as300/500 pressure sealer - Neopost Technologies Ltd
Contents
1. Double document sensor adjustment is carried out in Engineer Test Mode see section 3 3 3 Page 3 12 Issue 2 APR 2008 World Leaders AS300 500 PRESSURE SEALER Service Manual PFE 3 3 2 PCB PHYSICAL LAYOUTS Shown below are the layouts of the CPU and Control Panel PCBs used on this machine indicating the position of connectors pots pin header etc PS6 CPU BOARD 127 185 ISS 3 O 00 SdL 27d reece Sessesee a vrg Connector TPS Ronnenien CPU PCB 180 687 or 180 703 PS6 CONTROL PANEL 12 156 ISS 2 CONTROL PANEL PCB 180 688 Page 3 13 Issue 1 Mar 2001 Mee World Leaders IN MAILROOM TECHNOLOGY AS300 500 PRESSURE SEALER Service Manual 3 3 3 ENGINEER TEST MODE Engineer Test Mode allows the engineer to carry out a variety of test functions and set tings To enter the mode switch off the machine fit a link part no 141 182 413 to J4 on the CPU board and switch the machine back on The display will indicate the scrolling message EnGInEEr to confirm that Test Mode has been entered To step down through the various functions press the Reset button 0s on the control panel A scrolling display will show the number and name of each test as described below 0 Panel Test 1 Button Test 2 Covers Test 3 Drive Direction Test 4 Solenoid Test 5 Sensors Test 6 Disc Test Activates every display segment on the screen If any ar2. The drive belt should be adjusted to allow 3 4mm deflection each side This can be gauged by inserting a 3 4mm dia pin between the belt and a straightedge placed over the belt across the pulleys in the middle of its longest span If adjustment is required slacken the two motor screws A and B see Fig 4 below The motor drive pulley pivots about screw B swing the upper end of the bracket assembly to achieve the correct adjustment then tighten the screws Re check the belt tension to ensure it has not moved after tightening Drive belt Screw A Disc sensor Screw B Fig 4 Drive belt replacement The drive belt must be replaced if it is damaged or excessively worn Remove the 2 plastic rivets securing the disc sensor PCB and slacken the grub screw in the disc hub Slide the disc and PCB off the motor shaft Remove screws A and B and withdraw the bracket assembly and belt looping the belt clear over the end of the drive pulley Fit the new belt and the bracket and replace screws A and B The threaded holes in the end of the motor plate may not align with the screws as their removal frees the motor To ease alignment raise the lower fold plate and manipulate the motor whilst doing up the screws Tension the belt as described above and reassemble the disc and PCB ensure that the grub screw aligns with the flat on the shaft and the disc is centrally located in the slot of the senso
3. If the action is not smooth too loose or notchy the spring plate may require adjustment or replacement To gain access tilt the machine backwards on its rear edge sufficiently to gain access to the underside Caution ensure that the machine does not tilt too far or it may topple The spring plate is retained with two self locking nuts which may be adjusted as required or removed for spring plate replacement Page 3 5 Issue 2 JUL 2004 World Leaders AS300 500 PRESSURE SEALER Service Manual 3 2 4 FEED WHEEL REPLACEMENT PFE The feed wheels are located in front of the hopper and feed the paper into the fold rollers The centre of the three feed rollers is directly above the separator pad The feed wheels will need replacing if they are visibly ragged or damaged or constant misfeeds occur that cleaning cannot remedy The feed wheel shaft assembly is replaced as a whole Remove both side covers section 3 1 2 and fold plate 1 assembly complete To do this remove the E clip at the RH end of the fold plate assembly pivot bar and also the screw at the LH end Push the assembly rightwards to free the D end from the chassis note that it may be tight then work the assembly free of the chassis On the RH side remove the restrictor rings and spring and then the E clip and plastic bearing at the end of the feed wheel shaft On the LH side pull out the clutch pin and slide the clutch and gear off the shaft Remove the E
