MBM Corporation 102 User Manual

Page 1
Stapler Folder Model 102
Operator Manual
February 1999
Part No. 87499
Page 2
1. Introduction
Table of contents
1.1 Operational safety
2. Getting to know the Model 102
2.1 Main components
2.2 Control panel
3. Operator instructions
3.1 Switching on the Model 102
3.2 Setting up the Model 102
3.3 Feeding and adjusting a test set
3.4 Making fine adjustments
3.5 Beginning the production
3.6 Restoring the factory set A3, A4 or A5 program
3.7 Jam indications
4. Maintenance
4.1 Removal/replacement of the staple cartridge
4.2 Removal/replacement of the stapler head
4.3 Cleaning fold rolls
4.3 Lubrication of parts
1-1
2-1 2-4
3-1 3-2 3-5 3-7 3-8 3-9
3-10
4-1 4-4 4-6 4-7
5. Specifications
5.1 Specifications
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1. Introduction
1.1 Operational safety
Attention to the following notes ensures the continued safe operation of your equipment.
Always connect the equipment to a prop­erly grounded power source receptacle. In doubt, have the receptacle checked by a qualified 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 receptacle 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 recepta­cle and call your customer service engineer to correct the problem.
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2. Getting to know the Model 102
2.1 Main components
The Model 102 can be quickly and easily connected to the Air Feed Collator Model 100 for on-line booklet making. The Model 102 also makes an ideal manual hand feed booklet maker with an optional manual feed tray .
The Model 102 is equipped with motor driven stapler heads (5000 staples per head), the anvils are of the clinch type, ensuring professional flat staples. In addition, the operation that fold the paper provide a sharp booklet fold.
T ake a few minutes to get familiar with the main components of the Model 102.
23 4
1
left side
1 Castor lock 2 Control panel 3 T op cover 4 Power switch
front side
5
6
7
rear side
8
right side
5 Ground fault interrupter 6 Power receptacle/main fuse 7 Machine positioning scale 8 Foot pedal
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2.1 Main components, continues
The belt stacker is used when stapling/folding or folding only is selected. The function of the belt stacker is the same whether the feed is automatic or manual. The back of the belt stacker is normally angled upward (about 15 degrees to horizontal), but can be lowered to allow booklets to drop into a box. The output wheels should be positioned at the innermost notch for A4, A5 ( 8.5”x14”,
8.5”x1 1”) and similar sizes, at the middle notch for A3 (1 1”x17”) and similar sizes, and at the outermost notch for storage. Using customized formats the output wheels should be positioned approximately 50mm from the leading edge of the first set.
1
2
3
1 Set output wheel 2 Belt stacker 3 Delivery tray (optional)
The optional delivery tray is used for side or corner stapling if there is no trimmer attached. When side or corner stapling is selected, the fold stop moves away automatically and the stapled sets are delivered onto the tray .
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2.1 Main components, continues
The Model 102 interior has parts that you will come in contact with when making the fine adjustments to the booklet or when performing maintenance.
12 5 7
4
3
6
11
12
13
8
9
10
14 15 16 17 18 19 20
1 T otal set counter 2 Paper guide 3 Ball cage 4 Fold adjust lever 5 Staple stop 6 Lock pin 7 Side jogger 8 Anvil position scale 9 Back jogger 10 Anvil 11 Upper fold roll 12 Fold roller guide cassette
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13 Lower fold roll 14 T ool box including balls, allen key
and open end wrench 15 Hex grip, upper fold roll 16 Thumb screw for stapler assembly 17 Staple detection switch 18 Side jogger incorrectly positioned
actuator 19 Side jogger incorrectly positioned
switch 20 Staple cartridge 21 Stapler head
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2.2 Control panel
1
43
7a6
8
11
1413
6
2
5
9
12
151016
7b
U.S. paper sizes
1 Automatic set feed mode 2 Manual set feed mode 3 Stapling and folding 4 Folding only 5 Side stapling or corner stapling 6 Factory preprogrammed paper size
(Can also be used to store customer
programmable paper size) 7a Customer programmable paper size 7b Factory preprogrammed paper size/
Customer programmable paper size
8 Programming access/format ad-
justment access 9 Memory 10 Fold position adjustment 11 Back jogger position adjustment 12 Side jogger position adjustment 13 Staple(s) missing indicator 14 Stacker full Indicator 15 Paper jam indicator 16 Staplers or side jogger incorrectly
positioned indicator
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3. Operator instructions
3.1 Switching on the Model 102
This chapter explains the operations for making the booklets, whether the Model 102 is in automatic or manual mode.
