SPECTRUM
Preventive Maintenance
Manual
This document is confidential, proprietary and the sole property of Ohio Gravure Technologies Inc (“Ohio GT”). This document shall be used by the customer only in connection with the use of Ohio GT products and only pursuant to Ohio GT’s Terms and Conditions of Sale and License. Information in this manual is believed to be accurate on the publication date, but is subject to change without notice due to continuing product development. No part of the contents of this book may be reproduced or transmitted in any form or by any means without the written permission of Ohio Gravure Technologies Inc. © 2013‐2016 Ohio Gravure Technologies Inc. Ohio Gravure Technologies Inc 1241 Byers Road, Miamisburg, OH 45434 USA Email: Phone: Website: [email protected] [email protected] 1‐937‐428‐1700 OhioGT.com Gravostar Spectrum Document number: 9420‐0046 Publication Date: October 2016 Third Release Contents
INTRODUCTION .................................................................................................. 1
About the Gravostar Spectrum Engraver ....................................................................... 1
Purpose Of Manual....................................................................................................... 1
About this manual ......................................................................................................... 1
Document Conventions .......................................................................................... 2
Safety............................................................................................................................ 2
SCHEDULE ........................................................................................................ 3
Preventive Maintenance Schedule .................................................................................. 3
Master PM Schedule .................................................................................................... 4
List of Materials ............................................................................................................ 4
Vacuum Bag ................................................................................................................. 5
Engrave Head Air Filters .............................................................................................. 6
Cooling Fans, Electrical Enclosure ............................................................................... 7
Manual Chuck & Auto-Chuck ....................................................................................... 8
Auto-Chuck Drive Chain ............................................................................................... 9
Cylinder Supports ......................................................................................................... 9
Head & Tailstock Drive Nut ........................................................................................ 10
Head & Tailstock Rail Guides (Bearings) ................................................................... 10
Carriage Rail Guides (Bearings) ................................................................................ 11
Carriage Linear Drive Track ....................................................................................... 11
Engrave Head Drive Nut............................................................................................. 12
Engrave Head Sub-Carriage Guides (Bearings) ........................................................ 12
Expandable Vacuum Hose ......................................................................................... 13
Embedded Computer ................................................................................................. 13
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i
Contents
PROCEDURES .................................................................................................. 15
Preventive Maintenance Procedures .............................................................................15
Grease Gun Configurations ........................................................................................17
Vacuum Bag................................................................................................................19
Engrave Head Air Filters .............................................................................................21
Cooling Fans ...............................................................................................................23
Manual Chuck .............................................................................................................25
Head & Tailstock Drive Nut .........................................................................................27
Head & Tailstock Rail Guides (Bearings)....................................................................33
Carriage Rail Guides (Bearings) .................................................................................35
Carriage Linear Drive Track ........................................................................................37
Engrave Head Drive Nut .............................................................................................39
Engrave Head Sub-Carriage Guides (Bearings) ........................................................41
Replacing the Vacuum Hose ......................................................................................45
Embedded Computer ..................................................................................................49
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Chapter 2
Schedule
Preventive Maintenance Schedule
An important piece of maintaining equipment is performing the maintenance on a routine
schedule. The remainder of this document identifies the various routine maintenance procedures
that must occur as well as the schedule.
The Master PM Schedule on the next page provides a quick review of all the necessary
procedures and the required schedule. The Master PM Schedule is a table that shows the
assembly or item, the procedure, the page number for the procedure, and the period for
performing the procedure. Use this table to determine which procedures need to be performed
and the necessary schedule.
The Schedules on pages 4–14 are individual checklists to be used with the maintenance
procedures on the following pages. The checklists provide a simple way to track when
maintenance is performed and who performed it. Each block on the checklist indicates a
maintenance routine must take place. A dated and initialed block indicates that the maintenance
has been performed for that period. Questions regarding the structuring of your particular
maintenance program can be directed to the Ohio Customer Support.
Schedule and Checklists
Master PM Schedule .................................................................................................................. 4
List of Materials .......................................................................................................................... 4
Vacuum Bag ............................................................................................................................... 5
Engrave Head Air Filters ............................................................................................................. 6
Cooling Fans, Electrical Enclosure .............................................................................................. 7
Manual Chuck & Auto-Chuck ...................................................................................................... 8
Auto-Chuck Drive Chain .............................................................................................................. 9
Cylinder Supports ........................................................................................................................ 9
Head & Tailstock Drive Nut ...................................................................................................... 10
Head & Tailstock Rail Guides (Bearings) ................................................................................. 10
Carriage Rail Guides (Bearings) .............................................................................................. 11
Carriage Linear Drive Track ...................................................................................................... 11
Engrave Head Drive Nut ........................................................................................................... 12
Engrave Head Sub-Carriage Guides (Bearings) ....................................................................... 12
Expandable Vacuum Hose ........................................................................................................ 13
Embedded Computer ................................................................................................................ 13
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Chapter 2 Schedule
Master PM Schedule
Master PM Schedule
Checklist
Procedure
Page
Page
Vacuum Bag
5
19
Replace
Engrave Head Air Filters
6
21
Monthly
Check
Cooling Fans
7
23
Monthly
Lubricate
Manual Chuck & Auto-Chuck
8
25
Twice Yearly
Lubricate
Auto-Chuck Chain Drive
9
27
Twice Yearly
Lubricate
Cylinder Supports
9
29
Yearly
Lubricate
Head & Tailstock Drive Nut
9
31
Yearly
Lubricate
Head & Tailstock Rail Guides
(Bearings)
10
33
Yearly
Lubricate
Carriage Rail Guides (Bearings)
11
35
Yearly
Clean
Carriage Linear Drive Track
11
37
Yearly
Lubricate
Engrave Head Drive Nut
12
39
Yearly
Lubricate
Engrave Head Sub-Carriage
Guides (Bearings)
12
41
Yearly
Replace
Vacuum Hose
13
45
Twice Yearly
Clean
Embedded Computer
13
49
Period
Action
Item
Bi-Weekly
Replace
2x Monthly
List of Materials
The following items are required for one or more of the maintenance procedures:
 Vacuum Bag – D1475-0027*
 Kit, Air Filter, Engraving Head – D 803.900.042*
 Multi-purpose Grease – D1645-0024
 Spray Lubricant– Tirox Chain Wax (not supplied by OHIO)
 Grease Gun – D1650-0024
 Push-On Coupler – D1650-0025
 Needletip Nozzle – D1650-0026
 Expandable Vacuum Hose – D817.400.110*
* Part of the yearly consumables kit.
