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001109MIU
001109MIU
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FOREWORD
Stapler and Folder Model SPF-9R
Important Information
This service manual is designed to help you repair and maintian the SPF-9R in good operating condition. Read and understand the instructions in this service manual before attempting to perform repair and maintenance.
SM
SPF-9R
Safety Precautions
- Read and understand all safety instructions especially words such as WARNING, and CAUTION. If safety instructions are ignored, personal injury may result. - The repair & maintenance and safety instructions in this manual are valid only when the repair and maintenance is performed according to the procedure in this manual. - WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices.
- Every possible situation that might involve a potential hazard cannot be anticipated. The instructions in this manual and warning labels on the machine are therefore not all inclusive. - All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or any electrical device when it is locked or tagged out. - Some of the drawings in this manual show the machine uncovered for explaining details on the inside of the machine.
SM
II
SPF-9R
2. In this manual the following abbreviations represent electronic and electrical parts. Meaning Clutch Brake Switch Proximity Switch Micro-switch Motor Light Emitted Diode Potentiometer Relay Assembly
SPF-9R
SM
[Parts Description]
Stacker
Delivery Section ED
Copy Machine
[Term Description] Staple ; To Staple the center of the sheets with two staples. Fold ; To fold the sheet in the center.
Staple(L) ;
Bend the top of the staples in the staple unit. Clinch Section Finishing Device ; Generic name for a machine that binds the books.
Staple unit composed by staple section which insert the staples, and clinch section which bend the inserted staples. Stitch the sheet by staples Staples in the staple unit, insert section
IV SPF-9R
SM
Contents
FOREWORD ........................................................................ I. Important Information ......................................................... I. Safety Precautions ................................................................ II. I. Necessary Tools for Maintenance and Repair ........... III. II. Codes and Abbreviations in This Manual ..................... III. III. Description of Terms Used in This Manual ................. IV.
2. Troubleshooting
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(1) ................................................................... 2-14 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(2) ............................................................ 2-15 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(3) .................................................................. 2-16 2-1-2 Booklet is not trimmed completely ......................... 2-17 2-1-3 Skew Trimming Occurs ........................................... 2-17 2-1-4 Wrinkle Appears on the Bound Booklet ................ 2-18 2-1-5 Booklets Are Stained ................................................ 2-18 2-1-6 Sheets Comes Off from the Booklet ....................... 2-19 2-1-7 Sheets Are Not Jogged Properly ............................ 2-20 2-1-8 Stapler Does Not Staple ........................................... 2-21 2-2-1 Cover Feeder Does Not Feed Covers .................... 2-22 2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down) .................... 2-23 2-2-3 Double Feed Occurs Frequently in Cover Feeding2-24 2-2-4 No Feed Occurs Frequently in Cover Feeding ..... 2-25 2-2-5 Sheets Are Not Off-set ............................................. 2-26 2-2-6 Stack Tray Does Not Move Up and Down............ 2-27 2-2-7 Stack Tray Does Not lower although there are many sheets ............................................................... 2-28 2-3-1 Booklet Jam Occurs Frequently at Staple Section 2-29 2-3-2 Booklet Jam Occurs Frequently at Fold Section(1)2-30 2-3-2 Booklet Jam Occurs Frequently at Fold Section(2)2-31 2-3-3 Booklet Jam Occurs Frequently at Trim Section 2-32
SM
SPF-9R
3. Parts Adjustment
3-1-1 Entrance Section Transport Belt Tension Adjustment .................................................................. 3-34 3-1-2 Feed Belt Tension Adjustment ................................... 3-34 3-1-3 Stacker Tray Up/Down Motor Belt Tension Adjustment .................................................................. 3-34 3-1-4 Cover Transport Belt Tension Adjustment .............. 3-35 3-1-5 Feed Belt Pusher Parallel Adjustment ..................... 3-35 3-2-1 Transport Belt Tension Adjustment .......................... 3-36 3-2-2 Folding Roller Drive Belt Tension Adjustment ........ 3-36 3-2-3 Chain Tension Adjustment ......................................... 3-36 3-2-4 Folding Roller Gap Adjustment ................................. 3-37 3-2-5 Press Roller Gap Adjustment .................................... 3-37 3-2-6 Staple Unit Lean Adjustment ..................................... 3-38 3-2-7 Top-and-Tail Guide Parallel Adjustment ................. 3-38 3-2-8 Stapling Stopper Adjustment ..................................... 3-39
4-2-7 Replacing Guide Roller ............................................ 4-49 4-2-8 Replacing Feed Roller .............................................. 4-50 4-2-9 Replacing Feed Ring ................................................. 4-51 4-2-10 Replacing Blower Motor ........................................... 4-52 4-2-11 Replacing Valve Motor ............................................. 4-52 4-2-12 Replacing Stacker Tray Up/Down Motor ............... 4-52 4-2-13 Replacing Reduction Motor ..................................... 4-53 4-2-14 Replacing Entrance Motor ....................................... 4-53 4-2-15 Replacing Main Motor .............................................. 4-53 4-2-16 Replacing Cover Feed Motor ................................... 4-54 4-2-17 Replacing Width Adjustment Motor ....................... 4-54 4-2-18 Replacing Shift Motor ............................................... 4-54 4-2-19 Replacing Worm on the Upper/Lower Stacker ...... 4-55 4-2-20 Replacing Clutch ..................................................... 4-55 4-2-21 Replacing Stacker Height Detect Lever ............. 4-55 4-2-22 Replacing Feed ........................................................ 4-56 4-2-23 Replacing Bearing at Shift Section ...................... 4-56 4-3-1 Removing Staple Section .......................................... 4-57 4-3-2 ReplacingUpper Staple Section ............................... 4-57 4-3-3 Replacing Lower Staple Section ............................. 4-58 4-3-4 Positioning Upper/Lower Staple Unit .................... 4-58 4-3-5 Replacingthe Fold Guide .......................................... 4-59 4-3-6 Replacing Knife Section ........................................... 4-60 4-3-7 Replacing Press Roller ............................................. 4-60 4-3-8 Replacing Fold Roller ................................................ 4-61 4-3-9 Replacing Jog Section Solenoid ................................. 4-61 4-3-10 Replacing Stapling Stopper Solenoid ................... 4-61
4. Parts Replacement
4-1-1 Removing the Cover of CFS Section ..................... 4-42 4-1-2 Removing the Cover of SPF Section .......................... 4-43 4-1-3 Removing the Cover of FC Section ............................ 4-44 4-2-1 Replacing Cover Detect Sensor .................................. 4-45 4-2-2 Replacing Sheet Height Detect Sensor ....................... 4-46 4-2-3 Replacing Double Feed/No Feed Detect Sensor ........ 4-47 4-2-4 Replacing Double Feed Stop Plate ............................. 4-48 4-2-5 Replacing Tray Lift Motor ......................................... 4-49 4-2-6 Replacing Rack Plate .................................................. 4-49 SM VI
SPF-9R
4-3-11 Replacing Transport Roller R Solenoid .............. 4-62 4-3-12 Replacing Transport Roller F Solenoid ................. 4-62 4-4-1 Replacing Stopper Solenoid ...................................... 4-63 4-4-2 Replacing Cutter ........................................................ 4-64
Locations ................................................................... 7-79 7-1-2 CFS Control Board and QPM-144 Connector Connections (1) ........................................................... 7-80 7-1-2 CFS Control Board and QPM-144 Connector Connections (2) ........................................................... 7-81 7-1-2 CFS Control Board and QPM-144 LED Locations .. 7-82
5. Service Mode
5-1 Basic Movement of CFS Section ................................ 5-66 5-2 Basic Movement of SPF Section ................................. 5-67 5-3 Basic Movement of FC Section .................................. 5-68
7-1-2 CFS Control Board and QPM-144 LED lighting conditions .................................................................... 7-83 7-1-3 CFS Correspondence Board and QPW-591 Connector Locations and Connections ..................... 7-84 7-1-4 CFS Panel Board and QPW-587 Connector-LED Locations ..................................................................... 7-85 7-1-5 SPF Control Board and QPW-503 Connector Locations ..................................................................... 7-86 7-1-5 SPF Control Board and QPW-503 Connector Connections (1) ............................................................ 7-87 7-1-5 SPF Control Board and QPW-503 Connector Connections (2) ........................................................... 7-88 7-1-5 SPF Control Board and QPW-503 Connector Connections (3) ........................................................... 7-89 7-1-5 SPF Control Board and QPW-503 Connector Connections (4) ........................................................... 7-90 7-1-6 SPF Knife Motor Board and QPW-522 Connector-LED Locations ........................................ 7-91 7-1-7 SPF Panel Board and QPW-491 Connector-LED Locations ..................................................................... 7-92
6. Electrical Parts
6-1 Identification and Location of Motors ...................... 6-70 6-2-1 Identification and Location of Sensors [CFS Section] ............................................................. 6-71 6-2-2 Identification and Location of Sensors [SPF, FC Section] ...................................................... 6-72 6-3 Identification and Location of Switch and Breaker 6-73 6-4 Identification and Location of Solenoid .................... 6-74 6-5 Identification and Location of Other Major Electrical Parts ............................................................. 6-75
SPF-9R
7-1-8 SPF P.C.B QPW-518 Connector-LED Locations 7-93 7-1-9 FC Control Board and QPW-484 Connector-LED Locations ..................................................................... 7-94 7-1-9 FC Control Board and QPW-484 Connector Connections (1) ............................................................ 7-95 7-1-9 FC Control Board and QPW-484 Connector Connections (2) ............................................................ 7-96 7-1-10 FC Panel Board and QPW-493 Switch-Connector-LED Locations ........................... 7-97 7-2 CFS Section Power Locations ................................... 7-98 7-2-2 SPF Section Power Locations ..................................... 7-99 7-2-3 FC Section Power Locations ...................................... 7-100 7-3 SPF Section Flat Cable Connections ........................ 7-101 7-4-1 CFS Section Terminal Board Locations .................... 7-102 7-4-2 SPF Section Terminal Board Locations .................... 7-103 7-4-3 FC Section Terminal Board Locations ...................... 7-104 7-5 Wiring and Connections among Machines ................... 7-105
SM
VIII
SPF-9R
SM
1-1
SPF-9R
1-1 Specifications
Cover Feed And Stacker Section CFS Cover Feed=Art Coat;63-135 kg Fine quality paper, Normal paper;45-135 kg Stacker = Off-set stack/Straight stack Changed by copy machine
Staple And Fold Section SPF Staple Type=Staple Staple Distance=120 mm (Fixed) Staples=5000 staples/cartridge
Fore-Edge Trimmer And Delivery Section FC&ED Maximum Trimming Length [Width x Length] 323 x 225 mm Minimum Trimming Length [Width x Length] 210 x 135 mm
Correspond to the speed of copy machine (Distance between booklets are a minimum of 2.2 seconds) Sheet size will correspond to the copy machine automatically : Maximum width= A3 : Maximum length=17 inch
Fine Quality Paper 64gsm-128gsm, Normal Paper 890 (W) x 621 (D) x 795 (H) Delivery; 680 (W) x 460 (D) x 300 (H) Trim; 445 (W) x 621 (D) x 795 (H)
Machine Weight
SM
1-2
SPF-9R
Copy Machine (RICOH) Stack the sheets for 1 booklet, which is Cover Feed and delivered from copy machine, and add a Stacker Section cover. Then transport it to staple and fold (CFS-9R) section. Or stack and offset the sheets in stack section. Staple and Fold Staple and fold the sheets for one booklet. Stapled sheets Section (SPF-9R) are folded and transported to fore-edge trimmer section. Fore-edge Trimmer Trim Fore-edge section of the booklet which is stapled and folded at Section (FC-9R) staple and fold section. When only folding, trimming will not be done.
