RolsplicerTM

Maintenance Manual

And Illustrated Parts List

List of Illustrations

Figure Page 1. Rolsplicer 3 2. Roller Adjustment 4 3. Rolsplicer 6 4. Lid Hold Down Assembly 8 5. Automatic Lid Speed Adjustment 10 6. Splicing Sequence 11 7. Structure 18 8. Mounting Tube – Idler 19 9. Mechanical System 21 10. Swivel Hinges – Lumber Hold Down Lid 22 11. Roller Chain Configuration 23 12. Roller Adjustment 24 13. Idler Configuration 25 14. Guide and Clamp Configuration 26 15. Electrical Configuration 28 16. Wiring Diagram 30 17. Pneumatic System 32 18. Pneumatic – Clamp 33 19. Cylinder – Clamp 34 20. Piping Diagram 35 21. OPTIONAL CONVEYOR CONNECTION PHOTO 36

List of Tables

Table Page 1 Cleaning, Lubricating and Inspection 13 1 Troubleshooting and Repair 14

Table of Contents

Section Page 1. Introduction 1 2. Rolsplicer Description 2

a. Motor/Electrical b. Compressed Air c. Rollers d. Frame

3. Operating Instructions 5

a. General b. Operating Controls c. Operating Rolsplicer for the First Time d. Roller Adjustment e. Lumber Size f. Automatic Lid Speed Adjustment g. Splicing Process

4. Cleaning, Lubricating and Inspection 12 5. Troubleshooting and Repair 15 6. Illustrated Parts List 15

a. Introduction b. Parts List c. Ordering Replacement Parts

WARRANTY

WARRANTY AND DISCLAIMER OF WARRANTIES: Klaisler warrants the goods, other than “Component Parts,” as defined below, to be free from defects in materials or workmanship for one (1) year from the date of delivery to the Purchaser ("Warranty"). This Warranty excludes and does not cover (i) goods that are not properly installed, operated, used, maintained, adjusted, cleaned and lubricated by the Purchaser; (ii) goods that are altered or modified by any person other than Klaisler; and (iii) starters, motors, gear reducers, or microswitches which are not manufactured by Klaisler (the "Component Parts"). KLAISLER HEREBY DISCLAIMS ANY AND ALL OTHER WARRANTIES, WHETHER EXPRESS, STATUTORY, OR IMPLIED, APPLICABLE TO THE GOODS SOLD, INCLUDING WITHOUT LIMITATION, ALL EXPRESS OR IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. The Component Parts may be governed by separate warranties provided by the respective Component Parts manufacturers, which warranties may be shorter than or longer than the Klaisler one (1) year Warranty offered above. Any repair or replacement of Component Parts shall be determined solely by the Component Part manufacturer, and it shall be Purchaser’s responsibility to enforce any warranty claims related to Component Parts directly with the Component Part manufacturer. EXCLUSIVE REMEDY FOR BREACH OF WARRANTY: All goods claimed to be defective must be returned to Klaisler for inspection, charges prepaid. All collect shipments will be refused. If, upon inspection, Klaisler determines to its satisfaction that any part of the goods does not conform to the Warranty, Klaisler shall, at its option, correct the defect by repair or replacement. This is the sole and exclusive remedy for breach of the Warranty. If defective goods are replaced by Klaisler, the replaced goods shall become the property of Klaisler. If, upon inspection, the goods are found to conform to the Warranty, the goods will be returned to Purchaser only upon Purchaser’s request and at Purchaser’s expense.

1. Introduction a. The Rolsplicer machine is designed to produce chord splices with 2 x 3, 2 x 4 and 2 x 6 lumber.

Continuous splicing without clamping, in seconds rather than minutes, is possible with this technically advanced machine. The unique double roll design consistently produces the tightest possible splices.

b. Although the machine is ruggedly, but simply designed, following prescribed operational and maintenance procedures will assure optimum production for the maximum period of time. These procedures are outlined in this manual.

c. Appropriate safety guards and switches are provided for the protection of the operator. Nevertheless, it is necessary for all operating procedures to be followed exactly as specified.

WARNING

EQUIPMENT MUST NEVER BE OPERATED WITH SAFETY COVERS REMOVED. TO DO SO COULD RESULT IN SERIOUS INJURY.

d. This manual is a guide for operating, cleaning, lubricating, inspecting and adjusting the

Rolsplicer. Strict adherence to these procedures will ensure an efficient operation and optimum utilization of the machine.

