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Ricoh SK5040 Field Service Manual

High capacity stacker
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High Capacity Stacker SK5040
Machine Code: D3DK
Field Service Manual
Ver 1.0
Latest Release: Feb, 2018
Initial Release: Feb, 2018
(c) 2018 Ricoh Co.,Ltd.

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Summary of Contents for Ricoh SK5040

  • Page 1 High Capacity Stacker SK5040 Machine Code: D3DK Field Service Manual Ver 1.0 Latest Release: Feb, 2018 Initial Release: Feb, 2018 (c) 2018 Ricoh Co.,Ltd.
  • Page 3 Symbols, Abbreviations This manual uses several symbols and abbreviations. The meaning of those symbols and abbreviations are as follows: Symbol What it means Clip ring Screw Connector Clamp E-ring Flat Flexible Cable Timing Belt Short Edge Feed Long Edge Feed Black Cyan Magenta...

  • Page 5: Table Of Contents

    Table of Contents Replacement and Adjustment ......................3 Common Procedures ..........................3 Roll-Away Cart D456 .......................... 3 Covers ..............................3 Jogger Unit ............................11 Straight Paper Path ..........................17 Motors ............................... 17 Sensors ............................. 18 Proof Tray ............................. 22 Motors ............................... 22 Sensors .............................
  • Page 6 Sensors ............................. 93 Electrical Components ........................94 Paper Path ............................98 Jogger Unit ............................99 Paper Path ............................100 Paper Path Motors .......................... 100 Paper Path Sensors ........................101 Paper Shift and Alignment ........................102 Paper Shift ............................102 Paper Alignment: Jogging ......................103 Shift Tray Lift and Height Adjustment .....................

  • Page 7: Replacement And Adjustment

    1.Replacement and Adjustment 1. Replacement and Adjustment Common Procedures Roll-Away Cart D456  To prevent damage to the tray switches at the back of the machine, always remove the tray cart before moving the stacker unit.  Always remove the cart before servicing. Open the front door.
  • Page 8 1.Replacement and Adjustment Remove the rear lower cover [A] ( Remove the rear upper cover [A] ( Corner Cover Remove the rear lower cover and rear upper cover (see the previous section). Remove the corner cover [A] ( x4). Left Exit Cover Plate If a peripheral unit has been installed downstream of the stacker, this cover was removed at installation.
  • Page 9 1.Replacement and Adjustment Remove the left exit cover plate [A] ( Left Cover Remove the left exit cover plate (Left Exit Cover Plate) Remove the left cover [A] (  Remove the last screw carefully. The left cover may fall suddenly because there are no hooks holding it in place.
  • Page 10 1.Replacement and Adjustment Pull the door away from the stacker. You may want to re-insert the "L" hinges in their holes so that they do not get misplaced. Front Door Remove the top door (Top Door) Open the front door. Remove the covers [A] ( x2 each)
  • Page 11 1.Replacement and Adjustment Remove screws from the hinge covers [A] ( x1 each). Open the front door so it is at a 90 degree angle to the unit. Slide the hinge cover [A] toward you and remove it. Lift the front door [A] and remove it.
  • Page 12 1.Replacement and Adjustment Front Right Cover Push the front right cover [A] to the right to remove it ( x3). Right Inner Cover Remove the front right cover (Front Right Cover) Remove the top door. (Top Door) Remove the right inner cover [A] ( Front Left Cover Remove the front door (Front...
  • Page 13 1.Replacement and Adjustment Left Inner Cover Remove the front left cover (Front Left Cover) Remove the left inner cover [A] ( Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover  Remove these covers in the following order. ...
  • Page 14 1.Replacement and Adjustment Top Front Cover Remove the right inner cover (Right Inner Cover) Remove the left inner cover (Left Inner Cover) Remove the proof tray Remove the top front cover [A] ( Top Center Cover Remove the proof tray Remove the top front cover...

