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Maximailer HD Service Manual

Contents

1.
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3. WIRED ENV PICKUP TO OTHER SIDE ENV CONV CLUTCH TA A JIS CLOSER COVER ENV FEED a SENSOR Le WETTER DENM gt SWITCH SOLENOID ENV UPPER O er EEN DRIVE CLUTCH SENSOR E J12 N
4. CLOSER REVERSE DRIVE BRAKE 181 129 L D D 5 INSERT PAWL TRACK DRIVE CLUTCH 181 128 182 8330F WETTER OUTPUT DRIVE 80 759 CLUTCH 179 110 ane m WETTER DOWN SOLENOID 182 8330A 1
5. Issue 1 Mar 2010
6. Issue 1 Mar 2010 MPWR VCC VCC O L L R1 R2 d VCC 47K U1 0 01uF 68K 5 2 R17 J1 INI VS o D1 U3A C2 eM Ti cm E 10R PSIR EN 1 2 1 m 3 N e e e e 2 9 OUT1 1 VREF 1N4148 74HC14 0 1uF E C3 C19 74HCTO8 C4 1 J2 a OUT2 aes 0 01uF 22nF J9 3 0 22uF SENSE E e 9 e 1 i d PS1T 3 2 Ite e 1 L6203 l 3 Red 1 White Yellow Brown J3 5 i L White Orange e e 6 Sy ed U4 0 01uF 7 Orange PS2R S 5 2 White Brown n VS TN 3 O vec e B E C1 S O vec VCC Da 1 10R STEPPER 1 J4 9 VREF ki 3 US co UB 2 R4 VCC DIR f zg a Lt C7 l C20 PS2T i R6 270R R5 STEP 8 6 E 8 0 01uF SCL 1KO 9 CLK B 7 0
7. VOLTAGE ADJUSTME GRN YEL a BLK 7 BLU 6 5 an 240W 26v PSU i E P 9 m I RED BRN BLU GRN YEL 4 I BRN 3 3 2 2 E BLU 1 26V SWITCHED 6 3 4 I EXPANSION BLK OV PCB J6 BRN BRN 26V CONSTANT BLU BRN BLU WHT BLU AC MOTOR CW L BRN lao SA RE 1 YEL 4 26V 2 ORC 2 MAINS fura 181 069 230V 586 3 29v sw C ITO INLET L 181 569 115V HP p Bi GRN YEL BLK y a 6 CD 418 pore SCH C4 INIERLOCK C x 2 P 180 831 Q 9 GEN o CROWBAR MAINS p RED GER BLU BLK SRN YEL NOTE Items shown except for motor components dashed are part of Power Supply Unit 184 2150 5 13 Inserter Head PSU Motor amp Interlock Wiring Diagram Page 5 26
8. Issue 1 Mar 2010 JP2 R270 470R vec vec R271 470R u1 vee 3 8 3 e li RS vcc u s U42A R219 4K7 1 2 D p 5 53 CANH J CANH TXD SS CANTTX E U36 L293B 6 4 74HC14 U41 To 516 510 516 510 AL CANL RXD CAN a 0428 2 H37 5 2 R220 AK 3 P 4 1Y1 g B R5 Q VREF GND c2 9 ei 142 1Y2 MIEN amp E gt 5 e lt MOTT
9. Electrical and Circuits Wiring Issue 1 Mar 2010
10. D10 T e l 08 D91 J1 IP9DRV 510 CH D J10 amp J11 VCC amp GND to be thick tracks and Q7 1 3 directly routed ER BCB46B R33 100R FZT1053A D11 S1G R70 ce y i007 3 P15 ag D92 23 B4 5 R181 1K Up 74HCT273 T OUT2 510 IP1 a2 4 APR RI de E U11E Mount on heatsink 1000 3 2 R34 330R OUTI 5 py R81 47OR 44 TSHD RST i 10 LPWR ER 4 Ars R35 330R OUT2 6 FZTIOS3A D12 IPPU2 21 SZ o U17 IOD2 raj R36 5505 OUT3 7 Le S16 82 D3 Q3 i IP12 DL i 20 e spo Lie R162 4K7 4 74HC14 L4940V5 TODS 8 pa gt 9 00T4A Q10 593 IP2 19 1 3 IoD4 13 A 12 OUTA R38 330R OUTS a P33 OUT3 S16 R83 470R 14 9 M 005 95 Gelee R39 L 330R OUTS A lt IP33DRV R227 220R i v 1 l IPPU3 ml ay 8 SDI U11F 8 E IZ Ce R40 330R OUT 12 1 FZTTOBSA L4 D14 SIG us TIE SUK ap REs c19 c20 1907 T8 na os 5 R41 330R OUTE OP4 IP3 18 7POTCS S PS 1 i Q11 D69 R86 4705 4 ji 74HC14 1000uF B 0 1uF OP1TO8WR TA Rete G OPADRV S1G 1 l IPPU4
11. Electrical and Circuits Wiring
12. D 0 15 7 ul A O 21 VCC J1 t U3 U5 AO HI ABO ANO PoLo apo 100 20 Al 24 po 125 Do Al sl 1 ANT a Em a2 551 7d Do 28 Di 22 11 14 Di A2 BB ANO ANZ 29 M 102 D2 23 22 27 DZ 23 l 51 15 D2 A3 67 352 H ANT ANS ag PS 2 AN2 POL2 AD2 o3 D3 4 21 D2 28 D3 4 e D2 17 ms A eg B3 1 ANZ ANA SCH POL3 AD3 Ta4 D4 25 20 55 52 DA 25 s 03 Mis D4 AB a5 B ANS ANS 55 PAAR POL A AD4 D5 46 19 At D 33 DS 46 ze D 18 D5 A6 gi 385 43 6 Go ANS Ss P5 5 AN5 POL S ADS Her T A TR 45 pe Lies A i 5 Ds 5 ABE LCDPWR AN5 AN7 SCH DON POL 6 AD6 o7 D7 48 9 D6 38 DZ 48 5 38 D6 21 D7 B 82 8 P5 7 AN7 POL 7 AD7 AS o D7 5 St D7 E BB 9 AB AB A SA ABS AN7 ANB 35 10 ANG ANS 35 PS8 ANB POH O ADB ps AT 45 AT 25 9 ATI 7 11 P5 9 AN9 POH 1 AD9 A10 A10 A ABIT ANS AN10 39 112 D10 A12 13 A12 25 A12 56 R33 27R R34 27R 12 P5 10 AN10 POH 2 AD10 AM AM A29 ABI AN10 ANTI 40 113 Dil A13 8 AIS 4 A13 55 R35 27R R38 27R 13 P5 11 AN11 POH 3 AD11 A12 A12 Ae Ap ANTI AN12 41 114 D12 A14 7 ATA 28 A14 54 R37 27R R38 27R 14 P5 12 AN12 POH 4 AD12 A13 A13 AIt AB14 AN12 AN13 42 115 D13 A15 6 A15 A A15 53
13. 14v vec MPWR MPWR Oo IOD 0 7 6 25v moe o RI iy di R81 1 2 100K R2 RA R82 4 2 100K kd 270R VIN 2 C41 R3 R83 1 2 100K 4 MOTSEN i E 0 033R AW CIT HPWR 1 2 PWR R84 2 100K Si Fault IOUT O 1uF R89 15K R88 1 2 100K N e f R5 Re eg S 1 1 2 1 9 1uF a R88 4 2 100K 1 T LD1 BR Qi U2C RB7 2 100K 1 Wire colours 100R 470K U3 RED ZXCT1008 10K 1 4 2 4 4 1 x S IOD7 1 2 100K 1 a 4 s 1 B8 pe HEN IoA1 R90 2 100K 1 J3 5 ensor 8 1K2 BC856B e 1 2 5 j L 10 m IOA2 R91 1 2 100K 4 5 U4 g Sensor 2 MES 2K2 L 74HC132 EE PWM3 R82 2 100K Bs 5 Sensor 3 5 1 2 R11 2K2 47K 74HC132 74HC132 JIOWR R93 4 2 10 f E S 3 i 2 hs u 1 1 2 R12 2K2 R10 JORD R94 4 2 100K 1 es gt 2 i 3 ME mae us 24 1 2 EXP R88 4 2 100K 1 Blue 1 Ensor 4 01 APS 23 Cie 15K RES R98 1 2 100K Black 1 B In A kO 1 2 Brake 9 RU HEN 7 e SE FLTLED o kd E e Hall Sensors oo E A 21 US c CA Z dew 6 Drive L1 l 55 uckib 1000pF MC33039DG 14v Drive L2 ro DI R13 0 01uF S ii gi 18 Drige 3 I D3 R14 D4 8 R15 N Ve LIA CLA R16 Eaut 15V 9 5W 0 01uF 2K2 ZN iN HDIR 3 au m 15V 0 5W 2k2 m 15V 0 5W 2K2
14. BLOWER eb COLLATE n n COLLATE POCKET l POCKET LOAD SENSOR SENSOR mds INSERT TOP l PAWL D 3 DRIVE ANE BRAKE SENSOR WS dy l NO SA l o BOTTOM PAWL a 38 NE 4o SENSOR SES EE In 32 ur KL Sar ane N Zu 914 TE3 S gt GET m o An 5 5 a rs db arrow ANGLE s 58 sl s 1 O gt 0 a e WIDE ANGLE ki TOP COVER REED SWITCH 182 417 O Q JB J7 Ede Pd S A 5 i N M ti M ti H SIDE COVER N REED SWITCH E n n TM H COLLATE A n POCKET M INPUT t ji SENSOR NN B d INPUT CONVEYOR CLUTCH l l ie j 2 2 9 E J28 n 525 J13 Pon JIS NE Je 4 J18 J20 R148 J1QUPPER PC TERMINATOR LOWER EXTERNAL For drive side see following page Page 5 4 Issue 2 Mar 2010 Maximailer HD Service Manual Electrical and Circuits Wiring 5 1 3 Sensor diagram drive side ENV CONV SENSOR J7 J8
15. 82 8320Q 1234 J 15 12345678 123 4 5 Boy INPUT CONVEYOR CLUTCH 179 109 COLLATE 178 110 SIDE 182 418 TOP COVER SWITCH COVER SWITCH 23456789 10 YEL L 024 624 Lo basi oe K I CAN LINK JP2 J16 J52 UPPER EXTERNAL J19 LOWER PC TERMINAT ENTRY FAST CLUTCH DR Section 5 11 Inserter Head Wiring Diagram J s CONVEYOR OUTPUT 182 417 182 8330J 160 514 2 26W IDC 180 8370 8W RJ45 C4 COMMS INTERFACE PCB 8W DIN SKI 15W DTYPE SKT QW DTYPE PLG 9W DTYPE SKI J4 JB MPPC amp INF CAN LINK TO PC ENERAL IOS COMMS LINK TO UNIT 1 Page 5 24 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010
16. AW ac 18 d 35 87 q 4 18 Finger Assembly A2 1062 A 91101436 Page 4 46 Maximailer HD Service Manual Item Part No 169 145 181 070 181 1610 181 1610 180 760 B2 1244 A B2 1246 A B2 1251 A B2 1492 A B2 1493 A B3 1108 Z B3 1109 Z B3 1110 A B3 1111 A B3 1112 A B3 1113 A B3 1114 A B3 1249 A B3 1251 A B3 1325 A B3 1326 A B4330A B7433A C2 1062 A C2 1116 A C2 1191 A C3 0714 A C3 0715 A C3 0739 A C3 0740 A C4 0548 A C4 0564 A C5 1062 A C5 1127 A C6 0432 A D1040A D1076A D1080A E0204A E0291A 9104649E 9100788M 9109568H 9109568H 91007455 9110128R 91101295 9110130T 9110131U 9110132V 9110133W 9110134X 9110135Y 91101362 9110137A 9110138B 9103641 91055215 9103744R 9105793A Exploded Views Description RIVET 3 5mm 2 0 3 0 GRIP WIRED MOTOR SOLENOID W D 179 3550 MIDDLE SOLENOID W D 179 3550 DR PCB SPLITTER 3 SEN 4 SOL H D No 7 FINGER CHASSIS FINGER STOP BRACKET DR FINGER SOLENOID BRACKET INNER SOLENOID BRACKET SOLENOID SUPPORT BRACKET FINGER OUTER DRIVES C4 FINGER OUTER OPERATOR C4 FINGER MIDDLE DRIVES C4 FINGER MIDDLE OP C4 FINGER SENSOR FLAG FINGER DISK SENSOR BKT INSERTION FINGER SUPPORT INNER FINGER DRIVE BKT FINGER PIVOT BRACKET DR FINGER S GUIDE OPERATOR FINGER S GUIDE DRIVES DISC ASSEMBLY SENSOR BRACKET FINGER PIN C4 FINGER SPACER FINGER BUSH FINGER PIVOT SOLEN
17. Fig 8 Maximailer HD Service Manual The machine may be fitted with either OMR or barcode top or bottom read ing vertical or horizontal barcode for top reading but horizontal only for bottom reading An optional shortform upgrade can be fitted so the folder can double as a feeder but this cannot be Barcode or OMR enabled Operation A form feeds through the pre feed rollers monitored by the pre feed sensor and up to the deskew and double document sensors mounted side by side The leading edge is driven into the stationary rollers ahead to correct any skew The deskew sensor also acts as a hold point When the path ahead is clear the drive is engaged to the rollers to feed the form forwards As soon as the trailing edge is clear of the pre feed sensor the next form starts to move towards hold point deskew thus allowing minimum time delay be tween forms If an OMR head is fitted the OMR Gate paper sensor detects the leading edge of the forms and times the start of the marks from the distance input by the user the timing operation is carried out by the encoder tacho fit ted to the end of the feed roller shaft just ahead of the DD Deskew sensors If a barcode reader is fitted no sensor or tacho is required or fitted and a different shorter feed shaft is used After reading any marks barcode the form is fed into fold plate 1 whose backstop is motor driven to b
18. VCC O U1D U1 U1F ge 13 12 11 9 8 E e gt E 4 5 4HC14 1N4148 4HC14 4HC14 2 e CS R4 1MO 1OuF e 4 Title 3 C4 Env Wetter PCB 1 02 Size Document Number Rey A4 12 196 cct 1 Date Friday September 04 2009 Sheet 1 of 1 Page 5 19 Section 5 6 C4 Envelope Wetter PCB Circuit Diagram Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010
19. Feeder l encoder ree FPre T amp sd Tellers OMR Gate ef Legend bos c 5 fa 3 Slotted Sensor encoder Sensor reflective typ hue kend SOOO BCR Reader option option Sensor thro beam type pu H u OMR head for A Paper Path cascode feed option Wrap Spring Clutch OD pee Daily post sensor EL EK Friction Clutch Daily Post Brake ma End st End stop X Encoder disc rold Plate 2 Divert gate conveyor pawl Hold Point 4 Sensor Upper Fold lo next Module IC f oreppaer gk encoder Track exit sensor Lower Fold Rollers Fold Plate 3 Fig 7 Fold Plate 1 Description of Operation Sheet Feeder Collate tray sensor End stong gulo Setting Page 2 6 Issue 1 Mar 2010 Operation A form feeds through the pre feed rollers monitored by the pre feed sensor and up to the deskew and double document sensors mounted side by side The leading edge is driven into the stationary rollers ahead to correct any skew The deskew sensor also acts as a hold point When the path ahead is clear the drive is engaged to the rollers to feed the form fowards As soon as the trailing edge is clear of the pre feed sensor the next form starts to move towards hold point deskew thus allowing minimum time delay be tween forms If an OMR or barcode head is fitted the OMR Ga
20. 3 19 3 18 Adjustment of wetter lever 3 19 3 19 Engineering mode 3 20 3 19 1 Hardware setup 3 20 9 19 2 UNS e uu 3 21 3 19 3 Firmware 8 3 27 3 19 4 Ee ne re 3 28 3 20 Recommended Spares Parts List 3 31 Exploded Views een ie 4 1 4 1 Chassis Drive Side Front 4 2 4 2 Chassis Drive Side Rear nennen 4 5 4 3 Chassis Operator Side a 4 8 4 4 Chassis Assembly dunnassiauentacarateaewacete 4 11 Z5 Shalt LOCAWO MS 4 14 4 6 Envelope Feeder Assy A Z 1O0p4 A 4 16 4 7 Envelope Separator Assy A2 1065 A 4 19 4 8 Envelope Tractor Assy A2 1067 A 4 21 4 9 Envelope Feed Shaft Assy A2 1068 A 4 23 4 10 Envelope Conveyor Assy A2 1066 A
21. 3 5 3 5 Removal a tena ade 3 6 3 5 1 Drive side cover 3 6 3 5 2 Operator side Cover 3 6 3 5 3 Internal black covers 3 3 5 4 Front vertical 3 3 6 Removal of envelope feeder ee 3 8 3 7 Removal adjustment of envelope separator 3 9 3 8 Replacement of envelope conveyor belts 3 10 3 9 Removal of collate pocket clam 8556 0 3 11 Issue 2 Dec 2011 3 10 Replacement of collate chains pawls 3 12 3 11 Removal of finger assembly 3 13 3 12 Adjustment OF fingers 3 14 3 13 Removal of side guide adjust assembly 3 16 3 14 Adjustment of side guides i 3 17 3 15 Removal of power Supp 3 17 3 16 Removal or sealer rollers 3 18 3 17 Removal of sealer assembly
22. 4 25 4 11 Envelope Conveyor Backstop Assy A Z 1200 A 4 28 4 12 Collate Pocket Clam Assy A2 1069 A 4 30 4 13 Head Input Conveyor Upper Assy 1054 4 33 Maximailer HD Service Manual Issue 2 Dec 2011 4 14 Head Input Conveyor Lower Assy A2 1055 A 4 36 5 8 Interlock PCB Circuit DIaQEalIm sina since intr icr e a ra ean 5 21 4 15 Motor Assy A2 1056 A 115V A2 1057 A 230 4 38 5 9 Stepper Motor PCB Circuit Diagram 0 22 4 16 Sealer Assembly A2 1058 A nennen 4 41 5 10 R Splitter amp Disk PCBs Circuit Diagrams 5 23 4 17 Split Shaft Sub Assys A2 1059 1060 1061 A 4 44 5 11 anserter Head Wiring Diagram 5 24 4 18 Finger Assembly A2 1062 A 4 46 5 12 Inserter Head Splitter PCB s Wiring Diagram 5 25 4 19 Finger Bkt Op Assy A2 1073 A 4 49 5 13 Ins Head PSU Interlock Wiring Diagram 0 26 4 20 Side Guide Adjust Assy A2 1063 A 4 51 4 21 Pa
23. 0 LES AAD A R Spares See Spares Assy 1 See Spares Assy 1 See Spares Assy 1 Issue 4 Jan 2011 Page 4 6 Maximailer HD Service Manual Exploded Views Issue 3 Sept 2010 Fixings Item Part No Description Qty Spares 50 E2651A SCREW M3 x 6 PAN HD 3 51 E2 0836 A SCREW M4 x 6 TORX PAN HD 2 52 E2826A SCREW M4 x 8 TORX PAN HD 2 53 E2507A SCREW M4 x 10 CAP HD 2 54 E4 0078 A 3mm SCHNORR WASHER 3 55 E3505A M4 NYLOC NUT 4 56 F5103A 3 DIA x 10 DOWEL PIN 3 SEE FIXING KIT FOR THIS ASSEMBLY 57 E5071A 3 DIA x 14 DOWEL PIN 1 A0 0541 A 91100095 58 E5086A 3 DIA x 16 DOWEL PIN A NOTE FIXINGS ARE NOT AVAILABLE 59 E5073A 9 5mm E CLIP 2 INDIVIDUALLY 60 E5092A 12mm E CLIP 4 61 E0475A WAVED WASHER 10 5 ID 2 62 E0367A WAVED WASHER 23 ID 4 63 E4033A WAVED WASHER 8 8ID 1 64 E2834A SCREW M4 x 10 TORX CSK HD 2 Spares Assemblies SA1 AO 0553 A 9110050K LENZE CLUTCH ASSY A R 4 2 Chassis Drive Side Rear Page 4 7 Maximailer HD Service Manual 2 2 Issue 4 Aug 2011 Exploded Views 4 x Ki
24. 4 COOC B ODO BED as HB SOUT2 JA ER TE NURSE SE RXA l 20UT lt 4 5 OD2 BEI ANE a S2 tal a RXD2 AE OD3 56 5 9 _ 8 TXD2 a D3 RTSA 7 R20U R2IN 2 5 a SM DSRA H 8 1 5 OD5 58 3 ST232CD D D5 DTRA 9 E 29 pe jena 50 OD7 60 6 KA D7 RIA 51 40 0 SOUT3 IORD IOR TXB IOWR IOW RXB SU 6 LPWR ZEB ES C H52 J16 UARTA T UART pr EEN RTSB CO 453 T UARTB sert ED DSRB z H54 E fe UARTC CSC H55 OP24 CA UARTD CSD CDB CO H56 6 9 J33 RIB H57 ETC ne 23 9 39 SOUT4 RXD3 4 5 4 IQA2 A TXC 5 5 BADO oa 22 29 SIN4 TXD3 L TXD5 IOA3 A2 RXC rs 2 9 NEC SI MA E A e O H58 1 8 1 u INTA RTSC H59 VCC 12 NTR DSRC 2 H60 INTC 37 34 KA N Z Gre 4s INTC DTRC C H61 INTD CDC Fp 162 C86 0 1uF en C87 0 1uF e RIC H63 I C17 2 1 gr BRST lt lt RESET MEE d C1 V4 NI m RxD LS dl e 47 4 6 1 CTSD C H64 puc na V IP36 2 22pF XT RTSD H65 l R37 3 48 5 C89 0 1uF DSRD H66 69 IP38 4 3 6864MHz S 46 SS KA T DTRD 45 Q 11 14 T S CDD H68 TAIN 10U XD4 IP11 LL 6 26 nec pon 50 SOUT5 101 _ 7 TXD5 xv QAQA JRID H69 2IN 20U a 65 5 fn 12 BOUT ari LL RXD4 R291 220R 8 33pF 9 R20UT R2IN Bsus 9 Xr SC16C554B OP24 1 SI2526D OP28 1 OP29 2 que 24V J 3 OP24 i 4 N This circuit is in three parts RXD4 x 2 1 9 6 see also previo
25. e e kd k e e e e OcNp ZE o ka a 11 KOM u KI ERA TP2 12 OPS MOT1B GND GND 13 GND 14 lt OP26 Title C4 Control Mk2 part 2 180 8360 Size Document Number Rev A2 127 2920 cct 1 Date Thursday Auqust 20 2009 Sheet 3 Section 5 3 Control PCB Circuit Diagram part 2 ge 5 15 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 VCC VCC C72 0 1uF U44 C73 0 1uF 1 ci v II 3 LPWR Si J15 uU 4 6 U59 fio C75 C2 26V N ce 5 C7 O 1uF 8 ES x C2 7 CD C363 a IODL0 7
26. 100K Fwd Rev 6 25v u T5 Current amp i e N 1 e N 1 Ce R17 MGND Current amp B e e e e o SPEED 1 2 11 Ref odp 92 5 Q4 6 1uF AMP MTA bi Error Amp i p SUP65P06 20 SUP65PO8 20 SUPESPOS 20 85 0 158 100K e 13 Error Amp i p A Ai Error Amp Out Te ler 1 PS 1 White Red iy 10 z P2 2 IPA1 2 e Oscillator 5 PT 2 White Black R18 2 220R 3 c8 con R19 MC33035 T 4 3 White Yelow PAZ 4 3 N C R20 2 2205 Lu 4 7uF O 1uF O 1uF 1M R21 J5 IPAS 6 5 VCC kl al S 1 2 R22 1 2 220R P 92 ki T T MGND Motor IPA4 8 7 S a 8 r i i C10 5K6 C11 25 ap 96 me Y 1 R234 2 220R 9 A HDIR em p 10 Direct 2 3 HPWR 0 01uF 0 1uF 1 2 1 1 2 1 1 21 10 Motor ija SPEED N 8 1 Cortial 560R IRFZ34N 560R IRFZ34N 560R IRFZ34N hd 13 12 ontrol 5 k 9 bd n m m T4 13 6 14 wW 15 ii OUT 16 R27 MGND VCC OUT2 7 i5 4 1 2 8 1 1 1 OUT3 18 i OUT4 18 1K2 ii vcc TP1 PWM3OUT 20 19 c12 R28 R29 C 30 ill R31 USA 0 01uF 270R R30 100K 1 2 IPA1 a 1 2 i U6B B 0 033R 4W S 5 AKT TP2 74HC14 2 6 U7 414v ei MPWR 6 R33 USR R32 T ICP6022 1 2 PAQ e 3 4 e 9 Ti 26V 3 2 MGND w 2 DUT Leg MORD 100K 4K7 TRS 74HC14 i vec O R34 R35 5 R36 USC ka 1 2 IPAS 5 6 220R 390R 1 2 k SS v
27. gt gt MGND x Z 2 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 100uF 25V GND I i e EL Page 5 22 34 e e e e e e e e 9 e e e Ribbon Cable from J5 on MGND 3 Plate Folder Board PFE INTERNATIONAL LTD OOOOO Oo00o OQ OO OO i OOOOOO OOOOO OOOOO LOUGHTON BO 709 VCC oo oo OO oo ENGLAND U2D OO OOO LED 12 LD2 00000 ET e R15 1KO ae Section 5 9 St Motor PCB Circuit Diagram Lal K 5 488 48888 AM4 5 dli ection 2 32 5tepper Motor Ir Cul lagra BW IN 74HCTO8 GREEN 5mm OCTOBER 2003 PCB NO 127 172 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 VCC J16 21 il O O 2 7 PS1R J2 JA J6 J8 J10 PS1T 22 or 3 3 3 3 3 23 5 PS2T PS1T 2 PS2T 2 PS3T 2 PSAT 2 PSST 2 S 1 1 1 1 24 fl a PS3T 8 ERR J1 J3 J5 J7 J9 25 3L ud 3 3 3 3 3 0 PS5R PS1R PS2R PS3R PS4R PS5R OPB370 N 55 26 1 55 MPWR 1 1 1 1 1 4 O O 3 27 3 D 28 5 a Pin 6 SOL1 View MPWR 29 EM
28. MOTOR 181 050 AM4 T E SSO 20 OWE SUP LY WIRING Issue 1 Mar 2010 BLK BIK 182 8450B BRN BRN ORG RED amp ruo o omi 2545 23 4 5 a s eme 182 550 YEL BLU RED 182 8450A um SPLITTER PCB E4 CONNECTIONS 182 8330 JS 182 550A SPLIITER PCB 1 FINGER SOLENOID 181 1610 COLLATE POCKET EXTRA LONG STOP SOLENOID 181 1600 82 550C SP ER PCB 3 82 550D Bp ER PCB 4 82 550E BP ER PCB S 82 550B SP ER PCB 2 82 550F ap F lt PCB 6 82 550G SP Ex PCB 7 e JP1 BOOTLOAD or LD3 26V LD4 SV TP1 GND TROL MK Z os 6 POWER SU PPLY WIRING J14 J PANSION
29. abiret unus t XO uus LLL a cf i r T mr mail i LI ae E LE k CR 3 miri 4 Fy 3 w it lei A m n Pat Tear EK LETT 181 1600 Collate Pocket backstop Extra Long EI d TTT te ven Pere A q TENTI dng i 181 1610 fy I Ki Mmmm E Ze Solenoid W D N 7 C o Fingers E i IA TE L z T NM eet 4 a jn d BATI mmm rrr T jem li w w rs I DE IR ILE L EH E mk Ri d g di an Eh ities mrs mil LI EE se E kal in om LI n S H T K d 1 ir j r d ER Te bt Pe Lee a ib WE ETES a e dd Me 7 ely i j migas SR ae e nr i m n i Pm S i i 1 d MU l ri H M m LA A4 1 l 182 8330 X SW W deiten Kat 180 8360 Ribbon Cable PCB Assy AM4 Control k Page 5 12 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 180 759 Splitter PCB NoE4 pa M 179 109 EC3OLL W Envelope Upper Drive Brake 182 8330H Ribbon Cable Eccentric fitted shaft turns in one direction 182 8330E Ribbon r Cable e ther 7 TP T 179 109 EC30LL Envelope Lower Drive Brake EH T h ioc L Bers af
30. Description of Operation Page2 3 Issue 1 Mar 2010 Whilst the pack is feeding an envelope will have been fed to the envelope feed sensor which acts a hold point if necessary and then into the station ary deskew rollers which straightens any skew the deskew rollers are con trolled by the deskew sensor The envelope tractor facilitates feeding of envelopes and operates on a pivot When pushed forward by the envelope stack the envelope conveyor sensor switches off the feed conveyor as envelopes are fed and the tractor relaxes the sensor is cleared and the conveyor starts again The amount of delay before feeding restarts can be controlled in software The envelope is then driven past the tilting flap opener and into place ready OSER SE SENSOR FLAP CR d DATUM POINT ENVELOPE TRACTOR EAS COLLATE POCKET Li OAD SENSOR INPUT CONVEYOR SENSOR WETER OUTPUT J aK POSITION SENSOR PAWL CHAIN E PATH ER PATH Fig 4 ELOPE PATH Page 2 3 Maximailer HD Service Manual Description of Operation Page 2 4 Issue 1 Mar 2010 for insertion Here it is held with the flap crease at the datum
31. Circuit Diagrams Sect Page 5 3 Control POB Circuit DON RE 5 14 5 4 Processor PCB Circuit Diagram 5 17 5 5 Comms PCB Circuit Diagram 5 18 5 6 Wetter PCB Circuit Diagram 5 19 oT Expansion PCB Circuit Diagram esee 5 20 5 8 Interlock PCB Circuit Diagram 5 21 5 9 Stepper Motor PCB Circuit Diagram 5 22 5 10 R Splitter amp Disk PCBs Circuit Diagrams 5 23 Electrical and Circuits Wiring Issue 3 Dec 2010 Wiring Diagrams Sect Page 5 11 Inserter Head Wiring Diagram eese eese 0 24 5 12 Inserter Head Splitter PCB s Wiring Diagram 5 25 5 13 Ins Head PSU Interlock Wiring Diagram 0 26 Page 5 1 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 2 Mar 2010 SECTION 5 1 SENSORS 5 1 1 Sensor List There are three sensor types fitted to the machine Thro beam Emitter Receiver pair Reflective 1 part Encoder for slotted disks amp flags All are supplied as part of a sensor amp lead assembly with the attached con nector Replacement is a matter of ascertaining the sensor s PCB connector and fitting the new item in its p
32. Item Description Envelope Flap RX Collate Pocket Input RX Collate Pocket Load RX Collate Pocket TX Top Pawl RX Top Pawl TX Lower Pawl RX Lower Pawl TX Envelope Seal RX Envelope Seal TX Wetter Output RX Wetter Output TX Closer Output reflective N EQ GE Fa OTE 1 BRIDGE CLAMPS G4092A Lf WITH x 12 TORX 4 SCREWS E BSDA ARE FITTED IN ALL LOCATIONS MARKED 4 4 Chassis Assembly Ai Page 4 11 Maximailer HD Service Manual Item Part No WON AU Q N B2 1195 A B2 1199 A B2 1200 A B2 1203 A B2 1204 A B2 1216 A B2 1242 A B2 1941 A B2 1734 A B3 1090 A B3 1098 A B3 1106 A B3 1115 A B3 1116 A B3 1117 A B3 1121 A B3 1123 A B3 1124 A B3 1125 A B3 1140 A B3 1232 A B3 1242 A B3 1245 A B3 1246 A B3 1346 A B7696A B3 1122 A G1 0261 A G6 0218 A B0 0203 A P2190A B3 1088 A B3 1055 A B2 1253 A B2 1256 A B2 1259 A C9278A 180 760 E0291A B2 1197 A 9110028M 9110029N 9110030P 9110031Q 9110032R 9110033S 9115793A Exploded Views Description WETTER BRIDGE INPUT BRIDGE OUTPUT BRIDGE HEAD SIDE PLATE DRIVES HEAD SIDE PLATE OPS MAIN BRIDGE WIRE PROTECTOR BRACKET SEAL PLATE OUTPUT GUIDE BKT WETTER SENSOR BKT PIVOTING COLLATE PANEL
33. tor the separator setting to the software which will then flag an error if the measured thickness of the insert is outside the range of the setting Operation Inserts feed through the separator and up to the stationary deskew roll ers ahead This straightens any skew and as the leading edge is detected by the deskew sensor the drive clutch actuates to drive the insert forward to the hold point sensor where it is stopped by the drive brake just ahead of this point The double document sensor is also located next to the hold SEI EED CLUTCH DD amp H POINT point and if required a calibration cycle will be performed to guage the document length and thickness otherwise the DD sensor will detect if a SENSOR gt double has been fed When the path ahead is clear drive will again engage to move the insert LE wk forward to the track feed sensor where it is halted The paper width sensor AC e located to one side is used by Select amp Go to detect if the insert width is E A too wide for the envelope if it is an error will be flagged If the insert is to be collated with one from the following feed unit as described in sec tion 2 2 it will wait at the track feed sensor until the following insert has reached it timed from the t
34. To avoid this use adhesive tape to hold the car riers to the lead screw during reassembly as shown in Fig 18 Reach in through the PSU opening to help guide the lead screw through the T bearing opening on the operator side Adhesive tape When the assembly is in place with the carriers the right way up remove the tape 6 Replace the T bearing and clip on the operator side screw the PCB back into place and reconnect the cables Also reconnect the cables on the drive side 7 Replace the side guide brackets and side guides in the collate area The side guides must now be adjusted see section 3 14 Page 3 16 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 3 14 Adjustment of Side Guides 3 15 Removal of Power Supply The side guide width is automatically set according to document size How The power supply unit can be removed from the drive side of the machine ever the side guides are factory set to toe in at the front If the guides after disconnecting cables on the operator side have to be removed or disturbed the toe in must be reset to toe in at the AER J Operator side front al AO gd XJ p p Bam STEEL The PSU must first be discon i nected on the operator side im mm 1 Open the collate pocket assembly in the collate area Slacken the 2 screws indi cated in Fig 19 to allow the guides to swivel 1 Disconnect the two cables indicated in Fig 20 Unplug th
