:ssisnacestensetteun a inenmtanhiiopRasoRasecesr soe System 4000 DYNAMIC BOOKLET MAKER DBM-400 _stanamnestenesseeeceoesesianeammsmmttomntseerasnsesaetasaasaRIS Maintenance I Manual sevesrepereszenntenataurnnimmin DUPLO CORPORATIONCONTENTS PART 1 MECHANISM SECTION cm OUTLINE OF MECHANISMS AND ADJUSTMENTS ... 4-4, Stitehing Mechanism, 1-2. Adjusting the Stepping Motor Unit. 1-3. Adjusting the Back Jog Unit 1-4, Adjusting the Side Guide 1-5. Adjusting the Rear Guide... 1-6, Adjusting the Saddle-Stitching Stopper ..1-16 Adjusting the Folding Stopper. Adjusting the Back Stopper ... 1-9. Adjusting the Side-Stitching Stopper 1-10.Winding the Staintess Steel Wires .. 1-11.Adjusting the Conveyance Roller Solenoids... 1-12.Adjusting the Paper Holder at the Stitching Head and Peripheral Parts. 1-13.Adjusting the Conveyance Clutch 1-14.Adjudting the Tension of the Conveyance Flat Belt at the Entrance E 1-18.Adjusting the Positioning of the Gentral Conveyance Flat Belt 1-46.Adjusting the Folding Section 1-17. Adjusting the Stitching, Folding 4-18, Adjusting the Tension ofthe Belt Chain. MAINTENANCE.. HONER UNIVERSAL ‘STITCHER HEAD 3-1. Periodic Inspection and Replacement of Parts .... 3-2. Troubleshooting 3-3, Exploded View .. PART 2 ELECTRICAL SECTION 1. Service Mode... 11, Entering the Service Mode 1-2. ON/OFF Operations 1 (Solenoid) . 1-3. ON/OFF Operations 2 (Clutch) . 4-4. Independent Operations (Stepping Motor) .. 1-5. Single Operations (Stepping Motor) 16. Checking and Setting Data {Stepping Motor Counter) 4-7. Checking the Sensor . 1-8. Other Operation Modes .. 2, Replacing the Main Board 2-43 2-1. It Memorized in Main Board Memory ......2-43 2-2. If not Memorized in Main Board Memory 2-43 2-3. inputting Offset Data svseenteese . Adjusting the Paper Sensor... 3. 4, Adjusting the Interlock SW 5. 6. 247 }. List of Service Modes 7. Error Codes and Troubleshooting. 2-51 7-1. Error Codes 251 7-2, 4 (Down Arrow) 01 to 08 and OE (Jam Errors) 7-8. T (Up Arrow) 11 to 18 (Serious Unit Error)... 7-4. T (Up Arrow) 21 to 26 (Moderate Unit Error). . 7-5. T (Up Arrow) 31 (Warning to Operator ‘When Changed to Small Size) 7-6, 1 (Up Arrow) 41 10 48 (Stepping Motor Error 7-7. 4 (Down Arrow) 51 to 52 (Downstream Processing Unit Error 7-8, Main Unit DIP Switches Releasing the DBM-400 Pr 7-10.Electrical System Problems Overall Schematic Diagram... Component Wiring ...PART 1 MECHANISM SECTION Table of Contents 4. OUTLINE OF MECHANISMS AND ADJUSTMENTS: 1-1. Stitehing Mechanism jo... 2. MAINTENANCE... 3. HONER UNIVERSAL 1) Mechanism for moving stitcher head 1-3 STITCHER HEAD 2) Positioning of stitcher head. 14 3-1. Periodic inspection and 2-1) Attaching the stitcher head Replacement of Parts .......... (Method 1) .. 1) Names and Functions of Parts .. 2-2) Attaching the stitcher head 2) Wire ... (Method 2) annennnene 8) Positioning the clincher... 4) Adjusting the peripheral mechanism of stitcher 4-1) Adjusting the clincher slide «1.0. 4-2) Adjusting the guide 4-3) Adjusting the lever... see AT 5) Adjusting the curvature of the needle ...1-8. 3). Straightening wires .. 4) Basic settings of wire length .. 5) Setting the leg length. 8) Adjusting the forming unit. 7) Adjusting the bender 8) Replacing the knife .. 9) Replacing the bender.. 10) Replacing the screwdriver ... 5-1) Adjusting the clincher point. 11) Adjusting the tower limit position 5-2) Adjusting the driving slide of the bender. stroke level 12) Adjusting the lower limit position 6) Winding the wire ... Of the CrIVEF nner 1-42, 7) Adjusting stitching position 43) Replacing the clincher ... and needle se 8-2. Troubleshooting ..nmenmnrnnrne 1-2. Adjusting the Stepping Motor Unit. 3-3. Exploded View 1-3. Adjusting the Back Jog Unit... 1-4. Adjusting the Side Guide ..mannn 1-8, Adjusting the Rear Guide... 1-6. Adjusting the Saddle-Stitching Stopper ..1-16 1-7. Adjusting the Folding Stopper... 1-8. Adjusting the Back Stopper swmnrm 1-9. Adjusting the Side-Stitching Stopper... 1-10.Winding the Stainless Steel Wires... 1-11.Adjusting the Conveyance Oo Roller Solenoids ........ 1-12.Adjusting the Paper Holder at the Stitching Head and Peripheral Parts..... 1-23 24 1-13.Adjusting the Conveyance Clutch 4-14.Adjudting the Tension of the Conveyance Flat Belt at the Entrance 1-15. Adjusting the Positioning of the Central ‘Conveyance Fiat Bett 4) Central conveyance guide 2) Central conveyance belt. 3) Central conveyance roller shatt desorption portion 1-16.Agjusting the Folding Section 1) Folding knife . 2) tet press rollers, 3) 3rd press rollers 4) Side quide .. 5) Ejection section paper holder 1-17, Adjusting the Stitching, Folding Clutch 4-18. Adjusting the Tension of the Belt Chain .. 1-2 14 ‘998-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 1-1. Stitching Mechanism 1) Mechanism for moving stitcher head Decelerates the rotation of the stepping motor by 1/10 using the worm gear and worm wheel, accelerates it by four times via the timing gear, and conveys to the screw shat. The head holder moves together with the female serew attached to the screw shaft. A stainless stee! wire is fixed to the head holder and clincher holder so that they are in synchronization. ‘The stitcher head moves by 2 mm (0.08 inch) with each rotation of the screw shaft. ‘+ Eliminates the shaking of the screw shaft in the thrust direction completely (to 0) using the collar. « Reduces the shaking of the female screw at the R side to 0.1 mm (0.004 inch), If overload is detected in the horizontal movement of the stitcher head, it may indicate thatthe screw shaft is dimty or the female sctew is scratched. Clean or tubricate accordingly. 935-1124 fe (998-8007 fame, 995-1023 $95- | ‘Channel ‘al putey 45 ” * =] ee 102: ome - aoe 995-1023) “F a ~ eal cs sxe “PY Nees Na seul ae > ea A Beta 6 lt L, aan os = se em 4a Sori waster me Fer — ae Holding ft t* + a ‘water [> 995-1030 non 8 Strat on ne " a2 99S-M22S0-0004-0 131. QUTLINE OF MECHANISMS AND ADJUSTMENTS 2) Positioning of stitcher head 21) Attaching the sttcher head (Method 1) + Insert the stitcher head into the holder unit, and check that the head is attached vertically at the position where the two stopper pins ofthe side ofthe head are adhered closely to the holder unt. After checking, tighten the two Fixing screws equally. 95-1011, Takder ari ‘Unit: inen (inch) { ) Cy ak] Gh 5 ae (9 Wow k LE e) es so pore iat or ° 9 Sami Fy Yo f © f H 1°] | eress against the see © ead sew h LE rome Y sal —O sar Vv ie) Q 2 Bek stati foal esa raf BT ‘Tr attng wt08-008 eae “Bent presi trip 2-2) Attaching the stitcher head (Method 2) + To position the paper in the direction itis fed, insert a spacer (tape) between the stitcher head and hotder unit. Paste spacers at the top and bottom limits of the area in which the stitcher head and holder unit are adhered closely, Place spacers with the same thickness over each other and paste the same number for each area. Use tape that is 0.1 10 0.15 mm (0.004 to 0.006 inch) thick Tape size ‘Sto 18mm (02 100.58 inch) art 217 me + For details on the positioning of the paper along its width, refer to “Positioning the Clincher 3)”, Fine adjustments of the positioning can only be performed in this direction where the stopper pins are moved away from the holder unit. To adjust the opposite direction, adjust by moving the clincher. Perform stitching tests, and while checking the needle shape, adjust so that stitching is performed normally. For details om the needle shape, refer to “3. Honer Universal Stitcher Head” ‘99S-M22S0-0004-0 +41. OUTLINE OF MECHANISMS AND ADJUSTMENTS: 3) Positioning the clincher + Position ihe clincher in the horizontal direction by loosening the screws fixing the angle unit fixed to the clincher holder and the wire of the bracket unit, and adjusting the clincher tothe stitcher head. Side L faaenee 24.5130.5 Unt Gc (1.20) (0.96); ( 995-1011 Head holer uit ‘Sub frame Frame R ccs Le Adjust serew Al ‘Angle unit SeH-1222 Bracket unt Clincher holder 18 ‘99S-M22S0-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 4) Adjusting the peripheral mechanism of stitcher Driving side SBH-1080, ‘Sticher head Apply grease: oO 320.2 $95-1125 (0.120.008) Gude unit Assembly reference hole ‘995-1111 Staft ge 11 Giineher holder 995-1111 Shaft Unit: (ne) more than 0.5(0,02) ‘Should move up and down smoothly i ‘99S-M2280-0004-0 16© 1. OUTLINE OF MECHANISMS AND ADJUSTMENTS 4-1) Adjusting the clincher stide + Adjust the clearance between the clincher slide and bar (0 0.} to 0.3 mm (0.004 to 0.012 inch) using the guide attached to frames L and R. 93xX-1028 Guide 995-1117 a Bar {>| 3 Ls [995-1117 Falls Bar 4-2) Adjusting the guide + Adjust the guide so that the top of the guide is more than 0.5 mm (0.02 inch) above the top of the clincher. ‘more shan 0.5(0.02) incher ‘Unit: mm Gch) 4-3) Adjusting the lever ‘+ Attach the guide 0.1 mm (0.004 inch) away from the lever so that the lever is positioned nearer to the stitcher head, + Attach the stopper plate firmly so that the guide does not move during use, 17 998-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 5) Adjusting the curvature of the needle ‘+ Align the front, back, left, and right sides of the stitcher head and clincher. If not aligned properly, stitching will not be cartied out propery. + The driving force from the main motor is conveyed to the stitching clutch so thatthe clutch shaft rotates when stapling is performed. The driving slide descends according to this rotation, the stitcher head conveys a certain number of needles, cuts the needles, bends the needle into a U shape, and pushes the needle into the paper. Italso rotates the cam, lifts the bearing on the cam, and atthe same time raises the clincher slide, and bends the back of the needle based on the clincher point. Mee Bering Paper entering side Pane ejation side 995-117 Br ‘99S-M2280-0004-0 181, OUTLINE OF MECHANISMS AND ADJUSTMENTS 5-1} Adjusting the clincher point ‘+ With the clincher slide raised to the very top using the stitching clutch cam, adjust so that the bent side of the clincher ‘point needles becomes horizontal. For how to do this is o loosen the fixing screws fixed tothe side ofthe bar, loosen the. fixing nut atthe top, and position the clincher point using the adjusting screw. After adjusting, tighten the fixing nut and fixing screw. Fix the bracket where itis at right angles to the bar. Attaching it sideways may cause the bearing to detach from the cam, and disable norma stitching. Clincher point Horizontality Adjust screw Clincher slide 9BH-1118 Bracket Fixing screw Clincher slide 5-2) Adjusting the driving slide stroke level ‘+ Change the position for fixing the bearing of the lever so that the stroke level of the driving slide changes (stroke amount is consistent). ‘The amount of changes is 3 mm atthe most, and this is adjusted at shipment, Use of this method if the stitcher head and clincher leave distinct marks on the paper will belp reduce the problem. However changing the position for fixing the bearing will change the length of the needle, resulting in the need to pesform adjustments for this. For a paper with different thickness, an adjustment may be required again, Try not to usc this method. 150.08), Paper ejection sido 19 ‘998-M22S0-0004-04. OUTLINE OF MECHANISMS AND ADJUSTMENTS 6) Winding the wire Adjust the hotizontal direction of the stitching head and clincher using the adjusting screw shown in the figure. + Wind the wire as shown in the figure. Attach the wire so that it does not get caught. sme L Stitching center ine [30.5 (1.20) 995-1011 i Z) Head holder unit R \ g9s-t2i8 a M261) (108) ‘Angie unit B { La sai-1222 23 ‘Bracket unit Lay Lo Oe 5 Adjusting sorew 0H 108 wee ‘Clincher holder (0.79=0.08) C, ‘Unit: mm finch) 998-M220-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS, 7) Adjusting stitching position and needle + Move the bracket (needle) so that the bracket (needle) scale indicated on the stitcher position Iabel and center of the stitching sample are coincide. (s] 995-1017 ‘Urit men inch) Ang 996-1011 ‘Move the bracket(99S-1016)and adjust to the stitcher name plate Stitehing center line 4.5] 30.5 (0.96) | (1.20) 995-1011, Head holder unit Frame R ‘Angle unit Ceo yee ‘S8H-1108 Clincher holder é me 08) + 99S-M22S0-0004-01, OUTLINE OF MECHANISMS AND ADJUSTMENTS Adjusting the Stitching Motor U The vibrations caused by intermittent rotations of the stepping motor are absorbed by the spring, and the speed is decreased to 1/10 by the worm gear and worm wheel. + The back lash of the worm gear and worm wheel is adjusted using the plate. Rotate the worm wheel for one round, and minimize the backlash in a clog-less state, Double-secure the boss using FR 4x4 screws so that the thrust of the shaft unit is 0 ‘Secure the stepping motor using a torque wrench, and tighten with a 300 gecm torque. Then tighten with a NS. ‘Seoure the disc unit atthe center of the photo-interrupter HEAXI6 a torque ver NS. ‘960-8051 ator BH-1054 FLO Bie int = 16-10161 Grommet sot A ‘89H-1039 ‘ejsting pel Fe ‘soe-1040 998-1061 ‘Motor bracket Shat unt ‘38H- 1059 Car 9aw.3039 im SoH-1048 Ser ite = Worm gear f (+) | ochre’ A 998-M2280-0004-0 4421, OUTLINE OF MECHANISMS AND ADJUSTMENTS Adjusting the Back Jog Unit By changing the stepping motor from rotary movements to linear movements, the base will move to and fro, and as a result, the pusher attached