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GBR Systems M-40, Operator'S And Service Manual

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M-40 OPERATOR & SERVICE MANUAL

ISSUE 05/01

REPAIR AND REPLACEMENT

SECTION F – PAGE 4

•

See Section B page 16

3.

Place one sheet of the current stock in the sensor area and adjust the
sensor with the sheet blocking the sensor. Check that printing on the
stock is not interfering with the sensor.

Y

N

•

Check the wiring to PLC

•

Check the amplifier

F.1e

Paper Could Not Be Fed RAP

Refer to Section H Schematics.
Initial Action: clear the paper that was jammed in the machine and remove
any obstructions.

1.

Are mechanical settings correctly made?

Y

N

Check the wiring and connections for intermittent connections.

•

Adjust the singulator roller.

•

Adjust the auxiliary feed belts.

•

Adjust the Demand Switch plate.

•

Adjust the Creeping Conveyor.

•

Check that the paper guides ensure that the paper passes under the
sensor.

•

Ensure that the drive pulleys are tight.

•

Check the feed clutch.

2.

Clean the sensors. Do the sensor keys light up on diagnostic display
screen?

Y

N

•

Replace the sensor.

3.

See section B page 16

Y

N

•

Check the wiring to PLC (CPU).

•

Check the amplifier

F.1d

Paper Jam in Feeder RAP

Refer to Section H Schematics.

Initial Action: clear the paper that was jammed in the machine and remove
any obstructions.

1.

Are mechanical settings correctly made?

Y

N

Check the wiring and connections for intermittent connections.

•

Adjust the singulator roller.

•

Adjust the auxiliary feed belts.

•

Adjust the Demand Switch plate.

•

Adjust the Creeping Conveyor.

•

Check that the paper guides ensure that the paper passes under the
sensor.

•

Ensure that the drive pulleys are tight.

•

Check the feed clutch.

•

Check that the paper feed is set up to run the length of stock that is
being used.

2.

Are the lights on the Feed Sensor illuminated?

Y

N

•

Go to step 4.

3.

Place a sheet of the current stock in the sensor area and adjust the
sensor so that the red LED goes on with a sheet blocking the sensor.
Check that printing on the stock is not interfering with the sensor. Does
the red LED on amplifier light when a sheet is under the sensor?

Y

N

•

Check the wiring to PLC

•

Check the amplifier

4.

Select page 6 “DIAGNOSTICS”. Block sensor with paper. Does selected
sensor button light up on the display screen?

Y

N

•

Check wiring connection of the sensor

5.

Is there 24 VDC at connectors?

Y

N

Summary of Contents for M-40

Page 1: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 COVER 071 27939 400 1 GO TO TABLE OF CONTENTS M 40 Operator Service Manual ISSUE 05 01 071 27939 400...

Page 2: ...omer s actions and Customer agrees to indemnify defend and hold GBR Systems Corporation harmless from any third party claims which arise directly or indirectly from such service Prepared by GBR System...

Page 3: ...n only Section A begins with page 1 section B begins with page 1 etc There are not necessarily any subdivisions beyond level 1 in a Parts Catalog This manual is divided into Section A through I A deta...

Page 4: ...THIS REVISION ECN 7517 Date 05 01 Previous release M 40 Service Manual Issue Rev Changes incorporated in this manual M 40 Service Manual Issue 05 01 Rev Section Change Sect A 05 01 Sect B 05 01 Sect C...

Page 5: ...D Adjustments This section contains the instructions for adjustment of the moving parts Section E Alarm Messages This section contains messages that occur when a problem arises with operation A brief...

Page 6: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 COVER 071 27939 400 6 NOTES...

Page 7: ...5 A 3 EMERGENCY STOP 5 A 4 GLUE SYSTEM DESCRIPTION 6 A 5 THEORY OF OPERATION 8 A 5a Programmable Logic Controller PLC 8 A 5b Exit Conveyor 9 A 5c Sensor Input 9 A 6 SENSORS 10 A 6a Feed Sensor 10 A 6...

Page 8: ...folder rollers Unable to continue traveling in the buckle plate the sheet bends or buckles inside of the folder rollers and is pinched by the next set of rollers making the fold in the sheet The fold...

Page 9: ...i n c h 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 2 0 2 1 2 2 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 2...

Page 10: ...are covered with nonstick material to facilitate cleanup 220 32 1C 1B 1A 1D 2D 2A 2B 2C 3C 3B 3A 3D 4D 4A 4B 4C DECREASE INCREASE RESET TIP SELECT J8 J11 J6 J5 J3 J4 J7 J9 J10 J2 J1 GLUE BOARD V SIG...

Page 11: ...folder It is red in color and is a latching switch This means that once it is pressed it remains off until reset When the EMERGENCY STOP is pressed the 24 volt DC supplied to the machine is removed T...

Page 12: ...guns by electronically pulsing the glue guns according to operator set parameters Specific glue placement parameters are coordinated with timing information that the operator sets through the touch s...

Page 13: ...ue when operation begins When an extended period of inactivity is to occur the glue system should be flushed thoroughly with warm water NOTE Whenever glue system is left idle either filled with glue o...

