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Installation, Disassembly, and Adjustments

• After installation, maintenance, or adjustment, always check the operation of the machine to make

sure that it is operating normally. This ensures that all shipping materials, protective materials, wires
and tags, metal brackets, etc., removed for installation, have been removed and that no tools
remain inside the machine. This also ensures that all release interlock switches have been restored
to normal operation.

• Never use your fingers to check moving parts causing spurious noise. Never use your fingers to

lubricate moving parts while the machine is operating.

Special Tools

• Use only standard tools approved for machine maintenance.
• For special adjustments, use only the special tools and lubricants described in the service manual.

Using tools incorrectly, or using tools that could damage parts, could damage the machine or
cause injuries.

During Maintenance

General

• Before you begin a maintenance procedure: 1) Switch the machine off, 2) Disconnect the power

plug from the power source, 3) Allow the machine to cool for at least 10 minutes.

• Avoid touching the components inside the machine that are labeled as hot surfaces.

Safety Devices

• Never remove any safety device unless it requires replacement. Always replace safety devices

immediately.

• Never do any procedure that defeats the function of any safety device. Modification or removal of

a safety device (fuse, switch, etc.) could lead to a fire and personal injury. Always test the
operation of the machine to ensure that it is operating normally and safely after removal and
replacement of any safety device.

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Содержание SR4080

Страница 1: ...Finisher SR4080 Machine Code D610 Field Service Manual May 2016 ...

Страница 2: ......

Страница 3: ...t of symbols and abbreviations used in this manual Symbol Abbreviation Meaning Blue screw Bushing C ring Connector E ring Flexible film cable Harness clamp Hook Screw Spring Timing belt JG Junction Gate LEF Long Edge Feed SEF Short Edge Feed TE Trailing Edge of paper 1 ...

Страница 4: ...ge to originals loss of valuable data and to prevent damage to the machine This information provides tips and advice about how to best service the machine General Safety Instructions For your safety please read this manual carefully before you use this product Keep this manual handy for future reference Safety Information Always obey the following safety precautions when using this product Safety ...

Страница 5: ...the machine Before Installation Maintenance Power Always disconnect the power plug before doing any maintenance procedure After switching off the machine power is still supplied to the main machine and other devices To prevent electrical shock switch the machine off wait for a few seconds then unplug the machine from the power source Before you do any checks or adjustments after turning the machin...

Страница 6: ... use only the special tools and lubricants described in the service manual Using tools incorrectly or using tools that could damage parts could damage the machine or cause injuries During Maintenance General Before you begin a maintenance procedure 1 Switch the machine off 2 Disconnect the power plug from the power source 3 Allow the machine to cool for at least 10 minutes Avoid touching the compo...

Страница 7: ...of silicone oil or other materials to prevent slippery surfaces that could cause accidents leading to hand or leg injuries Use My Ace Silicone Oil Remover or dry rags to soak up spills For more details please refer to Technical Bulletin Silicone Oil Removal A024 50 Ozone Filters Always replace ozone filters as soon as their service life expires as described in the service manual An excessive amoun...

Страница 8: ...fter Installation Servicing Disposal of Used Items Always dispose of used items developer toner toner cartridges OPC drums etc in accordance with the local laws and regulations regarding the disposal of such items To protect the environment never dispose of this product or any kind of waste from consumables at a household waste collection point Dispose of these items at one of our dealers or at an...

Страница 9: ...n off the main power switch on the right side of the machine then disconnect the power cord from the power source 6 Locate the machine on a sturdy flat surface where it will not be exposed to excessive vibration 7 To avoid fire hazard confirm that the ventilation ports are not blocked so air can flow freely 8 Gas generated by the molten glue can irritate the eyes throat and nose The machine should...

Страница 10: ... Other product names used herein are for identification purposes only and may be trademarks of their respective companies We disclaim any and all rights involved with those marks 8 ...

