Signode TENSION-WELD VXL-2000-Z Instruction Manual

VXL-2000-Z and VXM-2000-Z
TENSION-WELD®
STRAPPING TOOLS

2
READ THESE INSTRUCTIONS CAREFULLY.
FAILURE TO FOLLOW THESE INSTRUCTIONS CAN RESULT IN SEVERE PERSONAL INJURY.
GENERAL SAFETY CONSIDERATIONS
1. STRAP BREAKAGE HAZARD.
Improper operation of the tool or sharp corners on the load can result in strap
breakage during tensioning, which could result in the following:
!A sudden loss of balance causing you to fall.
!Both tool and strap flying violently towards your face.
Failure to place the strap properly around the load or an unstable or shifted load could result in
a sudden loss of strap tension during tensioning. This could result in a sudden loss of
balance causing you to fall.
Read the tool's operating instructions. If the load corners are sharp use edge protectors.
Place the strap correctly around a properly positioned load.
!Positioning yourself in-line with the strap, during tensioning and sealing, can result in
severe personal injury from flying strap or tool. When tensioning or sealing, position
yourself to one side of the strap and keep all bystanders away.
!Using strap not recommended for this tensioner can result in strap breakage during
tensioning. Use the correct Signode products for your application.
2. TRAINING.
This tool must not be used by persons not properly trained in its use. Be certain that you
receive proper training from your employer. If you have any questions contact your Signode
Representative.
3. EYE INJURY HAZARD.
Failure to wear safety glasses with side shields can result in severe eye injury or
blindness. Always wear safety glasses with side shields which conform to ANSI
Standard Z87.1 or EN 166.
4. FALL HAZARD.
Maintaining improper footing and/or balance when operating the tool can cause you to fall. Do
not use the tool when you are in an awkward position.
5. CUT HAZARD.
Handling strap or sharp parts could result in cut hands or fingers. Wear protective
gloves.
6. TOOL CARE, MAINTENANCE & PARTS REPLACEMENT.
!Take good care of the tool. Inspect and clean it daily, lubricate it weekly and adjust when
necessary. Replace any worn or broken parts.
!ALWAYS disconnect the pneumatic connection to the tool when performing part removal
and replacement procedures. NEVER connect a pneumatic source to a disassembled tool
unless otherwise specified.
7. WORK AREA.
Keep work areas uncluttered and well lighted.

3
Signode tools and machines are designed and warranted to work together with Signode
strapping and seals. Use of non-Signode strap, seals and/or manufactured or specified
replacement parts may result in strap breakage or joint separation while applying strapping
to a load or during normal shipping and handling. This could result in severe personal injury.
Several types of strap can be used with this tool. Use the correct Signode products for your
application. If you need help contact your Signode Representative.
SAFETY PROCEDURES FOR TOOL OPERATION
1. Before using this tool, read its Operation and Safety instructions.
!Do not exceed the operating air pressures stated elsewhere in the manual.
!Use Signode's approved filter-regulator-lubricator unit (P-008559).
!Never operate a pneumatic tool with a bottled air or gas source.
!For tension adjustments, follow instructions in this manual. For all other adjustments,
repairs or cleaning of the tool, disconnect air supply.
!This tool is a Tension Weld® type sealer. A properly made joint
will appear as shown in the illustration. If the joint does not
appear as shown, then the operator must proceed as follows:
A. Insure that the tools operating instructions are
being followed before applying another strap.
B. Cut the strap off and apply another.
If the joint still does not appear as shown, then inspect the tool for worn and/or damaged parts.
Replace tool parts as needed. NEVER HANDLE OR SHIP ANY LOAD WITH IMPROPERLY FORMED
JOINTS. Misformed joints may not secure the load and could cause serious injury.
!Tuck strap end back into the dispenser when not in use.
CUTTING TENSIONED STRAP
Use only cutters designed for cutting strap; never use claw hammers, crowbars, chisels, axes or
similar tools. Such tools will cause the strap to fly apart with hazardous force. Before using any
Signode product, read its Operation and Safety Manual.