SM
1-3
SPF-9R
Cover Tray Accumulate Section Sheets are stocked here temporarily until it forms 1 set. Delivery Section Receive the sheets from copy machine. Transport Belt Range the sheets at accumulate section. Then transport it by pusher when it formed 1 set. Power Switch This switch supplies power to the rear service outlets that powers the stapler/ folder, and fore-edge trimmer.
Vacuum Feed Roller Vacuum lifts the cover for transport Sheet Height Detect Section There is a sensor used to keep the pile of sheets at a specific height. Cover Tray Motor Moves cover tray up and down Change Gate Used to direct sheets, which are not going to be bound, to the stacker section by opening the gate.
Stacker Section Sheets which will not be bound are off-set by sets or booklet and stacked for delivery.
SM
1-4
SPF-9R
Top Cover SPF-9R does not move when top cover is opened Top-and-tail Guide (drive side) Jog the sheets
Transport Belt
Staple Section Two Staple Units are set under this cover. Remove this cover to replace staples.
Operation Panel
SM
1-5
SPF-9R
Jog Plate Transport Roller Press Roller Bend folded part with this roller. Fold Roller [Inside of the machine] Fold Knife Thrust center of the sheets to put the sheets into fold roller Stopper Booklet hits the stopper to be set at correct position to be folded.
SM 1-6 SPF-9R
Air Nozzle Blow air from this nozzle to clear the paper dust
Transport Belt Bar When a sheet jam occurs under transport belt, this bar must be pulled up to access jammed sheets Delivery Belt Transports the booklet
Transport Unit This section Holds booklet while trimming. After trimming, transport booklets with delivery belt Transport Belt
Transport Unit Stopper Booklet hits the stopper to be set at correct position to be folded. Lower Knife FC Lower Sensor Entrance Belt Used to detect the booklet when it comes Sensor to the stopper Detect the booklet Stopper Unit Moves the stopper up and down [Trim Section Figure in Details]
Operation Panel
1-7
SPF-9R
Power Code
The power of delivery section is supplied by staple and fold section Fore-edge Section Tray
Conveyor Belt This belt moves engaging to cutter section movement at staple and fold section.
SM 1-8 SPF-9R
1-7 Description of the Panel on Cover Feeder and Stacker (CFS) Section
Cover is opened
Cover Feed Section Cover, sheet jam No feed Double feed There is no cover, Front door is opened or feed tray is not in the right position Delivery Section to feed Cover is opened
Eject Tray Empty Check Stack Tray Check Staple Section Check Trim Section Stack Tray Up Stack Tray Down
Eject Button Used to eject the sheets remaining inside SPF-9R Feed Tray Up Button Feed tray goes up while this button is pressed. Double Feed Detect On/Off Button To turn on and off the double feed detect button Feed Detect ON/OFF On-lights Off-light out
Error Message Table Cover Open Sheet Jam Doube Feed No Feed
Feed Tray Up
Feed Tray Down Button Feed tray goes down while this button is pressed. Shift Tray Up/Down Button Shift tray moves up/down while this button is pressed.
Stacker Section Sheet jam Stacker is full, or stacker tray is not in the upper position. Horizontal Transport Section
SM 1-9
SPF-9R
Adjust Buttons Used to adjust guide, stopper and unit position for the sheets which are out of standard.
Clear
Unit Position Front Guide Rear Guide Left Stopper Right Guide Set Position
Run
Counter Function Mode Select Button Choose moving mode when SPF-9R is engaged with copy machine. Adjust Part Select Button This button is used to select the part requiring adjustment
SM
1-10
SPF-9R
Stopper Set Buttons These buttons are used to set stopper position to adjust trim length. Choose size adjustment at mode button on SPF-9R. Right Arrow Direction-Longer trimmings (shorter booklet) Left Arrow Direction-Shorter trimmings (longer booklet)
Cover Open
Cover Open Lamp This lamp lights when top cover is opened, or joint plate for stapler is opened Knife Lock Lamp This lamp lights when knife operation stops in the middle of trimming.
Stopper
CutterAction
Cutter Single Action Button This button is used to return cutter to the upper position when cutter operation stops in the middle of trimmings.
Jam Lamp This lamp lights when there is a jammed set at booklet entrance Jam Jam section. Jam Lamp Full Trimmings This lamp lights when Trimmings Box Open trimmed booklet does not move to the delivery section. Full Trimmings Lamp This lamp lights when trimmings box becomes full. Trimmings Box Open Lamp This lamp lights when trimmings box is not closed completely.
Cutter Lock
SM
1-11
SPF-9R
(8) Fold Section A fold knife pushs up the center of the sheets, and moves the sheets into the fold rollers.
(4) Accumulate Section Accumulate and jog the sheets one by one and when the set is complete, transport it to staple and fold section.
(3) Stacker Section Off-set the sheets forward and backward set by set . Tray moves down automatically as sheets are stacked. When the tray becomes full, the machine stops.
SPF-9R
SM
1-12
2. Troubleshooting
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (1) ................. 2-14 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (2) ................. 2-15 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (3) ................. 2-16 2-1-2 Booklet is not trimmed completely ................................................................ 2-17 2-1-3 Skew Trimming Occurs .................................................................................. 2-17 2-1-4 Wrinkle Appears on the Bound Booklet ....................................................... 2-18 2-1-5 Booklets Are Stained....................................................................................... 2-18 2-1-6 Sheets Comes Off from the Booklet............................................................... 2-19 2-1-7 Sheets Are Not Jogged Properly .................................................................... 2-20 2-1-8 Stapler Does Not Staple .................................................................................. 2-21 2-2-1 Cover Feeder Does Not Feed Covers ............................................................. 2-22 2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down) ............................................................................................... 2-23 2-2-3 Double Feed Occurs Frequently in Cover Feeding ..................................... 2-24 2-2-4 No Feed Occurs Frequently in Cover Feeding ............................................ 2-25 2-2-5 Sheets Are Not Off-set ................................................................................... 2-26 2-2-6 Stack Tray Does Not Move Up and Down ................................................... 2-27 2-2-7 Stack Tray Does Not lower although there are many sheets .................... 2-28 2-3-1 Booklet Jam Occurs Frequently at Staple Section ....................................... 2-29 2-3-2 Booklet Jam Occurs Frequently at Fold Section(1) .................................... 2-30 2-3-2 Booklet Jam Occurs Frequently at Fold Section(2) .................................... 2-31 2-3-3 Booklet Jam Occurs Frequently at Trim Section ........................................ 2-32
SM
2-13
SPF-9R
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (1)
[Explanation] Stapling and Folding occur in two parts. First staple the sheets and then fold the sheets. Therefore problems may occur in two areas, and three cases (See Figures below and at right) according to the way of occurring are considered.
Case A
Staple Line
[Case A] Both fold line and staple line are not in the center] Sheet size is not within specification If the sheets are out of specification, Sheets can not be stapled, or folded in the center. [Standard size includes A3, A4, B4] Adjust the position of the guide and the stopper by adjust buttons. Refer to [1-8].
Case B
Staple Line
Fold Line
Stopper position is not correct - Run just one sheet from copy machine, fold it without stapling and trimming. - If the sheet is not folded in the center, adjust the stopper position. Refer to the operation manual [3-5 When Fold Line Is Not in the Center of the Booklet.]. - If the position can not be corrected by stopper adjust knob ( 2 mm), the position of the stopper is not correct. Check if settings of timing pulley which moves the fold stopper is not loosened. If it is, adjust stopper position. Refer to [3-2-8 Stapling Stopper Adjustment].
Stitch Line Case A Case B Case C Not in the center Correct Not in the center
Case C
Staple Line
Fold Line
SM
2-14
SPF-9R
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (2)
[Case B] Staple line is OK, but fold line is not in the center. The position of home position sensor is not correct - Stopper for stapling and folding are driven by timing belt, and there is only one home position. If this home position sensor is not in the correct position, both the stopper for stapling and folding are shifted the same distance.
Timing Belt
A foreign object or a piece of jammed sheet is left in the fold guide or near the stopper - Fold line will be changed when there is a foreign object
The number of the sheets are three or less and the sheets are too soft. - When using a few soft sheets, sheets are bent inside the fold guide and fold line will not be in the center. Use thicker sheets [about 80 gsm (70 Kg)] Sheet grain direction is not proper
- When using the horizontal grain direction sheet, sheets are too thin to fold correctly. Use vertical grain direction sheets.
Knife
FFFoldFold
If the operator selects more than 16 sheets (64 originals) the timing belt will slip and cause the fold to be in the incorrect place. Fold stopper error.
Joint Belt
Timing Belt
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (3)
[Case C] Fold line is OK, but staple line is not in the center. Edge of the sheet is curled upward - When edge of the sheets are curled upward they may run over the stopper and the stop position can not be decided correctly. In this case, fix the curl before printing. - When sheet is stapled diagonally as the figure above Top-and-tail guide is deformed. - If guide is deformed, sheets are set diagonally and stapled. Repair the guide so that it is at right angles to the stopper. Staple unit is set diagonally - This problem can be solved by resetting the position of stitch section. Refer to [3-2-6 Staple Unit Lean Adjustment] for repairing.
R side (drive side) Fixing Metal R Pin Hole R
Sheet
Pin Hole F
SM
2-16
Trimming Remain
Thickness of the booklet is not within specification - Maximum sheet thickness to trim is 32 sheets when using 70 Kg paper. (16 sheets can be stapled and folded) If using heavier sheets, booklet can not be trimmed completely by trimmer. Trimming knife does not trim well - Life for trimming knife is fifty thousand times when using fine quality paper. Replace it by following [4-4-2 Replacing Cutter].
