Javelin J800 User manual

Javelin
the leading edge in converting technology for the Paper Film and Foil industries
Javelin Machinery (Australia)
A.C.N. 005 543 411 ABN 18 005 543 411
Email: [email protected]
Website: www.javelinmachinery.com.au HEAD OFFICE
PO Box 805, GLEN WAVERLEY Vic 3150 Australia
Phone: [phone]
Model: J800/900
MANUAL SINGLE KNIFE SLITTER
JULY 2016
OPERATION MANUAL
INCL. TROUBLESHOOTING
MACHINE PROBLEMS

JAVELIN MACHINERY (AUSTRALIA) J800 /J900 OPERATION MANUAL
(incl. Troubleshooting Machine Problems)
JULY 2016 Page 1
IMPORTANT NOTE
SINGLE KNIFE SLITTING
The principle on which this type of slitting is based, depends on
the knife being able to displace the roll width being slit.
Materials which are too dense or have been wound too tightly
may be unsuitable to slit by this method.
In this case either the roll must be rewound to a lesser tension
or the material cut on a machine known as a slit/rewinder.
Knife parameters are crucial in successful Single Knife Slitting
(Refer Knife Selection Section)
As widths being slit increase so must the secondary or back
bevel on the knife in order to balance the forces and achieve a
straight cut.
Failure to pay attention to choosing a knife with the correct
bevel will result in the knife chipping or in an extreme case
shatter.
An Operation & Maintenance Manual was supplied with
machine, ensure operators have read, understood and
familiarized themselves with machine before operating
Javelin Machinery (Australia)

JAVELIN MACHINERY (AUSTRALIA) J800 /J900 OPERATION MANUAL
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OPERATOR SAFETY
PLEASE NOTE FOLLOWING BEFORE COMMENCING OPERATION:
Safety should be a constant concern of everyone around any type of machinery.
While more than normal precautions were taken in the manufacture of this
machine, everyone connected with its operation should be made fully aware of
the High Voltages, High Speed Motion and Sharp, Rotating Automatically
Actuated Cutting Tools involved.
To prevent injury, the suggestions below should be followed:
1. KEEP CLEAR of cutting blade, rotating mandrel, chuck and material when the
machine is in motion.
2. ENSURE all GUARDS in position & safety systems operational before starting
the machine..
3. DO NOT place your hands between the knife and rolls when loading or
unloading. ENSURE knife is in its furthest back position.
4. KEEP the area around the machine CLEAN and DRY proof surface or mats.
Only the operator to work within area designated by hazard tape.
5. ENSURE main isolator is switched OFF before any maintenance is carried
out.
6. USE suitable PROTECTIVE GLOVES when handling blades.
7. Ensure KNIFE IS REMOVED OR KNIFE EDGE COVERED with the flexible
plastic cover provided when servicing or cleaning and when machine not in
use.
8. Request ASSISTANCE when CHANGING knives or LOADING heavy
material onto the mandrel.
9. Ensure operators & maintenance personnel have read and understood
the Manual before operating or carrying out maintenance on this
machine.
Ensure only qualified electricians work on the electrical components of the
machine. Operators must not open the electrical cabinet, motor drive
cabinet or operator panel. In the case of an electrical malfunction qualified
electrical personnel/contractor should be called.

