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Section 3 - Neopost Technologies Ltd

1. the sliders C6223A should be roughly evenly distributed about it cont Mie Paso ASSENELY foe vor am OOT NS LIST OF OMR READER POSITION OPTIONS F See C6182A Gone SCREW M4x6 G W al a E2505A QTY 1 CIRPIN 1 16 x 1 2 1 USE SAME PARTS FOR 3 TRAY SINGLE A3 0375 OB OMR TRAY 1 BTM LE K D 5060A we OMR KIT AS SHOWN OR 1 STATION KIT ee ue Viet eile we SPRING eg OMR SHOE 2 R H TOP READ IS SHOWN FOR L H A3 0375 OTL OMR TRAY 1 TOP G1073A 7a om MOVE OMR HEAD amp FOOT TO OTHER END A3_0375_OTR OMR TRAY TOP RIGHT SCREW M4 X 8 Si OF OMR BAR FOR BOTTOM READ SWAP F2624A QTY 5 SCREW M3 x 10 PAN POSITIONS OF OMR HEAD amp FOOT E2559A a CLAMP PLATE RH 2 MNIE RIOS5A QTY 7 3
2. AUTOMAILER 4 PC COM PORI OW PLG 7 PIN DIN 7 PIN DIN SOCKET LUG op GND GE 56 GND an GRN Je 3 O TAE S RED a GE D E E 4 See 4 ve 4 2 RED S O 7 2 RX O7 RED S 1 O OTs D SS vcc J2 1 i vec O73 YEL 7 7 CO O BOMA QW SKT ALL ABOVE COMPRISES PART NO 184 176 Fig 17 With the computer connected as above and the machine switched on start Trace Tools This will display the RX screen shown in Fig 18 opposite show ing data received from the machine Select ComPort from the menu bar and ensure that the correct port is selected usually COM1 or select Con fig to choose your own more advanced port settings to suit specific pur poses Note that other function buttons are duplicates of functions found in Engi neer mode of the GUI software and should not normally be used use the GUI version instead see also section 3 14 4 Page 3 26 Issue 7 Sep 2008 3 14 2 Debugging Fig 18 Fig 18 above shows the initial status of the job after first switching on and selecting the job from the job menu When the machine is running the operating software code will be shown scrolling on the screen When try ing to trace operating problems this data will be of limited use unless the engineer is familiar with th
3. ccc ceeceeeceeeceseeeeeeeeeeeeees 3 67 Page 3 2 100 140 ServiceManual EE Te 7 EP OTE IMPORTANT NOTE FOR ORACLE JDE SIEBEL SYSTEMS PART NUMBERS SHOWN IN THIS MANUAL SHOULD BE CONVERTED AS FOLLOWS PFE ORACLE JDE SIEBEL B1 2345 A PFEB12345A B1234A PFEB1234A 123 456 PFE123456 Page 3 3 100 140 Service Manual CAUTION Prior to carrying out any maintenance procedures on the Maximail er the following safety precautions must be observed Switch the machine OFF and disconnect the mains cable from the power supply do not remove any cover before doing this Za ure to isolate the mains Could result in death or injury Before switching the machine back on after completion of maintenance work ensure all external covers are in place and un damaged Replace any covers that are damaged PUT SAFETY FIRST 3 1 PRELIMINARY OPERATIONS 3 1 1 PREVENTATIVE MAINTENANCE GENERAL This section details the removal of the machine covers and Preventative Maintenance 3 1 2 REMOVAL OF COVERS Note throughout this manual references to LH and RH are viewed from the far end of the machine looking towards the insert head ie LH is opera tor side RH is drive side Some or all of the following covers may require removal for service operations and Preventative Maintenance Ensure all covers are undamaged Check action of opening covers to confirm correct operation and that safety microswitches function correctly Chec
4. Mark Reading Upper Transport A7337A 1 Feed Shaft OMR 9107754T Mark Reading Upper Transport Feed Shaft Barcode Paper Transport Shaft A2843A Assy 9105453W Two Plate Eject shaft assy A2790A 1 Folder 9106855G Two Plate Eject shaft assy A2701A 1 Folder 9107297S Page 3 67 Issue 2 May 2012 Three Plate 181 128 9100807G Amount for single bin Lenze Clutch folder 3 24 4 Replacement at 3 million inserts or 1 5 million inserts if us age is over 8 hours per day The following parts are recommended to be changed at 3 million inserts in addition to the parts shown in 3 24 3 or at 1 5 million inserts if the ma chine is being used for more than 8 hours per day NOTE Part Nos shown in brackets thus are SAP numbers Module Description Part No Qty Notes Insert Head Lenze Clutch 181 128 1 Request items 9100807G assembled Insert Head Pulley 104T F1404A 1 Request items 9105629E assembled 3 24 5 Replacement at 4 million inserts The following parts are recommended to be changed at 4 million inserts Module Description Part No op Notes Qty 3 Three Plate Paper Direction Roller A7176A Amount 2 for single bin Folder 9105430X Page 3 67
5. VO OO a Gg Tree Zb ze uge Zrv fihsd Page 0 Co em r Ol droga Leg rare Egon Hei l E Fig 21 Usage Wait until the machine comes to rest then click the Get Traces button This will retrieve up to the 10 most recent traces captured by the module electronics Trace O is the most recent document Click on the Previous and Next buttons to step through the 10 most recent documents cont Page 3 28 100 140 Service Manual Interpreting the traces The red trace is the signal from the OMR head This is low when the head reads white paper high when it reads a black OMR mark The green trace shows where the software opens a window of time to look for a mark The window is open when this signal is low The peaks of the other two traces must occur within this window for the mark to be read The blue trace goes high to indicate that a mark has been detected It Should peak at about the same time as the red trace What to look for The base of the red trace trace should ideally be below 200 on a plain white paper background A low base level indicates good head sensitivity Marks will appear as humps on the red trace This hump should be greater than 50mv on the voltage scale Small humps could be due to poor print quality contrast or an insensitive OMR head On a plain background the base of the red trace ignoring the humps Should be fairly flat Ripples of more than 25mv indicates that the p
6. return springs for the no fold beams to ensure they are replaced cor rectly 8 Replacement of all parts is a reversal of removal Fig 61 below shows the correct belt route Page 3 55 Issue 7 Sep 2008 Page 3 55 100 140 Service Manual 3 22 OMR FEEDER 3 22 1 Separator amp Feed Tray The separator fitted to the OMR feeder is identical to that fitted to the Standard feeder and is adjusted in the same way as described in section 3 2 1 Note that the feed tray fitted is the same as that fitted to the Tower feeder and is approx 75mm shorter than the tray fitted to the standard feeder This longer tray can be fitted as an alternative if required but only if the unit behind is a standard feeder OMR feeder or Datacard Turnover Unit The part number for the tray assembly is A7031A 3 22 2 Changing top or bottom OMR Barcode The read head for top read OMR or barcode is mounted on a sliding bracket on a square section slider bar at the front of the machine The bar passes through the chassis on the drive side and is retained on the operator side by a single screw through the chassis side plate The read head for bottom read OMR or barcode is mounted on a lead screw in a sub chassis assembly which lifts out of the unit on the drive side Note that top read machines still have the side plate for the sub chassis fitted on the drive side bt no other parts If it is required to change from top to bottom read OMR or barcode or
7. 2million or 1million if m c running for 4c2 A7080A gt 8hrs day Ac23 24 Clean gears and apply grease silicon based if required Check gear 1 Gears Replace A R It is advised to keep movement sideways and rocking replace gears if required stock of F4150Ax1 F4156A and F4152Ax1 2 Track Feed Clutch 181 127 3 Track feed brake 181 127 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 2million Other parts Eject shaft assy A7079A Eject shaft assy A7080A aL E EN E eee Remove Reni bls DEE Assy A7117A Clean all T bearings Apply light oil Level 3 lt 5 2million or 1million if m c running for 4c 14 and clean off any excess Clean check belt condition Replace if required gt 8hrs day 1 8mm T bearing D1040Ax2 2 Timing belt F5136A 1set 3 Accumulator belts clutch 181 117 4 Clutch Pin GOO79A Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers Preventative Maintenance Schedule Page PM 37 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and aan complete Interval Cycle mins Remove Accumulator assembly A7118A if fitted Clean all T bearings Level 3 2million or 1million if m c running for 4c 11 and check belt pawl condition and replace if required Check pawl are alignment us
8. Adjust further if required sme e a 5mm ee e A e a 3 2 4 Lateral adjustment Fees The separator plate must be laterally located so that the separator pads are exactly central between the tyres If adjustment is required turn the nut shown in Fig 3 below located on the LH side of the unit Adjustment nut Page 3 6 100 140 Service Manual 3 2 5 Pickup roller tyres If the tyres on the pickup rollers become ragged or worn they must be replaced Note that tyres cannot be replaced separately as they are ground concentric on the cores see section 4b 5 for part numbers The shaft is held in place under spring pressure as shown in Fig 2 above Ensure the drive peg is fully engaged when replacing 3 2 6 Alternative tyres rollers Various alternative tyres or rollers are available to provide better pickup for problem paper types as listed below These are supplied either as a tyre only or as a tyre and core assembly where the tyre must concentrically ground in place on the core Note that for the lobed tyres D0052A only the outer 2 tyres on the shaft are replaced For assistance in specifying the correct tyre roller for a particular applica tion contact the Technical Support department Hi Grip Roller C8193A Slotted Roller C8194A Ro
9. To set the adjustment of the wetter beam setting gauge C7403A must be obtained This is a shaped aluminium bar that sets the adjustable stops cor rectly F ee A Le e Wetter beam KC Setting gauge Zero play C7403A on spring Up solenoid Adjustable Rar A sS ali Se sto Ue BN Ee own P si ita 1 4 e Noh solenoid Fig 13a Setting procedure refer to Fig 13a above il Remove lower both side covers section 3 1 2 2 Slacken the screws on the adjustable stop each side Remove the wet ter tank and replace it with the setting gauge C7403A 3 Hold down the wetter beam to that it contacts the guage then slide the adjustable stops so that they contact the spigots on the beam Tighten the screws on the stops 4 Slacken the adjustment screws on the down solenoid each side Hold down the wetter beam and slide the solenoids so that the plunger is bottomed when the arm is pulling downwards to take out any play in the pivots Tighten the screws Page 3 15 Issue 7 Sep 2008 5 With the wetter beam in its raised position slacken the screws on the up solenoid and slide it so that with the plunger bottomed any free play is taken out of the spring without the spring being tensioned Tighten the screws 6 Replace the side covers The wetter beam is now correctly set Wetter adjustments in Engineer mode It is important to note that the wetter beam must be correctly set as de scribed prior to making wetter adjustments in
10. adhering to the PM schedule The extent of preventative maintenance required will depend upon machine usage and is divided into three levels Operator Intermediate and Full The time required for each level differs considerably and estimated times are given in the schedule for each operation The first page provides guidelines for how often each level should be carried out The schedule is sectioned for insert head feeders folders and DTI As well as specific times for each operation the total estimated time required for each level is shown at the end of each of the sections The full PM schedule is shown on the following page Page 3 5 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Preventative Maintenance Guidance and Schedule The Maintenance schedule below is applicable to the 100 140 product range and must be strictly followed to guarantee machine performance and reliability This schedule is based on a monthly cycle count of 200 000 or 50 hours running which is considered the normal maximum If the machine is running less than this the PM should still be carried out with the same frequency but fewer parts will be required See typical examples below on when to carry out a PM this may apply to your machine a If the machine is running for lt 4 hours per day then a Full PM must be carried out every 125 working days or 6 months a If the machine is running for 4 8 hours per day then an
11. and check all track transport and drive Level 3 belts for wear and fit Clean belts and ensure the drive is free to rotate area etc with Rubber Roller Restorer E0483A B13 Remove Upper conveyor A7035A and check all track transport and drive Level 3 belts for wear and fit Clean belts with Rubber Roller Restorer E0483A and ensure the main drive shaft C9259A is free to rotate Level 3 Check for any tight spots in the main drive and belt tension Check all unit screw security pay particular attention to all handles tighten as required Tighten Latch handle C3561E and ensure assembly opens and latches B16 Check sensor cable JST connectors are all properly plugged in Also check ribbon cables headers these are more likely to be dislodged Check for squealing noise from clutches If so remove and clean and replace if necessary Check side guides for movement stop position and parallelism to chassis B14 B15 Level 3 Level 3 Level 3 lt 1 lt 5 lt 5 B17 lt 5 B18 Level 3 lt 1 Ensure side guides retaining screws are tight Check rolling backstop rolls down the feed tray Level 3 Check all clutch pins G0167P or G0079A are intact Level 3 Go though the Engineer menu to check all Analogue and Digital sensors A R calibrate if required Go through the Engineer menu to check each clutch brake and solenoid A R B19 B20 B21 22 B Preventative Maintenance Schedule Preventative Main
12. sensors are analogue Main Disc encoder on motor drive disc on RH side 2 Plate Folder Main Disc encoder on motor drive disc on RH side 3 Plate Folder Form in Hopper 1 2 3 reflective sensor on bridge at lower end of tray Deskew 1 2 3 just in front of pickup rollers Daily Post at bottom of daily post slot Accumulator Tray at lower end of liftable tray Divert Bin 1 at top of tray just before diverter Accumulator Index inside accumulator detects belt pawl to establish reference Stepper Flag slotted vane disc on stepper motors inside accumulator Form in hopper 1 2 3 FP1 2 3 Disc slotted vane disc on fold plate motors Main Disc encoder on motor drive disc Cardfolder Geneva 1 Up Centre Down above Geneva mechanism on LH side Main Disc Page 3 19 Issue 7 Sep 2008 Calibrations CALIBRATIONS 0 ker Pocket to 710mm i gt Collate kt Guide 0 1mm B et Fingers to 710mm bFingers Cal 0 1mm This screen applies only to the insert head and is used to set the collate pocket side guides and the insert fingers to A4 size 210mm When these options are selected the motors for the settings will automatically adjust to the correct size They should then be measured and any difference should be corrected out using the adjustment boxes positive numbers increase the width Note that the measured distances should be 210mm exactly Appropriate clearances will then be automatically app
13. 0 75 to 1 5mm Position C 1 5 to 2 0mm Lower Hopper Position A 0 to 0 75mm Position B 0 75 to 1 5mm Position C 1 5 to 2 5mm Position D 2 5 to 4mm The procedure for adjusting the separators on both hoppers is the same as the standard feeder as described in section 3 2 Page 3 51 Issue 8 Aug 2009 3 20 2 Removal of transport roller assembly Fig 50 Transport roller assembly The transport roller assembly is located roughly in the middle of the ma chine visible after removing the sprung pickup shaft from the lower hopper A number of sensors are located on the assembly and can only be accessed by removing it The removal procedure is described below 1 Remove the clutch pins clutches and drive pins on the two 104T pul leys see Fig 51 below Also remove the screw on the clutch bracket and move it clear within the confines of the cables 104T pulleys amp clutches Clutch bracket Page 3 51 100 140 Service Manual 2 Slacken the drive belt tensioner and remove the belt Slide the 104T pulleys off the shaft Remove two idlers and the 40T gear as shown in Fig 52 below Also remove the safety plate Ze VE ett CE 3 j ZA Safety plate 40T gear Idlers Fig 52 Disconnect the ribbon cable from the main PCB J27 and release the ribbon from the chassis clips Remove the 2 screws each side securing the lower feed tray and with draw the tray as far as possible ensure the reflective se
14. 10 Rdr gt Accumulator Fitted gt Divert Fitted gt Continue Fig 29 Enter Module Settings in Engineer mode and select the relevant OMR or barcode reading unit s Calibrate OMR Gate 1 and or 2 sensors as shown in Fig 30 below Check that the voltage shown circled is lt 0 5v with no paper between Note that Gate 1 is top tray Gate 2 is middle tray ANALOGUE SENSORS 4 gt Greieedi gt Deskew bDDI gt OMR Gatel gt Prefeed gt Deskew pop OMR Gate 20 21 22 23 24 Page 3 34 Issue 8 Aug 2009 Exit Engineer mode Now enter Edit mode for the relevant job and select Edit Item for stations 1 2 on the tower unit set Mark Reading to OMR or barcode as required and tick Cascade if a reader is also fitted to the middle tray as shown in Fig 31 below SHEET ITEM 2 Feed always Feed Mode b Packlength b Fold Type gt View Fold Settings b Feed orientation Face down I Fold mode Via accumulaty gt Mark Reading gt Cascade Use cable ties to secure added wires and cables away from any mov ing parts snag points or sharp edges Replace all covers unless station 2 cascade OMR is also to be fitted in which case see section 3 16 2 The OMR barcode job is now ready to be run If OMR read problems are encountered use the OMR scope function in the Trace Tools de bugging utility described in section 3
15. 181 127 x1 4 Clutch Pin GOO79Ax3 spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers B12 Remove and check motor assembly A7039A Clean area and ensure all Level 3 2million 4b 6 parts are intact tight spots belt noise or signs of wear Clean clock disk 1 Motor Pulley F1372A 220v or F1373A on the motor assembly Check motor pulley is tight on the motor shaft 110v B13 Remove Lower conveyor A7036A and check all track transport and drive Level 3 2million or 1million if m c running for belts for wear and fit Clean belts and ensure the drive is free to rotate gt 8hrs day area etc with Rubber Roller Restorer E0483A 1 Belt 330XL F5122A 1set 2 8mm T bearing D1040Ax4 B14 Remove Upper conveyor A7035A and check all track transport and drive Level 3 2million or 1million if m c running for belts for wear and fit Clean belts with PFE cleaning fluid and ensure the gt 8hrs day main drive shaft C9259A is free to rotate 1 Belt 330XL F5121A 1set 2 8mm T bearing D1040Ax6 2million It is advised to keep stock of F4150Ax2 F4151Ax2 and F4235Ax1 B15 Check for any tight spots in the main drive and belt tension e 3 2million Belt 100 S2M F5113Ax1 B16 Check all unit screw security pay particular attention to all handle
16. 24 2 these parts are in addition to the list below Feeder Belt 100 S2M F5113A 1 ID Gill 1 ll es y Mark Reading Eject Shaft roller A2790A 1 feeder Assy 9106855G Mark Reading Upper Transport A2792A 1 feeder Roller Shaft Assy 9106799Y Mark Reading Upper transport roller A2793A 1 feeder shaft assembly 9107753S Mark Reading Lower Transport shaft A7340A 1 feeder assy 9119828V Mark Reading Middle Transport A7 347A 1 feeder shaft assembly 9119833A Mark Reading Motor Pulley 220v F1372A 1 feeder 9105627C Mark Reading Motor Pulley 110v F1373A 1 feeder 9104297S Mark Reading Belt 100 S2M F5151A 1 feeder 9105217A Mark Reading Gear 40T x 8mm F4150A 7 feeder 9104398xX Mark Reading Gear 48T x 8mm F4151A feeder 9104399Y Mark Reading Gear 25T x 8mm F4152A feeder 9104400Z Tower Feeder Upper transport roller A2792A Shaft assy 9106799Y Tower Feeder Tower Access shaft A2845A assy 9105463G Tower Feeder Transport shaft upper A7232A 1 assy 9109119Q Tower Feeder Transport shaft lower A7233A 1 assy 9106628V NOTE Part Nos shown in brackets thus are SAP numbers Module Description Test No Ton Notes__ Qty Insert Head Feed roller shaft assy A2993A 1 9105468M Insert Head Insert roller shaft A2994A 1 Assy 9105467L Insert Head Envelope Clutch Shaft A2997A 1 Assy 9105466K Insert Head Clutch Brake Shaft A2998A 1 Assy 9105465 Insert Head Opener ass
17. 25 DIA PICKUP ROLLER SHAFT ASSY BEARING HSG T 8mm MIN BELT 100 S2M 900 INFEED RESTRICTOR CORK Issue 9 May 2012 Qty 1 1 1 230v 115v 1 1 1 1 1 1 1 1 1 1 1 2 1 1 2 3 1 6 1 2 Page 3 60 100 140 Service Manual Tower Feeder order AO438A 230v or A0439A 115v NTL Pt No 179 755 180 746 180 759 180 760 180 761 180 762 180 785 181 069 181 569 181 117 181 127 182 338 182 437 182 440 182 443 182 444 182 445 182 723 C8098A DOOS51A F5113A F5151A G0079A SAP Pt No 9100561A 9100741N 9100744R 9100745S 9100746T 9100747U 9105209S 9105274K or 9100831G 9100800Z 9100806F 9100976H 9101007Q 9101010T 9101013W 9101014x 9101015Y 9107073 9103501N 9103618K 9104495Y 9105217A 9104579L Description PSU LAMBDA ZWS50 24 PCB ASSY HI RES SENSOR PCB SPLIT 5SEN 5SOL H D PCB SPLIT 3SEN 4SOL H D PCB SPLITTER 6TX H D PCB SPLITTER 6RX H D PCB ASSY AM4 TWR FEEDER MTR WD 179 072 4WJST CW MTR WD 179 073 4WJST CW CLUTCH W D XH 102 10 CW CLUTCH W D XH 102 20 CCW LOOM RECEIVER W A 100 LOOM EMITTER 100 XH LOOM EMITTER 200 XH LOOM EMITTER 300 XH LOOM RECEIVER W A 300 XH LOOM RECEIVER N A 300 XH LOOM AM4 TWR FDR RIBBONS ROLLER ENVELOPE FEED SEPARATOR PAD 45 55 BELT 100 S2M 710 BELT 100 S2M 900 CLUTCH PIN 230v 115v Page 3 61 Datacard DTI order A0436A 230v or A0437A 115v NTL Pt No 117 240 179 213 179 214 180 776 180 783 180 78
18. 28 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule 2 Plate Folder module Level 1 Operator level frequency will depend on usage and applications Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the PFE website Maintenance item 2 Folder Module Frequency Time to Replacement Part Numbers and complete Interval Cycle Ref a Manual Clean all paper transport rollers using water or recommended cleaning Level 1 2 amp 3 fluid Check joggler tyres if fitted for alignment Clean all sensors with approved air dusters Level 1 2 amp 3 Remove Folder covers Level 2 amp 3 si Vacuum clean to remove internal dust Clean all covers Check for pickup problems from loaded pack to empty hopper by running Level 2 amp 3 lt 10 machine 2 Plate Folder Pickup Shaft Assy A7095A 2 Plate Folder Separator Shaft Assy A7096A Plate Folder Separator Shaft Assy A7096A Infeed restrictor cork GO152Ax2 2million or 1million if m c running for gt 8hrs day Separator Pickup Clutch 181 117 x1 Separator Pad GO154Ax1 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers Inspect Module for ee eee and safety covers are all intact interlocks Level 3 ee ee eee warning labels in place Preven
19. 9104133W Insert Head 9 5mm E Clip E5073A 16 9104134X Insert Head Dowel Pin 3x 8mm _ E5074A 12 9104135Y Insert Head Polycord Belt FOO52A 1 9106615G Insert Head Pulley 220 V F1372A 1 9105627C Insert Head Pulley 110 V F1373A 1 9104297S Insert Head Jockey Sprocket F3004A 2 9104322T Insert Head Gear 40T x 8mm F4150A 9104398xX Insert Head Gear 48T x 8mm F4151A 16 9104399Y Insert Head Gear 25T x 8mm F4152A 3 9104400Z Insert Head Gear 30T x 8mm F4156A 3 9104402B Insert Head Belt 100 S2M 280 F5112A 1 9104493W Insert Head Belt set 140XL Poly F5119A 1 urethane 9104497A Insert Head Belt set 130XL Poly F5120A 1 urethane 9104499C Insert Head EC25 Clutch Pin G0079A 12 9104579L Insert Head Wetter Foam Edge G0135A 2 9104598F Insert Head Wetter Foam Centre G0136A 1 9104599G Insert Head EC30 Clutch pin G0167A 2 91056002 Page 3 65 Module Description Part No Ton Notes Ton Insert Head Spring G1152A 2 9104699L Insert Head Shim G6028A 10 9104879Y Insert Head Envelope Shim G6180A 2 9105641S Issue 2 May 2012 Insert Head EC30 Dowel Pins P2232A 9105657 Insert Head Bearings 6x8x13 8 9103829E Clutch EET 1 91008002Z Feeder Clutch 181 127 4 9100806F Feeder 8mm T Bearing D1040A 14 91036413J Feeder Belt 300XL set F5121A 1 9104501E Feeder Belt 330XL set F5122A 1 9104502F Feeder Clutch Pin G0079A 5 9104579L Feeder Pulley 220 V F1372A 1 91056270
20. E1070Ax2 2 Envelope Shim G6180Ax2 2million 3 Envelope Clutch Shaft Assy A2997Ax1 4 Clutch Brake Shaft Assy A2998Ax1 A12 Check clean finger assembly ensure finger bodies are not sticking on Level 2 amp 3 lt 20 2million or 1million if m c running for 4a 24 the lead screw shaft Remove from machine if required gt 8hrs day DEEN 1 Finger Drives B9320A x1 Check fingers tips for wear sharpening and replace if required 2 Finger Operator B9319A x1 25 3 Middle finger Extension Drive B7638A x1 4 Middle finger extension Operator B7637A x1 Or replace optional fingers that may be fitted A13 If Brass finger Overguides are fitted remove and clean Ensure they Level 2 amp 3 Replace A R 4a 39 rotate freely on the bore Also check for any distortion and wear Ad Refit envelope feeder Level 2 amp 3 A A15 Check finger stops are adjusted to 0 1mm behind envelope crease line Level 2 amp 3 lt 10 2million or 1million if m c running for See appendix guidelines for good Insertion note 10 for instructions gt 8hrs day 1 Finger Solenoid 181 142x2 Finger solenoids clean plungers with dry cloth and use air duster to 2 EC25 Clutch pin GOO79Ax2 remove dust Check and adjust solenoid stroke 4mm 3 Spring G1152Ax2 Preventative Maintenance Schedule Page PM 10 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Comp
