TABLE OF CONTENTS

SUBJECT

PAGE

DESCRIPTION

SPECIFICATIONS

UNPACKING

SETUP

CONTROL PANEL

SAFETY GUIDELINES

OPERATION

SELECTING NON-STANDARD PAPER SIZE

RECALLING A PAPER SIZE FROM MEMORY

SETTING THE STAPLE TRIGGER TIMING

RESETTING FACTORY DEFAULTS

MAKING BOOKLETS

CORRECTING STAPLE MISALIGNMENT

CORRECTING FOLD MISALIGNMENT

COUNTER RESET

EMERGENCY STOP

CLEARING JAMMED STAPLES

SERIAL # INDICATOR

TROUBLESHOOTING

DAILY MAINTENANCE

PARTS LIST

SPECIFICATIONS

FUNCTION:

The Formax FD 180 Automatic Booklet Maker offers an easy-to-use solution for creating booklets in small-run or in-plant applications. It’s lightweight, portable, and sets up in seconds.

Capacity: Paper Size: Speed: Stapling Heads: Dimensions: Weight: Voltage:

Folds & staples up to15 sheets of 20# bond for 60-pag booklets 10” - 17” L x 8.25” - 12” W Up to 500 booklets per hour (operator-dependent) Two automatic stapling heads with fi ve stapling positions 22” L x 17.25” W x 6.5” H 60 lbs 110 Volts AC, 60Hz

UNPACKING

Check package for shipping damage. If there is shipping damage, do not discard the box.

1. Remove unit from box, along with accessories: paper side guide, press roller, power cord, and magnetic stoppers.

SETUP

Open the top cover and remove wire tie from folding roller (fi g. 1).

Lift up the stapler head lever. Remove the protective sponge pad under the stapler head.

Open the cassette from the stapler head and load staples (fi g. 2).

Move the stapler heads to the correct position to match paper size. Refer to stapler head position sticker (fi g. 3) on the underside of the top cover.

Close the top cover and plug power cord into receptacle on back of unit, and into appropriate wall receptacle (fi g. 4).

CONTROL PANEL

Part # Name LCD Display

Function Lights when power is on Displays selected paper size and counter Displays options when Menu button is pressed Displays error message if an error occurs Menu Button Press to enter Options Menu Press again to exit Options Menu Scroll Up Button Increase standard paper size Select options within Menu Increase size of non-standard paper within Options Menu Scroll Down Button Decrease standard paper size Select options within Menu Decrease size of non-standard paper within Options Menu Enter Button Accept a revised paper setting Confi rm the setting is complete Return to standby mode

SAFETY GUIDELINES

• When machine is running, keep hands away from the rollers.
• Do not remove any covers. The machine contains high-voltage parts and hazardous moving parts, which may cause electrical shock or personal injury.
• Don’t touch the motor, the surface may be hot during operation.
• Always turn off and clean machine after use.

OPERATION

STANDARD PAPER SIZE SELECTION

Switch power on (fi g. 4).

Select the paper size by pressing the scroll up or down button. Scroll through choices until you reach the correct size. Then press Enter button to confi rm paper size.

LD = LEDGER = 11” X 17”

LG = LEGAL = 8 1/2” X 14” LT = LETTER = 8 1/2” X 11”

Open top cover. Move the stapler heads to the correct position (fi g. 5) by following the stapler head position sticker. Close top cover.

Press the Enter button to return to ready.

SELECTING NON-STANDARD PAPER SIZE

RECALLING A PAPER SIZE FROM MEMORY

Press Menu button to enter Options Menu.

To recall a paper size saved in Memory, press the scroll up or down button until you reach the correct size (example M3).

Select “1.Memo” then press the Enter button.

Press Enter button to confi rm chosen size.

Open top cover. Move the stapler heads to the correct position (fi g. 5) by following the stapler head position sticker. Close top cover.

Press the Enter button to return to ready.

Choose one of the 6 pre-set paper sizes by using the scroll up/down buttons. Press Enter to enter the paper size setting (example Mem2).

To adjust the paper size, press and hold the scroll button until the proper value is reached (example 14 in).

Press Enter button to input the data to the selected Memory location, and return to ready status.

SETTING STAPLE TRIGGER TIMING

RESETTING FACTORY DEFAULTS

Press Menu button to enter Option Menu.

Press the Menu button to enter Option Menu.

Select ”2.Time” by pressing the scroll down button.

Select “5.Reset All” by pressing the scroll down button.

Press Enter button to enter trigger timer setting.

Press Enter button to reset all data to factory default settings. WARNING: All the values in Memory will be restored to the factory default value (297mm).

Press Enter button to return to ready.

Press scroll up or down button to change the setting (example 8 seconds).

Press the Enter button to rewrite the previous value and return to ready.

MAKING BOOKLETS

Select the appropriate paper size and adjust stapler heads according to position reference sticker (see page 2).

Open the top cover and insert a set of sheets to be stapled. Align the paper with the edge of the scale (fi g. 6).

Place the paper side guide by aligning it with the edge of the paper (fi g. 7).

Use the cylindrical magnetic alignment stoppers if needed (fi g. 8).

Close the top cover. The machine will start operation in 5 seconds. Once the fi rst booklet is complete, remove it from the output slot on the top. Insert the next set of sheets (fi g. 9) and continue operation.

