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Sharp AR-FN8 Service Manual

Finisher punch unit
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AR-FN8
[1]
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
[2]
Finisher Unit Basic Operation. . . . . . . . . . . . . . . . . . . . . 2-1
[3]
SADDLE STICHER UNIT BASIC OPERATION . . . . . . . . . . . . . 3-1
[4]
PUNCHER UNIT BASIC OPERATION . . . . . . . . . . . . . . . . . . . . 4-1
[5]
Mechanical Construction . . . . . . . . . . . . . . . . . . . . . . . . 5-1
[6]
Maintenance And Inspection. . . . . . . . . . . . . . . . . . . . . . 6-1
[7]
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
[8]
Unpacking And Installation . . . . . . . . . . . . . . . . . . . . . . . 8-1
Parts marked with "
" are important for maintaining the safety of the set.
Be sure to replace these parts with specified ones for maintaining the safety and performance of the set.
SERVICE MANUAL
AR-PN2
AR-FN9

CONTENTS

SHARP CORPORATION
CODE : 00ZARFN8//A1E
AR-FN8
AR-FN9
AR-PN2A
AR-PN2B
AR-PN2C
AR-PN2D
MODEL
This document has been published to be used for
after sales service only.
The contents are subject to change without notice.

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  • Page 1 SERVICE MANUAL CODE : 00ZARFN8//A1E FINISHER PUNCH UNIT AR-PN2 AR-FN8 AR-FN9 AR-PN2A AR-PN2B AR-PN2C AR-PN2D MODEL AR-FN9 AR-FN8 CONTENTS GENERAL DESCRIPTION ......1-1 FINISHER UNIT BASIC OPERATION.
  • Page 2 INTRODUCTION This Service Manual contains the basic data and figures for the Finisher AR-FN8/Saddle Finisher AR-FN9 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 CONTENTS CHAPTER 1 GENERAL DESCRIPTION I. FEATURES ........1-1 E. Supplying the Saddle Stitcher Unit with Staples (Saddle II. SPECIFICATIONS ....... 1-2 Finisher) ......... 1-22 A. Finisher specification ....1-2 F. Removing Staple Jams B. Punch unit specification ..1-10 from the Saddle Stitcher Unit C.
  • Page 5 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION I. 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 E.
  • Page 6 CHAPTER 6 MAINTENANCE AND INSPECTION I. PERIODICALLY REPLACED A. Finisher Unit ......6-2 PARTS ......... 6-1 B. Saddle Stitcher Unit ....6-2 A. Finisher Unit ......6-1 C. Puncher Unit (option) ....6-2 B. Saddle Stitcher Unit ....6-1 III. PERIODICAL SERVICING ..6-2 C.
  • Page 7 APPENDIX A. SIGNAL AND E. SADDLE STITCHER UNIT ABBREVIATIONS ....... A-1 PCB .......... A-17 B. FINISHER UNIT CIRCUIT PUNCHER UNIT (OPTION) DIAGRAM ........A-2 CIRCUIT DIAGRAM ....A-25 C. FINISHER CONTROLLER G. PUNCH DRIVER PCB ....A-26 PCB ..........A-5 H.
  • Page 8 CHAPTER 1 GENERAL DESCRIPTION I. FEATURES ........ 1-1 E. Supplying the Saddle Stitcher II. SPECIFICATIONS ..... 1-2 Unit with Staples (Saddle A. Finisher specification ... 1-2 Finisher) ......1-22 B. Punch unit specification ..1-10 F. Removing Staple Jams C. Cross Section..... 1-13 from the Saddle Stitcher Unit III.
  • Page 9 2 holes (70mm pitch) 3 holes (108mm pitch) USA/Canada AR-PN2C 4 holes (80mm pitch) France AR-PN2D 4 holes (70/21mm pitch) Sweden Stapler for Finisher Cartridge for AR-FN8 and AR-FN9 Staple Cartrige 5000×3 SF-SC11 5000 sheets Common w ith S55,S55N Stapler for Finisher AR-FN8 and AR-FN9 Staple Cartrige 5000×3...
  • Page 10 CHAPTER 1 GENERAL DESCRIPTION II. SPECIFICATIONS Finisher specifications Basic specifications General Type 2-tray finisher * Stretching paper exit tray Installation type Floor installation, field option Fixing method Latch method (Fixed with brackets in the upper side of the PPC exit side) Vertical adjustment feature Available...
  • Page 11 CHAPTER 1 GENERAL DESCRIPTION In the case of simple load, job offset load, and staple load Single load (Non-sort) Job offset load (Sort/Group) Staple load Mode Tray No. A5 long, ST long 147mm 147mm B5 long 74mm 74mm 110mm, 750 110mm, 750 A4 short, sheets, or 50...
  • Page 12 CHAPTER 1 GENERAL DESCRIPTION Staple section Type Unit assembly type Staple load system Staple cartridge (5,000 staples) Installation Inside of the front cover Fixing Magnet catch Stapling capacity (A4 short, B5 short, LT short): 50 sheets (A3 long, B4 long, A4 long, LD long, LT long, FOLIO, COMPUTER): 30 sheets Stapling direction Face-up stapling...
  • Page 13 CHAPTER 1 GENERAL DESCRIPTION Stapling position One-point staple in the front Paper feeding direction Paper width (30˚) One-point staple at that back Paper feeding direction Size Paper width A4-Long, FOLIO 204.0 LG-Long, LT-Long 210.0 One-point staple at the back (30˚) (Slant staple) Paper feeding Size...
  • Page 14 CHAPTER 1 GENERAL DESCRIPTION Saddle stitch section (AR-FN9 only) Staple type Unit assembly type Staple load Staple cartridge (2,000 staples) Staple empty detection Available Installing direction Inside of the front lower cover Stapling capacity 15 sheets Stapling system Center stapling, two-fold, * Fixed stapling pitch Folding position Center folding...
  • Page 15 With no punch, with latch unit installed, with sub tray closed. Package external W1162 x D817 x H951m dimensions * Including the cardboard pallet About 32kg (AR-FN8) About 52kg (AR-FN9) Weight Machine weight * Machine body (excluding the connection rail) Package weight...
  • Page 16 (6) Alignment of mixed sizes is out of the above specifications. (Loadable) Conforming standards Safety standards (1) UL (2) C-UL (3) TUV (4) CE (Applied by Sharp) Obstruction wave standards (19 VCCI (As a system) (2) FCC (IC) (As a system)
  • Page 17 CHAPTER 1 GENERAL DESCRIPTION System comparison of AR-S650/650 Paper size and load height (cascade setup) Mode Simple load (Non-sort/group) Job offset load (Sort) Staple load Tray no. A5 long, ST long X B5 long 93mm, 637 93mm, 637 A4 short, sheets, or 42 sheets, or 42 B5 short,...
  • Page 18 CHAPTER 1 GENERAL DESCRIPTION Punch unit specifications Basic specifications General Installation type Field option Number of 2-hole (Ø6.5) Japan, Europe punch holes and 2-hole/3-hole North America hole dia. auto selection * For details of (Ø8.0) punch positions, 4-hole (Ø6.5) France (80mm pitch) refer to the next page.
