Portek Ultra Mk4 Service manual

1
Read and fully understand the
instructions before operating
the Portek Ultra Mk4
Operators Handbook
portek.co.uk
Hydraulic autoclamp
chainsaw sharpener
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2
READ AND UNDERSTAND THIS MANUAL
FULLY BEFORE OPERATING THE ULTRA Mk4
This user manual accompanies this chainsaw sharpener and contains important information
on setup and handling.
Before using the equipment, read the user manual carefully. This particularly applies to the
safety notes. Failure to do so may result in personal injury or damage to the equipment.
Store the user manual for further use.
This graphic accompanied by the words WARNING and DANGER
highlights an act or a condition which can lead to SERIOUS INJURY
ALWAYS WEAR EYE PROTECTION.
Residual risks
This machine is only designed for sharpening chainsaws. Before commissioning, the device
must be fixed to a workbench or another similar surface. Use the chain - saw sharpener only
if you fully understand all the functions and can perform without restrictions or have received
appropriate instructions. Respect technical data and safety precautions.
Do not use this product in any other way as stated for normal use. Not observing general
regulations in force and instructions from this manual does not make the manufacturer liable
for damages.
Please note that our equipment has not been designed for commercial, trade or industrial
use. If the equipment is used in commercial, trade or industrial operation or for similar
activities, we cannot assume any liability.
Specifications, descriptions and illustrative material in this manual are as accurate as known
at the time of publication, but are subject to change without notice. Illustrations may include
optional equipment and accessories, and may not include all standard equipment.
Before you start
!
ALWAYS WEAR SAFETY CLOTHING IN CONJUNCTION WITH HAND, EYE, HEARING
AND FOOT PROTECTION TO HSE/EN SPECIFICATIONS
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Residual risks
Even when the device is used properly and all safety regulations are complied with, there still
may be some residual risks.
Important safety information
• Noise emissions
• Dust emissions
• Vibrations to hand and arms
• Danger of burns
• Tool and workpiece heat up during operation.
• Risk of injury
• Sharp tools and workpiece edges
Symbols
!Danger! Do not touch the
grinding wheel.
Children shall not play with
the appliance.
Information of the acoustic
power level.
Dispose appliances according to the
regulation and requirement of
the local council.
Denotes risk of personal injury or
damage to the tool.
Read instruction manual before use.
Wear eye protection.
Do not use the appliance in the rain
or in wet places.
Essential Equipment for Your Protection
The Chainmaster Ultra Mk4 sharpener complies with all current safety standards. For your
safety you must wear full protection as specified below.
Eye protection
Eye protection to EN166 – B
Hand protection
Gloves to EN 12477:2001
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4Ultra Mk4
1
2
3
7
4
5
8
13
11
12
10
6
9
14
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5
1. Chain stopper
2. Chain stopper adjustment
3. Scale for setting chain vice cut angle
4. Vice grinding angle adjuster
5. Tilt angle scale - lock wheel below
6. Chain thickness adjuster
7. Chain setting wheel
8. Grinding depth adjustment
9. Top plate angle adjustment
10. Grinding wheel
11. On/Off switch
12. LED work light
13. Grinding wheel cover
14. Grinding wheel guard
Contents
CONTENTS
Before you start 2
Safety introduction 3
Ultra Mk4 main features 4 - 5
General safety information 6 - 7
Sharpener safety 8 - 9
Assembly 10
Set up and operation 11-13
Grinding wheel changing 14
Useful chain tips 15 - 16
Chain data 17
Dressing Stone 18
Chain gauge 19
Parts listing 20
Technical data and disposal 21
Troubleshooting 21
Declaration of Conformity 22
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6General Safety Information
1. Keep children and bystanders away while operating a power tool. Distractions cause a loss
of control.
2. Check for signs of wear or damage, before using the tool and after any impact, and repair as
necessary.
3. The tool is designed for use by adults. Young people over 16 years may use the tool under
supervision only.
4. The manufacturer is not liable for damage which is caused through inappropriate use or
incorrect operation.
1. Work area safety
• Keep work area clean and well lit. Cluttered or dark areas invite accidents.
• Do not operate power tools in explosive atmospheres, such as in the presence of flammable
liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes.
2. Electrical safety
• Do not expose power tools to rain or wet conditions. Water entering a power tool will
increase the risk of electric shock.
• Keep power cable away from heat, oil, sharp edges or moving parts. Damaged or entangled
cords increase the risk of electric shock.
• The use of a RCD (residual current device) with a rated residual current of 30 mA or less is
advised for additional safety when using the unit.
