Plockmatic SR 85 User manual

February 2001
Part No. 75672
Service Manual
Bookletmaker SR 85

Bookletmaker SR 85 February 2001PAGE
REPAIRS / ADJUSTMENTS (REP) PAGE
Cover removal
REP 1.1 Front and rear cover 1.1.1
REP 1.2 Top cover 1.2.1
REP 1.3 Panels + Infeeder 1.3.1
REP 1.4 Infeed and outfeed cover 1.4.1
Input area
REP 2.1 Infeed module 2.1.1
REP 2.2 Infeed transport belt 2.2.1
REP 2.3 Side guides 2.3.1
REP 2.4 Side guide assy. 2.4.1
REP 2.5 Side guide jogger motor MOT 3 2.5.1
REP 2.6 Back jogger motor MOT 7 2.6.1
Stapler area
REP 3.1 Stapler head 3.1.1
REP 3.2 Stapled set stop gate solenoid SOL 2 3.2.1
REP 3.3 Staple stop gate position, Adjustment 3.3.1
REP 3.4 Stapler assembly drive bar position, Adjustment 3.4.1
REP 3.5 Stapler home position, Adjustment SW 1 3.5.1
REP 3.6 Stapler head retraction, Adjustment 3.6.1
REP 3.7 Saddle stapling sensor, Adjustment SEN 1 3.7.1
Output area
REP 4.1 Upper folder roller 4.1.1
REP 4.2 Lower folder roller 4.2.1
REP 4.3 Fold pressure, Adjustment 4.3.1
REP 4.4 Fold knife home position, Adjustment SW 2 4.4.1
REP 4.5 Outfeed sensor, Adjustment SEN 4 4.5.1
Staple/Fold quality adjustments
REP 5.1 Staple stop gate parallelism, Adjustment 5.1.1
REP 5.2 Staple/Fold position, Adjustment 5.2.1
REP 5.3 Stapler position to anvil, Adjustment 5.3.1
REP 5.4 Stapler pressure, Adjustment 5.4.1
REP 5.5 Stapled set transport drive alignment, Adjustment 5.5.1
REP 5.6 Pressure roller height, Adjustment 5.6.1
REP 5.7 Stapled set stop gate release solenoid, Adjustment SOL 1 5.7.1
PROGRAMMING (PRG)
PRG 6.1 Reset of EE-prom values 6.1.1
ELECTRICAL DETAIL INFORMATION (EDI)
EDI 7.1 Wiring diagram SR85 7.1.1
EDI 7.2 Connection cable wiring diagram SR85 7.2.1
EDI 7.3 Electrical components list 7.3.1
EDI 7.4 Electrical components location 7.4.1
EDI 7.5 Test points 7.5.1
FAULT ISOLATING PROCEDURE (FIP)
FIP 8.1 Self diagnostic system control (SDS) 8.1.1
PREVENTIVE MAINTENANCE (MAI)
MAI 9.1 Preventive Maintenance 9.1.1
Contents
i

Bookletmaker SR 85 February 2001PAGE
REP 1.1 Front and rear cover
REMOVAL
Front cover
1. Switch off the main power switch and disconnect the power cord.
2. Open the Top cover and loosen the two screws (1) securing the top end of the Front
cover.
3. Loosen the two nuts (2).
4. Pull out the lower end and lift up carefully to remove.
Rear cover
Removal of the rear cover is performed the same way as removal of the front cover.
INSTALLATION
Installation is an exact reversed procedure of removal.
1
2
1.1.1

Bookletmaker SR 85 February 2001PAGE
REP 1.2 Top cover
REMOVAL
1. Open the Top Cover
2. Disconnect the Gas spring (4).
3. Remove four screws (1) from the brackets.
4. Lift off the Top cover.
INSTALLATION
1. Mount the four screws (1) onto the brackets and tighten.
2. Connect the Gas spring (4).
3. Close the Top cover and check:
- That the magnet (5) locks on the sheet plate (3).
- That both rubber bushings (2) contacts the surface.
- That the Top cover front side is parallel to the front cover.
- That the Interlock switch activates when the distance between the magnet (5)
and the sheet plate (3) is 2 to 5 mm.
ADJUSTMENT
1. Loosen the screws (1).
2. Move the Top cover to adjust.
3. Tighten the screws (1).
4. Repeat the check.
123 4 2
5
1.2.1

