PowerLine Operating Instructions

PowerLine™ Electric Cutter

Installation, Operating and Maintenance Instructions
PowerLine Models PL2650 and PL2150

Specifications Table of Contents

Functional 1.0 Introduction . . . . . . . . . . . . . . . . . . . . . . Page 2
Cut Length x Width (behind blade): 2.0 Nomenclature . . . . . . . . . . . . . . . . . . . . . Page 2
21" EC . . . . . . . . . . . . . . . . . . . . . . 21" x 21" 3.0 Controls . . . . . . . . . . . . . . . . . . . . . . . . . Page 3
26" EC . . . . . . . . . . . . . . . . . . . . . . 26" x 26" 4.0 Installation . . . . . . . . . . . . . . . . . . . . . . . Page 4
Cut Height: 5.0 The Back Gauge . . . . . . . . . . . . . . . . . . . Page 6
2 7/8" Maximum 6.0 Operation . . . . . . . . . . . . . . . . . . . . . . . . Page 7
Physical 7.0 Maintenance . . . . . . . . . . . . . . . . . . . . . . Page 12
Weight: 8.0 Error Codes . . . . . . . . . . . . . . . . . . . . . . Page 16
21" EC . . . . . . . . . . . . . . . . . . . . . . . 720 lbs. 9.0 Diagnostic Tests . . . . . . . . . . . . . . . . . . . Page 17
26" EC . . . . . . . . . . . . . . . . . . . . . . . 800 lbs. 10.0 Troubleshooting . . . . . . . . . . . . . . . . . . . Page 19
Shipping Weight: Fraction to Decimal Conversion Chart . . . . . . . . . Page 22
21" EC . . . . . . . . . . . . . . . . . . . . . . . 743 lbs. Parts Diagrams and Parts Lists . . . . . . . . . . . . . . . Page 23
26" EC . . . . . . . . . . . . . . . . . . . . . . . 823 lbs. Wiring Diagrams 1, 2, & 3 . . . . . . . . . . . . . . . . . Page 29
Color:
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gray
Dimensions:
21" EC 33 3/4"W x 50 3/4"H x 42 3/4"D Serial Number
26" EC 38 3/4"W x 50 3/4"H x 47 3/4"D
Electrical
AC Voltage: . . . . . . . . . . . . . . . . . . . . .230/240VAC _______________________________________
Load Current: . . . . . . . . . . . . . . . . . . . . .16 Amperes

Optional
Side Tables

WARNING! This machine contains a powered cutting knife which can

cause serious or even fatal injury. Never connect power to the machine
until you are ready to set up and operate the electric cutter. The AC outlet
must be nearby and not blocked. To prevent injury, never place hands or
arms under the cutting blade, do not operate the machine with any covers
removed or safety features disabled, and cut only paper materials. The
front blade guard must be in the lowered position before the clamp or
blade will operate. Before attempting any maintenance procedure, be sure
power is disconnected and locked out.

© 1997 by Martin Yale Industries, Inc. 1

 PowerLine Operating Instructions

1.0 Introduction
Thank you for selecting the Martin Yale PowerLine Electric Cutter. PowerLines are
designed to provide a high level of safety, accuracy, flexibility, and ease of operation.
Each component has been engineered to perform reliably and is 100% factory tested to
ensure years of quality service.

We recommend that you familiarize yourself with the cutter by carefully reading this
manual. Reading and thoroughly understanding this manual will help you avoid the
most common operational problems and help eliminate operational errors.

2.0 Nomenclature

1. Chassis - Houses the electrical and mechanical components.

2. Stand - Consists of legs and shelves. The stand can be separated from the chassis.
3. Keyboard Control - 20-character, 2-line Liquid Crystal Display at the top with a
keypad below.
4. Right Switch Panel - Contains key switch, clamp switch, and blade switch.
5. Left Switch Panel - Contains On/Off toggle switch, reset switch, and clamp/blade
switch.
6. Ready Light - Amber light indicates when safety conditions are met and the
machine is ready for the next cutting cycle.
7. Paper Guides - Guide paper and maintains paper position.
8. Rear Safety Cover - Fixed cover over the rear deck.
9. Back Gauge - Controls the movement of paper through the cutting area.
10. Knife - Honed steel blade provides cutting action.
11. Clamp - Secures paper during the cutting process.

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 PowerLine Operating Instructions

12. False Clamp - Can be attached to the bottom of the permanent clamp.
13. Cutting Stick - Protects the knife edge at the bottom of the cutting cycle.
14. Leg Levelers - Adjustable feet ensure a level cutting surface.
15. Storage Shelf - Front and rear shelves for operator convenience.
16. Fuseholders - Two fuseholders (located under the front portion of the chassis) con-
tain replaceable power fuses.
17. Circuit Breakers - Resettable circuit protector located under the front portion of the
chassis.
18. Shroud - Housing for the blade and clamp drive components.
19. Serial Label - Identifies the serial number, electrical ratings, and agency approvals.
20. Line Cord - Connects the electric cutter to the AC power source.
21. Blade Adjustment - Compensates for blade wear/sharpening.
22. Front Safety Cover - Interlocked front deck cover.
23. Side Tables - Optional accessories to add working surface area to one or both sides.
3.0 Controls
3.1 Blade, Clamp, and Power Controls

4 5 6
1 2 3

1. AC power on/off toggle switch. Controls power to all circuits. The switch bracket
allows insertion of a lock to prevent power activation of the electric cutter.
2. Reset switch - Enables the blade and clamp circuits for the next cutting operation
when the blade and clamp are in the up position. Returns the clamp to the up posi-
tion when only the clamp is used. The ready light will come on when safety condi-
tions are met. (Figure 1, Item 6)
3. Clamp/Blade switch - When pressed simultaneously with the clamp switch (in the
right switch panel), the clamp will travel independently of the blade to the clamping
position. When pressed simultaneously with the blade switch (in the right switch
panel), both the clamp and blade will cycle through the cutting process.
4. Blade switch - When pressed simultaneously with the Blade/Clamp switch (in the
left switch panel), both the clamp and blade will cycle through the cutting process.
5. Clamp switch - When pressed simultaneously with the Blade/Clamp switch (in the
left switch panel), the clamp will travel independently of the blade to the clamping
position.
6. Key switch - Controls power to the blade and clamp. The key can be removed to
prevent operation of the blade and clamp.

3.2 Back Gauge Control Panel

NOTE: The default language of the back gauge programmable controller
is English. The default for movement of the back gauge and subsequent
readout is in inches. To change either, see Section 5.0.

1. Display - During setup, the LCD provides prompts and information. During opera-
tion, the LCD provides the cutting length and program status.

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 PowerLine Operating Instructions

2. Longer/Previous - In the manual mode, press this key to move the back gauge away
from the cutting area (LONGER). In the automatic mode, press this key to move
the back gauge to the last or previous cutting position of the current setup.
3. Shorter/Next - When in the manual mode, press this key to move the back gauge
toward the cutting area. When in the automatic mode, press this key to move the
back gauge to the next cutting position of the current setup.
4. Speed/Advance - When in the manual mode, press this key to change the back
gauge running speed to Fast or Slow. In the automatic mode, press this key to acti-
vate the Auto Advance feature.
5. Stop/Undo - When in the setup or programming mode, press the UNDO key to
change the selection to the previous choice. Press the STOP key to stop the back
gauge from moving.
NOTE: The Undo key does not clear an incorrect numerical entry.
6. Number and decimal point Keys - Use these keys to respond to choices offered by
the prompts.
7. CE (CLEAR ENTRY) - Press this key to clear an incorrect numerical entry.
8. Set Up - Press this key to enter setup for programming the automatic mode cutting
positions.
9. Enter - Press this key to install the operator entries into the operating system, or to
review the current setup.
10. Mode - Press this key to toggle the operating mode to manual or automatic, or to
select a stored setup.
4.0 Installation
WARNING! To prevent serious personal injury, always use a mechanical
lifting device, such as a fork lift or pallet jack, to move the machine or to
separate the chassis from the frame.

