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Ricoh FD5000 Manual

Ricoh FD5000 Manual

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Multi Folding Unit FD5000
Machine Code: D454-17
January 2009

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Summary of Contents for Ricoh FD5000

  • Page 1 Multi Folding Unit FD5000 Machine Code: D454-17 January 2009...

  • Page 3: Safety, Conventions, Trademarks

    Safety, Conventions, Trademarks Conventions Common Terms This is a list of symbols and abbreviations used in this manual. Symbol What it means  Core Tech Manual  Screw  Connector  E-ring  C-ring  Harness clamp Flexible Film Cable Junction Gate Leading Edge of paper Long Edge Feed...

  • Page 4: Warnings, Cautions, Notes

    The notations "SEF" and "LEF" describe the direction of paper feed, with the arrows indicating paper feed direction. Warnings, Cautions, Notes In this manual, the following important symbols and notations are used. • A Warning indicates a potentially hazardous situation. Failure to obey a Warning could result in death or serious injury.

  • Page 5: Responsibilities Of The Customer Engineer

    Safety During Operation In this manual, the following important symbols and notations are used. Switches and Symbols Where symbols are used on or near switches on machines for Europe and other areas, the meaning of each symbol conforms with IEC60417. Responsibilities of the Customer Engineer Reference Material for Maintenance •...

  • Page 6: Before Installation, Maintenance

    Before Installation, Maintenance Power • Always disconnect the power plug before doing any maintenance procedure. After switching off the machine, power is still supplied to the main machine and other devices. To prevent electrical shock, switch the machine off, wait for a few seconds, then unplug the machine from the power source. •...

  • Page 7: During Maintenance

    During Maintenance General • Before you begin a maintenance procedure: 1) Switch the machine off, 2) Disconnect the power plug from the power source, 3) Allow the machine to cool for at least 10 minutes. • Avoid touching the components inside the machine that are labeled as hot surfaces. Safety Devices •...

  • Page 8: After Installation, Servicing

    Ozone Filters • Always replace ozone filters as soon as their service life expires (as described in the service manual). • An excessive amount of ozone can build up around machines that use ozone filters if they are not replaced at the prescribed time. Excessive ozone could cause personnel working around the machine to feel unwell.

  • Page 9: Safety Instructions For This Machine

    • To protect the environment, never dispose of this product or any kind of waste from consumables at a household waste collection point. Dispose of these items at one of our dealers or at an authorized collection site. Points to Confirm with Operators At the end of installation or a service call, instruct the user about use of the machine.
  • Page 10 • Dust • Water • Direct sunlight • Open flame • Corrosive gases Trademarks • Microsoft®, Windows®, and MS-DOS® are registered trademarks of Microsoft Corporation in the United States and /or other countries. ® • PostScript is a registered trademark of Adobe Systems, Incorporated. ®...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS Safety, Conventions, Trademarks........................1 Conventions..............................1 Warnings, Cautions, Notes...........................2 General Safety Instructions..........................2 Responsibilities of the Customer Engineer....................3 Before Installation, Maintenance........................4 During Maintenance............................5 After Installation, Servicing..........................6 Safety Instructions for this Machine.......................7 1. Replacement and Adjustment Exterior and Inner Covers..........................13 Front Door Upper Cover..........................13 Top Cover..............................14 Inner Upper Cover............................15 Front Door..............................15...
  • Page 12 Registration Roller Transport Motor......................29 Electrical Components: 1st Stopper........................31 Fold Plate Motor............................31 Direct-Send JG Motor..........................31 1st Fold Motor..............................33 FM6 Pawl Motor............................33 2nd Fold Motor............................34 Jogger Fence Motor............................35 1st Stopper Unit............................36 Positioning Roller Motor..........................39 1st Stopper Motor............................40 Jogger Fence HP Sensor..........................40 Positioning Roller HP Sensor........................42 1st Stopper Paper Sensor..........................42 1st Stopper HP Sensor..........................43 Registration Sensor............................44...
  • Page 13 Top Tray Exit Sensor............................62 Electrical Components: Main 1........................64 Top Tray Full Sensor (E)..........................64 Top Tray Full Sensor (R)..........................65 Vertical Path Paper Sensor..........................65 Horizontal Path Paper Sensor........................66 Horizontal Path Exit Sensor.........................67 Discharge Brush 1............................68 Discharge Brush 2............................69 Discharge Brush 3............................70 PSU................................70 First Fold Unit..............................71 Dynamic Roller HP Sensor..........................74 Electrical Components: Main 2........................76...
  • Page 14 Stopper Locations............................135 Folding Methods............................135 Crease Rollers............................144 Tray Full................................145 Electrical Components...........................146 Transport Sensors............................146 Operation Sensors............................147 Motors, Solenoids.............................148 Paper Transport Motors..........................149 Fold Motors..............................150 Motors, Solenoids Around the Top Tray....................151 Motors, Sensors Top..........................152 Motors, Sensors Bottom..........................153 Sensors Around Top Tray.........................154 Fold Motors, Sensors, Solenoids......................155 Boards, Switches, Fan..........................157 Component List............................157...

  • Page 15: Replacement And Adjustment

    1. Replacement and Adjustment Exterior and Inner Covers Front Door Upper Cover 1. Open the front door [A]. 2. Hinge cover [A] ( x 1)

  • Page 16: Top Cover

    1. Replacement and Adjustment 3. Cross-piece [A] ( x 2) 4. Front door upper cover [A] ( x 2) Top Cover 1. Open the front door. 2. Hinge cover (* p.13 "Front Door Upper Cover") 3. Cross-piece (* p.13 "Front Door Upper Cover")

  • Page 17: Inner Upper Cover

    Exterior and Inner Covers 4. Top cover [A] ( x 2) Inner Upper Cover 1. Top cover (* p.14) 2. Remove the knobs [A] ( x 1 each). 3. Inner upper cover [B] ( x 2) • Release the hooks [C] to remove the inner upper cover. Front Door 1.