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Chapter 2 Schedule
Vacuum Bag
Vacuum Bag
Replace the bag every two weeks
Instructions on page 19
January
Week 1
Week 3
February
Week 1
Week 3
March
Week 1
Week 3
April
Week 1
Week 3
May
Week 1
Week 3
June
Week 1
Week 3
July
Week 1
Week 3
August
Week 1
Week 3
September
Week 1
Week 3
October
Week 1
Week 3
November
Week 1
Week 3
December
Week 1
Week 3
Each block indicates required b-weekly maintenance. Check and initial block when maintenance
is completed.
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Chapter 2 Schedule
Engrave Head Air Filters
Engrave Head Air Filters
Replace twice a month
Instructions on page 21
January – 20____
January – 20____
Week
1
Week
1
Week
3
Week
3
February – 20____
February – 20____
Week
1
Week
3
Week
1
Week
3
Week
1
March – 20____
Week
1
March – 20____
April – 20____
Week
1
Week
3
Week
1
Week
3
Week
1
Week
3
June – 20____
Week
3
Week
1
July – 20____
Week
1
Week
3
May – 20____
June – 20____
Week
1
Week
3
April – 20____
May – 20____
Week
1
Week
3
Week
3
July – 20____
Week
3
Week
1
Week
3
August – 20____
August – 20____
Week
1
Week
1
Week
3
Week
3
September – 20____
September – 20____
Week
1
Week
1
Week
3
Week
3
October – 20____
October – 20____
Week
1
Week
1
Week
3
Week
3
November – 20____
November – 20____
Week
1
Week
1
Week
3
Week
3
December – 20____
December – 20____
Week
1
Week
1
Week
3
Week
3
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
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Chapter 2 Schedule
Cooling Fans
Cooling Fans
Check and clean once a month
Instructions on page 23
January
Year 1
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
February
Year 1
March
Year 1
April
Year 1
May
Year 1
June
Year 1
July
Year 1
August
Year 1
September
Year 1
October
Year 1
November
Year 1
December
Year 1
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
Spectrum Preventive Maintenance Manual
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Chapter 2 Schedule
Manual Chuck & Auto-Chuck
Manual Chuck & Auto-Chuck
Lubricate once a month
Instructions on page 25
January
Year 1
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
Year 2
Year 3
Year 4
Year 5
February
Year 1
March
Year 1
April
Year 1
May
Year 1
June
Year 1
July
Year 1
August
Year 1
September
Year 1
October
Year 1
November
Year 1
December
Year 1
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
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Chapter 2 Schedule
Auto-Chuck Drive Chain
Auto-Chuck Drive Chain
Lubricate twice a year
Instructions on page 27
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
Cylinder Supports
Lubricate twice a year
Instructions on page 29
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Year 20____
Year 20____
Year 1A
Year 1A
Year 1B
Year 1B
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
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9
Chapter 2 Schedule
Head & Tailstock Drive Nut
Head & Tailstock Drive Nut
Lubricate once a year
Instructions on page 27
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required yearly maintenance. Check and initial block when maintenance is
completed.
Head & Tailstock Rail Guides (Bearings)
Lubricate once a year
Instructions on page 33
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required yearly maintenance. Check and initial block when maintenance is
completed.
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Chapter 2 Schedule
Carriage Rail Guides (Bearings)
Carriage Rail Guides (Bearings)
Lubricate once a year
Instructions on page 35
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required yearly maintenance. Check and initial block when maintenance is
completed.
Carriage Linear Drive Track
Clean and inspect once a year
Instructions on page 37
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
Spectrum Preventive Maintenance Manual
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Chapter 2 Schedule
Engrave Head Drive Nut
Engrave Head Drive Nut
Lubricate once a year
Instructions on page 39
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
Engrave Head Sub-Carriage Guides (Bearings)
Lubricate once a year
Instructions on page 41
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
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Chapter 2 Schedule
Expandable Vacuum Hose
Expandable Vacuum Hose
Replace once a year
Instructions on page 45
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required monthly maintenance. Check and initial block when maintenance is
completed.
