Ricoh D391 Service Manual Download Page 9 | Manualshive

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Ricoh D391 Service Manual Download Page 9

Power Plug and Power Cord

• Before servicing the finisher (especially when responding to a service call), always make sure that the

power plug has been inserted completely into the power source. A partially inserted plug could lead
to heat generation (due to a power surge caused by high resistance) and cause a fire or other
problems.

• Always check the power plug and make sure that it is free of dust and lint. Clean it if necessary. A

dirty plug can generate heat which could cause a fire.

• Inspect the length of the power cord for cuts or other damage. Replace the power cord if necessary.

A frayed or otherwise damaged power cord can cause a short circuit which could lead to a fire or
personal injury from electrical shock.

• Check the length of the power cord between the finisher and power supply. Make sure the power

cord is not coiled or wrapped around any object such as a table leg. Coiling the power cord can
cause excessive heat to build up and could cause a fire.

• Make sure that the area around the power source is free of obstacles so the power cord can be

removed quickly in case of an emergency.

• Make sure that the power cord is grounded (earthed) at the power source with the ground wire on

the plug.

• Connect the power cord directly into the power source. Never use an extension cord.
• When you disconnect the power plug from the power source, always pull on the plug, not the cable.

After Installation, Servicing

Disposal of Used Items

• Always dispose of used items (developer, toner, toner cartridges, OPC drums, etc.) in accordance

with the local laws and regulations regarding the disposal of such items.

• To protect the environment, never dispose of this product or any kind of waste from consumables at

a household waste collection point. Dispose of these items at one of our dealers or at an authorized
collection site.

Points to Confirm with Operators

At the end of installation or a service call, instruct the user about use of the finisher. Emphasize the following
points.

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Summary of Contents for D391

Page 1: ...Perfect Binder Machine Code D391 SERVICE MANUAL 8 December 2010 Revised...

Page 2: ......

Page 3: ...his manual Symbol What it means Core Tech Manual Screw Connector E ring C ring Harness clamp FFC Flexible Film Cable JG Junction Gate LE Leading Edge of paper LEF Long Edge Feed SEF Short Edge Feed TE...

Page 4: ...e commonly used binding terms that appear in this service manual 1 Signature The sheets collected and aligned for binding to the book cover are collectively referred to as the signature Once the signa...

Page 5: ...bey a Warning could result in death or serious injury A Caution indicates a potentially hazardous situation Failure to obey a Caution could result in minor or moderate injury or damage to the finisher...

Page 6: ...fety guidelines for customer engineers In regard to other safety issues not described in this document all customer engineers shall strictly obey procedures and recommendations described the CE Safety...

Page 7: ...brackets etc removed for installation have been removed and that no tools remain inside thefinisher Thisalsoensuresthatallreleaseinterlockswitcheshavebeenrestoredtonormaloperation Never use your finge...

Page 8: ...e organic solvents in small amounts to avoid breathing the fumes and becoming nauseous Switch the finisher off unplug it and allow it to cool before doing preventive maintenance To avoid fire or explo...

Page 9: ...ling the power cord can cause excessive heat to build up and could cause a fire Make sure that the area around the power source is free of obstacles so the power cord can be removed quickly in case of...

Page 10: ...mall metallic objects to fall into the finisher Safety Instructions for this Finisher 1 The installation must be done by trained service technicians 2 This finisher weighs 316 kg 695 lb At least four...

Page 11: ...Incorporated PCL is a registered trademark of Hewlett Packard Company Ethernet is a registered trademark of Xerox Corporation PowerPC is a registered trademark of International Business Finishers Cor...

Page 12: ...tion added describing the required adjustments when replacing the Inserter Control Board Jam 255 5 Troubleshooting Jams Low Performance Mode Cancelling Low Performance Mode Deleted the procedures desc...

Page 13: ...the adjustment is required only when replacing the EEPROM and its procedure is described in 3 above 12 Troubleshooting Output Checks Perfect Binder D391 Output Check Bookbinder Test Mode Descriptionad...

Page 14: ...tion Requirements 17 Choosing a Location 17 Power Supply 18 What You Need 18 Perfect Binder D391 Installation 19 Bookbinder Accessories 19 Bookbinder Installation 19 Inserter C1 D391 18 Installation 6...

Page 15: ...t 122 Cover Transport Unit 126 Trimming Unit 128 Opening Locked Doors Manually 132 Signature Thickness Sensor S50 Recalibration 133 Resetting Counters 137 Cover Skew Adjustment 141 Path Entrance Motor...

Page 16: ...on Unit 191 Blade Cradle 195 Trimming Blade Trimmings Catcher 200 Ball Screw 210 Trimmings Buffer Motor M37 215 Horizontal Path Rollers 217 Exit Idle Roller Unit 217 Exit Roller Horizontal Transport R...

Page 17: ...n Error Occurs 276 Low Performance Mode 283 Service Board Basics 284 Service Board Switches 284 Service Board LEDs 285 Service Mode 311 Before You Begin 311 Critical Adjustments 314 Other Adjustments...

Page 18: ...404 Trimming Unit 417 Jam Detection 437 Overview 437 Jams 438 Power Supply 443 Overview 443 Electrical Circuit Protection Features 444 Energy Save Mode 444 Inserter C1 D391 446 Overview 446 Basic Ele...

Page 19: ...r near the power source with at least the minimum amount of clearance around it as shown below These are minimum space requirements More space is recommended for easier maintenance A At least 900 mm 3...

Page 20: ...bookbinder is extremely heavy 316 kg 695 lb At least four persons are needed to unload the bookbinder safely from its pallet After removing the packing straps and cardboard cover you will need a manu...

Page 21: ...ed to a new location Due to the large number of braces that must be retained there are over 20 they should be marked for future reference as they are removed Here are some simple rules to follow durin...

Page 22: ...nload the bookbinder from its pallet You will need a manual forklift to position the pallet for unloading 1 Remove the packing straps and cardboard cover 2 Use a manual forklift A to position the pall...

Page 23: ...are provided on the right and left side of the bookbinder To avoid physical injury always use these handles to lift either the right or the left side of the bookbinder Never attempt to raise the left...

Page 24: ...le 7 Position one person at the right to prevent the bookbinder from tipping over 8 On the left B have two people use the handles to lift while another removes the Styrofoam block and the plastic cove...

Page 25: ...ramps is free of obstacles As the bookbinder is being pulled off the pallet never step across either of the ramps and place your foot in the area between the ramps C 12 With one person D behind the b...

Page 26: ...ch ramp and reattach the ramps B and C to the pallet 15 Tape the nails D to the pallet Bookbinder Exterior Tape Braces Braces cushions and screws removed from the machine for installation should be re...

Page 27: ...1 Remove all strips of tape and packing from the front and top 2 Remove tape A 3 Pull out the glue supply drawer B and remove long tape C Perfect Binder D391 Installation 25 1...

Page 28: ...Left Side 4 Remove upper braces A and B x3 ea Left Side 5 Remove lower braces A B C x2 ea 1 Installation 26 1...

Page 29: ...Mark the two large upper braces D 7 Mark the three small lower braces H Rear 8 At the rear remove all tape as shown from the back top power cord and interface cable Perfect Binder D391 Installation 27...

Page 30: ...brace x1 A brace B x1 and tags x2 ea 10 Mark the removed large brace I and mark the removed small brace H Left Side 11 Open the top cover A 12 Remove tape cushions B and C Slide the cushion at C down...

Page 31: ...ape at C then lower lever Mk4 15 Carefully cut the strips of tape at D then remove the strips of tape and the cushions Pulling on the strips of tape without cutting them could damage the roller shaft...

Page 32: ...Bookbinder Interior Tape Braces Rear 1 Remove rear cover A x8 1 Installation 30 1...

Page 33: ...2 Remove rear upper cover A x5 3 Remove tape cushion A Perfect Binder D391 Installation 31 1...

Page 34: ...4 Remove A Brace tag x2 B Brace tag x4 C Brace tag x4 These four screws are tagged with wire 5 Mark the removed braces G A B as shown 1 Installation 32 1...

Page 35: ...While holding the left front door with one hand behind the top hinge B push the black lever 1 in the direction of the arrow to release the top hinge Swing the top hinge 2 out slightly While still supp...

Page 36: ...top hinge A and bottom hinge B then remove the right front door C You may have to lower lever Mk11 so you can remove the right door 4 Remove the strips of tape and cushions from the jam release lever...

Page 37: ...e the screws of the upper inner cover on the left side A and right side B x6 3 Release jam release levers C and D then hold them in the released position as you remove the upper inner cover Perfect Bi...

Page 38: ...Rear 1 At the left rear corner push the book stack release lever A completely to the right to release the book stacking tray 1 Installation 36 1...

Page 39: ...cking tray A and trimmings box B together 3 Remove the strips of tape and cushions shown above 4 Remove A Tape cushion B Jam clear knob Mk10 Mk10 must be reattached at the end of installation Perfect...

Page 40: ...5 Remove the screws of the lower inner cover A x7 6 Raise the jam clear levers B and C as you remove the cover A 7 Return the jam clear levers B and C to their original positions 1 Installation 38 1...

Page 41: ...Main Grip Cover Transport Tape Braces etc Front 1 Remove the strips of tape and cushions from the horizontal transport unit at the left A right B and center C Perfect Binder D391 Installation 39 1...

Page 42: ...2 Remove tape A with tag 3 Slide the registration unit to the rear then remove tape cushion B 4 Remove cushion A shown above 1 Installation 40 1...

Page 43: ...ckwise about 3 mm to release the pressure on the cushion Rotate the pulley only enough to release the cushion Rear Second attherear manuallyrotatethegripmotorpulley A counter clockwiseabout3mmtoreleas...

Page 44: ...he gap is about 18 mm no wider To prevent changing the correct value 15 mm do not make this gap wider than 18 mm 1 Remove the cushion at the front Front 2 Remove A Brace tag x4 B Brace tag x3 C Brace...

Page 45: ...3 Mark the braces F C E as shown Rear 4 Rotate knob A in the direction of the arrow to raise the grip unit until the actuator B reaches sensor C Perfect Binder D391 Installation 43 1...

Page 46: ...Rear 5 Push up the right side of the timing belt A to rotate the gear counter clockwise until the actuator B reaches sensor C 6 At the rear remove the tape and cushions A 1 Installation 44 1...

Page 47: ...Front 7 At the front remove the tape and cushion A 8 Lift and push Mk7 A to the left and remove the tape and cushion B Perfect Binder D391 Installation 45 1...

Page 48: ...9 Raise lever Mk7 A 10 Remove all strips of tape and cushions 11 Return Mk7 to its original position 12 Raise Mk9 A 13 Remove the long strips of tape B and C 1 Installation 46 1...

Page 49: ...cushions B and the large cushions C Right Side 1 Remove the two strips of tape A 2 At the front lower lever Mk8 3 Remove the cushion B 4 Return lever Mk8 to its original position Perfect Binder D391...

Page 50: ...Trimming Unit Tape Right Side 1 Remove front right corner cover x3 1 Installation 48 1...

Page 51: ...2 Remove A Brace tag x3 B Brace tag x3 3 Remove delivery bracket A x4 Perfect Binder D391 Installation 49 1...

Page 52: ...4 Remove A Brace tag x2 B Brace tag x2 C Long tapes x2 5 Label both braces H 1 Installation 50 1...

Page 53: ...d screw tag A x1 2 Mark the stepped screw 1 Cushion B shown in the previous illustration is firmly clamped in place and must be released before it can be removed 3 To remove cushion B Perfect Binder D...

Page 54: ...Left Side Remove left flat panel A x4 1 Installation 52 1...

Page 55: ...Remove tape cushions A and B Perfect Binder D391 Installation 53 1...

Page 56: ...Corner Behind the brace A near the carrying handle B rotate the white knob C to release the clamped cushion One full rotation should be enough to release the cushion Front Remove cushion A 1 Installa...

Page 57: ...awer 2 Remove A Tape tag B Tape tag C Knurled head screw x1 Remove with fingers 3 Label the screw 2 Confirming Removal and Storing Braces Cushions Screws 1 Visually inspect the machine and confirm tha...

Page 58: ...Mark Item Quantity A Brace A 1 B Brace B 1 C Brace C 1 D Brace D 2 E Brace E 1 F Brace F 1 G Brace G 1 H Brace H 6 I Brace I 1 J Brace J 2 1 Installation 56 1...

Page 59: ...Screws Mark Item Quantity 1 Step Screw 1 2 Plastic head Screw 1 Cushions Mark Item Quantity A Cushion A Long 1 B Cushions B Short 2 Perfect Binder D391 Installation 57 1...

Page 60: ...s must be reattached if the bookbinder is moved to a new location For more details please refer to Preparing the Bookbinder for Moving Check List Confirm that the following parts have been reinstalled...