Folded part of the booklet is swelled - When using thick sheets, it prevents the booklet from being transported correctly. Booklet can not hit the stopper correctly, so the booklet is trimmed diagonally. Use thin paper to reduce the swell. Transport belt is stained and does not transport the sheets well - When transport belt is stained by paper dust, it can not transport the booklets correctly, and does not hit the stopper. Clean the belt. O = OK X = NG
2-17
Stopper itself is not straight. - When sheets are trimmed diagonally although it hits the stopper correctly, stopper itself is not straight. Refer to [4-4-1 Stopper Solenoid Replacement] to adjust the stopper.
SM
SPF-9R
Wrinkle
Stain
Gap adjustment of fold roller and press Roller is not correct - When gap between fold roller and press roller is not set correctly, the difference of each roller's speed makes wrinkles when they catch the booklet. Adjust the gap by following [3-2-4] Fold Roller Gap Adjustment, [3-2-5] Press Roller Gap Adjustment.
Uneven parts of the sheets are stained - When uneven areas of a pair of fold rollers are stained by ink, all bound booklets will be stained in exactly the same areas. Clean the roller. Setting of lower cutter is loosened.
WARNING
- Turn off the power and remove the power cord to adjust the cutter section.
If the lower cutter fixing screws are loosened, grease comes out of the gap between the lower cutter and fixing block, and stains the booklet. Tighten the fixing screws on the lower cutter.
SM
2-18
SPF-9R
Press Roller
Sheets are slippy because of silicon -Silicon on sheets delivered from the copy machine make the paper very slippy. Especially high speed copy machines, which apply much silicon on the sheets. If the sheets are slippy, when the knife pushes up the center of the booklet (Fig1), only a cover comes faster than the rest. Fold roller folds the cover first, then folds the rest. In this time cover tears at the staple and comes off. -Insufflate silicon spray to fold roller, so that only a cover will not be folded first, and the cover will not come off. -Lessen the number of sheets to fold or use sheets under recommendation.
Fold Roller
Cutter section is stained -If top of the fold knife edge (Fig.1) becomes dirty, the inner sheet can stick to the knife. When the knife is pulled out, sheets inside the booklet comes off the booklet. -As well as cleaning the top of the knife, applying silicon spray to knife will prevent the knife from sticking to the sheets, and the sheets inside the booklet will not come off.
Sheets
Fold Knife
SM
2-19
SPF-9R
Top
Home position sensor of top-and-tail guide is not set properly - Is the sensor adjustment tight? - Is sensor connector pushed to the bottom? Top-and-tail guide are transformed - When top-and-tail guide is not parallel to the side frame or bent, sheets can not be arranged properly. Sheets sticks to each other by static electricity
F Frame Top-and-tail Guide Sheet should be (operation side) parallel to the jog plate
Top-and tail guide (both operation and drive side) not set correctly [Fig1] - To check the gap between top-and tail guides, put a sheet, the same size as the selected sheets, into the top-and-tail section of the stapler and folder. Check the gap by moving the sheet from operation side to drive side. If there is over 1 mm gap, it is not set correctly. Adjust the position of the guide. See [3-2-7 Top-and-tail Guide Parallel Adjustment] for adjustment. O = OK X = NG
Fig1
Motor
- If the sheets stick to other sheets due to static electricity, sheets can not be arranged properly.
Fig2
SM 2-20
Connection of bracket cable is not correct - Check if flat cable is put into the connector, of staple section up/down unit, completely. The flat cable is like a thin film, so it may not be inserted to the end. - Remove the staple assembly with care, two flat ribbon cables go to the stapler heads. These flat ribbon cables are easily damaged. Voltage of drive motor is not 24 VDC - Motor at staple section is 24 VDC - Measure the voltage at motor terminal section. - If the voltage is not 24 VDC, check the connection between motor connector and 24 VDC switching power supply.
Gear Section
Punch Section
SM
2-21
SPF-9R
Feed Rotor
Feed Tray Tray Bracket Rack and Pinion Tray Lift Motor Stepping Motor
SM
2-22
SPF-9R
2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down)
Pinion and rack of the motor is not fully engaged
Fully Engaged
Pinion
Pinion Rack
Rack Plate
Pinion is not set properly - Loosen four fixing screws on the motor cover and remove the motor assembly and cover from the unit. Turn the pinion section by hand. If it is not normal, the motor shaft and pinion has a problem. Replace whole motor. Note: Motor pinion and rack can be observed through a small access slot on the left side of the motor cover.
- If the cog of rack plate is chipped, replace the rack plate - If the cog of pinion is chipped, replace whole motor. The motor itself does not move correctly. - Loosen four fixing screws on the motor and separate rack section from pinion, so that rack and pinion have no load. Then move feed tray up and down. If the motor does not rotate, remove the connector on the motor and check the voltage. If 24 VDC is not measured, check the power section of the 24V system.
- Loosen four fixing screws on the motor while rack and pinion are separated. When moving the rack part shown above up and down by hand, check if two guide rollers rotates smoothly. If the guide roller does not rotate or does not rotate smoothly, guide roller section has a problem. - If guide roller does not move smoothly, apply grease to the gap between the guide roller and the shaft inside it.
SM
2-23
SPF-9R
- The rubber plate at the edge of gate board is not touching the back of the sheets, so next sheet can not be stopped and double feed occurs. - Raise gate board so that gate board and rubber section touch the upper feed guide board. - When edge of the rubber is worn out, replace double feed stop plate.
SM
2-24
SPF-9R
Sheets are pushed to upper section of the guide plate - If tray height detect sensor bracket has a problem, tray height can not be detected and tray keeps raising with the sheets until it stops by hitting the sheet height detect section. Sheets are pushed to the guide plate and no feed occurs.
Feed Rotor
Sheets are warped -Warp shown in the figure below causes no feed. Fix the warp.
- If the rubber at the edge of gate board attaches to the vacuum rotor, vacuumed sheets are dropped and no feed occurs. Lower the gate board. Feed ring is worn out - If the feed rings of the feed rotor are worn out, by long time use, misfeeds or no feed occurs.
Sheet Warp
SM
2-25
SPF-9R
Slide bearing at Off-set section has a problem - Off-set swing at stacker section is performed by the slide movement of four bearings on two shafts - When this bearing section breaks and be comes heavy, it can not be moved by the power of off-set motor, and circuit breaker trips. In this case, replace the bearing by following [4-2-23 Replacing Bearing at Shift Section].
Bearing
SM
2-26
SPF-9R
15 mm square guide
Tray bracket
SM
2-27
SPF-9R
2-2-7 Stack Tray Does Not lower although there are many sheets
Sheet height detect lever is broken - Sheets pile height at stacker section is detected by detect lever. When the sheet pile comes to a predetermined height, sensor A detects it and lowers the tray by sending the proper signal. Then sensor B detects the low ered tray and stops it. If detect lever is bent, it can not detect sheet height correctly. Sheet height detect sensor has a problem - Lift the detect lever by hand and put it into sensor A, B. And check if LED19, LED18 on the control board (QPW-114) lights. - If the LED does not light, check if the connec tor to the sensor or wiring has a problem. - If the LED lights, check if output signal is coming. Output signal is coming if LED43, LED44 on control board lights. Tray up/down motor section has a problem - If the motor does not move when the output signal is coming to tray up/down motor and there is no problem at detect lever or sensors, there is a problem on the motor. - If the motor is not trying to rotate when the output signal is coming, check connector and electrical circuit of the motor. - If the motor is trying to rotate, there is a prob lem at motor drive section. Check [2-2-6 Stack Tray Does Not Move Up and Down].
CON 10
MO1
DC
LED 19
QPM-144
[B02,03 QPM144-M01]
SM
2-28
SPF-9R
NOTE - If the head of the staple section stopped in the middle of the operation, turn off the power to the stapler and folder. Wait about 10 sec., then turn on the power. Head moves back to the home position [upper limit].
SM
2-29
SPF-9R
Situation -It occurs only in stitching and folding. -Booklets remain in front of the fold roller -Booklet does not come out when [Eject] button is pressed. -Monitor lamp at staple and fold section lights The pressure of press roller is too strong - When a booklet is too thick, or the pressure between press rollers is too strong, the booklet may stop between the press rollers. Move the position of the hook for spring between press rollers to inside.
Situation -It occurs only in stitching and folding. -Booklets remain in front of the cutter. -Booklet does not come out when [Eject] button is pressed. Sheets are curled downward - When sheets are curled downward, it may jam and stop inside the fold guide after passing the gate. - Booklet is not delivered when pressing [Eject] button, because it does not reach the cutter section. - When fixing the curl, check if there is anything in the way of the sheets inside the fold guide.
Gate
Situation -It occurs only when stitching and folding. -Booklets are inside the fold guide and not folded. -Booklet does not come out when [Eject] button is pressed. Using thick sheets or covers - Maximum sheet thickness for stapling and folding is 16 sheets of 81.4 gsm paper (70 Kg) including the cover. When using thick and hard sheets, it may not be bent by the fold knife. In this case, use thinner soft sheets. - Knife is not in the home position. Turn off the power to remove the booklet, then wait about 10 sec. and turn on the power again. Then press [Eject] button on the CFS section.
Fold Roller Thick Cover
Fold Roller Sheet Fold Roller Lever Press Roller Fold Roller Fold Guide Fold Knife
Stopper
SM
2-30
SPF-9R
Situation - It occurs only when stapling and folding. - A part of the booklet is getting into the fold roller diagonally. - Booklet in CFS section does not come out when [Eject] button is pressed. Booklet is getting into fold roller section diagonally - Sheets delivered from copy machine may be curled or has static electricity. If the sheets are curled, the edge of the booklet will be bent during transportation. When it forms one set (booklet) bent pages becomes thick, so that it gets into the fold guide section diagonally. If fold knife is operated in this situation, both sides of the booklet catches and a booklet jam occurs. In this case, change the direction of the paper curl in the copier to limit or eliminate curl when copying.
SM
2-31
SPF-9R
Situation -It occurs at trim section. -Jam lamp on the monitor of trim section lights. Booklet is not completely trimmed - When the cutter becomes dull, it can not trim the booklet completely and a booklet jam may occur. In this case, replace the cutter. - Booklet may be too thick. Maximum thick ness that can be trimmed is 32 sheets of 81.4 gsm (70 Kg) (16 sheets stapled and folded). Although the number of the sheet is within specification, the sheets may not be trimmed completely when cutter became dull and/or when using coated paper. Use thinner sheets or fine quality paper.