4. Remove the 4 Allen screws securing the base of the sub chassis to the main chassis 2 each side With suitable assistance lift the sub chassis forwards and out be aware of the outfeed tray The sub chassis can now be stripped as required see section 4 5 for exploded view Sub chassis Replacement Replacement is a reversal of removal Note that fold plate 2 will have to be lifted clear of the main chassis when lifting the sub chassis into position Use new cable ties to secure the cables to the chassis Page 3 9 Issue 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual 3 2 10 SEALING ROLLER ADJUSTMENT Mee The front sealing roller is adjustable for tension and while this is factory set re adjustment may be required after a long period of service or if forms are failing to seal properly A special tool will be needed to perform this and may be obtained by ordering part number AQ277A To gain access to the adjusters remove both side covers section 3 1 2 The adjusters are located at the upper front corners as shown in Fig 6 below Back off the grub screw and slacken both locknuts on the top of each adjuster Using the special tool turn the adjusting ring counter clockwise until the ring is free from spring pressure approx 1 full turn Now turn it back down until contact with the springs is just felt then a further 1 turn applied 1 2 turn each side at a time Remove the tool and turn the lower locknut d
5. clip and plastic bearing and work the feed wheel shaft out of the chassis Reassembly is a reversal of the above noting the following lightly oil the outer face of the RH T bearing and fit the 2 new restrictor rings with the spring between them Note that the bosses on the rings are directed inwards and the outer ring is fitted with a grub screw Compress the spring so that the outer ring is 5mm in from the inner circlip groove in the shaft then tighten the grub screw When replacing the clutch ensure that the locator is between the two lugs on the clutch Take care not to damage the microswitch 3 2 5 DISC SENSOR The disc sensor for monitoring rotational speed is located under the RH side cover see Fig 4 on the following page As this is not readily accessible by the operator cleaning it does not form part of the Operator Maintenance hence it must be cleaned by the PFE Service Engineer at service visits To gain access to the disc sensor remove the RH side cover see section 3 1 2 the disc sensor is located at the bottom of the chassis on the motor shaft Note that the motor rotates in a counter clockwise direction Ensure both sides of the disc and the slotted sensor are cleaned using the airduster Page 3 6 Issue 2 JAN 2005 World Leaders AS300 500 PRESSURE SEALER Service Manual 3 2 6 DRIVE BELT ADJUSTMENT REPLACEMENT PEE Remove the RH side cover and front vertical cover to gain access section 3 1 2
6. section 3 2 4 Roller spring tension incorrect check and reset if necessary section 3 2 10 Roller skidding due to glazing clean rollers Issue 2 JAN 2005
7. to the service count will not be saved until the Reset button is pressed Press the Reset button to return again to the start of Engineer Test Mode To exit finally switch the machine off and remove the link on J4 When next switched on it will be ready to run in normal mode 3 3 4 SUPERVISOR MODE Supervisor Mode reveals various statistics about the machine namely Eprom version number total running hours and overall forms count To enter the mode press the Stop button while the machine is displaying the HELLO message after switching on The message SUPErViSOr on the display indicates that the mode has been entered To step down through the various functions press the Reset button on the control panel The functions are described below Eprom Displays the Eprom version number in the format Vn nn where n nn is the version of the Eprom fitted to the CPU board Hours Count Displays the total number of hours to date that the machine has run The format is nnn_n which equates to the number of hours eg 082_7 means 82 7 total running hours to date Overall Count Displays the total number of forms to date that the machine has processed The format is nnnnn where nnnnn is the forms count in units of 100 Note that this count is not reset by pressing the Zero Reset button Pressing the Reset button again displays the message End to indicate that the end of Supervisor mode is reached Pressing the button again loops back to th
