Page 1: Service Manual
SERVICE MANUAL CODE: 00ZARF16//A2E DIGITAL COPIER/PRINTER/ MULTIFUNCTIONAL SYSTEM OPTION FINISHER/PUNCH MODULE AR-F15 AR-F16 AR-F15 AR-F16 AR-PN4 MODEL AR-PN4 CONTENTS CHAPTER 1 GENERAL DESCRIPTION ......1-1 CHAPTER 2 FINISHER UNIT BASIC OPERATION .
Page 2 The installation and service should be done by a qualified service technician. 1. When installing the Finisher AR-F15/F16, Hole punch unit AR-PN4 to the Plain Paper Copier, be sure to follow the instructions described in the “Unpacking/Set-Up Procedure for the AR-F15/F16/AR-PN4”...
Page 3 INTRODUCTION This Service Manual contains basic data and figures for the Finisher (AR-F15)/Saddle Finisher (AR-F16) needed to service the machine in the field. This manual comprises the following chapters: Chapter 1 “General Description” introduces the finisher’s features, specifications, and names of parts, and shows how to operate the finisher.
Page 4: Table Of Contents
D. Removing Paper Jams from the II. SPECIFICATIONS ....... 1-2 Saddle Stitch Unit A. Finisher specifications (Saddle Finisher) ....1-18 (AR-F15/F16) ......1-2 E. Supplying the Saddle Stitch B. Punch unit specifications Unit with Staples (AR-PN4) ........1-8 (Saddle Finisher) ....1-20 C.
Page 5 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION BASIC OPERATION ....3-1 C. Controlling the Movement of A. Outline ........3-1 Sheets ........3-21 B. Electrical Circuitry ....3-2 D. Aligning the Sheets ....3-23 C. Inputs to and Outputs from the E.
Page 6 CHAPTER 6 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED III. Consumable parts replacement PARTS ......... 6-1 procedures ........6-3 A. Finisher Unit ......6-1 A. Paddle replacement ....6-3 B. Saddle Stitch Unit ....6-1 B. Knurled belt replacement ..6-4 C. Puncher Unit (option) ....6-1 IV.
Page 7 D. Removing Paper Jams from the II. SPECIFICATIONS ....... 1-2 Saddle Stitch Unit A. Finisher specifications (Saddle Finisher) ..... 1-18 (AR-F15/F16) ......1-2 E. Supplying the Saddle Stitch B.Punch unit specifications Unit with Staples (AR-PN4) ........1-8 (Saddle Finisher) ..... 1-20 C.
Page 9: Chapter 1 General Description
AR-PN4C 4 holes (φ6.5) (80mm pitch) France AR-PN4D 4 holes (φ6.5) (70, 21mm pitch) Sweden Stapler for Finisher Staple cartridge Cartridge for AR-F15/16 5000 x 3 SF-SC11 5000 staples Common with S55,S55N,FN8/9 F15/F16 Stapler for Saddle Staple cartridge For AR-F16 (Saddle Stitch Finisher)
Page 10: Specifications
CHAPTER 1 GENERAL DESCRIPTION II. SPECIFICATIONS Finisher specifications (AR-F15/F16) Finisher (AR-F15) (1) Stack section Type Floor installation Stacking method Upper/Lower tray: Ascent/descent type offset tray Transport speed 55 to 70 sheet/minute Tray type Upper/Lower Tray Ascent/descent type offset tray Output paper size...
Page 11 CHAPTER 1 GENERAL DESCRIPTION Height of mixed load When power is turned 29mm ± 7mm on. (When there is Equivalent to 150 sheets/50 sets paper on the tray.) Size mixed load 74mm ± 7mm (No bind, mixed load) Equivalent to 500 sheets Staple mixed load 74mm ±...
Page 12: Stapling Position
CHAPTER 1 GENERAL DESCRIPTION : Jan. 9 2004 (Stapling position) Staple in the front Paper transport direction * Stapling position when viewed with the Paper width copy surface up 4.4 ± 2.5 mm (30˚) 4.4 ± 2.5 mm One-point staple at the back 5.0 ±...
Page 13 : Jan. 9 2004 CHAPTER 1 GENERAL DESCRIPTION 2. Saddle stitch finisher (AR-F16) (1) Stack section Type Floor installation Stacking method Upper/Lower tray: Ascent/descent type offset tray Transport speed 55 to 70 sheets/minute Tray type Upper/Middle Tray Ascent/descent type offset tray Lower Tray Book tray for saddle stitch Output paper size...
Page 14 CHAPTER 1 GENERAL DESCRIPTION : Jan. 9 2004 Height of mixed load When power is turned 29mm ± 7mm Equivalent to 150 sheets/50 sets Size mixed load 74mm ± 7mm (No bind, mixed load) Equivalent to 500 sheets Staple mixed load 74mm ±...
Page 15 : Jan. 9 2004 CHAPTER 1 GENERAL DESCRIPTION Number of sheets Max.: 15 sheets (256g/m 1 sheet + 80g/m 14 sheets) stapled Number of sets loaded 10 sets (11 to 15 sheets), 20 sets (6 to 10 sheets), 25 sets (1 to 5 sheets) Staple load type Staple cartridge type (2,000 staples) Staple empty detection Available...
Page 16: Punch Unit Specifications (Ar-Pn4)
CHAPTER 1 GENERAL DESCRIPTION : Jan. 9 2004 Punch unit specifications (AR-PN4) Finisher available for Finisher and saddle stitch finisher installation of the punch module Kind of hole punch 2-hole / 3-hole / 4-hole/ 4-hole (Broad space) One of the above four punch unit can be attached. Paper size to be punch 2-hole A3, A4, A4R, B4, B5, B5R, 11 x 17, 8.5 x 14,...
Page 17: Engine Specification (Ar-F15/F16/Pn4)
CHAPTER 1 GENERAL DESCRIPTION . Engine specification (AR-F15/F16/PN4) Paper capacity 4000 sheets (small size), 2000 sheets (large size) Tray1/Tray2 Lift type tray 2000 sheets (small size: 80 g/m²) 1000 sheets (large size: 80 g/m²) Face-down Job offsetting Paper full detection...
Page 18 CHAPTER 1 GENERAL DESCRIPTION : Jan. 9 2004 (Combination of functions) – Offset Staple Punch Saddle stitch Offset – Staple – Punch – Saddle stitch – (Staple sheet capacity) Size Capacity 50 sheets Letter Letter-R Legal Foolscap 30 sheets 11 x 17 Saddle stitch 15 sheets (60 pages) (Sheet capacity of stack trays)
Page 19: Cross Section
CHAPTER 1 GENERAL DESCRIPTION Cross Section Finisher Unit [2] [3] [4] [5] [6] [10] [11] [16] [17] [15] [14] [13] [12] Tray 1/2 [10] Saddle stitch flapper Shutter [11] Inlet feed roller Delivery roller [12] Feed roller 1 Swing guide [13] Vertical path Feed roller 2 [14] Stapler...
Page 20 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitch Unit [10] [11] [12] Guide plate No.1 flapper Paper folding roller No. 2 flapper Delivery guide plate Stitch mount Holding roller [10] Paper pushing plate Stitch (front, rear) [11] Crescent roller Inlet roller [12] Paper positioning plate Figure 1-205 1-12...
Page 21 CHAPTER 1 GENERAL DESCRIPTION Puncher Unit (option) Punch motor LED PCB Horizontal registration motor Hole puncher (Punch blade) Scrap full detector PCB unit Punched scrap container Photosensor PCB Figure 1-206 1-13...
Page 22: Using The Machine
CHAPTER 1 GENERAL DESCRIPTION III. Using the Machine 3) Open the upper cover, and check the inside of the finisher. Removing Paper Jams from the Finisher Unit If the host machine indicates the finisher paper jam message, perform the following to remove the jam.
Page 23: Supplying The Finisher Unit With Staples
: Jan. 9 2004 CHAPTER 1 GENERAL DESCRIPTION Supplying the Finisher 6) Return the buffer roller and the buffer roller cover to their original positions, and close the Unit with Staples upper cover. If the host machine indicates the finisher unit staple supply message, perform the following to supply it with staples.
Page 24 CHAPTER 1 GENERAL DESCRIPTION : Jan. 9 2004 4) Hold the empty staple case on its sides, and 6) Pull the length of tape (used to hold the sta- slide it out. ples in place) straight out. Figure 1-311 Figure 1-313 5) Set a new staple case.
Page 25: Removing Staple Jams From The Finisher Unit
: Jan. 9 2004 CHAPTER 1 GENERAL DESCRIPTION Removing Staple Jams 4) When the staple cartridge has slightly slid out, hold and pull it out. from the Finisher Unit If the host machine indicates the finisher unit staple jam message, perform the following to remove the jam.
Page 26: Removing Paper Jams From The Saddle Stitch Unit (Saddle Finisher)
CHAPTER 1 GENERAL DESCRIPTION Removing Paper Jams 7) Return the tab on the staple cartridge to its original position. from the Saddle Stitch Unit (Saddle Finisher) 8) Return the staple cartridge to its original If the host machine indicates the saddle stitch position, and close the front cover.
Page 27 CHAPTER 1 GENERAL DESCRIPTION 3) Turn the knob on the left side. 6) Open the inlet cover, and remove the jam. Figure 1-328 Figure 1-325 7) Close the front lower cover. 4) Turn the knob on the right side while pushing it in.
Page 28: Supplying The Saddle Stitch Unit With Staples (Saddle Finisher)
CHAPTER 1 GENERAL DESCRIPTION Supplying the Saddle 3) Pull the stitch unit to the front once, and then shift it up. Stitch Unit with Staples (Saddle Finisher) If the host machine indicates the saddle stitch unit staple supply message, perform the following to supply it with staples.
