Installation Manual: SR90, CF90, TR90, SR90+
Contents
1. 72 B Finisher seen from above 1 Loosen the two positioning pins B with the Multi tool 2 Dock the Booklet maker to the Docking assembly NOTE Make sure that the Exit arm catcher have clearance 3 Adjust the gap between the infeeder assembly and the finisher Adjust by moving the Booklet maker NOTE The two black studs on the infeeder assembly should just have contact with the finisher cover C 15 IMPORTANT THAT THE BOOKLET MAKER IS NOT INSTALLED TO CLOSE TO THE FINISHER 1 11 BOOKLET MAKER INSTALLATION 12 January 2004 Adjust the distance between the front of the Booklet maker Infeeder and the front of the finisher panel Adjust by moving the Booklet maker NOTE The distance should be within the first cut out A on the Multi tool 5 Tighten the two positioning pins with the Multi tool NOTE Before tightening the two positioning pins make sure that both adjustments are correct 6 Ifinstalling Rail Install it now 7 Remove the front cover by loosening two screws and removing two screws x4 8 Adjust the height on the Booklet maker Adjust by turning the four nuts on the Booklet maker with the Multi tool one revolution the nuts is 2 mm 5 64 in height Adjust on front side and rear side NOTE Place the Multi tool on the infeeder of the Booklet maker make sure that it is not placed on the manual feed guides The distance shou2. 72 B G Finisher seen from above Finisher seen from front side 1 Remove the finisher rear cover x 2 Open the finisher door and pull out the stapling tray Remove black plastic covers A x2 at the bottom of the finisher x 2 gt N Install the docking assembly B in the holes under the black plastic covers NOTE Both of the nuts C that are installed on the docking assembly have different diameters on each side of the nut A big diameter D on one side and a smaller diameter E on the other side 5 Secure the docking assembly with the two nuts C using the multi tool NOTE Make sure you fit the nuts in the correct position The bigger diameter should fit in the hole nearest the rear side F of the finisher And the smaller diameter should fit in the hole nearest the front side G of the finisher NOTE The Multi tool is located behind the rear cover of the Booklet maker x 3 There shall be no play in the Docking assembly if mounted correctly 1 9 BOOKLET MAKER INSTALLATION 12 January 2004 Interface Finisher Main PCB B A C 1 Install the Communication cable A from the installation kit to connector CN132 the finisher main board x1 2 Secure the Communication cable in the finisher C with a tie wrap from the installation kit 1 10 12 January 2004 BOOKLET MAKER INSTALLATION 1 3 3 ADJUSTMENTS
3. 5 Remove the four nuts and two brackets on the top side of the Mounting bracket 4 brackets x 2 1 29 COVER FEEDER INSTALLATION 12 January 2004 Install the Cover Feeder 1 Remove the Front and Rear cover on the Cover Feeder Service Manual CF90 1 1 1 2 Place the Cover Feeder on top of the Mounting bracket 3 Secure the Cover Feeder by replacing the brackets B and tightening the nuts A 4 NOTE No adjustments is needed 4 Reinstall the Front and Rear cover on the Cover Feeder Service Manual CF90 1 1 1 1 30 12 January 2004 COVER FEEDER INSTALLATION Reinstalling the new Gas spring prar amp 72 A 1 Openthe Top cover on the Booklet maker NOTE Open the Top cover carefully because of the weight of the Cover Feeder 2 Install the upper end A of the Gas spring to the Top cover NOTE Make sure you install the Gas spring in the upper hole in the Top cover bracket The lower hole is used when a Cover Feeder is not installed 3 Secure the Gas spring by tightening the nut you removed earlier gt x 1 1 31 COVER FEEDER INSTALLATION 12 January 2004 1 5 3 CONNECTORS Connectors when only a Cover Feeder is installed 1 oF 10 11 Install the Bin extension plate Connect the Bin extension plate cable A x1 Connect the ground cable to the Cover Feeder E x1 Rem
