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cardfolder service manual

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2. 0868 CAN TERMINATOR 182 557 b wd FEEDER GAN LINK 160 814 HEAD UNIT CAN LINK 160 512 mea any mo t kam Pad LOOM CARDFLDER INTERFACE 182 450 LOOM 4W 4W XH LINK 0 25M s mm e pu 35 AM4 MODULE PCB A RB 180 785 luta os 8 182 512 LOOM 4W 4W XH 0 5M fra oor o z A FOLD 2 CLUTCH 5 no I l J13 ET o 181 147 9 P8 ji ii a FH M25 FOLD PLATE u 1 BRAKE COVER LINK lm us 182 563 bns E COVER LINK Lis LONGUBANGE 182 565 Se cen E SENSOR PCB B EL 182 423 LOOM ZWSM 22WXH 0 24M exse ee 182 421 LOOM 4R7 RESISTOR LINK 182 717 LOOM CRD FOR RIBBON SET 4 PART SET 180 790 lis u 1 1 H woror le le 181 069 E E ui e B CERE ESTEE MTR W D 179 072 8B S E Em AC MOTOR CW f ji z Ie E 8 e
3. 2 8 2 8 Drive Components aee rh aaepe ER ga Pda 2 9 2 9 Over uide Components RR ERR IR YR EE EUER RIA 2 10 2 10 Conveyor Components ne ex 2 11 2 11 Fold RONGE S sen i a i i da a 2 12 2 12 Idle Posts Hinges Drive Belts etc see eenennnennznni 2 13 2 13 ate EA RE YQ Un ae EE bieba i 2 14 2 14 List of Fasteners iius se eere e 2 15 2 15 CIM Interface Kit eire ER taa ERR EER E ERA oa 2 16 Section 3 Electrical items amp Wiring Diagrams Page 3 1 List of Electrical 5 3 2 3 2 Feeder Folder PCB Circuit Part 1 3 3 3 2 Feeder Folder PCB Circuit Part 2 3 4 3 3 Cardfolder Interface PCB 3 5 3 4 Cardfolder Long Range Sensor PCB Circuit 3 5 3 5 Cardfolder Mk 2 Wiring Diagram eese 3 6 3 6 Cardfolder Mk 1 Wiring Diagram eese 3 7 cont Pagei CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Section 4 Description of Operation Page 4 1 General xo MANU e PE dX E ak 4 2 4 2 Cardfolder 5 4 2 4 2 1 Infeed 4 2 4 2 2 Infeed Operatlon
4. CARDFOLDER SERVICE MANUAL Page2 14 100 140 CARDFOLDER SERVICE MANUAL 2 14 List of Fasteners Used SCREWS E2502A E2559A E2815A E2512A E2509A E2624A E2520A E2507A E2581A E2516A E2824A E2527A E2508A E2523A E2567A E2574A WASHERS amp NUTS E4011A E4012A E4051A E0367A E0367A G6001A G6002A E3501A M3 x 8 CSK HD SCREW M3 x 10 POZI PAN HD SCREW M4 x 4 POZI PAN HD SCREW M4 x 6 CAP HD SCREW M4 x 8 CAP HD SCREW M4 x 8 POZI PAN HD SCREW M4 x 8 GRUB SCREW M4 x 10 CAP HD SCREW M4 x 12 POZI PAN HD SCREW M5 x 10 CAP HD SCREW M5 x 10 POZI CSK HD SCREW M5 x 16 CSK HD SCREW M5 x 12 CAP HD SCREW M5 x 20 CAP HD SCREW M5 x 20 CSK HD SCREW M5 x 45 CAP HD SCREW M4 WASHER M5 WASHER WAVED WASHER 22ID FOR 12mm FL BRG E1087A WAVED WASHER 23ID FOR 8mm FL BRG E1078A WAVED WASHER 23ID FOR 3 8 FL BRG E1080A WASHER SPRING 8mm PLASTIC WASHER YELLOW M5 NUT DOWEL PINS amp CIRCLIPS E5074A E5071A E5122A E5098A E5004A E5005A E5027A E5025A E5073A E5019A E5092A 3mm x 8 DOWEL PIN 3mm x 14 DOWEL PIN 3mm x 14 GROOVED PIN S8 3mm x 18 DOWEL PIN 01 8 x 3 4 ROLL PIN 01 8 x 7 8 ROLL PIN 1 8 x 1 ROLL PIN 8mm CIRCLIP 9 5mm E CLIP 12mm CIRCLIP 12mm E CLIP CARDFOLDER SERVICE MANUAL Page 2 15 100 140 CARDFOLDER SERVICE MANUAL 2 15 Interface Kit An interface kit is available for CIM card processing machines For full details of connecting the interfa
5. Fig 14 NOTE Early machines are fitted with 2 fold plates instead of a cassette Both fold plates are adjusted as described above CARDFOLDER SERVICE MANUAL Page 1 10 100 140 CARDFOLDER SERVICE MANUAL 1 3 Cardfolder setup This section provides assistance to field technicians to setup the Cardfolder module and also highlight corrective actions required to reduce form skew and fold variation Please ensure that the Cardfolder Lenze clutch retrofit kit A0431A has been fitted as per fitting instruction K4049A and also ensure firmware version 4 1 0 0 or later has been installed to ensure consistent cassette detent positioning also improves inconsistent folding in the Cassette Mechanical Setup there are a number of mechanical adjustments required to setup the cardfolder module which is always carried out by End of Line testing However there may be some cases where fine tuning may be required to ensure consistent feed and folding with certain supplies paper and card positions Th j men nsi f the following 1 3 1 The infeed convevor height on the cardfolder module can be adjusted to suit forms being fed from the card svstem Adjustment is bv slackening the screws located inside the Cardfolder back cover B9113T The lateral adjustment should also be made so that the form does catch either sideguide and enters the cardfolder cleanly If adjusted incorrectly this can lead to skew feeding folding see Fig 15 below Ensure
6. ire ec e en rre 4 2 4 2 3 Fold 1 RE Edo ER Rad 4 3 4 2 4 Fold 1 Operation siwi kai aa eon iere ena 4 3 4 2 5 Fold 2 D scmpblofi sues meet Da oae eee P ue vcre 4 3 4 2 6 Fold 2 Operation 4 4 CARDFOLDER SERVICE MANUAL Page ii 100 140 CARDFOLDER SERVICE MANUAL Section 1 Service operations and Adjustments 1 1 Preventative maintenance 1 1 1 Preventative maintenance checklist 1 1 2 Removal of covers 1 1 3 Service at 6 months or 1 million inserts 1 2 Service operations 1 2 1 Removal of cassette 1 2 2 Removal of fold plate 1 1 2 3 Conveyor belt replacement 1 2 4 Pressure arm adjustment 1 2 5 Fold plate adjustment 1 3 Cardfolder Setup 1 4 Recommended Spares Page 1 1 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Section 1 Maintenance and Adjustments CAUTION Prior to carrying out any maintenance procedures on the Cardfolder the following safety precautions must be observed e Switch the machine OFF and disconnect the mains cable from the power supply do not remove any cover before doing this Failure to isolate the mains could result in death or injury e Before switching the machine back on after completion of maintenance work ensure all external covers are in place and undamaged Replace anv covers that are damaged PUT SAFETV FIRSTI Note All items shown in this section relate only to the Cardfolder unit and are in
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8. A0359A Cardfolder Mk 1 PART DESCRIPTION QTY 181 147 CLUTCH W D 179 159 SMCLUTCH LENZE 1 181 148 BRAKE W D 179 108 2WXH LENZE 1 182 340 LOOM EMITTER 200 SM 1 182 341 LOOM RECEIVER W A 200 SM 1 C8074A ROLLER FOLD LOWER 1 C8076A ROLLER FOLD UPPER 1 D0022A ROLLER TRANSPORT 25 x 8 8 F4150A GEAR 40T x 8mm 1 0M 1 F4151A GEAR 48T x 8mm 1 0M 1 F4156A GEAR 30T x 8mm 1 0M 1 F5004A BELT 160XL 037 1 F5008A BELT 220XL 037 1 F5011A BELT 120XL 037 1 F5014A BELT 100XL 037 1 F5054A BELT 188T HTD 564 3M 09 1 F5153A BELT 490 XL 037 BANDO 1 Page 1 21 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Blank Page CARDFOLDER SERVICE MANUAL Page 1 22 100 140 CARDFOLDER SERVICE MANUAL Section 2 Parts Identification 2 1 Chassis LH 2 2 Chassis RH 2 3 Chassis assembly 2 4 Outer cassette components 2 5 Inner cassette components 2 6 Pressure arm assembly 2 7 Fold plate 1 components 2 8 Drive components 2 9 Overguide components 2 10 Conveyor components 2 11 Fold rollers 2 12 Idle posts hinges drive belt amp sundries 2 13 Covers 2 14 List of fasteners used 2 15 Interface Kit Page 2 1 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Section 2 Parts Identification Using this section This section portrays components used on the 100 140 Cardfolder and their part numbers To enable the relevant area to be identified the Chassis LH and RH sides shown at the beginning will indicate the page