  • Page 18: Folding Unit Cover

    1. Replacement and Adjustment 3. Remove the screw [A]. 4. Loosen three screws [B]. 5. Lift up the hinge bracket [C]. 6. Front door [D] Folding Unit Cover 1. Open the front cover. 2. Remove the knob [A] ( x 1). 3.

  • Page 19: Rear Upper Cover

    Exterior and Inner Covers 2. Inner lower cover [A] ( x 1, hook) Rear Upper Cover 1. Rear upper cover [A] ( x 4) Rear Lower Cover 1. Rear upper cover (* p.17)

  • Page 20: Top Rear Cover

    1. Replacement and Adjustment 2. Rear lower cover [A] ( x 3) Top Rear Cover 1. Rear upper cover (* p.17) 2. Top rear cover [A] ( x 4) Top Tray 1. Top rear cover (* p.18) 2. Inner upper cover (* p.15)

  • Page 21: Top Tray Right Cover

    Exterior and Inner Covers 3. Release the hook [A], and remove the top tray [B] ( x 1). Top Tray Right Cover 1. Top tray (* p.18) 2. Top tray right cover [A] ( x 1)

  • Page 22: Pulling Out The Folding Unit Drawer

    1. Replacement and Adjustment Pulling Out the Folding Unit Drawer 1. Open the front door [A] 2. Pull out the folding unit drawer [B].

  • Page 23: Electrical Components: Rear Side

    Electrical Components: Rear Side Electrical Components: Rear Side Main Board 1. Rear upper cover ( p.17) 2. Main board [A] ( x all, x 7) Horizontal Transport Motor 1. Rear upper cover ( p.17) 2. Top rear cover ( p.18)

  • Page 24: Top Tray Exit Motor

    1. Replacement and Adjustment 3. Horizontal transport motor bracket [A] ( x 1, x 2) 4. Horizontal transport motor [A] ( x 2) Top Tray Exit Motor 1. Rear upper cover ( p.17) 2. Top rear cover ( p.18)

  • Page 25: Top Tray Transport Motor

    Electrical Components: Rear Side 3. Top tray exit motor bracket [A] ( x 1, x 1, x 2) 4. Top tray exit motor [A] ( x 2) Top Tray Transport Motor 1. Rear upper cover ( p.17) 2. Top rear cover ( p.18)
  • Page 26 1. Replacement and Adjustment 3. Main board bracket [A] ( x all, x 5, ground cable x 1) 4. Top tray transport motor bracket [A] ( x 1, x 2)

  • Page 27: Entrance Jg (Junction Gate) Motor

    Electrical Components: Rear Side 5. Top tray transport motor [A] ( x 2) Entrance JG (Junction Gate) Motor 1. Rear upper cover ( p.17) 2. Entrance JG motor [A] ( x 1, x 1, x 2) Dynamic Roller Lift Motor 1.

  • Page 28: Crease Motor

    1. Replacement and Adjustment 5. Dynamic roller lift motor bracket [A] ( x 1, x 2) 6. Dynamic roller lift motor [A] ( x 2) Crease Motor 1. Rear upper cover ( p.17) 2. Rear lower cover ( p.17) 3. Top rear cover ( p.18) 4.

  • Page 29: Dynamic Roller Transport Motor

    Electrical Components: Rear Side 5. Crease motor [A] ( x 2, x 4) Dynamic Roller Transport Motor 1. Rear upper cover ( p.17) 2. Dynamic roller transport motor bracket [A]( x 1, x 2)

  • Page 30: Registration Roller Release Motor

    1. Replacement and Adjustment 3. Dynamic roller transport motor ( x 2) Registration Roller Release Motor 1. Rear upper cover ( p.17) 2. Rear lower cover ( p.17) 3. Registration roller release motor bracket [A] ( x 1, x 2)

  • Page 31: Registration Roller Transport Motor

    Electrical Components: Rear Side 4. Registration roller release motor [A] ( x 2) Registration Roller Transport Motor 1. Rear upper cover ( p.17) 2. Rear lower cover ( p.17) 3. Registration roller transport motor bracket [A] ( x 1, x 2)
  • Page 32 1. Replacement and Adjustment 4. Registration roller transport motor [A] ( x 2)

  • Page 33: Electrical Components: 1St Stopper

    Electrical Components: 1st Stopper Electrical Components: 1st Stopper Fold Plate Motor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3. Fold plate motor bracket [A] ( x 3, x 1, x 2) 4. Fold plate motor [A] ( x 2) Direct-Send JG Motor 1.
  • Page 34 1. Replacement and Adjustment 2. Rear lower cover (* p.17) 3. Rear lower stay [A] ( x 5, x 2) 4. Direct-Send JG motor bracket [A] ( x 1, x 1, x 2)

  • Page 35: 1St Fold Motor

    Electrical Components: 1st Stopper 5. Direct-Send JG motor [A] ( x 2) 1st Fold Motor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3. 1st fold motor [A] ( x 1, x 4) FM6 Pawl Motor 1.

  • Page 36: 2Nd Fold Motor

    1. Replacement and Adjustment 3. FM6 pawl motor bracket [A] ( x 1, x 1, x 2) 4. FM6 pawl motor [A] ( x 2) 2nd Fold Motor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17)

  • Page 37: Jogger Fence Motor

    Electrical Components: 1st Stopper 3. 2nd fold motor bracket [A] ( x 1, x 1, x 3) 4. 2nd fold motor [A] ( x 2) Jogger Fence Motor 1. Pull out the folding unit drawer (* p.20).