8. SPRING 2 G1116A SPRING INTERMEDIATE PRESSURE 2 G1117A SPRING HEAVY PRESSURE 2 G1137A SPRING FINE PRESSURE 2 G1152A SOLENOID SPRING 1 G3339A CONTROL PANEL OVERLAY 1 G6026A INFEED GUIDE SHIM 2 G6050A 12mm JOCKEY SHIM 6 G6139A GUIDE TAPE 1 Recommended Spares Electrical PART NO DESCRIPTION QTY 131 106 MICROSWITCH 1 131 907 EMERGENCY STOP SWITCH 1 135 103 FUSE T3 15A 2 168 334 MAINS SWITCH 4A 1 180 687 CPU PCB ASSY AS500 1 OR 180 703 CPU PCB ASSY AS300 1 180 688 SWITCH PCB ASSY 1 180 689 MOTOR DISC SENSOR PCB ASSY 1 181 126 SOLENOID 1 181 127 JST CLUTCH 1 182 343 OUTPUT SENSOR LEAD ASSY TX 1 182 345 OUTPUT SENSOR LEAD ASSY RX 1 182 413 ENGINEER LINK 1 182 440 H POINT SENSOR LEAD ASSY TX 1 182 441 H POINT SENSOR LEAD ASSY RX 1 182 442 DIVERT SENSOR LEAD ASSY RX 1 182 443 DIV amp D DOC SENS LEAD ASSY TX 2 182 444 D DOC SENSOR LEAD ASSY RX 1 Page 3 17 Issue 2 Jan 2005 World Leaders AS300 500 PRESSURE SEALER Service Manual SECTION 3 5 ERROR MESSAGES Mee If operating faults occur a code will appear on the control panel display for example T where nn one of the numbers CLC M indicated below The fault code will alternate with a scrolling description of the problem If more than one fault has caused the machine to stop each code and description will cycle through before repeating If you press the Run button while any error is displayed you will be asked if you wi
9. World Leaders IN MAILROOM TECHNOLOGY AS300 500 PRESSURE SEALER Service Manual SECTION 3 Operating and Service Adjustments Page 3 1 Issue 1 Mar 2001 Mee World Leaders AS300 500 PRESSURE SEALER Service Manual 3 1 3 1 1 3 1 2 PREVENTATIVE MAINTENANCE CHECK LIST GENERAL ay Ask how the machine has been working lately and use this information as a guide for checking the machine 2 Ask if there has been a change of use e g high volume production runs or a change of material 3 Check the operator adjustments of the machine and the material being processed 4 Switch on machine and if any operating faults are occurring clean all sensors and then adjust section 3 3 1 5 Ifnecessary generally instruct the operators again with regard to their specific problem area and their maintenance responsibilities see Operating Instructions section 8 6 Enter the total forms count on the service sheet and alert your service department if the machine is being used for more than 30 000 insertions per month 7 When all service or repair operations have been carried out the machine must be left with all parts reassembled leaving no risk of injury REMOVAL OF COVERS Note Throughout this section references to LH and RH are viewed standing behind the hopper tray The rear of the machine is the hopper end Some or all of the following covers may require removal for maintenance opera tions Ensure al
10. ation mounts If the pressure roller bearings require replacement the subframe must be removed WARNING The Sealing Rollers are extremely heavy and removal of the subframe should not be undertaken without suitable assistance To make removal more manageable it is advised that the following procedure is adhered to in the order stated Notes should be taken of the positions of cable connectors prior to their removal 1 Remove all covers section 3 1 2 2 Remove fold plate 1 assembly complete To do this cut the cable ties securing the divert sensor cable trace the cable back to the PCB and unplug the connector Remove the E clip at the RH end of the fold plate assembly pivot bar and also the screw at the LH end On the RH side remove the screw securing the microswitch bracket Push the assembly rightwards to free the D end from the chassis note that it may be tight then work the assembly free of the chassis 3 Unplug the solenoid cable from the control panel CPU 4 Cut the cable ties securing the divert sensor cable from the pivoting front cover 5 On the LH side cut the cable ties securing the clutch cable to the chassis Also remove one end of the earth braid in the lower rear corner 6 On the underside of the Control Panel PCB remove the following connectors J2 J3 J8 J9 and J10 see section 3 3 2 for connector identification 7 Raise fold plate 2 and reach inside to unplug the 2 spade connectors to the motor 8