21. Engineer mode see Settings on page 3 19 for 100 series or Units Setup on page 3 24 for 140 series If the beam is not correctly set engineer adjustments will not be able to eradicate wetting problems Page 3 15 100 140 Service Manual 3 12 POWER SUPPLIES amp PCBs There is a power supply fitted to the insert head of the machine and also to each separate unit Units for standard feeder 3 tray feeder and 2 plate folder are the same Unit for insert head is different as is the 3 plate folder If failure occurs the power supplies can be removed without major disman tling To remove proceed as follows 1 On the RH side remove the appropriate side cover and lower edge cover On the LH side open the side cover and remove the lower edge cover see section 3 1 2 2 On the LH side remove the single screw retaining the unit to the chassis side plate this is located close to the fuse on each unit 3 On the RH side unplug the cables and remove the 2 screws securing the PSU Withdraw it from the chassis The PSUs are shown below and on the following page Insert Head PSU Feeder Folder 3 Tray Feeder PSU Page 3 16 Issue 7 Sep 2008 3 Plate Folder PSU Fig 16 PSU Part Numbers The three power supplies fitted to the machine are as follows Insert Head PSU 184 167 Feeder Folder PSU 184 168 3 Plate Folder PSU 184 169 See following page for part number of P
22. F1373A 110v 2 Belt F5145A D10 Operator side gears clutches applicable to all clean idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems D11 Remove and check motor assembly Clean area and ensure all parts are intact tight spots belt noise or signs of wear Clean clock disk on the motor assembly Check motor pulley is tight on the motor shaft tighten as required 1 5 a Check sensor cable JST connectors are all properly plugged in Also check Level 3 a 5 5 5 lt D12 Check all unit screw security pay particular attention to all handles Level 3 13 lt D ribbon cables headers these are more likely to be dislodged replace if necessary Go though the Engineer menu to check all Analogue and Digital sensors A lt Replace A R calibrate if required Go through the Engineer menu to check each clutch brake and solenoid A lt 10 Replace A R D14 D15 D16 17 R D R Preventative Maintenance Schedule Page PM 42 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Ref Complete complete IMEC SL Manual y mins Page When all service
23. F4152A 2 9104400Z Tower Feeder Gear 30T x 8mm F4156A 9104402B ee E Folder Assy 9106693N for single bin Sg f Two Plate Upper Transport A2792A 2 Ir Three Plate Idler shaft collation A2852A Amount Folder Roller Shaft Assy 9106799Y Folder deskew 9106694P for single Folder cess Assy 9107327Y for single bin Three Plate Drive Shaft Collation A2851A Amount Three Plate Drive Shaft Jam Ac A2849A Amount Two Plate Motor Pulley 220v F1372A bin Folder 9105627C Three Plate Eject shaft assy A7079A Amount Two Plate Motor Pulley 110v F1373A 1 Folder 9106894X for single Folder 9104297S bin Two Plate Gear 25Tx8mm F4152A 3 Three Plate Eject drive shaft assy A7O80A Amount Folder 9104400Z Folder 9106830F for single Two Plate Gear 30Tx8mm F4156A 2 bin Folder 9104402B Two Plate Belt 100 S2M F5151A 1 Folder 91052174A Two Plate Spring Heavy pres G1117A Folder sure 9104686X Two Plate Gear 40T x 8mm F4150A Folder 9104398X Three Plate Bracket Idler wheel B4376A Amount Folder assy 9105542P for single bin Three Plate Roller Fold Rollers C8175A Amount Folder 9103539C for single bin Page 3 63 100 140 Service Manual Page 3 64 Issue 2 May 2012 Three Plate Transport roller D0044A Amount 3 24 2 Replacement at 2 million inserts or 1 million inserts if usage Folder 9103613E for single is over 8 hours per day bin The following parts are recommended to be changed at 2 million inserts in Three P
24. Intermediate Service must be carried out every 3 months followed by a FULL PM at 6 months a If the machine is running for gt 8 hours per day then an Intermediate Service must be carried out every month followed by a FULL PM at 6 months See Page 8 for definitions Preventative Maintenance Schedule Page PM 1 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Note the information above is only a guideline and may vary depending on individual applications A very large departure from the above volume may require a lower frequency of PM Useful guidelines before implementing the schedule If the machine has been running for some time and you start to get issues ask What has changed Try not to panic and adjust the machine settings because it had been working Ask how the machine has been working lately and use this information as a guide for checking the machine Why am I getting Insertion crashes Possible causing could be a Envelope feed problems struggle to feed when the hopper is fully loaded Do you have the correct set up to run these envelopes Tractor feed or standard feed Check and Implement actions 1 7 as per the guideline document for good feeding see appendix on page 41 Preventative Maintenance Schedule Page PM 2 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 b Skewed envelopes at insertion resulting in finger entry
25. LL CCW XH 24v 181 104 Clutch W D 102 10 CW 181 1590 Clutch W D EC25 LL CW SM 24v 181 105UL Clutch W D 102 20 CCW 181 140 WD Clutch EC25LL 24v SM CCW Preventative Maintenance Schedule Page PM 6 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 d Fingers not returning cleanly and finger digging into the envelope 1 Fingers not returning cleanly home and sticking during insertion This check can be done in situ without taking the finger assembly out of the machine Energise the fingers by hand by lifting up the finger arm the finger arm should fall back to rest It may be worth trying this a couple of times to highlight the problem If they fail to fall back then the finger assembly will need to be removed from the machine to locate the problem Check finger body pivots are free on the shaft To check this remove the e clips that hold the middle finger arm and slide the finger body sideways If binding there will be a dark green residue on the lead screw Shaft once the arm is moved sideways This residue can be easily removed with a cloth and using Rubber Roller Restorer E0483A Use an air duster to remove any free particles before re assembling Preventative Maintenance Schedule Page PM 7 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Slide finger body to check for binding 2 Fingers digging into the envelope Check and implement note 10 and 13 as p
26. OM ADERS amp 2 TRACK ADERS LISTED IN THE TABLES ALL USE TOWER LOCATION PLATE RH E B7659A QTY 1 SINGLE OMR KIT No A O9SA 2 TRACK READER OPTIONAL es B SCREW M4 x 6 e ae eS 479 8550 op Ue ue E C larza lg ENCOD KR z 179 704 QTY 1 3 OMR HEAD MIRRORED OMR SLIDER 179 8540 QTY 1 C6225A QIY 5 Sen i F2647A QTY 2 S eet nce LOCATION PLATE LH 3 WASHER S PROO E B7650A QTY 1 FAQ21A QTY 2 Fa OMR HEAD KC 179 724 GIy 1 LIST OF 2 TRACK READER POSITION OPTIONS SCREW M4 x 6 GRU ART No DESCRIPTION Ge SES TOWER OMR BAR A3 0375 TB TWIN OM AY 1 BTM L Seefe OLY 1 A3 0375 TBR TWIN O AY 1 BTM R SC SNE SE SCREW M4 X 8 SCREW M4 x 10 CSK POZ 0575 11 rR L i E2624A QTY 5 E2711A QTY 4 Fig 22 CLAMP PLATE LH Pos S7o 15 TWIN OMR TRAY 1 TOP R RIOZ2A QTY 1 Page 3 30 100 140 Service Manual Fitting the OMR assembly to the machine L Remove the RH side cover and the tower access assy front amp top cover the tower access assy is the pivoting section at the top front of the tower Remove tower access assy this is not essential but is quick to do and greatly improves access The pivot bar is retained with a screw at each end and a nylon strap On the RH side remove the jockey gears shown in Fig 23 This pro vides access to the end of the transport roller shaft and OMR plate SCeEWS Remove gears Remove the E clips T bearings and springs from both ends of the transport ro
27. PFE website Maintenance item 3 Folder Module Frequency Time to Replacement Part Numbers and complete Interval Cycle mins Ci Clean all paper transport rollers using water or recommended cleaning Level 1 2 amp 3 lt 5 fluid Check joggler tyres if fitted for alignment e Ne E EE GEN 6 Ref Complete Manual Vv C4 Vacuum clean to remove internal dust Clean all covers Level 3 C5 Check for pickup problems from loaded pack to empty hopper by running Level 2 amp 3 lt 10 machine Other things to check for include doubles streaming etc 1 Pickup Shaft Assy A7095Ax3 Check Separator Gap and adjust accordingly 2 Separator Shaft Assy A7O096Ax3 3 Separator Assy A7097Ax3 4 Infeed Restrictor Cork GO152Ax2 2million or 1million if m c running for gt 8hrs day 1 Separator Pickup Clutch 181 117 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers Inspect Module for damage and safety covers are all intact interlocks Level 3 lt 5 function warning labels in place Preventative Maintenance Schedule Page PM 34 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei mins C7 3 Station Tower Access Assy A7091A or A7092A Level 2 amp 3 lt 15 2million or 1million if m c running for 4c 34 or gt 8hrs day 35 1 8mm T beari
28. and applications but at least weekly Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the PFE website Maintenance item Tower Feeder Clean all paper transport rollers using water or recommended cleaning fluid Check joggler tyres if fitted for alignment Clean all sensors with approved air dusters Remove Feeder covers external internal Vacuum clean to remove internal dust Clean all covers Check for pickup problems from loaded pack to empty hopper by running machine Check Feed tyres for wear and separator gap A7032A Insert Separator assembly and Feed Shaft Assembly A7030A Clean Adjust Replace if required Tower Feeder Assembly A5135A Part 1 page 4b 11 Clean all T bearings and rollers note can apply light oil and clean off any excess Preventative Maintenance Schedule Frequency Level 1 2 amp 3 Level 1 2 amp 3 Level 2 amp 3 Level 3 Level 2 amp 3 Level 3 Level 2 amp 3 Time to Replacement Part Numbers and Ref Complete complete Interval Cycle Manual Gei 2million or 1million if m c running for gt 8hrs day 1 8mm T Bearing D1040Ax4 2million 2 Transport Shaft Assy A7236Ax2 3 Lower Fdr Roller Assy A7235A 1 Roller C8098A x4 2 Separator Pads D0051Ax2 Or replace optional tyres if fitted Page PM 20 100 140 Series Serv
29. enve lope If the rollers become excessively worn or gummed and cause slipping they must be replaced Note cleaning should be carried out using a cloth dampened with water rather that Roller Cleaning Fluid The rollers cannot be removed only shaft assemblies are available Shafts in insert head body To remove the the shafts in the body of the head removed clutches E clips gears and drive pins as required to lift the shafts out of the chassis Points to note 1 To remove the upper shaft the bridging plate above it will also require removal 2 Removal of the clutch at the LH end may require removal of the wet ter fluid spout though this should flex sufficiently oF When refitting the upper shaft fit the 25T gear to the RH end before assembling the flanged bearing into the chassis the locator bracket will block the gear otherwise Shafts in opening cover Replacement of the shafts in the cover is a straightforward matter of re moval of E clips springs and T bearings to free the shafts Page 3 14 100 140 Service Manual 3 11 WETTER BEAM SETTING The wetter beam descends on the passing filled envelope pressing the open flap against the damp spong on the wetter tank There is an adjustable stop each side to control the settings and a solenoid each side to pull the beam down A single solenoid on the LH side lifts it back up Correct adjustment of all these elements is critical to ensure effective wetting
30. existing versions higher than 4 1 0 0f To carry out the upgrade select Download from the menu bar then Via Head The same file select dialogs will appear as with direct downloading the difference being that each module can be upgraded through the con nector on the head without the need to remove covers and connect to the PCBs Note that if a new PCB is fitted in field the direct method must still be used Bootload Bootloading is a similar process to downloading and uses the same files Under normal circumstances should not need to be used However if prob lems occur when downloading bootloading may well be more successful Symptoms of such problems would be for example absence of trace of Signs in the RX window when attempting to download or the indicator LED on the PCB failing to flash when the machine is switched on If after boot loading the PCB is still malfunctioning contact Technical Support To use bootload fit a jumper to JP1 to the PCB on the relevant unit then reset by either pressing the reset button on the PCB or switching off on Select Bootload from the menu bar and follow the same process as for downloading Page 3 27 100 140 Service Manual 3 14 4 Engineer Mode Engineer mode is available from the menu bar and is a duplicate of Engi neer in the GUI software This should normally be used in preference but the use of Trace Tools may offer greater convenience if the computer is con
31. for CW rotation from operator side Positive further Factory default 0 Mk 2 only FP2 Counter CW Cal Controls paper travel into FP2 for CCW rotation from operator side Positive further Factory default 0 Mk 2 only Up Detent CW Controls detent landing position for cassette home position Positive increases rotation Factory default 0 Mk 2 only Down Detent CW Controls detent landing position for cassette after 180 rotation Positive increases rotation Factory default 0 Mk 2 only Up Down Detent Counter CW As for CW but rotating Counter CW Factory defaults 4 amp 3 Mk 2 only Conclusion of Settings section Power This provides a read only display of voltages and currents of various supply sources The voltage current readings are displayed to two decimal places Drivers Allows various components to be switched on or off to test them and pro vide a readout of current rating Components shown will depend upon type Page 3 21 Issue 7 Sep 2008 of unit selected and will include some or all of clutches brakes solenoids and indicator LEDs Drive motor is also included for each module as this must be switched on to test some other components Motors This allows you to switch motors on or off to test them and provide a read out of current rating Motors shown will depend upon type of unit selected and will include some or all of accumulator stepper insert fingers collate
32. full OMR specification by ordering the appropriate kit of parts A3247A A3248A A3266A Also available is A3261A OMR Head amp Foot Kit This comprises the OMR 3 Tray 3P Folder OMR on Station 1 only 3 Tray 3P Folder OMR on Stations 1 amp 2 cascade Single Tray 3P Folder Page 3 30 Issue 10 Mar 2011 3 16 1 3 Tray 3P Folder OMR on station 1 only Kit A3247A Fig 22 below shows the assembly of the parts prior to fitting to the ma chine If not already built when received assemble parts now Tower OMR Bar C9382A with head foot assembly fits into the Tower Access assembly as described later Note that top read is shown if bottom read is required swap over the positions of the OMR head and foot assembly opposite The location along the bar of the OMR head depends upon the required approxi mate position to align with the marks on the paper Wherever it is located head together with the aluminium foot with spring loaded nylon shoe The full upgrade kits also include all brackets sliders and slider bars
33. housing and reconnect the sensor cables securing with cable ties as required Page 3 9 100 140 Service Manual 3 5 3 PLATE FOLDER ACCUMULATOR 3 plate folders may include an optional accumulator unit for collating or di vering forms The accumulator may also include a diverter tray for receiving diverted forms otherwise these will remain in the accumulator for manual removal 3 5 1 Accumulator conveyor access Should problems occur in the accumulator conveyor it can be pivoted down in the chassis for access to the belts stepper motor or sensors Proceed as follows 1 Remove the 6 screws securing the underpanel below the accumulator 2 Remove the 2 screws securing each sideguide as shown in Fig 9 be low Support the conveyor from below as the screws are removed pg les _ Sideguide T a a screws _ Me Fig 9 3 Lower the conveyor downwards to gain access to the belts stepper motor pawl sensor and vane sensor as shown in Fig 10 below Vane sensor Stepper motor Pawl sensor Page 3 10 Issue 7 Sep 2008 3 5 2 Accumulator sideguides The sideguides are adjustable for parallelism should they be found to run ning out of true Slightly slacken both of the screws shown inFig 9 and twist the sideguide to suit note it will pivot slightly about the countersunk screw 3 5 3 Accumulator overguide removal To remove the accumulator or overguide proceed as follows 1 Remove the RH side cover
34. lower trays where fitted pull out the hopper trays and the pickup roller shaft will be visible inside the unit When fitting a replacement roller note that it is fitted with one way clutches reassemble so that when viewing the end of the shaft from the spring side the roller rotates freely in a clockwise direction contd Page 3 7 100 140 Service Manual Page 3 8 Issue 7 Sep 2008 3 3 3 Separator pad replacement 3 4 3 PLATE FOLDER ROLLERS The separator pad is permanently bonded to an extrusion and both items are replaced as an assembly Access to all three is gained by pulling out Form Entry the hopper tray then withdrawing the infeed plate as shown in Fig 5 2 J below Fig 6 Form Exit NG Showing schematic infeed blat ce 1 view of 3 Plate Folder nteed plate Separator pad SHONN Upper rollers x 2 assembly 4 3 dene Lower rollers x 3 3 4 1 Lower roller removal There are 5 fold rollers in the 3 plate folder 3 lower rollers and 2 upper All can be removed in situ relatively easily as described in the procedure below 1 Open the LH side cover remove the RH side cover and also the LH amp RH lower side covers see section 3 1 2 Fig 5 8 2 Remove the 2 screws either side securing the fold plate box and lift Remove the screw retaining the pad assembly and fit the new item noting ou the box from the rear This provides access to all 3 lower fold roll that it is free to rock slightly w
35. machine and View INI buttons allow the module information stored in the firmware to be compared with the information in the INI file on the computer these should match This is a read only function as Plug amp Play will allow module settings to be restored if physical changes are made When finished save changes and exit Units Setup Equivalent to 100 Series Settings Select each module in turn to make any changes Note that Calibrations apply only to insert head and are equivalent to 100 Series Calibrations After making a change press Apply Please fill settings _ Settings Calibrations Collate Pkt Cal 0 1mm Change ingers Cal 0 4mm Change Wetter Start mm Change Wetter Stop mm Change Env Stop Pos Cal mm Change Env Insert Pos Cal mm Change Env Reverse Pos Cal mm go Chmpg Env Seal Pos Cal mm C Env Depth Cal Measured mm Change Env Flap Cal Measured mm Change Ins pawl stop pos cal mm Change Pocket backstop cal ms e default Module 0 Head Select Unit When finished save changes and exit Page 3 24 Issue 7 Sep 2008 Firmware Download Firmware downloading allows selected units to be upgraded with selected files usually sourced from the company website Select the unit s to be upgraded and use the Browse button to find the appropriate am4 file s Note
36. move this clear of the hole do not disconnect cables See Fig 41 below Replace the bracket when the screw is tightened Chassis cut out for cable Slide bar re EP taining screw Splitter PCB bracket Fig 41 9 Fit the laser warning label to the inside of the tower access assembly after degreasing the surface see Figs 35 amp 36 Connection 10 Route the scanner cable through the chassis cutout shown in Fig 40 and retain it using existing chassis clips as shown in Fig 42 opposite Connect the extender cable to the scanner cable and attach this to existing ribbons using cable ties Connect the cable to J7 on the ex pansion PCB see step 11 for single tray machines Extender cable connected to J7 Page 3 42 Issue 8 Aug 2009 Scanner cable Expansion PCB and ribbon cable Single tray machines only 11 Single tray machines are not fitted with an Expansion PCB as stand ard hence the upgrade kit includes this item together with 4 spac ers with screws for mounting it and a ribbon cable for connection To fit the Expansion PCB remove the screw in each corner of the main PCB and lift it away from the chassis sufficiently to insert and tighten the M4 x 6 Cap Head screws for the spacers Refit the main PCB and assemble the Expansion PCB to the spacers using M4 x 6 Cap Head screws Connect the ribbon cable between main and Expansion PCBs as shown in Fig 42 cont See also connect
37. necessary as per A22 amp A23 Ee ea parallelism to chassis ss Let Let distorted Check Polycord belt for damage Has it stretched Should not be longer a 3 E GE or 1million if m c running for than 930mm Replace as required gt 8hrs day Polycord Belt FOO52Ax1 Preventative Maintenance Schedule Page PM 14 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei mins A36 Check the Lenze clutch for the collate pocket entry slow when Level 3 3million switched ON in engineer you should not be able to turn the Polycord 1 Slow down clutch assy A7366A drive If so check set the clutch gap replace the clutch and the clutch disc if required lt 5 A38 Collate pocket Backstop assembly A7058A solenoids clean plungers Level 3 lt 10 2million or 1million if m c running for with dry cloth and use air duster to remove dust Ensure collate pocket gt 8hrs day 1 Solenoid Long Stop 181 142x1 2 Solenoid Short Stop 181 142x1 3 Clutch Pin GOO79Ax2 A39 Engineer Calibrations Check and adjust if required the finger and eee kk collate pocket to 210mm A40 Go though the Engineer menu to check all Analogue and Digital sensors ec ee oe rr ae ae calibrate if required WEE Teese a Tess fingers Rc aai O ENER ST solenoid function warning labels in place lt 30 A4
38. nected anyway To use Engineer select it from the menu bar and choose the required mod ule Use the tabs to select the area concerned solenoids sensors currents etc Fig 20 below shows an example display for the feeder for a full explanation of the Engineer functions see section 3 13 of this manual Li PFE Trace food TIAME LD EN Rx Stlog Steptea On on 8 pg BS jen e i l Toini bai Jm Cani Tega dE Du Matzet epes een pa EE T EF PERT EECH is WFi Cote Fake rn Cirsa Pia po aiian Ll Ss Pimia Eieren cn WESSEN pes CC el 1 ge Calas Fu mp rn Eimiin i SS 2 Gg cere gr ie Dr l ry eisen ee Menne ee ee i Eie Ead Cations FO Caisa D Land poser See ER EET ge ae EES oo Er i y i ie ae e Ss BEEN en pa Tomb eircom Pula i D a i P Fig 20 Page 3 28 Issue 7 Sep 2008 3 14 5 OMR Scope The OMR scope function is available on the menu bar and can be used for analysing OMR problems It displays the trace of the output from the OMR reader for up to the most recent 10 document reads see Fig 21 below Notes a Before using the scope to trace OMR problems ensure the reader is correctly installed and set up as described in section 3 16 b The computer must be connected directly to the OMR reading unit usually a 3 plate folder see section 3 14 1 for details of connect ing to the machine Sa 4 Zeg ae Ou Km E P z E 18
39. on hinge 4 LH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged Tower Feeder 1 RH side cover 1 x countersunk screw inside chassis at front top 1 x screw inside chassis face below lower tray RH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged LH side drop down Lower cover then remove 2 x retaining straps amp 3 x nuts on hinge LH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged Top tray undercovers Remove RH cover lower LH cover Remove 3 screws each side on chassis 1 x screw each side on top of tray Bottom tray undercovers Lower LH cover Remove 1 screw on side of chassis 1 x screw each side on top of tray Front cover Remove retaining strap inside cover Remove 1 x screw each side on pivots unclip ribbon cable and unplug connector from PCB Feed ribbon through hole while removing Page 3 4 100 140 Service Manual 3 Plate Folder 1 RH side cover Open front roller platten and daily post cover Re move 1 screw at top inside chassis in front of feed tray 1 x screw in front of daily post tray Lift cover upwards to free lugs 2 R
40. or repair operations have been carried out the machine Level 2 3 lt 5 must be left with all parts reassembled leaving no risk of injury Complete service log sheet Times Level 1 lt 15 mins Level 2 lt 25 mins Level 3 lt 2 5 hrs Preventative Maintenance Schedule Page PM 43 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Appendix to PM Schedule Preventative Maintenance Schedule Page PM 44 100 140 Series Service Manual Preventative Maintenance 2 Issue 3 Jul 2008 Envelope Feeding Set up Options Please note that any combination of these tips could help with particular envelope types Setup Envelope type Option Envelope lead edge curled twisted and does not sit parallel to the separator pickup roller resulting in Side Pick up feed Separator Separator Spring guides system gap Action settings required setting Clearance Pre feed up to tractor part 2mm Max no A7217A Separator pad overlap gt 0 5mm Envelope sitting away from pickup roller Envelope sitting in pickup roller Envelope Twist o Max 6 5mm Preventative Maintenance Schedule If the envelope is skewing into the sideguide s then initially remove and reload entire hopper If problem persists then re adjust the side guides to give slightly greater clearance The use of the tractor should help to flatten the curled envelopes at the point of separation to prevent this N
