4154079
4154079
4154079
4.14 Head Input Conveyor Lower Assy A2-1055-A..................................... 4-36 5.8 Interlock PCB Circuit Diagram.............................................................. 5-21
4.15 Motor Assy A2-1056-A (115V) / A2-1057-A (230V)............................. 4-38 5.9 Stepper Motor PCB Circuit Diagram..................................................... 5-22
4.16 Sealer Assembly A2-1058-A . ............................................................. 4-41 5.10 R/Splitter & Disk PCBs Circuit Diagrams............................................ 5-23
4.17 Split Shaft Sub Assys A2-1059 / 1060 / 1061-A ................................. 4-44 5.11 Inserter Head Wiring Diagram............................................................. 5-24
4.18 Finger Assembly A2-1062-A . ............................................................. 4-46 5.12 Inserter Head Splitter PCB’s Wiring Diagram..................................... 5-25
4.19 Finger Bkt Op Assy A2-1073-A . ......................................................... 4-49 5.13 Ins. Head PSU & Interlock Wiring Diagram......................................... 5-26
4.20 Side Guide Adjust Assy A2-1063-A .................................................... 4-51
4.21 Pawl Tension Bracket Assy A2-1072-A .............................................. 4-53
4.22 Wetter Lever Assy A2-1352-A............................................................. 4-55
4.23 Wetter Beam Assembly ...................................................................... 4-57
4.24 Wetter Tank Assy A2-1070-A............................................................... 4-59
4.25 No Seal Assembly A2-1214-A ............................................................ 4-61
4.26 Head Ribbon Bkt. Assy 184-2260....................................................... 4-63
4.27 Universal Head PSU 184-2150 .......................................................... 4-65
4.28 Mains Input Hardwired 184-2250........................................................ 4-66
4.29 Head Covers ..................................................................................... 4-67
4.30 External Float Switch A3-0421-A . ...................................................... 4-70
4.31 Lift Beam Assy A2-1520-A................................................................... 4-72
5 Electrical & Circuits................................................................................... 5.1
5.1 Sensors ....................................................................................... 5-2
5.1.1 Sensors List................................................................................. 5-2
5.1.2 Sensors Diagram, Operator Side................................................. 5-4
5.1.3 Sensors Diagram, Drive Side....................................................... 5-5
5.2 Electrical Components.......................................................................... 5-6
5.2.1 Physical Locations of Components.............................................. 5-8
5.3 Control PCB Circuit Diagram................................................................ 5-14
5.4 Processor PCB Circuit Diagram............................................................ 5-17
5.5 Comms PCB Circuit Diagram................................................................. 5-18
5.6 Wetter PCB Circuit Diagram.................................................................. 5-19
5.7 Expansion PCB Circuit Diagram........................................................... 5-20
Page ii
Maximailer HD Service Manual Installation Page 1 - 1 Issue 1 Mar 2010
Section 1
Installation
Instructions
Sect. Page
Page 1 - 1
Maximailer HD Service Manual Installation Page 1 - 2 Issue 1 Mar 2010
Page 1 - 2
Maximailer HD Service Manual Installation Page 1 - 3 Issue 1 Mar 2010
Important!
This equipment is supplied with an unterminated, three-core lead for connection to the mains supply. The connection
must only be made by a qualified electrician, or by a qualified Service Engineer.
Caution
High leakage current. An earth connection is essential before connecting to the supply.
Page 1 - 3
Maximailer HD Service Manual Installation Page 1 - 4 Issue 2 Sept 2011
with stands supplied in flat-pack form. Check that the following de- A3-0417-A
A7048A =+A3239A
A3241A
A3-0417-A
A7050A + A3241A
= A3239A + A3240A
+ A3240A
Insertion Head
A7051AA3-0417-A
= A3239A ++ A3240A
A3240Ax+A3241A
2
Comms Lead, Long 160-511 Qty. 1
A3-0417-A
A7259A+=A3241A ++
(A3240A
(A3240xx2)
Plug IEC60309 Yel 16A 168-347 (US) Qty. 1 A3239A 2)
or A3-0417-A
A7256A = A3239A + A3240A
+ (A3240 x 2) x+ 3A3241A
Important: Check that all covers are in place and undamaged. Check
that all warning labels are in place and legible (see section x for locations).
Check that the mains lead and its connectors are sound and undamaged.
Page 1 - 4
Maximailer HD Service Manual Installation Page 1 - 5 Issue 1 Mar 2010
1.3.1 Assemble the HD head stand to the single stand supplied; this will
replace the previous Maximailer Plus stand that supported a single
Maximailer HD module as well as the insert head.
Insert Head
1.3.2 Lift the Maximailer HD head onto the stand, ensuring that the
wetter tube passes through the hole in the top of the front section
of the stand.
1.3.3 Place the sealing fluid bottle and PC into the stand as shown. Do
not connect the PC at this stage.
PC
Sealing
Fluid
Page 1 - 5
Maximailer HD Service Manual Installation Page 1 - 6 Issue 1 Mar 2010
1.3.4. Screw all stands together and fit the supplied attachment bracket
R2904T to the end stand. Note: Use holes marked ‘L’. This is
Datacard machine required for the alignment of the wider Maximailer HD and Datac-
(shown connected ard system.
to attachment
bracket)
1.3.5 Lift all feed modules (if applicable) and the DTI onto the stands.
Assemble them together using the supplied screws.
Attachment
bracket R2904T
End module
stand
1.3.6
Attach the Datacard machine to the attachment bracket R2940T,
as shown opposite.
cont.
Page 1 - 6
Maximailer HD Service Manual Installation Page 1 - 7 Issue 1 Mar 2010
1.4 Setting up the machine 1.4.6 Check network connections between Maximailer HD PC and the
Datacard machine.
1.4.1 Connect the power and comms cables for all modules as follows:
1.4.7 Program the Maximailer HD with jobs and test run.
• Datacard machine to DTI serial lead
• Datacard machine to PC comms lead 1.4.8 When all is satisfactory, replace all covers.
• Cancard from PC to Maximailer HD
• Power leads between modules and then to Maximailer HD head
• Power lead from Maximailer HD head to mains supply
• Power lead to PC
• Power lead to Datacard machine
1.4.2 Check the DIP switches on the head and module PCBs are set as
follows:
1 X
2 X
3 X X
4 X
5 X X
6 X X
7 X X X
8 X
Page 1 - 7
Maximailer HD Service Manual Description of Operation Page 2 - 1 Issue 1 Mar 2010
Section 2
Description
of
Operation
Sect. Page
Page 2 - 1
Maximailer HD Service Manual Description of Operation Page 2 - 2 Issue 1 Mar 2010
SECTION 2 DESCRIPTION OF OPERATION The sequencing between the stages of machine operation is shown in the
diagrams below, which begin part way through a complete cycle – the
2.1 General Description preceding sequence of operations from the start of the cycle will have been
The machine is a high-volume folder/inserter capable of up to 200,000 cy- similar, but with fewer documents having been gathered.
cles per month at a speed of up to 4500 filled envelopes per hour (DL with
1 insert). It is of modular construction and consists of an insert head and
any or all of a: insert feeder; b: tower feeder; c: mark reading feeder; d:
feeder folder; d: tower folder (with built-in tower). This may be fitted with
either 1 or 3 trays and an optional accumulator for collating/diverting, with
or without a diverter tray. It is always fitted in the end station position.
The insert head also includes a collator, as well as the envelope hopper,
wetter and closer.
