Page 1
Service Manual
Bookletmaker SR 85
August 2000
Part No. 75672
Page 2
Contents
REPAIRS / ADJUSTMENTS (REP) PAGE
Cover removal
REP 1.1 Front and rear cover 1.1.1
REP 1.2 Top cover 1.2.1
REP 1.3 Panels + Infeeder 1.3.1
REP 1.4 Infeed and outfeed cover 1.4.1
Input area
REP 2.1 Infeed module 2.1.1
REP 2.2 Infeed transport belt 2.2.1
REP 2.3 Side guides 2.3.1
REP 2.4 Side guide assy. 2.4.1
REP 2.5 Side guide jogger motor MOT 3 2.5.1
REP 2.6 Back jogger motor MOT 7 2.6.1
Stapler area
REP 3.1 Stapler head 3.1.1
REP 3.2 Stapled set stop gate solenoid SOL 2 3.2.1
REP 3.3 Staple stop gate position, Adjustment 3.3.1
REP 3.4 Stapler assembly drive bar position, Adjustment 3.4.1
REP 3.5 Stapler home position, Adjustment SW 1 3.5.1
REP 3.6 Stapler head retraction, Adjustment 3.6.1
REP 3.7 Saddle stapling sensor, Adjustment SEN 1 3.7.1
Output area
REP 4.1 Upper folder roller 4.1.1
REP 4.2 Lower folder roller 4.2.1
REP 4.3 Fold pressure, Adjustment 4.3.1
REP 4.4 Fold knife home position, Adjustment SW 2 4.4.1
REP 4.5 Outfeed sensor, Adjustment SEN 4 4.5.1
Staple/Fold quality adjustments
REP 5.1 Staple stop gate parallelism, Adjustment 5.1.1
REP 5.2 Staple/Fold position, Adjustment 5.2.1
REP 5.3 Stapler position to anvil, Adjustment 5.3.1
REP 5.4 Stapler pressure, Adjustment 5.4.1
REP 5.5 Stapled set transport drive alignment, Adjustment 5.5.1
REP 5.6 Pressure roller height, Adjustment 5.6.1
REP 5.7 Stapled set stop gate release solenoid, Adjustment SOL 1 5.7.1
PROGRAMMING (PRG)
PRG 6.1 Reset of EE-prom values 6.1.1
ELECTRICAL DETAIL INFORMATION (EDI)
EDI 7.1 Wiring diagram SR85 7.1.1
EDI 7.2 Connection cable wiring diagram SR85 7.2.1
EDI 7.3 Electrical components list 7.3.1
EDI 7.4 Electrical components location 7.4.1
EDI 7.5 Test points 7.5.1
FAULT ISOLATING PROCEDURE (FIP)
FIP 8.1 Self diagnostic system control (SDS) 8.1.1
PREVENTIVE MAINTENANCE (MAI)
MAI 9.1 Preventive Maintenance 9.1.1
Bookletmaker SR 85 August 2000PAGE
i
Page 3
REP 1.1 Front and rear cover
REMOVAL
Front cover
1. Switch off the main power switch and disconnect the power cord.
2. Open the Top cover and loosen the two screws (1) securing the top end of the Front
cover.
3. Loosen the two nuts (2).
4. Pull out the lower end and lift up carefully to remove.
Rear cover
Removal of the rear cover is performed the same way as removal of the front cover.
1
2
INSTALLATION
Installation is an exact reversed procedure of removal.
Bookletmaker SR 85 August 2000PAGE
1.1.1
Page 4
REP 1.2 Top cover
REMOVAL
1. Open the Top Cover
2. Disconnect the Gas spring (4).
3. Remove four screws (1) from the brackets.
4. Lift off the Top cover.
1 23 4 2
5
INSTALLATION
1. Mount the four screws (1) onto the brackets and tighten.
2. Connect the Gas spring (4).
3. Close the Top cover and check:
- That the magnet (5) locks on the sheet plate (3).
- That both rubber bushings (2) contacts the surface.
- That the Top cover front side is parallel to the front cover.
- That the Interlock switch activates when the distance between the magnet (5)
and the sheet plate (3) is 2 to 5 mm.
ADJUSTMENT
1. Loosen the screws (1).
2. Move the Top cover to adjust.
3. Tighten the screws (1).
4. Repeat the check.
Bookletmaker SR 85 August 2000PAGE
1.2.1
Page 5
REP 1.3 Panels + Infeeder
REMOVAL
1. Loosen the four 7 mm screws (1).
2. Slide the top of the panels (2) away from the screws. Remove the shelf (3), remove the
two panels.
3. Loosen the four 7 mm screws (4).
4. Lift up the infeeder (5) and remove it.
5
4
2
2
1
3
INSTALLATION
Installation is an exact reversed procedure of removal.
Bookletmaker SR 85 August 2000PAGE
1.3.1
Page 6
REP 1.4 Infeed and Outfeed cover
REMOVAL
Infeed cover
1. Switch off the main power switch and disconnect the power cord.
2. If the unit is online, disconnect the connection cable.
3. Remove the two panels and the shelf.
4. Loosen the two nuts (1).
5. Pull out the lower end of the infeed cover and remove thecover down wards.
1
Outfeed cover
1. Switch off the main power switch and disconnect the power cord.
2. Remove front and rear cover according to REP 1.1.
3. Loosen the two screws below the stacker frame securing the stacker.
4. Disconnect and remove the stacker (3).
5. Tip the SR 85 by placing 50 mm or greater distances between the outfeed end of the
SR 85 and the base.
6. Loosen the two screws (5) securing the outfeed bottom cover.
7. Slide the bottom cover towards the outfeed, until it releases from the infeed bottom
cover. Slide the bottom cover towards
the infeed until it releases from the
2
screws (5).
8. Remove the four screws (4).
3
9. Pull the cover carefully out to avoid
damage on the outfeed sensor
harness on the front side.
NOTE: Cut the ty-wraps and disconnect the outfeed
sensor to fully remove the outfeed cover.
4
4
5
5
INSTALLATION
Installation is an exact reversed procedure of removal.
NOTE: Make sure the plastic guide (2) does not get jammed between the stackers left side
and the outfeed cover when installing the stacker.
Bookletmaker SR 85 August 2000PAGE
1.4.1
Page 7
REP 2.1 Infeed module
REMOVAL
1. Remove the front and rear cover according to REP 1.1.
2. Remove the two panels,shelf and the infeed assy.
3. Remove the infeed cover according to REP 1.3
4. Disconnect the five connectors (1).
5. Remove the spring (2).
VIEW INSIDE INFEED COVER
1
23
6. Disconnect the length adjust strap (3).
7. Remove the two screws (5) on the front side.
8. Remove the two screws (5) on the rear side.
1
1
4
5
9. Lift out the Infeed module (4). Carefully so the side guides does not bend.
INSTALLATION
Installation is an exact reversed procedure of removal.
Bookletmaker SR 85 August 2000PAGE
2.1.1
Page 8
REP 2.2 Infeed transport belt
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed module according to REP 2.1
3. Remove the four screws (1).
4. Slide the drive coupling (5) off of the drive shaft (4) and remove the transport belt asÂsembly.
5. Remove the belt (2) from the assembly.
1
5
INSTALLATION
Installation is an exact reversed procedure of removal.
