Page 2: Explanation Of Symbols
When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition of this manual.
Page 3 Introduction Symbols Explanation Symbols Explanation Disconnect the connector. Connect the power cable. Connect the connector. Disconnect the power cable. Remove the cable/wire from the Turn on the power. cable guide or wire saddle. Install the cable/wire to the cable Turn off the power. guide or wire saddle.
Page 4: Table Of Contents
Contents Contents Safety Precautions....................1 Notes Before it Works Serving......................2 Points to Note at Cleaning........................2 1. Product Overview.....................3 Product Specifications.........................4 Names of Parts............................5 External View............................5 Cross Section............................6 2. Technology....................... 7 Basic Operation...........................8 Basic Operation of the Fore-edge Trimmer..................... 8 Communication Between the Host Machine and the Fore-edge Trimmer..........
Page 5 Contents 4. Disassembly/Assembly................. 32 Electrical Components/Functions......................33 Sensors..............................33 Switches.............................34 Motors..............................35 Printed Circuit Boards and Other Parts....................36 Part Replacement Procedures......................37 External Covers..........................37 Drive System............................38 Document Feeding System........................52 Electrical System..........................65 5. Adjustment..................... 70 Service Mode............................ 71 Home Position Calibration........................71 Setting Position Check.........................72 Motion Test............................72 Flat Belts Installing Direction......................
Page 6 Contents E0005a7-8052: Stopper Move Motor M06 Remaining in Home Position..........92 E0005a7-8055: Stopper EEPROM Error....................92 E0005a7-8061: Conveyor Delivery Roller Positioning Motor M08 Home Positioning Incompletion.....92 E0005a7-8062: Conveyor Delivery Roller Positioning Motor M08 Remaining in Home Position....93 E0005a7-8065: Conveyor Delivery Roller EEPROM Error..............94 E0005a7-8073: Main Drive Motor M10 Driver Problem................
Page 7: Safety Precautions
Safety Precautions Notes Before it Works Serving....2 Points to Note at Cleaning....2...
Page 8: Notes Before It Works Serving
Safety Precautions Notes Before it Works Serving CAUTION: • At servicing, be sure to turn OFF the power source according to the specified steps and disconnect the power plug. • At the time of assembly and disassembly, be sure to place a sheet of paper under the parts to prevent them from being soiled or foreign matter from entering the parts.
Page 9: Product Overview
Product Overview Product Specifications......4 Names of Parts........5...
Page 10: Product Specifications
1. Product Overview Product Specifications Item Description Product Name Booklet Trimmer-D1 Description of Product Upper knife reciprocating fore-edge trimmer with delivery tray Maximum Number of Sheets Trimmable 50 sheets (80 g/m *1, *2 48 sheets (80 g/m ) + 2 sheets (300 g/m Possible Trimming Size *3 A3, B4, A4R, 13"...
Page 11: Names Of Parts
1. Product Overview Names of Parts External View Conveyor Delivery Section Section Trim Section Infeed Section Booklet Lifter Serial Port For upgrading software 1 2 3 4 Service Maintenance Panel DIP Switches inside this cover Conveyor Connector Communication Connector to the Top and Bottom Trimmer Communication Cable...
Page 12: Cross Section
1. Product Overview Cross Section [ 10 ] [ 9 ] [ 8 ] [ 7 ] [ 3 ] [ 6 ] [ 1 ] [ 2 ] [ 4 ] [ 5 ] Top-bottom guides Trim section entrance transport belts Transport hooks Trim section transport belts...
Page 13: Technology
Technology Basic Operation........8 Transport Drive System...... 12 Fore-edge Trim Operation....14 Pass Through Operation (Without Trimming)........18 Detecting Jams........21 Power Source........25...
Page 14: Basic Operation
2. Technology Basic Operation Basic Operation of the Fore-edge Trimmer The fore-edge trimmer receives a booklet which has been stitched and folded by the host machine, trims it on its fore-edge or passes it thorough without trimming, and delivers it to the conveyor. The basic operation of the fore-edge trimmer is as follows: ■...
Page 15: Communication Between The Host Machine And The Fore-Edge Trimmer
2. Technology Communication Between the Host Machine and the Fore-edge Trimmer The control commands from the host machine enter the trimmer controller PCB QPM-220. This function uses a serial communication link. If another finisher machine is connected downstream of the fore-edge trimmer, the finisher machine communicates with the host machine via the fore-edge trimmer.
Page 16 2. Technology 1. The fore-edge trimmer sends the trimmer model information to the host machine. When the host machine receives this, it returns the Ack signal. 2. The host machine sends the finisher model information to the fore-edge trimmer. When the fore-edge trimmer receives this, it returns the Ack signal.
Page 17 2. Technology Host Machine Fore-edge Trimmer Cover Open Trimmer Status Information (Cover Open Information) Other Covers Open Trimmer Status Information Update (Cover Open Information) Cover Closed Trimmer Status Information (Cover Open Information Update) Cover Closed Trimmer Status Information (Cover Open Information Update) ■...
Page 18: Transport Drive System
2. Technology Transport Drive System Overview Each booklet which is delivered from the host machine enters the infeed section. The booklet is transported by the infeed belts and transport hooks from the infeed section to the trim section. In the trim section, the booklet is transported by the upper and lower belts to the booklet lifter.
Page 19 2. Technology ■ Booklet Sensors The following booklet sensors are installed on the sheet path, and they detect arrival or passage of each sheet: Infeed section • Entrance booklet sensor (PI01) • Exit booklet sensor (PI02) Trim section • Entrance booklet sensor (PI07) •...