  • Page 38: 1St Stopper Unit

    1. Replacement and Adjustment 2. Jogger fence motor bracket [A] ( x 1, x 1, x 2) 3. Jogger fence motor [A] ( x 2) 1st Stopper Unit 1. Folding unit cover (* p.16) 2. Rear upper cover (* p.17) 3.
  • Page 39 Electrical Components: 1st Stopper 4. Drawer stopper [A] ( x 1) 5. Belt tension bracket [A] ( x 2) 6. Release two clamps [A].
  • Page 40 1. Replacement and Adjustment 7. Disconnect two connectors [B]. 8. Remove two screws [A]. 9. Release two clamps [A]. 10. Disconnect two connectors [B]. 11. Pull out the folding unit drawer (* p.20).

  • Page 41: Positioning Roller Motor

    Electrical Components: 1st Stopper 12. Hold the 1st stopper unit [A], and then remove it ( x 2). • The 1st stopper unit cannot hang the folding unit drawer without the two screws. If you remove the 1st stopper unit without any support, the 1st stopper unit can fall and be broken. Positioning Roller Motor 1.

  • Page 42: 1St Stopper Motor

    1. Replacement and Adjustment 3. Positioning roller motor [A] ( x 2) 1st Stopper Motor 1. 1st stopper unit ( p.36) 2. 1st stopper motor [A] ( x 1, x 1, x 2) Jogger Fence HP Sensor 1. 1st stopper unit (* p.36)
  • Page 43 Electrical Components: 1st Stopper 2. Jogger fence motor bracket [A] ( x 2) 3. Jogger fence timing belt bracket [A] ( x 2) 4. Jogger fence HP sensor [A] (hooks, x 1)

  • Page 44: Positioning Roller Hp Sensor

    1. Replacement and Adjustment Positioning Roller HP Sensor 1. 1st stopper unit (*p.36) 2. Positioning Roller HP sensor [A] (hooks, x 1) 1st Stopper Paper Sensor 1. 1st stopper unit (* p.36) 2. 1st stopper paper sensor bracket [A] ( x 1)

  • Page 45: 1St Stopper Hp Sensor

    Electrical Components: 1st Stopper 3. 1st stopper paper sensor [A] (hooks) 1st Stopper HP Sensor 1. 1st stopper unit (* p.36) 2. 1st stopper HP sensor bracket [A] ( x 1)

  • Page 46: Registration Sensor

    1. Replacement and Adjustment 3. 1st stopper HP sensor [A] (hooks) Registration Sensor 1. Pull out the folding unit drawer (* Pull Out the Folding Unit Drawer) 2. Jam removal door [A] ( x 3, x 1, x 1)
  • Page 47 Electrical Components: 1st Stopper 3. Registration sensor bracket [A] ( x 1) 4. Registration sensor [B] (hooks, x 1)

  • Page 48: Electrical Components: 2Nd Stopper

    1. Replacement and Adjustment Electrical Components: 2nd Stopper 2nd Stopper Unit 1. 1st stopper unit (* p.36) 2. Jam removal door (* p.44 "Registration Sensor") 3. Remove two screws [A] at the rear side of the folding unit drawer. 4. Remove the spring [A] for the solenoid spring [B] for the guide plate. 5.
  • Page 49 Electrical Components: 2nd Stopper 6. Release the clamp [A] and disconnect two connectors [B]. 7. Pull out the folding unit drawer. 8. Top stay [A] ( x 3)

  • Page 50: 2Nd Stopper Motor

    1. Replacement and Adjustment 9. Move down the 2nd stopper unit [A] a little bit ( x 2). 10. Open the jam removal door [A], and then remove the 2nd stopper unit [B]. 2nd Stopper Motor 1. 2nd stopper unit (* p.46)

  • Page 51: 2Nd Stopper Hp Sensor

    Electrical Components: 2nd Stopper 2. 2nd stopper motor [A] ( x 1, x 1, x 2) 2nd Stopper HP Sensor 1. 2nd stopper unit (* p.46) 2. 2nd stopper HP sensor bracket [A] ( x 1)

  • Page 52: 2Nd Stopper Paper Sensor

    1. Replacement and Adjustment 3. 2nd stopper HP sensor [A] (hooks, x 1) 2nd Stopper Paper Sensor 1. 2nd stopper unit (* p.46) 2. 2nd stopper paper sensor bracket [A] ( x 1)

  • Page 53: Bypass Exit Paper Sensor

    Electrical Components: 2nd Stopper 3. 2nd stopper paper sensor [A] ( x 1) Bypass Exit Paper Sensor 1. Pull out the folding unit drawer. 2. 2nd stopper unit (* p.46) 3. Bypass exit paper sensor bracket [A] ( x 1)
  • Page 54 1. Replacement and Adjustment 4. Bypass exit paper sensor [A] ( x 1)

  • Page 55: Electrical Components: 3Rd Stopper

    Electrical Components: 3rd Stopper Electrical Components: 3rd Stopper 3rd Stopper Unit 1. Folding unit cover (* p.16) 2. Rear upper cover (* p.17) 3. Rear lower cover (* p.17) 4. Drawer stopper [A] ( x 1) 5. Release the clamp [A]. 6.

  • Page 56: 3Rd Stopper Motor

    1. Replacement and Adjustment 8. Remove two screws [A]. 9. Hold the 3rd stopper unit [A], and then remove it ( x 2). • The 3rd stopper unit cannot hang the folding unit drawer without the two screws. If you remove the 1st stopper unit without any support, the 3rd stopper unit can fall and be broken.

