Polar 115 clamp system

[USACUSTOMPAD]

the clamp on one of my polar 115 is sluggish. Only on the way down and only when using the foot pedal. It zips down the first half an hour of the day then starts to slow to the point where it will barely move. We had this problem before and had the whole pump system relaced probably only 18 months ago. the foot pedal system is mechanically correct as far as the plastic cams and everything there goes and im just wondering if anyone has any insight into this problem. Why is it happening and can I fix it without replacing the whole pump again? why is it happening after only 18 months.

 

[Bert van Gompel]

the clamp on one of my polar 115 is sluggish. Only on the way down and only when using the foot pedal. It zips down the first half an hour of the day then starts to slow to the point where it will barely move. We had this problem before and had the whole pump system relaced probably only 18 months ago. the foot pedal system is mechanically correct as far as the plastic cams and everything there goes and im just wondering if anyone has any insight into this problem. Why is it happening and can I fix it without replacing the whole pump again? why is it happening after only 18 months.

What kind of Polar is it EM ED, or what year is the machine?
Because it probably has to do with the oil filter in the hydraulic tank.
If a machine is from after 1995, the filter is likely clogged.

This filter often looks clean on the outside, but if you disassemble it and try to blow or suck through it, you will notice that it is difficult.

The easiest thing is to test the machine without the oil filter.

 

[USACUSTOMPAD]

It is ED, 1999. Where is the filter located? will I have to drain the unit to remove it?

 

[Bert van Gompel]

It is ED, 1999. Where is the filter located? will I have to drain the unit to remove it?

The oil filter is located on the bottom right of the hydraulic box.

 

[USACUSTOMPAD]

cleaned filter (it was already pretty clean) and it's doing the same thing.

 

[Koenig]

Dear, have a look on the attached picture, tried to make it simple and easier for any Tech/non-tech individual. Sluggish clamp movment means, either less pressure or leakage on cylinder or faulty valves.

Try this:
Turn On main motor --> Open hydraulic unit's cover and have a look at the hydraulic unit --> ask operator to press foot padel and have a look if there is any leakge at the valves/main cylinder (Cylnder is behind this Hydraulic unit), --> Now enable cut (because when the cut is enabled all solenoid valves operates and you can observe the leakage. If no leakage is observed, thats great but if there is any leakage, fix that.
but if there is no leakage and still the clamp movement is slow --> Then observe the function of Solenoid valves # 2 & 3 as shown on the attachment.
Note: Going slow up : There is Spring which moves the clamps up and downward movement is clontrolled by hydraulic valves
SLow down movement when only the foot padel is pressed: Check valve # 1 and 2 and adjust using point A Locked screw
Slow down movement when foot padel is not pressed but cut enabling switchs are pressed: Check valve # 2
Less clamping pressure or paper slips when the cutting active: Check Valve # 3

see the leakage at the cyonder :

20260325_145600.mp4

drive.google.com

It would be great if you make a video while performing above sequence, we can directly guide you to the malfunctionig section. Hoping this will help everyone in the forum.

Reagrds

KOENIG

 

[USACUSTOMPAD]

Dear, have a look on the attached picture, tried to make it simple and easier for any Tech/non-tech individual. Sluggish clamp movment means, either less pressure or leakage on cylinder or faulty valves.

Try this:
Turn On main motor --> Open hydraulic unit's cover and have a look at the hydraulic unit --> ask operator to press foot padel and have a look if there is any leakge at the valves/main cylinder (Cylnder is behind this Hydraulic unit), --> Now enable cut (because when the cut is enabled all solenoid valves operates and you can observe the leakage. If no leakage is observed, thats great but if there is any leakage, fix that.
but if there is no leakage and still the clamp movement is slow --> Then observe the function of Solenoid valves # 2 & 3 as shown on the attachment.
Note: Going slow up : There is Spring which moves the clamps up and downward movement is clontrolled by hydraulic valves
SLow down movement when only the foot padel is pressed: Check valve # 1 and 2 and adjust using point A Locked screw
Slow down movement when foot padel is not pressed but cut enabling switchs are pressed: Check valve # 2
Less clamping pressure or paper slips when the cutting active: Check Valve # 3

see the leakage at the cyonder :

20260325_145600.mp4

drive.google.com

It would be great if you make a video while performing above sequence, we can directly guide you to the malfunctionig section. Hoping this will help everyone in the forum.

Reagrds

KOENIG

View attachment 17001 View attachment 17002

WOW,
Thank you so much for the detailed response. It was super helpful. We have found a leak and I am attaching the video. It seems to come from the block and not from a solenoid itself.

Cutter leak

drive.google.com

we had the entire system replaced 18 months ago so hopefully its something we can take care of easier.