35. envelope into the upper seal rollers sealing the envelope flap the reverse point is timed from the closer output sensor The envelope leading edge reaches the closer seal sensor and the envelope reverses again to drive it out of the eject monitored by the closer output sensor This completes the cycle See fig 5 above ig 5 The insert finger widths and collate pocket side guides are automatically adjusted to suit the appropriate paper widths as determined by the sizes set in the operating software For the fingers the finger datum flag sensor determines when the fingers are at their narrowest position The finger disc sensor then clocks their movement to set them to the correct position The finger out flag sensor is blocked when the fingers are in the relaxed posi tion out of the envelope For the collate pocket the guide datum flag sensor determines when the guides are at their widest position The guide disc sensor then clocks their movement to set them to the correct position Page2 4 Maximailer HD Service Manual Description of Operation Page 2 5 Issue 1 Mar 2010 2 4 Description of Insert Feeder see Fig 6 opposite Insert feeders on the machine are fitted with a top feed hopper capable of holding up to 300 reply paid envelopes or 150 2mm thick booklets The separator has 4 manual settings each one automatically adjusting for a range of thicknesses 2 slotted sensors use a simple binary code to moni
36. n HYBRID 2 MOTOR uo IPR U DISC g fle AW Wop SENSOR F ENV SEAL ll o soles a CS Ly l fm l i no SENSOR H RED D S 22 H 2 fale hel 4 ENV LOWER S E ll ajo gi DRIVE CLUTCH S e Ml s M ce 3 i e js r UI E K A d BLUE B Sie Da E COLLATE H T EJ Ha g POCKET i CLOSER INPUT Z S WETTER DRIVE l seNsoR O A J Es e BRAKE T 7 a QE COLLATE I POCKET COLLATE ae 3s LOAD POCKET A N SENSOR SENSOR PM COLLATE SENSOR C FORWARD 48 d ENTRY O WETTER Se CLOSER F H BRAKE et DRIVE Bu OUTPUT S ye ee ful FINGERS KE FINGER M n MON CLUTCH SENSOR 24 i E DISC DATU INSERT PAWL SENSOR SENSOR SENSOR DRVE d KA SOLDATE Lei n 65 180 760 ENTRY 1 x di e bns E WETTER OUTPUT SLOW WI bM LUTEH Br L G DETECT SENSOR A Gs TE 9 10 HYBRID MoToR S l s T lt amp CLOCK uM ss OR FINGER ae BOTTOM ADJUST PAWL MOTOR S Kee SENSOR Iu ex OO M Ex uet j 5 p pr eee o A u ee SS 19585 i ARRow ANGLE UL TET 7 ta at e WIDE ANGLE AC MOTOR SENSOR PCB ROTATED FOR__ ILLUSTRATION For operator side see previous page Page 5 5 Issue 2 Mar 2010 Maximailer HD Service Manual Electrical and Circuits Wiring SECTION 5 2 ELECTRICAL COMPONENTS Electrical components on the 200 300 include PCBs motors clutc
37. o R79 R68 O37 1 P12 V E OFL MD gt ai OtuF LI 10K IK 0 1uF UR 1K our 1K 330R ZIX658 LN AN aW m ADCOB2OCCWM ni a ni RU B C4 Expansion PCB 180 8300 N N N L Ld k Ld kd kd Size Document Number Rev A4 127 2850 2 Se MGND Date Friday September 04 2009 Sheet 1 of Section 5 7 Expansion PCB Circuit Diagram Page 5 20 Maximailer HD Service Manual 26V OV JI Electrical and Circuits Wiring nput PSU Output otor nput PSU Output L Motor Issue 1 Mar 2010 MPWR Ci GO01uF O PWR Heat Sink Required O 8 D U1 LM2596T ADJ RTO RI e 9 LEVIN 4 750mA FB e L Ee 5 AK7 NON OFF E C2 C3 2 Q2 OUTPUT e e u 220uF 220uF GND 47uH 7V D1 bs R2 M n C4 2N6508 SCHOT
38. uss FZT1053A U D89 m 9 2 R176 R177 R178 R179 N 1 ij z ZXCT1009 1 m e c5 D63 N R19 47K 10K 10K 10K 10K J28 N oP R249 1K S U47B J13 0 1uF 067 2 uso S 1 Cover E REM3 5 RP j i Remote 3 Switch R20 47K A 4 N REM2 A 4 E Ae OP30 a ZXCT1009 K M3g8D 2 SET i 3 Contro FZT1053A m E 7 U46B R245 BZX84012 R21 47K R22 47K REMO 1 m l z D79 l C82 1000pF X13 s g D67 and D68 fitted 6 1 cem Wi A 3 1 x Z MERE D87 D90 not fitted tA Pc no itted N LM339D rud 2 E R2sg B7XB4012 R255 1K 1 47K R24 47K Tour N bel l 26 6 C77 1000pF 4 cover lt l ji ORO47 E U56 NU R250 1K ZXCT1009 e be i A jaye vec qe d z 2 us 14 Ja A 5 Vcc e z 4 E ZXCT1008 IN LM339D le _ mE BZXB4C12 ANS 3 m on 9 U46C R244 R180 voc i IQD2 H s T T CB 1000pF 470R Se IS CIFCUIT IS IN ree parts A LA A S 1K J14 X14 ki IOD4 IN Ar 113380 ORO47 R175 LDS A l 5 LS RRA zap sw ech Jil sm ian see also following Dage BEXSI IZ C78 1000pF R256 1K m Som 2 5 i007 L 24V D 1 A i 4 2K2 YELLOW l 1 ip IOA1 a v 11 IOA2 ORO47 S uer C61 18 C4SEL cea R251 1K E V 13 PWM3 2 ZXCT1009 4700pF JONR m o 14 U47D vec J20B 15 IORD m D86 4 16 EXPINT u U52 13 v S1 17 EXP 5 7 i 9 9 7 Serial Comms Port 1 s2 18 ZS 8 ZXCT1009 JN LM339D 48 m nis BZX84C12 jia 20
39. 10K D15 RD 13 a vi 11 KBDRD KBDWR ti CR 1 8 14 10 KBDWR RSTO 1 P2 15 KBD 15 i 3 H13 ER NVMEN S2 SW 4 POLE 74HC273 KI Startup mode 74HCT139 U22A 0228 U23A 0228 o o L a al 2 Q 05 3 11 d t ey wa n ek CLK 3 ek U ouk WE U24 s 5 255 GI x a l6 EREN E e 74ACT32 U10 U21 ut 1 RSTI i 2 fi pa Z si H a 2 Al ii L8 na KBINO Fi 10K 7AACT7A 74ACT74 74ACT74 74ACT74 D1 B2 7 OD A2 El 35s iva E JOA2 RT L TOK KBINT B 10K D2 4 A3 RT9 TOK BIND 20 TOK CND 74ACT32 D3 EAM ba 15 1003 A4 wa 22 D i RZT TOK BING R22 10K BETTE S 54 ZNVMSEL 6 NVMWRL_ D4 6 14 IOD4 AS 1 9 IOA5 R23 TOK 4 5 D5 85 13 1005 D 13 7A joA6 R25 TOK mE l 6 ok t O m KBINS 5z i is ef ae Z T a aa R Tox DUE R65 R86 R67 R68 74ACT32 R29 TOK S7 Bg 3 Ag ga ODA RE 17 24 2v 13 AWR KBIN7 RSO 10K vec 1K 1K 1K 1K 18 1 T 6 16 RD 1 7 m ACEN TA de 4 4 4 74ACT245 74ACT244 VCC k k LA LA k k LA LA k 9 L k L mite C4 Processor Board 180 720 C36 fag i 6x5 Ge an as Se mE C14 C15 C16 C17 C19 C20 C21 C22 C23 C24 C25 C28 C27 028 C30 C31 32 C33 054 ch Seet eet ee pula LA Feed Set Fee ce Hk ca ee cla ca cla cc ET Document Number Re
40. 1158 A E1077A E2 0836 A E2826A 9110308D 9103834K 9110004M 9108961A Exploded Views Description Qty WETTER BEAM BEAM PIVOT BASE FLANGED BEARING 4mm BORE M4 x 6mm TORX PAN HD SCREW M4 x 8mm TORX PAN HD SCREW N N N N FR 4 23 Wetter Beam Assembly Spares lt lt lt lt 2 Issue 1 Apr 2010 Page 4 58 Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010 B L 4 24 Wetter Tank Assy A2 1070 A 9110168H Page 4 59 Maximailer HD Service Manual Item Part No A2 1070 A 9110168H 1 A2 1304 A 2 B3 1105 A 3 C3482A 4 D0054A 5 E0235A 6 P2375A A2 1304 A 9110169 10 169 115 11 B4 0448 A 12 G0 0181 A B4 0448 A 15 B3 1334 A 16 B3 1335 A 17 C2 1167 A Exploded Views Description WETTER TANK ASSY FELT ON FELT BRIDGE WETTER TANK OVERFLOW PIPE CAP RECT VINYL 23x13x1 5 O RING 12 1 x 1 6 NUT M12 5mm FELT ON FELT BRIDGE RIVET 5mm 2 5 3 5mm GRIP FELT BRIDGE ASSEMBLY WETTER FELT C4 FELT BRIDGE ASSY FELT BRIDGE 2 FELT BRIDGE 1 SPACER RIVET 4 24 Wetter Tank Assy A2 1070 A 9110168H Qty HH Spares Z Z lt Z Z Z lt A Issue 3 May 2010 Page 4 60 Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010 lt 15 Lei a g 7 10 Ce Bak
41. 25 0 JA 9 P3 11 RXD P6 7 BREQ AB AM UU ba Sr SVNRX 75 nde ATO 24 48 ATS a 7 ls lo lee l 1 18 n SYNTX 76 ATI 21 28 21 DEVE WAIT gem eee eroe oe 51 AN13 Tz P3 9 MTSR E iu A10 A13 COREVDD2 16 veo 23 A18 3 41 49 CNFO 1 8 VIN 3 PPS 138 MAREE 3g AIG Ed vec eee CNFO 48 HE 2 E24 KBINO TF dees 137 AGNES ga T Sa 26 2 28 NVMVCC AT 2 55 FER CNFT CNF2 Ee KBIN1 5 7 14 xa NC 318 A5 VCC TB 39 16 18 CNF2 curs A 4 m et 15 ORS A14 xa AU r jg um CNF3 oT A Ge Si e E ocs Vcc NVMSEL 20 L il 2 JOVDD2 4 POLE KBOUTO SIS OAI RD 22 RCS1 22 IOVDD3 KBOUT1 8 18 18 E cs e IOA2 a ZNvMWRL 27 qe cup LI RD es C6 O iuF KBOUT2 TO gt IOA3 R74 WRL 28 KBOUTS 11 20 A IoA4 R31 m 32Kx8 SRAM AWE 7 20 12 KBOUA T 20 L 12r KBOUT4 GAS osc 3 2 M5M5408 C7 0 1uF 27 VSS 11 H10 KBOUTS 15 21 m JOAB OBC 1K U16 vss2 T s 2 o IORD 330R 10 11 Da U8 id so Yess SOU te j C JONR 22 s 00 12 pa 12 13 08 50 S54 74ACT32 F VIN 5MHz 23 sl A 13 Do 22 er 0 50 14 ms t ze TE Keyboard C 7 JRSTI Ad 7 ja 15 BTI A3 10 n ni 15 D10 80 gt C B BSL 45 5 e D12 4 A 2 17 Dh 4 6 26 5 4 os bis a5 8 by 18 m 4 IOEN al AT i os 18 pi4 76 X he 39 D13 KA 51013708 5 a RSTO 28 age o 18 es AT 6
42. 29 4 30 Description Sealer Assembly A2 1058 A Split Shaft Sub Assys A2 1059 1060 1061 A Finger Assembly A2 1062 A Finger Bkt Op Assy A2 1073 A Side Guide Adjust Assy A2 1063 A Pawl Tension Bracket Assy A2 1072 A Wetter Lever Assy A2 1352 A Wetter Beam Assembly Wetter Tank Assy A2 1070 A No Seal Assembly A2 1214 A Head Ribbon Bkt Assy 184 2260 Universal Head PSU 184 2150 Mains Input Hardwired 184 2250 Peda GOO paints quippe d pui V DUE External Float Switch A3 0421 A Lift Beam Assembly A2 1520 A Issue 4 Dec 2011 Page 4 1 Issue 5 Feb 2011 Exploded Views Ce ae Maximailer HD Service Manual Z i SD EM E Fd o Doe Oy dia Ze SE amp M e a 6 A P M Oa gt l Ce e Kas 27 52 7 50 D SCH Pa i He p T e es SS eg EX amp 34 I e i m Q 51 58 gu d ss lt i l 29 63 di ic 4q 56 SAT NOTE FOR CONNECTOR PANEL DETAILS SEE SECTION 4 28 SENSORS Item Description Ref S1 Hybrid Motor Disc Page 4 2 4 1
43. 330R OUT20 12 FZT1053A 7 D20 516 U22 AD5204BR50 veg lt R71 ART 13 am ee Sp Es 04 12 R 330R OUT21 13 ogg R118 470R R75 Av GR R73 AKT 14 wan O PET GI 14 DS Q5 R74 330R OUT22 de Muss Q18 1 t D71 IPPUS 24 R76 4K7 Danz CH IOD6 06 88 ug R 330R OUT23 15 P10 S OUTS Sit NI t 23 B4 5 R185 1K IP15 R7S AKT 18 AN14 N flocs 18 IR 1g 0 07 19 RBO 330R OUT24 16 W4 NPR 17 17 IOCS D8 QB MOT2A vi IP9 38 7 R186 1K MUX R82 AKT ANTS 10AT IOA1 17 FZT1053A 3 D21 510 R120 470R Ad SHD R78 AKT 18 GND Ioa2 18 0P171024WR 11 18 MOT2B Le 19 PwMO oz 119 IOA2 L CLK e OPTI LI DEI 1 IPPU10 21 o men 85 cO E OAS RST DE 18 Sen aig D97 55 spo 10 o SC MEN Sat DE a OBE 5 IOA4 T BER IP10 ws M3EN 25 PWM2 IOA5 IOA5 R121 470R 9 o m PWM3 IOA6 ian x9 vec F7T1053A Il D22 eT IPPUTI 18 8 23 GND JORD 24 JORD LPWR vec J3 A1 spi R84 AK e 24 p20 O IOWRL 24 o Oo IPIDRV DEI 1 TEJ Wi ms 4 IP16 RBS AKT E o E ous XSDA 9 020 Q21 D98 IP11 18 R87 AKT IP17 R88 AKT P2 1 5 VIN XSCL 1 PIO BC846B R89 100R OUT11 sic R122 470R 9 BI 4 P7 IPT8 R91 4K 26 P2 2 D JRSIN 26 JPT 2 IP1D FF v t IPPU12 B 4 NES IPB IP19 R93 AKT e P2 3 o BSL e 6 t 1 i l R209 220R Ech K Zb wa Ret te E Ree ane 28 Ge 28 dd R107 R111 R232 IP11D 0P12 IP12 13 1 R96 4K7 IP21 R97 AKT WJ Z 5 Q22 1 1 D72 e ZE R98
44. B2 1299 T B2 1313 A B3 1136 T Bs 1159 5 B3 1142 T B3 1231 F B3 1233 F B3 1236 S B3 1238 S C2436A C4366A C5 1116 A C6358E G1006A G3068A G3410A G3463A G7 0179 A G7154A G7155A P2230A R2211T R2229F 131 824 9110147L 9110148M 9110149N 9110150P 9110151Q 9110152R 9110153S 9110154T 9110155U 9110156V 9110157W 9110158X 9110159Y 91101602 9110161A 9110162B 91025407 9106257 9110163C 9106403L 9104609S 9105609 9105917E 9110164D 9110165E 9108948M 9105676D 9110166F 9105121A 9100302F Exploded Views Description SEALER COVER ASSY TRACTOR INFEED COVER ASSY HEAD SIDE COVER DRIVES MAIN COVER LOWER ASSY HEAD SIDE COVER OP ASSY UPPER COVER ASSY C4 A4 CONV PLATE COVER PIVOT BKT LH SIDE COVER LATCH COVER PIVOT BKT RH HEAD COVER SKIRT OP HEAD OUTPUT COVER DRIVES SKIRT INTERNAL COVER 2 INTERNAL COVER 1 CONVEYOR UNDER COVER CONVEYOR END CAP PIVOT BUSH HINGE PIN LATCH PIVOT HINGE TRACTOR SPRING WARNING PLATE WARNING LABEL MAXI DATACARD NAME PLATE VIEWING PANEL HEAD SIDE COVER DRIVES HEAD SIDE COVER OP TRAY SPIGOT CATCH TRAY TOP COVER HANDLE SWITCH MAGNET SMALL 4 29 C4 Head Covers Qty NJ LP N HA BN H NJ H kA pP IS kA kA Spares lt Z lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt lt 2 lt lt lt lt lt lt
45. CHAIN GUIDE INNER DRIVES CHAIN GUIDE INNER OP CHAIN GUIDE OUTER DRIVES CHAIN GUIDE OUTER OP COLLATE POCKET SENSOR BKT PART OF 184 2270 SPLIT SHAFT COVER COLLATE POCKET GUIDE OP COLLATE POCKET GUIDE DR HEAD UNDER COVER FLANGE PLATE INSERT PANEL CENTRE INSERTION PANEL OP INSERTION PANEL DRIVES OUTPUT GUIDE SIDE GUIDE BRACKET SPRING RETAINING PLATE COLLATE PANEL SPRING CHAIN TAPE NARROW INSERT GUIDE GUIDE SPIGOT OUTPUT SENSOR BRACKET CONVEYOR SENSOR BRACKET RIBBON PROTECTOR BRACKET INSERTION SENSOR BRACKET PART OF 184 2280 PAWL SENSOR BRACKET SENSOR POST 106mm PCB SPLITTER 3 SEN 4 SOL H D No 4 FOOT PUSH IN WETTER TANK CHANNEL 4 4 Chassis Assembly Qty EA Hp H H dB pmP FA FA FA N N N N N N IP kA kA BR HR HN IS kA EA Spares ow Z Z lt Z lt Z lt lt lt lt Z uu Z Z Z Z Z Z Z Z Z Z lt lt Z Z Z Z Z Z Z Z Z Z Z Z lt Issue 3 Aug 2011 Page 4 12 Maximailer HD Service Manual Exploded Views Item Part No Fixings 50 E2 0848 A 51 E2 0842 A 52 E2 0836 A 53 E2826A 54 E2829A 55 E3557A 56 E3505A Description SCREW M3 x 6 TORX CSK HD SCREW M3 x 8 TORX CSK HD S ST SCREW M4 x 6 TORX PAN HD S ST SCREW M4 x 8 TORX PAN HD SCREW M4 x 8 TORX PAN HD T T M3 NYLOC NUT M4 NYLOC NUT 4 4 Chassis Assembly Qty PS Ob Issue 2 Feb 2012 Spares SEE FIXING KIT FOR THIS ASSEMBLY A0 0543 A 9110036V
46. CL COLLATE OVERGUIDE SPRING COLLATE CLAM ROOF ASSY OPENER ASSEMBLY C4 COLLATE CLAM SIDE PL OP COLLATE CLAM SIDE PL DR COLLATE CLAM BRIDGE UPR LATCH PLATE COLLATE CLAM COVER COLLATE SENSOR BRACKET COLLATE CENTRAL OVERGUIDE GUIDE LATCH BRACKET BLOWER MOUNT BRACKET T BEARING HOUSING OVERGUIDE PIVOT SHAFT OPENER PIVOT OPERATOR C4 OPENER PIVOT DRIVES C4 COLLATE CLAM HANDLE COLLATE LATCH SHAFT CAP RECT VINYL 23x13x1 5 M3 STUD CAP BUSH SNAP 12 71Dx6 4L BEARING BALL 6x13x5 BEARING FLANGED 6x13x5 SPRING PRESSURE CONVEYOR LATCH SPRING LATCH SPRING LH SHIM BRAKE GUIDE SHIM GUIDE SPIGOT LATCH CLAMP SPIGOT Qty N NJ DD DD D N Spares lt 2 lt lt lt lt lt lt lt lt lt lt 22222 lt lt 22 lt lt 222222 lt 2 lt lt lt lt lt lt lt Issue 1 Mar 2010 Page 4 31 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 Item Part No Description Qty Spares Fixings 50 E2826A SCREW M4x8 TORX PAN HD 8 51 E2 0848 A SCREW M3x6 TORX CSK HD 2 52 E2827A SCREW M4x12 TORX PAN HD 2 53 E2830A SCREW M4x12 TORX PAN HD T T 4 54 E2834A SCREW M4x10 TORX CSK HD l SEE FIXING KIT FOR THIS ASSEMBLV 95 E3505A NUT M4 NYLOC 4 A0 0559 A 9110097J 56 E3507A NUT M4 HALF 2 NOTE FIXINGS ARE NOT AVAILABLE 57 E5003A CIRCLIP 7mm E TYPE 4 INDIVIDUALLY 58 E5073A CIRCLIP 9 5mm E T
47. DIA x 16 DOWEL PIN 9 5mm E CLIP 12mm E CLIP WAVED WASHER 10 5 ID WAVED WASHER 23 ID PLASTIC RIVET 3 5mm 2 0 3 0 GRIP WASHER 10 2x 17 x2 WASHER WAVED 8 8 ID 2 5 DIA x 16 DOWEL PIN SCREW M3 x 10 CHEESE HD M3 NYLOC NUT LENZE CLUTCH ASSY CLOSER REVERSE BRAKE ASSY LENZE CLUTCH ASSY 30T Qty N N O Q O Q OQ N O O N N NS WE ON A R A R A R 4 1 Chassis Drive Side Front Issue 3 Sept 2010 Spares SEE FIXING KIT FOR THIS ASSEMBLY A0 0541 A 9110009S NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Page 4 4 Maximailer HD Service Manual BELI S Pde or FIT S 2A SEE NOTE PULLEY 151 S2M OTOR 115V IDLER P2448A x1 E1061A x2 NOTE PULLEY 181 52M OTOR 230V Fo112A ITEM 34 2 Note Belt F5112A Item 34 is also shown on Motor Assy A2 1056 A see Section 4 15 FITTING DIAG RAM Exploded Views Issue 4 Mar 2012 61 15 6 2 30 Sat d 59 0 o e p C sm 62 2 d 28 B PA 60 12 61 hsc dd 28 gt C orm 2 4 2 Chassis Drive Side Rear Page 4 5 Maximailer HD Service Manual Item Part No 1 la 2 179 109 179 109 180 759 180 759 181 128 181 1600 181 1600 A2 1302
48. Frequency Time to Replacement Part Numbers and Ref Manual Complete Complete Interval cycle Page All Clean wetter solenoid with dry cloth and air duster Smins to remove dust particles Wetter solenoid Inspect after 2million ki al k d A12 Clean pawl chain 10mins E Chain Inspect after 2 million x Track Pawl ES th N Inspect after 2 million Check gears and tension on pawl chain Lightly grease chain FA 7 Jm el A d i Chain and Track Pawl A13 Al4 A15 A16 A17 Als A19 A20 A2 Clean all sensors both transmitter and receiver With approved air duster Check all gears Check pins are intact Clean and lightly grease gears Vacuum all areas to remove internal dust Refit Input conveyor assembly ensuring connector is plugged in Refit collate assembly ensuring all connections are securely fitted Refit envelope feed section ensuring all connectors are securely fitted Refit envelope conveyor Checking connector is pushed fully in Engineer calibrations Calibrate sensors and check All are working Engineer Calibrations Check fingers to 235 Check collate pocket size 10mins 30mins 5mins 5mins 5mins 10mins 10mins 15mins 10mins Engineer settings check clutch brake and solenoids 15mins All work A25 Run in envelope only mode checking for envelope stop 10mins position and good envelope feed A26 Run customers
49. Important ELECTRICAL INSTALLATION NOTES THESE NOTES MUST BE READ PRIOR TO INSTALLING THIS MACHINE This equipment is supplied with an unterminated three core lead for connection to the mains supply The connection must only be made by a qualified electrician or by a qualified Service Engineer 1 2 3 4 5 6 230 Volt Machines This equipment must be earthed For continued protection against the risk of fire fuses must only be replaced by those of the same type and rating Caution This equipment is internally fused in both Live and Neutral leads Maximum input current is 10A for 115V and 6 3A for 230V Maximum leakage current shall not exceed 5 of the input current Euro only An appropriate disconnect device shall be provided as part of the building installation and be readily accessible Euro and US Can Where the plug is fitted the socket outlet shall be installed near the equip ment and shall be easily accessible Wire Colours Live Brown Neutral Blue Earth Green Yellow 115 Volt Machines Wire Colours Live Brown Neutral Blue Earth Green Yellow Caution High leakage current An earth connection is essential before connecting to the supply Page 1 3 Maximailer HD Service Manual Installation Page 1 4 Issue 2 Sept 2011 Installation Instructions 1 2 1 Stand Assembly Note This secton covers installation of a complete Maximailer HD Stands are supplied dependent upon machine configuration
50. Issue 2 Apr 2010 Page 4 68 Maximailer HD Service Manual Exploded Views Item Part No Fixings 40 E2565A 41 E2 0838 A 42 E2827A 43 E2834A 4 4 E2829A 45 E2826A 46 E2559A 47 E2 0842 A 48 E3505A 49 E3502A 50 E3557A 51 E4048A 52 E5003A Description SCREW M5 x 12mm TORX CSK HD SCREW M4 x 12mm TORX CSK HD T T SCREW M4 x 12mm TORX PAN HD SCREW M4 x 10mm TORX CSK HD SCREW M4 x 8mm TORX PAN HD T T SCREW M4 x 8mm TORX PAN HD SCREW M3 x 10mm PAN HD SCREW M3 x 8mm TORX CSK HD NUT M4 NYLOC NUT M4 FULL NUT M3 NYLOC WASHER M4 FORM C CIRCLIP 7mm E TYPE 4 29 C4 Head Covers Qty N COCO N N N OO N kA N N Issue 2 Apr 2010 Spares SEE FIXING KIT FOR THIS ASSEMBLY A0 0571 A 9110167G NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Page 4 69 Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010 C KA H 4 d U p 4 30 C4 External Float Switch A3 0421 A 9110289J Page 4 70 Maximailer HD Service Manual Exploded Views Item Part No 1 2 3 A 125 432 169 107 184 2300 E0 0631 A Description Qty Spares TUBE CLEAR FOR PERI PMP 0 4 M N CABLE TIE 200 x 2 6 4 N FLOAT SWITCH WAND ASSY 1 N PIPE CONNECTOR 5mm I D 1 N NOTE FOR REPLACEMENT ONLY THE COMPLETE ASSY 9110289J CAN BE ORDERED 4 30 C4 External Float Switch A3 0421 A 9110289J Issue 1 Apr 2010 Page 4 71 Maximailer HD Service Manual Exploded Views Issue 2 Dec 201
51. Issue 2 Jul 2011 Item Part No Description Qty Spares 1 B2 1153 A PULLEY IDLER BRACKET 6 N 2 B2 1164 A LOWER CONVEYOR BODY 1 N 3 C2 1036 A CONVEYOR WHEEL 6 N 4 N R 5 C3 0678 A BEARING POST 2 N 6 C3 0685 A 9110101N IDLER PIN 6 Y 7 C5 1036 A LOWER CONV DR SHAFT 1 N 8 D1040A 9103641 T BEARING 8mm 12 SQ 12 Y 9 E0367A 9103789N WASHER WAVED 23mm ID 1 Y 10 E1 0138 A 9109987U BEARING BALL FL 10x22x6 2 Y 11 E1078A 9103835L BEARING FL 8x22x7mm 12 Y 12 E4033A 9104072H WASHER WAVED 8 89ID 12 5OD 12 Y 13 F1 0461 A 91121068 PULLEY 25T XL x 10 BORE 6 Y 14 F5120A 9104499C BELT 130XL 037 POLYURETHENE 1 5 Y 15 G1111A 91046815 SPRING LIGHT PRESSURE 12 Y Fixings 20 E3505A M4 NYLOC NUT 1 SEE FIXING KIT FOR THIS ASSEMBLY 22 E5073A 9 5mm E TYPE CIRCLIP 4 2 NOTE FIXINGS ARE NOT AVAILABLE Sai NA INDIVIDUALLY 4 14 C4 Head Input Conv Lower A2 1055 A 9110116D Page 4 37 Maximailer HD Service Manual Exploded Views Issue 3 Jan 2011 4 SENSORS Item Description S1 AC Motor Disc Note Belt F5112A Item 13 is also shown on Chassis Drive Side Rear see Section 4 2 4 15 Motor Assy A2 1056 A 9110111Y 115V or A2 1057 A 91101122 230V ae age 4 Maximailer HD Service Manual Item Part No 1 181 569 2 180 776 3 B2 1149 A 4 B2 1150 A 5 B3 1053 A 6 C3 0678 A 7 E0181A 8 E1061A 9 E4033A 10 F1373A 11 G1006A 12 P2448A
52. J 4 OP24 2 OP28 5 OP29 3 6 RXD4 4 7 TXD4 5 l 8 J2A CANHI CANLO 3 LL 4 5 LL 6 4 7 8 RJ45 KI l T MO m Arim 8 P SOC J7 6 OP24 l 1 2 4 1 gon 45 nc 24V J 3 KA IP11 B 8 R7 5 I 1 Ss 1RO DELTRON PIN NOs ON SYMBOL Issue 1 Mar 2010 5 O R2 CANLO 2 CANHI sO 9 WAY D TYPE 3 O PLUG 15W D TYPE ST SOCKET RO Lo KA J6A J4A VCC i Eel 6 RXD2 2 TXD3 7 TXD2 3 9 WAY D TYPE RXDS 8 O SOCKET O 9 O 9 O JSA FIH fixing hole DIN ET Neopost Pin Nos These are pin numbers for actual DIN plug Title I C4 Comms PCB 180 8370 Size Document Number Rey A4 127 2930 1 Date Friday September O4 2009 Sheet 1 of 1 Section 5 5 Comms PCB Circuit Diagram Page 5 18 Maximailer HD Service Manual Electrical and Circuits Wiring RS RI C1 e 1 10K 2 uF 5 J1 U1A 1 2 VCC 74HC14 C2 TUF C3 R2 0 1uF 100K U1B A 4 NOR 74HC14 VCC e C6 C 10uF O 1uF e 10K C4 74nC14 Issue 1 Mar 2010
53. Lever Assy A2 1352 A 9110421W Page 4 55 Maximailer HD Service Manual Exploded Views Issue 2 Apr 2011 Item Part No Description Qty Spares 1 169 145 9100469E PLASTIC RIVET 3 5mm 2 0 3 0 GRIP 2 Y 2 181 1610 9109568H SOLENOID W D 179 3550 XH SDT2652L628 1 Y 3 B2 1942 A PIVOT ARM 1 N 4 B2 1943 A WETTER SOLENOID BKT 1 N 5 B2 1944 A WETTER LEVER 1 N 6 B3 1401 A BEAM ADJ PLATE 1 N 7 C2 1164 A BEARING SPIGOT 1 N 8 C2 1213 A LEVER BEARING HOLDER 1 N 9 C2 1214 A PIVOT BEARING HOLDER 1 N 10 C2 1215 A BEARING SPIGOT 2 N 11 C3 0759 A ACTUATOR ROD 1 N 12 E1 0140 A 9110065A BEARING NEEDLE 4 IDx8x8 1 Y 13 E1 0146 A 9110385J BEARING 5IDx7ODx10LONG 1 Y 14 E1088A 9103839Q BEARING BALL 4x12x4 SHLD 604ZZ 4 Y 15 G1 0255 A 9110574P SPRING SOLENOID 1 Y 16 180 776 9100753A PCB WIDEBODY DISK SENSOR 1 Y Fixings 20 E2 0836 A SCREW M4x6MM TORX PAN HD ST STL 2 21 E2 0837 A SCREW M4x16MM TORX CSK HD 2 SEE FIXING KIT FOR THIS ASSEMBLY 22 E2 0841 A SCREW M3x8 TORX PAN HD 4 A0 0612 A 9110736Z 23 E4011A WASHER M4 FORM A BZP 2 NOTE FIXINGS ARE NOT AVAILABLE 24 E5099A GROOVED PIN S80 3x18LG 1 INDIVIDUALLY 4 22 Wetter Lever Assy A2 1352 A 9110421W Page 4 56 Maximailer HD Service Manual Exploded Views Issue 1 Apr 2010 DETAIL SHOWN IS PART OF WETTER ACTUATOR ASSEMBLY A2 1286 A SEE EXPLODED VIEW SECTION 4 22 4 23 Wetter Beam Assembly Page 4 57 Maximailer HD Service Manual Item Part No U BR WN B3 1320 A C2
54. Mar 2010 Spares lt lt SEE FIXING KIT FOR THIS ASSEMBLY A0 0557 A 9110079Q NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 11 C4 Envelope Conveyor Backstop A2 1200 A 9110080R Page 4 29 Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010 SENSORS Description Collate Pocket RX Envelope Deskew TX Collate Pocket Load TX BRIDGE CLAMPS G4092A G ITEM 60 WITH x 12 TORX HD SCREWS E2830A ITEM 53 ARE FITTED IN ALL LOCATIONS MARKED 4 12 C4 Collate Pocket Clam Assy A2 1069 A 9110098K Page 4 30 Maximailer HD Service Manual Item Part No WON Q1 Q N 169 128 181 1630 A2 1311 A A2 1312 A A2 1313 A B0 0206 A B1 0936 A B1 0982 A B2 1205 A B2 1206 A B2 1215 A B2 1472 A B3 1093 F B3 1100 A B3 1103 A B3 1329 A B3 1330 A C2 1028 A C4 0527 A C4 0568 A C4 0569 A C5 1046 V C5 1060 A D0054A E0227A E0375A E1107A E1108A G1025A G1186A G1189A G6028A G6200A P2001A P2057A 9108602B 9109557W 9110091C 9110092D 9110093E 9110094F 9110095G 9110096H 9109991Y 9105522T 9103755C 9105804M 9105507C 9105506B 9104625 9106068F 9106087G 9104879Y 9105820D 91056962 4 12 C4 Collate Pocket Clam Assy A2 1069 A 9110098K Exploded Views Description RIVET 4mm 3 5 4 5mm GRIP WIRED 24V BLOWER SM INPUT SHAFT ASSY CLAM OPENER I P SHAFT ASSY CL OPENER O P SHAFT ASSY
55. NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Page 4 13 Maximailer HD Service Manual Exploded Views Issue 5 Feb 2012 F OPERATOR HEAD SIDE PI B2 1204 A 3 AN 3 VE m oR 6 gt PAWL TENSION BRACKET ASSEMB A2 1072 A LOWER CONVEYOR DRIV PART OF HEAD INPUT CONVEYO OWER 2 1055 DRIVES B2 1205 A OTE OR SUPPORT DETAILS LANGE BEARING E1 0138 A SEE SECTION 4 4 CHASSIS ASSEMBLY E N Page 4 14 4 5 Shaft Locations Maximailer HD Service Manual Item Part No WON A Un N C8 0206 A C8 0207 A A2 1305 A C5 1022 A A2 1306 A C5 1017 A C5 1066 A C5 1020 A F3 0045 C F3 0046 C F4 0299 A C5 1019 A C5 1122 A D0 0062 A D0 0063 A F6023A F6 0054 A C2 1064 A B3 1340 A Per Machine Spares Assembly SA1 E2834A E5092A E5086A E5098A A0 0688 A 9109564D 9109579U 9110038X 9110039Y 9110040Z 9110041A 9109581W 9110042B 9110037W 9110090B 9109983Q 91065775 9109567G 9109566F 9110320R 9112526P Exploded Views Description LOWER SEAL ROLLER 48 DIA LOWER SEAL
