EF-35 - Service Manual

Kyoto,Japan
030904/EF35/00E/NT
EF-35
Paper Folder
SERVICE MANUAL
510 Kuze Ooyabu-cho, Minami-ku, Kyoto, 601-8206, Japan
Phone:+81-(0)75-934-6700, Fax:+81-(0)75-934-6708, www.horizon.co.jp
US503008-00
FOREWORD
Paper Folder
Model EF-35
Important Information
- This service manual is designed to help you to repair and maintain the EF-35 in order to keep it in good operating condition.
Please read and understand the instructions in this service manual before performing any repair or maintenance.
- Horizon International Inc. shall not be liable for incidental or consequential damages resulting from: improper or inadequate
maintenance by the customer; unauthorized modification or misuse; or operation outside of the environmental specifications
for the product.
- Horizon International Inc. follows a policy of continuing improvement in design and performance of the product. Therefore,
the product design and specifications are subject to change without prior notice and without our legal obligation.
- All rights are reserved. No part of the manual may be photocopied, reproduced or translated to another language without the
prior written consent of Horizon International Inc.
Safety Precautions
- Please read and understand all safety instructions with include the terms
instructions are ignored, personal injury may result.
WARNING, and
CAUTION. If these safety
- The repair, maintenance and safety instructions in this manual are valid only when the repair or maintenance work is performed
according to the procedures described in this manual.
- The term WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
- The term CAUTION indicates a potentially hazardous situation which, if not avoided, may result in damage on machines. It may
also be used to alert against unsafe practices.
- Horizon International Inc. cannot anticipate every possible situation that might involve a potential hazard. The instructions in this
manual and the warning labels on the machine are therefore not all-inclusive.
- All equipment shall be locked out or tagged out to protect against accidental or inadvertent operation when such operation, repair
or maintenance could cause injury to personnel. Do not attempt to operate any switch, valve, or other energy isolating device
when it has been locked or tagged out.
- Some of the drawings in this manual show the machine uncovered for explanations of details inside the machine.
II
Service Operation Precaution

1. Turn off power switch and pull out the plug for precaution
except in case of neccesity before parts replacement or other
maintenance operations.
2. Mind rotating parts such as belt and pulley or electric cables
when operating with covers removed.
3. A single operator must operate yourself only. This manual
supposes operations by a single operator.
4. Caution that other persons do not touch the machine during
your service operations.
5. When turning on power switch again, wait for a dozen of
seconds after turning off.
6. When replacing parts, use parts shown in parts book except
when the same functions can be found among commercial
parts.
III
Handling Precautions for P.C.Board and ROM

P.C.Board and ROM can be damaged by humanly imperceptible static electricity.
Handle P.C.Board and ROM with following care.
Keep P.C.Board in a shield bag.
Acrylic
Cover
Do not put P.C.Board and ROM on the

machine, especially on the acrylic cover.
(No problem on the conductive plate.)
And keep the P.C.Board and ROM away
from the insulators.
Insulators: Plastic, form polystyrene,
chemical fiber fabric, dry paper, etc.
Shield Bag
P.C.Board
Conductive
Sponge
Clip
Put the ROM on a conductive sponge

and keep in a shield bag.
Machine
Frame
Shield Bag
Wrist
Strap
IV
When replacing the P.C.Board and ROM,

or setting the dip switches and volumes
on the P.C.Board, wear a wrist strap, and
connect the clip to the machine frame
(not painted surface).
Description of Abbreviations in This Manual

1. Cable Colors
Abbr. BRN RED
Color Brown Red
ORN YEL
GRN
Orange Yellow Green
BLU VIO
GRY
Blue Violet Gray
WHT BLK
White Black
BRN-g=The description "g" in cable color means the gray band tying the connector.
RED-BLU=The description means that the wire is blue matrix with red stripe.
2. Electrical Symbols
Abbr.
Axx
Bxx
Cxx
Fxx
Gxx
Kxx
Description
Inverter
Sensor
Capacitor
Fuse
Power Supply
Contactor
Abbr.
Lxx
Mxx
Hxx
Qxx
QPMxx
QPWxx
Description
Lamp, LED
Motor
Heater
Circuit Protector/ Breaker
Multi-layer circuit board
Single-layer circuit board
Abbr.
Sxx
Txx
Uxx
Xxx
Yxx
Zxx
Wxx
Description
Switch
Transformer
Driver/ Inverter
Terminal Board, Connector
Valve
Noise Filter
Power Plug
3. Other Symbols
Abbr.
AC
BK
CL
CON
CW
CCW
DC
Description
Alternating Current
Brake
Clutch
Connector
Clockwise
Counterclockwise
Direct Current
Abbr.
DSW
F.G
JSW
MS
PB
RY
SSR
Description
Dip Switch
Frame Ground
Jumper Switch
Microswitch
Parts Book
Relay
Solid State Relay
V
Abbr.
VR
Sig
S/N
Description
Volume
Signal
Serial Number (of machines)
CONTENTS
3. Troubleshooting for Folding Quality
FOREWORD ........................................................................ I
Important Information ........................................................ I
3-1 The Sheets are Folded Diagonally ................................ 3-2
Service Operation Precaution ............................................. III

Handling Precautions for P.C.Board and ROM ............... IV
3-2 The Fold Line Moves Gradually ................................... 3-3

3-3 The Fold Lines are not Even ......................................... 3-3
Description of Abbreviations in This Manual ................... V
3-4 The Thick (Hard) Sheets Delivered

are not Arranged Straight ............. 3-4
1. Before You Begin
3-5 Either or both sides of the sheet edge are bent ............ 3-5
3-6 Double Step Folding Occurs ......................................... 3-6
1-1 Machine Description ...................................................... 1-2

1-1-1 Overview .................................................................... 1-2
3-7 The Sheet is Wrinkled Crossing the Fold Line ........... 3-6
1-1-2 Control Panel (1) ........................................................ 1-3

1-1-2 Control Panel (2) ........................................................ 1-4
4. Replacement and Adjustment
1-2 Other Information ........................................................ 1-5
4-1 Removing Feed Table .................................................... 4-2

4-2 Replacing the Fold Roller .............................................. 4-4
2. Troubleshooting
4-3 Adjusting the Fold Roller Gap ..................................... 4-6