Note: Make sure the flat side on the bearing (3) is up when installing.
2
3
4
Bookletmaker SR 85 August 2000PAGE
2.2.1
Page 9
REP 2.3 Side guides
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the infeed cover according to REP 1.4
3. Loosen the Ob screw (3) and the Ib screw (4) on the front side guide.
4. Remove the side guide.
5. Same procedure on the rear side guide.
Rear side
5
4
3
Stapler area seen from
above, with the stapler
heads removed.
2
Front side
1
2
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Move the front (1) sideguide to the two holes (2) in the paper path according to the
figure.
2. Check the distance between the two holes and the sideguide. The distance should be
equal ± 0.3 mm between the lower hole and the sideguide and the upper hole and the
sideguide. If not go to step 3.
3. Loosen the Ob screw (3) and the IB screw (4) on the side guide. Adjust the sideguide
according to step 2.
4. Perform the same check on the rear (5) sideguide, adjust if needed.
Bookletmaker SR 85 August 2000PAGE
2.3.1
Page 10
REP 2.4 Side guide assy.
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1
3. Remove the infeed cover according to REP 1.4
4. Remove the infeed module according to REP 2.1
5. Remove the sideguides according to REP 2.3
6. Turn the infeed module up side down.
7. Remove the e-clip (1).
8. Remove the two screws (2) who secures the shaft.
9. Push the shaft (3) out of the hole (4).
10. Remove five nuts (5).
11. Remove four 7 mm screws (6).
2
5
6
3
4
INSTALLATION
Installation is an exact reversed procedure of removal.
5
1
5
6
Bookletmaker SR 85 August 2000PAGE
2.4.1
Page 11
REP 2.5 Side guide jogger motor MOT 3
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1
3. Remove the infeed cover according to REP 1.4
4. Remove the infeed module according to REP 2.1
5. Turn the infeed module up side down.
6. Remove 7 mm screw (1).
7. Remove wheel (2) by loosen one 4 mm allen screw.
8. Remove three 7 mm screws (3).
9. Cut two tie raps and remove the motor.
2
1
3
INSTALLATION
Installation is an exact reversed procedure of removal. But before you tighteen the three
screws, you must put the side joggers in the out position, look at the picture above. You
should have 0.1-0.3 mm play between the plate and the flange bushing on both sides (1).
Tighteen the three screws.
1
1
Bookletmaker SR 85 August 2000PAGE
2.5.1
Page 12
REP 2.6 Back jogger motor MOT 7
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the infeed module according to REP 2.1.
3. Disconnect the ground wire (1).
4. Loosen the setscrew in the collar (3).
5. Remove the motor (2).
12 3
45
INSTALLATION
1. Install the motor.
2. Ensure that the pin on the motor is inserted in the grommet (4).
3. Push the collar (5) of the flange bushing firmly against the bracket.
4. Tighten the setscrew (3) on the flat of the shaft.
5. Connect the ground wire (1).
6. Install the infeed module according to REP 2.1.
7. Check/adjust the Staple/fold position according to REP 5.2.
Bookletmaker SR 85 August 2000PAGE
2.6.1
Page 13
REP 3.1 Stapler head
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Disconnect the staple detection lead (5).
3. Push down latch (2) and lift the stapler head (1) out.
NOTE: If removing the stapler head use the pivot pin (6) from the old stapler head and install it in the
new head.
1
3
4
5
2
6
4
6
5
O-Rings
INSTALLATION
1. Install the plunger (4) in the plunger retraction swing arm (3).
2. Push the Stapler head down so that the pivot pin (6) locks under the latch (2).
3. Connect the staple detection lead (1).
Bookletmaker SR 85 August 2000PAGE
3.1.1
Page 14
REP 3.2 Stapled set stop gate solenoid SOL 2
REMOVAL
1. Move the front side guide to the outermost position.
2. Adjust the sheet size on the control panel to align the mounting screws (2) for the
solenoid with the access holes (1) in the paper path.
3. Switch off the main power switch and disconnect the power cord.
4. Remove the infeed cover according to REP 1.3.
5. Cut the ty-wrap securing the cable.
6. Disconnect the solenoid connector.
7. Loosen the two screws (2).
8. Slide the solenoid towards the infeeder to remove.
1
2
INSTALLATION
Installation is an exact procedure of removal.
Bookletmaker SR 85 August 2000PAGE
3.2.1
Page 15
REP 3.3 Staple stop gate position, adjustment
PURPOSE
The purpose is to position the Staple stop gate fingers in the center of each opening in the
paper path so that binding does not occur.
1. Adjust to the smallest length size on the control panel.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the Infeed cover according to REP 1.3.
4. Insert a 0.3 mm feeler gauge (3) to ensure 0.3 ± 0.2 mm endplay.
5. Disengage the Staple stop gate release solenoid (1). PO/PO
VIEW INSIDE INFEED COVER
12 3
0.3±0.2 mm
4
ADJUSTMENT
1. Check that the fingers (2) are centered in the openings in the paper path.
2. Loosen the two allen screws (4)(5) securing the collars.
3. Center the fingers (2).
4. Tighten the front allen screw(4).
5. Insert a 0.3 mm feeler gauge (3) to obtain 0.3 ± 0.2 mm endplay.
6. Tighten the rear allen screw (5).
5
Bookletmaker SR 85 August 2000PAGE
3.3.1
Page 16
REP 3.4 Stapler assembly drive bar position, adjustment
PURPOSE
The purpose is to limit the front-to-rear movement of the Stapler assembly drive bars
without causing them to bind.
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed cover according to REP 1.3.
3. Remove the Front cover according to REP 1.1.
1
0.05 to 0.25 mm
2
3
2
ADJUSTMENT
Top bearing
1. Push the drive bar (1) toward the rear.
2. Insert a feeler gauge to check that the gap is 0.05 mm to 0.25 mm.
3. Loosen the locknut (3).
4. Rotate the screw (2) to adjust.
5. Tighten the locknut (3).
2
3
Bottom bearing
Adjustment of the Bottom bearing is performed the same way as adjustment of the Top
bearing.
Bookletmaker SR 85 August 2000PAGE
3.4.1
Page 17
REP 3.5 Stapler home position, adjustment SW 1
PURPOSE
The purpose is to position the Stapler motor home position switch (SW 1) so that the StaÂpler motor (MOT 8) stops in the correct position after stapling a set.
1. Switch off the main power switch and disconnect the power cord.
2. Remove the infeed cover according to REP 1.3.
3. Rotate the motor linkage (3) to the top dead center.
123
0.0 - 0.2 mm
ADJUSTEMENT
1. Check that the gap is 0.0 mm to 0.2 mm.
2. Loosen the two screws (1).
3. Move the switch (2) to adjust.
4. Tighten the two screws (1).
Bookletmaker SR 85 August 2000PAGE
3.5.1
Page 18
REP 3.6 Stapler head retraction, adjustment
PURPOSE
The purpose is to ensure the staple feed.