56. NUT M4 NYLOC DIN 985 BZP WASHER WAVED 8 891D12 50D0 18THICK CIRCLIP 7mm PIN DOWEL 3 DIA x 14 m6 CIRCLIP 9 5mm E TYPE PIN DOWEL 3 DIA x 8 M6 PIN DOWEL 2 5 DIA x 10 m6 PIN DOWEL 3 DIA x 30 m6 Qty N Q R N BRN Q OF N Issue 1 Mar 2010 Spares SEE FIXING KIT FOR THIS ASSEMBLY A0 0558 A 9110087Y NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 10 C4 Envelope Conveyor Assy A2 1066 A 9110088Z Page 4 27 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 4 11 C4 Envelope Conveyor Backstop A2 1200 A 9110080R Page 4 28 Maximailer HD Service Manual Item Part No 1 BO145A 2 B3 1281 A 3 B3 1317 A 4 B3 1318 S 5 B3 1319 S 6 C2 1155 A 7 C5 1052 A 8 C8098A 9 E0330A 10 G1166A 11 G6176A 12 R2392C Fixings 15 E2 0839 A 16 E2826A 17 E3502A 18 E5071A 19 E5073A 20 E4012A 21 E4011A 9105556D 9110077N 9110078P 9103501N 9105861W 9105852M 9105814X 9105896H Exploded Views Description SPRING GUIDE DAMPER ENVELOPE BACKSTOP BACKSTOP SUPPORT BRACKET ENVELOPE BACK REST OP ENVELOPE BACK REST DR BACKSTOP SLIDER SPIGOT BACKSTOP SHAFT ROLLER ENVELOPE FEED HANDWHEEL M5 MALE RETAINING SPRING SIDE GUIDE TAPE SPACER PLATE SCREW M3x6MM TORX PAN HD SCREW M4x8 TORX PAN HD NUT M4 FULL BZP PIN DOWEL 3 DIA x 14 M6 CIRCLIP 9 5mm E TYPE M5 WASHER M4 WASHER et gt NANN Ne B Fa N N N N N Issue 1
57. R39 27R R40 27R 15 iR SR tE P5 13 AN13 POH 5 AD13 8 6T4 I AM I dp 414 AIEO AB15 9 16 A ANTS L PSJA ANTA POH 6 AD14 BTS AT 4 415 AT T A1 Ab To 16 17 p P5 15 AN15 POH 7 AD15 i 3 ie MEME me as as UT CAR 19 UM 12 P7 0 POUTO PILO AO 18 48 a 2 MB x i 1 fi FPFRAME 35 E Ee PWMO PWM1 20 20 Gren Gros P7 1 POUTI P1L 1 A1 i i5 pee 1 Aus ES HE e FPLINE E 220pF 220pF 220pF 220pF J3 21 Setz Bad 22 P7 2 POUT2 PIL2 A2 WS eg R B 29 O E AC D m FPSHIFT 57 A PWM3 Pea POUTS a 122 Ad RD 37 E IWRC 28 ja D1 18 s DREN R41 27R R42 27R FPSHIFT E P2 0 5367269010 oleae Lie m 7wRL 58 We DZ De R43 ZR 1 R44 278 LCDPWR 3 22 2 p20 P2 1 Hy onn A Jm MS5M5408 D3 18 R45 27R M R46 27R FPLINE 4 P2 1 ER 49 6 88 495 A7 M29F080A D4 is DBS R47 27R T R48 27R FPFRAME 5 23 26 ES P2 2 60210 P1L 7 47 u Be 984 9 m H 27 P2 3 CC3IO If pgs P2 3 P24 51 128 A8 12 13 D8 D6 13 RSTOUT 724 P2 4 P2 5 sc DACH PIH O A8 159 Ag U4 22 ij DO 14 DS D7 DBE 37 049 C50 C51 052 FPDATO 8 29 P2 5 P2 6 sc DAC PIH A A9 T30 A10 Al 24 25 D8 23 ol l D 15 Do DS fn 987 I Rg A m FPDATI 9 28 ao P2 6 P2 7 sa 28ZCCGIO PIH 2 M0 T37 ATT 22 23 50 26 bg Ba al D2 17 Di D a FER FPDATI 35 220pF 220pF 220pF 220pF FPDAT2 WEIS 31 P2 7 CC7IO P1H 3 A11 D1 A3 D3 DEn FPDAT2 P P P P a P2 7 L132 AT2 23 2 D L27 25 8 3 D 18 D12 D10 SI
58. ROLLER 25 DIA WET O P SHAFT UPPER ASSY IDLER SHAFT WET O P SHAFT LOWER ASSY SPROCKET DRIVE SHAFT LOWER SPROCKET IDLE SHAFT SLOW DOWN SHAFT DRIVE SPROCKET 15T IDLE SPROCKET 15T GEAR 25T 1M 10ID PRESSURE WHEEL SHAFT OPENER INPUT SHAFT RUBBER WHEEL 40 DIA SOFT RUBBER WHEEL 40 DIA CHAIN 1 4 PITCH 83 LINKS PAWL CHAIN LINK CHAIN ROLLER INSERTION PAWL SCREW M4 x 10 TORX CSK M C 12mm E CLIP DOWEL PIN 3 DIA x 16LG DOWEL PIN 3 DIA x 18LG INSERTION PAWL ASSEMBLY 4 5 Shaft Locations Qty A R Spares lt lt lt lt 2Z2222 lt lt lt lt lt lt lt lt lt lt lt lt Issue 5 Feb 2012 Page 4 15 Maximailer HD Service Manual Exploded Views SENSORS Item Description Envelope Flap TX Envelope Feed TX Envelope Feed RX Envelope Deskew RX Envelope in Hopper Reflective EI MA PP RACTOR ASSY CTION 48 NOTE BRIDGE CLAMPS 640924 WITH M4 x 12 TORX HD SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED 4 6 C4 Envelope Feeder Assy A2 1064 A 9110075L Issue 5 Sep 2011 Page 4 16 Maximailer HD Service Manual Item Part No WOON NM 179 109 179 109 179 109 179 110 179 109 180 759 A2 1065 A A2 1067 A A2 1068 A A2 1281 A B
59. Rollers x Ve E Form 1x3 iG OR Stage 3 Form 1 prime address carrying document for this pack is driven into the collation pocket by the retard rollers Form 1b prime address carrying document for a following pack is fed from feeder 4 down onto the conveyor track The feed operation between all stages is governed by software timings to set a controlled gap pitch length between the prime documents on the track Form 1a held is stationary at the exit hold point sensor of insert feeder 1 After the prime document has been fed into the collation pocket on top of the 3 documents already collated the pack is inserted into the envelope described in more detail below 2 3 Description of Insert Head see Fig 4 opposite The insert head includes the envelope hopper collation pocket insert fingers wetter and closer The insert pack ar rives into the input conveyor as moni tored by the input conveyor sensor When its trailing edge passes this sen sor the drive rollers ahead reduce speed as necessary to allow the collate pocket to clear The pack is then driven into the collate pocket where it contacts a solenoid actuated backstop to prevent overrun there are 3 backstops the one used being determined by the pack length Its arrival is monitored by the collate pocket load sensor the collate pocket sensor confirms it is in place in the pocket
60. S F VO Q e l 39 85 56 45 OS 41 8 17 Y 4 3 Chassis Operator Side Page 4 8 Maximailer HD Service Manual Item Part No WON A Un N 179 109 179 110 181 128 181 129 180 720 7 180 8300 180 8360 180 702 180 759 180 8320 181 1600 125 432 B2 1263 A B2 1291 A B2 1293 A B2 1294 A B2 1295 A B2 1313 A B2 1853 A B3 1230 A B3 1232 A B4 0447 A C2 1024 A C2 1025 A C2 1027 A C2 1029 A C2 1030 A C2 1032 A A2 1489 A C2 1107 A C2 1178 E G4 0149 A C3 0681 A C3 0688 A C3 0697 A C4 0544 A C8078A D1077A E0367A E0425A E0475A 9108382X 9108383Y 9100723U 9108643U 9109914T 9100715L 9100744R 9109590F 9109569 9100213N 9109565E 9109975G 9110015Y 9110017A 9110018B 9109970B 9110019C 9110020D 9110021E 9105500V 9105874K 9103789N 9110007Q 9103795U Exploded Views Description INPUT CONVEYOR CLUTCH COLLATE ENTRY FAST CLUTCH CLOSER REVERSE DRIVE CLUTCH INSERT PAWL TRACK DRIVE BRAKE PCB ASSY AM4 PROCESSOR PCB C4 EXPANSION PCB ASSY C4 CONTROL MK2 PCB ENV WETTER PCB SPLITTER No 1 PCB MAXI DONGLE COLL POCKET BACKSTOP EXT LNG SOL TUBE CLEAR FOR PERI PMP BACKSTOP SOLINOID BKT OPERATOR COVER PIVOT BKT LH SCISSOR STAY 1 SCISSOR STAY 2 RH SCISSOR STAY 2 LH COVER PIVOT BKT RH WETTER BRAKE BRACKET GEAR SHIELD FLANGE PLATE WETTER PIPE BKT ASSEMBLY CLUTCH PLATE STA
61. SOL2 RA B SOL3 poe m MOTOR DISC 180 46 SOLS LJ SOL1 SOL2 _ SOL3 S SOL4 SOL5 gt gt Ge NO 211 J11 J12 J13 J14 J15 GE UM bag cuu 2 O VEC VCC J2 J4 J6 5 1 9 3 3 3 1 Q O 2 2 PSIR 2 2 2 ab 8 E PS1 PS1T PS2T PS3T I I EL J 4 PS2R l 7 PS2T 2 F3 6 PSSR J1 J3 J5 34 ig 7 PS3 MPWR 3 3 m 8 PS1R PS2R PS3R 2 2 3 3 l 1 1 1 0PB370 N 55 SOL n e SOL2 4 OO Ts 21 13 SOLS 14 SOL MPWR Pin View DISC PCB 127 18701 MOTO lt T ER b O SOLI 2 SOL2 x SOL3 x SOL4 PCB No 127 233 I i i li PFE INTERNATIONAL LID LOUGHTON ENGLAND 33885 AM4 RIBBON SPLITTER ES amp MOTOR DISC PC LU OCTOBER 2003 Section 5 10 Ribbon Splitters Motor Disk PCB Circuit Diagrams Page 5 23 Maximailer ECURITY DONGLE 180 8320 HD Service Manual 182 745 Electrical and Circuits Wiring A AD
62. Slacken the screws indicated in Fig 4 and move the shield as required The shield is factory set in its lowest fully forward position and should not normally need adjustment Certain problem envelopes that will not separate properly may benefit from moving the shield back This is a trial and error method but try setting it fully back to start 8 Refitting the separator assembly is a reversal of removal Remember to reset the separator gap Page 3 9 Maximailer HD Service Manual Maintenance and Servicing 3 8 Replacement of Envelope Conveyor Belts The envelope conveyor belts should not normally require replacement as they have a very long life but if replacement is required due to damage etc proceed as follows 1 Remove the envelope conveyor assembly as described in 3 6 2 Remove the end cover together with the backstop 2 screws under neath 3 Turn the conveyor upside down and remove the springs on the rollers at the far end of the conveyor 4 Now remove the roller carrier see Fig 5 This will allow the belt to be looped off over the side of the conveyor 5 Fit the new belt in a reverse manner and replace the roller carrier and springs 6 Repeat for the other belt Refit the end cover and reassemble the conveyor back on the ma chine Remember to reconnect the motor cable onto the connec tor mounted on the chassis bridge Issue 1 Mar 2010 Page 3 10 Maximailer HD Service Manual Mainte
63. Usage is as and assumes a DTI is to be fitted with optional feeders shown in Fig 1 below 1 2 DETACHABLE ITEMS Insert Feed Feed Feed The machine is supplied on site with each module packaged separately and REESE e d eed EE Sd with stands supplied in flat pack form Check that the following de E EE EE EE j E tachable items are all present Insertion Head Comms Lead Long 160 511 Qty I Plug IEC60309 Yel 16A 168 347 US Qty 1 or Plug IEC60309 Blu 16A 168 346 EURO Qty 1 PC Fittings Kit A7226A Qty 1 Fia 1 Set of Castors E0563A Qty 2 g hT R2211T 1 eel MS S ch E2516A Ca 4 Unpack and assemble the stands using the supplied assembly instructions Operator Manual K1 0271 A Oty 1 If the machine uses more than one stand join these together using the Stands see 1 2 opposite l supplied fasteners in the 4 corners of the mating faces Declaration of Conformity 230v only Feeder single and dual Comms Lead Short 160 510 Qty 1 Screw M5 x 10 Cap E2516A Qty 1 Infill Cover R2263S Qty 1 Output Conveyor optional Mains Lead 162 210 UK Qty 1 or Mains Lead 162 321 US Qty 1 or Mains Lead 162 311 EURO Qty 1 DIN Lead 182 707 Qty 1 Operator Manual K1 0283 A Qty 1 Important Check that all covers are in place and undamaged Check that all warning labels are in place and legible see section x for locations Check that the mains lead and its connectors are sou
64. and place a straight edge so that it is flat on the plate as shown in Fig 13 The finger should be at the same level as the plate at the point indicated 4 If adjustment is required slacken the 2 screws securing the so lenoid and while still compressed slide it so that the finger just touches the straight edge and tighten the screws Note that a right angled torx driver will be required for the screws Page 3 14 Maximailer HD Service Manual Maintenance and Servicing Inner Fingers The inner fingers are adjusted using a special setting gauge with the finger assembly removed from the machine as described in section 3 11 The setting gauge is located in the top corner of the drive side chassis face unscrew it to use l After removing the finger assembly attach the setting gauge as shown in Fig 14 us ing 2 x M4 screws 2 Pullin the solenoid to advance the fingers the un derside should be 1 1 5mm above the edge of the setting guage at the points indicated in Fig 14 3 If adjustment is required slacken the 2 screws securing the solenoid and slide it as required Tighten the screws and check that the setting has not changed 4 Replace the finger assembiv in reverse order to removal B Remember to replace the setting gauge when adjustment is complete Issue 1 Mar 2010 Page 3 15 Maximailer HD Service Manual 3 13 A Removal of Side Guide Adjust Assembly In order to remove the side
65. as the first document passes underneath d At the insert head all documents will arrive in the collation pocket either individually or as a pack already collated by the above methods The topmost item is the prime address docu ment The pack is then inserted in the envelope 2 2 Track collation description Jobs with more than one feed unit will in most cases collate together as described in paragraph 2 above and will arrive in the collation pocket as a pack with the exception of the prime document which will be fed on top of the pack as a separate item The exception to this is if the prime station is No 1 in which case the document would be finally collated on top of the pack from preceding feed units then finally delivered to the collate pocket Documents are trailing edge located due to the pack being inserted by pushing it into the envelope with chain driven pawls Timing is controlled by the track conrol sensor located behind each hopper of Operation Page2 2 Issue 1 Mar 2010 The sequencing between the stages of machine operation is shown in the diagrams below which begin part way through a complete cycle the preceding sequence of operations from the start of the cycle will have been similar but with fewer documents having been gathered Track Control Stage 1 Form 1 is fed from feeder 1 down onto the conve
66. guide assembly the Power Supply Unit must be removed first see section 3 15 The side adjust assembly consists of a motor powered lead screw and pro vides the mechanism for adjusting the side guides above the chassis sur face in the collate area It is removed from the drive side of the chassis 1 Fig Ne Operator side The leadscrew shaft must first have the T bearing removed This is located under the PCB on the operator side 1 Remove the ribbon cables on the LH and upper edges of the PCB Take out the screws and pull down the top of the PCB to reveal the T bearing see Fig 15 Remove the E clip and bearing 2 Raise the collate clam as sembly in the collate area and remove the side guide brack ets and side guides as shown in Fig 16 These are attached to the side guide adjust as sembly below Maintenance and Servicing Issue 1 Mar 2010 Drive Side 3 Remove the solenoid bracket screws to allow access for the side guide adjust as sembly Fig 17 It is not nec essary to remove the bracket 4 Disconnect the 2 disc sensor cables shown in Fig 17 and also the motor cable Remove the 2 screws indi cated Withdraw the assem bly reaching in through the chassis opening vacated by the PSU in order to hold the side guide carriers free of any obstructions Solenoid bracket Replacement 5 Replacement can be awkward due to the side guide carriers swinging up side down
67. is selected in the job setup When the Run button is then pressed the machine will await a group of up to 8 forms stapled or not to be inserted into the daily post hopper When these pass the daily post sensor they will be automatically fed and the machine will await the next group Forms from other feeders in the tower folder can be collated with the daily post up to the maximum of 8 of 80gsm and forms from other feed units can also be included in the job Description of Operation Page 2 7 Issue 1 Mar 2010 2 6 Description of Feeder Folder see Fig 8 below The 2 plate feeder folder is fitted with a top feed hopper capable of holding up to 500 sheets of 80gsm paper The hopper and separator are identical to the upper hopper of the tower folder The unit is available as either an end unit or in line mounted on the track the difference being a blanking cover fitted to the rear of the end unit and no conveyor is fitted An optional handfeed slot may be specified located in front of the paper hopper this can fold up to 3 sheets of 80gsm C or Z or 5 sheets V Stapled sheets must be Z fold only DD amp PICKUP PRE FEED ROLLER SENSOR SENSORS SEPARATOR DAILY POST BT OMR GATE SENSOR EXIT CLUTCH BRAKE e y m CONVEYOR CLUTCH CONVEYOR BRAKE Page 2 7
68. job check finger setup feeding 15mins Insertion wetting and closing A27 Refit all covers and clean 15mins Run machine machine to make sure no covers are Rubbing Maximailer HD Service Manual 3 4 Information for Engineers 3 4 1 Service Procedures and adjustments The procedures described on the following pages are the recommended methods to be employed when removing or replacing various items Note that not all individual spare parts may be available for replacement in some cases only the assemblies containing those parts can be obtained For further clarification see section 4 3 4 2 Tools required No special tools are required for service operation on the machine though a variety of standard engineer s tools will be needed including e Torx drivers 10 15 20 25 e Pozidrive screwdrivers 1 2 e Set of metric Allen Keys e Pointed snipe nosed pliers e Right angled bit drivers e Side cutters e In addition a stock of cable ties 100 x 2 6mm 169 102 3 4 3 Electrical Connectors and Sensors Sensors are supplied as a cable assembly with the sensor at one end and its two connectors at the other All sensors with the exception of flag or disc sensors consist of a pair Emitter and Receiver The receiver is usually mounted below the emitter though this can vary All connectors are marked with the number of the appropriate PCB connec tor to which it joins Maintenance and Servicing I
69. point shown in Fig 4 timed from the trailing edge passing the deskew sensor and ar riving at the envelope flap sensor The solenoid actuated insert fingers hold the envelope throat open With the envelope then in place ready for the ar riving pack the backstop drops and the pack is driven into the envelope Note that it is possible in the software to adjust whether the outer pair of fingers move forward first or the inner pair This can assist certain enve lopes depending on design As the chain pawls are pushing the pack in the pawls below the track are detected by the pawl position sensor which times precisely how long it take to push in the pack At that point the envelope is released Just prior to release the chain track pauses momentarily so that the tips of the pawls do not catch on the edge of the departing envelope While in sertion is taking place the next envelope is fed into place and held at the deskew rollers ready for the next insertion Timed from the leading edge of the envelope passing the wetter output detect sensor the wetter beam is pulled down by solenoid action so that the flap is wetted by the wetter felt below As the trailing edge passes this sen sor the beam will retract The envelope is driven forward into the seal rollers Due to the angle of the roller axis the flap edge of the envelope is lifted up forcing the flap downwards against the roller at which point the rollers reverse to drive the
70. s ba 20 4 ASYTX 29 25 2 28 5 6 21 D15 SS ASYRX A16 24 29 A BF R2 74HCTO2 SYNTX A11 ane ATO 26 P 35 SYNRX A12 25 Au ATI 25 o 10k at SYNCK 36 U19 LP2980 3V3 Als 2 A12 ple 25 An NEE P7 4 ATA 26 2 veo l 28 SE 4 aa B i RE a P7 5 A15 kia A14 28 74ACT244 s Z NVMVCC e P7 6 R77 Cl om zU VDD3V3 A15 3 fej po 1e Lu ale KBINO U14D 9 2 ie P7 7 JNWMSEL 20 A16 m Di 16 E KBIN1 RSTI T A 045 C44 P 1K RD 22 ALT ED D2 JIE ias 8 13 P8 0 3 awer 5 NWWRH 27 cup Lt A18 30 55 D 7 DB KBIN3 S3 id e P8 1 Z C35 A19 D 9 M gar KBIN4 1 18 68uF 6 3V 68uF 6 3V ad P8 2 32Kx8 SRAM D5 7 ako 13 KBINS l 74HCTO2 P83 CB 33uF RCs1 22 D 5 15 KBIN6 Ein ng U14C ic 45 PRA N CS 2Y3 2A3 i JRD 24 D7 3 17 KBIN7 4 5 8 46 O 1uF T JOE 2 4 2A4 kd ji P8 5 WRH 28 10 H12 ii P8 6 WE 1 4 POLE P8 7 T M5M5408 16 Ps KBDRD KA KA U18A ee 74HCTO2 50 A20 2 ne U17 A21 5 b NWSEL p 5 mls KBOUTO R69 R70 R71 ES NVMEN D a o E KBOUTI wv d e U EZ D Dz D 26 KBOUT2 1K 10K 10K BSL RB 10K DA D3 B va qa 3 KBOUT3 R9 10k pe 74HCT139 D413 oe Ae 13 KBOUT4 R10 10K p D5 14 15 KBOUTS Use ACT D6 17 D6 Q6 16 KBOUTE H15 R11 10K D11 D7 07 Oo S 2 Ss 1 NG i CLKCFGO R12 10K pia 8158 D7 281 re qa ji CLKCFG1 R13 10K p14 WRL 14 vo B2 H17 L 6 3 CLKCFG2 R14
71. side is similar AS a 2 Lift the assembly out of 4 the machine A Ne Reassembly is a reverse of removal 9 gx 6 Cg When replacing the pivot screws insert a screwdriver or drift in one hole to align the assembly whilst fitting the other one Issue 1 Mar 2010 Page 3 19 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 3 18 ENGINEERING MODE To enter Engineering mode select the Engineering button from the setup screen Touch the Statisti Touch the Engines Touch the Admin t Engineering mode allows the following functions e Hardware Setup e Units Setup e Firmware Download e Diagnostics e Reader Setup e Machine ID e Plug and Play Note Engineering mode will only be available to personnel with appropriate access rights Engineering mode applies to the whole machine hence this section covers feed fold modules as well as the insert head Modules not relevant to the actual machine setup should be ignored 3 18 1 Hardware Setup Configures the physical machine When the machine is first set up or if new units are added or altered eg a reader is added Hardware Setup must be set to reflect each unit and its features th MR Feeder Module 0 Hopper 2h Feeder Module 1 3h Feeder Module 1 Hopper 2p1h Folder Module 2 3p1h Folder Module 2 Hopper 3p3h Folder Module 3 DTI Module 3 Hopper C4 Feeder Module 3 Hop
72. the chassis face Visible inside sealer cavity after opening the sealer Visible below envelope separator Maintenance and Servicing Issue 1 Mar 2010 Visible after opening perspex top cover When screws are removed lift the cover upwards of the lower location lugs and lift it off 3 5 2 Front vertical cover This is located below the sealer and provides access to the wetter piping and no seal solenoid First remove the drive side cover as above and open the side cover on the operator side uP We On the operator side remove B the screw indicated located below the idler gear f E cont Page 3 6 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 3 5 4 Upper Cover This is located on the operator side by the perspex cover and covers the On the drive side remove the Expansion PCB It is secured by 5 screws and removal is shown below screw indicated uppermost Also shown is one of the lower skirt screws see 3 5 3 below Open the perspex cover and remove the 3 fixed screws Note that the 2 screws in keyhole slots only need to be Slackened vi iN PORT B PORTA NS Qm v7 dee eee Tel dE ses With the screws removed lift the cover upwards to release 2 hooked lugs and lift it out When replacing ensue the hooks are properlav located 3 5 3 Drive side lower skirt This is located below the drive s
73. 0 0229 A 181 A0005751 9100302F 910999 LY 9109975G 9110117E 9109970B 9109563C 9103789N 9103795U 9109987U 9105507C 9110108V 9109980M 9105633 91099922 9104665A 9104827U 9110118F 9113670F Exploded Views Description SWITCH MAGNET SMALL SEALER ROLLER BKT ASSY SEALER COVER ASSY LATCH BRACKET SEALER ASSY BRIDGE SEALER LATCH ARM DR SEALER LATCH ARM OP SEALER SIDE ARM DR SEALER SIDE ARM OP SEALER LATCH COVER GUIDE PLATE T BEARING HOUSING GEAR SPACER SEALER ASSY PIVOT IDLER POST SEALER LATCH PIVOT UPPER SEAL ROLLER 48 DIA WASHER WAVED 23mm I D WAVED WASHER EPL5 BEARING BALL FL 10x22x6 BEARING BALL 6x13x5 WAVY WASHER 6 73 I D 0 76H GEAR 48T 1M IDLER GEAR 35Tx8mm 1 0M SEALER SPRING SPRING SEPARATOR BRIDGE CLAMP CLOSER SPRING 1 2 N mm GUIDE SPRING EARTH BRAID 0 75M Qty A N O NK N MN Hm P OO S N m N F S kA Spares lt lt lt lt lt lt lt lt lt lt lt lt lt lt 2 lt lt lt lt Z2222222222 lt 4 16 Sealer Assembly A2 1058 A 9110121J Issue 2 Sep 2012 Page 4 42 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 Item Part No Description Qty Spares Fixings 35 E2 0840 A M5 x 10 TORX PAN HD SCREW 1 36 E2826A M4 x 8 TORX PAN HD SCREW 4 37 E2834A M4 x 10 TORX CSK HD SCREW 4 38 E2 0838 A M4 x 12 TORX CSK HD SCREW 4 39 E2 0842 A M3 x 8 TORX CSK HD SCREW 2 40 E2559A M3 x 10 PAN HD SCR
74. 0 A 9110145 NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 20 Side Guide Adjust Assembly A2 1063 A 9110146K Page 4 52 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 Sp LRA 4 2 1 2 4 21 Pawl Tension Bracket Assy A2 1072 A 9110173N Page 4 53 Maximailer HD Service Manual Item Part No WON AU Q N 15 17 B2 1245 A C4 0526 A C5 1065 A D1040A E1102A F3 0046 C F4156A G1117A G6028A E3505A E5071A E5073A 9103641J 91038415 9110090B 9104402B 9104686X 9104879Y Exploded Views Description PAWL TENSION BRACKET GEAR IDLER SHAFT UPPER SPROCKET IDLE SHAFT T BEARING 8mm 12 SQ BEARING FL 8x19x6mm IDLE SPROCKET 15T GEAR 30Tx8mm 1 0M SPRING HEAVY PRESSURE SHIM BRAKE M4 NYLOC NUT DOWEL PIN 3 DIA x 14mm CIRCLIP 9 5mm E TYPE Qty N N N ZS O N N gt Issue 1 Mar 2010 Spares lt lt lt lt lt lt 2Z22 SEE FIXING KIT FOR THIS ASSEMBLY A0 0573 A 9110172M NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 21 Pawl Tension Bracket Assy A2 1072 A 9110173N Page 4 54 Maximailer HD Service Manual Exploded Views Issue 3 Apr 2011 we P d n m P EN je g f TA X ue m EM Se V y a dista zd Jr Noe pe X 22 RS BLAN os p ND Fa p lt Q oN AN p p qx SENSORS Item Description Ref S1 Wetter Down flag 5 12 22 4 22 Wetter