!
Read all safety warnings. Failure to follow the warnings may result in serious
injury or even death.
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7
General Safety Information
3. Personal Safety
• Stay alert, watch what you are doing and use common sense when operating a
power tool. Do not use a power tool while you are tired or under the influence of
drugs, alcohol or medication. A moment of inattention while operating power tools
may result in serious personal injury.
WARNING! Use protective equipment. ALWAYS wear safety glasses when
working with the machine.
• The use of protective clothing is recommended, such as protective gloves and
safety goggles/glasses. Wear a hairnet if you have long hair.
• Ensure the switch is in the off-and the power supply disconnected by removing the
plug before picking up, adjusting or carrying the tool.
• Never reach into the danger area of the machine when it is running.
• WARNING! Always allow the grinding wheel to come to a stop
4. Service
• Have your power tool serviced by a qualified repair person using only identical
replacement parts. This will ensure that the safety of the power tool is maintained.
!
!
!
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8Sharpener Unit Safety
• Do not force the power tool. Use the correct power tool for your application. The correct
power tool will do the job better and safer at the rate for which it was designed.
Do not use the power tool if the switch does not turn it on and off. Any power tool
that cannot be controlled with the switch is dangerous and must
be repaired.
• Disconnect the plug from the power source and/or the battery pack from the power tool
before making any adjustments, changing accessories, or storing power tools. Such preventive
safety measures reduce the risk of starting the power tool accidentally.
• WARNING! ALL adjustment nuts/bolts/knobs etc.. must be tightened before starting to work
with the machine.
• Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts
and any other condition that may affect the power tool’s operation. If damaged, have the
power tool repaired before use. Many accidents are caused by poorly maintained power tools.
• WARNING! Always use the protective shields on the machine.
• Do not use a damaged grinding wheel. Before each use inspect the wheel for chips and
cracks or excess wear. The grinding wheel must be properly mounted and turn freely. Perform
a test run for at least 30 seconds without load. Do not use damaged, out of round or vibrating
grinding wheels.
• Immediately switch off the machine in case of considerable vibrations or if other malfunctions
occur. Check the machine in order to find out the cause.
• The outside diameter and the thickness of your accessory must be within the capacity rating
of your power tool.
!Safety Warnings for Chainsaw Sharpener
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9
Before Each Use
Inspect the whole condition of the sharpener for good working condition.
Check the grinding disc for damage prior to installation.
Wear the proper protective equipment including compliant eye protection, compliant
dust protection.
Do not use grinding wheels that have a max RPM less than the marked RPM rating
on the tool.
Keep hands clear from grinding wheel during use.
Electric shock hazard. Do not expose to rain or use in damp locations.
Do not use for wet grinding.
Do not use grinding wheel if cracked or chipped.
Reduce the risk of unintentional starting. Make sure switch is in off position before
plugging in.
Before Each Use
!
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10 Assembly
!
Initial Assembly and Bench Mounting
!
Assembly and mounting must be performed with the
sharpener unplugged!
Always unplug the sharpener before doing any work on
it (cleaning, disc replacement, etc.)
The sharpener is delivered assembled. Carefully cut the
cable tie that is used to compress the unit in the box
The sharpener is designed to be bench mounted.
1. When installing it on a bench, place the sharpener
on the edge of the bench to the stop and bolt it to the
worktop using the holes in the base.
2. Fit the handle to the grinding wheel casing by sliding
the nut into the slot and then tightening the handle.
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11
Ultra Mk4 Adjustments
The Ultra Mk4 is infinitely adjustable to allow many types of chains to be sharpened correctly.
Before starting, the chain cutting angles need to be checked, there is a typical specifications
table on page 17:
Adjust the angle of the grinding disc head by
slackening locking knob. Top Plate Angle 60˚
shown. Can be adjusted between 90˚ and 40˚
to suit many types of chains.
Set up
TOP PLATE ANGLE
1
TILT ANGLE ADJUSTMENT
2a
TILT ANGLE LOCK
VICE ANGLE LOCK
To adjust the tilt angle: If a chain needs
angle of 10 degrees then:
Right teeth: pull the head that holds the
chain towards the end of the machine.
Left teeth: push the head that holds the
chain towards the hinge.
In each case this can be locked off with the
small knob underneath before getting the
angle correct for the vice angle.
2b
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12 Setting up to sharpen
Loosen the locknut and rotate knurled knob
to adjust the depth of the grinding wheel;
should be checked by lowering the grinding
disc when not running onto the chain.
