Watkiss Automation BookMaster Service Manual
  1. Manuals
  2. Brands
  3. Watkiss Automation Manuals
  4. Booklet makers
  5. BookMaster
  6. Service manual

Watkiss Automation BookMaster Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Watkiss BookMaster Service Manual - Issue 1 - 14/12/00
Watkiss BookMaster
Service Manual
Including BookMaster and TrimMaster Standard and Pro Versions
Issue Date :
14 December 2000
Issue Number : 1
Part Number : 969-240
Watkiss
Automation
Limited
1 Blaydon Road
Middlefield Industrial Estate
Sandy, Bedfordshire
SG19 1RZ U.K.
Tel: +44 (0)1767 682177
Fax: +44 (0)1767 691769
Email: info@watkiss.com

Advertisement

Table of Contents
loading
Need help?

Need help?

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

Questions and answers

Related Manuals for Watkiss Automation BookMaster

Summary of Contents for Watkiss Automation BookMaster

  • Page 1 Issue Number : 1 Part Number : 969-240 Watkiss Automation Limited 1 Blaydon Road Middlefield Industrial Estate Sandy, Bedfordshire SG19 1RZ U.K. Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769 Email: info@watkiss.com Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 2 The information contained in this document is subject to change without notice. Watkiss Automation Limited makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose.

  • Page 3: Table Of Contents

    3.2.6 Replacing the Staple Latch Solenoid.........21 3.2.7 Removal and Fitting of Fold Rollers ........22 3.2.8 Fold Roller / Blade Alignment..........23 3.2.9 Fold Blade Replacement............25 3.2.10 Fold Blade Clutch Replacement........25 3.2.11 Squaring Up Procedure...........28 Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 4 4.2.2 900-152b, Position Motor Control Board (PIC)....63 4.2.3 900-155b, Auto VTR Control Board ......... 64 4.2.4 900-156, Staple Head Control Board ....... 65 4.2.5 900-157, BookMaster Pro Main Control Board ....66 4.2.6 900-164, BookMaster Interface Board ......67 4.2.7 900-165a, BookMaster Clinch Drive......... 67 4.2.8 900-168, BookMaster Standard Main Control Board ..
  • Page 5 7.5.1 Using the BMI as a collecting station......101 7.6 BookMaster Infeed Guide (BIG) ......... 101 7.7 BookMaster Offline Control Panel (BCP) ...... 101 7.8 Installing the BookMaster with a Watkiss Vario collator ..102 7.8.1 Accessories..............104 7.8.2 Connecting to the Watkiss Vario Oscillating Floor Base. .105 7.8.3 Nagle Panel and Settings ..........105...
  • Page 6 Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 7: System Description

    System Description • Introduction Chapter 1 System Description 1.1 Introduction The Watkiss BookMaster and TrimMaster have been designed to be used on- line to the Watkiss Vario or other manufacturers’ benchtop collators. They may also be used offline for hand feeding.

  • Page 8: Bms Bookmaster Standard 115V

    System Description • Compatibility & Configurations Notes : 1. The Offline Control Panel (BCP) will control the TrimMaster Pro, but is fitted to the BookMaster Pro. Table 1-2 : Module Compatibility BMS (BookMaster Standard) BMP (BookMaster Pro) Off-line • Use off-line for hand feeding •...

  • Page 9: Bookmaster Overview

    Figure 1:1 ‘‘BookMaster : Overview of key components’’ identifies the vari- ous components involved in the BookMaster cycle. Note that items 2a, 2b and 3 are present only on the BookMaster Pro. 1.3.1 Normal Operating Cycle (when booklet-making) Jogging: Collated sets drop into the tamper area of the BookMaster.
  • Page 10 (11). The fold knife (9) pushes the set through the two steel fold rollers (12), which then open up (via a planet Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 11: Status Indication

    AC input, 100 times a second (50hz) or 120 times a second (60hz) which is used primarily as a timing signal for the BookMaster. The Zerox will also react to mains power fluctuation by turning the motor off.
  • Page 12 • Single short bleep when infeed Internal comms error, or sensor is covered uncleared jam condition. This bleep is also emitted when Top Jog is disabled Table 1-6 : Error bleeps Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 13: Trimmaster Overview

    (2) and then between the blade and anvil. A solenoid, trig- gered by a signal from the staple sensor in the BookMaster, pushes the paper stop latch (10) into its vertical position. The latch stops the book in the re- quired position.