75. 0322T QTY A R Page 4 18 Maximailer HD Service Manual Exploded Views Issue 3 Oct 2011 NOTE BRIDGE CLAMPS G4092A lt ws ITEM 19 WITH M4 x 12 TORX HD SCREWS E2830A ITEM 34 ARE FITTED IN ALL LOCATIONS MARKED 4 7 C4 Envelope Separator Assy A2 1065 A 9109900D Page 4 19 Maximailer HD Service Manual Item Part No 181 0850 B2 1465 A B2 1466 A B2 1792 A B3 1362 A B4 0444 A C2755A C2887A C3707 11 5 10 C3420A 11 C4269A 12 C5 1120 A 13 C6 0427 A WON A Un N kA 14 C8135A 15 E1068A 16 E0062A 17 G1 0280 A 18 G1046A 19 G4092A 20 G6150A Fixings 30 E2774A 31 E2 0839 A 32 E2505A 33 E2826A 34 E2830A 35 E2 0838 A 36 E2517A 37 E2 0874 A 38 E5079A 39 E5092A Spares Assemblies SA1 A0 0548 A SA2 A0 0549 A SA3 A0 0547 A 9108955U 9109905 9102934X 9103513A 9103828D 9103705A 91095607 9104636V 9104817N 9110045E 91100446 9110044D Exploded Views Description WIRED MTR 179 802 2W SM SEPARATOR SIDE PLATE SEPARATOR MOUNT BRACKET SEPARATOR BRIDGE SHIELD PROTECTOR PLATE SEPARATOR ACTUATOR ASSY DRIVE ECCENTRIC CLUTCH HOLDER SEPARATOR ADJUSTOR KNOB INNER TIE BAR SEPARATOR SHAFT SEPARATOR ADJUSTOR SHAFT SEPARATOR ADJUSTOR BLOCK SEPARATOR ROLLER ROLLER CLUTCH 6x10x12mm STEEL BALL 4mm DIA SEPARATOR SHIELD SPRING INDEX BRIDGE CLAMP WASHER SCREW M2 x 6 POZI CSK HD SCREW M3 x 6 TORX PAN HD SCREW M4 x 6 SKT SET SCREW M4 x 8 TORX PAN HD SCREW M4 x 12 TO
76. 07 9110023G 9110024H 91049215 9105998P 91052677 9105294F 9110052M 9110027L Exploded Views Description KEY 2mm SQ X101g RAD ENDS BEARING BALL FL 10x22x6 BEARING BALL 8x16x5 FOOT PUSH IN PVC TUBE 8mm I D 11mm O D GEAR 48T 1M 10ID GEAR 40T 1M IDLER GEAR 30T 1M CLUTCH GEAR 25T 1M 10ID CLUTCH PIN SPRING TORSION LH SPRING TORSION RH SHIM CLUTCH MODULE LOCATION SPIGOT CONVEYOR CLUTCH BRACKET HEAD SIDE PLATE OP REED SW SML SWSM REED SW 3WHH UL MOTOR PUMP W D 24V CONVEYOR PIVOT POST SCREW M3 x 6 PAN HD SCREW M3 x 6 TORX PAN HD SCREW M4 x 6 TORX PAN HD SCREW M4 x 8 TORX PAN HD T T SCREW M4 x 8 TORX PAN HD SCREW M4 x 10 CAP HD SCREW M5 x 20 POZI PAN HD T T M4 NYLOC NUT M4 WASHER FORM C M3 SCHNORR WASHER 3 DIA x 16 DOWEL PIN 3 DIA x 10 DOWEL PIN 3 DIA x 8 GROOVED PIN 12mm E CLIP SCREW M4 x 6 SOCKET SET SCREW M3 x 10 PAN HD M3 NYLOC NUT LENZE CLUTCH ASSY 30T INSERT PAWL TRACK BRAKE ASSY 4 3 Chassis Operator Side Qty LP NS F kA N D kA PD PP N N N N O N Oo Q N N WON LW 2 JJ A R Issue 5 Aug 2011 Spares ZZZ SEE FIXING KIT FOR THIS ASSEMBLY A0 0542 A 9110025J NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY ASSY A2 1299 A IS SIMILAR TO SPARES ASSY SA2 EXCEPT FOR 1TEMS 31 42 54 amp 84 WHICH ARE NOT INCLUDED Page 4 10 Maximailer HD Service Manual Exploded Views Issue 4 Oct 2011 SENSORS
77. 1 NOTE WING ITEM 6 IS ONLY FITTED SECURE LIFI BEAM IO UNIT WHEN LIFTING HOOKS MARKED THUS ARE USED 10 A 7 4 31 Lift Beam Assembly A2 1520 A Page 4 72 Maximailer HD Service Manual 1 B2 2355 H 2 B2 2428 G 3 B4 0472 H 4 B4 0473 H D E0 0654 A 6 E0342A Fixings 8 E2582A 9 E2698A 10 E2834A 11 E3525A 12 E4044A 13 E4026A Exploded Views LIFTING BEAM LIFT BEAM HANDLE LIFTING BKT ASSY LH LIFTING BKT ASSY RH LOBE KNOB BLACK M8 x 16 WING HANDWHEEL SCREW M8 SKT CAP HD x 20 SCREW M8 SKT CAP HD x 12 SCREW M4 x 10 TORX CSK HD M8 NYLOC NUT M8 WASHER FORM D M6 WASHER 4 31 Lift Beam Assembly A2 1520 A N P NON OF N L L Z Issue 2 Dec 2011 Page 4 73 Maximailer HD Service Manual Section 5 Electrical and Circuit Wiring Diagrams Sect Page Dal e 5 2 5 1 1 5 2 5 1 2 Sensors Diagram Operator Side 5 4 Sensors Diagram Drive Side 5 5 5 2 Componente LLULLA SNR RRR 5 6 Physical Locations of Components 5 8
78. 13 F5112A Fixings 15 E2 0840 A 16 E2505A 17 E2502A 18 E3505A 19 E5073A 9100831G 9110109w 9103738K 9103826B 9104072H 9104297S 9104609S 9105669w 9104493W Description MOTOR W D 179 073 PCB WIDEBODY DISK SENSOR TENSION BRACKET MOTOR BRACKET SINGLE SLOT DISC BEARING POST FAN 2 5 8 DIA CCW BEARING BALL 8x16x5mm WASHER WAVED 8 89ID 12 5 OD PULLEY 15T S2M MOTOR SPRING TRACTOR BELT IDLER BELT 100 S2M 280 SCREW M5 x 10mm TORX PAN HD SCREW M4 x 6mm SOCKET SET SCREW M3 x 8mm CSK HD M4 LOCKNUT 9 5mm E CLIP See following page for 230V Motor Assy 4 15 Motor Assy A2 1056 A 9110111Y 115V Exploded Views Qty MOTOR ASSEMBLY 115V A2 1056 A 9110111Y N N NO N Spares lt lt lt lt lt lt lt 2Z2222 lt lt lt SEE FIXING KIT FOR THIS ASSEMBLY A0 0563 A 9110110X NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Issue 2 Jan 2011 Page 4 39 Maximailer HD Service Manual Item Part No l 181 069 2 180 776 3 B2 1149 A 4 B2 1150 A 5 B3 1053 A 6 C3 0678 A 7 E0181A 8 E1061A 9 E4033A 10 F1372A 11 G1006A 12 P2448A 13 F5112A Fixings 15 E2 0840 A 16 E2505A 17 E2502A 18 E3505A 19 E5073A 9105274K 9110109W 9103738K 9103826B 9104072H 9105627C 9104609S 9105669W 9104493W Description MOTOR W D 179 072 PCB WIDEBODY DISK SENSOR TENSION BRACKET MOTOR BRACKET SINGLE SLOT DISC B
79. 182 339 9100977J 4 12 S1 Sedd Collate pocket TX 182 337 9100975G 4 4 S4 Bid Top pawl RX 182 442 9101012V 4 4 S5 5 12 Top pawl TX 182 443 9101013W 4 4 S6 5 12 Lower pawl RX 182 339 9100977 4 4 57 5 12 Lower pawl TX 182 337 9100975G 4 4 S8 5 12 Finger disc 180 776 9110109W 4 18 S2 5 12 Finger datum flag 180 776 9110109W 4 18 S1 5 12 Side guide disc 180 776 9110109W 4 20 S1 5 12 Side guide datum flag 180 776 9110109W 4 20 S2 5 12 Envelope seal RX 182 441 9101011V 4 4 S9 5 12 Envelope seal TX 182 440 9101010T 4 4 S10 5 12 Wetter output RX 182 345 9100983Q 4 4 S11 5 12 Wetter output TX 182 443 9101013W 4 4 S12 5 12 Wetter down flag 180 776 9110109W 4 22 S1 5 12 Closer output reflective 182 693 9101087Y 4 4 S13 5 12 AC motor disc 180 776 9110109W 4 15 S1 nd Hybrid motor disc 180 746 9100741N 4 1 S1 5 12 Electrical and Circuits Wiring Sensor PCB only detachable from cable Issue 2 Mar 2010 Sensor shown in both drawings For diagrams of sensor locations see following page Page 5 3 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 2 Mar 2010 5 1 2 CLOSER OUTPUT SENSOR Sensor diagram operator side CLOSER REVERSE DRIVE CLUTCH 0 L ENV SEA SENSOR WETTER OUTPUT DETECT SE
80. 2 13 1 M3EN DN 1 oursa s c U43B U43C R116 330R LD1 55 EO YO gt MSDEM 12 R171 330R 20 REDLED 3 4 5 6 5 4 OUT4A n 330R Fzriossa ILL S ie l IP8D i we t E We t 15 24V F e OP9A 4 74HC14 74HC14 RED CASEL Sy 85 pg vor 8 R210 m R142 046 D64 R172 3505 zn C91 C92 C93 084 C95 096 OPADRV 1E F M kd 18 pes ous sis l ipso 430 vase RI17 om OE ee 2a m 18 OP6 Y GREENLED 13 N12 11 x90 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF R201 25 2 220R H ES 330R FZT1053A D48 sic R173 3505 1K Le ee IP10D 74HC14 74HC14 GREEN 20 R145 Q47 t 7 D108 CD74HC4066M ACMOT 510 N NZ vec 330R FZT1053A MOIR 510 LPWR Mount on heatsink J7 R141 220R 4 U27 Re IP22DRV VSOL y D64 D65 D69 D76 L4940V5 e IP22 2 and D99 fitted 1 3 2 R143 220R VN VO 9 kd kd kd kd kd L 3 SS IP25 IP25DRV D91 D83 D85 D98 s 4 kd D13 e c21 B 022 23 C24 C25 C26 027 C28 028 050 C31 C32 C33 C34 C35 C36 C37 C38 C39 C40 C67 C68 C69 C70 C65 C66 and D100 D108 not 5 m R144 290R L _ S aw au f ed E E a ES ES ES ES ES 7 IP20DRV 1 U 100uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 6 1uF 0 1uF 0 1uF 0 1uF 6 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF o 1uF o 1uF 0 1uF 0 1uF 0 1uF DT a MGND 8 N 9 e k e e k e e 9 kd e
81. 2 IODO 74HCT139 74HCT139 MGND D14 kal D15 IQD1 OUT 2 M 1 1 3 NA 5 56 1002 IOD 0 7 M s Ls IQD3 U15 Q9 ois S16 BAS16 6 IQD4 IORD 2 OUTB1 R50 1 2 3308 2 P Ke 6 DI 91 D16 R52 7 IOD5 5 OUTB2 R51 1 2 9508 1 LI MGND l D2 Q2 ZTX653 7 lt l s B IQDe D3 as L6 QUTB3 R53 1 2 330R z 9 L 10D7 U16 pa a 9 OUTB4 R54 1 2 330R D17 BZX84C12 100K ja IOA1 L IOA1 vo b 5 b os CZ OUTBS R55 1 2 330R OUT2 2 1 1 uL IOA2 1 IOA2 vi 5 OPBCS n os 15 R56 1 2 330R 12 E 13 OPCCS 18 R57 1 2 330R Q10 3 S1G SOLCUR 12 BWHS vec c Y2 D7 07 a 5 e ep M Be E is 5 IORD 8 ME OPCCS Wh Ag VCC ZTX653 R58 C22 J7 15 16 IOWR 4 dak va RES 1 Ern R59 R60 LD2 D18 i 1 17 EXP EXP 5 1 2 2 KALA 1 1 ous 2 1 1K 0 1uF vec MPWR 2 IPA5 17 628 Y7 AK7 A N o 2 ig 8 RES 74HCT273 IN et 3 13 ig l B 74HCT1 38 E qu na Sch RED 832 7 3 510 J8 ENS c I 2o l 20 R61 1 2 i U 24V B s 15 J11 L 2 tg 9 5 2 1 R62 R63 5 2 OUTS ME IPAS zl 1K BC846B 7TX653 7 NU E 3 ih 3 D19 270R 2K2 He LEE Expansion Pu KA our 2 1 J9 8 9 t 1 2 Interface NA Es m 1 8 10 24V B 1 R64 013 3 eio S 3 2 1 oure E 11 OUTS A n 8 2 SVREF MOTSEN 2 LD3 LD4 oL OUT6 J12 1 RED YELLOW 13 OUT IPA6 4 100R ZTx653 J10 3 4 C C zi IOD 0 7 R65 m m D26 S 14 U17 D20 D21 D22 D23 D24 55 ours 2 1 1 3 OUT7 lt IODO 3 2 HDIR 3K
82. 22uF 10 22nF nie 47K HLF e SENSE m R7 270R 9 14 U7A gi PSI D LS L6203 SDA l ue Lus 3 cmn del E in Dn J3 o 3 1 VREF D hs VOC E A osc senser 13 SENSE m 7 AQ H HOME SENSE2 SENSES ae wi L al Pee swe L UEN 5 3 IDX E A2 L1 9 3 1500pF L297 R8 E R9 G PS3T 2 DS1803 050 et D2 AN DS SCHOTTKY 1A 0 47R SCHOTTKY 1A NL NA A b J7 PS4R MGND VCC NET1 AKT J8 VCC U2B 10 r O O m 00 S 5 4 A RIO Aki J16 6 PSAT E SENSEA 5 j o o e U3B SENSEB 2 E anne 3 74HCTOB pe 5 gt 6 STEP VREF U2C jns 74HC14 5 e Hr 820R 74HC14 4 J12 3p S NZ Test NL 13 12 DIR MPWR 5 2 R1 150R Connector 74HCTO8 l U3E STEP 74HC14 11 10 3 U3F UBA 9 DIR 1 P 4 9 8 1 2 EN PEDI Xm 5 Fr EF J14 74HC14 2 s hae E IER UBC IDX 3 4 SIDX 5 6 x E 74HC14 m 74HC14 l SCH e 9 8 1 EN 13 12 UEN 74HC14 74HC14 1 9 IF SOL2 SCLK 44 SCL USE 2 SIDX SIDX I 74HC14 J15 gt his ST SE 74HC14 D SAR ay P i R12 150R USF PS2T S2T 9 8 PS3R l PS3R ee Ps3T 74HC14 PS4R S4R ML D PS4T KI oa RI 20 1 GND 22 e SOL 2 SOLI R13 VCC SOLE SOL2 10K PWR 25 e e e e e e R14 p D4 e F C18 C9 e pwr I 1000uF 50V 1000uF 50V 28 e 1RO PWR 1N5368B 0 1uF LD1 C11 C12 5 C14 C15 C16 C17 CND 29 e es 30 YELLOW 5mm
83. 22x 6 BEARING BALL 8 x 16x 5 BEARING BALL 6x 13x 5 KEY 2mm x 10 SENSOR DISC CLUTCH SHIM EC30 CLUTCH PIN MOTOR SPACER T BEARING HOUSING GEAR 25T IM 6ID SEALER SPRING WIRED REED SW CLOSER COVER BRAKE BEARING HOLDER 4 1 Chassis Drive Side Front FN NUI LP N PU 4 NI 5 p Hop Hp H i EP lt aa 5 Spares lt lt lt See Spares Assy 1 See Spares Assy 3 See Spares Assy 2 See Spares Assy 1 See Spares Assy 3 See Spares Assy 1 2 3 See Spares Assy 2 Issue 6 Feb 2012 Page 4 3 Maximailer HD Service Manual Exploded Views Fixings Item Part No 50 E2 0839 A 51 E2651A 52 E2684A 53 E2782A 54 E2 0836 A 55 E2826A 56 E2507A 57 E2523A 58 E4 0078 A 59 E4011A 60 E3501A 61 E5126A 62 E5103A 63 E5086A 64 E5073A 65 E5092A 66 E0475A 67 E0367A 68 169 145 69 E0425A 70 E4033A 71 E5110A 72 E2604A 73 E3557A Spares Assemblies SA1 A0 0553 A 9110050K SA2 A0 0554 A 9110051L SA3 A0 0555 A 9110052M Description SCREW M3 x 6 TORX PAN HD SCREW M3 x 6 PAN HD SCREW M3 x 14 CAP HD SCREW 3mm PLAS TECH 30 SCREW M4 x 6 TORX PAN HD SCREW M4 x 8 TORX PAN HD SCREW M4 x 10 CAP HD SCREW M5 x 20 CAP HD 3mm SCHNORR WASHER M4 WASHER M5 FULL NUT 3 DIA x 8 GROOVED PIN 3 DIA x 10 DOWEL PIN 3
84. 23 A Fixings 40 E2826A 41 E5071A 42 E5092A 43 E5073A Exploded Views Description SPLIT SHAFT OPERATOR SPLIT SHAFT HOUSING SPLIT SHAFT SHORT ROLLER TRANSPORT NOTCHED WASHER WAVED 23mm I D BEARING BALL FL 10 x 22 x 6 SPIGOT SPLIT SHAFT COVER SPLIT SHAFT CENTRE SPLIT SHAFT HOUSING SPLIT SHAFT CENTRE ROLLER TRANSPORT NOTCHED BEARING FL 8x19x6mm WASHER WAVED GEAR 25Tx8mm 1 0M SHIM BRAKE COLLATE SENSOR BRACKET COLLATE PANEL PIVOT SPRING SPLIT SHAFT DRIVES SPLIT SHAFT HOUSING SPLIT SHAFT LONG ROLLER TRANSPORT NOTCHED WASHER WAVED 23mm I D BEARING BALL FL 10x 22x 6 SPIGOT SPLIT SHAFT COVER SCREW M4 x 8mm TORX PAN HD PIN DOWEL 3 DIA x 14mm 12mm E TYPE CIRCLIP 9 5mm E TYPE CIRCLIP Issue 2 June 2010 Qty Spares 1 Y 1 N 1 N 1 N 1 N 2 N 2 N 1 N 1 Y 1 N 1 N 2 N 2 N 1 N 1 N 1 N 1 N 1 N 1 Y 1 Y 1 N 1 N 1 N 1 N 2 N 2 N 1 N N N SEE FIXING KIT FOR THIS ASSEMBLY A0 0568 A 9110127Q ORDER THIS KIT FOR ANY ONE ASSY OR ALL 3 NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 17 Split Shaft Sub Assemblies A2 1059 1060 1061 A 911012M 9110125N 9110126P Page 4 45 Maximailer HD Service Manual Exploded Views Issue 3 Oct 2010 NOTE BRIDGE CLAMPS G4092A i ITEM 48 WITH M4 x 12 TORX HD SCREWS E2830A ITEM 63 ARE FITTED IN ALL LOCATIONS MARKED SENSORS Item Description Ref J S1 Finger Datum flag ale 92 Finger Disc 5 12
85. 3 Sa 5V 24VSW 2 1 Di a T Z I0D1 45 m qo L5 HPWR 18 BAS16 BAS16 BAS16 BAS16 BAS16 BZX84C12 Q14 ia 510 10D2 calle os LS 1 AH13 Fl Ae v 14 VREF 2 a 4 E B E E GAY IOD3 54 a L 1 H14 ue DS MOTCUR J 4 gt 1 R66 R67 IOD4 13 ps os 12 1 5H15 vs LS SOLCUR 2169 IQD5 Ls 31 ie ae 6VMON 1 D27 220R 220R 10D6 17 57 16 10 lt vs 2 TAWON 1 1 ours 2 1 1 N IQD7 18 na a 19 vo L19 34VMON 4 9 V 14 Su 015 3 sic OPBCS 11 3 13 SPEED 2 KA CLK z Yd 4 CLR 4He4681 VCC 46 25v 14y 26V ZTX653 U19 SH VCC R68 e o o FE D28 L4940V5 IOD 0 7 our 2 N i LPWR 1 3 U20 1K a ER i kd e 1 pj R70 R71 A R72 F3 p R73 016 3 S1G C23 si C24 6025 sl 26 C27 ei cae 030 7 C32 C40 DO VIN gt Di a a i a ie 12 10K 22 4K7 10K 1 1000uF 100uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF 0 1uF D2 V ZTxe53 x P N N TP7 D3 T N N N N 1 D4 VR D29 9 k e k e e O Leem e o e o e o e sp L PWM3OUT 2 ND GND 8 IOWR ki RBO vi KA 4 40 _ _ e eo Se WR Uu ADCS R74 E E Q17 3 510 H1 1 CS 633 R75 R76 554 c35 R77 Cap R78 e PWM3 1 2 2 NW 1 INT 7 3K3 r l
86. 60 16 D z Wed 78 Oct 2049 Maintenance and Servicing Issue 1 Mar 2010 Change Params this is a legacy feature and should not normally be required unless a different CAN type were used The default set tings are USB CAN Packet 4 Send Interval 1 O Flow Timeout 10 When downloading is complete select Exit Page 3 27 Maximailer HD Service Manual 3 18 4 Diagnostics Diagnostics allows sensors to be calibrated and components motors clutches brakes solenoids etc to be tested The voltage and cur rent drawn by the sensors is shown as a read only display and their clear or blocked status is indicated Component tests will run each selected component to confirm it functions Note the screens may vary in appearance from that shown de pending upon the module type Solenoids This includes other clutches brakes and AC motors also Allows vari ous components to be switched on or off to test them and provide a readout of current rating Components shown will depend upon type of unit selected and will include some or all of clutches brakes solenoids and indicator LEDs Drive motor is also included for each module as this must be switched on to test some other components PTS Zeta HT ffe TP Era pex bog ech E 3 inei ccena veer c hack i Era upper clutch tech 2 mamara sea Ier aka L Erra upp brska Talllafr eiry Rand H Pire leye rji ET esr l i Fira beaver tm adie
87. 68 A 9110060V Exploded Views Description ENVELOPE FEED BEARING BEARING NYLON ENVELOPE FEED SHAFT ENV FEED ROLLER 10mm DIA PIN GROOVED S8 2 5x14 CIRCLIP E TYPE 6mm PIN DOWEL 3 DIA x 16 m6 SS CIRCLIP E TYPE 12mm SPRING RELEASE Qty FOO NO Spares Issue 1 Mar 2010 Page 4 24 Maximailer HD Service Manual Exploded Views Issue 4 Mar 2011 U l 2 ENV CONVEYOR BACKSTOP A2 1200 A SEE SECTION 4 11 54 NOTE BRIDGE CLAMPS G4092A g WITH M4 x 12 TORX HD fe SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED 21 4 10 C4 Envelope Conveyor Assy A2 1066 A 91100887 Page 4 25 Maximailer HD Service Manual Item Part No O OO zl A Un N 181 0870 A2 1200 A B2 1209 A B2 1212 A B2 1220 A B2 1221 A B2 1222 A B2 1469 A B2 1470 A B2 1682 A EE B3 1238 S B3 1522 5 B3 1323 5 E 1053 V C3 0689 A C3 0710 A C3 0741 A C4 0534 A C4 0535 A C4 0563 A C5 1053 A C5 1055 A C5 1056 A D0007A D1040A E1102A F1 0445 A F4 0306 A F4150A F4151A F4152A F4278A F5007A G1117A G5074A G6002A P2520A 9109558X 9110080R 91100815 9110082T 9110083U 9110084V 9110085W 91035916 9103641 91038415 9109822X 9110086X 9104398X 9104399Y 9104400Z 9106542F 9104435L 9104686X 9107152W 4 10 C4 Envelope Conveyor Assy A2 1066 A 91100882 Exploded Views De
88. 82 8330C J1 J15 J12 WEITER PUMP MOTOR BLU 182 32 2 2 2 Ro J16 J16 CLOSER FORWARD DRIVE COLLATE POCKET SHORT hd CLUTCH 181 128 6 BACKSTOP SOLENOID 181 1600 3 A A NO SEAL SOLENOID BLK i dee Ze l I il m 81 1610 ORG 21 ER 2 COLLATE POCKET LONG FI 2 21 2 BACKSTOP SOLENOID 181 1600 ver fes ae a L I WETTER DOWN SENSOR m 182 451 CLOSER REVERSE DRIVE J13 Ji4 J13 J14 Bx EU CE CLUTCH 81 128 2 S 24V BLOWER MOTOR 181 1630 Jee I 1807778 LT NU z 32 32 INSERT PAWL TRACK DRIVE T T EN fae edie 3 FE 182 8320F BRAKE 32 33 COLLATE POCKET mega 32 32 81 129 182 339 RX il 182 8320 RX Twa LOAD SENSOR O TERM 82 345 O 35 32 T 3 JA i _ J 7 WETTER OUTPUT SENSOR RED A CLOSER OUTPUT REFLECTIVE e ku 3 2 3 2 COLLATE POCKE jeb ee ait 32 32 82 443 O kw i a I O BLK 9 Ail J7 JB SENSOR 182 693 ORG SENSOR I E ME Fl E I e ENVELOPE SEAL SENSOR VEL O d d RX Twa 3 2 3 2 32 82 1 O WHT E RED A 182 85208 o a J9 J10 ES WETTER FLUID ENVELOPE DESKEW 182 337 O TX mk w F ENVELOPE SEAL SENSOR RED A 32 321 n o PROBE LINK E E SENSOR SR JU 2 82 440 C mx o Le eH 182 8520 80 759 180 759 WETTER PCB CLOSER COVER SWITCH S RED 3 JTO J9 82 494 180 8580 I BLUE 2 32 32 32 3 pe SC TOP PAWL SENSOR LI 82 443 PO TX mx 82 8330D YEL C WTO HY
89. 846B 47K gt 1 u66 IOWR 4 8 NP 00 BOOC VAV H 10 lt IP38DRy R217 220R R157 1K Q57 BCB56B 24 OPSEL gi DA 4B EE Q 00 BOOE J27 x27 11 4 B4 A6 G2B Y7 Qui FZT1053A D40 S16 NU 23 2 l t TI op22 jP7pRy T 22 1 oe t 1 15 Q37 9 D65 A a B6 A 74AC138 5 H 14 4 VCC R158 1K Q58 BC856B U64 15 VE ours m N R164 3305 a B2 5 IQA1 1 425 x25 m OP1 gt vi A m u IP33TO40 00 B000 OP FZT1053A D42 510 IP1D IP8DRV 19 7 IOA2 2 IPA1TO48 17 es GEN A A e gt a SDI os 3 B Ya 00 B002 1 L apos 1 18 DF28 Q38 D104 R165 330R R159 1K QSg BC856B 18 B VCC c Y2 00 B004 2 2 19 5 Ai CLK Y3 OUT23 510 IP2D 7 8 00 B006 OP29 LH 20 R130 220R ae Bays I I bl vss R288 JK 8 ie Qd Bode J26 x26 RE IP21DRV FZT1053A Ly D43 SiG R166 330R gt l IORD 4 CH yE 00 BOOA 4 IP6DRV IP3D R160 1K Q60 BC856B 15 10 OPSEL ES 00 BOOC op20 7 J6 039 Q40 D105 hd q BS Ab d 00 BOOE 2 2 BCB46B R132 100R OUT24 sic R167 330R IPIODRV WS WS ro 1 B3 A5 74AC138 J24 IP21 IP4D X24 2 A gt n A IPSDFV FZT1053A S16 R161 1K Q6T 8568 K 3 IP6 Q41 f D46 R168 330R AD5206BRS0 1 apex 1 4 Ger BC846B R134 100R MOT3EN IPSD 2 2 P3 R139 Q44 t D106 t 7 IP3D ore io M3DRV R169 3505 IP6D 8 SI IP16DRV 220R FZT1053A D47 S1G t e IP26 RT R 9 a OPSA l R170 3205 bh ves U11A 74HC14 U39 IP26DRV R140 Q45 D107 IP7D ij
90. A 4HC14 B 129 Ire lt lt P35 PP 1A4 1Y4 ta 3 PCAB2C250T O 1uF 24VLED 1 1 zu 2Y1 4 i ERES R221 4K7 13 lt 390R A E ig 242 2 2 7 6 2A3 2Y3 MB C L HB O1B lt MOTIB lt IP36 74HG14 17 244 2Y4 LPWR 7 RI24 lt U42D R222 4K7 13 1 12 1 g 11 A 16 M2EN lt EN2 02A C MOT2A R148 47K KI 470K J oc M2A lt lt 10 ing ag 4 BRST lt P37 74HC14 Eom 15 14 Xi 24VSENSE R223 AKT 1 2 IP33T040 MB 4 gt 128 02B Ae lt MOT2B S1G B gt lt D4 Q50 L IRLML6401 lt lt IP38 74HC14 c ge ME lt J20A N R273 R274 072 R128 lt U43F aa o R224 4K7 22285 D44 D45 D52 D53 RELAY 9 8 5 6 CANH 1 W 100K 155 CANL 2 4K7 4K7 BC846B pi SHE Se ale SIG CORTAS S SS RELAY at x Das 74HC14 CONTB 4 5186 REDIED lt RELA 5 KI D66 A A A REB 6 D55 510 NUT U42E U42F LPWR 7 2 LA 1 11 10 8 B GND 8 JP3 3 N N d MGND J19B A i ma BAS16 74HC14 74HC14 R269 100K R272 OR 9 Ed R67 47K CANH 1 l pos LPWR RELAYB 8 SW RELAY x18 LPWR LPWR 24V8W 9 CANL 2 A 3 e lt Jey 18 071 REA 3 j 1 LS REB 4 24VSW 26V CONTA 10 94 U38 LP2980 3V3 2 OCUR 5 3 2 CONTB 6 R200 4 3 4 A LPWR 7 1 I 5 D58 5 4 VOC FOP27P06 GND a8 1K n VIN VOUT kd ver 5 U40 74HCT273 062 bi lt 7 vec 6 kar C42 NUT 3 vee 2 R21 330R OUT25 i 510 OP25 8 7 REL MO
91. A B2 1203 A B2 1148 A B2 1198 A B2 1260 A B2 1264 A C2 1038 A C3 0681 A C3 0682 A C2 1024 A C2 1029 A C2 1027 A C4 0515 A C4 0517 A C4 0519 A F4 0292 A F4 0293 A F4 0294 A F4 0295 A F4 0298 A F4 0299 A F4 0302 A F1404A E1 0138 A E1 0139 A E1061A G0167A R2874A E1078A F5112A 9108382X 9108382X 9100744R 9100744R 9109569J 9109569J 9109994B 9109970B 9109971C 9109975G 9110001 9110002K 9109977 9109978K 9109979L 9109980M 9109993A 9109983Q 9109986T 9107011U 9109987U 9110003L 9103826B 91056002 91035551 9104493W Exploded Views Description COLLATE ENTRY BRAKE INPUT CONVEYOR BRAKE PCB SPLITTER 5SEN 5SOL H D No 2 PCB SPLITTER 5SEN 5SOL H D No 3 COLL POCKET ENTRY SLOW CLUTCH COLL POCKET BACKSTOP SHORT SOL COLL POCKET BACKSTOP LONG SOL I P CONV STUB BRG ASSY HEAD SIDE PLATE DRIVES PRIMARY DRIVE PLATE CLUTCH LOCATOR SP SH BACKSTOP SOL BRKT DRIVES DUAL SOLENOID BRACKET CONVEYOR BEARING HOUSING IDLER POST COMPOUND IDLER POST CLUTCH PLATE STANDARD GEAR SPACER CLUTCH SPACER PLATE POST PRIMARY DRIVE SHAFT CONVEYOR DRIVE STUB GEAR 48T 1M 10ID GEAR 40T 1M IDLER GEAR 40T 1M 10ID GEAR 48T IM IDLER GEAR 30T 1M 10ID GEAR 25T 1M 10ID GEAR 25 48T PULLEY 104T S2M M DRIVE BEARING FL 10x 22x 6 BEARING FL 10 x 19x 8 BEARING BALL 8 x 16 x 5 EC30 CLUTCH PIN BRAKE BRACKET BEARING FL8x 22x 7 BELT 100 S2M 280 4 2 Chassis Drive Side Rear Qty
92. A G1182A G1184A 9110099L 9110100M 9110101N 9103641J 9103789N 9105805M 9103795U 9109987U 9103835L 9110108V 9104072H 9112106B 9112445E 9104497A 91 10102P 9104715C 9105602B 4 13 C4 Head Input Conveyor Upper A2 1054 A 9110107U Exploded Views Description CONVEYOR SIDE PLATE DR CONVEYOR SIDE PLATE OP BOBBIN BRACKET LATCH CONVEYOR DRIVE LATCH CONVEYOR OP CONVEYOR BRIDGE CENTRAL OVERGUIDE T BEARING HOUSING BELT BOBBIN CONVEYOR WHEEL WASHER D SHAFT IDLER PIN LATCH HANDLE CONVEYOR LATCH SHAFT OVERGUIDE PIVOT SHAFT IDLER PULLEY SHAFT UPPER CONV DRIVE SHAFT 10mm CONV P WHEEL SHAFT SENSOR POST 106mm SOFT RUBBER WHEEL 40 DIA T BEARING 8mm 12SQ WASHER WAVED 23mm BUSH SNAP 12 7I D x 6 4L WAVED WASHER EPL5 BEARING BALL FL 10x 22x 6 BEARING FL 8 x 22 x 7mm BEARING BALL 6x 13x 5 BEARING BALL 8 x 22 x 7 WAVY WASHER 6 73 I D 0 76 H 9 32 O D WASHER WAVED 8 89 I D 12 5 O D PULLEY 25T XL x 10 DIA GEAR 40T 1M 10 I D BELT 140XL 037 POLYURETHANE BELT TENSION SPRING 0 51 DIA SEALER SPRING SPRING CONVEYOR SPRING LATCH RH Qty FON A i kA B P N F O N MO N N O N N N kA ON ML P N 3 Issue 4 Feb 2012 Spares et lt ue lt See Spares Assy 2 See Spares Assy 1 lt lt Z Z Z See Spares Assy 1 See Spares Assy 1 See Spares Assy 2 See Spares Assy 1 lt lt 2 lt lt lt lt lt lt 22 lt lt lt lt lt
93. AKT IP22 Ee AKT 30 P26 RsTo 30 7 RST 6 31 31 vec 7 IP7D OUT12 510 1 U23 AD5204BR5O R101 AKT IP23 R102 AKT P2 7 ASYTX E SOUTI AKT AKT 1k d P34 d Nu 1 R103 4K7 IP24 R104 4K7 oe Ru Me SIN1 IPS4DRV 226 SEHE LENS D24 510 R105 4K7 P25 R106 AKT PAS SYNTX A M f opis t IP26 34 p2 10 SYNRX 34 XSDA B 0 P35 S n 1 4 R108 4K7 R109 4K7 38 O 35 d 1 E n IP35DRV R218 220R 1 Q25 D99 DONGLE 36 P2 11 SYNCK 36 i XSCL 3 GUT13 S1G R112 AK7 P2 12 P7 4 12 T 57 pai D PES 31 ue 1 E 24V 1 R113 AK wo M1B 13 FZT1053A D25 sic 155 amp 38 P214 Pze 38 NM 14 H Le 39 39 OP14 X23 P2 45 PEZ KA b P17 EE KA 024 t t pio DANT 9 ap A GND 40 SEH J31 ha OPTB OUT14 to f 1 JEXPINT Ps o ego 4 17 S16 A 2 2 MUXO 42 Slag CAN1RX BIETET P3 1 P8 1 DONGLE e 18 OP25 gt MUXI 43 43 CANITX 2 2 FZT1053A D26 SE P3 2 P8 2 19 OP27 opis J22 X22 MESS ti pas Pa 3 44 ANE S 20 ESO 925 i D101 45 P3 4 PRA 45 SDi GANE l E A 1 T 9 1 46 46 vcc ams SS 1 2 2 NE a 47 pas pas 5 e This circuit is in gt ACMOT PRBS Iip POTCS Ta JA IPADRV FZT1053A D27 510 REDLED P3 7 PB 7 GREENLED 026 opi6 J21 X21 49 GND GND 39 2 jPB IP1g 808468 R119 100R Q27 D73 Tp SR t ree pa rts see a SO CL S IPAD OUT16 sic i 3 OP23 n P16 NU NU 4 z vec I I FZT1053A D28 S1G WI r VI 5 IPA opi7 SEM 3 S IP45 Q28 7 D74 IP1DRV o Us 8 OUT17 16 4 X Q68
94. BRID MOTOR DISK SENSOR e Hee LOWER PAWL SENSOR 182 339 RX ew Hili T va SVP era Q 51 RED A ZL LOWER PAWL SENSOR 182 337 TX Jf i O BLK 9 21 2 J9 J10 2 1 2 307280 182 83306 J1 J2 ENVELOPE FLAP SENSOR WHT 32 32 FINGER ADJUST MOTOR J11 COLLATE POCKET ENTRY 182 439 CO RX em 181 070 RED 7 SLOW CLUTCH 181 128 J3 J4 J7 J8 182785508 TOP PAWL SENSOR WHT C 32 3 2 2 2 INPUT CONVEYOR BRAKE oe 182 442 RX em FINGER 2 SOLENOID 180 760 179 109 J16 181 1610 2 2 Se 3 3 MIDDLE FINGER SOLENOID i SIDE GUIDE DRIVE MOTOR eee M ORG Fit PS F312 JB J6 181 1610 Ni ii 2 1 2 1 2 d i Z E YEL C 182 8330E 4 LYEL FINGER DATUM SENSOR RED AJ COLLATE ENTRY BRAKE An J13 J14 180 776 el BLU E ud J3 J4 79 109 ME 182 8320L 21 2 O BLK 32 32 ENVELOPE PICKUP CLUTCH J16 180 758 WHT C Ts sb JI JI 182 8300C vEL C 182 451 COLLATE POCKET INPUT SENSOR O Dee sll ms 321 SC 5 FINGER DISK SENSOR O li LRE5 s 82 342 ENVELOPE LOWER DRIVE CLUTCH 8 RXZTx BLU E et Ji JIS 412 180 776 C5 Es 3 3 COLLATE POCKET INPUT SENSOR G7 te u aia 79 110 TE 21 12 U u 82 340 TUL 321 32 E t ENVELOPE LOWER DRIVE BRAKE YEL C 79 109 HIP 2 2 SIDE GUIDE DISK SENSOR C2 i RED A 5 JB Ie Tn CH BLU E 182 481 521 3 2 80 776 C 2 E 1 i J1 2 ENVELOPE DESKEW SENSOR w
