASSEMBLED COVER

1

186897

B100032

PIPE 6x8

0,08 mt

*

189707

B100307

CONN. DIR 10 1/4 RL1 (2L01012)

1

189137

B100310

SWING ELBOW RL31 8 1/4 (2L31011)

1

*

189185

B100313

CONNECTION RL1 08 1/4 (2L01010)

1

*

189154

B200356

VALV 2VIE TEMP AZ10.017.4

1

*

189704

B200374

KIT AIR STOPPER 1/8"F0.5 AZ 11.005.2

1

189126

B200375

KIT MICROVALVE NC AZ 08.022.2

1

189471

B300022

O-RING 3300 (D85)

1

189472

B300019

GASKET RING RP6287.85

1

189120

B300020

GASKET TEFLON + BRONZE 1.5x6.1 IN MTS

0,11

189667

B300086

O-RING OR108 (D9)

4

189146

B400003

ROLLER BEARING HK0808 INA

2

189176

B400004

BEARING 6001 2Z

2

189149

B400005

ROLLER BEARING NK1616

1

189699

B500034

SCREW UNC 10-24x5/8" ANSI B18.3

3

189136

B500039

SCREW UNC10-24x1/2"

6

*

189141

B500040

SCREW M6x16 UNI5931

4

*

189179

B500043

SCREW M5x12

2

189698

B500047

SCREW M5x8 UNI5925

1

189438

B500048

SCREW M4x6 UNI5933

1

*

190161

B500068

SCREW M3X8 UNI 5931

2

189700

B500097

SELFLOCK M5 DIN985 5S

2

189819

B500143

SCREW M6X6 UNI5927

1

189703

B500235

SCREW M3X4 UNI5929

1

189761

B500386

SCREW M4x30 DIN7984

2

189153

B600013

CIRCLIP H5

1

189705

B600417

RUBBER GRIP

2

189500

B700030

PIN 3x24 DIN6325

1

190062

B700076

PIN 4x12 DIN6325 R220

1

189134

B900348

PNEUMATIC BOSCH MOTOR 0607951449

1

189820

B900406

PNEUMATIC MOTOR AM-004

1

189157

D000780

LOCKING STRAP PLATE

1

§ *

189133

D001260

CUTTER

1

§ *

189282

D001620

CONNECTING ROD PIN

1

189150

D001630

CONNECTING ROD

1

189482

D001640

EXCENTRIC SHAFT

1

189152

D001650

WELDING FOOT PIN

1

189160

D001700

COVER

1

189121

D001710

PISTON SPRING

1

189232

D001720

STRONG CUTTER SPRING

1

189586

D001800

REAR STRAP GUIDE

1

189821

D003000

CUTTER (1”STRAP)

1

§ *

189822

D003010

WELDING FOOT (1”STRAP)

1

§ *

189823

D003040

LOCKING STRAP PLATE (1”STRAP)

1

§ *

189598

D003980

FRONT STRAP GUIDE

1

189824

D004000

PNEUMATIC VALVE

1

189708

D004010

MAIN FRAME

1

189701

D004030

BOTTOM PLATE

1

189826

D004170

189706

D004510

GRIP PIN

2

189764

D004570

WELDING FOOT

1

§ *

189702

D004790

WELDING START LEVER

1

189765

D004850

CUTTER PIN

1

189766

D004860

PISTON

1

189827

D004920

BOTTOM PLATE (1”STRAP)

1

189828

D004930

MAIN FRAME (1”STRAP)

1

§

WEARING PART

* PART THAT SHOULD BE STOCKED

PWT

400-0060 (B200356) – TIMER VALVE

REF.

JDE ITEM #

ITEM

DESCRIPTION

QNTY

1 X 10.077.0

SPILLO 1/8.1 TAGLIO CACC RIBASS

1

2 X 12.002.1

NIPPLO REGOLATORE 1814

1 3 189296

OR 2043

OR 2043

1

4

189499

OR 102

OR 102 DA LUBRIFICARE

1

5

189983

12.103.1

PREMIGUARNIZIONE REG. 908

1 6 X

5*3*11

OR NBR 70 5*3*11

1

7 X 12.104.0

OTTURATORE REG. 908

1 8 190015

M4*20

VITE TCCE M4*20 UNI 5931 8G

2

9 X 12.101.0

GUIDA OTTURATORE PER REG.908

1

10 X OR 103

OR 103

1

11 X 12.102.0

MOLLA 908

1

12 X OR 101

OR 101

1

13 X 10.089.1

COMAND 2 VIE OTTURAT+RFU+VNR

1

14

189989

OR 2081

OR 2081 2 15 X 01.014.0

GUARNIZ LABBRO DE20

1

16

204100

10.040.1

CORPO VALV 2 VIE OTTUR CON TEMP

1

17

189499

OR 102

OR 102 3 18

189155

M4*30

VITE TCCE M4*30 UNI 5931 ZINC.BIANCO

2

19

190016

10.043.0/S

PISTONE D.20 CON SPOLA

1

20

189711

03.032.0

OTTURATORE VERDE

1

21

189631

03.025.0

GUIDA MOLLA

1

22 X OR 2093

OR 2093

1

23

190002

11.040.0

MOLLA RSW 1/8

1

24 X 10.042.1

FONDELLO VALV 2 VIE OTTUR

1

25 X M4*10

VITE TCCE M4*10 UNI 5931 8G

2

REF.

ITEM

DESCRIPTION

Q.TY

1 AM0004-01

End Plate

1

2 AM0004-02

End Washer

1 3 AM0004-03

Front Washer

1

4 AM0004-04

Front Plate

1

5 AM0004-05

Cylinder

1

6 AM0004-06

Silencer

1

7 AM0004-07

Roller

1

8 AM0004-08

Cap 1 9

AM0004-09

Housing

1

10

AM0004-10

Washer

1

11

AM0004-11

Blade

5

12

AM0004-12

Roll Pin

1

14

AM0004-14

Screw

1

15

AM0004-15

Bearing

1 16

AM0004-16

Bearing

1

BOSCH 0 607 951 449 – POLYCHEM 400-0036

REF.

ITEM

DSCRPT.

QTY

JDE PART #

3 605 125 063

Housing

3 604 090 009

Cylinder

3 604 220 005

Roller

3 605 700 167

Front plate

1 900 905 127

Bearing

3 605 700 010

End plate

1 900 905 029

Bearing

2 600 202 007

Washer

10

3 600 202 004

Washer

11

2 916 011 012

Washer

12

2 911 061 150

Screw

26

3 606 337 209

Pin

40

3 600 390 040

Cap

55

3 600 100 048

Washer

61

3 603 462 017

Silencer

66

3 604 710 032

Roll pin

95

3 601 108 047

Label

804

3 607 030 280

Blade

WELDING MOTOR

AM-0004-P-0703B-MI– POLYCHEM 401-0274

WELDING MOTOR

Polychem Corporation declares under own responsibility that the under mentioned machinery, to
which this declarations refers, is in conformity with

2006/42/CE

Directive and successive

modifications, as well as with standards

EN12100-1 / EN12100-2

POLYCHEM CORPORATION

6277 HEISLEY ROAD

MENTOR, OHIO 44060

Tel.: [phone] Fax: [phone] www.polychem.com

Manufactured in Italy

Series PWT

MACHINE TYPE