  • Page 19 CHAPTER 1 GENERAL DESCRIPTION Punch position (Unit : mm) 2-hole ( Ø 6.5) : Japan/Europe (80mm pitch) 2-hle ( Ø 8.0) : North America (70mm pitch) 12 3 12 3 35 3 40 3 80 1 70 1 3-hole ( Ø 8.0) : North America 4-hole ( Ø...
  • Page 20 CHAPTER 1 GENERAL DESCRIPTION Machine specifications External dimensions Machine external W76 x D581x H373mm dimensions * Punch dimension does not include the punch lower cover. Package external W726 x D514 x H339mm dimensions Weight Machine weight About 6kg Package weight About 11kg Package weight Punch unit body (1)
  • Page 21 CHAPTER 1 GENERAL DESCRIPTION Cross Section Finisher Unit [2] [3] [4] [5] [6] [8] [9] [10] [11] [18] [19] [17] [16] [15] [14] [13] [12] [1] Tray 1/2 [11] Inlet feed roller [2] Shutter [12] Feed roller 1 [3] Delivery roller [13] Vertical path [4] Swing guide [14] Stapler...
  • Page 22 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitcher Unit [10] [11] [12] [1] Guide plate [7] No. 1 flapper [2] Folding roller [8] No. 2 flapper [3] Delivery guide plate [9] Stitcher plate (front, rear) [4] Holding roller [10] Butting plate [5] Stitcher (front, rear) [11] Crescent roller [6] Inlet roller [12] Paper positioning plate...
  • Page 23 CHAPTER 1 GENERAL DESCRIPTION Puncher Unit (option) [1] Punch motor [6] LED PCB [2] Cam [7] Horizontal registration motor [3] Hole puncher (Punch blade) [8] Scrap-full detector PCB unit [4] Die [9] Punched scrap container [5] Photosensor PCB Figure 1-206 1-15...
  • Page 24 CHAPTER 1 GENERAL DESCRIPTION 3) Open the upper cover and check the inside IV. USING THE MACHINE of the finisher. Removing Paper Jams from the Finisher Unit If the host machine indicates the finisher pa- per jam message, perform the following to re- move the jam.
  • Page 25 CHAPTER 1 GENERAL DESCRIPTION 6) Return the buffer roller and the buffer roller Supplying the Finisher Unit cover to their original positions, and close with Staples the upper cover. If the copier indicates the finisher unit staple supply message, perform the following to sup- ply it with staples.
  • Page 26 CHAPTER 1 GENERAL DESCRIPTION 4) Push the blue knob and pull out the empty 6) Pull the length of tape (used to hold the staple case. staples in place) straight out. Figure 1-311 Figure 1-313 5) Set a new staple case. 7) Set the staple cartridge.
  • Page 27 CHAPTER 1 GENERAL DESCRIPTION 4) Draw out the stapler unit and then lift it up. Removing Staple Jams from the Finisher Unit If the copier indicates the finisher unit staple jam message, perform the following to remove the jam. 1) Remove the stack waiting to be stapled from the delivery tray.
  • Page 28 CHAPTER 1 GENERAL DESCRIPTION staple cover. Removing Paper Jams from the Saddle Stitcher Unit (Saddle Finisher) 8) Return the stapler unit to its original posi- tion, and turn the blue knob clockwise to lock it. If the host machine indicates the saddle stitcher unit paper jam message, perform the fol- lowing to remove the jam.
  • Page 29 CHAPTER 1 GENERAL DESCRIPTION 3) Turn the knob clockwise. 6) Open the inlet cover and remove the jam. Figure 1-325 Figure 1-328 4) Turn the knob counterclockwise while push- 7) Close the front lower door. ing it in. Figure 1-329 Figure 1-326 8) Connect the saddle finisher to the host ma- 5) Remove the jam.
  • Page 30 CHAPTER 1 GENERAL DESCRIPTION 3) Pull the stitcher unit to the front once and Supplying the Saddle then shift it up. Stitcher Unit with Staples (Saddle Finisher) If the host machine indicates the saddle stitcher unit staple supply message, perform the following to supply it with staples.
  • Page 31 CHAPTER 1 GENERAL DESCRIPTION 6) Pull the stitcher to the front once and then Removing Staple Jams return it to its original position. from the Saddle Stitcher Unit (Saddle Finisher) If the host machine indicates the saddle stitcher unit staple jam message, perform the fol- lowing to remove the jam.
  • Page 32 CHAPTER 1 GENERAL DESCRIPTION 4) Hold the cartridge on its sides and remove 7) Return the cartridge to its original position. Figure 1-343 8) Pull the stitcher of the stitcher unit to the Figure 1-340 front once, and then return it to its original position.
  • Page 33 CHAPTER 1 GENERAL DESCRIPTION 4) Open the upper cover. Removing Paper Jams 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 door of the puncher unit. Figure 1-349 5) Remove the jam.
  • Page 34 CHAPTER 1 GENERAL DESCRIPTION 4) Return the punched scrap container to its Removing Punched Scrap original position. from the Puncher Unit (option) If the display indicates a punched scrap full state on the puncher unit, perform the follow- ing to remove the punched scrap: 1) Open the front door of the puncher unit.
  • Page 35 CHAPTER 1 GENERAL DESCRIPTION V. MAINTENANCE BY THE USER Maintenance by the User Item Timing Replacing the staple cartridge (finisher unit) When the appropriate indication is made Replacing the staple cartridge (saddle on the host machine’s display. stitcher unit) Note: The finisher unit and the saddle stitcher unit use different cartridge types.
  • Page 36 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 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 stapling. All operations involved in these modes are controlled by the finisher controller PCB, according to the appropriate commands from the host machine.
  • Page 38 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 stitcher PCB communication controller PCB (Saddle Finisher) Solenoid Switch EEP-ROM Punch driver PCB (Puncher unit (option)) Sensor Communication Host machine EP-ROM (DC controller PCB CPU) Q8/Q89 Regulator IC Figure 2-102...
  • Page 40 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Inputs to the Finisher Controller PCB Finisher controller PCB J106-3 J17-7 +5V When the sensor detects PENT Inlet sensor paper, “1”. J134-1 J11-3 When the sensor detects Delivery sensor PDEL paper, “1”.
  • Page 41 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB Inputs to the Finisher Controller PCB PI10 J120-1 J9A-9 +5V Delivery motor While the delivery motor DELCLK is rotating, alternately clock sensor between “0” and “1”. PI11 J101-3 J14-1 +5V Tray 1 paper When paper is present on FSTTRAY* sensor...
  • Page 42 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Finisher controller PCB PI20 J125-1 J9B-5 Swing motor When the swing motor is SWGCLK clock sensor rotating, alternately between “0” and “1”. J114-3 J6-2 Measures the distance between the sensor and the top of the Height sensor stack on the tray.
  • Page 43 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Stapler unit Finisher controller PCB Staple home When the stapler is at the home position sensor position, “0”. Staple switch When staples are present in the cartridge, “0”.
  • Page 44 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB +24V Flapper solenoid J12A-10 When "0", the solenoid is turned on. FLPSL* +24V Buffer inlet solenoid J12B-9 When "0", the solenoid is turned on. ENTSL* +24V Buffer outlet solenoid J24-7...
  • Page 45 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB Delivery motor According to rotation direction/speed, changes between + and -. Alignment motor According to rotation direction/speed, changes between + and - in sequence. MOVE Stapler shift motor According to rotation direction/speed, changes...