  • Page 15: Jogger Unit

    1.Replacement and Adjustment Remove the top center cover [A] ( Top Rear Cover Remove the proof tray Remove the top front cover Remove the top center cover Remove the top rear cover [A] ( Jogger Unit Jogger Unit Removal Remove the rear lower cover and rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the right inner cover...
  • Page 16 1.Replacement and Adjustment At the rear, remove three screws and disconnect five connectors ( x5). Remove the center plate [A] and right plate [B] ( x1 each). Remove the four steel jogger unit legs.
  • Page 17 1.Replacement and Adjustment Remove the lock plate [A] ( Disconnect the jogger unit ( x3). The jogger unit is held in place by four hooks. It will not fall after the screws have been removed. Screw each leg removed in step 6 into the bottom of the jogger unit. 10.
  • Page 18 1.Replacement and Adjustment 12. Slowly lower the jogger unit to the right and pull it out of the stacker. 13. Set the jogger unit on a flat surface. Main Jogger Cover Plate The main jogger cover plate must be removed to service these parts: ...
  • Page 19 1.Replacement and Adjustment Rear Disconnect the dual harness [A] for the main jogger fence retraction HP sensor and front fence HP sensor ( x3, x6). Front Disconnect the front fence motor harness [A] ( x2). Remove the plate: [A] Front ( [B] Rear (...
  • Page 20 1.Replacement and Adjustment...

  • Page 21: Straight Paper Path

    1.Replacement and Adjustment Straight Paper Path Motors Entrance Motor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the motor bracket [A] ( Separate the entrance motor and the bracket ( x2).

  • Page 22: Sensors

    1.Replacement and Adjustment Remove the motor bracket [A] ( Separate the transport motor and the bracket ( Sensors Entrance Sensor The entrance sensor is on the right side of the stacker. Remove the sensor bracket [A] (...
  • Page 23 1.Replacement and Adjustment Remove the entrance sensor [A] ( x1, x4) Transport Sensor You can see the sensor bracket on the bottom of the transport plate from inside the stacker. Preparation  Remove the jogger unit (Jogger Unit Removal)
  • Page 24 1.Replacement and Adjustment Remove the sensor bracket [A] ( Remove the sensor plate [A] ( Remove the transport sensor [B] ( x1, x4) Exit Sensor Preparation  Remove the Left Exit Cover Plate (Left Exit Cover Plate) Note: The illustration below shows the left cover removed, but this is not required. Remove the sensor bracket [A] (...
  • Page 25 1.Replacement and Adjustment Remove the exit sensor [A] (...

  • Page 26: Proof Tray

    1.Replacement and Adjustment Proof Tray Motors Proof Tray JG Motor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the proof tray JG motor [A] ( Proof Tray Exit Motor Preparation Remove these parts:...

  • Page 27: Sensors

    1.Replacement and Adjustment Separate the proof tray exit motor and the bracket ( Sensors Proof Tray JG HP Sensor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the sensor bracket [A] (...
  • Page 28 1.Replacement and Adjustment Remove the proof tray JG HP sensor [B] ( x1, x5) Proof Tray Exit Sensor, Proof Tray Full Sensor Proof Tray Full Sensor Located above the proof tray. Proof Tray Exit Sensor Shown with the top center cover removed. Preparation Remove these parts: ...
  • Page 29 1.Replacement and Adjustment Pull away the plate [A] ( x1, x4). Remove the tray full sensor, or the tray exit sensor. See below. Tray Full Sensor Turn the plate over. Remove the sensor bracket [A] (...
  • Page 30 1.Replacement and Adjustment Remove the proof tray full sensor [A] ( x1, Tray Exit Sensor Remove the sensor bracket [A] ( Remove the lower screw, not the upper screw. Remove the proof tray exit sensor [A] ( x1, x5)

