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GBR Systems M-40 Operator's And Service Manual

Gbr systems m-40 no envelope mailer operator & service manual
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M-40 Operator & Service Manual
ISSUE 05/01
071-27939-400(-)
M-40 OPERATOR & SERVICE MANUAL
ISSUE 05/01
COVER
071-27939-400(-)
- 1 -

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Summary of Contents for GBR Systems M-40

  • Page 1 GO TO TABLE OF CONTENTS M-40 Operator & Service Manual ISSUE 05/01 071-27939-400(-) M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 COVER 071-27939-400(-) - 1 -...
  • Page 2 NOTICE While every care has been taken in the preparation of this manual, no liability will be accepted by GBR Systems Corporation arising out of any inaccuracies or omissions. All service documentation is supplied to GBR Systems Corporation external customers for informational purposes only. GBR Systems Corporation service documentation is intended for use by certified, product trained service pe rsonnel only.
  • Page 3 The particular issue listed in the center is an internal tracking device. The top line of information along the right side states the title of the particular section. The bottom line lists the section and the page number within that section. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 COVER...
  • Page 4 3. LIST OF CHANGES IN 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...
  • Page 5 NOTICE! Section D - Adjustments This section contains the instructions for adjustment of the The labels shown may be affixed to the M-40 at appropriate moving parts. locations. Observe safety precautions as indicated by these. Section E – Alarm Messages This section contains messages that occur when a problem arises with operation.
  • Page 6 NOTES: M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 COVER 071-27939-400(-) - 6 -...

  • Page 7: Table Of Contents

    Double Detect Sensor................10 A.6c Feeder Encoder ..................10 A.6d Side Glue Sensor .................. 10 A.6e Folder Encoder..................10 A.6f Discharge Sensor.................. 10 A.6g Flap Glue Sensors ................10 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 INTRODUCTION 071-27939-400 SECTION A – PAGE 1...

  • Page 8: Section A - Introduction

    They are called buckle plates The M-40 is designed to securely seal open edges of a C-folded sheet of paper. To because they cause the paper to buckle in the folder rollers. When the sheet...
  • Page 9 FEEDER SINGULATOR ALIGNMENT FOLDER EXIT CONVEYOR CONTROL PANEL GLUE DISTRIBUTION SYSTEM M-40 Machine Diagram M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 INTRODUCTION 071-27939-400 SECTION A – PAGE 3...
  • Page 10 KEYBOARD GLUE BOARD GLUE GLUE GLUE GLUE J9 J10 CHANNEL INPUTS KEYBOARD RS 232 INCREASE DECREASE RESET SELECT SHUT OFF GLUE VALVE FILTER GLUE TANK COMPRESSOR M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 INTRODUCTION 071-27939-400 SECTION A – PAGE 4...

  • Page 11: Setup

    This causes all of the peripheral devices connected to the PLC to turn off. Once the EMERGENCY STOP is depressed, the M-40  Glue Compressor stops processing paper immediately. To start the machine processing paper ...

  • Page 12: Glue System Description

    As paper pressurized container, with air inlet and glue outlet tubes. Glue and air are travels past the singulator and through the alignment portion of the M-40 distributed to the glue guns through a manifold.
  • Page 13 The M-40 is configured with four glue guns: two side glue guns and two flap glue guns. The glue gun controller individually controls each gun. The glue gun controller can control up to 16 glue guns. An optional Business Reply Envelope (B.R.E.) feature is available.

  • Page 14: Theory Of Operation

    CPU to know the main feed velocity. Slot 4: High-speed counter – Accepts pulses from the encoder on the folder and measures their frequency, allowing the CPU to know the folder velocity. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 INTRODUCTION 071-27939-400...

  • Page 15: A.5B Exit Conveyor

    Then the PLC checks if the batch count number has been reached or the M-40 is single sheet cycling. If 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.

  • Page 16: Sensors

    The encoder is connected to the transfer drive shaft by a timing belt. The encoder sends the CPU sixty (60) pulses for every revolution of the shaft. The CPU calculates the speed at which the M-40 is operating. inch FLAP GLUE...
  • Page 17 PURGING THE GLUE GUNS ........25 COMPRESSOR OPERATION ........28 B.7a Startup ....................28 B.7b Fault finding and Repair ..............28 B.7c Compressor Preventive Maintenance ..........32 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 1...

  • Page 18: Directory Of Page Files

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 2 MAIN CONTROL PANEL DIRECTORY OF PAGE FILES PAGE DESCRIPTION MAIN SETUP DOUBLE DETECT SENSOR DIAGNOSTIC 1 DIAGNOSTIC 2 ALARMS 1 ALARMS 2 GLUE CHANNEL PURGE MAINTENANCE SIDE GLUE SETUP...

  • Page 19: Touchscreen Operation & Maintenance

    TOUCHSCREEN OPERATION & MAINTENANCE When the M-40 has been turned on for operation, make sure that the cooling fan is running. The fan goes on when the main power switch is turned on. The PanelMate unit’s touchscreen is designed for finger or gloved finger operation only.

