1. Manuals
  2. Brands
  3. Plockmatic Manuals
  4. Booklet makers
  5. SR 85
  6. Service manual

Plockmatic SR 85 Service Manual

Hide thumbs Also See for SR 85:
Table of Contents

Advertisement

Quick Links

Service Manual
Bookletmaker SR 85
February 2001
Part No. 75672

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the SR 85 and is the answer not in the manual?

Questions and answers

Related Manuals for Plockmatic SR 85

Summary of Contents for Plockmatic SR 85

  • Page 1 Service Manual Bookletmaker SR 85 February 2001 Part No. 75672...

  • Page 2: Table Of Contents

    Connection cable wiring diagram SR85 7.2.1 Electrical components list 7.3.1 Electrical components location 7.4.1 Test points 7.5.1 FAULT ISOLATING PROCEDURE (FIP) Self diagnostic system control (SDS) 8.1.1 PREVENTIVE MAINTENANCE (MAI) MAI 9.1 Preventive Maintenance 9.1.1 Bookletmaker SR 85 PAGE February 2001...

  • Page 3: Rep 1.1 Front And Rear Cover

    4. Pull out the lower end and lift up carefully to remove. Rear cover Removal of the rear cover is performed the same way as removal of the front cover. INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE 1.1.1 February 2001...

  • Page 4: Rep 1.2 Top Cover

    - That the Interlock switch activates when the distance between the magnet (5) and the sheet plate (3) is 2 to 5 mm. ADJUSTMENT 1. Loosen the screws (1). 2. Move the Top cover to adjust. 3. Tighten the screws (1). 4. Repeat the check. Bookletmaker SR 85 PAGE 1.2.1 February 2001...

  • Page 5: Rep 1.3 Panels + Infeeder

    2. Slide the top of the panels (2) away from the screws. Remove the shelf (3), remove the two panels. 3. Loosen the four 7 mm screws (4). 4. Lift up the infeeder (5) and remove it. INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE February 2001 1.3.1...

  • Page 6: Rep 1.4 Infeed And Outfeed Cover

    3. Loosen the two screws below the stacker frame securing the stacker. 4. Disconnect and remove the stacker (3). 5. Tip the SR 85 by placing 50 mm or greater distances between the outfeed end of the SR 85 and the base.

  • Page 7: Rep 2.1 Infeed Module

    8. Remove the two screws (5) on the rear side. 9. Lift out the Infeed module (4). Carefully so the side guides does not bend. INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE 2.1.1 February 2001...

  • Page 8: Rep 2.2 Infeed Transport Belt

    4. Slide the drive coupling (5) off of the drive shaft (4) and remove the transport belt as- sembly. 5. Remove the belt (2) from the assembly. INSTALLATION Installation is an exact reversed procedure of removal. Note: Make sure the flat side on the bearing (3) is up when installing. Bookletmaker SR 85 PAGE 2.2.1 February 2001...

  • Page 9: Rep 2.3 Side Guides

    3. Loosen the Ob screw (3) and the IB screw (4) on the side guide. Adjust the sideguide according to step 2. 4. Perform the same check on the rear (5) sideguide, adjust if needed. Bookletmaker SR 85 PAGE 2.3.1...

  • Page 10: Rep 2.4 Side Guide Assy

    8. Remove the two screws (2) who secures the shaft. 9. Push the shaft (3) out of the hole (4). 10. Remove five nuts (5). 11. Remove four 7 mm screws (6). INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE 2.4.1 February 2001...

  • Page 11: Rep 2.5 Side Guide Jogger Motor Mot 3

    You should have 0.1-0.3 mm play between the plate and the flange bushing on both sides (1). Tighteen the three screws. Bookletmaker SR 85 PAGE 2.5.1...

  • Page 12: Rep 2.6 Back Jogger Motor Mot 7

    4. Tighten the setscrew (3) on the flat of the shaft. 5. Connect the ground wire (1). 6. Install the infeed module according to REP 2.1. 7. Check/adjust the Staple/fold position according to REP 5.2. Bookletmaker SR 85 PAGE 2.6.1 February 2001...

  • Page 13: Rep 3.1 Stapler Head

    1. Install the plunger (4) in the plunger retraction swing arm (3). 2. Push the Stapler head down so that the pivot pin (6) locks under the latch (2). 3. Connect the staple detection lead (1). Bookletmaker SR 85 PAGE 3.1.1...

