Note: Because various 203 Saddle Stitchers are equipped
differently, some of these remedies may not apply to your saddle stitcher.
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Saddle
Stitcher Problem Solving Tips-n-Hints
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Problem
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What
to look for...
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What
should you do...
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Stitcher
does not run
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a.
RESET indicator off.
b.
RESET indicator on.
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a.
Make sure that I/O selector is switched to I
(on) and that the key operated switch is ON.
If these conditions exist, make sure motor starter is reset; press
overload button to be sure. If
stitcher is still OFF, check input power from machine’s (I/O) isolator
switch. If you have power at
this point, make sure circuit breakers are not tripped.
b.
Release EMERGENCY STOP then press RESET control,
indicator should turn off.
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Stitcher
heads driven each cycle
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a.
Clutch switched OFF.
b.
LS7 not actuated or is defective.
c.
Photo detector defective.
d.
Head clutch defective, or misadjusted.
e.
Defective solenoid in head clutch assembly.
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a.
Switch clutch ON/OFF selector to ON.
b.
Make sure LS7 is being actuated, if actuated,
check for ON/OF switch action in each cycle.
Also, verify that wiring from LS7 to head clutch is good.
c.
Make sure reflective tape is located on stitcher saddle.
With LS7 closed and CLUTCH ON, wave hand to break beam from photo
detector to stitcher saddle. Solenoid
in head clutch should be turning on & off.
d.
Verify operation of head clutch.
e.
Verify solenoid is operating as indicated in
step c.
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Stitcher
heads drive remains off, CLUTCH ON
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a.
Repeat checks/condition checks given in previous
problem.
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a.
Repeat actions described in b.,c.,d., and e., of
previous problem.
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Stitcher
heads are down too far
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a.
Brake drag too low.
b.
Phase reversal at input to drive motor running
backwards.
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a.
Check brake drag without booklets. Cycle clutch, if it stops momentarily at normal height and
then goes down further adjust brake shoe drag.
b.
Problem should only occur after wiring changes
in three-phase input line to stitcher.
Reverse any two, three phase leads to drive motor.
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Booklet
does not head properly
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a.
Signatures not even.
b.
Centering back stop (s) incorrectly set.
c.
Obstruction in path of booklet.
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a.
Jog signatures in booklet to head before
feeding.
b.
Adjust backstops.
c.
Check that movement path for booklets along
saddle ridge are clear of obstruction.
Also, make sure backstops move freely, center on saddle ridge as
needed.
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Booklet
(s)
not advanced on saddle, stitches out of position
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a.
Slide and/or centering backstops incorrectly set
for size of booklet.
b.
Shear pin sheared.
c. When Stagger
Stitching, stagger adjustment incorrect.
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a.
Adjust feed finger slide and centering
backstops.
b.
Replace shear bolt securing power and actuating
arms.
c.
See Stagger
Stitch Setup Sheet for adjustments.
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Staples
not located on center of crown
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a.
Pamphlet hold-downs incorrectly adjusted.
b.
Centering guides and/or centering supports
incorrectly adjusted.
c.
Brushes incorrectly adjusted.
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a.
Readjust pamphlet hold-downs.
b.
Readjust centering guides and/or centering
supports.
c.
Readjust brushes.
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Unable
to make a tight stitch
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a.
Head drive casting set too high for booklet
thickness.
b.
Clincher points not driven up high enough.
c.
Head casting drive stroke too short.
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a.
Readjust head drive casting for booklet
thickness.
b.
Adjust clincher points.
c.
Only consider this adjustment after replacing
reducer and/or head clutch. Adjust
head pull rod.
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Stapes
not formed correctly
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a.
Clincher height incorrect.
b.
Clincher pints worn or broken.
c.
Wire jammed in clinchers.
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a.
Adjust clincher pints.
b.
Replace points.
c.
Remove wire; examine clincher points for signs
of damage. Replace if
damaged.
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Stitcher
heads do not feed wire
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a.
Grippers in head not closing during upstroke.
b.
Defective head assembly.
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a.
Face plate too high.
b.
Service as indicated in manufacturer’s manual.
After replacing head adjust for book thickness.
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Booklets
fly hitting heads and/or ejector rolls
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a.
Centering supports and/or centering guides
incorrectly adjusted.
b.
Spring tension too great on centering backstop.
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a.
Readjust guides and/or supports.
b.
Readjust spring tension on centering backstop.
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Booklet
delivery poor, skewed and/or uneven
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a.
Delivery stop not set for booklet length.
b.
Tucker fingers lift height too low.
c.
Ejector rolls misadjusted.
d.
Booklets hitting ejector rolls.
e.
Deflector roll arm assembly misadjusted.
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a.
Readjust delivery stop.
b.
Readjust lift height
c.
Readjust ejector rolls
d.
Readjust centering guides and/or centering
supports
e.
Readjust roll arm & deflector wheels.
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Booklets
not transported on delivery table
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a.
Tape drive not engaged.
b.
Loose tapes.
c.
Defective drive train.
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a.
Push tape drive control-knob in until drive
engages.
b.
Move extension of delivery table out to tighten
tapes, keep both delivery rollers parallel to each other.
c.
Check delivery train.
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Stitcher coasts before
stopping or stops too early or late in cycle
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a.
Integral brake at drive motor is defective or
worn.
b.
Early or late stop, stop cam for LS3
misadjusted.
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a.
Readjust brake as indicated.
Replace brake if lining is worn.
b.
Readjust cam that actuates LS3.
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