Page 20: Fore-Edge Trim Operation
2. Technology Fore-edge Trim Operation Preparation Stage Control When the fore-edge trimmer receives the operation startup command from the host machine, the following parts return to their home positions. Home Positions Infeed section: Top-bottom guides (to outside), transport hooks (to the right) Trim section: Stopper (to the left) Conveyor section: Transport roller (to the right) Next, when the fore-edge trimmer receives the booklet information (size, thickness, trim direction) from the host machine, the...
Page 21 2. Technology Host Machine Fore-edge Trimmer Operation Startup Command - Top-bottom guides, transport hooks, stopper, and transport roller move to their home positions. Booklet Information (size, thickness, trim direction) - Top-bottom guides, transport hooks, stopper, and transport roller move Preparation to the setting positions.
Page 22: Infeed Section Control
2. Technology Host Machine Fore-edge Trimmer - When a booklet is detected by the trim section entrance booklet sensor ( PI07 ), stopper ( M07 ) rises. Then the booklet arrives at the stopper booklet sensor ( PI08 ). Transport belts (M04) stop Trimming operation (M05) begins.
Page 23: Booklet Lifter And Delivery Section Control
2. Technology Booklet Lifter and Delivery Section Control The booklet passes the trim section exit booklet sensor (PI10), booklet lifter booklet sensor (PI11), and the delivery section booklet sensor (PI12), and is delivered to the conveyor. After that, the fore-edge trimmer sends the “booklet delivery complete” command to the host machine.
Page 24: Pass Through Operation (Without Trimming)
2. Technology Pass Through Operation (Without Trimming) Preparation Stage Control When the fore-edge trimmer receives the operation startup command from the host machine, the following parts return to their home positions. Home Positions Infeed section: Top-bottom guides (to outside), transport hooks (to the right) Trim section: Stopper (to the left) Conveyor section: Transport roller (to the right) Next, when the fore-edge trimmer receives the booklet information (size, thickness, trim direction) from the host machine, the...
Page 25: Infeed Section Control
2. Technology Host Machine Fore-edge Trimmer Operation Startup Command - Top-bottom guides, transport hooks, stopper, and transport roller move to their home positions. Booklet Information (size, thickness, trim direction) - Top-bottom guides, transport hooks, Preparation stopper, and transport roller move to the setting positions.
Page 26: Trim Section Control
2. Technology Trim Section Control The booklet passes the trim section entrance booklet sensor (PI07), and the stopper booklet sensor (PI08), and then it is transported to the booklet lifter. The stopper (M07) remains lowered during this period. Booklet Lifter and Delivery Section Control The booklet passes the trim section exit booklet sensor (PI10), booklet lifter booklet sensor (PI11), and the delivery section booklet sensor (PI12), and it is delivered to the conveyor.
Page 27: Detecting Jams
2. Technology Detecting Jams In order to detect a booklet being moved or a booklet left in the machine, the following booklet sensors are installed: Infeed section • Entrance booklet sensor (PI01) • Exit booklet sensor (PI02) Trim section • Entrance booklet sensor (PI07) •...
Page 28 2. Technology Host Machine Fore-edge Trimmer Jam occurs Jam Information Cover open Trimmer Status Information (Cover Open Information) Remove jammed booklets Jam Information Update Cover closed Trimmer Status Information (Cover Open Information Update) - The fore-edge trimmer goes to idling mode and checks whether the sensors detect a booklet.
Page 29 2. Technology Error description Sensor Cause Error Code A booklet has not arrived at the PI08 A booklet which was detected by 10C8 trim section stopper booklet sen- the trim section entrance booklet sor. sensor has not arrived at the trim section stopper booklet sensor within the timeout period.
Page 30 2. Technology Error description Sensor Cause Error Code An incorrect size data of booklet The trimmer declared that a size 1FDF has been transmitted. data out of specification had been transmitted.
Page 31: Power Source
2. Technology Power Source 208-240V Power Supply Route 208-240V is supplied to the power entrance for fore-edge trimmer, and then it goes through the power relay K00. Power relay K00 is turned on or off by the host machine. From K00, the 208-240V power goes through circuit breaker CB01 and line filter LF01, and then it is supplied to power supply G01.
Page 32: 5V/24V Power Supply Route
2. Technology LF01 CB01 100/200VAC 5V/24V Power Supply Route Power supply G01 provides two voltages: 24VDC and 5VDC. G01 supplies the 24 VDC and 5VDC for the logic system to the trimmer controller PCB QPM-220. 24VDC used to power the motors is supplied to the DC motor driver PCBs and stepper motor driver PCBs from G01 via interlock relay K01.
Page 33 2. Technology When either the front cover SW01 or the delivery section cover SW03 opens, this relay also opens. Interlock Relay Motor System Trimmer Controller PCB QPM-220 Sensor System Power Supply Logic System...
Page 34: Periodical Service
Periodical Service User Maintenance....... 29 Maintenance and Inspection....30...
Page 35: User Maintenance
3. Periodical Service User Maintenance There are not any parts which can be maintained by the user.
Page 36: Maintenance And Inspection
3. Periodical Service Maintenance and Inspection Periodic Parts Replacement There are not any parts to be replaced periodically. Consumables The following parts may need to be replaced once or more during the warranty period, because they have failed or been damaged. Replace the following parts when they are worn out: Part Name Quantity...
Page 37 3. Periodical Service Booklet Sensors PI13 PI12 PI08 PI07 PI01 PI02 Booklet Sensors...
Page 38: Disassembly/Assembly
Disassembly/ Assembly Electrical Components/Functions..33 Part Replacement Procedures.... 37...
