Ricoh D454-17 Manual Download

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Multi Folding Unit FD5000

Machine Code: D454-17

January 2009

Summary of Contents for D454-17

Page 1: ...Multi Folding Unit FD5000 Machine Code D454 17 January 2009 ...

Page 2: ......

Page 3: ...this 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 Trailing Edge of paper S31E The Emitter sensor of a sensor pair S31R The Receptor sensor of a sensor pair 1 ...

Page 4: ...uation Failure to obey a Caution could result in minor or moderate injury or damage to the finisher or other property Obey these guidelines to avoid problems such as misfeeds damage to originals loss of valuable data and to prevent damage to the machine This information provides tips and advice about how to best service the machine General Safety Instructions For your safety please read this manua...

Page 5: ... Maintenance Maintenance shall be done using the special tools and procedures prescribed for maintenance of the machine described in the reference materials service manuals technical bulletins operating instructions and safety guidelines for customer engineers In regard to other safety issues not described in this document all customer engineers shall strictly obey procedures and recommendations d...

Page 6: ...f the fusing unit gears timing belts etc Installation Disassembly and Adjustments After installation maintenance or adjustment always check the operation of the machine to make sure that it is operating normally This ensures that all shipping materials protective materials wires and tags metal brackets etc removed for installation have been removed and that no tools remain inside the machine This ...

Page 7: ... devices not designed for use with the machine could lead to a fire and personal injuries Organic Cleaners During preventive maintenance never use any organic cleaners alcohol etc other than those described in the service manual Make sure the room is well ventilated before using any organic cleaner Use organic solvents in small amounts to avoid breathing the fumes and becoming nauseous Switch the ...

Page 8: ...ther 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 machine 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 ...

Page 9: ...t 2 service or repair of the product is necessary 3 the product cover has been damaged Caution operators about removing paper fasteners around the machine They should never allow paper clips staples or any other small metallic objects to fall into the machine Safety Instructions for this Machine 1 The installation must be done by trained service technicians 2 This machine weighs 316 kg 695 lb At l...

Page 10: ...ed trademark of Adobe Systems 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 Machines Corporation Other product names used herein are for identification purposes only and may be trademarks of their respective companies We disclaim any and all rights involved wi...

Page 11: ...vers 13 Front Door Upper Cover 13 Top Cover 14 Inner Upper Cover 15 Front Door 15 Folding Unit Cover 16 Inner Lower Cover 16 Rear Upper Cover 17 Rear Lower Cover 17 Top Rear Cover 18 Top Tray 18 Top Tray Right Cover 19 Pulling Out the Folding Unit Drawer 20 Electrical Components Rear Side 21 Main Board 21 Horizontal Transport Motor 21 Top Tray Exit Motor 22 Top Tray Transport Motor 23 Entrance JG ...

Page 12: ...Paper Sensor 42 1st Stopper HP Sensor 43 Registration Sensor 44 Electrical Components 2nd Stopper 46 2nd Stopper Unit 46 2nd Stopper Motor 48 2nd Stopper HP Sensor 49 2nd Stopper Paper Sensor 50 Bypass Exit Paper Sensor 51 Electrical Components 3rd Stopper 53 3rd Stopper Unit 53 3rd Stopper Motor 54 3rd Stopper Paper Sensor 55 3rd Stopper HP Sensor 56 Direct Send JG Junction Gate HP Sensor 57 Regi...

Page 13: ...oller HP Sensor 74 Electrical Components Main 2 76 Bypass Entrance Paper Sensor 76 First Second Third Fold Roller 78 Fourth Fifth Fold Roller 81 Crease Rollers 86 Fold Adjustments 91 Fine Fold Adjustment 91 Skew Adjustment 105 Manual Adjustments by Service Technician 105 2 Details Overview 117 Motors Rollers 117 Junction Gates Junction Gate Solenoids 118 Stoppers Stopper Motors 119 Paper Path 120 ...

Page 14: ...ransport Sensors 146 Operation Sensors 147 Motors Solenoids 148 Paper Transport Motors 149 Fold Motors 150 Motors Solenoids Around the Top Tray 151 Motors Sensors Top 152 Motors Sensors Bottom 153 Sensors Around Top Tray 154 Fold Motors Sensors Solenoids 155 Boards Switches Fan 157 Component List 157 12 ...

Page 15: ...1 Replacement and Adjustment Exterior and Inner Covers Front Door Upper Cover 1 Open the front door A 2 Hinge cover A x 1 13 1 ...

Page 16: ...3 Cross piece A x 2 4 Front door upper cover A x 2 Top Cover 1 Open the front door 2 Hinge cover p 13 Front Door Upper Cover 3 Cross piece p 13 Front Door Upper Cover 1 Replacement and Adjustment 14 1 ...

Page 17: ...er Upper Cover 1 Top cover p 14 2 Remove the knobs A x 1 each 3 Inner upper cover B x 2 Release the hooks C to remove the inner upper cover Front Door 1 Top cover p 14 2 Inner upper cover p 15 Exterior and Inner Covers 15 1 ...

Page 18: ...ift up the hinge bracket C 6 Front door D Folding Unit Cover 1 Open the front cover 2 Remove the knob A x 1 3 Remove four knobs B x 1 each 4 Folding unit cover C x 3 hook x 2 Inner Lower Cover 1 Open the front cover 1 Replacement and Adjustment 16 1 ...

Page 19: ...2 Inner lower cover A x 1 hook Rear Upper Cover 1 Rear upper cover A x 4 Rear Lower Cover 1 Rear upper cover p 17 Exterior and Inner Covers 17 1 ...

Page 20: ...2 Rear lower cover A x 3 Top Rear Cover 1 Rear upper cover p 17 2 Top rear cover A x 4 Top Tray 1 Top rear cover p 18 2 Inner upper cover p 15 1 Replacement and Adjustment 18 1 ...