The following steps apply to both automatic and manual feed.
1 Plug the Model 102 into the wall outlet. 2 Set ON/OFF switch to ON position.
2
3 Wait until there is steady illumination of the paper size
indicator. If you previously used the Model 102, the paper size that was last used will illuminate.
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3.2 Setting up the Model 102
This section explains how to set up the Model 102 and do a test run. After the test run you can do fine adjustments of the settings, if necessary . When you are satisfied with the test run you can begin production.
Select a paper feed mode
1 If the papers are fed from a collator , press the AUT O button.
NOTE: Make sure the Model 102 is correctly positioned on the base. Press
the green foot pedal on the base and move the Model 102 to the corresponding format according to the machine positioning scale.
2 Or, if the p apers are fed manually , press the MANUAL button.
Select the type of finishing
Y ou can select staple and fold, fold only , corner st apling or side stapling for your booklets.
NOTE: For corner stapling and side stapling an optional delivery tray is
necessary if a trimmer is not installed. If a trimmer is present, consult the trimmer operator manual.
Pressing any of the following buttons will start the paper size program indicators to light up in sequence (running light), waiting for you to select the correct paper size program.
3 Press this button for stapled and folded booklets. 4 Press this button for non stapled, folded booklets. 5 Press this button for corner stapling or side stapling. Disable either
stapler by removing it according to section 4.2, and switch off the staple detection switch if corner stapling is chosen.
NOTE: Side stapling or corner stapling of A3 paper format is not possi-
ble.
6. Depending of the actual paper size and/or the selected booklet form you might want to change the position of the staples.
Use the allen key to loosen the anvil(s). Move the anvil(s) to the de­sired position and tighten the screw(s). Loosen the thumb screw(s) for the stapler assembly . Centre the stapler assembly over the anvils and thighten the thumb screw(s).
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3.2 Setting up the Model 102, continues
min 8 mm
min 8 mm
NOTE1:If the distance between the stapler and the side jogger is to
narrow, the staplers or side joggers incorrectly positioned indi­cator will be illuminated (also see section 3.7.). Make sure the distance between the actuator and the switch is no less than 8 mm.
NOTE2:Depending of the previous job setup you might have to select
paper size program before you move the staplers apart.
The anvil position scale indicates the distance, in millimetres, from centre to centre (cc) of the staples.
T ype of finishing Paper format Setting (cc)
booklet making 5,5”, CD 98 booklet making A5 105 booklet making 8,5”, A4 120 booklet making 11”, A3 120 or 200 side stapling 1 1”, A4 144 (Recommended) corner stapling 11” 255 (Recommended) corner stapling A4 273 (Recommended)
NOTE: Using other settings could result in poor staple/fold result.
lead edge
trail edge
U.S. paper sizes
Select a paper size program
For your convenience, the A3, A4 and A5 (8.5"x1 1", 8.5x14", 11"x17" and
5.5”x8.5”) paper size programs were factory set with appropriate jogging, staple position and fold line position. The jogging, staple position and the fold line position may need fine adjustments depending on the type of paper used.
NOTE: If you want to use a custom format, select the next bigger (dis-
tance between the lead edge and the trail edge) paper size pro­gram. Fine adjustments will be explained in section 3.3 and 3.4.
7 Press the appropriate button to select paper size program.
The A3 button for 297 x 420 mm. - Position the output wheel at the
middle notch.