  • Page 14: Bookmaster Outfeed Conveyor (Boc)

    1.5 BookMaster Outfeed Conveyor (BOC) The BookMaster Outfeed Conveyor takes finished documents from the out- feed of the BookMaster or the TrimMaster and conveys them to an integral payout table. Power may be taken from the TrimMaster or the BookMaster.

  • Page 15: Bookmaster Infeed Guide (Big)

    1.7 BookMaster Infeed Guide (BIG) The BookMaster Infeed Guide is designed to aid hand feeding sets into the BookMaster. It is a low cost alternative to the Motorised Infeed. It can NOT be used as an infeed when connecting the BookMaster to collators.

  • Page 16: Bookmaster Offline Control Panel (Bcp)

    System Description • BookMaster Offline Control Panel (BCP) 1.9 BookMaster Offline Control Panel (BCP) The BookMaster Offline Control Panel (BCP) provides control of the Book- Master Pro and TrimMaster Pro when they are used off-line (see Table 1:3, BookMaster Configurations).

  • Page 17: Bookmaster Pro

    PCB. Details of the tap settings are shown in the tables below. TAP SETTING INPUT 93 - 110V 105 - 127V 187 - 220V 210 - 254V Table 1-10 : Transformer Tap Settings Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 18 System Description • Fuses Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 19: Tools And Materials

    6” Rule (steel) 952-013 12” Rule 3,4,5mm Pin Punches 3/4LB Ball Pein Hammer 952-183 ‘E’ Clip Applicator 7B - Straight BookMaster Setting Plate - Watkiss Tool 10106 Table 2:1 Recommended Tools Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 20: Consumables

    Tools and Materials • Consumables 2.2 Consumables PART NO. DESCRIPTION Lint Free Cloth 951-007 Loctite 242 (Thread Locking Compound) 951-152 Anti-seize Compound Lubricant Table 2:2 Consumables Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 21: Service Procedures

    Figure 3:1 and Figure 3:2 identify machine covers that are removed during some service procedures. Top cover Rear panel Stapler cover panel R/H side cover L/H side cover Fold latch cover panel Figure 3:1 BookMaster Machine Covers Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 22: Bookmaster Standard

    Figure 3:2 TrimMaster Machine Covers 3.2 BookMaster Standard The procedures in this section (3.2) refer to both the BookMaster Standard and the BookMaster Pro. A separate section includes additional procedures which apply only to the BookMaster Pro (see section 3.3 ‘‘BookMaster Pro’’).

  • Page 23: Fitting A Third Staple Head

    Note: Provision is made to fit the third staple head on either the L/H or R/H side of the BookMaster. The unit is manufactured with the necessary wiring installed for fix- ture on the L/H side. If fixture is required on the R/H side, then the wiring for the clincher and staple head PCBs must be re-routed and secured using cable ties.
  • Page 24 5. Using a 3mm allen key, undo the five M5 x 10mm screws that secure the stapler cover panel, lower the staple lid and remove the stapler cover panel. 6. Remove the L/H side panel on the BookMaster to give access to the Book- Master Interface PCB.

  • Page 25: Staple Sensor Calibration

    • move the edge staple selector lever to the edge staple position • use the staple head selection button to select the third head • hand feed two sheets of A4 paper into the BookMaster and check the staple. If a well-formed staple is not produced, adjust the position of the staple head by sliding further backwards or forwards in the adjustment slots.

  • Page 26: Edge Staple Latch Solenoid Adjustment

    / pre-jog function is selected. Refer to IPC 964-410 - BookMaster Standard, Issue 1 - Figure 27. PARTS REQUIRED TOOLS REQUIRED...