  • Page 46 CHAPTER 2 FINISHER UNIT BASIC OPERATION 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 Simple Stacking The finisher delivers copies directly to the tray. Tray Copies Feed roller 1 elivery 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 Stapling 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 stitcher by the paper deflecting plate. The saddle stitcher executes stitching and saddling operations on the copy and then delivers it to the saddle stitcher tray.
  • Page 51 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 Length or width 182 mm or less Typical copy examples...
  • 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 stapling 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. 1st copy 2nd copy 3rd copy Figure 2-214 4) The first, second and third copies are simultaneously pulled into the stapling tray. 2nd copy 3rd copy 1st copy...
  • Page 54 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 stitcher 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 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 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 guide.
  • Page 58 CHAPTER 2 FINISHER UNIT BASIC OPERATION Alignment guide Guide plate Alignment guide 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 knurled belts move the sheet to the stapling tray. Swing guide Offset sheet Feed roller 2 Knurled belts Tray 1/2 Delivery roller...
  • Page 60 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling 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 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 switches 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 2nd 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 feed roller 2 to make the feed 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 nurled belts Escape direction Belt escape solenoid (SL7) Figure 2-228 Paddles Paddles Paddle solenoid (SL5) 2nd and subsequent sheets 1st sheet Stapler 2nd 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 guide to the alignment position (to butt the guide 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 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapler Unit Stapling is executed by the stapler motor (M6). A single rotation of the cam by the motor results in one stapling operation. The cam is checked by the stapling 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 1st sheet 2nd sheet Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8) Delivery motor (M2) Staple 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 waiting 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 Guide plate...
  • Page 73 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2-Point Stapling The stapler is kept waiting at the center of paper. Stapling occurs at two points, first at the rear and then at the front. Stopper Stapling position Wait position Stapling tray Stapler delivery direction Stapling position Stopper...
  • Page 74 CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray Operation The finisher has two delivery trays for normal delivery, each accepting sheets. Each tray is moved up and down by the tray lift motor (M5). The position of tray is identified with reference to the number of clock pulses of the tray lift motor clock sensor 1/2 (PI9/PI19) coming from the tray home position sensor (PI8).
  • Page 75 CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray guide Tray 1 Tray upper limit detecting switch (MS5) Tray 2 Encoder Tray lift motor clock sensor 2 (PI19) Tray lift motor clock sensor 1 (PI9) Safety zone switch (MS3) Tray home position sensor (PI8) Tray lift motor (M5) Figure 2-239 2-39...
  • Page 76 CHAPTER 2 FINISHER UNIT BASIC OPERATION 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 eight sensor (PS1) Paper Figure 2-240 2-41...
  • Page 78 CHAPTER 2 FINISHER UNIT BASIC OPERATION Shutter Operation Before the tray on which sheets are output is shifted by the tray lift motor (M5) to another tray, the finisher controller PCB closes the shutter mounted on the delivery slot before moving the tray, protecting the existing stack on the tray from the delivery slot and intrusion of hands.
  • Page 79 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2) The tray lift motor rotates and the new tray moves to the stacking lower limit. The distance of movement is detected by the tray lift motor clock sensor 1/2 (PI9/PI19). Tray lift motor Figure 2-242 3) The second feed motor rotates counterclockwise and the shutter moves down.
  • 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 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 Shutter Tray Shutter Tray closed moved opened moved Second feed motor (M8) Tray lift motor (M5) Shutter closed detecting switch (MS4) Shutter open sensor (PI5) Correct height detected Height sensor (PS1)
  • Page 82 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 stapling 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. 1st sheet 2nd sheet Buffer path paper sennsor (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. 2nd sheet 1st 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. 2nd sheet 1st sheet 3rd 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) goes 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 CHAPTER 2 FINISHER UNIT BASIC OPERATION 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) elivery 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 inlet sensor when an equivalent of twice the feeding length of the sheet has been fed after the sensor has been 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 550 mm has been fed after the inlet sensor has been turned on. Equivalent of 550 mm Equivalent of 550 mm 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) has been turned on. 1 sec 1 sec am check am check Normal Stapling tray Stapling tray...
  • Page 92 CHAPTER 2 FINISHER UNIT BASIC OPERATION III. POWER SUPPLY SYSTEM Outline The finisher controller PCB is supplied with 24 V C and 5V C power when the host machine is turned on, 24V C is used to drive the motor solenoids. 5V C is used for sensors and ICs. 24V C and 5V C are also used to feed power from the finisher controller PCB to the saddle stitcher controller PCB.
  • Page 93 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the stitcher’s functions, and the prin- ciples of operation used for the stitcher 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 94 CHAPTER 3 SADDLE STITCHER 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 stitcher controller PCB in response to commands from the host machine via the finisher unit.
  • Page 95 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Electrical Circuitry The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher controller PCB. The saddle stitcher 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 fin- isher controller PCB.
  • Page 96 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to and Outputs from the Saddle Stitcher Controller PCB Inputs to the Saddle Stitcher Controller PCB Saddle stitcher 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 97 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher 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 98 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher 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 99 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB +24V No.1 paper deflecting solenoid J15-1 When “0”, the solenoid comes SL1S FLPSL1* +24V No.2 paper deflecting solenoid J15-3 When “0”, the solenoid comes SL2S FLPSL2* +24V...
  • Page 100 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB Stitcher unit (front) J315-4 J8-4 The states (+ and -) change according to the rotation of the motor. Stitcher motor (front) Stitcher unit (rear) J316-4 J8-11 The states (+ and -) change...
  • Page 101 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION FEEDING/DRIVE SYSTEM Outline The stitcher 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 102 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Receiving Sheets The stitcher 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 103 CHAPTER 3 SADDLE STITCHER 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 104 CHAPTER 3 SADDLE STITCHER 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 105 CHAPTER 3 SADDLE STITCHER 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 106 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Folding/Delivering the Stack The paper pushing plate pushes again 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 107 CHAPTER 3 SADDLE STITCHER 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 108 CHAPTER 3 SADDLE STITCHER 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 109 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Saddle stitcher controller PCB (1/2) PI18S PI19S PI20S PI21S PI15S PI14S Saddle stitcher controller PCB (2/2) Figure 3-302 3-16...
  • Page 110 CHAPTER 3 SADDLE STITCHER 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 111 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A3/LD Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S No.1 paper deflecting SL1S plate solenoid Non-passage of paper No.2 paper sensor PI19S SL2S No.2 paper deflecting plate solenoid Non-passage of paper No.3 paper sensor PI20S Top edge...
  • Page 112 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION B4 Paper Path (3 sheets) Passage of paper No.1 paper sensor PI18S SL1S Passage of paper No.2 paper sensor PI19S SL2S No.3 paper sensor No passage of paper PI20S PI18S PI19S Top edge PI20S PI18S PI19S...
  • Page 113 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A4-R/LT-R Paper Path (3 sheets) Passage of paper No.1 paper sensor PI18S SL1S Passage of paper No.2 paper sensor PI19S SL2S No.3 paper sensor Passage of paper PI20S PI18S PI19S Top edge PI20S PI18S PI19S PI20S...