Page 14: ...operator interface PLC rack slot by slot description Far left PLC power supply provides DC power for the PLC equipment Slot 1 CPU Contains the main control program communicates to the I O modules in...

Page 15: ...either case is true the feeding process is stopped and the feed clutch is shut off Otherwise the PLC checks if continuous or noncontinuous feeding is selected If noncontinuous feeding is selected the...

Page 16: ...40 is operating A 6d Side Glue Sensor The side glue sensor is a proximity sensor This glue sensor is used to trigger side glue gun activation once the trailing edge of a sheet has passed A 6e Folder E...

Page 17: ...CREEN OPERATION MAINTENANCE 3 B 2 TOUCHSCREEN OPERATOR INTERFACE 4 B 2a Steps 4 B 3 PREVENTATIVE MAINT RECOMMENDATION 21 B 4 GLUE GUN ADJUSTMENT 22 B 5 FILLING THE GLUE TANK 23 B 6 PURGING THE GLUE GU...

Page 18: ...ANEL DIRECTORY OF PAGE FILES PAGE DESCRIPTION 00 MAIN 01 RUN 02 SETUP 05 DOUBLE DETECT SENSOR 06 DIAGNOSTIC 1 07 DIAGNOSTIC 2 08 ALARMS 1 09 ALARMS 2 10 GLUE CHANNEL PURGE 11 MAINTENANCE 15 SIDE GLUE...

Page 19: ...me result as a heavy one CAUTION Never use foreign objects pens screwdriver or similar to activate the touchscreen Foreign objects will scratch the touch screen and affect transmissivity causing unrel...

Page 20: ...RATOR INTERFACE B 2a Steps 1 Select SETUP NOTE All numbers that appear in the selected SETUP parameter buttons are recommended starting parameters 2 Select GLUE COMPRESSOR 3 Select ON NOTE Remember to...

Page 21: ...e last job saved You can save up to 40 jobs in memory NOTE Always use job 1 for all other job setups that are not necessary to save Just change the setup parameters for each job 6 Select CREEPER VELOC...

Page 22: ...ntity for the next production run if you need to verify with a batch count This does not reset automatically after the batch count is reached NOTE Whenever you change SHEETS PER HOUR you must also cha...

Page 23: ...11 Select SIDE GLUE SETUP 12 The SIDE GLUE SETUP PAGE 15 menu appears Select SIDE GLUE 13 Select ON This turns the side glue channel 1 on which controls the side glue guns electronically LINE BEAD SP...

Page 24: ...eyor speed Example 7 6 divided by 200 per second 038 Drop the decimal point and the zero when entering the number You do this only with side glue DURATION 16 Select PITCH The pitch is the distance bet...

Page 25: ...back on again before the full sheet has passed under the sensor 99 of the time mechanical adjustment will solve the application problem This is used as a last resort 19 DELAY TIME is seldom used It co...

Page 26: ...hen using delay time the following calculation is used Divide the distance from the centerline of the sensor to the buckle plate stop by the speed of the folder Example 1 5 100 per second 015 ms delay...

Page 27: ...Select MAIN page 0 30 Select FLAP GLUE 2 SETUP NOTE If it is also required to dispense glue with FLAP GLUE 2 use the same setup parameters as FLAP GLUE 1 31 Select FLAP GLUE 2 32 Select ON from side m...

Page 28: ...ed when folding and gluing a Z or accordion fold with simplex printed paper All other applications do not require flap 2 gluing and it is turned off See step 24 on page 9 Time Delay Calculation 39 Sel...

Page 29: ...ETUP page is for future applications and is not needed for use at the present time When used and the ON button is selected it will turn on channel 4 which will control the Z side glue guns electronica...

Page 30: ...hown 47 Select DELAY TIME with BRE gluing Setup is necessary to enter a delay time from the lead edge of the sheet to start the side glue line that creates the business return envelope BRE 48 Enter th...

Page 31: ...electing RUN mode it takes you to the run page that allows you to turn ON and OFF conveyors folder and feed paper continuously or single sheet It also allows jogging of the discharge conveyor to clear...

Page 32: ...elect DISCHARGE CONVEYOR 57 Select CLEAR This will run the conveyor long enough to clear a full conveyor of documents 58 Select JOG This will allow intermittent conveyor movement to clear jammed of ba...

Page 33: ...stop and declare a DOUBLE DETECT ALARM on the touchscreen operator interface Once the problem has been corrected select CLEAR ALARMS button 61 If your production is with 24 pound paper place a strip o...

Page 34: ...tle lower than the actual detected percentage you can change it with manual input 64 Select the 24 POUND ONE SHEET button 65 Select the percentage from the number menu 66 Select ENTER 67 Select MAIN t...

Page 35: ...ning speeds and compare against the MACHINE TOTAL SHEETS per hour display This page is used to help diagnose feed and fold problems that can be caused by paper jams and slipping mechanical components...

Page 36: ...ngulation and feeding By blocking each sensor individually and watching the touchscreen you can determine whether they are functioning properly Each sensor display on the screen will light up when the...