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SET UP MACHINE IN PREPARATION FOR SLITTING
1. Connect machine to a power point.
2. Fill up lubricator bowl with light hydraulic oil (ATF).
3. Connect compressed air line to machine.
4. Fit mandrel and lock it in position and raise LH mandrel support.
5. Select appropriate knife (refer to the operator reference sheets or knife
selection guide (Section 8.1)) and fit on to spindle taking note of the
following:
•Clean the locating surfaces of knife spindle, backing plate, knife, and
washer.
•Slide backing plate, knife and washer onto the spindle.
•Do up the nut until finger tight and then tighten spindle nut (LH thread) with
the two spanners supplied (do not overtighten).
•NOTE: The knife is engraved and must be positioned on the spindle with
“TOP” uppermost and the two lines pointing to the mandrel.
6. Set knife forward stroke
•Bring knife edge gently against mandrel.
•Adjust knife forward stop (black knob behind knife pedestal ) (see Fig 2.7)
until knife is about 3mm (1/8”) off mandrel.
7. Set knife grinder back to ensure it will not touch the knife during test running
(Turn clockwise black thumb screw fully in).
8. The machine is now ready for test run.
9. Test lubricant system. Fill water bottle and add a mild detergent such as a
“car wash” detergent. Dilute 1:50.
NOTE : 1) Setting the knife too far forward will prematurely damage the mandrel
sleeve.
2) Setting the knife too far back will prevent it cutting through the core.
Knife Brake
Knife Forward Stop
–
Adjustable mechanical
stop to prevent knife
contacting steel
mandrel
Fig. 2.
7
Knife Forward Stop

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KNIFE SELECTION
~ always use cut resistant gloves when handling knives ~
KNIFE BEVELS When slitting narrow widths only a primary bevel is required
but with wider widths a back bevel is needed to balance the forces on either
side of the knife so that it will cut straight through the roll without deflecting
(See note re bevels below)
CAUTION: Knife may be damaged or shatter if insufficient back bevel on knife
when slitting wide widths. Trying to slit a roll to a wide width from a tightly wound
log roll, using a knife with insufficient back bevel, risks chipping or shattering the knife.
Diagram No.
Slitting range
Knife requirements
1
Up to 22 mm (7/8”)
No Back Bevel
2
25.4 mm (1”)
-
38 mm (1½”)
0.5 mm (1/64”) Back Bevel
3
40 mm (1 5/8”)
-
96mm (4”)
1.5 mm (1/16”) Back Bevel
4
Over 100mm (4”)
Equal Bevel both sides of knife
5
Any width (very hard materials)
Tightly wound denser rolls will require
test slitting to determine
the best knife bevel & edge for product Additional angle on
primary bevel
Dense materials that will not displace
Must be rewound to a lesser tension
THE ABOVE DIMENSIONS ARE A GUIDE ONLY AND WILL VARY ACCORDING TO THE DENSITY OF THE MATERIAL TO BE
SLIT.
Diagram 1:
Knife with no
back bevel
Diagram 2:
Knife with 0.5mm
(1/64”)back bevel
Diagram 3:
Knife with 1.5mm
(1/16”)back bevel
Diagram 4:
Knife with equal
bevel both sides
Diagram 5:
Knife with reinforced
edge (No. 2 angle)
(refer to manual for
details)
NOTE: A rounded edge is preferred for most adhesive tapes. Some exceptions
would be, for example, foam sealant & paper tapes which require a sharp
edge. Too sharp an edge can result in edge breaking down (chipping).
Edge should be slightly rounded with Shielded oil stone to prevent this
occurring.
KNIFE DIAMETER The rule is to use the smallest diameter knife possible to minimise any run out. Using a dial indicator, check
the knife for excessive run out.
KNIFE BEVELS .The primary bevel on each knife has a long bevel at 8º with a smaller bevel at the outer edge of the knife at
11º to strengthen knife edge. All Javelin grinders are factory set to 11º and care must be taken for this not to change. We
recommend knives be either ground on your machine or returned to Javelin in order to maintain 11º bevel. Knives sent to
contractors may result in bevel angle being changed with resultant slitting problems. To ensure knives are sharpened to the edge
we suggest running a thin mark around the outer edge with a black pental pen. This mark will disappear once the knife has been
sharpened to the edge.
NOTE:It is imperative records be kept for specific materials so the operator knows which knife to choose each time a particular
product is to be slit. Ref: Operator Reference Sheets in the Manual.
No. 1 angle
No. 2 angle
1
-
2mm (1/16”
-
3/32”)
**With interlined materials it may be necessary to glue end of log roll to prevent centre of roll moving out,
also if tightly wound a Diagram 3 bevel may be required. (Ensure log roll is pushed up against chuck face
or spacer roll)