  • Page 31: Shift Tray

    1.Replacement and Adjustment Shift Tray Paper Shift Operation Shift Tray JG Motor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the shift tray JG motor [A] ( Shift Tray JG HP Sensor Preparation Remove these parts:...
  • Page 32 1.Replacement and Adjustment Remove the shift tray JG HP sensor [B] ( x1, x5) Shift Motor, Shift HP Sensor Shift Motor Shift HP Sensor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Common...
  • Page 33 1.Replacement and Adjustment Disconnect the motor bracket [A] ( x2, x1). Remove the motor bracket [A] ( x2). Shift Motor...
  • Page 34 1.Replacement and Adjustment Separate the bracket and the shift motor ( Shift HP Sensor Remove the shift HP sensor [A] ( Shift Exit Motor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover)
  • Page 35 1.Replacement and Adjustment Remove the vertical plate [A] ( Remove the belt cover plate [A] ( Remove the plate [A] (...
  • Page 36 1.Replacement and Adjustment Disconnect the motor bracket [A] ( Push the shaft [A] out of the hole and remove the motor bracket [B]. Separate the shift exit motor and the bracket ( Shift Tray Exit Unit Preparation Remove these parts: ...
  • Page 37 1.Replacement and Adjustment  Rear upper cover (Rear Lower Cover, Rear Upper Cover)  Jogger unit (Jogger Unit Removal) Common Remove the plate [A] ( Release the clamp and disconnect the five connectors as shown and noted below. ( x1, Disconnect the white and gray harness connectors, and the three purple harness connectors (twelve, seven, and four pins) as shown in the diagram below.
  • Page 38 1.Replacement and Adjustment Release the six clamps. ( x6) Remove the inner cover [A]. ( Remove the bracket [A]. (...
  • Page 39 1.Replacement and Adjustment Remove the shift tray exit unit [A]. (...
  • Page 40 1.Replacement and Adjustment Shift Tray Exit Sensor Remove the shift tray exit unit. (Shift Tray Exit Unit) Use a short screwdriver to remove the sensor bracket [A] ( Remove the shift tray exit sensor [A] ( Shift Tray Exit Fan, Shutter Motor, Shutter Home Position Sensor, Paper Height Sensor (Inside the Paper Exit Unit) Remove the shift tray exit unit.
  • Page 41 1.Replacement and Adjustment Remove four screws as shown below. ( The diagram below shows the locations of these components in the shift tray exit unit. [A] Shift Tray Exit Fan [B] Shutter Motor [C] Shutter Home Position Sensor [D] Paper Height Sensor Shift Tray Exit Fan Remove the screws and connector of each of the fans, and then, if necessary, release the clamp.
  • Page 42 1.Replacement and Adjustment Shutter Motor Remove and disconnect the belt and connector, and then remove the screws. (...
  • Page 43 1.Replacement and Adjustment Shutter Home Position Sensor Disconnect the connector and release the hooks. ( Paper Height Sensor Disconnect the connector and release the hooks. (...

  • Page 44: Paper Jogging

    1.Replacement and Adjustment Paper Jogging Main Jogger Front Fence Motor, Front Fence HP Sensor Main Jogger Front Fence Motor Main Jogger Front Fence HP Sensor Preparation Remove these parts:  Jogger unit (Jogger Unit Removal)  Main jogger cover plate (Main Jogger Cover Plate) Front Fence Motor...
  • Page 45 1.Replacement and Adjustment Separate the front fence motor and the bracket ( Front Fence HP Sensor Remove the front fence HP sensor [A] ( x5)
  • Page 46 1.Replacement and Adjustment Main Jogger Rear Fence Motor, Rear Fence HP Sensor Main Jogger Rear Fence Motor Main Jogger Rear Fence HP Sensor Preparation Remove these parts:  Jogger unit (Jogger Unit Removal)  Main jogger cover plate (Main Jogger Cover Plate) Rear Fence Motor Remove the motor bracket [A] (...
  • Page 47 1.Replacement and Adjustment Separate the rear fence motor and the bracket ( Rear Fence HP Sensor Remove the rear fence HP sensor [A] ( x5) Main Jogger Fence Retraction Motor, Fence Retraction HP Sensor Preparation...
  • Page 48 1.Replacement and Adjustment Remove these parts:  Jogger unit (Jogger Unit Removal) Fence Retraction Motor Disconnect the dual harness [A] for the main jogger fence retraction HP sensor and front fence HP sensor ( x3, x6). Front Remove the motor bracket [A] (...
  • Page 49 1.Replacement and Adjustment Separate the fence retraction motor and the bracket ( Fence Retraction HP Sensor Remove the motor bracket Remove the fence retraction HP sensor [A] ( x5) LE Stopper Motor, LE Stopper HP Sensor LE Stopper Motor LE Stopper HP Sensor...
  • Page 50 1.Replacement and Adjustment Preparation Remove these parts:  Jogger unit (Jogger Unit Removal) LE Stopper Motor Remove the motor bracket [A] ( Separate the LE stopper motor and the bracket ( LE Stopper HP Sensor Remove the sensor [A] ( x1, x5)
  • Page 51 1.Replacement and Adjustment Sub Jogger Motor Preparation  Jogger unit (Jogger Unit Removal) Disconnect these harnesses: [A] Sub jogger fence HP sensor ( x1, x1) [B] Tray guard sensor 1 ( x1, x1) [C] Tray guard sensor 2 ( x1, x1) [D] Sub jogger motor ( x1, x1)
  • Page 52 1.Replacement and Adjustment Remove the cover [A] ( Remove the sub jogger motor [A] ( x2, Belt x1, Sub Jogger HP Sensor Preparation  Jogger unit (Jogger Unit Removal)