Embedded Computer
Clean every two years
Instructions on page 49
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Year 20____
Each block indicates required bi-yearly maintenance. Check and initial block when maintenance
is completed.
Spectrum Preventive Maintenance Manual
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13
Chapter 2 Schedule
Embedded Computer
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Chapter 3
Procedures
Preventive Maintenance Procedures
This section contains the various preventive maintenance procedures for the GS Spectrum
engraving system. Information contained here includes procedures for standard equipment as
well as optional equipment, auto-chucks and cylinder supports for example.
Photographs used in this section may differ slightly from your machine. This is due to on-going
development with the Spectrum engraver. In some photographs, the machine is shown with the
enclosures removed. This was done to provide a better view of the item being identified for
maintenance. The maintenance instructions will refer to the missing enclosures where
appropriate.
Procedures
Grease Gun Configurations ....................................................................................................... 17
Vacuum Bag ............................................................................................................................. 19
Engrave Head Air Filters ........................................................................................................... 21
Cooling Fans ............................................................................................................................. 23
Manual Chuck ........................................................................................................................... 25
Tailstock Drive Nut ................................................................................................................... 27
Tailstock Rail Guides (Bearings) .............................................................................................. 33
Carriage Rail Guides (Bearings) .............................................................................................. 35
Carriage Linear Drive Track ...................................................................................................... 37
Engrave Head Drive Nut ........................................................................................................... 39
Engrave Head Sub-Carriage Guides (Bearings) ....................................................................... 41
Expandable Vacuum Hose ....................................................................................................... 45
Embedded Computer ................................................................................................................ 49
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Chapter 3 Procedures
Embedded Computer
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Chapter 3 Procedures
Grease Gun Co
onfigurations
Grea
ase Gun Configura
C
ations
Grease Gu
un – D1645-0
0027
Push-On Coupler
C
and Dispensing
D
Tu
ube – D1650--0025
Needletip Nozzle – D16
650-0026
The base grease
g
gun re
equires some
e simple config
guration chan
nges to work ffor the two diffferent
types of grrease fittings. There are tw
wo configuratio
ons required, as explained
d below.
Normal Grease Fitting
g Configuration
1. The ba
asic grease gun has a pum
mp
assem
mbly and a tub
be with press--fit
grease
e coupling.
2. Remov
ve the press-ffit grease cou
upling
from th
he tube. If nec
cessary, insta
all the
tube onto the pump
p assembly.
D1645-002
27
3. Locate
e the push-on
n coupler. This
s
consis
sts of two piec
ces, a lower push-on
p
couplin
ng and a disp
pensing tube.
ew the dispen
nsing tube fro
om the
Unscre
push-o
on coupling.
s
4
The dispensing tube is used in step
and wo
orks with the majority of the
grease
e fittings on th
he machine. This
T
type off dispenser re
equires you to
o push
the tub
be against the
e grease fitting.
D1650-002
25
Disassembled
ensing tube on
n the right
Dispe
Spectrum Preventive Mainte
enance Manual
28-Sep-16
17
C
Chapter 3 Proced
dures
V
Vacuum Bag
4. Thread the
e dispenser tu
ube onto the
grease gun
n tube.
e gun is now ready to use..
The grease
be installed
Grrease gun with push-on-tub
ease Fitting Configuration
C
n
Flush Tip Gre
n
configuration,
1. From the normal
unscrew th
he dispensing
g tube from the
longer tube
e of the greas
se gun.
2. Re-install the
t original prress-fit coupling
onto the grrease gun tub
be, as shown to
the right.
3. Locate the
e Needlepoint nozzle.
4. Insert the assembly
a
into
o the press-fitt
coupling. If the needletip assembly
won’t go in
n, loosen the press-fit
coupling slightly, insert the assembly
y,
and tighten
n the coupling
g to hold the
flush-tip as
ssembly.
This config
guration is use
ed for
lubricating the Chuck, on
o page
Engrave Head
H
25 and the
Sub-Carria
age Guides on page 41.
D1650-0026
To convertt back to the Normal
N
configuration, unscrew the entire
oupling and flush tip
press-fit co
assembly from
f
the tube
e, then install the
dispenser tube.
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Chapter 3 Procedures
V
Vacuum Bag
Vac
cuum Bag
g
Replace th
he bag every two weeks
Vacuum Bag: P/N D147
75-0025
To replace
e the vacuum bag
5. Ensure
e the machine
e is not engra
aving.
6. Open the
t vacuum cover
c
found on the rear of tthe machine.
3. Pull the existing ba
ag off the exh
haust nozzle.
4. Clean
n the exhaustt nozzle at the
e top right of tthe
cavity
y to remove excess
e
copper chips and to
o
promote a good se
eal. Also clean out any cop
pper
s from inside the
t vacuum cavity.
chips
A view of the exxhaust nozzle
e (top)
Spectrum Preventive Mainte
enance Manual
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19
C
Chapter 3 Proced
dures
V
Vacuum Bag
5.
5 Gently pu
ull a new bag to open it slig
ghtly then placce
over the exhaust
e
nozzle. Slide the bag
b back unti l a
good seal is achieved over the large
e diameter off
the exhau
ust nozzle. Ma
ake sure the bag is over th
he
large diam
meter of the nozzle
n
to prev
vent copper
chips from
m escaping from the bag and
a filling the
cavity.
6.
