High Capacity Stacker-E1 SM

654321

High Capacity Stacker-E1

Service Manual

March 10, 2009

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ApplicationThis manual has been issued by Canon Inc. for qualified persons to learn technical theory, installation, maintenance, and repair of products. This manual covers all localities where the products are sold. For this reason, there may be information in this manual that does not apply to your locality.

CorrectionsThis manual may contain technical inaccuracies or typographical errors due to improvements or changes in products. 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.

The following paragraph does not apply to any countries where such provisions are inconsistent with local law.

TrademarksThe product names and company names used in this manual are the registered trademarks of the individual companies.

CopyrightThis manual is copyrighted with all rights reserved. Under the copyright laws, this manual may not be copied, reproduced or translated into another language, in whole or in part, without the written consent of Canon Inc.

(C) CANON INC. 2009

CautionUse of this manual should be strictly supervised to avoid disclosure of confidential information.

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Explanation of SymbolsThe following symbols are used throughout this Service Manual.

Symbols Explanation Symbols Explanation

Check. Remove the claw.

Check visually. Insert the claw.

Check the noise. Use the bundled part.

Disconnect the connector. Push the part.

Connect the connector. Plug the power cable.

Remove the cable/wire from the cable guide or wire saddle.

Turn on the power.

Set the cable/wire to the cable guide or wire saddle.

Remove the screw.

Tighten the screw.

The following rules apply throughout this Service Manual:

1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with reference to the timing of operation.

In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol, the arrow indicates the direction of the electric signal. The expression "turn on the power" means flipping on the power switch, closing the front door, and closing the delivery unit door, which results in supplying the machine with power.

2. In the digital circuits, '1' is used to indicate that the voltage level of a given signal is "High", while '0' is used to indicate "Low". (The voltage value, however, differs from circuit to circuit.) In addition, the asterisk (*) as in "DRMD*" indicates that the DRMD signal goes on when '0'.

In practically all cases, the internal mechanisms of a microprocessor cannot be checked in the field. Therefore, the operations of the microprocessors used in the machines are not discussed: they are explained in terms of from sensors to the input of the DC controller PCB and from the output of the DC controller PCB to the loads.

The descriptions in this Service Manual are subject to change without notice for product improvement or other purposes, and major changes will be communicated in the form of Service Information bulletins.All service persons are expected to have a good understanding of the contents of this Service Manual and all relevant Service Information bulletins and be able to identify and isolate faults in the machine.

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ContentsSafety Precautions 0-1

Points to Note About Turning Off the Main Power Switch ----------0-2Notes Before it Works Serving ---------------------------------------------0-3

Product Outline 1-1Features -------------------------------------------------------------------------1-2Specifications ------------------------------------------------------------------1-3Names of Parts ----------------------------------------------------------------1-4

Technology 2-1Basic Configuration -----------------------------------------------------------2-2

Functional Configuration --------------------------------------------------------- 2-2Overview of Electrical Circuitry ------------------------------------------------- 2-2Component Configuration ------------------------------------------------------- 2-3Drive Configuration ---------------------------------------------------------------- 2-4Basic Operation Outline ---------------------------------------------------------- 2-5Interval Speed ---------------------------------------------------------------------- 2-6

Controls --------------------------------------------------------------------------2-7Overview ----------------------------------------------------------------------------- 2-7Inlet Feed Block -------------------------------------------------------------------- 2-8Branch Feed Block ---------------------------------------------------------------2-13Top Tray Block ---------------------------------------------------------------------2-14Relay Feed Block -----------------------------------------------------------------2-17Stack Feed Block -----------------------------------------------------------------2-18Stack Tray Block ------------------------------------------------------------------2-27Fan control --------------------------------------------------------------------------2-31Detecting jams ---------------------------------------------------------------------2-32Power Supply ----------------------------------------------------------------------2-35

Periodic Servicing 3-1

List of Work for Scheduled Servicing ------------------------------------3-2

Parts Replacement and Cleaning Procedure 4-1

Removing this Equipment ---------------------------------------------------4-2List of Parts ---------------------------------------------------------------------4-4

External / Internal Covers -------------------------------------------------------- 4-4Main Units --------------------------------------------------------------------------- 4-5Consumable Parts Requiring Periodic Replacement and Cleaning Points --------------------------------------------------------------------------------- 4-6List of Solenoids -------------------------------------------------------------------- 4-7List of Motors ------------------------------------------------------------------------ 4-8List of Cooling Fans --------------------------------------------------------------4-10List of Sensors --------------------------------------------------------------------- 4-11List of Switchs ---------------------------------------------------------------------4-14List of PCBs ------------------------------------------------------------------------4-15

External Covers ------------------------------------------------------------- 4-16Removing the Front Upper Cover (Left) -------------------------------------4-16Removing the Front Upper Cover (Right) -----------------------------------4-17Removing the Upper Cover (Middle) -----------------------------------------4-17Removing the Front Cover (Right) --------------------------------------------4-18Opening the Front Cover (Left) -----------------------------------------------4-18Removing the Front Cover (Left) ----------------------------------------------4-19Removing the Upper Tray Cover ----------------------------------------------4-20Removing the Upper Tray Rear Cover --------------------------------------4-20Removing the Foreign Matter Detection Cover ---------------------------4-21Removing the Rear Upper Cover (Right) -----------------------------------4-22Removing the Rear Cover (Lower) -------------------------------------------4-22Removing the Rear Cover (Upper) -------------------------------------------4-23Removing the Rear Upper Cover (Left) -------------------------------------4-23Removing the Upper Tray Vertical Face Cover ---------------------------4-24Removing the Inner Cover (Left) ----------------------------------------------4-24Removing the Inner Cover (Right) --------------------------------------------4-25

Main Units --------------------------------------------------------------------- 4-26Removing the Insertion Unit ----------------------------------------------------4-26

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Removing the Decurler Unit ----------------------------------------------------4-27Removing the Power Supply ---------------------------------------------------4-28Removing the Controller --------------------------------------------------------4-28Removing the Stack Tray 1/2 Loading Plate -------------------------------4-29Moving the Stack Tray Up and Down ----------------------------------------4-30Removing the Horizontal Registration Detection Unit -------------------4-31Removing the tray2 eject 1 unit -----------------------------------------------4-32Removing the Alignment/Accessory Plate Unit----------------------------4-34

Consumable Parts Requiring Periodic Replacement and Cleaning Points -------------------------------------------------------------------------- 4-35

Removing the Sponge Roller --------------------------------------------------4-35Removing the Insertion Belt ----------------------------------------------------4-36

Removing the Solenoid ---------------------------------------------------- 4-37Removing the Flapper-coupled Solenoid (SL1) ---------------------------4-37Removing the Front Door Lock Solenoid (SL2) ---------------------------4-38Removing the Flapper Top Tray Solenoid (SL3) --------------------------4-38Removing the Stack Tray (1/2) Lock Solenoid (SL4/SL5) --------------4-39

Removing Motors ---------------------------------------------------------- 4-40Removing the Inlet Motor 1 (M1) ----------------------------------------------4-40Removing the Inlet Motor 3 (M2) ----------------------------------------------4-41Removing the Inlet Motor 2 (M3) ----------------------------------------------4-41Removing the Nip Release Motor 1 (M4) -----------------------------------4-42Removing the Nip Release Motor 2 (M5) -----------------------------------4-42Removing the Horizontal Registration Feed Motor (M6) ----------------4-43Removing the Horizontal Registration Shift Motor (M7)-----------------4-43Removing the Inlet Motor 4 (M8). ---------------------------------------------4-44Removing the Horizontal Registration Detection Motor (M9) ----------4-45Removing the Stack Tray Eject Motor 1 (M10) ----------------------------4-45Removing the Decurler Shift Motor (M11) ----------------------------------4-46Removing the Coupled Inlet Motor (M12) ----------------------------------4-46Removing the Coupled Eject Motor 1 (M13) -------------------------------4-47Removing the Decurler Feed Motor (M14) ---------------------------------4-47Removing the Coupled Eject Motor 2 (M15) -------------------------------4-48Removing the Coupled Eject Motor 3 (M16) -------------------------------4-48Removing the Trailing End Retaining Shift Motor (M17) ----------------4-49Removing the Stack Tray 2 Shift Rear Motor (M18) ---------------------4-49

Removing the Stack Tray Lift Motor 2 (M19) -------------------------------4-51Removing the Stack Tray Lift Motor 1 (M20) -------------------------------4-52Removing the Stack Tray 1 Shift Rear Motor (M21) ---------------------4-54Removing the Stack Tray 1 Alignment Rear Motor (M22) --------------4-54Removing the Stack Tray 2 Alignment Rear Motor (M23) --------------4-56Removing the Stack Tray 1 Shift Front Motor (M24) ---------------------4-57Removing the Stack Tray 1 Alignment Front Motor (M25)--------------4-58Removing the Stack Tray 2 Shift Front Motor (M26) ---------------------4-59Removing the Stack Tray 2 Alignment Front Motor (M27)--------------4-60Removing the Stack Tray Eject Motor 2 (M28) ----------------------------4-61Removing the Trailing End Retaining Motor (M29) -----------------------4-62Removing the Insertion Shift Motor (M30) ----------------------------------4-62Removing the Tap Motor 2 (M31) ---------------------------------------------4-63Removing the Tap Motor 1 (M32) ---------------------------------------------4-63Removing the Insertion Motor (M33) -----------------------------------------4-64Removing the Insertion Belt Lift Motor (M34) ------------------------------4-65Removing the Gripper Motor (M35) ------------------------------------------4-66Removing the Upper Tray Lift Motor (M36) --------------------------------4-67Removing the Upper Tray Eject Motor (M37) ------------------------------4-68