  • Page 53: Shift Tray Lift Control

    1.Replacement and Adjustment Disconnect pulley [A] and belt ( x1, Pulley x1, Belt x1). Remove the sub jogger HP sensor [A] ( x1, x5) Shift Tray Lift Control Roll Away Cart Set Switch...
  • Page 54 1.Replacement and Adjustment Preparation Remove these parts:  Cart (Roll-Away Cart D456)  Rear lower cover (Rear Lower Cover, Rear Upper Cover) At the rear, disconnect the connector [A] ( x1). At the inside, remove the switch with the bracket [A] ( x2).
  • Page 55 1.Replacement and Adjustment Shift Tray Paper Sensor Preparation Remove these parts:  Jogger unit (Jogger Unit Removal)  Main jogger cover plate (Main Jogger Cover Plate) Disconnect sensor bracket [A] and rails x4). Slide the rails to the rear. Remove the shift tray paper sensor [B] ( x1, x5)
  • Page 56 1.Replacement and Adjustment Tray Lift Motor Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) Remove the vertical plate [A] ( Remove the belt cover plate [A] (...
  • Page 57 1.Replacement and Adjustment Remove the tray lift motor [A] ( Re-installation Whenever the belt cover plate has been removed, you should check and re-set the tension of the transverse belt before re-attaching the belt cover plate. Remove the spring [1]. Loosen screw [2] (do not remove it) to raise the tension bracket to the left.
  • Page 58 1.Replacement and Adjustment Make sure the bearings are snug in the holes. Attach screws and tighten. Attach screws but do not tighten. Re-attach the removed spring Above the spring, pull the tension bracket down [1] as far as it will go, and tighten the tension screw [2]...
  • Page 59 1.Replacement and Adjustment Tighten all the screws ( x8). Paper Height Sensor The paper height sensor is mounted on the same bracket as the shift entrance sensor. For details about this procedure, please refer to Shift Tray Exit Sensor, Paper Height Sensor (after the Shift Tray Exit Unit removal procedure).
  • Page 60 1.Replacement and Adjustment Disconnect the tray high limit switch [A] ( x1, x1) Remove the tray high limit switch [A] ( x2). Tray Guard Sensors 1, 2 Preparation  Jogger unit (Jogger Unit Removal) Tray Guard Sensor 1...
  • Page 61 1.Replacement and Adjustment Remove tray guard sensor 1 [A] ( x1, x3) Tray Guard Sensor 2 Remove tray guard sensor 2 [A] ( x1, x3) Tray Full Sensors 1, 2, 3, 4 There are four tray full sensors mounted on the same vertical support.
  • Page 62 1.Replacement and Adjustment Tray Full Sensor 1: 25% Tray Full Sensor 2: 50% Tray Full Sensor 3: 75% Tray Full Sensor 4: 100% Preparation Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover) ...
  • Page 63 1.Replacement and Adjustment The pawls of these sensors are visible behind the frame ( x1, x5 each) Tray Full Sensor 4 See the next procedure below. Tray Full Sensor 4, Tray Low Limit Sensor, Tray Low Limit Switch Tray Full Sensor 4 100% Tray Low Limit Sensor Tray Low Limit Switch Preparation...
  • Page 64 1.Replacement and Adjustment Remove the switch bracket [A] ( x1, ground screw x1, x2) Remove the cover plate [A] ( Remove (in any order):  Tray full sensor 4 [A] ( x1, x5)  Tray low limit sensor [B] ( ...