4
TABLE OF CONTENTS
General Safety Instructions 2
Specifications 4
Air Line Piping Installation 5
Operating Instructions 8
Adjustments 10
Parts Removal and Replacement 12
Air Logic and Diagram 20
Air Motor Identification 21
Parts List, Air Motors 22
Parts List, Tool 28
Troubleshooting 30
Maintenance 34
Tool Options 35
EU Declaration of Conformity 39
Maximum operating air pressure is 90
psig (6.2 bar).
Strap could possibly break at less than
90 psig (6.2 bar) depending on strap
size and type of package.
VXL-2000-Z VXM-2000-Z
Part No. 306540NT Part No. 306541NT
SPECIFICATIONS
MODEL
STRAP
TYPE WIDTH THICKNESS
VXL-2000-Z {302}, {304}, 306 Dymax
{502}, {504}, 506, 508 Dymax
{714}, {716}, 718 Contrax
{814}, {816}, 818 Contrax
{1716}, 1718 Tenax
{1816}, 1818, 1822 Tenax
7/16"(10.5mm)
1/2"(12.7mm)
7/16"(10.5mm)
1/2"(12.7mm)
7/16"(10.5mm)
1/2"(12.7mm)
0.017" to 0.029" (.43-.73mm)
0.015" to 0.030" (.38-.76mm)
0.019" to 0.030" (.48-.76mm)
0.017" to 0.026" (.43-.66mm)
0.021" to 0.024" (.53-.60mm)
0.017" to 0.028" (.43-.71mm)
VXM-2000-Z {304}, 306 Dymax
{504}, 506, 508 Dymax
{716}, 718 Contrax
{816}, 818 Contrax
{1716}, 1718 Tenax
{1816}, 1818, 1822 Tenax
7/16"(10.5mm)
1/2"(12.7mm)
7/16"(10.5mm)
1/2"(12.7mm)
7/16"(10.5mm)
1/2"(12.7mm)
0.023" to 0.029" (.58-.73mm)
0.020" to 0.030" (.50-.76mm)
0.025" to 0.030" (.63-.76mm)
0.022" to 0.026" (.55-.66mm)
0.021" to 0.024" (.53-.60mm)
0.017" to 0.028" (.43-.71mm)
NOTE: Strap sizes shown in brackets { } indicates strap sizes that (due to tension capabilities) may
require use of the VXL model only or the use of Tension Control Kit (Signode Part No. 422540
shown on page 33). Successful use of these strap sizes depends upon air pressure, tool condition
and package characteristics.

5
PNEUMATIC INFORMATION
AIR PRESSURE REQUIREMENTS
The VXL/VXM tools are designed to operate at air pressures ranging between 70 and 90 psig (4.8 -
6.2 Bar). Operating these tools outside this pressure range could result in strap breakage due to
over tensioning or poor quality welds.
AIR PRESSURE VS. PERFORMANCE
The air pressure supplied to the VXL/VXM tools must be a minimum of 70 psig (4.8 Bar) If the air
supply pressure can be adjusted within a range from 70 psi to 90 psi (4.8 - 6.2 Bar) the tool's
performance can be fine tuned to a particular application or operation preferences. Raising the
VXL/VXM air supply pressure to the tool will directly alter the rate at which the tool will take-up the
strap slack and the strap tension. Increasing or decreasing the VXL/VXM air supply within the
suggested 70 to 90 psig (4.8-6.2 Bar) range will not seriously affect the actual welding portion of
the strap cycle.
After an initial "Break-In" period, the air motor may become more powerful. If the tool's
performance is effected by this increase in performnace, reduce the air pressure at the regulator
as required (but not below 70 psig).
AIR SUPPLY INSTALLATION
If compressor has a good dryer unit, use black pickled pipe. When a dryer unit is not installed, use
galvanized or copper pipe. To perform reliably, a pneumatic tool requires a continuous source of
clean, water-free air at adequate pressure.
Never operate this tool using a bottled air or gas source.
Bottled air/gas sources do not provide consistant operating pressure.
A filter-regulator-lubricator unit
(Signode P/N 008559) must be
installed as close to the air tool as
possible, preferably within 10
feet. It should be placed in a
convenient location where it can
easily be drained, adjusted, and
filled with oil. The air hose
(Signode P/N 008558) must have
at least a 3/8" I.D. A quick-
connect press-on socket
(Signode P/N 008569) is installed
on the stress spring end of the
hose for convenient hookup to
the air tool.

