fd 540 main man.pdf

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FD 540

Burster

AINTENANCE

FIRST EDITION

MANUAL



MAINTENANCEGeneral 1

Safety Warning 1

Electrical 1

Mechanical 1

Preventive Maintenance 1

TECHNICAL ADJUSTMENTSRoller Tension Adjustment 2

Motor Belt Adjustment 3

Jam Detection Grill Adjustment 3

Stacker Drive Belt Tension Adjustment 4

Roller To Roller Timing 4

Sequence Stacker Grill Adjustment 4

REMOVAL AND REPLACEMENT PROCEDURESDrive Chain Replacement 5

Feed Roller Drive Chain Replacement 5

Teon Blind Replacement 5

Stacker Pulley Drive Belt Replacement 6

Static Wand Replacement & Installation 7

Slitter Blade Replacement 7

Center Slitter Operation & Illustration 9

Tractor Removal & Replacement 9

Ink Roll Removal & Replacement 10Speed Control Replacement 10

WIRING DIAGRAMS

SERIAL NO. 1963 THRU 3969Serial No. 1963 thru 3969 12

Serial No. 1963 thru 3969 Export 13

Serial No. 1963 thru 3969 14

SERIAL NO. 3970 AND HIGHERSerial No. 3970 and Higher 15

Serial No. 3970 and Higher Export 15

Serial No. 3970 and Higher 16

Top View All Models 16

SCHEMATIC DIAGRAMS

SERIAL NO. 1962 AND LOWERBurster Schematic 17

TABLE OF CONTENTS



SERIAL NO. 1963 THRU 3969 All Models, Ladder Diagram 18

SERIAL NO. 3970 AND HIGHER All Models, Ladder Diagram 19

ILLUSTRATED PARTS BREAKDOWNFrame Assembly 20

Drive Conguration Assembly 22

Stacker Tray Assembly 24

Slitter Box Assemblies 25

Imprinter & Tractor Assemblies 26

Stacker-Tractor Assembly 28

Decal 30



MAINTENANCE

GENERAL

This section includes electrical and mechanical

descriptions, preventive maintenance, technical

adjustments, and replacement procedures.

SAFETY WARNING

Always be sure that the machine is unplugged before

any attempt to do any maintenance covered in this

section.

EXPORT MODELS

DO NOT test the 115 volt components using the 230 volt

power line. DO NOT jumper the AUTOTRANSFORMER

or connect it in any other fashion - than is marked.

Catastrophic failure of the components may result.Reversal of the transformer wires can double the voltage

on the components, cause their immediate destruction,

and create a potential hazard to service personnel.

ELECTRICAL

The 540 Series Bursters operate on standard line

voltage of 115 volts, 50-60 Hertz (US models) or 230

volts, 50-60 Hertz (Export Models). Both models use a

solid state electronic speed control and a permanent

magnet DC main drive motor.

Refer to wiring schematic. Power enters the Burster via

the line cord that terminates at the line (on/off) switch,

When switched on, it activates the neon indicator light.

Also activated is the speed control. DC power goes

through the run relay and the surge resistor to the motor

If a jam occurs the jam detector switch will drop out the

run relay and complete the braking circuit. The rotationa

energy in the motor will be dissipated in the brake

resistor and the burster will come quickly to a halt.

MECHANICAL

Power is transmitted from the Motor to a Pulley /

Sprocket Cluster via a Drive Belt. It is transmitted to the

Feed and Snap Roller Carriages via chain and sprocket

idlers.

The form is fed at one rate by the Feed Rollers, when

the form reaches the Snap Rollers it is pulled at a faster

rate up against the Tear Points. This causes a piercing

effect at the perforation. As the form is pulled taut

against the points, the bottom ply starts to separate atthe tip of the tear point, followed in succession by the

plies above.

The upper Feed Roller has one at running the length

of it which releases the form during each revolution. It is

during these release moments that the paper is allowed

to pivot and any deviation in paper feeding is corrected.

PREVENTIVE MAINTENANCE

Preventive maintenance or PM is scheduled or

unscheduled cleaning, inspections, parts replacement,

or adjustments performed to prevent possible future

machine failures. PM is one basic requirement of an

economical machine installation.

ITEM EVERY INSPECT CLEAN LUBE ACTION

Idler Sprockets 3 mos. X Lt, machine oil

Chain 3 mos. X X X Oil, Grease

Rack 3 mos. X X X Grease

Gears 3 mos. X X X Grease

Static Eliminator Wand 3 mos. X X Vacuum

The following table shows PM activities and

their recommended frequencies. Extra-shift or

extra-heavy usage may require more frequent

performance of these activities or more emphasis on

certain parts of the machine.

1



TECHNICAL

ADJUSTMENTS

ADJUSTING ROLLER TENSION

There are many adjustments that are required for the

proper operation of your burster. Your burster has beenadjusted at the factory to operate with a variety of form

sizes and weights.

Before any of the factory settings are changed to remedy

a form problem, be sure of the following:

1. The form you are using is not a “bad” form i.e. poor or

inconsistent perforations, bad crimps or excessive glue,

trim that has weak perforations, etc.

2. All operator adjustments have been adjusted property,

i.e. form length, tear point height, proper timing of 3 1 /2”and 7” forms, placement of stacker wheels, etc.

3. The problem has been traced down to a single cause

or a set of causes.

4. If it is found that the burster is out of adjustment,

proceed with the necessary adjustments, following the

instructions as outlined below.

ROLLER TENSION ADJUSTMENT

Tools Required:

Phillips Screwdriver

Roller Tension Scale

Roller Tension Strap

1/8” T Allen Wrench

3/16” Allen Wrench

NOTE: The procedure for checking and adjusting Roller

Tension is the same for Feed and Snap Rollers.

