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Ricoh D179 Detailed Descriptions Manual
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Ricoh D179 Detailed Descriptions Manual

Ricoh D179 Detailed Descriptions Manual

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D179/D180/D181
DETAILED
DESCRIPTIONS
MANUAL

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Summary of Contents for Ricoh D179

  • Page 1 D179/D180/D181 DETAILED DESCRIPTIONS MANUAL...
  • Page 2 D179/D180/D181 DETAILED DESCRIPTIONS TABLE OF CONTENTS 1. D179/D180/D181 OVERVIEW ............1 1.1 GENERAL LAYOUT ..................1 1.2 PAPER PATHS ....................2 1.3 PERIPHERAL CONFIGURATION RULES ............ 3 1.4 EXAMPLE CONFIGURATIONS ..............4 1.4.1 EXAMPLE 1 ..................4 1.4.2 EXAMPLE 2 ..................4 1.4.3 EXAMPLE 3 ..................
  • Page 3 8.1.1 LAYOUT (ROLLERS, MOTOR, SENSORS ........53 8.1.2 UNIT CONFIGURATION ..............54 8.1.3 DETAILS ..................... 54 8.1.4 TONER AND DEVELOPER MIXING ..........55 8.1.5 DEVELOPER UNIT DRIVE ..............56 8.1.6 VENTILATION ..................57 9. IMAGE TRANSFER UNIT ............58 D179/D180/D181 Detailed Descriptions...
  • Page 4 LAYOUT ..................79 12.2 DETAILS ....................80 12.2.1 PAPER SEPARATION MECHANISM ........... 80 12.2.2 PTR CLEANING ................81 12.2.3 LUBRICANT APPLICATION ............81 12.2.4 PTR LIFT AND SEPARATION ............82 13. PTB UNIT ..................83 13.1 LAYOUT ....................83 Detailed Descriptions D179/D180/D181...
  • Page 5 Environment A-1 ..................97 Environment B-1 ..................98 Environment B-2 ..................99 Environment C-1 .................. 100 7. During Job Paper Feed ..............101 Environment A-1 .................. 101 Environment B-1 .................. 102 Environment B-2 .................. 103 Environment C-1 .................. 104 D179/D180/D181 Detailed Descriptions...
  • Page 6 OVERVIEW ................. 135 16.1.2 MECHANICAL CONFIGURATION ..........136 Transport Unit ..................136 16.1.3 TRANSPORT PATH, SENSOR LAYOUT ........136 16.1.4 DRIVE LAYOUT ................138 16.2 DETAILS ....................139 16.2.1 DOUBLE-FEED DETECTION ............. 139 Double-feed Related SP Code ............. 140 Detailed Descriptions D179/D180/D181...
  • Page 7 20. DECURL UNIT DU5030 (D741) ..........174 20.1 SPECIFICATIONS ................174 20.2 DECURL UNIT OPERATION ............... 175 20.2.1 DECURL UNIT MOVEMENT ............176 21. LCIT RT5070 (D733) ..............178 21.1 OVERVIEW ..................178 21.1.1 SPECIFICATIONS ..............178 D179/D180/D181 Detailed Descriptions...
  • Page 8 A3/DLT LCT D732 LAYOUT (WITH BYPASS) ........212 22.15 ELECTRICAL COMPONENT SUMMARY .......... 213 23. BOOKLET FINISHER SR5060/FINISHER SR5050 (D734/D735)217 23.1 SPECIFICATIONS ................217 Booklet Finisher SR5060 ..............217 Finisher SR5050 .................. 221 23.2 DRIVE LAYOUT ................... 224 Detailed Descriptions D179/D180/D181...
  • Page 9 Folding Mode FM3 ................276 Folding Mode FM4 ................276 Folding Mode FM5 ................277 Folding Mode FM6 ................277 24.2 OVERVIEW ..................278 24.2.1 MOTORS, ROLLERS ..............278 24.2.2 JUNCTION GATES, JUNCTION GATE SOLENOIDS ....279 D179/D180/D181 viii Detailed Descriptions...
  • Page 10 DOWNSTREAM DELIVERY EXIT ..........328 25.6.2 BOOKBINDING DELIVERY EXIT ..........329 25.7 DOWNSTREAM DELIVERY ..............330 25.8 BLANK PAPER HANDLING ..............331 25.8.1 DOWNSTREAM DELIVERY MODE WITH BLANK PAPER ..331 25.8.2 BOOKBINDING MODE WITH BLANK PAPER ......331 Detailed Descriptions D179/D180/D181...
  • Page 11 26.5.1 LIFT TO PRE-FEED POSITION ..........399 26.5.2 DRIVE SELECTION ..............400 26.5.3 PAPER PICKUP AND FEED ............401 26.5.4 SKEW CORRECTION AT THE REGISTRATION ROLLER ..401 26.5.5 TRANSPORT 1: FEED TO STANDBY POSITION ...... 402 D179/D180/D181 Detailed Descriptions...
  • Page 12 LOCATIONS OF COMPONENTS ..........452 27.10 PRE-BIND JOGGER ................456 27.10.1 STACK TAMPER MECHANISM ..........457 27.10.2 PRE-BIND JOGGER MECHANISM ......... 459 27.10.3 PADDLE ROLLER MECHANISM ..........461 27.10.4 SHUTTER MECHANISM ............463 27.10.5 ALIGNMENT PIN MECHANISM ..........465 Detailed Descriptions D179/D180/D181...
  • Page 13 SUB BOARD SENSORS ..............497 27.16.1 PAPER JOGGING UNIT (FRONT), BINDER UNIT ....497 27.16.2 PAPER JOGGING UNIT: SIDE VIEW ........499 27.16.3 PAPER JOGGING UNIT: INSIDE VIEW ........499 27.16.4 CARTRIDGE UNIT: INSIDE VIEW .......... 500 27.17 SWITCHES ..................501 D179/D180/D181 Detailed Descriptions...
  • Page 14 General Layout 1. D179/D180/D181 OVERVIEW GENERAL LAYOUT Name Name Status Light PCDU Operation Panel ITB Unit Registration Unit (Main Path) PTR Unit (Paper Transfer Scanner Roller) ITB Cleaning Unit Vertical Transfer Unit (VTU) Fusing Unit Tray 1 (FM 1) PTB (Paper Transport...
  • Page 15 Paper Paths PAPER PATHS Name Name Paper Transport Belt Paper Bank Straight-through Path Exit Vertical Transport Unit Invert Exit Registration Unit Duplex Return Path ITB Unit (Image LCIT (Option) Transfer) PTR Unit (Paper Multi Bypass Tray (Option) Transfer) D179/D180/D181 Detailed Descriptions...
  • Page 16 Peripheral Configuration Rules PERIPHERAL CONFIGURATION RULES Main Machine D179/D180/D181 LCIT RT5080 D732 LCIT RT5070 D733 Multi Bypass Tray BY5010 D517 Decurl Unit DU5030 D741 Transit Pass Unit D391 Perfect Binder GB5010 D736 Cover Interposer Tray for Perfect Binder Type S1 D736...
  • Page 17 Trimmer Unit TR5040 1.4.2 EXAMPLE 2 Main Machine LCIT RT5080 (A3) Multi Bypass Tray BY5010 Transit Pass Unit for Perfect Binder Type S1 Perfect Binder GB5010 Cover Interposer Tray for Perfect Binder Type S1 Booklet Finisher SR5060 D179/D180/D181 Detailed Descriptions...
  • Page 18 Multi-Folding Unit FD5020 Booklet Finisher SR5060 Trimmer Unit TR5040 1.4.4 EXAMPLE 4 Main Machine LCIT RT5080 (A3) Multi Bypass Tray BY5010 Cover Interposer Tray CI5030 Booklet Finisher SR5060 1.4.5 EXAMPLE 5 Main Machine LCIT RT5070 Finisher SR5050 Detailed Descriptions D179/D180/D181...
  • Page 19 Dimensions (w x d x h) 591 x 520 x 175 mm (23 x 21 x 7 in.) Weight Less than 14 kg (31 lb.) Power supply DC24 V、DC12 V、DC5 V (from main machine) Power consumption Less than 82.5W D179/D180/D181 Detailed Descriptions...
  • Page 20 52.3 Thickness Paper Size A3/A4 B4/B5 DLT/LG 70 kg 90 kg 110 kg Translucent TA、TE、 81.4 Thickness Paper Size A3/A4 B4/B5 DLT/LG Comments : Simplex, duplex both possible : Simplex mode only : SADF simplex mode only Detailed Descriptions D179/D180/D181...
  • Page 21 5. Original Double-Feed Detection. A pair of ultra-sound sensors, one mounted above and one mounted below the original path detect double feeding. D179/D180/D181 Detailed Descriptions...
  • Page 22 2.1.4 ADF DRIVE LAYOUT Rollers driven by DC motors comprise the ADF drive. 1 Transport Motor 5 Bottom Plate Lift Motor 2 Entrance Motor 6 Exit Motor 3 Feed Motor 7 Scan Motor － 4 Pickup Roller Lift Motor Detailed Descriptions D179/D180/D181...
  • Page 23 A4 SEF or LT SEF paper passes the registration sensor).  Pickup Roller Operating Position (Down) Timing When the leading edge of the original passes the skew correction sensor at  At Power On  When Feed Cover Opens  This causes an original jam. D179/D180/D181 Detailed Descriptions...
  • Page 24  This mechanism keeps the position of the top of the stack (up to 250 sheets) at the correct position for continuous original feeding.  After the last original is fed, the bottom plate descends as far as the bottom plate HP sensor [C], and the motor turns off. Detailed Descriptions D179/D180/D181...
  • Page 25 (to send the double fed sheets back to the tray), and then releases so the top sheet can continue to feed. D179/D180/D181 Detailed Descriptions...
  • Page 26  You can use SP6020-001 to make the scanning entrance roller stop for the second skew adjustment of any size paper (not just small paper). Detailed Descriptions D179/D180/D181...
  • Page 27 B5 SEF (182×257) B5 LEF (257×182) B6 SEF (128×182) B6 LEF (182×128) 11"×17" SEF (DLT) 11"×15"SEF 8 1/2"×11" SEF (LT) 11"×81/2" LEF (LT) SP6016-001 can be used to choose size detection or either 11"x17" P or 11"x5"P, D179/D180/D181 Detailed Descriptions...
  • Page 28 This prevents the paper from skewing diagonally in the original feed path. After skew adjustment at the grip roller, grip motor [A] and relay motor [B] turn the rollers [C] that feed the original to the scanner unit below. Detailed Descriptions D179/D180/D181...
  • Page 29 When exit sensor [A] detects the original, exit motor [B] turns on and rotates exit rollers [C] which feed the original out onto the exit tray. D179/D180/D181 Detailed Descriptions...
  • Page 30 Double-feed detection can be switched by the operator with an operator setting: Operator Adjustment > 1. Main: Image Position Adjustment > 0108 ADF Double Feed Detection Operation (On (default), Off). The service technician can also switch double-feed detection off/on with SP60040-00 [0 to 1/1/1] (Default 1: On) Detailed Descriptions D179/D180/D181...
  • Page 31 Details 2.2.8 DUPLEX SCANNING White Roller Main Scanner LED To improve productivity, this machine is equipped with a color CIS [A] to scan the back sides of original while the front side is being scanned. D179/D180/D181 Detailed Descriptions...
  • Page 32 Details 2.2.9 JAM SENSOR LAYOUT Skew Correction Sensor Separation Sensor Exit Sensor Registration Sensor Skew Correction Sensor Double-Feed Detection Sensor (Lower: emitter, Upper: receiver) Detailed Descriptions D179/D180/D181...
  • Page 33 Trailing edge not detected after registration sensor detected trailing edge and enough time has elapsed for 130 mm of feed. Double-feed jam Double-feed sensor pair (ultrasound) detected a single weaker than that expected for the original is use and signaled double-feed. D179/D180/D181 Detailed Descriptions...
  • Page 34 ASIC boot in CIS abnormal 186-00 CIS light Cycle main At power on element power switch One or both connectors of CIS LED abnormal off/on damaged During original feed Leads of CIS LED damaged ADF main control board defective Detailed Descriptions D179/D180/D181...
  • Page 35 189-00 CIS gray Cycle main CIS device abnormal balance power switch Adjustment chart damaged, dirty, adjustment off/on deteriorated error Note: Errors that occur twice in succession are treated as jams, three times in succession as SC errors. D179/D180/D181 Detailed Descriptions...
  • Page 36 Scanning Path 3.1.2 CONFIGURATION Scanner LED exposure lamp SBU (3-line CCD with 600 dpi resolution) Scanning Scanner motor (dual-phase stepper motor) Mechanism Wire pulleys Scanner HP sensor Original Size APS (Length Sensor x1) Detection Miscellaneous Anti-condensation heater (option) Detailed Descriptions D179/D180/D181...
  • Page 37 FC or B&W. When scanning with the ADF, shading correction is done before the first original is scanned, and then executed again at prescribed intervals (more than one minute), regardless of whether the originals are FC or B&W. D179/D180/D181 Detailed Descriptions...
  • Page 38 The movement of the scanner is controlled by wire pulleys driven by the scanner motor. The position of the scanner (1st carriage) [A] is controlled by the scanner HP sensor [B]. The scanner HP sensor [B] is positioned at the sheet-through document feeder scanning position. Detailed Descriptions D179/D180/D181...
  • Page 39  The photosensor detects the area where shading is present and where it is absent, and then confirms the reading of the original length sensor as pre-scanning starts.  When the status is "no shading", the original size detection data is used immediately after [Start] is pressed. D179/D180/D181 Detailed Descriptions...
  • Page 40 Display A3/DLT 00000011 B4/LG 00000011 A4 SEF 00000011 － LT SEF 00000001 － － A4 /LT LEF 00000000 － B5 SEF 00000001 － － B5 LEF 00000000 － － A5/HLT SEF 00000000 － － A5/HLT LEF 00000000 Detailed Descriptions D179/D180/D181...
  • Page 41 If the value detected by the CCD and displayed with SP4310-001 to 009 is greater than 18, then it is determined that an original is present in the width direction. The value that is displayed with this SP codes is always that of the most recent detection. D179/D180/D181 Detailed Descriptions...
  • Page 42 OFF)  SP4020-002: DF Dust Detection Setting Level Switching  SP4020-003: DF Dust Detection Setting - Correction Level Switching  SP7852-001: DF Scan Glass - Dust Detection Counter  SP7852-002: DF Scan Glass - Dust Detection Counter Detailed Descriptions D179/D180/D181...
  • Page 43 HP (default) to the right 0.52 mm (b), and to the left 0.52 mm (c): a > b > c > a > b. Normally, the shift is done a > b > c > a > b. D179/D180/D181 Detailed Descriptions...
  • Page 44  When the machine is switched off with the operation switch at the end of the work day, the heater will switch on to prevent condensation from forming while the machine is idle. Detailed Descriptions D179/D180/D181...
  • Page 45  SP4-011-001 Main Scan Registration  SP4-688-002 Scan Image Density Adjustment 1  Preventing Dust Contamination with ADF Scanning An SP code, SP4-688-002 (Scan Image Density Adjustment 1), is designed to prevent dust contamination of images scanned with the ADF. D179/D180/D181 Detailed Descriptions...
  • Page 46 2-bit/pixel digital signals.  IPU Data Flow For more about image processing flow, please refer to the block diagram above. Detailed Descriptions D179/D180/D181...
  • Page 47 7 Lens1 2 Cylindrical Lens 1 8 Lens2 3 Cylindrical Lens 2 9 Beam Detector Mirror 4 Polygon Mirror 10 Synchronizing Detector Board (Leading Edge) 5 Polygon Motor 11 Synchronizing Detector Board (Trailing Edge 6 1st Mirror D179/D180/D181 Detailed Descriptions...
  • Page 48 (slit), the sides of the polygon mirror in the path of the beams reflects them onto the drum.  VCSEL slows the rotation of the polygon motor to suppress heat and electrical discharge. Detailed Descriptions D179/D180/D181...
  • Page 49 5V power supply line from the PSU that supplies power to the laser unit. Opening either front door [C] or removing the front edge cover [A] opens the circuit and interrupts the power supply to the laser unit to prevent the laser from accidentally firing. D179/D180/D181 Detailed Descriptions...
  • Page 50 When either the right door or left door, or font cover (toner bank) is opened, or when the front edge cover is removed, the +5V line connecting each LD driver on the LD control board is disconnected to disable the laser units. Detailed Descriptions D179/D180/D181...
  • Page 51  The speed of rotation of the polygon mirror motor for the models listed in the table below is the same for OHP transparency, thick paper, and normal paper feed. Model RICOH Pro 8100S 29156 RICOH Pro 8110S 29528...
  • Page 52 Name Name Toner Bottles 6 Bottle Inner Cap Motors (x2) Bottle Set Sensors 7 Toner End Sensors Bottle Motors (x2) 8 Sub Hopper Toner Agitator Motor 9 Toner Feed Motor － － Bottle Inner Cap Sensors (x2) Detailed Descriptions D179/D180/D181...
  • Page 53  Each of the two toner bottles has its own bottle motor that rotates the bottle to feed toner from the bottle into the toner hopper. D179/D180/D181 Detailed Descriptions...
  • Page 54  The toner feed motor rotates the coil that feeds toner from the toner sub hopper to the development unit. Detailed Descriptions D179/D180/D181...
  • Page 55  Once the near-end alert appears, the machine can continue operating for approximately 1000 prints (A4 with 6% coverage), and then the toner end alert appears and the machine stops. Toner Flow from Toner Bottle to Sub Hopper D179/D180/D181 Detailed Descriptions...