at the top of the base will move to push in the paper according to the guiding plate attached to the jog base. + Loosen screws © to align the @ Tine o the paper. + To-adjust the pusher alone, move the © angle until shaking stops, or adjust the ® angle and not the ® reference angle. When the height is changed, the position in the moving direction is also changed, + If the machine detects overload while moving the unit, it may mean that the shaft has dusts adhered. Clean ot lubricate as necessary. Fix the collar a the center of the D cut ofthe motor shaft where the ring becomes parallel when secured with a FR 4x4 double ring. + Check that the plate is a the 2 to 3 mm (0.08 to 0.12 inch) position when it blocks the photo-interrupter, | ie maz | | | | sl ee er | ‘tia I sony goer | a es.130 | oe 2] Guide q [ 1330 i Jost = | cole rs rade sont Fee 113 99S-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS LAX) ting the Side Guide Two stainless steel wires are wound around the pulley, going through the stepping motor. This is to prevent the wire from moving coe even when load is imposed when jammed =, paper is removed. This side guide moves to the 8 mm (0.31 inch) position when the paper comes in, ganas and moves to the reference position of the paper when paper is aligned. + Attach the wire so thatthe paper side becomes 0 to 1 mm, (010 0.04 inch) when the block touches the reference part of the support attached to frame L. Sena Loosen the screw of the channel, and secure the screw where the block touches the support. + When changing tothe small size, attach the side guide so that the roller is pushed in by the stay so that it does not ‘come in the way of the horizontal bet. Set the clearance from 0.2 to 1 mm. (0.008 t0 0.04 inch) + Loosen screw @ to adjust the angle @cmue After adjusting the angle, secure side guides ® and ® so that the faces of the paper holding sides become one straight line. ‘Unit: men men) 99S-M2280-0004-0 1141, OUTLINE OF MECHANISMS AND ADJUSTMENTS: Adjusting the Rear Guide Change the movement of the solenoid from linear to rotary/reciprocating, move the rear guide using the cam, and perform jogging. + Secure the cam so that it becomes parallel to frame R within the D range. At this time, secure the head so that it becomes parallel. + When the solenoid turns ON, the rear guide moves to the paper crossing line (40 mim (1.57 inch) from frame R). ‘When OFF, the rear guide is controlled by the stopper unit. ‘At this time, itis 2,540.5 mm (0.40.02 inch) away from the paper crossing line. Wnt kz} ae pee hea ate p56 108-9) trance se 995-1510 teccsew Move ore a e144 ‘Unit: rn Gch) ‘99S-M22S0-0004-01, OUTLINE OF MECHANISMS AND ADJUSTMENTS ial Stopp Adjusting the Saddl Increase the linear movement of the solenoid using the lever. When the down solenoid is ON, it will work to lower the stopper. When the up solenoid is ON, it will work to raise the stopper. The spring works to reduce the load on the stopper. + Tighten the two screws ® where the base and L stay become parallel. + Secure the eccentric collar in the direction shown in the. figure, Adjust using screws ® even when the paper is currently passing + To adjust the base assembly, taking bearings B and D. attached to the angle as the reference, push the bearing C using the spring against the base. + Adjust the stopper horizontal using the angle + Adjust the protrusion of the stopper using the angle 50 that itis 1040.5 mam (0-40.02 inch) from the guide, + Adjust the solenoid so that when the stopper has descended completely, the base touches the rubber plate, ‘and atthe same time, there is a clearance of 0.5 mm (0.02 inch) between the rubber plate and solenoid, Loasening screws ® and changing the base angle changes the position of the shield plate, As this will require the offset, data ta be changed, it will disable use of this method. ‘Unit; mm gnch) 99S-M22S0-0004-0 1-161. OUTLINE OF MECHANISMS AND ADJUSTMENTS. 1-7. Adjusting the Folding Stopper Increases the linear movement of the solenoid using the lever. When the solenoid is ON, it will work to lower the stopper. The stopper is raised by the force of the spring. * Tighten the two screws A where the base and L stay = become peraltel. ‘+ Secure the eccentric collar in the direction shown in the figure. ‘Adjust using screw A if paper is currently passing Bere through. an-2537 + To adjust the base assembly, taking bearings B and D attached to the angle as the reference, push the bearing C using the spring against the base. + Adjust the stopper horizontal using the angle, + Adjust the protrusion of the stopper using the bracket so that itis 840.5 mm (0.31+0.02 ineh) from the guide. + Adjust the solenoid so that when the stopper has descended completely, the base touches the rubber plate. Loosening screws ® and changing the base angle changes the position of the shield plate. As this will require the offset data to be changed, it will disable use of this method. ficient SH 152; = ee = 24 H i bss-sots ‘laranc wren sed BONO UD) Unit: ren Gch ‘99S-M2280-0004-0 1-171, OUTLINE OF MECHANISMS AND ADJUSTMENTS 1-8. Adjusting the Back Stoppe Increases the linear movement of the solenoid using the lever. When the solenoid is ON, it touches the folding stopper and returns the paper which mot back to its original position. + Tighten the two screws ® where the box and L stay become parallel. + Adjust so thatthe stopper touches the rubber plate when the solenoid is ON. ‘Adjust the angle so that the stopper is 150.5 mm (0.59:0.02 inch) from the guide when the solenoid is OFP. + Loosen the screw and tighten it where the stopper becomes parallel with the blade. (0) ssa. = a ‘Rub sate Koo ren os. a : = Se ‘Stoner 96 a/ & vat ty Guide es! 998-M22S0-0004-0 1181, OUTLINE OF MECHANISMS AND ADJUSTMENTS, Adjusting the Side-Stitching Stopper Increases the linear movement of the solenoid using the lever. When the solenoid is ON, it will work to lower the stopper. The stopper is raised by the force of the spring. + Adjust so that the stopper plate protrudes 2.50.5 mm (0.10.02 inch) from the top of the clincher when the solenoid is ON. + Adjust so that the stopper plate protrudes 10.540.5 mm (0.41+0.02 inch) from the top of the clincher when the solenoid is OFF. save-2007 (2) Under guide j= 981126 ‘Face is aligned to clincher top = Suse ee ad see Soper ea al ee cite } 38H-2005 ar pa (995-8315. ‘Sees S DEAS ODT wen caeATON ‘935-2013 ‘Solenoid base ‘Unit: mm {inch) 99S-M22S0-0004-0 1191. OUTLINE OF MECHANISMS AND ADJUSTMENTS es 0. Winding the Stainless Steel Stainless steel wires are used for moving each unit. Each unit moves by 100 mm (3.94 inch) when the pulley attached to the output side of the stepping motor unit makes one rotation. ley is used so that the wire and pulley do not separate when a unit stops halfway ante it is moving to due to excessive negative load. ‘+ Asshownin the figure, after winding the wires, secure the angle with the stainless wire pulled out completely in the long hole. ‘The stopper is attached so that the spring absorbing the stack wire dees not expand more than required, excluding the side guide unit, (Check that the stainless wire is noi touching this absorption spring. + Check that the stainless wire is wound around the pulley. oo pee may ens Rom Unit: mm (inch) 99S-M2280-0004-0 1-204, OUTLINE OF MECHANISMS AND ADJUSTMENTS Botiern aH 1646 ‘S0H-1644 3s1515 Blckunit 3aH-1521 hanes Side aide unit 985-1650, Ades washer E geo. aoa0st 98H-1634 ley tan Teo sare we 995-3335, f Sais wer le -. Ls — e 7 Oo Oo q ° e| ga sot {] ° ° Ge 2. = — $ sek lo} ey Unit: min cinch) 421 998-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 1-11. Adjusting the Conveyance Rolier Soleno: The stitched paper ejection 1 solenoid moves the paper after it is stitched. The roller of the stitched paper ejection 2 solenoid is attached with a rubber ring, which works to convey small paper and prevent the paper from bending when being discharged. The paper ejection 3 solenoid works to convey paper not to be folded. *+ Inthe OFF state, position the stitched paper ejection I solenoid 7.5°2s mm (0.28 “be inch) from the conveying side. + With the stitched paper ejection 1 solenoid in the ON state, adjust the plate so that the rollers of the two lever units press the rollers evenly as shown in the figure. + Inthe OFF state, position the stitched paper ejection 2 solenoid 440.5 mm (0.1620.02 inch) from the conveying side. + Check that the lever unit is able to move over the square stay smoothly. *+ Inthe OFF state, position the paper ejection 3 solenoid 7.520.5 mm (0.2840.02 inch) from the conveying side. in jen eat Utd o_o) gett weed Gesaree o2 ETO RES Siascibronle pe ee) ner ther sg(985-E20i eral (95-4825, tse enter in ss 1540-51mm (0.284000 rch) Goleaic FF} | 430.5 ran (1630.0 inc) (Solenoid OFF) elt of ere sron ee faceane Hse rete ere (toopersrg site) ss-005 Seana seca fe] en (Ce ‘Sted sper gon soe Unit: mm Ginch) ‘99$-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS sting the Paper Holder at the Stitching Head an Peripheral Parts Holds paper touching the stopper when side-stitching is selected so that it is not crushed by the contact section. + Adjust the paper holder using the eccentric collar inside the range shown in the figure so that there is clearance of 0.3 to 0.6 1mm (0.01 to 0.02 inch) with the side plate. Ae Tate postin Lota asthe eee pdsteg eae ‘Adjust 984-9078 and 304-5077 ‘Assembling the Homer head paper holder Reidehead Lsidehead ye. © saa ves oe Papere holder PG oa oti > Oe sen a Tegplge sen sesmesr EG BB meer ae Rete 2ao vat mn1, OUTLINE OF MECHANISMS AND ADJUSTMENTS 3. A When the folding blade lifts up the paper, the conveyance clutch stops the conveying belt and stabilizes the paper. Insert the 998-4514 collar 08-12-02 between 013-00180 bearing ofthe frarae support part and the clutch rotor so thatthe side with the bearing chamfer fits with the bearing + ress and fix the collar 08-12-02 on the rotor side ofthe clutch, stting the dhrust gutter of the shaft to 0. Adjust the adjustment washer of the clutch mechanism so that there is a 0.1 - 0.2mm (0.004 -0.008 inch) space between the rotor side ofthe clutch and the amateur side (atached to the pulley unit), Fix the 995-4518 set collar 08-14-05 so thatthe thrust gutter of the 995-4515 pulley unit is set t0 0. 995-4514 Caller 8-12-02 ggs-4518 O.1~9.2 /SetColler HH _(0004-0.608 ) L I 003-CO160 013-00180 Bearing Bearing x } fd to —_———_-___|} tt i 995-4505 : \ ‘Shait de . E-64 385-6005 __ 995-4513 Bracket 995-4515 j Pulley unit S8H-8060 Electromagnetic clutch Screw to stop rotation MSK 3x28 Unt me Get 998-Mm2280-0004-0 1-241. OUTLINE OF MECHANISMS AND ADJUSTMENTS of the Conveyance Flat Belt at the Entrance ng the Ten: Adjust the tension so that it becomes 1545 mm (0.59402 inch) between the 995-4325 under guide and 998-4320 flat belt when the belt is pulled with a 500g weight at the center of the 99S-4305 rollet and 921-3038 roller, Adjust using the adjusting screw (HS) so that the flat belt comes to the center ofthe 92-3038 roller, and secure it using the ‘998-4319 bolt stopper so that the hexagonal head of the HS screw does not tum. 2-WI0 995-4317 Haha C0 Units mm fic) VA HB 4X18(2NB) Adhudting sore (@m 1-15 Adjusting the Positioning of the Central Conveyance Flat Belt 1) Central conveyance guide + The 7 screws for the 998-4550 underguide and 998-4453, 998-4454 guides are M4X8(F) TP screws (regular metal screws). 99S-M2250-0004-0 1-251. OUTLINE OF MECHANISMS AND ADJUSTMENTS 2) Central conveyance belt + Please install as shown below and be sure that 966-1404 square metal plat is installed as shown in the diagram, 3) Central conveyance roller shaft desorption portion ‘+ When shaft 995-4631 of ASSY is mounted, screw column 998-4655 to the frame so that itis parallet with paper presser foot 998-4639. | | Central conveyance roller shaft Adjust the angles of 99-4652 paper presser foot desorption portion ‘guide base so that they do nai touch, (however, be sure thal the end of the papar presser is the carving Spor) ‘99S-M22S0-0004-0 1-261, OUTLINE OF MECHANISMS AND ADJUSTMENTS: oa usting the Folding Section 1) Folding knife View B Base + Atach the blade to the base with MSK3 x 6 and we WS Below the long hole ofthe Blade. — PV 888.3008 Blade ‘Attach to the frame, using the bracket so that the blade does not shake. Secure the blade using a tool so that the clearance between the square hole of the frame and bracket ofthe reference side ~ becomes 19:740.1 mm. (0:7840.004 inch) View A SED 20.32 01 Shaft 995-5603 1.190.004) View 8 2) 1st press rollers ‘Adjust the lower limit postion ofthe block. Adjust the clearance between the shaft ends of the. View A ! Angle Ist press rollers become 30.3 mm (1.19 inch} ‘SGH-5735 (Clearance:0.3 ram (0.012 inch)). Fix the angle to h the stopper screw attached to the block using the |, ¥ Screw for stoper fixing screw. I CFRAXE + At this time, please adjust the gears so that they ! mesh in such a way that the roller for dial no. 1 is \ set at 1 (see illustration). Pushed against here Block, 98H-5733 998-M2280-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 3) 3rd press rollers ‘Screw in the clearance sdjusting serew 2, and adjust it 0 that dhe clearance between the 3rd pees rollers Become 0.5 1mm (0.02 inch), and thea tighten the nut so that the screw docs not become loose. After adjusting clearance adjusting 2, move the clearance adjusting screw 1 against the angle unit, and Gghten the lockserew. ‘The angle unit serves as the stopper of the 3rd press roller. Press it against the block, and in tis stae, secure itto the sub frame. Clearance adjusting screw 2 CFR4X22 Angle unit justi SEH-5591 Clearance adjusting screw 1 Attach to clearance 0 Frame View A Clearance:0.5mm (0.02inch) Block 952-6129 S8H-5580 ‘Angle attaching View A position fas Z Center pin 3rd press roller For roller gap 3. clearance is 1to 1.5mm. {(0.004t00.06inch) 2nd press roller + Insert adjustment washer 12 x 18 x 0.5 (internal radius x external radius X thickness) on the L. side of the bearing. ‘support of press rolicr no. 3 of the drive and adjust so thatthe thrust direction gutter of the press rollers 0.5 - 1.0 mm (0.02 - 0.04 inches). Adjustment width 12 X 18 X 0.5 Thrust direction gutter 0.5 - 1.0 mm (0.02 - 0.04 inches} i R side Press roller No. 3 (Drive side) ‘998-M22S0-0004-0 4-281, OUTLINE OF MECHANISMS AND ADJUSTMENTS: 4) Side guide + Secure the side guide so that the distances from the frame L.1 and L2 are equivalent, and then adjust the angle of the side guide using the adjusting sorew so that the folding deviation when paper is passing is within the specification. ‘Adjust the angle of the auxiliary side guide using the adjusting screw so thatthe auxiliary side guide becomes parallel to the side guide. ‘Adjust the height for attaching the shaft so that the bottom side of the auxiliary side guide is level with the conveying side, Adjusting screw. CFR CFR 3X6 Side guide Tighten /99S-4551 995-4555 Fixing screw Li=40 Adjusting screw. 