Stage 1: Form 1 is fed from feeder 1 down onto the conveyor track. This
Collation can be carried out a number of ways, depending upon the particu- form is trail edge collated with the upstream documents arriving from feed-
lar job. The software works out the optimum feed pattern, as well as the ers 2 and 3. The feed timings for the collate operation are triggered when
best feed units to use if more than one possibility exists. Collation possibili- the trailing edge of the documents from feeders 2 and 3 pass through the
ties are: track control sensor.
1. Using the accumulator in a 3-tray, tower folder - 3 forms are fed
into the accumulator, folded and ejected on towards the insert
head.
2. Collation on the track - a folded sheet or insert is timed to trail-
ing-edge collate with the document fed from the following feed
unit as the first document passes underneath.
3. At the insert head - all documents will arrive in the collation
pocket, either individually or as a pack already collated by the
above methods. The topmost item is the prime (address) docu-
ment. The pack is then inserted in the envelope. Stage 2: The three collated documents (for pack 1) from feeders 1, 2 and
3 are driven into the collation pocket by the retard rollers. This roller set
2.2 Track collation description ensures that the final presentation of the collated pack is suitable for enve-
Jobs with more than one feed unit will in most cases collate together as lope insertion by slowing down whilst feeding.
described in paragraph 2 above, and will arrive in the collation pocket as a Form 1a is fed from insert feeder 2 down onto the conveyor track. This
pack, with the exception of the prime document, which will be fed on top form is trail edge collated with the upstream document arriving from feeder
of the pack as a separate item. The exception to this is if the prime station 3. The feed timings for the collate operation are triggered when the trailing
is No. 1, in which case the document would be finally collated on top of the edge of the document from feeder 3 passes through the track control sen-
pack from preceding feed units, then finally delivered to the collate pocket. sor.
Documents are trailing-edge located due to the pack being inserted by Form 1b is held stationary at the exit hold point of insert feeders 3 and 4.
pushing it into the envelope with chain-driven pawls. Timing is controlled by
the track conrol sensor located behind each hopper.
Page 2 - 2
Maximailer HD Service Manual Description of Operation Page 2 - 3 Issue 1 Mar 2010
Whilst the pack is feeding, an envelope will have been fed to the envelope
feed sensor which acts a hold point if necessary, and then into the station-
ary deskew rollers which straightens any skew; the deskew rollers are con-
trolled by the deskew sensor.
The envelope tractor facilitates feeding of envelopes and operates on a
Fig. 3 pivot. When pushed forward by the envelope stack, the envelope conveyor
sensor switches off the feed conveyor; as envelopes are fed and the tractor
Stage 3: Form 1 (prime/address carrying document for this pack) is relaxes, the sensor is cleared and the conveyor starts again. The amount of
driven into the collation pocket by the retard rollers. delay before feeding restarts can be controlled in software.
Form 1b (prime/address carrying document for a following pack) is fed from The envelope is then driven past the tilting flap opener and into place ready
feeder 4 down onto the conveyor track.
The feed operation between all stages
is governed by software timings to set
a controlled gap (pitch length) between
the prime documents on the track.
Form 1a held is stationary at the exit
hold point sensor of insert feeder 1.
After the prime document has been fed
into the collation pocket on top of the 3
documents already collated, the pack is
inserted into the envelope, described in
more detail below.
2.3 Description of Insert Head (see
Fig. 4 opposite)
The insert head includes the envelope
hopper, collation pocket, insert fingers,
wetter and closer. The insert pack ar-
rives into the input conveyor, as moni-
tored by the input conveyor sensor.
When its trailing edge passes this sen-
sor, the drive rollers ahead reduce speed
as necessary to allow the collate pocket
to clear. The pack is then driven into
the collate pocket where it contacts a
solenoid-actuated backstop to prevent
overrun (there are 3 backstops, the
one used being determined by the pack
length). Its arrival is monitored by the
collate pocket load sensor; the collate
pocket sensor confirms it is in place in
the pocket.
Page 2 - 3
Maximailer HD Service Manual Description of Operation Page 2 - 4 Issue 1 Mar 2010
for insertion. Here it is held with the flap crease at the datum point shown finger out (flag) sensor is blocked when the fingers are in the relaxed posi-
in Fig. 4, timed from the trailing edge passing the deskew sensor and ar- tion (out of the envelope).
riving at the envelope flap sensor. The solenoid-actuated insert fingers hold
For the collate pocket, the guide datum (flag) sensor determines when the
the envelope throat open. With the envelope then in place ready for the ar-
guides are at their widest position. The guide disc sensor then clocks their
riving pack, the backstop drops and the pack is driven into the envelope.
movement to set them to the correct position.
Note that it is possible in the software to adjust whether the outer pair of
fingers move forward first, or the inner pair. This can assist certain enve-
lopes, depending on design.
As the chain pawls are pushing the pack in, the pawls below the track are
detected by the pawl position sensor which times precisely how long it take
to push in the pack. At that point, the envelope is released.
Just prior to release, the chain track pauses momentarily so that the tips of
the pawls do not catch on the edge of the departing envelope. While in-
sertion is taking place, the next envelope is fed into place and held at the
deskew rollers ready for the next insertion.
Timed from the leading edge of the envelope passing the wetter output
detect sensor, the wetter beam is pulled down by solenoid action so that the
flap is wetted by the wetter felt below. As the trailing edge passes this sen-
sor, the beam will retract.
The envelope is driven forward
into the seal rollers. Due to the
angle of the roller axis, the flap
edge of the envelope is lifted
up, forcing the flap downwards
against the roller, at which point
the rollers reverse to drive the
envelope into the upper seal
rollers, sealing the envelope flap
- the reverse point is timed from
the closer output sensor. The
envelope leading edge reaches
the closer seal sensor and the
envelope reverses again to drive
it out of the eject, monitored by
the closer output sensor. This
completes the cycle. See fig. 5 above.
The insert finger widths and collate pocket side guides are automatically
adjusted to suit the appropriate paper widths, as determined by the sizes
set in the operating software. For the fingers, the finger datum (flag) sensor
determines when the fingers are at their narrowest position. The finger disc
sensor then clocks their movement to set them to the correct position. The
Page 2 - 4
Maximailer HD Service Manual Description of Operation Page 2 - 5 Issue 1 Mar 2010
Page 2 - 5
Maximailer HD Service Manual Description of Operation Page 2 - 6 Issue 1 Mar 2010
Fold plate settings are automatic in operation, set by the data input in the 2.6 Description of Feeder Folder (see Fig. 8 below)
job setup, or more usually by the automeasure facility using standard form
The 2 plate feeder folder is fitted with a top feed hopper capable of holding
sizes. Fold plate that are not used are blanked off by a no-fold beam actu-
up to 500 sheets of 80gsm paper. The hopper and separator are identical to
ated by a lug attached to the motor-driven end stop.
the upper hopper of the tower folder.
The accumulator can also be used for diverting forms for subsequent hand
The unit is available as either an end unit, or in-line (mounted on the
removal (the cover over the conveyor can be raised), or if the optional di-
track), the difference being a blanking cover fitted to the rear of the end
verter tray is fitted at the top end of the accumulator, the forms will be fed
unit and no conveyor is fitted. An optional handfeed slot may be specified,
directly into it - passing the divert bin sensor confirms their presence. Note
located in front of the paper hopper – this can fold up to 3 sheets of 80gsm
that diverted forms will always pass into the divert tray if it is fitted.
(C or Z) or 5 sheets (V). Stapled sheets must be Z fold only.
The accumulator is an optional item, and if it not fitted there is no divert
facility, and a maximum of 3 forms can be folded together. If more than 3
forms are to be fed, these will be folded singly and fed onto the track one
after the other, then collated together in the collate pocket in the insert
head.