Removing the Cooling Fan ----------------------------------------------- 4-69Removing the Cooling Fan 1 (FAN1) ----------------------------------------4-69Removing the Cooling Fan 2 (FAN2) ----------------------------------------4-70Removing the Cooling Fan 3 (FAN3) ----------------------------------------4-70Removing the Cooling Fan 4/5/6 (FAN4/5/6) ------------------------------4-71

Removing the Sensor ------------------------------------------------------ 4-72Removing the Horizontal Registration Shift Sensor (S1). -------------------- -----------------------------------------------------------------------------------------4-72Removing the Coupled Eject Sensor 2 (S10)------------------------------4-73

Removing the Switch ------------------------------------------------------- 4-74Removing the Front Cover Open/Close Switch 1/2/3--------------------4-74Removing the Stack Tray 1 Approach Disabled Area Switch ----------4-75Removing the Stack Tray 1 Safety Switch ----------------------------------4-76Removing the Dolly Set Switch ------------------------------------------------4-76Removing the Jam Open/Close Switch 1/2/3 ------------------------------4-77

Removing the PCB --------------------------------------------------------- 4-78Removing the Master Controller PCB (PCB1) -----------------------------4-78

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Removing the Slave Controller PCB (PCB2) ------------------------------4-79Removing the Option Controller PCB (PCB3) -----------------------------4-79Removing the Transceiver PCB Unit (PCB4) ------------------------------4-80Removing the Power Supply PCB1/2/3 (PCB5/6/7) ---------------------4-80Removing the Noise Filter PCB (PCB8) ------------------------------------4-81Removing the AC Relay PCB 1 (PCB9) -------------------------------------4-82Removing the AC Relay PCB 2 (PCB9) -------------------------------------4-82Removing the Jam LED PCB (PCB10) --------------------------------------4-83Removing the Panel PCB (PCB11) ------------------------------------------4-83Removing the Front Switch (PCB12) ----------------------------------------4-84Removing the Insertion Unit Relay PCB (PCB13) ------------------------4-85Removing the Service PCB (PCB14) ----------------------------------------4-86Removing the Horizontal Registration Relay PCB (PCB15) -----------4-86

Adjustment 5-1Overview ------------------------------------------------------------------------5-2Basic adjustment --------------------------------------------------------------5-3Adjustment during parts replacement ------------------------------------5-8Switches/LEDs on the PCB ---------------------------------------------- 5-12

Installation 6-1Checking Before Installation -----------------------------------------------6-2

Checking the Power Supply ----------------------------------------------------- 6-2Checking the Installation Site --------------------------------------------------- 6-2Points to Note on installation ---------------------------------------------------- 6-3

Checking the Contents ------------------------------------------------------6-4How to Utilize This Installation Procedure ------------------------------6-5

When Using the Contained Parts (Bundled Components in the Shipping Carton) -------------------------------------------------------------------------------- 6-5Symbols in the Illustration ------------------------------------------------------- 6-5

Unpacking -----------------------------------------------------------------------6-6Unpacking Procedure ------------------------------------------------------------- 6-6

Installation Procedures ---------------------------------------------------- 6-13Preparing the Upstream Host Machine for Installation ------------------6-13Connecting to the Upstream Host Machine -------------------------------6-16Checking and Adjusting Height ------------------------------------------------6-17

Fixing Stacker Stoppers ---------------------------------------------------------6-20Connecting Cables ---------------------------------------------------------------6-21Doubly Connecting Stackers ---------------------------------------------------6-24Attaching the Labels -------------------------------------------------------------6-27Operations/Settings --------------------------------------------------------------6-28

Work when moving the equipment ------------------------------------- 6-29Preparation -------------------------------------------------------------------------6-29Setting distribution position mode --------------------------------------------6-30Fixed item installation procedure ---------------------------------------------6-31

Appendix 7-1Service Tools -------------------------------------------------------------------7-2General Circuit Diagram -----------------------------------------------------7-3

General Circuit Diagram --------------------------------------------------------- 7-3

Safety PrecautionsPoints to Note About Turning Off the Main Power SwitchNotes Before it Works Serving

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Points to Note About Turning Off the Main Power SwitchThis machine has two switches related to power supply, the Power switch and the breaker.Turning on the Power switch powers this machine.The breaker detects an excess current and electric leakage to protect you against an electric shock.

MEMO:

Explain to the customer that the breaker must be checked once or twice a month and the result must be recorded.

power switch

leakage breaker

F-0-1F-0-1

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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.

Caution:

Do not turn off the power switch when downloading is under way.

Turning off the main power switch while downloading is under way can disable the machine.

11 Product Outline

Product OutlineFeaturesSpecificationsNames of Parts

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Product Outline > Features

Product Outline > Features

Features

Bulk loading of up to 10,000 sheets of small-sized paper (when com-pared with up to 5,000 sheets of large-sized paper).

Loading of up to 1,000 sheets in the top tray.

Through-passing to downstream optional equipment.

Loading paper movable on a dolly.

MEMO:

While either of the two independently driven stack trays is being loaded with small-sized paper, paper can be delivered from the other tray on a dolly.

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Product Outline > Specifications

Product Outline > Specifications

Specifications

Loading method Face-up loading/face-down loading

Top tray Mode types Non-shift stack, shift stack, escape delivery in a media mode not supported by the stack tray

Paper sizes A3, B4, A4, A4R, B5, B5R, 13" x 19" (330.2 x 482.6 mm), 12" x 18" (304.8 x 457.2 mm), 11"x 17", LGL, LTR, LTRR, EXEC, EXECR, 12 5/8" x 17 3/4" (320 x 450 mm) and Irregular Size (7 1/8" x 7 1/8" to 13" x 24 7/8" (182 mm x 182 mm to 330.2 mm x 630 mm))

Shift amount 30mmPaper weighing capacity

52 to 300 g/m2

Loading capacity Up to 13X19.2, 1,000 sheetsLoading height Up to 147mm Loading weight 22kgMixed paper loading

Yes

Paper types Thin, Plain, Heavy, Recycled, Color, Pre-punched, Bond Paper, Labels, Transparency, Tab Paper, Coated, Texture Paper, Vellum

Stack tray Mode types Non-shift stack, shift stackPaper sizes A3, B4, A4, A4R, B5, B5R, 13" x 19" (330.2 x 482.6 mm), 12" x 18"

(304.8 x 457.2 mm), 11"x 17", LGL, LTR, LTRR, EXEC, EXECR, 12 5/8" x 17 3/4" (320 x 450 mm) and Irregular Size (10 1/8" x 7 1/8" to 13" x 19 1/4", 8 1/4" x 11" to 10 1/8" x 19 1/4" (257 x 182mm to 330.2 x 487.7mm, 210 x 279.4mm to 256.9 x 487.7mm))

Shift amount 20mmPaper weighing capacity

52 to 300 g/m2

Loading capacity B5,Exe,A4,LTR

10,000 sheets (80g/m2 equivalent) *Must be continuous run-ready

None of the above

5,000 sheets (80g/m2 equivalent)

Loading height Up to 575mm (plain paper) *If the coated paper, max 450mm.

Loading weigh 106kgMixed paper loading

Yes

Paper types Thin, Plain, Heavy, Recycled, Color, Pre-punched, Bond Paper, Labels, Tab Paper, Coated, Texture Paper, Vellum

Down-stream deliverypart

Mode types Delivery to downstream equipmentPaper sizes A3, B4, A4, A4R, B5, B5R, 13" x 19" (330.2 x 482.6 mm), 12" x 18"

(304.8 x 457.2 mm), 11"x 17", LGL, LTR, LTRR, EXEC, EXECR, 12 5/8" x 17 3/4" (320 x 450 mm) and Irregular Size (10 1/8" x 7 1/8" to 13" x 19 1/4", 8 1/4" x 11" to 10 1/8" x 19 1/4" (257 x 182mm to 330.2 x 487.7mm, 210 x 279.4mm to 256.9 x 487.7mm))

Paper weighing capacity

52 to 300 g/m2

Mixed paper loading

Yes

Paper types Thin, Plain, Heavy, Recycled, Color, Pre-punched, Bond Paper, Labels, Transparency, Tab Paper, Coated, Texture Paper, Vellum

Paper delivery reference

Center

Physical dimensions 997 (width) X 792 (depth) X 1362(height)mmMass About 210kgPower supply 100V/12A,120V/12A,230V/6A

Maximum power consumption

Up to 580W

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Product Outline > Names of Parts


Names of Parts

External View(Front)

Top tray Stack ON/OFF switch

Power switch

Left front cover

Right front cover

Front cover open button

F-1-1F-1-1

External View(Rear)

Upper left cover

Lower left cover

Upper rear cover

Lower rear cover

Leakedge breaker

Power plug

F-1-2F-1-2

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External View(Internal)

Dolly

Left inner cover Right inner cover

F-1-3F-1-3

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Cross Section(Front)

[1]

[3]

[2]

[5]

[8]

[9]

[10]

[6]

[7]

[17][18][19][20][21][22][23][24][25][26][27][28][29]

[4]

[14]

[11]

[13]

[12]

[15]

[16]

F-1-4F-1-4

[1]Inlet roller 1[2]Inlet roller 2[3]Inlet roller 3[4]Inlet roller 4[5]Inlet roller 5[6]Inlet roller 6[7]Inlet roller 7[8]Horizontal registration roller 1[9]Horizontal registration roller 2[10]Inlet roller 8[11]Decurler sponge roller [12]eject belt[13]Stack tray 2 eject roller[14]Insertion belt[15]Stack tray 1[16]Stack tray 2[17]Coupled feed roller 1[18]Coupled feed roller 2[19]Top tray feed roller 1[20]Top tray feed roller 2[21]Top tray feed roller 3[22]Top tray eject roller [23]Coupled feed roller 3[24]Coupled feed roller 4[25]Coupled feed roller 5[26]Coupled feed roller 6[27]Coupled feed roller 7[28]Coupled feed roller 8[29]Coupled eject roller

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Switch/LED

a

bc

de

[1] Power Switch

[2] Stack ON/OFF button

[3] Front cover open button

[4] Internal LED

F-1-5F-1-5

[1] Power SwitchUsed to turn ON/OFF the power of this machine.