Procedure:

1. Remove Hand Wheels and side covers.

2. Slide safety cover open.

UNPLUG MACHINE

3. Measure Roller Tension to know

where you are working.

NOTE: There is no specic roller tension to start with.

Different forms require different tensions. Tension readings

are for a reference gure only. Therefore roller tension

is set to burst all the forms that a customer has. Outfeed

(snap) roller tension should always be at least I to 2 lbs.

lower than infeed roller tension. If the Signature is creeping

on imprinters, check that the infeed Roller Tension is highenough that the form is not being pulled through the Rollers.

4. To measure roller tension, insert a roller Tension Strap,

(part # 301-6025), outfeed to infeed side, between the two

rollers, insuring you are not on a at. If you have metal

upper rollers insert a piece of paper between metal roller

and strap. Connect the roller tension scale to the strap. Pull

scale with strap so the strap moves slowly and smoothly

without stopping, thus trying to get the lowest reading

possible. Read scale on the pounds scale and record. Most

rollers can be checked at three points (ends and middle)

under normal circumstances. When trouble shooting

however, all lobes should be checked. When pulling strapfor readings be sure rollers do not turn.

5. Advance the feed roller carriage so that the holes

centered between the feed roller cover retaining screws are

visible through the holes centered in the safety cover slides.

6. The screws used to adjust the roller tension are

accessible through these holes and the holes in the top of

the snap roller assembly.

7. Loosen the screws (Two each) that retain the upper

bearing plate on each side of the feed roller or snap roller

assemblies. (Figure 1)

2



8. Insert the 1/8” allen wrench into the adjustment

holes and turn it clockwise to increase roller tension

and counterclockwise to decrease roller tension. Make

small adjustments to the original tension setting to arrive

at the new setting (no more than 1/8 of a turn at a time).

(Figure 1)

Fig. 1

9. Tighten the retaining screws on the bearing plate and

test this new tension. If tension checks out, replace the

side cover and handwheels.

10. Test run machine.

MOTOR BELT ADJUSTMENT

Tools Required:

Allen Wrench, 3/16 .

Small Truarc Pliers

Medium Size Phillips Screwdriver

2 Short 4x4 Wooden Blocks

Procedure:

1. Unplug machine and remove operator and drive

side covers.

2. Roll the carriage out to the 7” position.

3. Remove the truarc “C” Clip from the drive side of

the infeed teon blind anchor shaft.

4. Remove the shaft and loosen the front portion of

the Blind to see the drive motor. Place 2 short 4x4

wooden blocks under machine to gain access to the

motor nuts.

5. Loosen the four mounting bolt nuts to the Motor and

adjust its position such that there is a 1/4” deection

in the middle of the drive belt.

6. Tighten the nuts while checking the position of the

motor and the tension on the belt.

7. Reinstall the front portion of the blind on its support

shaft and secure it with the truarc “C” Clip.

8. Test the machine and replace the side covers.

JAM DETECTION GRILL

ADJUSTMENT

The jam detection grill is adjusted to guide a variety of

form sizes and weights to stop the machine in case a

form deviates from its normal path. If the jam detection

grill is bent or becomes misadjusted, or if you are using

a heavy or a light form, adjustment of the grill may be

necessary.

Tools Required:


Procedure:

1. Unplug machine.

2. Remove the side covers.

3. If heavy or multipart forms cause the jam detection

switch to stop the machine prematurely, then the jam

detection grill or the switch will need adjustment. Raise

the grill stop, after loosening the two screws, to make

the grill less sensitive to thicker forms. Lowering the jam detection switch will decrease the jam detection

sensitivity.

4. Reverse the above procedure to improve the detection

of jams when running light weight or single copy forms.

5. Replace side covers and test the machine.

3



STACKER DRIVE BELT

TENSION ADJUSTMENT

Tools Required:

Medium size Phillips Screwdriver

Procedure:

1. Unplug the machine.

2. Remove the operator side cover.

3. Loosen the screw that fastens the pulley

gear shaft to the inside of the side frame.

4. Adjust the gear shaft so that the large pulley

gear meshes with the large gearpulley. This should

also provide a 1/4” deection in the stacker drive belt.

(Figure 2)

Fig. 2

5. Tighten screw and check belt tension..

6. Replace the side cover and test the machine.

ROLLER TO ROLLER TIMING

(Imprint Models Only)

1. Set carriage to 7.0” Imprint position. (Form

Length)

2. Turn clutching hand wheel until white dots on both

upper rollers are visible through openings in roller

covers.

3. Set infeed roller dot to top dead center, (TDC) note

location of the snap roller dot. If timing is correct, dot will

be at TDC. If more than 1/2 Dot off, adjustment is

required.

4. If dot is Left 1/2 dot or more timing is off one tooth or more

If dot is Right more than 1/2 dot timing is off one tooth on

sprocket.

5. Loosen the idler sprocket that maintains tension on the

drive chain. When the chain clears the sprocket for the upper

snap roller, rotate the proper number of teeth in correct

direction to correct timing.

6. Tighten chain with idler sprocket andrecheck timing.

SEQUENCE STACKER GRILL

ADJUSTMENT

The grill has two positions, 15 and 25 degrees off vertical.

A rule to follow is the stiffer the form, the higher the grill. So

if card stock is being run, they will stack better if the grill is

almost vertical.