  • Page 27: Replacing The Staple Latch Solenoid

    6. Replace the clincher guard plate (if previously removed for checking the solenoid travel). 7. Position yourself so that you can look down into the BookMaster infeed and loosen the four solenoid assembly fixing screws. 8. Position the solenoid assembly so that the edge staple latch is as close as possible to the clincher guard, but not protruding into the paper path.

  • Page 28: Removal And Fitting Of Fold Rollers

    13. Set the solenoid position so that the staple is aligned with the fold on 6 sheets of paper. 3.2.7 Removal and Fitting of Fold Rollers Refer to IPC 964-401 - BookMaster Pro, Issue 2 - Figures 5, 6 and 7 (Fold Roller Assembly and Fold Roller Drive Assembly). PARTS REQUIRED...

  • Page 29: Fold Roller / Blade Alignment

    (908-897). 13. Repeat step 12 to remove the L/H inner lever arm (908-892). 14. Both sets of fold rollers can now be withdrawn from the BookMaster via the apertures in the side plates. Note: Make a note of roller position and orientation for reassembly.
  • Page 30 • If either one or both rules do not align with the blade then adjustment is required. 7. On BookMaster models the fold blade is used as a datum on all squaring up procedures. The fold rollers therefore need to be adjusted so that they are aligned with the blade.

  • Page 31: Fold Blade Replacement

    10. Replace the side and back covers. 3.2.9 Fold Blade Replacement The fold blade is used as the datum for squaring the BookMaster unit, so if damage has occurred requiring the blade to be replaced, the unit must be checked for squareness afterwards.
  • Page 32 11. Remove the clutch assembly. Procedure - Fitting 1. Remove the earth strap, pulley and anti-rotation nuts and screw from the existing clutch and fit them to the new assembly. The anti-rotation screw Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 33 2. Fit a new securing pin to the collar on the clutch. Only insert it a small amount so that the clutch shaft can still pass through. 3. Fit the new clutch assembly to the BookMaster. 4. Fit the clutch shaft.

  • Page 34: Squaring Up Procedure

    14. Run the machine and check the drive belt tension. Adjust if necessary. 15. Refit the rear cover. 3.2.11 Squaring Up Procedure When squaring up the BookMaster unit, the fold blade is used as a datum to which the sidelays, stitch latch and fold latch are aligned. Procedure - Sidelay Tampers...
  • Page 35 1. Set the BookMaster axes for A3>A4 size booklets. Switch off the staple heads by pressing the orange on/off button.

  • Page 36: Drive Motor Replacement

    Service Procedures • BookMaster Standard Procedure - Staple Lid The staple lid assembly is mounted to the BookMaster on two pivot block adjusters. Essentially this means that the whole assembly can be tilted to allow fine tuning of the staple position.

  • Page 37: Pcb Removal And Fitting - General Comments

    2. Loosen the 2 x M4 nyloc nuts which secure the guard switch (905-310) to the R/H side plate. 3. Close and secure the stapler cover panel and switch on the BookMaster. 4. Adjust the position of the guard switch horizontally. To function correctly, the plunger should have 1mm of travel remaining before full compression.

  • Page 38: Bookmaster Pro

    (265-567) on each side of the machine. The same thickness ring must be used on each side. Use the thinnest ring first. 4. Run some sample booklets through the BookMaster. If scuffing of the cover still occurs, change the spacer ring to the next thickness up. Continue until satisfactory performance is obtained.

  • Page 39: Axis Home Position Calibration - Sidelays

    2. Disconnect the TrimMaster Pro (if fitted). 3. Manually feed an A4 (8.5” x 11”) sheet into the BookMaster. If the fold is uneven (i.e. one half of the resulting booklet is longer than the other), re- calibration of the fold home position will be necessary. Ensure that the sheet is dropped squarely onto the fold stop, and that the sidelays aren’t set...

  • Page 40: Top Jog Belt Calibration

    If so adjustment is required. 4. Insert a 3mm allen key through the hole in the top cover panel and locate into the M5 button head adjustment screw. Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 41: Top Jog Belt Clutch Replacement

    760-336 Clutch 3 & 4mm Allen Key Procedure Refer to IPC 964-401 - BookMaster Pro Issue 2 - Figure 22 1. Switch off the mains power supply and disconnect the power lead. 2. Remove the rear panel. 3. Slacken the belt tensioner plates (253-233/234) and pull them towards you to release the belt tension.