41. pin replacing the 3 x 8mm pin ensure that the spring tang is located in the small slot outer fingers or lips over the finger body inner fingers Check the condition of the spring also and replace if broken Note that the fingers are handed left and right with the outer pair nylon and the inner pair steel Later 2 part inner fingers From Sept 2006 a revised 2 part design was introduced for the two inner fingers These provide improved opening of the envelope throat particularly on envelopes with long flat central throat sections They can also accom modate very deep and often out of specification envelopes Adjust by removing the finger and slackening the M3 nut and using the setting criteria shown below OMINAL SET POSITION SHOULD BE OK FOR j OST IN SPECIFICATION W ENVELOPES FORWARD SET POSITION REQUIRED FOR DEEP THROAT ENVELOPES Le BACK EDGES OF tL PARTS ALIGNED QTE THAT ALTHOUGH THE FINGERS CAN BE SET BETWEEN THESE TWO POSITIONS IT IS EXPECTED THAT THEY WILL SUIT MOST APPLICATIONS NOTE THAT ALTHOUGH THE FINGERS CAN BE SET BETWEEN THESE TWO POSITIONS IT IS EXPECTED THAT THEY WILL
42. place Clip the cover onto the base and tighten the grub screw onto the end of the transport shaft Pull out the Allen key and turn the ad justor slot fully clockwise to position 2 Note when the encoder cover has been clipped in place it cannot then be removed 10 Page 3 38 Issue 8 Aug 2009 Connect the supplied encoder cable 182 703 from the encoder to the upper Splitter PCB on the LH side Wires are connected BLK WHT to Ji RED BRN to J2 Remove the infill cover and pivot plate shown in Fig 34 below Also remove the paper transport bridge just below the infill cover and the extrusion under it Infill cover and E bh pivot plate Paper transport bridge Fig 34 Fit the new extrusion C7401A but do not fully tighten the screws In sert 3 sheets of 80gsm 20Ibs bond paper between the extrusion and the white roller below it Bias the extrusion so that the paper just fits in the gap and tighten the screws Check that there is slight drag on the paper as it is pulled out of the gap Fit the new OMR transport bridge B7670A in place of the paper trans port bridge On the OMR assembly ensure that the gate sensors are in place and correctly connected RED BLK wires inside the tower unit Fit the unit into the tower feeding the sensor and OMR head wires through the plastic bush on the RH side On the LH side ensure the pip on the assembly side plate locates into the notch in the chassis edge Refit the infill cover and
43. pocket and foldplates Interlocks amp Covers Reports on state open or closed of covers and interlocks feed trays present for each unit Use this to test for deficient switch or magnet OMR Barcode Setup Feed Units only Currently a null function Burn in Mode If this is selected when Engineer mode is exited and the machine is run it will operate indefinitely using the last selected job Remove all stationery first Switch to another job if required and burn in will then operate with those job parameters Note that burn in does not increment the total machine count Env Only Mode Allows machine to run with envelopes only to help fix envelope problems Set Default Supervisor PIN Allows the Supervisor PIN to be set to its system default of 123 Use this feature if the Supervisor PIN has been changed and then forgotten The PIN is changed by the user in Supervisor menu View throughput If deselected suppresses output per hour rate on display when running Use when conditions require output rate not to be shown Sensor Cal Super If selected adds analogue sensors to Supervisor menu to allow calibration Page 3 21 100 140 Service Manual Configure system Insert Head ken He supply gt Second wetter fitted _ Before the machine is able to operate it must first be configured to re flect the actual hardware setup For example if the last station is a 3 bin 3 plate folder thi
44. removed or changed to a different type the new configuration will be detected and can be readily updated e if a board is changed on the head or module the new board will be detected and settings can be readily restored from the INI file of the PC e if a new PC is fitted the configuration can be read from the machine IMPORTANT DIP switches must be correctly set to the module address on power up see section 1 3 Description of Button Functions mos TTT TT Burin t Page 3 25 100 140 Service Manual 3 14 TRACE TOOLS Firmware downloading and debugging on the 100 series not 140 requires the use the Trace Tools utility This runs on a PC laptop and is connected to the machine via serial port The utility can also be used for Engineer set tings machine configuration and job configuration though these should normally be carried out on the GUI for non PC versions of the machine and using the operating software for PC versions Another built in function is OMR scope analysis for troubleshooting OMR problems 3 14 1 Connecting the machine To connect the computer to the machine an adaptor box 184 176 will be required note that the lead is specific to Automailer 4 The adaptor box plugs via a DIN D type lead into the COM port on the computer and the serial lead then connects to the debug connector next to the mains socket see Fig 17 below
45. separator pads are spring mounted hence a range of thicknesses can be accepted for each setting for thicker inserts the sepa rator can open up to accommodate the material Pickup Separator shaft plate Gap adjustor 3 2 2 Separator replacement If doubles are continually being fed or damage occurs the separator may need replacement This is effected by replacement of the plate assembly that the separator pads are permanently bonded to To gain access remove the RH side cover see section 3 1 2 and lower the LH side cover Remove the 2 screws either side of the hopper located near the top of the chassis sides Lift out the hopper unclipping the sensor block as it is withdrawn The separator is now visible as shown in Fig 1 above Remove the central screw and lift out the separator plate When replacing no further adjust ment is necessary Page 3 6 Issue 7 Sep 2008 3 2 3 Separator gap The separator gap is factory set using a jig and should not normally require adjustment but if for any reason it does so proceed as follows 1 Slacken the central screw on the alignment adjustor shown in Fig 1 2 With the smallest setting A selected turn the brass adjustor so that there is approx 0 5mm negative gap as shown in Fig 2 below This can be gauged by winding in a piece of 80gsm pa per and observing that it corrugates slightly Tighten the central screw when the setting is correct and test run the machine
46. that each file includes the module name in the filename ie for head 3P folder or feeder 2P folder Cardfolder The lower windows show the version number and status of the file These can be compared with the centre window showing the same details for the cur rent firmware in the unit When downloading the righthand window shows download status in progress Engineering Firmware download Cua a Amama Pr Ca Bt vera a 1d Bad m e EN Build date Fri 14 Pet SR s Medilo 8 2 Foster i at 4 4 F Mesdula 2 1h Mi Feadar Jee merge Wea ng Z Modula J Zei Folder Seed dates Fri 14 Fet mm d Module 4 Sp Sh Folder d Bugd pre j ar Pra PE emer Ae e Pasi iera l Br ll vr ey 1 0 P D mumie TAF vg CAPe Filana FEM aa ler Pa Fire ee iC Bod dee Toe 20 ab ET Ero ORT a T T f CRG Fikes APE Wan migdier Pile Fa v Cross File FP ieee ile Pe Freire rt eetlpnt M pnd ver ier W 38 20 Budd nuer 1871 CRS ithe Tensrertlsl E Ww Budd dete Toe 20 Fab ant D EN Sistas pe eregreerireg te Use Change Params for existing firmware higher than 4 1 0 0c as fol lows PCI CAN USB CAN Packet 19 4 Send Interval 1 1 O Flow Timeout 10 10 Press Save Params to save For existing versions prior to 4 1 0 0c use Trace Tools for upgrading as per 100 Series see 3 14 3 Page 3 24 100 140 Service Manual Broadcast Mode This allows multiple feeders 2P folders Cardfolder to be upgraded simult
47. the sponge can be washed with soapy water 1 Wetter foam edge G0135Ax2 2 Wetter foam centre GO136Ax1 A5 Clean all sensors both Transmitter and Receiver if applicable with Level 1 2 amp 3 approved air dusters Note punched arrow indicators on machine to identify sensors A7 Ensue no pickup problems from loaded pack to empty hopper run Level 2 amp 3 be machine in envelope mode only to check for feed problems refer to appendix items 1 7 A8 Check Feed tyres for wear and separator gap Clean Adjust Replace if Level 1 2 amp 3 600K 4a 22 required 1 Joggler Tyres D0052A x2 lt 15 Level 3 Roller C8098A x4 2 3 3 Separator Pads D0051Ax2 Or replace optional tyres if fitted A8 Check rolling backstop rolls down the feed tray p el3 poo a Al 2 A Preventative Maintenance Schedule Page PM 9 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei E mins Check wetting setup and adjustments run machine in envelope mode eet e Bt sc 15 only to check wetting All Remove envelope feeder A7061A or A7351A Then check clean or Level 2 amp 3 2million or 1million if m c running for 4a replace flap grip rollers if not turning freely no flat spots should be gt 8hrs day visible Also check spring action and rollers clear edges of flap plate 1 Bearings 6x8x13 8mm
48. will then allow the label to be programmed to create a definition The 140 series does not require a licence full programming is available as Standard within IMOS This procedure assumes that the licence key has already been obtained This key must then be entered into the software before an OMR or barcode definition can be created the definition can then be selected by the opera tor for use within a job Full details of entering the 100 licence key and then programming 100 and 140 for OMR or barcode Advanced or Flex are detailed in Appendix 1 Licencing and Programming 100 140 Series Page 3 50 Issue 9 May 2010 Page 3 50 100 140 Service Manual 3 20 TOWER FEEDER The tower feeder is a 2 hopper version of the single feeder It adopts a sim ilar but not identical version of the feed mechanism as used by the 3 plate folder Paper specifications for the hoppers are as the standard feeder with the exception that the maximum thickness limit for the upper hopper is 2mm due to the paper path being too tight for thicker items The lower half of the unit including the conveyors is identical to the standard feeder There is no OMR option for the tower feeder 3 20 1 Separator adjustment The separator is the same as the standard feeder except that the upper hopper has only three settings as opposed to four for the lower hopper The ranges for each are shown below Upper Hopper Position A 0 to 0 75mm Position B
49. 1 127 x1 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 3million Plate Folder Paper Direction Roller A7176A Page PM 30 100 140 Series Service Manual Maintenance item Head Unit Time to complete TI mins Remove 2 Plate Folder Fold Box Assembly A7193A from machine and check travel of fold plate 1 and 2 backstops Clean fold plate belts and ensure they are held within the slider tighten as required Oil brass Slider and clean off any excess Drive side gears clutches applicable to all clean idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Operator side gears clutches applicable to all clean idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Remove and check motor assembly Clean area and ensure all parts are intact tight spots belt noise or signs of wear Clean clock disk on the motor assembly Check motor pulley is tight on the motor shaf
50. 100 140 Service Manual Page 3 1 Issue 7 Sep 2008 Section 3 Seon De 3 Plate Folder Accumulator Service 3 5 1 Accumulator Conveyor Access sssssseereesesserrrrrerrrrrrresrrrrrrre 3 10 Operations and Adjustments 3 5 2 Accumulator Sid QuideS ccscccccssssescsccssssssesssssssseesessssssecesesseseesee 3 10 Sect Page 3 5 3 Accumulator Overguide Removal cceecesesesssesseseseeseseeeeteeen 3 10 3 1 Preliminary Operations 3 5 4 Alternative DD Sensor Poelton 3 11 3 1 1 Preventative Maintenance General ENEE 3 4 3 6 Envelope Feeder Removal nnnnnnnnnnnnnnennneennnnnsnnnnnsseeesenas 3 12 3 1 2 Removal of COG ege deteietde rg eege Eege eEEEe de Z anata 3 4 3 7 Collate Chain Replacement cccccceccccececseceececeecereseereeees 3 12 3 1 3 Se ete og lt 0 6 lt Seana eee eee 3 5 3 8 Insert Finger Replacement 3 13 3 2 Feeder Separator 3 9 Collate Feed Roller Repnlacement 3 14 3 2 Feeder Separator eae cctessuicdueneededeieneacisviiebsdedandewsacvivaaveesosesaeedend enis 3 6 3 10 Closer Roller Replacement ccccccceccesseccereeceeseesseseeseseees 3 14 3 2 1 SEENEN ee eege 3 6 3 11 Wetter Beam Adiustment 3 15 3 2 2 separator Replacement 2 ccccceseeeeeceeeeseeeeeeeeeeseeeeeeeeeeneeeees 3 6 3 12 Power Supplies amp PCBS aiaisiononosonanarasisnsnerereririririnrsrnrerern 3 16 3 2 3 elas eege 3 6 3 13 Engineer Mode aasananaoananaoanenennoenenereneneiennnnnnnnnnnnnnrrnnrnr
51. 14 of the service manual Page 3 34 100 140 Service Manual Page 3 35 Issue 8 Aug 2009 DS 140 Configuration 27 In Engineer mode select Diagnostics then Analogue Sensors tab 25 Enter Engineer mode from the setup screen and select Hardware preset lia et sages Mae CS ee for any Setup Select the Edit tab then the appropriate hopper of the mark ppers g s reading unit s Set the number of readers for each hopper as re quired as shown in Fig 31a below Engineering Diagnostics Solenoids Motors Analg sentons Digtal sensors Covers Power Micetaneous Reader setup ja Analog sensors More Analog sensors D Faase WS stra Meteedt Cal omr Wabe of asb en 9 a vow Dech ee Cal one i fr trees end moders Ut ut gesergr Leners s i if 4 gt Head standard bopper Setting Dim oM pan 1 mm emm Uz readers Modalo 5 Hepper 1 FA o A LEN A pines Paze e resid P Nodete handieed hopper Module 5 iepp Modules Module 6 iepper 1 Geiee orm Module 8 3p3h Folder _ a Gin Seem j b ar Fig 31a Fig 31c cont 26 Select Module for the tower unit then select the type of reader for each relevant channel number as shown in Fig 31b Ch 1 4 are for OMR reader Ch 9 amp 10 for barcode See connection diagram at 3 17 1 fig 43 for further explanation of channels Made A Hoppas I th WR Foeter eline Module 5 2h Tesdai
52. 23A should be roughly evenly distributed about it STATION 2 SIMILA OR STATION 2 S SIGHT OTE TOP AD IS SHOWN OR BOITO EAD LOCATIONS OF THIS ASS 3LY AND OMR IFAD AR REVERSED ENCODER 179 704 QTY 1 E SCREW M4 x 10 CSK POZI SCREW M3 x 6 PAN 179 704 QTY 1 F2711A QTY 5 F2647A QTY 2 SCREW M3 x 6 PAN ITEMS AS STATION1 OMR SENSOR SLIDER M3 WASHER S PROOF E6474 QIY 2 C6352A QTY 2 F4021A QTY 2 3 WASHER S PROOF CLAMP PLATE RH eee We ee enue F4021A QTY 2 R2057A QTY 1 F2ZO0SA QTY 2 SENSOR BRKT UPPE B7667A QTY 1 SCREW M4 X 8 T T E2701A QTY 1 LOCATION PLATE R2056A QTY 1 OMR SLIDER E C6223A QTY 5 K Ba LOCATION PLATE LH OMR HEAD i R2055A QTY 1 CLAMP PLATE LH 179 724 QTY 1 9 R2032A QTY 1 SCREW M4 x 6 GRUB GS X JAX E2505A QTY 1 D NASZ AN La Ke eg x SE D ke a a Bi dio i i i S SENSOR BRKT LOWER OMR HEAD SLI oD B7668A QTY 1 CLAMP PLATE LH 179 8550 QTY 1 S SCREW M4 X 8 T T OMR SLIDER R2058A
53. 2958A TOWER ACCESS LATCH R2033F NOT PART OF HORIZONTAL BARCODE ASSEMBLY A3 0375 BBH 5 ONA M4 x 8 POZI PAN HD SCREW __ M3 WASHER E2624A QTY 2 E4009A QTY 2 d O Q HORIZONTAL BARCODE TRANSPORT PLATE M3 x 8 CAP HD SCREW B9171A E2503A QTY 2 Fig 36 Horizontal Barcode Upgrade Kit A3293A or A3297A Page 3 40 100 140 Service Manual 3 17 1 Fitting a vertical barcode assembly to the machine 1 Remove the RH side cover and open the LH side cover 2 Remove the tower access assy this is not essential but is quick to do and greatly improves access the tower access assy is the pivoting section at the top front of the tower The pivot bar is retained with a screw at each end and a nylon strap 3 Remove the paper tranport plate opposite the tower access assem bly this is retained by 2 screws on the lower edge 1 screw on the LH side Note that the plate will be different depending on whether the machine is a 3 tray or a single tray both are retained similarly Also remove the extrusion see Fig 37 that the paper transport plate attaches to 2 screws at each end and fit the replacement item Note that to access the screws on the LH side the gear idler must be re moved as shown in Fig 38 opposite 4 Assemble the paper skis location plates clamp plates and ski slide bar as shown in Fig 35 on the previous page but do not tighten the M4 x 25 screws at this stage Slide the assembly into t
54. 3 insertion wetting and closing A45 When all service or repair operations have been carried out the Level 2 3 lt 5 machine must be left with all parts reassembled leaving no risk of injury Complete service log sheet Times backstops are working and not sticking Check solenoid stroke 4mm Level 1 lt 30 mins Level 2 lt 4hrs Level 3 lt 7hrs Preventative Maintenance Schedule Page PM 15 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule Feeder Level 1 Operator level frequency will depend on usage and applications but at least weekly Level 2 Intermediate Service frequency usually 2 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the PFE website Maintenance item Insert Feeder Frequency Time to Replacement Part Numbers and complete Interval Cycle Clean all paper transport rollers using water or recommended cleaning Level 1 2 amp 3 lt 5 fluid Check joggler tyres if fitted for alignment Clean all sensors with approved air dusters Level 1 2 amp 3 a 600K Ref Complete Manual Vv Page Vacuum clean to remove internal dust Clean all covers Check for pickup problems from loaded pack to empty hopper by running Level 2 amp 3 machine Check Feed tyres for wear and separator gap Level 3 lt 5 3 6 A7032A Insert Separator assembly and F
55. 5 180 794 181 069 181 132 182 337 182 339 182 416 182 443 182 450 182 664 182 665 182 728 184 168 A7331A E5121A F4283A F5145A G0079A G0167P G5072A SAP Pt No 9100130B 9100518F 9100519G 9100753A 9107050K 9108256R 91052716 9105274K 9100811L 9100975G 9100977 9105267C 9101013W 9105292D 9105284V 9105283U 9105282T 9101137A 9107313 91058162 9106926F 91055055 9104579L 91056002 9105614P Description OPTO PAIR LONG RANGE CLUTCH EC30 CW 8mm 24V CLUTCH EC30 CCW 8mm 24V PCB WIDEBODY DISK SENSOR PCB RS232 INTERFACE PCB ASSY AM4 TWR FEEDER PCB ASSY PHOTOLOGIC DISK MTR WD 179 072 4WJST CW CLUTCH W D 179 154 2WXH LENZE LOOM EMITTER 100 LOOM RECEIVER N A 100 LOOM 4W 4W XH LINK 0 3M LOOM EMITTER 300 XH LOOM 4W 4W XH LINK 0 25M LOOM PIE 310 TX 300 XH LOOM PIE 310D RX 300 XH LOOM DTI MC LINKS AM4 FDR FOLDER PSU ASSY BRAKE LENZE O3 Loctite assy reqd PIN SPLIT 2 5Dx20LG SS Cotter 1501234 GEAR CLUTCH 48T 1M x8mm BELT 100 S2M 322 CLUTCH PIN USE G0167A BELT SET 666mmx1i5mm x2 S Issue 8 May 2012 Qty A Fb kk bk bh FA kA FA FA Fb bh Fb kk kk Fi kA kA kA Fb Eh KA kk kk kk Eh Page 3 61 100 140 Service Manual Page 3 62 Issue 2 May 2012 Suan PRRTS REPLACEMENT by Vance Module Description __ Part No on Notes Ton 3 24 1 Replacement at 2 million inserts me EE et LL The following parts are recommended to be changed at 2 million inserts 91044002 See also 3
56. 5121A 1set 2 8mm T bearing D1040Ax6 2million Gears Replace A R It is advised to keep stock of F4150Ax2 F4151Ax2 and F4235Ax1 2million Gears Replace A R 2million It is advised to keep stock of F4150Ax1 F4156A and F4152Ax1 Level 3 2million or 1million if m c running for gt 8hrs day Track Feed Clutch 181 12 x1 Track feed brake 181 127 x1 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 3 million Eject shaft assy A2790A Eject shaft assy A2701A With ALL parts re assembled Check for any tight spots in the drive and Level 3 belt tension re tension main drive belt Check all side guides for movement feed trays and accumulator stop Level 3 le WE NL NEE position and parallelism to chassis Check all unit screw security pay particular attention to all handles Level 3 ee tighten as required Check sensor cable JST connectors are all properly plugged in Also check Level 3 e ee se ribbon cables headers these are more likely to be dislodged A Ul C18 Clean rollers on Folder Eject Shaft Assemblies A7201A A2790A Clean gears and apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Preventative Maintenance Schedule Page PM 32 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Num
57. C Feeder Pulley 110 V F1373A 1 9104297S Mark Reading Clutch 181 117 1 Feed 9100800Z Mark Reading Clutch 181 127 Feed 9100806F Mark Reading 8mmT Bearing D1040A 16 Feed 9103641 Insert Head Closer Bearings P2226A 9105695Y E1070A 2 Feeder 100 140 Service Manual Module Description part No Qty Notes Qty Mark Reading Belt 300XL F5121A Leet Feed 9104501E Mark Reading Belt 330XL F5122A Leet Feed 9104502F Mark Reading Clutch Pin G0079A 7 Feed 9104579L Mark Reading EC30 clutch pin G0167A 91056002Z DEN Tower Feeder Brake 179 214 2 9100519G Tower Feeder Brake 181 105UL i 9100792R Tower Feeder Clutch 181 117 2 91008002 Tower Feeder Brake 181 127 5 9100806F Tower Feeder Feed wheel tyre D0038A 4 91036110C Tower Feeder 8mm T Bearing D1040A 22 91036413 Tower Feeder Belt 330XL F5122A 1 9104502F Set Tower Feeder Clutch pin GO079A 9104579L Tower Feeder EC30 clutch pin GO167A 2 91056002 Tower Feeder Belt 300XL F5121A Leet 9104501A Two Plate Separator Pickup 181 117 1 NN folder Clutch 9100800Z Two Plate Clutch 181 127 folder 9100806F Page 3 66 Two Plate Separator Assy A7097A 1 folder 9101747L Issue 2 May 2012 Two Plate 8mm T bearing D1040A 22 folder 91036413 Two Plate Belt 300XL F5121A Leet folder 9104501E Two Plate Belt 330XL F5122A Leet folder 9104502F Two Plate Clutch Pin G0079A fold
58. CBs Page 3 16 100 140 Service Manual PCB Part Numbers The PCBs fitted to the machine are as follows PCB Insert Head LH AM4 Control PCB Processor Control Panel PCB Display Inverter Ribbon Splitter Insert Head RH Ribbon Splitter x 2 Ribbon Splitter Motor Disc Fingers flag Collate Sideguide flag Feeder RH AM4 Feeder Folder PCB Motor Disc Feeder LH Ribbon Splitter Ribbon Splitter Ribbon Splitter 3 Plate Folder RH 3 Plate Folder Main PCB Expansion PCB Ribbon Splitter x 3 Motor Disc 3 Plate Folder LH Ribbon Splitter 180 721 180 720 mounted on Control 180 723 180 765 180 759 180 759 180 760 inside 180 746 180 689 180 689 180 722 180 689 180 759 180 761 centrally located 180 762 centrally located 180 724 180 768 Mounted onto Main PCB 180 758 180 746 180 759 Ribbon Splitter x 2 LED Indicator PCB Stepper PCB Power Supply Unit Interlock PCB Page 3 17 180 760 180 764 180 769 180 756 Issue 7 Sep 2008 Page 3 17 Page 3 18 Issue 7 Sep 2008 100 140 Service Manual 3 13 ENGINEER MODE 3 13 1 100 Series see 3 13 2 for 140 Series Engineer mode can only be accessed by input of the correct PIN It allows the engineer to test the machine functions and configure the system to re flect the machine hardware and options ENGINEER Display contrast Module Settings Insert Head gt Burn in Mode gt Env Only Mode Set Default Supervis
59. Dian Module 5 Hopes 3h Feeder Aeresulaeg Module 5 Hoppe pth Febser Seoni wenn Module G I ap ih Pete O fuere Made 6 Hoppas 8 wm eg Dy Va a Mini Fetter Lee LET Made G Happeed e ell SE 01 1 Chelle meraca anre r e o Treck Sec Fined Madike T Hopped 8 Module T Hopped Module T Hoppes 3 Kale F Blorssab CAES Fig 31b Page 3 35 100 140 Service Manual 4 Enter Configuration and select the required setup Select Edit then select the appropriate hopper of the mark reading unit Set Mark Reading to OMR Marks or Barcode as required set Fold Mode to Together via accumulator and set Reader Head ID to 1 or 2 de pending on which side of the hopper the reader is fitted Save and exit the configuration Note the document used in the hopper must have an OMR setup associated with it or Mark Reading will not be enabled See Fig 31d below The machine is now ready for operation Important Before OMR reading can be used the licence key must en tered and an OMR setup defined see section 3 19 See the following page for Cascade OMR Page 3 36 Issue 8 Aug 2009 Page 3 36 100 140 Service Manual 3 16 2 3 Tray Tower Unit with Cascade Kit A3248A The procedure described in section 3 16 1 must first be carried out in full with the exception that the tower access assembly is not refitted until th
60. EL 9 IN USE CABLE 182 782 SICK ONR READER ee 179 765 oe USE FOR SICK KT3 IIS READER OMR AS DEFAULT OMR READER a 179 724 USE FOR STANDARD 715 READER OMR TOWER FOLDE 2L 2 TRACK TOP TRAY Meee CHANNEL 2 HEAD ID 2 D 179 8550 TOP TRAY USE FOR 2 TRACK aur 7m READER OMR READER SE 179 724 MIRRORED USE FOR STANDARD Zi nN ANE OMe Ger 4 TIN READER OMR HEAD ID 1 179 8540 USE FOR STANDARD Ger CIN READER OMR READER CHANNEL 2 ee HEAD ID 2 USE FOR STANDARD WIR READER OMR O CABLE 182 781 MSZ I F PCB SANNER CHANNEL 10 180 805 a MP EAD ID 2 179 764 USE ONLY FOR MS 3 GN READER BARCODE CABLE 182 732 D o CHANNEL 9 ooo a a HEAD ID 1 EXPANSION PCB USE FOR MS 3 180 768 ZINN READER BARCODE CABLE 182 8150 pm100 I F PCB Ta CHANNEL 9 180 8250 ee HEAD ID 1 3 PLATE FOLDER PCB USE FOR DM100 READER 180 724 Git 2D DATAMATRIX MIDDLE TRAY OMR READER CHANNEL 4 n HEAD ID 2 ue 2 TRACK MIDDLE TRAY TN EE on CHANNEL 4 l READER SE ee USE FOR 2 TRACK OMR ZS READER OMR READER SC SS MIRRORED USE FOR STANDARD OMR WII READER OMR CHANNEL 3 ga HEAD ID 1 179 8540 USE FOR STANDARD 7I S READER OMR Issue 9 Aug 2009 Page 3 43 100 140 S
61. Flap grip roller Assembly Pinch Rollers Preventative Maintenance Schedule Page PM 4 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 2 Wrap Spring Type Clutch brakes if this starts to make a squealing noise then this is a sign of fretting wear debris caused by loss of lubrication within the clutch Other signs include dark brown debris around the clutch case As a temporary measure the clutch can be removed and cleaned EC25 versions only and some lubricant mineral based oil can be applied carefully underneath the rotating control ring Then spray the spring coil with roller cleaning fluid and run a sheet of paper through each coil to remove debris Dry spring and reassemble clutch If after cleaning the variation is still not consistent then the clutch will require replacing Alternatively Long life versions can be fitted for part numbers see below Lubricate underneath control ring Preventative Maintenance Schedule Page PM 5 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Long Life Clutch part numbers Standard Clutch Part Number Long Life Clutch Part Number 179 213 Clutch EC30 CW 8mm 24v YLW 179 109 Clutch ECO LL CW 24v 6mm YLW 1 9 214 Clutch EC30 CCW 8mm 24v BLU 179 110 Clutch EC30 LL CCW 24v 8mm BLU 181 117 Clutch W D XH 102 10 CW 181 155 Clutch W D EC25 LL CW XH 24v 181 127 Clutch W D XH 102 20 CCW 181 156 Clutch W D EC25
