MyBinding Plockmatic Stapler 88 102 Service Manual User
2013-06-04
User Manual: MyBinding Plockmatic-Stapler--88-102-Service-Manual
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Page Count: 84
Stapler Folder Model 88 / 102
Service Manual
April 2002
Part No. 87609
Stapler Folder Model 88 / 102 Page April 2002
T08079
Page
iii Direction of the Model 88 / 102 iii
iiii Special Tools iiii
Covers
REP 1.1 Front, Rear and Infeed Cover 1.1.1
REP 1.2 Lower and Upper Outfeed Cover 1.2.1
REP 1.3 Deck Plate 1.3.1
Main Assemblies
REP 2.1 Infeed Module 2.1.1
REP 2.2 Infeed Idler Arm Assembly 2.2.1
REP 2.3 Stapler Assembly 2.3.1
Sensors and Switches
REP 3.1 Fold Position Adjustment Sensor (SEN1) 3.1.1
REP 3.2 Side Jogger Adjustment Sensor (SEN2) 3.2.1
REP 3.3 Back Jogger Adjustment Sensor (SEN3) 3.3.1
REP 3.4 Outfeed Sensor (SEN4) 3.4.1
REP 3.5 Start Cycle Sensor (SEN5) 3.5.1
REP 3.6 Infeed Sensor (SEN6) 3.6.1
REP 3.7 Edge Stapling Sensor (SEN14) 3.7.1
REP 3.8 Side Jogger Home Position Switch (SW1) 3.8.1
REP 3.9 Side Jogger Limit Switches (SW2, SW3) 3.9.1
REP 3.10 Side Jogger Motor Off Switch (SW4) 3.10.1
REP 3.11 Stapler/Clincher Motor On Switch (SW5) 3.11.1
REP 3.12 Stapler/Clincher Home Switch (SW6) 3.12.1
REP 3.13 Registration Carriage Limit/Home Pos. (SW7, SW8) 3.13.1
REP 3.14 Fold Knife Home Switch (SW9) 3.14.1
REP 3.15 Back Jogger Carrier Limit/Home Position (SW15, SW16) 3.15.1
REP 3.16 Staple Detection Switches (SW20, SW21) 3.16.1
REP 3.17 Interlock Switches (INTLK1, INTLK2) 3.17.1
REP 3.18 Interlock Bypass Switch (INTLK3) 4.18.1
Solenoids
REP 4.1 Registration Stop Solenoid (SOL4) 4.1.1
REP 4.2 Back Jogger Solenoid (SOL6) 4.2.1
REP 4.3 Edge Staple Stop Solenoid (SOL14) 4.3.1
REP 4.4 Edge Stapling Transport Solenoid (SOL18) 4.4.1
Motors and Assemblies
REP 5.1 Fold Roller Drive Motor (MOT1) 5.1.1
REP 5.2 Lower Fold Roller and Ball Bearing 5.2.1
REP 5.3 Upper Fold Roller and Ball Bearing 5.3.1
REP 5.4 Stapler/Clincher Drive Motor (MOT2) 5.4.1
REP 5.5 Clincher Assembly 5.5.1
REP 5.6 Clincher Timing and Height 5.6.1
REP 5.7 Stapler Compression 5.7.1
REP 5.8 Fold Knife Motor (MOT3) 5.8.1
REP 5.9 Eject Motor and Drive O-ring (MOT5) 5.9.1
i
Contents
Revision
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Stapler Folder Model 88 / 102 Page April 2002
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ii
Contents cont.
REP 5.10 Side Jogger Drive Motor (MOT7) 5.10.1
REP 5.11 Side Jogger Channel Centering 5.11.1
REP 5.12 Side Jogger Push Rod Centering 5.12.1
REP 5.13 Infeed Belt Motor (MOT8) 5.13.1
REP 5.14 Fold Stop Gate Motor (MOT9) 5.14.1
REP 5.15 Fold Position Adjustment Motor (MOT15) 5.15.1
REP 5.16 Fold Position Adjustment 5.16.1
REP 5.17 Back Jogger Adjustment Motor (MOT16) 5.17.1
REP 5.18 Side Jogger Adjustment Motor (MOT17) 5.18.1
O-rings and Drive Belts
REP 6.1 Infeed Drive O-ring 6.1.1
REP 6.2 Infeed Belt 6.2.1
REP 6.3 Prefold Transport Belt 6.3.1
Circuit Boards
REP 7.1 Logic Board (PCB 88-1) 7.1.1
REP 7.2 Motor Drive Board (PCB 88-2) 7.2.1
REP 7.3 Communication PCB 7.3.1
REP 7.4 Control Panel 7.4.1
Electrical Detail Information
EDI 8.1 Wiring Diagram Model 102 8.1.1
EDI 8.2 Wiring/Circuit Diagram Model 88 8.2.1
EDI 8.3 Wiring Diagram Model 88 8.3.1
EDI 8.4 Staple Detection Wiring Diagram 8.4.1
EDI 8.5 Connection Cable Diagram 8.5.1
EDI 8.6 PCB Electronical Component Location (PCB 88-1) 8.6.1
EDI 8.7 PCB Electronical Component Location (PCB 88-1) 8.7.1
EDI 8.8 PCB Electronical Component Location (PCB 88-2) 8.8.1
EDI 8.9 PCB Electronical Component Location (PCB 88-2) 8.9.1
Programming
PRG 9.1 Reset EEPROM 9.1.1
PRG 9.2 Set up Paper Size & Store into Operator Memory 9.2.1
PRG 9.3 Store Paper Size into Factory Memory 9.3.1
PRG 9.4 Retrieve Paper Size from Factory Memory 9.4.1
PRG 9.5 Increasing/Decreasing Software Time Delays 9.5.1
Fault Isolating Procedure
FIP 10.1 Diagnostic Component Control 10.1.1
FIP 10.2 Fault Isolating Procedure 10.2.1
Maintenance
MAI 11.1 Preventive Maintenance 11.1.1
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Stapler Folder Model 88 / 102 Page April 2002
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iii
left side rear side
front side
right side
left side
rear side
front side
right side
iii Direction of Model 88 / 102
This service manual cover both Model 88 and Model 102. The two models have the same
base design. Therefor many parts, components and adjustments are common. Where
nothing else is indicated throughout the manual, the instruction is common for the two
models.
Model 88
Model 102
Stapler Folder Model 88 / 102 Page April 2002
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iiii
In order to facilitate the service of the Model 88/102 there are a few special tools available.
iiii Special Tools
Hand crank generator.
Part no. 551249
ESD Ground strap.
Part no. 901044
Stapler Folder Model 88 / 102 Page April 2002
T08079
REMOVAL
Front and Rear Cover
1. Switch off the main power and disconnect the power cord.
2. Loosen the two screws (1) at bottom of cover.
CAUTION: There is a ground strap attached to the centre of the cover. Pull out bottom and
disconnect ground strap before lifting cover off.
3. Lift cover off.
REP 1.1 Front, Rear and Infeed Cover
Infeed CoverRemoval
1. Switch off the main power and disconnect the power cord.
2. Disconnect connection cables.
3. Loosen the two screws (2) at (Model 102).
4. Remove the two screws (3)
5. Pull out bottom and lift cover off.
INSTALLATION
Installation is an exact reversed procedure of removal.
1
3
2
1.1.1
Stapler Folder Model 88 / 102 Page April 2002
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REP 1.2 Lower and Upper Outfeed Cover
REMOVAL
Lower Outfeed Cover
1. Switch off the main power and disconnect the power cord.
2. Remove trimmer unit if any or belt stacker.
3. Loosen the two screws (1) at the bottom of cover.
4. Remove the two screws (2) at the surface of the cover
INSTALLATION
Installation is an exact reversed procedure of removal.
REMOVAL
Upper Outfeed Cover
1. Switch off the main power and disconnect the power cord.
2. Remove trimmer unit if any or belt stacker.
3. Remove the slide stay from the top cover.
4. Disconnect the exit sensor and remove the sensor wires from the cover.
5. Loosen the two screws holding the interlock switches and lift out the switches.
6. Remove the six screws (3) that are mounting the cover to the side frames.
INSTALLATION
1. Installation is an exact reversed procedure of removal.
2. Adjust the Outfeed sensor according to REP 3.4.
3. Adjust the interlock switches according to REP 3.17.
1
2
3 (x6)
1.2.1
Stapler Folder Model 88 / 102 Page April 2002
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REMOVAL
1. On the control panel, adjust the side guides to the widest position and the stop gate to
the middle position.
2. Switch off the main power and disconnect the power cord.
3. Remove front and rear cover according to REP 1.1.
4. Remove infeed module according to REP 2.1.
5. Remove the guide plates (2), note the location before removal.
6. Remove the six screws (1) along the sides of the deck plate.
7. Move the front ball cage guide to reveal the counter sunk screw (on Model 102).
Remove the screw.
8. Push down the stop gate and remove the deck plate through the fold area.
1.3.1
REP 1.3 Deck Plate
INSTALLATION
Installation is an exact reversed procedure of removal.
CAUTION: Tighten the screws with a matched screw driver so no burrs will arrise on the screw head.
Check for burrs and polish, using a very fine emery cloth, if needed.
1 (x6)
1
2
Stapler Folder Model 88 / 102 Page April 2002
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REP 2.1 Infeed Module
REMOVAL
1. On the control panel, adjust the side guides to the widest position.
2. Switch off the main power (1) and disconnect the power cord.
3. Remove the Infeed cover (2) according to REP 1.1.
4. Disconnect the three middle plugs under the infeed module (3).
5. Remove the idler roller shaft (4) by removing the screws on each end.
For Model 88 only: Remove idler paper path.
6. Remove the two screws (5).
7. Lift out the infeed module.
5
4
1
2
INSTALLATION
Installation is an exact reversed procedure of removal.
2.1.1
3
Stapler Folder Model 88 / 102 Page April 2002
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REP 2.2 Infeed Idler Arm Assembly
REMOVAL
1. From the control panel, select A3 (8.5”x17”) size.
2. Switch off the main power and disconnect the power cord.
3. Open the top cover.
4. Loosen the knobs (1).
4. Move stapler assemblies to the sides
5. Remove the two screws (2) and nuts and washers below.
6. Unhook the paper guide extensions (3) from the holes in the idler arm assembly.
7. Turn the idler arm assembly (4) over.
8. Disconnect the plug (5).
9. Remove the idler arm assembly (4).
INSTALLATION
Installation is an exact reversed procedure of removal.
CAUTION: Make sure the paper guide extensions (2) are properly seated in the holes of the idler arm
assembly.
2 34
5
2.2.1
1
Stapler Folder Model 88 / 102 Page April 2002
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REP 2.3 Stapler Assembly
REMOVAL
1. From the control panel, select A3 (8.5”x17”) size.
2. Switch off the main power and disconnect the power cord.
3. Remove the front and rear cover according to REP 1.1 and safety guard.
4. Remove the stapler heads.
5. Remove the stapler bar (1) by removing the screws on each end.
6. Remove bolts in each end of rod (2) from the outside of the side frames.
CAUTION: Do not loosen the red painted bolts.
7. Loosen the knobs (3) and move stapler assemblies to the sides to gain more slack in
the wires.
8. Tilt the whole assembly up and backwards to access the underside of the stapler
assemblies.
9. To remove the whole stapler assembly:
Remove bolts in each end of rod (4) from the outside of the side frames.
Note the position of the wires and disconnect.
1
2
4
INSTALLATION
Installation is an exact reversed procedure of removal.
