SPF-9R BOOKLETMAKER DOCUMENTATION

RICOH GROUP COMPANIES

001109MIU

SPF-9R BOOKLETMAKER DOCUMENTATION

RICOH GROUP COMPANIES

SPF-9R SERVICE MANUAL

001109MIU

It is the reader's responsibility when discussing the information contained within this document to maintain a level of confidentiality that is in the best interest of Ricoh Corporation and its member companies. NO PART OF THIS DOCUMENT MAY BE REPRODUCED IN ANY FASHION AND DISTRIBUTED WITHOUT THE PRIOR PERMISSION OF RICOH CORPORATION. All product names, domain names or product illustrations, including desktop images, used in this document are trademarks, registered trademarks or the property of their respective companies. They are used throughout this book in an informational or editorial fashion only and for the benefit of such companies. No such use, or the use of any trade name, or web site is intended to convey endorsement or other affiliation with Ricoh products.

2001 RICOH Corporation. All rights reserved.

FOREWORD
Stapler and Folder Model SPF-9R

Important Information
This service manual is designed to help you repair and maintian the SPF-9R in good operating condition. Read and understand the instructions in this service manual before attempting to perform repair and maintenance.

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SPF-9R

Safety Precautions
- Read and understand all safety instructions especially words such as WARNING, and CAUTION. If safety instructions are ignored, personal injury may result. - The repair & maintenance and safety instructions in this manual are valid only when the repair and maintenance is performed according to the procedure in this manual. - WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices.

- Every possible situation that might involve a potential hazard cannot be anticipated. The instructions in this manual and warning labels on the machine are therefore not all inclusive. - All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or any electrical device when it is locked or tagged out. - Some of the drawings in this manual show the machine uncovered for explaining details on the inside of the machine.

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II

SPF-9R

I. Necessary Tools for Maintenance and Repair

The following tools are necessary for maintenance and repair. 1. 2. 3. 4. 5. 6. Screw Driver Screw Driver Allen Wrenches Open-ended Wrench Box Wrench Snap-ring Expander No. 2 6 to 7 mm 1.5, 2, 2.5, 3, 4, 5, and 6 mm 5.5 x 7, 8 x 10, 13 x 17 mm 5.5 mm

II. Codes and Abbreviations in This Manual

1. The following signs in this manual represent wire color. Code BRN RED ORN YEL GRN BLU VIO GRY Color Brown Red Orange Yellow Green Blue Violet Gray Code Color Abbreviation PNK LBL YEG YEO Pink Light Blue Yellow Green Yellow Orange CL BK SW PS mSW M LED VR RY AS
III

2. In this manual the following abbreviations represent electronic and electrical parts. Meaning Clutch Brake Switch Proximity Switch Micro-switch Motor Light Emitted Diode Potentiometer Relay Assembly
SPF-9R

LYE Light Yellow GND Ground

WHT White BLK Black

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III. Description of Terms Used in This Manual

Cover Feeder

[Parts Description]

Stacker

Names Machine Type

Delivery Section ED

Fore-edge Trimmer Section Staple and Fold Section FC SPF SPF-9R

Cover Feed and Stacker Section CFS

Copy Machine

[Term Description] Staple ; To Staple the center of the sheets with two staples. Fold ; To fold the sheet in the center.

Fore-edge ; Open side is called Fore-edge. (Stapled side is called [spine])

Staple(L) ;

Bend the top of the staples in the staple unit. Clinch Section Finishing Device ; Generic name for a machine that binds the books.

Staple ; Staple and Fold ; To fold the sheet after stapling

Staple ; Staple (U) ;

Staple unit composed by staple section which insert the staples, and clinch section which bend the inserted staples. Stitch the sheet by staples Staples in the staple unit, insert section
IV SPF-9R

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Contents
FOREWORD ........................................................................ I. Important Information ......................................................... I. Safety Precautions ................................................................ II. I. Necessary Tools for Maintenance and Repair ........... III. II. Codes and Abbreviations in This Manual ..................... III. III. Description of Terms Used in This Manual ................. IV.

2. Troubleshooting
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(1) ................................................................... 2-14 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(2) ............................................................ 2-15 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet(3) .................................................................. 2-16 2-1-2 Booklet is not trimmed completely ......................... 2-17 2-1-3 Skew Trimming Occurs ........................................... 2-17 2-1-4 Wrinkle Appears on the Bound Booklet ................ 2-18 2-1-5 Booklets Are Stained ................................................ 2-18 2-1-6 Sheets Comes Off from the Booklet ....................... 2-19 2-1-7 Sheets Are Not Jogged Properly ............................ 2-20 2-1-8 Stapler Does Not Staple ........................................... 2-21 2-2-1 Cover Feeder Does Not Feed Covers .................... 2-22 2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down) .................... 2-23 2-2-3 Double Feed Occurs Frequently in Cover Feeding2-24 2-2-4 No Feed Occurs Frequently in Cover Feeding ..... 2-25 2-2-5 Sheets Are Not Off-set ............................................. 2-26 2-2-6 Stack Tray Does Not Move Up and Down............ 2-27 2-2-7 Stack Tray Does Not lower although there are many sheets ............................................................... 2-28 2-3-1 Booklet Jam Occurs Frequently at Staple Section 2-29 2-3-2 Booklet Jam Occurs Frequently at Fold Section(1)2-30 2-3-2 Booklet Jam Occurs Frequently at Fold Section(2)2-31 2-3-3 Booklet Jam Occurs Frequently at Trim Section 2-32

1. Before You Begin

1-1 Specifications ................................................................. 1-2 1-2 General View .................................................................. 1-3 1-3 Description of Cover Feeder and Stacker Section (CFS) ................................................................................ 1-4 1-4 Description of Staple and Fold Section - SPF (1) ......... 1-5 1-4 Description of Staple and Fold Section - SPF (2) ......... 1-6 1-5 Description of Fore-edge Trimmer FC section ............ 1-7 1-6 Description of Delivery Section (EC) ............................ 1-8 1-7 Description on the Panel of Cover Feeder and Stacker (CFS) Section .................................................... 1-9 1-8 Description on the Panel of Staple and Fold (SPF) Section ................................................................... 1-10 1-9 Description on the Panel of Fore-edge Trimmer (FC) Section .................................................................... 1-11 1-10 Mechanism of SPF-9R .................................................. 1-12

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SPF-9R

3. Parts Adjustment
3-1-1 Entrance Section Transport Belt Tension Adjustment .................................................................. 3-34 3-1-2 Feed Belt Tension Adjustment ................................... 3-34 3-1-3 Stacker Tray Up/Down Motor Belt Tension Adjustment .................................................................. 3-34 3-1-4 Cover Transport Belt Tension Adjustment .............. 3-35 3-1-5 Feed Belt Pusher Parallel Adjustment ..................... 3-35 3-2-1 Transport Belt Tension Adjustment .......................... 3-36 3-2-2 Folding Roller Drive Belt Tension Adjustment ........ 3-36 3-2-3 Chain Tension Adjustment ......................................... 3-36 3-2-4 Folding Roller Gap Adjustment ................................. 3-37 3-2-5 Press Roller Gap Adjustment .................................... 3-37 3-2-6 Staple Unit Lean Adjustment ..................................... 3-38 3-2-7 Top-and-Tail Guide Parallel Adjustment ................. 3-38 3-2-8 Stapling Stopper Adjustment ..................................... 3-39

4-2-7 Replacing Guide Roller ............................................ 4-49 4-2-8 Replacing Feed Roller .............................................. 4-50 4-2-9 Replacing Feed Ring ................................................. 4-51 4-2-10 Replacing Blower Motor ........................................... 4-52 4-2-11 Replacing Valve Motor ............................................. 4-52 4-2-12 Replacing Stacker Tray Up/Down Motor ............... 4-52 4-2-13 Replacing Reduction Motor ..................................... 4-53 4-2-14 Replacing Entrance Motor ....................................... 4-53 4-2-15 Replacing Main Motor .............................................. 4-53 4-2-16 Replacing Cover Feed Motor ................................... 4-54 4-2-17 Replacing Width Adjustment Motor ....................... 4-54 4-2-18 Replacing Shift Motor ............................................... 4-54 4-2-19 Replacing Worm on the Upper/Lower Stacker ...... 4-55 4-2-20 Replacing Clutch ..................................................... 4-55 4-2-21 Replacing Stacker Height Detect Lever ............. 4-55 4-2-22 Replacing Feed ........................................................ 4-56 4-2-23 Replacing Bearing at Shift Section ...................... 4-56 4-3-1 Removing Staple Section .......................................... 4-57 4-3-2 ReplacingUpper Staple Section ............................... 4-57 4-3-3 Replacing Lower Staple Section ............................. 4-58 4-3-4 Positioning Upper/Lower Staple Unit .................... 4-58 4-3-5 Replacingthe Fold Guide .......................................... 4-59 4-3-6 Replacing Knife Section ........................................... 4-60 4-3-7 Replacing Press Roller ............................................. 4-60 4-3-8 Replacing Fold Roller ................................................ 4-61 4-3-9 Replacing Jog Section Solenoid ................................. 4-61 4-3-10 Replacing Stapling Stopper Solenoid ................... 4-61

4. Parts Replacement
4-1-1 Removing the Cover of CFS Section ..................... 4-42 4-1-2 Removing the Cover of SPF Section .......................... 4-43 4-1-3 Removing the Cover of FC Section ............................ 4-44 4-2-1 Replacing Cover Detect Sensor .................................. 4-45 4-2-2 Replacing Sheet Height Detect Sensor ....................... 4-46 4-2-3 Replacing Double Feed/No Feed Detect Sensor ........ 4-47 4-2-4 Replacing Double Feed Stop Plate ............................. 4-48 4-2-5 Replacing Tray Lift Motor ......................................... 4-49 4-2-6 Replacing Rack Plate .................................................. 4-49 SM VI

SPF-9R

4-3-11 Replacing Transport Roller R Solenoid .............. 4-62 4-3-12 Replacing Transport Roller F Solenoid ................. 4-62 4-4-1 Replacing Stopper Solenoid ...................................... 4-63 4-4-2 Replacing Cutter ........................................................ 4-64

Locations ................................................................... 7-79 7-1-2 CFS Control Board and QPM-144 Connector Connections (1) ........................................................... 7-80 7-1-2 CFS Control Board and QPM-144 Connector Connections (2) ........................................................... 7-81 7-1-2 CFS Control Board and QPM-144 LED Locations .. 7-82

5. Service Mode
5-1 Basic Movement of CFS Section ................................ 5-66 5-2 Basic Movement of SPF Section ................................. 5-67 5-3 Basic Movement of FC Section .................................. 5-68

7-1-2 CFS Control Board and QPM-144 LED lighting conditions .................................................................... 7-83 7-1-3 CFS Correspondence Board and QPW-591 Connector Locations and Connections ..................... 7-84 7-1-4 CFS Panel Board and QPW-587 Connector-LED Locations ..................................................................... 7-85 7-1-5 SPF Control Board and QPW-503 Connector Locations ..................................................................... 7-86 7-1-5 SPF Control Board and QPW-503 Connector Connections (1) ............................................................ 7-87 7-1-5 SPF Control Board and QPW-503 Connector Connections (2) ........................................................... 7-88 7-1-5 SPF Control Board and QPW-503 Connector Connections (3) ........................................................... 7-89 7-1-5 SPF Control Board and QPW-503 Connector Connections (4) ........................................................... 7-90 7-1-6 SPF Knife Motor Board and QPW-522 Connector-LED Locations ........................................ 7-91 7-1-7 SPF Panel Board and QPW-491 Connector-LED Locations ..................................................................... 7-92

6. Electrical Parts
6-1 Identification and Location of Motors ...................... 6-70 6-2-1 Identification and Location of Sensors [CFS Section] ............................................................. 6-71 6-2-2 Identification and Location of Sensors [SPF, FC Section] ...................................................... 6-72 6-3 Identification and Location of Switch and Breaker 6-73 6-4 Identification and Location of Solenoid .................... 6-74 6-5 Identification and Location of Other Major Electrical Parts ............................................................. 6-75

7. System Wiring and Connections

7-1 Board Locations .............................................................. 7-78 7-1-2 CFS Control Board and QPM-144 Connector SM VII

SPF-9R

7-1-8 SPF P.C.B QPW-518 Connector-LED Locations 7-93 7-1-9 FC Control Board and QPW-484 Connector-LED Locations ..................................................................... 7-94 7-1-9 FC Control Board and QPW-484 Connector Connections (1) ............................................................ 7-95 7-1-9 FC Control Board and QPW-484 Connector Connections (2) ............................................................ 7-96 7-1-10 FC Panel Board and QPW-493 Switch-Connector-LED Locations ........................... 7-97 7-2 CFS Section Power Locations ................................... 7-98 7-2-2 SPF Section Power Locations ..................................... 7-99 7-2-3 FC Section Power Locations ...................................... 7-100 7-3 SPF Section Flat Cable Connections ........................ 7-101 7-4-1 CFS Section Terminal Board Locations .................... 7-102 7-4-2 SPF Section Terminal Board Locations .................... 7-103 7-4-3 FC Section Terminal Board Locations ...................... 7-104 7-5 Wiring and Connections among Machines ................... 7-105

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VIII

SPF-9R

1. Before You Begin

1-1 Specifications ......................................................................................................1-2 1-2 General View ......................................................................................................1-3 1-3 Description of Cover Feeder and Stacker Section (CFS) ................................1-4 1-4 Description of Staple and Fold Section - SPF (1) ............................................ 1-5 1-4 Description of Staple and Fold Section - SPF (2) ............................................ 1-6 1-5 Description of Fore-edge Trimmer FC section ................................................ 1-7 1-6 Description of Delivery Section (EC) ................................................................ 1-8 1-7 Description on the Panel of Cover Feeder and Stacker (CFS) Section ..........1-9 1-8 Description on the Panel of Staple and Fold (SPF) Section ............................ 1-10 1-9 Description on the Panel of Fore-edge Trimmer (FC) Section .......................1-11 1-10 Mechanism of SPF-9R ..................................................................................... 1-12

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1-1

SPF-9R

1-1 Specifications

Parts Descriptions (Machine Type) Functions

Cover Feed And Stacker Section CFS Cover Feed=Art Coat;63-135 kg Fine quality paper, Normal paper;45-135 kg Stacker = Off-set stack/Straight stack Changed by copy machine

Staple And Fold Section SPF Staple Type=Staple Staple Distance=120 mm (Fixed) Staples=5000 staples/cartridge

Fore-Edge Trimmer And Delivery Section FC&ED Maximum Trimming Length [Width x Length] 323 x 225 mm Minimum Trimming Length [Width x Length] 210 x 135 mm

Production Speed Sheet Size

Correspond to the speed of copy machine (Distance between booklets are a minimum of 2.2 seconds) Sheet size will correspond to the copy machine automatically : Maximum width= A3 : Maximum length=17 inch

Sheet Type Machine Size 897 (W) x 621(D) x 1150 (H)

Fine Quality Paper 64gsm-128gsm, Normal Paper 890 (W) x 621 (D) x 795 (H) Delivery; 680 (W) x 460 (D) x 300 (H) Trim; 445 (W) x 621 (D) x 795 (H)

Machine Weight

100 kg / 220 lbs.

154 kg / 338.8 lbs.

100 kg / 220 lbs. (Fore-edge trim) 8 kg / 17.6 lbs. (Delivery Section)

Power Consumption Maximum Pile Height Stacker Section 225 mm

115-120V 50/60Hz 8.8/9.2A

220-240V 50Hz 4.2A Delivered by conveyor

Maximum thickness = 16 sheets

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1-2

SPF-9R

1-2 General View

Delivery Section (ED 9) Deliver and stack the booklet

Copy Machine (RICOH) Stack the sheets for 1 booklet, which is Cover Feed and delivered from copy machine, and add a Stacker Section cover. Then transport it to staple and fold (CFS-9R) section. Or stack and offset the sheets in stack section. Staple and Fold Staple and fold the sheets for one booklet. Stapled sheets Section (SPF-9R) are folded and transported to fore-edge trimmer section. Fore-edge Trimmer Trim Fore-edge section of the booklet which is stapled and folded at Section (FC-9R) staple and fold section. When only folding, trimming will not be done.

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1-3

SPF-9R

1-3 Description of Cover Feeder and Stacker Section (CFS)

Cover Tray Accumulate Section Sheets are stocked here temporarily until it forms 1 set. Delivery Section Receive the sheets from copy machine. Transport Belt Range the sheets at accumulate section. Then transport it by pusher when it formed 1 set. Power Switch This switch supplies power to the rear service outlets that powers the stapler/ folder, and fore-edge trimmer.