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ROUNDING KNIFE EDGE
Operator MUST wear cut proof gloves when performing this function.
Turn off power at main isolating switch and using a Shielded Oil Stone (see Fig 3.3.1)
hold the stone flat against knife ege and slowly rotate the knife with the other gloved
hand. This will have the effect of dulling the sharp edge. Polish knife edge with Scotch
Bright™
IMPORTANT NOTE
If knife is slightly chipped you will
need to retun it to JAVELIN for
repair. The knife grinder on this
machine is not intended for heavy
Fig 3.3.1

JAVELIN MACHINERY (AUSTRALIA) J800 /J900 OPERATION MANUAL
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OPERATOR REFERENCE SHEET
J800 Knife & Machine Settings
Date: Ref:
Customer Name :
Product Description :
Manufactured By :
Brand :
End Use/s :
Log Roll : Diameter Width
Length Core size
Material thickness
Mandrel Speed:
Width To Be Cut :
Density Of Material :
Tolerance Required :
Weight of Log Roll :
Knife : Diameter Thickness
No. of Backing Plates
Back Bevel : Size
(Note: As a general rule, prior to selecting knife required, check notes on previous page)
Knife Drive (if fitted) : On Off
Knife Braking : On Off
Knife Edge : Rounded Sharp
Sprays : Off On
Chuck Grip : Internal External
Support Plate To Prevent
1st Roll From Collapsing : Yes No

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PRINCIPLE OF OPERATION - SLITTING
The JAVELIN series J800/J900 are Manually Operated Single Knife, lathe type
slitting machines for cutting log rolls of adhesive tape, foils, films, paper and fabrics.
They will accept a log roll up to ∅305 mm (∅12”) x 1700 mm (67”) wide (machines
up to Serial No. 134 - 1600mm (63”) wide) & core diameter of ∅76.2 mm (∅3”) is
standard. Other mandrels from ∅1” diameter are available on request.
The log roll is slid onto a rubber covered metal mandrel from the left hand end of the
machine and secured internally by an expanding section of the mandrel or externally
by a 3 jaw chuck when fitted as an option.
The width of cut is set by using the Manual Width Indexer. A more precise width of
cut can be monitored by the Digital Width Counter.
When the machine is turned ON, the spindle will rotate the log roll. By pulling the
hand lever forward manually, the knife will move forward making its first cut through
to the core. Upon completion of the cut, the hand lever is pushed all the way back
until the knife clears the diameter of log ready for indexing to the right for the next
cut.
SET UP AND OPERATION PROCEDURE
1. Load log roll onto mandrel. Slide log roll up to chuck face and raise mandrel
support arm.
2. Expand the mandrel to secure log roll by turning clockwise the black knob at
the right hand end of machine. Use chuck pins as alternative to gripping
material.
3. Traverse knife carriage to the left hand end of log roll to where the first cut is
to be made.
4. Set the width required by locking the index stop alongside the graduation on
the index dial.
5. Turn mandrel motor switch ON.
6. Turn knife drive on if required. ( Some material such as Hot Stamp Foil
require that the knife be braked so that it rotates only when cutting through
the cardboard or plastic core ).
7. Turn spray ON if cutting adhesive tape to lubricate knife.
8. Pull hand lever gently to make the first cut until the knife cuts through the
core. (Index handle must be held downwards while slitting to stop carriage moving.)
9. When the first cut is completed, push the hand lever all the way back until
the digital counter is reset to zero. Move the knife to the next slitting position
by indexing the carriage.
See Section 3.14.1 HOW TO SET INDEX UNIT for detail.