Procedure:

1. Remove the grill from the rst set of holesand place in the second set of holes or visa

versa. (Figure 3)

Fig. 3

4



REMOVAL &

REPLACEMENT

PROCEDURES

DRIVER CHAIN REPLACEMENT

Tools Required:Small Flat Blade Screwdriver

Medium size Phillips Head Screwdriver

Allen Wrench set

Procedure:

1. Unplug machine.

2. Remove the drive side cover.

3. Locate the Master Link on the Chain. Spread the

holding clip with a ne screwdriver. Lift the clip over the

heads of the cross-pins and remove the spacer. (Figure

4)

4. Loosen Chain Idler.

5. Install replacement chain and adjust the Idler.

6. Replace the covers and test the machine.

FEED ROLLER DRIVE

CHAIN REPLACEMENT

Tools Required:

Small Flat Blade Screwdriver Medium Size Phillips Screwdriver

Procedure:

1. Locate and remove the Master Link (see step 3 of the

Drive Chain Replacement Procedure), (Figure 5)

Fig. 5

2. Remove Chain.

3. Install replacement and fasten Master Link.

TEFLON BLIND REPLACEMENT

Tools Required:

Small Truarc Pliers

Needlenose Pliers


Small Flat Blade Screwdriver

GUIDE DIAGRAM

5



REF. PART NO. DESCRIPTION

A 342-8136 Spring, Guide

B 392-8709 Infd Cover Assy.

C 332-8874 Cross Rod, 3/8”

- 379-2839 Truarc, 3/8”

D 332-8871 Long Rod, 1/4”

- 379-1716 Truarc, 1/4”

E 323-8812 Teon Blind

F 332-8872 Short Rod, 1 /4”

G 341-8817 Outfeed Stacker Guide

H 342-7758 Extension Spring

J 390-8729 Guide Wire

K 332-0009 Carriage Advance Rod

L 334-8821 Feed Roller Brace Shaft

- 379-5498 “C” Clip, 3/8”

M 334-8820 Guide Wire Shaft

Procedure:

1. Unplug Machine.

2. Remove Stacker Tray.

3. Remove Side Covers.

4. Position the carriage to 7” forms length position.

5. Note routing of Teon Blind before removal.

6. Remove Teon Blind Tension Springs (H) from both

ends of the 1/4” Rod (F).

7. Remove Truarc from 1/4 Rod (D) on infeed end of the

Blind, remove the Rod from the Drive Side.

8. Remove the Blind and Short 1/4” Rod (F) from

outfeed end of the Blind.

9. Before installing the new Blind. Remove both Rod (C)

on infeed end and Shaft (L) below the Tear Bar.

10. Place new Teon Blind in position loosely, install Rod

(D) through end of the blind and secure with Truarcs so

there is no end-to-end play.

11. Install Rod (C) above Rod (D) with Blind over the top

of Rod (C) secure with no end-to-end play.

12. Place Rod (F) through opposite end of Teon Blind, hook

springs (H) on both ends of Rod (F).

13. Install Rod (C) at infeed roller with Blind routed over Rod

(C). Secure with no end-to-end Play.

14. Push up evenly on Blind to prevent tearing at edges.

Push shaft (L) through so blind is routed over top of shaft (L).

Secure with “C” clips.

15. Install Stacker Tray and side Covers.

STACKER PULLEY DRIVE BELT

REPLACEMENT

Tools Required:


Small Truarc Pliers

Set of Allen Wrenches

Procedure:1. Unplug Machine.

2. Remove Side Cover, Operator Side.

3. Remove Truarc “C” clip from end of the Stacker Drive

pulley-gear.

4. Remove the pulley and belt, (Figure 6)

Fig. 6

5. Install replacement belt in the reverse order and

tighten belt with idler.

6



STATIC WAND REPLACEMENT &

INSTALLATION PROCEDURE

Tools Required:


Short Phillips Screwdriver

Slip Joint Pliers

2 each 4 x 4 x 18” Wood Blocks

Procedure:

1. Unplug Machine.

2. Lift each end of machine and place a 4 X 4

wood block under ends to gain access to bottom

of machine.

3. Remove Base Plate Cover by removing the

four feet.

4. Position the Static Wand Transformer next to the Drive

Motor. (Must be done through bottom of machine or

removal of the Teon Blind is required.)

5. Place the Transformer with the power cord closest to

the outfeed end of the machine.

6. Fasten the Transformer with two screws.

(Front and Back)

NOTE: If you have a problem reaching these two

screws, remove the carriage rod from the drive side of

the machine and you can reach in under the Teon Blind.

7. Route the power cord through chassis access hole,

forward of the Speed Control.

8. Fasten the White and Black Wires. Black to pin 5 of the

terminal strip and the White to pin 6 or 7.

9. Slide the connector end of the Static Wand into the

Transformer. Fasten by turning the threaded collar

clockwise. Attach the Ground wire to the Transformer

Ground Stud.

10. Insert the Static Wand into the outfeed ngers.

(Figure 7)

11. Hold Static Wand in place with retaining brackets and

tighten Screws. The other end of Green Ground Wire

(Step 9) should be connected to the Bracket screw before

tightening.

Fig. 7

SLITTER BLADE REPLACEMENTWhen the cutting characteristics of the Slitter begins to

deteriorate it will be necessary to alternate them. Slitter

Blade Assemblies are designed to be interchangeable. By

exchanging the Upper and Lower Slitter Blade Assemblies in

each Edge Slitter Box. Double Slitter Blade life is obtained.

When both cutter edges are worn, a new set of Slitter Blade

Assemblies must be ordered and installed. (Figure 8)

Fig. 8

Tools Required:

Medium Phillips Screwdriver

Small Retaining Ring Pliers

Small Blade Screwdriver Procedure;

7



1. Unplug the machine.

2. Remove both Side Covers.

3. Remove the Chain from the Slitter Drive

sprocket. Remove the Sprocket. (Figure 9)

Fig. 9

4. Remove the Retaining Ring, Spacer Washer, and

Wavy Washer from upper and lower Slitter Shafts.