9. F1434A PULLEY 20XL CLUTCH BBRG 1 13 C6380A GENEVA BLOCK 2 14 181 117 CLUTCH W D EC25CW XH 24V 2 15 2 PULLEY 32 XL 1 16 F1243A PULLEY 18 XL x 8mm 2 17 F5014A BELT 100 XL 1 18 E1054A 12mm BRG 9 19 D0022A ROLLER TRANSPORT 28mm x 8 32 20 E1134A BEARING BALL 8 x 16 x 5mm 2 21 E5073A 9 5mm E CLIP A R 22 P2420A GENEVA PIN 2 23 D1077A PAPER EJECT KNOB not shown 1 24 H0011A POLYESTER SHIM 0 32m 25 E5126A PIN GROOVED 3 DIA x 8 St Stl not shown 6 26 B2 1428 A FPI DEFLECTOR PLATE 1 CARDFOLDER SERVICE MANUAL Page 2 8 100 140 CARDFOLDER SERVICE MANUAL 2 8 Drive Components Ref Part No Description Qty 1 F1251A PULLEY 20T HTD3 x 8mm 230V 1 la F1428A PULLEY 16T HTD3 x 8mm 115V 1 181 069 MTR W D 179 072 4WJST CW 230V 1 2a 181 569 MTR W D 179 073 4WJST CW 115V 1 3 F1196A PULLEY MOULDED 96T HTD3 1 4 B7708A SENSOR DISC 130 SLOT 1 5 F4150A GEAR 40T 1M x 8mm INBOARD 3 6 C9645A MAIN DRIVE SHAFT 1 7 F1375A PULLEY ASSY 25 XL 1 8 C0035A 12mm BEARING HSG 6 9 E1054A 12mm BEARING 9 10 C9641A PULLEY SHAFT 1 11 E5010A ROLL PIN 01 8 x 1 1 4 1 12 F1127A PULLEY 48 XL 1 13 F5054A BELT 188T HTD3 564 3M FOR ITEM 1 1 14 F5004A BELT 160X L FOR ITEM 12 1 15 F5011A BELT 120 XL FOR ITEM 17 1 16 C9649A CLUTCH SHAFT 2 17 F1367A PULLEY 16 XL x 8mm 2 18 F1366A PULLEY 20 XL x 8mm 1 19 F4151A GEAR 48T 1M x 8mm 2 19a A2 1125 A 48T GEAR amp HUB ASSY for Lenze clutch outside 1 C2 1080 A BEARING BUSH Assem
10. General 4 2 Cardfolder Sub Modules 4 2 1 Infeed Description 4 2 2 Infeed Operation 4 2 3 Fold 1 Description 4 2 4 Fold 1 Operation 4 2 5 Fold 2 Description 4 2 6 Fold 2 Operation CARDFOLDER SERVICE MANUAL Page 4 1 100 140 CARDFOLDER SERVICE MANUAL Section 4 Description of Operation 4 1 General The sole function of the Cardfolder CF is to receive a document with card cards attached from a card affixing machine prepare this for inserting and pass this onto the inserter Typically the CF will fold the document into Z C or V fold although it is theoretically possi ble to pass a document through the unit unfolded which must be envelope sized Furthermore it is theoretically possible to perform a Double V fold although as yet un tried The CF can process documents with up to 4 cards attached however these cannot be placed in the upper panel The CF spec7 document defines the allowable card positions relative to the folds The CF must be the end module of the Maximailer system which can then support up to a further 3 modules from the standard range The 3 plate folder is not a possible option The Maximailer system when using the CF module acts as a slave to the feed machine waiting for and reacting to an incoming document The system will wait ready indefinitely but will shut down the drives after a short time out until the entry sensor is blocked If the CF module is not selected then the remaining modules
11. U1 co cO 45 CA N 1 2 3 4 5 6 7 8 Busy Error J2 Co cn cu GT pro FI SB WI Ph oO 5 Connect 4 Oram TH fixing hole 99909 90999 90090 PFE INTERNATIONAL LTD 180 789 ki CODD 5305 Geo to the mounting holes of 8095 98000 8538 CARDFOLDER INTERFACE connectors J2 SEPTEMBER 2005 PCB NO 127 261 3 3 Cardfolder Interface PCB Circuit Diagram 180 789 VCC vcc J1 R1 TOR Rx S ud a J3 1 4 5 J2 2 R2 105 ES LX 3 2 II l R3 v 100R D1 8888 98888 e 180 790 CARDFOLDER LONG KA oe A88 185089 RANGE SENSOR SEPTEMBER 2005 PCB NO 127 262 3 4 Cardfolder Long Range Sensor PCB Circuit Diagram 180 790 Page3 5 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL ASSY fiSd 430104 svO PAV
12. addition to the 100 140 service schedule See also the 100 140 Service Manual 1 1 Preventative maintenance check list When all items have been carried out worksheet must be signed to confirm 1 1 1 General 1 Ask how the machine has been working lately and use this information as a guide for checking the machine 2 Ask if there has been a change of use e g high production runs or a change of material 3 Check the operator adjustments of the machine and the material being proc essed 4 Switch on machine and confirm that no errors appear on the display screen 5 If necessary generally instruct the operators again with regard to their spe cific problem area 6 Enter the total forms count on the service sheet 7 When all service or repair operations have been carried out the machine must be left with all parts reassembled leaving no risk of injury 1 1 2 Removal of covers Note throughout this manual references to LH and RH are viewed from behind the paper path looking towards the insert head LH is also sometimes referred to as operator side and drive side for RH side Some or all of the following covers may require removal for maintenance operations Ensure all covers are undamaged Check action of opening covers to confirm correct operation and that safety microswitches function correctly Check that all warning labels are legible Exer cise caution with moving parts and exposed electrical apparatus when cov
13. euo ML ez Hoo A sr l a0 ema k ai 9814 E zH Ed m cova ML su E E T FI l ya ayy ear 1 ia H ena d ML cm E EI E als E zwa m m E PE sess Law on wool ola Moe ogia E Thyme E gt gt sina cova 1 5 f asseoa 16 x su E Mc snis ay Tao ki Thee I ais gt gt una avez aoseon EMMNET ES 5 Morc azia susce 55 x SZ uu 15 E een Was fx gt gt une 1 DM asseoa i6 0c Mo zie als T05 5 z K Mo duis T DESEE 20 ES CARDFOLDER SERVICE MANUAL Page 3 3 100 140 CARDFOLDER SERVICE MANUAL z Hed uiej6eiq 110241 804 HI9PJO4 49P994 T E 80Z ZZL 89d 00Z 4380190 c Lavd e2099 7
14. form enters side guides centrally with adequate clearance see 1 3 2 on following page Fig 15 Page 1 11 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 1 3 2 The infeed conveyor side guides should be set parallel to the side plates see Fig 16 below Adjustments can be carried out by placing a sheet of A4 or Letter in the conveyor and then adjusting the lock nuts underneath the conveyor bed to imm total clearance on either side Note if adjusted incorrectly this can lead to skew feeding folding In some cases the side guides will perform better if set slightly tapered open at the entry with 1mm clearance total at the exit Note access to the locknuts is from rear of module Side Guide L L mwg 18m M a CA T3173 L Side Guide E ET p Set side guides with 1mm clearance either side Fig 16 1 3 3 The forms are driven though the convevor and controlled bv the 4 guide springs that can be adjusted to increase or decrease the tension on the paper If these are adjusted incorrectly this may also lead to skew feeding folding Note do not apply too much tension drive or it may cause jams in the conveyor The tension should be the same on all 4 guides The guides are set just touching the bed and then locked in position without any additional tension applied making sure whilst locking no additional tension is applied Check for equal
