Smart-binder Maintenance Training Course (5 days)
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A. Introduction |
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| A 1 | Introduction to IBIS and the Smart-binder system |
| A 2 | Introduction to Smart-binder manuals and Documentation CD |
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B. Smart-binder System |
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| B 1 | Indentification of all elements of the Smart-binder system |
| B 2 | Glossary of terms used in operating the machine |
| B 3 | Overview of general operation of the Smart-binder system |
| B 4 | Safety issues relating to operating and servicing of the Smart-binder System |
| B 5 | How to start/stop the system |
| B 6 | Running demonstration of the Smart-binder in operation |
| B 7 | Review important factors relating to the presentation of sheets from the upstream equipment |
C. Infeed Table |
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| C 1 | Adjusting the Infeed for different sheet sizes. Calibrating the Dial |
| C 2 | Adjusting the Infeed for straight accurate folding |
| C 3 | Ball placement and effects |
| C 4 | Belt replacement |
| C 5 | Discuss folding position (centre fold / off centre fold) relating to paper size and barcode |
D. Sheet Folding and Scoring |
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| D 1 | Setting and adjusting the Nip Rollers |
| D 2 | Setting and adjusting the Scoring Rollers |
| D 3 | Setting and adjusting the Folding lane Belts |
| D 4 | Polycord Belt welding and replacement |
| D 5 | Setting and adjusting the Folding Nip Rollers |
| D 6 | Setting the Entry Guides and guide wire replacement |
| D 7 | Demonstrate correctly folded and scored sheets |
E. Collator |
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| E 1 | Collator Backstop operation, setting and Dial calibration |
F. Pusher/Shuttle |
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| F 1 | Introduction to Pusher and Shuttle operation |
| F 2 | Shuttle timing and Gripper timing (Timing belt replacement) |
| F 3 | Pusher automatic and manual adjustment |
| F 4 | Saddle removal |
| F 5 | Pusher belt replacement |
| F 6 | Pusher Torque Limiter operation and drive belt replacement |
| F 7 | Saddle End Stop setting and adjustment (If fitted) |
G. Stitching Head Operation and Adjustment |
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| G 1 | Introduction to Hohner Stitching Head |
| G 2 | Setting and adjusting Stitch positions and Lower Guides |
| G 3 | Setting and adjusting Stitch pressure and V Clamps |
| G 4 | Setting, adjusting and servicing Clinchers |
| G 5 | Stitcher Head timing and Clincher timing. (Belt replacement) |
| G 6 | Complete Stitching Head training (view Hohner video if available), how to change wire spools, clear jams, adjust wire length and balance leg lengths |
| G 7 | Fault diagnosis relating to Stitch quality. (Hohner manual) |
| G 8 | Run the Smart-binder with paper to produce correctly Stitched books |
H. Trimmer and Trimmer Transfer |
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| H 1 | Introduction to Trimmer Transfer and Trimmer |
| H 2 | Review safety issues relating to Stitcher and Trimmer operation |
| H 3 | Belt replacement on Trimmer Transfer |
| H 4 | Setting and adjusting the Upper Transfer Assembly |
| H 5 | Adjusting Front Knife and Side Knife Backstops to give ‘square’ books |
| H 6 | Adjusting Backstops and Frontstops for different book sizes |
| H 7 | Adjusting Side Knives for different book sizes |
| H 8 | Adjusting Trimmer Side Joggers |
| H 9 | Setting and adjusting the Book Guides |
| H 10 | Setting and adjusting the Transfer Nip Rollers |
| H 11 | Transfer Nip Roller drive belt replacement |
| H 12 | Backstop Drive Belt replacement |
| H 13 | Setting and adjusting the Reject Gate |
| H 14 | Setting and adjusting the Trimmer Con-Rods |
| H 15 | Setting and adjusting the Front knife |
| H 16 | Setting and adjusting the Side Knives |
| H 17 | Run the Smart-binder with paper to produce correctly trimmed books |
I. 4th/5th Knife Installation, Setting and Operation (if supplied) |
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| I 1 | Review safety issues relating to 4th/5th Knife and Knife handling |
| I 2 | Fitting and setting the 4th/5th Knife assembly |
| I 3 | Run the Smart-binder with paper and produce 2-up stitched and trimmed books |
J. Outfeed Conveyor |
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| J 1 | Introduction to Outfeed Conveyor |
| J 2 | Batch counting |
| J 3 | Book separation |
| J 4 | Belt replacement |
K. Cover Feeder |
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| K 1 | Introduction to the Cover Feeder |
| K 2 | Adjusting the Infeed for different cover sizes |
| K 3 | Setting the Pile Guides |
| K 4 | Replacing the Cover Feeder belts |
| K 5 | Run the Smart-binder with paper to product correctly trimmed books with covers |
L. Touch Screen |
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| L 1 | Operator functions and settings |
| L 2 | Service functions and settings |
| L 3 | Log files |
| L 4 | PC and PMAC Software updates |
M. Fault Finding and Resolution |
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| M 1 | Review possible book quality problems, causes and rectification |
| M 2 | Review possible paper jam conditions, causes, prevention and jam clearance |
| M 3 | Practical Fault Diagnosis including fault insertion tests |
| M 4 | Review of Make-ready Charts and carry out sheet length change |
| M 5 | Review of Make-ready Charts and carry out Web size change |
N. Electrical Overview |
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| N 1 | Function and setting of all sensors |
| N 2 | Review all electrical systems |
| N 3 | Review all electrical drawings |
O. Parts Replacements, Maintenance and Spare Kits |
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| O 1 | Review contents and use of standard Smart-binder accessories kit |
| O 2 | Review basic spares kit |
| O 3 | Review extended spares kit |
| O 4 | Review use of parts manua |
| O 5 | Carry out routine maintenance procedures |
P. ISG Gluing System |
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| P 1 | Overview of Gluing system |
| P 2 | Operation of Gluing system, sensor and settings |
| P 3 | Carry out routine maintenance procedures |
Q. Off-line Pile Feeder |
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| Q 1 | Introduction to the pile feeder and offline operation |
| Q 2 | Adjusting the feeder for different sheet sizes |
| Q 3 | Setting the Pile Guides and Pile Height Sensor and air and vacuum |
| Q 4 | Maintenance of sheet feeder |
| Q 5 | Run the Smart-binder with paper to produce correctly trimmed books |
R. Roller Table |
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| R 1 | Introduction to the roller table and on-line/offline operation |
| R 2 | Adjusting for different sheet sizes |
| R 3 | Setting the sheet guides for on-line and for off-line operation |
| R 4 | Maintenance of roller table |
| R 5 | Run the Smart-binder with paper on-line and off-line |