  • Page 14: Rep 3.2 Stapled Set Stop Gate Solenoid Sol 2

    5. Cut the ty-wrap securing the cable. 6. Disconnect the solenoid connector. 7. Loosen the two screws (2). 8. Slide the solenoid towards the infeeder to remove. INSTALLATION Installation is an exact procedure of removal Bookletmaker SR 85 PAGE 3.2.1 February 2001...

  • Page 15: Rep 3.3 Staple Stop Gate Position, Adjustment

    3. Center the fingers (2). 4. Tighten the front allen screw(4). 5. Insert a 0.3 mm feeler gauge (3) to obtain 0.3 ± 0.2 mm endplay. 6. Tighten the rear allen screw (5). Bookletmaker SR 85 PAGE 3.3.1 February 2001...

  • Page 16: Rep 3.4 Stapler Assembly Drive Bar Position, Adjustment

    3. Loosen the locknut (3). 4. Rotate the screw (2) to adjust. 5. Tighten the locknut (3). Bottom bearing Adjustment of the Bottom bearing is performed the same way as adjustment of the Top bearing. Bookletmaker SR 85 PAGE 3.4.1 February 2001...

  • Page 17: Rep 3.5 Stapler Home Position, Adjustment Sw 1

    3. Rotate the motor linkage (3) to the top dead center. ADJUSTEMENT 1. Check that the gap is 0.0 mm to 0.2 mm. 2. Loosen the two screws (1). 3. Move the switch (2) to adjust. 4. Tighten the two screws (1). Bookletmaker SR 85 PAGE 3.5.1 February 2001...

  • Page 18: Rep 3.6 Stapler Head Retraction, Adjustment

    1. Push down the stapler head (1). 2. Check that the gap is 1.0 to 2.0 mm. 3. Loosen the three screws (3). 4. Rotate the screw (2) to adjust. 5. Tighten the three screws (3). Bookletmaker SR 85 PAGE 3.6.1 February 2001...

  • Page 19: Rep 3.7 Saddle Stapling Sensor, Adjustment Sen 1

    2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked. NOTE: Use white paper to block the sensor. 2. Loosen the nut (4). 3. Move the sensor (3) to obtain the voltages. 4. Tighten the nut (4). Bookletmaker SR 85 PAGE 3.7.1 February 2001...

  • Page 20: Rep 4.1 Upper Folder Roller

    0.1 to 0.5 mm between the sprocket (2) and the plastic spacer. Also check that the enplay on the rear side is 0.1 to 0.5 mm between the collar and the plastic spacer. 2. Adjust the fold pressure according to REP 4.3. Bookletmaker SR 85 PAGE 4.1.1 February 2001...

  • Page 21: Rep 4.2 Lower Folder Roller

    Removal of the Lower left folder roll is performed the same way as removal of the Lower right folder roll, in addition the Outfeed cover has to be removed according to REP 1.3. INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE 4.2.1 February 2001...

  • Page 22: Rep 4.3 Fold Pressure, Adjustment

    (8) in order to align the folder roll movement with the spring load . Rear fold pressure assembly Adjustment of the Rear fold pressure assembly is performed the same way as adjustment of the Front fold pressure assembly. Bookletmaker SR 85 PAGE 4.3.1 February 2001...

  • Page 23: Rep 4.4 Fold Knife Home Position, Adjustment Sw 2

    1. Check that the gap (3) between the switch housing and the actuator arm is 0.1 mm to 0.5 mm. 2. Loosen the two screws (1). 3. Move the switch (2) to adjust. 4. Tighten the two screws (1). Bookletmaker SR 85 PAGE 4.4.1 February 2001...

  • Page 24: Rep 4.5 Outfeed Sensor, Adjustment Sen 4

    2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked. NOTE: Use white paper to block the sensor. 2. Loosen the nut (2). 3. Move the bracket (1) to obtain the voltages. 4. Tighten the nut (2). Bookletmaker SR 85 PAGE 4.5.1 February 2001...

  • Page 25: Rep 5.1 Staple Stop Gate Parallelism, Adjustment

    2. Insert a screwdriver in the notches (3) and rotate to align the holes (1) with the straight edge fold (2). 3. Tighten the screw (4). 4. Check/adjust the Staple/Fold position according to REP 5.2. Bookletmaker SR 85 PAGE 5.1.1 February 2001...

