Service Manual Herkules

E00: Check Interlock on OLP NOTE: There are three interlock switches - processor lid - dryer cover - filter
housing cover no Are the covers in place and triggering the interlock switches? yes Is interlock switch ok? yes Is continuity present between interlock switches and pcb GCB? yes Has fuse F510 blown? no Replace pcb GCB Service / Error Messages at the ONLINE Processor
-1-
Replace cover and switch on
no
Replace switch
no
Replace wiring
yes
Replace fuse 1.5A (S) 6.3 x 32mm
E01: Film Jam in Conveyor Lift conveyor cover: is there film inside? yes Has the film reached the processor input sensor? yes Has the film reached the input rollers of the sensor? no Are the input sensors seated correctly? yes no Are input sensors operating correctly ? I.e... jammed. continued on next page yes Service / Error Messages at the ONLINE Processor
-2-
no
Inverstigate location of film in Herkules.
no
no
**
no yes Check the position of guides, rollers and grip of rollers.
yes
Are the rollers turning?
no
Reseat sensors
Replace sensors
E01: Film Jam in Conveyor
Is input sensor electrical circuit operating correctly? Check by triggering sensors in service mode yes parameter 32 + 33. Does display status toggle on and off? no Is 5 volts DC present across pcb GCB plug X201 and X202 when plug is removed? yes Reconnect plug does voltage return to 0 volts? no Is there 5 volts DC at input sensor? no Change wiring yes yes no
Change pcb GCB
Change pcb GCB
Change pcb GCB
Change sensor
Service / Error Messages at the ONLINE Processor
-3-
E01: Film Jam in Conveyor
**
no
no
Has the film been released by the Herkules? yes Trigger interlock switch. Do the conveyor rollers rotate? no Has fuse F301 blown? no Is there 24 volts DC supplied to the conveyor? no Is there 24 volts across plug X301 on pcb OCM04? no Change pcb OCM04 yes yes
Cut and remove the film
Check the position of the rollers and look for worn belts
Replace fuse 2A (S)
yes
Change conveyor motor
yes
Check wiring to conveyor motor
-4-
E02: Film Jam in Processor yes Is the processor exit sensor too high or dislodged from its mounting and not being triggered by the film? no Is the processor output sensor being held up by a sheet of film? no Is the processor output sensor stuck in the up position? no Is the film stuck in the processor racks or in the bottom of the tanks? no yes Remove film and check for ... yes Release sensor arm and clean or replace sensor yes Remove film and empty basket Reposition sensor
a) ... all racks are located under the drive bar b) ... missing worm geer clips causing loss of drive to the racks c) ... damaged geers causing loss of drive in racks d) ... correct location of guides and rollers in racks
continued on next page Service / Error Messages at the ONLINE Processor

-5-
E02: Film Jam in Processor Is the film stuck in the conveyor and triggering the processor input sensor? yes Remove the processor lid and trigger the interlock switch. Do the processor rollers turn? no Is there power to the main drive motor? no Is there continuity of the wiring between pcb GCB and main drive motor? no yes Change pcb GCB yes Change motor yes Check for non gripping rollers no Check speed control timing
Replace wiring
-6-
E03: Conveyer Cover open Is conveyor cover open? no Is interlock switch on conveyor ok? yes Is there continuity in the wiring through the interlock switch to plug X902 on pcb OCM04? yes Replace pcb OCM04 no Replace wiring no Replace switch yes Close cover
-7-
E04: Level Error Developer Are errors E07, E10, E13 or E25 also displayed? no Is the level low? no yes Does the dev account = 500? no Replace pcb OCM04 Is there continuity in the wiring between pcb GCB plug X101 and the level sensor? yes With plug X101 removed is there 24V AC at the output from the pcb GCB? no Check fuse F511 Service / Error Messages at the ONLINE Processor
-8-
yes
Address errors
yes
Is the O-ring seal at the base of the overflow pipe leaking? no Top up with water ja Replace O-ring
no
Replace cable
yes
Check pcb GCB
E05: Level Error Fixer Are errors E08, E11, E14 or E26 also displayed? no Is the level low? no yes Does the fix account = 500? no Change pcb OCM04 Is there continuity in the wiring between pcb GCB plug X102 and the level sensor? yes With plug X102 removed is there 24V AC at the output from the pcb GCB? no Check fuse F511 Service / Error Messages at the ONLINE Processor
-9-
yes
Address errors
yes
Is the O-ring seal at the base of the overflow pipe leaking? no Top up with water yes Replace O-ring
no
Replace cable
yes
Check pcb GCB
E06: Level Error Wash (Applies only to Wash Tank 1) Is E15 showing? no Is the level low in wash tank 1 no Is there continuity in the wiring between pcb GCB plug X103 and the level sensor? yes With plug X103 removed is there 24V AC at the output from the pcb GCB? no Check fuse F511 yes Check pcb GCB no Replace wiring yes Follow flow diagram for E15 yes Follow flow diagram for E15
- 10 -
E07: Change Developer Replenisher Container Is E10 also displayed? no Follow flow diagram for E13 yes Follow flow diagram for E10
- 11 -
E08: Change Fixer Replenisher Container Is E11 also displayed? no Follow flow diagram for E14 yes Follow flow diagram for E11
- 12 -
E09: Low Flow Mix- with-Fix Pump Are E06 or E15 also displayed? no Remove fixer replenisher fuse F507, pulse fixer rep button, is wash solution delivered to the fix tank? no Is there a restriction in the hose between the base of wash tank 1 and the flow sensor? no Check mix- with-fix pump using replenisher pump check guide yes Remove restriction yes Check mix- with-fix flow sensor using flow sensor guide yes Follow flow diagram E6 or E15
- 13 -
E10: Dev Waste Container full Is the developer waste container full? no Is the dry break connector seated correctly? yes Is the developer waste hose restricted? no Is the float sensor short circuit? yes Is 18V AC supplied to the switch? no continued on next page yes no Investigate switch failure, possibly: - float stuck in up position - float dropped off spine yes Remove restriction no yes Change developer waste container and reset on Herkules panel refit
- 14 -
E10: Dev Waste Container full Is fuse F18 blown? no Is the power supply to pcb GCB correct? yes Check transformer output voltage no yes Replace fuse 500 mA (F) 250V
Replace pcb GCB
- 15 -
E11: Fixer Waste Container full Use flow diagram for E10 replacing fixer for developer.
- 16 -
E12: Wash Waste Container full Is jumper plug X203 pin 1 to 3 in place? yes Replace pcb GBP01 no Install jumper
- 17 -
E13: Dev Rep Container empty When arriving in this column clear error code by pulsing dev rep button. If error does not clear continue with process. yes Change dev rep container
Is the developer replenisher container empty? no Is the dry break connector seated correctly? yes Has the rep bag collapsed over its exit? no Is the red dev rep hose restricted or is the filter blocked? no continued on next page
no
Refit
yes
Release obstruction
yes
Remove restriction
- 18 -
E13: Dev Rep Container empty Is fuse F508 blown? no Does dev rep reach the tank when the rep button is pressed? yes Check flow sensor using flow sensor guide no Check rep pump using rep pump guide yes Replace fuse 500 mA (F) 6.3 x 32 mm
WARNING: the replenisher pumps will not work when the processor lid is removed unless the interlock switch and daylight slot magnet is triggered.
- 19 -
E14: Fixer Replenisher Container empty Use flow diagram for E13 replacing fixer for developer. Fixer replenisher hose is blue. Fixer fuse number is F507.
- 20 -
E15: Wash Replenisher Container empty Use flow diagram for E13 replacing wash for developer. Wash replenisher hose is green. Wash fuse number is F18.
- 21 -
E16 / E17: Low / High Processing Speed Check service parameters (green LED) 46 and 47 or static data 10045 and 10046 on herkules panel. Do the values equal -3 and +3 respectively? Is service parameter 51, developer rack length 330 mm? yes Has OLP been switched off / on during film processing? yes Set service parameter 35 or static data ID 10034 = processing speed auto-calibrate to 0, and run a few films through the OLP. Observe value of auto-calibrate parameter. Does values stay between -10 and +10? yes Check adjustment of film speed on pcb GCB no Check adjustment of film speed on pcb GCB
no
Set to correct value
no
continued on next page
- 22 -
E16 / E17: Low / High Processing Speed NOTE: The most likely source of this error is the "processing speed autocalibrate" system. This system measures the complete processing time for a film from input sensor to output sensor. For example: If a film is left in the machine at power off, and an additional film is sent through immediately after power on, the film arrives too soon, thus fooling the system. Normally the errors E16 and E17 are a combination of motor control maladjustment and technician / user interference with the system. The OLP calculates a "measured processing speed" based on input-to-output time and machine length. The value can been seen in casual user parameter 26 (no LED) or measure data 10009 on the herkules interface panel.
- 23 -
E18: Total idle Time exceeded Check casual user parameters (no LED) 27 and 28, or measure data ID 10017 + 10018 (time on since last job and time off since last job measured in minutes). Is the sum of these values large? I.e.... > 10000 minutes no Check service parameter (green LED) 52, or static data ID 10051 (alarm for total idle time). Does the value = 14400 min. (= 10 days)? yes Check service parameter 66, or static data ID 10065 (idle on time scaling factor). Does the value = 2.0? yes Carry out a system check to establish if the processor chemicals are exhausted. no Set to 2.0 no Set to default value. Carry out a system check to establish if the processor chemicals are exhausted.
yes
- 24 -
E20: Developer Filter blocked Change developer string filter, does error remain? yes Is pressure sensor open circuit? yes On pcb GBP short circuit plug X104 pin 1 to 3. Does the error clear after 30 seconds? no Replace pcb GBP1 yes Check continuity of wiring between pressure sensor and pcb GBP plug X104 no no Reset filter lifetime counter on Herkules panel
Replace pressure sensor
- 25 -
E21: Fixer Filter blocked Follow flow diagram for E20 but use plug X105 pin 1 to 3 on pcb GBP.
- 26 -
E22: Wash 1 Filter blocked Follow flow diagram for E20 but use plug X205 pin 1 to 3 on pcb GBP.
- 27 -
E23: Wash 2 Filter blocked Follow flow diagram for E20 but use plug X206 pin 1 to 3 on pcb GBP.
- 28 -
E24: Biocide Container empty Plumbed system: Follow flow diagram for E13 but use biocide in place of developer (there is no dedicated fuse for this pump). Plumbless system: Check that a jumper is installed on pcb GBP plug X204 pin 1 to 3.
- 29 -
E25: Dev Rep Container empty Is E10 also displayed? no Follow flow diagram for E13 yes Follow flow diagram for E10
- 30 -
E26: Fixer Replenisher Container empty Is E10 also displayed? no Follow flow diagram for E14 yes Follow flow diagram for E11
- 31 -
E27: Replace Fixer Filter The fixer filter lifetime has elapsed. Replace with a new carbon filter and reset on the Herkules panel.
Does the error remain after changing the filter and resetting on the Herkules panel? no
yes
Is fixer filter lifetime counter service parameter 55 (green LED) set to the default value? yes no Reset to default
System is now operable
Replace pcb OCM04
- 32 -
E28: Replace Wash 1 Filter Follow flow diagram for E27 replacing the carbon filter for a string filter and using service parameter 53.
- 33 -
E29: Replace Wash 2 Filter Follow flow diagram for E27 and using service parameter 54.
- 34 -
E30: Developer Temperature incorrect Is the developer temperature set to 35C? Check using casual user parameter 13 (no LED). yes Is the developer temperature above 35C? Check using casual user parameter 23. no Is the developer temperature below 35C and not increasing? yes Is E04 displayed on the processor panel? no Is fuse F504 (dev heat) blown? no continued on next page Service / Error Messages at the ONLINE Processor
- 35 -
no
Set to 35 C.
yes
Check recirculation inside dev tank.
no
Wait until it comes up to temperature.
yes
Follow flow diagram for E04. Replace fuse 5A (F) 250V (6.3 x 32 mm).
yes
E30: Developer Temperature incorrect Is 230V AC arriving at dev heater element? yes no Has heater element thermofuse blown? no Replace heater element ja Replace thermofuse
Is there 230V at the output from pcb GCB? Measure between plug X508 red wire and plug X507 black wire. nein Is the temperature probe resistance (ex. 1200 ohms approx.) in a similar range to the other temperature probes? no Replace temperature probe
yes
Check continuity of wiring between pcb GCB and heater element.
yes
Replace pcb GCB
- 36 -
E31: Fixer Temperature incorrect Follow flow diagram for E30 replacing developer with fixer. Referring to fuse F503 5A (F) 250V 6.3 x 32 mm and measuring pcb GCS output voltage between plug X507 brown wire and plug X507 orange wire.
- 37 -
How to check a Replenisher Pump NOTE: Replenisher pumps will not operate when: - The processor lid is removed unless the interlock switch and the daylight slot magnet switch is triggered. - When the corresponding replenisher account is equal to 500. Trigger the operation of the replenisher pump by: - Pulsing the rep button for FIX, DEF and MIX-WITH-FIX pump. - Using service parameters 16 (fix) or 17 (dev) on pcb gcb. - Dropping the level in wash tank 1 to operate the wash rep pump. Check internal popet valve and replace if damaged, if not replace pump.
Does the replenisher pump oscillate? no Is there 180 to 230 V AC supplied to the replenisher pump? Measure on the terminal block under the dryer rack. no continued on next page
yes
yes
Replace pump
- 38 -
How to check a Replenisher Pump Is the supply voltage at the output of the pcb GCB? no Has the corresponding fuse on the pcb GCB blown? no Replace pcb GCB yes yes Check the continuity of the wiring between the pump and the pcb GCB.
Replace fuse
- 39 -
How to check a Flow Sensor Observe the replenishment accounts found in extended parameters (yellow LED). Dev account parameter 12. Fix account parameter 13. Mix with fix account parameter 14. Does the account change value when squeezing the online rubber gather next to the flow sensor. no Remove the plug connection from the flow sensor and connect an alternative plug from another flow sensor. Pump replenisher through the flow sensor and monitor the alternative account. Does the account change value? yes continued on next page no Replace flow sensor yes Check the hose between the pump and flow sensor, are there any floating obstructions? no Carry out procedure for calibrating flow sensors yes Remove obstruction
NOTE
**
- 40 -
How to check a Flow Sensor Is there continuity in the wiring between the flow sensor and pcb GBP? yes Is there 10V DC between pin 1 and 3 of the flow sensor? no Has fuse F19 blown? no Is there 18V AC at input to pcb GBP? no Check transformer supply yes Replace pcb GBP yes Replace fuse 500 mA (S) 250V yes Replace pcb GBP no Replace wiring
- 41 -
How to check a Flow Sensor
** NOTE:
The MIX-WITH-FIX flow sensor may malfunction due to a build up of black particles on its internal sensor. Removing the particles: - exchange MIX-WITH-FIX flow sensor. - pump fixer through the defective flow sensor. The flow sensor should start to operate after approx. 0.5 to 1 liter of fixer has passed through it.
- 42 -
Pcbs Printed circuit boards must not be energized when being pulle out. Carry out operations on modules only when they are pulled out and not energized.
General Remarks
-1-
Electrostatic Discharge (ESD) Observe ESD (Electrostatic-Sensitive Device) safety regulations! PCBs and semiconductor modules should remain as long as possible in their original packing. When shipped or stored, use either the original or adequate protective packing. Machines, soldering irons, work surfaces and persons should have the same potential as the semiconductor modules. Avoid static charge caused by synthetic floor coverings, synthetic clothing etc. at any cost to prevent destruction or damage of the semiconductor modules. Therefore: - When working on modules, wear a wristlet and establish a ground. - Use a grounded work surface. - Do not disconnect the ground before having finished all operations. For this purpose, use the ESD set (Order No. 02302683).
General Remarks
-2-
Soldering Operations For soldering operations, only mains isolated low-voltage soldering irons equipped with leakage resistors may be used. E.g. WELLER soldering unit WECP 20 (Order number 02289245, Weller order number 52501199). While soldering, make sure the arising vapor does not get into contact with any optical parts.
General Remarks
-3-
Measurements Prior to each measurement, make sure that electrical isolation exists, otherwise take respective measures, e.g. use isolating transformer.
General Remarks
-4-
Optical Parts Avoid contact of the optical parts with any metal object. Do not leave any small parts on the glass panes. Clean optical parts according to "Cleaning Procedure (order No. 02064634)".
General Remarks
-5-
Floppy Disk Observe the manufacturers instructions for handling floppy disks and drives. The following items are of special importance: - Always store floppy disks in clean protective covers. - Neither bend nor fold floppy disks. - Do not place heavy articles on floppy disks. - Protect floppy disks from magnetic influences and do not touch magnetic surfaces.
General Remarks
-6-
Copyright by Heidelberger Druckmaschinen Aktiengesellschaft, 24107 Kiel Adobe and Adobe Illustrator are registered trademarks of Adobe Systems Incorporated. Apple, Apple-Logo, AppleTalk, EtherTalk and Macintosh are registered trademarks of Apple Computer, Inc. Ethernet is a trademark of Xerox Corporation. LinoColor, Linotype, Linotronic, Linotype Library, Centennial, Helvetica and Times are registered trademarks of Heidelberger Druckmaschinen Aktiengesellschaft. PostScript is a registered trademark of Adobe Systems, Inc. Taxi is a registered trademark of AMD. We point out that companies, trademarks and product names mentioned in this manual fall within the regulations regarding protection of trademarks and patents.
Copyright
-7-
No.
Measure
No. FollowMe documentation corresponds to This Measure the hardware version indicated on the modification label with which the machine or the respective component is provided. Modification states are indicated by the number marked on the modification label. If the hardware has a different modification state, please refer to the respective Service Information.
No.
Measure
No.
Measure
Dimensions Height Width Depth
930 mm 780 mm 1510 mm
Weight Operating weight
ca. 500 kg
Technical Data
-1-
Ambient Conditions Operating temperature +18 ... +28 C Transport temperature -10 ... +50 C Relative humidity 45 - 80 % (not condensing) Atmospheric pressure 700 - 1060 mbar Heat dissipation ca. 3200 kJ/h
Technical Data
-2-
Power Requirements Mains voltages 1 N PE AC 100 V, 110 V, 120 V, 127 V, 200 V, 220 V, 230 V, 240 V Connecting 115 V to 120 V Mains frequency Power consumption 47 - 63 Hz ca. 0.9 kW with 200 V ... 240 V
Technical Data
-3-
Floor The floor at the installation site must be level. As a rule, the floor (covering) must meet the following quality requirements: Permanently antistatic, i.e. Max. static charge <= 500 V/cm Half-life period <= 30 s Leakage resistance <= 10 E9 ohms Volume resistance <= 10 E10 ohms Abrasionproof and easy to clean with a smooth surface Indentation resistance = 80-100 N/mm
Technical Data
-4-
Operating Noise Level Operating noise level < 55 dB (A) Emission value related to job area
Technical Data
-5-
MAC RS 232 ETHERNET
MAC
2x RIP 60
Herkules Extension XA20 Speedway A08/ XA21 Speedway A07 XB6 XA7 A04 A02
TAXI
RS 232
VT 100 OPS (SERVICE) System Configuration -7-
Herkules must be installed firmly on the transport pallet during transport! Avoidance of condensation: - remove packaging only when the machine has been at the installation site for 24 hours Machine parts: - carefully remove from cardboards - check for transport damages - check for completeness against delivery note
Transport, Packaging, Completeness
-1-
General Notes The appliance plug and/or the power outlets of the house installation must be easily accessible since the power plug must be pulled to disconnect the machine completely from the power supply, for example, in the case of emergencies. The mains connection is established using the delivered mains cable with the 3-pole plug. The machine may only be operated with the protective conductor connected. The mains connection and the fuses are at the rear of the machine. During installation, it must be ensured that there is sufficient distance between the side panels and the walls or other objects to guarantee an adequate ventilation. The dimensions are to be taken from the installation instructions. During installation, do also observe the notes in the technical data.
General Notes
-2-
Wooden screws (1) of the transport safeguard brackets: - remove 4x Bolt (2): - insert into the square tubes Plates (3): - position as shown Screws (4): - screw into the bolts until the machine is raised off the pallet Pallet: - pull out parallel to the axis 3 1 (6x) 2 Transport safeguard bracket Removing the Transport Pallet -3-
5 (4x) 4 Square tube
Machine feet: - unscrew slightly 4x Screws (4): - unscrew Machine: - is lowered down and stands on the machine feet NOTE: The transport safeguard brackets must not make contact with the floor. Screws (5): - remove 3 1 (6x) 2 Transport safeguard bracket Transport safeguard bracket: - remove Machine feet: - insert
5 (4x) 4 Square tube
Removing the Transport Pallet
-4-
Machine: - transport to installation site using the transporting rollers 4x Machine feet: - unscrew until the transporting rollers are relieved Machine: - align in longitudinal and lateral direction (use spirit level) 5 (4x) 4 Square tube 3 1 (6x) 2 Transport safeguard bracket Removing the Transport Pallet -5Alignment: - performed by rotating the machine feet NOTE: Store transport safeguard bracket and installation accessories.
Select installation site according to the following criteria: No direct irradiation of the machine through: - sunlight - radiators installed in the room Do not install machine near air-conditioning equipment! Machine must be protected against humidity at the installation site!
Installation Instructions (Advantage Option)
-6-
ON-LINE Operation Side view Transport channel
Supply cassette
1450 Collecting basket
940
Recorder
OnLine-Processor Typ 860 1020 115
1100
25
90 760 475 850 345 NOTE: All dimensions in mm Installation Instructions (Advantage Option) -7-
ON-LINE Operation Top view
Power cable length: 4 m Cable exit: 200 >700 ca. 140 265
- OnLine-Interface (establish - RIP-Interface shield)
Recorder
OnLine-Processor Typ 860 1510 Film run 1080 1230
>700 >700 >700 >1000
NOTE: All dimensions in mm Installation Instructions (Advantage Option) -8-
-9-
- 10 -
- 11 -
- 12 -
3. Spindle Motor 2. Trough
1. Guide Panel and Film Exit Unit
Transport safeguards: - Remove only at the final location in the mentioned order!
Transport safeguards are marked with red varnish and/or a red adhesive label. Store removed transport safeguards for transport at a later time (Order No. 04587960).
4. Carriage
6. Compr. Air Unit
5. Vacuum Pump Transport Safeguards - 13 -
Adhesive foam tape Interior, Guide Panel and Film Exit Unit Machine cover: - remove Remove cable strap from the axle of the movable holders Foam strips between: - movable holders and guide panel - film exit unit and cast wall must be removed
Transport Safeguards
- 14 -
Cover
Large cover
Trough (left-hand side of machine) Remove the following components: - front cover - rear cover - large covers (right and left) - small covers (right and left) - EMC plates
Rear
Right
Left
Front
EMC plate Small covers Cover
- 15 -
4x
Remove the following components: - lock nuts (1), nuts (2) and washers (3) - screws (4) with strain washers (5) - plates (6) - screw (7) Screws (8) and sealing plates (9): - remove from the bag at the rack Sealing plates (9, 4x): - fasten with four screws (8) each time
6 5 4 3
7 9
8 Transport Safeguards - 16 -
1 (4x)
Spindle Motor (interior) Fixing screws (1): - loosen Plates (2): - slide radially outside 3 NOTE: Follow adjustment instructions on the adhesive label (3). Fixing screws (1): - tighten 2
- 17 -
X Y Carriage (interior) Remove: - nut (1) with washer (2) Lock nut (3): - unscrew Remove screw (4) between spindle nut and hinge. Spacer (5): - remove from carriage 5 1 4 3
View Y Transport Safeguards - 18 -
Carriage: - slide towards the spindle nut Four screws: - remove from the bag at the carriage Spindle nut and hinge: - connect with screws (6) View X
6 (4x)
- 19 -
Vacuum Pump, Base Remove six screws (1) with strain washers (2).
1, 2 (6x each time)
- 20 -
Compressed Air Unit, Base Remove screws (1) with strain washers (2). Brackets (3, 4): - remove Screws (5): - unscrew from the base plate 4 X NOTE: The screws are secured with Loctite 222.
1, 2 (2x each time)
3 1, 2 (2x each time) 5 View X Transport Safeguards - 21 5
Cover
Large cover Attach covers and EMC plates.
Rear
Right
Left
Front
EMC plate Small covers Cover
- 22 -
Switching on the machines: - Herkules - RIP - MAC(s) Test programs: - start, if necessary NOTE: For start-up and parameter setting, refer to the RIP dcumentation.
SW Installation / Start-up
- 23 -
General Notes Factory settings: - 100, 115, 230 V NOTE: The set voltage is marked on the adhesive label next to the machine's power outlet. If another voltage is set, attach a corresponding label on top of the existing label. CAUTION: If the machine is switched off, the power supply is not interrupted. To separate the machine from the power supply, always pull out the power plug.
Mains Connection
- 24 -
Power Cables / Connector Adaptation Connection to 230 V: Delivered power cable: - must be used! NOTE: Power cable is designed for 230 V AC. CAUTION: If connections are established using power cables that were not provided by Heidelberg, or if connectors need to be adapted, the national regulations are to be observed. The power cables used in the USA and the Canada must at least be of the SJT type.
Mains Connection
- 25 -
Connection to 100-127 V AC Use the following cable:
Plug type
Country
Connect. voltage
Regulations
Cable type
North America 125V 15A
ANSI C73.11 110-120V NEMA 5-15-P IEC 83
Listed, Certified Type SJT, 14AWG
Mains Connection
- 26 -
Connection to 200-240 V AC Use one of the following cables in accordance with the national requirements: Plug type Country Connect. voltage 230V Regulations CEE(7).II. IV.VII IEC 83 IEC 127 Cable type
Europe 250V 10/16A
<HAR> H05VV-F
B.S. 1363 United Kingdom 220-240V IEC 83 240V 6A IEC 127 Australia 240V 10A A.S. C112 IEC 127 ANSI C73.20 NEMA 6-15-P IEC 83 UL 198.6
<HAR> H05VV-F
240-250V
<HAR> H05VV-F
240V
Listed, Certified Type SJT, 14AWG - 27 -
Mains Connection
Connection to 200-240 V AC Use one of the following cables in accordance with the national requirements: Plug type Country Connect. voltage 230V Regulations CEE(7).II. IV.VII IEC 83 IEC 127 Cable type
Europe 250V 10/16A
<HAR> H05VV-F
B.S. 1363 United Kingdom 220-240V IEC 83 240V 6A IEC 127 Australia 240V 10A A.S. C112 IEC 127 ANSI C73.20 NEMA 6-15-P IEC 83 UL 198.6
<HAR> H05VV-F
240-250V
<HAR> H05VV-F
240V
Listed, Certified Type SJT, 14AWG - 28 -
Mains Connection
Note for Installations in the UK The cores in the mains lead are colored in accordance with the following codes: - green and yellow: earth - blue: neutral - brown: live Since the colors of the mains lead may not correspond to the colors identifying the terminals in your plug, proceed as follows: - Connect the green and yellow colored core to the terminal in the plug which is marked with the letter "E", or with the earth symbol, or which is colored green and yellow. - Connect the blue colored core to the terminal in the plug which is marked with the letter "N" or which is colored black. - Connect the brown colored core to the terminal in the plug which is marked with the letter "L" or which is colored red.
Mains Connection
- 29 -
100 V / 115 V / 230 V Check by means of the label next to the machine's power outlet whether the machine is prepared for the local voltage. CAUTION: Only connect the mains cable, if the supplied and the preset voltages are identical.
Mains Connection
- 30 -
Other Voltages Power supply module X7 X6 X33 X35 X30 X28 Strapping plug: - plug onto a corresponding jumper (X28...X35) 100 V -> X28 110 V -> X29 120 V -> X30 127 V -> X31 200 V -> X32 220 V -> X33 230 V -> X34 240 V -> X35
Voltages not listed, e.g. 115 V: - select the connector for the next higher voltage (here 120 V -> X30) Plug jumper: - onto X5 (U <= 127 V) - onto X6 (U > 127 V)
X5
X32 X34 X31 X29
"LINK 110 V" jumper at the power supply: - plugged (U <= 127 V) - pulled (U > 127 V)
Pcb AC-CONTROLLER (5.950) Mains Connection - 31 -
F1 Checking Mains Input Fuse CAUTION: Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse: - in the case of U <= 127 V: T 15 A / 250 V - in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Label Stick the label indicating the set voltage on top of the old one. Label Fuse F1 T 6.3 A T 15 A Order No. 00138215 04188713 230 V 115 V all other voltages Order No. 04137655 04258673 04258703
Mains Connection
- 32 -
MAC
MAC
RS 232 ETHERNET
CAUTION: To comply with the interference regulations, only shielded data cables must be used.
RIP 60
Herkules
TAXI
XA3 Speedway A08 XB6 XA7 A04 A02
RS 232
VT 100 OPS (SERVICE) Cabling - 33 -
MAC
MAC
Establish the following connections: XA3 pcb RIP-INTERFACE <--> TAXI RIP: - Speedway - pull off rear panel at the upper edge and lift out of lower guide - loosen clamp screw (below the nest) - unhook upper section of clamp - center dismantled cable 20 mm (Speedway) on lower section of clamp - hook upper section of clamp and set screw
RS 232 ETHERNET
RIP 60
Herkules
TAXI
RS 232
MAC
MAC
Optional OPS link: - XA7 Pcb MATERIAL-CONTROL <--> on-line processor RIP <--> MAC, ETHERNET: - EtherTalk phase 1 or - EtherTalk phase 2 or - TCP / IP RIP <--> MAC: - RS 232 Mains connection to: - RIP - Herkules - MAC
RS 232 ETHERNET
RIP 60
Herkules
TAXI
RS 232
General It is possible to set and monitor up to 4 time intervals (dates for maintenance work) using the maintenance control. Parameter setting and checking takes place via the Service terminal. Output when reaching a date additionally takes place via the unit terminal. The maintenance control is available as of the following software versions: Herkules Pro 5.01.001
Preventive Maintenance / Maintenance Control
-1-
General The maintenance control is available via the Service terminal after password entry. ATTENTION PID 900 = 1 must be set in order to edit the "Maintenance control" menu. PID list: PID 900-"Maintenance control" Off (0) / On (1) PID 901-Maintenance interval 1 (in days) PID 902- 2 PID 903- 3 PID 904- 4 PID 905-Next service date 1 (in days) PID 906- 2 PID 907- 3 PID 908- 4 NOTE A maximum of 4 maintenance controls can be configured.
Machine xx Release Version: xxx Date: xx xx xx 1. speedway commands menue 2. parameter menue 3. test menue ... ... ... j. consumption k. maintenance control (ON) (ON)
(ON)
- Basic menu
-2-
Start Start: - in basic menu Select "Maintenance control". MAINTENANCE CONTROL menu - Display of remaining days until next service - only those intervals are displayed which have been set to greater than 0.
MAINTENANCE CONTROL 1. Service task A is due in 29 days Interval A = 30 days 2. Service task B is due in 179 days Interval B = 180 days 3. Service task C is due in 359 days Interval C = 360 days 4. Service task D is due in 719 days Interval D = 720 days e. set interval values q. quit maintenance console to reset a interval counter, select key (1..4) - Basic menu > Maintenance control
-3-
Output Output (terminal): - Output to the terminal (MAINTENANCE CONTROL menu) when exceeding a maintenance interval (Interval 1) - Intervals 3 and 4 are set to 0.
MAINTENANCE CONTROL 1. Since 5 days the service task A is overdue Interval A = 30 days 2. Service task B is due in 145 days Interval B = 180 days
e. set interval values q. quit maintenance console to reset a interval counter, select key (1,2) - Basic menu > Maintenance control
-4-
Reset Resetting the maintenance counter: - Enter the number of the corresponding maintenance interval in the MAINTENANCE CONTROL menu. NOTE Resetting a higher-level maintenance interval also acknowledges the intervals with shorter periods of time. Respond to the alert message with "No" (n): - the maintenance intervals are output without change Respond to the alert message with "Yes" (y): - the maintenance intervals are output in an updated state - the parameters are stored to floppy disk and in the Touchmemory. - Basic menu - maintenance control > e. set interval values
MAINTENANCE CONTROL
Please confirm, that the service task A has been completely executed. y/n>
-5-
Parameterize Parameterizing the maintenance counter: - Press the e key in the MAINTENANCE CONTROL menu (e. set interval values) - Enter the line number to change an interval. Examples: - Set the interval to 90 > Enter line number 1 < Output Maintenace interval 1 New Value = > Enter value and acknowledge 90 ENTER - Set the interval to 720 > Enter line number 4 etc... NOTE Intervals are stored in ascending order. 0 values are stored after the interval with the highest parameter setting.
MAINTENANCE CONTROL 1. Maintenance interval A = 30 days 2. Maintenance interval B = 180 days 3. Maintenance interval C = 360 days 4. Maintenance interval D = 0 days
q. quit to set a new interval counter, select key (1..4) - Basic menu - Maintenance control > Reset an interval counter (..)
-6-
Parameterize The MAINTENANCE CONTROL menu is displayed with the new values after changing. NOTE The changed intervals are displayed with the current status (time since the last reset). ATTENTION A slight time delay occurs after entering a new value for an interval, as the new value is stored in the Touchmemory and to diskette.
MAINTENANCE CONTROL 1. Service time A has to become in 89 days Interval A = 90 days 2. Service time B has to become in 179 days Interval B = 180 days 3. Service time C has to become in 359 days Interval C = 360 days 4. Service time D has to become in 720 days Interval D = 720 days e. set interval values q. quit maintenance console to reset a interval counter, select key (1..4) - Basic menu - Maintenance control
-7-
Mains Input Pcb Configuration Nest Mains Distributor Control Unit Compressed Air Unit Vacuum Unit
Base
-1-
1 04578503 # VOLTAGE-REG - 5.970
1 2
A 09 A 08 A 07
2 04860160 # HERK-IF - 2081.524 (for machine with mod. 27) 04859987 # HERK-IF - 2081.523 (for machines with mod. 28) 3 04122119 # FEED-CONTROL - 5.941 4 05262569 # TOP_MAINCONTROL - 6.276 cpl. 00049356 # FD drive, FD235HF-7529 05241251 # Adapter, FDD - Data 05130247 # Adapter, FDD - power
A 06 A 05
A 04 A 03
A 02 A 01
with modification 27 or 28 Base / Pcb Configuration
-2-
1 04577698 # H-MOTHERBOARD - 5.949
7 (4x)
2 05318483 # Power supply unit 3 04591402 # TOUCH MEMORY 4KX1
5 4 E1
4 04595467 # TOUCH MEMORY + TIME 5 04595874 # Fan, axial 6 05356393 # Encoding connector 10 kOhm (Herkules PRO) 05356407 # Encoding connector 6.81 kOhm (Herkules) 7 02133113 # Flex. loc-element
with modification 40 Base / Nest
-3-
1 04597575 # Bayonet joint (USA/CND, Japan) 04597583 # Bayonet joint (Europe, UK) 2 00138215 # Fuse T 6.3 A (Europe, UK) 04602080 # Fuse T 15 A (USA/CND, Japan) 3 04597567 # Fuse holder
6* (2x)
5*
3 2 1 7 8*
4 04597591 Protective cover 5 04745469 Bracket 6 02079836 Screw - M3x8 DINEN 7045
* only for 115V Base / Mains Input