998-4552 Ri]; Paper holder R GR Angle CFR 3X6 Tighten Adjusting screw iz =. = u Frame side = 1 round hole 998-M22S0-0004-0 4-291. OUTLINE OF MECHANISMS AND ADJUSTMENTS 5) Ejection section paper holder ‘+ Adjust the parts of the shaft secured to the left and right so that the block moves smoothly. Fix at the bottom of the long hole SBS 15 ees Paper holder (| 9 Paper holder ‘Secure the shaft (998-5628) so that the block (9BH-5665) moves smoothly and there is @ gap between the stay (998-6115) and the block (98H-5665) and the tip of the paper holder (98-4662) does not face down. wo Folding Clutch + Check that the input side of the clutch can be rotated easily. + To adjust the stopping position, remove the C ring, and move to the chain. Move the stop case tothe chain side, release the clutch from the inner teeth, and insert into the desired position. The stopping, Position depends on whether rotation is manual ot by the motor. Perform the final adjustment according to rotation by the motor. Vv 998-M2280-0004-0 4-301. OUTLINE OF MECHANISMS AND ADJUSTMENTS: + Adjust as shown in the diagram so thatthe clutch stops. 15° Main shatt unt 40N sprocket ‘Sprocket unit ‘9H-5 123 saH5030_ + ‘Clutch case Bracket Ca (SSE ‘9732 octagonal wrench ha ‘38H-51 I Pate Boss unit 1-31 ‘aT goar =P Sprockat unt teler unt ring for shart ‘landard postin) ‘Stop postion, raleed GFRIZ4 nchXO ‘Oposie side fr Sm Gclagonal wrench 99S-Mz2S0-0004-01. OUTLINE OF MECHANISMS AND ADJUSTMENTS 1-18. Adjusting the Tension of the Belt Chain ‘+ To adjust the tension of the Ist deceleration belt from the main motor, loosen the lock nut, Loosen the four fixing screws attaching the motor base to the cabinet. In this state rotate the adjusting screw to the right and pall the motor base to tauten the belt ©. + Move and adjust the sprockets, ete. with the «~ —> mark so that the tension of the other belts and chains becomes as shown in the following = a ‘S— 15m] 5 15m 998-M2280-0004-0 1-322. MAINTENANCE @ Cleaning ‘+ Horizontal belt Use neutral detergent. + Rubber roller Use neutral detergent. * Press roller Use neutral detergent. + Sensors Use a vacuum cleaner. + Index ‘Metal label ene Use a vacuum cleaner. Fit Wipe with a dry cloth. + Leaving stitchs in the paper conveyance route may cause paper to jam. Be sure to remove them. + Remove paper bits using a vacuum cleaner. @ Points to be greased (Equivalent to Kyodo Oil Uniloop No.2) Apply a thin + Sliding side of the driving slide of the sttcher head + Clincher cam spur gear + Part engaged with worm gear and worm wheel of stepping moor deceleration mechanism + Chain Moving shaft screw of stapling head Moving shaft of clincher Solenoid link rotation supports + Support shaft of moving unit + Sintered bearing used in driving system @ Olling Points Lubricate part ® once a week and part ® once a month, Lubricate two to three drops of the lubricant provided each, ‘ime, 1-33 oe 71 Oo pial ‘@))o [S-eT TS_= ce 998-M2280-0004-03. HONER UNIVERSAL STITCHER HEAD Precautions on Work . Check that the power is off before performing adjustments and maintenance. . Keep your hands, tools, hair, and clothing away from the stitching area. Please familiarize yourself with the operating parts of the machine. Do not place your hand where you may injure your hands. }. A well-maintained machine is a safer machine. Ciean and oil your machine periodically. Also inspect the machine periodically for damages and wear of parts, and replace if necessary. Do not operate the machine if damages of parts are detected. » ene * This stitcher head may be modified for improvements without prior notice. 99S-M2280-0004-0 1343. HONER UNIVERSAL STITCHER HEAD 3-1. Per 1) Names and Functions of Parts Inspection and Replacement of Parts 1 i. 135 995-M2250-0004-03. HONER UNIVERSAL STITCHER HEAD No. Name Function © |Wire Guide Pin Guides the wire. @ |Wire Move-Back Stopper Unit. _| Prevents the wire supplied from being pulled back. @ [Felt Cleans the wire surface and lubricates slightly. @ | Adjusting Washer Use to remove the needle, ©® |Fixing Knob Fixes the wire bow to the wire tube, © [Wire Tube ‘Wire path. © | Wire Length Knurled Nut Rotating in the clockwise direction increases the wire length. Rotating in the counterclockwise direction decreases the wire length. ® [Triangular Handle ‘Used to manually switch whether to stitch or not. © | Supply Wheel Used to set the wire, When the ® triangular handle is set to “stitch”, it grips the wire, and when, in this state, the adjusting handle is inserted into the head of this wheel and rotated, it feeds the wire ® | Wire Tube Path of wire. © | Cap Screw ‘Secure the stitcher head and head holder using this cap screw (4 mn across). ® |Bot Adjusts the left and right bending and length of the wire when the adjusting handle is inserted into the head of this bolt and the cutting nit is moved. ® | Wire Straightener Straightens the wire. ® | Leaf Spring ‘Holds the © former. ® | Former ‘Holds the wire horizontally and forms in the C shape. @ | Adjusting handle Used for seting and adjusting the wire. (Provided with the unit.) 2) Wire + European wires:No. 26 to 30 + American wires:No. 25 to 28 ‘The wire diameter corresponding to these numbers will differ according to the region. Wire diameters from 0.500 0.35 mm (0.020 inch to 0.014 inch) can be used, but use ofthe 0.50 mmn (0.020 inch) wire enables stitching to be carried out most stably. 99S-M2280-0004-0 136. Vv3. HONER UNIVERSAL STITCHER HEAD 3) Straightening wires ‘+ Stitching operations are more stable when the wire reels are stright. If wires are not straight or when a problem has occurred, rotate the wite strainer slightly and change the wire path, If the problem does not go away after attempting various types of adjustments, remove the forming unit ®. Detach the ‘plate spring @ from the forming unit by pulling the lower part ofthe plate spring ® towards you and rotating it, and then pall out the forming unit towards you. Next feed the wire with the adjusting handle of the tool provided and observe if is fed crookedly or straight Ifthe wire is not horizontal, rotate the wire strainer © until the wire becomes straight. ‘After adjusting, remove unnecessary stitching needles by hitting the top of the cutting pusher lightly with a tool such as a screwdriver, etc, Install the forming unit back in and return the plate spring to its original position. ‘Adjusting in drection A et Agjusteg merecton B 8 \ Wire strainer 137 99S-M22S0-0004-03. HONER UNIVERSAL STITCHER HEAD 4) Basic settings of wire length ‘The wite length requited for stitching two sheets of paper is about 26mm (1.02 inch). To set to the compression for this type of stitching, rotate the adjusting screw until the top ofthe gear rack points wn Rotate the adjusting screw. Perform fine adjustments as follows. ~ Rotating the adjusting sorew to the right=Wire becomes long. + Rotating the adjusting screw to the left=Wire becomes short. “The total length of the 1.6 mm (0.06 inch) changes with every turn. Use “L” for the Loop stitch. 5) Setting the leg length ‘ice setting the total length of the wire, set so that the bent legs become equal Rotate the triangular handle © to the right, and open the supply wheel ®. Rotating the adjusting handle in the clockwise direction lengthens the right leg and shortens the Ieft eg. Rotating the adjusting handle in the counterclockwise direction lengthens the left leg and shortens the right leg. Adjust the center of the wire held by the forming tnt by this adjustment. ‘The wires should be of the same length as seen from the two sides of the forming unit, 99S-M22S0-0004-0 4-38, ‘Ajusting sorow Gear rok 2er ‘Adjusting handloG 3. HONER UNIVERSAL STITCHER HEAD 6) Adjusting the forming unit + Thestitching needle should be located at the center of the groove of the bender to ensure proper stitching operations. + Remove the stitcher head and adjust the forming unit, Loosen nut @ and adjusting using adjusting screw 6 TAN’ After adjusting, tighten the nut again carefully. 7) Adjusting the bender + Before performing this adjustment, adjust the machine to the minimum booklet thickness (0 compression for two sheets of paper). When the head is at the stop position, corrections may be required ifthe bender latch does not protrude 2.5 mm (0.1 inch) from the side. If adjustments are required, set the stitcher unic to the bottom most position, and remove the forming unit. Loosen the hexagonal screw ®, and loosen adjusting sorew @ by 1 to2 turns. “Afler adjusting, tighten the hexagonal screw again. Repeat this procedure until the bender operates normally. ‘The latch should project out just before the top dead center. epffox 25 mm (tine) 1-39 99S-M2280-0004-03. HONER UNIVERSAL STITCHER HEAD 8) Replacing the knife The quality ofthe stitching depends mainly on the knife state, The knife can be used many times by rotating it. a) Replacing the flet knife Loosen the hexagonal setscrew ®, remove the upright bolt ®, and then remove the cutting box. ‘Loosen the M4 flat head screw © of the flat knife and replace the knife. Assemble in the opposite procedure of disassembly, and using the adjusting handle (refer to "5)Setting the teg length”) 10 check that the upright bolt © is ightened enough for the cutting box to be adjusted, and tighten the hexagonal setscrew ®. 1b) Replacing the round knife “Loosen the hexagonal sotscrew @, remove the upright bolt @® and remove the cutting box. ‘Next, remove the cutting pusher (as the compression spring will he attached in the loaded state, be careful when removing it) loosen the hexagonal bolt ®, push out the round knife from the lef, and replace it. Assemble in the opposite onder of disassembly. ‘When assembling @ new knife, make sure the round knife protrudes out withthe cutting mouth on the opposite side 50 that reliable cutting effects can be obtained. To obtain good results, push the new round knife, and adjust so that a slight presario on te lt if When sing the ajsing hale (refer “Senge eg lenghchecktbat the ( "upright bolt @ is tightened enough for the cutting box to be adjusted, and tighten the hexagonal seiscrew ®. 998-M2280-0004-0 1-40JONER UNIVERSAL STITCHER HEAD 9) Replacing the bender Rotate the plate spring @ and remove the forming unit ©. Remove the hexagonal bolt ® and carrier unit, Remove the stopper while paying careful attention to the adjusting. washer. Push the bender downwards. ‘Assemble in the opposite order of assembly. 10) Replacing the screwdriver Rotate the spring @ and remove the forming unit ©. Remove the two studs (omamental screws) of the driver, and remove the driver downvvards. Assemble in the opposite order of assembly. ‘When the tip of the screwdriver becomes worn out or damaged, move the driver up and down to use it. ern ‘Adjusting washer Shoe tSogue 4-44 ‘998-M22S0-0004-03, HONER UNIVERSAL STITCHER HEAD 11) Adjusting the lower limit position of the bender + Loosen screw @, place the adjusting washer between the stoppers, and adjust the lower limit position of the bender. Adjust so that the bender and clincher box do not leave marks when stitching 2 sheats of 64 g/m fine quality paper. Push the adjusting washer completely with the stopper, and secure it. If not pushed completely, it may drop off. it~ ‘Adjusting washer 12) Adjusting the lower limit position of the driver + Loosen locknut ®, rotate the eccentrie bolt with hexagonal bolt, and adjust the lower limi position of the driver to 20.25 mm (20.01 inch). (normally located at the center.) 