1. Check/adjust the Stapler home position according to REP 3.5.
2. Switch off the main power switch and disconnect the power cord.
12 3
1.0 - 2.0 mm
ADJUSTMENT
1. Push down the stapler head (1).
2. Check that the gap is 1.0 to 2.0 mm.
3. Loosen the three screws (3).
4. Rotate the screw (2) to adjust.
5. Tighten the three screws (3).
Bookletmaker SR 85 August 2000PAGE
3.6.1
Page 19
REP 3.7 Saddle stapling sensor, adjustment SEN 1
PURPOSE
The purpose is to position the saddle stapling sensor (SEN 1) so that it will switch on the
stapler motor (MOT 8) when a set reaches the Staple stop gate.
1. Remove the rear cover according to REP 1.1 and pull out the interlock bypass switch
actuator.
2. Remove the nut (1).
3. Remove the black shield (2).
21
34
ADJUSTMENT
1. The voltage between TP1 on the controller PCB and common ground should be greater
than 2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked.
NOTE: Use white paper to block the sensor.
2. Loosen the nut (4).
3. Move the sensor (3) to obtain the voltages.
4. Tighten the nut (4).
Bookletmaker SR 85 August 2000PAGE
3.7.1
Page 20
REP 4.1 Upper folder roller
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front and rear cover according to REP 1.1.
3. Remove the outfeed cover according to REP 1.3.
4. Remove the drive chain (6).
6. Note the position of the sprockets (2&3) on the shaft. Remove the sprockets and the
plastic spacer from the front of the spring-loaded bearing block.
7. Remove the collar and the plastic spacer from the
8. Remove the front bearing block (4) by removing the two screws from the inside of the
machine.
9. Remove the front and rear spring-loaded bearing block assemblies by removing
screws (5), front and rear, from the inside of the machine.
10. Note the position of the front plastic bearing (1). Remove the bearing.
11. Pull out the upper fixed roll to remove.
12. Pull out the upper spring-loaded roll to remove.
rear of the spring-loaded roll.
1
5
2
6
3
4
INSTALLATION / ADJUSTMENT
1. Installation is an exact reversed procedure of removal.
Note 1: Push the upper side of the bearing block (4) towards the outfeed before tightening.
Note 2: Before tightening the spring-loaded bearing blocks, use a feeler gauge to check
that the endplay is 0.1 to 0.5 mm between the sprocket (2) and the plastic spacer.
Also check that the enplay on the rear side is 0.1 to 0.5 mm between the collar and
the plastic spacer.
2. Adjust the fold pressure according to REP 4.3.
Bookletmaker SR 85 August 2000PAGE
4.1.1
Page 21
REP 4.2 Lower folder roller
REMOVAL
Lower right folder roll
1. Switch off the main power and disconnect the power cord.
2. Remove front and rear cover according to REP 1.1.
3. Remove the drive chain (3).
4. Note the sprockets (2) position on the shaft and remove the sprocket (2).
5. Remove the spring (4) on both front and rear side.
WARNING: When compressing, pry the spring onto a screwdriver in order to avoid injury
when removing it.
7. Loosen the screws (1) from the inside of the the machine.
8. Wiggle the folder roll shaft up and down in order to release it from the brackets (5) se-
curing the shaft.
9. Pull the folder roll through the cut out in the side frame until the shaft releases from the
bearing on the opposite side. Then lift out the folder roll through the inside of the maÂchine.
CAUTION: In order to compensate for variations between machines, there could be shim
washers placed on the inside of the bushing at the end of the Folder roll shaft.
Note the position of the washers when removing.
Lower left folder roll
Removal of the Lower left folder roll is performed the same way as removal of the Lower
right folder roll, in addition the Outfeed cover has to be removed according to REP 1.3.
3
1
4
5
2
INSTALLATION
Installation is an exact reversed procedure of removal.
Bookletmaker SR 85 August 2000PAGE
4.2.1
Page 22
REP 4.3 Fold pressure, adjustment
PURPOSE
The purpose is to ensure that when running 2-5 sheets, only the soft spring (upper spring)
will be compressed and when running more than 5 sheets both springs will be
compressed.
1. Switch of the main power switch and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1.
2
ADJUSTMENT
1
43
56 7
8
9
10
Front fold pressure assembly
1. Compress upper spring (3) until head of screw (2) contacts bar.
2. Check (1) for 34.0 ± 0.5 mm.
3. Adjust by loosen one nut (4) (Pull spring down to access locking nut) and reposition the
other to obtain the dimension. When tightening the nuts make sure the screw is in the
outermost position of the slot.
4. Check (10) for 36.5 ± 0.5 mm.
5. Adjust nut (9) to obtain the dimension.
6. Check (5) for 36.5 ± 0.5 mm.
Note: Push downwards on the screw (9) when measuring the distance (5).
7. Adjust by loosen the two screws (7) (from the inside of the machine) and reposition the
spring bracket (6) to obtain the dimension.
When tightening the screws make sure the spring bracket (6) is parallel to the
nut plate (8) in order to align the folder roll movement with the spring load .
Rear fold pressure assembly
Adjustment of the Rear fold pressure assembly is performed the same way as adjustment
of the Front fold pressure assembly.
Bookletmaker SR 85 August 2000PAGE
4.3.1
Page 23
REP 4.4 Fold knife home position, adjustment SW 2
PURPOSE
The purpose is to ensure that the Fold knife is clear from the paper path in home position.
1. Visually check that the Fold knife is not visible above the paper path.
2. Switch of the main power switch and disconnect the power cord.
3. Remove the outfeed cover according to REP 1.3.
4. Rotate linkage (4) to the down dead center.
SHOWN IN TIPPED POSITION FOR CLARITY
12
ADJUSTMENT
1. Check that the gap (3) between the switch housing and the actuator arm is
0.1 mm to 0.5 mm.
2. Loosen the two screws (1).
3. Move the switch (2) to adjust.
4. Tighten the two screws (1).
Bookletmaker SR 85 August 2000PAGE
34
4.4.1
Page 24
REP 4.5 Outfeed sensor, adjustment SEN 4
PURPOSE
The purpose is to position the Outfeed sensor (SEN 4) so that it will switch on the Stacker
motor (MOT 1) when a set enters the stacker tray.
1. Remove the rear cover according to REP 1.1 and pull out the interlock bypass switch
actuator.
VIEW INSIDE THE TOP COVER
OVER THE FOLDER ROLLS
12
ADJUSTMENT
1. The voltage between TP8 on the controller PCB and common ground should be greater
than 2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked.
NOTE: Use white paper to block the sensor.
2. Loosen the nut (2).
3. Move the bracket (1) to obtain the voltages.
4. Tighten the nut (2).
Bookletmaker SR 85 August 2000PAGE
4.5.1
Page 25
REP 5.1 Staple stop gate parallelism, adjustment
PURPOSE
The purpose is to ensure that the staples are parallel to the edge of the sets.
1. Remove the rear Stapler head according to REP 3.1.
2. Move the side guides to the outermost position.
3. Select the Fold mode on the Control panel.
4. Select the Adjustment mode on the Control panel.
5. Fold an A4 (8.5“ x 11“) sheet of paper lengthwise by hand in order to form a straight
edge.
6. Feed the folded paper sidewise into the machine so that the straight edge fold (2) is po-
sitioned against the Staple stop gate.
7. Adjust the sheet size on the control panel to align the straight edge fold (2) with the locat-
ing holes (1) in the paper path.
8. The straight edge fold (2)
must align with both of the locating holes (1).