Page 29: Removing Staple Jams From The Saddle Stitch Unit (Saddle Finisher)
CHAPTER 1 GENERAL DESCRIPTION Removing Staple Jams 6) Pull the stitch to the front once, and then return it to its original position. from the Saddle Stitch Unit (Saddle Finisher) If the host machine indicates the saddle stitch unit staple jam message, perform the following to remove the jam.
Page 30 CHAPTER 1 GENERAL DESCRIPTION 4) Hold the cartridge on its sides, and remove it. 7) Return the cartridge to its original position. Figure 1-340 Figure 1-343 5) Push down on the area identified as A, and 8) Pull the stitch of the stitch unit to the front pull up the tab identified as B.
Page 31: Removing Paper Jams From The Puncher Unit (Option)
CHAPTER 1 GENERAL DESCRIPTION Removing Paper Jams 4) Holding the finisher unit as shown, move it to detach it from the most machine. from the Puncher Unit (option) If the display indicates a paper jam on the puncher unit, perform the following to remove the jam: 1) Open the front cover of the puncher unit.
Page 32 CHAPTER 1 GENERAL DESCRIPTION 8) Return the buffer roller and the buffer roller cover to their original position, and close the upper cover. Figure 1-353 9) Connect the finisher to the host machine. Figure 1-354 10) Operate as instructed on the display. 1-24...
Page 33: Removing Punched Scrap From The Puncher Unit (Option)
CHAPTER 1 GENERAL DESCRIPTION Removing Punched Scrap 4) Return the punched scrap container to its original position. from the Puncher Unit (option) If the display indicates a punched scrap full state on the puncher unit, perform the following to remove the punched scrap: 1) Open the front cover of the puncher unit.
Page 34: Maintenance By The User
CHAPTER 1 GENERAL DESCRIPTION IV. MAINTENANCE BY THE USER Maintenance by the User Item Timing Replacing the staple cartridge (finisher unit) When the appropriate indication is made on the host machine’s display. Replacing the staple cartridge (saddle stitch unit) Caution: The finisher unit and the saddle stitch unit use different cartridge types.
Page 35 CHAPTER 2 FINISHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the finisher’s functions, and the prin- ciples of operation used for the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated. The symbol in drawings indicates transmis- sion of mechanical drive, and signals marked by together with the signal name indicates...
Page 37: Chapter 2 Finisher Unit Basic Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION I. BASIC OPERATION Outline The finisher is designed to deliver copies arriving from its host machine, and its modes of (Note) delivery include simple stacking, job offset , and staple. All operations involved in these modes are controlled by the finisher controller PCB, according to the appropriate commands from the host machine.
Page 38: Outline Of Electrical Circuitry
CHAPTER 2 FINISHER UNIT BASIC OPERATION Outline of Electrical Circuitry The finisher’s sequence of operation is controlled by the finisher controller PCB. The finisher controller PCB is a 16-bit microprocessor (CPU), and is used for communication with the host machine (serial) in addition to controlling the finisher’s sequence of operations. The finisher controller PCB responds to the various commands coming from the host machine through a serial communications line to drive solenoids, motors, and other loads.
Page 39 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller Motor Saddle stitch PCB communication controller PCB (Saddle Finisher) Solenoid Switch EEP-ROM Punch driver PCB (Puncher unit (option)) Sensor EP-ROM Host machine (DC controller PCB CPU) IC6/IC7 Regulator IC Connecting with inserter Finisher controller Motor Saddle stitch...
Page 40: Inputs To And Outputs From The Finisher Controller Pcb
CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Inputs to the Finisher Controller PCB Figure 2-103...
Page 41 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Figure 2-104...
Page 42 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Figure 2-105...
Page 43 CHAPTER 2 FINISHER UNIT BASIC OPERATION : Jan. 9 2004 Inputs to and Outputs from the Finisher Controller PCB +24V JS1-1 J2-5 Communication line Figure 2-106...
Page 44 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Figure 2-107...
Page 45 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB Stapler shift motor According to rotation direction/speed, changes between + and - in sequence. Staple motor According to rotation direction/speed, changes between + and -. Tray 1 lift motor J115-1 According to rotation...
Page 46: Feed/Drive System
CHAPTER 2 FINISHER UNIT BASIC OPERATION II. FEED/DRIVE SYSTEM Outline The finisher is designed to operate according to the commands from its host machine to deliver arriving copies to trays in the appropriate mode: simple stacking, job offset, stapling. See Figure 2-201 for a diagram of the three modes of delivery (four for the Saddle Finisher). Normal Method of delivery Simple stacking...
Page 47 CHAPTER 2 FINISHER UNIT BASIC OPERATION Normal Delivery a. Simple Stacking The finisher delivers copies directly to the tray. Tray Tray Copies Copies Feed roller 1 Delivery roller Feed roller 2 Figure 2-203 2-11...
Page 48 CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset The finisher forwards all copies of each sort job to the stapling tray. The first sort job on the stapling tray is delivered with a shift to the front of about 30 mm, and the second sort job is deliv- ered without being shifted.
Page 49 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling The finisher stacks copies arriving from its host machine on the stapling tray. Then, it staples and delivers the copies to the appropriate tray. Tray Copies Staple Swing guide Stopper Stapling tray Delivery roller Feed roller 1 Figure 2-207 Paper width/2...
Page 50 CHAPTER 2 FINISHER UNIT BASIC OPERATION Saddle Stitch Delivery (Saddle Finisher) A copy arriving in the finisher from the host machine is routed to the saddle stitch by the paper deflecting plate. The saddle stitch executes stitching and saddling operations on the copy and then delivers it to the saddle stitch tray.
Page 51: Type Of Delivery Paths
CHAPTER 2 FINISHER UNIT BASIC OPERATION Type of Delivery Paths The finisher has three different paper paths for delivery, each selected to suit paper size and delivery mode. Straight Path When stacking copies shown in Table 2-201, the copies pass under the buffer roller. Copy size The paper length is less than 182mm, or the paper width is less than 182mm, or the paper length is 251mm or more.
Page 52 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Paper Path 2 This is the paper path when copy sizes shown in Table 2-203 are stacked. A maximum of three copies (three originals or more in the staple mode) are wrapped round the buffer roller, during which job offset and stapling are performed on the stapling tray.
Page 53 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) The second copy is laid over the first copy and, at the same time, the third copy arrives from the host machine. First copy Second copy Third copy Figure 2-214 4) The first, second and third copies are simultaneously pulled into the stapling tray. Second copy Third copy First copy...
Page 54: Feeding And Delivering
CHAPTER 2 FINISHER UNIT BASIC OPERATION Feeding and Delivering Outline The finisher moves copies arriving from the host machine to the delivery tray, stapling tray, or the saddle stitch unit (Saddle Finisher) according to the mode of delivery. On the stapling tray, the copies are subjected to job offset or stapling as instructed by the host machine.
Page 55 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI19 PI20 PI10 PI24 PI23 Figure 2-216 2-19...
Page 56 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI17 PI14 PI11 PI12 Figure 2-217 2-20...
Page 57: Job Offset
CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset Outline In the job offset mode, sort jobs and entire copy groups are shifted to the front for delivery to the tray, and other copies are delivered to the tray without a shift. The copies are shifted by the alignment plate.
Page 58 CHAPTER 2 FINISHER UNIT BASIC OPERATION Alignment plate Guide plate Alignment plate home position sensor (PI6) Alignment motor (M3) Paper Escape solenoid (SL6) Figure 2-218 Sequence of Operation (job offset) Start signal Host machine delivery signal Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8)
Page 59 CHAPTER 2 FINISHER UNIT BASIC OPERATION Flow of Job Offset Operations 1) The swing guide moves up and, at the same time, the feed belts move the sheet to the stapling tray. Swing guide Offset sheet Feed roller 2 Knurled belts Tray 1/2 Delivery roller...
Page 60: Staple Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Staple Operation Outline The stapler unit staples a stack of as many sheets as specified. The stapling position differs according to the selected staple mode and paper size. The stapler unit is checked by the stapler shift home position sensor (PI7) to find out whether it is at the home position.
Page 61 CHAPTER 2 FINISHER UNIT BASIC OPERATION Paper width/2 2-point stapling Front diagonal stapling Rear 1-point stapling Rear diagonal stapling Figure 2-224 2-25...
Page 62 CHAPTER 2 FINISHER UNIT BASIC OPERATION First Sheet The finisher controller PCB stops the delivery motor (M2) as soon as the trailing edge of the first sheet has moved past the feed roller 2. Then, it rotates the delivery motor clockwise to switch the gear drive to the swing motor (M7), causing the swing guide to move up.
Page 63 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Swing guide open sensor (PI18) Swing guide closed Delivery roller detecting switch 1,2 (MS2/MS6) Swing motor clock sensor (PI20) Delivery motor clock sensor (PI10) Swing motor (M7) Delivery motor (M2) Figure 2-226 2-27...
Page 64 CHAPTER 2 FINISHER UNIT BASIC OPERATION Second and Subsequent Sheets The finisher controller PCB turns on the belt escape solenoid (SL7) before the trailing edge of the second and subsequent sheets have moved past the feed roller 2 to make the knurled belt escape. This operation is performed to reduce the time it takes for the trailing edge of the paper to fall on the stapling tray, and to improve the product duty.
Page 65 CHAPTER 2 FINISHER UNIT BASIC OPERATION Knurled belts Escape direction Belt escape solenoid (SL7) Figure 2-228 Paddles Paddles Paddle solenoid (SL5) Second and subsequent sheets First sheet Stapler Second feed motor Stopper Figure 2-229 2-29...
Page 66 CHAPTER 2 FINISHER UNIT BASIC OPERATION Last Sheet When the last sheet has been put in order, the finisher controller PCB turns on the alignment motor (M3) to move the alignment plate to the alignment position (to butt the plate against the stack).
Page 67 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Delivery roller Swing motor (M7) Delivery motor (M2) Figure 2-231 2-31...