15. of the Maximailer will perform as normal There is a signal interface from the CF to the feed machine that provides 2 signals 1 System Ready Fault a status signal which can be displayed on the feed machine control 2 Busy Ready to receive inhibits the feed machine if not clear to 1st hold point There is no feed back from the feed machine 4 2 Cardfolder Sub Modules There are 3 functional sub modules within the Cardfolder Infeed Fold 1 amp Fold 2 The main drive is by a motor within the Cardfolder which drives the various constantly running rollers conveyor and clutch inputs via various belt amp gear drives There is a slotted disc amp sensor monitoring the main drive The cardfolder utilises the same PCB as a standard feed er although has unique firmware at this time 4 2 1 Infeed Description The CF infeed consists of a conveyor amongst which there are 2 sensors the first be ing the entry sensor the second the deskew sensor The conveyor is driven direct from the main drive and runs constantly whilst the drive is on 4 2 2 Infeed Operation A document detected at the first sensor will set the machine to start the process If the system is in the non running Waiting for Prime state then it will run up the drive at this point The document will be transferred along the conveyor to block the deskew sensor and continue to the input rollers of Fold 1 where it will be held for the deskew period
16. on which a shaft or assembly can be found Fasteners used throughout are not shown in the illustrations instead a list of fasteners with part numbers is shown in Section 2 14 References to LH amp RH are viewed as standing from behind the paper path ie at input end of the machine References are also made in some part descriptions to Operator side LH and Drive side RH Quantities shown where applicable are per machine This will apply even if the item is commonly used eg bearings springs etc and is shown on multiple pages On each oc currence the quantity shown will the total for the machine Any fasteners shown will be for reference only hence quantity in each case will be A R as required Electrical Items Part numbers for PCBs clutches brakes and sensors are shown in Section 3 Their approxi mate physical locations on the machine are shown in the saddle back wiring diagram in Section 3 5 Cardfolder Mk 2 Wiring and Section 3 6 Cardfolder Mk 1 Wiring CARDFOLDER SERVICE MANUAL Page 2 2 100 140 CARDFOLDER SERVICE MANUAL SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE SEE 2 2 Chassis RH Drive Page2 3 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL SEE NOTE BELOW 2 3 Chassis Assembly Ref Part No Description 1 R2859A CARDFOLDER CHASSIS OP LH 1 2 R2840A INFEED BRIDGE 1 3 R2860A CARDFOLDER CHASSIS DR RH 1 4 R2850A MAIN BRIDGE 1 5 C8078A RUBBER FOOT UNDE
17. timed from blocking the sensor This position can also act as a hold point should there be a hold up upstream Whilst a document is on the conveyor the system will be sending a busy signal to the feed machine which should inhibit further items being sent If all is clear upstream after the deskew period the document is ready to enter the Fold 1 sub module Page 4 2 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 4 2 3 Fold 1 Description The foldi sub module consists of a pivotable fold plate assembly on which are mount ed 2 pairs of feed roller shafts each with 4 rollers The upper shaft of each pair is spring loaded against the lower driven shaft The 2 pairs of rollers are connected by a belt drive and controlled by a wrap spring clutch brake arrangement which takes its drive from the main drive Also mounted on the fold plate assembly is a sensor pair FP1 This assembly is capable of adopting one of 3 positions Up Centre amp Down and is moved between them by a Geneva mechanism driven via a belt drive by either of a pair of wrap spring clutches one acting clockwise the other counter clockwise There are 3 sensor pairs mounted on the side plate to detect the position of the Fold plate assy The outfeed from the Fold 1 sub module is via a pair of spring loaded fold rollers driven direct from the main drive 4 2 4 Fold 1 Operation Depending on the fold type selected the process would have started wit
18. to receive again Page 4 4 CARDFOLDER SERVICE MANUAL
19. 100 140 CARDFOLDER SERVICE MANUAL 100 140 Cardfolder Service Manual Contents Section 1 Service Operations and Adjustments Page 1 1 1 Preventative ee 1 2 1 1 2 Removal of 1 2 1 1 3 Service at 6 months 1 million inserts eee 1 3 1 2 1 Removal of cassette sseseennenzennnenznnnnenznnnunenzenzenzi 1 4 1 2 2 Removal of fold 8 61 1 6 1 2 3 Conveyor belt replacement nn 1 8 1 2 4 Pressure arm adjustment esses 1 9 1 2 5 Fold plate adjustment nn nn 1 10 1 3 Cardfolder Setup 1 11 1 4 Recommended 5 8 685 1 20 Section 2 Parts Identification Page 2 1 Chassis LH 2 3 2 2 Chassis RH Drive o RR EROR RI 2 3 2 3 Chassis ASSY 2 4 2 4 Outer Cassette Components sseeeenenzannnzznnanznnzznna 2 5 2 5 Inner Cassette Components cee eee tenet 2 6 2 6 Pressure Armi ASSY ka a tees 2 7 2 7 Fold Plate 1 Components
20. 181 127 CLUTCH W D EC25CCW XH 24V 1 181 132 CLUTCH W D 179 154 2WXH LENZE 1 181 147 CLUTCH W D 179 159 SM LENZE 1 181 148 BRAKE W D 179 108 2WXH LENZE 1 182 353 LOOM RX TX 300 4WSM PLG 1 182 437 LOOM EMITTER 100 XH 1 182 438 LOOM RECEIVER W A 100 XH 1 182 440 LOOM EMITTER 200 XH 1 182 442 LOOM RECEIVER N A 200 XH 1 182 443 LOOM EMITTER 300 XH 1 182 445 LOOM RECEIVER N A 300 XH 1 182 664 LOOM PIE 310 TX 300 XH 1 182 665 LOOM PIE 310D RX 300 XH 1 C6385A PRESSURE PAD 2 D0022A ROLLER TRANSPORT 25 x 8 8 D1040A BEARING HSG T 8mm 12 Sq 4 E5004A ROLL PIN 1 8 x 3 4in 6 E5005A ROLL PIN 1 8 x 7 8in 6 E5019A CIRCLIP 12mm 6 E5025A CIRCLIP 8mm D1400 6 E5027A ROLL PIN 1 8 x 1in 6 E5071A PIN DOWEL 3 DIA x 14 m6 6 E5073A CIRCLIP 9 5mm E TYPE 6 E5074A PIN DOWEL 3 DIA x 8 m6 S S 6 E5092A CIRCLIP E TYPE 12mm 6 E5098A PIN DOWEL 3 DIA x 18 m6 S S 6 E5122A PIN GROOVED S8 3 x 14LG 6 F4134A GEAR FOLD 20T x 8mm 2 0M 1 F4135A GEAR FOLD 20T x 12mm 2 0M 1 F4150A GEAR 40T x 8mm 1 0M 1 F4156A GEAR 30T x 8mm 1 0M 1 F5004A BELT 160XL 037 1 F5008A BELT 220XL 037 1 F5011A BELT 120XL 037 1 F5014A BELT 100XL 037 1 F5054A BELT 188T HTD 564 3M 09 1 F5153A BELT 490 XL 037 1 G0079A CLUTCH PIN 6 G1008C SPRING PRESSURE WHEEL 4 G1094A SPRING INT PRESSURE 4 G1117A SPRING HEAVY PRESSURE 4 G1136A SPRING OMR SHAFT 4 G4005A T BEARING 8mm 15 Sq 4 G5022A CONVBELT MAT5P 666 x 15 25 1 CARDFOLDER SERVICE MANUAL Page 1 20 100 140 CARDFOLDER SERVICE MANUAL
