Lectra 543156da Preventive Maintenance Guide 500 1000h Vector IQ80 IQ50 IH8 IH5 Q80 Q50 en

Vector® iQ80, iQ50, iH8, iH5, Q50, Q80
500H-1000H Preventive maintenance guide
January 2017
Edition 4
543156 DA
lectra.com 1/91
PREFACE
Copyright
Translation of the original document.
©2017 Lectra. Any copy, reproduction or complete or partial translation of the information contained in
this document, without the written consent and agreement of Lectra, is prohibited by copyright law.
Guarantees
Lectra reserves the right to modify the information relating to its products, without prior notice, with the
aim of improving their reliability and operation. Publication does not imply that the material included is
free of all industrial property rights and does not grant any license over these rights. Moreover, Lectra
takes no responsibility regarding the consequences of its use for whatever purpose. The dimensions,
weights, performance measurements and other data mentioned in this documentation are approximate
and have no contractual value.
Registered trademarks
Vector® is a registered trademark of Lectra SA, France.
Loctite is a registered trademark of Loctite Corporation, USA. Klüberpaste is a registered trademark of
Klüber Lubrification München KG.
Update monitoring
Sheet
Edition Purpose of the update
Number
November 2012 Document creation.
January 2015 Modification of sheets. M13, M25.
Addition of a sheet. E1
April 2015
Addition of a note with a tightening torque. M1
January 2017 500-1000H maintenance plan update
This document contains:

• A plan consisting of the tasks to be performed and their scheduling over time.
• The sheets necessary for the replacement of parts contained in the preventive maintenance kits.
A Lectra course must be taken to perform the maintenance described in this document.
Key to icons used in this document
Note Personal danger
Advice or suggestion Risk of machine breakage
January 2017 - 543156 DA lectra.com 2/91

CONTENTS
Safety instructions and general indications................................................................................................. 3
Specifications of adhesive products............................................................................................................. 4
Specifications of greasing products ............................................................................................................. 5
Maintenance plan for 500 hours and 1000 hours of vibration .................................................................... 8
Conveyor
Replacing slats and blocks
Cutting bed maintenance
Cleaning the BBC (slab bed cleaner) and the roller ramps
Greasing the vacuum turbine
Replacing the X drive rails and sliders
Greasing the X drive rails and sliders
Cutting head
Removing the head covers
Removing the cutting head
Replacing the Y drive motor or pinion
Replacing the Y rails and sliders
Greasing the Y rails and bearings
Blade guide and presser foot

Removing the blade guide
Replacing and adjusting the sharpening unit guide
Fitting and adjusting a bracket with lateral bearings
Replacing the presser foot raising/lowering jack
Replacing the presser foot rim or dish
Stress sensor test
Adjusting the blade

Replacing the conical stops
Adjusting the upper conical limit stop
Replacing the blade raising/lowering jack kit
Adjusting the blade zero
Blade penetration adjustment
Sharpening
Replacing the arm pin. Cleaning, greasing or replacing the sharpener arms
Replacing the sharpener cable
Extracting a worn driver without the Lectra tool and gluing a new driver to the sharpener
Sharpener cable or sharpener control kit tension adjustment
Sharpening arm adjustment
Adjusting the sharpening system pressure
Chronological order of sharpening system adjustment
Checking the sharpening quality
Adjusting the sharpening symmetry
Vibration assembly
Replacing the vibration drive belt
Replacement of the vibration box rails and bearings

Adjusting the vibration belt tension

Replacing the crank pin + oblique bearing assembly
Adjustments and calibration in "Pilot"

Adjustments controlled by an Assistant in the "Maintenance" session

SAFETY INSTRUCTIONS AND GENERAL INDICATIONS
1. DEFINITION OF THE STANDARD INITIAL STATE
All the dismantling operations described must be carried out, unless otherwise specified, with the
cutter switched off: electrical and pneumatic lines switched off and isolated at the circuit breakers.
The machine must be isolated by two padlocks immobilizing the electrical switches in the "0" position
for the isolating switch on the control cabinet and the "Off" position for the power circuit breaker on
the control cabinet.
(The padlocks are not supplied by Lectra.)
Control Cabinet line circuit breaker.
"Vacuum" line power circuit breaker.
The tools, blade and punch needle, are removed.

(Use suitable protective gloves.)
Before starting any maintenance, briefly clean the head.
Some of the specific tools necessary for the servicing and maintenance of the Vector, which are referred to
in this document, are delivered with the cutter, and the remainder can be ordered using the Lectra item code.
2. SAFETY DATA SHEETS
You can get information about the safety data sheets of greasing and gluing products stated in this document
by contacting your Lectra call-center.
3. TESTS AND CALIBRATION THAT MUST BE PERFORMED FOLLOWING A

MAINTENANCE OPERATION
1. Beam Squaring
2. Blade Zero adjustment (essential after squaring)
3. Spot Calibration
4. Drill Calibration (drill)
5. Pen Calibration
6. X and Y Calibration
7. Blade Calibration
8. Clockwise and trigonometric circles test

SPECIFICATIONS OF ADHESIVE PRODUCTS
4. PRESENTATION OF PRODUCTS USED
Description Area of use Item code
Weak screwlock M2.5 screws and blade

116062
LOCTITE 222 raising/lowering limit stops.
Normal screwlock
M3 to M10 screws. 111683
LOCTITE 243
Immobilizing a bearing ring

Bearing glue (to prevent surface
LOCTITE corrosion and to prevent
107537
SCELROULEMENT rotation of the ring in
603 the case of bearings
that spin very quickly).
Fitting glue Assembling needle

LOCTITE bushings and adjusting the 116855
BLOCPRESSE 648 three sharpener arms.
Degreaser Degreasing any part

124924
3M cleaning pouch before gluing.
5. REMOVAL PROCEDURE
Elements assembled using glue (vibration bearings, presser foot and drill needle bushings) should only
be dismantled after heating with a hot air gun.
- A temperature of 150-160°C must be reached to destroy the glue joint.
- The heating time will depend on the size of the parts to be dismantled (10 to 20 minutes).

SPECIFICATIONS OF GREASING PRODUCTS
Greasing products used for the cutting head:

KLÜBER ISOFLEX NBU 15
G1 grease
- Blade guide roller bearings
130255
- Presser foot roller bearings
KLÜBER MICROLUBE GBU-Y 131: - Vibration box guide rails and sliders
G10 grease pump
- Recirculation ball bearings
124528
- Sharpener cable
- Drill block hinge axis
KLÜBER ISOFLEX TOPAS NB 152:

G11 grease pump
- Crank rod and blade holder piston
124529
box greaser
KLÜBER ISOFLEX TOPAS NB 52:

G12 grease pump
- Crank rod head needle bearing 124530
Situation of products used:
G12: Crank rod head

needle bearings.
G10: Vibration box guide
G10: Vibration box guide
rails and bearings.
rails and bearings.
G11: Crank rod and

blade holder piston.
G10: Drill block hinge axis.

G10: Sharpener cable.
G1: Rollers of the

blade guide.
G1: Rollers of the

presser foot.

Beam: greasing the Y rails and bearings:

KLÜBER MICROLUBE GBU-Y 131:
G10 grease pump
G10 code 124528

with extension and
Y rails and sliders connector and fine
on the beam nozzle included in
the greasing case
code 132001
G10: Front right

grease nipple
G10: Front left

G10: Rear grease
grease nipple
nipple
Beam: greasing the X drive rails and sliders

KLÜBER MICROLUBE GBU-Y 131:
G10 grease pump G10 code 124525
and hollow nozzle
X rails and sliders included in the
greasing case
code 132001

G10: 2 grease nipples on
either side of the beam

Products used for greasing the vacuum turbine:

KLÜBER ISOFLEX NBU 15 grease
Vacuum turbine 115361
130255
All markets EXCEPT AUTO
Grease pump