Page 61: ...b Mk10 1 Rear cover upper 2 Rear cover lower To protect the boards from damage due to accidental short circuiting as result of contact with a metal tool the rear lower cover should never remain off lo...

Page 62: ...es Check the accessories and their quantities against this list No Description Q ty 1 Inserter Unit 1 2 Shoulder Screws M5 2 3 Limiter Brace 1 4 Clamp 1 5 Cap Nut 1 6 Screw M4x7 1 7 Brace 1 8 Screws M...

Page 63: ...pair of nippers to remove the knockout A covering the interface cable hole 2 Smooth the edges of the hole with a knife or file to prevent damage to the interface cable 3 Remove all visible strips of...

Page 64: ...4 Open the top cover A as well as strips of tape and cushion 5 Attach the shoulder screws A and B x2 M4 1 Installation 62 1...

Page 65: ...and completely into holes If the positioning pin fits snugly in the hole no adjustment is necessary or If the pin does not insert completely into the hole do the adjustment procedure described in the...

Page 66: ...ustment screw Rotating the screw clockwise moves the inserter to the right Rotating the screw counter clockwise moves the inserter to the left 5 Tighten the hinge screws x2 M4 6 Lower the inserter aga...

Page 67: ...the clamp C around the harnesses and ground wire 4 Fasten the clamp x1 M4 x8 Inserter Gap Measurement 1 Measure the gap between the inserter and bookbinder at A 2 Measure the gap between the inserter...

Page 68: ...stment is necessary Skip the next section or If the difference is more than 1 mm you must go to the next section and adjust the height Inserter Gap Adjustment 1 Remove the inserter rear cover A x2 2 R...

Page 69: ...de of the adjustment mechanism loosen A Screw B Hex nut With a hex wrench turn adjustment screw C to adjust the gap by raising or lower the inserter Turning clockwise raises the inserter Turning count...

Page 70: ...ft Theprocedure is the same as Step 5 7 Reattach Inserter front cover x2 Top cover angle adjustment shaft x1 Inserter Limiter Brace The limiter brace limits the movement of the inserter unit when it i...

Page 71: ...2 Retrieve the items shown above from the relay unit accessories 3 Set the limiter brace A on the two posts front and back Inserter C1 D391 18 Installation 69 1...

Page 72: ...er brace A upright so it does not slip off its posts attach brace B x1 Make sure that this screw is tight 5 Attach cap nut A to the exposed threads of the screw 6 Reattach the rear cover of the insert...

Page 73: ...ion Q ty 1 Transit Pass Unit D391 Relay Unit 1 2 Ground Plate 1 3 Joint Bracket Left 1 4 Joint Bracket Right 1 5 Scoop for loading glue pellets 1 6 Shoe Plates for host machine 4 7 Screws 28 8 Cover L...

Page 74: ...Relay Unit Installation 1 From the relay unit remove A Strips of tape x2 1 Installation 72 1...

Page 75: ...of the host machine A lower the relay unit B onto the two shoulder screws front and rear 3 Confirm that the slots on the left side of the relay unit are both hooked correctly on the heads of the shoul...

Page 76: ...ssory screws long knurled heads to fasten the relay unit to the side of the host machine x4 5 Route the two relay unit harnesses through the grommet and hole A 6 Attach the harnesses at B below 1 Inst...

Page 77: ...7 Attach the rear cover to the relay unit A x2 B x3 8 Attach the ground plate A x4 Transit Pass Unit D391 19 Installation 75 1...

Page 78: ...9 Attach the front cover to the relay unit A x2 B x3 10 At the left rear corner of the host machine attach the cover A x6 1 Installation 76 1...

Page 79: ...joint bracket L x2 B Right joint bracket R x2 12 Open the front door of the relay unit 13 Remove screw A 14 Pull the lock bar B out to lower it 15 Slowly push the bookbinder against the side of the ho...

Page 80: ...it in the cutouts of the joint brackets attached to the host machine 17 Reattach screw B to fasten the lock bar in the raised position 18 Remove the brace A from the right front door of the bookbinder...

Page 81: ...use the wrench A to turn the nut in the direction of the arrow to raise the bookbinder B until the caster C raises off the floor 23 Place a level on the top edge of the front and right edge of the mac...

Page 82: ...is is the ON position Ignore this step if the breaker switch is already at the position 5 Use the tip of a small screwdriver to push the breaker test button C The breaker switch should flip to the O O...

Page 83: ...he Bookbinder 1 At the left rear corner of the host machine confirm that cover A has been reattached x6 2 On the right side of the host machine attach A Left joint bracket L x2 B Right joint bracket R...

Page 84: ...out to lower it 6 Slowly push the bookbinder against the side of the host machine 7 Push in lock bar A to raise it and lock it in the cutouts of the joint brackets attached to the host machine 8 Reat...

Page 85: ...binder x1 10 Remove wrench B 11 Place a shoe A under the stoppers at each corner of the bookbinder 12 Use your fingers or the wrench to turn the nut in the direction of the arrow until the nut stops o...

Page 86: ...ster C raises off the floor 14 Place a level on the top edge of the front and right edge of the machine to confirm that the bookbinder is level 15 Adjust the corner stoppers until the machine is level...

Page 87: ...1 Pull out the glue supply drawer until it stops 2 Raise the two covers A and B 3 Note the load limit marks C inside the drawer on both sides Docking Completing the Installation 85 1...

Page 88: ...perature range 20 C to 40 C Never expose pellets to direct flame Keep the pellets out of the reach of small children If pellets are accidentally ingested contact a physician immediately Never dispose...

Page 89: ...N position Ignore this step if the breaker switch is already at the position 5 Use the tip of a small screwdriver to push the breaker test button C The breaker switch should flip to the O OFF position...

Page 90: ...Final Check 1 Connect the power cord of the copier to its power source 2 Connect the power cord of the bookbinder to its power source 3 Turn on the host machine 1 Installation 88 1...

Page 91: ...procedure to move the internal units to their home positions before moving the machine This procedure must be done before reattaching any braces to the perfect binder 1 Switch the host machine off 2...

Page 92: ...5 Remove the service board cover 1 x1 6 On the SW1 bank set DIP SW1 to ON 7 On the SW2 bank set DIP SWs 1 2 4 7 to ON 1 Installation 90 1...

Page 93: ...gain No Operation Target Unit 1 Moves the blade cradle to its initial position Moves the signature press blade to its END position Moves inside the trimming unit Opens the rotation guide plate Lowers...

Page 94: ...d light after all units have been moved to their shipping positions 10 Set all the SW1 and SW2 DIP SWs to the down positions 11 Switch off the host machine 12 After moving the machine to its new locat...

Page 95: ...Gluing Unit Brace Quantity Brace B x4 1 Brace G x4 1 Sub Grip Unit Preparing the Bookbinder for Moving 93 1...

Page 96: ...nder will be moved by elevator to a different floor in the same building attach the braces to stabilize the gluing unit sub grip unit described above and the two additional locations described below L...

Page 97: ...to their correct moving positions before you reattach any braces See procedure above Make sure the braces are fastened with their screws and clearly marked for removal with the original red tags or i...

Page 98: ...1 Installation 96 1...

Page 99: ...2 Preventive Maintenance PM Tables For details about PM Tables for this peripheral see the main service manual 97 2...

Page 100: ...2 Preventive Maintenance 98 2...

Page 101: ...stment Basics Parts Dangerous to Touch This section points out some areas inside the machine where you should exercise extra precaution when working around the machine with the covers off Covers Off R...

Page 102: ...Top 1 Sub Grip Area Front 2 Sub Grip Area Rear 3 Replacement and Adjustment 100 3...

Page 103: ...t The gluing unit becomes extremely hot to keep the glue melted and ready for use The glue and gluing unit remain hot for several minutes after the bookbinder is turned off Always allow the gluing uni...

Page 104: ...the covers touch the gluing unit only when necessary and only after it has cooled completely Gluing Unit 1 Gluing Unit The illustration shows the glue vat with the top cover removed 3 Replacement and...

Page 105: ...Sub Grip Unit Front and Back Never put your fingers or a tool in or near the exposed areas of the sub grip unit at the front 1 or at the rear 2 while the bookbinder is powered on Basics 103 3...

Page 106: ...r the exposed areas of the main grip unit at 1 while the bookbinder is powered on Main Grip Unit at Turnover to Trimming Unit After Gluing Never put your fingers or a tool in or near the exposed areas...

Page 107: ...Spine Fold Plate Never put your fingers or a tool in or near the exposed areas of the spine plates at 1 while the bookbinder is powered on Basics 105 3...

Page 108: ...ing Unit Gripper and Press Plate Never put your fingers or a tool in or near the exposed areas of the press plates at 1 or gripper at 2 while the bookbinder is powered on 3 Replacement and Adjustment...

Page 109: ...sharp Never touch the edge of the blade 1 Always work carefully where the blade is exposed Using the Dials Gluing Unit The gluing unit is equipped with two dials that are used to raise and lower the...

Page 110: ...to lower the stacking tray Turn this dial counter clockwise to raise the stacking tray Main Grip Unit Lift Dial The photo above shows the main grip lift dial 1 viewed from the rear of the bookbinder...

Page 111: ...blade from side to side There are also two pulleys where you can use a plus screwdriver to raise and lower the book lift tray and move the trimmings buffer from side to side Slide Lift Dial The photo...

Page 112: ...from the front 1 Main Grip Dial 2 Press Plate Dial Main Grip Dial Turn clockwise to close the main grip Turn counter clockwise to open the main grip Press Plate Dial Turn clockwise to open the press...

Page 113: ...cutting position Turn the dial counter clockwise to pull the blade away from the cutting position Book Lift Tray Trimmings Buffer Pulleys The photo above shows the book tray lift pulley 1 and the trim...

Page 114: ...rimmings buffer pulley Turn the pulley clockwise to move the trimmings buffer to the left Turn the pulley counter clockwise to move the trimmings buffer to the right 3 Replacement and Adjustment 112 3...

Page 115: ...n continue to operate but only for straight through downstream delivery The machine can be released from the low performance mode by the service technician only Set the bookbinder in low service mode...

Page 116: ...ash for 2 sec Low Performance Mode LED2 flashes for 2 sec LED flashes for 0 3 sec 9 If LED2 LED3 are both flashing at 2 sec intervals Normal Mode push PSW2 to select low performance mode or If LED2 is...

Page 117: ...e allows the bookbinder to perform downstream delivery so it does not interfere with other operations bookbinding and trimming however are not available As soon as the problem has been corrected do th...

Page 118: ...rear upper cover 4 Disconnect the inserter I F cable 1 x2 x3 5 Raise the inserter 1 6 Disconnect the inserter 2 from the bookbinder and remove it x2 Front Doors 1 Open the right front door and left f...

Page 119: ...oor with one hand behind the top hinge push the black lever 4 in the direction of the arrow to release the top hinge Swing the top hinge out slightly While still supporting the left door with one hand...

Page 120: ...3 Repeat Step 2 to remove the top hinge 1 and bottom hinge 2 then remove the right front door 3 You may have to lower Mk11 so you can remove the right door 3 Replacement and Adjustment 118 3...

Page 121: ...Covers Rear Cover 1 Rear cover 1 x8 Rear Upper Cover Common Procedures 119 3...

Page 122: ...1 Rear upper cover 1 x5 Left Upper Cover 1 Open the inserter and upper cover 2 Remove the front bar 1 of the stacking tray unit x3 3 Remove the left upper cover 1 x4 3 Replacement and Adjustment 120 3...

Page 123: ...Upper 1 Remove both the left and right front door 2 Raise jam lever Mk12 1 3 Remove the front inner cover upper 2 x6 Front Inner Cover Lower 1 At the right rear corner unlock the book stack door Commo...

Page 124: ...clear knob Mk10 3 Mk10 must be reattached 4 Remove the screws of the lower inner cover 4 x7 5 Raise the jam clear levers Mk8 5 and Mk9 6 as you remove the cover 6 Return the jam clear levers to their...

Page 125: ...1 Remove the inserter 2 Remove the stacking tray front cover 1 x3 3 Remove the top cover 1 x3 4 Remove the harness cover 1 x2 Common Procedures 123 3...

Page 126: ...Remove the covers around the back and the rear upper cover 6 Remove 1 x1 2 Flange x1 3 Belt x1 4 Gear x1 5 Lock pin x1 6 x1 7 Bearing x1 7 Disconnect connectors 1 x2 3 Replacement and Adjustment 124...

Page 127: ...it Remove the signature path exit unit carefully and avoid dropping the belt 1 of the drive motor into the bookbinder The belt must be reattached to its gear 2 at reinstallation First removing the TE...