62. H lower edge cover Remove 1 x countersunk screw at rear 1 x screw inside chassis at front 3 LH side cover Cover hinges open Black safety cover inside is held with 2 x screws at top edge inside chassis open jam access assy to reveal 4 Accumulator underpanel Remove 6 x screws from below 2 Plate Folder 1 RH side cover 1 x screw inside chassis at front top 1 x screw inside chassis face below tray 2 RH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged 3 LH side drop down Lower cover then remove 2 x retaining straps amp 3 x nuts on hinge 4 LH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged 5 Opening top cover Remove open side covers first then remove 1 x cap head screw each side inside 6 Front cover Remove open side covers first then remove 1 x screw each side at top and 3 x screws on LH chassis face Note depending upon configuration infill cover may be fitted held by lower 2 of the 3 screws Page 3 5 Issue 7 Sep 2008 3 1 3 PM SCHEDULE The preventative maintenance schedule must be carried out as defined in this section Service and breakdown statistics gathered from past field ex perience show that failure and breakdown rates are dramatically reduced by
63. M4 Feeder Folder PSU Assy 3dia x 24lg Dowel Pin 2 5dia x 16lg Dowel Pin Belt 140xl 037 Belt 100 S2M 710 Belt Set 300xI 037 Polyurethane set 4 Belt Set 330xI 037 Polyurethane set 4 Other requirements are included in the Insert Head list Page 3 Q et KA kk kk Eh kA Fb kk kk Fb P kA kA kA 59 100 140 Service Manual Tower Folder order A0343A 230v or A0346A 115v NTL Pt No 179 704 179 724 180 692 180 724 180 764 180 768 180 769 181 062 182 574 182 701 182 702 184 169 A7097A A7120A C8175A C8176A C8177A C8186A C8187A E1030A E1059A E1102A E1105A F5123A F5124A F5136A G0152A G1026A G1029C G1160A G1203A G1207A SAP Pt No 9100537A 9100547L 9100711G 9100727Y 9100748V 9108260V 91080242 9100784H 9101053N 91010882 9101089A 9101138B 9101747L Sak 9103539C 9103540D 9103541E 9103542F 9103543G 9103807G 91038242 910384158 9103842T 9104503G 9104504H 9104506K 9104603L 9104626K 9110058T 9104701N 9104721 9104723L Description Shaft Encoder Loom AM4 OMR Head Assembly PCB Vane sensor PCB AM4 3 Plate Folder PCB Led Module PCB AM4 3 Plate Expansion PCB AM4 Stepper Motor wired stepper Loom wired Reed Switch 2X3W XH Loom OPB715 wired sensor 4WXH Loom OPB715 wired sensor 4WSM 3P Folder PSU Assembly Separator Pad Gearbox Assembly Cast Lower Fold Roller Upper Fold Roller A Upper Fold Roller B Pick Up Roller Shaft Assy Separator Roller Rolle
64. QTY 1 a E2 01A QTY 1 C6183A QTY 5 OMR HEAD MIRRORED GRUB SCREW M4 x 6 OMR SLIDER LZ QIY i E2505A QTY 5 SCREW Wa ee tyr e a a ae E2701A QTY 1 GRUB SCREW M4 x 6 e WEE E2505A QTY 6 2 TRACK READER rr OPTIONAL FOR TOP OR MIDDLE TRAY Fig 32 Page 3 37 100 140 Service Manual Fitting the OMR assembly to the machine 4 At this stage it is assumed that the machine will still have covers and tower access assembly removed as described in 3 16 1 steps 1 amp 2 and that sta tion 1 OMR assembly has been fitted as described For station 2 proceed as 5 follows 1 On the RH side remove the the gears shown in Fig 33 below This provides access to the end of the transport roller shaft and extrusion SCrews Cl Remove these gears 6 Fig 33 2 Remove the E clips T bearings and springs from both ends of the transport roller shaft and lift it out of the chassis In its place fit the 7 OMR transport roller shaft A2844A supplied in the kit Assemble this with the nylon encoder mount P2150A in place of the T bearing on the LH end Note that the stepped end of the shaft runs through this 8 mount S Assemble the encoder base plate to the nylon mount using 2 off M3 x 6 screws amp lockwashers see Fig 32 On the encoder cover align the small grub screw hole with the slot on the curved part of the cover and insert the Allen key this is normally supplied with the Allen key in 9
65. SUIT MOST APPLICATIONS Page 3 13 100 140 Service Manual 3 9 COLLATE FEED ROLLER REPLACEMENT Forms are driven into the collate area by an upper and lower pair of feed rollers either side as shown in Fig 13 The lower rollers are gear driven and supported in bearing assemblies The upper rollers are supported on a Shaft in T bearings If the rollers become worn ragged or otherwise dam aged they must be replaced as described below 1 Remove the pocket clam assembly see Fig 13 To do this locate the 2 clutches near the end of the feed rollers on the LH side Remove the clip of the upper clutch and withdraw it and also remove the clutch locator This will allow removal of the E clip gear and dowel pin of the gear on the end of the feed roller shaft Remove the screw on the Spigot plate that acts as a pivot for the pocket clam assembly but do not remove the plate at this stage On the RH side disconnect from the ribbon splitter PCB the 2 sensors for the pocket clam assembly Now pull out the spigot plate on the LH side and lift out the clam as sembly leading the sensor wires through the chassis cutout 2 Remove the LH feed roller bearing assembly see Fig 13 by taking out the 2 vertical screws on the bracket and sliding the assembly to wards the chassis to free the latch spigots underneath The assembly can now be angled out of the chassis The feed roller is tightly pressed on the shaft and replacement is a matt
66. ad the cable through the chassis bush shown in Fig 24 Retain the cable through existing clips and connect to J14 OMR 1 on the main PCB OMR assy screws Bush for emitter wires Bush for OMR head and receiver wires Fig 24 Fit the OMR bridge B7649A leading the emitter wires through the bush shown in Fig 24 Connect to J8 on the upper splitter PCB Slack en the grub screw on each OMR slider and align them as far as pos sible with the rubber bands on the roller as shown in Fig 25 on the following page Important If centre OMR marks are being used OMR Bridge B3 1366 A must be fitted in place of the standard item Page 3 31 100 140 Service Manual OMR foot assembly Align sliders with example shown is black rubber bands top read Emitter OMR assembly LS OMR bridge 2 k gt a Fig 25 Tower Access Assembly 10 Referring to Fig 26 below remove the existing access bridge Fit the square slider bar C9382A as shown in Fig 22 after sliding on either the OMR head for top read or foot assembly for bottom read If fitting the OMR head lead the cable out through the bush adjacent to the pivot Receiver OMR head on slider bar OMR access bridge Note Shown fully reassembled 11 12 13 14 15 Page 3 32 Issue 8 Aug 2009 Fit the supplied receiver sensor to the OMR access bridge Also fit the 2 supplied P clips using M4 nuts amp washers then feed the wires thro
67. and open the LH side cover Also remove the black safety cover on the LH side section 3 1 2 Overguide Removal 2 Lift out hopper 3 if fitted and remove the two collate covers shown in Fig 11 below Collate cover LH side RH side is similar Overguide shaft Overguide assembly cont Page 3 10 100 140 Service Manual 3 On the RH side remove the clutch E clips gear with 3 dowels and flanged bearing from the end of the overguide shaft see Fig 12 be low On the LH side at the end of the same shaft remove the flanged bearing noting the waved washer underneath Clutch and gear on end of over guide shaft 4 Lift the overguide assembly out of the chassis Accumulator Removal 5 On the RH side unplug the ribbon cable from the connector and re move the accumulator screw shown in Fig 13 below Also remove the screw on the LH side Lift the acumulator out of the chassis Accumulator Ribbon cable Connector Fig 13 RH side screw LH side is similar 6 Reassembly is a reversal of removal When refitting the clutch on the overguide shaft ensure the lug is engaged with the clutch locator Page 3 11 Issue 7 Sep 2008 3 5 4 Alternative DD sensor position On later machines from mid 2006 the double document sensor located just after the separator on all feed trays can be clipped into an alterna tive mount on the other side of the deskew sensor This may be used i
68. aneously saving time It should be used only on exist ing versions higher than 4 1 0 0f Diagnostics These are identical to 100 Series Module Settings Note that the tab marked Solenoids is equivalent to 100 Series Drivers and Covers is the same as Interlocks amp Covers Engineering Diagnostics tm or Mat wjf let SSC im mm Hei ajej od l Module 0 Head Geteras Taisi Ganni mm i Press Get Currents to fill the boxes with the current drawn for each item this takes about 1 minute As each component is switched ON the total current is shown in the status box at the bottom Currents apply only to Solenoids and Motors tabs note that there is no Get current button for Motors Foldplate motors can be run in both directions Exit the screen when done Page 3 25 Issue 7 Sep 2008 Plug and Play On power up or if Plug amp Play is pressed the software determines how many modules are fitted which module types and any calibration information This is the detected machine configuration The detected machine configuration is then compared with the programmed machine configuration in the INI file If there is a mismatch the user is given the option to accept the detected configuration accept the current programmed configuration or go to the engineer setup screen and edit the current configuration The key benefits are if a module is added
69. aper is flapping under the OMR head Saving the trace The trace can be saved as a bitmap to your chosen location by clicking Save as Bitmap This can be used for later analysis or for sending to Tech nical Support should this be necessary The trace can also be printed as Suming a printer is connected to the computer Page 3 29 Issue 7 Sep 2008 3 15 ERROR CODES A number of error codes and messages are programmed into the machine to cater for all potential operating faults If an error occurs the machine will stop and display the problem The machine graphic on the display will flash the appropriate area of the machine for example FAULT STOPPED incert Head Error 351 Envelope feed empty Refill Press RUN to continue If the button on the control panel is pressed further help will be displayed to assist in correcting the problem as shown below ERROR HELP Ensure hopper is correctly loaded check side guides It problem persists clean sensors see Manual li problem persists call Technical Service Due to the large number of error codes these are not listed in the Service Manual but are available as a separate document Maximailer Error Codes which can be downloaded from the company website Note there are differ ent versions of this doccument according to firmware version Page 3 29 100 140 Service Manual 3 16 FITTING AN OMR HEAD Machines not fitted with OMR can be upgraded to
70. ate assembly the assembly piv ots upwards before sliding out ES Referring to Fig 57 below on the RH side remove the bracing plate take off the drive belt and lift out the gear cluster supported in the plate Also remove the idle gear shown by unscrewing the post 4 From behind remove the pivoting latch plate assembly by loosening the pivot spigots 10mm AF Also remove the transport plate 2 x screws in each chassis side plate See Fig 58 below Idle gear Bracing plate with gear cluster underneath Page 3 54 Issue 7 Sep 2008 Transport plate Latch plate assembly shown pivoted down Fig 58 Referring to Fig 59 below from the front remove the LH pivot plate for the output plate assembly Move the plate forward clear of the area but do not disconnect the sensor wire Also remove the upper portion of the transport plate underneath the output plate 2 screws in each chassis side plate Note that to access the screws on the LH side the green knob brake and gear must be removed Also take out the screws for the brake locating bracket but do not remove it Output plate assembly with transport plate underneath Page 3 54 100 140 Service Manual 6 Remove the 3 slot headed screws each side securing the folder as sembly and lift out the assembly from the front Fig 60 below shows the removed assembly Fig 60 7 When disassembling the folder carefully note the orientation of the
71. bal Count gt MPPC gt mode gt Job Count gt OMR set up SS eee gt Batch OMR SET UP gt BAJVEC _ __ o o o y O pomRcalibrate B40B BARCODE SET_UP gt modi hopper 1id 1 p Imoa 4 hopper 1 id 7 gt mode Mead iS p ios gt BAJVECACGACAAQAAAABBCCDDE INFORMATION BARCODE SET_UP Position beam just b before an OMR mark Press tick to continue x o abort Repeat calibration if OMR beam is flashing a gt BAJVECACGACAAGAAAABBCCDDE calibration failed Otherwise calibration has been successful Press tick to finish If the calibration consistently fails the mark contrast is too weak 3 18 6 OMR reader calibration Standard read head ak igeeg problems persist with setup or calibration contact Technical This is carried out from Analogue Sensors in Engineer mode Select this from the Module Settings for the module that has the head fitted Select the required OMR head OMRI1 2 etc and press v You will then be prompted to plaece a piece of white paper under the head on press v again After successful calibration a confimation will be displayed The OMR head need only be calibrated if it is changed or if the con trol board is changed or if read problems are occurring Page 3 48 100 140 Service Manual 3 18 8 Using Trace Tool 100 series only The Trace Tool uitility is primarily used for downloading firmware and also provi
72. bers and Complete complete Interval Cycle Gei Check for squealing noise from clutches If so remove and clean and Replace A R replace if necessary Check all restraint straps are intact replace if required el z Replace A R i 5 lt 5 Go though the Engineer menu to check all Analogue and Digital sensors A lt 5 Replace A R calibrate if required 5 5 R Go through the Engineer menu to check each clutch brake and solenoid Replace A R Check and adjust if required fold lengths in View Fold Settings for Level 3 lt Maxi or Module Options Fold Plate Lengths in Maxit Check and adjust if required the collation of forms in the engineer ao window When all service or repair operations have been carried out the machine Level 2 3 lt 5 must be left with all parts reassembled leaving no risk of injury Complete service log sheet C26 C27 C28 C29 30 C C31 32 C Times Level 1 lt 20 mins Level 2 lt 1 hrs Level 3 lt 4 hrs Preventative Maintenance Schedule Page PM 33 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule 3 Plate Folder module Level 1 Operator level frequency will depend on usage and applications but at least weekly Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the
73. bs Fingers not returning into This is a visual check during machine running for fingers returning to home either side see home position below Corrective actions if they fail to return fully home are 1 increase the return spring tension either side as shown 2 look for sticking finger assembles d Ki H Check during running if the finger arm fails to return home Check both sides ke Envelope Streaming If the envelope has stream fed then there is a tendency for the envelope to dive between the Preventative Maintenance Schedule Page PM 54 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Option Fingers digging into This is a visual check during machine running for fingers not pulling in fully either side of envelope not pulling In envelope this can also leave finger pierce marks on the envelope see below The corrective cleanly action is dress the fingertip to remove any sharp edge until a replacement is fitted 3 Finger dig into envelope Preventative Maintenance Schedule Page PM 55 100 140 Service Manual MAINTENANCE amp ADJUSTMENTS 3 2 FEEDER SEPARATOR 3 2 1 Separator adjustment The feeder separator has 4 user adjustable settings Position A 0 to 0 75mm Position B 0 75 to 1 5mm Position C 1 5 to 2 5mm Position D 2 5 to 4mm The separator is largely automatic in operation with a negative gap on the smallest settings The
74. ck Control 181 127 x1 Clutch pin GOO79Ax5 EC30 clutch pin GO167Px1 CON Oh Un P AM FA Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 2million or 1million if m c running for gt 8hrs day Deskew Brake 181 127 x1 Track Control Brake 181 127 x1 ECD30Track feed brake 179 214 x1 Deskew brake 181 105UL x1 Clutch pin GO079Ax3 EC30 clutch pin GO167Px1 On Om PS DOMM FA Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 3million 4b 6 1 Motor Pulley F1372A 220v or F1373A 110v Page PM 22 100 140 Series Service Manual Time to Maintenance item Head Unit Frequency complete mins B17 Remove Lower conveyor and check all track transport and drive belts for Level 3 lt 15 wear and fit Clean belts bobbins in collate input area etc with Rubber Roller Restorer E0483A B18 Remove Upper conveyor and check all track transport and drive belts for Level 3 lt 15 wear and fit Clean belts bobbins in collate input area etc with Rubber Roller Restorer E0483A Level 3 Check for any tight spots in the drive and belt tension Check all unit screw security pay particular attention to all handles tighten as required Tighten Latch handle C3561E and ensure assembly opens and latches B19 B20 Level 3 B21 Check sensor cable JST connectors are all properly plu
75. cy Time to Replacement Part Numbers and Ref Complete complete SISSIES fel Manual Ka mins Page B30 Inspect Module for damage and safety covers are all intact interlocks Level 2 amp 3 function warning labels in place ILL When all service or repair operations have been carried out the machine Level 2 3 lt 5 must be left with all parts reassembled leaving no risk of injury Complete service log sheet Times Level 1 lt 10 mins Level 2 lt 1 hrs Level 3 lt 4 hrs Preventative Maintenance Schedule Page PM 24 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule Mark Reading Feeder Level 1 Operator level frequency will depend on usage and applications but at least weekly Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the PFE website Time to Replacement Part Numbers and Ref Complete Interval Cycle Manual Gei Frequency Maintenance item Mark Reading Feeder complete Clean all paper transport rollers using water or recommended cleaning Level 1 2 amp 3 fluid Check joggler tyres if fitted for alignment Clean all sensors with approved air dusters Level 1 2 amp 3 Remove Feeder covers external internal Level 2 amp 3 Vacuum clean to remove internal dust Clean all covers Level 3 Check for pickup
76. d Page 3 45 Issue 8 Aug 2009 Retaining screws for scanner Note M3 x 10 Pozi Pan Head screws are shown using Cap Head screws instead will allow adjust ment in situ Refit the tower access assembly remember to fit the nylon strap Fit the laser warning label to the inside of the tower access assembly after degreasing the surface see Figs 35 amp 36 cont Page 3 45 100 140 Service Manual Connection 8 The procedure for connecting the scanner is identical to the procedure for vertical barcode This is described in 3 17 1 steps 10 amp 11 Important Before barcode reading can be used the licence key must entered and a barcode setup defined see section 3 19 Configuration 9 The procedure for configuring the machine is identical to the proce dure for vertical barcode This is described in 3 17 1 step 12 10 The scanner beam must now be aligned with the barcode Switch on the machine and providing the upper hopper tray is removed the beam can be seen from the rear the hopper interlock detects when the hopper is removed and switches on the scanner Wind a piece of OMR printed paper into the rollers so that the barcode passes the beam Slide the scanner bracket until the beam is centrally aligned on the barcode and tighten the screw See also section 3 18 opposite for alignment and calibration details Page 3 46 Issue 8 Aug 2009 3 18 OMR BARCODE ALIGNMENT amp CALIBRATION 3 18 1 OMR hea
77. d alignment 100 Series This is described in detail under section 3 16 1 step 15 Note there is no calibration procedure required for 100 Series 3 18 2 OMR head calibration 140 Series mark reading feeder fitted with SICK read head only After alignment of the OMR head it must be calibrated To carry this out on a 140 Series with an OMR feeder fitted with a SICK read head enter the Run Screen Select the hopper of the appropriate feeder on the graphic to display Fie Soniye seraa r 7 Feed Control Mode Feed always Off On Doubles Detect Off Off On Deskew Low Select Calibrate reader Separator Position A 0 00 0 75mm Select gt eer T y Document Fine Tuning X Abort Press Calibrate reader and follow the on screen instructions 5 MOS Q Confirm Position pm MOS x Mark Press Ok to Information Move mark l hos x position bea ion EC Ci Information Repeat calibration if OMR beam is flashing calibration failed Otherwise calibration has been successfull Press Ok to finish Page 3 46 100 140 Service Manual If no errors are displayed the head is now calibrated and need only be cali brated again if read errors occur or the unit fails to read at all A working reader will flicker on and off as the marks are slowly fed past the head 3 18 3 Barcode reader calibration 140 Series Calibration of the barcode reader requires no
78. des useful information about the machine function and of the degree of read quality It can be used for both OMR or barcode though the OMR Scope function for viewing or capturing a trace is applicable only to OMR reading Connect the computer as described in 3 14 1 of the service manual and set up the reader as described above As the paper is wound into line with the reader this should repeatedly beep if the marks or barcode are being read To determine how well the marks or barcode are read the information area of the screen in Trace Tools will show a percentage good read A reading will be shown only when the eject sensor of the 3 plate folder is blocked most easily performed by lifting the green knob in front of the daily post tray to raise the roller platten as shown below A log of the display can be captured for later analysis by Technical Support Select Start Log and select a directory This will start the capture of the data and stop when Stop Log is selected creating a logfile in the directory An example screen display is opposite for a barcode In this case this Shows the percentage read quality of a barcode reader and the decoded data The read should be as near 100 as possible and while a figure be low this may well work quite acceptably steps should be taken to try to in crease the read quality Moving the scanner to a position closer to the paper may well increase the percentage otherwise t
79. e actions described in this section are carried out Fig 32 below shows the assembly of the parts prior to fitting to the ma chine If not already built when received assemble parts now Note that RH Sos SCREW M4 X 8 T T EZAQIA QIY 5 CLAMP PLATE LOCATION R2035A QTY 1 EW M4 x E27 11A QTY 4 IO CSK PLATE B7 659A QIY 1 TOWE OM BA C9582A QIY 1 OMR HEAD Lrg 24 SCREW M4 x 6 G E2505A QIY 1 Silke 1 STATION 1 OMR OR fro OT Aart A ZOSA 1 16 GEES C6182A CIRPIN x 1 2 F5060A R SCREW M4 x 6 GRU p F2505A QTY 1 i an K OMR SHOE RK E C6181A La SPRING 7 l G1073A S E SCREW M3 x 10 PAN E2559A De EW M4 X 8 et Eze Ts 2 GRUB SCREW M4 x 6 E2505A LOWER OMR BAR Goof ge OT 2 LOCATION P B 650A OI lt i Sp E gg Page 3 3 7 Issue 9 Mar 2011 top read is shown if bottom read is required swap over the positions of the OMR head and foot assembly opposite If LH is required the OMR head foot are assembled at the other end of the slider bar The location along the bar of the OMR head depends upon the required approximate position to align with the marks on the paper Wherever it is located the sliders C62
80. e Separator outer lower pad overlap tyres from the gt 0 5mm pre feed assembly as shown curled twisted envelopes no longer having stream or double issues but only experiencing skew Clearance up to 2mm Max total See note 1 Standard Feed Separator shaft part no pad overlap A7073A 0 5mm or less Envelope is sitting flat in the hopper and does not have any curl across the lead edge As above but as above If poor pick up Separator experiencing pick up is experienced pad overlap issue it is always 0 5mm Preventative Maintenance Schedule Page PM 47 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Option guides system gap Action settings required setting best to ensure that side guides are not set too tight and restrictive on the envelope pack As above and pick up as above Loosen the Separator Current options include slotted or silicon types issues persist separator if pad overlap Note the joggler is fitted standard to the this doesn t lt 0 5mm outside only It is essential that bumps in line help or leads across the shaft otherwise this will encourage to doubles envelope skew then try alternative rollers and then the tractor Preventative Maintenance Schedule Page PM 48 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Additional Notes for good envelope feeding 1 Hopper capacity is very depe