Page 21: ...3 Release the hook A and remove the top tray B x 1 Top Tray Right Cover 1 Top tray p 18 2 Top tray right cover A x 1 Exterior and Inner Covers 19 1 ...

Page 22: ...Pulling Out the Folding Unit Drawer 1 Open the front door A 2 Pull out the folding unit drawer B 1 Replacement and Adjustment 20 1 ...

Page 23: ...Electrical Components Rear Side Main Board 1 Rear upper cover p 17 2 Main board A x all x 7 Horizontal Transport Motor 1 Rear upper cover p 17 2 Top rear cover p 18 Electrical Components Rear Side 21 1 ...

Page 24: ...3 Horizontal transport motor bracket A x 1 x 2 4 Horizontal transport motor A x 2 Top Tray Exit Motor 1 Rear upper cover p 17 2 Top rear cover p 18 1 Replacement and Adjustment 22 1 ...

Page 25: ...3 Top tray exit motor bracket A x 1 x 1 x 2 4 Top tray exit motor A x 2 Top Tray Transport Motor 1 Rear upper cover p 17 2 Top rear cover p 18 Electrical Components Rear Side 23 1 ...

Page 26: ...3 Main board bracket A x all x 5 ground cable x 1 4 Top tray transport motor bracket A x 1 x 2 1 Replacement and Adjustment 24 1 ...

Page 27: ...Gate Motor 1 Rear upper cover p 17 2 Entrance JG motor A x 1 x 1 x 2 Dynamic Roller Lift Motor 1 Rear upper cover p 17 2 Top rear cover p 18 3 Main board bracket p 23 Top Tray Transport Motor 4 Rear upper stay A x 3 x 6 Electrical Components Rear Side 25 1 ...

Page 28: ...otor bracket A x 1 x 2 6 Dynamic roller lift motor A x 2 Crease Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Top rear cover p 18 4 Main board bracket p 23 Top Tray Transport Motor 1 Replacement and Adjustment 26 1 ...

Page 29: ...5 Crease motor A x 2 x 4 Dynamic Roller Transport Motor 1 Rear upper cover p 17 2 Dynamic roller transport motor bracket A x 1 x 2 Electrical Components Rear Side 27 1 ...

Page 30: ...Dynamic roller transport motor x 2 Registration Roller Release Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Registration roller release motor bracket A x 1 x 2 1 Replacement and Adjustment 28 1 ...

Page 31: ...ration roller release motor A x 2 Registration Roller Transport Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Registration roller transport motor bracket A x 1 x 2 Electrical Components Rear Side 29 1 ...

Page 32: ...4 Registration roller transport motor A x 2 1 Replacement and Adjustment 30 1 ...

Page 33: ...st Stopper Fold Plate Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Fold plate motor bracket A x 3 x 1 x 2 4 Fold plate motor A x 2 Direct Send JG Motor 1 Rear upper cover p 17 Electrical Components 1st Stopper 31 1 ...

Page 34: ...2 Rear lower cover p 17 3 Rear lower stay A x 5 x 2 4 Direct Send JG motor bracket A x 1 x 1 x 2 1 Replacement and Adjustment 32 1 ...

Page 35: ...Send JG motor A x 2 1st Fold Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 1st fold motor A x 1 x 4 FM6 Pawl Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 Electrical Components 1st Stopper 33 1 ...

Page 36: ...3 FM6 pawl motor bracket A x 1 x 1 x 2 4 FM6 pawl motor A x 2 2nd Fold Motor 1 Rear upper cover p 17 2 Rear lower cover p 17 1 Replacement and Adjustment 34 1 ...

Page 37: ...3 2nd fold motor bracket A x 1 x 1 x 3 4 2nd fold motor A x 2 Jogger Fence Motor 1 Pull out the folding unit drawer p 20 Electrical Components 1st Stopper 35 1 ...

Page 38: ...2 Jogger fence motor bracket A x 1 x 1 x 2 3 Jogger fence motor A x 2 1st Stopper Unit 1 Folding unit cover p 16 2 Rear upper cover p 17 3 Rear lower cover p 17 1 Replacement and Adjustment 36 1 ...

Page 39: ...4 Drawer stopper A x 1 5 Belt tension bracket A x 2 6 Release two clamps A Electrical Components 1st Stopper 37 1 ...

Page 40: ...7 Disconnect two connectors B 8 Remove two screws A 9 Release two clamps A 10 Disconnect two connectors B 11 Pull out the folding unit drawer p 20 1 Replacement and Adjustment 38 1 ...

Page 41: ...ng the folding unit drawer without the two screws If you remove the 1st stopper unit without any support the 1st stopper unit can fall and be broken Positioning Roller Motor 1 1st stopper unit p 36 2 Positioning roller motor bracket A x 1 x 1 x 2 Electrical Components 1st Stopper 39 1 ...

Page 42: ...3 Positioning roller motor A x 2 1st Stopper Motor 1 1st stopper unit p 36 2 1st stopper motor A x 1 x 1 x 2 Jogger Fence HP Sensor 1 1st stopper unit p 36 1 Replacement and Adjustment 40 1 ...

Page 43: ...2 Jogger fence motor bracket A x 2 3 Jogger fence timing belt bracket A x 2 4 Jogger fence HP sensor A hooks x 1 Electrical Components 1st Stopper 41 1 ...

Page 44: ...ng Roller HP Sensor 1 1st stopper unit p 36 2 Positioning Roller HP sensor A hooks x 1 1st Stopper Paper Sensor 1 1st stopper unit p 36 2 1st stopper paper sensor bracket A x 1 1 Replacement and Adjustment 42 1 ...

Page 45: ...3 1st stopper paper sensor A hooks 1st Stopper HP Sensor 1 1st stopper unit p 36 2 1st stopper HP sensor bracket A x 1 Electrical Components 1st Stopper 43 1 ...

Page 46: ...3 1st stopper HP sensor A hooks Registration Sensor 1 Pull out the folding unit drawer Pull Out the Folding Unit Drawer 2 Jam removal door A x 3 x 1 x 1 1 Replacement and Adjustment 44 1 ...