Page 37: ...ft or production run it is recommended that all paper path surfaces where glue is deposited and where paper travels through the folder buckle plates and bypass plates be inspected and cleaned Glue bui...

Page 38: ...g screw counterclockwise to increase the size of the glue spot Adjusting screw should never be rotated more than 1 5 flats CCW from full CW stop position NOTE THIS ADJUSTMENT IS VERY DELICATE SLIGHT A...

Page 39: ...e guns This is necessary to keep all internal surfaces wet Glue Tank Components B 5 FILLING THE GLUE TANK WARNING Use rubber gloves and eye protection Observe caution when opening and pouring glue The...

Page 40: ...tate tank cover lock handle CAUTION Make sure all air pressure is relieved from tank before opening Rotate cover 90 and tilt cover to vertical orientation STEP 3 Remove glue tank cover and place glue...

Page 41: ...loor and tip upside down several times When glue goes bad it will smell like rotten eggs CAUTION Never reuse leftover glue from previous production runs that has been removed from the system prior to...

Page 42: ...URGE 10 Touch GLUE CHANNEL 2 PURGE for flap 1 glue guns Select the ON key to start the purge 11 Make sure that clear water flows from each gun before completing the flush 12 Select the OFF key to stop...

Page 43: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 OPERATION SECTION B PAGE 27 Purge Screen Glue System Diagram...

Page 44: ...equipment We recommend Teflon Viton etc Do not use polycarbonate filter bowls Contact GBR Systems Corporation if you need further information HANDLING always keep the compressor in a vertical positio...

Page 45: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 OPERATION SECTION B PAGE 29 receiver to leak back into the compressor motor Dismount the non return valve and change O ring...

Page 46: ...rating Check or replace the relief valve e Defective valve plate Contact GBR Systems Corporation 3 Compressor gets very hot and or uses a lot of oil a Incorrect oil level The level must appear in the...

Page 47: ...ectly Adjust as follows Adjustment of pressure switch A Maximum pressure adjustment cut out B Differential adjustment cut in b The cut in pressure is set by adjustment of differential screw B Turn clo...

Page 48: ...the drain cock is closed 3 Start the compressor and note how long it takes until it switches off Make sure that the pressure in the air receiver is 8 bar 120 psi as deviations may indicate the wrong r...

Page 49: ...r and empty Check compressor air tubes and equipment for leaks and check pumping time Inspect clean or replace intake filter Clean the compressor with a soft damp cloth Dust and dirt prevent cooling T...

Page 50: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 OPERATION SECTION B PAGE 34 NOTES...

Page 51: ...stop FEED A sheet of paper did not pass the feed sensor in time or did not reach the feed sensor in time or the Creeper Conveyor is not feeding paper to the hopper DOUBLE DETECT A double sheet was de...

Page 52: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 ALARM MESSAGES SECTION E PAGE 2 NOTES...

Page 53: ...et RAP 3 F 1e Paper Could Not Be Fed RAP 4 F 1d Paper Jam in Feeder RAP 4 F 1e Small Sheet RAP 6 F 1f Feeder Speed is too slow RAP 6 F 1g Creeper Conveyor Motor RAP 7 F 1h Incorrect Folds RAP 7 F 2 PM...

Page 54: ...s or instruct the operator on the proper actions 3 Switch the main power OFF 4 Check all areas of the machine for paper or other obstructions including inside the folder Remove any paper or obstructio...

Page 55: ...Detect Sensor illuminated Y N Is there 24 VDC at TB1 7 and TB1 8 Check the connection from the PLC to the Feeder Check the wiring Check 24 VDC power supply 3 After cleaning sensors do the LEDs come o...

Page 56: ...LC CPU Check the amplifier F 1d Paper Jam in Feeder RAP Refer to Section H Schematics Initial Action clear the paper that was jammed in the machine and remove any obstructions 1 Are mechanical setting...

Page 57: ...RVICE MANUAL ISSUE 05 01 REPAIR AND REPLACEMENT SECTION F PAGE 5 Check the connection from the PLC to the Feeder Check the wiring Check the power supply 6 Clean the sensors Do the LEDs come on Y N Rep...

Page 58: ...urled Adjust the singulator roller Adjust the auxiliary feed belts F 1f Feeder Speed is too slow RAP Initial Action Refer to Section H Schematics Remove the covers from the feeder 1 Does the feed moto...

Page 59: ...he optical relay Check optical relay fuse Replace the opto module 4 The creeper motor runs when there is demand for paper Y N Check fuses Check relay Make sure the speed pot is correctly set Check for...

Page 60: ...is Loosen the setscrews on the drive rollers and on the auxiliary pulley then you should be able to slide shaft outward through the bearings Note do not remove or loosen bearings if not necessary Loos...

Page 61: ...e very careful not to loosen the spacer for the encoder to make note how you took it off Make sure your replace them properly On the outer left side of chassis remove pulley and timing belt Make sure...

Page 62: ...place with new ones Replace unit and belts in reverse order F 2h Folder Perf Knives See Section G Folder Assembly All perf knives come in two 2 pieces they are held on the shaft by two 2 screws same w...

Page 63: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 REPAIR AND REPLACEMENT SECTION F PAGE 11 NOTES...