131962
All markets EXCEPT AUTO
KLÜBERSYNTH BEP 72- 82 grease

135177
AUTO market ONLY
Grease pump

705037
AUTO market ONLY
All markets
EXCEPT AUTO:
Greasing every
Turbine grease nipple 1000 hours
AUTO market ONLY:

Greasing every
750 hours

MAINTENANCE PLAN FOR 500 HOURS AND 1000 HOURS

OF VIBRATION
Every 500 hours of blade vibration: use the 500h kit
Operations to be performed Pieces Sheets
Cutting head
As desired: leave the cutting head in place or remove it and place it on a surface. M6-M7
Replace the vibration box crank rod housing bearing kit. 3 M34
Replace the vibration box conical limit stops. 1 M17-M18
Replace the 2 central blade guides. 5 M11 -M12
Replace the small bearings in the presser foot fork. 8 M13-M14
Replace and grease the bronze roller in the presser foot fork. 12 M13-M14
Replace the sharpener cable kit. 9 M23-M25
Replace the sharpener return spring. 16 M22
Grease the attachments of the sharpener return spring. 16 M22
Replace the sharpener driver. 15 M24
Replace the sharpener arm pin and diabolos. 6-7 M22-M25
Check the uniformity and symmetry of the sharpening, and then replace the sharpener
/ M28
belts, if necessary.
Replace the screw and captive washer in the drill support. 4 /
Replace the blade raising/lowering jack on the vibration box. 13 M19
Replace the presser foot raising/lowering jack. 2 M14
Grease the Y drive rails and sliders. / M9
Conveyor
Replace the turbine filter (and its seals) (see operator sheets). 10-11 /
Grease the X drive rails and sliders. / M4

The parts illustrated below may differ in size and number according to the machines (Vector iQ80, iQ50, iH8, iH5,
Q80, Q50) and / or the markets (Automotive, Fashion, Furniture ...)
500H Kit
10
3
11
10 1
13 4
9
2
6
5
16
15
7
12

Every 1000 hours of blade vibration: use the 1000h kit

Cutting head (as desired: leave the cutting head in place or remove it and place it on a surface).
Repeat the actions for the 500 hour kit, and then,
Replace the Y motor pinion and circlips. 17-18 M8
Replace the upper bearings in the presser foot fork. 19 M13-M14
Conveyor
Remove the conveyor slats for cleaning. / M1
Replace 180 bristle blocks (1 box of 30 blocks, item code 131181 x 6). / M1
The parts illustrated below may differ in size and number according to the machines (Vector iQ80, iQ50, iH8, iH5,
Q80, Q50) and / or the markets (Automotive, Fashion, Furniture ...)
1000H Kit
17
18
19

Every 1200 hours of vacuum:

Turbine
Grease the turbine. / M3
Conveyor
Clean the banks of bearings. / M1-M2
Clean the BBC (slab bed cleaner). / M1-M2
Adjustments controlled by an assistant in the Maintenance session

“Blade zero adjustment” / M35

“Sharpening angle adjustment” / M35
“Spot offset calibration” / M35
“Needle offset calibration” / M35
“Drill 1 offset calibration” / M35

Conveyor
Replacing slats and blocks M1
Index 1
Vector® iQ80, iQ50, iH8, iH5, Q50, Q80 - 500H-1000H Preventive maintenance guide Page 1/2
Aim:
To replace the worn slats and blocks.
Tools:
Standard tools - Loctite 243 normal screwlock.
Initial state:
Standard initial state, described in paragraph 1 of the "Safety instructions" chapter.
Dismantling procedure:
1. Remove the screws (1) from each front and rear flap flange.
2. Remove the screws (2) over the entire length of the side fastening plates.
3. Remove the flanges, the fastening plates and then the flaps (3).
2 3
1
4. Unscrew the stop blocks (4) on both sides of the slats.
- Remove the slats containing the worn blocks and place them on the trestles.
5. Extract the blocks (5) through one of the sides of the slat.
4 5
Replacement procedure:
1. Normal Loctite 243 screwlock must be put on the slat fixing points.
2. Position the slats so that the oblong holes (6) are on the right side of the conveyor.
Tighten the screws of the stop blocks to a torque of 4,5 Nm.
Place the last slat by fitting it at a slant between the previous two.

Replacing slats and blocks M1
Index 1
3. Perform a complete turn of the conveyor to verify all the slats.

4. Refit the flaps, the lateral fastening plates and then the flanges.
- Below, the position of the flaps on the front comb (7) and the rear comb (8).
8
7

Cutting bed maintenance E1
index 1
Entretien
Page 1/5
Frequency
Daily, Weekly and 100 h
Tools
- Cloth
- G10 grease pump (Kübler Microlübe GBU-Y 131 Grease) - code 124528
- Vacuum cleaner
Check the grease use-by date, indicated on the packaging.
For cleaning operations, do not use a compressed air blower.

When removing dust, cleaning or replacing the various machine air filters, you are recommended
to wear:
- Safety goggles with side protectors.
- Anti-dust mask type FFP3.
- Protection gloves specially adapted for cut material.
- Specially adapted work clothing (especially if the Vector is cutting Technical Textiles).
This equipment is not supplied with the machine.
Initial state
The two electrical power supplies (Control and Vacuum) and the air supply are switched off at the cutter
main switches.
Daily maintenance
When cleaning the translucent covers (head cover and beam ends), use only mild soapy water to
avoid chemical damage (cracks) in these covers.
1. Run the vacuum cleaner over the X rails (1) and racks (2).
2. Check the cleanliness of the X rails.
2 3

index 1
Entretien
Page 2/5
Weekly maintenance
1. Check that the conveyor's steel sealing flaps (3) have not deteriorated.
2. Check the condition of the front and rear combs (4): The teeth should not be broken or bent.
3. Reapply a light film of oil on the X rails (1) using the G10 grease.
4. Check that ALL the plugs (5) on the rail fixing screw heads are present. The X rail plugs (5) can be
ordered in quantities of 100 under the reference 131139.
The absence of a plug could cause the destruction of the slider sealing joints. Dust could then penetrate into
the slider, which would considerably reduce its lifespan.
5. With the vacuum cleaner, clean the cable carrier (6). Move the beam over its entire track to remove
all the cutting waste.
6. Visually check the condition of the cable carrier (6).

7. Check the condition of the cutting conveyor bristle blocks.
8. Clean the grilles on the air inlets (7) and outlets (8):
- Unclip the grille from its support.
- Retrieve the filters from the grilles equipped with them (air inlets (7)).

index 1
Entretien
Page 3/5
- Remove any accumulated dust from grilles and filters before re-fitting them.
8
7
7 7
The 6 dust filters on the air inlets (7) should be replaced every 2000 h of operation (Maintenance Kit).
Check regularly that no plastic or paper is obstructing the air inlet.

If a cutting waste recovery tray is used, this should not obstruct it in any way.
9. Open the electro-technical Control cabinet access door and purge the pneumatic plate regulator filter.
The purge is manual; simply press the button (9) at the bottom of the filter to perform the purge.
10. Check the cleanliness of the filter: If the filter is dirty and clogged, replace it. The filter should be replaced
every 2000 h of operation (Maintenance kit).
- Unscrew the filter bracket.
- Fit the new filter in its support and re-tighten it.
Depending on the brand of the regulator filter in the cutter, it may have a semi-automatic purge. In this case,
the purge is performed automatically when the air supply is switched off (on/off switch).
11. Clean the vacuum turbine filter:

- Unscrew and withdraw the vacuum pipe access cover at the front right of the cutter. If the
vacuum pipe access cover is difficult to remove, switch on the vacuum to facilitate the operation.

index 1
Entretien
Page 4/5
- Release the filter / cylindrical grille unit from the pipe.
10
13
12
11
- Remove the 2 sealing joints (10).

- Remove the filter (11) from the cylindrical grille (12).
- Using a vacuum cleaner, clean the entire length of the pipe (13) and the cylindrical grille (12).
- Remove the dust from the filter (11) using the vacuum cleaner.
- Put the cleaned filter (11) back on the cylindrical grille (12), taking care to correctly fold the two
ends inside the grille.
- Check the condition of the 2 sealing joints (10). The 2 joints should be replaced every 500 h
(Maintenance kit).
- Put the 2 sealing joints back so as to correctly hold the filter. The joint should cover the filter fold.
- Replace the filter/cylindrical grille unit in the pipe.
- Close the vacuum pipe access cover.
The frequency of the vacuum filter cleaning and replacement depends on the type of material being cut.
The frequency should be adjusted based on the application.

index 1
Entretien
Page 5/5
100 h maintenance
1. Replace the vacuum turbine filter (Tubular dust filter: 129335).
If, after a number of dismantlings, the threaded

rod fixing the access cover to the pipe has
deteriorated, use a hot air gun to remove it.
Refit a new 12.9 class screw (410480) with

strong screwlock, complying with the minimum
measurement of 23 mm.
23 mm
The filters and sealing joints required for the 500 hour maintenance and beyond are included in the different
Maintenance Kits.
250 h maintenance
1. Open the covers of the electrical cabinets and remove all the dust from the cabinets using a vacuum
cleaner.
The other operations related to preventive maintenance of the cutter (Maintenance Kits) are set out in the
Preventive Maintenance Guide.