[2] Stack ON/OFF buttonON: Loading on stack tray is allowedOFF: Loading on stack tray is not allowed. *Loading is allowed only on top tray.

[3] Front cover open buttonSymbol Name Descriptiona Internal

error LEDOFF No error

Flash (Orange) Internal error occurred Internal jam occurred Stack tray duplicately set Loading error occurred* Following are not included in internal error. Foreign matter detected at bottom of top tray error Service error (host machine unit control panel is ON) When there is no dolly or tray

b Stacked LED (right)

ON (Green) Stack tray 1 full

Flash (Green) Loading on stack tray 1

c Stacked LED (left)

ON (Green) Stack tray 2 full

Flash (Green) Loading on stack tray 2

d Front cover OPEN button LED (Right)

ON (Green) Cover lock released after stack tray 1 is fully descended

Flash (Green) Stack tray 1 is ascending or descending

e Front cover OPEN button LED (left)

ON (Green) Cover lock released after stack tray 2 is fully descended

Flash (Green) Stack tray 2 is ascending or descending

[4] Internal LEDWhen jam occurs, the location is indicated with LED.If a message has been received from the stacker, it is displayed.

22 Technology

TechnologyBasic ConfigurationControls

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Technology > Basic Configuration > Overview of Electrical Circuitry

Technology > Basic Configuration > Overview of Electrical Circuitry

Basic Configuration

Functional ConfigurationThe components of this stacker are organized into six major blocks: inlet feed, stack feed, stack tray, branch feed, relay feed and top tray.

1.Inlet feed block

2.Branch feed block

3.Top tray block

4.Relay feed block

5.stack feed block

6.Stack tray block

F-2-1F-2-1

Overview of Electrical CircuitryThe machine's sequence of operations is controlled by its master controller PCB and slave controller PCB.The master controller PCB is the 16-bit CPU, and the master controller PCB also controls the communication with the host machine by way of the option controller PCB in addition to controlling the machine's operation sequence.The CPU on the master controller PCB is equipped with a built-in ROM used to store se-quence programs.The individual controller PCBs respond to the various commands coming from the hos tma-chine through the communication line to drive their respective motors.These controller PCBs also serve to indicate to the host machine the status of the various sensors and switches thorough the communication line.

Option controller PCB

Host machine

Master controller PCB

CPU

Motor driver

Motor

FAN

Solenoid

Switch

Sensor

Motor

FAN

Solenoid

Switch

Sensor

Motor driver

Gate array

Gate array

Slave controller PCB

F-2-2F-2-2

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Technology > Basic Configuration > Component Configuration > Roller Layout

Technology > Basic Configuration > Component Configuration > Roller Layout

Component ConfigurationRoller Layout

[15][16][17][18][19][20][21][22][23][24][25][26][27]

[14]

[11]

[13][12]

[1]

[3]

[2]

[5]

[8]

[9]

[10]

[6]

[7]

[4]

F-2-3F-2-3

[1] Inlet roller 1[2] Inlet roller 2[3] Inlet roller 3[4] Inlet roller 4[5] Inlet roller 5[6] Inlet roller 6[7] Inlet roller 7[8] Horizontal registration roller 1[9] Horizontal registration roller 2[10] Inlet roller 8[11] Decurler sponge roller [12] eject belt[13] Stack tray 2 eject roller[14] Insertion belt[15] Coupled feed roller 1[16] Coupled feed roller 2[17] Top tray feed roller 1[18] Top tray feed roller 2[19] Top tray feed roller 3[20] Top tray eject roller [21] Coupled feed roller 3[22] Coupled feed roller 4[23] Coupled feed roller 5[24] Coupled feed roller 6[25] Coupled feed roller 7[26] Coupled feed roller 8[27] Coupled eject roller

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Technology > Basic Configuration > Drive Configuration

Technology > Basic Configuration > Drive Configuration

Sensor LayoutIt describes only all optical sensors on the feed path.

S8

S9

S11

S1

S7

S13S12S10 S35S36

S62

S1 Horizontal registration shift sensorS7 Horizontal registration timing sensorS8 Gripper timing sensorS9 Paper inlet sensor 2S10 Coupled eject sensor 2]S11 Paper inlet sensor 1

S12 Coupled eject sensor 1S13 Coupled inlet sensorS35 Stack tray eject sensor 1S36 Stack tray eject sensor 2S62 Top tray eject sensor

F-2-4F-2-4

Drive Configuration

M1

M3

M2M8

M12

M28

M15

M13M16

SL1

M37

M10

M14

M6

SL3

M1 Inlet motor 1M2 Inlet motor 3M3 Inlet motor 2M6 Horizontal registration feed motorM8 Inlet motor 4M10 Stack tray eject motor 1M12 Coupled Inlet motorM13 Coupled eject motor 1

M14 Decurler feed motorM15 Coupled eject motor 2M16 Coupled eject motor 3M28 Stack tray eject motor 2M37 Top tray feed motorSL1 Flapper-coupled solenoidSL3 Flapper top tray solenoid

F-2-5F-2-5

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Technology > Basic Configuration > Basic Operation Outline

Technology > Basic Configuration > Basic Operation Outline

Basic Operation OutlineThe stacker delivers the paper that has been fed from the equipment connected to it.It supports three modes of eject as follows:

Loading into the top tray (stacked job offset loading or non-offset loading)Loading into the stack tray (stacked job offset loading or non-offset loading)Simple eject (feeding to succeeding equipment)

Where this stacker is assembled on a duplex configuration, paper passes through the inside of the upstream stacker and is fed from the downstream eject part to the downstream stacker so it will be delivered in one of the three modes mentioned above. Up to two units of this stacker can be assembled on a duplex configuration.

MEMO:

Stacked job offset loading is the mode of eject in which stacks are loaded, shifted in loading position from stack to stack, for identification purposes.

Loading into the top tray

Simple eject

Loading into the stack tray

F-2-6F-2-6

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Technology > Basic Configuration > Interval Speed

Technology > Basic Configuration > Interval Speed

Interval Speed

:1500mm/s

Inlet acceleration area

:1300mm/s

:500mm/s

:300mm/s

Stack tray 1 eject deceleration area


Simple eject deceleration area

Top tray eject deceleration area

F-2-7F-2-7

Speed change point Speed Speed shift reference

Inlet acceleration area 1300 mm/s->1500 mm/s Paper leading edge

Top tray eject deceleration area 1500 mm/s->300 mm/s* Paper leading edge

Simple eject deceleration area 1500 mm/s->1300 mm/s Paper leading edge


1500 mm/s->500 mm/s Paper leading edge


Paper leading edge

*The quantity of slowdown is different by paper.

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Technology > Controls > Overview

Technology > Controls > Overview

Controls

OverviewItem Reference1.Inlet feed block Inlet feed operation 2-8

Horizontal registration detection 2-9Horizontal registration shift control 2-11

2.Branch feed block Branch feed operation 2-13

3.Top tray block Top tray feed operation 2-14Lift control operation 2-15Paper detection 2-16Paper level detection 2-16Tray full detection 2-16Foreign matter detection 2-16

4.Relay feed block Relay feed operation 2-175.Stack feed block Outline 2-18

Decurler control 2-19Feed belt control 2-20Gripper control 2-21Insertion unit control 2-21Eject unit control 2-23Alignment operation 2-23Trailing end tap lever control 2-26

6.Stack tray block Stack tray lift operation 2-27Paper level detection 2-27Paper detection 2-27Tray detection 2-27Tray full detection 2-27Stack tray duplicate setting detection 2-28Dolly setting detection 2-28Safety assurance features 2-28Front cover opening/closing operation 2-30

7. Fans Fan control 2-318. Detecting Jams Detecting jams 2-329. Power supply system Outline 2-35

Protective functions 2-3510.Work of service When replacing the components 2-37

Periodical service 2-37Points to note about service 2-37Upgrading 2-37

3.Top tray block

2.Branch feed block

1.Inlet feed block

4.Relay feed block

5.Stack feed block

6.Stack tray block

F-2-8F-2-8

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Technology > Controls > Inlet Feed Block > Inlet Feed Operation

Technology > Controls > Inlet Feed Block > Inlet Feed Operation

Inlet Feed BlockInlet Feed Operation

Allows the paper that has been fed from the upstream equipment to the branch feed block.Paper feeding is driven by the following motors

Inlet motor 1(M1)Inlet motor 3(M2)Inlet motor 2(M3)Horizontal registration feed motor (M6)Inlet motor 4(M8)Coupled Inlet motor (M12)

The following sensors detect the arrival or passing of paper along the feeding pathHorizontal registration shift sensor(S1)Horizontal registration timing sensor (S7)Gripper timing sensor (S8)Paper inlet sensor 2(S9)Paper inlet sensor 1(S11)

In order to correct the horizontal shift and shift the paper, this stacker is equipped with a horizontal registration detection unit to detect the horizontal registration and a shift roller unit to perform horizontal registration correction and shift. When performing horizontal registration correction control of large size paper, inlet rollers 6 and 7 are cleared because the paper cannot be shifted with its end nipped by the roller. Clearing is performed by the nip release motor 1 (M4) and nip release motor 2 (M5). The pressed/cleared state of the roller is detected by nip release HP sensor 1 (S3) and nip release HP sensor 2 (S4).