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8&9 Control & Gauge for pneumatic
brake which provides tension control
on unwind
1. Emergency Stop
Electrical
Cabinet
housing Allan
Bradley
Variable Speed
Drive
Only on Fully
Optioned
Machines
Main Electrical
Cabinet &
Operator Control
Panel
6. Speed Controller for
chuck mandrel
Digital Electronic
Length Counter
4. Chuck ON/OFF
Button 5. Knife ON/OFF
Button
Located at r
ear of machine
on older models
Control Panel.
(NOTE:) Control Panel Configuration may vary from machine to
machine depending on options.
The panel shown is for a Fully Optioned machine

JAVELIN MACHINERY (AUSTRALIA) J800 /J900 OPERATION MANUAL
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PRINCIPLE OF OPERATION - REWINDING/LOGGING (Optional)
The unwind stand (if fitted) is an additional facility which enables the J800/J900 to
rewind materials to desired length and core diameter ready for slitting. It is fitted with
a variable friction pneumatic brake to control tightness/density and a mechanical
counter to measure desired length of finished material.
The jumbo or master roll is loaded on the unwind shaft and is threaded over its idler
roller and under the spreader bar & inspection roller (if fitted). The leader is taped on
a core on the expanding mandrel ready for rewinding.
The spreader bar on the unwind stand should be adjusted so that it contacts the full
width of the tape evenly to prevent wrinkles occurring. The spreader bar mounted on
the machine bed is generally only used when logging single ply material.
Stamping Foils

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SETTING UP & OPERATION - UNWIND STAND (if fitted)
Load a jumbo roll onto the unwind shaft. Keep the right end of material about
170mm(7”) from disc brake and tighten RH core lock. A grub screw and hexagonal
key are all supplied with the machine. Push LH core lock into core ( use rubber
mallet if necessary ) then tighten in same manner as LH core lock. Load unwind
shaft on roller guides making sure that disc brake is between the pneumatic brake
pads. Lock unwind shaft with toggle clamp on both ends and replace lock pin (on a
chain).
Material threading diagram ref. to Fig 4.2 &Fig. 4.3 then tape leader on to the core
on the mandrel. Ensure material is square to mandrel when taped.
Reset counter then set chuck speed knob to zero.
Switch on chuck. Gently increase chuck speed. Adjust pressure on disc brake as
required.

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INDEXING
Indexing is achieved by traversing the knife to a preset width. The knife pedestal traverses
by rack and pinion and is also fitted with linear bearings for smooth movement.
There are two indexing methods installed - an indexing dial and an electronic counter that
provides a digital display for the width of cut.
HOW TO SET INDEXING DIAL (Imperial or Metric)
* Set the width required to be slit by locking the index stop alongside the width indicated
on the dial. (See Fig 3.13)
* The indexing handle is rotated in an anti-clockwise direction to the adjustable index
stop and then back to the fixed stop. As an example, if the adjustable index stop is
set to 38mm or 1½”, this width can be achieved continuously by rotating the index
handle between the two stops.
* If a greater width is required the index handle can be lifted and traversed rapidly.
For a precise width of cut, stop the index handle just before the required width and
turn knurled handle at centre of index plate firmly but slowly until desired dimension
is met. Check the width on the tape measure or digital counter (if fitted).
NOTE: Knurled knob on the aluminium/nylon slide must be released before attempting to move the
carriage left or to move the slide.
Dial Indexer
Fixed Stop
The adjustable stop is moved to width required. Operator then rotates handle to fixed stop and
back again to advance the knife required distance. The adjustable stop can be set at any point
between widths on the dial. For example for 10mm set stop just below 9mm and then check
against electronic counter for accuracy

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DIGITAL COUNTER (WIDTH DISPLAY) (when fitted)
The Digital Counter is connected to a rotary encoder and is graduated in .2mm (.008”)
increments. It is used where:
I) greater slit width accuracy is required.
ii) to verify the width set on the index dial.
iii) can be more convenient to use instead of the indexing dial
when slitting very wide widths (ie 76mm (3”) and over)
Electronic digital counter
displays width
to be slit
NOTE: As an alternative to
the dial indexer when slitting
wide widths the operator can
advance the knife down the
machine by raising the
knurled black handle and
reading off the electronic
digital counter, move the
knife to the required position.