  • Page 114 CHAPTER 3 SADDLE STITCHER 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 115 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 2) The solenoid is turned OFF when the paper buts against the paper positioning plate. The feed motor continues to rotate. SL4S Figure 3-307 3) The solenoid is turned ON when the next sheet arrives and the feed plate comes into contact. SL4S Figure 3-308 3-22...
  • Page 116 CHAPTER 3 SADDLE STITCHER 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 motor is a 4-phase stepping motor. The position of alignment plate is identified in reference to the number of motor pulses from the alignment plate home position sensor (PI5S).
  • Page 117 CHAPTER 3 SADDLE STITCHER 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 118 CHAPTER 3 SADDLE STITCHER 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...
  • Page 119 CHAPTER 3 SADDLE STITCHER 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 resulting 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 align- ment.
  • Page 120 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Alignment plates Crescent roller phase sensor(PI12S) Sensor flag Crescent roller If the crescent roller was in contact with the stack, the alignment operation could be obstructed. Figure 3-318 The alignment operation is started when the flag has covered the sensor and the crescent roller is away from the stack.
  • Page 121 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 1st sheet 3rd sheet 2nd sheet 4th sheet Feed motor Crescent roller phase stops sensor (PI12S) Alignment operation Feed motor (M1S) Figure 3-320 3-28...
  • Page 122 CHAPTER 3 SADDLE STITCHER 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 STITCHER 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 STITCHER UNIT BASIC OPERATION Mount Figure 3-404 3-31...
  • Page 125 CHAPTER 3 SADDLE STITCHER 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 as to prevent sheets from coming into contact with the folding rollers during output.
  • Page 126 CHAPTER 3 SADDLE STITCHER 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 STITCHER 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 STITCHER 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 STITCHER 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 STITCHER 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 STITCHER 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 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Gripping of paper stack (reverse feeding) Equivalent of 20 mm Equivalent of 20 mm Paper folding motor (M2S) Paper pushing plate motor (M8S) Paper pushing plate home position sensor (PI14S) Paper pushing plate top position sensor (PI15S) Delivery sensor...
  • Page 133 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VI. CHECKING FOR A JAM Checking for a Jam The saddle stitcher 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 the copying operation and indicate the presence of a jam on its control panel.
  • Page 134 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inlet Delay Jam The No.1 paper sensor (PI18S) on the paper sensor PCB does not come ON for a specific period of time after the inlet sensor (PI1) of the finisher has been turned ON. Inlet sensor (PI1) Inlet sensor (PI1) No.1 paper...
  • Page 135 CHAPTER 3 SADDLE STITCHER 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 136 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Delivery Delay Jam By delivery sensor The delivery sensor (PI11S) does not come ON within a specific period of time after the paper pushing plate top position sensor has been turned ON. Paper pushing plate top Paper pushing plate top Normal position sensor...
  • Page 137 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION By delivery sensor The delivery sensor (PI11S) does not go OFF within a specific period of time (feeding) after it has been turned ON. Normal Delivery sensor Delivery sensor Paper folding motor Paper folding motor Load stops Paper length Paper length...
  • Page 138 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VII. POWER SUPPLY Outline When the host machine power switch is turned ON, two 24V power lines are supplied by the finisher controller PCB. The 24V line is used to drive motors and solenoids. The 24V power from the finisher controller PCB to solenoids does not pass through any protective mechanisms (microswitches, or the like).
  • Page 139 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 140 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION BASIC OPERATION Outline The puncher unit (option) is attached on the feed path between the host machine and the fin- isher. 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 141 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 SREGHP registration home unit is at the home position sensor position, “1”.
  • Page 142 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Outputs from Punch Driver PCB (2/3) Punch driver PCB LED PCB J7-1 LED5 LEDON5 LED4 LEDON4 LED3 When “ 1” , LED is ON. LEDON3 LED2 LEDON2 LED1 LEDON1 Scrap-full detector PCB LED6 J1B-8 LEDON* PTR6...
  • Page 143 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Outputs from Punch Driver PCB (3/3) Punch driver PCB Finisher controller PCB 21A-14 3A-1 21B-13 3B-2 Figure 4-104...
  • Page 144 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION 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 145 CHAPTER 4 PUNCHER UNIT (OPTION) BASIC OPERATION Punch driver PCB (1/2) PTR1 LED1 Punch driver PCB (2/2) Figure 4-201...
  • Page 146 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 detected by the punch home position sensor (PI3P). In all there are four types of puncher unit depending on the destination: 2-hole type (Puncher unit AP-PN2AE), 2-/3-hole Dual Use (Puncher unit AP-PN2AN), and two 4-hole types (Puncher unit AP-PN2AF and Puncher unit AP-PN2AS).
  • Page 147 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 148 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 149 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 150 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 151 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 hori- zontal registration motor (M2P) drives the punch slide unit to a predetermined position further towards the front, and stops the unit at this position.
  • Page 152 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. 5) Even if paper to be punched continues to arrive, the punch slide unit returns to its home posi- tion for each arriving sheet, and steps 1 to 4 are repeated.
  • Page 153 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 154 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 155 CHAPTER 5 MECHANICAL CONSTRUCTION FINISHER UNIT Externals and Controls [1] Tray [2] Rear cover (3) [3] Front door [4] Upper cover assembly Figures in parentheses ( ) indicate the number of mounting screws. Figure 5-101...
  • Page 156 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Front Door Assembly 1) Open the front door assembly [1]. 2) Remove the screw [2] and take out the bush- ing [3] (center). 3) Remove the screw [4] and take out the bush- ing (top) [5]. Then remove the front door assembly.
  • Page 157 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Upper Cover Assembly 1) Open the upper cover assembly [1]. 2) Remove the two claws [2] and take out the upper cover assembly. Figure 5-104 Removing the Front Cover 1) Open the front door assembly [1]. 2) Remove the screw [2] and take out the front cover [3].
  • Page 158 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Tray Assembly 1) Remove the rear cover. (See I-A-2.) 2) For the Saddle Finisher, remove the rear lower cover also. (See II-A-2.) 3) Disconnect J201 [1] and the grounding wire [2], and release the harness stop [3]. Figure 5-106 4) Remove the slide guide [4].
  • Page 159 CHAPTER 5 MECHANICAL CONSTRUCTION Note: When installing the removed tray assembly back to the finisher assembly, be sure to release the tray lift motor gear clutch [1] with a screwdriver or similar object when inserting it. Take extra care during this operation. Figure 5-108 Removing the Grate-Shaped Upper Guide...
  • Page 160 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Grate-Shaped Lower Guide 1) Remove the tray assembly. (See I-A-5.) 2) Remove the three screws [1] (M4). 3) Remove the three screws [2] (M3) and open the grate-shaped lower guide [3] to the front. Figure 5-110 4) Free the harness [5] from the harness stop [4].
  • Page 161 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Right Guide Assembly 1) Remove the four screws [5] to take out the latch unit [4]. 2) Remove the rear cover. (See I-A-2.) 3) Open the front door assembly [1]. 4) Remove the two screws [2] to take out the right guide assembly [3].
  • Page 162 CHAPTER 5 MECHANICAL CONSTRUCTION FEEDING SYSTEM Removing the Swing Unit 1) Remove the tray assembly. (See I-A-5.) 2) Remove the grate-shaped upper guide. (See I-A-6.) 3) Remove the grate-shaped lower guide. (See I-A-7.) 4) Remove the harness from the two harness stops [1] and disconnect the four connec- tors [2].