Page 64: ...500 GLUE SYSTEM 6 GUN 24 705 27183 500 GLUE TANK ASSEMBLY 26 703 27277 500 FOLDER 4 PLATE PAGE 1 28 703 27277 500 FOLDER 4 PLATE PAGE 2 30 703 27277 500 FOLDER 4 PLATE PAGE 3 32 703 27277 500 FOLDER...

Page 65: ...3 1 2 1 1 1 0 8 7 6 5 4 3 2 15 14 13 12 11 10 8 7 6 5 4 3 2 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 3 8 3 7 3 6 3 5 3 4 3 3 3 2 3 1 3 0 2...

Page 66: ...27486 500 ELECTRONICS ASSEMBLY 3 549 27234 500 FEEDER ASSEMBLY 4 579 28024 500 RIGHT FEEDER COVER 5 579 28023 500 LEFT FEEDER COVER 6 579 27643 500 RIGHT FOLDER COVER 7 579 27644 500 LEFT FOLDER COVE...

Page 67: ...MANUAL ISSUE 05 01 PARTS SECTION G PAGE 4 005 27276 500 CABINET ASSEMBLY 19 16 13 8 24 25 11 11 10 9 7 33 1 4 4 20 36 5 2 2 30 29 28 31 3 3 21 14 15 15 34 6 6 12 23 32 35 26 26 VIEW SHOWN WITH DOOR R...

Page 68: ...INSERT 13 026 ARC68A14 CABLE CLAMP 14 027 27859 500 FAN ASSEMBLY 15 027 4C551 FAN GUARD 16 035 83011220 POWER OUTLET 17 041 25066 ROCKER SWITCH 18 046 27759 500 CABLE AC POWER 19 058 27318 000 TOUCH...

Page 69: ...7 K8 TS2 K9 TS1 F7 F9 F11 F13 F15 F17 F19 F8 F10 F12 F14 F16 F18 F20 K3 K2 K1 K4 K5 K6 TS3 GLUE BOARD J2 J10 J9 J7 J4 J3 J5 J6 J11 J8 J3 SSR1A SSR1B SSR2B SSR2A DR4 DR3 DR2 DR1 LF1 20VR1 L I N E L O A...

Page 70: ...99 27889 000 SLC 500 ANALOG OUTPUT MODULE SLOT 8 SLOT 9 099 27886 000 SLC 500 16 PT DC HIGH SPEED INPUT SLOT 10 099 27891 000 SLC 500 16 PT DC SINK OUTPUT SLOT 11 099 27890 000 SLC 500 8 PT SOURCE OUT...

Page 71: ...CTION G PAGE 8 549 27234 500 FEEDER ASSEMBLY PAGE 1 1 2 3 4 C C A A C SEE DETAIL E C A B B 9 41 2 39 27 4 37 36 36 5 30 17 31 13 32 12 50 42 44 28 10 23 24 3 20 45 14 29 22 11 35 34 33 25 38 55 53 54...

Page 72: ...200220037 TIMING BELT 22 PL 24 113 200290037 TIMING BELT 29 PL 25 118 27274 600 UPPER BELT 26 118 27275 600 LOWER BELT 27 123 6AL CLAMP COLLAR 28 126 SC25 COLLAR 29 172 24280 ADJUSTING LEVER 30 172 24...

Page 73: ...34 500 FEEDER ASSEMBLY PAGE 2 32 37 36 7 6 46 13 31 38 18 18 18 15 29 29 29 43 10 28 26 26 12 11 27 8 14 25 39 40 19 44 44 52 51 48 4 4 3 54 49 49 45 5 50 1 20 42 35 35 35 35 41 41 34 34 21 21 2 2 53...

Page 74: ...IMING PULLEY 30T 23 112 27264 500 TIMING PULLEY ASSEMBLY 24 112 27264 501 TIMING PULLEY ASSEMBLY 25 113 20008003712 TIMING BELT 8 PL 26 113 200090037 TIMING BELT 9 PL 27 113 200290037 TIMING BELT 29 P...

Page 75: ...05 01 PARTS SECTION G PAGE 12 549 27234 500 FEEDER ASSEMBLY PAGE 3 2 29 28 10 22 8 15 14 31 12 32 3 1 36 43 45 46 19 6 16 16 23 24 25 17 20 34 26 44 37 7 5 49 49 42 40 41 48 47 38 39 21 27 9 11 18 30...

Page 76: ...BELT 21 118 27275 600 LOWER BELT 22 176 27197 501 DRIVER ROLLER RIGHT 23 516 25060 600 SWIVEL MOUNT 24 516 25064 600 SWIVEL CLAMP MOUNT 25 516 25333 600 LEFT RAIL GUIDE 26 549 27265 500 SINGULATOR AS...

Page 77: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 14 549 27265 500 SINGULATOR ASSEMBLY 5 7 16 10 9 19 4 2 1 17 18 RAISE LOWER 12 14 11 6 15 8 13 3...

Page 78: ...SEMBLY 6 177 25913 600 SINGULATOR ROLLER 7 181 03000301000 COMPRESSION SPRING 8 181 05000808125 COMPRESSION SPRING 9 600A 16435 003 ADJUSTING SCREW 25 56 10 600A 16435 004 ROLLER AXLE 11 600A 16435 00...