Page 47: ...3 Registration sensor bracket A x 1 4 Registration sensor B hooks x 1 Electrical Components 1st Stopper 45 1 ...

Page 48: ...er unit p 36 2 Jam removal door p 44 Registration Sensor 3 Remove two screws A at the rear side of the folding unit drawer 4 Remove the spring A for the solenoid spring B for the guide plate 5 Remove the arm C for the guide plate 1 Replacement and Adjustment 46 1 ...

Page 49: ...6 Release the clamp A and disconnect two connectors B 7 Pull out the folding unit drawer 8 Top stay A x 3 Electrical Components 2nd Stopper 47 1 ...

Page 50: ...9 Move down the 2nd stopper unit A a little bit x 2 10 Open the jam removal door A and then remove the 2nd stopper unit B 2nd Stopper Motor 1 2nd stopper unit p 46 1 Replacement and Adjustment 48 1 ...

Page 51: ...2 2nd stopper motor A x 1 x 1 x 2 2nd Stopper HP Sensor 1 2nd stopper unit p 46 2 2nd stopper HP sensor bracket A x 1 Electrical Components 2nd Stopper 49 1 ...

Page 52: ...3 2nd stopper HP sensor A hooks x 1 2nd Stopper Paper Sensor 1 2nd stopper unit p 46 2 2nd stopper paper sensor bracket A x 1 1 Replacement and Adjustment 50 1 ...

Page 53: ...3 2nd stopper paper sensor A x 1 Bypass Exit Paper Sensor 1 Pull out the folding unit drawer 2 2nd stopper unit p 46 3 Bypass exit paper sensor bracket A x 1 Electrical Components 2nd Stopper 51 1 ...

Page 54: ...4 Bypass exit paper sensor A x 1 1 Replacement and Adjustment 52 1 ...

Page 55: ...pper Unit 1 Folding unit cover p 16 2 Rear upper cover p 17 3 Rear lower cover p 17 4 Drawer stopper A x 1 5 Release the clamp A 6 Disconnect two connectors B 7 2nd fold motor bracket p 34 2nd Fold Motor Electrical Components 3rd Stopper 53 1 ...

Page 56: ...ove it x 2 The 3rd stopper unit cannot hang the folding unit drawer without the two screws If you remove the 1st stopper unit without any support the 3rd stopper unit can fall and be broken 3rd Stopper Motor 1 3rd stopper unit p 53 1 Replacement and Adjustment 54 1 ...

Page 57: ...2 3rd stopper motor A x 1 x 1 x 2 3rd Stopper Paper Sensor 1 Pull out the folding unit drawer 2 3rd stopper paper sensor bracket A x 1 Electrical Components 3rd Stopper 55 1 ...

Page 58: ...3 3rd stopper paper sensor A x 1 3rd Stopper HP Sensor 1 Pull out the folding unit drawer 2 3rd stopper HP sensor bracket A x 1 1 Replacement and Adjustment 56 1 ...

Page 59: ...3 3rd stopper HP sensor A x 1 Direct Send JG Junction Gate HP Sensor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Direct Send JG HP sensor bracket A x 1 x 1 Electrical Components 3rd Stopper 57 1 ...

Page 60: ...4 Direct Send JG HP sensor A hooks Registration Roller HP Sensor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Registration roller HP sensor bracket A x 1 x 1 1 Replacement and Adjustment 58 1 ...

Page 61: ...4 Registration roller HP sensor A hooks Fold Plate HP Sensor 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Fold plate HP sensor bracket A x 1 x 1 Electrical Components 3rd Stopper 59 1 ...

Page 62: ...4 Fold plate HP sensor A hooks Entrance JG Junction Gate HP Sensor 1 Rear upper cover p 17 2 Entrance JG HP sensor A hooks x 1 Top Tray Exit Sensor 1 Top cover p 14 1 Replacement and Adjustment 60 1 ...

Page 63: ...2 Top tray exit sensor bracket A x 1 3 Top tray exit sensor A x 1 Electrical Components 3rd Stopper 61 1 ...

Page 64: ...Entrance Sensor 1 Entrance sensor bracket A x 1 2 Entrance sensor A hooks x 1 Top Tray Exit Sensor 1 Top tray right cover p 19 1 Replacement and Adjustment 62 1 ...

Page 65: ...2 Top tray exit sensor bracket A x 1 3 Top tray exit sensor A hooks x 1 Electrical Components 3rd Stopper 63 1 ...

Page 66: ...Electrical Components Main 1 Top Tray Full Sensor E 1 Top tray p 18 2 Paper exit cover A x 1 3 Top tray full sensor E bracket x 1 1 Replacement and Adjustment 64 1 ...

Page 67: ...4 Top tray full sensor E A x 1 x 1 Top Tray Full Sensor R 1 Top tray p 18 2 Top tray full sensor R A x 1 x 1 Vertical Path Paper Sensor 1 Top tray p 18 Electrical Components Main 1 65 1 ...

Page 68: ...2 Remove the bracket x 5 3 Vertical path paper sensor A x 1 hooks Horizontal Path Paper Sensor 1 Top tray p 18 1 Replacement and Adjustment 66 1 ...

Page 69: ...2 Remove the bracket x 2 3 Horizontal path paper sensor A x 1 Horizontal Path Exit Sensor 1 Top tray p 18 Electrical Components Main 1 67 1 ...

Page 70: ...2 Remove the bracket x 5 3 Horizontal path exit sensor A x 1 Discharge Brush 1 1 Top cover p 14 1 Replacement and Adjustment 68 1 ...

Page 71: ...2 Discharge brush 1 A x 2 Discharge Brush 2 1 Top tray p 18 2 Discharge brush 2 A x 1 Electrical Components Main 1 69 1 ...