Cleaning the BBC (slab bed cleaner) and the roller ramps M2
Index 1
Frequency:
Every 6 months (3 shifts) / 1 year (2 shifts).
Aim:
To clean entirely the interior of the conveyor.
Tools:
Standard tools. Normal Loctite 243 screwlock. A high-volume industrial vacuum cleaner.
Initial state:
Standard initial state, described in paragraph 1. of the "Safety instructions" chapter.
1. Remove all the slats (please refer to sheet M1).
2. Place all the slats on trestles.
3. Use the vacuum cleaner to clean:
- The slats and bristle blocks.
- The roller ramps and the interior of the conveyor (1).
- The conveyor motor (2).
- The BBC (slab bed cleaner) (3).
2
3
1. Perform the reassembly operations (please refer to sheet M1).

Greasing the vacuum turbine M3
Index 1
Frequency:
Grease the 115361 turbines (all markets except AUTO): Every 1000 hours of operation.
Grease the 134700 turbines (AUTO market only): Every 750 hours of operation.
Initial state:
Tools:
- All markets except AUTO: Grease pump (131962).
ISOFLEX NBU 15 grease cartridge (130255).
- AUTO only: Grease pump (705037).
KLÜBERSYNTH BEP 72- 82 grease cartridge (135177).
A: Grease cartridge
B: Empty cartridge supplied with the pump (used as a cartridge when filled with grease)
C: Piston with chain attached
D: Greasing nozzle
E: Hose
F: Top of pump
G: Pump body
A
B
C
Warning, the piston (C) is essential to

operate the pump!
Do not lose it.
E F G
1. Unlock the latches (1) to open the panel.
Grease pump assembly and preparation:

2. Unscrew the top (2) of the pump.

Index 1
3. Pull the cap (3) out of the grease cartridge.

4. Insert the piston (4), with its chain until it reaches the edge of the cartridge.
5. Place the chain in the piston (5).

6. Insert the grease cartridge into the tube, while simultaneously pressing the air release valve (6).
5 6
7. Remove the "PULL-OFF" cap with the loop handle (7).
8. Screw the top of the pump (8) to the body of the pump.

Index 1
9. Screw the flexible hose (9) to the end of the pump.
10. Pump sufficiently to pressurize the air pressure accumulator (10).
10
11. Activate the lever (11) several times until the grease begins to come out of the hose nozzle.
11
Launching the assistant:
- Click on the button to enter the cutter operating software’s "Maintenance" session.
- Click the test tab:
- Click on "Test Assistant".

- Click on "Vacuum turbine run-in" and the following dialog box appears:
Touch here

Index 1
- The following dialog box appears:
Touch here
- A message appears:
12. Place some paper and polyethylene film (12) over the entire surface of the bed and flaps.
12
- Press the keypad validation button .
- The following message appears:

- Click on "Yes", and the turbine begins to rotate at 5% of its maximum speed.
You can now start the greasing.
Touch here

Index 1
Greasing the turbine:

13. Fit the nozzle of the hose into the grease nipple (13) in the cabinet.
13
14. Press 35 times:

- Activate the pump 35 times to inject the grease into the turbine bearing.
15. Raise the lever to its stop in the upper position (14) and then press it down as far as it will go.
Warning! During the greasing operation the lever (14) should offer resistance to the pressure; if it does
not, this means the pump is not injecting grease into the turbine.
In this case, reprime the pump: disconnect the pump and refer to points 9 and 10.
14
Keep the hose nozzle straight

so that the grease does not leak
from the sides.
16. Ensure that the pressure is maintained in the air accumulator (15):
Check this by operating it to ensure it offers sufficient resistance to pressure.
15

Index 1
17. After 10 minutes the following message (16) appears:
- Answer "Yes" if the 35 grease injections have been performed.

- Answer "No" if the operation is not finished, and the turbine will keep running for 10 more minutes
at 5% speed.
16
Automatic turbine run-in:

18. If you clicked on "Yes" the window (17) displays, giving the remaining running-in time.
17
12
The turbine goes through the following stages automatically:
- 3 minutes at 15%
- 3 minutes at 25%
- 3 minutes at 35%
- 3 minutes at 45%
- 3 minutes at 55%
- 3 minutes at 65%
- 3 minutes at 75%
- 3 minutes at 85%
- 3 minutes at 100% and then finishes with
- 3 minutes at 50%
The complete breaking-in cycle lasts 33 minutes.

Index 1
19. When the running-in has finished, press the button on the right.
Touch here
20. Remove the pump: hold the hose pipe nozzle (18) and pull hard.
18
Check that grease is still coming out the hose nozzle (19) when you operate the pump, to ensure that it
was still primed.
19
21. Purge the pump by pressing the air release valve (20).
20

Replacing the X drive rails and sliders M4
Index 1
Aim:
To replace the used sliders (lifespan: ~ 8000 to 12000 hours) with the "2 T25 sliders kit":
INA sliders, code 132060.
Every time a slider has a lower lifetime: greasing procedure has not been respected or daily
maintenance not (or not correctly) performed.
Sliders can only be replaced 3 times (at maximum) on the same rail, after which the complete rail must
be changed.
Replace the rails equipped with their sliders (lifespan: ~ 12000 to 16000 hours) using the:
"2 prismatic rails and 2 T15 X sliders kit", code 704556 (cutter without the PostPrint option).
"2 prismatic rails and 3 T15 X sliders kit", code 704660 (cutter without the PostPrint option).
Tools:
Standard tools. Torque wrench. Loctite 243 normal screwlock.
Initial state:
The beam must be removed or raised in order to replace the sliders or the rails and sliders (see the
"Beam removal" sheet).
Slider only kit:
1. Remove or raise the beam (see the "Beam removal" sheet).
2. Remove the worn sliders (2) from one end of the rail.
3. Place the new sliders on the rails.
The machined surfaces (3) and the grease nipples (4) on the sliders should face upward.
3
4 4
4. Reinstall the beam (see the "Beam removal" sheet).
Perform the greasing procedure described in sheet M5.

Index 1
Rails and sliders kit:
1. Remove or raise the beam (see the "Beam removal" sheet).
2. Using a small screwdriver, remove every second protective cap (2), starting at the end of the rail
(the fixing screws are in every second hole on the rail).
3. Remove the fixing screws (3) over the entire length of the rails.
4. Remove the rails equipped with sliders.
Clean the surfaces of the rails and racks before fitting them.
5. Position the new rails on the racks so that:

The machined surfaces (4) and grease nipples (5) face upward.
5 5
6. Fix the rails (6) by:

- Gluing the screws with Loctite 243 screwlock.
- Locking the screws with a torque wrench to a torque of 16,680 Nm.
16,680 Nm
+

Index 1
7. Insert the new caps using the tool supplied with the kit.
- The caps should not protrude beyond the rail, they should be slightly sunken.
8. Reinstall the beam (see the "Beam removal" sheet).
Perform the greasing procedure described in sheet M5.
9. Adjust the beam squaring (see the "Beam squaring procedure" sheet).

Greasing the X drive rails and sliders M5
Index 1
Frequency:
500 hours
Tools:
Standard tools. G10 grease pump, Lectra code 124528.
Initial state:
Greasing procedure:
1. Use a G10 grease cartridge (1), Lectra code 124528.
2. Screw the nozzle (2) on the pump if it was not already fitted with one.
G10
1 2
3. Position the pump nozzle on each grease nipple (3); there are two grease nipples on each side of the
beam; press the pump to inject.
4. Grease each slider by moving the beam along the entire length of the rails so that the grease fills
the space between the bearings.
The slider has been correctly greased when the grease spills out of it.

Cutting head
Removing the head covers M6
Indice 1
Aim:
To remove the head covers for access for maintenance operations.
Tools:
Set of Allen wrenches.
Initial state:
The head front cover (1) should be closed at the start of the dismantling operations.
The photos show a Vector iX9, the procedure is identical for iX6, iQ80, iQ50, iH8, iH5, Q80, Q50.
1. Unlock the latch (2) securing the rear head cover (3), using the key provided for this purpose.
2. Carefully remove the cover toward the rear (4).