M5

M4

M6

M12

M8

M3

M2

M1S8

S11

S4

S1

S3

S9

S7

Horizontalregistrationdetection unit

Shift roller unit

Inlet roller 6

Inlet roller 7

F-2-9F-2-9

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Technology > Controls > Inlet Feed Block > Horizontal registration detection


Horizontal registration detection

Horizontal registrationHP sensor (S2)

Horizontal registrationdetection motor (M9)

Horizontal registrationdetection unit

Paper

Horizontal registrationtiming sensor (S7)

Horizontal registrationshift sensor (S1)

F-2-10F-2-10

The horizontal registration detection unit detects the left end of the paper with the horizontal registration shift sensor (S1) for each paper that is fed.The correction value against the designed center (width-wise) is calculated from the detected position. This value is reflected in the shift distance of the shift roller unit.

1) The horizontal registration detection unit detects that the horizontal registration HP sensor (S2) turns OFF at the start of a job, moves to the wait position (13mm outside the end of the paper) corresponding to the paper and then stops.

S1

S7 S7

standby positionHomeposition

Horizontal registration detection unit

S1

F-2-11F-2-11

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2) When the end of the paper passes the horizontal registration timing sensor (S7), the hori-zontal registration detection motor (M9) is driven. The horizontal registration detection unit moves and detects the end of the fed paper with the horizontal registration shift sensor (S1). The horizontal registration is calculated based on this detection result.

M2

S1

S7 S7

Paper

S1

M2

standby position

Horizontal registration detection unit

3) The horizontal registration detection motor (M9) is driven and the horizontal registration detection unit is moved to the wait position.

F-2-12F-2-12

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Technology > Controls > Inlet Feed Block > Horizontal Registration Shift Control


Horizontal Registration Shift Control

Horizontal registrationshift HP sensor (S6)

Horizontalregistration roller 2

Paper

Horizontal registrationshift motor (M7)

Horizontalregistrationfeed motor (M6)

Shift roller unit

Horizontalregistration roller 1

F-2-13F-2-13

For each fed paper, the shift roller unit shifts the paper to the front or back. It also centers the paper if paper is to be fed to the next equipment.

1) The shift roller unit detects that the horizontal registration shift HP sensor (S6) turns OFF at the start of a job, moves to the wait position corresponding to the paper and then stops.

S1

S7S7

S1

standby positionHomeposition

Shift roller unit

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2) When the horizontal registration timing sensor (S7) turns ON, the horizontal registration shift motor (M7) is driven as the end of the paper exits the horizontal registration roller 2. The shift roller unit moves either forward or backward. This causes the paper gripped between horizontal registration roller 1 and horizontal registration roller 2 within the shift roller unit to move forward or backward as it is fed. This corrects the horizontal registration of the paper to prescribed value.

M7

S1

S7

Shift roller unitM7

Paper

Before Correction Regularposition

Regularposition

After Correction

The horizontal registration correction and shift actions are as follows depending on the paper ejection destination.When shift loading to the top tray, shifting is performed by the shift roller unit. It is not per-formed by the top tray.When shift loading to the stack tray, shifting is performed by the shift roller unit and also by the stack feed block to increase precision.

Eject destination No shift Shift enabledTop tray Rear shift First sheet shifted to the rear

second to the front and subsequently shifted alternately by 30mm.

Stack tray Rear shift First sheet shifted to the rear,second to the front and subsequently shiftedalternately by 20mm.

Succeeding equip-ment

Middle shift

*OHP paper and longer paper are not subject to horizontal registration shift control.(Because the end of the OHP paper cannot be detected. The end of long paper hangs on the inlet roller because it is unable to clear it.)

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Technology > Controls > Branch Feed Block > Branch Feed Operation

Technology > Controls > Branch Feed Block > Branch Feed Operation

Branch Feed BlockBranch Feed Operation

Switches the flapper and feeds paper to each feed path.The feed path is switched by the flapper when flapper-coupled solenoid (SL1) and flapper top tray solenoid (SL3) turn ON at the start of the job.The paper is fed by the coupled inlet motor (M12).There is a coupled inlet sensor (S13) at the feed path to detect the arrival or passing of the paper.

Flapper top traysolenoid (SL3)

Flapper

Flapper-coupledsolenoid (SL1)

Coupled inlet sensor (S13)M12

:OFF(default)

:ON

Flapper

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Technology > Controls > Top Tray Block > Top Tray Feed Operation

Technology > Controls > Top Tray Block > Top Tray Feed Operation

Top Tray BlockTop Tray Feed Operation

Loads the paper that has been fed from the branch feed block into the tray.Paper feeding is driven by the following motors:

Top tray eject motor (M37)Coupled eject 2 motor (M15)

The following sensor detects the arrival or passing of paper along the feeding path:Top tray eject sensor 1 (S62)

Top tray feed roller

M37

M15

Top tray eject sensor 1(S62)

Top tray feed roller 1



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Technology > Controls > Top Tray Block > Lift Control Operation

Technology > Controls > Top Tray Block > Lift Control Operation

Lift Control OperationThe top tray is driven by the top tray lift motor (M36) to move up and down.The upper limit to the top tray position is detected by the top tray paper level sensor (S57). The lower limit to the top tray position is detected by the top tray full sensor (S56).The position that the top tray reaches when it moves up is controlled by a pulse count at-tained by the motor following the detection of the paper level by the top tray paper level sensor (S57).The top tray is detected home by the top tray paper level sensor (S57). If paper is already loaded in the top tray, the top tray is detected home with reference to the top surface of the loaded paper. If no paper is loaded in the top tray, the top tray is assumed home when the top tray edge is detected.When the power switch is turned on or when a job starts, the stacker controller circuit board drives the top tray lift motor (M36) to bring the top tray home. If the top tray is already home, it is once removed from the home position and then brought back home. Once paper is loaded in the top tray, the tray lift motor (M36) is driven by the specified number of pulses per five, ten, or fifteen sheets according to the basis weight of paper, thus moving down the top tray. Subsequently, the top tray is brought home to prepare for the next run of loading.

Top tray emptysensor (S55)

Top tray paper level sensor (S57)

Top tray liftclock sensor (S61)

Top tray full sensor (S56)

Top tray lift motor (M36)

Top tray front objectsensor (S58)

Top tray rear objectsensor (S59)

Top Tray

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Technology > Controls > Top Tray Block > Foreign Matter Detection

Technology > Controls > Top Tray Block > Foreign Matter Detection

Paper DetectionThe presence or absence of paper loaded in the tray is detected by the top tray empty sensor (S55)

Paper Level DetectionThe level of the paper loaded in the tray is detected by the top tray paper level sensor (S57).When paper is loaded in the tray, its paper level pushes up a paper level detection lever linked to the top tray paper level sensor.When the paper level is thus detected, the top tray lift motor is driven to move down the top tray.

Tray Full DetectionThe top tray full condition is detected by the top tray full sensor (S56).

Foreign Matter DetectionThe presence or absence of foreign matter under the top tray is detected by the top tray front foreign matter sensor (S58) and the top tray rear foreign matter sensor (S59).When a foreign matter is placed on top of the foreign matter detection cover, the foreign mat-ter detection cover lowers and the top tray foreign matter sensor detects the foreign matter. When either of the two sensors detects a foreign matter, the message is displayed on the host machine.

Top tray foreign matter sensor (S58/S59)

Foreign matter detection cover Foreign matter

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Technology > Controls > Relay Feed Block > Relay Feed Operation

Technology > Controls > Relay Feed Block > Relay Feed Operation

Relay Feed BlockRelay Feed Operation

Allows the paper that has been fed from the branch feed block to the downstream equipment.Paper feeding is driven by the following motors:Coupled eject motor 1 (M13)Coupled eject motor 2 (M15)Coupled eject motor 3 (M16)The following sensors detect the arrival or passing of paper along the feeding pathCoupled eject sensor 2 (S10)Coupled eject sensor 1 (S12)

Coupled eject roller 3




Coupled eject sensor 1 (S12)



M16

M15

M13


Coupled eject sensor 2 (S10)

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Technology > Controls > Stack Feed Block > Outline

Technology > Controls > Stack Feed Block > Outline

Stack Feed BlockOutline

Aligns the paper that has been fed from the branch feed block and shift-loads it into the stack tray block. Two stack trays are available. The paper is loaded from stack tray 1. When the stack tray 1 became it to the tray full, the paper is loaded stack tray 2. In case of large-size paper, stack tray 1 and 2 are used for loading.There are three ways to load paper as follows:(1) Shift loading into stack tray 1 (small-sized paper )(2) Shift loading into stack tray 2 (small-sized paper )(3) Shift loading into stack tray 1 and 2 (large-sized paper)* In case of large size paper, stack tray 1 and 2 are used for shift loading.