21. 626A IDLE POST SEE NOTE 8 E1078A 8mm FLANGED BEARING SEE NOTE 9 F4156A GEAR 30T 1M x 8mm SEE NOTE 10 P2156A GEAR POST SEE NOTE 11 P2418A CONVEYOR POST SPACER SEE NOTE 12 G0079A CLUTCH PIN A R 13 G6002A 8mm PLASTIC WASHER YELLOW A R 14 P2247A MODULE LOCATION SPIGOT 2 15 C3627A POST GEAR CLUTCH PLATE 4 16 E2502A M3 x 8 CSK HD SCREW 4 17 C2927A IDLER T BOLT not shown 2 18 R2858A COMMS BRACKET 1 Later versions extended for 4 way SM connectors Later versions swaged into plate NOTE Idler comprising items 6 7 amp 11 used in 1 off location Idler comprising items 7 amp 8 used in 4 off locations Idler comprising items 9 amp 10 used in 2 off locations Page 2 13 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 1 12 33 4 5 6 11 9 SHOWN 2 7 SHOWN 10 OPPOSITE SIDE 8 OPPOSITE SIDE 2 13 Covers Ref Description Part No Qty 1 TOP COVER HANDLE R2869F 1 2 SWITCH MAGNET SMALL 131 824 4 3 CARDFOLDER VIEWING PANEL G7162A 1 4 HINGE C6358E 2 5 HINGE PIN C4366A 2 6 CARDFOLDER BACK COVER B9113T 1 7 CARDFOLDER WIRING SKIRT OP LH B9111T 1 8 CARDFOLDER WIRING SKIRT DR RH B9112T 1 9 CARDFOLDER SIDE COVER OP LH B1887T 1 10 CARDFOLDER SIDE COVER DR RH B1886T 1 11 INFEED PLATE R2854T 1 Item 11 used only on later versions early version is shown 12 FOAM TAPE E0056A 0 81m ALSO USED WHEN FEEDER IS FITTED CARDFOLDER FEEDER COVER PLATE B9118S QTY 1 WITH COVER STOP E0003A QTY 250mm
22. DE RH 1 7 R2842A CONVEYOR BED 1 8 B9106A SIDE GUIDE LH 1 9 G1117A SPRING HEAVY PRESSURE RED 2 10 D1040A T BRG MIN 8mm 16 11 C9643A CONVEYOR IDLE SHAFT 1 12 P2145A CONVEYOR DRIVE ROLLER 2 13 C9691A OVERGUIDE SUPPORT SHAFT 3 14 E1087A BEARING FL 12 x 21 x 5mm 2 15 E5098A PIN DOWEL 3 DIA x 18 4 Page 2 11 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 4 n E 9 1 i ika 2 11 Fold Rollers Ref Part No Description Qty 1 C9691A OVERGUIDE SUPPORT SHAFT 3 2 F4134A GEAR FOLD 20T 2M x 8mm 1 3 C8076A FOLD ROLLER UPPER 1 4 E5004A 01 8 x 3 4 ROLL PIN 1 5 E5097A 3 x 20mm DOWEL PIN 1 6 G1094A SPRING INT PRESSURE RED 2 7 G4005A 8mm T BEARING LARGE 2 8 F4135A GEAR FOLD 20T 2M x 12mm 1 9 C8074A FOLD ROLLER LOWER 1 10 F1136A PULLEY 32 XL 1 11 C0035A 12mm BEARING HOUSING 2 12 E1054A 12mm BALL BEARING 2 Fitted to first innermost roller pair only CARDFOLDER SERVICE MANUAL Page 2 12 100 140 CARDFOLDER SERVICE MANUAL 1 16 5 6 8 9 12773 EA o 4 C eS e 6 r m hl 18 10 1 7 3 7 P w gt 2 12 Idle Posts Hinges Drive Belt amp Sundries Ref Part No Description Qty 1 C4366A HINGE PIN 2 2 C6358E HINGE 2 P2414A SPRING COVER POST 2 4 F5153A BELT 490 XL 037 MAIN DRIVE 1 4a F5008A BELT 220 XL 037 CASSETTE DRIVE 1 NOT SHOWN 5 R2853A SENSOR BRACKET 1 6 F4134A GEAR 20T 2M x 8mm SEE NOTE 7 C3
23. ING TIE BAR 4 5 USE ITEM 4 early versions not drilled tapped 6 C1035A INDEXING BRAKE SHAFT ASSY 1 7 C1034A INDEXING CLUTCH SHAFT ASSY 1 8 G1136A OMR SPRING BLUE 6 9 D1040A T BRG MIN 8mm 16 10 5073A 9 5mm E CLIP A R 11 E5122A PIN GROOVED 3mm x 14 A R 12 F4266A GEAR FEED 15T 1M x 8mm 2 13 R2836A INDEXING PLATE 2 14 F0053A INDEXING PULLEY ASSY 1 15 D0022A ROLLER TRANSPORT 25mm x 8 32 16 F5008A BELT 220XL 1 17 E1061A BEARING BALL 8 x 16 x 5 1 18 E1103A BEARING BALL 12 x 21 x 5 1 CARDFOLDER SERVICE MANUAL Page 2 6 ANAURWNE A Part No P2437A G1008C B9164A E5027A C6385A C9640A E5005A C2751A 100 140 CARDFOLDER SERVICE MANUAL 2 6 Pressure Arm Assembly Description PRESSURE PAD COLLAR SPRING PRESSURE WHEEL PRESSURE PAD BRKT ROLL PIN 21 8 x 1 PRESSURE PAD INDEXING SENSOR BAR CIRPIN 01 8 x 7 8 WASHER D SHAFT not shown Page2 7 A R CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL y e N e 7422025 1 TT A pw 2 7 Fold Plate 1 Components Ref Part No Description Qty 1 R2856A INPUT FOLD PLATE LOWER 1 2 R2855A INPUT FOLD PLATE UPPER 1 3 C0046A 12mm BRG HSG 2 4 C3625A GENEVA CAM 2 5 C9646A CAM SHAFT 1 6 C9648A INPUT F PLATE DRIVE SHAFT 1 7 C9647A INPUT F PLATE SHAFT 3 8 R2848A INPUT F PLATE CARRIER OP 1 9 R2849A INPUT F PLATE CARRIER DR SHOWN 1 10 R2864A CLUTCH BRAKE BRACKET 2 11 F4134A GEAR FOLD 20T 2M x 8mm 4 12
24. LOFSTWI 4 z VINOO 49 XZ i 1 wo sza L aisva HNVO yal MOL NL or velr 0ssom za anvo 198 oco TIOHRL Mee ji pi 59 sy 458 n 9 ncs sso gt co 2 LN ima SL sl sors Age g 59 SO uomo l ols oszn 2118 8n za LAQA NA 2 5 L tl Loszazevad uose sia 0s62d HEN enm A 334A Oo se l z S OzH POSH M AO XU LNVO gt ac e WY Dg TWO A 4 E hdi z XLLNVO gt i z EE a aa o E 40 i 3 as sin SON S rano 9s P zet vezn S ZOHbL wo b osw 001 Era amn H 8435 IA ANG kk oso0i veas 354 68 so ga E S11 iq Ha l aL St op gq H geveog Sao si gy sa e auo OL OL vao ZHAO o 0 8 cb ea 4 d g vo 6518 agra 99 oria Siz 6 23 9 LHAQ co S ip La womudx3 l l swoon z ano fg l l AAL oen 6 osx IDA asveos y o I SS wasx 09 li Ist ola ler xot eco Joi C n i sola EL goveog E PLOHL C3 os t a CI s A ae cL m MOL PN cue E E i aszn 8218 IN A ee or 2d Az vaan Ws 9 e L PLIHEL JIL s Sato dH ate sS xd co LVQA3T e t um OHOVL 9 858 AOL e 13031 zi s PJ YO ree agen eis OL ug ola L our PLOHL ML sr 188 a m 410431 5 99 66 o PS e 20A fe 99 29 Page 3 4 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL E
25. LUTCH 181 105UL CLUTCH WIRED 102 20 SM C cow DOWN CENTRE UP e Io 1O DESKEW HOPPER SENSOR SENSOR 182 442 LOOM RECEIVER N A 200 XH 182 443 LOOM EMITTER 300 XH 182 441 LOOM RECEIVER W A 200 XH 3 OFF 182 440 LOOM EMITTER 200 XH 3 OFF 8 Ol n 8 Ol LH SIDE FOLD 2 CLUTCH 181 117 CLUTCH W D 182 440 LOOM EMITTER 200 XH 3 OFF DESKEW CLUTCH FOLD 1 CLUTCH 181 117 CLUTCH W D sm 102 10 XH 102 10 XH cw CW 5 GENEVA 2 1 EX rue FIT DOWN CLUTCH DOWN CLUTCH s m E C G 155 amp ss ecw ki E 181 105UL CLUTCH 181 T08UL CLUTCH m O TOP COVER REED SW m WIRED 102 20 WIRED 102 20 3 6 Maximailer Cardfolder Mk 1 Wiring plan view see also previous page for Mk 2 version Page 3 7 This diagram shows the approximate physical locations of sensors and components CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Section 4 Description of Operation 4 1
26. RANGE SENSOR 1 12 180 794 PCB ASSY PHOTOLOGIC DISK 4 13 182 437 LOOM EMITTER 100 XH 1 14 182 438 LOOM RECEIVER W A 100 XH 3 15 182 440 LOOM EMITTER 200 XH 3 16 182 442 LOOM RECEIVER N A 200 XH 1 17 182 443 LOOM EMITTER 300 XH 1 18 182 445 LOOM RECEIVER N A 300 XH 1 19 182 664 LOOM PIE 310 TX 300 XH L R SENSOR 1 20 182 665 LOOM PIE 310D RX 300 XH L R SENSOR 1 Sensor PCB for these looms is separate item 117 240 Qty 1 matched pair for items 19 amp 20 together 21 182 557 100 140 T101 LINK 1 22 182 417 WIRED REED SW 3WSM UL 4 23 182 563 LOOM REED SW LINK 3W 2 24 184 180 AM4 CARD FOLDER PSU ASSY 1 For PCB looms and ribbon cables contact Technical Support Department 3 1 100 140 Cardfolder Electrical Items CARDFOLDER SERVICE MANUAL Page3 2 100 140 CARDFOLDER SERVICE MANUAL T Wed wesbeig 111511 Gd J9pIo3 49opoed T E Scu MELLE Sujincosg ndo Ea suce L anro Lee Dania see L ano anoo s roo LL dod H3MOL H30103 330334