6 Replace the
t vacuum cover.
c
2
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Chapter 3 Procedures
Engrave Hea
ad Air Filters
Engrave Hea
ad Air Filtters
Replace tw
wice a month
Engrave Head
H
Air Filterr: P/N D803.9
900.042
The Engra
ave Head Air Filters
F
are loc
cated on the b
bottom of the engrave head. These filte
ers clean
the air ente
ering the head to cool the head motor. IIt is importantt to replace th
hese filters on
na
regular bas
sis to preventt the filters fro
om becoming blocked and also to preve
ent dirt from e
entering
the engrav
ve head.
Note: Dirt in the engrav
ve head will affect the perfo
ormance of th
he head and w
will require fa
actory
ad.
service to clean the hea
To access the Engrave Head Air Filters:
1. Remov
ve the cylinde
er from the machine if nece
essary.
ntil it stops.
2. Positio
on the head clear
c
from the chucks or co
ones and lowe
er the head un
3. Remov
ve the two (2)) screws hold
ding the engra
ave head cove
er and slide th
he cover off the
carriag
ge.
4. Using a pair of need
dle-nose plierrs, remove th e air filters fro
om the nozzle
es beneath th
he
engrav
ve head.
Lefft Air Filter
Right Air Filter
5. Using your fingers, insert a new air filter into e
each nozzle.
Note: If it is also tim
me to perform
m the yearly lu brication on tthe Engrave H
Head Drive Nut, this is
the perfect time to do
d it. See Eng
grave Head D
Drive Nut on p
page 37.
6. Re-ins
stall the head cover and se
ecure using th
he two screwss.
7. Retrac
ct the engrave
e head.
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enance Manual
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Chapter 3 Procedures
Engrave Head Air Filters
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Chapter 3 Procedures
C
Cooling Fans
Coo
oling Fans
s
Check onc
ce a month, cllean if necess
sary
The fans on
o the electronics rack prov
vide cooling a
air to the pow
wer supplies and engrave h
head
amplifiers. Verify the fan
ns are running and that the
ey are clean ffrom excessivve dust and d
dirt.
To check the
t cooling fans:
1. Ensure
e the machine
e is not engra
aving but pow
wer is ON to th
he machine.
2. Remov
ve the end pa
anel from the electronics e nclosure by turning six (6)) quick release
e
handle
es. The end panel
p
will lift off the machin e. Set it aside
e in a safe pla
ace.
3. Use a flashlight to lo
ook under the
e electronics rack at the fa
ans beneath. V
Verify that all are three
(3) fan
ns are running
g.
DANG
GER: There is
s electricity running to the u
unit. Do not to
ouch anything
g, simply lookk under
the rac
ck to verify the
e fans are run
nning.
4. Turn OFF
O power to the machine. This stops th
he fans rotation.
5. The fa
ans are mountted in a sliding tray. Remo
ove the two (2
2) black thumb
bscrews, one from
each side,
s
holding the
t tray and slide
s
the fan trray out from u
under the electronics rack..
Spectrum Preventive Mainte
enance Manual
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23
Chapter 3 Procedures
6. Clean the fans if they are excessively dirty using a vacuum and soft brush.
NOTE: If the fans are extremely dirty, with one mm or more of dirt attached to the fan blades
and housing, call Ohio GT or an authorized service organization. The power supplies and
amplifiers in the electrical rack will need to be cleaned to prevent the possibility of serious
electronic failures.
7. Slide the fan tray back under the electronics rack and secure with the two thumbscrews.
8. Re-install the end panel by sitting it in place and turning the six (6) quick release handles.
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Chapter 3 Procedures
M
Manual Chuck & Auto-Chuck
Man
nual Chuc
ck & Auto
o-Chuck
Lubricate once
o
a month
h
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
To lubricatte the chuck:
1. Remov
ve cylinder fro
om the machiine.
2. Chang
ge the grease gun to use th
he needletip cconfiguration..
3. Add tw
wo (2) pumps of grease in the
t button he
ead grease fittting on the face of the chuck.
4. Open the
t chuck to expose
e
the slliding surface
es of the jaws..
CAUTION: Do not remove
r
the ja
aws from the cchuck.
5. Place a small amou
unt of grease on a piece off cloth or yourr finger and a
apply a light co
oating to
the six
x (6) sliding arreas of the jaw
ws.
6. Move the
t jaws in an
nd out to distrribute the gre ase on the sliding areas.
Spectrum Preventive Mainte
enance Manual
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25
Chapter 3 Procedures
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Chapter 3 Procedures
Auto-Chuckk Chain Drive
Auto
o-Chuck Chain
C
Driive
Lubricate twice
t
a year
Lubricant: Spray lubrica
ant, Tirox Cha
ain-Wax
To lubricatte the chain drive:
d
1. Remov
ve cylinder fro
om the machiine.
2. Remov
ve the covers
s from the autto-chuck drive
e units by pullling the coverrs away from the
headsttock and tails
stock. These covers
c
are he
eld on by mag
gnets.
Ta
ailstock Auto--Chuck shown
3. Isolate
e the chain area by placing
g paper behin d and beneatth the chain to
o prevent ove
erspray of
lubrica
ant. Do this fo
or both units.
4. Spray a light coating of lubricantt over the cha
ain on each un
nit. The corre
ect amount will result in
a virtually invisible coating
c
on the
e chain after sseveral minuttes of drying. Too much will show
droplets on the surffaces when th
he lubricant d ries.