Page 68: Stapler Unit
CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapler Unit Stapling is executed by the staple motor (M6). A single rotation of the cam by the motor results in one stapling operation. The cam is checked by the staple home position sensor (PI22) to find out whether it is at the home position.
Page 69 CHAPTER 2 FINISHER UNIT BASIC OPERATION Figure 2-232 Finisher controller PCB Figure 2-233 2-33...
Page 70 CHAPTER 2 FINISHER UNIT BASIC OPERATION Start signal Host machine delivery signal Stacking Stapling Delivery First sheet Second sheet Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8) Delivery motor (M2) Stapling tray sensor (PI4) Alignment motor (M3) Alignment guide home...
Page 71 CHAPTER 2 FINISHER UNIT BASIC OPERATION Shifting the Stapler Unit The stapler unit is moved by the stapler shift motor (M4). Its home position is detected by the stapler shift home position sensor (PI7). When the start signal arrives from the host machine, the stapler moves to the center of its movement range.
Page 72 CHAPTER 2 FINISHER UNIT BASIC OPERATION Rear 1-Point Stapling The stapler is kept in wait at the center position. The stapler is moved to and from the stapling position for each stapling operation. Stopper Stapling position Wait position Stapling tray delivery direction Stapler Stopper...
Page 73 CHAPTER 2 FINISHER UNIT BASIC OPERATION d. 2-Point Stapling The stapler is kept in wait at the center of the paper. Stapling occurs at two points, first at the rear and then at the front. Stopper Stapling position Wait position Stapler Stapling tray delivery direction...
Page 74: Tray Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray Operation The finisher has two delivery trays-upper tray 1 and lower tray 2. The upper and lower trays move up and down independently. Tray 1 is moved up and down by the tray 1 lift motor (M5), and tray 2 by the tray 2 lift motor (M10).
Page 75 CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray 1 lift motor One way gear Tray coming close detection switch Tray 1 lift motor clock sensor / and 2 Rack Tray 2 lift motor One way gear Tray 2 lift motor clock sensor / and 2 Figure 2-239 2-39...
Page 76: Detecting The Height Of Stack On The Tray
CHAPTER 2 FINISHER UNIT BASIC OPERATION : Jan. 9 2004 Detecting the Height of Stack on the Tray Outline The number of sheets delivered to the tray and the number of sets (number of stapling opera- tions) are stored in memory by the finisher controller PCB. The height of the stack is checked by the height sensor (PS1).
Page 77 CHAPTER 2 FINISHER UNIT BASIC OPERATION Height sensor (PS1) Paper Figure 2-240 2-41...
Page 78: Shutter Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Shutter Operation When the tray 1 passes the delivery slot, the finisher controller PCB closes the shutter mounted on the delivery slot before moving the tray, preventing the existing stack on the tray by the delivery slot and intrusion of the hands.
Page 79 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2) The tray 1,2 lift motor rotates, and the new tray moves to the stacking lower limit. The distance of movement is detected by the tray 1 lift motor clock sensor 1/2 (PI9/19) or tray 2 lift motor clock sensor 1/2 (PI22/PI24).
Page 80 CHAPTER 2 FINISHER UNIT BASIC OPERATION 4) The tray lift motor rotates, and the tray moves to suit the height of the stack. The appropriate height in relation to the existing stack is checked by the height sensor (PS1). Height sensor (PS1) Tray 2 lift motor Figure 2-244 Claw...
Page 81 CHAPTER 2 FINISHER UNIT BASIC OPERATION Sequence Operations (shutter drive) Move from Tray 1 to Tray 2 Tray moved Shutter Shutter closed opened Second feed motor (M8) Tray 1 lift motor (M5) Tray 2 lift motor (M10) Shutter closed detecting switch (MS4) Shutter open sensor (PI5)
Page 82: Buffer Path Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Operation Outline This machine is provided with a buffer paper path for continuously receiving paper from the host machine during stapling and job offset operation on the stapling tray. A maximum of three copies (three originals or more in the staple mode) are wrapped around the buffer roller.
Page 83 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) When the leading edge of the sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the second sheet. First sheet Second sheet Buffer path paper sensor (PI14) Figure 2-249 4) When the second sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer...
Page 84 CHAPTER 2 FINISHER UNIT BASIC OPERATION 5) The buffer roller continues to rotate, and the second sheet overlaps the first sheet. Second sheet First sheet Figure 2-251 6) When the trailing edge of the second sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the third sheet.
Page 85 CHAPTER 2 FINISHER UNIT BASIC OPERATION 7) When the third sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again. Second sheet First sheet Third sheet Inlet sensor (PI1) Figure 2-253 8) When the leading edge of the third sheet reaches the inlet sensor (PI1), the buffer outlet sole- noid (SL3) turns off so that the path is directed in the direction of delivery.
Page 86 CHAPTER 2 FINISHER UNIT BASIC OPERATION 9) The buffer roller continues to rotate, the third sheet overlaps the first and second sheets, and the three sheets are fed together towards the delivery roller. Figure 2-255 2-50...
Page 87: Detecting Jams
CHAPTER 2 FINISHER UNIT BASIC OPERATION K. Detecting Jams The following sensors are used to detect the presence/absence of paper and to make sure that sheets are moved properly: Inlet sensor (PI1) Delivery sensor (PI3) Stapling tray sensor (PI4) Buffer path paper sensor (PI14) A jam is identified with reference to the presence/absence of paper at each specific sensor at the times programmed in the memory of the microprocessor (CPU) on the finisher controller PCB.
Page 88 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inlet Sensor Delay Jam The inlet sensor does not detect paper when feeding an equivalent of 400 mm from when the host machine delivery signal has been issued. Host machine delivery signal Host machine delivery signal Equivalent of 400 mm Equivalent of 400 mm Jam check...
Page 89 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Paper Sensor Stationary Jam The sheet does not move past the buffer path paper sensor when an equivalent of twice the F15/F16 feeding length of the sheet has been fed after the sensor turned on. Equivalent of size x 2 Equivalent of size x 2 Jam check...
Page 90 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path The delivery sensor does not detect paper when an equivalent of 652 mm has been fed after the F15/F16 inlet sensor turned on. Equivalent of 652 mm Equivalent of 652 mm F15/F16 Jam check Jam check Normal...
Page 91 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling Tray Sensor Stationary Jam The sheet does not move past the stapling tray sensor 1 sec after the delivery motor (M2) turned 1 sec 1 sec Jam check Jam check Normal Stapling tray Stapling tray sensor (PI4) sensor (PI4)
Page 92: Power Supply System
CHAPTER 2 FINISHER UNIT BASIC OPERATION III. POWER SUPPLY SYSTEM Outline The finisher controller PCB is supplied with 24 VDC power when the host machine is turned F15/F16 on. Power is also supplied from the finisher controller PCB to the saddle stitch controller PCB. In addition, power is also supplied to the punch driver PCB when the optional puncher unit is mounted.
Page 93: Basic Operation
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the saddle stitch functions, and the principles of operation used for the stitch mechanical and electrical systems. It also explains the timing at which these systems are operated. symbol in drawings indicates transmission of mechanical drive, and signals marked together with the signal name indicates the flow of electrical signals.
Page 95: Outline
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION BASIC OPERATION Outline The unit “stitches” (2 points) a stack of sheets delivered by the finisher unit and folds it in two for delivery. All these operations are controlled by the saddle stitch controller PCB in response to commands from the host machine via the finisher unit.
Page 96: Electrical Circuitry
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Electrical Circuitry The sequence of operations used for the saddle stitch is controlled by the saddle stitch control- ler PCB. The saddle stitch controller PCB has a microprocessor. This microprocessor is used to control the sequence of operations and to handle serial communications with the finisher controller PCB, driving solenoids and motors in response to the various commands from the finisher control- ler PCB.
Page 97: C. Inputs To And Outputs From The Saddle Stitch Controller Pcb
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Inputs to and Outputs from the Saddle Stitch Controller PCB Inputs to the Saddle Stitch Controller PCB Saddle stitch controller PCB PI1S J107-1 J11-15 Paper pushing When the paper pushing plate LUNGECLK plate motor motor is rotating, alternately clock sensor between “1”...
Page 98 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Inputs to the Saddle Stitch Controller PCB Saddle stitch controller PCB PI8S J105-3 J6-1 +5V Paper positioning When paper is present at the PPOSPAR plate paper sensor paper positioning plate, “1”. PI9S J124-3 J10-6 +5V When the inlet cover is Inlet cover sensor...
Page 99 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Inputs to the Saddle Stitch Controller PCB Saddle stitch controller PCB Paper sensor PCB PI18S No.1 paper sensor When paper is present at J123-5 J10-1 the No.1 paper sensor, “1”. PI19S 1STPA When paper is present at 2NDPA No.2 paper sensor the No.2 paper sensor, “1”.
Page 100 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Outputs from the Saddle Stitch Controller PCB Saddle stitch controller PCB +24V No.1 paper deflecting solenoid J15-1 When “0”, the solenoid turns ON. SL1S FLPSL1* +24V No.2 paper deflecting solenoid J15-3 When “0”, the solenoid turns ON. SL2S FLPSL2* +24V...
Page 101 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION : Jan. 9 2004 Outputs from the Saddle Stitch Controller PCB +24V Figure 3-107...
Page 102: Feeding/Drive System
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION II. FEEDING/DRIVE SYSTEM Outline The stitch unit aligns the sheets coming from the finisher unit and stitches the resulting stack for delivery to the delivery tray according to the commands coming from the finisher controller PCB.
Page 103 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Receiving Sheets The stitch unit receives sheets from the finisher unit and outputs them inside the vertical path in vertical orientation. The vertical path, while sheets are being output, is configured by two paper deflecting plates. The position of the sheets being output is set by the paper positioning plate so that the center of the stack matches the stapling/folding position.