Daily post
This function will be enabled if ‘Handfeed’ is selected in the job setup. When
the Run button is then pressed, the machine will await a group of up to 8
forms, stapled or not, to be inserted into the daily post hopper. When these
pass the daily post sensor, they will be automatically fed, and the machine
will await the next group. Forms from other feeders in the tower folder can
be collated with the daily post (up to the maximum of 8 of 80gsm), and
forms from other feed units can also be included in the job.
Fig. 8
Page 2 - 7
Maximailer HD Service Manual Description of Operation Page 2 - 8 Issue 1 Mar 2010
The machine may be fitted with either OMR or barcode, top or bottom read- barcode head is fitted, shortform option is not available with either. In use,
ing, vertical or horizontal barcode for top reading, but horizontal only for both fold plates are blanked off by the no-fold beams. For forms clearance
bottom reading. An optional shortform upgrade can be fitted so the folder in the event of a crash, the rear roller shaft can be pivoted backwards after
can double as a feeder, but this cannot be Barcode or OMR enabled. removing the hopper. Shortform option can be specified with the unit or
retrofitted (A3302A).
Operation
Handfeed option
A form feeds through the pre-feed rollers, monitored by the pre-feed sensor
and up to the deskew and double document sensors, mounted side-by-side. This is fitted in front of the unit, as shown in Fig. 8. It allows folding of up
The leading edge is driven into the stationary rollers ahead to correct any to 3 sheets of 80gsm (C or Z) or 5 sheets (V). Stapled sheets must be Z
skew. The deskew sensor also acts as a hold point. When the path ahead is fold only. In operation, handfeed (daily post) is selected in the job. When
clear, the drive is engaged to the rollers to feed the form forwards. As soon the machine is started, the operator is prompted to feed the paper, detected
as the trailing edge is clear of the pre-feed sensor, the next form starts to by a reflective sensor. The machine will wait for up to 1½ minutes for paper
move towards hold point (deskew), thus allowing minimum time delay be- to be inserted in the handfeed hopper, after which it will switch off. Hand-
tween forms. feed option can be specified with the unit or retrofitted (A3301A).
If an OMR head is fitted, the OMR Gate paper sensor detects the leading
edge of the forms and times the start of the marks from the distance input
by the user: the timing operation is carried out by the encoder (tacho) fit-
ted to the end of the feed roller shaft just ahead of the DD/Deskew sensors.
If a barcode reader is fitted, no sensor or tacho is required or fitted, and a
different, shorter feed shaft is used. After reading any marks/barcode, the
form is fed into fold plate 1 whose backstop is motor-driven to be set short
(ie. approx. 1/3 form length) for C fold, or long (approx. 2/3 form length)
for Z fold. When the leading edge contacts the backstop, the form buckles
and drives the buckle into the nip of the first fold rollers. It is driven into
the second fold plate (set short for both C and Z fold) where it buckles
again and is fed, fully folded, towards the exit path where it is held by a
brake at the track feed sensor. For V fold, the form is driven into fold plate
1, set to half form length, and the buckle is driven into the first set of fold
rollers. The no-fold beam for fold plate 2 is solenoid-actuated to bypass the
fold plate, so the folded form is driven towards the exit path as for C or Z
fold.
For in-line units a conveyor is fitted, where forms approaching from the
unit behind are fed through, monitored by the track sensor. This is timed
in conjunction with the track exit sensor so the folded form is trailing-edge
collated with the preceding document, as described in section 2.2.
For end units, no conveyor is fitted and the unit normally feeds the prime
document. This travels through the machine to be fed on top of the collated
pack in the collate pocket in the insert head.
Shortform option
This option allows the folder to be used as a feeder by the addition of the
two roller shafts shown in Fig. 8. As these are placed where the OMR or
Page 2 - 8
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Section 3
Maintenance
and
Service Adjustments
Sect. Page Sect. Page
3.3 Preventative maintenance guidance & schedule.....................3-4 3.16 Removal of sealer rollers.........................................................3-18
3.1.2 Safety instructions The objectives of the European Community’s environment policy are, in
particular, to preserve, protect and improve the quality of the environment,
3.1.1.1 General protect human health and utilise natural resources prudently and rationally.
• This machine must be operated by competent personnel. That policy is based on the precautionary principle and principles that pre-
ventive action should be taken, that environmental damage should as a
The manufacturer accepts no responsibility for accidents or injuries priority be rectified at source.
caused by operation by incompetent personnel.
Separate collection of waste is the precondition to ensure reuse and recy-
• Covers may only be opened by skilled persons, who know the risks cling of waste that is generated at the disposal of electrical or electronical
involved. equipment and is necessary to achieve the chosen level of protection of hu-
For safety reasons, the machine will not function with opened cov- man health and the environment in the European Community.
ers. More particularly, certain materials and components of waste electrical and
• Keep away long hair, fingers, jewelry, etc. from rotating and mov- electronical equipment needs selective treatment as their injudicious han-
ing objects of the system. dling or disposing of on or into land, water or air would represent a major
threat to the environment and human health.
• Switch off the system at the end of the day.
cont.
3.1.1.2 Electrical safety
• Disconnect the mains power supply before performing any mainte-
nance to any kind of mains power supply/high voltage related items.
• The power connection must be easily accessible, preferably close
to the machine.
• For safety reasons it is essential that the machine is connected to a
socket outlet with protective earth connection.
• Over-current protection in the equipment also relies on the branch
circuit protection.
• Disconnect the machine from the power supply when it is not in
use for a longer time.
• Potential hazard may exist to electronic hardware in conditions
with static electricity. It is advised that, when handling electronic
parts, an earth connected wrist band is used in order to be perma-
nently discharged from static electricity.
Page 3 - 2
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
In order to facilitate collection and treatment separated from normal 3.2 Conventions used in this manual
domestic waste, electrical and electronical equipment is marked with the
following logo: 3.2.1 Symbols
3.2.2 Orientation
Not only are you by law not allowed to dispose of the waste equipment via Throughout this manual, reference will be made to Operator and Drive side
other waste-streams, but we encourage you to actively contribute to the to indicate the side of the machine in question. These are defined as:
success of such collection and to the common good and better quality of life
of present and future generations. Operator Side: The side of the machine where the operator
normally stands, viewing the screen. The side
For more information on the correct disposal of this product please contact covers can be opened by the operator.
your local dealer. Drive Side: The opposite side to the Operator side. The side
covers cannot be opened by the operator and are
only able to be removed by the Engineer. Gear/
drive trains are located on this side.
Page 3 - 3
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
The Maintenance schedule on the following pages is applicable to the Maximailer HD product range and must be strictly followed to guaran-
tee machine performance and reliability.
This schedule is based on a monthly cycle count of 350k / month which is considered the normal maximum. If the machine is running less
than this, the PM visits should still be carried out with the same frequency, but fewer parts will be required.
• DS300 (Maxi HD)—Duty Cycle 350k / Month = 4.2 million / year = 4 PMV / year (pm every 3 months)
• DS200 (Maxi HD)—Duty Cycle 200k / Month = 2.4 million / year = 2 PMV / year (pm every 6 months)
• DS100/140 Feeders –Duty Cycle 200k / Month = 2.4 million / year = 2 PMV / year (pm every 6 months)
Note: If feeders are running at same duty cycle as the machine = 4 PMV / year (pm every 3 months).