-4-
1 04575431 AC-CONTROL - 5.950 2 04966708 Mains filter
6 (4x)
5 (4x)
3 04720393 # Toroidal transformer, cpl.
2 7 (4x) 8 (4x)
4 04555597 Transformer, cpl. 5 00146552 Nut - M4 DINEN 24032
3 9 (2x)
6 00219991 Serrated washer - DI 4.1 7 02288400 Washer - DI 6.4 DIN 6796
10 (2x) 4 11 Base / Mains Distributor
8 00166375 Nut - M6 DINEN 24032
-5-
9 00219991 Serrated washer - DI 4.1 10 00160202 Screw - M4x6 DIN 912
6 (4x)
5 (4x)
11 04551540 Housing, cpl.
2 7 (4x) 8 (4x)
3 9 (2x)
10 (2x) 4 11 Base / Mains Distributor
-6-
1 04596692 # Control unit for stepping motor 2 00044946 Screw - M4x12 DIN 912 3 02288389 Washer - DI 4.3 DIN 6796 4 Fan 00028004 #
2 (2x) 3 (2x)
Base / Control Unit
-7-
Compressor
1 2 12
1 04771982 # Line filter - 0.2 m 2 04857364 # Vacuum hose 130 mm long 3 04717015 # Screw connection 4 04772652 # Prefilter - 25 m 5 Case 05012546
Frame
Heat Sink
11 3 4 E2 10 8 9 5
6 04716086 # Flex. loc-element 7 05012732 # Filter unit 04772660 # Microfilter - 0.1 m
6 (2x) 8
with modification 35
7 (without item 6) Base / Compressed Air Unit

-8-
Compressor
1 2 12
9 Case
04571347 #
Frame
Heat Sink
10 04307046 # Fan, axial 11 00136603 Protective grille 12 04585666 # Compressed air chamber
11 3 4 E2 10 8 6 (2x) with modification 35 7 (without item 6) Base / Compressed Air Unit

-9-
S 11 1 2 3
1 04186192 # Compressed air switch 2 00292788 # Gasket 3 04568982 Frame, cpl.
14 13 (4x)
5 6 7 8 15 16 (2x) 4
4 04718100 Collecting tray 5 00292788 # Gasket 6 04771532 # G-quick-fastening attachment 7 04857364 # Vacuum hose 60 mm long 8 04717023 # T-plug-in connector
12 (4x)
11 (2x)
10 (6x)
with modification 35 Base / Compressed Air Unit / Frame

- 10 -
S 11 1 2 3
9 04857364 # Vacuum hose 390 mm long 10 01288148 Screw - M4x6 11 02455765 Setscrew - M6x35 DIN 916
14 13 (4x)
5 6 7 8 15 16 (2x) 4
12 00169498 Screw - M3x20 DIN 912 13 04716086 # Flex. loc-element 14 04718194 Plate, cpl. 15 05137497 # Splash guard 16 00127787 Cable holder
12 (4x)
11 (2x)
10 (6x)
with modification 35 Base / Compressed Air Unit / Frame

- 11 -
1 (2x) 2 (2x) 4 (2x) 3 (2x)
6 (4x) 8
1 00218979 Nut - M4 DIN 917 2 02034077 # Pressure spring
9 10 24 17 13 18 23 (2x) 25 (2x) 22 17
11 12 14 13 15 (2x)
3 00055301 Washer - DI 4.3 DIN 9021 4 04219597 Insulating bushing 5 04587707 Insulating sleeve 6 00033605 Screw - M3x8 DINEN 7045 7 04975790 # AIR-CONTROL - 6.165 8 05014085 # Temperature sensor, cpl.
16 (2x) 19 20 21
with modification 35 Base / Compressed Air Unit / Heat Sink

- 12 -
1 (2x) 2 (2x) 4 (2x) 3 (2x)
6 (4x) 8
9 04766652 # Peltier, cpl. 10 04973755 # Heat sink, cpl.
9 10 24 17 13 18 23 (2x) 25 (2x) 22 17
11 12 14 13 15 (2x)
11 00938297 Screw 12 04261976 # Sealing ring 13 04261976 # Sealing ring 14 04218337 # Screw, hollow 15 04219597 Insulating bushing 16 00578762 Screw - M4x50 DIN 912
16 (2x) 19 20 21

- 13 -
1 (2x) 2 (2x) 4 (2x) 3 (2x)
6 (4x) 8
17 01876910 # Quick-fatening attachment 18 04857364 # Vacuum hose 230 mm long
9 10 24 17 13 18 23 (2x) 25 (2x) 22 17
11 12 14 13 15 (2x)
19 04857364 # Vacuum hose 220 mm long 20 05013658 # Magnetic valve 21 04857364 # Vacuum hose 200 mm long 22 04857364 # Vacuum hose 280 mm long 23 00033605 Screw - M3x8 DINEN 7045
16 (2x) 19 20 21

- 14 -
1 (2x) 2 (2x) 4 (2x) 3 (2x)
6 (4x) 8
24 04662857 Heat sink 25 01212729 Screw - M4x16
9 10 24 17 13 18 23 (2x) 25 (2x) 22 17
11 12 14 13 15 (2x)
16 (2x) 19 20 21

- 15 -
13 1 9 8 (4x) 12 7 (4x)
1 04186206 # Compressor 2 04717007 # W- plug in connector 3 00964727 # Tension spring 4 00636738 # Tension spring 5 00044938 Screw - M4x10 DIN 912 6 02288389 Washer - DI 4.3 DIN 6796 7 00164909 Screw - M4x20 DIN 912 8 02288389 Washer - DI 4.3 DIN 6796
2 3 (4x) 10 (2x)
5 (4x) 6 (4x) 11
4 (4x)
with modification 35 Base / Compressed Air Unit / Compressor

- 16 -
13 1 9 7 (4x)
9 04857364 # Vacuum hose 330 mm long 10 04179536 Bracket
8 (4x) Plate 2 3 (4x) 10 (2x) 5 (4x) 6 (4x) 11 4 (4x) 12
11
04179528
12 04213343 # Piston 13 Filter 04204719 #
with modification 35 Base / Compressed Air Unit / Compressor

- 17 -
Vacuum Pump
1 01459678 # Compressed air hose 580 mm long 2 01459678 # Compressed air hose 210 mm long 3 01459678 # Compressed air hose 720 mm long 4 04716795 # Non-return valve
3 4 Base / Vacuum Unit

- 18 -
1
1 04596021 # Vacuum pump 2 00166375 Nut - M6 DINEN 24032
14 2 (3x) 9 (6x) 10 (6x) 11 6 (3x) 12 (2x) 8 (3x) 7 (3x) 3 (3x) 4 (3x) 5 (3x)
3 02288400 Washer - DI 6.4 DIN 6796 4 00055557 Washer - DI 6.4 DIN 9021 5 04722299 Bracket 6 04686098 # Shock absorber 7 00055557 Washer - DI 6.4 DIN 9021 8 04899822 Setscrew - M6x45 DIN 916
13 (2x)
15 S 12 Base / Vacuum Unit / Vacuum Pump

- 19 -
1
9 00139335 Screw - M5x8 DIN 912 10 02288397 Washer - DI 5.3 DIN 6796
14 2 (3x) 9 (6x) 10 (6x) 11 6 (3x) 12 (2x) 8 (3x) 7 (3x) 3 (3x) 4 (3x) 5 (3x)
11 04765826 # Valve, cpl. 12 00207098 Screw - M4x40 DIN 912 13 02288389 Washer - DI 4.3 DIN 6796 14 04204638 # Piston 15 00281166 # Microswitch
13 (2x)
15 S 12 Base / Vacuum Unit / Vacuum Pump

- 20 -
ECC Carrier Drive Loading Platform Optics Head Rotating Mirror Unit Bottom Punch Bottom Punch Adapter Lateral Punch
Basic Machine (left)
-1-
Cutting Device Loop Switch Film Exit Unit Top Punch Punch Adapter Mains, Safety Switch
Basic Machine (right)
-2-
2 (5x) 7
1 04743482 Cover 2 02936038 Screw - M4x10 3 00207047 Screw - M3x6 DIN 912
6 8 E5 3 (8x) 4 (8x) 5
4 02288370 Washer - DI 3.2 DIN 6796 5 04896904 # EC-CONTR EXT - 6.125 6 04541707 ECC carrier 7 04661478 # Cable guide 8 Fan 04743490 #
with modification 27 Basic Machine / ECC Carrier

-3-
Pcb MOD. CONNECT Spindle

1 6
1 02172550 # Rubber buffer 2 04717058 # Bearing unit (SP set) 3 00045047 Screw - M6x20 DIN 912
Polling Unit
Opto Switch
4 04852222 # Flywheel 5 04721659 # Ring, cpl. 6 04847741 # Ball screw 04852419 # Ball screw (Herkules - M)
(2) 5 4
Stepping Motor
3 (2x)
Guide Panels
with modification 22 Basic Machine / Drive

-4-
2 1 (4x) 3 6 7 5 15 14 (4x) 8
1 00044989 Screw - M5x16 DIN 912 2 04847741 # Ball screw 04852419 # Ball screw (Herkules - M)
(8) 3
Flange
04853156 #
10 11 (4x)
4 04772717 # Sliding bearing 5 Hose 04793471 #
6 00079936 Screw - M3x12 DIN 912
13 (2x) with modification 21
12
7 04852834 # Bushing, cpl.
Basic Machine / Drive / Spindle
-5-
2 1 (4x) 3 6 7 5 15 14 (4x) 8
8 04717058 # Bearing unit (SP set) 9 Ring 04551885
10 01507133 # Thrust piece, resilient
(8) 11
00166790 Screw - M6x30 DIN 912 12 04270355 Holder
10 11 (4x)
13 02253356 # Pressing screw - M8x12 14 00207314 Screw - M5x35 DIN 912
13 (2x) with modification 21
12
15 04270452 Holder
Basic Machine / Drive / Spindle
-6-
1 (4x)
M8
1 00044946 Screw - M4x12 DIN 912 2 04745418 # Stepping motor
5 6
3 04721659 # Ring, cpl. 4 00044938 Screw - M4x10 DIN 912
7 (4x) 11 10 9 8
5 00409383 Thrust piece 6 Stop 04212975 #
7 00146552 Nut - M4 DINEN 24032 8 Stop 04212975 #
Parts Catalog / Basic Machine / Drive / Stepping Motor
-7-
1 (4x) 2 (4x) 3
1 00044938 Screw - M4x10 DIN 912 2 02288389 Washer - DI 4.3 DIN 6796 3 04575423 # MODULE CONNECT - 5.952
Basic Machine / Drive / Pcb MOD. CONNECT
-8-
2 (2x) 3 (2x) 1 B2 4 (2x) 6 5 (2x)
1 02343533 # Opto switch 1 2 00049158 Screw - M4x8 DIN 912 3 02288389 Washer - DI 4.3 DIN 6796 4 00045039 Screw - M6x16 DIN 912 5 04188039 Cable clamp 6 04270347 Block
Basic Machine / Drive / Opto Switch
-9-
1 00044938 Screw - M4x10 DIN 912 2 02288389 Washer - DI 4.3 DIN 6796 3 04662261 # Adapter X82-X87
4 3 5
4 04556054 Bracket 5 04662342 Bracket
2 (2x) 1 (2x) 10 (2x)
8 (2x)
6 (2x) 7 (2x)
6 02288389 Washer - DI 4.3 DIN 6796 7 00049158 Screw - M4x8 DIN 912 8 02944863 Pressure spring
Basic Machine / Drive / Polling Unit (MAT-WIDTH I)
- 10 -
9 04576497 # MAT-WIDTH I - 6.004 10 00079936 Screw - M3x12 DIN 912
4 3 5
2 (2x) 1 (2x) 10 (2x)
8 (2x)
6 (2x) 7 (2x)
Basic Machine / Drive / Polling Unit (MAT-WIDTH I)
- 11 -
1 01288148 Screw - M4x6
1 (2x) 2 (2x) 4
2 02288389 Washer - DI 4.3 DIN 6796 3 04662261 # Adapter X82-X87 4 04764641 Bracket 5 04700805 # MAT-WIDTH II - 6.063
5 6 (2x) 7 (2x)
6 02288389 Washer - DI 4.3 DIN 6796 7 00049158 Screw - M4x8 DIN 912
Basic Machine / Drive / Polling Unit (MAT-WIDTH II)
- 12 -
2 (2x) 3 (2x) 4 (2x) 5
1 04970527 # Guide panel 2 00207381 Screw - M4x25 DIN 912 3 00055301 Washer - DI 4.3 DIN 9021 4 00602981 6 (2x) Pressure spring 7 (2x)
1 8 (2x) 10 (3x)
5 04971590 # Cover "Bacher" 04971612 # Cover "Stsser" 04719247 Cover "customer-specific systems" 6 00602981 Pressure spring
11 (6x)
9 (6x)
for Machines with Lateral Punch Basic Machine / Drive / Guide Panels
- 13 -
2 (2x) 3 (2x) 4 (2x) 5
7 00055301 Washer - DI 4.3 DIN 9021 8 00207381 Screw - M4x25 DIN 912 9 00049638 Nut - M3 DINEN 24032 10 04971620 # 6 (2x) Mount 7 (2x)
1 8 (2x) 10 (3x)
11 00577014 Screw - M3x6 DINEN 7046
11 (6x)
9 (6x)
for Machines with Lateral Punch Basic Machine / Drive / Guide Panels
- 14 -
1 00207381 Screw - M4x25 DIN 912
1 (2x)
2 (2x) 3 (2x) 4
2 00055301 Washer - DI 4.3 DIN 9021 3 00602981 Pressure spring 4 04719344 # Guide plate
6 5 (2x) 7 (2x) 8 (2x) 12 11 (2x) 9 (2x)
5 00156566 Screw - M4x16 DIN 912 6 04663136 Block 7 00602981 Pressure spring 8 00055301 Washer - DI 4.3 DIN 9021
10 for Machines without Lateral Punch (without modification 25) Basic Machine / Drive / Guide Panels
- 15 -
9 00207381 Screw - M4x25 DIN 912
1 (2x)
2 (2x) 3 (2x) 4
10 04719344 # Guide plate 11 00156566 Screw - M4x16 DIN 912 12 04663136 Block
6 5 (2x) 7 (2x) 8 (2x) 12 11 (2x) 9 (2x)
10 for Machines without Lateral Punch (without modification 25) Basic Machine / Drive / Guide Panels
- 16 -
1 04854209 Screw - M4x20 DIN 912 2 04258193 # Elastic buffer 3 04552121 # Loading platform, cpl. (for machines without modification 90)
1 (4x) 2 (2x)
Guide Panels
3 4
2 (2x)
04766725 # Loading platform, cpl. (for machines with modification 90) 4 00094684 # Elastic buffer
5 04585208 # Polling unit
Rewind Unit Stepping Motor

Basic Machine / Loading Platform
- 17 -
1 (4x) 2 (2x)
Guide Panels
3 4
2 (2x)
Rewind Unit Stepping Motor

Basic Machine / Loading Platform
- 18 -
1 04588568 # Guide panel
4 (5x) 5 (5x)
6 (5x)
2 04588657 # Antistatic rail 3 00051209 # Deep-groove ball bearing - DI 6
1 (2x)
7 (5x) 2 (2x)
4 00206903 Screw - M3x6 DINEN 7045 5 02288370 Washer - DI 3.2 DIN 6796 6 00206903 Screw - M3x6 DINEN 7045 7 02288370 Washer - DI 3.2 DIN 6796
3 8
8 04081226 # Position indicator, cpl.
Basic Machine / Loading Platform / Guide Panels
- 19 -
6 (4x)
1 Pin
04270215 #
3 M6 10
2 01318403 # Tension spring 3 02594129 # Stepping motor 4 Pin 04541014 #
5 04148762 # Spur wheel 6 02080702 Screw - M4x12 DIN 965
5 4 12 (2x)
7 (4x)
8 (4x)
7 00049921 Washer - DI 4.3 DIN 433 8 00146552 Nut - M4 DINEN 24032
11 (2x) Basic Machine / Loading Platform / Stepping Motor

- 20 -
6 (4x)
9 04538978 Bracket 10 00183989 Lock washer - DI 6 DIN 6799
3 M6 10
11 00213101 Setscrew - M4x4 DIN 916 12 00213101 Setscrew - M4x4 DIN 916
5 4 12 (2x)
7 (4x)
8 (4x)
11 (2x) Basic Machine / Loading Platform / Stepping Motor

- 21 -
1 04685113 # Tension spring 2 01487531 Screw - M3x10 DINEN 7045
3 04535367 Rewind motor 4 04534301 Bushing 5 00166499 Lock washer - DI 5 DIN 6799
3 Rewind Motor 2 (2x)
6 04768302 Side panel
5 Basic Machine / Loading Platform / Rewind Unit

- 22 -
1 04148568 # Spur wheel
2 04078926 # Gear wheel 3 04186184 # Microswitch 4 04067282 # Motor w. gear unit
3 S4
M5
Basic Machine / Loading Platform / Rewind Unit / Rewind Motor
- 23 -
1 04661397 # Optics head, cpl. 2 05000483 Knurled screw - M4x35 DIN 653 3 00055301 Washer - DI 4.3 DIN 9021
6 7, 8 1 9 (2x) 2 (4x) 5 (4x) 10 3 (4x) 4 (4x)
4 04114957 Pressure spring 5 04586190 Bushing 6 04718275 Bracket 7 00049158 Screw - M4x8 DIN 912 8 02288389 Washer - DI 4.3 DIN 6796
Basic Machine / Optics Head
- 24 -
9 04222768 # Holder 10 Plate 04222571 #
6 7, 8 1 9 (2x) 2 (4x) 5 (4x) 10 3 (4x) 4 (4x)
Basic Machine / Optics Head
- 25 -
7 (2x) 8
1 05126053 # Rotating mirror unit
2 05000483 Knurled screw - M4x35 DIN 653 3 00055301 Washer - DI 4.3 DIN 9021 4 04114957 Pressure spring 5 04586190 Bushing 6 04853091 Fishplate
2 (4x) 5 (4x) 4 (4x) 3 (4x)
7 00044938 Screw - M4x10 DIN 912 8 00164909 Screw - M4x20 DIN 912
with modification 27 Basic Machine / Rotating Mirror Unit

- 26 -
7 (2x) 8
9 04771834 # W-quick fastening attachment
2 (4x) 5 (4x) 4 (4x) 3 (4x)
with modification 27 Basic Machine / Rotating Mirror Unit

- 27 -
1 04244311 # Solenoid
1 Y2 3
2 04569962 # Retainer 3 00240982 # Tension spring
Y1
without modification 90 Basic Machine / Trough

- 28 -
Solenoid, left Punch Body Opto Switch Punch Drive
Pressure Rail Solenoid, right
Basic Machine / Bottom Punch
- 29 -
M 19 1
2 (2x) 3 4 5 8 6
1 04597443 # Motor with gear unit 2 00044903 Screw - M3x10 DIN 912 3 04768493 Clamp 4 04768752 Eccentric 5 04768566 Connecting rod
10 (2x)
9 (2x)
8 11
6 00101028 # Sleeve 7 Pin 04768655
8 04883284 # Spare parts set -bottom punchCustomer-specific spare parts set acc. to customer sheet
Basic Machine / Bottom Punch / Punch Drive
- 30 -
M 19 1
2 (2x) 3 4 5 8 6
9 00213101 Setscrew - M4x4 DIN 916 10 00164909 Screw - M4x20 DIN 912 11 Bar 04768396
10 (2x)
9 (2x)
8 11
Basic Machine / Bottom Punch / Punch Drive
- 31 -
2 3 4 (6x) 5 (6x) 12 6
1 05139597 Bracket 2 04772474 # Reflection strip 3 04883284 # Spare parts set -bottom punchCustomer-specific spare parts set acc. to customer sheet 4 00049158 Screw - M4x8 DIN 912 5 02288389 Washer - DI 4.3 DIN 6796 6 04772474 # Reflection strip
13 (4x)
11 10 9 (2x)
7 (2x)
8 (2x)
7 00217662 Screw - M3x25 DIN 912
Basic Machine / Bottom Punch / Punch Body
- 32 -
2 3 4 (6x) 5 (6x) 12 6
8 00044946 Screw - M4x12 DIN 912 9 02288389 Washer - DI 4.3 DIN 6796 10 04767985 Collecting try 11 02288389 Washer - DI 4.3 DIN 6796 7 (2x) 12 00044946 Screw - M4x12 DIN 912 13 00207098 Screw - M4x40 DIN 912
13 (4x)
11 10 9 (2x)
8 (2x)
Basic Machine / Bottom Punch / Punch Body
- 33 -
1 Bar 11 (2x) 2 Plate 10 9 1
04768396 04722132
3 00183334 Screw - M2x4 DINEN 1207 4 04765737 Screw - M3x3x3.5 5 00055255 Washer - DI 4.3 DIN 125 6 00240982 # Tension spring 7 04765168 # Pressure rail 6 5 (3x) 4 (3x) 3 (2x) - 34 8 00183334 Screw - M2x4 DINEN 1207
8 (2x) 7 2
Basic Machine / Bottom Punch / Pressure Rail
9 00240982 # Tension spring 11 (2x) 10 Plate 10 9 1 04722132
11 00184241 Straight pin - M6x10 DINEN 22338
8 (2x) 7 2
5 (3x) 4 (3x) 3 (2x) - 35 -
Basic Machine / Bottom Punch / Pressure Rail
1 04794028 Bracket
2 (2x)
2 01288121 Screw - M3x6 DIN 965 3 02608588 # Opto switch
4 (2x) 5 (2x)
B 19 3
4 00391611 Washer - DI 2.7 DIN 125 5 01212664 Screw - M2.5x6 6 Bar 04768396
Basic Machine / Bottom Punch / Opto Switch
- 36 -
1 04244311 # Solenoid 2 00045330 Setscrew - M3x4 DIN 916 3 04979834 # Sleeve
2 1 3 Y2 7 (2x)
4 02288370 Washer - DI 3.2 DIN 6796 5 00207047 Screw - M3x6 DIN 912 6 04768485 Bracket
4 (2x) 5 (2x) 6
8 (2x)
Basic Machine / Bottom Punch / Solenoid, Left
- 37 -
2 1 3 Y2 7 (2x)
4 (2x) 5 (2x) 6
8 (2x)
Basic Machine / Bottom Punch / Solenoid, Left
- 38 -
1 00045330 Setscrew - M3x4 DIN 916 2 04979834 # Sleeve 3 04244311 # Solenoid
7 (2x) 8 (2x) 1
4 04768477 Bracket 5 02288389 Washer - DI 4.3 DIN 6796 6 00044946 Screw - M4x12 DIN 912
5 (2x) 6 (2x)
2 4 Y1 3
Basic Machine / Bottom Punch / Solenoid, Right
- 39 -
7 (2x) 8 (2x) 1
5 (2x) 6 (2x)
2 4 Y1 3
Basic Machine / Bottom Punch / Solenoid, Right
- 40 -
Solenoid, left
Pressure Rail
Solenoid, right
Basic Machine / Bottom Punch Adapter
- 41 -
10 (4x) 11 (4x) 8 7 6 (2x) 3 2 1 5 (6x) 4 (6x) 17 18 16 (3x) 13 9 12 1 Bar 04768299
2 05139597 Bracket 3 04772474 # Reflection strip 4 02288389 Washer - DI 4.3 DIN 6796 5 00049158 Screw - M4x8 DIN 912 6 00183334 Screw - M2x4 DINEN 1207
15 14 (3x) (2x) 7 00240982 # Tension spring 8 Plate 04722132
Basic Machine / Bottom Punch Adapter / Pressure Rail
- 42 -
10 (4x) 11 (4x) 8 7 6 (2x) 3 2 1 5 (6x) 4 (6x) 17 18 16 (3x) 13 9 12 9 04765168 # Pressure rail 10 02288389 Washer - DI 4.3 DIN 6796 11 00156566 Screw - M4x16 DIN 912 12 04767969 Carrier 13 Plate 04722132
15 14 (3x) (2x) 15 04765737 Screw - M3x3x3.5
14 00183334 Screw - M2x4 DINEN 1207
16 00055255 Washer - DI 4.3 DIN 125
- 43 -
10 (4x) 11 (4x) 8 7 6 (2x) 3 2 1 5 (6x) 4 (6x) 17 18 16 (3x) 13 9 12 17 00240982 # Tension spring 18 04772474 # Reflection strip
15 14 (3x) (2x)
- 44 -
1 04244311 # Solenoid 2 00045330 Setscrew - M3x4 DIN 916 3 04979834 # Sleeve
2 1 3 Y2 7 (2x) 8 (2x)
4 02288370 Washer - DI 3.2 DIN 6796 5 00207047 Screw - M3x6 DIN 912 6 04768485 Bracket
4 (2x) 6 5 (2x)
Basic Machine / Bottom Punch Adapter / Solenoid, Left
- 45 -
2 1 3 Y2 7 (2x) 8 (2x)
4 (2x) 6 5 (2x)
Basic Machine / Bottom Punch Adapter / Solenoid, Left
- 46 -
1 00045330 Setscrew - M3x4 DIN 916 2 04979834 # Sleeve 3 04244311 # Solenoid
7 (2x)
8 (2x) 1
4 04768477 Bracket 5 02288389 Washer - DI 4.3 DIN 6796 6 00044946 Screw - M4x12 DIN 912
5 (2x) 6 (2x) 4 Y1 3
Basic Machine / Bottom Punch Adapter / Solenoid, Right
- 47 -
7 (2x)
8 (2x) 1
5 (2x) 6 (2x) 4 Y1 3
Basic Machine / Bottom Punch Adapter / Solenoid, Right
- 48 -
Punch Replacement Parts

3 (3x)
1 04718550 Punch body
2 00207098 Screw - M4x40 DIN 912 3 04715330 Screw - M6x55 DIN 912
2 (2x)
2 (2x) 1 2 (2x)
Basic Machine / Lateral Punch
- 49 -
Lateral Punch "Bacher" 3 2 (2x)
1 04766520 Holder 2 04715381 Screw - M3x30 DIN 7984 3 04719182 # Punch head
1 6 4 (2x)
4 01487825 Screw - M4x8 DINEN 7046 5 00167339 Screw - M3x16 DIN 7984
5 (2x) 6 6
6 04882512 # Spare parts set "Bacher" Customer-specific spare parts set acc. to customer sheet
Basic Machine / Lateral Punch / Punch Replacement Parts
- 50 -
Lateral Punch "Stsser" 3 2 (2x)
1 04766520 Holder 2 04715381 Screw - M3x30 DIN 7984 3 04719182 # Punch head
1 6 4 (2x)
4 01487825 Screw - M4x8 DINEN 7046 5 00167339 Screw - M3x16 DIN 7984
5 (2x) 6 6
6 04881710 # Spare parts set "Stsser" Customer-specific spare parts set acc. to customer sheet
Basic Machine / Lateral Punch / Punch Replacement Parts
- 51 -
Drive
1 00055301 Washer - DI 4.3 DIN 9021 2 00160202 Screw - M4x6 DIN 912 3 00049158 Screw - M4x8 DIN 912
2 (2x) 4
04552040 # Cutting device
Cutting Rail
4
1 (2x)
Cutting Wheel
3 (2x)
Parts Catalog / Basic Machine / Cutting Device
- 52 -
1 3 4 (2x) 18 (4x) 17 (4x) 5 6 19 7 8 9 10 16 M4 12 13 14 11 2
1 Knob
04039203
2 04295544 # Toothed belt 3 04081293 # Toothed belt pulley 4 00045292 Setscrew - M4x8 DIN 915 5 Ring 04081838 #
6 04081633 Housing 7 04081226 # Position indicator, cpl.
15
8 00146552 Nut - M4 DINEN 24032
Basic Machine / Cutting Device / Drive
- 53 -
1 3 4 (2x) 18 (4x) 17 (4x) 5 6 19 7 8 9 10 16 M4 12 13 14 11 2
9 02288389 Washer - DI 4.3 DIN 6796 10 Axle 04212428
11 04086058 Retaining disk 12 01111132 # Deep-groove ball bearing - DI 4 13 04086058 Retaining disk 14 00055255 Washer - DI 4.3 DIN 125 15 00062847 Lock washer - DI 3.2 DIN 6799
15
16 04237900 # Motor w. gear unit
- 54 -
1 3 4 (2x) 18 (4x) 17 (4x) 5 6 19 7 8 9 10 16 M4 11 12 13 14 15 2
17 02288370 Washer - DI 3.2 DIN 6796 18 00044903 Screw - M3x10 DIN 912 19 00422142 # Magnet
- 55 -
1 2 7 (2x) 8 (3x) 9 10 12 (2x) 16 13 14 (2x) 17 (6x) 18 19 15 11 3 (3x) 4

1 00106178 Adhesive label 2 04552210 Cassette mount 3 01424238 Screw - ST 2.9x13 DIN 7981 4 04534271
5 Bracket 6 (2x) 5
00049158 Screw - M4x8 DIN 912 6 01424238 Screw - ST 2.9x13 DIN 7981 7 01424238 Screw - ST 2.9x13 DIN 7981 8 01424238 Screw - ST 2.9x13 DIN 7981
Basic Machine / Cutting Device / Cutting Rail
- 56 -
1 2 7 (2x) 8 (3x) 9 10 12 (2x) 16 13 14 (2x) 17 (6x) 18 19 15 11 3 (3x) 4