  • Page 57: 3Rd Stopper Paper Sensor

    Electrical Components: 3rd Stopper 2. 3rd stopper motor [A] ( x 1, x 1, x 2) 3rd Stopper Paper Sensor 1. Pull out the folding unit drawer. 2. 3rd stopper paper sensor bracket [A] ( x 1)

  • Page 58: 3Rd Stopper Hp Sensor

    1. Replacement and Adjustment 3. 3rd stopper paper sensor [A] ( x 1) 3rd Stopper HP Sensor 1. Pull out the folding unit drawer. 2. 3rd stopper HP sensor bracket [A] ( x 1)

  • Page 59: Direct-Send Jg (Junction Gate) Hp Sensor

    Electrical Components: 3rd Stopper 3. 3rd stopper HP sensor [A] ( x 1) Direct-Send JG (Junction Gate) HP Sensor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3. Direct-Send JG HP sensor bracket [A] ( x 1, x 1)

  • Page 60: Registration Roller Hp Sensor

    1. Replacement and Adjustment 4. Direct-Send JG HP sensor [A] (hooks) Registration Roller HP Sensor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3. Registration roller HP sensor bracket [A] ( x 1, x 1)

  • Page 61: Fold Plate Hp Sensor

    Electrical Components: 3rd Stopper 4. Registration roller HP sensor [A] (hooks) Fold Plate HP Sensor 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3. Fold plate HP sensor bracket [A] ( x 1, x 1)

  • Page 62: Entrance Jg (Junction Gate) Hp Sensor

    1. Replacement and Adjustment 4. Fold plate HP sensor [A] (hooks) Entrance JG (Junction Gate) HP Sensor 1. Rear upper cover (* p.17) 2. Entrance JG HP sensor [A] (hooks, x 1) Top Tray Exit Sensor 1. Top cover (* p.14)
  • Page 63 Electrical Components: 3rd Stopper 2. Top tray exit sensor bracket [A] ( x 1) 3. Top tray exit sensor [A] ( x 1)

  • Page 64: Entrance Sensor

    1. Replacement and Adjustment Entrance Sensor 1. Entrance sensor bracket [A] ( x 1) 2. Entrance sensor [A] (hooks, x 1) Top Tray Exit Sensor 1. Top tray right cover (* p.19)
  • Page 65 Electrical Components: 3rd Stopper 2. Top tray exit sensor bracket [A] ( x 1) 3. Top tray exit sensor [A] (hooks, x 1)

  • Page 66: Electrical Components: Main 1

    1. Replacement and Adjustment Electrical Components: Main 1 Top Tray Full Sensor (E) 1. Top tray (* p.18) 2. Paper exit cover [A] ( x 1) 3. Top tray full sensor (E) bracket ( x 1)

  • Page 67: Top Tray Full Sensor (R)

    Electrical Components: Main 1 4. Top tray full sensor (E) [A] ( x 1, x 1) Top Tray Full Sensor (R) 1. Top tray (* p.18) 2. Top tray full sensor (R) [A] ( x 1, x 1) Vertical Path Paper Sensor 1.

  • Page 68: Horizontal Path Paper Sensor

    1. Replacement and Adjustment 2. Remove the bracket ( x 5) 3. Vertical path paper sensor [A] ( x 1, hooks) Horizontal Path Paper Sensor 1. Top tray (* p.18)

  • Page 69: Horizontal Path Exit Sensor

    Electrical Components: Main 1 2. Remove the bracket ( x 2) 3. Horizontal path paper sensor [A] ( x 1) Horizontal Path Exit Sensor 1. Top tray (* p.18)

  • Page 70: Discharge Brush 1

    1. Replacement and Adjustment 2. Remove the bracket ( x 5) 3. Horizontal path exit sensor ( [A] x 1) Discharge Brush 1 1. Top cover (* p.14)

  • Page 71: Discharge Brush 2

    Electrical Components: Main 1 2. Discharge brush 1 [A] ( x 2) Discharge Brush 2 1. Top tray (* p.18) 2. Discharge brush 2 [A] ( x 1)

  • Page 72: Discharge Brush 3

    1. Replacement and Adjustment Discharge Brush 3 1. Discharge brush 3 [A] ( x 2) 1. Left lower bracket ( x 6)

  • Page 73: First Fold Unit

    Electrical Components: Main 1 2. PSU [A] ( x 6,  x 4) First Fold Unit 1. 1st stopper unit (* p.36) 2. Jam removal door [A] ( x 1, x 3, x 1)
  • Page 74 1. Replacement and Adjustment 3. Remove two guide plates [A] (each  x 2) 4. Registration roller transport motor bracket [A] (* p.29 "Registration Roller Transport Motor") 5. Registration roller release motor bracket [B] (* p.28 "Registration Roller Release Motor") 6.
  • Page 75 Electrical Components: Main 1 8. Remove three screws on the rear side. 9. Disconnect four harnesses [A] on the rear side.