Vacuum Feed Roller Vacuum lifts the cover for transport Sheet Height Detect Section There is a sensor used to keep the pile of sheets at a specific height. Cover Tray Motor Moves cover tray up and down Change Gate Used to direct sheets, which are not going to be bound, to the stacker section by opening the gate.

Stacker Section Sheets which will not be bound are off-set by sets or booklet and stacked for delivery.
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Shift Tray Bracket Moves up and down according to paper height

Off-set Motor Used to off-set the sets delivered to stacker section.

1-4

SPF-9R

1-4 Description of Staple and Fold Section - SPF (1)

Transport Roller Unit Transport the booklet which is stapled.

Top Cover SPF-9R does not move when top cover is opened Top-and-tail Guide (drive side) Jog the sheets

Stapling Stopper Unit Sheets to be stapled will hit this stopper.

Transport Belt

Top-and-tail Guide (operation side)

Staple Section Two Staple Units are set under this cover. Remove this cover to replace staples.

Operation Panel

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1-5

SPF-9R

1-4 Description of Staple and Fold Section - SPF (2)

Stapling Stopper Sheets stop by hitting this stopper, to be set at the correct position Gate Board This gate opens to transport booklets to fold section Stapling Stopper Unit Transport Roller (R) Unit Staple Unit Transport Roller (F) Unit Transport stapled booklet Jog Roller

Jog Plate Transport Roller Press Roller Bend folded part with this roller. Fold Roller [Inside of the machine] Fold Knife Thrust center of the sheets to put the sheets into fold roller Stopper Booklet hits the stopper to be set at correct position to be folded.
SM 1-6 SPF-9R

Transport Belt Transport sheets and booklet

1-5 Description of Fore-edge Trimmer FC Section

Top Cover SPF-9R does not move when top cover is opened Stripper Holds the booklet to trim Upper Knife Trim fore-edge of the booklet with lower knife as a scissors FC Upper Entrance Belt

Air Nozzle Blow air from this nozzle to clear the paper dust

Transport Belt Bar When a sheet jam occurs under transport belt, this bar must be pulled up to access jammed sheets Delivery Belt Transports the booklet

Transport Unit This section Holds booklet while trimming. After trimming, transport booklets with delivery belt Transport Belt

Transport Unit Stopper Booklet hits the stopper to be set at correct position to be folded. Lower Knife FC Lower Sensor Entrance Belt Used to detect the booklet when it comes Sensor to the stopper Detect the booklet Stopper Unit Moves the stopper up and down [Trim Section Figure in Details]

Transport Unit Knob Loosen this knob to remove transport unit.

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Operation Panel

1-7

SPF-9R

1-6 Description of Delivery Section (EC)

Power Code

[A figure seen from the top]

Delivery Sec- Fore-edge Section tion

Staple and Fold Section

Cover Feed and Stacker Section

The power of delivery section is supplied by staple and fold section Fore-edge Section Tray

Conveyor Belt This belt moves engaging to cutter section movement at staple and fold section.
SM 1-8 SPF-9R

1-7 Description of the Panel on Cover Feeder and Stacker (CFS) Section

Cover is opened

Cover Feed Section Cover, sheet jam No feed Double feed There is no cover, Front door is opened or feed tray is not in the right position Delivery Section to feed Cover is opened
Eject Tray Empty Check Stack Tray Check Staple Section Check Trim Section Stack Tray Up Stack Tray Down

Eject Button Used to eject the sheets remaining inside SPF-9R Feed Tray Up Button Feed tray goes up while this button is pressed. Double Feed Detect On/Off Button To turn on and off the double feed detect button Feed Detect ON/OFF On-lights Off-light out

Error Message Table Cover Open Sheet Jam Doube Feed No Feed

Feed Tray Up

Feed Tray Down

Error at staple section Error at trimmer section

Delivery Section Vertical Transport Section

Feed Tray Down Button Feed tray goes down while this button is pressed. Shift Tray Up/Down Button Shift tray moves up/down while this button is pressed.

Stacker Section Sheet jam Stacker is full, or stacker tray is not in the upper position. Horizontal Transport Section
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SPF-9R

1-8 Description of the Panel on Staple and Fold (SPF) Section

Error Lamp - No Staple Lamp Lights:When there is no staple Blinks:When staple cartridge is not set correctly. - Cover Open Lamp This lamp lights when top cover, cover of delivery guide or joint stage, and transport unit is opened. - Jam Lamp This lamp lights when sheet jam occurs at jog section or delivery section of SPF-9R.
Cover Open Jam Jam No Staple Size Set Mode

Clear Button Used to reset counter at zero.

Adjust Buttons Used to adjust guide, stopper and unit position for the sheets which are out of standard.

Clear

Unit Position Front Guide Rear Guide Left Stopper Right Guide Set Position

Run

Counter Function Mode Select Button Choose moving mode when SPF-9R is engaged with copy machine. Adjust Part Select Button This button is used to select the part requiring adjustment

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1-10

SPF-9R

1-9 Description of the Panel on Fore-edge Trimmer (FC) Section

Stopper Set Buttons These buttons are used to set stopper position to adjust trim length. Choose size adjustment at mode button on SPF-9R. Right Arrow Direction-Longer trimmings (shorter booklet) Left Arrow Direction-Shorter trimmings (longer booklet)
Cover Open

Cover Open Lamp This lamp lights when top cover is opened, or joint plate for stapler is opened Knife Lock Lamp This lamp lights when knife operation stops in the middle of trimming.

Stopper

CutterAction

Cutter Single Action Button This button is used to return cutter to the upper position when cutter operation stops in the middle of trimmings.

Jam Lamp This lamp lights when there is a jammed set at booklet entrance Jam Jam section. Jam Lamp Full Trimmings This lamp lights when Trimmings Box Open trimmed booklet does not move to the delivery section. Full Trimmings Lamp This lamp lights when trimmings box becomes full. Trimmings Box Open Lamp This lamp lights when trimmings box is not closed completely.
Cutter Lock

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1-11

SPF-9R

1-10 Mechanism of SPF-9R

(10) Delivery Section (7) Change Direction Gate (6) Staple Section Receive bound booklets When sheets should be folded, When selected, staple at one by one. this gate opens and transports the center of the sheets. the sheets to fold section [8]. (5) Cover Feed Section Transport a cover to mate with the set transported from accumulate section (4). (2) Gate Section Change the transport direction with the gate, to staple & fold section or stack section. (1) Entrance Section Receives the sheets from the printer

(9) Trim Section Trim fore-edge of the booklet

(8) Fold Section A fold knife pushs up the center of the sheets, and moves the sheets into the fold rollers.

(4) Accumulate Section Accumulate and jog the sheets one by one and when the set is complete, transport it to staple and fold section.

(3) Stacker Section Off-set the sheets forward and backward set by set . Tray moves down automatically as sheets are stacked. When the tray becomes full, the machine stops.
SPF-9R

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1-12

2. Troubleshooting
2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (1) ................. 2-14 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (2) ................. 2-15 2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (3) ................. 2-16 2-1-2 Booklet is not trimmed completely ................................................................ 2-17 2-1-3 Skew Trimming Occurs .................................................................................. 2-17 2-1-4 Wrinkle Appears on the Bound Booklet ....................................................... 2-18 2-1-5 Booklets Are Stained....................................................................................... 2-18 2-1-6 Sheets Comes Off from the Booklet............................................................... 2-19 2-1-7 Sheets Are Not Jogged Properly .................................................................... 2-20 2-1-8 Stapler Does Not Staple .................................................................................. 2-21 2-2-1 Cover Feeder Does Not Feed Covers ............................................................. 2-22 2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down) ............................................................................................... 2-23 2-2-3 Double Feed Occurs Frequently in Cover Feeding ..................................... 2-24 2-2-4 No Feed Occurs Frequently in Cover Feeding ............................................ 2-25 2-2-5 Sheets Are Not Off-set ................................................................................... 2-26 2-2-6 Stack Tray Does Not Move Up and Down ................................................... 2-27 2-2-7 Stack Tray Does Not lower although there are many sheets .................... 2-28 2-3-1 Booklet Jam Occurs Frequently at Staple Section ....................................... 2-29 2-3-2 Booklet Jam Occurs Frequently at Fold Section(1) .................................... 2-30 2-3-2 Booklet Jam Occurs Frequently at Fold Section(2) .................................... 2-31 2-3-3 Booklet Jam Occurs Frequently at Trim Section ........................................ 2-32

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2-13

SPF-9R

2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (1)

[Explanation] Stapling and Folding occur in two parts. First staple the sheets and then fold the sheets. Therefore problems may occur in two areas, and three cases (See Figures below and at right) according to the way of occurring are considered.

Case A
Staple Line

[Case A] Both fold line and staple line are not in the center] Sheet size is not within specification If the sheets are out of specification, Sheets can not be stapled, or folded in the center. [Standard size includes A3, A4, B4] Adjust the position of the guide and the stopper by adjust buttons. Refer to [1-8].

Case B
Staple Line

Fold Line

Stopper position is not correct - Run just one sheet from copy machine, fold it without stapling and trimming. - If the sheet is not folded in the center, adjust the stopper position. Refer to the operation manual [3-5 When Fold Line Is Not in the Center of the Booklet.]. - If the position can not be corrected by stopper adjust knob ( 2 mm), the position of the stopper is not correct. Check if settings of timing pulley which moves the fold stopper is not loosened. If it is, adjust stopper position. Refer to [3-2-8 Stapling Stopper Adjustment].

Stitch Line Case A Case B Case C Not in the center Correct Not in the center

Fold Line Not in the center Not in the center Correct

Fold Line

Case C
Staple Line

Fold Line

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2-14

SPF-9R

2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (2)

[Case B] Staple line is OK, but fold line is not in the center. The position of home position sensor is not correct - Stopper for stapling and folding are driven by timing belt, and there is only one home position. If this home position sensor is not in the correct position, both the stopper for stapling and folding are shifted the same distance.
Timing Belt

A foreign object or a piece of jammed sheet is left in the fold guide or near the stopper - Fold line will be changed when there is a foreign object

The number of the sheets are three or less and the sheets are too soft. - When using a few soft sheets, sheets are bent inside the fold guide and fold line will not be in the center. Use thicker sheets [about 80 gsm (70 Kg)] Sheet grain direction is not proper

Folding Roller Fold Guide Section A Foreign Object

- When using the horizontal grain direction sheet, sheets are too thin to fold correctly. Use vertical grain direction sheets.

Home Position Sensor Folding Stopper

Stapling Stopper Stopper

Knife

FFFoldFold
If the operator selects more than 16 sheets (64 originals) the timing belt will slip and cause the fold to be in the incorrect place. Fold stopper error.

Joint Belt

Timing Belt

Fold Section at Stapler and Folder

Staple and Fold Stopper Section

SM 2-15 SPF-9R

2-1-1 Staple Line or Fold Line is not in the Center of the Booklet (3)

[Case C] Fold line is OK, but staple line is not in the center. Edge of the sheet is curled upward - When edge of the sheets are curled upward they may run over the stopper and the stop position can not be decided correctly. In this case, fix the curl before printing. - When sheet is stapled diagonally as the figure above Top-and-tail guide is deformed. - If guide is deformed, sheets are set diagonally and stapled. Repair the guide so that it is at right angles to the stopper. Staple unit is set diagonally - This problem can be solved by resetting the position of stitch section. Refer to [3-2-6 Staple Unit Lean Adjustment] for repairing.
R side (drive side) Fixing Metal R Pin Hole R

The edge is curled Stopper Section

Staple Section R Frame

Top-and-tail guide (drive side) Staple Unit Staple Base

Sheet

Pin Hole F

Staple and Fold Section at Stapler and Folder

F Frame Top-and-tail guide (Operation side)

Fixing Metal F F side (operation side)

Staple section at stapler and folder

SPF-9R

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2-16

2-1-2 Booklet is not trimmed completely

2-1-3 Skew Trimming Occurs

Trimming Remain

Thickness of the booklet is not within specification - Maximum sheet thickness to trim is 32 sheets when using 70 Kg paper. (16 sheets can be stapled and folded) If using heavier sheets, booklet can not be trimmed completely by trimmer. Trimming knife does not trim well - Life for trimming knife is fifty thousand times when using fine quality paper. Replace it by following [4-4-2 Replacing Cutter].

Folded part of the booklet is swelled - When using thick sheets, it prevents the booklet from being transported correctly. Booklet can not hit the stopper correctly, so the booklet is trimmed diagonally. Use thin paper to reduce the swell. Transport belt is stained and does not transport the sheets well - When transport belt is stained by paper dust, it can not transport the booklets correctly, and does not hit the stopper. Clean the belt. O = OK X = NG
2-17

Stopper itself is not straight. - When sheets are trimmed diagonally although it hits the stopper correctly, stopper itself is not straight. Refer to [4-4-1 Stopper Solenoid Replacement] to adjust the stopper.

SM

SPF-9R

2-1-4 Wrinkle Appears on the Bound Booklet

2-1-5 Booklets Are Stained

Wrinkle

Stain

Gap adjustment of fold roller and press Roller is not correct - When gap between fold roller and press roller is not set correctly, the difference of each roller's speed makes wrinkles when they catch the booklet. Adjust the gap by following [3-2-4] Fold Roller Gap Adjustment, [3-2-5] Press Roller Gap Adjustment.

Uneven parts of the sheets are stained - When uneven areas of a pair of fold rollers are stained by ink, all bound booklets will be stained in exactly the same areas. Clean the roller. Setting of lower cutter is loosened.

WARNING
- Turn off the power and remove the power cord to adjust the cutter section.
If the lower cutter fixing screws are loosened, grease comes out of the gap between the lower cutter and fixing block, and stains the booklet. Tighten the fixing screws on the lower cutter.

SM

2-18

SPF-9R

2-1-6 Sheets Comes Off the Booklet

[Case A] Cover comes off

[Case B] Sheets inside the booklet comes off

Cover Sheet inside the booklet

Press Roller

Sheets are slippy because of silicon -Silicon on sheets delivered from the copy machine make the paper very slippy. Especially high speed copy machines, which apply much silicon on the sheets. If the sheets are slippy, when the knife pushes up the center of the booklet (Fig1), only a cover comes faster than the rest. Fold roller folds the cover first, then folds the rest. In this time cover tears at the staple and comes off. -Insufflate silicon spray to fold roller, so that only a cover will not be folded first, and the cover will not come off. -Lessen the number of sheets to fold or use sheets under recommendation.
Fold Roller

Cutter section is stained -If top of the fold knife edge (Fig.1) becomes dirty, the inner sheet can stick to the knife. When the knife is pulled out, sheets inside the booklet comes off the booklet. -As well as cleaning the top of the knife, applying silicon spray to knife will prevent the knife from sticking to the sheets, and the sheets inside the booklet will not come off.
Sheets

Fold Knife

Fig.1 Fold Section Mechanism

SM

2-19

SPF-9R

2-1-7 Sheets Are Not Jogged Properly

Changing sheets size at copy machine, top-and-tail guide does not move correctly - Check following items. - Is drive motor (Fig2) for top-and-tail guide (Fig1) rotating? - Does each gear on motor gear section move correctly? - Is the top-and-tail guide setting loose?
Tail Booklet is uneven for topand-tail direction Adjust Screw B R Frame Adjust Screw A Top-and-tail Guide (Drive side)

Top

Adjust Screw D Adjust Screw D Jog Plate

Home position sensor of top-and-tail guide is not set properly - Is the sensor adjustment tight? - Is sensor connector pushed to the bottom? Top-and-tail guide are transformed - When top-and-tail guide is not parallel to the side frame or bent, sheets can not be arranged properly. Sheets sticks to each other by static electricity

F Frame Top-and-tail Guide Sheet should be (operation side) parallel to the jog plate

Top-and tail guide (both operation and drive side) not set correctly [Fig1] - To check the gap between top-and tail guides, put a sheet, the same size as the selected sheets, into the top-and-tail section of the stapler and folder. Check the gap by moving the sheet from operation side to drive side. If there is over 1 mm gap, it is not set correctly. Adjust the position of the guide. See [3-2-7 Top-and-tail Guide Parallel Adjustment] for adjustment. O = OK X = NG

Fig1

Top-and-tail Guide Section

Output Shaft

Motor

- If the sheets stick to other sheets due to static electricity, sheets can not be arranged properly.