  • Page 56  The operator should replace the bottle as quickly as possible because toner supply halts when the door is opened and will not resume until the door has been closed. Detailed Descriptions D179/D180/D181...
  • Page 57 Mechanisms 7. AROUND THE DRUM MECHANISMS 7.1.1 LAYOUT Name 1 OPC Drum 2 CGB Unit 3 Development Unit 4 Image Transfer Unit D179/D180/D181 Detailed Descriptions...
  • Page 58  Development Unit Drive Development motor system  Toner Density Control TD sensor monitors toner density level  Drum Ventilation Cooling fans provide cooling Lubricant End Detection Two new lubricant end sensors on the ends of the cleaning unit Detailed Descriptions D179/D180/D181...
  • Page 59 MECHANISMS AROUND THE DRUM 7.2.1 LAYOUT Name Name 1 Drum Potential Sensor 6 Lubricant Brush Roller 2 Drum 7 Lubricant Bar 3 Quenching Lamp 8 Lubricant Blade 4 Toner Collection Coil 9 Drum Charge Unit 5 Cleaning Blade D179/D180/D181 Detailed Descriptions...
  • Page 60  The quenching lamp (an LED) mounted below the drum quenches the charge of the drum after every drum rotation to erase the drum for the next application of charge and image. Detailed Descriptions D179/D180/D181...
  • Page 61  After cleaning the cleaning pads move to the cleaning pad HP sensor and then stop.  The charge corona wires are cleaned automatically after every 6,000 printed pages. D179/D180/D181 Detailed Descriptions...
  • Page 62  SP9-900-001 Total Charge Cleaner Unit Cleanings Displays the total number of pages (service life of the charge cleaning unit count).  SP9-900-001 Total Charge Cleaner Unit Cleaning Clears This SP clears the charge cleaner count display of SP9-900-001. Detailed Descriptions D179/D180/D181...
  • Page 63  A lubricant bar and lubricant roller apply lubricant to the surface of the drum to improve the efficiency of drum surface cleaning.  Paper dust and toner cleaned from the surface of the drum drop into a rotating toner collection for transport to the toner collection bottle. D179/D180/D181 Detailed Descriptions...
  • Page 64  The lubricant end sensors [A] are mounted at the top of the unit behind the lubricant blade.  One is mounted at the front, and another at the rear, and either one can trigger a near-end alert. Detailed Descriptions D179/D180/D181...
  • Page 65  The ozone laden air is filtered through both an air filter [6] to remove dust and an ozone filter to neutralize the ozone.  The air passes through another ozone filter in the air duct before it finally passes out of the machine. D179/D180/D181 Detailed Descriptions...
  • Page 66 Development Unit Mechanism 8. DEVELOPMENT UNIT DEVELOPMENT UNIT MECHANISM 8.1.1 LAYOUT (ROLLERS, MOTOR, SENSORS Name Name Transport Augur Doctor Blade TD Sensor Development Sleeve Detailed Descriptions D179/D180/D181...
  • Page 67  About 7% of the developer is carrier. D179/D180/D181 Detailed Descriptions...
  • Page 68  Any carrier from the developer that adheres to the drum is removed collected by the toner collection roller.  The developer transported y the development sleeve roller and toner collection roller falls into the transport augur below and is circulated. Detailed Descriptions D179/D180/D181...
  • Page 69 This shows how the two development sleeves, three transport augers, and toner collection coil are driven. A toner density sensor [1] is located at the higher end of the canted toner collection coil, opposite the driven gears [2]. D179/D180/D181 Detailed Descriptions...
  • Page 70 Development Unit Mechanism 8.1.6 VENTILATION Two fans cool the development unit, one at the front [A] and one at the rear [B]. Fan [B] also prevents toner scatter by suctioning toner from below the development unit. Detailed Descriptions D179/D180/D181...
  • Page 71 PTR unit. At the PTR unit the image on the image is taken from the belt and transferred to paper.  The paper is separated from the ITB and then transported over the PTB unit to the fusing unit. D179/D180/D181 Detailed Descriptions...
  • Page 72 Applied quenching bias and curvature separation separate paper from ITB  PTR Cleaning Counter blade system  PTR Lubrication Lubricant bar, lubricant brush roller, lubricant blade system  PTR Mechanism Cam operated PTR separation Transport to Fusing Unit  Transport Belts Detailed Descriptions D179/D180/D181...
  • Page 73 Belt Centering Motor 9.2.2 DRIVE The ITB is driven by gears, transport belt roller [A] and the transport belt motor [B]. The line speed of the belt is controlled by the drive board of the transport belt motor. D179/D180/D181 Detailed Descriptions...
  • Page 74  A negative bias is applied to the roller opposing the paper transfer roller to separate the paper from the belt (repulsive separation) in the PTR unit farther downstream.  The bias at both points is supplied the same power pack, the transfer power pack. Detailed Descriptions D179/D180/D181...
  • Page 75 [B] and the belt [C], and the PTR unit must be removed to prevent scouring of the paper transfer roller.  When lever [D] is lowered before pulling out the drawer, this separates the PTR from the drum and belt. D179/D180/D181 Detailed Descriptions...
  • Page 76  If the position of the belt cannot be corrected with the belt steering roller HP sensor, or if there is no output from the belt centering sensor, the machine will issue SC471-01 (Belt Position Ready Timeout) and the machine will stop to prevent damage to the belt. Detailed Descriptions D179/D180/D181...
  • Page 77 A small fan both cleans and cools the area on the side of the ITB where the fusing unit generates heat. A thermostat [3] monitors the temperature around the ITB unit. This is a safety device. If the area around the ITB overheats, the thermostat will blow and shut down the system. D179/D180/D181 Detailed Descriptions...
  • Page 78 A small fan [A] on the right side of the drawer keeps the detecting surface of the ID sensor [B] clean. The air blown over the surface of the ID sensor where it reads patterns on the belt below keeps it free of paper dust and other matter. Detailed Descriptions D179/D180/D181...
  • Page 79 C, the ITB heater will switch ON.  If the heater is ON and machine temperature rises to 32 C±5 C, the heater will switch OFF. The thermostat performs no function when the heater is not connected. D179/D180/D181 Detailed Descriptions...
  • Page 80 Layout 10. ITB CLEANING UNIT 10.1 LAYOUT Name Name 1 Lubricant Brush Roller Used Toner Exit Port 2 Cleaning Blade Lubricant Bar 3 Cleaning Roller Stopper 4 Paper Dust Scraper Lubricant Blade 5 Collection Coil Detailed Descriptions D179/D180/D181...
  • Page 81 7 Lubricant Bar 4 Cleaning Roller A cleaning blade and lubricant blade comprise the counter blade system. In order to improve cleaning, a light lubricant is applied evenly to the surface of the belt with the lubricant blade. D179/D180/D181 Detailed Descriptions...
  • Page 82 Process control can be divided into two separate phases:  Potential control. Performs adjustments for development that affect basic image quality such as gradation levels, line width.  Toner supply control. Standardizes the image density by controlling toner supply. Detailed Descriptions D179/D180/D181...
  • Page 83 PCDU and one below the used toner bottle, monitor the temperature around the PCDU and ambient temperature.   ID Sensor. A non-contact sensor above the ITB that reads a pattern projected onto the drum to determine the amount of toner on the drum (level of image density). D179/D180/D181 Detailed Descriptions...
  • Page 84 After the ID sensor reads these image patterns projected onto the belt, they are removed by first the ITB cleaning unit and then the PTR cleaning unit and then discarded as used toner. Detailed Descriptions D179/D180/D181...
  • Page 85  SP3011-001. Manual Process Control Execution: Executes normal process control. *  SP3011-002 Manual Process Control Execution - Toner Density Adjustment Process Control sets the initial setting for toner density. * These two SP codes indicate “Process Control 1: Potential Control” describe below. D179/D180/D181 Detailed Descriptions...
  • Page 86 Setting the following SP codes to OFF cancels image quality adjustment, so leave them set to their default ON settings.  SP3500-001 Image Quality Adjustment ON/OFF All  SP3500-002 Image Quality Adjustment ON/OFF Process Control  SP3500-002 Image Quality Adjustment ON/OFF - TD Sensor Initialization Detailed Descriptions D179/D180/D181...
  • Page 87 20 pages of A4 LEF, for example).  The ID sensor can read the reflectivity of the image (affected by how much toner is present), and then the machine uses these readings to adjust toner supply. D179/D180/D181 Detailed Descriptions...
  • Page 88 Insufficient data enabled At least 2 points are needed for gamma correction 60 Potential LD inoperative ID sensor patterns not adjustment created Vr ＞-200 V Vr: Residual voltage abnormal Vd: Charge potential Vd out of range, target voltage cannot adjust to Detailed Descriptions D179/D180/D181...
  • Page 89 OFF, or machine not ready Result display examples.  [00] No execution (SP default)  [99] Adjustment start time  [55] Development Gamma abnormal (High)  [11] Succeeded  [22] ID sensor LED current abnormal (too high) D179/D180/D181 Detailed Descriptions...
  • Page 90 Result display examples. [0] No execution (SP default)  [9] Adjustment start time  [1] TD calibration at factory before shipping succeeded  [3] TD calibration at factory before shipping failed  [1] Next execution succeeded  [0] NVRAM clear Detailed Descriptions D179/D180/D181...
  • Page 91  [4] Developer replacement after installation at factory before shipping returned used toner full  [1] Developer installation after installation at the factory before shipping succeeded.  [3] Developer installation after installation at the factory before shipping failed (no developer).  [1] Next execution succeeded D179/D180/D181 Detailed Descriptions...
  • Page 92 Name Name 1 Paper Transfer Roller (PTR) Lubricant Bar 2 Anti-static brush Cleaning Blade 3 Cleaning Roller Paper Transfer Roller Unit 4 Used Toner Collection Coil PTR Idle Roller 5 Lubricant Brush Roller Image Transfer Belt (ITB) Detailed Descriptions D179/D180/D181...
  • Page 93 ITB and PTR are in contact to transfer the image. After the image has been transferred to the paper, the paper discharge plate (connected to the separation power pack) applies AC and DC charge to neutralize the charge on the paper and the ITB. D179/D180/D181 Detailed Descriptions...
  • Page 94 A lubricant roller (a soft brush roller) picks up lubricant from the lubricant bar behind it an applies a very thin coat of lubricant to the surface of the PTR to ensure easier cleaning of the roller surface. Detailed Descriptions D179/D180/D181...
  • Page 95  The PTR separation motor opens the nip between the rollers, and a feeler on the shaft of the PTR idle roller falls into the gap of the PTR separation HP sensor (this is the home position). D179/D180/D181 Detailed Descriptions...
  • Page 96 Layout 13. PTB UNIT 13.1 LAYOUT Name Paper Transport Fans PTB Sensor Paper Transport Belt PTB Unit Paper Transfer Unit Detailed Descriptions D179/D180/D181...
  • Page 97  This system keeps the paper with the unfixed toner on its surface on the paper transport path so it can enter straight into the fusing unit.  The PTB sensor monitors the passing of the leading and trailing edges of the paper to check for a paper jam. D179/D180/D181 Detailed Descriptions...
  • Page 98 Heating Roller Lamps 4 Fusing Belt (1150/900 W) 5 Fusing Temperature Sensor 12 Fusing Belt Paper Sensor 6 Fusing Temperature Sensor 13 Fusing Exit Guide Plate 7 Heating Roller Thermostats (x2) 14 Stripper Pawls 15 Hot Roller Detailed Descriptions D179/D180/D181...
  • Page 99 Fusing Temperature Sensor 21 Retention Roller (Pressure Roller) 17 Pressure Roller Thermostat 22 Cleaning Web 18 Pressure Roller Fusing Lamp 23 Pressure Roller Stripper Pawls 19 Pressure Roller 24 Pressure Roller Stripper Plate 20 Pressure Roller Thermistor D179/D180/D181 Detailed Descriptions...
  • Page 100 Mechanisms, Configuration Name Fusing Pressure Cam Main Machine: Fusing Roller Removed Name Thermopiles (Rear, Front, Near Front) Detailed Descriptions D179/D180/D181...
  • Page 101 Direction) 148 mm Center A 148 mm < L 225 mm Center A, Center B 225 mm < L 304.8 mm Center A, Center B, End-to-End Center A, Center B, End-to-End, Ends 304.8 mm < L Only D179/D180/D181 Detailed Descriptions...
  • Page 102 Fusing lamp inside pressure roller. Hot roller idling after reload temp. Before printing Before paper feed Ready Ends only, Fusing lamp inside pressure roller Low power mode Same as “Fusing Lamp Operation by After paper feed Paper Size” table above/ Detailed Descriptions D179/D180/D181...
  • Page 103 7 Pressure Roller Thermistor (Heating Roller End) Fusing Temperature NC Sensor 8 Heating Roller Thermostat (End) (Heating Roller Center) Fusing Temperature NC Sensor Heating Roller Thermostat (Hot Roller Center) (Center) Fusing Temperature NC Sensor － － (Pressure Roller - Center) D179/D180/D181 Detailed Descriptions...
  • Page 104 Monitors the temperature of the heating roller and Function pressure roller. These thermistors are also a safety device. One: Fusing Heat Roller Thermistor Heating Roller (Rear) Location, Hot roller None Function Pressure Roller One: Pressure Roller Thermistor Detailed Descriptions D179/D180/D181...
  • Page 105 The thermopile, extremely sensitive to temperature change, resides apart from the fusing unit. The NC sensors, slightly less sensitive to temperature than the thermopile, are located inside the fusing unit to control the fusing temperature. D179/D180/D181 Detailed Descriptions...
  • Page 106  Environment B-1: Normal temp.: Cannot adjust with SP if Machine Temp. 10°C  Environment B-2: Normal temp. 2: Cannot adjust with SP if 23°C＜Machine Temp. 32°C  Environment C-1: High Temp.: Cannot adjust with SP if 32°C Machine Temp. Detailed Descriptions D179/D180/D181...
  • Page 107 Details Machine Type Key Type a: RICOH Pro 8100S Type b: RICOH Pro 8110S Type c: RICOH Pro 8120S 1 Warm-up Time Machine start-up step after power on.  Once the set temperature is reached, after the prescribed time shifts to next step, Reload Mode.
  • Page 108 Temperatures and Adjust Temperatures can be adjusted with the listed SP codes. Environment A Set Temp. Adjust Temp. Roller Type a Type b Type c Default Heating 150°C 155°C 160°C SP1107-001 +10°C SP1111-003 Pressure 90°C 90°C 90°C SP1107-002 +10°C SP1111-003 Detailed Descriptions D179/D180/D181...
  • Page 109  Adjust Temp. 2: SP1119-010 to 018 In cases where adjustment must be done for “Adjust Temp. 2”, the paper temperature settings can be done for a tray for different paper thickness (Thick 1 to 8) . 10. IMSS D179/D180/D181 Detailed Descriptions...
  • Page 110 Details An SP can be selected to adjust temperature for the user tool paper settings assigned for different paper thickness beforehand (allocated with Ricoh IMSS software). Environment A-1 The target temperatures for the heating roller and pressure roller in this environment are calculated as: [User Paper Type Set Temp.
  • Page 111 For example “Adjust. Temp 2” (*C) can be used to adjust the initial temperature at the start of paper feed.  Adjusted temperature *B: Compensates for ambient temperature (paper temperature)  Adjusted temperature *C: Compensates for a drop in temperature at initial paper feed. D179/D180/D181 Detailed Descriptions...
  • Page 112 For example “Adjust. Temp 2” (*C) can be used to adjust the initial temperature at the start of paper feed.  Adjusted temperature *B: Compensates for ambient temperature (paper temperature)  Adjusted temperature *C: Compensates for a drop in temperature at initial paper feed. Detailed Descriptions D179/D180/D181...
  • Page 113 For example “Adjust. Temp 2” (*C) can be used to adjust the initial temperature at the start of paper feed.  Adjusted temperature *B: Compensates for ambient temperature (paper temperature)  Adjusted temperature *C: Compensates for a drop in temperature at initial paper feed. D179/D180/D181 Detailed Descriptions...
  • Page 114 ― ― Thk4 10°C SP1111-005 ― ― ― Thk5 10°C SP1111-007 Thk6 10°C SP1111-007 ― ― ― ― ― ― Thk7 10°C SP1111-007 ― ― ― Thk8 10°C SP1111-007 Pressure － ― ― ― ― ― ― Detailed Descriptions D179/D180/D181...
  • Page 115 10°C ― ― ― Thk3 SP1111-005 10°C ― ― ― Thk4 SP1111-005 10°C ― ― ― Thk5 SP1111-007 10°C ― ― ― Thk6 SP1111-007 10°C ― ― ― Thk7 SP1111-007 10°C ― ― ― Thk8 SP1111-007 10°C D179/D180/D181 Detailed Descriptions...
  • Page 116 Thk2 ― ― ― SP1111-006 Thk3 0°C ― ― ― SP1111-006 Thk4 0°C ― ― ― SP1111-008 Thk5 0°C ― ― ― SP1111-008 Thk6 0°C ― ― ― SP1111-008 Thk7 0°C ― ― ― SP1111-008 Thk8 0°C Detailed Descriptions D179/D180/D181...
  • Page 117 The default (or the temperature selected with the SP code) is calculated: (Machine Temperature (Machine Temperature－23°C)/(32°C－23°C) 8. After Paper Passing The target temperature is set for each roller depending on detected ambient temperature as described below. (See Step 3. Roller Rotation After Reload Temperature). D179/D180/D181 Detailed Descriptions...