  • Page 42: Trimmaster Standard

    Service Procedures • TrimMaster Standard 3.4 TrimMaster Standard 3.4.1 Cycling the TrimMaster by Hand The TrimMaster and BookMaster are cycled separately, to cycle the Book- Master by hand see section 3.2.1 ‘‘Cycling the BookMaster by Hand’’ PARTS REQUIRED TOOLS REQUIRED...

  • Page 43: Squaring The Trim Stop

    4mm Allen Key 150mm/6” Rule A4 Paper Procedure 1. Set the BookMaster and TrimMaster to make A4 to A5 booklets (11x17” to 8½x11”) 2. Take approximately six sheets of A4 paper and drop them into the Book- Master. 3. Mark the front cover of the produced booklet for your reference.

  • Page 44: Infeed Conveyor Pivot Point And Removal

    Procedure Refer to IPC 964-430 - TrimMaster IPC, Issue 1 - Figures 9 and 10. 1. Disconnect the mains power supply from the BookMaster/TrimMaster. 2. Disconnect the TrimMaster and place in suitable working area. 3. Remove the outfeed conveyor from the TrimMaster.

  • Page 45: Replacing Main Conveyor Belt

    914-405 Conveyor belt 514mm (top) Loctite 242 Threadlock 1. Set the TrimMaster axis to A4 (8.5”). 2. Disconnect the TrimMaster from the BookMaster and move it into a clear working area. 3. Remove both side panels. 4. Remove: rear cover (253-274) - TMS motor guard (253-200) - TMP 5.

  • Page 46: Replacing Waste Conveyor Belt

    180-302 8mm ‘C’ Clip Refer to IPC 964-430 - TrimMaster Standard IPC, Issue 1 - Figure 6. 1. Disconnect the mains power supply from the BookMaster/TrimMaster. 2. Disconnect the TrimMaster and place in suitable working area. 3. Remove both side panels.

  • Page 47: Centralising Waste Conveyor Belt

    • DO NOT make adjustments whilst the machine is running. • Make sure that you can easily reach the mains input lead. 1. Disconnect the mains power supply from the BookMaster/TrimMaster. 2. Disconnect the TrimMaster and place in suitable working area.

  • Page 48: Removing And Regrinding The Trimmer Blade

    Handle the blade with extreme caution and keep hands clear of cut- ting edges at all times. PARTS REQUIRED TOOLS REQUIRED None 3, 4, 6 & 10mm Allen Key 19mm Spanner Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 49 Service Procedures • TrimMaster Standard Procedure Separate the TrimMaster from the BookMaster. Open the TrimMaster conveyor cover. Remove the two orange hand screws and washers that secure the conveyor assembly to the TrimMaster unit (see Figure 3:21). Conveyor Securing Hand Screws...
  • Page 50 Tighten all the blade fixing screws starting from the centre and working out. Push the anvil firmly forwards against the blade (pushing from behind with your fingers at each end). Maintain a light pressure on the Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 51 Perform another test cut and make further adjustments if necessary. Hook the conveyor assembly onto the support posts and push into position. Secure with two orange hand screws and washers. Fit the side cover and secure. Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 52: Blade And Anvil Grinding Instructions

    3.5.1 Trim Axis Home Position Calibration If books are not being trimmed to the size selected on the control panel, the axis position may need calibrating. PARTS REQUIRED TOOLS REQUIRED None 3 & 4mm Allen Key Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 53 Note: It is essential that after each adjustment has been made is selected RE-REF from the adjust menu on the control panel. 5. Repeat ‘steps 1 - 5’ until trim is calibrated correctly. 6. Replace the rear cover. Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 54 Service Procedures • TrimMaster Pro Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 55: Electronics & Software