2.3.1
3
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.1 Fold Position Adjustment Sensor SEN 1
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front cover according to REP 1.1 and safety guard.
3. Note position of connectors (1) and sensor orientation.
4. Disconnect the plugs from the sensor
5. Remove sensor by removing screws and nuts.
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Move sensor bracket (3) until 2mm gap between bottom of sensor and disc is
obtained.
2. Center the disc on motor shaft in sensor opening.
Loosen set screws (5) and move disc if necessary.
ARROW SHAPE
Short leg=Orange
Long leg=Black FLAT SHAPE
Short leg = Yellow
Long leg = Black
2
1
4
3
4
5
3.1.1
2 mm
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.2 Side Jogger Adjustment sensor SEN 2
ARROW SHAPE
Short leg=Orange
Long leg=Black FLAT SHAPE
Short leg = Yellow
Long leg = Black
4
5
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove Infeed cover according to REP 1.1.
3. Note position of connectors (1) and sensor orientation.
4. Loosen the screws (2) and remove sensor bracket (3)
5. Disconnect the plugs (1) from the sensor.
6. Remove sensor.
4
1
2
3
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Move sensor bracket (3) until 2mm gap between bottom of sensor and disc is
obtained.
2. Center the disc on motor shaft in sensor opening.
Loosen set screws (5) and move disc if necessar
3.2.1
2 mm
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.3 Back Jogger Adjustment sensor SEN 3
REMOVAL.
1. On the control panel, adjust the machine into A4 (8.5x11”) position and then adjust the
side guides to the widest position.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the infeed module according to REP 2.1.
4. Disconnect the drive O-ring.
Model 88
5. Loosen the four nuts holding infeed
paper path.
6. Carefully lift out paper path.
7. Note the orientation of connectors (1)
wire colours and sensor orientation/
markings.
8. Disconnect leads from sensor pins.
9. Remove the two screws (3) holding the
sensor bracket (4).
Model 102
5. Remove the four small shafts that the
infeed belt is routed around.
6. Loosen the four nuts holding bracket for
the whole carriage assembly.
7. Carefully pull out the whole assembly.
8. Note the orientation of connectors (1).
wire colours and sensor orientation/
markings.
9. Disconnect leads from sensor pins.
10. Remove the two screws holding the
sensor (2).
12 5 3 4
2
5
6
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. For Model 88 only (bracket for Model 102 is fixed):
Move bracket (4) until 2mm gap is obtained between bottom of sensor and disc (5).
2. Center the disc on motor shaft in sensor opening. Loosen set screws (6) and move
disc if necessary.
CAUTION: Ensure that the disc does not touch the sensor side.
ARROW SHAPE
Short leg=Orange
Long leg=Black
FLAT SHAPE
Short leg = Yellow
Long leg = Black
3.3.1
2 mm
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.4 Outfeed Sensor SEN 4
REMOVAL
LED
1. Switch off the main power and disconnect the power cord.
2. Disconnect and remove belt stacker or Trimmer if installed.
3. Remove the lower outfeed cover according to REP 1.2.
4. Remove the LED bracket (1).
5. Note the position of the wires and remove the plug.
6. Remove the LED.
1
2
Sensor
1. Switch off the main power and disconnect the power cord.
2. Disconnect and remove belt stacker or Trimmer if installed.
3. Remove the nut holding the sensor bracket and remove bracket.
4. Note the position and colour of the wires and remove the plug.
5. Remove the sensor.
INSTALLATION
Installation is an exact reversed procedure of removal.
Note: If the sensor is adjusted incorrectly or dirty, false trimmer jam can occur if a trimmer is
installed.
ADJUSTMENT
1. Remove the rear cover and pull out the interlock bypass switch.
2. Connect the power cord and switch on the main power switch.
If Trimmer is installed
3. Measure voltage between TP2 on
Trimmer PCB and common ground.
- With the sensor path clear >14 VDC
- With the sensor path blocked <1 VDC
If only Stacker is installed
3. Measure voltage between J1-18A and
common ground.
- With the sensor path clear <6 VDC
- With the sensor path blocked >8 VDC
3.4.1
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.5 Start Cycle Sensor SEN 5
REMOVAL
Sensor
1. Switch off the main power and disconnect the power cord.
2. Trace wires (1) to terminal block.
Note the position and the colour of the
wires and remove wires.
3. Remove screws (2) and remove the
sensor (3).
NOTE: If screws are unaccessable;
move carriage (MOT15) towards the outfeed
using the diagnostic component control
according to FIP 10.1 or using
the hand crank generator.
LED
1. Switch off the main power and disconnect
the power cord.
2. Remove the infeed module according to REP 3.10.
3. Open the top cover.
4. Move the stapler heads toward the side frames.
5. Hold the LED with a pair of pliers. Remove the screw and washer (4).
NOTE: If screws are unaccessable; move carriage (MOT15) towards the outfeed using the
diagnostic component control according to
FIP 10.1 or using the hand crank generator.
6. Disconnect wires from the LED and remove
LED from the bracket.
4
5
INSTALLATION
Installation is an exact reversed procedure of
removal.
ADJUSTMENT
1. Remove the rear cover and pull out the interlock bypass switch.
2. Connect the power cord and switch on the main power switch.
3. Measure voltage between J1-8C and common ground.
- With the sensor path clear <6 VDC
- With the sensor path blocked >8 VDC
3.5.1
1
2
3
MACHINE CYCLE
In order for the jogger action, stapling cycle etc. to proceed: Start cycle sensor must be
blocked and Infeed sensor clear.
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.6 Infeed Sensor SEN 6
ADJUSTMENT
1. Open the top cover.
2. Make sure the sensor actuator moves freely without binding.
3. Make sure the sensor actuator sticks up in the paper path enough to actuate the
sensor when sheets are passing.
Form the actuator bracket if necessary (on Model 88 only, for Model 102 the position is
fixed).
4. Remove the rear cover and pull out the interlock bypass switch.
5. Connect the power cord and switch on the main power switch.
6. Measure voltage between J1-12C and common ground.
- With the sensor clear <6 VDC
- With the sensor blocked >8 VDC
SEN 6
3.6.1
MACHINE CYCLE
In order for the jogger action, stapling cycle etc. to proceed: Start cycle sensor must be
blocked and Infeed sensor clear.
- If Infeed sensor is functioning: Start cycle sensor is blocked, machine waits for the Infeed
sensor to be cleared. When cleared; the jogger action, stapling cycle etc. will start.
- If Infeed sensor is faulty (always clear): The jogger action, stapling cycle etc. will start
immediatly when Start cycle sensor is blocked, resulting in the sets being stapled shingled.
- If Infeed sensor is faulty (always blocked): The paper jam indicator on the control panel
will come on after a few seconds.
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.7 Edge Stapling Sensor SEN14 Model 102
REMOVAL
1. Remove the infeed idler arm assembly according to REP 2.2.
2. Note the position of the sensor wires and remove the plug.
3. Remove the LED (1) by loosening the nut.
4. Remove the sensor by removing the sensor bracket opposite the LED.
NSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Remove the rear cover and pull out the interlock bypass switch.
2. Connect the power cord and switch on the main power switch.
3. Measure voltage between J1-8A and common ground.
- With the sensor clear <6 VDC
- With the sensor blocked >8 VDC
1
3.7.1
Stapler Folder Model 88 / 102 Page April 2002
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3.8.1
REP 3.8 Side Joggers Home Position Switch SW 1
REMOVAL
1. Remove the in feed module according to REP 2.1.
2. Remove switch by removing screws (1).
NOTE: Use tape to keep the nut plate in position, while changing the switch.
3. Transfer the leads from old switch to corresponding terminals on new switch.
NSTALLATION
Installation is an exact reversed procedure of removal.
JUSTMENT
1. Check the side jogger chanel centering according to REP 5.11.
Model 88
2. Adjust side jogger home switch so that
it actuates when there is a 40mm
distance between side jogger
(inbetween side jogger and mounting
block (2)) and side frame.
Model 102
2. Adjust side jogger home switch so that
it actuates when there is a 1mm
distance between side jogger (end of
long nuts fastening side guides) and
side frame.
3. Make sure the largest specified sheet size can be run. If not, adjust the switch to make
it possible without reaching mechanical stop.
4. If the switch position has been altered, the factory set paper sizes must be
reprogramed according to PRG 9.2 - 9.3.
2
1
Stapler Folder Model 88 / 102 Page April 2002
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3.9.1
REP 3.9 Side Joggers Limit Switches SW 2 and SW 3
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Access the underside of the stapler head assembly according to REP 2.3.
3. Unsolder wires and remove the switch (1).
INSTALLATION / ADJUSTMENT
1. Mount and solder new switch.
2. Fit stapler holders into place.
3. Make sure the smallest specified sheet size can be run. If not, adjust the switch
actuator screw on the side guide to make it possible without reaching mechanical stop.
1
Stapler Folder Model 88 / 102 Page April 2002
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3.10.1
REP 3.10 Side Jogger Motor off Switch SW 4
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front cover according to REP 1.1.
3. Note the position of inner/outer switch and remove screws (1) and lift out switches.
NOTE: Use tape to keep the nut plate in position, while changing the switch.
4. Transfer leads from old switch to the corresponding terminal on new switch.
INSTALLATION / ADJUSTMENT
1. Switch 4 should be placed inside the switch 5.
2. Rotate the jogger cam (2) clockwise until push rod is seated on cam lobe.
3. Adjust until switches is fully actuated but not bottomed out.
1 (x2)
2
Stapler Folder Model 88 / 102 Page April 2002
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3.11.1
REP 3.11 Stapler/Clincher Motor on Switch SW 5
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front cover according to REP 1.1.
3. Note the position of inner/outer switch and remove screws(1) and lift out switches.
NOTE: Use tape keep the nut plate in position, while changing the switch.
4. Transfer leads from old switch to the corresponding terminal on new switch.
INSTALLATION / ADJUSTMENT
1. Switch 5 should be placed outside the switch 4.
2. Rotate the jogger cam (2) clockwise until push rod is seated on cam lobe.
3. Adjust until switches is fully actuated but not bottomed out.
1 (x2)
2
Stapler Folder Model 88 / 102 Page April 2002
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3.12.1
REP 3.12 Stapler/Clincher Home Switch SW 6
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove infeed cover according to REP 1.1.
3. Remove the switch by removing the two screws (1).
NOTE: Use tape to keep the nut plate in position, while changing the switch.
4. Transfer the leads of old switch to corresponding terminal on new switch.
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Ensure that the actuated roller is near the center of the cam lobe.
2. Adjust until switches is fully actuated but not bottomed out.
3. Check the clincher timing according to REP 5.6.
1 (x2)
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.13 Registration Carriage Limit / Home Position SW 7 / 8
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front cover according to REP 1.1.
3. Remove the infeed cover according to REP 1.1.
NOTE: Use tape to keep the nut plate in position, while changing the switch.
4. Remove the old switch by removing the two screws (1 for the home position switch or
2 for the limit switch).
CAUTION: Always exchange one switch at a time, to prevent exchanging of switches position.
5. Transfer the leads from the old switch to corresponding terminal on new switch.
3 (x4) 2 (x2) 1 (x2)
Home position
switch SW 8
Limit switch
SW 7
NSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Loosen the motor bracket screws (3) to be able to move carriage to the limit or home
position. Or use the hand crank generator on the adjustment motor to move the
carriage to limit or home position.
CAUTION: Hold carriage while loosening the fourth screw.
2. Adjust with screw (1 or 2) until the switch is actuated 2-3 mm before mechanical end of
travel.
