EASTMAN FALCON IV User manual

Falcon IV End Cutter
With Lifting Mechanism
779 Washington St., Buffalo, N.Y. 14203-1396 U.S.A. • [phone] • Fax [phone] or [phone]
ManufacturersofEastmanClothCuttingandClothSpreadingMachines
Website: www.EastmanCuts.com
THE EASTMAN
FormC-1587
®
WARNING
Thismachineisequippedwithaverysharpknife. Keep
hands, arms, and hair away from the knife area at all
times.
Misuse of this machine or failure to follow all safety
instructions on this machine and in the instruction
manual may result in serious personal injuries.
Instruction Manual and Parts List
Please read completely before attempting
to operate your Falcon IV End Cutter.

2FormC-1601
Table of Contents
Safety Information.................................................... 3
General Safety Precautions..................................... 3
Installation ................................................................ 4
Falcon IV System Installation ............................... 4
End Cutter, Track & Lifter Installation .................... 4
BeltThreadingDiagram......................................... 4
Operation .................................................................. 5
Familiarization ......................................................... 5
Falcon IV System................................................. 5
Maintenance ............................................................. 5
KnifeMotor ........................................................... 5
AirRegulator(System Lift Pressure)..................... 5
KnifeSharpening .................................................. 5
KnifeReplacement................................................ 5
ShearPlate Replacement ..................................... 5
ShearPlateAdjustment ........................................ 6
SharpenerReplacement ....................................... 6
MotorBrush Replacement .................................... 6
MicroSwitchReplacement ................................... 6
FuseReplacement................................................ 6
Lubricationof Knife Gear....................................... 6
Service ................................................................. 6
OrderingReplacement Parts................................. 6
Push/PullOption 820C1-83 ......................................... 7
WiringDiagram ........................................................... 7
Falcon IV End CutterAssembly .................................. 8
Track & LifterAssembly ............................................ 10
ClothAlignment Bar & LifterAssembly ...................... 12
AirLiftAssembly840C1-18 ....................................... 14
AirLift Operation................................................. 14
ElectricalConnections .............................................. 16
Limited Warranty. Eastman warrants to the buyer that the equipment shall be free from defects in materials or workmanship
for a period of 180 days commencing on the date of invoice. Any goods or parts claimed by the buyer to be defective must be
returned to Eastman, freight charges prepaid, within the 180 day warranty period. If Eastman determines that the goods or parts
aredefectivein materials orworkmanship,Eastman’ssole obligationunderthiswarranty shallbe,atEastman’s soleoption,torepair
or replace the defective goods or parts or to provide the buyer a credit equal to the portion of the purchase price allocable to the
defective goods or parts. This warranty shall not apply if defects are caused by product misuse or neglect, if the machine has
beenalteredormodifiedbythebuyer,orifotherthangenuineEastmanbelts, emery wheels, knives orparts areused inthemachine.
THISWARRANTYISTHEONLYWARRANTYAPPLICABLETOTHISPURCHASE. SELLERDISCLAIMSALLOTHERWARRANTIES,
EXPRESSORIMPLIED,INCLUDING,BUTNOTLIMITEDTO,THEIMPLIEDWARRANTIESOFMERCHANTABILITYANDFITNESSFOR
APARTICULARPURPOSE.
Limitation of Liability. Eastman’s liability to the buyer, and the buyer’s remedies from Eastman, whether in contract, negligence,
tort, under any warranty or otherwise, shall be limited to the remedies provided in the foregoing Limited Warranty. In no event shall
Eastman have any responsibilityor liability to the buyer for (a) anyspecial, indirect, incidental, or consequential damages, including,
but not limited to, loss of use, revenue, or profit, even if Eastman has been advised of the possibility of such damages, or (b) any
claim against the buyer by any third party. The price stated for the product sold is a consideration for limiting Eastman’s liability.

3
FormC-1601
Throughoutthis manual, safety information is presented by
useofthetermsWarning,Caution, andNote. Theseterms
havethe followingmeanings:
WARNING
Awarning containscriticalinformationregarding poten-
tial safety hazards that can occur during proper use or
misuse of the machine. Failure to follow these proce-
dures may result in serious personal injury to the user.
CAUTION
A caution contains instructions for the use or mainte-
nance of the machine. Failure to follow these proce-
dures may result in damage to the machine.