4-4 Adjusting the Tension of Drive Belt ............................. 4-8
2-1 The Sheet is not Fed (Although Feed Rotor Rotates) 2-2
2-1 The Sheet is not Fed
4-5 Replacing the Delivery Conveyor Belt

and Adjusting the Belt Tension ................... 4-9
(Because Feed Rotor does not Rotate) ........ 2-4

2-2 A Sheet Jam Occurs Frequently ................................... 2-6
4-6 Replacing the Feed Rotor Belt

and Adjusting the Belt Tension ................... 4-10
2-3 The Total Counter does not Count Up ......................... 2-7

2-4 The Counter Sensor Keeps Lighting Up ...................... 2-7
4-7 Replacing the Motor Driver .......................................... 4-12

4-8 Installing Standard for Other Parts ............................. 4-13
2-5 The Circuit Breaker (Q01) is Tripped ......................... 2-8

2-6 The Folding Speed Reduces .......................................... 2-8
2-7 The Delivery Conveyor does not Operate .................... 2-9
VI
5. Electrical Parts Layout and Description

5. Electrical Parts Layout and Description ........................ 5-2
6. P.C.B and Wiring Diagram

6-1 QPW-589 Control P.C.B ............................................... 6-2
6-2 100VAC Power Circuit Diagram .................................. 6-4
6-3 24VDC Wiring Diagram ............................................... 6-5
VII
This page is intentionally left blank.
VIII
1. Before You Begin
1-1
1. Before You Begin
1-2
1. Before You Begin
1-1 Machine Description

1-1-1 Overview
Fixed Fold Roller
First Roller
First Nut
First Buckle Plate
The gap between the first roller

and the fixed fold roller can be
adjusted using this nut.
Second Nut
Feed Rotor
The gap between the second

roller and the first roller can be
0
Second Roller
Third Roller
Third Nut
The gap between the third roller

and the second roller can be
Feed Table
Second Buckle Plate
Tension Pulley Shaft

The tension of the feed rotor belt can
be adjusted by this shaft position.
Feed Rotor Drive Shaft

Drive Belt
Conveyor Belt
Conveyor Motor
Timing Belt
Drive Motor M01
Conveyor Motor M02

Idle Pulley Bracket
Drive Belt Tension Spring
The tension of the conveyor belt can be adjusted

by moving this bracket.
The drive belt is tensed up with

this spring.
Tension Adjusting Nut

The tension of the drive belt can be

1-1-2 Control Panel (1)
Feed Rotor Vacuum LED
This LED lights while the feed rotor is
providing vacuum to sheet, and blinks when
the continuous folding mode is selected.
Feed Sensor LED

This LED lights each time a sheet passes
through the feed section.
Pause LED
This LED lights while the machine is
paused, and also after a preset stop.
Feed Interval Knob

This knob is used to adjust the feed interval.
Pump Switch
Vacuum Time Knob
When switched on in motor running, the

air blow into feed table.
This knob is used to adjust the vacuum time for

the feed rotor. When the knob is turned all the
way to the right, the LED blinks and the feed
rotor provides vacuum continuously.
Fold Speed Knob
Pause Time Knob
This knob is used to adjust the rotating

speed of the fold rollers.
When the knob is turned all the way to
the left, the fold rollers might stop
rotating.
This knob is used to adjust the pause time

between one batch of sheets and the next
batch when the preset pause mode is selected.
Test Feed Button
3
4
When this button is pressed while the motor is

running, one sheet will be fed.
Conveyor Switch
This switch is used to change the operating mode of the conveyor.
When
is selected, the conveyor
operates continuously.
When
is selected, the conveyor
operates only after a sheet has passed
through the feed sensor, and during the
pause time.
1-3
Roller/ Feed Start Button

3
4
This button is used to start feeding the sheets.

Press this button once to start the motor, the
roller, delivery conveyor, and the pump. Press
this button again to start the feeding operation.
Conveyor Speed Adjusting Knob
Roller/Feed Stop Button
This knob is used to adjust the conveyor

belt speed. When the knob is turned all
the way to the left, the delivery conveyor
belts might stop rotating.
When this button is pressed once, the machine stops feeding the sheets. Press this
button again to stop the motor, the roller,
delivery conveyor and the pump.
1. Before You Begin
1-4
1. Before You Begin

1-1-2 Control Panel (2)
Total Counter
This indicates the total number of folded
sheets.
Total Counter Clear Button

The total counter can be reset using this button.
Preset Counter
This indicates the number of sheets to be folded
in preset stop mode or preset pause mode.
Preset Number Save Button

This button is used to save the preset number. The preset
number can be viewed again by pressing this button even if
the machine has stopped during the folding operation
because it reached the preset stop number.
3
4
Preset /Number Set Button

3
4
These button are used to set the preset number. The

buttons set the units, tens, hundreds, and thousands
digit from the right respectively.
Each number can be changed by pressing the
correct button.
Mode Select Button

When the continuous folding mode is selected, the preset
stop lamp and the pause mode lamp are turned off.
This button is used to change the mode for

continuous folding, preset stop, and the preset
pause counter.
1-2 Other Information

The angle of the feed table
~S/N008899
Up to S/N008899
Installed by inclining about 10 degrees upward to
the sheet feeding direction.
10
The angle of the feed table is changed to

the level to feed the thin sheets stably.
S/N009001-014899
S/N009001-014899
Installed on the level.
1-5
1-2 Other Information
1. Before You Begin
1-6
1. Before You Begin
2. Troubleshooting
2-1
2. Troubleshooting
2-2
2. Troubleshooting
2-1 The Sheet is not Fed (Although Feed Rotor Rotates)

First Check
- The gap between the gate plate and the
feed rotor is too narrow.
- The vacuum time is too short.
- Too many sheets are loaded.
- The feed guides are set too tight.
- The vacuum position of the feed rotor is not
correct.
- The sheets are not separated correctly.
- The blower air is too weak.
If the pump filter is clean, make the air pressure
stronger using the regulator on the blower. Even if
the blower air is still weak after adjusting the air
pressure, check that the blower air hose is
connected tightly using the hose clamp.
The blower and vacuum pump do not

operate.
- Check if the pump switch is turned on.
- Check if the pump connector X01 is
plugged in the machine. (Fig.1)
- Check if the pump circuit breaker Q20 is
tripped. (Fig.1)
If the circuit breaker is tripped again, check if the
filter element of the blower and vacuum pump is
clogged, or the blower and vacuum pump is
overloaded.
If all of the outlets (five cocks) are closed

completely, or closed almost, the blower
and the vacuum pump is overloaded.
Release the air from the unused outlet.
- The vacuum of the feed rotor is too weak.