Shift Loading into Stack TraysThe stack feed block performs a standby operation in the following sequence when a job starts.1.If small-sized paper is loaded into stack tray 2, the tray 2 eject unit 2 in the eject unit shifts

to the standby position (with the wrapping film stretching to guide the paper to stack tray 2).

2.The insertion unit shifts to the standby position.3.The alignment plate shifts to the standby position.4.The accessory plate shifts to the standby position.

Tray 2 eject unit 1

Accessoryplate

Alignment plate

Insertion unit

Tray 2 eject unit 2

Accessoryplate

Alignment plate

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While the job is in progress, the stack feed block operates in the following sequence:1.When the paper is fed from the branch feed block, the upward curl is curled downward by

the decurler unit and fed by the feed belt. Deculer unit

PaperFeed belt

2.Pinches the leading end of paper measuring 355mm (B4) or larger with the gripper and belt, and feeds it to the insertion unit.

Paper

Gripper

Belt

3.Holds upward curls in the trailing end of the incoming paper with trailing end retaining levers in the eject unit, so the paper pass for the next sheet of paper in sequence will not be blocked.

Paper

Trailing end retaining lever

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Technology > Controls > Stack Feed Block > Decurler Control

Technology > Controls > Stack Feed Block > Decurler Control

4.Inserts the paper with the insertion unit, pressing its leading end against levers for align-ment.

Paper

Stopper

Insertion unit

5.The alignment plate presses the paper against the accessory plate to align the paper on the left and right sides.

Paper

Alignment plateAccessory plate

6.Because, in a self-weight drop fall mode, the next sheet of paper in sequence comes in before the current sheet is stacked, the trailing end tap lever taps the trailing end of the paper to expedite its loading

Paper

Trailing end tap lever

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Decurler Control upward curls in the incoming paper to a downward curl to prevent an upward curl from occur-ring in the stack tray block.The sponge roller is pressed against the decurler roller. Upward curls in the paper are cor-rected to a downward curl as the paper passes between the two rollers.

Sponge roller

Upward-curled paperDownward-curled paperDecurler roller

paper

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Technology > Controls > Stack Feed Block > Feed Belt Control

Technology > Controls > Stack Feed Block > Feed Belt Control

When the power switch is turned on, the decurler shift motor (M11) starts rotating until the decurler roller is detected home by the decurler shift HP sensor (S14).When a job starts, the decurler shift motor (M11) is driven to rotate the cam. The amount by which the sponge roller presses the decurler roller varies with each cam position. The amount of rotation attained is detected by counting feed pulses transmitted from the decurler shift HP sensor (S14). When downward curl is corrected, the curl corrective pressure changes depending on the paper type.

M11

M14

Cam

Decurler roller

Backup roller

Sponge roller

Cam

Decurler shift HP sensor (S14)

Decurler roller

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Feed Belt ControlFeeds incoming paper to stack tray 1 on a feed belt.With stack tray 2 that does not have paper guides along the feed belt, the film stretches to guide the paper to stack tray 2 when the stack tray 2 eject unit shifts. The paper is fed to stack tray 2 on the feed belt and the stack tray 2 feed rollers.Paper feeding is driven by the following motors:

Stack tray eject motor 1 (M10)Stack tray eject motor 2 (M28)

The following sensors detect the arrival or passing of paper along the feeding pathStack tray eject sensor 1 (S35)Stack tray eject sensor 2 (S36)

Feed belt

Stack tray ejectsensor 1 (S35)

Stack tray 2eject roller

Stack tray ejectsensor 2 (S36)

Feed film

Stack tray 2eject unit 2


M28

M10

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Technology > Controls > Stack Feed Block > Insertion Unit Control


Gripper ControlPinches the leading end of paper measuring 355mm (B4/LGL) or larger with the gripper and belt, and feeds it to the insertion unit.The timing at which the paper is pinched is adjusted by driving the gripper motor (M35) by a predetermined pulse count on the basis of the gripper timing sensor (S8) in the inlet feed block turning on. The gripper is detected home by the gripper HP sensor (S15) recognizing a white mark on the belt.

Gripper motor (M35)

Belt

Gripper HP sensor (S15)Gripper

Reflection sheet

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Insertion Unit ControlThe insertion unit inserts the paper on the insertion belts, pressing its leading end against stoppers for alignment.The insertion shift motor (M30) is driven to shift the insertion unit to a position aligned with the stack tray to stack.The insertion unit is detected home by the insertion shift HP sensor (S42).

Insertion shift mortor (M30)

Insertion shift HP sensor (S42)

Insertion belt

Sub stoppers

Stoppers

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The insertion belts are driven by the insertion motor (M33). The insertion belt lift motor (M34) is driven to move the insertion belts up and down, so the size of the area of contact between the insertion belts and paper will vary to product a feeding force appropriate to the kind of paper being fed.The insertion belts are detected home by the insertion belt HP sensor (S45) recognizing the edges of the lift levers.The paper level of the paper loaded in stack tray 1 or 2 is detected by the stack tray 1 /2 pa-per level front sensor (S44) and the stack tray 1 /2 paper level rear sensor (S43) turning on. The stack tray moves down about 0.3mm when the paper level is detected.

Insertion beltlift motor (M34)

Insertion motor (M33)

Insertion beltHP sensor (S45)

Stack tray paper levelfront sensor (S44)

Stack tray paper levelrear sensor (S43)

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The size of the area of contact between the insertion belts and paper can be varied at six levels (0 to 4).

Insertion belt

SERVICE MODE:SORTER> ADJUST> ST> PULLTo adjust the position of up/down motor of lead-in belt at the feed direction side on the stacker unit on the stacker.As the value is increased, lead-in force is reduced.Display/adj/set range 0 to 4

Settings Size of the area of contact between the insertion belts and paper

0 3.5mm (default)1 3.3mm2 3.0mm3 2.5mm4 2.0mm

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Technology > Controls > Stack Feed Block > Alignment Operation


Eject Unit ControlTailing end retaining levers in the eject unit hold upward curls in the incoming paper, so the paper pass for next sheet of paper in sequence will not be blocked.Stack tray 2 does not have paper guides along the feeding path. When small-sized paper is loaded into stack tray 2, the stack tray 2 eject unit shifts to stretch the wrapping film to guide the paper to stack tray 2.The trailing end retaining shift motor (M17) is driven to cause the stack tray 2 eject unit to shift.The stack tray 2 eject unit is detected home by the trailing end retaining shift HP sensor (S46) detecting its edge.The trailing end retaining levers are driven by the trailing end retaining motor (M29).The trailing end retaining levers are detected home by the trailing end retaining HP sensor (S49).

Trailing end retaining HP sensor(S49)

Trailing end retainingshift HP sensor(S46)

Film guide

Trailing endretaining lever

M17

M29


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Alignment OperationThe front alignment plate and the rear alignment plate align each sheet of paper ejected to either the front or rear. The first sheet is shifted to the rear. The rear alignment plate presses the paper against the front accessory plate. The second and subsequent sheets are alter-nately shifted to the front and rear against the shift-side alignment plate. Without shifting enabled (simple loading), sheets are shifted to the rear.The alignment plates shift back and forth as they are driven by the stack tray 1 alignment mo-tors (M22/25) and stack tray 2 alignment motors (M23/27). The accessory plate is shifted up and down as it is driven by the stack tray 1 shift motors (M21/24) and stack tray 2 shift motors (M18/26).The alignment plates are detected home by the stack tray 1 alignment HP sensors (S33/48) and stack tray 2 alignment HP sensors (S40/51).The accessory plate is detected home by the stack tray 1 shift HP sensors (S34/47) and stack tray 2 shift HP sensors (S41/50).Both the left- and right-side alignment plates are used to align large-sized paper.

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S33

S34

S40S40

S41

S47

S48

S50M18

M21

M22

M25

M27

Alignment plate

Accessory plateM24

M26

M23

S51

M18:Stack tray 2 shift rear motor S33:Stack tray 1 alignment HP rear sensorM21:Stack tray 1 shift rear motor S34:Stack tray 1 shift HP rear sensorM22:Stack tray 1 alignment rear motor S40:Stack tray 2 alignment HP rear sensorM23:Stack tray 2 alignment rear motor S41:Stack tray 2 shift HP rear sensorM24:Stack tray 1 shift front motor S47:Stack tray 1 shift HP front sensor M25:Stack tray 1 alignment front motor S48:Stack tray 1 alignment HP front sensor M26:Stack tray 2 shift front motor S50:Stack tray 2 shift HP front sensor M27:Stack tray 2 alignment front motor S51:Stack tray 2 alignment HP front sensor

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Shift Operation (when shifting to the rear end)1) The horizontal registration unit shifts the paper 14mm to the rear with respect to the

center as paper feed reference and feeds it to the stack tray.

Center

14mm shift

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2) The front and rear alignment units move to the wait position.

3) The accessory plate descends.

* The front accessory plate and rear side alignment plate move 4mm forward from the paper.

Alignment plate

Accessory plate

4mm4mmPaper

Accessory plate

MEMO:The shift amount is different by paper size. If paper size is more than 355mm (B4), the front accessory plate and rear side alignment plate moves 22mm forward from the paper.

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4) The rear alignment plate pushes the paper against the accessory plate and aligns it.

Alignment plate

Accessory plate

5) The rear alignment plate returns to the wait position. The second paper is fed.