  • Page 163 CHAPTER 5 MECHANICAL CONSTRUCTION 9) Remove the three screws [5] and slide out the swing unit [6] towards you. Remove the swing unit. Figure 5-114 Removing the Feed Drive Unit 1) Remove the finisher controller PCB. (See I-C-1.) 2) Remove the harness leads [2] from the two harness stops [1] at the PCB base and dis- connect the two connectors [3].
  • Page 164 CHAPTER 5 MECHANICAL CONSTRUCTION 3) Remove the ground lead [4] and the three screws [5] and pull down the PCB base [6] towards you. Figure 5-116 4) Remove the harness leads [8] from the two edge saddles [7] and remove the PCB base. Figure 5-117 5-10...
  • Page 165 CHAPTER 5 MECHANICAL CONSTRUCTION 5) Remove the three screws [9] and take out [10] the feed drive unit [10]. Figure 5-118 Note: Before reattaching the removed feed drive unit on the finisher unit, loosen the move gear stop screw [11] to relieve the tension, and then fasten the screw after attaching the feed drive unit.
  • Page 166 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Buffer Roller Assembly 1) Remove the finisher controller PCB. (See I-C-1.) 2) Remove the feed drive unit. (See I-B-2.) 3) Take out the screw [1] and remove the guide support plate assembly [2] to slide out the harness leads [3] towards the buffer roller assembly side.
  • Page 167 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Stapler 1) Open the front cover, and move the stapler assembly to the front. 2) Remove the screw [1], and slide out the sta- pler assembly [2]. 3) Remove the right front cover [1] (2 screws). Figure 5-122 4) Remove the stepped screws (2 pcs.) which support the stapler unit.
  • Page 168 CHAPTER 5 MECHANICAL CONSTRUCTION 6) Disconnect the ring terminal [5] of the sta- pler assembly. Figure 5-125 7) Remove the M4 screws (3 pcs.) which fix the stapler cover. Figure 5-126 8) Remove the M4 screws (2 pcs.) which fix the stapler.
  • Page 169 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Transit Path Assembly 1) Remove the two screws [2], and remove the right cover [1]. 2) Open the upper cover assembly [3], remove the three screws [5], and remove the rear cover [4]. Figure 5-128 3) Disconnect the three connectors [6], and free the harness from the two harness stops [7].
  • Page 170 CHAPTER 5 MECHANICAL CONSTRUCTION PCBs Removing the Finisher Controller 1) Remove the rear cover. (See I-A-2.) 2) Disconnect the 16 connectors [1]. 3) Remove the four screws [2] and take out the finisher controller PCB [3]. Figure 5-130 5-16...
  • Page 171 CHAPTER 5 MECHANICAL CONSTRUCTION II. SADDLE STITCHER UNIT Externals and Controls [1] Rear lower cover (4) [2] Front lower door Figures in parentheses ( ) indicate the number of mounting screws. Figure 5-201 5-17...
  • Page 172 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Front Lower Door Assembly 1) Open the front lower door assembly [1]. 2) Remove the screw [2] and take out the bush- ing [3]. Then remove the front lower door assembly. Figure 5-202 Removing the Rear Lower Cover 1) Remove the four screws [1] and take out the rear lower cover [2].
  • 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 take out the fold- ing roller knob [3]. 3) Remove the five screws [4] and take out the front inside cover [5].
  • Page 174 CHAPTER 5 MECHANICAL CONSTRUCTION 2) Remove the door shaft [3] in the direction of the arrow and slide out towards the front of the saddle delivery tray assembly [4]. Figure 5-206 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].
  • Page 175 CHAPTER 5 MECHANICAL CONSTRUCTION Removing Upper Delivery Guide Assembly 1) Remove the grate-shaped lower guide. (See I-A-7.) 2) Remove the two screws [1] and the ground lead [2]. Then remove the upper delivery guide assembly [3]. Figure 5-208 Removing the PCB Cover 1) Remove the four screws [4] and take out the PCB cover [2].
  • Page 176 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-8.) 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.
  • Page 177 CHAPTER 5 MECHANICAL CONSTRUCTION 11) Remove the screw [5]. Figure 5-212 12) Remove the two screws [6] and take out the saddle stitcher unit [7] by moving it in the pick-up direction. Figure 5-213 5-23...
  • Page 178 CHAPTER 5 MECHANICAL CONSTRUCTION Note: When removing the saddle unit from the finisher unit body, prevent the timing belt [8] from catching on the communications cable bracket [9]. Figure 5-214 Removing the Paper Folding Roller 1) Remove the front lower door assembly. (See II-A-1.) 2) Remove the front inside cover.
  • Page 179 CHAPTER 5 MECHANICAL CONSTRUCTION 7) Remove the tension springs (front [5], rear [6]). Figure 5-217 Figure 5-218 5-25...
  • Page 180 CHAPTER 5 MECHANICAL CONSTRUCTION 8) Remove the two C-rings [7] and take out the sensor flag [8] and two bearings [9] at the rear. Figure 5-219 9) Remove the two C-rings [10] and take out the two gears [11] at the front. [11] [10] Figure 5-220...
  • Page 181 CHAPTER 5 MECHANICAL CONSTRUCTION 10) Remove the two bearings [12]. [12] Figure 5-221 [ 16] 11) Open the saddle delivery tray assembly [13]. 12) Remove the two screws [14] and take out 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 182 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Stitcher Mount Unit 1) Remove the front inside cover. (See II-A- 2) Remove the E-ring [1] and take out the roll [2] and the shaft [3]. Figure 5-224 3) Pull out the stitcher mount unit [4] to the front.
  • Page 183 CHAPTER 5 MECHANICAL CONSTRUCTION 6) Remove the stitcher positioning tool [3] from the back of the cover. Figure 5-227 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 184 CHAPTER 5 MECHANICAL CONSTRUCTION 9) Insert the tool [10] into the staple slot of the stitcher [9]. [10] Figure 5-230 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 185 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 deflect- ing plate bushing and pull out the No.1 de- flecting plate shaft [2] toward the rear.
  • Page 186 CHAPTER 5 MECHANICAL CONSTRUCTION PCBs [ 2 ] [ 2 ] [ 2 ] [ 3 ] [ 1 ] [ 1 ] Removing the Saddle Stitcher Controller PCB 1) Remove the PCB cover. (See II-A-6.) 2) Remove the four screws [1] and 14 con- nectors [2] and take out the saddle stitcher controller PCB [3].
  • Page 187 CHAPTER 5 MECHANICAL CONSTRUCTION III. PUNCHER UNIT (OPTION) Externals and Controls [1] Upper cover (3) [2] Front door [3] Right guide assembly (4) Figures in parentheses ( ) indicate the number of mounting screws. Figure 5-301 Removing the Right Guide Assembly 1) Remove the two screws [3] and take out the latch unit.
  • Page 188 CHAPTER 5 MECHANICAL CONSTRUCTION Removing the Upper Cover 1) Remove the right guide assembly (See III- A-1). 2) Open the front door [1], remove the three screws [2], and take off the upper cover [3]. Front side Rear side Figure 5-303 Puncher Driver System Removing the Punch Motor 1) Remove the upper cover.
  • 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 1) Remove the right guide assembly.
