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ZL25
OPERATION MANUAL
SAFETY INSTRUCTIONS
Please read these instructions carefully. Failure to follow
these instructions could result in severe injury.
| 1. |
Before using the tool, read
the entire operation manual thoroughly. |
| 2. |
Always wear safety glasses
and face protection when operating the tool. |
| 3. |
Always wear protective gloves
when handling strapping. |
| 4. |
Always use only replacement
parts from an authorized dealer. |
| |
These tools are designed for use with high tensile strapping
and all parts are manufactured or treated for these extreme
conditions. Performance of your tool will be affected
if any other parts are used, which may cause injury. |
SPECIFICATIONS
| Weight: |
10.6
lbs. (4.8 kg) |
| Base
Length: |
4.2"
(105 mm) |
| Base
Width: |
2.4"
(60 mm) |
| Height: |
4.2" (105 mm) |
Strapping Qualities:
Designed for use with regular duty strapping (107,000
psi / 750 N / mm2) to high tensile strapping
(156,000 psi / 1100 N / mm2). |
| Model Number |
Strap Width |
Strap Thickness |
| ZL25-1 |
1/2" (13 mm) |
*015"-.025" (0.38 mm - 0.635 mm) |
| ZL25-2 |
5/8" (16mm) |
*015"-.025" (0.38 mm - 0.635 mm) |
| ZL25-3 |
3/4" (19mm) |
*015"-.025" (0.38 mm - 0.635 mm) |
| |
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*015"-.019" (0.38 mm - 0.635 mm)
requires knife ZR-0070.
|
This tool is not designed to be used with strapping
above .025" (0.635 mm) thickness. |
Top of page
OPERATING
INSTRUCTIONS
| A
Place strapping tightly around the package and hold
in place with left hand. Make sure lever ZL is in fully
open position as shown in diagram.
Take tool with right hand and pull the feedwheel lever
towards the sealing lever.
Insert both portions of the strap with left hand into
the sealing section.
Release the feedwheel lever and make certain strapping
is held by strap guide.
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B
Hold tool firmly with left hand on the sealing lever.
With right hand move the tension lever forward and
backward until the desired tension is obtained.
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C
Place right hand firmly on the tension lever for supporting
the tool.
With left hand push the sealing lever forward until
it reaches the stop.
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D
Move the sealing lever back to its original position.
Place right hand firmly on the tension lever for supporting
the tool.
With left hand pull lever ZL towards you until it reaches
the stop.
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E
Move the lever ZL back to fully open position as shown
in the diagram.
To release the tool, with right hand pull the feedwheel
lever towards the sealing lever, pushing the lever to
the left away from the sealing section.
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Top of page
MAINTENANCE
Clean
the sealing section regularly with compressed air to remove
any dust and particles.
Lubricate the die (position 16), punch (position 37) and punch
ZL (position 31) daily with a thin grade of oil.
This will reduce friction and extend the life of the tool
as well as the parts.
Spray the entire tool daily with a rust preventative, this
will prevent any rust formation.
Top of page
ADJUSTMENTS
TO
ADJUST SEALING DEPTH
Loosen nut (position 44), adjust hexagon socket set screw
(position 61) with a hexagon key, turn counter clockwise to
increase sealing depth, or turn clockwise to decrease sealing
depth, retighten nut.
TO
ADJUST CLEARANCE BETWEEN THE FEEDWHEEL (POSITION 5) AND GRIPPER
(POSITION 38)
The clearance between the feedwheel and the gripper should
be .012" (.31 mm). If the clearance is more or less than
this, it must be adjusted.
To reduce the clearance: loosen nut (position 44A),
turn hexagon socket set screw (position 43) counter clockwise
with a ball hexagon key, retighten nut.
To increase the clearance: loosen nut (position 44A),
turn hexagon socket set screw (position 43) clockwise with
a ball hexagon key, retighten nut.