11. centre of the pivot shaft and also the E clip at the LH end Move the shaft leftwards to free the other end then lift out the tray and shaft complete with the spring on the underside This may then be unclipped for replacement Section 4 2 may assist when dismantling the tray The RH side guide is fixed and the LH guide moves within a limited range The action should be smooth without being loose To adjust tighten or loosen the spring plate nuts on the underside refer again to section 4 2 The area under the spring plates should also be lightly greased When replacing the tray ensure that the spring is properly located on the carrier studs 3 2 2 SEPARATOR ADJUSTMENT The separator is spring loaded and is self adjusting to an extent However it has a gap which is initially factory set and may later require adjustment which is not an operator function There is also a separator block which provides a degree of pre separation this is adjustable for rotation The block should be set first to provide a gap of 004 006 0 1 0 15mm between the rear tip of the aluminium block and the roller as shown in Fig 1 below The gap is then set so that a sheet of 20lbs bond 80gsm paper just grips as it is pulled through the gap by hand Access for both adjustments is underneath the hopper tray The block screw is through a central slotted hole and the gap adjustment nuts are at each side Slacken the block screw and use the Allen key as a leve
12. e missing the Control Panel PCB must be replaced Identifies each button on the control panel as it is pressed If any fail the Control Panel PCB must be replaced Note that the Reset button cannot be tested as pressing this passes to the next function Indicates when a cover is opened to test the microswitch Tests motor direction relay Press the Run button to toggle motor ON or OFF Press the Calibrate button to choose direction Display will show For forward normal rEv reverse Press the Stop button to switch off Also tests the motor and clutch Press the Calibrate button to toggle between the functions and the Run button to switch the function on or off Pressing the Stop button stops all functions Display Component drOn or drOFF Drive Motor FdOn or FdOFF Feed Clutch dvOn or dvOFF Diverter Solenoid The clutch should be heard to click when activated but as this is faint touch ing the clutch whilst activating should confirm by feel Alternatively switch on both clutch and motor and the feed rollers should rotate Test sensors for blocked or clear condition Displays the sensor name when blocked with paper or when all are clear Sensors tested are feed hold point eject and diverter To test the disc sensor the message Sc nn will appear on the display where nn is the number of disc slots This number will increase as the disc is turned by hand and should be exactly 30 for a complete re
13. e start of Supervisor Mode Press the Stop button or switch off the machine to exit the mode Page 3 15 Issue 1 Mar 2001 Pee IN MAILROOM TECHNOLOGY World Leaders i AS300 500 PRESSURE SEALER Service Manual 3 4 RECOMMENDED SPARES The following list indicates the spares recommended to be held by Customer Service Engineers Quantities stated are for every 5 machines A complete set of spares can be obtained by ordering part No A0280A for AS300 machines or AO278A for AS500 machines Recommended Spares Mechanical PART NO DESCRIPTION QTY A0277A PRESSURE ADJUSTER TOOL 1 A2663A MOTOR 230V DC SLEEVED 1 B0064A SPRING PLATE 2 B0107A ANTI STATIC BRUSH 1 C0038A KEYWAY 2 C8123A FOLD ROLLER 3 C8131A INFEED SHAFT 1 D1039A SENSOR MOUNT D1040A T BEARING HOUSING 12 E0326A ANTLVIBRATION MOUNT HARD 2 E0328A 1 4 TURN RETAINER 1 E0329A CLIP ON RECEPTACLE E0330A M5 HANDWHEEL 1 E0338A DISC SPRING 24 E0339A ANTLVIBRATION MOUNT SOFT 2 E1056A PL OILITE 12 x 15 x 12 2 E1087A FLANGED BEARING 2 E1101A FLANGE BEARING E1114A 8mm BEARING 3 E5071A 3 x 14 DOWEL PIN 2 E5098A 3mm DRIVE PIN J F4205A 15T CLUTCH GEAR 2 F4206A 12T FOLD GEAR 3 F4211A 12T REDUCTION GEAR 1 F5135A BELT 180 S3M 420PU 1 Page 3 16 Issue 4 JuL 2007 World Leaders AS300 500 PRESSURE SEALER Service Manual Recommended Spares Mechanical contd Pee PART NO DESCRIPTION QTY G0079A CLUTCH PIN 3 G1023A SPRING FOLDER 1 G1078A PLATFORM