  • Page 190 CHAPTER 5 MECHANICAL CONSTRUCTION 5) Remove the upper inlet guide [3b] (three [3b] screws). Figure 5-306a 6) Remove the connector. 7) Remove the E-ring [4] and the puncher spring [5]. Figure 5-307 5-36...
  • Page 191 CHAPTER 5 MECHANICAL CONSTRUCTION 8) Turn the gear [6] in the direction of the ar- row and move the punch unit section [7] to the front side. Figure 5-308 9) Disconnect the connector [8] and remove [10] the screw [9]. Then take out the horizontal registration sensor [10].
  • Page 192 CHAPTER 5 MECHANICAL CONSTRUCTION 10) Turn the gear [6] in the direction of the ar- row and move the punch unit section [7] to the inner side. Figure 5-310 11) Lift up the front side of the punch unit sec- tion [18] first, then move it in the direction of the arrow to remove the punch unit sec- tion [18].
  • Page 193 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 5-312 Removing the Photosensor PCB 1) Remove the upper cover. (See III-A-2.) 2) Remove the screw [1] and take out the sen- sor bracket [2].
  • Page 194 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 take out the scrap-full de- tector PCB unit [3]. Figure 5-314 Removing the Punch Driver PCB 1) Remove the puncher unit from the finisher.
  • Page 195 CHAPTER 6 MAINTENANCE AND INSPECTION I. PERIODICALLY REPLACED II. CONSUMABLES AND PARTS ........6-1 DURABLES ....... 6-2 A. Finisher Unit ......6-1 A. Finisher Unit ......6-2 B. Saddle Stitcher Unit ..... 6-1 B. Saddle Stitcher Unit ..... 6-2 C. Puncher Unit (option) ... 6-1 C.
  • Page 196 CHAPTER 6 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED PARTS Finisher Unit The finisher unit does not have parts that must be replaced on a periodical basis. Saddle Stitcher Unit The saddle stitcher 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 197 CHAPTER 6 MAINTENANCE AND INSPECTION CONSUMABLES AND DURABLES Some of the parts of the machine may must be replaced once or more times because of wear or tear during the machine’s warranty period. Replace them as necessary. Finisher Unit Name Q’ty Estimated Life Remarks...
  • Page 198 CHAPTER 7 TROUBLESHOOTING I. ADJUSTMENTS ......7-1 III. ARRANGEMENT OF ELECTRICAL A. Electrical System PARTS ........7-10 (finisher unit) ......7-1 A. Finisher Unit ....... 7-10 B. Electrical System (saddle B. Saddle Stitcher Unit ... 7-18 stitcher unit) ......7-3 C.
  • Page 199 CHAPTER 7 TROUBLESHOOTING ADJUSTMENTS Adjusting the Alignment Position Adjust as follows if you have replaced the Electrical System (finisher finisher controller PCB or if an alignment fault occurs. unit) 1) Set DIP_SW (SW3) on the finisher con- troller PCB as indicated. Adjusting the Height Sensor (PS1) Perform the following adjustments when- ever you have replaced the finisher controller...
  • Page 200 CHAPTER 7 TROUBLESHOOTING • When the finisher detects the paper, it low- Alignment guide ers the swing guide and performs stapling shift direction Alignment (rear, 1-position). Note, however, that by SW2 guide manually stapled paper should be taken out Alignment guide as delivery is not performed.
  • Page 201 CHAPTER 7 TROUBLESHOOTING Electrical System (saddle Stapler stitcher unit) Alignment guide Adjusting the Folding Position The folding position is adjusted by chang- ing the settings of bits 6 through 8 of DIP_SW1 on the saddle stitcher controller PCB to match the stitching position (that is, by adjusting the Stopper distance over which the paper positioning plate...
  • Page 202 CHAPTER 7 TROUBLESHOOTING Mark Positive Width Adjustment Mark Folding position Stitching position A3 LD sheet Unit mm Example) if L is 1 mm, set to 1 mm . Insert direction Negative Width Adjustment Mark Figure 7-107 5) Open the inlet cover and insert two sheets of paper.
  • Page 203 CHAPTER 7 TROUBLESHOOTING 9) Change the settings of bits 6 through 8 of Electrical System (puncher DIP_SW1 to match distance L referring to unit (option)) the table below. • If the width adjustment is “0” Sensor output adjustment The stitching position and the folding po- Perform this adjustment when the punch sition match, requiring no change.
  • Page 204 CHAPTER 7 TROUBLESHOOTING 3) Set bits 7 and 8 on DIPSW3 on the fin- 3) Press SW1 on the finisher controller PCB. isher controller PCB to match the number Pressing this switch lights LED1 on the of punch holes of the attached puncher unit finisher controller PCB as indicated in according to Table 7-102.
  • Page 205 CHAPTER 7 TROUBLESHOOTING Tray shift up check TEST MODE Raise the bin. (DIP_SW all OFF) 1) Pressing PUSH_SW1 causes the bin to Finisher Unit rise. 2) Bin shift is canceled when PUSH_SW1 is Feeding speed check pressed at the No.2 bin position. Confirm that the feeding speed is 650 mm sec or more with the delivery motor in a fully Tray shift down check...
  • Page 206 CHAPTER 7 TROUBLESHOOTING Saddle Stitcher Unit Paper pushing plate motor opera- tion check Paper pushing plate motor operation mode Feed motor operation check Feed motor operation mode Figure 7-206 Figure 7-204 1) Pressing PUSH_SW2 twice starts the op- eration. Each press of PUSH_SW2 1) Pressing PUSH_SW2 starts the operation.
  • Page 207 CHAPTER 7 TROUBLESHOOTING Paper positioning plate motor operation check Paper positioning plate motor operation mode Figure 7-208 1) Pressing PUSH_SW2 twice starts the op- eration. Each press of PUSH_SW2 changes control as follows The (1) Folding position → (2) Stapling position →...
  • Page 208 CHAPTER 7 TROUBLESHOOTING III. ARRANGEMENT OF ELECTRICAL PARTS Finisher Unit Sensors PI18 PI17 PI10 PI20 PI14 PI19 PI16 PI15 PI11 PI12 PI22 Figure 7-301 7-10...
  • Page 209 CHAPTER 7 TROUBLESHOOTING Name Notation Function Photointerruptor 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 guide at home position Detects the stapler at home position Detects the tray at home position PI10 Detects delivery motor clock pulses...
  • Page 210 CHAPTER 7 TROUBLESHOOTING Microswitches Figure 7-302 7-12...
  • Page 211 CHAPTER 7 TROUBLESHOOTING 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 tray at the upper limit Detects the state (closed) of the swing guide 2 Detects the presence absence of staples (inside stapler) Table 7-302...
  • Page 212 CHAPTER 7 TROUBLESHOOTING Motors Figure 7-303 7-14...
  • Page 213 CHAPTER 7 TROUBLESHOOTING Name Notation Function Motor First feed motor Delivery motor Alignment motor Stapler shift motor Tray lift motor Staple motor Swing motor Second feed motor Inlet feed motor Table 7-303 7-15...
  • Page 214 CHAPTER 7 TROUBLESHOOTING Solenoids Figure 7-304 Name Notation Function Solenoid Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Escape solenoid Belt escape solenoid Table 7-304 7-16...