27. RNEATH 4 FOR COVER AND HINGE DETAILS SEE PAGE 2 14 NOTE OUTFEED GUIDE PLATE R2981A IS EXTERNALLY ATTACHED ON FRONT FLANGES LIP FACING INBOARD AND DOWN CARDFOLDER SERVICE MANUAL Page2 4 100 140 CARDFOLDER SERVICE MANUAL ux RU aes 7 i ig 4 e GER F DA l 17 18 19 N o wm 148 VN 1 3 2 4 Outer Cassette Components Ref Part No Description Qty 1 E3525A M8 NYLOC NUT 2 2 E4039A M8 WASHER A R 3 R2847A INDEXING SENSOR DISC OUTER 1 4 P2415A BRAKE SPACER 1 5 R2846A INDEXING SENSOR DISC INNER 1 6 E3527A M8 FULL NUT 1 7 R2845P CASSETTE MOUNTING BRKT BRAKE 4 8 E1102A 8mm FLANGED BRG 1 9 181 148 BRAKE LENZE 1 10 P2451A BEARING SPACER 12 4mm 2 11 P2417A CLUTCH SPACER PULLEY 2 12 181 147 CLUTCH LENZE 1 13 C0035A 12mm BRG HSG 1 14 E1054A 12mm BALL BRG 9 15 E1136A BEARING BALL 8 x 19 x 6mm 1 16 R2844P CASSETTE MOUNTING BRKT CLUTCH 1 17 C4428A INDEXING ROD 2 18 E1061A 8mm BALL BRG 2 19 E2565A SCREW M5 x 10 CSK 2 20 G1136A OMR SPRING BLUE 6 21 C6378A INDEXING ROD HOUSING 2 NOTE On later models Sensor Mounting Bracket B9108A added amp Cassette Strengthening Bracket B9233P is also used on LH side Page2 5 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 2 5 Inner Cassette Components Ref Part No Description Qty 1 C6397A CASSETTE SHOE 4 2 R2841E CASSETTE PLATE 2 3A C9638A FEED GEAR SHAFT 2 3B C9699A FEED SHAFT 2 4 C9639A INDEX
28. S BUE p 8 m S 3 21 eg E EO i summ s Be E DISC 8 g BI Hoj E 8 18 SENSOR O 180 762 PCB SLITIER SRX H D 2 i E Ei 1 MANT 180 794 POB ASSY PHOTOLOGIC DISK i 8 E x 8 7 an 2 FOLDPLATE 1 182 437 EMIT 100 XH 1B2 443 EMIT 300 XH SENSOR 8 2 1 117 240 oPTO PAIR LONG RANGE m x S AU m x o EXIT SENSOR OI JO taz 353 sia lal lo TX RX 1 2 LOOM RX TX PAIR 4WSM PLG 8 m J5 46 Q kal DESKEW 180 761 PCB SPLITTER 6TX H D HOPPER SENSOR SENSOR O FOLD 2 CCW FOLD 1 UP CLUTCH CLUTCH J14 J11 3 OFF 182 440 LOOM EMIT 200 XH Ip 178 77 DOWN CENTRE UP 1 1 1 8 182 420 e o LE o O o Oo Bo TOP COVER REED SW 3 TOP COVER REED SW 182 417 180 758 182 417 fn fn PCH SPUT SSEN SSOL H D 3 OFF 182 438 LOOM REC W A 100 XH AQ IQ zB Ji Ji Ji Ji ki E 182 425 5 s s 5 fe fs FOLD2 BRAKE SIDE COVER REED SW 182 417 3 amp 4 182 561 46 up IN LLI 3 POSITION SIDE COVER REED SW es e 18287 180 794 i i l o 181 148 J14 E 4 181 117 DOWN A 1 amp 2 182 45 180 794 FOLD PLATE um 2 Is 3 fal 5 aenea 1 CLUTCH Lia a E ok le je dE 182 717 LOOM CRD FDR RIBBON SET 4 PART SET 180 759 PCB SPLIT BSEN 5SOL H D FOLD 2 J13 FOLD 1 181 132 DOWN CLUTCH CLUTCH 3 5 Maximailer Cardfolder Mk 2 Wiring plan view see also following page for Mk 1 ver
29. al of the above Ensure that the timing disc arrangement is assembled as shown in Fig 3 Page 1 5 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 1 2 2 Removal of fold plate 1 1 Remove both side covers as described in section 1 1 2 2 On the RH side slacken the clutch locator screw and move it clear of the clutch lug Disconnect the sensor cable and remove the clutch drive belt and pulleys complete with drive pins Remove the flanged bearing waved washer in the side plate See Fig 6 below Sensor connector Fig 7 showing fold plate after stripdown 3 On the LH side slacken the drive belt tensioner and remove the belt Referring to Fig 8 slacken the clutch locator and move it clear of the clutch lug then remove the clutch gear and pulley 5 Remove all T bearings and springs in the side plate and remove the side plate 3 x Screws See Fig 9 CARDFOLDER SERVICE MANUAL Page 1 6 100 140 CARDFOLDER SERVICE MANUAL Fig 8 showing fold plate before Fig 9 showing fold plate after stripdown removal 6 From the RH side withdraw fold plate 1 assembly complete with the 3 roller shafts see Fig 10 below Fig 10 7 Reassembly is a reversal of the above Note the belt route shown in Fig 11 below Fig 11 Page 1 7 CARDFOLDER SERVICE MANUAL 1 2 3 100 140 CARDFOLDER SERVICE MANUAL Conveyor belt replacement The green conveyor belts should be cleaned at service inte
30. bled together see 1 C2 1081 A ARMATURE SPACER also document K4049A 1 E1061A BEARING BALL 8 x 16 x 5mm 2 Page2 9 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Ref Part No Description Qty 20 F4150A GEAR 40T 1M x 8mm 2 20a A2 1126 A 40T GEAR amp HUB ASSY for Lenze clutch outside 1 C2 1080 A BEARING BUSH uad C2 1081 A ARMATURE SPACER CMS 2 79 E1061A BEARING BALL 8 x 16 x 5mm 2 21 F4156A GEAR 30T 1M x 8mm 2 22 R2857A CLUTCH BRAKE LOCATOR 2 23 P2156A GEAR POST 2 24 R2852A GEAR CLUTCH PLATE 1 25 FAN 2 5 8 DIA CCW not shown 1 26 E5098A PIN DOWEL 3 DIA x 18 not shown 2 27 E1080A BEARING BALL 3 8 FLANGE MINATURE 1 28 C3134A SLEEVE 1 29 181 127 CLUTCH W D EC25CCW XH 24V 1 30 181 132 CLUTCH W D 179 154 2WXH 1 Wm 4 2 9 Overguide Components Ref Part No Description Qty 1 C9644A OVERGUIDE PIVOT SHAFT 1 2 R2843A SENSOR OVERGUIDE BRIDGE 1 3 P2414A SPRING COVER POST 4 4 B0188A GUIDE SPRING CONVEYOR 4 5 C2181C FORM CONTROLLER COLLAR 4 6 D1030A LOCK LEVER 4 7 C2404A LOCK SCREW 4 8 E2560A SCREW M3 x 6 CSK HD A R 9 169 106 CABLE TIE 7 6 x 370mm 2 CARDFOLDER SERVICE MANUAL Page 2 10 100 140 CARDFOLDER SERVICE MANUAL 2 10 Conveyor Components Ref Part No Description Qty 1 B9105A CONVEYOR GUIDE PLATE 1 2 C9642A CONVEYOR DRIVE SHAFT 1 3 C8130A CONVEYOR DRIVE ROLLER 2 4 F4135A GEAR FOLD 20T 2M X12mm 3 5 G5022A CONVEYOR BELT 1 SET 6 B9107A SIDE GUI
31. bration Cycle ve moves up and ve moves down To view these effects go into the Advanced fold window highlighted below To increase decrease the fold lengths to suit fit into an envelope change either in Custom Fold window or Advanced fold window but not both Z Fold Top Address Custom Fold Window Advanced Fold Window Z Fold Bottom Address b Length adiest 9 D Longth B nijunt 1 5 Custom Fold Window Advanced Fold Window b Feld 2 direction b Done CARDFOLDER SERVICE MANUAL Page 1 18 100 140 CARDFOLDER SERVICE MANUAL C Fold Top Address Custom Fold Window Advanced Fold Window V Fold Top Addr Db Length A adjust a ES Length B adjust T T8 Custom Fold Window FOLD PLATES ITEM 2 piat mm aco p Fold 1 direction b Pinto 2 mm Fe Used B Advanced Fold Window b eld 2 dirmction Page 1 19 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 1 4 Recommended Spares The list below shows the spares recommended to be held by Service Agents The quantities indicated are per 2 machines The full set can be obtained by ordering A0442A Mk 2 or A0359A Mk 1 A0442A Cardfolder Mk 2 PART DESCRIPTION QTY 117 240 OPTO PAIR LONG RANGE 1 180 759 PCB SPLIT 5SEN 5SOL H D 1 180 761 PCB SPLITTER 6TX H D 1 180 762 PCB SPLITTER 6RX H D 1 180 790 PCB LONG RANGE SENSOR 1 180 794 PCB ASSY PHOTOLOGIC DISK 2 181 117 CLUTCH W D EC25CW XH 24V 2
32. ce contact Techncial Support Department CIM INTERFACE KIT A3295A B2046C WHEEL SIDE ARM QTY 2 B9185W CIM INPUT COVER QTY 1 C2137J CRANK PIN QTY 4 C2171E EJECT WHEEL 12mm QTY 2 C2499C WHEEL PIVOT QTY 2 C9686A PIVOT ROD QTY 1 E1038A OILITE PL 8x12x12mm QTY 2 R2970P INTERFACE BRACKET QTY 1 CARDFOLDER SERVICE MANUAL Page 2 16 100 140 CARDFOLDER SERVICE MANUAL Section 3 Electrical items and Wiring Diagrams 3 1 Electrical items Bill of Material 3 2 Feeder folder PCB circuit diagram part 1 3 2 Feeder folder PCB circuit diagram part 2 3 3 Cardfolder interface PCB circuit diagram 3 4 Long range sensor PCB circuit diagram 3 5 Cardfolder wiring diagram Mk 2 3 6 Cardfolder wiring diagram Mk 1 Page 3 1 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 3 1 100 140 Cardfolder electrical items Bill of Material Ref Part No Description Qty 1 181 069 MTR W D 179 072 4WJST CW 230v 1 or la 181 569 MTR W D 179 073 4WJST CW 115v 1 2 181 117 CLUTCH W D EC25CW XH 24V 2 3 181 127 CLUTCH W D EC25CCW XH 24V 2 3a 181 132 CLUTCH W D 179 154 2WXH LENZE 2 4 181 147 CLUTCH W D 179 159 SM LENZE 1 5 181 148 BRAKE W D 179 108 2WXH LENZE 1 6 180 759 PCB SPLIT 5SEN 5SOL H D 2 7 180 761 PCB SPLITTER 6TX H D 1 8 180 762 PCB SPLITTER 6RX H D 1 9 180 785 PCB ASSY AM4 TWR FEEDER 1 10 180 789 PCB CARDFOLDER INTERFACE 1 11 180 790 PCB LONG