Bookletmaker SR 85 February 2001PAGE
REP 1.3 Panels + Infeeder
REMOVAL
1. Loosen the four 7 mm screws (1).
2. Slide the top of the panels (2) away from the screws. Remove the shelf (3), remove the
two panels.
3. Loosen the four 7 mm screws (4).
4. Lift up the infeeder (5) and remove it.
INSTALLATION
Installation is an exact reversed procedure of removal.
1
22
3
4
5
1.3.1

Bookletmaker SR 85 February 2001PAGE
1
REMOVAL
Infeed cover
1. Switch off the main power switch and disconnect the power cord.
2. If the unit is online, disconnect the connection cable.
3. Remove the two panels and the shelf.
4. Loosen the two nuts (1).
INSTALLATION
Installation is an exact reversed procedure of removal.
NOTE: Make sure the plastic guide (2) does not get jammed between the stackers left side
and the outfeed cover when installing the stacker.
REP 1.4 Infeed and Outfeed cover
1.4.1
Outfeed cover
1. Switch off the main power switch and disconnect the power cord.
2. Remove front and rear cover according to REP 1.1.
3. Loosen the two screws below the stacker frame securing the stacker.
4. Disconnect and remove the stacker (3).
5. Tip the SR 85 by placing 50 mm or greater distances between the outfeed end of the
SR 85 and the base.
6. Loosen the two screws (5) securing the outfeed bottom cover.
7. Slide the bottom cover towards the outfeed, until it releases from the infeed bottom
cover. Slide the bottom cover towards
the infeed until it releases from the
screws (5).
8. Remove the four screws (4).
9. Pull the cover carefully out to avoid
damage on the outfeed sensor
harness on the front side.
5. Pull out the lower end of the infeed cover and remove thecover down wards.
NOTE: Cut the ty-wraps and disconnect the outfeed
sensor to fully remove the outfeed cover.
2
3
4
5
5
4

Bookletmaker SR 85 February 2001PAGE
REMOVAL
1. Remove the front and rear cover according to REP 1.1.
2. Remove the two panels,shelf and the infeed assy according to REP1.3.
3. Remove the infeed cover according to REP 1.4
4. Disconnect the five connectors (1).
5. Remove the spring (2).
9. Lift out the Infeed module (4). Carefully so the side guides does not bend.
INSTALLATION
Installation is an exact reversed procedure of removal.
REP 2.1 Infeed module
2.1.1
4
5
6. Disconnect the length adjust strap (3).
7. Remove the two screws (5) on the front side.
8. Remove the two screws (5) on the rear side.
VIEW INSIDE INFEED COVER
111
23

Bookletmaker SR 85 February 2001PAGE
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed module according to REP 2.1
3. Remove the four screws (1).
4. Slide the drive coupling (5) off of the drive shaft (4) and remove the transport belt as-
sembly.
5. Remove the belt (2) from the assembly.
INSTALLATION
Installation is an exact reversed procedure of removal.
Note: Make sure the flat side on the bearing (3) is up when installing.
REP 2.2 Infeed transport belt
1
2
3
4
5
2.2.1

Bookletmaker SR 85 February 2001PAGE
ADJUSTMENT
1. Move the front (1) sideguide to the two holes (2) in the paper path according to the
figure.
2. Check the distance between the two holes and the sideguide. The distance should be
equal ± 0.3 mm between the lower hole and the sideguide and the upper hole and the
sideguide. If not go to step 3.
3. Loosen the Ob screw (3) and the IB screw (4) on the side guide. Adjust the sideguide
according to step 2.
4. Perform the same check on the rear (5) sideguide, adjust if needed.
REP 2.3 Side guides
2.3.1
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the infeed cover according to REP 1.4
3. Loosen the Ob screw (3) and the Ib screw (4) on the front side guide.
4. Remove the side guide.
5. Same procedure on the rear side guide.
INSTALLATION
Installation is an exact reversed procedure of removal.
Front side
Rear side
Stapler area seen from
above, with the stapler
heads removed.
3
4
1
2
2
5