  • Page 65: Shift Tray Level Adjustment

    1.Replacement and Adjustment Shift Tray Level Adjustment The shift tray timing belts can be adjusted to ensure that the shift tray is level:  Front-to-rear. This adjustment is done first.  Left-to-right. This adjustment is done after front-to-rear adjustment.  Always do the front-to-rear adjustment first on both sides and then do the left-to-right adjustment.
  • Page 66 1.Replacement and Adjustment If they are not at the same level, do the front-to-rear adjustment, then the left-to-right adjustment. Front-to-Rear Adjustment Right Side Remove:  Top door (Top Door)  Front right cover (Front Right Cover)  Right inner cover (Right Inner Cover) Remove the right vertical stay [A] (...
  • Page 67 1.Replacement and Adjustment Adjust the belt:  If the front end is low, pull up the left side of the belt [1] to raise the front.  If the front end is high, pull up the right side of the belt [2] to lower the front. ...
  • Page 68 1.Replacement and Adjustment Left Side Remove:  Top door (Top Door)  Front door (Front Door)  Front left cover (Front Left Cover) Loosen the tension on the belt:  Loosen tension screw [A].  The tension bracket [B] will rise. ...
  • Page 69 1.Replacement and Adjustment Set the belt tension:  Loosen screw [A].  Pull down the spring [B] to apply tension to the belt.  Tighten screw [A] with the bracket down. Left-to-Right Adjustment Check the markings on the tray brackets to determine if the tray is slanting to the left or right. Remove: ...
  • Page 70 1.Replacement and Adjustment Remove the vertical plate [A] ( Remove the belt cover plate [A] ( Release the tension on the timing belt:  Remove spring [1].  Loosen tension screw [2].  Slide bracket [3] up to the left. Adjust the belt position:...
  • Page 71 1.Replacement and Adjustment  To lower the right side of the tray below the stacker entrance, pull the belt in the direction of the arrow at [A] while rotating the top of the tray lift motor [B] counter-clockwise.  To raise the right side of the tray below the stacker entrance, pull the belt in the direction of the arrow at [A] while rotating the top of the tray lift motor [B] clockwise.
  • Page 72 1.Replacement and Adjustment Loosen screw [2] (do not remove it) to raise the tension bracket to the left. Hang the belt cover plate [A] on the hook Make sure the bearings are snug in the holes. Attach screws and tighten. Attach screws but do not tighten.

  • Page 73: Paddle Roller

    1.Replacement and Adjustment Above the spring, pull the tension bracket down [1] as far as it will go, and tighten the tension screw [2] Tighten all the screws ( x8). Paddle Roller Paddle Roller Cleaning Preparation  Open the front door ...

  • Page 74: Cleaning The Exit/Shift Rollers And Shafts

    1.Replacement and Adjustment You can see the paddles at six locations behind on the right side between the jogger fences. Use a dry cloth to clean: [A]: Top and bottom surfaces of each paddle [B]: Tip of each paddle Rotate the exit roller [A] to expose the next paddle [B]. Repeat steps 1 and 2 at each location until all the paddles have been cleaned.
  • Page 75 1.Replacement and Adjustment You can see the roller shaft exposed at six cutouts above the paddles of the paddle roller. Use a soft dry cloth to clean the shaft. Rotate the exit roller [A] and push it from side to side while holding the cloth in place. Repeat steps 1 and 2 at each location.

  • Page 76: Anti-Static Brush Replacement

    1.Replacement and Adjustment Clean the rollers [A] and [B]. Anti-Static Brush Replacement Preparation  Open the front door  Remove the roll-away cart (Roll-Away Cart D456) Remove the anti-static brush [A].