CORRECTING STAPLING MISALIGNMENT

Fold the paper in half manually to create the center line of the booklet. Check to see if the staples align with the center line. Fine adjustments to staple position can be made by following the instructions below. Repeat until staples and center line are aligned.

CORRECTING FOLDING MISALIGNMENT

Check folded position by aligning with the center line. Fine adjustments to fold position can be made by following the instructions below. Repeat until center line and fold are aligned.

COUNTER RESET

Remove all paper from the machine.

Press Enter button to reset the counter to “0000”.

SERIAL NUMBER INDICATION

Press Menu button to enter Option Menu.

Select “6.Show Serial” by pressing the scroll down button.

Press Enter button to check the Serial Number.

Press Enter button to return to ready status.

EMERGENCY STOP

Press any button on the control panel to stop the machine during the booklet-making process.

Switch off the machine, then power on the machine to return to ready status.

CLEARING JAMMED STAPLES

Open the top cover and lift up the stapler head lever. Open the cassette from the stapler head and remove the jammed staple using tweezers.

TROUBLESHOOTING

ERROR MESSAGE

POSSIBLE CAUSE

SOLUTION

Top cover opened in ready status.

Top cover opened during booklet making process.

Close top cover, press Enter button.

Cover has been closed following “Cover is Open” message.

Press Enter button to reset.

Too much paper loaded, causing motor overload.

Remove all paper. Turn off power for 3 seconds. Turn on power to return to ready status.

One of the control panel keys has been pressed during booklet making process.

Turn off power for 3 seconds, then turn on to return to ready status.

DAILY MAINTENANCE

• Be sure to turn off power before cleaning.
• Use a soft clean cloth dampened with alcohol or neutral detergent. The folding rollers may cause paper slipping or smudging with paper dust or ink if they are dirty.
• Always disconnect power plug from outlet after use.

PARTS LIST - BASE SECTION

ITEM

DESCRIPTION

QTY.

BASE ASSEMBLY

SCALE

PLATE

ANVIL

FRAME F

CONTROL PANEL

PANEL P.W.B. UNIT

ACRYLIC PLATE

PANEL BRACKET

SCREW

PART

ASSEMBLY UNIT

RUBBER FOOT

BMT 29

PAPER SIDE GUIDE

MAGNETIC STOPPER

MAGNETIC STOPPER

FRAME B

PAPER JOGGER SECTION

ITEM

PART

DESCRIPTION

QTY.

GUIDE BLOCK ASSEMBLY

GUIDE BLOCK

COLLAR

ASSEMBLY UNIT

ANGLE

TIMING BELT

PLATE

SHAFT

COLLAR

ANGLE

GEAR

GEAR

STUD

SIDE GUIDE

BALL RETAINER

STEP MOTOR

BMT 26

FOLDING BLADE SECTION

ITEM

PART

DESCRIPTION

QTY.

SHAFT

HOLDER

COLLAR

KEY

CAM F

BEARING

FOLDING BLADE

SHAFT

COLLAR

SPRING T

LEVER F

LEVER B

BMT 30

BMT 20

STAPLING SECTION

ITEM

PART

ASSEMBLY UNIT

BMT 31

DESCRIPTION

QTY.

STAPLE ASSEMBLY

LEVER F

LEVER B

STAPLER HEAD COVER

BALL RETAINER

STAPLER HEAD

PRESS ROLLER HEAD

BEARING

BMT 1

COLLAR

BMT 16

SENSOR HOLDER R

BMT 17

SENSOR HOLDER L

BLOCK

SPRING T

DRIVING SECTION

ITEM

PART

DESCRIPTION

QTY.

PLATE ASSEMBLY

PLATE

MOTOR (110V)

BLOCK

SPRING T

SPROCKET IV

MOTOR SPROCKET

CHAIN

SPROCKET

CHAIN

KEY

SPROCKET ASSEMBLY

BMT 27

BMT 19

FOLDING SECTION

ITEM

PART

ASSEMBLY

UNIT

DESCRIPTION

QTY.

ROLLER ASSEMBLY

ROLLER

SQUARE METAL

SPROCKET IV

SQUARE METAL

SPRING C

EXTERIOR SECTION

ITEM

PART

DESCRIPTION

QTY.

COVER B

BMT 21

ACRYLIC COVER

BMT 22

TOP COVER

MAGNETIC

COVER F

BASE PLATE

COVER STOPPER

COVER SCREW

PILLAR

PILLAR

COLLAR

TOP COVER SWITCH ASSEMBLY

BRACKET

ELECTRICAL SECTION 1

ITEM

PART

DESCRIPTION

QTY.

SENSOR BRACKET

SENSOR ASSEMBLY

MAIN BOARD BRACKET

TRANSFORMER (110V)

MOTOR CAPACITOR (110V)

MAIN POWER SWITCH

FUSE HOLDER

FUSE

INLET

POWER CORD

ELECTRICAL SECTION 2

ITEM

PART

DESCRIPTION

QTY.

BMT 23

MAIN P.W.B.

BUNDLE WIRE

BUNDLE WIRE 8P

BUNDLE WIRE 4P

BUNDLE WIRE 3P

BUNDLE WIRE 8P

BUNDLE WIRE 20P

BUNDLE WIRE 2P

POWER SUPPLY UNIT (110V)

COLLAR

BOARD SPACER

MAIN BOARD BRACKET

BMT 24