4. 2004 TRIMMER INSTALLATION Installation Manufact no E076A 00104 TA 0 2 gt 252 11 9 z 1 f i ri 1 23 TRIMMER INSTALLATION 12 January 2004 Connectors when a Trimmer and Cover Feeder is installed CONNECTOR PLATE SR90 1 Communication cable A to finisher The connector B to the Belt stacker on 5 90 should be empty Communication cable between Cover Feeder CF90 and Booklet maker 5 90 Communication cable D between Trimmer TR90 and Booklet maker 5 90 Powercord E from the wall outlet Powercord between Cover Feeder CF90 and Booklet maker 5 90 NO oO A Powercord between Trimmer TR90 and Booklet maker 5 90 B C D E A Booklet maker SR90 F 1 24 12 January 2004 TRIMMER INSTALLATION CONNECTOR PLATE TR90 1 Communication cable H to Belt stacker 72 2 Communication cable between Cover Feeder CF90 and Booklet maker 5 90 3 Terminator plug J 4 Powercord K between Trimmer TR90 and Booklet maker 5 90 H 1 Trimmer 90 CONNECTOR PLATE CF90 1 Terminator plug L 2 Communication cable M between Cover Feeder CF90 and Booklet maker 5 90 3 Communication cable N to Bin extension plate 4 between Cover Feeder CF90 and Booklet maker 5 90 L M N O Cover F
5. amp x 2 NOTE Make sure that the Trimmer locking bracket B locks in the outer slots C on the positioning pins 1 20 12 January 2004 TRIMMER INSTALLATION Install Belt stacker 72 A 1 Install the Belt stacker on to the Trimmer 2 Secure the Belt stacker with the screws A you removed from the Booklet maker fx 2 1 21 TRIMMER INSTALLATION 12 January 2004 1 4 4 CONNECTORS Connectors when only a Trimmer is installed 1 2 3 4 5 10 Connect the Belt stacker cable A to the Trimmer x1 Remove the Terminator plug from the Booklet maker E x1 Connect the Terminator plug on the Trimmer EZ x1 Remove the Interlock jumper D from the Booklet maker x1 Connect the Interlock jumper to the Booklet maker frame x1 see next page Connect the communication cable to the Trimmer F EE x1 NOTE The communication cable you received with the Trimmer Connect the other end of the communication cable to the Booklet maker G x1 see next page Connect the powercord to the Trimmer x1 Connect the other end of the powercord to the Booklet maker EZ x1 see next page Secure the cables between the Booklet maker and the Trimmer in the cable holders on the Booklet maker base Booklet maker SR90 D F C H Trimmer TR90 Continued on next page 1 22 12 January
6. maker power cord is unplugged The wall outlet should be near the Booklet maker and easily accessible Note that some components of the Booklet maker and peripherals are supplied with electrical voltage even if the main power switch is turned off 4 adjustment or operation check has to be made with exterior covers off or open while the main switch is turned on keep hands away from electrical or mechanically driven components OBSERVANCE OF ELECTRICAL SAFETY STANDARDS 1 The Booklet maker and its peripherals must be installed and maintained by a customer service representative who has completed the training course on those models SAFETY AND ECOLOGICAL NOTES FOR DISPOSAL 1 Dispose of replaced parts in accordance with local regulations Page intentionally blank 12 January 2004 INSTALLATION REQUIREMENTS 1 INSTALLATION PROCEDURE 1 1 INSTALLATION REQUIREMENTS 1 1 1 MINIMUM SPACE REQUIREMENTS prar 72 5 90 1690 mm 1 1 INSTALLATION REQUIREMENTS 12 January 2004 1 1 2 POWER REQUIREMENTS CAUTION Make sure that the wall outlet is near the main machine and easily accessible Make sure the plug is firmly inserted in the outlet Avoid multi wiring Be sure to ground the machine 1 Input voltage level North America 115V 50HZ 60Hz More than Europe Asia 230V 50HZ 60Hz More than 1 5A Permissible voltage fluctuation 10 Never se
7. the two cardboard handles underneath the Booklet maker straight out A 2 Remove the two cardboard handles 1 5 BOOKLET MAKER INSTALLATION 12 January 2004 Panels and Shelf C 1 Loosen A x 4 2 Slide the top of the Panels B away from the screws Remove the Panels and the Shelf 1 6 12 January 2004 BOOKLET MAKER INSTALLATION Exit arm catcher prar 72 A 1 Remove the adhesive backing from the Exit arm catcher 2 Install the Exit arm catcher so that the Exit paper arm is as high as possible The nut on the Exit arm catcher should be centred over the Exit paper arm on the finisher according to figure 3 the Exit paper arm and set it onto the Exit arm catcher 1 7 BOOKLET MAKER INSTALLATION 12 January 2004 Copier exit tray D gt N A C D B Make sure that the Exit paper arm is in the upper position A Turn ON the Copier the shift tray will go down to the lower position Turn OFF the copier Remove the finisher exit tray B x 4 Remove the plastic deflector underneath the finisher exit tray Install the Shift tray plate on to the finisher 5 4 counter screws from installation kit Install the Exit tray plate D on to the finisher exit tray x 4 from installation kit 1 8 12 January 2004 BOOKLET MAKER INSTALLATION Docking assembly F