14. eferable to remove the sub chassis first Reassembly of all fold rollers is a reversal of their removal 3 2 13 REPLACEMENT OF ANTI VIBRATION MOUNTS The anti vibration mounts should be replaced as a set of four if only one is worn or damaged the others will be nearing the same state It is not necessary to remove the sub chassis Note that the front output end of the machine is fitted with hard rubber mounts E0326A and the rear end is fitted with soft rubber mounts E0339A This is essential due to the weight distribution vibration will result if the mounts are fitted incorrectly Remove and replace the mounts one at a time by first removing the large cap head screw then the two smaller screws securing the mount to the main chassis Lever or lift the sub chassis upwards to fit the new mount in place and replace the screws Repeat this procedure for each of the insulators Page 3 11 Issue 1 Mar 2001 fis World Leaders AS300 500 PRESSURE SEALER Service Manual ELECTRONICS AND SOFTWARE SENSOR ADJUSTMENTS All sensors apart from eject sensors are connected to the Control Panel PCB the signals then being routed to the CPU PCB via the ribbon cable between the two To replace a sensor cut the cable ties securing it along the length of the cable unclip the sensor from its housing and replace with a new sensor lead assembly as indicated in section 5 1 Sensors are adjusted on the CPU PCB mounted in the base of the machi
15. l covers are undamaged Check action of opening covers to confirm correct operation and that safety microswitches function correctly Check that all warning labels are legible Exercise caution with moving parts and exposed electrical apparatus when covers are removed 1 Unplug main power supply lead from machine Ensure thatmain power supply leadand its connectors are sound and undamaged 2 Remove LH side cover 2 x M4 screws washers at front edge 1 x M4 screw on tab in front of hopper 1 x M4 screw washer at bottom of rear face Lift bottom of cover outwards then upwards toremove contd Page 3 2 Issue 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual 3 Remove RH side cover Same as for LH cover HA 4 Remove front vertical cover 2 x M4 screws washers each side inside lower edge and 3 x M4 screws in face of cover Exercise caution when removing due to sensor wires on the inside when cover is free unplug the sensor wires to remove 5 Removerear electronics cover under fold plate 2 4x M4 screws washers on lower edge When replacing pass the studs that retain the hairsprings through the cutouts on the top face then slide the cover forward ensuring that the hairsprings press it down 3 1 3 SERVICE AT EVERY SITE VISIT 1 Refertosection3 1 1 General 2 Removeall machine covers Section 3 1 2 3 Check spring tension and side guide action of hopper tray Replace adjust if necessa
16. le to replace all of them without removing the sub chassis although the lower rear roller with fold plate 2 attached to its shaft 1s quite awkward to remove with the sub chassis in place Unless just a single roller has incurred damage all three rollers should be replaced together Removal of upper and lower front fold roller 1 At each end of the roller remove the E clip plastic bearing and spring fitted only to upper roller It is now possible to work the roller out of the chassis Removal of lower rear fold roller 1 If the sub chassis has been removed remove the E clip at each end of the roller followed by the plastic bearing and spring The roller can now be lifted out complete with fold plate 2 attached If the sub chassis is to remain in place proceed as shown below 2 Remove the upper fold roller to provide clearance see above 3 On the LH side remove the E clip next to the plastic gear note that the gear is retained to the shaft with a pin behind it this pin will be loose when the gear slides outwards 4 On each side remove the E clip next to the plastic bush retaining the fold plate Slide the plastic bushes outwards to allow the two fold plate components to be freed from the roller shaft and lift them out The fold roller can now be worked out of the chassis Note this method of removing the lower fold roller can be quite awkward particularly when replacing the plastic bearings it is generally pr