Page 128: ...emove the signature path exit unit 2 x 2 Left x 2 Right Cover Transport Unit 1 Remove Rear cover p 119 Both doors p 116 Front inner lower cover p 121 Front inner upper cover p 121 2 Remove screw x1 3...

Page 129: ...3 Disconnect connectors at 1 x5 and 2 x6 4 Remove 1 Left brace x4 2 Right brace x4 3 Lock plate x2 Common Procedures 127 3...

Page 130: ...left rear corner of the bookbinder 2 Gently move the screwdriver in the direction of the arrow to release the stacking tray lock 3 At the front pull open the book tray door and the trimmings box draw...

Page 131: ...6 Remove 1 Left brace x2 2 Right brace x2 3 Lock plate x2 7 Pull out the trimming unit 1 on its rails Before Closing the Trimming Unit Drawer Common Procedures 129 3...

Page 132: ...nfirm that it is not near the press limit sensor S89 4 as shown in the illustration on the right If the small plate is blocking the sensor turn the knob 1 toward you to move the small plate 3 away fro...

Page 133: ...he motor knob 2 away from you to move the plate to the rear until the plate edge reaches the left edge of the PCB 3 or If the edge of the plate 4 is not even with the left edge of the PCB turn the mot...

Page 134: ...the bookbinder was operating cycling the bookbinder off on will usually unlock the doors However if the front doors remain locked after cycling the machine off on or if you cannot switch the machine o...

Page 135: ...of the bookbinder 2 Move the screwdriver in the direction of the arrow to release the stacking tray lock If the rear cover has been removed just push the lever 2 to the right to unlock the book stack...

Page 136: ...master control board Special Tools Two special plastic jigs are provided with a new signature thickness sensor S50 These jigs are required for the adjustments 1 If the system is on turn the host machi...

Page 137: ...home position 8 Confirm that there is no paper in the main grip unit 9 With nothing in the main grip unit press PSW1 to set signature width for 0 mm The main grip closes opens and retracts 10 Check th...

Page 138: ...25 mm 13 Check the LED display to confirm that the maximum value has been set LED1 ON LED2 ON LED3 Flash Saving maximum setting LED1 Flash LED2 OFF LED3 OFF Adjust standby or adjust END 14 Remove bot...

Page 139: ...s for PM parts stored in the EEPROM of the bookbinder 1 If the system is on turn the host machine off 2 Insert piece of cardboard or folded piece of paper into the slot 1 of the left door switch and t...

Page 140: ...ipple Roller Up Up Up Torque Diode Limiter Signature Rotation Up Up Up Up Timing Belt Signature Rotation Up Up Up Up Ball Screw Unit Up Up Up Up Up Cutting Blade Up Up Up Blade Cradle Up Up Up Deodori...

Page 141: ...horizontal transport path Up Up Up Sheets fed through signature path Up Up Up Up Books bound Up Up Up Number of blade cuts Up Up Up Up Blade cradle usage blade cradle movements to change cutting posi...

Page 142: ...down PSW2 and PSW3 together until LED1 LED2 and LED3 go ON for 2 sec and then release LED2 LED3 go OFF then LED1 resumes flashing at 1 sec intervals LED1 flashes at 1000 ms intervals LED2 LED3 go OFF...

Page 143: ...p Up Lower Tray Pickup Roller Up Up Up Lower Tray Separation Roller Up Up Up Up Lower Tray Transport Roller Up Up Lower Tray Torque Limiter 5 Push and hold down PSW2 and PSW3 together until LED1 LED2...

Page 144: ...ition of the cover horizontal registration unit 1 Remove the right and left front door 2 Remove the lower inner cover x6 3 Loosen the screw on the scale indicator 4 Move the scale to the right 2 or to...

Page 145: ...5 Do some test prints and then repeat the adjustment until the cover and signature are correctly aligned Common Procedures 143 3...

Page 146: ...tor M5 INS 1 Remove the rear cover p 119 2 Remove the vertical transport motor M5 INS 1 x2 x1 Re installation 1 Be sure to reattach the timing belt 1 with the belt hung on the motor drive gear as show...

Page 147: ...10 1 Remove the rear cover x8 p 119 2 Remove the entrance motor M10 1 x2 x1 Reinstallation 1 Be sure to reattach the timing belt 1 with the belt hung on the motor drive gear as shown above Path Entran...

Page 148: ...path exit unit p 122 2 Remove the 5 ripple idle rollers x1 ea 3 Reset the counter for the ripple rollers p 137 TE Press Roller Unit 1 Remove the signature path exit unit p 122 2 Release harness 1 x11...

Page 149: ...4 Remove sensor plate 1 x1 5 Remove 1 x1 2 Bearing x1 Signature Path Exit Unit 147 3...

Page 150: ...6 Slide the pressure roller 1 in the direction of the arrow release it from the ring 2 then remove the roller 7 Remove the TE press plate unit 1 x4 3 Replacement and Adjustment 148 3...

Page 151: ...8 Remove the TE press roller unit 1 2 x1 3 Gear x 1 4 Lock pin x1 5 x1 6 Bearing x1 7 Ripple idle rollers x2 x1 ea 8 x1 9 Bearing x1 Signature Path Exit Unit 149 3...

Page 152: ...Reinstallation 1 Pressure levers 1 must be positioned between the shaft of the TE pressure plate 2 and the rib 3 3 Replacement and Adjustment 150 3...

Page 153: ...t p 115 Top cover p 122 2 Open the transport guide 1 3 Remove the upper anti static brush 2 x2 4 Remove the lower anti static brushes 3 Front x2 4 Rear x2 5 Reset the counter after replacing the brush...

Page 154: ...back Roller 1 Remove Inserter p 115 Top cover p 122 2 Remove control plates 1 and 2 x2 ea 3 At the front and rear remove 1 Collar x1 2 Collar x1 4 Remove the switchback rollers 3 and 4 3 Replacement a...

Page 155: ...k roller p 137 Anti Static Brush 1 Remove Inserter p 115 Top cover p 122 2 Remove the top cover of the jogging unit 1 x4 3 Disconnect the stacking weight motor 1 M6 x2 4 Slide the motor to the side an...

Page 156: ...he weight 1 to the left in the direction of the arrow as far as it will go 7 Slowly rotate the anti static brush 2 to the front and remove it 8 Reset the counter after replacing the anti static brush...

Page 157: ...ger Motors Front Back M4 M5 1 Remove Inserter p 115 Top cover p 122 2 Remove the top cover of the jogging unit 1 x4 3 Remove 1 Front jogger motor M4 x2 x1 2 Rear jogger motor M5 x2 x1 Stacking Tray 15...

Page 158: ...50 1 Open the right door and left door 2 Remove the service board cover 1 x1 3 If the system is on switch off the host machine 4 Insert piece of cardboard or folded piece of paper into left door switc...

Page 159: ...der Before entering Service Mode the trimmer unit must be inside the machine 6 Turn the host machine on The bookbinder is now in Service Mode 7 On the SW2 bank set DIP SW 1 2 and 7 to ON Make sure you...

Page 160: ...ingposition itshouldbevertical 10 Turn the host machine off and disconnect the host machine bookbinder and any other peripheral devices from the power supply 11 Confirm that all devices have been swit...

Page 161: ...move the rear cover of the bookbinder 14 Remove the sensor plate 1 x1 Work carefully with the protective plate removed to avoid hitting and damaging the exposed sensor 1 and actuator 2 Main Grip Unit...

Page 162: ...e sensor plate confirm that the sensor pin 1 is positioned between the sides of the cutout 2 as shown above 2 After replacement the signature thickness sensor must be recalibrated See Recalibrating Se...

Page 163: ...piece of paper into the slots of the left 1 and right 2 door switches 4 Remove the service board cover x1 5 On the SW1 bank set DIP SW1 to ON Confirm that the trimmer unit is inside the bookbinder Be...

Page 164: ...allychecktoconfirmthatthemaingripunithasmovedtothebindingposition itshouldbevertical 10 Turn the host machine off and disconnect the host machine bookbinder and any other peripheral devices from the p...

Page 165: ...12 Remove the bracket screws 1 x3 13 Disconnect the connector 2 x1 Work carefully during removal to avoid damaging the encoder wheel 2 and sensor 1 Main Grip Unit 163 3...

Page 166: ...14 To free the motor 1 remove 2 Band x1 3 x1 4 x1 15 Remove the sensor bracket 1 x2 3 Replacement and Adjustment 164 3...

Page 167: ...16 Remove the motor 1 from the bracket 2 x2 Reinstallation Before reinstalling the motor confirm that the harness 1 and gear 2 are positioned as shown above Main Grip Unit 165 3...

Page 168: ...4 1 Turn the host machine off 2 Open the right door and left door 3 Remove service board cover 1 4 Insert piece of cardboard or folded piece of paper into the left door switch slot 1 3 Replacement and...

Page 169: ...der Before entering Service Mode the trimmer unit must be inside the machine 6 Turn the host machine on The bookbinder is now in Service Mode 7 On the SW2 bank set DIP SW 1 2 and 7 to ON Make sure you...

Page 170: ...rn the host machine off and disconnect the host machine bookbinder and any other peripheral devices from the power supply 11 Confirm that all devices have been switched off and disconnected The power...

Page 171: ...14 Remove the deodorization filter bracket 1 x4 15 Remove the relay board 1 Plate x1 2 Flexible press plates x2 3 FFC x1 4 x3 x3 5 x1 Main Grip Unit 169 3...

Page 172: ...16 Disconnect the motor bracket 1 x3 Work carefully during removal to avoid damaging the encoder wheel 1 and sensor 2 3 Replacement and Adjustment 170 3...

Page 173: ...17 Remove the sensor plate 1 x1 Reinstallation Before reinstalling the motor confirm that the harness 1 and gear 2 are positioned as shown above Main Grip Unit 171 3...

Page 174: ...t Rotation Motor M21 1 Open the inserter 2 Remove Top cover p 122 Rear upper cover p 119 Rear cover p 119 3 Remove the harness cover 1 x4 4 Remove the top cover switch 1 x2 3 Replacement and Adjustmen...

Page 175: ...5 Remove the top cover frame 1 x5 6 Remove the protection plate 1 x1 x1 x3 7 While holding the main gripper steady with one hand remove the grip unit rotation motor Main Grip Unit 173 3...

Page 176: ...bing the position of the main gripper Main Grip Lift Motor M22 1 Remove the rear cover p 119 2 Remove the main gripper lift motor 1 x1 x2 Reinstallation 1 When you reinstall the main grip lift motor d...

Page 177: ...luing Unit 1 Remove the rear cover p 119 2 Remove the rear upper cover p 119 3 Remove the filter case 1 x4 4 Remove the filter case 1 x3 5 Remove the filters 2 6 Reset the counters after replacing the...

Page 178: ...Heater 1 If the system is on turn it off 2 Allow the glue heater to cool for at least 30 min The glue heater heats the glue to about 160C F At this temperature the glue is a liquid that flows easily A...

Page 179: ...dboard or folded piece of paper into the slot 1 of the left door switch 5 Remove the cover 1 of the service board x1 6 If the system is on switch off the host machine 7 On the SW1 bank set DIP SW1 to...

Page 180: ...sure your hands loose clothing and tools are well clear of the bookbinder 10 Press PSW1 to move the main grip to its initial position 11 Switch the system off and disconnect the host machine and bookb...

Page 181: ...13 Remove the glue unit transport stay 1 x4 14 Disconnect the harnesses x8 x5 Gluing Unit 179 3...

Page 182: ...15 Remove 1 Standoff x1 2 x2 16 Release the thermistor harness 1 at the front side of the glue heater unit x4 3 Replacement and Adjustment 180 3...

Page 183: ...17 Remove sensor bracket 1 x1 18 Remove sensor bracket and sensor 1 x1 x1 Gluing Unit 181 3...

Page 184: ...19 Remove the screw from the bottom of the glue heater unit 1 x1 20 Remove the glue heater unit 1 x3 3 Replacement and Adjustment 182 3...

Page 185: ...Reinstallation 1 Reconnect the timing belt 1 to the motor drive gear 2 and shaft gear 3 2 Reset the counter after replacing the glue heater p 137 Gluing Unit 183 3...

Page 186: ...and left door 2 Remove the switchback rollers 1 x2 3 Reset the counter after replacing the switchback rollers p 137 Torque Limiter 1 Pull out the cover transport unit drawer p 126 2 Remove the roller...

Page 187: ...Remove the torque limiter 1 x1 Gear x1 Reinstallation When you reinstall the roller release lever shaft make sure that the pawls 1 of the shaft are below the roller holders 2 Cover Transport Unit 185...

Page 188: ...1 Pull out the cover transport unit 2 Disconnect the roller 1 x1 Bearing x1 3 Push the shaft of roller 1 to the rear 4 Remove bearing free the timing belt and remove the roller Anti Static Brush Upper...