  • Page 76: Dynamic Roller Hp Sensor

    1. Replacement and Adjustment 10. Release two clamps [A]. 11. Lower guide plate [A], keep the upper guide plate [B] up a little and remove the first fold unit ( x 3, snap fit [C] x 1) Dynamic Roller HP Sensor 1.
  • Page 77 Electrical Components: Main 1 2. Dynamic roller HP sensor bracket ( x 1) 3. Dynamic roller HP sensor [A] ( x 1)

  • Page 78: Electrical Components: Main 2

    1. Replacement and Adjustment Electrical Components: Main 2 Bypass Entrance Paper Sensor 1. Folding unit cover (* p.16) 2. Rear upper cover (* p.17) 3. Rear lower cover (* p.17) 4. Disconnect the bypass entrance paper sensor harness [A] from the connector [B] ( x 2). 5.
  • Page 79 Electrical Components: Main 2 6. Push the bypass entrance guide plate [A] to the rear, then slide it to the left, and remove it. 7. Bypass entrance paper sensor bracket [A] ( x 1) 8. Bypass entrance paper sensor [A] ( x 1,  x 1,  x 1)

  • Page 80: First/ Second/ Third Fold Roller

    1. Replacement and Adjustment Reinstalling the bypass entrance paper sensor Put the harness of the bypass entrance paper sensor through the hole [A] in the rear frame of the drawer. First/ Second/ Third Fold Roller 1. First fold unit (* p.71) 2.
  • Page 81 Electrical Components: Main 2 4. Remove the gear [A] ( x 1) 5. Guide plate [A] ( x 1) 6. Remove the spring [A] at the front side. 7. Remove six gears (clip x 1 each)
  • Page 82 1. Replacement and Adjustment 8. Remove the links [A] (clip x 1 each). 9. Tension bracket [A] ( x 1) 10. Remove the front bracket [B] ( x 2). 11. Third fold roller with the guide plate [A] 12. Remove the guide plate [B].

  • Page 83: Fourth / Fifth Fold Roller

    Electrical Components: Main 2 13. Second fold roller [C]. 14. Remove the gear [A] ( x 1), and then the first fold roller [B]. Fourth / Fifth Fold Roller 1. Rear upper cover (* p.17) 2. Rear lower cover (* p.17) 3.
  • Page 84 1. Replacement and Adjustment 6. Remove the links [A] (pin x 1 each) 7. Remove the gear [B] ( x 1), and the gear [C] (timing belt x 1). 8. Remove the spring [A] and the tension bracket [B] ( x 1). 9.
  • Page 85 Electrical Components: Main 2 10. Lift up the hook [A] to release the guide plate shaft [B]. 11. Move the guide plate shaft [B] to the front side (arrow direction), and then remove the guide plate [C]. 12. Remove the cam [A] on the front side. 13.
  • Page 86 1. Replacement and Adjustment 14. 2nd fold motor [A] (* p.34) 15. 2nd fold pulley gear [B] ( x 1) and idle gear 16. Timing belt [C] 17. Spring [D] 18. FM6 pawl motor [E] (* p.33) 19. Pulley gear [F] 20.
  • Page 87 Electrical Components: Main 2 24. Remove the entrance guide plate [A] at the 2nd fold unit ( x 4). 25. Hold the fourth fold roller cam [A] at the rear of the drawer unit. 26. Pull the fourth fold roller [B] to the front side À. 27.

  • Page 88: Crease Rollers

    1. Replacement and Adjustment 28. Remove the fifth fold roller [A]. Crease Rollers Crease Rollers: Idle Rollers 1. Folding Unit Cover (* p.16) 2. Drawer stopper (* p.53 "3rd Stopper Unit") 3. Pull out the folding unit drawer fully (* p.20). 4.
  • Page 89 Electrical Components: Main 2 6. Tension brackets [A] ( x 1 each/ front: 4, rear: 4) There are two types of tension brackets at the crease roller area. The difference between these brackets is the number of screw holes ([A]: one hole, [B]: two holes). •...
  • Page 90 1. Replacement and Adjustment 7. Magnet attachment bracket [A] ( x 1) 8. Crease rollers: idle rollers [A] Crease Rollers: Drive Rollers 1. Crease Rollers: Idle Rollers (described above) 2. Rear upper cover (* p.17) 3. Rear lower cover (* p.17) 4.
  • Page 91 Electrical Components: Main 2 6. Drawer connector bracket [A] ( x 3) 7. Crease motor (* p.26) 8. Crease path guide plate [A] ( x 5) 9. Crease roller pulley gears [A] ( x 1 each)
  • Page 92 1. Replacement and Adjustment 10. Crease roller fixing plate [A] ( x 2) 11. Crease rollers: drive rollers [A]...

