SR85-TR85 SM

SR85 BOOKLET MAKER TR85 TRIMMER SR85 COVER FEEDER
DOCUMENTATION
RICOH GROUP COMPANIES
001094MIU
SR85 Bookletmaker/TR85 Trimmer SR85 Cover Feeder Documentation
SR85 BOOKLETMAKER TR85 TRIMMER SR85 COVER FEEDER
DOCUMENTATION
001094MIU
It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION. All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies. They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.
2001 RICOH Corporation. All rights reserved.
WARNING
The Service Manual contains information regarding service techniques, procedures, processes and spare parts of office equipment distributed by Ricoh Corporation. Users of this manual should be either service trained or certified by successfully completing a Ricoh Technical Training Program. Unt rained and uncer tified users utilizing information contained in this service manual to repair or modify Ricoh equipment risk personal injury, damage to property or loss of warranty protection. Ricoh Corporation
LEGEND
PRODUCT CODE GESTETNER N/A N/A N/A COMPANY LANIER RICOH SR85 Bookletmaker TR85 Trimmer SR85 Cover Feeder SAVIN
DOCUMENTATION HISTORY
REV. NO. * 1 DATE 3/2001 2/2002 COMMENTS Original Printing SR85 Cover Feeder Addition
SR85 BOOKLETMAKER/ TR85 TRIMMER SR85 COVER FEEDER

TABLE OF CONTENTS SR85/TR85 INSTALLATION MANUAL
1. Minimum Space Requirements 2. Installing The Bookletmaker 3. Installing The Trimmer
SR85 BOOKLETMAKER SERVICE MANUAL

1.Repairs / Adjustments (Rep) 2.Programming (Prg) 3.Electrical Detail Information (Edi) 4.Fault Isolating Procedure (Fip) 5.Preventive Maintenance (Mai)
TR85 TRIMMER SERVICE MANUAL

1. Repairs/Adjustments (Rep) 2. Electronic Detail Information 3. Fault Isolating Procedure 4. Preventive Maintenance
SR85 COVER FEEDER INSTALLATION MANUAL

1. Installing the Feed Cover
Service Manual
SR85Bookletmaker/TR85 Trimmer/ SR85 Cover Feeder
SR85 COVER FEEDER SERVICE MANUAL

1. Covers Remove Instruction (Cri) 2. Repairs/Adjustment (Rep) 3. Electrical Detail Information (Edi) 4. Service Mode (Srm) 5. Preventive Maintenance (Mai) 6. Specifications
SR85 Bookletmaker/TR85 Trimmer SR85 Cover Feeder
ii
Service Manual
TAB POSITION 8
TAB POSITION 7
TAB POSITION 6
TAB POSITION 5
SR85 COVER FEEDER SERVICE MANUAL
TAB POSITION 4
SR85 COVER FEEDER INSTALLATION MANUAL
TAB POSITION 3
TR85 SERVICE MANUAL TRIMMER
TAB POSITION 2
SR85 SERVICE MANUAL BOOKLETMAKER
TAB POSITION 1
SR85/TR85 INSTALLATION MANUAL
Installation Manual Trimmer Bookletmaker SR 85 and Trimmer TR 85
Introduction
This install manual covers the installation of the Booklet maker SR 85 and the Trimmer TR 85. If you have any comments or remarks, please contact us on one of the following numbers: Email: Phone: support.oem@plockmatic.se +46 8 602 50 41 1 800 648 57 73 +46 8 722 9970
Fax:
Installation manual SR85
Table of contents
1. Minimum space requirements

1.1 Space requirements
Page 1-1
2. Installing the Bookletmaker

2.1 Unpacking 2.2 Power requirements 2.3 Installing the infeeder 2.4 Preparing the printer 2.5 Interface 2.6 Wiring communication cable 2.7 Connectors communication cable 2.8 Adjustments 2-1 2-3 2-4 2-4 2-7 2-8 2-9 2-10
3. Installing the Trimmer

3.1 Unpacking 3.2 Power requirements 3.3 Attaching the Trimmer to the Bookletmaker 3-1 3-2 3-3
SR85/TR85 Installation Manual
1. Minimum space requirements

1.1 Space requirements
1. Ensure that the minimum required floor space is available for an installation of the Bookletmaker SR 85 including the Trimmer TR 85 as shown in figure 1.
Figure 1
1-1
2. Installing the Bookletmaker

2.1 Unpacking
1. 2. Remove all parts from the pallets. Unpack installation kit. Box 1 containing: Box 2 containing: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Pipe 1 containing: Base EPROM (For B302 finisher Main Board) Exit arm catcher Template Communication cable Powercord Shift tray plate with four 6 x 5.5 mm countersink screws. Exit tray plate with four 6 x 5.5 mm screws. Docking assembly for the B302 Finisher with two screws. Docking assembly for the Bookletmaker with four MRX 8 x 7 mm screws. Tapping cable Belt stacker wheel with one 7 mm allen screw.
13. Front panel 14. Rear panel 15. Shelf 16. Infeeder assembly Pipe 2
Pipe 2 containing: Box 1
1. Base
16. Infeeder assembly
Box 2
2. EPROM
3. Exit arm Catcher
4. Template
5. Comunication Cable
2-1
Box 2
6. Powercord
7. Shift tray plate
8. Exit tray plate
9. Docking assembly for the printer
10. Docking assembly for the Bookletmaker
11. Tapping cabel
12. Belt stacker wheel
Pipe 1
13. Front panel
14. Rear panel
15. Shelf
3.
Ensure all of the packaging material is removed from the outside of the Bookletmaker. Take the base (1) and turn it up side down and install the docking assembly (2) with four 7 mm screws. Turn the base around and put it on the floor. Take the Bookletmaker (3) and install it on the base, according to figure 2. (The four screws on the Bookletmaker fits in the four holes on the base). (Do not remove the nuts). nuts) Take the Belt stacker wheel (4) and install it on the Belt stacker with one 7 mm allen screw.
4
4.
1 Figure 2
2-2
2.2 Power Requirements

Bookletmaker Max. Current (A) 0.5 A 1.0 A With Trimmer Max. Current (A) 2.0 A 4.0 A
Configuration Europe N&S America
Nom. Voltage (V) 220/230 230/240 230 105/115 115/125
1.
Remove the right cover (1) by loosen two 8 mm screws, figure 3.
Two 8 mm screws
Figure 3
2. 3.
Check wall outlet voltage. Check the transformer (2) tapping for the correct configuration, figure 4. (Machines are tapped for 230V or 115V depending on configuration)
Figure 4
4.
Reinstall the right cover.
2-3
1.
Take the infeeder assembly (1) and install it on the Bookletmaker with four 7mm screws, figure 5. 1
7 mm screws (4x)
Figure 5
2.4 Preparing the printer

1. Take the mounting template (1) and hold it to the output on the printer finisher (2). Take the exit arm catcher (3), remove the adesive from the back of the catcher. Install the catcher on the printer. Lift up the exit paper arm and set onto the catcher (4). Figure 6
Figure 6
2-4
2.3 Installing the infeeder
2. 3. 4. 5.
Remove the rear cover on the printer finisher (1). Open the printer finisher door and pull out the stapling tray. Remove the two black plastic covers (2) at the bottom of the printer finisher by removing two 5.5 mm screws, figure 7. Take the docking assembly (3) and install it with two positioning screws in the holes found under the black plastic covers (2). Secure the docking assembly with the two nuts (4). Make sure you install the nuts correctly, one diameter(19.9mm) for the small hole and one diameter(21.9mm) for the big hole. correctly. There shall be no play in the Docking assembly if mounted correctly.
1 4 Big hole
Small hole
Finisher seen from above
Finisher seen from front side
Figure 7
2-5
6.
Remove the finisher exit tray (1) from the printer by removing four 5.5 mm screws, figure 8.
Figure 8
7.
Install the exit tray plate (2), with four 5.5 x 6mm screws, from the installation kit) to the bottom of the finisher exit tray, figure 9.
Four 5.5 mm screws
Figure 9
2-6
8.
Take the shift tray plate (2) with the four counter holes and install it on the finisher with four 5.5 x 6 mm counter screws (from the installation kit), figure 10.
Four 5.5 mm counter screws
Figure 10
2.5 Interface
1. 2. Change EPROM on the Main board PCB1 in the printer finisher. Remove the printer finisher connectors CN115, CN120 and CN125 from the Main board PCB1. Take the Communication cable from the installation kit and connect connectorsCN115, CN120 and CN125 on the Main board PCB1. Note, make correctly, sure you connect the connectors correctly, the yellow wire should always be on top, figure 12. Connect the printer finisher connectors CN115, CN120 and CN125 to the harness. Secure the harness in the finisher with tie raps from the installation kit.
3.
4. 5.
2-7
Figure 11
2-8
2.6 Wiring communication cable
2.7 Connectors communication cable
Figure 12
2-9
1.
Make sure the exit paper arm is in the upper position (1), figure 13 a. Turn on thecopier the shift tray will go down to the lower position. Turn off the copier. Adjust the gap between the infeeder assembly and the finisher. Adjust by movingthe two positioning pins (5) with the caster tool. The caster tool is located behind the front cover in the Bookletmaker. The two black studs on the infeeder assembly should just have contact with the printer cover (6), figure 13 a.
6 1
2.
Figure 13 a
3.
Adjust the distance between the front of the Bookletmaker infeeder and the front of the Finisher panel (7). Adjust by moving the two positioning pins (5) with the castor tool. The distance should be 5 - 7 mm, figure 13 b.
2 4
7
5
-7
Figure 13 b
2-10
2.8 Adjustments
4. 5.
If installing a Docking Rail. Install it now. Take the template (2) and hold it to the output on the printer. Adjust the height on the Bookletmaker. Adjust by turning the four nuts on the Bookletmaker with the caster tool (3). Raise or lower the casters to achieve the correct height. The lower edge on the template should be against the stainless plate at the infeeder (4), figure 13 b. Tighten the two positioning pins. Undock the Bookletmaker. Take the front (1) and the rear (2) panels, slide them with the bottom first onto the docking assembly. Put the shelf (3) between the panels, make sure you position the shelf correctly. The cut out should be away from the Bookletmaker, not towards.Slide the top of the panels under the screws on the infeeder. Tighten the four 7 mm screws. Take the finisher exit tray and put it on the shelf, figure 14.
6. 7. 8.
Four 7 mm screws
Figure 14 1
9.
Connect the communication cable and the power cord through the hole in the rear panel.
10. Make sure the exit paper arm is in the upper position. Move the Bookletmaker up to the printer and dock it.
2-11
11. 12.
Power on the Bookletmaker. Set up the Bookletmaker for A4/8.5 x 11 saddle stapling and folding according to the operation manual 4.2. Press the yellow Run / Adjustment button on the Bookletmaker. Send one A4/8.5 x 11 proof set from the copier by pressing the proof button on the copier. Check for the correct feeding of the paper. The paper should enter in the middle of the infeeder, if not perform Adjustment 2.8 on page 2-9. Open the top cover on the Bookletmaker the set is now in the stapling area. Check length and width, adjust if needed according to the operation manual 4.2. Close the top cover, press the yellow Run / Adjustment button. Take the book from the stacker and check the fold and the staples, adjust if needed. Set up the Bookletmaker for A3/11 x 17 saddle stapling and folding according to the operation manual 4.2. Press the yellow Run / Adjustment button on the Bookletmaker. Send one A3/11 x 17 proof set from the copier by pressing the proof button on the copier. Open the top cover on the Bookletmaker the set is now in the stapling area. Check length and width, adjust if needed according to the operation manual 4.2. Close the top cover, press the yellow Run / Adjustment button. Take the book from the stacker and check the fold and the staples, adjust if needed. If installing a Trimmer TR85 go to the Trimmer installation.
13.
14.
15.
16.
17.
18.
19.
20.
21.
2-12
3. Installing the Trimmer
3.1 Unpacking
1. 2. Remove all parts from the pallets. Unpack installation kit. Installation kit box is located in the waste bin on the Trimmer. Box 1 containing: 1. 2. 3. 4. Exit guide bracket Two 8 mm screws with 20 mm washers and two nuts (to secure the trimmer to the Booklet maker) Plastic distance with one M5x25 screw Tapping cable
Box 1
2x
1. Exit guide bracket 2. Screw with 20 mm washer 3. Plastic distance
4. Tapping cable
3.
Ensure all of the packaging material is removed from the outside of the Trimmer TR85.
3-1
4.
Remove the front cover (1) on the Trimmer by loosen two 8 mm screws, figure 15
Figure 15
3.2 Power requirements

1. 2. 3. Power requirements, see page 2-2 Check wall outlet voltage. Check the transformer (2) tapping for the correct configuration, figure 16. (Machines are tapped for 230V or 115V depending on configuration) Reinstall the rear cover.
4.
2 Figure 16
3-2
3.3 Attaching the Trimmer to the Bookletmaker

1. Remove the two 8 mm screws (1), figure 17, which secures the Beltstacker,to the Bookletmaker Remove the Beltstacker(10), figure 17. Remove the two black positioning pins for the Beltstacker (2) from the Bookletmaker, figure 17. Take the two screws with the 20 mm washers, install them in the holes where you removed the two black positioning pins (2), figure 17. Remove the old exit guide bracket (3) from the Bookletmaker. Make sure to cut the cable tie on the old exit guide bracket. Replace it with the new one (4), figure 17. Note Install it as high as possible! Note: Move the Trimmer up to the Bookletmaker, connect the communication cable (6) and the power cord (7), figure 17. Adjust the height on the Trimmer by turning the four nuts (8), figure 17. So that the two black positioning pins fits in the holes on theTrimmer. Lower the Trimmer so that the Trimmer just hangs on the two positioning pins. Make sure the cable not interferes with the fold pocket. Take the allen screw and the plastic distance and attach it to the Trimmer and the Bookletmaker (9), figure 17. Take the stacker and install it on the Trimmer (10), turn the two stacker height brackets (11) a half turn so that the stacker is in the up position, figure 17. Secure the Beltstacker with the screws (1), you removed in step 2, figure 17.
2. 3.
4.
5.
6.
7.
8.
9.
3-3
1 6 8
3 4
10 11
Figure 17
3-4
Service Manual Bookletmaker SR 85
Contents
REPAIRS REPAIRS / ADJUSTMENTS (REP) Cover removal
REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP REP 1.1 1.2 1.3 1.4 2.1 2.2 2.3 2.4 2.5 2.6 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Front and rear cover Top cover Panels + Infeeder Infeed and outfeed cover Infeed module Infeed transport belt Side guides Side guide assy. Side guide jogger motor Back jogger motor Stapler head Stapled set stop gate solenoid Staple stop gate position, Adjustment Stapler assembly drive bar position, Adjustment Stapler home position, Adjustment Stapler head retraction, Adjustment Saddle stapling sensor, Adjustment Upper folder roller Lower folder roller Fold pressure, Adjustment Fold knife home position, Adjustment Outfeed sensor, Adjustment Staple stop gate parallelism, Adjustment Staple/Fold position, Adjustment Stapler position to anvil, Adjustment Stapler pressure, Adjustment Stapled set transport drive alignment, Adjustment Pressure roller height, Adjustment Stapled set stop gate release solenoid, Adjustment 1.1.1 1.2.1 1.3.1 1.4.1 2.1.1 2.2.1 2.3.1 2.4.1 2.5.1 2.6.1 3.1.1 3.2.1 3.3.1 3.4.1 3.5.1 3.6.1 3.7.1 4.1.1 4.2.1 4.3.1 4.4.1 4.5.1 5.1.1 5.2.1 5.3.1 5.4.1 5.5.1 5.6.1 5.7.1
PAGE
Input area
MOT 3 MOT 7
Stapler area
SOL 2
SW 1 SEN 1
Output area
SW 2 SEN 4
Staple/Fold quality adjustments
SOL 1
PROGRAMMING (PRG)
PRG 6.1 EDI EDI EDI EDI EDI FIP 7.1 7.2 7.3 7.4 7.5 8.1 Reset of EE-prom values Wiring diagram SR85 Connection cable wiring diagram SR85 Electrical components list Electrical components location Test points Self diagnostic system control (SDS) Preventive Maintenance 6.1.1 7.1.1 7.2.1 7.3.1 7.4.1 7.5.1 8.1.1 9.1.1
ELECTRICAL DETAIL INFORMATION (EDI) DETAIL INFORMATION
AULT ISOLATING FAULT ISOLATING PROCEDURE (FIP) PREVENTIVE MAINTENANCE (MAI)

MAI 9.1
Bookletmaker SR 85
REP 1.1 Front and rear cover

REMOVAL Front cover 1. Switch off the main power switch and disconnect the power cord. 2. Open the Top cover and loosen the two screws (1) securing the top end of the Front cover. 3. Loosen the two nuts (2). 4. Pull out the lower end and lift up carefully to remove. Rear cover Removal of the rear cover is performed the same way as removal of the front cover. 1
INSTALLATION Installation is an exact reversed procedure of removal.
Bookletmaker SR 85
PAGE 1.1.1
SR85 Service Manual
Top REP 1.2 Top cover

REMOVAL 1. Open the Top Cover 2. Disconnect the Gas spring (4). 3. Remove four screws (1) from the brackets. 4. Lift off the Top cover. 1 2 3 4 2
5 INSTALLATION 1. Mount the four screws (1) onto the brackets and tighten. 2. Connect the Gas spring (4). 3. Close the Top cover and check: - That the magnet (5) locks on the sheet plate (3). - That both rubber bushings (2) contacts the surface. - That the Top cover front side is parallel to the front cover. - That the Interlock switch activates when the distance between the magnet (5) and the sheet plate (3) is 2 to 5 mm. ADJUSTMENT 1. Loosen the screws (1). 2. Move the Top cover to adjust. 3. Tighten the screws (1). 4. Repeat the check.
Bookletmaker SR 85
PAGE 1.2.1
REP 1.3 Panels + Infeeder

REMOVAL 1. Loosen the four 7 mm screws (1). 2. Slide the top of the panels (2) away from the screws. Remove the shelf (3), remove the two panels. 3. Loosen the four 7 mm screws (4). 4. Lift up the infeeder (5) and remove it.
SR85 Service Manual
5 4 2 2
Bookletmaker SR 85
PAGE 1.3.1
REP 1.4 Infeed and Outfeed cover

REMOVAL Infeed cover 1. Switch off the main power switch and disconnect the power cord. 2. If the unit is online, disconnect the connection cable. 3. Remove the two panels and the shelf. 4. Loosen the two nuts (1). 5. Pull out the lower end of the infeed cover and remove thecover down wards.
Outfeed cover 1. Switch off the main power switch and disconnect the power cord. 2. Remove front and rear cover according to REP 1.1. 3. Loosen the two screws below the stacker frame securing the stacker. 4. Disconnect and remove the stacker (3). 5. Tip the SR 85 by placing 50 mm or greater distances between the outfeed end of the SR 85 and the base. 6. Loosen the two screws (5) securing the outfeed bottom cover. 7. Slide the bottom cover towards the outfeed, until it releases from the infeed bottom cover. Slide the bottom cover towards 2 the infeed until it releases from the screws (5). 8. Remove the four screws (4). 3 9. Pull the cover carefully out to avoid damage on the outfeed sensor 4 4 harness on the front side.
NOTE: Cut the ty-wraps and disconnect the outfeed cover. sensor to fully remove the outfeed cover.

NOTE: Make sure the plastic guide (2) does not get jammed between the stackers left side and the outfeed cover when installing the stacker.
Bookletmaker SR 85
PAGE 1.4.1
REP 2.1 Infeed module

REMOVAL 1. Remove the front and rear cover according to REP 1.1. 2. Remove the two panels,shelf and the infeed assy. 3. Remove the infeed cover according to REP 1.3 4. Disconnect the five connectors (1). 5. Remove the spring (2).
SR85 Service Manual
VIEW INSIDE INFEED COVER 1 1 1
6. Disconnect the length adjust strap (3). 7. Remove the two screws (5) on the front side. 8. Remove the two screws (5) on the rear side. 4
9. Lift out the Infeed module (4). Carefully so the side guides does not bend. INSTALLATION Installation is an exact reversed procedure of removal. Bookletmaker SR 85 PAGE 2.1.1
REP 2.2 Infeed transport belt

REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Remove the Infeed module according to REP 2.1 3. Remove the four screws (1). 4. Slide the drive coupling (5) off of the drive shaft (4) and remove the transport belt assembly. 5. Remove the belt (2) from the assembly. 1
4 5

Note: Make sure the flat side on the bearing (3) is up when installing.
Bookletmaker SR 85
PAGE 2.2.1
REP 2.3 Side guides

REMOVAL 1. 2. 3. 4. 5. Switch off the main power switch and disconnect the power cord. Remove the infeed cover according to REP 1.4 Loosen the Ob(Outboard) screw (3) and the Ib screw (4) on the front side guide. Remove the side guide. Same procedure on the rear side guide.
Stapler area seen from above, with the stapler heads removed.
2
Rear side
Front side
1 2
ADJUSTMENT 1. Move the front (1) sideguide to the two holes (2) in the paper path according to the figure. 2. Check the distance between the two holes and the sideguide. The distance should be equal 0.3 mm between the lower hole and the sideguide and the upper hole and the sideguide. If not go to step 3. 3. Loosen the Ob screw (3) and the IB screw (4) on the side guide. Adjust the sideguide according to step 2. 4. Perform the same check on the rear (5) sideguide, adjust if needed.
Bookletmaker SR 85
PAGE 2.3.1
SR85 Service Manual
assy. REP 2.4 Side guide assy.

REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Remove the front and rear cover according to REP 1.1 3. Remove the infeed cover according to REP 1.4 4. Remove the infeed module according to REP 2.1 5. Remove the sideguides according to REP 2.3 6. Turn the infeed module up side down. 7. Remove the e-clip (1). 8. Remove the two screws (2) who secures the shaft. 9. Push the shaft (3) out of the hole (4). 10. Remove five nuts (5). 11. Remove four 7 mm screws (6).
5 5
6 6 3 4 1 5
Bookletmaker SR 85
PAGE 2.4.1
REP 2.5 Side guide jogger motor MOT 3

REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Remove the front and rear cover according to REP 1.1 3. Remove the infeed cover according to REP 1.4 4. Remove the infeed module according to REP 2.1 5. Turn the infeed module up side down. 6. Remove 7 mm screw (1). 7. Remove wheel (2) by loosen one 4 mm allen screw. 8. Remove three 7 mm screws (3). 9. Cut two tie raps and remove the motor.
1 3
INSTALLATION Installation is an exact reversed procedure of removal. But before you tighten the three screws, you must put the side joggers in the out position, look at the picture above. You should have 0.1-0.3 mm play between the plate and the flange bushing on both sides (1). Tighteen the three screws. 1 1
Bookletmaker SR 85
PAGE 2.5.1
SR85 Service Manual
REP 2.6 Back jogger motor MOT 7

REMOVAL 1. Switch off the main power and disconnect the power cord. 2. Remove the infeed module according to REP 2.1. 3. Disconnect the ground wire (1). 4. Loosen the setscrew in the collar (3). 5. Remove the motor (2). 1 2 3
INSTALLATION 1. Install the motor. 2. Ensure that the pin on the motor is inserted in the grommet (4). 3. Push the collar (5) of the flange bushing firmly against the bracket. 4. Tighten the setscrew (3) on the flat of the shaft. 5. Connect the ground wire (1). 6. Install the infeed module according to REP 2.1. 7. Check/adjust the Staple/fold position according to REP 5.2.
Bookletmaker SR 85
PAGE 2.6.1
REP 3.1 Stapler head

REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Disconnect the staple detection lead (5). 3. Push down latch (2) and lift the stapler head (1) out.
NOTE: If removing the stapler head use the pivot pin (6) from the old stapler head and install it in the new head.
SR85 Service Manual
5 2 6
6 5 O-Rings
INSTALLATION 1. Install the plunger (4) in the plunger retraction swing arm (3). 2. Push the Stapler head down so that the pivot pin (6) locks under the latch (2). 3. Connect the staple detection lead (1).
Bookletmaker SR 85
PAGE 3.1.1
REP 3.2 Stapled set stop gate solenoid SOL 2

REMOVAL 1. Move the front side guide to the outermost position. 2. Adjust the sheet size on the control panel to align the mounting screws (2) for the solenoid with the access holes (1) in the paper path. 3. Switch off the main power switch and disconnect the power cord. 4. Remove the infeed cover according to REP 1.3. 5. Cut the ty-wrap securing the cable. 6. Disconnect the solenoid connector. 7. Loosen the two screws (2). 8. Slide the solenoid towards the infeeder to remove.
2 INSTALLATION Installation is an exact procedure of removal.
Bookletmaker SR 85
PAGE 3.2.1
REP 3.3 Staple stop gate position, adjustment

PURPOSE The purpose is to position the Staple stop gate fingers in the center of each opening in the paper path so that binding does not occur. 1. 2. 3. 4. 5. Adjust to the smallest length size on the control panel. Switch off the main power switch and disconnect the power cord. Remove the Infeed cover according to REP 1.3. Insert a 0.3 mm feeler gauge (3) to ensure 0.3 0.2 mm endplay. Disengage the Staple stop gate release solenoid (1). VIEW INSIDE INFEED COVER 1 2 3
0.30.2 mm 4 5
ADJUSTMENT 1. Check that the fingers (2) are centered in the openings in the paper path. 2. Loosen the two allen screws (4)(5) securing the collars. 3. Center the fingers (2). 4. Tighten the front allen screw(4). 5. Insert a 0.3 mm feeler gauge (3) to obtain 0.3 0.2 mm endplay. 6. Tighten the rear allen screw (5).
Bookletmaker SR 85
PAGE 3.3.1
SR85 Service Manual
REP 3.4 Stapler assembly drive bar position, adjustment

PURPOSE The purpose is to limit the front-to-rear movement of the Stapler assembly drive bars without causing them to bind. 1. Switch off the main power switch and disconnect the power cord. 2. Remove the Infeed cover according to REP 1.3. 3. Remove the Front cover according to REP 1.1.
1 0.05 to 0.25 mm 2 2 3 3
ADJUSTMENT Top bearing 1. Push the drive bar (1) toward the rear. 2. Insert a feeler gauge to check that the gap is 0.05 mm to 0.25 mm. 3. Loosen the locknut (3). 4. Rotate the screw (2) to adjust. 5. Tighten the locknut (3). Bottom bearing Adjustment of the Bottom bearing is performed the same way as adjustment of the Top bearing.
Bookletmaker SR 85
PAGE 3.4.1
REP 3.5 Stapler home position, adjustment SW 1

PURPOSE The purpose is to position the Stapler motor home position switch (SW 1) so that the Stapler motor (MOT 8) stops in the correct position after stapling a set. 1. Switch off the main power switch and disconnect the power cord. 2. Remove the infeed cover according to REP 1.3. 3. Rotate the motor linkage (3) to the top dead center. 1 2 3
ADJUSTEMENT 1. Check that the gap is 0.0 mm to 0.2 mm. 2. Loosen the two screws (1). 3. Move the switch (2) to adjust. 4. Tighten the two screws (1).
Bookletmaker SR 85
0.0 - 0.2 mm
PAGE 3.5.1
SR85 Service Manual
REP 3.6 Stapler head retraction, adjustment

PURPOSE The purpose is to ensure the staple feed. 1. Check/adjust the Stapler home position according to REP 3.5. 2. Switch off the main power switch and disconnect the power cord. 1 2 3
ADJUSTMENT 1. Push down the stapler head (1). 2. Check that the gap is 1.0 to 2.0 mm. 3. Loosen the three screws (3). 4. Rotate the screw (2) to adjust. 5. Tighten the three screws (3).
Bookletmaker SR 85
1.0 - 2
.0 mm
PAGE 3.6.1
sensor, REP 3.7 Saddle stapling sensor, adjustment SEN 1

PURPOSE The purpose is to position the saddle stapling sensor (SEN 1) so that it will switch on the stapler motor (MOT 8) when a set reaches the Staple stop gate. 1. Remove the rear cover according to REP 1.1 and pull out the interlock bypass switch actuator. 2. Remove the nut (1). 3. Remove the black shield (2).
ADJUSTMENT 1. The voltage between TP1 on the controller PCB and common ground should be greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked.
sensor. NOTE: Use white paper to block the sensor.
2. Loosen the nut (4). 3. Move the sensor (3) to obtain the voltages. 4. Tighten the nut (4).
Bookletmaker SR 85
PAGE 3.7.1
SR85 Service Manual
REP 4.1 Upper folder roller

REMOVAL 1. Switch off the main power and disconnect the power cord. 2. Remove front and rear cover according to REP 1.1. 3. Remove the outfeed cover according to REP 1.3. 4. Remove the drive chain (6). 6. Note the position of the sprockets (2&3) on the shaft. Remove the sprockets and the plastic spacer from the front of the spring-loaded bearing block. 7. Remove the collar and the plastic spacer from the rear of the spring-loaded roll. 8. Remove the front bearing block (4) by removing the two screws from the inside of the machine. 9. Remove the front and rear spring-loaded bearing block assemblies by removing screws (5), front and rear, from the inside of the machine. 10. Note the position of the front plastic bearing (1). Remove the bearing. 11. Pull out the upper fixed roll to remove. 12. Pull out the upper spring-loaded roll to remove.
1 2
6 3 4
INSTALLATION / ADJUSTMENT 1. Installation is an exact reversed procedure of removal.

Note 1: Push the upper side of the bearing block (4) towards the outfeed before tightening. Note 2: Before tightening the spring-loaded bearing blocks, use a feeler gauge to check that the endplay is 0.1 to 0.5 mm between the sprocket (2) and the plastic spacer. Also check that the enplay on the rear side is 0.1 to 0.5 mm between the collar and the plastic spacer.
2. Adjust the fold pressure according to REP 4.3.
Bookletmaker SR 85
PAGE 4.1.1
REP 4.2 Lower folder roller

REMOVAL Lower right folder roll 1. Switch off the main power and disconnect the power cord. 2. Remove front and rear cover according to REP 1.1. 3. Remove the drive chain (3). 4. Note the sprockets (2) position on the shaft and remove the sprocket (2). 5. Remove the spring (4) on both front and rear side.
WARNING: When compressing, pry the spring onto a screwdriver in order to avoid injury when removing it.
7. Loosen the screws (1) from the inside of the the machine. 8. Wiggle the folder roll shaft up and down in order to release it from the brackets (5) securing the shaft. 9. Pull the folder roll through the cut out in the side frame until the shaft releases from the bearing on the opposite side. Then lift out the folder roll through the inside of the machine.
CAUTION: In order to compensate for variations between machines, there could be shim washers placed on the inside of the bushing at the end of the Folder roll shaft. Note the position of the washers when removing.
Lower left folder roll Removal of the Lower left folder roll is performed the same way as removal of the Lower right folder roll, in addition the Outfeed cover has to be removed according to REP 1.3.
3 1 4 5 2
Bookletmaker SR 85
PAGE 4.2.1
SR85 Service Manual
REP 4.3 Fold pressure, adjustment

PURPOSE The purpose is to ensure that when running 2-5 sheets, only the soft spring (upper spring) will be compressed and when running more than 5 sheets both springs will be compressed. 1. Switch of the main power switch and disconnect the power cord. 2. Remove the front and rear cover according to REP 1.1. 1 5 6 7
9 2 3 4 10
ADJUSTMENT Front fold pressure assembly 1. Compress upper spring (3) until head of screw (2) contacts bar. 2. Check (1) for 34.0 0.5 mm. 3. Adjust by loosen one nut (4) (Pull spring down to access locking nut) and reposition the other to obtain the dimension. When tightening the nuts make sure the screw is in the outermost position of the slot. 4. Check (10) for 36.5 0.5 mm. 5. Adjust nut (9) to obtain the dimension. 6. Check (5) for 36.5 0.5 mm.
Note: Push downwards on the screw (9) when measuring the distance (5).
7. Adjust by loosen the two screws (7) (from the inside of the machine) and reposition the spring bracket (6) to obtain the dimension. When tightening the screws make sure the spring bracket (6) is parallel to the nut plate (8) in order to align the folder roll movement with the spring load . Rear fold pressure assembly Adjustment of the Rear fold pressure assembly is performed the same way as adjustment of the Front fold pressure assembly. Bookletmaker SR 85 PAGE 4.3.1
REP 4.4 Fold knife home position, adjustment SW 2

PURPOSE The purpose is to ensure that the Fold knife is clear from the paper path in home position. 1. 2. 3. 4. Visually check that the Fold knife is not visible above the paper path. Switch of the main power switch and disconnect the power cord. Remove the outfeed cover according to REP 1.3. Rotate linkage (4) to the down dead center. SHOWN IN TIPPED POSITION FOR CLARITY
ADJUSTMENT 1. Check that the gap (3) between the switch housing and the actuator arm is 0.1 mm to 0.5 mm. 2. Loosen the two screws (1). 3. Move the switch (2) to adjust. 4. Tighten the two screws (1).
Bookletmaker SR 85
PAGE 4.4.1
SR85 Service Manual
sensor, REP 4.5 Outfeed sensor, adjustment SEN 4

PURPOSE The purpose is to position the Outfeed sensor (SEN 4) so that it will switch on the Stacker motor (MOT 1) when a set enters the stacker tray. 1. Remove the rear cover according to REP 1.1 and pull out the interlock bypass switch actuator.
VIEW INSIDE THE TOP COVER OVER THE FOLDER ROLLS
ADJUSTMENT 1. The voltage between TP8 on the controller PCB and common ground should be greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC unblocked.
NOTE: Use white paper to block the sensor.
2. Loosen the nut (2). 3. Move the bracket (1) to obtain the voltages. 4. Tighten the nut (2).
Bookletmaker SR 85
PAGE 4.5.1
REP 5.1 Staple stop gate parallelism, adjustment

PURPOSE The purpose is to ensure that the staples are parallel to the edge of the sets. 1. 2. 3. 4. 5. Remove the rear Stapler head according to REP 3.1. Move the side guides to the outermost position. Select the Fold mode on the Control panel. Select the Adjustment mode on the Control panel. Fold an A4 (8.5 x 11) sheet of paper lengthwise by hand in order to form a straight edge. 6. Feed the folded paper sidewise into the machine so that the straight edge fold (2) is positioned against the Staple stop gate. 7. Adjust the sheet size on the control panel to align the straight edge fold (2) with the locating holes (1) in the paper path. 8. The straight edge fold (2) must align with both of the locating holes (1).
ADJUSTMENT 1. Loosen the screw (4). 2. Insert a screwdriver in the notches (3) and rotate to align the holes (1) with the straight edge fold (2). 3. Tighten the screw (4). 4. Check/adjust the Staple/Fold position according to REP 5.2.
Bookletmaker SR 85
PAGE 5.1.1
SR85 Service Manual
REP 5.2 Staple/Fold position, adjustment

PURPOSE The purpose is to ensure that the sets are folded in the center of the set, that the fold is parallel to the edge of the sets and that the staples are aligned with the fold. 1. Select Fold mode and Adjustment mode on the Control panel 2. Handfeed a 2-sheet set using A4 (8.5x 11) paper. 3. Adjust the sheet size on the control panel to align the Back jogger with the trail edge of the set without producing a buckle in the set. 4. Select Run mode and run a few sets. 5. Check that the fold is parallel to the edge of the set. If not perform Adjustment 1.
NOTE: After adjustment 1 is performed , return to this procedure and continue from step 1.
6. Check that the fold is in the center of the set (that the edges of the booklet are aligned). If not perform Adjustment 3.
NOTE: After adjustment 3 is performed , return to this procedure and continue.
7. Repeat step 1 to 4 but run 4-sheet sets in Staple/Fold mode. 8. Check that the staples are aligned with the fold. If not perform Adjustment 2.
SHOWN IN TIPPED POSITION FOR CLARITY 1
ADJUSTMENT 1 1. Adjust to the largest sheet size on the control panel. 2. Place the stacker module in upright position. 3. Switch of the main power switch and disconnect the power cord. 4. Loosen the two mounting screws (2). 5. Rotate the two screws (3) to adjust. 6. Push in the fold stop assembly when tighten the two screws (2). 7. Repeat Adjustment 1 until the fold is parallel to the edge of the set. Bookletmaker SR 85 PAGE 5.2.1
Continue REP 5.2 Staple/Fold position, adjustment

ADJUSTMENT 2 1. Loosen the locknut and rotate the setscrew (1) clockwise if the staples are located on the top, counterclockwise if the staples are located on the bottom and tighten the locknut.
Top NOTE: Top of the booklet is the side that contacts the output wheel.
SR85 Service Manual
2. Repeat Adjustment 2 until the staples are aligned with the fold.
ADJUSTMENT 3 1. Rotate screw (4) clockwise to lengthen the top of the booklet, counter clockwise to shorten the top of the booklet.
Top NOTE: Top of the booklet is the side that contacts the output wheel.
2. Select Adjustment mode on the Control panel 3. Handfeed a 2-sheet set using A4 (8.5x 11) paper. 4. Adjust the sheet size on the control panel to align the Back jogger with the trail edge of the set without producing a buckle in the set. 5. Select Run mode and run a few sets. 6. Repeat Adjustment 3 until the edges of the booklet are aligned.
NOTE: Recalibrate the length in Manual Mode before proceeding.
Bookletmaker SR 85
PAGE 5.2.2
REP 5.3 Stapler position to anvil, adjustment

PURPOSE The purpose is to ensure that the stapler assemblies are aligned correctly to the anvils. 1. Run a 2-sheet set in the edge staple mode. 2. Check that the staples are formed properly. The ends of the staples should be folded so that they are aligned with the middle of the staple.
Good Staple
Bad Staple
3. Switch off the main power switch and disconnect the power cord. 4. Remove the Stapler head according to REP 3.1. 5. Push the plunger (4) manually and note where the staple exits the Stapler head, then return the plunger to the home position.
WARNING: Be careful when handeling the Stapler head. The ends of the staples are sharp and difficult to see.
6. Remove the Staple cartridge (3) and tear the staples at the tear line. 7. Reinstall the cartridge (3) but do not make any staple strokes. 8. Position an allen wrench (2) - app. 2 mm - as shown to relieve the pressure on the staple former. 9. Install the Alignment tool (1) as shown.
NOTE: Head alignment tool is located at the bottom of the front side frame.
10. Remove the allen wrench (2). 1 2
Bookletmaker SR 85
PAGE 5.3.1
Continue REP 5.3 Stapler position to anvil, adjustment

11. Reinstall the Stapler head only on the pivot pin side not in the plunger retraction swing arm (7).
8
SR85 Service Manual
ADJUSTMENT 1. Loosen the left (6) and the right (8) mounting screw. 2. Rotate the adjusting screw (5) counterclockwise as far as it will go without removing it. 3. Push down the Stapler head and move it by turning the adjustment screw (5) clockwise until the tool engages the slot in the anvil. 4. Tighten the left mounting screw (6). 5. Position the Stapler head so that the Alignment tool is centered (side to side) in the slot. 6. Tighten the right mounting screw (8). 7. Return the machine to operational condition. 8. Run a test set to verify the adjustment.
Bookletmaker SR 85
PAGE 5.3.2
REP 5.4 Stapler pressure, adjustment

PURPOSE The purpose is to ensure that adequate pressure is applied to the Stapler heads when forming the staples. 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord. Remove the Infeed cover according to REP 1.3. Remove the Stapler head according to REP 3.1. Rotate the motor linkage (3) to the down dead center.
70 to 71 mm
3 ADJUSTMENT 1. Use a sliding caliper and check that the distance between the anvil and the upper side of the sheet plate is 70 mm to 71 mm. Check both front and rear side. 2. Loosen the four screws (1). 3. Move the upper stapler bar (2) to adjust. 4. Tighten the screws (1). 5. Check/Adjust the Stapler assembly drive bar position according to REP 3.4.
Bookletmaker SR 85
PAGE 5.4.1
REP 5.5 Stapled set transport drive alignment, adjustment

PURPOSE The purpose is to horizontally align the Stapled set drive rollers with the Idler wheels to ensure the correct set transportation into the fold area. 1. Adjust to the smallest sheet size on the control panel. 2. Ensure that the tires (3) are centered on the hubs (4) of the drive rollers. 3. Manually move the Drive rollers (2) up against the Pressure rollers (1) by pushing the Staple stop gate down. 4. Push down the staple stop gate and visually check that the Drive rollers are centered on the Pressure rollers. 1 2 3 4
ADJUSTMENT 1. Switch off the main power switch and disconnect the power cord. 2. Remove the Infeed cover according to REP 1.3. 3. Loosen the allen screw (8). 4. Move the shaft (7). 5. Insert a 0.3 mm feeler gauge (9) to ensure 0.3 0.2 mm endplay.
NOTE The endplay 0.3 mm is to prevent the Staple stop gate shaft from binding.
6. 7. 8. 9.
Tighten the allen screw (8). Loosen the two allen screws (6). Move the assembly (5) so that the tires (3) are centered on the Pressure rollers (1). Tighten the two allen screws (6).
Bookletmaker SR 85
PAGE 5.5.1
SR85 Service Manual
REP 5.6 Pressure roller height, adjustment

PURPOSE The pupose is to position the Pressure rollers for the correct engagement with the Drive rollers. 1. Adjust to the largest sheet size on the Control panel. 2. Switch off the main power switch and disconnect the power cord. 3. Rotate the shield (2). VIEW OF STAPLED SET TRANSPORT AREA
ADJUSTMENT 1. Check that the gap (3) is 4 mm to 5 mm.