Страница 11: ...ce 4 General 4 Safety Devices 4 Organic Cleaners 5 Ozone Filters 5 Power Plug and Power Cord 5 After Installation Servicing 6 Disposal of Used Items 6 Points to Confirm with Operators 6 Safety Instructions for this Machine 7 Trademarks 7 1 Replacement and Adjustment Door Covers Trays 13 Front Door Left Inner Cover Inner Cover 13 Side Table and Upper Tray 14 Left Covers Rear Cover Top Cover 15 Shif...

Страница 12: ... Fold Jogger Unit 34 Z Fold Jogger Unit Cover 34 Z Fold Jogger Unit 34 Top Fence Motor 35 Bottom Fence Motor 35 Stapler 37 Stapler Removal 37 Staple Waste Hopper Sensor 37 Stapler Rotation HP Sensor Stapler Return Sensor 38 Punch Unit B531 Option 39 Punch Position Adjustment 39 Front to Rear Adjustment 39 Right to Left Adjustment 39 Output Jogger Unit B513 Option 40 Jogger Unit 40 Jogger Unit PCB ...

Страница 13: ...Movement 56 Stapler 58 Feed Out 62 Stapling Z Folded Paper 63 Stack Output 64 Paper Exit and Stacking 64 Shift Tray 65 Overview 65 Shift Tray Raising and Lowering 65 Shift Tray Lower Limit Detection 67 Shift Tray Side to Side Movement 67 Jam Conditions 68 Punch Unit B531 Option 69 Punch Unit Drive 69 Punch Waste Collection 70 Output Jogger Unit B513 Option 71 Jogger Unit Mechanical Layout 71 Jogge...

Страница 14: ...12 ...

Страница 15: ...and Adjustment Door Covers Trays Front Door Left Inner Cover Inner Cover 1 Remove the front door screw A 2 Remove the front door B 3 Remove the front door 4 Remove the left inner cover C 5 Remove the inner cover A 13 ...

Страница 16: ...Side Table and Upper Tray 1 Remove the side table A Slide to the right to remove it 2 Click the release lever B and remove the upper tray C 1 Replacement and Adjustment 14 ...

Страница 17: ...ver C 6 Remove the upper tray page 14 7 Remove the step screws D 8 Remove the top cover E Slide to the right to remove 9 Remove the rear cover F Shift Tray 1 If you need to lower the shift tray support the bottom of the tray with your hand then pull the gear toward you to release the tray and lower it 2 Remove the shift tray 3 Remove the shift tray rear cover and front cover Door Covers Trays 15 ...

Страница 18: ...1 Replacement and Adjustment 16 ...

Страница 19: ... Roller 1 Above the shift tray pull the roller mount A out 2 Remove the rollers B and C Positioning Roller 1 Open the front door 2 Remove the snap ring A 3 Release the rubber belt B 4 Replace the positioning roller C Rollers 17 ...

Страница 20: ...he staple unit 2 Remove the rear cover 3 Remove the main board and all connectors 4 Remove the screw A and tension spring B for the tension bracket C and release the tension of the timing belt 5 Remove the pulley D and bushing E 1 Replacement and Adjustment 18 ...

Страница 21: ...6 Remove the inner cover A 7 Open the guide B then remove the alignment brush roller assembly C 8 Remove the alignment brush roller D Rollers 19 ...

Страница 22: ...1 Replacement and Adjustment 20 ...

Страница 23: ...rom the stays 8 Remove the old belt E from the bottom center then the top 9 Make sure the ribbed side of the new belt and pawl F are facing down 10 Make sure the new belt is engaged at all three rollers Jogger Fence 1 Open the front door 2 Pull out the jogger and stapler unit 3 Push both fences to the center 4 Remove the left jogger fence A 5 Remove the right jogger fence B 6 If the screws are dif...

Страница 24: ...1 Replacement and Adjustment 22 ...