Safety and Indemnification
Duringthelifeofthemachine,thepurchaseragreestopro-
videtoallmachineusers (including its own employees and
independentcontractors) all relevant safety information, in-
cluding warning labels and instruction manuals. The pur-
chaseralsoagreestomaintainthesafetyfeatures andwork-
ing condition of the machine, and to adequately train all
usersin thesafeuseand maintenance ofthemachine. The
purchaser agrees to defend, protect, indemnify, and hold
EastmanMachineCompanyharmlessfromandagainstall
claims, losses, expenses, damages, and liabilities to the
extent that they have been caused by the purchaser’s fail-
ureto complywiththeterms andinstructionsofthis manual.
SafetyInformation
• Thepurchaser must provide appropriate safety mea-
suresandequipmentasrecommendedinthismanual.
Observeallstatutoryrequirementsconcerningtheuse
of hazardous machinery that apply to your location.
• Donotmodifythis machineordisable safetyfeatures.
Unauthorizedmodificationmayresultin serious per-
sonal injuries to the user. Electrical connections to
thismachinemustbe made by a qualified electrician
familiar with applicable codes and regulations. To
prevent electrocution, a ground lead must be con-
nected to terminal “E” on the attachment plug.
• This machine may be equipped with a remote start
interface. Misuse of this machine or use of this ma-
chine as part of another machine may result in seri-
ous personal injuries to the user.
• Safety labels must be kept clean and legible at all
times. Call the Eastman Machine factory to order
replacementlabels.
WARNING
• Thismachine is equipped with a very sharp and dan-
gerousknife. Keep hands, arms, and hair away from
the knife area at all times. When the machine is not
in use, keep the knife guard lowered at all times.
Safetyglasses and appropriate clothing may prevent
seriouspersonal injuries.
• Disconnect the power and air supply from the ma-
chine when it is not in use or during routine mainte-
nance,includinglubrication.
• Thepurchasermust instructalloperatorsintheproper
use of the machine according to the instructions on
the machine and in this manual. This training must
includeinstructiononthepotentialsafety hazardsaris-
ingfrom theuseormisuse ofthemachine.In addition
tosuch training, the purchasershouldprovidewritten
workinstructions as necessary to ensure correct use
of the machine for specific cutting applications.
General Safety Precautions

4FormC-1601
Installation
Beforeoperatingmachine,readtheseinstructionscarefully.
Familiarizeyourselfwithallfunctionsandadjustmentsofthis
equipment.
TheFalconIVisshippedpartiallydisassembledwithallthe
necessarypartsforpropersetup and operation. To get the
bestperformance,familiarizeyourselfwithallthefunctions
andadjustmentsofthisequipment.Beforeanyoperationcan
takeplace, it is important that you carefully read and follow
the instructions in this manual in the same sequence in
whichtheyarepresented.
Falcon IV System Installation
TheFalcon IV weighs approx. 130 lbs,(59 Kg.) uncrated
for a 72" machine. Open shipping crate and inspect all
parts as shown.
Thepartsincludedare:
(1) Part andInstructionManual.
(1)FalconCutter.
(1) Track Assembly.
(1) RearLifterAssembly(Optional)
(1) FrontLifterAssembly(Optional)
(1) Attachment Plug.
(*)OptionalAccessories.
Warning
This machine is equipped with a sharp knife. Keep hands
away from knife area at all times. Use handle and control
leverwhenoperatingorhandling the machine. Knife guard
should be raised only enough to clear the material being
cut. When not in use, knife guard should be set at the low-
est position..
DONOTOPERATETHISMACHINE WITHKNIFEGUARD
REMOVED.
Caution
Read instructions carefully before starting motor. Be sure
that voltage is the same as stamped on nameplate.
End Cutter, Track & Lifter Installation
RemoveyourFalconEnd Cutterfrom theshippingpackage.
Locate and loosen the lift belt clamping screws (A). Mount
the front lift assembly (B) and back lift assembly (C) to the
cuttingtable.Pulltheliftbelt(D)tightandsecuretheclamping
screws(A).Placethetrackinplaceandsecuretothelifting
mechanism. The track should be mounted squarely to the
table.