6
PNEUMATIC INFORMATION, Continued
Filter and lubricator bowls are made of polycarbonate material. Do not install where bowls may be
exposed to materials incompatible with polycarbonate. Certain oils, solvents, and chemicals or
their fumes can weaken these bowls and possibly cause them to burst. Clean only with warm
water. A cut-off valve placed ahead of the filter will be useful when cleaning the filter or
replenishing the lubricator.
MOISTURE
Moisture is always present in air lines due to condensation within the lines as the air cools. Steps
must be taken to remove this moisture and to keep it from the air tool. This is because water tends
to wash away lubricants and cause corrosion, sticking and failure of internal parts.
The main line should be pitched so the far end terminates in a water leg. Branch lines are taken
from the top of the main, never off the bottom. Every branch should have a water leg at its lowest
point, with a drain cock which is drained daily.
If these precautions are taken and water is still present, an after cooler and a moisture separator
are required between the compressor and the air receiver tank. A large air line separator can be
installed in the air tool line, but precautions must be taken to insure that it will be drained daily,
before the air tool is operated.
Water in air lines is a constant threat to the proper operation of air tools. Even near freezing
operating conditions, a good refrigerant type dryer is essential. A good dryer will remove 95% or
more of water right at the compressor. The remaining moisture is removed at the water leg in the
piping system or in the filter (Signode Part No. 008559).
NOTE: Additional information is available in the Signode publication, "Air Supply Manual" (E-
186038). If you have any questions, contact your local Signode Representative.
LUBRICATION
The air motor must be properly lubricated. This is achieved by keeping the air line lubricator filled
with oil and correctly adjusted. Without proper lubrication, the motor will become sticky and the
tool will give low and erratic tension and be difficult to release from the strap.
Install the lubricator as close to the air tool as possible. The arrow on the lubricator's top surface
must point in the direction of air flow. For proper operation, oil must drop through the lubricator
sight glass at a rate of 1 to 4 drops per minute. This rate is checked while the air tool is running
free. Only 20% of this oil is actually delivered to the tool. The remaining oil drops back into the oil
reservoir. The unit is factory set and should require no adjustment. If an adjustment is required,
the adjusting screw on top of the lubricator may be turned as marked to reduce or increase the
flow of oil.
The correct grade of oil must be used in the lubricator; too heavy an oil will not provide sufficient
lubrication and will cause sticking and sluggish operation of the air tool. Recommended oils are
any good grade of rust and oxidation inhibiting oil with a viscosity of 80-120 S.U.S. at 100 degrees
Fahrenheit. (0.15 to 0.25 cm2/sec. at 38 degrees Celsius), such as:
Non Fluid Oil Co., grade #LS-1236 Signode oil - Part No. 008556
If necessary, use SAE #5 or SAE #10 non-detergent, cut 1 to 1 with kerosene.
NOTE: Some oils contain anti-wear additives which may disable the air motor. Be certain to use
recommended oil.
Several drops of lubricator oil added to the inlet of the air motor or into the air line each day will
help insure good operation. A noticeable reduction of air motor performance can usually be
corrected by squirting a few drops of oil into the air line.

7
STRAP TENSION
Strap tension is controlled by air pressure. Adjust the pressure regulator, within a range of 70 - 90
psig (4.8-6.2 bar), to provide the desired tension. Once the regulator is set the tension will be
uniform on all straps, provided the operator allows the air motor to stall. The air pressure gauge
must be accurate. Confirm calibration by comparing it to a master gauge.
The VXL-2000Z tool is factory tested to ensure that at least 90 lbs. (400N) of tension is drawn at 90
psig (6.2 bar) and the VXM-2000Z tool is factory tested to ensure that at least 140 lbs. (621 N) of
tension is drawn at 90 psig (6.2 bar).
Review the instructions on page 10 of this manual for information on how to adjust strap tension.
Strap breakage hazard.
Strap can break if inlet air pressure to tool exceeds 90 psig (6.2 bar).
Strap breakage can result in severe personal injury.
Maximum operating air pressure is 90 psig (6.2 bar).
AIR CONSUMPTION - Air consumption in cubic feet per minute (cfm) for the VXL/M can be
calculated as follows: cfm = (a) x (b) x (0.17)
a = Number of straps applied per minute.
b = Number of seconds motor is on per strap during tensioning, from start to deceleration
to stall including stall time while making joint.
0.17 = VXL/M efficiency ratio.
Example Calculation: Peak strapping load is 4 straps/min. so a = 4
Air motor is on 5 seconds/strap, so b = 5
VXL/M efficiency ratio is 0.17
(a)x(b)x(0.17) 64x5x0.17=3.4 cubic ft/min.
4x5x0.28=5.6 cubic meters/hr. (5.6M3/hr.)
Air pressure is assumed to be 90 psig (6.2 Bar) with recommended size and length of air hose.
Volume of air is at room temperature and sea level pressure, or so-called "free air" conditions. For
more detailed information about air supply systems refer to Signode manual Part No. 186038.
COLD WEATHER OPERATION
If a tool does not operate satisfactorily in freezing temperatures, certain steps can correct the
problem. The following steps can be taken to improve cold weather operation of the tool:
a. An air line dryer adjacent to the compressor.
b. Use lubricant recommended by Signode. Signode has tested the use of anti-freezes, none
work well in air tools; the tool will gum up when anti-freezes are introduced and will not
function properly. The best lubricant for freezing weather is the 1 to 1 oil and kerosene
combination.
c. If possible, run the air supply line to a indoor located Filter-Regulator-Lubricator or relocate the
F-L-R to a warmer operating area.