If the pump filter is clean, make the vacuum
stronger using the regulator on the vacuum pump.
Even if the vacuum is still weak after adjusting the
vacuum, check that the vacuum hose is connected
tightly using the hose clamp.
Also, check if the electrical leak occurs on the

wiring between the Q20 and M03 (Fig.1)
- Check if the wiring between the power

switch S01 and the pump M03 is correct.
(Fig.2)
- When the start button is pressed, check if

the pump contactor K20 is turned on.
(Fig.1)
When K20 is not turned on, if there is no defect
in the wiring between the pump contactor K20,
terminal A1, A2 and the Control P.C.B, CON 3,
Pin 9, 10, replace the contactor and the control
P.C.B in order.
- Check if the wiring between the pump

switch S14 and the Control P.C.B, CON 3
is correct. (Fig.2)
- When the pump switch is turned on, the
circuit is closed.
R
DE
OL
RF
PE
PA
EF
-35
- After pressing the start button and rotating

the feed rotor, press the start button or
the test button again. The sheet starts
being fed and the feed rotor vacuum LED
lights up.
If the suction air valve does not work, check
the followings.
- When the suction air valve works, check if
the feed rotor vacuum LED on the control
panel lights up. (L2 in section 6-2)
If it lights up, check the wiring between the
Control P.C.B, CON 3 and the feed rotor Y01.
X01
6-3 24VDC Wiring Diagram)
If there is no defect in the wiring, replace the

suction air valve and the control P.C.B in order.
If it does not light up, check if the input signal of
the start button is input into the P.C.B (L4 in
section 6-2). If there is no problem in the input
signal of the start button, replace the P.C.B.
Q20
K20
Fig.1
2-3
2. Troubleshooting
2-4
2. Troubleshooting
2-1 The Sheet is not Fed (Because Feed Rotor does not Rotate)
Adjust the roller speed using the fold speed knob.
S14
WHT
First Check
- The roller speed setting is too slow.
Pump Switch
2 4 6
S01
WHT
RED
WHT
BLK
FG
7
6
4
3
E
7
6
4
3
E
2
29
M01
BRUSHLESS DC MOTOR
DRIVER FBLD120AW
SPEED
POWER
S.S.
ALARM
S.D.
EXT-INT
Power Lamp
Alarm Lamp
MOTOR
GRN
BLK
RED
Connector
Q20
Pump Breaker
2
3
4
5
A1
K20
A2
Pump Contactor
I/O
7
GRN
2 4 6 14
- Check if the power LED (green) of the

main motor driver (U01) lights up.
WHT
BLK
32
WHT
BLK
If it does not light up, check if the input wiring is

connected with the driver.
Main Motor
X01
WHT
BLK
BLK
1. The motor is overloaded.

2. The input wiring is connected with the driver.
And the input voltage is 100V+/-10V.
3. The wiring to the main motor (M01) is OK.
Control P.C. Board
QPW-589
GRN
RED
BLK
WHT
FG
- Check if the alarm LED (red) of the main

motor driver (U01) lights up.
If it lights up, check the followings.
CON3
BLK
BLK
BLK
9 10 11 12
WHT
WHT
The motor driver (U01) is normal. (Fig.2)
WHT
- If it is tripped again, check if the roller

motor is overloaded. And check if the
electrical leak occurs in the wirings from
the circuit breaker Q10 to the followed
wiring.
1 3 5
BLK
The circuit breaker Q10 is tripped.
RED
WHT
BRN
RED
Power Switch
X03
GRN
10
NC
11
12
FG
VEXTA
1 2 3
U01
Terminal Board
Pump
AC100-115V~
Main Motor Driver
M03
Fig.2
The drive mechanism of the feed rotor is
normal. Check the followings. (Fig.3)
- Check if the belts slip on the pulley.
Even If the belts are cleaned up and they still
slip, replace them.
- Check if the reduction pulley rotates

smoothly.
- Check if the pulley of the feed table is
fixed with the shaft tightly.
- Check if the feed rotor belts slip on the
feed rotor.
Even If the belts are cleaned up and they still
slip, adjust the belt tension. (
Reduction Pulley
4-6
M01
Replacing the Feed Rotor Belt and Adjusting the

Belt Tension)
Pulley
Belt
Feed Rotor Section

- Check if the feed rotor rotates smoothly.
Tension Roller
Remove the feed rotor belt and check the feed

rotor.
Feed Rotor Belt
Fig.3
2-5
2. Troubleshooting
2-6
2. Troubleshooting
2-2 A Sheet Jam Occurs Frequently

First Check
- The sheets are curled.
- The buckle plate is not set correctly.
- If the sheet does not enter the first buckle,
the gap between the buckle plate and the
fold roller is too wide. (Fig.1)
- If the sheet is thick and it does not enter
the first buckle, widen the gap between the
buckle plate and the fold roller. (Fig.1)
- Actually, the double feeding occurs.
Point Driver
If the double feeding occurs, check the followings.
1. Fan the sheets.

2. Turn the rear blower air nozzle away from
the sheets to reduce the blower air.
3. Narrow the gap between the gate plate and
the feed rotor.
4. Shorten the vacuum time.
5. Make the feed interval longer.
Guide Screw
The fold roller is not cleaned up.

The gaps between the fold rollers are not
provided correctly.
- Refer to 4-3 Adjusting the Fold Roller
Gap and adjust the gaps between the
fold rollers.
Fig.1
2-3 The Total Counter does not Count Up
2-4 The Counter Sensor Keeps Lighting Up
The position of the counter sensor is not

correct
First Check
- The paper dust sticks to the sensor.
The counter sensor does not work correctly.