  • Page 93: Fold Adjustments

    Fold Adjustments Fold Adjustments Fine Fold Adjustment Before You Begin The fold positions can be adjusted in the User Tools (Operators, Skilled Operators) and the engine SP mode. Mode Fold User Tools* 0501 Adjust Z-fold Position 1 6750 0502 Adjust Z-fold Position 2 6751 0503 Adjust Half Fold Position 6752...
  • Page 94 1. Replacement and Adjustment Size Setting Default Range A3 SEF 2 mm 2 to 25 mm B4 SEF 2 mm 2 to 17 mm A4 SEF 2 mm 2 to 17 mm 2 mm 2 to 20 mm 2 mm 2 to 17 mm LT SEF 2 mm...
  • Page 95 Fold Adjustments Size Setting Default Range Setting Default Range A3 SEF 0 mm ±4 mm 0 mm ±4 mm B4 SEF 0 mm ±4 mm 0 mm ±4 mm A4 SEF 0 mm ±4 mm 0 mm ±4 mm 0 mm ±4 mm 0 mm ±4 mm...
  • Page 96 1. Replacement and Adjustment Size Setting Default Range A3 SEF 0 mm ±10 mm B4 SEF 0 mm ±10 mm A4 SEF 0 mm ±10 mm 0 mm ±10 mm 0 mm ±10 mm LT SEF 0 mm ±10 mm Other 0 mm ±10 mm...
  • Page 97 Fold Adjustments Size Setting Default Range 13"x19.2" 0 mm ±4 mm 13"x19" 0 mm ±4 mm 12.6"x19.2" 0 mm ±4 mm 12.6"x18.5" 0 mm ±4 mm 13"x18" 0 mm ±4 mm SR A3 (320x450 mm) 0 mm ±4 mm SR A4 (225x320 mm) 0 mm ±4 mm 226x310 mm...
  • Page 98 1. Replacement and Adjustment Size Setting Default Range 8-Kai 0 mm ±4 mm Other 0 mm ±4 mm Pitch Adj. 0.2 mm FM3 Letter Fold-out User Tool Adjustment (Operator, Skilled Operator) The following standard adjustment of "S1" can be done by the operator or skilled operator in the User Tools mode.
  • Page 99 Fold Adjustments Engine SP Adjustment The following fine adjustment of "S2" and "L" can be done by the customer engineer in the SP mode. Size Setting Default Range Setting Default Range A3 SEF 0 mm ±4 mm 0 mm ±4 mm B4 SEF 0 mm ±4 mm...
  • Page 100 1. Replacement and Adjustment The following standard adjustment of "S1" can be done by the operator or skilled operator in the User Tools mode. Only "S1" can be adjusted by the operator as shown in the table below. Size Setting Default Range Setting...
  • Page 101 Fold Adjustments Size Setting Default Range Setting Default Range A3 SEF 0 mm ±4 mm 0 mm ±4 mm B4 SEF 0 mm ±4 mm 0 mm ±4 mm A4 SEF 0 mm ±4 mm 0 mm ±4 mm B5 SEF 0 mm ±4 mm 0 mm...
  • Page 102 1. Replacement and Adjustment Size Setting Default Range A3 SEF 0 mm ±10 mm B4 SEF 0 mm ±10 mm A4 SEF 0 mm ±10 mm 0 mm ±10 mm 0 mm ±10 mm LT SEF 0 mm ±10 mm Other 0 mm ±10 mm...
  • Page 103 Fold Adjustments Size Setting Default Range Setting Default Range A3 SEF 0 mm ±4 mm 0 mm ±4 mm B4 SEF 0 mm ±4 mm 0 mm ±4 mm A4 SEF 0 mm ±4 mm 0 mm ±4 mm B5 SEF 0 mm ±4 mm 0 mm...
  • Page 104 1. Replacement and Adjustment FM6 Gate Fold User Tool Adjustment (Operator, Skilled Operator) The following standard adjustment of "S1" and "S2" can be done by the operator or skilled operator in the User Tools mode. Size Setting Default Range A3 SEF S1, S2 2 mm 2 to 12 mm...
  • Page 105 Fold Adjustments Size Setting Default Range A3 SEF 0 mm ±4 mm B4 SEF 0 mm ±4 mm A4 SEF 0 mm ±4 mm B5 SEF 0 mm ±4 mm 0 mm ±4 mm 0 mm ±4 mm LT SEF 0 mm ±4 mm 8-Kai...
  • Page 106 1. Replacement and Adjustment Size Setting Default Range Other 0 mm ±4 mm Pitch Adj. 0.2 mm Size Setting Default Range A3 SEF 0 mm ±4 mm B4 SEF 0 mm ±4 mm A4 SEF 0 mm ±4 mm B5 SEF 0 mm ±4 mm 0 mm...

  • Page 107: Skew Adjustment

    Skew Adjustment Skew Adjustment Manual Adjustments by Service Technician Before You Begin These adjustments can be done by the service technician adjusting the set and adjustment screws on the multi-folder unit. The illustration above shows the positions of the three stoppers inside the machine. The positioning of the stoppers is critical because this determines the types of folding.
  • Page 108 1. Replacement and Adjustment Front and Rear The terms "Front" and "Rear" are critical to understanding how paper is skewing during folding. These terms are defined relative to the positioning of the paper in the paper path as it feeds and exits. •...
  • Page 109 Skew Adjustment The black arrow shows the direction of paper feed from right to left. When the skew sheet is opened the Front edge is longer than the Rear edge. Example 2: FM2: Low (Stopper to Close to the Nip)
  • Page 110 1. Replacement and Adjustment The black arrow shows the direction of paper feed from right to left. When the skew sheet is opened the Front edge is shorter than the Rear edge. Skew Correction Reference Diagrams and Table Skew Correction Reference Diagrams Symbol/Color What It Means Stopper 1 needs adjustment...
  • Page 111 Skew Adjustment...
  • Page 112 1. Replacement and Adjustment General Procedure 1. Retrieve the first folded paper from the top of the multi-folder. The first sheet is on the bottom of the stack. 2. If a fold is skewed, spread the paper out in the direction of paper feed shown in the diagrams above. 3.
  • Page 113 Skew Adjustment Skew Correction Reference Table F Long F Long Lower F Raise F F Short F Short Raise F Lower F F Long Raise F F Short Lower F F Long F Long Raise F Lower F F Short F Short Lower F Raise F...
  • Page 114 1. Replacement and Adjustment First, compare the L2 measurements. • In this example, imagine that L2 is longer at the front than at the rear. • Look at the table, in the row for FM1, and the column for L2. •...
  • Page 115 Skew Adjustment 2. Now you are ready to do the adjustment on the multi-folder unit. 3. The illustration above shows the location for each stopper adjustment. • Each stopper is equipped with two screws. • The black plastic screw is the Set screw and the metal silver screw is the Adjustment screw. 4.
  • Page 116 1. Replacement and Adjustment 5. Turn the Adjustment screw to do the adjustment for the stopper. 1st, 3rd Stopper • Turn the Adjustment screw clockwise to lower the front end of the fence. -or- • Turn the Adjustment screw counter-clockwise to raise the front of the fence. 2nd Stopper •...
  • Page 117 Skew Adjustment • The diagonal cut may be above or below the original hole, depending on which stopper you are adjusting. • The photo above shows the Set screw for Stopper 2. 7. Tighten the Set screw so the plate holds the adjustment.
  • Page 118 1. Replacement and Adjustment...