Fig2
SM 2-20

Top-and-tail Guide Drive Section

SPF-9R

2-1-8 Stapler Does Not Staple

Staples Are Stacked inside the Cartridge at Staple Section - When staples jam or the cartridge is not set correctly, it can not be detected or indicate by the LED on the motor section. The sensor is not able to detect if staples are available. - Remove the cartridge to check it. See [4-1 How to Remove Jammed Staples] on the operation manual . - Check if stapled sheet in the staple cartridge moves smoothly. - If stapled sheet does not move freely because of sticking of the staple glue, remove the individual sheet of staples or replace the cartridge refill. There is a problem on gear section at staple section - Staple section is driven by a 24 VDC motor and a three gear reduction unit. When transmission from the gear section is not good, punch section does not move up/down and it can not staple. In this case, replace whole unit.
Flat Cable

Connection of bracket cable is not correct - Check if flat cable is put into the connector, of staple section up/down unit, completely. The flat cable is like a thin film, so it may not be inserted to the end. - Remove the staple assembly with care, two flat ribbon cables go to the stapler heads. These flat ribbon cables are easily damaged. Voltage of drive motor is not 24 VDC - Motor at staple section is 24 VDC - Measure the voltage at motor terminal section. - If the voltage is not 24 VDC, check the connection between motor connector and 24 VDC switching power supply.

Gear Section

Staple sheet moves lightly

Punch Section

SM

2-21

SPF-9R

2-2-1 Cover Feeder Does Not Feed Covers

Feed Tray Is Not Raised - When the Feed Tray Up button is pressed the tray lift motor raises the feed tray and covers. When raised, the tray pushes the sensor lever up and the tray stops raising when metal chip on the back of sensor lever is detected by the sensor. Go to [2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down)]. Feed Rotor Is Not Rotating - A cover vacuumed by feed rotor is transported by feed rotor rotation. - Feed rotor is driven by a stepping motor at the back of the machine. - When rotor does not rotate, check the timing belt and timing pulley. If there is no problem, check stepping motor. And if the motor is OK, there is a problem at control board. Feed Rotor does not suck cover - When feed rotor is rotating and cover is not sucked, check if blower motor M13 is operating. - If blower motor M13 is operating, there is a problem at valve motor section M11, or a duct is not connected. - If M13 is not operating, check breaker for blower Q01 and SSR for M13.
Valve Motor M11 Vacuum Side Duct Feed Rotor Sensor Sensor Lever Covers Feed Rotor

Feed Rotor

Feed Tray Tray Bracket Rack and Pinion Tray Lift Motor Stepping Motor

Blower Motor M13

SM

2-22

SPF-9R

2-2-2 Cover Feed Tray Does Not Move Properly (Tray Does Not Move Up and Down)
Pinion and rack of the motor is not fully engaged
Fully Engaged

The cog of rack plate/pinion is chipped

Guide roller is not rotating

Guide Roller

Pinion

Pinion Rack

Rack Plate

Pinion is not set properly - Loosen four fixing screws on the motor cover and remove the motor assembly and cover from the unit. Turn the pinion section by hand. If it is not normal, the motor shaft and pinion has a problem. Replace whole motor. Note: Motor pinion and rack can be observed through a small access slot on the left side of the motor cover.

- If the cog of rack plate is chipped, replace the rack plate - If the cog of pinion is chipped, replace whole motor. The motor itself does not move correctly. - Loosen four fixing screws on the motor and separate rack section from pinion, so that rack and pinion have no load. Then move feed tray up and down. If the motor does not rotate, remove the connector on the motor and check the voltage. If 24 VDC is not measured, check the power section of the 24V system.

Guide Roller Rack Plate

- Loosen four fixing screws on the motor while rack and pinion are separated. When moving the rack part shown above up and down by hand, check if two guide rollers rotates smoothly. If the guide roller does not rotate or does not rotate smoothly, guide roller section has a problem. - If guide roller does not move smoothly, apply grease to the gap between the guide roller and the shaft inside it.

SM

2-23

SPF-9R

2-2-3 Double Feed Occurs Frequently in Cover Feeding

Sheets are too thin (See specifications) - Minimum sheet thickness for SPF-9R is 45 kg. Too many sheets are stacked - Maximum sheet pile height is 80 mm. When using thin sheets, the booklet swells due to blower air. Sheets are not separated well - Sheets right after printing are not dried and may stick to each other. Double feed may occur in this way. Sheets are warped -Warp shown in the figure below causes double feed. Fix the warp within 0.5 mm. Gate board position is too low
Feed Rotor

Gap is too wide Rubber Double Feed Stop Plate Sheets

- The rubber plate at the edge of gate board is not touching the back of the sheets, so next sheet can not be stopped and double feed occurs. - Raise gate board so that gate board and rubber section touch the upper feed guide board. - When edge of the rubber is worn out, replace double feed stop plate.

SM

2-24

SPF-9R

2-2-4 No Feed Occurs Frequently in Cover Feeding

Sheets are too thick (See specifications) - Maximum sheets weight for SPF-9R is 157 gsm (135 Kg). - If the condition is good, 209.3 gsm (180 Kg) of A3 sheets can be fed, (but it is not guaranteed). Sheets are not separated well - Sheets right after printing are not dried and sticks to each other. No feed may occur. Dry and separate the sheets completely to set.
Rubber Plate Gate Board

Gate board position is too high

Sheets are pushed to upper section of the guide plate - If tray height detect sensor bracket has a problem, tray height can not be detected and tray keeps raising with the sheets until it stops by hitting the sheet height detect section. Sheets are pushed to the guide plate and no feed occurs.

Feed Rotor

Sheets are warped -Warp shown in the figure below causes no feed. Fix the warp.

- If the rubber at the edge of gate board attaches to the vacuum rotor, vacuumed sheets are dropped and no feed occurs. Lower the gate board. Feed ring is worn out - If the feed rings of the feed rotor are worn out, by long time use, misfeeds or no feed occurs.

Sheet Warp

SM

2-25

SPF-9R

2-2-5 Sheets Are Not Off-set

Off-set motor has a problem - Off-set at stacker section is operated by DC motor. - Measure the voltage at motor connector. If it is 24 VDC, it is OK. - Off-set is not operating although the voltage is 24 VDC and motor is trying to rotate. The motor gear head may be broken or a section of the motor drive shaft has a problem. Eccentric part has a problem. Output shaft on Off-set motor has a problem - Off-set is performed by the rotation of the bearing which is set at the eccentric position on the crank. - When the crank section to the motor output shaft is not tight enough, eccentric motion can not occur. - If bearing is broken, off-set can not be done.
Crank Bearing Off-set Motor Motor

Slide bearing at Off-set section has a problem - Off-set swing at stacker section is performed by the slide movement of four bearings on two shafts - When this bearing section breaks and be comes heavy, it can not be moved by the power of off-set motor, and circuit breaker trips. In this case, replace the bearing by following [4-2-23 Replacing Bearing at Shift Section].

Motor Bracket Sensor Plate

Bearing

SM

2-26

SPF-9R

2-2-6 Stack Tray Does Not Move Up and Down

Tray up/down motor has a problem - Stack tray moves up and down by DC motor. - Check the voltage of the connector when removing the connector at motor, and pressing stack tray up/down button on the panel. 24 VDC should be measured. - When the voltage is OK, and the motor moves or is trying to move when pressing stack tray up/down button, gear head of the motor is broken or there is a problem at drive section of the motor drive shaft. There is a problem at drive section of the motor drive shaft - Stack tray moves up and down by worm, worm wheel and timing pulley set on the DC motor. When attach screws of each part are loosened, the power of the motor can not be conducted. Check the attach screws. - Check if there is a problem with the timing belt or related components. Guide section of the tray bracket is broken - The stacker tray and bracket moves up and down using a 15 mm square post as a guide. Tray bracket moves up and down the 15 mm square post on two guide roller. If there is a problem with the guide rollers or post, tray section can not move up and down smoothly. Check if guide roller moves correctly and the condition of grease.
Guide Roller

Worm Worm Wheel Timing Pulley

15 mm square guide

Tray Up/ Down Motor Tray Up/Down Motor

Tray bracket

SM

2-27

SPF-9R

2-2-7 Stack Tray Does Not lower although there are many sheets
Sheet height detect lever is broken - Sheets pile height at stacker section is detected by detect lever. When the sheet pile comes to a predetermined height, sensor A detects it and lowers the tray by sending the proper signal. Then sensor B detects the low ered tray and stops it. If detect lever is bent, it can not detect sheet height correctly. Sheet height detect sensor has a problem - Lift the detect lever by hand and put it into sensor A, B. And check if LED19, LED18 on the control board (QPW-114) lights. - If the LED does not light, check if the connec tor to the sensor or wiring has a problem. - If the LED lights, check if output signal is coming. Output signal is coming if LED43, LED44 on control board lights. Tray up/down motor section has a problem - If the motor does not move when the output signal is coming to tray up/down motor and there is no problem at detect lever or sensors, there is a problem on the motor. - If the motor is not trying to rotate when the output signal is coming, check connector and electrical circuit of the motor. - If the motor is trying to rotate, there is a prob lem at motor drive section. Check [2-2-6 Stack Tray Does Not Move Up and Down].

Sensor B Sensor A B02 Sensor A

1 2 3

CON 10

Tray Up/Down Motor

LED 18 CON 13

MO1
DC

Detect Lever B03 Sensor B

1 2 3

LED 19

QPM-144

[B02,03 QPM144-M01]

SM

2-28

SPF-9R

2-3-1 Booklet Jam Occurs Frequently at Staple Section

Situation -Booklet which is stapled is left in the staple section There is a problem at upper part of staple unit - If trouble occurs at upper part of staple unit and staples are not stapled correctly, booklet can not be clinched (staple can not be bent) and jams. Remove staples. - Check the function of staple unit by test copying (it can be set at copy machine) before restarting the operation. Lower section of staple unit (clinch section) does not move properly - If clinch section does not move well, staples are not bent correctly, so the booklet is hooked inside the machine. In this way, a jam occurs. - Check if flat cable at clinch section is inserted correctly. - Drive motor at clinch section is 24 VDC. Check the voltage.

NOTE - If the head of the staple section stopped in the middle of the operation, turn off the power to the stapler and folder. Wait about 10 sec., then turn on the power. Head moves back to the home position [upper limit].

It is not clinched correctly

SM

2-29

SPF-9R

2-3-2 Booklet Jam Occurs Frequently at Fold Section (1)

Situation -It occurs only in stitching and folding. -Booklets remain in front of the fold roller -Booklet does not come out when [Eject] button is pressed. -Monitor lamp at staple and fold section lights The pressure of press roller is too strong - When a booklet is too thick, or the pressure between press rollers is too strong, the booklet may stop between the press rollers. Move the position of the hook for spring between press rollers to inside.

Situation -It occurs only in stitching and folding. -Booklets remain in front of the cutter. -Booklet does not come out when [Eject] button is pressed. Sheets are curled downward - When sheets are curled downward, it may jam and stop inside the fold guide after passing the gate. - Booklet is not delivered when pressing [Eject] button, because it does not reach the cutter section. - When fixing the curl, check if there is anything in the way of the sheets inside the fold guide.
Gate

Situation -It occurs only when stitching and folding. -Booklets are inside the fold guide and not folded. -Booklet does not come out when [Eject] button is pressed. Using thick sheets or covers - Maximum sheet thickness for stapling and folding is 16 sheets of 81.4 gsm paper (70 Kg) including the cover. When using thick and hard sheets, it may not be bent by the fold knife. In this case, use thinner soft sheets. - Knife is not in the home position. Turn off the power to remove the booklet, then wait about 10 sec. and turn on the power again. Then press [Eject] button on the CFS section.
Fold Roller Thick Cover

Fold Roller Sheet Fold Roller Lever Press Roller Fold Roller Fold Guide Fold Knife

Press Roller Press Roller Lever Press Spring

Thick Sheet Fold Knife

Stopper

SM

2-30

SPF-9R

2-3-2 Booklet Jam Occurs Frequently at Fold Section (2)

Situation - It occurs only when stapling and folding. - A part of the booklet is getting into the fold roller diagonally. - Booklet in CFS section does not come out when [Eject] button is pressed. Booklet is getting into fold roller section diagonally - Sheets delivered from copy machine may be curled or has static electricity. If the sheets are curled, the edge of the booklet will be bent during transportation. When it forms one set (booklet) bent pages becomes thick, so that it gets into the fold guide section diagonally. If fold knife is operated in this situation, both sides of the booklet catches and a booklet jam occurs. In this case, change the direction of the paper curl in the copier to limit or eliminate curl when copying.

SM

2-31

SPF-9R

2-3-3 Booklet Jam Occurs Frequently at Trim Section

Stapled and folded booklet swells - When using hard paper or thick paper, stapled and folded booklet swells. Especially making small size booklets such as folding 16 pages of A4 sheets to make A5 booklet. - Swelled booklet may jam at entrance or deliv ery section of the trim section. In this case, use thinner or soft paper. Transport belt slips - When the surface of the transport belt is slippery, from paper dust, ink or toner, it can not transport the booklets and booklet jam occurs. In this case, clean the surface of the belt. Stopper does not move smoothly? - Remove transport roller and lift the stopper by hand. If it moves easily, it is OK. When the stopper does not move well, booklets hit the stopper and jam.

Situation -It occurs at trim section. -Jam lamp on the monitor of trim section lights. Booklet is not completely trimmed - When the cutter becomes dull, it can not trim the booklet completely and a booklet jam may occur. In this case, replace the cutter. - Booklet may be too thick. Maximum thick ness that can be trimmed is 32 sheets of 81.4 gsm (70 Kg) (16 sheets stapled and folded). Although the number of the sheet is within specification, the sheets may not be trimmed completely when cutter became dull and/or when using coated paper. Use thinner sheets or fine quality paper.

Swell

Transport Roller

Upper Knife

Upper Transport Belt

Stopper

Transport Belt

Lower Knife

Lower Transport Belt SPF-9R

SM

2-32

3. Parts Adjustment
3-1-1 Entrance Section Transport Belt Tension Adjustment ................................3-34 3-1-2 Feed Belt Tension Adjustment .......................................................................3-34 3-1-3 Stacker Tray Up/Down Motor Belt Tension Adjustment ............................3-34 3-1-4 Cover Transport Belt Tension Adjustment ..................................................3-35 3-1-5 Feed Belt Pusher Parallel Adjustment ......................................................... 3-35 3-2-1 Transport Belt Tension Adjustment .............................................................. 3-36 3-2-2 Folding Roller Drive Belt Tension Adjustment ............................................ 3-36 3-2-3 Chain Tension Adjustment ............................................................................3-36 3-2-4 Folding Roller Gap Adjustment .................................................................... 3-37 3-2-5 Press Roller Gap Adjustment ........................................................................ 3-37 3-2-6 Staple Unit Lean Adjustment ......................................................................... 3-38 3-2-7 Top-and-Tail Guide Parallel Adjustment ..................................................... 3-38 3-2-8 Stapling Stopper Adjustment ......................................................................... 3-39

SM

3-33

SPF-9R

3-1-1 Entrance Section Transport Belt Tension Adjustment

3-1-2 Feed Belt Tension Adjustment

3-1-3 Stacker Tray Up/Down Motor Belt Tension Adjustment

Idler Shaft

Entrance Motor

1. Adjust the tension by moving entrance section up and down. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.

1. Adjust the tension by moving idler shaft from operation side, and arrow A showing part at drive side board. 2. Adjust the tension so that when pressing the belt at the arrow above by 200g~300g, the flexure should be 5 mm.

1. Adjust the tension at bracket which locates under stacker tray. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.

SM

3-34

SPF-9R

3-1-4 Cover Transport Belt Tension Adjustment

3-1-5 Feed Belt Pusher Parallel

Clutch
A

Timing Pulley

Pusher

Pusher
B

Lower Jog Guide Plate

Cover Transport Motor

Feed Belt

Idler Shaft

1. Adjust the tension at idle pulley A and B. 2. Adjust the tension so that when pressing the arrow above by 200~300g, the flexure should be 5 mm.

Adjust the pusher on both feed belts to be parallel to lower jog guide plate (figure shown above A=B) 1. Turn off the power of SPF-9R. 2. Loosen the idler shaft. 3. Move the pusher on feed belts so that A and B shown on the figure above become of equal distance. 4. Extend the tension by following [3-1-2 Feed Belt Tension Adjustment]

SM

3-35

SPF-9R

3-2-1 Transport Belt Tension Adjustment

Staple Section

3-2-2 Folding Roller Drive Belt Tension Adjustment

3-2-3 Chain Tension Adjustment

Tension Pulley Tension Sprocket Tension Roller Shaft Motor Shaft Motor Pulley Motor Shaft

1. Adjust the tension by moving the tension roller shaft right and left. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm. NOTE - When moving the shaft, operation side and drive side of the tension shaft should be moved exactly same distance. If not, the belt may move from the crown of the pulley.