Loosenthetracklatchscrews(E)andswinglatchup.Slide
theswitchcamin the track as shown. Slide theFalcon End
Cutter in the track. Swing down the latch and secure in
place. Connect electric power line. The Falcon End Cutter
isreadyforoperation. Belt Threading Diagram

5
FormC-1601
Operation
Loadthe roll of material on a roll rack. Pull the material over
the falcon track and to the desired length. Pull the Falcon
Cutter across to cut the material and return to the home
position. Lift the track using the lift handle. The cut end of
the material will lay under the track. The track will hold the
material in position. The next ply can now be spread.
Familiarization
Falcon IV System
1. Rear LiftAssembly: Liftsthe non-operatorsideof the
track assembly. The lift Belt is adjusted on this side.
2. TrackAssembly:Usedtoguidethecuttingheadacross
the table to provide a straight cut through the material.
3. Falcon Cutting Head: Cuts material when moving
across the track. The quick change feature reduces
down time during maintenance. Optional cutting head
stylesavailable(consultfactory).
4. Electrical Terminal Block: Electrical connection is
madehere.Checkforpropervoltagebeforeconnecting
theattachment plug.
5. FrontLiftAssembly:Liftstheoperatorsideofthetrack
assembly. Lift handle to raise track.
6. Filter Regulator: Air supply connection is made here.
AdjustPressureasrequired.Autodrainfeatureremoves
moisturefrom incoming air supply. (Air LifterOnly)
Maintenance
CAUTION
Beforeperforminganyofthefollowingprocedures,make
surethattheattachmentplugisdisconnectedfromthis
system.
KnifeMotor
WARNING
Thismachineisequippedwithasharpknife.Keephands
awayfromknifeareaatalltimes.DONOThandlecutting
machine at any time unless terminal block is discon-
nectedfrompowersupply.Knifeguardshouldberaised
only enough to clear the material being cut. When
machine is not in use, knife guard should be set at its
lowest position. DO NOT OPERATE THIS MACHINE
WITHSAFETYGUARDSREMOVED.
AirRegulator (System Lift Pressure)
To adjust pressure, pull the “Adjust” knob up and turn
clockwise to increase pressure and counterclockwise to
decrease pressure. After adjustment is made, push knob
down to lock in place.
Knife Sharpening
TurnPowerswitchtoON(useCAUTIONwhensharpening
blade).TheFalconCutter remainsinits homepositionand
the blade turns. To obtain a fine, keen edge on the blade,
Simultaneouslypressandholdsharpenbuttonwhilepress-
inglightly against sharpener button which is locatedonthe
side of the Falcon Cutter. Press and hold button with
constantpressurefor 10 seconds, then release.
WARNING
Beforeperforminganyofthefollowingprocedures,make
surethattheattachment plugis disconnectedfromthe
system.
Knife Replacement
Lay machine on its side, knife slide up. Place a small drift
or screwdriver through the hole to keep from rotating, and
removeknife bolt. Removeknifeguardand liftouttheknife.
Warning:
Thisknifeissharp. Useproperprecautionsagainstcutting
handswhilehandling. Discardused knifewith care!
Insertnewknifeblade,bevelsidein,byslidingitundershear
plate“N”.Makesureslotsinknifealignwithtabsonknifehub
and that knife is seated flush on hub. Replace all parts in
reverse order and check that all fasteners are tightened
securelybeforeresumingoperation.
NOTE: Itisnotnecessarytoremovecuttingmachinefrom
track or shear plate from machine when replacing
knife.
Shear Plate Replacement
Removeknifeblade(seeknifereplacement). Removescrews
“M”andshearplate“N”. Replacewithnewshearplateand
reassemblein reverse order.Adjust shearplate andcheck
tightnessof “M” before resuming operation.

6FormC-1601
Shear Plate Adjustment
Afterreplacingshearplate,adjustangleofspringsocarbide
contactsknife edgeata 3degreeangle.Refer todiagrams
forexplanationofproperangle.
Top
View Front
View
MicroSwitchReplacement
Remove cover plate and cover insulation. Remove (2) two
switch screws and lift out microswitch being careful not to
loseswitch spacers. Remove leadsandre-solder the leads
ofthe new switch. Replace partsin reverseorder.
CAUTION
Excessivesolderingheat will damage switch.
FuseReplacement
With cover plate and cover insulation removed, fuse is vis-
ible. Liftburned out fuse out offuseholderand replace with
identicalfuse. Replacecover plate and insulation.