Swell
Transport Roller
Upper Knife
Stopper
Transport Belt
Lower Knife
SM
2-32
3. Parts Adjustment
3-1-1 Entrance Section Transport Belt Tension Adjustment ................................3-34 3-1-2 Feed Belt Tension Adjustment .......................................................................3-34 3-1-3 Stacker Tray Up/Down Motor Belt Tension Adjustment ............................3-34 3-1-4 Cover Transport Belt Tension Adjustment ..................................................3-35 3-1-5 Feed Belt Pusher Parallel Adjustment ......................................................... 3-35 3-2-1 Transport Belt Tension Adjustment .............................................................. 3-36 3-2-2 Folding Roller Drive Belt Tension Adjustment ............................................ 3-36 3-2-3 Chain Tension Adjustment ............................................................................3-36 3-2-4 Folding Roller Gap Adjustment .................................................................... 3-37 3-2-5 Press Roller Gap Adjustment ........................................................................ 3-37 3-2-6 Staple Unit Lean Adjustment ......................................................................... 3-38 3-2-7 Top-and-Tail Guide Parallel Adjustment ..................................................... 3-38 3-2-8 Stapling Stopper Adjustment ......................................................................... 3-39
SM
3-33
SPF-9R
Idler Shaft
Entrance Motor
1. Adjust the tension by moving entrance section up and down. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.
1. Adjust the tension by moving idler shaft from operation side, and arrow A showing part at drive side board. 2. Adjust the tension so that when pressing the belt at the arrow above by 200g~300g, the flexure should be 5 mm.
1. Adjust the tension at bracket which locates under stacker tray. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.
SM
3-34
SPF-9R
Clutch
A
Timing Pulley
Pusher
Pusher
B
Feed Belt
Idler Shaft
1. Adjust the tension at idle pulley A and B. 2. Adjust the tension so that when pressing the arrow above by 200~300g, the flexure should be 5 mm.
Adjust the pusher on both feed belts to be parallel to lower jog guide plate (figure shown above A=B) 1. Turn off the power of SPF-9R. 2. Loosen the idler shaft. 3. Move the pusher on feed belts so that A and B shown on the figure above become of equal distance. 4. Extend the tension by following [3-1-2 Feed Belt Tension Adjustment]
SM
3-35
SPF-9R
Tension Pulley Tension Sprocket Tension Roller Shaft Motor Shaft Motor Pulley Motor Shaft
1. Adjust the tension by moving the tension roller shaft right and left. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm. NOTE - When moving the shaft, operation side and drive side of the tension shaft should be moved exactly same distance. If not, the belt may move from the crown of the pulley.
1. Adjust the tension by moving the tension pulley up and down. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.
1. Extend the tension by moving the tension sprocket shaft up and down. 2. Press tension sprocket shaft down by hand and lock it where chain is fully extended. Extend the chain so that it does not sag.
SM
3-36
SPF-9R
Folding Roller Urethane 0.1~0.15 mm. Gap Press Roller Moving Press Roller Allen Bolt with Urethane Fold Roller Trough Section About 0.6 mm Knife Fixed Press Roller
Folding Roller
1. Turn off the power to remove the cover. 2. Adjust the allen bolt with urethane tip so that the gap between the fold rollers becomes 0.1~0.15 mm. 3. Turn the motor section of the fold knife by a hand, and press the knife to furthest position. 4. Adjust the allen bolt with urethane tip so that gap between the trough section of fold roller and flat section of the knife becomes about 0.6 mm. NOTE - When folding roller gap is not adjusted correctly, the face of the book may be torn, or the booklet may be delivered diagonally and causes booklet jam.
SM
NOTE - Procedure 2 and 4 should be performed at the same time. Press the knife beforehand, then perform procedure 2. In this way it is easier to set. - Lock the roller after adjustment. At this time, make sure that allen bolt does not rotate. Check the gap after locking the roller. REFERENCE - The thickness of one sheet of fine quality paper (63 gsm/55 Kg) is about 0.1 mm.
1. Put one 63 gsm/55 Kg fine quality paper between the rollers, then attach moving press roller to the sheet by allen bolt with urethane tip. 2. Remove the sheet and adjust the gap. Cut the sheets into 2~5 cm strips. Then put one strip at the right end, and left end of the roller and rotate the roller by a hand. Adjust the gap so that the strips are moved through the rollers lightly at this time. 3. Lock the nut.
3-37
SPF-9R
Top-and-tail guide
Staples Parallel
NOTE - When staple line looks like figures above although sheet guide and stopper are set correctly, adjust the staple line at the staple unit. - Loosen four fixing screws at the stitch unit, then rotate whole unit and tighten it. Unit is able to move 2 mm.
NOTE - The top-and-tail guide (operation and drive side) should be adjusted parallel to the side frames. - Top-and-tail guide is mounted only by a slide block which drives this guide. - Positions of each guide are set by home position sensor and detecting plate. 1. Loosen the plate screw, the attaching screw of the (1) top-and-tail guide. 2. Loosen screw (2) to do parallel adjust ment. (Guide moves around the screw (1). 3. After the parallel adjustment, turn off the power once. Wait about 10 sec., and turn on the power again to move each parts to the home position.
(1)
(2)
Slide Block
Detecting Plate
SM
3-38
SPF-9R
Timing Pulley A
Stapling Stopper
1. Measure the fold deviation beforehand. 2. Loosen the fixing screws of timing pulley A. 3. Rotate timing pulley A by hand to move stapling stopper to correct position. 4. Tighten the fixing screws of timing pulley A. 5. Perform stapling and folding to check the fold line. Refer to [2-1-1 Staple Line or Fold Line is not in the Center of the Book let] on manual for fine tuning.
SM 3-39 SPF-9R
SM
3-40
SPF-9R
4. Parts Replacement
4-1-1 Removing the Cover of CFS Section .............................................................. 4-42 4-2-18 Replacing Shift Motor .................................................................................. 4-54 4-1-2 Removing the Cover of SPF Section .............................................................. 4-43 4-2-19 Replacing Worm on the Upper/Lower Stacker ............................................. 4-55 4-1-3 Removing the Cover of FC Section ................................................................ 4-44 4-2-20 Replacing Clutch ........................................................................................... 4-55 4-2-1 Replacing Cover Detect Sensor ...................................................................... 4-45 4-2-21 Replacing Stacker Height Detect Lever ....................................................... 4-55 4-2-2 Replacing Sheet Height Detect Sensor ........................................................... 4-46 4-2-22 Replacing Feed ............................................................................................ 4-56 4-2-3 Replacing Double Feed/No Feed Detect Sensor ............................................. 4-47 4-2-23 Replacing Bearing at Shift Section .............................................................. 4-56 4-2-4 Replacing Double Feed Stop Plate ................................................................. 4-48 4-3-1 Removing Staple Section ............................................................................... 4-57 4-2-5 Replacing Tray Lift Motor .............................................................................. 4-49 4-3-2 Replacing Upper Staple Section .................................................................... 4-57 4-2-6 Replacing Rack Plate ...................................................................................... 4-49 4-3-3 Replacing Lower Staple Section .................................................................... 4-58 4-2-7 Replacing Guide Roller .................................................................................. 4-49 4-3-4 Positioning Upper/Lower Staple Unit ............................................................ 4-58 4-2-8 Replacing Feed Roller .................................................................................... 4-50 4-3-5 Replacing the Fold Guide ............................................................................4-59 4-2-9 Replacing Feed Ring ....................................................................................... 4-51 4-3-6 Replacing Knife Section ................................................................................ 4-60 4-2-10 Replacing Blower Motor ............................................................................... 4-52 4-3-7 Replacing Press Roller ................................................................................... 4-60 4-2-11 Replacing Valve Motor ................................................................................. 4-52 4-3-8 Replacing Fold Roller .................................................................................... 4-61 4-2-12 Replacing Stacker Tray Up/Down Motor ..................................................... 4-52 4-3-9 Replacing Jog Section Solenoid ..................................................................... 4-61 4-2-13 Replacing Reduction Motor .......................................................................... 4-53 4-3-10 Replacing Stapling Stopper Solenoid .......................................................... 4-61 4-2-14 Replacing Entrance Motor ............................................................................ 4-53 4-3-11 Replacing Transport Roller R Solenoid ....................................................... 4-62 4-2-15 Replacing Main Motor .................................................................................. 4-53 4-3-12 Replacing Transport Roller F Solenoid ....................................................... 4-62 4-2-16 Replacing Cover Feed Motor ........................................................................ 4-54 4-4-1 Replacing Stopper Solenoid ........................................................................... 4-63 4-2-17 Replacing Width Adjustment Motor ............................................................. 4-54 4-4-2 Replacing Cutter ............................................................................................ 4-64 SM 4-41 SPF-9R
Rear Cover
SM
4-42
SPF-9R
Cross Binding Screw Top Cover Cross Binding Screw (inside the machine)
Put this tab into the slit at a bottom of an upper cover to position the cover. Remove two screws from inside and pull out the upper section toward operation side, then lift it to remove.
Cross Binding Screw Move the upper section of the unit rearward and push this area back to locate lower cover screws. Loosen these screws and pull the lower cover toward the front, then lift it to remove. Lower Cover Put the head of the screw into the hole at a bottom of a lower cover to position the cover.
Lower Cover
Lower Cover
SM
4-43
SPF-9R
Top Cover Put this tab into the slit at a bottom of an upper cover to position the cover.
Move the upper section of the unit rearward and push this area back to locate lower cover screws. Loosen these screws and pull the lower cover toward the front, then lift it to remove.
Top Cover Remove two screws from inside and pull out the upper section toward operation side, then lift it to remove.
Lower Cover Lower Cover Put the head of the screw into the hole at a bottom of a lower cover to position the cover.
Lower Cover
SM
4-44
SPF-9R
When cover detect sensor is broken or contaminated with paper dust, it may detect the cover although there is no cover, and No Feed Error occurs. To check if sensor is working correctly or not, block the hole at detect section on the feed tray with white paper. If LED on the sensor lights, it is working correctly.
1. Raise feed tray to upper limit in order to make replacing operation easy. 2. Cover detect sensor B12 can be seen under the cover feed tray. 3. Remove connector section at sensor B12 and remove B12.
CAUTION - The detector of the sensor can be blocked easily by paper dust. If the LED lights although there is no paper, clean the detector of the sensor.
SM
4-45
SPF-9R
If sheet height detect sensor B17 (cover height) does not function, feed tray keeps raising and stops. To check if sheet height detect sensor is broken, confirm that the connector is connected and put a metal chip to detect section of the sensor. If LED on the upper sensor section does not light, height detect sensor is broken.(See section 7-1-2, LED No. L20) NOTE - If the board indicated sensor error although the sensor has no problem, the following four reasons should be considered. (1) Connector section is not connected well (2) Wiring is disconnected (3) Board is not working correctly (4) Detecting plate on the back of sensor cover is missing.
Sensor Lever Metal Plate is on the back of the sensor lever SM 4-46
SPF-9R
If double feed/no feed detect sensor section does not function, double feed or no feed can not be detected. When detection at sensor section is unstable, clean projector and receiver of the sensor. The receiver gets blocked easily by paper dust. (See section 7-1-2, LED L50)
1. Remove front cover at cover feed section. 2. Remove the connector of double feed/no feed detect sensor B16. 3. Remove sensor plate and pull it out. 4. Remove sensor B16 from sensor plate.