8. 3 5 CHECK THE INSTALLATION 1 D a N 10 11 If installing a Trimmer TR90 or Cover Feeder CF90 continue to that section 1 4 1 5 Power on the Booklet maker NOTE Make sure that the finisher connector is connected to the copier 72 Remove the two Stapler heads according to section 3 4 12 Perform a Detailed self diagnostic according to section 5 3 3 Reinstall the two Stapler heads according to section 3 4 12 Power on the Copier NOTE Make sure that the Booklet maker is powered ON before the Copier Set up the Booklet maker to Auto paper size send one A4 8 5 x 11 job to the Booklet maker Check for the correct feeding of the paper NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 48 1 3 3 send 11 17 job to the Booklet maker Check for the correct feeding of the paper NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 48 1 3 3 TRIMMER INSTALLATION 12 January 2004 1 4 TRIMMER INSTALLATION 1 4 1 ACCESSORY CHECK P SiN 4 fl Llp w 7 B A Check the quantity and condition of the accessories in the box against the following list NOTE The Installation Box is located in the trim bin on the Trimmer NOTE The trim bin is tie wraped on the rear side Desc
9. INSTALLATION MANUAL 5 90 5 90 SYSTEM January 12 2004 Subject to change Page intentionally blank IMPORTANT SAFETY NOTICES PREVENTION OF PHYSICAL INJURY Always connect the equipment to a properly grounded power source In doubt have the power source checked by a quali fied electrician WARNING Improper connection of the equipment grounding conductor can result in electrical shock Always follow all warnings marked on or supplied with the equipment Always locate the equipment on a solid support surface with adequate strength for the weight of the machine Always exercise care in moving or relocating the equipment Always keep magnets and all devices with strong magnetic field away from the machine Never use a ground adapter plug to connect the equipment to a power source that lacks a ground connection terminal Never attempt any maintenance function that is not specifically described in this documentation Never remove the covers or guards that are fastened with screws Never install the unit near a radiator or any other heat source Never override or cheat electrical or mechanical interlock devices Never operate the equipment if you notice unusual noises or odours Disconnect the power cord from the power source and call your customer service engineer to correct the problem 1 Before disassembling or assembling parts of the Booklet maker and peripherals make sure that the Booklet
10. e wall outlet Powercord between Cover Feeder CF90 and Booklet maker 5 90 NO oO A Powercord between Trimmer TR90 and Booklet maker 5 90 B C D E A Booklet maker SR90 F 1 34 12 January 2004 COVER FEEDER INSTALLATION CONNECTOR PLATE TR90 1 Communication cable H to Belt stacker 72 2 Communication cable between Cover Feeder CF90 and Booklet maker 5 90 3 Terminator plug J 4 Powercord K between Trimmer TR90 and Booklet maker 5 90 H 1 J Trimmer 90 K CONNECTOR PLATE CF90 1 Terminator plug L 2 Communication cable M between Cover Feeder CF90 and Booklet maker 5 90 3 Communication cable N to Bin extension plate 4 O between Cover Feeder CF90 and Booklet maker 5 90 L M N O Cover Feeder CF90 1 35 COVER FEEDER INSTALLATION 12 January 2004 1 5 4 CHECK THE INSTALLATION 1 2 3 4 10 11 12 13 14 15 16 17 18 19 20 21 22 Power on the Booklet maker Remove the two Stapler heads according to section 3 4 12 Perform a Detailed self diagnostic according to section 5 3 3 Ifa Trimmer is installed remember to key in the Index 16 value TR90 knife Zero iF page 1 26 step 3 Power on the Copier Make sure that the covers are well fanned to avoid misfeeds or double feeds Align the covers well to ach