Page 39: Electrical Components/Functions
4. Disassembly/Assembly Electrical Components/Functions Sensors PI14 PI13 PI12 PI11 PI08 PI05 PI10 PI06 PI07 PI03 PI01 PI04 PI09 PI02 Code Name Function Error Trimmer controller QPM-220 PI01 Infeed section en- Booklet detection at 10C2 CON10 trance booklet sensor the entrance of the in- 11C3 (Photoelectric) feed section...
Page 40: Switches
4. Disassembly/Assembly Code Name Function Error Trimmer controller QPM-220 PI10 Trim section exit Booklet detection at 10CA CON11 booklet sensor the trim section exit 11CB (Photoelectric) PI11 Booklet lifter booklet Booklet detection at 10CC CON12 sensor the booklet lifter sec- 11CD (Photoelectric) tion...
Page 41: Motors
4. Disassembly/Assembly Motors Code Name Function Error Infeed belt motor Transports the booklets in the in- feed section Transport hook motor Moves the transport hooks E0005a7-8011 E0005a7-8012 Top-bottom guide motor Moves the top-bottom guides E0005a7-8021 E0005a7-8022 Trim section transport motor Transports the booklets in the E0005a7-8033 trim section...
Page 42: Printed Circuit Boards And Other Parts
4. Disassembly/Assembly Code Stepper Mo- Stepper Mo- Motor Driver Motor Driver Motor Driver Fuse PCB Trimmer Con- tor Driver tor Driver QPW-786 troller PCB QPM-220 QPW-727 QPW-740 CON103/ CON24 CON102 CON103/ CON24 CON102 CON104/ CON24 CON102 CN3/CN2 CON17 CN3, 4/CN2 CON18 CON104/ CON24...
Page 43: Part Replacement Procedures
4. Disassembly/Assembly 2. Loosen the 2 screws [2]. Part Replacement Procedures Reinstall any removed parts by reversing the removal procedure, unless instructed otherwise. [ 1 ] CAUTION: [ 1 ] [ 1 ] • Turn off the power switch before you remove the [ 1 ] [ 1 ] external covers.
Page 44: Drive System
4. Disassembly/Assembly 2. Remove the 4 screws [1] and remove the booklet ■ Trim Section Top Cover lifter cover. 1. Remove the 4 screws [1] and the trim section top cover. [ 1 ] [ 1 ] [ 1 ] [ 1 ] ■...
Page 45 4. Disassembly/Assembly 2. Move the top-bottom guides out as far as possible. 6. Loosen the screw [6] and remove the timing belt [7]. [ 4 ] [ 5 ] Move out as far as possible. [ 4 ] 3. Remove the snap rings [2] from the guide shafts, and pull out the guide shafts [3] from the rear of the [ 5 ] machine.
Page 46 4. Disassembly/Assembly 8. Loosen the idler pulley [6]. 13. Remove the transport hook drive timing belt [8]. 9. Remove the snap ring [12] and remove the pulley [13]. [ 10 ] [ 5 ] 10. Remove the snap ring [16] and remove the pulley [17] [18].
Page 47 4. Disassembly/Assembly 3. Remove the lower guide plate [1]. 2. Remove the trim unit. (Refer to “Trim Unit” on page • Stand up the trim unit as shown below. • Support the trim unit so that it is stable by putting [ 1 ] magazines etc.
Page 48 4. Disassembly/Assembly 2. Install the connecting rod [6]. 6. Remove the 2 screws [5] and remove the transport drive section. • Lock them in place using the snap rings. 7. Remove the transport belts [4]. 8. Loosen the idler pulley [6]. 9.
Page 49 4. Disassembly/Assembly ■ Knife Motor M05 6. Swing the trim section transport belt unit [5] up. [ 5 ] WARNING: Keep your hands away from both knife-edges when you remove the knife motor. 1. Remove the upper knife assembly. (Refer to “Upper Knife Assembly”...
Page 50 4. Disassembly/Assembly 12. Remove the knife motor [11]. 16. Push the tension roller for the left pulley against the belt and lock it in position. • Remove the motor with the timing pulley attached. • Turn the motor clockwise not to hit the wiring of •...
Page 51 4. Disassembly/Assembly 3. Remove the 3 screws [1] and remove the lower guide 5. Remove the transport table [3]. plate [2]. [ 2 ] [ 1 ] [ 3 ] [ 1 ] [ 1 ] [ 2 ] Move out as 6.
Page 52 4. Disassembly/Assembly 3. Remove the 2 screws [1] and remove the bracket [2]. 2. Remove the 2 screws [2] and remove the sensor bracket [3]. [ 3 ] [ 2 ] [ 1 ] [ 2 ] 3. Disconnect the connector. 4.
Page 53 4. Disassembly/Assembly 4. Push in on the stopper [2] on the end of the rail and 2. Open the transport belt mechanism [1]. pull out the trim unit with the stopper released. 3. Remove the screw [2] to separate the ground wire [3] from the upper knife cover [4].
Page 54 4. Disassembly/Assembly 5. Remove 3 screws [6] using a 6 mm Allen wrench, and 2. Remove the 4 screws [1] and lift the infeed lower remove the upper knife assembly [8]. guide [2] upward. • When you remove the upper knife assembly, be sure to hold the bracket [7].
Page 55 4. Disassembly/Assembly 7. Remove the 2 screws [9] and bracket [10]. [ E ] [ D ] [ 9 ] [ 10 ] [ 8 ] [ A ] [ 9 ] [ A ] [ A ] [ A ] [ C ] [ B ] [ A ]...