  • Page 20: Touchscreen Operator Interface

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 4 TOUCHSCREEN OPERATOR 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”.
  • Page 21 (sheets per hour) this will assure that the paper supply in the hopper does not run out. CLEAR ENTER CANC M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 5...
  • Page 22 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 6 8. Continue to enter all of the other parameters as shown using the procedure as previously described. ENTER NEW VALUE NOTE: Make sure you are deliberate when touching the buttons to allow for the screen to respond.
  • Page 23 13. Select “ON”. This turns the side glue channel 1 on which controls the side glue guns electronically. DOT SIZE AS DEFINED BY SPOT TIME PITCH LINE (BEAD) SPOT Glue Placement Parameters M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 7...
  • Page 24 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 8 14. Select “SPOT” mode. This mode controls the method of dispensing glue. In “SPOT” mode the glue guns are electronically cycled to dispense droplets of glue equally spaced for a duration of time which determines the length of glue dots on the side edges of the paper.
  • Page 25 CANC the sheet with the lead edge at the center of the side glue nozzles. 20. Select “MAIN”. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 9...
  • Page 26 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 10 21. Select “FLAP GLUE 1 SETUP” 22. Select “FLAP GLUE 1”. 23. Select “ON” from side menu. This turns on channel 2 that controls the flap 1 guns electronically.
  • Page 27 2”, use the same setup parameters as “FLAP GLUE 1”. 31. Select ‘FLAP GLUE 2”. 32. Select “ON” from side menu. This turns on channel 3 that controls the flap 2 guns electronically. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 11...
  • Page 28 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 12 33. Select “DELAY TIME”. ENTER NEW VALUE 34. Enter the number shown. 35. Select “SPOT TIME”. 36. Enter the number shown. 37. Select lockout time. 38. Enter the number shown.
  • Page 29 “ON” button is selected it will turn on channel 4 which will control the Z side glue guns electronically. This channel should be turned “OFF” as shown. 41. Select “MAIN”. 42. Select “BRE GLUE SETUP”. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 13...
  • Page 30 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 14 43. Select “BRE GLUE”. 44. Select “ON” from side menu. This turns the side glue BRE channel 4 on which controls the BRE guns electronically. 45. Select “LOCKOUT TIME”.
  • Page 31 It also allows jogging of the discharge conveyor to clear folded documents from under conveyor pressure wheels. 51. Select “CONVEYORS”. 52. Select “ON”. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 15...
  • Page 32 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 16 53. Select “FEED”. 54. Select “ON” for continuous feeding. 55. Select “SINGLE” for single sheet feeding. 56. Select “DISCHARGE CONVEYOR”. 57. Select “CLEAR”. This will run the conveyor long enough to...
  • Page 33 62. Select “SET 24 POUND ONE SHEET”. This automatically sets the sensor for this paper stock and enters the setting in the “24 POUND ONE SHEET PERCENT” button for future reference. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 17...
  • Page 34 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 18 ENTER 63. If you need to enter a percentage that is a little lower than NEW VALUE the actual detected percentage, you can change it with manual input.
  • Page 35 69. Select “MAIN” to go to other pages for functions and modes. 70. Select “DIAGNOSTIC”. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 19...
  • Page 36 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 20 The diagnostic pages 6 and 7 are used to determine if all sensors that are used to control various functions of the machine are set and working properly. The first display “HOPPER”...
  • Page 37 Don’t wait until the condition gets so bad that it takes hours to clean. get the proper seal when setting up the job. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 21...

  • Page 38: Glue Gun Adjustment

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 22 GLUE GUN ADJUSTMENT Adjusting screw for The glue guns are adjusted mechanically at the factory for dispensing uniform mechanical adjustment glue spot size for all glue guns. Normally, mechanical adjustments of the glue of glue spot size guns is not necessary once they leave the factory.

  • Page 39: Filling The Glue Tank

    Shut off valve Air in STEP 1: Open the cabinet and remove the glue tank. Place the glue tank on the floor next to the M-40, making sure not to over extend or tangle the air and glue tubing. Glue out...
  • Page 40 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 24 STEP 3: Remove glue tank cover and place glue tank cover on a clean surface. Make sure rubber seal is clean and free of glue. Rubber Seal STEP 2: Lift up and rotate tank cover lock handle.

  • Page 41: Purging The Glue Guns

    Refer 5. Fill the glue tank with warm water. 6. Close and secure the glue tank cover. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 25...
  • Page 42 This simplifies the placement of buckets to receive the outflush. NOTE: You can leave the glue in the system without running the M-40 for up to 3 days without cleaning. However, it is better to clean the 9.
  • Page 43 Purge Screen Glue System Diagram M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 27...

  • Page 44: Compressor Operation

    No power from mains. Check fuses and plug. b) Breakage or loose joints in electrical connections Pressure c) The starting relay is defective. Contact GBR Systems Corporation. Switch d) The pressure switch is defective and does not switch on the compressor.
  • Page 45 Dismount the non-return valve and change O-ring. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 29...
  • Page 46 Air leaks from the relief valve when the compressor is operating. 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 oil level glass.
  • Page 47 (Cut-in pressure + differential = cut-out pressure). Turn clockwise to increase cut-out pressure. The switch is normally factory set for operation at 6-8 bar (approximately. 0-120 psi). See figure below. Pressure Switch M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 31...