95. Chassis Drive Side Front Maximailer HD Service Manual Item Part No l 2 3 4a 4b 181 050 180 759 180 746 181 128 181 128 181 129 179 110 B2 1203 A B2 1187 A B2 1178 A C3 0681 A C3 0682 A C3 0683 A C2 1024 A C2 1025 A C2 1026 A C2 1031 A C2 1029 A C2 1027 A F4 0292 A F4 0293 A F4 0294 A F4 0295 A F4 0296 A F4 0297 A F4 0299 A F4 0302 A F4 0301 A E1 0138 A E1061A E1107A E0 0597 A B7708A G6168A G0167A C2 1033 A C2 1028 A F4 0300 A G1 0258 A 182 494 C2 1032 A 9100779C 9100744R 9100741N 9108383Y 9109970B 9109971C 9109972D 9109565E 9109973E 9109974F 9109975G 9109977 9109978K 9109979L 9109980M 9109981N 9109982P 9109983Q 9109986T 9109985S 9109987U 9103826B 9105507C 9109988V 9105533E 91056002 9109991 9109954 91099927 9101052 91100162 Exploded Views Description MTR W D 179 093 IN LINE PCB SPLITTER 5SEN 5SOL H D No 6 PCB ASSY HI RES SENSOR CLOSER FORWARD DRIVE CLUTCH INSERT PAWL TRACK DRIVE CLUTCH CLOSER REVERSE DRIVE BRAKE WETTER OUTPUT DRIVE CLUTCH HEAD SIDE PLATE DRIVES SENSOR DISC BRACKET CLOSER CLUTCH BRACKET DRIVE IDLER POST COMPOUND IDLER POST SENSOR DISC POST CLUTCH PLATE STANDARD CLUTCH PLATE 30T GEAR CONNECTOR BRAKE POST GEAR SPACER CLUTCH SPACER GEAR 48T 1M 10ID GEAR 40T 1M IDLER GEAR 40T 1M 10ID GEAR 48T IM IDLER GEAR 30T IM CLUTCH GEAR 25T IM IDLER GEAR 25T 1M 10ID GEAR 25 48T ISSUE B GEAR 16T 1M 8ID BEARING FL 10x
96. Cole Say Baake Ermi sites Pha eal es Bek d Eri riet Stuerz a Bk mcp HHA ikma eil bi Bach miop r amp e i lox rd S i ake Pa ac Gio Jud Seet E a el a a a e a Le e e Le Le e e Le aaa HBHHHHH bra lee mien H Era blow Full Pari Csil H Ceneri KU nao Select Unit Mode d Head Maintenance and Servicing Issue 1 Mar 2010 Motors Tests the DC motors for collate pocket fingers and foldplates Ap plies only to insert head and tower folder Fehmi Meiner Ansleg zarem Digital zanean Cavers Poser Marebasssur L zue Mattes ELLE ri Su Rag onim pia EUM BL Run EC il Total Carrel i ens The Fwd button toggles between forward reverse and forward reverse alternating Select the required direction then On to start Off to stop The right hand column indicates the status Start Sync applies only to Tower Folder fold plates It will cause the backstops to travel to the far end of the fold plate then reset for the selected job Select each module as required using the Select Unit button Analogue sensors Page 3 28 Maintenance and Servicing Issue 1 Mar 2010 Maximailer HD Service Manual Analoque sensors are those that respond over a graduated range unlike digital sensors which are read as either On or Off They are usually adustable The screen displays the status of analogue sensors and all
97. E 1 N RIBBON BRIDGE 1 N M4 NYLOC NUT 2 Y M4 WASHER 2 Y 4 26 Head Ribbon Bkt Assy 184 2260 9110179U Issue 3 May 2010 Page 4 64 Issue 2 Apr 2010 Exploded Views Maximailer HD Service Manual bye o SERO PIE bech HEAD DA C4 UNIV M4 x omm TORX PAN HD 5 2 WS D 2826A 9108961A 4 27 C4 Universal Head PSU 184 2150 9109570K Page 4 65 Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010 M4 x omm TORX PAN HD SCREWS CA 9108961A Q Li a SN C4 MAINS INPUT HARDWIR 184 7750 9 101560V 4 28 C4 Mains Input Hardwired 184 2250 9110180V Page 4 66 Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010 PART OF ENVELOP CONVEYOR ASSY A2 1066 A PART OF HEAD UNIT ASSEMBLY A5 0154 A 40 4 4 29 C4 Head Covers Page 4 67 Maximailer HD Service Manual Item Part No WOON A Un Q N B1 0934 S p1 0939 5 B1 0940 T B1 0942 T B1 0943 T B1 0981 A B2 1290 T B2 1291 A
98. EARING POST FAN 2 5 8 DIA CCW BEARING BALL 8x16x5mm WASHER WAVED 8 89ID 12 5 OD PULLEY 15T S2M MOTOR SPRING TRACTOR BELT IDLER BELT 100 S2M 280 SCREW M5 x 10mm TORX PAN HD SCREW M4 x 6mm SOCKET SET SCREW M3 x 8mm CSK HD M4 LOCKNUT 9 5mm E CLIP See previous page for 115V Motor Assy 4 15 Motor Assy A2 1057 A 9110112Z 230V Exploded Views Qty MOTOR ASSEMBLY 230V A2 1056 A 9110112Z N N PN E Spares lt lt lt lt lt lt lt 2Z2222 lt lt lt SEE FIXING KIT FOR THIS ASSEMBLY A0 0563 A 9110110X NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Issue 2 Jan 2011 Page 4 40 Maximailer HD Service Manual Exploded Views Issue 4 Sep 2012 KA 3K Ib OK p al 6 c W x e JP Sh 46 NOTE BRIDGE CLAMPS G4092A v GG ITEM 27 WITH M4 x 12 TORX HD SCREWS E2827A ITEM 37 ARE FITTED IN ALL LOCATIONS MARKED oe dE 4 16 Sealer Assembly A2 1058 A Page 4 41 Maximailer HD Service Manual Item Part No O OO zl A Un Q N kA 131 824 B1 0933 A B1 0934 S B2 1177 F B2 1179 A B2 1180 A B2 1181 A B2 1182 S B2 1183 S B3 1079 S B3 1345 A C2 1028 A C2 1029 A C2 1046 A C3 0681 A C5 1049 A C8 0208 A E0367A E0475A E1 0138 A E1107A E4 0073 A F4 0295 A F4182A G1 0258 A G1091A G4092A G1 0285 A B
99. ER WHEEL 40 DIA FOR 10mm DIA SHAFT WASHER WAVED 23mm ID EMOEPL20 4 6 C4 Envelope Feeder Assy A2 1064 A 9110075L Spares 0 See Spares Assy 2 3 4 amp 5 OO R N N aN B N N D a kA FA kA kA kA R kA kA a kA kA Page 4 17 Maximailer HD Service Manual Item Part No 45 E0475A 46 E1 0138 A 47 E1 0139 A 48 E1 0140 A 49 E1054A 50 E1061A 51 E1078A 52 E4 0074 A 53 F4 0293 A 54 F4 0295 A 55 F4 0299 A 56 F4 0302 A 57 F4 0307 A 58 G0167A 59 G4051A 60 G4092A 61 G6 0220 A 62 G6 0221 A 63 G6 0223 A 64 P2001A 65 B3 1247 A 66 D0051A 67 E0448A 68 C5 1051 A 69 C3 0758 A Fixings 80 E2 0839 A 81 E2826A 82 E2834A 83 E2827A 84 E4009A 85 E4011A 86 E3557A 87 E3505A 88 E3502A 89 E5126A 90 E5103A 91 E5086A 92 E5081A 93 E5092A 94 169 126 95 E2 0836 A 96 E5073A Description 9105795U WAVED WASHER EPL5 9109987U BEARING BALL FL 10x22x6 BEARING BALL FL 10x19x5 9110065A BEARING NEEDLE 4 IDx8x8 9103819U BEARING BALL 12x28x8mm 9103826B BEARING BALL 8x16x5mm 9103835L BEARING FL 8x22x7mm 9110066B WASHER 4 06x7 24x0 81 9109978K GEAR 40T 1M IDLER 9109980M GEAR 48T 1M IDLER 9109983Q GEAR 25T 1M 10ID 9109986T GEAR 25 48T 1M 9110067C GEAR 30
100. EW lt SEE FIXING KIT FOR THIS ASSEMBLY 41 E3505A M4 NYLOC NUT 2 A0 0566 A 9110119G 42 E3557A M3 NYLOC NUT NOTE FIXINGS ARE NOT AVAILABLE 43 E5071A PIN DOWEL 3 DIA x 14 2 INDIVIDUALLY 44 X E5092A CIRCLIP 12mm E TYPE 2 dp E5073A CIRCLIP 9 5mm E TYPE 2 46 E5003A CIRCLIP 7 0mm E TYPE 4 47 G6028A BRAKE SHIM A R 4 16 Sealer Assembly A2 1058 A 9110121J Page 4 43 Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010 f G k A NOTE ITEMS MARKED ARE NOT gt A ART OF ASSEMBLIES SHOWN l NN N f Og h Sa ii SENSORS 5 LA cL Eu eL Item Description Ref 4 A TC eS 91 10126P S1 Collate Pocket Load RX 5 12 1 4d 5 A SPLIT SHAFT DRIVES A2 1060 A 9110125N oH Saari A2 1059 A 9 4 17 Split Shaft Sub Assemblies A2 1059 1060 1061 A 911012M 9110125N 9110126P Page 4 44 Maximailer HD Service Manual Item Part No A2 1061 A 9110126P 1 C4319A 2 C5 1035 A 3 D0045A 4 E0367A 5 E1 0138 A 6 P2048A 7 B3 1123 A A2 1059 A 9110124M 10 C3 0679 A 11 C4 0514 A 12 D0045A 13 E1102A 14 E4033A 15 F4152A 16 G6028A 17 B3 1121 A 18 C4 0528 A 19 G1016A 9104618B A2 1060 A 9110125N 25 C4319A 26 C5 1034 A 27 D0045A 28 E0367A 29 E1 0138 A 30 P2048A 31 B3 11
101. H3 REAy i i me iW men A18 LES reserg FPDAT11 GFIO4 7 P3 6 73 E m 98 H6 A19 2 ARP RCSO 22 DISP 74 P37 74 P36 mA A20 1 JRD 24 CS esi C57 C58 c59 ceo 49 P3 7 T21N fea Tag eer VCC A18 E us JOE S c c da 80 W RSTIN R B LO ARH 281 P7 4 23 141 RSTO ECS 9 READY 220pF 220pF 220pF 220pF P7 4 CC2BIO RSTOUT CE P7 5 SEI tere ur CE JRD ar Zoe M5M5408 2 CLKOUT 7 wee 25 P7 6 CC30I0 P3 Re ZINCK ZWRH S pe un S P7 7 26 5 13 4 U7 74HCTO2 51 P7 7 CC3110 85 A16 12 13 DO e 0 1 uF ES P4 0 A16 AD po E VCC P8 0 9 P8 0 CANIRXD P4 1 A1 86 A17 A2 T VDD3V3 P8 1 10 PEI CANTTED paoata EE A18 U15 A3 10 15 Di war 2 vec P8 2 11 6 2 88 ATS Al 10 11 DO 24 g D2 17 D3 C2 our WAIT o P8 2 CAN2RXD P4 3 A19 AO 00 A3 D3 TP l P8 3 L era 89 A20 22 51 A o 32 Di a5 8 18 D4 s p 9 9 9 9 9 B IoDO PRA a ue ER A1 BS g amp o 15 52 26 z D 119 D5 44 UL DO op P8 5 14 an 5 91 H4 m 7 18 D3 AT ej D5 20 D6 63 our TESTEN 4 PB 5 CC2110 P4 6 A22 Qus A3 03 AG De IGD2 P8 6 15 92 45 6 16 54 28 5 21 p7 5 P8 6 CC2210 P4 7 A23 CH A4 04 AT D7 A 2 Sr P8 7 m E 26 5 o 17 D 29 27 S IoD4 TE AT 4s L18 pe ATO 26 38 C4 our vec 1005 ASYTX usb H2 48 mA 06 18 07 AT 23 9 nm IGD6 ASYRX 78 a H3 29 25 AIZ
102. LIP 7mm E TYPE PIN GROOVED 2 5 x 12 M2 x 6mm POZI CSK HD SCREW Qty 5 kA N Q N N OF N Issue 3 Apr 2010 Spares lt SEE FIXING KIT FOR THIS ASSEMBLY A0 0569 A 9110142F NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 18 Finger Assembly A2 1062 A 9110143G Page 4 48 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 4 19 Finger Bkt Op Assembly A2 1073 A 9110171L Page 4 49 Maximailer HD Service Manual Item Part No 1 181 1610 2 B2 1250 A 3 B2 1251 A 4 B2 1254 A 5 B3 1250 A 6 C3 0714 A 7 D1040A 8 E0204A 9 G0079A 10 G1 0256 A 11 G1152A Fixings 20 E2826A 21 E2 0857 A 22 E4072A 23 E4011A 24 E3502A 25 E5073A 9109568H 9103641 9104579L 91095750 9104699L Exploded Views Description SOLENOID W D 179 3550 XH FINGER BRACKET OPERATOR FINGER SOLENOID BRACKET FINGER STOP BKT OPERATOR FINGER PIVOT BRACKET OP FINGER PIVOT T BEARING 8mm 12SQ VINYL PROTN CAP 3 5x12 7 CLUTCH PIN SPRING LINK SPRING SOLENOID SCREW M4 x 8mm TORX PAN HD SCREW M4 x 25mm TORX PAN HD WASHER M20 INT SH PROOF M4 WASHER M4 FULL NUT CIRCLIP 9 5mm E TYPE Qty NNNF FN Issue 1 Mar 2010 Spares SS Z lt Z Z Z Z Z lt SEE FIXING KIT FOR THIS A
103. Maximailer HD Service Manual TABLE OF CONTENTS Installation Instructions a 1 1 1 1 Safety NO GS Eege 1 2 1 2 Detachable ltems 1 5 1 2 1 Machine e e TEE 1 5 1 2 2 Machine StandS i e 1 5 1 3 Machine Assembly 1 6 1 3 1 Connecting the Ulnts a nanna 1 6 1 3 2 We CUNO pm 1 8 Description of 2 1 2 1 General Description 2 2 2 2 Track Collation Description 2 2 2 3 Description of Insertion Head 2 3 2 4 Description of Insert Feeder 2 5 2 5 Description of Tower Folder 2 6 Service Operations and Adjustments sese 2 1 3 1 Health safety amp environment 3 2 3 2 Conventions used in this manual 3 3 3 3 Preventative maintenance guidance schedule 3 4 3 4 Information TOF engineers
104. NDARD CLUTCH PLATE 30T CLUTCH SPACER GEAR SPACER BRAKE SPACER 16mm BRAKE BEARING HOLDER CLAM PIVOT POST OP SPRING ADJUST CAM BRAKE KNOB FOOT SPIGOT IDLER POST WETTER FUNNEL STAY SPACER LL SENSOR BLOCK RUBBER FOOT MOULDED PAPER EJECT KNOB WASHER WAVED 23mm I D WASHER 10 2 x 17 x 2 WAVED WASHER EPL5 Qty NN el DO DD DO DD DD DD 4 3 Chassis Operator Side Spares lt lt lt lt lt lt lt lt lt 2 lt lt 22 lt lt 22 lt 2Z222Z2Z22Z22Z22Z22 lt lt lt lt lt lt lt lt 22 lt lt See Spares Assy 1 See Spares Assy 2 See Spares Assy 1 amp 2 See Spares Assy 2 Issue 4 Nov 2011 Page 4 9 Maximailer HD Service Manual Item Part No 42 EO 0597 A 43 E1 0138 A 4 4 E1061A 45 E0291A 46 E0 0602 A 47 F4 0292 A 48 F4 0293 A 49 F4 0296 A 50 F4 0299 A 51 GO167A 52 G1 0278 A 53 G1 0279 A 54 G6168A 55 P2247A 56 B2 1155 A 57 B2 1204 A 58 182 417 59 182 418 60 181 0890 61 A2 1490 A Fixings 70 E2651A 71 E2 0839 A 72 E2 0836 A 73 E2829A 74 E2826A 75 E2507A 76 E2809A 77 E3505A 78 E4048A 79 E4 0078 A 80 E5086A 81 E5103A 82 E5126A 83 E5092A 84 E2505A 85 E2559A 86 E3557A Spares Assemblies SA1 AO 0555 A SA2 AO 0545 A 9109988V 9109987U 9103826B 9105793A 9110022F 9109977 9109978K 9109981N 9109983Q 910560
105. NSOR vi cl SL WETTER PUMP MOTOR 181 148 WETTER FLOW SENSOR 6SZ 08 gt gt ENV CONV MOTOR ENV UPPER DRIVE CLUTCH DRIVE SIDE O ENV PICKUP CLUTCH T olla all DRIVE SIDE SR 1 H4 a SS E ae ee 5 A N ENV IN HOPPER SENSOR e ENV FEED SENSOR 5 lal x 3 ENV LOWER B e xl gle DRIVE CLUTCH DRIVE SIDE ENV UPPER NI DRIVE BRAKE z ENV DESKEW 4 SENSOR ENVELOPE LOWER DRIVE BRAKE DE D7 21 Ez 9 ejo ojo ojo ojo ej o o a2 05 o TP2 J9 be Bend bal 10 bj e 4 ju qe
106. O 0205 A B1 0937 A B1 0975 A B2 2039 A B2 1214 A B2 1217 A B2 1218 A B2 1219 A B2 1224 A B2 1225 A B2 1229 A B2 1230 A B2 1240 A B2 1270 A B2 1296 A B2 1603 A B2 1630 A C3 0680 A C2 1199 A C3 0682 A C4 0516 A C4 0522 A 180 759 C5 1122 A C5 1194 A DO 0062 A E0367A 9108383Y 9108382X 9108382X 9108382X 9108382X 9100744R 9109900D 9110059U 9110060V 9110062X 9110063Y 9109565E 9109973E 9109975G 9109971C 9110064Z 9100744R 9103789N Exploded Views Issue 5 Sep 2011 Description Qty ENV PICK UP CLUTCH ENV UPPER DRIVE CLUTCH ENV UPPER DRIVE BRAKE ENV LOWER DRIVE CLUTCH ENV LOWER DRIVE BRAKE PCB SPLITTER 5SEN 5SOL H D No E4 C4 ENV SEPARATOR ASSY C4 ENV TRACTOR ASSY C4 ENV FEED SHAFT ASSY FLAP GRIP CLUTCH ASSY SPRING PLATE 0 25MM ENV INFEED BRIDGE ASSY FLAP GRIP BRIDGE ASSY ENVELOPE CLUTCH BRACKET ENVELOPE BRAKE PLATE ENV FEED SIDE PLATE DR ENV FEED SIDE PLATE OP ENVELOPE FEED BRIDGE UPPER ENV FEED BRIDGE LOWER UPPER ENVELOPE GUIDE MOUNT PLATE OPERATOR MOUNT PLATE DRIVES SENSOR BRACKET SENSOR BRACKET COVER LATCH BRACKET ENVELOPE FLAP PLATE INSERT GUIDE OPERATOR INSERT GUIDE DRIVES REFLECTIVE SENSOR BRACKET CLUTCH PLATE STANDARD GEAR CONNECTOR GEAR SPACER CLAM GUIDE SPIGOT CLAM LATCH SPIGOT BEARING STUB HOUSING IDLER POST SHORT COMPOUND IDLER POST ENV DRIVE STUB FLAP GRIP ROLLER BAR PCB SPLITTER 5SEN 5SOL H D No 5 OPENER INPUT SHAFT ENVELOPE STOP SHAFT RUBB
107. O SS 32 ENVELOPE TRACTOR MOTOR C VEL C 324 32 182 445 O PX em 181 0810 ij 7 veL SIDE GUIDE DATUM SENSOR 3 RED j I l z RES 180 776 RX TX 3 BLU E ENVELOPE FEED SENSOR Rx WHT C go 32 ENVELOPE SEPARATOR MOTOR O Eto 5 JO 182 444 2 YEL E 181 0850 TR 8 2 7 A 2 J16 wc 182 8190 ENVELOPE FEED SENSOR J5 6 PA EN AC MOTOR DISK SENSOR C i RED A 182 443 PO ex 9 a s ENVELOPE UPPER DRIVE BC EE BLU_ E L 1 TE 180 776 O ARTE 182 8300F J15 J2 ENVELOPE IN HOPPER WHT ae 5 2 2 2 32 32 E 182 83006G COLLATE POCKET 182 339 RX o SEENEN 182 8310 A 0870 TIE SENSOR Q Sam ey jn z 2 RED A ENVELOPE FLAP SENSOR RED A pus ENVELOPE UPPER DRIVE BRAKE COLLATE POCKET LOAD alfa i 1852 83001 EOF 182 557 O TX ek 9 31 F 182 443 TX mx 179 109 at e J1 J2 52 32 J3 J4 4 YEL C 32 32 ENVELOPE CONVEYOR SENSOR C 3 REB Ay Cs BLU E 2 2 180 776 C 182 8510 32 32 J J8 3 32 180 759 5 1 2 I J9 J10 3 2 QUE 12 Inserter Head Splitter PCBs Wiring Diagram Page 5 25 Lazio dai Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010
108. OID PIN FINGER NUT OPERATOR FINGER NUT DRIVES INNER FINGER DRIVE SHAFT INNER FINGER PIVOT ADJUSTMENT SHAFT FINGER ROD INNER FINGER BODY T BEARING 8mm 12 SQ T BEARING 6mm 10 SQ MOULDED FINGER BODY VINYL PROTN CAP 3 5x12 7 FOOT PUSH IN 4 18 Finger Assembly A2 1062 A 9110143G Qty LD kA MM PM kA kA kA B N PO kA kA H p p p p p kA kA Spares lt lt Z lt lt lt lt Z lt lt lt lt lt Z lt lt lt Issue 3 Apr 2010 Page 4 47 Maximailer HD Service Manual Item Part No 40 EO375A 41 F4175A 42 F4176A 43 G0079A 44 G1 0256 A 45 G1 0257 A 46 G1 0277 A 47 G1152A 48 G4092A 49 P2031A 50 180 776 50a 180 776 Fixings 60 E2 0857 A 61 E2571A 62 E2826A 63 E2830A 64 E3557A 65 E4072A 66 E5073A 67 E5076A 68 E5082A 69 E2774A 9104405E 9104406F 9104579L 91095750 9110139C 9110140D 9104699L 9100753A 9100753A Exploded Views Description BUSH SNAP 12 7 I D x 6 4L GEAR 45Tx6mm 0 7M GEAR 35Tx6mm 0 7M CLUTCH PIN SPRING LINK FINGER SPRING C4 INNER FINGER SPRING SPRING SOLENOID BRIDGE CLAMP SHAFT ADAPTOR SENSOR PCB FINGER DATUM FLAG SENSOR PCB FINGER DISC M4 x 25mm TORX PAN HD SCREW M3 x 5mm SOCKET SET SCREW M4 x amm TORX PAN HD SCREW M4 x 12mm TORX PAN HD SCREW M3 NYLOC NUT M20 WASHER INT SH PROOF CIRCLIP 9 5mm E TYPE CIRC
109. R152 1K Q52 BC8S6B 24 U63 9 4 B4 d lees EM FZT1053A U D29 sic 4 aen l 25 54 E R187 1K IOA4 if va by 15 OPSEL 00 B000 00 BOOF OP18 IP2DRV 22 7 R18 TK IOA5 2 14 11 9 9 A4 XSHD B Y1 UARTA 00 BO10 DD BOIF vec Z Q29 D75 gt IOA6 3 13 00 B020 00 BO2F 12 IP7DRV OUT18 FQP27P06 R234 R153 1K Q53 BC8S6B 21 VCC e Y2 UARTB J34 13 OP27 Q30 NE 516 B2 m o Y3 UARTC OG B030 00 BO3F 14 OP30 gt 4 29 wo spo 2 D UARTD 00 BO40 00 BO4F 5 BC846B R123 100R FZT1053A D30 S1G 100K IP3DRV 19 R286 1K 6 10 EXP 00 BD50 DO BOSF IP13 FN op19 7 hi AD Jos 4 Sl Ys 7 XSDA vec Q31 9 D76 R154 1K Q54 BC856B 18 8 R287 1K 50 GA Y6 Q Quas a nee 5 M pud XScL 1 3 J8 IP2DRV OUT19 S16 i l 1 17 a a g SCLK E i uso Q32 IP4DRV 16 AW 74AC138 1 BCB46B R125 100R FZTIOS3A 3 D31 510 R229 M B1 4 LEDPeT 2 IP7D wow opoo R155 IK Qs5 8568 15 NCS 9 X U24 i IP2 Q33 M D102 220K l hi 14 ja EI fin og Lis oP1To8WR 00 B000 S IP2D R126 3508 1 OUT20 S16 4 IPSDRV H d i 15 ai ses LR TOAD SI ha 14 OPSTO18WR 00 B002 E IP17 IP8DRV M PP NN ee IOA3 3 6 v2 15 0P171024WR 00 B004 S IP17DRV Q35 FZT1053A 1 D32 S1G Q69 R228 R156 1K Q58 65 AD5204BR50 z pe Z JOP25T032WR 00 B006 IP4 BC846B R128 100R OP21 C4SEL 11 00 B008 8 e e Vec Y4 Q H14 8 IP8D 1 956 D103 IPEDRV 1 R195 1K vs D10 H13 00 BOOA IP36 OUT21 S1G BC
110. RX PAN HD SCREW M4 x 12 TORX CSK HD SCREW M5 x 10 SKT SET SCREW M5 x 10 TORX C SK HD 6mm E CLIP 12mm E CLIP CLUTCH LOCATOR OP ASSY CLUTCH LOCATOR DR ASSY SEP ACTUATOR ASSY 4 7 C4 Envelope Separator Assy A2 1065 A 9109900D Issue 2 Mar 2011 Qty Spares N P kA D N a aR R N Ea aR N SEE FIXING KIT FOR THIS ASSEMBLY A0 0550 A 9110047G NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY kA MM kA MM MM A R A R A R Page 4 20 Maximailer HD Service Manual Exploded Views Issue 2 Mar 2010 SENSOR Item Description Ref S1 Envelope Conveyor Flag 5 12 4 8 C4 Envelope Tractor Assy A2 1067 A 9110059U Page 4 21 Maximailer HD Service Manual Item Part No 1 180 776 2 181 0810 3 B2 1473 A 4 B2 1548 A 5 B3 1241 A 6 C2 1136 A 7 C3 0720 A 8 C4 0565 A 9 C5 1070 A 10 C5 1146 A 11 C8194A 12 D1076A 13 E0367A 14 E1030A 15 E1061A 16 E1078A 17 F4 0311 A 18 F4 0312 A 19 G1029A Fixings 30 169 145 31 E2760A 32 E2 0848 A 33 E2518A 34 E2826A 33 E2 0857 A 36 E3502A 37 E3505A 38 E5003A 39 E5073A 40 E5071A Spares Assemblies SA1 A0 0551 A 9100753 9110054P 9110055Q 9103545J 91055215 9103789N 9103826B 9103835L 9110056R 9110058T 9110048H Explod
111. S 34 FPDATS 11 26 bu P2 8 c RENE o 28 DT 6 X be 19 Di DTI Z A n FPDATS as R49 27R Gan 27R FPDATA LCD Output P2 9 58 1 134 M4 25 20 32 D12 AT 6 20 D14 D12 6 FPDATT 732 R51 27R T R52 27R FPDATS 13 27 Dd P2 10 sg 2 9 CC9IO PIH 6 A14 Af5 26 D 33 D13 38 5 46 D6 21 D13 5 DEI EPBATS Cer R53 27R t R54 27R FPDAT 44 3 P2 11 sp 22107661010 PIFLZZA1S AT TE D5 34 D14 29 ar M Re D14 4 DB13 FPDATS Cas R55 27R 1 R56 27R FPDAT7 15 28 46 P2 12 er F2 11 CC1410 1 ECS 17 8 D6 D15 A10 2g 48 D15 ele MA t FPDAT8 15 i P2 13 ez 2 12 CG12I0 P5 0 C80 5 RCSO 48 16 7 Br ATI 23 9 Ee ol pole FPDATS 17 28 SS P2 14 Ba BEE 6 1 051 RCS1 5 ato 8 A12 25 0 053 C54 C55 C56 FPDAT10 3 P215 Ba P2 14 0C140 6 2 552 PERI e ATI 14 9 ATS 4 A RD 78 Ee Jh E FPDATTI 19 50 40 P2 15 CC15IO P6 3 CS3 we ATO A12 RD WR E Er Er e P 7 nl VAZ Gas A14 Se WRH m s 220pF 220pF 220pF 220pF 20 P30 65 i ATS 8 D I 3 WRL 77 1 M P3 66 81 R32 A16 mp Ad n 76 WEOf 26 R57 27R id ep 27R 43 E a gt P3 1 T6OUT P3 15 CLKOUT Se jen AIS As RD FPDAT8 GPID 1 l 55 a A 44 Br aa P3 2 CAPIN RD 55 A NR iu AM me BS FPDATSGPIO2 7 9 eT SC 42 P3 4 gg PS 3 T3OUT WRL g WRH AT7 4 5 A19 T Al RSTI 73 FPDATIO GPIOS 77 R63 27R T R64 27R 46 Sin Ze P3 4 T3EUD Pa 12 WR
112. SSEMBLY A0 0572 A 9110170K NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 19 Finger Bkt Op Assembly A2 1073 A 9110171L Page 4 50 Maximailer HD Service Manual Exploded Views Issue 3 Dec 2010 SENSORS Item Description Ref S1 Side Guide Disc 5 12 S2 Side Guide Datum flag 5 12 2 14 4 20 Side Guide Adjust Assembly A2 1063 A 9110146K Page 4 51 Maximailer HD Service Manual Item Part No WOON A Q1 Q N Spares Assemblies A0 0597 A SA2 A0 0598 A SA1 169 145 181 070 180 776 B4330A B7478A B7498A C3476A C3477A C5 1062 A C6340A D1076A E0 0618 A F4175A F4176A P2031A E2826A E2571A E2774A E5082A E5076A 9100469E 9100788M 9110109W 91055215 9110144H 9104405E 9104406F 9110630P 9110631Q Exploded Views Description RIVET 3 5mm 2 0 3 0 GRIP WIRED MOTOR PCB WIDEBODY DISC SENSOR DISC ASSEMBLY SIDEGUIDE MOTOR BRACKET GUIDE CARRIER FINGER NUT RH FINGER NUT LH ADJUSTMENT SHAFT GUIDE CARRIER T BEARING 6mm 10SQ O RING 6 1I D x 9 30 D GEAR 45Tx6mm 0 7M GEAR 35Tx6mm 0 7M SHAFT ADAPTOR SCREW M4 x 8mm TORX PAN HD SCREW M3 x 5mm SOCKET SET SCREW M2 x 6mm POZI CSK HD PIN GROOVED 2 5 DIA x 12mm CIRCLIP 7mm E TYPE GUIDE CARRIER ASSY RH GUIDE CARRIER ASSY LH Qty aF FN a F N F F N BRNNN A R A R Issue 2 Dec 2010 Spares GA lt S Z Z lt lt SEE FIXING KIT FOR THIS ASSEMBLY A0 057
113. Safety instructions 3 1 1 1 General e This machine must be operated by competent personnel The manufacturer accepts no responsibility for accidents or injuries caused by operation by incompetent personnel e Covers may only be opened by skilled persons who know the risks involved For safety reasons the machine will not function with opened cov ers e Keep away long hair fingers jewelry etc from rotating and mov ing objects of the system e Switch off the system at the end of the day 3 1 1 2 Electrical safety e Disconnect the mains power supply before performing any mainte nance to any kind of mains power supply high voltage related items e The power connection must be easily accessible preferably close to the machine e For safety reasons it is essential that the machine is connected to a socket outlet with protective earth connection e Over current protection in the equipment also relies on the branch circuit protection e Disconnect the machine from the power supply when it is not in use for a longer time e Potential hazard may exist to electronic hardware in conditions with static electricity It is advised that when handling electronic parts an earth connected wrist band is used in order to be perma nently discharged from static electricity Maintenance and Servicing Issue 1 Mar 2010 3 1 2 End of life The objectives of the European Community s environment policy are in particular to preser
114. T 1M IDLER 91056000Z EC30 CLUTCH PIN BEARING HOUSING 12mm MOD BRIDGE CLAMP 9109561A GUIDE TAPE UPPER 9109576R GUIDE TAPE LOWER 9109562B FLAP GUIDE SHIM GUIDE SPIGOT RESTRICTOR ARM SEPARATOR PAD 45 55 3M VHB TAPE 9469 x 14mm CHASSIS TIE BAR IDLER POST SOLO LONG SCREW M3 x 6 TORX PAN HD SCREW M4 x 8 TORX PAN HD SCREW M4 x 10 TORX CSK HD SCREW M4 x 12 TORX PAN HD M3 WASHER M4 WASHER M3 NYLOC NUT M4 NYLOC NUT M4 FULL NUT 3 DIA x 8 GROOVED PIN 3 DIA x 10 DOWEL PIN 3 DIA x 16 DOWEL PIN 4 5mm E CLIP 12mm E CLIP PLASTIC RIVET 3 5 DIA 1 2 2 1mm GRIP SCREW M4 x 6 TORX PAN HD 9 5mm E CLIP 4 6 C4 Envelope Feeder Assy A2 1064 A 9110075L Exploded Views Qty 9 NJ a Se ee qo pe ANAAAAAAAAAAVAAON AON Issue 4 Sep 2011 Spares See Spares Assy 1 See Spares Assy 6 See Spares Assy 6 See Spares Assy 6 ZZ2ZzZzz2z2z2 lt lt lt 22 lt lt lt lt lt lt lt lt lt lt lt 2 lt lt lt SEE FIXING KIT FOR THIS ASSEMBLY A0 0546 A 91100450 NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Spares Assemblies SA1 ENV P UP STUB BRG ASSY A2 1303 A 9110070F QTY A R SA2 ENV FEED I P SHAFT ASSY A2 1307 A 9110071G QTY A R SA3 ENV OPENER I P SHAFT ASSY A2 1308 A 9110072H QTY A R SA4 ENV OPENER O P SHAFT ASSY A2 1309 A 91100731 QTY A R SA5 ENV FEED O P SHAFT ASSY A2 1310 A 9110074K QTY A R SA6 RESTRICTOR ARM ASSY A2 1380 A 911
115. TKY 5A T 1KO 220uF JA e e e e e e D2 D3 5 26V Constant i O MI A S MTG HOLE 2 ov ME WIS D4 1N4007 1N4007 26V Switched JN RLI O Connect MGND to a track 1N4007 MGND o1 connected to one of the SUP65P06 20 mounting holes e 3 5 e 9 e MPWR K D6 B J2 5V 12A R3 R4 1N5352B 100K 1 12K C5 an C6 9 1uF 63V O 1uF e 4 RT1 2 5A RL2 J3 a 7 D5 8 n A L BL 26VSW 9 24V 16A 220K a 2 Bes 5 E 1N4007 OMM SA RD 4 7V 5 OV MGND Wi OV e 7 Motor G g Relay 8 9 R6 09 U2 FS MGND 252 1 6 BZX55C12 VCC IND 2 i i 5 e SEN 1 REM 9 ex 34 3 i 8 RIG SEN2 OUT R7 4 P 58 C8 ISRC VEE L 1K8 C7 TE 1KO EN 0 01uF e e e Title C4 Interlock Board 180 5310 Size Document Number Rev A4 127 2880 cct Date Monday August 10 2009 Sheet of Section 5 8 Interlock PCB Circuit Diagram Page 5 21 Maximailer HD Service Manual Electrical and Circuits Wiring
116. TOR ON OFF 2 c59 26V P a1 F5 R212 330R OUT26 1 tX 9 m 8 cuu 7 D56 e FIRES D2 92 FE mori 3308 QUT27 FZTIOS3A 7 D67 10 E huF VIN i A CURRENT C60 3 3UF Do aries R214 330R OLT28 N EMF 11 10 R245 IOUT K s R9 R10 Ds Ee 12 R215 330R GUT29 D58 vi 12 U37 D2 Da 05 15 R216 330R OUT3O 3 BZX84C12 D6 Q6 A S1G R133 LOAD R151 C62 10K 10K K M 16 OUT31 lt LEDPOT Q63 m hd BASI6 T D3 T 4 US ZXCT1009 a aa Le OUT32 H70 16 1K 1 0 1uF gt OP26 an U7 BAS18 44 FZT1053A lt D68 7 R241 3 13 OP25TO32WR i CLK LA A MUX K 2 yo RE RST Ale cir D60 caer 11 as N 516 MUXO SD Y2 5VIP A 9 e OR047 S Z MUX1 10 Sp 43 12 24VIP i 4 Q64 MUXS 9 i5 RR COVERT sic R236 5 R139 IK 8 FzTto5aA 4 L 24 A vec E v6 H VREF z 2 U54 o VEE Y7 Hg R11 R12 D109 Te 74HC4051 z 1 ZXCT1009 X 10K 1K 1 a R247 av w D87 vec U47A N e D83 9 2 u49 2K 2 De1 A 5 5 A R13 47K R14 47K re 4 510 E ZXCT1009 M3390 KA gS L t t or BZX84C12 SCH 510 5 U46A R242 J12 C4 gt OP28 D78 A X Bade STR sija FZT1053A U D88 A 9 C Switch 3 EE 26V N 1 ANI M339D ORO47 C81 1000pF 3 TA va 562 A R16 47K NE R23 BZX84C12 e ij 066 510 E x12 ki D57 R S1G 24V B R254 1K R17 47K 47K t T 1 12V 3W o 3 l Y OP29 ORO47 C76 1000pF z 2