  • Page 118 However, the low power mode temperature for Type c is set lower, so more time is necessary for recovery. 10 Off/Sleep Modes The heating roller lamps, pressure roller lamp, and fusing motor are shut down, and the pressure roller remains up against the fusing belt. Detailed Descriptions D179/D180/D181...
  • Page 119 Here is a diagram and key for the tables below. Fusing Heat Thermistor (Rear) Fusing Temperature NC Sensor (Heating Roller End) Fusing Temperature NC Sensor (Heating Roller Center) Fusing Temperature Thermistor (Hot Roller Center) Fusing Temperature NC Sensor (Pressure Roller - Center) Pressure Roller Thermistor D179/D180/D181 Detailed Descriptions...
  • Page 120 Continuous On Sensor Func. Fusing Lamp Temp. － － － Control Safety Feature The SC codes listed above can be released by cycling the machine off/on after entering the SP mode for releasing level A SC codes. Detailed Descriptions D179/D180/D181...
  • Page 121 － － Continuous On 565-00 － － Sensor Fusing Lamp Temp. Control Func. － Safety Feature Here is a key for the table above: Thermopile: Heating Roller Center Thermopile: Heating Roller Front End Thermopile: Near Front End D179/D180/D181 Detailed Descriptions...
  • Page 122 Determine accum. temp. at warmup Determine reload temp.? Determine printing possible? High temp. CPM down?* Hot roller idling?* Over temp. idling? * In the table above: Thermopile: Heating Roller Center Thermopile: Heating Roller Front End Thermopile: Near Front End Detailed Descriptions D179/D180/D181...
  • Page 123 14.2.9 FUSING DRIVE LAYOUT The hot roller [A], pressure roller [B] and the fusing belt [C] are rotated by gears driven by the fusing motor [D]. D179/D180/D181 Detailed Descriptions...
  • Page 124 The following parts comprise the pressure roller unit.  Entrance Guide (Lower)  Pressure roller temperature control components  Pressure roller, separation plate (applied pressure)  Fusing Exit Guide Plate (Center)  Sensors (Hot Roller Exit, Jammed Paper)  Fusing Cleaning Unit Detailed Descriptions D179/D180/D181...
  • Page 125 Separation pawls. Separate paper that passes through the fusing nip from the surface of the pressure roller and guide it toward the fusing unit exit. The tips of the pawls contact the surface of the pressure roller with very light pressure D179/D180/D181 Detailed Descriptions...
  • Page 126 Paper remains detection? Detects paper that Detects accordion Detects paper that wraps fails to leave the jams at the fusing around the fusing belt. fusing unit exit. unit nip. Detailed Descriptions D179/D180/D181...
  • Page 127 The width of the nip of between the hot roller and pressure roller is 15.9 mm and is not adjusted in the field. The width of the nip is adjusted manually at the factory with a screwdriver by raising and lowering the pressure roller. (This method is the same as the Pro907EX Series machines. D179/D180/D181 Detailed Descriptions...
  • Page 128 [B] and web take-up roller. Once the web spools off the web supply roller, the feeler drops into the gap of the web end sensor [C]. The sensor signals the machine to issue the web end alert and the machine stops. Detailed Descriptions D179/D180/D181...
  • Page 129 4 Paper Sensors 1 to 5 3rd Feed Sensor 5 1st Paper End Sensor 3rd Paper Size Sensor 6 1st Feed Sensor 3rd Paper End Sensor 7 Bank Exit Sensor 2nd Paper Size Sensor 8 Vertical Transport Sensor 2nd Paper End Sensor D179/D180/D181 Detailed Descriptions...
  • Page 130 Tray LED Display During Operation Tray LED displays during machine operation Tray Heaters Tray locks of Tray 1, Tray 2, Tray 3 when trays opened and closed Tray Handle Lock Mechanisms Manual release lock mechanisms for each tray. Detailed Descriptions D179/D180/D181...
  • Page 131 1 Bank Exit Motor 6 2nd Feed Motor 2 Main Relay Separation Motor 7 2nd Grip Motor 3 Vertical Transport Motor 8 3rd Feed Motor 4 1st Paper Feed Motor 9 3rd Grip Motor 5 1st Grip Motor D179/D180/D181 Detailed Descriptions...
  • Page 132 The machine can feed thick paper quietly and smoothly from each paper feed unit to the vertical transport unit. Name Duplex Transport Rollers Main Relay Rollers Bank Exit Rollers Vertical Transport Rollers 3rd Transport Roller 3rd Feed Roller 3rd Pickup Roller 3rd Separation Roller Detailed Descriptions D179/D180/D181...
  • Page 133  The pressure slide arm lowers and raises the separation roller when the tray is removed and inserted so jammed paper can be removed easily. D179/D180/D181 Detailed Descriptions...
  • Page 134  When the paper tray lift motor switches on and lifts the bottom plate and stack, the tray is at paper feed standby position and ready to feed paper after the paper feed and transport motors switch on. Detailed Descriptions D179/D180/D181...
  • Page 135  The amount of rotation to bring the stack to the optimum feed position is measured by a small metal plate [E] in contact with a gear [F] inside the motor mount (the amount of rotation tells the machine how much paper remains in the tray). D179/D180/D181 Detailed Descriptions...
  • Page 136  The tray lift sensor actuator [D] ascends gradually as sheets are fed for printing until it actuates the tray lift sensor and signals the machine to switch on the lift motor to raise the tray again to the correct paper feed position. Detailed Descriptions D179/D180/D181...
  • Page 137 Tray 2, 3 (Universal Trays) 15.5.3 PAPER END SENSOR Each PFU is equipped with a paper end sensor [A] (a photosensor) that signals when there is no more paper in the paper tray. D179/D180/D181 Detailed Descriptions...
  • Page 138 F4 (8.5 x 13”) 330.2 215.9 Folio (8.25” x 13”) 330.2 209.55 F (8” x 13”) 330.2 203.2 Exec SEF (7.25” x 10.5”) 266.7 184.2 Exec LEF (7.25” x 10.5”) 184.2 266.7 8-Kai SEF 16-Kai SEF 16-Kai LEF Detailed Descriptions D179/D180/D181...
  • Page 139  A damper [F] slows the speed of the descent to prevent the tray from falling too fast.  The lower limit sensor [G] detects the bottom position of the tray. D179/D180/D181 Detailed Descriptions...
  • Page 140 5 levels of paper remaining alerts on the operation panel.  When the tray is full no sensors are de-activated (100%).  The paper end sensor [B] indicates when the tray is out of paper after the last sheet feeds from the tray. Detailed Descriptions D179/D180/D181...
  • Page 141 If the fences do not close correctly, a message on the operation panel alerts the user to reset the tray. D179/D180/D181 Detailed Descriptions...
  • Page 142  When the actuator on the rear fence activates the rear fence return sensor [D], the rear fence drive motor reverses to retract the rear fence.  The motor switches off when rear fence HP sensor [E] detects the rear fence at its home position. Detailed Descriptions D179/D180/D181...
  • Page 143 15.6.7 RIGHT TRAY LOCK When lock release solenoid [A] goes on, lock lever [B] opens.  The lock lever on the left tray catches on the pin of the right tray, so only the left tray is caught and opens. D179/D180/D181 Detailed Descriptions...
  • Page 144  This allows the left tray to be pulled out to load more paper while paper is still feeding from the right tray. Detailed Descriptions D179/D180/D181...
  • Page 145 After the tandem tray is closed and the bottom plate is raised, or when the right tray paper end sensor detects no paper, and there is paper in the left tray, after the bottom plate of the right tray is lowered, the following operation takes place. D179/D180/D181 Detailed Descriptions...
  • Page 146  Paper Jam, Other Problem LED goes off when a paper jam or other problem occurs (SC codes other than logging SC codes).  When Tray Is Removed LED on/off status continues even if tray is removed. Detailed Descriptions D179/D180/D181...
  • Page 147 In order to open Tray 1, 2, or 3, the operator must grip the handle and squeeze to disengage a lock lever [A].  Tray 1 [B] (the top tray) is provided with two handle releases.  Squeezing and pulling either handle will it release for opening. D179/D180/D181 Detailed Descriptions...
  • Page 148 Registration Entrance Transfer Timing Roller Roller 2 LCT Relay Roller Image Transfer Belt (ITB) 3 Registration Timing Roller PTR Unit 4 Registration Gate Roller Paper Separation Power Pack 5 CIS Main Relay Roller 6 Paper Dust Tray Detailed Descriptions D179/D180/D181...
  • Page 149  During duplex printing, once the paper leaves the fusing unit (after the first side is printed) the paper is sent down into the inverter path and then reverse fed back across the machine to the junction of the VTU and then sent once more through the paper registration unit above. D179/D180/D181 Detailed Descriptions...
  • Page 150 7 CIS Checks paper position in the path to determine the amount of correction needed. 8 Transfer Timing Monitors paper movement for jam detection Sensor and controls the timing of paper release to the PTR unit. Detailed Descriptions D179/D180/D181...
  • Page 151 1 Bank Exit Motor 6 Registration Gate Motor 2 Main Relay Separation Motor 7 Transfer Timing Motor Registration Shift Motor 3 Registration Entrance Motor (LE) Registration Shift Motor 4 LCT Relay Separation Motor (TE) 5 Registration Timing Motor D179/D180/D181 Detailed Descriptions...
  • Page 152  If a double feed occurs, the space between the sheets will generate a lower signal. When the emitter detects this lower signal (lower than that of a single sheet) it causes the machine to issue Jam Code J099 (double-feed detected) and the paper is fed to the purged paper tray.. Detailed Descriptions D179/D180/D181...
  • Page 153 LCT relay motor [D] to open the nip of the LCT relay rollers. In both cases the paper is released in front of the registration timing roller [C] so it is free to move for image registration in the main scan direction. D179/D180/D181 Detailed Descriptions...
  • Page 154 The raising and lowering of the registration timing roller [D] is controlled by three gears driven by the rotary gate motor [E] that rotate cam [F]. The lever [G] attached to the cam raises drive roller [H] to separate it Detailed Descriptions D179/D180/D181...
  • Page 155 [A] of the registration gate roller [B]. This buckles the paper slightly and aligns its leading edge with the gate and corrects any skew. After skew correction the rotary gate roller is rotates, grips the paper, and then feeds it to the leading edge shift unit. D179/D180/D181 Detailed Descriptions...
  • Page 156 If paper longer than A4 SEF (297 mm) has been fed, the TE (trailing edge) shift unit [C] moves with the LE shift unit to correct paper registration in the main scan direction. Detailed Descriptions D179/D180/D181...
  • Page 157 The TE registration shift motor [C] moves the TE shift unit to the front and rear. The TE shift unit HP sensor [D] determines the home position of the TE shift unit where the shift unit resides while it is idle. D179/D180/D181 Detailed Descriptions...
  • Page 158 16.2.6 SUB SCAN REGISTRATION (IMAGE HORIZONTAL) After image correction in the main scan direction by the shift units, the paper is fed to the transfer timing roller [A]. The nip of the registration gate roller [B] opens to free the paper. Detailed Descriptions D179/D180/D181...
  • Page 159  Scraper [B] picks up and removes any paper dust missed by the first scraper.  The paper dust scraped away from the roller falls down into a tray.  The can be easily removed and emptied. D179/D180/D181 Detailed Descriptions...
  • Page 160 CIS cleaning fan [B] to keep it clear of dust.  The cleaning fan blows air over the CIS to prevent dust from collecting on the surface of the paper were the image will be written onto the paper. Detailed Descriptions D179/D180/D181...
  • Page 161 The following mechanisms comprise the invert, exit, and duplex section.  PTB unit that transports the paper from the PTR unit to fusing unit  Invert/exit mechanisms  Duplex transport path Name Straight-through Exit Unit Invert/Exit Unit Duplex Exit Unit D179/D180/D181 Detailed Descriptions...
  • Page 162 Duplex Transport Sensor 3 Exit/Invert Sensor 10 Duplex Transport Sensor 4 Purge Relay Sensor 11 Duplex Transport Sensor 5 Purged Paper Sensor 12 Duplex Transport Sensor 6 Duplex Invert Sensor 13 Duplex Exit Sensor Duplex Transport Sensor 1 Detailed Descriptions D179/D180/D181...
  • Page 163 Purging paper in main machine paper path when a jam occurs downstream Duplex • Drive Duplex/invert motor, duplex transport motor 1, 2 • Duplexing Switchback system Interleave Interleave control system (5-sheet interleave with LT LEF and smaller paper sizes D179/D180/D181 Detailed Descriptions...
  • Page 164 Details 17.2.2 DRIVE Name Name Exit Motor Duplex Transport Motors 2 Invert Entrance Motor Exit JG Motor Exit/Invert Motor Exit/Invert Separation Motor Duplex/Invert Motor Invert JG Solenoid Duplex Transport Motors 1 Detailed Descriptions D179/D180/D181...
  • Page 165  The fins of the baffle conduct heat away from the water in the pipe. Air moving around the fins dissipates the heat into the air.  Paper cooling fans (1) in the duct dissipate the heat around the fins. D179/D180/D181 Detailed Descriptions...
  • Page 166 [D] The coolant condenses and heat the is lost through the surface of the pipe and into the fins at the back. [E] The coolant is pushed from rear to front by the super heated water and steam behind it and the cycle repeats. Detailed Descriptions D179/D180/D181...
  • Page 167  The exit JG sensor [B] in the exit path detects the arrival and passing of the paper.  The exit sensor [C] detects the leading edge and trailing edge of the paper as it exits the machine. D179/D180/D181 Detailed Descriptions...
  • Page 168 [B] turns on and feeds the paper down into the inverter unit.  When the leading edge of the paper passes the exit junction gate sensor [F] the exit junction gate motor [C] rotates cam [D] which opens exit junction gate [E] and opens the invert path. Detailed Descriptions D179/D180/D181...
  • Page 169  The invert entrance motor [B] stops  The exit/invert motor [C] reverses, and then feeds the paper to the exit above.  After the paper passes the invert/exit roller, the exit/invert separation motor [D] turns on and separates the exit/invert rollers. D179/D180/D181 Detailed Descriptions...
  • Page 170  The purged paper relay sensor [A] detects the leading and trailing edge of each sheet shunted to the purge unit. The purged paper sensor [A] detects when paper has been shunted into the purge tray after a jam occurs in the line. Detailed Descriptions D179/D180/D181...
  • Page 171 When the duplex/invert sensor [A] detects the trailing edge of the paper:  The invert JG solenoid [B] goes on.  The invert junction gate [C] opens.  The paper brushes past transfer junction gate [D].  The duplex invert motor [E] feeds the paper down. D179/D180/D181 Detailed Descriptions...
  • Page 172 Details When the duplex invert sensor [A] detects the trailing edge of the paper, the duplex inverter motor [A] reverses and feeds the paper up past the open junction gate above. This is the "switchback" operation. Detailed Descriptions D179/D180/D181...
  • Page 173 Longer than 139.7（HLT LEF）shorter than 216（LT LEF) Longer than 216（LT LEF）shorter than 297（A4 SEF) Longer than 297（A4 SEF）shorter than 364（B4 SEF) Longer than 364（B4 SEF）shorter than 432（DLT SEF） Longer than 432（DLT SEF）shorter than 457.2（12"x18") Longer than 457.2（12×18in）shorter than 487.7（13"x19.2") D179/D180/D181 Detailed Descriptions...
  • Page 174 > 4th front side > 5th front side > 6th back side > 2nd back side > 7th front side > 3rd back side > 8th front side > 4th back side > 9th front side, and so on. Refer to the illustration below. Detailed Descriptions D179/D180/D181...
  • Page 175 Paper dust and excess toner from the drum, ITB unit, and PTR unit is collected and transported automatically to the used toner bottle. There are four sections in the used toner path:  Horizontal path  PTR path  Vertical path  Lower path D179/D180/D181 Detailed Descriptions...
  • Page 176 If one of the transport coils becomes jammed in the used toner path, the used toner lock sensor will signal an alert and stop the used toner transport motor, and the machine will issue SC488 (Used toner transport abnormal). Detailed Descriptions D179/D180/D181...
  • Page 177  An agitator [C] creates a mild vibration so the used toner dumped into the bottle does not clump.  The agitator, collection unit toner coil, and used toner bottle coil are all driven by the used toner bottle motor [D]. D179/D180/D181 Detailed Descriptions...
  • Page 178  Full sensor. The full sensor [C] detects when the used toner bottle comes full. Once the machine detects the full condition and issues the alert, the machine stops and cannot be used until the used toner bottle has been replaced. Detailed Descriptions D179/D180/D181...
  • Page 179  As soon as the machine issues the bottle full alert, the machine stops.  If there is a job in progress it will shut down immediately and an alert will appear on the operation panel.  The capacity of the used toner bottle is about 1200 K sheets. D179/D180/D181 Detailed Descriptions...
  • Page 180 Layout 19. BOARDS 19.1 LAYOUT 19.1.1 MAIN MACHINE: REAR Name EDRB CGB Power Pack AC Drive Detailed Descriptions D179/D180/D181...
  • Page 181 Layout 19.1.2 CONTROLLER BOX Name Name 1 BCU 2 CNB Controller Board 3 HDD PSU-A 4 IPU Sub Board PSU-B D179/D180/D181 Detailed Descriptions...
  • Page 182 Layout 19.1.3 CONTROLLER BOX (REVERSE SIDE) Name PSU-C Detailed Descriptions D179/D180/D181...
  • Page 183 Layout 19.1.4 ITB UNIT Name TDRB Transfer Power pack 19.1.5 REGISTRATION UNIT Name D179/D180/D181 Detailed Descriptions...