1
234
ADJUSTMENT
1. Loosen the screw (4).
2. Insert a screwdriver in the notches (3) and rotate to align the holes (1) with the straight
edge fold (2).
3. Tighten the screw (4).
4. Check/adjust the Staple/Fold position according to REP 5.2.
Bookletmaker SR 85 August 2000PAGE
5.1.1
Page 26
REP 5.2 Staple/Fold position, adjustment
PURPOSE
The purpose is to ensure that the sets are folded in the center of the set, that the fold is parÂallel to the edge of the sets and that the staples are aligned with the fold.
1. Select Fold mode and Adjustment mode on the Control panel
2. Handfeed a 2-sheet set using A4 (8.5“x 11“) paper.
3. Adjust the sheet size on the control panel to align the Back jogger with the trail edge of
the set without producing a buckle in the set.
4. Select Run mode and run a few sets.
5. Check that the fold is parallel to the edge of the set. If not perform Adjustment 1.
NOTE: After adjustment 1 is performed , return to this procedure and continue from step 1.
6. Check that the fold is in the center of the set (that the edges of the booklet are aligned).
If not perform Adjustment 3.
NOTE: After adjustment 3 is performed , return to this procedure and continue.
7. Repeat step 1 to 4 but run 4-sheet sets in Staple/Fold mode.
8. Check that the staples are aligned with the fold. If not perform Adjustment 2.
SHOWN IN TIPPED POSITION FOR CLARITY
3
ADJUSTMENT 1
1. Adjust to the largest sheet size on the control panel.
2. Place the stacker module in upright position.
3. Switch of the main power switch and disconnect the power cord.
4. Loosen the two mounting screws (2).
5. Rotate the two screws (3) to adjust.
6. Push in the fold stop assembly when tighten the two screws (2).
7. Repeat Adjustment 1 until the fold is parallel to the edge of the set.
1
2
Bookletmaker SR 85 August 2000PAGE
5.2.1
Page 27
Continue REP 5.2 Staple/Fold position, adjustment
ADJUSTMENT 2
1. Loosen the locknut and rotate the setscrew (1) clockwise if the staples are located on
the top, counterclockwise if the staples are located on the bottom and tighten the
locknut.
NOTE: Top of the booklet is the side that contacts the output wheel.
2. Repeat Adjustment 2 until the staples are aligned with the fold.
ADJUSTMENT 3
1. Rotate screw (4) clockwise to lengthen the top of the booklet, counter clockwise to
shorten the top of the booklet.
NOTE: Top of the booklet is the side that contacts the output wheel.
2. Select Adjustment mode on the Control panel
3. Handfeed a 2-sheet set using A4 (8.5“x 11“) paper.
4. Adjust the sheet size on the control panel to align the Back jogger with the trail edge of
the set without producing a buckle in the set.
5. Select Run mode and run a few sets.
6. Repeat Adjustment 3 until the edges of the booklet are aligned.
4
Bookletmaker SR 85 August 2000PAGE
5.2.2
Page 28
REP 5.3 Stapler position to anvil, adjustment
PURPOSE
The purpose is to ensure that the stapler assemblies are aligned correctly to the anvils.
1. Run a 2-sheet set in the edge staple mode.
2. Check that the staples are formed properly. The ends of the staples should be folded so
that they are aligned with the middle of the staple.
Good Staple Bad Staple
3. Switch off the main power switch and disconnect the power cord.
4. Remove the Stapler head according to REP 3.1.
5. Push the plunger (4) manually and note where the staple exits the Stapler head, then
return the plunger to the home position.
WARNING: Be careful when handeling the Stapler head. The ends of the staples are sharp
and difficult to see.
6. Remove the Staple cartridge (3) and tear the staples at the tear line.
7. Reinstall the cartridge (3) but do not make any staple strokes.
8. Position an allen wrench (2) - app. 2 mm - as shown to relieve the pressure on the sta-
ple former.
9. Install the Alignment tool (1) as shown.
NOTE: Head alignment tool is located at the bottom of the front side frame.
10. Remove the allen wrench (2).
12
34
Bookletmaker SR 85 August 2000PAGE
5.3.1
Page 29
Continue REP 5.3 Stapler position to anvil, adjustment
11. Reinstall the Stapler head only on the pivot pin side not in the plunger retraction swing
arm (7).
56 7 8
ADJUSTMENT
1. Loosen the left (6) and the right (8) mounting screw.
2. Rotate the adjusting screw (5) counterclockwise as far as it will go without removing it.
3. Push down the Stapler head and move it by turning the adjustment screw (5) clockwise
until the tool engages the slot in the anvil.
4. Tighten the left mounting screw (6).
5. Position the Stapler head so that the Alignment tool is centered (side to side) in the slot.
6. Tighten the right mounting screw (8).
7. Return the machine to operational condition.
8. Run a test set to verify the adjustment.
Bookletmaker SR 85 August 2000PAGE
5.3.2
Page 30
REP 5.4 Stapler pressure, adjustment
PURPOSE
The purpose is to ensure that adequate pressure is applied to the Stapler heads when
forming the staples.
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed cover according to REP 1.3.
3. Remove the Stapler head according to REP 3.1.
4. Rotate the motor linkage (3) to the down dead center.
1
70 to 71 mm
2
1
3
ADJUSTMENT
1. Use a sliding caliper and check that the distance between the anvil and the upper side
of the sheet plate is 70 mm to 71 mm.
Check both front and rear side.
2. Loosen the four screws (1).
3. Move the upper stapler bar (2) to adjust.
4. Tighten the screws (1).
5. Check/Adjust the Stapler assembly drive bar position according to REP 3.4.
Bookletmaker SR 85 August 2000PAGE
5.4.1
Page 31
REP 5.5 Stapled set transport drive alignment, adjustment
PURPOSE
The purpose is to horizontally align the Stapled set drive rollers with the Idler wheels to enÂsure the correct set transportation into the fold area.
1. Adjust to the smallest sheet size on the control panel.
2. Ensure that the tires (3) are centered on the hubs (4) of the drive rollers.
3. Manually move the Drive rollers (2) up against the Pressure rollers (1) by pushing the
Staple stop gate down.
4. Push down the staple stop gate and visually check that the Drive rollers are centered on
the Pressure rollers.
1
23 4
1256
78
9
ADJUSTMENT
1. Switch off the main power switch and disconnect the power cord.
2. Remove the Infeed cover according to REP 1.3.
3. Loosen the allen screw (8).
4. Move the shaft (7).
5. Insert a 0.3 mm feeler gauge (9) to ensure 0.3 ± 0.2 mm endplay.
NOTE The endplay 0.3 mm is to prevent the Staple stop gate shaft from binding.
6. Tighten the allen screw (8).
7. Loosen the two allen screws (6).
8. Move the assembly (5) so that the tires (3) are centered on the Pressure rollers (1).
9. Tighten the two allen screws (6).
Bookletmaker SR 85 August 2000PAGE
5.5.1
Page 32
REP 5.6 Pressure roller height, adjustment
PURPOSE
The pupose is to position the Pressure rollers for the correct engagement with the Drive
rollers.