Page 79: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 16 002B 18043 AUXILIARY FEED BELTS 1 2 3 4 5 6 7...

Page 80: ...GE 17 002B 18043 AUXILIARY FEED BELTS INDEX PART NUMBER DESCRIPTION 1 002A 16439 PULLEY REAR IDLER 2 002B 16440 HOUSING OUTSIDE BELT 3 019 511562 RETAINING RING 4 152 B81012 BUSHING 5 600A 16438 001 P...

Page 81: ...SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 18 750 27401 500 CREEPER CONVEYOR 27 26 29 29 19 19 25 8 7 18 17 14 14 13 13 24 24 16 23 28 28 11 11 15 15 9 9 5 12 6 H AN D HA ZA RD L AB EL 1 10 20 2...

Page 82: ...25 9 112 200NOA14638 TIMING PULLEY 14T 10 113 200080037 DRIVE BELT 11 113 200500037 CONVEYOR BELT 12 126 SSC25 SETSCREW COLLAR 13 144 27381 600 RIGHT STACK GUIDE 14 144 27382 600 LEFT STACK GUIDE 15 6...

Page 83: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 20 002B 16631 FRONT SHAFT ASSEMBLY 7 1 2 3 4 5 6...

Page 84: ...16631 FRONT SHAFT ASSEMBLY INDEX PART NUMBER DESCRIPTION 1 112 26947 500 IDLER PULLEY 2 014 10221132 SHCS 10 32 X 2 00 3 020 RN010C0604 SPACER 10CL 25 4 181 03000401000 SPRING 5 600A 15841 008 FRONT...

Page 85: ...AC INPUT KEYBOARD ENC CHANNEL INPUTS CHANNEL 4 OUTPUT CHANNEL 3 OUTPUT CHANNEL 2 OUTPUT CHANNEL 1 OUTPUT 24 SLOT 1 0 OUT 11 SLOT 11 O U T 3 SLOT 11 O U T 2 SLOT 11 O U T 1 C SLOT 11 O U T 0 CH4 CH3 CH...

Page 86: ...FILTER MESH SCREEN 17 186 54727319 MANIFOLD GLUE AIR 18 186 54727695 FITTING 10 32 X 125 T 19 186 547B268P06X FITTING 25NPT X 375 T 20 186 547B3109561 ELBOW 125 X 25 T 21 186 547B6256 STRAIGHT CONN 25...

Page 87: ...T 2 POR T 2 AC INPUT KEYBOARD ENC CHANNEL INPUTS CHANNEL 4 OUTPUT CHANNEL 3 OUTPUT CHANNEL 2 OUTPUT CHANNEL 1 OUTPUT 24 S L OT 10 OU T 1 1 S L OT 11 OU T 3 S L OT 11 OU T 2 S L OT 11 OU T 1 C S L OT 1...

Page 88: ...CLS780 GLUE FILTER MESH SCREEN 17 186 54727319 MANIFOLD GLUE AIR 18 186 54727695 FITTING 10 32 X 125 T 19 186 547B268P06X FITTING 25NPT X 375 T 20 186 547B3109561 ELBOW 125 X 25 T 21 186 547B6256 STRA...

Page 89: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 26 705 27183 500 GLUE TANK ASSEMBLY 8 3 4 4 5 7 6 6 9 2 1 1 10...

Page 90: ...2 600 CONDUIT 2 130 1KQH0735S FITTING 25NPT X 25 HOSE 3 130 27187 000 BRASS HEX NIPPLE 25 4 130 27188 000 FITTING ADAPTOR 5 130 27189 000 FITTING PLUG 6 130 27190 000 FITTING COMPRESSION 90 DEG 7 135...

Page 91: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 28 703 27277 500 FOLDER 4 PLATE PAGE 1...

Page 92: ...9 186 031103006 SCREW M5 X 12mm 10 186 031108003 WASHER LOCK M5 11 186 034007861 MOTOR 230V 12 600A 18840 MOUNT PLATE 13 186 031167001 SCREW M4 X 8mm 14 186 032036056 CHASSIS 15 186 032021495 COVER 1...

Page 93: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 30 703 27277 500 FOLDER 4 PLATE PAGE 2...

Page 94: ...66 COUPLING PIN 14 186 034001367 ROLLER 15 186 031170006 SCREW M4 X 10mm 16 186 034002724 BRACKET 19 186 031170002 SCREW M5 X 25mm 20 186 032041073 SCREW 21 186 032011586 PIN 22 186 034001364 PULLEY 2...

Page 95: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 32 703 27277 500 FOLDER 4 PLATE PAGE 3...

Page 96: ...EARING 16 186 034001307 186 031052010 186 031150003 RIGHT BEARING NEEDLE BEARING DOWEL PIN M6 X 8mm 17 186 034001321 OUTSIDE RIGHT BEARING PLATE 18 186 031101022 DOWEL PIN M6 X 24mm 19 186 031107003 W...

Page 97: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 34 703 27277 500 FOLDER 4 PLATE PAGE 4...