  • Page 184 Board Circuit Diagram 19.2 BOARD CIRCUIT DIAGRAM Detailed Descriptions D179/D180/D181...
  • Page 185 PSU-A supplies power for the operation panel, laser writing, paper transport drive mechanisms, and the fusing unit. PSU-B supplies 5V power for the machine in low energy mode, and supplies power to the LCT (option). PSU-C supplies power for image creation components and finishers. D179/D180/D181 Detailed Descriptions...
  • Page 186  URTB (Ultrasonic Transfer Board). This is the small PCB on the double feed sensor mounted below the original path in the ADF. In issues the signals received by the double-feed sensor above the original paper path in the ADF. Detailed Descriptions D179/D180/D181...
  • Page 187 210x340SEF, Postcard SEF, 8KSEF, 16K LEF SEF, 12"x18” SEF, 11"x15” SEF, 11"x14” SEF, 10"x15” SEF, 10"x14” SEF, 13"x19 1/5” SEF, 13"x19” SEF, 12 3/5"x19 1/5” SEF, 12 3/5"x18 1/2” SEF, 13"x18” SEF, SRA3 SEF, SRA4 LEF SEF, Custom Size D179/D180/D181 Detailed Descriptions...
  • Page 188 Face curl correction (weak) Lower path 1.5 mm Face curl correction (strong) Lower path 1.8 mm Normal (not selected) Upper path 0.3 mm Back curl correction (weak) Upper path 1.5 mm Back curl correction (strong) Upper path 1.8 mm Detailed Descriptions D179/D180/D181...
  • Page 189  The decurl feed motor [A] drives the rollers that feed paper through the decurl unit.  The decurl unit motor [B] drives the timing belt and gear that raise and lower the decurl unit on the paired rack and pinions at the rear [C] and front [D]. D179/D180/D181 Detailed Descriptions...
  • Page 190  The next screen presents options for adjusting the amount of curl applied (Weak or Strong) for all the trays (Tray 1 to 7).  To adjust the amount of pressure applied for "Weak" or "Strong", use SP1906-1 to 7. Detailed Descriptions D179/D180/D181...
  • Page 191 HLT SEF (full bleed 305 mm wide) Power source DC24V±10% supplied from main machine Power consumption Less than 224W Dimensions (w x d x h) 540 x 730 x 1000 mm (21 x 29 x 39 in.) Weight Less than 106 (233 lb.) D179/D180/D181 Detailed Descriptions...
  • Page 192 5th Paper Feed Unit 8 Horizontal Transport Roller 6th Paper Feed Unit 9 LCT Exit roller 4th Tray Drive Belt 10 Upper Transport Rollers 5th Tray Drive Belt 11 Feed Slot (from Bypass Tray) 6th Tray Drive Belt Detailed Descriptions D179/D180/D181...
  • Page 193 5th Grip Motor 5th Lift Motor LCT Exit Motor 5th Transport Motor 6th Lift Motor 6th Paper Feed Motor 4th Transport Motor 6th Grip Motor 4th Grip Motor 6th Transport Motor 4th Paper Feed Motor 5th Paper Feed Motor D179/D180/D181 Detailed Descriptions...
  • Page 194 6th Paper Feed Sensor 5th Paper Size Sensors 6th Lift Sensor 5th Paper Height Sensor 3 6th Pick-up Solenoid 5th Paper Height Sensor 2 Items 22, 23, 25 and 26 are duplicated in the 4th and 5th units. Detailed Descriptions D179/D180/D181...
  • Page 195 4. 4th Paper Feed Motor 12. Anti-Condensation Heaters 5. 5th Grip Motor 13. Cooling Fan 6. 5th Paper Feed Motor 14. 6th Grip Motor 7. 4th Lift Motor 15. 6th Transport Motor 8. Main Control Board 16. LCT Exit Motor D179/D180/D181 Detailed Descriptions...
  • Page 196 7 4th Paper Feed Sensor 6th Grip Motor 8 4th Grip Motor 6th Transport Sensor 9 4th Transport Sensor 6th Transport Motor 10 4th Transport Motor LCT Exit Motor 11 4th Relay Sensor LCT Exit Sensor 12 5th Paper Feed Motor Detailed Descriptions D179/D180/D181...
  • Page 197 6th tray to the LCT exit motor. LCT Exit Motor Feeds the paper out the LCT and into the entrance of the copier. PCBs Name Description PCB1 Main Control Board Controls the operation of all motors and sensors in the LCT unit. D179/D180/D181 Detailed Descriptions...
  • Page 198 5th Paper Height 6th from the bottom of the 5th tray, detects stack Sensor 3 height: 50% 5th Paper Height 4th from the bottom of the 5th tray, detects stack Sensor 4 height: 25% and signals near-end. Detailed Descriptions D179/D180/D181...
  • Page 199 6th Transport Sensor Detects jams in the paper path where the transport motor feeds the paper from the 6th tray. LCT Exit Sensor Detects jams at the exit of the LCT unit. D179/D180/D181 Detailed Descriptions...
  • Page 200 Switches Name Description Door Safety Switch An interlock safety switch that detects when the front door is opened and closed. Other Name Description H1, H2 Anti-Condensation Evaporates moisture around the trays in the LCT (230V Heaters 18W). Detailed Descriptions D179/D180/D181...
  • Page 201 Total: 4,550 sheets Each tray contains four rollers: [A] Pick-up roller [B] Paper feed roller [C] Separation roller [D] Grip roller The pick-up roller, paper feed roller, and separation roller are a standard FRR paper feed system. D179/D180/D181 Detailed Descriptions...
  • Page 202 [B] Grip motor The paper feed motor drives the pick-up roller [C] and the paper feed roller [D]. The grip motor drives the grip roller [E] that feeds the paper out of the tray, and the separation roller [F]. Detailed Descriptions D179/D180/D181...
  • Page 203  The upper tray and middle tray are detected when any one of the paper size switch signals is low.  The lower tray is detected when the switch 1 signal of the paper size switch is low. D179/D180/D181 Detailed Descriptions...
  • Page 204 [I], the remaining paper capacity is detected. When pulling out the tray, the coupling gear [B] separates from the pin [C], so that the tray bottom plate moves downward. In the bottom tray, the damper [J] lets the tray bottom plate drop slowly. Detailed Descriptions D179/D180/D181...
  • Page 205 [E] to stop the lift motor. After several paper feeds, the paper level gradually lowers, then the lift sensor is activated and the lift motor turns on again until the lift sensor is de-activated again. D179/D180/D181 Detailed Descriptions...
  • Page 206 The bottom tray has the same switch as the top and middle trays. However, it is only used for detecting when the tray is pushed in. For the bottom tray, the paper size must be selected with SP5019-007: Detailed Descriptions D179/D180/D181...
  • Page 207 When the actuator enters the gap of the near end sensor [E], the machine signals near end. Finally, when the last sheet feeds, the paper end sensor signals that the tray is empty. D179/D180/D181 Detailed Descriptions...
  • Page 208 When the paper tray runs out of paper, the paper end sensor does not receive the reflected light due to the cutout [B]. Then, the tray lift motor rotates backwards 2 seconds to drop the tray bottom plate. Detailed Descriptions D179/D180/D181...
  • Page 209 4 photo interrupt sensors monitor the level of the tray bottom detection plates Paper end Photosensors mounted above each paper feed unit detect detection paper out Motor drive Stepper motor control only (no clutches) Heater (option) Two heaters (200 to 240V 18W) D179/D180/D181 Detailed Descriptions...
  • Page 210 11. Feed Slot (from Bypass Tray) 6. 6th Tray Drive Belt * Each feed unit has 1 paper feed motor that drives the pick-up roller and paper feed roller, and 1 grip motor that drives the separation roller and grip roller. Detailed Descriptions D179/D180/D181...
  • Page 211 3. 6th Lift Motor 10. LCT Exit Motor 4. 6th Paper Feed Motor 11. 4th Transport Motor 5. 6th Grip Motor 12. 4th Grip Motor 6. 6th Transport Motor 13. 4th Paper Feed Motor 7. 5th Paper Feed Motor D179/D180/D181 Detailed Descriptions...
  • Page 212 Each tray contains four rollers:  [A]: Pick-up roller  [B]: Paper feed roller  [C]: Separation roller  [D]: Grip roller The pick-up roller, paper feed roller, and separation roller are a standard FRR paper feed system. Detailed Descriptions D179/D180/D181...
  • Page 213  [B] Grip motor The paper feed motor drives the pick-up roller [C] and the paper feed roller [D]. The grip motor drives the grip roller [E] that feeds the paper out of the tray, and the separation roller [F]. D179/D180/D181 Detailed Descriptions...
  • Page 214 SP codes to remain on (or off) for a selected tray. 1-923-001 LCT Pickup Assist ON/OFF A3LCT Tray4 1-923-002 LCT Pickup Assist ON/OFF A3LCT Tray5 1-923-003 LCT Pickup Assist ON/OFF A3LCT Tray6 [0 to 2/0/1] 0: Auto 1: Force ON 2: Force OFF Detailed Descriptions D179/D180/D181...
  • Page 215  The pick-up roller raises.  Next, the paper feed motor switches on to feed the paper to the grip rollers [G] which pull the paper out of the tray. D179/D180/D181 Detailed Descriptions...
  • Page 216 When the tray is pulled out:  Coupling gear [B] separates from pin [C] and the tray bottom plate goes down.  A damper [I] slows the descent of the bottom plate. For the D732, all three trays have this damper. Detailed Descriptions D179/D180/D181...
  • Page 217 [E] to stop the lift motor. After several paper feeds, the paper level gradually lowers, then the lift sensor is activated and the lift motor turns on again until the lift sensor is de-activated again. D179/D180/D181 Detailed Descriptions...
  • Page 218 Paper Width Sensor 3 Paper Width Sensor 1 Paper Width Sensor 2 Paper Length Sensor Each tray has three paper width sensors and one paper length sensor. The illustration above shows how four sensors are arranged in the tray. Detailed Descriptions D179/D180/D181...
  • Page 219 HLT SEF 5½"×8½" YES: Detected automatically NO: Not detected automatically. Requires size setting change with the "Tray Paper Setting" key on the copier operation panel to detect the desired paper size. H: Sensor OFF L: Sensor ON D179/D180/D181 Detailed Descriptions...
  • Page 220 When the actuator enters the gap of the near end sensor [E] and the paper height sensor 2 [D] does not detect the actuator, the machine signals near end. 22. Finally, when the last sheet feeds, the paper end sensor signals that the tray is empty. Detailed Descriptions D179/D180/D181...
  • Page 221 This assists in the separation of the top sheet from the sheet below and prevents double-feeding. This only works when feeding the following paper types: Thick 2, Thick 3, Special 2, Coated Paper 1, Coated Paper 2 and Coated Paper 3. D179/D180/D181 Detailed Descriptions...
  • Page 222 When the paper tray runs out of paper, the paper end sensor does not receive the reflected light due to the cutout [B]. Then, the tray lift motor rotates backwards 2 seconds to drop the tray bottom plate. Detailed Descriptions D179/D180/D181...
  • Page 223 34. 6th Pick-up Solenoid 16. 5th Paper Height Sensor 4 35. 6th Relay Sensor 17. 5th Paper Height Sensor 3 36. 5th Transport Sensor 18. 5th Paper Height Sensor 2 37. 5th Relay Sensor 19. 5th Paper Height Sensor 1 D179/D180/D181 Detailed Descriptions...
  • Page 224 7. LCIT Cooling Fan 16. LCT Exit Motor 8. 4th Lift Motor 17. Tray Front Fan 9. Main Control Board 18. Tray Rear Fan Each of the three trays is provided with a front fan (17) and rear fan (18). Detailed Descriptions D179/D180/D181...
  • Page 225 9. 4th Transport Sensor 24. 5th Relay Sensor 10. 4th Transport Motor 25. LCT Exit Motor 11. 4th Relay Sensor – Upper 26. LCT Exit Sensor 12. 4th Relay Sensor – Lower 13. 5th Paper feed Motor D179/D180/D181 Detailed Descriptions...
  • Page 226 LCT exit motor. LCT Exit Motor Feeds the paper out the LCT and into the entrance of the copier. PCBs Name Description PCB1 Main Control Board Controls the operation of all motors and sensors in the LCT unit. Detailed Descriptions D179/D180/D181...
  • Page 227 5th Paper Feed Sensor Detects the paper when it arrives at the 5th paper feed roller and checks for misfeeds. 5th Paper Height 4th from the bottom of the 5th tray, Sensor 1 detects stack height: 100% D179/D180/D181 Detailed Descriptions...
  • Page 228 1 of a set of 3 sensors that detect the Sensor 2 (D732) width of the paper in the 6th tray. 6th Paper Width 1 of a set of 3 sensors that detect the Sensor 3 (D732) width of the paper in the 6th tray. Detailed Descriptions D179/D180/D181...
  • Page 229 Switches Name Description Door Safety Switch An interlock safety switch that detects when the front door is opened and closed. Other Name Description H1, H2 Anti-Condensation Heaters Evaporates moisture around the trays in the LCT (230V 18W). D179/D180/D181 Detailed Descriptions...
  • Page 230 B4, 8 1/2"x14" more than: 30 sheets With Z-fold A4, 8 1/2"x11" less than: 20 sheets Paper weights: Proof tray （45.0 to 185.7 kg） No Z-fold 52.3 to 216.0g/m （55.1 to 90.3 kg） With Z-fold 64.0 to 105.0g/m Detailed Descriptions D179/D180/D181...
  • Page 231 1 to 10 sheets book staple: 30 to 3 doc.（Z-folded A3 SEF, A4 Stapling LEF, Z-folded B4/B5 LEF, Z-folded 11"x17" SEF/8 1/2"x11" LEF, Z-folded 8K SEF/16K LEF） Shift tray paper thicknesses （45.0 to 258.0 kg） No Z-fold 40.0 to 350.0g/m （55.1 to 90.3 kg） With Z-fold 64.0 to 105.0g/m D179/D180/D181 Detailed Descriptions...
  • Page 232 13"x18" SEF, SR A3 SEF, 8 1/2"x13" SEF, 8 1/4"x14" SEF, 8 1/4"x13" SEF, 8"x13" SEF, 7 1/4"x10 1/2" SEF, 8K SEF, 16K SEF, 12"x18" SEF, 11"x15" SEF, 11"x14" SEF, 10"x15" SEF, 10"x14" SEF, SR A4 SEF, 226x310 mm SEF, 310 x 432m SEF, Custom Size Detailed Descriptions D179/D180/D181...
  • Page 233 One sheet of paper (thickness 90.1 to 163 g/m (77.5 to 140 kg) can be inserted as a cover and stapled once. Folded paper max.: 6 sheets Multi center folded (no booklet stapling): 6 sheets 64 to 90 g/m D179/D180/D181 Detailed Descriptions...
  • Page 234 A3 SEF, B4 SEF, A4 SEF, B5 SEF, 11"x17" SEF, 8 1/2"x14" SEF, 8 1/2"x11" SEF, SR A4 LEF, SEF, 226x310 mm LEF, SEF: 1,500 sheets 12"x18" SEF, 13"x19 1/5" SEF, SR A3 SEF, 13"x18" SEF, 12 Detailed Descriptions D179/D180/D181...
  • Page 235 Shift tray capacity: Z-folded sheets (Normal paper) No stapling 30 sheets Stapling Mixed sizes: 1 to 10 sheets Book stapled: 30 to 3 doc. （Z-folded A3 SEF, A4 LEF, Z-folded B4/B5 LEF, Z-folded 11"x17" SEF, 8 1/2"x11" LEF, Z-folded 8K SEF, 16K LEF） D179/D180/D181 Detailed Descriptions...
  • Page 236 Paper thickness up to 200 g/m2 (55 to 172 kg), and two sheets of A4 or 8 1/2x11 can be inserted as covers and booklet stapled once, but overall stack thickness must be less than 11 mm. （55.0 to 90.3 kg） Z-fold 64.0 to 105g/m Detailed Descriptions D179/D180/D181...
  • Page 237 Stacked output shifted with movable tray. Stacks are Shift mechanism raised and lowered by tray. Pre-stacking employs switch-back transport. Pre-stacking Large size paper pre-stacking employs switch-back mechanism transport and roller-release mechanisms. Booklet Stapling Booklet stapling, and folding are done in the same unit. Mechanism D179/D180/D181 Detailed Descriptions...
  • Page 238 Drives the paper punch mechanism inside the punch unit. Registration motor Drives the registration roller. Entrance Motor Drives the entrance roller. Horizontal Drives the transport roller on the downstream side of transport motor the punch unit. Punch unit is an option Detailed Descriptions D179/D180/D181...
  • Page 239 Sensors 23.4 SENSORS A: Reflective sensor B: Permeable sensor C: CIS (Contact Image Sensor) D179/D180/D181 Detailed Descriptions...
  • Page 240 Detects the leading edge of each sheet as it Entrance Sensor enters the finisher. Detects when the punch-out hopper is full and 10 Punchout hopper full sensor when the hopper is out of the finisher. Detailed Descriptions D179/D180/D181...
  • Page 241 Drives the positioning roller that positions paper motor in the stapling tray. Pre-stack motor Drives the pre-stack roller. Stapler entrance Drives the rollers that feed paper into the motor stapling tray. Trailing edge press Operates the pressure plate that presses against D179/D180/D181 Detailed Descriptions...
  • Page 242 These are the air assist fans positioned at the shift tray exit. They provide a weak cushion of air Exit fan motor (front) below each sheet of paper to make it easier to exit the finisher. *1 Punch unit is an option Detailed Descriptions D179/D180/D181...
