GREENBRIDGE T189901 Pneumatic Plastic Strapping Tool Instruction Manual

GREENBRIDGE T189901 Pneumatic Plastic Strapping Tool

Product Information

Specifications

• Tool Size:
  • Length:
  • Width:
  • Height:
  • Weight:
• Required Air:
  • Pressure Range:
• Performance:
  • Sealing:

Product Usage Instructions

Safety Instructions
Please read the operating instructions carefully before using the tool. When operating the tool, always wear eye, face, and hand safety protection.

General Safety Instructions:

• 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 the air supply.
• Always use dry, clean, and lubricated compressed air.

Installation
Tool Air Connection
To replace the cutter, follow these steps:

1. Disconnect the air pipe from the welding motor (pic.F1).
2. Remove the 2 locking motor screws (pic.F2).
3. Remove the motor (pic.F3).
4. Pull out the cutter spring with pliers (pic.F4).
5. Remove the cutter by inserting air into the disconnected pipe to push the piston down and free the cutter, then remove it from its seat with pliers (pic.F5).
6. Replace the cutter and reassemble in reverse order, applying grease on the spring and cutter seat.

Grippers Replacement
To replace the grippers, follow these steps:

1. Remove the 4 bottom plate screws (pic.G1).
2. Unscrew the gripper screw (pic.G2).
3. Replace the parts (pic.G3).
4. Reassemble in reverse order.

Welding Gripper Replacement
To replace the welding gripper, follow these steps:

1. Remove the cutter as shown in F1 to F5 sequence.
2. Remove the bottom plate as point G1.
3. Remove the safety circlip from the welding gripper pin (pic.H1).
4. Remove the pin from the welding gripper (pic.H2).
5. Replace the worn-out part (pic.H3).
6. Reassemble all parts in reverse order. It is advised to replace the safety circlip with a new one.

Troubleshooting

Problem: Air Leaking
Remedy: Check the air connection. May need to replace the gaskets (contact the after-sale service).

Problem: Weak Seal, Incomplete Cutting, Inconsistent Cutting
Remedy:

• Set the weld time adjustment properly.
• Check if the sealing foot and the cutter are damaged or worn out.
• Check if the sealing foot is dirty or slides on the 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 and check the air circuit.

Problem: Strap Breaking While Sealing
Remedy: Set the weld time adjustment properly. It may be too long.

Problem: Both Straps are Cut While Sealing
Remedy:

• Check if the gripper plate is dirty or damaged (clean or replace it).
• Set the weld time adjustment properly. It may be too long.

Problem: Inconsistent Sealing Time
Remedy: The timer valve may have a problem. Try to clean, lubricate, or replace it (contact the after-sale service).

FAQ

• Q: How do I replace the cutter?
  A: To replace the cutter, follow the steps mentioned in the “Tool Air Connection” section above.

• Q: How do I replace the grippers?
  A: To replace the grippers, follow the steps mentioned in the “Grippers Replacement” section above.

• Q: How do I replace the welding gripper?
  A: To replace the welding gripper, follow the steps mentioned in the “Welding Gripper Replacement” section above.

• Q: What should I do if there is air leaking?
  A: Check the air connection and consider replacing the gaskets. If the issue persists, contact the after-sale service.

• Q: How can I fix weak seals, incomplete cutting, or inconsistent cutting?
  A: Ensure that the weld time adjustment is set properly. Check for any damage or wear on the sealing foot and cutter. Clean the sealing foot if it’s dirty or sliding on the strap. Verify the air pressure value and ensure that the strap qualities are suitable for the tool. If the problem continues, check the sealing motor and pneumatic valve for any locking or dirt issues. Cleaning the timer valve and checking the air circuit may also help. Contact the after- sale service if needed.

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.

TECHNICAL DATA

| 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

PET 25mm – 1”

| >0.016” – 0.055”<

WARRANTY

GREENBRIDGE warrants all its tools during a period of 4 months from the shipping date document. Warranty includes free replacement of faulty parts ex works. 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, and missing serial number. The warranty excludes the wearing parts shown on spare parts list. No compensation can be claimed for production shutdowns and for damages to people and objects due to tools defects. GREENBRIDGE reserves the right to modify the tools and documentation without any obligation to update previous ones.

INSTALLATION

It is recommended to always use a dryer unit near the compressor and a filter- regulatorlubricator unit with pressure gauge (Greenbridge 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

OPERATING ELEMENTS-ADJUSTMENTS

• 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 pie.A; turning clockwise will increase the time, and counter clockwise will decrease the time.

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

OPERATION

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

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:

SERVICING

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) (pie. E)

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.

Grippers replacement
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.