Page 98: ...186 034001322 OUTSIDE LEFT BEARING PLATE 15 186 031107003 WASHER 16 186 031122003 HEX NUT M5 17 186 031101022 DOWER PIN M6 X 24mm 18 186 031021239 WASHER 19 186 032012385 SPACER RING 20 186 034001486...

Page 99: ...27277 500 FOLDER 4 PLATE PAGE 5 D A N G E R Y O U R F I N G E R S W A T C H H A N D H A Z A R D H A N D H A Z A R D W A T C H Y O U R F I N G E R S D A N G E R 1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 1...

Page 100: ...186 031031061 TRANSPORT BELT 15 186 032011702 TIMING PULLEY 16 186 031033011 TIMING BELT 17 186 032022112 RIGHT PLATE 18 186 032022113 LEFT PLATE 19 186 034002556 TRANSPORT ROLLER 20 600A 18459 GUIDE...

Page 101: ...15 1 4 13 12 11 10 8 7 6 5 4 3 2 15 14 1 3 12 11 10 8 7 6 5 4 3 2 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 22 21 20 19 18 17 16 15 14 13 12 11 1 0 9 8 7 6 5 4 3 2 1 38 3 7 36 35 34 33 32 31 30 29...

Page 102: ...3 014 24283 SHOULDER SCREW 4 095 24260 600 SENSOR BAR 5 057 27830 500 GLUE SENSOR 6 186 034004810 FOLD PLATE C FOLD 7 503 24261 600 PIVOT ARM 8 516 24253 600 RIGHT MOUNTING BLOCK 9 516 24254 600 LEFT...

Page 103: ...3 9 3 8 3 7 3 6 3 5 3 4 3 3 3 2 3 1 3 0 2 9 2 8 2 7 2 6 2 5 2 4 2 2 2 1 2 0 1 9 1 8 1 7 1 6 1 5 1 4 1 3 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 22 21 20 19 18 17...

Page 104: ...563 27998 500 FOLD PLATE 1 Z FOLD OPTION INDEX PART NUMBER DESCRIPTION 1 007 24250 600 GUN MOUNTING BRACKET 2 007 24255 600 MOUNTING BRACKET 3 095 24260 600 SENSOR MOUNTING BAR 4 186 5412A11211 SENSO...

Page 105: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 42 186 034007856 PAPER STOP FOLD PLATE 1003031 1131003 1155004 1133002 M4x20 1155004 4001285 2032012 2041070...

Page 106: ...1 inch inch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 5 16 17 18 19 20 21 22 24 2 5 26 27 28 29 3 0 31 32 33 34 35 36 37 38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 2 6 27 28 29 30 31...

Page 107: ...inch inch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 3 6 37 38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33...

Page 108: ...3 4 5 6 7 8 9 10 11 12 13 14 1 5 16 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1 8 19 2 0 21 22 24 25 26 27 28 29 30 31 32 33 34 35 36 3...

Page 109: ...inch 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 1 6 17 18 19 20 21 22 24 25 26 27 28 29 30 31 32 33 34 35 3 6 37 38 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2 1 22 24 25 26 27 28 29 30 31 32 33 34...

Page 110: ...563 27999 500 FOLD PLATE 4 Z FOLD OPTION INDEX PART NUMBER DESCRIPTION 1 007 24250 600 GUN MOUNTING BRACKET 2 007 24255 600 MOUNTING BRACKET 3 095 24260 600 SENSOR MOUNTING BAR 4 186 5412A11211 SENSO...

Page 111: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 48 186 034004814 BYPASS PLATE 1 3 1025046 1025047 2016257 2026370 2066128 2026370 2016257 2016256 4001374 4001375...

Page 112: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 49 186 034004815 BYPASS PLATE 2 4 2027872 2 4 2027872 2066130 4001375 4001374 2016256 2016257 2016257 1025047 1025046...

Page 113: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 50 186 034007855 BYPASS PLATE 2 4 Z FOLD 2032011 2027872 2066130 4001375 4001374 2016256 2016257 2016257 1025047 1025046 2032011...

Page 114: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 51 NOTES...

Page 115: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 52 750 27291 500 EXIT CONVEYOR PAGE 1 3 2 1 4 5 6 7 8 9 10 3 8 6 7 1 1 2 4 5...

Page 116: ...IT CONVEYOR page 1 INDEX PART NUMBER DESCRIPTION 1 007 27384 600 RIGHT BRACKET 2 007 27385 600 LEFT BRACKET 3 010 24286 RULE LABEL 4 014 M05003016 PHILLIPS SCREW M5 X 16 5 035 83011080 PLUG 6 600A 187...

Page 117: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 54 750 27251 000 EXIT CONVEYOR PAGE 2...

Page 118: ...231179 FUSE 5A 250V 115V 60Hz FUSE 3A 250V 220V 50HZ 30 186 371230080 C CLIP 3 16 31 186 37CD30061 PIN 32 186 375710078 MOTOR PULLEY 28T 33 186 371230301 STRAIN RELIEF 34 186 371230125 SCREW 8 32 X 18...

Page 119: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 PARTS SECTION G PAGE 56 NOTES...