Rolsplicer Data

Floor Space 6 feet x 55 feet (maximum anticipated for longer splices) Machine Size 38 inches x 52 inches x working height Machine Weight 1,500 pounds (approximate) Power Required Refer to name plate data on motor Lumber Feed Rate Up to 720 splices per hour Lumber Size 2 x 3, 2 x 4, 2 x 6 2. Rolsplicer Description

a. A 3 HP gear motor, installed in a horizontal position, provides power. The motor nameplate includes wiring data. In any case, local electrical codes provide guidelines for hook-up of electrical equipment.

b. Compressed air is used to operate the lumber hold down lid and splice plate clamps. Four inserts with wheels pressing on the lumber are part of the lid. They can be adjusted to accommodate the three lumber sizes for which the machine was designed. (Figure 1)

c. Our mechanically driven, synchronized half rollers in two sets run simultaneously. These connect to a chain and sprocket system mounted at the opposite ends of four shafts. The sprockets are mounted in bushings, while the rollers are mounted in flanged bearings. (Figure 2)

d. Heavy steel plate sides are secured with screws on all four sides of the welded steel frame. Safety covers on each side of the top protect the operator form possible injury. Operating buttons are located on the top safety cover on the operator’s side. Adjustment wheels for controlling roller pressure are positioned on the side cover where the operator stands.

3. Operating Instructions a. General

All individuals assigned as operators for the Rolsplicer should read this manual prior to training. This will enable operators to familiarize themselves with the machine quickly and thus become proficient with its operation in the minimum time.

b. Operating Controls Before attempting to operate the Rolsplicer, operators must know the location and function of each control. Figure 3 shows location of controls.

c. Operating Rolsplicer for the First Time (Figure 3) Prior to any production, the following must be done: (1) Connect incoming power to the exterior control box. (2) Place power disconnect in the ON Position

(3) Plug compressed air supply into the rear of the machine. Although operating pressure should be approximately 90 PSI, it may be necessary to adjust so the hold down lid operates without excess shock.

CAUTION WHEN COMPRESSED AIR HOSE IS ATTACHED, LUMBER HOLD DOWN

LID WILL OPEN. d. Roller Adjustment (Figures 2 and 3)

(1) Bring the press and push rollers into position by means of the jog button at the side of the machine. This starting will move the rollers into position independently of the normal cycle sequence.

(2) With the lumber hold down lid open, place a representative piece of lumber in position between the rollers.

(3) Loosen the two locknuts on the hand wheel shafts at the front of the machine.

(4) Adjust the rollers by turning the hand wheels. Tightness should be as follows:

(a) Plate press rollers set for slip fit. (b) Push rollers must be very tight to drive the lumber forward

during the operating cycle. (5) Tighten the locknuts on the hand wheel shafts. Push the jog button

again to move the rollers into the beginning position so the machine is again in normal sequence and ready for production.

(6) Repeat the above procedure if additional adjustment is necessary. (7) Adjust mounting bracket weldment arm to provide from .030 to

.050 tolerance with mini-valve cut-off switch. (Figure 18) (8) To set up for 2 x 6 lumber, turn the adjustment nuts clockwise on

top of the four lumber hold down wheel assemblies until the nut stops. Do not force these adjusters past their stopping point.

e. Automatic Lid Speed Adjustment (Figure 5) (1) Opening and closing speeds of the lid are pre-set at the factory for

safe operation. However, some adjustment may be necessary or desirable.

(2) Two airflow control valves are located on the lid-driving cylinder.

One each for opening and closing speed. To adjust these speeds, loosen the tiny locknut on the appropriate valve. Turn clockwise for slower operation or counter-clockwise for faster operation. Be sure to TIGHTEN LOCKNUT after adjustment, since increasing lid operation speed can create a safety hazard. Adjustment is manual, according to the numbers stamped on the top. Figure 19

f. Splicing Sequence (Figure 6)

(1) Place the two chords to be spliced in the machine as shown in the illustration, centering the trailing edge of the first piece in the connector holding brackets. Position the second piece against the front piece, although they can be separated by as much as ½ inch.

(2) Insert the connector plates into the connecting plate holding brackets, one on each side of the joint.

(3) Place both hands, palm down, on control buttons. Push both buttons simultaneously to actuate the machine.

(4) Push rollers will move trailing 2 x ? to end of leading 2 x ? with connector plates in position.

(5) As lumber (chords) passes between press rollers, connector plates are embedded and splice is complete. Lumber hold down lid will open and completed splice is in view. Remove from machine and Rolsplicer is ready for the next splice.