9 00049158 Screw - M4x8 DIN 912 10 04552563 Bracket 11 04295544 # Toothed belt 12 00051055 #
5 Deep-groove ball bearing - DI 4 6 (2x) 13

04551788 # Cutting rail 14 00045292 Setscrew - M4x8 DIN 915 15 00226017 Straight pin - 8x24 DINEN 22338 16 Rail 04551974 #
- 57 -
1 2 7 (2x) 8 (3x) 9 10 12 (2x) 16 13 14 (2x) 17 (6x) 18 19 15 11 3 (3x) 4 5 6 (2x)

17 00049158 Screw - M4x8 DIN 912 18 00103837 Double-stick tape 19 05181259 Gasket
- 58 -
1 04082869 # CUT REED 2 - 5.894 2 04082869 # CUT REED 2 - 5.894
3 2 4 6 5 7 8
3 04209656 Holder 4 00158135 Cable holder 5 02079658 Screw - M4x6 DINEN 7045 6 04144937 # Cutting wheel, cpl. 7 00055255 Washer - DI 4.3 DIN 125 8 00164909 Screw - M4x20 DIN 912
Basic Machine / Cutting Device / Cutting Wheel
- 59 -
3 (2x) 1 2
1 Plate
04078551
2 04661885 Holder 3 00044946 Screw - M4x12 DIN 912
4 S2 5 (2x) 6 (2x)
4 04595890 # Microswitch, Hall 5 00143472 Insulating washer - DI 3.2 6 02080095 Screw - M2.5x16 DINEN 7045
Basic Machine / Loop Switch
- 60 -
1 04542444 # Film exit unit, cpl.
Block Diode Holder

1 2 (10x) 3 (10x)
2 00044946 Screw - M4x12 DIN 912 3 02288389 Washer - DI 4.3 DIN 6796 4 04847962 # Guide panel
Roller Drive
Control Unit Stepping Motor

Gear Unit Motor, Solenoid

Basic Machine / Film Exit Unit
- 61 -
8 2 1 3
1 04766369 Screw - M6x30
10
2 04661192 Block 3 00233102 Washer - DI 5.2
4 5
B9 19
4 00409383 Thrust piece 5 04588274 # Tapped plate 6 04661702 # Diode holder
16 18 17 15 (3x) 14
13 (2x) 12 11
7 04721594 Guide 8 00441759 Spacer
Basic Machine / Film Exit Unit / Diode Holder
- 62 -
8 2 1 3
9 00055352 Washer - DI 3.2 DIN 9021
10
10 01424238 Screw - ST 2.9x13 DIN 7981 11 04588703 # Toothed belt pulley
4 5
B9 19
12 00552496 # Toothed belt 13 00206849 Setscrew - M4x6 DIN 916 14 Ring 04081838 #
16 18 17 15 (3x) 14
13 (2x) 12 11
15 00233102 Washer - DI 5.2 16 00392006 # Deep-groove ball bearing - DI 5
- 63 -
8 2 1 3
17 01359002 Spacer
10
18 04661966 # Threaded rod 19 04661168 # Flat cable
4 5
B9 19
16 18 17 15 (3x) 14
13 (2x) 12 11
- 64 -
Stepping Motor
14 (2x) 15 2 3 4 13 12 6 5
1 04542258 # Front guide panel 2 04662059 # Holder
16
3 00044938 Screw - M4x10 DIN 912 4 00055301 Washer - DI 4.3 DIN 9021 5 02288389 Washer - DI 4.3 DIN 6796 6 00146552 Nut - M4 DINEN 24032 7 00166499 Lock washer - DI 5 DIN 6799
11 (2x)
10 9
8 7
8 00051209 # Deep-groove ball bearing - DI 6
with modification 32 Basic Machine / Film Exit Unit / Roller Drive

- 65 -
Stepping Motor
14 (2x) 15 2 3 4 13 12 6 5
9 04551796 # Roller 10 00051209 # Deep-groove ball bearing - DI 6
16
11 01212729 Screw - M4x16 12 01430211 Spacer 13 Ring 04081838 #
14 00206849 Setscrew - M4x6 DIN 916 15 00552496 # Toothed belt
11 (2x)
10 9
8 7
16 04081293 # Toothed belt pulley
with modification 32 Basic Machine / Film Exit Unit / Roller Drive

- 66 -
1 (2x) 2 (2x) 3 (2x) 4 (2x) 5 (2x) 8 (2x)
1 00044938 Screw - M4x10 DIN 912 2 02288389 Washer - DI 4.3 DIN 6796 3 00100811 Spacer 4 00055379 Washer - DI 5.3 DIN 9021 5 02288389 Washer - DI 4.3 DIN 6796
M3
6 (2x) 11
9 10 12 (2x)
13 (2x) 14
6 00055891 Screw - M4x10 DIN 6912 15 16 (5x) 7 02594129 # Stepping motor 8 00206849 Setscrew - M4x6 DIN 916
17
Basic Machine / Film Exit Unit / Roller Drive / Stepping Motor
- 67 -
1 (2x) 2 (2x) 3 (2x) 4 (2x) 5 (2x) 8 (2x)
9 Ring
04081838 #
10 00552496 # Toothed belt 11 04078373 # Toothed belt pulley 12 01288148 Screw - M4x6 13 02288389 Washer - DI 4.3 DIN 6796
M3
6 (2x) 11
9 10 12 (2x)
13 (2x) 14
14 00593745 # Sliding bearing - DI 8 15 16 (5x) 15 04640829 Washer 16 04662148 # Roller
17
- 68 -
1 (2x) 2 (2x) 3 (2x) 4 (2x) 5 (2x) 8 (2x)
17 04765621 # Vibration damper, cpl.
M3
6 (2x) 11
9 10 12 (2x)
13 (2x) 14
15 16 (5x)
17
- 69 -
Control Rollers 1, 2, 4 Rear Guide Panel Control Roller 3

2 (6x) 1 (3x) 1 04574451 # Magnetic lock 2 02079917 Screw - M3x4 DINEN 7045 3 02288389 Washer - DI 4.3 DIN 6796 4 01288148 Screw - M4x6 5 04542517 Block
S 16 8
3 (2x) 4 (2x) 9 (5x) 7 6 5
6 00593745 # Sliding bearing - DI 8 7 04640829 Washer 8 00099228 # Safety switch
10
Basic Machine / Film Exit Unit / Control Unit
- 70 -
Control Rollers 1, 2, 4 Rear Guide Panel Control Roller 3

2 (6x) 1 (3x) 9 04662148 # Roller 10 04765621 # Vibration damper, cpl.
S 16 8
3 (2x) 4 (2x) 9 (5x) 7 6 5
10
Basic Machine / Film Exit Unit / Control Unit
- 71 -
1 (6x) 2 (9x) 3 (6x)
1 00100064 Spacer 2 04587618 # Roller 3 00233064 Adjusting washer - DI 5.2 4 00062847 Lock washer - DI 3.2 DIN 6799 5 Axle 04085256
4 (6x) 5 (3x) 6 (3x)
7 (3x)
8 (6x)
6 04567927 # Holder 7 00510882 # Pressure spring 8 02080257 Screw - M4x8 DIN 965
9 (3x)
with modification 32 Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4
- 72 -
1 (6x) 2 (9x) 3 (6x)
9 04947827 # Block
4 (6x) 5 (3x) 6 (3x)
7 (3x)
8 (6x)
9 (3x)
with modification 32 Basic Machine / Film Exit Unit / Control Unit / Control Rollers 1, 2, 4
- 73 -
1 (2x) 2 (3x) 3 (2x) 4 (2x) 6 15 7 8 1 00100064 Spacer 2 04587618 # Roller 3 00233064 Adjusting washer - DI 5.2 4 00062847 Lock washer - DI 3.2 DIN 6799 5 Axle 9 17 (3x) 18 (3x) 19 14 20 10 11 13 12 04085256
M 14
16
6 04567927 # Holder 7 00510882 # Pressure spring 8 02080257 Screw - M4x8 DIN 965
with modification 32 Basic Machine / Film Exit Unit / Control Unit / Control Roller 3
- 74 -
1 (2x) 2 (3x) 3 (2x) 4 (2x) 6 15 7 8 9 04947827 # Block 10 01338811 Screw - M4x16 DINEN 7045 11 00051101 # Deep-groove ball bearing - DI 4 12 00102040 Spacer 13 Lever 9 17 (3x) 18 (3x) 19 14 20 10 11 13 12 04661893
M 14
16
14 00413216 Setscrew - M6x6 DIN 916 15 04067282 # Motor w. gear unit 16 04567242 Bracket
- 75 -
1 (2x) 2 (3x) 3 (2x) 4 (2x) 6 15 7 8 17 00391611 Washer - DI 2.7 DIN 125 18 00216534 Screw - M2x6 DINEN 1207 19 04566459 # Block 20 00206849 Setscrew - M4x6 DIN 916
M 14
16
9 17 (3x) 18 (3x) 19 14 20 10 11 13 12
- 76 -
1 2
3 6
1 00146552 Nut - M4 DINEN 24032 2 02288389 Washer - DI 4.3 DIN 6796 3 05132819 Guide 4 01487477 Screw - M3x6 DINEN 7045 5 00975427 Screw - ST 2.9x6.5 DIN 7982
5 (2x)
6 04662881 # Block 8 7 04767519 # Reflection strip 8 04848306 # Guide panel
11
10 (3x)
9 (3x) - 77 -
Basic Machine / Film Exit Unit / Control Unit / Rear Guide Panel
1 04661966 # Threaded rod 2 01359002 Spacer 1 2 3 4 (3x) 3 00392006 # Deep-groove ball bearing - DI 5 4 00233102 5 Washer - DI 5.2 (2x) 6 5 00206849 Setscrew - M4x6 DIN 916 6 Ring 04081838 #
14 (2x) 15 (2x) 9 13
7 8 10 (2x)
7 04588703 # Toothed belt pulley 12 11 M 2 8 00552496 # Toothed belt
Basic Machine / Film Exit Unit / Stepping Motor
- 78 -
9 02034441 Spacer 10 00044938 Screw - M4x10 DIN 912 1 2 3 4 (3x) 11 04586956 # Stepping motor 12 04588703 # 5 Toothed belt pulley (2x) 6 13 04081838 # Ring 14 00206849 Setscrew - M4x6 DIN 916 15 00055379 Washer - DI 5.3 DIN 9021 12 11 M 2
14 (2x) 15 (2x) 9 13
7 8 10 (2x)
Basic Machine / Film Exit Unit / Stepping Motor
- 79 -
1 00206849 Setscrew - M4x6 DIN 916 2 00216534 Screw - M2x6 DINEN 1207 3 00391611 Washer - DI 2.7 DIN 125 4 04067282 # Motor w. gear unit 5 04148568 # Spur wheel 6 04244311 # Solenoid 1 (2x) 7 (2x) 5 9 6 2 (3x) 3 (3x) 7 02288370 Washer - DI 3.2 DIN 6796
8 (2x)
M1
4
8 00207047 Screw - M3x6 DIN 912
Y 10
Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid
- 80 -
9 04662245 # Sleeve
8 (2x) 7 (2x) 5 9 6
1 (2x)
2 (3x) 3 (3x)
M1
4
Y 10
Basic Machine / Film Exit Unit / Gear Unit Motor, Solenoid
- 81 -
1 04662881 # Block 2 04720512 Leaf spring 3 00975427 Screw - ST 2.9x6.5 DIN 7982
1 2 3 (2x)
Basic Machine / Film Exit Unit / Block
- 82 -
Solenoid
Left Rollers
Right Rollers
Punch Replacement Parts Stepping Motor
Basic Machine / Top Punch
- 83 -
2 (4x) 3 (4x) 15 (2x) 1 (2x) Y6 Y8 12 (3x)

4
1 04244311 # Solenoid 2 00207047 Screw - M3x6 DIN 912
14 (2x) 13 (3x)
Right Connecting Rod 6 B 17

5 (2x) 8 9 (2x) 7 (2x)
3 02288370 Washer - DI 3.2 DIN 6796 4 04587251 Side panel, cpl. 5 01212664 Screw - M2.5x6 02608588 # Opto switch 7 00391611 Washer - DI 2.7 DIN 125 8 04585305 Bracket
13 12 11
10 (2x) 6
Basic Machine / Top Punch / Solenoid
- 84 -
2 (4x) 3 (4x) 15 (2x) 1 (2x) Y6 Y8 12 (3x)

4
14 (2x) 13 (3x)
Right Connecting Rod 6 B 17

5 (2x) 8 9 (2x) 7 (2x)
11 04721969 Spacer hex. 12 02288389 Washer - DI 4.3 DIN 6796 13 00044938 Screw - M4x10 DIN 912 04979834 # Sleeve 15 00045330 Setscrew - M3x4 DIN 916
13 12 11
10 (2x) 14
Basic Machine / Top Punch / Solenoid
- 85 -
2 3 1 6
8 (2x) 9
1 00167258 Circlip - 8x0.8 DIN 471 2 00232882 Washer - DI 8.1 10 (2x) 3 02121492 # Sleeve 13 14 15 4 01181041 Washer - DI 8.1
11 (2x)
12
M 17
19 20
18 (3x)
5 Pin
01763814 #
21
(6) 26
6 04661257 # Connecting rod 17 (3x) 16 (3x) 7 04979826 Flange 8 00206830 Setscrew-M4x10 DIN 916 27 - 86 -
22 23 24
(13) 25
Basic Machine / Top Punch / Solenoid / Right Connecting Rod
2 3 1 6
8 (2x) 9
9 00051578 # Deep-groove ball bearing - DI 10 10 00164909 Screw - M4x20 DIN 912 10 (2x) 11 02288389 Washer - DI 4.3 DIN 6796 13 14 15 12 01764241 # Toothed belt pulley
11 (2x)
12
M 17
19 20
18 (3x)
13 04715535 # Toothed belt 14 04661354 Motor plate
21
(6) 26
17 (3x)
16 (3x)
15 02121328 # Motor w. gear unit 16 00044938 Screw - M4x10 DIN 912
22 23 24
(13) 25 27
- 87 -
2 3 1 6
8 (2x) 9
17 02288389 Washer - DI 4.3 DIN 6796 18 04722043 Spacer, hex. 10 (2x) 19 04661265 Bearing block 13 14 15 20 00167258 Circlip - 8x0.8 DIN 471
11 (2x)
12
M 17
19 20
18 (3x)
21 00232882 Washer - DI 8.1 22 02121492 # Sleeve
21
(6) 26
17 (3x)
16 (3x)
23 01181041 Washer - DI 8.1 24 Pin 04720997 #
22 23 24
(13) 25 27
- 88 -
2 3 1 6
8 (2x) 9
25 00408557 Clamping pin - 2.5x14 DINEN 28752 26 01763652 # Toothed belt pulley 10 (2x) 27 Shaft 13 14 15 04585348
11 (2x)
12
M 17
19 20
18 (3x)
21
(6) 26
17 (3x)
16 (3x)
22 23 24
(13) 25 27 - 89 -
14 (3x) 15 (3x) 16 1 04244311 # Solenoid 2 00207047 Screw - M3x6 DIN 912 3 02288370 Washer - DI 3.2 DIN 6796 4 00206849 Setscrew - M4x6 DIN 916 5 Ring 5 6 8 (4x) 7 (4x) 04081838 #
Y9 A
1 (2x) 13
Left Connecting Rod

12 10 9 (4x) 11
Y7
4 (2x)
M7
6 04078373 # Toothed belt pulley 7 00044946 Screw - M4x12 DIN 912 8 02288389 Washer - DI 4.3 DIN 6796
A
17 (2x)
18 (2x)
2 (4x) 3 (4x) 1 (2x)
Basic Machine / Top Punch / Stepping Motor
- 90 -
14 (3x) 15 (3x) 16 9 00146552 Nut - M4 DINEN 24032 10 02594129 # Stepping motor 11 00044938 Screw - M4x10 DIN 912 12 02288389 Washer - DI 4.3 DIN 6796 13 04721969 Spacer hex. 5 6 8 (4x) 7 (4x) 14 02288389 Washer - DI 4.3 DIN 6796 15 00044938 Screw - M4x10 DIN 912 16 04585534 Side panel, cpl.
Y9 A
1 (2x) 13
Left Connecting Rod

12 10 9 (4x) 11
Y7
4 (2x)
M7
A
17 (2x)
18 (2x)
2 (4x) 3 (4x) 1 (2x)
- 91 -
14 (3x) 15 (3x) 16 17 04979834 # Sleeve 18 00045330 Setscrew - M3x4 DIN 916
Y9 A
1 (2x) 13
Left Connecting Rod

12 10 9 (4x) 11 5
Y7
4 (2x)
M7
6 8 (4x) 7 (4x)
A
17 (2x)
18 (2x)
2 (4x) 3 (4x) 1 (2x)
- 92 -
1 2 4 (2x) 6 (2x) 5 (2x) 9 (2x) 3 (2x)

1 Shaft 04585348
2 00164828 Circlip - 10x1 DIN 471 3 00164909 Screw - M4x20 DIN 912 4 02288389 Washer - DI 4.3 DIN 6796
10 (2x) 11 (2x)
8 12
13
14
15
18 (18) 23 20 22 21 19
17
16
7 04661265 Bearing block 8 00051578 # Deep-groove ball bearing - DI 10
Basic Machine / Top Punch / Stepping Motor / Left Connecting Rod
- 93 -
1 2 4 (2x) 6 (2x) 5 (2x) 9 (2x) 3 (2x)

9 00055301 Washer - DI 4.3 DIN 9021 10 02285908 Screw - M4x5 DIN 58450 11 00206830 Setscrew-M4x10 DIN 916 12 04979826 Flange
10 (2x) 11 (2x)
8 12
13
14
15
13 Pin
01763814 #
18 (18) 23 20 22 21 19
14 01181041 Washer - DI 8.1
17
16
15 02121492 # Sleeve 16 00167258 Circlip - 8x0.8 DIN 471
- 94 -
1 2 4 (2x) 6 (2x) 5 (2x) 9 (2x) 3 (2x)

17 00232882 Washer - DI 8.1 18 04661257 # Connecting rod 19 00167258 Circlip - 8x0.8 DIN 471 20 00232882 Washer - DI 8.1
10 (2x) 11 (2x)
8 12
13
14
15
21 02121492 # Sleeve 22 01181041 Washer - DI 8.1
18 (18) 23 20 22 21 19
17
16
23 Pin
04720997 #
- 95 -
1 2 4 (2x) 6 (2x) 5 (2x) 9 (2x) 3 (2x)
10 (2x) 11 (2x)
8 12
13
14
15
18 (18) 23 20 22 21 19
17
16
- 96 -
8 (2x) 9 (2x) 1 (2x) 2 3 (2x) 4 5 (2x) 6 (4x) 7 (2x)
1 00166499 Lock washer - DI 5 DIN 6799 2 04078918 # Tension spring 3 04084632 # Roller 4 Plate 04586271
5 04533534 Washer 6 00206849 Setscrew - M4x6 DIN 916 7 04148762 # Spur wheel 8 04177398 # Deep-groove ball bearing - DI 7
Basic Machine / Top Punch / Right Rollers
- 97 -
8 (2x) 9 (2x) 1 (2x) 2 3 (2x) 4 5 (2x) 6 (4x) 7 (2x)
9 04794060 # Roller
Basic Machine / Top Punch / Right Rollers
- 98 -
1 (2x) 2 (2x) 3 (2x) 1 04794060 # Roller 2 00166499 Lock washer - DI 5 DIN 6799 3 04177398 # Deep-groove ball bearing - DI 7 4 5 6 4 Tube 04588363
7 (2x) 8 9 10
17 (2x) 16 (2x) 18 19 (4x) 20 (3x) 21 (3x) 15 14
5 04081293 # Toothed belt pulley 6 04715527 # Toothed belt
13 7 00206849 (2x) 12 11 (2x) Setscrew - M4x6 DIN 916 8 Ring 04081838 #
Basic Machine / Top Punch / Left Rollers
- 99 -
1 (2x) 2 (2x) 3 (2x) 9 04533410 Washer 10 Plate 04586271
11 00166499 Lock washer - DI 5 DIN 6799 4 5 6 12 04078918 # Tension spring 13 04084632 # Roller 14 04533534 Washer 14 13 15 (2x) 12 11 (2x) Tube 04553268
7 (2x) 8 9 10
17 (2x) 16 (2x) 18 19 (4x) 20 (3x) 21 (3x) 15
16 00240982 # Tension spring
- 100 -
1 (2x) 2 (2x) 3 (2x) 17 Plate 04722132
18 04765168 # Pressure rail 19 00183334 Screw - M2x4 DINEN 1207 4 5 6 20 00055255 Washer - DI 4.3 DIN 125 21 04765737 Screw - M3x3x3.5
7 (2x) 8 9 10
17 (2x) 16 (2x) 18 19 (4x) 20 (3x) 21 (3x) 15 14
13 (2x) 12 11 (2x)
- 101 -
1 00217662 Screw - M3x25 DIN 912 2 00217662 Screw - M3x25 DIN 912 3 Plate 04585054
5 5 2
4 00169498 Screw - M3x20 DIN 912 5 Spare parts set (standard) 04851129 # Bacher
3 5 5 4 5
04852540 # Stsser 04852370 # LHLTD Customer-specific spare parts set acc. to customer sheet
Basic Machine / Top Punch / Punch Replacement Parts
- 102 -
5 5 2
3 5 5 4 5
- 103 -
5 5 2
3 5 5 4 5
- 104 -
1 04719581 # Punch adapter
Holder
Drive
Basic Machine / Punch Adapter
- 105 -
1 (4x)
Stepping Motor
30 (2x)
1 00207047 Screw - M3x6 DIN 912 2 02288370 Washer - DI 3.2 DIN 6796 3 04244311 # Solenoid 4 00045330 Setscrew - M3x4 DIN 916 5 04979834 # Sleeve 6 04722280 Spacer - 26 mm, size 6 13 (2x) 7 Tube 04588363
2 (4x)
Y7
4 (2x)
Y9
5 (2x) 3 (2x)
29 (2x) 28
6 (2x) 26 27 20 (2x) 21 (2x) 25 24 (3x) 23 (3x) 22 (4x) 19 18 17 16 (2x) 15 7 8 9 10 11 12
14 (2x)
8 04081293 # Toothed belt pulley
Basic Machine / Punch Adapter / Drive
- 106 -
1 (4x)
Stepping Motor
30 (2x)
9 04715470 # Toothed belt 10 00206849 Setscrew - M4x6 DIN 916 11 Ring 04081838 #
2 (4x)
Y7
4 (2x)
Y9
5 (2x) 3 (2x)
29 (2x) 28
12 04533410 Washer 13 00062847 Lock washer - DI 3.2 DIN 6799 14 00166499 Lock washer - DI 5 DIN 6799 13 (2x) 15 04078918 # Tension spring
6 (2x) 26 27 20 (2x) 21 (2x) 25 24 (3x) 23 (3x) 22 (4x) 19 18 17 16 (2x) 15 7 8 9 10 11 12
14 (2x)
16 04084632 # Roller
- 107 -
1 (4x)
Stepping Motor
30 (2x)
17 Plate
04722124
2 (4x)
Y7
4 (2x)
18 04533534 Washer 19 Tube 04553268
Y9
5 (2x) 3 (2x)
29 (2x) 28
20 00240982 # Tension spring 21 Plate 04722132
6 (2x) 26 27 20 (2x) 21 (2x) 25 24 (3x) 23 (3x) 22 (4x) 19 18 17 16 (2x) 15 7 8 9 10 11 12
22 00183334 Screw - M2x4 DINEN 1207 13 (2x) 23 04765737 Screw - M3x3x3.5 24 00055255 Washer - DI 4.3 DIN 125
14 (2x)
- 108 -
1 (4x)
Stepping Motor
30 (2x)
25 04765168 # Pressure rail 26 01487736 Screw - M4x8 DINEN 7045 27 02288389 Washer - DI 4.3 DIN 6796 28 04721853 Bracket 29 00044946 Screw - M4x12 DIN 912 30 02288389 Washer - DI 4.3 DIN 6796 13 (2x)
2 (4x)
Y7
4 (2x)
Y9
5 (2x) 3 (2x)
29 (2x) 28
6 (2x) 26 27 20 (2x) 21 (2x) 25 24 (3x) 23 (3x) 22 (4x) 19 18 17 16 (2x) 15 7 8 9 10 11 12
14 (2x)
- 109 -
2 (6x) 3 (6x)
1 04722205 Guide plate 2 01487736 Screw - M4x8 DINEN 7045
4 5
3 02288389 Washer - DI 4.3 DIN 6796 4 04720237 Guide plate 5 04720431 Side panel, cpl. 6 02288389 Washer - DI 4.3 DIN 6796 9 7 00044938 Screw - M4x10 DIN 912 8 00206849 Setscrew - M4x6 DIN 916
6 (2x) 7 (2x) 18 (2x) 15 17 16 (2x) (2x) 8 (2x)
14 (4x)
M7
11 10 13 (4x) 12 (4x)
Basic Machine / Punch Adapter / Drive / Stepping Motor
- 110 -
2 (6x) 3 (6x)
9 04078373 # Toothed belt pulley 10 04715470 # Toothed belt
4 5
11 Ring
04081838 #
6 (2x) 7 (2x) 18 (2x) 15 17 16 (2x) (2x) 8 (2x) 9 14 (4x)
12 00044946 Screw - M4x12 DIN 912 13 02288389 Washer - DI 4.3 DIN 6796 14 00146552 Nut - M4 DINEN 24032 15 02594129 # Stepping motor 16 04177398 # Deep-groove ball bearing - DI 7
M7
11 10 13 (4x) 12 (4x)
- 111 -
2 (6x) 3 (6x)
17 00166499 Lock washer - DI 5 DIN 6799 18 04794060 # Roller
4 5
6 (2x) 7 (2x) 18 (2x) 15 17 16 (2x) (2x) 8 (2x) 9 14 (4x)
M7
11 10 13 (4x) 12 (4x)
- 112 -
1 00166499 Lock washer - DI 5 DIN 6799 1 (2x) 2 04078918 # Tension spring 5 (2x)
4 (2x)
Solenoid
3 (2x) 6 (2x) 14 7 (2x) 13 (2x)
3 04084632 # Roller 4 00062847 Lock washer - DI 3.2 DIN 6799 5 04722035 Spacer - 21.5 mm, size 6 6 00206849 Setscrew - M4x6 DIN 916
11 12
10
9 (2x)
8 (2x)
7 04148762 # Spur wheel 8 00044946 Screw - M4x12 DIN 912
Basic Machine / Punch Adapter / Holder
- 113 -
9 02288389 Washer - DI 4.3 DIN 6796 1 (2x) 10 04720881 Bracket 5 (2x)
4 (2x)
Solenoid
3 (2x) 6 (2x) 14 7 (2x) 13 (2x)
11 01487736 Screw - M4x8 DINEN 7045 12 02288389 Washer - DI 4.3 DIN 6796 13 04533534 Washer 14 Plate 04722124
11 12
10
9 (2x)
8 (2x)
Basic Machine / Punch Adapter / Holder
- 114 -
2 (4x)
14 (2x) 13 (2x) 12 (2x)
Y6 3 (4x) Y8
5 1 (2x) 4
6 (6x) 7 (6x) 8
1 04244311 # Solenoid 2 00207047 Screw - M3x6 DIN 912 3 02288370 Washer - DI 3.2 DIN 6796 4 04720261 Side panel 5 04720237 Guide plate 6 01487736 Screw - M4x8 DINEN 7045
11 (2x)
10 (2x) 9 (2x)
7 02288389 Washer - DI 4.3 DIN 6796 8 04722205 Guide plate
Basic Machine / Punch Adapter / Holder / Solenoid
- 115 -
2 (4x)
14 (2x) 13 (2x) 12 (2x)
Y6 3 (4x) Y8
5 1 (2x) 4
6 (6x) 7 (6x) 8
9 04794060 # Roller 10 04177398 # Deep-groove ball bearing - DI 7 11 02288389 Washer - DI 4.3 DIN 6796 12 00044938 Screw - M4x10 DIN 912 13 04979834 # Sleeve 14 00045330 Setscrew - M3x4 DIN 916
11 (2x)
10 (2x) 9 (2x)
Basic Machine / Punch Adapter / Holder / Solenoid
- 116 -
1 S 15
1 02690764 # Safety switch 2 04313623 # Rocker-type switch 3 02690764 # Safety switch 4 01746073 # Key-operated switch
4 S 18
3 S 14
S1
Basic Machine / Power Switch, Safety Switch
- 117 -
CAUTION: This module is equipped with a Lithium battery. Observe Technical Remarks on Safety (chapter "General")!
1 04588282 # Supply cassette without reel holder and nut segment
Reel Holder
Rollers
Catch
1
Supply Cassette
-1-
2 20 21
4
1 04541332 # Reel holder, PRO 05003008 # Reel holder, offset foil (option)
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
05108667 # Reel holder, NP (option) 2 04720717 # Gear wheel 3 04541162 # Knurled screw - M5x15 4 Cap 04541065 #
14
10 9
5 04686047 PT. screw - 3x12 6 04142462 # Nut segment
19
Supply Cassette / Reel Holder
-2-
2 20 21
4
7 04080106 # Vibration damper, cpl. 8 04162404 Washer - DI 3.2
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
9 01487396 Screw - M3x6 DINEN 7046 10 04586921 # Holder (TOUCH MEMORY) 11 00207985 Screw - M4x8 DINEN 1207 12 04142195 # Transmission unit
14
10 9
13 00492302 Setscrew-M4x12 DIN 916 14 04148762 # Spur wheel
19
-3-
2 20 21
4
15 00213101 Setscrew - M4x4 DIN 916 16 04142616 # Bearing
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
17 04686039 PT. screw - 3x10 18 02533871 # Adhesive foam tape 19 04662474 Shaped plate 20 00051195 # Deep-groove ball bearing
14
10 9
21 00234397 Circlip - 9,3x4 DIN 6799 22 00195677 # Sliding bearing
19
-4-
1 17 16 (2x) 18 3 4 5 6 (2x)
1 05181305 # Gasket 2 04553101 Guide
3 04588746 # Roller 4 01608959 # Pressure spring 5 Plate 02894289
14 (2x) 13 15 (2x)
6 04242963 Screw - M3x5 DINEN 7045
12
11 10 9 (2x) 8 7
7 04013999 # Bearing 8 00052973 # Deep-groove ball bearing - DI 6
Supply Cassette / Rollers
-5-
1 17 16 (2x) 18 3 4 5 6 (2x)
9 01700758 Screw - M3x12 DINEN 7045 10 04663160 # Roller
11 00052973 # Deep-groove ball bearing - DI 6 12 04013999 # Bearing 13 04148762 # Spur wheel 14 00213101 Setscrew - M4x4 DIN 916
14 (2x) 13 15 (2x)
12
11 10 9 (2x) 8 7
15 01700758 Screw - M3x12 DINEN 7045 16 04242963 Screw - M3x5 DINEN 7045
-6-
1 17 16 (2x) 18 3 4 5 6 (2x)
17 04084845 Segment 18 01608959 # Pressure spring
14 (2x) 13 15 (2x)
12
11 10 9 (2x) 8 7
-7-
1 04270061 Catch 2 02288370 Washer - DI 3.2 DIN 6796 3 04686039 PT. screw - 3x10 4 00055352 Washer - DI 3.2 DIN 9021
1 2 3 4
Supply Cassette / Catch
-8-
1 04793307 # Supply cassette (small)
Reel Holder
Rollers
Catch
1
Supply Cassette (Small)
-9-
2 20 21
4
1 04079442 # Reel holder 2 04720717 # Gear wheel
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
3 04541162 # Knurled screw - M5x15 4 Cap 04541065 #
14
5 01487736 Screw - M4x8 DINEN 7045 6 04142462 # Nut segment
10 9
19
Supply Cassette (Small) / Reel Holder
- 10 -
2 20 21
4
9 01487396 Screw - M3x6 DINEN 7046 10 04586921 # Holder (TOUCH MEMORY)
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
11 00207985 Screw - M4x8 DINEN 1207 12 04142195 # Transmission unit 13 00492302 Setscrew-M4x12 DIN 916 14 04148762 # Spur wheel
14
10 9
19
- 11 -
2 20 21
4
17 04242963 Screw - M3x5 DINEN 7045 18 02533871 # Adhesive foam tape
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
19 04143353 Shaped plate 20 00051195 # Deep-groove ball bearing 21 00234397 Circlip - 9,3x4 DIN 6799 22 00195677 # Sliding bearing
14
10 9
23 00234397 Circlip - 9,3x4 DIN 6799
19
- 12 -
1 17 16 (2x) 18 3 4 5 6 (2x)
1 05181305 # Gasket 2 Profil 04148215
14 (2x) 13
15 (2x)
6 04242963 Screw - M3x5 DINEN 7045 7 04013999 # Bearing
12 11 10 9 (2x) 8 7
8 00052973 # Deep-groove ball bearing - DI 6
Supply Cassette (Small) / Rollers
- 13 -
1 17 16 (2x) 18 3 4 5 6 (2x)
11 00052973 # Deep-groove ball bearing - DI 6 12 04013999 # Bearing 13 04148762 # Spur wheel 14 00213101 Setscrew - M4x4 DIN 916 15 01700758 Screw - M3x12 DINEN 7045
14 (2x) 13
15 (2x)
12 11 10 9 (2x) 8 7
16 04242963 Screw - M3x5 DINEN 7045
- 14 -
1 17 16 (2x) 18 3 4 5 6 (2x)
14 (2x) 13
15 (2x)
12 11 10 9 (2x) 8 7
- 15 -
1 04270061 Catch 2 02288370 Washer - DI 3.2 DIN 6796 3 00215139 Screw - M3x5 DIN 912 4 01733680 Washer - DI 4.3
1 2 3 4
- 16 -
1 04886704 # Supply cassette (middle)
Reel Holder
Rollers
Catch
1
Supply Cassette (Middle)
- 17 -
2 20 21
4
1 04541332 # Reel holder, PRO 2 04720717 # Gear wheel
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
3 04541162 # Knurled screw - M5x15 4 Cap 04541065 #
14
5 04686047 PT. screw - 3x12 6 04142462 # Nut segment
10 9
19
Supply Cassette (Middle) / Reel Holder
- 18 -
2 20 21
4
9 01487396 Screw - M3x6 DINEN 7046 10 04586921 # Holder (TOUCH MEMORY)
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
11 00207985 Screw - M4x8 DINEN 1207 12 04142195 # Transmission unit 13 00492302 Setscrew-M4x12 DIN 916 14 04148762 # Spur wheel
14
10 9
19
- 19 -
2 20 21
4
17 04686039 PT. screw - 3x10 18 02533871 # Adhesive foam tape
17 (2x) 16 15 (2x) 13 12 11 (2x)
5 18 7 6 22 23
19 04662474 Shaped plate 20 00051195 # Deep-groove ball bearing 21 00234397 Circlip - 9,3x4 DIN 6799 22 00195677 # Sliding bearing
14
10 9
23 00234397 Circlip - 9,3x4 DIN 6799
19
- 20 -
1 17 16 (2x) 18 3 4
1 04141490 # Gasket 2 04553101 Guide
14 (2x) 13 15 (2x)
5 6 (2x)
6 04242963 Screw - M3x5 DINEN 7045
12 11 10 9 (2x) 8
7 04013999 # Bearing 8 00052973 # Deep-groove ball bearing - DI 6
7
- 21 -
Supply Cassette (Middle) / Rollers
1 17 16 (2x) 18 3 4
11 00052973 # Deep-groove ball bearing - DI 6 12 04013999 # Bearing 13 04148762 # Spur wheel 14 00213101 Setscrew - M4x4 DIN 916
14 (2x) 13 15 (2x)
5 6 (2x)
12 11 10 9 (2x) 8
15 01700758 Screw - M3x12 DINEN 7045 16 04242963 Screw - M3x5 DINEN 7045
7
- 22 -
1 17 16 (2x) 18 3 4
14 (2x) 13 15 (2x)
5 6 (2x)
12 11 10 9 (2x) 8
7
- 23 -
1 04270061 Catch 2 02288370 Washer - DI 3.2 DIN 6796 3 04686039 PT. screw - 3x10
1 2 3 4
- 24 -
1 04662652 # Collecting cassette
Cover
Housing
Collecting Cassette, Standard
- 25 -
1 2 (4x) 20 3 5 (2x) 4 (2x) 7 (2x) 6 (2x) 8 (2x) 9 (2x)
1 Reel
04662555 #
2 00213101 Setscrew - M4x4 DIN 916 3 Foil 04766261 #
4 01615912 # Tension spring 5 00225274 Straight pin - 8x12 DINEN 22338 6 00611395 Setscrew - M2.5x8 DIN 916 7 Lever 04640489
10 (2x) 11 (2x) 12 (2x) 14 (2x) 15 13 19 17 16 18 Collecting Cassette / Housing
8 00089893 Washer - DI 6.1
- 26 -
1 2 (4x) 20 3 5 (2x) 4 (2x) 7 (2x) 6 (2x) 8 (2x) 9 (2x)
9 04662792 # Handle 10 00054151 Lock washer - DI 4 DIN 6799 11 04771990 # Pressure spring 12 Shaft 04553055 #
13 00415790 Sliding bearing w. shoulder - DI 6 14 00213101 Setscrew - M4x4 DIN 916 15 04722108 # Gear wheel 16 00062847 Lock washer - DI 3.2 DIN 6799
- 27 -
1 2 (4x) 20 3 5 (2x) 4 (2x) 7 (2x) 6 (2x) 8 (2x) 9 (2x)
17 Lock 18 Pin
04586980 # 04586891 #
19 04662733 Housing 20 05181259 Gasket

