AC-6000

AC-8000S
COLLATOR AC-8300

Important Information
- This manual is designed to help you to install, operate and maintain Collator, AC-6000/
AC-8000S/AC-8300. Read, understand and keep this manual in a safe and convenient place.

- Do not operate AC-6000/AC-8000S/AC-8300 until you read and understand the instruc-
tions in this manual.

- Horizon International Inc. shall not be liable for incidental consequential damages result-
ing from : improper or inadequate maintenance by customer; unauthorized modification or
misuse; operation outside of the environmental specifications for the product.

- Horizon International Inc. pursues a policy of continuing improvement in design and

performance of the product. Therefore, the product design and specifications are subject to
change without prior notice and without our legal obligation.

- All rights are reserved. No part of the manual may be photocopied, reproduced or trans-
lated to another language without the prior written consent of Horizon International Inc.

171727/AC6000/8000S/8300/01E/DV I UM201035-01
 Safety Precautions
- The signal word WARNING indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

- The signal word CAUTION indicates a potentially hazardous situation which, if not
avoided, may result in damage on machines. It may also be used to alert against unsafe
practices.

- Read and understand all safety instructions with signal word such as WARNING and
CAUTION. If safety instructions are ignored, personal injury may result.

- Horizon International Inc. cannot anticipate every possible situation that might involve
a potential hazard. The instructions in this manual and warning labels on the machine are
therefore not all inclusive.

- All equipment shall be locked out or tagged out to protect against accidental or inad-
vertent operation when such operation could cause injury to personnel. Do not attempt to
operate any switch, valve, or other energy isolating device where it is locked or tagged out.

- Do not operate the machines when any covers are removed.

- Some of the drawings in this manual show the machine uncovered for explaining the
detail or inside of machine.

II
 CONTENTS
Important Information ............................................................................................ I

Safety Precautions .................................................................................................... II

1. Before You Begin

1-1 Specifications ...................................................................................................... 2

1-1-1 AC-6000, AC-8000S and AC-8300 ............................................................... 2

1-1-2 CF-20 and CF-23 (Options) ........................................................................... 3
1-1-3 CR-14/Criss Cross Receiving Tray (Option) ................................................. 4
1-2 Machine Descriptions ........................................................................................ 5

1-2-1 Major Machine Parts 1 ................................................................................... 5

1-2-2 Major Machine Parts 2 ................................................................................... 6
1-2-3 Bin and Feeder Section 1................................................................................ 7
1-2-4 Bin and Feeder Section 2................................................................................ 8
1-2-5 Jogger Table 1 ................................................................................................ 9
1-2-6 Jogger Table 2 ................................................................................................ 10
1-2-7 Detector and Controls ..................................................................................... 11
1-2-8 Detector and Controls ..................................................................................... 12
1-2-9 CF-20 & CF-23 Cover Feeder (Option) ......................................................... 13
1-2-10 CR-14 Crisscross Receiving Tray (Option) ................................................. 14
1-3 Construction Features ....................................................................................... 15

1-3-1 Feeding Mechanism and Sensor ..................................................................... 15

1-3-2 Detectors ......................................................................................................... 16
1-3-3 Jogger Table/Delivery Section ....................................................................... 17
1-4 General Hints ..................................................................................................... 18

1-4-1 When running small size sheet ....................................................................... 18

1-4-2 When the sheets loaded into bin tend to be sloped because they contain
perforations or spot carbon(s) .................................................................................. 18

2. Operation Procedure

2-1 Before Starting Operation ................................................................................ 20

2-2 Operation Procedure ......................................................................................... 21

2-3 For Efficient Operation ..................................................................................... 28

2-4 CR-14 (Option) Operation Procedure ............................................................. 35

III
3. Troubleshooting

3-1 General Hints to Remedy Cover Stock Feed Troubles .................................. 38

3-1-1 Misfeed ........................................................................................................... 38

3-1-2 Double Feed ................................................................................................... 38
3-2 Detector's Display and Operation .................................................................... 39

3-2-1 When jam, misfeed and double-feed lamps light ........................................... 39

3-2-2 When jam lamp lights..................................................................................... 39
3-2-3 When misfeed lamp lights every time a set of collated sheets is ejected. ...... 39
3-2-4 Double lamp lights on and the machine stops without any collating fault. .... 39
3-3 When Monitor Lamp Lights ............................................................................. 40

3-3-1 When counter stop lamp lights ....................................................................... 40

3-3-2 When full jogger table lamp lights ................................................................. 40
3-3-3 When no cover lamp lights ............................................................................. 40
3-3-4 When memorizing sheet caliper lamp lights .................................................. 40
3-3-5 When jam detector lamp lights ....................................................................... 40
3-4 Troubleshooting Hints ....................................................................................... 41