(1) Paper dust is collected on the receiver. (2) Receiving lamp, or receiving element turns off. This problem can be checked by each tester. (3) Light shaft is shifted. Light shaft may be shifted by using the machine for long time. (4) Connector section is not connected well
SM
4-47
SPF-9R
When the rubber of double feed stop plate is worn out, double feed or skew feeding occurs frequently. 1. Lower the feed tray, so that replacement is operated easily. 2. Turn off the power of SPF-9R. 3. Loosen the fixing screw of double feed stop plate and pull out the gate plate to remove it to operation side.
To Attach Attach double feed stop plate in the reverse order of removal. NOTE - When setting the double feed stop plate, press it down to tighten the screws. (To bring the plate level)
When to replace Replace double feed stop plate when the flat section at the top of the rubber is worn out. NOTE - In normal use, flat part will be worn out when it is used about one million times.
Replace double feed stop plate when flat section at is worn out
Rubber Section
Motor Cover
(5)
Rack Plate
1. Raise the feed tray to upper limit, so that tray will not be lifted by the spring when tray lift motor is removed. 2. Turn off the power of SPF-9R. 3. Remove rear cover 4. Remove the connector of Tray Lift Motor 5. Remove motor cover from the machine. 6. Remove Tray Lift Motor from motor cover.
1. Remove tray lift motor unit from SPF-9R by following procedures 1-5 on [4-2-5 Replacing Tray Lift Motor]. 2. Remove rack plate from Tray bracket, and replace it with a new one. NOTE - Apply grease to cog section of the Rack Plate.
1. Remove rack plate by following [4-2-6 Replacing Rack Plate]. 2. Pull out roller shaft to replace guide roller. NOTE - If the roller shaft is worn out, remove it, too. - Apply grease lightly to outside of the guide roller.
SM
4-49
SPF-9R
(3)
Vacuum Cock
Slot Tab
Timing Belt
(4)
Feed Rotor
4. Remove timing belt from timing pulley. (Rotate pulley by a hand, and it is removed easily.) 5. Remove vacuum cock. Feed Roller will fall off, so hold it to remove.
6. Remove rotor section by keeping it level and pulling it out to the operation side.
1. Turn off the power of SPF-9R. 2. Open delivery side cover of cover feed section. 3. Remove upper cover at cover feed section.
NOTE - There is a tab inside the vacuum cock, and this fits to the slot of the pipe. When setting the vacuum cock, insert the tab into the slot.
CAUTION - Drive side of the rotor section is put into valve block, so keep the rotor section level and pull it out at a right angle to the side frame.
SM
4-50
SPF-9R
0.3 mm
Thrust Ring
1. Remove rotor section by following [4-2-8 Replacing Feed Roller]. 2. Cut the feed ring with nippers and remove it. 3. Place new feed ring to the certain position. Stretch the new feed ring in from the edge of the pipe, over the Thrust Ring and into the individual slots. NOTE - To more easily fit the feed rings into their slots, press the vacuum rotors against the wave washer. This will allow the feed ring to fit easily.
Wave Washer
Feed ring is 0.3 mm larger than the feed rotor on each side (0.6 mm total). If this diameter is worn down, the function to feed will go down.
CAUTION: - DO NOT LOOSEN THRUST RING. It is assembled to regulation distance at factory. If Thrust Ring is loosened, the regulation distance changes and the function as a feed rotor may decline.
Operation side Thrust Ring Vacuum Rotor Vacuum Rotor Feed Ring
SM
4-51
SPF-9R
(5)
(5)
(6)
(8)
Valve housing
(7) Valve
(6)
(5) (4)
1. Turn off the power of SPF-9R. 2. Remove cover (R) 3. Remove the connector of blower motor M13. 4. Remove hose duct. 5. Remove blower motor section from SPF-9R. 6. Remove it with the whole box.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector and duct hose of valve motor M13. 4. Remove two screws (inside) on valve block and remove valve block from SPF-9R. 5. Remove hose connector. 6. Valve spacer has a specific direction. Mark the spacer in order to set it back in the same direction. 7. Loosen the fixing screws on the valve. 8. Remove four fixing screws on valve motor M11 to replace it.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the cover of Stacker tray up/ down motor M01. 4. Remove the timing belt. 5. Remove motor section on M01 from SPF-9R. 6. Loosen the worm shaft fixing screws. 7. Remove 4 screws on motor M01 and replace the motor.
SM
4-52
SPF-9R
Motor bracket
(4) (5)
(5)
(4)
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of reduction motor M04. 4. Loosen two connecting screws between motor output shaft and reduction shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor from motor bracket and replace it.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of entrance motor M03. 4. Remove transport belt. 5. Remove motor bracket from SPF-9R. 6. Remove timing pulley, then remove entrance motor.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of M06. 4. Loosen two connecting screws between motor output shaft and reduction shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor M06 from motor bracket and replace it.
SM
4-53
SPF-9R
(4)
(6)
Motor Bracket
(4)
Motor
(5)
(5) (6)
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of cover feed motor M12. 4. Loosen two connecting screws between motor output shaft and pulley shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor M12 from motor bracket to replace it.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of width adjustment motor M02 4. Remove timing belt. 5. Remove motor bracket from SPF-9R. 6. Remove timing pulley. 7. Remove motor M02 from motor bracket to replace it.
1. Turn off the power of SPF-9R. 2. Remove cover (R). 3. Remove the connector of shift motor M05 and the connector of a sensor. 4. Remove motor bracket from SPF-9R. 5. Remove Crank section from motor output shaft. 6. Remove motor M05 from motor bracket to replace it.
SM
4-54
SPF-9R
Bearing
(3)
(2)
Sensor Plate
(4)Worm
Clutch
(3)
1. Remove motor unit from the unit position by following [4-2-12 Stacker Tray Up/Down Motor] 2. Remove upper bracket. 3. Pull out the middle shaft. 4. Loosen the fixing screws of the worm and pull out the worm from motor output shaft. 5. Remove timing pulley and loosen the snap ring of the worm wheel, then pull out the shaft to remove the worm wheel.
[Enlarged Section] 1. Turn off the power of SPF-9R. 2. Remove rear cover at cover feed section. 3. Remove the connector on clutch section. 4. Remove the belt. 5. Remove snap furniture. 6. Remove the snap ring of the shaft and remove the clutch.
Lever
1. Turn off the power of SPF-9R. 2. Remove front cover. 3. Remove the fixing screws of sensor plate and remove detect lever section. At this point the wires of the sensor are still connected. Remove it slowly. 4. Remove two connectors on the sensor. 5. Remove lever from sensor plate to replace it.
CAUTION - The two connectors are the same. Mark each connector when removing it in order to put it back properly.
SM 4-55 SPF-9R
Feed Belt
(3) (2)
(4)
[A Section] 1. Turn off the power of SPF-9R. 2. Loosen screw (2) (Loosen the opposite side too.) After feed belt is loosened, remove screw (2) (Remove the opposite side too). 3. Remove the belt shaft from the hole (3). 4. Remove the snap ring of drive shaft at (4). The other side of that shaft is tied to motor output shaft. Loosen this two snap screws.
Bearing
(5)
(3)
5. Pull the drive shaft so that edge at the bottom of drive shaft comes out of the bearing on the side frame. 6. Remove middle guide. Remove by passing it through loosened timing belt. 7. Remove feed belt by passing it through the inner part of drive shaft.
1. Turn off the power of SPF-9R. 2. Remove right and left cover to open the front door. 3. Remove shift motor section by following [42-18 Replacing Shift Motor]. 4. Remove blower motor by following [4-210 Replacing Blower Motor] 5. Remove motor stay plate. 6. Remove two slide shaft. 7. Remove the bearing stuck to the shift tray and replace it.
SM
4-56
SPF-9R
Guide Plate
1. Turn off the power of SPF-9R. 2. Remove top cover. Remove two hinges and a stay fixing shaft section. 3. Remove the cover on stitch section by pulling up two knobs. 4. Remove two guide plates. Remove it by passing through the staple unit. 5. Remove the connector of transport unit F/R. 6. Remove bracket cable connected to staple section. - To remove upper unit, remove two bracket cable on staple board. - To remove lower unit, remove CON 12 and14 on control board QPW-503 (Refer to 7-1-5).
SM
7. Remove four fixing screws on staple unit. 8. Lift staple section slowly.
NOTE - If staple section has a problem, it will be better to replace whole staple unit. Please return removed unit to the factory. It can be recycled. 1. Remove whole staple section by following [43-1 Removing Staple Section]. 2. Remove four fixing screws. 3. Press down the upper staple section and remove it from positioning pin. 4. Move the upper staple section forward and remove motor section by lifting it.
CAUTION - Flat cables (2) connected to the lower staple units must be carefully disconnected. - Connector of the solenoid at the bottom of the staple section must also be disconnected.
9. Remove the connector on solenoid. Now whole staple section is removed.
CAUTION - When installing a new unit, aligning it to the lower unit is needed. Go to [4-3-4 Positioning Upper/Lower Staple Unit].
SPF-9R
4-57
(3)
Positioning Pin
Positioning Instrument
NOTE - If staple section has a problem, it will be better to replace whole staple unit. Please return removed unit to the factory. It can be recycled. 1. Remove whole staple section by following [4-3-1 Removing Staple Section]. 2. Remove upper staple section by follow [4-3-2 Replacing Upper Staple Section]. 3. Remove four fixing screws of lower staple section and remove lower staple unit.
CAUTION - When installing a new lower staple section, aligning it with the upper staple section is needed. Go to [4-3-4 Positioning Upper/Lower Staple Unit].
SM
4-58
SPF-9R
Stay B (6) Stopper Guide Stick Timing Belt (4) Spacer Lower Left Cover Stay A Stopper Block
1. Turn off the power of SPF-9R. 2. Remove upper and lower cover at front, at back and lower left cover. 3. Remove upper fold guide (four nuts and two screws). Operate removing from the opening part on lower part of the right side. 4. Remove spacer and lower fold guide.
5. Remove drive shaft - Remove the rear belt of drive shaft. - Remove a snap ring at operation side and press the shaft in the drive side. - Remove timing belt from pulley. 6. Remove stopper section - Remove the bracket which fixes the timing belt and the stopper block. - Loosen the screw which fixes the guide stick, and loosen the snap screw. - Remove fixing screws of stay A and B, then remove guide stick from stay A and B.
SM
4-59
SPF-9R
Fold Roller Knife Holder Fold Knife Link B Sensor Detect Cam Knife Holder Fixing Screws Press Roller Press Roller Lever Press Spring Guide Post FoldKnife Motor
When replacing only the fold knife 1. Turn off the power of SPF-9R. 2. Remove upper and lower rear cover. 3. Remove four fixing screws of knife holder on two guide post from square window section on the back. 4. Remove link A. 5. Remove a knife holder with a knife, and replace the knife. NOTE -When setting the fold knife, fix the knife after deciding the position by two positioning holes.