  • Page 48: B.7C Compressor Preventive Maintenance

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 32 B.7c Compressor Preventive Maintenance Adding Lubricant to Compressor: CAUTION: Always use SJ-27 oil as other types of oil may cause serious Remove filler cap. mechanical damage to the compressor. Consequently the warranty Insert unstopped end of tubing into filler hole.
  • Page 49 Check the O-ring in the check valve and replace if necessary. NOTE: Empty receiver of air before dismounting. NOTE: See Section C Maintenance for more information on Compressor parts. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 33...
  • Page 50 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 OPERATION SECTION B – PAGE 34 NOTES:...
  • Page 51 A sheet passed the feed sensor but did not reach the flap glue 1 sensor. DISCHARGE SENSOR JAM A jam has occurred at the folder discharge sensor. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ALARM MESSAGES SECTION E – PAGE 1...
  • Page 52 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ALARM MESSAGES SECTION E – PAGE 2 NOTES:...
  • Page 53 SECTION F REPAIR AND REPLACEMENT F.1 REPAIR ANALYSIS PROCEDURES .........2 F.2 PM PROCEDURE .............. 8 F.1a Initial Actions ..................2 F.2a Feeder: Feed Belt ................... 8 F.1b Drive Motor RAP................... 3 F.2b Drive Rollers................... 8 F.1c Double Detection RAP................3 F.2b Auxiliary Belts..................

  • Page 54: Section F

    The Repair Analysis Procedures section is used to isolate an identified problem to a faulty component or subassembly. It contains this Introduction 5. Turn ON the M-40, select “RUN” from main page and turn on conveyors: and the Repair Analysis Procedures (RAPs).

  • Page 55: F.1B Drive Motor Rap

    Analysis: Each time the Feed Clutch energizes, the Double Detect Sensor board replacement does not fix the problem go to the next step. expects to see one document. If a second document is detected the M-40 will d) Replace the Main Drive Motor.

  • Page 56: F.1E Paper Could Not Be Fed Rap

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 4  • See Section B page 16 Initial Action: clear the paper that was jammed in the machine and remove 3. Place one sheet of the current stock in the sensor area and adjust the any obstructions.
  • Page 57 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?  • Replace the sensor. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 5...

  • Page 58: F.1E Small Sheet Rap

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 6 F.1e Small Sheet RAP Initial Action: Clear the paper that was jammed in the machine and remove any obstructions. 1. Does the paper move through the feeder properly? ...

  • Page 59: F.1G Creeper Conveyor Motor Rap

    • Replace the Feed Clutch. Refer to Section H Schematics. 1. When the M-40 is powered up and the 450 Feeder is selected, power is F.1h Incorrect Folds RAP supplied to the Feeder via the AC outlet of the M-40. The Creeper Motor goes on? 1.

  • Page 60: Pm Procedure

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 8 auxiliary asm off this shaft to remove previous shaft out of the way, in PM PROCEDURE order to change feed belt. PM’s are done to replace any worn parts on this machine. This prevents any ...

  • Page 61: Singulator Roller

    1/8" red belting are also on the shaft before putting shafts the shaft. in proper place. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 9...

  • Page 62: Folder Perf Knives

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 10  At this point, you should be able to remove the transport unit from the folder.  Remove one side of the transport unit, by removing two (2) screws, take the side plate off, at this point you should be able to remove the grey belt and replace with new ones.
  • Page 63 NOTES: M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 REPAIR AND REPLACEMENT SECTION F – PAGE 11...
  • Page 64 SECTION G PARTS 700-27278-500, M-40 TOP ASSEMBLY ............2 703-27277-500, FOLDER, 4 PLATE, PAGE 3 ..........32 005-27276-500, CABINET ASSEMBLY ............4 703-27277-500, FOLDER, 4 PLATE, PAGE 4 ..........34 502-27486-500, ELECTRONICS ASSEMBLY ..........6 703-27277-500, FOLDER, 4 PLATE, PAGE 5 ..........36 549-27234-500, FEEDER ASSEMBLY, PAGE 1 ...........

  • Page 65: 700-27278-500, M-40 Top Assembly

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 2 700-27278-500, M-40 TOP ASSEMBLY inch...

  • Page 66: Cabinet Assembly

    579-27643-500 RIGHT FOLDER COVER 579-27644-500 LEFT FOLDER COVER 703-27277-500 FOLDER,4 PLATE 705-27642-500 4 GUN GLUE SYSTEM 705-27740-500 6 GUN GLUE SYSTEM 750-27291-500 EXIT CONVEYOR 750-27401-500 CREEPER CONVEYOR M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 3...
  • Page 67 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 4 005-27276-500, CABINET ASSEMBLY VIEW SHOWN WITH DOOR REMOVED.
  • Page 68 FIXED CASTER WHEEL 547-27198-600 FRAME,FEEDER 579-27233-600 DOOR 580-27199-600 CABINET DECK 580-27200-600 END PANEL 580-27201-600 END PANEL 580-27203-600 BASE PLATE 584-25590-600 PLATE 600A-13967 LOCATING PIN 600B-16133-007 SPACER BLOCK M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 5...
  • Page 69 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 6 GLUE BOARD SSR1A SSR1B SSR2A SSR2B 20VR1 502-27486-500, ELECTRONICS ASSEMBLY...
  • Page 70 POWER SUPPLY,12 V,1.7A FUSES 024-27870-000 JUMPER 033-27874-000 FUSE HOLDER F1, F2 032-00150250 FUSE,15A,3AB F3, F4 032-00100250 FUSE,10A,3AB F5, F6 032-00015250 FUSE,1.5A,3AG F7, F8 032-00080250 FUSE,8A,3AG F9, F10 032-00075250 FUSE,.75A,3AG M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 7...
  • Page 71 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 8 SEE DETAIL E 549-27234-500, FEEDER ASSEMBLY, PAGE 1...