  • Page 77: Switches, Solenoid

    1.Replacement and Adjustment Switches, Solenoid Door Switches Front Door Switch Preparation Remove these parts:  Top front cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover)  Top center cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover) Loosen the connectors [A] ( Depress the releases [B] on both sides of the switch and remove the switch (...
  • Page 78 1.Replacement and Adjustment Top Door Switch Preparation Remove these parts:  Top front cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover)  Top center cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover) Remove the bracket [A] ( x4,...

  • Page 79: Front Door Lock Solenoid

    1.Replacement and Adjustment Disconnect the connector [A] ( Depress the release [A] then remove the switch [B]. Front Door Lock Solenoid Preparation  Open the front door  Remove the front right cover (Front Right Cover)
  • Page 80 1.Replacement and Adjustment Remove the right vertical stay [A] ( Remove the cover plate [A] from the right vertical stay ( x1, x2, x2). Turn the right vertical stay over and then remove two screws ( x2).
  • Page 81 1.Replacement and Adjustment Turn the right vertical stay over again and then remove the front door lock solenoid [A].

  • Page 82: Fans

    1.Replacement and Adjustment Fans Cooling Fan Motor for Paper Transport Motors Preparation  Remove the rear lower cover and rear upper cover. (Rear Lower Cover, Rear Upper Cover) Remove the cooling fan motor with the bracket ( x1). Remove the cooling fan motor ( Cooling Fan for Entrance Motor Remove the rear lower cover and rear upper cover.

  • Page 83: Paper Cooling Fan Motors

    1.Replacement and Adjustment Remove the cooling fan motor with the bracket. ( x1 , x1 , Remove the cooling fan motor. ( Paper Cooling Fan Motors Below the stacker entrance, three fan motors are mounted on the same plate:  Fan Motor 1 ...
  • Page 84 1.Replacement and Adjustment Remove these parts:  Rear lower cover (Rear Lower Cover, Rear Upper Cover)  Rear upper cover (Rear Lower Cover, Rear Upper Cover)  Right inner cover (Right Inner Cover)  Top center cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover) Remove the plate [A] ( Disconnect the motor mount.
  • Page 85 1.Replacement and Adjustment Front ( Rear ( Raise the cover plate [A] as high as possible. Disconnect the harnesses and fans to clear the area in front of the motor mount [B] ( x9, x3).
  • Page 86 1.Replacement and Adjustment Disconnect the entrance sensor bracket [A] and pull it aside ( x1, x3) Disconnect the front door switch bracket [A] to create some slack in the white harness ( x2, x2) Disconnect the tray high limit switch harness ( x1, x2).
  • Page 87 1.Replacement and Adjustment Pass the paper cooling fan motor harnesses, entrance sensor harness and tray high limit switch harness through the hole to the rear side. 10. Pass the harnesses [A][B][C] from the rear side through the hole to the right side ( x3).
  • Page 88 1.Replacement and Adjustment 11. Pull out the fan motor mount [A] ( x2). 12. Remove each of the fan motors ( x2 each)

  • Page 89: Boards

    1.Replacement and Adjustment Boards Main Board Preparation  Remove the rear lower cover (Rear Lower Cover, Rear Upper Cover) Remove the stay [A] ( Remove the main board [A] ( x all,...

  • Page 90: Psu

    1.Replacement and Adjustment  Do not touch solder connections or electronic parts on the PSU after removing it because electrical charge can remain on the PSU even after it has been removed.  After removing the PSU, never place put it on a conductive material such as metal. Preparation ...

  • Page 91: Operation Panel Pcb

    1.Replacement and Adjustment Operation Panel PCB Preparation  Remove the top front cover (Proof Tray, Top Front Cover, Top Center Cover, Top Rear Cover) Turn over the top front cover. Remove the cover [A] ( Remove the operation panel PCB [B] ( x1).

  • Page 92: Registration Adjustment / Skew Correction

    1.Replacement and Adjustment Registration Adjustment / Skew Correction Before the adjustment, when you undock the stacker from the upstream unit, be sure to remove the roll- away cart from the stacker. Otherwise, the cart set switch can be damaged. Skew Check Let the main machine feed A3 or 11"x17"...