1. Adjust to the largest sheet size on the Control panel.
2. Switch off the main power switch and disconnect the power cord.
3. Rotate the shield (2).
VIEW OF STAPLED SET TRANSPORT AREA
1
2
3
ADJUSTMENT
1. Check that the gap (3) is 4 mm to 5 mm.
NOTE: Use a 4 mm allen wrench - as shown on drawing - to check that it fits in the gap and
a 5 mm allen wrench to check that it does not fit in the gap.
2. Loosen one nut (1) and reposition the other (1) as required to obtain the gap.
3. Check/adjust the Stapled set transport solenoid according to REP 5.7.
Bookletmaker SR 85 August 2000PAGE
5.6.1
Page 33
REP 5.7 Stapled set stop gate release solenoid, adjustment SOL 1
PURPOSE
The purpose is to ensure adequate engagement of the stapled set drive rollers.
1. Check/adjust the Pressure roller height according to REP 5.6.
2. Adjust to the smallest sheet size on the control panel.
3. Switch off the main power switch and disconnect the power cord.
4. Remove the infeed cover according to REP 1.3.
VIEW SHOWN WITH INFEED MODULE
REMOVED FOR CLARITY
1
2
3
ADJUSTMENT
1. Measure the hight (1).
2. Push and hold the plunger (3) up.
NOTE: Push on the plunger of the solenoid only, do not push on the linkage. If pushing on
linkage the measurement will not be correct.
3. Measure the hight (1) again. The difference should be 0.5 mm to 1.0 mm
4. Loosen the two screws (2) and move the solenoid to obtain the dimension.
5. Tighten the screws.
Bookletmaker SR 85 August 2000PAGE
5.7.1
Page 34
PRG 6.1 Reset of EEPROM values
PURPOSE
The purpose is to transfer the original values from the Micro processor to the EEPROM.
This procedure should be performed in response to minor logic problems such as failure in
the operating sequence. Also perform this procedure if the controller PCB is replaced or if
the power is lost during SDS.
PROCEDURE
1. Switch of the main power switch.
2. Remove the rear cover according to REP 1.1.
3. Move DIP switch no. 1 on the controller PCB to the right (right when facing the PCB).
4. Switch on the main power switch.
• The adjust LED on the control panel is flashing: The processor is transferring the default
values to the EEPROM.
5. When the adjust LED stops flashing, switch off the main power switch.
6. Move DIP switch no. 1 on the controller PCB to the left (left when facing the PCB).
7. Reinstall the rear cover according to REP 1.1.
Normal mode < > Reset EEPROM
Ricoh mode
Not used
Not used
location of DIP switch
rear view
Bookletmaker SR 85 August 2000PAGE
6.1.1
Page 35
EDI 7.2 Connection cable wiring diagram SR85
Bookletmaker SR 85 August 2000PAGE
7.2.1
Page 36
Continue EDI 7.2 Connection cable wiring diagram SR85
Bookletmaker SR 85 August 2000PAGE
7.2.2
Page 37
EDI 7.3 Electrical components list
MOT 5 Stacker drive motor PAGE 7.4.2
MOT 4 Stapled set transport motor PAGE 7.4.3
MOT 6 Length adjustment motor PAGE 7.4.2
MOT 10 Edge stapling stop motor PAGE 7.4.1
MOT 7 Back jogger motor PAGE 7.4.4
MOT 11 Edge stapling transport motor PAGE 7.4.4
MOT 9 Infeed transport belt motor PAGE 7.4.4
MOT 1 Stapler motor PAGE 7.4.3
MOT 2 Fold knife motor PAGE 7.4.3
MOT 8 Folder roller motor PAGE 7.4.1, 7.4.3
MOT 12 Fold stop gate motor PAGE 7.4.2
MOT 3 Side jogger motor PAGE 7.4.4
SOL 1 Stapled set stop gate release solenoid PAGE 7.4.3
SOL 2 Stapled set stop gate solenoid PAGE 7.4.3
SW 1 Stapler home position switch PAGE 7.4.3
SW 2 Fold knife home position switch PAGE 7.4.2
SW 3 Length adjustment maximum limit switch PAGE 7.4.1
SW 4 Length adjustment minimum limit switch PAGE 7.4.1
SW 5 Interlock switch PAGE 7.4.1
SW 6 Interlock bypass switch PAGE 7.4.1
SW 7 Main power switch PAGE 7.4.1, 7.4.3
SEN 1 Saddle stapling sensor PAGE 7.4.4
SEN 2 Fold stop sensor PAGE 7.4.2
SEN 3 Edge stapling sensor PAGE 7.4.4
SEN 4 Outfeed sensor PAGE 7.4.2
SEN 5 Infeed sensor PAGE 7.4.4
SEN 6 Side jogger home position sensor PAGE 7.4.4
SEN 7 Side jogger hall sensor PAGE 7.4.4
F 1 Main power fuse PAGE 7.4.3
F 2 10 VAC fuse, T500 mA PAGE 7.4.3
F 3 10 VAC fuse for staple detection, T500 mA PAGE 7.4.3
F 4 26 VAC fuse, T6.3 A PAGE 7.4.3
GFI Ground fault interrupter PAGE 7.4.3
T 1 Transformer PAGE 7.4.3
REC 1 Rectifier PAGE 7.4.1
FL 1 Filter PAGE 7.4.1
C 1 Capacitor PAGE 7.4.1
J 5 Interface receptacle PAGE 7.4.3
J 6 Stacker receptacle PAGE 7.4.1
PCB PL75-1 Controller Printed circuit board PAGE 7.4.1
Bookletmaker SR 85 August 2000PAGE
7.3.1
Page 38
EDI 7.4 Electrical components location
REAR VIEW
SW 5 PCB PL75-1
J 2
J 1
TP 1-16
J 4
J 3
SW 3
SW 6
Interlock bypass
switch actuator
FL 1
SW 4
FRONT VIEW
Set counter MOT 10 MOT 8 SW 7
J 6Common ground C 1 REC 1
Bookletmaker SR 85 August 2000PAGE
7.4.1
Page 39
Continue EDI 7.4 Electrical components location
VIEW INSIDE OUTFEED COVER
SEN 2
FOLD AREA SHOWN IN TIPPED POSITION
LEFT VIEW
SEN 4
MOT 5
MOT 6 SW 2 MOT 12
Bookletmaker SR 85 August 2000PAGE
7.4.2
Page 40
Continue EDI 7.4 Electrical components location
VIEW INSIDE INFEED COVER
SOL 2 MOT 4 SOL 1
SW 7
J 5
T 1
RIGHT VIEW INFEED COVER REMOVED
F3 F2 F4
MOT 2
MOT 1SW 1
F 1
AC Receptacle
GFI
Bookletmaker SR 85 August 2000PAGE
7.4.3
Page 41
Continue EDI 7.4 Electrical components location
VIEW OF INFEED AREA
SEN 3
SEN 5
BOTTOM VIEW OF
REMOVED INFEEDER
SEN 7
MOT 3
SEN 6
STAPLER AREA
MOT 7
MOT 9
SEN 1
Bookletmaker SR 85 August 2000PAGE
7.4.4
Page 42
EDI 7.5 Test points
PURPOSE
The purpose of the Test points (see location on page 7.4.1, TP 1-16) is to use them as the
(+) connector when adjusting sensors or when checking the function of some components
and there wires. Use any common ground as (-) connector.