13) Replacing the clincher + Remove the two fixing scrows of the guide. ‘Tighten one temporarily and tit it refer to “1-1-4 1)Adjusting the clincher slide) and pull the clincher bar downwards, (refer to the service A manual ofthis unit) Rotate the two clinchers inthe clincher box upwards, and pull out from support ®. Push in the new clincher into the support, and rotate the clincher to the center of the clincher box. Insert the clincher bar again, ‘Ckincher box Cincher ber 99S-M2280-0004-0 410823. HONER UNIVERSAL STITCHER HEAD 3-2. Tr bleshooting The following describes several examples of malfunctions. Determine the causes and adjust accordingly. Replace all worn out or damaged parts. +The log should be adjusted longer than indicated for stable stitching so that the leg does not hit the needle, Jf the legis shor, it will bend or face outwards, ‘+ Applying a coating of oil over the needle will help reduce the load when rotating inside the pipe, and reduce the impact when the leg touches the clincher, Oiling is therefore very ‘important. 1, Arched spine + The wire may be weak or soft. ‘The wire is not straight.: Refer to “3)Straightening the wire” “The knife is worn out. -Refer o “8)Replacing the wire”. ‘The wire groove af the bender is dirty, or worn out, or damaged. Remove the bender, clean the left and right wire grooves (Refer to “9)Replacing the bender”), and replace the bender. ‘+ The direction in which the paper flows is not the same between the head and clincher. 2. The spine is not aligned + The driver was not pushed firm enough: Adjust the eccentricity bolt ofthe head. eS 3. The leg is not bent sufficiently + ‘The pressure of the stitch is too weak: The direction in which the paper flows is not the a a same between the head and clincher, + The clincher does not raise sufficiently:Adjust the clincher. 4. The spine is not aligned, or is curved + ‘The stitching pressure is to weak:Adjust the stitchi thickness of the stiteher unit. === + The wite is too weak or soft ‘+ Theshoe tongue pressure is weak, or a wire fragment got stuck. Remove the stuck wire fragment, or replace the shoe tongue compression spring:Refer to “6)Adjusting the forming unit”. 5. The leg is in contact and cannot bend correctly ite may be weak o soft. = Tete: is not straight. Refer to “3)Straightening wires” ‘The direction in which the paper flows is not the same between the clincher box and head. ‘The fength of the legs is not equal:Refer to “5)Setting the leg length”. ‘The total length of the wire is too short Refer to “4)Basic setting of wi ‘The round knife or flat knife is wora out-Refer to “8)Replacing the kni length” 6. The needle does not pierce ‘The wire may be weak or soft ‘A wire fragment got stuck in the bender groove, ‘The knife is worn out:Refer to “8)Replacing the knife” The wire groove of the driver is dirty or wor out, or damaged:Remove the driver, clean the left and right wire grooves (refer to “10)Replacing the driver”), and replace the driver. + The shoe tongue spring pressure is weak: A wire fragment got stuck, or replace the shoe tongue compression spring: Refer to "6)Adjusting the forming unit”. + The clincher box position is not appropriate 4-43 995-M2280-0004-03. HONER UNIVERSAL STITCHER HEAD 7, The log is bent ‘The latch is not adjusted:Refer to “7)Adjusting the bender”, * The wire is fragi Ise other quality wires. ‘+The spring or gripper in the forming unit is damaged. *+ Wire pieces are stuckin the forming unit:Remove the forming unitand remove the wire fragment stuck, + The latch spring or latch is broken. + The hook spring of the bender is broken. + The wire diameter is not appropriate for the bender and driver parts, 8. One side is swollen The wire is weak or soft. + The driver is broken:Refer to “10)Replacing the driver” + The knife is worn out-Refer to “8)Replacing the knife” + The width direction of the paper is not correct between the clincher box and head. 9. The legs are overlapping or separated + The wire is not straight:Refer to “3)Straightening the wire” + The knife is worn out: Refer to “8)Replacing the knife 10. One leg is bent in the opposite direction +The wire is not straight-Refer to "3)Straightening the wire™ +The width direction of the paper is not correct between the. 11. One or both legs are formed crookedly +The wire may be weak or soft, ‘The wire is not straight Refer to “3)Straightening the wire” ‘The knife is worn out:Refer to “8)Replacing the knife” ‘The clincher is damaged‘Refer to “13)Replacing the clincher” “The head is attached twisted tothe clincher. 12, The legs are formed crookedly in the same direction + The wire is not straight:Refer to “3)Straightening the wire” + The direction in which the paper flows is not the same between the clincher box and head. 13. Slightly bend wire falls from the head + The wire is not straight:Refer to “3)Straightening the wire” + The spring of the bender hook is damaged 14. The wire is bent between the supply wheel and wire tube ‘The wite is not straight:Refer to “3)Straightening the wire” ‘+ The tip of a wire cannot enter the round knife and is jammed:Refer to “3)Straightening the wire” ‘+ The lower wire tube is at the wrong posit up or down, ‘+ The forming unit is not adjusted comectly:Refer to “6)Adjusting the forming unit” + There are needles stuck in the wire tube, n, or is not adjusted correctly:Move slightly ‘99S-M2280-0004-0 4-44 ec Zz Le3, HONER UNIVERSAL STITCHER HEAD 3-3. Exploded View 46 00 098 32 67 113 4400 098 32 63 105 Ab 00105 Ab 00 037 32 63 104 4h 00 099 7403 010 32 63 109 36 61 006 76 03 025 80 06 008 74.03.040 80 06 008 ~S 37 63 108 38 51 105 83 04 008. 80 06025 3 32 67 105 92 00012 37 67 515 7806 4011 38 63 103 9300002 99S-M2250-0004-03. HONER UNIVERSAL STITCHER HEAD ¢ og 4 44 00096. “| 80 05 004 3 8006010 3161 009 9961 208 44 00 099 4011 6014 32 61210 94 59 210 998-M2260-0004-0 1-46 32 61 206 3251016 3461117 3963 123 6205 016 3163 124 4400159 5206 005 3.05 000 9h 61 2043. HONER UNIVERSAL STITCHER HEAD ©—— 66 06 000 92 00 002 36 61 007 80 05 006 31 63126 66 08 000 4100 013 37 63 015 79 04 006 998-1004 4-47 998-M2280-0004-03. HONER UNIVERSAL STITCHER HEAD 79:03 005 31 63 134 47 03 210 0 05 006 32 63111 (83 06 014) 32 63 320. 66 08 000. 31 63 20° 76 04010 s 62 04 010 (32 65 117) 92 00 010 Kennzahl-code"0*| {32 53 514) (99 63 342) 99S-M22S0-0004-0. 1-483. HONER UNIVERSAL STITCHER HEAD 3851319 3161322 37 51 316 16 03 006 31 63326 3951318 32 63 310 a 32 $1322 37 63 305 > 34 53 309 39 63 334. * u 75 03 008 z 37 63 398 32 63 397 46 00 036 a 63 307 32 63 312 99 61 316 1-49 998-M2280-0004-03. HONER UNIVERSAL STITCHER HEAD 76 04 008. 32 54 213 96 51 213 39 61 205 34 61 202 70 04 000 4 . 47 04 320 ( 40.00 801 ] | vw 36 61 207 32 65 210 I 96 65 240 ty 62 04010 a> 37 59 209 62 04 012 —— “ 76 05 012 a - , (e) 84 04008 32 61 109 79 03 006 33 61 213 70030001 99S-M22S0-0004-0 1-503. HONER UNIVERSAL STITCHER HEAD 31 63 187 9463168 (94 61172) 85 04 0061 94 63 188 3751129 3354 128 3954017 70 06 0001 9300 022 39 63 182 50 01 400 (99 63 179) +61 ‘998-M22S0-0004-03. HONER UNIVERSAL STITCHER HEAD 68 04 000 80 04016 3267520 3251 322 3163 339 9200 013 3967518 3167 512 99 63 335 .99S-M2280-0004-0 1523. HONER UNIVERSAL STITCHER HEAD 99 61 600 3138

Stitching Position Lamp. [E15 & Folding Position Lamp (@ © Input Memory Lamp SESBSFEBSe38eo9ea 22 @ ® @ @ ® ® @ ® ® @ @ @ @ @ ® @ ® @ @ @ 7 @ Select Memory Key © Execute Memory Key Escape Key Fupetion Key @® shin Key ‘Change Key © Number Keys ]) Cancel Key © sekey @ Select Stitch Key (@} Select Fold Key Step Mode Key ©@ Select Unit Key Move (7 >) Key Move (<4) Key @] Select Parallel Movement Key G Parattet Movement (> )Key EJ Paraltet Movement (—) Key (8) input Memory Key Jog KeyoO 1. Service Mode PSC me oad miele sy First, turn ON the power of the DBM-400. When tured ON, a buzzer will be sounded and at the same time the following will be displayed on the LCD panel. POWER ON 1. [99882774] 1 fBRSR277H nog. se sie dipyetin on Blinks «--~ Standby OK. ‘Tocenter the service mode (each test mode), check that no errors have occurred (if an error as occurred, recover first), and while pressing the SHIFT key and CHANGE key (5) , press the FUNCTION key . Menu 1 will be displayed on the LCD. ‘The following items are described from this stat. 1-2. ON/OFF Operations 1 (Solenoid) 1) Press TEN key @) ©, or select [2. SOLENOID] on the LCD using the MEMORY key ©, and press the ENTER key ©. (Pressing the ENTER key © enables selection of the following ‘sub-menus.) + Menu 1. NOT USE + 2. SOLENOID 3. CLUTCH 4, STEPPING 5. OTHER 6. SETTING 7. SEN CHECK 8, MODE SELECT 2) Toturn ON/OFF the desired solenoid, while viewing the contents of the LCD, select the following menu using the MEMORY key ®, select the desired solenoid, and then press the ENTER key © to turn ON the solenoid. Pressing the ENTER key @ another time turns OFF the solenoid. Each time the ENTER key © is pressed, the solenoid tus ON/OFF repeatedly. Topertorm ON/OFF operations drectly, press the TEN key corresponding to the menu number. When connecting DC-48LU2, pressing the TEN key @_) © enables the reject solenoid to be turned ON/OFF. (The ON/OFF display only changes.) ‘+ Side jog is performed three times when [1. SIDE JOG] is set while pressing the SHIFT key 5. ‘+ Perform ON/OFF operations while taking note of the duty ratio of the solenoid. 2. SOLENOID Duty ratio 1.SIDEJOG Side jogger ON/OFF = (I/i) 2C_STOPPER — Saddle-stitching stopper. ON/OFF = (1/1) 3.S STOPPER Side-sttching stopper ON/OFF (1/1) 4.B_STOPPER Back stopper ON/OFF = (172) S.FSTOPPER Folding stopper ON/OFF = IN) 6 $0UT1 (Stitcher front) roller 1 ON/OFF (1/2) 7.$0UT2 (Stitcher back) roller2 ON/OFF (12) 8.FOUT! (olding back) rolier3. ON/OFF == (Nt) 9729 ABLU reject ONOFF (1/3) 28 ‘99-M2280-0004-01. Service Moda ON/OFF Operations 2 (Clutch) 1) Press TEN key @) ©, or select [3. CLUTCH] on the LCD using the MEMORY key ©, and press the ENTER key ©. (Pressing the ENTER key © sets the following sub-menus.) * Menu 1. NOT USE, 2. SOLENOID — 3.CLUTCH 4. STEPPING 5. OTHER 6, SETTING 7. SEN CHECK 8, MODE SELECT 2) To turn ON/OFF the desired clutch, while viewing the contents of the LCD, select the (.) following menu using the MEMORY key ©, select the desired clutch, and then press the ENTER key @ to turn ON the clutch. Pressing the ENTER key another time turns OFF the clutch. Each time the ENTER key © is pressed, a clutch turns ON/OFF. To tum the clutches ON/OFF directly, press the TEN key corresponding to the menu number. if the main motor is rotating, the following can be performed. = Stitching (one time) is performed when [1.STITCHER] is set while pressing the SHIFT key ©. + Folding (half rotation) is performed when [2. F_BLADE} is set while pressing the SHIFT key ©. 3. CLUTCH I.STITCHER —Stitcher/spring clutch ON/OFF. 2. F_BLADE Folder/spring clutch ON/OFF 3. DELIVERY Conveyance belt/clutch ON/OFF 4.MAIN.M Main motor ON/OFF 5. NOTUSED 6, NOT USED oO T.STACKER Stacker motor ONIOFF 8. FAN Fan motor ON/OFF es is mode very carefully as it is very dangerous. In particular, do not use it while the interlock has been released intentionally as it is very dangerous. When more than two persons are using unit, precautions should be taken to ensure the safety of one another. ‘998-M2280-0004-0 241. Service Mode. 1-4. Independent Operations (Stepping Motor) 1) Press TEN key G_) ©, or select [4. STEPPING] on the LCD using the MEMORY key ©, and press the ENTER key ©. (Pressing the ENTER key ® enables selection of the following sub-menus.) + Menu 1. NOT USE 2. SOLENOID 3. CLUTCH + 4. STEPPING 5. OTHER 6. SETTING 7. SEN CHECK 8, MODE SELECT 2) To turn ON/OFF the desired stepping motor, while viewing the contents of the LCD, select the following menu using the MEMORY key ©, or press the TEN key corre- sponding to the menu number to select it directly. After selecting the stepping motor, press the ENTER key © to begin operations. 3) The stepping motor can be rotated in the desired direction by pressing the corre- sponding Move key &, ©. The stepping motor moves by about 0.1 mm (0.004 inch) each time the Move key ®, ® is pressed. Itcan be moved by about 1 mm (0.04 Inch) by pressing the Move Key @, @ while press- ing the SHIFT key ©. 4. STEPPING: 1. SIDE-G Side guide Moves 2.J0G Jogger Operates 3.BACK} Back Jogger Moves 4.S-STOP, Saddile stitching stopper ‘Moves: S.BSTOP Back stopper Moves 6. F-STOP, Folding stopper ‘Moves 4. STIT-R Right stitcher head Moves, SSTIT-L Left sttcher head Moves + Toselect a different unit, first press the ESCAPE key @. + Tho 6 digits displayed immediately after pressing the arrow key @, © correspond to the number of pulses from the origin of the unit, ‘The following cannot be performed if the service mode (8. MODE SELECT- I, Memory Switch-1, Protect-]] is not set to OFF. ‘When Mave key ©, © is pressed while pressing the CANCEL key @, that unit can be moved together continuously. E « In this mode, as software restriction of disturbances between units is not effective, be careful that units do not touch or hit each other. + When the ESCAPE @ is pressed in this mode, and the main menu is returned, the Input Memory Lampli8liights up, indicating that the memory number currently displayed can be overwritten. If it is not to be overwritten, press the CANCEL key ® so that is goes off. 25 ‘99S-M2280-0004-01. Service Mode 1) 2) gle Operations (Stepping Motor) Press TEN key G_) @, or select [5. OTHER] on the LCD using the MEMORY key ©, and press the ENTER key ©. (Pressing the ENTER key © enables selection of the following sub-menus.) Menu 1. NOT USE 2. SOLENOID. 