Smart-binder Maintenance Training Course (5 days)

A. Introduction
A 1 Introduction to IBIS and the Smart-binder system
A 2 Introduction to Smart-binder manuals and Documentation CD

B. The Smart-binder System
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
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
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
E 1 Collator Backstop operation, setting and Dial calibration

F. Pusher/Shuttle
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
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
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)
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
J 1 Introduction to Outfeed Conveyor
J 2 Batch counting
J 3 Book separation
J 4 Belt replacement

K. Cover Feeder
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
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
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
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
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
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
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
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