- 28 -
2 (4x)
1 04640608 # Vibration damper 2 00478091 Screw - M4x12 DINEN 7045 3 02288389 Washer - DI 4.3 DIN 6796 4 04542304 # Cover
3 (4x)
1 (4x)
5 04661591 # Roller 6 04640136 Block
5 (4x) 6 (4x)
Collecting Cassette / Cover
- 29 -
1 05126126 # Collecting cassette, midlle (NP)
Cover
Housing
Collecting Cassette, Middle (NP)
- 30 -
1 2 3 5 6 10 11 12 13 19 17 16 18 14 15 7 8 9
1 Reel
05126223 #
20
8 00991015 # Washer - DI 6.1
Collecting Cassette, Middle (NP) / Housing
- 31 -
1 2 3 5 6 10 11 12 13 19 17 16 18 14 15 7 8 9
20
- 32 -
1 2 3 5 6 10 11 12 13 19 17 16 18 14 15 7 8 9
17 Lock 18 Pin
04586980 # 04586891 #
20
19 05126134 Housing 20 04848934 # Gasket
- 33 -
1 04640608 # Vibration damper 2 00478091 Screw - M4x12 DINEN 7045 3 02288389 Washer - DI 4.3 DIN 6796 4 05006155 Cover
3 4
5 04661591 # Roller 6 04640136 Block
5 6
Collecting Cassette, Middle (NP) / Cover
- 34 -
1 04794591 # Collecting cassette, short
Cover
Housing
Collecting Cassette, Short
- 35 -
1 2 (4x) 20 3 4 5 6 (2x) 7 (2x) 8 (2x) 9 (2x)
1 Reel
04846915 #
10 (2x) 11 (2x) 12 (2x) 14 (2x) 15 13 19 17 16 18 Collecting Cassette, Small / Housing
8 00991015 # Washer - DI 6.1
- 36 -
1 2 (4x) 20 3 4 5 6 (2x) 7 (2x) 8 (2x) 9 (2x)
- 37 -
1 2 (4x) 20 3 4 5 6 (2x) 7 (2x) 8 (2x) 9 (2x)
17 Lock 18 Pin
04586980 # 04586891 #
19 04847253 Housing 20 05181259 Gasket

- 38 -
2 (3x) 3 (3x)
1 04640608 # Vibration damper 2 00478091 Screw - M4x12 DINEN 7045 3 02288389 Washer - DI 4.3 DIN 6796 4 04848942 # Cover
1 (3x)
5 04661591 # Roller 6 04640136 Block
5 (3x) 6 (3x)
Collecting Cassette, Small / Cover
- 39 -
Supply cassette flap open
1 04908872 # Barcode reader pen 2 04904605 # Cable, Advantage
1 2
Barcode Reader Pen
-1-
1 2 (2x) 3 4
1 04541529 # Cover 2 02339587 Hinge 3 04244184 # Operating panel 4 04585917 Front cover 5 04556356 # Signal lamp, cpl.
7 6
A 9 10
04596773 # Lamp - 28V 40MA 6 04991729 # Flap, cpl. 7 04768361 # Gas spring
11
Covers
-2-
1 2 (2x) 3 4
8 05116155 # Cover 9 04574451 # Magnetic lock 10 04662059 # Holder 11 Flap 04640039 #
7 6
A 9 10
11
Covers
-3-
Mount
E3
2 E4
3 4 5
1 Panel 2 Panel 3 Panel
04775015 # 04640330 # 04556585 # 04557298 #
10
14 (2x) 9 8 16 (4x) 15 (4x) 13 (4x) 12 6 11
4 Panel
5 00440191 # Locking pin 6 Panel 7 Panel 8 Panel 04640446 # 04557476 # 04557557 #
7 Side Panels
-4-
Mount
E3
2 E4
3 4 5
9 Panel 10 Lock
04640330 # 01700677 #
10
11 04555953 Front cover
14 (2x) 9 8 16 (4x) 15 (4x) 13 (4x) 12 6 11
12 04643291 # EMC plate 13 Lock 01927965 #
14 04597451 # Fan, axial 15 04138589 # Roller 16 02968754 # Machine foot
7 Side Panels
-5-
1 04551532 # Mount
2 (5x) 3 (5x)
4 (8x) 5 (8x)
2 02115387 Screw - M4x6 DINEN 7046 3 00220345 Washer - DI 5 4 02115387 Screw - M4x6 DINEN 7046
5 00220345 Washer - DI 5
Side Panels / Mount
-6-
Barcode Reader Pen
Covers Collecting Cassette
Supply Cassette
Basic Machine (left)
Basic Machine (right)
Side Panels
Base
=>marked items are described in the Removal, Installation and Adjustment Instructions. Parts Catalog / Overview
-1-
Spare parts which are available for delivery are marked with #. Certain parts not inlcuded in the classification system also appear in these lists, e.g. parts required for mounting, parts belonging to the vicinity of spare parts. If necessary, we also deliver spare parts not included in the spare parts program when to do so - is technically acceptable and - does not adversely affect the quality assurance after reviewing description of fault. For parts not represented the following specifications are required: - machine type / model / system component - locality in machine / in machine component / in module - documentation reference number(s) - further features / special features (e.g. combinations of numbers / letters)
Further information on spare parts can be obtained from:
Heidelberger Druckmaschinen Aktiengesellschaft Siemenswall 24107 Kiel Germany Telephone (0431) 386-0 Telefax (0431) 386-1502
Notes on Parts Catalog
-2-
Parts manufactured for Heidelberger Druckmaschinen Aktiengesellschaft, if not covered in the documentation provided by Heidelberger Druckmaschinen Aktiengesellschaft, can be found in the manufacturer's documentation. Spare parts must be ordered exclusively from Heidelberger Druckmaschinen Aktiengesellschaft Customer Support Logistics (CSL) if not, overall warranty and quality assurance are invalid.
Further information on spare parts can be obtained from:
Heidelberger Druckmaschinen Aktiengesellschaft Siemenswall 24107 Kiel Germany Telephone (0431) 386-0 Telefax (0431) 386-1502
Notes on Parts Catalog
-3-
If required (by the customer) - Cleaning trough and loading platform - Cleaning the rubber rollers of the supply cassette; monthly When using photo material with a thickness of 0.18 mm; weekly - Cleaning the dust collecting roller of the supply cassette (option) - Cleaning the rubber rings of the collecting cassette; monthly
After every service, check the safety loop for proper funcitoning! Preventive Maintenance / Maintenance Intervals
Maintenance Control Check List

-1-
Quarterly (by the service department) - Starting the test programs - Checking the compressed air, peltier control, drain valve - Cleaning trough, loading platform and interior - Cleaning the collecting trays for punching waste - Cleaning the rubber rollers of the supply cassette - Cleaning the dust collecting roller of the supply cassette (option) - Cleaning the rubber rings of the collecting cassette - Cleaning the rubber rollers - Checking the voltages - Test exposure

-2-
Half-yearly (by the service department) - Starting the test programs - Checking the compressed air, peltier control, drain valve - Cleaning trough, loading platform and interior - Cleaning the collecting trays for punching waste - Cleaning the rubber rollers of the supply cassette - Cleaning the dust collecting roller of the supply cassette (option) - Cleaning the rubber rings of the collecting cassette - Cleaning the rubber rollers - Cleaning the prefilter case - Exchanging the compressor (after approx. 5000 operating hours) - Exchanging the line filter of the compressed air unit - Checking the voltages - Test exposure

-3-
Yearly (by the service department) - Starting the test programs - Checking the compressed air, peltier control, drain valve - Checking the elastic buffers (Loading platform) - Checking the pressure rail (Bottom punch adapter) - Cleaning trough, loading platform and interior - Cleaning the collecting trays for punching waste - Cleaning the rubber rollers of the supply cassette - Cleaning the dust collecting roller of the supply cassette (option) - Cleaning the rubber rings of the collecting cassette - Cleaning the rubber rollers - Cleaning the foam and textile rollers - Clean mirror motor and optics (checking the geometry) - Exchanging the compressor (after approx. 5000 operating hours) - Exchange all filters in the compressed air unit - Checking the voltages - Test exposure After every service, check the safety loop for proper funcitoning! Preventive Maintenance / Maintenance Intervals

-4-
Flap (left)
Trough, Loading Platform ans Interior Switch off machine, pull out power plug. Open (left) flap. Remove supply cassette. Remove front panel by pulling it out (direction of the arrow).
Front panel
Remove protective plate (loosen bayonet joints by turning through 90 degrees).
Protective plate
Preventive Maintenance / Cleaning
-5-
Trough, Loading Platform ans Interior CAUTION: Only use vacuum cleaner with plastic nozzle, otherwise, surface damages of the trough and/or spindle are possible. Clean trough and loading platform using a vacuum cleaner. Attach protective plate in such a way that the safety switch is actuated. Lock protective plate (lock bayonet joints by turning through 90 degree) in position. Insert front panel in guide and press it against the machine until it engages. Insert supply cassette. Close flap (left). Trough Collecting tray
-6-
Top Punch Switch off the machine, pull out the power plug. Pull off right-hand side panel at the upper edge Protective plate and lift out of the lower guide. Loosen screws of the protective plate (but do not unscrew), slide protective plate upwards a little and remove it. Use a vacuum cleaner to remove the punching waste from the 3 stubs. Hook protective plate into the screws, tighten screws. Insert right-hand side panel in lower guide and press against the machine until it engages.
Side panel
Stubs Preventive Maintenance / Cleaning -7-
Flap (left)
Lateral Punch Switch off machine, pull out power plug. Remove front panel. Loosen bayonet joints of the protective plate by turning through 90 degrees. Remove protective plate.
Front panel
Protective plate
Use vacuum cleaner to remove the punching waste from the collecting tray. CAUTION: Do not damage cable leading to the punch heads Attach protective plate in such a way that the safety switch is actuated. Lock protective plate in position (lock bayonet joint by turning through 90 degrees)
Trough Collecting tray
-8-
Flap (left)
Lateral Punch Insert front panel in guide and press against the machine until it engages.
Front panel
Protective plate
Trough Collecting tray
-9-
Bottom Punch Pull off left-hand side panel at the upper edge and lift out of the lower guide. Loosen screws of the protective plate (but do not unscrew). Slide protective plate upwards a little and remove it. Use a vacuum cleaner to remove the punching waste from the stub. Hook protective plate into the screws, tighten screws. Insert left-hand side panel in the lower guide and press against the machine until it engages. Side panel Protective plate
- 10 -
Rubber rollers (supply cassette) Take the supply cassette out of the machine and open it.
4 3 (2x) 1
Clean rubber rollers [1] and [2] with a damp cloth (cleaner's naphtha).
5 3 (2x)
- 11 -
Dust collecting roller (option) NOTE: To clean the dust collecting roller, remove it from the cassette!
1
4 3 (2x)
Take the supply cassette out of the machine and open it. Unscrew screws [3]. Mount segment [4] and plate [5].
5 3 (2x)
Remove the dust collecting roller from the supply cassette und clean it under running water. Allow dust collecting roller to air-dry.
- 12 -
Dust collecting roller (option) CAUTION: Install dust collecting roller only if it is dry!
1
4 3 (2x)
Insert the dust collecting roller into the supply cassette. Mount segment [4] and plate [5] and fasten with screws [3].
5 3 (2x)
- 13 -
Rubber Rings (collecting cassette) Clean the rubber rings on the collecting cassette reel if photo material with a thickness of 0.18 mm is used. Open flap, remove and open collecting cassette. Reel Clean rubber rings with a cloth soaked in methylated spirit. When doing so, turn reel manually. Close collecting cassette and insert it. Close flap.
Rubber ring
- 14 -
Rubber Rollers Switch off machine, pull out power plug. Remove flap (right). Flap (left) Flap (right)
- 15 -
Rubber Rollers 5 rubber rollers in the film exit unit (4 x short = control rollers, 1 x long = roller) Clean rubber rollers with a cloth soaked in methylated spirit. When doing so, turn rollers manually. Close flap.
Control rollers (4x) Roller
- 16 -
Foam and Textile Rollers Supply cassette: Switch off machine, pull out power plug. Flap (left) Flap (right) Open flap (left), remove supply cassette and open it. Clean foam and/or textile rollers using a brush. Close and insert supply cassette. Close flap (left).
- 17 -
Foam and Textile Rollers Trough exit: Open flaps. Flap (left) Flap (right) Remove film exit unit and cutting device. (T1) Clean foam and/or textile rollers using a brush. Install film exit unit and cutting device. (T2) Close flaps.
- 18 -
Prefilter case Remove filter unit. (T1) Unscrew filter case. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2)
Compressed air filter
- 19 -
Compressor The failure rate of the compressor increases after approx. 5000 operating hours. There is no indication of a failure in advance and thus results in a machine standstill. If the compressor has more than 5000 h (according to elapsed time meter), it should be exchanged. CAUTION: For quality analyses, the operating time of the exchanged compressor is required. Note the operating time on the return form.
Preventive Maintenance / Checking and Exchanging
- 20 -
Line filter
Line filters Pull the hoses off the line filter. Exchange line filter. CAUTION: Observe installation position! Fit hoses.
- 21 -
Replacement of all filter inserts in the compressed air unit Switch off machine, pull out power plug. Remove front panel by pulling it out (direction of the arrow). Remove EMC plate. Front panel The filter inserts of the following units must be exchanged: - line filter - prefilter (25 m) - submicrofilter (0.01 m) - compressor
EMC plate Preventive Maintenance / Checking and Exchanging - 22 -
Line filter
Line filters Pull the hoses off the line filter. Exchange line filter. CAUTION: Observe installation position! Fit hoses.
- 23 -
Prefilter (25 m) Remove filter unit. (T1) Unscrew filter case. Disassemble filter element and exchange filter. Assemble filter element and screw in. Clean filter case in the area of the sensors. Screw on filter case. Install the filter unit. (T2) Prefilter
- 24 -
Submicrofilter (0.01 m) Unscrew case of the submicrofilter (0.01 m). Exchange filter element. Clean and screw on case of the submicrofilter.
Submicrofilter
- 25 -
Compressor Remove screw and washer. Remove cover. Exchange filter element (in the cover). Insert O-ring into the groove if necessary. Screw CAUTION: Observe that the O-ring is correctly positioned! Mount cover and lock in position with screw.
Cover
- 26 -
1 (2x)
1 (2x)
Elastic buffer Check the condition and position of the elastic buffers [1] and [3].
620 mm
1 (2x) 2 3 4 1 (2x)
The outer elastic buffers [1] must adhere to the profile [2], flush with the front and outside edges. The inner elastic buffers must be flush with the front and adjacent to the outer buffers. NOTE: If there is only one elastic buffer at each side, these must be removed! Two buffers must then be adhered to each side! The elastic buffer [3] must be flush with the rear edge of the guide plate [4] and 620 mm from the right-hand side.
- 27 -
Pressure rail, bottom punch adapter 2 1 Check that the fastening screws [4] sit firmly: Remove the bottom punch pdapter. [T1] Tighten the fastening screws [4]. Grease the slots for the pressure rail [1] and the screw shafts [4] with Arconal L78. 3 4 (3x) Remove excess grease. Check the functionality of the pressure rail. Install the bottom punch pdapter. [T2]
- 28 -
Test Exposure Following the yearly maintenance, perform a test exposure. See operating manual RIP 50 or RIP 60.
- 29 -
Check the Safety Loop Switch on the machine and let it run up to operating speed. Flap (right) Move the carriage (material must not be loaded) - Press the following keys at the operating panel: or
Front panel
Protective plate
The carriage must stop, when - opening the right-hand flap OR - removing the protective plate. The carriage must continue moving, when - the protective plate is returned AND - the right-hand flap is closed.
- 30 -
Exposure Unit Lower Section Output
Prior to all service work: - switch off machine - pull out power plug NOTE: Before beginning the service work, remove corresponding side panels and EMC plates in accordance with menu item "Side Panels". SAFETY LOOP: Upon completion of repair work, the safety loop function is to be checked by opening the dust cover! Check the protective covers for completeness while reassembling them and make sure that they show no cracks or other damage.
Input / Side Panels
Punches (Option)
When performing service work to the upper section: Protect the trough against damage! Removal, Installation, Adjustment -1-
Removal, Cable Guide ECC carrier (1): - move to the middle of the machine - unscrew and remove cover Disconnect electrical connections: - pull coaxial connectors X77 and X78 off optics head - pull coaxial connectors X72 and X79 off pcb EC-CONTR. - pull flat cables X84, X85 and X86 off pcb EC-CONTR. - unscrew ground cable - pull coaxial connector XA4 off pcb RIP INTERFACE or HERK-IF (slot A08) - pull flat cables X58, X59 and X69 off pcb MODUL-CONNECT
X58, X59, X69 XA4
X72, X79, X84, X85, X86
X77 X78 Removal, Installation, Adjustment / Cable Guide -2-
NOTE: The following work must be carried out in order to dismount the coaxial cable XA4 and the air hose. X Coaxial cable: - unscrew nest (2) and pull it out for approx. 5 cm - open cable strap at cable duct (4) - remove bracket of cable duct (4) - pull coaxial cable (3) through cable duct (4) upwards Air hose: - loosen hose at compressed air unit (1) - pull hose through cable duct (4) upwards
1 View "X" 4 XA4
2 3 Removal, Installation, Adjustment / Cable Guide -3-
2 (2x)
4 (2x)
Retainer (3): - remove screws (2) - remove retainer Flat cables (1): - tilt to the side
View X 5
CAUTION: During the following work, make sure that the tapped plate (5) does not fall down. Cable guide (7): - open cable strap (8) - remove screws (4, 6) - remove cable guide
View Y
8 (2x) Y 7 X
Removal, Installation, Adjustment / Cable Guide
-4-
Installation, Cable Guide Marking 2 (2x) 3 4 (2x) Cable guide (7): - insert in machine - screw screws (4) into tapped plate (5) and tighten - screw in and tighten screw (6) - attach cable strap (8) CAUTION: During the following step, align the flat cable in such a way that the marking of the flat cable coincides with the edge of the retainer! Retainer (3): - screw on loosely using screws (2) - align flat cable (1) - tighten retainer 7 X
View X 5
View Y
8 (2x) Y
Removal, Installation, Adjustment / Cable Guide
-5-
NOTE: The following work must be carried out in order to install the coaxial cable XA4 and the air hose. X Air hose: - pull down hose through cable duct (4) - connect hose to compressed air unit (1) Coaxial cable: - pull down (3) through cable duct (4) - screw on bracket of cable duct (4) - attach cable strap to cable duct (4) - insert and screw on nest (2) CAUTION: After assembly, make sure that the cable duct is light-proof!
1 View "X" 4 XA4
2 3 Removal, Installation, Adjustment / Cable Guide -6-
X58, X59, X69 XA4
X72, X79, X84, X85, X86
Establish electrical connections: - plug flat cables X58, X59 and X69 onto pcb MODUL-CONNECT - plug coaxial connector XA4 onto pcb RIP INTERFACE or HERK-IF (slot A08) - screw on ground cable - plug flat cables X84, X85 and X86 onto pcb EC-CONTR. - plug coaxial connectors X72 and X79 onto pcb EC-CONTR. - plug coaxial connectors X77 and X78 onto optics head ECC carrier (1): - screw on cover
X77 X78 Removal, Installation, Adjustment / Cable Guide -7-
Optics Head Removal Cut cable straps A, B and C. X83 Unscrew and remove cover [1] of ECC carrier [2]. C 2 1 Unscrew bracket [6]. Pull connectors X74, X77 and X78 off the optics head [5]. 6 A Pull X83 connector off pcb EC-CONTR.
X77 X78 X74 B 5
3 4
Removal, Installation, Adjustment / Optics Head
-8-
The laser diode must never be operated if the optics head is removed! Optics Head Removal Loosen screws [4] and pull bracket [3] off the optics head. 11 CAUTION: During the following work, make sure that the optics head [5] cannot fall down. Loosen screws [8] (do not unscrew). 10 9 (4x) 3 4 5 7 8 (4x) Lower the plate [7] until the optics head [5] can be moved. Remove the optics head from the machine.
-9-
The laser diode must never be operated if the optics head is removed! Optics Head Installation CAUTION: Prior to installation, note down the value for I (max) which is shown on the optics head! Insert optics head [5] in the holder [10] and slide it up to the stop. CAUTION: The straight pin [11] of the optics head must be positioned in the guide groove of the carrier! Tighten screws [8] until the optics head is securely positioned in the prism of the carrier. CAUTION: The bushings [9] (4x) must be positioned in the bore holes of the plate [7]. Press the bracket [3] onto the optics head and tighten screws [4].
11
10 9 (4x)
3 4 5 7 8 (4x)
- 10 -
Optics Head Installation X83 Connect connector X74, X77 and X78 to the optics head. Connect connector X83 to pcb EC-CONTR. C 2 1 Attach cable straps A, B and C and tighten manually. CAUTION: Fasten coaxial cable in such a way that it is squeezed when the exposure unit moves. A Screw on plate [6] (do not squeeze cable) Screw cover [1] onto ECC carrier [2]. X77 X78 X74 B 5 Removal, Installation, Adjustment / Optics Head 3 4 Perform parameter set-up.
- 11 -
8 10 (2x)
7 1
Rotating Mirror Unit Removal Pull off connector X71. Pull off air duct [3]. Loosen stop screw [9]. Turn out screws [10] and remove fishplate [8].
9 6
X71 6 11 5 (4x) 4
2 3
CAUTION: During the following work, make sure that the rotating mirror unit [2] cannot fall down. Loosen screws [5] (do not unscrew). Lower plate [4] until the rotating mirror unit [2] can be moved. Remove the rotating mirror unit [2] from the machine. Remove straight pin [7].
Removal, Installation, Adjustment / Rotating Mirror Unit
- 12 -
8 10 (2x)
7 1
Rotating Mirror Unit Installation Screw in straight pin [7]. Insert rotating mirror unit [2] in the holder [6] and slide it up to the stop. CAUTION: The straight pin [7] of the rotating mirror unit must be positioned in the guide groove of the carrier [1]! Tighten screws [5] until rotating mirror unit is securely positioned in the prism of the carrier. CAUTION: The bushings [11] (4x) must be positioned in the bore holes of the plate [4]. Fasten fishplate [8] onto the carrier using screws.
9 6
X71 6 11 5 (4x) 4
2 3
- 13 -
8 10 (2x)
7 1
Rotating Mirror Unit Installation Tighten stop screw [9] to a torque of 0.1 Nm. Fit connector X71. Fit air duct [3].
9 6
X71 6 11 5 (4x) 4
2 3
- 14 -
Stepping Motor Removal Remove covers and coverings. (T1) Remove transport safeguard [1] and distance plate [2].
1 3 4 2 M8 8
Removal, Installation, Adjustment / Stepping Motor
- 15 -
6 (4x)
M8
View X 5
Stepping Motor Removal CAUTION: Do no loosen stopper [8 and 10] fixing screws [6 and 12]! Pull connector X143 off stepping motor. Loosen screws [13] until the ring [5] no longer jams the spindle end [14]. Pull the stepping motor [3] out of the spindle end [14] and stoppers [8 and 10].
14 6 7 8 X 9 (4x) 13 (2x)
12 10 11
Remove screws [6]. Remove lever [4] from stepping motor [3].
- 16 -
6 (4x)
M8
View X 5
Stepping Motor Installation CAUTION: Do no loosen stopper [8 and 10] fixing screws [6 and 12]! Turn spindle [14] so that the spindle slot is in vertical position! Fasten lever [4] onto stepping motor [3] using screws, but do not tighten screws [6]. Place stepping motor with lever into the spindle end [14] and stoppers [8 and 10]. Tighten screws [6]. Set a distance of 0.5 mm between lever [4] and stopper [8 or 10] (View Y).
14 6 7 8 X 9 (4x) 13 (2x)
12 Y 10 11
View Y
4 0.5 mm
8 or 10
- 17 -
6 (4x)
M8
View X 5
Stepping Motor Installation Turn ring [5] until the ring slot is at an angle of 90 to the spindle slot. Tighten screw [13].
14 6 7 8 X 9 (4x) 13 (2x)
12 10 11
- 18 -
Stepping Motor Installation Mount distance plate [2] and transport safeguards [1]. Fit connector X143 onto stepping motor. Mount covers and coverings.
1 3 4 2 M8 8
- 19 -
Flywheel Functions Test Use an adhesive tape to attach a thread to the flywheel [3]. Hook a spring balance into the thread, pull it in the direction of the arrow and measure the tractive force; tractive force 0.45 +0.1 N. If the tractive force is not achieved, exchange the flywheel.
4 1 2 3
Removal, Installation, Adjustment / Flywheel
- 20 -
Flywheel Removal Remove stepping motor [1]. (T1) Pull ring [2] off the spindle. Loosen the setscrew of the flywheel [3]. Pul flywheel off the spindle.
4 1 2 3
- 21 -
Flywheel Installation Degrease the spindle end. Slide flywheel [3] onto the spindle. Distance to nut [4]: 0.2 mm. Tighten the setscrews of the flywheel. Install the stepping motor [1]. (T1)
4 1 2 3
- 22 -
CAUTION: Before installing the spindle, measure the diameter of the spindle passage A ! The removal and installation of the spindle must be performed according to the diameter (46 mm or 49 mm)!
Removal, Installation, Adjustment / Spindle
- 23 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Remove covers and coverings. (T1) Protect the trough (e.g. cover with film). Remove pcb EC-CONTROL with box. (T2) Remove screws [1]. Turn spindle nut [2] out of the flange. Unscrew flange [5] from holder [14].
13 (4x)
- 24 -
A = 46 mm Spindle Removal Remove flywheel [16] and stepping motor [15]. (T3) Mark position of bearing [21]. Remove bearing.
17 15 16 18 20
19
21 - 25 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Pull carriage with spindle [3] out of the bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindle and mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.
13 (4x)
- 26 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Move the carriage to the center. Move spindle in the direction of the floating bearing until the spindle end has no longer contact with the fixed bearing side. Lift spindle end and take the spindle with the flange [5] out of the holder [14].
13 (4x)
- 27 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Mount flange [5] onto spindle [3]. Insert the spindle into the holder [14] and move it in the direction of the floating bearing until the spindle end has no longer contact with the fixed bearing side. Move spindle to the fixed bearing side. Move carriage to the fixed bearing side.
13 (4x)
- 28 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle. Screw in clamping screw [8] but do not tighten it! Insert ball bearing [10] into the ring [11] exerting uniform pressure. CAUTION: Observe installation position! Place ring with ball bearing onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring [11] and ball bearing [10] into the bearing unit.
13 (4x)
- 29 -
A = 46 mm Spindle Installation Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 1 Nm. Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward. 17 15 16 18 20 21 - 30 19
A = 46 mm Spindle Installation Install flywheel [16] and stepping motor [15]. (T1)
17 15 16 18 20
19
21 - 31 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation NOTE: The carriage must be at the fixed bearing side. Screw flange [5] onto the holder [14]. Press carriage with flange against the spindle nut. Use your hand to lightly tighten the box nut of the flange. Fit metal needle (dia. of 2.5 mm) into a bore hole at the outside of the box nut.
13 (4x)
- 32 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Tighten box nut by 35 5 (angle distance of bore holes = 30). This setting corresponds to a torque of 4.6 1 Nm. Tighten screw [4] to a torque of 0.4 0.05 Nm. Pull the carriage with the flange off the spindle nut and then press carriage and flange against the spindle nut again. It must be possible to move the spindle nut into the flange and out of the flange smoothly and noiselessly. If necessary, loosen the screws [13] and tighten them again.
13 (4x)
- 33 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Move carriage to the center. Turn in the screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].
13 (4x)
- 34 -
A = 46 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Set distance X between bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Install pcb EC-CONTROL. (T2) A X Remove the trough protection. Mount coverings and covers.
13 (4x)
8 Removal, Installation, Adjustment / Spindle - 35 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Remove covers and coverings (T1). Protect the trough (e.g. cover with film). Remove screws [1]. Turn spindle nut [2] out of the flange.
13 (4x)
- 36 -
A = 49 mm Spindle Removal Remove flywheel [16] and stepping motor [15]. (T2) Mark position of bearing [21]. Remove bearing.
17 15 16 18 20
19
21 - 37 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Pull carriage with spindle [3] out of the bearing block. Pull ring [11] off the ball bearing [10]. Remove circlip [12]. Pull ball bearing [10] off the spindle and mark installation position. Loosen clamping screw [8]. Pull bushing [9], hose [7] and sliding bearing [6] off the spindle.
13 (4x)
- 38 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Removal Move carriage with spindle to the fixed bearing side. Take the spindle out of the machine through the bore hole at the front.
13 (4x)
- 39 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Move the carriage to the fixed bearing side. Carefully slide spindle [3] through the front bore hole, the flange [5] and the holder [14]. Mount sliding bearing [6], hose [7] and bushing [9] onto the spindle. Screw in clamping screw [8] but do not tighten it! Insert ball bearing [10] into the ring [11] exerting uniform pressure.
13 (4x)
- 40 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation CAUTION: Observe installation position! Place ring [11] with ball bearing [10] onto the spindle. Mount circlip [12]. Carefully slide the spindle with the ring and ball bearing into the bearing unit.
13 (4x)
- 41 -
A = 49 mm Spindle Installation Mount bearing [21]. Observe installation position! Turn nut [17] onto the spindle and tighten to a torque of 9 1 Nm. Use an open-end wrench at the other end of the spindle to secure it against turning. Insert the protective plate in the bore hole of the nut [17] and tighten locking screw [18]. The labeling of the spindle and the marking of the spindle nut must face upward. 17 15 16 18 20 21 - 42 19
A = 49 mm Spindle Installation Install flywheel [16] and stepping motor [15]. (T1)
17 15 16 18 20
19
21 - 43 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Move the carriage to the center. Press carriage with flange against the spindle nut. Turn in screws [1] and fasten the spindle nut onto the flange but do not tighten the screws. Move the carriage to the fixed bearing side. Tighten the upper screws of the spindle nut. Move the carriage to the center. Tighten the lower screws of the spindle nut. Loosen the clamping screw [8].
13 (4x)
- 44 -
A = 49 mm 2 3 1 (4x) 4 5 6 7 14 8 9 10 11 12 Spindle Installation Set distance X between bushing [9] and ring [11] (see Ill. A): X = 62 - 0.5 mm (Herkules) X = 165 - 0.5 mm (Herkules M) Tighten clamping screws [8]. Move the carriage in both directions for 5 times and remove excess grease. Remove the trough protection. A X Mount coverings and covers.
13 (4x)
8 Removal, Installation, Adjustment / Spindle - 45 -
2 (8x) 1 3 (8x) 7 8 9 (4x) 10
4 5 6 (4x) Removal Manually move the carriage to the machine center. Remove the screws [4 and 6] from the cover [5]. Carefully lift the cover and pull the fan cable off pcb EC-CONTROL [1]. Remove the cover. Remove all connectors from pcb EC-CONTROL. Remove the screws [2]. Slide pcb EC-CONTROL under the cable and take it out of the machine.
Removal, Installation, Adjustment / Pcb EC-CONTROL
- 46 -
2 (8x) 1 3 (8x) 7 8 9 (4x) 10
4 5 6 (4x) Removal Unscrew the cable guide [7] from the box [10]. Remove the flat cable [8] from the box. Screw out the screws [9] and remove the box.
- 47 -
2 (8x) 1 3 (8x) 7 8 9 (4x) 10
4 5 6 (4x) Installation Mount box [10] onto the carriage. Clamp the flat cable [8] onto the box. Fasten the cable guide [7] onto the box using screws. CAUTION: The photo diode of pcb EC-CONTROL [1] must be fit into the centering of the ECC carrier! Position pcb EC-CONTROL in the box and screw on lightly. Plug all connectors onto the pcb.
- 48 -
Pcb Installation K3 X73 S2 Start the diagnostic software DIAGHERK. Call up test program 49 - Input: r49 Abort the test - Input: STOP S2 (HS4) max. amplitude Connect the oscilloscope to S2 and X73. Move the pcb until the signal to your left appears (max. symmetry amplitude). Tighten the screws of the pcb. Plug the fan cable onto the pcb and mount the cover. 40 ... 90 secs Removal, Installation, Adjustment / Pcb EC-CONTROL - 49 -
X73 (SOL)
Installation Mount pressure spring [8] between bracket [5] and pcb MAT-WIDTH I [9]. Insert screw [10] with LOCTITE 222 and set a distance of 6 0.2 mm between pcb MAT-WIDTH I [9] and bracket [5]. 6 0,2 8 5 Fit connector X 87. Perform alignment according to: Pcb MAT-WIDTH I Alignment (T1).
10
Removal, Installation, Adjustment / Pcb MAT-WIDTH I
- 50 -
Order No. 04699629 Alignment