1. Adjust the tension by moving the tension pulley up and down. 2. Adjust the tension so that when pressing the belt at the arrow above by 200~300g, the flexure should be 5 mm.

1. Extend the tension by moving the tension sprocket shaft up and down. 2. Press tension sprocket shaft down by hand and lock it where chain is fully extended. Extend the chain so that it does not sag.

SM

3-36

SPF-9R

3-2-4 Folding Roller Gap Adjustment

3-2-5 Press Roller Gap Adjustment

Folding Roller Urethane 0.1~0.15 mm. Gap Press Roller Moving Press Roller Allen Bolt with Urethane Fold Roller Trough Section About 0.6 mm Knife Fixed Press Roller

Folding Roller

Allen Bolt with Urethane Gap of One 55 kg Fine Quality Paper

1. Turn off the power to remove the cover. 2. Adjust the allen bolt with urethane tip so that the gap between the fold rollers becomes 0.1~0.15 mm. 3. Turn the motor section of the fold knife by a hand, and press the knife to furthest position. 4. Adjust the allen bolt with urethane tip so that gap between the trough section of fold roller and flat section of the knife becomes about 0.6 mm. NOTE - When folding roller gap is not adjusted correctly, the face of the book may be torn, or the booklet may be delivered diagonally and causes booklet jam.
SM

NOTE - Procedure 2 and 4 should be performed at the same time. Press the knife beforehand, then perform procedure 2. In this way it is easier to set. - Lock the roller after adjustment. At this time, make sure that allen bolt does not rotate. Check the gap after locking the roller. REFERENCE - The thickness of one sheet of fine quality paper (63 gsm/55 Kg) is about 0.1 mm.

1. Put one 63 gsm/55 Kg fine quality paper between the rollers, then attach moving press roller to the sheet by allen bolt with urethane tip. 2. Remove the sheet and adjust the gap. Cut the sheets into 2~5 cm strips. Then put one strip at the right end, and left end of the roller and rotate the roller by a hand. Adjust the gap so that the strips are moved through the rollers lightly at this time. 3. Lock the nut.

3-37

SPF-9R

3-2-6 Staple Unit Lean Adjustment

3-2-7 Top-and-Tail Guide Parallel Adjustment

Drive side of the side frame

Top-and-tail guide
Staples Parallel

NOTE - When staple line looks like figures above although sheet guide and stopper are set correctly, adjust the staple line at the staple unit. - Loosen four fixing screws at the stitch unit, then rotate whole unit and tighten it. Unit is able to move 2 mm.

NOTE - The top-and-tail guide (operation and drive side) should be adjusted parallel to the side frames. - Top-and-tail guide is mounted only by a slide block which drives this guide. - Positions of each guide are set by home position sensor and detecting plate. 1. Loosen the plate screw, the attaching screw of the (1) top-and-tail guide. 2. Loosen screw (2) to do parallel adjust ment. (Guide moves around the screw (1). 3. After the parallel adjustment, turn off the power once. Wait about 10 sec., and turn on the power again to move each parts to the home position.

(1)

Operation side of the side frame

(2)

Slide Block

Detecting Plate

SM

3-38

SPF-9R

3-2-8 Stapling Stopper Adjustment

Timing Pulley A

Stapling Stopper

1. Measure the fold deviation beforehand. 2. Loosen the fixing screws of timing pulley A. 3. Rotate timing pulley A by hand to move stapling stopper to correct position. 4. Tighten the fixing screws of timing pulley A. 5. Perform stapling and folding to check the fold line. Refer to [2-1-1 Staple Line or Fold Line is not in the Center of the Book let] on manual for fine tuning.
SM 3-39 SPF-9R

SM

3-40

SPF-9R

4. Parts Replacement
4-1-1 Removing the Cover of CFS Section .............................................................. 4-42 4-2-18 Replacing Shift Motor .................................................................................. 4-54 4-1-2 Removing the Cover of SPF Section .............................................................. 4-43 4-2-19 Replacing Worm on the Upper/Lower Stacker ............................................. 4-55 4-1-3 Removing the Cover of FC Section ................................................................ 4-44 4-2-20 Replacing Clutch ........................................................................................... 4-55 4-2-1 Replacing Cover Detect Sensor ...................................................................... 4-45 4-2-21 Replacing Stacker Height Detect Lever ....................................................... 4-55 4-2-2 Replacing Sheet Height Detect Sensor ........................................................... 4-46 4-2-22 Replacing Feed ............................................................................................ 4-56 4-2-3 Replacing Double Feed/No Feed Detect Sensor ............................................. 4-47 4-2-23 Replacing Bearing at Shift Section .............................................................. 4-56 4-2-4 Replacing Double Feed Stop Plate ................................................................. 4-48 4-3-1 Removing Staple Section ............................................................................... 4-57 4-2-5 Replacing Tray Lift Motor .............................................................................. 4-49 4-3-2 Replacing Upper Staple Section .................................................................... 4-57 4-2-6 Replacing Rack Plate ...................................................................................... 4-49 4-3-3 Replacing Lower Staple Section .................................................................... 4-58 4-2-7 Replacing Guide Roller .................................................................................. 4-49 4-3-4 Positioning Upper/Lower Staple Unit ............................................................ 4-58 4-2-8 Replacing Feed Roller .................................................................................... 4-50 4-3-5 Replacing the Fold Guide ............................................................................4-59 4-2-9 Replacing Feed Ring ....................................................................................... 4-51 4-3-6 Replacing Knife Section ................................................................................ 4-60 4-2-10 Replacing Blower Motor ............................................................................... 4-52 4-3-7 Replacing Press Roller ................................................................................... 4-60 4-2-11 Replacing Valve Motor ................................................................................. 4-52 4-3-8 Replacing Fold Roller .................................................................................... 4-61 4-2-12 Replacing Stacker Tray Up/Down Motor ..................................................... 4-52 4-3-9 Replacing Jog Section Solenoid ..................................................................... 4-61 4-2-13 Replacing Reduction Motor .......................................................................... 4-53 4-3-10 Replacing Stapling Stopper Solenoid .......................................................... 4-61 4-2-14 Replacing Entrance Motor ............................................................................ 4-53 4-3-11 Replacing Transport Roller R Solenoid ....................................................... 4-62 4-2-15 Replacing Main Motor .................................................................................. 4-53 4-3-12 Replacing Transport Roller F Solenoid ....................................................... 4-62 4-2-16 Replacing Cover Feed Motor ........................................................................ 4-54 4-4-1 Replacing Stopper Solenoid ........................................................................... 4-63 4-2-17 Replacing Width Adjustment Motor ............................................................. 4-54 4-4-2 Replacing Cutter ............................................................................................ 4-64 SM 4-41 SPF-9R

4-1-1 Removing the Cover of CFS Section

Front cover at cover section

Rear Cover at Cover Section

Rear Cover

Cover (R) Cover (L)

SM

4-42

SPF-9R

4-1-2 Removing the Cover of SPF Section

Cross Binding Screw Top Cover Cross Binding Screw (inside the machine)

Put this tab into the slit at a bottom of an upper cover to position the cover. Remove two screws from inside and pull out the upper section toward operation side, then lift it to remove.

Cross Binding Screw Move the upper section of the unit rearward and push this area back to locate lower cover screws. Loosen these screws and pull the lower cover toward the front, then lift it to remove. Lower Cover Put the head of the screw into the hole at a bottom of a lower cover to position the cover.

Lower Cover

Lower Cover

SM

4-43

SPF-9R

4-1-3 Removing the Cover of FC Section

Top Cover Put this tab into the slit at a bottom of an upper cover to position the cover.

Move the upper section of the unit rearward and push this area back to locate lower cover screws. Loosen these screws and pull the lower cover toward the front, then lift it to remove.

Top Cover Remove two screws from inside and pull out the upper section toward operation side, then lift it to remove.

Lower Cover Lower Cover Put the head of the screw into the hole at a bottom of a lower cover to position the cover.

Lower Cover

SM

4-44

SPF-9R

4-2-1 Replacing Cover Detect Sensor

Cover Detect Sensor

When cover detect sensor is broken or contaminated with paper dust, it may detect the cover although there is no cover, and No Feed Error occurs. To check if sensor is working correctly or not, block the hole at detect section on the feed tray with white paper. If LED on the sensor lights, it is working correctly.

1. Raise feed tray to upper limit in order to make replacing operation easy. 2. Cover detect sensor B12 can be seen under the cover feed tray. 3. Remove connector section at sensor B12 and remove B12.

CAUTION - The detector of the sensor can be blocked easily by paper dust. If the LED lights although there is no paper, clean the detector of the sensor.

SM

4-45

SPF-9R

4-2-2 Replacing Sheet Height Detect Sensor

1. Remove the connector of sheet height detect sensor B17. 2. Remove Sensor Box. 3. Remove sensor cover. 4. Check that metal plate for detecting is attached to the back of the sensor lever. If there is no metal plate, sensor B17 is OK. Attach metal plate by following the figure shown below.
Sensor BOX

If sheet height detect sensor B17 (cover height) does not function, feed tray keeps raising and stops. To check if sheet height detect sensor is broken, confirm that the connector is connected and put a metal chip to detect section of the sensor. If LED on the upper sensor section does not light, height detect sensor is broken.(See section 7-1-2, LED No. L20) NOTE - If the board indicated sensor error although the sensor has no problem, the following four reasons should be considered. (1) Connector section is not connected well (2) Wiring is disconnected (3) Board is not working correctly (4) Detecting plate on the back of sensor cover is missing.

5. Replace sensor B17.

Sensor B17 Detect Section

CAUTION - Clean the position to glue on the sensor lever.

Detecting Plate (M072571-XX)

Sensor Lever Metal Plate is on the back of the sensor lever SM 4-46

Sensor Lever (M072564-XX)

SPF-9R

4-2-3 Replacing Double Feed/No Feed Detect Sensor

Sensor Mechanism
Projector Lamp (12V) White Black Receiver Sensor Plate Purple Brown

Following reasons are considered for the sensor trouble

Double feed/no feed detect sensor B16

If double feed/no feed detect sensor section does not function, double feed or no feed can not be detected. When detection at sensor section is unstable, clean projector and receiver of the sensor. The receiver gets blocked easily by paper dust. (See section 7-1-2, LED L50)

1. Remove front cover at cover feed section. 2. Remove the connector of double feed/no feed detect sensor B16. 3. Remove sensor plate and pull it out. 4. Remove sensor B16 from sensor plate.

(1) Paper dust is collected on the receiver. (2) Receiving lamp, or receiving element turns off. This problem can be checked by each tester. (3) Light shaft is shifted. Light shaft may be shifted by using the machine for long time. (4) Connector section is not connected well

Light shaft is shifted by the transformation of plastic part

SM

4-47

SPF-9R

4-2-4 Replacing Double Feed Stop Plate

When the rubber of double feed stop plate is worn out, double feed or skew feeding occurs frequently. 1. Lower the feed tray, so that replacement is operated easily. 2. Turn off the power of SPF-9R. 3. Loosen the fixing screw of double feed stop plate and pull out the gate plate to remove it to operation side.

To Attach Attach double feed stop plate in the reverse order of removal. NOTE - When setting the double feed stop plate, press it down to tighten the screws. (To bring the plate level)

When to replace Replace double feed stop plate when the flat section at the top of the rubber is worn out. NOTE - In normal use, flat part will be worn out when it is used about one million times.
Replace double feed stop plate when flat section at is worn out

Double Feed Stop Plate

Rubber Section

Worn Out Part

[Double Feed Stop Plate]

SM 4-48 SPF-9R

4-2-5 Replacing Tray Lift Motor

4-2-6 Replacing Rack Plate

4-2-7 Replacing Guide Roller

Motor Cover

Cog Roller Shaft

(5)

Rack Plate

Tray Lift Motor

Tray Bracket Rack Plate Guide Roller

1. Raise the feed tray to upper limit, so that tray will not be lifted by the spring when tray lift motor is removed. 2. Turn off the power of SPF-9R. 3. Remove rear cover 4. Remove the connector of Tray Lift Motor 5. Remove motor cover from the machine. 6. Remove Tray Lift Motor from motor cover.

1. Remove tray lift motor unit from SPF-9R by following procedures 1-5 on [4-2-5 Replacing Tray Lift Motor]. 2. Remove rack plate from Tray bracket, and replace it with a new one. NOTE - Apply grease to cog section of the Rack Plate.

1. Remove rack plate by following [4-2-6 Replacing Rack Plate]. 2. Pull out roller shaft to replace guide roller. NOTE - If the roller shaft is worn out, remove it, too. - Apply grease lightly to outside of the guide roller.

SM

4-49

SPF-9R

4-2-8 Replacing Feed Roller

(3)

Vacuum Cock

Slot Tab

Timing Belt
(4)

Feed Rotor

4. Remove timing belt from timing pulley. (Rotate pulley by a hand, and it is removed easily.) 5. Remove vacuum cock. Feed Roller will fall off, so hold it to remove.

6. Remove rotor section by keeping it level and pulling it out to the operation side.

Transport Roller Shaft

1. Turn off the power of SPF-9R. 2. Open delivery side cover of cover feed section. 3. Remove upper cover at cover feed section.

NOTE - There is a tab inside the vacuum cock, and this fits to the slot of the pipe. When setting the vacuum cock, insert the tab into the slot.

CAUTION - Drive side of the rotor section is put into valve block, so keep the rotor section level and pull it out at a right angle to the side frame.

SM

4-50

SPF-9R

4-2-9 Replacing Feed Ring

Wave Washer

0.3 mm

Thrust Ring Feed Ring

Thrust Ring

1. Remove rotor section by following [4-2-8 Replacing Feed Roller]. 2. Cut the feed ring with nippers and remove it. 3. Place new feed ring to the certain position. Stretch the new feed ring in from the edge of the pipe, over the Thrust Ring and into the individual slots. NOTE - To more easily fit the feed rings into their slots, press the vacuum rotors against the wave washer. This will allow the feed ring to fit easily.
Wave Washer

Timing Belt Feed Ring

Feed ring is 0.3 mm larger than the feed rotor on each side (0.6 mm total). If this diameter is worn down, the function to feed will go down.

Transport Roller Shaft

CAUTION: - DO NOT LOOSEN THRUST RING. It is assembled to regulation distance at factory. If Thrust Ring is loosened, the regulation distance changes and the function as a feed rotor may decline.

Operation side Thrust Ring Vacuum Rotor Vacuum Rotor Feed Ring

SM

4-51

SPF-9R

4-2-10 Replacing Blower Motor

4-2-11 Replacing Valve Motor

4-2-12 Replacing Stacker Tray Up/Down Motor

Valve Motor M11

(4)

(5)

(5)
(6)

(8)

Valve housing
(7) Valve

(6)

Valve Spacer Blower Motor M13

(5)

Stacker tray up/ down motor M01

(5) (4)

1. Turn off the power of SPF-9R. 2. Remove cover (R) 3. Remove the connector of blower motor M13. 4. Remove hose duct. 5. Remove blower motor section from SPF-9R. 6. Remove it with the whole box.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector and duct hose of valve motor M13. 4. Remove two screws (inside) on valve block and remove valve block from SPF-9R. 5. Remove hose connector. 6. Valve spacer has a specific direction. Mark the spacer in order to set it back in the same direction. 7. Loosen the fixing screws on the valve. 8. Remove four fixing screws on valve motor M11 to replace it.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the cover of Stacker tray up/ down motor M01. 4. Remove the timing belt. 5. Remove motor section on M01 from SPF-9R. 6. Loosen the worm shaft fixing screws. 7. Remove 4 screws on motor M01 and replace the motor.

SM

4-52

SPF-9R

4-2-13 Replacing Reduction Motor

4-2-14 Replacing Entrance Motor

4-2-15 Replacing Main Motor

Motor bracket
(4) (5)
(5)
(4)

Reduction Motor M04 Reduction Shaft

(6)

Entrance Motor M03 Pulley Shaft

(5)

Main Motor M06 (Book Block Delivery Motor)

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of reduction motor M04. 4. Loosen two connecting screws between motor output shaft and reduction shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor from motor bracket and replace it.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of entrance motor M03. 4. Remove transport belt. 5. Remove motor bracket from SPF-9R. 6. Remove timing pulley, then remove entrance motor.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of M06. 4. Loosen two connecting screws between motor output shaft and reduction shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor M06 from motor bracket and replace it.