- When the counter sensor detects the
sheet, check if the L7 on the P.C.B lights
6-1 QPW-589 Control
- When the counter sensor detects nothing,

check if the L7 on the P.C.B does not light
up. (Fig.1)
B01
Counter Sensor
When L7 lights up,

- The signal wiring might be short circuited, or
13
CON5
CON1
the P.C.B might be damaged.

If there is no defect between the control
CON8
5 6 7
CON3
L8
L7
P.C.B, CON3 and the counter sensor, replace

the counter sensor and the control P.C.B in
- The signal of the counter sensor is input to the

P.C.B, but there is a defect on the P.C.B.
Replace the P.C.B.
- The voltage between CON3-Terminal 5 and 7
measures 24VDC always. When the sensor
detects the sheet, the voltage between CON3Terminal 6 and 7 measures 24VDC.
When does not light up,
- The signal of the counter sensor might not be
5 6 7
24V
SIG
0V
When lights up,
order.
- The voltage between CON3-Terminal 5 and 7
CON3
always measures 24VDC. When the sensor

detects the sheet, the 24VDC between CON3-
L2
L1
L3
Terminal 6 and 7 is measured.
Control P.C.Board
QPW-589
1234
P.C.B)
13
When L7 does not light up,
L9
ON
up. (
The counter sensor works correctly.
BRN
BLK
BLU
- Refer to 4-8 Installing Standard for Other

Parts and check the installing position of
the count sensor.
L4 L5 L6
L10
- There are no defect in the counter sensor and

the wiring. There is a defect on the control
CON7
CON2
P.C.B. Replace the P.C.B.
input to the P.C.B, or the P.C.B might be

damaged. Check the wiring between the
control P.C.B, CON 3 and the counter sensor
B01. (Fig.1)
- If there is no defect in the wiring, replace the
counter sensor and the control P.C.B in order.
2-7
2-3 The Total Counter does not Count Up / 2-4 The Counter Sensor Keeps Lighting Up
Fig.1
2. Troubleshooting
2-8
2. Troubleshooting
2-5 The Circuit Breaker (Q01) is Tripped
2-6 The Folding Speed Reduces
The alarm LED of the main motor driver

lights up.
The drive belt slips on the pulleys.

- When the drive belt slips on the pulleys,
even if the belt is cleaned up, adjust the
- If it lights up, turn the power off and check

if the rotation of the fold rollers is heavy.
belt tension. (
4-4 Adjusting the
Tension of Drive Belt)
The following wiring circuit is short circuited. (Fig.1)

- The wiring between the power switch S01
and the power supply.
- The wiring between the power switch S01
and the main motor driver.
Power Supply
WHT
WHT
BLK
WHT
WHT
Drive Belt
WHT 1 ACIN
BLK ACIN
3
GRN FG
5
2 4 6
S01
Q10
Power Switch
Breaker
1 3 5
230V 50Hz
115V 60Hz
BLK
WHT
BLK
W01
0V 1
0V 2
0V 3
G01
4
5
24V 6
24V 7
24V 8
Main Motor Driver
U01
BLK
FBLD120AW
WHT L
BLK N
WHT
GRN
M01
NC
FG
M01
1
2
3
4
5
6
7
8
9
10
11
12
(Tension Adjustment for the new belt)
Screw Part of Hook
Main Motor
12mm
(0.47)
Fig.1
Stopper Shaft
2-7 The Delivery Conveyor does not Operate

The delivery conveyor is operated in two
modes.
- Continuous Mode:
The delivery conveyor works while
the fold rollers rotates.
- Intermittent Mode:
The delivery conveyor works only
when a sheet has passed through the
counter sensor and during the pause
time.
First Check
- The connector of the delivery conveyor is
connected with the control P.C.B.
- The speed of the delivery conveyor is set to
the minimum.
GRN FG
9 9 GRN
GRN
3 3 RED
WHT
BLK
34
GRN
BLK
11
CON5
CON1
1
M02
Conveyor Motor
CON8
L7
L8
The wiring between the control P.C.B

(QPW-589), CON8 and the conveyor motor
M02 is not correct. (Fig.1)
X02
1 2
CON3
11
- If it is correct, replace the conveyor motor

and the control P.C.B in order.
L1
L3
L2
Control P.C. Board

QPW-589
1234
ON
L9
L4 L5 L6
L10
1
CON7
CON2
Fig.1
2-9
2-7 The Delivery Conveyor does not Operate
2. Troubleshooting
2-10
2. Troubleshooting
3-1
3-2
3-1 The Sheets are Folded Diagonally

First Check
- The feed guides are not parallel to the
feeding direction.
- The gap between the feed guide and the
sheet is too wide.
- The buckle stopper is inclined.
- The guide screws for the buckle on each
side project by the same amount. (The
buckle plate is inclined in the relation to the
rest of the machine.)
- The sheet is not square because it has
been trimmed incorrectly.
- The sheets are wavy because of the
humidity.
- The sheets are curled.
The inner ring in the needle bearing is

worn out.
The gaps between the fold rollers are not

provided correctly.
- Refer to 4-3 Adjusting the Fold Roller
Gap and check the gaps between the
fold rollers.
- Check if the roller tension spring is damaged. (Fig.1)
There is a thrust play in the fold rollers.
- Check if there is any play in the fold
rollers because the washer is worn out.
(Fig.1)
Set Screw
Link Spring Stopper
Roller Tension Spring
Washer
Nut
Washer
Link
Fig.1
Needle Bearing
Inner Ring
3-2 The Fold Line Moves Gradually

First Check
- The buckle stopper locking screw is tightened completely.
- The buckle plate is not correctly set in
relation to the rest of the machine.
The drive belt slips on the pulleys.
- When the drive belt slips on the pulley,
even if the belt is cleaned up, adjust the
belt tension. (
3-3
3-4
3-4 The Thick (Hard) Sheets Delivered are not Arranged Straight
The position of the delivery rollers are not
correct. (Fig.1)
- Set the delivery rollers so that the delivered sheet is held under the delivery
rollers immediately.
Delivery Guide
Delivery Roller
The position of the delivery guides are not

correct. (Fig.1)
- Set the delivery guides according to the
sheet size so that the sheets are hold by
them.
The angle of the delivery conveyor is not
correct. (Fig.2)
Fig.1
- Set the delivery conveyor to reduce the

angle for the sheets which are thick and
easy to open.
Conveyor (Normal Angle)
Delivery Conveyor
Conveyor (Low Angle)
Easy to open
Set the flat plate under

the conveyor to make the
angle low.
Fig.2
3-5 Either or both sides of the sheet edge are bent

(The sheet is bent downward)
(The sheet is bent upward) (Fig.2)
(Either side of the sheet is bent)
(Inner edge of the sheet rolls)
(Fig.1)
- The sheet is curled upward.