1. Remove the fold guide by following [4-3-5 Replacing the fold guide]. 2. Remove the bearing 25 in diameter at the end of the fold guide section [Parts Book Fig. 2-10]. 3. Remove connectors of motor and sensor. Then remove the terminal connected to the condenser. 4. Remove link A and B. There is a spacer between them. Do not lose it. 5. Remove detect cam. 6. Remove four fixing screws of knife motor to replace the motor.
4-60
1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover 3. Remove timing belt on operation side. 4. Remove Press Spring. 5. Remove the bearing of Press Roller Lever (Both drive and operation side). 6. When removing the press lever, upper roller becomes free. 7. Remove the bearing of side board to remove lower roller. NOTE - Apply grease to needle bearing section when replacing press roller.
SM
SPF-9R
Fold Roller Fold Roller Lever Jog Plate Guide Stay (2) Solenoid Cover Solenoid Bracket Solenoid
Guide
1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover. 3. Remove timing belt on operation side. 4. Remove press spring. 5. Remove the bearing of fold roller lever (Both drive and operation side) 6. When removing the fold roller lever, roller becomes free. Replace it to new one. NOTE - Apply grease to needle bearing section when replacing it.
1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove solenoid connector. 4. Remove solenoid from square window sec tion on the back and replace it. [To remove whole jog section] 1. Remove right, front, rear cover of SPF-9R. 2. Remove the shaft at drive side of the timing belt. 3. Remove two guide stay. 4. Remove guide from guide stay.
1. Turn off the power of SPF-9R. 2. Remove solenoid cover. 3. Remove solenoid connector. 4. Remove the connection between joint plate and the solenoid. 5. Remove solenoid from solenoid bracket and replace it.
SM
4-61
SPF-9R
4-3-12
Solenoid
Joint Plate
1. Turn off the power of SPF-9R. 2. Remove solenoid connector. 3. Remove solenoid bracket from guide stay and remove whole transport roller R section. 4. Remove solenoid cover. 5. Cut off the connection between link and the plunger. 6. Remove solenoid from solenoid bracket and replace it.
1. Turn off the power of SPF-9R. 2. Remove the cover at stitch section. 3. Remove solenoid connector. 4. Remove fixing screws from solenoid bracket and transport roller F. 5. Remove joint plate. 6. Remove solenoid from solenoid bracket and replace it.
SM
4-62
SPF-9R
1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover. 3. Remove lower left side plate [Black]. 4. Remove holding plate 5. Remove timing belt. 6. Remove connector on solenoid. 7. Remove furniture A from roller stay. 8. Remove furniture B from lower cutter stay. Stopper unit becomes free. Remove the unit. 9. Remove joint plate. 10. Remove solenoid from solenoid furniture to replace it.
[Parallel Adjustment of the Stopper] 1. Loosen two fixing screws on the stopper. 2. Tighten the fixing screw so that lower cutter set block becomes parallel to the stopper.
SM
4-63
SPF-9R
Lower Cutter
WARNING
Sensor Connector
WARNING
Keep your hand off from the cutter blades when replacing them.
1. Remove two cables on fore-edge section, then remove fore-edge section from the connection to the staple and fold section. 2. Remove cover at stitch and fold section side (two fixing screws). 3. Turn the air nozzle sideways (two fixing screws). 4. Remove three fixing screws of upper cutter blade and remove upper cutter blade from upper position.
SM
NOTE - Apply glue to the part that arrow shows when NOTE setting the upper cutter. - Adjust the lower cutter by height adjust screw so that the top of the cutter becomes flat 5. Remove carry guide (two fixing screws). to the trim section when fixing the lower 6. Remove two lower carry belt. cutter. 7. Remove center connector and remove carry table (four fixing screws). 8. Remove four fixing screws and remove lower cutter blade from lower position. 9. When setting new cutter blade, procedure should be reverse order.
4-64 SPF-9R
5. Service Mode
5-1 Basic Movement of CFS Section ....................................................................... 5-66 5-2 Basic Movement of SPF Section ........................................................................ 5-67 5-3 Basic Movement of FC Section ......................................................................... 5-68
SM
5-65
SPF-9R
[To stacker=No staple or fold] 1. Gate opens so that sheets are guided to stacker section. 2. When sheets for 1 set of booklet are stacked and Off-set is selected, off-set motor (Fig.2) moves a signal from the copy machine shifts the stacker table forward table forward and backward by 30mm.
Jog Belt
CAUTION -When stacker table is not in the upper limit, copying does not start. -Copy machine indicates Finisher Error. -Raise the tray by pressing Shift Tray Up button on the CFS operation panel.
REFERENCE - Shift tray does not raise automatically for safety.
Off-set Motor
CAUTION -When covers exists in the cover feed tray but the tray does not raise, copying does not start. -Copy machine indicates Finisher Error. -Raise feed tray by pressing Feed Tray Up button on operation panel section.
5-66
5. When positions are decided to criterional position [A3,staple and fold], Data for next operation are sent from CFS. Then each part will be positioned again for next operation by following that data. The movement will be same as procedure 4. 6. When positions are set, machine is on the sheets waiting mode. Operating Movement
Guide (R)
Fig1 (SPF guide location upside view) 1. Sensor B10 detects (Fig.2) that 1 booklet Left is transported from CFS. Stopper 2. When a booklet is detected by sensor B11, guide (operation side), guide (drive side), Stitcher and right guide (jogger) moves to set the Gate booklet to the correct position. 3. Staple section operates to staple. Press Roller 4. When stapling, gate opens to transport B10 B11 booklets to fold section. Booklets are folded when next booklet comes to SPF, Right (If next booklet does not come to SPF, the Guide booklet which are in the fold section can Fold Knife not be folded.) but the last booklet for the operation will be folded by END Signal from the copy machine. Fig2 (SPF guide location side view) 5. Folded booklets are transported to FC side by passing through press roller.
5-67
SPF-9R
B11 Stopper
B10
Fig1
REFERENCE - When delivery motor at SPF section stops, FC section trims the last booklet and delivers it to ED section, then stops the delivery motor on FC section.
Upper Knife
Fig2
SM
5-68
SPF-9R
6. Electrical Parts
6-1 Identification and Location of Motors ..........................................................6-70 6-2-1 Identification and Location of Sensors [CFS Section] ............................ 6-71 6-2-2 Identification and Location of Sensors [SPF, FC Section] ..................... 6-72 6-3 Identification and Location of Switch and Breaker .................................... 6-73 6-4 Identification and Location of Solenoid ........................................................ 6-74 6-5 Identification and Location of Other Major Electrical Parts ................... 6-75
NOTE: Part numbers not listed in the following tables can be found in the SPF-9R Bookletmaker Parts Book.
SM
6-69
SPF-9R
M05
M10
M22
M04
M01 M10 Belt Drive M11 Knife Motor M10 M12 M13 6-70
FC
ED
SM
SPF-9R
B13
Number
Names, Roles
Parts No.
Maker No.
B15
B18
B14
B09 B20 B07 B19 Upper Limit Switch S04 B04 B01 B02 B05 B08 B06
B03 B10
B11
B01 B02 B03 B04 B05 B06 B07 B08 B09 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 S04 S05 S06
Width Adjustment Home Position Sensor Stacker Height Detect Sensor (U) Stacker Height Detect Sensor (L) Transport Pusher Home Position Sensor Stacker Transport Way Cover Detect Sensor Entrance Sensor Transport Section Entrance Sensor Stacker Entrance Sensor Gate Section Sheets Exist Sensor Stacker Exit Sensor Shift Stop Position Sensor Stacker Full Sensor Cover Near End Sensor Cover Tray Lower Limit Sensor Cover Jam Sensor Double Feed Detect Sensor Cover Height Detect Sensor Cover Detect Sensor Exit Sensor Sheets Detect Sensor in Stapling Tray Stacker Upper Limit Stacker Upper Limit Switch Stacker Lower Limit Switch Feed Tray Upper Limit Switch
4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4009730-00 4009730-00 4009730-00 4005225-00 4009730-00 4007567-00 4007567-00 4007567-00
EE-SX460-P1 EE-SX460-P1 EE-SX460-P1 EE-SPY302 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 EE-SX460-P1 E2R-A01 E2R-A01 E2R-A01 EE-SPY302 Our own product E2R-A01 PM2-LF10 PM2-LF10 PM2-LF10 V5412DK V5412DK V5114D
SM
6-71
SPF-9R
B24 B25
[Staple and Fold Section] Number B10 B11 B12 B13 B14 B15 B20 B21 B22 B23 B24 Booklet Detect Booklet Detect and Jam Detect Fold Knife Home Position Detect Book Block Detect in the Backle Staple and Fold Section Unit Position Home Position Detect Staple and Fold Section Unit Position Limit Detect Jog Unit Home Position Detect Stitching Stopper Home Position Detect Width Adjustment (operation side) Home Position Detect Width Arrangement (operation side) Limit Detect Width Arrangement (drive side) Home Position Detect Width Arrangement (drive side) Limit Detect Puls Detect Names, Roles Parts No. 4005225 4005225 4005256 4005225 4005256 4005256 4005256 4005256 4005256 4005256 4005256 4005256 4005256 Maker No. EE-SPY302 EE-SPY302 SIU700 EE-SPY302 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700
B25 B26
[Trim Section] Number B10 B11 B12 B13 B14 B15 B16 Names, Roles Sheet Entrance Detect (Entrance) Sheet Entrance Detect (front stopper) Trim KnifeUpper Limit Detect Stopper Home Position Detect Stopper Limit Detect Full Trimmings Detect Projector Full Trimmings Detect Receiver Parts No. 4005225 4005225 4009730 4005256 4005256 Maker No. EE-SPY302 EE-SPY302 E2R-A01 SIU700 SIU700
[Trimmer section/FC9]
SM
6-72
SPF-9R
S06
S02
S00
Q11 Q12 Q13 Q01 Q02 Q03 Q04 S06 S04 S05 S3 S2 Q21
S05
Number CFS S00 S01 S02 S03 S04 S05 S06 SPF S00 S1 S2 S3
Names, Roles Power Switch Cover Feed Section Cover Switch Entrancw Section Cover Switch Door Switch Stacker Upper Limit Switch Stacker Lower Limit Switch Feed Tray Upper Limit Switch Power Switch Delivery Section Cover Switch Top Cover Open/Close Switch Jogger Limit Switch Stapling Stopper Limit Switch Trimmings Box Detect Switch Top Cover Open/Close Switch Connection Detect Switch
S1
FC
S4 S1 S2 S3
SM
6-73
SPF-9R
Y02
Number CFS Y01 Y02 Names, Roles Gate Solenoid Clutch Parts No.
