Model 912 Cutsheet Document Signer

Transcription

1 Model 912 Cutsheet Document Signer Installation, Operation, and Maintenance Instructions Serial Number 1.0 Introduction Thank you for selecting the Martin Yale Model 912 CutSheet Document Signer/Imprinter. This programmable electronic signer was designed to provide a high level of security, operational flexibility and easy programming. Each signer component has been engineered to perform reliably and is 100% factory tested to ensure years of quality service. We recommend that you familiarize yourself with the signer by carefully reading this manual. Reading and thoroughly understanding this manual will help you avoid the most common problems and eliminate operator-associated errors. Remember, signature plates cannot be manufactured for every application, they must be custom made. Therefore, signature plates must be ordered separately. If you did not order signature plates when you ordered your 912, do so now by calling your Martin Yale Dealer or Martin Yale. WARNING! Never connect power to the machine until you are ready to set up and operate the 912. This machine contains moving parts. During setup, operation, and maintenance keep hands, hair, loose clothing, and jewelry away from all moving parts. Serious bodily injury could result. Service, or disassembly of covers should only be performed by qualified personnel with the power disconnected and locked out. 251 Wedcor Avenue Wabash, IN Phone: (260) Fax: (260) website: info@martinyale.com

2 1.1 Model 912 Specifications Functional Paper Weight # to 70# Form Width Form Length Speed ,400 81/2 x 11 sheets Signature Block Adjusts in 1/6 and 1/56 increments Signature Plates Must Be Ordered Separately Physical Color Gray Dimensions x 12 x 19.5 Weight lbs. Shipping Weight lbs. Electrical Power V/120V, 50Hz./60Hz. Optional V/240V, 50Hz./60Hz. Fuse Amp./250V, 1A fuse for 220/240V 1.2 Table of Contents 1.0 Introduction Page Specifications Page Table of Contents Page Features Page Nomenclature Page Installation Page The Control Panel Page Programming Page Operation Page Maintenance Page Troubleshooting Guide Page Diagnostic Tests Page Error Message Explanations Page 12 Parts Diagrams Page Parts List Page Wiring Diagram Page Features 2.1 Security Five digit security codes at one of two levels guard against unauthorized usage. Cover lock restricts access to signature plates until executive security code is entered. Executive control of batch quantity is optional for each run. Lock key required to reprogram security codes and stored setups. Standard tri-colored ink roller (red, blue, and purple). 2.2 Convenience The Martin Yale 912 CutSheet Signer is a table top office appliance that will sign checks and a wide variety of other documents. Customized signature plates are easily ordered and installed. Signature locations can be found without form measurements or calculations. Signature locations and batch control are easily entered or selected from five stored setups. Variable signature placement, electronically controlled, can be easily adjusted during a run. Long life pre-inked roller is spring loaded for easy removal and quick access to signature plates. 3.0 Nomenclature (See Figures 1, 2, & 3) 1. Ink Roller - saturated with fast drying permanent ink and rotates freely on the ink roller shaft. The ink roller guide holds the ink roller in position. The ink roller shaft is spring loaded into floating brackets. 2. Cover Lock - one on each side of the cover. 3. Control Panel - has a 20-character by 2-line display at the top and a keypad below. 4. Power Switch - has international symbols, 0 for OFF and 1 for ON. 5. Bezel - durable, flame retardant ABS. 6. Feed Table - supports the documents to be signed. 7. Paper Guides - maintain document alignment during feeding. 8. Bracket - one each side, supports the ink roller shaft. FIGURE 1 9. Ink Roller Adjustment Screw - one each side, determines the amount of contact between the ink roller and signature plates. 10. Signature Plate Holder - clamp is spring loaded for easy installation and removal of signature plates. (2)

3 11. Signature Plate - two signature plates required (must be ordered separately). 12. Idler Wheels - a pair of rollers that feed the paper after the paper leaves the drive rollers. 13. Signature Plate Shaft - supports and drives the signature plate holder. 14. Feed Roller - feeds the documents from the bottom of the stack into the drive roller. 15. Retarder - adjusts to allow only one document to feed at a time. 16. Platen - supports the paper during impression. 17. Line Cord - connects the singer to the AC power source. 18. Fuse Holder - contains the replaceable power fuse. 19. Key Switch - is used only to program the security codes and the stored setup parameters. 20. Serial Label - shows the serial number, electrical ratings, and agency approvals. 21. Receiving Tray - catches the signed documents. The backstop adjusts to different document lengths. FIGURE Installation After careful unpacking, place the 912 on a flat level surface for operation. Remove the plastic bag containing the programming keys, hex key (Allen) wrench, and one plastic glove. Plug the power cord into an AC outlet and press the POWER switch. Make sure the programming key is out of the key switch in the rear. NOTE: In this manual, prompts and messages are shown in quotation marks, e.g., New Executive Code?. When prompted for the executive code, press the 1 key 5 times. Open the cover within 5 seconds. If a mistake is made, press CE and re-enter (The factory preset executive security code is If the display shows invalid code when this number is used, use the lock key to reprogram the executive security code. See Section 6.0, Programming.) The platen (backup roller) is normally held in place by friction. For shipping, the platen has been tightened down at the factory. Adjust the platen s sliding friction by using the Allen wrench provided to turn the platen setscrew 3/4 turn counterclockwise from snug. Remove the brown packaging tape that is holding the signature plate holder and platen in place. Also remove the tape from the plexiglass reference guide. 4.1 Positioning The Signature Plate Holder Remove the ink roller shaft by grasping each end and sliding the shaft to the left or right until it clears the bracket. Set the assembly (ink roller, guide and shaft) aside, with the flat side of the ink roller guide down. NOTE: Be careful to keep the shaft horizontal so the ink roller does not slide off the end of the shaft. Rotate the signature plate shaft manually until the setscrew in the signature plate holder is accessible. Use the hex key (Allen) wrench provided to loosen the setscrew. Slide the signature plate holder left or right to the approximate location of the signature block on the documents. Note: The idler disk assembly moves with the signature plate holder. Retighten the setscrew. Slide the platen into place directly beneath the signature plate holder. The platen is held in place by friction. CAUTION: Do not tighten the setscrew in the platen. 4.2 Installing The Signature Plates The 912 requires two identical signature plates to be installed on the signature plate holder. FIGURE 3 Install a signature plate by sliding the plate holder clamp to the left and slipping the notch in the signature plate onto a pin in the right end of the plate holder. Release the plate holder clamp. Manually rotate the signature plate shaft backward until the signature plate touches the platen from behind. Slight contact between the signature plate and the platen prevents the first signature plate from falling off when the opposite signature plate is installed or removed. Install the second signature plate in the same manner as the first. Ensure that both signature plates are seated correctly, flat against the signature plate holder. (3)