- The buckle plate is set close to the
fold roller too much.
- The pressure of the first fold roller
(press roller) is too strong.
- The deflector is inclined.

(The buckle plate installing the
deflector might be inclined in rest
of the machine.)
- The buckle plate is set so that the

inner side of sheet is too long. If it
still rolls after adjusting the inner
length, curl it in reverse to prevent
the inner edge rolling, and load the
sheets.
- The sheet is curled downward.

- The buckle plate is set at the high
position.
(Hitting the deflector) (Fig.3)

- The sheet hits a scratch on the
deflector surface.
- The pressure of the second fold
roller (press roller) is too strong.
- The distance between the buckle
chute and the fold roller is too
narrow.
2
3
2
Fig.1 Dog Ears-Downward Folding
Fig.2 Dog Ears-Upward Folding
Fig.4 Inner Folding
3
Fig.3 Hitting the Deflector
3-5
3-5 Either or both sides of the sheet edge are bent
3-6
3-6 Double Step Folding Occurs
3-7 The Sheet is Wrinkled Crossing the Fold Line
The roller pressure of the third fold roller

is too strong.
- The sheets are wavy because of the

humidity.
- The gate plate is set too low.
- The roller pressure of the first fold roller is
too strong.
- Reduce the roller pressure to allow the air

to release.
The third fold roller rotates correctly.
- Check that the pulley is fixed with the
roller shaft firmly. (Fig.2)
Third Fold
Roller Shaft
Pulley
3
Air Pocket:
It is caused that the
roller pressure is too
strong and the air can
not be released from
the sheet inside.
Fig.1 Double Step Folding
Fig.2 Pulley and Fold Roller Shaft
Fig.1 Wrinkled Crossing the Fold Line
4-1
4-2
4-1 Removing Feed Table

Removal
1.
2.
3.
Remove the front cover.
4.
Remove the feed table from the

machine.
Remove the belt. (Fig.1)

Remove the vacuum hose and the
blower air hose from the bottom of
the feed table. (Fig.1)
- Remove the feed table, lifting up it.
Vacuum Hose
Blower Air Hose
Belt
To Pump
Fig.1
4-3
4-4
4-2 Replacing the Fold Roller

Remove
Install
1.
2.
3.
4.
5.
1.
Turn off the main power.
Remove the drive belt. (Fig.1)
2.
Remove the manual drive knob. (Fig.1)

Remove the roller pulley. (Fig.1)
- The washer is also removed.
7.
8.
Remove the side plate only on the

front side. (Fig.1)
Remove the roller link on the front
side, which should be removed. (Fig.2)
1. Fasten the nut to widen the gap between the
fold rollers. (Both side)
2. Loosen the set screw of the roller link spring
stopper on the front side and remove the
roller link. (Only on the front side)
- If the fixed roller is replaced, remove the
screw with the hexagon socket. (Fig.2)
- The roller link on the rear side is not necessary to remove.
9.
Remove the fold roller to the front

side.
Install the roller link.

- Before installing the roller link, lubricate the
inner ring of needle bearing and the hole of
the roller link. (Fig.2)
- Install all the roller links facing to the outside
so that you can see the letters carved on the
bearing.
- If the roller link can not be installed smoothly,
install the roller link into the fulcrum shaft by
turning the nut. (Fig.2)
- If the roller link is installed on the fixed fold
roller, loosen the link stopper shaft, fit it with
the rounded part of the link and lock the screw
with hexagon socket using the nut (Fig.2).
And then lock the link stopper shaft.
- The washer is also removed.
6.
- Lock the roller pulley, pulling the fold

roller to the front side and pushing the
pulley to the rear side.
- After installing the roller pulley, check
if the fold rollers can be rotated
smoothly.
If it is difficult to rotate, install the
pulley at the front side a bit more.
- At the end, check if all the four fold
rollers can rotate smoothly and the
play of the fold rollers to both side are
least.
4-1
Removing Feed Table)
3.
Insert the washer and the roller pulley

into the fold roller.
Insert the fold roller.

- Before installing the fold roller, lubricate the
inner ring of needle bearing.
Remove the front and the rear cover.

Remove the feed table. (
4.
Install the side plate.
5.
6.
Install the manual drive knob.

Install the drive belt. (Fig.4)
- Attach it by the correct direction.
- After attaching the belt, adjust the tension of
it. (
7.
Drive Belt)
Adjust the gap between the fold

rollers.
(
After installing the side plate, check if the

roller link can be moved by pressing the
roller links as shown by the arrow. (Fig.3)
8.
9.
4-4 Adjusting the Tension of
4-3 Adjusting the Fold Roller Gap)
Install the feed table into the machine.

Install the front and the rear cover.
Side Plate
W5
SB5-12
Link
Washer
SS6-6 SS6-6
Manual Drive Knob

Washer
Roller Pulley
Drive Belt
Side Plate
Fig.1
Fig.3
Screw with
Hexagon Socket
Rounded Part
Buckle Locking Knob
Link Stopper Shaft
Fixed Fold
Roller Link
Set Screw
Roller Link Spring Stopper
Hole of Roller Link
Nut
Lubricate here, Before
installing.
Link
12mm
Fig.2
4-5
Fig.4
4-6
4-3 Adjusting the Fold Roller Gap

Before Adjusting
Adjust
1.
1.
Prepare the test strip.