  • Page 72: Feeder Assembly

    LOWER BELT 123-6AL CLAMP COLLAR 126-SC25 COLLAR 172-24280 ADJUSTING LEVER 172-24281 ADJUSTING LEVER 173-2194 RUBBER BUMPER 181-3600401000 COMPRESSION SPRING 320-25234-600 SENSOR SLIDE BLOCK 320-25236-600 SENSOR ADJUST BLOCK M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 9...
  • Page 73 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 10 SECTION B - B SECTION A - A SECTION D - D 549-27234-500, FEEDER ASSEMBLY, PAGE 2...
  • Page 74 TIMING PULLEY ASSEMBLY 113-20008003712 TIMING BELT,8”PL 113-200090037 TIMING BELT,9”PL 113-200290037 TIMING BELT,29”PL 113-S290XL100 TIMING BELT 122-27767-500 FRICTION CLUTCH ASSEMBLY 123-8AL CLAMP COLLAR,.50ID 126-2X737 SETSCREW COLLAR 152-27392-000 BEARING,.375ID,.187” M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 11...
  • Page 75 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 12 SECTION C - C DETAIL E COVER VIEW 549-27234-500, FEEDER ASSEMBLY, PAGE 3...
  • Page 76 549-27265-500 SINGULATOR ASSEMBLY 579-27273-600 FEEDER TRAY 579-27357-600 TOP COVER 579-27358-600 SINGULATOR COVER 592-27245-500 RIGHT PAPER RAIL 600A-15839-117 FLAT WASHER 600A-15915-052 HOLE PLUG XXXX XXXX 600A-16349-020 DRIVE PULLEY M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 13...
  • Page 77 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 14 LOWER RAISE 549-27265-500, SINGULATOR ASSEMBLY...
  • Page 78 600A-16435-005 WAND,PAPER DETENT 600A-16435-006 AXLE,PAPER DETENT 600A-16914 NUT,.25-56 600B-15915-044 STACK SWITCH ACTUATOR 600B-16435-002 ROLLER GUARD 600B-16435-007 ADJUSTING FORK 600B-16435-008 ADJUSTING PLATE 600B-16435-009 ADJUSTING KNOB 014-SW15 ADJUSTING SCREW M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 15...

  • Page 79: 002B-18043, Auxiliary Feed Belts

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 16 002B-18043, AUXILIARY FEED BELTS...
  • Page 80 002B-18043, AUXILIARY FEED BELTS INDEX PART NUMBER DESCRIPTION 002A-16439 PULLEY,REAR IDLER 002B-16440 HOUSING,OUTSIDE BELT 019-511562 RETAINING RING 152-B81012 BUSHING 600A-16438-001 PULLEY,FLAT BELT 600A-16438-002 AXLE 600B-16438-003 BELT M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 17...

  • Page 81: 750-27401-500, Creeper Conveyor

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 18 750-27401-500, CREEPER CONVEYOR...

  • Page 82: 16631 Front Shaft Assembly

    600A-23344 BRACKET 600A-23367 PULLEY 600A-23385 CLIP 600A-23482 COUPLING 600B-15841-014 TENSION BAR 600B-15841-019 LOCK ANGLE 600B-23368 SHAFT 600B-23475 MYLAR COVER 600B-23483 MOTOR SPACER 600C-15841-001 600D-23346 REAR CREEPER COVER M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 19...
  • Page 83 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 20 002B-16631, FRONT SHAFT ASSEMBLY...
  • Page 84 002B-16631, FRONT SHAFT ASSEMBLY INDEX PART NUMBER DESCRIPTION 112-26947-500 IDLER PULLEY 014-10221132 SHCS,#10-32 X 2.00 020-RN010C0604 SPACER,#10CL,.25” 181-03000401000 SPRING 600A-15841-008 FRONT SHAFT 600B-15841-007 FRONT SHAFT BRACE 019-710037 RETAINING RING M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 21...

  • Page 85: 705-27642-500, Glue System, 4 Gun

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 22 220/32 GLUE IN CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 OUTPUT OUTPUT OUTPUT OUTPUT AIR IN LEFT SIDE RIGHT SIDE LEFT FLAP RIGHT FLAP AC INPUT...