    Position Motor Control Board 900-155b Auto VTR Control Board 900-156 Staple Head Control Board 900-157/168 BookMaster Pro & Standard Main Control Boards (3 pages) 900-164 BookMaster Interface Board 900-165 Clinch Drive PCB Table 4-1 : Block and Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 56 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 57 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 58 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 59 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 60 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 61 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 62 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 63 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 64 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 65 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 66 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 67 Electronics & Software • Connection Diagrams Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 68: Pcbs

    Electronics & Software • PCBs 4.2 PCBs The following PCBs are used in the BookMaster and TrimMaster. PART NO. DESCRIPTION USAGE 900-141c Eco-Vario Interface Board BMS, BMP 900-152b Position Motor Control Board BMP, TMP 900-155b Auto VTR Control Board TMS, TMP...

  • Page 69: 900-152B, Position Motor Control Board (Pic)

    Note: If the home microswitch is broken or missing the motor will drive for- ward for approximately 3 seconds. Full details of the diagnostics for the PIC board may be found in Chapter 8 ‘‘Trouble Shooting’’ (see section 8.3.1 ‘‘Position Motor Control Board’’). Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 70: 900-155B, Auto Vtr Control Board

    LED5 Not used TrimMaster Drive Motor ON/OFF LED6 Drive motor running Trimmer Clutch LED7 Clutch actuated Trim Bin Full Sensor LED8 Sensor actuated Table 4:4 Auto VTR Control Board (900-155b) Layout Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 71: Staple Head Control Board

    Table 4:5 Staple Head Control Board (900-156) Test Mode: The staple head can be put into test mode to allow the staple head to be fired manually (see section 8.3.4 ‘‘Manually firing the staple head’’). Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 72: Bookmaster Pro Main Control Board

    Infeed Clutch Brake (Top Jog) Side staple latch solenoid (edge staple) Connection to Axis Motor PCBs (power and comms) Connections to the guard switch, conveyor outfeed socket on BookMaster and side-stitch microswitch Connection to TrimMaster socket Remote Interface Socket (742-391) opto isoltated input and output...

  • Page 73: Bookmaster Interface Board

    28V power supply connector Output to clinchers Side knock solenoid connections Stitch latch solenoid (bottom latch) Figure 4:7 900-164, BookMaster Interface Board 4.2.7 900-165a, BookMaster Clinch Drive Figure 4:8 900-165a, BookMaster Clinch Drive Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 74: Bookmaster Standard Main Control Board

    Table 4:7 900-168, BookMaster Standard Main Control Board 4.3 BookMaster Pro Software The BookMaster Pro software is stored in an area of ‘flash’ memory on the Main Control PCB (900-157). This memory is re-writable, meaning that the software can be over-written and upgraded at any time. The software is loaded...

  • Page 75: Loading Software

    Please contact us if you require the password. 4.3.1 Loading Software 1. Switch off the power on the BookMaster Pro. Remove the rear panel to access the Interface PCB. 2. Move the link switch LK1 to the ON (1) position.
  • Page 76 Electronics & Software • BookMaster Pro Software Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 77: Machine Inspections