  • Page 243 Detects when the hopper is full of staple sensor trimmings. Staple trimmings hopper set Detects when the staple trimmings hopper is in or sensor out of the unit. Detects when the corner stapler unit is at its Stapler HP sensor home position. D179/D180/D181 Detailed Descriptions...
  • Page 244 Detects paper as it is fed to the shift tray in staple 31 Shift tray exit sensor long mode. 32 Paper height sensor (shift) Detects the height of the stack on the shift tray. Detailed Descriptions D179/D180/D181...
  • Page 245 40 Shift tray full sensor (3000) Detects when the shift tray is full (D735 only). Detects when the shift tray is at its highest 41 Shift tray limit switch position. 42 Emergency stop switch Stops paper output the shift tray. D179/D180/D181 Detailed Descriptions...
  • Page 246 Operates the jogger fence that aligns the trailing fence motor edge of the stack for stapling in the booklet stapler unit. Booklet stack tray The small motor inside the booklet tray that drives motor the belts of the tray. Detailed Descriptions D179/D180/D181...
  • Page 247 Stapler Transport, Staple, Jogger, Shift Units 23.5.4 BOOKLET STAPLE SENSORS A：Reflective sensor B: Permeable sensor D179/D180/D181 Detailed Descriptions...
  • Page 248 Booklet stapler side fence the trailing edge of the stack for booklet stapling HP sensor (rear) is in or out of its home position. Detects the presence of paper on the booklet 11 Booklet tray paper sensor tray. Detailed Descriptions D179/D180/D181...
  • Page 249  In shift mode the junction gate does not move and remains level so paper feeds straight and level to the shift tray.  In the staple mode, the junction gate guides to paper down to the stack/staple unit. D179/D180/D181 Detailed Descriptions...
  • Page 250  When a sheet of paper feeds, its leading edge strikes the pre-stack gate and forces it open against the weak spring that normally holds it in place [A-1].  After the paper passes [A-2] the spring pulls the gate back to its original closed position. Detailed Descriptions D179/D180/D181...
  • Page 251  Thereafter, it becomes possible to stack several sheets through repetition of this operation (pre-stacking).  One or the other mode is employed, depending on the paper size, stapling mode, and the number of sheets to be pre-stacked. D179/D180/D181 Detailed Descriptions...
  • Page 252  The reverse feed time (and distance) after the paper passes the pre-stack gate is shortened in order to improve the efficiency of the job.  When the paper is reverse fed, the nip of 1st pre-stack roller is opened so the paper feeds more smoothly. Detailed Descriptions D179/D180/D181...
  • Page 253 1st pre-stack roller and pauses (standby), and then waits for the next sheet (blue) to feed.  At this time, the next sheet and sheet are made to wait at the 3rd pre-stack roller. D179/D180/D181 Detailed Descriptions...
  • Page 254  Thereafter, it becomes possible to stack several sheets through repetition of this operation (pre-stacking).  One or the other mode is employed, depending on the paper size, stapling mode, and the number of sheets to be pre-stacked. Detailed Descriptions D179/D180/D181...
  • Page 255 The 2nd pre-stack roller [B] at the rear and 3rd pre-stack roller are used to align the leading edges of the paper and send them to the stapling tray in the same way that the 1st pre-stack roller [A] is used in the older method to perform the same task. D179/D180/D181 Detailed Descriptions...
  • Page 256 Adj Pre Stack Number 8-Kai SEF [0 to 4/4/1] 6-225-012 Adj Pre Stack Number 16-Kai SEF [0 to 4/4/1] 6-225-013 Adj Pre Stack Number 160-Kai LEF [0 to 6/6/1] 6-225-014 Adj Pre Stack Number Other [0 to 9/0/1] Detailed Descriptions D179/D180/D181...
  • Page 257 Shift tray full sensor (1500) Paper height sensor (staple) Shift tray full sensor (low limit) Paper height sensor feeler Paper height sensor (shift) Shift tray full sensor (500) Paper height sensor feeler Shift tray full sensor (1000) D179/D180/D181 Detailed Descriptions...
  • Page 258  1: The air assist fan always operates, regardless of the size or type of paper selected for the job.  2: The air assist fan remains off. Detailed Descriptions D179/D180/D181...
  • Page 259 Paper and Stack Output Trailing edge press lever Air vents Configuration Name Drag roller motor Exit fan Shutter D179/D180/D181 Detailed Descriptions...
  • Page 260 The movement of the shutter inside the air vent is synchronized with the timing of the operation of the trailing edge lever to reduce the amount of air from the fans to prevent the trailing edge of the sheet from blowing too high as it exits. Name Shutter open Shutter closed Detailed Descriptions D179/D180/D181...
  • Page 261 Shutter Press Lever position Open Down  Step 2: 1st sheet trailing edge emerges, press lever starts to retract Press lever and shutter joint movement Shutter/press lever position Shutter Press Lever Open > Down > Up Close D179/D180/D181 Detailed Descriptions...
  • Page 262 Air stream diminishes, prevents trailing edge of sheet from rising on completion of exit Shutter/press lever position Shutter Press Lever Closed Retract  Step 4: Press lever operation start Press lever and shutter joint movement at cover operation Shutter/press lever position Shutter Press Lever Open > Close Down > Up Detailed Descriptions D179/D180/D181...
  • Page 263 Press lever presses down trailing edge to prevent slippage Shutter/press lever position Shutter Press Lever Open Down  Step 6: 2nd sheet trailing edge emerges, press lever starts to retract  Shutter/press lever position Shutter Press Lever Open > Close Down > Up D179/D180/D181 Detailed Descriptions...
  • Page 264 Air Vent Mechanism  Step 7: 2nd Sheet Exit End  Shutter/press lever Shutter Press Lever position Closed Retract  The sequence repeats for subsequent sheets 4, 5, 6, 7 and so on. Detailed Descriptions D179/D180/D181...
  • Page 265 Trailing edge press plate Base fence lift motor Stapler tray exit sensor Base fence movement motor Positioning Roller Base fence Positioning roller rotation motor Leading edge Stopper Positioning roller lift motor Trailing edge press motor Leading edge stopper motor D179/D180/D181 Detailed Descriptions...
  • Page 266 (with the trailing edge firmly clamped), greatly improves the efficiency of stapling. Detailed Descriptions D179/D180/D181...
  • Page 267 Movement Adjustment of Jogger Fences During Horizontal Alignment Front booklet stapling Front 7 mm Rear (diagonal) booklet stapling Rear 7 mm Dual stapling (Booklet, B5 SEF) Front and rear 3.5 mm booklet D179/D180/D181 Detailed Descriptions...
  • Page 268  At this time, as the trailing edge is depressed the stapler is moving front and back, and before and after each compression of the trailing edge, the edge is compressed to remove curl.  Front and rear compression of the trailing edge is not done at the booklet stapling position. Detailed Descriptions D179/D180/D181...
  • Page 269  If a staple jams the stapling mechanism, bracket lever [A] slides in the direction of the arrow so the jammed staple can be removed from the staple cartridge. D179/D180/D181 Detailed Descriptions...
  • Page 270  The staple trimmings hopper full sensor [B] below the hopper signals when the hopper is full, and then triggers a message on the operation panel to alert the operator that the hopper needs to be emptied. The hopper capacity is about 15,000 trimmed scraps. Detailed Descriptions D179/D180/D181...
  • Page 271 HP sensor [C]. 23.13.4 CORNER STAPLER ROTATION When diagonal-stapling at one corner, after the stapler moves to the stapling position it is rotated before it staples. The rotation is performed by the stapler rotation motor [A]. D179/D180/D181 Detailed Descriptions...
  • Page 272  A rotation of a disc mounted above the exit guide plate motor controls the OFF timing of the exit guide plate motor that operates the opening and closing of the exit.  Also, the position of the feed-out belt is monitored by the feed-out belt HP sensor [C]. Detailed Descriptions D179/D180/D181...
  • Page 273 Detects home position of the front and rear jogger fences (up). Shift tray jogger HP sensor Switches the shift jogger HP actuator sensor off/on. Shift jogger retract HP sensor Switches the shift jogger retract HP actuator sensor off/on. D179/D180/D181 Detailed Descriptions...
  • Page 274 After the last sheet exits both arms rise, stop, and then remain up at the home position (standby position). The standard paper sizes that can be jogged and aligned upon exit (with no folding) are the standard sizes A3 to A5, DLT to HLT, 12"x18", 13"x14". Detailed Descriptions D179/D180/D181...
  • Page 275 Sensors and rollers comprise the junction gate that sends the stack into the booklet stapling unit. Leading edge stopper Transport roller – idle roller Fold roller idle roller Booklet stapler unit Trailing edge fence D179/D180/D181 Detailed Descriptions...
  • Page 276 With the new mechanism, multiple sheets can be center folded, even if they are not to be booklet stapled. With this finisher up to 6 sheets of paper (64 to 90 gsm2) can be creased. Detailed Descriptions D179/D180/D181...
  • Page 277 ) can be inserted 1.0 mm into the nip for folding.  The horizontal fold roller is spring loaded, so that when it is forced to the rear the crease of the fold in the sheets is increased. D179/D180/D181 Detailed Descriptions...
  • Page 278 5 Crease roller Guide plate 6 Spring The spring loaded crease roller mounted on a steel guide shaft applies pressure to the stapled and folded edge as it is driven rear to front and the front to rear. Detailed Descriptions D179/D180/D181...
  • Page 279 ON and punch the paper. The positions of the punch holes can be adjusted with SP codes and shims. Name Name Punch movement motor Punch motor Punch Unit HP sensor Timing Belt Punch Horizontal Registration Punch Position Sensor D179/D180/D181 Detailed Descriptions...
  • Page 280 Also, there is a set sensor for the punch-out hopper that triggers a hopper not set alert when the hopper is out of the unit. Detailed Descriptions D179/D180/D181...
  • Page 281 (the position of the punch unit is adjusted for each sheet based on the CIS reading).  The position of the punch unit is positioned in this way before each sheet of paper is punched. D179/D180/D181 Detailed Descriptions...
  • Page 282 Exit guide plate HP sensor, shift HP sensor (front, rear), jogger fence HP sensor, jogger retraction HP sensor, drag roller HP sensor Stapling jam Stapler movement motor HP sensor, stapler rotation HP sensor (front, rear), bottom fence HP sensor, corner stapler HP sensor Detailed Descriptions D179/D180/D181...
  • Page 283 Center stapler junction gate HP sensor, center stapler HP sensor, center stapler jogger HP sensor (front, rear), center stapler trailing edge fence HP sensor Fold jam Horizontal fold HP sensor, fold cam HP sensor, fold plate HP sensor D179/D180/D181 Detailed Descriptions...
  • Page 284 Less than 5 mm deviation at front/back, left/right Weight 92 kg (203 lb) Noise Level (dB A) Mode Alone System No Folding < 72 dB Folding < 72 dB < 76 dB Folding Methods (Six: FM1 to FM6) Detailed Descriptions D179/D180/D181...
  • Page 285 12x18, 8-kai (64 to 105 Multiple Folding Not allowed Max. 3 (64 to 80 g/m only) Max. 3 (64 to 80 g/m only) Max. 3 (64 to 80 g/m , B4, A4, LT, B5 only) Not allowed D179/D180/D181 Detailed Descriptions...
  • Page 286 FM6 1 Sheet: Same as main machine as far as 3rd Stopper. At 3rd stopper feeds 50 mm at 100 mm/sec. 350 mm/sec. to top tray (paper < 420 mm long) 250 mm/sec. to top tray (paper < 420 mm long) Detailed Descriptions D179/D180/D181...
  • Page 287  Folding Methods (FM1 to FM6)  Paper size  Paper weight Folding Mode FM1 Size Weight (Standard) Weight (Heavy) 64 to 80 g/m 64 to 80 g/m 8-kai 12x18" A3 SEF B4 SEF LG SEF A4 SEF LT SEF D179/D180/D181 Detailed Descriptions...
  • Page 288 Weight (Heavy) (Standard) 64 to 80 g/m 64 to 80 g/m 13x19.2" 13x19" 12.6x19.2" 12.6x18.5" 13x18" SRA3 (320x450 SRA4 (225x320 226x310 mm 310x432 mm 8-kai 12x18" A3 SEF B4 SEF LG SEF A4 SEF LT SEF B5 SEF Detailed Descriptions D179/D180/D181...
  • Page 289 LG SEF A4 SEF LT SEF B5 SEF Folding Mode FM4 Size Weight (Standard) Weight (Heavy) 64 to 80 g/m 64 to 80 g/m 8-kai 12x18" A3 SEF B4 SEF LG SEF A4 SEF LT SEF B5 SEF D179/D180/D181 Detailed Descriptions...
  • Page 290 LG SEF A4 SEF LT SEF B5 SEF Folding Mode FM6 Size Weight (Standard) Weight (Heavy) 64 to 80 g/m 64 to 80 g/m 8-kai 12x18" A3 SEF B4 SEF LG SEF A4 SEF LT SEF B5 SEF Detailed Descriptions D179/D180/D181...
  • Page 291 Overview 24.2 OVERVIEW 24.2.1 MOTORS, ROLLERS The illustration above shows the roller groups and their related motors. D179/D180/D181 Detailed Descriptions...
  • Page 292 Overview 24.2.2 JUNCTION GATES, JUNCTION GATE SOLENOIDS The illustration above shows the paper path junction gates and the solenoids and motors that operate them. Detailed Descriptions D179/D180/D181...
  • Page 293 Overview 24.2.3 STOPPERS, STOPPER MOTORS The illustration above shows the stoppers and the motors that operate them. D179/D180/D181 Detailed Descriptions...
  • Page 294  The upstream rollers continue to rotate 5 mm.  The leading edge of the paper buckles against the stationary registration roller to correct skew.  The registration roller starts rotating again after the paper has been straightened in the paper path. Detailed Descriptions D179/D180/D181...
  • Page 295 [B]. The TE stop pawl returns to its home position [C] after the trailing edge of the sheet passes. After the trailing edge of the paper passes the dynamic roller, the positioning roller [D] starts to rotate and feeds the paper as far as stopper 1 [E]. D179/D180/D181 Detailed Descriptions...
  • Page 296 1st sheet. The dynamic roller [A] raises after the leading edge of the 3rd (and last sheet) passes the TE stop pawl. The position roller [B] rotates twice only after the last sheet has been pre-stacked. Detailed Descriptions D179/D180/D181...
  • Page 297 Next, with the TE stop pawl pressing down on the trailing edges of the stacked sheets, the stack [B] is jogged horizontally (front to back). Finally, after all three sheets have been pre-stacked and jogged, the fold blade [A] pushes the stacked sheets into the nip of the fold rollers [B]. D179/D180/D181 Detailed Descriptions...
  • Page 298 Junction Gates 24.4 JUNCTION GATES Detailed Descriptions D179/D180/D181...
  • Page 299  Upper entrance junction gate remains at default position.  Lower junction gate rotates up and guides paper down. When draft copies are sent to the top tray:  The upper entrance junction gate rotates down.  The lower junction gate remains at default position. D179/D180/D181 Detailed Descriptions...
  • Page 300 This is the direct send junction gate at its home position. The junction gate rotates to the right and paper is sent downstream without passing stopper 2. This is down for FM2 mode only when the paper is folded into equal halves. Detailed Descriptions D179/D180/D181...
  • Page 301 Junction Gates The illustration above shows the actual location and appearance of the direct send junction gate. D179/D180/D181 Detailed Descriptions...
  • Page 302  After the job is finished the motor rotates the junction gate back to its home position [A]. For the other fold modes (FM1, FM3 to FM6) the junction gate remains at its home position and does not touch the paper. Detailed Descriptions D179/D180/D181...
  • Page 303 2. For fold modes other than FM1, FM6 the bypass junction gate remains at it default position. Paper passes over the top of the bypass junction gate and into the bypass paper path. D179/D180/D181 Detailed Descriptions...
  • Page 304 Note: Only Z-folded paper is allowed to exit the multi-folder and pass downstream to other peripheral units. In this case, the junction gates remain at their default positions. The exit junction gate sensor (5) guides the paper toward the multi-folder exit above. Detailed Descriptions D179/D180/D181...
  • Page 305 When two or more sheets are fed together, a fold assist plate  pushes the flexed paper toward the rotating fold rollers. The fold plate is used only when more than one sheet of paper is fed at a time. Up to three sheets can be fed. D179/D180/D181 Detailed Descriptions...
  • Page 306 Paper Folding 24.5.2 STOPPER LOCATIONS The illustration above shows the stopper locations. Note the locations of Stopper 1, Stopper 2, and Stopper 3. Detailed Descriptions D179/D180/D181...
  • Page 307 Folding Methods 24.6 FOLDING METHODS There are six Folding Methods (FM): Z-Folding Half Fold Letter Fold-out Letter Fold-in Double Parallel Fold Gate Fold D179/D180/D181 Detailed Descriptions...
  • Page 308  Next, the paper is stopped by Fold Stopper 3. The paper flexes toward the nip of fold rollers  and  which performs the second fold and feeds the paper into the exit path.  Fold Stopper 1 is not used. Detailed Descriptions D179/D180/D181...
  • Page 309  and .  Fold rollers  and  feed the paper into the exit path.  Fold Stoppers 2, and 3 are not used. D179/D180/D181 Detailed Descriptions...
  • Page 310  Fold Stopper 2 stops the paper and flexes it into the nip of fold rollers  and .  Fold rollers  and  perform the second crease and feed the folded paper in exit path.  Fold Stoppers 3 is not used. Detailed Descriptions D179/D180/D181...