Page 104 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Aligning the Sheets The alignment plates operate to put the sheets in order each time a sheet of paper is output to the vertical path assembly. The alignment plates are mounted at the edge of the vertical path assem- bly.
Page 105 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Stitching When all sheets have been output, the two stitchers stitch the stack. The stitchers are positioned so that they face the center of a stack. The two stitchers are not operated simultaneously so as to prevent the paper from wrinkling between two staples and to limit the load on the power supply.
Page 106 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Feeding the Stack The unit folds the stitched stack of sheets, and then feeds it to the point of delivery. This point is where the center of the stack, i.e., stapling position, matches the height of the paper pushing plate and the paper folding roller nip.
Page 107 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Folding/Delivering the Stack The paper pushing plate pushes against the center of the stack to move it in the direction of the paper folding rollers. In response, the paper folding rollers pick the stack along its center and fold it in two.
Page 108: Paper Output Mechanism
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION III. PAPER OUTPUT MECHANISM Outline The paper output mechanism serves to keep a stack of sheets coming from the finisher in place for the next steps (stapling, folding). The paper inlet is equipped with the No.1 flapper and the No.2 flapper, which operate to con- figure the paper path to suit the size of paper.
Page 109 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Saddle stitcher controller PCB (1/2) SL1S SL2S M6S/ SL4S PI1S PI4S Saddle stitcher controller PCB (2/2) Figure 3-301 3-15...
Page 110 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Figure 3-302 3-16...
Page 111: Controlling The Inlet Flappers
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Controlling the Inlet Flappers Outline The two flappers mounted at the paper inlet are operated to configure the feed path according to the size of paper. The flappers are used to enable the following: 1.
Page 112 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION A3/LD Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S No.1 paper deflecting SL1S solenoid Non-passage of paper No.2 paper sensor PI19S SL2S No.2 paper deflecting solenoid Non-passage of paper No.3 paper sensor PI20S Top edge PI18S...
Page 113 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION B4 Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S SL1S No.2 paper sensor Passage of paper PI19S SL2S No.3 paper sensor Non-passage of paper PI20S PI18S PI19S Top edge PI20S PI18S PI19S PI20S...
Page 114 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION A4-R/LT-R Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S SL1S Passage of paper No.2 paper sensor PI19S SL2S No.3 paper sensor Passage of paper PI20S PI18S PI19S PI20S Top edge PI18S PI19S PI20S...
Page 115: Controlling The Movement Of Sheets
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Controlling the Movement of Sheets When the leading edge of a sheet has moved past the inlet flapper, the intermediate feed roller and the crescent roller start to move the sheet forward. The intermediate feed roller is normally not in contact with the path bed. When the leading edge of a sheet reaches the intermediate feed roller contact section, the feed plate contact solenoid (SL4S) causes the roller to come into contact with the path bed so as to move the sheet.
Page 116 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION 2) The solenoid turn OFF when the paper butts against the paper positioning plate. The feed motor continues to rotate. SL4S Figure 3-307 3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact. SL4S Figure 3-308 3-22...
Page 117: Aligning The Sheets
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Aligning the Sheets The alignment motor (M5S) drives the alignment plates each time a sheet is output, putting both left and right edges of the sheet in order. The alignment plate motor is a 4-phase stepping motor.
Page 118 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION 3) The alignment plates escape to points 10 mm from the edge of the stack. Figure 3-311 4) When the following stack arrives, steps 1 through 3 above are repeated. 5) The alignment plates butt against the stack once again, during which stitching takes place. Figure 3-312 6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding and delivery take place.
Page 119 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION In case of 2 sheets: Entry of Entry of 1st sheet of follow- 1st sheet 2nd sheet ing stack entry [2] [3] [4] Alignment plate home position sensor (PI5S) Alignment motor (M5S) Paper positioning plate motor (M4S) : Alignment : Escape...
Page 120: Controlling The Phase Of The Crescent Roller
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Controlling the Phase of the Crescent Roller Outline If alignment was executed with the crescent roller in contact with the stack of sheets, the result- ing friction against the roller causes the stack to move inappropriately (Figure 3-317). To prevent this problem, the phase of the roller is identified and used to determine the timing of alignment.
Page 121 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Alignment plates Crescent roller phase sensor(PI12S) Sensor flag Crescent roller If the crescent roller was in contact with the stack, alignment opera- tion could be obstruct- Figure 3-318 Alignment operation is started when the flag has covered the sensor and the crescent roller is away from the stack.
Page 122: Stitching System
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION IV. STITCHING SYSTEM Outline The stitching system “stitches” the center of an output stack with staples. To enable stitching at two locations on a stack, two stitcher units (front, rear) are used. Each stitcher unit is equipped with a stitcher motor (M7S, M6S) for drive, a stitcher home position sensor (MS7S, MS5S) for detection of position and a staple sensor (MS6S, MS4S) for detection of the presence/absence of staples.
Page 123 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Stitcher Unit Operation The stitcher base unit consists of two stitchers and stitcher bases. The stitchers are fixed in position, and are not designed to slide or swing. Stitching is executed by driving the rotary cam by the stitcher motor (M7S, M6S). The front and rear stitcher units are operated with a time delay so as to prevent wrinkling of paper and to limit the load applied to the power supply.
Page 124 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Mount Figure 3-404 3-30...
Page 125: Folding/Delivery System
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION FOLDING/DELIVERY SYSTEM Outline The paper folding mechanism consists of a guide plate, paper folding rollers, paper pushing plate, and paper positioning plate. The guide plate is used to cover the folding rollers while sheets are output so as to prevent sheets from coming into contact with the folding rollers during output.
Page 126 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Controlling the Movement of Stacks When a stack has been stitched (2 points), the paper positioning plate lowers so that the stack will move to where the paper folding rollers come into contact with the stack and where the paper pushing plate is located.
Page 127 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Folding a Stack A stack is folded by the action of the paper folding rollers and the paper pushing plate. The paper pushing plate pushes against the center of a stack toward the roller contact section. The paper pushing plate starts at its home position and waits at the leading edge position until the stack has been drawn to the paper folding roller and is gripped for a length of 10 mm.
Page 128 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Paper pushing plate home Paper pushing plate top position sensor position sensor (PI14S) (PI15S) Sensor flag Paper folding home position sensor (PI21S) Paper pushing plate Paper pushing plate motor Paper folding motor Figure 3-503 [Paper folding start position] Stack of sheets Paper pushing plate...
Page 129 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION [Paper folding roller stop position] Delivery outlet Paper feed inlet Sensor flag Paper folding home position sensor (PI21S) Paper folding/feeding is performed. Paper feeding is performed. Figure 3-505 Paper folding motor (M2S) Paper pushing plate motor (M8S) Paper pushing plate home...
Page 130 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Double Folding a Stack To fold a stack consisting of 10 or more A4-R or LT-R sheets, folding is executed twice for the same sheet. The paper folding rollers rotate in reverse for an equivalent of 20 mm after gripping the stack for a length of 20 mm, enabling the paper folding rollers to apply an increased degree of pressure along the crease on the stack.
Page 131 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION 3) The paper folding rollers rotate in reverse, pushing back the stack for a length of about 20 mm (reverse feeding). Paper folding motor Figure 3-509 4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns to its home position.
Page 132: Checking For A Jam
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION VI. CHECKING FOR A JAM Checking for a Jam The saddle stitch unit identifies any of the following conditions as a jam, and sends the jam signal to the host machine. In response, the host machine may stop copying operation and indicate the presence of a jam on its control panel.
Page 133 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Inlet Delay Jam The No.1 paper sensor (PI18S) on the paper sensor PCB does not turn ON for a specific period of time after the inlet sensor (PI1) of the finisher turned ON. Inlet sensor (PI1) Inlet sensor (PI1) No.1 paper...
Page 134 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION B4 Stack No.1 paper sensor Normal No.1 paper sensor (PI18S) (PI18S) No.2 paper sensor No.2 paper sensor Normal (PI19S) (PI19S) Feed motor Feed motor Load stops T: feeding of (paper length x 1.5) mm T: feeding of (paper length x 1.5) mm Note: The diagram shows two sensors checking for jams.
Page 135 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION Delivery Delay Jam a. By delivery sensor The delivery sensor (PI11S) does not turn ON within a specific period of time after the paper pushing plate top position sensor has turned ON. Paper pushing plate top Paper pushing plate top Normal position sensor...
Page 136 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION By delivery sensor The delivery sensor (PI11S) does not turn OFF within a specific period of time (feeding) after it has turned ON. Normal Delivery sensor Delivery sensor Paper folding motor Paper folding motor Load stops Paper length Paper length...
Page 137: Vii.power Supply
CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION VII.POWER SUPPLY Outline When the host machine power switch is turned ON, 24V and 5V power lines are supplied by the finisher controller PCB. The 24V power is used to drive solenoids. The 24V power from the finisher controller PCB to solenoids does not pass through any protective mechanisms (microswitches, or the like).
Page 138 CHAPTER 3 SADDLE STITCH UNIT BASIC OPERATION 3-44...
Page 139: Basic Operation
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 1. This chapter discusses the purpose and role of each of the puncher unit’s functions, and the principles of operation used for the puncher unit mechanical and electrical systems. It also explains the timing at which these systems are operated. symbol in drawings indicates transmission of mechanical drive, and signals marked together with the signal name indicates the flow of electrical signals.
Page 141: Outline
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION I. BASIC OPERATION Outline The puncher unit (option) is attached on the feed path between the host machine and the finisher. The puncher unit does not have a paper feed mechanism. Paper from the host machine is fed by feed drive from the finisher via the puncher unit.
Page 142: Inputs To And Outputs From Punch Driver Pcb
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Inputs to and Outputs from Punch Driver PCB Inputs to Punch Driver PCB (1/3) Punch driver PCB PI1P J102-3 J1A-1 Horizontal When the punch slide registration home SREGHP unit is at the home position sensor position, “1”.