GRINDING DEPTH ADJUSTER
4
Adjust the vice angle to suit the specfication of the
chain to be sharpened. One set of teeth can be
sharpened with the vice angle set at the correct
setting then the vice rotated to the same angle on
the other scale.
The lever on top of the vice angle adjuster is used
to adjust the chain clamp - adjust to clamp the
chain when the grinding disk is lowered - do not
overtighten.
Once the chain clamp lever is adjusted it will not
need moving unless a different width of chain is
used. The clamping of same width chains will be
done automatically by the hydraulic action each
time the grinding disc is brought down.
30˚ 30˚
CHAIN THICKNESS
VICE ANGLE
3
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13
Operating the Ultra Mk4
!WARNING: Before adjusting the unit, make sure the machine is switched ‘OFF’ at the
power supply to prevent unintended starting.
1. Clean and inspect the chain before sharpening. Look for the most worn-out cutting tooth, this
is important in order to sharpen all the other teeth to the same depth!
2. Position the chain between the clamping
plates of the guide vise. Fold down the
chain stop, pulling on the chain, slide the
chain up against the chain stop. The chain
stop prevents the chain moving and allows
fine tuning of the grinding wheel position
on the chain.
3. Check the various setup angles are set
according to the chain specification.
4. As the wheel is brought into contact with
the chain the clamp bars automatically grip
the chain.
6. Bring the grinding wheel down without the
unit running to check position and angle.
Once satisfied, after raising the grinding
wheel, switch on the Ultra MK4 and then
sharpen that tooth. Check that the tooth
has sharpened completely, adjusting the
chainstop if necessary.
7. The chain can now be moved to the next tooth in that row to sharpen.
8. The angle plate will need to be rotated to sharpen the alternate teeth on the chain and then
repeat the process. When sharpening the alternate teeth double check that the tooth length
is the same as the first row that have been sharpened. Very fine adjustment of the chainstop
may be necessary.
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14 Changing the Grinding Wheel
1. To change or fit a replacement grinding wheel,
remove the socket screw from the grinding wheel
housing.
2. Unscrew the clear plastic cover from the housing
3. Unscrew the socket screw from the centre of the
disc, making a note of the orientation of the
clamp washer.
4. Check that the new grinding wheel is free from any
chips and cracks. To check it is crack free an audible
check as well as visible check is essential. Balance
the grinding wheel on a screw driver or similar in
the central hole, then lightly tap the outer edge. A
clear “ring” should be noticeable, If a “dull” sound
is heard the the grinding wheel has a crack and
should not be used.
5. Install the new grinding disc and replace the
washer, socket screw and clear cover. Only “pinch”
the grinding wheel when tightening the socket
screw. Do not overtighten.
!WARNING: Before adjusting the unit, make sure the
machine is switched ‘OFF’ at the power supply to
prevent unintended starting.
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15
Before beginning to sharpen a chain please carefully read the following hints
• A chain consists of several cutter links,
drive links and tie straps. The cutter links
consist of the cutting tooth and the
depth gauge.
• The pitch of the chain is measured in
inches. The pitch is determined by
measuring the distance ‘A’ of the three
rivets and dividing by two. Example:
8.25 mm = .325”
• Example of a chain description: .325”/1.3
- 56. Where .325” stands for the chain
pitch, 1.3 mm stands for the width of
drive links, 56 stand for the number of
drive links.
• The top plate cutting angle is important in order to chisel out
wood fibres and lift them up and out of the kerf. For most
chains the top plate cutting angle has to be 60°.
• As the length of the tooth is reduced during sharpening so is
the cutting tip height. To ensure ultimate cutting performance,
the depth gauge has to be reduced too. The depth gauge setting
in respect to the top plate is approximately .025” = 0.64mm.
Make sure that all depth gauges are the same.
Sharpening hints
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16
• The filing angle must be equal for all cutting teeth. The angle has to be approximately
25° - 35° according to the chain type. The chain consists of left and right teeth.
• Sharpening teeth to unequal blade lengths can cause a side drift when sawing;
resulting in unwanted inclined saw cuts.
• Before you start to sharpen the chain carefully check it for damage, such as: bent or
broken drive links, broken cutter teeth, loose rivets or broken rivet heads. If any
damage is found, replace the whole chain or have the damage repaired by an
authorized service centre.
• Badly sharpened chains increase the risk of kickback.
Sharpening hints
• A sharp chain when cutting properly
will produce small chips of wood,
but when a chain becomes blunt fine
saw dust will form during the cutting
operation. You have to sharpen the chain
when you notice that excessive force is
needed to cut through the timber and
the saw does not “pull” anymore.