33. d document 1 5mm Max C or Z and 2 5mm Max V Fold Fold Variation 2 0mm on each fold Examples Example 1 Running Z fold bottom address and experiencing skew in 1 Fold Corrective actions required 1 1 1 2 1 3 1 4 and 1 5 If problem still persists the deskew value can be increased to Medium 250mS or High 400mS Note the default is Low 150mS Example 2 Running Z fold bottom address and experiencing inconsistent fold lengths in 274 fold cassette Corrective actions required initiallv check that the cassette clutch is engaging disengaging in the Engineer window Then rotate the cassette bv hand to check the pressure applied from the pressures arms onto cassette cassette should rotate with ease light pressures from both upper lower blocks Re adjust if pressure is heavv both upper lower blocks as per 1 3 6 Once the pressure is adjusted the detents and fold lengths will require re calibration in the Engineer window section 1 3 7 Example 3 Running Z fold Top address and experiencing skewed forms in 274 fold cassette skewed towards LH Operator side Corrective actions required 1 3 6 the pressure on the LH side needs increasing until the skew is within specification section 1 3 6 Page 1 17 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Appendix fold types To move the address position this is normally carried out in the Address Adjust within Cali
34. e 1 13 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Adjustment screw either end Gap Set with 2 card thicknesses Fig 20 1 3 6 Pressure arm adjustment Fig 21 below to reduce skew in the 2 fold cassette Excessive block pressure restricts cassette rotation causing erratic stop position This in turn produces inconsistent fold lengths This adjustment is critical if experiencing skewed documents caused by the second fold cassette The pressure blocks maintain tension on the paper keeping the form away from the fold roller during rotation For T r Z fol h r nterclockwise when viewed from h rator side Upper pressure blocks are active Nominal position shown RH pressure arm collars in picture shown set to correct spring tension ie setscrew secured next to cable slot in spring slackening direction not tightening LH pressure arm tension is then adjusted equal to RH If skew folding is experienced LH pressure arm tension is increased or decreased until fold is acceptable For B m r Z fol h r lockwise when viewed from th rator si Lower pressure blocks are active located underneath machine Nominal position and adjustment as for upper pressure blocks RH collar set screw next to cable slot ee a mm ji ee Fig 21 CARDFOLDER SERVICE MANUAL Page 1 14 100 140 CARDFOLDER SERVICE MANUAL Rotate cassette to check pressure if too heavy this can cause inconsistent
35. e document as the cassette revolves The nylon pressure pads should be inspected at service intervals see section 1 1 3 and re placed if worn or damaged The spring tension of the arm is set as described below 1 The pressure arms should be adjusted so that the springs are in the approximate position shown in Fig 13 below This will provide reasonably firm contact between the nylon pad and the aluminium shoe 2 To adjust slacken the grub screws 1 in each collar and twist the collars so that the springs are correctly tensioned Tighten the grub screws Grub screws 3 Testrun the machine to ensure the trailing part of the document is being properly re strained Examine the document carefully to ensure the springs are not over tensioned and causing marks on the paper Page 1 9 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL 1 2 5 Fold plate adjustment The gap between the upper and lower plates on the oscillating fold plate must be correctly adjusted or operating faults will occur To adjust the gap The gap must be set to the the minimum possible to allow the card to pass through freely To adjust turn the screw at each end of the front edge of the plate see Fig 14 below Each screw must be turned an equal amount and locked with thread lock adhesive such as Loctite 241 red or similar Note Failure to use an adhesive will result in the screws vibrating loose Adjustment screw Gap to adjust each end
36. ers are removed CARDFOLDER SERVICE MANUAL Pagel 2 100 140 CARDFOLDER SERVICE MANUAL 1 RH drive side cover Remove the screw at the upper corner inside the chassis face Lower edge of the cover slots into the wiring skirt 2 Rear cover Remove both side covers first then remove 2 x nuts on the inside of the chassis flange Note the slotted sub cover and underpanel are sandwiched between rear cover and chassis 3 Each wiring skirt Remove both side covers first then on the upper edge remove 2 X screws at the rear and 1 x screw at the front 4 Top cover Remove 2 screws in each hinge securing the perspex cover to the hinge do not remove the hinge from the chassis unless replacing 5 Underpanel Remove rear cover first then slide underpanel out When replacing note that the locating tags at the front edge must be properly in place 1 1 3 Service at 6 months or 1 million inserts 1 Implement the actions in section 1 1 1 General 2 Remove all machine covers 3 Vacuum clean to remove internal dust Clean all covers 4 Autocalibrate sensors then check their settings see Analogue Digital Sen sors in Engineer mode in the 100 140 Service Manual then clean all sensors and re check calibration If any fail check wiring carefully particularly where wires enter the connector housing Replace if necessary Note sensors must be cleaned using only a non flammable airduster such as part no E0070A 5 Check infeed side guide
37. es the armature of a friction clutch that is mounted on the cassette pivot shaft There is a friction brake mounted at the opposite end of the cassette which brakes the cassette to the chassis Outside the brake mounting there are 2 sensor discs the inner is 180 degree dark light the outer has 2 slots The inner has 2 slotted disc sensors diametrically opposed the outer has 1 slotted disc sensor set at 90 degrees The single sensor monitors the zero positions whilst the 2 sensors are used to moni tor the rotation and orientation of the cassette Mounted on each side of the cassette are 2 semicircular shoes These have pressure pads bearing on them 2 positioned on the topside 2 on the underside These arrangements are to grip the document as the cassette rotates holding it in a consistent position prior to folding Each end plate of the cassette assy has a spring loaded detent acting on it The plates are profiled such that these detents locate the cassette in a zero position per 12 rotation There is a long range sensor pair mounted around the cassette The outfeed from the Fold 1 sub module is via a pair of spring loaded fold rollers driven direct from the main drive CARDFOLDER SERVICE MANUAL Page 4 3 100 140 CARDFOLDER SERVICE MANUAL 4 2 6 Fold 2 Operation The friction brake acts to lock the cassette to the chassis The friction clutch acts to lock the input drive and hence the feed rollers to the cas sette Therefore