3. Make sure the largest and smallest specified sheet size can be run. If not, adjust the
switch to make it possible without reaching mechanical stop.
4. If the switch position has been altered, the factory set paper sizes must be
reprogramed according to PRG 9.2 - 9.3.
3.13.1
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.14 Fold Knife Home Position SW 9
REMOVAL
1. If a trimmer is installed, remove trimmer.
2. Switch off the main power switch and disconnect the power cord.
3. Remove lower outfeed cover according to REP 1.2.
4. Remove front cover according to REP 1.1.
5. Cut the cable-tie (1) from the wires.
6. Remove the two screws (2).
NOTE: Use tape to keep the nut plate in position, while changing the switch.
7. Lift out switch with wires, nut plate and switch spacer.
8. Note the position of the wires and exchange the switch.
1 2 (x2)
NSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Switch actuator arm should be placed in middle position of the switch.
2. With the knife in bottom position (against mechanical stop), there should be 0.1-1mm
play between switch arm and knife beam when switch arm is bottomed out.
NOTE: The knife cam follower is normally outside cam in home position which allows performing
the adjustment.
3.14.1
Stapler Folder Model 88 / 102 Page April 2002
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REP 3.15 Back Jogger Carrier Limit / Home Position SW 15 / 16
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove infeed cover according to REP 1.1.
NOTE: Use tape to keep the nut plate in position, while changing the switch.
3. Remove the bad switch by removing the two screws (1 for the home position switch or
2 for the limit switch).
CAUTION: Always exchange one switch at a time, to prevent exchanging of switches position.
4. Transfer the leads from the old switch to corresponding terminal on new switch.
12
ADJUSTMENT
Model 88
1. Adjust switch by screw (1 or 2) until
actuated when distance A is:
10-11mm Limit position
99-100mm Home position
2. Make sure the largest and smallest specified sheet size can be run. If not, adjust the
switch to make it possible without reaching mechanical stop.
3. If the switch position has been altered, the factory set paper sizes must be
reprogramed according to PRG 9.2 - 9.3.
Model 102
1. Adjust switch by screw (1 or 2) until
actuated 1-2mm form mechanical stop.
3.15.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 3.16 Staple Detection Switches SW 20 / 21
3.16.1
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Access the underside of the stapler assembly according to REP 2.3.
3. Note the position of the wires.
4. Unsolder wires (1).
5. Hold the switch (2) while removing screws.
INSTALLATION
1. Solder wires onto switch.
2. Fit stapler bracket into place.
1
2
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 3.17 Interlock Switches INTLK 1 / 2
2
3
1
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Open the top cover.
3. Cut the cable-tie (1) next to the interlock switch.
4. Loosen the two screws (2) and lift out the switches fitted into keyholes.
INSTALLATION
1. Connect jumper (3) to the middle pin of each switch.
2. Connect the black and white wire to the lower pin of each switch.
3. Mount the interlock switches into the keyholes and tighten the screws (2).
4. Remove rear cover according to REP 1.1.
5. Check the interlock function by measuring resistance between J1-18C and common
ground.
NOTE: Make sure the service switch is not pulled out when checking the interlock switches.
CAUTION: Main power should be switched off when checking the interlock switches.
There should be less than 0.5 ohms with the top cover closed.
There should be no contact (infinite resistance) when top cover is open.
3.17.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 3.18 Interlock Bypass Switch INTLK 3
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to REP 1.1.
3. Remove the two screws (1).
4. Note the position of the wires and disconnect and remove the switch.
1
INSTALLATION
Installation is an exact reversed procedure of removal.
3.18.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 4.1 Registration stop solenoid SOL 4
1
2
7
6
3
5
4
PURPOSE
To ensure the transport of the set from stapling to folding area by providing adequate eject
drive pressure.
REMOVAL.
1. Remove the infeed module according to REP 2.1.
2. Remove the front cover according to REP 1.1.
3. Loosen the four screws (1).
Push down motor bracket (2).
Slide the registration carriage to the left (towards the outfeed area).
4. Remove the deck plate according to REP 1.3.
5. Disconnect the spring (3).
6. Note the position of the wires at the rear of the solenoid.
CAUTION: Hold the solenoid body while removing the last screw.
7. Remove the four screws holding the solenoid to the bracket.
ADJUSTMENT
1. Install the solenoid.
2. Loosen screw (4) so the linkage (5) can move.
3. Use a 2mm feeler gauge or spacer between plunger washer and solenoid body.
4. Push down stop gate (6) completely and move linkage until O-rings touch the idler
roller.
5. Tighten the screw (4).
6. Install the spring (3).
7. Check for 0.5-1.5mm idler arm (7) deflection when solenoid is energized.
See FIP 10.1 how to energize the solenoid or push on the solenoid plunger.
4.1.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 4.2 Back Jogger Solenoid SOL 6
REMOVAL.
1. On the control panel, adjust the machine into A4 (8.5x11”) position and then adjust the
side guides to the widest position.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the in feed module according to REP 2.1.
4. Disconnect the drive O-ring.
Model 88
5. Loosen the four nuts holding infeed
paper path.
6. Carefully lift out paper path.
7. Disconnect spring (1) and transfer
leads (2) to new solenoid.
8. Remove old solenoid by removing the
two screws (3).
Model 102
5. Remove the four small shafts that the
infeed belt is routed around.
6. Loosen the four nuts holding bracket for
the whole carriage assmebly.
7. Carefully pull out the whole assembly.
8. Remove the screw securing plunger to
back jogger.
9. Disconnect spring (1) and transfer leads
(2) to new solenoid.
10. Remove old solenoid by removing the
two screws (3).
2
3
1
NOTE: The spring is
attached across the
solenoid on Model 102
INSTALLATION
Installation is an exact reversed procedure of removal.
ADJUSTMENT
1. Ensure the back jogger is against the stop.
For Model 102, place the shaft with the stop in position and ensure the back jogger is
against that stop.
2. Adjust solenoid body until there is 1-2mm clearence between body and plunger
washer, by loosen/tighten screws (3).
4.2.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 4.3 Edge Staple Stop Solenoid SOL 14 Model 102
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front cover according to REP 1.1.
Solenoid
3. Note the position of the wires and disconnect the plugs from the solenoid (5)
4. Remove the two screws (4) to remove solenoid (5).
Switch
3. Note the position of the wires and disconnect the plugs from the switch (3).
4. Remove the two screws (6) to remove switch (3).
INSTALLATION
Installation is an exact reversed procedure
of removal.
ADJUSTMENT
Edge staple stop height
1. Open the top cover.
2. Move stapler assemblies fully apart.
3. Make sure the stop finger height is even on both sides. Use the clincher housing as
refference while moving stop finger linkage up/down.
4. Loosen screw (1) on front and/or rear side and level shaft (2) until even height is
obtained.
5. Push down the plunger to the bottom position.
6. Make sure the stop fingers are about 1mm below the top surface of the clincher
housing.
7. Loosen screws (7) and move solenoid to obtain measurement.
Switch position
1. Adjust the switch (3) so it activates when there is 1-2mm between solenoid body and
plunger washer.
1
3
4
5
6
7
2
4.3.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 4.4 Edge Stapling Transport Solenoid SOL 18 Model 102
REMOVAL
1. Remove the infeed idler arm assembly according to REP 2.2.
2. Remove the solenoid (1) by removing the screws (2).
INSTALLATION / ADJUSTMENT
1. Mount the solenoid and fasten the screws (2) in the middle of the elongated holes.
2. Mount the idler arm assembly.
3. Make sure there is about 1mm clearence between solenoid body and plunger washer
when the idler rollers (3) contacts the infeed belt.
Fine adjust solenoid position with screws (2) if necessary.
1
23
4.4.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.1.1
REP 5.1 Fold Roller Drive Motor MOT 1
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove front cover and infeed cover according to REP 1.1.
3. Remove transformer cover.
4. Note the position of wires and disconnect motor leads at terminal block (1).
5. Remove safety guard.
6. Disengage the drive chain (2) from sprocket (3) on motor.
7. Remove the three screws (4) and lift out the motor.
8. Transfer sprocket to new motor.
INSTALLATION
Installation is an exact reversed procedure of removal.
1
2
3
4 (x3)
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.2 Lower Fold Roller and Ball Bearing
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1 and safety guard.
3. Remove the driver PCB.
4. Remove the chain (1).
5. Remove retaining ring (2).
NOTE: Use a screw driver as a lever between spring bracket (2) and bearing bracket to release
the spring tension.
6. Remove the tension arm assembly (4).
7. Remove the two chains (6).
8. Remove the two lower sprockets (5).
NOTE. There might be shim washers by the sprockets. Note their position and quantity for
installation.
Ball Bearings
9. Remove bearings.
Fold Rollers
9. Open the top cover.
10. Lift up (Remove for Model 88) the guide plate between lower and upper fold rollers.
11. Pull out the fold roller through the inside of the machine.
12. Remove the lower outfeed cover according to REP 1.2.
13. Pull out the other fold roller through the fold area of the machine.
INSTALLATION
Installation is an exact reversed procedure of removal.
1
2
3
6
5
4
5.2.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.3 Upper Fold roller Ball Bearing
1
24
3
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1 and safety guard.
3. Remove the driver PCB.
4. Remove the chain (1).
NOTE: Open the top cover and move the pressure knobs in the different positions to release/
unrelease the spring tension.
5. Remove the two upper sprockets (2).
6. Remove the tension arm assembly (3).
7. Remove the two chains (5).
8. Remove the two upper sprockets (4).
NOTE. There might be shim washers by the sprockets. Note their position and quantity for
installation.
9. Remove bearings.
5
INSTALLATION
Installation is an exact reversed procedure of removal.
5.3.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.4.1
REP 5.4 Stapler/Clincher Drive Motor MOT 2
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover and infeed cover according to REP 1.1.
3. Remove safety guard.
4. Loosen the three screws (1) and remove chain from sprocket.
5. Remove sprocket from motor.
6. Remove the transformer cover.
7. Note position of the wires and disconnect the motor leads at terminal block.
8. Remove screws(1) and lift out motor.
9. Transfer sprocket to new motor.
1 (x3)
INSTALLATION
1. Install the motor in reversed procedure of removal.
ADJUSTMENT
2. Adjust the motor so it is possible to move the chain 4-10 mm up or down when screws
are tightened.
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.5 Clincher assembly
REMOVAL
1. From the control panel, select A3/17” size.
2. Switch off the main power and disconnect the power cord.
3. Open the top cover.
4. Loosen the knob and move the stapler assmebly away from the clincher.
5. For Model 88 only: Ensure that the clincher position is marked with a scribed line (1).
6. Remove the two screws (2) while holding the clincher bracket (3).
7. Carefully lift out the bracket (3) with clincher.
Model 88
5. Install the clincher assembly aligned
with the scribe line and top surface of
the clincher bracket flush with the top
surface of the clincher beam.
Model 102
5. Install the clincher assembly so the top
surface of the clincher bracket is flush
with the top surface of the clincher beam.
6. Loosen set screw (4).
7. Tighten the screws (3) not harder than
making it possible to easilly slide the
clincher assembly throughout the width of
the clincher beam.
8. Secure the assembly with set screw (4).
MAINTENANCE
1. Remove the retaining plate.
2. Clean the components of the clincher.
3. Check for wear and burrs. If any sign of wear or burrs the clincher assembly must be
replaced.
4. Lubricate the components with thin oil.
CAUTION: Do not alter position of the clincher components.