Страница 25: ...ve the left upper panel and left upper cover 3 Remove the protector plate A 4 Remove the sensor feeler B 5 Remove the sensor bracket C 6 Replace the stack height sensor 1 D 7 Replace the stack height sensor 2 E Exit Guide Open Sensor 1 Remove the sensor bracket F 2 Replace the exit guide open sensor G Sensors 23 ...

Страница 26: ...the upper tray paper limit sensor C Upper Tray Exit Sensor 1 Remove the sensor bracket D 2 Replace the upper tray exit sensor E Shift Tray Exit Sensor 1 Remove the top cover 2 Open the front door 3 Remove the inner cover 4 Release the upper exit guide springs A 5 Disconnect the link B from the cam 6 Remove the upper exit guide C 1 Replacement and Adjustment 24 ...

Страница 27: ...7 Remove the guide stay A 8 Replace the shift tray exit sensor B Entrance and Stapler Tray Entrance Sensors Entrance Sensor Sensors 25 ...

Страница 28: ... the copier 2 Remove the sensor bracket A 3 Replace the entrance sensor B Stapler Tray Entrance Sensor 1 Open the front door 2 Remove the sensor bracket A 3 Replace the stapler tray entrance sensor B 1 Replacement and Adjustment 26 ...

Страница 29: ...Pre Stack Paper Sensor 1 Remove the rear cover 2 Remove the main board A 3 Release the guide A Sensors 27 ...

Страница 30: ...4 Open the front door 5 Remove the left vertical transport guide A 6 Remove the middle vertical transport guide B 7 Replace the pre stack paper sensor C 1 Replacement and Adjustment 28 ...

Страница 31: ...Sensors 29 ...

Страница 32: ...move the front door and all covers with the exception of the left lower cover and top cover labeled C and E 2 Be sure to lower the shift tray by pulling the gear toward you The shift tray must be down 3 Remove the shift tray motor See previous page 4 Remove the left stay A 5 Unhook the stay at top B 6 Remove the shift tray mounting plate C 1 Replacement and Adjustment 30 ...

Страница 33: ...7 Remove the end fence A and plate A 8 Disengage the end fence races B from the rollers C behind the fence 9 Remove the upper stay E 10 Remove the lower stay F Motors 31 ...

Страница 34: ...e sure the motor and sensor connectors are disconnected before removing 14 Remove the stacking motor bracket A 15 Remove the stacking motor B 16 Remove the roller drag motor bracket A 17 Remove return HP sensor B 18 Remove the roller drag motor C 1 Replacement and Adjustment 32 ...

Страница 35: ...Motors 33 ...

Страница 36: ...t door 2 Pull out the stapler tray unit A 3 Remove the Z fold jogger unit cover B Z Fold Jogger Unit 1 Open the front door and pull out the stapler tray unit 2 Remove the Z fold jogger unit cover 3 Remove the Z fold jogger unit A 1 Replacement and Adjustment 34 ...

Страница 37: ... and pull out the stapler tray unit 2 Remove the Z fold jogger unit cover 3 Remove the motor bracket A 4 Remove the jogger top fence motor B Bottom Fence Motor 1 Open the front door and pull out the stapler tray unit Z Fold Jogger Unit 35 ...

Страница 38: ...2 Remove the jogger bottom fence motor A 1 Replacement and Adjustment 36 ...

Страница 39: ...er A 3 Remove the stapler cover B 4 Lift the stapler off of the pegs C Staple Waste Hopper Sensor 1 Open the front door pull out the stapler unit then remove the rear cover 2 Remove the rear cover 3 Remove the staple waste hopper A 4 Remove the hopper holder B 5 Replace the staple waste hopper sensor C Stapler 37 ...

Страница 40: ... HP Sensor Stapler Return Sensor 1 Remove the stapler unit See above 2 Remove the stapler mount bracket A 3 Replace the stapler rotation HP sensor B 4 Replace the stapler return sensor C 1 Replacement and Adjustment 38 ...