4 4.3 Installing The Ink Roller CAUTION: The ink roller is saturated with permanent ink. Always use the protective glove supplied with your 912 (or similar hand protection) when working with ink rollers. Put the ink roller back onto the machine by first positioning the ink roller guide so that it straddles the signature plate shaft, with the flat side of the ink roller guide at the top. Insert the ink roller shaft first into one bracket, then the other. The springs inside the brackets hold the shaft in place. The ink roller adjustment screws determine the inking of the signature plates. 4.4 Adjusting The Ink Roller The depth of inking is adjusted at the factory. If readjustment is necessary, first rotate the signature plate shaft so that a signature plate is facing the ink roller. Look in from the side to see the gap between the signature plate and the ink roller. Adjust the ink roller adjustment screws with a crosspoint (Phillips) screwdriver until the ink roller just contacts the rubber stamp evenly. Turn each screw one more turn counterclockwise. 4.5 Installing The Feed Tray At each end of the retarder bar, raise the feed tray latches and use the 3/32" hex key (Allen) wrench provided to snug the screws. Tilt the feed tray up and slide the top black hook on each side of the feed tray onto its respective support pin. Lower the feed tray into position. Release the tray latches and tighten the screws to lock the tray latches in position. 4.6 Installing The Receiving Tray Slide the receiving tray hooks into the slots in the rear panel window and lower the receiving tray. Install the backstop on the receiving tray in the shortest position that will allow a sample form to lay flat on the receiving tray. Note that the tabs on either end of the backstop fit into the slots in the receiving tray, providing length adjustment from 3" to 17" in 2" increments. 4.7 Adjusting The Retarder Select a sample sheet of the thinnest paper to be processed through the 912. Slide the feed tray paper guides apart to the stops. Use the Diagnostic Test #9 to run the paper drive motor as follows: Restart the 912 by turning it off and back on again. Insert the key into the lock in the rear panel and turn the key clock wise. At the prompt or 2 to Change Stored Forms, press STOP and then press the 9 key 5 times. At the prompt Diagnostic Tests, Depress 1-9, press the 9 key. After 2 seconds, press the RUN key. Pull out the Feed Tray Extension. Hold the sample form by the trailing edge 5" above the feed tray. Feed the leading edge of the sample form into the machine to just below the retarder bar (1/2" past the line of contact between the feed wheel and the retarder). Turn the retarder thumbwheel clockwise until the feed wheel exerts a constant pull on the sample form. Release the form and let it pass through the 912. Press the STOP key. (4)

5 5.0 The Control Panel (See Figure #4) BATCH COUNTER DISPLAY - keeps a running count of documents signed. During setup, this display informs and prompts the operator. JOG FORWARD KEY AND JOG REVERSE KEY - Jog Forward Key Jog Reverse Key These keys are used during setup to align the signature line with the reference line. Each jog step is approximately 1/16. RUN KEY Run Key This key is used at the last step in setup to begin the signing process. PAUSE/STOP KEY Pause/Stop Key NUMBER AND DECIMAL POINT KEYS Decimal Point Key This key is used during operation to stop or pause the singing process. Any other key will do the same. These keys are used to enter security codes and respond to choices offered by the prompts. Figure 4 CLEAR ENTRY KEY CE Clear Entry Key This key is used to clear an incorrect entry. FORMS LENGTH KEY FL Forms Length Key This key is used at any time to have the signer display the current setup. ENTER KEY UNDO KEY - Enter Key Undo Key This key is used to define signature locations, and to skip the five second cover access period. This key is used to back up one step during setup or programming. NOTE: The UNDO KEY is not used to clear an incorrect numerical entry, it will back up to the previous mode choice. 6.0 Programming Two features of the 912 can be programmed. One is the executive and operator security codes that allow the 912 to operate. The other feature is the setup parameters of signature locations and batch control. NOTE: In this manual, prompts and messages are shown in quotation marks e.g., New Executive Code?. To program, first restart the 912. Insert the lock key into the key switch and turn the lock key clockwise. Follow the prompt to select programming of either the Passwords (security codes) or the Stored Forms (stored setups). (5)