Page 120: ...SECTION H SCHEMATICS Schematic Page Compressor schematic 1 M 40 Machine schematic 2 M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 SCHEMATICS SECTION H PAGE 1...

Page 121: ...C1 1 2 1 2 M3 M2 M1 MOTOR FOLDER RED BLACK M3 2 A RED L1 DR3 FOLDER DRIVE KBIC 240DS 1 L2 A BLACK 1 2 K4 8 F13 8 F14 MOTOR MAIN FEED BLACK RED M2 1 2 RED A A BLACK L1 L2 DR2 MAIN FEED DRIVE KBIC 240DS...

Page 122: ...RED BLACK RED BLACK INSERTER CONVEYOR DRIVE M 8 DR4 FOLDER DRIVE DR3 MAIN FEED DRIVE DR2 DRIVE CREEPER DR1 RED BLACK SIG COM RED BLACK SIG COM RED BLACK SIG COM BLACK RED MS1 MS1 MULTI FEED SENSOR 3 4...

Page 123: ...24 C C 24 IN 15 IN 14 24 C IN 8 IN 9 IN 10 IN 11 RED 1 WHITE 3 BLACK RED 1 2 WHITE 2 1 3 1 2 2 PE8 PE7 RED 3 3 2 BLACK WHITE 1 RED 1 2 3 BLACK WHITE 3 3 2 1 CARD SENSOR 1 2 3 CARD SENSOR PE9 PE10 SENS...

Page 124: ...126 OUT 6 OUT 5 127 OUT 7 K2 2 1 GREEN WHITE 2 1 RED BLACK IF2 SSR1A SSR1B SSR2B SSR2A 128 OUT 8 DC COM 129 OUT 9 130 OUT 10 131 OUT 11 40 K7 K8 132 133 134 OUT 14 OUT 13 OUT 12 135 C OUT 15 43 42 41...

Page 125: ...LACK RED PE15 PE14 24 C 116 TB RED BLACK E1B BLACK RED ES3 BLACK RED ES2 BLACK RED ES1 EB1 BLACK RED WHITE PP1 IF2 IF1 RED BLACK RED BLACK RED BLACK FC1 RED BLACK RED WHITE WHITE RED BLACK BLACK PE13...

Page 126: ...nt 2 I 2b Storage 2 I 2c Moisture Curl 2 I 2d Trial Run 2 I 2e Wire and Felt Side 2 I 3 STIFFNESS 3 I 3a The Rigidity or Bending Resistance of Paper 3 I 4 Paper Grain 3 I 5 OPACITY 4 I 6 POROSITY 4 I...

Page 127: ...ading to misfeed paper and jams I 2a Correct Moisture Content Paper with moisture content between 4 6 will minimize problems Moisture content should be uniform throughout a ream box or roll Porosity c...

Page 128: ...n Which Most of the Paper Fibers Lie There are two quick field tests that can be used to determine a paper s grain direction Tear Showing Grain Tear Test Tear the paper in question lengthwise and then...

Page 129: ...l Direction The short edges of the sheets curl toward or away from the imaged side I 8 CONTROLLING HUMIDITY Dramatic changes in operating performance in the mailroom could occur when marginal moisture...

Page 130: ...nting and mailing equipment General Storage guidelines 1 Store paper in original cartons and ream wrappers 2 Store paper between 64 90 F 10 30 C and 40 60 Relative Humidity 3 Always store paper up and...

Page 131: ...elow shows EQUIVALENT PAPER WEIGHT CHART in reams of 500 sheets Copier Offset Cover Bristol Index Gram mage 17x22 25x38 20x26 22 5x 28 5 25 5x 30 5 g m2 13 33 18 22 27 49 16 41 22 27 33 61 20 51 28 34...

Page 132: ...14x25 356x635 17x22 432x559 18x24 457x610 20x26 508x660 22 5x28 5 572x724 22 5x35 572x889 24x36 610x914 25x38 635x965 25 5x30 5 648x762 SHEET SIZE INCHES MILLIMETERS 4A 66 22 x 93 62 1692 x 2377 95 2A...

Page 133: ...A Maximum of 0 04 Per Tie On Perforations Property Rating Paperweight 20 24 lbs 75 90g m Porosity 20 Gurley Seconds Grain Direction Stiffness 20 Lb Stock 175 225 Gurley Stiffness Units 24 Lb Stock 250...

Page 134: ...ew moments and are easily performed The requirements of glue reservoir replenishment and checking of the glue system are essential daily tasks which if done consistently serve to reduce overall mainte...

Page 135: ...uns and the flap glue dots have been covered with a nonstick tape to make cleaning as easy as possible Special tools called a Spudger and a Cleaning Tool are shipped with each machine for the operator...

Page 136: ...extreme caution Use the special tools to minimize danger Because the folder rollers will be subjected to processing documents with wet glue on them it is imperative that they be kept clean The action...

Page 137: ...er off and clean as needed Relatch the bar by returning it to its normal position making sure to engage the latching screw Flap Glue Tip Sealer Access 7 Overnight shutdown If machine is to be shut dow...