NOTE: Place the cutter on a flat, level foundation sufficient to support its
weight. Be sure to allow adequate work space on all sides of the cutter.

4.1 Leveling the Machine

Level the cutter (check the top surface in two planes) by adjusting the leg leveler in the
bottom of each stand leg. Turn the leg leveler clockwise to shorten the leg length. Turn
the leg leveler counterclockwise to increase the leg length.

4

4.2 Releasing the Back Gauge
1 cover.
4.3 False Clamp
Short Cut
When cutting carbonless paper,
install the false clamp to help pre-
vent bruising and marking.
21" False Clamp Screw Location
4.4 Separating the Stand and Chassis
PowerLine Operating Instructions
To prevent shipping damage, the back gauge is locked in place by two thumb screws(1)
located near the ends of the top rear surface of the back gauge. Remove these screws
before operating the electric cutter. To do so, first remove the rear safety cover by
loosening the crosspoint screws holding the cover to the rear of the shroud and the
decks. Remove the two thumb screws that secure the back gauge and reattach the safety
The false clamp, made from clear polycarbonate, is used to reduce bruising (marking)
on carbonless paper. It is not necessary to use the false clamp when cutting standard
paper stock. Use of the false clamp affects the minimum cutting distance. When
installed, the minimum cutting distance is 2.37". When not installed, the minimum cut-
ting distance is 1.37". Section 6.0, Operation, includes the false clamp set up informa-
tion. The false clamp is held in place by four (three on the 21" EC) 10/32x3/8 flathead
hex socket screws. To install the false clamp, proceed as follows:
1. Turn the on/off toggle switch, located in the left switch panel, to off.
2. Turn the key switch, located in the right switch panel, to off (key vertical).
3. Raise the front safety cover.
4. Locate the position of the screws on the bottom of the false clamp. Install and
tighten the screws.
26" False Clamp Screw Location
WARNING! To prevent serious personal injury, always use a mechanical
lifting device, such as a fork lift or pallet jack, to separate the chassis from
the frame. The weight of the chassis is unbalanced. Most of the weight is
in the front 2 feet of the chassis.
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 PowerLine Operating Instructions

To separate the chassis from the stand, remove the carriage bolt and acorn nut from the
top of each stand leg (see illustration). Lift the chassis from the stand using a mechani-
cal lifting device. To reassemble the stand and chassis, lower the chassis onto the stand
and install the carriage bolt and acorn nut through each stand leg.

4.5 Power Requirements

WARNING! The AC power outlet must be installed near the electric cutter
and easily accessible.

The electric cutter is equipped with a 20 Amp power plug (NEMA #6-20P). This cutter
requires a 20 Amp circuit with a 20 Amp receptacle (NEMA #6-20R). Have a qualified
electrician install the appropriate branch circuit and receptacle.

4.6 Optional Side Tables

To install the optional side tables, align the holes in the tables with the screw holes in
the side machine chassis. Install and tighten the provided screws.
5.0 The Back Gauge
5.1 General
The default language of the back gauge programmable controller is English. The default
for movement of the back gauge and subsequent readout is inches. You may change the
language by following these instructions:

Press the SETUP key as you activate power to the machine. Press the 8 key.
The display will show:
Configure the Choose Configuration
System - 8 1=Language 2=Units

Press the 1 key:

Jog Keys to Select
Enter for English

Press either of the jog keys to scroll through menu options or press the ENTER key for
English. You may choose Spanish, Italian, French, German, or English. When the lan-
guage you require is displayed, press ENTER key. Press UNDO to exit configuration.

You may change the units of measure designation by following these instructions:

Press the SETUP key as you activate power to the machine. Press the 8 key.
The display will show:
Configure the Choose Configuration
System - 8 1=Language 2=Units

Press the 2 key:

Choose Units
1=English 2=Metric

Press the appropriate key.

English/Metric
Units Confirmed

Press UNDO to exit configuration.

The electronic back gauge can be set at any location from 1.37" from the cut line (2.37"

6
 PowerLine Operating Instructions

with the false clamp installed) to 21.00" or 26.00", depending on the model. While the
back gauge can be operated in either a manual or automatic mode, the manual mode is
the default mode when you power up the machine.

When you power up the machine, the LCD will show the Logo and software revision
number, as well as prompting for the false clamp. The back gauge moves to the Home
position as part of the initialization routine. When the back gauge position is valid at
power up, the LCD will prompt:
Back Gauge Free To Move?
Hit Enter Key

Press the ENTER key and the back gauge moves toward the Home position at the fast
speed. If the back gauge position is not valid when power is supplied, the LCD will
prompt:
Warning! Unknown Back Gauge
Position
Back Gauge Free To Move?

Press the ENTER key and the back gauge moves toward the Home position at Slow
speed.

In the manual mode, the LCD shows the current back gauge position and the run speed,
Fast or Slow. Position the back gauge by pressing the appropriate jog key. Enter a cut-
ting position by pressing the numerical, decimal point and ENTER keys. Change the
run speed by pressing the SPEED key. Return the back gauge to the initial position at
any time by pressing the CE key followed by the ENTER key. In manual mode, the ini-
tial position is at 26" (21" for the 21" Electric Cutter). In automatic mode, the initial
position is the first position in the series of programmed positions.

In automatic mode, the LCD shows the current position of the back gauge:
Position xx.xx
Auto Advance: OFF

In this mode, the back gauge moves to predefined positions automatically when Auto
Advance feature is activated, or semi-automatically when Auto Advance feature is off.
To review the predefined positions, press the ENTER key. The predefined cutting posi-
tions can be changed. You may cut with the changed positions with or without storing
them in the system. There are two methods to enter a predefined position. For the run-
ning method, press the jog keys to move the back gauge to the desired position. Press
the ENTER key to install the current position. For the key entry method, press the
numerical and decimal point keys to select the required position. Press the ENTER key
to install the selected position.

There are two types of predefined positions, fixed and variable. The fixed type uses a
starting position and moves the back gauge at a fixed interval automatically when Auto
Advance is activated, or semi-automatically when Auto Advance is off. The variable
type moves the back gauge to as many as ten distinct positions automatically when Auto
Advance is activated, or semi-automatically when Auto Advance is off. Return the back
gauge to the first operating position at any time by pressing the CE key, followed by the
ENTER key.
6.0 Operation
WARNING! This machine contains a powered cutting knife which can
cause serious or even fatal injury. Never connect power to the machine
until you are ready to set up and operate the electric cutter. To prevent

7
 PowerLine Operating Instructions

injury, never place hands or arms under the cutting blade, do not operate
the machine with any covers removed or safety features disabled, and cut
only paper materials.

Before plugging in the Electric Cutter power cord, be sure the following conditions have
been met:
1. All safety covers are in place.
2. No objects are resting below the cutting area or on the rear decks.
3. The back gauge locking screws have been removed.
4. The power cord will be connected to a 230VAC 20 Amp branch circuit.
5. The On/Off toggle switch is off and that the key switch is off (key vertical).

6.1 Supply Power to the Electric Cutter

1. Plug the power cord into a 230VAC 20 Amp outlet.

2. Turn the On/Off toggle switch, (located in the left switch panel) to the on position.
The cutting line lights illuminate when power is supplied.
3. Insert the key into the key lock switch (located in the right switch panel) and turn
the key to the on position.

6.2 Manual Mode Setup

NOTE: The controls were previously discussed in Section 3.0 of this manu-
al. Please refer to Section 2.0 if you have any questions concerning the
function of a particular control or key.

When the electric cutter is activated, the LCD will briefly show the Martin Yale logo
and software revision:
(Logo) Smart Back Gauge False Clamp
Martin Yale Rev. xx.xx 1 = No or 2 = Yes

1. False Clamp - This selection controls the minimum cutting distance (1.37" without
the false clamp or 2.37" with the false clamp). If you have not installed the false
clamp, press 1.
Back Gauge Free To Move? Warning! Unknown Back Gauge
Position
Hit Enter Key Back Gauge Free To Move?