  • Page 86: Glue System, 6 Gun

    AIR VALVE,MECHANICAL 186-5490A125 PLUG,.125 186-5490A250 PLUG,.250 186-5490A500 PLUG,.50 186-5490Q250X12 HEX NIPPLE,.25 X .125 NPT 186-5490XISO564 FITTING,M5 X 6 186-54727636 SHUT OFF VALVE 186-5490Q500X25 HEX NIPPLE,.5 X .25 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 23...
  • Page 87 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 24 220/32 GLUE IN CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 OUTPUT OUTPUT OUTPUT OUTPUT AIR IN LEFT SIDE RIGHT SIDE LEFT FLAP RIGHT FLAP LEFT FLAP...
  • Page 88 AIR VALVE,MECHANICAL xxxx xxxx xxxx xxxx 186-5490A500 PLUG,.50 186-5490Q250X12 HEX NIPPLE,.25 X .125 NPT 186-5490XISO564 FITTING,M5 X 6 186-54727636 SHUT OFF VALVE 186-5490Q500X25 HEX NIPPLE,.5 X .25 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 25...
  • Page 89 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 26 705-27183-500, GLUE TANK ASSEMBLY...
  • Page 90 FITTING,.25NPT X .25 HOSE 130-27187-000 BRASS HEX NIPPLE,.25 130-27188-000 FITTING, ADAPTOR 130-27189-000 FITTING,PLUG 130-27190-000 FITTING,COMPRESSION,90 DEG 135-27185-000 VALVE,RELIEF 141-27184-000 REGULATOR,MINI PNEUMATIC 145-27186-000 PRESSURE GAUGE 705-27182-000 TANK,PRESSURE GLUE MODULE M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 27...

  • Page 91: Folder, 4 Plate

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 28 703-27277-500, FOLDER, 4 PLATE, PAGE 1...
  • Page 92 020-27751-600 SPACER,.812 020-27750-600 SPACER,.750 014-M0421140 SCREW,M4 X 40mm 014-M0621140 SCREW,M6 X 40mm 016-M10600 WASHER,LOCK,M6 016-M10400 WASHER,LOCK,M4 007-27914-600 COVER BRACKET 007-27915-600 COVER BRACKET 039-67295001 CONNECTOR 039-76484002 MALE PIN M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 29...
  • 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 POLYFLEX BELT 186-034001366 SUPPORT 186-032006185 186-032021493 WASHER 186-034001365 SUPPORT WITH BUSHING 186-031107001 WASHER 186-032011588 186-034001419 SPRING ANCHOR 186-031108001 LOCKWASHER 186-031122001 HEX NUT,M6 186-033000384 WASHER 186-032012389 SPACER BUSHING M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 31...
  • 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: Folder, 4 Plate

    186-031107003 WASHER 186-031122003 HEX NUT,M5 186-034001488 RIGHT ADJUSTMENT 186-034001499 RIGHT BEARING 186-032006480 186-032006481 186-032016909 186-032016910 186-032006479 186-032006478 186-034002158 COLLAR 186-032051148 RIGHT BAR 186-032011845 WASHER 186-033500015 SET SCREW M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 33...

  • Page 97: Folder, 4 Plate

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 34 703-27277-500, FOLDER, 4 PLATE, PAGE 4...

  • Page 98: Folder, 4 Plate

    LEFT ADJUSTMENT 186-032012387 SPACER BUSHING 186-034001503 LEFT BEARING 186-032006480 186-032006481 186-032016909 186-032016910 186-032006479 186-032006478 186-034002158 COLLAR 186-032051152 LEFT BAR 186-032011845 WASHER 186-033500015 SET SCREW 186-031167005 SCREW,M5 X 12mm M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 35...
  • Page 99 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 36 703-27277-500, FOLDER, 4 PLATE, PAGE 5...
  • Page 100 BHSCS,#4-40 X .625 095-24260-600 SENSOR MOUNT SHAFT 014-06251104 SHSS,#6-32 X .25 014-02600008 PHMS,#2-56 X .50 007-27399-600 BRACKET 014-08251106 SHSS,#8-32 X .375 600B-16891 SLIDE 186-034002476 HOLDDOWN ASSEMBLY 186-031027387 GUIDE STRIP M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 37...

  • Page 101: Fold Plate 1

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 38 563-27650-500, FOLD PLATE 1 2027937 2032014 2016819 2052219 2016820 1025047 1025046 0071014 4007856 2018066 1043018 1017103 2016247 1110014 2016244 2032015 4001685 2041068...
  • Page 102 PIVOT ARM 516-24253-600 RIGHT MOUNTING BLOCK 516-24254-600 LEFT MOUNTING BLOCK 516-24259-600 MOUNTING BLOCK 584-24251-600 RIGHT MOUNTING PLATE 584-24252-600 LEFT MOUNTING PLATE 586-24284 PLUNGER,RETRACTABLE SPRING 007-27774-600 SENSOR BRACKET M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 39...

  • Page 103: 563-27998-500, Fold Plate 1, Z Fold Option

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 40 563-27998-500, FOLD PLATE 1, Z FOLD OPTION 2016390 2016819 2018066 1025046 2032015 2041068 2016244 inch 4007856 2016819 1043018 1025047 1017103 2016247 2052219 2032014 2027937...
  • Page 104 563-27998-500, FOLD PLATE 1, Z FOLD OPTION INDEX PART NUMBER DESCRIPTION 007-24250-600 GUN MOUNTING BRACKET 007-24255-600 MOUNTING BRACKET 095-24260-600 SENSOR MOUNTING BAR 186-5412A11211 SENSOR 584-24256-600 MOUNTING PLATE 584-24257-600 MOUNTING PLATE M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 41...