5. Remov
ve the paper from each un
nit.
6. Re-ins
stall the coverrs onto each unit.
u
Spectrum Preventive Mainte
enance Manual
28-Sep-16
27
Chapter 3 Procedures
Auto-Chuck Chain Drive
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Chapter 3 Procedures
Cylind
der Supports
Cylinder Sup
pports
Lubricate twice
t
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
To lubricatte the cylinder supports:
1. Remov
ve cylinder fro
om the machiine.
2. Add on
ne pump of grease to each
h jackscrew g
grease fitting.
He
eadstock cylin
nder support sshown
3. Cycle the cylinder supports
s
up and down at le
east once to sspread the gre
ease through the
crew gearbox.
jacksc
Spectrum Preventive Mainte
enance Manual
28-Sep-16
29
Chapter 3 Procedures
Cylinder Supports
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9420-0046 – Ohio Gravure Technologies Inc
Chapter 3 Procedures
Head & Tailsto
ock Drive Nut
Hea
ad & Tails
stock Driv
ve Nut
Lubricate once
o
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
The tailsto
ock is driven by
b a leadscrew
w on the top o
of the machin
ne. The tailsto
ock has a drivve nut
riding on th
he ballscrew.
To lubricatte the tailstock leadscrew drive
d
nut:
1. Turn OFF
O power to the machine.
2. Locate
e the carriage
e to the Home
e position.
3. Discon
nnect the bellows from the tailstock. Do this by pullin
ng the bellowss up off the locating
screws
s.
4. Inspec
ct the leadscre
ew for dirt and
d debris. If de
ebris is present, use a clea
an soft-bristled brush
to rem
move the dirt and
a debris. If necessary
n
forr inspection a
and cleaning, turn the leadsscrew
using the
t Stock In/O
Out controls on
o the rear co
ontrol panel.
Tailstock Drrive Nut show
wn with bellow
ws removed
5. Unscre
ew the dispen
nsing tube fro
om the grease
e gun tube.
6. Apply two (2) pump
ps of grease to
o the carriage
e side of the d
drive nut.
7. Re-ins
stall the bellow
ws by aligning
g the slots witth the screw h
heads.
Note: Step
ps 5 through 9 are for Deco
orative Specttrums with a m
moving headsstock.
8. Discon
nnect the bellows from the headstock byy pulling the b
bellows up offf the locating screws.
9. Inspec
ct the leadscre
ew for dirt and
d debris. If de
ebris is present, use a clea
an soft-bristled brush
to rem
move the dirt and
a debris. If necessary
n
forr inspection a
and cleaning, turn the leadsscrew
using the
t Stock In/O
Out controls on
o the rear co
ontrol panel.
10. Apply two (2) pump
ps of grease to
o the carriage
e side of the d
drive nut.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
31
Chapter 3 Procedures
Head & Tailstock Drive Nut
11. Re-install the dispensing tube onto the grease gun tube.
12. Re-install the bellows by aligning the slots with the screw heads.
13. Move the stock(s) towards the center of the machine to spread the grease over the leadscrew
and through the drive nut.
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Chapter 3 Procedures
Head & Tailsstock Rail Guide
es (Bearings)
Hea
ad & Tails
stock Rail Guides (Bearings
s)
Lubricate once
o
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
Rail guides
s (also called bearings) rid
de on the fron t and back lin
near rails of th
he engraver. T
There are
either four or eight rail guides
g
to lubrricate:
-
For Pa
ackaging Spectrums, there
e are four (4) rrail guides on
n the tailstockk.
-
For De
ecorative and Large Forma
at Spectrums,, there are eig
ght (8) rail guides, four (4) each on
the tailstock and he
eadstock.
To lubricatte the rail guid
des:
1. Remov
ve the cylinde
er from the machine if a cyylinder is loaded.
2. Turn OFF
O power to the machine.
3. Remov
ve the bellow
ws from both sides
s
of the ta
ailstock. Lift th
he bellows up
p over the loca
ating
screws
s. Do not rem
move the silver locating scre
ews from the black bar.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
33
C
Chapter 3 Proced
dures
H
Head & Tailstock
k Rail Guides (Be
earings)
4. Locate the
e four rail guid
des on the corrners of the ta
ailstock unit. T
The grease fittings are
mounted on
o the rail guid
des, over the linear rails.
Grease fitting on rrail guide.
Shown
S
before black bar is rremoved in sttep 3.
5. Add two (2
2) pumps of grease into ea
ach fitting.
6. For machin
nes with moveable headstocks, repeat steps 1 throu
ugh 5 on the h
headstock raill
guides.
7. Turn ON power
p
to the machine
m
and move
m
the tailsstock across the guide rails to distribute
e the
grease thro
ough the rail guides and on the guide ra
ails. This ope
eration will alsso distribute th
he
grease in the
t headstock
k of decorativ
ve and large fo
ormat machin
nes. Leave the tailstock at the
furthest rig
ght position an
nd move on to
o the next pro
ocedure, Carrriage Rail Guides.
3
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Chapter 3 Procedures
Carrriage Rail Guide
es (Bearings)
Carrriage Rail Guides (Bearings
s)
Lubricate once
o
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
The carriag
ge has three (3) rail guides
s, also known
n as bearings . These guide
es ride on line
ear rails.
Two (2) gu
uides ride on the
t front linea
ar rail, the thirrd on the rearr linear rail.