CAUTION
Replace only with identically rated fuse. Use of different
fusemaycauseelectricalhazardordamageelectronicparts.
Lubrication of Knife Gear
Knifegear“Z”shouldberemovedandreplacedifnecessary
orrepackedwithgreaseeverythreemonths.
Removeknifeasdescribedabove,toexposebearingretainer
plate79C12-286.Inserta#10-32x11/2"screwintocenter
ofknifeflange“X”sothatgear,bearingandknifeflangecan
beremovedasoneunit.Removethree(3)screws“W”andlift
outgearassembly.Inspectandreplacegear“Z”ifnecessary
or repack gear teeth ONLY with grease. Reassemble in
reverseordermakingsurethatbearing“Y”isseatedsquarely
beforesecuringknifeflange“X”andretainerplate.
IMPORTANT: Use of too much grease when repacking
knifegear“Z”mayresultinunduestrainon
knifemotor.
Service
Daily:
-Cleanworkarea.
-Clean track assembly.
-Cleanand lubricate guide tubeswith lightmachine oil.
-Checkbladeandsharpeningstoneforwear.
Weekly:
-Checkforanyunusualwearanddeterminewhy.
-Check entire machine for loose nuts and bolts.
Ordering Replacement Parts
Your Eastman Falcon lV has been carefully designed to
provide many hours of trouble free operation. The
comprehensiveexplodedpartillustrationshavebeencarefully
preparedtoenableyoutoeasilyorderreplacementparts,as
required.Replacementpartsforthismachinemaybeordered
throughyournearestEastmanrepresentativeordirectlyfrom
the Eastman factory.
Sharpener Replacement
To replace sharpener stone, first remove knife blade (see
knife replacement). Insert screwdriver into slotted head of
sharpenerbutton"P"andholdhexbushing“Q”inplace. Turn
counterclockwiseandremovesharpenerbuttonandspring
“S”. Set these parts aside for later reassembly. Remove
screw “T” to separate hex bushing, spring washer “U” and
emerywheel“V”. Replaceemerywheelandreassemblein
reverseorder.Check that screw “P” is tightenedsecurely.
MotorBrushReplacement
Remove (4) four screws, cover plate and cover insulation,
being careful not to damage insulation material. Loosen
and disengage (2) two screws holding down micro switch
andliftoutswitch beingcarefulto retainthetwoswitchspac-
ers. Remove (2) two screws and carefully lift out the com-
binedassemblyofthemotorbrushcardcircuitboard. Move-
ment of the parts will be restricted by wires but have ad-
equate length to work without disconnecting. Loosen (2)
twobrush screws and remove the motorbrushpigtailsfrom
underthefasteners. Turnbrushcardoverandslidebrushes
outofguides.
When inserting new brushes, bevel corner at wire pigtail
must face slot in brush holder. Pigtail runs through slot to
screw fastener. Wrap pigtails around screw fasteners and
tighten. Turn assembly back to its original position. With
yourfingers,separatebrushes enoughtofitaroundcommu-
tatorbarsand begin working the assembly inside cavityin-
sulation. Continue working assembly down until it is flat to
inside of standard and brushes snap into position around
commutator. Replace (2) two screws holding down circuit
board and motor brush card. Replace switch spacers and
switchand secure with(2)twoscrews. Replace cover insu-
lationandcoverandfasten with (4) four screws.

7
FormC-1601
Wiring Diagram
Blue Print No. 668C1-266
Push/Pull Option
820C1-83
Part No.
Number Req’d. Description
4C2-116 1 Locking Nut
12C1-34 1 Lock Washer
14C1-23 2 Handle Grip Plastic
15C1-29 1 Handle Adapter
20C13-95 2 Screw, #6-32 x .250 Type F Self Tap
73C7-135 2 Tube Handle (Specify Length)
300C15-3 2 Screw #10-32 x .375 Lg. Round Hd.
309C12-2 4 Setscrew, #8-32 x .312 Lg.
531C2-3 1 Switch & Handle Adaptor
580C1-48 1 Tongue Switch
783C1-4 1 Ground Wire Ass'y-Handle Switch
827C1-18 1 Mounting Bracket

8FormC-1601
Falcon IV
NOTE:
Please specify model and serial number of
machine when ordering parts.