  • Page 26: Rep 5.2 Staple/Fold Position, Adjustment

    5. Rotate the two screws (3) to adjust. 6. Push in the fold stop assembly when tighten the two screws (2). 7. Repeat Adjustment 1 until the fold is parallel to the edge of the set. Bookletmaker SR 85 PAGE 5.2.1...
  • Page 27 4. Adjust the sheet size on the control panel to align the Back jogger with the trail edge of the set without producing a buckle in the set. 5. Select Run mode and run a few sets. 6. Repeat Adjustment 3 until the edges of the booklet are aligned. Bookletmaker SR 85 PAGE 5.2.2 February 2001...

  • Page 28: Rep 5.3 Stapler Position To Anvil, Adjustment

    8. Position an allen wrench (2) - app. 2 mm - as shown to relieve the pressure on the sta- ple former. 9. Install the Alignment tool (1) as shown. NOTE: Head alignment tool is located at the bottom of the front side frame. 10. Remove the allen wrench (2). Bookletmaker SR 85 PAGE 5.3.1 February 2001...
  • Page 29 5. Position the Stapler head so that the Alignment tool is centered (side to side) in the slot. 6. Tighten the right mounting screw (8). 7. Return the machine to operational condition. 8. Run a test set to verify the adjustment. Bookletmaker SR 85 PAGE 5.3.2 February 2001...

  • Page 30: Rep 5.4 Stapler Pressure, Adjustment

    Check both front and rear side. 2. Loosen the four screws (1). 3. Move the upper stapler bar (2) to adjust. 4. Tighten the screws (1). 5. Check/Adjust the Stapler assembly drive bar position according to REP 3.4. Bookletmaker SR 85 PAGE 5.4.1 February 2001...

  • Page 31: Rep 5.5 Stapled Set Transport Drive Alignment, Adjustment

    6. Tighten the allen screw (8). 7. Loosen the two allen screws (6). 8. Move the assembly (5) so that the tires (3) are centered on the Pressure rollers (1). 9. Tighten the two allen screws (6). Bookletmaker SR 85 PAGE 5.5.1 February 2001...

  • Page 32: Rep 5.6 Pressure Roller Height, Adjustment

    5 mm allen wrench to check that it does not fit in the gap. 2. Loosen one nut (1) and reposition the other (1) as required to obtain the gap. 3. Check/adjust the Stapled set transport solenoid according to REP 5.7. Bookletmaker SR 85 PAGE 5.6.1...

  • Page 33: Rep 5.7 Stapled Set Stop Gate Release Solenoid, Adjustment Sol 1

    3. Measure the hight (1) again. The difference should be 0.5 mm to 1.0 mm 4. Loosen the two screws (2) and move the solenoid to obtain the dimension. 5. Tighten the screws. Bookletmaker SR 85 PAGE 5.7.1 February 2001...

  • Page 34: Prg 6.1 Reset Of Eeprom Values

    6. Move DIP switch no. 1 on the controller PCB to the left (left when facing the PCB). 7. Reinstall the rear cover according to REP 1.1. Normal mode < > Reset EEPROM Ricoh mode Not used Not used location of DIP switch rear view Bookletmaker SR 85 PAGE 6.1.1 February 2001...

  • Page 35: Edi Connection Cable Wiring Diagram Sr85

    EDI 7.2 Connection cable wiring diagram SR85 Bookletmaker SR 85 PAGE 7.2.1 February 2001...
  • Page 36 Continue EDI 7.2 Connection cable wiring diagram SR85 Bookletmaker SR 85 PAGE 7.2.2 February 2001...

  • Page 37: Edi 7.3 Electrical Components List

    Transform er PAGE 7.4.3 REC 1 Rectifier PAGE 7.4.1 FL 1 Filter PAGE 7.4.1 Capacitor PAGE 7.4.1 Interface receptacle PAGE 7.4.3 Stacker receptacle PAGE 7.4.1 PCB PL75-1 Controller Printed circuit board PAGE 7.4.1 Bookletmaker SR 85 PAGE 7.3.1 February 2001...