Страница 41: ...fastened with a screw to the rear frame of the finisher under the rear cover and slightly above the lock bar Right to Left Adjustment The position of the punched holes can be adjusted right to left in the sub scan direction with SP6 113 Punch Hole Position Adjustment The position can be adjusted in the range 7 5 mm in 0 5 mm steps The default setting is 0 Press the key to toggle the selection A VE...

Страница 42: ...513 Option Jogger Unit 1 Remove the jogger unit cover A 2 Remove the jogger unit A Jogger Unit PCB 1 Remove the jogger unit from the finisher See above 2 Remove the jogger unit control PCB A 1 Replacement and Adjustment 40 ...

Страница 43: ...EF staple mode 0 0 0 1 Free run staple and tray shift Do not use any other settings Shift Jogger Motor Fence Lift Motor 1 Remove the jogger unit from the finisher See above 2 Remove the shift jogger motor A 3 Remove the shift jogger lift motor B Output Jogger Unit B513 Option 41 ...

Страница 44: ...1 Replacement and Adjustment 42 ...

Страница 45: ...tion Provided Shift Tray Paper Capacity 80 g m2 3000 sheets A4 LEF B5 LEF 8 5 x 11 LEF 1500 sheets A3 A4 SEF B4 and B5 SEF 11 x 17 8 5 x 14 8 5 x 11 SEF 12 x 18 500 sheets A5 LEF 5 5 x 8 5 LEF 100 sheets A5 SEF 5 5 x 8 5 SEF Paper Size A3 to A5 11 x 17 to 5 5 x 8 5 12 x 18 including tab paper Paper Weight 52 to 216 g m2 14 to 58 lb Shift Tray Full Detection Provided Stapler Stapling Stack Size A4 ...

Страница 46: ...eplacement Stapled Stack Size Sheets Sets Sizes 10 to 100 200 to 30 A4 SEF B5 SEF 8 5 x 11 SEF A4 LEF B5 LEF 8 5 x 11 LEF 2 to 9 150 10 to 50 150 to 30 A3 B4 11 x 17 8 5 x 14 2 to 9 150 Trim Waste Staple Capacity 30 000 or more Waste Staple Hopper Full Detection Provided Power Consumption Less than 100 W Power Source DC 24 V From Mainframe Size W x D x H 800 x 730 x 980 mm 31 5 x 28 7 x 38 6 Weigh...

Страница 47: ...e Waste Hopper 2 Middle Transport Rollers 14 Stapler 3 Upper Tray Exit Roller 15 Alignment Brush Roller 4 Upper Transport Rollers 16 Positioning Roller 5 Tray Junction Gate 17 Stack Feed out Belt 6 Stapler Junction Gate 18 Shift Tray Drive Belt Overview 45 ...

Страница 48: ...t Guide Opens and closes the upper exit guide M04 Lower Transport Drives the lower transport rollers the positioning roller and the alignment brush roller M05 Shift Moves the shift tray from side to side M06 Positioning Roller Moves the positioning roller into contact with the paper M07 Stacking Roller Drag Moves the stacking roller in and out M08 Stacking Roller Rotates the stacking roller M09 Jo...

Страница 49: ...ning the stack then reverses and lowers them when returning to the home position Jogger Unit B513 option M21 Jogger Top Fence Moves the top jogger fence M22 Jogger Bottom Fence Moves the bottom jogger fence BOARDS PCB Main Controls the finisher and communicates with the copier PCB Stapler Controls the stapler unit PCB Punch Passes signals between the punch unit and the finisher main board Punch Un...

Страница 50: ...ift tray is at either the front or home HP S15 Pre Stack Tray Paper Determines when to turn off the pre stack paper stopper solenoid S16 Stapler Tray Exit Detects jams at the staple tray exit S17 Positioning Roller HP Detects the home position of the positioning roller S18 Stack Feed Out Belt HP Detects the home position of the stack feed out belt S19 Stapler Tray Paper Detects the copy paper in t...