8
OPERATING INSTRUCTIONS
Wear safety glasses.
Stand to one side of the strap when
tensioning. Make sure all bystanders
are clear before proceeding.
1. With the dispenser placed behind you,
bring the strap over the top and around
the package, pulling out excess slack.
Press the operating lever with your right
hand and, with your left hand, insert the
overlapped straps under the feedwheel
and welding mechanism. Leave only a
short tail ahead of the feedwheel and
make sure straps are aligned behind the
tool. Do not make a joint over a void area
of the package.
2. Recheck the strap alignment at the rear
of the tool and realign if necessary.
Release the operating lever and, while
standing to one side of the strap line,
squeeze the motor control lever to
tension the strap.
3. When the motor stalls, indicating
completion of tension, continue to hold
the motor lever fully closed against the
motor housing and pull back the weld
handle with your left hand. The handle
should be pulled quickly all the way back
without hesitation. When the weld lever is
pulled back it traps the motor lever in the
ON position.
4. The internal weld timer is energized. The
strap is welded and the supply end of the
strap is cut-off. Pull the cut strap away
during welding. The tool will continue
through the weld cycle and stop with the
motor lever being held in place. When the
timer times out, the weld action stops.
Allow the tool to remain stationary for at
least 3 seconds to ensure that the weld is
fully cooled.
Failure to wait 3 seconds can result
in an improperly formed joint which
may lead to joint separation.
5. Push the weld handle to the forward

9
position with your left hand. The motor
lever will return to the OFF position as
the weld handle is moved forward.
6. Press the operating lever and swing the
tool off the strap, rear of tool first. Inspect
the joint to make sure the straps have
been properly welded.
SEALING OPERATION
This tool is a Tension Weld® type
sealer. A properly made joint will
appear as shown in the illustration.
If the joint does not appear as shown,
then the operator must proceed as
follows:
1. Insure that the tools operating
instructions are being followed
before applying another strap.
2. Cut the strap off and apply another.
A good weld will show some material
displacement along the edges.
TOP VIEW
SIDE VIEW
The welded area should extend the
full length and width of the gripper
impression.
If the joint still does not appear as
shown, then inspect the tool for worn
and/or damaged parts. Replace tool
parts as needed. NEVER HANDLE OR
SHIP ANY LOAD WITH IMPROPERLY
FORMED JOINTS. Misformed joints
may not secure the load and could
cause serious injury.

10
TOOL ADJUSTMENTS
WELD TIME
Weld time has been factory adjusted to
provide acceptable weld strength when using
Tenax (polyester) or Contrax (polypropylene)
type strap. When using Dymax (nylon) strap
the weld time must be increased.
Weld time may need to be adjusted due to air
supply differences, tool wear, etc.
Adjustments are made by turning the small
slotted screw, located beneath the weld
housing at the rear of the tool, using a small
screwdriver.
Establishing the correct weld time is a matter
of trial and error and should be conducted as
follows.
NOTE: Turning the adjustment screw
clockwise increases weld time and
counterclockwise decreases the weld time.
1. Adjust the screw in 1/8 to 1/4 turn
increments only.
2. Apply a strap and make a weld.
3. Compare the weld made with the
illustrations shown on page 9 of this
manual. A good weld will displace some
material along the outer edges of the
joint.
4. If you are unable to produce an
acceptable joint or if you have any
questions as to whether your tool is
producing good weld strength, contact -
your Signode Sales Representative.
STRAP TENSION
Strap tension can be accurately controlled by
turning the adjustment screw in 1/4
increment turns counter-clockwise using a
3/32 hex wrench (P/N 422587) to reduce strap
tension and clockwise to increase strap
tension. Operating air pressure must be set
between 85 and 90 psi (5.7-6.2 Bar). With
accurately controlled air pressure the tension
will be uniform on all straps, provided the
operator allows the air motor to stall.
STRAP GUIDES
The VXL/VXM tool is manufactured with a
strap guide for 7/16" (10.5mm) strap. When
using 1/2" (12.7mm) strapping material, the
standard strap guide must be replaced with
the 1/2" (12.7mm) strap guide for proper
strap alignment. One 1/2" (12.7mm) strap
guide is packaged with each VXL/VXM tool.
To remove a strap
guide from the tool,
remove the screw
from the bottom of
the tensioner foot.
Once the screw has
been removed the
strap guide can be
lifted over the
alignment pin and
out of the tool.
Replace the new
strap guide in the
same manner in
which the old guide
was removed.