3. CLUTCH 4, STTEPPING > 5.OTHER 6. SETTING 7. SEN_CHECK 8. MODE SELECT To perform the desired operation, while viewing the contents of the LCD, select the W following menu using the MEMORY key ©, select the desired operation, and then press the ENTER key © to begin the operation. The operation can aiso be selected directly by pressing the TEN key © corresponding to the menu number. When a single operation is executed, the back jogger and side jogger move to the paper holder. When executed again, they move back to the paper feeding position. A single operation can be executed every time this is repeated. + Jogging is performed N times (the number of times set according to the number of jogs) when (1.BACK JOG} is set while pressing the SHIFT key © + Jogging is performed N times (the number of times set according to the number of jogs) when [3.JOGGER is set while pressing the SHIFT key ©. ‘When pressed another time, only the pusher recovers. When pressed yet another time, the side guide recovers. 5. OTHER, 1.BACJOG — Back jogger Operates Only the back jogger operates 2,SIDE_G Side guide Operates Only the side guide operates 3.JOGGER Jogger Operates The whole jogger operates Execute [3. JOGGER] operations individually only. Avoid performing together with {1. BACK JOG] and [2. SIDE G) operations. In this mode, after completing operations, return the jogger and side guide promptly to their original position (paper feed position). if the side guide state, the machi When the back jogger is left raised for more than one minute at the paper holder position in [3. JOGGER] operations, the driver may be subjected to excess load and malfunction as a result. moved with the back jogger left in the paper holder position (raised) (pusher (back jogger) and side guide, etc.) may damage. 99S-M2280-0004-0 26 04. Service Mode g Motor Counte: 1) Press TEN key @ ©, or select [6. SETTING] on the LCD using the MEMORY key ©, and press the ENTER key ©. (Pressing the ENTER key © enables selection of the following sub-menus.) * Mena 1. NOT USE 2. SOLENOID. 3, CLUTCH 4, STEPPING 5, OTHER + 6,SETTING 7, SEN_CHECK 8, MODE SELECT 2) To perform the desired operation, while viewing the contents of the LCD, select the following menu using the MEMORY key ©, or press the TEN key ® corresponding to the menu number to select it dil After selecting the desired item, press the ENTER key @ so that the following check item can be selected. Each item is described below with specific examples. 1. Checking/setting counter data of each size memorized currently. For example, check and reset the counter data of the memory number 5 [*5. M2 170 x 120] ([*5. M2.6.7 x 4.7]) side guide. First, select No. 1 [*1, ROM CNT CHECK] on the menu as follows. Press TEN key () ©, or select {*]. ROM CNT CHECK] on the LCD using the MEMORY key ©, and press the ENTER key © (Pressing the ENTER key ® enables the following check items to be selected. 6. SETTING -* LROMCNT — CHECK 2. OFF-SET CHECK 3.RAMCNT CHECK 4. IDX CNT CHECK 5.COUNTER CHECK 6. INITIALIZ 7. PARAMETER [Noxt, select MEMORY No. 5 [#5.M2 170 x 120] ([¢5. M2 6.7 x 4.71) on the menu as follows, Press TEN key @_) ©, orselect [*5. M2 ### x ###] on the LCD using the memory key ©, and press the ENTER key ®. (Pressing the ENTER key @ enables the following check items to be selected.) 1, ROM CNT CHECK 1.03 (LD) 2AaLT 3.A4LD 4M ~ 5M2 6.M3 7.M4 8.MS Finally, select motor number | [*1. SIDE-G 00 ####] as fotlows. 27 995-M2280-0004-01. Service Mode Press TEN key () @, or select [*1. SIDE-G 00 ####] on the LCD using the MEMORY key 1. * The 6 digit character displayed at this ime is the desired data. “This data is the number of pulses of the stepping motor. “The folding stopper and side guide (motor numbers 3 to 6, 1)is about 0,05 mm (0.002 inch) per pulse from the back jog, and the stitcher head (motor numbers 7 to 8) is about 0.004 mm (0.0002 inch) per pulse 3. ML Wi x 8 + LSIDE-G — 00H 0.050 mm/Pulse 2.506 Onset 3.BACKI — O0#HH# 0.050 mmvPulse 4.S-STOP OOH (0.050 mm/Pulse S.BSTOP OOH (0.050 mmvPulse 6.FSTOP OOH 0.050 mmvPulse 7STIER — OwHiHH 0.004 mm/Pulse S.STIT-L Gi 0.004 mny/Pulse + The following describes how to reset (change) this data. First, press the CHANGE key ® in the current state (above state). Next, press TEN key 0 © more than 6 times, and clear the data. (The ERASE key @ cannot be used at the moment.) ‘Then input the new data (6 digits) using the TEN key ©. Finally press the MEMORY key ® and save (change) the data. ‘When the other data has changed, pressing the Escape Key @ enables selection, Advantage of this mode ‘When the main board must be replaced due to malfunction, if the data can be checked like as above, data until now ean be used efficiently by extracting the data before replacement and setting the new board again. + Menu-* — 6,SETTING-* — 1. ROMCNT CHECK LABLD) MX BE 1.-8, 2AMLT) tx HH 1-8. B.AM(LT) ie HE 18. 4.M1 White He 18 5.M2 tx He + L.SIDE.G OOH 2.50G OE 3.BACK- OORHEE 4.$-STOP OO S.B-STOP OO##R 6. RSTOP Omit TSTIE-R Ont 8.STIT-L Ome 6.M3 si HAE TR, 998-M2280-0004-0 28Go 1. Service Mode 2. Checking/setting offset data currently memorized. For example, to check and reset the offset data ofthe side guide of motor number 1 [+1. SIDE-G 00 #4), First, select (#2. OFF-SET CHECK] on tbe menu as follows. Press TEN key @_) ©, or sclect [*2. OFF-SET CHECK] on the LCD using the MEMORY key ©, and press the ENTER key ®. (Pressing the ENTER key @ sets the following sub-menus.) 6, SETTING L.ROMCNT — CHECK 2. 0FF-SBT CHECK 3.RAMCNT CHECK 4, IDX CNT CHECK S.COUNTER CHECK 6. NITIALIZ 7. PARAMETER Finally, select motor number I [*1. SIDE-G 00 ####] as follows. Press TEN key (L_) ©, or select [*1. SIDE-G 00 st] on the LCD using the MEMORY key @. + ‘The 6 digit character displayed at this time isthe desired data. ‘This data isthe number of pulses of the stepping motor. ‘The folding stopper and side guide (motor numbers 3 to.6, 1) is about 0.05 mm (0.002 inch) per pulse from the back jog, and the stitcher head (motor numbers 7 108) is about 0.00 mm (0.0002 inch) per pulse 2. OFF-SET CHECK + LSIDE-G —O0#HHE 0.050: mmvPulse 2.J0G Cd 3.BACK-J OOH 0.050 mm/Pulse 4.S-STOP OHHH 0.050 mmvPulse S.B-STOP OOH 0.050 mnvPulse 6.E-STOP — OOH#HHE 0,050 munyPulse 7.STIT-R OHH 0.004 mm/Pulse .STIT-L — OBHRHE 0.004 mnvPulse + The following describes how to reset (change) this data, First, press the CHANGE key © in the current state (above state). Next, press TEN key @_) ® more than 6 times, and clear the data, (The ERASE key ® cannot be used at the moment.) ‘Then input the new data (6 digits) using the TEN key ©. Finally press the MEMORY key @ and save (change) the data, ‘When the other data has changed, pressing the Escape Key ® enables selection. * Advantage of this mode ‘When the main board must be replaced due to malfunction, if the data can be checked like as above, data until now can be used efficiently by extracting the data before replacement and setting the new board again + Role of offset data Basically, this offset data is not required ifthe machine origin isthe absolute value. However itis difficult for it t0 be ‘elative, and to perform origin adjustment when assembling the device. ‘Therefore, by calculating how much the origin has deviated using the above modes in the adjustment step, and inputting it as offset data, it will be possible to match the actual position and the displayed position without performing origin adjustments. 29 99S-M2280-0004-01. Sarvice Mode + Calculating the offset data Calcutate the offset data based on A3 (420x297). First, adjust the guides and stoppers to A3 paper by inputting numbers and fine adjustments. (For details, refer to "6-4. Finely Adjusting the Step Mode",) ‘Next, write the memorized data using methods —1 (described earlier) and -3 (described later). (Note down the memorized data) Basic calculating method Offset data=Counter data-reference data Ifthe results of the above equation is positive, it can be used. If negative, perform the following calculation. Offset data-65536 + (-) above results ‘Motor No. Name Reference Data ‘Counter Data, ‘Offset Date Data(A3) | Data(LD) ( Dala(aa) | Data (LO) # ‘Side guide 1100 1652 1034 0 2 Jouaer = = = 6 Back jog 30 BE 3052 12 7 380 1 37 (65503 e 880 12 2 S458 #6 380 762 907 2 #7 Stitcher head R. 15313 12 15800 14659 287 #8 Stitcher head L. 328 30388 32550 30500 12 -3. Checking and setting the current counter data For example, to check and reset the counter data of the side guide of motor number 1 [*1, SIDE-G 00 ###]; First, select [*3. RAM CNT CHECK] on the menu as follows. Press TEN key @_) ©, or select [*3. RAM CNT CHECK] on the LCD using the MEMORY key ®, and press the ENTER key 8. (Pressing the ENTER key ® sets the following sub-menus.) 6. SETTING 1, ROM CNTCHECK 2. OFF-SET CHECK + 3.RAMCNT = CHECK 4.1DX CNT. CHECK S.COUNTER CHECK 6. INITIALIZ 7. PARAMETER Finally, select motor number I (*1. SIDE-G 00 #####] as follows. Press TEN key () @, or select [*1, SIDE-G 00 #t##] on the LCD using the MEMORY key 1. + The 6 digit character displayed at this time is the desired data, This data is the number of pulses of the stepping motor. ‘The folding stopper and side guide (motor numbers 3 to 6, 1) is about 0.05 mm (0.002 inch) per pulsc from the back jog, and the stitcher head (motor numbers 7 to 8) is about 0.004 mm (0.0002 inch) per pulse. 998-M2280-0004-0 2-101. Service Mode 3. RAM CNT CHECK + L.SIDE-G QOH 0.050 mun/Pulse 2.506 Onn = 3.BACK-J OOH 0.050 mnvPulse 4,S-STOP — O0###H 0.050 mm/Pulse 5.B-STOP O0##H# 0.050 mm/Pulse 6.F-STOP OOH 0.050 mmvPulse T.STIT-R — OmHHEE 0,004 mm/Pulse B.STIP-L — OmMHEE 0.004 mmvPulse ‘+ The following describes how to reset (change) this data. First, press the CHANGE key @ in the current state (above state). Next, press TEN key @_) © more than 6 times, and clear the data. (The ERASE key ® cannot be used at the moment.) ‘Theo input the new data (6 digits) using the TEN key @. ‘Finally press the MEMORY key © and save (change) the data. When the other data has changed, pressing the Escape Key @ enables selection. * Advantage of this mode ‘When the main board must be replaced due to malfunction, if the data can be checked like as above, data until now can be used efficiently by extracting the data before replacement and setting the new board again. If the current guide and stopper positions are considerably different from the counter data, this data can be reset beforehand to prevent accidents and malfunctions. 4. Checking the current index counter data For example, to check and reset the index counter data of the side guide of motor number 1 [*1. SIDE-G 00 #4}, First, select [*4. IDX CNT CHECK] on the ment as follows. Press TEN key @_) ©. or select {*4, IDX CNT CHECK) on the LCD using the MEMORY key ©, and press the ENTER key ® (Pressing the ENTER key @ sets the following sub-menus.) 6, SETTING 1.ROMCNT CHECK 2. OFF-SET CHECK 3.RAMCNT CHECK + 4.IDXCNT CHECK S.COUNTER CHECK 6. INITIALIZ 7. PARAMETER Finally, select motor number I [*1. SIDE-G 00 ####] as follows. Press TEN key (_) @, or select [*1. SIDE-G 00 #####] on the LCD using the MEMORY key @. The 6 digit character displayed at this time isthe desired data. ‘This data is the mumber of pulses of the stepping motor. ‘The folding stopper and side guide (motor numbers 3 to 6, 1) is about 0.1 mm (0.004 inch) per pulse from the back jog, and the stitcher head (motor numbers 7 t0 8) is about 0.008 mm (0.0003 inch) per pulse. ott 998-M2280-0004-01. Service Mode 4,1IDX CNT CHECK > LSIDEG — 00m 0.1 mm/Puse 2.506 One 0.1 mnm/Puse B.BACK} Ooi 0.1 mmPuse 4S-STOP — OOi#HHH 0.1 mmPuse S.B-STOP OW 0.1 mmvPuse 6.RSTOP OOH 0.1 mm/Puse 7.STIT-R — OWMHHH —0.008 mm/Puse S.STIT-L ORM 0.008 mm/Puse + Validity of this mode Use this mode to check if the stepping motor loses its synchronization, etc. ‘The index plate is set to “100 pulses/totation” in respect to the “200 pulses/rotation” ofthe stepping mode. For instance, if there are scratches on the index plate and pulses (1 pulse) cannos be detected; ‘And the “*1.SIDE-G” data of the [*3.RAM CNT CHECK] described previously is “2000”, since the normal value of {*1 SIDE-G) daia ofthe [*4.1DX CNT CHECK] should be “1000”, the number of rotations of te stepping motor would ‘be “2000/200=10 rotations”, the index counted data would be “990" from “(100+1) x 10 rotations”, which is 10 pulses Tess. ‘As detection if the moving unit loses its synchronization is performed by (RAM CNT DATA)+2 - (IDX CNT DATA) =120 pulses (Within: OK, Outside:Erron, iferrors occur (41 10 48) only if the moving distance is lang, it can be checked easily by the above check. 5. Checking the operation counters For instance, to check the number of [*1.ST 1st stitch operations; First, select Menu No. § [*5.COUNTER CHECK} on the menu as follows. Press TEN key ©) © or select [*5.COUNTER CHECK] on the LCD using the MEMORY key ©, and press the ENTER key ® (Pressing the ENTER key © enables selection ofthe following sub-menus.) 