81. e code the preferable course of action will be to capture the text and send this to Technical Support for analysis To cap ture a trace press Start Log and select a directory for the logfile Run the machine until the problem occurs and press Stop Log The logfile gener ated can then be sent to Technical Support To pause the trace momentarily for closer examination of a specific part press Off press On to resume While the trace is paused a selected area can be copied then pasted into Notepad to create a file Page 3 26 100 140 Service Manual 3 14 3 Downloading firmware Upgrading of firmware is carried out for each module of the machine insert head feeder folder amp 3 plate folder All of these can be upgraded directly to each module separately or collectively via the serial connection on the insert head Direct upgrades should be used on existing firmware up to and including V4 1 0 0f or if a new PCB is fitted in field when boot infor mation may not be loaded in the EEPROM Later firmware can be upgraded via the head Prior to downloading the upgrade files they must be present on the PC and are normally obtained from website download Directly to each module separately To carry out the upgrade select Download from the menu bar then Di rect This will open the Download Direct dialog box then click the but ton to open the file selector dialog and select the appropriate fi
82. e that channels 3 amp 4 are located on the expansion PCB this will only be fitted for machines with more than 2 OMR heads fitted or for cascade machines ie 3 tray units see section 3 16 2 for cascade OMR The read head IDs are identified as 1 and 2 on both top and middle trays viewed L amp R from behind respectively Top tray ID 1 is con nected to channel 1 ID 2 to channel 2 Middle tray ID 1 is connected to channel 3 ID 2 to channel 4 This should be followed whether there is 1 read head or 2 on each tray Twin read heads If twin heads are fitted for 2 track OMR these can be fitted on the top or middle tray but not both They are connected to channels 1 amp 2 on the top tray 179 8540 to channel 1 179 8550 to channel 2 or to channels 3 amp 4 on the middle tray 179 8540 to channel 3 179 8550 to channel 4 See also connection diagram at 3 17 1 fig 43 Page 3 33 100 140 Service Manual DS 100 Configuration see 2 5 for DS 140 configuration 18 19 The machine must now be configured so that the OMR or barcode reader is recognised Switch on and enter Engineer mode In Config ure System repeatedly select continue until the settings for the OMR reading unit appear Assign readers by channel number as shown in Fig 29 below Ch 1 4 are for OMR Ch 9 amp 10 for barcode 2D see also connection diagram at 3 17 1 step 11 Module 4 1 Rdr 2 Rdr 3 Rdr 4A Rdr 93 Rdr
83. e to be for example 153mm for A4 enter 1530 in Foldplate 1 Cal steps 0 1mm The software will then subtract this difference to correct the folplate setting 5 Run the job to check the length is now correct 148mm in this case 6 To calibrate foldplate 2 return to the job and enter View fold set tings Advanced Set foldplate 1 to not used and re peat steps 3 to 5 entering the figure into Foldplate 2 Cal if it is wrong 7 Repeat for foldplate 3 except that both foldplates 1 amp 2 are set to not used and an incorrect figure is entered into Foldplate 3 Cal Page 3 20 100 140 Service Manual b calibration of no fold blanking beams 1 2 amp 3 Adjusts gap between tip of beam and fold roller If forms are not entering a fold plate when they should gap must be increased and vice versa Units are 0 1mm of motor actuator which equates to 1mm at beam tip Positive numbers only c alignment of leading edges when collating before feeding Applies to feeders 2 amp 3 Units are 0 1mm and positive further for ward Cardfolder adjustment of FP1 Up Cal Controls paper travel into FP1 in up position Positive further Factory default 4 Mk 1 2 FP1 Down Cal Controls paper travel into FP1 in down position Posi tive further Factory default 0 Mk 1 2 FP2 Up Down Cal As for FP1 Factory defaults 0 amp 0 Mk 1 only FP2 Clockwise Cal Controls paper travel into FP2
84. ear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Operator side Clutches applicable to all Remove and check motor assembly A7084A or A7085A Clean area and ensure all parts are intact tight spots belt noise or signs of wear Clean clock disk on the motor assembly Check motor pulley is tight on the motor shaft Preventative Maintenance Schedule E Preventative Maintenance S Time to complete mins lt 5 Issue 3 Jul 2008 Complete Aal 8 E 8 Replacement Part Numbers and Interval Cycle 2million or 1million if m c running for gt 8hrs day 1 Gears Replace A R It is advised to keep stock of F4150Ax2 and F4151Ax2 2 Track Control clutch 181 127 x1 3 Clutch Pin GOO79Ax1 2million or 1million if m c running for gt 8hrs day 1 Track Control brake 181 127 x1 or 3 2 Clutch Pin GOO79Ax1 or 3 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers Page PM 36 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle Gei complete mins Clean rollers on Eject Shaft Assy A7079A and Eject drive shaft assy Level 3 lt 5
85. ed during routine cleaning and hence should be cleaned at every site visit The rollers are part of the transport roller assembly and are located below the upper roll ers visible in Fig 50 There are two ways to clean the rollers 1 On the lower hopper remove the spring loaded pickup shaft the side guides must be fully open to do this Dampen a clean cloth with Roller Cleaning Fluid then using the green knob on the operator side turn the rollers whilst feeding the cloth into the nip of the rollers while holding the cloth back so that it can just be felt to drag This will ensure that both upper and lower rollers are cleaned see Fig 56 opposite 2 Remove the lower infill cover below the tray 2 screws each side with 1 on the the top surface Clean the upper rollers from above as seen on Fig 56 Clean the lower rollers by reaching in below the hopper with a piece of fluid dampened cloth the lower rollers can easily be felt Use the green knob to rotate Page 3 53 Issue 8 Aug 2009 Feed cloth into the nip Sa of each roller pair Fig 56 3 20 4 Clearing paper crashes If a paper crash occurs this is most likely to be at the eject sensor at the exit To clear the jam it can be awkward to pull the paper out if raising the roller carrier at the exit An easier method is described below 1 Lower the operator side cover of the tower feeder and the feed unit in front if the unit in front is the insert head raise the pe
86. eed Shaft Assembly A7030A 1 Roller C8098A x4 Clean Adjust Replace if required 2 Separator Pads DOO51Ax2 Or replace optional tyres if fitted TI B7 Clean all T bearings note can apply light oil and clean off any excess in Level 2 amp 3 Level 2 lt 5 2million or 1million if m c running for the Paper Transport Assembly A7033A Level 3 lt 15 gt 8hrs day 1 8mm T Bearing D1040Ax4 2 million 2 Upper transport roller shaft assembly A2793A 3 Upper Transport Roller Shaft Assy A2792A 4 Transport roller shaft assembly A2791A 5 Eject Shaft roller Assy A2790A Bi B2 B3 B4 5 B Preventative Maintenance Schedule Page PM 16 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei e Check clean and ensure free turning of the bearings on the out feed body Level 2 amp 3 4b 6 assy A 7034A Drive side gears clutches applicable to all Remove clean idler Level 3 bes 2 lt 15 2million gears and posts Apply grease silicon based if required Check gear Level 3 lt 30 Gears Replace A R It is advised to keep movement sideways and rocking replace gears if required Check for stock of F4150Ax2 F4151Ax2 and any tight spots in the drive Check all gear drive pins are in tact and not F4152Ax2 loose If so replace gear and pin This can cause loss of drive and noi
87. ees Using Trace Tool 100 Series cccccseseeceeseeeceeseeseaeeessaaees OMR Barcode Licence amp Definition 100 Series Tower Feeder Separator Adiustrment uk Removal of Transport Roller Assembly nnnnannnennnennnnannenennenenne Cleaning of Lower Transport Rollers Clearing Paper Crasbes 2 Plate Folder sviciisisivsicccdscsedassdevaevarseesvavaowaesserddosueatuaaedvantewensciacd Separator Acdustmeni Hepnlacement Fold Roller Replacement cccccccsccceeeceeeceseecueeseeeseeeeeaeesaees OMR TE 3 22 1 322 2 3 22 3 3 22 4 3 23 3 24 3 24 1 3 24 5 3 24 3 3 24 4 3 24 5 Page 3 2 Issue 9 May 2010 Separator amp Feed Tra 3 56 Changing Top or Bottom OM JPBarcocde 3 56 OMR Barcode Alignment amp Calibration c ccccccsssseesseeeesseeees 3 56 Transport Roller Assy Hemoval 3 57 Recommended Spares 00nnnannnannnannnannnnnnnnnnrnronnernrrrrnrnnrrnne 3 58 Parts Replacement by Usage 3 62 Replacement at 2 Million Inserts ceccceceeeceeeeeeeeeeeeeeeeeseeees 3 62 Replacement at 2 Million Inserts or 1 Million Inserts if usage is Over 8 hours day cccseeeeeeeeeeeeeeeeeeeeeeeaeeeeeeesaneeeeeas 3 64 Replacement at 3 Million Inserts uk 3 66 Replacement at 3 Million Inserts or 1 5 Million Inserts if usage is Over 8 hours day cccseeeeeeceeeeeeeeeeeeeeseaeeeeeeeaeneeeeeas 3 67 Replacement at 4 Million Inserts
88. embly A7022A 1 9101739C Insert Head Opener assy curled A7 413A 1 flap option 9107060V Insert Head Notched Rollers DOO45A 2 9105523U Insert Head T bearing D1040A 1 91036413J Insert Head All long life clutches LS E Feeder Upper transport roller A2793A 1 shaft assembly 9107753S Feeder Upper Transport A2792A 1 Roller Shaft Assy 9106799Y Feeder Transport roller shaft A2791A 1 assembly 9106765N Feeder Eject Shaft roller A2790A 1 Assy 9106855G Feeder Gear 40T x 8mm F4150A 2 9104398xX Feeder Gear 48T x 8mm F4151A 2 9104399Y 100 140 Service Manual Page 3 63 Issue 2 May 2012 Module Description __ Part No Ton Notes__ Qty Module Description Part No on Notes__ Qty Tower Feeder Eject shaft Assy A7234A 1 Two Plate Gear 48T x 8mm F4151A i 9106726X Folder 9104399Y Tower Feeder Lower Fdr Roller Assy A7235A 1 Two Plate Gear 30T x 8mm F4156A 1 9106707C Folder 9104402B Transport Shaft Assy _ A7236A MEN ll 9106811L Three Plate Paper Transport Shaft A2843A Amount Tower Feeder Clutch brake shaft A7237A 1 Folder 9105453W for single assy 9107115C bin Tower Feeder Belt 100 S2M F5151A 1 Three Plate OMR paper Transport A2844A Amount 9105217A Folder Assy 9105461E for single Tower Feeder Gear 40T x 8mm F4150A 12 bin 9104398xX Three Plate Tower access shaft A2845A Amount Tower Feeder Gear 48T x 8mm F4151A 10 EE ASETON 91054636G for single 9104399Y Tower Feeder Gear 25T x 8mm
89. er 9104579L Three Plate Folder Three Plate Folder Three Plate Folder Three Plate Folder Three Plate Folder Three Plate Folder Three Plate Folder Three Plate Folder Solenoid Collate clutch Eject Roller Shaft Assy Rollers 8mm T bearing Timing belt Clutch Pin 161 117 9100800Z 181 119 9100801A 181 127 9100806F A2894A 9109132D DOO21A 9103602T D1040A 91036413 F5136A 9104506K G0079A 9104579L e Amount for single bin 8 i Amount for single bin Amount for single bin 8 Amount for single bin Amount for single bin Amount for single bin Amount for single bin Amount for single bin Page 3 66 100 140 Service Manual 3 24 3 Replacement at 3 million inserts The following parts are recommended to be changed at 3 million inserts See also 3 24 4 these parts are in addition to the list below NOTE Part Nos shown in brackets thus are SAP numbers Module Description PartNo Lon Notes op Insert Head Slow down clutch A7366A 1 assy 9107374X Insert Head Pin Grooved 2 5 x E5078A 4 x4 As 14mm 9104138B sembled Insert Head Sprocket 15T F3004A 4 x2 As 9104322T sembled Insert Head Sprocket Hub P2033A 2 x2 As 9105679G sembled F1372A 1 9105627C Mark Reading Motor Pulley 220v Feed A7339A 9107755U Tower Feeder Motor Pulley 220V F1372A 1 9105627C R Two Plate Folder l
90. er of pulling off the old one Do not use adhesive on the new item Also check the condition of the bearings and replace if necessary SS Remove the RH feed roller bearing assembly see Fig 13 as follows remove the clutch pin and gear from the end of the shaft by remov ing or withdrawing the surrounding gears clutch and clutch loca tor Remove the roller bearing assembly by taking out the 2 vertical screws on the bracket and sliding the assembly towards the chassis to free the latch spigots The assembly can now be angled out of the chassis Replace roller bearings as required in the same way as for the LH assembly Upper roller replacement Removal of the upper feed roller shaft is simply a matter of taking out the springs and T bearings Note that the rollers are not removable from the Shaft fit a new shaft assembly instead Page 3 14 Issue 7 Sep 2008 When roller replacement is complete refit the pocket clam assembly in reverse order to removal Note that the sensor wire connections are green white to J9 red black to J10 3 10 CLOSER ROLLER REPLACEMENT There are 4 closer roller shafts on the machine 2 shafts in the body of the insert head 2 shafts in the opening cover located below the envelope hop per the shafts all rotate together and are fitted with a clutch and brake at alternating ends allowing bi directional movement This movement closes and seals the flap in one direction then reverses to eject the sealed
91. er the guidelines for good insertion see pages 50 52 If the fingers are still digging then replace with the appropriate type Standard fingers for use with the 4mm pin are B9346A and B9347A Standard fingers for use with the 3mm pin are B9202A and B9203A Wide fingers for use with 3mm pin are B9156A and B9157A Wide fingers for use with 4mm pin are B9319A and B9320A Preventative Maintenance Schedule Page PM 8 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule Head Level 1 Operator level frequency will depend on usage and applications Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s every Level 3 Service Interval available on the PFE website Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Ref pag Interval Cycle Manual complete mins Page SE fluid Check joggler tyres if fitted for alignment Clean wetter area use a damp cloth to remove all wetter fluid deposits Level 1 2 amp 3 around the wetter and closer rollers Excess water is usually a sign of over wetting and it may require adjusting Do not make any adjustments in the GUI initial A4 Remove and clean wetter sponge and tank A7042A Clean area ee 1 2 amp 3 ee EE or 1million if m c running for 4a Ee where the wetter tank sits gt 8hrs day Note
92. ervice Manual Machine configuration 12 After fitting the barcode scanner the machine must be configured to recognise it The procedure for both 100 amp 140 is described in 3 16 1 step 18 Important Before barcode reading can be used the licence key must entered and a barcode setup defined see section 3 19 Scanner alignment 13 14 The scanner beam must now be aligned with the centre line of the barcode Switch on the machine and providing the upper hopper tray is removed the beam can be seen from the rear the hopper interlock detects when the hopper is removed and switches on the scanner Wind a piece of OMR printed paper into the rollers so that the barcode passes the beam Slide the scanner bracket until the beam is cen trally aligned on the barcode and tighten the screw The angle of the bracket can also be adjusted to allow the beam to run in line with the barcode Remove the paper and from the front of the machine slide the paper skis so that they are approximately equally spaced over the length of the slider bar then tighten the screws Ensure that the beam is not obstructed by any of the skis See also section 3 18 for further alignment and calibration details Page 3 44 Issue 8 Aug 2009 Page 3 44 100 140 Service Manual 3 17 2 Fitting a horizontal barcode assembly to the machine 1 2 Remove the RH side cover and open the LH side cover Remove the tower access assy this is not
93. essential but is quick to do and greatly improves access the tower access assy is the pivoting section at the top front of the tower The pivot bar is retained with a screw at each end and a nylon strap Remove the paper tranport plate opposite the tower access assem bly this is retained by 2 screws on the lower edge 1 screw on the LH side Note that the plate will be different depending on whether the machine is a 3 tray or a single tray both are retained similarly Fit the new item in its place as shown in Fig 45 below mm _ Paper transport a plate A st j J j Ki 7 Ba T A W A af N D d d ee d Fig 45 Fe At the rear of the machine remove the upper hopper Assemble the scanner to the bracket as shown in Fig 46 opposite Note that there are different hole positions depending upon requirement Generally the scanner should be as far away from the paper as possible mov ing it to a more forward position if the barcode is very dense or other read problems occur Fit the M4 x 12 Cap Head screw to the scanner bracket but do not tighten at this stage Slide the bracket onto the bar and fit it into the rear of the machine as shown in Fig 47 opposite Note The bar is retained with 1 screw at the RH end to access the hole remove the bracket for the upper splitter PCB and move this clear of the hole do not disconnect cables see 3 17 1 step 8 Replace the bracket when the screw is tightene
94. f for example an area of heavy black printing is in line with the default sen sor causing a false read For locations see sections 4c 23 3 station top tray 4c 24 3 station middle tray 4c 25 3 station bottom tray amp 4c 26 1 station Page 3 11 100 140 Service Manual 3 6 ENVELOPE FEEDER REMOVAL Access to any operations in the collate area will be greatly eased by the re moval of the envelope feeder This is a straightforward matter as described below 1 Remove LH amp RH Insert Head side covers section 3 1 2 2 On the LH side remove the control panel assembly When facing the assembly remove 2 x screws and loosen 1 x screw inside the chas sis at the LH end the loosened screw is in the keyhole slot At the RH end remove 1 x screw outside the chassis and loosen 1 x screw inside Unplug the ribbon cables and lift the assembly clear of the ma chine 3 On the LH side of the chassis remove the 2 x screws shown in Fig 11 below Unplug the ribbon cable and the JST connector Remove 2 screws Fig 11 Page 3 12 Issue 7 Sep 2008 3 On the RH side of the chassis remove the 3 x envelope feeder screws as shown in Fig 12 below Also remove the screw for the chain ten sion shaft if the collate chains are to be removed see following sec tion 3 7 Note that the top envelope feeder screw is inside the chas S S a Remove 1 screw for envelope feeder Remove 3 screws for envelo
95. f either 4 x OMR or 1 x Barcode readers If the Daily Post option is fitted tick this box When operating the machine will then wait for manual insertion of forms in the handfeed tray When finished select Continue to move to the next module Page 3 22 100 140 Service Manual Module 4 PE OMA renders top JS bf OMA readers mid D DE Barcode readers logit JS P Daily Posi Fitted DW OnLine Filled gt Accumulator Fitted gt Divert Fitted ly gt Continue Module 4 bth 3 Rdr Hone Ch 10 Rdr Hone P Online interface Standard 2 gt Continue 3 Plate Folder If the unit is reading OMR or Barcode select the number of readers up to a maximum of either 4 x OMR or 1 x Barcode readers on the top tray or 4 x OMR readers on the middle tray Read heads can be either top or bottom reading If using Daily Post tick this box When oper ating the machine will then wait for manual insertion of forms in the handfeed tray Other forms from the 3 trays may be col lated with it If the machine is being fed from an on line source select the On line Fitted option Select Accumulator Fitted and Divert Fit ted if either of these is present When finished select Continue to move to the next module Cardfolder Select if an online interface is fitted allow ing the cardfolder to be automatically fed from a card processing device Selec
96. g rj Dat d B9169A 5N I R2954A J SN D M4 x 8 POZI PAN HD SCREW E2624A SKI LOCATION PLATE OP H M4 x 8 POZI PAN HD SCREW R2955A De E2624A PAPER SKI NARROW B9169A SKI SLIDE BAR C9677C PAPER SKI SLIDE BRACKET R2953A QTY 5 VERTICAL BARCODE GUIDE PLATE B9172A en M4 x 8 POZI PAN HD SCREW E2624A M4 x 10 CSK POZI SCREW Le E2711A QTY 6 a PAPER SKI WIDE OP B9170A NOTE PAPER DEFLECTOR C7401A IS USED FOR VBC SEE 4c 24 3 ST or 4c 26 1 ST PAPER SKI NARROW SKI CLAMP PLATE DR B9169A R2956A be Ae d i ei SCH M4 x 8 T T SCREW E2701A QTY 4 M4 x 8 POZI PAN HD SCREW e E2624 Fig 35 Vertical Barcode Upgrade Kit A3292A or A3296A Page 3 40 Issue 9 Aug 2009 Both vertical and horizontal use the same barcode scanner 179 764 For a 3 tray 3 plate folder the assemblies can only be fitted to the upper tray The single tray kit differs by including an Expansion PCB and ribbon cable needed for connection these are fitted as standard on 3 tray machines TOWER TOP COVER ek B7645T P bare NOT PART OF HORIZONTAL ae Dee BARCODE ASSEMBLY A3 0375 BBH 4 SCH Ba a A BARCODE SLIDE BAR C9676C BARCODE SCANNER MS 3 179 764 M4 x 8 POZI PAN HD T T SCREW M4 x 16 CAP HD SCREW E2701A E2524A Nw rai re S e M4 x 8 POZI PAN HD SCREW E2624A i LASER CAUTION LABEL G3363A HORIZONTAL BARCODE SLIDE BRACKET R
97. gged in Also check Level 3 ribbon cables headers these are more likely to be dislodged B22 Check for squealing noise from clutches If so remove and clean and Level 3 replace if necessary ref B11 and B12 Check side guides for movement stop position and parallelism to chassis guides retaining screws are tight Check rolling backstop rolls down the feed tray Check all clutch pins GO167P or GOO79A are intact Level 3 Go though the Engineer menu to check all Analogue and Digital sensors A R calibrate if required Go through the Engineer menu to check each clutch brake and solenoid A R Level 3 Ensure side Level 3 m lt lt lt lt lt lt lt LU N LA 10 5 5 5 1 B26 B27 5 B28 5 29 10 B lt Preventative Maintenance Schedule Preventative Maintenance 2million Belt 100 S2M F5151A Ref B11 and B12 Replace A R Replace A R Issue 3 Jul 2008 Replacement Part Numbers and Interval Cycle Complete v 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F5122A 1set 2 8mm T bearing D1040Ax4 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F5121A 1set 2 8mm T bearing D1040Ax6 2million Gears Replace A R It is advised to keep stock of F4150Ax2 F4151Ax2 and F4235Ax1 Page PM 23 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequen
98. he cavity of the machine as shown in Fig 37 below Retain the LH end using 2 screws as shown Fit the guide plate so that the angled flange is un der the tips of the skis Paper ski as sembly Guide plate attached to Retaining new extru screws sion NO Page 3 41 Issue 8 Aug 2009 At the RH end remove the idler gear shown in Fig 38 below This will provide access to the 2 screw holes for fitting the retaining screws Refit the idler gear Stud for idler gear Remove this idler J to access extru a A sion screws Retaining screws Kam m Fig 38 Refit the tower access assembly remember to fit the nylon strap At the rear of the machine remove the upper hopper Assemble the scanner to the bracket as shown in Fig 39 below Note that there are different hole positions depending upon requirement Generally the scanner should be as far away from the paper as possible moving it to a more forward position if the barcode is very dense or other read problems occur Retaining screws for scanner Note M3 x 10 Pozi Pan Head screws are shown using Cap Head screws instead will allow adjust ment in situ Page 3 41 100 140 Service Manual 8 Slide the bracket assembly with scanner onto the barcode slide bar and assemble this into the rear of the machine see Fig 40 below The bar is retained with 1 screw at the RH end to access the hole remove the bracket for the upper splitter PCB and
99. he print quality of the barcode Should be looked at see opposite Page 3 FYFE Tres foul OCI File ComPort DownLoad BootLoad Engineer OmrScope Jobs Settings Help Rx Start Log Stop Log 49 OFf F8 Issue 9 Feb 2010 BC 100 BCAAEF Flags BC 100 BCAAEF RO 1NN amp RCAARF To capture an OMR trace select OmrScope then Save as bitmap to save to a chosen filename and directory This can be used for analysis by Techni cal Support department Test run the machine with representative paper If read errors are occur ring or if the barcode quality is poor eg bad or too dense printing move the scanner further forward on its bracket see step 4 The scanner should be as far back as possible without read errors Note to preserve scanner life the beam is actuated only when scanning a barcode printed page thus it is actually switching on and off rapidly as documents are processed It is also switched on when the upper hopper is removed to allow alignment For further assistance in diagnosing OMR or barcode reading prob lems contact Technical Support department Page 3 49 100 140 Service Manual 3 19 OMR AND BARCODE LICENCE amp DEFINITION FOR 100 140 SERIES Important this section must be read in conjunction with the OMR or Barcode Specifications document for 100 140 Series For the 100 series to be enabled for OMR or barcode an Advanced or Flex licence must be obtained This
100. hen the screw securing the brass spigot is L wer fold rollers tightened Important when replacing the infeed plate ensure it is properly located it can sometimes appear to be while still being slightly misplaced 3 3 4 Curled paper Guides ed PCB amp To assist the feeding of curled paper two optional guides are available bracket A3310A Curled Paper Guide Light A3311A Curled Paper Guide Heavy These mount on the bridge of the feed trays on either 3 Plate or 2 Plate folders Fixings are supplied to utilise the two esisting holes on the bridge They present a wire frame light or rollers heavy to the paper as it feeds helping to remove the curl Fold box screws 3 On the RH side remove the 3 nuts retaining the PCB bracket and withdraw it as far as the cables allow do not disconnect any cables 4 Slacken the 2 screws retaining the Lenze clutch see Fig 7 on the previous page and slide it off the shaft Support it suitably to avoid Page 3 8 100 140 Service Manual straining the cable Remove the E clip next to the gear and slide this back as far as the clutch locator allows Remove the 3 screws and gears on the lower fold rollers and witdraw them then remove the dowel pins and spigots On the LH side remove the 3 screws on the ends of the roller shafts then remove the flanged bearings on both sides with the waved washers on the LH side Reaching in from behind lift the fold rollers out of the chassis Fit new