17. lean double document sensor or call Service Dept to replace Machine can only be used for handfeed until fault is fixed FIt15 Drive stall Motor has stalled ensure forms do not exceed maximum weight Page 3 19 Issue 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER PFE Service Manual 3 6 ENGINEER S TROUBLESHOOTING GUIDE The following guide should be read in conjunction with that shown in the Operating Instructions PROBLEM Forms not feeding although machine is running Forms feeding skewed Double documents occurring frequently 4 Jam occurring in folder Fold rollers working erratically or not at all Document exits through top tray but is not a double document Double document not being diverted but is entering rollers Documents not sealing or failing to seal completely Documents not exiting sealing rollers Page 3 20 SUGGESTED CAUSE AND REMEDY Drive belt broken replace Infeed shaft clutch faulty replace Hopper tray misaligned realign section 3 2 1 Separator gap too wide or pad worn reset gap or replace separator block section 3 2 2 Fault with fold plate or folder output sensors check voltages section 3 3 1 Gear train damaged or too tight check backlash section 3 2 5 Diverter solenoid stuck down check action adjustment section 3 2 8 Restrictor on infeed shaft is too loose adjust
18. med To adjust raise fold plate 1 to reveal the top peak of the diverter the lower tip will also just be visible Slacken the screws retaining the solenoid to the chassis located inside the chassis hold the solenoid plunger fully bottomed and slide the solenoid so that the tip shown in Fig 5 is clear of the sealing roller by 008 012 0 2 0 3mm This can be gauged by inserting two sheets of 20 lbs bond 80 gsm paper until they are under the diverter tip This will necessitate holding the separator open by inserting a wedge between the separator adjustment screw and the heel of the separator beam see Fig 2 on the previous page Tighten the solenoid screws while the tip is held down onto the paper remove the paper and check that the diverter does not contact the roller when the solenoid is engaged When adjustment is complete replace the side cover and test the machine by running a double document calibration the folded unsealed document should be ejected into the slot in front of fold plate 1 Note 0 008 0 2mm is equal to 2 thicknesses of 20lbs bond 80gsm paper Solenoid Diverter peak Solenoid link Diverter Sealing roller Fig 5 Page 3 8 IssuE 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual PFE 3 2 9 SUB CHASSIS REMOVAL REPLACEMENT The pressure sealing rollers and motor are mounted within a sub chassis which in turn is mounted into the main chassis using anti vibr
19. ne under the rear electronics cover see section 3 1 2 for removal The voltage is measured between TPS pin 8 Ov and TPS pin 1 4 depending upon sensor Two readings are taken with sensors clear of paper and then blocked The clear voltage is adjusted using the pot indicated See section 5 1 for locations of sensors and section 3 3 2 overleaf for PCB physical layout showing TPS and adjustment pots Note that TPS and the pots are located close to the rear edge of the board requiring only removal of the rear cover for access Sensors must first be cleaned before adjustment If the settings shown cannot be achieved the sensor must be replaced Hold Point Sensor TPS pin 1 Adjust VR1 to give 0 3v between TPS pins 1 and 8 with sensors clear Now insert 20Ibs bond 80gsm paper between sensors to block fully Confirm gt 4 0v between TPS pins 1 and 8 Divert Sensor TPS pin 2 Adjust VR2 to give 0 3v between TPS pins 2 and 8 with sensors cleat Now insert 20lbs bond 80gsm paper between sensors to block fully Confirm gt 4 0v between TPS pins 2 and 8 Eject Sensor TPS pin 3 Adjust VR3 to give 0 3v between TPS pins 3 and 8 with sensors clear Now insert 201lbs bond 80gsm paper between sensors to block fully Confirm gt 4 0v between TPS pins 3 and 8 Motor Disc TPS pin 4 Voltage between TPS pins 4 and 8 should alternate between lt 0 5v clear and gt 4 0v blocked as disc is slowly turned Double Document