Coated Paper, 73-79 gsm,
Width: about 20 mm (0.8),
Length: about 100 mm (4.0)
2.
Remove the first and the second

buckle plates.
3.

machine.
(
4-1 Removing Feed Table)
4.
Remove the front and the rear covers.
5.
Check if the set screw of the roller

link spring stopper is fasten firmly.
WARNING
When adjusting the fold roller
gap, keep your hands and fingers
off the fold rollers. Otherwise the
fold rollers can cause severe
personal injury.
Turn on the main power and rotate

the fold rollers.
3.
- Set the roller speed to 3 or 4.
2.
Insert the one strip between the fixed

fold roller and the first fold roller, and
check the pulling force.
- First, fasten the nut to provide the roller gap.
- Loosen the first nut gradually to adjust so that
the pulling is adjusted as indicated below.
- The pulling force will be stronger by loosing
the nut.
- Loosen the nuts on front and rear side gradually and evenly.
When the nut is loosen for one round, the

fold roller gap will be narrower about 0.8
mm (0.03).
(Standard)
- A little wider than roller gap where the
inserted test strip is torn.
- The pulling force is even on front and rear
side.
- Adjust the roller gap so that the speed of the
fold rollers does not reduce by the friction of
the test strip and the fold rollers.
Also, insert the one strip between the

first fold roller and the second fold
roller (Fig. 2), and adjust the pulling
force.
- Adjust it using the second nut.
4.
Next, insert the two strips between

the second fold roller and the third
fold roller (Fig. 2), and check the
pulling force.
- Adjust it using the third nut.
5.
After adjusting the pulling force,

check the roller gap as well after
changing the speed of the fold rollers.
Check
- The pulling force is even on both front and
rear side at any speed, but it can be changed
according to the speed.
6.
After inserting the thick sheet of the

210 gsm or thicker between each fold
rollers a few times, check the pulling
force of each fold roller again.
Set Screw
Check
- Before and after inserting the thick sheet, the
pulling force does not change.
- The pulling force might change until the parts
related on the fold roller gap are settled. If it
changes, adjust the fold roller gap until it does
not change.
7.
Feed Table
First Buckle Plate
Second Nut
Install the buckle plate and the feed

table, and fold the required sheets
thirty times continuously.
After that, check the pulling of strip in
step 2, 3 and 4.
Check
- Check if the pulling force does not change.
- The pulling force might change until the parts
related on the fold roller gap are settled. If it
changes, adjust the fold roller gap and check
the pulling of the strip repeatedly until it does
not change.
Set Screw
Set Screw
3
First Nut
Third Nut
Second Buckle Plate
Number of insert
test strip
One
Strip
Drive Motor
One
Strip
0
1
2
3
Two
Strips
Rotating
Direction
Fig.2
Fig.1
4-7
4-8
4-4 Adjusting the Tension of Drive Belt

Adjust
1.
2.

Adjust the tension of the drive belt
using the hook screw.
Drive Belt

- The screw part of hook comes out about 12
mm (0.47) from the stopper shaft.
M01
Screw Part of Hook
12mm
(0.47)
Stopper Shaft
Fig.1
4-5 Replacing the Delivery Conveyor Belt and Adjusting the Belt Tension
Remove
1.
2.
Install
1.

Remove the delivery conveyor from
the machine.
3.
Remove the receiving tray from the

delivery conveyor. (Fig.1)
4.
5.
Remove the motor cover. (Fig.1)
6.
Remove the conveyor stay from the

delivery conveyor. (Fig.2)
Install the delivery conveyor in the

reverse order of the removal.
Conveyor Stay
Idle Pulley
(Adjusting the tension of the delivery conveyor

belt)
- The standard tension: The idle pulley bracket
is 30 mm (1.2) from the delivery conveyor
side plate (Fig.3). After adjusting the tension,
lock the tension adjusting screw using the nut.
Conveyor Stay
Motor Bracket Locking Screws
Remove the idle pulley bracket from

the delivery conveyor. (Fig.2, 3)
- Loosen the tension adjusting screw.
- Remove the four locking screws.
- The delivery conveyor belts can be
removed. (Fig.1)
Locking Screw
Idle Pulley Bracket
Fig.2
Receiving Tray
Tension Adjusting Screw

Delivery Conveyor Side Frame
Delivery Conveyor Belt

Idle Pulley Bracket
Locking Nut
Locking Screw
Motor Cover
Fig.1
4-9
4-5 Replacing the delivery Conveyor Belt and Adjusting the Belt Tension
30mm
(1.2)
Fig.3
4-10
4-6 Replacing the Feed Rotor Belt and Adjusting the Belt Tension
Remove
Install
1.
2.
1.
Replace the feed rotor belt.

machine. (
4-1 The Feed Table
2.
Install the tension pulley shaft and

the feed adjusting shaft to the feed
rotor.
Removal)
3.
Remove the rotor link A and B together. (Fig.1)
4.
5.
Remove the rotor cover. (Fig.1)
6.
Remove the N6 nut and the W6 large

washer locking the feed rotor side
frame. (Fig.1)
Remove the bearing of the feed rotor
drive shaft from the feed table frame.
- Lock the tension pulley shaft at the lowest

position of the hole. (Fig.3)
- The screw of hexagon socket (SB4-30) is not
only the locking screw but also the stopper, so
fix the screw as shown in the Fig. 4.
3.
4.
- Do not need to remove the bearing from the

shaft.
7.
Attach the rotor cover.

Install the rotor link A and B.
- Install them to the rotor so that you can
see the slit of the feed adjusting shaft
from the window of the feed table in the
view A. (Fig.5)
- After attaching them, check that the
rotor link B has no play and moves in
the B direction smoothly. (Fig.1)
Remove the tension pulley shaft and

the feed adjusting shaft from the feed
rotor. (Fig.2)
- Remove the feed adjusting shaft by lifting up
the feed rotor side plate.
- The feed rotor belts can be removed.
5.
Install the feed table to the machine.
Tension Pulley Shaft
Rotor Cover
Feed Adjusting
Shaft
N6
W6(L)
Feed Adjusting Shaft
22 to 23mm
(0.86 to 0.90)
Feed Rotor Drive Shaft