* The rear alignment plate moves 4mm forward from the paper.

4mmPaper

Alignment plate

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Technology > Controls > Stack Feed Block > Trailing End Tap Lever Control

Technology > Controls > Stack Feed Block > Trailing End Tap Lever Control

6) The rear alignment plate pushes the paper against the accessory plate and aligns it.

Alignment plate

Accessory plate

F-2-40F-2-40

Trailing End Tap Lever ControlWhen the trailing end of paper falls into the stack tray, the rear end tap lever taps the trailing end of the paper once to expedite its loading.Because, in a self-weight drop fall mode, the next sheet of paper in sequence comes in before the current sheet is stacked, the trailing end tap lever taps the trailing end of the paper to expedite its loading.Both the left- and right-side trailing end tap levers are used to load paper measuring 355mm (B4) or larger. The trailing end tap levers are driven by tap motor 1 (M32)/tap motor 2 (M31). The curls in it are also detected by the trailing end tap levers.At power ON and job start, the paper level on the stack tray is detected by the tap paper level sensor (S30) and tap paper level sensor 2 (S37).When loading paper, the paper level is detected by the stack tray paper level sensors (S43/44) in the pull-in unit.When an upward curl is detected at the trailing end of the paper, operation is stopped after processing the current paper.

Tap paper levelsensor(S37)

Stack tray 2 curlsensor(S38)

Tap HP sensor 2 (S39)

Tap paper level sensor 1 (S30)

Stack tray 1curl sensor (S31)

Tap HP sensor 1 (S32)

Tap motor 2 (M31)

Tap motor 1 (M32)

Trailing end tap lever

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Technology > Controls > Stack Tray Block > Tray Full Detection

Technology > Controls > Stack Tray Block > Tray Full Detection

Stack Tray Block

Stack tray 1

Stack tray 2

Tray 2 arm unit

Tray 1 arm unit

S26

S27

SL4

SL5

S17

S18

S19

S20

S21

S23

S24

S25

S16

S53S54

SW8

M19

M20

SW4

SW6

SW7

SW5S28S29

S22

S16:Tray 1 approach disabled area sensor S28:Stack tray 2 empty sensorS17:Stack tray 1 coated paper full sensor S29:Stack tray 2 sensorS18:Stack tray 1 paper full sensor S53:Stack tray 1 duplicate setting sensorS19:Arm avoidance sensor 1 S54:Stack tray 2 duplicate setting sensorS20:Stack tray 1 lift clock sensor SL4:Stack tray 2 lock solenoidS21:Tray 2 approach disabled area sensor SL5:Stack tray 1 lock solenoidS22:Stack tray 2 coated paper full sensor SW4:Stack tray 1 approach disabled area switchS23:Stack tray 2 paper full sensor SW5:Stack tray 2 approach disabled area switchS24:Arm avoidance sensor 2 SW6:Stack tray 1 safety switchS25:Stack tray 2 lift clock sensor SW7:Stack tray 2 safety switchS26:Stack tray 1 empty sensor SW8:Dolly set switchS27:Stack tray 1 sensor

F-2-42F-2-42

Stack Tray Lift OperationThe stack tray lift motor 1 (M20) and stack tray lift motor 2 (M19) are driven to cause the stack tray to move up and down.The stack tray position is controlled by a pulse count attained by the motors following the detection of the paper level by the paper level sensors (S30, 37, 43, 44).The stack tray 1 lift clock sensor (S20) and the stack tray 2 lift clock sensor (S25) detect locks on the lift motors by recognizing rotation flags.

Paper Level DetectionThe stack trays are detected home by the paper level sensors (S30, 37, 43, 44). If paper is already loaded in a tray, the tray is detected home with reference to the top surface of the loaded paper. If no paper is loaded in a tray, the tray is assumed home when the top surface of the tray is detected.

Paper DetectionThe presence or absence of paper loaded in the stack trays is detected by the stack tray 1 empty sensor (S26) and the stack tray 2 empty sensor (S28).

Tray DetectionThe presence or absence of a stack tray set on the stack tray arm is detected by the stack tray 1 sensor (S27) and the stack tray 2 sensor (S29).

Tray Full DetectionThe paper full state of paper loaded in the stack trays is detected by the Stack tray 1 paper full sensor (S18) and the Stack tray 2 paper full sensor (S23).If use coated paper, The paper full state of paper loaded in the stack trays is detected by the Stack tray 1 coated paper full sensor (S17) and the Stack tray 2 coated paper full sensor (S22).

MEMO:Coated paper is thin and heavy. Therefore, 5,000 sheets cannot be loaded because the weight limit will be exceeded. The maximum load is approximately 4,000 sheets when using coated paper.

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Technology > Controls > Stack Tray Block > Safety Assurance Features


Stack Tray Duplicate Setting DetectionThe stack tray 1 duplicate setting sensor (S53) and the stack tray 2 duplicate setting sensor (S54) are in position to prevent a stack tray from being set in duplicate.Stack trays set in duplicate are detected by the work of the following combinations of sen-sors:Stack tray 1 set in duplicate: The stack tray 1 sensor (S27) and the stack tray 1 dupli-cate setting sensor (S53) have turned on.Stack tray 2 set in duplicate: The stack tray 2 sensor (S29) and the stack tray 2 dupli-cate setting sensor (S54) have turned on.When duplicate setting is detected, the internal error LED flashes.

Dolly Setting SetectionWhether a dolly has been set in position or not is detected by the dolly set switch (SW8).

Safety Assurance Features1. Limitation on lowering of the tray with the front cover openThe tray 1 approach disabled area sensor (S16) and the tray 2 approach disabled area sen-sor (S21) are in position to prevent the stack tray in motion from lowering below a specified level while the front door is open. After about 50 sheets are loaded in the stack tray after either the tray 1 or 2 approach disabled area sensor has turned on, Stacker stops.When the tray does not stop by any chance, the stack tray 1 approach disabled area switch (SW4) and the stack tray 2 approach disabled area switch (SW5) are actuated to cut off the +38 V power supply. The stack tray lift motor 1 (M20) and stack tray lift motor 2 (M19) stops movement.

S21

SW5

S16

SW4

Lowering Limitposition

Stack tray

paper

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2. Prevention of tray lifting with the front cover open The stack tray is disabled from lifting up with the front cover open. The stack tray 1 lock sole-noid (SL5) and the stack tray 2 lock solenoid (SL4) are in position to cut off the transmission of power to the stack tray lift motor 1 (M20)and the stack tray lift motor 2 (M19) if the stack tray should lift.

Stack tray

Paper

SL5SL4

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3. Prevention of the workers hands from being stuck between trays with the front cover openThe stack tray 1 safety switch (SW6) and the stack tray 2 safety switch (SW7) are in position to prevent the workers hands from being stuck between stack trays 1 and 2 in motion with the front door open.When either stack tray level is actuated, the stack tray 1 safety switch (SW6) or the stack tray 2 safety switch (SW7) is actuated to cut off the +38 V power supply. The stack tray lift motor 1 (M20) and stack tray lift motor 2 (M19) stops movement.

Lever

Stack tray

Paper

SW6

SW7

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Technology > Controls > Stack Tray Block > Front cover opening/closing Operation

Technology > Controls > Stack Tray Block > Front cover opening/closing Operation

Front cover opening/closing OperationWhether the stack tray is lowered first or the front cover is opened immediately depends on the presence of a dolly, presence of a stack tray at removal position (duplicate setting sen-sor), presence of a stack tray on the arm, position of the arm, and the status of other trays.The basic operation for opening the front cover is described below.

1. When the front cover open button is pressed, the stack tray starts to descend.

When the arm avoidance sensors (S19/24) detects that the stack tray reached the removal position, the front cover solenoid (SL2) is released and the front cover opens.

If the front cover open button is pressed once more before the stack tray reaches the removal position, the front cover opens and the paper can be removed.

2. If the stack tray is already at the removal position when the front cover open button is pressed, the front cover opens.

3. If duplicate setting of the stack tray is detected when the front cover open button is pressed, the front cover opens immediately because the stack tray cannot descend.

4. When stack trays 1/2 are both descending when the front cover open button is pressed, the front cover opens when stack tray 1/2 reaches the removal position.

If the other tray is still descending, the front cover does not open even when one of the trays reaches the removal position.

If the front cover open button is pressed once more before the stack tray reaches the removal position, the front cover opens and the paper can be removed.

Tray 1 arm unit

SL2

S19

S24

Tray 2 arm unit

Stack tray 2

Front cover open button

Stack tray 1

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Technology > Controls > Fan control

Technology > Controls > Fan control

Fan controlThe stacker has six fans to cool the motors and electric elements on the power supply PCBs. The fan is controlled by the CPU on the master controller PCB. Its operating conditions are as follows:

Name Function Error CodeCooling fan 1 (FAN1) Cools the horizontal registration shift motor

(M7).E587-0001

Cooling fan 2 (FAN2) Cools the horizontal registration detection motor (M9).

E587-0002

Cooling fan 3 (FAN3) Cools the inlet motor 1 (M1). E587-0003Cooling fan 4 (FAN4) Cools the power suply PCB 2 (38V1). E587-0004Cooling fan 5 (FAN5) Cools the power suply PCB 1 (24V). E587-0005Cooling fan 6 (FAN6) Cools the power suply PCB 3 (38V2). E587-0006

Cooling fan 7 (FAN7) Cools the top tray feed motor (M37). E587-0007

Cooling fan 9 (FAN9) Cools the coupled eject motor 3 (M16). E587-0009

When a job starts

When a job is finished

FAN1

FAN2

FAN3

FAN4

FAN5

FAN6

FAN7

FAN9

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Technology > Controls > Detecting jams


Detecting jamsThis machine is provided with the paper sensors shown below to detect presence of paper and whether paper is fed properly.