Page 189: ...5 Remove the anti static brush 1 x2 Anti Static Brush Lower Right 6 Remove the idle roller unit of transport roller 1 1 x2 Cover Transport Unit 187 3...

Page 190: ...ounter after replacing the brushes p 137 Anti Static Brush Left 1 Pull out the cover transport unit p 126 2 Open cover 1 3 Remove anti static brushes 2 and 3 4 Reset the counter after replacing the br...

Page 191: ...Exit Rollers 1 2 Unit 1 Pull out the cover transport unit p 126 2 Open cover 1 3 Remove guide plate 2 x1 4 Remove exit idle roller unit 5 Open cover 1 Cover Transport Unit 189 3...

Page 192: ...Confirm that the pressure arms 1 on the rear of the exit roller unit are inserted into the holes 2 of the spine fold unit If the fit is difficult manually turn the gear 3 of the motor to move the spi...

Page 193: ...Trimming Unit Torque Diode Signature Rotation Unit 1 Pull out the trimming unit drawer p 128 2 Remove left stay 1 x4 3 Remove harness plate 1 x4 x9 x1 Trimming Unit 191 3...

Page 194: ...te knob 1 counter clockwise until sensor plate 2 separates from sensor 3 5 Rotate wheel 1 to raise the rotation unit 2 then remove sensor plate 3 x1 6 Disconnect sensor 4 3 Replacement and Adjustment...

Page 195: ...e connector 1 8 While gently pressing down on the rotation unit 2 remove harness guide 3 x2 9 Turn wheel 1 to move rotation unit until you can see the screw 10 Remove the sensor plate 2 x1 Trimming Un...

Page 196: ...haft x1 3 Gear x1 12 Move the rotation unit to a position where it is easy to work and remove the torque diode 1 x3 13 Reset the counter after replacing the torque limiter diode p 137 3 Replacement an...

Page 197: ...rewdriver in the direction of the arrow to release the stacking tray lock 3 At the front open the book tray door and the trimmings box drawer 4 Remove the front lower cover p 121 5 Insert piece of car...

Page 198: ...1 bank set DIP SW1 to ON Confirm that the trimmer unit is inside the bookbinder Before entering Service Mode the trimmer unit must be inside the machine 9 Turn the host machine on The bookbinder is no...

Page 199: ...Make sure your hands loose clothing and tools are well clear of the bookbinder 11 Press PSW1 Trimming Unit 197 3...

Page 200: ...ral devices from the power supply 13 Confirm that all devices have been switched off and disconnected 14 Remove 1 Left brace x2 2 Right brace x2 3 Lock plate x2 15 Pull out the trimming unit 4 on its...

Page 201: ...e cradle are inserted in the holes of the trimming unit 2 and locked in the groove 3 2 After the blade cradle has been reinstalled at the front and rear confirm that blade cradle is aligned correctly...

Page 202: ...ing blade and trimmings catcher are always replaced together Removing the Trimming Blade 1 Insert the tip of a small screwdriver into the small hole 1 near the left rear corner of the bookbinder 2 Mov...

Page 203: ...rdboard or folded piece of paper into the slot 1 of the left door switch and the slot 2 of the right door switch 6 Remove the service board cover 1 x1 7 If the system is on switch off the host machine...

Page 204: ...ring Service Mode the trimmer unit must be inside the machine 9 Turn the host machine on The bookbinder is now in Service Mode 10 On the SW2 bank set DIP SW 1 2 3 and 7 to ON Make sure your hands loos...

Page 205: ...etracts to the safe position 12 Turn the host machine off and disconnect the host machine bookbinder and any other peripheral devices from the power supply 13 Confirm that all devices have been switch...

Page 206: ...le pushing the lever 1 to the left with a screwdriver insert the sheath 2 provided with the new blade along the edge of the old blade inside the bookbinder Make sure that the edge of the blade 1 slide...

Page 207: ...lade 2 18 Use the accessory screw provided with the sheath to fasten the sheath at 3 x1 Do not apply excessive force to this screw Turn the screw until it is snug against the side of the sheath 19 Whi...

Page 208: ...sheath The edge of the blade can cause a serious cut if the sheath becomes separated Always hold the sheath and blade with two hands one on the handle and one hand on the end near the screw Never hold...

Page 209: ...2 Remove 1 x1 2 Bracket x1 3 Underneath the trimming unit remove the trimmings catcher unit 1 Trimming Unit 207 3...

Page 210: ...Springs x 2 2 x 2 Installing the New Blade 1 Pick up the new blade with the sheath attached Never remove the sheath of the new blade until the blade and sheath have been set in the trimmer unit 3 Rep...

Page 211: ...3 While pressing the blade to the rear attach the blade with the accessory screws x4 You must use the lock screws to fasten the blade They are lock screws specially designed for use with the blade 4...

Page 212: ...awer p 128 2 To prevent SC795 30 always check to make sure that the blade cradle plate is aligned with the left edge of the PCB where the trimmer limit sensor S86 is mounted p 128 3 Reset the counter...

Page 213: ...row x3 5 Remove e ring 1 and bearing 2 If the bearing is too difficult to remove now you can remove it later when the ball screw is removed 6 Remove the sensor frame 3 x1 7 Turn knob 1 to raise the ro...

Page 214: ...8b lb of pressure on a book caught and jammed in the trimming unit Removing the edge press plate motor with this much pressure on the edge press plate could cause injury The reference line toward the...

Page 215: ...he four harness clamps before you remove them 10 Disconnect harness 3 x8 11 Remove the screws from the motor frame 1 x6 12 Move the motor frame 1 in the direction the arrow then remove the shaft 2 x1...

Page 216: ...ut the shafts 1 and 2 15 Remove the rings 1 bearing 2 and bushing 3 from the end of the ball screw 16 Remove the ball screw 1 x4 If it is difficult to remove rotate the shaft 3 Replacement and Adjustm...

Page 217: ...it p 137 Trimmings Buffer Motor M37 1 Open the book stack door p 133 2 Pull out the book output tray 3 Pull out the trimmings box drawer and remove the box from the drawer 4 On the right loosen screw...

Page 218: ...7 Remove the trimmings buffer motor M37 x2 x1 3 Replacement and Adjustment 216 3...

Page 219: ...Exit Idle Roller Unit 1 Pull out the cover transport unit p 126 2 Raise lever Mk8 to open the exit roller cover 1 3 Remove the guide plates 2 Front x1 3 Rear x1 4 Remove the exit roller cover 1 Horizo...

Page 220: ...and remove the rollers x2 ea Exit Roller Horizontal Transport Roller 5 1 Pull out the cover transport unit p 126 2 Remove the exit idle roller unit p 217 3 Raise lever Mk8 to open the left horizontal...

Page 221: ...connector protection plate 1 x1 6 Disconnect the connector 2 x1 7 Remove the guide plate 3 turn it over and lay it on a flat surface 8 To replace the rollers 1 Springs x2 2 Rollers x2 Horizontal Path...

Page 222: ...elts x3 Gears x2 Bushings x2 Reinstallation Make sure that the pressure arms 1 behind the exit unit 2 go through the holes of the left spine fold unit 3 If this is difficult to do turn the pulley 4 of...

Page 223: ...it p 126 2 Remove the exit idle roller unit p 217 3 Remove the exit roller unit p 218 4 Disconnect harness x4 1 4 5 6 Standoffs x2 2 3 x1 7 5 Manually rotate the spine fold drive gear 1 to move the le...

Page 224: ...pine fold unit 3 8 Remove the screws 1 x2 then remove the brace 2 from the side of the left spine fold unit 9 Remove the screws 1 x3 and remove the roller bracket 2 10 Turn over the roller bracket and...

Page 225: ...a Left Cover Transport Path Guide Roller 1 Pull out the cover transport unit p 126 2 Raise lever Mk7 to open the cover 1 3 Replace the guide rollers 2 Front x2 Timing belt x1 Gears x2 Bushings x2 3 Re...

Page 226: ...2 At the front disconnect the roller 1 x1 Bearing x1 3 Push the roller 2 slightly to the rear 4 At the rear disconnect the roller 3 Timing belt x1 Gear x1 Bearing x1 1 Remove the horizontal transport...

Page 227: ...Horizontal Transport Roller 2 1 Pull out the cover transport unit p 126 2 Raise lever Mk9 1 to see the rollers 3 Remove the harness protection plate 1 x1 Horizontal Path Rollers 225 3...

Page 228: ...4 Disconnect the harness 1 x1 2 x2 5 Remove the screws at the front 1 and rear 2 x4 3 Replacement and Adjustment 226 3...

Page 229: ...emove the plate 1 guide the connectors 2 under the plate 7 Turn over the plate and lay it on a flat surface 8 Remove the roller shaft springs 1 Springs x2 ea 9 Remove the rollers 2 x2 ea Horizontal Pa...

Page 230: ...his is difficult to do turn the pulley 4 of the spine fold motor manually to move the spine fold unit Horizontal Transport Roller 3 1 Remove Horizontal transport roller 1 and idle rollers p 224 Horizo...

Page 231: ...e guide plate shaft forward and out of the hole at 1 4 Push the guide plate to the rear and through the hole at 1 5 Pull the guide plate forward again to remove it from the shaft Horizontal Path Rolle...

Page 232: ...6 Remove 1 Front door interlock unit 1 x3 2 Guide standard plate 2 x1 7 Remove plate 1 x1 3 Replacement and Adjustment 230 3...

Page 233: ...to mark the current position of the notch on the graduated scale The notch must be realigned at this mark when it is reattached 9 Remove the notch plate 1 x1 10 Disconnect the harness 1 x2 x3 Horizont...

Page 234: ...11 Disconnect the harness 1 x1 2 x1 3 x3 12 Disconnect harness 1 Band x1 x2 x4 3 Replacement and Adjustment 232 3...

Page 235: ...right cover transport path guide 1 16 Manually turn the pulley 2 to move the right spine fold plate unit completely to the right 17 Remove the right spine fold plate 3 x2 At reinstallation the right s...

Page 236: ...18 Remove plates 1 2 x4 ea 19 Remove the roller assembly screws 3 x2 20 Remove the screws 1 x4 21 Replace the old roller set 2 with the new one 3 Replacement and Adjustment 234 3...

Page 237: ...Perfect Binder Boards Master Control Board PCB1 Slave Control Board PCB2 Cutter Control Board PCB3 Relay Board PCB12 Power Supply Unit 1 PCB20 Power Supply Unit 2 PCB21 Perfect Binder Boards 235 3...

Page 238: ...nstalling a new EEPROM in the master control board Refer to the factory setting data sheet which has been kept in the right front door for details about necessary settings to be input in the EEPROM Re...

Page 239: ...where 2 4 mm is the actual value The LEDs remain OFF for 2 sec if the current value is 0 The LED2 and LED3 displays automatically alternate 4 Input a value for the CV REG L on the factory setting dat...

Page 240: ...to the current value or PSW3 to subtract 0 1 mm from the current value 4 CLCT SB Stacking Tray Switchback Roller Adjustment SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up...

Page 241: ...to add 0 1 mm to the current value or PSW3 to subtract 0 1 mm from the current value 6 ALG R A4 Jogger Motor Adjustment Rear jogger motor Small size less than 298 mm SW1 1 2 3 4 Up 1 Set the SW1 bank...

Page 242: ...add 0 1 mm to the current value or PSW3 to subtract 0 1 mm from the current value 8 ALG R L Jogger Motor Adjustment Rear jogger motor Large size 298 mm or more SW1 1 2 3 4 Up 1 Set the SW1 bank as sho...

Page 243: ...05 mm from the current value To lower the main grip unit to increase the pressure between the spine and gluing vat roller below adjust in the plus direction The amount of glue will increase To raise...

Page 244: ...the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 LED3 to read the current setting 4 Input a value for the GRP CHNG on the f...

Page 245: ...ge cut adjust SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 LED3 to read the current setting 4 Inpu...

Page 246: ...djustment L1 Square Adj For 10 Sheet Signature 1 SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 L...

Page 247: ...lue 17 10RGT 3 Square Cut Adjustment L3 Square Adj For 10 Sheet Signature 3 SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up 2 Set the SW2 bank as shown above 3 Push PS...

Page 248: ...3 to subtract 0 1 mm from the current value 19 200RGT 2 Square Cut Adjustment L2 Square Adj For 200 Sheet Signature 2 SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up U...

Page 249: ...et by pushing PSW2 to add 0 1 mm to the current value or PSW3 to subtract 0 1 mm from the current value 21 SLD MTR Slide Motor HP Adjustment SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3...