Page 3 - 4
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval Cycle (Page)
Clean and
regrease all
spring loaded
bearings
Ensure side
guides are
tapered to feed
the envelope
freely into
envelope
pickup
Clean all
feed tyres-
replace if
needed
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
A2 cont Clean and check gears on track assembly 10mins Gears---Inspect and replace if worn
Clean and grease bearings after 4 million
Lenze clutches-Inspect after 2million
A3 Remove separator from envelope feed assembly 15mins separator roller---C8135A
Check separator roller Replace after 4 million
Check separator shield Shield ---D164_03A
Replace roller or shield if worn or damaged Replace after 4 million
Separator rollers
and shield
A4 Check flap guide tapes on flap grip assembly 10mins Flap guide shim---G6-0223-A
(Replace if required) Inspect after 2 million
Check and clean needle bearings ensuring no tight spots Needle bearings---
Inspect after 2 million
Needle bearings
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
A6 Clean wetter tank and replace felt . 10mins Wetter Felt--- G0-0181-A
Replace after 1 million
Wetter felt
Spring loaded
bearings
ITEM # Maintenance Item – Head Unit Frequency Time to Replacement Part Numbers and Ref Manual Complete
Complete Interval cycle (Page)
Bearings—
Inspect after 2 million
Lead screw—
A10 Check , clean and regrease finger assembly 30mins
Inspect after 4 million
Ensure fingers are not sticking on lead screw shaft or
Catching on frame of machine
(remove and check if needed)
Lead screw
A11 Clean wetter solenoid with dry cloth and air duster 5mins
to remove dust particles . Wetter solenoid—
Inspect after 2million
Wetter Solenoid
A13 Clean all sensors (both transmitter and receiver) 10mins Replace when faulty
With approved air duster
A25 Run in envelope only mode checking for envelope stop 10mins
position and good envelope feed.
• Pozidrive screwdrivers #1 & #2 When removing items such as the envelope feeder assembly, note that
some items are very heavy and lifting should not be undertaken unless you
• Set of metric Allen Keys feel confident to do so. Seek assistance otherwise.
• Pointed (snipe) nosed pliers
• Right-angled bit drivers
• Side-cutters
• In addition, a stock of cable-ties 100 x 2.6mm 169-102
Page 3 - 5
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
When screws are removed, lift the cover upwards of the lower location lugs
and lift it off.
3.5.2 Front vertical cover
Visible inside sealer cavity, This is located below the sealer and provides access to the wetter piping
after opening the sealer. and no-seal solenoid.
First remove the drive-side cover as above and open the side cover on the
operator side.
cont.
Page 3 - 6
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Page 3 - 7
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
1 The envelope conveyor must be removed before the feeder assembly Remove the 6 Remove the screws marked ‘F’ on both the
is lifted out of the chassis. feeder drive and operator sides (Figs 1 & 2).
5 Open the sealer cover under the conveyor and lift the conveyor away
from the feeder assembly.
4 With the assembly removed from the chassis, the rollers or motor can
be replaced, or the roller shield can be adjusted (see opposite).
Page 3 - 9
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
2 Remove the end cover together with the backstop (2 screws under-
neath).
7 Refit the end cover and reassemble the conveyor back on the ma-
chine.
Page 3 - 10
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
The collate pocket clam assembly pivots on a spigot post each side. Remov-
al entails taking out the spigot on the operator side only.
Removing the assembly is quick to carry out, and allows much improved ac-
ces to the collate area.
1 On the drive side, trace the sensor cables for the assembly back to
the chassis hole, detach them from the clips and disconnect them
from the PCB.
Fig. 6
2 On the operator side,
remove the clutch/gear, idler
and gear indicated in Fig. 6.
Slacken the clutch locators to
allow this.
4 Reassembly is a reverse
of removal.
Page 3 - 11
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
3.10 Replacement of collate chains or chain pawls Fig. 9 5 Use a screwdriver or simi-
lar tool to compress the spring
tensioner.
1 Remove the insert panels – this will allow the chains to flex sideways.
Pawl misalignment
2 At the pawl link, remove Fig. 10
Fig. 8 the spring clip on the outer 6 If the chain pawls be-
side and pull out the rollers to come misaligned, they can be
separate the chain (see Fig. brought back into line by the
8). Caution: jam the chain following procedure.
at the input end to prevent
it sliding inside the chassis. 7 Slacken the screw indicat-
ed in Fig. 10 and release the
3 Use the link to connect tension shaft.
one end of the new chain with
one end of the existing one. 8 Hold the forwardmost
maintaining chain tension, pawl, and using pointed nose
Insert panel shown
dtoraw it round the pulleys pliers drag the other chain
removed
until the other end appears on over the required number of
the chassis surface. sprocket teeth at the output end. When the pawls are aligned, replace
the tension shaft.
4 Jam the chain to hold it and separate the link to remove the old chain.
Join the 2 ends of the newFone.FIf necessary, the chain tension can be 9 Replace the insert panels and run the machine to check that the
relieved by using a screwdriver (or other suitable tool) to compress chains operate correctly.
the tensioner at the input end (see Fig. 9).
Page 3 - 12
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Page 3 - 13
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
lenoid on each side. The fingers are therefore individually adjusted. The solenoids can be actuated in Engineer mode diagnostics.
To operate the machine, close the top cover and place a mag-
1 Ensure the envelope net over the side cover interlock switch.
Fig. 13 feeder is removed (see section
3.6).
Page 3 - 14
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Inner Fingers
The inner fingers are adjusted using a special setting gauge with the finger
assembly removed from the machine, as described in section 3.11.
3 If adjustment is required,
slacken the 2 screws securing
the solenoid and slide it as required. Tighten the screws and check that the
setting has not changed.
Page 3 - 15
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
7 Replace the side guide brackets and side guides in the collate area.
The side guides must now be adjusted – see section 3.14.
Page 3 - 16
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
The side guide width is automatically set according to document size. How- The power supply unit can be removed from the drive side of the machine
ever, the side guides are factory set to toe-in at the front. If the guides after disconnecting cables on the operator side.
have to be removed or disturbed, the toe-in must be reset to toe-in at the
Operator side
front. Fig. 20
The PSU must first be discon-
nected on the operator side.
A A 1 Open the collate pocket
assembly in the collate area.
1 Disconnect the two cables
Network indicated in Fig. 20. Unplug
Fig. 19 Slacken the 2 screws indi- Cable
the network cable to allow
cated in Fig. 19 to allow the
access for the PSU cables to
guides to swivel.
pass through the opening.
Adjust the guides so that
point B is 1.5mm (1/16”)
wider each side than point A.
This is most easily achieved Drive side
by placing a piece of pa-
B
per between the guides and 2 Remove the 2 screws indi-
B winding the gears by hand to cated in Fig. 21 and withdraw
move them. The gap can then the PSU, feeding the connec-
be easily measured. tors through the chassis open-
Tighten the screws and check that the setting has not altered. The toe-in ing on the operator side.
applies to all document sizes. Replacement
Hold the cables and reach in
the chassis opening on the
drive side and feed the con-
Fig. 21 nectors through the opening
on the operator side. Push the
PSU home. The lugs on the
operator side must locate in the chassis plate before the PSU will fit.
Page 3 - 17
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
There are four sealer rollers: two in the chassis, two in the opening sealer
assembly. They should be checked for wear or damage at every site visit
and replaced at 2 million envelopes. When fitting the new rollers, take care not to damage the
To remove the rollers, this can be done with the envelope feeder in place, lower roller as it is refitted. Do not get grease on the rollers.
but the sealer assembly will have to be removed first (see section 3.17).
Having done so, proceed as follows.
Page 3 - 18
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
The sealer assembly can be quickly removed for replacement of sealer roll-
ers (see section 3.16). Proceed as follows.