Page 56 4. Disassembly/Assembly 17. Pull out the shaft [31]. ● How to remove the [D] metal bushing: 1. Remove the snap ring [1] and metal bushing [2]. [ 2 ] [ 28 ] [ 27 ] [ 26 ] [ 1 ] [ 31 ] ●...
Page 57 4. Disassembly/Assembly 3. Disconnect the connector [2]. 6. Turn the pulley [4] to move the stopper [5] in the middle of stroke. 4. Remove the belt cover [3]. 7. Disconnect the motor connector. 5. Remove the 2 screws [4] to remove the motor bracket.
Page 58: Document Feeding System
4. Disassembly/Assembly 4. Remove the 4 screws [5] and the cable cover [9]. 4. Remove the bracket [2] for the infeed section exit booklet sensor PI02. [ 5 ] [ 9 ] [ 5 ] Move out as [ 2 ] far as possible.
Page 59 4. Disassembly/Assembly 10. Remove the transport belts [11]. 5. Remove the upper belt. • Remove each transport belt through the timing belt which was removed in step 6. [ 11 ] [ 9 ] [ 11 ] [ 10 ] [ 7 ] [ 8 ] NOTE:...
Page 60 4. Disassembly/Assembly 10. Remove the snap ring [6] and move the idler shaft 3. Remove the trim section rear drive belt [1]. [7] to the rear, and then remove the lower belts. [ 1 ] [2] [3] 4. Pull out the trim section unit. 5.
Page 61 4. Disassembly/Assembly 10. Move the shaft [10] to the drive side and remove each 6. Pull out the trim unit and remove the drive shaft belt from the front. assembly [6] to the front. [ 6 ] [ 5 ] [ 10 ] [ 9 ] [ 8 ]...
Page 62 4. Disassembly/Assembly 3. Remove the trim section rear drive belt [1]. 3. Remove the trim section rear drive belt [1]. [ 1 ] [ 1 ] 4. Remove the snap ring [2] and metal bushing [3]. 4. Remove the trim section transport belt unit [2]. (Refer to the steps 1 to 4 of “How to remove type [C] transport belts:”...
Page 63 4. Disassembly/Assembly 9. Remove the 2 screws [8], move the shaft toward the 2. Remove the 2 screws [2], loosen the 4 screws [3] and drive side, and remove the bearing bracket [9]. remove the conveyor from the trimmer. [ 2 ] [ 2 ] [ 3 ] [ 3 ]...
Page 64 4. Disassembly/Assembly 5. Remove the 4 screws [9] and remove the transport 2. Remove the 2 screws [2], loosen the 4 screws [3] and roller unit. remove the conveyor from the trimmer. [ 9 ] [ 2 ] [ 2 ] [ 3 ] [ 3 ] [ 9 ]...
Page 65 4. Disassembly/Assembly 6. Remove the 4 screws [8] and remove the motor. 9. Remove the screw from shaft L on the operator side. And remove the booklet lifter unit with the belts. NOTE: Connect the wirings referring the wire color shown in the figure above.
Page 66 4. Disassembly/Assembly 5. Remove the 2 screws [3] and remove the sensor. 2. Open the transport belt mechanism [1]. 6. Disconnect the connector. [ 3 ] [ 1 ] 3. Remove the 4 screws [2] and swing the lower infeed guide [3] upward.
Page 67 4. Disassembly/Assembly 3. Move the transport belts [2] sideways. 3. Remove the 4 screws [2] and swing the lower infeed guide [3] upward. • The transport belts are elastic. Stretch the belts and move them off the transport table [3]. 4.
Page 68 4. Disassembly/Assembly 2. Remove the 2 screws [1] and remove the sensor 3. Remove the screws [2] and remove the sensor bracket. bracket. [ 1 ] [ 2 ] [ 1 ] 3. Disconnect the connector. 4. Remove the sensor from the bracket. ■...
Page 69 4. Disassembly/Assembly 4. Stand up the conveyor as shown below, and remove 7. Remove the sensor from the bracket. the lower cover [3]. [ 4 ] [ 7 ] [ 6 ] NOTE: • Before you install the sensor, set the volume for sensitivity and switch for operation mode with a screwdriver.
Page 70 4. Disassembly/Assembly 6. Remove the 2 screws [4] and the bracket. 6. Remove the motor bracket [5]. [ 3 ] [ 4 ] [ 4 ] 7. Remove the motor with pulley from the bracket. NOTE: • The drive belt has a direction to install it. 7.
Page 71: Electrical System
4. Disassembly/Assembly 8. Remove the motor from the bracket. 4. Remove the switch from the bracket. • Pinch both sides of the switch and pull it upward. CAUTION: When reconnecting the wiring, match the numbers on the terminals with the numbers on the cables. [ 4 ] [ 1 ] [ 3 ]...
Page 72 4. Disassembly/Assembly 7. Pull out the connector [6]. 2. Open the chassis. [ 3 ] [ 4 ] [ 5 ] [ 2 ] [ 2 ] [ 2 ] [ 6 ] 3. Disconnect the 2 connectors [1] from the power 8.
Page 73 4. Disassembly/Assembly 3. Remove the trimmer controller PCB from the circuit 3. Stand up the conveyor as shown below, and remove board spacers [2]. the delivery tray [8] and the lower cover [4]. [ 8 ] [ 1 ] [ 2 ] [ 1 ] [ 2 ] [ 2 ]...
Page 74 4. Disassembly/Assembly 5. Remove the stepper motor driver PCB from the 3. Remove the 2 screws [2]. circuit board spacers [6]. • The board bracket is removed. [ 6 ] [ 6 ] [ 1 ] [ 5 ] [ 6 ] [ 6 ] [ 2 ] [ 6 ]...