Bookletmaker SR 85 February 2001PAGE
REP 2.4 Side guide assy.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1
3. Remove the infeed cover according to REP 1.4
4. Remove the infeed module according to REP 2.1
5. Remove the sideguides according to REP 2.3
6. Turn the infeed module up side down.
7. Remove the e-clip (1).
8. Remove the two screws (2) who secures the shaft.
9. Push the shaft (3) out of the hole (4).
10. Remove five nuts (5).
11. Remove four 7 mm screws (6).
INSTALLATION
Installation is an exact reversed procedure of removal.
1
2
3
4
5
5
5
6
6
2.4.1

Bookletmaker SR 85 February 2001PAGE
REP 2.5 Side guide jogger motor MOT 3
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1
3. Remove the infeed cover according to REP 1.4
4. Remove the infeed module according to REP 2.1
5. Turn the infeed module up side down.
6. Remove 7 mm screw (1).
7. Remove wheel (2) by loosen one 4 mm allen screw.
8. Remove three 7 mm screws (3).
9. Cut two tie raps and remove the motor.
2.5.1
1
3
2
INSTALLATION
Installation is an exact reversed procedure of removal. But before you tighteen the three
screws, you must put the side joggers in the out position, look at the picture above. You
should have 0.1-0.3 mm play between the plate and the flange bushing on both sides (1).
Tighteen the three screws.
11

Bookletmaker SR 85 February 2001PAGE
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the infeed module according to REP 2.1.
3. Disconnect the ground wire (1).
4. Loosen the setscrew in the collar (3).
5. Remove the motor (2).
INSTALLATION
1. Install the motor.
2. Ensure that the pin on the motor is inserted in the grommet (4).
3. Push the collar (5) of the flange bushing firmly against the bracket.
4. Tighten the setscrew (3) on the flat of the shaft.
5. Connect the ground wire (1).
6. Install the infeed module according to REP 2.1.
7. Check/adjust the Staple/fold position according to REP 5.2.
REP 2.6 Back jogger motor MOT 7
2.6.1
12 3
45

Bookletmaker SR 85 February 2001PAGE
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Disconnect the staple detection lead (5).
3. Push down latch (2) and lift the stapler head (1) out.
NOTE: If removing the stapler head use the pivot pin (6) from the old stapler head and install it in the
new head.
INSTALLATION
1. Install the plunger (4) in the plunger retraction swing arm (3).
2. Push the Stapler head down so that the pivot pin (6) locks under the latch (2).
3. Connect the staple detection lead (1).
REP 3.1 Stapler head
3
4
1
2
5
4
5
6
6
O-Rings
3.1.1

Bookletmaker SR 85 February 2001PAGE
REMOVAL
1. Move the front side guide to the outermost position.
2. Adjust the sheet size on the control panel to align the mounting screws (2) for the
solenoid with the access holes (1) in the paper path.
3. Switch off the main power switch and disconnect the power cord.
4. Remove the infeed cover according to REP 1.3.
5. Cut the ty-wrap securing the cable.
6. Disconnect the solenoid connector.
7. Loosen the two screws (2).
8. Slide the solenoid towards the infeeder to remove.
INSTALLATION
Installation is an exact procedure of removal.
REP 3.2 Stapled set stop gate solenoid SOL 2
2
1
3.2.1

Bookletmaker SR 85 February 2001PAGE
PURPOSE
The purpose is to position the Staple stop gate fingers in the center of each opening in the
paper path so that binding does not occur.
1. Adjust to the smallest length size on the control panel.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the Infeed cover according to REP 1.3.
4. Insert a 0.3 mm feeler gauge (3) to ensure 0.3 ±0.2 mm endplay.
5. Disengage the Staple stop gate release solenoid (1). PO/PO
ADJUSTMENT
1. Check that the fingers (2) are centered in the openings in the paper path.
2. Loosen the two allen screws (4)(5) securing the collars.
3. Center the fingers (2).
4. Tighten the front allen screw(4).
5. Insert a 0.3 mm feeler gauge (3) to obtain 0.3 ±0.2 mm endplay.
6. Tighten the rear allen screw (5).
REP 3.3 Staple stop gate position, adjustment
12 3
4
0.3±0.2 mm
3.3.1
VIEW INSIDE INFEED COVER
5