  • Page 93: Skew Correction

    1.Replacement and Adjustment screw. ( Loosen the screws on the docking bracket and slide the bracket to adjust the registration, and then secure the screws. ( Dock the stacker to the docking bracket and check the registration. If the skew is 1 or more division, do the adjustment procedure again.
  • Page 94 1.Replacement and Adjustment Remove the right front cover ( x3). Remove the spacers ( x1). [A]: Spacer Loosen the screws on the docking bracket and insert the spacer under the end (either the right or left end) of the docking bracket. Then, secure the docking bracket.
  • Page 95 1.Replacement and Adjustment [A]: Upstream unit [B]: Docking bracket The thickness of the spacer is 2mm. Insert the required number of spacers (up to 2). Dock the stacker to the docking bracket and check the skew. If the skew is 1 or more division, do the adjustment procedure again.

  • Page 96: Detailed Descriptions

    2.Detailed Descriptions 2. Detailed Descriptions Overview Main Motors Name Name Cooling Fan Motor for Paper Transport Motors Paper Cooling Fan Motor 1 / 2 / 3 Transport Motor Shift Tray Exit Fan 1 / 2 / 3 / 4 Proof Tray Exit Motor Main Jogger Fence Retraction Motor Main Jogger Rear Fence Motor Shutter Motor...

  • Page 97: Sensors

    2.Detailed Descriptions Name Name Entrance Motor LE Stopper Motor Shift Tray JG Motor Sensors Transport Name Name Exit Sensor Shift Tray Paper Sensor Transport Sensor Shift Tray Exit Sensor Proof Tray Full Sensor Entrance Sensor Proof Tray Exit Sensor Paper Height Sensor...

  • Page 98: Electrical Components

    2.Detailed Descriptions Mechanism Name Name LE Stopper HP Sensor Front Door SW Sub Jogger HP Sensor Shutter Home Position Sensor Top Door SW Tray High Limit SW Tray Guard Sensor 2 Roll Away Cart Set SW Tray Guard Sensor 1 Tray Low Limit SW Rear Fence HP Sensor Tray Low Limit Sensor...
  • Page 99 2.Detailed Descriptions Motors Transport Motor Drives the transport rollers that feed paper through the finisher between the entrance and the exit. Shift Exit Motor Drives the shift exit rollers that output paper to the shift tray. Shift Motor Moves the shift roller set (drive roller and idle roller) to the front and back. For every other document set, the shift roller will take each sheet of paper and move it to the front so every other stack is staggered.
  • Page 100 2.Detailed Descriptions Motors Fan Motor 3 Cooling Fan for Cools the entrance motor. Entrance Motor Shutter Motor Switches the shutters for the shift tray exit fans on/off. Shift Tray Exit When thin or coated paper is used, this fan assists in preventing the paper from getting buckled while the paper stacks up on the shift tray.
  • Page 101 2.Detailed Descriptions Sensors Transport Sensor Monitors the passage of each sheet of paper in the feed path between the entrance and exit of the stacker. LE Stopper HP Detects the leading edge stopper when it reaches its home position and Sensor switches off the LE stopper motor Sub Jogger HP...

  • Page 102: Paper Path

    2.Detailed Descriptions Switches to shut it off. Roll Away Cart Detects when the tray cart is in the stacker. If the tray cart is not set inside the Set SW stacker, the power supply to the tray lift motor and the stacker drive system remains off.

  • Page 103: Jogger Unit

    2.Detailed Descriptions Jogger Unit Name Name Main Jogger Rear Fence Motor Tray Guard Sensor 1 Rear Fence HP Sensor Sub Jogger Fence Motor Shift Tray Paper Sensor LE Stopper HP Sensor Main Jogger Front Fence Motor LE Stopper Motor Front Fence HP Sensor Sub Jogger Fence HP Sensor Main Jogger Fence Retraction HP Sensor Tray Guard Sensor 2...