  • Page 215 CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-305 Reference Name Finisher controller PCB Relay PCB 4 Relay PCB 3 Sensor PCB 7-17 Table 7-305...
  • Page 216 CHAPTER 7 TROUBLESHOOTING Saddle Stitcher Unit Photointerruptors PI18S PI19S PI20S PI16S PI9S PI21S PI14S PI2S PI15S PI11S PI17S PI12S PI6S PI13S PI5S PI8S PI3S PI7S PI4S PI1S Figure 7-306 7-18...
  • Page 217 CHAPTER 7 TROUBLESHOOTING Name Notation Function Photointerruptor PI1S Detects clock pulses from the paper pushing plate motor PI2S Detects the state (open) of the front cover 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 218 CHAPTER 7 TROUBLESHOOTING Microswitches MS1S MS4S, MS5S MS6S, MS7S MS2S MS3S Figure 7-307 7-20...
  • Page 219 CHAPTER 7 TROUBLESHOOTING Name Notation Function Microswitches MS1S Detects the state (open) of the inlet cover MS2S Detects the state (open) of the front cover MS3S Detects the state (open) of the delivery cover MS4S Detects the presence of staples (rear) MS5S Detects stitching home position (rear) MS6S...
  • Page 220 CHAPTER 7 TROUBLESHOOTING Motors Figure 7-308 7-22...
  • Page 221 CHAPTER 7 TROUBLESHOOTING 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 7-308 7-23...
  • Page 222 CHAPTER 7 TROUBLESHOOTING Solenoids SL1S SL2S SL4S Figure 7-309 Name Notation Function Solenoid SL1S No. 1 paper deflecting plate solenoid SL2S No. 2 paper deflecting plate solenoid SL4S Feed plate contact solenoid Table 7-309 7-24...
  • Page 223 CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-310 Reference Name Saddle stitcher controller PCB Paper sensor PCB Table 7-310 7-25...
  • Page 224 CHAPTER 7 TROUBLESHOOTING Puncher Unit (option) Photointerruptors Pl2P PI3P PI1P Figure 7-311 Name Notation Function Photointerruptor PI1P Horizontal registration home position detection PI2P Punch motor clock detection PI3P Punch home position detection Table 7-311 7-26...
  • Page 225 CHAPTER 7 TROUBLESHOOTING Microswitches MS2P Figure 7-312 Name Notation Function Microswitch MS2P Front door open detection Table 7-312 7-27...
  • Page 226 CHAPTER 7 TROUBLESHOOTING Motors Figure 7-313 Name Notation Function Motor Punch motor Horizontal registration motor Table 7-313 7-28...
  • Page 227 CHAPTER 7 TROUBLESHOOTING PCBs Figure 7-314 Reference Name Punch driver PCB Photosensor PCB LED PCB Scrap-full detector PCB Table 7-314 7-29...
  • Page 228 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. Note: 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 a to high degree of accuracy.
  • Page 229 CHAPTER 7 TROUBLESHOOTING Saddle Stitcher Controller PCB DIP SW1 Figure 7-316 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 7-316 7-31...
  • Page 230 CHAPTER 7 TROUBLESHOOTING IV. TROUBLESHOOTING Finisher Unit Fault in communication with host machine Cause Step Checks Yes/No Action Finisher controller PCB, Turn the host machine OFF, End. Host machine DC then ON. Is the problem controller PCB corrected? Wiring Is the wiring between the Correct it.
  • Page 231 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 between...
  • Page 232 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 between...
  • Page 233 CHAPTER 7 TROUBLESHOOTING Faulty alignment motor Cause Step Checks Yes/No Action Alignment guide home Check the alignment guide 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 motor normal? Alignment guide Is there any mechanical...
  • Page 234 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 235 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 sensor Is the swing guide open Replace the sensor.
  • Page 236 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 swing Replace the finisher motor between J11-6 and -7 controller PCB.
  • Page 237 CHAPTER 7 TROUBLESHOOTING 16. Faulty tray lift motor (related to MS5) Cause Step Checks Yes/No Action Tray position Is the tray at the tray upper Lower the tray. limit switch? Tray upper limit switch Check the tray upper limit Replace the switch. (MS5) switch.
  • Page 238 CHAPTER 7 TROUBLESHOOTING 18. Faulty second feed motor (related to PI5) Cause Step Checks Yes/No Action Second feed motor (M8) Does the second feed motor Replace the second rotate in reverse at a specific feed motor or the timing? finisher controller PCB.
  • Page 239 CHAPTER 7 TROUBLESHOOTING 20. Faulty second feed motor (related to MS3) Cause Step Checks Yes/No Action Safety range switch Check the safety range switch. Replace the switch. (MS3) Is the switch normal? Is the safety range detection Correct mechanical switch passed correctly? operation.
  • Page 240 CHAPTER 7 TROUBLESHOOTING Saddle Stitcher 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. Is (PI7S) the sensor normal? Saddle stitcher controller Do the paper positioning Replace the saddle plates operate at a specific...
  • Page 241 CHAPTER 7 TROUBLESHOOTING Faulty paper folding motor Cause Step Checks Yes/No Action Paper folding motor Check the paper folding motor Replace the sensor. clock sensor (PI4S) clock sensor. Is the sensor normal? Paper folding home Check the paper folding home Replace the sensor.
  • Page 242 CHAPTER 7 TROUBLESHOOTING Faulty alignment motor Cause Step Checks Yes/No Action Alignment plate home Check the alignment plate Replace the sensor. position sensor (PI5S) home position sensor. Is the sensor normal? Saddle stitcher controller Does the alignment motor Replace the saddle operate at a specific timing? stitcher controller PCB.
  • Page 243 CHAPTER 7 TROUBLESHOOTING Faulty paper pushing plate motor (related to PI14S) Cause Step Checks Yes/No Action Paper pushing plate Check the paper pushing plate Replace the sensor. home position sensor home position sensor. Is the (PI14S) sensor normal? Saddle stitcher controller Does the paper pushing plate Replace the saddle motor operate at a specific...
  • Page 244 CHAPTER 7 TROUBLESHOOTING Faulty paper pushing plate motor (related to PI1S) Cause Step Checks Yes/No Action Paper pushing plate Check the paper pushing plate Replace the sensor. motor clock sensor motor clock sensor. Is the (PI1S) sensor normal? Saddle stitcher controller Does the paper pushing plate Replace the saddle motor operate at a specific...
  • Page 245 CHAPTER 7 TROUBLESHOOTING 10. Disconnected sensor connector (related to PI14S) Cause Step Checks Yes/No Action Paper pushing plate Are the connectors of the Connect the home position sensor paper pushing plate home connectors. (PI14S; disconnected) position sensor and the saddle stitcher controller PCB connected correctly? Wiring...
  • Page 246 CHAPTER 7 TROUBLESHOOTING 12. Faulty microswitch (related to MS1S) Cause Step Checks Yes/No Action Switch actuator Check the switch actuator of Correct the the inlet door. Do the switch mechanism. and the sensor operate correctly? Inlet door switch (MS1S) Check the inlet door switch. Is Replace the switch.
  • Page 247 CHAPTER 7 TROUBLESHOOTING 14. Faulty microswitch (related to MS3S) Cause Step Checks Yes/No Action Switch actuator Check the delivery door Correct the switch actuator. Do the switch mechanism. and the sensor operate correctly? Delivery switch (MS3S) Check the delivery door Replace the switch.