Page 143 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Outputs from Punch Driver PCB (2/3) Punch driver PCB LED PCB LED5 J10-6 J116-6 J7-1 LEDON5 LED4 LEDON4 LED3 When “1”, LED is ON. LEDON3 LED2 LEDON2 LED1 LEDON1 Scrap full detector PCB LED6 J112-3 J1B-8...
Page 144 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Outputs from Punch Driver PCB (3/3) Punch driver PCB Finisher controller PCB J21A-14 J3A-1 J21B-13 J3B-2 +24V J23-4 J4-4 Figure 4-104...
Page 145: Punch Operation
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION II. PUNCH OPERATION Outline The puncher unit is located on the feed path between the host machine and the finisher, and successively punches holes when the paper stops temporarily. When the trailing edge of the paper reaches the puncher unit, the inlet roller of the finisher unit temporarily stops the paper and holes are punched on the trailing edge of the paper.
Page 146 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Punch driver PCB (1/2) PTR1 LED1 Punch driver PCB (2/2) Figure 4-201...
Page 147: Punch Operation
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION PUNCH OPERATION The hole puncher is driven by the punch motor (M1P). The hole puncher home position is de- tected by the punch home position sensor (PI3P). In all, there are four types of puncher units depending on the destination: 2-hole type (Puncher unit AR-PN3B), 2-/3-hole Dual Use (Puncher unit AR-PN3A), and two 4-hole types (Puncher unit AR-PN3C and Puncher unit AR-PN3D).
Page 148 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 2) A hole is punched in the trailing edge of the second sheet. [punch shaft stopped/ [punch shaft rotated 90˚ [punch shaft rotated 180˚ home position] in the reverse direction/ in the reverse direction/ hole punched] punch operation completed] Figure 4-203...
Page 149 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 2-/3-hole Dual Use Type At the home position, the punch home position sensor is ON. To punch two holes, punching of the first sheet ends when the punch shaft half peripheral area has rotated in the forward direction 180°, and the state of the punch home position sensor has changed from OFF to ON.
Page 150 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 2) A hole is punched in the trailing edge of the second sheet. [punch shaft stopped/ [punch shaft is rotated 90˚ [punch shaft is rotated 180˚ home position] in the reverse direction/ in the reverse direction/ hole punched] punch operation completed] Figure 4-206...
Page 151: Horizontal Registration Operation
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Horizontal Registration Operation Horizontal registration drive of the punch slide unit is performed by the horizontal registration motor (M2P). The home position of the punch slide unit is detected by the horizontal registration home position sensor (PI1P).
Page 152 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 2) After the horizontal registration sensors (LED1 to 4, PTR1 to 4) detect the edge of the paper at its inner side in keeping with the paper size signals arriving from the host machine, the horizontal registration motor (M2P) drives the punch slide unit to a predetermined position further towards the front, and stops the unit at this position.
Page 153 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 4) When punching ends, drive of the inlet feed motor (M9) and first feed motor (M1) on the finisher is started, the horizontal registration motor (M2P) is operated in the reverse direction, and the punch slide unit is returned to its home position where it comes to a stop.
Page 154: Power Supply System
CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION III. POWER SUPPLY SYSTEM Outline 24V power and 5V power are supplied from the finisher controller PCB when the power switch on the host machine is turned ON. 24V power is used for driving motors, while 5V power is used for driving sensors and the ICs on the punch driver PCB.
Page 155 CHAPTER 5 MECHANICAL CONSTRUCTION This chapter describes the mechanical features and operations, and disassembly and assembly procedures. Be sure to observe the following points when disassembling and assembling the machine: Before performing disassembly and assembly, be sure to unplug the power plug for safety’s sake.
Page 157: Finisher Unit
CHAPTER 5 MECHANICAL CONSTRUCTION FINISHER UNIT Externals and Controls [1] Upper door F15/F16 [2] End cap [3] Front door [4] Front lower door [5] Tray 1 [6] Tray 2 [7] Grate-shaped upper guide (6) [8] Grate-shaped lower guide (6) [9] Saddle delivery tray [10] Sub-support upper cover (2) [11] Sub-support lower cover (2) [12] Rear cover (3)
Page 158 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Front Door Assembly 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the bush- ing [3] (center). 3) Remove the screw [4], and remove the bush- ing (top) [5]. Then, remove the front door assembly.
Page 159 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Upper Door Assembly 1) Open the upper door assembly [1]. 2) Remove the two claws [2], and remove the upper door assembly. Figure 5-105 Removing the Front Cover 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the front cover [3].
Page 160 CHAPTER 5 MECHANICAL CONSTRUCTION How to Lower the Tray 1/2 Unit 1) Insert a screwdriver or similar object into the hole [2] while supporting the tray as- sembly [1]. 2) Release the tray lift motor one-way gear, and lower the tray 1/2 unit. Figure 5-107 Removing the Tray 1 Unit 1) Open the upper cover and remove the end...
Page 161 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Tray 2 Unit 1) Remove the tray 1 unit. 2) Disconnect the two connectors [1] and grounding wire [2] and remove harness [3]. 3) Lift the tray 2 unit to remove. Figure 5-110 Removing the Tray 1/2 Lift Motor 1) Remove the tray 1/2.
Page 162 CHAPTER 5 MECHANICAL CONSTRUCTION 5) Disconnect the connector [1], and remove the two screws [2]. Figure 5-113 6) Pull out the motor slightly, and remove the parallel pin [1] and the motor. Figure 5-114 Removing the Grate-Shaped Upper Guide 1) Remove the slide guide [1] and end caps [2].
Page 163 CHAPTER 5 MECHANICAL CONSTRUCTION 10. Removing the Grate-Shaped Lower Guide 1) Remove the tray assembly. 2) Remove the five screws [1] (M4), and re- move the front sub-support [2]. 3) Remove the three screws [3] (M4). 4) Remove the three screws [4] (M3), and open the grate-shaped lower guide [5] to the front.
Page 164 CHAPTER 5 MECHANICAL CONSTRUCTION 11. Installing the Rear Sub-Support 1) Install the front sub-support [1]. Loosely fasten the rear sub-support [2]. 2) Install tray 2. Fasten the rear sub-support so that the tray drive gear [3] is placed at the center of the rack gear [4] of the rear sub-support when tray 2 is at the upper limit position and the lower limit position.
Page 165: Feeding System
CHAPTER 6 MECHANICAL CONSTRUCTION : Jan. 9 2004 FEEDING SYSTEM Swing unit disassembly 1) Remove the tray section. (Refer to I-A-6, 2) Remove the grate-shaped upper guide. (Re- fer to I-A-9.) 3) Remove the grate-shaped lower guide. (Re- fer to I-A-10.) 4) Remove four connectors [1].
Page 166 CHAPTER 6 MECHANICAL CONSTRUCTION : Jan. 9 2004 8) Remove the knurled belt holders [5] in the following procedures. 8)-1. Rotate the holder [8] in the arrow direc- tion and disengage the pawl [9]. 8)-2. Slide the holder [5] downward to release the hook [7] from the metal plate.
Page 167 CHAPTER 6 MECHANICAL CONSTRUCTION : Jan. 9 2004 2) Remove one connector [2] in the stapler section and remove three screws [3] which are fixing the PWB base. (When installing the punch unit, remove two connectors [4] for punch.) Figure 5-124 3) Pull out the PWB base, and remove two connectors [5] of the transport drive unit and three fixing screws [7] of the bracket.
Page 168 CHAPTER 5 MECHANICAL CONSTRUCTION 3) Lift the buffer roller unit [2] and install the transport drive unit with three screws [3], and insert two connectors [4]. Figure 5-126b 4) Loosen the screw [5] of the pendulum gear section so that it can be moved in the arrow direction.
Page 169 CHAPTER 5 MECHANICAL CONSTRUCTION 5) Insert a thickness gauge (0.3mm) [8] be- tween the pendulum gear [6] and the swing unit gear [7]. 6) Turn the oscillation unit gear counterclock- wise to engage thickness gauge, and turn a few times further counterclockwise. Check that both flanges are in contact.
Page 170 CHAPTER 5 MECHANICAL CONSTRUCTION 4) Remove the front cover (see I-A-4). 5) Remove the screw [4], and remove the guide support plate assembly [5]. Then, remove the buffer roller assembly [6]. Figure 5-128 Removing the Stapler 1) Open the front cover, and move the stapler assembly to the front.
Page 171: Pcbs
CHAPTER 5 MECHANICAL CONSTRUCTION 4) Remove the two screws [6] from the sta- [ 6 ] pler cover [5], and remove the stapler. [ 5 ] Figure 5-131 PCBs Removing the Finisher Controller 1) Remove the rear cover. 2) Disconnect the 17 connectors [1]. 3) Remove the four screws [2], and remove the finisher controller PCB [3].
Page 172: Saddle Stitch Unit
CHAPTER 5 MECHANICAL CONSTRUCTION II. SADDLE STITCH UNIT Externals and Controls Removing the Front Lower Door Assembly 1) Open the front lower door assembly [1]. 2) Remove the screw [2] and remove the bush- ing [3], and then remove the front lower door assembly.
Page 173 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Front Inside Cover 1) Open the front lower door assembly [1]. 2) Remove the screw [2], and remove the fold- ing roller knob [3]. 3) Remove the five screws [4], and remove the front inside cover [5]. Figure 5-203 Removing the Saddle Delivery Tray Assembly...
Page 174 CHAPTER 5 MECHANICAL CONSTRUCTION 3) Remove the harness leads from the harness stop [5] and edge saddle [6]. 4) Disconnect the two connectors [7], and re- move the saddle delivery tray assembly [8]. Figure 5-206 Removing Upper Delivery Guide Assembly 1) Remove the grate-shaped lower guide (see I-A-10).