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KNIFE GRINDER FUNCTION
1. Ensure sufficient air pressure – 600 – 700 kpa (80 – 90 psi) (see
Section 2.6 Connection to pneumatic Supply).
2. There is no air control valve only an off/on switch.
3. Flow valves only control sideways motion of cylinder/grinder. Check
that there are no kinks in airline.
HOW TO SHARPEN THE KNIFE
1. Mark with felt marker pen the bevelled surface of blade to be sharpened.
2. The grinder does not have to grind the full width of the bevel, approximately
2mm width of bevel is ground to the cutting edge of a new knife. The knife
bevel will gradually become wider as the knife is ground.
3. Loosen the knob at the top of the slotted grinder mounting bracket.
4. Position the grinder bracket so that the grinding wheel is approximately
central across the width of knife bevel.
5. Start knife motor.
6. Switch grinder ON. Adjust grinder travel stop gradually so that grinding wheel
touches the knife evenly and continues to grind until the knife is sharpened
right to the cutting edge and mark from felt pen removed.
7. Use the dressing stick to clean the face of the grinding wheel if it becomes
dirty or clogged.
8. Use the shielded deburring stone whilst grinding to remove the burr from the
back edge of the knife.
NOTE: 1) Knife must be rotating when engaging or disengaging grinding wheel to avoid
grinding a flat spot on the bevelled surface of knife.
2) Knives must be sharpened on the machine to ensure they run true. If any major
regrinding is required, we recommend you return the knife to JAVELIN.
3) Knife motor will not start if chuck is on, the hood is up or knife brake is on.
4) Use a steel mesh glove when using the shielded deburring stone.
SIDEWAY MOTION
CONTROL ONLY.
UNRESTRICTED
AIRLINE – NO FLOW
CONTROL VALVE

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KNIFE BRAKE (when fitted)
A knife brake is fitted to the spindle (see Fig. 3.10). The
knob 2behind the knife pedestal should be tightened just
enough to slow down the knife rotation as it cuts through
the material. This will help if there is a problem with
double cutting or when slitting narrow widths.
When slitting hot stamp foils the knife spindle brake
should be tightened so that the knife is stationary until it
contacts the core. The knife must rotate when it contacts
the core, so that a new section of knife edge is exposed,
thus preventing a dull spot forming on cutting edge.
Note:
When knife brake is on (tightened), knife drive motor is
switched off by trip dog 5. Trip dog is mounted on
knurled knob 2. When sharpening knife, brake must be
off (trip dog is not to be in contact with switch 7,
otherwise knife drive motor will not turn on).
KNIFE LUBRICANT SYSTEM (when fitted)
The knife spray is used to keep heat down which results from friction between the knife and
the material being slit, and to prevent adhesive build up on knife and slit roll.
VENTURI SYSTEM:
The system is fitted using a vacuum generator. Compressed air flowing through the vacuum
generator draws water into the air stream to form a mist. The unit is located on top of the
knife guard and the mist is directed onto the knife through a hole in the guard.
As a lubricant, add approximately two tablespoons of truck wash (CT18) or car wash to the
water container. We recommend the use of a product which is salt free to minimise rust.
If problems arise see Section 6.4 for trouble shooting.

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ROTATING EXPANDING MANDREL
The expanding mandrel rotates with the chuck spindle. It is held in place in the chuck spindle
by two opposing screws 16 Fig. 7.3. It can be removed from the machine by sliding it out
after loosening the 2 lock screws which lock into dimples in the mandrel. The mandrel is
fitted with rubber sleeves to protect the knife edge from the steel mandrel. Log roll is gripped
by turning the black knob clockwise to expand the pin holders (jaws) inside the mandrel. The
knob is located at the right hand end of the machine protruding from the motor cover.
NOTE:
When rotating the black knurled knob to release the expansion jaws to remove slit
rolls it may be necessary to “tap” the knob with a rubber hammer so it will release
Note: The mandrel rotates with
chuck, therefore the
mandrel lock must be left
undone and the two cap
screws in the chuck spindle
locked up, to stop the
mandrel from sliding out the
chuck.