Voltage when low: Less than 0.9 VDC
Voltage when high: Greater than 2.2 VDC
Measured value
Test point Description after switched on
TP 1 Saddle stapling sensor SEN 1 Low inactivated
TP 2 Fold stop sensor SEN 2 High inactivated
TP 3 Home position side registration High inactivated
TP 4 Fold knife home position switch SW 2 Low activated
TP 5 Stapler home position switch SW 1 Low activated
TP 6 Jam signal from Trimmer High inactivated
TP 7 Edge stapling sensor SEN 3 High inactivated
TP 8 Outfeed sensor SEN 4 Low inactivated
TP 9 Infeed sensor SEN 5 High inactivated
TP 10 Trimmer knife activated High inactivated
TP 11 Length adjustment maximum limit switch SW 3 High inactivated
TP 12 Not used
TP 13 Length adjustment minimum limit switch SW 4 High inactivated
TP 14 Trimmer connected High inactivated
TP 15 Rear staple detection High inactivated
TP 16 Front staple detection High inactivated
Bookletmaker SR 85 August 2000PAGE
7.5.1
Page 43
FIP 8.1 Self diagnostic system control (SDS)
PURPOSE
The purpose of the Self diagnostic system control (SDS) is to provide a functional check of
the components of the Bookletmaker SR 85.
PROCEDURE
NOTE1: The Interlock switch or the Interlock bypass switch has to be actuated and the four
DIP switches on the controller PCB has to be to the left (left when facing the PCB)
and the SR 85 has to be cleared from paper sheets in order to perform the SDS.
NOTE2: If the SDS is repeated, switch off the power, wait a few seconds, switch on the
power again to return the motors and solenoids to home position.
CAUTION1: Always handle the PCB and micro processor in accordance with electrostatic
discharge procedures (ESD). The PCB contains components that are sensitive
to ESD damage.
CAUTION2: Do not switch of the power during SDS. If there is a loss of power during SDS,
reset the EEPROM according to PRG 6.1.1
1. Switch off the power.
2. Press and hold the Auto/Manual button. Switch on the power. Release the Auto/Manual
button.
• First the Auto LED is flashing: The SR 85 is testing the EEPROM.
• Then the Manual LED is flashing: The SR 85 is testing the 24 voltage, the 36 voltage,
motors and solenoids.
• At last all of the LEDs are lighting on the control panel: The test is complete.
3. Press the five buttons on the control panel one at the time.
• All of the LEDs should be switched off except the Staples LED.
4. Press the two buttons to the left on the control panel at the same time.
• The last LED on the control panel should be switched off.
If all of the LEDs are off, the SDS is complete, no errors found.
If any faults was detected during SDS, the last six LEDs will provide a fault code pattern.
Press the Auto/Manual button to display any other faults that were detected during the
SDS.
Refer to SDS Fault code table and locate the lighting pattern of the LEDs.
Bookletmaker SR 85 August 2000PAGE
8.1.1
Page 44
FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause
1. EEPROM error
2. 36 VDC error
3. 24 VDC error
4. Interlock switch SW 5,
activated.
5. Stapler home position
switch SW 1, not
activated.
EEPROM values incorrect. Reset the EE-prom according to PRG 6.1.
EEPROM defective. Replace the controller PCB.
Interlock switch SW 5 activated. See fault code 5.
Rectifier REC 1 defective. Replace Rectifier.
Transformer T 1 defective. Replace Transformer.
Capacitor C 1 defective. Replace Capacitor.
Wires defective. Check the wires for an open circuit using
Controller PCB defective. Replace controller PCB.
Controller PCB defective. Replace controller PCB.
Top cover open or Interlock
switch not activated.
Top cover misadjusted. Check/Adjust the Top cover according to
Micro switch defective. Disconnect the wires from the switch.
Wires defective. Disconnect the wires from the switch.
Controller PCB defective. If checks above is good, replace the
Stapler motor in faulty position.
Stapler home position
misadjusted.
Micro switch defective. Disconnect the wires from the switch.
Wires defective. Check that the voltage between TP5 on
Controller PCB defective. If checks above is good, replace the
Fault isolating / repair
a voltmeter. Measure from 3, 4 and 5 on
connector J8 to the capacitor.
Close the Top cover or pull out the
Interlock bypass switch actuator.
REP 1.2.
Check the function of the switch using a
voltmeter. Check both Interlock micro
switch and Interlock bypass micro switch.
Check the wires for an open circuit using
a voltmeter. Measure from 10C and 17A
on connector J1 to the Interlock switch
and 10C and 12A to the bypass switch.
controller PCB.
Switch off the power and switch on the
power again.
Check/Adjust the Stapler home position
according to REP 3.5.
Check the function of the switch using a
voltmeter.
the controller PCB and common ground is
less than 0.9 VDC when the switch is
activated and greater than 2.2 VDC when
the switch is inactivated.
controller PCB.
Bookletmaker SR 85 August 2000PAGE
8.1.2
Page 45
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause
6. Fold knife motor home
po sition sw itc h S W 2,
not activated.
7. Side jogger home
position sensor SEN 6,
faulty.
8. Edge stapling sensor
SEN 3, activated.
9. Saddle stapling sensor
SEN 1, activated.
Fold knife motor in faulty position.
Fold knife home position
misadjusted.
Micro switch defective. Disconnect the wires from the switch.
Wires defective. Check that the voltage between TP4 on
Controller PCB defective. If checks above is good, replace the
Sensor defective.
Wires defective. Disconnect the sensor connector. Check
Controller PCB defective. Replace the controller PCB.
Paper is blocking the sensor.
Sensor defective.
Wires defective. Disconnect the sensor connector. Check
Controller PCB defective. If checks above is good, replace the
Paper is blocking the sensor.
Sensor misadjusted.
Sensor defective.
Wires defective. Disconnect the sensor connector. Check
Controller PCB defective. If checks above is good, replace the
Fault isolating / repair
Switch off the power and switch on the
power again.
Check/Adjust the Fold knife home position
according to REP 4.4.
Check the function of the switch using a
voltmeter.
the controller PCB and com mon ground is
less than 0.9 VDC when the switch is
activated and greater than 2.2 VDC when
the switch is inactivated.
controller PCB.
Check that the voltage between TP3 on
the controller PCB and com mon ground is
less than 0.9 VDC with the sensor
blocked and greater than 2.2 VDC with
the sensor unblocked.
the wires for an open circuit using a
voltmeter. Measure from 30A and 30C on
connector J1 to the sensor connector.
Measure from 30A and 4C on connector
J1 to the sensor connector.
Remove the paper.
Check that the voltage between TP7 on
the controller PCB and com mon ground is
less than 0.9 VDC with the sensor
blocked and greater than 2.2 VDC with
the sensor unblocked.
the wires for an open circuit using a
voltmeter. Measure from 26C and 26A on
connector J1. Meassure from 2C and 8A
on connector J1.
controller PCB.
Remove the paper.
Check/Adjust the Saddle stapling sensor
according to REP 3.7.
Check that the voltage between TP1 on
the controller PCB and com mon ground is
greater than 2.2 VDC with the sensor
blocked and less than 0.9 VDC with the
sensor unblocked.
the wires for an open circuit using a
voltmeter. Measure from 32C, 32A on
connector J1. Measure from 1C and 23A
on connector J1.
controller PCB.