  • Page 38: Edi 7.4 Electrical Components Location

    EDI 7.4 Electrical components location REAR VIEW TP 1-16 SW 5 PCB PL75-1 SW 3 SW 6 Interlock bypass switch actuator SW 4 Common ground REC 1 FRONT VIEW Set counter MOT 10 MOT 8 SW 7 Bookletmaker SR 85 PAGE 7.4.1 February 2001...
  • Page 39 Continue EDI 7.4 Electrical components location VIEW INSIDE OUTFEED COVER LEFT VIEW SEN 4 SEN 2 FOLD AREA SHOWN IN TIPPED POSITION MOT 5 MOT 6 SW 2 MOT 12 Bookletmaker SR 85 PAGE 7.4.2 February 2001...
  • Page 40 Continue EDI 7.4 Electrical components location VIEW INSIDE INFEED COVER SOL 2 MOT 4 SOL 1 F3 F2 F4 SW 1 MOT 2 MOT 1 RIGHT VIEW INFEED COVER REMOVED SW 7 AC Receptacle Bookletmaker SR 85 PAGE 7.4.3 February 2001...
  • Page 41 Continue EDI 7.4 Electrical components location VIEW OF INFEED AREA SEN 3 SEN 5 BOTTOM VIEW OF REMOVED INFEEDER SEN 7 MOT 7 MOT 3 SEN 6 MOT 9 STAPLER AREA SEN 1 Bookletmaker SR 85 PAGE 7.4.4 February 2001...

  • Page 42: Edi 7.5 Test Points

    Not used TP 13 Length adjustment minimum limit switch SW 4 High inactivated TP 14 Trimmer connected High inactivated TP 15 Rear staple detection High inactivated TP 16 Front staple detection High inactivated Bookletmaker SR 85 PAGE 7.5.1 February 2001...

  • Page 43: Fip 8.1 Self Diagnostic System Control (Sds)

    DIP switches on the controller PCB has to be to the left (left when facing the PCB) and the SR 85 has to be cleared from paper sheets in order to perform the SDS. NOTE2: If the SDS is repeated, switch off the power, wait a few seconds, switch on the power again to return the motors and solenoids to home position.
  • Page 44 PCB and common ground is less than 0.9 VDC when the switch is activated and greater than 2.2 VDC when the switch is inactivated. Controller PCB defective. If checks above is good, replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.2 February 2001...
  • Page 45 If c h e c k s a b o v e is g o o d , re p la c e th e c o n tro lle r P C B . Bookletmaker SR 85 PAGE 8.1.3...
  • Page 46 2.2 VDC when not in contact. Use a screw driver to connect the stapler head with the anvil. Controller PCB defective. If check above is good, replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.4 February 2001...
  • Page 47 Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 14 and 7 on connector J8 to the motor connector. Controller PCB defective. Replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.5 February 2001...
  • Page 48 Wires defective. Disconnect the solenoid connector. Check the wires for an open circuit using a voltmeter. Measure from 5 on connector J2 to 5 on connector J9. Controller PCB defective. Replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.6 February 2001...
  • Page 49 When you are running a SDS with a NOTE: Trimmer. The Bookletmaker is only running SDS on itself. So the machine will not feel anything behind the Bookletmaker, and will think that the Beltstacker is not connected. Bookletmaker SR 85 PAGE 8.1.7 February 2001...
  • Page 50 Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 1 and 2 on connector J8 to the motor connector. Controller PCB defective. Replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.8 February 2001...
  • Page 51 Measure on connector J1 between 15C and 19A. And between 19A and 1A. Controller PCB defective. If check above is good, replace the controller PCB. Bookletmaker SR 85 PAGE 8.1.9 August 2000...

  • Page 52: Mai 9.1 Preventive Maintenance

    MAI 9.1 Preventive Maintenance Note: All INSTRUCTIONS are referring to the Bookletmaker SR 85 Service Manual. The REFERENCE column is referring to the Spare parts list of Model SR85. CHECK POINT INSTRUCTION REFERENCE 125000 250000 All machine, Paper paths etc.
  • Page 53 REP 3.6 when replacing stapler heads. Staple stop gate release arm Apply silicon grease on Page 1.9 Grease/ solenoid. SOL 2 both friction areas. Check Item 3 Check that the stop gate latches and releases correctly. Bookletmaker SR 85 PAGE 9.2.1 February 2001...
  • Page 54 REP 2.3 for adjustment. Booklet quality Check the booklet quality according to REP 5.1 - 5.2 and REP 5.4 - 5.7 Check/Adjust Check/ Adjust Bookletmaker SR 85 PAGE February 2001 9.3.1...
  • Page 55 Molex Minifit 8-pol CONTROL PANEL SEN 7 MOLEX HALL SEN 6 SENSOR M3 HOME POSITION M3 SENSOR AMP CT MOLEX Molex Minifit 2-pol (From Motorcablage) J1-15C J1-19A SIDE JOGGER MOTOR [+12V] J1-1A Mate'N lock J2-8 [+12V] J1-4C J2-1 FOLD KNIFE MOTOR J1-30A J2-9 SEN 1, SADDLE STAPLING SENSOR (LED)

Table of Contents