Indice 1
3. Raise the front cover (1) and then lock it in position using its prop (5).
4. Remove the 2 cover pin fixing screws (6).
5. Hold the raised cover with your hand and then:

- remove the screw (7) securing the top of the prop,
- remove the pin (8), by sliding it outward.
6. Remove the front cover.
7 8

Indice 1
1. First re-fit the front cover:
- Position the pin (8) in its housing (see the previous page).
- Fix the two screws (6) to the pin (8) using Loctite 243 screwlock.
Take care with the positioning of the fixing screws (6):

Badly positioned, as shown below, they will prevent the closing of the rear cover and may cause its
breakage.
NO!
Deformation
OK!
+
2. Hold the front cover partly open and then engage and position the rear cover.
3. Lock the latch (2) of the rear head cover.

Removing the cutting head M7
Indice 1
Aim:
To remove the cutting head.
Tools:
Standard tools. Loctite 243 normal screwlock.
Initial state:
The head covers are removed.
Adjustment procedure:
1. Remove the four screws (1).
2. Remove the protective plate (2) from the cable carrier.
1
1
1
2
3. Position the beam at the machine zero position (3) in order to allow free passage of the
mechanical limit stop (4) when removing the head.

Indice 1
4. Remove the electrical and pneumatic connectors from the circuit board (5).
5. Remove the screws (6) fixing the connector support plate to the top of the head.
6. Remove the screws (7) fixing the support plate connected to the side of the head.

Indice 1
7. Slacken the screws (8) without removing them.

8. Pivot the motor around itself to release its pinion from the rack.
8
8
9. Remove the screws (9) from one side of the head and then the screws (10) from the other side.
9
+
10
10. Remove the four screws (11) from the rear of the head.
11 +

Indice 1
11. Locate a suitable screw in the holes (12) and secure with a nut.
Warning! Never use the holes (13), which are for fixing the cover.
12. Lift the head using a hoist.

13. Place the head on a stable support.
13
12
1. Position the front of the head fully against the bearings with the plate attached (4).
- The heads of the screws (15) should sit in the holes drilled in the lower plate of the head.
15
14 16
15
14
2. Tighten the head screws (9), (10) and (11) using Loctite 243 normal screwlock.
Check that there is no play between the part (16) of the head and the equipped sliders (14).
3. Pivot the Y motor in its housing until the rack and pinion mesh with only sufficient clearance for
them to run freely.
4. Reverse the operations described in the dismantling chapter.
Move the head manually on the beam to check that there is no stiffness.

Replacing the Y drive motor or pinion M8
Index 1
Aim:
To replace the Y drive motor or pinion.
Tools:
Standard tools. Normal Loctite 243 screwlock. Re-fitting tool No. 131722.
Initial state:
Note: The Y pinion can be replaced with the head positioned on the beam.
1. Disconnect the motor electrical power supply cables.
2. Unscrew the Y motor locking part screws (2).
3. Pivot the motor to position the flat sides (3) of the plate opposite the locking parts (2).
4. Pull the motor (4) upward to release it from its housing.

5. Place the motor and its fittings (5) on a workbench.
4
5
6. Remove the circlips (6) securing the pinion using circlips pliers.
7. Screw the two screws (7) provided into the two threaded holes located at the top of the Y pinion to
withdraw it from its spindle. Warning: Do not twist the pins (A).
7
6
A

Index 1
1. Screw the threaded rod (1) as far as it will go into the motor shaft, without forcing it.
(Screw supplied with the reinstallation tool No. 131722.)
2. Place a new pinion on the motor shaft (2) and push it down.
3. Place the part (3) of the tool on the pinion and across the screw.
Take care with the positioning: The clearance in part (3) directed downward.
Warning!
1 2 Positioning of 3
threads here.
4. Position the nut (4) (supplied with the tool) on the screw (1).
5. Using an Allen wrench, hold the nut in place, and then tighten it with an open-ended wrench until the
pinion is positioned at its stop on its spindle (5).
6. Remove the reinstallation tool and fit a new circlips in position (6).
4 5 6
7. Position the motor in its housing (7) so that:

- a flat side (B) is aligned with the edge of the support,
- the electrical cables (C) are correctly positioned.
7 C

Index 1
8. Pivot (8) the motor clockwise to bring it into contact with the Y pinion and the rack without play but
without restriction.
9. Lock the screws (9) with normal Loctite 243 screwlock.
9
+
10. Connect the motor electrical cables.
Move the head manually on the beam to check that there is no stiffness. If there is, find its origin and
redo the adjustment.

Replacing the Y rails and sliders M9
Index 1
Aim:
To replace the used sliders (lifespan: ~ 6000 to 10.000 hours) with the "3 T15 bearings kit"
(INA code 132147).
Every time a slider has a lower lifetime: greasing procedure has not been respected or daily
maintenance not (or not correctly) performed.
Bearings can only be replaced 3 times (at maximum) on the same rail, after which the complete rail
must be changed.
To replace the rails and sliders (lifespan: ~ 10.000 to 14.000 hours) using the
"2 prismatic rails kit and 3 YT15 sliders", code 704559 for the 72".
"2 prismatic rails kit" and 3 YT15 sliders", code 704562 for the 86".
Tools
Standard tools. Torque wrench. Loctite 243 screwlock.
Initial state:
Slider only kit : (The covers and the head are removed.)
1. Remove the link plate (1) by taking out the four screws.
2. Remove the three worn sliders (2) from the ends of the rail.
3. Place the new sliders (3) on the rails:

- The machined surfaces(A) of the sliders must be placed outward.
- The slider grease nipples (B) must be directed to the exterior of the trolley.
3 B
A
B
4. Fix the link plate (1).

5. Refit the head on the bearings (see the "Removing the head" sheet).
Grease the sliders (see sheet M10).

Index 1
Rails and sliders kit: (The covers and the head are removed.)
1. Remove the support plate (1).
2. Remove all the plugs (2) using a small screwdriver.
3. Remove all the fixing screws (3) and then the rails and sliders (4).
4. Place the rails (4), equipped with their sliders, on the beam.
- The machined face (A) of the sliders should be positioned facing toward the outside of the beam.
- The grease nipples (B) should be facing toward the outside.
5. Apply Loctite 243 screwlock on all the screws (5) and then tighten over the entire length of the rails
without locking them.
+ 5

Index 1
6. Hold the rail against the machined surface (6) of the beam and then lock the screws one by one
with a torque of 4.5 Nm.
- You must tighten them in the direction shown below (7) as this enables the rail to naturally
lie flat against its support.
6
7
4.5 Nm
7. Position plugs (8) on the new rails and press them in using the tool supplied with the kit.
The plugs must not protrude above the surface of the rail.
8. Fix the link plate (1).
Grease the bearings (see sheet M10).

M10
Greasing the Y rails and bearings Index 1
Frequency:
500 hours
Tools:
Standard tools. G10 grease code 124528 and nozzle with extension in the greasing case code 132001.
Initial state:
Standard initial state, described in paragraph 1 of the "Safety instructions" chapter..
To grease the bearings, raise the front cover and remove the rear cover from the head.
Greasing procedure:
Greasing the sliders at the front of the head:
1. Position the pump nozzle on the grease nipple (1).
2. Press the pump to inject grease (2), release the pressure and repeat until the grease overflows
out of the bearing.
3. Grease each bearing while moving the head along the entire length of the rails so that the
grease fills the space between the bearings.
2
3
G10 THK
BOSCH
REXROTH
G10
INA

Greasing the Y rails and bearings M10
Index 1
Greasing the rear bearing of the head:
Fit the extension to the pump to grease the rear bearing of the head.
4. Place the pump nozzle on the grease nipple (4) at the back of the head.
5. Press the pump to inject grease (5), release the pressure and repeat until the grease overflows out of
the bearing.
6. Grease each bearing while moving the head along the entire length of the rails so that the
grease fills the space between the bearings.
!
G10
#3
!
G10
THK
BOSCH
REXROTH
INA

Blade guide and presser foot
Removing the blade guide M11
Indice 1
Aim:
To access the blade guide rollers or the sharpening central guide.
Tools:
Standard tools – Loctite 243 normal screwlock.
Initial state:
1. Remove the screws (1) securing the blade guide to the revolving support.
2. Remove the blade guide (2) by pulling it downwards.
1
1
1. Reposition the blade guide on the revolving support, taking account of the positioning tab (3).
2. Refit and tighten the screws (1) using Loctite 243 normal screwlock.