3-4-1 When the double sheets are fed ...................................................................... 41

3-4-2 When misfeed occurs ..................................................................................... 41
3-4-3 The machine is stopped because of double-feed though sheets are correctly
collated ..................................................................................................................... 41
3-4-4 When jam lamp remains lighting ................................................................... 41

4. Maintenance

4-1 Cleaning .............................................................................................................. 44

4-1-1 Compressor Filter ........................................................................................... 44

4-1-2 Sensor ............................................................................................................. 44
4-2 Lubrication ......................................................................................................... 45

4-2-1 The Elevating UP/DOWN Mechanism of Jogger Table ............................... 45

4-3 Replacement ....................................................................................................... 46

4-3-1 Sucker Rubber Ring and Brush ...................................................................... 46

4-3-2 Feed Roller of CF-20 (Optional Cover Feeder) ............................................. 46
4-3-3 Double-feed Stop Pad ..................................................................................... 47
4-3-4 Fuse ................................................................................................................ 47
4-4 Adjustment ......................................................................................................... 48

4-4-1 Detector Sensitivity ........................................................................................ 48

IV
5. Installation

5-1 Installation Instructions .................................................................................... 50

5-1-1 Installation Place ............................................................................................ 50

5-1-2 Jogger Table Installation ................................................................................ 50
5-1-3 Crisscross Receiving Tray Installation ........................................................... 51
5-1-4 Air Hose Connection ...................................................................................... 52
5-1-5 Air Accumulator Installation (Option for AC-6000) ..................................... 52
5-1-6 Power Cord Connection ................................................................................. 53
5-1-7 Cover Feeder CF-20/CF-23 Installation (Option) .......................................... 54

V
VI
 1. Before You Begin

1. Before You Begin

1-1 Specifications ........................................................................................... 2

1-2 Machine Descriptions .............................................................................. 5
1-3 Construction Features ............................................................................. 15
1-4 General Hints ........................................................................................... 18

1
1. Before You Begin

1-1 Specifications
1-1-1 AC-6000, AC-8000S and AC-8300
Model AC-6000 AC-8000S AC-8300
Number of Bins 6 8 8
Max. Sheet Size 318 x 470 mm (12.5" x 8.3") 394 x 545 mm (15.5" x 21.5")
Sheet Weight Range 23 gsm to 209 gsm
Feed Pile Height Max. 100 mm (3.9")
Sheet Feeding System Air Suction System
Production Speed 1600 to 2400 collate/hr (variable depending on operating condition)
Delivery Pile Height Max. 120 mm (4.7")
Jogger Vibration Unbalanced Weight System
Detector Jam, Misfeed, Double, Preset Counter Stop, Full Receiving Tray
Power 200 V/3-phase 50 or 60 Hz, 380 V/450 V/3-phase 50 Hz
Power Consumption 1.7 kW 1.8 kW 2.0 kW
Machine Dimensions 1650x650x1650 cm 1650x650x2065 cm 1850x730x2010 cm
(W x D x H) (65" x 25.6 " x 65") (65" x 25.6 " x 81") (72.8"x28.7"x79.1")
Machine Weight 400 kg (880 lb) 450 kg (990 lb) 510 kg (1124 lb)

The machine design and specifications are subject to change without any notice.
Others
1. 3-digit Total Counter
2. 5-digit Total Counter
3. Automatic Sheet Caliper Memorizing System
4. Automatic Jogger Descending Motion to Be effected by Delivery Height Detector
5. Powered Elevation UP/DOWN of All Bins
6. Static Eliminator at Delivery Station
7. Compressor encased in Soundproof Box Which Can Be Used as a Work Step
8. Intermittent Feeding Is Possible in Bin No.1 and No.2. (AC-8300)
9. Air Shower (AC-8300)

Standard Accessories
1. Bin Sheet Guide 3 each on a bin
2. Jogger Auxiliary Guide 1
3. Mount 4
4. Brush 1 each on a bin
5. Tools
Philips Screwdriver JIS No.2 1
Single Open End Wrench (24) 1
Allen Wrench 3, 5 and 6 (across width) 1 each
Tool Bag 1
Sensor Cleaning Brush 1
Grease 1