TO
ADJUST SEALING DEPTH FOR LEVER ZL (POSITION 25)
Loosen nut (position 27), adjust hexagon socket screw (position
26) with a hexagon key, turn counter clockwise to increase
sealing depth, or turn clockwise to decrease sealing depth,
retighten nut.
Top of page
REPLACEMENT
OF PARTS
Note: If you are not familiar with the following replacement
procedures, please contact your authorized dealer
for a demonstration or for service.
To Replace The Feedwheel (Position 5)
| 1. |
Remove external retaining
ring (position 3). |
| 2. |
Remove tensioning assembly
(consisting of tension lever (position 11) and feedwheel
shaft (position 2)). |
| 3. |
Install new feedwheel with
the "O" marking facing the strap guide (position
4), reinstall tensioning assembly observing the key way
position during assembly. |
| 4. |
Reposition strap guide onto
the protruding feedwheel shaft. |
| 5. |
Reinstall external
retaining ring. |
To Replace The Gripper (Position 38)
Note: The gripper is held in a nonadjustable
position with spring tension pin (position 39).
| 1. |
To remove
gripper, use drift pin matching the dimension of the spring
tension pin (position 39) and drive the spring tension
pin into the tool base, until the gripper comes loose
from its position. |
| 2. |
Lift feedwheel lever (position
7) to access gripper. |
| 3. |
Clean cavity area and add one
drop of a thin grade of oil in the cavity. |
| 4. |
To install new gripper, place
the gripper into the cavity of the tool base. Reinstall
the spring tension pin and drive it into the hole of the
tool base, until it is flush with the tool base. |
To Replace The Knife (Position 17)
| 1. |
Remove housing cover ZL (position
68), by removing 3 hexagon socket shoulder screws (position
66) and 1 hexagon socket shoulder screw (position 65).
Important: This screw in position 65 must be reinstalled
in this exact position (lower left hand corner) as it
is shorter. It must also sit flush against the housing
cover ZL when reinstalled |
| 2. |
With pliers, pull knife from
slot on die and knife block (position 13). |
| 3. |
Install new knife observing
spring tension pin (position 18) aligns with same slot
on die and knife block. |
| 4. |
Make certain that the area
is clean and well greased with white grease. |
| 5. |
Important: Make certain
that the roller (position 79) is in its position. |
| 6. |
Reinstall housing cover ZL,
then reinstall hexagon socket shoulder screws with a drop
of Loctite* No. 222 on the thread of each screw. |
To Replace The Punch (Position 37)
| 1. |
Remove 2 cheese head machine
screws (position 35) located on the underside of the housing
(position 60). |
| 2. |
Remove punch, clean area, replace
with new punch, then reinstall cheese head machine screws
with a drop of Loctite* No. 222 on the thread of each
screw. |
To Replace The Die (Position 16)
| 1. |
Remove housing cover ZL (position
68), by removing 3 hexagon socket shoulder screws (position
66) and 1 hexagon socket shoulder screw (position 65).
Important: This screw in position 65 must be reinstalled
in this exact position (lower left hand corner) as it
is shorter. It must also sit flush against the housing
cover ZL when reinstalled |
| 2. |
Remove sealing lever (position
64), by loosening hexagon socket cap screw (position 63). |
| 3. |
Remove woodruff key (position
1). |
| 4. |
Remove eccentric shaft (position
74). |
| 5. |
Remove the total internal assembly
by tilting it at a 20 degree angle (see diagram below)
and pull out with pliers by eccentric shaft plunger (position
78), at the same time making sure to hold internal assembly
together with other hand, exposing die on the underside
of the die and knife block (position 13). |
| 6. |
Remove 2 cheese head machine
screws (position 15). |
| 7. |
Remove die, clean area, and
replace with new die, then reinstall cheese head machine
screws with a drop of Loctite* No. 222 on the thread of
each screw. |
| 8. |
To reinstall the internal assembly
follow the installation of internal assembly instructions
below. |
| 9. |
Reinstall the eccentric shaft
observing its relative position to the cam (position 47). |
| 10. |
The cam lever (position 73)
must engage with its tip into the cavity of the cam. The
components should align together and operate smoothly,
please do not force the parts together. |
| 11. |
Make sure area is clean and
well greased with white grease. |
| 12. |
Important: Make certain
that the roller (position 79) is in its position. |
| 13. |
Reinstall housing cover ZL,
then reinstall hexagon socket shoulder screws with a drop
of Loctite* No. 222 on the thread of each screw. |
| 14. |
Reinstall woodruff key and
sealing lever. |
| Removal of Internal Assembly ZL25 |
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Installation of Internal Assembly ZL25
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Figure 1A
Place the cam as per drawing, with the long width
sitting flat in the die and knife block. Add white
grease throughout. Then place the eccentric shaft
plunger on top of the cam and fasten by pushing the
connection pin, position 19 (making sure the groove
on this pin is facing the outside of the die and knife
block) through hole in die and knife block and into
like hole on eccentric shaft plunger.