6. SETTING 1.ROMCNT CHECK 2. OFFSET CHECK 3.RAMCNT CHECK > 4.IDXCNT CHECK S.COUNTER = CHECK 6. INITIALIZ 7. PARAMETER Next, select the number of stitch operations [* LST Ist] as follows. Press TEN key (©) ®, or select [*1.ST 1st] on the LCD using the MEMORY key ©. ‘The 6 digits displayed is the counter data of the first register. Finally while pressing the Shift key ©, press the TEN key ® to display the counted data of the second register on the LCD. The counted data of the second register is “1=65536” and the total with that of the first register is the desired count data. (The maximum value of the register is 65535 (from OFFFFh}). For instance, if the second register is “3” and the first register is “12000”, then 65536 x “3"+"12000"=208608. ‘The maximum values when the counters are added are 4294967295.) (5 million rotations=Second register “76”, first register “19264".) 998-M2280-0004-0 2421. Service Mode 6. SETTING 5, COUNTER CHECK LST ist 2. FD Ist 3.RN Ist 4ST 2nd 5. BD 2nd 6.RN 2nd T.SIEC 8&.P-ON 9. START ‘Total stitching operations counter ‘otal folding operations counter Total running time counter Stitching operations counter Folding operations counter Running time counter Total no. of size changes ‘Total no. of power “ON"s Total no. of starts ‘Counter data [*6 SETTING-S COUNTER-1. 0 9.} Refer to [J], [4] for the endurance limit of the stitch components parts. Refer to [2], [5] for the endurance limit of the folder component parts. Refer 10 [3), (6} for the endurance limit of the main motor and driving unit Refer to [7] for the endurance limit of the components relating to size change. Refer to [8] for the endurance limit ofthe power switch and power supply. Refer to [9] for the endurance limit ofthe main motor and main relay. LCD Display [4ST Ist 065535] [2.ED Ist 065535] [°3.RN Ist 003600] [4.ST 2nd 003600] [*5.FD2nd 065535) [*6.RN2nd 065535] [7.SIZEC 065535) [°8.P-ON 065535} [9. START 065535} ‘When the correspor LCD Display F1.ST Ist 065535] (2.FD Ist 065535) [73.RN Ist 065535] [4ST 2nd 065535) [*5.PD 2nd 065535] [*6.RN 2nd 065535} (*7.SIZBC 065535] [*8.P-0N 000000] 19, START 065535] “1,2,4, 5,7 t0 9” counts up the second register every time the first register becomes “65535-*0", Data (st register) Stitch toxal counter Upper limit of display=65535 Folder total counter Upper limit of disptay=65535 Running total counter Counted down from 3600 seconds Stitch second counter Upper limit of display=65535, Folder second counter Upper limit of display=65535 Running second counter Counted down from 3600 seconds Size change counter Upper limit of display=65535 Power [ON] counter Upper limit of display=65535 Start counter Upper limit of display=65535 “TEN key is pressed while pressing the [Shift] key @ Data ‘Ond register) ‘Stitch total counter Upper limit of display=65535 Folder total counter Upper limit of display=65535 Running total counter Upper limit of display=65535 ‘Stitch second counter Upper limit of display=65535 Folder second counter Upper limit of display=65535 Running second counter Upper limit of display=65535 Size change counter Upper limit of display=65535 Limit processing counter Upper limit of display=65535, Start counter Upper limit of display=65535 Unit No. of times No. of times Seconds No. of times No, of times Seconds No. of times No. of times No. of times Unit No, of times No. of times Hours No. of times No, of times Hours No, of times Sets No. of times “3 and 6” count the index pulse of the main and count down the firs register by one (about 1 second) taking 528 pulses as 1 count ((792 rpm/60 seconds) x 40 index =528 pulses) and count up the second register by 1 (about 1 hour) when the first repister becomes “3600-*0”. For instance, if the second register is “123”, and the first register is "600", the first register becomes “(3600-600)160 seconds=50 minutes”, and the operating time is about 123 hours 50 minutes. 243 ‘996-M22S0-0004-01. Service Mode + Maintenance Even when replacing the main unit due to malfunctions, if the counted data can be reed normally, its recommended that the data be noted down before replacing the maia unit, and the various data of the new unit be then re-input (set). ‘This enables maintenance to be continued from the previous maintenance. For instance, if its known after how many hours or times a part has become worn out or malfunctioned, it would be. possible to replace the problem part (or warn the user, etc.) before the machine stops due to malfunction of the part, thus ‘enhancing customer services. Re-inputting (setting) the counted data; Details displayed on the LCD 1) Setthe service mode. (%6. SETTING] 2) Press the TEN key ©] &. {*1. ROM CNT CHECK], 3) Press the ENTER key ®. (5. COUNTER] 4) Press the TEN key @)) ©. [*5. COUNTER] 5) Press the ENTER key ®. [e4. ST 2nd Come 6) Press the TEN key (©) ® (for example). [*4. ST 2nd OOF] 7) Pross the CHANGE key ©. 8) Input any number using the TEN key. For instance, to set to 0, input Osix times. (4. STP 2nd 000000] 9) Noxt, press the MEMORY INPUT key © to memorize. [*4. ST 2nd 000000} 10) Press the ESCAPE key ® 11) To input for other counters, return to step 6) above, 12) To end, press the ESCAPE key © 3 times slowly. ‘The above is a basic procedure, * To re-input (reset) the counted data 1 to 3, and 7 10 9, the protect must be cleared. As counted data I to 3 and.7 to 9 are, {otal counters and therefore difficult to rewrite, so they are protected or the aim may not be achicved. For details on clearing the protect, refer to “7-9. Releasing the DBM-400 Protect”. ‘995-M2250-0004-0 2441. Service Mode 6. Initialization The content and functions of “6-6, INKTIALIZ” in DBM’s service mode are as follows. However, these functions can only bbe operated ifthe “8-1-1. Protect” setting is OFF. Please also be aware that the content for the DBM-200 and 250 may be partially modified. [Overview] “This mode has functions prepared for factory adjustments and settings and is only used by service personne! in special cases. ‘By selecting a menu, holding the Shift key © down and pressing the SET key ®, functions will change as shown below, becoming avaitable for use depending on the purpose. Menu 1 6. SETTING 6. INITIALIZ, (Linplemented after menu has been selected) L.INITIALER2ROM —_ Initializes E2-ROM size data (nos. 1 o 8) 2. RESET S-RAM Initializes S-RAM SM end LED systems, 3, COUNTER RESET _ Initializes S-RAM counter data 4, OFF-SET CAL. Caleulates F2-ROM offset data (only no. 2is set to 0) S.BACKUPE2ROM Saves £2-ROM counter data (E2-ROM < RAM) 6.PARAMBTER RES Initializes E2-ROM parameters 6. INFTIALIZ (+ Shift) (Implemented with Shift key © held down, after menu has been selected) LINITIALE2ROM —_ Initializes E2-ROM size data (nos. 410 8) 2. RESET S-RAM Initializes S-RAM function group 3. COUNTER RESET Initializes E2-ROM counter data 4, OFFSET CAL. Calculates E2-ROM offset data S.BACKUPE2ROM Reads E2-ROM counter data (RAM < E2-ROM) 6. PARAMETER RES Initializes E2-ROM parameters Note) EZROM : EEP-ROM (programmable read-only memory that can be electrically erased) S-RAM: —S-RAM (static random-access memory) SM ‘Stepping motor [Detaited Content] ‘There are two possible patterns of operation while confirming LCD content: using the SET key ® alone or using the SET key ® with the Shift key ® pressed. As the content will differ depending on the menu, please use these patterns according to your purpose. 1) Pressing the SET key ® only after confirming selection (1) 1 INITIAL E2ROM: Initializes E2-ROM size data (nos. 1 to 8) Initializes (sets to the standard) all data (nas. | to 8) within service mode “6-1. ROM CNT CHECK” based on the offset data. (2)2.RESETS-RAM: Initializes S-RAM’s stepping motor (SM) and LED systems Initializes all SM- and LEsD-related data in $-RAM and writes the S-RAM data check code (99). UNTER RESET ; Initializes S-RAM counter data izes (resets) all counter data in S-RAM, (4. OFF-SETCAL.: Computes and modifies E2-ROM offset data Based on paper-size data in accord with the DIP-SW-1 setting, computes and modifies all offset data within service ‘mode's “6-2. OFF-SET CHECK,” setting only 10. 20 2et0, (9) 5. BACKUP E2ROM : Saves E2-ROM counter data (ROM < RAM) Backs up and stores to E2P-ROM all counter data within service mode's "6.5. COUNTER CHECK.” 245 998-M22S0-0004-01. Service Mode (66. PARAMETER RES : Initializes E2-ROM parameters Initializes (sets to the standard) all paramcter data within service mode's “6.7 Parameter”. 2) Pressing the SET key ® with the Shift key ® held down after confirming selection (2) LINTTIAL E2ROM: Initializes E2-ROM size data (nos. 4 10 8) Initializes sets to the standard) data (nos. 4 to 8) within service mode “6-1. ROM CNT CHECK” based on the offset data. (2)2.RESETS-RAM: Ini S-RAM function group Initializes all function data (nos. } to 9), as well as service mode's “8-1. Memory Switch” and “8-2. Memory Switch” (@)3. COUNTER RESET : Initializes E2-ROM counter data Initializes (resets) all backup data in B2P-ROM corresponding to service mode's "6.$ COUNTER CHECK". (4)4,OFE-SETCAL.: Calculates B2-ROM offset data Based on paper-size data in accord with the DIP-SW- setting, computes and modifies all offset data within service ‘mode's “6-2. OFF-SET CHECK”. (5) 5. BAKCUP E2ROM : Reads E2-ROM counter data (RAM (ROM) Overwrites E2P-ROM’s backup data to all counter data within service mode's “6.5 COUNTER CHECK.” (©6. PARAMETER RES : Initializes E2-ROM parameters Initializes (sets to the standard) all parameter data within service mode's “6.7 Parameter". Note) ‘When functions have been initialized, be aware that the “8-1-1. Protect” setting will be tumed ON. Also be aware that the ‘content for the DBM-200 and 250 differs in part. [Offsct Computation Method] ‘The following preparation is necessary prior to implementing service mode’s "6-6-4, OFF-SET CAL” ‘The paper size used will differ depending on the main unit's dip-switch settings, DIP-SW1 ON: A3 paper (mm display) DIP-SW1 OFF: Double leter paper (inch display) 1) Turn ON the power for the DBM-400. 2) Confirm that no errors with the DBM-400 occur. If an error occurs, rectify it 3) Use the saddle-stitch and fold setting to input the paper size to be used in memory no. 1 and modify the size, 4) ‘Through the step mode (fine adjustment), match the type of stopper guide tothe paper and accurately adjust the stitch and fold position '5) When adjustment has been made with the step mode, make sure to press the Memory Input key @ to save it overwriting 6) Call up memory no. 1. 7) Return to step 4, above, and readjust Repeat until its no longer necessary to adjust the position of the stopper guide with stop mode, 8) Change service mode's "8-1-1. Protect” setting to “OFF”. 9) Implement service mode's “6-6-4. OFF-SET CAL", 10) Press the Escape key ® several times to restore the LCD display to normal. 11) Next, confirm offset data, as described in the next section. ia Note) Tf step 9, above, is done with the pusher’s top position adjusted, by implementing “6-6-4. OFF-SET CAL." with the Shift key © pressed, offset data that includes the pusher can be computed. ‘998-M2280-0004-0 24161. Service Mode [Confirming Offset Data} ‘After computing offset asin the provious section, you must confirm whether the offset data falls within the stipulated values, ‘To confirm offset data, confirm that the data for nos. 1 8 of service mode's “6-2. OFF-SET CHECK” is as follows, Unit Name Lep ‘Content to Conficm 1) Side guide U. SIDE-G] 65498 (39) -39 2) Pusher 12,306] 65498 39) ~39 3) Back joz 1B. BACK] 65458 (- 78) ~79 4) Saddle-stitch stopper [4. S-STOP} 65458 (78) ~79 5) Back stopper 15. B-STOP] 6545878) ~79 6) Folding stopper (6. F-STOP} 65458 (78) -79 ‘7) Right stitcher head (7. STIER] 65038 (-498)~ 499 8) Left stitcher head 18. STIT-L] 65038 (498) ~ 499 ‘Note) Indicates that 65536 = 0 and 65457 =-79. For units with values outside the ranges shown in the above table, deviation in theit original position or the position of the light-shielding board is possible. Thus, adjust the position of the relevant parts and then proceed from -3., “Offset ‘Computation Method.” ‘After confirming offset data, enter it onthe designated tack sheet and form for note-taking. Parameter Content ‘The content and functions of "6-7. Parameter” in DBM-400 service mode are as follows. However, these functions can only bbe operated if the “8-1-1. Protect" setting is OFF. [Overview] In this mode, the parameters related to DBM-400 movement are stored in E2ROM, and it is possible to confirm and modify individual parameters. Menu 1 Standard Sertings 6. SETTING 7. Parameter J.STADJ 05376 Stitch timing data 2.NU2 00000 (Not set) 3.N/U3 00000 (Not set) 4.NU4 — 00000 (Notset) S.EDADJ 11520 Fold timing data 6.SM Spe, 00013 Stepping motor’s max. spoed data 7.NUT — 00000 (Not set) 8.N/U8 00000 (Not set) J) [1ST ADJ HMM]: Stitch timing parameter ‘When “F-1. Hi-Speed ON” is set, moves according to the content of “[1) Stitch Timing Data”. 2) (2. NU 2] : Not set 3) [3.NMU 3]; Notset 4) (4. NAY 4}: Not set 5) (5. FD ADJ #4) : Fold timing parameter ‘When “S-5.FD Fast ON” is set, moves according to the content of “{5} Feld Timing Data”. 6) (6.SM Spe. #HH##] : Stepping motor’s max. speed parameter. 7) (7. NUT): Not set 8) (8. NU 8) : Not set Note} Here, “F" stands for “function” and *S" for “service mode”. 