11
CUTTER ADJUSTMENTS
When the strap cutter begins to wear or
strapping seems difficult to cut off the strap
cutter may need adjustment. Contact the
Signode tool repair center or your Signode
representative for information on accessing
the adjustment screw.
Before attempting to adjust the cutter, first
place a single layer of strapping in the tool
and pull the weld handle to the full back
position.
Adjust the cutter blade position by turning
the adjustment screw inward (clockwise) or
out (counter-clockwise) using 1/8 turn
increments. Adjust the cutter blade so that
the cutting edge of the blade places a slight
impression into the single layer of strap.
Remove the
single layer of
strap. Run one
or more tool
cycles and
continue to
adjust the
cutter as
necessary until
proper strap
cut-off has
been obtained.
NOTE: Do not over tighten cutter mechanism
as lower strap damage or poor strap cut-off
will occur.
FEEDWHEEL TO GRIPPER PLUG
The feedwheel to gripper plug clearance may
require readjustment if the feedwheel,
tensioner foot or gripper plug has been
replaced. The feedwheel clearance should
also be inspected during routine tool
maintenance procedures. Adjust the
feedwheel clearance as follows:
1. Open the tensioner foot and place 1 to 2
layers of .002", 1/2" wide (.05 x 12mm)
shim stock between the feedwheel and
the gripper plug.
NOTE: Using a single .004" (.10mm) shim is
not recommended because a single thicker
shim may not conform to the feedwheel
shape, resulting in inaccurate clearance
measurements.
2. Release the tensioner foot to pinch the
shims between the feedwheel and the
gripper plug. Holding the shims with one
hand, jog the air motor on and off to
rotate the feedwheel at least one full
revolution. If properly adjusted the tool
should lightly tug at the shims while
rotating. Clearance between the
feedwheel and gripper plug at this point
should fall between .002"-.004" (.05-
.10mm).
3. If the feedwheel needs to be adjusted,
use a 3/32" hex wrench to rotate the
adjustment screw located in the
tensioner foot.
Turn the adjustment screw clockwise for
greater clearance and counter-clockwise
for less clearance. Turn the adjustment
screw only in 1/8 turn increments. After
each 1/8 turn, repeat the adjustment
testing as described in step 2.
4. Once the proper clearance has been
found the tool can be returned to service.
NOTE: Never turn out the adjustment screw
more than 1/8 turn at a time without testing
or completely removing the adjustment
screw. These actions will severely damage
both the feedwheel and gripper plug.

12
PARTS REMOVAL & REPLACEMENT
FEEDWHEEL AND GRIPPER PLUG
1. Place the tool on its side and remove the
two socket head cap screws (75) from the
weld housing (24).
2. Pull upward on the weld housing and
raise it slightly.
3. Insert a thin rod or screwdriver and
disengage the torsion spring (23) from
the tab on the weld housing (24).
4. Pull the weld housing off the tool.
5. Lift the feedwheel (22) from the feedwheel
shaft (21).
6. Lift the torsion spring (23) and the
tensioner foot (16) off the support pin
(25). This allows the gripper plug (17) to
be replaced if necessary. Turn the
tensioner foot over, remove the flat head
cap screw (19) and with a small punch,
drive the roll pin (20) upward to remove
the gripper plug and strap guide, (18).
7. Replace the feedwheel if necessary,
making sure the hollow face of the
feedwheel faces inward.
8. Lubricate the support pin and the end of
the feedwheel shaft with Mo-Lith No. 2
lubricant to allow the tensioner foot to
pivot freely.
9. Reassemble the parts in reverse order if
further parts removal and replacement
are not needed.