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Figure 1B
Tilt the internal assembly approximately 20 degrees
and place into housing making sure the back up hook
is sitting in its slot in the housing.
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Figure 1C
Make sure the cam lever is attached to the eccentric
shaft. Then push it through the hole of eccentric
shaft plunger and the housing until it is flush.
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Figure 1D
Turn the cam with pliers in a clockwise direction
until it sits in position shown in this drawing.
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Figure 1E
Turn cam lever in a clockwise direction with fingers
until it sits in front of the cavity of the cam.
Important: Make certain that the roller (position
79) is in its position.
Then install the housing cover and the sealing lever
making sure they sit properly and operate smoothly,
do not force.
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To Replace The Lower Cutter ZL25 (Position 57)
| 1. |
Remove cheese head machine screw (position 15A) located
on the underside of the housing (position 60). |
| 2. |
With small flathead screwdriver push out lower cutter
ZL25 from its position. |
| 3. |
Install and position new lower cutter ZL25 making
sure the thinner end faces toward outside of housing. |
| 4. |
Reinstall cheese head machine screw with a drop of
Loctite* No. 222 on the thread of each screw. |
To Replace the Punch ZL (Position 31)
| 1. |
Remove lever ZL (position 25) by loosening hexagon
socket cap screw (position 24). |
| 2. |
Remove woodruff key (position 29). |
| 3. |
Remove lock housing assembly ZL by removing 4 hexagon
socket cap screws (position 54) and 2 hexagon socket
cap screws (position 53). |
| 4. |
Remove lock housing cover ZL (position 34).
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| 5. |
Remove open link ZL (position 52) and link pin (position
50). |
| 6. |
Remove punch ZL, replace with new punch ZL, then reinstall
link pin and open link ZL. |
| 7. |
Make certain that the area is clean and well greased
with white grease. Attach lock housing cover ZL. Then
reattach lock housing assembly ZL to front of housing
(position 60). |
To Replace The Compression Spring (Position 70) and
Ball (Position 69)
| 1. |
Remove housing cover ZL (position 68), by removing
3 hexagon socket shoulder screws (position 66) and 1
hexagon socket shoulder screw (position 65). Important:
This screw in position 65 must be reinstalled in this
exact position (lower left hand corner) as it is shorter.
It must also sit flush against the housing cover ZL
when reinstalled. |
| 2. |
Remove spring holder ZL (position 71) by removing
2 cheese head machine screws (position 15B) from the
inside of housing cover ZL. |
| 3. |
Remove compression spring, then ball and replace with
new in this order. |
| 4. |
Reinstall spring holder ZL to housing cover ZL with
cheese head machine screws and add a drop of Loctite*
No. 222 on the thread of each screw. |
| 5. |
Important: Make certain that the roller (position
79) is in its position. |
| 6. |
Reinstall housing cover ZL, then reinstall hexagon
socket shoulder screws with a drop of Loctite* No. 222
on the thread of each screw. |
| 7. |
Reinstall woodruff key and lever ZL. |
*Loctite is a registered trademark of the Loctite Corporation.