Page 75 4. Disassembly/Assembly 2. Attach the board to the bracket temporarily. 8. Install the parts in the reverse order from the step 3 in the removal procedures. • Attach the board so that CON512 comes upward. • Attach the board so that it does not run off from the edge of the bracket.
Page 76: Adjustment
Adjustment Service Mode........71 Flat Belts Installing Direction....74 Lower Knife Height Adjustment...75 Upper Knife Upper Limit Sensor PI06 Height Adjustment......76 Trim Section Drive Belt Tension Adjustment........78 Adjusting the Position of Front Cover Switch SW01........79 Stopper Angle Adjustment....80...
Page 77: Service Mode
5. Adjustment 4. Press the "A4" or "LTR" button. Service Mode ADJ-SET When the machine is placed the service mode, you can perform the following: • Home position calibration of the top-bottom guides, stopper and conveyor transport rollers. Each guide moves to the position for LTR size.
Page 78: Setting Position Check
5. Adjustment 8. Press the "cut" button. SUB Menu • The booklet is trimmed and delivered. Single A moment after the Stopper 2070(+000) changeover, the display returns to the Sub Menu NEXT 9. Measure the length of the trimmed and delivered Changeover to the booklet.
Page 79 5. Adjustment SUB Menu Single InfeedTransport Belt NEXT NEXT The belts run, and stop when pressed again. InfeedTransport Hook push NEXT NEXT Infeed T-B guide NEXT Narrow Wide NEXT (by 1 mm) TrimTransportBelt NEXT NEXT The belts run, and stop when pressed again.
Page 80: Flat Belts Installing Direction
5. Adjustment Flat Belts Installing Direction The flat belts have a direction to install them. The direction is shown on the belts by arrow. If you replace one of the flat belts on the rear of the machine, install the belt so that the rotating direction of the belt matches the arrow printed on the belts.
Page 81: Lower Knife Height Adjustment
5. Adjustment 5. Lock the screws [1] on the lower knife, and fasten Lower Knife Height the lock nuts [2] on the adjusting screw. Adjustment When you replace the lower knife, make the following adjustment. NOTE: If the lower knife is not aligned with the bracket, the booklet may be caught and not transported smoothly.
Page 82: Upper Knife Upper Limit Sensor Pi06 Height Adjustment
5. Adjustment ■ Check Upper Knife Upper Limit Sensor PI06 Height 1. Hold down the "INT+" button of the Knife Motor in the test mode. (Refer to “Motion Test” on page Adjustment • Trimming motion is done once, and the upper knife stops at upper position.
Page 83 5. Adjustment 2. Check that the distance between the upper surface of the upper knife stay and the lower knife stay is within the range of 84 to 85 mm. If they are not, adjust them. (See next page.) ■ Adjustment 1.
Page 84: Trim Section Drive Belt Tension Adjustment
5. Adjustment 7. Measure the distance between two black lines again. Trim Section Drive Belt Tension Adjustment In factory setting, the drive belt is stretched by 2.5 to 3.0%. However, the belt tension is decreased in use and the belt is slipped on the pulley.
Page 85: Adjusting The Position Of Front Cover Switch Sw01
5. Adjustment Adjusting the Position of Front Cover Switch SW01 If the actuator [2] is not inserted smoothly into the Front Cover Switch [3] when closing the Front Cover [1], make the following 2 adjustments. 1. Adjusting the Position in Vertical Direction (Front Cover Switch Side) 1.
Page 86: Stopper Angle Adjustment
5. Adjustment 6. Return the trim unit into the trimmer, and do a cutting Stopper Angle Adjustment operation as a test. • If the angle of the stopper still needs adjusting, repeat from step 1. If the front trim width and the rear trim width are not the same, •...
Page 87: Troubleshooting
Troubleshooting Trimming Problems......82 Malfunction..........83 Upgrading the Control Software..85...
Page 88: Trimming Problems
6. Troubleshooting Trimming Problems Skewed Trimming • When the top-bottom guides jog the booklet in the infeed section, is there clearance between the top-bottom guides and the booklet? YES: In the service mode, calibrate the home position of the top-bottom guides. (Refer to “Home Position Calibration”...
Page 89: Malfunction
6. Troubleshooting Malfunction Soiled Booklet/Stacking Fault due to Heavy Stacking at The Conveyer Area • Symptom Depending on the number of sheets or the paper type in a booklet, paper full detection (conveyer area booklet sensor [P113]) may fail despite heavy stacking at the conveyer area, resulting in the possible failure as follows. 1.
Page 90 6. Troubleshooting NOTE: The knurled screws should be attached on the shaft of the transport rollers while the transport rollers are removed. (This prevents the loss of the knurled screws.)
Page 91: Upgrading The Control Software
6. Troubleshooting Upgrading the Control Software Overview In order to upgrade the software which controls the fore-edge trimmer, connect the fore-edge trimmer with the host machine, and connect a PC directly to the fore-edge trimmer. Turn on the power for the fore-edge trimmer from the host machine, and upgrade the program.
Page 92 6. Start up the upgrade program (.exe program), and if necessary, select the communications port to be used for the upgrade. Flash Writer EX Booklet Trimmer-D1 Export Module ID :10150066 This is the upgrading program for Booklet Trimmer-D1. Main Program Version X.XX Boot program download Programming Verify...
Page 93 6. Troubleshooting Error message Cause Corrective Action An error occurred during communication. • After downloading was canceled, • Restart the fore-edge trimmer and re- "START" was clicked without restarting peat the upgrade procedure. the fore-edge trimmer. • A verification error occurred during the •...