NOTE: Although one person can operate the Rolsplicer for many chord lengths, long chords require two persons to handle more easily. Connector plates not designed for roller application are unsuitable for use with this machine. 4. Cleaning, Lubrication and Inspection

a. Regular maintenance should be provided on a routine, scheduled basis by shop personnel. Major items of concern include the following: (1) Cleaning to remove build-up dirt or other debris, which may cause

jamming and/or binding of moving parts, chains and sprockets. (2) Lubrication to keep moving parts operating smoothly and reduce

wear. (3) Inspection to detect problems of wear and breakdown before

becoming major problems, which would prevent operation. b. A recommended schedule for cleaning, checking and lubrication is shown

as Table I.

CAUTION KEEP AREA UNDER MACHINE FREE FROM ALL DIRT, WOOD SCRAPS OR OTHER DEBRIS. ACCUMULATION OF FOREIGN MATTER MAY JAM THE

CHAIN AND/OR SPROCKET, THUS CAUSING ROLSPLICER TO MALFUNCTION.

Table I Cleaning, Lubrication and Inspection

Frequency

Procedure

Materials/Equipment

Daily Daily Daily Weekly Weekly Quarterly Quarterly

Clean and remove all debris from under machine Drain water in air hose Air pressure adjustment Grease idler sprocket Adjust chain to 35 lbs. Torque Grease roller shaft bearings (8) Tighten all loose fittings, nuts, bolts etc

Push valve Wrench – locknut General purpose grease Torque wrench General purpose grease

Table II

Symptom Possible Cause

Corrective Action

Machine won’t work Motor won’t start Machine won’t work Motor will start Rollers continue to rotate after palm buttons are released Irregularly placed Plates Gap in splice between lumber

Electrical Faulty air valves Mounting bracket arm is out of adjustment with mini valve cut-off switch Cylinder for clamp system may be broken on end Machine may be out of time Cylinder clamp may have slipped Chain loose, or machine out of time

Check fuses and replace if necessary Push re-set button Jog rollers into correct position Push palm buttons If machine doesn’t work then replace one/both air valves Adjust arm for tolerance of from .030 to .050 – see item 3d (7) Replace Re-time – see below Readjust clamp and retighten Re-time as follows: 1. Loosen idler 2. Jump chain back into position 3. Put chain back on sprockets to point where push rollers are one (1) inch ahead of press rollers (link = 1 inch) 4. Tighten idler to 35 pounds torque

* It is recommended that both items be replace simultaneously

c. While cleaning and lubricating, look for signs for cracking, extreme wear, bending or breakage of chains, sprockets, bearings and basic structure.

5. Trouble Shooting and Repair

a. Although the intent has been to design a low maintenance machine, breakdowns may occur. A systematic approach should be used to isolate the cause(s) and make repairs when a malfunction takes place.

b. Table II outlines symptoms, possible causes and repair procedures. Following these recommendations should solve most problems.

6. Illustrated Parts List a. Introduction

(1) This section breaks down the Rolsplicer into four basic sections: structure assembly, mechanical system, electrical system and pneumatic system. Each assembly/system is followed by its component parts. Those parts or systems, which interface with that system/assembly, are also referenced.

(2) Parts which are of maintenance significance are listed. Those not shown are bulk materials such as wire and hosing, or parts, which lose their identity. These include parts of weldment or parts permanently joined in assembly. Common parts, such as fasteners, screws, nuts, bolts, pins, etc. may also be omitted.

b. Parts List (1) Figure and Index Number

The number in the first column refers to the illustration and index number for a specific item on that illustration. Each illustration is identified by a figure number, which is followed by an item number identifying a specific part.

(2) Part Number The manufacture’s part number is listed in this column. As stated in the introduction, common hardware is usually not shown. A dash (-) preceding the index number means the part is not on the accompanying figure.

(3) Description Parts are identified by name in this column. In some cases usage and other descriptive information is included.

(4) Units Per Assembly This column indicates the number of parts required for the assembly or sub-assembly being described. When more than one assembly is being used, the total number of parts is the units per assembly quantity times the number of assemblies in the machine. “Ref” (referenced) in this column indicates that the item is listed elsewhere with proper quantity, but is shown now for reference only.

c. Ordering Replacement Parts

(1) Addressing all orders to: Klaisler Mfg. Corp., 3314 Prospect Street, Indianapolis, IN 46203. Phone: (317) 357-3898; Fax: (317) 357-3921

(2) Specify serial number of your unit. (3) List quantity of each item required.

(4) List the part number and description for each item as shown in this manual.