Item numbers are for reference only.
Please specify PART NUMBERS when ordering
replacement parts.
End Cutter Assembly
Part No.
Number Req’d. Description
1C13-26 1 Cord Sleeve
4C1-198 2 Hex Nut #4-40
4C1-197 2 Allen Nut #10-32
4C2-116 1 Locking Nut
4C2-82 2 Locking Nut, #6-32
8C13-81 1 Cavity Insulation
8C15-4 1 Cover Insulation
10C1-47 1 Motor Fan
12C1-34 1 Lock Washer
12C1-49 2 Lock Washer
12C15-57 1 Spring Washer
12C15-95 1 Flat Washer #6
12C15-106 1 Spring Washer
14C1-23 1 Handle Grip Plastic
15C13-64 1 Stud, Counter Weight
17C15-133 2 RollPin
18C6-74 1 Tolerance Ring
20C3-31 2 Tie Rod Screw
20C5-21 1 Clamp Screw
20C13-95 1 Screw, #6-32 x .250 Type F Self Tap
20C13-103 2 U-Lock Screw
20C12-160 1 Sharpener Screw Button Hd.
20C13-56 1 Set Screw #6-32 x 6
21C5-5 1 Sharpener Bushing (Hex)
21C6-4 1 Sharpener Bushing
25C4-180 1 Knife Guard
34C10-158 1 Sharpener Spring
34C10-172 2 Brush Spring
50C7-27 1 CordClamp
53C2-113 1 CoverPlate
53C11-107 1 Knife Flange Cover
53C11-136 1 Cover, Counterweight
55C4-113 2 Switch Spacer
61C2 1 MotorShell
73C7-146-L 1 Tube Handle (Specify Length)
79C1-120 1 Falcon Nameplate Label, 110v
79C1-121 1 Falcon Nameplate Label, 220v
79C2-61 1 Decal, Guard Caution
79C2-62 1 Decal, Sharp Blade Caution
79C12-286 1 BearingRetainingPlate
79C12-317 1 Lint Deflector
80C1-141 1 Knife 4” Round
83C4-26 1 Knife Flange
87C7-40 1 Knife Gear
87C7-45 1 Worm-4 Lead
90C1-165 1 Bearing Housing
90C4-81 4 Needle Bearing
90C6-48 1 Ball Bearing Front
90C6-50 1 Ball Bearing Rear
90C6-53 1 Ball Bearing Knife Flange
98C4-32 1 On-Off Switch Clip
115C1-15 4 Wear Disc, Bearing Skate
136C1-26 1 Counterweight
Part No.
Number Req’d. Description
190C1-5 1 Armature, 110v
190C1-6 1 Armature, 220v
262C1-15 1 Fuse, 1-1/2 amp. (220v)
262C1-16 1 Fuse, 3 amp (110v)
300C8-2 2 Screw #4-40x .500 Lg. Round Hd.
300C15-3 2 Screw #10-32 x .375 Lg. Round Hd.
301C5-1 2 Screw #3-48 x .750 Lg. Fillister Hd.
301C8-2 2 Screw #4-40 x .875 Fillister Hd.
301C10-9 1 Screw #6-32 x .188 Lg. Fillister Hd.
302C8-1 3 Screw #4-40 x .375 Lg. Flat Hd.
302C15-10 2 Screw #10-32 x 1.375 Flat Hd.
302C15-19 2 Screw #10-32 x 1.000 Lg. Soc Flat Hd.
305C8-1 8 Screw #4-40 x .250 Lg. Blinding Hd.
305C8-4 3 Screw #4-40 x .125 Lg. Blinding Hd.
309C10-3 1 Setscrew #6-32 x .500 Lg.
309C12-2 2 Setscrew #8-32 x .312 Lg.