13
CUTTER BLADE
1. Place the tool on its side and remove the
two socket head cap screws (75) from the
weld housing (24).
2. Pull upward on the weld housing and
raise it slightly.
3. Insert a thin rod or screwdriver and
disengage the torsion spring (23) from
the tab on the weld housing (24).
4. Pull the weld housing off the tool.
5. Remove the three socket head cap
screws (76) that hold the motor mount
(41) to the tool.
6. Separate the motor mount from the tool.
Lift the cutter blade (46) from its pivot pin
(74).
A small compression spring (84) is
contained under the cutter blade. Use
care in removing the two halves of the
tool so as not to damage or lose the
spring.
7. Examine the cutter blade (46), spring (84)
and pin (74) for a worn or damaged areas.
Replace if necessary.
8. Reassemble the tool in reverse order,
except for the small compression spring
if further parts removal and replacement
is not required.
Refer to page 25, assemble the clutch
spring (36) and the clutch (37) on the
spline of the Spiroid worm and press
down to weld position. Remove the weld
handle subassembly from the weld
housing and insert it into the gear
housing in the sealing position. The cam
on the pressure eccentric will be engaged
with the groove of the clutch. This will
hold the clutch assembly in place when
reassembling the tool.
9. Lift up the cutter blade and gently insert
the compression spring into the cavity
found on the underside of the cutter
blade.

14
WELDING MECHANISM & DRIVE GEARS
1. Remove the idler gear (27) from the pin
(30) and examine both parts for wear.
2. Remove the eccentric shaft (26) and
examine it for wear.
3. Lift the slider link (48) from the gear
housing (72). Examine the teeth on the
upper gripper (52) for wear. The upper
gripper can be replaced by removing the
pin (51).
4. Examine the teeth of the lower gripper
(78). If the part is to be replaced, it may
be removed by first removing the
mounting screw (87) from underneath,
then punching it out from underneath
through the two holes.
When reinstalling a lower gripper, use
Loctite "380 Black Max" (Signode Part
No. 274111) or an equivalent instant
adhesive to ensure the lower gripper will
be held securely. Note that mating
surfaces must be free of dirt and grease.
NOTE: When using 380 Black Max adhesive,
directly follow the manufacturers cleaning
and preparation instructions.
5. Remove th needle bearing (29) from the
housing by threading a 1/4 x 20 screw
through the bearing into spacer (86) refer
to Figure “C” on the following page.
Clamp the screw head in a vise and
lightly tap the casting to extract the
bearing. If bearing removal becomes
difficult use the detailed instructions on
the following page.

15
FIGURE-A
FIGURE-B
FIGURE-C
FIGURE-D
NEEDLE BEARING (ECCENTRIC SHAFT)
Use a 1/4-20x3 socket head cap screw and an
extra spacer (86) to remove the needle
bearing (29) from the back of the gear
housing (72).
1. Thread extra spacer (86) on to the SHCS
approximately 3/16" to 1/4" from the end.
2. Insert the screw and spacer through the
seal (58) and into the needle bearing.
With the gear housing firmly braced,
strike the end of the screw firmly with a
hammer to drive the bearing into the
spacer. This action will prevent the
spacer from rotating while screw is
threaded in.
3. Remove the extra spacer from the SHCS
and thread the screw into the spacer.
Clamp the screw head in a vise and
lightly tap the gear housing to extract the
bearing, spacer and seal.
Only replace the bearing, spacer and seal
with new components.
ASSEMBLY NOTES:
A. When installing spacer (86) be sure that it
is squarely aligned at the bottom of the
bore.
B. When installing bearing (29), the text side
should face away from the gear housing.
Install the bearing flush to the housing
surface. Failure to set the bearing flush
with the housing will result in
interference with the slider link (48).
C. When installing seal (58), the seal lips
should face inwards towards bearing.
Install seal flush to housing surface.