Y5 (Jogger)) Y7 Y1 Y1 (Stopper) Y8
Y01
SM
6-74
SPF-9R
Counter K1
Condenser
6-75
SPF-9R
SM
6-76
SPF-9R
Correspondence Board
Control Board
7-1-8
Staple & Fold Section Transport Motor M10, P.C.B on Unit Position QPW-518 P.C.B
Move Motor M12
7-1-2
7-1-3
Staple & Fold Section Control motor and solenoid movement exept fold knife QPM-503 Control Board
Fore-edge Trimmer (FC-9)
SM
7-78
SPF-9R
7-1-6
Staple & Fold Section Control the fold knife movement QPW-522
7-1-7
7-1-4
There are operation switches and monitor lamp, which indicats troubles.
CON20 CON22
CON2 CON1
CON9
CON8 CON10
CON11 CON14
CON12
SM
7-79
SPF-9R
CON8 1 2 RED 3 ORN 4 YIO 5 GRN 6 BLU 7 8 9 10 11 12 13 14 CON9 1 2 3 4 5 6 CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 HRY
CON11 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 9 10 CON12 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU CON14 1 BRN 2 RED 3 ORN 4 YEL 5 GRY 6 BLU 7 VIO 8 HRY 9 WHT 10
12V To QPW-492 GND CON11 Full Tray Emergency Stop+ Emergency StopFull Tray Sensor (Projector) Auto Start
CON15 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 GRY CON16 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 8 9 10 CON17 1 ORN 2 ORN 3 YEL 4 YEL 5 6 CON18 1 BRN 2 3 RED
5V QPW-492 Off-set Signal CON12 Feed Error On Collating Transport Motor Emergency Stop Output to Receiving Tray 24V SIG 24V GND 24V SIG 24V GND Jam Sensor (F) Jam Sensor (R)
Not Used
Send Receive GND 24V SIG 24V GND Send Receive 5V GND Send Receive 5V GND Send Receive 5V GND
24V SIG 24V GND 24V SIG 24V GND SIG 24V GND
To Communicate Connector with SPF-20A To Communicate Connector with Front Tower To Communicate Connector with Rear Tower
+12V GND
+24 GND
SM
7-80
SPF-9R
CON11 1 BRN 2 RED 3 ORN 4 Vacant 5 Vacant 6 BLU 7 VIO 8 WHT CON12 1 BRN 2 Vacant 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON13 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU
Stacker Full Sensor Pusher Home Position Sensor Shift Stop Position Sensor
CON14 1 BRN 2 RED 3 ORN 4 YEL CON15 1 BRN 2 RED CON16 1 BRN 2 RED 3 ORN 4 YEL CON17 1 2 3 4 CON18 1 BRN 2 RED 3 WHT 4 Vacant 5 GRN 6 BLU
Front Door Sensor Entrance Section Covewr Switch To S03 To S02 Cover Feeder Cover Switch To S01
COM DATA 0 DATA 1 DATA 2 DATA 3 Eject Switch Signal SPF Start ACK
CON19 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 WHT 9 BLK 10 Vacant 11 Vacant 12 Vacant 13 Vacant 14 Vacant CON21 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 VIO
To Copy Machine
1 2
M01
3 4
To SPF Section
Not Used
5 6
M10
M05 Tray Shift Motor M01 Stacker Up/Down Motor M10 Cover Feeder Up/Down Motor
To B11-1
SM
7-81
SPF-9R
L50 L1
L8 L9 CPU
QPM-144
L24 L25
L32 L33
DL7 DL1
L49 L50 L51 L52 L53 L54 L55 L56 L57 L41 L42 L43 L44 L45 L46 L47 L48
L40
SM
7-82
SPF-9R
S03
M05 M05 M01 M01 M10 M10 Y01 Y02 M13 B16 M02 M11 S02
SM
7-83
SPF-9R
7-1-3 CFS Correspondence Board and QPW-591 Connecter Locations and Connections
HORIZON QPW-591
CON1 1
SM
7-84
1
CON2
SPF-9R
[Switch]
Names. Roles Stack Tray Up Switch Stack Tray Down Switch Covber Feed Tray Up Switch Covber Feed Tray Down Switch Feed Error Detect On/Off Switch Not Used
Functions
CON1
SW2 SW5
1
SW3
16 To Control Board QPM-144 CON 19 BRN RED ORN YEL GRN BLU VIO GRY WHT BLK BRN RED ORN YEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14
[LED conditions to light] LED No. React Sensor.SW L1 SPF Signal SPF Signal B19 B15.B16 B17.B18 B16 B16 B09.B20 S03 B07 B08.B05 B10 B02.B03.B12 B06 S01 SW6 S02 Conditions to light Error at finishing machine Machine can not start [Adjusting] Sheet Jam Cover Sheet Jam No Cover No Feed Double Feed Sheet Jam Front Door Open Sheet Jam Sheet Jam Sheet Jam Stacker Tray is not in the upper limit Sheet Jam Cover Section Cover Open Error Detect ON/OFF Entrance Cover Open Functions
15 6
4 7
5 17 9 14 10 12 13 11
3 1 2
SM
7-85
SPF-9R
Caution: When control PCB is removed many similar connectors exist. Mark or in some way identify each before removal SM
7-86
SPF-9R
CON1 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK
PC+ Sig Sig Sig Sig Sig Sig Sig Sig Sig
Connector Pin NO 14 15 16 17 18 19 20 21 22 23
CON2 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 Vacant 11 Vacant 12 Vacant
1 2 3 4 5 6 7 8 9
CON3 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON4 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON5 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant
M21
M22
Not Used
M23
M24
Unit Position Move Pulse Detect B26 To QPW18 CON15-5 To QPW18 CON15-6 To QPW18 CON15-7 To QPW18 CON15-8
CON8 1 BRN 2 BRN 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK
To Relay K1 Staple Stopper Solenoid Y1,Y2. Gate Change Solenoid Y3 Delivery Belt Clutch Y4
SM
7-87
SPF-9R
CON9 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 67
CON11
Jog Solenoid Y5
Width Adjustment Solenoid Y6 Delivery Roller 1 Solenoid Y7 Delivery Roller 2 Solenoid Y8 To QPW518 CON5-3 To QPW518 CON5-4 To QPW522 CON1-2 To QPW522 CON1-3
Connector Pin NO 14 15 16 17 18 19 20 21 22
CON16 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED
Booklet Detect1 B10 Booklet Detect2 B11 Fold Knife Home PositionB12 Booklet Detect in the Backle SectionB13
SPF Unit Position Home Position B14 SPF Unit Position Limit B15
SM
7-88
SPF-9R
CON19 1 BRN 2 RED 3 WHT 4 WHT 5 GRN 6 GRN CON20 1 BRN 2 RED 3 Vacant 4 Vacant 5 Vacant 6 Vacant 7 Vacant 8 Vacant
POWER SUPPLY G01 CON2-2 CON2-1 To Relay K1 POWER SUPPLY G02 CON2-5,6
CON21 1 BRN 2 RED 3 ORN 4 Vacant 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 Vacant 11 BRN 12 RED CON22 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED 13 Vacant 14 Vacant
Jog Unit Home Position B20 Jog Unit Limit S3 Staple Stopper Home Position B21 Staple Stopper Limit S4
K1 Relay
CON24 1 BRN 2 RED 3 ORN Width Adjust Guide 4 YEL Operation Side Width 5 GRN Adjust GuideB22 6 BLU 7 VIO Width Adjust Guide GRY Operation Side Limit B23 8 WHT 9 10 Vacant Width Adjust Guide Drive Side Home Position 11 Vacant 12 Vacant B24 Width Adjust Guide Drive Side Limit B25
Connector Pin NO 1 2 3 4 5 6 7 8 9
66 To Connector to FC
SM
7-89
SPF-9R
CON25 1 Vacant 2 Vacant 3 ORN 4 YEL 5 Vacant 6 Vacant 7 Vacant 8 Vacant CON26 1 2 3 4 5 6 7 8 9 10 11 12
CON27 1 2 3 4 5 6
Not Used
Not Used
SM
7-90
SPF-9R
CON1 1 RED 2 BRN 3 Vacant CON2 1 WHT 2 Vacant 3 BLK CON3 1 BLK 2 Vacant 3 WHT 4 Vacant 5 GRN
QPW503 To CON9-11 To CON9-12 Terminal Board X101 2A Q2 Fold Knife Motor M11 To S00 To S00
SSR 1
SSR 2
QPW522
CON3
CON2
CON1
SM
7-91
SPF-9R
[Switch] Functions SW1 SW8 Mode Names. Roles Mode Select SW ; Change automatic settings
SW9 Upper. Right Adjustment Button ; Moves object to to arrow direction while it is pressed SW10 Lower . Left Adjustment Button ; Moves object to to arrow direction while it is pressed SW11 Clear Clear SW ; Clear the counter
[LED Conditiond to light] LED No. Functions Automatic Set Feed Error Sheet Jam No Staple Sheet Jam Unit Position Guide (drive side) Stopper (L) Stopper (R) Up Down Right Left React Sensor.SW SW1 SW1 S01.S02 B11 M31.M32 B13 SW1.SW8 SW1.SW8 SW1.SW8 SW1.SW8 SW9 SW10 SW9 SW10 Selected by SW1 Top cover or delivery section is opened When booklet detect sensor id on Trouble Signal from M31.M32 Booklet does not come within predetermined time Select set position by set mode Select set position by set mode Select set position by set mode Select set position by set mode Select set position by set mode Selected by SW9 Selected by SW10 Selected by SW9 Selected by SW10 Conditions to light When the power is on
SW11 L25 SW10 L28 L26 SW9 L27 L20 L21 L22 L23 L24 L3 L1
CON1
SW8 SW1
CON2
SM
7-92
SPF-9R
CON1 1 BLK 2 Vacant 3 WHT 4 Vacant 5 Vacant CON2 1 GRN 2 Vacant 3 YEL 4 Vacant 5 BLK CON3 1 BLK 2 Vacant 3 YEL 4 Vacant 5 WHT
LED4 LED3 CON5 LED2 LED1
CON4
CON3
CON2
CON1
LED No. L1 L2 L3 L4
React Sensor.SW
Conditions to light
Signal from QPW503 When ED-9 is operating Signal from QPW503 When main motor is operating Signal from QPW503 When unit position move motor is operating Signal from QPW503 When unit position move motor is operating
To Control Board QPW503 CON25-4 CON25-3 CON9-9 CON9-10 CON5-4 CON5-5 CON5-6 CON5-7
1 2 3 4
S00
SM
7-93
SPF-9R
CON5
CON7
CON6
L10 11 12 13 L6 7 8 9 L14 15 16 17
CON8
1
CON2
SM
1 1 1 1 1 1
CON10
L3 L3 L4
CON9 CPU
L5 L6 L7 L8 L9
1
CON1
7-94
SPF-9R
CON1 Panel Board QPW403 To CON1-1 1 BRN Top Cover LED To CON1-2 2 RED Cutter Lock LED 3 ORN Entrance Secrtion JamLED To CON1-3 4 YEL Exit Section Jam LED To CON1-4 5 GRN Full Trimmings LED To CON1-5 6 BLU Trimmings Box OpenLED To CON1-6 To CON1-7 7 VIO To CON1-8 8 GRY 9 Vacant Curtter Avtion SW To CON1-9 To CON1-10 10 BLK Right Stopper SW To CON1-11 11 BRN Left Stopper SW To CON1-12 12 RED To CON1-13 13 ORN To CON1-14 14 YEL CON2 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BRN 11 RED 12 ORN
CON3 1 BRN 2 RED 3 ORN 4 YEL CON4 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU CON5 1 BRN 2 RED 3 ORN 4 YEL 5 Vacant 6 BLU
+5V DC GND
CON6 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant CON7 1 BRN 2 RED 3 Vacant 4 Vacant 5 Vacant 6 Vacant 7 Vacant 8 Vacant 9 WHT 10 BLK 11 Vacant 12 Vacant 13 ORN 14 YEL
+24V DC GND
Stopper SolenoidY1
Entrance Section Booklet Detect B10 Stopper Section Booklet Detect B11 Trim Section Upper Limit Detect B12 Stopper Home Positin Detect B13
1 3 8 4 7
Connector to SPF-9
SM
7-95
SPF-9R
CON8 1 BRN 2 RED 3 ORN 4 Vacant 5 BLU 6 VIO 7 GRY 8 WHT 9 Vacant 10 Vacant