(Figure 10)

Fig. 10

5. Remove the Collar from the Ops. Side, Slitter Locking

Rod and remove Rod from the Drive Side of machine.

6. From the Drive Side of the machine, Cut and remove

the Safety wire from the drive pins. Push the Plastic

Slitter Drive Gears inward, on the shaft, and remove the

Drive Pins. Remove the Slitter Drive Gears and Wavy

Washers.

7. Remove the four Slitter Drive Bearings.

8. Remove the whole Slitter Assembly in tact.

9. Place the Slitter Assemblies, on shafts, in

front of you on a suitable protected table.

10. Remove the Edge Slitters Top Caps,

11. Remove the Top Slitter Bearing Retainers, Bearings,Washers, and Springs from both Edge Slitters. (Figure 11)

Fig. 11

12. (If applicable) From the right side of the Upper Center

Slitter Assembly, remove the Bearing Retainer, Bearing,

Washer and Spring.

13. (If applicable) Loosen the Setscrew in the Lower Center

Slitter Assembly Hub.

14. Withdraw each Slitter Assembly from the shafts with care

15. Turn Edge Slitters Upside-down and install new Lower

Blade Hub Assemblies and related hardware, while inserting

the Lower Slitter Shaft.

16. Turn Edge Slitters right side up and install new Upper

Blade Hub Assemblies and related hardware, while inserting

the Upper Slitter Shaft.

8



17. While installing the spring, Washer, Bearing Retainer

and Bearing in the Upper Blade Assembly of each Slitter

box, be sure that the Upper Slitter Assembly is sprung

against the Lower Blade Assembly.

18. Replace the Edge Slitter Top Caps.

19. Replace Slitter Assemblies and Shafts into

the Machine using the reverse of the disassembly

procedures (steps 1 - 12) to reassemble the Machine.

CENTER SLITTER OPERATION

AND ILLUSTRATION

Tools Required:

Allen Wrench Set

Procedure;

1. Rotate the Handwheel to bring the Setscrew in the

Lower Center Slitter Blade Assembly in line with the slot

in the Lower Paper Table.

2. Position the Lower Center Slitter Assembly so that

the right edge of the blade is in line with the point on the

form to be slit.

3. Use the Allen Wrench to tighten the Setscrew. Slidethe Upper Center Slitter Assembly against the Lower

Blade. Slide it far enough so that the spring in the Upper

Center Slitter Assembly applies light pressure to the

Lower Blade. Do not fully compress the Spring.

TRACTOR REMOVAL AND

REPLACEMENT

Tools Required:



Procedure;

1. Unplug Machine.

2. Remove both side covers.

3. Remove the belt from the plastic tractor

drive gear on the drive side of machine.

4. Remove collar from operations side of drive shaft.

5. Pull tractor drive Shaft, with oilite bushing, from the frame

on the drive side of the machine.

6. Remove the mounting screws from both ends of the tracto

support shaft and remove tractors from the machine.

7. To install new tractors place left tractor on left end and

right tractor on right end of the support shaft.

8. Reinstall tractor support shaft, leaving the

end mounting screws loose.

9. Install tractor shaft on to frame from the drive side of the

machine. When extending shaft through the tractors make

sure they are in time with each other. This is noted by looking

on side of tractor toward the middle of the machine. Therewill be a stationary dot or line and a dot or line on the rotating

part where the shaft passes through the tractor. These dots

and or lines must be aligned with each other as the shaft is

extended through the tractor. This sets the tractor timing. If

the tractor timing is off when these marks are aligned with

each other the belt has jumped a cog in the tractor and the

tractor should be replaced.

10. Extend tractor drive shaft on through the operations side

with oilite bushings seated properly on both ends of the shaft

With the collar, on the drive side, snugly against the oilite

bushing, install the collar on the operations side of machine

so there is no play end to end.

9



11. Reinstall belt on pulley and slitter pulley.

NOTE; The tractor drive pulley should be free moving for

the length of the slot in the pulley. The setscrew in this

slot does not go all the way through the shaft. Shaft is

threaded part way so damage to the setscrew or shaft

will result if forced. If there is no play in the tractor drive,

signature creeping and breaking of tractor belts will

result.

12. Set edge of tractors level with infeed tray and tighten

screws on ends of support Rod.

13. Test run machine and install side covers.

INK ROLL REMOVAL &

REPLACEMENT

Tools Required:


Allen Wrench Set

NOTE: It is suggested that disposable gloves be worn

for this operation. Part No. 357-0001 Disposable Glove,

Part No. 357-0002 Ink Cleaning Towlettes

Procedure:

1. Lift and slide the Ink Roll Cover out of the

way.

2. Remove the right Adjustment block. (Figure 12)

Fig. 12

3. Slide the Ink Roll Rod and Bushings out of the adjustment

tracks, (Figure 13)

Fig. 13

4. Remove the bushing and collar from oneend of the Ink Roll Rod.

5. Remove one of the collars holding the Ink

Roll in place.

6. The Ink Roll may now be removed and

replaced.

NOTE: When replacing the Ink Roll holding collar, leave

about 1/16” gap so that the Ink Roll spins freely.

7. For reassembly follow steps 1 through 5 in the reverse

order.

SPEED CONTROL REPLACEMENT

AND ADJUSTMENT

DO NOT ADJUST POTENTIOMETER WITH THE

MACHINE PLUGGED INTO POWER SOURCE.