BARCODE
X2
Film material required: - Reference film (20% screen or transparent unexposed infrared film) - Black film (100% black). Remove loading platform (T1).
X87
R5
R6
Start test software (T2) Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Pcb MAT-WIDTH I (6.004)
- 51 -
Order No. 04699629

BARCODE
X2
Display: Bit sequence 7654 3210 - Bit 4 = 1 > Film is in both opto switches - Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION: Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.
X87
R5
R6
- 52 -
Order No. 04699629 Cover right-hand opto switch with the black film.
BARCODE
So adjust left-hand pot (R5) that bit 4 changes from "0" to "1".
X2
X87
Perform a test at the end positions and in the middle of the travel: - without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1".
R5 R6
Install loading platform (T3). Note: If the setting is not possible alter the distance between pcb and carrier.
- 53 -
Preparations: - switch off machine Rear panel: - remove from upper edge - lift out of lower guide Mac, PC with terminal emulation or WYSE terminal: - connect using VT 100 connector (SERVICE) Insert floppy disk. Switch on Mac, PC with terminal emulation or WYSE terminal. Switch on Herkules. Input: R0 <ENTER> Check configuration.
Starting the Test Software
- 54 -
Installation Mount pcb MAT-WIDTH II. 5,5 X2 Check that there is a distance of 5.5 mm between pcb and bracket; if necessary, turn screws (1). Fit connectors X2 and X 87. Perform alignment according to: Pcb MAT-WIDTH II Alignment (T1). X87
1 ( 6x)
Removal, Installation, Adjustment / Pcb MAT-WIDTH II
- 55 -

X87 X2
R5
R6
Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2) Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
Pcb MAT-WIDTH II (6.063)
- 56 -
Order No. 04700805 Display: Bit sequence 7654 3210 - Bit 4 = 1 > Film is in opto switch - Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch.
R5 R6
X87 X2
Caution: Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution: At the ends of the reflection strip, the film must be safely recognized.
- 57 -
Order No. 04700805 Stop test 82 Input: stop

X87 X2
<Enter>
Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] Input: y Input: y Input: y <Enter> <Enter> <Enter> <Enter>
R5
R6
So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution: At the ends of the reflection strip, the film must be safely recognized.
- 58 -
Order No. 04700805 Install loading platform (T3).

X87 X2
Note: If the setting is not possible alter the distance between pcb and carrier.
R5
R6
- 59 -
- 60 -
Supply cassette flap
Barcode Reader Pen Removal 15 40 75 Reader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.
A
280 750
All dimension in mm
Supply cassette
Removal and Installation / Barcode Reader Pen
-1-
1 Barcode Reader Pen Removal Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: E Unscrew the cable holder [2]. Do not remove the cable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6]. 3 2 XA7 6 3 -2-
4 5
1 Barcode Reader Pen Removal Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. E Disconnector connectors [1] and take out the cable.
4 5
XA7 6
3 -3-
Barcode Reader Pen Installation 15 40 75 Reader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them (hand-tight).
A
280 750
All dimension in mm
Supply cassette
-4-
1 Barcode Reader Pen Installation Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: E Lower cable: Unscrew the cable holder [2]. Do not take off the cable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. 3 2 XA7 6 3 -5-
4 5
1 Barcode Reader Pen Installation Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. E Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.
4 5
XA7 6
3 -6-
Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen Transferring the parameters to the recorder software via the service terminal.
NOTE: After the parameter set-up, reset the recorder by switching it off and then on again.
Parameter Set-up of Advantage Option
-7-
Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor. Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.
Transferring the parameters to the recorder software via the service terminal.
-8-
Parameter PID 527 'Use Online Processor' Transfer parameter using the user software. - Press the following key at the operating panel: - General imagesetter parameter set-up: If the parameter record is not "static data": - Press the following keys to select the parameter:
- Press the following keys in succession to edit the parameter:
- To save the parameter after editing, press the following keys: Return to "Edit Parameter" menu Save the parameter
- To return to the main menu, press the following key repeatedly: Parameter Set-up of Advantage Option
-9-
General imagesetter parameter set-up Select parameter record To jump to the level below the current one, press the following key:
To select the parameter record, press the following key repeatedly:
To jump to the next higher level, press the following key:
- 10 -
Input / Side Panels
Punches (Option)
Removal Remove pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). NOTE: Before replacing any components, check whether the fault occurred due to bad pressure spring contact. Lift the pressure spring a little and remove the TOUCH MEMORY to the side. TOUCH MEMORY 4K x 1 TOUCH MEMORY + Timer CAUTION: Do not bend the pressure spring.
Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)
-2-
Installation If necessary, tension the pressure spring before installing it. Insert the TOUCH MEMORY from the side. CAUTION: Do not bend the pressure spring. Insert pcb MAINCONTROLLER (slot A04/05) and pcb FEED-CONTROL (slot A06). Perform parameter set-up. TOUCH MEMORY 4K x 1 TOUCH MEMORY + Timer
Removal, Installation, Adjustment / TOUCH MEMORY (Motherboard)
-3-
Removal Press the flap [4] against the plug-in connector [1] and hold it. 2 3 4 5 Pull the hose [5] out of the plug-in connector.
Removal, Installation, Adjustment / Vacuum Hoses
-4-
Installation CAUTION: Cut the hose [5] straight! 2 3 4 5 Insert the hose into the plug-in connector [1] until you can feel the resistance of the collet [3]. Exert pressure to slide the hose through the O-ring [2] (approx. 2-3 mm). Slightly pull back the hose (flap [4] has a distance of approx. 1 mm to the plug-in connector).
Removal, Installation, Adjustment / Vacuum Hoses
-5-
Input / Side Panels
Punches (Option)
General Notes Rear panel Large side panel Side panels / rear panel / front panel: - remove by pulling them out NOTE: Remove large side panels before removing the small side panels. EMC plate: - loosen bayonet joint - remove EMC plate
Right
Left Front panel EMC plate Small side panels
Removal, Installation, Adjustment / Side Panels
-2-
Guide Panels, Antistatic Rails
Caution: Remove the loading platform before exchanging individual components!
Loading Platform
Stepping Motor M6
Cassette Polling Unit
Rewind Motor M5
Removal, Installation, Adjustment / Loading Platform
-3-
Loading Platform Removal Switch off the machine, pull out the power plug. 1 2 Remove supply cassette. Remove side panels [3, 4 and 5]. Remove rear panel [6] and EMC plate [7]. Open the dust cover [2]. Loosen the screw used to attach the gas spring [1] to the inner side of the dust cover. 5 4 3 Swing dust cover to the rear.
6, 7
-4-
10
11 (7x) 12 (7x)
Loading Platform Removal Remove lateral screw [9] with washer [10]. Remove screws [11] with washers [12].
Lift the cassette mount [8] out of the machine. Pull connector X52 off pcb MODULE-CONNECT.
Pcb MODULE-CONNECT
-5-
14 (4x)
Loading Platform Removal CAUTION: Do not loosen the guide disks screws (the screws are secured with gray varnish)!
13
Loosen the screws [14]. Lightly lift laoding platform, pull it to the rear and lift it out of the machine. Lift loading platform out of the machine.
-6-
14 (4x)
Loading Platform Installation CAUTION: Do not loosen the guide disks screws (the screws are secured with gray varnish)!
13
Insert the loading platform [13] in the machine. The guide disks must be positioned in the bore holes of the loading platform. Tighten screws [14].
-7-
10
11 (7x) 12 (7x)
Loading Platform Installation Connect connector X52 to pcb MODULE-CONNECT. Insert cassette mount [8] in the machine.
Turn in screws [9] and [11] with washers [10 and 12].
Pcb MODULE-CONNECT
-8-
Loading Platform Installation Mount the gas spring [1] onto the inner side of the dust cover. 1 2 Close dust cover [2]. Mount coverings [3...7]. Insert the supply cassette. 6, 7
5 4 3
-9-
Removal X NOTE: Antistatic rails [4] are found under the guide panels [2]. Guide panels [2]: - remove 5 fixing screws with washers [1] each time - remove Antistatic rails [4]: - remove 5 fixing screws with washers [3] each time - remove
3 (5x)
1 (5x) 2
View X Removal, Installation, Adjustment / Loading Platform / Guide Panels
- 10 -
Installation X Antistatic rails [4]: - insert - screw in 5 fixing screws with washers [3] each time Guide panels [2]: - insert - screw in 5 fixing screws with washers [1] each time CAUTION: The brushes of the antistatic rails [4] must not become caught under the beading of the guide panels [2]!
3 (5x)
1 (5x) 2
View X Removal, Installation, Adjustment / Loading Platform / Guide Panels
- 11 -
Removal Coverings: - remove Guide: -remove Cable (red, gray): - pull off Two setscrews: - loosen Setscrew (2x) Polling unit: - slide in direction of the arrow - remove
Cable, red Cable, gray
Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit
- 12 -
Installation Polling unit: - insert into the guide - slide in direction of the arrow CAUTION: Observe installation measure 318 mm (sensor center)! Two setscrews: - tighten manually Setscrew (2x) Cable (red, gray): - plug on Guide: - insert Cable, red Cable, gray Coverings: - mount
318
Removal, Installation, Adjustment / Loading Platform / Cassette Polling Unit
- 13 -
8 (4x) 5
Removal Loading platform: - remove 1 Cable strap: - remove between X93 and stepping motor Connector X93: - pull off CAUTION: During the following work, make sure that the stepping motor [1] cannot fall down! 6 Circlip [2]: - remove Spring [3]: - unhook on both sides
4 9 2
10 7 4x
Removal, Installation, Adjustment / Loading Platform / Stepping Motor M6
- 14 -
8 (4x) 5
Removal Stepping motor [1]: - pull with bracket [4] off pin [5] 1 Nuts [6] with washers [7]: - remove Stepping motor [1]: - remove from bracket [4]
4 9 2
Two setscrews [10]: - loosen Pin [9]: - pull off motor shaft with installed spur wheel [11] For the replacement of pin [9]: - dismount spur wheel [11] where necessary
10 7 4x 6
- 15 -
Installation Spur wheel [11]: - fasten to pin [9] where necessary Pin [9] with spur wheel [11]: - slide on the motor shaft Two setscrews [10]: - tighten NOTE: Observe installation measurement (Ill. A)! Stepping motor [1]: - fasten to bracket [4] with screws [8], washers [7] and nuts [6] CAUTION: Observe installation position of the motor! 6.5 Ill. A - 16 -
M6
Pin
Stepping motor
Installation Pin [5]: - grease slightly with Arcanol L78 Stepping motor [1] with bracket [4]: - slide on the pin [5] Circlip [2]: - slide on Spring [3]: - hook in on both sides Connector X93: - plug Pin Stepping motor Cable strap: - fasten between X93 and stepping motor Loading platform: - install 6.5 Ill. A - 17 -
M6
Removal 1 4 Supply cassette: - remove where necessary Loading platform: - remove Two cables (gray, red): - unsolder from machine Cable strap: - remove Circlip [1]: - remove 4 Spring [2] - unhook on both sides Rewind motor [3]: - pull out of bushing [4] in the direction of the arrow
2 3
Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5
- 18 -
Removal Exchange defective parts: - spur wheel [1] - gear wheel [2] - microswitch [3] - DC motor with gear unit [4]
3 1
- 19 -
Installation 1 4 Rewind motor [3]: - insert in bushing [4] contrary to the direction of the arrow Spring [2]: - hook in on both sides Circlip [1]: - mount 2 3 4
1 Removal, Installation, Adjustment / Loading Platform / Rewind Motor M5 - 20 -
Installation Solder two cables onto the machine: - red, left side -> plus (see Ill.) - gray, right side -> minus Cable: - fasten with cable strap Loading platform: - install Capacitor red + gray
When connecting, observe correct polarity!
- 21 -
Solenoid, Left
Bottom Punch Adapter
Solenoid, Right
Removal, Installation, Adjustment / Bottom Punch
- 22 -
Removal 1 (4x) Remove the loading platform. (T1) Disconnect the connector X91. Remove the fixing screws [1]. Remove the bottom punch adapter from the machine.
Removal, Installation, Adjustment / Bottom Punch Adapter
- 23 -
Installation 1 (4x) Insert the bottom punch adapter in the machine. Use the screws [1] to fasten the bottom punch adapter onto the trough. Connect the connector X91. Install the loading platform. (T1)
Removal, Installation, Adjustment / Bottom Punch Adapter
- 24 -
Removal Pull the flat connector off the solenoid [1]. Turn out the screws [5] and remove the solenoid. Loosen the setscrew [2] and pull the sleeve [3] off the magnet armature.
2 1 3 Y2 7 (2x)
4 (2x) 5 (2x) 6
8 (2x)
Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Left
- 25 -
Installation X GY OG Slide the sleeve [3] onto the magne armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. 3 Y2 7 (2x) Connect the flat connector, observe polarity. 4 (2x) 5 (2x) 6 Install the bottom punch adapter and adjust the solenoid.
2 1
8 (2x)
- 26 -
Adjustment A Armature pulled out 1 Loosen the solenoid fixing screws. With the armature pushed back, slide the solenoid against the pressure rail [1] until the pressure rail can no longer be moved (Ill. A). Tighten the solenoid fixing screws. Release the armature: The pressure rail must push back the armature smoothly. 1 Push back the aramture completely: There must be a gap between the armature and the pressure rail (Ill. B).
Armature pushed back
Gap
- 27 -
Removal Pull the flat connector off the solenoid [3]. Turn out the screws [7] and remove the solenoid. Loosen the setscrew [1] and pull the sleeve [2] off the magnet armature. 8 (2x) 1
7 (2x)
5 (2x) 6 (2x) 4 Y1 3
Removal, Installation, Adjustment / Bottom Punch Adapter / Solenoid, Right
- 28 -
Installation X OG GY Fit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 0.2 mm. Tighten the setscrew [1]. 7 (2x) 8 (2x) 1 Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observe polarity. 5 (2x) 6 (2x) 4 Y1 3 2 Install the bottom punch adapter and adjust the solenoid.
- 29 -
Gap
- 30 -
Barcode Reader Pen Removal 15 40 75 Reader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. Cut cable straps A, B and C.
A
280 750
All dimension in mm
Supply cassette
- 31 -
1 Barcode Reader Pen Removal Remove the rear panel. Disconnect the connectors [1]. Remove the reader pen from the holder. Lower cable: E Unscrew the cable holder [2]. Do not remove the cable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. Pull off the supply voltage connector [6]. 3 2 XA7 6 3 - 32 -
4 5
1 Barcode Reader Pen Removal Pull off connector XA7. Pull the cable with the connector through cable passage D into the exposure compartment. Cut cable strap E. E Disconnector connectors [1] and take out the cable.
4 5
XA7 6
3 - 33 -
Barcode Reader Pen Installation 15 40 75 Reader pen and upper cable: Open the supply cassette flap. Remove the cassette. Remove the cassette insert. If necessary, drill holes (3.6 mm) for the reader pen holder and mount the holder. Insert the reader pen into the holder. Attach cable straps A, B and C and tighten them (hand-tight).
A
280 750
All dimension in mm
Supply cassette
- 34 -
1 Barcode Reader Pen Installation Remove the rear panel. Insert the cable from above into the exposure compartment. Connect connectors [1]: E Lower cable: Unscrew the cable holder [2]. Do not take off the cable. Remove the screws [3] from the electronics rack and pull the rack to the front. Loosen the screws of the left holding bracket [4]. Remove the screws from the right holding bracket [5]. Pull the right holding bracket with the cable harness to the side. 3 2 XA7 6 3 - 35 -
4 5
1 Barcode Reader Pen Installation Fit connector XA7. Fit the supply voltage connector [6]. Pull the cable with the connector through cable passage D into the exposure compartment. E Attach cable strap E and tighten it (hand-tight). Connect connectors [1]. Fasten holding bracket [4] and [5] using screws. Insert the electronics rack and screw tight. Screw on the cable holder [2]. Attach the rear panel.
4 5
XA7 6
3 - 36 -
Input / Side Panels
Punches (Option)
Stepping Motor M3
Prior to removing components or parts, remove the complete film exit unit!
Film Exit Unit, cpl. Diode Holder Roller Threaded Rod
Front Guide Panel Holder Assembly Control Rollers Rear Guide Panel Motor M14 Stepping Motor M2 Solenoid
Removal, Installation, Adjustment / Film Exit Unit -2-
Motor M1
Removal Open flap. Remove collecting cassette where appropriate. 1 Disconnect electrical connection 2 (10x) X54. 3 (10x) Remove 10 fixing screws [2]. Tilt film exit unit [1] slightly forward and pull it out carefully.
Removal, Installation, Adjustment / Film Exit Unit
-3-
Installation Carefully insert film exit unit [1]. NOTE: Screw in marked screw (x) first! 1 2 (10x) x 3 (10x) Loosely screw in fixing screws [2]. Tighten fixing screws [2]. If necessary, insert collecting cassette and close flap. Establish electrical connection X54.
Removal, Installation, Adjustment / Film Exit Unit
-4-
Removal 2 1 Cut the cable strap at the diode holder [6]. 3 Pull off flat cable [9]. Loosen screw [1] (approx. 1 revolution). 6 4 5 B9 9 7 Move block [2] to the left across the assembly opening in the shaped strip [7]. CAUTION: Do not lose the washer [3]! Manually turn the threaded rod [8] until the diode holder [6] no longer touches the threaded rod.
Removal, Installation, Adjustment / Film Exit Unit / Diode Holder
-5-
Removal 2 1 Remove the diode holder through the assembly opening. 3 Remove screw [4]. Remove tapped plate [5] from the diode holder. 6 4 5 B9 9 7
-6-
Installation 2 1 Insert tapped plate [5] int diode holder [6] and secure in position using screw [4]. Insert the diode holder through the assembly opening of the shaped strip [7] and push it against the threaded rod [8]. Turn threaded rod into the tapped plate [5]. Place washer [3] onto the threaded rod shoulder. Push bearing block [2] against the threaded rod and tighten screw [1] (approx. 1 revolution).
6 4 5
B9 9
-7-
Installation 2 1 Lightly grease threaded rod using LOSOID 1160B. 3 Fit flat cable [9]. Fasten cable using cable straps. 6 4 5 7 9 Perform parameter set-up.
B9
-8-
8 2 1 9 3 10
Removal Remove the toothed belt [12] from the toothed belt pulley [11]. Cut the cable strap at the diode holder [6]. Disconnect the electrical connection. Loosen the screw [1] (approx. 1 revolution). Move the block [2] to the left across the assembly opening in the shaped strip [7].
7 4 5 6
18 17
16
13 (2x) 12 11
CAUTION: Do not lose the washer [3]! Manually turn the threaded rod [18] until the diode holder [6] no longer touches the threaded rod. -9-
15 (3x) 14
Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod
8 2 1 9 3 10
Removal Remove the screw [10] with the washer [9] and spacer [8]. Pull the threaded rod out of the film exit unit. Loosen the setscrew [13] by one revolution. Pull the toothed belt pulley [11] and the ring [14] off the threaded rod. Pull the washers [15], ball bearing [16] and bushing [17] off the threaded rod.
7 4 5 6
18 17
16
13 (2x) 12 11
15 (3x) 14 Removal, Installation, Adjustment / Film Exit Unit / Threaded Rod - 10 -
8 2 1 9 3 10
Installation Slide the bushing [17], the ball bearing [16] and the washers [15] onto threaded rod [18]. Slide the ring [14] and the toothed belt pulley [11] and lock in position using setscrews [13].
7 4 5 6
Insert the threaded rod in the film exit unit. Insert the ball bearing [16] in the bore hole of the housing. 13 (2x) 12 17 15 (3x) 14 11 Place the washer [9] and spacer [8] onto the screw [10]. Turn in the screw [10] using Loctite 222 and tighten it slightly.
18
16
- 11 -
8 2 1 9 3 10
Installation Insert the diode holder [6] through the assembly opening of the shaped strip [7] and slide it up to the threaded rod [18]. Turn the threaded rod into the tapped plate [5].
7 4 5 6
Mount the washer [3] onto the sholder of the threaded rod. Slide the bearing block [2] against the threaded rod and tighten the screw [1] (approx. 1 revolution). 16 17 15 (3x) 14 13 (2x) 12 11 Lightly grease the threaded rod using LOSOID 1160B. Establish the electrical connection.
18
- 12 -
8 2 1 9 3 10
Installation Fasten the cable using cable straps. Check axial backlash: - diode holder -> no backlash - threaded rod -> max. backlash 0.2 mm
7 4 5 6
Position the toothed belt [2] onto toothed belt pulley [11]. NOTE: It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side. 11 15 (3x) 14 Perform the paramter set-up.
18 17
16
13 (2x) 12
- 13 -
Removal Remove cable strap. Unsolder red (+) and gray ( - ) cables. Spur wheel [1]: - loosen two setscrews [2] - pull spur wheel off the motor shaft X 2 Side panel When connecting, observe correct polarity! red + View X Removal, Installation, Adjustment / Film Exit Unit / Motor M1 - 14 gray CAUTION: Observe installation position of the stepping motor and, if necessary, mark it! Motor [3]: - remove three fixing screws [4] with washers [5] - remove motor
1 4
M1
Installation Motor [3]: - insert in correct installation position - fasten with three fixing screws [4] and washers [5] 5 3 Fixing screws [4]: - secure with Loctite 242 Spur wheel [1]: - slide onto the motor shaft - fasten with two setscrews [2] Solder on red (+) and gray ( - ) cables (see view X). Attach cable strap.
1 4
M1 X
Side panel When connecting, observe correct polarity! red + View X gray
Removal, Installation, Adjustment / Film Exit Unit / Motor M1
- 15 -
X92
Removal Remove cable strap. Remove screw [1]. Stepping motor [2]: - rotate in direction of the arrow NOTE: The toothed belt [3] is now released. Toothed belt [3]: - remove from toothed belt pulley [4] Stepping motor [2]: - remove fixing screw [5] - remove stepping motor [2]
8 3 7 1 6 4 1 5 2 to X92
Removal, Installation, Adjustment / Film Exit Unit / Stepping Motor M2
- 16 -
X92
Installation Toothed belt pulley [4] with ring [6]: - slide on the motor shaft - tighten with two setscrews [7] Stepping motor [2]: - hold onto spacers [8] - tighten with fixing screw [5]
8 3 7 1 6 4 1 5 2 to X92
Toothed belt [3]: - position onto toothed belt pulley [4] Stepping motor [2]: - rotate contrary to the direction of the arrow - fasten with screw [1]
- 17 -
X92
Installation NOTE: It must be possible to easily press the toothed belt [3] by approx. 9 mm centrally between the gear wheels on one side! If necessary, tension or release toothed belt [3].
8 3 7 1 6 4 1 5 2 to X92
Check whether the toothed belt runs straight. Attach cable strap.
- 18 -
Removal Remove cable strap. Disconnect electrical connection X89. CAUTION: Observe installation position of the stepping motor and, if necessary, mark it! Remove screws [1] with washers [2]. Remove toothed belt [10] from toothed belt pulley [11]. Remove stepping motor [7]. Loosen setscrews [8] by one revolution.
- 19 ->
Installation Slide ring [9] with toothed belt pulley [11] on the shaft. Fasten setscrews [8]. Position toothed belt [10] on toothed belt pulley [11]. Position Stepping motor [7] onto spacer [3] in correct installation position. Fasten screws [1] with washers [2]. NOTE: It must be possible to easily press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!
- 20 ->
11
Removal Preconditions: - front guide panel is dismounted. Remove two nuts [1] with washers [2]. Tilt motor [3]. Unsolder red (+) and gray ( - ) cables. NOTE: Observe polarity, if necessary, note down! Loosen setscrew [4]. Remove block [5].
Axle 7 6 1 2 10 9 5 4 8
- 21 -
11
Removal NOTE: Observe installation position, note down if necessary! Remove three screws [6] with washers [7]. Remove motor from bracket [8].
Axle 7 6 1 2 10 9 5 4 8
NOTE: Observe installation position of the motor, note down if necessary!
- 22 -
11
Installation Motor M14 [3]: - use three screws [6] and washers [7] to fasten to bracket [8] in correct installation position Block [5]: - use setscrew [4] to fasten onto the motor shaft in correct installation position Solder on red (+) and gray ( - ) cables. CAUTION: The cables may not touch the strut [11]!
Axle 7 6 1 2 10 9 5 4 8
- 23 -
11
Installation Motor [3]: - tilt and position in installation position - fasten with two nuts [1] and washers [2] CAUTION: When tilting the block [5], the ball bearing [9] always has to be remain in the grasp of the lever [10]! 7 6 1 2 - mount front guide panel.
Axle
10
4 8
- 24 -
Removal NOTE: Observe installation position of block [1]! Block [1]: - loosen setscrew - pull off the axle Remove from both sides: - 2 screws [2] - washers [3] Holder assembly [4]: - pull out of milling [5]
2 (2x)
3 (2x)
6 1
Removal, Installation, Adjustment / Film Exit Unit / Holder Assembly
- 25 -
Installation Holder assembly [4]: - insert into milling [5] On both sides: - fasten washer [6] with washers [3] and 2 screws [2] Block [1]: - slide onto axle in correct installation position - set in position with setscrew Perform holder adjustment.
3 (2x) 2 (2x)
6 1
- 26 -
Adjustment Pivot point 3 1 5 2 The holders must reach the following measurements: - as far as the screw [1]: 58 1 mm - as far as the bracket [2]: 1 +0.6 mm Adjustment: Block [3]: - loosen setscrew [4] Holder: - use your hand to set to 58 1 mm Holder 1 +0.6 Block [3]: - lightly press against screw [1] until it has contact - tighten setscrew [4] Guide panel
4 58 1
- 27 -
Adjustment Pivot point 3 1 5 2 Bracket [2]: - loosen fixing screw [5] by one revolution Holder: - set to 1 +0.6 mm using feeler gauge Bracket [2]: - lightly press against block [3] until it has contact - tighten fixing screws [5]
4 58 1
Holder 1 +0.6
Guide panel
- 28 -
Removal Remove film exit unit. (T1) Remove front guide panel. (T2) Remove screws [4]. Remove solenoid [1] from the film exit unit.
4 (2x) 3 (2x)
Removal, Installation, Adjustment / Film Exit Unit / Solenoid
- 29 -
Installation Degrease solenoid armature [1] in the adhering area. Note: Hold solenoid vertically and plug the sleeve [2] onto the armature from below! Adhere the sleeve with Loctite 638 to the armature. Screw the solenoid to the film exit unit. Grease the tip of the sleeve with Losoid 1160B.
3 (2x)
4 (2x)
Check the holder adjustment. (T1)

2
- 30 -
Installation Install the front guide panel. (T2) Install film exit unit. (T3)
4 (2x) 3 (2x)
- 31 -
M3
Removal Remove a fixing screw of the stepping motor M3.
Left Left: 1 3 Side panel 11
Swing stepping motor M3, remove toothed belt. Toothed belt pulley [1] with ring [3]: - loosen two setscrews [2] by one revolution - pull off roller shaft Spacer [4]: - pull off roller shaft Clamp [5]: - remove screw [6] with washer [7] - remove clamp [5]
2 4 Right: 11
10 Side panel 8 9
10
6 7 - 32 -
Removal, Installation, Adjustment / Film Exit Unit / Roller
M3
Removal Screw [8] and washer [9]: - remove
Roller [10]: - remove Ball bearing [11]: - remove from both sides
2 4 Right: 11
10 Side panel 8 9
10
6 7 - 33 -
M3
Installation Ball bearing [11]: - slide on the roller axle on both sides
Roller [10]: - insert Screw [8]: - attach with washer [9] Clamp [5]: - mount - fasten with screw [6] and washer [7] Spacer [4]: - slide on the roller shaft
2 4 Right: 11
10 Side panel 8 9
10
6 7 - 34 -
M3
Installation Toothed belt pulley [1] with ring [3]: - slide onto the roller shaft as far as the stop - lock in position on the roller shaft using two setscrews [2] Toothed belt: - position on toothed belt pulley [1] and toothed belt pulley of the stepping motor M3 Stepping motor M3: - move into installation position - lock in position with fixing screw NOTE: It must be possible to press the toothed belt by approx. 9 mm centrally between the gear wheels on one side!
2 4 Right: 11
10 Side panel 8 9
10
6 7
- 35 -
Removal Pull the front guide panel [1] up from the screws.
Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel
- 36 -
Installation Place the front guide panel [1] from the top onto the screws [2].
Removal, Installation, Adjustment / Film Exit Unit / Front Guide Panel
- 37 -
Removal Remove front guide panel. (T1) Remove roller. (T2) Remove screws [5] with distance sleeve [4]. Remove rear panel [1] with guide panel [3].
3 1
5 (3x)
4 (3x) - 38 -
Removal, Installation, Adjustment / Film Exit Unit / Rear Guide Panel
Installation Screw the rear guide panel [1] with the screws [5] and distance sleeves [4] loosely to the back panel of the film exit unit. CAUTION: Observe the installation position of the guide panel [3], upper rim must point in the direction of the exit unit! Insert guide panel [3] and press on the middle screw, align horizontally and sidewards. Tighten screws [5]. 3 1
5 (3x)
4 (3x) - 39 -
Installation When exchanging the guide panel [1] adhere strips [2] as follows: Edge "a" even with outer edge Edge "b" 0.1 +0.15 mm lapping over the metal edge Mount front guide panel. (T1) Mount roller. (T2)
2 b 3
5 (3x)
4 (3x) - 40 -
General Strut Only control roller 3 is moved with motor M14 (see Ill.). The other rollers are moved synchronously over struts around their pivot point. The force transmission from the motor to the control roller 3 is performed via lever impact. Prior to removing a control roller, remove the cable harness mounted onto it.
Cable harness
Drive M14
Removal, Installation, Adjustment / Film Exit Unit / Control Rollers
- 41 -
Removal Remove front guide panel. (T1) CAUTION: Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.
1 (4x)
Removal, Installation, Adjustment / Film Exit Unit / Control Rollers 1, 2, 4
- 42 -
5 (2x)
6 (3x) 7 (2x)
Removal Remove fixing screws [4] on the back side. Remove entire unit.
10 8 9 11
Pull the fork [11] out of the holder [13] and remove pressure spring [12]. Remove lock washer [8].
4 (2x)
12
Carefully pull axle [9] out of the fork and rollers [6].
13
- 43 -
5 (2x)
6 (3x) 7 (2x)
10 8 9
Installation Pack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8].
11
Mount pressure spring [12] onto the shaft of the fork.