6 6.1 Programming The Executive Security Code When Passwords (security codes) is selected, the display will prompt New Executive Code?. To bypass programming of the executive code, press ENTER at this time. To program the executive code, enter a 5-digit number of your choice. Each digit entered will be acknowledged by the moving cursor in the display. If you make a wrong entry, press CE and start again. After the fifth digit, the display will confirm New Executive Code Installed. 6.2 Programming The Operator Code The display will then ask for a New Operator Code?. To bypass programming of the operator code, press ENTER at this time. To program the operator code, enter a 5-digit number. Each digit entered will be acknowledged by the moving cursor in the display. If a mistake is made, press CE and start again. After the fifth digit, the display will confirm New Operator Code Installed. The display will again offer the choice of programming the Passwords (security codes) or Stored Forms (stored setups). CAUTION: If the executive code and the operator code are programmed to be the same, then the 912 will request only the executive code during setup. The second security level will be eliminated. To exit the programming mode, turn the lock key counterclockwise and remove it. 6.3 Programming The Stored Forms Insert the key and turn clockwise, to program the signature locations and/or batch mode for any of the five stored setups. Select Stored Forms at the Passwords/Stored Forms prompt by pressing 2 on the key pad. The display will then ask for a Form Number?. Enter the desired program number (1 through 5). The display will show form parameters currently stored under that program number. Those parameters are: number of signatures per sheet, the location of each signature, and the batch mode. If that stored setup is to be kept under that program number, press CE and enter another program number. Press the Enter Key to Re-Define if you wish to modify that stored setup. The display will prompt Define New Signature Locations. Follow instructions at Load One Sheet; Use Jog Forward Key to advance a sample form into the signer. When the signature line on the form is under the reference line, press the ENTER Key. Follow the prompts to define other signature locations on the form. After the last signature location has been defined, press STOP. The signer will feed out the sample form and prompt for a Batch Mode?. Select Count Up if the signer is to sign and count without limit. Select Count Down if the signer is to sign a predetermined quantity. If desired, follow the prompts to select another form number to re-define. 7.0 Operation Follow the display prompts to enter codes (passwords). Open the cover to install signature plates or adjust the horizontal location of the signature block. Select a stored setup or enter a setup manually by jogging a sample form through the 912 to define the new signature locations. Select the batch mode (count down from a preset quantity or count up until paper is depleted), and initiate the signing process. At each step, the 912 displays a prompt for an entry or action. At some of the steps, supplemental messages are displayed. To eliminate supplemental messages, press any key immediately after power is switched on, before the prompt Enter Executive Code appears. NOTE: In this manual, prompts and messages are shown in quotation marks e.g., New Executive Code?. 7.1 Setup Steps The display prompts and messages are self-explanatory. For reference, here is a list of steps for setup and the choices available at each step. (6)

7 1. Enter Executive Code Enter the 5-digit code that has been programmed as the executive security code. Each digit entered will be acknowledged by the moving cursor in the display. If you make an incorrect entry, press CE and try again. If the code is not accepted, use the lock key to reprogram the executive security code (see Section 6.0, Programming, in this manual). The factory preset executive code is If a form is in the Model 912 and blocking the paper sensor while the prompt Enter Executive Code is displayed, remove forms from the feed tray and press RUN to pass the form out quickly. This method of clearing the Model 912 is faster than using the JOG keys. 2. Cover May Be Opened If you are installing or removing the signature plates, or if you need to adjust the signature plate holder horizontally, open the cover within 5 seconds. To proceed to the next step, press ENTER at this prompt. The 912 will sequence to the next step automatically if this prompt is displayed for 5 seconds, or if the cover is opened and closed. Once the cover is opened, it may be left opened indefinitely. Once the cover is closed, it will be locked until the executive code is entered again. 3. Press 1 for Stored or 2 for Manual If you desire to use the most recent setup again, press CE at this time. The 912 will skip this step and the next two steps. To select a stored setup, press key 1, then press a key 1-5 for the setup number. The 912 will then skip the next two steps. To Define New Signature Locations for the current setup, press key Load One Sheet, Use Jog Forward Key On the feed tray, adjust the paper guides for the width of a sample form. Place it in the feed tray and use the JOG FORWARD key to advance the sample form until the first signature line is directly below the reference line on the clear plastic bar. Press ENTER to define that location. Repeat the JOG FORWARD and ENTER procedure until the last signature location has been defined. To feed out the sample form, press STOP. NOTE: The retarder must be adjusted for correct paper feeding (see Section 4.7, Adjusting The Retarder). 5. Press 1 for Count Up or 2 for Count Down When the count up mode is chosen, the BATCH COUNTER keeps a running total of signatures. The 912 will continue to run until it is out of paper. When the count down mode is chosen, the desired number of signatures must be entered to preset the counter before each batch is run. 6. Enter Batch Amount If the count up mode was chosen, the 912 will skip this step. If the count down mode was chosen, a quantity must be entered, followed by ENTER. 7. Enter Operator Code Enter the operator code if it has been programmed to be different from the executive code. The factory preset operator code is If the operator code has been programmed to be the same as the executive code, the 912 will skip this step. (To reprogram the operator code, see Section 6.0, Programming.) 8. To Begin, Press the RUN key Fan the stack of forms so the stack is tilted away from the 912 (see Figure 5). Place the stack on the feed tray with the bottom form at the line of contact between the feed roller and the retarder roller. To begin the signing process, press the RUN key. The 912 will run until another key is pressed, or the paper is depleted, or the count is down to zero (count down mode). After a few forms have been signed, you may want to pause the 912 to verify the signature alignment and to ensure the forms are stacking correctly. When paused, the 912 displays Batch Count _, HOLD RUN to Continue, with the HOLD flashing. Press RUN to continue. Figure #5 - Fanned Paper The 912 automatically terminates the run if no paper feeds in 8 seconds, or if the count is down to zero (count down mode). To manually terminate the run, press STOP, then press UNDO. The 912 then displays Final Batch _, Press Any Key. To return to the prompt Enter Executive Code, press UNDO again. If a form has been left in the Model 912, remove the stack from the feed tray and press RUN to pass the form out quickly, or use a JOG key. 7.2 Adjusting the Signature Locations To adjust a signature location during a run, first press STOP to pause the 912. Then, press the number of the signature you wish to move. For example, press the 2 key to select the 2nd signature on the form. The 912 prompts Adjust Signature Number 1 (2, 3, or 4). To move the selected signature up, press the JOG FORWARD key. To move the selected signature down, press the JOG REVERSE key. The 912 acknowledges Sig #1 (2, 3, or 4) Moved Up (Down) 1/16 of an inch. NOTE: Only one signature location adjustment can be made during each pause. 7.3 Storing The Adjusted Signature Locations To program the new signature locations into a stored setup, first complete the run. Press UNDO twice to return to the prompt Enter Executive Code. Press the FL key. Insert the lock key into the lock on the rear panel and turn the key clockwise. The 912 prompts Form Number (1-5) to be Updated. Press the number of the stored setup to be updated. The 912 acknowledges Programmed Form Number 1 (2, 3, 4, or 5) Updated. Then the 912 reminds you to Turn Key to Continue. Turn the lock key to the vertical position and remove it. (7)