Tools Required:

Very Small Screwdriver


Lug Crimping Pliers

Procedure:


2. Remove the two Phillips Head screws

holding Speed Control to frame.

10



17. While installing the spring, Washer, Bearing Retainer

and Bearing in the Upper Blade Assembly of each Slitter

box, be sure that the Upper Slitter Assembly is sprung

against the Lower Blade Assembly.

18. Replace the Edge Slitter Top Caps.

19. Replace Slitter Assemblies and Shafts into

the Machine using the reverse of the disassembly

procedures (steps 1 - 12) to reassemble the Machine.

CENTER SLITTER OPERATION

AND ILLUSTRATION

Tools Required:

Allen Wrench Set

Procedure;

1. Rotate the Handwheel to bring the Setscrew in the

Lower Center Slitter Blade Assembly in line with the slot

in the Lower Paper Table.

2. Position the Lower Center Slitter Assembly so that

the right edge of the blade is in line with the point on the

form to be slit.

3. Use the Allen Wrench to tighten the Setscrew. Slidethe Upper Center Slitter Assembly against the Lower

Blade. Slide it far enough so that the spring in the Upper

Center Slitter Assembly applies light pressure to the

Lower Blade. Do not fully compress the Spring.

TRACTOR REMOVAL AND

REPLACEMENT

Tools Required:



Procedure;

1. Unplug Machine.

2. Remove both side covers.

3. Remove the belt from the plastic tractor

drive gear on the drive side of machine.

4. Remove collar from operations side of drive shaft.

5. Pull tractor drive Shaft, with oilite bushing, from the frame

on the drive side of the machine.

6. Remove the mounting screws from both ends of the tracto

support shaft and remove tractors from the machine.

7. To install new tractors place left tractor on left end and

right tractor on right end of the support shaft.

8. Reinstall tractor support shaft, leaving the

end mounting screws loose.

9. Install tractor shaft on to frame from the drive side of the

machine. When extending shaft through the tractors make

sure they are in time with each other. This is noted by looking

on side of tractor toward the middle of the machine. Therewill be a stationary dot or line and a dot or line on the rotating

part where the shaft passes through the tractor. These dots

and or lines must be aligned with each other as the shaft is

extended through the tractor. This sets the tractor timing. If

the tractor timing is off when these marks are aligned with

each other the belt has jumped a cog in the tractor and the

tractor should be replaced.

10. Extend tractor drive shaft on through the operations side

with oilite bushings seated properly on both ends of the shaft

With the collar, on the drive side, snugly against the oilite

bushing, install the collar on the operations side of machine

so there is no play end to end.

11



11. Reinstall belt on pulley and slitter pulley.

NOTE; The tractor drive pulley should be free moving for

the length of the slot in the pulley. The setscrew in this

slot does not go all the way through the shaft. Shaft is

threaded part way so damage to the setscrew or shaft

will result if forced. If there is no play in the tractor drive,

signature creeping and breaking of tractor belts will

result.

12. Set edge of tractors level with infeed tray and tighten

screws on ends of support Rod.

13. Test run machine and install side covers.

INK ROLL REMOVAL &

REPLACEMENT

Tools Required:


Allen Wrench Set

NOTE: It is suggested that disposable gloves be worn

for this operation. Part No. 357-0001 Disposable Glove,

Part No. 357-0002 Ink Cleaning Towlettes

Procedure:

1. Lift and slide the Ink Roll Cover out of the

way.

2. Remove the right Adjustment block. (Figure 12)

Fig. 12

3. Slide the Ink Roll Rod and Bushings out of the adjustment

tracks, (Figure 13)

Fig. 13

4. Remove the bushing and collar from oneend of the Ink Roll Rod.

5. Remove one of the collars holding the Ink

Roll in place.

6. The Ink Roll may now be removed and

replaced.

NOTE: When replacing the Ink Roll holding collar, leave

about 1/16” gap so that the Ink Roll spins freely.

7. For reassembly follow steps 1 through 5 in the reverse

order.

SPEED CONTROL REPLACEMENT

AND ADJUSTMENT

DO NOT ADJUST POTENTIOMETER WITH THE

MACHINE PLUGGED INTO POWER SOURCE.

Tools Required:

Very Small Screwdriver


Lug Crimping Pliers

Procedure:


2. Remove the two Phillips Head screws

holding Speed Control to frame.

12



545, 547 WIRING DIAGRAM

SERIAL NO. 1963 THRU 3969, EXPORT

13



546-40, 546-50 WIRING DIAGRAM

SERIAL NO. 1963 THRU 3969,

14



544, 546 WIRING DIAGRAM

SERIAL NO. 3970 AND HIGHER

15



540-40, 540-50, 547-40, 547-50 WIRING DIAGRAM


16



544, 546 BURSTER SCHEMATIC

SERIAL NO. 1962 AND LOWER

17



BURSTER LADDER DIAGRAM

SERIAL NO. 1963 THRU 3969

18





19



FRAME ASSEMBLY

21



FRAME ASSEMBLYREF. PART NO. DESCRIPTION REF. PART NO. DESCRIPTION REF. PART NO. DESCRIPTION

A 392-8750 Power Cord Assy.