The A4 button for 297 x 210 mm. - Position the output wheel at the
or
The A5 button for 148 x 210 mm. - Position the output wheel at the The * button for customised size. - Position the set output wheel
innermost notch. innermost notch. appro. 50 mm from the leading
edge of the first set.
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3.2 Setting up the Model 102, continues
8. When selecting staple and fold, or fold only the configuration of the balls in the ball cage is important. The purpose is to apply enough pressure on the set to ensure proper alignement against the fold stop before the set is being folded. By doing that the set will be correctly folded at the middle of the set. The Model 102 is delivered with glass balls at the left side and plastic balls at the right side of the ball cage which should cover most jobs. Depending on the number of sheets in each set and the stiffness of the papers used you might need to change the configuration. In the tool box you can find 2 steel balls, 2 glass balls and 2 plastic balls. The heaviest configuration, for several sheets with high stiffness, is 2 steel balls at the left side and 2 glass balls at the right side. The light­est configuration, when running just a few sheets with low stiffness, is plastic balls at the left only .
If your booklets comes out with the staples on the back of the booklet the configuration is to heavy . T o many and/or to heavy balls allowed the set to buckle (travel too far) before it was folded.
123
If your booklets comes out with the staples on the front, and/or with a skew fold, the configuration is to light. By using not enough and/or to light balls the set did not travel all the way down to the fold stop and was not aligned correctly .
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3.3 Feeding and adjusting a test set
The first time you use the Model 102, or when you change to a different paper size pro­gram, you run one test set and make necessary adjustments before you begin production. Y ou can use automatic feed from the collator , using the calibration option or manual feed.
Coarse adjustment
Y ou have already selected either automatic or manual operation, type of finishing, and paper size program.
1 Press the program access button. 2 Open the cover. 3 Look at the side jogger scale.
back jogger arm
side jogger scalestaple/fold line scale
4 Press and hold the side jogger button until the side jogger reaches the
position on the side jogger scale for the test set.
5 Look at the staple/fold line scale.
6 Press and hold the back jogger button until the back jogger reaches
the position on the staple/ fold line scale for the test set. (Manually lift the back jogger arms)
NOTE: The staple/fold line scale does not show the correct position for
the set when corner stapling or side stapling is chosen.
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3.3 Feeding and adjusting a test set, continues
7 Close the top cover. 8 Feed one set of the chosen paper size into the model 102 (The ma-
chine will repeatedly make a jog cycle).
9 Open the top cover.
moving the staple stop towards the infeed
moving the staple stop towards the outfeed
10 Press and hold the staple stop adjustment button until the trail edge of
the set reaches the paper size mark on the staple fold/line scale. If the required paper size mark not is visible (the set is to close to the infeed), press the staple stop adjustment button until the set passes the required paper size mark (towards the outfeed). Ensure that the set is aligned against the staple stop and press the staple stop adjust­ment button until the trail edge of the set reaches the paper size mark on the staple fold/line scale.
11 Press the side jogger button until the side joggers jogg the set firmly
without making a buckle in the set.
12 Press and hold the back jogger button until the back jogger is approxi-
mately 1 mm from the set.
13 T o store your settings:
press the format adjustment access button (the +/- button) to keep your settings temporarily . Y our settings are not stored but will remain until a paper size format button is pressed even if the power is switched off.
press the memory button to store your settings on the actual paper size button, earlier selected according to section 3.2.
or, select any other paper size program button and then press the memory button.
NOTE1:Side stapling or corner stapling of A3 paper format (or similar
sizes) is not possible.
NOTE2:You can store 4+4 different settings. Four in the staple/fold or
fold only finishing mode, and four in the corner or side stapling finishing mode.
14 Close the top cover. The paper set moves to the belt stacker . 15 In booklet finishing mode: If the cover is torn from the body sheets
increase the gap between the fold rolls by adjusting the fold adjust levers from the factory setting 1 to a higher number.
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3.4 Making fine adjustments
This section shows you how to make fine adjustments of the booklet. The test run has just been completed and the Model 102 is switched ON. Y our selection for paper size program is still in effect.