    Machine Inspections • Chapter 5 Machine Inspections Before leaving the factory, each Watkiss BookMaster and TrimMaster is systematically checked and tested. The inspection schedules listed in this section should be used as indicated before a machine is installed at a customer’s premises.
  • Page 78 1. Check that the machine is clean 2. Record serial no.’s of PCBs, staple heads and machine 3. Cross-check machine voltage with serial label Checks completed by: Date: Table 5:1 BookMaster Standard - Pre-Delivery Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 79 • Visually check all controls are correctly fitted • Adjust the sidelays through their minimum and maximum travel • Adjust the BookMaster bottom lay through its full travel • Move the edge staple latch in and out, checking both positions 2.
  • Page 80 CHECKED COMMENTS / NOTES PASSED 1. Check that the machine is clean 2. Record the machine’s serial no. Checks completed by : Date : Table 5:2 TrimMaster Standard - Pre-Delivery Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 81 Section 5 - Running checks 1. Hand-feed 2, 4, 8, 16 and 20 sheets of A4 into the BookMaster and check that all the booklets are cut squarely and cleanly (pay particular attention to the first sheet cut, look for a ragged edge).
  • Page 82 1. Check that the machine is clean 2. Record serial no.’s of PCBs, staple heads and machine 3. Cross-check machine voltage with serial label Checks completed by: Date: Table 5-3 : BookMaster Pro - Pre-Delivery Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 83 • Voltage labels Section 5 - Pre-delivery checks 1. Check that the machine is clean. 2. Record serial no.’s of PCBs, staple heads and machine. 3. Cross-check the machine voltage with serial label. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 84 CHECKED COMMENTS / NOTES PASSED 1. Check that the machine is clean 2. Record the machine’s serial no. Checks completed by : Date : Table 5:4 TrimMaster Pro - Pre-Delivery Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 85 1. Set up machines to run A4 to A5 booklets. Hand-feed 2, 4, 8, 16 and 20 sheets of A4 into the BookMaster Pro and check that all the booklets are cut squarely and cleanly (pay particular attention to the first sheet cut, look for a ragged edge).
  • Page 86 1. Check that the machine is clean 2. Record serial no.’s of PCBs, staple heads and machine 3. Re-check all painted surfaces Checks completed by : Date : Table 5:5 BookMaster Standard - After-Build Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 87 • Check quality and consistency of squareness of fold • Check position and quality of staple • Make any adjustments and repeat if required 3. Repeat steps 1. and 2. above, but with BookMaster set to edge staple mode. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 88 • Voltage labels Section 5 - Pre-delivery checks 1. Clean all parts of the machine. 2. Record serial no.’s of PCBs, staple heads and machine. 3. Re-check all painted surfaces for scratches. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 89 1. Check that the machine is clean 2. Record the machine’s serial no. 3. Re-check all painted surfaces Checks completed by : Date : Table 5:6 TrimMaster Standard - After-Build Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 90 Section 5 - Running checks 1. With the TrimMaster connected to the BookMaster, hand-feed sets of 2, 4, 8, 16 and 20 sheets of A4 into the BookMaster and check the booklets: • Check all the booklets are cut squarely and cleanly (pay particular attention to the first sheet cut, look for a ragged edge) 2.
  • Page 91 Machine Inspections • TrimMaster Standard - After-Build Inspection Section 7 - Pre-delivery checks 1. Clean all parts of the machine. 2. Record the serial no. of the machine. 3. Re-check all painted surfaces for scratches. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 92 1. Clean all parts of the machine 2. Record Serial No.’s of PCBs, staple heads and machine 3. Check all painted surfaces Checks completed by : Date : Table 5-7 : BookMaster Pro - After-Build Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 93 • Check that the tampers engage and disengage crisply and do not stick or drag in any way 7. Hand-feed 2-sheet sets and 6-sheet sets of A4 into the BookMaster Pro and check booklets: • Check all the booklets are square, correctly folded, check the staple quality, and check both staples are central on the spine 8.
  • Page 94 Machine Inspections • BookMaster Pro - After-Build Inspection Section 3 - Running checks 1. Using as many bins as possible, run the BookMaster Pro under the Vario to make A4 > A5 booklets of 6 sheets: • Check the sets feed cleanly into the machine •...
  • Page 95 1. Check that the machine is clean 2. Record the machine’s serial no. 3. Re-check all painted surfaces Checks completed by : Date : Table 5:8 TrimMaster Pro - After-Build Inspection Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 96 Caution voltage Section 5 - Running Checks 1. Hand-feed 2, 4, 8, 16 and 20 sheets of A4 into the BookMaster Pro and check books: • Check all the booklets are cut squarely and cleanly (pay particular attention to the first sheet cut, look for a ragged edge) 2.