Bearing
SB4-8
Fig.4
ETW-5
W4S
W4
Feed Rotor
Side Frame
Rotor Link B
W-4
B4-6BC
Rotor
Link A
N6
W4
W4S
B
View A
Fig.1
You can see the wide hole of

the feed adjusting shaft.
N4
SB4-30
Fig.5
Feed Rotor Side Frame
Fig.2
Feed adjusting shaft
Feed Table
4-11
Lock the tension pulley shaft at

the lowest of the hole.
Fig.3
4-12
4-7 Replacing the Motor Driver

Remove
To Control
P.C.B.
CON7
Remove the delivery conveyor.
To
Motor
M01
Fig.1
12
VEXTA
GRN FG
GRN
11
N.C.
BRN
9
BLK
EF-35 is not
necessary to
adjust them.
10
RED
WHT
Power Box
Cover
Driver Cover
Locking Screw
WHT
YEL
4
I/O
ALARM
POWER
Remove the driver. (Fig.1)
AC100-115V
8.
S.S.
Remove the power box cover. (Three

locking screws) (Fig.1)
GRN
EXT
Remove the connector and the cable

from the driver. (Fig.2)
INT
EXT-INT
Remove the driver cover. (Four locking

screws) (Fig.1)
15
Turn the
lever to INT
Driver Cover
S.D.
Remove the rear cover.
SPEED
7.
Remove the second buckle plate.
BRUSHLESS DC MOTOR
DRIVER FBLD120AW
6.
MOTOR
1.
2.
3.
4.
5.
Fig.2
To Power Switch
S01
4-8 Installing Standard for Other Parts

The installing position of the main
motor pulley
- Install the motor pulley 13 mm (0.5)
apart from the side plate.
- Fasten the set screw on the flat face of
the motor shaft.
The installing position of the delivery conveyor motor pulley

- Insert the motor pulley up to the flat face
of the motor shaft.
- Fasten the one of set screws on the flat
face of the shaft.
The install position of the counter

sensor
- Install the counter sensor, pushing up it.
Fasten the one of set

screws on the flat face of
the shaft.
Delivery Conveyor Motor
Lubricate 242
Adhesives
Sheet Sensor (B01)
- Set the volume to 14A.
Installing Position of Sheet

Sensor
M02
Motor
Pulley
N4F
Ground
Wire
Teethed
Washer
Installing Position of Delivery

Conveyor Motor Pulley
The current setting of the pump

breaker
Fix the sheet sensor,

pushing it up.
Pump Breaker Q20
a
a
Set
Screw
14A
14
ON
M01
9
Q20
Current Setting of
the Pump Breaker
4-13
4-8 Installing Standard for Other Parts
13mm
(0.5)
Motor Pulley
Roller Motor
Installing Position of Main

Motor Pulley
4-14
5-1
5-2

QPW-589
R
PE
PA
-35
EF
Y01
VR2
S15
VR1
R
DE
OL
RF
-35
EF
B01
PE
PA
ER
LD
FO
M02
S13
S14
G01
Q10
U01
X01
M01
X02
S01
Q20
K20
X03
M03
Code
B01
G01
K20
M01
M02
M03
Q10
Q20
QPW-589
S01
S11
S12
S13
S14
S15
U01
VR1
VR2
X01
X02
X03
Y01
S11
S12
Name
Counter Sensor
Power Supply
Pump Contactor
Main Motor
Conveyor Motor
Pump
Breaker
Pump Breaker
Control P.C.B
Power Switch
Roller / Feed Start
Roller / Feed Stop
Test Feed
Pump Switch
Conveyor Switch
Main Motor Driver
Conveyor Speed
Feed Speed
Pump Connector
Conveyor Connector
Pump Terminal Board
Suction Air Valve
Remarks
Light sensitive sensor
24VDC
Brushless DC motor
Gear Motor
750W
5A
Setting Value: 14A
The circuit is closed during turning on

The circuit is closed during turning on
24VDC
6-1
6-2
6-1 QPW-589 Control P.C.B
CON1
1
CON5
1
CON3
1
L8
CON8
1
L7
Control ROM
L2
L1
L3
1234
ON
L9
L4 L5 L6
L10
1234
CON7
ON
DSW
CON2

Control ROM Revision Chart
Control
ROM
Control
P.C.B.
S/N -
V3.1
QPW-589A
1. The preset counter Off mode is added to the

002001- operation mode of the preset counter. (Mode changes
OFF-STOP-PAUSE-OFF.)
V3.4.1.1
QPW-589B
008001-
V3.4
QPW-589E
011001-
V4.2
QPW-589F
020001-
V4.2
QPW-589G
021001-
V4.2
QPW-589H
024001-
Improvement
The ROM version number can be indicated on display from V2.10.
(Indicated pressing the start button, stop button and test feed button at
the same time.)
After replacing ROM, the total counter and the preset counter might not
2. The valve sounds even when the vacuum timing is set
function correctly. Press the total counter clear button and the preset
at minimum.
number save button.
3. The feed rotor vacuum LED lights up even if a sheet is When this ROM is installed on the machine up to serial number -004938,
fed by the test feeding.
tell the new function to the users.
The delivery conveyor can be operated only
The ROM V3.4 can be used from QPW-589D.
continuously. (ROM only for QPW-589B)
The delivery conveyor had worked only while the fold
Replace the control panel and P.C.B (QPW-589E or later).
roller is driving. The intermittent operation mode is
When the P.C.Board of QPW-589E or later is installed on the machine up
added. The conveyor runs when a sheet has passed
to the serial number 010899, plug the short circuit connector into the
through the count sensor, and during the pause time.
P.C.Board, CON5. (The short circuit connector is supplied with P.C.B.)
When this P.C.Board is replaced from QPW-589F or older, plug the short
The connector (CON4) for KTU-35 is added.
circuit connector into the CON4.
The front and the back side of the ROMs are changed.
This board has a compatibility with the QPW-589F.
The spare DIP switch is installed. This board has a
compatibility with the QPW-589F.
LED Lighting Conditions