Page 94: Error/Jam/Alarm
Error/Jam/Alarm Error Codes.........89 Jam Code..........95...
Page 95: Error Codes
7. Error/Jam/Alarm Error Codes CAUTION: After replacing the trimmer controller PCB, calibrate the home position in the service mode. (Refer to “Home Position Calibration” on page E0005a7-8011: Transport Hook Motor M02 Home Positioning Incompletion • Is there an obstacle which prevents the transport hook from moving? YES: Remove the obstacle.
Page 96: E0005A7-8021: Top-Bottom Guide Motor M03 Home Positioning Incompletion
7. Error/Jam/Alarm • CHECK 3 When the power is turned off, does the transport hook move smoothly by hand? YES: Replace M02. If the error is still not corrected, replace the stepper motor driver PCB QPW-727, and then trimmer controller PCB QPM-220. (Refer to “Trimmer Controller PCB QPM-220”...
Page 97: E0005A7-8033: Trim Section Transport Motor M04 Driver Problem
7. Error/Jam/Alarm E0005a7-8033: Trim Section Transport Motor M04 Driver Problem • Is there a booklet jammed in the trim section? YES: Remove the booklet and close the front cover. • Does the transport roller too much load to rotate? YES: Correct the cause of the overload. No: Replace the driver PCB A04.
Page 98: E0005A7-8052: Stopper Move Motor M06 Remaining In Home Position
7. Error/Jam/Alarm • CHECK 1 Motor M06 is OK. When the stopper is above the stopper home position sensor PI05 (leftmost), does L12 on the trimmer controller PCB QPM-220 light up? YES: PI05 is OK. Replace QPM-220. (Refer to “Trimmer Controller PCB QPM-220” on page 66) If the error is still not corrected, replace the option controller PCB.
Page 99: E0005A7-8062: Conveyor Delivery Roller Positioning Motor M08 Remaining In Home Position
7. Error/Jam/Alarm • CHECK 1 Motor M08 is OK. When the delivery roller is above the delivery roller home position sensor PI14 (rightmost), does L21 on the trimmer controller PCB QPM-220 light up? YES: PI14 is OK. Replace QPM-220. (Refer to “Trimmer Controller PCB QPM-220”...
Page 100: E0005A7-8065: Conveyor Delivery Roller Eeprom Error
7. Error/Jam/Alarm E0005a7-8065: Conveyor Delivery Roller EEPROM Error • Is the error still not corrected after turning off the power of the finisher and turning it on again? YES: Replace the trimmer controller PCB QPM-220. E0005a7-8073: Main Drive Motor M10 Driver Problem •...
Page 101: Jam Code
7. Error/Jam/Alarm Jam Code 11C7: The Booklet Jam Occurs Freguently in Entrance of trim section. • Does The Trim section drive belt slip on the pulley ? YES : Adjust the tension of drive belt. (Refer to “Trim Section Drive Belt Tension Adjustment” on page 11CF: The Booklet Jam Occurs Freguently in Delivery section.
Page 102: Installation
Installation Before Installation....... 97 Unpacking Procedure......99 Installation Procedure....... 105 Adjustments........113...
Page 103: Before Installation
8. Installation Before Installation Checking the Included Parts [10] [11] [12] [13] [10] [14] [15] [16] [17] [18] [19] [20] [21] Booklet Hold Plate 2 pcs Screw for Booklet Hold Plate (W Sems 4 pcs Round End; M4 x 8 mm) Conveyor 1 pc Screws for Conveyor (W Sems Round End;...
Page 104: Selecting The Installation Site
8. Installation In some regions where this product is sold, the following names may be registered instead. F268500 Selecting the Installation Site To confirm the space required for the maintenance operation, refer to the installation procedure of the printer. CAUTION: For the emergency interception, make 1,000 mm or more space at rear and side of the machine.
Page 105: Unpacking Procedure
8. Installation Unpacking Procedure Unpacking Procedure NOTE: When the machine is shipped, it is held in place by tape and padding to protect against vibration and shocks during shipment. Remove all of the tape and padding before installing the machine. Save the removed padding in cace you need to use them again to transport the machine for relocation or repair.
Page 106 8. Installation 1. Open the top of the plastic bag [1], remove 2 belts [2] and remove 2 accessory boxes [3] and wooden blocks [4]. 2. Remove the polystyrenes [2] while lifting the carrying handles [1] up. At this time, pass the plastic bag [3] to the other side.
Page 107 8. Installation 4. Push the slopes [1] up from the space between the wooden pallet, then pull out the slope to the direction shown in the illustration below. Remove the accessory pin [2]. 5. Lock the slopes [2] using the accessory pins [1]. Place 2 wooden blocks [3] under the slopes. 6.
Page 108 8. Installation 8. Remove a protect sheet [1]. 9. Remove the pieces of orange tape shown by arrow. Remove the 2 screws (TP) [1] and open the front cover. Hold the nut [4] from the back of the front cover and remove the screw (W Sems) [3] and the front cover lock plate [2]. 10.
Page 109 8. Installation 11. Remove a piece of padding and pull out the trim unit [1]. 12. Remove 2 vinyl ties and a padding which hold the guide inside the machine, and remove 3 card boards. 13. Pull out the trimmer booklet waste tray [1].
Page 110 8. Installation 14. Remove the pieces of tape on the trimmer booklet waste tray. 15. Set the trimmer booklet waste tray and trim unit inside the machine, and close the covers. 16. Remove the pieces of tape shown by arrow. Remove the carrying handles [1]. Fit the bolt caps [2] into the 2 holes on the left (machine viewed from the front).