Replacing and adjusting the sharpening unit guide M12
Index 1
Aim:
To replace or invert the two parts of the central guide (when re-fitting, the play necessary for correct
blade sharpening must be complied with).
The photos below show the central guide of a 2-arm sharpening system, but the procedure is the same for
the central guide of a 3-arm sharpener.
Tools:
Standard tools – Loctite 222 weak screwlock – Cutting blade.
Initial state:
When over-pronounced wear on the lower area of the two parts (symmetric) of the central guide is
discovered, they can be inverted.
Aim: To optimize the lifespan of these parts and to eliminate the play caused by wear.
1. Remove the presser foot block (please refer to sheet M11).
2. Remove the screws (1).
3. Depending on wear, invert, replace or refit the two parts of the central guide.
1. Using Loctite 222 screwlock replace the screws (1) without tightening them.
2. Engage a 2.4 x 8.5 cutting blade in the blade guide the wrong way round.
1
3. On one side:
- Hold the blade flat against the guide (2).
- Push the central guide (3) against the blade and lock the two screws (1).
4. Perform the same operation on the other side.

Index 1
Checking the adjustment:
There should not be any play between the blade and the two parts of the guide.
1. Position the blade in the guide and put the unit on a workbench.
2. Hold the blade guide and release the blade, which should not fall.
Verification of the passage of the blade in the sharpening central guide lower rollers:
The presser foot and the blade are positioned on the head (see sheet M11).
1. Use the crankshaft the position the blade away from the lower rollers (4) of the guide.
2. Make a mark (5) with a felt-tip pen on the top of each roller.
3. Use the crankshaft to move the blade through the lower rollers.
The blade must not turn the rollers, observe the mark (5). Adjust if necessary.

Index 1
Adjusting the rear gauge:

Aim: To avoid damaging the point of the blade during cutting.
1. Place the presser foot (1) in the upper position.
2. Lower the blade until the heel of the sharpened part (2) is in contact with the lower conical rollers (3)
of the effort sensor (see cut).
3 2
0 mm
3. Remove screw Hc (4) which holds the gauge on the blade guide.
4. Put the gauge (5) in contact with the blade (6).
5
6
+
4
5. Retighten screw Hc (4) using Loctite 222 screwlock only on the thread.

Fitting and adjusting a bracket with lateral bearings M13
Indice 2
Aim:
To replace and adjust a bracket with lateral bearings.
To replace the bearings in the bracket.
Tools:
Size 5.5 and 10 open-ended wrenches. Set of feeler gauges. Hot air gun. Loctite 603 glue (Lectra
107537). Small brush. 3M cleaning cloth (Lectra 124924). G10 grease (Lectra 124528).
Initial state:
Standard initial state, described in paragraph 1 of the “Safety instructions” chapter.
Removal procedure:
1. Hold the jack axis using an open-ended wrench positioned on the flat parts and then unscrew the
locking nut (1).
2. Unscrew the jack axis and take it out of the bracket (2).
1 2
3. Remove the bracket by tilting it towards the outside (3) to release the small lower bearing from
the groove in the presser foot rim.
Replacing the upper bearings:
1. Remove the bearings by taking out the screws (1) and (2).
2. Fix the new bearings in position, applying Loctite 243 normal screwlock to the screws (3).
Tighten the screws (1) and
(2) to a torque of 4.5 Nm
3
1 2

Indice 2
Replacing the lateral bearings:

3. Unglue the damaged lateral bearings (8) using a hot air gun.
Degrease the new bearings and pins using a 3M cleaning cloth.
4. Glue each bearing aligned with the end of its pin (9) with Loctite 603 block seal.
Do not apply too much glue, otherwise it will penetrate into the bearing.
+
9
Reinstalling the bracket on the presser foot:

1. Grease the axis (1) and the bronze roller (1B) with G10 grease (Lectra code 124528).
The roller (1B) must rotate freely on its greased axis, it must never be glued.
2. Engage the bronze ring (1B) in the channel under the rim (2).
3. Position the bracket vertically (3).
2 3
1 1B
G10

Indice 2
4. Screw the jack axis (4) into the bracket.
Adjusting the presser foot upper stop:

5. Manually raise the presser foot to the upper stop (5).
Screw or unscrew the jack pin in the bracket to obtain play of 2 mm at location (6).
6
2 mm
6. Hold the jack stem using an open-ended wrench positioned on its flat surfaces and then tighten the
locking nut (7).
Check that there is play of 2 mm at location (6).

Indice 2
Adjusting the play of the lateral bearings:

7. Restore the pneumatic supply and put the presser foot in the raised position (8).
8. Unscrew the jack fixing nut by 1 turn (9).
8 9
9. Position a 0.1 millimeter feeler gauge between the lateral bearings and the rim (10).
10. Hold the feeler gauge in place and tighten the nut securing the jack (11).
10 11
Checking the play:
The play should be between 0.05 mm and 0.1 mm.
Check the condition of the presser foot rim: wear of the rim can cause the presser foot to become loose and
the jack to break. To replace the rim, please refer to sheet M15.

Replacing the presser foot raising/lowering jack M14
Indice 1
Aim:
To replace the blade raising/lowering jack.
Tools:
Initial state:
The bracket must be removed first, as there is a risk of damaging its small lower bearing.
1. Remove the presser foot bracket (please refer to sheet M13).

2. Mark the position of the sensor (1) on the jack.
3. Remove the pneumatic pipes from the elbow connectors (2).
4. Unscrew the fixing nut (3) from the jack.
5. Remove the jack by making the jack stem pass through the gap in the support (4).
4
1
6
3
1. Reverse the removal procedure.
2. Reinstall the sensor (1) by referring to the position marked during dismantling.
WARNING! The detector must be properly perpendicular to the jack. If it is mounted slightly crosswise,
this can upset the position detection.
3. Reinstall the presser foot bracket (please refer to sheet M13).
4. Adjust the la position of the jack in the support (4) to remove any stiffness between the
bracket bearings and the bracket (5) and the rim (6).

Replacing the presser foot rim or dish M15
Indice 1
Aim:
To replace the presser foot rim, dish and/or spiral cable.
Tools:
Standard tools, Loctite 243 normal screwlock, G1 grease.
Initial state:
The presser foot block is removed (sheet M14).
1. Remove the screws (1) and the protective plate (2) from the stress sensor.
2. Remove the screw (3) holding the spiral cable, and its washer.
3. Disconnect the spiral cable from the presser foot terminal (4).
4. Release the presser foot from the revolving support: take care with the spiral guide passageway and
do not damage the spiral cable.
5. Take out the three screws (5) to remove the rim (6).
6. Remove the four screws (7) fastening the dish (8) to remove it.
2 5
3
6
7 7
5
7
1 7
+ 4 8
5
Replacement procedure
1. Reinstall a new rim to the presser foot, gluing the 3 screws (5) with Loctite 243 normal screwlock.
2. Reposition the presser foot above the revolving support.
3. Wind the spiral cable coming from the revolving support on to the spiral guide and then re-screw the
2 guide columns.
4. Re-connect the spiral cable to the presser foot terminal.
Follow the wiring shown on the label
Terminal
- Brown wire ...................... terminal No. 1
- Yellow wire ...................... terminal No. 2
- Green wire ...................... terminal No. 3
- White wire ....................... terminal No. 4

Replacing the presser foot rim or dish M15
Indice 1
5. Replace and glue the screws (7) securing the dish (8) with Loctite 243 normal screwlock.
6. Replace and glue the spiral cable screw (3) and its washer with Loctite 243 normal screwlock.
7 7
+ 8
7. Replace and glue the screws (1) securing the protective plate (2) with Loctite 243 normal screwlock.
Warning! The protective plate (2) should not touch the stress sensor (9) to avoid putting any strain on it.
2 2
1 +
8. Engage the jack fork in the presser foot rim (see sheet M13).
9. Ensure that the jack is correctly aligned (see sheet M14).
10. Reconnect the Flex sensor connector to the head integrated circuit board (see sheet M14).
11. Perform an operational test on the stress sensor (see sheet M16).