To lubricatte the carriage
e rail guides:
1. Turn OFF
O the powe
er to the mach
hine.
2. Locate
e the rail guide on the back
k of the carria
age, directly b
beneath the re
ear pod. The g
grease
fitting is
i mounted on
n the rail guid
de facing out a
away from the
e machine.
Rearr grease fitting
g on the carria
age.
3. Add tw
wo (2) pumps of grease into the grease fitting.
4. Move to
t the operato
or side of the machine.
5. Releas
se the bellows from each side
s
of the carriage. Locate
e the grease fitting on each rail
guide.
wo (2) pumps of grease into each greasse fitting.
6. Add tw
7. Re-ins
stall the bellow
ws to the carrriage by aligniing the slots w
with the locating screws.
View
w of the right front rail guid
de showing th
he grease fitting.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
35
Chapter 3 Procedures
Carriage Rail Guides (Bearings)
8. Turn ON power to the machine and move the carriage left and right over the length of the
machine.
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9420-0046 – Ohio Gravure Technologies Inc
Chapter 3 Procedures
Carriage Linearr Drive Track
Carrriage Line
ear Drive
e Track
Clean and
d inspect once
e a year
Items Required: Comprressed air use
ed for cleanin g computer e
equipment
CAUTION: Do not use shop air due to likely conta
aminants.
The carriag
ge uses a line
ear drive to move
m
the carri age horizonta
ally across the machine. T
The linear
drive consists of a moto
or unit attache
ed to the carriiage, and a lo
ong track of very powerful magnets.
Dirt collectting in the ma
agnet track an
nd on the mag
gnet faces ma
ay create prob
blems with ca
arriage
movementt. To clean an
nd inspect the
e magnet trac k:
1. Home the carriage.
2. Lift the
e bellows up at
a the headsto
ock and tailsttock until theyy are clear of tthe panhead screws.
These are the easie
est places to free
f
the bello
ows from theirr mounting po
oints.
e the linear drrive track runn
ning the
3. Locate
length of the machine.
CAUT
TION: The trac
ck consists off a series
of blac
ck magnets mounted
m
in a row
r
along
the tra
ack frame. These magnets are
extrem
mely powerful. Do not place
e any
items that will be atttracted by the
e
magne
ets near the track. Also be cautious
of wris
stwatches.
4. Inspec
ct the bottom of the track fo
or dirt and
debris
s. If large piec
ces of dirt are seen, use
comprressed air to blow
b
the dirt out
o of the
track. Only used cle
ean canned air,
a never
a A brush ca
an also be us
sed to
shop air.
move the dirt towarrds the end off the track
and ou
ut.
5. Inspec
ct the magnett faces for any
y dirt or
metallic debris. With bellows in place,
p
dirt
should
d not fall onto these surfaces. If
there is
i dirt and it is
s on the magn
net face, it
will tak
ke some efforrt to remove the dirt.
Use plastic tweezers or other no
onetic tools to re
emove dirt stu
uck to the
magne
face of
o the magnets
s.
6. Re-connect the bellows to the he
eadstock
ailstock.
and ta
Spectrum Preventive Mainte
enance Manual
28-Sep-16
37
Chapter 3 Procedures
Carriage Linear Drive Track
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9420-0046 – Ohio Gravure Technologies Inc
Chapter 3 Procedures
Engrave Hea
ad Drive Nut
Engrave Hea
ad Drive Nut
N
Lubricate once
o
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
The engrave head is drriven into and away from th
he cylinder byy a small lead
dscrew. The d
drive nut is
mounted on
o the moving
g base below the engrave h
head. To lubrricate the drivve nut:
1. Remov
ve the cylinde
er from the machine if a cyylinder is loaded.
2. Positio
on the head away
a
from the
e chucks or co
ones and lowe
er the head u
until it stops.
3. Turn OFF
O power to the machine.
4. Remov
ve the bellow
ws from between the engravve head and operator side
e pod. The be
ellows are
ulling away frrom each end
attached using Velc
cro so remove
e simply by pu
d.
5. Add tw
wo (2) pumps of grease to the grease fittting on the drrive nut. See the picture fo
or
locatio
on.
6. Perform the next prrocedure, Eng
grave Head S
Sub-Carriage Guides (Bearrings), on
page 41.
4
E
Engrave Head Drive Nut
Spectrum Preventive Mainte
enance Manual
28-Sep-16
39
Chapter 3 Procedures
Engrave Head Drive Nut
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9420-0046 – Ohio Gravure Technologies Inc
Chapter 3 Procedures
En
ngrave Head Sub
b-Carriage Guide
es (Bearings)
Engrave Hea
ad Sub-Ca
arriage Gu
uides (Be
earings)
Lubricate once
o
a year
Lubricant: Multi-purpose
e grease, P/N
N D1645-0024
4
The engrave head moves into and away from the cylinder on rrail guides tha
at ride on two rails.
Note: There are two ve
ersions of instructions for lu
ubricating these guides. Th
he first set of
instructions are for mac
chines with se
erial numbers of 103? And higher. The ssecond set off
instructions are for mac
chines 103? and
a earlier.
Instruction Set 1 for machine
m
seria
al numbers 1
1036, 1037, a
and 1039 and
d higher
To lubricatte bearings:
1. Remov
ve the cylinde
er from the machine if a cyylinder is loaded.