2. Is Back Gauge Free to Move? (With valid back gauge position.) or Warning!
Unknown Back Gauge Position. Is back gauge free to move? (When back gauge
position is not valid.)
Press the ENTER key to move the back gauge toward the Home position at the
appropriate speed.
Position xx.xx
Speed: Fast

3. Position: xx.xx
Speed: Fast - The display shows the current back gauge position and back gauge
speed. Reposition the back gauge by pressing the jog keys, LONGER, SHORTER
or by entering a position using the numerical keys, followed by the ENTER key.
Change the back gauge speed to slow by pressing the SPEED key.

NOTE: As the back gauge moves, the position readout is continuously

updated and the selected speed is displayed. When the back gauge stops,
the current position and selected speed are displayed.

4. Position the paper stack squarely against the back gauge and either the left or right
guides.

8
 PowerLine Operating Instructions

5. Press the RESET button located on the left switch panel. If all safety conditions are
met, the amber colored Ready Light will illuminate indicating the machine is ready
to cut.

NOTE: The front blade guard must be in the lowered position before the
clamp or blade will operate.

6. The clamp and blade can be operated simultaneously or independently. To operate

simultaneously, press the CLAMP/BLADE switch (on the left switch panel) and the
BLADE switch (on the right switch panel). To operate the clamp independently,
press the CLAMP/BLADE switch (on the left switch panel) and the CLAMP switch
(on the right switch panel). When you are ready to cut paper, press the
CLAMP/BLADE switch and the BLADE switch.
7. After the cutting cycle is complete, the Blade and Clamp automatically return to the
up position. You may reposition the back gauge (step 6) and make the next cut
(step 4).

6.3 Automated Mode Setup

NOTE: The controls were previously discussed in Section 3.0 of this manu-
al. Please refer to Section 3.0 if you have any questions concerning the
function of a particular control or key.

When the electric cutter is activated, the LCD will briefly show the Martin Yale logo
Short Cut and software revision:
For the most accurate cuts, make
sure the paper stack is firmly against (Logo) Smart Back Gauge False Clamp
the left or right guide. Martin Yale Rev. xx.xx 1 = No or 2 = Yes

1. False Clamp - This section controls the minimum cutting distance (1.37" without
the false clamp, 2.37" with the false clamp). If you do not install the false clamp,
press 1.
Back Gauge Free To Move? Warning! Unknown Back Gauge
Position
Hit Enter Key Back Gauge Free To Move?

2. Back Gauge Free to Move? (With valid back gauge position.) or

Warning! Unknown Back Gauge Position. Back Gauge Free to Move? (When back
gauge position is not valid.)
Press the ENTER key to move the back gauge toward the Home position at the
appropriate speed.
Position xx.xx
Speed: Fast

3. Position: xx.xx Speed: Fast

Short Cut 4. Press the MODE key.
When cutting carbonless paper,
install the false clamp to help pre-
vent bruising and marking. 5. Press 1 for Automatic Mode or 2 to Retrieve a Stored Set. Pressing 1 will select the
last pre-defined program. The back gauge moves to the first cutting position.
When the back gauge stops moving, you can review the program by pressing
ENTER.

Press 2 to initiate the prompt, “Set Number? 1 to 5.” When you select a program,
the values of that program are displayed. To select a different program, simply
enter a new set number.

NOTE: Your PowerLine Cutter has been factory programmed for test pur-
poses. You may reprogram the settings by following instructions in Sec. 6.4.

9
 PowerLine Operating Instructions

When the required setup is indicated, press the ENTER key. The display will
show:
Position: xx.xx
Auto Advance OFF

The Auto Advance feature will automatically move the back gauge to the next pro-
grammed position. To select Auto Advance, press the SPEED key.

NOTE: The front safety cover must be in the lowered position before the
clamp or blade will operate.

The back gauge moves to the first cutting position. To verify the setup, move the
back gauge through the pre-defined program positions by pressing the Next or Last
keys.

6. Position the paper stack against the back gauge and either the left or right guides.
Press the Reset switch (1). Lower the front safety cover. If all safety conditions are
met, the amber colored Ready Light illuminates indicating the machine is ready for
the cutting cycle.
The clamp and blade can be operated simultaneously or independently. To operate
simultaneously, press and hold the CLAMP/BLADE switch (2) and the Blade
switch (3). To operate the clamp independently, press and hold the
CLAMP/BLADE switch (2) and the Clamp switch (4). When you are ready to cut
paper, press and hold the CLAMP/BLADE switch and the Blade switch.
After the cutting cycle is complete, or if you release the push buttons simultaneous-
ly, the clamp and blade return to the up position. If you release either of the push
buttons singly, the blade and clamp will stop, then return to the up position when
the the other push button is released.
After the initial cut, press the NEXT key to advance the back gauge to the next pro-
grammed position. Make the next cut by following previous instructions. If the
Auto Advance feature has been activated, the back gauge will automatically move
to the next programmed position after each cut. If Auto Advance is not active, push
the NEXT key to move the back gauge to the next programmed position after each
cut.

6.4 Programming the Back Gauge

6.4.1 Programming Fixed Back Gauge Positions
Fixed cutting programs are useful for cutting a series of identical stacks from a larger
stack. A fixed cutting program moves the back gauge toward the cut line in identical
intervals. (See diagram.) To define and store a fixed cutting program in your cutter:
1. Activate the cutter by turning the ON/OFF toggle switch and key switch to the on
position. Answer the false clamp prompt.
2. After the Back Gauge Position and Speed are displayed, press the SETUP key to
change the system to the automatic mode.
Define a New Set of Positions Choose Type of Set 1= Fixed
2= Variable

3. Press 1 on the keypad.

Initial Position?
Fixed cutting programs start Enter Value or Jog
at a programmed point and
move the back gauge by a 4. At the display prompt, select either 1) the running method or 2) the key entry
fixed interval after each cut.
method.
Position: xx:xx
Speed: Fast

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 PowerLine Operating Instructions

If you select the running method, press the jog keys to position the back gauge to
the required starting location and then press the ENTER key. If you select the key
entry method, enter the back gauge starting position by pressing the appropriate
numerical and decimal point keys. Press the ENTER key to install the selected posi-
tion.
Initial Position Installed Interval Amount? Enter Value

5. At the display prompt, press the numerical and decimal keys to enter the required
dimension.
Enter Position
Short Cut xx.xx Inches
Store settings for the jobs you’ll
need most often as one of your
Press the ENTER key to install the interval.
cutter’s 5 programs. Both variable
and fixed programs can be stored Fixed Set Store This Set?
in your cutter’s memory. Installed 1=No 2=Yes

6. At the display prompt, press 1 to not store the positions. (Unstored positions are
deleted when cutter power is interrupted or switched off.) After this selection, the
back gauge moves to the first cutting position. Verify the positions by pressing the
NEXT key. To return the back gauge to the first operating position, press the CE
key followed by the ENTER key.
7. Press 2 to store this program in your PowerLine’s memory, where it will remain
until you alter it.
Set Number (1-5)?
To Be Updated ___

8. Your PowerLine Cutter can store up to five (1 - 5) programmed cutting sequences.

Press the appropriate number on the keypad to store this set.
Programmed Set
Number x Updated

9. The back gauge moves to the initial cutting position and the cutter changes to the
automatic mode. You may begin to cut.

6.4.2 Programming Variable Back Gauge Positions

Variable cutting programs are useful for cutting a series of non-identical stacks from a
larger stack. A variable cutting program moves the back gauge toward or away from the
cut line in intervals that you program according to the following instructions:

1. Activate the cutter by turning the ON/OFF toggle switch and key switch to the on
position. Answer the false clamp prompt.
2. After the back gauge Position and Speed are displayed, press the SETUP key to
change to the automatic mode.
Define a New Set of Positions Choose Type of Set 1=Fixed
2-Variable

3. Press 2 on the keypad.

Variable cutting programs start at a
programmed point and move the
back gauge by varying intervals
after each cut.
4.
Position 1?
Enter Value or Jog
At the display prompt, select either 1) the running method or 2) the key entry
method. If you select running method, press the jog keys to move the back gauge
to the required first cutting position. Press the ENTER key to install the current
position.