TROUBLESHOOTING

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)

SPARE PARTS LIST

GREENBRIDGE PART NUMBER| ITEM| DESCRIPTION| QTY| |
---|---|---|---|---|---
401- 0279| A000107| ASSEMBLED COVER| 1| |
200- 0027| B100032| PIPE 6×8| 0,08 mt| | ***
401- 0149| B100307| CONN. DIR 10 1/4 RL1 (2L01012)| 1| |
400- 0039| B100310| SWING ELBOW RL31 8 1/4 (2L31011)| 1**| |

400- 0094| B100313| CONNECTION RL1 08 1/4 (2L01010)| 1| |

400- 0060| B200356| VALV 2VIE TEMP AZ10.017.4| 1| |
401- 0146| B200374| KIT AIR STOPPER 1/8″F0.5 AZ 11.005.2| 1| |
400- 0025| B200375| KIT MICROVALVE NC AZ 08.022.2| 1| |
400- 0014| B300022| O-RING 3300 (D85)| 1| |
400- 8004| B300019| GASKET RING RP6287.85| 1| |
400- 0019| B300020| GASKET TEFLON + BRONZE 1.5×6.1 IN MTS| 0,11| |
401- 0109| B300086| O-RING OR108 (D9)| 4| |
400- 0049| B400003| ROLLER BEARING HK0808 INA| 2| |
400- 0085| B400004| BEARING 6001 2Z| 2| |
400- 0054| B400005| ROLLER BEARING NK1616| 1| |
401- 0141| B500034| SCREW UNC 10-24×5/8″ ANSI B18.3| 3| |
400- 0038| B500039| SCREW UNC10-24×1/2″| 6| |
400- 0044| B500040| SCREW M6x16 UNI5931| 4| |
400- 0088| B500043| SCREW M5x12| 2| |
401- 0140| B500047| SCREW M5x8 UNI5925| 1| |
400- 7135| B500048| SCREW M4x6 UNI5933| 1| |
401- 2149| B500068| SCREW M3X8 UNI 5931| 2| |
401- 0142| B500097| SELFLOCK M5 DIN985 5S| 2| |
401- 0273| B500143| SCREW M6X6 UNI5927| 1| |
401- 0145| B500235| SCREW M3X4 UNI5929| 1| |
401- 0205| B500386| SCREW M4x30 DIN7984| 2| |
400- 0059| B600013| CIRCLIP H5| 1| |
401- 0147| B600417| RUBBER GRIP| 2| |
400- 8033| B700030| PIN 3×24 DIN6325| 1| |
401- 2047| B700076| PIN 4×12 DIN6325 R220| 1| |
400- 0036| B900348| PNEUMATIC BOSCH MOTOR 0607951449| 1| |
401- 0274| B900406| PNEUMATIC MOTOR AM-004| 1| |
400- 0063| D000780| LOCKING STRAP PLATE| 1| §|
400- 0035| D001260| CUTTER| 1| §|
400- 0205| D001620| CONNECTING ROD PIN| 1| |
400- 0055| D001630| CONNECTING ROD| 1| |
400- 8014| D001640| EXCENTRIC SHAFT| 1| |
400- 0058| D001650| WELDING FOOT PIN| 1| |
400- 0067| D001700| COVER| 1| |
400- 0020| D001710| PISTON SPRING| 1| |
400- 0149| D001720| STRONG CUTTER SPRING| 1| |
401- 0024| D001800| REAR STRAP GUIDE| 1| |
401- 0275| D003000| CUTTER (1”STRAP)| 1| §| ***
401- 0276| D003010| WELDING FOOT (1”STRAP)| 1| §**|

401- 0277| D003040| LOCKING STRAP PLATE (1”STRAP)| 1| §|
401- 0036| D003980| FRONT STRAP GUIDE| 1| |
401- 0278| D004000| PNEUMATIC VALVE| 1| |
401- 0150| D004010| MAIN FRAME| 1| |
401- 0143| D004030| BOTTOM PLATE| 1| |
401- 0280| D004170| HOOK SUPPORT PLATE| 1| |
401- 0148| D004510| GRIP PIN| 2| |
401- 0208| D004570| WELDING FOOT| 1| §|
401- 0144| D004790| WELDING START LEVER| 1| |
401- 0209| D004850| CUTTER PIN| 1| |
401- 0210| D004860| PISTON| 1| |
401- 0281| D004920| BOTTOM PLATE (1”STRAP)| 1| |
401- 0282| D004930| MAINFRAME (1”STRAP)| 1| |
| | |
GREENBRIDGE PART NUMBER| ITEM| DESCRIPTION| QTY| |
---|---|---|---|---|---
| §| WEARING PART|
| *****| PART THAT SHOULD BE STOCKED

BOSCH 0 607 951 449 – POLYCHEM 400-0036
WELDING MOTOR

AM-0004-P-0703B-MI– POLYCHEM 401-0274
WELDING MOTOR

400-0060 (B200356) – TIMER VALVE

CE DECLARATION OF CONFORMITY

Greenbridge 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

MODEL: series PWT

MACHINE TYPE: PNEUMATIC PLASTIC STRAPPING TOOL

GREENBRIDGE
6277 Heisley Road Mentor, Ohio 44060
Tel. 440-357-1500
Fax 440-352-9553
www.greenbridge.com

References

• Greenbridge | Strapping Solutions, Tools & Equipment

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