117. W XH 0 2M LOOM A5 WETTER PROBE 7 la 10 11 17 13 14 15 16 17 18 19 20 21 22 MOTORASSY 115V LL _ CLUTCH EC30LL CW 8mm 24V 1 MTR W D 179 093 IN LINE 1 CLUTCH W D 179 155 2WXH__ 1 BRAKE W D 179 105 wen 1 SOLENOID W D 179 3540 XH 1 LOOM CA HYBRID MIRUINK 1 PCB ASSY ENV WETTER 1 1 PCB ASSY AM4 PROCESSOR 1 PCB ASSY AM4 CNTRLBRD 1 PCB SPLIT 5SEN 5SOL H D 1 PCB WIDEBODY DISK SENSOR 1 PCB C4 EXPANSION 1 MTR ASSY PERISTALTIC 24V 1 LOOM EMITTER 200 SM 1 LOOM RECEIVER N A200 SM 1 LOOM RECEIVER N A300SM 1 LOOM EMITTER200 XH 1 LOOM RECEIVER W A200XH_ 1 LOOM EMITTER30 XH 1 LOOM 4W 3W 3W XH O 2M 1 LOOM A5 WETTER PROBE f 1 Issue 3 May 2010 Page 3 32 Maximailer HD Service Manual Maintenance and Servicing Issue 2 Mar 2010 ITEM P N PFE P N SAP DESCRIPTION QTY CONS 23 182 693 9101087Y OPB715 WIRED SENSOR ZOGW 1 24 182 8320 91098159 LOOMC4HEADLHNKS i 25 182 8330 91095551 LOOM C4 HEAD RIBBON SET 1 184 2150 9109570K CA HEADPSU i J 180 760 91007455 PCBSPLIT3SEN4SOLH D J 1 ele e 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 52 181 0850 9108955U WIRED MTR 179 802 2W SM 53 C8194A 9103545 SLOTTED FEED WHEEL Page 3 33 Maxima
118. YPE 2 59 E5081A CIRCLIP 4 5 E TYPE 2 60 G4092A BRIDGE CLAMP A R 4 12 C4 Collate Pocket Clam Assy A2 1069 A 9110098K Page 4 32 Maximailer HD Service Manual Exploded Views Issue 7 Mar 2012 SENSORS Item Description S1 Collate Pocket Input TX E x 3 DA l 1 M Sy 5 OC 55 34 7 F1 0461 A x6 PULLEY 25T XL ITEM 34 ITEM 10 F5119A x1 5 BELT SET e p s NOTES C2 1034 A x6 BELT BOBBIN ITEM 11 140XL O37 ITEM 36 m P d Z D Z is p D Y C2 1036 A x6 V d A E e C2 1036 A x6 CONVEYOR WHEEL x 1 BRIDGE CLAMPS G4092A 2 ITEM 43 WITH M4 x 12 TORX HD CONVEYOR SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED WHEEL ITEM 11 l E 2 ITEMS 35 amp 59 MUST BE ORDERED TOGETHER d ELI FITTING DIAG RAM 4 13 C4 Head Input Conveyor Upper A2 1054 A 9110107U Page 4 33 Maximailer HD Service Manual Item Part No WON A Un GAMM B2 1151 A B2 1152 A B2 1154 A B2 1156 A B2 1157 A N R B2 1161 A B9313A C2 1028 A C2 1034 A C2 1036 A N R N R C2751A C3 0685 A C5 1038 V C5 1042 A C5 1043 A C5 1045 A C5 1312 A C5 1048 A C9278A D0 0063 A D1040A E0367A E0375A E0475A E1 0138 A E1078A E1107A E1114A E4 0073 A E4033A F1 0461 A F4 0319 A F5119A G1 0254 A G1 0258
119. arator from envelope feed assembly Check separator roller Check separator shield Replace roller or shield 1f worn or damaged Separator rollers lt and shield Replacement Part Numbers and 10mins Gears Inspect and replace if worn after 4 million Lenze clutches Inspect after 2million 15mins separator roller C8135A Replace after 4 million Shield D164_03A Replace after 4 million lOmins Flap guide shim G6 0223 A Inspect after 2 million Needle bearings Inspect after 2 million Check flap guide tapes on flap grip assembly Replace if required Ref Manual Complete Maintenance Item Head Unit Wetter Section Clean silicone rollers and check for wear Replace if worn Clean and grease all bearings Frequency Time to Replacement Part Numbers and Ref Manual Complete Flap guide shims Replace after 1million Lower seal roller 48 dia C8 0206 A Inspect and Replace after 2 million Lower seal Roller 25 dia C8 0207 A Upper seal roller C8 0208 A Replace after 2 million ITEM Maintenance Item Head Unit Frequency Time to Replacement Part Numbers and A6 Clean wetter tank and replace felt lOmins Wetter Felt GO 0181 A Replace after 1 million E A7 Remove collate pocket assembly 30mins Bearings Inspect at 2 million Clean all feed rollers Rollers Inspect at 2million Check clean and grease all bearings Spring loaded bearings Ref Manual Complete ITEM Mai
120. e Operator side Drive side of of Maximailer Maximailer HD HD connected connected to to module 1 module 1 1 3 6 Attach the Datacard machine to the attachment bracket R2940T as shown opposite cont Page 1 6 Maximailer HD Service Manual Installation Page 1 7 Issue 1 Mar 2010 1 4 SETTING UP THE MACHINE 1 4 6 Check network connections between Maximailer HD PC and the Datacard machine 1 4 1 Connect the power and comms cables for all modules as follows 1 4 7 Program the Maximailer HD with jobs and test run Datacard machine to DTI serial lead Datacard machine to PC comms lead 1 4 8 When all is satisfactory replace all covers Cancard from PC to Maximailer HD Power leads between modules and then to Maximailer HD head Power lead from Maximailer HD head to mains supply Power lead to PC Power lead to Datacard machine 1 4 2 Check the DIP switches on the head and module PCBs are set as follows DIP Switch ON Position 1 4 3 Connect remaining PC leads to monitor and keyboard 1 4 4 Switch the PC and the Maximailer HD ON 1 4 5 Check the software firmware version Pagel 7 Maximailer HD Service Manual Description of Operation Page 2 1 Issue 1 Mar 2010 Section 2 Description of Operation Sect Page 2 1 MEB E TT TT 2 2 2 2 Track Collation Description 2 2 2 3 Description of Insertion Head 2 3 2 4 Descripti
121. e ep 4 Wi Page 5 13 NT 2 b Maximailer HD Service Manual Electrical and Circuits Wiring
122. e includes the module name in the filename ie for head 3P folder or feeder 2P folder Cardfolder The lower windows show the version number and status of the file These can be compared with the main window showing the same details for the current firmware in the unit Normally all modules should be ticked in the left hand column and Broadcast Mode should be ticked also This will allow multiple mod ules of similar type feed fold modules or Cardfolder to be upgraded Simultaneously saving time only untick if a module is specifically not to be upgraded It does not matter if for example the head were ticked whilst feed fold modules were being upgraded When downloading the righthand window shows download status in progress E Please fill settings Unite Current firmware bulld datas File C Program Files PFECA IMOS Firmware 4PlusPC HI V5 0 6 16 am4 Module 4 Module 0 Head Buia version V5 6 9 0 r568v6m MM Build number 733 unt Checked and selected unite Bulla date Tue 27 Vet 2099 Module 1 th Feeder Build time 11 51 18 Bytes left 584058 Bytes cent 55584 now Unknown Statue DOVAILOADING FA Module 1 Build version V5 0 0 0_1534a DOWNLOADING Bulld number 33 CrProgram Files PFE C4 IMOS Firmware C APIuoPC HI V5 0 e Te am1 Build date Tue 05 May 2009 il Head Build timo 13 16 54 Unk C Program Files PFEC I IMOS Firmware C IPlusPC HI V5 0 6 16 am1 Busld version V5 0
123. e network cable to allow access for the PSU cables to pass through the opening Adjust the guides so that point B is 1 5mm 1 16 wider each side than point A This is most easily achieved by placing a piece of pa per between the guides and winding the gears by hand to move them The gap can then be easily measured Drive side 2 Remove the 2 screws indi cated in Fig 21 and withdraw the PSU feeding the connec tors through the chassis open ing on the operator side Tighten the screws and check that the setting has not altered The toe in applies to all document sizes Replacement Hold the cables and reach in the chassis opening on the drive side and feed the con nectors through the opening on the operator side Push the PSU home The lugs on the operator side must locate in the chassis plate before the PSU will fit Cg Tape or bind the cables together to assist with feeding them through the operator side opening Page 3 17 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 3 Lift the rollers out of the chassis utilising the access slots to do so The lower roller can be removed by springing the surrounding metalwork Slightly 3 16 Replacement of Sealer Rollers There are four sealer rollers two in the chassis two in the opening sealer assembly They should be checked for wear or damage at every site visit and replaced at 2 million envelopes when fitting the new ro
124. e set short ie approx 1 3 form length for C fold or long approx 2 3 form length for Z fold When the leading edge contacts the backstop the form buckles and drives the buckle into the nip of the first fold rollers It is driven into the second fold plate set short for both C and Z fold where it buckles again and is fed fully folded towards the exit path where it is held by a brake at the track feed sensor For V fold the form is driven into fold plate 1 set to half form length and the buckle is driven into the first set of fold rollers The no fold beam for fold plate 2 is solenoid actuated to bypass the fold plate so the folded form is driven towards the exit path as for C or Z fold For in line units a conveyor is fitted where forms approaching from the unit behind are fed through monitored by the track sensor This is timed in conjunction with the track exit sensor so the folded form is trailing edge collated with the preceding document as described in section 2 2 For end units no conveyor is fitted and the unit normally feeds the prime document This travels through the machine to be fed on top of the collated pack in the collate pocket in the insert head Shortform option This option allows the folder to be used as a feeder by the addition of the two roller shafts shown in Fig 8 As these are placed where the OMR or Description of Operation Page2 8 Issue 1 Mar 2010 barcode head is fitted shortform option is not a
125. ec VIN 1 4K7 TP4 74HC14 S O 1uF IOD 0 7 o C14 e IOUT P 0XZ ZxZ V tz 3 LOAD 26V R37 USD e c 4 ga C15 14 0 1uF 1 2 IPA4 13 12 Ess R38 Do VCC N 9 m ZXCT1009 19 4K TPS 74HC14 HIE D2 SENSA 2K2 T8 NU R39 e M E SENSB co U6A MPWR 24N A R40 USE bs vour l 20 1 He 98 3 de U10 10K 4 1 2 5 1 u Vo 1 1 po J6 R41 MC7824CT Dii IOD 0 7 De 2 2 NI 1 1 2 1 3 3 1 AKT TP6 74HC14 UTI OPACS Tal 7 enor LZ CP6022 BCg46B T BZX84612 We 1 TAT LT M 1 Ale 13 15 3 LPWR 0 1R G RA2 USF 17 MGND CS GND2 S g Bas RAN oe CH cs cig BAS16 j 2 IPAS v 8 82 A2 AD557JPZ 4 8 28V E t RK fs 35 2 330uF 0 1uF 0 1uF 0 1uF M 47 74HC14 14 84 A s lt 5ov 8 S F 15 85 x ET R44 B6 AG R43 1 2 FLTLED 121 us I e SPEED RAS D13 11 1 470K AKT BB B Si 1 2 U13 BAS16 Lt IPACS R46 R47 R48 hd 7 2d n MC7824CT U2D SS U14A U14B 1RO A Lb vL 12 DIR 9 9 t 9 IOA1 2 ein Eh 14 vo 1 H4 1K 1 1K 1 1K 1 U12 11 24VSENSE 4HCT245 IOA2 3 5 13 11 IPACS MGND pe Un G 24v B 13 vd R49 IOD 0 7 B Os 1 LF B Yl Oo 7 8 A N ZXCT1009 2 c20 C21 E H6 8 L J1 JEXP 1 Y O yapes 15 X D3 t 74HC132 1K G Y3 G Y3 CH E ye i SVREF NU d _ our 0 1uF m 2
126. ed Views Description PCB SENSOR FLAG MOTOR WIRED 179 802 0 2M SM TRACTOR MOUNT BRACKET TRACTOR OVERGUIDE TRACTOR MOUNT PLATE TRACTOR PIVOT POST TRACTOR MOTOR STAND OFF TRACTOR BEARING SHAFT TRACTOR FEED SHAFT TRACTOR PIVOT SHAFT SLOTTED FEED WHEEL T BEARING 6mm 10SQ WASHER WAVED 23mm ID ROLLER CLUTCH 8x12x12mm BEARING BALL 8x16x5mm BEARING FL 8x22x7mm 16T TRACTOR DRIVE GEAR 321 GEAR x 12mm BORE SPRING D D RIVET 3 5mm 2 0 3 0 GRIP SCREW M2 x 5 POZI CSK HD SCREW M3 x 6 TORX CSK HD SCREW M4 x 4 SKT SET SCREW M4 x 8 TORX PAN HD SCREW M4 x 25 TORX PAN HD M4 FULL NUT M4 NYLOC NUT 7mm E CLIP 9 5mm E CLIP PIN DOWEL 3 DIA x 14 32T GEAR ROLLER CLUTCH ASSY Issue 1 Mar 2010 Qty Spares 1 Y 1 Y 1 N 1 N 1 N 1 Y 3 N N 1 N 1 N 2 Y 2 Y 2 Y 1 N See Spares Assy 1 4 Y 2 Y 1 Y 1 N See Spares Assy 1 1 Y 2 2 2 1 2 SEE FIXING KIT FOR THIS ASSEMBLY 2 A0 0552 A 9110094J 2 NOTE FIXINGS ARE NOT AVAILABLE 1 INDIVIDUALLY 2 4 1 A R 4 8 C4 Envelope Tractor Assy A2 1067 A 9110059U Page 4 22 Maximailer HD Service Manual Exploded Views Issue 1 Mar 2010 4 9 C4 Envelope Feed Shaft Assy A2 1068 A 9110060V Page 4 23 Maximailer HD Service Manual Item Part No O OO zl A Un N kA C2653A 9102919G C2655A 9102920H C5 1058 A C8 0209 A E5078A E5079A 9104139C E5086A E5092A G1139A 9104698K 4 9 C4 Envelope Feed Shaft Assy A2 10
127. ee P d Aw 4 9 SS e E D 53 16 VA S O 5 m d Ps Ba Cy Ma TO a 9 e 1 5 4 25 No Seal Assembly A2 1214 A 9110309E Page 4 61 Maximailer HD Service Manual Item Part No zl aU BR WN 181 1610 B2 1185 A B2 1518 A B3 1256 A E0204A E0253A E1077A G0167A G1 0256 A G1152A Fixings E2827A E2826A E4072A E4011A 9109568H 9103834K 91056002 91095750 9104699L Exploded Views Description SOLENOID W D 179 3550 XH NO SEAL SOLENOID BKT NO SEAL BRACKET NO SEAL COMB VINYL PROTN CAP 3 5 x 12 7 INSERT FOOT 049 1000 FLANGED BEARING 4mm BORE EC30 CLUTCH PIN SPRING LINK SPRING SOLENOID SCREW M4 x 12mm TORX PAN HD SCREW M4 x 8mm TORX PAN HD WASHER M20 INTERNAL SH PROOF WASHER M4 Qty NJ HL HL N Q N F N N Issue 1 Apr 2010 Spares lt lt lt lt Z Z Z Z Z SEE FIXING KIT FOR THIS ASSEMBLY A0 0580 A 9110307C NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY 4 25 No Seal Assembly A2 1214 A 9110309E Page 4 62 Maximailer HD Service Manual Exploded Views Issue 2 Apr 2010 o co gt 4 26 Head Ribbon Bkt Assy 184 2260 9110179U Page 4 63 Maximailer HD Service Manual Exploded Views Item Part No 1 2 3 4 5 182 8330 9109555U B3 1130 A B3 1131 A E3505A 9104039Y E4011A 9104059U Description Qty Spares LOOM C4 HEAD RIBBON SET 1 Y RIBBON PLAT
128. eg Al ae m Sean es Ins pawl stop pos cal mm TT Pocket backstop cal ms 4 In Foldplate 1 Cal enter the difference between the meas ured length and the length displayed in Configuration ie if the measured length is 152mm select Change and enter 3 5 Run the job to check the length is now correct 149mm in this case 6 To calibrate foldplate 2 return to Configuration and enter the dialog box described in step 2 Change the fold type to Custom Fold and hit the Fold Plate Lengths button to open the Foldplate Settings box see opposite Fold I2nstirsattirsz Custom Fold Warning User will not be restricted whilst editing these settings Fold Type Custom Fold Fold panels lengths mm FP2 2 al ep Address Position Middle Bottom Feed orientation 5 Face up Face down GES l Document orientation Ze Feet first Envelope Depth mm 44 Head first Form Length mm 297 Folded Length mm um Address adjust mm 0 vx COD X Cancel 6 Set F1 and F3 to 0 this will blank off foldplates 1 3 7 Repeat steps 3 to 5 for Foldplate 2 Cal 7 Repeat for foldplate 3 except that F1 amp F3 are set to O and make any necessary corrections for Foldplate 3 Cal b calibration of no fold blanking beams 1 2 amp 3 Adjusts gap between tip of beam and fo
129. emove the insert panels this will allow the chains to flex sideways Insert panel shown removed 2 Atthe pawl link remove the spring clip on the outer side and pull out the rollers to separate the chain see Fig 8 Caution jam the chain at the input end to prevent it sliding inside the chassis 3 Use the link to connect one end of the new chain with one end of the existing one maintaining chain tension dtoraw it round the pulleys until the other end appears on the chassis surface 4 Jam the chain to hold it and separate the link to remove the old chain Join the 2 ends of the new one If necessary the chain tension can be relieved by using a screwdriver or other suitable tool to compress the tensioner at the input end see Fig 9 round them or the pawls will be misaligned If this hap I Try not to let the chain slip on the sprockets as it is drawn pens see step 6 Maintenance and Servicing Issue 1 Mar 2010 5 Use a screwdriver or simi lar tool to compress the spring tensioner Pawl misalignment 6 Ifthe chain pawls be come misaligned they can be brought back into line by the following procedure Slacken the screw indicat ed in Fig 10 and release the tension shaft 8 Hold the forwardmost pawl and using pointed nose pliers drag the other chain over the required number of sprocket teeth at the output end When the pawls are aligned replace the tension shaft Replace the insert pa
130. enze 179 110 EC30LL baa CAN Closer forward Wetter Drive z drive clutch Clutch Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 5 r wir F CALE T m aa l y D MU d Ch E 1 1 i d bat EM t 3 a a ad Te ast m d P LIA MOV hel y 180 759 Splitter 182 8330B 179 109 EC30LL PCB No2 Ribbon Cable Input Conveyor Brake 180 759 Splitter PCB No3 179 109 EC30LL Collate Entry Brake Collate pocket A2 1057 A entry clutch 230V or A2 1056 A 115V AC motor assy 182 8330C Ribbon Cabl 181 1600 180 776 AC 181 1600 motor disk Collate Pocket Collate Pocket sensor backstop backstop long short 184 2150 Head Power Supply Page 5 10 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 181 128 Lenze Closer Reverse Drive Brake 181 129 Lenze Insert Pawl Drive Brake 182 8320 Wetter fluid probe link 182 8330A Ribbon Cable 180 702 Envelope Wetter PCB 180 759 Splitter PCB No1 Page 5 11 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 179 109 EC30LL P 179 110 EC30LL Input Conveyor Collate Entry FAST Clutch OF mp Op sj Ss 180 720 PCB Assy AM4 Processor arnt duod
131. ervicing Issue 1 Mar 2010 3 12 Adjustment of fingers 5 Slacken the backstop screw and repeat steps 2 to 4 to adjust the other side 6 Check that the adjustments are correct by actuating both solenoids together and ensuring that the settings have not changed If necessary make corrections Only the outer fingers are adjusted with the finger assem bly in situ it must be removed for the inner fingers Note as an alternative to using the backstop screws the solenoid can be be compressed by hand and with the screws loosened adjusted as de i scribed whilst holding the straight edge in place Outer Fingers To avoid flexing of the actuator bar the outer fingers are actuated bv a so lenoid on each side The fingers are therefore individually adjusted The solenoids can be actuated in Engineer mode diagnostics L To operate the machine close the top cover and place a mag l Ensure the envelope net over the side cover interlock switch feeder is removed see section 3 6 2 Onthe side not being adjusted turn down the back stop screw shown in Fig 12 so that the pivot lever is fully raised Be careful not to strain it Lock the screw 3 Onthe side being ad justed pull down the solenoid by hand so the fingers are fully forward The top surface of the fingers should now be at the same level as the centre insert plate To check prop the insert plate with a screwdriver or similar to prevent it com pressing the springs
132. hes brakes solenoids etc The relevant exploded view and wiring diagram for each component is indicated in the list below See also section 5 2 for pictorial illustration of the physical locations of key components on the drive and operator chassis sides Insert Head Component P N PFE P N SAP Drawing Wiring Motors Main drive motor assy 230V A2 1057 A 91101122 4 15 5 13 Main drive motor assy 115V A2 1056 A 9110111Y 4 15 5 13 Motor W D 179 093 Hybrid 181 050 9100779C 4 1 5 11 Motor W D Pump 24V 181 0890 9110257A 4 3 5 12 Motor W D 179 802 Fingers 181 070 9100788M 4 18 5 12 Motor W D 179 802 Side Guide 181 070 9100788M 4 20 5 12 Motor W D 179 802 SM Env Sep 181 0850 9108955U 4 7 5 12 Motor W D 179 056 Env Conv 181 0870 9109558X 4 10 Sls Motor W D 179 802 Env Tract 181 0810 9110054P 4 8 5 12 Motor W D 24V Blower SM 181 1630 9109557W 4 12 5 12 Solenoids Solenoid W D 179 3450 Short 181 1600 9109569J 4 2 5 12 Solenoid W D 179 3450 Long 181 1600 9109569 4 2 5 12 Solenoid W D 179 3450 Ex Long 181 1600 9109569 4 3 5 11 Solenoid W D 179 3550 Finger Op 181 1610 9109568H 4 19 5 11 Solenoid W D 179 3550 Finger Dr 181 1610 9109568H 4 18 5 12 Solenoid W D 179 3550 Finger Mid 181 1610 9109568H 4 18 5 12 Solenoid W D 179 3550 Wetter 181 1610 9109568H 4 22 5 12 cont Page 5 6 Maximailer HD Service Manual Component Clutches amp Brakes Closer reverse drive clutch Closer reverse drive brake Closer forward drive clutch Inse
133. hich respond over a graduated ranges AEN are net Displays the status open or closed of all operator opening covers and hopper interlocks This will indicate if a reed switch has failed or The screen displays the On Off status of each sensor To check if a is badly adjusted sensor is working it should be On when blocked Off when clear Any semnsor that does not respond this way should be replaced luma PT Lese Dua k Collate Pat Soda Guda aim Select Unik Module 0 Head Module 0 Head Select each module as required using the Select Unit button Select each module as required using the Select Unit button Page 3 30 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 Power Miscellaneous Displays the voltage or current drawn by each component The com Displays the total count for each module For insert head Feed ponent name indicates the nominal voltage current while the display Count 1 is the number of envelopes fed Output Count is the number indicates the actual rating of filled envelopes ejected and Pack Count is the number of packs that have arrived at the collate area for insertion into the envelope For tower folder feed counts 1 to 4 relate to the hoppers where hopper 4 is the hand feed hopper Micara Prova Core ard AA spy aa Comiral Board Sj upy EI Comins Board 13V
134. ide cover which must be removed first in MM f order to access the screws see 3 5 1 Most other covers will either not require removal or should not present a m l problem to do so The skirt is secured with 2 screws and 1 nyloc nut The front screw is shown in the figure above the other is located in a similar manner midway the nut is located at the back end 2 hooked lugs on the lower edge secure the bottom of the skirt When replacing the skirt ensure the lugs are properly hooked onto the chassis before replacing the screws nut Page 3 Maximailer HD Service Manual 3 6 Removal of Envelope Feeder 1 The envelope conveyor must be removed before the feeder assembly is lifted out of the chassis a E ay Drive side 2 Remove the screws marked C on both the drive and operator side Figs 1 amp 2 3 Unclip the ribbon cable and lift it out of the way 4 Disconnect the ribbon cables from the PCB Rika amp N L J W88BBEE a e RENE Our EB C NINE ge KI ERE EN bU at X NN 3 VS N D Open the sealer cover under the conveyor and lift the conveyor away from the feeder assembly A Disconnect the sensor cable on the inner edge of the con veyor as it is being withdrawn Maintenance and Servicing Issue 1 Mar 2010 Remove the screws marked F on both the drive and operator sides Figs 1 amp 2 Remove the 6 feeder Lift the feeder assembl
135. ide cover reed switch Closer cover reed switch Power Supply Unit C4 Universal Head PSU C4 Mains Input Hardwired SECTION 5 2 1 ELECTRICAL COMPONENTS PHYSICAL LOCATIONS Electrical and Circuits Wiring P N PFE 180 759 180 759 180 759 180 760 180 759 180 759 180 760 180 759 182 417 182 418 182 494 184 2150 184 2250 P N SAP Drawing Wiring 9100744R 9100744R 9100744R 91007455 9100744R 9100744R 91007455 9100744R 9105287Y 9105294F 9101032R 9109570K 9110180V The following pages show clutches brakes solenoids PCBs ribbon cables etc that are external to the chassis sides both drive and operator Note that other components are internal and can be found from the refer ences in the previous section 4 3 4 2 4 2 4 4 4 6 4 1 4 18 4 6 4 3 4 3 4 1 4 25 4 26 U U U U U U U Ul 12 12 12 12 12 12 12 12 5 14 5 11 5 12 ome Li 11 Issue 2 Mar 2010 Page 5 8 Maximailer HD Service Manual Electrical and Circuits Wiring Issue 1 Mar 2010 179 109 EC30LL Drive Side Key Components ee see also part 2 pickup clutch em 182 8330F Ribbon Cable 179 110 EC30LL 179 109 EC30LL drive clutch a 2 i YLW Envelope _ T EM 7 5 lower drive 4 b SS Zap UNDE clutch l ep b N m 180 746 Hybrid motor disk sensor 181 129 Lenze Closer reverse drive brake 181 128 Lenze Insert pawl drive clutch d 181 128 L
136. iler HD Service Manual Maintenance and Servicing Issue 3 Aug 2011 ITEM 10 54 55 56 58 59 61 62 63 64 65 67 70 71 72 73 74 75 76 77 78 79 O Piel RPE N NI NI EI NINI NINIE Page 3 34 Maximailer HD Service Manual Section 4 Exploded Views Section Description Page 4 1 Chassis Drive Sido Froni eee 4 2 4 2 Chassis Drive Side Rearb 4 5 4 3 Chassis Operator Side 4 8 4 4 kt i FIN Me 4 11 4 5 Sp MT 4 14 4 6 Envelope Feeder Assy A2 1064 A 4 16 4 1 Envelope Separator Assy A2 1065 A 4 19 4 8 Envelope Tractor Assy A Z 710p A i 4 21 4 9 Envelope Feed Shaft Assy A Z 710pG8A 4 23 4 10 Envelope Conveyor Assy 1066 4 25 4 11 Envelope Conveyor Backstop Assy A2 1200 A 4 28 4 12 Collate Pocket Clam Assy A2 1069 A 4 30 4 13 Head Input Conveyor Upper Assy A2 1054 A 4 33 4 14 Head Input Conveyor Lower Assy A2 1055 A 4 36 4 15 Motor Assy A2 1056 A 115V A2 1057 A 230V 4 38 Exploded Views Section 4 16 4 17 4 18 4 19 4 20 4 21 4 22 4 23 4 24 4 25 4 26 4 27 4 28 4