- 310-5052 Power Cord 11 5V A-R 334-8568 Safety Cover Guide, Dr C-L 379-2840 1/2” Retaining Ring

B 311-0008 Push Button Switch A-S 334-8924 Infeed Brush Bar C-M 392-8709 Infeed Cover Assembly

C 311-0009 On-Off Switch A-T 341-8556 Jam Detection Grill C-R 334-8820 Shaft Guide Wire

D 311-8838 Switch Interlock A-U 341-8816 Blind Finger Guide C-S 312-8837 Timer, #1963 - #3969

E 311-8839 Jam Detection Switch A-V 341-8817 Outfeed Guide Stacker C-T 319-0030 Speed Potentiometer

F 312-7700 Speed Control A-X 342-7758 Module Lock Spring - 377-5467 Wafer Washer

G 314-8335 9 Term Terminal Board A-Y 342-8163 Guide Strap Spring C-U 382-0006 .50 Tinnerman Clip

H 314-8854 #4 Ring Connect A-Z 357-0005 5/8” Hole Plug

J 314-8855 1/4 Ring Connector B-A 360-0053 Speed Pot. Mt. Brkt. NOT SHOWN:

K 315-0003 Cap, Color Code-Green B-B 360-0054 Control Panel

L 315-0004 Cap, Color-Red - 325-0054 Control Panel Inlay X- 392-0033 Cooling Fan Assembly

M 315-5096 Tie Mount B-C 360-0083 Infeed Table X- 313-0004 Cooling Fan.

N 319-5330 Fuse Holder B-D 360-0084 Extended Table X- 341-0006 Fan Guard

P 319-0006 Fuse 3 Amp Slo Blow - 360-8894 Short Table (2546-40) X- 392-8316 5 KV Static Trans. Assy.

R 319-5762 Resistor Ohmite F403 B-E 360-4092 Hole Cover Plate X- 316-8317 Static Transformer

S 319-8318 Static Bar B-F 360-8315 Static Wand Ret. Brkt. X- 378-0004 #10 Kepnut (10-32)

T 319-8336 Relay Deltrol B-G 360-8379 Mt. Bracket Interlock X- 314-5084 #6 Ring Connect

U 320-0008 Thumb Wheel B-H 360-8456 Static Wand Bracket X- 325-0057 Close Cover Decal

V 320-0009 Barrier Bezel B-J 375-0004 6-32 x 1/4 Screw X- 360-0133 Bottom Cover M2540

W 320-6348 Paper Guide B-K 360-8805 Jam Detection Stop

X 320-6371 Spacer Bracket B-L 360-8822 Infeed Cover Plate

Y 320-8890 Infeed Brush B-M 362-4089 Extended Frame, Dr

Z 321-8554 Safety Cover B-N 362-4090 Extended Frame, Ops

A-A 390-0393 Side Cover Assy., Ops B-P 372-6544 Non Swivel Adj. Glide

- 390-0356 Cover Assy. w/counter B-R 372-9587 1/8” Push-On Clips

- 322-0001 Side Cover, Ops B-S 373-2842 6-32 x 5/8 Screw

- 322-0003 Cover Ops w/Counter B -T 373-5826 3-48 x 3/4 Screw

- 320-9586 Control Panel Bezel B-U 373-5869 6-32 int.”Sems” Screw

- 325-5131 TAB Logo B-V 373-5893 6-32 x 3/8 int.”Sems”

- 325-5146 Warning Decal B-W 373-6550 10-24 x 1 1/4 Screw

- 372-9587 1/8”Push-on clips B-X 375-6625 6-32 x 3/8 Screw

A-B 390-0394 Cover Assy., Drive Sside B-Y 375-6537 3-48 x 5/8 screw

- 322-0002 Side Cover, Drive Side B-Z 375-6588 6-32 x 5/16 Screw

A-C 323-8812 Teon Blind C-A 377-2809 # 10 Ext. Tooth Washer

A-G 328-8770 Carriage Guide Rod C-B 377-5855 #3 Int. Star Washer

A-H 390-8729 Guide Wire Assy. C-C 377-5481 Curved Spring Washer

A-J 330-5730 Collar 3/8” C-D 377-2811 #6 SAE Washer

- 376-2804 1/4-28 x 1/4, Setscrew C-F 378-0071 6-32 Hex Nut

A-L 332-8871 1/4” Cross Rod, Long C-G 378-5836 3-48 Hex Nut

A-M 332-8872 1/4” Cross Rod, Short C-H 378-6549 1/4 x 20 Kepnut Nut

A-N 332-8874 3/8” Cross Rod C-J 379-1716 1/4” Retaining Ring

A-P 334-8567 Safety Cover Guide, Op C-K 379-2839 3/8” Retaining Ring



DRIVE CONFIGURATION

23



DRIVE CONFIGURATIONREF. PART NO. DESCRIPTION PART NO. DESCRIPTION REF. PART NO. DESCRIPTION

A 392-8710 Motor Assy. A-G 362-8786 Up Snap RlIr. Plt.,Ops. B-W 377-5290 #10 Fender Washer

313-8835 1/6 HP Motor A-H 362-8788 Up Snap Rllr PIt.,Dr. B-X 377-5481 Curved Spring Washer

315-8533 Motor Brush A-J 365-1072 Synchronous Belt B-Z 378-6549 1/4-20 Kep Nut

C 320-5087 Small Gear Pulley A-K 365-8780 18T Plly, to Ser. #4219 C-A 379-2839 3/8” Retaining Ring

E 328-8783 Stacker Drive Gear 365-0005 22T Gear Bit Plly -40-50 C-B 379-5498 Truarc #5103-37

F 330-5394 Idler Stud and all machines Ser. # 4220 up) C-C 381-5784 Spring Pin, 1/8 x 5/8

G 330-8789 Idler Stud 376-0078 10-32 x 1/4 Setscrew C-D 381-6563 1/8” Dia. Drive Rivet

J 332-0008 Extended Drive Shaft A-L 365-8784 60-23 Combo Pulley C-E 390-0001 Idler Sprocket Assy.