NOTE: Use a 4 mm allen wrench - as shown on drawing - to check that it fits in the gap and a 5 mm allen wrench to check that it does not fit in the gap.
2. Loosen one nut (1) and reposition the other (1) as required to obtain the gap. 3. Check/adjust the Stapled set transport solenoid according to REP 5.7.
Bookletmaker SR 85
PAGE 5.6.1
REP 5.7 Stapled set stop gate release solenoid, adjustment SOL 1
PURPOSE The purpose is to ensure adequate engagement of the stapled set drive rollers. 1. 2. 3. 4. Check/adjust the Pressure roller height according to REP 5.6. Adjust to the smallest sheet size on the control panel. Switch off the main power switch and disconnect the power cord. Remove the infeed cover according to REP 1.3. VIEW SHOWN WITH INFEED MODULE REMOVED FOR CLARITY
ADJUSTMENT 1. Measure the hight (1). 2. Push and hold the plunger (3) up.
only, NOTE: Push on the plunger of the solenoid only, do not push on the linkage. If pushing on linkage the measurement will not be correct.
3. Measure the hight (1) again. The difference should be 0.5 mm to 1.0 mm 4. Loosen the two screws (2) and move the solenoid to obtain the dimension. 5. Tighten the screws.
Bookletmaker SR 85
PAGE 5.7.1
SR85 Service Manual
PRG 6.1 Reset of EEPROM values

PURPOSE The purpose is to transfer the original values from the Micro processor to the EEPROM. This procedure should be performed in response to minor logic problems such as failure in the operating sequence. Also perform this procedure if the controller PCB is replaced or if the power is lost during SDS(Self Diagnostic System) testing. PROCEDURE 1. Switch off the main power switch. 2. Remove the rear cover according to REP 1.1. 3. Move DIP switch no. 1 on the controller PCB to the right (right when facing the PCB). 4. Switch on the main power switch. The adjust LED on the control panel is flashing: The processor is transferring the default values to the EEPROM. 5. When the adjust LED stops flashing, switch off the main power switch. 6. Move DIP switch no. 1 on the controller PCB to the left (left when facing the PCB). 7. Reinstall the rear cover according to REP 1.1. Normal mode < > Reset EEPROM
Ricoh mode
Not used
Not used
location of DIP switch
rear view
Bookletmaker SR 85
PAGE 6.1.1
EDI 7.2 Connection cable wiring diagram SR85
Bookletmaker SR 85
PAGE 7.2.1
SR85 Service Manual
Continue EDI 7.2 Connection cable wiring diagram SR85
Bookletmaker SR 85
PAGE 7.2.2
EDI 7.3 Electrical components list

MOT 5 MOT 4 MOT 6 MOT 10 MOT 7 MOT 11 MOT 9 MOT 1 MOT 2 MOT 8 MOT 12 MOT 3 SOL 1 SOL 2 SW 1 SW 2 SW 3 SW SW SW SW 4 5 6 7 1 2 3 4 Stacker drive motor Stapled set transport motor Length adjustment motor Edge stapling stop motor Back jogger motor Edge stapling transport motor Infeed transport belt motor Stapler motor Fold knife motor Folder roller motor Fold stop gate motor Side jogger motor Stapled set stop gate release solenoid Stapled set stop gate solenoid Stapler home position switch Fold knife home position switch Length adjustment maximum limit switch Length adjustment minimum limit switch Interlock switch Interlock bypass switch Main power switch Saddle stapling sensor Fold stop sensor Edge stapling sensor Outfeed sensor Infeed sensor Side jogger home position sensor Side jogger hall sensor Main power fuse 10 VAC fuse, T500 mA 10 VAC fuse for staple detection, T500 mA 26 VAC fuse, T6.3 A Ground fault interrupter Transformer Rectifier Filter Capacitor Interface receptacle Stacker receptacle Controller Printed circuit board PAGE 7.4.2 PAGE 7.4.3 PAGE 7.4.2 PAGE 7.4.1 PAGE 7.4.4 PAGE 7.4.4 PAGE 7.4.4 PAGE 7.4.3 PAGE 7.4.3 PAGE 7.4.1, 7.4.3 PAGE 7.4.2 PAGE 7.4.4 PAGE 7.4.3 PAGE 7.4.3 PAGE 7.4.3 PAGE 7.4.2 PAGE 7.4.1 PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE 7.4.1 7.4.1 7.4.1 7.4.1, 7.4.3 7.4.4 7.4.2 7.4.4 7.4.2
SEN SEN SEN SEN
SEN 5 SEN 6 SEN 7 F1 F2 F3 F4 GFI T1 REC 1 FL 1 C1 J5 J6 PCB PL75-1
PAGE 7.4.4 PAGE 7.4.4 PAGE 7.4.4 PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE PAGE 7.4.3 7.4.3 7.4.3 7.4.3 7.4.3 7.4.3 7.4.1 7.4.1 7.4.1 7.4.3 7.4.1 7.4.1
Bookletmaker SR 85
PAGE 7.3.1
SR85 Service Manual
EDI 7.4 Electrical components location

REAR VIEW SW 5 J2 J1 TP 1-16 J4 PCB PL75-1 J3
SW 3 SW 6 Interlock bypass switch actuator
SW 4
Common ground
C1
REC 1
J6
FRONT VIEW Set counter MOT 10 MOT 8 SW 7
Bookletmaker SR 85
PAGE 7.4.1
Continue EDI 7.4 Electrical components location

VIEW INSIDE OUTFEED COVER
LEFT VIEW SEN 2
SEN 4
FOLD AREA SHOWN IN TIPPED POSITION
MOT 5
MOT 6
SW 2
MOT 12 PAGE 7.4.2
Bookletmaker SR 85
SR85 Service Manual

VIEW INSIDE INFEED COVER SOL 2 MOT 4 SOL 1
SW 1
T1
F3 F2 F4
MOT 2 MOT 1
RIGHT VIEW INFEED COVER REMOVED
SW 7 J5 F1 AC Receptacle
GFI
Bookletmaker SR 85
PAGE 7.4.3
VIEW OF INFEED AREA SEN 3
BOTTOM VIEW OF REMOVED INFEEDER
SEN 7 MOT 7 MOT 3 SEN 6
MOT 9 STAPLER STAPLER AREA SEN 1
Bookletmaker SR 85
PAGE 7.4.4
SR85 Service Manual
SEN 5
Test EDI 7.5 Test points

PURPOSE The purpose of the Test points (see location on page 7.4.1, TP 1-16) is to use them as the (+) connector when adjusting sensors or when checking the function of some components and there wires. Use any common ground as (-) connector. Voltage when low: Less than 0.9 VDC Voltage when high: Greater than 2.2 VDC Measured value Test point TP 1 TP 2 TP 3 TP 4 TP 5 TP 6 TP 7 TP 8 TP 9 TP 10 TP 11 TP 12 TP 13 TP 14 TP 15 TP 16 Description Saddle stapling sensor SEN 1 Fold stop sensor SEN 2 Home position side registration Fold knife home position switch SW 2 Stapler home position switch SW 1 Jam signal from Trimmer Edge stapling sensor SEN 3 Outfeed sensor SEN 4 Infeed sensor SEN 5 Trimmer knife activated Length adjustment maximum limit switch SW 3 Not used Length adjustment minimum limit switch SW 4 Trimmer connected Rear staple detection Front staple detection High inactivated High inactivated High inactivated High inactivated after switched on (At Ready) Low inactivated High inactivated High inactivated Low activated Low activated High inactivated High inactivated Low inactivated High inactivated High inactivated High inactivated
Bookletmaker SR 85
PAGE 7.5.1
FIP 8.1 Self diagnostic system control (SDS)

PURPOSE The purpose of the Self diagnostic system control (SDS) is to provide a functional check of the components of the Bookletmaker SR 85. PROCEDURE
SR85 Service Manual
NOTE1: The Interlock switch or the Interlock bypass switch has to be actuated and DIP switches 1, 3 and 4 on the controller PCB must be (in normal position) to the left (left when facing the PCB), DIP switch 2 must be to the right and the SR 85 has to be cleared from paper sheets in order to perform the SDS. off power, NOTE2: If the SDS is repeated, switch off the power, wait a few seconds, switch on the power again to return the motors and solenoids to home position. CAUTION1: Always handle the PCB and micro processor in accordance with electrostatic discharge procedures (ESD). The PCB contains components that are sensitive to ESD damage. CAUTION2: Do not switch of the power during SDS. If there is a loss of power during SDS, reset the EEPROM according to PRG 6.1.1
1. Switch off the power. 2. Press and hold the Auto/Manual button. Switch on the power. Release the Auto/Manual button. First the Auto LED is flashing: The SR 85 is testing the EEPROM. Then the Manual LED is flashing: The SR 85 is testing the 24 voltage, the 36 voltage, motors and solenoids. At last all of the LEDs are lighting on the control panel: The test is complete. 3. Press the five buttons on the control panel one at the time. All of the LEDs should be switched off except the Staples LED. 4. Press the two buttons to the left on the control panel at the same time. The last LED on the control panel should be switched off. If all of the LEDs are off, the SDS is complete, no errors found. If any faults was detected during SDS, the last six LEDs will provide a fault code pattern. Press the Auto/Manual button to display any other faults that were detected during the SDS. Refer to SDS Fault code table and locate the lighting pattern of the LEDs.
Bookletmaker SR 85
PAGE 8.1.1
FIP 8.1 Self diagnostic system control, Fault code table

Fault code 1. EEPROM error Possible cause EEPROM values incorrect. EEPROM defective. Fault isolating / repair Reset the EE-prom according to PRG 6.1. Replace the controller PCB.
2. 36 VDC error
Interlock switch SW 5 activated. Rectifier REC 1 defective. Transformer T 1 defective. Capacitor C 1 defective. Wires defective.
See fault code 5. Replace Rectifier. Replace Transformer. Replace Capacitor. Check the wires for an open circuit using a voltmeter. Measure from 3, 4 and 5 on connector J8 to the capacitor. Replace controller PCB.
Controller PCB defective. 3. 24 VDC error
Controller PCB defective.
Replace controller PCB.
4. Interlock switch SW 5, activated.
Top cover open or Interlock switch not activated. Top cover misadjusted. Micro switch defective.
Close the Top cover or pull out the Interlock bypass switch actuator. Check/Adjust the Top cover according to REP 1.2. Disconnect the wires from the switch. Check the function of the switch using a voltmeter. Check both Interlock micro switch and Interlock bypass micro switch. Disconnect the wires from the switch. Check the wires for an open circuit using a voltmeter. Measure from 10C and 17A on connector J1 to the Interlock switch and 10C and 12A to the bypass switch. If checks above is good, replace the controller PCB. Switch off the power and switch on the power again. Check/Adjust the Stapler home position according to REP 3.5. Disconnect the wires from the switch. Check the function of the switch using a voltmeter. Check that the voltage between TP5 on the controller PCB and common ground is less than 0.9 VDC when the switch is activated and greater than 2.2 VDC when the switch is inactivated. If checks above is good, replace the controller PCB.
Wires defective.
Controller PCB defective. 5. Stapler home position switch SW 1, not activated. Stapler motor in faulty position. Stapler home position misadjusted. Micro switch defective.
Wires defective.
Bookletmaker SR 85
PAGE 8.1.2
Continue FIP 8.1 Self diagnostic system control, Fault code table
F a u lt c o d e 6 . F o ld k n ife m o to r h o m e p o s itio n s w itc h S W 2 , n o t a c tiv a te d . P o s s ib le c a u s e F a u lt is o la tin g / re p a ir F o ld k n ife m o to r in fa u lty p o s itio n . S w itc h o ff th e p o w e r a n d s w itc h o n th e p o w e r a g a in . F o ld k n ife h o m e p o s itio n m is a d ju s te d . M ic ro s w itc h d e fe c tiv e . C h e c k /A d ju s t th e F o ld k n ife h o m e p o s itio n a c c o rd in g to R E P 4 .4 . D is c o n n e c t th e w ire s fro m th e s w itc h . C h e c k th e fu n c tio n o f th e s w itc h u s in g a v o ltm e te r. C h e c k th a t th e v o lta g e b e tw e e n T P 4 o n th e c o n tro lle r P C B a n d c o m m o n g ro u n d is le s s th a n 0 .9 V D C w h e n th e s w itc h is a c tiv a te d a n d g re a te r th a n 2 .2 V D C w h e n th e s w itc h is in a c tiv a te d . If c h e c k s a b o v e is g o o d , re p la c e th e c o n tro lle r P C B . C h e c k th a t th e v o lta g e b e tw e e n T P 3 o n th e c o n tro lle r P C B a n d c o m m o n g ro u n d is le s s th a n 0 .9 V D C w ith th e s e n s o r b lo c k e d a n d g re a te r th a n 2 .2 V D C w ith th e s e n s o r u n b lo c k e d . D is c o n n e c t th e s e n s o r c o n n e c to r. C h e c k th e w ire s fo r a n o p e n c irc u it u s in g a v o ltm e te r. M e a s u re fro m 3 0 A a n d 3 0 C o n c o n n e c to r J 1 to th e s e n s o r c o n n e c to r. M e a s u re fro m 3 0 A a n d 4 C o n c o n n e c to r J 1 to th e s e n s o r c o n n e c to r. R e p la c e th e c o n tro lle r P C B . R e m o v e th e p a p e r. C h e c k th a t th e v o lta g e b e tw e e n T P 7 o n th e c o n tro lle r P C B a n d c o m m o n g ro u n d is le s s th a n 0 .9 V D C w ith th e s e n s o r b lo c k e d a n d g re a te r th a n 2 .2 V D C w ith th e s e n s o r u n b lo c k e d . D is c o n n e c t th e s e n s o r c o n n e c to r. C h e c k th e w ire s fo r a n o p e n c irc u it u s in g a v o ltm e te r. M e a s u re fro m 2 6 C a n d 2 6 A o n c o n n e c to r J 1 . M e a s s u re fro m 2 C a n d 8 A o n c o n n e c to r J 1 . If c h e c k s a b o v e is g o o d , re p la c e th e c o n tro lle r P C B . R e m o v e th e p a p e r. C h e c k /A d ju s t th e S a d d le s ta p lin g s e n s o r a c c o rd in g to R E P 3 .7 . C h e c k th a t th e v o lta g e b e tw e e n T P 1 o n th e c o n tro lle r P C B a n d c o m m o n g ro u n d is g re a te r th a n 2 .2 V D C w ith th e s e n s o r b lo c k e d a n d le s s th a n 0 .9 V D C w ith th e s e n s o r u n b lo c k e d . D is c o n n e c t th e s e n s o r c o n n e c to r. C h e c k th e w ire s fo r a n o p e n c irc u it u s in g a v o ltm e te r. M e a s u re fro m 3 2 C , 3 2 A o n c o n n e c to r J 1 . M e a s u re fro m 1 C a n d 2 3 A o n c o n n e c to r J 1 . If c h e c k s a b o v e is g o o d , re p la c e th e c o n tro lle r P C B .
W ire s d e fe c tiv e .
C o n tro lle r P C B d e fe c tiv e . 7 . S id e jo g g e r h o m e p o s itio n s e n s o r S E N 6 , fa u lty . S e n s o r d e fe c tiv e .
C o n tro lle r P C B d e fe c tiv e . 8 . E d g e s ta p lin g s e n s o r S E N 3 , a c tiv a te d . P a p e r is b lo c k in g th e s e n s o r. S e n s o r d e fe c tiv e .
C o n tro lle r P C B d e fe c tiv e . 9 . S a d d le s ta p lin g s e n s o r S E N 1 , a c tiv a te d . P a p e r is b lo c k in g th e s e n s o r. S e n s o r m is a d ju s te d . S e n s o r d e fe c tiv e .
C o n tro lle r P C B d e fe c tiv e .
Bookletmaker SR 85
PAGE 8.1.3
SR85 Service Manual
Fault code 10 Outfeed sensor SEN 4, . activated. Possible cause Paper is blocking the sensor. Sensor misadjusted. Sensor defective. Fault isolating / repair Remove the paper. Check/Adjust the Outfeed sensor according to REP 4.5. Check that the voltage between TP8 on the controller PCB and common ground is greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC with the sensor unblocked. Disconnect the sensor connector. Check the wires for an open circuit using a voltmeter. Measure on connector J1 between 25A and 25C. And between 21A and 3C. If checks above is good, replace the controller PCB. Remove the paper. Reposition the sensor to obtain the voltages below. Check that the voltage between TP2 on the controller PCB and common ground is greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC with the sensor unblocked. Disconnect the sensor connector. Check the wires for an open circuit using a voltmeter. Measure on connector J1 between 31A and 31C. And between 31A and 4A. If checks above is good, replace the controller PCB. Find what causes the short circuit and perform appropriate action. Check that the voltage between TP15 on the controller PCB and common ground is less than 0.9 VDC when the stapler head is in contact with the anvil and greater than 2.2 VDC when not in contact. Use a screw driver to connect the stapler head with the anvil. If check above is good, replace the controller PCB.
Wires defective.
Controller PCB defective. 11 Fold stop sensor . SEN 2, activated. Paper is blocking the sensor. Sensor misadjusted. Sensor defective.
Wires defective.
Controller PCB defective. 12 Rear staple detection, . activated. Stapler head short circuit to chassis ground Wires defective.
Bookletmaker SR 85
PAGE 8.1.4
Fault code 13 Front staple detection, . activated. Possible cause Stapler head short circuit to chassis ground. Wires defective. Fault isolating / repair Find what causes the short circuit and perform appropriate action. Check that the voltage between TP16 on the controller PCB and common ground is less than 0.9 VDC when the stapler head is in contact with the anvil and greater than 2.2 VDC when not in contact. Use a screw driver to connect the stapler head with the anvil. If check above is good, replace the controller PCB. If a Trimmer is not connected. Connect the Interface cable and the Power cord from the Trimmer to the Model 85. Check the wires for an open circuit using a voltmeter. Measure from 6 on connector J9 to pin 8 on the DIN receptacle. Measure from 13 on connector J9 to pin 5 on the DIN receptacle. See technical documentation for Trimmer. Replace the controller PCB. Remove the paper. Reposition the sensor to obtain the voltages below. Check that the voltage between TP9 on the controller PCB and common ground is greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC with the sensor unblocked. Disconnect the sensor connector. Check the wires for an open circuit using a voltmeter. Measure on connector J1 between 24A and 24C. And between 24A and 2A. If checks above is good, replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 14 and 7 on connector J8 to the motor connector. Replace the controller PCB.
Controller PCB defective. 14 Trimmer not . connected. Model 85 intact. Cabels not connected.
Wires defective.
Trimmer faulty. Controller PCB defective. 15 Infeed sensor SEN 5, . activated. Paper is blocking the sensor. Sensor misadjusted. Sensor defective.
Wires defective.
Controller PCB defective. 16 Infeed transport belt . motor MOT 9, open circuit. Motor defective.
Wires defective.
Bookletmaker SR 85
PAGE 8.1.5
SR85 Service Manual
Fault code 17 Back jogger motor . MOT 7, jogger up, open circuit. Possible cause Motor defective. Fault isolating / repair If both fault code 17 and 18 was detected. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. If both fault code 17 and 18 was detected. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 10 and 11 on connector J8 to the motor connector. If only one of fault code 17 and 18 was detected. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 8 and 1 on connector J9 to the motor connector. Replace the controller PCB.
Wires defective.
Controller PCB defective. 18 Fold stop gate motor . MOT 12, open circuit. Motor defective.
Wires defective.
19 Stapler motor MOT 1, . open circuit.
Motor defective.
Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 9 and 2 on connector J2 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 7 and 14 on connector J9 to the motor connector. Replace the controller PCB. Disconnect the solenoid connector. Check the solenoid for an open circuit using a voltmeter. Disconnect the solenoid connector. Check the wires for an open circuit using a voltmeter. Measure from 5 on connector J2 to 5 on connector J9. Replace the controller PCB.
Wires defective.
Controller PCB defective. 20 Stapled set transport . motor MOT 4, Open circuit Motor defective.
Wires defective.
Controller PCB defective. 21 Stapled set transport . solenoid SOL 1, open circuit. Solenoid defective.
Wires defective.
Bookletmaker SR 85
PAGE 8.1.6
Rev. 08/2002
Fault code 22 Staple stop gate . release solenoid SOL 2, open circuit. Possible cause Solenoid defective. Fault isolating / repair Disconnect the solenoid connector. Check the solenoid for an open circuit using a voltmeter. Disconnect the solenoid connector. Check the wires for an open circuit using a voltmeter. Measure from 4 and 11 on connector J2 to the solenoid connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 11 and 12 on connector J9 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 8 and 1 on connector J2 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 11 and 14 on connector J2 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 13 and 6 on connector J9 to the motor connector. Replace the controller PCB.
Wires defective.
Controller PCB defective. 23 Side jogger motor MOT3, Motor defective. . open circuit. Wires defective.
Controller PCB defective. 24 Fold knife motor . MOT 2, open circuit. Motor defective.
Wires defective.
Controller PCB defective. 25 Folder roller motor . MOT 8, open circuit. Motor defective.
Wires defective.
Controller PCB defective. 26 Stacker motor MOT 5, . open circuit. Motor defective.
Wires defective.
Note: When running SDS with the TR85 installed, only the SR85 is tested. Therefore the test software will assume that the Belt Stacker is not connected and a Fault Code 26 will occur.
Bookletmaker SR 85
PAGE 8.1.7
SR85 Service Manual
Fault code 27 Length adjustment . maximum limit switch SW 3, activated. Possible cause Fault isolating / repair Adjusted to maximum paper size. Adjust to a smaller paper size. It it is allowed to run the Model 75 adjusted to the largest paper size Micro switch defective. Disconnect the wires from the switch. Check the function of the switch using a voltmeter. Check that the voltage between TP13 on the controller PCB and common ground is less than 0.9 VDC when the switch is activated and greater than 2.2 VDC when the switch is inactivated. If checks above is good, replace the controller PCB.
Wires defective.
Controller PCB defective. 28 Length adjustment . minimum limit switch SW 4, activated.
Adjusted to minimum paper size. Adjust to a larger paper size. It it is allowed to run the Model 75 adjusted to the smallest paper size Micro switch defective. Disconnect the wires from the switch. Check the function of the switch using a voltmeter. Check that the voltage between TP11 on the controller PCB and common ground is less than 0.9 VDC when the switch is activated and greater than 2.2 VDC when the switch is inactivated. If checks above is good, replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 8 and 9 on connector J8 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 12 and 13 on connector J8 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 1 and 2 on connector J8 to the motor connector. Replace the controller PCB.
Wires defective.
Controller PCB defective. 29 Edge staple stop motor . MOT 10, open circuit. Motor defective.
Wires defective.
Controller PCB defective. 30 Edge stapling transport Motor defective. . motor MOT 11, open circuit Wires defective.
Controller PCB defective. 31 Length adjustment . motor MOT 6, open circuit. Motor defective.
Wires defective.
Bookletmaker SR 85
PAGE 8.1.8
Fault code 32.Side jogger, 32. Side jogger, hall sensor faulty. SEN7, faulty. Sensor defective. Check that the voltage between 15C and 19A on connector J1. Is greater than 2.2 VDC with the sensor blocked and less than 0.9 VDC with the sensor unblocked. Disconnect the sensor connector. Check the wires for an open circuit using a voltmeter. Measure on connector J1 between 15C and 19A. And between 19A and 1A. Possible cause Fault isolating / repair
Wires defective.
If check above is good, replace the controller PCB.
Bookletmaker SR 85
PAGE 8.1.9
MAI 9.1 Preventive Maintenance Note: All INSTRUCTIONS are referring to the Bookletmaker SR 85 Service Manual. The REFERENCE column is referring to the Spare parts list of Model SR85. The 125 000, 250 000 is referring to the number of Booklets produced.
CHECK POINT All machine, Paper paths etc. INSTRUCTION Use a vacuum cleaner, towels and brushes to clean the machine from paper dust. Use an alcohol to clean from ink. Apply grease. Check according to REP 3.4. Apply grease between vertical rods and Fold knife plate. REFERENCE 125000 Clean 250000 Clean
Stapler assy. drive bars (2 pcs.)
Check
Grease/ Adjust Grease
Fold knife drive bars (2 pcs.)
Page 1.13 Item 10
Check
Fold stop bars (2 pcs.)
On square shaped bar Page 1.13 holding the fold stop assy, apply silicon grease on the bottom side of the bars (between the bar and the ty-wrap). Check ty-wraps for wear. If worn, replace. Apply silicon grease between Crank journal and Rod. Apply silicon grease between Crank elbow and Rod. Page 1.9 Item 14
Check
Grease/ Check
Stapler motor crank arm (2 pcs.)
Check
Grease
Fold knife motor crank arm (2 pcs.)
Page 1.13 Item 12
Check
Grease
O-ring for eject feed wheel
Check for wear. If worn, replace. Always replace at 250 000. Check for wear. If worn, replace. Use chain oil. Check for wear, if worn/stretched replace. Always replace every 100 00 00.
Page 1.9 Item 4
Check/Clean
Replace
O-ring for edge staple motor
Page 1.5 Item 3 Page 1.5 Item 20
Check
Check
Chain
Oil
Oil
Chain idler rollers (3 pcs.)
Apply grease between Page 1.5 idler roller and pin. Check Item 12 for wear. If worn, replace. Use grease at 500 000. Page 1.9 Item 10
Check/Grease Replace
Threaded adjustment rod
(Grease)
Bookletmaker SR 85
PAGE 9.1.1
Continue MAI 9.1 Preventive Maintenance
CHECK POINT Lower fold roller holder bracket (2 pcs.)
INSTRUCTION
REFERENCE
125000 Check/Grease
250000 Grease
Upper fold roller bearings (2 pcs.)
Under the top cover, use Page 1.5 oil between bearings and Item 10 shaft. Apply silicon grease between bearing and side frame. Use a rubber reactivator alcohol fluid. Page 1.13 Item 1
Oil
Oil/ Grease
Upper fold rollers
Clean
Clean
Stapler heads (2 pcs.)
Check stapler heads by stapling 20 sheets. If poor staple result, replace stapler head. The poor staple result is due to worn driver points. Apply silicon grease on plastic guide posts and between top of drive post and stapler drive bracket. Use thin oil on stapler driver (without staining the paper). Apply silicon grease on bearing points. Check adjustment according to REP 3.6 when replacing stapler heads. Apply silicon grease on Page 1.9 both friction areas. Check Item 3 that the stop gate latches and releases correctly.
Grease/Check
Replace
Stapler retraction swing arm (2 pcs.)
Grease
Grease/ Adjust
Staple stop gate release arm solenoid. SOL 2
Grease/ Check
Bookletmaker SR 85
PAGE 9.2.1
SR85 Service Manual
Apply grease between the Page 1.5 spacer bracket and the Item 18 side frames. Check for wear, if worn replace.
Continue MAI 9.1 Preventive Maintenance