Страница 51: ...es are at the lowered position and ready to move against the sides of the stack Jogger Unit B513 option S33 Top Fence HP Detects the top fence home position for Z fold paper staple mode S34 Bottom Fence HP Detects the bottom fence home position for Z fold paper staple mode SOLENOIDS SOL1 Upper Tray Junction Gate Drives the tray junction gate SOL2 Stapler Junction Gate Drives the stapler junction g...

Страница 52: ...he operator to remove paper from the shift tray Drive Layout No Part No Part 1 Upper Transport Roller 2 14 Lower Transport Roller 1 2 Upper Tray Exit Roller 15 Transport Roller 1 3 Lower Transport Roller 2 16 Entrance Roller 2 4 Shift Tray Lift Motor 17 Entrance Roller 2 Detailed Descriptions 50 ...

Страница 53: ...tor 7 Shift Tray 20 Stack Feed out Motor 8 Shift Motor 21 Jogger Motor 9 Staple Tray Exit Roller 22 Jogger Fence 10 Positioning Roller 23 Stack Plate Motor 11 Lower Transport Roller 3 24 Stapler Motor 12 Lower Transport Motor 25 Stack Feed out Belt 13 Lower Transport Rollers 2 26 Stapler Rotation Motor Overview 51 ...

Страница 54: ...Mechanisms Tray and Stapler Junction Gate Depending on the finishing mode the copies are directed up straight through or down by the combinations of open and closed junction gates 2 Detailed Descriptions 52 ...

Страница 55: ...till being stapled It only works during the second and subsequent sets of a multi set copy job The pre stack junction gate solenoid A turns on 120 mm after the 1st sheet of paper turns on the entrance sensor and this directs the sheet to the pre stack tray B This sheet cannot be fed to the stapler yet because the first set is still being stapled The pre stack paper stopper solenoid C turns on 350 ...

Страница 56: ...iling edge of the paper against the stack stopper E Horizontal Paper Alignment When the print key is pressed the jogger motor F turns on and the jogger fences G move to the wait position about 7 2 mm wider than the selected paper size on both sides When the trailing edge of the paper passes the staple unit entrance sensor the jogger motor moves the jogger fences 3 7 mm towards the paper Next the j...

Страница 57: ...Main Mechanisms 55 ...

Страница 58: ...t the front For the second stack the stapler staples the front corner first then moves to the rear corner and staples For continuous stapling jobs the corners are stapled rear then front for the odd number stacks and stapled front then rear for even number stacks After the job is completed the stapler returns to its home position This is detected by the stapler HP sensor C Rotation 1 In the obliqu...

Страница 59: ...ge A This allows the user to add new staples Once the staples have been installed and the front door closed the stapler unit returns to its home position As the stapler unit is returning to the home position the stapler return sensor A is activated the return solenoid B turns on and it assists the guide roller C to return to its guide this guide directs the stapler during rotation Stapling 57 ...

Страница 60: ...ught to the stapling position by the positioning roller and jogger fences the staple hammer motor A starts stapling During stapling the stapler trims off the excess length B of the staples by lowering the cutter C 2 Detailed Descriptions 58 ...

Страница 61: ...o the tray A in the stapler When the stapler unit returns to its home position the tray hits the shaft B and the tray opens The staple waste drops into the staple waste hopper A When the staple waste hopper is full the actuator on its base activates the staple waste hopper sensor B An SC737 Full Finisher Staple Waste Hopper is displayed Stapling 59 ...

Страница 62: ...The stapler has a staple end sensor A cartridge set sensor B and staple hammer HP sensor C 2 Detailed Descriptions 60 ...

Страница 63: ...dge If this condition is detected during a copy job the indication will appear and the copy job will stop The staple cartridge has a clinch area A where jammed staples collect The operator can remove the jammed staples from the clinch area by pressing in the releases B on both sides then lowering the bracket lever C Stapling 61 ...