123
4
INSTALLATION / ADJUSTMENT
5.5.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.6 Clincher Timing and height
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1 and safety guard.
3. Remove the infeed module according to REP 2.1.
ADJUSTMENT
1. Position the push rod (1) on top of the clincher cam lobe (2).
2. Make sure that crank elbow (4) and link arm (3) is in position as shown in figure on
both sides.
3. Adjust angle of crank elbow (4) if necessary.
12 34
4. With the push rod on cam lobe:
Check that clincher fingers are flush with the top surface of the clincher bracket
within 0.1mm.
5. Adjust the flushness by adjusting nuts (5).
1
5
5
6. With the link arm in home position (9):
Check that the switch actuator (6) is near the center
of the switch cam lobe (7).
7. Adjust by loosening the screws (8) and turn the
cam lobe (7) to correct position.
6
7
8
9
5.6.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.7 Stapler Compression
ADJUSTMENT
1. Open the top cover.
2. Make sure the stapler heads are properly installed.
3. Check with a feeler gauge in the cut through the elongated hole (1).
The clearance should read 0.5-0.7mm.
NOTE: The elongated hole is smaller than standard feeler gauges.
The feeler gauge may need to be modified.
4. Adjust on the nut (2) to obtain measurement.
2
1
Stapler head bracket
Plastic spring stop
(mounted behind the plate)
PURPOSE
The spring stop, stops the movement smoothly before the stop position for the stapler
head. If not correctly adjusted, the stapler head can wear out premature causing the
plastic post on the stapler head to break. This adjustment is in relation to the stapler
retraction lift bracket. If the lift bracket is deformed it causes the same symptom. The lift
bracket can be deformed if stapler head once has been installed incorrectly. Replace lift
bracket if deformed before proceding with this adjustment.
5.7.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.8.1
REP 5.8 Fold Knife Motor MOT 3
REMOVAL.
1. Switch off the main power switch and disconnect the power cord.
2. Remove front, rear and infeed cover according to REP 1.1.
3. Remove PCB drive board according to REP 7.2.
4. Move the fold roller motor (REP 5.1) to allow tilting the fold knife motor bracket. Do not
disconnect the leads, just move the motor towards the in feed side.
5. Locate the four bracket screws (1 and 2) outside of the side frames.
6. Remove the three upper screws (1) and loosen the lower (2) on front and rear side.
7. From the inside, remove screws securing motor bracket (3) to the frame bracket.
8. Note position of wires, disconnect motor leads and lift out motor and Cam assembly.
9. Loosen the clamp (4) and remove the Cam (5).
10. Remove motor from bracket.
INSTALLATION
1. Install the motor in reversed procedure of removal.
2. Ensure that the fold knife cam follower, situated on the fold knife, is seated in the
cam (5).
1
2
3
4
5
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.9.1
REP 5.9 Eject Motor and Drive O-ring MOT 5
REMOVAL.
1. Remove the infeed module according to REP 2.1.
2. Disconnect spring (1)
Cut cable-tie and disconnect the plug (2).
3. Disconnect the drive O-ring (3).
4. Loosen the lower two screws (5) holding the motor.
Rotate motor CCW and lift out motor (4) with pulley, fitted into keyholes.
INSTALLATION
Installation is an exact reversed procedure of removal.
13 52 4
CAUTION: Replace the drive O-ring if slightest evidence of wear or loss of friction. The O-ring is a
wear-out part. If the O-ring is worn thicker sets will not be ejected from the staple area.
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.10.1
REP 5.10 Side Jogger Drive Motor MOT 7
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear and infeed cover according to REP 1.1.
3. Disconnect the plug (1) from frame.
4. Remove the switch bracket by removing the two screws(2).
5. Raise the cam follower by tilting the plastic upper rocker arm of the assembly away
from side frame.
NOTE: Use a screwdriver to block tilt arm in this position as shown in figure.
6. Loosen the set screws (3) in cam holder and remove cam assembly.
7. Remove motor by removing the four screws.
CAUTION: Do not allow motor to fall into machine. Hold motor while removing last screws.
INSTALLATION
1. Mount the motor in the top position of the elongated holes.
2. Check the side jogger push rod centering according to REP 5.12.
CAUTION: Do not loosen the two screws in face plate
of cam assembly, otherwise cam timing relationship
will be lost. Loosen only the set screws (3) securing
the cam assembly to motor shaft.
If cam assembly has been tampered with replace the
complete cam assembly.
1
3
2 (x2)
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.11 Side Jogger Channel Centering
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the rear cover according to REP 1.1.
3. Remove the infeed module according to REP 2.1.
1
2
ADJUSTMENT
1. Measure the distance between side jogger bearing plate (1) to side frame on both
sides. The difference should be less than 1mm.
2. Loosen the gear by loosening set screw (2).
3. Rotate shaft to obtain measurement.
4. Tighten the set screw.
5. Follow the adjustment of the side jogger home position switch according to REP 3.8.
5.11.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.12 Side Jogger Push Rod Centering
REMOVAL
1. From the control panel, select A3/17” size.
2. Switch off the main power and disconnect the power cord.
3. Remove the front cover according to REP 1.1.
ADJUSTMENT
1. With the pushrod (1) on the cam lobe (2):
Measure the distance (5) from upper rocker arm (4) to edge of bracket (3).
2. Turn the pushrod (1) off the cam lobe (2):
Measure the distance (5) from lower rocker arm (4) to edge of bracket (3).
3. The difference between two measurements should not exceed 2mm.
4. Adjust the push rod block (6) by adjusting nuts (7) to obtain equal distance within 2mm.
5. Follow the adjustment of the side jogger home position switch according to REP 3.8.
1
2
34
5
5
4
4
6
7
7
1
5.12.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.13.1
REP 5.13 Infeed Belt Motor MOT 8
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove infeed cover according to REP 1.1.
3. Remove drive O-ring (1)
4. Remove the tension adjustment nuts and washers (2), while holding the motor.
5. Lift out motor and bracket (3).
6. Note the positions and disconnect wires at terminal block (4).
7. Remove motor from bracket.
INSTALLATION
1. Transfer pulley (5) to new motor.
2. Mount the pulley so the O-ring is aligned to the runner pulley. Use the smaller diameter
of the pulley.
3. Tension drive O-ring and tighten adjustment nuts. Ensure correct tension of the drive
O-ring.
NOTE: The infeed belt motor usually wears out too soon because the machine is left in manual mode
(where the motor continoulsy run).
Instruct the operator to press Auto (switching off the motor) on the front panel when not hand
feeding.
4 2 (x2) 3 5 1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 5.14 Fold Stop Gate Motor MOT 9 Model 102
REMOVAL
1. From the control panel, select A3/17” size.
2. Switch off the main power and disconnect the power cord.
3. Fold down the fold stop gate (5).
4. Remove screws (1) to remove motor assembly.
5. From PCB plug J3; remove white wire at pin 9 and blue wire at pin 10.
6. Note how the wires are routed and cut cable-tie to remove wires from the harness.
7. Remove crank elbow (3) from the motor.
8. Remove the three screws holding the motor (4) to the motor bracket.
1
23 4 5
INSTALLATION
1. Make sure the crank elbow (3) is hooked on to the shaft (2) before tightening
screws (1).
CAUTION: Go from smallest to largest paper size and make sure the wires do not get stretched
or interfear with moving parts.
5.14.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.15.1
REP 5.15 Fold Position Adjustment Motor MOT 15
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front and infeed cover according to REP 1.1.
Remove safety guard.
CAUTION: When loosening the screws the registration carriage comes loose and will slide
towards the outfeed. If sliding uncontrolled it could damage the limit and home position switch.
If damaged see REP 3.13.
3. Loosen the four screws (1) and slide the registration carriage towards the output area.
4. Disconnect the motor wires at the connector (2).
5. Hold the bracket and remove screws (1).
CAUTION: Do not allow motor to fall into machine. Hold motor while removing the last screw.
Avoid damaging the SOS sensor when removing motor from bracket.
6. Remove the gear (3) and remove motor from bracket.
ADJUSTMENT
1. When motor is installed in bracket, install gear 5.5 mm
from end of shaft as show in figure.
2. Before tightening the screws (1);
move carriage slightly towards the infeed,
push bracket up to engage the gear with gear rack,
do not push up so hard that the gear rack becoms bent.
3. Adjust sensor bracket (4) so there is a 2 mm gap between bottom of sensor and
disc (5) at rear end of motor.
2
1 (x4)
5
4
3
INSTALLATION
Installation is an exact reversed
procedure of removal.
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.16.1
REP 5.16 Fold Position Adjustment
PROCEDURE
1. Set the machine up for A3 (11”x17”).
NOTE: When the adjustments are completed, double check that the output quality remains for
A4 (8.5”x 11”) paper size. If not the fold stop gate could be uneven.
2. On the control panel, select manual mode [MAN].
3
ADJUSTMENT
NOTE: Before initiating the adjustment, make sure the paper is perfectly square (90°) and the oposite
edges are the exact same length.
Skew fold
1. Run a few sets.
2. Check that the fold is parallel to the lead edge of the set. If not perform Adjustment 1.
3. Place the stacker module in upright position
(if a trimmer is installed, remove trimmer).
4. Switch off the main power switch and disconnect the power cord.
5. Loosen the two mounting screws (2) on one side.
6. Rotate the adjustment screw (3) on the same side to adjust.
7. Tighten the two mounting screws (2).
8. Repeat this adjustment until the fold is parallel to the edge of the set.
Staples not centered in spine
1. Run a few sets.
2. Check that the staples are in the middle of the fold.
3. Loosen the locknut (1)
4. Rotate the setscrew (1) clockwise if the staples are located on the top.
Rotate the setscrew (1) counterclockwise if the staples are located on the bottom.
NOTE: Top of the booklet is the side that contacts the output wheel.
5. Tighten the locknut.
6. Repeat this adjustment until the staples are aligned with the fold.
1
2
Stapler Folder Model 88 / 102 Page April 2002
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5.17.1
REP 5.17 Back Jogger Adjustment Motor MOT 16
REMOVAL.
1. On the control panel, adjust the machine into A4 (8.5x11”) position and then adjust the
side guides to the widest position.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the in feed module according to REP 2.1.
4. Disconnect the drive O-ring.
INSTALLATION
1. Transfer disc assy and gear to new motor. Center the disc on motor shaft in sensor
opening.
ADJUSTMENT
2. Fit screws through carrier into motor housing.
3. Move carrier to enable gear to fit into gear rack, before tightening screws. Ensure
correct fitting of gear on adjustment motor into rack.
21
3
Model 88
5. Loosen the four nuts holding infeed
paper path.
6. Carefully lift out paper path.
7. Note position of connector, remove
cable-tie (1) and disconnect plug (2).
8. Remove the three screws holding
adjustment motor to carrier lift out
motor.
Model 102
5. Remove the four small shafts that the
infeed belt is routed around.
6. Loosen the four nuts holding bracket (3).
7. Carefully pull out the whole assembly.
8. Note position of connector, remove tie-
wrap (1) and disconnect plug (2).
9. Remove the three screws holding
adjustment motor to carrier lift out motor.
Stapler Folder Model 88 / 102 Page April 2002
T08079
5.18.1
REP 5.18 Side Jogger Adjustment Motor MOT 17
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front cover and infeed cover according to REP 1.1.
3. Disconnect the plug (1).
4. Loosen screw (2) two revolutions and remove sensor bracket (3). Note position of
connectors or make sure that wire connectors stays on sensor pins.
5. Remove screws (4) from front frame and remove motor.
CAUTION: Do not allow motor to fall into the machine.