SM

4-53

SPF-9R

4-2-16 Replacing Cover Feed Motor

4-2-17 Replacing Width Adjustment Motor

4-2-18 Replacing Shift Motor

(4)

(6)

Motor Bracket
(4)

Cover Feed Motor M12

(6) (5)

Motor

Shift Motor M05

(5)
(5) (6)

Width Adjustment Motor M02 Crank Sensor

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of cover feed motor M12. 4. Loosen two connecting screws between motor output shaft and pulley shaft. 5. Remove motor bracket from SPF-9R. 6. Remove motor M12 from motor bracket to replace it.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove the connector of width adjustment motor M02 4. Remove timing belt. 5. Remove motor bracket from SPF-9R. 6. Remove timing pulley. 7. Remove motor M02 from motor bracket to replace it.

1. Turn off the power of SPF-9R. 2. Remove cover (R). 3. Remove the connector of shift motor M05 and the connector of a sensor. 4. Remove motor bracket from SPF-9R. 5. Remove Crank section from motor output shaft. 6. Remove motor M05 from motor bracket to replace it.

SM

4-54

SPF-9R

4-2-19 Replacing Worm on the Upper/Lower Stacker

4-2-20 Replacing Clutch

4-2-21 Replacing Stacker Height Detect Lever

Bearing
(3)

(2)

Sensor Plate

(4)Worm

Shaft Bearing Motor Bracket

Worm Wheel Bearing

Clutch

Shaft Stacker Up/Down Motor

(5) Timing Pulley

Snap Ring Snap Furniture

(3)

1. Remove motor unit from the unit position by following [4-2-12 Stacker Tray Up/Down Motor] 2. Remove upper bracket. 3. Pull out the middle shaft. 4. Loosen the fixing screws of the worm and pull out the worm from motor output shaft. 5. Remove timing pulley and loosen the snap ring of the worm wheel, then pull out the shaft to remove the worm wheel.

[Enlarged Section] 1. Turn off the power of SPF-9R. 2. Remove rear cover at cover feed section. 3. Remove the connector on clutch section. 4. Remove the belt. 5. Remove snap furniture. 6. Remove the snap ring of the shaft and remove the clutch.

Lever

1. Turn off the power of SPF-9R. 2. Remove front cover. 3. Remove the fixing screws of sensor plate and remove detect lever section. At this point the wires of the sensor are still connected. Remove it slowly. 4. Remove two connectors on the sensor. 5. Remove lever from sensor plate to replace it.

CAUTION - The two connectors are the same. Mark each connector when removing it in order to put it back properly.
SM 4-55 SPF-9R

4-2-22 Replacing Feed

4-2-23 Replacing Bearing at Shift Section

(5) Top Plate Shift (7) Middle Guide

(7)Plate (6) Slide Shaft

Feed Belt
(3) (2)

Motor Stay Plate

(4)

[A Section] 1. Turn off the power of SPF-9R. 2. Loosen screw (2) (Loosen the opposite side too.) After feed belt is loosened, remove screw (2) (Remove the opposite side too). 3. Remove the belt shaft from the hole (3). 4. Remove the snap ring of drive shaft at (4). The other side of that shaft is tied to motor output shaft. Loosen this two snap screws.

Bearing

(5)

(3)

Shift Motor Section

5. Pull the drive shaft so that edge at the bottom of drive shaft comes out of the bearing on the side frame. 6. Remove middle guide. Remove by passing it through loosened timing belt. 7. Remove feed belt by passing it through the inner part of drive shaft.

1. Turn off the power of SPF-9R. 2. Remove right and left cover to open the front door. 3. Remove shift motor section by following [42-18 Replacing Shift Motor]. 4. Remove blower motor by following [4-210 Replacing Blower Motor] 5. Remove motor stay plate. 6. Remove two slide shaft. 7. Remove the bearing stuck to the shift tray and replace it.

SM

4-56

SPF-9R

4-3-1 Removing Staple Section

4-3-2 Replacing Upper Staple Section

Stay Fixing Shaft

Transport Unit F Upper Staple Section Positioning Pin

Guide Plate

1. Turn off the power of SPF-9R. 2. Remove top cover. Remove two hinges and a stay fixing shaft section. 3. Remove the cover on stitch section by pulling up two knobs. 4. Remove two guide plates. Remove it by passing through the staple unit. 5. Remove the connector of transport unit F/R. 6. Remove bracket cable connected to staple section. - To remove upper unit, remove two bracket cable on staple board. - To remove lower unit, remove CON 12 and14 on control board QPW-503 (Refer to 7-1-5).
SM

7. Remove four fixing screws on staple unit. 8. Lift staple section slowly.

NOTE - If staple section has a problem, it will be better to replace whole staple unit. Please return removed unit to the factory. It can be recycled. 1. Remove whole staple section by following [43-1 Removing Staple Section]. 2. Remove four fixing screws. 3. Press down the upper staple section and remove it from positioning pin. 4. Move the upper staple section forward and remove motor section by lifting it.

CAUTION - Flat cables (2) connected to the lower staple units must be carefully disconnected. - Connector of the solenoid at the bottom of the staple section must also be disconnected.
9. Remove the connector on solenoid. Now whole staple section is removed.

CAUTION - When installing a new unit, aligning it to the lower unit is needed. Go to [4-3-4 Positioning Upper/Lower Staple Unit].
SPF-9R

4-57

4-3-3 Replacing Lower Staple Section

4-3-4 Positioning Upper/ Lower Staple Unit

Upper Staple Section

(3)

Lower Staple Section

Positioning Pin

Positioning Instrument

NOTE - If staple section has a problem, it will be better to replace whole staple unit. Please return removed unit to the factory. It can be recycled. 1. Remove whole staple section by following [4-3-1 Removing Staple Section]. 2. Remove upper staple section by follow [4-3-2 Replacing Upper Staple Section]. 3. Remove four fixing screws of lower staple section and remove lower staple unit.

CAUTION - When installing a new lower staple section, aligning it with the upper staple section is needed. Go to [4-3-4 Positioning Upper/Lower Staple Unit].

CAUTION - Position upper/lower staple unit by using special positioning instrument.

1. Set lower staple unit first temporarily (Fix it after it is positioned). 2. Fix upper staple Section. 3. Pull out staple cartridge of upper staple unit and set the positioning instrument. 4. Turn the gear section on the upper staple by hand and lower the head section little by little, then adjust the lower staple so that positioning pin enters to the hole under the unit. 5. Fix lower staple Section.

SM

4-58

SPF-9R

4-3-5 Replacing the Fold Guide

(4) Fold Guide (L)

(5) Drive Shaft

(3) Fold Guide (U)

Stay B (6) Stopper Guide Stick Timing Belt (4) Spacer Lower Left Cover Stay A Stopper Block

1. Turn off the power of SPF-9R. 2. Remove upper and lower cover at front, at back and lower left cover. 3. Remove upper fold guide (four nuts and two screws). Operate removing from the opening part on lower part of the right side. 4. Remove spacer and lower fold guide.

5. Remove drive shaft - Remove the rear belt of drive shaft. - Remove a snap ring at operation side and press the shaft in the drive side. - Remove timing belt from pulley. 6. Remove stopper section - Remove the bracket which fixes the timing belt and the stopper block. - Loosen the screw which fixes the guide stick, and loosen the snap screw. - Remove fixing screws of stay A and B, then remove guide stick from stay A and B.

SM

4-59

SPF-9R

4-3-6 Replacing Fold Knife Section

Cutter Clank Section
Link A

4-3-7 Replacing Press Roller

Fold Roller Knife Holder Fold Knife Link B Sensor Detect Cam Knife Holder Fixing Screws Press Roller Press Roller Lever Press Spring Guide Post FoldKnife Motor

Knife Guide Section

Fold Knife Motor

When replacing only the fold knife 1. Turn off the power of SPF-9R. 2. Remove upper and lower rear cover. 3. Remove four fixing screws of knife holder on two guide post from square window section on the back. 4. Remove link A. 5. Remove a knife holder with a knife, and replace the knife. NOTE -When setting the fold knife, fix the knife after deciding the position by two positioning holes.

When replacing the fold knife motor

1. Remove the fold guide by following [4-3-5 Replacing the fold guide]. 2. Remove the bearing 25 in diameter at the end of the fold guide section [Parts Book Fig. 2-10]. 3. Remove connectors of motor and sensor. Then remove the terminal connected to the condenser. 4. Remove link A and B. There is a spacer between them. Do not lose it. 5. Remove detect cam. 6. Remove four fixing screws of knife motor to replace the motor.
4-60

1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover 3. Remove timing belt on operation side. 4. Remove Press Spring. 5. Remove the bearing of Press Roller Lever (Both drive and operation side). 6. When removing the press lever, upper roller becomes free. 7. Remove the bearing of side board to remove lower roller. NOTE - Apply grease to needle bearing section when replacing press roller.

SM

SPF-9R

4-3-8 Replacing Fold Roller

4-3-9 Replacing Jog Section Solenoid

4-3-10 Replacing Stapling Stopper Solenoid

Fold Roller Fold Roller Lever Jog Plate Guide Stay (2) Solenoid Cover Solenoid Bracket Solenoid

Press Roller Press Roller Lever Press Spring Link Block

(4) Connecting Plate S Solenoid Stapling Stopper

Guide

1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover. 3. Remove timing belt on operation side. 4. Remove press spring. 5. Remove the bearing of fold roller lever (Both drive and operation side) 6. When removing the fold roller lever, roller becomes free. Replace it to new one. NOTE - Apply grease to needle bearing section when replacing it.

1. Turn off the power of SPF-9R. 2. Remove rear cover. 3. Remove solenoid connector. 4. Remove solenoid from square window sec tion on the back and replace it. [To remove whole jog section] 1. Remove right, front, rear cover of SPF-9R. 2. Remove the shaft at drive side of the timing belt. 3. Remove two guide stay. 4. Remove guide from guide stay.

1. Turn off the power of SPF-9R. 2. Remove solenoid cover. 3. Remove solenoid connector. 4. Remove the connection between joint plate and the solenoid. 5. Remove solenoid from solenoid bracket and replace it.

SM

4-61

SPF-9R

4-3-11 Replacing Transport Roller R Solenoid

4-3-12

Replacing Transport Roller F Solenoid

Solenoid bracket Link Solenoid bracket Guide Stay Link Plate

Solenoid

Joint Plate

1. Turn off the power of SPF-9R. 2. Remove solenoid connector. 3. Remove solenoid bracket from guide stay and remove whole transport roller R section. 4. Remove solenoid cover. 5. Cut off the connection between link and the plunger. 6. Remove solenoid from solenoid bracket and replace it.

1. Turn off the power of SPF-9R. 2. Remove the cover at stitch section. 3. Remove solenoid connector. 4. Remove fixing screws from solenoid bracket and transport roller F. 5. Remove joint plate. 6. Remove solenoid from solenoid bracket and replace it.

SM

4-62

SPF-9R

4-4-1 Replacing Stopper Solenoid

(1) Stopper Fixing Screw Stopper Transport Screw Stopper Shaft Roller Stay (7) Lower Left Side Plate Furniture A (8) Furniture B Solenoid
A

Lower Cutter Stay

Upper Cutter Lower Cutter Lower cutter set block

(4) Holding Plate

(9) Connecting Plate (10) Solenoid Furniture

1. Turn off the power of SPF-9R. 2. Remove front cover and rear cover. 3. Remove lower left side plate [Black]. 4. Remove holding plate 5. Remove timing belt. 6. Remove connector on solenoid. 7. Remove furniture A from roller stay. 8. Remove furniture B from lower cutter stay. Stopper unit becomes free. Remove the unit. 9. Remove joint plate. 10. Remove solenoid from solenoid furniture to replace it.

[Parallel Adjustment of the Stopper] 1. Loosen two fixing screws on the stopper. 2. Tighten the fixing screw so that lower cutter set block becomes parallel to the stopper.

SM

4-63

SPF-9R

4-4-2 Replacing Cutter Blades

(3) Air Nozzle (4) Fixing Screws Upper Cutter Carry Table Fixing Screws

Lower Cutter

WARNING

(6) Lower Carry Belt

Sensor Connector

WARNING
Keep your hand off from the cutter blades when replacing them.
1. Remove two cables on fore-edge section, then remove fore-edge section from the connection to the staple and fold section. 2. Remove cover at stitch and fold section side (two fixing screws). 3. Turn the air nozzle sideways (two fixing screws). 4. Remove three fixing screws of upper cutter blade and remove upper cutter blade from upper position.
SM

NOTE - Apply glue to the part that arrow shows when NOTE setting the upper cutter. - Adjust the lower cutter by height adjust screw so that the top of the cutter becomes flat 5. Remove carry guide (two fixing screws). to the trim section when fixing the lower 6. Remove two lower carry belt. cutter. 7. Remove center connector and remove carry table (four fixing screws). 8. Remove four fixing screws and remove lower cutter blade from lower position. 9. When setting new cutter blade, procedure should be reverse order.
4-64 SPF-9R

5. Service Mode
5-1 Basic Movement of CFS Section ....................................................................... 5-66 5-2 Basic Movement of SPF Section ........................................................................ 5-67 5-3 Basic Movement of FC Section ......................................................................... 5-68

SM

5-65

SPF-9R

5-1 Basic Movement of CFS Section

Movement at Beginning 1. Turn on the power. 2. Following three CFS section actions occur at a same time and each part stops at each home position. - Width direction guides (Fig1) move inside, then move to outside in order to stop at the home position. - When jog belt is not in the home position, it rotates to stop at home position. - Rotate cover feed section valve motor for a time, then stop it at the home position. 3. When signals such as sheet size and fold style are sent, width direction guide and jog belt move to certain position and stop. At this time, signal from copy machine is to SPF-9R too. 4. Delivery belt moves and wait for the sheets. Operating Movement [To staple and fold] 1. Sheets are jogged each time a new sheet is delivered to the accumulate section. 2. When sheets for 1 complete booklet are stacked, transport it to SPF. If it requires a cover, cover will be transported and join to the booklet at delivery section.
SM

[To stacker=No staple or fold] 1. Gate opens so that sheets are guided to stacker section. 2. When sheets for 1 set of booklet are stacked and Off-set is selected, off-set motor (Fig.2) moves a signal from the copy machine shifts the stacker table forward table forward and backward by 30mm.

Jog Belt

Width Direction Guide

Fig1 (CFS section upside view)

Valve Motor (At Rear) Gate

CAUTION -When stacker table is not in the upper limit, copying does not start. -Copy machine indicates Finisher Error. -Raise the tray by pressing Shift Tray Up button on the CFS operation panel.
REFERENCE - Shift tray does not raise automatically for safety.

Off-set Motor

CAUTION -When covers exists in the cover feed tray but the tray does not raise, copying does not start. -Copy machine indicates Finisher Error. -Raise feed tray by pressing Feed Tray Up button on operation panel section.
5-66

Fig2 (CFS section side View)

SPF-9R

5-2 Basic Movement of SPF Section

Movement at Beginning 1. Turn on the power. (Operate at CFS) 2. The following four actions occur and each part moves to home position rapidly. Each part moves so rapidly that it overruns the home position and stops. (Fig1) - Guide (operation side) - Left Stopper - Guide (drive side) - SPF 3. Following five actions occurs slowly in turn. (1). Guide (operation side) moves to stop at home position (2). Guide (drive side) moves to stop at home position (3). Right guide (jogger) moves to stop at home position (4). Left stopper (stapling stopper) moves to stop at home position (5). SPF moves to stop at home position. Now each home position is decided. 4. Each parts moves to criterional position (A3,staple and fold) in following turns. - Guide (operation and drive side), right guide, and left stopper moves rapidly to close to A3 position, - Then guide (operation side), guide (drive side), right guide, and left stopper moves slowly in turn to A3 position and stop. - At last, SPF unit position first moves rapidly then slowly to A3 position and stop.
SM

5. When positions are decided to criterional position [A3,staple and fold], Data for next operation are sent from CFS. Then each part will be positioned again for next operation by following that data. The movement will be same as procedure 4. 6. When positions are set, machine is on the sheets waiting mode. Operating Movement

Guide (drive side)

Guide (R)

Guide (operation side)

Fig1 (SPF guide location upside view) 1. Sensor B10 detects (Fig.2) that 1 booklet Left is transported from CFS. Stopper 2. When a booklet is detected by sensor B11, guide (operation side), guide (drive side), Stitcher and right guide (jogger) moves to set the Gate booklet to the correct position. 3. Staple section operates to staple. Press Roller 4. When stapling, gate opens to transport B10 B11 booklets to fold section. Booklets are folded when next booklet comes to SPF, Right (If next booklet does not come to SPF, the Guide booklet which are in the fold section can Fold Knife not be folded.) but the last booklet for the operation will be folded by END Signal from the copy machine. Fig2 (SPF guide location side view) 5. Folded booklets are transported to FC side by passing through press roller.