  • Page 105: 186-034007856, Paper Stop, Fold Plate

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 42 186-034007856, PAPER STOP, FOLD PLATE 2041070 1155004 4001285 M4x20 1155004 2032012 1133002 1131003 1003031...

  • Page 106: 186-034004811, Fold Plate 2

    186-034004811, FOLD PLATE 2 2027902 2027901 2032018 2016820 2016819 1025047 1025046 4007856 1043018 1017103 2016247 2016390 2016244 4001685 1017121 2032015 2041068 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 43...

  • Page 107: 186-034004812, Fold Plate 3

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 44 2027902 2027899 2016820 2032038 1025047 1025046 2016819 2016242 4007856 1017103 2016247 1043018 2016390 4001685 2016244 186-034004812, FOLD PLATE 3 1017122 2032037 2041068...

  • Page 108: 186-034004813, Fold Plate 4

    186-034004813, FOLD PLATE 4 2027902 2027901 2016820 2032038 2016819 1025047 1025046 4007856 1017103 2016971 2016247 4001685 2016390 1043018 1110014 2032037 2016244 1017123 2041068 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 45...

  • Page 109: 563-27999-500, Fold Plate 4, Z Fold Option

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 46 563-27999-500, FOLD PLATE 4, Z FOLD OPTION 2027902 2027901 2032018 2016820 2016819 1025047 1025046 2016819 4007856 1043018 1017103 2016247 2016390 2016244 4001685 1017121 2032015 2041068...
  • Page 110 563-27999-500, FOLD PLATE 4, Z FOLD OPTION INDEX PART NUMBER DESCRIPTION 007-24250-600 GUN MOUNTING BRACKET 007-24255-600 MOUNTING BRACKET 095-24260-600 SENSOR MOUNTING BAR 186-5412A11211 SENSOR 584-24256-600 MOUNTING PLATE 584-24257-600 MOUNTING PLATE M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 47...
  • Page 111 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 48 186-034004814, BYPASS PLATE 1 & 3 2066128 2026370 2016257 2016256 2016257 1025046 1025047 4001375 4001374 2026370...
  • Page 112 186-034004815, BYPASS PLATE 2 & 4 2066130 2016257 2027872 2016256 2016257 1025046 1025047 4001375 2027872 4001374 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 49...

  • Page 113: 186-034007855, Bypass Plate 2 & 4, Z Fold

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 50 186-034007855, BYPASS PLATE 2 & 4, Z FOLD 2066130 2016257 2016257 2027872 2016256 1025046 1025047 2032011 2032011 4001375 4001374...
  • Page 114 NOTES: M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 51...

  • Page 115: Exit Conveyor

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 52 750-27291-500, EXIT CONVEYOR, PAGE 1...
  • Page 116 007-27384-600 RIGHT BRACKET 007-27385-600 LEFT BRACKET 010-24286 RULE LABEL 014-M05003016 PHILLIPS SCREW,M5 X 16 035-83011080 PLUG 600A-18745 S.C. BRACKET 600A-18855 EXIT GUIDE STRIP 750-27251-000 EXIT CONVEYOR, ASTRO M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 53...
  • Page 117 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 54 750-27251-000, EXIT CONVEYOR, PAGE 2...
  • Page 118 186-37CDR0125 COVER 186-371230683 SCREW,#6-32 X 5/16”PH UNDERCUT 186-37CD50001 WIRE HARNESS,SWITCH – TRANS 186-371230089 FUSE HOLDER 186-371230680 FUSE,.5A,250V (115V,60Hz) FUSE,.3A,250V (220V,50HZ) 186-371231179 186-371230080 C-CLIP,3/16” 186-37CD30061 186-375710078 MOTOR PULLEY,28T M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PARTS SECTION G – PAGE 55...
  • 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 M-40 Machine schematic M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 SCHEMATICS SECTION H - PAGE 1...
  • Page 121 BLUE CLEAR GREEN/YELLOW GLUE BOARD INSERTER FEEDER 2 AC INPUT 32 VAC BROWN BLACK BLUE CLEAR GREEN/YELLOW 220/32 VAC GBR SYSTEMS CORPORATION 250 VA 12 INSPIRATION LANE, CHESTER, CT. 06412 TEL: 860-526-9561 T-1-81057 TITLE SCHEMATIC M-40 NO ENVELOPE MAILER page...
  • Page 122 WHITE BLACK PULSE (HP RES. 0.1) BLACK ANL COM +VDC GLUE BOARD BLACK BLACK DB-9F DB-9M PORT 2 RS-232 WHITE BLACK GBR SYSTEMS CORPORATION 12 INSPIRATION LANE, CHESTER, CT. 06412 TEL: 860-526-9561 TITLE TITLE SCHEMATIC M-40 NO ENVELOPE MAILER page...
  • Page 123 Z SIDE GLUE IN 15 INSERTER 1 BROWN SETUP AT STAGE 1 ORANGE IN 13 SENSOR BLUE BLACK BLACK BLACK IN 14 IN 15 GBR SYSTEMS CORPORATION 12 INSPIRATION LANE, CHESTER, CT. 06412 TEL: 860-526-9561 TITLE SCHEMATIC M-40 NO ENVELOPE MAILER page...
  • Page 124 OUT 11 SSR2A SSR2B OUT 12 SPARE OUT 13 FEED DRY CONTACT OUT 14 INSERTER 1 POWER GBR SYSTEMS CORPORATION 12 INSPIRATION LANE, CHESTER, CT. 06412 TEL: 860-526-9561 OUT 15 INSERTER 2 POWER TITLE SCHEMATIC M-40 NO ENVELOPE MAILER page...
  • Page 125 GND TB BLACK WHITE GND TB GROUND TO GLUE BOARD BLACK BLACK WHITE WHITE GND TB GROUND TO PLC GBR SYSTEMS CORPORATION TO OPTIONAL 12 INSPIRATION LANE, CHESTER, CT. 06412 EQUIPMENT TEL: 860-526-9561 TITLE SCHEMATIC M-40 ONE STEP MAILER page...
  • Page 126 I.9 PAPER STORAGE ............5 I.3a The Rigidity or Bending Resistance of Paper........... 3 I.10 PAPER SPECIFICATIONS ..........5 Paper Grain ....................3 I.5 OPACITY ................4 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 1...