2
 1. Before You Begin

1-1 Specifications
1-1-2 CF-20 and CF-23 (Options)
Model CF-20 for AC-6000/8000S CF-23 for AC-8300
Number of Feeder 2 (upper and lower)
Max. Cover Stock Size 318 x 470 mm (12.5" x 18.5") 394 x 545 mm (15.5" x 21.5")
Min. Cover Stop Size 210 x 297 mm (8.3" x 11")
Cover Stock Weight Upper feeder : 45 to 300 kg (52 gsm to 350 gsm)
Lower Feeder : 45 to 180 kg (52 gsm to 210 gsm)
Cover Feed Pile Height Max. 20 mm (0.8")
Feeding System Friction Feeding System Using Rubber Roller
Power 100 V/15 W Connected to AC-6000 or AC-8300
Machine Dimensions 580 x 500 x 380 mm 630 x 580 x 380 mm
(W x D x H) (22.8" x 19.7" x 15") (24.8" x 22.8" x 15")
Machine Weight 16 kg (35 lb) 22 kg (49 lb)

The machine design and specifications are subject to change without any notice.

Others
Double Feed Stop Pad

Standard Accessories
1. Feed Roller 1
2. Double Feed Stop Pad 1
These optional attachment are used only ion combination with either AC-6000, AC-8000S or
AC-8300 automatic collator so that they can not be operated independently.

3
1. Before You Begin

1-1 Specifications
1-1-3 CR-14/Criss Cross Receiving Tray (Option)
Model CR-14
Maximum Sheet Size 148 x 210 mm (5.8" x 8.3") to 318 x 410 mm (12.5" x 18.5")
Maximum Pile Sheet 120 mm (4.7") (Automatic Stop with Full Tray)
Criss Cross Mechanism Cam mechanism in sync with collating signal from collator
Power 100 V/60 W Connected to AC-6000, AC-8000S or AC-8300
Machine Dimensions 570 x 500 x 380 mm (22.4" x 19.7" x 15")
Machine Weight 20 kg (44 lb)

The machine design and specifications are subject to change without any notice.

Standard Accessories
1. Pressure Roller Set for Delivery Station
2. Receiving Tray with Stopper
3. Auxiliary Delivery Guide
These optional attachment are used only ion combination with either AC-6000, AC-8000S or
AC-8300 automatic collator so that they can not be operated independently.

4
 1. Before You Begin

1-2 Machine Descriptions

1-2-1 Major Machine Parts 1

Sheet Transport Belt

This belt transports collated sheets of sets
to jogger table.

Belt Frame Handle

When this handle is raised, the entire belt
frame will be opened.
This handle must be used only for jammed-
sheet removal, setup or service.

Belt Frame

Delivery Guide
This guide guides collated sets of sheets to
jogger table. When belt frame is opened,
this guide must be raised upright where it
is hooked.

Jogger Table

Delivery Height Detector

This detector detects the height of the
stacked collated sets, and actuate relay
to lower jogger table to an optimum
working level as the height of the
delivered sheets.

Jogger Control Switch

Speed Control Knob

This knob is used to vary the collating
speed according to the sheet weight and
quality. A slower speed range must be
used when running lightweight stocks.

5
1. Before You Begin

1-2 Machine Descriptions

1-2-2 Major Machine Parts 2

Preset Counter
When a predetermined number of
collated sets finishes, the machine
will be stopped.
When CF-20 is used, tab sheets or Total Counter
cover sheets can be inserted into This counter counts the total number of
every predetermined number of collated sets.
collated sheets automatically.
Control Switch Panel
This panel is equipped with error detector,
display lamp, LED adjust dials and switches.

Bin
Sheets to be collated are load on this bin.

Emergency Stop Button

Work Step
Air compressor is housed under this
work step box with soundproofed.

Power Switch
This switch is used to supply power to
the control unit with the machine stand-
ing by for operating.

Compressor
The air source for suction air and blower
for sheet separation.

Mount (4 pcs)
This mount must be set at the position
where is free from load to caster.

Caster (4 pcs)

6
 1. Before You Begin

1-2 Machine Descriptions

1-2-3 Bin and Feeder Section 1

Sucker
Each sucker bar has 6 suckers. Suckers
pick up a sheet one by one to transport the
sheet to transport belt.
Suckers can be closed by turning the thumb
knob to close position.

Suction Air Adjust Valve

This valve is used to adjust the suction
power of sucker, which must be adjusted
according to the sheet quality and or weight.
WEAK : for NCR sheet or light
weight stocks.
MODERATE : for medium weight stocks. 2
STRONG : for heavier weight or
cardboard stocks.