8 8.0 Maintenance Maintenance information included in this manual consists of an Operators Troubleshooting Guide, Diagnostic Tests, Parts Diagrams with a Parts List, and a Wiring Diagram. For technical assistance, call Martin Yale Technical Support line, CAUTION: Make sure power to the machine is disconnected and locked out before attempting any maintenance procedure. 8.1 Cleaning 1. General As often as needed (but at least weekly), vacuum paper dust and other contaminant from the 912. Clean the main body of the machine with a soft dry cloth. 2. Feed Roller and Jog Roller As often as needed (but at least weekly), clean the feed roller and the jog roller (located on the feed tray) with a cloth dampened with a mild soap and water solution. 3. Idler Roller As often as needed (but at least weekly), clean the long idler roller with Martin Yale Rubber Roller Cleaner Rejuvenator. Spray roller cleaner on a dry cloth and clean until no residue remains on the idler roller. 4. Optical Sensor As often as needed (but at least weekly), clean the optical sensor with a soft cloth dampened with a mild soap and water solution. 5. Platen and Signature Plates When the quality of signatures begins to noticeably deteriorate, clean the platen and signature plates. To clean the signature plates, remove them from the signature plate holder. Clean the plates with a cloth dampened with alcohol. Wipe the signature plate holder, idler wheels, and platen with a cloth dampened with alcohol. CAUTION: The ink roller is saturated with permanent ink. Always use the protective glove supplied with your 912 (or similar hand protection) when working with ink rollers. WARNING! Never use cleaning solvents near fire or flame. Always wear eye and skin protection when using cleaning solvents. 8.2 Lubrication After each eight hours of running time, lubricate all accessible bearings with one drop of light machine oil that contains no detergent or wax. Do not use a penetrating oil; it will displace the existing oil and evaporate. Also lubricate gears and plastic bearings with lithium grease or other synthetic grease. 9.0 Operators' Troubleshooting Guide If an error is made during setup or programming, the 912 displays a specific message describing the error and prescribing a corrective action. Follow the prompt to retry the last step. If the error message is repeated, turn the 912 off and on again, and repeat the setup or programming steps. To clear an error message, press CE. Following is a listing of possible problems and corrective actions. Also see Section 10.0, Diagnostic Tests, and Section 11.0, Error Code Explanations. 1. No message in the display Make sure the power cord is plugged into a live AC outlet. Check the power fuse in the rear panel for an open filament or a burnt spot. If necessary, replace the fuse with the same type and rating. 2. Any ERROR message in the display Press CE and try again. If the error message repeats, call for assistance. 3. First prompt after power on is not Enter Executive Code Check to see that the lock key is out of the rear panel switch. 4. Security code is not recognized Press CE and re-enter your security code. If the security code is still not recognized, reprogram it by the procedure in Section 6.0, Programming. 5. Display indicates Cover May Be Opened, but cover is stuck Rock the cover up and down at both sides while the message is displayed. If necessary, press UNDO and re-enter the security code. (8)