  • Page 127: Section I

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 2 GENERAL GUIDELINES AND INFORMATION IMPORTANT NOTE: ALTHOUGH GBR IS WILLING TO ASSIST CUSTOMERS IN THE DEVELOPMENT OF CRITERIA FOR THE SPECIFICATION OF PAPER AND FORMS Porosity can also affect moisture problems in paper. Paper that SUPPLIES IN PARTICULAR APPLICATIONS, THE is very porous absorbs moisture quickly.

  • Page 128: Stiffness

    The Direction in 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 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 3...

  • Page 129: Opacity

    This can increase the wavy edge GBR Systems often includes electronic OMR and 3 of 9 problem. Paper in the range of 10 Gurley seconds (porosity Barcode Reading. The paper used in these applications should rating) will tend to cause this type of problem.

  • Page 130: I.8B Adjusting Relative Humidity (Rh)

    NOTE: The minimum paperweight recommended for use in be required during dry winter seasons or during rainy summer the M-40 and M-8 INS is 24-pound bond paper. (90 GSM) seasons. Grams Per Square Meter PAPER STORAGE The unit “Grams per Square Meter”(GSM or g/m2) is universally...
  • Page 131 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 6 Chart Of Equivalent Paper Weights EQUIVALENT PAPER WEIGHT CHART This chart gives weights of different paper types that are all (in reams of 500 sheets) equal to the same grams per square meter. Weights are based...
  • Page 132 500 x 707 24x36 610x914 13.9 x 19.68 353 x 500 25x38 635x965 9.84 x 13.9 250 x 353 25.5x30.5 648x762 6.93 x 9.84 176 x 250 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 7...
  • Page 133 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 PAPER SELECTION SECTION I – PAGE 8 MAILHANDLING PAPER SPECIFICATIONS (Cut Sheet, Continuous Forms, Envelopes, And Inserts) Property Rating Paperweight 20 - 24 lbs (75-90g/m²) Porosity 20 Gurley Seconds Grain Direction Stiffness: 175-225 Gurley Stiffness 20 Lb.
  • Page 134 SECTION C MAINTENANCE DAILY MACHINE MAINTENANCE DUTIES....2 Operator maintenance is critical to efficient operation of the M-40. Operational adjustments of machine components and daily machine maintenance require PART MAINTENANCE ...........5 only a few moments and are easily performed. The requirements of glue reservoir replenishment and checking of the glue system are essential daily C.2a...

  • Page 135: Section C

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 2 DAILY MACHINE MAINTENANCE DUTIES 2. Clean the folder with Spudger and Cleaning Tool. Inspect all undercut areas in the rollers for glue build up and carefully At the beginning of each day of operation the following simple steps should be remove the glue residue.
  • Page 136 6. Purge the glue gun nozzles. M-40 It is generally recommended to use a damp soft cloth and the Spudger. During the production of documents the flap glue nozzles may become fouled with small amounts of glue.
  • Page 137 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 4 It may be necessary from time to time to remove the glue gun nozzle tip Adjustment of Tip Sealer sealers and wipe excess glue from the glue orifice. This can be done without removing the flap glue guns from the buckle plate.
  • Page 138 M-4 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 5...

  • Page 139: Part Maintenance

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 6 PART MAINTENANCE C.2a Compressor Filters Air service equipment should be initially maintained annually. 1. Before attempting to service any unit, shut off the air supply and exhaust the system completely.
  • Page 140 Shutoff Valve 137-28138-000 Check Valve 138-28136-000 Filter Regulator 141-27789-000 Pressure Switch Relief Valve 041-28140-000 138-28139-000 Mist Separator Unit 141-27784-000 Compressor Pressure Switch Compressor Filter Regulator O’ Ring 186-556243000 Check Valve O’ Ring M-4 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C –...
  • Page 141 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 8 C.2b Glue Gun Parts Replacement 1. Shut off glue valve. 2. Purge glue and residual pressure from the gun. 3. Remove the nozzle and replace the parts.