4 (2x)
12
Grease shaft with Losoid 1160B. Insert fork into the holder [13].
13
- 44 -
Installation Install the entire unit into the film exit unit. Check foam rubber stopper [3] and exchange, if required. CAUTION: Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with bore holes onto the pins of the fork. 1 (4x) 2 Set circlip [1] onto the pins. Adjust control rollers. (T1)
- 45 -
Removal Remove front guide panel. (T1) CAUTION: Do not loosen screws (3x) secured with Loctite from the strut [2] ! Remove circlip [1]. Remove strut [2] from the fork pins.
1 (4x)
Removal, Installation, Adjustment / Film Exit Unit / Control Roller 3
- 46 -
5 (2x) 6 (3x) 7 (2x) 10 8 9 11 12 4 (2x)
Removal Loosen setscrew [15]. Remove level [14]. Remove fixing screws [4] on the back side. Remove entire unit. Pull the fork [11] out of the holder [13] and remove pressure spring [12].
13
Remove lock washer [8]. Carefully pull axle [9] out of the fork and rollers [6].
15
14
- 47 -
5 (2x) 6 (3x) 7 (2x) 10 8 9 11 12 4 (2x)
Installation Pack the rollers [6], distance sleeves [5] and washers [7] in the fork [11] together to one set. Thread the axle [9] into the fork and the roller set. Mount lock washer [8]. Mount pressure spring [12] onto the shaft of the fork.
13
Grease shaft with Losoid 1160B. Insert fork into the holder [13].
15
Mount lever [14] centered to the fork.

14
- 48 -
Installation Install the entire unit into the film exit unit. Check foam rubber stopper [3] and exchange, if required. CAUTION: Do not loosen screws (3x) secured with Loctite from the strut [2]! Set the complete strut [2] with bore holes onto the pins of the fork. 1 (4x) 2 Set circlip [1] onto the pins. Adjust control rollers. (T1)
- 49 -
Adjustment Strut Auxiliary tools Prerequisites: 1. Struts have to be fastened to the control rollers! 2. Struts are secured with the locking rings! Position tools with a flat surface on the front of the control rollers. NOTE: Control rollers are aligned straight, if they have contact with the flat surface over the entire length of the auxiliary tools.
Cable harness
Drive M14
- 50 -
Rollers Strut
Adjustment Motor M14 CAUTION: The lever has to be adjusted in such a way that the rollers can be moved uniformly when starting at the zero position. The greatest allowable tolerance between the two rollers may be 1. Adjustment: - loosen setscrew - turn lever on axle - tighten setscrew Check adjustment. If necessary, repeat the adjustment. Install front guide panel. (T1)
Axle
Setscrew
Lever
- 51 -
Before removing the cutting device, the film exit unit must be removed!
Cutting Device
Before removing individual components, remove the complete cutting device!
Cutting Rail Gear Unit Motor M4
Cutting Wheel
Removal, Installation, Adjustment / Cutting Device
- 52 -
Removal Remove the film exit unit. (T1) Pull off connector X55. Loosen screw [1] by one revolution. 2 (2x) Remove the screw [2]. 3 (2x) Remove the washer [3]. Remove the cutting device.
1 (2x)
- 53 -
Installation Insert the cutting device into the machine. Tighten screw [1]. Tighten screw [2] with washer [3]. 2 (2x) NOTE: The washer [3] must be positioned onto the shaped strip of the cutting 3 device. (2x) Fit connector X55. Install the film exit unit. (T1) 1 (2x)
- 54 -
View X X 1 7 8 4 5 2 Ill. A Motor shaft 6 Remove four fixing screws [4] with washers [5]. Motor [6]: - tilt - remove toothed belt from toothed belt pulley [7] 3 Removal Knob [1]: - pull off motor shaft Cable strap [2]: - cut and remove Pull connector [3] off motor. NOTE: Observe installation position of motor [6], mark if necessary.
M4
Flat surface Setscrew red gray +
Removal, Installation, Adjustment / Cutting Device / Gear Unit Motor M4
- 55 -
View X X 1 7 8 4 5 2 Ill. A Motor shaft 6 Removal Two setscrews [8]: - loosen by one revolution at the ring [9] Toothed belt pulley [7] with ring [9]: - pull off motor shaft Remove gear unit motor [6].
M4
Flat surface Setscrew red gray +
- 56 -
View X X 1 7 8 4 5 2 Ill. A Motor shaft 6 Installation Gear unit motor [6]: - insert motor shaft through the bore hole Toothed belt pulley [7] with ring [9]: - slide on the motor shaft Screw in setscrew [8] so that it reaches the flat surface (Ill. A). Slide up toothed belt pulley [7] with ring [9] until the setscrew [8] touches the end of the flat surface (Ill. A). In this position (Ill. A): - tighten both setscrews [8] red gray + 3
M4
Flat surface Setscrew
- 57 -
View X X 1 7 8 4 5 2 Ill. A Motor shaft 6 Installation Motor [6]: - tilt - position toothed belt on toothed belt pulley [7] Gear unit motor [6]: - fasten with four fixing screws [4] and washers [5] Fit connector [3]. CAUTION: Observe polarity: red to +, gray to - ! Attach cable strap [2]. Flat surface Setscrew red gray + Knob [1]: - position on the motor shaft 3
M4
- 58 -
Removal Assembly opening Precondition: Cutting device is removed. CAUTION: During the following procedure, press back the cutting wheel be means of an appropriate tool before reaching the assembly opening so that it does not slip off the cutting rail [2]! 4 3 Cutting wheel [1]: - use the handwheel to move in the direction of the assembly opening as far as the stop - press axially - remove carefully
Danger of being cut while removing or installing the cutting wheel! Removal, Installation, Adjustment / Cutting Device / Cutting Wheel
- 59 -
Installation Assembly opening Use methylated spirit to clean the cutting wheel [1] and, if necessary, remove protruding burr with a grindstone. CAUTION: Cutting wheel [1] blade must not touch the cutting rail [2]! Cutting wheel [1]: - press axially - insert in assembly opening - press back; while the cutting wheel is pressed back, use the handwheel to move it in the direction of the arrow
4 3
Danger of being cut while removing or installing the cutting wheel! Removal, Installation, Adjustment / Cutting Device / Cutting Wheel
- 60 -
Removal Remove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3]. 3 (6x) 2 (2x)
Removal, Installation, Adjustment / Cutting Device / Cutting Rail
- 61 -
Removal Remove cutting wheel [1]. (T1) Turn out setscrews [2]. Loosen screws [3]. 3 (6x) 2 (2x)
- 62 -
4 Installation Use methylated spirit to clean the cutting rail [4] and, if necessary, remove protruding burr with a grindstone. CAUTION: Observe the installation position of the cutting rail (bore holes for setscrews [2], s. Ill. A)! Slide cutting rail into the cutting device and screw tight. 2 (2x)
5 A 4
3 (6x)
- 63 -
B 7 C B 6 5 Installation Loosen setscrew [6] and remove tensioner [7]. Insert toothed belt [5], the setscrews [2] must engage in the first two gaps (s. Ill. C). Turn in setscrew against slight resistance. 5 1 4 2 Mount tensioner [7]. Slightly tighten the toothed belt using the setscrew [6]. Insert cutting wheel [1] and install cutting device. (T1)
3 (6x) 2 (2x) C
- 64 -
Solenoids
Solenoids Punch Adapter
Stepping Motor M7
Removal, Installation, Adjustment / Punch Adapter
- 65 -
Removal 1 Holder [1] and safety switch [2]: - loosen fixing screws - swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61: - punch adapter <->pcb MODULE CONNECT
2 1
- 66 -
Removal Three fixing screws: -loosen at the marked positions NOTE: Screws remain at the punch adapter. - Lift out punch adapter
- 67 -
Installation - Insert punch adapter from above Punch adapter: - position in correct installation position at the trough (screws reach into the milling at the trough) - use three fixing screws to fasten at the marked positions
- 68 -
Installation 1 Establish electrical connection X61: - punch adapter <->pcb MODULE CONNECT Install film exit unit and cutting device. Holder [1] and safety switch [2]: - swing into installation position - fasten with fixing screws
2 1
- 69 -
Installation, Solenoids Film exit side X 1 2 Y8 Y9 Solenoids: - fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]: - slide onto the solenoid - lightly press against the armature - set sleeve [1] into position with setscrew [2] X Y6 Y7 Trough side
Removal, Installation, Adjustment / Punch Adapter / Solenoids
- 70 -
Installation, Solenoids Installation of the solenoids: - loosely fasten slenoids - position solenoids to measure 1 mm - tighten fixing screws
1 mm
1 mm
Removal, Installation, Adjustment / Punch Adapter / Solenoids
- 71 -
Removal 1.5 mm Remove cable strap. Disconnect electrical connection X61. 5 4 CAUTION: Observe installation position of the stepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. 6 2 3 1 Motor holder Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7
- 72 -
Installation 1.5 mm Ring [5] with toothed belt pulley [4]: - slide onto the shaft - use two setscrews [6] to fasten onto motor shaft Position toothed belt on toothed belt pulley [4]. Stepping motor: - position in correct installation position at the motor holder - fasten with four nuts [1], screws [2] and washers [3] NOTE: It must be possible to easily press in the toothed belt by approx. 9 mm centrally between the toothed belt pulleys on one side.
5 4
6 2 3 1 Motor holder
Observe the distance of 1.5 mm for the toothed belt pulley (4)! Removal, Installation, Adjustment / Punch Adapter / Stepping Motor M7 - 73 -
Adjustment 1 CAUTION: Prior to installing the collecting cassette [1], the following functions must be checked! X View "X" Functions check of handles [2]: - it must be possible to press the handles easily and without resistance into the cassette [1] - when releasing the handles, they must be automatically pressed out of the cassette by means of the elastic force of their pressure springs
2 (2x)
3 Removal, Installation, Adjustment / Collecting Cassette - 74 ->
Input / Side Panels
Punches (Option)
The top punch is an option. If no top punch is installed, the punch adapter must be installed. The top punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.
Gear Unit Motor M17 Top Punch
Solenoids
Solenoids
Punch Replacement Parts Stepping Motor M7
Removal, Installation, Adjustment / Top Punch
-2-
Removal 1 2 Holder [1] and safety switch [2]: - loosen fixing screws - swing out of position Remove film exit unit and cutting device. Disconnect electrical connection X61: - top punch <-> pcb MODULE CONNECT
-3-
Removal Fasten two long cable straps or a suitable tape at both sides as handles. CAUTION: Ensure, that pressure strip [3] is not twisted or damaged due to the handles! Loosen the three fixing screws at the marked positions. NOTE: Screws remain in the top punch! Hold top punch at the handles and lift out.
-4-
Installation Fasten two long cable straps or a suitable tape at both sides as handles. CAUTION: Make sure that pressure strip [3] is not twisted or damaged due to the handles! Hold top punch at the handles and insert from above. Top punch: - position in correct installation position at the trough (screws reach into the milling at the trough) - use three fixing screws to fasten at the marked positions
-5-
Installation 1 2 Establish electrical connection X61: - top punch <-> pcb MODULE CONNECT Manually move the pressure rail back and forth to check for easy movements. Install film exit unit and cutting device. Holder [1] and safety switch [2]: - swing into installation position - fasten with fixing screws Check and, if necessary, perform the parameter set-up.
-6-
Removal Toothed belt pulley [1]: - loosen two setscrews [6] by one revolution - pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION: Observe installation position of the gear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]: - take out of holder [4]
Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17
-7-
Removal Toothed belt pulley [1]: - loosen two setscrews [6] by one revolution - pull off motor shaft together with toothed belt [2] Unsolder two cables (red, gray). CAUTION: Observe installation position of the gear unit motor, mark if necessary. Remove nut [3]. Gear unit motor [5]: - take out of holder [4]
Removal, Installation, Adjustment / Top Punch / Gear Unit Motor M17
-8-
Parts Catalog
Installation, Solenoids Film exit side Xa 1 2 Y8 Y9 Solenoids: - fastened on each side with two screws and washers Set a corresponding distance X for each solenoid: X for the trough side: 2.5 mm X for the film exit side: 5.0 mm Sleeve [1]: - slide onto the solenoid - lightly press against the armature - set sleeve [1] into position with setscrew [2] Xm Y6 Y7 Trough side
Removal, Installation, Adjustment / Top Punch / Solenoids
-9-
Parts Catalog
Installation, Solenoids Installation of the solenoids: - loosely fasten slenoids - position solenoids to measure 1 mm - tighten fixing screws
1 mm
1 mm
Removal, Installation, Adjustment / Top Punch / Solenoids
- 10 -
Exchange the punch replacement parts in the specified order!
Cutting Plate Removal NOTE: As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough.
2 1 3
5 6
Remove the film exit unit. (T1) Remove the cutting device. (T2) Remove the top punch. (T3) 5 Cut the cable strap. Pull the connector off the punch motor.
Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
- 11 -
Cutting Plate Removal Unhook the springs [6] (2x).
2 1 3
Unscrew the screws [4] from the brackets [3]. Remove the screws [1] (6x) from the holding brackets [2] and [5]. Remove the holding brackets with the rollers from the top punch.
5 6
- 12 -
Cutting Plate Removal Remove the screws [8] (5x).
7 8
Remove the collecting tray [7]. Perform the following steps on both sides: - Remove the circlips [10] (2 at each side) and washers [11] (2 at each side). - Remove the connecting rods [9] (2 x). - Remove the washers [12] (2 at each side). Remove screws [13] (3 x).
15 14 6 12 11 10
Remove the pressure rail [14]. CAUTION: Do not unscrew the lever [15].
13 (3x) Removal, Installation, Adjustment / Top Punch / Punch Replacement Parts
- 13 -
Cutting Plate Removal Remove the screws [17] (3 x) and remove holding brackets [18]. 17 Unscrew bearing blocks [16] (2 x) and take off the motor unit.
18 16
16
- 14 -
Cutting Plate Removal Remove the screws [19] (4 x).
19
Remove the holder [22]. 20 NOTE: Remove the securing varnish from the hexagon socket of the fixing screws [20] using a pointed device. Remove the fixing screws [20] and take the cutting plate [21] off the carrier. 21
22
Install the cutting plate
- 15 -
Cutting Plate Installation CAUTION: Punch needle, cutting plate and guide panel fit together precisely. Components of different spare parts sets must not be mixed!
19
20
Take the components included in the spare parts set out of the bag and degrease them. Mark installation positions and replacement parts accordingly.
21 22
Distinctive feature of cutting plate or guide panel: Cutting plate = 4.8 mm thick Guide panel = 3.8 mm thick
- 16 -
Cutting Plate Installation Insert cutting plate [21] and tighten screws [20] slightly. Position the cutting plate: - lateral distance: 1 mm - distance to lower contact surface: 0.2 mm Tighten screws [20]. CAUTION: The screw ends must no protrude beyond the cutting plate. The position of the guide panels may be checked by mounting a register pin row.
19
20
21 22 A
1 mm
1 mm
0.2 mm
Remove punch needle and guide panel
- 17 -
Punch Needle and Guide Panel Removal Remove the screws [28] from the plate [24]. Swing bar [23] away. 25 Remove the plate [24]. Pull the pin [26] out of the punch needle [25] and remove the punch needle from the guide panel [29]. NOTE: Remove the securing varnish from the hexagon socket of the fixing screws [30] using a pointed device.
23
24
27 28
26
29 31 30
- 18 -
Punch Needle and Guide Panel Removal Unscrew guide panel from holder [31].
23
24
25 27 28 26
Install punch needle and guide panel
29 31 30
- 19 -
Punch Needle and Guide Panel Installation CAUTION: Make sure, the punch needle, cutting plate and guide panel belong to the same set! 25 Insert punch needle [25] in the guide. Insert pin [26].
23
24
27 28
26
Insert guide panel [29] and screw on loosely. It must still possible to move the guide panel. 29 31 30 Push the punch needle into the guide panel.
- 20 -
Punch Needle and Guide Panel Installation Carefully position the bar onto the carrier.
19
20
CAUTION: The punch needle must not slip out of the guide panel. Insert the screws [19] (4x) into the carrier from below and tighten them slightly.
21 22
The lateral surfaces of the holder [22] and of the carrier musut be flush with each other. Tighten the screws and check the position of the holder to the carrier.
- 21 -
Punch Needle and Guide Panel Installation Insert punch needle [25] through the guide panel [29] into the cutting plate. Swing up bar. 25
23
24
27 28
26
Install the punch in the machine. Press guide panel upward slightly, carefully press punch needle into the cutting plate and pull it out again. Tighten screws [30] of guide panel alternately and uniformly. Check the punch needle for smooth and easy movement (manually).
29 31 30
- 22 -
Punch Needle and Guide Panel Installation NOTE: If smooth and easy movement of the punch needle is not achieved by moving the guide panel, then check the position of the holder in relation to the carrier. Adjust all guide panels and screw tight. Remove the punch again. Insert new balls [27].
23
24
25 27 28 26
29 31 30
Lift punch needle and position plate [24] between holder and pin.
- 23 -
Punch Needle and Guide Panel Installation Position pin [26] centrally in the punch needle and press punch needle downward as far as the stop. 25 Swing bar onto the holder. Insert screws [28], position plate [24] carefully and tighten screws.
23
24
27 28
26
29 31 30
- 24 -
Punch Needle and Guide Panel Installation Observe installation position of pressure rails [14]! Mount pressure rail and tighten screws [13] (3x). Check pressure rail for smooth and easy movement. CAUTION: The bar must touch the carrier! The punch needle must not slip out of the guide panel!
7 8
15 14 6 12 11 10
- 25 -
Punch Needle and Guide Panel Installation Mount motor unit with blocks [16]. 17 Mount holding bracket [18].
18 16
16
- 26 -
Punch Needle and Guide Panel Installation Perform the following steps on both sides: - Mount washers [12] (2 at each side). - Mount connecting rod [9] (2x). - Mount washers [11] (2 at each side). - Mount circlip [10] (2 at each side)
7 8
15 14 6 12 11 10
- 27 -
Punch Needle and Guide Panel Installation Mount holding brackets with rollers. Check that the ball bearings (4x) in the guides are sitting correctly.
2 1
35 3 32 4
35 5 6 33 34
NOTE: The slotted disk [34] must run centrally through the opto switch [32]. Hook in springs [6] (2x). Mount collecting tray.
Plug connector onto the motor [33] (observe polarity). Fasten cables onto the holder [35] using cable straps.
OG
GY
- 28 -
Punch Needle and Guide Panel Installation Install the top punch and check the parameters. (T1) Install the cutting device. (T2) Install the film exit unit. (T3)
2 1
35 3 32 4
35 5 6 33 34
OG
GY
- 29 -
Removal Remove cable strap. Disconnect electrical connection X61. CAUTION: Observe installation position of the stepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
Removal, Installation, Adjustment / Top Punch / Stepping Motor M7
- 30 ->
Removal Remove cable strap. Disconnect electrical connection X61. CAUTION: Observe installation position of the stepping motor, mark if necessary. Remove four nuts [1] with screws [2] and washers [3]. Remove toothed belt from toothed belt pulley [4]. Remove stepping motor.
Removal, Installation, Adjustment / Top Punch / Stepping Motor M7
- 31 ->
Lateral punch: - produced according to customer specifications - can be equipped with different numbers of punch bodies - is delivered as a pre-assembled module
Punch Replacement Parts