Page 111: Installation Procedure
8. Installation Installation Procedure Preparing the Booklet Trimmer 1. Remove the 7 screws (TP) [2] on the rear cover [1]. 2. Loosen the 2 screws (TP) [2] on the rear cover [1] and remove the rear cover [1]. 3. Loosen the 2 screws (TP) [1] and remove the plate [2]. Remove the 4 screws (Binding) [3] and remove the trim section top cover [4].
Page 112 8. Installation 4. Fasten 4 screws (W Sems; M4 x 6 mm) [2] pushing the receiver unit [1] toward left. Then lead the connector cable [3] to the hole on the rear frame [4]. 5. Plug in 3 wiring connectors [1]. 6.
Page 113: Preparing The Stitcher
8. Installation Preparing the Stitcher 1. Remove 2 screws [1] of the stitcher and remove 2 caster covers [2]. 2. Remove 2 screws [1] and pull the saddle stitcher delivery tray [2] looking after a connector [3]. 3. Remove the connector [1] and remove the saddle stitcher delivery tray. 4.
Page 114: Connecting To The Stitcher
8. Installation 5. Pull the booklet press guide [4] and remove it. CAUTION: Booklet press guide may be repositioned when installing the booklet trimmer to the stitcher, and it may cause sheet jam. Make sure to remove the booklet press guide in advance. Connecting to the Stitcher CAUTION: Check that the power switch on the stitcher is turned off, and its power plug is unplugged from the outlet.
Page 115 8. Installation 1. Move the booklet trimmer up against the Stitcher so that the Booklet Trimmer [3] fits into the inner faces of positioning bracket A [1] and positioning bracket B [2], which are already attached to the Stitcher. CAUTION: When you move the Booklet Trimmer, be careful that the top of the bottom plate [1] of the Booklet Trimmer does not hit the bottom plate [2] of the stitcher, and the side frame of the Booklet Trimmer [3] does not hit the positioning bracket [4].
Page 116: Checking The Height And Tilt
8. Installation Checking the Height and Tilt CAUTION: If the booklet trimmer is installed on an uneven floor, you must adjust its height and tilt. If the height and tilt are not adjusted properly, this may cause problems such as sheet jams in the infeed section of the booklet trimmer. Follow the instructions below to check the height and tilt.
Page 117 8. Installation 1. Check the height and tilt of the booklet trimmer. • Measure the gap between the bottom frame of the booklet trimmer and the bottom plate of the stitcher at the 4 points [1] shown below. At each point the gap should be 3 mm (0.12”) to 3.5 mm (0.14”). •...
Page 118 8. Installation 3 mm (0.12”) to 3.5 mm (0.14”) Rear Front 3 mm (0.12”) to 3.5 mm (0.14”) 2. If the height and slant are correct, perform "Check After Adjustment" and the following procedures.(Refer to: “Check After Adjustment” on page 115) If the height or slant needs to be adjusted,proceed to the section of "Adjustments"...
Page 119: Adjustments
8. Installation Adjustments Adjusting the Height and Tilt CAUTION: If the gap between the bottom frame of the booklet trimmer and bottom plate of the stitcher is not 3 mm (0.12”) or if the booklet trimmer is not level, adjust the booklet trimmer using the following procedure. First, adjust the height, and then adjust the tilt.
Page 120 8. Installation 3. Remove the 2 screws (TP) [2] on the small cover [1] on the rear of the machine. Using a 24 mm wrench (0.94”), loosen the lock nut [3] on the caster. ■ Adjusting the Height and Tilt Adjust the height using the 4 casters [1] on the booklet trimmer.
Page 121 8. Installation 3. Install the small cover [1] using 2 screws (TP) [2]. ■ Check After Adjustment 1. Once again check the gap between the bottom frame of the booklet trimmer and the bottom plate of the stitcher, and the tilt of the booklet trimmer. If these are out of specification, adjust them again.
Page 122 8. Installation 3. Loosen the Lock Nut [2], turn the stopper [1] behind the machine until the stopper reaches the floor, and then tighten the Lock Nut [2]. CAUTION: To prevent the machine from moving unexpaectedly, tighten the lock nut [2] completely. ■...
Page 123: Installation After Check/Adjustment
8. Installation 2. Adjusting the Position in Horizontal Direction 1. Loosen the 2 Fixation Screws (W Sems Round End) [5] on the bracket. 2. Keep the Front Cover [1] slightly open, and adjust the position of the Front Cover Switch [3] by moving it from side to side, so that it is aligned with the actuator [2].
Page 124 8. Installation 2. Loosen 4 screws (W Sems Round End) [2] on the booklet trimmer. Install the conveyor [1] and tighten 4 screws (W Sems Round End) [2]. Then install 2 screws (W Sems Round End; M4 × 8mm) [3]. CAUTION: Lift the conveyor when tightening screws.
Page 125 8. Installation 5. Connect the cable [1] of the conveyor to the socket [2], and turn the end of the cable [3] in the direction of the arrow to secure it in place. 6. Install 2 wire holders [1] and lead the cable for the conveyor [2] through the wire holders. When connecting the Booklet Trimmer to the Saddle Finisher - V2/V2L/AB2 Go to step 7.
Page 126 8. Installation 8. Remove 2 screws [1] and remove the Face plate [2](Removed Face Plate is not used). 9. Lead the signal cable [2] through the hole [1]. 10. Install the plate [2] using 2 screws [1] (Which was removed in the step 8). 11.
Page 127 8. Installation 13. Connect the signal cable [1]. CAUTION: Before connecting the signal cable, be sure to turn off the power switch on the stitcher and unplug the power cable from the outlet. Otherwise, there is a risk of an electric shock. -Then, go to step 23.