Page 72: ...Discharge Brush 3 1 Discharge brush 3 A x 2 PSU 1 Left lower bracket x 6 1 Replacement and Adjustment 70 1 ...

Page 73: ...2 PSU A x 6 x 4 First Fold Unit 1 1st stopper unit p 36 2 Jam removal door A x 1 x 3 x 1 Electrical Components Main 1 71 1 ...

Page 74: ...rt motor bracket A p 29 Registration Roller Transport Motor 5 Registration roller release motor bracket B p 28 Registration Roller Release Motor 6 Fold plate motor bracket C p 31 Fold Plate Motor 7 Timing belt of the 1st plate motor D 1 Replacement and Adjustment 72 1 ...

Page 75: ...8 Remove three screws on the rear side 9 Disconnect four harnesses A on the rear side Electrical Components Main 1 73 1 ...

Page 76: ...e two clamps A 11 Lower guide plate A keep the upper guide plate B up a little and remove the first fold unit x 3 snap fit C x 1 Dynamic Roller HP Sensor 1 First fold unit p 71 1 Replacement and Adjustment 74 1 ...

Page 77: ...2 Dynamic roller HP sensor bracket x 1 3 Dynamic roller HP sensor A x 1 Electrical Components Main 1 75 1 ...

Page 78: ... Sensor 1 Folding unit cover p 16 2 Rear upper cover p 17 3 Rear lower cover p 17 4 Disconnect the bypass entrance paper sensor harness A from the connector B x 2 5 Remove the clip A for the bypass entrance guide plate 1 Replacement and Adjustment 76 1 ...

Page 79: ...the bypass entrance guide plate A to the rear then slide it to the left and remove it 7 Bypass entrance paper sensor bracket A x 1 8 Bypass entrance paper sensor A x 1 x 1 x 1 Electrical Components Main 2 77 1 ...

Page 80: ... Put the harness of the bypass entrance paper sensor through the hole A in the rear frame of the drawer First Second Third Fold Roller 1 First fold unit p 71 2 Tension bracket A spring x 1 x 1 3 Rear bracket B x 3 1 Replacement and Adjustment 78 1 ...

Page 81: ...4 Remove the gear A x 1 5 Guide plate A x 1 6 Remove the spring A at the front side 7 Remove six gears clip x 1 each Electrical Components Main 2 79 1 ...

Page 82: ...8 Remove the links A clip x 1 each 9 Tension bracket A x 1 10 Remove the front bracket B x 2 11 Third fold roller with the guide plate A 12 Remove the guide plate B 1 Replacement and Adjustment 80 1 ...

Page 83: ...nd then the first fold roller B Fourth Fifth Fold Roller 1 Rear upper cover p 17 2 Rear lower cover p 17 3 Drawer stopper p 53 3rd Stopper Unit 4 Remove the links A on the front side clip x 2 each 5 Remove four gears B Electrical Components Main 2 81 1 ...

Page 84: ...6 Remove the links A pin x 1 each 7 Remove the gear B x 1 and the gear C timing belt x 1 8 Remove the spring A and the tension bracket B x 1 9 Left lower bracket x 6 1 Replacement and Adjustment 82 1 ...

Page 85: ...the guide plate shaft B 11 Move the guide plate shaft B to the front side arrow direction and then remove the guide plate C 12 Remove the cam A on the front side 13 Fold roller fixing front plate B x 3 Electrical Components Main 2 83 1 ...

Page 86: ...6 Timing belt C 17 Spring D 18 FM6 pawl motor E p 33 19 Pulley gear F 20 1st fold motor A p 33 21 FM6 pawl HP sensor bracket B 22 FM6 pawl cam gear C 23 Release the tension bracket D and then remove the transmission pulley gear E pin x 1 1 Replacement and Adjustment 84 1 ...

Page 87: ...h fold roller cam A at the rear of the drawer unit 26 Pull the fourth fold roller B to the front side À 27 Keep the FM6 pawl C open and then remove the fourth fold roller Á Hold the holder A when pulling the fourth fold roller B in the À direction Electrical Components Main 2 85 1 ...

Page 88: ... 1 Folding Unit Cover p 16 2 Drawer stopper p 53 3rd Stopper Unit 3 Pull out the folding unit drawer fully p 20 4 Crease jam removal door A 5 Tension springs B front 4 rear 4 The lowest spring should be a black one when reinstalling the springs 1 Replacement and Adjustment 86 1 ...

Page 89: ...reaserollerarea Thedifferencebetweenthesebrackets is the number of screw holes A one hole B two holes Attach a bracket A with one hole to the crease roller frame with one hole Attach a bracket B with two holes to the crease roller frame with two holes Electrical Components Main 2 87 1 ...

Page 90: ...ers A Crease Rollers Drive Rollers 1 Crease Rollers Idle Rollers described above 2 Rear upper cover p 17 3 Rear lower cover p 17 4 Main board bracket p 23 Top Tray Transport Motor 5 Rear upper stay p 25 Dynamic Roller Lift Motor 1 Replacement and Adjustment 88 1 ...

Page 91: ...6 Drawer connector bracket A x 3 7 Crease motor p 26 8 Crease path guide plate A x 5 9 Crease roller pulley gears A x 1 each Electrical Components Main 2 89 1 ...

Page 92: ...10 Crease roller fixing plate A x 2 11 Crease rollers drive rollers A 1 Replacement and Adjustment 90 1 ...

Page 93: ...r Fold in Position 1 6755 2nd 0507 Adjust Letter Fold in Position 2 6756 FM5 1st 0508 Adjust Double Parallel Fold Position 1 6757 2nd 0509 Adjust Double Parallel Fold Position 2 6758 FM6 1st 0510 Adjust Gate Fold Position 1 6759 2nd 0511 Adjust Gate Fold Position 2 6760 3rd 0512 Adjust Gate Fold Position 3 6761 1 These numbers are the same for Operators and Skilled Operators FM1 Z Folding User Too...