38. fold lengths If pressure is too heavy with top address Z fold adjust upper blocks as shown 1 3 7 Engineering Settings Fig 23 a Clarification of Fold Plate Setting and Calibrations it is important to adjust the correct settings for folds The table below highlights which fold plates are active when viewed from the operator side Fold Plate 1 position Fold 2 Cassette ro poe 1st amp 2nd settings tation 3rd amp 4th settings Z Top Address Counterclockwise C Top Address Counterclockwise Engineering Settings global for all jobs Down Cal p FP2 Clockwise Cal bUp Detent CW gt Down Detent CW b gt Up Detent Counter CW n S D Down Detent Counter CW I cont Fig 23 Page 1 15 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL b Detent Position Setting ensure the Lenze Clutch upgrade kit is fitted This will ensure consistent cassette detent positioning and improves inconsistent folding in the cassette Note a job must be run to check the cassette rotates into detent positions To calibrate for the Up down detents CW you must run a bottom address Z To calibrate for the Up down detents Counter CW you must run either C or Z Top Address Definitions Cassette UP no springs visible in cassette when looking from above NB The cassette folding cycle always starts from the UP position Up detent CW this adjusts the cassette positio
39. h FP1 in one of the 3 positions Up Standard Z fold V fold with address on reverse side Down C fold Standard V fold Bottom address Z fold Centre No fold Ignore this for now Assuming all is clear up stream at the end of the Deskew timer the fold feed roller clutch will energize The document will advance until the FP1 sensor is blocked thence continue for a distance according to the selected fold length then apply brake and disengage clutch The fold plate assy will now move to the centre position After a short delay the Fold feed rollers will restart moving the partially folded docu ment into the nip of the fold rollers which completes the fold and transfers the docu ment towards the Fold 2 sub module If no fold had been selected the fold plate assy would start in the centre position with the document being passed straight through Whilst this mode is technically possible it is questionable whether it would ever have a practical application 4 2 5 Fold 2 Description Fold 2 sub module comprises a rotary folding cassette in which are mounted 2 pairs of feed roller shafts each with 4 rollers One shaft of each pair is spring loaded against the other driven shaft The drive to these rollers is by gears in mesh with a compound pulley gear which is driven via a series of 2 belt drives by either of a pair of wrap spring clutches one acting clockwise the other counter clockwise This compound pulley gear also carri
40. n in degrees rotation when returning to the UP detent cassette rotating CW having ejected the folded document For ex ample if the cassette is not entering undershooting then increase the Up detent position Down detent CW this adjusts the cassette position in the down detent when the cassette is rotating CW during the folded operation Up detent Counter CW as above but Counter CW Down detent Counter CW as above but Counter CW c Engineering Drives Fig 24 Drive clockwise and Drive anti clockwise these 2 clutches which comprise the clutch upgrade kit control the direction of the drive belt to the cassette The clutches should not and cannot both be set to ON Clutch cassette Causes the cassette to rotate when ON The direction of rotation is determined by either Drive Clockwise or Drive anti clockwise being ON Note that Brake cassette needs to be OFF during cassette rotation Clutch cassette when OFF causes the cassette feed rollers to turn The direction is determined by Drive Clock wise or Drive anti clockwise Brake cassette when ON prevents the cassette from rotating while the feed rollers are turning D Brake Foldplate 1 D Clutch Geneva up gt Clutch Geneva 1 down gt Clutch cassotle bBrake cassette gt Derive clockwise gt Drive anti clock CARDFOLDER SERVICE MANUAL Page 1 16 100 140 CARDFOLDER SERVICE MANUAL 1 3 8 Skew and Fol ification Total Skew with folde
41. rae pn Ud KE ema i g EU sin 7 INS Ere b KAN H z g i ams Tal Eum oiv zeia E pe o cm aoi sala s9208 Morc zaw EXI a 554 io sad l sa 8 A on J EJ E z T E l us THU KEE Dm b II jcro 2814 wool reni a9v808 aoe dens ecu aan H HE gu i Orb Zu kd wa 1 E O ow 1 E oF L EI z Sees toro x sen wool gala espace aose von E if pa sau A zas m ayon Bao i Fa Fa nna nt E E E sfa fd nece 5 z sc ag E iz MOTA SESS ao z b 5 4 ze EI i oiu Par sen H Ep S i wan 534 t 5 T t 40 5 z vuv t i xxugenzan Lia t t em ES n T sa L2 Em E E lea m yp oo 298 quon s 4n ia 5 ios z Z aJi v 158 dal ar es Em cot ois sis L as ais elg cous ane osu 292959 ras Tsar zo iea oea era 2338 5 E 8888 ayon fe SC wo sra gi E AOTC Fi Ben Tk 89808 n ams mw SR fee MEL van px zz xj L vzo E ao o svia EN g IE Em 0m x Ly eee o sar alo au 5 aa SON 3 T ze g vu INA v ora z vi E wat E Pa cw Th xuma z 005 m a Pg um in ET poe ry 8 i eis L ois L ois L eT sz an EEA ad a sa l na alg Tki ais Sw E m sazioa sia T E g oO ay zo 546 ano L EFA 5 99 O ES zia Tki vida bas o E oa js l ma 5 z sai wo S sis NEST 5 oer E E na T E ais LA A oia f 1 ois soseoa_Lizb o scm woo i sa T 1 ois p aeeson
42. rvals see sectioni 1 3 If either is split damaged or excessively worn they must be replaced as a pair only This requires removal of the conveyor assembly as described below 1 2 Remove both side covers as described in section 1 1 2 Trace the conveyor sensor cables back to the PCB and disconnect Cut any cable ties securing them On the RH side remove the flanged bearing waved washer on the lower shaft and the screw from the upper and support shafts see Fig 12 below On the LH side remove the gear and the flanged bearing form the lower shaft and the screw from the upper and support shafts note that the rear end of the conveyor is now free to drop Support shaft Upper shaft _ Lower shaft Lift the convevor assembiv out of the chassis Remove the upper shaft with overguide from the assembiv Remove the T bearings and springs on the rear tension shaft and lift out the shaft Depending on the width setting of the side guides it should now be possible to slip the conveyor belts over the ends of the lower shaft If the side guides are obstructing this they must be removed Fit the new belts and reassemble in reverse order to removal Reset the side guides if necessary to provide 1 5mm clearance each side on a piece of representative paper CARDFOLDER SERVICE MANUAL Page 1 8 100 140 CARDFOLDER SERVICE MANUAL 1 2 4 Pressure arm adjustment The pressure arm controls the trailing part of th