20. own until it contacts the adjusting ring then a further 1 flat Using two suitable wrenches tighten the upper locknut onto it Repeat for the other adjuster and replace the side covers Test the machine using MCP paper and make fine adjustments if required Adjusting ring Grub screw Locknuts 3 2 11 DISC SPRING REPLACEMENT If adjustment of the sealing rollers as decribed in section 3 2 10 above does not resolve sealing problems the disc springs on the adjustable front roller may require replacement To gain access to the springs remove the locknuts washer and adjuster ring shown in Fig 6 above This will reveal the disc springs which may be removed using a probe magnet or altenatively by pushing them up from below using a fine screwdriver There are 12 springs fitted on each adjuster and these must be fitted in the orientation shown in Fig 7 below When the new springs are fitted adjust as described in section 3 2 10 above Adjuster block Q Locknuts Adjusting ring Disc springs 12 Fig 7 Page 3 10 IssuE 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual Ree 3 2 12 FOLD ROLLER REPLACEMENT The fold rollers will require replacement if documents are constantly crashing or slipping in the folder and cleaning does not remedy the situation There are three fold rollers and it is possib
21. r 3 2 7 MOTOR REPLACEMENT To replace the motor remove the RH side cover rear electronics cover and front vertical cover section 3 1 2 Remove the screw retaining the disc sensor bracket and move it clear of the disc Take off the drive chains and sprockets as described above Reach inside to pull the two spade connectors off the motor and remove the tie bar behind the front vertical cover Steady the motor while removing its two retaining screws see Fig 4 above and lift it out of the front Refitting is a reversal of the removal After fitting readjust the drive chains as described above and lubricate if necessary Ensure that the sensor disc is centrally located in the sensor Page 3 7 Issue 3 APR 2007 World Leaders AS300 500 PRESSURE SEALER Service Manual Pee 3 2 8 DIVERTER ADJUSTMENT The purpose of the diverter is to eyect double documents and forms being calibrated into the diverter tray at the top of the machine so that they do not pass through the sealing rollers It is solenoid actuated and is controlled automatically by the software It may need adjusting if forms are not being diverted properly are crashing at the diverter or the diverter tip is contacting the sealing roller To adjust remove the RH side cover to gain access to the solenoid see Fig 5 below The cotrect setting is for the tip of the diverter to be just clear of the sealing roller when the solenoid is fully engaged and the plunger is botto
22. r to rotate the block as required tighten the screw then adjust each nut equally to achieve the gap Note that the block may need further fine adjustment if documents are still not separating properly 004 006 0 1mm 0 15mm rN Fig 1 Separator Replacement If after a long period of time double documents are constantly being fed and adjustment cannot cure this it may be that the separator pad has worn out and will require replacement As the pad is permanently glued to the block it cannot be replaced separately the whole block must be renewed Page 3 4 Issue 4 JAN 2005 World Leaders AS300 500 PRESSURE SEALER Service Manual 1 Remove the infeed hopper tray by taking out the two pozi pan head screws on each side Pee inside the chassis face and lifting out the tray depress the tray against the spring to reach the screws The separator block will now be visible Block securing nuts Separator block Fig 2 2 Remove the two nuts shown in Fig 2 above and slide the separator block and rod off the screws 3 Fit the new block pad to the rod and reassemble to the separator plate ensuring that the block is centrally located in the slot in the separator plate 4 Reassemble the feed hopper and adjust the separator block for rotation and gap as described in the preceding section 3 2 3 RECEIVING TRAY The receiving tray slides in and out and is retained in position by a spring plate