Top of page
ZL25
DIAGRAM
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This Diagram is available in a Portable Document Format
(PDF) file. To view it, you need to have Adobe Acrobat
Reader version 4.0 installed on your system. Acrobat
Reader is available as a free download from the Adobe
Acrobat Reader site.
These documents are fully printable and searchable.
For complete information on using Adobe Acrobat features,
including the option of downloading a free copy of Acrobat
Reader 4.0, go to the Adobe
Acrobat Reader site. |
Top of page
ZL25
PARTS LIST
|
Position
|
Part Number
|
Part Name
|
Parts per Tool
|
| 1,1A |
ZR-0001 |
Woodruff Key |
2
|
| 2 |
ZR-0002 |
Feedwheel Shaft |
1
|
| 3 |
ZR-0003 |
External Retaining Ring |
1
|
| 4 |
ZR-0004 |
Strap Guide 1/2" (13 mm) |
1
|
| 4 |
ZR-0005 |
Strap Guide 5/8" (16 mm) |
1
|
| 4 |
ZR-0006 |
Strap Guide 3/4" (19 mm) |
1
|
| 5 |
ZR-0007 |
Feedwheel 25 |
1
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| 6 |
ZR-0008 |
Roller Bearing |
1
|
| 7 |
ZR-0009 |
Feedwheel Lever |
1
|
| 8 |
ZR-0010 |
Washer |
1
|
| 9 |
ZR-0011 |
Roller Clutch and Bearing Assembly |
1
|
| 10 |
ZR-0012 |
Roller Clutch |
1
|
| 11 |
ZR-0013 |
Tension Lever |
1
|
| 12 |
ZR-0014 |
Handle |
3
|
| 13 |
ZR-0015 |
Die and Knife Block |
1
|
| 14 |
ZR-0016 |
Dowel Pin |
2
|
| 15, 15A, 15B |
ZR-0017 |
Cheese Head Machine Screw |
5
|
| 16 |
ZR-0018 |
Die 1/2" (13 mm) |
1
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| 16 |
ZR-0019 |
Die 5/8", 3/4" (16mm, 19mm) |
1
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| 17 |
ZR-0020 |
Knife (Includes ZR-0021) |
1
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| 17 |
ZR-0070 |
Knife 15-for strap thickness of .015"-.019"
(0.38-0.48mm) only. (Includes ZR-0021) |
1
|
| 18 |
ZR-0021 |
Spring Tension Pin |
1
|
| 19 |
ZR-0022 |
Connection Pin |
1
|
| 20 |
ZR-0023 |
Back Up Hook |
1
|
| 21 |
ZR-0024 |
Spring Tension Pin |
2
|
| 22 |
ZR-0025 |
External Retaining Ring |
2
|
| 23 |
ZR-0026 |
Shaft |
1
|
| 24 |
ZR-0203 |
Hexagon Socket Cap Screw |
1
|
| 25 |
ZR-0200 |
Lever ZL |
1
|
| 26 |
ZR-0206 |
Hexagon Socket Set Screw |
1
|
| 27 |
ZR-0208 |
Nut |
1
|
| 28 |
ZR-0207 |
Eccentric Shaft ZL |
1
|
| 29 |
ZR-0213 |
Woodruff Key |
1
|
| 30 |
ZR-0214 |
Bronze Bushing |
1
|
| 31 |
ZR-0212 |
Punch ZL |
1
|
| 32 |
ZR-0209 |
Lock Housing ZL |
1
|
| 33 |
ZR-0215 |