Bookletmaker SR 85 August 2000PAGE
8.1.3
Page 46
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause
10. Outfeed sensor SEN 4,
activated.
11. Fold stop sensor
SEN 2, activated.
Paper is blocking the sensor.
Sensor misadjusted.
Sensor defective.
Wires defective.
Controller PCB defective. If checks above is good, replace the
Paper is blocking the sensor.
Sensor misadjusted.
Sensor defective. Check that the voltage between TP2 on
Fault isolating / repair
Remove the paper.
Check/Adjust the Outfeed sensor
according to REP 4.5.
Check that the voltage between TP8 on
the controller PCB and common ground is
greater than 2.2 VDC with the sensor
blocked and less than 0.9 VDC with the
sensor unblocked.
Disconnect the sensor connector. Check
the wires for an open circuit using a
voltmeter. Measure on connector J1
between 25A and 25C. And between 21A
and 3C.
controller PCB.
Remove the paper.
Reposition the sensor to obtain the
voltages below.
the controller PCB and common ground is
greater than 2.2 VDC with the sensor
blocked and less than 0.9 VDC with the
sensor unblocked.
12. Rear staple detection,
activated.
Wires defective.
Controller PCB defective. If checks above is good, replace the
Stapler head short circuit to
chassis ground
Wires defective. Check that the voltage between TP15 on
Controller PCB defective.
Disconnect the sensor connector. Check
the wires for an open circuit using a
voltmeter. Measure on connector J1
between 31A and 31C. And between 31A
and 4A.
controller PCB.
Find what causes the short circuit and
perform appropriate action.
the controller PCB and common ground is
less than 0.9 VDC when the stapler head
is in contact with the anvil and greater
than 2.2 VDC when not in contact. Use a
screw driver to connect the stapler head
with the anvil.
If check above is good, replace the
controller PCB.
Bookletmaker SR 85 August 2000PAGE
8.1.4
Page 47
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code
13. Front staple detection,
activated.
14. Trimmer not
connected.
15. Infeed sensor SEN 5,
activated.
Possible cause
Stapler head short circuit to
chassis ground.
Wires defective. Check that the voltage between TP16 on
Controller PCB defective. If check above is good, replace the
Model 75 intact.
Cabels not connected.
Wires defective. Check the wires for an open circuit using
Trimmer faulty. See technical documentation for Trimmer.
Controller PCB defective. Replace the controller PCB.
Paper is blocking the sensor.
Sensor misadjusted.
Fault isolating / repair
Find what causes the short circuit and
perform appropriate action.
the controller PCB and common ground is
less than 0.9 VDC when the stapler head
is in contact with the anvil and greater
than 2.2 VDC when not in contact. Use a
screw driver to connect the stapler head
with the anvil.
controller PCB.
If a Trimmer is not connected.
Connect the Interface cable and the
Power cord from the Trimmer to the
Model 75.
a voltmeter. Measure from 6 on connector
J9 to pin 8 on the DIN receptacle.
Measure from 13 on connector J9 to pin 5
on the DIN receptacle.
Remove the paper.
Reposition the sensor to obtain the
voltages below.
16. Infeed transport belt
motor MOT 9,
open circuit.
Sensor defective. Check that the voltage between TP9 on
the controller PCB and common ground is
greater than 2.2 VDC with the sensor
blocked and less than 0.9 VDC with the
sensor unblocked.
Wires defective. Disconnect the sensor connector. Check
the wires for an open circuit using a
voltmeter. Measure on connector J1
between 24A and 24C. And between 24A
and 2A.
Controller PCB defective.
Motor defective. Disconnect the motor connector. Check
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
If checks above is good, replace the
controller PCB.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 14 and 7 on
connector J8 to the motor connector.
Bookletmaker SR 85 August 2000PAGE
8.1.5
Page 48
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code
17. Back jogger motor
MOT 7, jogger up,
open circuit.
18. Fold stop gate motor
MOT 12, open circuit.
19. Stapler motor MOT 1,
open circuit.
Possible cause
Motor defective. If both fault code 17 and 18 was detected.
Wires defective. If both fault code 17 and 18 was detected.
Controller PCB defective. If only one of fault code 17 and 18 was
Motor defective. Disconnect the motor connector. Check
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
Fault isolating / repair
Disconnect the motor connector. Check
the motor for an open circuit using a
voltmeter.
Disconnect the motor connector. Check
the wires for an open circuit using a
voltmeter. Measure from 10 and 11 on
connector J8 to the motor connector.
detected. Replace the controller PCB.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 8 and 1 on
connector J9 to the motor connector.
the motor for an open circuit using a
voltmeter.
20. Stapled set transport
motor MOT 4,
Open circuit
21. Stapled set transport
solenoid SOL 1,
open circuit.
Wires defective. Disconnect the motor connector. Check
the wires for an open circuit using a
voltmeter. Measure from 9 and 2 on
connector J2 to the motor connector.
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
the motor for an open circuit using a
voltmeter.
Wires defective. Disconnect the motor connector. Check
the wires for an open circuit using a
voltmeter. Measure from 7 and 14 on
connector J9 to the motor connector.
Controller PCB defective. Replace the controller PCB.
Solenoid defective. Disconnect the solenoid connector. Check
the solenoid for an open circuit using a
voltmeter.
Wires defective. Disconnect the solenoid connector. Check
the wires for an open circuit using a
voltmeter. Measure from 5 on connector
J2 to 5 on connector J9.
Controller PCB defective. Replace the controller PCB.
Bookletmaker SR 85 August 2000PAGE
8.1.6
Page 49
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause Fault isolating / repair
22. Staple stop gate
release solenoid
SOL 2, open circuit.
23. Side jogger motor MOT3,
open circuit.
24. Fold knife motor
MOT 2, open circuit.
Solenoid defective. Disconnect the solenoid connector. Check
the solenoid for an open circuit using a
voltmeter.
Wires defective. Disconnect the solenoid connector. Check
the wires for an open circuit using a
voltmeter. Measure from 4 and 11 on
connector J2 to the solenoid connector.
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
the motor for an open circuit using a
voltmeter.
Wires defective. Disconnect the motor connector. Check
the wires for an open circuit using a
voltmeter. Measure from 11 and 12 on
connector J9 to the motor connector.
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
the motor for an open circuit using a
voltmeter.
Wires defective. Disconnect the motor connector. Check
the wires for an open circuit using a
voltmeter. Measure from 8 and 1 on
connector J2 to the motor connector.
25. Folder roller motor
MOT 8, open circuit.
26. Stacker motor MOT 5,
open circuit.
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 11 and 14 on
connector J2 to the motor connector.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 13 and 6 on
connector J9 to the motor connector.
Bookletmaker SR 85 August 2000PAGE
8.1.7
Page 50
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause Fault isolating / repair
27. Length adjustment
maximum limit switch
SW 3, activated.
28. Length adjustment
minimum limit switch
SW 4, activated.
Adjusted to maximum paper size. Adjust to a smaller paper size. It it is
allowed to run the Model 75 adjusted to
the largest paper size
Micro switch defective.