INSTALLATION
1. Transfer components from old to new motor as required.
2. Center the disc on motor shaft in sensor opening.
Loosen set screws (5) and move disc if necessary.
CAUTION: Ensure that the disc does not touch the sensor side.
3. Adjust sensor bracket (REP 3.1)
ADJUSTMENT
4. Allow the motor to be hanging in the chain before tightening the screws (4), to get
correct chain tension.
1
2
3
4
5
ARROW SHAPE
Short leg = Orange
Long leg = Black
FLAT SHAPE
Short leg = Yellow
Long leg = Black
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 6.1 Infeed Drive O-ring
REMOVAL.
1. On the control panel, adjust the machine into A4 (8.5x11”) position and then adjust the
side guides to the widest position.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the infeed module according to REP 2.1.
4. Disconnect the drive O-ring.
Model 88
5. Loosen the four nuts holding infeed
paper path.
6. Carefully lift out paper path.
7. Remove the bracket to infeed idler rod,
turn paper path over and remove
bracket to infeed bearing (1) on front
side.
8. Remove O-ring.
Model 102
5. From the top of the paper path; remove
the two screws holding bracket (1).
6. Tilt the infeed shaft and remove O-ring.
12
INSTALLATION
Installation is an exact reversed procedure of removal.
6.1.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 6.2 Infeed Belt
REMOVAL.
1. On the control panel, adjust the machine into A4 (8.5x11”) position and then adjust the
side guides to the widest position.
2. Switch off the main power switch and disconnect the power cord.
3. Remove the infeed module according to REP 2.1.
4. Disconnect the drive O-ring.
Model 88
5. Loosen the four nuts holding infeed
paper path.
6. Carefully lift out paper path.
7. Push/pull the belt off the pulley (1) and
remove the infeed belt (2).
Model 102
5. Remove the four small shafts that the
infeed belt is routed around.
6. From the top of the paper path; remove
the two screws holding bracket (3).
7. Tilt the infeed shaft and remove the
Infeed belt (2).
INSTALLATION
Installation is an exact reversed procedure of removal.
1
2
3
6.2.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 6.3 Prefold Transport Belt
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove the front and rear cover according to REP 1.1 and safety guard.
3. Remove the infeed module according to REP 2.1.
4. Remove the driver PCB.
5. Mark the position of bracket (1).
Remove collar (2) and washer by loosening set screw.
6. Remove bracket (1) by removing the two screws (3).
7. Move ball cage (5) off the belts (also spring (4) on Model 88).
8. Remove the belts (6) as shown in the figure.
Roll the belts up around the shaft.
Remove belts through opening in the side frame (7).
1
3 (x2)
2
7
6
4
5
INSTALLATION
1. Install the belts with the black side out.
2. Make sure the tension is equal on both transport belts.
Adjust bracket (1) to obtain equal tension.
CAUTION: If the belts have become stiff it is very likely that the drive sprocket also has been
worn/damaged. In that case also replace sprocket.
6.3.1
Stapler Folder Model 88 / 102 Page April 2002
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7.1.1
REP 7.1 Logic Board PCB 88-1
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to REP 1.1.
3. Disconnect the plugs (1).
4. Remove the four screws (2) and carefully lift PCB to disengage from motor drive
board.
INSTALLATION
1. Install the board in reversed procedure of removal.
2. The Logic board is delivered without EPROM. If the old board has an up to date fully
functioning EPROM it can be moved from the old to the new board. If any dought
replace to a new EPROM. The first digit of the EPROM version must match.
Version 4.XX = Model 88
Version 5.XX = Model 102 to Model 100
Version 6.XX = Model 102 to Model 310
3. Reset EEPROM according to PRG 9.1.
4. Program the paper sizes according to PRG 9.2.
5. Store into factory set memory according to PRG 9.3.
CAUTION: Handle the logic PCB according to Electrostatic Discharge (ESD) procedures. The logic
board contains components that are susceptible to ESD damage.
NOTE: By replacing the Logic board all factory set paper sizes will be lost and must be
reprogrammed.
1
2 (x4)
Stapler Folder Model 88 / 102 Page April 2002
T08079
7.2.1
REP 7.2 Motor Drive Board PCB 88-2
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to REP 1.1.
3. Disconnect the plugs (1).
4. Remove the four screw (2) and carefully pull PCB down to disengage from logic board.
INSTALLATION
1. Installation is an exact reversed procedure as removal.
NOTE: Model 102 drive board is compatible with both Model 88 and Model 102. Model 88 drive board
is not compatible with Model 102. If the drive board is fully compatible it is labeled:
880245C-UL or greater.
1
2 (x4)
CAUTION: Handle the motor drive PCB according to Electrostatic Discharge (ESD) procedures. The
driver board contains components that are susceptible to ESD damage.
Stapler Folder Model 88 / 102 Page April 2002
T08079
REP 7.3 Communication PCB Model 102
REMOVAL
1. Switch off the main power switch and disconnect the power cord.
2. Remove rear cover according to REP 1.1.
3. Disconnect the plugs (1).
4. Remove the screws (2) holding the PCB, remove PCB.
INSTALLATION
1. See figures above:
Make sure both DIP switches are in off position (3).
Make sure that on the upper three pins there is a jumper on the two leftmost pins (4).
Make sure that on the right lower two pins there is a jumper (5).
CAUTION: Handle the PCB according to Electrostatic Discharge (ESD) procedures. The PCB
contains components that are susceptible to ESD damage.
12 (x4)
ON
12
7.3.1
3
4
5
Stapler Folder Model 88 / 102 Page April 2002
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7.4.1
REP 7.4 Control panel
REMOVAL
1. Switch off the main power and disconnect the power cord.
2. Remove front cover according to REP 1.1.
3. Disconnect the panel from the ribbon cable plug.
4. Remove the old panel. (When tearing off the panel it will be damaged).
INSTALLATION
1. Clean the panel bracket with alcohol cleaner and remove the protective film on the
back of new panel.
2. Place the panel centred on the panel bracket, and run the connector through opening
in the panel bracket.
3. Connect the panel to the ribbon cable plug.
CAUTION: Handle the front panel according to Electrostatic Discharge (ESD) procedures. The front
panel components that are susceptible to ESD damage.
T08079
Stapler Folder Model 88 / 102 Page April 20028.3.1
Stapler Folder Model 88 / 102 Page April 2002
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8.4.1
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Stapler Folder Model 88 / 102 Page April 20028.5.1
Stapler Folder Model 88 / 102 Page April 2002
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8.6.1
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Stapler Folder Model 88 / 102 Page April 20028.7.1
Stapler Folder Model 88 / 102 Page April 2002
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8.8.1
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Stapler Folder Model 88 / 102 Page April 2002
8.9.1
Stapler Folder Model 88 / 102 Page April 2002
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9.1.1
PRG 9.1 Reset EEPROM
PURPOSE
To initiate the EEPROM reset process in responce to major logic problems. The
procedure restores default machine cycle values.
CAUTION: If resetting the EEPROM all factory set paper sizes will be lost and must be
reprogrammed.
CAUTION: Handle the logic PCB according to Electrostatic Discharge (ESD) procedures. The logic
board contains components that are susceptible to ESD damage.
Before initiating the procedure make sure you have the following paper sizes, preferably
of 80 gsm or 20 pound bond.:
Model 102 (metric)
100 x A3
150 x A4
100 x A5
Model 102 (inch)
100 x 11x17”
100 x 8.5x14”
150 x 8.5x11”
100 x 5.5x8.5”
Model 88 (metric)
100 x A3
100 x A4
Model 88 (inch)
100 x 11x17”
100 x 8.5x14”
100 x 8.5x11”
PROCEDURE
1. Switch on the power.
2. Remove cover according to REP 1.1.
2. Slide switch [F] and switch [T] to the far right position.
3. Press and release the [Reset] switch.
NOTE: All the control panel indicator LEDs will come on and go off.
4. Slide switch [F] and switch [T] back to the far left position.
5. Press and release the [Reset] switch.
NOTE: On the control panel only the [MAN] indicator LED will come on.
6. Set up and store a paper size into operator memory according to PRG 9.2.
Store the paper size into the factory memory according to PRG 9.3.
Repeat step 6 for each paper size to be programmed.
Reset
Switch F
Switch T
Stapler Folder Model 88 / 102 Page April 2002
T08079
9.2.1
PRG 9.2 Set up Paper Size & Store into Operator Memory
Procedure
1. Press the Staple/fold button or Edge/Corner staple button, which ever to be set up.
2. Press a paper size button, which ever to be set up.
3. Press the [+/-] button.
4. Open the top cover.
5. Adjust the side joggers to the scale mark for the paper size selected.
Press or pulse side jogger button to adjust.
6. Adjust the back jogger slightly larger than the scale mark for the paper size selected.
Press or pulse back jogger button to adjust.
7. Adjust the registration carriage to the far left position or large enough for the paper
size selected.
Press or pulse registration carriage button to adjust.
or
NOTE: Paper is used as reference in this procedure. Therefor it is important that the paper quality
is good and that the paper size tolerances are kept at a minimum. Paper weight should preferably
be 80 gsm or 20 pound bond.
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.2 Set up Paper Size & Store...
8. Feed a 4-sheet set into the machine.
NOTE: When the set reaches the registration stop, the side joggers and back jogger will
start cycling.
9. Adjust the registration position so top of the set is at the scale mark for the paper size
selected.
Press or pulse registration carriage button to adjust.
10. Adjust the back jogger so there is 1mm clearence between trail edge of the set and
back jogger.
Press or pulse back jogger button to adjust.
11. Adjust the side joggers so they touch the sides of the set without buckle the set.
Press or pulse side jogger button to adjust.
12. Press the memory button.
NOTE: The paper size selected is now stored into the operator memory. It can be verified by
retrieving the paper size by pressing the paper size button (and booklet mode button) when
top cover is closed.
13. Close the top cover.
NOTE: The set will be processed through the machine.
14. Hand feed five test sets of 4-sheets through machine.
15. Check the test sets by placing them on a flat surface and make sure:
- The fold is centered, edges aligned
- The sheets are jogged together length and side ways.
- There are no marks from the back jogger or side joggers.
16. Fine adjust if necessary according to following:
a) Press the [+/-] button.
b) Open the top cover:
c) Feed a 4-sheet set into the machine.
d) Perform necessary adjustments.
e) Repeat step 12 through 16 until perfect result.
Note: If any of the limit or home position switches are actuated the paper size will not be stored
into the memory.
Check/adjust limit or home position switches according to: REP 3.8 (side jogger home), REP 3.9
(side jogger limit), REP 3.13 (registration carriage) or REP 3.15 (back jogger) if necessary.
9.2.2
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.3 Store Paper Size into Factory Memory
The following paper sizes should be stored into the factory memory.
Model 102 (metric)
A3 Staple/Fold
A4 Staple/Fold
A5 Staple/Fold
A4 Edge staple
Model 102 (inch)
11x17” Staple/Fold
8.5x14” Staple/Fold
8.5x11” Staple/Fold
5.5x8.5” Staple/Fold
8.5x11” Edge staple
Model 88 (metric)
A3 Staple/Fold
A4 Staple/Fold
Model 88 (inch)
11x17” Staple/Fold
8.5x14” Staple/Fold
8.5x11” Staple/Fold
Switch F
Reset
PROCEDURE
1. Make sure paper size to be stored is selected on the control panel.
2. Press the [+/-] button on the control panel.
3. Slide switch [F] to the far right position.
NOTE: The red control panel indicator LEDs will come on and go off.