Page 94: ... 2 to 20 mm LG S 2 mm 2 to 17 mm LT SEF S 2 mm 2 to 17 mm Other S 2 mm 2 to 17 mm Pitch Adj 1 mm Engine SP Adjustment The following fine adjustment of S and L can be done by the customer engineer in the SP mode L can be adjusted only for the paper sizes listed in the table below 1 Replacement and Adjustment 92 1 ...

Page 95: ...LT SEF S 0 mm 4 mm L 0 mm 4 mm 12 x18 S 0 mm 4 mm L 0 mm 4 mm 8 Kai S 0 mm 4 mm L 0 mm 4 mm Other S 0 mm 4 mm L 0 mm 4 mm Pitch Adj 0 2 mm FM2 Half Fold User Tool Adjustment Operator Skilled Operator The following standard adjustment of S can be done by the operator or skilled operator in the User Tools mode Only S can be adjusted by the operator as shown in the table below Fold Adjustments 93 1 ...

Page 96: ... 0 mm 10 mm LG S 0 mm 10 mm LT SEF S 0 mm 10 mm Other S 0 mm 10 mm Pitch Adj 1 mm Notes No folding adjustment can be done for 13 x19 2 13 x19 12 6 x19 2 Engine SP Adjustment The following fine adjustment of S can be done by the customer engineer in the SP mode 1 Replacement and Adjustment 94 1 ...

Page 97: ... S 0 mm 4 mm 13 x18 S 0 mm 4 mm SR A3 320x450 mm S 0 mm 4 mm SR A4 225x320 mm S 0 mm 4 mm 226x310 mm S 0 mm 4 mm 310x432 mm S 0 mm 4 mm A3 SEF S 0 mm 4 mm B4 SEF S 0 mm 4 mm A4 SEF S 0 mm 4 mm B5 SEF S 0 mm 4 mm DLT S 0 mm 4 mm LG S 0 mm 4 mm LT SEF S 0 mm 4 mm 12 x18 S 0 mm 4 mm Fold Adjustments 95 1 ...

Page 98: ... of S1 can be done by the operator or skilled operator in the User Tools mode Only S1 can be adjusted by the operator as shown in the table below Size Setting Default Range Setting Default Range A3 SEF S1 0 mm 10 mm B4 SEF S1 0 mm 10 mm A4 SEF S1 0 mm 10 mm DLT S1 0 mm 10 mm LG S1 0 mm 10 mm LT SEF S1 0 mm 10 mm Other S1 0 mm 10 mm Pitch Adj 1 mm 1 Replacement and Adjustment 96 1 ...

Page 99: ...m 4 mm B4 SEF L 0 mm 4 mm S2 0 mm 4 mm A4 SEF L 0 mm 4 mm S2 0 mm 4 mm B5 SEF L 0 mm 3 mm S2 0 mm 3 mm DLT L 0 mm 4 mm S2 0 mm 4 mm LG L 0 mm 4 mm S2 0 mm 4 mm LT SEF L 0 mm 4 mm S2 0 mm 4 mm 12 x18 L 0 mm 4 mm S2 0 mm 4 mm 8 Kai L 0 mm 4 mm S2 0 mm 4 mm Other L 0 mm 4 mm S2 0 mm 4 mm Pitch Adj 0 2 mm FM4 Letter Fold in User Tool Adjustment Operator Skilled Operator Fold Adjustments 97 1 ...

Page 100: ...Size Setting Default Range Setting Default Range A3 SEF S1 2 mm 2 to 7 mm B4 SEF S1 2 mm 2 to 7 mm A4 SEF S1 2 mm 2 to 7 mm DLT S1 2 mm 2 to 7 mm LG S1 2 mm 2 to 7 mm LT SEF S1 2 mm 2 to 7 mm Other S1 2 mm 2 to 7 mm Pitch Adj 1 mm Engine SP Adjustment The following fine adjustment of L1 and L2 can be done by the customer engineer in the SP mode 1 Replacement and Adjustment 98 1 ...

Page 101: ... 0 mm 4 mm LT SEF L1 0 mm 4 mm S1 0 mm 4 mm 12 x18 L1 0 mm 4 mm S1 0 mm 4 mm 8 Kai L1 0 mm 4 mm S1 0 mm 4 mm Other L1 0 mm 4 mm S1 0 mm 4 mm Pitch Adj 0 2 mm FM5 Double Parallel Fold User Tool Adjustment Operator Skilled Operator The following standard adjustment of S1 can be done by the operator or skilled operator in the User Tools mode Only S1 can be adjusted by the operator as shown in the tab...

Page 102: ... mm A4 SEF S1 0 mm 10 mm DLT S1 0 mm 10 mm LG S1 0 mm 10 mm LT SEF S1 0 mm 10 mm Other S1 0 mm 10 mm Pitch Adj 1 mm Engine SP Adjustment The following fine adjustment of S1 and S2 can be done by the customer engineer in the SP mode 1 Replacement and Adjustment 100 1 ...

Page 103: ... 0 mm 4 mm A4 SEF S1 0 mm 4 mm S2 0 mm 4 mm B5 SEF S1 0 mm 4 mm S2 0 mm 4 mm DLT S1 0 mm 4 mm S2 0 mm 4 mm LG S1 0 mm 4 mm S2 0 mm 4 mm LT SEF S1 0 mm 4 mm S2 0 mm 4 mm 12 x18 S1 0 mm 4 mm S2 0 mm 4 mm 8 Kai S1 0 mm 4 mm S2 0 mm 4 mm Other S1 0 mm 4 mm S2 0 mm 4 mm Pitch Adj 0 2 mm Fold Adjustments 101 1 ...

Page 104: ...Setting Default Range A3 SEF S1 S2 2 mm 2 to 12 mm B4 SEF S1 S2 2 mm 2 to 12 mm A4 SEF S1 S2 2 mm 2 to 12 mm DLT S1 S2 2 mm 2 to 12 mm LG S1 S2 2 mm 2 to 12 mm LT SEF S1 S2 2 mm 2 to 12 mm Other S1 S2 2 mm 2 to 12 mm Pitch Adj 1 mm Engine SP Adjustment The following fine adjustment of S1 S2 and S3 can be done by the customer engineer in the SP mode 1 Replacement and Adjustment 102 1 ...