  • Page 97: Routine Maintenance

    TABLE ROUTINE MAINTENANCE SCHEDULE SHEET BookMaster Standard Routine Maintenance Schedule TrimMaster Standard Routine Maintenance Schedule BookMaster Pro Routine Maintenance Schedule TrimMaster Pro Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 98 10. Check tacho magnet is clean and free from debris. Check magnet head is secure 11. Check flywheel on motor is tight Checks completed by : Date : Table 6:1 BookMaster Standard Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 99 6. Check the condition of all electrical cables. Ensure all connectors are seated correctly 7. Check output to outfeed conveyor Checks completed by : Date : Table 6:2 TrimMaster Standard Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 100 12. Check tacho magnet is clean and free from debris. Check magnet head is secure 13. Check flywheel on motor is tight Checks completed by : Date : Table 6:3 BookMaster Pro Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 101 8. Check adjustment axis is accurate i.e. the home position is calibrated correctly (see section 3.5.1 ‘‘Trim Axis Home Position Calibration’’). Checks completed by : Date : Table 6:4 TrimMaster Pro Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 102 Routine Maintenance • TrimMaster Pro Routine Maintenance Schedule Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 103: Installation

    7.2 Connecting the BookMaster and TrimMaster Procedure Open the BookMaster stapler cover panel by turning the handle to the left and lifting (see Figure 7:1). The lid is supported by a strut on the right side. Figure 7:1 Opening the BookMaster stapler cover Line up the TrimMaster docking plates (see Figure 7:2) with the BookMaster.

  • Page 104: Outfeed Conveyor (Boc)

    Figure 7:4 Stapler cover panel support strut Connect the Outfeed Conveyor (see section 7.3 ‘‘Outfeed Conveyor (BOC)’’). 7.3 Outfeed Conveyor (BOC) The Outfeed Conveyor can be fitted to either the BookMaster or the TrimMas- ter. Procedure Refer to IPC 964-440 - BookMaster Accessories - Figure 1 1.

  • Page 105: Bookmaster Receiving Tray (Brt)

    Interface socket Waste conveyor Figure 7:6 TrimMaster location pegs and interface socket 5. Connect the outfeed conveyor plug to the socket on the BookMaster or TrimMaster. 7.4 BookMaster Receiving Tray (BRT) The BookMaster Receiving Tray fits only on the BookMaster, not the Trim- Master.

  • Page 106: Motorised Infeed (Mif)

    BMP (see Figure 7:9). Motorised Infeed Socket Figure 7:9 Motorised Infeed Socket Position the Motorised Infeed on the BMP, so that the fixing clips (see Figure 7:8) locate inside the BMP infeed. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 107: Using The Bmi As A Collecting Station

    The Offline Control Panel is compatible only with the BookMaster Pro (BMP), it is NOT compatible with the BookMaster Standard (BMS) The BCP is fitted on the top edge of the BookMaster Pro in place of the black curly communications cable. It can be positioned for viewing from either the left hand or right hand side of the machine.

  • Page 108: Installing The Bookmaster With A Watkiss Vario Collator

    13. Reconnect the BCP cable into the BookMaster control board. 14. The original black curly communications cable should be stored with the machine, and we recommend it is stored in the base of the BookMaster for future use if required.
  • Page 109 Installation • Installing the BookMaster with a Watkiss Vario collator BMS (BookMaster Standard) BMP (BookMaster Pro) BCH VARIO • Fit the motorised infeed to the BMS. • Fit the motorised infeed to the BMP. Benchbase • Fit the Nagle Interface panel onto the •...

  • Page 110: Accessories

    Oscillating Floor Stand Conversion Kit. This PCB 900-166 enables control of the Bookmaster Pro from the Vario control panel. It is included in the OFB and may be fitted in the base of the OSC. It would also work in the BCH, but no provision has been made for its location in the base of the BCH.

  • Page 111: Connecting To The Watkiss Vario Oscillating Floor Base

    Installation • Installing the BookMaster with a Watkiss Vario collator ure to do this will result in damage to the collator. Refer to the Watkiss Vario service manual for further details. Interface Sockets (hidden) Front Feedout Conveyor (in upper position)
  • Page 112 POSITION Table 7:2 Eco DIL Switch Positions for Nagel Interface Note: When using the BookMaster with an Oscillating Base, Oscillate must not be selected from the control panel when feeding into the BookMaster. Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 113: Trouble Shooting