5-67

SPF-9R

5-3 Basic Movement of FC Section

Movement at Beginning 1. Turn on the power (operate at CFS) 2. Stopper (Fig.1) moves to home position (left side) rapidly. Stopper moves so fast that it overrun the home position and stops. 3. Then stopper moves to right side slowly to stop at home position. In this way, stopper home position is decided. 4. Stopper moves rapidly to intended position by following the data sent from SPF (signal such as sheet size), then overruns intended position and stops. 5. Then stopper moves slowly to intended position and stops. REFERENCE - The purpose of rapid moving of each part is to reduce the time for positioning. But moving speed is so fast that it overruns and can not stop at intended position. So next each part moves slowly to stop fairly at intended position. Operating Movement 1. When delivery motor at SPF moves, delivery motor and the belt at FC moves too. 2. Sensor B10 at entrance section detects the booklet. 3. Sensor B11 at stopper section detects that the booklet came to trim section. 4. Stop the transport belt to trim fore-edge section of the booklet. 5. Lower the stopper and move transport belt to send trimmed booklet to ED side. 6. Stopper raises to wait next booklet.
Transport Belt Knife

B11 Stopper

B10

Fig1

(FC section upside view)

REFERENCE - When delivery motor at SPF section stops, FC section trims the last booklet and delivers it to ED section, then stops the delivery motor on FC section.

Upper Knife

Stopper Stopper Sensor B11 Entrance Sensor B10

Fig2

(FC section side view)

SM

5-68

SPF-9R

6. Electrical Parts
6-1 Identification and Location of Motors ..........................................................6-70 6-2-1 Identification and Location of Sensors [CFS Section] ............................ 6-71 6-2-2 Identification and Location of Sensors [SPF, FC Section] ..................... 6-72 6-3 Identification and Location of Switch and Breaker .................................... 6-73 6-4 Identification and Location of Solenoid ........................................................ 6-74 6-5 Identification and Location of Other Major Electrical Parts ................... 6-75

NOTE: Part numbers not listed in the following tables can be found in the SPF-9R Bookletmaker Parts Book.

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6-69

SPF-9R

6-1 Identification and Location of Motors

Number CFS M01 M02 M03 M04 M05 M06 M10 M11 M12 M13 Names, Roles Stacker Tray Up/Down Motor Width Adjustment and Arrangement Motor Entrance Motor Reduction Motor Shift Motor Main Motor Feed Tray Up/Down Motor Valve Motor Cover Transport Motor Blower Motor 4013033-00 4012790-00 4012793-00 4013033-00 Vol. Parts No.

M23 (Rear Stopper) M21 (Front Width Arrangement)

M05

M10

M11 M11 M13

M12 (Whole Unit Move) M03 M02 M06 M12

SPF

M24 (Stapling Stopper Move)

Number M10 M11 M12 M21 M22 M23 M24 M10 M11 M12 M13 Names, Roles Vol. Parts No. Main Motor 4013033-00 Knife Motor Unit Move Motor Operation Side Width Arrangement Motor Drive Side Width Arrangement Motor Jogger Move Motor Stapling Stopper Move Motor Belt Drive Motor Trimming Knife Drive Motor Stopper Move Motor Belt Drive Motor

M22

M04

M01 M10 Belt Drive M11 Knife Motor M10 M12 M13 6-70
FC

ED

SM

SPF-9R

6-2-1 Identification and Location of Sensors [CFS Section]

Upper Limit Switch S06 B17 B16

B13

Number

Names, Roles

Parts No.

Maker No.

B15

B18

B14

B09 B20 B07 B19 Upper Limit Switch S04 B04 B01 B02 B05 B08 B06

B03 B10

Lower Limit Switch S05 B12

B11

B01 B02 B03 B04 B05 B06 B07 B08 B09 B10 B11 B12 B13 B14 B15 B16 B17 B18 B19 B20 B21 S04 S05 S06

Width Adjustment Home Position Sensor Stacker Height Detect Sensor (U) Stacker Height Detect Sensor (L) Transport Pusher Home Position Sensor Stacker Transport Way Cover Detect Sensor Entrance Sensor Transport Section Entrance Sensor Stacker Entrance Sensor Gate Section Sheets Exist Sensor Stacker Exit Sensor Shift Stop Position Sensor Stacker Full Sensor Cover Near End Sensor Cover Tray Lower Limit Sensor Cover Jam Sensor Double Feed Detect Sensor Cover Height Detect Sensor Cover Detect Sensor Exit Sensor Sheets Detect Sensor in Stapling Tray Stacker Upper Limit Stacker Upper Limit Switch Stacker Lower Limit Switch Feed Tray Upper Limit Switch

4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4007567-00 4009730-00 4009730-00 4009730-00 4005225-00 4009730-00 4007567-00 4007567-00 4007567-00

EE-SX460-P1 EE-SX460-P1 EE-SX460-P1 EE-SPY302 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 PM2-LF10 EE-SX460-P1 E2R-A01 E2R-A01 E2R-A01 EE-SPY302 Our own product E2R-A01 PM2-LF10 PM2-LF10 PM2-LF10 V5412DK V5412DK V5114D

SM

6-71

SPF-9R

6-2-2 Identification and Location of Sensors [SPF, FC Section]

B13 (Stopper Home Position) B21 (Stapling Stopper Home Position)

B24 B25

[Staple and Fold Section] Number B10 B11 B12 B13 B14 B15 B20 B21 B22 B23 B24 Booklet Detect Booklet Detect and Jam Detect Fold Knife Home Position Detect Book Block Detect in the Backle Staple and Fold Section Unit Position Home Position Detect Staple and Fold Section Unit Position Limit Detect Jog Unit Home Position Detect Stitching Stopper Home Position Detect Width Adjustment (operation side) Home Position Detect Width Arrangement (operation side) Limit Detect Width Arrangement (drive side) Home Position Detect Width Arrangement (drive side) Limit Detect Puls Detect Names, Roles Parts No. 4005225 4005225 4005256 4005225 4005256 4005256 4005256 4005256 4005256 4005256 4005256 4005256 4005256 Maker No. EE-SPY302 EE-SPY302 SIU700 EE-SPY302 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700 SIU700

B14 (Stopper Limit) B12

B23 B15 B20 B22 B14

B11 B10 B26 B11 B10 B13 B12

B25 B26

[Trim Section] Number B10 B11 B12 B13 B14 B15 B16 Names, Roles Sheet Entrance Detect (Entrance) Sheet Entrance Detect (front stopper) Trim KnifeUpper Limit Detect Stopper Home Position Detect Stopper Limit Detect Full Trimmings Detect Projector Full Trimmings Detect Receiver Parts No. 4005225 4005225 4009730 4005256 4005256 Maker No. EE-SPY302 EE-SPY302 E2R-A01 SIU700 SIU700

[Trimmer section/FC9]

[Staple and fold section/SPF-9]

SM

6-72

SPF-9R

6-3 Identification and Location of Switch and Breaker

Number CFS Q01 Q02 Q03 Q04 SPF Q11 Q12 Q13 FC Q21 Names, Roles Power Breaker Breaker for Blower Breaker for SPF Breaker for FC Main Circuit Breaker Breaker for Fold Knife Motor Breaker for 24V Power Supply Main Circuit Breaker Vol. 15A 6A 4009365-00 6A 4009365-00 6A 4009365-00 5A 4009365-00 2A 4011044 2A 4011044 3A 4009017 Parts No.

S06

S02

S01 S04 S3 S2 S4 S00 S01 S03

S00

Q11 Q12 Q13 Q01 Q02 Q03 Q04 S06 S04 S05 S3 S2 Q21

S05
Number CFS S00 S01 S02 S03 S04 S05 S06 SPF S00 S1 S2 S3

Names, Roles Power Switch Cover Feed Section Cover Switch Entrancw Section Cover Switch Door Switch Stacker Upper Limit Switch Stacker Lower Limit Switch Feed Tray Upper Limit Switch Power Switch Delivery Section Cover Switch Top Cover Open/Close Switch Jogger Limit Switch Stapling Stopper Limit Switch Trimmings Box Detect Switch Top Cover Open/Close Switch Connection Detect Switch

Parts No. 12042468

Maker No. JW-L21RKK AV1225 V5212DK AV1225 V5212DK V5212DK V-5114D

4012779 4000803 4000803 4000803 4000803 4000803 4000803 4000803

JW-L22RKK-K1N V5414DK V5414DK V5414DK V5414DK V5414DK V5414DK V5414DK

S1
FC

S4 S1 S2 S3

SM

6-73

SPF-9R

6-4 Identification and Location of Solenoid

Y02
Number CFS Y01 Y02 Names, Roles Gate Solenoid Clutch Parts No.

Y5 (Jogger)) Y7 Y1 Y1 (Stopper) Y8

Y01

Y02 Y4 Y3 (Gate Switch Cover) Y6 (Jogger) Y01

SPF Number Y1 Y3 Y4 Y5 Y6 Y7 Y8 FC Y1 Names, Roles Stapling Stopper Solenoid Gate Switch Over Stopper Solenoid Clutch Solenoid Jogger Stopper Solenoid Width Arrangement Solenoid Delivery Roller1 Solenoid Delivery Roller2 Solenoid Stopper Solenoid Parts No.

SM

6-74

SPF-9R

6-5 Identification and Location of Other Major Electrical Parts

[Switching Power Supply] Number G01 G02 G11 G12 G21 G22 Names, Roles For DC5 at CFS Section For DC24 at CFS Section For DC5 at Staple and Fold Section For DC24 at Staple and Fold Section For DC5 at Trim Section For DC24 at Trim Section Parts No. Maker No. 4012632 ZWS10-5/J 4013162 ZWS300-24/T 4011267 4011029 4011267 4009275

Counter K1

G11 G12 (5V) (24V) G22 G21 Driver K4 K2

Names Noise Filter Number Z01 For Trimming Motor Drive K1 K2.3 K4 Emergency Stop Emergency Stop Input Relay 4006272 4012662 4012661 Roles Parts No.

G02 Inter Lock Relay 401312300AHE2232 G01 Z01 K3 (Relay) SM

Driver Relay Relay Relay

Condenser

6-75

SPF-9R

SM

6-76

SPF-9R

7. System Wiring and Connections

7-1 Board Locations ................................................................................................. 7-78 7-1-2 CFS Control Board and QPM-144 Connector Locations ............................ 7-79 7-1-2 CFS Control Board and QPM-144 Connector Connections (1) .................. 7-80 7-1-2 CFS Control Board and QPM-144 Connector Connections (2) .................. 7-81 7-1-2 CFS Control Board and QPM-144 LED Locations ..................................... 7-82 7-1-2 CFS Control Board and QPM-144 LED lighting conditions .......................7-83 7-1-3 CFS Correspondence Board and QPW-591 Connector Locations and Connections ............................................................................................. 7-84 7-1-4 CFS Panel Board and QPW-587 Connector-LED Locations ...................... 7-85 7-1-5 SPF Control Board and QPW-503 Connector Locations ............................ 7-86 7-1-5 SPF Control Board and QPW-503 Connector Connections (1) .................. 7-87 7-1-5 SPF Control Board and QPW-503 Connector Connections (2) .................. 7-88 7-1-5 SPF Control Board and QPW-503 Connector Connections (3) .................. 7-89 7-1-5 SPF Control Board and QPW-503 Connector Connections (4) .................. 7-90 7-1-6 SPF Knife Motor Board and QPW-522 Connector-LED Locations ........... 7-91 7-1-7 SPF Panel Board and QPW-491 Connector-LED Locations ...................... 7-92 7-1-8 SPF P.C.B QPW-518 Connector-LED Locations ......................................... 7-93 7-1-9 FC Control Board and QPW-484 Connector-LED Locations .................... 7-94 7-1-9 FC Control Board and QPW-484 Connector Connections (1) .................... 7-95 7-1-9 FC Control Board and QPW-484 Connector Connections (2) .................... 7-96 7-1-10 FC Panel Board and QPW-493 Switch-Connector-LED Locations ......... 7-97 7-2 CFS Section Power Locations ........................................................................... 7-98 7-2-2 SPF Section Power Locations ......................................................................... 7-99 7-2-3 FC Section Power Locations .......................................................................... 7-100 7-3 SPF Section Flat Cable Connections ................................................................ 7-101 7-4-1 CFS Section Terminal Board Locations ........................................................ 7-102 7-4-2 SPF Section Terminal Board Locations ........................................................ 7-103 7-4-3 FC Section Terminal Board Locations .......................................................... 7-104 7-5 Wiring and Connections among Machines ...................................................... 7-105 SM 7-77 SPF-9R

7-1 Board Locations

Correspondence Board

Control Board
7-1-8

Staple & Fold Section Transport Motor M10, P.C.B on Unit Position QPW-518 P.C.B
Move Motor M12

7-1-2

CFS Section QPW-144

Control whole CFSsection movement

7-1-3

CFS Section QPW-591

Correspond to copy machine

Panel Board Staple & Fold Section QPW-491 Panel Board

There are operation switches

Knife Motor Board

7-1-5 7-1-9 7-1-10

Staple & Fold Section Control motor and solenoid movement exept fold knife QPM-503 Control Board
Fore-edge Trimmer (FC-9)

QPW-493 Panel Board

Indicates the trouble at fore-edge trim section by lamp

Fore-edge Trimmer (FC-9) Control the fore-edge section

QPW-484 Control Board

movement by engaging with the staple and fold section

SM

7-78

SPF-9R

7-1-6

Staple & Fold Section Control the fold knife movement QPW-522

7-1-7

Indicates the trouble at staple and fold section by lamp

7-1-4

CFS Section QPM-587

There are operation switches and monitor lamp, which indicats troubles.