137. ion of Settings section Page 3 24 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 Calibrations tab Note also that the collate pocket side guides are adjustable for taper and are factory set to taper intowards the closer end The 210mm setting above applies to the narrowest D point the widest point is set to approx 3 4mm wider either EA side Specific jobs may require a diferrent setting to adjust slacken the screw near the middle of the guide and twist the Set Collate Pocket Guide to 210 mm Calibration 0 1mm KA Change Iw E g Beal m guide to suit Module 0 Head This screen applies only to the insert head and is used to set the collate pocket side guides and the insert fingers to A4 size 210mm When these options are selected the motors for the settings will automatically adjust to the cor rect size They should then be measured and any difference Should be corrected out using the adjustment boxes posi tive numbers increase the width Note that the measured distances should be 210mm exactly Appropriate clearances will then be automatically applied by the software which will suit most job applications It it is required to alter the settings use the adjustment boxes as described above These settings will then remain until set otherwise Page 3 25 Maximailer HD Service Manual Hybrid Motor Calibrations tab Current
138. la Ad RST TY cik ae noen 7 D16 510 IP4 E vss HH I e OP14 OP5 U19 74HCT273 l OP15 012 t kd D70 U21 AD5204BRB0 100 Siwe a 2 OUTOA 330R OP16 OUTS SiC R100 470R 10D1 4 5 R43 330R OUT1O 55 v l IPPUS 22D ui IGP2 re ome el R44 330R ou FZT1053A D17 S1G 23 5 R183 1K IPA R45 4K7 IOD3 8 9 R46 330R OUT12 VCC e Wa NPR TK 9 B4 Q4 IPSDRV 0 6 IPS 22 7 R184 P2 R47 AKT J11 J10 IOD4 13 12 R48 330R OUT13 J2 Q13 Q14 t t D94 R110 470R is NGHD P3 R49 HI Vcc vec IoD5 14 B Gelee R50 330R OUT14 B BC846B RS1 100R OUTE sic i l IPPU6 al R163 P4 R52 4 1 i VCC f re 7 16 R53 330R OUT15 IP5 20 10 AKT IP5 R54 AK ANO IODO IODO 10D7 18 Q 19 R55 330R OUT16 2 PsD R56 OR FZH053A D18 S16 IP6 2 m t Ce R57 HI 3 ANI ipi 3 IDD D8 08 PS y a P24 IP24DRV 4 CD 4 R114 470R A2 IP7 IP18 R58 a AN2 IOD2 TODD OPSTOTEWR Wh ak i R58 R Q15 D95 4 IPPU7 18 E Sil 8 IPB IP19 R60 AKT ANS I9D3 j IOD3 RST 1 CR IP23 IP23DRV OUT7 S1G 17 8 AN4 IOD4 IOD4 i M IP7 IP18 16 MI LN M 7 AN5 Iop5 7 IOD5 P20 IP10DRV FZTIOS3A 9 D19 sic R115 4705 B1 4 8 AN6 IOD6 8 IOD6 U20 74HCT273 IP2ODRV 016 CDL i l IPPUB TAN 355 b 1o ANT 1007 E oz lopo 3 gt mE R61 330R QUT17 er IP1 BC846B mi R62 100R Q17 D96 14 W3 IPS R63 4K7 AN8 GND i IOD1 4 55 EA 5 R64 330R OUT18 IPTOD OUT8 Sic IPB IP19 13 11 IP10 R65 AKT IOD2 7 6 RBG 330R OUT19 11 B3 vss Ki D RES FU 12 AN10 12 IR g B 93 Tg R69
139. lace In most cases sensors connect to a ribbon splitter PCB which in turn connects to a Module or Control PCB Wir ing diagrams showing the connections can be identified below and found at the end of this section Physical locations of the sensors are shown on the relevant exploded view section number whose reference is shown below The list in the exploded view will also reference to this page The relevant wiring diagram section number is also referenced below The part number of the cable sensor assy is shown and the Splitter Module or Stepper PCB Connector that it con nects to Insert Head Sensor P No PFE P No SAP Drawing Ref Wiring Envelope feed RX 182 444 9101014X 4 6 S3 5 12 Envelope feed TX 182 443 9101013W 4 6 52 5 12 Envelope deskew RX 182 445 9101015Y 4 6 S4 S 12 Envelope deskew TX 182 337 9100975G 4 12 S2 Seld Envelope flap RX 182 439 9101009S 4 4 S1 Sdz Envelope flap TX 182 443 9101013W 4 6 S1 5 12 Envelope in hopper reflective 182 8310 9109571L 4 6 S5 5 12 Envelope conveyor flag 180 776 9110109W 4 8 51 5 12 Collate pocket input RX 182 342 9100980M 4 4 S2 5 12 Collate pocket input TX 182 340 9100978K 4 13 S1 Sls cont Page 5 2 Maximailer HD Service Manual Sensor P No PFE P No SAP Drawing Ref Wiring Collate pocket load RX 182 3394 9100977J 4 4 S3 5 12 Collate pocket load RX 182 3394 9100977J 4 17 S1 5 12 Collate pocket load TX 182 337 9100975G 4 12 53 5 12 Collate pocket RX
140. ld be 149mm and F2 amp F3 should be O For Letter Length A should be 140mm and F2 amp F3 should be 0 Module 2 nT Envelope Reverse Position Cal Adjusts amount of envelope forward travel after flap wetting before reversing to enter sealing rollers Posi tive further forward into rollers towards exit direction Envelope Seal Position Cal amount of envelope travel into seal roll ers Positive further forward away from exit direction 3p3h Folder Please select and modify settings Envelope depth Measured auto measured depth of envelope which Address Position will be displayed Adjust up or down to suit actual envelope size Posi tive greater Ins Pawl Stop Position Cal Adjusts stop position of insert pawls be hind insert pack in collate pocket If the pawls are stopped too high by lege oder in the software inserts entering the collate pocket will contact the tips 149 hence position must be adjusted back Positive further forward Pocket Backstop Cal As inserts enter the collate pocket thev contact a backstop to prevent overrun and stop The backstop is then lowered and the insert drives forward This setting increases the time delav before the insert drives forward Use if backstops are slow to drop for anv reason causing crashing If set to Off backstop remains lowered alwavs Feeders dual only Collate Feeder 2 Cal Moves the form in hopper 2 to adjust collate point Positive further forwa
141. ld roller If forms are not entering a fold plate when they should gap must be increased and vice versa Units are 0 1mm of motor actuator which equates to 1mm at beam tip Positive numbers only c alignment of leading edges when collating before feeding Applies to feeders 2 amp 3 Units are 1mm and positive further for ward Cardfolder adjustment of FP1 Up Cal Controls paper travel into FP1 in up position Positive further Factory default 4 Mk 1 2 FP1 Down Cal Controls paper travel into FP1 in down position Posi tive further Factory default 0 Mk 1 2 FP2 Up Down Cal As for FP1 Factory defaults 0 amp 0 Mk 1 only Page 3 23 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 FP2 Clockwise Cal Controls paper travel into FP2 for CW rotation from operator side Positive further Factory default 0 Mk 2 only FP2 Counter CW Cal Controls paper travel into FP2 for CCW rotation from operator side Positive further Factory default 0 Mk 2 only Up Detent CW Controls detent landing position for cassette home position Positive increases rotation Factory default 0 Mk 2 only Down Detent CW Controls detent landing position for cassette after 180 rotation Positive increases rotation Factory default 0 Mk 2 only Up Down Detent Counter CW As for CW but rotating Counter CW Factory defaults 4 amp 3 Mk 2 only Conclus
142. llers take care not to damage the To remove the rollers this can be done with the envelope feeder in place lower roller as it is refitted Do not get grease on the rollers but the sealer assembly will have to be removed first see section 3 17 Having done so proceed as follows SEU Drive side chassis rollers Sealer Assembly Rollers p B n 1 Open the sealer assem bly and remove the clutches gears E clips bearings and waved washers indicated in Fig 22 Slacken but do not remove the clutch location bracket to facilitate this 1 Open the sealer assembly and on both sides remove the bearing springs shown in Fig 2 Remove the E clips on the ends of both sides of the uppermost roller only 3 The roller sub chassis can now be lifted out of the sealer assembly and the rollers re moved 4 Reassemble in reverse order to replacement Operator side chassis rollers 2 Remove the clutch gears E clips bearings and waved washers indicated in Fig 23 Remove the screws for the float switch bracket to facili tate this but do not remove the bracket Page 3 18 Maximailer HD Service Manual Maintenance and Servicing 3 17 Removal of Sealer Assembly The sealer assembly can be quickly removed for replacement of sealer roll ers see section 3 16 Proceed as follows 1 Open the sealer assembly and remove the pivot screw on each side Fig 25 shows drive side operator
143. lt 2Z22222222 lt 2 Page 4 34 Maximailer HD Service Manual Item Part No 41 G1185A 9105590P 42 G1206A 43 G4092A EE G1 0289 A 9111631G 45 E0425A 9110007Q Fixings 50 E2826A 51 E2832A 52 E2830A 53 E2 0858 A 54 E3505A 55 E5092A 56 E5073A 57 E5076A 58 E5086A 59 E5105A Spares assemblies SAT AO 0560 A 9110104R SA2 9110105S 4 13 C4 Head Input Conveyor Upper A2 1054 A 9110107U Exploded Views Description SPRING LATCH LH OVERGUIDE SPRING BRIDGE CLAMP SPRING CONV INPUT WASHER 10 2 x 17 x 2 M4 x 8mm TORX PAN HD SCREW M4 x 10mm TORX PAN HD SCREW M4 x 12mm TORX PAN HD SCREW T T M4 x 16mm TORX PAN HD SCREW M4 NYLOC NUT 12mm E TYPE CIRCLIP 9 5mm E TYPE CIRCLIP Zmm E TYPE CIRCLIP PIN DOWEL 3 DIA x 16mm PIN DOWEL 3 DIA x 24mm CONV P WHEEL SHAFT ASSY CENTRAL OVERGUIDE ASS Y Qty eNO Ov N OY N N S O N A R A R Issue 5 Feb 2012 Spares Y N See Spares Assy 2 N Y Y SEE FIXING KIT FOR THIS ASSEMBLY A0 0562 A 9110106T NOTE FIXINGS ARE NOT AVAILABLE INDIVIDUALLY Page 4 35 Maximailer HD Service Manual Exploded Views Issue 4 Mar 2012 F1 0461 A x6 C2 1036 A x6 PULLEY 25T XL Fs120A x15 CONVEYOR ITEM 13 BELT SET WHEEL 130XL 037 ITEM 3 ITEM 14 4 14 C4 Head Input Conv Lower A2 1055 A 9110116D Page 4 36 Maximailer HD Service Manual Exploded Views
144. ma Linear Speed mm s More Hybrid Motor Calibrations Hybrid Motor Calibrations Calibrate Motor Statue pem Hybrid Motor Control Linear Speed mmis Current ma Voltage V Module 0 Head This screen applies only to the insert head and is used to calibrate and test the hybrid motor This should not nor mally be required as the motor is factory calibrated but if operating problems may indicate the motor it should be carried out The machine should be clear of stationery when doing so When the Calibrate button is selected the motor slowly increases in speed up to a maximum and sets 4 calibration points as it does so low medium normal amp high These unitless points are displayed in the Settings cell The linear speed of the paper current and voltage are also displayed Selecting the Speed button allows the motor to be tested at low medium and normal speeds The motor will continue running until Off is selected Settings Calibrations Hybrid Motor Calibrations Maintenance and Servicing Calibrate Calibrating we seams 0 51 Issue 1 Mar 2010 Page 3 26 Maximailer HD Service Manual 3 18 3 Firmware Download Firmware downloading allows selected units to be upgraded with se lected files usually sourced from the company website Select the unit s to be upgraded and use the Files button to find the appropriate am4 file s Note that each fil
145. mum If the machine is running less than this the PM visits should still be carried out with the same frequency but fewer parts will be required e DS300 Maxi HD Duty Cycle 350k Month 4 2 million year 4 PMV year pm every 3 months e DS200 Maxi HD Duty Cycle 200k Month 2 4 million year 2 PMV year pm every 6 months e DS100 140 Feeders Duty Cycle 200k Month 2 4 million year 2 PMV year pm every 6 months Note If feeders are running at same duty cycle as the machine 4 PMV year pm every 3 months Click here to view the full PM Schedule Page 3 4 Remove envelope conveyor and backstop Pulleys Replace after 4million Clean all spring loaded bearings and Regrease Belts Replace after 6million Clean shaft and regrease Bearings Replace after 8million Check side guides are movingly freely x e ij Clean shafts li and regrease nam Clean and regrease all spring loaded bearings Ensure side guides are tapered to feed the envelope freely into envelope pickup Remove envelope feed assembly Slotted feed wheel C8194A Check all feed tyres replace if needed l Replace after 2million Clean and check gears on track assembly Feed tyres C8 0209A Clean and grease bearings Replace after 2million Clean all feed tyres replace if needed ITEM Maintenance Item Head Unit A2 cont Clean and check gears on track assembly Clean and grease bearings A3 Remove sep
146. nance and Servicing 3 9 Removal of Collate Pocket Clam Assembly The collate pocket clam assembly pivots on a spigot post each side Remov al entails taking out the spigot on the operator side only Removing the assembly is quick to carry out and allows much improved ac ces to the collate area 1 On the drive side trace the sensor cables for the assembly back to the chassis hole detach them from the clips and disconnect them from the PCB 2 Onthe operator side remove the clutch gear idler and gear indicated in Fig 6 Slacken the clutch locators to allow this 3 Remove the spigot indi cated in Fig 7 whilst holding the collate pocket clam as sembly Free the assembly from the other spigot and lift it out of the chassis leading the chassis cable out as it is removed 4 Reassembly is a reverse of removal Issue 1 Mar 2010 Page 3 11 Maximailer HD Service Manual 3 10 Replacement of collate chains or chain pawls Before removing the collate chains the Envelope Feeder N see 3 6 and Collate Pocket Clam see 3 9 must be re moved to allow access The collate chains need checking as Preventative Maintenance only every 2 million envelopes and will not normally need replacing However if they break or otherwise become damaged proceed as follows The chains can be replaced complete with pawls or one or more pawls only retaining the chains The chains must always be replaced as a pair 1 R
147. nd and undamaged Page 1 4 Maximailer HD Service Manual Installation Page 1 5 Issue 1 Mar 2010 Y 1 3 ASSEMBLY OF MAXIMAILER HD HEAD ONTO STAND a e E 1 3 1 Assemble the HD head stand to the single stand supplied this will ma replace the previous Maximailer Plus stand that supported a single Maximailer HD module as well as the insert head Insert Head 1 3 2 Lift the Maximailer HD head onto the stand ensuring that the Maximailer HD Head Stand Wetter pipes passed through stand into bottle Sealing Fluid 1 3 3 wetter tube passes through the hole in the top of the front section of the stand Caution The machine is extremely heavy and will require a number of people to lift it Do not attempt to lift if you do not feel confident to do so A Place the sealing fluid bottle and PC into the stand as shown Do not connect the PC at this stage Pagel 5 Maximailer HD Service Manual Installation Page 1 6 Issue 1 Mar 2010 1 3 4 Screw all stands together and fit the supplied attachment bracket R2904T to the end stand Note Use holes marked L This is Datacard machine required for the alignment of the wider Maximailer HD and Datac shown connected ard system to attachment bracket 1 3 5 Lift all feed modules if applicable and the DTI onto the stands Assemble them together using the supplied screws Attachment bracket R2904T End module stand Note Viewed from abov
148. nels and run the machine to check that the chains operate correctly Page 3 12 Maintenance and Servicing Maximailer HD Service Manual Remove the 3 11 Removal of Finger Assy finge asSy Before removing the finger assembly the envelope feeder assembly must be removed first see previous section 1 The finger assembly is withdrawn from the drive side of the chassis after disconnecting the pivot shaft on the operator side Operator side Fig 11 84 uuo 1 A lt KA 2 Onthe operator side re move the E clip on the end of the pivot shaft Do not remove the solenoid from the chassis y Drive side a Backstop 3 Onthe drive side remove the screws indicated 4 Disconnect the ribbon cable from the PCB and unclip it from the finger chassis Issue 1 Mar 2010 Withdraw the finger assembly from the chas sis folding the fingers clear of obstructions Do not apply undue force when remov ing the assembly or the fingers may be damaged Reassembly is a reverse of removal With the envelope feeder removed the fingers should also be adjusted see the following section Note to adjust the inners fingers the finger assembly must also be removed from the chassis Solenoids and solenoid springs can be ob tained as separate items but the rest of the assembly can be obtained only as a complete spare Page 3 13 Maximailer HD Service Manual Maintenance and S
149. ntenance Item Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete Complete Interval cycle Page AS Remove upper Input convevor assemblv Belts 140 XL F5120A Check and clean all upper transport belts 4 in set 6 belts required Inspect and clean after 500 000 Clean and regrease sprung loaded bearings Clean feed rollers Rollers Inspect after 2 million Bearings Inspect after 2 million ITEM Maintenance Item Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete Complete Interval cycle Page Clean lower input conveyor belts lOmins Belt 130XL F5120 A Inspect after 2 million Lower input conveyor belts Sprung loaded Bearings Sprung loaded bearings and springs Inspect after 2 million ITEM Maintenance Item Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete Complete Interval cycle Page Lead screw A10 Check clean and regrease finger assembly 30mins Ensure fingers are not sticking on lead screw shaft or Catching on frame of machine remove and check if needed 5 3 b in a Check inner and outer finger tips for wear replace if needed an Aic me i Tp M Inner finger tips Inspect and replace after 1 million Outer finger tips Inspect and replace if needed after 2 million a Outer and inner p g Finger tips ITEM Maintenance Item Head Unit
150. on of Insert Feeder 2 5 2 5 Description of Tower Folder 2 6 2 6 Description of Feeder Folder 2 7 Page 2 1 Maximailer HD Service Manual Description SECTION 2 DESCRIPTION OF OPERATION 2 1 General Description The machine is a high volume folder inserter capable of up to 200 000 cy cles per month at a speed of up to 4500 filled envelopes per hour DL with 1 insert It is of modular construction and consists of an insert head and any or all of a insert feeder b tower feeder c mark reading feeder d feeder folder d tower folder with built in tower This may be fitted with either 1 or 3 trays and an optional accumulator for collating diverting with or without a diverter tray It is always fitted in the end station position The insert head also includes a collator as well as the envelope hopper wetter and closer Collation can be carried out a number of ways depending upon the particu lar job The software works out the optimum feed pattern as well as the best feed units to use if more than one possibility exists Collation possibili ties are m Using the accumulator in a 3 tray tower folder 3 forms are fed into the accumulator folded and ejected on towards the insert head 2 Collation on the track a folded sheet or insert is timed to trail ing edge collate with the document fed from the following feed unit
151. ont vertical cover 3 6 Drive side lower skirt 3 Upper cover 3 7 Removal of envelope feeder 3 8 Removal adjustment of envelope separator 3 9 Replacement of envelope conveyor belts 3 10 Removal of collate pocket clam assembly 3 11 Replacement of collate chains pawls 3 12 Removal of finger assembly 3 13 Adjustment er del S PE 3 14 Removal of side guide adjust assembly 3 16 Sect 3 14 3 15 3 16 3 17 3 18 3 18 1 3 18 2 3 18 3 3 18 4 3 27 Maintenance and Servicing Adjustment of side guides Removal of power supply Removal of sealer rollers Removal of sealer assembly Engineering mode Hardware setup Units setup Firmware download DIagnosli68 Recommended Spares Parts List Issue 1 Mar 2010 Page 3 1 Maximailer HD Service Manual 3 1 Health safety and environment 3 1 2
152. ounding feature provides extra protec tion in the event of an electrical problem The apparatus must be earthed As the colors of the wires may not correspond with the colored markings identifying the termi nals in your plug proceed as follows The wire which is colored GREEN must be con nected to the terminal in the plug which is marked by the letter E or by the safety earth symbol or colored GREEN The wire which is colored WHITE must be con nected to the terminal which is marked with the letter N The wire which is colored BLACK must be con nected to the terminal which is marked with the letter L Warning The mains input supply is fused on both live and neutral sides Service personnel should be aware that a mains voltage can exist even if no lighted neon shows Installation Warning Most of the moving parts are protected by covers Don t operate the machine unless all of the covers are in place Opening cov ers include safety interlock switches If a cover is opened the switch will stop the machine from running Don t try to bypass the interlocks and don t use the machine if the interlocks are not working Warning Don t wear any loose clothing when you are working near the machine If a bit of clothing becomes caught in one of the moving parts you may be pulled into the machine very quickly This force can be surprisingly power ful you may not be able to resist it Take care with neckties sashes long sleeve
153. ows their calibration The read only displays translate as follows Example T 2 6V 222 R 12 C 0 2V Where T Threshold voltage generally over 2 5V I current required to read across the sensor halves R of pot value on PCB C or B clear or blocked and sensor voltage effort of Percentage which should lt 0 5 clear gt 4 5V blocked Golenakis Matos Digit een Cavers Fe Ben alice iri iriri Dec sie Collate Peek Load Cal Peck a Erra Ba mhi asas Erra Map iva Fred ET W e 1 Chan aal Chem DHA 344 Balen Unk Calibration Module 0 Head De ELITSE ca aaa cow EH us Eds gs cam ca ream ae Rees cum EN Tet Ie Re CAN remises casv el Pe s Can EN Tal EV la PLR W Xo Sensors can be calibrated individually or all together by using the Cal All Paper sensors button Generally the readings are best used as a comparison guide for like sensors from one machine to another However if a sensor has failed the readings are likely to be very low or zero Select each module as required using the Select Unit button Digital sensors Page 3 29 Maintenance and Servicing Issue 1 Mar 2010 Maximailer HD Service Manual Analoque sensors are those that respond over a graduated range unlike digital sensors which are read as either On or Off They are usually adus
154. pel 13 R290 CB4 1000pF R259 R260 R261 Expansion 10 jf si KA Interface m ent 1K 22K 10K 32 JN LM339D S3 R240 BZX84C12 c79 1000pF R257 1K R262 21 U11B U48A lt 24V E 4 a P i o 1 5 A BS R202 1K s oum ORO47 10K 4l SCREEN CONNECTION R252 1K 2 uer Masa 74HC14 5 R230 470R mae o 2 ZXCT1009 i i R203 1K 5 6 yas f z x U53 U48D w S D110 4 is 4 188 oer Vcc R235 470R 74HC14 5 ed P U3 a ZXCT1009 gt 1 OCUR A U11D 8 6 3 8 R204 1K LM339D d e 6 J19A 13 12 9 U48C JN R268 LM339D 220K VEG RS Ors B D82 4 m BZXBAC12 lt F e CAN2TX TXD CANH 1 JCANH 74HC14 A E C90 1000pF f NL CT AN LM339D 4 BESTE CAN2RX lt lt RXD CANL 3 CONTA BZX84C12 Bos 4 CONTB 2 5 C80 1000pF ee E i N GND VREF O 5 RELA 4 Wi 6 RELB ik i j EN es PCAB2C250T 3 ous R253 cL 8 GND Title Q70 RA66 R267 O tuF ne C4 Control Mk 2 Part 1 180 8360 R248 1K4 NT R263 R264 C85 RELAY EL E Document Number Rev A 10K 10K 6 1uF BCBABB 4K7 AK7 ne 127 2920 cct 1 Date Thursday August 20 2009 Sheet 2 of 9 9 k Section 5 3 Control PCB Circuit Diagram part 1 Page 5 14 Maximailer HD Service Manual 1 Splitter Board Splitter Board 2 Splitter Board 3 Splitter Board 4 Splitter Board 5 Splitter Board 6 Splitter Board 7
155. per C4 Feeder 2 Module 4 Module 4 Hopper Module 5 Module 5 Hopper Module 5 Hopper Module 6 Module 6 Hopper Module 6 Hopper Module 7 To make changes select the Edit tab Select each unit in turn in the left hand column choose the unit type in the centre column and select the required options in the right hand column Extra settings relating to readers are shown in the pane on the right hand side For Feed fold units the read ers fitted are selected with the module highlighted then the reader options for each hopper are selected with the module hopper highlighted To view all settings without making changes select the View tab and select each module or its hoppers To add new modules to the end of the existing ones use the p button and configure to suit cont Page 3 20 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 4 3 18 2 Units Setup To delete existing modules use the button Important modules are deleted from the end If a module is removed that is not the end module This allows adjustment of various settings depending upon the module se all module settings after that one must be re configured lected using the button at the bottom However in practice when a module is added or removed providing that the DIP switches have been correctly set the modules can be automatically re configured using Plug and Play see later in this section for details Set