16
CLUTCH AND BRAKE
1. You now have access to the clutch (37)
and the drive gear assembly (39).
Normally, the drive gear will remain in the
motor mount and can be removed by
pulling it straight out. The clutch will be
loose in the gear housing as the spring
behind the clutch forces it outward.
2. With these parts removed, wipe out all
the surrounding grease to remove any
metal chips that may be present. The
idler gear (27) and the eccentric shaft (26)
have been previously removed to
facilitate cleaning and allow repacking of
the needle bearings (29, 80) in the gear
housing and motor mount prior to
reassembly. Check idler gear pin (30) for
wear. This portion of the tool is to be
repacked about 50% full with Non-fluid
Oil No. K-55.
3. Check the teeth of the clutch (37) and the
drive gear assembly (39A) for wear.
Replace if necessary. Also, check the
needle bearing (38) in the center of the
drive gear for wear and make certain the
needles turn freely.
4. With a moderate amount of grease added,
a new clutch can be installed on the
spline of the Spiroid worm (28) and a new
drive gear assembly (39A) can be
installed into the motor mount.
5. Remove spacer sleeve subassembly (32,
33, 34, and 35). Disassemble by
grinding or filing the two stakes, if
necessary. Replace the brake (34).
Make certain that the flat surface of the
brake is facing the brake springs (33) and
insert the springs with the concave side
towards the washer (32). Stake the
spacer sleeve twice and replace the
spacer sleeve subassembly.
6. Assemble the clutch spring (36) and the
clutch (37) on the spline of the Spiroid
worm and press down to weld position.
Remove the weld handle subassembly
from the weld housing and insert it into
the gear housing in the sealing position.
The cam on the pressure eccentric will
be engaged with the groove of the clutch.
This will hold the clutch assembly in
place when reassembling the tool.
7. Add lubricant to the drive gear assembly
(39A) and insert it into the motor mount
(41). Also add lubricant to the idler gear
(27) and the eccentric shaft (26) then
insert them into the tool. Reassemble the
motor mount to the gear housing and
secure it with the three socket head cap
screws.
8. Refer to the illustration on page 14.
Examine the small dowel pin (50) that sits
in the groove in the contact stem (44), for
wear. Replace if necessary. Liberally
lubricate with MO-Lith No. 2. This will
also hold the pin in place during
reassembly. Remove the weld handle
from the tool and reassemble it into the
weld mechanism with the following
components. Inspect and replace the
parts as needed and add lubricant:
!Pressure eccentric (66)
!Lift tab (49)
!Compression plate (43)
!Die spring (45)
!Shim (81)
!Contact stem (44)
!Dowel pin (50)
!Cutter spring (47)
!Weld housing (24)
Examine the bushings (64 and 65) in the
weld housing (24) for wear and replace as
required.
9. Check the valve components for cut
tubing or loose fittings, reassemble all
parts, being careful not to crimp or pinch
the tubing, and operationally test the tool.

17
AIR MOTOR
This tool is manufactured with one of two
available air motors. Inspect the air motor
housing to determine which specific air
motor instructions to follow. The two motors
available for this tool are part number 422550
and 423150.
These instructions also apply to the older
VXL/VXM air motor 273830 (20R38V).
Make sure the air line has been
disconnected from the quick
disconnect plug before attempting
the following procedures. Failure to
disconnect the air may result in
personal injury.
1. Remove the lower cover (31) by removing
the two mounting screws (37), then
remove the valve housing (36) by
removing the three socket head cap
screws (32).
2. Remove the O-ring (34) from the end of
the air motor housing. Set it to the side
for reuse.
3. Swing the valve housing (36) to the side,
being careful not to damage the air lines
(39).
4. Remove the three socket head cap
screws which secure the motor mount to
the gear housing.
A small compression spring (84) is
contained under the cutter blade.
Separate the motor mount from the gear
housing and remove the drive gear and
bearing.
5. Remove the locking ring from the motor
mount. NOTE: The locking ring has left-
hand threads.
NOTE: Use of Assembly Fixture (Part No.
306871) may be useful in removing the
locking ring. This fixture allows the air motor
to be clamped in a secure position while the
locking ring can be removed with the
accompanying special 5/8" hex adapter (Part
No. 422340).