Page 105: ...DLT S1 0 mm 4 mm LG S1 0 mm 4 mm LT SEF S1 0 mm 4 mm 8 Kai S1 0 mm 4 mm Other S1 0 mm 4 mm Pitch Adj 0 2 mm Size Setting Default Range A3 SEF S2 0 mm 4 mm B4 SEF S2 0 mm 4 mm A4 SEF S2 0 mm 4 mm B5 SEF S2 0 mm 4 mm DLT S2 0 mm 4 mm LG S2 0 mm 4 mm LT SEF S2 0 mm 4 mm 8 Kai S2 0 mm 4 mm Fold Adjustments 103 1 ...

Page 106: ...ze Setting Default Range A3 SEF S3 0 mm 4 mm B4 SEF S3 0 mm 4 mm A4 SEF S3 0 mm 4 mm B5 SEF S3 0 mm 4 mm DLT S3 0 mm 4 mm LG S3 0 mm 4 mm LT SEF S3 0 mm 4 mm 12 x18 S3 0 mm 4 mm 8 Kai S3 0 mm 4 mm Other S1 0 mm 4 mm Pitch Adj 0 2 mm 1 Replacement and Adjustment 104 1 ...

Page 107: ...n be done by the service technician adjusting the set and adjustment screws on the multi folder unit The illustration above shows the positions of the three stoppers inside the machine The positioning of the stoppers is critical because this determines the types of folding Skew Adjustment 105 1 ...

Page 108: ...ning of the paper in the paper path as it feeds and exits High means the distance from the nip of the fold roller to the stopper is too far on one end of the fence Low means the distance from the nip of the fold roller to the stopper is too short Two examples are shown below Example 1 High Stopper Too Far From The Nip 1 Replacement and Adjustment 106 1 ...

Page 109: ...black arrow shows the direction of paper feed from right to left When the skew sheet is opened the Front edge is longer than the Rear edge Example 2 FM2 Low Stopper to Close to the Nip Skew Adjustment 107 1 ...

Page 110: ...orter than the Rear edge Skew Correction Reference Diagrams and Table Skew Correction Reference Diagrams Key Symbol Color What It Means Stopper 1 needs adjustment Á Stopper 2 needs adjustment Stopper 3 needs adjustment Blue line Peak fold points left Green line Valley fold points right 1 Replacement and Adjustment 108 1 ...

Page 111: ...Skew Adjustment 109 1 ...

Page 112: ... is skewed spread the paper out in the direction of paper feed shown in the diagrams above 3 Carefully measure the distances between the folds between L1 L2 L3 4 Compare the Front and Rear measurements 5 Refer to the table below to determine where the paper is skewing and what type of adjustment is required 1 Replacement and Adjustment 110 1 ...

Page 113: ...se F F Short F Short F Short Raise F Raise F Lower F Table Key You must refer to the Skew Correction Reference Diagrams The following abbreviations are used in the table above Term What It Means F Long Front measurement of L1 L2 or L3 is longer than Rear F Short Front measurement of L1 L2 or L3 is shorter than Rear S1 S2 S3 Refers to Stopper 1 Stopper 2 Stopper In the diagrams these are annotated ...

Page 114: ...surements In this example imagine that L3 is longer at the front than at the rear Look at the table in the row for FM1 and the column for L3 F Long means Front measurement longer than Rear F Short means Rear measurement longer than Front L3 is longer at the front so we have an F Long situation again Then look at the next line below F Long It says Raise F on S3 This means you must raise the front e...

Page 115: ...der unit 3 The illustration above shows the location for each stopper adjustment Each stopper is equipped with two screws The black plastic screw is the Set screw and the metal silver screw is the Adjustment screw 4 Remove the Set screw Skew Adjustment 113 1 ...

Page 116: ... the Adjustment screw counter clockwise to raise the front of the fence 2nd Stopper Turn the Adjustment screw clockwise to raise the front end of the fence or Turn the Adjustment screw counter clockwise to lower the front of the fence 6 Fasten the Set screw in the hole of the diagonal cutout near the hole where you removed it 1 Replacement and Adjustment 114 1 ...

Page 117: ...ut may be above or below the original hole depending on which stopper you are adjusting The photo above shows the Set screw for Stopper 2 7 Tighten the Set screw so the plate holds the adjustment Skew Adjustment 115 1 ...

Page 118: ...1 Replacement and Adjustment 116 1 ...

Page 119: ...2 Details Overview Motors Rollers The illustration above shows the roller groups and their related motors 117 2 ...

Page 120: ...Junction Gates Junction Gate Solenoids The illustration above shows the paper path junction gates and the solenoids and motors that operate them 2 Details 118 2 ...

Page 121: ...Stoppers Stopper Motors The illustration above shows the stoppers and the motors that operate them Overview 119 2 ...

Page 122: ...ect skew Leading edge of the sheet hits the registration roller and stops The upstream rollers continue to rotate 5 mm The leading edge of the paper buckles against the stationary registration roller to correct skew The registration roller starts rotating again after the paper has been straightened in the paper path 2 Details 120 2 ...

Page 123: ...Pre Stacking Up to three sheets of paper can be pre stacked for folding The left illustration shows the parts that operate during pre stacking Paper Path 121 2 ...

Page 124: ...o it can pass The dynamic roller A raises after the leading edge of the paper passes the TE stop pawl B The TE stop pawl returns to its home position C after the trailing edge of the sheet passes After the trailing edge of the paper passes the dynamic roller the positioning roller D starts to rotate and feeds the paper as far as stopper 1 E 2 Details 122 2 ...