9 6. Signature plate holder won t slide Check to make sure that the setscrew is loose. Gently tap the right end of the signature plate holder. 7. Platen won t slide Gently tap either end of the platen. Slide the platen back and forth several times. If necessary, loosen, but do not remove, the setscrew using the hex key (Allen) wrench provided. (The factory setting for proper tension is 3/4 turn counterclockwise from snug.) 8. Cover won t close completely Check to see that the ink roller assembly was installed with the flat side of the ink roller guide at the top. 9. Cover is OPEN message when cover is closed Jiggle cover slightly. 10. Paper skews to one side during feeding Tap the paper guide away from the paper, at the end of the paper guide closest to the feed roller. 11. No signature on the paper Make sure the platen is beneath the signature plate holder. Make sure the signature plates and the ink roller have been installed. 12. Every other signature is out of alignment Determine which signature plate has a misaligned rubber pad and realign it by viewing a signature plate with the notch to the right. The signature will be upside down and the imaginary signature line should align with the top edge of the notch. The signature should be centered left to right. If a rubber pad is not positioned correctly, remove it and realign the rubber pad. 13. Signature is consistently too high or too low Check alignment of the rubber pads of the signature plates. See above. 14. Signature placement is not consistent Call for assistance. 15. Signature impressions smeared or slow to dry Check ink roller adjustment. (See Sections 4.1, 4.2, 4.3, 4.4, and 8.1 of this manual.) 16. Signature impressions too light or uneven Check ink roller adjustment. Replace the ink roller if the ink roller has been in use for 50,000 impressions or 18 months. 17. Every other signature is light Determine which signature plate needs to be raised. Install a piece of masking tape under each end of the signature plates directly on the signature plate holder. 18. Machine rattles while running Open the cover and check the tightness of the signature plates. If one signature plate is loose, put a small strip of masking tape on the beveled end of the signature plate. 19. Machine squeaks Oil sparingly with one drop of light machine oil in each bearing. 20. Machine makes a growling sound or squeals continuously Stop the machine and immediately call for assistance Diagnostic Tests NOTE: These tests should only be performed by qualified personnel. In the diagnostic test mode, a series of tests can be performed on the subsystems of the 912. There are two methods of entering into the diagnostic test mode. If the right side cover has been removed for servicing, press the small push-button switch on the logic board. To enter the diagnostic test mode from the keypad, repeatedly press UNDO until the prompt Enter Executive Code is displayed. Turn the lock key clockwise, as though entering the programming mode. At the prompt or 2 to Change Stored Forms, press STOP, then press 9 five times. The 912 will acknowledge Diagnostic Tests, Depress 0-9. To return to the signing mode from this point, turn the lock key back to the vertical position and press UNDO. To select a diagnostic test, press the number of the test. To return to the diagnostic tests entry screen from any diagnostic test, press UNDO. Following are the diagnostic tests and explanations for each. Diagnostic Test 0 Test 0 is used to Change System Parameters of logo and double sheet checking. Use the JOG FORWARD and JOG REVERSE keys to scroll through the choices of Logo On or Off, and Double Sheet Checking On or Off. To have the manufacturer s logo and model number displayed at start up, press ENTER while Logo On is displayed. To have a different model number displayed, press ENTER while Logo Off is displayed. Insert Model Number by typing in your desired model number, up to six digits, and pressing ENTER. The logo on/off option only affects the logo and model number information displayed when the 912 is first activated. The double sheet checking feature works as follows. When a setup is performed manually by jogging a single sheet through the 912 and pressing ENTER to define the signature locations, the 912 measures the length of the sample form. During a run, the 912 checks for double sheet feeding by measuring the length of each form as it passes over the photoelectric sensor. If any form appears to be longer than the sample form, the 912 stops and displays Sheet-Feed ERROR, Reload Missed Sheet. To turn on or off this double sheet checking feature, press ENTER while your choice is displayed. (9)

10 Diagnostic Test 1 Test 1 is used to view and alter the values stored in the non-volatile RAM (Random Access Memory). The non-volatile RAM stores signature locations, security codes, and user-selectable options in the diagnostic tests. User-selectable options in Test 1 are: A) calibration of the signature placement, and B) reloading the default values into the non-volatile RAM. These values are preset and should not be changed. If you suspect the non-volatile RAM values have been corrupted, e.g., the actual signature location is grossly different from the signature location displayed, then the non-volatile RAM can be reloaded with default values. To do so, first press 0 to jump to address 00. Press 1 to change the value from AB to AC. Press ENTER, then press UNDO. The microprocessor checks the value at address 00 when returning to the diagnostic tests entry screen. If the value at address 00 is not AB, the microprocessor reloads the non-volatile RAM with default values from the EPROM (Electronically Programmable Memory). While the default values are being reloaded, the 912 asks that you Please Wait. Diagnostic Test 2 Test 2 is used to check the switch and sensor inputs and the keypad. When both the left and right cover switches are pushed down, the Cvr value changes from 0 to 1. When the photoelectric sensor sees an object within 5 millimeters, the Pap value changes from 0 to 1. When the key is turned to the horizontal position, the Key value changes from 0 to 1. When the diagnostic test switch on the logic board is pressed, the Dsw value changes from 1 to 0. When any keypad switch except UNDO is pressed, that keypad switch is displayed. When UNDO is pressed, the 912 returns to the diagnostic tests entry screen. Diagnostic Test 3 Test 3 is used to test the paper feeding system. The paper drive motor will run in the forward direction with or without speed control (tracking). To toggle the speed control on or off, press CE. Set the motor speed by selecting the average period of the encoder disk pulses as follows. Press 1 for a 1000 microsecond period, press 2 for a 1100 microsecond period, or press 3 for a 1200 microsecond period. To run the motor, press JOG FORWARD. The period is continuously read and displayed. To take an instantaneous reading, press RUN. To to stop the motor, press STOP. The paper drive motor will run in the reverse direction, but only without speed control, by pressing JOG REVERSE. To stop the motor, press STOP. Test the paper feeding system as follows: In Diagnostic Test 3, press CE to turn off the speed control (tracking). Press FL to toggle to Display Measured Paper While Running. Load 10 sheets of 8-1/2" by 11" copier paper onto the feed tray. Press JOG FORWARD. Observe the measured values, in encoder pulses, for the individual sheets of paper. When the last sheet of paper has fed through, press STOP. For 11" paper, the values should be /-5. (Each encoder pulse equals 1/96" of paper.) If the values differ by more than 10, check the roller pressure. To check the minimum gap between sheets, press 5. The time between sheets should be no less than 70 msec. To check the maximum paper length in microseconds, press 6. To check the maximum paper length in encoder pulses, press 7. To check the number of sheets, press 8. Diagnostic Test 4 Test 4 is used to calibrate and test the stepper motor system, including the signature plate shaft. In Test 4, the display shows the values for the home flag sensor, the setting for the stepper motor current (power), and the phase code (step). When the flag sensor sees one of the two flags, the Home value will be 1. A Current value of 11 means the stepper motor power is set to zero. To set the stepper motor power to 1/3, press 1 ( Current value of 10). To set the power to 2/3, press 2 ( Current value of 01). To set the power to 3/3 (full power), press 3 ( Current value of 00). The Phase value simply tells into which of the four repeating steps the stepper motor is locked. r To single-step the stepper motor in the forward direction, press 4. To single-step the stepper motor in the reverse direction, press 5. If the stepper motor only steps at every other key press, one of the two stepper motor windings is not being energized. To check the stepper motor windings, unplug the stepper motor and check continuity. To set the home orientation, first press 3 to set full power for the stepper (10)