7-1-2 CFS Control Board and QPM-144 Connector Locations

CON20 CON22

CON2 CON1

CON9

CON8 CON10

CON11 CON14

CON12

CON15 CON16 CON17 CON18 CON19

SM

7-79

SPF-9R

7-1-2 CFS Control Board and QPM-144 Connector Connections (1)

CON8 1 2 RED 3 ORN 4 YIO 5 GRN 6 BLU 7 8 9 10 11 12 13 14 CON9 1 2 3 4 5 6 CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 HRY

SIG 24V GND 24V SIG 24V GND

Emergency Stop Switch SPF-20A Recognition Signal

CON11 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 9 10 CON12 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU CON14 1 BRN 2 RED 3 ORN 4 YEL 5 GRY 6 BLU 7 VIO 8 HRY 9 WHT 10

12V To QPW-492 GND CON11 Full Tray Emergency Stop+ Emergency StopFull Tray Sensor (Projector) Auto Start

CON15 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 GRY CON16 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 8 9 10 CON17 1 ORN 2 ORN 3 YEL 4 YEL 5 6 CON18 1 BRN 2 3 RED

5V QPW-492 Off-set Signal CON12 Feed Error On Collating Transport Motor Emergency Stop Output to Receiving Tray 24V SIG 24V GND 24V SIG 24V GND Jam Sensor (F) Jam Sensor (R)

Not Used

Send Receive GND 24V SIG 24V GND Send Receive 5V GND Send Receive 5V GND Send Receive 5V GND

Communication with Touch Screen Pulse Sensor

24V SIG 24V GND 24V SIG 24V GND SIG 24V GND

Left-side Delivery Sensor Right-Side Delivery Sensor Door Open/Close Switch

To Communicate Connector with SPF-20A To Communicate Connector with Front Tower To Communicate Connector with Rear Tower

+12V GND

+24 GND

SM

7-80

SPF-9R

7-1-2 CFS Control Board and QPM-144 Connector Connections (2)

CON11 1 BRN 2 RED 3 ORN 4 Vacant 5 Vacant 6 BLU 7 VIO 8 WHT CON12 1 BRN 2 Vacant 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON13 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU

Stacker Full Sensor Pusher Home Position Sensor Shift Stop Position Sensor

To B12-2 To B04-2 To B11-2

CON14 1 BRN 2 RED 3 ORN 4 YEL CON15 1 BRN 2 RED CON16 1 BRN 2 RED 3 ORN 4 YEL CON17 1 2 3 4 CON18 1 BRN 2 RED 3 WHT 4 Vacant 5 GRN 6 BLU

Y01 Gate Solenoid Y02 Clutch Solenoid

Front Door Sensor Entrance Section Covewr Switch To S03 To S02 Cover Feeder Cover Switch To S01

SSR M13 Blower Motor ~

COM DATA 0 DATA 1 DATA 2 DATA 3 Eject Switch Signal SPF Start ACK

TXD RXD 5V GND

CON19 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 WHT 9 BLK 10 Vacant 11 Vacant 12 Vacant 13 Vacant 14 Vacant CON21 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 VIO

Operation Panel To QPW-587 Stack Trauy Upper/Lower Limit Switch

To Copy Machine

1 2

M01

3 4

To SPF Section

Not Used

5 6

M10

Cover Feed Try Upper Limit Switch

M05 Tray Shift Motor M01 Stacker Up/Down Motor M10 Cover Feeder Up/Down Motor

To B11-1

Double Feed Detect Sensor B16

SM

7-81

SPF-9R

7-1-2 CFS Control Board and QPM-144 LED Locations

L50 L1

L8 L9 CPU

L16 ROM L17

QPM-144
L24 L25

L32 L33
DL7 DL1
L49 L50 L51 L52 L53 L54 L55 L56 L57 L41 L42 L43 L44 L45 L46 L47 L48

L40

SM

7-82

SPF-9R

7-1-2 CFS Control Board and QPM-144 LED lighting conditions

LED No. L1 L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17 L18 L19 L20 L21 L22 L23 L24 L25 L26 L27 L28 L29 L30 React Sensor Correspond No. From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) From SPF to CFS (message data) B07 B09 B08 B05 B06 B10 B13 B14 B01 B03 B02 B17 B18 B19 B15 B20 B12 B04 B11 Conditions to light Data Receiving Completed Host Start Prohibited Moving Jam Data Exist SPF Cover Open DATA2 DATA1.Booklet Delivery Completed DATA0 Transport Section Entrance Sensor Gate Section Sheet Exist Stacker Entrance Sensor Stacker Transport way Sheet Exist Sensor Entrance Sensor Stacker Exit Sheet Exist Cover Near End Cover Tray Lower Limit Width Adjustment Home Position Stacker Height Detect (L) Stacker Height Detect (U) Cover Height Cover Exist Exit Sensor Cover Jam Temporarily Stock Section Sheet Exist Stacker Full Transport Pusher Home Position Shifter Stop Position LED No. 100 L32 L33 L34 L35 L36 L37 L38 L39 L40 DL1 DL2 DL3 DL4 DL5 DL6 DL7 L41 L42 L43 L44 L45 L46 L47 L48 L49 L50 L54 L55 L56 React Sensor Correspond No. S02 S01 From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) From CFS to SPF (message data) Conditions to light Entrance cover Open Cover Section Cover Open DATA0 DATA1 DATA2 DATA3 Eject Signal Staple Signal SPF Movement Start Signal CFS Signal Receive (ACK) For Debug For Debug For Debug For Debug For Debug For Debug For Debug Shifter Movement Stack Tray Up Stack Tray Down Cover Tray Up Cover Tray Down Gate Solenoid ON Cover Clutch ON Blower ON Double Feed Sensor Adjustment LED Current Down at Width Adjustment Motor Current Down at Valve Motor Panel LED (Entrance Cover Open)

S03

Front Door Open

M05 M05 M01 M01 M10 M10 Y01 Y02 M13 B16 M02 M11 S02

SM

7-83

SPF-9R

7-1-3 CFS Correspondence Board and QPW-591 Connecter Locations and Connections

CON1 1 BRN 2 RED 3 ORN 4 YEL

TDX RXD +5V GND

To the Connector to the Copy Machine

HORIZON QPW-591

CON2 1 BRN 2 RED 3 ORN 4 YEL 5 Vacant 6 Vacant

TXD RXD +5V GND

To Control Board QPM-144 CON 16

CON1 1

SM

7-84

1
CON2

SPF-9R

7-1-4 CFS Panel Board and QPW-587 Connector-LED Locations

[Switch]

SW1 SW4 SW6 SW7

SW1 SW2 SW3 Eject Switch

Names. Roles Stack Tray Up Switch Stack Tray Down Switch Covber Feed Tray Up Switch Covber Feed Tray Down Switch Feed Error Detect On/Off Switch Not Used

Functions

CON1

SW2 SW5
1

SW4 SW5 SW6 SW7

SW3

16 To Control Board QPM-144 CON 19 BRN RED ORN YEL GRN BLU VIO GRY WHT BLK BRN RED ORN YEL 1 2 3 4 5 6 7 8 9 10 11 12 13 14

[LED conditions to light] LED No. React Sensor.SW L1 SPF Signal SPF Signal B19 B15.B16 B17.B18 B16 B16 B09.B20 S03 B07 B08.B05 B10 B02.B03.B12 B06 S01 SW6 S02 Conditions to light Error at finishing machine Machine can not start [Adjusting] Sheet Jam Cover Sheet Jam No Cover No Feed Double Feed Sheet Jam Front Door Open Sheet Jam Sheet Jam Sheet Jam Stacker Tray is not in the upper limit Sheet Jam Cover Section Cover Open Error Detect ON/OFF Entrance Cover Open Functions

15 6

4 7

5 17 9 14 10 12 13 11

L2 L3 L4 L5 L6 L7 L8 L9 L10 L11 L12 L13 L14 L15 L16 L17

3 1 2

[LED Locations] [Connector Connections]

SM

7-85

SPF-9R

7-1-5 SPF Control Board and QPW-503 Connector Locations

L1 Jog Guide (drive side) Motor Pulse L2 Jog Guide (Operation side) Motor Pulse L3 Jog Plate Motor pulse L4 Staple Section Stopper Motor Pulse L5 Unit Move Motor Pulse L8 Collating L9 Feed Error L10 Transport Belt Motor L11 Knife Motor L12 Jog Plate Home Position Sensor L13 Staple Section Stopper Home Position Sensor L14 Jog Guide (drive side) Home Position Sensor L15 Jog Guide (operation side) Home Position Sensor L16 Jog Plate Max. Position Sensor L17 Staple Section Stopper Max. Position Sensor L18 Jog Guide (drive side) Max. Position Sensor L19 Jog guide (operation side) Max. Position Sensor L20- L27 NOT USED L28 Cover Limit Switch L29 NOT USED L30 Sheet Pass Sensor L31 Knife Home Position Sensor L32 Unit Move Home Position Sensor L33 Pattern Button L34 Sheet Sensor L35 Fold Section Sheet Sensor L36 Unit Move Max. Position Sensor L37 Mode Button L39 Memory Button L40 Eject Button L41 Guide Set (Right) Button L42 Memory Select Button L43 NOT USED L44 Guide Set Select Button L45 Guide Set (Left) Button Blinks when motor rotating. Blinks when motor rotating. Blinks when motor rotating. Blinks when motor rotating. Blinks when motor rotating. Not light when collating Not light when feed error occurs Lights when motor rotating Not light when knife cycling Not light when home Not light when home Not light when home Lights when Max. Lights when Max. Not light when Max. Not light when Max. Lights when open Lights when open Lights when no sheet Lights when home Not light when home Lights when pressed Lights when no sheet Lights when no sheet Not light when Max. Lights when pressed Lights when pressed Lights when pressed Lights when pressed Lights when pressed Lights when pressed Lights when pressed

Caution: When control PCB is removed many similar connectors exist. Mark or in some way identify each before removal SM

7-86

SPF-9R

7-1-5 SPF Control Board and QPW-503 Connector Connections (1)

CON1 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK

PC+ Sig Sig Sig Sig Sig Sig Sig Sig Sig

Connector Pin NO 14 15 16 17 18 19 20 21 22 23

CON2 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 Vacant 11 Vacant 12 Vacant

+5v Sig Sig Sig Sig Sig Sig Sig Sig

1 2 3 4 5 6 7 8 9

CON3 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON4 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK CON5 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant

M21

Width Adjustment Operation Side Motor Encorder in the Motor

M22

Width Adjustment Drive Side Motor Encorder in the Motor

CON6 1 2 3 4 5 6 7 8 CON7 1 RED 2 YEL 3 GRN 4 BLU 5 WHT 6 BLK

Not Used

M23

Jog Unit Move Motor Encorder in the Motor

M24

Stapling Stopper Move Motor Encorder in the Motor

Connector Pin NO 1 3 4 6 7 8 To Connectoer on 31 X2IO FC Section

Unit Position Move Pulse Detect B26 To QPW18 CON15-5 To QPW18 CON15-6 To QPW18 CON15-7 To QPW18 CON15-8

To Connectoer on CFS Section

CON8 1 BRN 2 BRN 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK

To Relay K1 Staple Stopper Solenoid Y1,Y2. Gate Change Solenoid Y3 Delivery Belt Clutch Y4

SM

7-87

SPF-9R

7-1-5 SPF Control Board and QPW-503 Connector Connections (2)

CON9 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 67

CON11
Jog Solenoid Y5

CON15 To Staple Unit Motor 1 M31 To Panel Board QPW491 CON2

Width Adjustment Solenoid Y6 Delivery Roller 1 Solenoid Y7 Delivery Roller 2 Solenoid Y8 To QPW518 CON5-3 To QPW518 CON5-4 To QPW522 CON1-2 To QPW522 CON1-3

CON12 To Clinch Unit Motor 1 M32

Connector Pin NO 14 15 16 17 18 19 20 21 22

CON13 To Staple Unit Motor 2 M33

CON16 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED

Booklet Detect1 B10 Booklet Detect2 B11 Fold Knife Home PositionB12 Booklet Detect in the Backle SectionB13

CON14 To Connector to FC Section To Clinch Unit Motor 2 M34

CON17 1 RED 2 YEL 3 GRN 4 BLU 5 WHT 6 BLK

SPF Unit Position Home Position B14 SPF Unit Position Limit B15

SM

7-88

SPF-9R

7-1-5 SPF Control Board and QPW-503 Connector Connections (3)

CON18 To Panel Board QPW491 CON1

CON19 1 BRN 2 RED 3 WHT 4 WHT 5 GRN 6 GRN CON20 1 BRN 2 RED 3 Vacant 4 Vacant 5 Vacant 6 Vacant 7 Vacant 8 Vacant

DC+5V 5V GND DC+24V 24V GND

POWER SUPPLY G01 CON2-2 CON2-1 To Relay K1 POWER SUPPLY G02 CON2-5,6

CON21 1 BRN 2 RED 3 ORN 4 Vacant 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 Vacant 11 BRN 12 RED CON22 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED 13 Vacant 14 Vacant

Jog Unit Home Position B20 Jog Unit Limit S3 Staple Stopper Home Position B21 Staple Stopper Limit S4

CON23 1 BRN 2 RED 3 ORN 4 YEL 5 Vacant 6 Vacant 7 Vacant 8 Vacant

Not Used Connector is connected, but it is cut at the end.

K1 Relay

CON24 1 BRN 2 RED 3 ORN Width Adjust Guide 4 YEL Operation Side Width 5 GRN Adjust GuideB22 6 BLU 7 VIO Width Adjust Guide GRY Operation Side Limit B23 8 WHT 9 10 Vacant Width Adjust Guide Drive Side Home Position 11 Vacant 12 Vacant B24 Width Adjust Guide Drive Side Limit B25

Connector Pin NO 1 2 3 4 5 6 7 8 9

66 To Connector to FC

SM

7-89

SPF-9R

7-1-5 SPF Control Board and QPW-503 Connector Connections (4)

CON25 1 Vacant 2 Vacant 3 ORN 4 YEL 5 Vacant 6 Vacant 7 Vacant 8 Vacant CON26 1 2 3 4 5 6 7 8 9 10 11 12

To Control Board QPW518 CON5-2 CON5-1

CON27 1 2 3 4 5 6

Not Used

Not Used

SM

7-90

SPF-9R

7-1-6 SPF Knife Motor Board and QPW-522 Connector-LED Locations

CON1 1 RED 2 BRN 3 Vacant CON2 1 WHT 2 Vacant 3 BLK CON3 1 BLK 2 Vacant 3 WHT 4 Vacant 5 GRN

QPW503 To CON9-11 To CON9-12 Terminal Board X101 2A Q2 Fold Knife Motor M11 To S00 To S00

SSR 1

SSR 2

QPW522

CON3

CON2

CON1

SM

7-91

SPF-9R

7-1-7 SPF Panel Board and QPW-491 Connector-LED Locations

[Switch] Functions SW1 SW8 Mode Names. Roles Mode Select SW ; Change automatic settings

Set Position Set Position Select SW ; Select the object to move

SW9 Upper. Right Adjustment Button ; Moves object to to arrow direction while it is pressed SW10 Lower . Left Adjustment Button ; Moves object to to arrow direction while it is pressed SW11 Clear Clear SW ; Clear the counter

[LED Conditiond to light] LED No. Functions Automatic Set Feed Error Sheet Jam No Staple Sheet Jam Unit Position Guide (drive side) Stopper (L) Stopper (R) Up Down Right Left React Sensor.SW SW1 SW1 S01.S02 B11 M31.M32 B13 SW1.SW8 SW1.SW8 SW1.SW8 SW1.SW8 SW9 SW10 SW9 SW10 Selected by SW1 Top cover or delivery section is opened When booklet detect sensor id on Trouble Signal from M31.M32 Booklet does not come within predetermined time Select set position by set mode Select set position by set mode Select set position by set mode Select set position by set mode Select set position by set mode Selected by SW9 Selected by SW10 Selected by SW9 Selected by SW10 Conditions to light When the power is on

SW11 L25 SW10 L28 L26 SW9 L27 L20 L21 L22 L23 L24 L3 L1

L14 L16 L15 L17

L1 L3 L14 L15 L16 L17 L20

CON1
SW8 SW1

CON2

L21 L22 L23 L24

Guide (operation side) SW1.SW8

To Control Board QPW 503 CON15

To Control Board QPW 503 CON15

L25 L26 L27 L28

SM

7-92

SPF-9R

7-1-8 SPF P.C.B QPW-518 Connector-LED Locations

CON1 1 BLK 2 Vacant 3 WHT 4 Vacant 5 Vacant CON2 1 GRN 2 Vacant 3 YEL 4 Vacant 5 BLK CON3 1 BLK 2 Vacant 3 YEL 4 Vacant 5 WHT
LED4 LED3 CON5 LED2 LED1

ED Power Cord E02

Main Motor M10

CON4

CON3

CON2

CON1

Unit Position Move Motor M12

CON4 1 BLK 2 Vacant 3 BLK

Relay K2 Terminal Board X101To Main Switch S00

Spark Killer

LED No. L1 L2 L3 L4

React Sensor.SW

Conditions to light

Signal from QPW503 When ED-9 is operating Signal from QPW503 When main motor is operating Signal from QPW503 When unit position move motor is operating Signal from QPW503 When unit position move motor is operating

CON5 1 YEL 2 ORN 3 WHT 4 BLK 5 YEL 6 GRN 7 BLU 8 VIO

To Control Board QPW503 CON25-4 CON25-3 CON9-9 CON9-10 CON5-4 CON5-5 CON5-6 CON5-7

1 2 3 4

S00

SM

7-93

SPF-9R

7-1-9 FC Control Board and QPW-484 Connector-LED Locations

CON4 CON11 L3 L2 CON3 L1

CON5

CON7

CON6
L10 11 12 13 L6 7 8 9 L14 15 16 17

CON8

1
CON2

SM

ROM ROM ROM

[LED conditions to light] LED No. L1 React Sensor.SW X201 X201 X201 Conditions to light When no signal is coming from SPF When staple mode is selected at SPF side When no signal is coming from SPF When transport motor M10 is moving Not used B10 B11 B12 B13 B14 Not used S2 S1 SW1 SW3 SW2 Not used When top over is opened When trimmings box is opened When knife single action switch SW1 is pressed When right stopper move SW13 is pressed Swhen left stopper move SW13 is pressed When there is no booklet on the sheet entrance sensor B10 When there is no booklet on the front stopper B11 When cutter upper limit sensor B12 operates When stopper home position sensor B13 does not detect When stopper limit sensor B14 does not detrect

1 1 1 1 1 1

CON10

L3 L3 L4

CON9 CPU

L5 L6 L7 L8 L9

1
CON1

L10 L11 L12 L13 L14 L15 L16 L17

7-94

SPF-9R

7-1-9 FC Control Board and QPW-484 Connector Connections (1)