K 332-0009 Carriage Advance Shaft - 376-2807 1/4-20 x 1/4 Setscrew C-F 390-8506 Lower Snap Roller, Nit

L 332-8804 Stacker Drive Shaft A-M 366-0683 Motor Belt 390-8539 Lower Snap Roller,Poly

M 390-4109 Tear Bar Assembly A-N 366-3171 Fork Clutch Pulley C-G 390-8507 Upper Snap Roller,Nit.

334-8679 Tear Bar 376-0075 10-24 x 3/16 Setscrew - 390-8538 Upper Snap Roller,Poly

320-6238 Tear Point A-P 367-1092 Master Link C-H 390-8508 Upper Feed Roller,Nit.

342-6345 Spring Clip 367-2953 Half Link 390-8536 Upper Feed Roller,Poly

342-8180 Tear Point Bar Spring A-R 367-8778 24T Sprkt, to Ser.#4219 C-J 390-8509 Lower Feed Roller,Nit.

N 342-3121 Roller Shaft Spring 376-0003 1/4-20 x 3/8 Setscrew 390-8537 Lower Feed Roller,Poly

S 342-8883 Bearing Spring, Upper 367-4087 32T Spkt,Ser.#4220 Up C-K 390-8575 Clutch Handwhl Assy.

T 342-8884 Bearing Spring, Lower A-S 367-8781 Mn Dr Ch,to Ser.#4219 - 376-0085 1/4-28 x 1/2 Setscrew

V 343-8775 16T Drive Sprocket 367-4088 Main Drive Chain

367-4087 32T Sprocket (-40,-50) -40,-50,& Ser.#4220 up ASSEMBLIES

and all machines Ser.# 4220 up A -T 367-8782 Feed Roller Chain

376-2807 1/4-20 x 1/4 Setscrew A-U 368-8691 Stacker Gear X- 390-8716 Feed Roller Carr. Assy.

W 360-5314 Bearing Retainer 1.75 381-8693 Groove Pin X- 390-8723 I’d Roller Pit. Assy.,Ops

X 360-6663 Snap Roller Cover AN 368-8771 Carriage Adj. Rack X- 390-8724 Fd Roller Pit. Assy.,Dr.

Y 360-8759 Guard Plate A-W 368-8772 Rack Carr. Lock Seg. X- 390-8726 Snp RIr Car. Pit AssyDr

Z 360-8828 Feed Roller Cover A-X 368-8774 15T Spur Gear X- 390-8727 Snp RIr Car. Pit Assy,0p

A-A 360-8878 Bushing A-Y 370-2824 3/8” Sheilded Bearing

A-B 390-8689 Tension Arm Assembly A-Z 370-5992 Ball Bearing NOT

- 360-8985 Tensioner Arm B-A 390-0106 Form Length Knob

- 377-5481 Curved Spring Washer 376-6559 10-32 x 1/2 Setscrew X- 360-0258 Side Frame Idler Brace

- 330-8983 Tension Stud B-B 373-5745 10-24 x 3/8 Screw X- 360-8760 Wire Guard, Ops Side

- 377-6626 7/16” Nylon Washer B-C 373-5869 6-32 Int. “sems” Screw

- 390-0001 Idler Sprocket B-D 373-5893 6-32 x 3/8 Int. “sems”

- 378-6549 1/4-20 Kep Nut B-E 373-2816 1/4-20 x 1/2 Bolt

- 342-8986 Torsion Spring B-F 374-0040 1/4-20 x 1/2 Screw

- 330-5394 Stud B-G 374-0047 10-24 x 1/2 Screw

- 377-5290 # 10 Fender Washer B-H 375-0004 6-32 x 1/4 Screw

- 374-0047 10-24 x 1/2 Screw B-J 375-6538 10-32 x 1/2 button HD

A-C 362-8766 Up Feed RIlr Plt., Ops B-N 377-1813 1/4” Washer

A-D 362-0011 Pit. Rt. RlIr, #2313-up B-R 377-1086 #6 Split-lock Washer

362-8767 Pit. Rt. Rl1r, #2312-Dn B-S 377-1813 Washer 1/4”

A-E 362-0010 Pit. Lft. RIIr, #2313-up B -T 377-2611 1/4” Split-lock Washer

362-8768 Pit. Lft. RIIr, #231 2-Dn B-U 377-2809 # 10 Ext. Tooth Washer

A-F 362-8769 Up Feed Rllr Plate,Dr. B-V 377-4077 3/8 Flat Washer



STACKER TRAY ASSEMBLY

REF PART NO. DESCRIPTION REF PART NO. DESCRIPTION

A 320-6368 Stacker Whl Adj. Rack S 390-8572 Outfd Stack Shft Assy.