156. r motor end stop drive The forms are fed into fold plate 1 or 2 depending upon fold type where the leading edge contacts the motor driven end stop forming a buckle This buckle is driven through the next set of fold rollers and into the next fold plate where a similar action is performed They are then finally driven out onto the track their exit being monitored by the track exit sensor Page 2 6 Maximailer HD Service Manual Fold plate settings are automatic in operation set by the data input in the job setup or more usually by the automeasure facility using standard form sizes Fold plate that are not used are blanked off by a no fold beam actu ated by a lug attached to the motor driven end stop The accumulator can also be used for diverting forms for subsequent hand removal the cover over the conveyor can be raised or if the optional di verter tray is fitted at the top end of the accumulator the forms will be fed directly into it passing the divert bin sensor confirms their presence Note that diverted forms will always pass into the divert tray if it is fitted The accumulator is an optional item and if it not fitted there is no divert facility and a maximum of 3 forms can be folded together If more than 3 forms are to be fed these will be folded singly and fed onto the track one after the other then collated together in the collate pocket in the insert head Daily post This function will be enabled if Handfeed
157. rack sensor They will then be fed together with trailing edges collated into the conveyor of the next feed unit or the insert head conveyor TRACK SENSOR CONVEYOR CLUTCH CONVEYOR BRAKE All feed unit conveyors can operate independently but normally move in unison and will only stop if for any reason an expected insert for collation has failed to arrive at the exit hold point sensor this would only be result SLOTTED DISC of a fault condition such as a paper jam or hopper empty Fig 6 Page 2 5 Maximailer HD Service Manual 2 5 Description of Tower Folder see Fig 7 below The 3 plate tower folder may be fitted with either 1 or 3 feeder trays If OMR or Barcode reading is being used the reader is fitted to either or both of feeders 1 or 2 top or bottom read barcode reader on feeder 1 bottom read only An accumulator may optionally be fitted to allow up to 8 sheets of 80 gsm paper to be folded together or it may be used as a diverter for hand removal As a further option a divert tray may be fitted for forms to be diverted into A hand feed daily post tray is fitted to allow up to 8 sheets of 80gsm paper stapled or not to be folded and inserted The folder unit allows for a wide range of fold options on forms up to 16 406mm length and it can be opened up for jam clearance r de Desken Pre feed sensor
158. ral am Comins Board 244 anb pred cur ami mm Eat DEN El TREN 14 ribs L HI NE a sepgdy 15513 Erp 6 165 P tz Saraya seid sepa LED ET Tai ip Pi rai dis con ca a ra li Ep fi carat exc buds moter Ep Hrbsidi maler umami am Select lift Module 0 Head Module 0 Head Select each module as required using the Select Unit button Select each module as required using the Select Unit button Page 3 31 Maximailer HD Service Manual Maintenance and Servicing 3 19 RECOMMENDED SPARE PARTS Shown below are the spare parts recommended to be held by Service Agents Quantities shown are per machine Consumable items are marked in the right hand column these might need to be ordered more frequently To obtain a 230V list order part number A0 0530 A 9110259C To obtain a 115V list order part number A0 0531 A 9110260D ITEM P N PFE P N SAP DESCRIPTION 1 A2 1057 A 91101122 MOTOR ASSY 230V MOTOR ASSY 115V CLUTCH EC30LL CW 8mm 24V MTR W D 179 093 IN LINE CLUTCH W D 179 155 2WXH BRAKE W D 179 105 2WXH SOLENOID W D 179 3540 XH LOOM C4 HYBRID MTR LINK PCB ASSY ENV WETTER PCB ASSY AM4 PROCESSOR PCB ASSY AM4 CNTRL BRD PCB SPLIT 5SEN 5SOL H D PCB WIDEBODY DISK SENSOR PCB C4 EXPANSION MTR ASSY PERISTALTIC 24V LOOM EMITTER 200 SM LOOM RECEIVER N A 200 SM LOOM RECEIVER N A 300 SM LOOM EMITTER 200 XH LOOM RECEIVER W A 200 XH LOOM EMITTER 300 XH LOOM 4W 3W 3
159. rd in steps of 1mm ee Marc For X cancer Feeder Folder Folplate 1 2 Cal amp No Fold 1 2 cal These are the same as 1 amp 2 of the 3 Plate folder see below 3 Save the job and run Measure the length of the first panel which should be 149mm A4 or 140mm Letter If not exit Tower Folder adjustment of Configuration and enter Units Setup in Engineering mode Select a settings of foldplates 1 2 amp 3 Figure shown will be the set the Tower Folder in the module box at the bottom of the screen ting for the job and may be adjusted if required Units are 1mm and this will display the settings boxes for the foldplate calibrations positive greater To set up for the first time or if parts have been see following page replaced 1 Set up a job with the following parameters European Envelope C5 162 x 229 Paper A4 single sheet from top hopper Fold V US Envelope No 7 Booklet 159 x 244 Paper Letter size single sheet from top hopper Fold V Page 3 22 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 Settings Calibrations Hybrid Motor Calibrations Settings More Settings Collate Pkt Cal 0 1mm Fingers Cal 0 1mm Wetter Start mm Env Stop Pos Cal mm Env Insert Pos Cal mm Env Reverse Pos Cal mm Env Seal Pos Cal mm Env Depth Cal Measured mm d D
160. rd with it 7 Indicates a piece of advice tip or quick technique to ce Remem assist in carrying out this operation complet Equipment produced after August 13 2005 3 2 2 Orientation Not only are you by law not allowed to dispose of the waste equipment via Throughout this manual reference will be made to Operator and Drive side other waste streams but we encourage you to actively contribute to the to indicate the side of the machine in question These are defined as success of such collection and to the common good and better quality of life I of present and future generations Operator Side The side of the machine where the operator normally stands viewing the screen The side For more information on the correct disposal of this product please contact covers can be opened by the operator your local dealer Drive Side The opposite side to the Operator side The side covers cannot be opened by the operator and are only able to be removed by the Engineer Gear drive trains are located on this side Page 3 3 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 3 3 Preventative Maintenance Guidance and Schedule The Maintenance schedule on the following pages is applicable to the Maximailer HD product range and must be strictly followed to guaran tee machine performance and reliability This schedule is based on a monthly cycle count of 350k month which is considered the normal maxi
161. rt pawl track drive clutch Insert pawl track drive brake Collate pocket entry slow clutch Collate entry fast clutch Collate entry brake Input conveyor clutch Input conveyor brake Envelope pick up clutch Envelope upper drive clutch Envelope upper drive brake Envelope lower drive clutch Envelope lower drive brake Wetter output drive clutch PCBs PCB Assy C4 Control PCB Assy C4 Processor PCB Assy C4 Expansion PCB Assy Brainless Dongle PCB Assy Env Wetter Electrical and Circuits Wiring P N PFE 151 128 181 129 181 128 181 128 181 129 181 128 179 110 179 109 179 109 179 109 179 109 179 109 179 109 179 110 179 109 179 110 180 8360 180 720 180 8300 180 8320 180 702 P N SAP Drawing Wiring 9100807G 9100808H 9100807G 9100807G 9100808H 9100807G 9108383Y 9108382X 9108382X 9108382X 9108382X 9108382X 9108382X 9108383Y 9108382X 9108383Y 9109914T 9100723U 9108643U 9109590F 9100715L 4 3 4 1 4 1 4 1 4 3 4 2 4 3 4 2 4 3 4 2 4 6 4 6 4 6 4 6 4 6 4 1 4 3 4 3 4 3 4 3 4 3 cont Ul Un U Un U Un unin Ul Un Un Un Un oO Un Ul Ul Un U1 U Uil m 12 12 12 12 12 11 12 11 12 12 12 12 12 12 12 13 Li 11 11 12 Issue 2 Mar 2010 Page 5 7 Maximailer HD Service Manual Component PCB Splitter 1 PCB Splitter 2 PCB Splitter 3 PCB Splitter 4 PCB Splitter 5 PCB Splitter 6 PCB Splitter 7 PCB Splitter E4 Switches Top cover reed switch S
162. s or any other loose clothing Dangling jewelry can also present a hazard Remove any of these items of loosely fitting clothing or tie the loose sections out of the way so they can t be caught by the machine Long hair can also be dangerous when working near this type of machine If you have long hair tie it back or tuck it under a hat Be especially careful around the folding rolls near the center of the machine Caution Keep the machine clean Wipe off the outside of the cabinet from time to time to keep the paper dust from collecting If you notice that paper dust is collecting inside the machine open the covers and vacuum it out or blow it out with an airduster Caution Keep the work area around the machine clean Don t allow paper trim and waste to pile up If the work area includes a lot of loose paper scraps an operator may slip and fall Pagel 2 Issue 1 Mar 2010 BEFORE DISASSEMBLING THE MAIN POWER CABLE MUST REMAIN UNPLUGGED UNTIL END OF ASSEMBLY DO NOT TOUCH INSIDE POWER SUPPLY UNIT TO PREVENT ELECTRICAL DISCHARGE DUE TO CHARGED CAPACITOR ALTHOUGH MANUFACTURER TAKES CARE TO REDUCE RIDGE DANGER PLEASE HANDLE STEEL SHEETS CAREFULLY TO AVOID ALL RISKS OF CUTTING IMPORTANT IN THE EVENT OF ANY EMERGENCY OR TO STOP THE MACHINE FOR ANY OTHER REASON STRIKE THE RED EMERGENCY STOP KNOB NEXT TO THE CONTROL PANEL Page 1 2 Maximailer HD Service Manual Installation Page 1 3 Issue 1 Mar 2010
163. scription MTR W D 179 056 2WSM H1 J13 ENV CONVEYOR BACKSTOP BELT TENSIONER BRACKET ENV CONVEYOR CHASSIS CONVEYOR BRIDGE SIDE GUIDE OPERATOR SIDE GUIDE DRIVES CONV STRENGTHENING BKT GEAR SUPPORT PLATE SIDE GUIDE LOCATOR BRACKET CONVEYOR UNDER COVER CONVEYOR END CAP CONVEYOR INFILL PLATE OP CONVEYOR INFILL PLATE DR SIDE GUIDE ADJUSTOR KNOB SEALER LATCH POST CONVEYOR GEAR POST SCROLL SCREW ENV CONV DRIVE ROLLER ENV CONV IDLER ROLLER SIDE GUIDE SLIDER CONVEYOR DRIVE SHAFT SIDE GUIDE ADJUST SHAFT CONVEYOR TENSIONER SHAFT TYRE JOGGLER T BEARING 8mm 1250 BEARING FL 8x19x6mm F698ZZ PULLEY 12 XL x 8mm GEAR 12 TOOTH CONVEYOR GEAR 40Tx8mm 1 0M GEAR 48Tx8mm 1 0M GEAR 25Tx8mm 1 0M GEAR 20T 1M x 6mm BELT 200XL 037 SPRING HEAVY PRESSURE BELT CONVEYOR HAT 5E 1165x60 WASHER M4 LOCK CAP et B FEE N F F N N N O F A N FF ANNAN N N E R F N Spares e o UM OX CX o o o HC o woe fa uL uL o UM UM um lt lt Z Issue 2 May 2010 Page 4 26 Maximailer HD Service Manual Item Part No Fixings 45 E2 0838 A 46 E2505A 47 E2826A 48 E2834A 49 E3501A 50 E3505A 51 E4033A 52 E5003A 53 E5071A 54 E5073A 55 E5074A 56 E5123A 57 E5111A Exploded Views Description SCREW M4X12MM TORX CSK TAPTITE SCREW M4 SOCKET SETx6 KCP SCREW M4x8 TORX PAN HD SCREW M4x10 TORX CSUNK HD NUT M5 FULL BZP
164. ssue 1 Mar 2010 3 4 4 Potential Hazards Take extreme care if running the machine with the covers open To run with the covers open a magnet will be needed to override the safety interlocks A spare magnet such as fitted to the opening cover 131 824 is most suitable still be present even after switching off at the mains The machine is double pole fused This means that power may Always disconnect the machine from the mains source before re moving covers Don t just switch off Ensure the black inner covers on the operator side are in place when work is finished These covers protect the operator from hazardous areas when the cover is opened When removing items such as the envelope feeder assembly note that some items are very heavy and lifting should not be undertaken unless you feel confident to do so Seek assistance otherwise Page3 5 Maximailer HD Service Manual 3 5 Removal of covers Some or all of the covers on the machine will need to be removed for ser vice operations In some cases where fixing screws are plainly visible re moval is self explanatory In less obvious cases removal is described below When service operations are complete covers must be replaced fully failure to do so could result in a hazard to the operator 3 5 1 Drive side cover Open the perspex top cover and hinge open the sealer assembly below the envelope conveyor Remove the screws shown below accessed from inside
165. table The screen displays the status of analogue sensors and allows their calibration The read only displays translate as follows Example T 2 6V 222 R 12 C 0 2V Where T Threshold voltage generally over 2 5V I current required to read across the sensor halves R of pot value on PCB C or B clear or blocked and sensor voltage effort of Percentage which should lt 0 5 clear gt 4 5V blocked Golenakis Matos Digit een Cavers Fe Ben alice iri iriri Dec sie Collate Peek Load Cal Peck a Erra Ba mhi asas Erra Map iva Fred ET W e 1 Chan aal Chem DHA 344 Balen Unk Calibration Module 0 Head De ELITSE ca aaa cow EH us Eds gs cam ca ream ae Rees cum EN Tet Ie Re CAN remises casv el Pe s Can EN Tal EV la PLR W Xo Sensors can be calibrated individually or all together by using the Cal All Paper sensors button Generally the readings are best used as a comparison guide for like sensors from one machine to another However if a sensor has failed the readings are likely to be very low or zero Select each module as required using the Select Unit button Digital sensors Page 3 29 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 Analoque sensors are those that are read as either On or Off unlike Covers w
166. te paper sensor detects the leading edge of the forms and times the start of the marks from the dis tance input by the user the timing operation is carried out by the encoder disk sensor The form travels towards the accumulator and if further forms in hoppers 2 amp 3 are part of the OMR group they will also be fed into the accumulator following hopper 1 form Their entry into the accumulator is monitored by the collate tray sensor and are prevented from sliding forward by the collation gate sheet Feeder 2 Up to 8 forms can be folded together in this way and when all are in the accumulator the collation gate drops by solenoid ac tion and the conveyor belts drive the forms into the folder If there are more than 8 forms up to 12 in the group these can sheet Feeder 5 be diverted to the diverter tray if fitted or held in the accumu lator for removal If 3 or fewer non OMR forms are to be folded together they are not by default directed by the solenoid into the accumulator but pass directly to the folder They will be leading edge collated ie as form 1 passes hopper 2 that form will be fed so the leading ever on edges align and then on to hopper 3 where the same occurs Sensor Non OMR groups can also be directed in software to use the ac cumulator and be folded together or they can be collated on the track one at a time or if 3 or fewer folded together as described above Belt Steppe
167. tings Calibrations Hybrid Motor Calibrations Settings More Settings Collate Pkt Cal 0 1mm Fingers Cal 0 1mm Wetter Start mm A H Env Stop Pos Cal mm Env Insert Pos Cal mm A H Env Reverse Pos Cal mm Env Seal Pos Cal mm Env Depth Cal Measured mm Ins pawl stop pos cal mm HEEBBEEEEH BUHHHEEHHE H HHI Pocket backstop cal ms Module 0 Head Settings tab This allows adjustment of various settings depending upon the module Module 0 Head adjustment of Collate Pocket Cal amp Fingers Cal These settings are in addition to any changes made in Calibrations see later in this section Use if the settings need to be different from the calibrated sizes Wetter Start Adjusts the point at which the wetter beam drops to wet the flap ve more wetting In steps of 1mm Note this setting applies to the machine and can be further adjusted for the job in Ad vanced Envelope Stop Position Cal Adjusts envelope stop position Positive further forward towards exit direction Page 3 21 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 Envelope Insert Position Cal Adjusts amount of insertion of insert 2 In the configuration screen select the number at the top of pack into envelope Positive further forward past flap crease the fold module icon check the Fold Plate Length settings in the dialog box see below For A4 F1 shou
168. uit Diagram 5 17 5 5 Comms PCB Circuit RTL uU u u ua vaut secs 5 18 5 6 Wetter PCB Circuit Diagram 5 19 5 7 Expansion PCB Circuit Diagram 5 20 Page il Maximailer HD Service Manual Installation Page 1 1 Issue 1 Mar 2010 Section 1 Installation Instructions Sect Page 1 1 1 2 1 2 KONE ee 1 4 1 3 Assemblty of HD Head onto Stand 1 5 1 4 Senna p he Machine qu nea Ti din t 1 7 Pagel 1 Maximailer HD Service Manual 1 1 SAFETY NOTES Warning Do not work inside the machine unless you are a trained mechanic or electrician Stop the machine and disconnect the power cord before you open the machine Only a trained electrician should work with the electrical parts A voltage of 120 Volts may be present inside this machine The power source can produce enough voltage and current to be very dangerous Warning This machine is equipped with a three pronged plug One of the prongs on the plug provides a safety grounding feature Be sure the plug is always connected to a properly wired three prong outlet Do not use a two prong adapter without grounding the machine properly Never remove the third prong from the plug The safety gr
169. us page TXD4 x29 RXD2 a IOD 0 7 gt V 1 9 20 e 2 TXD2 S U61 T RXD3 22 INTA iy 18 1000 23 INTB 4 16 IOD1 KA 1A2 1Y2 1 TXD3 a INTC alee iva 115 1602 U68A 25 INTD 8 12 10D3 INTA d e 26 pp we PH rg OD4 3 REMO ol AS ODS INTB 2 U68C 2A2 2Y2 5 5 OD6 L 9 AR ea OD7 74ACT32 pe REM3 2A4 2Y4 uN b us U68B m ali 9 T A 3 INTC Ap l 74ACT32 74ACT244 INTD RM J IP41T048 ES 74ACT32 U68D 12 11 1345 74ACT32 Title R283 R284 C4 Control Part 3 Comms 180 8360 1K 1K Size Document Number Rev A3 127 2920 cct 1 Date Thursday August 20 2009 Sheet 1 of 3 Na Section 5 3 Control Comms PCB Circuit Diagram part 3 Page 5 16 Maximailer HD Service Manual
170. v 7 Fau 33pF Gur 33pF OluF 33pF O 1uF 33PF OtuF 33pF 0 1uF Tour O3uF OduF O1uF O1uF O1uF O1uF O1uF O 1uoF O 1uoF O 1uoF O 1uF O 1uF O 1uF 0 1uF O 1uF O tuF 0 1uF 127 206 cct Date Thursday June 16 2005 Sheet 1 of 1 e e e e 9 e e e 9 e a 9 E E o 9 o i e e e 9 e A E e O TP1 KA CPU Decoupling Device Decoupling GND Section 5 4 Processor PCB Circuit Diagram Page 5 17 Maximailer HD Service Manual Electrical and Circuits Wiring JI GND P36 IP36 P37 x IP37 P38 S IP38 GND 4 P11 5 PI VCC GND 6 o 7 VCC OP24 OP24 OP28 OP28 OP29 OP29 24v 14 24V J GND RXD4 x RXD4 GND 5 TXD4 B TXD4 GND RXD2 lt RXD2 GND 9 TXD2 CND 21 RXD3 lt lt RXD3 CND 123 P ME TXD3 GND 25 26 VCC JZ IP11 1 OP24 S 24V d RXD2 x TXD2 x RXD3 TXD3 8 9 10 XH R3 J4B 16 S16 1RO RA J5B 10 S10 1RO R5 J6B 10 S10 1RO R6 S1 J2B S2 i 1RO VCC 1 IP36 9 IP37 2 IP38 0 IP11 3 1 24V
171. vailable with either In use both fold plates are blanked off by the no fold beams For forms clearance in the event of a crash the rear roller shaft can be pivoted backwards after removing the hopper Shortform option can be specified with the unit or retrofitted 3302 Handfeed option This is fitted in front of the unit as shown in Fig 8 It allows folding of up to 3 sheets of 80gsm C or Z or 5 sheets V Stapled sheets must be Z fold only In operation handfeed daily post is selected in the job When the machine is started the operator is prompted to feed the paper detected by a reflective sensor The machine will wait for up to 112 minutes for paper to be inserted in the handfeed hopper after which it will switch off Hand feed option can be specified with the unit or retrofitted A3301A Page2 8 Maximailer HD Service Manual Section 3 Maintenance and Service Adjustments Sect 9 1 3 2 3 3 3 4 99 3 5 1 3 5 2 3 5 3 3 5 4 3 6 3 7 3 8 3 9 Page Health safety environment 3 2 Conventions used in this manual 3 3 Preventative maintenance guidance amp schedule 3 4 Information Tor engineers 3 5 Romoval ol akk rc 3 6 Drive side cover 3 6 Fr
172. ve protect and improve the quality of the environment protect human health and utilise natural resources prudently and rationally That policy is based on the precautionary principle and principles that pre ventive action should be taken that environmental damage should as a priority be rectified at source Separate collection of waste is the precondition to ensure reuse and recy cling of waste that is generated at the disposal of electrical or electronical equipment and is necessary to achieve the chosen level of protection of hu man health and the environment in the European Community More particularly certain materials and components of waste electrical and electronical equipment needs selective treatment as their injudicious han dling or disposing of on or into land water or air would represent a major threat to the environment and human health cont Page 3 2 Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010 In order to facilitate collection and treatment separated from normal 3 2 Conventions used in this manual domestic waste electrical and electronical equipment is marked with the following logo 3 2 1 Symbols Do not mix with normal domestic waste Please use the subjoined return or collection system dedicated to electrical and electronical waste Draws to your attention a particular difficulty as Disconn sociated with this operation or indicates a potential N being WI haza
173. wl Tension Bracket Assy A2 1072 A 4 53 4 22 Wetter Lever Assy A2 1352 A 4 55 4 23 Wetter Beam Assembly 4 57 4 24 Wetter Tank Assy A ZTO070 A A 59 4 25 No Seal Assembly A2 1214 A 4 61 4 26 Head Ribbon Bkt Assy 184 2260 4 63 4 27 Universal Head PSU 184 2150 4 65 4 28 Mains Input Hardwired 184 2250 4 66 4 29 Head Covers E 4 67 4 30 External Float Switch A3 0421 A 4 70 4 31 Lift Beam Assy A2 1520 A 4 72 5 Electrical FX ed og 0 cc 5 1 5 2 5 1 1 Sensors L I E 5 2 5 1 2 Sensors Diagram Operator Side 5 4 5 1 3 Sensors Diagram Drive Side 5 5 5 2 Electrical Components asians iterare ergeet ao ct RO des Lone esse inedia 5 6 5 2 1 Physical Locations of Components 5 8 5 0 Control PCB Circuit Diagram 5 14 5 4 Processor PCB Circ
174. y out of the chassis When placing the feeder assembly onto a surface ensure the overguide underneath is not damaged 8 Reassembly of the feeder and conveyor is a reverse of removal Remember to recon nect the sensor cable at the inner edge of the conveyor 9 For replacement of conveyor belts see 3 8 Page 3 8 Maximailer HD Service Manual 3 7 Removal Adjustments of Separator The separator gap is operator adjustable by reaching in below the envelope feeder and turning the green knob Turning the knob clockwise opens the gap Removal of the separator assembly allows replacement of the separator rollers and also adjustment if needed of the shield To remove proceed as follows 1 Remove the envelope conveyor assembly as described in 3 6 T Fig 3 2 Turn the green knob fully clockwise to back off the roll ers and remove the 3 screws indicated in Fig 3 3 Disconnect the motor cable at the connector on the chassis bridge push the as sembly forward to unhook the two lugs and lift it out of the chassis 4 With the assembly removed from the chassis the rollers or motor can be replaced or the roller shield can be adjusted see opposite Maintenance and Servicing Issue 1 Mar 2010 5 To replace the rollers simply slacken the set screws and slide the rollers off the shaft Fig 4 6 To replace the motor the assembly will have to be stripped to reach the screws To adjust the shield
175. yor track This form is trail edge collated with the upstream documents arriving from feed ers 2 and 3 The feed timings for the collate operation are triggered when the trailing edge of the documents from feeders 2 and 3 pass through the track control sensor FEEDER 1 FEEDER FEEDER 3 FEEDER 4 ext Prime Document Arrived From Feed Hopper Next Document Arrived From Feed Hopper NO Retard Rollers d gt GE lo H o e o i o O F i A Track Control Sensor Stage 2 The three collated documents for pack 1 from feeders 1 2 and 3 are driven into the collation pocket by the retard rollers This roller set ensures that the final presentation of the collated pack is suitable for enve lope insertion by slowing down whilst feeding Form 1a is fed from insert feeder 2 down onto the conveyor track This form is trail edge collated with the upstream document arriving from feeder 3 The feed timings for the collate operation are triggered when the trailing edge of the document from feeder 3 passes through the track control sen Sor Form 1b is held stationary at the exit hold point of insert feeders 3 and 4 Page 2 2 Maximailer HD Service Manual FEEDER 1 FEEDE Next Document Arrived From Feed Hopper AO 3 Retard

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