LED NO.
L1
L2
L3
L4
L5
L6
L7
L8
L9
L10
6-3
Lightening Condition
During the pause time and after a preset stop.
Sheet is being vacuuming. (While vacuuming the sheets continuously, it blinks.)
While the counter sensor is detecting the sheet.
While the roller/feed start button is being pressed.
While the roller/feed stop button is being pressed.
While the test feed button is being pressed.
While the counter sensor is detecting the sheet.
When the EF-354 is connected with the ED-354.
When the preset stop mode is being selected.
When the preset pause mode is being selected.
L1 to L3, L9, L10: The output device of micon, which lights up

and turns off according to the program.
L4 to L8: The direct monitor LED according to the signal input.
6-4
WHT
WHT
BLK
WHT
WHT
6-2 100VAC Power Circuit Diagram
Q10
2 4 6
Breaker
S01
BLK
WHT
BLK
GRN
7 7
RED
WHT 6 6 BLK
4 4
BLK
WHT
3 3 FG
FG
29
U01
X01
BLK
RED
BLK
WHT
Connector
WHT L
BLK N
GRN
NC
FG
Q20
Pump Breaker
A1
K20
A2
Pump Contactor
32
1 2 3
Terminal Board
M03
GRN
WHT
BLK
BLK
2 4 6 14
Pump
4
5
24V 6
24V 7
24V 8
Main Motor Driver
EE
X03
0V 1
0V 2
0V 3
WHT
BLK
W01
G01
WHT 1 ACIN
BLK ACIN
3
GRN FG
5
GRN
230V 50Hz
115V 60Hz
Power Supply
Power Switch
WHT
BLK
1 3 5
M01
Main Motor
1 INPUT COM
2 EXT.VR.
3 CW
4 CCW
5 SLOW DOWN Input Signal Terminal
6 N.C.
7H
8M
9L
10 GND
Input /Output Ground
11 SPEED OUT
12 ALARM OUT Output Signal Terminal
6-3 24VDC Wiring Diagram
X02
BLK
WHT
GRN FG
GRN
BLK
40
B01
Y01
1 2
Suction Air Valve 1 2
Main Motor
6-5
GRN
BLK
WHT
BLK
RED
WHT
BLK
GRN
WHT
BLK
BRN
BLK
BLU
24V
SIG
0V
CON8
W01
S01
FG
4 4
3 3 FG
EE
29
X01
QPW-589
Connector
Pump Breaker
12 11 10 9 8 7 6 5 4 3 2 1
RED
A1
K20
A2
Pump Contactor
3 2 1 1 2 3 4 3
4 3
4 3
NC
NC
NC
VR2 VR1 S13 S12 S11

Feed Conveyor Test
Speed Speed Feed
Stop
6-3 24VDC Wiring Diagram
2 4 6 14
GRN
RED
BRN
Q20
CON2
YEL
ORN
6 5 4 3 2 1
BLU
GRN
GND
CW
VR-H
VR-M
VR-L
CON7
U01
M01
WHT 7 7 GRN
RED 6 6 RED
Control P.C. Board
Main Motor Driver
1 GRN
2 YEL
3
4
5
6
7 WHT
8 RED
9 BRN
10 GRN
11
12
CON3
Conveyor Motor
1 2
CON1
CN2
INPUT COM
EXT.VR.
CW
CCW
SLOW DOWN
N.C.
H
M
L
GND
SPEED OUT
ALARM OUT
CON5
11
1 2 3 4 5 6 7 8 9 10 11 12
WHT
GRY
VIO
CN1
4
5
24V 6
24V 7 WHT
24V 8 RED
1 2 3 4 5 6
13
RED
BRN
BLK
WHT
GRY
VIO
BLU
GRN
YEL
ORN
RED
BRN
WHT 1 ACIN
BLK ACIN
3
GRN FG
5
1 2 3 4
RED
BRN
BLK
S01
GRN
0V 1
0V 2 BLK
0V 3
24V
24V
0V
0V
G01
GRN
YEL
WHT
RED
BRN
Power Supply
RED
ORN
14
M02
RED
WHT
BRN
RED
Conveyor switch
16
Contact Signal for ED-354

2
No use in EF-35
5
9 GRN
34
3 RED
WHT
1
WHT
BLK
S15
S14
Counter Sensor
Pump switch
2
5
9
3
1
M04
M03
Pump
Pump
Start
6-6

EF-35 - Service Manual

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EF-35 - Service Manual

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Kyoto,Japan

CAUTION. If these safety

Service Operation Precaution

Handling Precautions for P.C.Board and ROM

Keep P.C.Board in a shield bag.

Do not put P.C.Board and ROM on the

Put the ROM on a conductive sponge

When replacing the P.C.Board and ROM,

Description of Abbreviations in This Manual

3-1 The Sheets are Folded Diagonally ................................ 3-2

Service Operation Precaution ............................................. III

3-2 The Fold Line Moves Gradually ................................... 3-3

Description of Abbreviations in This Manual ................... V

3-4 The Thick (Hard) Sheets Delivered

1. Before You Begin

1-1 Machine Description ...................................................... 1-2

1-1-2 Control Panel (1) ........................................................ 1-3

4. Replacement and Adjustment

1-2 Other Information ........................................................ 1-5

4-1 Removing Feed Table .................................................... 4-2

4-3 Adjusting the Fold Roller Gap ..................................... 4-6

4-5 Replacing the Delivery Conveyor Belt

(Because Feed Rotor does not Rotate) ........ 2-4

4-6 Replacing the Feed Rotor Belt

2-3 The Total Counter does not Count Up ......................... 2-7

4-7 Replacing the Motor Driver .......................................... 4-12

2-5 The Circuit Breaker (Q01) is Tripped ......................... 2-8

5. Electrical Parts Layout and Description

6. P.C.B and Wiring Diagram

This page is intentionally left blank.

1. Before You Begin

1. Before You Begin

1. Before You Begin

1-1 Machine Description

First Buckle Plate

The gap between the first roller

The gap between the second

The gap between the third roller

Second Buckle Plate

Tension Pulley Shaft

Feed Rotor Drive Shaft

Drive Motor M01

Conveyor Motor M02

Drive Belt Tension Spring

The tension of the conveyor belt can be adjusted

The drive belt is tensed up with

Tension Adjusting Nut

1-1 Machine Description

Feed Sensor LED

Feed Interval Knob

Vacuum Time Knob

When switched on in motor running, the

This knob is used to adjust the vacuum time for

Fold Speed Knob

Pause Time Knob

This knob is used to adjust the rotating

This knob is used to adjust the pause time

Test Feed Button

When this button is pressed while the motor is

Roller/ Feed Start Button

This button is used to start feeding the sheets.

Conveyor Speed Adjusting Knob

Roller/Feed Stop Button

This knob is used to adjust the conveyor