CHECK POINT INSTRUCTION REFERENCE 125000 250000
Infeed module removed

Infeed transport belt Use a rubber reactivator alcohol fluid. Check for wear. If worn, replace, check bushings, oil. Page 1.11 Item 6 Clean Check
With the infeed module installed

Side guide parallelism Check that the side guides are parallel according to reference holes in the lower paper path. REP 2.3 for adjustment. Check the booklet quality according to REP 5.1 - 5.2 and REP 5.4 - 5.7 Check/Adjust Check/ Adjust
Booklet quality
Check/Adjust
Check/ Adjust
Bookletmaker SR 85
PAGE 9.3.1
Service Manual Trimmer TR 85
Contents
REPAIRS/ADJUSTMENTS REPAIRS/ADJUSTMENTS (REP)
REP 3.1 REP 3.2 REP 3.3 REP 3.4 REP 3.5 REP 3.6 REP 3.7 REP 3.8 REP 3.9 REP 3.10 REP 3.11 REP 3.12 REP 3.13 REP 3.14 REP 3.15 REP 3.16 REP 3.17 REP 3.18 REP 3.19 REP 3.20 REP 3.21 REP 3.22 REP 3.23 REP 3.24 REP 3.25 REP 3.26 REP 3.27 REP 3.28 REP 3.29 REP 3.30 Front cover Rear cover Upper cover, outfeed side Lower cover, outfeed side Protective cover Deck plate Stop carriage Exchanging PCB Front panel Knife motor Transmission motor Adjustment motor Trimmer stop motor Infeed switch Control switch infeed, upper shaft Stop carriage switch, lower position Stop carriage switch, upper position Interlock switch Control switch, outfeed Start switch Outfeed LED and sensor Scrap paper bin LED Scrap paper bin sensor Knife Infeed shaft Lower outfeed belts Upper outfeed belts Transmission chain Knife support chain Knife chain
PAGE
3.1.1 3.2.1 3.3.1 3.4.1 3.5.1 3.6.1 3.7.1 3.8.1 3.9.1 3.10.1 3.11.1 3.12.1 3.13.1 3.14.1 3.15.1 3.16.1 3.17.1 3.18.1 3.19.1 3.20.1 3.21.1 3.22.1 3.23.1 3.24.1 3.25.1 3.26.1 3.27.1 3.28.1 3.29.1 3.30.1
(MOT1) (MOT2) (MOT3) (MOT4) (SW1) (SW2) (SW4) (SW5) (SW6&7) (SW8) (SOS10) (LED1&PT1) (LED2) (PR1)
DETAIL INFORMATION ELECTRONIC DETAIL INFORMATION

EDI 3.31 EDI 3.32 Test points Wiring diagram 3.31.1 3.32.1
AULT ISOLATING FAULT ISOLATING PROCEDURE

FIP 3.33 Fault isolating procedure 3.33.1
PREVENTIVE MAINTENANCE
MAI 3.34 Preventive maintenace 3.34.1
Trimmer TR 85
PAGE PAGE
REP 3.1 Front cover

REMOVAL 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord. Loosen the two screws (1). Pull the lower side out as indicated in drawing and lift off the cover. Disconnect the ground lead.
INSTALLATION / ADJUSTMENT INSTALLATION Installation is an exact reversed procedure of removal.
WARNING: Avoid direct light on slotted optical sensors (SOS). It may cause knife to start when power is on. Make sure that ground wire is connected.
Trimmer TR 85
PAGE PAGE 3.1.1
TR85 Service Manual
REP 3.2 Rear cover

REMOVAL 1. 2. 3. 4. Switch off the main power switch and disconnect the main power cord. Loosen the two screws (1). Pull the lower side out as indicated in drawing and lift off the cover. Disconnect the ground lead.

WARNING: Make sure ground wire is connected.
Trimmer TR 85
PAGE PAGE 3.2.1
cover, REP 3.3 Upper cover, outfeed side

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Switch off the main power switch and disconnect the power cord. Remove front and rear cover according to REP 3.1 & 3.2. Open top cover. Remove interlock switches according to REP 3.18 and remove tie-wrap from cover. Remove spring (1) holding compressing brackets. Remove self-tapping screws (8 pcs). Disconnect out feed sensor and remove tie-wraps holding cable. Remove upper cover (2).
INSTALLATION / ADJUSTMENT INSTALLATION 1. Connect out feed sensor according to REP 3.21. 2. Mount upper cover. 3. Switch on main power and check voltage on exit sensor according to REP3.21. 4. If sensor is exceeding values, adjust by slightly bending bracket on upper cover. 5. Check interlock function according to REP 3.18.
Trimmer TR 85
PAGE PAGE 3.3.1
TR85 Service Manual
cover, REP 3.4 Lower cover, outfeed side

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Switch off the main power switch and disconnect the power cord. Remove belt stacker. Remove front and rear cover according to REP 3.1 & 3.2. Remove scrap paper bin. Loosen the four screws holding deck plate to cover. Remove the two screws holding protective cover to lower cover. Remove the four screws holding cover to side frames. Remove cover (1).
Trimmer TR 85
PAGE PAGE 3.4.1
REP 3.5 Protective cover

REMOVAL 1. 2. 3. 4. Switch off the main power s=witch and disconnect the power cord. Remove scrap paper bin. Remove the four screws holding protective cover to lower cover out feed side. Loosen the four screws (10mm wrench) holding protective cover to lower knife beam one turn (do not remove screws). 5. Pull protective cover (1) in out feed direction and remove cover.
INSTALLATION /ADJUSTMENT INSTALLATION Installation is an exact reversed procedure of removal.

cover. CAUTION: Make sure cover is clear from harnesses when mounting cover.
Trimmer TR 85
PAGE PAGE 3.5.1
TR85 Service Manual
REP 3.6 Deck plate

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power switch and disconnect the power cord. Open top cover. Move out feed compressing bracket to upper position. Remove screws (1). Remove the six screws holding deck plate to lower cover, out feed side (REP 3.4). Remove deck plate through out feed opening.
INSTALLATION / ADJUSTMENT INSTALLATION Align support rollers on deck plate when mounted. When compressing foam rollers manually, support rollers should rise 1mm.
CAUTION: Avoid damaging support rollers when deck plate is removed.
Trimmer TR 85
PAGE PAGE 3.6.1
REP 3.7 Stop carriage

REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Position the stop carriage in between A3 and A4 position, adjust on front panel. Switch off the main power and disconnect the power cord. Remove the scrap paper bin. Remove front and rear cover acc. to REP 3.1 and 3.2. Remove the protective cover acc. to REP 3.5. Remove the lower out feed cover acc. to REP 3.4. Disconnect the two connectors (1) from the side frame (not shown in figure). Remove the stop carriage assy. By pulling on the plate (2).
INSTALLATION /ADJUSTMENT Installation is an exact reversed procedure of removal.

CAUTION: When removing the stop carriage, stay clear of the SOS (Slotted Optical Sensor) switches on the circuit board.
Trimmer TR 85
PAGE PAGE 3.7.1
TR85 Service Manual
REP 3.8 Exchanging PCB

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power switch and disconnect the power cord. Remove rear cover according to REP 3.2. Disconnect front panel extension at PCB connector (1). Remove the two nuts and washers (2) and remove the knife position indicator (3). Disconnect the two connectors (4). Remove the four nuts (5) and remove the PCB.
3 2 1
4 5
INSTALLATION / ADJUSTMENT INSTALLATION 1. Mount PCB on to screws. 2. Connect harness and panel connectors. 3. Mount knife position indicator. 4. Make sure that top end of indicator is positioned flush to upper end of upper knife position SOS, when knife is in top position.
Trimmer TR 85
PAGE PAGE 3.8.1
REP 3.9 Front panel

REMOVAL 1. 2. 3. 4. Switch off the main power and remove the power cord. Remove front cover according to REP 3.1. Disconnect the panel from the adaptor board. Remove the old panel, the panel is mounted with self-adhesive tape. (When tearing off, the panel will be damaged.)
INSTALLATION / ADJUSTMENT INSTALLATION 1. Clean top surface of side frame with alcohol cleaner and remove protective film on back of new panel. 2. Place the panel centered sideways (80mm from edges) and 3mm off the edge according to figure above. 3. Connect the panel to adaptor board.
Trimmer TR 85
PAGE PAGE 3.9.1
3 mm
TR85 Service Manual
REP 3.10 Knife motor (MOT1)

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power and remove the power cord. Remove rear cover according to REP 3.2. Disconnect the wires from the motor at the terminal block (positioned on side of frame). Use a 13 mm wrench to turn camshaft (1) clockwise until the knife is in lower position. Remove knife chain according to REP 3.30. Remove the sprocket (2) by loosening the two setscrews holding the sprocket to the motor shaft and pull off the sprocket. 7. Remove the three screws (3) and lift out the motor.
BLK
RED
VIO BRN
BLK
INSTALLATION / ADJUSTMENT PURPOSE The purpose is to ensure correct drive to the camshaft without any slack in the drive chain. ADJUSTMENT 1. Mount the motor to the side frame, without tightening the screws, and connect the wires to the terminal block according to figure. 2. Mount the sprocket (2) all the way into the clamp ring (4) and tighten the setscrews. One of the sets screws must be in the key-way of the shaft. 3. Tension the knife chain by moving the motor (5) and tighten the screws (3). There should be NO slack in the knife chain.
WARNING: Stay clear from knife edge when turning camshaft and disengaging drive chain.
Trimmer TR 85 PAGE PAGE 3.10.1
3.11 Transmission REP 3.11 Transmission motor (MOT2)

The main function of MOT 2 and the transmission chain is main drive for feed belts. By altering the polarity (reversing direction) MOT 2 and the knifs support chain will function as a support motor for MOT 1, during the lower part of the cutting stroke.
REMOVAL 1. Switch off the main power and remove the power cord. 2. Remove front cover according to REP 3.1. 3. Disconnect the wires from the motor at the terminal block (fig. 2) positioned on side of frame. 4. Remove the four screws (6). 5. Remove the support plate (7) by pulling it off the shaft assy (2). 6. Remove the transmission chain and knife support chain according to REP 3.28 and 3.29. 7. Remove the shaft assy (2) by pulling it out. The shaft assy is mounted with a wedge. (Note the shim washers location when removing the shaft.) 8. Remove the three screws (3) and lift out the motor. 2 1 3 BLK RED 5 6 7 4
BLU FIGURE 1
WHT FIGURE 3
FIGURE 2
INSTALLATION / ADJUSTMENT PURPOSE The purpose is to permit the correct drive without any slack in drive chains. ADJUSTMENT 1. Mount the motor to the side frame without tightening the screws (3). 2. Place the shim washer on to the motor shaft. 3. Mount the shaft assy (1) all the way into the motor hub. 4. Mount the knife support chain (4) according to fig. 3. 5. Tension the chain (4) by moving the motor and tighten the screws (3). 6. Mount the transmission chain (5) according to REP 3.28. 7. Mount the support plate (7). The bushing in the support plate can be adjusted up/down for alignment. 8. Connect wires from motor according to fig.2. Trimmer TR 85 PAGE 3.11.1 PAGE 3.11.1
TR85 Service Manual
REP 3.12 Adjustment motor (MOT3)

REMOVAL 1. 2. 3. 4. 5. Switch off main power and remove the power cord. Remove the stop carriage according to REP 3.7. Remove the return spring (2). Disconnect the connector (1). Loosen the four nuts (3) and remove the motor. (The motor is fitted into keyholes.)
INSTALLATION/ADJUSTMENT Installation is an exact reversed procedure of removal.

CAUTION: When installing, make sure that the wires from the motor stays clear from SOS switches when moving the carriage.
Trimmer TR 85
PAGE PAGE 3.12.1
Trimmer REP 3.13 Trimmer stop motor (MOT4)

REMOVAL 1. 2. 3. 4. Switch off the main power and disconnect the power cord. Remove the stop carriage according to REP 3.7. Remove tie-wrap and disconnect the connector (1). Loosen the four nuts (2) and remove the motor while lifting the plastic guide (3) off the scored pulley (4).
4 2 1
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure that the pulley moves freely in the plastic guide. ADJUSTMENT 1. Place the shaft (5) according to figure when mounting motor. 2. Align the pulley with the plastic guide and tighten the setscrew on to the cut out part of the shaft.
NOTE: Motor is fitted into keyholes.
Trimmer TR 85
PAGE PAGE 3.13.1
TR85 Service Manual
REP 3.14 Infeed switch (SW1)

The function of the switch is to set a control time to check if the books are too long for the adjusted cutting margin or is miss folded.
REMOVAL 1. 2. 3. 4. 5. 6. 7. Switch off the main power and remove the power cord. Open top cover. Remove scrap paper bin. Remove protective cover according to REP 3.5. Disconnect the connector (1). Loosen the two 7mm nuts (2) holding the switch bracket (3). Lift out switch bracket (3) and remove the switch.
INSTALLATION/ADJUSTMENT ADJUSTMENT The switch should activate when inserting one sheet of 80gsm/20lbs. offset paper. Check that no part of the switch is over the paper path when switcharm is in fully down position. Check that the switch arm does not touch the wheel on in feed shaft when not activated.
Trimmer TR 85
PAGE PAGE 3.14.1
REP 3.15 Control switch infeed, upper shaft (SW2)

REMOVAL 1. 2. 3. 4. Switch off the main power and disconnect the power cord. Remove rear cover according to REP 3.2. Disconnect the wires from the switch. Remove the two screws (1) and lift out the switch.
INSTALLATION/ADJUSTMENT ADJUSTMENT 1. The micro switch should trip when roller is 1-3mm above lower position (measured while closing). 2. Connect the wires according to the drawing.
Trimmer TR 85
PAGE PAGE 3.15.1
TR85 Service Manual
REP 3.16 Stop carriage switch, lower position (SW4)

REMOVAL 1. 2. 3. 4. Switch off the main power and remove the power cord. Remove the stop carriage according to REP 3.7. Disconnect the wires from the switch. Remove the two screws (1).
VIO BLK
2-3 mm
INSTALLATION/ADJUSTMENT ADJUSTMENT 1. The micro switch should activate when the stop fork is 2-3mm from the stop carriage plate (2) according to fig. 2. 2. Connect the wires according to fig. 2.
Trimmer TR 85
PAGE PAGE 3.16.1
REP 3.17 Stop carriage switch, upper position (SW5)

REMOVAL 1. 2. 3. 4. Switch off the machine and disconnect the power cord. Remove the stop carriage according to REP 3.7. Disconnect the two wires from the switch. Remove the screws (1).
BLK
GRN
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure correct position of the trimmer stop. ADJUSTMENT 1. The micro switch should activate just before top position of the trimmer stop (2). 2. Connect the wires according to figure.
Trimmer TR 85
PAGE PAGE 3.17.1
TR85 Service Manual
REP 3.18 Interlock switch (SW6 & 7)

REMOVAL 1. Switch off the main power and remove the power cord. 2. Open top cover. 3. Loosen the two screws (1) and remove the interlock assy. The interlock assy. is fitted into key holes on the inside of the upper cover, outfeed side. 4. Disconnect the wires.
INSTALLATION/ADJUSTMENT ADJUSTMENT 1. Connect jumper wire (2) to the middle pins on both switches. 2. Connect the orange and red wire to the two lower pins. 3. Mount the interlock switches into the keyholes and tighten the screws (1). 4. Remove rear cover according to REP 3.2. 5. Check interlock function by measuring resistance between red and orange wire on terminal block, mounted on side frame next to PWB. Value should be less than 0,5 ohms with top cover closed. There should be no connection when top cover is open.
NOTE: Make sure that service switch is in off position when checking interlock switches.
Trimmer TR 85
PAGE PAGE 3.18.1
REP 3.19 Control switch outfeed compressing bracket (SW8)