Page 3 - 19
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Note:
Engineering mode will only be available to personnel
with appropriate access rights.
Engineering mode applies to the whole machine, To make changes select the Edit tab. Select each unit in turn in the left-
hence this section covers feed/fold modules, as well hand column, choose the unit type in the centre column and select the
as the insert head. Modules not relevant to the actual required options in the right-hand column. Extra settings relating to readers
machine setup should be ignored. are shown in the pane on the right-hand side. For Feed/fold units, the read-
ers fitted are selected with the module highlighted, then the reader options
for each hopper are selected with the module hopper highlighted.
To view all settings without making changes, select the View tab and select
each module or its hoppers.
To add new modules to the end of the existing ones, use the button
and configure to suit.
cont.
Page 3 - 20
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Settings tab
This allows adjustment of various settings, depending upon the module.
Module 0: Head adjustment of:
Collate Pocket Cal & Fingers Cal: These settings are in addition to any
changes made in ‘Calibrations’ (see later in this section). Use if the
settings need to be different from the calibrated sizes.
Wetter Start: Adjusts the point at which the wetter beam drops to wet
the flap (+ve = more wetting). In steps of 1mm. Note: this setting
applies to the machine, and can be further adjusted for the job in ‘Ad-
vanced’.
Envelope Stop Position Cal: Adjusts envelope stop position. Positive =
further forward towards exit direction.
Page 3 - 21
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Envelope Insert Position Cal: Adjusts amount of insertion of insert 2. In the configuration screen, select the number at the top of
pack into envelope. Positive = further forward past flap crease. the fold module icon: check the Fold Plate Length settings in the
dialog box (see below). For A4, F1 should be 149mm and F2 &
Envelope Reverse Position Cal: Adjusts amount of envelope forward
F3 should be 0. For Letter, Length A should be 140mm and F2 &
travel after flap wetting, before reversing to enter sealing rollers. Posi-
F3 should be 0.
tive = further forward into rollers, towards exit direction..
Envelope Seal Position Cal: amount of envelope travel into seal roll-
ers. Positive = further forward, away from exit direction.
Envelope depth Measured: auto-measured depth of envelope, which
will be displayed. Adjust up or down to suit actual envelope size. Posi-
tive = greater.
Ins. Pawl Stop Position Cal: Adjusts stop position of insert pawls be-
hind insert pack in collate pocket. If the pawls are stopped too high by
the software, inserts entering the collate pocket will contact the tips,
hence position must be adjusted back. Positive = further forward.
Pocket Backstop Cal: As inserts enter the collate pocket, they contact
a backstop to prevent overrun, and stop. The backstop is then lowered
and the insert drives forward. This setting increases the time delay
before the insert drives forward. Use if backstops are slow to drop for
any reason, causing crashing. If set to Off, backstop remains lowered
always.
Feeders (dual only): Collate Feeder 2 Cal: Moves the form in hopper
2 to adjust collate point. Positive = further forward, in steps of 1mm.
Feeder Folder: Folplate 1/2 Cal. & No Fold 1/2 cal: These are the
same as 1 & 2 of the 3-Plate folder (see below). 3. Save the job and run. Measure the length of the first panel,
which should be 149mm (A4) or 140mm (Letter). If not, exit
Tower Folder: adjustment of:
Configuration and enter Units Setup in Engineering mode. Select
a: settings of foldplates 1, 2 & 3. Figure shown will be the set- the Tower Folder in the module box at the bottom of the screen:
ting for the job, and may be adjusted if required. Units are 1mm and this will display the settings boxes for the foldplate calibrations
positive = greater. To set up for the first time, or if parts have been (see following page).
replaced:
1. Set up a job with the following parameters:
European: Envelope = C5 (162 x 229), Paper = A4 single sheet from
top hopper, Fold = V.
US: Envelope = No. 7 Booklet (159 x 244), Paper = Letter size single
sheet from top hopper, Fold = V.
Page 3 - 22
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Page 3 - 23
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
FP2 Clockwise Cal: Controls paper travel into FP2 for CW rotation,
(from operator side). Positive = further. Factory default = 0. (Mk.2
only).
FP2 Counter CW Cal: Controls paper travel into FP2 for CCW rotation,
(from operator side). Positive = further. Factory default = 0. (Mk.2
only).
Up Detent CW: Controls detent landing position for cassette home
position. Positive increases rotation. Factory default = 0. (Mk.2 only).
Down Detent CW: Controls detent landing position for cassette after
180° rotation. Positive increases rotation. Factory default = 0. (Mk.2
only).
Up/Down Detent Counter CW: As for CW, but rotating Counter CW.
Factory defaults = -4 & -3. (Mk.2 only).
Conclusion of Settings section.
Page 3 - 24
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Calibrations tab Note also that the collate pocket side guides are adjustable
for taper and are factory set to taper intowards the closer
end. The 210mm setting above applies to the narrowest
point - the widest point is set to approx. 3-4mm wider either
side. Specific jobs may require a diferrent setting; to adjust,
slacken the screw near the middle of the guide and twist the
guide to suit.
Page 3 - 25
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Calibrating
54/76/94/116
984mm/s
0.51
24.0V
Page 3 - 26
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
3.18.3 Firmware Download Change Params: this is a legacy feature and should not normally
be required unless a different CAN type were used. The default set-
Firmware downloading allows selected units to be upgraded with se-
tings are:
lected files, usually sourced from the company website.
USB CAN
Select the unit(s) to be upgraded and use the ‘Files’ button to find
the appropriate .am4 file(s). Note that each file includes the module Packet 4
name in the filename, ie. for head, 3P folder or feeder/2P folder/
Send Interval 1
Cardfolder. The lower windows show the version number and status
of the file. These can be compared with the main window showing O/Flow Timeout 10
the same details for the current firmware in the unit. When downloading is complete, select Exit.
Normally, all modules should be ticked in the left-hand column and
Broadcast Mode should be ticked also. This will allow multiple mod-
ules of similar type (feed/fold modules or Cardfolder) to be upgraded
simultaneously, saving time; only untick if a module is specifically
not to be upgraded. It does not matter if, for example, the head
were ticked whilst feed/fold modules were being upgraded.
When downloading, the righthand window shows download status in
progress.
Page 3 - 27
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Page 3 - 28
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Analoque sensors are those that respond over a graduated range, Sensors can be calibrated individually or all together by using the
unlike digital sensors which are read as either On or Off. They are Cal All (Paper sensors) button.
usually adustable.
Generally, the readings are best used as a comparison guide for
The screen displays the status of analogue sensors and allows their like sensors from one machine to another. However, if a sensor has
calibration. The read-only displays translate as follows: failed, the readings are likely to be very low or zero.
Example: T=2.6V I=222% R=12% C 0.2V Select each module as required using the Select Unit button.
Where T = Threshold voltage, generally over 2.5V, I = ‘effort’ of Digital sensors
current required to read across the sensor halves, R = Percentage
of pot value on PCB, C (or B) = clear or blocked and sensor voltage,
which should <0.5 clear, >4.5V blocked.
Calibration
Page 3 - 29
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Analoque sensors are those that respond over a graduated range, Sensors can be calibrated individually or all together by using the
unlike digital sensors which are read as either On or Off. They are Cal All (Paper sensors) button.
usually adustable.
Generally, the readings are best used as a comparison guide for
The screen displays the status of analogue sensors and allows their like sensors from one machine to another. However, if a sensor has
calibration. The read-only displays translate as follows: failed, the readings are likely to be very low or zero.