Horizontal registration timing sensor (S7)Gripper timing sensor (S8)Paper inlet sensor 2 (S9)Paper inlet sensor 1 (S11)Coupled eject sensor 1 (S12)Coupled inlet sensor (S13)Stack tray eject sensor 1 (S35)Stack tray eject sensor 2 (S36)Top tray eject sensor 2 (S62)

S8

S9

S11

S7

S13S12S10 S35S36

S62

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The presence/absence of a jam is checked by the master controller PCB at such times as programmed in advance. When the master controller PCB detects a jam, it suspends the ongoing feed/eject operation and communicates the presence of a jam to the host machine.

Jam Sensor Description Code Service PCB indication code

Paper inlet sensor 1 delay jam S11 The paper inlet sensor 1 (S11) does not detect ON within a specific time after the start signal ON from the host ma-chine has been received.

J1010 J-10

Paper inlet sensor 2 delay jam S9 The paper inlet sensor 2 (S9) does not detect ON within a specific time after the paper inlet sensor 1 (S11) has detected ON.

J1011 J-11

Horizontal registration timing sensor delay jam S7 The horizontal registration timing sensor (S7) does not detect ON within a specific time after the paper inlet sensor 2 (S9) has detected ON.

J1012 J-12

Gripper timing sensor delay jam GS8 The gripper timing sensor (S8) does not detect ON within a specific time after the horizontal registration timing sensor (S7) has detected ON.

J1013 J-13

Stack tray eject sensor 1 delay jam S35 The stack tray eject sensor 1 (S35) does not detect ON within a specific time after the gripper timing sensor (S8) has detected ON.

J1014 J-14

Stack tray eject sensor 2 delay jam S36) The Stack tray eject sensor 2 (S36) does not detect ON within a specific time after the stack tray eject sensor 1 (S35) has detected ON.

J1015 J-15

Coupled inlet sensor delay jam S13 The coupled inlet sensor (S13) does not detect ON within a specific time after the gripper timing sensor (S8) has de-tected ON.

J1016 J-16

Top tray eject sensor delay jam S62 The top tray eject sensor (S62) does not detect ON within a specific time after the coupled inlet sensor (S13) has detected ON.

J1017 J-17

Coupled eject sensor 1 delay jam S12 The coupled eject sensor 1 (S12) does not detect ON within a specific time after the coupled inlet sensor (S13) has detected ON.

J1018 J-18

Coupled eject sensor 2 delay jam S10 The coupled eject sensor 2 (S10) does not detect ON within a specific time after the coupled eject sensor 1 (S12) has detected ON.

J1019 J-19

Paper inlet sensor 1 stationary jam S11 The paper inlet sensor 1 (S11) detects paper, but the paper does not leave the sensor within a specific time. J1120 J-20Paper inlet sensor 2 stationary jam S9 The paper inlet sensor 2 (S9) detects paper, but the paper does not leave the sensor within a specific

time.J1121 J-21

Horizontal registration timing sensor stationary jam

S7 The horizontal registration timing sensor (S7) detects paper, but the paper does not leave the sensor within a specific time.

J1122 J-22

Gripper timing sensor stationary jam S8 The gripper timing sensor (S8) detects paper, but the paper does not leave the sensor within a specific time. J1123 J-23Stack tray eject sensor 1 stationary jam S35 The stack tray eject sensor 1 (S35) detects paper, but the paper does not leave the sensor within a specific time. J1124 J-24Stack tray eject sensor 2 stationary jam S36 The Stack tray eject sensor 2 (S36) detects paper, but the paper does not leave the sensor within a specific time. J1125 J-25Coupled inlet sensor stationary jam S13 The coupled inlet sensor (S13) detects paper, but the paper does not leave the sensor within a specific time. J1126 J-26Top tray eject sensor stationary jam S62 The top tray eject sensor (S62) detects paper, but the paper does not leave the sensor within a specific time. J1127 J-27

Coupled eject sensor 1 stationary jam S12 The coupled eject sensor 1 (S12) detects paper, but the paper does not leave the sensor within a specific time. J1128 J-28Coupled eject sensor 2 stationary jam S10 The coupled eject sensor 2 (S10) detects paper, but the paper does not leave the sensor within a specific time. J1129 J-29Power-on jam S7, S8, S9, S10,

S11, S12, S13, S35, S36, S62

The front cover open/close sensor (S52) has detected an open front cover or the front cover open switch 1/2/3 (SW1/2/3) has detected an open front cover during job.

J1303 J-03

Door open jam SW1, SW2, SW3, SW4, SW5, SW6, S5, S52, S60

The stacker has detected an open front cover during job. J1404 J-04

Emergency stop jam - When performing emergency stop operation because of emergency stop command from the host machine during a job JFF06 J-06

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Stationary jam S7, S8, S9, S10, S11, S12, S13, S35, S36, S62

After closing the front cover, there is no paper on the sensor, but paper is detected when idling the feed motor during initialization after closing the front cover.

J1707 J-07

Error detection jam - When the first error occurs (it is an error if it is detected once more when recovering from an error detection jam). J1C0C J-0C

Curled paper detection jam S31, S35, S36, S38 When stack tray eject sensor stationary jam is detected during curl detection. J1C0A J-0AEarly arrival jam 1 - When the inlet motor did not start, the signal of the stacker transfer was sent.

When the paper tip arrived at the eject entrance of the stack part, loading preparations for stack part are not over.J1230 J-30

Mixed width paper stacking jam - When stacking of sheets with different widths has been detected . J1C31 J-31Mixed length paper stacking jam - When stacking of sheets with different lengths has been detected J1C32 J-32Early arrival jam 2 - When paper has arrived at the stacker inlet earlier than the time notified by the stacker J1200 J-06

T-2-1T-2-1

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Technology > Controls > Power Supply > Protective Functions


Power SupplyThis machine incorporates three power supply PCBs to supply DC power to every PCB.The following table summarizes functions of DC power supply units and so on as well as the names of the circuits supplied with DC and AC power.

Name Function

Power supply PCB 1 Generates DC power (24V) and supplies DC power to the master controller PCB and slave controller PCB.

Power supply PCB 2 Generates DC power (38V1) and supplies DC power to the master controller PCB .

Power supply PCB 3 Generates DC power (38V2) and supplies DC power to the master controller PCB and slave controller PCB.

Power switch Turns on/off the power supply PCB 1/2/3.

Microswitch (SW1 - 7, SW9 -11) Turns on/off the 24V and 38V systems.

Leakage breker Shuts off the power when the machine becomes out of order.

Protective FunctionsThe 24VDC/38VDC circuits (used for driving solenoids, etc.) on the master controller PCB and slave controller PCB are provided with a fuse or a motor driver with an overcurrent pro-tective function. The 24VDC/38VDC input circuit of each controller PCB is also provided with a fuse which is blown when an excessive current flows.Power supply units 1/2/3 are provided with an overcurrent/overvoltage protective function to shut off the output voltage automatically when an excessive current or voltage occurs due to a problem on the load side (e.g., short-circuiting), thus protecting electric circuits.When the overcurrent/overvoltage protective function is activated, turn off the Power switch, solve the load-side problem, and then turn on the Power switch.Each circuit is provided with a fuse which is blown when an excessive current flows in the AC line, thus shutting off the excessive AC current.

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+3.3V

For doubly connecting

Breaker

SW12

AC relay PCB

Noise filter PCB

AC relay PCB

Remote signal(DC+38V2)

Remote signal(DC+24V)

Motor

Motor

M20

M19

M10,M28

PowersupplyPCB 3(38V2)

Remote signal(DC+38V1)

PowersupplyPCB 1(24V)

SW2

SW3

SW4

SW5

SW1Motor

Motor

Motor

Motor

Motor

Fan

Motor

Slave controller PCB

Solenoid

Solenoid

M17,M18,M23,M24,M25,M26,M27,M35

M22,M21,M29,M30,M31,M33,M34,M32

SL4,SL5

SL2,SL3

Motor,Solenoid

M6,M7

M9,M11,M12,M13,M15,M16,M36

M1,M2,M3,M4,M8,M37

FAN1,FAN2,FAN3,FAN4,FAN5,FAN6

M14,SL1

Master controller PCB

SW9

SW10

SW11

Option controller PCB

+5V

Sensors

Sensors

PowersupplyPCB 2(38V1)

DC/DCconverter (IC5)

DC/DCconverter (IC5)

Logic system

Motor driver IC

Motor driver IC

+3.3V logic system

Motor driver IC+5V logic system

SW6

SW7

SW1: Front cover open/close switch 1 SW7: Stack tray 2 safety switchSW2: Front cover open/close switch 2 SW9: JAM open/close switch 3SW3: Front cover open/close switch 3 SW10: JAM open/close switch 2SW4: Stack tray 1 approach disabled area switch SW11: JAM open/close switch 1SW5: Stack tray 2 approach disabled area switch SW12: power switchSW6: Stack tray 1 safety switch

F-2-48F-2-48

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Technology > Controls > Power Supply > Work of service

Technology > Controls > Power Supply > Work of service

Work of serviceWhen replacing the parts

When replacing the following parts, perform the operations.(Refer to the adjustment chapter for more information.)