Bronze Bushing |
1
|
| 34 |
ZR-0217 |
Lock Housing Cover ZL |
1
|
| 35 |
ZR-0027 |
Cheese Head Machine Screw |
2
|
| 36 |
ZR-0028 |
Dowel Pin |
2
|
| 37 |
ZR-0029 |
Punch 1/2" (13mm) |
1
|
| 37 |
ZR-0030 |
Punch 5/8", 3/4" (16mm, 19mm) |
1
|
| 38 |
ZR-0031 |
Gripper |
1
|
| 39, 39A |
ZR-0032 |
Spring Tension Pin |
2
|
| 40 |
ZR-0033 |
Cheese Head Machine Screw |
2
|
| 41 |
ZR-0034 |
Spring Tension Pin |
2
|
| 42 |
ZR-0035 |
Strap Stop Front 1/2" (13mm) |
1
|
| 42 |
ZR-0036 |
Strap Stop Front 5/8" (16mm) |
1 |
| 42 |
ZR-0037 |
Strap Stop Front 3/4", 1 1/4"
(19mm, 32mm) |
1 |
| 43 |
ZR-0038 |
Hexagon Socket Set Screw |
1
|
| 44, 44A |
ZR-0039 |
Nut |
2
|
| 45 |
ZR-0040 |
Extension Spring |
1
|
| 46 |
ZR-0041 |
Hexagon Socket Cap Screw |
1
|
| 47 |
ZR-0042 |
Cam |
1
|
| 48 |
ZR-0045 |
Die Block Back Up |
1
|
| 49 |
ZR-0046 |
Spring Tension Pin |
1
|
| 50 |
ZR-0216 |
Link Pin |
2
|
| 51 |
ZR-0210 |
Closed Link ZL |
1
|
| 52 |
ZR-0211 |
Open Link ZL |
1
|
| 53 |
ZR-0220 |
Hexagon Socket Cap Screw |
2
|
| 54 |
ZR-0221 |
Hexagon Socket Cap Screw |
4
|
| 55 |
ZR-0047 |
Spacer |
1
|
| 56 |
ZR-0048 |
Pin |
1
|
| 57 |
ZR-0201 |
Lower Cutter ZL25 |
1
|
| 58 |
ZR-0049 |
Strap Stop Rear 1/2" (13mm) |
1 |
| 58 |
ZR-0050 |
Strap Stop Rear 5/8" (16mm) |
1 |
| 58 |
ZR-0051 |
Strap Stop Rear 3/4" (19mm) |
1 |
| 59 |
ZR-0052 |
Nut |
1 |
| 60 |
ZR-0218 |
Housing ZL25 |
1 |
| 61 |
ZR-0054 |
Hexagon Socket Set Screw |
1 |
| 62 |
ZR-0055 |
Roller Bearing |
1 |
| 63 |
ZR-0056 |
Hexagon Socket Cap Screw |
1 |
| 64 |
ZR-0057 |
Sealing Lever |
1 |
| 65 |
ZR-0223 |
Hexagon Socket Shoulder Screw |
1 |
| 66 |
ZR-0058 |
Hexagon Socket Shoulder Screw |
3 |
| 67 |
ZR-0059 |
Roller Bearing |
1 |
| 68 |
ZR-0204 |
Housing Cover ZL |
1 |
| 69 |
ZR-0043 |
Ball |
2 |
| 70 |
ZR-0224 |
Compression Spring |
1 |
| 71 |
ZR-0205 |
Spring Holder ZL |
1 |
| 72 |
ZR-0061 |
Cheese Head Machine Screw |
2 |
| 73 |
ZR-0078 |
Cam Lever |
1 |
| 74 |
ZR-0063 |
Eccentric Shaft |
1 |
| 75 |
ZR-0064 |
Roller Bearing |
1 |
| 76 |
ZR-0044 |
Compression Spring |
1 |
| 77 |
ZR-0075 |
Spring Tension Pin |
1 |
| 78 |
ZR-0065 |
Eccentric Shaft Plunger
(Includes ZR-0043, ZR-0044, ZR-0064, ZR-0075)
|
1 |
| 79 |
ZR-0076 |
Roller |
1
|
| 80 |
ZR-0077 |
Roller Pin |
1
|
| -- |
ZR-0225 |
Operation Manual and Parts List for ZL25
Series Tools. |
1 |
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