Page 250: ...setting data of the STK VR25 24 GLU LOW Glue Remain Thermistor Lower Limit 1 Enter the SP mode of the mainframe 2 Use SP6525 001 to input the factory setting data of the GLU LOW 25 GLU UP Glue Remain...

Page 251: ...nt SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 LED3 to read the current setting 4 Input a valu...

Page 252: ...ation at Corners Adjustment Bottom Edge 3 Cuts SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 LED3 t...

Page 253: ...alue 31 GLU EDG4 Glue Application at Corners Adjustment Bottom Edge No Trimming or Top Only SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up 2 Set the SW2 bank as shown...

Page 254: ...r PSW3 to subtract 0 05 mm from the current value 33 GLU AMT2 Glue Amount Adjustment 2 stack thickness 1 5 3 4mm SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1 2 3 4 5 6 7 8 Up Up Up Up 2 Set...

Page 255: ...add 0 05 mm to the current value or PSW3 to subtract 0 05 mm from the current value 35 GLU AMT4 Glue Amount Adjustment 4 stack thickness 6 5 11 4mm SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2...

Page 256: ...0 05 mm to the current value or PSW3 to subtract 0 05 mm from the current value 37 GLU AMT6 Glue Amount Adjustment 6 stack thickness 22 5 25 0mm SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above SW2 1...

Page 257: ...o add 1000 to the current value or PSW3 to subtract 1000 from the current value 39 TBPCOUNT Setting Threshold Value for Shifting the Cutting Position SW1 1 2 3 4 Up 1 Set the SW1 bank as shown above S...

Page 258: ...LED3 to read the current setting 4 Input a value for the TBPCOUNT on the factory setting data sheet by pushing PSW2 to add 1 to the current value or PSW3 to subtract 1 from the current value 41 TBP MV...

Page 259: ...P 11 Up Up Up Up Up DIP 12 Up Up Up Up Up Up DIP 13 Up Up Up Up Up Up DIP 14 Up Up Up Up Up Up Up DIP 15 2 Set the SW2 bank as shown above 3 Push PSW1 then look at LED1 LED2 LED3 to read the current s...

Page 260: ...he rear cover p 119 2 Remove the slave control board 1 FFC x all x all x1 Standoffs x5 Cutter Control Board 1 Remove the rear cover p 119 2 Remove the cutter control board 1 x all x1 Standoffs x3 3 Re...

Page 261: ...2 Remove the relay control board 1 x all x4 3 Remove the EEPROM 2 from the old board and install it on the new board Power Supply Unit 1 1 Remove the rear cover p 119 2 Remove power supply unit 1 asse...

Page 262: ...3 Remove the protector plate 1 Top x2 2 Bottom x2 4 Remove the power supply unit 1 PCB 1 x9 3 Replacement and Adjustment 260 3...

Page 263: ...cover p 119 2 Remove power supply unit 2 assembly 1 x 3 x4 Push the board to the right and pull it out from behind the fan It is not necessary to remove the fan 3 Remove the protector plate 1 Top x2 2...

Page 264: ...4 Remove the power supply unit 2 PCB 1 x9 3 Replacement and Adjustment 262 3...

Page 265: ...Inserter Common Procedures Rear Cover 1 Rear cover 1 x2 Releasing Top and Middle Covers 1 Remove rear cover p 263 Inserter 263 3...

Page 266: ...the limiter brace x1 3 Open the top cover 2 completely 4 Open the middle cover 1 5 Remove the limiter brace 2 x2 6 Open the middle cover completely Front Cover 1 Release and open top cover 3 Replaceme...

Page 267: ...2 Remove the front cover 1 x2 Feed Rollers Feed Roller Tray A 1 Remove the inserter rear cover p 263 2 Release and open the top cover completely p 263 3 Remove the transport guide 1 x2 Inserter 265 3...

Page 268: ...4 Remove 1 Feed roller x1 2 Feed roller x1 Feed Roller Tray B 1 Remove the inserter rear cover p 263 2 Release and open the top and middle cover completely p 263 3 Replacement and Adjustment 266 3...

Page 269: ...ller x1 2 Feed roller x1 Separation Rollers Separation Roller and Torque Limiter Tray A 1 Remove the inserter rear cover p 263 2 Release and open top cover completely p 263 3 Remove transport guide 1...

Page 270: ...ration roller 1 x1 Bushing x1 5 Remove the torque limiter 2 6 Reset the counter after replacing the separation roller or torque limiter p 140 Separation Roller Torque Limiter Tray B 3 Replacement and...

Page 271: ...and open top and middle cover completely p 263 3 Remove transport guide 1 x5 4 Remove the separation roller 1 1 Bushing x1 5 Remove the torque limiter 2 6 Reset the counter after replacing the separat...

Page 272: ...emove the inserter rear cover p 263 2 Release and open top cover completely p 263 3 Remove front transport guide 1 x2 4 Remove the pickup roller unit 1 2 Front Spring x1 x1 Bushing x1 3 Rear x1 Bushin...

Page 273: ...tor x1 6 Reset the counter after replacing the pickup roller p 140 Pickup Roller Tray B 1 Remove the inserter rear cover p 263 2 Release and open top and middle cover completely p 263 3 Remove the rea...

Page 274: ...pickup roller unit 1 2 Front Spring x1 x1 Bushing x1 3 Rear x1 Bushing x1 5 Remove the pickup roller 1 x3 Actuator x1 6 Reset the counter after replacing the pickup roller p 140 3 Replacement and Adju...

Page 275: ...and lower trays of the Inserter 1 Open the right door and remove the service board cover x 1 2 Turn on the left door switch somehow with the left door open Keep the left door open and the machine turn...

Page 276: ...ON LED2 ON LED3 OFF 8 Set the side fences to LANDSCAPE for the required size A4 or LTR then press PSW1 again to start the adjustment LED status during adjustment LED1 ON LED2 ON LED3 FLASH at 1000 ms...

Page 277: ...4 Troubleshooting Service Call Tables For details about Service Call Tables for this peripheral see the main service manual 275 4...

Page 278: ...ts are output to the stacking tray and stop there However if one of the aforementioned jams occurs in the paper path at power on recovery processing does not execute until after the jam has been remov...

Page 279: ...he front doors remain locked after the power was turned off while the bookbinder was operating normally cycling the bookbinder off on will unlock the doors However if the front doors remain locked aft...

Page 280: ...opening the book stacking tray For example a strip of trimming stuck to the blade and jammed between the trimming unit and trimming buffer could block these mechanisms and prevent the stacking tray do...

Page 281: ...uffer by checking the position of the actuator of the trimmings buffer full sensor 7 Continue to turn the trimmings buffer drive pulley until you see the actuator behind the hole then stop turning If...

Page 282: ...ook stack door 10 Open the book stack door Signature Trimmings Removal Follow the procedure below if an problem occurs that prevents the removal of a signature or trimmings from the trimming unit For...

Page 283: ...s 1 2 3 from the trimming unit frame x3 ea 5 Pull out the trimming unit 1 6 Retract the grip unit open the press plates or retract the blade trimmings buffer as required 7 Remove the signature and tri...

Page 284: ...een the trimming unit and trimming buffer could block the removal of the signature or trimmings 1 Turn off the bookbinder 2 Remove the right and left door 3 Remove the inner lower cover 4 Open the boo...

Page 285: ...only the horizontal feed path can be used but only for downstream delivery The machine must be cycled off on to put the bookbinder in the low performance mode Low Performance Conditions Here is a sum...

Page 286: ...ow The Service Board is located behind a protective cover held in place by one screw The front door switches must be ON to set the machine in the Service Mode This is done by opening the right and lef...

Page 287: ...For more about alarms jams errors etc please refer to the appropriate sections Display Items Mode Status Detail Normal Mode Yes No Service Mode Yes No Doors Open Yes Yes Alarm Yes Yes Jam Yes Yes Err...

Page 288: ...If multiple abnormal statuses occur only one of the statuses is indicated according to the above order of priority Details Display Once the status is determined from the above table normal error jam...

Page 289: ...LED3 OFF repeat 2 Alarm To indicate the detailed alarm status LED1 lights and LED2 LED3 both flash Flash duration 0 3 sec LED2 remains ON for 2 sec to indicate 0 The LED2 and LED3 display alternate a...

Page 290: ...5 Glue Out Vat Empty 0 6 Replace Gluing Unit 0 8 Bookbinding Malfunction 1 1 Trim Scrap Box Near Full 1 2 Trim Scrap Box Full 1 3 Near Time for Blade Replacement 2 1 Near Time for Blade Cradle Replace...

Page 291: ...OFF LED2 LED3 OFF 1 sec 3 ON OFF FLASH x1 Flash duration 0 3 sec 4 ON OFF OFF LED2 LED3 OFF 1 sec Display Switching with PSW3 Presses Sequence 5 8 LED1 LED2 LED3 Comment 5 OFF ON OFF LED2 ON 2 sec 6 O...

Page 292: ...r Registration Sensor Late 1 0 1 10 Cover Registration Sensor Late During Cover Switchback 1 0 1 11 Cover Horizontal Registration Sensor Small Sensor Late 1 0 1 12 Cover Horizontal Registration Sensor...

Page 293: ...Width Over 1 15 10 2 Finish Size Over 1 15 10 3 Inserter At Power On 1 3 0 0 Door Open 1 4 0 0 Separation Sensor Tray A Late 1 0 6 2 Separation Sensor Tray B Late 1 0 6 4 Vertical Transport Sensor 1 L...

Page 294: ...Name Error Details Error Information Sequence 1 4 Sequence 5 8 LED2 LED3 LED2 LED3 Bookbinder Internal Communication Master Slave Control Board Communication Error 1 0 1 8 0 Bookbinder Internal Commun...

Page 295: ...5 0 0 2 24V Check Signal Error 2 0 3 24V Check Signal Error 3 0 4 24V Check Signal Error 4 0 5 Fan Lock Detection Power Supply Fan Right 5 1 0 1 Power Supply Fan Center 0 2 Power Supply Fan Left 0 3...

Page 296: ...tors Trimmings buffer did not leave the HP position on the left 10 2 8 1 Trimmings buffer did not reach the HP position on the left 8 2 Trimmings buffer did not leave the trimmings dump port 8 3 Trimm...

Page 297: ...not arrive at END at release 8 4 Blade reached the limit position 8 5 Cutter Signature Slider Motors Slide motor did not leave HP position 10 5 8 1 Rotate motor 2 did not reach home position 8 2 Cutt...

Page 298: ...the rear the blade did not reach the blade cradle 0 6 The blade reached the limit position 0 7 Book Stacking Unit Book Lift Tray Motors Book lift tray does not raise 10 11 0 1 Book lift tray does not...

Page 299: ...gluing unit detected an abnormally high temperature 0 6 Abnormal thermostat detection 0 7 Glue level thermistor Error 1 0 8 Glue level thermistor Error 2 0 9 Glue level thermistor broken 0 12 Glue App...

Page 300: ...n sensor small exceeded the upper limit 0 3 The value for the adjustment of the cover horizontal registration sensor large exceeded the upper limit 0 4 Sensor Automatic Adjustment 2 The value for the...

Page 301: ...sor small was lower than the limit 1 3 The value for the adjustment of the cover horizontal registration sensor large was lower than the limit 1 4 Sensor Automatic Adjustment 2 The value for the adjus...

Page 302: ...ble on grip side 0 7 Cannot detect presence of paper in main grip 0 8 Could not detect the absence of paper at the cutter entrance 1 2 Transport Path Sensors 2 Signature registration sensor could not...

Page 303: ...P sensor at the rear of the bookbinder failed to go OFF 0 2 Glue Vat Roller Motor The glue vat roller was not rotating 11 8 0 1 Glue Supply Motor The glue supply motor did not arrive at its home posit...

Page 304: ...or turned ON at the same time 0 5 Spine Plate Motor The spine plate open sensor did not go ON 11 12 0 1 Spine plate open sensor did not go OFF 0 2 Spine plate close sensor did not go ON 0 3 Spine plat...

Page 305: ...Small S12 did not go ON 12 2 0 1 Jog Fence HP Sensor Front Small S12 did not go OFF 0 2 Jog Fence HP Sensor Front Large S14 did not go ON 0 3 Jog Fence HP Sensor Front Large S14 did not go OFF 0 4 Jo...

Page 306: ...nsor on the front of the stacking tray did not go OFF 0 4 The paper detection sensor on the rear of the stacking tray did not go ON 0 5 Stacking Tray Lift Motor 2 The paper detection sensor on the rea...

Page 307: ...Motor Right The Cover Guide HP Sensor Right S22 did not go ON 12 10 0 1 Cover guide HP sensor right and cover guide open sensor right went ON at the same time 0 2 The Cover Guide Open Sensor Right S2...

