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ZL90
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: |
13.4
lbs. (6.0 kg) |
| Base
Length: |
4.9"
(125 mm) |
| Base
Width: |
2.8"
(70 mm) |
| Height: |
4.4" (110 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 |
| ZL90-1 |
1 1/4" (32mm) |
.025"-.031" (0.635 mm - 0.80 mm) |
This tool is not designed to be used with
strapping below .025" (0.635 mm) thickness
or above .031" (0.80mm) 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 lever ZL back to fully open position as
shown in 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 18), punch (position 36)
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 42), adjust hexagon socket set
screw (position 59) 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 37)
The clearance between the feedwheel and the gripper
should be .020" (.51 mm). If the clearance is more
or less than this, it must be adjusted.
To reduce the clearance: loosen nut (position
42A), turn hexagon socket set screw (position 41) counter
clockwise with a ball hexagon key, retighten nut.
To increase the clearance: loosen nut (position
42A), turn hexagon socket set screw (position 41) 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.
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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 37)
Note: The gripper is held in
a nonadjustable position with spring tension pin (position
38).
| 1. |
To
remove gripper, use drift pin matching the dimension
of the spring tension pin (position 38) 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 19)
| 1. |
Remove housing cover
ZL (position 66), by removing 4 hexagon socket shoulder
screws (position 64) |
| 2. |
With pliers, pull knife
from slot on die and knife block (position 15).
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| 3. |
Install new knife observing
spring tension pin (position 20) 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 78) 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 36)
| 1. |
Remove 2 cheese head
machine screws (position 63) located on the underside
of the housing (position 58). |
| 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 18)
| 1. |
Remove housing cover
ZL (position 66), by removing 4 hexagon socket shoulder
screws (position 64). |
| 2. |
Remove sealing lever
(position 62), by loosening hexagon socket cap screw
(position 61). |
| 3. |
Remove woodruff key (position
1). |
| 4. |
Remove eccentric shaft
(position 72). |
| 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 76), 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 15). |
| 6. |
Remove 4 cheese head
machine screws (position 13). |
| 7. |
Remove die, clean area,
and replace with new die, then reinstall cheese
head machine screws with a drop of Loctite* No.
222 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 45). |
| 10. |
The cam lever (position
71) 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 certain that the
area is clean and well greased with white grease. |
| 12. |
Important: Make certain
that the roller (position 78) 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 ZL90 |
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Installation of Internal Assembly ZL90
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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
21 (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 slot
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
78) 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 (Position 55)
| 1. |
Remove cheese head machine screw (position 17)
located on the underside of the housing (position
58). |
| 2. |
With small flat head screwdriver push out lower
cutter ZL90 from its position. |
| 3. |
Install and position new lower cutter ZL90 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 52) and
2 hexagon socket cap screws (position 51). |
| 4. |
Remove lock housing cover ZL (position 34).
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| 5. |
Remove open link ZL (position 50) and link pin
(position 48). |
| 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 58). |
To Replace The Compression Spring (Position 68)
and Ball (Position 67)
| 1. |
Remove housing cover ZL (position 66), by removing
4 hexagon socket shoulder screws (position 64). |
| 2. |
Remove spring holder ZL (position 69) by removing
3 cheese head machine screws (position 17A) 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
78) 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
ZL90
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. |