Page 175: Saddle Unit
CHAPTER 5 MECHANICAL CONSTRUCTION SADDLE UNIT Removing the Saddle Unit 1) Remove the grate-shaped lower guide (see I-A-7). 2) Remove the right guide assembly (see I-A- 3) Remove the front lower door assembly (see II-A-1). 4) Remove the rear lower cover (see II-A-2). 5) Remove the front inside cover (see II-A-3).
Page 176 CHAPTER 5 MECHANICAL CONSTRUCTION 11) Remove the screw [5]. Figure 5-211 12) Remove the two screws [6], and remove the saddle stitch unit [7] by moving it in the pick-up direction. Figure 5-212 Caution: When removing the saddle unit from the finisher unit body, prevent the timing belt [8] from catching on the communications cable bracket [9].
Page 177 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Paper Folding Roller 1) Remove the front lower door assembly (see II-A-1). 2) Remove the front inside cover (see II-A-3). 3) Remove the upper delivery guide (see II- A-5). 4) Remove the PCB cover (see II-A-6). 5) Disconnect the two connectors [1].
Page 178 CHAPTER 5 MECHANICAL CONSTRUCTION 7) Remove the tension springs (front [5], rear [6]). Figure 5-216 Figure 5-217 5-22...
Page 179 CHAPTER 5 MECHANICAL CONSTRUCTION 8) Remove the two C-rings [7], and remove the sensor flag [8] and two bearings [9] at the rear. Figure 5-218 9) Remove the two C-rings [10], and remove the two gears [11] at the front. [11] [10] Figure 5-219...
Page 180 CHAPTER 5 MECHANICAL CONSTRUCTION 10) Remove the two bearings [12]. [12] Figure 5-220 [16] 11) Open the saddle delivery tray assembly [13]. 12) Remove the two screws [14], and remove the two alignment plates [15]. 13) Slide the paper folding roller [16] to the front, and pull it out in the delivery direc- tion.
Page 181 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Stitcher Mount Unit 1) Remove the front inside cover (see II-A-3). 2) Remove the E-ring [1], and remove the roll [2] and the shaft [3]. Figure 5-223 3) Pull out the stitcher mount unit [4] to the front.
Page 182 CHAPTER 5 MECHANICAL CONSTRUCTION 6) Remove the stitcher positioning tool [3] from the back of the cover. Figure 5-226 7) If you must adjust the front stitcher, remove the center guide plate [5] and front guide plate [4] (one screw each). If you must ad- just the rear stitcher, remove the center guide plate [5] and the rear guide plate [6] (one screw each).
Page 183 CHAPTER 5 MECHANICAL CONSTRUCTION 9) Insert the tool [10] into the staple slot of the stitcher [9]. [10] Figure 5-229 10) Shift down the stitcher, and turn the stitcher gear so that the boss on the tool [11] and the recess of the mount match. Then, tighten the screws [12] on the mount to fix the two in place.
Page 184 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the No.1 and No.2 Paper Deflecting Plates 1) Remove the rear cover (see I-A-2). 2) Remove the lower rear cover (see II-A-2). 3) Remove the claw [1] of the No.1 deflecting plate bushing, and pull out the No.1 deflect- ing plate shaft [2] toward the rear.
Page 185: Pcbs
CHAPTER 5 MECHANICAL CONSTRUCTION PCBs [ 2 ] [ 2 ] [ 2 ] [ 3 ] [ 1 ] [ 1 ] Removing the Saddle Stitch Controller PCB 1) Remove the PCB cover (see II-A-6). 2) Remove the four screws [1] and 14 connec- tors [2], and remove the saddle stitch con- troller PCB [3].
Page 186: Accessory
CHAPTER 5 MECHANICAL CONSTRUCTION Accessory Support tray Install the support tray (accessory) to the saddle delivery tray when the paper stacking on the saddle delivery tray is significantly dete- riorated, causing paper to drop, etc. * 2 screws are needed to install the support tray. * Refer to the pats list for the parts numbers and so on.
Page 187: Puncher Unit (Option)
CHAPTER 5 MECHANICAL CONSTRUCTION III. PUNCHER UNIT (OPTION) Externals and Controls [1] Front door [2] Punch cover (6) Figures in parentheses ( ) indicate the number of mounting screws. Figure 5-301 Punch Cover Disassembly 1) Remove the punch cover fixing screws (6 pcs.), and lift the punch cover slightly to remove it from the finisher.
Page 188: Puncher Driver System
CHAPTER 5 MECHANICAL CONSTRUCTION Puncher Driver System Removing the Punch Motor 1) Remove the upper cover (see III-A-2). 2) Disconnect the connector [1]. 3) Remove the two screws [2], and remove the punch motor [3]. Figure 5-304 5-32...
Page 189 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Horizontal Registration Motor 1) Remove the right guide assembly (see III- A-1). 2) Disconnect the connector [1]. 3) Remove the two screws [2], and slide the horizontal registration motor [3] in the di- rection of the arrow. Figure 5-305 Removing the Punch Unit Caution:...
Page 190 CHAPTER 5 MECHANICAL CONSTRUCTION 4) Turn the gear [4] in the direction of the ar- row, and move the punch unit section [5] to the front side. Figure 5-307 5) Remove the three screws [5], and remove the sensor mount (upper) [7]. Then, remove the connector on the photosensor PCB.
Page 191 CHAPTER 5 MECHANICAL CONSTRUCTION 6) Disconnect the connector [9] and remove [11] the screw [10], and remove the horizontal registration sensor [11]. [10] Figure 5-309 7) Turn the gear [12] in the direction of the arrow, and move the punch unit section [13] [13] to the inner side.
Page 192 CHAPTER 5 MECHANICAL CONSTRUCTION 8) Remove the tie wrap with lock [14] while holding its claw between your fingers. (The tie wrap must be removed without being [15] cut.) 9) Disconnect the three connectors [15] and remove the screw [16], and remove the har- ness guide [17].
Page 193 CHAPTER 5 MECHANICAL CONSTRUCTION 12) Remove the slide shaft support [20], the sensor mount (lower) [21] and the puncher [20] knob [22] from the punch unit section. Caution: The slide shaft support [20] is not attached to punch unit sections that are currently set as consumable parts.
Page 194 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Punch Unit Harness Caution: When removing the punch unit, the punch unit section sometimes opens. If necessary, perform work with the punch unit section in an open state. 1) Remove the punch unit from the finisher assembly.
Page 195 CHAPTER 5 MECHANICAL CONSTRUCTION 8) Turn the gear [7] in the direction of the ar- row, and move the punch unit section [8] to the front side. Figure 5-317 9) Remove the three screws [9] and sensor mount (upper) [10]. Disconnect the connec- tor [11] on the photosensor PCB and the connector [12] on the LED PCB.
Page 196 CHAPTER 5 MECHANICAL CONSTRUCTION 10) Draw out the punched scrap container [13]. [13] Figure 5-319 11) Remove the two tie wraps with lock [14] while holding its claw between your fin- gers. (The tie wraps must be removed with- out being cut.) [14] Figure 5-320 12) Disconnect the three connectors [15], and...
Page 197 CHAPTER 5 MECHANICAL CONSTRUCTION 13) Free the harness [19] from the four harness [18] stops [18]. [18] [19] [18] Figure 5-322 14) Disconnect the connector [20] of the hori- [20] zontal registration and the connector [21] of the horizontal registration home position sensor, and remove the pun.
Page 198 CHAPTER 5 MECHANICAL CONSTRUCTION Installing the Punch Unit Harness Caution: If the punch unit harnesses shift away from their installation positions, this may cause defective operation. The punch unit harnesses must be firmly installed at the positions described below. 1) Fasten the punch unit harnesses at the po- sitions where the two tie wraps [1] of the punch unit harnesses are outside the two respective harness fasteners [2].
Page 199: Pcbs
CHAPTER 5 MECHANICAL CONSTRUCTION PCBs Removing the LED PCB 1) Remove the punch unit assembly (see III- B-3). 2) Remove the screw [1] and the LED PCB [2]. Figure 5-326 Removing the Photosensor PCB 1) Remove the upper cover (see III-A-2). 2) Remove the two screws [1], and remove the sensor plate [2].
Page 200 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Scrap Full Detector PCB Unit 1) Remove the right guide assembly (see III- A-1). 2) Remove the screw [1], disconnect the con- nector [2], and remove the scrap full detec- tor PCB unit [3]. Figure 5-328 Removing the Punch Driver PCB 1) Remove the puncher unit from the finisher.
Page 201: Maintenance And Inspection
CHAPTER 6 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED CONSUMABLES AND PARTS ......... 6-1 DURABLES ......... 6-2 A. Finisher Unit ....... 6-1 A. Finisher Unit ....... 6-2 B. Saddle Stitch Unit ...... 6-1 III. PERIODICAL SERVICING ..6-2 C. Puncher Unit (option) ....6-1...
Page 203: Chapter 6 Maintenance And Inspection
CHAPTER 6 MAINTENANCE AND INSPECTION I. PERIODICALLY REPLACED PARTS Finisher Unit The finisher unit does not have parts that must be replaced on a periodical basis. Saddle Stitch Unit The saddle stitch unit does not have parts that must be replaced on a periodical basis. Puncher Unit (option) The puncher unit does not have parts that must be replaced on a periodical basis.
Page 204: Ii. Consumables And Durables
CHAPTER 6 MAINTENANCE AND INSPECTION II. CONSUMABLES AND DURABLES Some of the parts of the machine may need to be replaced one or more times because of wear or tear during the machine’s warranty period. Replace them as necessary. Finisher Unit Name Estimated Life Remarks...
Page 205: Paddle Replacement
CHAPTER 6 MAINTENANCE AND INSPECTION : Jan. 9 2004 III. Consumable parts replacement procedures Paddle replacement 1) Open the upper door [1] to allow visual check of the paddle [2]. Figure 6-101 2) Hold the resin section [3] of the paddle with radio nippers and remove it from the shaft section.