  • Page 142: Bimonthly Machine Maintenance Duties

    2. Check document for square folds. Documents that are sent into the BIMONTHLY MACHINE MAINTENANCE DUTIES folder exactly perpendicular to the folder rollers will fold perfectly square provided the stop bar in the buckle plate is also square. The feeder’s 1.

  • Page 143: Purging The Glue Guns

    D. Adjust the paper infeed guides to match the side rails. The infeed guide’s NOTE: This activity is necessary only when the M-40 is scheduled to be put width should be equivalent to the width of the paper stock. (Hand feed a off-line and remain unused for greater than one week.
  • Page 144 Before loading glue in the system after an extended shutdown period, first purge all residual water from the glue lines. Refer to section B.5. Glue System Schematic Note: Residual water that is not removed from the glue system will lower the viscosity of the glue resulting in poorly glued packages.

  • Page 145: Authorized Outside Service

    Customer Service Engineer. Use the following guidelines to aid in determining what is wrong and what may need to be done. Determine which subsystem of the M-40 exhibits the problem. The alarm messages displayed on the M-40 operator interface indicate to the operator which subsystem is affected: ...

  • Page 146: C.6B Folder Alarms

    Feeder Area Singulator and Demand 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 there is no paper jammed in the folder and the display persists, then contact the Customer Service Engineer.
  • Page 147 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 MAINTENANCE SECTION C – PAGE 14 NOTES:...
  • Page 148 Side Glue Application Adjustment ............. 12 D.2g Flap Glue System Adjustment ............13 D.2h Sensor Adjustment................13 opposite side frame, the part is centered. Feed Belt on Feeder M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 1...

  • Page 149: Section D

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 2 D.1a Centering of the Feed Belt D.1c Auxiliary Feed Belts NOTE: It is recommended that the feed belt be centered first. The red auxiliary feed belts support and help feed the bottom shingle stacked sheet.

  • Page 150: D.1D Singulating Area

    4. Tighten the sides in position. NOTE: Be sure the side rails are feeding the paper parallel to the Singulator Roller (i.e.: each rail must be parallel to the sides of the Singulator Roller). M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS...
  • Page 151 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 4 8. This will tell you if you need to lower the Singulating Roller if more than D.1fa Position of Singulator Roller one sheet is fed, lower the Singulator two knob clicks. If after adjusting...
  • Page 152 ORANGE FEED 5. Secure all three screws. ROLLERS LOOSEN TWO BRAKE PLATE SCREWS Singulator Roller Parallelism LOOSEN SET SCREW Singulator Roller Rotation M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 5...

  • Page 153: Folder

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 6 FOLDER Adjusting the Fold Plate D.2a Folder Plates 1. Remove the Fold Plate as illustrated below. 2. Place the Fold Plate onto a table or secure flat surface.

  • Page 154: D.2B Standard Folds

    Accordian Fold (Z) option Buckle Plate #1 When running the M-40 at throughout speeds of 26,000 sheets/hour or more, position the Flap 1 Glue Sensor as far away from the Buckle Plate Stop as possible by moving the sensor bracket assembly to the opposite ends of the adjustment slots.
  • Page 155 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 8 FOLDING STYLES Single Fold Parallel Letter Fold Accordian or Double Parallel Fold Statement Fold Starting Point Type Fold Sheet Size Fold Stop Folder Plate Location Setups Single 8 ½”x11”...
  • Page 156 Plate #1 Buckle Plate Plate #1 Buckle Plate Plate #2 Buckle Plate Plate #2 Bypass Plate #3 Bypass Plate #3 Bypass Plate #4 Bypass Plate #4 Bypass M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 9...
  • Page 157 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 10 Accordian Fold Double Parallel Fold with Flap Accordian Fold Address down Double Parallel Fold Leading Edge Address down Leading edge EXIT EXIT Plate #1 Buckle Plate OPERATOR SIDE...

  • Page 158: D.2C Folder Roller Tension Adjust

    CAUTION: This tension is set at the factory and does not have to be changed. When knives wear out and no longer perforate to proper depth, replace with a new set of knives. M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS...

  • Page 159: D.2E Exit Conveyor

    M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 12 D.2e Exit Conveyor Exit Conveyor D.2f Side Glue Application Adjustment The Exit Conveyor is located at the output end of the Folder. The merged documents exiting the Folder are shingle stacked on the Exit Conveyor. As The starting point of the side glue is controlled by the location of the side each document exits the Folder it passes through the Discharge Sensor.

  • Page 160: D.2G Flap Glue System Adjustment

    CAUTION: Do not adjust the sensors until making sure that simply cleaning the lens will correct any operating problem. Qualified service personnel should adjust sensors. This is the flap glue system that is located on the #4 Buckle Plate on the M-40 Sensor Amplifier for performing the “Z” fold (optional).
  • Page 161 M-40 OPERATOR & SERVICE MANUAL ISSUE 05/01 ADJUSTMENTS SECTION D – PAGE 14 The proper method of adjustment for these sensors is as follows: All sensors Light-ON mode  Order Operation Trimmer Indicators Adjustment GREEN 1. With the target removed, turn the trimmer ...

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