The function of SW8 is to disable machine operation when the compressing bracket moves into the Upper position, opening SWB contacts. REMOVAL 1. Switch off the main power and disconnect the power cord. 2. Remove the rear cover according to REP 3.2 and open the top cover. 3. Disconnect the wires from the switch. 4. Remove the two screws (1) and lift out the switch and insulating plate.
BRN WHT
INSTALLATION/ADJUSTMENT ADJUSTMENT 1. The micro switch should activate when the middle compressing bracket is 2-8mm from the =upper lock position. 2. Connect the wires according to figure above.
NOTE: Fit nut plate onto top screw while holding other end of nut plate. Then swing nut Then screw. plate to correct position and fit the other screw.
Trimmer TR 85
PAGE PAGE 3.19.1
TR85 Service Manual
REP 3.20 Start switch (SOS10)

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power switch and disconnect the power cord. Remove the stop carriage according to REP 3.7. Note position of connectors and disconnect them. Note position of SOS10 and diode mark placement before removal. Remove screws and washers (1) while holding SOS with a pair of pliers. Lift out SOS between trimmer stop and stop carrier. 1
INSTALLATION/ADJUSTMENT INSTALLATION 1. Note diode mark on top of SOS before mounting. 2. Mount the SOS with the diode mark turned as indicated in the drawing or as noted at removal. 3. Connect the SOS according to the drawing. 4. Remove rear cover according to REP3.2. 5. Connect power cord and switch on main power. 6. Connect a V-meter between TP3 on PCB PL89-1 and common, select DC voltage. 7. Press the switch activator manually until it is flush with the trimmer stop, the sensor is now blocked, the value should be less than 1 volt. 8. With the optical path clear, the value should be more then 14 volt.
CAUTION: The pins on the SOS (Slotted Optical Sensor) are fragile, do not use excessive force when mounting.
Trimmer TR 85
PAGE PAGE 3.20.1
REP 3.21 Outfeed LED & sensor (LED1 & PT1)

REMOVAL Switch off the main power and remove the power cord. Remove sensor, fig. 1. 1. Pull the connector (1) off the pins from the sensor. 2. Remove the nut (2). Remove LED, fig. 2. 1. Remove lower cover out feed according to REP 3.5. 2. Remove the stop carriage according to REP 3.8. 3. Pull the connectors off the pins from the LED (3). 4. Remove the nut (4).
TR85 Service Manual
BLK () 1 5
3 2 BLK ()
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure that the correct output sensor voltage is obtained. ADJUSTMENT 1. With the optical path from the LED to sensor clear, check that there is more than 10 VDC measured between TP4 on PCB PL89-1 and common. With the path blocked, the voltage should be less than 1 VDC. 2. Move the sensor bracket (5) to obtain the correct voltage.
Trimmer TR 85
PAGE PAGE 3.21.1
REP 3.22 Scrap paper bin LED (LED2)

REMOVAL Switch off the main power and remove the power cord. 1. Remove scrap paper bin. 2. Pull the connector (1) off the pins from the LED. 3. Remove the 10mm nut and remove LED assy (2) from LED bracket (3).
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure that the correct sensor voltage is obtained. ADJUSTMENT 1. Mount the LED assy in bracket. 2. Connect short pin on LED with blue wire on connector (ground). 3. Remove rear cover according to REP 3.2. 4. Connect the power cord and switch on the main power. 5. Connect a V-meter between TP6 and common on PCB PL89-1. the value should be min. 8 VDC with the optical path to the sensor clear. With the light beam blocked, the voltage should be max. 3.5 VDC. Adjust on trimmer TR1.
NOTE: Colours on wires can also be brown and black. Black is equal to blue. WARNING: Avoid direct light on SOS sensors. It may cause knife motor to start when power is on.
Trimmer TR 85
PAGE PAGE 3.22.1
REP 3.23 Scrap paper bin sensor (PR1)

REMOVAL 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord. Remove the scrap paper bin. Pull the connector 1 off the pins of the photoreceiver. Remove the photoreceiver assy by removing the two 6mm nuts located behind the plate 2.
INSTALLATION/ADJUSTMENT Installation is an exact reversed procedure of removal.

NOTE: After installing check adjustment of sensor according to REP 3.22.
Trimmer TR 85
PAGE PAGE 3.23.1
TR85 Service Manual
REP 3.24 Knife

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power switch and disconnect the power cord. Remove the belt stacker. Lift off the TR85 from the SR85. Lift the outfeed compressor assembly to upright position. Remove the upper infeed cover. Remove protective cover according to REP 3.5.
WARNING: Stay clear from upper knife. The knife edge may cause serious injuries. Use the safety block (14) to put between lower knife and upper knife beam as REP. much of the time as possible throughout this REP.
Upper knife 7. Place the safety block (14) between lower knife and upper knife beam. NOTE: The safety block is located inside the rear cover by the interlock bypass switch. 8. Remove knife protection plate (7) by removing the three screws (2). 9. Move transport protection plate from the new to the old knife or use the transport protection plate supplied in the Trimmer installation kit. 10. Release the set clamp by releasing the E-clip on the middle plunger. 11. Remove the six screws (4) with the cup spring washers.
NOTE: When removing screws the nuts (7) will fall down through the cut-out in bottom of knife beam.
12. Lift out the upper knife.

Lower knife 7. Remove the four screws (11) in the middle with the washers. 8. Remove the two screws (11) at each end of the knife with cup spring washers. 9. Lift out the lower knife.
1 2 3 8 4 5 9 10
INSTALLATION
Upper knife 1. Move transport protection from the old to the 6 new knife. 7 2. Clean and apply grease on guide bars (6) and side guides (3). 3. Fit knife onto guide bars. Apply grease on the cup spring washers closest to the knife. Mount screws (4). 4. Remove transport protection and mount it on the old knife. 5. Mount knife protection plate (7). 6. Mount the set clamp.
Upper knife Lower knife
Lower knife 1. Place the lower knife onto the lower knife beam. 2. Apply grease on all washers. 3. Mount the two screws (11) at each end of the knife with cup spring washers. 4. Mount the four screws (11) in the middle with the washers.
Trimmer TR 85
PAGE PAGE 3.24.1
REP 3.24 Knife, continues

ADJUSTMENT 1. Turn the six mounting screws (4) so there is no tension and no play between cup spring washers and upper knife. Then turn the mounting screws (4) one revolution clockwise. 2. Loosen the nuts (9) and turn the three adjustment screws (10) fully counter clockwise. Loosen the six mounting screws (11) on lower knife. Push the lower knife against the bracket (8). 11
10
FIGURE 1
3. Use the safety block (14) to put between lower knife and upper knife beam as much of the time as possible throughout this adjustment. 4. Use a feeler gauge and check that the space (12) between upper knife and the two red marked screws in the middle (1) is 0.50 mm. Adjust the space if necessary on the two outer adjustment screws and nuts (1). 1
4
0.50 mm
12
Trimmer TR 85
PAGE PAGE 3.24.2
TR85 Service Manual
13
14
5. Lower the upper knife to the bottom position by turning crank shaft (13) using a 13 mm wrench. Caution: When bringing the upper knife down make sure it does not touch the lower knife. 6. Push in the lower knife against the upper knife a couple of times on both ends to make sure it is against the upper knife at the whole cutting area. 7. Raise the upper knife to the top position by turning crank shaft (13). 8. First tighten the screws (11) a little according to the sequence A-F Figure 1. Then tighten a little harder to finally fully tighten the screws according to the sequence. 9. Turn the adjustment screws (10) so they touch the lower knife. 10. Slowly and carefully without paper lower the upper knife to the bottom position by turning crank shaft (13). If the upper knife touches the lower knife, back up the upper knife and start over from step 2.
NOTE: Look through the cut out in the side frame while turning crank shaft.
11. Make a two sheet folded (or staple and folded) A3 (11x17) 80 gsm set and place it in cutting position. Trim the set by turning crank shaft (13).
NOTE: Use the SR85 to staple and fold the required sets.
12. If the set is not correctly cut on one of the ends, loosen the five mounting screws (11) on that end and keep the one mounting screw tightened at the good end. Turn the adjustment screw (10) on the bad end 1/36 revolution or 10. See figure 2. Repeat step 8 and 9, then return to this step until it cuts clean on both ends. 13. Make a 15 sheet folded (or staple and folded) A3 (11x17) 80 gsm set and place it in cutting position. Trim the set by turning crank shaft (13). Repeat step 12. 14. Make a 20 sheet folded (or staple and folded) A3 (11x17) 80 gsm set ==and place it in cutting position. Trim the set by turning crank shaft (13). Repeat step 12.
FIGURE 2 Trimmer TR 85 PAGE PAGE 3.24.3

15. If the set is not correctly cut in the middle, loosen the four mounting screws (11) in the middle and keep the mounting screws tightened at the ends. Turn the adjustment screw (10) in the middle 1/36 revolution or 10. See figure 2. Repeat step 8 and 9, then return to this step until it cuts the set clean on 20 folded sheets.
NOTE: As guidance you can trim a 25 sheet set to clearly see if the result of the adjustments are correct.
16. If the set is not correctly cut on one of the ends after step 15, loosen the adjustment screw (10) in the middle and start over from step 12. 17. Tighten the lock nuts (9). 18. Return the machine to operational condition.
TR85 Service Manual
CAUTION: If the one or both knives have been damaged, they must be replaced or sharpened even if a correct result is obtained, because their cutting life has been shortened. NOTE: When the upper knife becomes dull it is possible to sharpen it. The upper knife can be sharpened until it is 70 mm wide at the shorter end.
70 mm
Trimmer TR 85
PAGE PAGE 3.24.4
REP 3.25 Infeed shaft

If this action is due to old or broken o-rings, skip item 9-10. If removing drive shaft sprocket is intended, do this before removing E-clip. REMOVAL 1. Switch off main power switch and remove power cord. 2. Remove front and rear cover according to REP 3.1 and 3.2 3. Remove transmission chain (1) according to REP 3.28. 4. Remove springs (2) from infeed linkage (3) on both sides. 5. Remove screws holding compressing shaft (4) to infeed linkage. 6. Move all o-rings to front end of shafts and lift out compressing shaft. 7. Remove rear E-clip on drive shaft (5) and push shaft into bearing in rear side frame. 8. Remove o-rings from drive shaft. 9. Remove sprocket (6) from drive shaft and remove infeed linkage and washers. 10. Push/Pull rear bearing out of side frame and lift out shaft. 1
4 5 6 3 2
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure that the compressing shaft is aligned with paper path. INSTALLATION 1. Fit shaft and rear bearing into side frame and fit o-rings on shafts. 2. Mount E-clip, washers, infeed linkage and sprocket on drive shaft. 3. Mount infeed linkage on compressing shaft, make sure that shaft is aligned with paper path and tighten locknuts on screws. 4. Fit springs on screws and mount transmission chain. Trimmer TR 85 PAGE PAGE 3.25.1
REP 3.26 Lower outfeed belts

REMOVAL 1. 2. 3. 4. 5. 6. 7. Switch the TR85 to A3 (11X17) position. Switch off the main power switch and disconnect the power cord. Remove lower cover, outfeed side according to REP 3.4. Open top cover and remove deck plate according to REP 3.6. Remove transmission chain from lower out feed shaft according to REP 3.28. Remove E-clip at rear side frame bearing on out feed shaft. Loosen the two screws (1) holding the adjustable out feed shaft (2) to knife beam brackets(3). 8. Push/pull feed shaft out of bearing in front side frame. 9. Remove one of the screws holding the adjustable shaft and remove the lower out feed belts (4). 1 2 4 3
TR85 Service Manual
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure correct out feed by equal tension of the out feed belts. INSTALLATION 1. Fit belts on rollers. 2. Fit out feed shaft into bearing and mount E-clip and transmission chain. 3. Fit belts on rollers, tension belts and tighten screws on adjustable shaft. 4. Mount deck plate and lower out feed cover.
CAUTION: Avoid damaging the support rollers on deck plate when removed.
Trimmer TR 85
PAGE PAGE 3.26.1
REP 3.27 Upper outfeed belts

REMOVAL 1. Switch off the main power switch and disconnect the power cord. 2. Remove belt stacker and remove front and rear cover according to REP 3.1 and 3.2. 3. Remove springs (7) and six of the screws holding upper out feed cover (top pair remains). 4. Open top cover and tilt upper out feed cover according to fig. 1. 5. Remove E-clip, spring bracket (1), plastic washers and needle bearings (2) from compressing shaft. 6. Remove E-clips (6) at outer compressing brackets and push/pull out shaft. 7. Remove transmission chain from sprocket on upper out feed shaft according to REP 3.28. 8. Remove E-clips next to bearing (3) in side frames and pull bearings out of side frame. 9. Remove out feed compressing assy. 10. Loosen the two screws (4) and remove the upper feed belts (5).
6 7 1 5 4 2 5 3
6 FIGURE 1 FIGURE 2
INSTALLATION/ADJUSTMENT PURPOSE The purpose is to ensure correct out feed by equal tension of the out feed belts. INSTALLATION 1. Tension the out feed belts and tighten the screws. 2. Insert compressing assy into TR85, fit bearings into side frames and continue in reversed order compared to removal.
CAUTION: Avoid damaging the support rollers on deck plate when mounting compressassy. ing assy.
Trimmer TR 85
PAGE PAGE 3.27.1
Transmission REP 3.28 Transmission chain

REMOVAL 1. 2. 3. 4. 5. 6. Switch off the main power and remove the power cord. Remove front cover according to REP 3.1. Lift off chain tensioner (1) from transmission chain (2). Lift off chain from sprocket on upper out feed shaft. Lift off chain from sprocket on lower out feed shaft. Remove chain. 1 2
INSTALLATION/ADJUSTMENT INSTALLATION Install chain as in figure.

CAUTION: Make sure that chain lock is in right direction.
Trimmer TR 85
PAGE PAGE 3.28.1
TR85 Service Manual
REP 3.29 Knife support chain

REMOVAL 1. 2. 3. 4. 5. Switch off the main power switch and remove the power cord. Remove front cover according to REP 3.1. Remove transmission chain according to REP 3.28. Remove chain tension spring (1) and flip tensioner (2) over to crank shaft sprocket (3). Loosen the three screws (4) holding MOT 2 one to two turns and push the motor towards the crankshaft. 6. Lift the knife support chain off the motor sprocket and remove chain.
4 5
1 2
INSTALLATION/ADJUSTMENT INSTALLATION 1. Mount knife support chain on to crankshaft sprocket. 2. Mount chain on motor sprocket. 3. Tension the chain by moving the motor and tightening the screws. 4. Mount transmission chain according to REP 3.28.
CAUTION: Make sure that chain locks is in right direction. There should be no slack in chain.
Trimmer TR 85
PAGE PAGE 3.29.1
REP 3.30 Knife chain

REMOVAL
WARNING: Remove the safety block (1) from the interlock bypass bracket and place it between the knife beams, or rotate the upper knife beam to the down position, to prevent knife from falling.
1. 2. 3. 4.
Switch of the main power switch and remove the power cord. Remove rear cover according to REP 3.2. Disconnect front panel extension from front panel (2). Loosen the three screws (3) holding knife motor 1-2 turns, and push motor towards the crankshaft. 5. Lift the knife chain off the motor sprocket (4) and remove chain.
INSTALLATION/ADJUSTMENT INSTALLATION 1. Mount knife chain on to crankshaft sprocket (5). 2. Mount chain on motor sprocket. 3. Tension the chain by moving the motor and tightening the screws. 4. Remove safety block from knife beams and place it on the bypass bracket.
CAUTION: Make sure that the chain locks in its right direction. There should be no slack in chain.
Trimmer TR 85
PAGE PAGE 3.30.1
TR85 Service Manual
Test EDI 3.31 Test points

The test points can be used to verify components function. Any common ground can be used as a negative connection. Test points 1-6 are numbered from left to right.
TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11
Turning of stop carriage (SOS on PCB) Exit sensor signal from SR85 Signal from start sensor SOS 10 Out feed sensor LED1/PT1 End position for stop carriage (SOS on PCB) Scrap bin sensor PR1 (Adjust on trimmer) Knife home position sensor (SOS on PCB) Start of transmission motor (SOS on PCB) 11/A4 sensor (SOS on PCB) 14 sensor (SOS on PCB) 17/A3 sensor (SOS on PCB)
Not activated 14-15 VDC >14 VDC >14 VDC >9 VDC 14-15 VDC 8.5-10 VDC 14-15 VDC 14-15 VDC 14-15 VDC 14-15 VDC 14-15 VDC
Activated <2 VDC <1VDC <2VDC <2VDC <2VDC <2VDC <2VDC <2VDC
photointerupter. Note: SOS (Slotted Optical Sensor) is similar to a photointerupter.
Trimmer TR 85
PAGE PAGE 3.31.1
Trimmer TR85
Page 3.32.1
FIP 3.33 Fault isolating procedure

GUIDELINES The fault isolating procedure is showing the operating sequence of the trimmer from switching on for a specific job to stacking of sets as a reference. Follow the guide below to systematically locate information in the fault isolating procedure.
SEQUENCE OF OPERATION
-Were in the operating sequence does the problem occur?
OBSERVED FAULT
-What is the observed fault?
POSSIBLE CAUSE
-What are the possible causes for the problem to occur?
FAULT ISOLATION/REPAIR
-Guidelines and reference for corrective actions.
Trimmer TR 85
PAGE 3.33.1
August 2000

OPERATION SEQUENCE OF OPERATION
Trimmer switched on.
OBSERVED FAUL AULT OBSERVED FAULT

No machine initialization.
POSSIBLE CAUSE
Secondary fuse in trimmer. 24 VDC supply to PCB 89-1.
AULT/ISOLA T/ISOLATING REPAIR FAULT/ISOLATING REPAIR

Located at the transformer Check for 30 VDC at connector J1 pin C12 and common ground on PCB 89-1. Check voltage at power cord from stapler folder. Replace PCB 89-1 see REP 3.8.
Primary circuit from stapler folder 220/115 Volts. Main PCB defective.
Belts running continuously.
Phototransistor/LED in stapler folder defective. Start signal circuit stapler folder to trimmer interrupted. Main PCB defective.
Check test point TP2 on PCB 89-1 see EDI 3.31. Check connection of interface cable.
Replace PCB 89-1 see REP 3.8.
Trimmer knife cycling continuously.
Knife position indicator misadjusted. Knife home position sensor defective. Main PCB defective.
Adjust according to REP 3.8.
Check test point TP7 see EDI 3.31.
Jam indication printer.
Interlock switches on top cover defective. Interface cable not connected.
Replace/adjust SW6, SW7 see REP 3.18. Connect interface cable.
Trimmer TR 85
PAGE 3.33.2
TR85 Service Manual
August 2000

Set up procedure.

Format setting inoperative.
POSSIBLE CAUSE
PTC recistor on main PCB activated (stop carriage has to activate and reverse from end switch in two seconds). Insufficient connection on stop carriage. Slotted optical switches on PCB defective. Stop carriage motor MOT 3 defective. Main PCB defective.

Switch off stapler folder for five seconds M/C will regain operative mode when switched on.
Check connection of stop carriage.
Check test points TP5,9,10 and 11 see EDI 3.31. Check for app. 24 VDC at J1 pin C8 and J1 pin C6. Replace PCB 89-1 see REP 3.8.
folder. Paper transport in stapler folder.
Jam indication trimmer.
Control switch SW2 defective/ misadjusted. Compressing brackets remaining in upper jam/clearance position. Control switch compressing brackets SW8 defective/misadjusted. Infeed switch SW1 defective/ misadjusted.
Check according to REP 3.15.
Check compressing brackets.
Trimmer TR 85
PAGE 3.33.3
August 2000

Paper transport in stapler folder cont.

Scrap paper bin full indication.
POSSIBLE CAUSE
Scrap paper bin full. LED2/PR1 defective/misadjusted. Main PCB defective.

Empty scrap paper bin. Check voltage on PR1 see REP 3.22. Replace PCB 89-1 see REP 3.8.
trimmer. Infeed trimmer.
Belt, transport not running.
Photo transistor, outfeed stapler folder defective. Transmisssion motor MOT2 defective. Main PCB defective.
Check voltage on test point TP2 see EDI 3.31. Check for 24 VDC on motor MOT2.
Check for 24 VDC on connector J2 pin 1 and 2 see EDI 3.32. Check for loose hardware.
Transmission defective.
Set entering belt transport.
Skew cutting.
Incorrect belt tension.
See REP 3.26 and 3.27 for adjustment.
Position of cut variable.
Incorrcet belt tension. Incorrect position of stop carriage switches. Mechanical obstacles.
See REP 3.26 and 3.27 for adjustment. See REP 3.16 and 3.17 for adjustment.
Grease, oil, burrs etc. on paper path.
Incorrect position of cut.
Incorrect position of stop carriage indi- Adjust indicator on stop carriage so that the cutting margin is 4-5mm. cator. Slotted optical switches defective. Check test points TP9-11 see EDI 3.31.
Trimmer TR 85
PAGE 3.33.4
TR85 Service Manual
August 2000

Set entering belt transport cont.

Incorrect position of cut cont.
POSSIBLE CAUSE
Main PCB defective.