  • Page 311  In FM4 Fold Stopper 1 is positioned low so a long length of paper is allowed to feed before flexing toward the hip starts.  This positioning of Fold Stopper 1 accounts for the difference in folding at the next nip. D179/D180/D181 Detailed Descriptions...
  • Page 312  In FM5 Fold Stopper 1 is positioned so the paper will fold into halves when it enters the first nip.  This critical positioning of Fold Stopper 1 accounts for the difference in folding at the next nip. Detailed Descriptions D179/D180/D181...
  • Page 313  Fold roller  and  form the third crease and feed the folding paper into the exit path.  All three stoppers are used with this method. A mechanism is provided to prevent the leading edge from catching and folding over on itself [A] when the 3rd fold is done. D179/D180/D181 Detailed Descriptions...
  • Page 314 The edge of the FM6 pawl is raised to flatten the leading edge so it cannot bend back on itself as the paper enters the nip of the fold rollers. When the 3rd fold starts the FM6 pawl returns to its home position. Detailed Descriptions D179/D180/D181...
  • Page 315 Double Parallel 6757 6758 Gate Fold 6759 6760 6761 : These numbers are the same for Operators, Skilled Operators. : The ranges for these SP codes are the same: [-4 to +4 / 0 / 0.2 mm] D179/D180/D181 Detailed Descriptions...
  • Page 316 -9.5 N A projection fixed in slot and attached to a spring shortens the length to roller can be lowered. There are four crease rollers. Springs at the front and rear ends of each roller can be adjusted. Detailed Descriptions D179/D180/D181...
  • Page 317  When the top of the stack grows high enough to interrupt the signal between the tray full sensors [D], this will signal the machine to shut down the line temporarily.  After the operator removes the stack from the top tray, folding and paper exit will resume. D179/D180/D181 Detailed Descriptions...
  • Page 318 Electrical Components 24.9 ELECTRICAL COMPONENTS 24.9.1 TRANSPORT SENSORS Detailed Descriptions D179/D180/D181...
  • Page 319 Electrical Components 24.9.2 OPERATION SENSORS D179/D180/D181 Detailed Descriptions...
  • Page 320 Electrical Components 24.9.3 MOTORS, SOLENOIDS Detailed Descriptions D179/D180/D181...
  • Page 321 Fold Plate Motor Top Tray Transport Motor 10. Registration Roller Transport Motor Horizontal Exit Motor 11. Registration Roller Release Motor Crease Motor 12. Dynamic Roller Transport Motor FM6 Pawl Motor 13. Dynamic Roller Lift Motor 1st Fold Motor D179/D180/D181 Detailed Descriptions...
  • Page 322 Fold Motors 24.11 FOLD MOTORS 1. Entrance JG Motor 2. Direct Send JG Motor 3. Stopper 3 Motor 4. Stopper 1 Motor 5. Jogger Fence Motor 6. Stopper 2 Motor Detailed Descriptions D179/D180/D181...
  • Page 323 24.12 MOTORS, SOLENOIDS AROUND THE TOP TRAY 1 Reverse JG Solenoid 2 Exit JG Solenoid 3 Top Tray Transport Motor 4 Top Tray JG Solenoid 5 Entrance JG Solenoid 6 Horizontal Transport Motor 7 Top Tray Exit Motor 8 Horizontal Exit Motor D179/D180/D181 Detailed Descriptions...
  • Page 324 Motors, Sensors Top 24.13 MOTORS, SENSORS TOP 1. Dynamic Roller Lift Motor 2. Dynamic Roller Transport Motor 3. Dynamic Roller HP Sensor 4. Fold Plate Motor 5. Registration Sensor Detailed Descriptions D179/D180/D181...
  • Page 325 24.14 MOTORS, SENSORS BOTTOM 1. Registration Roller Release Motor 2. Jogger Fence HP Sensor 3. Fold Plate HP Sensor 4. FM6 Pawl HP Sensor 5. 1st Fold Motor 6. Direct Send JG HP Sensor 7. Registration Roller Transport Motor D179/D180/D181 Detailed Descriptions...
  • Page 326 2. Entrance JG HP Sensor 3. Top Tray Full Sensor (E) 4. Top Tray Exit Sensor 5. Top Tray Paper Path Sensor 6. Entrance Sensor 7. Horizontal Path Paper Sensor 8. Vertical Path Paper Sensor 9. Horizontal Path Exit Sensor Detailed Descriptions D179/D180/D181...
  • Page 327 3. Jogger Fence Motor 9. Stopper 3 HP Sensor 4. Stopper 2 Paper Sensor 10. Stopper 3 Motor 5. Stopper 1 Paper Sensor 11. Direct Send JG Motor 6. Stopper 1 Motor 12. LE Stop Pawl Solenoid D179/D180/D181 Detailed Descriptions...
  • Page 328 Fold Motors, Sensors, Solenoids 1. Bypass Entrance Paper Sensor 2. Bypass Exit Paper Sensor 3. FM6 Pawl HP Sensor 4. 2nd Fold Motor 5. FM6 Pawl Motor 6. Bypass JG Solenoid 7. Crease Motor Detailed Descriptions D179/D180/D181...
  • Page 329 Boards, Switches, Fan 24.17 BOARDS, SWITCHES, FAN 1. Main Board 2. Front Door Switch 3. PSU 4. PSU Fan 5. Breaker Switch D179/D180/D181 Detailed Descriptions...
  • Page 330 Moves Stopper 3 to the correct position for folding according to the paper size. 2nd Fold Motor Drives 3rd fold roller. Reverses when the paper does not pass through the 3rd fold unit. Crease Motor Drives the crease rollers. Detailed Descriptions D179/D180/D181...
  • Page 331 Detects when Stopper 2 is in and out of its Sensor home position. Bypass Exit Paper Checks for the presence of paper at power on. Sensor Bypass Entrance Checks for the presence of paper at power on. D179/D180/D181 Detailed Descriptions...
  • Page 332 Supplies the 24V power for the operation of the motors and solenoids, and the 5V power for the main board and sensors. PSU Fan Cools the PSU. Main Controls operation of the motors, solenoids, sensors, Board and interface with the main machine. Detailed Descriptions D179/D180/D181...
  • Page 333 621 x 679 x 213 mm (24.5 x 26.7 x 8.4 in.) Weight Approximately 17 kg (37.4 lb) Power Supply DC 24V (supplied from host machine via Perfect Binder) Power Less than 103 W (maximum at operation) Consumption D179/D180/D181 Detailed Descriptions...
  • Page 334 Paper Weight 52 to 300 g/m Book Output Tray Max.: 23 mm (80g/m Book door locked during operation Warm-up Time Less than 440 sec. (6.3 min.) Glue Capacity Glue vat 380 g (continuous pellet supply) Approximately A4 to B5 100 books Detailed Descriptions D179/D180/D181...
  • Page 335 1090 x 791 x 1387 mm (43 x 31 x 53.5 in.) Weight 350 kg (770 lb) Power Supply EU: 220 to 240V 50/60 Hz NA: 208 60 Hz Power Consumption Less than 623 W (with inserter) D179/D180/D181 Detailed Descriptions...
  • Page 336 Overview 25.2 OVERVIEW Detailed Descriptions D179/D180/D181...
  • Page 337 The trimming unit/stacking unit is comprised of four units:  Signature rotation  Trimmer (cutter)  Trimmings collection  Book stacking The inserter installed on top of the bookbinder feeds covers through the vertical feed path to the bookbinder below. D179/D180/D181 Detailed Descriptions...
  • Page 338  The boards control and drive motors using commands sent from the host machine.  The board circuits are also to communicate a steady stream of information from the bookbinder to the host machine. Detailed Descriptions D179/D180/D181...
  • Page 339 Once the commands are received for binding sheets into a book, the operational control passes to the master control board, slave control board, and cutter control board. D179/D180/D181 Detailed Descriptions...
  • Page 340 The book (cover and signature now glued together) is moved to the trimming unit. The book is rotated three times for trimming on the bottom, top, and fore edge. The trimmed book is sent to the book stacking tray. 25.5 Detailed Descriptions D179/D180/D181...
  • Page 341 Paper from the host machine enters the bookbinder at the entrance rollers [1]. The entrance junction gate solenoid at [2] remains OFF so the entrance junction gate remains UP so paper can pass through the horizontal transport rollers [3]. The paper exits the bookbinder at [4]. D179/D180/D181 Detailed Descriptions...
  • Page 342 Next, the book descends to the trimming unit [11] where the top, bottom, and fore edges of the book are trimmed. Finally, the trimmed book is lowered into the book tray buffer and output to the stacking tray [12]. Detailed Descriptions D179/D180/D181...
  • Page 343 The rotation of the entrance roller feeds the paper into the horizontal feed path on top of the cove registration unit. The entrance roller and all other rollers rotate at the same speed as the exit roller of the host machine until the paper exits the bookbinder. D179/D180/D181 Detailed Descriptions...
  • Page 344 In all other cases, if one of the control boards determines whether the signature can be removed manually, the bookbinder does not enter automatic exit mode. Detailed Descriptions D179/D180/D181...
  • Page 345 The grip unit drops the spine of the signature once onto the spine alignment plate to align the edges of the sheets in the spine so they are even. The main grip unit once again clamps the signature and D179/D180/D181 Detailed Descriptions...
  • Page 346 The trimmer unit expels the trimmings from the cutting mechanism and they fall into the trimmings collection box [K]. Finally, the finished book is lowered to the book stacking tray [L]. Detailed Descriptions D179/D180/D181...
  • Page 347 Vertical transport sensors 1 and 2 (S19/S18 (INS)) detect the leading and trailing edges of each cover and signal a jam if a cover stops or fails to arrive at the prescribed time. D179/D180/D181 Detailed Descriptions...
  • Page 348 Paper/Signature Transport 25.12 PAPER/SIGNATURE TRANSPORT 25.12.1 SIGNATURE PATH TRANSPORT OPERATION Entrance Roller Signature Transport Roller 1 Entrance Junction Gate Signature Transport Roller 2 Signature Transport Roller 3 Signature Transport Roller 4 Signature Transport Roller 5 Signature Exit Roller Detailed Descriptions D179/D180/D181...
  • Page 349 (S19) detect the leading and trailing edges of each sheet and signal a jam if a sheet stops or fails to arrive at the sensor position at the prescribed time. 25.12.2 SIGNATURE PATH EXIT Signature Exit Roller Stacking Roller TE Press Lever D179/D180/D181 Detailed Descriptions...
  • Page 350 (S3) when the lever returns to its home position. The signal from the paper detection sensors (front/rear) (S1/S2) lower the stacking tray. These sensors (mounted on the TE press lever) control the operation of the TE press lever motor (M3). Detailed Descriptions D179/D180/D181...
  • Page 351 The stacking tray stacks and aligns (jogs) the front side, rear side, and trailing edge of each sheet as it arrives in the tray. After the last sheet has been fed and its edges aligned, this forms the signature to be bound to the cover. D179/D180/D181 Detailed Descriptions...
  • Page 352 S11 Switchback Roller HP Sensor S12 Jog Fence HP Sensor (Front: Small) S13 Jog Fence HP Sensor (Rear: Small) S14 Jog Fence HP Sensor (Front: Large) S15 Jog Fence HP Sensor (Rear: Large) S16 Stacking Weight HP Sensor Detailed Descriptions D179/D180/D181...
  • Page 353 [5] to the start position for the paper size where it will remain during jogging. Next, the jog motor (front) (M4) moves the front jog fence to the start position for the paper size. The front fence pushes the paper against the stationary rear fence during jogging. D179/D180/D181 Detailed Descriptions...
  • Page 354 (M1) resumes its rotation at the same speed of the host machine exit rollers. The size of the paper selected for the job determines:  Standby positions of the side fences  Which sensor pair is used to detect the home positions of the fences Detailed Descriptions D179/D180/D181...
  • Page 355 S12 Jog Fence HP Sensor: Front: Small S13 Jog Fence HP Sensor: Rear: Small Paper Wider Than 298 mm Front Jog Fence Rear Jog Fence Paper S14 Jog Fence HP Sensor: Front: Large S15 Jog Fence HP Sensor: Rear: Large D179/D180/D181 Detailed Descriptions...
  • Page 356 Paper/Signature Transport 25.12.4 SUB GRIP OPERATION The sub grip unit [1] takes the aligned stack (signature) from the stacking tray unit and passes it to the main grip [2]. Detailed Descriptions D179/D180/D181...
  • Page 357 Sub Grip Size Motor Sub Grip Motor Signature HP Sensor Signature Main Grip Position Sensor Main Grip Rotate Enable Sensor Sub Grip HP Sensor Size HP Sensor Sub Grip Signature Sensor Sub Grip Open Sensor Sub Grip Close Sensor D179/D180/D181 Detailed Descriptions...
  • Page 358 With the signature [1] firmly clamped, the stacking tray lift motor (M2) and sub grip lift motor (M17) switch on and lower both the stacking tray [2] and sub grip unit [3] as far as the stacking tray lower limit sensor (S7) and then stop. Detailed Descriptions D179/D180/D181...
  • Page 359 After the signature is released by the sub grip unit [3], the sub grip lift motor (M17) turns on and raises the sub grip unit about 5 mm away from the signature [4], then returns the sub grip unit to its home position. D179/D180/D181 Detailed Descriptions...
  • Page 360 The main grip unit [1] receives the signature from the sub grip unit [2], tamps the spine of the signature to align it for gluing, lowers the signature onto the gluing unit for the application of glue to the spine, and then passes the signature to the trimming unit. Mini-Gripper Main Gripper Detailed Descriptions D179/D180/D181...
  • Page 361 Main Grip Open Sensor: Rear Main Grip Press Sensor 1 Main Grip Press Sensor 2 Signature Thickness Sensor Main Grip Open Sensor: Front Main Grip Encoder: Front Main Grip Close Sensor: Front Main Grip Close Sensor: Rear Main Grip Signature Sensor D179/D180/D181 Detailed Descriptions...
  • Page 362 [2] clamped by the mini-gripper [3] and main gripper [4]. The main grip lift motor (M22) turns on and lowers the main grip unit [1] and signature [2] as far as the signature guide plate [3]. Detailed Descriptions D179/D180/D181...
  • Page 363 The signature thickness sensor (S50) measures the thickness of the signature the first time the grip unit closes onto the signature. A corresponding AD value is stored in EEPROM for mm readings from 0 to 25 mm as shown above. D179/D180/D181 Detailed Descriptions...
  • Page 364 25.13 COVER TRANSPORT AND REGISTRATION Horizontal Transport Roller 1 Horizontal Transport Roller 2 Horizontal Transport Roller 3 Horizontal Transport Roller 4 Horizontal Transport Roller 5 Buffer Roller Cover Transport Guide: Right Cover Transport Guide: Left Cover Gripper [10] Cover Registration Unit Detailed Descriptions D179/D180/D181...
  • Page 365 Cover Registration Sensor Cover Guide HP Sensor: Right Cover Guide Open Sensor: Right Cover Guide HP Sensor: Left Cover Guide Open Sensor: Left Registration Unit HP Sensor (S70) Cover Horizontal Registration Sensor : Small Cover Horizontal Registration Sensor: Large D179/D180/D181 Detailed Descriptions...
  • Page 366 The spine fold motor: left (M28) turns on and lowers the transport rollers 1, 2 on the left side of the cover, releasing the cover from the nip. The cover grip solenoid (SOL1) energizes and opens the cover gripper [3]. Detailed Descriptions D179/D180/D181...
  • Page 367  Cover registration sensor (S) (S71). Used for small paper sizes up to 297 mm wide.  Cover registration sensor (L) (S72). Used for large paper sizes over 297 mm wide. D179/D180/D181 Detailed Descriptions...
  • Page 368 [1] and cover [2] until the sensor turns on, continues to move the cover the prescribed distance and then turns off.  Next, the cover horizontal registration motor (M31) reverses and moves the cover the prescribed distance away from the sensor after the sensor turns off. Detailed Descriptions D179/D180/D181...
  • Page 369 (The distance is prescribed according to the signature thickness reading performed by the signature thickness sensor (S50)). Finally, the cover grip solenoid (SOL1) turns off and closes the gripper . D179/D180/D181 Detailed Descriptions...
  • Page 370 25.14 GLUING 25.14.1 GLUING UNIT OPERATION The gluing unit applies glue to the spine of the signature that will be joined with the cover to form the book. Glue Hopper Glue Dispenser Glue Feeder Gluing Unit Glue Vat Detailed Descriptions D179/D180/D181...
  • Page 371 Glue Vat Empty Sensor (S32E/S32R) Glue Supply Cover Sensor Glue Temperature Thermistor Glue Abnormal Temperature Thermistor Glue Level Thermistor Glue Vat Roller Rotation Sensor Glue Vat HP Sensor: Rear Glue Roller HP Sensor S124 Machine Temperature Sensor Thermostat Glue Heater D179/D180/D181 Detailed Descriptions...
  • Page 372 The glue vat motor (M32) turns on. As the motor drives the glue vat from the rear to the front along the length of the signature spine [5], the glue roller applies glue to the spine. Detailed Descriptions D179/D180/D181...
  • Page 373 The glue vat move motor (M32) turns on and moves glue vat [4] from the front to the rear. As the vat moves from front to rear the glue applicator plate applies another layer of glue the signature spine [5]. D179/D180/D181 Detailed Descriptions...
  • Page 374 [5].  Each movement of the glue feeder (90° rotation) feeds four 0.22 g pellets to the glue vat.  The feeder rotates three times (270°) to feed a total of 12 pellets. Detailed Descriptions D179/D180/D181...