4. Slide switch [F] back to the far left position.
5. Press and release the [Reset] switch.
NOTE: The paper size selected is now stored into the factory memory. It can be verified by
retrieving the paper size according to PRG 9.4.
6. Repeat this procedure for each paper size to be stored into the factory memory.
9.3.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.4 Retrieve Paper Size from Factory Memory
PROCEDURE
1. Switch on the power.
2. Press and hold the paper size button for the paper size to be retrieved from the factory
memory.
3. Hold the button until the corresponding indicator LED goes out and comes on again.
4. Release the paper size button.
5. Select booklet making mode.
NOTE: The paper size programmed in the factory memory will be retrieved for the selected
paper size.
or
9.4.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.5 Increasing/Decreasing Software Time Delays
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dna, 5NES, r osnese l c yct r a tSeh t f ogn i z i g r eneeh tneewt ebya l edehT . 7TOM, r o t omev i r dr eggo jed i Seh t f ot r a t seh t 1ce s0 , 0
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t r a t seh tdnade r ae l cs i , 4NES, r osnesl l u fdee f t uOeh tneew t ebya l edehT .11TOM, rotomrekcatSehtfo 4ce s4 , 0
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34 . 4no i s r ev88l edoMr oF*
PURPOSE
To allow adjustment of the machine cycle time delays, within the stapler/folder software, in
order to compensate for variable times of the mechanical sub assemblies to the logic
program. This can be used to increase the reliability when nonstandard configurations are
used.
PROCEDURE
1. Remove the rear cover according to REP 1.1.
2. Swith on the power
3. Pull out the Interlock bypass switch
4. Slide switch [T] to the far right position.
5. See table 1 below. Locate the description of the Delay function to be adjusted and note
associated function number.
NOTE: Remove the rear cover and locate lable attached on the side frame explaining delays for
installed program version. The “original time” shown in the table below might vary between different
program versions.
9.5.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.5 Increasing/Decreasing Software Time Delays (Cont.)
no i t cnu fegnahcemi Tno i t cnuF r e bmu N
emi tya l edeh tesae r cn I1
emi tya l edeh tesae r ceD2
emi tlanigi rootnruteR3
6. Locate the Control button with the function number. Press the button in order to enter
the programmable memory of the time delay.
7. See table below. Locate the time change function which is required. Note associated
function number.
8. Find the control panel button with the function number. Press the button in order to
change time delay. Each time one of the buttons are pressed, the delay time is
changed with 0.01 sec.
9.5.2
1
2
3
4
5
6
321
Stapler Folder Model 88 / 102 Page April 2002
T08079
PRG 9.5 Increasing/Decreasing Software Time Delays (Cont.)
NOTE: If the return to original value button is pressed, the manual and auto indicator LED´s will
come on. If the time delay period is increased or decreased, the total time delay increase or decrease
can be calculated.
The control panel LED´s will come on in a sequence which indicates the total selected delay in a
binary code. Add the iluminated LEDs for the total time delay.
After the binary count reaches 32 x 0,01 second, the LED display sequence will repeat and the 1 x
0,01 second LED will remain on as a reminder that the count has cycled once. During the second
cycle, the displayed binary value must be added to the original maximum count of 32 x 0.01 second.
The location and value assigned to each LED is shown below.
100
1SEC
100
2SEC
100
8SEC
100
4SEC
100
16 SEC
100
32 SEC
9. After approprate time delay period is entered;
slide switch [T] to the far left position.
10. Press the [Reset] switch. The new time delay period is entered into the memory. The
machine will initialize and go back to the normal operating mode.
9.5.3
Stapler Folder Model 88 / 102 Page April 2002
T08079
FIP 10.1 Diagnostic Component Control
emant nenopmoCedoCemant nenopmoCedoC
) no i t a t o rB( 71TOM, r o t omt nemt su j dAr eggo jed i SB71M)H( ; r e t emt nuocypocl aunaM41S
) no i t a t o rF (61TOM, r o t omt nemt su j dAr eggo jkcaBF61M6LOS, d i one l osr eggo jkcaB6S
) no i t a t o rB(51TOM, r o t omno i t i sopd l oFB51M4LOS, ed i one l ospo t sno i t a r t s i geR4S
) no i t a t o rF (71TOM, r o t omt nemt su j dar eggo jed i SF7 1M
) no i t a t o rB(61TOM, r o t omt nemt su j dAr eggo jkcaBB6 1M
) no i t a t o rF (51TOM, r o t omno i t i sopd l oFF5 1M
11TOM, rotomrekcatS11M
8TOM, r o t omt l ebdee f n I8M
7TOM, r o t omev i r dr eggo jed i S7M
5 T OM , r o t o m t c e j E5M
3TOM, rotomef inkdloF3M
2TOM, rotomevi rdrehcni lC/ relpatS2M
1TOM, rotomevi rdre l lord loF1M
PURPOSE
This feature allows the energizing of each motor and soleniod for diagnostical purpose.
The feature can be used when trouble shooting supposebly faulty motors and solenoids
with associated assemblies and subsystem. The feature can also be used to move
assemblies and simulate functions. When performing the diagnostic component control the
logic PCB is overridden but the motor drive PCB is in use.
WARNING: When doing the diagnostic comopnent control procedure, be sure to stay clear of all
mechanical assemblies in order to avoid personal injury. Sudden mechanical movements may occur
when electromechanical components are energized.
PROCEDUR
1. Switch on the power.
2. Pull out the interlock bypass switch, INTLK 3.
3. Locate the connector J4 on PCB PL88-1.
4. Connect a jumper to the pin marked with an inverted common ground symbol.
CAUTION: Do not allow free end of wire to contact any machine surface or pins other than
intended, to prevennt damage to the Machine components.
5. See table below. Locate the code for the component to be checked.
6. On connector J4, locate the pin labeled with that code.
7. Make a brief contact on that pin with the other end of the jumper wire.
NOTE: The component will energize immediatly upon contact and stay energized until
jumper is removed from the pin.
NOTE: Reversing motors are
listed twice, once per direction:
B=Backward, F=Forward.
CAUTION: When energizing a component with a
jumper wire, home- and limit position switches are
overridden. Do not run motors to their mechanical
stops as it may cause damage to the machine.
10.1.1
T08079
Stapler Folder Model 88 / 102 Page April 2002
FIP 10.2 Fault Isolating Procedure cont.
NOTE: During the time that the machine is setting the Paper size (indicated by flashing paper size LED’s) the Stapler/folder will ignore any attempt to
clear a jam before the size setting is complete.
If Top cover is open during the size setting, the Paper size setting will stop and the Stapler/folder has to be switched off and then back on again and
papersize has to be reselected. This is to prevent any missettings of the paper sizes.
After approximately 25 seconds the setting is completed and the LED’s on the Front panel will have a solid light.
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10.2.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
FIP 10.2 Fault Isolating Procedure cont.
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10.2.2
T08079
Stapler Folder Model 88 / 102 Page April 2002
FIP 10.2 Fault Isolating Procedure cont.
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. t f ahsnoeso lye l l uP 1 . 1 1r o6 . 5PERo t . c c ae c a l p e R / t s u j d A
. ye l l upnosp i l st l ebev i rD 6 . 5PERo t . c c an o i t i s o p r o t omt s u j dA
. de t cennocy l r epo r pt onse r i wr o t oM . kco l bl an imr e to t r o t omt cennocdnakcehC
.evi tcefedrotoM eca l peR. 1 . 01P I Fo t . ccar o t omkcehC .evi tcefedf i31.5PERot.cca
eh to t n ide fneebsaht esA . redlof / relpatS eh to t n ide fs i t esehT eh t t aspo t st ubr ed l o f / r e l pa t S s ign i ggo joN. e t agno i t a r t s i geR . enod
oddnas r eggo jed i Snokcu t ss i t eS . r osnesno i t a r t s i ge r t eSeh thcae r t on o t t su j dA. wo r r anoo tno i t i sops r eggo jed i S . 2 . 9GRPo tccano i t i sopr ed i w
eh tde r ae l ct onsaht esf odner aeR . 6NESr osnesdee f n i ynamo r fs r eggo jed i Seh t r ae l C sas r eggo jed i St su j dar o / dnase l ca t sbo . evoba
r oev i t ce f eds i6NESr osnesdee f n I . de t su j das im 6 . 3PERo t . ccar osnest ah tkcehC
.del iafDELelcyct ratS kcehC. t hg i lde rgn i t t imes iDELf ikcehC . ppA. dnuo r gnommoco tA6 - 2Jmo r fega t l ov CDV82. ppA. KOs iDELsnaemCDV2 .ma r ga i dgn i r i weeS. ev i t ce f edDELsnaem
. de l i a f5NESr osnese l c yct r a t S.5 . 3PERo t . ccar osneskcehC
10.2.3
Stapler Folder Model 88 / 102 Page April 2002
T08079
FIP 10.2 Fault Isolating Procedure cont.
NO I T AREPOFOECNEUQESTLUAFDEVRESBOESUACELB I SSOPRI APER/ GN I TALOS I T LUAF
. deggo js i t eS sdaehr e l pa t Sdnas r eggo jed i S . y l suoun i t nocnu r ) 4WS(hc t i wsf f or eggo jed i S .evi tcefed . 0 1 . 3PERo t . c c ah c t i wse c a l p eR
. de l pa t St ont ubdeggo js i t eS . ) nesohcs ign i l pa tS( )5WS(hc t iwsnorotomre lpatS .evi tcefed . 1 1 . 3PERo t . c c ah c t i w se c a l p eR
.delpatSsiteS . y l suoun i t nocnu rsdaehe l pa t S)6WS (h c t i w semo h r o t omr e l p a t S .evi tcefed . 2 1 . 3PERo t c c ah c t i wse c a l p eR
t eSeh tevae l t onseodt eS . no i t i sopno i t a r t s i ge r d i one l oS / d i one l ospo t sno i t a r t s i geR . de l i a fegakn i l .1.4PERot.ccadionelostsujdA/ecalpeR
ronekorbgni r -Oevi rdrotomtce jE . t u on r ow . 9 . 5PERo t . c c ag n i r - Oe c a l p eR
.evi tcefedrotomtcejE .9.5PERot.ccarotomtsujdA/ecalpeR
n idemma j r e l pa t Sdemr o f eD y l b i ssopr ehcn i l cr odaehr e l pa t S n i t ondaehr e l pa t Sybdesuac . no i t i sopt ce r r oc
o t . ccar ed l oHmo r fdaehr e l pa tSt uot f i L , e l pa t Sdemma jevome r , l aunamr o t a r epO l l a t sn i e rdnano i t cnu fdaehr e l pa t Skcehc daehr e l pa t Seh t t ah tkcehC. daehr e l pa t S dnas r ehcn i l ceh to tdeno i t i sopy l t ce r r ocs i . dene t hg i te r aswe r csbmuh teh t t ah t
r ewo ln isppo t ssdaehr e l pa t S r e l pa t seh ty l b i ssoP. no i t i sop . l l ewsat ekco rpseh tspmu jn i ahc
. s r r ubevahr oy r ds r ehcn i lC n i h th t i wde t ac i r bu lebd l uohcs r ehcn i l cehT kcehC. se l c yc00002y r evet sae l t al i o . 5 . 5PERo t . c c as r e h c n i l c
.t ubae r ar e l pa t Seh tsevae l t eS no i t i sopd l oFhcae r t onseod s i r o t omt r opsna r t r epaP. y l t ce r r oc . gn i nnu r
r oneko r bs t l ebt r opsna r td l o f e rP . n r ow . 3 . 6PERo t . c c as t l e be c a l p eR
r o t omt r opsna r t r epaPnot ekco r pS .evi tcefed/esol n iswe r csne t hg i T / t ekco r pSeca l peR . t e k c o r pS
noeso ls ye l l upt l ebt r opsna r td l o f e rP . t f ahs . s ye l l upeca l peR/ swe r csne t hg i T
10.2.4
T08079
Stapler Folder Model 88 / 102 Page April 2002
FIP 10.2 Fault Isolating Procedure cont.