11 motor. Then use the 4 and 5 keys to step the signature plate shaft until the index pins for the signature plates are horizontally in line with the center of the signature plate shaft. Press 4 seven times. Loosen the setscrews in the flag hub and rotate the flag and hub assembly until a flag is centered in the flag sensor. Tighten the setscrews in the flag hub. Check the centering of the flag in the sensor by rocking the signature plate shaft slightly out of detente until the Home value changes to 0. Release the shaft and check to make sure the Home value goes back to 1. Rock the shaft out of detente in the other direction until the Home value changes to 0. Release the shaft and check to make sure the Home value again goes back to 1. If the flag is not centered in the sensor, reposition the flag and hub assembly, or loosen the mounting screws for the flag sensor. Move it slightly in the appropriate direction, and retighten the mounting screws. Check the other flag by rotating the signature plate shaft 180 degrees and repeating the centering check. In an extreme case, it may be necessary to bend one flag. To run the stepper motor, first ensure the signature plates are not installed. The normal running speed of the stepper motor is 140 pulses per second. To run the stepper motor in the forward direction at 100 pulses per second, press 7. At 100 pulses per second, (full power), the stepper motor will run with moderate torque, but it will be noisy. To run the stepper motor at 200 pulses per second, press 8. At 200 pulses per second, (full power), the stepper motor will run with moderate torque, smoothly and quietly. To activate the stepper motor at 400 pulses per second, press 9. The stepper motor normally will not run at 400 pulses per second. Diagnostic Test 5 Test 5 is used to test the logic board outputs, including the homing routine for the signature plate shaft, and the photoelectric sensors on the encoder board. To pulse (100 msec duration) the non-resetable counter, press 1. To retract the cover latching solenoids for two seconds, press 2. To test the inking routine, press 3. To test the homing routine, first turn the signature plate shaft by hand to get it out of home position ( Hme value = 0), then press RUN. The stepper motor should search for and find one of the two home positions ( Hme value = 1). The two photoelectric sensors in one package on the encoder board form a quadrature detector. Each sensor, primary and auxiliary, sends a 1 when it sees a tooth of the encoder disk and a 0 when it sees a gap between teeth. The latch is set to 1 when the encoder disk rotates in the forward direction and 0 when the encoder disk rotates in the reverse direction. To test the encoder board sensors, reach over the roller guard on the retarder bar and contact the top drive roller (idler roller) with your fingers. Slowly push the back of the roller down, which will rotate the roller in the reverse direction. The primary and auxiliary signals should change one at a time, and the latch signal should change to 0. Slowly pull the back of the roller up to rotate the roller in the forward direction. Again, the primary and auxiliary signals should change one at a time, but the latch signal should change to 1. If either sensor fails to change, check the encoder cable and check the duty cycle settings in Test 9. Diagnostic Test 6 Test 6 is used to check the values stored in the microprocessor internal RAM. The meaning of the values stored there is beyond the scope of this maintenance procedure. Diagnostic Test 7 Test 7 is used to adjust the jog speed. Both the duty cycle and the frequency of the pulse train that is sent to the paper drive motor during jogging can be adjusted. Use the decimal point key to toggle between the two parameters, jog speed (duty cycle) and jog frequency. The default values are 15 and 02, respectively. In both, the JOG FORWARD key increases the hexadecimal value for faster jogging and the JOG REVERSE key decreases the value for slower jogging. To test the current value, press RUN. The paper drive motor will run briefly at the new speed. To load the new value into the non-volatile RAM, press ENTER. Martin Yale recommends the jog speed be adjusted in preference to jog frequency. Diagnostic Test 8 Test 8 is another test for the stepper motor and the paper drive motor. To test the homing routine, press 1. To step the signature plate shaft in the forward direction, press JOG FORWARD. The limit of travel is 15 steps from the home position. To step the signature plate shaft in the reverse direction, press JOG REVERSE. The limit of travel is 6 steps from the home position. To run the paper drive motor, press RUN. To stop the paper drive motor, press STOP. (11)