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TROUBLE SHOOTING – MACHINE PROBLEMS
KNIFE LUBRICANT SYSTEM (Venturi)
PROBLEM/EFFECT
REMEDIES
Spray not working.
(N.B. spray starts when
knife is brought forward)
No air supply
Valve turned off
Flow control shut
Pedestal on rear stop
Air but not water. Check ….
Water pick-up tube is pushed into bottle
Water bottle is full
Flow valve adjustment
Loose fitting or split tubes
Air pressure of flow rate too high forcing water back into bottle
Water pick-up filter blocked
NOTE: Low grade detergents cause rust & can congeal and block tubes.
Javelin has sourced a good quality lubricant which is now available
in 1 Litre containers from Javelin

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MANDRELS
FIXED MANDRELS (NON ROTATING)
PROBLEM/EFFECT
CAUSE
REMEDIES
Mandrel vibrates 25.4mm (1”) adaptor not fitted
to mandrel support.
Core I/D oversize.
Log roll out of round or bowed.
Incorrect cutting speed.
Incorrect knife fitted.
Sprays not working.
Fit nylon adaptor block
Use correct size cores.
Slow mandrel speed.
Check operator reference sheet
Check operator reference sheet
See ‘Trouble Shooting Sprays’
Slit rolls difficult to
remove from Mandrel Worn or rough fibre strip.
Poor quality cores.
Replace fibre strip.
Use plastic cores if possible.
Rolls sticking together Insufficient Lubrication.
Incorrect knife
Check sprays.
Ref. Operator Reference Sheet.
Chuck spindle
becoming warm Lack of lubrication between non rotating mandrel and
chuck spindle
Grease mandrel through chuck.
Remove mandrel and lubricate.
Knife not cutting
through core towards
centre part of log
Knife Dull or mandrel flexing or
bowed. Sharpen knife to ensure it slits through the core cleanly. A knife
with a dull edge can tend to push
the core away rather than slit
through as the mandrel flexes at its
centre point.
Check mandrel for straightness.

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EXPANDING MANDRELS
PROBLEM/EFFECT
CAUSE
REMEDIES
Mandrel vibration Worn mandrel sleeve.
Core ID oversize.
Log roll out of round.
Knife forward stop not set
correctly.
Replace sleeve.
Use correct core size.
Slow mandrel speed if possible.
Set knife close to mandrel.
Slit rolls difficult to
remove from Mandrel Worn Mandrel Sleeves
Core I/D undersized
Replace Sleeve
Purchase undersized sleeves from
Javelin
Strands protruding
from rubber mandrel
sleeve.
Knife cutting too deep. Adjust knife depth.

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MANDREL SUPPORT ARM
PROBLEM/EFFECT
CAUSE
REMEDIES
Mandrel vibrates Worn pivot bearings or shaft
on mandrel support arm. Replace bearings and housings.
Sideways movement
between mandrel
support arm and
mandrel support
bearing.
Bearing loose in bearing
housings. Loosen grub screws in bearings and tap bearing outwards in
bearing housing - lock grub screws.
Replace housings and bearings.
Knife not slitting
through core and/or
knife cutting into
mandrel at one end of
machine.
Mandrel support not aligned
parallel to knife carriage.
•
Raise mandrel support.
•Traverse carriage to extreme
right.
•Adjust forward knife stop so
that the knife just touches
mandrel.
•Traverse knife to the extreme
left and move knife forward to
mandrel.
•Loosen grub screws locking
mandrel support arm to
bearings and move arm side-
ways so that knife touches the
mandrel fractionally harder than
at other end of machine (0.1mm
or 0.004”).
•Lock grub screws and re-check.