101. ice Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei mins Tower Feeder Assembly A5135A Part 2 page 4b 12 Clean all T bearings and rollers note can apply light oil and clean off any excess Check clean and ensure free turning of the bearings on the out feed body assy A 034A Clean all T bearings on the Access Assy A7228A Apply light oil and clean off any excess Clean all T bearings on the Insert Direction Roller Assy A7229A Apply light oil and clean off any excess Remove Transport Roller Assy A7231A from Tower Feeder and clean all T bearings Apply light oil and clean off any excess Remove Insert Deflector Assy A7230A from Tower Feeder and clean paper deflector extrusion ensure extrusion surface is free from damage Ensure the directions rollers turn freely Preventative Maintenance Schedule 7 2million or 1million if m c running for gt 8hrs day 1 8mm T Bearing D1040Ax2 2million 2 Eject shaft Assy A7234A 3 Clutch brake shaft assy A7237A 2million or 1million if m c running for gt 8hrs day 8mm T Bearing D1040Ax6 2million Tower Access shaft assy A2845Ax3 2million or 1million if m c running for gt 8hrs day 8mm T Bearing D1040Ax4 Feed wheel tyre DOO38Ax4 7 m o o 2million Upper transport roller shaft assy A2792A 2million or 1millio
102. ing a sheet of paper Check pulley and belt condition on the accumulator stepper motor Accumulator Gate solenoids clean plungers with dry cloth and use air duster to remove dust Check and adjust gt 8hrs day 1 8mm T bearing D1040Ax2 2 Solenoid 181 119x1 2million 1 Belt 384XL F5137A set 2 Belt 100 S2M F5124Ax1 solenoid stroke 4mm Check when the solenoid is pulled in by hand that the gate clears the paper path Tower accumulator bracket idler wheel assembly B4376A Clean and lubricate brass bearings If divert is fitted 3 Bracket Idler wheel assy B4376A Transport roller D0044Ax2 Remove Fold Plate 2 Assy A7078A Check travel of backstops Clean Level 3 lt 5 4c 10 fold plate belts and ensure they are held within the slider tighten as required Clean No Fold beam and ensure it dies not stick when pushed by the backstops by hand Oil brass slider and clean off any excess Remove Fold Plates 1 amp 3 Assy A7044A Check travel of fold plate 1 Level 3 lt 5 and 3 backstops Clean fold plate belts and ensure they are held within the slider tighten as required Clean No Fold beam and ensure it dies not stick when pushed by the backstops by hand Oil brass slider and clean off any excess C20 Check clean and ensure free turning of the bearings on the paper guide ee BEEN 4c 17 assembly A7087A C21 Clean all T bearings on the Eject Roller Carrier Assy A7075A note can Level 3 2million or 1milli
103. ing wavy washer Alo remove the 3 screws and disconnect the encoder cable on OMR models see Fig 72b below Remove screws Remove green knob amp brake flanged bearing and wavy wash er from transport shaft Fig 72b operator side J Disconnect the ribbon cable from the splitter PCB at the front and lift the assembly out of the machine disconnecting the ribbon cable from the splitter PCB behind the unit as it is withdrawn Lift the transport shaft out also See sections 4b 37 amp 4b 38 for disassembly 6 Encoder Removal OMR only this is required to replace the shaft The encoder is held to the shaft by an small Allen screw visible by turn ing the recessed knob to the 1 dot position Slowly turn the shaft until the screw becomes visible in the aperture then slacken it using a 0 9mm Allen key supplied with a new encoder or available from PFE Slide the shaft out of the encoder After replacing turn the knob to the 2 dot position UNLOCKED SCREEN ROLE 7 Reassembly of the tranport assembly is a reversal of removal Re member to reconnect the ribbon cables Page 3 57 Issue 7 Sep 2008 Page 3 57 100 140 Service Manual 3 23 RECOMMENDED SPARES The following spares are recommended to be held by Service Agents There is a separate list for each module both 230v and 115v To order each list of Spares quote the part numbers shown Quantities shown are per machine I
104. ion diagram on the following page Page 3 42 100 140 Service Manual Barcode Reader Connection There are two barcode reader types available Microscan MS 3 and Cognex DM 100 the DM 100 is primarily used as a 2D Datamatrix reader but can also be used for barcode reading The diagram below shows the connectivity of the readers with their part numbers Connections are also shown for the standard or 2 track OMR reader and the SICK KT3 OMR reader as this may be used in conjuction with a barcode reader and would affect its connection Note that the SICK reader can only be used on the mark read ing feeder not the 2 plate folder 2 track OMR readers can be fitted to the top or middle tray of the tower unit Fig 43 FOLDE MARK CABLE 182 781 EADING FEEDE SCANNER Page 3 43 MS 3 I F PCB CHANNEL 9 EG SE Ee GE 3 READER CABLE 182 8140 Zo E L DM100 I F PCB SE CHANNEL 9 180 8240 ee HEAD ID 1 USE FOR DM100 READER ARN 2D DATAMATRIX MS 3 I F PCB oe CHANNEL 10 180 805 a MP EAD ID 2 setts hae USE ONLY FOR MS 3 Gffts E EE TIN READER BARCODE OMR READER EnF 179 724 S USE FOR STANDARD SEIN READER OMR CABLE 182 782 SICK OMR READER SE E 179 765 ae USE FOR SICK KT3 ZS READER OMR IF CHANN
105. ions gt 22mm then the middle fingers will require extending Look through the viewing hole both sides with the fingers engaged to ensure middle fingers are going in cleanly Middle fingers opening the throat of the envelope Collate pocket width is Ensure the widest document insert once placed the collate pocket gives 2mm clearance to correct for envelope narrowest point Also note any Fine Tuning or Engineer adjustments will adjust the outer finger position If these adjustments are carried out then re check point 3 and adjust if required Preventative Maintenance Schedule Page PM 51 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Option Envelope Stop Position Adjust such that it falls within the Notch position ve value moves the envelope towards the wetter sealer and ve back see below e Notch start BE ech point y Notch end Envelope crease line point to be positioned within or advanced of notch in bridge 7 Envelope pickup issues see Envelope feeding Setup points 2 3 6 and 7 8 Envelope skew issues see Envelope feeding Setup points 1 and 4 Preventative Maintenance Schedule Page PM 52 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Action Required Description Option Envelope skew at insertion area The check for this is to see whether the envelope crease line is parallel to the notch on either side The s
106. ition and check by placing a handful of envelopes in the hopper for clearance and pickup To be set even and equal to approx 0 5mm overlap default Generally this setting is light with a standard pick up roller types and slightly heavier with the Tractor pre feed assembly In addition the separator can be locked in position see point 3 Envelope feeding setup To test for this mark the extreme edges of the external fingers on the chassis bridge that they sit against see below Run an envelope though the system by hand and stop it at the insertion area The finger position marks on the chassis can then be used to check their position relative to the envelope These marks should be equally spaced either side from the edge of the envelope The default finger setting is approx 5 7mm from the edge of the envelope and can be adjusted inboard if required In addition check if the insert is fully coved by extremes of the outer fingers Finger position marked on the bridge Page PM 50 100 140 Series Service Manual vw Preventative Maintenance Issue 3 Jul 2008 Option Again feed an envelope by hand and stop it slightly forward from the start of the notch position Engage the fingers manually or within engineer and then check for middle finger entry using the viewing hole on either side of the envelope feed side plates see below Note if the fingers are not supporting opening the middle of the throat envelope throat dimens
107. k that all warning labels are legible Exercise caution with moving parts and exposed electrical apparatus when covers are removed Insert head 1 RH side cover Lift top perspex cover and remove screw at rear end inside chassis face Lift closer closer and remove screw at front end inside chassis face 2 RH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged ES LH side drop down Lower cover then remove 2 x retaining straps amp 2 x E clips securing pivot bar 4 LH side main cover Drop down the front cover then remove 1 x Page 3 4 Issue 7 Sep 2008 screw on front inside edge at top 2 x screws rear inside edge midway 5 LH side control panel cover Attached to panel assy with 4 nuts Remove assembly by 2 x screws at rear edge 1 inside chassis 1 out side then 3 x screws at front edge inside chassis raise roller platten to access 6 Closer cover Remove lower side covers then 1 x screw each side at the pivots Feeder 1 RH side cover 1 x screw on both front and rear top corners inside chassis face open top closer covers to access 2 RH lower edge cover Remove side cover first then remove 2 x screws on brackets inside drop cover slightly to clear lugs when re placing ensure lugs are properly engaged cP LH side drop down Lower cover then remove 2 x retaining straps amp 3 x nuts
108. kew limits are within the start end points of the notch see photo in setup option 6 above If experiencing skew beyond this then check points 1 2 7 8 and for any catch points through the envelope path In addition Improved guidance into the envelope deskew rollers can be provided by fitting tapes onto the sensor support assembly B4427A and envelope feed bridge part numbers TBA Finger actuation start Mark the inside of the crease line and then feed an envelope by hand to the start of the notch position position Then using the viewing hole on the envelope feeder side plates check the finger start position on either side is sitting on or slightly behind the marked creaseline see figure below If this is not set then the stops need to be adjusted to position Once this is OK ensure 4mm stroke is set on the finger solenoids either side Looking through the viewing hole the finger sits on or slightly behind the envelope creaseline Finger stop Adjustment drive side Preventative Maintenance Schedule Page PM 53 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Option 3 a 4 d i wg coe Increase the spring tension both sides Finger stop Adjustment operator side fingers and brass overguides If this has occurred carefully remove the filled envelope and check point 2 and 7 Note brass overguides should only be fitted for problem jo
109. l 3 17 FITTING A BARCODE HEAD Machines not fitted with a Barcode reader can be upgraded to full barcode specification by ordering the appropriate kit of parts A3292A Vertical Barcode Upgrade Kit 3 tray machines A3293A Horizontal Barcode Upgrade Kit 3 tray machines A3296A Vertical Barcode Upgrade Kit 1 tray machines A3297A Horizontal Barcode Upgrade Kit 1 tray machines z NOTE FIXING SCREWS ARE SUPPLIED amp WITH READER IF SPARES ARE REQUIRED H TOWER TOP COVER ORDER PART No E2 0885 A 9112132D M4 NYLOC NUT B7645T H e E3505A QTY 2 M3 x 10 CAP HD SCREW j M4 WASHER E2500A QTY 2 NOT PART OF VERTICAL Teo d E4011A QTY 2 M3 WASHER hs BARCODE ASSEMBLY eos i E4009A QTY 2 ae A3 0375 BBV J ye l 7 SR z Bre ig Ba l Ss s s Ce 8 SEET E a i we LD VERTICAL BARCODE MOUNT BRACKET a we R2951A a Ze we effet SE M4 x 12 CAP HD SCREW a SH ae Cara s PLASTIC PLATE a s 7 e fs VERTICAL BARCODE S w ii SUPPLIED WITH READER SLIDE BRKT R2952A LASER CAUTION LABEL i DATAMAN 100Q 2D READER G3363A 179 8460 EE SK CLAMP PLATE OP k ee eg BARCODE SCANNER MS 3 JQ S lt TOWER ACCESS LATCH SEH NOT BART OF VERTICAL BARCODE ASSEMBLY A3 0375 BBV BARCODE SLIDE BAR C9676C gt Oo D GN OO M4 x 25 CAP HD SCREW eta SE SKI WIDE DR 8 4 eA S PAPER SKI NARROW ok ao l ISS SKI LOCATION PLATE DR d D i e
110. late Belt F5123A Amount addition to the parts shown in 3 24 1 or at 1 million inserts if the machine Folder 9104503G for single is being used for more than 8 hours per day bin NOTE Part Nos shown in brackets thus are SAP numbers Folder 9104504H for single EEN Qty Notes Ton bin Insert Head EC30 Clutch 179 214 ay Three Plate Belt 384XL F5137A Amount 9100519G Folder 9104507L for single Insert Head EC25 Clutch 181 104 1 bin 9100790P Three Plate Gear 40T x 8mm F4150A Amount Insert Head EC25 Clutch 181 105UL i Folder 9104398X for single 9100792R bin Insert Head EC25 Brake 181 117 1 Three Plate Gear 48T x 8mm F4151A Amount 9100800Z Folder 9104399Y for single Insert Head Solenoid 181 119 1 bin 9100801A Three Plate Gear 30T x 8mm F4156A Amount Insert Head EC25 Clutch 181 127 1 Folder 9104402B for single 9100806F SH Insert Head Solenoid 181 142 9100816R Insert Head Middle finger Ext op B7637A 1 erator side 9105535G Insert Head Finger Operator side B9319A 1 9105583G Insert Head Finger Drive side B9320A 1 9105582F Insert Head Sealer roller Top C8166A 2 9103532V Insert Head Sealer roller 40mm C8167A 1 dia 9103533W Insert Head Sealer roller 25mm C8168A 1 dia 9103534X Insert Head A Finger Drives 3 dia A7368A 1 9106905 J Insert Head T Bearing D1040A 20 91036413J 100 140 Service Manual Module Description part No Lon Notes Qty Insert Head Dowel pin 3 x 14mm _ E5071A 17
111. le for down load this will be a am4 format file A PPE Trace Tool 3 0 0 4 fe ofat feeeniesd otiosi rees mome JobalSeltngs Hep a Stet Log Stop Lag ow Download Direct File Prag acn Filles PFE d es Fir Te died Fiada Vi 4 Filles Lod j Ei ar SR fonds Frzsumge ee ee IC Am Di ath isPC_ 4 1 414 ant Elamo Bese GL ap Chon send bonis ele iming add Emio lead pg cenmected ie LUHHEG ie Fie rara 7 fies a he Pages hes Peal ered OD pers ae por Fig 19 Page 3 27 Issue 7 Sep 2008 Note that a separate file exists for each module type and carries a descrip tive name Select the appropriate file and click Start A status bar will show the progress of the download which may take a few minutes for the insert head and less for feed units Correct progress of the download is confirmed by continuous signs displaying in the RX screen of Am4Go Any errors will be displayed in the Info window in the bottom RH corner Important When connecting the adaptor to the module this will plug directly into the serial connector on the PCB This means that the DIN to D type lead on the adapator will not be suitable use the DIN to PCB connec tor lead instead this is supplied with the adaptor kit 184 176 The serial connectors on the respective PCBs are as follows Insert Head J14 Feeder 2 Plate Folder Cardfolder J19 3 Plate Folder J21 Via Head for
112. lete complete Interval Cycle mins Check envelope stop position is consistent within 2mm by running Level 2 amp 3 2million or 1million if m c running for machine in envelope mode only If the variation is greater then replace gt 8hrs day the drive clutch and brake on the envelope feed 1 EC25 Envelope pickup clutch 181 105UL x1 2 EC25 Envelope Drive Clutch 181 104 x1 3 EC25 Envelope Drive Brake 181 117 x1 4 EC25 Clutch pin G0079Ax3 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers A17 Check envelope opener is returning and not sticking clean the T Level 2 amp 3 2million or 1million if m c running for bearings and apply light oil Also clean and oil the t bearings on the gt 8hrs day Collate pocket and input rollers 1 Opener Assembly A7022A x1 2million 2 T bearings D1040Ax2 2million Or Curled Flap Opener assembly A7413A optional onl Sealer cover assembly A7046A apply oil behind the circlip groove Level 2 amp 3 lt 10 2million or 1million if m c running for 4a 12 that retains the closer roller bearings P2226A x4 gt 8hrs day 1 Sealer Roller Top C8166Ax2 2 Closer bearings P2226Ax4 3 Sealer Roller 40dia C8167Ax1 4 Sealer Roller 25dia C8168Ax1 Wetter solenoids clean plungers with dry cloth and use air duster to Level 2 amp 3 2million or 1million if m c running for 4a 17 18 remove dust Check solenoid stroke 4mm down and Omm up gt 8hr
113. lied by the software which will suit most job applications It it is required to alter the settings use the adjust ment boxes as described above These settings will then remain until set otherwise Note also that the collate pocket side guides are adjustable for taper and are factory set to taper intowards the closer end The 210mm setting above applies to the narrowest point the widest point is set to approx 3 4mm wider either side Specific jobs may require a diferrent setting to adjust slacken the screw near the middle of the guide and twist the guide to suit To exit Calibrations press the x button Settings This allows adjustment of various settings depending upon the module Head end adjustment of Collate Pocket Cal amp Fingers Cal These settings are in addition to any changes made in Calibrations Use if the settings need to be different from the calibrated sizes Wetter Start Adjusts the point at which the wetter beam drops to wet the flap ve more wetting In steps of 1mm Note this setting applies to the machine and can be further adjusted for the job in Ad vanced Page 3 19 100 140 Service Manual Wetter Stop Adjustment of the point at which the wetter beam lifts ve more flap length is wetted In steps of imm Note this set ting applies to the machine and can be further adjusted for the job in Advanced Envelope Stop Position Cal Adjusts envelope stop position Po
114. ller 30 35 Hardness C8203A Lobed Tyre DOO52A Silicon Feed Tyre D0037A Coated Silicone Tyre DOO59A Also available on complete shaft assy A7268A Also available on complete shaft assy A7271A Page 3 7 Issue 7 Sep 2008 3 3 3 PLATE FOLDER SEPARATOR 3 3 1 Separator adjustment Each tray of the 3 plate folder is fitted with a separator This is of the spring loaded type with zero gap and normally requires no adjustment However circumstances may arise which necessitate abnormal adjustment eg dou ble folded A3 paper which may require a gap to be set or setting a stop to ensure the gap cannot open The adjustor is located on the LH side of the folder accessed by removing the internal cover Front adjustor Rear adjustor Referring to Fig 4 above to open the gap slacken the lockscrew on the front adjustor and turn the screw to open the gap then tighten the lock nut To prevent the gap opening turn the rear adjustor so that it just con tacts the plate For normal running each screw is set to approx 1mm clearance from the plate 3 3 2 Separator roller replacement If doubles are continually being fed or damage occurs the separator pad or pick up roller may need replacement The pickup roller is mounted on a spring loaded shaft and removal is a matter of springing it out after gaining access For the top tray remove the top horizontal cover see section 3 1 2 the pickup roller shaft is visible below For the
115. ller shaft and lift it out of the chassis In its place fit the OMR transport roller shaft A2844A supplied in the kit Assemble this with the nylon encoder mount P2150A in place of the T bearing on the LH end Note that the stepped end of the shaft runs through this mount Assemble the encoder base plate to the nylon mount using 2 off M3 x 6 screws amp lockwashers see Fig 22 On the encoder cover align the small grub screw hole with the slot on the curved part of the cover and insert the Allen key this is normally supplied with the Allen key in place Clip the cover onto the base and tighten the grub screw onto the end of the transport shaft Pull out the Allen key and turn the ad justor slot fully clockwise to position 2 Note when the encoder cover has been clipped in place it cannot then be removed Connect the supplied encoder cable 182 703 from the encoder to the upper Splitter PCB Wires are connected BLK WHT to J1 RED BRN to J2 Page 3 31 Issue 8 Aug 2009 Fit the supplied emitter RED BLK wires to the sensor mount on the supplied OMR bridge B7649A Remove the existing paper transport bridge below the transport roller shaft the OMR bridge will fit in its place after fitting the OMR assembly Fig 25 on the following page shows the OMR bridge in place Fit the OMR assembly and retain it with 2 screws each side on the outside of the chassis as shown in Fig 24 below If the OMR head is fitted to the assembly le
116. ly grease silicon based if required Check gear Gears Replace A R It is advised to keep 4b 12 movement sideways and rocking replace gears if required Check for stock of F4150Ax2 F4151Ax2 and any tight spots in the drive Check all gear drive pins are in tact and not F4152Ax1 loose If so replace gear and pin This can cause loss of drive and noise problems 2million or 1million if m c running for gt 8hrs day 1 Pickup Clutch 181 117 x1 2 Deskew Clutch 181 127 x1 3 Track Feed Clutch 181 127 x1 4 Track Clutch 181 127 x1 5 Clutch Pin GOO79Ax4 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers complete Clean all T bearings note can apply light oil and clean off any excess in the OMR Transport Roller Assy A7345A or Barcode Transport Roller Assy A7346A Preventative Maintenance Schedule Page PM 26 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle complete mins Operator side gears clutches applicable to all clean idler gears Level 3 2million or 1million if m c running for and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight gt 8hrs day 1 Deskew Brake 181 127 x1 2 Track feed brake 181 127 x1 3 Track brake
117. m F4150Ax6 EC30 Pins P2232Ax6 Dowel Pin 3dia x14mm E5071Ax17 Dowel Pin 3x8mm E5074Ax12 9 5mm E Clip E5073Ax16 Shim G6028Ax10 Lo a a a Preventative Maintenance Schedule Page PM 12 100 140 Series Service Manual Maintenance item Head Unit ee ee ene main clock disk and ensure there is no excessive movement Ensure clean from ee ee ene grease Turn pawl chain track by hand and clean with cloth Also inspect for any tight spots or damage Replace if damaged Remove Sprocket Bracket Assy A7059A and ensure sprocket turns freely on the spigot Also lubricate the t bearings which holds the sprocket shaft C9264A Remove and check primary drive assembly Clean area and ensure all parts are intact tight spots belt noise or signs of wear Preventative Maintenance Schedule E Preventative Maintenance Issue 3 Jul 2008 Level 2 amp 3 Level 2 amp 3 Frequency Time to complete mins lt 5 AS ect Replacement Part Numbers and aan Interval Cycle Only Replace if damaged 1 Chain 1 4 Pitchx61 F6016Ax4 2 Chain 1 4 special Link F6041Ax4 Replace after 3 million 1 Sprocket 15T F30044AX2 Sprocket Hub P2033AX2 and Pin grooved 2 5diax14mm E5078AX4 assembled 2 Jockey Sprocket F3004Ax2 2million or 1million if m c running for gt 8hrs day on A7068A 220v or A7069A 110v 1 Belt 100 S2M 280 F5112Ax1 2 Pulley F1372Ax1 220v or F1373Ax1 110v 3 8mm T Bearing D1040A
118. ms 3million 1 Brake Lenze 03 assy A7331A D7 Remove and clean the Cassette Detent Assy A7293A Apply light oil and Level 3 lt 10 4 9 clean off any excess Inspect Module for damage and safety covers are all intact interlocks Level2 amp 3 lt 5 function warning labels in place Preventative Maintenance Schedule Page PM 41 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle Gei complete mins Level 3 lt 30 2million or 1million if m c running for gt 8hrs day Gears F4151Ax1 and F4182Ax2 Cassette Rotate Lenze clutch 181 132 Conveyor Clutch EC30 179 110 Cassette drive Lenze Brake 181 132 Cassette Rotate Lenze Brake 181 133 lt 15 Drive side gears clutches applicable to all clean idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Order A7331A for replacement Level 3 2million or 1million if m c running for gt 8hrs day 1 Gears F4151A A R 2 Conveyor Brake EC30 179 110x1 3 Cassette reverse clutch 179 110x1 4 Cassette forward clutch 179 109x1 Level 3 2million 4 9 1 Motor Pulley F1372A 220v or
119. n if m c running for gt 8hrs day 1 8mm T Bearing D1040Ax2 2million 2 Transport shaft upper assy A7232A 3 Transport shaft lower assy A7233A ha WW NM Page PM 21 B13 B14 B16 100 140 Series Service Manual Maintenance item Head Unit Drive side gears clutches A5135A Part 1 clean idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise problems Operator side clutches A5135 Part 2 Remove and check motor assembly Clean area and ensure all parts are intact tight spots belt noise or signs of wear Clean clock disk on the motor assembly Check motor pulley is tight on the motor shaft Preventative Maintenance Schedule Level 3 Preventative Maintenance Time to complete mins Issue 3 Jul 2008 Complete v Replacement Part Numbers and Interval Cycle 2million Gears Replace A R It is advised to keep stock of 40T F4150Ax2 48T F4151Ax2 25T F4152Ax2 30T F4156Axiand 32T F4235Ax1 2million or 1million if m c running for gt 8hrs day EC30 Clutch Track Feed 179 214 x1 Clutch Pickup posn 1 181 117 x1 Clutch Pickup posn 2 181 117 x1 Clutch deskew posn 1 181 127 x1 Clutch deskew posn 2 181 127 x1 Clutch Tra