12 Diagnostic Test 9 Test 9 is used to adjust the sensitivity (duty cycle) of the encoder board sensors, and also to adjust roller pressure. While the paper drive motor is running, the microprocessor automatically measures (at 1 second intervals) the duty cycle of each sensor and calculates the phase relationship between the two signals. An ideal phase shift of 90 degrees is represented by a value of.50. To run the paper drive motor, press RUN. To stop the paper drive motor, press STOP. CAUTION: Do not run paper through the 912 in Test 9. The fuse protection feature in the operating software is not active in Test 9, and a paper jam could blow the logic board fuse (F2) that protects the paper drive motor. Adjust the sensitivity of the encoder board sensors as follows. Press RUN to run the paper drive motor. Use a tuning tool to adjust the top pot on the encoder board for D1 =.50 +/-.05. Adjust the bottom pot for D2 =.50 +/-.05. The phase value should be.50 +/-.05. Press STOP to stop the paper drive motor. If the phase value is more than.60, loosen the mounting screws that fasten the encoder board bracket to the side frame and move the encoder board closer to the encoder disk. If the phase value is between.54 and.60, bend the bracket slightly to lower the phase value. Similarly, if the phase value is low, move or bend slightly the encoder board away from the encoder disk. RUN the paper drive motor to recheck the D1, D2, and Phase values. To adjust roller pressure, use a piece of shim stock 1/2" wide and.003" thick. Remove the feed tray and open the cover. Press RUN to run the paper drive motor. Grip the shim stock firmly and carefully insert it between the drive and idler rollers, next to the retarder. The rollers should exert a moderate pull on the shim. While the rollers are rotating, slide the shim sideways, but not more than 4" away from the retarder. The pull should almost double and the motor should slow down. Do not slide the shim closer than 3" to the end of the rollers. Use the shim to check the roller pressure on the other side of the retarder. Adjust the roller adjusting screws to achieve a good balance. The roller pressure must be enough to pull a sheet from the bottom of a 1-1/4" stack of paper, but not so much that roller pressure in the middle is reduced because of bowing. A good starting point is to turn the roller adjustment screws clockwise until they just meet resistance, then 3/4 turn farther. After roller pressure has been adjusted, tighten the lock nuts on the adjustment screws Error Message Explanations If the Model 912 displays System Error, Error, press STOP to see the Error Reference Number. Following is a list of error reference numbers, their meanings, and suggested remedies. Error Reference 01 No forms length set. Go through setup again. Error Reference 02 Sensor is blocked when it shouldn t be. Remove whatever is blocking the sensor. Error Reference 03 Signature location is off the form. Redefine the signature locations. Error Reference 04 Signature plate was moved during HOLD. Restart the batch of forms. Error Reference 05 No quantity set for countdown mode. Go through setup again. Error Reference 06 Second signature location invalid (repeat spacing). Redefine signature locations. Error Reference 07 Third signature location invalid (repeat spacing). Redefine signature locations. Error Reference 10 Flag on signature shaft not seen. Remove any obstruction that may prevent the signature shaft from rotating. With power off, check to make sure the signature shaft rotates freely. Use Diagnostic Test 8 to activate the homing routine. (12)

13 Error Reference 11 Signature step missed during a run cycle. Remove any obstruction. Error Reference 12 Paper sensor intermittent during a run cycle. Clean the paper sensor. Use Diagnostic Test 2 to check the paper sensor. Error Reference 13 Stored setup has invalid signature locations. Program new signature locations. Error Reference 14 Signing routine during HOLD. Restart the batch of forms. Error Reference 15 No encoder pulses seen while paper drive motor should be running. Use Diagnostic Test 9 to check the encoder pulses. Error Reference 16 Accelerate routine during HOLD. Restart the batch of forms. Error Reference 17 Missed signature interrupt signal. Remove any obstruction and restart the batch of forms. Error Reference 19 Encoder pulses slowed or stopped. Remove any obstruction and restart the batch of forms. Use Diagnostic Test 9 to check the encoder pulses. Error Reference 20 Signature shaft lost synchronization with the paper drive system. Remove any obstruction and restart the batch of forms. Error Reference 21 Invalid routine during a run cycle. Restart the batch of forms. Error Reference 22 Too many steps needed to reach home during a run cycle. With power off, check that the signature shaft rotates freely. Error Reference 23 Invalid run routine when home is reached. Clean the encoder disk and its sensor. Error Reference 24 Insufficient paper left when entering first dwell. Check paper length and feeding. Error Reference 25 Invalid routine during run cycle. Clean the encoder disk and its sensor. Error Reference 27 Out of paper before last signature. Check paper length and feeding. Error Reference 30 Non-volatile RAM did not write. Use Diagnostic Test 1 to reload the default values. Error Reference 31 Non-volatile RAM did not acknowledge. Use Diagnostic Test 1 to reload the default values. (13)

14 >> Parts Diagrams See Fig See Fig. 8 Figure 6 - Enclosure and Chassis Parts OBSERVE PIN ORIENTATION 1 OBSERVE PIN ORIENTATION 4 BATCHCOUNTER 1 >> < FL = J CE POWER - 2 Figure 7 - Bezel Assembly (14)

15 Figure 8 - Right Side Parts Figure 9 - Left Side and Center Parts (15)

16 31 RECEIVER TRAY FEED TRAY ASSEMBLY (COMPLETE) Figure 10 - Feed Tray and Receiver Tray Parts FEED DRIVE ASSEMBLY (COMPLETE) Figure 11 - Feed Drive Parts (16)