Example: T=2.6V I=222% R=12% C 0.2V Select each module as required using the Select Unit button.
Where T = Threshold voltage, generally over 2.5V, I = ‘effort’ of Digital sensors
current required to read across the sensor halves, R = Percentage
of pot value on PCB, C (or B) = clear or blocked and sensor voltage,
which should <0.5 clear, >4.5V blocked.
Calibration
Page 3 - 29
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Analoque sensors are those that are read as either On or Off, unlike Covers
digital sensors which respond over a graduated range. They are not
Displays the status (open or closed) of all operator-opening covers
adustable.
and hopper interlocks. This will indicate if a reed switch has failed or
The screen displays the On/Off status of each sensor. To check if a is badly adjusted.
sensor is working, it should be On when blocked, Off when clear. Any
semnsor that does not respond this way should be replaced
Page 3 - 30
Maximailer HD Service Manual Maintenance and Servicing Issue 1 Mar 2010
Power Miscellaneous
Displays the voltage or current drawn by each component. The com- Displays the total count for each module. For insert head, Feed
ponent name indicates the nominal voltage/current, while the display Count 1 is the number of envelopes fed, Output Count is the number
indicates the actual rating. of filled envelopes ejected and Pack Count is the number of packs
that have arrived at the collate area for insertion into the envelope.
For tower folder, feed counts 1 to 4 relate to the hoppers, where
hopper 4 is the hand-feed hopper.
Page 3 - 31
Maximailer HD Service Manual Maintenance and Servicing Issue 3 May 2010
Page 3 - 33
Maximailer HD Service Manual Maintenance and Servicing Issue 3 Aug 2011
Page 3 - 34
Maximailer HD Service Manual Exploded Views Issue 4 Dec 2011
Section 4
Exploded
Views
Section Description Page
4.1 Chassis Drive Side (Front).......................................................4-2 4.17 Split Shaft Sub Assys A2-1059 / 1060 / 1061-A ......................4-44
4.2 Chassis Drive Side (Rear).......................................................4-5 4.18 Finger Assembly A2-1062-A . ..................................................4-46
4.3 Chassis Operator Side.............................................................4-8 4.19 Finger Bkt Op Assy A2-1073-A ...............................................4-49
4.4 Chassis Assembly....................................................................4-11 4.20 Side Guide Adjust Assy A2-1063-A .........................................4-51
4.5 Shaft Locations........................................................................4-14 4.21 Pawl Tension Bracket Assy A2-1072-A ...................................4-53
4.6 Envelope Feeder Assy A2-1064-A...........................................4-16 4.22 Wetter Lever Assy A2-1352-A..................................................4-55
4.7 Envelope Separator Assy A2-1065-A.......................................4-19 4.23 Wetter Beam Assembly . .........................................................4-57
4.8 Envelope Tractor Assy A2-1067-A...........................................4-21 4.24 Wetter Tank Assy A2-1070-A....................................................4-59
4.9 Envelope Feed Shaft Assy A2-1068-A.....................................4-23 4.25 No Seal Assembly A2-1214-A .................................................4-61
4.10 Envelope Conveyor Assy A2-1066-A.......................................4-25 4.26 Head Ribbon Bkt. Assy 184-2260............................................4-63
4.11 Envelope Conveyor Backstop Assy A2-1200-A.......................4-28 4.27 Universal Head PSU 184-2150 ...............................................4-65
4.12 Collate Pocket Clam Assy A2-1069-A......................................4-30 4.28 Mains Input Hardwired 184-2250.............................................4-66
4.13 Head Input Conveyor Upper Assy A2-1054-A..........................4-33 4.29 Head Covers ...........................................................................4-67
4.14 Head Input Conveyor Lower Assy A2-1055-A..........................4-36 4.30 External Float Switch A3-0421-A ............................................4-70
4.15 Motor Assy A2-1056-A (115V) / A2-1057-A (230V)..................4-38 4.31 Lift Beam Assembly A2-1520-A . .............................................4-72
Page 4-1
Maximailer HD Service Manual Exploded Views Issue 5 Feb 2011
S1
NOTE:
FOR CONNECTOR PANEL DETAILS,
SEE SECTION 4-28.
SENSORS
Item Description
Ref.
S1 Hybrid Motor Disc 5.12
Fixings
Item Part No. Description Qty. Spares
50 E2-0839-A SCREW M3 x 6 TORX PAN HD 2
51 E2651A SCREW M3 x 6 PAN HD 6
52 E2684A SCREW M3 x 14 CAP HD 1
53 E2782A SCREW 3mm PLAS-TECH 30 3
54 E2-0836-A SCREW M4 x 6 TORX PAN HD 2
55 E2826A SCREW M4 x 8 TORX PAN HD 4
56 E2507A SCREW M4 x 10 CAP HD 2
57 E2523A SCREW M5 x 20 CAP HD 2
58 E4-0078-A 3mm SCHNORR WASHER 6
59 E4011A M4 WASHER 6 SEE FIXING KIT FOR THIS ASSEMBLY
60 E3501A M5 FULL NUT 2 A0-0541-A (9110009S)
61 E5126A 3 DIA x 8 GROOVED PIN 3 NOTE: FIXINGS ARE NOT AVAILABLE
62 E5103A 3 DIA x 10 DOWEL PIN 3 INDIVIDUALLY.
63 E5086A 3 DIA x 16 DOWEL PIN 6
64 E5073A 9.5mm ‘E’ CLIP 3
65 E5092A 12mm ‘E’CLIP 6
66 E0475A WAVED WASHER 10.5 ID 3
67 E0367A WAVED WASHER 23 ID 4
68 169-145 PLASTIC RIVET 3.5mm 2.0 - 3.0 GRIP 4
69 E0425A WASHER 10.2 x 17 x 2 1
70 E4033A WASHER WAVED 8.8 ID 1
71 E5110A 2.5 DIA x 16 DOWEL PIN 1
72 E2604A SCREW M3 x 10 CHEESE HD 2
73 E3557A M3 NYLOC NUT 2
Spares Assemblies
Fixings
Item Part No. Description Qty. Spares
50 E2651A SCREW M3 x 6 PAN HD 3
51 E2-0836-A SCREW M4 x 6 TORX PAN HD 2
52 E2826A SCREW M4 x 8 TORX PAN HD 2
53 E2507A SCREW M4 x 10 CAP HD 2
54 E4-0078-A 3mm SCHNORR WASHER 3
55 E3505A M4 NYLOC NUT 4
56 E5103A 3 DIA x 10 DOWEL PIN 3 SEE FIXING KIT FOR THIS ASSEMBLY
57 E5071A 3 DIA x 14 DOWEL PIN 1 A0-0541-A (9110009S)
58 E5086A 3 DIA x 16 DOWEL PIN 4 NOTE: FIXINGS ARE NOT AVAILABLE
59 E5073A 9.5mm ‘E’ CLIP 2 INDIVIDUALLY.
60 E5092A 12mm ‘E’CLIP 4
61 E0475A WAVED WASHER 10.5 ID 2
62 E0367A WAVED WASHER 23 ID 4
63 E4033A WAVED WASHER 8.8ID 1
64 E2834A SCREW M4 x 10 TORX CSK HD 2
Spares Assemblies
SENSORS
Item Description Ref.