Page 125: ...prescribed for feeding for the size of the paper selected for the job The TE stop pawl C presses on the 1st sheet to prevent the leading edge of the 2nd sheet from hitting it The operation sequence for stacking the 2nd and 3rd sheets is the same as that of the 1st sheet Paper Path 123 2 ...

Page 126: ...The dynamic roller A raises after the leading edge of the 3rd and last sheet passes the TE stop pawl The position roller B rotates twice only after the last sheet has been pre stacked 2 Details 124 2 ...

Page 127: ...stacked the TE stop pawl A lowers and the sheets are jogged vertically top to bottom Next with the TE stop pawl pressing down on the trailing edges of the stacked sheets the stack B is jogged horizontally front to back Paper Path 125 2 ...

Page 128: ...Finally after all three sheets have been pre stacked and jogged the fold blade A pushes the stacked sheets into the nip of the fold rollers B 2 Details 126 2 ...

Page 129: ...Junction Gates Paper Path 127 2 ...

Page 130: ...their home positions when paper is fed straight through the multi fold unit to the next unit downstream When folding is selected the lower entrance junction gate raises and guides the paper to the fold units below Upper entrance junction gate remains at default position Lower junction gate rotates up and guides paper down 2 Details 128 2 ...

Page 131: ...ion gate remains at default position Direct Send Junction Gate This is the direct send junction gate at its home position The junction gate rotates to the right and paper is sent downstream without passing stopper 2 This is down for FM2 mode only when the paper is folded into equal halves Paper Path 129 2 ...

Page 132: ...e For all fold modes other than FM2 Half Fold the direct send junction gate remains at its home position For FM2 the direct send junction gate motor rotates the junction gate B to position C After the job is finished the motor rotates the junction gate back to its home position A 2 Details 130 2 ...

Page 133: ...ins at its home position and does not touch the paper Bypass Junction Gate This is the bypass junction gate at its home position When FM1 Z fold or FM6 Gate Fold is selected the bypass junction gate raises and allows paper to pass to folder unit 2 Paper Path 131 2 ...

Page 134: ...ion gate remains at it default position Paper passes over the top of the bypass junction gate and into the bypass paper path Exit Reverse and Top Tray Junction Gates These three junction gates are shown above at their default positions 2 Details 132 2 ...

Page 135: ...e top tray Exit junction gate rotates left Reverse junction gate raises Top tray junction gate lowers This sequence guides the folded paper to the top tray Note Only Z folded paper is allowed to exit the multi folder and pass downstream to other peripheral units In this case the junction gates remain at their default positions The exit junction gate sensor 5 guides the paper toward the multi folde...

Page 136: ...ing fold rollers on the left When the paper reaches the rotating rollers it feeds into the nip The rollers catch the paper pull it into the nip and form the fold In this machine There are three fold stoppers placed at strategic positions in the fold path Not all the stoppers are used for folding Only the stoppers needed for the type of folding are used When two or more sheets are fed together a fo...

Page 137: ...cations The illustration above shows the stopper locations Note the locations of Stopper 1 Stopper 2 and Stopper 3 Folding Methods There are six Folding Methods FM FM1 Z Folding FM2 Half Fold Paper Folding 135 2 ...

Page 138: ... nip of fold rollers and Á The paper is stopped by Fold Stopper 2 The paper flexes toward the nip of fold rollers Á and which performs the first fold Next the paper is stopped by Fold Stopper 3 The paper flexes toward the nip of fold rollers and which performs the second fold and feeds the paper into the exit path Fold Stopper 1 is not used 2 Details 136 2 ...

Page 139: ...Fold Stopper 1 The paper flexes toward the nip of fold rollers and Á which performs the first fold and feeds the folded edge of the paper into the nip of fold rollers Á and Fold rollers Á and feed the paper into the exit path Fold Stoppers 2 and 3 are not used Paper Folding 137 2 ...

Page 140: ...er 1 The paper flexes toward the nip of fold rollers and Á which performs the first fold Fold Stopper 2 stops the paper and flexes it into the nip of fold rollers Á and Fold rollers Á and perform the second crease and feed the folded paper in exit path Fold Stoppers 3 is not used 2 Details 138 2 ...

Page 141: ... crease and feed the folded paper in exit path Fold Stopper 3 is not used FM3 and FM4 follow the same sequence but the resultant fold is different In FM3 Fold Stopper 1 is positioned high so a short length of paper is allowed to feed before flexing toward the nip starts In FM4 Fold Stopper 1 is positioned low so a long length of paper is allowed to feed before flexing toward the hip starts This po...

Page 142: ... nip of fold rollers Á and Fold rollers Á and perform the second crease and feed the folded paper in exit path Fold Stopper 3 is not used FM3 FM4 and FM5 follow the same sequence but the resultant fold is different In FM5 Fold Stopper 1 is positioned so the paper will fold into halves when it enters the first nip This critical positioning of Fold Stopper 1 accounts for the difference in folding at...

Page 143: ...rs Á and Fold rollers Á and perform the second fold and feed the folded paper to Stopper 3 Fold Stopper 3 stops the paper and flexes it into the nip of fold roller and Fold roller and form the third crease and feed the folding paper into the exit path All three stoppers are used with this method A mechanism is provided to prevent the leading edge from catching and folding over on itself A when the...

Page 144: ...nd fold the sheet s are sent to the 3rd stopper for the last fold B The leading edge of the sheets s hit stopper 3 and the upstream rollers continue rotate equivalent to 18 mm of feed to flex paper toward the fold rollers C The edge of the FM6 pawl is raised to flatten the leading edge so it cannot bend back on itself as the paper enters the nip of the fold rollers D When the 3rd fold starts the F...