Bookletmaker SR 85 February 2001PAGE
PURPOSE
The purpose is to limit the front-to-rear movement of the Stapler assembly drive bars
without causing them to bind.
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed cover according to REP 1.3.
3. Remove the Front cover according to REP 1.1.
ADJUSTMENT
Top bearing
1. Push the drive bar (1) toward the rear.
2. Insert a feeler gauge to check that the gap is 0.05 mm to 0.25 mm.
3. Loosen the locknut (3).
4. Rotate the screw (2) to adjust.
5. Tighten the locknut (3).
Bottom bearing
Adjustment of the Bottom bearing is performed the same way as adjustment of the Top
bearing.
REP 3.4 Stapler assembly drive bar position, adjustment
1
2
3
2
3.4.1
0.05 to 0.25 mm
2
3

Bookletmaker SR 85 February 2001PAGE
PURPOSE
The purpose is to position the Stapler motor home position switch (SW 1) so that the Sta-
pler motor (MOT 8) stops in the correct position after stapling a set.
1. Switch off the main power switch and disconnect the power cord.
2. Remove the infeed cover according to REP 1.3.
3. Rotate the motor linkage (3) to the top dead center.
ADJUSTEMENT
1. Check that the gap is 0.0 mm to 0.2 mm.
2. Loosen the two screws (1).
3. Move the switch (2) to adjust.
4. Tighten the two screws (1).
REP 3.5 Stapler home position, adjustment SW 1
0.0 - 0.2 mm
123
3.5.1

Bookletmaker SR 85 February 2001PAGE
1.0 - 2.0 mm
12 3
PURPOSE
The purpose is to ensure the staple feed.
1. Check/adjust the Stapler home position according to REP 3.5.
2. Switch off the main power switch and disconnect the power cord.
ADJUSTMENT
1. Push down the stapler head (1).
2. Check that the gap is 1.0 to 2.0 mm.
3. Loosen the three screws (3).
4. Rotate the screw (2) to adjust.
5. Tighten the three screws (3).
REP 3.6 Stapler head retraction, adjustment
3.6.1

Bookletmaker SR 85 February 2001PAGE
PURPOSE
The purpose is to position the saddle stapling sensor (SEN 1) so that it will switch on the
stapler motor (MOT 8) when a set reaches the Staple stop gate.
1. Remove the rear cover according to REP 1.1 and pull out the interlock bypass switch
actuator.
2. Remove the nut (1).
3. Remove the black shield (2).
ADJUSTMENT
1. The voltage between TP1 on the controller PCB and common ground should be greater
than 2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked.
NOTE: Use white paper to block the sensor.
2. Loosen the nut (4).
3. Move the sensor (3) to obtain the voltages.
4. Tighten the nut (4).
REP 3.7 Saddle stapling sensor, adjustment SEN 1
34
21
3.7.1

Bookletmaker SR 85 February 2001PAGE
1
2
3
4
5
6
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front and rear cover according to REP 1.1.
3. Remove the outfeed cover according to REP 1.3.
4. Remove the drive chain (6).
6. Note the position of the sprockets (2&3) on the shaft. Remove the sprockets and the
plastic spacer from the front of the spring-loaded bearing block.
7. Remove the collar and the plastic spacer from the rear of the spring-loaded roll.
8. Remove the front bearing block (4) by removing the two screws from the inside of the
machine.
9. Remove the front and rear spring-loaded bearing block assemblies by removing
screws (5), front and rear, from the inside of the machine.
10. Note the position of the front plastic bearing (1). Remove the bearing.
11. Pull out the upper fixed roll to remove.
12. Pull out the upper spring-loaded roll to remove.
REP 4.1 Upper folder roller
4.1.1
INSTALLATION / ADJUSTMENT
1. Installation is an exact reversed procedure of removal.
Note 1: Push the upper side of the bearing block (4) towards the outfeed before tightening.
Note 2: Before tightening the spring-loaded bearing blocks, use a feeler gauge to check
that the endplay is 0.1 to 0.5 mm between the sprocket (2) and the plastic spacer.
Also check that the enplay on the rear side is 0.1 to 0.5 mm between the collar and
the plastic spacer.
2. Adjust the fold pressure according to REP 4.3.