Stress sensor test M16
Indice 1
Aim:
To check the correct operation of the stress sensor.
Tools:
An electronic scale.
Initial state:
Cutter switched on, cutting blade in place.
Test procedure:
1. Touch the button to enter the cutter operating software’s "Maintenance" session.
2. Touch the "Tests" button .
3. Touch "Test assistants".

4. Select the "Stress sensor test" assistant.
- The "Stress sensor test" box opens.
5. Touch the arrow to follow the procedure described by the assistant.
6. Place the hook of the device against the blade.
7. Exert stress on the blade corresponding to the values required by the assistant.
8. Follow the instructions given by the test assistant.

Adjusting the blade
Replacing the conical stops M17
Index 1
Aim:
To replace the box lower and upper conical limit stops.
Tools:
Ruler and size 13 flat wrench.
Initial state:
Measure the distances (1) & (2) (from the upper surface of the extractor bob to the tip of the limit stop).
1. Unscrew the lock nut (3) from each limit stop.

2. Remove the limit stops (4).
4
1
3
3
2
4
1. Fit new conical limit stops.
Refer to the measurements (1) and (2); then adjust as necessary.
2. Tighten the locknuts (3).

Adjusting the upper conical limit stop M18
Index 1
Aim:
To adjust the upper conical limit stop to obtain correct blade sharpening.
Tools:
Standard tools.
Initial state:
1. Switch on the pneumatic supply to position the box at the top limit stop.
2. Position the crank head at its top dead center (1) as shown below, to have the blade at its highest point.
3. Adjust the upper conical limit stop (2) to obtain the value (3), this will ensure correct sharpening of
the lower part of the blade.
12 mm
(From the blade angle to

the bottom of the belt)

Replacing the blade raising/lowering jack kit M19
Index 1
Aim:
To replace and adjust it.
Tools:
Initial state:
1. Using a wedge, hold the vibration box in the upper position.
2. Remove the prop path (1) fixed to the left side of the cradle.
3. Remove the pneumatic pipes from the elbow connectors (2).
4. Mark the position of the sensors (3) on the jack to be changed.
5. Remove the nuts (4) and (5) and then remove the jack.
6. Remove the sensors (3).
3 4
1
3
5
1. Repeat the procedure, reversing the operations described.
When re-fitting the sensors, refer to the measurements taken previously.
Warning, the detector must be properly perpendicular to the jack. If it is mounted slightly crosswise,
this can upset the position detection.
2. Perform an entry/exit test in maintenance mode to refine the triggering of the cells.

Adjusting the blade zero M20
Index 1
Aim:
To adjust the blade zero.
Tools:
Blade zero adjustment tool 131091.
Initial state:
The cutting head is in place on the cutter and all connections are made.
Place the machine head on the operator side before making the adjustment.
1. Enter the machine "Maintenance" session.
2. Access the "Machine adjustment" function.
3. Start the "Blade zero adjustment" assistant.
4. Follow the procedure described in the assistant, up to the "Fitting the tool" chapter.
5. Open the head cover.
6. Place the tabs (1) the blade adjustment tool 131091 in the revolving collector (2).
7. Position the tool fork (3) against the tab (4).
8. Follow the procedure described by the assistant.
9. Remove the tool when the adjustment is completed.
When the tool is engaged the angular position of the blade is 180°:
The blade cutting edge is oriented along -X.
2
4

Blade penetration adjustment M21
Index 1
Aim:
To prevent damage to the cutting bed conveyor blocks (blade too low) and to prevent poor cutting of the
lower plies (blade too high).
Tools:
Standard tools, Pencil – Rule.
Initial state:
The head is in place on the machine. A new blade is fitted. The cover is open.
The blade zero adjustment has been performed (sheet M20).
The control cabinet is switched on, control part only.
Pre-adjustment:
1. Open the head cover.
2. Close the air inlet.
3. Turn the crankshaft by hand to position the blade at top dead center.
4. Raise the presser foot and, with the pencil, mark a line on the blade tangent with the rule placed on
the cutting bed, as shown in the figure below.
5. Remove the blade and check that the distance between the line and the point of the blade is equal to:
7 mm + the thickness of the rule.
2.4 x 8.5 blade (37°)

WITHOUT
VACUUM
2mm
Pencil
Thickness
of the rule
Rule Hydraulic shock

absorber
7 mm
Cutting
support
conveyor
Lower blade
detector
6. If required, adjust the position of the vibration box lower conical limit stops.
7. Check that the two hydraulic shock absorbers are set to 2mm.
8. Check the position of the blade bottom position sensor.
Adjust it if necessary, until the diode lights up.
It is essential that the check is performed in the operating conditions described hereafter.

Blade penetration adjustment M21
Index 1
Checking the adjustment

The covers are in position. The power part is switched on.
1. Open the air inlet.
2. Place a sheet of polyethylene and set the vacuum to maximum.
3. Move the head to the center of the cutting area.
4. Adjust the blade vibration speed to 10 rpm.
(Minimum vibration parameter in the machine parameters.)
5. Set the presser foot pressure to -2 bars.
(Negative value to keep the Presser Foot in the raised position.)
6. Activate the blade lowering command.
7. Activate the blade vibration command.
8. Visually check that at top dead center, the blade leaves the bed with a maximum value of 4 mm.
The blade point should be continuously in the bed but not excessively.
9. Return the head to normal operating conditions:
- Adjusting the minimum vibration speed.
- Adjusting the presser foot pressure.
WITH
MAXIMUM 2.4 x 8.5 blade (37°)
VACUUM
4 mm
Cutting
support
conveyor
To obtain a correct view, it is important that the blade is new.

To see the measurement, a spacer of a corresponding thickness can be placed beside the blade.
If the blade penetrates too far into the bed, this will cause premature deterioration of the bristle blocks
and cause cutting quality problems in the lower plies.

Sharpening
Replacing the arm pin. Cleaning, greasing or replacing M22
Indice 1
the sharpener arms
Aim:
When replacing the pin of the sharpener arm and the sharpener diabolos at 500 hours, clean and
grease the sharpener arms.
To replace the sharpener arms if necessary.
Tools:
Standard tools. G10 Grease. Sachet of 3M degreaser.
Loctite 243 normal screwlock. Loctite 222 weak screwlock.
Initial state:
The photos below show the sharpener assembly removed, but the procedure is the same if it is still in place on
the head.
The photos show a 3-arm sharpening system, but the procedure is identical for a 2-arm sharpener.
Removal of the sharpener arm pin:
1. Remove the sharpening belts (please refer to the operator guide).
2. Remove the screw (1) and then release the spring fastener (2) and the return spring (3).
1
3
3. Remove the screw and its washer (4).

4. Remove the arm pin (5) using a pin punch.
5. Remove the sharpening arms (6).
4
6

the sharpener arms Indice 1
Removal, cleaning, greasing and reassembly of the sharpener arms:

6. Remove the screw (7) securing the clip.
7
7
7. Remove the clip (8) and the diabolo (9).
8 8
9
8. Compress the arm and then remove the screw (10).

9. Gently release the sharpener arm.
Take care not to lose the spring (11).
11
10
10. Clean (12) with a 3M cleaning sachet.
12

11. Lightly grease the outside of the moving arm (13) with the G10 grease.
13
G10
12. Lightly grease the inside of the tensioning arm (14) with the G10 grease.
13. Clean up the surplus grease (15).
14 15
G10
Reinstalling the arms:

14. Compress the arm then secure the screw (16) with Loctite 243 screwlock.
16
15. Put the clip (17) and the new diabolo (18) supplied in the 500 hour maintenance kit.
16. Secure the fixing screw (19) with Loctite 222 screwlock.
- Warning! If the screw is too tight, it restricts the clip (17) which prevents the free movement
of the arm.
17
18
19

17. Remove the surplus grease (20) after assembly.

18. Check that the assembly is working properly (21).
20 21
1. Position the arms (1) in the sharpener.
Attention! There are two types of clip fitted to the arms; the shorter one must be on the lower arm.
2. Apply a small amount of G10 grease to the arm pin (2) before replacing it.
G10

3. Secure the screw and its washer (3) with Loctite 243 screwlock.
4. Fasten the spring fastener using the screw (4) glued with Loctite 222 screwlock.
5. Apply a little G10 grease to the return spring fasteners (5).
6. Put the return spring into position (6).
G10
5
5 6
It is essential that the sharpening arms be adjusted (sheet M26).
7. Fit the sharpening belts.