CON1 Panel Board QPW403 To CON1-1 1 BRN Top Cover LED To CON1-2 2 RED Cutter Lock LED 3 ORN Entrance Secrtion JamLED To CON1-3 4 YEL Exit Section Jam LED To CON1-4 5 GRN Full Trimmings LED To CON1-5 6 BLU Trimmings Box OpenLED To CON1-6 To CON1-7 7 VIO To CON1-8 8 GRY 9 Vacant Curtter Avtion SW To CON1-9 To CON1-10 10 BLK Right Stopper SW To CON1-11 11 BRN Left Stopper SW To CON1-12 12 RED To CON1-13 13 ORN To CON1-14 14 YEL CON2 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BRN 11 RED 12 ORN

CON3 1 BRN 2 RED 3 ORN 4 YEL CON4 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU CON5 1 BRN 2 RED 3 ORN 4 YEL 5 Vacant 6 BLU
+5V DC GND

Full Trimmings Sensor Projector Receiver

POWER SUPPLY +5V POWER SUPPLY +24V

CON6 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant CON7 1 BRN 2 RED 3 Vacant 4 Vacant 5 Vacant 6 Vacant 7 Vacant 8 Vacant 9 WHT 10 BLK 11 Vacant 12 Vacant 13 ORN 14 YEL

Start / Brake CW COM +5V SPEED COM ALARM

To Driver of Trimming Knife Motor M11, see 10 11 12 COM +5V SPEED 17 14

+24V DC GND

Stopper SolenoidY1

Printer No START Printer Operating ED-9

Entrance Section Booklet Detect B10 Stopper Section Booklet Detect B11 Trim Section Upper Limit Detect B12 Stopper Home Positin Detect B13

1 3 8 4 7

Connector to SPF-9

To Relay K3-1 To Relay K3-2 Counter P1

SM

7-95

SPF-9R

7-1-9 FC Control Board and QPW-484 Connector Connections (2)

CON8 1 BRN 2 RED 3 ORN 4 Vacant 5 BLU 6 VIO 7 GRY 8 WHT 9 Vacant 10 Vacant

Stopper Home Position Detect B13 Relay K1 Connected Point Trimmings Box Open Detect S1

CON9 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 Vacant 9 Vacant 10 Vacant

Data from SPF-9 INPUT

CON11 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 Vacant

M12

Stopper Move Motor M12 Motor Encorder Sensor

CON10 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 WHT 10 BLK 11 BRN 12 RED

Data for SPF-9 OUTPUT

SM

7-96

SPF-9R

7-1-10 FC Panel Board and QPW-493 Switch-Connector-LED Locations

SW2

SW3

LED 1

7
SW1

2 3 8 9

4 5 6

CON1 1 BRN 2 RED 3 ORN 4 YEL 5 GRN 6 BLU 7 VIO 8 GRY 9 Vacant 10 BLK 11 BRN 12 RED 13 ORN 14 YEL

Top Cover OPEN LED Cutter Lock LED Entrance Section Jam LED Delivery Section Jam LED Full Trimmings LED Trimmings Box Open LED Not Used Not Used Cutter Action SW Right Stopper SW Left Stopper SW Not Used Not Used To QPW484 CON1

1
React Sensor.SW

[Switch] Names and Roles SW1 SW2 SW3 Cutter Action Switch Left Stopper Move Switch Left Stoper Move Switch

[LED conditions to light] LED No. L1 L2,7 L3 L4 L 5,8 L6,9 Functions Cover Open Knife Lock Sheet Jam Sheet Jam Full Trimmings Trimmings Box Conditions to light When top cover is opened,connecting to SPF, or removing from SPF When trimming motor driver detects too much load When entrance sensor section B10 is ON When exite sensor section B11 is ON When full trimmings sensor B16 is ON When trimmings box switch S1 is OFF S2,S3 M11 driver B10 B11 B15.B16 S1

SM

7-97

CON 1

SPF-9R

7-2 CFS Section Power Locations

CR00

S00

Breaker

Breaker

Breaker

SSR L G01 N L G02 N M13 SPF-9

Power Point Blower

Breaker

FC-9
Power Point

Switching Power Supply

SM

7-98

SPF-9R

7-2-2 SPF Section Power Locations

Breaker

Main Switch

Terminal Board

Noise Filter

Q1

G01 Breaker

Q3 Delivery Section Cover Switch G02

Top Cover Switch

Relay

Contrl Board QPW503

Belt Drive Motor

Unit Position Move Motor AC Motor P.C.B

Breaker Q2

Fold Knife Motor Knife Motor Board

SM

7-99

SPF-9R

7-2-3 FC Section Power Locations

Relay

Belt Drive Motor

WHT
Protector

M10
YEL

K04

Terminal Board 1

Relay K3

Noise Filter 2 3 4

25
Knife Motor

14

M11

Control Board QPM484

Driver

Connector POWER SUPPLY 5V Relay K1

(Top cover (Open Input

G01
Top Cover Switch

Relay K2

G02

Switch for SPF Connector

POWER SUPPLY 24V

S3

SM

7-100

SPF-9R

7-3 SPF Section Flat Cable Connections

Staple Unit 1 Clinch Unit 1

Staple Unit 2 Clinch Unit 2

CON11

CON12

CON13

CON14

Panel Board QPW491

CPU

Contral Board QPW-503

CON15

CON18

SM

7-101

SPF-9R

7-4-1 CFS Section Terminal Board Locations

To Switching Power Supply S00 To Switching Power Supply G01 (5V) L To Breaker G00 To Switching Power Supply G01 (5V) N

To Power Cord for SPF To Power Cord forFC To SSR for Blower To Switching Power Supply G02 (24V) N To Power Cord forFC To Power Cord for SPF To Blower Motor To Switching Power Supply G02 (24V) L

[Wiring of CFS terminal board X01]

SM

7-102

SPF-9R

7-4-2 SPF Section Terminal Board Locations

To Switch S00

To Switch S00

Q2

2A

To Knife Motor Board QPW522 CON2-1 To P.C.B QPW518 CON4-1 To Switching Power Supply G01 (5V) N To Switching Power Supply G02 (24V) N

Relay K2

To P.C.BQPW518 CON4-2 To Knife Motor Board QPW522 CON2-2 To Switching Power Supply G01 (5V) L To Switching Power Supply G02 (24V) L

[Wiring of terminal board X01]

SM

7-103

SPF-9R

7-4-3 FC Section Terminal Board Locations

GRN WHT 13 WHT BLK 26 RED BLK 13

To Switching Power Supply G01 (5V) N To Switching Power Supply G02 (24V) N To Relay K3-4 for Belt Drive Motor M10 To Relay K3-3 for Belt Drive Motor M10 To Switching Power Supply(5V) L To Switching Power Supply (24V) L

Breaker

2A

WHT BLK WHT BLK

K3 25

To Belt Drive Motor M10 To Belt Drive Motor M10 To Trimming Knife Motor Driver 24

14

To Trimming Knife Motor Driver 23

[Wiring of terminal board X01]

SM

7-104

SPF-9R

7-5 Wiring and Connections among Machines

To Copy Machine

SPF FC

To Power Supply

SM

7-105

SPF-9R

SPF-9R BOOKLETMAKER INSTALLATION MANUAL

RICOH GROUP COMPANIES

BOOKLETMAKER

SPF-9R

Important Information
- This manual is designed to help you to install, operate and maintain bookletmaker, SPF-9RGS. Read, understand and keep this manual in a safe and convenient place. - Do not operate SPF-9RGS until you read and understand the instructions in this manual. - Horizon International Inc. shall not be liable for incidental consequential damages resulting from : improper or inadequate maintenance by customer; unauthorized modification or misuse; operation outside of the environmental specifications for the product. - Horizon International Inc. pursues a policy of continuing improvement in design and performance of the product. Therefore, the product design and specifications are subject to change without prior notice and without our legal obligation. - All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the prior written consent of Horizon International Inc.

Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. - The signal word CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may also be used to alert against unsafe practices. - Read and understand all safety instructions with signal word such as WARNING and CAUTION. If safety instructions are ignored, personal injury may result. - Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this manual and warning labels on the machine are therefore not all inclusive. - All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device where it is locked or tagged out. - Do not operate the machines when any covers are removed. - Some of the drawings in this manual show the machine uncovered for explaining the detail or inside of machine. - This machines noise level is more than 70 dB(A). Use proper soundproof device when this machine is operated.

II

Contents
Important Information ............................................................................................. I Safety Precautions .................................................................................................. II

1. Installation space Securement .......................................................................... 1 2. Before You Begin ................................................................................................ 2 3. Installation of CFS (Cover Feed and Stacker Section) ................................. 4 4. Installation of SPF (Staple and Fold Section) ................................................. 7 5. Installation of FC (Fore-edge Trim Section) .................................................. 9 6. Cable Connection ................................................................................................ 12 7. Accessories ........................................................................................................... 15

III

1. Installation Space Securement

Please prepare installation space for machine operation, daily check, replacing consumption parts, and to keep the machine in good condition.
500mm

SPF (Staple and Fold Section)

1000mm

Copy Machine
800mm

FC (Fore-edge Trim Section)

CFS (Cover Feed and Stacker Section)

Copy Machine

CFS (Cover Feed and Stacker Section) SPF (Staple and Fold Section) Delivery Tray FC (Fore-edge Trim Section) (1)

2. Before You Begin

Remove the support tape and strings for shipping. 1. Remove seven fixing tapes at stacker section door and delivery section

Fixing Tapes

Fixing Tapes

2. Open the stacker section door.

3. Remove a fixing tape of the sensor and two plastic cord strings.

Plastic Cord String Fixing Tape

4. Remove two fixing tapes at the stack tray.

Stacker

Fixing Tapes (2)

2. Before You Begin

5. Remove two fixing tapes at transport section.

Fixing Tapes

6. Remove a fixing string for guide at cover feed tray, a plastic cord string for the sensor, and two fixing tapes at cover feed section.

Fixing Tapes String

Plastic Cord Strings 7. Remove four fixing tapes at cover feed section a d transport section.

8. Set the attached film to the upper part of the delivery section on copy machine. 66 mm mm Film CFS

Film

Copy Machine

Delivery Section (3)

3. Installation of CFS (Cover Feed and Stacker Section)

1. Set up the attached joint latch to the left side of the copy machine. Copy Machine

Set Up the Latch

2. Set up the entrance guide plate to the delivery section of the CFS (cover feed and stacker section).
Set Up the Entrance Guise Plate

3. Remove the entrance cover at CFS. Entrance Section Cover Lever

Remove the Cover

4. Remove the fixing screw of the lever.

Remove the Fixing Screw of the Lever

(4)

3. Installation of CFS (Cover Feed and Stacker Section)

5. Pull the lever to the front.

Pull Out the Lever

6. Fit the copy machine and CFS, so that the latch on copy machine fits to the slit hole under the delivery section of the CFS.

7. Connect the copy machine and CFS by pushing the lever.

Push the Lever

8. Set the fixing screw to the lever and fix it.

Set Up the Fixing Screw of the Lever

(5)

3. Installation of CFS (Cover Feed and Stacker Section)

9. Set the entrance cover as before.

Set Up the Cover

Entrance Cover

(6)

4. Installation of SPF (Staple and Fold Section)

1. Set up the attached joint latch to the right side of the SPF (staple and fold section).

Set Up the Latch

SPF Operation Side

2. Turn on the power of SPF.

Power on

3. Open the CFS stacker section door and remove the screw of the lever which is at a lower left part of the machine.

Remove the Fixing Screw of the Lever

4. Pull the lever to the front.

Pull Out the Lever

(7)

4. Installation of SPF (Staple and Fold Section)

5. Fit the SPF to CFS so that the latch on the SPF fits to the slit hole at the lower left part of the CFS. NOTE - Place the machine on the flat floor where there is 1 cm gap between CFS and SPF. SPF Operation Side

CFS

6. Push the lever and connect CFS and SPF.

Push the Lever

7. Set the fixing screw of the lever at former position.

Set Up the Fixing Screw of the Lever

8. Close the stacker section door.

Stacker Section Door (8)

5. Installation of FC (Fore-edge Trim Section)

1. Remove the fixing screw of the transportation lock bracket. FC Operation Side

Fixing Screw Transportion Lock Bracket 2. Mount the rail plate to the lower part (left side) of the SPF. SPF

Rail Plate

3. Mount the transport guide to the belt section on the right side of the FC. Insert the transport guide to the very bottom and fix it with a fixing screw.

Transport Guide Joint Latch 4. Set up the joint latch to the left side of the SPF.

SPF (9)

5. Installation of FC (Fore-edge Trimmer)

5. Fit the hollow on the caster over the projected section on the rail plate. SPF

FC Caster

Rail Plate 6. Connect FC section to SPF. Raise the hook of the joint latch on SPF and move FC so that the latch enters to FC section. FC SPF

NOTE - Upper part of FC section slides back and forth.

(Seen from Above)

7. Open the FC section top cover.

8. Connect SPF to the FC section by latching the hook of the joint latch over the stud provided.

Joint Latch

Hook

(10)

5. Installation of FC (Fore-edge Trim Section)

9. Set the attached wire for a stopper at the lower drive side of SPF and FC.

Wire for a Stopper FC 10. Mount the hook of the delivery tray to the slit hole on the left side of the FC section.

Slit Hole Delivery Tray

Hook

11. Attach stopper.

Stopper

(11)

6. Cable Connection
1. Insert the connecting plug coming out from FC drive side to the round shaped connector on the SPF drive side, and then tighten the lock nut. Connecting Plug SPF Drive Side

FC Drive Side

2. Insert the attached signal cable to connector section on the drive side of FC and SPF section, and then fix it with the insertion screw.

Connector Section Signal Cable Connector Section

CFS Drive Side Connector Section 3. Insert the attached signal cable to the connector section on the drive side of SPF and CFS section, and then fix it with the insertion screw. Connector Section Signal Cable

SPF Drive Side

Copy Machine Signal Cable 4. Insert the signal cable of the CFS section to the connector section on the left side of the copy machine. Connector Section (12)

CFS Drive Side

6. Cable Connection
5. Plug the power cords of FC and SPF to the receptacles at the drive side. And then connect either plug of SPF power cord to the receptacle on the CFS drive side.

6. Connect the power cord of delivery tray to the SPF power source at drive side of the SPF.

SPF

7. Connect the power cords of CFS and FC to the power source in the building.

CFS

(13)

6. Cable Connection
8. Set the attached cord clamps to the drive side of machine (3 pcs) and then tie each cord with the cord clamp as mentioned below. Clamp A; Power cord of FCand SPF Signal cable of SPF Clamp B; Power cable of PC Clamp C; Power cord of the delivery tray signal cable of PC

9. Set the attached cord clamp on the delivery side of the FC (1 pc). Clamp D; Power cord for delivery tray

Delivery Tray

Clamp D

(14)

7. Accessories
7-1 Accessories for Cover Feed and Stacker Section
Unit Joint Stay F (Ml105012-00) 1pc Unit Joint Stay R (Ml105013-00) 1pc

Power Cord (4011012-00)

1pc

Signal Cable (DD1-25-SV-1.5)

1pc

Joint Stay F (4016548-00)

1pc

Joint Stay R (4013549-00) 1pc

Manual Case (M105050-00)

1pc

Entrance Guide Plate (A931099-00) 1pc

(15)

7. Accessories
Cover Feed End Plate (M004363-01) 1pc Cover Holding Plate (M004337-01) 1pc

Joint Screw 4-8 4pc

Cord Clamp

4pc

Film (M105425-00)

1pc

Stopper (S) (M105298-00)

1pc

Replaceable Film (M105300-00)

1pc

(16)

7. Accessories
7-2 Accessories for Fore-edge Trimmer Section
Joint Plate A (M072791-12) 1pc Entrance Guide (M072906-01) 1pc

Joint Plate B(M072794-02)

1pc

Power Cord (4011012-00)

1pc

Rail Plate [M072766-00) 1pc

Rope (M037765-00)

1pc

Signal Cable (DD1-25-SV-1.5)

1pc

Stopper (M105449-00)

1pc

(17)

7. Accessories
7-3 Accessories for Staple and Fold Section
Staple (4-010600-00) 2pc

Power Cord (4011012-00)

1pc

8. Consumption Parts
Consumption Parts Staple (4-010600-00) Staple Cartridge (4-010266-00)

Life Parts Knife (U) (M072822-01) Knife (L) (l072808-01)

(18)