Left
Right
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17
Useful chain data
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18
Dressing Stone and Gauge
The Ultra Mk 4 includes a block of coarse carborundum
for dressing worn or unbalanced wheels especially where
they have become dished or rounded by continuous
use. Just hold it against the stone for a short time and
it is returned to pristine condition. The grinding wheel
gauge can be used to check the grinding wheel shape
and thickness to ensure the correct wheel is used on the
chainsaw chain.
Grinding Wheel Dressing For Setting The Depth Gauge
Fit the 1/4" (6.3 mm) thick grinding wheel, following the
instructions given on pages 14. Turn the vice so that the
reference mark is on 0°.
Turn the motor unit to take the reference mark to 80°-75°
on the top plate angle adjuster. Position the dressing brick
on the vice jaws and against the chain stop preferably.
Hold the dressing brick firmly with one hand, keeping
fingers / hands clear of the grinding wheel.
Start the grinder. Lower the motor unit with handle.
Grind the wheel against the dressing brick until you obtain
a profile like the one illustrated below to achieve the most
effective sharpening angle.
Raise the motor unit. Stop the grinder and remove the
dressing brick from the vice.
WARNING
Physical contact with the
grinding wheel while it spins at
high speed will cause burning
and abrasions.
Dressing stone
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19
Setting the chain depth setting
Put the chain in the vice jaws, with a cutter link
up against the chain stop and turn the adjuster
to position the link under the wheel. Turn the
adjustment knob to position the chain stop centrally
with the chain.
Adjust the top plate angle to 75-80˚. Also position
the vice at 0˚ on the Tilt Angle Adjuster so the chain
is directly below the grinding wheel.
Check that the grinding wheel will not hit the chain
clamp lever when the disc is lowered. If it will then
adjust the vice angle to clear.
With the grinding wheel in the correct place laterally,
adjust the grinding depth by turning knob on top of
motor housing.
This part of chain can be skimmed to ensure the
correct amount of wood is removed after sharpening
the main cutting link.
A
CB
AMeasure the gauge depth
using the suitable shape
BMeasure the cutter length CMeasure the chain pitch
Chain Gauge Measurement Tool
Chain gauge
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20 Parts List
PT NO. DESCRIPTION QTY
1 Handle 1
2 Hex Nut M6 1
3 Motor Holder 1
4 Switch 1
5 Adjusting Bolt M8 1
6 Adjusting Nut M8 1
7 Rubber Washer M8 1
8 Tension Spring 1
9 Shaft Sleeve 2
10 Shaft Stand 1
11 Base 1
12 Flat Washing 11x28x2.5 2
13 Tightening Knob 2
14 Fixed Disc 1
15 Hex Screw M5x22 2
16 Small Pressure Spring A 2
17 Flat Washer 5x1 2
18 Hex Nut M5x22 1
19 Guide Wheel A 2
20 Rubber Washer M6 1
21 Adjusting Nut M6 1
22 Adjusting Screw M6 1
23 Outer Plate 1
24 Inner Plate 1
25 Steel Ball 4 1
26 Small Pressure Spring C 1
27 Cam 1
28 Flat Washer 5x15x1 1
29 Dial Bottom 1
30 Bolt M5x10 1
31 Fixed Stand A 1
32 Small Pressure Spring D 2
33 Lock Ring 2
34 Guide Cover 1
PT NO. DESCRIPTION QTY
35 Tension Spring 1
36 Positioning Plate 1
37 Small Pressure Spring B 1
38 Bolt M6x65 1
39 Locating Rod 1
40 Hex Nut M6 3
41 Socket Head Screw M8x35 1
42 Socket Head Screw M5x10 2
43 Cylinder Cover 1
44 Cylindrical Pin 4 1
45 Hydraulic Assist 1
46 Lock Ring 2
47 Hex Bolt M10x65 1
48 Socket Head Screw M6x12 1
49 Hydraulic Base 1
50 Pivot 1
51 Starter Capacitor 1
52 LED Light 2
53 Cover 1
54 Socket Head Screw M4x8 11
55 Clamp Plate 1
56 Power Cord 1
57 Socket Head Screw M6x20 2
58 Grinding Cover 1
59 Transparent Cover 1
60 Connect Ring 1
61 Hex Bolt M6x15 1
62 Pressing Plate 1
63 Grinding Wheel 1
64 Location Plate 1
65 Motor 1
66 Spring Washer 4x1 4
67 Socket Head Screw M4x20 4
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