43. s are tightly secured parallel and correctly adjusted 1 5mm clearance each side on a piece of representative paper 6 Check that steel overguide tapes in the insert area are not damaged or dis torted Also check plastic guide tapes for damage Ensure all tapes are correctly adjusted 7 If any of the nylon gear trains run noisily lubricate sparingly with grease 8 Sparingly lubricate with grease the planetary gears on the RH side of the cassette and the sliding detent plungers on both sides of the cassette 9 Clean all rubber rollers and the green conveyor belts using Rubber Roller Restorer part no E0483A Inspect the conveyor belts over their full length and replace if either is split or damaged see section 1 2 3 10 Inspect drive belts on both sides for damage and replace if required Check they are correctly tensioned they should feel reasonably tight but not over tight 11 Check that the cassette pressure arms upper and lower are correctly ten sioned and that the nylon pads are undamaged Clean the pads using a spirit based cleaner 12 Refit all covers and test run the machine Page 1 3 CARDFOLDER SERVICE MANUAL 100 140 CARDFOLDER SERVICE MANUAL Section 1 2 Service Operations CAUTION Prior to carrying out any service operation observe the safety precau tions in section 1 1 especially isolating from the mains power supply Ensure the working area is clear and the machine is securely supported Use onl
44. sion This diagram shows the approximate physical locations of sensors and components CARDFOLDER SERVICE MANUAL Page 3 6 100 140 CARDFOLDER SERVICE MANUAL RH SIDE AM4 MODULE PCB 180 722 na or FOLD 2 BRAKE 181 104 CLUTCH W D 102 10 SM FOLD 1 BRAKE nz 181 117 CLUTCH W D 102 10 XH DESKEW BRAKE NOT FITTED mener Gia one den Ricco e wwe eid PTERA COVER gt LINK 180 746 PCB ASSY HI RES SENSOR HI RES SLOTTED DISK SENSOR Q nn e AC MOTOR CW 181 069 MTR W 179 072 4W JST cw 182 342 LOOM RECEIVER 200 182 340 LOOM EMITTER 200 N A SM SM TOP DOWN CENTRE UP 182 441 LOOM RX W A 200 XH 3 OFF 182 340 LOOM EMITTER 200 SM 182 341 LOOM RECEIVER W A 200 SM e 182 340 LOOM EMITTER 200 SM 182 341 LOOM RECEIVER W A 200 SM FOLDPLATE 2 SENSOR GENEVA 2 UP_CLUTCH 181 105UL CLUTCH WIRED 102 20 SM C cew Oo FOLDPLATE 1 SENSOR GENEVA 1 UP C
45. tension by pulling a strip of paper between the deck and guide as shown see Figs 17 amp 18 Guide spring Fig 17 CARDFOLDER SERVICE MANUAL Page 1 12 100 140 CARDFOLDER SERVICE MANUAL Tension on strip of paper must be equal for all 4 guides Fig 18 Ensure the form does not buckle in the conveyor whilst being held in the deskew rollers If the form buckles near the deskew rollers then the tension must be reduced at the exit guides 1 3 4 Adjust the tension of the 2 off cable ties 169 106 to provide guidance into the deskew rollers as shown in Fig 19 These guides control the form into the nip of the deskew rollers Note if too much force is applied it can increase skew folding inaccu racy Adjust cable ties for guidance into deskew rollers Fig 19 1 3 5 Fold Plate Gap Adjustment this is the gap between the upper and lower plates on the oscillating fold plate FP1 and must be correctly adjusted or will cause skew and inconsistent folding Note that this gap has been already factory set and adjustment is not normally required if this proves necessary adjust as de scribed below To adjust the gap set to the minimum possible to allow the card to pass through freely 2 card thickness To adjust turn the screw at each end of the front edge of the plate see Fig 20 overleaf Each screw must be turned an equal amount and locked with thread lock adhesive eg Loctite 241 red or similar Pag
46. with brake on and clutch off the input drive will rotate the fold feed roll ers or with brake off and clutch on the input drive will rotate the cassette In this mode the feed rollers are locked to the cassette N b the cassette has 2 logical positions referred to as Up and Down by way of definition the cassette is in the Up position when the gear driven feed rollers are topside sprung ones underside If the selected fold is either V or None then the cassette only serves to transfer the document through itself to the output fold rollers and on to the Maximailer When folding the cassette can rotate Counter Clockwise or Clockwise depending on fold type CCW Standard Z fold C fold CW Bottom address Z fold The cassette will be in the up position at the start of the process FP1 will outfeed the document towards the cassette The feed rollers will start ready to receive it The document will enter the cassette pass through the long range sensor and continue for a distance according to the selected fold length The document will be stopped the cassette will rotate 180 degrees This point can be used as a hold point in the event of an up stream hold up If all is clear after a short delay the feed rollers will restart moving the partially folded document into the nip of the fold rollers which completes the fold and transfers the document out of the cardfolder The cassette will further rotate 180 degrees ready
47. y the correct tools for the job 1 2 1 Removal of cassette 1 Remove both side covers as described in section 1 1 2 2 On the RH side cut or remove all clips securing the clutch wiring cable and disconnect the cable from the PCB 3 Remove the drive belt tensioner shown in Fig 1 below Remove also the nut on the end of the shaft and the 4 x screws securing the bracket Slide the bracket off noting the spacer inside the bearing Remove the drive belt Cassette bracket Drive belt tensioner Fig 2 showing cassette end after removal of bracket CARDFOLDER SERVICE MANUAL Page 1 4 100 140 CARDFOLDER SERVICE MANUAL 4 On the LH side cut or remove all clips securing the brake wiring cable and disconnect the cable from the PCB 5 Remove a drive belt tensioner to slacken the belt Referring to Fig 3 below push the plastic rivets out of the 3 sensor PCBs and lift the PCBs away Remove the nut on the end of the shaft and take off the timing discs with spacer and the inner nut washers Remove the 4 x screws securing the bracket and slide it off complete with the brake Note disc with 2 slots is outermost BNIB Fig 3 Fig 4 showing cassette end after removal of bracket 6 With the cassette assembly now loose manipulate it to slide the spring loaded plungers out of the bronze blocks Withdraw the cassette from the RH side see Fig 5 below Fig 5 7 Reassembly is a revers

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