  • Page 248 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 249 CHAPTER 8 UNPACKING AND INSTALLATION I. FINISHER ........8-1 II. PUNCH UNIT......8-6...
  • Page 250 CHAPTER 8 UNPACKING AND INSTALLATION I. FINISHER 4)Remove the profectors WARNING The unpacking and set-up procedure shall be done by a qualifie d service technician. CAUTION 5)Remove the lock plate and the protectors AR-FN9 only 1)Unplug AR-FN9 only 6)Remove the protectors 2)Unpack the Finisher AR-FN9 7)Remove the protectors...
  • Page 251 CHAPTER 8 UNPACKING AND INSTALLATION 8)Remove the cover 12)Unpack the accessories AR-FN9 only 19-d 19-e 19-b 9)Remove the lock plate 13)Unpack the screws AR-FN9 only 19-d 19-e 10)Remove the lock plate 14)Remove the screws AR-FN9 only 11)Install the cover 15)Install the plates AR-FN9 only...
  • Page 252 CHAPTER 8 UNPACKING AND INSTALLATION 19-a)When inatalling the hole punch unit, follow the 16)Install the tray install instructions that come with the unit, if the punch unit is not being installed, perfome pro- cedures 19-b to 19-f to install the latch unit and cover.
  • Page 253 CHAPTER 8 UNPACKING AND INSTALLATION 19-c)Remove the screws 20)Install the rail 19-d)Install the latch unit 21)Fix the rail 19-e)Install the cover 22)Install the rail AR-FN9 19-f)Install the cover 23)Remove the cover AR-FN8...
  • Page 254 CHAPTER 8 UNPACKING AND INSTALLATION 24)Install the board 28)Connect the connecter 25)Install the board 29)Install the label 26)Fix the cover 30)END 27)Remove the connector cover...
  • Page 255 CHAPTER 8 UNPACKING AND INSTALLATION II. PUNCH UNIT 4)Remove the lock screws When installing a hole punch unit in a finisher AR- FN 8/9,follow these install instructions instead of pro- cedures 19-b to 19-f in the install instructions for the AR-FN 8/9.
  • Page 256 12-a)Fix the cover Two screws (A) are packed with the Finisher AR-FN9. 9)Install the punch unit 12-b)Fix the cover The screw (A) is packed with the Finisher AR-FN8. 10)Connect the connectors 13)Remove the screws 11)Install the cover 14)Fix the latch unit...
  • Page 257 CHAPTER 8 UNPACKING AND INSTALLATION 15)Install the cover 19)Install the label The part (A) is packed with the Finisher 16)Remove the cover 20)Open the covers 17)Install the label 21)Install the stopper 18)Fix the cover 22)END...
  • Page 258 A. 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 259 EJCVR DELIVERY COVER OPEN DETECT Signal FRONT COVER OPEN DETECT Signal FDRLHP CRESCENT ROLLER PHASE DETECT Signal FDROPN FRONT COVER OPEN DETECT SWITCH Signal FLDCLK FOLD MOTOR CLOCK Signal FLPSL1 FLAPPER DRIVE Signal 1 FLPSL2 FLAPPER DRIVE Signal 2 GIDHP PAPER GUIDE HOME POSITION DETECT Signal HKEMP1 HOOK EMPTY DETECT Signal 1...
  • Page 260 B. FINISHER UNIT CIRCUIT DIAGRAM (1/3) SWING_UNIT...
  • Page 263 FINISHER UNIT CIRCUIT DIAGRAM (2/3)
  • Page 264 FINISHER UNIT CIRCUIT DIAGRAM (3/3)
  • Page 267 C. FINISHER CONTROLLER PCB (1/10) A-10...
  • Page 268 FINISHER CONTROLLER PCB (2/10) A-11...
  • Page 269 A-12...
  • Page 270 A-13...
  • Page 271 FINISHER CONTROLLER PCB (3/10) A-14...
  • Page 272 FINISHER CONTROLLER PCB (4/10) A-15...
  • Page 273 A-16...
  • Page 274 A-17...
  • Page 275 FINISHER CONTROLLER PCB (5/10) A-18...
  • Page 276 FINISHER CONTROLLER PCB (6/10) A-19...
  • Page 277 ENTRANCE_SENS ENTRANCE_S0 A-20...
  • Page 278 A-21...
  • Page 279 FINISHER CONTROLLER PCB (7/10) A-22...
  • Page 280 FINISHER CONTROLLER PCB (8/10) A-23...
  • Page 281 A-24...
  • Page 282 A-25...
  • Page 283 FINISHER CONTROLLER PCB (9/10) A-26...
  • Page 284 FINISHER CONTROLLER PCB (10/10) A-27...
  • Page 285 A-28...
  • Page 286 A-29...
  • Page 287 D. SADDLE STITCHER UNIT CIRCUIT DIAGRAM (1/2) A-30...
  • Page 288 SADDLE STITCHER UNIT CIRCUIT DIAGRAM (2/2) A-31...
  • Page 289 STPL_UNIT1 (Rear) STPL_UNIT2 (Front) A-32...
  • Page 290 PUSHCW A-33...
  • Page 291 E. SADDLE STITCHER UNIT PCB (1/8) FOLD_NUKE FOLD_HP A-34...
  • Page 292 SADDLE STITCHER UNIT PCB (2/8) A-35...
  • Page 293 A-36...
  • Page 294 FOLDDIR0 ENTRANCE_COVER FOLDPWM0 FOLDDIR1 A-37...
  • Page 295 SADDLE STITCHER UNIT PCB (3/8) FOLD A-38...
  • Page 296 SADDLE STITCHER UNIT PCB (4/8) A-39...
  • Page 297 A-40...
  • Page 298 A-41...
  • Page 299 SADDLE STITCHER UNIT PCB (5/8) A-42...
  • Page 300 SADDLE STITCHER UNIT PCB (6/8) SEMILUNAR_SENS SEMILUNAR_S GUIDE H. P PUSH H. P FOLDTOP0 GUIDEM0 GUIDEM2 GUIDEM1 A-43...
  • Page 301 FOLD FOLD_CLK PUSH SENS PUSH_CLK0 A-44...
  • Page 302 ENTRANCE_COVER STAPLE UNIT SENNS A-45...
  • Page 303 SADDLE STITCHER UNIT PCB (7/8) ENNS A-46...
  • Page 304 SADDLE STITCHER UNIT PCB (8/8) PUSHCW PUSHPWM PUSHCCW FOLD_OUT FOLD_HP FOLD_HP A-47...
  • Page 305 A-48...
  • Page 306 A-49...
  • Page 307 F. PUNCHER UNIT (OPTION) CIRCUIT DIAGRAM (1/1) A-50...
  • Page 308 G. PUNCH DRIVER PCB (1/2) A-51...
  • Page 309 A-52...
  • Page 310 A-53...
  • Page 311 PUNCH DRIVER PCB (2/2) A-54...
  • Page 312 APPENDIX H. SOLVENT AND OIL 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 Silicone oil...
  • Page 313 APPENDIX A-56...
  • Page 314 COPYRIGHT © 2001 BY SHARP CORPORATION All rights reserved. Printed in Japan. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission of the publisher.

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