Page 308: ...pen sensor and sub grip close sensor went ON at the same time 0 5 Signature Move Motor Signature grip HP sensor did not go ON 13 3 0 1 Signature grip HP sensor did not go OFF 0 2 Signature main grip p...

Page 309: ...2 did not go OFF 0 6 Book Exit Sensor S64 did not go ON 0 7 The main grip HP sensor at the high position did not turn ON 0 8 The main grip HP sensor at the high position did not turn OFF 0 9 Grip Unit...

Page 310: ...ain grip encoder sensor rear defective 0 5 Main grip open sensor rear and main grip close sensor rear went ON at the same time 0 6 Grip Motor Front The main grip open sensor front did not go ON 13 7 0...

Page 311: ...M read error 0 5 1 0 EEPROM write error 1 1 Drive Switching Motor Inserter Drive JG sensor did not go OFF within the prescribed time after the drive switching motor turned on 14 0 0 1 Drive JG sensor...

Page 312: ...0 1 Inserter Tray B lower tray failed to arrive at its lower limit sensor within the prescribed time after Tray B lift motor turned on 0 2 Relay Unit Relay Unit EEPROM Error 2 0 0 0 ASAP communication...

Page 313: ...Normal Mode Factory setting Up Service Mode Up Bookbinder Test Mode 1 Up Up Bookbinder Test Mode 2 Without signature trimming Up Up Inserter Adjustment Mode For inserter Bookbinder Adjustment Mode Ea...

Page 314: ...mitter sensor LED D A output is changed when the value is at its maximum or minimum setting and if this new setting is out of the acceptable range for the receptor sensor LED A D input this causes a s...

Page 315: ...uration 300 ms LED3 Count Target Sensor 1 Timing Sensor 2 Cover Registration Sensor 3 Cover Horizontal Registration Sensor Small 4 Cover Horizontal Registration Sensor Large 5 Book Exit Sensor 6 Cutte...

Page 316: ...2 If LED3 flashes 4 times the right digit is 4 and the setting is read as 24 However the adjustment is done in 0 1 mm steps so the reading must be adjusted 24 x 0 1 mm 2 4 mm where 2 4 mm the actual c...

Page 317: ...r has slipped toward the rear adjust in the minus direction Always check the position of the cover at both ends of the spine There are two types of adjustments that can be done for cover horizontal re...

Page 318: ...he EEPROM and shift to adjustment mode standby LED1 flashes at 1 sec intervals LED2 LED3 go OFF Adjustment Range Adjustment Range Steps Default 5 0 mm 0 1 mm 0 mm How Values of the Settings Are Displa...

Page 319: ...ec Right Digit ON OFF FLASH x5 Flash duration 300 ms ON OFF OFF LED2 LED3 OFF 1 sec Example 3 A Reading of 1 0 mm LED1 LED2 LED3 Comment Left Digit OFF FLASH x2 OFF Flash duration 300 ms OFF OFF OFF L...

Page 320: ...essed down onto the cover 1 Set the SW1 bank as shown below SW1 1 2 3 4 Up 2 Set the SW2 bank as shown below SW2 1 2 3 4 5 6 7 8 Up Up 3 Push PSW1 then look at LED1 LED2 LED3 to read the current setti...

Page 321: ...he current setting from the LED display See How to Read the LEDs Adjustment 3 Stacking Tray Switchback Roller Adjustment Do the this adjustment for the switchback roller at the entrance of the stackin...

Page 322: ...2 LED3 to read the new adjusted value 7 Repeat the steps above if you want to change the value again 8 Push PSW1 to write the new value into the EEPROM and shift to adjustment mode standby LED1 flashe...

Page 323: ...he SW2 bank for the item to adjust SW2 Status 1 2 3 4 5 6 7 8 Up Up Front Jogger Motor Small Size Up Up Up Rear Jogger Motor Small Size Up Up Up Front Jogger Motor Large Size Up Up Up Up Rear Jogger M...

Page 324: ...o adjustment mode standby LED1 flashes at 1 sec intervals LED2 LED3 go OFF Adjustment Range Adjustment Range Steps Default 3 0 mm 0 1 mm 0 mm 9 Read the current setting from the LED display See How to...

Page 325: ...ue 5 LED1 LED2 LED3 light for 300 ms 6 Look at LED1 LED2 LED3 to read the new adjusted value 7 Repeat the steps above if you want to change the value again 8 Push PSW1 to write the new value into the...

Page 326: ...s Caused by Excess Glue If there is an excessive amount of glue present when the signature and cover are joined or when the three edges are trimmed glue seepage at the corners could transfer from the...

Page 327: ...completely during application of the glue to the spine Glue is applied in two passes by a roller in the glue unit that moves first from rear to front and then front to rear No glue is being applied to...

Page 328: ...ook at LED1 LED2 LED3 to read the new adjusted value 7 Repeat the steps above if you want to change the value again 8 Push PSW1 to write the new value into the EEPROM and shift to adjustment mode stan...

Page 329: ...Up Up Up Up Bottom Edge No Trimming or Top Only Note 3 cuts means the signature is trimmed 3 times bottom top fore edge No Trimming or Top Only means the signature is not trimmed or is trimmed only on...

Page 330: ...ment 0 0 mm Bottom Edge Default No Trimming or Top Cut Only 1 1 mm 2 2 mm Top Edge Default No Trimming or Top Cut Only 3 3 mm 4 4 mm 5 5 mm 8 Read the current setting from the LED display See How to R...

Page 331: ...no adjustment in the plus direction 4 Push PSW3 to subtract 0 1 mm from the current value 5 LED1 LED2 LED3 light for 300 ms 6 Look at LED1 LED2 LED3 to read the new adjusted value 7 Repeat the steps a...

Page 332: ...hift This adjustment elongates or reduces the width of the book by shift the fore edge cutting position toward or away from the fore edge Raising the setting increases the area and the size of the boo...

Page 333: ...n setting the trimming smaller than 6 mm will be ignored 1 Setting Up for the Adjustment 2 Set the SW1 bank as shown below SW1 1 2 3 4 Up 3 Set the SW2 bank as shown below SW2 Status 1 2 3 4 5 6 7 8 U...

Page 334: ...e LEDs Adjustment 10 Square Cut Adjustment Do this adjustment to correct the amount of rotation of the signature when you see that cuts are the edges are not straight These Service Mode settings affec...

Page 335: ...is no way do measurements before adjustment so input for the adjusted values must account for the square angle of the cuts and the differences in the lengths 1 Set the SW1 bank as shown below SW1 1 2...

Page 336: ...PSW1 to write the new value into the EEPROM and shift to adjustment mode standby 7 Print another book with 3 edge trimming and the steps above if you want to change the value again LED1 flashes at 1...

Page 337: ...the steps above if you want to change the value again 7 Push PSW1 to write the new value into the EEPROM and shift to adjustment mode standby LED1 flashes at 1 sec intervals LED2 LED3 go OFF Adjustme...

Page 338: ...de cradle If trimming is executing poorly we suggest doing the Blade Cradle Cutting Position adjustment described in the next section 1 Set the SW1 bank as shown below SW1 1 2 3 4 Up 2 Set the SW2 ban...

Page 339: ...50 Cut Threshold LED1 LED2 LED3 Comment Right Digit 100 OFF FLASH x5 OFF Flash duration 300 ms OFF OFF OFF LED2 LED3 OFF 1 sec Right Digit 10 OFF OFF FLASH x5 Flash duration 300 ms OFF OFF OFF LED2 LE...

Page 340: ...1 Blade 2 Blade Cradle 3 Cutting Positions 1 to 10 1 Set the SW1 bank as shown below SW1 1 2 3 4 Up 2 Set the SW2 bank as shown below SW2 1 2 3 4 5 6 7 8 Up Up Up Up Up 4 Troubleshooting 338 4...

Page 341: ...you want to change the value again 7 Push PSW1 to write the new value for the frequency of blade cradle shifts into the EEPROM and shift to adjustment mode standby LED1 flashes at 1 sec intervals LED...

Page 342: ...the current value To increase the length of time the signature exit roller remains in contact with the signature when it is transported to the trimming unit adjust in the plus direction To decrease t...

Page 343: ...to subtract 0 1 mm from the current value 5 LED1 LED2 LED3 light for 300 ms 6 Look at LED1 LED2 LED3 to read the new adjusted value 7 Repeat the steps above if you want to change the value again 8 Pu...

Page 344: ...w temperature setting into the EEPROM and shift to adjustment mode standby LED1 flashes at 1 sec intervals LED2 LED3 go OFF Adjustment Range Adjustment Range Steps Default 151 C to 155 C 303 8 F to 31...

Page 345: ...60 90 min 2 3 4 hours 1 Set the SW1 bank as shown below SW1 1 2 3 4 Up 2 Set the SW2 bank as shown below SW2 1 2 3 4 5 6 7 8 Up Up Up 3 Push PSW1 then look at LED1 LED2 LED3 to read the current setti...

Page 346: ...d the grippers released before doing maintenance 1 Set the SW1 bank as shown below SW1 1 2 3 4 Up 2 Set the SW2 bank as shown below SW2 Status 1 2 3 4 5 6 7 8 Up Up Grip release 1 Up Up Move main grip...

Page 347: ...th 5 Releases the cutter grip Ifthemaingripisatthebindingposition afteritisreleaseditmoves to the upper HP grip sensor If the gluing unit is not in its home position at the rear the grip cannot releas...

Page 348: ...the blade cradle to its initial position 10 5 away from its HP sensor so the blade can be replaced Do this before blade replacement Open cover path Pushing PSW1 opens the cover path Close cover path...

Page 349: ...LED1 LED2 LED3 Status ON FLASH OFF Maintenance Mode in progress LED1 flashes at 1 sec intervals FLASH ON ON Operation not possible LED1 flashes at 0 1 sec intervals Service Mode 347 4...

Page 350: ...o this procedure to check the operation of moving parts 1 If the system is on switch it off 2 Open the right and left front doors 3 Close the right door 4 Insert piece of cardboard or folded piece of...

Page 351: ...Full Sensor Up Up Up Up Press Limit Sensor S89 Up Up Up Up Blade Limit Sensor Front Up Up Up Up Up Blade Limit Sensor Rear Up Up Up Up Up Up Checkall excludingpresslimitandbladelimit sensors 8 Push PS...

Page 352: ...rvals FLASH FLASH FLASH Limit sensor self diagnostic check OK LED1 LED2 LED3 flash at 1 sec intervals FLASH FLASH FLASH Operation not possible LED1 LED2 LED3 flash at 0 1 sec intervals Check All Self...

Page 353: ...ng unit is moving and that the front sensor is going ON OFF The main grip unit is moved to the binding position before this sensor is checked if it is not already at the binding position 8 Trimmings B...

Page 354: ...n 297 mm for testing in no cut or single cut mode because paper longer than this will not stack properly in the stacking tray Operation cannot be guaranteed with paper longer than 297 mm The finished...

Page 355: ...peed latch The setting of SW6 on the SW2 bank determines whether the cover is fed from the host machine or the inserter on top of the bookbinder The cover feed source is enabled at power on and cannot...

Page 356: ...s SW5 Signature Speed Cover Speed 651mm s 651mm s Up 434mm s 434mm s SW2 Bank SW6 Cover Feed Source SW6 Cover Feed Source Mainframe Up Inserter Cover is fed only from the lower tray The cover feed sou...

Page 357: ...Inserter Control Board Rear Cover Removed Inserter control board DIP switches Default OFF Standby Mode LEDs 1 2 3 SW2 a push switch CPU IC7 Output Checks 355 4...

Page 358: ...the Service Mode Error Display If a problem is detected in the inserter the LEDs display changes in the order described below a b c d a Jam or error All LEDS light for 1 sec all go off for 1 sec b Er...

Page 359: ...sor S5 INS Tray A Lift Motor M3 INS OFF ON OFF Tray B Registration Sensor S13 INS Tray A Lift Motor M3 INS OFF ON ON Transport Sensor 1 S14 INS Drive Switch Motor M2 INS ON OFF OFF CPU flash memory ON...

Page 360: ...m s for Tray A press SW2 to stop 3 Push SW2 to run Tray Feed Motor M1 INS at 500 mm s for Tray A press SW2 to stop 4 Push SW2 to run Tray Feed Motor M1 INS at 1100 mm s for Tray A press SW2 to stop 5...

Page 361: ...pen the left door 2 Insert piece of cardboard or folded piece of paper into the slot of the left door switch If the right door has been removed insert piece of cardboard or folded piece of paper into...

Page 362: ...Check 1 Remove the rear cover of the inserter x2 2 Set the DIP SWs as shown above 3 Turn on the host machine Sensor Output Check 1 Open the left door 2 Insert piece of cardboard or folded piece of pa...