  • Page 119: Details

    2. Details Overview Motors, Rollers The illustration above shows the roller groups and their related motors.

  • Page 120: Junction Gates, Junction Gate Solenoids

    2. Details Junction Gates, Junction Gate Solenoids The illustration above shows the paper path junction gates and the solenoids and motors that operate them.

  • Page 121: Stoppers, Stopper Motors

    Overview Stoppers, Stopper Motors The illustration above shows the stoppers and the motors that operate them.

  • Page 122: Paper Path

    2. Details Paper Path Paper Registration When paper is fed to the pre-stacker, the position of each sheet in the paper path is adjusted to correct skew: • Leading edge of the sheet hits the registration roller and stops. • The upstream rollers continue to rotate 5 mm. •...

  • Page 123: Pre-Stacking

    Paper Path Pre-Stacking Up to three sheets of paper can be pre-stacked for folding. The left illustration shows the parts that operate during pre-stacking.
  • Page 124 2. Details • The paper enters the machine [A]. • The lower entrance junction gate [B] opens and guides the paper to the TE stop pawl [C]. • The paper pushes the TE stop pawl aside so it can pass. The dynamic roller [A] raises after the leading edge of the paper passes the TE stop pawl [B].
  • Page 125 Paper Path The dynamic roller [A] lowers when the leading edge reaches stopper 1 [B] within the time prescribed for feeding for the size of the paper selected for the job. The TE stop pawl [C] presses on the 1st sheet to prevent the leading edge of the 2nd sheet from hitting it. The operation sequence for stacking the 2nd and 3rd sheets is the same as that of the 1st sheet.
  • Page 126 2. Details 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.
  • Page 127 Paper Path After the last sheet has been pre-stacked, the TE stop pawl [A] lowers and the sheets are jogged vertically (top to bottom). 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).
  • Page 128 2. Details 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].

  • Page 129: Junction Gates

    Paper Path Junction Gates...
  • Page 130 2. Details Entrance Junction Gates There are two junction gates in the paper path at the entrance of the multi-folder. Both junction gates remain at their home positions when paper is fed straight through the multi-fold unit to the next unit downstream. When folding is selected, the lower entrance junction gate raises and guides the paper to the fold units below: •...
  • Page 131 Paper Path When draft copies are sent to the top tray: • The upper entrance junction gate rotates down. • The lower junction gate remains at default position. Direct Send Junction Gate 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.
  • Page 132 2. Details The illustration above shows the actual location and appearance of the direct send junction gate. For all fold modes other than FM2 (Half Fold) the direct send junction gate remains at its home position. • For FM2 the direct send junction gate motor rotates the junction gate [B] to position [C]. •...
  • Page 133 Paper Path For the other fold modes (FM1, FM3 to FM6) the junction gate remains at its home position and does not touch the paper. Bypass Junction Gate This is the bypass junction gate at its home position. When FM1 (Z-fold) or FM6 (Gate Fold) is selected, the bypass junction gate raises and allows paper to pass to folder unit 2.
  • Page 134 2. Details 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. Exit, Reverse, and Top Tray Junction Gates These three junction gates are shown above at their default positions.
  • Page 135 Paper Path For straight-through paper feed the junction gates remain at their home positions. Paper passes straight through the multi-folder to the next peripheral unit downstream. All three junction gates operate to guide folded paper to the top tray: • Exit junction gate rotates left •...

  • Page 136: Paper Folding

    2. Details Paper Folding Flex-Nip Folding This machine uses the flex-nip method to fold paper. In this method of folding a stopper fence ¬ is raised or lowered to the correct height for the size of the paper and the type of fold to be done. A sheet of paper Á descends, hits the stopper and stops. However, the upstream rollers continue to rotate.

  • Page 137: Stopper Locations

    Paper Folding Stopper Locations The illustration above shows the stopper locations. Note the locations of Stopper 1, Stopper 2, and Stopper Folding Methods There are six Folding Methods (FM): Z-Folding Half Fold...
  • Page 138 2. Details Letter Fold-out Letter Fold-in Double Parallel Fold Gate Fold FM1 Z-Folding In Fold Method 1 (FM1): • The leading edge of the paper feeds into the nip of fold rollers ¬ and Á. • The paper is stopped by Fold Stopper 2. The paper flexes toward the nip of fold rollers Á and ® which performs the first fold.
  • Page 139 Paper Folding FM2 Half Fold In Fold Method 2 (FM2): • The leading edge of the paper is stopped by Fold Stopper 1. • The paper flexes toward the nip of fold rollers ¬ and Á which performs the first fold and feeds the folded edge of the paper into the nip of fold rollers Á...
  • Page 140 2. Details FM3 Letter Fold-out In Fold Method 3 (FM3): • The leading edge of the paper is stopped by Fold Stopper 1. • The paper flexes toward the nip of fold rollers ¬ and Á which performs the first fold. •...
  • Page 141 Paper Folding FM4 Letter Fold-in In Fold Method 4 (FM4): • The leading edge of the paper is stopped by Fold Stopper 1. • The paper flexes toward the nip of fold rollers ¬ and Á which performs the first fold. •...
  • Page 142 2. Details FM5 Double Parallel Fold In Fold Method 5 (FM5): • The leading edge of the paper is stopped by Fold Stopper 1. • The paper flexes toward the nip of fold rollers ¬ and Á which performs the first fold. •...
  • Page 143 Paper Folding In Fold Method 6 (FM6): • The leading edge of the paper is stopped by Fold Stopper 1. • The paper flexes toward the nip of fold rollers ¬ and Á which performs the first fold. • Fold Stopper 2 stops the paper and flexes it into the nip of fold rollers Á and ®. •...
  • Page 144 2. Details Operation sequence for folding three sheets: • At power on (initialization) the FM6 junction gate [A] moves to home position. • The three sheets are pre-stacked then the first two folds are done • The FM6 stop pawl moves to the operation position [B]. After the 2nd fold the sheet(s) are sent to the 3rd stopper for the last fold.
  • Page 145 Paper Folding Fold Adjustments with SP Codes The fold positions can be adjusted in the User Tools (Operators, Skilled Operators) and the engine SP mode. Mode Name Fold User Tools* Z-Fold 0501 6750 0502 6751 Equal Halves 0503 6752 LT Fold Out 0504 6753 0505...