Page 206: Knurled Belt Replacement
CHAPTER 6 MAINTENANCE AND INSPECTION : Jan. 9 2004 3) Hold the resin section [3] of a new paddle and insert it into the shaft section (in the ar- row direction). Figure 6-104 4) After replacing two paddles, close the up- per door.
Page 207 : Jan. 9 2004 CHAPTER 6 MAINTENANCE AND INSPECTION 2) Remove the E-ring [1] and the bearing [2] on the front side of the knurled belt shaft. Figure 6-106 3) Release the pawl [3] on the rear side, and remove the arm [4]. [10] 4) Remove the E-ring [5], the cam [6], and the gear [7].
Page 208 CHAPTER 6 MAINTENANCE AND INSPECTION : Jan. 9 2004 7) Disengage three guide front pawls [12] and remove the guide front. Disengage five guide rear pawls [13] and remove the guide rear. [13] [12] Figure 6-109 8) Remove the knurled belt shaft [14]. Figure 6-110 9) Remove the knurled belt assembly [15] from the knurled belt shaft [14].
Page 209 : Jan. 9 2004 CHAPTER 6 MAINTENANCE AND INSPECTION 11) Install a new knurled belt. 12) Pass the knurled belt shaft through the knurled belt assembly. (Be careful of the di- rection of the roller holder.) Figure 6-112 13) Install the knurled belt shaft to the swing unit.
Page 210 CHAPTER 6 MAINTENANCE AND INSPECTION : Jan. 9 2004 15) Tighten three screws [20] and connect four [20] connectors [21]. [21] Figure 6-114 16) Put the shaft [23] in the shaft groove [22] on the grated-shaped lower guide. Caution: While turning the cam [26], adjust the shaft [23] [23] position and put it in the groove.
Page 211 : Jan. 9 2004 CHAPTER 6 MAINTENANCE AND INSPECTION 19) Install the knurled belt holder. Caution: Reverse the procedure of “5-1-B-1. knurled belt holder removing procedure” for installation. 14) Install the grated-shaped upper guide, and the tray. Caution: When assembling the swing unit or the transport drive unit after disassembly, perform the tension adjustment in the pendulum gear section on the transport...
Page 212: Puncher Unit (Option)
CHAPTER 6 MAINTENANCE AND INSPECTION IV. PERIODICAL SERVICING Item Interval Work Remarks Feed belt Use moist cloth Paddle Host machine minimum servicing interval Cleaning Transmission sensor (Puncher Unit) Use dry cloth (option) 6-10...
Page 213 CHAPTER 7 TROUBLESHOOTING ADJUSTMENTS ......7-1 C. Puncher Unit (option) ....7-22 A. Electrical System D. Light-Emitting Diodes (LED) (finisher unit) ......7-1 and Check Pins by PCB...7-26 B. Electrical System III. TROUBLESHOOTING....7-28 (saddle stitch unit) ...... 7-5 A. Finisher Unit ......7-28 C.
Page 215: Chapter 7 Troubleshooting
: Jan. 9 2004 CHAPTER 7 TROUBLESHOOTING 2) Place a paper on the tray. I. ADJUSTMENTS 3) Press SW1 on the finisher controller PCB. This causes the finisher to execute automatic Electrical System (finisher adjustment, in which the tray unit will shift. •...
Page 216: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING 3) If you are using A4 paper, press SW1 on the finisher controller PCB. If you are us- ing LT paper, press SW2 on the finisher con- Alignment plate troller PCB. Shift by SW2 • Pressing SW1/2 will open the swing guide and cause the feed belt to rotate.
Page 217: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING 5) If the stapling position is correct, set all bits Adjusting the Buffer Roller Winding on SW3 to OFF to end the adjustments. If Amount you need to change the stapling position, Perform this adjustment in the following on the other hand, go to the next step.
Page 218: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING 6) Measure the winding amount (shift) of the 10) Turn the host machine OFF, and then set stack of sheets, and compare this amount SW3 on the finisher controller PCB as in- with the standard amounts. dicated. •...
Page 219: (Saddle Stitch Unit)
CHAPTER 7 TROUBLESHOOTING Electrical System (saddle stitch unit) Mark Adjusting the Folding Position The folding position is adjusted by chang- ing the settings of bits 6 through 8 of DIPSW1 on the saddle stitch controller PCB to match the stitching position (i.e., adjusting the distance over which the paper positioning plate is moved to the folding position from the stitching position.) If you have replaced the saddle stitch con-...
Page 220: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING 8) Measure the distance (L) between the stitch- 9) Change the settings of bits 6 through 8 on ing position and the folding position. Then, DIPSW1 referring to Table 8-102 below. perform “positive width adjustment” or • If the width adjustment is “0”, “negative width adjustment”...
Page 221: Electrical System (Puncher Unit (Option))
CHAPTER 7 TROUBLESHOOTING 4) Press SW1 on the finisher controller PCB. Electrical System (puncher Press SW2 when setting a 2-/3-hole model unit (option)) (AR-PN3A). Pressing this switch registers the number of punch holes to the punch Sensor output adjustment driver PCB. Perform this adjustment when the punch driver PCB, transmission sensor (photosensor DIPSW3 bit...
Page 222: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING 3) Press SW1 on the finisher controller PCB. Pressing this switch lights LED1 on the fin- isher controller PCB as indicated in Table 8-104 so that you can check the sensitivity level of the transmission sensor. Number of Sensitivity Level lit LEDs Sensor not dirty...
Page 223: Finisher Unit
CHAPTER 7 TROUBLESHOOTING II. ARRANGEMENT OF ELECTRICAL PARTS Finisher Unit...
Page 224 CHAPTER 7 TROUBLESHOOTING Sensors PI19 PI23 PI24 PI18 PI17 PI10 PI20 PI14 PI16 PI15 PI11 PI12 PI21 PI22 PI25 Figure 7-201 7-10...
Page 225: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Name Notation Function Photointerrupter Detects paper in the inlet area Detects paper in the delivery area Detects paper on the stapling tray Detects the state (open) of the shutter Detects alignment plate at home position Detects the stapler at home position Detects the tray at home position PI10 Detects delivery motor clock pulses...
Page 226: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Microswitches Figure 7-202 Name Notation Function Microswitches Detects the state (open) of the front door and the upper door Detects the state (closed) of the swing guide 1 Detects the safety range Detects the state (closed) of the shutter Detects the state (closed) of the swing guide 2 Detects the cartridge (inside stapler) Detects the presence/absence of staples (inside stapler)
Page 227: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Motors Figure 7-203 Name Notation Function Motor First Feed motor Delivery motor Alignment motor Stapler shift motor Tray 1 lift motor Staple motor Swing motor Second feed motor Inlet feed motor Tray 2 lift motor Table 7-203 7-13...
Page 228: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Solenoids Figure 7-204 Name Notation Function Solenoid Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Escape solenoid Belt escape solenoid Table 7-204 7-14...
Page 229: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-205 Reference Name Finisher controller PCB Relay PCB 4 Relay PCB 3 Sensor PCB Table 7-205 7-15...
Page 230: Saddle Stitch Unit
CHAPTER 7 TROUBLESHOOTING Saddle Stitch Unit Photointerrupters PI18S PI19S PI20S PI16S PI9S PI21S PI14S PI2S PI15S PI11S PI17S PI12S PI6S PI13S PI5S PI8S PI3S PI7S PI4S PI1S Figure 7-206 7-16...
Page 231: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Name Notation Function Photointerrupter PI1S Detects clock pulses from the paper pushing plate motor PI2S Detects the state (open) of the front door PI3S Detects the state (open) of the delivery cover PI4S Detects clock pulses from the paper folding motor PI5S Detects the alignment plates at home position PI6S...
Page 232: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Microswitches MS1S MS4,5S MS6,7S MS2S MS3S Figure 7-207 Name Notation Function Microswitches MS1S Detects the state (open) of the inlet door MS2S Detects the state (open) of the front door MS3S Detects the state (open) of the delivery door MS4S Detects the presence of staples (rear) MS5S...
Page 233: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Motors Figure 7-208 Name Notation Function Motor Feed motor Paper folding motor Guide motor Paper positioning plate motor Alignment motor Stitcher motor (rear) Stitcher motor (front) Paper pushing plate motor Table 7-208 7-19...
Page 234: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Solenoids SL1S SL2S SL4S Figure 7-209 Name Notation Function Solenoid SL1S No. 1 paper deflecting plate solenoid SL2S No. 2 paper deflecting plate solenoid SL4S Feed plate contact solenoid Table 7-209 7-20...
Page 235: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-210 Reference Name Saddle stitch controller PCB Paper sensor PCB Table 7-210 7-21...
Page 236: Puncher Unit (Option)
CHAPTER 7 TROUBLESHOOTING Puncher Unit (option) Photointerrupters Pl2P Pl3P PI1P Figure 7-211 Name Notation Function Photointerrupter PI1P Horizontal registration home position detection PI2P Punch motor clock detection PI3P Punch home position detection Table 7-211 7-22...
Page 237: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Microswitches MS2P Figure 7-212 Name Notation Function Microswitch MS2P Front door open detection Table 7-212 7-23...
Page 238: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Motors Figure 7-213 Name Notation Function Motor Punch motor Horizontal registration motor Table 7-213 7-24...
Page 239: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-214 Reference Name Punch driver PCB Photosensor PCB LED PCB Scrap full detector PCB Table 7-214 7-25...
Page 240: Light-Emitting Diodes (Led) And Check Pins By Pcb
CHAPTER 7 TROUBLESHOOTING Light-Emitting Diodes (LED) and Check Pins by PCB This section discusses the LED s and check pins used in the machine that are needed in the field. Caution: The VRs and check pins not discussed in this section are for factory use only. Making adjustments and checks using these will require special tools and instruments and adjustments must be to high accuracy.