S1 Envelope Flap RX 5.12
S2 Collate Pocket Input RX 5.12
S3 Collate Pocket Load RX 5.12
S4 Collate Pocket TX 5.12
S11 S5 Top Pawl RX 5.12
S6 Top Pawl TX 5.12
S7 Lower Pawl RX 5.12
S8 Lower Pawl TX 5.12
S9 Envelope Seal RX 5.12
S10 Envelope Seal TX 5.12
S11 Wetter Output RX 5.12
S12 Wetter Output TX 5.12
S4 S12 S13 Closer Output (reflective) 5.12
S9
S3
S13
S5 S6
S1
S10
S8
S7
S2
*Per Machine
Spares Assembly
S5
S2
S3
S4
S1
SENSORS
Item Description Ref.
S1 Envelope Flap TX 5.12
S2 Envelope Feed TX 5.12
S3 Envelope Feed RX 5.12
S4 Envelope Deskew RX 5.12
S5 Envelope in Hopper 5.12
(Reflective)
Fixings
SEE FIXING KIT FOR THIS ASSEMBLY
80 E2-0839-A SCREW M3 x 6 TORX PAN HD 2 A0-0546-A (9110043C)
81 E2826A SCREW M4 x 8 TORX PAN HD 8 NOTE: FIXINGS ARE NOT AVAILABLE
82 E2834A SCREW M4 x 10 TORX CSK HD 2 INDIVIDUALLY.
83 E2827A SCREW M4 x 12 TORX PAN HD 8 Spares Assemblies
84 E4009A M3 WASHER 6 SA1 ENV P/UP STUB BRG ASSY A2-1303-A
85 E4011A M4 WASHER 8 (9110070F) QTY. A/R
86 E3557A M3 NYLOC NUT 4 SA2 ENV FEED I/P SHAFT ASSY A2-1307-A
87 E3505A M4 NYLOC NUT 4
(9110071G) QTY. A/R
88 E3502A M4 FULL NUT 4
SA3 ENV OPENER I/P SHAFT ASSY A2-1308-A
89 E5126A 3 DIA x 8 GROOVED PIN 6
(9110072H) QTY. A/R
90 E5103A 3 DIA x 10 DOWEL PIN 6
91 E5086A 3 DIA x 16 DOWEL PIN 6 SA4 ENV OPENER O/P SHAFT ASSY A2-1309-A
92 E5081A 4.5mm ‘E’ CLIP 4 (9110073J) QTY. A/R
93 E5092A 12mm ‘E’CLIP 4 SA5 ENV FEED O/P SHAFT ASSY A2-1310-A
94 169-126 PLASTIC RIVET 3.5 DIA 1.2 - 2.1mm GRIP 4 (9110074K) QTY. A/R
95 E2-0836-A SCREW M4 x 6 TORX PAN HD 2 SA6 RESTRICTOR ARM ASSY A2-1380-A
96 E5073A 9.5mm ‘E’ CLIP 4 (9110322T) QTY. A/R
NOTE
BRIDGE CLAMPS G4092A (ITEM 19) WITH M4 x 12 TORX HD
SCREWS E2830A ( ITEM 34) ARE FITTED IN ALL LOCATIONS MARKED
Fixings
Spares Assemblies
SENSOR
Item Description Ref.
S1 Envelope Conveyor (Flag) 5.12
Fixings
Spares Assemblies
48
C
C 48
45
16
12
C
C
6
47
D
D
45
45
D
D K
47
7
11
45
J
K
H
H 16 54
20
54
26
4 47
J 36
50 35
3 54
E
* 54
26
13 48 53 47
F F
5 15 23 D
54
E 26 10 D
C
54 C 49
E 49 18
27
J
F * 46
28 A
21
47
* F
D
26
51
10 D 37
B
F
8 49
J 50 18
H 50 23
H 54
36
22 * A
NOTE
49
1
BRIDGE CLAMPS G4092A WITH M4 x 12 TORX HD
SCREWS E2827A ARE FITTED IN ALL LOCATIONS MARKED* 21
25 G
17 26
55 51
19 37
57 30 32 54
G 27 46
25 47
47 29
17
56 33 52 47
32 9
55 31
Fixings
10
7
18
8
20 21
9 1 17 19
12
15
20
A
A 16
9
3
16
4 11 B
6 B
17
5
Fixings
SENSORS
Item Description Ref.
S1 Collate Pocket RX 5.12
S2 Envelope Deskew TX 5.12
S3 Collate Pocket Load TX 5.12
NOTE
BRIDGE CLAMPS G4092A (ITEM 60) WITH M4 x 12 TORX HD
SCREWS E2830A (ITEM 53) ARE FITTED IN ALL LOCATIONS MARKED*
Fixings
35 SEE NOTE 2
59
45
SENSORS 36
Item Description Ref. 55
28
S1 Collate Pocket Input TX 5.12
27
37
44 55
36
39
56 56
24
24
S1 36 3
15
56 58 33
26 24 29
20 10
52 29
55 33
34 24
19 56
28
1 55 55
52 22 28 44
11
19 25
53 28
55 55
28 39 24
11 56
54 25
14 28
SA1 50 55
4 24
56 7 56
41
38 16
51
SA2 C2-1034-A (x6)
50
F1-0461-A (x6) BELT BOBBIN
PULLEY 25T XL (ITEM 10)
17 2
(ITEM 34)
57 42
30 C2-1036-A (x6)
9 52
30 CONVEYOR
32 40 F5119A (x1.5) WHEEL
53 18 56 BELT SET (ITEM 11)
56 14 140XL O37
8 5 53 (ITEM 36)
56
31
56
Fixings
Spares assemblies
5 14
21
10
9 A
2
B
14
5
12
11
3
8 11
22
12
BELT FITTING DIAGRAM
15
7
1
8
15 6
21 20 22
F1-0461-A (x6) C2-1036-A (x6)
PULLEY 25T XL F5120A (x1.5) CONVEYOR 13
(ITEM 13) WHEEL 23
BELT SET
130XL O37 (ITEM 3) 10
(ITEM 14) 21
Fixings
S1
SENSORS
Item Description Ref.
S1 AC Motor Disc 5.12
Fixings
Fixings
K
H
H
K
L J
L
H
J
H
B M
E
B J
E J
A
G
A G
F D
C
NOTE
D BRIDGE CLAMPS G4092A (ITEM 27) WITH M4 x 12 TORX HD
SCREWS E2827A (ITEM 37) ARE FITTED IN ALL LOCATIONS MARKED
4.16 - Sealer Assembly - A2-1058-A Page 4-41
Maximailer HD Service Manual Exploded Views Issue 2 Sep 2012
SENSORS
Item Description Ref.
S1 Collate Pocket Load RX 5.12
S1
Fixings
SEE FIXING KIT FOR THIS ASSEMBLY
40 E2826A SCREW M4 x 8mm TORX PAN HD. 4 A0-0568-A (9110127Q). ORDER THIS
41 E5071A PIN DOWEL 3 DIA x 14mm 1 KIT FOR ANY ONE ASSY, OR ALL 3.
42 E5092A 12mm ‘E’ TYPE CIRCLIP 2 NOTE: FIXINGS ARE NOT AVAILABLE
43 E5073A 9.5mm ‘E’ TYPE CIRCLIP 2 INDIVIDUALLY
NOTE
BRIDGE CLAMPS G4092A (ITEM 48) WITH M4 x 12 TORX HD
SCREWS E2830A ( ITEM 63) ARE FITTED IN ALL LOCATIONS MARKED
SENSORS
Item Description Ref.