17 FIGURE 6 Item Part No. Qty. Description 1 W-O Left Side Frame 2 W-A Back & Cover Assy. 3 W-O Bottom Cover 4 W-O Right Side Frame 5 M-S #8 Tamper Proof Screw 6 W-O Right Side Cover 7 M-O Plastic Bezel 8 W-O Base Channel 9 M-S Rubber Foot 10 W-O Left Side Cover 11 M-S Snap Bushing 12 W-A New Edge Detector Cable FIGURE 7 Item Part No. Qty. Description 1 M-O Plastic Bezel 2 M-S On/Off Rocker Switch 3 M-S Display Cable 4 W-A Control Panel Assy. FIGURE 8 Item Part No. Qty. Description 1 W-O Right Side Cover 2 W-A /120V Power Cord Assy. 3 W-A /240V Power Cord Assy. 4 WRA Encoder Board Cable 5 M-O Encoder PC Board 6 W-O Encoder Bracket 7 W-O Right Side Frame 8 W-A Encoder Disc Assy. 9 M-S T - 32P Spur Gear 10 M-S T Aluminum Pulley 11 W-A Flag/Hub Assy. 12 M-S L X 037 Timing Belt 13 W-A Solenoid Assy. 14 W-O Switch Bracket 15 WRA Solenoid Cable Assy. 16 W-A New Stepper Motor Assy. 17 W-A New Optical Switch Assy. 18 M-S Terminal Strip 19 W-O Line Cord Plate 20 W-A New Key Switch Assy. 21 M-S Fuse Holder, Panel Mount 21A M-S Fuse, 3AG, 2A, For 110V** 21B M-S Fuse, 3AG, 1A, For 220V** 22 M-S Strain Relief, 5L - 1 Model 912 Parts List FIGURE 9 Item Part No. Qty. Description 1 W-O Switch Bracket 1A M-S Microswitch** 2 W-A Solenoid Assembly 3 W-O Left Ink Shaft Bracket. 4 W-O Platen, 912 4A M-O Drag Pin** 4B M-S Compression Spring** 4C M-S X 1/4" Set Screw** 5 W-A Sign. Plate Drum Assy. 5A M-O Key Screw 10-32** 6 W-O Idler Disc Bracket 7 WRA F 1 Tri-Color Ink Roll Kit** 8 W-O Ink Roller Shaft 9 W-O Tie Bar 10 M-S Compression Spring 11 M-O Shoulder Screw 12 W-O Ink Roller Shaft Spring 13 M-S /4" E-Ring 14 M-S Print Shaft Bushing 15 W-O Right Ink Shaft Bracket. 16 W-O Main Print Shaft 17 M-S /4" Set Collar 18 W-O Right Spacer Plate 19 W-A Drive Roller Assy. 20 W-O Spacer Plate, Left 21 W-O O.D. Fan Blade 22 W-A D.C. Motor Assy, Cksign 23 M-S /4" X 1/2" Flange Bushing 24 W-O T Motor Pulley 25 M-S T 3mm HTD Pulley 26 W-O X12 Pulley Idler 27 M-O /12 Dual Pulley 28 M-S X 9mm X 100Tooth Belt 29 M-O T Drive Pulley W-O Ink Roller Bracket** FIGURE 10 Item Part No. Qty. Description 1 W-A Feed Tray Assy. 2 W-O Extension Tray 3 M-O Tray Rail, Right 4 W-O Receiver Tray 5 W-O Receiver Backstop 6 M-S Spacer 1/4X1/8X3/16 7 M-S Hex Keps Nut 8 W-O Gear Rack, Feed Tray (17) **Not Shown

18 FIGURE 10 (cont.) Item Part No. Qty. Description 9 M-S Push Ring W-O Rack Slide, Feed Tray 11 W-O Left Stack Guide 12 M-S /8 External E-Ring 13 M-O T 24P 3/8 ID Gear 14 M-O Idler Gear Stud 15 M-S /32 X 3/8 Roll Pin 16 W-O Drill Spur Gear 17 M-S C-Ring # W-O Jog Shaft Bracket 19 M-S #10L1-FF Nyliner Bearing 20 W-O Feed Tray Top 21 W-A Jog Wheel Assy. 22 W-O Jog Wheel Shaft 23 W-O Right Stack Guide 24 M-S Nylon Tray Gear 12T 25 W-O Rack Cover 26 M-O Tray Pad 27 M-S Push Ring # W-O Feed Tray Cowl 29 M-O Left Tray Rail 30 M-S Magnetic Strip 31 W-O Paper Guide/Stop W-A v Transformer Assy.** W-A v Transformer Assy.** M-S Transformer Spacer** FIGURE 11 Item Part No. Qty. Description 1 W-A Feed Drive Assy (Complete) 2 W-O Right Support Casting 3 W-A Feed Roller Assy. 4 M-S Ext. "C" Ring 5 W-O Paper Deflector 6 W-O Feed Clutch Shaft 7 M-S Optical Sensor 8 M-S /32 X 3/8 Roll Pin 9 M-O Tray Stud 10 M-O Idler Shaft 11 W-O Drill Spur Gear 12 M-S Ext. E-Ring # M-S T Idler Gear 14 M-S Feed Gear, 42 Tooth 15 M-S /8 External E-Ring 16 M-S Fl. Bearing 3/8 ID X 1/2 17 W-O Support Casting, Left Model 912 Parts List (cont.) FIGURE 11 (cont.) Item Part No. Qty. Description 18 M-O Reference Guide, Lexan 19 W-O Retarder Support Bar 20 W-O Idler Roller 21 M-S #4-40 X 5/8 PHFHMS 22 W-O Paper Guide 23 W-O Retarder Block 24 W-O Retarder Roller Mold 25 M-S #8-32 X 3/8 FH Socket Sc. 26 M-O Shoulder Screw 27 M-S Roll Pin.187 X W-O Tension Bracket. 29 M-S #8-32 X 1/2 Flat Pt. Setscrew 30 M-S #6-32 X 1Ph. Pan Hd. Sc. 31 W-O Retarder Bracket 32 W-O Retarder Frame 33 M-S #10 Thumb Screw Knob 34 M-S #10-32 X 3/4 SHCS 35 M-S Spring, Retarder 36 M-S /8 X 1/2 Dowel Pin 37 W-A Retarder Assy 38 W-O Roller Cover W-O Tray Latch** 39 M-S Casting Standoff 40 M-S X 1.75 SHCS Accessories M-S /32" Allen Wrench MRS012014* 1/4" Dr. Security Socket, M-S Shipping Carton W-A Left Foam Mold, 911/912 W-A Right Foam Mold, 911/912 M-S Instruction Manual, 912 M-S A Resetable Fuse M-S Signature Plate Order Forms *Purchased Separately **Not Shown (18)