505C2-104 1 Base Plate Assembly, Bearing Skate
528C4-11 1 Standard With Cover Assembly
531C1-78-L 1 Operator Handle Assembly, Aluminum
531C2-3 1 Switch & Handle Adaptor
541C1-17 1 Emery Wheel, 180 Grit
541C1-23 1 Emery Wheel, 220 Grit
542C1-109 1 Armature Assembly, 110v
542C1-110 1 Armature Assembly, 220v
580C1-48 1 Tongue Switch
580C1-107 1 Track Switch
708C1-16 2 Motor Brush
726C1-28 1 Shear Plate Assembly
783C1-3 1 Ground Wire Ass'y., Green/Yellow
783C1-4 1 Ground Wire Ass'y-Handle Switch
820C3-107 1 Falcon Motor, 110v
820C3-108 1 Falcon Motor, 220v
827C1-13 1 Handle Bracket Assembly
829C1-3 1 Magnetic Ring Assembly
830C1-6 1 Circuit Board
830C1-7 1 Brush Card Assembly
A/R - As Required
* - Not included in this Assembly
L =Length

9
FormC-1601

10 FormC-1601
Track & Lifter Assembly
ITEM PART NO. DESCRIPTION QTY. ITEM PART NO. DESCRIPTION QTY.
1 302C18-2 Screw, Flat Head 1/4-20 X 1/2 2
2 79C12-296 Slider Plate, Bias Track "only" 1
3 171C1-25 Lift Locking Bracket 1
4 308C15-2 Screw, Socket Hd. #10-32 X 1/2 2
5-
6 760C1-3 Switch Bracket, Electric "only" 1
7 64C1-12 Switch Cam, Electric "only" 1
8 300C15-3 Screw, Round Head #10-32 x 3/8 1
9 17C15-134 Roll Pin 2
10 119C4-42 Support Plate 1
11 46C3-20 Clamp Block 1
12 302C15-3 Screw, Flat Head #10-32 x 1/2 2
13 823C1-12-TS Falcon Track Assembly 1
823C1-33-TS Falcon Track Assembly, 96" & larger 1
823C2-1-TS Falcon Track Assembly, Bias "only" 1
14 20C12-156 Latch Screw 4
15 97C3-38 Track Latch 2
15A 67C6-1 Latch Mount, 96" & larger 2
16 300C18-4 Screw, Round Head 1/4-20 x 5/8 4
17 193C1-14-TS Falcon Track, Solid 1
193C1-19-TS Hollow Falcon Track, 96" & larger 1
193C1-25-TS Bias Falcon Track 1
18 C9-27 Q Track Wear Strip A/R
19 211C1-2 Foam Tape A/R
20 840C1-1 Lifter Assembly 1
840C2-1 Bias Lifter Assembly 1
21 4C2-58 Nut, Hex 1/4-20 4
22 18C6-47 Grip Ring 6
23 763C1-27 Lift Tube 2
24 11C2-54 Shaft, Belt Roller 3
25 12C15-108 Washer, Flat 1/4 6
26 41C5-12 Belt Roller, Front 1
26A 41C5-14 Belt Roller, Back 1
26B 41C5-15 Belt Roller, Lower 1
27 181C4 Lift Belt A/R
28 311C14-2 Screw, Shoulder, 1/4 x 1-1/4 4
28A 311C14-1 Screw, Shoulder, 1/4 x 3/4 4
29 70C4-45 Roller Guide 8
30 55C4-118 Roller Spacer 4
31 15C13-59 Stud, Lift Spring, Long 2
31A 15C13-56 Stud, Lift Spring, Short 2
32 79C12-295 Main Frame, Lift Assembly 2
33 20C13-4 Setscrew #8-32 x 3/16 2
34 191C2-1 Swivel Pad 2
35 50C11-34 Clamp Base 2
36 302C18-2 Screw, Flat Head 1/4-20 x 1/2 4
37 17C15-126 Roll Pin 1/8 x 1/2 2
38 57C7-49 Clamp Lever 2
39 20C5-22 Clamp Screw 2
40 33C10-59 Belt Holder 2
41 302C15-3 Screw, Flat Head #10-32 x 1/2 2
42 34C10-181 Spring 4
43 18C6-65 Grip Ring, Large 4
44 35C7-35 Plate, Spring Mount 2
45 300C18-4 Screw, Round Head 1/4-20 x 5/8 4
46 62C16-265 Roller Bracket 1
47 55C4-117 Spacer, Front Belt Clamp 1
48 302C15-7 Screw, Flat Head #10-32 x 1 2
49 4C2-119 Square Nut, 1/4-20 2
50 22C3-9 Lift Handle 1
51 12C15-14 Spacer, Short 8
A/R - As Required
TS - Table Size
Please specify Table Width when ordering