Millings for further punch bodies (customer-specific)
Punch Body
Removal, Installation, Adjustment / Lateral Punch
- 32 -
Removal Remove the front covering and the front cover. 1 Disconnect electrical connections. Remove screws [2]. 2 (2x) Remove punch body [1] from the machine.
2 (2x) 1 2 (2x)
Removal, Installation, Adjustment / Lateral Punch / Punch Body
- 33 -
Installation Use screws to fasten the punch body [1] onto the trough, but do not tighten screws [2]. Position the available (punched) film into the trough. 2 (2x) Insert the punch needles of the punch bodies in the available punch holes. Tighten screws [2]. 2 (2x) 1 2 (2x) Establish electrical connections. Perform a functions test of the lateral punch and check the punch parameters.
Removal, Installation, Adjustment / Lateral Punch / Punch Body
- 34 -
Removal 3 2 (2x) NOTE: As a rule, all punch needles, cutting plate and guide panel should be exchanged. Remove the punch body. (T1) Turn out the screws [4] and take 4 (2x) the holder [1] out of the punch body. Remove the pin [6] from the punch needle [7]. Remove the punch needle from the holder. Remove the cutting plate [8] and the guide panel [9].
1 9
5 (2x) 8 6
Removal, Installation, Adjustment / Lateral Punch / Punch Replacement Parts
- 35 -
Installation 3 2 (2x) CAUTION: The punch needle, cutting plate and guide panel fit together precisely. Parts from different spare parts sets must not be mixed! Take the components out of the spare parts set and degrease them. 4 (2x) Insert the cutting plate [8] in the holder [1] and lightly tighten the screws [5]. Position the cutting plate: - make sure the sides of the cutting plate are flush with the holder sides - distance to the front edge 0.2 0.01 mm
1 9
5 (2x) 0.2 0.01 mm 8 6 9 7
8 1
- 36 -
Installation 3 2 (2x) Tighten the screws [5] and check the position of the cutting plate. Screw the guide panel [9] onto the holder, but do not tighten the screws [2]. Insert the punch needle [7] in the 4 (2x) cutting plate and guide panel and insert the pin [6]. NOTES: While locking the guide panel in position, move the punch needle back and forth. Tighten the screws [2] alternately in steps of 1/2 revolution.
1 9
5 (2x) 0.2 0.01 mm 8 6 9 7
8 1
- 37 -
Installation 3 2 (2x) Check the punch needle for smooth and easy movement. Insert the holder in the punch body [3]. Install the punch body and check the parameter set-up. (T1) 4 (2x)
1 9
5 (2x) 0.2 0.01 mm 8 6 9 7
8 1
- 38 -
The bottom punch is an option. If no bottom punch is installed, the bottom punch adapter must be installed. The bottom punch may only be actuated if it is installed! After removal of the entire unit, remove and install individual parts.
Bottom Punch
Gear Unit Motor Solenoid, Left Punch Replacement Parts Solenoid, Right
- 39 -
Removal 1 (4x) Remove the loading platform. (T1) Pull off connectors X66 and X91. Screw out the fixing screws [1]. Remove the bottom punch from the machine.
- 40 -
Installation 1 (4x) Insert the bottom punch in the machine. Fasten the bottom punch onto the trough using screws [1]. Check the bottom punch for proper functioning by turning the motor axle. Fit connectors X66 and X91. Install the loading platform. (T1) Perform the parameter set-up.
- 41 -
Removal A 1 2 (2x) M 19 3 4 (2x) Remove the screws [2]. Remove the bracket [1] with the opto switch and carefully put it to the side. 8 9 7 (2x) 10 Pull the flat connector off the motor [3]. Remove setscrew [7]from the eccentric [6]. Pull the pin [9] out of the eccentric. A Turn out the screws [4], remove the clamp [5]. Remove the motor with the connecting rod [8] and punch needle from the bottom punch.
OR GY
Removal, Installation, Adjustment / Bottom Punch / Gear Unit Motor
- 42 -
Removal A 1 2 (2x) M 19 3 4 (2x) Pull the connecting rod off the eccentric. 6 8 9 7 (2x) 10 Loosen the setscrew position at the motor [7] and pull the eccentric off the motor axle.
OR GY
- 43 -
Installation A 1 2 (2x) M 19 3 4 (2x) Place the eccentric [6] onto the motor axle and turn it until the setscrew [7] positioned at the motor exerts pressure onto the milled area of the motor axle. 8 9 7 (2x) 10 Tighten the setscrew. Position the connecting rod [8] onto the eccentric. Insert the punch needle [10] in the guide panel, move motor [3] into installation position and fasten the clamp [5] using screws.
OR GY
Insert the pin [9] in the eccentric. Screw in the setscrew [7] but do not tighten it.
- 44 -
Installation A 1 2 (2x) M 19 3 4 (2x) CAUTION: The switch lug of the pin [9] must run through the center of the opto switch. 6 8 9 7 (2x) 10 Mount the bracket [1] with the opto switch. Turn the motor axle until the punch needle is at its upmost position (setscrew [7] is at the top). Turn the pin [9] until the slot of the switching lug is in the opto switch. A
OR GY
Tighten the setscrew. Fit the flat connector onto the motor, observe polarity.
- 45 -
Removal Pull the flat connector off the solenoid [1]. Turn out the screws [5] and remove the solenoid. Loosen the setscrew [2] and pull the sleeve [3] off the magnet armature.
2 1 3 Y2 7 (2x)
4 (2x) 5 (2x) 6
8 (2x)
Removal, Installation, Adjustment / Bottom Punch / Solenoid, Left
- 46 -
Installation X GY OG Slide the sleeve [3] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 0.2 mm. Tighten the setscrew [2]. Fasten the solenoid onto the bracket [6] using screws. 3 Y2 7 (2x) Connect the flat connector, observe polarity. 4 (2x) 5 (2x) 6 Install the bottom punch and adjust the solenoid.
2 1
8 (2x)
- 47 -
Gap
- 48 -
Removal Pull the flat connector off the solenoid [3]. Turn out the screws [7] and remove the solenoid. Loosen the setscrew [1] and pull the sleeve [2] off the magnet armature. 8 (2x) 1
7 (2x)
5 (2x) 6 (2x) 4 Y1 3
Removal, Installation, Adjustment / Bottom Punch / Solenoid, Right
- 49 -
Installation X OG GY Fit the sleeve [2] onto the magnet armature. Exert pressure onto the magnet armature from the rear and set a distance of X = 33 0.2 mm. Tighten the setscrew [1]. 7 (2x) 8 (2x) 1 Fasten the solenoid onto the bracket [4] using screws. Connect the flat connector, observe polarity. 5 (2x) 6 (2x) 4 Y1 3 2 Install the bottom punch and adjust the solenoid.
- 50 -
Gap
- 51 -
Removal NOTE: As a rule, punch needle, cutting plate and guide panel should be exchanged. Remove coverings. Cover the trough.
Remove the bottom punch. (T1) Unhook the springs [1] and [5]. Remove the pressure rail [2]. 5 4 (3x) 3 (3x)
Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts
- 52 -
Removal Remove the collecting tray [11].
Remove bracket [8] with opto switch. Cut the cable strap at the gear unit motor, pull off the flat connector. Unscrew the cover plates [7] and [9]. 9 Unscrew holding bracket with solenoids [6] and [10] and remove it from the punch. Remove the gear unit motor. (T2) 11 10
8 6
- 53 -
Exchange the punch replacement parts in the specified order! 14 12 13 (2x) 16 15
Removal Press pin [14] out of the connecting rod [15] and remove the punch needle [16]. Unscrew the carrier [20] from the bar [12]. Turn out the screws [21] and take the cutting plate [18] off the carrier. Turn out the screws [13] and remove the guide panel [17].
18
17
21 (2x)
20 19 (4x)
- 54 -
Installation CAUTION: The punch needle, cutting plate and guide panel fit together precisely. Components of different spare parts sets must not be mixed! Take the components included in the spare parts set out of the bag and degrease them. Insert cutting plate [18] and tighten screws [21] lightly. Position the cutting plate: - distance parallel to the lower contact surface: 0.4 0.015 mm Tighten screws [21].
18
17
21 (2x)
20 19 (4x)
20
18
0.4 0.015 mm Removal, Installation, Adjustment / Bottom Punch / Punch Replacement Parts - 55 -
Installation CAUTION: The screw ends must not protrude beyond the cutting plate. Insert guide panel [17] and screw on loosely. It must be possible to move the guide panel. Carefully position the carrier [20] onto the straight pins of the bar [12]. Tighten the screws [19] (4x).
18
17
21 (2x)
20 19 (4x)
Insert pin [14] in punch needle [16]. Carefully insert the punch needle through the guide panel [17] in the cutting plate [18].
- 56 -
Installation Install the punch in the machine. NOTE: The guide panel is locked in position step by step. Between the individual steps, the punch needle must be moved in both directions. Tighten the screws [13] of the guide panel alternately by 1/2 revolution. Check the punch needle for smooth movement.
18
17
21 (2x)
20 19 (4x)
Remove the punch. Remove the pin [14] from the punch needle. Insert the punch needle in the connecting rod [15].
- 57 -
Installation Insert the pin and secure it in position by tapping lightly on both sides using a center punch. Mount the holding bracket with solenoids [6] and [10].
8 6 9
Install the gear unit motor. (T1) Fasten the cable onto the motor using cable straps. Fasten the cover plates [7] and [9] using screws. Mount the collecting tray [11].
11
10
- 58 -
Installation Observe the installation position of the pressure rail [2]! Mount the pressure rail and tighten the screws [3]. Check the pressure rail for smooth movement.
Attach the springs [1] and [5]. Install the bottom punch and check the parameters. (T2) Adjust the solenoids. 5 4 (3x) 3 (3x)
- 59 -
MODULE-CONNECT 5.952 X50 => B01 H-MOTHERBOARD 5.949 Adapter 2081.1080200.0 X51 => C01 H-MOTHERBOARD 5.949 Adapter 2081.1080200.0 X59 => X85 EC-CONTR. 5.951 Flat cable 2081.1080000.0 X60 => X8 AC-CONTROLLER 5.950 Adapter 2081.1080300.0 X63 => X113 lateral punch A (option) Adapter 2081.1081400.0 X64 => X114 lateral punch B (option) Adapter 2081.1081400.0 X65 => X115 lateral punch C (option) Adapter 2081.1081400.0 04640047 04640047 04537335 04640144 04556747 # 04556747 # 04556747 #
Adapter List, Exposure Unit
-1-
MODULE-CONNECT 5.952 X66 => X116 lateral punch D (option) Adapter 2081.1081400.0 X68 => Safety switches S14, S15, S18 Wiring 2081.2060012.0 X98 => X90 loop monitoring Cable 2081.1081500.0 04556747 # 04661214 04556488
-2-
EC-CONTR. 5.951 X70 => X71 rotating mirror Adapter 2081.1081001.0 X72/ => XA4 RIP-INTERFACE 5.976 X79 X77/X78 optics head Adapter 2081.1080100.0 X80 => X74 optics head Flat cable 2083.1081500.0 X82 => X87 MAT.WIDTH I 6.004 or MAT.WIDTH II 6.063 Flat cable 2083.1081500.0 X84 => X69 MODULE-CONNECT 5.952 Flat cable 2081.1080000.0 X85 => X59 MODULE-CONNECT 5.952 Flat cable 2081.1080000.0 X86 => X58 MODULE-CONNECT 5.952 Flat cable 2081.1080000.0 04743598
04587162 04156951
04156951 04537335 04537335 04537335
-3-
Optics head X74 => X80 EC-CONTR. 5.951 Flat cable 2083.1081500.0 X77/ => XA4 RIP-INTERFACE 5.976 X78 X72/X79 EC-CONTR. 5.951 Adapter 2081.1080100.0 04156951
04587162
-4-
H-MOTHERBOARD 5.949 B01 => X50 MODULE-CONNECT 5.952 Adapter 2081.1080200.0 C01 => X51 MODULE-CONNECT 5.952 Adapter 2081.1080200.0 X39 => Valve controller Adapter 2081.2056218.0 X44 => X140 Berger controller Adapter 2081.1080600.0 X47 => X147 operating panel Adapter 2081.1080900.0 X48 => X13 AC-CONTROLLER 5.950 Adapter 2081.1080500.0 X49 => Fan E2 Adapter 2081.2056014.0 04640047 04640047 04671511 04641027 04640756 04640586 04569237
Adapter List, Base
-5-
AC-CONTROLLER 5.950 X8 => X60 MODULE-CONNECT 5.952 Adapter 2081.1080300.0 X13 => X48 H-MOTHERBOARD 5.949 Adapter 2081.1080500.0 X15 => Vacuum pump Power cable 2081.2056216.0 X16 => Compressed air pump Power cable 2081.2056012.0 X17 => S1, H1 mains, illuminated display Adapter 2081.1080400.0 X20 => X142 Berger controller Adapter 2081.1080800.0 04640144 04640586 04671422 04569156 04640837 04640667
Adapter List, Base
-6-
RIP-INTERFACE 5.976 XA4 => X72/X79 EC-CONTR. 5.951 X77/X78 optics head Adapter 2081.1080100.0
04587162
Adapter List, Base
-7-
Berger controller X140 => X44 H-MOTHERBOARD 5.949 Adapter 2081.1080600.0 X141 => X143 stepping motor M8 Adapter 2081.1080701.0 X142 => X20 AC-CONTROLLER 5.950 Adapter 2081.1080800.0 04641027 04557182 04640667
Adapter List, Base
-8-
Cleaning Agents Cleaner's Naphtha Lubricating Agents Precision oil Clock 859 Oil Tonna T 68 Universal grease Arcanol L78 Special-purpose grease LOSOID 1160B Varnish Varnish retouching pen light gray Varnish retouching pen gray Sundries Thermolube, e.g. Electrolube HTC Securing varnish, f. screws, gray Adhesive, Loctite 222 Adhesive, Loctite 242 Adhesive, cyanoacrylate (Sicomet 99) Adhesive, Loctite 572 Adhesive, Loctite 638 Film material 150x30 mm Cleaning and Lubricating Agents, Adhesives, Varnish -902722070 00129003 01169939 # 01169920 # 02225360 # 04138856 02427052 04321928 # 04321936 # 02098318 # 00593850 00129631 # 02463253 #
Screwdrivers Screwdriver Hex. size 2 angled Screwdriver, ball head Hex. size 3 T-handle Screwdriver Hex. size 3 angled Screwdriver Hex. size 3 T-handle Screwdriver Hex. size 4 angled Screwdriver, ball head Hex. size 4 angled Screwdriver, ball head Hex. size 5 angled Screwdriver Size 1 Pozidriv Screwdriver Size 2 Pozidriv 00187119 00349712 02203294 02203359 02203251 01276786 01276778 01167057 01234188
Tools
- 10 -
Wrenches Open-end wrench set Combi. wrench set Square " Torque wrench 0.2-4 Nm " 02454769 01760491
Tools
- 11 -
Measuring Tools, Mechanical Dial gauge Div. 0.01 meas. range 5 mm Meas. tip f. dial gauge Meas. disk dia. 10 mm Magnetic stand with prism guide Contactor 500 - 2000 g Spring balance Div. 0.05 meas. range 0 - 5 N 00576212 02486725 02863286 00996521 04001745
Tools
- 12 -
Measuring Tools, Electrical Oscilloscope 2 channels 100 MHz Digital multimeter 4 1/2 digits Adapter 1:1 f. Service PC 9-pin SUB-D max.10 m Conv. adapter f. Service PC 9/25-pin Adapter SMC/BNC 1.5 m 01912593 01327852 04536576 04235045 01959891 #
Tools
- 13 -
Sundries Spring hook Rd 1.5 155 mm Wrench for filter container 00494534 05914469 #
Tools
- 14 -
-1-
Error messages are displayed on the operating panel display. Press the "?" key, the stored errors are displayed. Leaf through the messages using key.
Error Messages
-2-
MODULE-CONNECT (5.952) EC-CONTR. (6.500) [only Herkules extension] Pcb Configurration Nest
H-MOTHERBOARD (5.949) AC-CONTROLLER (5.950) MAT-WIDTH I MAT-WIDTH II
Overview
-3-
MODULE-CONNECT (5.952) EC-CONTR. (5.951) Pcb Configurration Nest
H-MOTHERBOARD (5.949) AC-CONTROLLER (5.950) MAT-WIDTH I MAT-WIDTH II
Overview
-4-
Order No. 04575423
X61
X98
X53
X55
X54
X52 X50 X56 X69X58 X59 X51 X57 X68 X60 X66 X65 X64 X63 X62 BARCODE
Pcb MODULE CONNECT (5.952)
-5-
Order No. 04577736 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (5.951) -6TP15: Light Measurement, Test Program 41 - Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.
Order No. 04577736 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (5.951) -7Connector X3 - Window signal for the SOL photo diode
Order No. 04577736 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (5.951) -8Connector X4 - 5 V for test purposes
Order No. 04577736 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (5.951) -9Wrong signal run Correct signal run Connector X73 - SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1
Order No. 04577736 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (5.951) - 10 Switch S2 - SOL window generation 60 s per motor rotation
Order No. 04896904 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (6.500) [only Herkules Extension] - 11 TP15: Light Measurement, Test Program 41 - Between 0 and 2.5V (10 mV are approx. 1 digit light value) Example: 200 LV = 2 V.
Order No. 04896904 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (6.500) [only Herkules Extension] - 12 Connector X3 - Window signal for the SOL photo diode
Order No. 04896904 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (6.500) [only Herkules Extension] - 13 Connector X4 - 5 V for test purposes
Order No. 04896904 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (6.500) [only Herkules Extension] - 14 Wrong signal run Correct signal run Connector X73 - SOL (analog) signal - Check of the direction of rotation, of the rotating mirror - In the case of incorrect direction of rotation actuate switch S1
Order No. 04896904 X82 X80 X83 X85 X86 X84 X3 X4 S3 TP15 K3 X72 X73 S2 S1 X70 X1 X38 X79 Pcb EC-CONTROL (6.500) [only Herkules Extension] - 15 Switch S2 - SOL window generation 60 s per motor rotation

BARCODE
X2
X87
R5
R6
Start test software (T2) Call up test 82 Input: r82[l,m] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
- 16 -
Order No. 04699629

BARCODE
X2
Display: Bit sequence 7654 3210 - Bit 4 = 1 > Film is in both opto switches - Bit 4 = 0 > Film is not in opto switches or only in one opto switche. Insert reference film in the trough in front of the two opto switches. CAUTION: Film must have the same position as with normal operation. Cover left-hand opto switch with the black film. So adjust right-hand pot (R6) that bit 4 changes from "0" to "1". Remove black film.
X87
R5
R6
- 17 -
Order No. 04699629 Cover right-hand opto switch with the black film.
BARCODE
So adjust left-hand pot (R5) that bit 4 changes from "0" to "1".
X2
X87
Perform a test at the end positions and in the middle of the travel: - without reference film > bit 4 = "0" - with reference film on both opto switches > bit 4 = "1".
R5 R6
Install loading platform (T3). Note: If the setting is not possible alter the distance between pcb and carrier.
- 18 -

X87 X2
R5
R6
Displace carriage in such a way that the right-hand opto switch is positioned over the right-hand reflection strip. Start test software (V > 2.00) (T2) Call up test 82 Input: r82[l,m,r] <Enter> Input: y <Enter> Input: y <Enter> Input: y <Enter>
- 19 -
Order No. 04700805 Display: Bit sequence 7654 3210 - Bit 4 = 1 > Film is in opto switch - Bit 4 = 0 > No film is in opto switch. Insert reference film in the trough in front of the right-hand opto switch.
R5 R6
X87 X2
Caution: Film must have the same position as with normal operation. So adjust right-hand pot (R4) that bit 4 changes from "0" to "1". Caution: At the ends of the reflection strip, the film must be safely recognized.
- 20 -
Order No. 04700805 Stop test 82 Input: stop

X87 X2
<Enter>
Position left-hand opto switch over the left-hand reflection strip. Call up test 82 Input: r82[l,m,l] Input: y Input: y Input: y <Enter> <Enter> <Enter> <Enter>
R5
R6
So adjust left-hand pot (R5) that bit 4 changes from "0" to "1". Caution: At the ends of the reflection strip, the film must be safely recognized.
- 21 -
Order No. 04700805 Install loading platform (T3).

X87 X2
Note: If the setting is not possible alter the distance between pcb and carrier.
R5
R6
- 22 -
Order No. 04575431 X13 X17
X3
K3 K2 K4 F2 F3 L1 K1
X20
X12
X8
X15
X16
X4
X18 K5 X2 X19 X... 7 X... 5 6 32 33 34 35 31 30 29 28 K7
F4 F6 F5 F7
Pcb AC-CONTROLLER (5.950)
- 23 -
Order No. 04577698 CAUTION: This module is equipped with a Lithium battery. Observe Technical Remarks on Safety (chapter "General")! X500 X42 X43 X49 X39 X44 X45 X46 X47
C01
B01
X48
Pcb H-MOTHERBOARD (5.949)
- 24 -
VOLTAGE REG (5.970) IF (2081.523 or 2081.524) ED-CONTROL (5.941) NCONTROLLER (5.933) ERIAL-CONTROL (5.948)
A 09 A 08 A 07 A 06 unoccupied A 05 A 04 unoccupied A 03 A 02 unoccupied A 01 Pcb Configuration, Nest - 25 -
VOLTAGE REG (5.970) P INTERFACE(5.976) ED-CONTROL (5.941) NCONTROLLER (5.933) ERIAL-CONTROL (5.948)
A 09 A 08 A 07 A 06 unoccupied unoccupied A 05 A 04 unoccupied A 03 A 02 unoccupied A 01 Pcb Configuration, Nest - 26 -
Order No. 04578503
X1
KK1
XA3
BARCODE
XB3
Meas. Points,
- 27 -
Pcb VOLTAGE REG (5.970) Slot 09
Diagnostic Connector
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points Pin 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 Signal MGND +5V -2VB - 15 V REF P1 - P4 REF TIGHT MOT SENSE FAN REF GUI MOT PWR FAN REF LOOP MOT MOT REG SPG CTRL REF B MOT + 15 V + 7.5 V MOT REG SPG EXT 2 EXT 4 + 24 V Meaning Supply logic unit for RIP IF ECL logic unit Supply analog system Reference voltage, punches 1-4 Reference voltage for M7 Electronics frame fan Reference voltage for M2 +24 V electronics frame Reference voltage for M3 Mirror motor Reference voltage for M5 Supply, analog system SOP supply Mirror motor n.c. n.c. Motors / solenoids supply
Block Diagrams, Overviews
- 28 -
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points Pin 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Signal 0V EXT 3 EXT 6 Ref SUP CAS - 5.2 V -2VA Ref 10 Ref P5-P6 + 12 V A SWI* - 12 V B MOT 1 TA MOT 1 0 V MOT REG SPG CRTL Ref TA MOT Ref VV Ext 5 Ext 1 + 28 V Meaning GND of the 24 V n.c. n.c. Reference voltage for M6 ECL & Peltier element supply for ECL RIP IF logic unit +10 V of the DAC for stepping motor Reference voltage for punches 5-6 Supply, RS 232 (MAINCONTROLLER) S11 compressed air monitoring unit Supply, RS 232 (MAINCONTROLLER) Supply cassette motor Collecting cassette motor Mirror motor Reference voltage for M1 Reference voltage for M15 n.c. Opto switch B9 reference voltage Supply, mirror motor
- 29 -
Order No. 04859987 (machines with mod. status 27) Order No. 04860160 (machines with mod. status 28)
XA4
X21
X20
X2
X1
Pcb HERK - IF (2081.523 or 2081.524) slot 07 / 08
- 30 -
Order No. 04576330
XA4 XA7
XA3
BARCODE
X2
X1
Pcb RIP INTERFACE (5.976) Slot 08
- 31 -
Order No. 04122119
XA3 BARCODE S2 S1
X2
X1
Pcb FEED-CONTROL (5.941) Slot 06
- 32 -
Order No. 05266521
S1
XA6 V2 V1
XB6 XC4 FD drive - FD235HF-7529
FD drive
BARCODE
XB5 XA5 X2
XA4 X1
Pcb MAINCONTROLLER (2081.526) Slot 04
- 33 -
Order No. 04576497
XA7 S1
BARCODE
X5
X2
X1
Pcb MATERIAL-CONTROL (5.948) Slot 02
- 34 -
F1 Checking Mains Input Fuse CAUTION: Machine must only be connected to the power supply if the F1 fuse is equipped correctly. F1 fuse: - in the case of U <= 127 V: T 15 A / 250 V - in the case of U > 127 V: T 6.3 A / 250 V NOTE: Fuses have different bayonet joints. Label Stick the label indicating the set voltage on top of the old one. Label Fuse F1 T 6.3 A T 15 A Order No. 00138215 04188713 230 V 115 V all other voltages Order No. 04137655 04258673 04258703
Mains Connection
- 35 -
Order No. 04575431 X13 X17
X3
K3 K2 K4 F2 F3 L1 K1
X20
X12
X8
X15
X16
Fuse X4 F2 F3 F4 F5 F6 F7 T 0.3 A T 0.125 A MT 10 A T4A T 1.5 A T8A
Order No. 00138452 01468367 00240699 00442836 00138525 04188691
X18 K5 X2 X19 X... 7 X... 5 6 32 33 34 35 31 30 29 28 K7
F4 F6 F5 F7
Pcb AC-CONTROLLER (5.950)
- 36 -
SOL, CLOCK, BIAS, VIDEO STEPPING MOTOR 5.941 5.976 XA4 M8 X143 FEEDRIP RIP 60 CONTROL INTERFACE REC-IF X141 X44 X140 XA3 SPEEDWAY AMPLIFIER A06 A08 A CPU Bus X100 Motherboard B Priv.Wir X200 C Priv.Wir X500 B01 C01 SENSORIK
Pcb EC-CONTR. / OPTICS HEAD
ACTUATORS
Pcb MODULE CONNECT
2081.526 VT 100 19200 bauds MAIN8 bits CONTROLLER No parity 1 stop bit XA6 FDD No handshake XB6 service A04, 05
5.948 MATERIALCONTROL
5.970 VOLTAGE-REG +7.5V SOP -2V A ECL -2V B ECL +28V MIRROR MOTOR XB3 XA3 C01 - 37 -
XA7
A01
Block Diagram
RIP INTERFACE SOL, CLOCK, BIAS, VIDEO 5.951
X72 X79 X80
X74 X77
X78
OPTICS HEAD EC-CONTR. X70 X71 ROT. MIRROR UNIT 6.004 X87 MAT-WIDTH
X84 X85 X86
X82
MODULE CONNECT
Block Diagram
- 38 -
EC-CONTR.
X69 X59 X58 5.952 X52 X53 X54 X98 DIAG SENSORS X61 X56 DIAG ACTUATORS X63 X57 X64 X65 X66 X60 X68 MODULECONNECT X55 LOADING PLATFORM EXPOSURE UNIT FILM EXIT UNIT CUTTING DEVICE X90 LOOP MONITORING UNIT TOP PUNCH (OPTION) X113 LATERAL PUNCH A (1) X114 LATERAL PUNCH B (2) (OPTIONS) X115 LATERAL PUNCH C (3) X116 LATERAL PUNCH D (4) SAFETY SWITCHES S14, S15, S18
X50 MOTHER BOARD ACTUATORSX51
SENSORS
AC-CONTROLLER X8 (5.950)
Block Diagram
- 39 -
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points Pin 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 Signal MGND +5V -2VB - 15 V REF P1 - P4 REF TIGHT MOT SENSE FAN REF GUI MOT PWR FAN REF LOOP MOT MOT REG SPG CTRL REF B MOT + 15 V + 7.5 V MOT REG SPG EXT 2 EXT 4 + 24 V Meaning Supply logic unit for RIP IF ECL logic unit Supply analog system Reference voltage, punches 1-4 Reference voltage for M7 Electronics frame fan Reference voltage for M2 +24 V electronics frame Reference voltage for M3 Mirror motor Reference voltage for M5 Supply, analog system SOP supply Mirror motor n.c. n.c. Motors / solenoids supply
- 40 -
Diagnostic connector XA 3 on pcb VOLTAGE-REG (slot 09): measuring points Pin 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Signal 0V EXT 3 EXT 6 Ref SUP CAS - 5.2 V -2VA Ref 10 Ref P5-P6 + 12 V A SWI* - 12 V B MOT 1 TA MOT 1 0 V MOT REG SPG CRTL Ref TA MOT Ref VV Ext 5 Ext 1 + 28 V Meaning GND of the 24 V n.c. n.c. Reference voltage for M6 ECL & Peltier element supply for ECL RIP IF logic unit +10 V of the DAC for stepping motor Reference voltage for punches 5-6 Supply, RS 232 (MAINCONTROLLER) S11 compressed air monitoring unit Supply, RS 232 (MAINCONTROLLER) Supply cassette motor Collecting cassette motor Mirror motor Reference voltage for M1 Reference voltage for M15 n.c. Opto switch B9 reference voltage Supply, mirror motor
- 41 -
Motors Abbreviations M1 M2 M3 M4 M5 M6 M7 M8 M9 M10 M11 M12 M13 M14 M15 M16 M17 M18 M19 Component Collecting Cassette Drive Stepping Motor, Lateral Guide Stepping Motor, Loop Cutter Motor Rewind Motor, Supply Cassette Stepping Motor, Feed Stepping Motor, Loading Unit Stepping Motor, Feed (Spindle) Stepping Motor, Focus Stepping Motor, Filter Wheel Stepping Motor, Shutter Compressed Air Pump Vacuum Pump Film Guide Drive Valve Controller Rotating Mirror Drive Gear Unit Motor, Top Punch Gear Unit Motor, Lateral Punch Gear Unit Motor, Bottom Punch Block Diagram, Overviews Allocation Film Exit Unit Film Exit Unit Film Exit Unit Cutting Device Loading Platform Loading Platform Exposure Unit Exposure Unit Optics Head Optics Head Optics Head Compressed Air Unit Vacuum Unit Film Exit Unit Vacuum Unit Exposure Unit Top Punch Lateral Punch Bottom Punch
- 42 -
Switches Abbreviations S1 S2 S4 S11 S12 S14 S15 S16 S18 Component On/Off Switch Polling Unit, Loop Film End, Remainder Pressure Switch Valve Controller Safety Switch Safety Switch Collecting Cassette Polling Unit Key-operated Switch Allocation Control Panel Film Exit Unit Loading Platform Compressed Air Unit Vacuum Unit Base Upper Section Film Exit Unit Base
Block Diagram, Overviews
- 43 -
For explanation on signal names ...please refer to the next pages
RECORDER - READY RECORDER - CUT RECORDER PROCESSOR - CONNECT PROCESSOR - ON PROCESSOR - WAIT FRAME - GND (shield) Transport channel / processor
Interface Timing
Interface Recorder <--> Transport Channel / Processor
- 44 -
X69 Sign. +24V Sign. +24V Sign. 01 09 02 10 03 11 04 12 Opto coupler 05 13 +24V / max. 150mA WAIT 05 13 +24V READY 01 09 02 10 03 11 04 12 +24V
Explanation on Signal Names RECORDER - READY The recorder is switched on and ready for operation. Opto coupler Now the CUT signal can be evaluated. READY = between pins 1 and 9 24 volts are applied that are evaluated by an opto coupler.
CUT
CONNECT
ON
SHIELD SUB - D 15-pin Transport channel - 45 -
SUB - D 15-pin XA7 Recorder interface Interface cable
Explanation on Signal Names RECORDER - CUT The signal appears -> for the time the film is Opto coupler being cut in the recorder or -> at film end, the supply cassette as simulated signal between galley proof and the rest of the film which is not cut. During this time, the film may not be transported. CUT = between pins 2 and 10, 24 volts are not applied that can be evaluated by an opto coupler.
CUT
CONNECT
ON
Explanation on Signal Names PROCESSOR - CONNECT Instead of the cassette, the transport channel is coupled with Opto coupler the recorder and connected via the interface cable. This coupling is ensured by signal CONNECT. Dependent on this, the film unloading sequence is switched from cassette operation to on-line operation. Via pins 3 and 11, a ground cable is looped through the transport channel and polled in the recorder via 5 volts. CONNECT = ground loop closed. The cassette switch must not be actuated if the transport channel is coupled. SUB - D 15-pin Transport channel - 47 -
CUT
CONNECT
ON
SHIELD
Explanation on Signal Names PROCESSOR - ON The on-line processor and the transport channel are connected Opto coupler to the mains and switched on. ON = at pins 4 and 12, 24 volts are applied which are evaluated in the recorder via opto couplers.
CUT
CONNECT
ON
Explanation on Signal Names PROCESSOR - WAIT For the following reasons, the processor Opto coupler can receive no galley proofs: -> The level regulations of the baths indicate an incorrect liquid level. -> The temperature sensors of the baths indicate an incorrect temperature (e.g. during the warm-up time after swiching on). -> There is still a galley proof in the transport channel or -> a malfunction in the processor makes it impossible to receive galley proofs.
CUT
CONNECT
ON
SHIELD SUB - D 15-pin Transport channel
- 49 -
Explanation on Signal Names WAIT = at pins 5 and 13, 24 volts are not applied that can be evaluated in the recorder via opto Opto coupler couplers. In the case of a contact error or line break, the error state or an uncritical state should always be entered.
CUT
CONNECT
ON
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
PROCESSOR ON PROCESSOR WAIT RECORDER CUT FILMLAUF WAIT WAIT
0V 24V 0V 24V CUT 0V
Pin Interface connector
-----------------> <---------->---------------> <-------> <-------------> <----------------->

Switch-on process of recorder and processor completed Interface Recorder <--> Transport Channel / Processor - 51 -
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
-----------------> <---------->---------------> <-------> <-------------> <----------------->

The recorder did not transport the galley proof continuously through the transport channel due to loop controlling. Interface Recorder <--> Transport Channel / Processor - 52 -
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
-----------------> <---------->---------------> <-------> <-------------> <----------------->

Galley proof is being cut, film transport not permissible Interface Recorder <--> Transport Channel / Processor - 53 -
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
-----------------> <---------->---------------> <-------> <-------------> <----------------->

Galley proof is continuously transported at a speed of approx. 140 mm / sec Interface Recorder <--> Transport Channel / Processor - 54 -
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
-----------------> <---------->---------------> <-------> <-------------> <----------------->

The recorder is ready for exposure, galley proof is slowly transported into the processor Interface Recorder <--> Transport Channel / Processor - 55 -
Interface - Timing
PROCESSOR CONNECT-L
5V 0V 24V
03 11 09 01 12 04 13 05 10 02
RECORDER READY
0V 24V
-----------------> <---------->---------------> <-------> <-------------> <----------------->