  • Page 146: Crease Rollers

    2. Details Crease Rollers The amount of pressure exerted by the crease rollers can be adjusted. This can be done to eliminate splitting that can occur with coated paper and other types of media. The adjustment is a manual adjustment done on springs.] Adjustment range Default Load...

  • Page 147: Tray Full

    Tray Full Tray Full A pair sensors are used to detect the tray full condition. At the start of every job: • Tray full sensor (Emitter) [A] emits a signal to tray full sensor (Receptor) [B]. • As long as the signal remains unbroken the multi-folder will continue to operate and feed folded paper to the top of the unit [C].

  • Page 148: Electrical Components

    2. Details Electrical Components Transport Sensors...

  • Page 149: Operation Sensors

    Electrical Components Operation Sensors...

  • Page 150: Motors, Solenoids

    2. Details Motors, Solenoids...

  • Page 151: Paper Transport Motors

    Electrical Components Paper Transport Motors 1. Horizontal Transport Motor 7. 2nd Fold Motor 2. Top Tray Exit Motor 8. 1st Fold Motor 3. Top Tray Transport Motor 9. Fold Plate Motor 4. Dynamic Roller Lift Motor 10. Registration Roller Release Motor 5.

  • Page 152: Fold Motors

    2. Details Fold Motors 1. Entrance JG Motor 2. Direct Send JG Motor 3. Positioning Roller Motor 4. Stopper 3 Motor 5. Stopper 1 Motor 6. Jogger Fence Motor 7. Stopper 2 Motor...

  • Page 153: Motors, Solenoids Around The Top Tray

    Electrical Components Motors, Solenoids Around the Top Tray 1. Horizontal Transport Motor 2. Top Tray Exit Motor 3. Reverse JG Solenoid 4. Exit JG Solenoid 5. Top Tray Transport Motor 6. Entrance JG Solenoid 7. Top Tray JG Solenoid...

  • Page 154: Motors, Sensors Top

    2. Details 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...

  • Page 155: Motors, Sensors Bottom

    Electrical Components 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. Positioning Roller Motor 7. Direct Send JG HP Sensor 8. Registration Roller Transport Motor...

  • Page 156: Sensors Around Top Tray

    2. Details Sensors Around Top Tray 1. Top Tray Full Sensor (R) 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.

  • Page 157: Fold Motors, Sensors, Solenoids

    Electrical Components Fold Motors, Sensors, Solenoids 1. Stopper 2 Motor 8. Stopper 1 HP Sensor 2. Stopper 2 HP Sensor 9. Stopper 3 Paper Sensor 3. Jogger Fence Motor 10. Stopper 3 HP Sensor 4. Stopper 2 Paper Sensor 11. Stopper 3 Motor 5.
  • Page 158 2. Details 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...

  • Page 159: Boards, Switches, Fan

    Electrical Components Boards, Switches, Fan 1. Main Board 2. Front Door Switch 3. PSU 4. PSU Fan 5. Breaker Switch Component List Motors Operates the entrance junction that directs paper from Entrance JG Motor the upstream device to the 1) horizontal paper path, 2) paper fold path, 3) top tray.
  • Page 160 2. Details Motors Drives the transport rollers that feed unfolded paper Top Tray Transport Motor to the downstream unit. Reverses and feeds folded paper to the folded paper tray. Drives the entrance roller at the entrance where the paper from the upstream device is received. Drives Horizontal Transport Motor the exit roller that feeds the paper out to the downstream unit.
  • Page 161 Electrical Components Motors Drives the double-flap pawl that prevents bending of FM6 Pawl Motor the leading edge when the 3rd fold is executed for FM6 folding (Fourths with 2 Flaps In) Moves Stopper 3 to the correct position for folding Stopper 3 Motor according to the paper size.
  • Page 162 2. Details Sensors Detects when the jog roller is in and out of its home Positioning Roller HP Sensor position. Checks for the presence of paper at power on. Also checks for jams during paper feed. Detects Stopper 1 Paper Sensor the condition of the stacked sheets during multi- sheet folding.
  • Page 163 Electrical Components Sensors Checks for the presence of paper at power on. Also checks for jams during paper feed. Used to Stopper 3 Paper Sensor create the timing that operates the 2nd fold motor during FM6 folding.. Detects when Stopper 3 is in and out of its home Stopper 3 HP Sensor position.
  • Page 164 2. Details Boards Controls operation of the motors, solenoids, sensors, and interface with Main Board the main machine.

This manual is also suitable for:

D454-17

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