Replacing the sharpener cable M23
Index 1
Aim:
To replace the cable.
Tools:
Set of Allen wrenches - G10 grease.
Initial state:
1. Unscrew the screw (1) locking the cable to the jack interface.
2. Release the head of the cable (2) from its housing (3).
3. Withdraw the cable and its bellows, and replace it.
G10
2
2
3
3
It is essential that the entire length of the cable is greased with G10 grease.
1. Position the new cable and then tighten the holding screw (1).
Perform the adjustment described in sheet M25.

Extracting a worn driver without the Lectra tool and M24
gluing a new driver to the sharpener Index 1
Aim:
To extract a worn driver without the Lectra tool and to fit a new driver to the sharpener.
Tools:
Set of Allen wrenches, 1 Ø 6mm pin punch. 1 small brush. A 3M cleaning pouch, Lectra code 124924.
Loctite 603 glue. A piece of paper.
Content of Kit 704634 Lectra code 124924
+
Initial state:
The head covers are removed.
Dismantling procedure
1. If the head is equipped with drills, remove the screw (1).
2. Pivot the drill support (2).
3. Disconnect the motor power supply connectors (3).
4. Withdraw the head of the cable from its housing (4).

5. Remove the screw securing the sharpener cable kit (5).

6. Unscrew the three screws (6) from the plate.

7. Remove the motor/sharpener unit (7).
6 7
The following operation requires two persons.
8. Put the sharpener in a vice (8) but do not tighten it.

9. Place a pin punch, size Ø 6mm, on the reverse side of the driver (9).
8 9
10. Tap the pin punch with a hammer to chase out the driver and its bearings (10).
10

The driver can be glued to the motor/sharpener unit either when removed or when fitted on the head.
1. Fix the motor/sharpener unit (1).

2. Fix the sharpener cable kit using the holding screw (2).
3. Re-connect the motor power supply connectors (3).
4. Clean the bearings of the new driver and its housing (4) in the sharpener using the Lectra cleaning
pouch 124924.
4B
4

5. Apply a little Loctite 603 glue using a small brush to all the bearings of the driver (5) .
5 5B
6. Apply a little Loctite 603 glue using a small brush to the driver housing in the sharpener (6).
6B
6
7. Place the new driver in its housing in the sharpener (7).

8. Provisionally place a piece of paper between the driver and sharpener to allow for operating
clearance (8).
Warning! Let the glue dry for 30 minutes.
8
7

9. Remove the piece of paper (9).
Check by hand that the driver can pivot freely and without restriction (10).
9
10
10. Put the head of the cable back in its housing (11).
11

Sharpener cable or sharpener control kit tension M25
Indice 2
adjustment
Aim:
To adjust, at the level of the sharpening jack interface, the tension of the cable or the control kit.
Tools:
Standard tools. 5 and 10 mm flat spanners.
Initial state:
1. Unscrew the nut (1).
2. Hold the interface (2).
3. Screw or unscrew the jack axis (3) to obtain a spacing of 2 mm between the sharpening arms (4)
in the exit position, and the presser foot support (5).
4 5
2 mm
6 7
8
4. Check that there is sufficient space (8) between the sharpening arms (6) in the retracted position and
the cradle upright (7).
The remaining space (8) depends on the measurement applied during the previous adjustment
(2 mm).
5. Lock the nut (1) when the adjustment is completed.

Sharpener cable or sharpener control kit tension M25
adjustment Indice 2
Having adjusted the position of the sharpener arms, you need to check that the position sensor is
correctly triggered. Perform the adjustment described below.
6. Check that the position sensor (9) is correctly adjusted at the switchover point (detection light on/off).
- Switch off the pneumatic supply to the cutter.
- Press on the driver (10). The detection light should go out as soon as the sharpener arms
move.
7. If the sensor is not adjusted correctly, unscrew the screw (11) or (12) to change its height position.
- Repeat the adjustment procedure.
12
9
10
11

Sharpening arm adjustment M26
Index 1
Aim:
To adjust the arms.
Tools:
Standard tools. Loctite block seal 648.
Initial state:
A new blade must be fitted.
The photos below show a 2-arm sharpening system, but the procedure is the same for a 3-arm sharpener.
1. Remove the sharpening belts (please refer to the operator guide).
2. Unlock the arms.
3. Put the sharpener block into contact with the blade.
Warning! Press on the top of the sharpener in order to avoid putting pressure on the arms.
4. Hold the position described above and then press with a finger on each of the arms to determine
on which arm the play must be adjusted .
Example below: The arm (1) is not touching the blade while the arms (2) and (3) are in contact.
5. Use the adjusting screw (4) of the unadjusted arm to bring it into contact with the blade.
4
2
+
3

Sharpening arm adjustment M26
Index 1
- Warning! The adjustment screws (4) should never be fully screwed in, this would mean that
the adjustment is incorrect.
- Warning! The adjustment screws (4) are fitted with blocpresse 648 (no nut) as the adjustment
values are very small: 0.1 mm = 1/4 turn maximum.
6. Check that all the arms bear equally on the blade.
7. Check that each arm has angular play (5).
- This play is mandatory for the operation of the arm.
8. Replace the sharpening belts.

9. Fit the sharpening belts (please refer to the operator guide).
10. Unlock the arms.
Important points regarding the sharpener arms:
The screw (6) is not used to guide the arms, it prevents the ejection of the sharpening arm in the case
of its breakage.
The screw (7) is not an adjustment screw, it holds the part in place (8).
- If it is too tight, it restricts the part (8) and prevents the free movement of the arm.
- If it is not sufficiently tight, the part (8) may move and fall off.

Adjusting the sharpening system pressure M27
Index 1
Aim:
To adjust the first angle and second angle call pressure to obtain equivalent sharpening on both sides of
the blade.
The motor drives the abrasive belts from the back to the front of the blade.
A greater pressure value must be applied to the first angle call pressure to obtain an equivalent
sharpening pressure to that operated by the second angle call pressure.
Test procedure:
The photos show a 3-arm sharpening system, but the principle is identical for a 2-arm sharpener.
1. Open the "Maintenance" session in the Pilot software.
2. Select "Machine Commands" .
3. Select "Parameters".
4. Select "Sharpener", the sharpener parameters are displayed:
5. Verify that the second angle start pressure displays at least 0.5 bar more than the start pressure of
the first angle (see the example below).
6. Apply a felt-tip pen to the entire length of the two cutting sides of the blade.
7. Order 1 sharpening cycle and then check the blade:
Blade/sharpener position
affected by the first angle
call pressure. Blade/sharpener position
affected by the second angle
start pressure.
The result obtained on one side of the blade should correspond to that of the other side.
Example: Felt-tip marks completely erased on each side of the blade or the same erasing on both sides.
Listen to check that the sharpener is making the same noise when it sharpens each side of the blade.

Chronological order of sharpening system adjustment M28
Index 1
Aim:
To perform, in chronological order, the different adjustments to achieve optimum blade sharpening.
List of adjustments:
1. Adjusting the blade zero.
2. Adjusting the sharpening cable tension.
3. Adjusting the sharpener central guide.
4. Adjusting the sharpening arms.
5. Adjusting the conical stops.
6. Adjusting the sharpening system pressure.
7. Adjusting the median and semi-rotation angles.
8. Verification of the blade cutting edge.

Checking the sharpening quality M29
Index 1
Aim:
To apply a method for monitoring the sharpening quality.
Tools:
1. Kitchen string.
The check must be performed with the blade in place so as not to break the cutting edge.
(Risk of contact between the rotating block and the blade when it is being reinstalled.)
Check that the blade cutting edge is not bent. If it is, then check the median sharpening angle (see sheet M30).
Procedure:
1. Normally perform a material cutting cycle then, when it is finished, perform the following check:
2. Place the presser foot in the raised position.
3. Place the blade in the lowered position.
4. Take a piece of the string and then perform a cutting test on:
- The upper part of the blade (photo 1),
- The middle part of the blade (photo 2),
- The lower part of the blade (photo 3).
Test:
- Hold the two ends of the string.
- Apply this against the blade.
- Push horizontally: The string should be cut without force.
1
2
If the sharpening quality is not homogenous between the top, middle and bottom of the blade, modify
the Flip Flop duration adjustment.