120. ndent upon envelope types If feeding problems are encountered it is best to try reducing the amount of envelopes loaded note this is particularly applicable on twisted envelopes For optimum performance load 300 envelopes max 2 It is very important that both separator pads are set at the same position it shouldn t be used to try and overcome skewing Note an uneven separator and sometimes a separator that is set too tight will deform the envelope resulting in crashes further downstream 3 If the separator is set very tight maybe necessary to overcome doubles etc and the deskew value is set to high this can result in too much drive on the envelope and it will deform badly as it enters the deskew rollers It is best to start with deskew values set to no low 4 Deskew tapes can be fitted onto the deskew and envelope feed bridge to provide assistance into the deskew rollers which reduce envelope skew Retrofit part numbers TBA Preventative Maintenance Schedule Page PM 49 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Guidelines for good Envelope Insertion Setup Action Required Option Set and lock side guides Separator setting and adjustments Outer finger setting set correctly to the envelope width Preventative Maintenance Schedule Description Set to 2mm Max 1mm either side Only open up clearances if experiencing envelope skew into the side guide Once set lock both sides into pos
121. ng D1040Ax4 or x2 2million 1 Tower access shaft assembly A2845Ax2 or xi C8 3 Plate folder Tower Assy Applicable on all feed stations Level2 amp 3 2million or 1million if m c running for Clean rollers and T bearings gt 8hrs day 1 8mm T bearing D1040Ax4 or x2 Clean Folder Paper Direction Roller A7176A 2 Collate clutch 181 127x3 Remove and clean paper deflector C7636A and or C7401A Then check 3 Collate Brake 181 127x3 and adjust gaps if required between paper deflector C7636A and rollers 4 Gears Replace gears A R It is advised 3 sheets 80gsm paper to keep stock of F4150Ax2 and F4156Ax2 2million 1 Paper Transport Shaft Assy A2843AX2 4million 1 Plate Folder Paper Direction Roller A7176Ax3 a ae Clean rollers and T bearings 2 OMR paper Transport Assy A2844A Clean rollers in the Collate Jam Access Assy A7054A Level 2 amp 3 lt 2million 4c 16 1 Drive Shaft Jam Access Assy A2849A 2 Drive Shaft Collation Assy A2851A lt 20 3 Plate folder Tower Assy with OMR fitted Level 2 amp 3 lt 10 2million or 1million if m c running for gt 8hrs day 1 8mm T bearing D1040Ax4 or x2 2million 1 Paper Transport Shaft Assy A2843A 10 Preventative Maintenance Schedule Page PM 35 C11 C12 C13 100 140 Series Service Manual Maintenance item Head Unit 1 Station or 3 station Tower Drive side gears applicable to all clean idler gears and posts Apply grease silicon based if required Check g
122. nrnrnrn 3 18 3 2 4 Lateral CS EE 3 6 313 1 Engineer Mode 100 Serres 3 18 3 2 5 POU ROIT KE 3 7 3132 Engineer Mode 140 Serres 3 23 3 2 6 ENER EE ee 3 3 14 Debug amp Download 3 26 3 3 3 Plate Folder Separator 3 15 aE ee ee 3 29 3 3 1 SEENEN cc ssicccuinscesecasnuedtuaxsncecsus geet 3 7 3 16 Fitting an OMR Head 3 30 3 3 2 Separator Roller Hepnlacement 3 7 3 16 1 3 Tray 3P Folder OMR on Station 1 Only cccccccesesceseseseseesereeees 3 30 3 0 0 Separator Pad Hepnlacement 3 8 3 16 2 3 Tray 3P Folder Cascade OMR Stns 1821 3 37 3 3 4 SEH eiert 3 8 3 16 3 Single Tray 3P Folder 3 39 3 4 3 Plate Folder Rollers 3 4 1 Lower Roller REMOVal ccccssercssseresssersesseerensserescuerscnsersenseere 3 8 3 4 2 Upper Roller Hemoval AE 3 9 coni Page 3 1 100 140 Service Manual Continued from page 3 1 Sect 3 17 3 17 1 3 17 2 3 18 3 18 1 3 18 2 318 3 3 18 4 SMS 3 18 6 3 18 7 3 19 3 20 3 20 1 3 20 2 3 20 3 3 20 4 3 21 3 21 1 3 21 2 3 22 Fitting a Barcode Head Vertical Barcode Aesembhy Horizontal Barcode Assembly s nnnennoennnnnesnnesnresrenrnnerreorrennnene OMR Barcode Alignment amp Calibration 000 000000nn00nna0nnaaane OMR Head Alignment 100 sees OMR Head Calibration 140 series with SICK Reader Barcode Reader Calibration 140 sees Barcode Reader Diagnosis 140 eeres OMR Reader Calibration 100 series with SICK Header Barcode Reader Calibration 100 s
123. nsert Head 100 140 Series order A0341A 230v or A0344A 115v NTL Pt No 169 115 169 145 179 213 179 214 180 689 180 720 180 8360 180 746 180 758 180 759 180 760 181 0770 181 5770 181 070 181 104 181 105UL 181 117 181 119 181 127 151 128 181 132 181 142 182 337 182 339 182 342 182 343 182 345 182 418 182 437 182 438 182 439 182 440 182 441 SAP Pt No 9100459U 9100469E 9100518F 9100519G 9100709E 9100723U 9109914T 9100741N 91007430 9100744R 9100745S 9108705 Or 9108706K 9100788M 9100790P 9100792R 9100800Z 9100801A 9100806F 9100807G 9100811L 9100816R 9100975G 9100977 9100980M 9100981N 9100983Q 9105294F 91010070 9101008R 9101009S 9101010T 9101011U Description Rivet 5mm 2 5 3 5 Grip Rivet 3 5mm 2 3 grip Clutch EC30 CW 8mm 24V Clutch EC30 CCW 8mm 24V PCB Assy Disc Sensor PCB AM4 Processor PCB C4 Control Mk 2 PCB Hi Res disk sensor PCB Splitter 5sens 2 sol PCB Splitter 5sens 5 sol PCB Splitter 3sens 4 sol Motor WD 179 072 4WJST CCW 230v Motor WD 179 073 4WJST CCW 115v Motor WD 24VDC 217RPM Clutch wired 102 10 CW Clutch wired 102 20 CW Clutch Wired XH 102 10 SM Wired Solenoid TDS 10SL A SS Clutch Wired XH 102 20 Clutch Wired Lenze 04 179 155 2WXH Clutch Wired Lenze 03 179 154 2WXH XH Wired solenoid TDS 10SL A SS Loom Emitter 100 Loom Receiver N A 100 Loom Receiver N A 200 Loom Emitter 300 Loom Receiver N A 300 SM Reed Switch 3WXH UL Lo
124. nsor cable is not being strained Take care if another unit is located behind as Space will be limited Remove the sprung feed shaft assembly from the lower hopper On the operator side remove the green paper eject knob drive pin and clutch as shown in Fig 53 opposite Page 3 52 Issue 8 Aug 2009 Eject knob with clutch behind Fig 53 Remove the grey infill cover below the upper hopper retained with 1 screw each side on the chassis 1 each side on the top surface of the tray later covers are in 2 parts with 3 screws each side Impor tant the infill cover can only be removed after removal of the lower feed tray as described in step 5 Remove the 2 screws each side securing the transport roller assembly and lift it out of the chassis from the drive side see Fig 54 below ao Br TE Cutout for d transport roller 5 assembly Page 3 52 100 140 Service Manual 10 To replace the transport roller assembly refit all parts in reverse order to removal Note when refitting the grey infill cover below the upper hopper it is possible to replace it incorrectly Take care to ensure it is assembled as described in Fig 55 below later covers are in 2 parts but the instruction applies equally ji Ensure no chassis fixing is visible in this area fixing must be inside the cover as shown 3 20 3 Cleaning of lower transport rollers Due to accessibility these rollers cannot easily be reach
125. o the top representing 100 read quality Less than 100 will result in shorter lines a poorly reading scanner will produce a histogram effect For further assistance in diagnosing barcode reading problems con tact Technical Support department Page 3 47 100 140 Service Manual Page 3 48 Issue 9 Feb 2010 3 18 5 OMR reader calibration 100 Series mark reading feeder with 3 18 7 Barcode reader calibration 100 Series SICK reed Head ONIY SEE 3107S LOr Standard read need Calibration of the barcode reader is carried out from the Run screen with Calibration of the OMR reader is carried out from the Run screen with the the machine paused Press the X button to reach the options then select machine paused Press the X button to reach the options then select OMR Barcode Setup as shown below Follow the on screen instructions Note Setup as shown below Follow the on screen instructions Note that the that the Barcode setup option will only appear if a job that uses a barcode OMR setup option will only appear if a job that uses an OMR marked docu marked document has been selected Results displayed as below are a ment has been selected and the unit is a mark reading feeder Calibration read only report of reader head efficiency should be carried out whenever the mark contrast is different from the last job or if read errors occur BARCODE SET_UP RUN MRF OMR1 p mod 4 hopper 1 id 1 gt Glo
126. of drive and noise problems Divert solenoids clean plungers with dry cloth and use air duster to remove dust Check and adjust solenoid stroke 4mm Check for squealing noise from clutches If so remove and clean and replace if necessary Check for any tight spots in the drive and belt tension re tension main drive belt Check Lenze clutch is set with the correct gap and is not binding or slipping Check all side guides for movement feed trays and accumulator stop position and parallelism to chassis Check all clutch pins G0167P or G0079A are intact 0 all clutch pins G0167P or G0079A are intact Preventative Maintenance Schedule Level 3 Time to complete mins 2million 3million Issue 3 Jul 2008 Replacement Part Numbers and Interval Cycle Complete v 2million or 1million if m c running for gt 8hrs day 8mm T bearing D1040Ax2 Fold entry brake 181 127 Track exit brake 181 127 Folder entry clutch 181 127 Folder exit clutch 181 127 Divert Solenoid 181 119 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 1 Gears Replace A R It is advised to keep stock of F4152Ax1 F4156Ax3 F4150Ax4 and F4151Ax3 Collate jam access A7054A Idler shaft collation deskew A2852A Eject shaft C B assy A7079A Eject drive shaft assy A7O80A Roller Fold Rollers C8175Ax3 Belt F5123A Lenze Clu
127. om Emitter 100 XH Loom Receiver W A 100 XH Loom Receiver N A 100 XH Loom Emitter 200 XH Loom Receiver W A 200 XH Qty Bee kA Fb kA Fi Fiir BRN KA Fb kk bk Fb FA FA FA FA Fb Fb Fb kk bk bh M kA kA kA Fb Eh NTL Pt No 182 442 182 443 182 444 182 445 182 557 182 567 162 572 182 693 183 7690 184 2350 C8098A C8166A C8167A C8168A DOO2Z1A DOO22A D0044A D0051A D0052A D1040A E0204A E0227A E0367A E1070A E1078A E5071A E5074A E5078A F5112A F5119A F5120A GO0135A G0136A G1111A G1116A G1117A G1136A G1152A G1180A G1181A G1182A SAP Pt No 9101012V 9101013W 9101014Xx 9101L01S 9101049 9101050K 9101052M 9101087Y 9108707L 9110540V 9108237W 9103532V 9103533W 9103534X 9103602T 9103603U 9103613E 9103618K 9103619L 9103641 9103744R 9103755C 9103789N 9103829E 9103835L 9104133W 9104135Y 9104138B 9104493W 9104497A 9104499C 9104598F 9104599G 910468158 9104685W 9104686xX 9104695G 9104699L 9104713A 9104714B 9104715C Page 3 58 Description Loom Receiver N A 200 XH Loom Emitter 300 XH Loom Receiver W A 300 XH Loom Receiver N A 300 XH Loom AM4 T101 link Terminator Loom AM4 Float switch Loom Wired Reed switch 3W SM OPB715 Wired Sensor Loom 350mm El Hsg Plg 4W El Hsg big AV AM4 Universal Head PSU Roller Envelope Feed Sealer Roller Top Sealer Roller 40 dia Sealer Roller 25 dia Transport Roller 30x8 Transport Roller 25x8 Transport Roller 40x15 Separato
128. on if m c running for apply light oil and clean off any excess gt 8hrs day 1 8mm T bearing D1040Ax2 2 Eject Roller Shaft Assy A2894Ax2 C22 Remove Folder Jam Access Assy A7077A Level 3 2million or 1million if m c running for Clean all T bearings Apply light oil and clean off any excess gt 8hrs day 1 8mm T bearing D1040Ax4 Clean gears and posts Apply grease silicon based if required Check 2 Gears Replace A R It is advised to keep gear movement sideways and rocking replace gears if required Check stock of F4151Ax1 and F4150A for any tight spots in the drive Check all gear drive pins are in tact and 3 Rollers DOO21Ax8 not loose If so replace gear and pin This can cause loss of drive and ise problems Preventative Maintenance Schedule Page PM 38 100 140 Series Service Manual Preventative Maintenance Maintenance item Head Unit Folder Base Assembly A5116A Clean all T bearings Apply light oil and clean off any excess Clean all rollers on the following areas Collate jam access A7054A Idler shaft collation deskew A2852A Eject shaft C B assy A7079A Eject drive shaft assy A7O80A Roller Fold Rollers C8175Ax3 Clean gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss
129. or PIN gt Yiew throughput gt Sensor Cal Super gt CONFIGURE SYS TE be Display contrast Higher figures enhance contrast to darken display Default is 53 Module settings The following settings are available for the insert head and each track module numbered 1 onwards that is fitted and configured All settings are described below Insert Head Analogue Sensors gt Digital Sensors gt Calibrations gt Settings gt Power gt Drivers gt Motors gt Interlacks amp Covers Y Analogue Sensors These are shown in the format abc d d Cor B The meaning of the numbers is as follows a emitter current value 0 9 b receiver pot setting value 0 9 Both a amp b are mostly of use only to Technical Support for fault checking in combination with other parameters c threshold voltage value 0 9 Should be approx 4 5 If the values differ substantially from those shown above the sensor is sus pect d dd receiver voltage in volts If clear should be approx 0 5v If blocked should be gt 4v C B clear or blocked Note depending upon unit fitted some sensors may show receiver voltage only and whether clear or blocked These figures are read only prior to analysing them sensors should be auto calibrated and if any sensor fails it should first be cleaned and its connector checked Re calibrate and then replace if failure still occurs The fig
130. ote the twist on the envelope Should not be more than 1 4 6 5mm when placed flat on a table Page PM 45 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Setup Envelope type Side Pick up feed Separator Separator Spring Option guides system gap Action settings required setting Tractor fitted but as above Remove the Separator outer upper pad overlap tyres from the gt 0 5mm pre feed assembly as shown experiencing streaming and doubles issue Separator adjustment is now limited need to back off the separator lock nuts before any adjustments can be made No operator intervention allowed Separator pad overlap gt 0 5mm Separator spring action locked to prevent any separator movement downwards This is carried out by adjusting the 2 locknuts to the underside of the sep bracket Set up as point 2 but as above still experiencing streaming and doubles issue Operator separator adjuster both sides turn ACW tighter setting turn CW loose setting Lock Separator using the lock nuts both sides Preventative Maintenance Schedule Page PM 46 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Setup Envelope type Side Pick up feed Separator Separator Spring Option guides system gap Action settings required setting Running as above Remove th
131. pe th Feeder 1h MR Feeder Module 0 Hopper 2h Feeder Module 1 3h Feeder Module 1 Hopper 2pth Folder Module 2 ze 4 3pth Folder Module 2 Hopper 3p3h Folder Camera Module 3 DTI Module 3 Hopper ui Module 4 Module 4 Hopper Module 5 Module 5 Hopper _ Module 6 Module 6 Hopper Module 7 Module 7 Hopper Module 7 Hopper N Bed Module 7 Hopper WR WE BN Na I Exit Click on each unit in the list shown above and the unit type will be shown and the equipments currently used If making changes eg adding an ac cumulator or an OMR head to a 3 plate folder select these to suit The number of OMR or barcode heads can be set in Extra settings After mak ing changes press the Send button to update the firmware and INI file When adding or removing a module it is possible to use the upper arrows to add or subtract modules to reflect the physical machine As changes will always be added or removed at the end of the list shown above all stations after the altered one will need to be re defined In practise however when a Page 3 23 100 140 Service Manual module is added or removed provided DIP switches have been correctly set see section 1 3 the machine will automatically detect changes at power up and restructure the above list as described in Plug amp Play at the end of this section The View
132. pe feeder Screw for collate chain tension shaft Fig 12 4 Lift the envelope assembly clear of the chassis 5 Reassembly is a reversal of removal Note When replacing the feeder assembly ensure the gear train is not tight there must be a small amount of backlash If gears are too tight slacken off the screws and move the feeder assembly slightly until some backlash is evident Retighten the screws 3 7 COLLATE CHAIN REPLACEMENT The collate chains or pawls must be replaced if they are excessively worn or damaged To gain access remove the envelope feeder assembly as described in the previous section 3 5 Also slacken but do not remove the screw for the chain tension shaft shown in Fig 12 The collate area is shown in Fig 13 on the following page Page 3 12 100 140 Service Manual Collate chain replacement continued 1 Remove the collate backstop assembly by taking out the 3 x screws shown in Fig 13 below As the assembly is lifted out disconnect the ribbon cable from the PCB and free the cable from the slots in the bracket The assembly with solenoids is now free Feed rollers Pocket clam assy Backstop Bemove 3 assembly g Screws Feed roller Chain bearing pawls assy Insert finger Kez Fig 13 2 Reach inside the chassis and free the end of the chain tension shaft from the slot in the chassis then withdraw the spigot at the other end This will relieve chain
133. pivot plate Refit the tower access assembly as described in section 3 16 1 step 13 Page 3 38 100 140 Service Manual Connection 11 Using the supplied 182 352 extension lead connect the sensor wires to the middle station 2 splitter PCB on the RH side YEL BLU to J7 RED BLK to J8 12 Connect the OMR head as described in section 3 16 1 step 16 If one head is fitted at station 2 connect to channel 3 If two heads connect to channels 3 amp 4 13 Use cable ties to secure added wires and cables away from any mov ing parts snag points or sharp edges 14 Follow the Engineer and job setup instructions described section 3 16 1 step 18 15 Replace all covers The OMR job is now ready to be run If OMR read problems are encountered use the OMR scope function in the Trace Tools debugging utility described in section 3 14 Important Before OMR reading can be used the licence key must en tered and an OMR setup defined see section 3 19 3 16 3 Single Tray Tower Unit Kit A3S266A The procedure for single tray machines is exactly the same as section 3 16 1 for 3 tray machines with OMR on one tray only except for the OMR Access bridge shown in Fig 26 This is replaced by B7614A and is Supplied in the kit Note that the pictures shown in section 3 16 1 will differ slightly from the single station machine but all actions will be the same Page 3 39 Issue 8 Aug 2009 Page 3 39 100 140 Service Manua
134. problems Check the obvious side guides clearances separator gap is even amp not too tight and joggler feed tyres are aligned Check the tapes leading into the deskew rollers if applicable are intact and free from damage c Variation in Envelope stop position this should be within the notch position with very little variation Max 2mm overall If this variation is greater than 2mm than the following actions must be carried out 1 Remove envelope feed assembly to check clean the pinch rollers These rollers are located on the flap grip assembly and can be susceptible to build of dust and toner with particular envelopes With time a dark layer of residue can build up leading to the pinch rollers not turning freely This residue can be easily removed with cloth and using Rubber Roller Restorer E0483A Use an air duster to remove any free particles before re assembling Nb Care must be taken not to score or damage the plastic rollers this will lead to paper catch points After cleaning check for any flat spots on the rollers this can also cause a variation in stop position If flat spots are found on the rollers they must be replaced Preventative Maintenance Schedule Page PM 3 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Note Lubrication on the flap roller bar and pinch rollers will cause particles to adhere and exacerbate the problem and therefore should be avoided
135. problems from loaded pack to empty hopper by running Level 2 amp 3 machine Check Feed tyres for wear and separator gap Level 3 A7032A Insert Separator assembly and Feed Shaft Assembly A7030A Clean Adjust Replace if required Bi B2 B3 B4 B5 1 Roller C8098A x4 2 Separator Pads DOO51Ax2 Or replace optional tyres if fitted 2million or 1million if m c running for 7 B7 Clean all T bearings note can apply light oil and clean off any excess in Level 2 amp 3 the OMR Eject Roller Carrier A7344A gt 8hrs day 1 8mm T Bearing D1040Ax4 2 million on A7344A 2 Upper transport roller shaft assembly A2793A 3 Upper Transport Roller Shaft Assy A2792A Others shafts include 4 Lower Transport shaft assy A7340A 5 Middle Transport shaft assembly A7347A 6 Eject Shaft roller Assy A2790A Preventative Maintenance Schedule Page PM 25 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle Gei 2million or 1million if m c running for 4b 50 gt 8hrs day 1 8mm T Bearing D1040Ax2 3million 2 Upper Transport Shaft A7337A for OMR or A7339A for Barcode Check clean and ensure free turning of the bearings on the out feed body Level 2 amp 3 assy A7034A B10 Drive side gears clutches applicable to all Remove clean idler Level 3 2million 4b 3 or gears and posts App
136. r Clutch 8 x 12 x 12 Needle bearing 8 x 12 x 8 Flanged Bearing 8 x 19x 6 Needle Bearing 3 x 6 5 x 6 Belt 100 S2M 480 Polyurethane Belt 100 S2M 300 Polyurethane Belt 430xI 037 Polyurethane Restrictor Cork Spring Fold Roller Spring DD Spring No Fold Return Spring Fold Roller Separator Spring Std Other parts are included in the Insert Head and Feeder lists Qty 1 OMR 1 OMR ACC Acc ACC Acc RPFNFrENABRNFPRPNNNFPRPRPRFPRPWHNRFPRFPRP kA kk RRP RE ki Fi Feeder Folder order A0434A 230v or A0435A 115v NTL Pt No SAP Pt No 180 746 180 785 181 069 181 569 181 117 181 127 182 337 182 344 182 345 182 441 182 443 182 444 182 450 184 168 A7097A A7120A A7179A C8142A C8143A C8186A D1040A F5151A G0152A 91007411N 9105209S 9105274K Or 9100831G 91008002 9100806F 9100975G 9100982P 9100983Q 9101011U 9101013W 9101014Xx 9105292D 9101137A 9101747L 9101752ZR 9101756V 9103515C 9103516D 9103542F 9103641J 9105217A 9104603L Page 3 60 Description PCB ASSY HI RES SENSOR PCB ASSY AM4 TWR FEEDER MTR WD 179 072 4WJST CW MTR WD 179 073 4WJST CW CLUTCH W D XH 102 10 CW CLUTCH W D XH 102 20 CCW LOOM EMITTER 100 LOOM RECEIVER W A 300 LOOM RECEIVER N A 300 LOOM RECEIVER W A 200 XH LOOM EMITTER 300 XH LOOM RECEIVER W A 300 XH LOOM 4W 4W XH LINK 0 25M AM4 FDR FOLDER PSU ASSY SEPARATOR ASSY GEARBOX ASSEMBLY CAST SEPARATOR ROLLER ASSY FOLD ROLLER 30 DIA FOLD ROLLER
137. r Pad 45 55 Envelope Jog Tyre 8mm T Bearing Vinyl Cap 3 5Id x12 7 M3 Stud Vinyl Cap Washer Waved 23mm ID Bearing 6x 8 x 13 8 Flanged Bearing 8 x 22 x 7 3dia x 14lg Dowel Pin 3dia x 8lg Dowel Pin 2 5dia x 14lg 058 Grooved Pin Belt 100 S2M 280 Belt Set 140xI 037 Polyurethane set 4 Belt Set 130xl 037 Polyurethane set 4 Wetter Foam Edge Wetter Foam Centre Spring Light Pressure Green Spring Intermediate Pressure Yellow Spring Heavy Pressure Red Spring OMR Shaft Blue Spring Solenoid Spring Link Spring Wetter Spring Conveyor Page 3 Issue 12 Nov 2012 eh KI RPHENNNNBENBFHBHENUUOCNNNBANBRODORDOHPENODAKPHBPHBHBPHBHBHHHY 58 100 140 Service Manual NTL Pt No G1183A G1206A G4092A G6181A HOOOOA SAP Pt No 9104716D 9104722K 9104827U 9104925W 9104983G Description Spring Tensioner Spring Overguide Bridge Clamp Chain Tape 6mm Polycord Qty NANN 1M Page 3 59 Issue 9 May 2012 Feeder order A0342A 230v or A0345A 115v NTL Pt No 180 761 180 762 180 785 181 069 181 569 182 333 184 168 E5105A E5110A F5002A F5113A F5121A F5122A SAP Pt No 9100746T 9100747U 91052098 9105274K 9100831G 9100973E 9101137A 9104150P 91041510 9104430F 9104495Y 9104501E 9104502F Description PCB Splitter 6TX H D PCB Splitter 6RX H D PCB AM4 Twr Feeder Motor Wired 179 072 4WJST CW 230v or Motor Wired 179 073 4WJST CW 115v Wired Reed Switch 3W SM A
138. rollers in reverse order to removal Ensure that the E clip is in place before refitting the Lenze clutch this acts an air gap spacer 3 4 2 Upper roller removal The easiest way to access the 2 upper rollers is to remove the pivoting fold box complete 1 Fold rollers Disconnect the sensor cables from the main PCB at J17 amp J18 and cut cable ties as required On the LH side remove the 2 screws securing the fold plate motor housing Remove the screw and flanged bearing at the RH end of the pivot bar and the screw flanged bearing and waved washer at the LH end Lift the fold box out of the chassis shown in Fig 8 below LE oe P ti e z No fold beam d gt Wo S Drive gears Fig 8 Remove 2 fold roller springs on each side and the screw at each end of the fold rollers On the RH side remove gears dowel pins and spigots Lift off the bearings plates on each side to free the roller Note that the no fold Page 3 9 Issue 7 Sep 2008 beam pivots on a plastic spigot bush at each end these will now be loose Fit the new fold rollers and reassemble in reverse order to removal ensuring that the no fold beam is properly located on the spigot bushes as the plates are replaced Note also that the gear spigots on the rollers are different sizes to account for the plate thickness Replace the fold box in the chassis ensuring that the waved washer at the LH end is properly located Refit the fold plate motor
139. rspex cover Use the green knob on the feed unit in front to swing down the lower conveyor or raise the rearmost clam assembly if the unit in front is the insert head Turn the green knobs on the tower feeder to wind the crashed docu ment into the cavity ahead Page 3 53 100 140 Service Manual 3 21 2 PLATE FOLDER The 2 plate folder is a simplied version of the 3 plate folder but is only available with one hopper this is the same assembly as used on the top as sembly of the 3 plate The unit is available as either an end unit or in line mounted on the track the difference being a blanking cover fitted to the rear of the end unit An optional handfeed slot may be specified located in front of the paper hopper The unit may be fitted with either OMR or bar code top or bottom reading 3 21 1 Separator Adjustment Replacement The procedures for adjustment or replacement are identical to that for the 3 plate folder described in section 3 3 1 3 21 2 Fold Roller Replacement The five fold rollers are contained within a removable assembly which is then stripped down for roller replacement To remove proceed as follows 1 Remove the RH side cover and open the LH side cover Also remove the upper and lower front covers The upper cover is secured with 2 screws in each chassis side plate the lower is withdrawn from the LH side after removing 2 screws in the LH chassis side plate p2 Pull out the paper hopper and fold pl