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 PowerLine Operating Instructions

Position 1 Position 2?
Installed Enter Value or Jog

Repeat this procedure for up to ten entries. If you select the key entry method, press
the numerical and decimal point keys to enter the first position. Press the ENTER
key to install the position.
Position 1
Installed

Repeat this procedure for up to ten entries.

In either running method or key entry, press the ENTER key to end the entry proce-
dure (if less than ten positions are desired).
Variable Set Installed Store This Set?
1=No 2=Yes

5.
Short Cut
Store settings for the jobs you’ll
need most often as one of your
cutter’s 5 programs. Both variable
and fixed programs can be stored
in your cutter’s memory.
6.
At the display prompt, press 1 to not store the positions. (Unstored positions are
deleted when cutter power is switched off.) After this selection, the back gauge will
move to the first cutting position. Verify the positions by pressing the Next key. To
return the back gauge to the first operating position, press the CE key followed by
the ENTER key.
Press 2 to store this program in your PowerLine’s memory, where it will remain
until you alter it.
Set Number (1-5)
To Be Updated ___

7. Your PowerLine Cutter can store up to five (1 - 5) programmed cutting sequences.

Press the appropriate number on the keypad to store this set.
Programmed Set Number x
Updated

8. The back gauge moves to the initial cutting position and the cutter changes to the
automatic mode. You may begin to cut.

7.0 Maintenance
WARNING! This machine contains a powered cutting knife which can
cause serious or even fatal injury. Never connect power to the machine
until you are ready to set up and operate the electric cutter. To prevent
injury, never place hands or arms under the cutting blade, do not operate
the machine with any covers removed or safety features disabled, and cut
only paper materials. Before attempting any maintenance procedure, be
sure power is disconnected and locked out.
7.1 Blade Removal
WARNING! The cutting blade is extremely sharp. Serious bodily harm
can result from mishandling.

NOTE: To prevent dulling the knife, do not let the knife edge contact any
surface except the cutting stick or blade carrier.

1. Activate machine power. Lower the cutting blade as if you are cutting paper. Turn
off the ON/OFF toggle switch when the blade contacts the cutting stick. Turn the
key switch to the OFF position (key vertical).
2. Remove the far right blade retaining screw.

CAUTION: Do not operate the blade or clamp with the blade holder tools
1 attached to the blade. Extensive equipment damage can occur.

12
 PowerLine Operating Instructions
3. Turn the ON/OFF toggle switch and key switch to the “ON” position so that the
blade and clamp will return to the up position. Turn the key switch to the OFF
position (key vertical). Remove the two center blade retaining screws. Install and
securely tighten the blade holder tools .

WARNING! When you loosen the blade holder tools, the blade will be free
to fall from the carrier. Make sure your have a firm grip on the blade hold-
er tools.

4. Loosen the remaining blade retaining screws. Slightly loosen the blade holder tools
slightly and carefully lower the blade from the blade carrier.
5. Move the blade to the right side and pull the left side of the blade toward the front
of the machine. Now remove the right side of the blade.
6. Secure the blade so the sharp edge will not be exposed and remove the blade holder
tools.
7.2 Blade Installation
WARNING! The cutting blade is extremely sharp. Serious bodily harm
can result from mishandling.

NOTE: To prevent dulling the knife, do not let the knife edge contact any
surface except the cutting stick or blade carrier. A newly sharpened or new
blade will require adjustment for proper cutting, see Section 7.3.

1. Turn the ON/OFF toggle switch and key switch off (key vertical).
2. Install the blade holders in the two center blade mounting holes so that 1/4" to
5/16"(1) of thread is visible between the blade and blade holder.
3. Lifting with the blade holders, carefully place the blade into the blade carrier and
securely tighten the blade holders.
4. Starting from the left end of the blade, insert and tighten two of the five blade
screws. Remove the blade holder tools and install and tighten the two blade retain-
ing screws in their place. To insert the far right blade screw, turn the ON/OFF tog-
gle switch and key switch on. Lower the blade using the blade switches, turn the
1 ON/OFF toggle switch and key switch off (key vertical) when the blade reaches a
position low enough to access the remaining blade screw hole. Insert and tighten
the remaining screw.
5. Switch the ON/OFF toggle switch and key switch on so that the blade will travel to
the up position.
7.3 Blade Adjustment
NOTE: When properly adjusted, the entire length of the blade should cut
cleanly through the last sheet of the stack. How deeply the blade indents the
cutting stick depends on blade condition. Remember to adjust the blade
position only to the depth needed to cut cleanly through the last sheet of the
stack.
WARNING! The blade must be adjusted so the cutting edge is above the
bottom edge of the clamp when both are in the full-up position.
1
Due to normal blade wear, sharpening, or blade replacement it will be necessary to
adjust the blade position. Blade adjustments control height and levelness.

There are three areas where the adjustments are made. (1) The blade screw holes in the
blade carrier are slotted so the blade can be move up/down in the carrier. (2) The blade
height adjustment is accessible through the right side chassis panel. (3) The leveling
adjustment set screws located in the top of the blade carrier. The following procedure
2 includes the removal of the shroud and complete adjustment of the blade.

13
 PowerLine Operating Instructions

WARNING! The cutting blade is extremely sharp. Serious bodily harm

can result from mishandling.

1. Disconnect power and remove the shroud.

A. Remove the two thumb knobs. One is at the bottom of the keyboard con-
trol panel. The other is located on the left front shroud.
B. Remove the two screws at the bottom rear of the shroud.
C. Remove the two screws from the top rear of the keyboard control panel.
3 Separate the control panel from the shroud and carefully disconnect (pull)
the ribbon cables (1) from the rear of the keyboard control panel. Feed the
cables through the hole in the shroud.
D. Slide the shroud toward the front of the machine so the ready light is sepa-
rated from the shroud.
E. Lift the shroud and rear safety cover from the electric cutter. Carefully
reconnect the cables to the rear of the keyboard control panel.
2. Make sure the blade is in the highest position (top of blade carrier slots). If neces-
sary, install and tighten the blade holders as instructed in Sections 7.1 & 7.2.
Loosen the blade retaining screws and move the blade to the top of the slot. (The
blade must be lowered to access the far right blade screw.) Retighten the blade
retaining screws. Remove the blade holders and install and tighten the two blade
retaining screws in their place.
1 3. With the blade in the up position, measure the distance from the top of the blade
carrier to the cutting stick. The distance should be 9 3/8". If necessary, adjust the
blade adjustment screw (accessible through the right side chassis panel) until the
distance is correct.
4. Activate power, lower the blade to the lowest cutting position and turn off the
On/Off toggle switch. Again measure from the top of the blade carrier to the cutting
stick. The distance should be 6 1/16". If necessary, raise the blade to its highest
position in the carrier and repeat step 4.
5. Place a 1/4" stack of paper over the entire length of the cutting stick and initiate the
cutting cycle. If the blade cuts evenly through the last sheet of paper and just
slightly into the cutting stick, no further adjustment is necessary. If the last sheet is
not cut evenly through, proceed as follows:
A. Loosen the blade retaining screws so they securely hold the blade in posi-
tion, but will allow movement when turning the blade leveling set screws.
B. Adjust the blade leveling set screws clockwise in 1/4 turn increments and
test cut until the bottom sheet of paper is cleanly cut with the blade cutting
slightly into the cutting stick. If the blade cannot be adjusted for a correct
cut using the blade leveling set screws, slide the blade to a lower position
in the blade carrier slots and repeat the leveling adjustment.
6. After the blade has been adjusted for a correct cut, disconnect power and remove
the front deck.
7. Inspect the trunnion gears on the blade adjustment shaft to ensure the gears are
meshing in the center. If necessary, adjust the shaft collars to obtain the proper gear
mesh.
8. Reinstall the front deck and carefully disconnect (pull) the cable from the rear of
the keyboard control panel.
9. Reinstall the shroud, carefully feeding the cable through the hole in the shroud.
10. Carefully reconnect the cable to the rear of the keyboard control panel and mount it
onto the shroud.
11. Reinstall the thumb screws and rear deck screws to secure the shroud.