Страница 64: ...e upper shift tray exit roller G in order to feed out the leading edge of the copy set smoothly The exit guide motor turns on again a certain time after stapling is complete and the upper exit guide plate is lowered Then the shift tray exit roller takes over the stack feed out The on off timing of the exit guide motor is detected by the exit guide open sensor H The stack feed out motor turns off w...

Страница 65: ...tapler tray 2 The positioning roller turns when each sheet is fed to the stapler tray 5 Each sheet is fed down against the lower jogger fence to align the bottom edge 6 After the set number of sheets come in the jogger top fence motor switches on and lowers the top fence against the top of the stack This aligns the stack for stapling 7 The bottom fence motor lowers the aligned stack to the staplin...

Страница 66: ...lockwise as the rollers move back The simultaneous rotation and backward movement of the roller assembly pulls each sheet back toward the copier to align the edges of the stack on the shift tray The actuator H is mounted on the cam and rotating with both rotating clockwise and detects the roller assembly home position when the actuator leaves the gap of the return drive HP sensor I and signals the...

Страница 67: ...n the lift motor which raises the tray until the tray pushes the actuator out of the sensor E Then the lift motor stops the shift tray this is the home position the actuator D is between the two sensors E and F The shift tray upper limit switch SW1 prevents the drive gear from being damaged if staple mode HP sensor 2 E fails In case of a failure when the shift tray pushes up the actuator G and pos...

Страница 68: ...t motor A which raises the tray until the actuator leaves the sensor Then the lift motor stops the tray this is the home position In sort stack mode if S12 fails when the tray is being lifted the shift tray upper limit switch SW1 prevents the drive gear from being damaged Staple Mode The shift tray moves to home position which is when the actuator B above is between the staple mode home position s...

Страница 69: ... will be displayed and copying will stop Shift Tray Side to Side Movement In sort stack mode the shift tray A moves from side to side to separate the sets of copies The horizontal position of the shift tray is controlled by the shift motor B and shift gear disk C After one set of copies is made and delivered to the shift tray the shift motor turns on driving the shift gear disk and the shaft D The...

Страница 70: ...ode the shift tray exit sensor does not turn on when the upper transport motor has fed paper 733 mm after the entrance sensor turned on 6 In sort stack mode the shift tray exit sensor does not turn off when the upper transport motor has fed paper 1 5 times the paper s length after it turned on 7 In staple mode the stapler tray entrance sensor does not turn on when the upper and lower transport mot...

Страница 71: ...nd punch holes in the paper After punching a sheet of paper the cam returns to home position and stops Home position depends on whether 2 holes or 3 holes are being made so there are two punch HP sensors Punch HP sensor 1 C is used when 2 hole punching is selected and punch HP sensor 2 D is used when 3 hole punching is selected When the cut out E enters the slot of the punch HP in use sensor 1 or ...

Страница 72: ...nd must be removed and emptied The job resumes automatically after the hopper is emptied and returned to the finisher The punch waste hopper sensor also functions as the hopper set sensor When the hopper is not in the finisher or if it is not inserted completely the spring loaded sensor arm rotates up and to the right with the punch waste sensor away from the hole in the hopper holder and a messag...

Страница 73: ...ger Fence Timing Belt 5 Shift Jogger Fences 6 Shift Jogger HP Sensor 7 Shift Jogger Lift HP Sensor Jogger Unit Drive At prescribed intervals the jogger motor A switches on and drives the jogger timing belt B gear C and jogger fence timing belt D which drives the shift jogger fences E against the sides of the stack to align its edges Output Jogger Unit B513 Option 71 ...

Страница 74: ...nsor H and shuts off the shift jogger fence lift motor At the same time the jogger motor reverses and drives the fences away from the sides of the stack until the actuator I deactivates the shift jogger fence HP sensor J and switches off the jogger motor The jogger fences remain up in the standby position until the next job starts 2 Detailed Descriptions 72 EN ...

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