WAIT extinguishes only if the transport channel is empty and a new galley proof can be transported out of the recorder Interface Recorder <--> Transport Channel / Processor - 56 -
BAR 1 BAR 2 BAR 3 BAR 4 BAR 5 BAR 6 BAR 7 Note BAR 8 BAR 9 BAR 10 BAR 11 BAR 12
Explanations on the Test Page
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General Introduction The setup of a technical test page (TTP 2083) is described. The data stock of this TTP 2083 is available as a Postscript file and it can be copied to Postscript imagesetter systems using a floppy disk. The file is protected by Heidelberger Druckmaschinen Aktiengesellschaft copyright. Application TTP 2083 can be used in all cases where the output quality of Postscript imagesetter systems is checked and the output is evaluated. By means of this file, a test pattern in the form of a test page is exposed on photo material in the output format of the imagesetter. This test page is analyzed visually, by means of a microscope or by means of an automatic measuring device. REMARK: This test page is used exclusively for evaluating the exposure quality. Notes on possible error sources can only contribute coarsely to the error identification.
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General Structure of test page The test page consists of different test patterns, BAR 1 - BAR 12. Base fog Base fog: - can be measured on every unexposed position of the test page, - depends to a high degree on the photo material and on the set threshold value of the imagesetter. If the imagesetter is correctly adjusted, the following values are valid: 0.3 - 0.5 density, orthochromatic 0.5 - 0.8 density, ultraviolet Measuring instruments: Densitometer with a corresponding measuring range Possible error sources If the base fog is too high, check the photo material, the developing processes, the storage and the handling of photo material.
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General Is there a pre-exposure? The imagesetter is adjusted by means of a light test including a threshold value adjustment. In the case of an incorrect adjustment of the threshold value, it may happen that the photo material is pre-exposed.
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BAR 1 and BAR 12: Explanation BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and M are line images consisting of lines of identical width and spacing. With these grid patterns, the geometrical reproduction accuracy can be checked. This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions. Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK: During evaluation of the absolute precision, it must be observed that an error-free calculation of the geometry data was performed by Postscript. Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises: - the test page designation TTP 2083 and its version number - 3 register marks which are used to accurately position the test page in a punch Explanations on the Test Page - 61 -
BAR 1 and BAR 12: Evaluation Geometry can be checked or measured using BAR 1 and BAR 12. Page lengths All four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system. Check the absolute deviation and the delta of the opposite side. Perpendicularity is the difference value between the diagonals (AM and CK). Linearity is the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set) Partial length(actual) = ---------------------------------------------------------Length(set) Linearity error = Partial length(set) - partial length(actual) Straightness The lines AC, KM, AK, CM must be straight.
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BAR 1 and BAR 12: Evaluation Line width The lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function. However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences. Depending on the used photo material, different results are to be expected.
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BAR 1 and BAR 12: Measuring instruments A ruler (glass ruler) is suitable for coarse measurements. For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis. The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points. Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).
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BAR 1 and BAR 12: Possible error sources Sharply focused exposure, but geometrical distortion -> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion -> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction -> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction -> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction -> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction -> Possible reason(s): failures in the travel distance of the exposure carriage.
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BAR 2: Explanation BAR 2 is a solid area density bar (100%). It is used to measure the solid area density during exposure in landscape and portrait format. The inserted recesses (bright rectangles) change the black and white information in such a way that possible density changes in large areas between different video dynamics can be detected. This only applies to FastScan direction. When changing the test page format, the bar height of 10 mm remains constant, the bar width changes symmetrically to the center axis.
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BAR 2: Evaluation If the test page is exposed in landscape and portrait format, the solid area density lets and its homogeneity can be measured at any point using a densitometer. The solid area density depends on the photo material and imagesetter specifications. At the bar recesses, the solid area density can be measured from transparency to black in FastScan direction, and vice versa.
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BAR 2: Measuring instruments Densitometer with measuring range in accordance with the selected solid area density. Microscope with 40- to 50-fold enlargement.
- 68 -
BAR 2: Possible error sources Continuous decline of density in FastScan direction and exceeding of the density tolerance -> Possible reason(s): excessive dirt accumulation of the rotating mirror. Continuous decline of density in FastScan and SlowScan directions -> Possible reason(s): interruption of the developing process, pre-exposure of photo material. Check material packing, cassette shutter, machine cover.
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BAR 3: Explanation In BAR 3, all page-specific parameters can be read off. The image parameters - width:... mm - height: ... mm - rotation: ... deg and the screen system - DotShape: ... - Screensystem: ... - HFactor: ... - resolution: ... pixel / cm [dots / inch] - Screenangle: ... deg - Screenruling: ... screen lines / cm [lines / inch] are selected for exposure via operation. Specifications - Version: ... - Revision: ... - Serial No.: ... are system parameters and are output on every test page exposure.
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BAR 3: Explanation In addition to the company name and the copyright note, the following fields are available for entries: MATERIAL: DATE: TIME: SIGN.: TESTNO.: CAUTION: Prior to each evaluation of the test page, the parameters set for exposure must be checked in order to avoid misinterpretations.
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BAR 4: Explanation The round test symbol is used for visual determination of the focus and the focus homogeneity. The size and the shape of the dark area in the center of the test symbol is a criterion for the focus evaluation. When changing the test page format, the size of the test symbol remains unchanged, their number, however, changes. The concentric rings are an aid for comparing the test symbols of an exposure.
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BAR 4: Evaluation The smaller the black area in the center - assumung that the work density is constant - the sharper is the adjustment of the imagesetter. In the case of an error-free exposure of the test symbol, the centers of all symbols must be identical. This is applies to FastScan and SlowScan directions. The size of the black area is a coarse indication for the resolution selected for the exposure. Coarse resolution --> large black area Fine resolution --> small black area NOTE: When using photographic paper, the dark area is larger.
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BAR 4: Measuring instruments Evaluation is performed purely visually.
- 74 -
BAR 4: Possible error sources A large black area in all symbols indicates poor focusing or excessive density if photo material was exposed, e.g., in the saturation area. Uneven black area sizes in the test symbols indicate that the photo material did not fit during exposure. This is applies to FastScan and SlowScan directions.
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BAR 5: Explanation Various resolution symbols (micro character = M ) can be found in BAR 5 across the entire test page width. Their distances are 10 mm. The resolution symbol is can be found on further positions in the test page so that it is possible to compare the results. The resolution symbol is used to evaluate the resolution and further criteria using a microscope. The structure of the symbol allows the evaluation in FastScan and SlowScan directions.
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Resolution symbol (enlarged representation) in BAR 5
- 77 -
BAR 5: Evaluation The essential evaluation criteria are: - repetition of lines - repetition of line spacings - geometry of the lines and line spacings - transitions between the lines or between spacings - fringing between transparency and solid density - density structure in the case of different line combinations - fine structure of the lines The repetition of the lines and the line spacings is especially important. This repetition (width and black density range) is strongly influenced by: - focus setting of the imagesetter - the selected resolution of the imagesetter - the used photo material
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BAR 5: Measuring instruments The evaluation of the criteria is performed using a microscope with 40- to 50-fold enlargement. A microdensitometer is required for more precise and objective evaluations.
- 79 -
BAR 5: Possible error sources The focus setting of the imagesetter is important. Different resolution symbols in the exposure positions -> Possible reason(s): photo material not fitting during exposure.
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BAR 6: Explanation This is a text bar with font sizes 1, 1.5 and 3 mm of all letters of the alphabet. It can be used to evaluate the repetition of the fonts, in particular the fine structure in the case of complex fonts.
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BAR 7: Explanation The large-area screen field in the 90% tone value is used to evaluate the area quality.
- 82 -
BAR 7: Evaluation The screen field must be a uniform 90% tone value area. It must be free of screen interferences, tone value changes and other patterns which can be detected by eyesight. This applies to exposure in landscape and portrait format.
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BAR 7: Measuring instruments Densitometer and visual evaluation.
- 84 -
BAR 7: Possible error sources Interferences (structures at periodic distances) -> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decline in FastScan direction -> Possible reason(s): excessive dirt accumulation of the rotating mirror, photo material not fitting during exposure. See also screen field with 90% tone value in BAR 1 and BAR 12.
- 85 -
Note The vertical middle of the test page is between BAR 7 and BAR 8. If the page is cut horizontally in this position, the halves can be placed on top of each other for a visual check of the exposure geometry.
- 86 -
BAR 8, 10, 11: Explanation These screen bars represent a total of a screen shading from 2% to 98%. BAR 8 includes graduations 60, 70, 80, 90, 92, 94, 96, 98%, that is, the shadow and middle ranges. BAR 11 includes graduations 2, 4, 6, 8, 10, 20, 30, 40%, that is, the highlights and middle ranges. BAR 10 represents the 50% tone value. By means of these screen bars, the following criteria are checked: - repetition of the screen tone value in %; all levels from 2% to 98% in the case of basic adjustment and with screen tone value correction performed (linearization) - recognition of interferences in shadow ranges >90% - determination of the screen homogeneity per screen bar - using the microscope, the increase and decline of the screen dot area
- 87 -
BAR 8, 10, 11: Evaluation The screen bars must be a uniform area according to the tone value. They must be free of screen interferences, tone value changes and other structures which are visible by eyesight. This applies to exposure in landscape and portrait format. In the case of a correct solid area density (depending on the film type), the exposed screen tone values only deviate slightly from the calculated ones (set input). However, depending on the selected resolution, differences are to be expected in the tone value repetitions.
- 88 -
BAR 8, 10, 11: Measuring instruments Microscope with 40- to 50-fold enlargement. Densitometer and visual evaluation.
- 89 -
BAR 8, 10, 11: Possible error sources Interferences (structures at periodic distance) -> Possible reason(s): defect in the feed system of the exposure carriage. Continuous tone value decrease in FastScan direction -> Possible reason(s): excessive dirt accumulation at the rotating mirror, photo material not fitting during exposure. Linearizations which might have been set with regard to used photo material and developing processes must be observed.
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BAR 9: Explanation This sample consists of a screen area and bars. It is used to determine possible tone value changes in the 90% screen during video changes differing in time. For this purpose, the bar must run in FastScan direction.
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BAR 9: Evaluation In the 90% screen field, no trailing strips in the rhythm of the "black -> screen" and "white -> screen" transitions may occur.
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BAR 9: Measuring instruments Evaluation is performed purely visually.
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- 94 -
- 95 -
- 96 -
- 97 -
- 98 -
- 99 -
- 100 -
- 101 -
BAR 1 and BAR 12: Explanation BAR 1, BAR 12 as well as the grid patterns between corner points A and K as well as C and M are line images consisting of lines of identical width and spacing. With these grid patterns, the geometrical reproduction accuracy can be checked. This applies to page width, page height, diagonal, linearity, straightness, line width in FastScan and SlowScan directions. Evaluation should be performed with an automatic measuring instrument. A coarse, fast evaluation can be performed visually. REMARK: During evaluation of the absolute precision, it must be observed that an error-free calculation of the geometry data was performed by Postscript. Otherwise, only the determination of the repetition accuracy is possible. An enlargement or reduction of the test page is always performed symmetrically to the X- or Y-axis. The 50% and the 90% screen areas in the four corners are used to measure of screen homogeneity in comparison with the screen areas in BAR 7, 9 and 10. In addition, BAR 1 comprises: - the test page designation TTP 2083 and its version number - 3 register marks which are used to accurately position the test page in a punch Explanations on the Test Page - 102 -
BAR 1 and BAR 12: Evaluation Geometry can be checked or measured using BAR 1 and BAR 12. Page lengths All four lengths (AC, KM, AK, CM) are compared with the lengths pre-set by the front-end system. Check the absolute deviation and the delta of the opposite side. Perpendicularity is the difference value between the diagonals (AM and CK). Linearity is the repetition accuracy of the partial distances of the lengths AC, KM, AK, CM. Length(actual) * partial length(set) Partial length(actual) = ---------------------------------------------------------Length(set) Linearity error = Partial length(set) - partial length(actual) Straightness The lines AC, KM, AK, CM must be straight.
- 103 -
BAR 1 and BAR 12: Evaluation Line width The lines AC, KM, AK, CM as well as all short horizontal lines must have the same width. The imagesetters offer a highly precise geometrical recording function. However, this is very strongly influenced by the photo materials. The photo materials in particular change under temperature, humidity and mechanical influences. Depending on the used photo material, different results are to be expected.
- 104 -
BAR 1 and BAR 12: Measuring instruments A ruler (glass ruler) is suitable for coarse measurements. For precise measurements, an automatic measuring instrument is required. For a further simple and coarse evaluation, the test page is cut into halves at that X or Y axis. The two halves of the test page are put on top of each other with the emulsion sides facing each other and brought to coincidence at the corner points. Thus, page length, linearity, straightness and perpendicularity can be evaluated using a microscope (40- to 50-fold enlargement).
- 105 -
BAR 1 and BAR 12: Possible error sources Sharply focused exposure, but geometrical distortion -> Observe photo material handling, such as transport, temperature, humidity, development. Unsharpness and distortion -> Possible reason(s): photo material not fitting during exposure. Linearity error and page length error in FastScan direction -> Possible reason(s): drive failure of the rotating mirror. Linearity error and page length error in SlowScan direction -> Possible reason(s): drive failure of the exposure carriage. Straightness error: deflection of lines in FastScan direction -> Possible reason(s): deadjustment of the beam position. Straightness error: deflection of lines in SlowScan direction -> Possible reason(s): failures in the travel distance of the exposure carriage.
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Modifying a Parameter (Brief Description) Modifying a Parameter (Example with Menu Description)
Parameter Set-up ...
... of the Punches ... of the Optics Head ... of the TOUCH MEMORY (Motherboard) ... of the TOUCH MEMORY (Supply Cassette) ... the Guide Opto Switch ... the Advantage Option
Setting the Parameters
-1-
Starting with the basic menu: Enter the password, for this purpose - press key f Search a parameter, for this purpose - press key 2 Select the data record "static data", for this purpose - press key 1 Change to default, for this purpose - press key d Enter the PID or the parameter name, for this purpose - press key 1 Enter new value Save the value (on floppy disk), for this purpose - press key s
Modifying a Parameter (Brief Description)
-2-
HERKULES Test Release version: 2.01.xxx date: xx xx xx 1. speedway commands menu 2. parameter menu 3. test menu 8. adjust tests 9. external tests a. recorder information b. recorder measurement c. quick set of geometry param d. quick set of other param e. toggle recorder status line f. password (ON) (ON) (PF1) (PF2) (PF3) (PF4) (OFF)
Basic menu: After entering the password (for this purpose, press key f), parameters can be modified. To modify a parameter (here: Punch Configuration) press key 2. Modifying a Parameter (Example with Menu Description)
-3-
PARAMETER MENU - WORK DATA q. Quit 1. static data 2. application data 3. action data 4. material data 5. measure data 6. save machine configuration 7. restore machine configuration 8.
This menu contains only data records, as well as commands for saving and restoring recorder-specific data. After selecting a data record (here: static data) you are ... Modifying a Parameter (Example with Menu Description)
-4-
WORK STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit d. Switch to Default
Description of the KEYS KEY 1 Extended parameter search function. You can either search for PID or parameter names. It does not matter how the name is written. If no corresponding parameter is found, the search function suggests a similar parameter. KEY 2 The parameters are listed according to their function (the most important parameters are shown in the first positions, the order corresponds to the one shown on the recorder display). KEY 3 This list is sorted according to the PID numbers.
DEFAULT STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit w. Switch to Work r. Read parameters s. Save parameters
... immediately in the new parameter editor. Press key d to go to the default data record. If, e.g., key 1 is pressed, you can either ...
KEY 4 This list is sorted according to the parameter names.
Modifying a Parameter (Example with Menu Description)
-5-
WORK STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit d. Switch to Default
Description of the KEYS KEY q Quits the parameter editor. KEY w Changes to work mode. Only temporary changes can be performed in the recorder. KEY d Changes to default mode. All changes are permanently effective (as soon as this data record is saved with "s"). KEY r The data record is read from the recorder floppy disk (only possible in default mode). KEY s The data record is written onto the floppy disk (only possible in default mode).
DEFAULT STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit w. Switch to Work r. Read parameters s. Save parameters
... immediately in the new parameter editor. Press key d to go to the default data record. If, e.g., key 1 is pressed, you can either ...
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DEFAULT STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit d. Switch to Default r. Read parameters s. Save parameters
Description of the KEYS KEY y The suggested parameter is correct. A list of all parameters containing the specified names is drawn up. KEY n Looks for more common criteria.
KEY q Quits the search function and return to the DEFAULT STATIC DATA Search PanchKonfugir previous menu. Do you mean 'punch configur' like 'Punch Configuration' ? (y)es, find this (n)o, continue with next proposal (q)uit ... enter the name or the PID. If the name is written incorrectly, a name as similar as possible is suggested. It is also possible to enter a partial string (e.g. 'punch'). After pressing key y ... Modifying a Parameter (Example with Menu Description)
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Continue with any key ... Enter an PID or Parameter name: PanchKonfugir
DEFAULT STATIC DATA 0. | Punch Shape P3 1. | Punch Shape P4 ..... ..... 9. | Punch Advance P0 a. | Punch Advance P1 ..... e. ..... (q)uit (p)rev (n)ext
Search punch | free | free ..... ..... | mm | mm ..... ..... |0 |0 ..... ..... |0 |0 ..... .....
Description of the KEYS KEY q Quits the list. KEY p Previous page of the list (key is only active if there is more than one page to be selected). KEY n Next page of the list (key is only active if if there is more than one page to be selected). KEYS 0 - e Selects the parameter to be edited.
| PID= 83 | PID= 84 ..... ..... | PID= 110 | PID= 111 ..... .....
... a list of all parameters containing this partial string is displayed (here: 'punch' ). If the key for 'Punch Configuration' is pressed, ...
-8-
PARAMETER EDIT Parameter Class Parameter Set Description Ident (PID) Unit Type Access Minimum Value Maximum Value Current Value : DEFAULT PARAMETER : STATIC DATA : Punch Configuration : 766 : free : UINT : User Read, Service Write :0 : 32 : 16
Description of the KEYS KEY ? Call up parameter-sensitive ONLINE help.
New value (?) help:
... the PARAMETER EDIT menu is displayed (no alphabetical character string can be assigned to a numerical parameter). If default parameters have been modified, then they must be ... Modifying a Parameter (Example with Menu Description)
-9-
DEFAULT STATIC DATA - FIND & EDIT 1. Find parameter 2. Normal sorted list 3. Pid sorted list 4. Name sorted list q. Quit d. Switch to Work r. Read parameters s. Save parameters
Continue with any key ... Default parameter changed. Save (y / n) ?
... saved in the parameter editor with key s. If you exit the editor without saving the modifed values an appropriate message is displayed.
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DEFAULT STATIC DATA PID sorted parameter Key | Name | PID | UNIT | 3 | 4 ..... ..... | 17 | 18 ..... | 22 | m | m ..... ..... | m | free ..... | m | VALUE |0 |0 ..... ..... |0 |0 ..... |0
Description of the KEYS KEY q Quits the list KEY p Previous page of the list KEY n Next page of the list KEY f First page of the list KEY l Last page of the list KEY g Go to a specific parameter (input options: PID or name) and show the list from this position onwards KEY 0 - e Selects the parameter to be edited
0. | SS2UZP 1. | FS2UZP ..... ..... 9. | SS2P2 a. | Punch Link P2 ..... e. | FS2P4
(q)uit, (p)rev, (n)ext, (f)irst of list, (l)ast of list, (g)o to
Example for a list sorted according to PID.
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Activating the Punches

Punch Type Punch Geometry Lateral... 1 Key 5 Punch Link PL0 = 1 PL1 = 2 PL2 = 4 PL3 = 8 PL4 = 8 PL5 - 9 = 16 each
NOTE: The parameter setting should be performed on a backup diskette. Precondition: - Switch off the punch on the RIP - Set the RIP to collect mode. At the service terminal: Input Explanation f Password Input check 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 1 Recorder geometry b Changing SS SOP -34500 New value Return to geometry
Bottom... Top...
1 2
5 6
Lateral punches
Top punches Bottom punch
Arrangement of Punches
Parameter Set-up of the Punches
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At the service terminal: Input Explanation Punch configuration (PID 766) X Adding the punch links according to the available lateral punches: 1+2+4+8 = X (variable value) Constant value of top punches = X (value of lateral punches) + 16 (const. value of top punches) = X (value of lateral punches) + 8 (const. value of bottom punches) + 16 (const. value of top punches) Example of punch configuration: Z = 31 = (1+2+4) + (8) + (16) lateral bottom top
Bottom... Top...
1 2
5 6
16 Y
Lateral punches
Z
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At the service terminal: Input Explanation Change punch links according to the list For non-available punch links enter value 0. q q w return return save
Bottom... Top...
1 2
5 6
Lateral punches
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Exposing the Test Film At the RIP terminal: - perform job Punch-li.ps. At the service terminal: Input Explanation 8 Adjust tests p Punching At the RIP terminal: - perform job Punch-Help.ps (measuring template).
- 15 -
Measuring the Test Film At the service terminal: Input Explanation a Recorder information Values Exposing window: - note down 'FS to begin' and 'SS to begin' on the exposed test film. NOTE: The parameter determination for the lateral punches described in the following is meant as example. The parameters for the other punches are determined accordingly. For the arrangement and allocation of the respective punches, refer to the test film: - Lateral punch = Punch 0 to punch 3 - Bottom punch = Punch 4 - Top punch = Punch 5 to punch 9
Lateral punches
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Measuring the Test Film

Template for 'b0' Punch hole 0 Punch
Take measurements on the film using the exposed measuring template (do not interchange scales for Stoesser or Bacher punches). Determine lateral punch - 'Punch 0 FS': - Position the template on top of punch 0 - The line reaching from the center of the punch hole to the two scales below the hole indicates the value 'b0' in mm - Calculate und enter 'Punch 0 FS'.
Value 'b0'
Punch 0 FS = 'FS to begin' + 'b0'
(all values in m)
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Measuring the Test Film Determine the lateral punch - Punch 0 SS: - Position the template on top of punch 0 - Measure the line from the center of the punch hole to the 20mm measuring edge = value a0 - Calculate und enter Punch 0 SS. Take the respective measurement and make the entries for all punches.
20mm measuring edge Template for 'b0'
Punch hole 0 Punch
Punch 0 SS = a0 + SS to begin (all values in m) Parameter Set-up of the Punches

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Measuring the Test Film Determine the lateral punch - Punchend SS: - Measure the black bar positioned opposit to punch hole 0 starting at 20mm measuring edge = value y - Value 'c' = 20000 - 'y' - Calculate und enter punchend SS.
Punch hole 0 Punch
c y
20mm measuring edge
Punchend SS = c + SS to begin (all values in m) Parameter Set-up of the Punches

- 19 -
Entering Punch Parameters At the service terminal: Input Explanation 2 Parameter menu d Set default data flag 1 Static parameter 3 Geometry 5/6 Punch geometry 1 / 2 Enter the measured or calculated parameters and save them Space w Enter and save value 'Punchend SS'. Reset the Herkules and wait for the message Recorder ready. At the RIP terminal: Activate the punch Expose the job Check the punch geometry and, if necessary, correct it.
- 20 -
Start the diagnostic software Determine I(max) of the laser head: - Input: r 42 (The program asks for the approximate value of I(max)) - Input: the noted down value for the optics head (After approx. 1.5 min., the determined value is displayed. Note down this value) Entries in the parameter list for the diagnostics: - Input: r 0 [c] > I(max) value of the laser diode: determined value Save value in the TOUCH MEMORY: - Input: r 0 [w] (determined value) Terminate the diagnostic software: - Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
Parameter Set-up of the Optics Head
- 21 -
Perform a RESET on slot A04. Transfer the determined parameter value ('Max Laser current') onto the recorder software.
'Max Laser current' (PID 563)

Transfer the parameters by means of the user software. - Press the following keys at the operating panel:
Perform filter, light, focus tests and calibration. NOTES: - The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks. - Enter the modified values in the machine manual.
Parameter Set-up of the Optics Head
- 22 -
Start the diagnostic software Format the TOUCH MEMORY: - Input: r 9 [w] (both TOUCH MEMORIES are created) Test the TOUCH MEMORY: - Input: r 9 (duration: approx. 2 minutes) Initialize the timer: - Input: r 9 [t, i] (The time, operating hours, number of switch-on processes are set to 0) Read the timer: - Input: r 9 [t, r] Enter the serial number (from the type label): - Input: r 0 [s, w] (for Herkules) - Input: r 0 [s, w, m] (for Herkules M) - Input: r 0 [s, w, n] (for Herkules NP)
Parameter Set-up of the TOUCH MEMORY (Motherboard)
- 23 -
Read the serial number: - Input: r 0 [s, r] Entries in the parameter list for diagnosis: - Input: r 0 [c] > Peltier temperature: 135 > Hall-Selekt fore mirror motors: 4 > I(max) value of the laser diode: machine-specific parameter (TEST 42) > Light sensor type: 1 > Work. current of guide opto switch: achine-specific parameter (TEST 82) m > Max. feed position (mm): 750 (for Herkules) or 550 (for Herkules M) Save values in the TOUCH MEMORY: - Input: r 0 [w] Terminate the diagnostic software: - Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
- 24 -
Perform a RESET on slot A04. Transfer the parameters by means of the user software. - Press the following keys at the operating panel:
Check whether the floppy disk is being accessed. NOTES: - The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks. - Enter the modified values in the machine manual.
- 25 -
Prior to removing the TOUCH MEMORY ask for the values and note them down (material must not be loaded) - Press the following keys at the operating panel: or Install new TOUCH MEMORY. Initialize TOUCH MEMORY: - Press the following keys at the operating panel:
Enter the material-specific values: - For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology online documentation NT-Utility NOTES: If the values of the old TOUCH MEMORY are unknown (TOUCH MEMORY defective), then test jobs must be run. For this purpose, see operating manual RIP 50, RIP 60 or operating manual delta technology online documentation NT-Utility
Parameter Set-up of the TOUCH MEMORY (Supply Cassette)
- 26 -
Starting the Diagnostic Software Position the opto switch over the reflection foil: - Input: r 86 [g,d,75,300] Start the current measurement: - Input: r82 [r,l,0] - Output: current value XY in mA Entries in the parameter list for diagnosis: - Input: r 0 [c) > working current of guide opto switch : XY + 7 Save the current value in the TOUCH MEMORY: - Input: r 0 [w] Terminate the diagnostic software: - Input: ex Remove the floppy disk containing the diagnostic software. Insert the floppy disk containing the recorder software.
Parameter Set-up of the Guide Opto Switch
- 27 -
Perform a RESET on slot A04. Transfer the parameter value XY + 7 ('Guide LB current') onto the recorder software.
'Guide LB current' (PID 549)

Transfer the parameters by means of the user software. - Press the following keys at the operating panel:
NOTES: - The data stocks in the TOUCH MEMORY and in the recorder software must be identical. - Update the backup floppy disks. - Enter the modified values in the machine manual.
Parameter Set-up of the Guide Opto Switch
- 28 -
Parameter PID 815 'Use ABC' Enabling/disabling the 'Advantage' option Parameter PID 837 'Use Barcode' Enabling/disabling the barcode reader pen Transferring the parameters to the recorder software via the service terminal.
- 29 -
Parameter PID 527 'Use Online Processor' Switching on/switching off the online processor. Even if the 'Advantage' option is enabled (PID 815 'Use ABC' has value "1"), the online processor can be switched off in the case of an error.
Transferring the parameters to the recorder software via the service terminal.
- 30 -
Parameter PID 527 'Use Online Processor' Transfer parameter using the user software. - Press the following key at the operating panel: - General imagesetter parameter set-up: If the parameter record is not "static data": - Press the following keys to select the parameter:
- Press the following keys in succession to edit the parameter:
- To save the parameter after editing, press the following keys: Return to "Edit Parameter" menu Save the parameter
- To return to the main menu, press the following key repeatedly: Parameter Set-up of Advantage Option
- 31 -
General imagesetter parameter set-up Select parameter record To jump to the level below the current one, press the following key:
To select the parameter record, press the following key repeatedly:
To jump to the next higher level, press the following key:
- 32 -
OV ADJ *)
V. ADJ 1 3 2 4 Potentiometer
Settings at the module *) By newer power supply modules this potentiometer is no longer available for the over-voltage protection. The over-voltage protection will be guaranteed during the alignment of the output voltage. **) Jumper at: - 90 - 132 V AC to be screwed in
110 V LINK L N GND
**)
25 AMPS 12 AMPS +S Module B -S +S C
4 AMPS
7 AMPS
6A TOTAL 0V E
- 180 - 264 V AC to be removed
-S +S
-S +S D
-S +15V +15V
+5.1V 0V +5.2V 0V +36V 0V +24V 0V 0V DRP
Service / Settings at the Power Supply Module
-1-
DRP module 1 3 2 4 Programmable connector Pin 1: NC Pin 2: NC Pin 3: Prog in | Resistance 0 ... 10 kOhms (see Pin 4: 0 V | table) between pins 3 and 4. 4 2 1: Power output 2: 0 volt 3: + ve sense Table 4: - ve sense R prog (kOhm) 0 1 2 3 4 5 6 7 8 9 10 Settings at DRP module Depending upon the desired output voltage, connect a resistor (see table) between pins 3 and 4.
3 1
U out (V) 12,0 14,4 16,8 19,2 21,6 24,0 26,4 28,8 31,2 33,6 36,0
-2-
Service / Settings at the Power Supply Module
1 04577698 # H-MOTHERBOARD - 5.949
7 (4x)
2 05318483 # Power supply unit 3 04591402 # TOUCH MEMORY 4KX1
5 4 E1
4 04595467 # TOUCH MEMORY + TIME 5 04595874 # Fan, axial 6 05356393 # Encoding connector 10 kOhm (Herkules PRO) 05356407 # Encoding connector 6.81 kOhm (Herkules) 7 02133113 # Flex. loc-element
with modification 40 Base / Nest
-3-
Proper Use The Herkules is a laser image setter for photo material and must only be used for this purpose in accordance with the operating instructions. Do not use the machine as a depository for any articles or fluids. Do not cover the ventilation slots.
Technical Remarks on Safety
-1-
General Non-observance of the safety regulations may result in the loss of accident insurance coverage. The mains plugs and the local supply sockets must be easily accessible because it may be necessary to disconnect the machine from the mains - for example, in an emergency - by unplugging the mains plug from the socket. The machine is connected to the mains using the supplied mains cable with a three-pole plug. The machine must not be used if the protective ground wire has been disconnected. The mains connector and the fuses are located at the rear of the machine. In order to provide proper ventilation, ensure that there is sufficient distance between the machine and the wall or between the machine sides and other equipment when the equipment is installed. Please refer to the chapters Installation and Technical Data when installing the machine. The machine must: - not be installed in the vicinity of air conditioning systems - be protected from direct sunlight or electric spotlights in the room - be protected from humidity
-2-
CAUTION: Lithium Battery VORSICHT: EXPLOSIONSGEFAHR BEI UNSACHGEMEM AUSTAUSCH DER BATTERIE. ERSATZ NUR DURCH DENSELBEN ODER EINEN VOM HERSTELLER EMPFOHLENEN GLEICHWERTIGEN TYP. ENTSORGUNG GEBRAUCHTER BATTERIEN NACH ANGABEN DES HERSTELLERS. CAUTION: DANGER OF EXPLOSION IF BATTERIE IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURER`S INSTRUCTIONS. ATTENTION: IL Y DANGER DEXPLOSION SIL Y A REPLACEMENT INCORRECT DE LA BATTERIE. REMPLACER UNIQUEMENT AVEC UNE BATTERIE DU MME TYPE OU DN TYPE RECOMMAND PAR LE CONSTRUCTEUR. METTRE AU RBUT LES BATTERIES USAGES CONFORMMENT AUX INSTRUCTIONS DU FABRICANT.
-3-
Mechanical Hazards CAUTION: If, in case of servicing, the dust cover is open and the key-operated switch has been actuated (safety switch is disabled), there is a danger of being squeezed in the carriage travel range!
-4-
Laser Safety Definitions - Laser equipment: - Laser unit: General The laser imagesetter Herkules is a laser equipment of laser class 1. This means that the laser radiation generated in the machine is screened using protective covers. The laser unit installed in the Herkules corresponds to class 3B (5 ... 500 mW). Companies which have servicing performed in Germany must appoint a representative for laser safety in accordance with the Regulation for the Prevention of Accidents VBG 93 of the trade unions. Equipment which includes a laser unit. Laser with laser power pack
Servicing must only be performed by persons which have been instructed correspondingly by the appropriate representative for laser safety.
-5-
Laser Safety Laser Standards and Regulations The laser imagesetter Herkules complies with the valid safety regulations. It is manufactured in accordance with the Regulation for the Prevention of Accidents VBG 93 and the EN 60825, IEC 825 ("Radiation safety of laser equipment"), and 21 CFR 1040 (USA) standards.
Service and Maintenance No laser adjustment should be performed at the Herkules since the modules have been adjusted at the factory and are to be used without any additional adjustments. CAUTION: If, in case of servicing, the Herkules is operated in an open state, with the key-operated switch actuated, there is a danger of class 3B laser radiation if the laser beam is lead outside by reflecting material. If necessary, a temporary laser area must be set up. The Regulation for the Prevention of Accidents VBG 93 ("Laser Radiation") as well as the implementation instructions for the VBG 93 must be met. In addition, the national safety regulations must be observed.
-6-
Laser Safety After repair work has been completed, correct functioning of the safety loop must be checked by opening the cover. During reassembly, the protective covers must be checked for completeness. It must be ensured that these covers do not show any cracks or other damages. CAUTION: If operating or a adjustment devices other than the ones mentioned are used, or if other procedures are applied, this may lead to dangerous exposure to radiation.
-7-
Laser Safety Adjusting goggles: - protective goggles with closed frame for wearers of glasses, order No. 02440628 - protective goggles with standard frame, order No. 04161793
Laser Labels See the illustration of the labels
-8-
Norms and Standards The machine meets the safety regulations of the standards listed below.
General - GSG - 73/23/EEC (law regarding machine safety, Germany) (law regarding technical equipment) (low-voltage directive, Europe)
Mechanical Safety - EN 292 (Europe) - Accident prevention regulations for trade associations (Germany)
-9-
Norms and Standards Electrical Safety - EN 60950 - IEC 950 - UL 1950 - CSA C22.2 No.950 - EN 60204-1 - IEC 204-1 (Europe) (international) (USA) (Canada) (Europe) (international)
Electromagnetic Compatibility (EMC) - EMVG - 89/336/EEC Law regarding electromagnetic compatibility of devices (Germany) EMC directive of the European Council (Europe)
- 10 -
Norms and Standards Interference Emission (interference radiation and interference voltage) - EN 50081-1 - EN 55022, limit B - CISPR 22 mod., limit B - FCC, Part 15, Subpart B, Class A - DOC, Radio Act SOR/88-475, Class A (Europe) (Europe) (international) (USA) (Canada)
Interference Immunity - EN 50082-2 - EN 60801-2 - IEC 801-2/-3/-4 (Europe) (Europe) (international)
- 11 -
Certifications and Markings GS UL cUL CE CDRH certified E156891 (NWGQ) E156891 (NWGQ 7) declaration of conformity applied (Germany) (USA) (Canada) (Europe) (USA)
For labels see section "Schilder-Uebersicht" (label overview).
- 12 -
Pollutants When using cleaning and lubricating agents, observe the manufacturer's instructions. If necessary, consider the safety data sheets, and for Germany the List of Threshold Values quoting the maximum permissible concentrations (List of Threshold Values issued by the Federal Ministry of Labor and Social Affairs) as well as the appropriate local regulations.
- 13 -
Cleaning Always disconnect the machine by pulling out the mains plug if liquid cleaning agents are used. The machine surface can be cleaned using a dry cloth. In the case of stubborn dirt, a dry cloth soaked in water with a cleaning agent and then wrung out may be used. Prevent water from reaching the machine interior and protect the connectors at the machine rear from the humidity. Do not use any abrasive detergents or solvents.
- 14 -
CE-Declaration of Conformity
in accordance with Council Directives 73/23/EEC relating to Electrical Equipment designed for use within certain voltage limits, and 89/336/EEC relating to electromagnetic compatibility Name des Herstellers / supplier`s name: Adresse / address: Heidelberger Druckmaschinen AG Siemenswall D- 24107 Kiel, Germany
declares, that the product
Produktname / product name: Gerteart / product class: Typenbezeichnung / type designation:
Herkules Laser Recorder 2081
conforms with the above mentioned Directives
- 15 -
Applicable Standards: - EN 60950 - EN 50081-1 - EN 55022, Klasse B - EN 50082-2 Safety of Information Technology Equipment including electrical business equipment EMC Generic Emission Standard EMC Generic Immunity Standard
Heidelberger Druckmaschinen Aktiengesellschaft W. Boppel Siemenswall - D-24107 Kiel Senior Vice President Kiel, 20. October 1997 ....................................................................................................................................................... Ort / place Datum / date gezeichnet / signed Stempel / stamp
- 16 -
- 17 -

Service Manual Herkules

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Service Manual Herkules

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E00: Check Interlock on OLP NOTE: There are three interlock switches - processor lid - dryer cover - filter

Replace cover and switch on

Replace fuse 1.5A (S) 6.3 x 32mm

Inverstigate location of film in Herkules.

Are the rollers turning?

E01: Film Jam in Conveyor

Change pcb GCB

Change pcb GCB

Change pcb GCB

Service / Error Messages at the ONLINE Processor

E01: Film Jam in Conveyor

Cut and remove the film

Replace fuse 2A (S)

Change conveyor motor

Check wiring to conveyor motor

Service / Error Messages at the ONLINE Processor

continued on next page Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Check pcb GCB

Check pcb GCB

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Replace pcb GCB

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Set to correct value

continued on next page

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Replace pressure sensor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

System is now operable

Replace pcb OCM04

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Check recirculation inside dev tank.

Wait until it comes up to temperature.

Check continuity of wiring between pcb GCB and heater element.

Replace pcb GCB

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

Service / Error Messages at the ONLINE Processor

How to check a Flow Sensor