Top Sheet Separate Air Nozzle 3

Sheet Ruffling Blower Nozzle

4
Top Sheet Separation Air Adjust Knob
This knob is used to adjust the amount of air
applied to separate the top sheet from the rest
of the sheets loaded on bin. 5
WEAK : for NCR sheet or light
weight stocks.
MODERATE : for medium weight stocks.
STRONG : for heavier weight or 6
cardboard stocks.
Sheet Ruffling Air Adjust Knob
This knob is used to separate loaded sheets
and to allow sucker to pick up only one sheet Sheet Height Control Knob
of sheet at one time. This knob must be This knob is used to adjust the height of
adjusted at each optimum working level as the sheets loaded on bin.
required. Sheet height control bar senses the loaded
WEAK : for NCR sheet or light height level automatically, keeping bin
weight stocks. always at an optimum working level.
MODERATE : for medium weight stocks. When sheet height control bar is adjusted
STRONG : for heavier weight or toward low position, bin must be lowered
cardboard stocks. a little bit by pressing bin DOWN button.

7
1. Before You Begin

1-2 Machine Descriptions

1-2-4 Bin and Feeder Section 2
Brush
This brush prevents sheets from floating
excessively and to prevent more that one sheet
from being fed at one time.

Sheet Height Control Bar

This bar senses the height of the loaded
sheets, sending a signal to elevate bin propor-
tionally as the loaded sheets decreases and
also to hold down the top sheet before being
forwarded to transported belt by sucker.
2
Front Loading Guide
This guide accepts piled sheets to be run. Bin
3 board moves up to the level of sheet height
control bar automatically .

Sheet Loaded on Bin

Sheet must be loaded on bin according to
4 the printed patterns and page order.

5 Moveable Sheet Guide

Each bin has 3 sheet-guides. These guides
are used to feed sheets properly.

6 Reference Mark for Jogger Operation

Reference Mark for Crisscross Operation

Bin DOWN Button

This button is used to lower bins. Each bin
has this button. Bin continues to lower all
while this button is being pressed.
This button is either to lower bin when sheet
height control bar is adjusted or to check up
bin after adjustment.

8
 1. Before You Begin

1-2 Machine Descriptions

1-2-5 Jogger Table 1

Eject Roller
Delivery Jam Sensor Connector
Sheet Reinforce Ring
This ring is used to give strength to the sheet so Static Eliminator Brush
that it can be ejected smoothly into jogger table. This brush eliminate static
You can move and relocate the rings over the electricity out of the sheets being
delivery roller shaft as required for operation. delivered for smooth sheet
With delivery pressure roller being located at the ejection.
center, this ring must be arranged at both sides.

Delivery Roller Speed Control Lever

This lever must be used at "fast" position. How-
ever, this lever must be used at "slow" position
when incorrect collating occurs as sheets fail to
paginate correctly at the delivery section while
running small-size sheets.

Delivery Blower Adjust Knob

This knob is used to adjust the amount of
blowing air.

Air Nozzle Cap

This cap is used to close air nozzle
which is not to suit the sheet size.

Delivery Air Nozzle

Blowing air is applied through this nozzle
to the sheet to be delivered so that the sheet
is neatly chuted to jogger table.

Delivery Smoother Guide

Jogger Auxiliary Guide

This guide jogs the sheets loaded on jogger
table. Air Nozzle Angle Adjust Screw
Jogger Table When this screw is turned counter-
clockwise, the angle of the nozzle can
be varied to suit the operating require-
ment.

9
1. Before You Begin

1-2 Machine Descriptions

1-2-6 Jogger Table 2

Guide Setscrew
This setscrew is used to change the setup position of the
delivery smoother guide according to the sheet size.

Pressure Roller Positioning Screw

The roller pressure can be adjusted with this screw. In
any setup, pressure roller must reciprocate smoothly.

Pressure Roller Spring

Pressure Roller
This is a smoothing roller to facilitate
efficient sheet delivery.

Delivery Jam Sensor

Manual Crisscross Button

The crisscrosss receiving tray is manually
operated when this button is pressed.

Jogger/ Crisscross ON/OFF Select

Switch
Bottom Smoother
This smoother prevents the leading Jogger DOWN Button
edge of the sheet from hitting the Jogger table continue lowering all while
loaded sheets or jogger table. this button is being pressed.

Jogger UP Button
Jogger table continue rising all while this
button is being pressed.

10
 1. Before You Begin

1-2 Machine Descriptions

1-2-7 Detector and Controls

Jam
If a sheet is jammed in an area around feed roller to
transport belt or sensor zone, this lamp will light and
the machine will stop.

Misfeed
When the sheets on bin run out or a sheet is misfed,
the machine will stop automatically with the indicator
lamp lighting.

Double
If two sheets are fed at one time or the sensor detects
a dark printed area, this lamp will light and the ma-
chine will stop.
This lamp may light if the memorizing level is not
correctly set up.

Preset Stop
The select switch is used to automatically stop the
operation when a predetermined sets of collation has
been completed.