1 Press the program access button. 2 Feed one set. 3 Open the top cover.
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4 Store your settings according to section 3.3, item 13. 5 Close the top cover. The booklet transport s to the set output tray . 6 Check the booklet. If it is still not good, repeat the fine adjustment.
Otherwise go to section 3.5 Beginning the production.
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3.5 Beginning the production
This section shows you how to begin production. Y ou have run a test set and made necessary adjustments. The Model 102 is switched ON.
Automatic operation
1 Verify that the indicator light s, associated with the paper size button
(example showing A3 selected) and type of finishing (example show­ing stapling and folding) that you selected, is on.
2 Check that the Model is correctly positioned on the base according to
the machine positioning scale.
3 Start your collator . The set s are automatically fed into the Model 102
and the booklets appear on the belt stacker .
NOTE: After a successful booklet production, if you change the paper
size or weight, you may need to go back to section 3.3 Feeding and adjusting a test set.
Manual operation
1 Verify that the indicator light s, associated with the paper size button
(example showing A4 selected) and type of finishing (example show­ing side/corner stapling) that you selected, is on.
2 Check that the optional delivery tray for side/corner stapling is in-
stalled. Or , if a trimmer is present, consult the trimmer operator manual.
T o facilitate hand feeding, use an optional feeding tray as shown in the drawing below .
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3.6 Restoring the factory set A3, A4 or A5 program
This section shows you how to restore the factory set program. Y ou might want to do this after you made fine adjustments of the A3, A4 or A5 program but no longer need those adjustments.
1 Select the type of finishing and paper size format, for which you want
to restore the factory preset paper size program.
2 Press and hold the paper size button until the indicator light goes off
and then comes back on after approximately 7 seconds.
3 Again, press the type of finishing button. The factory set program is
restored and the Model 102 will set up the retrieved format. Example:
Restoring the factory setting for side stapling of A4 paper size.
1 Press the side/corner stapling button. The paper size program indica-
tors will now lit up in sequence (running light). Press the A4 button. Wait until the Model 102 is finished setting up the “old” adjustments.
2 Press and hold the A4 button until the indicator light goes off and then
comes back on after approximately 7 seconds. The type of finishing indicators will now lit up in sequence (running light).
3 Press the side/corner stapling button. The factory set program is
restored and the Model 102 will set up the retrieved format.
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3.7 Jam indications
Staple(s) missing indicator
The staple(s) missing indicator is illuminated when a set is missing one or two staples. The model 102 will automatically shut down the on-line system when this indicator is lit. Check/replace the staple cartridge(s) according to section 4.1.
Stacker full indicator
The stacker full indicator is illuminated when the belt stacker is full. Re­move the completed sets.
Paper jam indicator
The paper jam indicator is illuminated when an operation in the Model 102 is not done within the preset time. Open the top cover and remove the jammed sets reachable. If necessary:
Lift the fold roll guide cassette.
Turn the upper fold roll using the open end wrench at the hex grip at the
front side of the roll. The Model 102 is delivered with an open end wrench for that purpose in the tool box.
Press the staple stop down and move the paper guides apart.
Fold down the fold roller guide cassette and reposition the paper
guides. There is a magnetic lock holding the paper guides together .
Close the top cover and the model 102 will automatically purge remaining jammed sets.
Staplers or side joggers incorrectly positioned indicator
The staplers or side joggers incorrectly positioned indicator is illuminated when the distance between the side jogger and the stapler is to narrow . Check/adjust the position of the staplers according to section 3.2. Switch the power off and then on again to reset the position of the side joggers.
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4. Maintenance
This chapter explains how to do routine maintenance of the Model 102. Maintenance of the Model 102 consists of removal and replacement of the stapler head and the staple cartridge, and lubrication of the parts associated with the staplers and joggers. The steps for how to do this are given next.
4.1 Removal/replacement of the staple cartridge
Y ou may remove and replace the staple cartridge while the stapler head assembly is in place.