  • Page 104: Paper Path

    2.Detailed Descriptions Paper Path Paper Path Motors These are the motors that drive the rollers of the stacker:  [1] Entrance motor. Drives the entrance rollers and other transport rollers that feed the paper straight through the stacker to the transport motor. ...

  • Page 105: Paper Path Sensors

    2.Detailed Descriptions paper passes over the junction gate into the paper path for the proof tray [7] above. The proof tray exit motor [8] drives the rollers in the paper path to the proof tray. When the proof tray junction gate is open, the paper passes below the junction gate towards the stacker exit.

  • Page 106: Paper Shift And Alignment

    2.Detailed Descriptions Paper Shift and Alignment Paper Shift In the shift mode, the paper is fed past the open shift tray junction gate and onto the shift tray. When the first set starts to feed:  The leading edge of the paper is fed into the nip of the shift rollers (drive and idle roller pair.) ...

  • Page 107: Paper Alignment: Jogging

    2.Detailed Descriptions  The amount of shift from the center is fixed at 10 mm. (This cannot be adjusted.) Paper Alignment: Jogging Leading Edge To keep the leading edges of the stacks aligned:  At the start of a job in the shift mode, the LE stopper motor [1] switches on. ...
  • Page 108 2.Detailed Descriptions Part Name LE Stopper Motor LE Stopper HP Sensor...
  • Page 109 2.Detailed Descriptions Main, Sub Jogger The following parts comprise the main jogger which operates the front fence and rear fence [1] Front fence motor [2] Front fence HP sensor [3] Rear fence motor [4] Rear fence HP sensor The movements of the front fence and rear fence during jogging (paper edge alignment) are controlled independently by two separate motors.
  • Page 110 2.Detailed Descriptions Jog points: Smaller Than 300 mm The jogger unit uses only the main jogger to align paper sizes smaller than 300 mm. The sub jogger does not operate. Set 1  The shift motor switches on and off, moving the shift rollers and each sheet 10 mm to the rear. ...
  • Page 111 2.Detailed Descriptions Jog points: 300 mm and Larger The jogger unit uses both the main jogger and one fence of the sub jogger to align paper of sizes 300 mm and larger. Set 1  The set (red above) is shifted and output to the tray. ...

  • Page 112: Shift Tray Lift And Height Adjustment

    2.Detailed Descriptions Shift Tray Lift and Height Adjustment Item Tray Lift Motor Shift Tray Shift Tray Paper Sensor (in jogger unit) Paper Height Sensor Tray High Limit Switch (micro-switch) Tray Guard Sensors 1, 2 Tray Full Sensors 1, 2, 3, 4 (25%, 50%, 75%, 100%) Tray Low Limit Sensor Tray Low Limit Switch (micro-switch) Sensor, Switch Summary...
  • Page 113 2.Detailed Descriptions There are two tray guard sensors [6] mounted side by side in the jogger unit. Each sensor is mounted above a swinging plate with an actuator on top. If the top of the stack pushes up either plate far enough to activate either sensor, this will shut down operation of the stacker immediately.

  • Page 114: Air Assistance

    2.Detailed Descriptions Air Assistance The paper exit for the shift tray has four air nozzles. From these nozzles, the shift exit fans [A] blow into the space between the ejected paper and the stacked paper in order to make an air layer there. This prevents the ejected sheet, especially thin paper, from getting buckled.
  • Page 115 2.Detailed Descriptions Related SP SP Name SP No. Option Stacker1 Air Assist Vol Adj SP6-605-001 : A3 SEF [0]: High -002: B4 SEF [1]: Low -003: A4 SEF [2]: Off (Default) -004: A4 LEF -005: A5 SEF -006: A5 LEF -007: B5 SEF -008: B5 LEF -009: DLT SEF...
  • Page 116 2.Detailed Descriptions SP Name SP No. Option -011: LT SEF -012: LT LEF -013: HLT SEF -014: HLT LEF -015: Other Stacker2 Air Assist Vol Adj SP6-611-001: A3 SEF [0]: High -002: B4 SEF [1]: Low -003: A4 SEF [2]: Off (Default) -004: A4 LEF -005: A5 SEF -006: A5 LEF...

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