Set arrives at the trimmer stop.
Trimmer stop not in upper position.
Off-line mode selected on front panel. Stop carriage switch SW5 defective. Trimmer stop motor MOT4 defective.
Select trimmer mode. See REP 3.17 for repair.
Check for DC voltage on connector J1 pin 8A and common ground on PCB 89-1. See REP 3.13 for repair. Replace PCB 89-1 see REP 3.8.
Main PCB defective.
Set does not activate start switch SOS10.
Low drive on infeed belts. Mechanical obstacles. Switch actuator misadjusted.
Clean/tension infeed belts. Grease, oil, burrs etc. on paper path. Adjust according to REP 3.20.
No knife operation despite switch actuation.
SOS10 defective. Main PCB defective.
Check/replace according to REP 3.20. Check for 24 VDC at connector J2 pin 2 and common ground on PCB 89-1 / replace PCB 89-1 see REP 3.8. Check for 24 VDC at motor / replace according to REP 3.10.
Knife motor MOT1 defective.
Trimmer TR 85
PAGE 3.33.5
August 2000

Set arrives at trimmer stop cont.

Jam indication and direct outfeed of the sets.
POSSIBLE CAUSE
Infeed switch SW1 misadjusted/defec- Check/adjust according to REP 3.14. tive. Mechanical obstacles in paper transport. Time from actuating SW1 to start switch SOS10 to long, see previous section set entering belt transport. Check replace according to REP 3.20. Replace PCB89-1 see REP 3.8.
Start switch SOS10 defective. Main PCB defective.
Stop, transport belts.
Belts does not stop.
Voltage on outfeed phototransistor PL8 to low. Stop signal to MOT 2 interrupted.
Check voltage on test point 2 see EDI 3.31. Replace PCB 89-1 see REP 3.8.
Knife, stroke down.
Marks on sheets. Trimmer stop remaining in upper position.
Feeding belts dirty. Loose connectors on stop carriage. Stop carriage switch, lower position SW4 defective/misadjusted. Trimmer stop motor MOT4 defective.
Clean feeding belts. Check connectors. Check/replace SW 4 according to REP 3.16. Check for 24 VDC on connector J1 pin 8A and common ground on PCB 89-1. Replace PCB 89-1 see REP 3.8.
Main PCB defective.
Trimmer TR 85
PAGE 3.33.6
TR85 Service Manual
August 2000

Cutting.

Knife jams.
POSSIBLE CAUSE
Set to thick.

More than specified maximum Qty of sheets. Check sprockets for knife action. Sharpen/replace knives See REP 3.24.
Loose hardware. Dull knife.
Degraded cutting performance.
Dull knives. Knives misadjusted.
Sharpen/replace knives.See REP 3.24. Check adjustments of knives.See REP 3.24.
Cutting stroke upwards.
Knife does not stop, double action.
Knife position indicator misadjusted.
See REP 3.8 for adjustment.
Outfeed.
Transport belts does not start.
Time out, dull knife indication on front panel. Stop carriage switch SW5 upper position,defected/misadjusted. Main PCB defective.
See previous section cutting.
Trimmer stop does not reach upper position.
Check replace SW5 according to REP 3.17. Replace PCB 89-1 see REP 3.8.
Sets coming out skew on belt stacker.
Not enough friction on feed belts.
Clean/tension feed belts.
Trimmer TR 85
PAGE 3.33.7
August 2000

Belt stacker operation.

Conveyor belt does not run.
POSSIBLE CAUSE
Belt stacker not connected.

Connect beltstacker / check connector.
Outfeed sensor defective/misadjusted. Check voltage at TP4 see EDI 3.31. (jam indication on front panel) Belt stacker motor defective. Main PCB defective. Check for 24 VDC at belt stacker motor. Check for 24 VDC at connector J1 pin A10 and common ground on PCB 89-1.
Trimmer TR 85
PAGE 3.33.8
TR85 Service Manual
August 2000
MAI 3.34 Preventive Maintenance

Note: All INSTRUCTIONS are referring to the Trimmer TR 85 Service Manual. The REFERENCE column is referring to the Spare parts list of Model TR85.
CHECK POINT All machine, Paper paths etc.
INSTRUCTION Use a vacuum cleaner, towels and brushes to clean the machine of paper dust. Use alcohol to clean away ink. Check the function of the switches, adjust according to REP 3.19. Make sure that both switches are activated when the Lid is closed. Check the function of the switch, adjust according to REP 3.15
REFERENCE
250000 Clean
500000 Clean
Interlock switch (SW6 & 7)
Check
Check
Infeed switch (SW1)
Page 1.9 Item 3
Check
Check
Control switch in feed, upper shaft (SW2)
Check function of the Page 1.5 switch, check adjustment Item 7 according to REP 3.16. Use a rubber reactivator alcohol fluid to clean the infeed belts. Check for wear, if worn replace. Apply grease between idler wheel and shaft. Check for wear, if worn replace. Replace every 1,000,000. Apply grease between idler wheel and shaft. Check for wear, if worn replace. Check adj. according to REP 3.32. Replace every 1,000,000. Apply chain oil. Check for wear, if worn replace. Replace every 1,000,000. Page 1.13 Item 3
Check
Check
Infeed belts (4 pcs)
Clean
Clean
Transmission chain
Page 1.7 Item 12
Oil
Oil
Trnsmission chain tensioner
Page 1.7 Item 24
Grease/ Check
Grease/ Check
Knife chian (1 pce) / Knife support chain (1 pce)
Page 1.5 & 1.7 Oil Item 15 & 20
Oil
Scrap bin full sensor / LED
Use compressed air to Page 1.9&1.21 Clean clean the sensor and LED. Item 2&14 Adjust according to REP 3.23.
Clean
Trimmer TR 85
PAGE PAGE 3.34.1
MAI 3.34 Preventive Maintenance, continues
CHECK POINT Upper transport belt (2pcs)
INSTRUCTION
REFERENCE
125000 Clean
250000 Clean
Use a rubber reactivator Page 1.15 alcohol fluid to clean the Item 7 transport belts. Check the tension of the belts, adjust by loosen the two screws holding the big idler wheel (the idler wheel closest to the knife), stretch the belt and tighten the screws. Check for wear if worn replace. Use a rubber reactivator alcohol fluid to clean the transport belts. Check for wear, if worn replace. frame. Use compressed air to clean the sensor. Adjust the sensor according to REP 3.21. Check function of the switch, adjust according to REP 3.17. Check function of the switch, adjust according to REP 3.18. Apply grease on format adjustment gear rack and on the gear. Use compressed air to clean the sensor and the LED. Adjust according to REP 3.22. Page 1.17 Item 5
Lower transport belt (2pcs)
Clean
Clean
Slotted optical switch (SOS 10)
Page 1.21 Item 4
Clean
Clean
Low position microswitch (SW4)
Page 1.21 Item 8
Check
Check
Top position microswitch (SW5)
Page 1.21 Item 9
Check
Check
Gear rack
Page 1.21 Item 19&20
Grease
Grease
Outfeed sensor & LED (PT1 & LED 1)
Page 1.11 Item 4&5
Clean
Clean
FINAL CHECK POINTS Trimming result check Run a 22 sheets booklet of 80-gsm paper to check the trimming result. If the trimming result is poor, replace the knives. Check Check/ Replace
Trimmer TR 85
PAGE PAGE 3.34.2
TR85 Service Manual
Installation Manual SR85 Cover Feeder for the SR85 Bookletmaker
Introduction
This install manual covers the installation of the SR85 Cover Feeder on to the Bookletmaker SR 85.
Installation Manual SR85 COVER FEEDER
Table of contents
1. Installing the Cover Feeder

1.1 Unpacking 1.2 Cleaning the Fold rollers 1.3 Remove the Red cable ties 1.4 Routing the Power Supply Harness, PSH 1.5 Attaching the Cover Feeder to the Top cover 1.6 Check the installation
Page 1-1 1-2 1-4 1-4 1-9 1-15
1. Installing the Cover Feeder

1.1 Unpacking
1. Remove all parts from the Box. Box containing. 1. 2. 3. 4. 5. 6. 7. Cover Feeder Bin extension plate Feed roller assembly Gas spring Front Installation Bracket Rear Installation Bracket Power Supply Harness, PSH Tie wraps Cable holders for the PSH Communication cable Cleaning plate and folder springs (4x)
8. 9.
1. Cover Feeder
2. Bin extension plate
3. Feed roller assembly
4. Gas spring
5. Front Installation Bracket
6. Rear Installation Bracket
7. Power Supply Harness
8.Communication cable
9.Cleaning plate 1-1
Cover Feeder Installation Manual
1.2 Cleaning and Polishing the Fold rollers

Note:This procedure is only necessary on Bookletmakers prior to serial number ZP 219 1000 01. Any unit above this serial number is equiped with polished rollers and new springs during manufacturing. 1. To avoid smearing and marks on the covers it is necessary to clean the fold rollers. Set up the Booklet maker for A3 / 11x17. Switch off the Main power switch on the Booklet Maker. Remove the two stapler heads from the Booklet Maker, according to REP 3.1 in the SR85 Bookletmaker Service manual. Remove the front and rear cover on the Booklet Maker, according to REP 1.1 in the SR85 Bookletmaker Service manual. Remove the two folder springs on the Front side according to figure 1.
Step 6.
2. 3. 4.
5.
6.
Figure 1
7. 8. 9.
Install two new springs from the Cover feeder box, item 9 on the front side. Remove the two folder springs on the rear side same location as the front side. Install two new springs from the Cover feeder box, item 9 on the rear side.
10. Remove the folder bracket by removing four 7mm screws according to figure 2.
Step 10. Two screws. Step 10. Two screws.
Figure 2
1-2
11.
Take the Cleaning plate, item 9 from the Cover feeder box.
12. Put the Cleaning plate between the two Fold rollers according to figure 3.
Figure 3
13. 14. 15.
Attach the two springs on the white bracket according to figure 3. Close the Top cover. Start the dead cycle program on the Booklet Maker by holding in the Program select button and switching on the Main power switch, according to figure 4.
Program select button
Figure 4
16. 17. 18. 19. 20. 21. 22.
Let the Bookletmaker run for approximately 2 minutes. Turn off the Main power switch. Remove the cleaning plate from the Bookletmaker. Install the folder bracket. Install the two stapler heads. Install the front cover on the Bookletmaker. Turn on the Bookletmaker and hand feed 10 sets through the machine to be sure that the fold rollers are clean. 1-3
1.3 Remove the red cable ties

1. Cut the three red cable ties and remove the cardboard between the Upper paper path and the frame. Figure 1 and Figure 2.
Cable tie
Cardboard pice
Cable tie Figure 1
Cable tie Figure 2
1.4 Routing the Power Supply Harness, PSH

1. 2. 3. Undock the Booklet maker. Remove the power cord and the communication cable from the Booklet maker. Remove the Infeed cover on the Booklet maker, according to REP 1.4 in the SR85 Bookletmaker Service manual. Open the Top cover. Route the Power Supply Harness, PSH, make sure that the connector is on the infeed side of the Booklet maker. Route it, between the inside of the Top cover and the reinforcement by the right hinge, according to figure 1.
4. 5.
1-4
Step 8. Secure the PSH with a cable tie.
Step 5. Route the Power Supply Harness, PSH, make sure that the connector is on the infeed side of the Booklet maker. Route it, between the inside of the Top cover and the reinforcement by the right hinge.
Step 6. Continue routing the PSH in to the hole in the frame. NOTE: Approximately 13cm / 5 of the shielded cable.
Step 7. Secure the PSH with the cable holder.
Figure 1, Top view
6.
Continue routing the PSH in to the hole in the frame, according to figure 1.
NOTE: Make sure that you route the PSH so that you have approximately 13cm / 5 of the shielded cable at the infeed side of the machine, according to figure 1. 7. 8. Secure the PSH with a cable holder, according to figure 1. Also secure the PSH with a cable tie, according to figure 1. 1-5
Step 17. Route the Orange and Purple cable into the Cutout in the rear frame of the machine.
Step 9. Loosen the screw, and fasten the ground cable.
Step 10. Route the PSH down by the existing Harness.
Step 11. Secure the PSH with two cable ties. Figure 2, Rear view
Step 16. Secure the cable to the existing harness, with a cable tie.
Step 14. Connect the red cable to the Power connector.
Step 15. Connect the black cable to the Ground connector.
9.
Loosen the screw, and fasten the ground cable, according to figure 2.
10. Route the PSH down by the existing Harness, according to figure 2. 11. Secure the PSH with two cable ties, according to figure 2.
12. Split the PSH. So that you have one end with the red and black cable. And one end with the Orange and Purple cable. 13. Route the Red and Black cable to the right of the machine, seen from the rear side. 14. Connect the red cable to the Power connector, according to figure 2. 15. Connect the black cable to the Ground connector, according to figure 2. 16. Secure the cable to the existing harness with a cable tie, according to figure 2. 17. Route the Orange and Purple cable into the Cutout in the rear frame of the machine, according to figure 2. Installation Manual SR85 COVER FEEDER 1-6
Step 18. Route the Orange and Purple cable along with the existing Harness.
Step 22. Loosen screw no. 10 and insert the Purple wire, secure the two wires by tightening the screw no.10
Figure 3, view of machine behind the Infeed cover
18. Route the Orange and Purple cable along with the existing Harness, according to figure 3. 19. Secure the Orange and Purple cable with two cable ties, according to figure 3. NOTE: Make sure that you loosen the screws towards the center of the transformer. 20. Loosen screw no. 9 on the terminal block and leave the White wire, according to figure 3. 21. Insert the Orange wire from the PSH and the existing White wire to no. 9 on the terminal block. Fasten the screw, according to figure 3. 22. Loosen screw no. 10 on the terminal block and leave the Blue wire, according to figure 3. Installation Manual SR85 COVER FEEDER 1-7
Step 20. Loosen screw no. 9 and insert the Orange wire, secure the two wires by tightening the screw no.9
Step 19. Secure the orange and Purple cable with two cable ties.
23.
Insert the Purple wire from the PSH and the existing Blue wire to no. 10 on the terminal block. Fasten the screw, according to figure 3. Reinstall the Infeed cover according to REP 1.4 in the SR85 Bookletmaker Service Manual. Reinstall the Rear cover according to REP 1.1 in the SR85 Bookletmaker Service Manual.
24.
25.
1-8
1.5 Attaching the Cover Feeder to the Top cover

NOTE: Make sure you notice the orientation of the original Gas spring. To be able to install the new Gas spring. 1. 2. Remove the Gas spring from the Bookletmaker by removing two 8mm nuts. Install the new and shorter Gas spring from the installation kit. Only mount the lower end to the black bracket in the machine, according to Figure 1.
Step 2. Only mount the lower end to the black bracket in the machine.
Figure 1, Gas spring
3.
Remove the Front cover on the Cover Feeder by removing a 7mm screw.
NOTE: The DFD(Double Feed Detection) calibration strip is located inside the front cover. Do not throw this away. 4. 5. Remove the Rear cover on the Cover Feeder by removing a 7mm screw. Make sure that the Top cover is open. Take the Rear Installation Bracket, item 6 page 1.1, and slide it between the Top cover and the Rear frame of the Booklet maker. Slide it from right to the left, according to figure 2.
Figure 2, Top view
1-9
6.
Take the Front Installation Bracket, item 5 page 1.1. Install it on the front side of the Top cover. Slide the Bracket upwards so the fold catches the edge of the Top cover, according to figure 3.
Figure 3
NOTE: Make sure you routed the PSH correctly, so it will not interfere when you are closing the Top cover. 7. While you are holding the Front Installation Bracket in position, close the Top cover.
1-10
NOTE: Make sure you routed the PSH correctly, so it wont be in the way when you are installing the Cover Feeder on top of the Top cover. 8. Put the cover Feeder on the top cover. Make sure that the lower paper path on the Cover Feeder goes down in the manual feed gap, check that all four rubber pads have contact with the Top cover of the Booklet maker. Lift the Cover Feeder on the front side, and install the Front Installation Bracket in the Cutout on the Cover Feeder frame, according to figure 4.
9.
Figure 4, view of lifting the Cover Feeder and installing the Front Installation Bracket.
Figure 5, view of the installation of the Front Installation Bracket.
10. Loosen the nut on the front Installation Bracket, so you can secure the Cover Feeder, according to figure 5. 11. Finger tighten the screw.
12. Lift the Cover Feeder on the rear side, and install the Rear Installation Bracket in the Cutout on the Cover Feeder frame. 13. Loosen the nut on the rear Installation Bracket, so you can secure the Cover Feeder. 14. Finger tighten the screw.
1-11
15. Push the Cover Feeder to the left so that the front installation bracket is against the Top cover, according to figure6.
Step 15. Push the Cover Feeder, so it touches this stop. Figure 6
16. Adjust the Cover Feeder, so that there is an equal gap between the Jam clearance baffle and the two brackets on the infeeder assembly. Figure 7.
Equ al g ap on bot h si des
es sid oth nb po l ga a Equ
Figure 7, Infeed view
1-12
17. Tighten the screws one and a half revolution. 18. Install the upper end of the Gas spring to the upper hole on the Top cover, according to figure 8
Gas spring installed in the upper hole
20. Install the Feed roller assembly. Figure 9. 21. Connect the two paper bin springs, according to figure 9.
Feed roller assembly
Paper Bin spring
Paper Bin spring
Figure 9, view of Feed roller assembly
1-13
19. Connect the PSH and the ground wire to the rear of the Cover Feeder. Secure the PSH with a cable holder on the rear side of the Booklet maker Top cover.
22. Reinstall the Front and Rear cover on the Cover Feeder. 23. Connect the Bin extension plate assembly to the Cover Feeder. Connect the connector and the ground wire, according to figure 10. NOTE: Make sure you connect the Communication cable from the Copier Finisher to the Cover Feeder, NOT the Booklet maker. 24. Connect the Communication cable from the Copier Finisher to the Cover feeder, according to figure 10. 25. Connect the Communication cable that was included in the Installation kit between the Cover Feeder and the Booklet maker, according to figure 10. 26. Connect the Power cord to the Booklet maker. 27. Dock and latch the Booklet maker with the Copier.
Step 25. Communication cable between the Cover Feeder and the Booklet maker.
Step 24. Communication cable between the Copier finisher and the Cover Feeder.
Step 23. Connector between the Bin extension plate assembly and the Cover Feeder.
Figure 10, view of Feed roller assembly
1-14
1.6 Check the installation

1. 2. 3. 4. 5. 6. 7. Switch on the main power switch on the Booklet maker. Make sure that the sets are well fanned to avoid misfeeds or double-feeds. Align the sheets well to achieve a reliable collating operation and good finishing result. Make sure that the ink has dried out well, to avoid smearing. Load the covers into the paper bin. Move the adjustable side guide up against the sheets until there is no clearance. Move the adjustable Air nozzle, so that the green stripe on the Air nozzle bracket is up against the paper stock.
8. 9.
Set the Online/Offline button to Online position. The Cover Feeder will prefeed the first cover to be ready for the set from the copier.
10. Send a set from the copier, and the Cover Feeder will automaticly feed covers to the sets. 11. The Cover Feeder will automaticly stop sending covers when the copier is not sending any sets. To stop the fan on the Bin extension plate, press the Online/ Offline button.
1-15
Service Manual SR85 Cover Feeder for the SR85 Bookletmaker
Service Manual SR85 COVER FEEDER
Table of contents
1. COVERS REMOVE INSTRUCTION (CRI)
CRI 1.1 Front and rear cover CRI 1.2 Top cover Page 1-1 1-2
2.
REPAIRS / ADJUSTMENTS (REP)

REP 2.1 Controller / Driver PWB and Panel REP 2.2 Bin motor assembly, M1 REP 2.3 Drive motor assembly, M2 REP 2.4 Paper blower motor, M3 REP 2.5 Sensor empty bin, Q1 REP 2.6 Sensor paper bin home position, Q2 REP 2.7 Phototransistor and LED assembly, Q3 REP 2.8 Sensor outfeed, Q4 REP 2.9 Sensor low bin, Q5 REP 2.10 Power supply harness REP 2.11 Upper paper path REP 2.12 Drive shaft assembly REP 2.13 Pinch roll shaft assembly REP 2.14 Feed roller assembly and Paper Sep pad REP 2.15 Bin extension plate assembly 2-1 2-3 2-4 2-5 2-6 2-7 2-8 2-9 2-10 2-11 2-14 2-15 2-16 2-17 2-18
3.
ELECTRICAL DETAIL INFORMATION (EDI)

EDI 3.1 Wiring diagram EDI 3.2 Electrical components list EDI 3.3 Electrical components location 3-1 3-2 3-3
4.
SERVICE MODE (SRM)

SRM 4.1 Enter Service Mode SRM 4.2 Service Mode List SRM 4.3 Calibration of DFD, Sensor Q3 SRM 4.4 Selfdiagnostic / Fault Isolating SRM 4.5 Total counter SRM 4.6 Software version 4-1 4-2 4-4 4-5 4-13 4-14
5.
PREVENTIVE MAINTENANCE (MAI)