Stopper Home Position Detect B13 Relay K1 Connected Point Trimmings Box Open Detect S1
CON9 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant 9 Vacant 10 Vacant
M12
CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED
SM
7-96
SPF-9R
SW2
SW3
LED 1
7
SW1
2 3 8 9
4 5 6
CON1 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 Vacant 10 BLK 11 BRN 12 RED 13 ORN 14 YEL
Top Cover OPEN LED Cutter Lock LED Entrance Section Jam LED Delivery Section Jam LED Full Trimmings LED Trimmings Box Open LED Not Used Not Used Cutter Action SW Right Stopper SW Left Stopper SW Not Used Not Used To QPW484 CON1
1
React Sensor.SW
[Switch] Names and Roles SW1 SW2 SW3 Cutter Action Switch Left Stopper Move Switch Left Stoper Move Switch
[LED conditions to light] LED No. L1 L2,7 L3 L4 L 5,8 L6,9 Functions Cover Open Knife Lock Sheet Jam Sheet Jam Full Trimmings Trimmings Box Conditions to light When top cover is opened,connecting to SPF, or removing from SPF When trimming motor driver detects too much load When entrance sensor section B10 is ON When exite sensor section B11 is ON When full trimmings sensor B16 is ON When trimmings box switch S1 is OFF S2,S3 M11 driver B10 B11 B15.B16 S1
SM
7-97
CON 1
SPF-9R
CR00
S00
Breaker
Breaker
Breaker
Breaker
FC-9
Power Point
SM
7-98
SPF-9R
Breaker
Main Switch
Terminal Board
Noise Filter
Q1
G01 Breaker
Relay
Breaker Q2
SM
7-99
SPF-9R
Relay
WHT
Protector
M10
YEL
K04
Terminal Board 1
Relay K3
Noise Filter 2 3 4
25
Knife Motor
14
M11
Driver
G01
Top Cover Switch
Relay K2
G02
S3
SM
7-100
SPF-9R
CON11
CON12
CON13
CON14
CPU
CON15
CON18
SM
7-101
SPF-9R
To Switching Power Supply S00 To Switching Power Supply G01 (5V) L To Breaker G00 To Switching Power Supply G01 (5V) N
To Power Cord for SPF To Power Cord forFC To SSR for Blower To Switching Power Supply G02 (24V) N To Power Cord forFC To Power Cord for SPF To Blower Motor To Switching Power Supply G02 (24V) L
SM
7-102
SPF-9R
To Switch S00
To Switch S00
Q2
2A
To Knife Motor Board QPW522 CON2-1 To P.C.B QPW518 CON4-1 To Switching Power Supply G01 (5V) N To Switching Power Supply G02 (24V) N
Relay K2
To P.C.BQPW518 CON4-2 To Knife Motor Board QPW522 CON2-2 To Switching Power Supply G01 (5V) L To Switching Power Supply G02 (24V) L
SM
7-103
SPF-9R
To Switching Power Supply G01 (5V) N To Switching Power Supply G02 (24V) N To Relay K3-4 for Belt Drive Motor M10 To Relay K3-3 for Belt Drive Motor M10 To Switching Power Supply(5V) L To Switching Power Supply (24V) L
Breaker
2A
K3 25
To Belt Drive Motor M10 To Belt Drive Motor M10 To Trimming Knife Motor Driver 24
14
SM
7-104
SPF-9R
To Copy Machine
SPF FC
To Power Supply
SM
7-105
SPF-9R
BOOKLETMAKER
SPF-9R
Important Information
- This manual is designed to help you to install, operate and maintain bookletmaker, SPF-9RGS. Read, understand and keep this manual in a safe and convenient place. - Do not operate SPF-9RGS until you read and understand the instructions in this manual. - Horizon International Inc. shall not be liable for incidental consequential damages resulting from : improper or inadequate maintenance by customer; unauthorized modification or misuse; operation outside of the environmental specifications for the product. - Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation. - All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.
Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. - The signal word CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices. - Read and understand all safety instructions with signal word such as WARNING and CAUTION. If safety instructions are ignored, personal injury may result. - Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this manual and warning labels on the machine are therefore not all inclusive. - All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device where it is locked or tagged out. - Do not operate the machines when any covers are removed. - Some of the drawings in this manual show the machine uncovered for explaining the detail or inside of machine. - This machines noise level is more than 70 dB(A). Use proper soundproof device when this machine is operated.
II
Contents
Important Information ............................................................................................. I Safety Precautions .................................................................................................. II
1. Installation space Securement .......................................................................... 1 2. Before You Begin ................................................................................................ 2 3. Installation of CFS (Cover Feed and Stacker Section) ................................. 4 4. Installation of SPF (Staple and Fold Section) ................................................. 7 5. Installation of FC (Fore-edge Trim Section) .................................................. 9 6. Cable Connection ................................................................................................ 12 7. Accessories ........................................................................................................... 15
III
1000mm
Copy Machine
800mm
Copy Machine
CFS (Cover Feed and Stacker Section) SPF (Staple and Fold Section) Delivery Tray FC (Fore-edge Trim Section) (1)
Fixing Tapes
Fixing Tapes
3. Remove a fixing tape of the sensor and two plastic cord strings.
Stacker
Fixing Tapes
6. Remove a fixing string for guide at cover feed tray, a plastic cord string for the sensor, and two fixing tapes at cover feed section.
Plastic Cord Strings 7. Remove four fixing tapes at cover feed section a d transport section.
8. Set the attached film to the upper part of the delivery section on copy machine. 66 mm mm Film CFS
Film
Copy Machine
2. Set up the entrance guide plate to the delivery section of the CFS (cover feed and stacker section).
Set Up the Entrance Guise Plate
(4)
6. Fit the copy machine and CFS, so that the latch on copy machine fits to the slit hole under the delivery section of the CFS.
(5)
(6)
Power on
3. Open the CFS stacker section door and remove the screw of the lever which is at a lower left part of the machine.
5. Fit the SPF to CFS so that the latch on the SPF fits to the slit hole at the lower left part of the CFS. NOTE - Place the machine on the flat floor where there is 1 cm gap between CFS and SPF. SPF Operation Side
CFS
Fixing Screw Transportion Lock Bracket 2. Mount the rail plate to the lower part (left side) of the SPF. SPF
Rail Plate
3. Mount the transport guide to the belt section on the right side of the FC. Insert the transport guide to the very bottom and fix it with a fixing screw.
Transport Guide Joint Latch 4. Set up the joint latch to the left side of the SPF.
SPF (9)
FC Caster
Rail Plate 6. Connect FC section to SPF. Raise the hook of the joint latch on SPF and move FC so that the latch enters to FC section. FC SPF
8. Connect SPF to the FC section by latching the hook of the joint latch over the stud provided.
Joint Latch
Hook
(10)
9. Set the attached wire for a stopper at the lower drive side of SPF and FC.
Wire for a Stopper FC 10. Mount the hook of the delivery tray to the slit hole on the left side of the FC section.
Hook
Stopper
(11)
6. Cable Connection
1. Insert the connecting plug coming out from FC drive side to the round shaped connector on the SPF drive side, and then tighten the lock nut. Connecting Plug SPF Drive Side
FC Drive Side
2. Insert the attached signal cable to connector section on the drive side of FC and SPF section, and then fix it with the insertion screw.
CFS Drive Side Connector Section 3. Insert the attached signal cable to the connector section on the drive side of SPF and CFS section, and then fix it with the insertion screw. Connector Section Signal Cable
Copy Machine Signal Cable 4. Insert the signal cable of the CFS section to the connector section on the left side of the copy machine. Connector Section (12)
6. Cable Connection
5. Plug the power cords of FC and SPF to the receptacles at the drive side. And then connect either plug of SPF power cord to the receptacle on the CFS drive side.
6. Connect the power cord of delivery tray to the SPF power source at drive side of the SPF.
SPF
7. Connect the power cords of CFS and FC to the power source in the building.
CFS
(13)
6. Cable Connection
8. Set the attached cord clamps to the drive side of machine (3 pcs) and then tie each cord with the cord clamp as mentioned below. Clamp A; Power cord of FCand SPF Signal cable of SPF Clamp B; Power cable of PC Clamp C; Power cord of the delivery tray signal cable of PC
9. Set the attached cord clamp on the delivery side of the FC (1 pc). Clamp D; Power cord for delivery tray
Delivery Tray
Clamp D
(14)
7. Accessories
7-1 Accessories for Cover Feed and Stacker Section
Unit Joint Stay F (Ml105012-00) 1pc Unit Joint Stay R (Ml105013-00) 1pc
1pc
1pc
1pc
1pc
(15)
7. Accessories
Cover Feed End Plate (M004363-01) 1pc Cover Holding Plate (M004337-01) 1pc
Cord Clamp
4pc
Film (M105425-00)
1pc
1pc
1pc
(16)
7. Accessories
7-2 Accessories for Fore-edge Trimmer Section
Joint Plate A (M072791-12) 1pc Entrance Guide (M072906-01) 1pc
1pc
1pc
Rope (M037765-00)
1pc
1pc
Stopper (M105449-00)
1pc
(17)
7. Accessories
7-3 Accessories for Staple and Fold Section
Staple (4-010600-00) 2pc
1pc
8. Consumption Parts
Consumption Parts Staple (4-010600-00) Staple Cartridge (4-010266-00)
(18)