NOTE: The bottom edge of the clamp should always be approximately

1/8" lower than the sharp edge of the blade.

7.4 Clamp Height Adjustment

14
 PowerLine Operating Instructions

WARNING! The cutting blade is extremely sharp. Serious bodily harm

can result from mishandling.

The paper clamp height should be adjusted so the bottom of the paper clamp is always
approximately 1/8" below the blade edge when both are in the maximum “up” position.
To adjust the clamp height: lower the paper clamp (only). Loosen the two hex key but-
tonhead screws on the paper clamp limit switch bracket.

Note: The slotted screw hole in the bracket allows vertical adjustment.

If the clamp is above the bottom (sharp edge) of the blade, lower the clamp limit switch
bracket slightly and tighten the bracket retaining screws. Raise the clamp and check.
Repeat until the clamp is approximately 1/8" below the blade. If the clamp is too far
below the edge of the blade, raise the paper clamp limit switch bracket. Check clamp
height and repeat, if necessary.

Note: Always securely tighten the bracket retaining screws.

7.5 Cutting Stick Rotation

The design of the PowerLine cutting stick allows rotation to eight cutting locations.
(The stick may be rotated to four surfaces and reversed from end to end.) To rotate the
stick proceed as follows:
1. Turn off power to the cutter and raise the front cover. Turn the key switch to the
off position (key vertical).
2. Carefully lift up one end of the cutting stick.
3. Place a flat tipped screwdriver under the raised end of the cutting stick and slide it
under the length of the stick to completely remove it from the channel.
4. Rotate the stick to a new surface and place it back into the channel. When all four
surfaces have been used, reverse the stick end to end and repeat the rotation process
as needed. Replace the stick when a correctly adjusted new, or resharpened blade
will no longer cut completely through the bottom sheet of a stack.

7.6 Back Gauge Squaring Adjustment

If the cutting distance is not within 1/64" from one end of the back gauge to the other,
proceed as follows:
1. Loosen the hex head bolt that secures the back gauge to the slider block (top rear
center of the back gauge).
2. Loosen or tighten the socket head screws on the rear side of the back gauge as fol-
lows:
A. Cut paper at each end of the back gauge to determine which end needs to
move closer to the cutting area. Slightly loosen the socket head screw on
the corresponding side. Slightly tighten the socket head screw on the oppo-
site side.
B. Recheck the back gauge squareness by cutting paper positioned at each
end of the back gauge.
C. Repeat the adjustment as necessary and retighten the hex head bolt.

7.7 Back Gauge Slider Block Adjustment

1. Position the back gauge to approximately 20".
2. Turn off power by turning the key switch to off (key vertical) and unplug the power
cord from the power outlet.
3. Remove the lower rear cover. First move the screws/nuts joining the lower front
and rear covers. Then remove the cross point screws that secure the lower rear
cover to the chassis. Allow the lower rear cover to drop until it clears the lower
front cover. Pull the lower rear cover forward and set it aside.

15
 PowerLine Operating Instructions

4. There are four screws that secure the nut plate assembly to the front of the slider
block. The bottom 2 screws are socket head cap screws, one of which also secures a
lock washer. The top 2 are cross point screws. Loosen only the cap screw with the
lock washer.
5. The adjustment system is a push/pull arrangement that features Two hex socket
screws extend approximately 1/4" from the side of the block. The other two screws
extend through the block and are secured by two nuts. Slightly loosen the front
socket head cap screw that extends from the side of the slider block. Slightly tight-
en the other front socket head cap screw that is threaded into the opposite side of
the slider block. Tighten the screw until a slight resistance/bind is felt when manu-
ally moving the back gauge. Next, slightly loosen the rear socket head cap screw
that extends from the side of the slider block. Slightly tighten the other rear socket
head cap screw that is threaded into the opposite side of the slider block to obtain
smooth movement of the back gauge with no binding. Verify that the back gauge
end play is minimal.
6. Retighten the cap screw on the slider block nut plate.
7. Slowly operate the back gauge the full length of travel. Verify that the back gauge
does not bind or stall. Repeat the slider block adjustment if necessary.
8. Reinstall the lower rear cover.
9. Reapply power to the cutter.

7.8 Back Gauge Calibration

The location of the back gauge is referenced from the “Home” position. “Home” posi-
tion is determined during the homing cycle when the homing flag (located on the back
gauge slider block, pg.28) enters and activates the homing sensor (mounted at the rear
of the chassis). When this happens, the read-out is reset to 26.00” on the Model 2650
and 21.00” on the Model 2150. If the back gauge is not at this distance from the cut
point (blade), all cuts made will be off the same amount. To calibrate the back gauge,
proceed as follows:
1. Determine if the stock is being cut too short or too long. If the cut is too short, the
“Home” flag must be moved toward the cutting blade. If the cut is too long, the
“Home” flag must be moved away from the cutting blade. Determine the exact dis-
tance the cut is off. This is the distance the home flag will need to move.
2. Position the back gauge to approximately 20”.
3. Switch the ON/OFF toggle switch, located in the left switch panel, to the OFF posi-
tion. Turn the key lock switch, located in the right switch panel, to the OFF
(Vertical) position.
4. Remove the lower rear cover. First remove the screws and nuts joining the lower
covers. Next remove the six screws that secure the cover to the chassis. Lower the
rear cover and set it aside.
5. Mark the initial position of the “Home” flag on the side of the slider block for ref-
erence. Slightly loosen the two screws that hold the “Home” flag to the slider
block. Slide the “Home” flag the direction and distance determined in step 1.
Retighten the “Home” flag screws.
6. Switch the ON/OFF toggle switch to the ON position. Answer the prompts so that
the back gauge will go to the “Home” position.
7. Check the accuracy of the adjustment by cutting a sheet of paper and precisely
measuring the cut sheet. The cut length should be within .01” of the back gauge
position (reading). If not repeat this procedure starting with step 1.
NOTE: The back gauge must be “Homed” each time the “Home” flag is
moved by turning the power OFF and ON.
8. When the correct calibration is achieved, re-install the lower rear cover and return
the machine to operation.

7.9 Lubrication
The mechanical components of the cutter require periodic lubrication depending upon

16

8.0 Error Codes
If a problem develops, error
codes help you analyze what
the problem is!
9.0 Diagnostic Tests
Diagnostic Test 1
PowerLine Operating Instructions
cutter use. A 30W oil, lithium-based grease, and 90W gear oil are the recommended
lubricants. Grease points should be cleaned and lightly recoated. Screws, pivot points,
and Oilite® bearings should be cleaned and lightly oiled. The gear box should be
drained and refilled.
Heavy use is 8,000 or more cutting cycles per week. Moderate use is 4,000 - 8,000
cutting cycles per week.This schedule is based on heavy use.
Part Frequency Lubricant
Tower Rails (1) Every blade change/monthly grease
Clamp drive screw (2) Every blade change/bi-monthly 30W oil
Clamp thrust bearing (3) Annually grease
Clamp gear lever pivot pin (4) Every blade change/monthly 30W oil
Clamp guides (5) Every blade change grease
Crank gear/Gear box gear (6) Bi-monthly grease
Gear box (7) Annually 90W oil
Back gauge Acme screw (8) Monthly 30W oil
All Oilite® bearings (9) Annually 30W oil
Limit switch bracket pivot pts. (10) Annually 30W oil
If the machine control circuitry senses a malfunction, a numerical error code is dis-
played on the keyboard control panel. There are seven possible error codes. If an error
code is displayed, it may be helpful to use the resident diagnostic tests. The tests are
explained in Section 10.
Error Code 10 (err 10) No detection of the back gauge home flag.
Error Code 11 (err 11) The back gauge position is too far positive.
Error Code 12 (err 12) The back gauge position is too far negative.
Error Code 19 (err 19) No detection of the encoder disk pulses.
Error Code 30 (err 30) Indicates a data verification error in the non-volatile
memory of the control circuitry.
Error Code 31 (err 31) Indicates a data access error in the non-volatile
memory of the control circuitry.
The electric cutter program provides 9 diagnostic tests to assist in analyzing back gauge
performance.
NOTE: These tests should only be performed by a qualified service techni-
cian.
There are two ways to initiate diagnostic tests. The most convenient is to press the
SETUP key as you activate power to the machine. (An alternate method is to remove
the front deck and press the small push button located in the center of the main logic
board.) In either case, the keyboard control panel will display:
Diagnostics Tests
Depress 1-9
To enter a particular test, press the corresponding numerical key for that test. Stop any
test by pressing the STOP key. Press the UNDO key to return to the diagnostic entry
screen. To exit the diagnostic test mode, press UNDO a second time.
NOTE: Perform this test only when you suspect a memory error has
17
 PowerLine Operating Instructions

occurred. The actual memory values can be obtained from Martin Yale
Technical Assistance (1-800-845-4011).