MAI 5.1 Preventive Maintenance 5-1
6.
SPECIFICATIONS
SPC 6.1 Specifications 6-1
1.
COVERS REMOVE INSTRUCTION
CRI 1.1 Front and Rear cover
REMOVAL Front and rear cover 1. 2. 3. 4. 5. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the 7 mm screw holding the front cover, according to Figure 1. Lift up and remove the cover, according to Figure 1. Remove the 7 mm screw holding the rear cover, according to Figure 1. Lift up and remove the cover, according to Figure 1.
Step 4. Step 5.
Step 3.
Step 2. Figure 1
INSTALLATION 1. Installation is an exact reversed procedure of removal.
1-1
Cover Feeder Service Manual
CRI 1.2 Top cover
REMOVAL Top cover 1. 2. 3. 4. 5. 6. 7. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the front and rear cover according to CRI 1.1 Loosen the two 7 mm screws on the front side of the Cover feeder. Loosen the two 7 mm screws on the rear side of the Cover feeder, according to figure 1. Lift up the Top cover to up position. Tighten the two 7 mm screws to secure the Top cover in up position. Loosen the four 7 mm screws holding the PWB plate, according to figure 2. Slide the PWB plate to the rear and hook it up on the two lower 7 mm screws, according to figure 3.
Step 6.
Step 3.
Figure 2
Step 7. Lower screws Figure 1
Figure 3
1-2
2.
Repairs / Adjustments
REP 2.1 Controller / Driver PWB and Panel
REMOVAL Controller / Driver PWB and Panel 1. 2. 3. 4. 5. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the front and rear cover according to CRI 1.1 Loosen and lift up the top cover according to CRI 1.2 Remove the seven 7 mm screws holding the PWB according to figure 1. Disconnect the 5 connectors J1, J2, J3, J6 and J11, according to figure 2
NOTE: The five connectors on the PWB are labelled on the rear side of the PWB. 6. If changing panel. Remove the five nuts, holding the panel according to figure 3.
Step 4.
Figure 1
Figure 3
J3
J6
24 25 2 1 1 2 25 24
J11
2 1
14 13
3 4 12 1 2 12 12 12 12 12
J1 J2
Figure 2
2-1
Step 6.
REP 2.1 Controller / Driver PWB and Panel
Note: The Total counter will be set to 0 when changing PWB
INSTALLATION AND CALIBRATION 1. 2. 3. 4. 5. 6. 7. Installation is an exact reversed procedure of removal. Enter the Service Mode, according to SRM 4.1 Select step 1, DFD(Double Feed Detection) calibration Sensor Q3, according to SRM 4.3 Select step 11, calibration of Bin motor M1. Select step 12, calibration of Bin motor M1 and Drive motor M2 with A4 / 8.5x11 paper. Select step 13, calibration of Bin motor M1 and Drive motor M2 with A3 / 11x17 paper. Select step 14, calibration of Paper blower motor M3.
2-2
REP 2.2 Bin motor assembly, M1
REMOVAL Bin motor assembly 1. 2. 3. 4. 5. 6. 7. 8. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the rear cover according to CRI 1.1 Remove the Feed roller assembly according to REP 2.14. Disconnect the motor connector according to figure 1. Remove the e-clip holding the push rod according to figure1. Remove the three seven 7 mm screws holding the Bin motor bracket according to figure 1. Loosen the 3 mm allen screw holding the Roller clutch assembly according to figure 2. Remove the three 2.5 mm allen screws holding the Bin motor according to figure 2.
Step 6
Step 4
Step 7
Step 5 Figure 2 Figure 1 Step 8
INSTALLATION AND CALIBRATION 1. 2. 3. 4. 5. Installation is an exact reversed procedure of removal. Enter the Service Mode, according to SRM 4.1 Select step 11 and perform calibration of Bin motor M1. Select step 12 and perform calibration with A4/8.5x11 paper. Select step 13 and perform calibration with A3/11x17 paper.
Sensor Q2
ADJUSTMENT Adjust the Bin motor roller clutch assembly so that the sensor activator is in the middle 0.5 mm of sensor Q2, according to figure 3. Adjust by loosen the 3 mm allen screw on the roller clutch assembly. Figure 2.
Figure 3
2-3
REP 2.3 Drive motor assembly, M2
REMOVAL Drive motor assembly 1. 2. 3. 4. 5. 6. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the front and rear cover according to CRI 1.1 Disconnect the motor connector according to figure 1. Remove the two seven 7 mm screws holding the Drive motor bracket according to figure 1. Loosen the 3 mm allen screw holding the drive clutch according to figure 2. Remove the three 2.5 mm allen screws holding the drive motor according to figure 2.
Step 3 Step 6
Step 4
Figure 2
Figure 1
Step 5
INSTALLATION AND CALIBRATION 1. 2. 3. 4. Installation is an exact reversed procedure of removal. Enter the Service Mode, according to SRM 4.1 Select step 12 and perform calibration with A4/8.5x11 paper. Select step 13 and perform calibration with A3/11x17 paper.
ADJUSTMENT Adjust the drive clutch so that there is a play between the coupling on the drive shaft and the clutch.The play should be 0.4 0.3 mm. Adjust by loosen the 3 mm allen screw on the drive clutch, according to figure 3.
0.4 0.3 mm play between the coupling and the clutch
Figure 3
2-4
REP 2.4 Paper blower motor, M3
REMOVAL Paper blower motor 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the Bin extension plate assembly according to REP 2.15 Loosen the 7 mm nut holding the ground cable according to figure 1. Remove the two 7 mm screws holding the blower motor according to figure 1.
Step 4
Step 3
Figure 1
2-5
REP 2.5 Sensor empty bin, Q1
REMOVAL Sensor empty bin 1. 2. 3. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the 2.5 mm allen screw holding the sensor according to figure 1. Disconnect the sensor connector according to figure 1.
Step 3
Step 2
Figure 1
2-6
REP 2.6 Sensor paper bin home position, Q2
REMOVAL Sensor paper bin home position 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the rear cover according to CRI 1.1 Remove the two 2.5 mm allen screws holding the sensor according to figure 1. Disconnect the sensor connector according to figure 1.
Step 4.
Step 3.
Figure 1
2-7
REP 2.7 Phototransistor and LED assembly, Q3
REMOVAL Sensor and LED assembly 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the 7 mm nut, according to figure 1. Disconnect the phototransistor connector according to figure 1. Remove the Drive shaft assembly, according to REP 2.12
NOTE: It is possible to reach the LED connector through the hole in the rear frame. It is not necessary to remove the Cover Feeder from the Booklet maker. 5. 6. Disconnect the LED connector according to figure 2. Loosen the 10 mm nut and slide off the LED connector, according to figure 2.
Step 2
Step 6 Step 3 NOTE: Figure 1 Step 5 Figure 2
INSTALLATION AND CALIBRATION NOTE: Make sure you install the LED connector according to figure 2, so it will not interfere with the Drive Shaft when performing REP 2.12. 1. 2. 3. 3. Installation is an exact reversed procedure of removal. Enter the Service Mode, according to SRM 4.1 Align the phototransistor with the LED to obtain the correct setting for the double sheet detector, according to SRM 4.3 Calibration of DFD Sensor Q3. Select step 1 and perform calibration of DFD, according to SRM 4.3
2-8
REP 2.8 Sensor outfeed, Q4
REMOVAL Sensor outfeed 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord to the Booklet maker. Lift up the upper paper path and open the Jam clearance baffle and remove it. Remove the 2.5 mm allen screw according to figure 1. Disconnect the sensor connector according to figure 1.
Step 4
Step 3
Figure 1
2-9
REP 2.9 Sensor low bin, Q5
REMOVAL Sensor low bin 1. 2. 3. 4. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the rear cover according to CRI 1.1 Remove the two 2.5 mm allen screws holding the sensor according to figure 1. Disconnect the sensor connector according to figure 1.
Step 3
Step 4
Figure 1
2-10
REP 2.10 Power supply harness
INSTALLATION 1. 2. 3. 4. 5. 6. Undock the Booklet maker. Remove the power cord and the communication cable from the Booklet maker. Remove the Rear Cover on the Booklet maker, according to REP 1.1 in the SR85 BookletmakerService manual. Remove the Infeed cover on the Booklet maker, according to REP 1.4 in the SR85 Bookletmaker Service manual. Open the Top cover. Route the Power Supply Harness, PSH, make sure that the connector is on the infeed side of the Booklet maker. Route it, between the inside of the Top cover and the reinforcement by the right hinge, according to figure 1.
Step 9 Step 6
Figure 1
Step 7
Step 8
NOTE: Approximately 13cm / 5 of the shielded cable.
7.
Continue routing the PSH in to the hole in the frame, according to figure 1.
NOTE: Make sure that you route the PSH so that you have approximately 13cm / 5 of the shielded cable at the Infeed side of the machine, according to figure 1. 8. 9. Secure the PSH with the cable holder, according to figure 1. Also secure the PSH with a cable tie, according to figure 1.
2-11
Step 18
Step 10
Step 11
Step 12 Figure 2 Step 17 Step 15 Step 16
10. 11. 12. 13. 14. 15. 16. 17. 18.
Loosen the screw, and fasten the ground cable, according to figure 2. Route the PSH down by the existing Harness, according to figure 2. Secure the PSH with two cable ties, according to figure 2. Split the PSH. So that you have one end with the red and black cable. And one end with the Orange and Purple cable. Route the Red and Black cable to the right of the machine, seen from the rear side. Connect the red cable to the Power connector, according to figure 2. Connect the black cable to the Ground connector, according to figure 2. Secure the cable to the existing harness with a cable tie, according to figure 2. Route the Orange and Purple cable into the Cutout in the rear frame of the machine, according to figure 2.
2-12
Step 19
Step 20
Step 21
Step 23 Figure 3
19. 20.
Route the Orange and Purple cable along with the existing Harness according to figure 3. Secure the Orange and Purple cable with two cable ties, according to figure 3.
NOTE: Make sure that you loosen the screws towards the center of the transformer. 21. 22. 23. 24. 25. 26. Loosen screw no. 9 on the terminal block, White cable, according to figure 3. Insert the Orange cable from the PSH and the existing White cable to no. 9 on the terminal block. Fasten the screw, according to figure 3. Loosen screw no. 10 on the terminal block, Blue cable, according to figure 3. Insert the Purple cable from the PSH and the existing Blue cable to no. 10 on the terminal block. Fasten the screw, according to figure 3. Reinstall the Infeed cover according to REP 1.4 in the SR85 Bookletmaker Service Manual. Reinstall the Rear cover according to REP 1.1 in the SR85 Bookletmaker Service Manual.
REMOVAL 1. Removal is an exact reversed procedure of installation.
2-13
REP 2.11 Upper paper path
REMOVAL Upper paper path 1. 2. 3. 4. 5. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the front and rear cover according to CRI 1.1 Remove the 7 mm screw holding the spring on the rear side, according to figure 1. Remove the 7 mm screw holding the spring on the front side same location as step 3. Remove the two 7 mm screws holding the Upper paper path according to figure 2.
Step 4 Figure 1
Step 5
Figure 2
2-14
REP 2.12 Drive shaft assembly

REMOVAL Drive shaft assembly 1. 2. 3. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the front and rear cover according to CRI 1.1 Remove the Drive motor assembly according to REP 2.3
NOTE: Be careful when removing the Drive shaft assembly, so it not will damage LED sensor Q3. See EDI 3.3 4. Remove the Drive shaft assembly by sliding it out through the rear frame according to figure 1.
Figure 1
INSTALLATION 1. 2. Installation is an exact reversed procedure of removal. Adjust the drive clutch according to REP 2.3.
2-15
REP 2.13 Pinch roll shaft assembly

REMOVAL Pinch roll shaft assembly 1. 2. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the Pinch roll shaft assembly by pressing it to the rear side according to figure 1.
Figure 1
2-16
REP 2.14 Feed roller assembly and Paper separator pad

REMOVAL Feed roller assembly and Paper separator pad 1. 2. 3. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the Fold roller assembly by pressing it to the front side according to figure 1. Remove the Paper separator pad by lifting it out (with a small screwdriver) from the holder according to figure 1. The paper separator pad is press fit into its holder, no adhesive is used. Paper separator pad
Feed rollers
Press to the front side
Figure 1
2-17
Lift out this side
REP 2.15 Bin extension plate assembly

REMOVAL Bin extension plate assembly 1. 2. 3. Switch off the main power switch and disconnect the power cord to the Booklet maker. Remove the Bin extension plate connector and ground wire, according to figure 1. Lift up the Bin extension plate and remove it according to figure 1.
Step 3
Step 2
Figure 1
2-18
3.
Electrical detail information (EDI)
EDI 3.1 Wiring diagram
WIRING DIAGRAM
3-1
EDI 3.2 Electrical components list
ELECTRICAL COMPONENTS LIST SENSOR Q1 SENSOR Q2 SENSOR Q3 SENSOR Q3 SENSOR Q4 SENSOR Q5 MOTOR 1 MOTOR 2 MOTOR 3 Empty Bin Paper Bin Home Position Phototransistor Sensor (DFD) LED Sensor (DFD) Outfeed sensor Low bin Bin motor Drive motor Paper blower motor Page 3-3-1 Page 3-3-2 Page 3-3-1 Page 3-3-1 Page 3-3-3 Page 3-3-2 Page 3-3-2 Page 3-3-2 Page 3-3-3
3-2
ELECTRICAL COMPONENTS LOCATION
Phototransistor Q3
Q1
LED Q3
3-3-1
Q2
M1
M2
Q5
3-3-2

Q4
M3
3-3-3
4.
Service Mode
SRM 4.1 Enter Service Mode
ENTER SERVICE MODE 1. 2. 3. 4. Switch off the main power switch. Hold down the Online/Offline button and the Operating select button according to figure 1. Switch on the main power switch while holding down the two buttons. Wait approximately 3 seconds and release the buttons.
Note: There shall be no light in the Single sheet mode indicator or the Copier cover mode indicator after entering the Service Mode. If light in either of these indicators switch off the main power and repeat from step 1. The only light you should see is on the Online indicator according to figure 1.
Hidden button
Single sheet mode indicator
Online indicator
Copier cover mode indicator
Online/Offline button
Operating select button
Step 2
Figure 1
USING THE SERVICE MODE 1. 2. 3. 4. 5. There are 18 selections in the Service mode. Change step by pressing the Online/Offline button according to figure 1. To get into the selected step press the hidden button according to figure 1. To get out of the selected step press the hidden button again. To get out of the Service Mode switch off the main power switch.
Note: After entering the Service mode you are on step 1 and the Online indicator has a constant light. To select step 2 press the Online/Offline button once. To get back to step 1 press the Operating select button once.
4-1
SRM 4.2 Service Mode List

SERVICE MODE LIST The selections are shown by the first six LEDs on the control panel shown in the table below.
Selections
1.
Comments
Calibration of DFD Sensor Q3. The DFD calibration is explained in SRM 4.3
2.
Starting the Bin motor M1 in forward direction.
3.
Starting the Bin motor M1 in reverse direction.
4.
Starting the Drive motor M2
5.
Starting the Paper blower motor M3
6.
Check Sensor, empty bin Q1 according to SRM 4.4
7.
Check Sensor, paper bin home position Q2 according to SRM 4.4
8.
Check Sensor assembly Q3 according to SRM 4.4
9.
Check Sensor, outfeed Q4 according to SRM 4.4
4-2
SRM 4.2 Service Mode List

Selections
10.
Comments
Check Sensor, low bin Q5 according to SRM 4.4
11.
Calibration of Bin motor, M1. Start the calibration by pressing the hidden button. The calibration will automatically stop.
12.
Calibration of Bin motor M1 and Drive motor M2. Make sure to have A4 or 8.5x11 paper loaded before calibration. Start the calibration by pressing the hidden button. The calibration will automatically stop. Calibration of Bin motor M1 and Drive motor M2. Make sure to have A3 or 11x17 paper loaded before calibration. Start the calibration by pressing the hidden button. The calibration will automatically stop. Calibration of Paper blower motor, M3. Ther are fifteen steps available. Select step by pressing the Online/Offline button, save by pressing the Operating Select button. Self diagnostic. The Self diagnostic is explained in SRM 4.4
13.
14.
15.
16.
Total counter. The Total counter is explained in SRM 4.5
17.
Software version. The Software version is explained in SRM 4.6
18.
Turn on/off the DFD, Q3. Turn on/off the DFD by pressing the Online/Offline button. The DFD is turned on if there is a constant light in the low bin indicator.
4-3
SRM 4.3 Calibration of DFD Sensor Q3
CALIBRATION OF DFD (Double Feed Detection) SENSOR 1. 2. 3. 4. 5. 6. 7. Switch off the Main power switch. Remove the front and rear cover according to CRI 1.1 Loosen and lift up the top cover according to CRI 1.2 Enter the Service Mode according to SRM 4.1 Select step 1 in the Service Mode according to SRM 4.2 Take the DFD calibration strip from the inside of the front cover and put it in-between the Phototransistor and LED assembly. Look at the control panel. There are six LEDs on the control panel, the two LEDs in the middle should have a constant light if the DFD Sensor Q3 is correctly adjusted according to figure 1. Adjust the DFD by turning the potentiometer on the Control / PWB according to figure 2.
8.
Figure 1
Turn here to adjust the DFD
Figure 2
4-4
SRM 4.4 Self diagnostic / Fault Isolating
SELF DIAGNOSTIC/ FAULT ISOLATING 1. 2. 3. 4. 5. 6. Enter the Service Mode according to SRM 4.1 Load one white A4 / 8.5x11 paper in the paper bin. Select step 15 in the Service Mode according to SRM 4.2 Start the Self diagnostic by pressing the hidden button. The Self diagnostic will check all sensors, motors and the PWB. If any fault should occur, it will be indicated on the six LEDs according to the fault code(s). Page 4-6
Fault Code 1.
2.
4-7
3.
4-8
4.
4-9
5.
4-10
6.
4-11
Fault Isolating.
4-12
4-5
Fault Code 1.
Possible Cause 1. Bad sensor Q2 2. Bad Motor M1 3. Wires defective 4. Driver PWB defective
Fault isolating / repair

Enter the Service mode and select step7, sensor Q2. Turn the Bin motor by hand and look for an indication on the Jam LED on the control panel. There is an indication on the Jam LED? Y N Measure the voltage between J11-4 and J11-6. The voltage is approximately 1.2 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB Measure the voltage between J11-6 and J11-5. When blocking / unblocking the sensor, the voltage varys between lower than 1.0 VDC and over 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q2. 2. Check the harness for short / open circuit. 3. Replace the PWB. Replace the PWB. Select step 3, Motor M1 in reversed direction. The motor starts? Y N Disconnect the Motor connector measure the voltage between J3-7 and J3-14. The voltage is approximately 37 VDC? Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M1. The Sensor and Motor appears to be operating correctly. Check the sensor and motor connectors to ensure there are no loose pins.
4-6
Fault Code 2.
Possible Cause 1. Bad sensor Q1 2. Bad Motor M1 3. Bad Motor M2 4. Wires defective 5. Driver PWB defective

Enter the Service mode and select step 6, sensor Q1. Cover the sensor and look for an indication on the Jam LED on the control panel. There is an indication on the Jam LED? Y N Measure the voltage between J11-1 and J11-3. The voltage is approximately 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB Measure the voltage between J11-2 and J11-3. When blocking / unblocking the sensor, the voltage varys between lower than 1.0 VDC and over 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q1. 2. Check the harness for short / open circuit. 3. Replace the PWB. Replace the PWB. Select step 2, Motor M1 in forward direction. The motor starts? Y N Disconnect the Motor connector measure the voltage between J3-7 and J3-14. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M1. Select step 4, Motor M2. The motor starts. Y N Disconnect the Motor connector measure the voltage between J3-6 and J3-13. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M2. The Sensor and Motors appears to be operating correctly. Check the sensor and motor connectors to ensure there are no loose pins.
4-7
Fault Code 3.
Possible Cause 1. Bad sensor Q3, PT and LED 2. Bad Motor M1 3. Bad Motor M2 4. Wires defective 5. Driver PWB defective

Enter the Service mode and select step 8, sensor Q3. Cover the sensor and look for an indication on the Jam LED on the control panel. There is an indication on the Jam LED. Y N Measure the LED voltage between J6-9 and J6-11. The voltage is approximately 3.4 VDC. Y N 1. Replace the LED sensor Q3 2. Check the harness for short / open circuit. 3. Replace the PWB. Measure the Phototransistor voltage between J6-10 and J6-22. The voltage is approximately 0.8 VDC. (uncovered) Y N 1. Replace the PT sensor Q3. 2. Check the harness for short / open circuit. 3. Replace the PWB. Cover the sensor with (8 pages of 80 gsm paper) and measure the PT voltage between J6-10 and J6-22. The voltage is 5 VDC. Y N 1. Replace the PT sensor Q3. 2. Check the harness for short / open circuit. 3. Replace the PWB. Replace the PWB. Select step 2, Motor M1 in forward direction. The motor starts. Y N Disconnect the Motor connector measure the voltage between J3-7 and J3-14. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M1. Select step 4, Motor M2. The motor starts. Y N Disconnect the Motor connector measure the voltage between J3-6 and J3-13. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M2. The Sensor and Motors appears to be operating correctly. Check the sensor and motor connectors to ensure there are no loose pins.
4-8
Fault Code 4.
Possible Cause 1. Bad sensor Q4 2. Bad Motor M1 3. Bad Motor M2 4. Wires defective 5. Driver PWB defective