2. Turn ON
O power to the
t machine and
a lower the
e head fully.
3. Turn OFF
O power to the machine.
4. Remov
ve the bellow
ws covering the engraver be
ed from each side of the carriage by lifting up on
the bellows and aw
way from the lo
ocating screw
ws. This exposses the bellow
ws mounting bars
ed on each sid
de of the carrriage.
secure
5. Locate
e the two hole
es through each bellows m
mounting bar. T
These holes should line up
p with the
grease
e fittings on th
he rail guides. The picture below showss the grease fittings with the bellows
mountting bars remo
oved.
6. Mountt the needlepo
oint grease tu
ube to the gre
ease gun.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
41
C
Chapter 3 Proced
dures
E
Engrave Head Su
ub-Carriage Guid
des (Bearings)
7. Press the needlepoint tube against the grease fitttings and add
d one (1) pump of grease to
o the
four (4) be
earings, two (2
2) on each sid
de of the subccarriage.
8. Re-attach the bellows to
o the carriage
e sides.
9. Turn ON power
p
to the machine.
m
10
0. Cycle the head
h
forward and backwarrd using the h
head raise an
nd lower contrrols.
11. Retract the
e head.
4
42
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9420 -0046 – Ohio Grravure Technolog
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Chapter 3 Procedures
En
ngrave Head Sub
b-Carriage Guide
es (Bearings)
Instruction Set 2 for machine
m
seria
al numbers 1
1038, and 1035 and lower
To lubricatte bearings:
1. Remov
ve the cylinde
er from the machine if a cyylinder is loaded.
2. Turn ON
O power to the
t machine and
a lower
the head fully.
3. Turn OFF
O power to the machine.
4. Remov
ve the eight (8) screws tha
at hold the
cover to
t the sub-carriage. There are four
(4) on each side of the head mou
unt. Allow
ver to move backwards
b
tow
wards the
the cov
operattor pod and ex
xpose the fou
ur rail
guides
s on the head mount.
5. Remov
ve the bellow
ws covering the
engrav
ver bed from each side of the
t
carriag
ge by lifting up
p on the bello
ows and
away from
f
the locatting screws.
6. Remov
ve the bellow
ws mounting bar from
each side
s
of the carrriage. There are five
(5) scrrews holding each
e
bar onto
o the
carriag
ge.
Ste
ep 4 – Removving screws
7. Mountt the needlepo
oint grease tu
ube to the
grease
e gun.
Needlepoint Gre
ease Nozzle
8. Add on
ne (1) pump of
o grease to th
he four (4) be
earings. A gre
ease fitting is found on eacch bearing
guide. See the follo
owing picture for
f location in
nformation.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
43
Chapter 3 Procedures
Engrave Head Sub-Carriage Guides (Bearings)
9. Re-attach the cover to the sub-carriage.
10. Turn ON power to the machine.
11. Cycle the head forward and backward using the head raise and lower controls.
12. Retract the head.
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Chapter 3 Procedures
R
Replacing the Va
acuum Hose
Rep
placing th
he Vacuum
m Hose
Replace on
nce a year
Part Required: Expanda
able Vacuum Hose, P/N D
D817.400.110
The expan
ndable vacuum
m hose conn
nects the engrrave head witth the primaryy vacuum hosse running
the length of the machin
ne. This hose
e stretches to accommodatte the movem
ment of the en
ngrave
er diameters. To replace th
he vacuum ho
ose:
head to diffferent cylinde
1. Remov
ve the cylinde
er from the machine if a
cylinde
er is loaded.
2. Turn ON
O power to the
t machine and
a lower the
e
head fully
f
until it sto
ops.
3. Turn OFF
O power to the machine.
4. Remov
ve the bellow
ws from between the back o
of
the engrave head and
a the operator pod.
5. If insta
alled, remove the hood cov
vering the
engrav
ve head. Two
o (2) screws hold
h
this coverr
onto th
he lower sub-carriage cove
er. Place the
screws
s in a safe pla
ace for reuse..
6. Remov
ve the lower sub-carriage
s
cover.
a. Re
emove the eig
ght (8) screws
s holding the
low
wer sub-carria
age cover. Place the screw
ws
in a safe place for reuse.
b. Slide the lower sub-carriage cover toward
ds the operato
or side and lifft free.
7. Remov
ve the operattor pod from
the fro
ont of the carriage.
a. Re
emove seven (7) screws and nylon wasshers securing
g the pod to tthe carriage. R
Remove
the
e side screws
s first, then the front screw
ws. Hold the po
od to preventt it from dropp
ping onto
the
e Carriage Intterface board
d underneath. Place the sccrews and wasshers in a saffe place
forr reuse.
b. Ca
arefully lift the
e pod up and disconnect tw
wo cables run
nning to the po
od. One is a U
USB
ca
able for the tou
uchpad and itt disconnectss from the USB repeater. T
The second ca
able is for
the
e Emergence
e Stop loop / Carriage
C
Direcction and requires a small latch be released to
se
eparate the tw
wo connectors
s.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
45
C
Chapter 3 Proced
dures
R
Replacing the Va
acuum Hose
8. Replace th
he expanding vacuum hose
e. This hose rruns along the carriage fro
om below the
engraving head to the front of the ca
arriage.
a. Re
elease two ho
ose clamps th
hat secure the
e hose to the ttwo metal tub
bes. An 8 mm
m nut
driver or sockett makes this an
a easy task.
b. Slide the hose off
o the inlet and exhaust tu
ubes.
c.