2A? 998-M2280-0004-01. Service Mode {Detailed Content) Specific parameter content is presented below, 1) [1 ST ADJ se]: Stitch timing parameter ‘When “F-1, Hi-Speed ON" is set, moves according to the content of “[1] Stitch Timing Data’. ‘Stitching operations start ftom the reference point for this data atthe pusher’s start time. [1] Stitch Timing Data Sec. 0.00 001 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.10 ont 0.12 013 ona 0.15 0.16 017 0.18 0.19 0.20 021 0.22 023 024 025 0.26 0.27 028 0.29 030 Data (at 9.8304MEiz) 90001D 00768D 01536D 02304D 03072D o3840D ‘04608D 05376D 961440 06912 07680 08448 09216 9984p 10752D 115200 12288D 13056D 13824D 14592D. 153600 16128D 16896D_ 17664 18432D 19200D 19968D. 20736 21504D 2272 28040D -0.10 0.05. Standard setting +0.00 Standard setting +0.10 (High-speed ON) (High-speed OFF) Note) If too stow a value is set, the next paper will ative before stitching operations have started, causing a jam, 2) (2. NAU2) : Not set 3) (3. NAD3]-Not set 4) (4. NU 4] : Not set 998-M2280-0004-0 24184. Service Mode 5) [5.FD ADI ###6#]; Pold When “S-5. ED ADJ ON” is set, moves according tothe content of “[5] Fold Timing Data” ‘When the third sensor has detected the back edge of the paper, folding operations begin from the reference point for this data atthe time (ata) set below. (This process has no relation to the *F-1. Hi-Speed ON” setting.) {5] Fold Timing Data See. 0.10 ot 012 03 O14 ous O16 0.17 0.18 O19 0.20 021 022 0.23 0.24 025 0.26 0.27 0.28 029 030 031 0.32 033 034 035 036 0.37 Note) Data (at 9.8304MHz) 0076800 008448 009216D o09984D 0107520 011520 012088D 013056D 013824D 0145920 0153600. 0161280. 016896D 017664D 018432) 0192000 019968D_ 020736D o21504D 922272 ‘9230400 023808D 024876D 5344p 9261120 926880D 0276480 o28416D o29184D 029952D 0307200 314g8D_ 032256D 0330240 033792D 0345600 0.13 Standard setting (FD. ADJ ON) 0.10 +0.00 Standard setting (FD. ADJ OFF) 40.05 40.10 40.18 IF too fast a value is set, folding operations will begin before the back stopper has restrained the paper. Ifthe value is to0 slow, the next paper will arrive before folding operations have started, causing a jam. 219 99S-M22S0-0004-01. Service Mode 6) (6.5M Spe. #HHHF#] : Stepping motor’s maximum speed parameter ‘When “S-6, SM Spe. ON” is set, moves according to the content of “[6] SM Maximum Speed Data” With the exception of the pusher, the maximum speed of the stepping motor can be set. 16] Stepping Motor Maximum Speed Data PPS Data (at 9.8304MHz) 028.2 000001 9360.6 000002D 0468.3 000003D 0556.5 00004) 0634.7 000005D 0704.6 .000006D 0768.0 ‘000007D 0825.8 ‘000008 0882.8 ‘00008 0936.6 900010 0984.5 000011D +0000 Standard setting (SM Spe. OFF) 1037.8 000012 1081.7 000013D +0100 Sstandard setting (SM Spe. ON) 1129.4 00014) 11636 00001SD, 1200.0 000016D +0200 1238.7 900017 1280.0 000018D +0300 1324.1 000019 1347.4 000020D 1396.4 000021D 40400 1422.2 ‘0000220, 1449.1 000023), 14769 000024D +0500 1536.0 000025D 1567.3 0000260 1600.0 000027D +0600 1600.0 000028D 1634.0 000029 1669.6 000030D +0700 1706.7 000031 1748.5 000032D 17455 0000330 1786.0 000034D +0800 1828.6 000035D 1828.6 000036 4873.2 000037D 1873.2 co0038D +0900 19200 000039D 1920.0 ‘90040D 1969.2 090041D 1969.2 000042D +1000 2021.1 00043D Note) Being parameters related to the stepping motor's maximum speed, parameters related to adjusted spoed adjusted speed time, gradient, etc, cannot be modified. In addition, in consideration of dispersions caused by mechanicat differences and the like, please set the maximum. As the foad on moving pars, etc, will change depending on the machine's setting environment and usage conditions, the largest margin possible must be taken if the machine is for long-term use. settings are not good, the stepping motor’s synchronization will frequently be negatively affected, 99S-M2280-0004-0 2201. Service Mode 7) (7. NAN 7}: Not set 8) [S.NAJ 8] ; Not set 6, SETTING 1. ROM CNT CHECK 1.43 (LD) 1, SIDE 2.506 3. BACKS 4.S-STOP, 5. B-STOP 6. STOP 7.STIT-R 8. STITL |— 2.41) }-— 3.A4T) +—~ 4.MI f—— 5.M2 — 6.M3 -— 7.M4 — s.ms 1. 1. SIDE. 2.506 3. BACK. 4.S-STOP S.B-STOP 6. F-STOP 7.STITR 8, SHT-L |— 2. OFF-SET CHECK }—— 3. RAM CNT CHCK ——— 1.8. (Same as 2. OFFSET CHECK) | 4. IDX CNT CHECK ——— 1-8. (Same as 2. OFF-SET CHECK) |-— 5. COUNTER CHECK—— 1. ST Ist* [-— 2. FD Ist* CG }— 3. RN Ist® [— 4.8T 2nd [-— 5.FD 2nd [-— 6. RN2nd |-— 7.8iz8c* [-—— 8. P-ON* —— 9, START* e 224 Side guide invalid) Back jog unit Stitch stopper Back stopper Fold stopper Stitcher head R Stitcher head L. 1.8, (Same as 1. A3 (LD)) 1-8, (Same as 1. A3 (LD)) 18. (Same as 1. A3 (LD)) (Same as 1. A3 (LD)) 18, (Same as 1,.A3 (LD)) 1-8. (Same as 1. A3 (LD)) 8. (Same as 1. A3 (LD)) guide Pusher Back jog unit Stitch stopper Back stopper Fold stopper Stiteher head R Stiteher head L Stitch counter (Total) Folder counter (Total) Running counter (Total) Stitching counter Folder counter Running counter Size change counter (Total) Power ON counter (Total) Start/Stop counter (Total) 99$-M220-0004-01. Service Mode ®@ 6. INTTIALIZ LINITIAL E2ROM* EZROM initialization (Memory) [-— 2.RESET —S-RAM* ‘S-RAM reset (SM) | 3. COUNTER RESET* Counter reset (S-RAM) [—— 4.OFFSET CAL* Offset calculate |-— 5. BACKUP E2ROM* Backup |. 6. PARAMETER RES* Parameter eset [— 6. INITIALIZ (+ Shift)* LINITIAL —E2ROM* .E2ROM initialization (Memory) 2.RESET — S-RAM* S-RAM reset (F) 3. COUNTER RESET* ‘Counter reset (E2-ROM) 4.0FE-SET CAL* Offset calculate 5.BACKUP E2ROM* Down load 6. PARAMETER RES* Parameter reset 7. Porameter* 1. STAD Stitch timing data -— 2.NA2* (Not set) pom ZN «Not set) v }— 4 4* Not set) [-— 5. FDADI* Fold timing dara }— 6.5M Spe.* Stepping motor’s max. speed data -— 7.NuT (Mot set) '— 8. nauge (Not set) Note) * mark means the protected (limited) area by “1. Protect 1”. 998-M2280-0004-0 2221. Service Mode 1-7. Checking the Sensi 4) Press TEN key @) ©, or select [7. SEN_CHECK] on the LCD using the MEMORY key ©, and press the ENTER key ©, (Pressing the ENTER key ® enables selection of the following sub-menus.) + Menu |.NOTUSED 2. SOLENOID 3. CLUTCH 4, STEPPING 5, OTHER 6. SETTING — 7,SEN_CHECK 8, MODE SELCT © 2) There are five types of sensors, namely paper detection sensor, home (origin) detec- tion sensor, limit (upper) detection sensor, and index detection sensor. To check the desired sensor, while viewing the contents of the LCD, select the follow- ing menu using the MEMORY key ©, or directly select the TEN key corresponding to the menu number to select the sensor. Pressing the ENTER key ® after selecting the desired item so that the following check item can be selected. Each item is described below with specific examples. |. Checking the paper detection sensor. For example, to check paper detection sensor 2 (back jogger sensor) [*P_SEN_2]. First, select (*1. PAPER SENSOR] on the menu as follows, Press TEN key (.) ©, ot select [*1. PAPER SENSOR] on the LCD using the MEMORY key J, and press the ENTER. key ®. {Pressing the ENTER key @ enables the following check items to be selected.) 7. SEN_CHECK o + I.PAPER SENSOR —_Papor detection sensor 2. PLLIMIT Photointerruptor home sensor (Origin) 3. PLLIMIT Photoiterruptor limit sensor (Upper) 4, PLINDEX Photointerruptor it 5.PL_OTHER ‘Other sensors Select paper detection sensor 2 [*P_SEN_2] as follows. Press TEN key @_) ©, or select {*P_SEN_2] on the LCD using the memory key ©, and press the ENTER key ®. The sensor state at the moment the TEN key @ or MEMORY key @ is selected is notified on the LCD and by a buzzer as follows. Sensor state LeDDisplay Buzzer 1) The sensor is not blocked (by a shield) [*P_SEN_2 OFF] Short buzzer 2) The sensor is blocked (by ashield) [*P_SEN_2ON] Long buzzer Pressing the ENTER key © after selecting with the TEN key © or MEMORY key will continuously notify the sensor state {at real-time) on the LCD and by a buzzer as follows. Sensor state LED Display Buzzer 1) The sensor is not blocked (by a shield) [*P_SEN 2 OFF] No buzecr 2) The sensor is blocked (by ashicld) _[*P_SEN_2ON] Continuous buzzer p23 995-M2250-0004-01. Service Mode 1. PAPER SENSOR 1. P_SEN_1 Paper sensor © (Paper feed section) + 2, PSEN 2 Paper sensor @ (Back jogger section) 3.P_SEN_3 Paper sensor @ Back stopper section) 4, PSEN_4 Paper sensor @ (Upper paper ejection section) 5.P_SEN_S Paper sensor ® (Lower paper ejection section) [Precautions) Jn the following states, the same signals as “when the sensor is blocked (by shield/object} and above are output. 1) When the power supply of the sensor is OFF. 2) When the connector of the sensor is disconnected. 3) When the bound-wire of the sensor is OFF. 4) The sensor is damaged. 5) The sensitivity adjustment was not performed properly ‘AS a separated type sensor is used only for the paper detection sensor (modulation type), pay attention to the following, points 1) Insufficient adjustment of the sensor (ight-recei sensor. 2) Insufficient adjustment of the sensor (light-emitting side and light-receiving side). In particular, make sure thatthe sensor is attached properly after it has been replaced. Side) sensitivity, Always adjust the sensitivity when replacing the ()) -2. Cheeking the home (origin) sensor (photointerruptor) For example, to check home sensor 3 (back jog) [*PI_HOME_3]. First, select [*2. PI_HOME] on the menu 2§ follows. Press TEN key @_) ©, or select [*2. PI_HOME] on the LCD using the MEMORY key ©, and press the ENTER key ®. (Pressing the ENTER key @ enables the following check items to be selected.) 7. SEN_CHECK J. PAPER SENSOR Paper detection sensor + 2,PLHOME Photointerruptor home sensor (Origin) 3.PELIMIT —_Photointerruptr limit sensor (Uippex) 4.PLINDEX _Photoinferruptor index sensor 5.PLOTHER Other sensors Select home sensor 3 [*PI_HOME_ 3] as follows. 0 Press TEN key @_) ©, or select [*PI HOME. 3] on the LCD using the MEMORY key ©. “The sensor state at the moment the TEN key @ ot MEMORY key © is selected is notified on the LCD and by a buzzer as follows. Sensor state LCD Display Buzzer 1) The sensors not blocked (by a shield) [*PIHOME_3 OFF] Short buzzer 2) The sensor is blocked (by ashield) _[*PI_HOME_3 ON] Long buzzer Pressing the ENTER key ® after selecting with the TEN key @ or MEMORY key © will continuously notify the sensor state (at real-time) on the LCD and by a buzzer as follows, Sensor state LCD Display Buzzer 1) The sensor is not blocked (by a shield) [*PI_HOME_3 OFF] No buzzer 2) The sensors blocked (by ashield) —_[*P HOME_3 ON] Continuous buzzer 99S-M2280-0004-0 2241. Service Mode 2. PLHOME 1.PLHOMB1 Side guide Moves 2.PILHOME_1 Back jogger Operates + 3.PLHOME 1 — Back jog Moves 4,PLHOME_1 — Saddle-stitching stopper Moves 5.PLHOME,1 Back stopper Moves 6.PLHOME_1 Folding stopper Moves 7.PLHOME1 Stitcher head R Moves 8.PLHOME 1 Stitcher head L Moves As the precautions are the same as those in 1, please refer to them, ‘Checking the Limit Sensor (Photointerruptor) For example, to check limit sensor 3 (back jog) {*PILLIMIT_S), Firs, select [*3. PE_LIMIT] on the menu as follows. Press TEN key @_) ©, ot select [*3. PI_LIMIT] on the LCD using the MEMORY key ®, and press the ENTER key ®. (Pressing the ENTER key © enables the following check items to be selected.) 7. SEN_CHECK 1. PAPER SENSOR Paper detection sensor 2. PLHOME, Photointerruptor home sensor (Origin) + 3.PLUMIT Photointerruptor limit sensor (Upper) 4, PILINDEX Photointerruptor index sensor 5, PLOTHER Other sensors ‘Select limit sensor 3 [*P1_LIMIT_3] as follows, Press TEN key @_) ©, or select [*PI_LIMIT_3} on the LCD using the MEMORY key ©. ‘The senscr state atthe moment the TEN key © or MEMORY key © is selected is notified on the LCD and by a buzzer as follows. Sensor state LCD Display Buzzer 1) The sensor is not blocked (by a shield) (*PILLIMIT_3 OFF|Short. buzzer 2) ‘The sensor is blocked (by a shield) (*PLLIMIT_3 ON} Long buzzer Pressing the ENTER key ® after selecting with the TEN key © or MEMORY key © will continuously notify the scnsor slate (at realtime) on the LCD and by a buzzer as follows. Sensor state LCD Display Buzzer 1) The sensor is not blocked (by a shield) [*PILLIMIT_3 OFF] No buzzer 2) The sensor is blocked (by a shield) [*PI_LIMIT_3 ON] Continuous buzzer 3. PLLIMIT LPLLIMIT.1 Side guide Moves (No) 2.PLLIMIT_2 Back jogger Operates (No) > 3.PLLIMIT3 Back jog Moves 4.PLLIMIT4 — Saddle-stitching stopper Moves S.PLLIMIT_S Back stopper Moves 6.PLLIMIT_6 Folding stopper ‘Moves 7.PLLIMIT_7 Stitcher bead R Moves (No) 8.PLLIMIT.8 Stitcher head L Moves (No) As the precautions are the sare as those in ~1, please refer to them, 2-25 99S-M2250-0004-01. Service Mode “4. Checking the Index Sensor (Photointerruptor) For example, to check index sensor 3 (back jog) (*PI_INDEX. 3]. First, select [*4, PLINDEX! on the menu as follows. Press TEN key @) ©, or select (*4. PI_INDEX] on the LCD using the MEMORY key ®, and press the ENTER key ©, Pressing the ENTER key © enables the following check items to be selected.) 