B 321-8696 Urge Roller - 320-6226 Stacker Spool

C 341-8695 Stacker Grill - 331-8692 Stacker Shaft

D 360-6660 Stacker Chassis - 381-6635 Groove Pin 1-1/4” Long

F 360-6662 Stacker Wheel Guide - 390-0357 Shft Assy. with Stacker

- 360-0246 Stacker Wheel Guide, - Tractor

Used with Stacker Tractors - 332-0042 Shft, W/Stacker Tractor

G 369-0910 Carrier Belt - 368-8690 Gear, Stacker Tractor

H 371-8699 Oilite Bearing T 392-8542 Stck Whl Pivt arm Assy

J 373-5745 10-24 x 3/8 Phil HD - 320-8135 Stacker Wheel

K 373-5869 6-32 Int.”sems” Screw - 330-8137 Stacker Wheel Axle

L 374-6583 6-32 Soc. HD Screw - 332-6664 Stacker Pivot Axle

M 377-8569 Nylon Washer - 361-8136 Stacker Wheel Arm

N 379-2840 112” Retaining Ring - 376-0077 Special Screw

P 379-5461 Retaining Ring - 376-5809 10-32 Knurled Setscrew

R 390-8571 lnfd. Stacker Shft Assy. - 380-5538 Nylon Pellet

- 320-6266 Stacker Spool

- 331-8692 Stacker Shaft COMPLETE ASSEMBLIES

- 368-8690 Stacker Gear

- 381-6635 Groove Pin,1-1/4” Long - 392-8541 Stacker Assembly

- 381-8693 Groove Pin,3/4” Long

25



SLITTER BOX ASSEMBLY

REF. PART NO. DESCRIPTION REF. PART NO. DESCRIPTION REF. PART NO. DESCRIPTION

A 305-6590 Magnetic Tape A-C 390-8655 Slitter Blade Assembly

B 321-8936 Paper Table Support - 330-8905 Male Slitter Hub

C 330-8909 Lock Collar - 330-8906 Female Slitter Hub X- 392-8653 Left Slitter Assembly

E 331-8989 Slitter Shaft - 343-8904 Slitter Blade X- 392-8654 Right Slitter Assembly

F 332-8871 1/4” Cross Rod A-D 392-0927 Slitter Thumbscrew X- 392-8658 Lower Ctr Slitter Assy.

G 342-8907 Slitter Pressure Spring - 395-0129 T-Handle Thumbscrew X- 392-8659 Upper Ctr Slitter Assy.

H 360-9800 Left Trim Guide A-E 390-0158 Lwr Ctr Slitter Blade Assy X- 392-0112 Lower Wide Slitter, Left

J 360-8901 Right Paper Table - 330-8937 Lwr Female Ctr Slit Hub X- 392-0113 Upper Wide Slitter, Left

K 360-8902 Left Paper Table - 330-8941 Male Slitter Hub/Taped X- 392-0110 Lower Wide Slitter, Righ

L 360-8903 Slitter Housing Cap - 343-8904 Slitter Blade X- 392-0111 Upper Wide Slitter, Righ

M 360-8928 Bearing Retaining Plate - 376-6591 1/4-28 Brass Tipped

N 360-8938 Lower Paper Table A-F 367-4073 1 OT Sprockt,For -40,-50 NOT SHOWN

P 360-8939 Upper Paper Table and all #4220 up X- 325-2632 Slitter Decal

R 362-8940 Uper Ctr Sitter Housing - 376-0078 10-32 x 1/4 SetscrewS 362-8898 Slitter Assy. Housing - 367-8992 18T Sprocket, thru

T 362-8899 Right Trim Guide Ser. #4219

U 370-8887 7/16 Flanged Hex Bearing - 376-0078 10-32 x 1/4 Setscrew

V 373-5868 6-32 x 1/4 Int “sems” A-G 377-5481 Curved Spring Washer

W 373-5869 6-32 x 1/4 Ext “sems” A-H 379-2839 Retaining Ring

X 375-2801 6-32 x 3/8 Flat HD A-J 380-6547 Spacer Washer

Y 376-6591 1/4-20 x 3/8 Brass Tip A-K 368-8921 Slitter Drive Gear

Z 377-2828 Special Washer A-L 381-5784 Groove Pin

A-A 379-5461 Retaining Ring - Safety Wire

A-B 380-8908 Thrust Washer A-M 323-5887 Fish Paper

26



IMPRINTER TRACTOR ASSEMBLY

27



STA19WR-TRACTOR FINGERS ASSEMBLYREF. PART NO. DESCRIPTION

A 360-0215 Stacker Tractor

B 371-5777 Bronze Bushing

C 330-5715 1/4” Collar

376-0078 10-32 x 1/4 Setscrew

D 365-0023 14T Pulley, 1 /4” Bore

376-2805 8-32 x 3/16 Setscrew

E 365-8118 140XL037 Belt

F 392-0055 14T Idler Pulley Assy.

365-0003 14T Drive Pulley

371-5808 1/4” ID Bronze Bushing

G 379-1716 1/4” Retaining Ring

H 332-0028 Tractor Idler Rod

I 371-0014 1/4” ID Flange Bushing

K 371-0013 3/8” ID Flange Bushing

L 371-8699 1/2” ID Flange Bushing

M 377-8569 Washer

N 379-2840 1/2” Retaining Ring

P 390-0357 Shaft Assy. w/Stacker

332-0042 Stacker Shaft

368-8690 Stacker Gear

320-6226 Stacker Spool

381-6635 Groove Pin 1 1/4”

381-8693 Groove Pin 3/4”

Q 332-0029 3/8” Stkr Tractor Dr Rod

R 365-0002 20T Gear Belt Pulley376-0069 8-32 x 1/4 Setscrew

S 360-0235 Stkr Tractor Dr Finger

U 360-0246 Stkr Wheel Guide29

V 368-8691 Stacker Gear

X 390-0099 3/4” Thumbscrew Assy

Y 332-0041 Finger Drive Shaft

AA 381-0013 Magnets

373-5482 6-32 x 1/2 Screw

378-9500 #6 Kepnut

COMPLETE ASSEMBLY

X- 390-0181 Stkr Tractor Finger Assy

28



DecalsREF. PART NO. DESCRIPTION

X- 325-0066 3 Amp, Fast Blow

X- 325-5078 Electrical Warning

X- 325-0001 7” Timing

X- 325-0002 Counter Mode

X- 325-0003 Last Form Defeat

X- 325-0057 CLOSE

X- 325-5146 Warning

X- 325-5131 Logo

X- 325-5940 Fuse Warning

X- 325-0041 Maintenance Warning

Mini Table

REF. PART NO. DESCRIPTION

X- 372-0008 Castors

29

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