Part name Operation ReferenceMaster controller PCB

Reinstall the EEPROM on the PCB to a new PCB. Or enter the value of the service label attached to the internal cover (right).

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Periodic ServicingWhen the parts are reaching the expected service life, perform the parts replacement orcleaning etc if needed.

Item Part name Expectedservice life

Qty Operation Refer-ence

Periodically replaced parts

No

Consumable parts Decurler sponge roller 1,000,000 sheets

1 Replace-ment

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Insention belt 1,000,000 sheets

2 Replace-ment

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Periodically serviced parts

Feed pass sensor 1,000,000 sheets

10 Cleaning 3-2

Points to note about serviceWhen handling the following parts, be careful not to get injury or break any part.

Part name Name of parts/action to take ReferenceForeign matter de-tection cover

When installing the foreign matter detection cover, fit two springs in the positioning holes.

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Insertion unit Before starting the work, remove the carry with the machine powered. After removing it, turn off the machine and then go through the steps. Removing the screw, the isertion unit drops. Therefore support its unit by hand.After installing the insertion unit, be sure to check that the belt holder has a nip at the timingbelt.

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Insertion belt When installing the insertion belt, put it between the shafts. 4-36

T-2-2T-2-2

UpgradingFlash ROM is used for IC3 (CPU) on the master controller PCB. Rewrite this IC when up-grading.There are two ways to upgrade.1. Upgrading from the host machine (using USB memory or service support tool)2. Upgrading the stacker alone (using download PCB (FY9-2034) and service support tool)

Machine name: HSTK_E1Unit name:- Master controller PCB: ST_CON- Option controller PCB: OP_CON, OP_BOOT

Machine name: HSTK_E1Unit name:- Master controller PCB: CN20- Option controller PCB: J11

Caution:

Before downloading the controller, set the SW to suit the kind of system software to be downloaded. When the download completes, reset SW to the default setting.

System software Description RemarksST_CON Turn the SW1 ON (right side) on

the master controller PCB .The default is OFF (left side).

OP_CON Turn the SW1-1 ON on the option controller PCB .

The default of SW1-1/2 is ON.

OP_BOOT As a default

33 Periodic Servicing

Periodic Servic-ing

List of Work for Sched-uled Servicing

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Periodic Servicing > List of Work for Scheduled Servicing


List of Work for Scheduled ServicingPR:Replacement (Periodically replaced parts) CR:Replacement (consumable parts) CL:Cleaning LU:Lubrication AD:Adjustment CH:MaintenanceAs of January 2009 Category Part name Part number Qty Interval

(1,000,000 sheets)Remarks Adjusted/ not

adjustedCounter Reference

1 Stack feed block Decurler sponge roller FB5-9103 1 CR No DRBL-2>ST1-RBLT*In the duplicate system, the downstream stacker is displayed as ST2-RBLT.

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2 Stack feed block Insention belt FC7-1141 2 CR No DRBL-2>ST1-D-RL*In the duplicate system, the downstream stacker is displayed as ST2-D-RL.

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3 ALL Feed pass sensor WG8-5736 10 CL No 3-3

Decurler unit

Insention unit

[1]Decurler sponge roller

[2]Insention belt MEMO:The center value of the evaluation result data is used to determine the replacement interval.The replacement interval may vary depending on the installation environment and the status of use.Part numbers are subject to change due to design change, etc.

F-3-1F-3-1

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- Cleaning the Feed Path Reflective Sensor

S8

S9

S11

S1

S7

S13S12S10 S35S36

S62Symbol Name Procedure Reference

S11 Paper inlet sensor 1 Open the jam removal lever (B).Clean this sensor through its optical path hole.

-

S9 Paper inlet sensor 2 pen the jam removal lever (C).Clean this sensor through its optical path hole.

-

S7 Horizontal registration timing sensor

Remove one screw, and then remove the jam removal lever (D2). Clean this sensor through its optical path hole.

-

S1 Horizontal registration shift sensor

1. Remove six screws, and then remove the guide (right) in the compartment block.2. Remove two screws, remove the sensor PCB, and then clean the sensor.

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S8 Gripper timing sensor

Open the jam removal lever (D1).Clean this sensor through its optical path hole.

-

S35 Stack tray eject sensor 1

Remove the decurler unit.Clean this sensor through the opening where the decurler unit was mounted.

-

S36 Stack tray eject sensor 2

With the stack tray lowered, clean this sensor from inside of the compartment block.

-

S62 Top tray eject sensor Open the jam removal lever of the upper cover.Clean this sensor through its optical path hole.

-

S13 Coupled inlet sensor Open the jam removal lever (F1).Clean this sensor through its optical path hole.

-

S12 Coupled eject sensor 1

Open the jam removal lever (F2).Clean this sensor through its optical path hole.

-

S10 Coupled eject sensor 2

Remove the static charge eliminator bracket. (Two screws) Remove the sensor.

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F-3-2F-3-2

44 Parts Replacement and Cleaning Procedure

Parts Replacement and Cleaning Procedure

Removing this EquipmentList of PartsExternal / Internal CoversMain unitsConsumable Parts Requiring Periodic Replacement and Cleaning PointsSolenoids

MotorsFansSensorsSwitchesPCBs

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Parts Replacement and Cleaning Procedure > Removing this Equipment


Removing this Equipment

1) Disconnect the power cable. 2) Remove the shunt cable securing the stacker to the upstream machine.

x2

3) Open the cable clamp, and then take out the interface cable from it. 4) Remove the interface cable from the stacker.

F-4-1F-4-1F-4-2F-4-2

F-4-3F-4-3 F-4-4F-4-4

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5) Remove the wrench (small).

x1x1

6) Using the wrench (small), loosen the adjuster to raise it above the floor.

7) Open the right front cover, remove the screw, and then release the lock using a screwdriver. Remove the stacker from the upstream machine.

x1

F-4-5F-4-5 F-4-6F-4-6

F-4-7F-4-7

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Parts Replacement and Cleaning Procedure > List of Parts > External / Internal Covers

Parts Replacement and Cleaning Procedure > List of Parts > External / Internal Covers

List of Parts

External / Internal Covers

[5]

[4]

[1]

[2]

[3]

[6]

[8]

[12][11]

[10]

[7]

[9]

[13]F-4-8F-4-8

F-4-9F-4-9

[14] [15]

No. Name Part No. Refer to

[1] Front Upper Cover (Left) FC3-5264 4-16[2] Front Upper Cover (Right) FC3-5237 4-17[3] Upper Cover (Middle) FC3-5239 4-17[4] Front Cover (Right) - 4-18[5] Front Cover (Left) - 4-18[6] Upper Tray Cover FC3-5171 4-20[7] Upper Tray Rear Cover FC3-5175 4-20[8] Foreign Matter Detection Cover FC3-5170 4-21[9] Rear Upper Cover (Right) FC3-5238 4-22[10] Rear Cover (Lower) FC3-5377 4-22[11] Rear Cover (Upper) FC3-5353 4-23[12] Rear Upper Cover (Left) FC3-5265 4-23[13] Upper Tray Vertical Face Cover FC3-5174 4-24[14] Inner Cover (Left) FC3-5240 4-24[15] Inner Cover (Right) FC3-5262 4-10

F-4-10F-4-10

T-4-1T-4-1

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Parts Replacement and Cleaning Procedure > List of Parts > Main Units

Parts Replacement and Cleaning Procedure > List of Parts > Main Units

Main Units

[1]

[7]

[8]

[2]

[4]

[5]

[3]

[6]

F-4-11F-4-11


[1] Insertion unit FG3-4209 4-26[2] Decurler unit FG3-4216 4-27[3] Main controller - 4-28[4] Power supply - 4-28[5] Horizontal registration

detection unitFG3-4192 4-31

[6] Tray2 eject 1 unit FG3-4208 4-32[7] Alignment/accessory plate unit

(F)FM4-5195 4-34

[8] Alignment/accessory plate unit (R)

FM4-5196

T-4-2T-4-2

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Parts Replacement and Cleaning Procedure > List of Parts > Consumable Parts Requiring Periodic Replacement and Cleaning Points > Cleaning Points

Parts Replacement and Cleaning Procedure > List of Parts > Consumable Parts Requiring Periodic Replacement and Cleaning Points > Cleaning Points

Consumable Parts Requiring Periodic Replacement and Cleaning Points

Consumable Parts

[1]

[2]


[1] Stack insertion belt FC7-1141 4-36[2] Decurler sponge roller FB5-9103 4-35

F-4-12F-4-12

T-4-3T-4-3

Cleaning Points

S8

S9

S11

S1

S7

S13S12S10 S35S36

S62


- Feed path reflective sensor WG8-5736 3-3

F-4-13F-4-13

T-4-4T-4-4

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Parts Replacement and Cleaning Procedure > List of Parts > List of Solenoids

Parts Replacement and Cleaning Procedure > List of Parts > List of Solenoids

List of Solenoids

SL2

SL5

SL1

SL3

SL4

F-4-14F-4-14

Name Part No. Refer toSL1 Flapper-coupled solenoid FH6-5138 4-37SL2 Front door lock solenoid FM3-2304 4-38SL3 Flapper top tray solenoid FH6-5138 4-38SL4 Stack tray 2 lock solenoid FH6-5131 4-39SL5 Stack tray 1 lock solenoid FH6-5131

T-4-5T-4-5

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Parts Replacement and

High Capacity Stacker-E1 SM

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Transcript of High Capacity Stacker-E1 SM