Page 241: Chapter 7 Troubleshooting
CHAPTER 7 TROUBLESHOOTING Saddle Stitch Controller PCB Figure 7-216 Switch Function DIPSW1 (bits 1-2) Starts correction of discrepancy between stitching position and folding position. DIPSW1 (bits 6-8) Stores corrected settings for stapling position and folding position. Starts correction of discrepancy between stitching position and folding position. Table 7-216 7-27...
Page 242: Troubleshooting
CHAPTER 7 TROUBLESHOOTING III. TROUBLESHOOTING Finisher Unit Fault in communication with host machine Cause Step Checks Yes/No Action Finisher controller Turn the host machine OFF End. PCB, Host machine DC then ON. Is the problem controller PCB corrected? Wiring Is the wiring between the Correct it.
Page 243 CHAPTER 7 TROUBLESHOOTING Faulty height sensor (communication) Cause Step Checks Yes/No Action Finisher controller PCB Turn the host machine OFF End. then ON. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the sensors normal? Power supply Measure the voltage...
Page 244 CHAPTER 7 TROUBLESHOOTING Faulty height sensor (adjustment) Cause Step Checks Yes/No Action Adjustment Try making adjustments using End. the DIP switch once again. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and sensors normal? Power supply Measure the voltage...
Page 245 CHAPTER 7 TROUBLESHOOTING Faulty alignment motor Cause Step Checks Yes/No Action Alignment plate home Check the alignment plate Replace the sensor. position sensor (PI6) home position sensor. Is it normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the alignment plate motor normal? Alignment plate...
Page 246 CHAPTER 7 TROUBLESHOOTING 10. Faulty stapler shift motor Cause Step Checks Yes/No Action Stapler shift home Check the stapler shift home Replace the sensor. position sensor (PI7) position sensor. Is the sensor normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the stapler shift motor normal?
Page 247 CHAPTER 7 TROUBLESHOOTING 12. Faulty swing motor (related to PI18) Cause Step Checks Yes/No Action Swinging mechanism Turn the delivery motor in Correct the swinging reverse by hand. Does the mechanism. swing guide move up and down? Swing guide open Is the swing guide open Replace the sensor.
Page 248 CHAPTER 7 TROUBLESHOOTING 14. Faulty swing motor (related to PI20) Cause Step Checks Yes/No Action Swing motor clock Check the swing motor clock Replace the sensor. sensor (PI20) sensor. Is the sensor normal? Finisher controller PCB Does the voltage of the Replace the finisher swing motor between J11-6 controller PCB.
Page 249 CHAPTER 7 TROUBLESHOOTING 17. Faulty tray 1 motor (related to PI9/PI19) Cause Step Checks Yes/No Action Does the tray 1 move up/ Go to step 2. down? Go to step 4. Is the motor supplied with Go to step 3. power by the finisher controller PCB as soon as Finisher controller PCB...
Page 250 CHAPTER 7 TROUBLESHOOTING 19. Faulty second feed motor (related to PI5) Cause Step Checks Yes/No Action Second feed motor Does the second feed motor Replace the second (M8) in reverse at a specific feed motor or the timing? finisher controller PCB.
Page 251 CHAPTER 7 TROUBLESHOOTING : Jan. 9 2004 21. Faulty second feed motor (related to MS3) Cause Step Checks Yes/No Action Safety range switch Check the safety range Replace the switch. (MS3) switch. Is the switch normal? Is the safety range detection Correct mechanical switch passed correctly? operation.
Page 252: Saddle Stitch Unit
CHAPTER 7 TROUBLESHOOTING Saddle Stitch Unit Faulty paper positioning plate Cause Step Checks Yes/No Action Paper positioning plate Check the paper positioning Replace the sensor. home position sensor plate home position sensor. (PI7S) Is the sensor normal? Saddle stitch controller Do the paper positioning Replace the saddle plates operate at a specific...
Page 253 CHAPTER 7 TROUBLESHOOTING Faulty guide motor Cause Step Checks Yes/No Action Guide home position Check the guide home Replace the sensor. sensor (PI13S) position sensor. Is the sensor normal? Saddle stitch controller Does the guide motor Replace the saddle operate at a specific timing? stitch controller PCB.
Page 254 CHAPTER 7 TROUBLESHOOTING Faulty stitcher Cause Step Checks Yes/No Action Stitcher (installation) Are the front and rear Install them correctly. stitchers and bases installed correctly? Stitching home position Is the stitching home position Replace the front or switch (MS7S/MS5S) switch of the front and the rear rear stitcher.
Page 255 CHAPTER 7 TROUBLESHOOTING Faulty paper pushing plate motor (related to PI15S) Cause Step Checks Yes/No Action Paper pushing top Check the paper pushing Replace the sensor. position sensor (PI15S) plate top position sensor. Is the sensor normal? Saddle stitch controller Does the paper pushing Replace the saddle plate motor operate at a...
Page 256 CHAPTER 7 TROUBLESHOOTING Disconnected sensor connector (related to PI13S) Cause Step Checks Yes/No Action Guide home position Are the connectors of the Connect the sensor (PI13S; guide home position sensor connectors. disconnected) and the saddle stitch controller PCB connected correctly? Wiring Is the wiring between the Correct the wiring.
Page 257 CHAPTER 7 TROUBLESHOOTING 11. Disconnected sensor connector (PI15S) Cause Step Checks Yes/No Action Paper pushing plate Are the connectors of the Connect the home position top paper pushing plate top connectors. position sensor (PI15S; position sensor and the disconnected) saddle stitch controller PCB connected correctly? Wiring Is the wiring between the...
Page 258 CHAPTER 7 TROUBLESHOOTING 13. Faulty microswitch (related to MS2S) Cause Step Checks Yes/No Action Switch actuator Check the switch actuator of Correct the the front door. Do the switch mechanism. and the sensor operate correctly? Front door switch Check the front door switch. Replace the switch.
Page 259: Puncher Unit (Option)
CHAPTER 7 TROUBLESHOOTING Puncher Unit (option) Faulty punch motor Cause Step Checks Yes/No Action Punch motor clock Check the punch motor clock Replace the sensor. sensor (PI2P) sensor. Is the sensor normal? Punch home position Check the punch home Replace the sensor. sensor (PI3P) position sensor.
Page 260 CHAPTER 7 TROUBLESHOOTING 7-46...
Page 261: Appendix
APPENDIX A. FINISHER UNIT GENERAL TIMING CHART ......A-1 B. SADDLE STITCH UNIT GENERAL TIMING CHART ..A-2 C. PUNCHER UNIT (option) GENERAL TIMING CHART ..A-3 D. SIGNAL AND ABBREVIATIONS ....... A-4 E. ACTUAL WIRING CHART ..A-6 SOLVENTS AND OILS ..... A-11...
Page 263 APPENDIX...
Page 264 APPENDIX...
Page 265 APPENDIX...
Page 266: Saddle Stitch Unit
APPENDIX D. SIGNAL AND ABBREVIATIONS The following presents the abbreviations of signals used in this manual and in drawings, and the meanings of each signal. Reference: Signals enclosed by brackets [ ] are electrical signals. However, the state “1” or “0” of these analog signals cannot be indicated.
Page 267 APPENDIX FRONT DOOR OPEN DETECT Signal FDRLHP CRESCENT ROLLER PHASE DETECT Signal FDROPN FRONT DOOR OPEN DETECT SWITCH Signal FLDCLK FOLD MOTOR CLOCK Signal FLPSL1 FLAPPER DRIVE Signal 1 FSPSL2 FLAPPER DRIVE Signal 2 GIDHP PAPER GUIDE HOME POSITION DETECT Signal HKEMP1 HOOK EMPTY DETECT Signal 1 HKEMP2...
Page 268: Actual Wiring Chart
APPENDIX E. ACTUAL WIRING CHART FINISHER (1/2)
Page 269 APPENDIX...
Page 270 APPENDIX FINISHER (2/2-A)
Page 271 APPENDIX...
Page 272 APPENDIX FINISHER (2/2-B) A-10...
Page 273 APPENDIX A-11...
Page 274 APPENDIX PUNCH UNIT (1/1) A-12...
Page 275: Solvents And Oils
APPENDIX F. SOLVENTS AND OILS Name Description Composition Remarks Cleaner Cleaning: Hydrocarbon • Do not bring near fire. e.g., glass, (fluorine family) • Procure locally. plastic, Alcohol • Isopropyl alcohol may be rubber parts, Surface activating substituted. external agent covers Water Lubricant Drive, friction...
Page 276 Memo...
Page 277 Memo...
Page 278 LEAD-FREE SOLDER The PWB’s of this model employs lead-free solder. The “LF” marks indicated on the PWB’s and the Service Manual mean “Lead-Free” solder. The alphabet following the LF mark shows the kind of lead-free solder. Example: <Solder composition code of lead-free solder> Solder composition Solder composition code Solder composition...
Page 279 CAUTION FOR BATTERY REPLACEMENT (Danish) ADVARSEL ! Lithiumbatteri – Eksplosionsfare ved fejlagtig håndtering. Udskiftning må kun ske med batteri af samme fabrikat og type. Levér det brugte batteri tilbage til leverandoren. (English) Caution ! Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer.
Page 280 Adobe, the Adobe logo, Acrobat, and the Acrobat logo are trademarks of Adobe Systems Incorporated. • All other trademarks and copyrights are the property of their respective owners. SHARP CORPORATION Digital Document System Group Products Quality Assurance Department Yamatokoriyama, Nara 639-1186, Japan...

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Sharp AR-F15 Service Manual

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Chapter 2 Finisher Unit Basic Operation

Chapter 3 Saddle Stitch Unit Basic Operation

Chapter 4 Puncher Unit (Option) Basic Operation

Chapter 5 Mechanical Construction

Chapter 7 Troubleshooting

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