Page 363: ...aper Each LED displays the status of these sensors LED1 Tray A Paper Set Sensor S1 INS LED2 Tray A Paper Feed Sensor S4 INS LED3 Tray A Registration Sensor S5 INS Sensor Check 2 1 Set the DIP SWs as s...

Page 364: ...s LED1 Tray B Paper Set Sensor S6 INS LED2 Tray B Paper Feed Sensor S10 INS LED3 Tray B Registration Sensor S13 INS Sensor Check 4 1 Set the DIP SWs as shown on the left 2 Push SW2 three times 3 After...

Page 365: ...ors LED1 Tray A Lower Limit Sensor S11 INS LED2 Tray B Lower Limit Sensor S12 INS LED3 Drive Switch Sensor S16 INS Sensor Check 6 1 Set the DIP SWs as shown on the left 2 Push SW2 three times 3 After...

Page 366: ...4 Troubleshooting 364 4...

Page 367: ...5 Service Tables Service Program Mode For details about Service Program Mode for this peripheral see the main service manual 365 5...

Page 368: ...5 Service Tables 366 5...

Page 369: ...Overview The bookbinder is divided into two parts the binding unit top half and trimming stacking unit bottom half In the binding unit paper sent from the host machine is stacked and aligned jogged t...

Page 370: ...of four units Signature rotation Trimmer cutter Trimmings collection Book stacking The inserter installed on top of the bookbinder feeds covers through the vertical feed path to the bookbinder below...

Page 371: ...ive motors using commands sent from the host machine The board circuits are also to communicate a steady stream of information from the bookbinder to the host machine Basic Operation In response to th...

Page 372: ...gate directs paper from the host machine to the signature path transport rollers 2 As each sheet arrives on the stacking tray the sides and trailing leading edges are jogged by side fences and positi...

Page 373: ...k is sent to the book stacking tray Exit Paths The path that paper follows through the bookbinder depends on whether bookbinding is selected for the job Downstream Delivery Paper enters the bookbinder...

Page 374: ...nters the bookbinder at the entrance rollers 1 The entrance junction gate solenoid at 2 remains OFF so the entrance junction gate remains UP so paper can pass through the horizontal transport rollers...

Page 375: ...path 5 and comes to rest below the signature and on top of the cover registration unit 6 After the last sheet is fed to the stacking tray the aligned signature stack is clamped in the sub grip 7 and...

Page 376: ...oller 4 9 Horizontal Transport Roller 5 10 Exit Roller 1 11 Exit Roller 2 12 Horizontal Exit Sensor S25 13 Cover Path Sensor 2 S26 The paper 1 sent from the host machine is fed by the entrance roller...

Page 377: ...tream delivery mode the entrance junction gate remains up so the paper goes into the horizontal transport path The blank paper passes straight through the horizontal transport rollers and exits the bo...

Page 378: ...nters the automatic exit mode However even if a signature is detected in the sub grip unit before the signature is passed to the main grip unit the bookbinder does not enter automatic exit mode to all...

Page 379: ...immed on its three open edges in the trimming unit Here is a summary of the bookbinding operation flow Paper sent from the host machine passes through the signature path A and out the signature path e...

Page 380: ...over below supported by the cover fold plate Once the cover and signature are joined at the spine the grip unit releases the signature rises to a higher position and then clamps the signature again Th...

Page 381: ...serter as far as the signature transport roller 1 Covers fed from the inserter enter the vertical path at vertical transport roller 1 The inserter control board connected to the master control board c...

Page 382: ...t Operation 1 Entrance Roller 2 Signature Transport Roller 1 3 Entrance Junction Gate 4 Signature Transport Roller 2 5 Signature Transport Roller 3 6 Signature Transport Roller 4 7 Signature Transport...

Page 383: ...itched on just before the leading edge of the first sheet arrives at the entrance roller and rotate at the same speed as the host machine exit rollers When the motors switch on the entrance junction g...

Page 384: ...Signature Path Exit 1 Signature Exit Roller 2 Stacking Roller 3 TE Press Lever 6 Details 382 6...

Page 385: ...ng tray Depresses the stacked trailing edges of the stack Detects the height of the stack in the stacking tray The master control board controls the operation of the stacking roller motor M1 This moto...

Page 386: ...tched off by the TE press lever HP sensor S3 when the lever returns to its home position The signal from the paper detection sensors front rear S1 S2 lower the stacking tray These sensors mounted on t...

Page 387: ...Stacking Weight Motor M7 Switchback Roller Lift Motor M8 Switchback Flapper Motor M9 Stacking Tray Motor S4 Top Cover Sensor S6 Stacking Tray Overflow Sensor S7 Stacking Tray Lower Limit Sensor S8 Tra...

Page 388: ...e following motors turn on and start rotating at the same speed of the host machine exit rollers entrance motor M10 signature transport motor M11 stacking roller motor M1 At the same time the entrance...

Page 389: ...by the timing sensor S5 and the paper has traveled the prescribed distance it stops at the switchback position After the paper stops the switchback flapper motor M8 turns on and moves the switchback...

Page 390: ...tacking tray These sensors mounted on the TE press lever control the operation of the stacking tray lift motor M2 After the TE press lever has clamped the trailing edges of the sheets in the stack the...

Page 391: ...e 3 Paper S14 Jog Fence HP Sensor Front Large S15 Jog Fence HP Sensor Rear Large Sub Grip Operation The sub grip unit 1 takes the aligned stack signature from the stacking tray unit and passes it to t...

Page 392: ...e Motor M20 Sub Grip Motor S34 Signature HP Sensor S35 Signature Main Grip Position Sensor S36 Main Grip Rotate Enable Sensor S37 Sub Grip HP Sensor S38 Size HP Sensor S39 Sub Grip Signature Sensor S4...

Page 393: ...signature 3 After the front and rear sub gripper plates close onto the sides of the signature in the sub grip unit the sub gripunitliftmotor M17 turnson lowersthesubgripunit10mm andthenreversesandmove...

Page 394: ...as far as the stacking tray lower limit sensor S7 and then stop The signature move motor M18 turns on and moves the signature 1 from the sub grip unit 2 to the main grip 3 transfer point Next the sta...

Page 395: ...by the sub grip unit 3 the sub grip lift motor M17 turns on and raises the sub grip unit about 5 mm away from the signature 4 then returns the sub grip unit to its home position Main Grip Operation Th...

Page 396: ...3 Gripper Motor Rear M23 Gripper Motor Rear M24 Grip Motor Front S42 Rotate to Binding Position Sensor S43 Main Grip Rotate HP Sensor S44 Main Grip HP Sensor S45 Main Grip HP Sensor H S46 Main Grip En...

Page 397: ...r Front S54 Main Grip Close Sensor Rear S55 Main Grip Signature Sensor The gripper motor front M24 the gripper motor rear M23 switch on and close the main grip 1 securely clamping the signature 2 pass...

Page 398: ...unit 1 and signature 2 as far as the signature guide plate 3 The gripper motor front M24 and gripper motor rear M23 switch on and open the main gripper 4 7 mm At this time the signature is held only...

Page 399: ...rip lift motor M22 turns on raises the grip unit and signature to the gluing position The signature thickness sensor S50 measures the thickness of the signature the first time the grip unit closes ont...

Page 400: ...1 2 Horizontal Transport Roller 2 3 Horizontal Transport Roller 3 4 Horizontal Transport Roller 4 5 Horizontal Transport Roller 5 6 Buffer Roller 7 Cover Transport Guide Right 8 Cover Transport Guide...

Page 401: ...Grip Solenoid S20 Cover Path Sensor 1 S21 Cover Registration Sensor S22 Cover Guide HP Sensor Right S23 Cover Guide Open Sensor Right S27 Cover Guide HP Sensor Left S28 Cover Guide Open Sensor Left S...

Page 402: ...ansport path If the cover is fed from the host machine when the entrance sensor S17 detects the leading edge of the cover the rotation speed of cover motors M12 and M13 slow to 196 35 mm s After the t...

Page 403: ...s fed to a position at a prescribed distance away from the cover registration sensor S21 then the motor stops This is the cover vertical position vertical means direction of paper feed After the cover...

Page 404: ...aper sizes up to 297 mm wide Cover registration sensor L S72 Used for large paper sizes over 297 mm wide If the cover registration sensor S71 Small or S72 Large in the cover registration unit 1 is ON...

Page 405: ...cover 1 in the roller nips The spine fold motor left M28 turns on raises the two transport rollers on the left and clamps the cover in the roller nips The cover grip solenoid SOL1 energizes and opens...

Page 406: ...Unit Operation The gluing unit applies glue to the spine of the signature that will be joined with the cover to form the book 1 Glue Hopper 2 Glue Dispenser 3 Glue Feeder 4 Gluing Unit 5 Glue Vat 6 D...

Page 407: ...32E S32R S33 Glue Supply Cover Sensor S56 Glue Temperature Thermistor S57 Glue Abnormal Temperature Thermistor S58 Glue Level Thermistor S59 Glue Vat Roller Rotation Sensor S73 Glue Vat HP Sensor Rear...

Page 408: ...32 turns on moves the glue vat 2 to within 5 mm the signature spine where the glue will be applied The main grip lift motor M22 turns on and lowers the main grip unit 3 and signature 4 to the glue app...

Page 409: ...motor M25 turns on and reverses the rotation of the glue vat roller 3 The glue vat move motor M32 turns on and moves glue vat 4 from the front to the rear As the vat moves from front to rear the glue...

Page 410: ...he glue vat 5 Each movement of the glue feeder 90 rotation feeds four 0 22 g pellets to the glue vat The feeder rotates three times 270 to feed a total of 12 pellets Glue Temperature Control The slave...

Page 411: ...n the heater and sets the target temperature for 173 C As soon as the glue temperature thermistor S56 detects the glue temperature over 120 C after 285 sec the target temperature is reset for 152 C At...

Page 412: ...tor Left M29 Spine Fold Motor Right S60 Spine Fold HP Sensor Left S61 Spine Fold Close Sensor Left S62 Spine Plate Open Sensor S63 Spine Plate Closed Sensor S66 Spine Fold HP Sensor Right S69 Spine Fo...

Page 413: ...een them is large enough for the signature 3 to pass between them and stop The run time is prescribed based on the signature thickness measured by the signature thickness sensor S50 The cover 4 is on...

Page 414: ...e left and right spine fold plates 3 4 which clamp the signature 5 near its glued spine After holding the signature clamped at its spine glued to the cover for the prescribed time the spine fold motor...

Page 415: ...main gripper 4 moves to the higher grip position the grip motor front M24 and grip motor rear M23 turn on and clamp the signature again The main grip lift motor M22 turns on lifts the main grip unit 1...

Page 416: ...th Guide M27 Signature Exit Roller Motor M30 Signature Path Exit Motor S64 Book Exit Sensors S64E Emitter S64R Receptor S65 Leading Edge Sensors S65E Emitter S65R Receptor S67 Signature Exit Path HP S...

Page 417: ...rollers 2 Two sensor pairs in the signature transport path detect the presence of the joined cover and signature 3 as it is lowered Book Exit Sensors S64E Emitter S64R Receptor Detects the leading edg...

Page 418: ...t 5 to its home position and stops The signature exit roller motor M27 rotates long enough to lower the signature to reach the point where the signature can be passed to the trimming unit and stops Th...

Page 419: ...ng unit to align the signature for trimming The spine plate motor M26 turns on and moves the spine plate to its home position At the same time the left and right spine fold motors M28 M29 turn on and...

Page 420: ...ook Rotation Motor 2 M42 Book Rotation Motor 1 M43 Book Grip Motor M44 Slide Motor S82 Slide HP Sensor S95 Book Rotation HP Sensor 1 S92 Trim Unit Entrance Sensors S92R S92E S93 Grip HP Sensor S94 Gri...

Page 421: ...ade Cradle 3 Edge Press Plate M35 Cutter Motor M36 Edge Press Plate Motor M40 Blade Cradle Motor SOL4 Trimmings Plunger Solenoid S83 Blade Cradle HP Sensor S84 Blade Sensor 1 S85 Blade Sensor 2 Book B...

Page 422: ...k falls on top of the blade 3 so the spine of the book is perfectly horizontal against the top of the blade The book grip motor M43 turns on again and pushes the right rotation plate against the right...

Page 423: ...ok and stops the motor The slide motor M44 turns on and lowers or raises the book to the proper trimming position The edge press plate motor M36 turns on and pushes the edge press plate 1 against the...

Page 424: ...ont to rear The slide motor M44 turns on and raises or lowers the book rotation grip unit 1 and the book 2 until the bottom edge of the book is at the cutting position The edge press plate motor M36 t...

Page 425: ...grip unit 1 and the book 2 until the bottom edge of the book is at the cutting position The edge press plate motor M36 turns on and pushes the edge press plate 1 against the book 2 to compress the ed...