23. ry Section 3 2 1 4 Check thatreceiving tray moves smoothly and that spring plate is not broken 5 Cleanfoldrollers using Roller Cleaning Fluid Ensure they are cleaned across their full width andround their full circumference 6 Clean sealing rollers using an alcohol based cleaner Check for surface damage or signs of erosion 7 Clean motor disk sensor under RH side cover Section 3 2 5 8 Check separator gap action and adjustif necessary Section 3 2 2 9 Check condition of drive belt and ensure itis correctly tensioned Replace if worn or damaged Section 3 2 6 10 Check gear trains for backlash which should be perceptible but minimal 11 Check condition of anti vibration mounts on subframe Replace if worn or perished Section 3 2 9 12 Check that all T bearing springs are in place and unbroken Replace if necessary 13 Check for wear in all bearings replace as necessary and lubricate 14 Check security of all PCB connectors including control panel and mains socket Also check motor connections raise fold plate 2 to gain access 15 Replace all covers Page 3 3 Issue 2 Nov 2003 World Leaders AS300 500 PRESSURE SEALER Service Manual PFE 3 2 MAINTENANCE AND ADJUSTMENTS 3 2 1 FEED HOPPER The feed hopper is fitted with a spring loaded tray and side guides If the tray has no tension or is weak the spring may be broken or flattened To gain access remove the screw and spigot in the
24. sh to operate the Jog function see Operating Instructions section 8 3 FAULT CODE DISPLAYED DESCRIPTION ACTION TO TAKE Fit1 Load hopper Hopper is empty or form not fed to hold point Reload or check paper is correctly loaded Check feed Clutch Flt2 Feed fault Paper jammed at infeed clear jam FIt3 Hand feed fault Form notfully inserted when hand feeding Ensure it is pushed fully down Fit4 Doc did not arrive at divert Form possibly a double or calibration document is jammed in fold rollers or infeed clear jam FIt5 Doc should not be at divert Diverter solenoid may be stuck replace FIt6 Divert full Unretrieved form is in divert hand feed slot remove it FIt7 Doc did not arrive at eject Form jammed on route to output clearjam FIt8 Doc failed to clear eject Form cannot eject properly check output tray is correctly adjusted FIt9 Doc should not be at eject Diverter solenoid may not be operating replace FIt10 Eject sensor obscured Clean all sensors Check form is not blocking sensors Page 3 18 Issue 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual Ree Fitt 1 Chip error Fault with EPROM chip replace Fit12 Diverted double doc Double document correctly diverted Remove and check paper in hopper is not stuck together Check separator gap Fit13 Undivertable double doc Double document could not be diverted check for jam in fold rollers Fit1 4 Ddcal fault C
25. volution Press Stop to reset count or Reset to continue Page 3 14 Issue 1 Mar 2001 World Leaders AS300 500 PRESSURE SEALER Service Manual Ree 7 Double Close all covers and place one sheet of 24 lbs bond pressure paper in hopper Document Press Run button twice to feed to hold point Display will show dd nn where Setting nn or nn is a two digit number which when the sensor is correctly set equals 00 05 If not adjust VR4 on the CPU board until this setting is achieved 8 Speed Test Displays motor speed in RPM Press the Run button to start Test lasts for approx seconds then switches off 9 Service Sets the number of machine cycles at which the display will indicate to the Count operator that a service is due When first entered the display will indicate the last setting which may either be a count or noSEr which indicates that Service Count has been disabled To set a count in units of 10 press the Ddcal or Stop button to show xy000 where x amp y can be changed Use the Stop button to increment x and the Ddcal button to increment y To test the function press the Run button to indicate 00001 which will run 10 cy cles after Engineer mode is exited and the machine is run Use the Run but ton to toggle between test count and noSEr When activated the display SErvICE dUE will appear when the machine is switched on indicating to the operator that a service is due Note Changes made
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