    Check and adjust switch if necessary (see 3.2.14 ‘‘Guard Switch Adjustment’’). Outfeed Conveyor does not work Cable not connected to BookMaster/ Connect TrimMaster Table 8:1 Trouble Shooting Chart Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 114 Removal and Fitting - General Com- ments’’) Jamming problems Paper jams in BookMaster infeed area Infeed sidelays too tight Adjust sidelays correctly BookMaster is not central under Vario Centralise BookMaster tower Table 8:1 Trouble Shooting Chart Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 115 Delivery from collator is poor Setup the collator correctly (see Vario operating manual) Set catching on BookMaster fold rollers Bend paper straight High static charge in paper Fan the paper by hand before inserting into feed bins If BookMaster is online to Watkiss...
  • Page 116 3.3.3 ‘‘Top Jog Belt Calibration’’) Top jog parking erratic Top Jog clutch faulty Replace clutch Top jog will not calibrate Top jog clutch sticking Replace clutch. Trimming Problems Table 8:1 Trouble Shooting Chart Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 117: Error Indicators

    Table 8:1 Trouble Shooting Chart 8.2 Error Indicators Errors Indicators on the BookMaster include the Status Indicator Light, the Staple Head Indicator Lights and audible bleeps. These are explained in sec- tion 1.3.2, but are repeated here for convenience.

  • Page 118: Staple Head Indicator Lights

    Not illuminated The Staple head is not selected Table 8:3 Staple Head Indicator Lights 8.2.3 Startup and Error Bleeps A series of audible ‘bleeps’ indicate the overall status of the BookMaster. • = short bleep — = long bleep ~ = pause...
  • Page 119 1. Remove power to the Motor PCB by disconnecting PL1 or turning off at source. 2. Press and hold button switch SW1. 3. Reapply power to the board. Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 120: Terminal Emulator Mode

    Terminal Emulator mode uses the PC screen to provide diagnostic information on the BMP status. 1. Switch off the power on the BookMaster Pro. Remove the rear panel to access the Interface PCB. 2. Insert the floppy disk into the computer disk drive.
  • Page 121 Table 8:8 Status Display HELP or F3 Some of the commands listed below are not included with BookMaster Pro software 1.3d onwards. Where this is the case, a note is included. All commands listed on the help screen may also be typed directly at the first prompt, without first entering the help screen.
  • Page 122 6 = Motor error (motor or board damaged) 6. Only if third head fitted. 7. Hexadecimal numbers, with following 'BIT' significance: 0x01 = outfeed jam 0x02 = outfeed jam 0x04 = stitch guard triggered Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 123: Staple Head Control Board (900-156)

    1. Undo the five retaining screws and remove the stapler cover panel. 2. With the BookMaster turned on; unplug the data/power bus from PL1 on the relevant staple head control PCB (900-156). Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...
  • Page 124 6. If the clincher is not operating then it is possible that there is a fault in the staple head. To check if this is the case, simply swap the staple heads over. 7. Switch the mains power off and on again to resume normal operation. Watkiss BookMaster Service Manual - Issue 1 - 14/12/00...

  • Page 125: Appendix

    Table 9:1 Paper Sizes PAPER WEIGHT GSM (G/M EQUIVALENT IN # (USA) 8 # bond 11 # bond 20 # bond 74 # cover 93 # cover 110 # cover Table 9:2 Paper Weights Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...

  • Page 126: Technical Documentation Feedback Form

    691769). Please make photocopies of this form if further copies are required NAME TELEPHONE JOB TITLE DATE COMPANY PUBLICATION REVISION DATE PAGE NUMBER COMMENT Table 9-3 : Technical Documentation Feedback Form Watkiss BookMaster Service Manual - Issue 1 - 04/12/00...
  • Page 128 Watkiss Automation 1 Blaydon Road, Middlefield Industrial Estate, Sandy, Bedfordshire SG19 1RZ U.K. Limited Tel: +44 (0)1767 682177 Fax: +44 (0)1767 691769 Email: info@watkiss.com Watkiss BookMaster Service Manual - Issue 1 - 04/12/00 Part Number 969-240...

This manual is also suitable for:

Trimmaster standardTrimmaster pro

Table of Contents