NO I T AREPOFOECNEUQESTLUAFDEVRESBOESUACELB I SSOPRI APER/ GN I TALOS I T LUAF
. no i t i sopd l oFsehcae r t eS r o t omd l oFnehws l i a f ) 1F (es uF .st rats . esuFf oepy t t ce r r ocn I . esuFwo l bwo lSA61h t i wesuFeca l peR
.dedloFsiteS .etatortonseodrel lordloFA.r e l l o rnoeso l t ekco r pSeca l peR / t ekco r psn iswe r csne t hg i T . t ekco r ps
. rekca t st l eBeh to t tuode fs i t eS . es i g r enet onseodr ekca t st l eBti nun i amo tde t cennoct ongu l pNID .er iwnekorbro . e r i w / gu l pN IDr i ape r / t cennoC
OTDETALERTONST LUAF . ECNEUQESGN I T AREPO emoct onseodr o t ac i dn i r e l pa tS . gn i ss ime r ase l pa t snehwno n ihc t i wsno i t ce t edgn i ss ime l pa t S . no i t i sopde l bas i d o t . ccano i t i sopde l baneo thc t i wsed i l S . l aunamr o t a r epO
dnadaehr e l pa t sn idemma j r e l pa t S r ehcn i lCh t iwt ca t nocsekam . t eshcaehguo r h tse i l bmessa
r e l pa t Smo r fdaehr e l pa t sdemma jevomeR dnano i t cnu fdaehr e l pa t SkcehC. t ekca r b o t . ccano i t i sopt ekca r bdaehr e l pa t S 5 . 5PERr o / dnal aunamr o t a r epO
. ev i t ce f edhc t i wsno i t ce t edr e l pa t S e l pa tSeh tgn i t cennocybhc t iwskcehC gn i r udema r fen i hcamo tdae lno i t ce t ed sehc t i wsno i t ce t edr e l pa t Seca l peR. gn i l pa t s . 6 1 . 3PERo t . c c a
sdaehr e l pa t snot sopc i t sa l P . y l t neuqe r fskae r b o teuddemr o f edt ekca r bt f i l r e l pa t S . y l t ce r r ocn ide l l a t sn isdaehr e l pa t s . t ekca r bt f i l r e l pa t seca l peR o t . ccano i sse r pmocr e l pa t skcehC . daehr e l pa t seca l peR. 7 . 5. PER
10.2.5
Stapler Folder Model 88 / 102 Page April 2002
T08079
MAI 11.1 Preventive Maintenance Model 88
Service interval: 250 000
NOTE: All instructions are refering to the stapler/folder model 88-102 Service Manual.
The reference colum is refering to the Spare Parts Manual.
CAUTION: If any of the checkpoints or other parts show indication of wear at any point, replace the
part. When lubricating, clean the surface if necessary before applying new lubricant.
T N I O PK C E H CNO I TCURT SN IECNEREFER000052000005
r epaP, en i hcaMl l A .cteshtap dnas l ewo t , r enae l cmuucavaesU mo r fen i hcameh tnae l co tsehsu r b nae l co t l ohoc l anaesU. t sudr epap . k n imo r f
nae lCnae lC
sehc t iwskco l r e t n Itsu j dA. sehc t i wseh t f ono i t cnu fkcehC . 7 1 . 3PERo t g n i d r o c c a j dA / k c e hCjdA / k c e hC
n i ahcev i r dr e l pa tSfi , r aewr o fkcehC. l i on i ahcy l ppA eca l pe rsyawl A. eca l pe rdehc t e r t s / n row . 0000001t a
94 . 1egaP 2 1m e t I liOliO
daehr e l pa t S y l bme s s a esae r gy l ppA. daehr e l pa t seh tevomeR eh tdnan i ped i ugev i r dr e l pa t sno . yssat ekca rbt f i l re l pa tS
52 . 1egaP 1m e t I eca l peRec a l peR
do rhsupr e l pa tS.do rhsupr e l pa tSnoesae r gy l ppA72 . 1egaP 1m e t I esae rGesae rG
do rhsupr ehcn i lC.do rhsupr ehcn i l Cnoesae r gy l ppA72 . 1egaP 9m e t I esae rGesae rG
y l bmessar ehcn i lC-sar ehcn i l Chcaen i l i of opo r day l ppA y l bmessar ehcn i l ceh tevomeR. y l bmes gn i nae l cro fr ehcn i l ceh te l t nams i ddna r ehcn i l ceh t t ah tkcehC. 000005y r eve . 5 . 5PERo tgn i d r occade t nuome r a
92 . 1egaP 9&7&4me t I k c e hC / l i Okc e hC / l i O
emohr ehcn i lC/ r e l pa tS ) 6W S ( h c t i w s t su j dA. hc t iwseh t f ono i t cnu fkcehC . 2 1 . 3PERo t g n i d r o c c a 52 . 1egaP 4 1m e t I j dA / k c e hCjdA / k c e hC
r osnese l c yct r a tS ) 5NE S ( gn i d r occat su j dA. r i adesse r pmocesU 5 . 3PERo t 13 . 1egaP 4m e t I j dA / nae lCjdA / nae lC
- t su j dano i t i sopd l oF ) 1NES ( r osnest nem gn i d r occat su j dA. r i adesse r pmocesU . 1 . 3PERo t 13 . 1egaP 7m e t I j dA / nae l CjdA / nae l C
no i t i sopd l oF r o t omt n em t s u j d a ) 5 1 T OM (
. kca r r aegdnar aegnoesae r gy l ppA PERo tgn i d r occat nemt su j dakcehC .51.5
13 . 1egaP 2m e t I esae rG
t l ebt r opsna r td l o f - e rPlohoc l ar o t av i t cae r r ebbu rah t i wnae lC dnaf f i t ss i t l ebt r opsna r teh t f I . d i u l f dlof -erPehtecalper, yl roopsetator . 3 . 6PERo tgn i d r occat l ebt r opsna r t
73 . 1egaP 6m e t I nae lCec a l peR
tekcorpSt lebd lof -erPeca l peR. t ekco r psnol i on i ahcy l ppA t r opsna r td l o f - e rPeh tnehwt ekco r pseh t . deca l pe rs i t l eb
74 . 1egaP 2m e t I liOec a l peR
r eppur e l l oRd l oFotd i u l f l ohoc l ar o t av i t cae r r ebbu raesU .knimor fsrel lordlofehtnaelc 54 . 1egaP 8m e t I nae lCnae lC
r eno i sne t r e l l o rd l oF ) r ewo l ( ed i l Sdnaema r Fneew t ebesae r gy l ppA . )X4 ( . gn i suoh 34 . 1egaP &2& 1m e t I 4&3
esae rG
niahCevi rddloFnr owf i , r aewr o fkcehC. l i on i ahcy l ppA . 0000001t aeca l pe rs yaw l A. eca l pe r 74 . 1egaP 5m e t I liOliO
11.1.1
Stapler Folder Model 88 / 102 Page April 2002
T08079
MAI 11.1 Preventive Maintenance Model 88 cont.
T N I O PK C E H CNO I TCURT SN IECNEREFER000052000005
niahcevi rdrel lordloF ) ed i st no r F ( r eno i sne t dnal eehwr e l d ineewt ebesae r gy l ppA . eca l pe rn r owf i , r aewr o fkcehC. t f ahs y r eves l eehwr e l d i ) 3 (ee r h teh teca l peR . 0000001
74egaP 1m e t I esae rGesae rG
niahcreldirel lordloF ) ed i sr aeR( r eno i sne t dnal eehwr e l d ineew t ebesae r gy l ppA . eca l pe rn r owf i , r aewr o fkcehC. t f ahs y r eves l eehwr e l d i ) 2 (owteh teca l peR . 0000001
94 . 1egaP 4m e t I esae rGesae rG
emohe f i nkd l oF ) 9WS (hc t i wsno i t i sop t su j dA. hc t i wsf ono i t cnu fkcehC . 4 1 . 3PERo t g n i d r o c c a j dA / k c e hCjdA / k c e hC
r osnesdee f t uOros - neseh tnae l co t r i adesse r pmocesU eh tnae l co t l ohoc l anaesU.DELdna eh t t su j dA. kn imo r f t ekca r bdee f t uo . 4 . 3PERo tgn i d r occar osnes
j dA / nae l CjdA / nae l C
t l ebt r opsna r t t up t uOlohoc l ar o t av i t cae r r ebbu rah t i wnae l C .diul f 35 . 1egaP 2 1m e t I nae lCnae lC
f f or o t omr eggo jed i S ) 4W S ( h c t i w s t su j dA. hc t i wseh t f ono i t cnu fkcehC . 0 1 . 3PERo t g n i d r o c c a me t I 51 . 1egaP 01 j dA / k c e hCjdA / k c e hC
rotomrehcni lC/ re lpatS ) 5W S ( h c t i w s n o t su j dA. hc t i wseh t f ono i t cnu fkcehC . 1 1 . 3PERo t g n i d r o c c a 51 . 1egaP 0 1m e t I j dA / k c e hCjdA / k c e hC
d e v ome r e l u d omd e e f n I
t amr o f r eggo jed i S ms i nahcem eh t f ot r apdedae r h teh tnoesae r gy l ppA . gn i hsubdegna l feh tnol i oesU. t f ahs 91 . 1egaP 3m e t I l i O/ esae rGliO/ esae rG
n i ahcr eggo jed i S y l bme s s a n r owf i , r aewr o fkcehC. l i on i ahcy l ppA . eca l pe r 91 . 1egaP 8m e t I esae rGesae rG
l ennahcr eggo jed i S gn i r e t nec kcehcdnas r aeg3eh tnoesae r gy l ppA . 1 1 . 5PERo t g n i d r o c c a t n em t s u j d a 91 . 1egaP 5 1m e t I esae rGesae rG
do rhsupr eggo jed i S gn i r e t nec hsupr eggo jed i Sneewt ebesae r gy l ppA kcehc, gn i hsubdegna l fdnado r 2 1 . 5PERo t g n i d r o c c a t n em t s u j d a
71 . 1egaP 3m e t I esae rGesae rG
ms i l e l l a r aped i uged i S.l e l l a r ape r ased i uged i seh t t ah tkcehC . y r assecenf i t su j dA kcehCkc e hC
- t su j dar eggo jed i S ) 2NES( r osnest nem o tgn i d r occat su j dA. r i adesse r pmocesU . 2 . 3PER 91 . 1egaP 0 1m e t I j dA / nae lCjdA / nae l C
t l ebt r opsna r tdee f n Ilohoc l ar o t av i t cae r r ebbu rah t i wnae l C ,eca lper,nrowf I. raewrofkcehC.di u l f . 2 . 6PERo t g i d r o c c a
7 . 1egaP 7 1m e t I l iO/ nae l CliO/ nae l C
gn i r -Or o t omdee f n Ilohoc l ar o t a v i t cae rr ebbu rah t i wnae l C , t es000005y r eveeca l peR. d i u l f . 1 . 6PERo t g n i d r o c c a
9 . 1egaP 5m e t I nae lCec a l peR
) 6NES( r osnesdee f n I.r osneseh tnae l co t r i adesse r pmocesU31 . 1egaP 6 1m e t I j dA / nae lCjdA / nae l C