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ZL90
PARTS LIST
|
Position
|
Part Number
|
Part Name
|
Parts per Tool
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| 1,1A |
ZR-0001 |
Woodruff Key |
2
|
| 2 |
ZR-0313 |
Feedwheel Shaft 1 1/4" (32
mm) |
1
|
| 3 |
ZR-0003 |
External Retaining Ring |
1
|
| 4 |
ZR-0315 |
Strap Guide 1 1/4" (32 mm) |
1
|
| 5 |
ZR-0312 |
Feedwheel 1 1/4" (32 mm) |
1
|
| 6 |
ZR-0316 |
Roller Bearing 1 1/4" (32 mm) |
1
|
| 7 |
ZR-0300 |
Feedwheel Lever 1 1/4" (32
mm) |
1
|
| 8 |
ZR-0010 |
Washer |
1
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| 9 |
ZR-0011 |
Roller Clutch and Bearing Assembly |
1
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| 10 |
ZR-0317 |
Roller Clutch 1 1/4" (32 mm) |
1
|
| 11 |
ZR-0301 |
Tension Lever 1 1/4" (32 mm) |
1
|
| 12 |
ZR-0014 |
Handle |
1
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| 13 |
ZR-0318 |
Cheese Head Machine Screw |
4
|
| 14 |
ZR-0319
|
Long Handle |
2
|
| 15 |
ZR-0304 |
Die and Knife Block 1 1/4"
(32 mm) |
1
|
| 16 |
ZR-0016 |
Dowel Pin |
3
|
| 17, 17A |
ZR-0017 |
Cheese Head Machine Screw |
4
|
| 18 |
ZR-0320 |
Die 1 1/4" (32 mm) |
1
|
| 19 |
ZR-0321 |
Knife 1 1/4" (32 mm) (Includes
ZR-0021) |
1
|
| 20 |
ZR-0021 |
Spring Tension Pin |
1
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| 21 |
ZR-0022 |
Connection Pin |
1
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| 22 |
ZR-0311 |
Back Up Hook 1 1/4" (32 mm) |
1
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| 23 |
ZR-0024 |
Spring Tension Pin |
2
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| 24 |
ZR-0203 |
Hexagon Socket Cap Screw |
1
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| 25 |
ZR-0200 |
Lever ZL |
1
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| 26 |
ZR-0206 |
Hexagon Socket Set Screw |
1
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| 27 |
ZR-0208 |
Nut |
1
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| 28 |
ZR-0207 |
Eccentric Shaft ZL |
1
|
| 29 |
ZR-0213 |
Woodruff Key |
1
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| 30 |
ZR-0214 |
Bronze Bushing |
1
|
| 31 |
ZR-0402 |
Punch ZL 1 1/4" (32 mm) |
1
|
| 32 |
ZR-0400 |
Lock Housing ZL 1 1/4" (32
mm) |
1
|
| 33 |
ZR-0215 |
Bronze Bushing |
1
|
| 34 |
ZR-0401 |
Lock Housing Cover ZL 1 1/4"
(32 mm) |
1
|
| 35 |
ZR-0033 |
Cheese Head Machine Screw |
2
|
| 36 |
ZR-0322 |
Punch 1 1/4" (32 mm) |
1
|
| 37 |
ZR-0310 |
Gripper 1 1/4" (32 mm) |
1
|
| 38, 38A |
ZR-0032 |
Spring Tension Pin |
2
|
| 39 |
ZR-0034 |
Spring Tension Pin |
2
|
| 40 |
ZR-0037 |
Strap Stop Front 3/4" , 1 1/4"
(19 mm, 32 mm) |
1
|
| 41 |
ZR-0038 |
Hexagon Socket Set Screw |
1
|
| 42, 42A |
ZR-0039 |
Nut |
2
|
| 43 |
ZR-0040 |
Extension Spring |
1
|
| 44 |
ZR-0041 |
Hexagon Socket Cap Screw |
1
|
| 45 |
ZR-0306 |
Cam 1 1/4" (32 mm) |
1
|
| 46 |
ZR-0045 |
Die Block Back Up |
1
|
| 47 |
ZR-0046 |
Spring Tension Pin |
1
|
| 48 |
ZR-0216 |
Link Pin |
2
|
| 49 |
ZR-0210 |
Closed Link ZL |
1
|
| 50 |
ZR-0211 |
Open Link ZL |
1
|
| 51 |
ZR-0220 |
Hexagon Socket Cap Screw |
2
|
| 52 |
ZR-0221 |
Hexagon Socket Cap Screw |
4
|
| 53 |
ZR-0323 |
Shaft |
1
|
| 54 |
ZR-0324 |
Pin |
1
|
| 55 |
ZR-0403 |
Lower Cutter 1 1/4"
(32 mm) |
1
|
| 56 |
ZR-0314 |
Strap Stop Rear 1 1/4" (32
mm) |
1
|
| 57 |
ZR-0052 |
Nut |
1
|
| 58 |
ZR-0302 |
Housing 1 1/4" (32 mm) |
1 |
| 59 |
ZR-0054 |
Hexagon Socket Set Screw |
1 |
| 60 |
ZR-0325 |
Roller Bearing 1 1/4" (32 mm) |
1 |
| 61 |
ZR-0056 |
Hexagon Socket Cap Screw |
1 |
| 62 |
ZR-0057 |
Sealing Lever |
1 |
| 63 |
ZR-0334 |
Hexagon Socket Cap Screw |
2 |
| 64 |
ZR-0058 |
Hexagon Socket Shoulder Screw |
4 |
| 65 |
ZR-0326 |
Roller Bearing 1 1/4" (32 mm) |
1 |
| 66 |
ZR-0305 |
Housing Cover 1 1/4" (32 mm) |
1 |
| 67 |
ZR-0043 |
Ball |
2 |
| 68 |
ZR-0327 |
Compression Spring 1 1/4" (32
mm) |
1 |
| 69 |
ZR-0307 |
Spring Holder ZL 1 1/4" (32
mm) |
1 |
| 70 |
ZR-0061 |
Cheese Head Machine Screw |
2 |
| 71 |
ZR-0308 |
Cam Lever 1 1/4" (32 mm) |
1 |
| 72 |
ZR-0309 |
Eccentric Shaft 1 1/4" (32
mm) |
1 |
| 73 |
ZR-0328 |
Roller Bearing 1 1/4" (32 mm) |
1 |
| 74 |
ZR-0044 |
Compression Spring |
1 |
| 75 |
ZR-0075 |
Spring Tension Pin |
1 |
| 76 |
ZR-0303 |
Eccentric Shaft Plunger 1 1/4"
(32 mm)
(Includes ZR-0043, ZR-0044, ZR-0064, ZR-0328) |
1 |
| 78 |
ZR-0076 |
Roller |
1 |
| 79 |
ZR-0077 |
Roller Pin |
1 |
| 80 |
ZR-0330 |
Washer |
1 |
| 81 |
ZR-0331 |
Button Head Screw |
1 |
| 82 |
ZR-0333 |
Spring Tension Pin |
1 |
| 83 |
ZR-0028 |
Dowel Pin |
1 |
| -- |
ZR-0332 |
Operation Manual and Parts List
for ZL90 Series Tools. |
1 |
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