140. s Ball 3 tighten as required Tighten Latch handle C3561E and ensure assembly opens and latches B17 Check sensor cable JST connectors are all properly plugged in Also check Baa 3 ribbon cables headers these are more likely to be dislodged Check for squealing noise from clutches If so remove and clean and e WE A R as per B11 and B12 replace if necessary Preventative Maintenance Schedule Page PM 27 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei mins Check side guides for movement stop position and parallelism to chassis Level 3 Ensure side guides retaining screws are tight Check rolling backstop rolls down the feed tray ei lt i Check all clutch pins G0167P or G0079A are intact teel3 z Il eS CL Go though the Engineer menu to check all Analogue and Digital sensors A R lt 5 Replace A R calibrate if required Go through the Engineer menu to check each clutch brake and solenoid Replace A R i Inspect Module for damage and safety covers are all intact interlocks Level 2 amp 3 lt 5 function warning labels in place i Pf When all service or repair operations have been carried out the machine Level 2 3 must be left with all parts reassembled leaving no risk of injury Complete service log sheet Preventative Maintenance Schedule Page PM
141. s day 1 Solenoid wetter down 181 119x1 2 Solenoid wetter down 181 142x1 3 Solenoid wetter Up 181 142x1 4 EC25 Clutch pin GOO79Ax3 Preventative Maintenance Schedule Page PM 11 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei mins A5115A Drive side gears clutches applicable to all clean Level 2 amp 3 Level 2 lt 15 2million or 1million if m c running for idler gears and posts Apply grease silicon based if required Check gear movement sideways and rocking replace gears if required or shim G6028A can be fitted Check for any tight spots in the drive especially around the envelope feed path Check all gear drive pins are intact and not loose If so replace gear and pin This can cause loss of drive and noise problems gt 8hrs day on A5115A drive side Leven lt 30 1 EC30Pawl track drive clutch 179 214 x1 2 EC30Closer Forward clutch 179 214 x1 3 EC25 Wetter output drive clutch 181 127 x1 4 EC25 Collate entry brake 181 117 x1 5 EC30 clutch pin GO167Ax2 6 EC25 Clutch Pin GOO79Ax2 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers 2million or 1million if m c running for gt 8hrs day on A5115A drive side Gear 48Tx8mm F4151Ax16 Gear 30Tx8mm F4156Ax3 Gear 25Tx8mm F4152Ax3 Gear 40Tx8m
142. s must be configured to reflect this gt Continue Use the drop down lists to select the appropriate modules as shown below CONFIGURATION k Me due 1 EtdFeed Zi gt Madula 3 p Module 3 Fpl Module 4 JpJbFld b Continue Module 1 KE OMR readers D l bF Anrcode randers i gt Continue If modules are changed or added at later date the machine must be config ured again to reflect the hardware fitted or it will not be recognised After selecting the module select Continue to move to the setup screen for the Insert Head as shown opposite Module 2 k OMR readers gt Barcode readers Daily Post Fitted b Continue Page 3 22 Issue 7 Sep 2008 Insert Head Select 60Hz supply only if the machine is 110v Select Second wetter fitted if the machine uses a high capacity wetter with a second wetter pump and drum of fluid in the stand When finished select Continue to move to the next module as shown below Feeder Standard Dual amp OMR Bar code If the unit is an OMR Barcode feeder se lect the number of OMR and Barcode read ers A maximum of either 4 x OMR or 1 x Barcode readers can be fitted For standard or dual feeders leave these options unselected When finished select Continue to move to the next module 2 Plate Folder If the unit is reading OMR or Barcode select the number the of readers up to a maxi mum o
143. se problems 2million or 1million if m c running for gt 8hrs day 1 Separator Clutch 181 117x1 2 Track control clutch 181 127x1 3 Main Paper Transport clutch 181 127 x1 4 Clutch Pin GOO79Ax3 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers B10 Operator side gears clutches applicable to all clean idler gears Level 3 15 2million and posts Apply grease silicon based if required Check gear movement Gears Replace A R sideways and rocking replace gears if required Check for any tight It is advised to keep stock of F4150Ax2 spots in the drive Check all gear drive pins are in tact and not loose If F4151Ax2 and F4152Ax2 so replace gear and pin This can cause loss of drive and noise problems 2million or 1million if m c running for gt 8hrs day 1 Track control Brake 181 127 x1 2 Main Paper Transport Brake 181 127x1 3 Clutch Pin G0079Ax2 Or replace Long life versions if fitted after 2 million see page 6 for corresponding part numbers Preventative Maintenance Schedule Page PM 17 100 140 Series Service Manual Time to Maintenance item Head Unit Frequency complete B11 Remove and check motor assembly A7039A Clean area and ensure all Level 3 parts are intact tight spots belt noise or signs of wear Clean clock disk on the motor assembly Check motor pulley is tight on the motor shaft B12 Remove Lower conveyor A7036A
144. sitive further forward towards exit direction Envelope Insert Position Cal Adjusts amount of insertion of insert pack into envelope Positive further forward past flap crease Envelope Reverse Position Cal Adjusts amount of envelope forward travel after flap wetting before reversing to enter sealing rollers Positive further forward into rollers towards exit direction Envelope Seal Position Cal amount of envelope travel into seal roll ers Positive further forward away from exit direction Envelope depth Measured automeasured depth of envelope which will be displayed Adjust up or down to suit actual envelope size Positive greater Envelope flap Measured automeasured flap length of envelope which will be displayed Adjust up or down to suit actual envelope size Posi tive greater Ins Pawl Stop Position Cal Adjusts stop position of insert pawls be hind insert pack in collate pocket If the pawls are stopped too high by the software inserts entering the collate pocket will con tact the tips hence position must be adjusted back Positive further forward Pocket Backstop Cal As inserts enter the collate pocket they contact a backstop to prevent overrun and stop The backstop is then lowered and the insert drives forward This setting increases the time delay before the insert drives forward Use if backstops are slow to drop for any reason causing crashing If set to Off backstop remains lowered alwa
145. t Remove Lower conveyor A7036A and check all track transport and drive belts for wear and fit Clean belts and ensure the drive is free to rotate area etc with Rubber Roller Restorer E0483A Phe Preventative Maintenance Schedule Preventative Maintenance Issue 3 Jul 2008 Replacement Part Numbers and Interval Cycle Complete v 8 NN i 8 8 2million Gears Replace A R It is advised to keep stock of F4150Ax2 F4151Ax2 and F4156Ax1 2million or 1million if m c running for gt 8hrs day Clutches 1 Track Control clutch 181 127 x1 2 Clutch Pin GOO79Ax1 2million Gears Replace A R 2million It is advised to keep stock of F4150Ax1 2million or 1million if m c running for gt 8hrs day 1 Track Control brake 181 127 x1 2 Clutch Pin G0079Ax1 mag cm ee fe 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F5122A iset 2 8mm T bearing D1040Ax4 8 Page PM 31 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle complete mins Level 3 Remove Upper conveyor A7035A and check all track transport and drive belts for wear and fit Clean belts with Rubber Roller Restorer and ensure the main drive shaft C9259A is free to rotate 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F
146. t number of OMR or Barcode readers fitted if applicable For Online Interface select Standard or Std Inv Bsy the opposite depending on Signal supplied by card processor For Standard green LED on interface PCB is on when busy Std Inv Bsy is opposite Red LED indicates cardfolder disabled or unavail able for both Standard and Std Inv Bsy When finished select Continue to move to the next module When all settings for all units have been made select Continue you will be prompted to save your changes The machine is now configured and ready for use Page 3 23 Issue 7 Sep 2008 3 13 2 ENGINEER MODE 140 SERIES Engineer mode for 140 Series makes available the same features as for standard 100 Series Therefore the explanations for each feature described for Maximailer should be used in conjunction with the following explanation of which of the features are found in the four engineering screens Hard ware setup Units setup Firmware download amp Diagnostics There is also the further function Plug amp play described at the end of this section Hardware Setup Configures physical machine equivalent to 100 Series Configure System To make changes check the Edit box Please fill settings Number of modules Edit View d Units Unit types and modifiers Unit equipments Extra settings Setting gt HAH 60Hz supply MPPC Reader ty
147. tative Maintenance Schedule Page PM 29 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 k Maintenance item Head Unit Clean all T bearings on the 2 Plate Folder Transport Shaft Assy A2843A Level 2 amp 3 Apply light oil and clean off any excess XKAKEEKXThis is Mandatory every level 2 and 3 Level 2 amp 3 Service 2 Plate Folder Roller Assy A7194A Clean and apply Silicon based grease onto the bore of the T bearings C9 Clean all T bearings 2 Plate Folder Eject Roller Carrier Assy A7290A Apply Level 2 amp 3 light oil and clean off any excess Plate Folder Paper Direction Roller A7176A Level 3 Check clean and ensure free turning of the bearings on the 2 Plate Folder Level 3 Outfeed Body Assy A7034A Preventative Maintenance Schedule Time to complete mins Replacement Part Numbers and Interval Cycle 2million or 1million if m c running for gt 8hrs day 1 8mm T bearing D1040Ax2 1million 3million 1 Paper Transport Shaft Assy A2843AX2 2million or 1million if m c running for gt 8hrs day 8mm T bearing D1040Ax6 2million 1 Spring Heavy pressure G1117Ax6 2 Gear 30Tx8mm F4156Ax2 3 Gear 25Tx8mm F4152Ax3 2million or 1million if m c running for gt 8hrs day 8mm T bearing D1040Ax4 2million Upper Transport Roller Shaft Assy A2792Ax2 2million or 1million if m c running for gt 8hrs day Paper Transport Clutch 181 127 x1 Paper transport Brake 18
148. tch 04 181 128 Page PM 39 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete complete Interval Cycle Gei Check all unit screw security pay particular attention to all handles Level 3 5 tighten as required NS ee es C26 lt C27 Check sensor cable JST connectors are all properly plugged in Also check Level 3 lt ribbon cables headers these are more likely to be dislodged Check all restraint straps are intact replace if required Replace A R Go though the Engineer menu to check all Analogue and Digital sensors A R lt 5 Replace A R calibrate if required Go through the Engineer menu to check each clutch brake and solenoid Replace A R a C31 Check and adjust if required fold lengths in View Fold Settings for Level 3 lt 5 Maxi or Module Options Fold Plate Lengths in Maxi NS a a Check and adjust if required the collation of forms in the engineer window C32 C33 When all service or repair operations have been carried out the machine Level 2 3 lt 5 must be left with all parts reassembled leaving no risk of injury Complete service log sheet C28 C29 Times Level 1 lt 20 mins Level 2 lt 1 5 hrs Level 3 lt 4 5 hrs Preventative Maintenance Schedule Page PM 40 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance Sched
149. tenance Ref B11 and B12 0 2million Belt 100 S2M F5113Ax1 ee i Issue 3 Jul 2008 Replacement Part Numbers and Complete Interval Cycle Gei 2million or 1million if m c running for gt 8hrs day 1 Motor Pulley F1372A 220v or F1373A 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F5122A iset 2 8mm T bearing D1040Ax4 2million or 1million if m c running for gt 8hrs day 1 Belt 330XL F5121A iset 2 8mm T bearing D1040Ax6 2million It is advised to keep stock of F4150Ax2 F4151Ax2 and F4235Ax1 Page PM 18 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Ref Complete complete Interval Cycle Manual Ka mins Page B23 Inspect Module for damage and safety covers are all intact interlocks Level 2 amp 3 function warning labels in place ILL When all service or repair operations have been carried out the machine Level 2 3 lt 5 must be left with all parts reassembled leaving no risk of injury Complete service log sheet Times Level 1 lt 10 mins Level 2 lt 40 mins Level 3 lt 3 hrs Preventative Maintenance Schedule Page PM 19 Bi B2 B3 B4 B5 B7 100 140 Series Service Manual E Preventative Maintenance Issue 3 Jul 2008 Maintenance Schedule Tower Feeder Level 1 Operator level frequency will depend on usage
150. tension cP Each pawl is fitted with a split link To separate the chain remove the clip The chain can now be pulled out of the chassis 4 The new chain can now be threaded into place or a the new pawl fit ted as required Important ensure that the pawls of each chain are aligned Note that one complete chain comprises 2 x 61 link chain sections 2 x pawls and 2 x split links The side plate supplied with the split link is discarded the side of the chain pawl is used instead 5 Refit the tension shaft to tension the chain Refit all other parts in re verse order to their removal Page 3 13 Issue 7 Sep 2008 3 8 INSERT FINGER REPLACEMENT If paper crashes when inserting are being encountered this may be caused by worn or broken insrt fingers or more likely a broken finger spring The fingers are fully exposed as shown in Fig 13 when the envelope feeder is removed described in section 3 6 Later Machines from mid 2006 are equipped with an inspection hole in the envelope feeder side plates to as sist with fault finding of finger entry problems The holes can be seen after removal of the head side covers Also from the same date the middle insert fingers consist of a 2 part design for greater adjust ment flexibility see section 4a 20 To replace the fingers remove the retaining clip and push out the pin with a 3 x 8mm dowel pin E5074A this will secure the spring in position After fitting the new finger and original
151. that 2 track heads have an alignment mark To align the head for top read head fitted to opening cover open the cover and remove the inner cover plate to provide access to the grub screw unclip the gate sensor as it is withdrawn and be careful not to open it too far with the restraining strap removed Now remove the hopper tray and move the OMR shoe in the tower unit out of the way so the OMR head is visible by looking through the tray aperture Wind in the paper and align the head using the same principle as for bottom read When aligned move the OMR shoe back so that it is op posite the OMR head and distribute the sliders evenly Tighten all grub screws and replace the cover plate when finished Note the OMR reader is not central within the window the cen treline of the marks must align with the head as shown in Fig 27 on the following page Page 3 32 100 140 Service Manual Page 3 33 Issue 8 Aug 2009 OMR channels 16 Was 7 SINGLE TRACK 17 7 7 Alignment marks aooo 2 RACK Fig 27 The machine can support up to 4 OMR heads in any combination The heads are assigned a channel number in the software which can be changed if required The channel number equates directly with the PCB connector that the head is plugged into see Fig 28 below Channel 1 Channel 2 Channel 3 Ben vi E a m d oo Channel 4 Fig 28 Not
152. thing more than confimation that it is working Switch on the power and start the operating software then wind a piece of barcode marked paper under the reader From the Run screen select the hopper of the appropriate feeder to and press Reader On Figs Oning sersa Unit Fine Tuning Module 8 Hopper 1 Feed Control Mode Feed always Off On Doubles Detect On Off On Deskew Off Select Reader On Reader Off Yy Document Fine Tuning X Abort Jf Dott When the marked paper is under the reader and being successfully read the reader will beep in confirmation Although the reading angle is quite large the marks should be centrally placed under the reader difficult to see with bottom read This is best achieved by moving the reader over to one side out of range of the marks then back until the unit beeps Continue until it stops then move back approximately half that distance 3 18 4 Barcode reader diagnosis 140 Series The calibration described above relates to the barcode for the specific job To carry out diagnosis for any barcode go to the Engineering screen and select Reader setup Press Start align test to turn on the reader and feed the paper in by hand so that the barcode is under the reader as shown op posite Page 3 4 7 Issue 8 Aug 2009 Module 5 3p3h Folder Reader on Ch 10 M53 100 BBANA1014 41 The vertical green lines should extend from the bottom of the display t
153. ugh the clips Assemble the OMR access bridge to the tower access assembly lead ing the receiver wires through the bush adjacent to the pivot Refit the top cover The assembly should now look as shown in Fig 26 Important If centre OMR marks are being used OMR Access Bridge B3 1365 A must be fitted in place of the standard item Reassemble the tower access assembly to the machine leading the receiver OMR head cables through the bush shown in Fig 24 Ensure the restraining strap on the assembly is in place Note if station 2 OMR cascade is also being fitted do not fit the assembly at this stage See section 3 16 2 for fitting cascade OMR If the OMR head is fitted to the assembly retain the cable through existing clips and connect to J14 OMR 1 on the main PCB Connect the receiver to the supplied link cable 182 622 and connect this to J7 on the upper splitter PCB Align the OMR head to suit the marks on the paper with the sliders evenly distrubuted as shown in Fig 22 The grub screw for retaining the OMR head tightens onto the slider bar which attaches the head to allow access for adjustment To align the head for bottom read head fitted to tower mark the edge of the reverse side of the paper to align with the centre of the marks either single or 2 track Wind the paper into the hopper by turning the pickup roller and the green knob Slacken the grub screw and slide the head to align the marks as shown in Fig 27 note
154. ule DTI Level 1 Operator level frequency will depend on usage and applications Level 2 Intermediate Service frequency usually 12 FULL PM Level 3 FULL PM Service Check software versions and implement mandatory updates within TB s and TT s available on the PFE website Maintenance item DTI Units Frequency Time to Replacement Part Numbers and Ref Complete complete Interval Cycle Manual Vv mins Page D1 Clean all paper transport rollers using water or recommended cleaning Level 1 2 amp 3 fluid Check joggler tyres if fitted for alignment D2 Clean all sensors with approved air dusters Level 1 2 amp 3 D Clean the belts on the Conveyor lower DTI assy A7264A with recommended cleaning fluid Replace as required Remove DTI covers Level 2 amp 3 Vacuum clean to remove internal dust Clean all covers Level 3 Remove the Turnover Cassette A7265A Clean gears and posts Apply Level 3 grease silicon based if required Check gear movement sideways and rocking replace gears if required Check for any tight spots in the drive Level 1 2 amp 3 2million or 1million if m c running for gt 8hrs day 1 Belts G5072A set 2 8mm T bearing D1040Ax2 D4 D5 2million or 1million if m c running for gt 8hrs day 1 Gears F4150Ax2 and F4201A 2 8mm T bearing D1040Ax4 Check all gear drive pins are in tact and not loose If so replace gear and pin This can cause loss of drive and noise proble
155. ures may help in fault finding if failure still occurs contact PFE Technical Support for further assistance Digital Sensors This provides a read only display of whether the sensor is on or off If a sensor passes auto calibration but still gives errors the paper may be at fault due to transparency Confirm by inserting a piece of the paper be tween the sensor halves to check that it passes from clear to blocked Also remove strong external light sources Sensors locations are described on the following page Note some sensors may differ from those shown de pending on unit configuration Insert Head Env Deskew in front of pickup rollers centrally located Env Flap on bracket below env hopper open front cover to access Fingers Out on RH side at the end of the finger arm Pawl Position below env hopper in RH chain track open front cover Page 3 18 100 140 Service Manual Wetter Home on RH side below disc Fingers Datum amp Side Fingers Disc withdraw finger assy to access Side Guide Datum on RH side in front of Lenze clutch Side Guide Disc just behind side guide datum sensor Main Disc on RH side next to env hopper Feeder Seprtr A amp B visible through chassis cutout on LH side on separator Slide Open side cover to access Main Disc encoder on motor drive disc on RH side Dual Feeder Hopper 1 Seprtr A amp B on separator slide Remove cover below hop per to access Note that Hopper 2 Sep
156. vice versa parts must be ordered as shown on section 4b 39 Note that the Same OMR or barcode reader is used for top or bottom read 3 22 3 OMR Barcode alignment amp Calibration This is described in section 3 18 Page 3 56 Issue 8 Aug 2009 3 22 4 Transport Roller Assembly Removal The transport roller assembly is mounted at the front of the unit just be low the infeed shaft It includes a feed roller shaft and also the hold point deskew and DD sensors Removal is required for replacement of feed roll ers and for access to the splitter PCB behind and at the same time the transport shaft behind can be removed if required As the rollers of the two Shafts are in contact if one set needs replacement the other will as well The assembly is the same for OMR and barcode except for an encoder and a longer feed shaft fitted on the OMR assembly only To remove 1 Remove both side covers front cover and infill cover section 3 1 2 2 Lift out the pickup shaft J On the drive side remove the clutch and gear loosen clutch locator to remove gear 2 idler gears and 3 screws Also remove the flanged bearing wavy washer under the clutch and gear see Fig 72a below Remove screws Remove clutch gear flanged bearing and wavy washer from transport shaft Remove idler gears Fig 72a drive side Page 3 56 100 140 Service Manual 4 On the operator side remove the green knob and brake and the flanged bear
157. x4 3million on A7068A or 1 5million if m c is running gt 8hrs day 1 Pulley 104T F1404Ax1 2 Lenze Clutch 181 128x1 Note Request Pulley to be assembled onto clutch rotor before shipping 2million or 1million if m c running for 4a 27 gt 8hrs day 1 8mm T Bearing D1040Ax2 2 Jockey Sprocket F3004Ax2 Page PM 13 100 140 Series Service Manual Preventative Maintenance Issue 3 Jul 2008 Maintenance item Head Unit Frequency Time to Replacement Part Numbers and Complete Interval Cycle Gei complete mins A26 Check all track transport and drive belts for wear and fit Clean belts Level 2 amp 3 Level 2 lt 10 2million or 1million if m c running for 4a 10 bobbins in collate input area etc with Rubber Roller Restorer L gt 8hrs day on A7041A upper clam Assy evel 3 lt 20 E0483A 1 8mm T Bearing D1040Ax6 2 Belt Set 140XL Polyurethane F5119Ax1 3 Lower Belt Set 130XL Polyurethane F5120Ax1 and T bearing D1040Ax2 to be replaced handles tighten as required Upgrade to Torx if required check ribbon cables headers these are more likely to be dislodged A29 Check collate pocket A7060A rollers aligned with rollers in the Level 3 2million 4a 11 envelope feeder assy deskew etc 1 Feed roller shaft assembly A2993Ax1 2 Insert roller shaft assembly A2994Ax1 2million or 1million if m c running for gt 8hrs day cr 8mm T Bearing D1040Ax4 Brake assy A7063A Notched rollers DOO45Ax2 replace if
158. ys Feeders dual only Collate Feeder 2 Cal Moves the form in hopper 2 to adjust collate point Positive further forward in steps of 1mm 2 Plate Folder Folplate 1 2 Cal amp No Fold 1 2 cal These are the same as 1 amp 2 of the 3 Plate folder see below 3 Plate Folder adjustment of a auto settings of foldplates 1 2 amp 3 Figure shown will be the setting for the job and may be adjusted if required Units are 0 1mm Page 3 20 Issue 7 Sep 2008 and positive greater To set up for the first time or if parts have been replaced 1 Set up a job with the following parameters European Envelope C5 162 x 229 Paper A4 single sheet from top hopper Fold V US Envelope No 7 Booklet 159 x 244 Paper Letter size single Sheet from top hopper Fold V 2 In the edit screen for the document go to View fold settings For A4 Length A should be 148mm and length B 149mm For Letter Length A should be 140mm and Length B 139mm 3 Save the job and run Measure the length of the first panel which should be 148mm A4 or 140mm Letter If not adjust Settings as described below SETTINGS 4 PFoldplaw 1 Cal 0 imm s90 S gt Foldplate 2 Cal 0 1mm 991 E bFoldplat 3 Cal 0 1mm f 030 1S No told 1 cal 0 1mm 5 L gt No fold cal 0 1mm SC Ho fold 3 cal 0 1mm E E Lollate feeder cal oO bCallats faaderd cal 4 4 If the measured length wer

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