Use this test to view the values stored in the non-volatile memory RAM (Random
Access Memory). Press the SHORTER key to step through the value of each memory
location.
1-Non Volatile xx FF
Ram Test Address Value

The data display is in the hexadecimal format. The display shows the address (the loca-
tion in memory), and the value (the data stored in the selected address).

Diagnostic Test 2
2-Inputs and SW Blde Clamp
Keypad Test 0 0 0

Use this test to check the functionality of the keypad keys, the clamp and blade sensor
and the small push button switch on the main logic board. To test the keypad, press
each key, except the UNDO, one at a time. The display should report the key that was
depressed.

Diagnostic Test 3
3-Manual Movement Mode Key to Change
of Back Gauge Movement Mode

Use this test to check the functionality of the back gauge motors and the movement of
the back gauge. While in this test press the MODE key to select AC motor only, stepper
motor only, or both motors.
Use the Jog Keys AC Motor
to Run the Motors Only

WARNING! During this test, the system does not automatically switch to
slow speed when it gets “close” to either end of the drive shaft. Use cau-
tion when moving the back gauge at high speed to prevent a damaging
collision.
The stepper motor moves the back gauge at slow speed. The LONGER and SHORTER
keys move the back gauge in the direction selected.

Diagnostic Test 4
4-Stepper Motor Home Current Phase
System Test xx xx xx

This test checks the functionality of the stepper motor and the back gauge home flag
sensor. The keyboard control display will show: The Home value will be 1 only when
the home sensor is blocked by the back gauge flag. The Current value changes with dif-
ferent power level selections. (The stepper motor can be enabled at three different power
levels, 1/3, 2/3, or full power.) The Phase value changes as the motor turns.

The following keys are used in this test:

1 Key Sets the stepper motor power The current value should be 10.
level to 1/3.
2 Key Sets the stepper motor power The current value should be 01.
level to 2/3.
3 Key Sets the stepper motor power The current value should be 00.
level to full.
4 Key Each press single steps the
back gauge away from the blade.

18
 PowerLine Operating Instructions

5 Key Each press single steps the

back gauge toward the blade
RUN Key Turns the fast motor to move
away from the blade.
STOP Key Turns off the fast motor and The current value should be 11.
the stepper motor.
MODE Key The slow motor moves the When Home position is
back gauge away from the reached, the Home value
blade to the Home position. should be 1 and the Current
value should be 11.

Diagnostic Test 5
5-Define Start Start Position?
Position _._ _

This test is used to define the back gauge limit positions. The prompt will guide you
through this procedure. The start position is always 1.37". The home position will be
21.00" for model PL2150 and 26.00" for model PL2650.

Diagnostic Test 6
6-Internal xx xx
Ram Test Address Value

Checks memory values and is beyond the scope of the maintenance procedure.

Diagnostic Test 7
This test performs a back gauge cycle test for functionality. The back gauge automati-
cally moves through the following positions: 26.00 (Home for 26" EC); 21.00 (Home
for 21" EC); 16.00; 11.00; 6.00; 1.37; 6.00; 11.00; 16.00; 21.00 (Home for 21" EC);
26.00 (Home for 26" EC).
7-Cycle Cycle Count xx:xx
Back Gauge Position xx:xx

To pause or stop the test, press the STOP key to stop the test. Press the SPEED key to
restart the test. Press the UNDO key to return the system to the diagnostic entry screen.

Diagnostic Test 8
This test allows the selection of one of five languages and the units of measure. The
default language of the back gauge programmable controller is English. The default for
movement of the back gauge and subsequent readout is in inches. To change either, see
Section 5.0.

Diagnostic Test 9
This test checks the alignment of the encoder disk and measures the duty cycle of each
channel used by the encoder circuitry. To begin the test, position the back gauge
approximately 3" from the blade using the LONGER and SHORTER keys as required.

9-Encoder Auto Measure

Alignment Test Depress Speed Key

Press the SPEED key to start the test. The slow motor moves the back gauge further
away from the blade. The system samples a measurement every 1/2 second while the
motor runs. If an error is detected during the measurements, the test stops and the dis -
play shows the message:
Alignment Error
Number x

X represents an error number (1-5). Error messages 1 - 4 identify a problem with the

19
 PowerLine Operating Instructions
detection of encoder disk teeth. Error message 5 identifies an encoder disk direction of
rotation error.

At the end of a measurement, the duty cycle of channel 1 and 2 is displayed as well as
their phase relationship. The display shows the message:
D1 D2 Phase
xx% xx% .xx

NOTE: The test will stop if the “Home” position is sensed.

The following keys are functional during this test:

STOP Turns off the motor.
1 Re-displays the entire message.
2 Displays the duty cycle of channel 2.
3 Displays the phase difference between channel 1 and 2.

10.0 Troubleshooting
Following is a list of possible problems and their recommended solutions. If you
encounter a problem not on the list or if the recommended solution does not solve the
problem, contact Martin Yale for technical assistance (1-800-845-4011).

Problem Solutions
1. The bottom sheet of a paper Rotate the cutting stick. Check the blade
stack is not cut. adjustment. Make sure the blade cuts slightly
into the cutting stick. Sharpen or replace the
blade. (See Sections 7.)
2. The bottom sheets of paper Check the blade adjustment. Make sure it
are only partially cut. is level and cuts slightly into the cutting
stick. Check the cutting stick to make sure
it is not bowed. (See Section 7.)
3. The electric cutter will not Make sure the power cord is plugged into
power up. a 20 Amp (NEMA #6-20R) receptacle. Check
the 2A (F1) input power fuse. Replace, if
necessary. Check the key switch to make sure
it is in the on position. (See Section 4.)
4. The blade will not operate. Reset the 12 Amp circuit breaker. Check
to make sure the key switch is in the on
position. Make sure both blade switches are
being pressed at the same time. Press the
reset button and make sure the ready light
is on. Make sure the back gauge is not
moving. (See Sections 2, 3, 4, 6.)
5. The clamp will not operate. Reset the 7 amp circuit breaker. Make sure the
key switch is in the on position. Press the
reset button and make sure the key switch is
in the on position. Make sure both clamp
switches are being pressed at the same time.
Press the reset button and check to make sure
the ready light is on. Make sure the back gauge
is not moving. (See Sections 3 & 6.)
6. The ready light is not on. Press the reset button. Make sure the back
gauge is not moving. (See Section 2, 3, & 6.)