Page 426: ...or M35 turns on and retracts the blade The edge press plate motor M36 turns on and retracts the edge press plate to release the book edge Book rotation motors 1 and 2 M42 M41 both switch on and turn t...

Page 427: ...he blade along the line of the cut so the blade can cut more efficiently and be pulled away smoothly from the cut edges Blade sensor 1 S84 and blade sensor 2 S85 both mounted on the cutter area sensor...

Page 428: ...de after the first and second cuts at the top and bottom of the book There may be an especially strong tendency for trimmings to adhere to the blade where it cuts into the glue on the end of the spine...

Page 429: ...lade when it performs the cut After the cut is done the cutter motor M35 retracts the blade and trimmings catcher mechanism The trimmings 5 are held in the trimmings seat as the blade is pulled away B...

Page 430: ...e that the blade cradle must be replaced The service life of the blade cradle is 5 550 cuts 550 cuts at each of the 10 positions Handling Trimmings Trimmings are dumped into the trimmings box which ca...

Page 431: ...r Motor S96 Trimmings Buffer Full Sensors S96R S96E S97 Trimmings Box Full Sensor S100 Trimmings Buffer HP Sensor Left S101 Trimmings Buffer Clock Sensor S103 Trimmings Buffer HP Sensor Right S104 Boo...

Page 432: ...he amount of movement to the left is controlled by a flag in the trimmings buffer clock sensor S101 The trimmings 1 taken from the third cut fore edge fall onto the trimmings sub buffer 2 The trimming...

Page 433: ...are allowed to fall directly into the trimmings buffer After 3rd Cut The trimmings buffer motor M37 turns on and moves the trimmings buffer 1 to the top of the trimmings box on the right The trimming...

Page 434: ...or S97 is turned on twice and the trimmings buffer full sensors S96E S96R turn ON this signals that the trimmings buffer and the trimmings box are full The cutter control board issues a warning to the...

Page 435: ...1 Book Lift Tray 2 Book Buffer Tray 3 Book Output Tray M34 Book Output Belt Motor M38 Book Lift Tray Motor M39 Book Buffer Tray Motor SOL5 Book Door Lock Solenoid Book Binding 433 6...

Page 436: ...the book press plate 1 in the transport path The operations described below are done while the next book is being trimmed The book tray lift motor M38 turns on and raises the book lift tray 2 The rig...

Page 437: ...ed distance The trimmings buffer motor M37 turns on and moves the trimmings buffer 5 and book press plate to the left The book press plate pushes the book onto the book buffer tray 6 The book buffer t...

Page 438: ...The trimmings buffer motor M37 turns on and returns the trimmings buffer 3 to its home position 6 Details 436 6...

Page 439: ...ocation at the correct time If a jam occurs the jam signal is sent to the CPU on the master control board slave control board or cutter control board The board CPU shuts down the operation of the book...

Page 440: ...thin the prescribed time after host machine sent the paper exit signal 1012 S18 Signature Path Sensor 1 Failed to detect the LE within the prescribed time after entrance sensor S17 detected the paper...

Page 441: ...2 Cover Horizontal Sensor Large Failed to detect side of the cover during horizontal registration of a small cover because it did not arrive within the prescribed time 1068 S19 INS Vertical Transport...

Page 442: ...tration unit within the prescribed time after switchback 112C S71 Cover Horizontal Sensor Small Failed to detect side edge of the cover during horizontal registration of a small cover because it did n...

Page 443: ...t door microswitch MSW1 detected that the right front door or left front door or both was open 1700 S5 S8 S17 S18 S19 S20 S21 S25 S26 After opening and closing covers and doors to check for paper rema...

Page 444: ...first or second cut because the length specified for the finished book measured top to bottom of the book was over 216 mm 8 5 1FA4 The signature jammed in the gluing unit because the cover was shorter...

Page 445: ...Power Supply Overview The bookbinder is driven by two DC power units power supply units 1 and 2 Power Supply Components Power Supply 443 6...

Page 446: ...y points If a short or other problem occurs in power supply units 1 or 2 due to current or power overload the affected power unit will shut down immediately in order to protect the board circuits Fuse...

Page 447: ...h of the idle time that triggers the energy save mode must be set on the operation panel of the host machine The default time is 0 so the bookbinder cannot enter energy save mode automatically until t...

Page 448: ...er binds to signatures Cross Section 1 Tray A 7 Tray B 2 Tray A Pickup Roller 8 Tray B Pickup Roller 3 Tray A Feed Roller 9 Tray B Feed Roller 4 Tray A Separation Roller 10 Tray B Separation Roller 5...

Page 449: ...eived from the bookbinder When the inserter receives the instructions for a bookbinding job the cover feed operation starts at whichever tray A was requested for the job on the operation panel of the...

Page 450: ...eed Sensor Tray A M1 INS Tray Feed Motor S5 INS Registration Sensor Tray A M2 INS Drive Switch Motor S6 INS Paper Set Sensor Tray B M3 INS Lift Motor Tray B S8 INS Paper Out Sensor 1 Tray B M4 INS Lif...

Page 451: ...Feed Position With paper loaded in the tray when the inserter receives a job start command from the bookbinder the lift motor M4 INS for Tray A 1 turns on and raises the top tray until paper feed sens...

Page 452: ...that the switching gear is positioned to rotate the drive gear of Tray B When the rack is to the front the actuator on the rack leaves the gap of the sensor and switches the sensor OFF The inserter k...

Page 453: ...s it out of the tray The separation roller 3 is equipped with a torque limiter to prevent double feeding Skew Correction at the Registration Roller The registration sensor S5 INS 1 goes ON just as the...

Page 454: ...ler 2 that feed the paper to the standby position 3 The tray feed motor M1 INS stops when the paper reaches the standby position about 105 mm in front of the bookbinder entrance Transport 2 Feed into...

Page 455: ...ort motor M5 INS to turn off Paper Detection Tray A 1 and Tray B 2 are both provided with one paper set sensor S1 INS for Tray A S6 INS for Tray B to detect the presence of paper on the trays When pap...

Page 456: ...tray when the operator sets the fences for the paper loaded in the tray Each tray has a paper width sensor S2 INS in Tray A and S7 INS in Tray B The sensor detects the position of the side fence rack...

Page 457: ...ding or trailing edge fails to appear or leave within the prescribed time these time intervals are checked against the prescribed time intervals stored in the CPU this signals a paper jam A jam alert...

Page 458: ...delivery roller past the registration roller and signals a jam if either edge fails to pass within the prescribed time S19 INS Vertical Transport Sensor 1 The first sensor in the vertical transport pa...

Page 459: ...feed paper S2 INS Paper Width Sensor Tray A Detects the position of the rear side fence This signals the width of the paper loaded in Tray A S3 INS Paper Out Sensor Tray A Detects when the last sheet...

Page 460: ...edge of every sheet that passes through the Tray B feed roller and signals a jam if either edge fails to pass within the prescribed time S11 INS Lower Limit Sensor Tray A Stops the tray lift motor to...

Page 461: ...s finished M5 INS Vertical Transport Motor Drives the delivery roller the last roller in the paper feed path of the inserter CL1 INS Registration Clutch Tray A Energizes and disengages the registratio...

Page 462: ...2 Paper Detection Sensor Rear Detects the sheet of paper S3 TE Press Lever HP Sensor Detects the home position of the TE press lever that compresses the trailing edge of the stack in the stacking tray...

Page 463: ...cking tray guide S10 Switchback Flapper HP Sensor Detects the home position of the switchback flapper S11 Switchback Roller HP Sensor Detects the home position of the switchback roller which moves up...

Page 464: ...ops or fails to arrive S19 Signature Path Sensor 2 Detects the leading and trailing edge of each sheet of paper in the path to the stacking tray and trigger jam alerts if the paper stops or fails to a...

Page 465: ...ence forward and backward to align the sides of each sheet with the edges of the signature stack M6 Stacking Weight Motor At the beginning of a job moves the stacking weight to the proper position for...

Page 466: ...ed ccw to the left where it can receive the signature from the sub grip on the left S35 Signature Main Grip Position Sensor Detects when the main grip unit is at its home position S36 Main Grip Rotate...

Page 467: ...the stacking tray after the signature is passed to the main grip unit M18 Signature Move Motor Moves the sub grip unit and signature down and to the right so the signature can be passed to the main g...

Page 468: ...Low Detects when the main grip unit can be rotated S45 Main Grip HP Sensor High Detects when the signature is positioned for binding to the cover S46 Main Grip Encoder Rear Detects the rotation posit...

Page 469: ...he signature spine S54 Main Grip Close Sensor Rear Detects when the main grip has closed fully onto the rear part of the signature spine S55 Main Grip Signature Sensor Detects when the main grip has r...

Page 470: ...he vat the receptor sensor of an Emitter Receptor pair S32E Glue Vat Full Sensor Emitter Detects when the glue vat is full the emitter sensor of an Emitter Receptor pair S32R Glue Vat Full Sensor Rece...

Page 471: ...Detects the home position of the glue applicator roller M32 Glue Vat Motor Drives the gluing unit from front to back and then back to front below the spine of the signature as the unit applies glue fr...

Page 472: ...ts when the spine plate is open S63 Spine Plate Close Sensor Detects when the spine plate is closed S64E Book Exit Sensor Emitter Detectstheleadingedgeofthebookduringbindingandreleaseofthebooktothetri...

Page 473: ...n the right spine fold plate is at its closed position M12 Cover Motor Right Drives s horizontal transport rollers transport roller 2 3 and the buffer roller to feed a cover into the cover registratio...

Page 474: ...ver registration unit and 2 Pushes the spine fold plate against the left side of the signature after the signature is pushed down on the cover against the spine plate M29 Spine Fold Motor Right Perfor...

Page 475: ...al Path Exit Sensor Detects the leading and trailing edge of each sheet as it exits the bookbinder during straight through feeding S26 Cover Path Sensor 2 Detects the cover in the paper path during ex...

Page 476: ...Motors and Sensors S82 Slide HP Sensor Detects the home position of the book rotation grip unit The book rotation grip unit is raised and lowered by the slide motor M44 when the book is being trimmed...

Page 477: ...e left book rotation plate and the book so the book can be trimmed at the bottom top and fore edges M42 Book Rotation Motor 1 After the right book rotation plate is pushed against the right side of th...

Page 478: ...xt cut M40 Blade Cradle Motor Raises and lowers the blade cradle to switch the cutting position The bottom and top cuts are done high on the cradle and the fore edge cut is done low on the cradle S83...

Page 479: ...is raising the book for cutting The emitter sensor of an Emitter Receptor sensor pair S88R Book Registration Sensor Receptor Stops the slide motor that is raising the book rotation grip unit that is r...

Page 480: ...ovesitrighttoitshomeposition S096E Trimmings Buffer Full Sensor Emitter Detectswhenthetrimmingsbufferisfulloftrimmedpaperstrips TheemitterofanEmitter Receptor pair S096R Trimmings Buffer Full Sensor R...

Page 481: ...ed strips are collected from under the blade Book Stacker Unit Motor Sensors and Solenoid M34 Book Output Belt Motor Moves the book output tray to the positioned prescribed for the thickness of the bo...

Page 482: ...sor Detects the home position of the book output tray S81 Book Output Tray Sensor Detects the presence of a book on the book output tray S98 Book Door Sensor Detects when the door of the book stacker...

Page 483: ...Detects when the right front door is open and closed MSW3 Top Cover Switch Detects when the top cover is open and closed MSW4 Left Front Door Switch Center Detects when the left front door is open and...

Page 484: ...Heater Button Starts heating the glue S30 Right Front Door Sensor Detects when the right front door is opened and closed SOL3 Right Front Door Solenoid Operates the lock of the right front door Energ...

Page 485: ...cools the area around the trailing edge of the signature clamped in the main grip FM08 Signature Fan 1 Front Mounted beside FM09 cools the area around the leading edge of the signature clamped in the...

Page 486: ...he signature is pressed onto the cover PCBs CB1 Breaker Switch Trips a switch that cuts of the power supply to perfect binder if a power surge drop occurs on the power supply line PCB1 Master Control...

Page 487: ...Sub Grip Relay Board 4 PCB11 Glue Applicator Relay Board Interfaces between the gluing unit and the slave control board PCB12 Relay Board Optional Control Board Not present not used with this machine...

Page 488: ...n PCB18 Service Board Located on the rear upper left corner of the machine the service board is used to set and release the modes 1 Normal Operation 2 Maintenance Mode 3 Low Power Mode Important setti...

Page 489: ...7 Specifications Specifications For details about Specifications for this peripheral see the main service manual 487 7...

Page 490: ...MEMO 488 EN...

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