7, SEN_CHECK L PAPER SENSOR Paper detection sensor 2. PLHOME Photointerruptor home sensor (Origin) 3. PLLIMIF Photointerruptor limit sensor (Upper) 4. PLINDEX Photointerruptor index sensor 5, PLOTHER Other sensors Sclect index sensor 3 [*PI_INDEX_3] 28 follows. Press TEN key @—) ©, or select [*PI_ INDEX_3} on the LCD using the MEMORY key ©. ‘The sensor state at the moment the TEN key @ or MEMORY key © is selected is notified on the LCD and by a buzzer as follows. Sensor state LCD Display Buzzer 1) The sensor is not blocked (by a shield) [*PI_INDEX_3 OFF] Short buzzer 2) The sensor is blocked (by ashield) —[*PLINDEX_30N] Long buzzer Pressing the ENTER key @ after selecting with the TEN key @ or MEMORY key © wall continuously notify the sensor state (at real-time) on the LCD and by a buzzer as follows. Sensor state LCD Display Buzzer 1) The sensor is not blocked (by a shield) [*PLINDEX_3 OFF] No buzzer 2) The sensor is blocked (by a shield) [*PLINDEX_30N] Continuous buzzer 4, PLINDEX I.PLINDEX_1 Side guide Moves 2,PLINDEX_2 Back jogger Operates > 3.PLINDEX_3 Back jog Moves 4.PLINDEX.4 — Saddle-stitching stopper Moves S.PLINDEX.5 Back stopper Moves 6.PLINDEX 6 Folding stopper ‘Moves 7,PILINDEX_7 Stitcher head R Moves 8.PLINDEX8 Stitcher head L Moves As the precautions are the same as those in ~1, please refer to them. 8. Checking Other Sensors and Switches 1, DC24V Fail DC24V power fail 2. DBMSTOP2 —_ ON when the interrupter SW is pressed 3. SIDSTOP3 ON when the side cover or sub cover, shutter are open, Same for left and right 4. TOPCOVER4 — When top cover is open [ON] Same for three covers (0 4 are given top priority Even if 3 and 4 are checked with the INTERRUPTER SW pressed, they witl always remain ON, which serves no meaning. This is the same when the 24V power is turned off, 998-M2280-0004-0 2:26 01. Service Modo: 6. PLHOME-FB Folding knife origin sensor 7. PLHOME-ST Stitcher origin sensor 8 AUXROLL ——_Auriliary roller deiection sensor (Same forall three rollers) ‘When auxiliary rollers are attached [ON} g The a contact points of the lead SW are used for the 8. auxiliary roller detection sensor. Three of these are connected in parallel. This means that no fail safe operation is performed for wire disconnections and contact defects. Therefore check ‘each sensor (including the bound-wires) one by one. 1. PAPER SENSOR, 7, SET_CHECK: [—2. PLHOME }—3.PLLIMIT 1. P_SEN-1 2. P_SEN-2 3.P_SEN-3 4,P_SEN4 S.P_SENS, 6. P_SEN-6 7.P_SEN-7 8. P_SEN-S TTT 1, PLHOME-1 2. PLHOME-2 3. PLHOME-3 4, PLHOME-4 5. PLHOME-5 6. PLHOME-6 7. PLHOME-7 8. PLHOME-8 1, PLLIMIT-1 2. PLLIMIT-2 3, PLLIMIT-3 4. PLLIMIT4+ 5. PLLIMIT-S 6, PLLIMIT-6 7. PLLIMIT-7 8, PLLIMIT-8 4. PLINDEX 1, PLINDEX-1 2. PLINDEX-2 3. PLINDEX-3 4, PLINDEX-4 5. PILINDEX-5 6. PLINDEX-6 7. PLINDEX-7 —— 8.PLINDEX8 5. PLOTHER 1, DC24V Fail 1 2. DBM STOP 2 3. SID COVER 3 4, TOP COVER4 5. PL_LIMIT-FB 6. PL_HOME-FB 7. PLHOME-ST 8, AUX. ROLL TTT 2.27 Paper sensor 1 Paper sensor 2 Paper sensor 3 Paper sensor 4 Paper sensor 5 None None None Side guide Pusher Back jog Stitch stopper Back stopper Folder stopper Stitcher head Stitcher head 1, None None Back jos lirwit Stitch stopper limit Back stopper limit Folder stopper limit None None Side guide index Pusher index Back jog index Stitch stopper index Back stopper index Folder stopper index Stitcher bead R- index Stitcher head L_ index DC24V power fail Interrupter SW Top cover Folding knife upper limit Folding knife origin Stitcher origin ‘Auxiliary roller 99S-M2280-0004-01. Service Mode Other Operation Modes 1) Press TEN key @_) ©, or select (8. MODE SELECT] on the LCD using the MEMORY key ©, and press the ENTER key @. (Pressing the ENTER key © enables selection of the following sub-menus.) * Menu 1. NOT USE, 2. SOLENOID. 3. CLUTCH 4, STEPPING 5. OTHER 6. SETTING 7. SEN_CHCK + 8. MODE SELECT 2) +The MODE SELECT menu consists of the Memory Switch setting, I/F (interface) Test mode, Panel Test mode, Free Running test mode, and continuous durability test mode, etc, To prevent unexpected accidents, etc., settings are disabled by the [8. MODE SELECT-1. Memory Switch-1. Protect] setting, So some modes cannot be set unless this is set to OFF. After clearing the restriction, select the desired menu using the Memory Key © while observing the LCD display. 8. MODE SELECT 1, Memory switch Memory switch 1 2. Memory switch Memory switch 2 3. UF Test Interface test (I/F) 4 Panel Test Panel test (LED & KEY) 5, Pree Running Pree running (Pseudo operations) 6. S_M Ret Home Size homing 7. S_M Set Upt Size setup 8.S_M Ret & Set Size change (Memory S/continuous) <1. MEMORY switch settings 1 AAs the user neods to fully understand the usages and restrictions, etc, the unit has been designed so that settings can be ‘changed by the service personnel. After pressing the TEN key @_) © corresponding to the menu number, press the ENTER key ©. ‘Next, press the TEN key @ corresponding to the menu mumber, or press the SELECT MEMORY key © while observing the contents of the LCD to check the settings of the memory switch, 8, MODE SELECT 1, Memory Switch 1. Protect ON/OFF Sets the restriction of some functions 2.Relative ON/OFF Sets the relative inpat of the head 3. Variable ON/OFF Varies and sets the stitching and folding settings, 4.BitSW 14 ON/OFF Reserves (Not set) S.BitSW15 ON/OFF Reserves (Not set) 6.45 ON/OFF Rounds off to whole number 1, Define ON/OFF Sets the maximurn processable sets 8.EMCY Time ON/OFF Sets interrupter input processing + Changing the ON/OFF setting of the Memory switch In the above state, while pressing the CHANGE key ©, press the TEN key ® corresponding to the desired menu number to change ON and OFF. 99S-M22S0-0004-0 2-281. Service Mode Description of Memory switch 1 [*1,. Memory Switch] 1) [1. Protect ON/OFF] Used to restrict some functions in the service mode. OFF: No restriction of some functions. ‘ON*: Restricts some functions. 2) [2.Relative ON/OFF Used to set the stitcher head to the relative input when inputting numbers. OFF: Absotute value input (Normal setting) ON: Relative input 3) [3. Variable ON/OFF] Used to enable temporary changes of the stitching and folding settings. However, the stitching mode cannot be changed between saddle stitching and side stitching Variable settings are only for saddle stitehing/side stitching—ono stitching, and folding—sno folding. Care must also be taken if set to no folding as the conveyance (roller positioning)is turned off . (OFF*: Fixed (Normal setting) ON: Variable 4) [4. Bit SW 14 ON/OFF} Used to reserve (Not set) OFF*; oN: 5) {5. Bit SW 15 ON/OFF ‘Used to reserve (Not set) OFF: ON: 6) 16.495 ON/OFF] ‘Used to half-adjust the first decimal (USA: second decimal) number of the size displayed on the LCD to round numbers, OFF: Round down the first decimal (USA: second decimal) number (normal setting) ON: Half-adjust the first decimal (USA: second decimal) number 7) (7.Define ON/OFF] Used to restrict the mimber of processable sets up to a maximum of 65534 sets. ‘To input the number of processable sets, set [*6 SETTING-S.COUNTER 8.P-ON] of the second register. ‘The unit will operate normatly tothe set-1 from the number input. But when the counter becomes 0, the unit will jam and stop, and cannot start due to jam error. (OFF*: No restriction (Normal setting) ON: Restricts the number of processable sets 8) [8.EMCY Time ON/OFF] Used to set input processing (noise-reduction) of the interrupter switch, Although this improves the noise, it will make detection of errors more difficult, resulting in error # 15 more frequently. OFF*: No input processing ON: Sets input processing Note) * mark indicates the setting at shipment. 228 99S-M22S0-0004-01. Service Mode <2. Memory switch setting 2 [Overview] In this mode, settings pertaining to DBM-400 operations are stored in $-RAM, and it is possible to confirm and modify individual parameters, As the user needs to fully understand the usages and restrictions, etc., the unit has been designed so that settings can be changed by the service personnel Also in order to check contents and change settings, the setting of [8. MODE SELECT-1. Memory Switch-1.Protect} must be set to “OFF”. Press the TEN key @—) © corresponding to the menu number, or press the MEMORY key @® while observing the contents of the LCD to select [*2. Memory Switch}, and then press the ENTER key @. Next, press the TEN key © corresponding to the menu number, or press the MEMORY key © while observing the contents of the LCD to check the settings of the MEMORY switch ‘Menv_I (Service Mode) 8. MODE SELECT 2. Memory Switch, Setting When Shipped L. Serial = ON/OFF OFF: Regular setting ON: Serial communication 2. Display 2. ON/OFF OFF: Regular setting ON : Liquid crystal display 2 3.BS Test ON/OFF OFF: Regular setting ON; Belt stacker test mode 4,Stopper ON/OFF OFF ; Regular setting ON: Stitching stopper timing ‘modification 5.FD ADI ON/OFF OFF: Regular seiting ON : Fold timing modification 6.SM Spe. ON/OFF OFF: Regular setting ON : Stepping motor max. speed modification 7. Bit SW27 ON/OFF OFF ; Regularsctting ON: Not set 8. Non Limit ON/OFF OFF : Regularsotting ON : S-head fimit ‘+ Changing the ON/OFF setting of the MEMORY switch In the above state, while pressing the CHANGE key ®, press the TEN key @ corresponding to the desired mene number to change ON and OFF. [Detailed Content] Specific parameter content is presented below. 1) EL. Serial ON/OFF] ‘Set ta determine whether the DBM-400 serial communication function (RS232) will be used. OFF*: No serial communication ON: Serial communication 2) (2 Display 2 ON/OFF] Sets the content of the DBM-400 LCD. OEF*: —— 3-digit display (regular seting) UK [*1.A3 420x297] USA [*LLD 17.0x 11.0} ON: Acdigit display UK [*1.420.0x 297.0] USA [*1.17.00 x 11.001 3) [3.BS Test ON/OFF] ‘This is the test mode for DBM-400 belt stacker durability. OFF! Regular setting ON: Belt stacker durability test operation 4) (4. Stopper ON/OFF] This is the setting for switching the DBM.400 stitching stopper operation timing range. OPF*: Regular setting ‘998-M2280-0004-0 2-301. Service Mode ON: Por high-speed processing (1) [F-4, $T_Stop #44) setting content for OFF setting -Tomscc — (+56.8 msec) Fast “Stmsec — ( +75.8msec) 38sec (+94.7msec) <19msee —_(+113.6msee) +Omsec —(+132.6msec) Standard 19msec —_(+151.Smsec) +38msec — (+170.5msec) +STmsec — (+189.4msec) "Témsec —(4+208.3msec) Slow wesaneune (1) [F-4, ST_Stop #44] setting content for ON setting 1 ~Bémsec — ( +0.0msec) Fast 2 -28msec —( +9.Smsec) 3 -19msee —_(419.0msec) 4 Smsec — (+28.Smsec) s +0msec —_(437.9msec) Standard 6 #9msec ——(4+47.4msec) 7 +19msec —(456.9msec) 8 #28msec —_ (+66.3msec) 9 438msec—_(+75.8msec) Slow Following is a visual expression of ON/OFE setting changes, Fast Slow OFF 123456789 ON 123456789 5) [5.ED ADJ ON/OFF] Sets the timing of DBM-400 folding operations. OFF: Regular setting ON: Operates with [S. FD ADS #####] setting content 6) [6. SM Spe. ON/OFF] ‘Sets the maximum speed for the stepping motor, excluding the DBM-400 pusher. OFF*; Regular setting ON: ‘Operates with [6.5M Spe. s####] setting content 1) (7. Bit SW 27 ON/OFF] This item is not set. OFF*: Regular setting ON: Not set 8) [8. Non Limit ON/OFF] ‘This setting is to release a sttch-prohibited area of 80mm {3.15 inch) in the center of the paper. However, as the arrangement balance will be negatively effected by the position of the first discharge roller and automatic settings, arrangement settings must be made manually. OFF*; Maintains a stitch-prohibited area (regular setting) ON Does not maintain a stitch-prohibited area Note) “Indicates setting at time of shipment. 231 ‘998-M22S0-0004-01, Service Mode 3. UE test mode ‘Test mode for checking the VF and connection cable unit of the main unit. A.commercially available and exclusive connecting cable unit are required for checking. 1) Check that the power of the DBM-400 is OFF, and that nothing is connected to the front and back interfaces (for connecting the collator and downstream processing unit. 2) ‘Turn ON the power of this unit, ‘Check that no error has occurred. If there is an error, clear it. 3) Clear the service mode protect (OFF). Set to [*8. MODE SELECT-1. Memory SW-1 Protect OFF], For details, refer 0 "7-9, Releasing the DBM-400 Protect”. 4) Select and execute [*8. MODE SELECT-3./F Test] of the service mode. ‘While observing the contents of the LCD, select [*3.UF Test] using the SELECT MEMORY key ©, and press the ENTER key ®, or press the TEN key @_) © corresponding to the menu number. ‘The ENTER key @ need not be pressed if the TEN key @_) © has been pressed. 5) Connecting the interface cable, Using the required connecting cable, connect the interface cables between the collator and down stream processing unit. + [fusing the 48ST connector, use the D-SUB (25P) straight (all units connected) 1.5 m extension cord (male-female). + [fusing the 48TW connector, connect the conversion cable (refer to separate page). Check also that nothing is connected to CN18 of the main unit. 6) Check that the contents of the LCD and “Check items of interface” below are matching. 1 they are not, the main unit or connecting cable may be abnormal. In the procedure hereafter, press the TEN key ©) © to proceed to the desired check item. After checking all items, check that the contents of the LCD and “Check items of interface” betow are matching. [Check items of interface} 48ST connector (LCD contents) Output Tnput 3UEI 80 80 0 > 40 20 + 20 0 + 10 oe OB, of of oO = oO - ot 0 -~ 00 302 10 > 10 08 + 08 OO a - 02 Oo ~ oO o = 0 + Press the TEN key @_) ® here (after completing the last check item) will cause the check buzzer to sound. Pressing the ESCAPE key ® will end the test mode. + Ifthe contents of the LCD differs from the above, note down the contents of the LCD to facilitate determining the fault. For details of the contents of the LCD, refer to “Appendix” ‘998-M2280-0004-0 oK OK OK oK OK OK oK OK oK OK OK OK OK OK OK 48TW connector {LCD contents) Output Input 30FL 80 0 40 > 40 0 + 0 1 = 10 08 = 00 o4 = 00 2 + 2 a + 0 0 + 0 302 10 (00 os 8 04 Ot 2 + 2 ao + OL 0 + 0 2-32 NG OK NG OK NG NG OK NG OK NG OK oK OK OK oK v