Page 145: ...501 6750 2nd 0502 6751 FM2 Equal Halves 1st 0503 6752 FM3 LT Fold Out 1st 0504 6753 2nd 0505 6754 FM4 LT Fold In 1st 0506 6755 2nd 0507 6756 FM5 Double Parallel 1st 0508 6757 2nd 0509 6758 FM6 Gate Fold 1st 0510 6759 2nd 0511 6760 3rd 0512 6761 1 These numbers are the same for Operators Skilled Operators 2 The ranges for these SP codes are the same 4 to 4 0 0 2 mm Paper Folding 143 2 ...

Page 146: ... media The adjustment is a manual adjustment done on springs Adjustment range R1 R2 R3 R4 Default Load 26 N 45 N Load Adjustment Possible Hook 4 mm Distance 4 5 N 9 5 N A projection fixed in slot and attached to a spring shortens the length to roller can be lowered There are four crease rollers Springs at the front and rear ends of each roller can be adjusted 2 Details 144 2 ...

Page 147: ... signal remains unbroken the multi folder will continue to operate and feed folded paper to the top of the unit C When the top of the stack grows high enough to interrupt the signal between the tray full sensors D this will signal the machine to shut down the line temporarily After the operator removes the stack from the top tray folding and paper exit will resume Tray Full 145 2 ...

Page 148: ...Electrical Components Transport Sensors 2 Details 146 2 ...

Page 149: ...Operation Sensors Electrical Components 147 2 ...

Page 150: ...Motors Solenoids 2 Details 148 2 ...

Page 151: ...Tray Exit Motor 8 1st Fold Motor 3 Top Tray Transport Motor 9 Fold Plate Motor 4 Dynamic Roller Lift Motor 10 Registration Roller Release Motor 5 Crease Motor 11 Dynamic Roller Transport Motor 6 FM6 Pawl Motor 12 Registration Roller Transport Motor Electrical Components 149 2 ...

Page 152: ...Fold Motors 1 Entrance JG Motor 2 Direct Send JG Motor 3 Positioning Roller Motor 4 Stopper 3 Motor 5 Stopper 1 Motor 6 Jogger Fence Motor 7 Stopper 2 Motor 2 Details 150 2 ...

Page 153: ...ds Around the Top Tray 1 Horizontal Transport Motor 2 Top Tray Exit Motor 3 Reverse JG Solenoid 4 Exit JG Solenoid 5 Top Tray Transport Motor 6 Entrance JG Solenoid 7 Top Tray JG Solenoid Electrical Components 151 2 ...

Page 154: ...Motors Sensors Top 1 Dynamic Roller Lift Motor 2 Dynamic Roller Transport Motor 3 Dynamic Roller HP Sensor 4 Fold Plate Motor 5 Registration Sensor 2 Details 152 2 ...

Page 155: ...ation Roller Release Motor 2 Jogger Fence HP Sensor 3 Fold Plate HP Sensor 4 FM6 Pawl HP Sensor 5 1st Fold Motor 6 Positioning Roller Motor 7 Direct Send JG HP Sensor 8 Registration Roller Transport Motor Electrical Components 153 2 ...

Page 156: ...ull Sensor R 2 Entrance JG HP Sensor 3 Top Tray Full Sensor E 4 Top Tray Exit Sensor 5 Top Tray Paper Path Sensor 6 Entrance Sensor 7 Horizontal Path Paper Sensor 8 Vertical Path Paper Sensor 9 Horizontal Path Exit Sensor 2 Details 154 2 ...

Page 157: ... 9 Stopper 3 Paper Sensor 3 Jogger Fence Motor 10 Stopper 3 HP Sensor 4 Stopper 2 Paper Sensor 11 Stopper 3 Motor 5 Stopper 1 Paper Sensor 12 Positioning Roller Motor 6 Positioning Roller HP Sensor 13 Direct Send JG Motor 7 Stopper 1 Motor 14 LE Stop Pawl Solenoid Electrical Components 155 2 ...

Page 158: ...1 Bypass Entrance Paper Sensor 2 Bypass Exit Paper Sensor 3 FM6 Pawl HP Sensor 4 2nd Fold Motor 5 FM6 Pawl Motor 6 Bypass JG Solenoid 7 Crease Motor 2 Details 156 2 ...

Page 159: ...Door Switch 3 PSU 4 PSU Fan 5 Breaker Switch Component List Motors M Entrance JG Motor Operatestheentrancejunctionthatdirectspaperfrom the upstream device to the 1 horizontal paper path 2 paper fold path 3 top tray Electrical Components 157 2 ...

Page 160: ...positioning roller when the paper strikes stopper 1 when more that one sheet of paper is stacked for folding M Stopper 1 Motor Moves Stopper 1 to the correct position for folding according to the paper size M Fold Plate Motor Operates the fold plate for the first fold during multi sheet folding Operates Stopper 1 1 during Z folding M Registration Roller Release Motor Releases the pressure of the r...

Page 161: ... power on Detectspaperjamsofpaperfedfromtheupstream unit Used to create timing for operation of the shift roller during multiple sheet folding S Entrance JG HP Sensor Detects when the entrance junction gate is in and out of its home position S Horizontal Path Paper Sensor Checks for the presence of paper at power on S Top Tray Paper Path Sensor Checks for the presence of paper at power on Also che...

Page 162: ...nt during paper feed Detects the condition of the stacked sheets during multi sheet folding S Registration Roller HP Sensor Detects when registration roller is in and out of its home position S Dynamic Roller HP Sensor Detects when dynamic roller is in and out of its home position S Fold Plate HP Sensor Detects when the fold plate is in and out of its home position S Direct Send JG HP Sensor Detec...

Page 163: ...up and out of the horizontal paper path SOL Exit JG Solenoid Operates the exit junction gate that directs paper from the multi fold unit to the exit for the downstream unit or to the exit for the folded paper tray SOL Reverse JG Solenoid Operates the junction gate that opens the horizontal feed path to paper sent from the fold crease unit SOL LE Stop Pawl Solenoid Operates the pawl that prevents b...

Page 164: ...Boards PCB Main Board Controls operation of the motors solenoids sensors and interface with the main machine 2 Details 162 2 ...

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