20
 PowerLine Operating Instructions

7. The blade stalls. The blade is dull. Sharpen the blade. The
dull blade may have caused the thermal
protection of the blade drive motor to stop
the motor, Make sure the blade drive cooling
fan is operating. (See Sections 6 & 7.)
8. The clamp will not raise Too much paper has been loaded which
after the first cut. has disabled the upper clamp limit switch.
(See Section 6.)
9. No cutting line. Make sure power is on. Check the 2 Amp
fuse (F1). Replace, if necessary. Check the
circuit breaker and reset, if necessary. Check
the light bulbs and replace, if necessary.
(See Sections 2, 4, 6, & 7.)
10. The back gauge won’t move Check the blade limit switches. Reset, if
in the fast mode. necessary. Check the 2 Amp Slo Blo® back
gauge fuse (F2) and replace, if necessary.
Run diagnostic test 3. (See Sections 2, 3, 5,
6, & 9.)
11. The back gauge will not Check the 7 Amp circuit breaker and reset,
move. if necessary. Check the 2 Amp Slo Blo®
back gauge fuse (F2) and replace, if necessary.
Run diagnostic tests 4 and 7. (See Sections
3, 5, 6, & 9.)
12. An error code 10 (err 10) The back gauge home flag is not entering the
is displayed. sensor. Reset the 7 ampere circuit breaker;
run diagnostic test 4. (See Sections 3, 5, 6, &
9.)
13. An error code 19 (err 19) The back gauge is not moving. Check the
is displayed. 7 ampere circuit breaker and reset, if neces-
sary. Run diagnostic tests 4, 7, and 9. (See
Sections 3, 5, 6, & 9.)

21
 PowerLine Operating Instructions

Fraction to Decimal Conversion Chart

Fraction Decimals Millimeters Fraction Decimal Millimeters
1/64 .0156 .3969 33/64 .5156 13.0969
1/32 .0313 .7938 17/32 .5313 13.4938
3/64 .0469 1.1906 35/64 .5499 13.8906
1/16 .0625 1.5875 9/16 .5625 14.2875
5/64 .0781 1.9844 37/64 .5781 14.6844
3/32 .0938 2.3813 19/32 .5938 15.0813
7/64 .1094 2.7781 39/64 .6094 15.4781
1/8 .125 3.1750 5/8 .625 15.8750
9/64 .1406 3.5719 41/64 .6406 16.2719
5/32 .1563 3.9688 21/32 .6563 16.6688
11/64 .1719 4.3656 43/64 .6719 17.0656
3/16 .1875 4.7625 11/16 .6875 17.4625
13/64 .2031 5.1594 45/64 .7031 17.8594
7/32 .2188 5.5563 23/32 .7188 18.2563
15/64 .2344 5.9531 47/64 .7344 18.6531
1/4 .250 6.3500 3/4 .750 19.0500
17/64 .2656 6.7469 49/64 .7656 19.4469
9/32 .2813 7.1438 25/32 .7813 19.8438
19/64 .2969 7.5406 51/64 .7969 20.2406
5/16 .3125 7.9375 13/16 .8125 20.6375
21/64 .3281 8.3344 53/64 .8281 21.0344
11/32 .3438 8.7313 27/32 .8438 21.4313
23/64 .3594 9.1281 55/64 .8594 21.8281
3/8 .375 9.5250 7/8 .875 22.2250
25/64 .3906 9.9219 57/64 .8906 22.6219
13/32 .4063 10.3188 29/32 .9063 23.0188
27/64 .4219 10.7156 59/64 .9219 23.4156
7/16 .4375 11.1125 15/16 .9375 23.8125
29/64 .4531 11.5094 61/64 .9531 24.2094
15/32 .4688 11.9063 31/32 .9688 24.6063
31/64 .4844 12.3031 63/64 .9844 25.0031
1/2 .500 12.7000 1 1.00 25.400

22
 PowerLine Operating Instructions

Cutter Assembly

Item Part Number Qty. Description Item Part Number Qty. Description
1. M-O210084 1 Cutting Stick (21" EC) 11. M-O210247 1 Front Safety Cover Panel
M-O260084 1 Cutting Stick (26" EC) M-O260247 1 Front Safety Cover Panel
2. W-O210160 1 Housing (21" EC) 12. W-O260245 1 Left End Cover
W-O260160 1 Housing (26" EC) 13. W-O260246 1 Right End Cover
3. W-O210086 1 Left Rear Deck (21" EC)
W-O260086 1 Left Rear Deck (26" EC)
4. W-O210101 1 Back gauge (21" EC) Not Illustrated:
W-O260101 1 Back gauge (26" EC) M-S033009 1 Front Safety Cover
5. W-A210164 1 Rear Safety Cover Assy Interlock Switch
(21" EC) M-S030046 2 Bumper
W-A260164 1 Rear Safety Cover W-O260251 2 Bumper Bracket
Assy (26" EC) W-O260244 1 Switch Cover
6. W-O210087 1 Right Rear Deck (21" EC) W-O260243 1 Brake Cover
W-O260087 1 Right Rear Deck (26" EC)
7. W-O260155 1 Control Box
8. M-S037048 4 Leg Leveler
9. M-S006003 4 5/16-181 3/4" Carriage Bolt
M-S007002 4 Acorn Nut

10. W-O210085 1 Front Deck (21" EC)

W-O260085 1 Front Deck (26" EC)

23
 PowerLine Operating Instructions

Control Panels

Item Part Number Qty. Description

1. M-S033006 1 On/Off Toggle Switch,
220VAC
2. M-S033002 3 Momentary Push button
Switch
3. M-S033022 1 Momentary Push button
Switch
4. M-O260090 1 Left Control Panel Housing
5. M-O260091 1 Right Control Panel
Housing
6. M-S045084 1 Keylock Switch

T-Frame Assembly
Item Part Number Qty. Description
1. M-S006011 4 3/8"-16x3 1/2” Bolt
2. M-S003034 2 1/4"-20x1 1/4" Hex Hd Bolt
M-S008010 2 1/4"ID Split Lock Washer
3. W-O210014 1 Tower Tie Bar (21" EC)
W-O260014 1 Tower Tie Bar (26" EC)
4. W-A260022 1 Right Rear Tower Ass’y
5. W-A260020 1 Right Front Tower
6. W-I210092 1 Rear Deck Spacer (21")
W-I260092 1 Rear Deck Spacer (26")
7. W-I210093 1 Front Deck Spacer (21")
W-I260093 1 Front Deck Spacer (26")
8. W-O260043 4 1” OD X 1.937” Spacer
9. W-O260257 8 Gib Adjuster
10. W-O260019 1 Left Front Tower
11. W-G260256 2 Gib Plate
12. M-S018031 8 1/4"x1" Dowel Pin
13. M-S006009 12 3/8"-16x1" Hex Hd Bolt
M-S008003 16 3/8" USS Split Lock Washer
14. W-W210015 1 T-Frame Base (21")
W-W260015 1 T-Frame base (26")
15. W-O260258 4 Tower Rail
16. M-S003015 16 5/16-18 X 3/4 Socket H.D.Screw
17. W-A260021 1 Left Rear Tower Ass’y

24
 PowerLine Operating Instructions

Clamp Drive, Front View

Item Part Number Qty. Description
1. W-O260050 1 Right Clamp Lever Link Arm
2. W-A260175 1 Left Clamp Lever Assy
3. W-O260057 1 Clamp Drive Shaft
4. ——- 1 Upper Bearing Mount
M-S020001 1 30mm Ball Thrust Bearing
M-S048010 1 Grease Fitting
M-S010002 2 5100-37 Retaining Ring
M-S011001 1 3/16"x1 1/2" Key
M-S010035 1 Internal Retaining Ring
M-S001084 1 4-40x5/16 Phil Pan Head Screw
W-O260056 1 Thrust Washer
5. W-A260058 1 Lower Bearing Assy
M-S013021 1 Oilite Bearing
W-O260058 1 Lower Bearing Mount
6. W-O260173 1 Clamp Sensor Bracket
M-S045170 1 Clamp Sensor
7. W-A260255 1 Right Clamp Lever Ass’y
8. W-O260254 1 Right Link Arm
9. W-O260253 1 Eccentric Bushing