18
20R38V N20R38V
N20R38VA
NOTE: If disassembling a tool with the
alternate style locking ring, use socket
adapter Part No. 422341.
6. Turn the air motor assembly clockwise to
separate it from the motor mount. NOTE:
The air motor has left-hand threads.
7. Unscrew the gear housing (30) from the
motor housing.
8. Slide out the cylinder (15) from the motor
housing (11). When reinstalling the
cylinder in the motor housing be sure to
line up the alignment pin (16) with the
aligning mark on the housing. This will
ensure that the alignment pin will slip
into the correct hole in the bottom of the
motor housing.
9. Remove each of the idler gear assemblies
(23) from the cage (24). Check the idler
pins, the bushing in the center of idler
gear, and pinion shaft teeth for wear.
Replace if necessary.
10. Remove the aligning pin
and tap on the end of the
rotor (18) to loosen the
assembly.
11. Disassemble the rotor by sliding off the
front end plate (20), and any ball
bearing(s) and spacers. Then slide the
back end plate (14) and the rotor
assembly (18), with the vanes (17), out of
the cylinder.
12. Loo
k for areas of wear on the face of the end
plates, the pinion teeth on the rotor and
the edges of the vanes. The vanes must
be kept clean to float freely in the rotor.
Note: If the vanes and/or the idler
assemblies have to be replaced, they
must soak in air line oil overnight before
assembling them into tool.
13. Once these parts have been examined,
cleaned and worn parts replaced, the air
motor may be reassembled. Keep in
mind the care required when
reassembling the alignment pin.
14. Temporarily install the O-ring (34) and the
valve housing assembly to the air motor
housing.
15. Add several drops of air line oil to the
motor. Lightly clamp the air motor into a
traditional vise. Connect air to the motor
at 20 psig and press the motor lever. The
motor must start and turn freely. With the
motor running, carefully tighten the gear
housing (30) by turning clockwise and
note the speed increase to peak RPM
using 275-450 in. lbs. of torque. Do not
over tighten as this will slow down the
motor. Disconnect air supply.

19
16. Remove the air motor from the vise.
Clean the motor mounting threads with
an appropriate solvent, also clean the
threads of the motor mount. Remove
the valve housing assembly and O-ring
from the air motor.
17. Place a few drops of Loctite #242
sealant on both the external threads of
the air motor and the internal threads of
the mount. Screw the air motor into the
motor mount until fully seated. Back out
the air motor only enough to align the
motor to the mount when placed into
the assembly fixture.
18. Place the air motor and mount into the
assembly fixture. Make sure the pin
which extends out from the base of the
fixture is properly aligned into the
cavity found in the rear of the motor
mount. Securely clamp the motor in
place.
19. Using an inch-pounds torque wrench,
install the locking ring to 450-550 in-lbs.
(50-60 Nm) of torque.
20.
Continue to reinstall the O-ring, valve
housing assembly, drive gear, bearing
and lower air motor cover.
21. The air motor/mount assembly can now
be mounted to the gear housing
assembly.
22. Lift up the cutter blade and install the
small compression spring (84).
HANSEN PLUG
When removing/connecting the Hansen plug,
hold the air motor inlet fitting with one
wrench and tighten the Hansen plug with
another. If this is not done, you will loosen
or over-tighten the air motor housing, thus
affecting performance.
AIR MOTOR VALVE
Remove the air valve as follows:
1. Remove the Truarc ring (4), permitting
removal of the valve sleeve (5), stem (7),
and spring (9).
2. Clean all parts to be sure any dirt causing
sticking of the valve is removed.
3. Replacing the O-rings (6, 8) should
correct any leaking air. Oil lightly and
replace the parts as disassembled.

20
PILOT VALVE
Remove the pilot valve as follows:
1. Remove the valve cap (35) using cap tool (P/N 422449). Lift out
the spring and pull out the pilot valve (33) from the valve housing
(36).
2. Replace the pilot valve assembly if necessary, being careful not to
cut the "O" rings. Wipe a small amount of air line oil on the "O"
rings and install the pilot valve and spring into the housing. The
pilot valve cannot be disassembled. Replace it as a unit.
3. Install the valve cap using the cap tool to 30-40 in-lbs. (3-5Nm) of
Torque.
AIR LOGIC AND DIAGRAM (AIR MOTORS N20R38V & 20R38V)
SEQUENCE OF OPERATION
1. Tool at Rest - Air flows through the pilot valve and stops at the air valve and also stops at the
3-way valve.
2. Motor control lever is depressed, initiating the tensioning portion of the cycle. Air flows
through the pilot valve and the air valve to the rotor/cylinder section of the air motor, causing
the air motor to turn. The motor runs until it stalls when strap tension has been reached. Air
also flows to and stops at the 3-way valve.
3. The weld handle is pulled back, initiating the welding cycle. Air flows through the pilot valve
and the air valve to the
rotor/cylinder section of the air
motor. Additionally, the act of
pulling the weld handle back
mechanically disconnects the
motor from the tensioning
mechanism so the air motor starts
running again. Air flows through
the 3-way valve, the flow control
and enters the volume chamber.
When sufficient pressure has built
up in the volume chamber the pilot
valve will actuate and shut off the
air flow to the air valve and the
rotor/cylinder. The air motor then
stops.
4. The motor lever and weld handle
are released and the tool returns to the "at rest" configuration, with air being routed past the
pilot valve and stopping at the air valve.