Se
eparate the tw
wo hose clamps from the h
hose. Discard the hose.
d. Slide a hose cla
amp over eac
ch end of the new vacuum hose (item 1). Open the
cla
amps as nece
essary to allow
w the hose to
o go through w
with minimal e
effort.
e. Slide the new vacuum
v
hose onto the
me
etal tubes. Ro
otate the clam
mps to
allow access to
o the locking screws
s
on
n the hose cla
amps. At the same
s
tim
me, avoid puttting the clamp
ps
wh
here they will rub any cable
es.
No
ote: Be sure the
t hose clam
mp
ne
earest the eng
grave head will not
intterfere with th
he head slide motor
wh
hen the head is retracted.
f.
Tig
ghten the two
o hose clamps
s. The
cla
amps must be
e secure to prrevent
co
opper chips fro
om escaping..
9. Re-install the
t operator pod.
p
a. Conne
ect the two ca
ables as appro
opriate.
b. Secure
e the pod usin
ng the seven (7) original sccrews and nyylon washers. Start a screw
w in
the right side first to
o hold the poe
e up and awa
ay from the Ca
arriage Interfa
ace board.
10
0. Turn ON power
p
to the machine.
m
The engrave hea
ad should retra
act when pow
wered up.
11. Turn ON th
he engrave he
ead and listen
n for the vacu
uum. Check fo
or air leaks arround the hosse
clamps. Co
orrect as nece
essary to elim
minate leaks.
12
2. Lower the head againstt the inner sto
op and turn O
OFF power.
4
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Chapter 3 Procedures
Replacing the Vacuum Hose
13. Re-install the lower sub-carriage cover using eight (8) screws and nylon washers.
CAUTION: If this engraver has the Kaman box relocated onto the sub-carriage, be sure to
use the two (2) M5 screws on the right side of the cover in the back two holes. All other
mounting screws (six total) are M4 screws.
14. Re-install the bellows between the pod and engrave head.
15. Re-install the engrave head hood and secure using two (2) of the original screws and nylon
washers.
16. Turn ON power to the machine and check machine operation.
Spectrum Preventive Maintenance Manual
28-Sep-16
47
Chapter 3 Procedures
Replacing the Vacuum Hose
48
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Chapter 3 Procedures
Embedde
ed Computer
Emb
bedded Computer
Clean everry two years
No Parts or
o Lubricant Required
R
The embed
dded computer is located in the electro nics enclosurre of the Specctrum. This co
omputer
should be checked for dirt
d and cleaned if necessa
ary every two years. To cle
ean the comp
puter:
1. Turn OFF
O the comp
puter. Do this using the Sh utdown routin
ne from the S
Spectrum application
softwa
are.
2. Turn OFF
O the mach
hine.
3. Remov
ve the end pa
anel from the
electro
onics enclosure by turning six (6)
quick release
r
handlles. The end panel will
lift off the
t machine. Set it aside in
n a safe
place.
4. Locate
e the embedd
ded computer setting in
the bottom of the be
ed cavity.
Note: There is a FirreWire hub mounted
m
on
the top
p of the comp
puter. Disconn
nect the
cable going
g
into the
e back of the hub
h to
allow clearance
c
for the top coverr to be
remov
ved.
There are two black
k thumbscrew
ws on the
top rea
ar of the embedded compu
uter.
Remov
ve these two screws.
Slide the
t top cover back and the
en lift up to
remov
ve from the co
omputer case.
Carefu
ully lay the top
p cover on the
e floor of
the ma
achine, being cautious of th
he
FireWiire hub on the
e top.
Spectrum Preventive Mainte
enance Manual
28-Sep-16
49
C
Chapter 3 Proced
dures
E
Embedded Comp
puter
5. Pull the sid
de panel away from the un
nit and
then pull up to remove iti from the
computer.
e interior of th
he computer for
f dirt
6. Inspect the
and dust. If
I necessary, clean the inte
erior
using a soft brush. Vacu
uum up the dust
and dirt be
eing careful no
ot to put the hose
h
too close to the parts inside. Using th
he
brush while
e holding the vacuum hose
e is a
good optio
on.
Pay particu
ular attention to the fans
mounted in
n the compute
er and be surre they
are clean.
g into the pow
wer
7. Clean the vents leading
supply. The power supp
ply is at the to
op of
the compu
uter.
o the power supply
s
location, it
Because of
may be diffficult to get th
he vacuum to the
vents. Ano
other option is
s to use a can
n of
clean compressed air.
Caution: Do
D not use sh
hop air from a hose.
Place a da
amp paper tow
wel over the fan
f at
the rear off the power su
upply to catch
h dust
when blow
wing out the po
ower supply with
w
air.
t side pane
el onto the
8. Re-install the
computer.
t top cover onto the com
mputer and se
ecure with the
e two black thumbscrews. A
Also
9. Re-install the
reconnect the FireWire cable to the rear
r
port of th
he hub.
0. Turn ON th
he computer by pressing th
he power buttton on the fro
ont. After startt-up, verify the
10
monitor sh
hows the Spec
ctrum desktop
p and the “Wa
aiting for Pow
wer’ graphic.
11. Replace th
he end cover on the electro
onics enclosu
ure.
5
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