Page 128 8. Installation 14. When connecting the Booklet Trimmer to the Saddle Finisher-AF2/AJ2/AK2/AM2/AN2 or the Booklet Finisher- F1/Q1/W1 < When the Arcnet Cable is connected > Turn the knob [1] in the finisher side in the direction of the arrow and disconnect the coaxial connector [2]. <...
Page 129 8. Installation 15. Remove the Rear cover [1] of finisher. - 7 screws [2] - 1 screw [3] (Just loosen) 16. Remove the Face plate [1] (Removed Face Plate is not used.) - 2 screws [2] 17. Lead the signal cable [1] through the hole.
Page 130 8. Installation 18. Install the locking plate [1] of signal cable. - Use 2 screws [2] removed in the step 16. 19. Connect the connector [1] with the J113 on PCB, and tie the signal cable [2] with 2 wire saddles [3]. 20.
Page 131 8. Installation 23. Install the caster cover [1] using 2 screws (W Sems; M3 x 6 mm) [2]. 24. Plug in the power cable for the booklet trimmer [1]. 25. Plug in the power cable [1] to the outlet [2] on the stitcher. Install the outlet cover [3] using screw (Binding;M4 x 8) [4](It is required that the optional power unit is already installed to the stitcher.) CAUTION: Check that the power cable is plugged into the outlet completely.
Page 132 8. Installation 26. Open the Front Cover, remove the 2 screws (W Sems) [2], loosen the screw (W Sems) [3], and then remove the Tool Cover [1]. Put away the attached tools (2 wrenches, 1 L-wrench, and 2 thumbscrews) inside the frame, install the Tool Cover [1] with the 2 screws (W Sems) [2] and the screw (W Sems) [3], and then close the Front Cover.
Page 133: Appendices
APPENDICES Service Tools........128 Timing Chart........129 Circuit Diagrams........131...
Page 134: Service Tools
Service Tools Service Tools Solvents Name Purpose Ingredients Remarks Alcohol cleaner Cleaning of belts, plastic Fluorine hydro carbon, al- Keep away from fire. or rubber parts including cohol, surface-active Substitute: IPA (Isopropyl rollers and exterior cov- agent, water alcohol) ers. Lubricating oil Lubrication of drive parts Super Lube Grease (85g)
Page 135: Timing Chart
Timing Chart Timing Chart Trimming Operation ■ When one booklet is trimmed and delivered Descriptions Home Positioning -Top-bottom guide M03 -Transport hook M02 Operation Startup Command -Stopper M06 -Delivery roller M08 Booklet Information Booklet Accept Not Ready Command Changeover (size/thickness/ Booklet Accept Ready Command (M02 / M03 / M06 / M08) trim direction)
Page 136: Pass Through (Without Trimming) Operation
Timing Chart Pass Through (Without Trimming) Operation ■ When one booklet is delivered Descriptions Home Positioning -Top-bottom guide M03 Operation Startup Command -Transport hook M02 -Stopper M06 -Delivery roller M08 Booklet Information Booklet Accept Not Ready Command Changeover (size/thickness/ Booklet Accept Ready Command (M02 / M03 / M06 / M08) trim direction) Booklet Delivery Start Command...
Page 137: Circuit Diagrams
Circuit Diagrams Circuit Diagrams Abbreviations for Signals and Wire Color This chart shows the abbreviations for signals and wire color. Abbreviations Descriptions ALARMOUT Alarm output ALARMRESET Alarm reset clock Pulse output Clockwise Counterclockwise N.C. No connection RUN/BRAKE Drive/Stop RxD* Serial Communication Signal (Input) Signal Voltage SPEEDOUT Speed Output...
Page 138: 120-127Vac / 220-240Vac Circuit Diagram
Circuit Diagrams 120-127VAC / 220-240VAC Circuit Diagram Single Phase 208 to 240VAC Power Supply Customer Power Inlet Circuit Breaker Line Filter CB01 LF01 Interface PCB QPW-908 Relay GND Relay +24VDC...
Page 139: 24 Vdc Circuit Diagram
Circuit Diagrams 24 VDC Circuit Diagram SW01 Front Cover Switch Trim Section Transport SW03 Delivery Section Motor Driver PCB Cover Switch Power Supply Knife Motor Driver PCB Main Drive Motor Driver PCB Trimmer Controller Stepper Motor QPM-220 Driver PCB QPW-727 Short Circuit...
Page 140: I/O Circuit Diagram
Circuit Diagrams I/O Circuit Diagram ■ I/O Circuit Diagram (1/3) Top-Bottom Transport Infeed Section Infeed Section Trim Section Booklet Lifter Upper Knife Stopper Guide Home Trim Section Hook Home Entrance Trim Full Stopper Booklet Exit Booklet Entrance Booklet Delivery Section Trim Box Delivery Section Upper Limit...
Page 141 Circuit Diagrams ■ I/O Circuit Diagram (2/3) Delivery Roller Conveyor Conveyor Section Home Position 100W Belt Motor Booklet Sensor Delivery Sensor Trim Section Knife Motor Main Motor Transport Motor Roller Motor Motor Driver Motor Driver Motor Driver K01_6 K01_2 K01_2 QPM-222_CON4 QPM-222_CON4 QPM-222_CON4...
Page 142 Circuit Diagrams ■ I/O Circuit Diagram (3/3) Stopper Stopper Move Top-Bottom Transport Hook Infeed Belt Open/Close Motor Guide Motor Motor Motor Motor LCD Display Download PCB Input Button PCB QPW-732 QPW-720 Buttons Stepper Motor Driver QPW-727 Trimmer Controller PCB QPM-220...

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