Not Illustrated
W-O260066 2 Clamp Lever Bushing

Clamp Drive, Rear View

Item Part Number Qty. Description
1. M-S021009 1 Clamp Drive Motor
M-S011004 1 1/8" x 1" Key
2. W-O260077 1 12L Clamp Motor Pulley
3. M-S025003 1 300XL100 Timing Belt
4. W-O260076 1 Drive Screw Collar
M-S002007 2 10-32x3/16 Set Screw
5. W-A260071 1 Clamp Pulley Assy
M-S003004 2 1/4"-20x1/2" Hex Hd Screw
M-S008029 2 1/4"ID Internal Lock Washer
M-S63751051 2 1/4"-20x1/2" Button Hd Screw
W-N260071 1 36L Pulley
W-O260068 1 Lower Pulley Hub Assy
W-O260072 1 36L Innter Pulley Hub
W-O260074 1 Upper Pulley Flange
W-O260075 2 Bumper
6. M-S037061 1 Fan Blade
7. M-S021014 1 Cooling Fan Motor, 230VAC
8. W-A210061 1 Clamp Assy (21" EC)
W-A260061 1 Clamp Assy (26" EC)
9. M-S045130 1 220V, 15lb Brake

Not Illustrated
W-O260252 1 Clamp Fan Motor Bracket

25
 PowerLine Operating Instructions

Blade Drive Assembly,

Front View

Item Part Number Qty. Description Item Part Number Qty. Description
1. W-O260185 2 Cut Line Lamp Bracket 20. M-S033012 2 Microswitch, Single Pole
M-S045146 2 Lamp Socket 21. M-S031013 3 Extension Spring
M-S045148 2 1141 Lamp 22. M-S033011 1 Microswitch, Double Pole
2. W-O260154 1 Ready Light Bracket Staggered
M-S045141 1 Ready Light, Amber 23. M-S022085 1 50T Aluminum Pulley
3. W-A210029 1 Blade Carrier Assy (21" EC) 24. M-S025008 1 144XL037 Timing Belt
W-A260029 1 Blade Carrier Assy (26" EC) 25. M-S037370 1 Motor Fan
4. M-S003006 5 7/16"-14x5/8" Socket 26. W-O260051 1 Clamp Limit Switch Bracket
Head Cap Screw M-S033009 1 Clamp Limit Switch
5. M-O210031 1 Knife (21" EC) 29. W-A260039 1 Short Trunnion Assy
M-O260031 1 Knife (26" EC)
6. W-A260032 2 Carrier Link Assy Not Illustrated
7. W-A260030 2 Bell Lever Assy M-S022086 1 44T Timing Pulley
8. W-A260042 1 Trunnion Adjustment Shaft (Back gauge)
9. M-O820584 3 1/2"ID Shaft Collar W-O260121 1 60T Timing Pulley
10. M-S031015 1 Compression Spring (Back gauge)
11. W-A260178 1 220VAC Back gauge Motor M-S025010 1 210XL037 Timing Belt
Assy (Back gauge)
12. W-O260040 1 Push Pull Shaft Assy (26” EC) W-O911029 1 Encoder Disc Assy
W-O210040 1 Push Pull Shaft Assy (21” EC) M-O911100 1 Encoder PC Board
13. W-A260136 1 60x15 Pulley Assy M-S025022 1 106T, 80P Timing Belt
14. M-S025007 1 230XL037 Timing Belt M-S022028 1 12T Pulley
15. W-A260145 1 Stepper Motor Assy W-A260147 1 Encoder Cable Assy
16. W-O260129 1 Lever, Right M-S021014 1 Cooling Fan Motor, 230VAC
17. W-A260038 1 Long Trunnion Assy M-S037061 1 Fan Blade
18. W-O260123 2 Lever, Left
19. W-A260036 1 Crank Gear Assy

26
 PowerLine Operating Instructions

Blade Drive Assembly, Rear View

Item Part Number Qty. Description
1. M-S002058 3 1/4"-20x1 1/2"
Set Screw
2. M-O260132 1 Gear Box, 40:1
3. M-S021010 1 Blade Drive Motor,
220VAC
4. M-S045130 1 220V, 15LB. Brake
5. W-O260113 1 Bearing Hub
M-S020002 1 Bearing
6. W-O260024 4 Blade Carrier Roller

Not Illustrated
M-S022084 1 18T, 8P Steel Spur Gear
W-A260170 2 Knife Holder Tool

Electric Component
Panel

Item Part Number Qty. Description

1. M-O210096 1 Electrical
Component Panel (21" EC)
M-O260096 1 Electrical
Component Panel (26" EC)
2. M-S045144 4 Contactor
M-S045145 5 Auxiliary Contactor
3. M-S045098 1 2 Amp Slow Blow Fuse, (F1), Main
M-S045065 1 Fuse Holder
4. M-S045098 1 2 Amp Slow Blow Fuse, (F2), Back gauge
M-S045065 1 Fuse Holder
5. W-A260144 1 220V Transformer Assy, Control
6. W-A260143 1 220V Transformer Assy, Back gauge (26VAC)
7. M-S033039 5 5 Position Terminal Block
8. M-S045102 1 8ufd Capacitor
9. M-O260142 1 Relay Board
10. M-S045142 1 7 Amp Circuit Breaker
12. M-S045143 1 12 Amp Circuit Breaker
13. M-O850421 1 25mfd 440V Capacitor, clamp
14. M-S045050 1 DC Rectifier
15. M-S045154 2 Filter
16. W-A260180 1 220V Transformer Assy, Back gauge (13VAC)

27
 PowerLine Operating Instructions

Back Gauge Drive Assembly, Top View

Item Part Number Qty. Description
1. W-O210111 1 Acme Drive Screw (21" EC)
W-O260111 1 Acme Drive Screw (26" EC)
2. M-O260120 1 Shock Mount Bushing
3. W-A260146 1 Optical Switch Assy
4. M-S033007 2 Microswitch
5. W-O260108 1 Flag
6. W-O260106 1 Front Mounting Plate
7. M-S020002 1 Bearing
8. M-S025008 1 144XL037 Timing Belt
9. M-O260134 1 Idle Stud
10. W-A260178 1 220VAC Back gauge Motor Assy
11. M-S037370 1 Motor Fan
12. W-A260136 1 60x15 Pulley Assy
13. M-S025007 1 230XL037 Timing Belt
14. M-S025010 1 210XL037 Timing Belt
15. M-S022085 1 50T, .375ID Timing Pulley
16. M-S022086 1 44T, .375ID Timing Pulley
17. M-S025022 1 106T, 80P Timing Belt
18. W-A260145 1 Stepper Motor Assy
M-S022027 1 24 XL 037 Timing Pulley
19. M-O911100 1 Encoder PC Board
20. W-A260119 1 Encoder Disc Assy
21. W-O260110 1 Encoder Idler Shaft
22. W-O260121 1 60T Timing Pulley
23. W-O260113 1 Bearing Hub
24. M-S007027 1 5/8-10, 2 Start Acme
Nut
M-S013019 2 Iglide Bearing
25. W-O260104 1 Slider Block
W-O260107 1 Slider Block Nut Plate
W-O260105 1 Rear Plate

Not Illustrated
M-O260140* 1 Main Logic Board
M-O260176 1 Display Cable
M-O260177 1 Control Cable
W-A260147 1 Encoder Cable Assy
W-A260141 1 Keypad Assy
M-O260148 1 Keypad overlay
W-O210100 1 Back gauge Guide Shaft (21" EC)
W-O260100 1 Back gauge Guide Shaft (26" EC)

*The Main Logic Board stepper motor circuit is protected by a 1 Ampere, miniature fuse. For continued protection against fire
hazard, replace only with the same type and rating of fuse: Type 2AG fast blow, 1 Ampere, 250VAC.

28
 PowerLine Operating Instructions

Wiring Diagram 1, Clamp and Blade Motor Section

29
 PowerLine Operating Instructions

Wiring Diagram 2, Clamp and Blade Controls Section

30
 PowerLine Operating Instructions

Wiring Diagram 3, Power Back Gauge Section

31
 PowerLine Operating Instructions

Martin Yale Industries, Inc. • 251 Wedcor Avenue • Wabash, IN 46992

Phone: 260/563-0641 • Fax: 260/563-4575

M-S027021 Rev. 2/02 32