r osnesr eggo jkcaB ) 3NE S ( . r osneseh tnae l co t r i adesse r pmocesU . 3 . 3PERo t g n i d r o c c a t s u j dA 31 . 1egaP 1 1m e t I j dA / nae l CjdA / nae l C
d i one l osr eggo jkcaB ) 6L OS ( eca l peR. eca l pe rn r owf i , r aewr o fkcehC . 2 . 4PERo tcca, 0000001y r eve 31 . 1egaP 4 1m e t I - eR / k c e hC eca l p
- ono i t ca r tev i r dt ce j E gn i r . d i u l f l ohoc l ar o t av i t cae r r ebbu raesU 000005y r evegn i r - or o t omeh teca l peR . 9 . 5PERo tgn i d r occa, t es
53 . 1egaP 5 1m e t I nae lCec a l peR
S TN I OPKCEHCL AN I F
y t i l auqt e l kooBte l koobehT. y t i l auqt e l koobeh tkcehC se l pa t sh t obdnaded l o fy l neveebd l uohs eh t f oe r t neceh tn ideca l pebd l uohs . en i ps
kcehCkc e hC
11.1.2
Stapler Folder Model 88 / 102 Page April 2002
T08079
MAI 11.1 Preventive Maintenance Model 102
T N I O PK C E H CNO I TCURT SN IECNEREFER000052000005
r epaP, en i hcaMl l A .cteshtap dnas l ewo t , r enae l cmuucavaesU mo r fen i hcameh tnae l co tsehsu r b nae l co t l ohoc l anaesU. t sudr epap . k n imo r f
nae lCnae l C
sehc t iwskco l r e t n Itsu j dA. sehc t iwseh t f ono i t cnu fkcehC . 7 1 . 3PERo t g n i d r o c c a j dA / k c e hCjdA / k c e hC
n i ahcev i r dr e l pa tSfi , r aewr o fkcehC. l i on i ahcy l ppA eca l pe rsyawlA. eca l pe rdehc t e r t s / n r ow . 0000001t a
94 . 1egaP 2 1m e t I liOliO
daehr e l pa t S y l bme s s a esae r gy l ppA. daehr e l pa t seh tevomeR eh tdnan i ped i ugev i r dr e l pa t sno . yssat ekca rbt f i l r e l pa tS
52 . 1egaP 1m e t I eca l peRec a l peR
do rhsupr e l pa tS.do rhsupr e l pa tSnoesae r gy l ppA72 . 1egaP 1m e t I esae rGesae rG
do rhsupr ehcn i lC.do rhsupr ehcn i l Cnoesae r gy l ppA72 . 1egaP 9m e t I esae rGesae rG
y l bmessar ehcn i lCrehcn i l Chcaen i l i of opo r day l ppA r ehcn i l ceh tevomeR. y l bmessa r o f r ehcn i l ceh te l t nams i ddnay l bmessa eh t t ah tkcehC. 000005y r evegn i nae l c o tgn i d r occade t nuome r as r ehcn i l c . 5 . 5PER
92 . 1egaP 9&7&4m e t I k c e hC / l i Okc e hC / l i O
e t agpo t se l pa t sed i S ) gn i suohr ehcn i l cn I ( kcehC. yssapo tShcaen i l i on i h ty l ppA . 3 . 4PERo t c c a t n em t s u j d a liOliO
emohr ehcn i lC/ r e l pa tS ) 6W S ( h c t i w s t su j dA. hc t iwseh t f ono i t cnu fkcehC .5.7.3PERotgnidrocca 52 . 1egaP 4 1m e t I j dA / k c e hCjdA / k c e hC
r osnese l c yct r a tS ) 5NE S ( gn i d r occat su j dA. r i adesse r pmocesU .5.9.3PERot 13 . 1egaP 4m e t I j dA / nae l CjdA / nae l C
- t su j dano i t i sopd l oF ) 1NES ( r osnest nem gn i d r occat su j dA. r i adesse r pmocesU . 1 . 9 . 3PERo t 13 . 1egaP 7m e t I j dA / nae l CjdA / nae l C
- t su j dano i t i sopd l oF ) 5 1TOM ( r o t omt n em . kca r r aegdnar aegnoesae r gy l ppA PERo tgn i d r occat nemt su j dakcehC .1.6.3
13 . 1egaP 2m e t I esae rG
t l ebt r opsna r td l o f - e rPlohoc l ar o t av i t cae r r ebbu rah t i wnae l C dnaf f i t ss i t l ebt r opsna r teh t f I . d i u l f dlof -erPehtecalper, yl roopsetator . 1 . 41 . 3PERo tgn i d r occat l ebt r opsna r t
73 . 1egaP 6m e t I nae lCec a l peR
tekcorpSt lebd lof -erPeca l peR. t ekco r psnol i on i ahcy l ppA t r opsna r td l o f - e rPeh tnehwt ekco r pseh t . deca l pe rs i t l eb
74 . 1egaP 2m e t I liOec a l peR
r eppur e l l oRd l oFotd i u l f l ohoc l ar o t av i t cae rr ebbu raesU .knimor fsrel lordlofehtnaelc 54 . 1egaP 8m e t I nae lCnae l C
r eno i sne t r e l l o rd l oF ) r ewo l ( ed i l Sdnaema r Fneew t ebesae r gy l ppA . )X4 ( . gn i suoh 34 . 1egaP 4&3&2&1me t I esae rG
niahCevi rddloFnr owf i , r aewr o fkcehC. l i on i ahcy l ppA . 0000001t aeca l pe rsyaw l A. eca l pe r 74 . 1egaP 5m e t I liOliO
niahcevi rdrel lordloF ) ed i st no r F ( r eno i sne t dnal eehwr e l d ineewt ebesae r gy l ppA . eca l pe rn r owf i , r aewr o fkcehC. t f ahs y r eves l eehwr e l d i ) 3 (ee r h teh teca l peR . 0000001
74 . 1egaP 1m e t I esae rGesae rG
Service interval: 250 000
NOTE: All instructions are refering to the stapler/folder model 88-102 Service Manual.
The reference colum is refering to the Spare Parts Manual.
CAUTION: If any of the checkpoints or other parts show indication of wear at any point, replace the
part. When lubricating, clean the surface if necessary before applying new lubricant.
11.1.3
Stapler Folder Model 88 / 102 Page April 2002
T08079
MAI 11.1 Preventive Maintenance Model 102 cont.
T N I O PK C E H CNO I TCURT SN IECNEREFER000052000005
niahcreldirel lordloF ) ed i sr aeR( r eno i sne t dnal eehwr e l d ineewt ebesae r gy l ppA . eca l pe rn r owf i , r aewr o fkcehC. t f ahs y r eves l eehwr e l d i ) 2 (owteh teca l peR . 0000001
94 . 1egaP 4m e t I esae rGesae rG
emohe f i nkd l oF ) 9WS(hc t i wsno i t i sop t su j dA. hc t iwsf ono i t cnu fkcehC . 4 1 . 3PERo t g n i d r o c c a j dA / k c e hCjdA / k c e hC
r osnesdee f t uO-neseh tnae l co t r i adesse r pmocesU nae l co t l ohoc l anaesU.DELdnar os eh t t su j dA. kn imo r f t ekca r bdee f t uoeh t . 4 . 3PERo tgn i d r occar osnes
j dA / nae lCjdA / nae l C
t l ebt r opsna r t t up t uOlohoc l ar o t av i t cae r r ebbu rah t i wnae l C .diul f 35 . 1egaP 2 1m e t I nae l C/k c e hC e c a l peR
f f or o t omr eggo jed i S ) 4W S ( h c t i w s t su j dA. hc t i wseh t f ono i t cnu fkcehC . 0 1 . 3PERo t g n i d r o c c a 51 . 1egaP 0 1m e t I j dA / k c e hCjdA / k c e hC
rotomrehcni lC/ relpatS ) 5W S ( h c t i w s n o t su j dA. hc t i wseh t f ono i t cnu fkcehC . 1 1 . 3PERo t g n i d r o c c a 51 . 1egaP 0 1m e t I j dA / k c e hCjdA / k c e hC
d e v ome r e l u d omd e e f n I
t amr o f r eggo jed i S ms i nahcem f ot r apdedae r h teh tnoesae r gy l ppA degna l feh tnol i oesU. t f ahseh t . gn i hsub
91 . 1egaP 3m e t -O/ esae rG li l i O/ esae rG
n i ahcr eggo jed i S y l bme s s a n r owf i , r aewr o fkcehC. l i on i ahcy l ppA . eca l pe r 91 . 1egaP 8m e t I esae rGesae rG
l ennahcr eggo jed i S gn i r e t nec kcehcdnas r aeg3eh tnoesae r gy l ppA . 1 1 . 5PERo t g n i d r o c c a t n em t s u j d a 91 . 1egaP 5 1m e t I esae rGesae rG
do rhsupr eggo jed i S gn i r e t nec do rhsupr eggo jed i Sneewt ebl i oy l ppA t nemt su j dakcehC. gn i hsubdegna l fdna . 2 1 . 5PERo t g n i d r o c c a
71 . 1egaP 3m e t I liOliO
ms i l e l l a r aped i uged i S.l e l l a r ape r ased i uged i seh t t ah tkcehCkcehCkc e hC
r eggo jed i S r osnest nemt su j da ) 2NE S (
gn i d r occat su j dA. r i adesse r pmocesU . 2 . 3PERo t 91 . 1egaP 0 1m e t I j dA / nae lCjdA / nae l C
t l ebt r opsna r tdee f n Ilohoc l ar o t av i t cae r r ebbu rah t i wnae l C ,eca lper, nrowf I. raewrofkcehC.di u l f . 2 . 6PERo t c c a
7 . 1egaP 7 1m e t I nae l Cnae lC
gn i r -Or o t omdee f n Ilohoc l ar o t av i t cae r r ebbu rah t i wnae l C o tcca, t es000005y r eveeca l peR. d i u l f . 1 . 6PER
9 . 1egaP 5m e t I nae l Cec a l p eR
) 6NES ( r osnesdee f n Ieh tnae l co t r i adesse r pmocesU . r osnes 31 . 1egaP 6 1m e t I j dA / nae lCjdA / nae l C
r osnest nemt su j dA ) 3N E S ( eh tnae l co t r i adesse r pmocesU . 3 . 3PERo tgn i d r occat su j dA. r osnes 31 . 1egaP 1 1m e t I j dA / nae lCjdA / nae l C
d i one l osr eggo jkcaB ) 6L OS ( .ecalpernrowf i, raewrofkcehC o tcca, 0000001y r eveeca l peR . 2 . 4PER
31 . 1egaP 4 1m e t I / k c e hC e c a l peR
- ono i t ca r tev i r dt ce j E gn i r . d i u l f l ohoc l ar o t av i t cae r r ebbu raesU 000005y r evegn i r - or o t omeh teca l peR .9.5PERotcca, tes
53 . 1egaP 5 1m e t I nae l Cec a l peR
S TN I OPKCEHCL AN I F
y t i l auqt e l kooBte l koobehT. y t i l auqt e l koobeh tkcehC h t obdnaded l o fy l neveebd l uohs e r t neceh tn ideca l pebd l uohsse l pa t s . en i pseh t f o
kcehCkc e hC
11.1.4