Page 138: ...M 4 OPERATOR SERVICE MANUAL ISSUE 05 01 MAINTENANCE SECTION C PAGE 5...

Page 139: ...Clean the bowl using soap and water only CAUTION Solvents can damage or destroy seals etc Bowls should be inspected for signs of mechanical damage or cracking 5 Replace the filter elements IMPORTANT W...

Page 140: ...ompressor Pressure Switch Compressor Filter Regulator Pressure Switch 041 28140 000 Relief Valve 138 28139 000 Check Valve 138 28136 000 Shutoff Valve 137 28138 000 O Ring 186 556243000 Check Valve O...

Page 141: ...Remove the nozzle and replace the parts NOTE This procedure can also be used to clean the internal parts from contaminants or solidified glue Glue Tank Glue Gun Parts WARNING These are the only parts...

Page 142: ...buckle plate is also square The feeder s paper guide rails play an important role in the presentation of the document to the folder Inspection of the alignment table geometry is possible by using plai...

Page 143: ...ollers E Adjust the paper hold downs so that no friction is achieved when the paper passes underneath If the paper stalls in this area raise the hold downs accordingly F Square the buckle plates being...

Page 144: ...not removed from the glue system will lower the viscosity of the glue resulting in poorly glued packages NOTE All glue guns should be flushed clean and filled with water and pressured when machine is...

Page 145: ...or If this alarm occurs and two pages were actually fed Singulator roller is too high Auxiliary feed belts are too high Double detect sensor is too high Paper hopper is not positioned properly Any one...

Page 146: ...d Switch C 6b Folder Alarms The following alarm indicates that the operator needs to check and clear the Folder of jammed or out of place documents DISCHARGE SENSOR JAM If inspection reveals that ther...

Page 147: ...M 40 OPERATOR SERVICE MANUAL ISSUE 05 01 MAINTENANCE SECTION C PAGE 14 NOTES...

Page 148: ...D 1 FEEDER Mechanical adjustments may be necessary when changing document types or if document handling errors persist Follow the step sequence provided here to save time and prevent repeating an adj...

Page 149: ...ed 1 Loosen the long setscrew 3 32 on the top stop collar of the Feed Belt tension knob shaft 2 Lay a straight edge across the top of the Feed belt lengthwise Make sure it lies across both pulleys 3 A...

Page 150: ...e creeper conveyor 3 Position a sheet of paper in singulator area and move the side rails to obtain 1 16 lateral motion of the paper along the entire length of the rails 4 Tighten the sides in positio...

Page 151: ...singulator should be reviewed D 1fb Set Singulator Roller Parallel to Lower Rollers The precise gap created by the Singulating Roller and the two lower rollers must be equivalent for both of the rolle...

Page 152: ...Roller off the auxiliary Singulating Rollers and belt 2 On left hand side of the Singulating Roller loosen the setscrew which keeps the Singulating Roller from rotating 3 Loosen the two screws for th...

Page 153: ...following Fold Plate or past a Bypass Plate 5 The process continues through all fold rollers Fold Plate Operation Adjusting the Fold Plate 1 Remove the Fold Plate as illustrated below 2 Place the Fol...

Page 154: ...the opposite ends of the adjustment slots The optional Accordian or Statement Fold runs at speeds less than 25 000 sheets hour and has a different assembly set up and is adjusted differently See Opera...

Page 155: ...1 1 5 6 Standard Parallel Letter Fold C 8 x11 8 x11 8 x14 8 x14 1 2 1 2 7 1 8 3 9 1 16 4 5 8 Standard Accordian or Statement Fold Z 8 x11 8 x11 1 2 4 15 16 4 13 16 Optional Double Parallel Fold 8 x14...

Page 156: ...6 5 4 3 2 1 EXIT 1 2 3 4 OPERATOR SIDE Single Fold Address down Leading edge Plate 1 Buckle Plate Plate 2 Bypass Plate 3 Bypass Plate 4 Bypass 6 5 4 3 2 1 EXIT 1 2 3 4 OPERATOR SIDE Letter Fold Addre...

Page 157: ...lap OPERATOR SIDE 4 3 2 1 EXIT 1 2 3 4 5 6 Accordian Fold Address down Leading Edge Plate 1 Buckle Plate Plate 2 Bypass Plate 3 Bypass Plate 4 Buckle Plate 6 5 4 3 2 1 EXIT 1 2 3 4 OPERATOR SIDE Doubl...

Page 158: ...n the folder NOTE The depth of perforating is also controlled by the pressure on the number 7 and 8 rollers Folder Side View CAUTION This tension is set at the factory and does not have to be changed...

Page 159: ...nt The starting point of the side glue is controlled by the location of the side glue sensor The side glue sensor signals the trailing edge of the sheet of paper When the sheet s trailing edge passes...

Page 160: ...D 2h Sensor Adjustment The paper detecting sensors in the paper feed section and folder buckle plates of the M 40 are diffuse reflective proximity sensors which are used for triggering the side glue...

Page 161: ...wise and find point A at which the red LED indicator light turns off If the red LED does not turn off even when the trimmer is turned to MAX take the position of MAX as point A 2 GREEN RED 2 With the...

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