(5) Note any special considerations concerning any assembly or part. (6) Show shipping address (and billing address if different).

Figure & Index No.

Part Number

Description 1,2,3,4,5,6

Units Per Assembly

Usable On Code

6- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 22 23

6000 6002-1 6002-1 6002-1 6100-1 6202-1 6106-1 6107-1 6211-1 6213-3 6211-5 6211-7 6216-1 6217-1 6000-28 6000-29 6000-30 6000-34 6110-1 6112-1

Rolsplicer Mechanical System Electrical System Pneumatic System Main Frame Weldment Leg Angle Extension Front Top Cover Rear Top Cover Front Lower Section Rear Lower Section Right End, Lower Section Left End, Lower Section Safety Pad Mounting Bar Decal – “Danger – Keep Hands Away When Machine Cycles” Decal – “Logo” Decal – Safety Strip (Yellow & Black Diagonal) Placard – Serial No., Model No., Voltage Rating Mounting Tube Weldment for Idler Sprocket Mounting Bracket Weldment for

1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1

Starter Box and Air Valves

Figure & Index No.

Part Number

Description 1,2,3,4,5,6

Units Per Assembly

Usable On Code

7- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

6002-1 6105-1 6215-1 6215-3 6216-5 6216-3 6103-3 6105-7 6105-10 6104-1 6104-3 6002-33 6002-35 6113-1 6209-1 6111-1 6111-3 6111-5 6203-5

Mechanical System Lid Weldment, Hold Down System Retainer Bar, Top Retainer Bar, Bottom Safety Pad Safety Pad Tube Weldment Compression Spring Wheel - 1.625” O.D. Connection Arm Weldment Connecting Arm Weldment Cylinder, Lid Hold Down System Valve, Air Flow Control Lumber Guide Weldment Splice Plate Holder Aft Clamp Weldment, Clamp System Fwd Clamp Weldment, Clamp System Aft Horizontal Weldment, Clamp System Fwd Horizontal Bar, Clamp

1 1 1 1 1 1 4 4 4 2 1 REF REF 1 2 1 1 1 1

19 20 21

6109-1 6109-3 6002-24

System Roller/ Shaft Weldment Roller/ Shaft Weldment Flanged Bearing

2 2 8

Figure & Index No.

Part Number

Description 1,2,3,4,5,6

Units Per Assembly

Usable On Code

7-22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

6205-1 6108-1 6218-1 6002-27 6002-28 6200-29 6002-30 6110-1 6114-1 6206-1 6009-25 6002-26 6220-1 6221-1 6002-77 6112-1

Activator Cam Bracket Weldment Bearing Shim Plate Sprocket, Driven Bushing, Driven Sprocket Roller Chain Master Link Mounting Tube Adjustment for Idler Sprocket *Sprocket & Hub Weldment, Idler *Idler Axle Sprocket, Driver Bushing Driver Sprocket Hand wheel Threaded Collar All Thread Rod Mounting Bracket Weldment for Starter Box and Sir Valves

1 2 2 4 4 1 1 REF 1 1 1 1 2 2 2 REF

* Recommend These Items Be Replaced As A Unit If Other Is Worn Of Damaged.

Figure & Index No.

Part Number

Description 1,2,3,4,5,6

Units Per Assembly

Usable On Code

8- 1 2 3 4 10 11 14

6002-1 6000-19 6009-38 6002-39 6002-40 6002-31 6112-1 6115-1

Electrical System Main Safety Switch 220/440 V Start Switch 440 VAC** Start Switch 220 VAC* Limit Switch Gear motor Mounting Bracket Weldment for Starter Box and Air Valves Actuator Ring w. Palm Button

REF 1 1 1 1 1 1 REF

Figure & Index No.

Part Number

Description 1,2,3,4,5,6

Units Per Assembly

Usable On Code

9- 1 5 6 7 8 9 10 11 12 13 14

6002-1 6115-1 6002-33 6002-35 6002-34 6111-1 6111-3 6111-5 6203-5 6002-36 6002-37 6112-1

Pneumatic System Actuator Ring w/ Palm Button Cylinder, Lid Hold Down System Valve, Air Flow Control Cylinder, Clamp System Aft Clamp Weldment, Clamp System Fwd Clamp Weldment, Clamp System Aft Horizontal Weldment, Clamp System Fwd Horizontal Bar, Clamp System Mini Valve, Air Direct Cut-Off Switch Main Valve, Air Supply Mounting Bracket Weldment for Starter Box & Air Valves

REF 2 1 2 1 REF REF REF REF 1 1 1