S1 Finger Datum (flag) 5.12
S2 Finger Disc 5.12
S1
S2
Fixings
60 E2-0857-A M4 x 25mm TORX PAN HD SCREW 1
61 E2571A M3 x 5mm SOCKET SET SCREW 1
62 E2826A M4 x 8mm TORX PAN HD SCREW 6
63 E2830A M4 x 12mm TORX PAN HD SCREW 2
64 E3557A M3 NYLOC NUT 4 SEE FIXING KIT FOR THIS ASSEMBLY
65 E4072A M20 WASHER INT SH/PROOF 2 A0-0569-A (9110142F)
66 E5073A CIRCLIP 9.5mm E TYPE 3 NOTE: FIXINGS ARE NOT AVAILABLE
67 E5076A CIRCLIP 7mm E TYPE 2 INDIVIDUALLY
68 E5082A PIN GROOVED 2.5 x 12 1
69 E2774A M2 x 6mm POZI CSK HD SCREW 1
S2
S1
SENSORS
Item Description Ref.
S1 Side Guide Disc 5.12
S2 Side Guide Datum (flag) 5.12
Spares Assemblies
SA1 A0-0597-A 9110630P GUIDE CARRIER ASSY RH A/R
SA2 A0-0598-A 9110631Q GUIDE CARRIER ASSY LH A/R
SENSORS
Item Description Ref.
S1 Wetter Down (flag) 5.12
Fixings
15 E2827A SCREW M4 x 12mm TORX PAN HD 2 SEE FIXING KIT FOR THIS ASSEMBLY
16 E2826A SCREW M4 x 8mm TORX PAN HD 2 A0-0580-A (9110307C)
17 E4072A WASHER M20 INTERNAL SH/PROOF 1 NOTE: FIXINGS ARE NOT AVAILABLE
18 E4011A WASHER M4 4 INDIVIDUALLY
Fixings
40 E2565A SCREW M5 x 12mm TORX CSK. HD 2
41 E2-0838-A SCREW M4 x 12mm TORX CSK. HD T/T 2
42 E2827A SCREW M4 x 12mm TORX PAN HD 1
43 E2834A SCREW M4 x 10mm TORX CSK. HD 1
44 E2829A SCREW M4 x 8mm TORX PAN HD T/T 2
SEE FIXING KIT FOR THIS ASSEMBLY
45 E2826A SCREW M4 x 8mm TORX PAN HD 8
A0-0571-A (9110167G)
46 E2559A SCREW M3 x 10mm PAN HD 2
NOTE: FIXINGS ARE NOT AVAILABLE
47 E2-0842-A SCREW M3 x 8mm TORX CSK. HD 2
INDIVIDUALLY
48 E3505A NUT M4 NYLOC 4
49 E3502A NUT M4 FULL 4
50 E3557A NUT M3 NYLOC 2
51 E4048A WASHER M4 FORM C 8
52 E5003A CIRCLIP 7mm ‘E’ TYPE 2
NOTE: FOR REPLACEMENT, ONLY THE COMPLETE ASSY. 9110289J CAN BE ORDERED.
Fixings
Section 5
Electrical
and
Circuit/Wiring Diagrams
Sect. Page
5.1 Sensors.........................................................................................5-2 Wiring Diagrams
5.1.1 Sensors List..................................................................................5-2 Sect. Page
5.1.2 Sensors Diagram, Operator Side..................................................5-4 5.11 Inserter Head Wiring Diagram...................................................... 5-24
5.1.3 Sensors Diagram, Drive Side........................................................5-5 5.12 Inserter Head Splitter PCB’s Wiring Diagram............................... 5-25
5.2 Electrical Components..................................................................5-6 5.13 Ins. Head PSU & Interlock Wiring Diagram.................................. 5-26
5.2.1 Physical Locations of Components...............................................5-8
Circuit Diagrams
Sect. Page
5.3 Control PCB Circuit Diagram........................................................5-14
5.4 Processor PCB Circuit Diagram....................................................5-17
5.5 Comms PCB Circuit Diagram.......................................................5-18
5.6 Wetter PCB Circuit Diagram.........................................................5-19
5.7 Expansion PCB Circuit Diagram...................................................5-20
5.8 Interlock PCB Circuit Diagram......................................................5-21
5.9 Stepper Motor PCB Circuit Diagram.............................................5-22
5.10 R/Splitter & Disk PCBs Circuit Diagrams......................................5-23
Page 5-1
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010
Insert Head
Page 5-2
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010
Page 5-3
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010
Solenoids
Solenoid W/D 179-3450 Short 181-1600 9109569J 4.2 5.12
Solenoid W/D 179-3450 Long 181-1600 9109569J 4.2 5.12
Solenoid W/D 179-3450 Ex. Long 181-1600 9109569J 4.3 5.11
Solenoid W/D 179-3550 Finger Op 181-1610 9109568H 4.19 5.11
Solenoid W/D 179-3550 Finger Dr 181-1610 9109568H 4.18 5.12
Solenoid W/D 179-3550 Finger Mid 181-1610 9109568H 4.18 5.12
Solenoid W/D 179-3550 Wetter 181-1610 9109568H 4.22 5.12
cont.
Page 5-6
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010
PCBs
PCB Assy C4 Control 180-8360 9109914T 4.3 5.11
PCB Assy C4 Processor 180-720 9100723U 4.3 5.11
PCB Assy C4 Expansion 180-8300 9108643U 4.3 5.11
PCB Assy Brainless Dongle 180-8320 9109590F 4.3 5.11
PCB Assy Env. Wetter 180-702 9100715L 4.3 5.12
cont.
Page 5-7
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 2 Mar 2010
Note that other components are internal and can be found from the refer-
ences in the previous section.
Page 5-8
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
179-109 EC30LL
179-110 EC30LL Drive Side Key Components
(BLU) Envelope
pickup clutch (see also part 2)
182-8330F
Ribbon Cable
179-109 EC30LL
179-110 EC30LL
Envelope upper
179-109 EC30LL
drive clutch 182-759 Splitter
(YLW) Envelope
lower drive PCB (No6)
clutch
180-746 Hybrid
motor disk sensor 181-129 Lenze
Closer reverse
drive brake
181-128 Lenze
Insert pawl drive
clutch
181-128 Lenze
179-110 EC30LL Closer forward
Wetter Drive drive clutch
Clutch
181-050 Hybrid DC
motor
IPSS Group
Page 5-9
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
179-109
EC30LL
Collate Entry
Brake
181-128 Lenze
Collate pocket
A2-1057-A
entry clutch -
(230V) or A2- Slow
1056-A (115V)
AC motor assy
182-8330C
Ribbon Cable
181-128 Lenze
Insert pawl drive
clutch
184-2150 Head
Power Supply
182-8320
Wetter fluid probe link
182-8330A
Ribbon Cable
180-702 Envelope
Wetter PCB
180-759
Splitter PCB (No1)
IPSS Group
Page 5-11
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
179-109 EC30LL
179-110 EC30LL Input Conveyor
Collate Entry FAST Brake
Clutch
180-720
PCB Assy AM4
Processor
181-1600
Collate Pocket
backstop –
Extra Long
181-1610
Solenoid W/D
Fingers
182-8330(x) 180-8360
Ribbon Cable PCB Assy AM4
Control
IPSS Group
Page 5-12
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
180-759 Splitter
Eccentric fitted –
PCB
shaft turns in one
(No5)
direction
182-8330E Ribbon
Cable
179-109 EC30LL
Envelope Lower Drive
Brake
IPSS Group
Page 5-13
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
Section 5.3 - Control (Comms) PCB Circuit Diagram (part 3) Page 5-16
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
Page 5-22
Section 5.10 -Ribbon Splitters/Motor Disk PCB Circuit Diagrams Page 5-23
Maximailer HD Service Manual Electrical and Circuits/Wiring Issue 1 Mar 2010
5.13 - Inserter Head PSU, Motor & Interlock Wiring Diagram Page 5-26