Enter the Service mode and select step 9, sensor Q4. Cover the sensor and look for an indication on the Jam LED on the control panel. There is an indication on the Jam LED. Y N Measure the voltage between J11-7 and J11-9. The voltage is approximately 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB Measure the voltage between J11-9 and J11-8. When blocking / unblocking the sensor, the voltage varys between lower than 1.0 VDC and over 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q4. 2. Check the harness for short / open circuit. 3. Replace the PWB. Replace the PWB. Select step 2, Motor M1 in forward direction. The motor starts. Y N Disconnect the Motor connector measure the voltage between J3-7 and J3-14. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M1. Select step 4, Motor M2. The motor starts. Y N Disconnect the Motor connector measure the voltage between J3-6 and J3-13. The voltage is approximately 37 VDC. Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M2. The Sensor and Motors appears to be operating correctly. Check the sensor and motor connectors to ensure there are no loose pins.
4-9
Fault Code 5.
Possible Cause 1. Driver PWB defective

Replace the Controller / Driver PWB, according to REP 2.1
4-10
Fault Code 6.
Possible Cause 1. Bad sensor Q5 2. Bad Motor M1 3. Wires defective 4. Driver PWB defective

Enter the Service mode and select step10, sensor Q5. Turn the Bin motor by hand and look for an indication on the Jam LED on the control panel. There is an indication on the Jam LED? Y N Measure the voltage between J11-10 and J11-12. The voltage is approximately 1.2 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB.
Measure the voltage between J11-12 and J11-11. When blocking / unblocking the sensor, the voltage varys between lower than 1.0 VDC and over 4.0 VDC? Y N The voltage is approximately 0 VDC? Y N The voltage is approximately 5 VDC? Y N 1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB. 1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB. Replace the PWB. Select step 3, Motor M1 in reversed direction. The motor starts? Y N Disconnect the Motor connector measure the voltage between J3-7 and J3-14. The voltageis approximately 37 VDC? Y N Check the wires for short circuit. If the wires are good, replace the Driver PWB. Check the wires for an open circuit. If the wires are good, replace Motor M1. The Sensor and Motor appears to be operating correctly. Check the sensor and motor connectors to ensure there are no loose pins.
4-11
1. Replace the sensor Q5. 2. Check the harness for short / open circuit. 3. Replace the PWB
Fault Isolating
SELF DIAGNOSTIC/ FAULT ISOLATING
PROBLEM
POSSIBLE CAUSES
Machine in jam condition.
ACTION
Clear jam. Load paper Correct the problem in the Bookletmaker.
The machine is inoperative as the Online/Offline button is pressed.
Empty Paper Bin. Bookletmaker shut down.
Feed rollers need cleaning. Paper separator pad needs cleaning. Drive rollers need cleaning. Repeated Misfeeds / Double feed Sheets are not fanned enough. (Ink / powder / cutting burres etc. will make this a very important step). Paper quality out of specification.
Check / clean Check / clean
Check / clean Check / fan sheets
Check
Incorrect Double feed / Jam indication
Different paper quality or print You have to select Offline impression in the bin, since before collating different paper previous calibration. qualities. The Cover Feeder will automatically perform a calibration when the first cover is fed. Mixed sheets (mixed paper qualities) Check the sheets.
4-12
SRM 4.5 Total Counter
TOTAL COUNTER 1. 2. 3. 5. Enter the Service Mode according to SRM 4.1 Select step 15 in the Service Mode according to SRM 4.2 Check the Total counter by pressing the hidden button. The Total counter is shown on the six LEDs according to figure 1.
Explanation: When facing the control panel, the Total counter will be shown using the LED as follows. The constant light indicates which LED that is about to flash. The Total counter will start from the right and move to the left. Example, if the machine has collated 213000 covers it will be shown as: the right LED will flash 3 times, the middle LED will flash 1 time and the left LED will flash 2 times.
Indicates ten thousands Indicates hundred thousands
Indicates thousands
Figure 1
Lower lights turn on to indicate where to look, then upper LEDs flash.
4-13
SRM 4.6 Software version

Software VERSION 1. 2. 3. 5. Enter the Service Mode according to SRM 4.1 Select step 17 in the Service Mode according to SRM 4.2 Check the Software version by pressing the hidden button. The Software version is shown on the six LEDs according to figure 1.
Explanation: When facing the control panel, the Software version will be shown as a constant and flashing light. The constant light indicates which led that is flashing. The Software version will start from right and is moving to the left. Example, if the machine has version 001 it will be shown as: The right LED will flash 1 time, the middle LED will not flash and the left LED will not flash.
Figure 1
4-14
5.
Preventive Maintenance (MAI)
MAI 5.1 Preventive Maintenance
PREVENTIVE MAINTENANCE CHECK POINT Feed roller assembly 1. Remove the Feed roller assembly, according to REP 2.14 2. Clean the Feed rollers with reactivator fluid. Paper separator pad 1. Remove the Feed roller assembly, according to REP 2.14 2. Clean the Paper separator pad with reactivator fluid. Drive shaft tires 1. Clean the tires on the drive shaft assembly with reactivator fluid. Sensors 1. Clean the sensors from paper dust.
5-1
6.
Specifications
6.1
Specifications
Number of bins Bin capacity Length range Width range Paper weight, minimum Paper weight, maximum Double feed detection Misfeed detection Empty bin detection Bin low detection Height installed on SR85 Width installed on SR85 Depth installed on SR85 Weight (Cover Feeder only) Voltage
1 200 Sheets (20 lb. Bond) 11 - 18 8.25 - 12.6 19 lb. Bond / 70 gsm 110 lb. Index / 200 gsm Yes Yes Yes Yes 39.5 (1003 mm) 54.3 (1378 mm) 23.4 (595 mm) 24.5 lb. (12.5 kg) 230V / 240V / 50 Hz 115V / 60 Hz
6-1
TECHNICAL SERVICE BULLETINS
TECHNICAL SERVICE BULLETIN

BULLETIN NUMBER: SR85 - 001 03/13/2002 MODEL: APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for 850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2085DP/2105DP/2585/25105
Note: This copy is intended as a master original for reproduction of additional bulletins.
SUBJECT:
DEFORMED STAPLES OR STAPLER JAMS !

MECHANICAL
SYMPTOM:
Bad staple forming or stapler head jams.
CAUSE 1:
If bad staple forming occurs, do not adjust the stapler head position or change the stapler head. In most cases when bad staple forming occurs it is because a staple is jammed in the stapler head assembly.
!
PARTS
SOLUTION 1:
Remove the stapler head and clear the stapler jam according to page 5.2 in the SR85 operator manual. If you still have deformed staples occurring you may have a staple jammed in the stapler head assembly. Remove the staple cartridge and make sure there is no staple jammed in the stapler head. Make sure there is no staple jammed between the driver and the stapler assembly, figure 1. It may be necessary to take apart the stapler head to reach the jammed staple. See next section regarding procedure of dismantling the stapler head.
No staple jammed between the driver and the stapler assy.
Figure 1
Continued
Copyright 2002 RICOH Corporation. All rights reserved. CONTROL NO. 069ALL
Tech Service Bulletin No. SR85 001 Page 2 of 4
CAUSE 2:
If bad staple forming still occurs, do not adjust the stapler head position or change the stapler head. If there is no staple jammed in the stapler head assembly and the staples are still not formed correctly it may be due to a worn or damaged stapler head driver. It is possible to see if the driver is worn or damaged by following the procedure below. Remove the stapler head and push in the plunger, check that the two points on each side of the driver are present and not worn, figure 2.
Figure 2
Check the two driver points
NOTE:
The impact on the stapler driver depends on the size of the booklets and the quality of the paper. For example coated paper will cause more wear than bond paper. The replacement driver has been improved and is available as a spare part.
SOLUTION 2:
Replace the driver.
NEW DRIVER INSTALLATION:

Step 1 Remove the staple cartridge. Step 2 Remove the upper front white spacer when facing the stapler head as in figure 3. Do not remove the rear insulator.
Upper front spacer Figure 3
Continued
Step 3 Make sure to notice the orientation of the staple belt feeder. Press out the pivot pin and remove the staple belt feeder, figure 4.
Press out the pivot pin in the same direction as the arrow.
Staple belt feeder
Figure 4
Step 4 Lift out the front bracket on the stapler head assembly and remove the staple driver, figure 5. Be careful when removing the driver.
Remove the staple driver Lift out the front bracket
Figure 5 Step 5 Remove the staple detection lead assembly and install it on the new staple driver, figure 6.
Staple detection lead assy.
Figure 6
Continued
Step 6 Install the new driver in reversed order. Put some oil between the driver and the upper part of the stapler head assembly. Move the driver up and down to make sure that it is correctly installed, figure 7.
Oil between the driver and the upper part
Figure 7
GENERAL:
The following parts corrections are being issued for all SR85 Parts Catalogs Sections.
PART NUMBER DESCRIPTION VRC11178 Staple Driver VRC11001 Stapler Head Assembly *DENOTES NEW ITEM NUMBER
REFERENCE QTY PAGE ITEM 1 1.15 13* 1 1.15 5

BULLETIN NUMBER: SR85 - 002 07/22/02 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for 850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2085DP/2105DP/2585/25105 SUBJECT: SYMPTOMS:
Jam occurs at the TR85 entrance. The TR85 does not turn on.
TR85 ENTRANCE JAMS

ELECTRICAL
CAUSE:
There might be some problem with the DIN Connector or the installation of the DIN Cable to the Socket. Therefore, causing a problem with the start signal to the TR85.
SOLUTION:
We have simplified the reading of the TR85 Wiring Diagram so it will be easier to understand the wiring of DIN Connector, and the socket it is connected to on the SR85. Make sure that the DIN Cable is correctly installed to the Socket, and that the tapping cable is correctly installed.
Continued
Copyright 2002 RICOH Corporation. All rights reserved.

BULLETIN NUMBER: SR85 003 08/09/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2085DP/2105DP/2585/25105 SUBJECT: SYMPTOM:
MECHANICAL
BROKEN CASTORS
If the TR85 is pushed sideways, the castors for the rail may break.
CAUSE:
The original style castors were not strong enough.
SOLUTION:
New style castors are stronger and will not break if the TR85 is pushed sideways.
GENERAL:
The following part update is being issued for all TR85 Parts Catalogs.
PARTS
OLD PART NO. VRC11117
NEW PART NO. VRC11171
DESCRIPTION Rail Castor TR85
QTY 4
INT -
REFERENCE PAGE ITEM 1.24 1
UNITS AFFECTED:
All TR85 Trimmers manufactured after the Serial Number listed below will have the new style Castors installed during production. MODEL NAME TR85 SERIAL NUMBER ZP41830007

When running self-diagnostics on the SR85 Booklet maker with the TR85 installed, a fault code number 26 (Stacker Motor MOT 5, Open Circuit) may occur.
FAULT CODE 26
!
SERVICE MANUAL
CAUSE:
The SR85 is only running SDS (Self Diagnostic System) on itself. Therefore the unit will not detect the TR85, and the software will assume that the Belt Stacker is not connected.
SOLUTION:
When you are running a SDS with a TR85 installed, the SR85 Booklet maker is only running SDS on itself. Therefore the machine will not detect anything behind the SR85, and it will think that the Belt Stacker is not connected. Add the following note to the SR85 Service Manual to page 8.1.7 - Fault Code 26: NOTE: When running SDS with the TR85 installed, only the SR85 is tested. Therefore the software will assume that the Belt Stacker is not connected and it will cause a Fault Code 26.
GENERAL:
The Service Manual pages listed below must be replaced with the pages supplied. Each bulletin package contains 1 set of replacement pages. PAGES: The revised areas have been highlighted by an arrow .
8.1.7
Updated Information (Self Diagnostic System Control)
Rev. 08/2002
Fault code 22 Staple stop gate . release solenoid SOL 2, open circuit. Possible cause Solenoid defective. Fault isolating / repair Disconnect the solenoid connector. Check the solenoid for an open circuit using a voltmeter. Disconnect the solenoid connector. Check the wires for an open circuit using a voltmeter. Measure from 4 and 11 on connector J2 to the solenoid connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 11 and 12 on connector J9 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 8 and 1 on connector J2 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 11 and 14 on connector J2 to the motor connector. Replace the controller PCB. Disconnect the motor connector. Check the motor for an open circuit using a voltmeter. Disconnect the motor connector. Check the wires for an open circuit using a voltmeter. Measure from 13 and 6 on connector J9 to the motor connector. Replace the controller PCB.
Wires defective.
Controller PCB defective. 23 Side jogger motor MOT3, Motor defective. . open circuit. Wires defective.
Controller PCB defective. 24 Fold knife motor . MOT 2, open circuit. Motor defective.
Wires defective.
Controller PCB defective. 25 Folder roller motor . MOT 8, open circuit. Motor defective.
Wires defective.
Controller PCB defective. 26 Stacker motor MOT 5, . open circuit. Motor defective.
Wires defective.
Note: When running SDS with the TR85 installed, only the SR85 is tested. Therefore the test software will assume that the Belt Stacker is not connected and a Fault Code 26 will occur.
Bookletmaker SR 85
PAGE 8.1.7
SR85 Service Manual

In Manual Mode, Edge Stapling was not available.
EDGE STAPLING
FIRMWARE
CAUSE:
ROMs prior to version 4.00 would not allow the unit to operate Edge Stapling in Manual mode.
SOLUTION:
The release of ROM version 4.00 allows the unit to perform Edge Stapling in Manual mode. NOTE: When 4.00 ROM is installed, Dipswitch number 2 must be in the left position. For the location of the Dipswitch see page 6.1.1 in the SR85 Service Manual..
PARTS
GENERAL:
PART NUMBER VRC11176 DESCRIPTION ROM version 4.00 QTY 1
UNITS AFFECTED:
All SR85 finishers manufactured after the Serial Numbers listed below will have the new ROM version 4.00 installed during production. MODEL NAME SR85 SERIAL NUMBER ZP218400007

BULLETIN NUMBER: SR85 006 09/12/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2085DP/2105DP/2585/25105 SUBJECT: GENERAL:
The part number for Touch Up Paint for the SR85 is now available. The following parts update is being issued for the SR85.
TOUCH-UP PAINT
PARTS
PART NUMBER VRC11172
DESCRIPTION Touch Up Paint
QTY 1
INT -

BULLETIN NUMBER: SR85 007 09/12/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2085DP/2105DP/2585/25105 SUBJECT: GENERAL:
The following parts updates are being issued for all SR85 Parts Catalogs.
PARTS CATALOG CORRECTIONS
PARTS
CORRECTION 1: Front Panel Extension Assembly The Front Panel Extension
Assembly was incorrectly numbered in the SR85 Spare Parts Manual. Please correct your SR85 Spare Parts Manual with the following information.
DESCRIPTION Front Panel Extension Assembly
QTY 1
INT -
CORRECTION 2: Retraction Swing Arm Assembly The Retraction Swing Arm
Assembly was incorrectly numbered in the SR85 Spare Parts Manual. Please correct your SR85 Spare Parts Manual with the following information.
DESCRIPTION Retraction Swing Arm Assembly
QTY 2
INT -

BULLETIN NUMBER: SR85 008 09/30/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3355/3370/3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 551/700/850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2055DP/2070DP/2085DP/2105DP/2585/25105 SUBJECT: SYMPTOM:
When running colored covers from the Cover Feeder, you may find scratches on the covers from the Lower Folder Rollers.
SCRATCHES ON COLORED COVERS
MECHANICAL
CAUSE:
The Lower Folder Rollers are not smooth enough.
PARTS
PERMANENT SOLUTION:
New style Lower Folder Rollers that are smoother with new springs have been installed starting with serial number ZP 219 1000 01. All units with this retrofit will be marked with Tag1. See illustration below.
MODEL BLK TAG CONFIGURATION A P 0 1 16 31 46 61 76 B Q 1 2 17 32 47 62 77 C R 2 3 18 33 48 63 78 D S 3 4 19 34 49 64 79 E T 4 5 20 35 50 65 80 F U 5 6 21 36 51 66 81 G V 6 7 22 37 52 67 82 H W 7 8 23 38 53 68 83 I X 8 9 24 39 54 69 84 J Y 9 10 25 40 55 70 85 K Z 10 11 26 41 56 71 86 L 11 12 27 42 57 72 87 M 12 13 28 43 58 73 88 N 13 14 29 44 59 74 89 O 14 15 30 45 60 75 90 SERIAL NO.
FIELD COUNTERMEASURE:
A retrofit kit has been created for correcting this symptom for field units. The kit includes new style Lower Folder Rollers and springs. Lower Folder Rollers Retrofit Kit P/N VRC12035

BULLETIN NUMBER: SR85 009 10/03/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3355/3370/3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 551/700/850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2055DP/2070DP/2085DP/2105DP/2585/25105
PARTS Note: This copy is intended as a master original for reproduction of additional bulletins.
SUBJECT: GENERAL:
INFEED TRANSPORT BELT MOTOR
The structure of the Infeed Transport Belt Motor has changed. Please change your SR85 Parts Catalog with the following information. The following part update is being issued for all SR85 Parts Catalogs.
DESCRIPTION Infeed Transport Belt Motor
QTY 1
INT -
UNITS AFFECTED:
SR85 Serial Number cut-in not available at time of publication.

BULLETIN NUMBER: SR85 010 10/10/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3355/3370/3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 551/700/850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2055DP/2070DP/2085DP/2105DP/2585/25105 SUBJECT: SYMPTOM:
It was not possible to connect the SR85 to the more than one of the applicable models listed above.
ENABLEMENT KIT
MECHANICAL
CAUSE:
No communications or alignment parts had been created to support this function.
FIELD COUNTERMEASURE:
An Enablement Kit has been created to solve this problem. Please order this kit if you need to connect the SR85 to more than one of the applicable models listed above.
PARTS
Enablement Kit The Enablement Kit includes the following items: Part Number VRC11179 VRC11180 VRC11181 VRC11182 VRC11183 VRC11184 VRC11173 VRC11010
P/N VRC11174
Description Template Nut Docking Exit Arm Catcher Assy Shift Tray Plate Assy Exit Tray Plat Assy Docking Assy ROM Connection Cable

BULLETIN NUMBER: SR85 011 10/10/2002 APPLICABLE MODEL: GESTETNER SR85 BOOKLETMAKER for 3355/3370/3285/32105/8502/10502 RICOH SR85 BOOKLETMAKER for AFICIO 551/700/850/1050/1085/1105 SAVIN SR85 BOOKLETMAKER for 2055DP/2070DP/2085DP/2105DP/2585/25105 SUBJECT: GENERAL:
PARTS
INSTALLATION KIT FOR TR85
An Installation Kit for the TR85 has been created. Please order this kit if you need to connect the TR85 to a SR85.
Installation Kit TR85
P/N VRC13146

SR85-TR85 SM

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SR85-TR85 SM

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SR85 BOOKLET MAKER TR85 TRIMMER SR85 COVER FEEDER

SR85 Bookletmaker/TR85 Trimmer SR85 Cover Feeder Documentation

RICOH GROUP COMPANIES

SR85 BOOKLETMAKER TR85 TRIMMER SR85 COVER FEEDER

2001 RICOH Corporation. All rights reserved.

SR85 BOOKLETMAKER/ TR85 TRIMMER SR85 COVER FEEDER

SR85 BOOKLETMAKER SERVICE MANUAL

TR85 TRIMMER SERVICE MANUAL

SR85 COVER FEEDER INSTALLATION MANUAL

SR85Bookletmaker/TR85 Trimmer/ SR85 Cover Feeder

SR85 COVER FEEDER SERVICE MANUAL

SR85 Bookletmaker/TR85 Trimmer SR85 Cover Feeder

SR85 COVER FEEDER SERVICE MANUAL

SR85 COVER FEEDER INSTALLATION MANUAL

TR85 SERVICE MANUAL TRIMMER

SR85 SERVICE MANUAL BOOKLETMAKER

SR85/TR85 INSTALLATION MANUAL

Installation Manual Trimmer Bookletmaker SR 85 and Trimmer TR 85

Installation manual SR85

1. Minimum space requirements

2. Installing the Bookletmaker

3. Installing the Trimmer

Installation manual SR85

SR85/TR85 Installation Manual

Installation manual SR85

1. Minimum space requirements

Installation manual SR85

SR85/TR85 Installation Manual

2. Installing the Bookletmaker

Pipe 2 containing: Box 1

16. Infeeder assembly

3. Exit arm Catcher

Installation manual SR85

7. Shift tray plate

8. Exit tray plate

9. Docking assembly for the printer

10. Docking assembly for the Bookletmaker

11. Tapping cabel

12. Belt stacker wheel

13. Front panel

14. Rear panel

Installation manual SR85

SR85/TR85 Installation Manual

2.2 Power Requirements

Configuration Europe N&S America

Nom. Voltage (V) 220/230 230/240 230 105/115 115/125

Remove the right cover (1) by loosen two 8 mm screws, figure 3.

Reinstall the right cover.

Installation manual SR85

2.4 Preparing the printer

Installation manual SR85

SR85/TR85 Installation Manual

2.3 Installing the infeeder

Finisher seen from above

Finisher seen from front side

Installation manual SR85

Four 5.5 mm screws

Installation manual SR85

SR85/TR85 Installation Manual

Four 5.5 mm counter screws

Installation manual SR85

Installation manual SR85