Adjusting the sharpening symmetry M30
Index 1
Aim:
To adjust the sharpening symmetry:
To perform a check (felt-tip pen test) and adjust the sharpening symmetry so that the three sharpening
belts are in correct contact with the faces of the blade.
Procedure:
1. Mark the sides of the blade cutting sides with a felt-tip marker.
2. Order a sharpening.
3. Visually check the state of the blade and based on the results, act on the median angle and half-rotation
parameters in the maintenance session (see diagram below).
WARNING! On the diagram below: Red color on blade = felt-tip pen erased.
Asymmetric sharpening => adjust the median angle
Felt-pen test
Reduce the sharpening Increase the sharpening
median Angle median Angle
Spot viewfinder Spot viewfinder
Symmetric sharpening => adjust the semi-rotation
Increase the sharpening Reduce the sharpening

Semi-rotation Semi-rotation
Spot viewfinder Spot viewfinder
Sharpening OK
Spot viewfinder

Vibration assembly
Replacing the vibration drive belt M31
Indice 1
Aim:
To replace the vibration belt, remove the tension pulley and the vibration box.
Tools:
Set of Allen wrenches – Loctite 243 normal screwlock.
Initial state:
1. Remove the screws (1) and (2) holding the slider support plate on both sides.
2. Remove the screws (3) to be able to remove the sliders upwards.
1
1
3 3
3. Release the self-locking nut (4).

4. Use the tensioning screw (5) to slacken the belt.
5. Release the belt from the tensioner pulley (6) and then from the motor pulley (6B).
Warning: Never twist the vibration belt!
6. Remove the screws (7).
6
5
7 6B
4
7

Replacing the vibration drive belt M31
Indice 1
7. Remove the nut (8) securing the blade raising/lowering jack and then tilt the jack to the side (to enable
the vibration box to be moved past it later).
8. Withdraw the slider support plate (9) upwards.
9. Slide the vibration box off the guide rails (10).
10
Replacement procedure
1. Make two marks (11) on the belt in order to be able to easily measure the distance separating them
(this will be used to adjust the tension).
2. Position the belt correctly on the removed box (12).
12
11
3. Engage the box, equipped with its belt, into the guide rails.
4. Reverse the removal procedure described above.
Adjust the belt tension (see sheet M33).

Replacement of the vibration box rails and bearings M32
Indice 1
Aim:
To replace the cylindrical rails and the ball bearings.
Tools:
Set of Allen wrenches – Normal Loctite 243 screwlock. Loctite 603 bearing cement.
Initial state:
The belt and box have been removed (see sheet M31).
1. Remove the fixing screws (1) holding the cylindrical rails (2) in their housings.
2
2
1
1
2. Put the vibration box (4) (previously removed) on a workbench and then, using a hot air gun, heat the
areas where the ball bearings are glued (5), to remove them.
1. Apply Loctite 603 bearing cement to the external face of the new bearings (5) before positioning
them in the box (clean up any excess glue).
2. Position the new rails in their housings and then fix them using Loctite 243 screwlock on the screws (1).
3. Resume the assembly in the "Reassembly procedure" chapter of the sheet M31.

Adjusting the vibration belt tension M33
Indice 1
But:
To optimize the tension value on the blade vibration belt.
Outillage:
Standard tools, 30cm rule.
Etat initial:
The belt is installed on the head.
Never twist the vibration belt as this can damage its armor.
Maximum tension not to be exceeded (Breakage of the Kevlar fiber of the armor) = 1.2%.
Adjustment procedure
1. If this has not already been done, make two marks on the belt so that the distance between them can
be easily measured.
2. Slightly unscrew the self-locking nut (1) on the tensioner spindle.

3. Maneuver the screw (2) so as to apply 0.8% tension to the belt:
- When a tension of 0.8% is applied to the belt, the measurement between the two marks is
multiplied by 1.008.
- Example: Measurement without tension = 200 mm
Measurement with belt tensioned = 200 x 1.008 = 201.6 mm
4. Unscrew the self-locking screw (1).
5. Turn the belt manually for 2 to 3 complete revolutions.
6. Using a rule, check the measurement between the two marks (3).
1
3
Each time a new belt is fitted to a head, the measurement, without tension, between the 2 marks should
be noted on the machine test sheet.

Replacing the crank pin + oblique bearing assembly M34
Index 1
Aim:
To replace the crank pin + oblique bearing assembly.
Tools:
Set of Allen wrenches - Bearing extractor tool 112169.
G12 Grease – Loctite 222 weak screwlock.
Initial state:
1. Remove the CHc screw (1) and then remove the connecting rod (2).
2. Remove the 3 screws (3) holding the bearing protector (4) and then remove it.
4
3 1
3. Fix the crank pin retainer (5) of tool 112169 to the crank pin (6) using a sufficiently long screw (7).
5 7
Tool 112169
4. Position the bob against the bearing and then move the bob quickly to tap it against the head of the
tool screw.
- Repeat this operation until the equipped crank pin is extracted from the bearing.
Extracted equipped crank pin

Replacing the crank pin + oblique bearing assembly M34
Index 1
1. Grease the bearing exterior (8) with G12 grease.
2. Press on the bearing exterior (9) to push it into its cage (10).
- Take care to position the bearing squarely.
3. Refit the bearing protector (11): the 3 screws (12) glued with Loctite 222 weak screwlock.
G12
9
10 11
9
12
4. Refit the connecting rod with the screw (13) glued with Loctite 222 weak screwlock.
13
5. Grease the crank pin bearing as described in the sheet M2.

Adjustments and calibration in "Pilot"
Adjustments controlled by an Assistant in the M35
Index 1
"Maintenance" session
On the machine operating workstation:
6. Click on the button to enter the cutter operating software’s "Maintenance" session.
7. Click on the "Machine adjustments" tab .
8. The window shown below appears:

- Click on the adjustment or calibration to be performed (designated by a red arrow).
- Follow the instructions given by the operating software.

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Vector® iQ80, iQ50, iH8, iH5, Q50, Q80

500H-1000H Preventive maintenance guide

This document contains:

Key to icons used in this document

Note Personal danger

Advice or suggestion Risk of machine breakage

January 2017 - 543156 DA lectra.com 2/91

Safety instructions and general indications................................................................................................. 3

Specifications of adhesive products............................................................................................................. 4

Specifications of greasing products ............................................................................................................. 5

Blade guide and presser foot

Adjusting the blade

January 2017 - 543156 DA lectra.com 3/91

Adjusting the vibration belt tension

Adjustments and calibration in "Pilot"

January 2017 - 543156 DA lectra.com 4/91

SAFETY INSTRUCTIONS AND GENERAL INDICATIONS

1. DEFINITION OF THE STANDARD INITIAL STATE

Control Cabinet line circuit breaker.

"Vacuum" line power circuit breaker.

The tools, blade and punch needle, are removed.

2. SAFETY DATA SHEETS

3. TESTS AND CALIBRATION THAT MUST BE PERFORMED FOLLOWING A

January 2017 - 543156 DA lectra.com 5/91

SPECIFICATIONS OF ADHESIVE PRODUCTS

4. PRESENTATION OF PRODUCTS USED

Description Area of use Item code

Weak screwlock M2.5 screws and blade

Immobilizing a bearing ring

Fitting glue Assembling needle

Degreaser Degreasing any part

January 2017 - 543156 DA lectra.com 6/91

SPECIFICATIONS OF GREASING PRODUCTS

Greasing products used for the cutting head:

Description Area of use Item code

KLÜBER ISOFLEX TOPAS NB 152:

KLÜBER ISOFLEX TOPAS NB 52:

Situation of products used:

G12: Crank rod head

G11: Crank rod and

G10: Drill block hinge axis.

G1: Rollers of the

G1: Rollers of the

January 2017 - 543156 DA lectra.com 7/91

Beam: greasing the Y rails and bearings:

Description Area of use Item code

G10 code 124528

Situation of products used:

G10: Front right

G10: Front left

Beam: greasing the X drive rails and sliders

Description Area of use Item code

Situation of products used:

January 2017 - 543156 DA lectra.com 8/91

Products used for greasing the vacuum turbine:

Description Area of use Item code

Vacuum turbine 115361

KLÜBERSYNTH BEP 72- 82 grease

Vacuum turbine 134700