  • Page 375 200 mm/s to stir the glue and then slows to 82.5 mm/s  The glue vat roller motor (M25) continues to rotate the glue vat roller for 30 sec. at 82.5 mm/s and then turns off.  The heater remains on to maintain the target temperature. D179/D180/D181 Detailed Descriptions...
  • Page 376 M28 Spine Fold Motor: Left M29 Spine Fold Motor: Right Spine Fold HP Sensor: Left Spine Fold Close Sensor: Left Spine Plate Open Sensor Spine Plate Closed Sensor Spine Fold HP Sensor: Right Spine Fold Closed Sensor: Right Detailed Descriptions D179/D180/D181...
  • Page 377 The main grip lift motor (M22) turns on, lowers the main grip unit [7] holding the signature , and presses the glued spine onto the center of the cover supported by the spine plate [8]. D179/D180/D181 Detailed Descriptions...
  • Page 378 The right spine fold motor remains on for the prescribed time and as it retracts the right fold plate, the grip motor: front (M24) and grip motor: rear (M23) turn on together and open the main gripper [6] 14 mm. Detailed Descriptions D179/D180/D181...
  • Page 379 The main grip lift motor (M22) turns on, lifts the main grip unit [1], pulls the joined signature and cover [2] away from the spine plate [3], then stops a short distance away from the plate. The spine plate motor (M26) retracts the spine plate to the right. D179/D180/D181 Detailed Descriptions...
  • Page 380 Signature Exit Path HP Sensor Signature Exit Path Press Sensor Now the cover is ready to be folded up around the joined signature to complete the formation of the book and the book is passed to the trimming unit. Detailed Descriptions D179/D180/D181...
  • Page 381 (M24) and grip motor: rear (M23) turn on and retract the main gripper [4] away from the sides of the signature. The main grip lift motor (M22) turns on, raises the main grip unit [5] to its home position and stops. D179/D180/D181 Detailed Descriptions...
  • Page 382 The spine plate motor (M26) turns on and moves the spine plate to its home position. At the same time the left and right spine fold motors (M28, M29) turn on and close the left and right spine fold plates [4] and [5]. Detailed Descriptions D179/D180/D181...
  • Page 383 M42 Book Rotation Motor 1 M43 Book Grip Motor M44 Slide Motor Slide HP Sensor Book Rotation HP Sensor 1 Trim Unit Entrance Sensors (S92R, S92E) Grip HP Sensor Grip End Sensor Book Rotation HP Sensor 2 D179/D180/D181 Detailed Descriptions...
  • Page 384 Edge Press Plate Motor Blade Cradle Motor SOL4 Trimmings Plunger Solenoid Blade Cradle HP Sensor Blade Sensor 1 Blade Sensor 2 Trimmer Limit Sensor Press End Sensor Book Registration Sensors (S88R/S88E) Press Limit Sensor Edge Press Plate HP Sensor Detailed Descriptions D179/D180/D181...
  • Page 385 (M41) turn on and rotate the book clockwise 90 degrees (rear to front). The rotated book [1] clamped in the grip unit [2] is raised or lowered by the slide motor (M44) to the trimming position [3]. D179/D180/D181 Detailed Descriptions...
  • Page 386 [4] and the book counter-clockwise 180 degrees (front to rear). The slide motor (M44) turns on and raises or lowers the book rotation grip unit [1] and the book [2] until the bottom edge of the book is at the cutting position. Detailed Descriptions D179/D180/D181...
  • Page 387 [4] and the book counter-clockwise 90 degrees (front to rear). The slide motor (M44) turns on and raises or lowers the book rotation grip unit [1] and the book [2] until the bottom edge of the book is at the cutting position. D179/D180/D181 Detailed Descriptions...
  • Page 388 [4] and the book clockwise 180 degrees (rear to front). The book grip motor (M43) turns on and releases the right book rotation plate [1]. The book falls into the book stacking tray. Detailed Descriptions D179/D180/D181...
  • Page 389 Blade Sn 1 Blade Sn 2 Blade Position (S84) (S85) Positioned for cutting stroke front to rear Retracting to front Retracted at front Retracting to rear Positioned for cutting stroke rear to front Retracted to rear D179/D180/D181 Detailed Descriptions...
  • Page 390 After the cut is done the cutter motor (M35) retracts the blade and trimmings catcher mechanism. The trimmings [5] are held in the trimmings seat as the blade is pulled away. Detailed Descriptions D179/D180/D181...
  • Page 391  After the last cut at the last position [4], the cutter control board issues a warning on the host machine that the blade cradle must be replaced.  The service life of the blade cradle is 5,550 cuts (550 cuts at each of the 10 positions.) D179/D180/D181 Detailed Descriptions...
  • Page 392  During a run of 100 to 200 books where trimming is done on three edges (top, bottom, fore edge) trimmings are sent to the trimmings box after the second cut and after the third cut. Trimmings Buffer Trimmings Box Trimmings Box Full Actuator Trimmings Sub Hopper Book Press Plate Detailed Descriptions D179/D180/D181...
  • Page 393 Trimming Unit Trimmings Buffer Motor Trimmings Buffer Full Sensors (S96R, S96E) Trimmings Box Full Sensor S100 Trimmings Buffer HP Sensor: Left S101 Trimmings Buffer Clock Sensor S103 Trimmings Buffer HP Sensor: Right S104 Book Press Plate Sensor D179/D180/D181 Detailed Descriptions...
  • Page 394  The trimmings buffer moves to the left until the trimmings buffer HP sensor: left (S103) goes ON then the amount of movement to the left is controlled by a flag in the trimmings buffer clock sensor (S101). Detailed Descriptions D179/D180/D181...
  • Page 395 [4] and returns to its home position, allowing the trimmings to fall into the trimmings buffer . 2nd Cut This operation cycle for the 2nd cut is the same as 1st cut. D179/D180/D181 Detailed Descriptions...
  • Page 396 First, the trimmings buffer and book press plate [2] stop at the home position with the dump port [3] of the book press plate over the trimmings box [4]. Next, the trimmings buffer moves over the dump port so the trimmings [5] can fall into the trimmings box below. Detailed Descriptions D179/D180/D181...
  • Page 397 25.15.6 STACKING TRIMMED BOOKS The trimmed books are sent to the book stacking unit where the books are delivered to the output tray for removal from the bookbinder by the operator. Book Lift Tray Book Buffer Tray Book Output Tray D179/D180/D181 Detailed Descriptions...
  • Page 398 SOL5 Book Door Lock Solenoid Book Arrival Sensor Book Buffer Tray HP Sensor Book Lift Tray HP Sensor Book Collection Tray HP Sensor Stacking Tray Book Sensor Book Door Sensor Trimmings Box Sensor S102 Book Lift Tray Lock Sensor Detailed Descriptions D179/D180/D181...
  • Page 399 [3] holding the book [4] in the trimming unit above retracts and releases the book. The book falls into the book lift tray. The book door lock solenoid (SOL5) (not shown above) keeps the book delivery door locked while the book lift tray is operating. D179/D180/D181 Detailed Descriptions...
  • Page 400 10 mm to the left and then 10 mm to the right to align the book on the output tray.  The trimmings buffer motor (M37) turns on and returns the trimmings buffer [3] to its home position. Detailed Descriptions D179/D180/D181...
  • Page 401 LCD.  The operator must then open the doors, remove the jam, and then close the doors so the machines can resume operation. D179/D180/D181 Detailed Descriptions...
  • Page 402 Tray Empty Sensor Entrance Sensor Signature Path Sensor 1 Signature Path Sensor 2 Cover Path Sensor 1 Cover Registration Sensor Horizontal Exit Sensor Cover Path Sensor 2 Sub Grip Signature Sensor Cover Horizontal Sensor (Small) Cover Horizontal Sensor (Large) Detailed Descriptions D179/D180/D181...
  • Page 403 101D: S72 Cover Horizontal Sensor (Large) Failed to detect side of the cover during horizontal registration of a small cover because it did not arrive within the prescribed time. D179/D180/D181 Detailed Descriptions...
  • Page 404 1169: S19 (INS) Vertical Transport Sensor 1 Detected the cover LE but failed to detect TE within the prescribed time. 116B: S18 (INS) Vertical Transport Sensor 2 Detected the cover LE but failed to detect TE within the prescribed time. Detailed Descriptions D179/D180/D181...
  • Page 405 The bookbinder received a command to stack fewer than 9 sheets of paper in the stacking tray. 1FA2: Book Jam 1 The book jammed in the trimming unit because the width of the third cut on the fore edge was wider than 40 mm (1.6"). D179/D180/D181 Detailed Descriptions...
  • Page 406 (S21) sensor detected that the size of the paper in the paper path did not match the paper size specified for the book binding job. 1FA6: --- Blank paper stopped in the paper path because a blank paper discard command was received. Detailed Descriptions D179/D180/D181...
  • Page 407 Supplies DC power to the slave control board, cutter control board Power Switch Turns power supply units 1, 2 on/off Microswitch Turns the DC 24V, 36V circuits on/off Breaker Switch Trips the breaker and cuts power supply to the bookbinder if a power overload occurs D179/D180/D181 Detailed Descriptions...
  • Page 408 (with the exception of the CPU on the master control board) turns off and the bookbinder enters the energy save mode. Full power and full operation is restored to the bookbinder when the host machine is turned on again. Detailed Descriptions D179/D180/D181...
  • Page 409 The CPU uses this information to run the inserter motors and clutches according to pre-set timings. The inserter is supplied with DC 24V power from the bookbinder. The inserter control board communicates with the sensors through serial connectors and harnesses. D179/D180/D181 Detailed Descriptions...
  • Page 410  The registration roller then feeds the sheet to the standby position [5] where it stops.  When the bookbinder requests the cover for the binding operation, the vertical transport roller 1 [6] feeds the paper to the bookbinder below. Detailed Descriptions D179/D180/D181...
  • Page 411  Lift to pre-feed position  Feed drive selection  Paper pickup and feed  Skew correction at the registration roller  Transport 1: Feed to standby position  Transport 2: Feed into vertical path  Next cover feed D179/D180/D181 Detailed Descriptions...
  • Page 412 This function keeps the tray at the proper feed position so the paper can be easily changed if the paper requested for the next job is different from the paper being used in the current job. Detailed Descriptions D179/D180/D181...
  • Page 413  If the switching gear is not positioned at the tray requested for the job, the drive switch motor (M2 (INS)) turns on (forward or reverse) to move the rack to the drive gear of the tray requested for the job. D179/D180/D181 Detailed Descriptions...
  • Page 414 When either type of paper is selected for the job, the registration clutch (CL1 (INS)) is switched on to keep the registration roller disengaged slightly longer than normal to allow more time for the paper to buckle against the registration roller and correct skew. Detailed Descriptions D179/D180/D181...
  • Page 415 The paper remains at the standby position until the bookbinder requests the cover. Once the bookbinder issues the request for the cover, the tray feed motor (M1 (INS)) and vertical transport motor (M5 (INS)) turn on and feed the paper through transport rollers [1] and delivery rollers [2]. D179/D180/D181 Detailed Descriptions...
  • Page 416 When this occurs S1 (INS) issues 1_EMPS and S6 (INS) issues 2_EMPS to the inserter control board. This tells the inserter control board that paper is loaded in one or both trays and lights the paper loaded display. Detailed Descriptions D179/D180/D181...
  • Page 417 Each tray has a paper width sensor (S2 (INS). The sensor detects the position of the side fence rack in front of it. The sensor reads this analog value and sends it to the inserter control board which uses the signal to identify the paper size. D179/D180/D181 Detailed Descriptions...
  • Page 418  Once the jam is removed all covers of the inserter must be closed in order to resume operation.  After all the covers are closed the inserter control board checks each sensor again for any remaining paper. Detailed Descriptions D179/D180/D181...
  • Page 419 The bookbinder supplies power to the inserter (DC +5V, +24V). The DC +24V power is supplied to the clutches and motors. The DC +5V power goes to the sensors. Opening any cover of the inserter cuts the power supply, closing the cover restores the power supply. D179/D180/D181 Detailed Descriptions...
  • Page 420 Detects the leading and trailing edge of each sheet of paper in the path to the stacking tray to monitor timing and trigger jam alerts if the paper stops or fails to arrive. Located in the perfect binder, this sensor is controlled by the inserter. Detailed Descriptions D179/D180/D181...
  • Page 421 When this occurs S1 (INS) issues 1_EMPS and S6 (INS) issues 2_EMPS to the inserter control board. This tells the inserter board that paper is loaded in one or both trays. This lights the paper loaded display. D179/D180/D181 Detailed Descriptions...
  • Page 422 Jam Detection The sensors shown above and listed below are used to detect the presence of paper in the inserter paper path and signal a jam when one occurs Paper Set Sensor Tray A (S1 (INS)) Detailed Descriptions D179/D180/D181...
  • Page 423 Tray A registration roller and signals a jam if either edge fails to pass within the prescribed time. S6 (INS) Paper Set Sensor: Tray B Detects paper on Tray A and signals that Tray B is ready to feed paper. D179/D180/D181 Detailed Descriptions...
  • Page 424 Lifts Tray A to the feed position and lowers the tray when the job is finished. M4 (INS) Lift Motor: Tray B Lifts Tray B to the feed position and lowers the tray when the job is finished. Detailed Descriptions D179/D180/D181...
  • Page 425 This allows a little more time for the thick or coated paper to buckle against the roller to correct skew. Operates only for thick or coated paper fed from Tray B. D179/D180/D181 Detailed Descriptions...
  • Page 426 Detects when the number of sheets on the stacking tray has exceeded the capacity of the tray. Stacking Tray Lower Limit Sensor Detects when the sub grip unit is at its lowest position where it can pass the signature to the main grip unit. Detailed Descriptions D179/D180/D181...
  • Page 427 Signature Path Sensor 2 Detects the leading and trailing edge of each sheet of paper in the path to the stacking tray and trigger jam alerts if the paper stops or fails to arrive. D179/D180/D181 Detailed Descriptions...
  • Page 428 Jogger Motor (Front) Moves the front jogging fence forward or backward once and stops at the base position for jogging the edge of each sheet against the front fence. Detailed Descriptions D179/D180/D181...
  • Page 429 Drives the entrance roller and transport roller 1 at the entrance of the perfect binder. Signature Transport Motor Drives the four transport rollers in the signature path that feeds paper from the entrance roller to the stacking tray. D179/D180/D181 Detailed Descriptions...
  • Page 430 Detects when the sub grip unit is at the correct home position for the width of the selected paper size. Sub Grip Signature Sensor Detects the signature in the sub grip unit. Sub Grip Open Sensor Detects when the sub grip unit is open. Detailed Descriptions D179/D180/D181...
  • Page 431 Sub Grip Motor Raises the front and rear plates of the sub gripper to clamp the signature in the sub grip unit. Opens the plates to release the signature from the sub grip unit to the main grip unit. D179/D180/D181 Detailed Descriptions...
  • Page 432 Detects the press position of the main gripper during signature alignment. Main Grip Press Sensor 2 Detects the press position of the main gripper when the main unit is ready to press the signature into the center of the cover. Detailed Descriptions D179/D180/D181...
  • Page 433 Opens and closes the rear half of the main gripper that grips the spine of the signature in the main grip unit. Grip Motor: Front Opens and closes the front half of the main gripper that grips the spine of the signature in the main grip unit. D179/D180/D181 Detailed Descriptions...
  • Page 434 If temperature exceeds upper range, triggers an alert and cuts off power to the bookbinder. Glue Level Thermistor Monitors the amount of glue in the vat (this sensor is inside the glue unit). Detailed Descriptions D179/D180/D181...
  • Page 435 Mounted inside the gluing unit, melts the glue in the gluing unit before the glue is applied to the spine. THSW1 Thermostat Switches off the power supply if it detects abnormally high temperature around the glue unit (this thermostat is inside the glue unit. D179/D180/D181 Detailed Descriptions...
  • Page 436 (the receptor of an Emitter/Receptor pair). S65E Leading Edge Sensor: Emitter Detects the leading edge of the book during binding and release of the book to the trimming unit (the emitter of an Emitter/Receptor pair). Detailed Descriptions D179/D180/D181...
  • Page 437 Signature Exit Roller Motor Drives the signature exit roller that feeds the bound signature to the trimming unit below. D179/D180/D181 Detailed Descriptions...
  • Page 438 Signature Exit Path Motor Projects and retracts the signature exit guide which closes and opens the nip of the signature exit rollers above the trimming unit. Detailed Descriptions D179/D180/D181...
  • Page 439 Cover Guide HP Sensor: Left Detects home position of the path guide on the left edge of the cover in the cover transport path. Cover Guide Open Sensor: Left Detects when the left cover guide is open and closed. D179/D180/D181 Detailed Descriptions...
  • Page 440 Opens and closes to control operation of the cover gripper in the cover registration unit. The cover gripper clamps the cover so the cover registration guide can move the cover front/rear to position the cover for binding to the signature. Detailed Descriptions D179/D180/D181...
  • Page 441 Detects when the signature grip operation in the main grip unit has ended. Book Rotation HP Sensor 1 Detects the position of rotate motor rotation motor 1 (M42) after it has been rotated to rotate the book for trimming D179/D180/D181 Detailed Descriptions...
  • Page 442 Projects and retracts the right book rotation plate to clamp and release the book between the left and right book rotation plates. Slide Motor Lowers the book (clamped between the left and right rotation plates) into the trimming unit and positions each edge for trimming. Detailed Descriptions D179/D180/D181...
  • Page 443 Blade Sensor 1 Detects the left/right positions of the cutter blade and the cutter end (cutter area sensor is inside the base plate) as the blade moves slightly from one side to the other during cutting. D179/D180/D181 Detailed Descriptions...