11. eeder CF90 1 25 TRIMMER INSTALLATION 12 January 2004 1 4 5 CHECK THE INSTALLATION 2 amp gt 18 19 20 21 If installing a Cover Feeder CF90 continue to section 48 1 5 Power on the Booklet maker In the Trimmer check the Index 16 value A Press the Tools button Scroll down to Service and press the OK button Key in the Password Scroll down to EEPROM Values and press the OK button Scroll to INDEX 16 TR90 Knife Zero and press the CHG button Key in the value you have in the trimmer Go down to Store and press the OK button Remove the two Stapler heads according to 3 4 12 12 13 14 15 16 17 Perform a Detailed self diagnostic according to section 5 3 3 Power on the Copier Set up the Booklet maker to Auto paper size Set up the Trimmer to Trimmer ON send one A4 8 5 x 11 job to the Booklet maker system Check for the correct feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 Check if the set have been trimmed correctly send 11 17 job to the Booklet maker system Check for the correct feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 Check if the set have been trimmed correct
12. ieve a reliable collating operation and good finishing result Make sure that the ink has dried out well to avoid smearing Load the covers into the Paper bin Move the adjustable side guides up against the covers until there is no clearance Move the adjustable Air nozzle so that the green stripe on the Air nozzle bracket is up against the paper stock Set up the Cover Feeder to Cover ON the Cover Feeder will prefeed the first cover to be ready for the set from the copier Ifa Trimmer is installed set up the Trimmer to Trimmer ON Set up the Booklet maker to Auto paper size send one A4 8 5 x 11 job to the Booklet maker system Check for the correct feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 Check that the cover are correctly fed into the Booklet maker Ifa Trimmer is installed check if the set have been trimmed correctly send 11 17 job to the Booklet maker system Check for the correct feeding of the set from the finisher NOTE The paper should enter in the middle of the infeeder If not adjust the Booklet maker according to section 1 3 3 Check that the cover are correctly fed into the Booklet maker Ifa Trimmer is installed check if the set have been trimmed correctly 1 36
13. ld be within the second cut out 119 4 11 16 on the Multi tool according to figures The distance on the right side and the left side of the Booklet maker should be equal D 1 12 12 January 2004 BOOKLET MAKER INSTALLATION Panels and Shelf prar 72 E D B C A 1 Undock the Booklet maker 2 Reinstall the front and rear cover 5 7 3 Slide the front A and rear B panels in place with the bottom first onto the docking assembly C 4 Putthe shelf between the panels Make sure to turn the shelf correct NOTE The cut out D should be away from the Booklet maker NOT TOWARDS 5 Slide the top of the panels under the screws on the infeeder tighten x 4 6 Take the finisher exit tray and put it on the shelf D BOOKLET MAKER INSTALLATION 12 January 2004 1 3 4 CONNECTORS 15 2 2 Connect the communication cable A from the finisher EE x1 Connect the Belt stacker cable x1 Install the Terminator plug C and the Interlock jumper E If not installing the optional Cover feeder CF90 NOTE The Terminators and Interlock jumpers are stored in the installation kit Install the Terminator plug D and the Interlock jumper F If not installing the optional Trimmer TR90 Connect the powercord G to the Booklet maker x1 B C D G A E F 12 January 2004 BOOKLET MAKER INSTALLATION 1
14. ly A 1 26 12 January 2004 COVER FEEDER INSTALLATION 1 5 COVER FEEDER INSTALLATION 1 5 1 ACCESSORY CHECK prar 72 C D E Check the quantity and condition of the accessories against the following list Description A Communication Cable between the Booklet maker and Cover Feeder Powercord between the Booklet maker and Cover Feeder Gas Spring Mounting bracket for Cover Feeder Feed roller assembly O O Bin extension plate 1 27 COVER FEEDER INSTALLATION 12 January 2004 1 5 2 INSTALLATION PROCEDURE Unpacking C C 1 Remove all parts from the Box 2 Cutthe three red tie wraps A and remove the cardboard B between the Upper paper path and frame 3 Connect the two paper bin springs 4 Install the Feed roller assembly D 1 28 12 January 2004 COVER FEEDER INSTALLATION Install mounting bracket prar amp 72 B A 1 Remove the nuts A to the Gas spring in the Booklet maker amp x 2 NOTE Make sure you notice the orientation of the Gas spring before removing it 2 Install the lower end of the new and shorter Gas spring from the installation kit to the black bracket in Booklet maker 5 x 1 3 Remove the stainless plate on the Top cover by removing nuts x 2 4 Install the Mounting bracket where you removed the stainless plate x 2