Wires defective. Check that the voltage between TP13 on
Controller PCB defective.
Adjusted to minimum paper size. Adjust to a larger paper size. It it is
Micro switch defective.
Wires defective.
Disconnect the wires from the switch.
Check the function of the switch using a
voltmeter.
the controller PCB and common ground is
less than 0.9 VDC when the switch is
activated and greater than 2.2 VDC when
the switch is inactivated.
If checks above is good, replace the
controller PCB.
allowed to run the Model 75 adjusted to
the smallest paper size
Disconnect the wires from the switch.
Check the function of the switch using a
voltmeter.
Check that the voltage between TP11 on
the controller PCB and common ground is
less than 0.9 VDC when the switch is
activated and greater than 2.2 VDC when
the switch is inactivated.
29. Edge staple stop motor
MOT 10, open circuit.
30. Edge stapling transport
motor MOT 11,
open circuit
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
31. Length adjustment
motor MOT 6,
open circuit.
Wires defective. Disconnect the motor connector. Check
Controller PCB defective.
Motor defective. Disconnect the motor connector. Check
Wires defective. Disconnect the motor connector. Check
Controller PCB defective. Replace the controller PCB.
Motor defective. Disconnect the motor connector. Check
Motor defective. Disconnect the motor connector. Check
If checks above is good, replace the
controller PCB.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 8 and 9 on
connector J8 to the motor connector.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 12 and 13 on
connector J8 to the motor connector.
the motor for an open circuit using a
voltmeter.
the wires for an open circuit using a
voltmeter. Measure from 1 and 2 on
connector J8 to the motor connector.
Controller PCB defective. Replace the controller PCB.
Bookletmaker SR 85 August 2000PAGE
8.1.8
Page 51
Continue FIP 8.1 Self diagnostic system control, Fault code table
Fault code Possible cause Fault isolating / repair
32.Side jogger, hall sensor
SEN7, faulty. Sensor defective. Check that the voltage between 15C and
19A on connector J1. Is greater than 2.2
VDC with the sensor blocked and less
than 0.9 VDC with the sensor unblocked.
Wires defective. Disconnect the sensor connector. Check
the wires for an open circuit using a
voltmeter. Measure on connector J1
between 15C and 19A. And between 19A
and 1A.
Controller PCB defective. If check above is good, replace the
controller PCB.
Bookletmaker SR 85 PAGE 8.1.9 August 2000
Page 52
MAI 9.1 Preventive Maintenance
Note: All INSTRUCTIONS are referring to the Bookletmaker SR 85 Service Manual.
The REFERENCE column is referring to the Spare parts list of Model SR85.
CHECK POINT INSTRUCTION REFERENCE 125000 250000
All machine, Paper paths etc. Use a vacuum cleaner, Clean Clean
towels and brushes to
clean the machine from
paper dust. Use an
alcohol to clean from ink.
Stapler assy. drive bars (2 pcs.) Apply grease. Check Grease/
Check according to Adjust
REP 3.4.
Fold knife drive bars (2 pcs.) Apply grease between Page 1.13 Check Grease
vertical rods and Fold Item 10
knife plate.
Fold stop bars (2 pcs.) On square shaped bar Page 1.13 Check Grease/
holding the fold stop assy, Check
apply silicon grease on the
bottom side of the bars
(between the bar and the
ty-wrap). Check ty-wraps
for wear. If worn, replace.
Stapler motor crank arm (2 pcs.) Apply silicon grease Page 1.9 Check Grease
between Crank journal Item 17 & 21
and Rod.
Fold knife motor crank arm (2 pcs.) Apply silicon grease Page 1.13 Check Grease
between Crank elbow Item 12 & 13
and Rod.
O-ring for eject feed wheel Check for wear. If worn, Page 1.9 Check/Clean Replace
replace. Always replace Item 5
at 250 000.
O-ring for edge staple motor Check for wear. If worn, Page 1.5 Check Check
replace. Item 3
Side jogger linkage Inside the infeed cover, Page 1.9 Check Grease
apply grease by screw Item 24
between jogger linkage
and lower stapler bracket
Chain Use chain oil. Check for Page 1.5 Oil Oil
wear, if worn/stretched Item 22
replace. Always replace
every 100 00 00.
Chain idler rollers (3 pcs.) Apply grease between Page 1.5 Check/Grease Replace
idler roller and pin. Check Item 12 & 17
for wear. If worn, replace. & 19
Threaded adjustment rod Use grease at 500 000. Page 1.9 (Grease)
Item 11
Bookletmaker SR 85 August 2000PAGE
9.1.1
Page 53
Continue MAI 9.1 Preventive Maintenance
CHECK POINT INSTRUCTION REFERENCE 125000 250000
Lower fold roller holder bracket Apply grease between the Page 1.5 Check/Grease Grease
(2 pcs.) spacer bracket and the Item 18
side frames. Check for
wear, if worn replace.
Upper fold roller bearings Under the top cover, use Page 1.5 Oil Oil/
(2 pcs.) oil between bearings and Item 10 Grease
shaft. Apply silicon grease
between bearing and side
frame.
Lower fold roller rubber rings Use a rubber reactivator Page 1.13 Clean Clean/
(16 pcs.) alcohol fluid. Check for Item 2 Check/
cracks. If worn, replace Replace
all rings. If applicable
Upper fold rollers Use a rubber reactivator Page 1.13 Clean Clean
alcohol fluid. Item 1
Stapler heads (2 pcs.) Check stapler heads by Grease/Check Replace
stapling 20 sheets. If poor
staple result, replace
stapler head. The poor
staple result is due to worn
driver points. Apply silicon
grease on plastic guide
posts and between top of
drive post and stapler drive
bracket. Use thin oil on
stapler driver
(without staining the paper).
Stapler retraction swing arm Apply silicon grease on Grease Grease/
(2 pcs.) bearing points. Check Adjust
adjustment according to
REP 3.6 when replacing
stapler heads.
Staple stop gate release arm Apply silicon grease on Page 1.9 Grease/
solenoid. SOL 2 bothfriction areas. Check Item 2 Check
that the stop gate latches
and releases correctly.
Bookletmaker SR 85 August 2000PAGE
9.2.1
Page 54
Continue MAI 9.1 Preventive Maintenance
CHECK POINT INSTRUCTION REFERENCE 125000 250000
Infeed module removed
Rear side guide release solenoid Apply grease between Page 1.11 Grease/Check Grease/
latch and tongue and Item 16 Check
between tongue and
square guide hole.
Check metal tongue
for wear. If worn, replace.
Check that the side guide
releases and latches
correctly. REP 2.4 for
adjustment.
Side guide shafts Apply a thin layer of Page 1.11 Clean/Grease Grease
grease. Item 14
Infeed transport belt Use a rubber reactivator Page 1.11 Clean Check
alcohol fluid. Check for Item 6
wear. If worn, replace,
check bushings, oil.
With the infeed module installed
Side guide parallelism Check that the side Check/Adjust Check/
guides are parallel Adjust
according to reference
holes in the lower paper path.
Booklet quality Check the booklet quality
according to REP 5.1 - 5.2
and REP 5.4 - 5.7 Check/Adjust Check/
Adjust
Bookletmaker SR 85 August 2000PAGE
9.3.1
Page 55
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