  • Page 444 (M36). SOL4 Trimmings Plunger Solenoid Pushes and retracts the trimmings plunger that grabs the paper strips under the blade which has cut them from the edges of the book. Detailed Descriptions D179/D180/D181...
  • Page 445 S104 Book Press Plate Sensor Detects the position of the book press plate. The book press plate presses against the side of the book when the trimmed strips are collected from under the blade. D179/D180/D181 Detailed Descriptions...
  • Page 446 Book Lift Tray HP Sensor Detects the home position (down) of the book lift tray. The book lift tray is raised to receive the book from the trimming unit above and lower it into the book buffer. Detailed Descriptions D179/D180/D181...
  • Page 447 SOL5 Book Stacker Lock Solenoid Operates the lock of the book door. Energizes and locks the book door while the machine is operating. This is a safety feature. D179/D180/D181 Detailed Descriptions...
  • Page 448 Detects when the right front door is opened and closed. SOL3 Right Front Door Solenoid Operates the lock of the right front door. Energizes and locks the right front door while the machine is operating. This is a safety feature. Detailed Descriptions D179/D180/D181...
  • Page 449 Mounted beside FM06 cools the area around the trailing edge of the signature clamped in the main grip. FM08 Signature Fan 1 :Front Mounted beside FM09 cools the area around the leading edge of the signature clamped in the main grip. D179/D180/D181 Detailed Descriptions...
  • Page 450 Mounted beside FM13 cools the area around the spine plate where the signature is pressed onto the cover. FM13 Spine Plate Fan :Upper Rear Mounted beside FM12 cools the area around the spine plate where the signature is pressed onto the cover. Detailed Descriptions D179/D180/D181...
  • Page 451 Controls signature rotation for trimming, trimming, trimmings collection, and book stacking. PCB4 Main Grip Relay Board 1 PCB5 Main Grip Relay Board 2 PCB6 Main Grip Relay Board 3 PCB7 Sub Grip Relay Board 1 PCB8 Sub Grip Relay Board 2 D179/D180/D181 Detailed Descriptions...
  • Page 452 Binding in progress PCB17 Glue Heater Button/LED Press this button to start heating the glue before a job starts. Ready FLASH Glue heating, please wait until ON Not ready. Max. wait time after job start: 6 min. Detailed Descriptions D179/D180/D181...
  • Page 453 Settings done with the service board are stored in the EEPROM. PCB19 Power Supply Relay Board Supplies power to the relay unit. PCB20 Power Supply Unit 1 Supplies power to the master control board. PCB21 Power Supply Unit 2 Supplies power to the slave control board. D179/D180/D181 Detailed Descriptions...
  • Page 454 51 to 100 Punching Only Up to 100 sheets Size 870 x 730 x 1010 mm (34.3 x 28.7 x 38.8 in.) Weight 140 kg (308 lb) Power Consumption Less than 400 W DIP SW Settings All OFF Detailed Descriptions D179/D180/D181...
  • Page 455 [1] Left Door [2] Top Cover [3] Right Door [4] Output Tray The open area below the output tray [4] must remain free of obstacles. This must not be used as a storage area for paper or other supplies D179/D180/D181 Detailed Descriptions...
  • Page 456 Important Parts 27.2.2 CROSS SECTION Pre-Punch Jogger Unit Punch Unit Binder Unit Pre-Bind Jogger Unit Ring Supply Unit (with Ring Cartridge) Clamp Unit Output Belt Unit Stacker Unit Detailed Descriptions D179/D180/D181...
  • Page 457 Output belt 1 [12] raises and catches the bound stack and then lowers back to the same level as output belt 2 [13]. Output belt 1 and 2 then feed the document to the stacking unit [14]. D179/D180/D181 Detailed Descriptions...
  • Page 458 Operates the jog roller that feeds the paper into the Motor pre-punch jogger unit. M303 Punch Unit Rotates the punch runout roller that feeds the punched Runout sheet out of the punch unit to the pre-bind jogger. Motor Detailed Descriptions D179/D180/D181...
  • Page 459 Pre-Punch Jogging and Punching 27.5 PRE-PUNCH JOGGING AND PUNCHING 27.5.1 SWITCHBACK The path junction gate motor (M201) [1] raises and lowers the switchback junction gate [2] D179/D180/D181 Detailed Descriptions...
  • Page 460 (late jam) or stops (lag jam). M103 Exit Motor Drives the 6th transport roller and exit roller in the horizontal paper path for downstream delivery (the paper passes straight through with no punching or binding). Detailed Descriptions D179/D180/D181...
  • Page 461 Opens and closes the stopper inside the punch unit that improves the accuracy of hole punching on the leading edge of each sheet. S301 Pre-Punch Detects the home position of the front and rear Jogger HP jogger fences in the pre-punch jogger unit. Sensor D179/D180/D181 Detailed Descriptions...
  • Page 462 The correct type of punch unit must be installed for A4/LT punching. The job will not execute if the paper size (A4 or LT) does not match the punch unit. The system always recognizes which type of punch is installed (based on the punch circuitry.) Detailed Descriptions D179/D180/D181...
  • Page 463 M304 Punch Motor Drives the punch unit that punches holes in the paper. There are two types of punches: 1) A4 23 hole-, 2) LT 21-hole. The punch unit must be replaced to switch between A4/LT punching. D179/D180/D181 Detailed Descriptions...
  • Page 464 Holds the ring cartridge that feeds a single ring to the clamp unit below. Clamp unit Takes a ring from the bottom of the ring cartridge and swings right to insert the ring into the holes in the stack in the pre-bind jog unit. Detailed Descriptions D179/D180/D181...
  • Page 465 Pushing the ring cartridge into the binder unit pushes the actuator arm [1] out of the gap of the interrupt sensor, and the cartridge is ready to feed rings. Pulling out the ring cartridge releases the actuator arm [2], turns on the sensor, and signals that the ring cartridge is not installed. D179/D180/D181 Detailed Descriptions...
  • Page 466 [1] on when it reaches the bottom of the ring stack. A graduated scale [2] attached to the front of the ring cartridge at installation also allows the operator to see the number of rings remaining in the ring cartridge. Detailed Descriptions D179/D180/D181...
  • Page 467 [5] Ring Size Detection: 500/100 Ring Detect Sensor (S804) This photo-sensor detects the ring size. There are only two ring sizes: 50-sheet, and 100-sheet. D179/D180/D181 Detailed Descriptions...
  • Page 468 The cover on the right side of the cartridge remains closed [1] when the 50-sheet size rings are installed. The cover opens [2] when the 100-sheet size rings depress the actuator. The sensor detects whether the cover is open (50-sheet rings) or closed (100-sheet rings). Detailed Descriptions D179/D180/D181...
  • Page 469 Determines the thickness of the Detection Mechanism stack (the thickness determines how far the paddle roller must be raised). Jogger Mechanism Jogs the top and bottom edges of the stack between the front fence and rear fence. D179/D180/D181 Detailed Descriptions...
  • Page 470 S612 Stack Tamper HP Detects the actuator of the tamper fence and Sensor stops the stack tamper motor (S607). The allowed arc of rotation is 90 degrees. Detailed Descriptions D179/D180/D181...
  • Page 471 (a cam controls this mechanism). D179/D180/D181 Detailed Descriptions...
  • Page 472 This jogs the edge of each sheet against the stationary front fence. S611 Side Fence 2 Detects the home position of side fence 2 (rear fence) in HP Sensor 2 the pre-bind jogger unit. Detailed Descriptions D179/D180/D181...
  • Page 473 1 which remains stationary. The side fence 2 HP sensor (S611) controls the operation of side fence motor 2 to make sure that side fence 2 moves the prescribed distance for the selected paper size. D179/D180/D181 Detailed Descriptions...
  • Page 474 (M601) so that the roller stops at its home position. S612 Stack Tamper Detects the actuator of the tamper fence and stops the HP Sensor stack tamper motor (S607). The allowed arc of rotation is 90 degrees. Detailed Descriptions D179/D180/D181...
  • Page 475 The height of the paddle roller is controlled by the thickness of the stack detected by the stack thickness sensor (S607). D179/D180/D181 Detailed Descriptions...
  • Page 476 The shutter is raised and stopped so that the leading edge of the stack in the pre-bind jogger can be aligned against the shutter, and then lowered and stopped so that the punched leading edge can be bound with the rings. Detailed Descriptions D179/D180/D181...
  • Page 477 Shutter HP sensor 1 (S605) [5] detects the open/closed positions of the shutter, and shutter HP sensor 2 (S613) (not shown above) detects the stop position for the motor through a slit in the shutter drive gear. D179/D180/D181 Detailed Descriptions...
  • Page 478 S604 Alignment Pin Detects the actuator of the alignment HP Sensor pin linkage, signals that the linkage has returned to its home position, and switches off the alignment pin motor (M602). Detailed Descriptions D179/D180/D181...
  • Page 479 (S610) [4] detects the pins at their highest point and reverses the motor to retract the pins to the home position. D179/D180/D181 Detailed Descriptions...
  • Page 480 The stack thickness sensor (S607) measures the stack through a cutout in the clamp upper arm plate. This reading is also used to adjust the height of the paddle roller. Detailed Descriptions D179/D180/D181...
  • Page 481 The jaws of the clamp (powered by large springs) close on the punched spine and do not release it until the rings have been inserted into the holes and closed. D179/D180/D181 Detailed Descriptions...
  • Page 482 During ring binding, the stack is clinched only at the spine by the upper and lower guide clamps and pulled in the direction of the arrow for ring binding by the clamp binder motor (M701). Detailed Descriptions D179/D180/D181...
  • Page 483  Rotates the cam> gear> linkage that pulls the closer [3] down to close the rings into the holes and around the spine of the document. D179/D180/D181 Detailed Descriptions...
  • Page 484 The clamp binder motor (M701) rotates a cam via a gear, and this pulls down a link that pulls the pre-bind jogger [1] into the clamp unit [2]. This lowers the clamped spine of the document, to prepare for the closing of the rings through the punched holes. Detailed Descriptions D179/D180/D181...
  • Page 485 The continued rotation of the motor, cams, and linkages retracts the plates of the closer, retracts the clamper of the pre-jog binder, and swings the clamp unit back to the right to fetch the next ring. D179/D180/D181 Detailed Descriptions...
  • Page 486 [1] and the binding pitch [2] must be adjusted for the size of the ring (50 or 100-sheet size). The 50/100 clamp adjust motor (M702) drives a gear and switching cams 1 and 2 above the same shaft. Switching cam 1 switches the binding pitch and switching cam 2 switches the linkage depth. Detailed Descriptions D179/D180/D181...
  • Page 487 (M610) that raises the runout roller in the pre-bind jogger unit. The roller is lowered to close the nip so that the bound stack can be fed out of the binder unit. The home position is up (nip released). D179/D180/D181 Detailed Descriptions...
  • Page 488 (M610) and stops the roller at its clinch position. While the runout press roller is descending and the runout roller is about 1 mm away from the surface of the travel guide at the upper part, the stacks feeds out of the binder unit. Detailed Descriptions D179/D180/D181...
  • Page 489 1 cw to the vertical, it reverses and rotates the book Sensor and belt ccw to the horizontal. The sensor detects when the belt reaches the horizontal and stops the output belt rotation motor (M403). Cw: clockwise, ccw: counterclockwise D179/D180/D181 Detailed Descriptions...
  • Page 490 Detects the home position of the pawls mounted on Sensor output belt 2. The pawls hook and push the book onto the output stacking tray. With the pawls at their home positions the belt is ready to move the next book from output belt 1. Detailed Descriptions D179/D180/D181...
  • Page 491 Emitter/Receptor pair. S502R Stack Height Sensor Detects the top of the document stack on the on the stacker tray and signals when the stacker tray is full. This is the receptor sensor of an Emitter/Receptor pair. D179/D180/D181 Detailed Descriptions...
  • Page 492 If something like a stack of magazines or newspapers is placed under the tray accidentally, the spring loaded bottom of the tray will trigger this switch and stop the tray when it contacts the top of the obstacle. Detailed Descriptions D179/D180/D181...
  • Page 493 Raises and lowers the stacking tray where the bound books are output from output belt 2. M402 Output Belt 2 Motor Drives the belt of output belt 2 which relays the book from output belt 1 to the book output tray. D179/D180/D181 Detailed Descriptions...
  • Page 494 SOL302 Top Fence SOL Opens and closes the stopper inside the punch unit that improves the accuracy of hole punching on the leading edge of each sheet. Detailed Descriptions D179/D180/D181...
  • Page 495 Cools the area around the motors in the binder unit. [5] M609 Runout Roller Motor Rotates the runout press roller that feeds the bound book out of the binder unit. [6] M602 Alignment Pin Motor Raises and lowers the alignment pins. D179/D180/D181 Detailed Descriptions...
  • Page 496 Paddle Roller Lift Raises and lowers the paddle Motor roller. [2] M601 Paddle Roller Drives the paddle roller in the Motor pre-bind jogger that pushes the leading edge of each sheet against the raised shutter to align the stack. Detailed Descriptions D179/D180/D181...
  • Page 497 (3) Rotates the cam> gear> linkage that pulls the closer down to close the rings. M702 50/100 Clamp Operates the switching cams (1 and 2) that adjust Adjust Motor the pitch and depth for the size of the rings so they will be closed properly. D179/D180/D181 Detailed Descriptions...
  • Page 498 [2] M608 Shutter Motor Raises and lowers the shutter. Detailed Descriptions D179/D180/D181...
  • Page 499 27.14 MAIN BOARD SENSORS 27.14.1 FRONT VIEW A Horizontal Paper Path B Pre-Punch C Post-Punch D Punchout Box E Output Belt 1 F Output Belt 2 G Stacker Well H Output Tray I Stacker Top J Stacker Side D179/D180/D181 Detailed Descriptions...
  • Page 500 (late jam) or stops (lag jam). S101 Entrance Detects the leading and trailing edge of each sheet at Sensor the entrance roller. Detects a jam if the paper fails to arrive (late jam) or stops (lag jam). Detailed Descriptions D179/D180/D181...
  • Page 501 Signals an error if either the leading or trailing edge of the sheet fails to arrive at the prescribed time. D179/D180/D181 Detailed Descriptions...
  • Page 502 Detects when the chad box is full. The emitter of an Emitter/Receptor pair. [3] S308 Chad Box Detects the presence of the chad box. Triggers an Sensor error if the box is not installed or is installed improperly. Detailed Descriptions D179/D180/D181...
  • Page 503 Checks the leading/trailing edge timing of the Entrance Sensor stacks (ring-bound or punched-only) fed from the pre-bind jogger unit. 27.14.7 F: OUTPUT BELT 2 [1] S402 Output Belt 2 Detects the home position of the HP Sensor pawls mounted on output belt 2. D179/D180/D181 Detailed Descriptions...
  • Page 504 Detects whether the stacker tray is pulled out or Sensor pushed in. Signals an alert after a job starts if the tray is pulled out. [2] S506 Obstacle Detects an obstacle below the output tray and stops the Detect operation. Microswitch Detailed Descriptions D179/D180/D181...
  • Page 505 Detects the top of the document stack on the on the Sensor stacker tray and signals when the stacker tray if full. This is the receptor sensor of an Emitter/Receptor pair. [4] S504 Stacker Detects a document on the stacker tray at power on. Detect Sensor D179/D180/D181 Detailed Descriptions...
  • Page 506 This is the emitter sensor of an Emitter/Receptor pair. [2] S507E Book Checks the position of the bound book to detect book Position skew or falling. The emitter of an Emitter/Receptor Sensor pair. Detailed Descriptions D179/D180/D181...
  • Page 507 Around Punch Unit, Pre-Punch Jogger 27.15 AROUND PUNCH UNIT, PRE-PUNCH JOGGER A Punch Unit B Pre-Punch Jogger Unit D179/D180/D181 Detailed Descriptions...
  • Page 508 Detects the home position of the punch unit. Signals Sensor an error if the punch unit is neither installed nor installed properly. S303 Punch Encoder Controls the start and stop timing of the punching Sensor operation by counting rotations of the punch motor (M304). Detailed Descriptions D179/D180/D181...
  • Page 509 (M201). S301 Pre-Punch Jogger Detects the home position of the front and rear HP Sensor jogger fences in the pre-punch jogger unit. D179/D180/D181 Detailed Descriptions...
  • Page 510 (M608). S609 Paper LE Detect Detects the arrival of each sheet in the pre-bind Sensor jogger under. Also signals an alert if it detects paper remaining in the pre-bind jogger unit at power on. Detailed Descriptions D179/D180/D181...
  • Page 511 Controls operation of the runout roller motor HP Sensor (M609) that raises the runout roller in the pre-bind jogger unit. [13] S613 Shutter HP 2 Detects the stop positions of the shutter and shuts Sensor off the shutter motor (M608). D179/D180/D181 Detailed Descriptions...
  • Page 512 Detects the descending paddle roller and switches off HP Sensor the paddle roller motor (M601) so the roller stops at its home position. [2] S612 Stack Tamper Detects the actuator of the tamper fence and stops HP Sensor the stack tamper motor (S607). Detailed Descriptions D179/D180/D181...
  • Page 513 Sensor top of the ring stack turns this sensor on when it reaches the bottom of the stack when there are only 5 rings remaining. [5] S802 Rings Reversed Detects when rings have been loaded incorrectly. Sensor D179/D180/D181 Detailed Descriptions...
  • Page 514 Switches 27.17 SWITCHES Left Door Switch Detects when left door opened/closed/ Right Door Switch Detects when right door opened/closed. Detailed Descriptions D179/D180/D181...

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