15. ove the Terminator plug from the Booklet maker x1 Connect the Terminator plug on the Cover Feeder E8 x1 Remove the Interlock jumper D from the Booklet maker x1 Connect the Interlock jumper to the Booklet maker frame x1 see next page Connect the communication cable to the Cover Feeder F x1 NOTE The communication cable you received with the Trimmer Connect the other end of the communication cable to the Booklet maker G E x1 see next page Connect the powercord the Cover Feeder H E x1 Connect the other end of the powercord to the Booklet maker E x1 see next page Booklet maker SR90 C F A H Cover Feeder CF90 Continued on next page 1 32 12 January 2004 COVER FEEDER INSTALLATION G prar 72 Booklet maker SR90 1 Manufact no 076A 00104 I 4 17 5 3 175 LE _ ntl Fpl 2 5 1 33 COVER FEEDER INSTALLATION 12 January 2004 Connectors when a Cover Feeder and a Trimmer is installed CONNECTOR PLATE SR90 1 Communication cable A to finisher The connector B to the Belt stacker on 5 90 should be empty Communication cable between Cover Feeder CF90 and Booklet maker 5 90 Communication cable D between Trimmer TR90 and Booklet maker 5 90 Powercord E from th
16. ription A Communication Cable between the Booklet maker and Trimmer B Powercord between the Booklet maker and Trimmer 12 January 2004 TRIMMER INSTALLATION 1 4 2 ADJUSTMENTS Unpacking prar amp 72 1 Remove all parts from the pallets 2 Ensure all of the packing material is removed from the outside of the Trimmer TRIMMER INSTALLATION 12 January 2004 Remove the belt stacker 1 Remove screws A 2 2 Disconnect the Belt stacker cable EZ x 1 3 Remove belt stacker from 5 90 1 18 12 January 2004 TRIMMER INSTALLATION Height adjustment prar amp 72 B C D 1 Remove the front cover by loosen two screws and removing two screws x 4 2 Move the Trimmer up to the Booklet maker 3 Adjust the height on the Trimmer so that the docking bracket B on the Trimmer fits the docking hole C on the Booklet maker one revolution on the nuts is 1 5mm 1 16 in height Adjust by turning the four nuts D on the Trimmer with the caster tool NOTE Make sure that the Ground plate on the docking bracket B is grounded correctly TRIMMER INSTALLATION 12 January 2004 1 4 3 INSTALLATION PROCEDURE Docking B A 1 Loosen nuts A to the Locking bracket B amp x 2 2 Dock the Trimmer to the Booklet maker 3 Secure the Trimmer by lifting the Locking bracket B and tightening nuts A
17. t anything on the power cord 1 2 12 January 2004 INSTALLATION FLOW CHART 1 2 INSTALLATION FLOW CHART The following flow chart shows how to install the optional units more efficiently 72 Unpack the Booklet maker Install the Booklet maker Does the user require Trimmer Yes Install the Trimmer Does the user require Cover Feeder Install the Cover Feeder Check the Installation TR9O Trimmer Enables On line trimming Especially thicker sets gt 4 sheets look unprofessional because of 90 will trim those edges up to 12 5 mm 1 2 CF90 Cover Feeder Enables the possibility to add colour covers to the booklets 1 3 BOOKLET MAKER INSTALLATION 12 January 2004 1 3 BOOKLET MAKER INSTALLATION 1 3 1 ACCESSORY CHECK i Check the quantity and condition of the accessories in the box against the following list Description Exit arm Catcher Communication Cable for finisher SR840 Docking assembly for the finisher Shift tray plate for finisher SR840 Exit tray plate Powercord Terminator CF90 Terminator 9 Interlock Jumper x2 For Conversion kit to finisher SR810 check Bulletin RZP7 001 1 4 gt 12 January 2004 BOOKLET MAKER INSTALLATION 1 3 2 INSTALLATION PROCEDURE Unpacking prar 72 1 Remove all parts from the pallets Slide the SR90 off the pallet by pulling
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