Trouble Shooting
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Watkiss BookMaster Service Manual - Issue 1 - 14/12/00
109
Curly paper is catching on infeed side-
lays
If possible, remove curl from paper or
turn the paper the other way up in the
Vario feed bin. Ensure stock is not curly
in future
Towers are out of line in Twin Tower
system
Align the towers correctly
Delivery from collator is poor
Setup the collator correctly (see Vario
operating manual)
Set catching on BookMaster fold rollers
Bend paper straight
High static charge in paper
Fan the paper by hand before inserting
into feed bins
If BookMaster is online to Watkiss
Vario, consider fitting the Anti-Static
module to the Vario
Paper jams in fold area
Fold knife damaged
Replace fold knife (see section 3.2.9
‘‘Fold Blade Replacement’’)
Booklets jamming between BookMaster
and TrimMaster
BookMaster and TrimMaster units
installed on uneven floor
Install whole system onto a level floor,
or onto a 25mm (1”) thick MDF board
Infeed conveyor belt on TrimMaster
loose/broken
Replace belt(s) on TrimMaster (see sec-
tion 3.4.5 ‘‘Replacing Infeed Conveyor
Belts’’)
Interface PCB 900-141 faulty
Replace PCB (see section 3.2.13 ‘‘PCB
Removal and Fitting - General Com-
ments’’)
Booklets jamming in TrimMaster
Conveyor belts broken or loose and slip-
ping
Replace belt(s) - see sections 3.4.5 and
3.4.6.
Conveyor clamp set too tight
Adjust (see section 3.4.2 ‘‘Conveyor
Clamp Adjustment’’)
Paper jams whilst edge stapling
Edge Staple latch has rough surface,
paper is catching
Polish latch with silicone polish
Edge staple latch not set correctly
Set latch postion and stroke correctly
(see 3.2.5 ‘‘Edge Staple Latch Solenoid
Adjustment’’)
Top jog is not set correctly
Adjust the setting or calibration of the
top job (BMP only) (see 3.3.3 ‘‘Top Jog
Belt Calibration’’)
Jam error but no paper jam
Faulty infeed sensor
Replace
General jamming problems
Debris in BookMaster
Remove debris
Stapling Problems
Staple LEDs off, no staple formed, audi-
ble bleep every 5 seconds
Staple head(s) not addressed properly
Manually address the heads, use PICI
for diagnostics (see 4.3.2 ‘‘Terminal
Emulator Mode’’). If necessary change
the 900-156 PCB(s).
Unable to corner staple
3rd staple head is not fitted or not
addressed correctly
Fit 3rd staple head and address (see
3.2.2 ‘‘Fitting a third staple head’’)
Edge Staple Problems
Edge staple solenoid travel is incorrect
Adjust the travel to 14mm (see section
3.2.5 ‘‘Edge Staple Latch Solenoid
Adjustment’’)
Top jog is not set correctly
Adjust the setting or calibration of the
top job (BMP only) (see 3.3.3 ‘‘Top Jog
Belt Calibration’’)
REPORTED FAULT
ACTUAL FAULT
SOLUTION
Table 8:1 Trouble Shooting Chart
Summary of Contents for BookMaster
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