1 Open the top cover. 2 Raise the staple cartridge locking lever as indicated in the drawing
below.
3 Gently twist the staple cartridge from side to side, and pull out the
staple cartridge from the stapler head.
32
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4.1 Removal/replacement of the staple cartridge, continues
4 If the staple cartridge is empty , discard it and replace it with a new
one. Before replacing the cartridge, pull at least 20 mm of the staples out and tear off at the staple tear line which is marked on the cartridge. If there has been a miss-feed, and the cartridge still contains staples, pull 20 mm of staples out of the cartridge and tear off at the stapler tear line. Check that the first staple is flat. If not, tear off another 20 mm, using less force.
4
5 Insert the cartridge into the stapler head with the staples facing to-
wards the head mechanism. The cartridge should be placed flat on the slide on the bottom of the stapler head and pushed firmly into the stapler head.
5
6 Hold the staple cartridge firmly in place and push down the cartridge
locking lever .
NOTE: If the cartridge is allowed to move away from the stapler head
before the locking lever is in engaged, remove cartridge and tear off 20 mm of staples level with the staple tear line.
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4.1 Removal/replacement of the staple cartridge, continues
NOTE: The staples will not be fed until a few booklets have passed
through the Model 102.
7 Move the staple detection switch to the disable position to prevent the
Model 102 from shutting down when it detects missing staples in the first few booklets. Reset the staple detection switch to normal position to enable future staple miss-feed indications, after checking that there are two staples in the booklet.
8 Continue production.
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4.2 Removal/replacement of the stapler head
1 Select the A3 (11"x17") position to ensure that the side joggers are
away from the stapler head.
2 Loosen the thumb screw . Rotate the lock spring towards the thumb-
screws and remove the lock pin from the stapler head assembly .
3 Disconnect the red wire. Push the stapler head towards the in-feed
side, out of the stapler head assembly .
NOTE: Whenever you remove a stapler head, be sure to manually eject
some staples before replacing it in the Model 102. To do this, rest the stapler head on a firm surface (for example, the top of a table or the Model 102) and actuate the staple driver post up/ down through full travel. Do this a number of times to ensure that the staples are ejected on each down movement. If you need to change the staple cartridge, see previous section, removal/ replacement of staple cartridge.
WARNING: When manually ejecting the stapler, stay clear from stapler
output area.
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4.2 Removal/replacement of the stapler head, continues
4 Before inserting the stapler head, centre the movable carrier over the
area that will receive the stapler head. Ensure that the staple driver post is in its uppermost position.
5 Place the stapler head back into the Model 102. The front tab of the
stapler assembly must be placed under the nylon tension spring and the driver post arm placed into the carrier .
4
driver post arm
5
CAUTION: If the driver post arm is not correctly positioned into the
carrier (4) it will cause permanent damage to the stapler head as well as the carrier. Subsequently, also future cor­rectly mounted stapler heads will be damaged.
6 Press on the lower front edge of the stapler head to align the hole in
the stapler bracket with the hole in the stapler head. Insert the lock spring so that it engages the stapler head and the metal sides of the stapler assembly .
8
7 Lock the pin by rotating it towards the in-feed side. Check that the
stapler head is correctly mounted by pushing the stapler head towards the infeed area.
8 Insert the red wire into its outlet.
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4.3 Cleaning fold rolls
The fold rolls will eventually need cleaning due to colour deposits from the print-out. Especially the upper fold rolls. How often depends of the printing method but you will notice that when you can see marks or deposits on the cover of the booklets. The fold rolls guide cassette can be folded up for better access. At the front end of the upper fold roll you will find a hex grip. Use the open end wrench delivered with the Model 102 in the tool box to turn the fold rolls. Use the same procedure to clean the lower fold rolls.
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4.3 Lubrication of parts
Lubrication of parts
The parts that need lubrication are shown in the table below .
Drive post Stapler drive bar Stapler drive carrier
Staple driver Clincher
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5. Specifications
5.1 Specifications
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Notes
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