Preset Cover
When optional cover feeder (CF-20 or CF-23) is used,
table sheets or cover stock can be automatically in-
serted into every predetermined sets with preset
counter.
Without use of the CF-20 and CF-23 it can be so
arranged to make 4-second dwell at every preset
number of collated sets.
NOTE
- No.1 and No.2 on AC-8300 can be used as cover
feeder.

Memorize Sheet Caliper Lamp

This lamp is on while the caliper of the sheet to be
run is being memorized.

Air ON/OFF Button

These buttons are used to turn on and off the air
compressor.
Start Button
Inch Button
When this button is pressed
The machine can be inched with this button.
with the "air" on, the collat-
This button is useful when feeding an initial
ing operation can be started.
sheet to the snorer zone for pre-adjustment.
When pressed during the collating operation, Stop Button
the machine will stop.

11
1. Before You Begin

1-2 Machine Descriptions

1-2-8 Detector and Controls

Preset Counter
The counter does not operate unless air switch is set to
"ON" position.
With the air "off", the counter does not operate if the
machine is operated in a jogging mode by the jog/stop
button.
Stock Quality Select Switch
OTHERS : Ordinary sheet
OFF : Although double sheet detector does not work,
the misfeed is detected.
CARBON : The sensor detects the spot carbon area or
full carbon solid.

Bin Setup Switch & Lamp

Each bin has this switch. If set to "ON" position, the
power switch on the bin to be used is pressed, the
pilot lamp lights and the error detectors are set ready
for the operation.

Cover Feed Button

This button is used to feed a cover sheet or tab sheet
manually when CF-20 or CF-23 is used.

Memorize Sheet Caliper Button

This button is used to memorize the caliper of the sheet
to be run. When this button is pressed, a set of collated
sheets is delivered with each caliper of the sheet on
each bin being memorized. When the caliper varies,
press this button again to renew the memory.

Monitor
This monitor display the cause of machine stop and
location where the automatic stop is effected except
the power pilot lamp.

Bin UP/DOWN Button

These buttons are used to raise or lower all bins
simultaneously.

12
 1. Before You Begin

1-2 Machine Descriptions

1-2-9 CF-20 & CF-23 Cover Feeder (Option)

Feed Shaft Bearing Setscrew Misfeed Adjust Spring

This setscrew is loosened only when feed This spring is located at the bottom
shaft is removed to replace feed roller. of the feed pile table, this spring
When cover feeder is used, bearing must be adjust the lifting up power of the
locked. feed pile table.
If misfeed occurs frequently, set
the spring at a lower hook.
Feed Roller
This roller feeds the tab or cover
sheet.
If this roller is smeared with ink or
stain, irregular feeding action is
likely to occur.

Double Feed Stop Pad

This pad prevents double-
sheet feeding.

Feed Table Set Lever

Double Feed Stop Pad Gap
This knob is used to adjust the gap be-
tween feed roller and double feed stop pad.
Cover Feed Table
Cover stock is loaded on this table.
Back covers must be placed on the upper feeder
table and front covers on the lower feed table
respectively.
This lever must be turned to LH-side
when cover stocks is set on the table and
to the right when the operation is started.
When cover stock is not used, turn this
lever to LH-side.
Side Guide
This guide is to feed the cover stock straight.
Adjust side guide in order that it slightly
touches the side edge of the cover stocks.
Otherwise, misfeed may occur.

13
1. Before You Begin

1-2 Machine Descriptions

1-2-10 CR-14 Crisscross Receiving Tray (Option)

Pressure Roller Unit

This unit used for crisscross receiving operation.
Pressure Roller Spring
Fitting Shaft
This shaft must be slid to the left to put
on and off the pressure roller unit.
Pressure Roller Positioning Screw
Delivery Height Detector The roller pressure can be adjusted by
This detector is used for both changing the fitting angle of the screw.
crisscross and jogger operations. Delivery pressure roller must recipro-
cate smoothly.
Center of Table Swivel

Pressure Roller
This roller presses a set of collated
sheets for smooth delivery.

Crisscross Receiving Unit Cord

End Stopper
This stopper receives the delivered
sheets neatly.
This stopper must be set up at the
position where the center of the
sheet is located at the center of table
swivel.
Crisscross Receiving Tray
This cord must be connected to the
crisscross connector.
Table Fix Screw
This screw is used when crisscross
receiving tray moves back and forth
to locate the table at the optimum
position.
Side Stopper
This stopper holds the sides of the
delivered sheets.

14
 1. Before You Begin

1-3 Construction Features

1-3-1 Feeding Mechanism and Sensor

The drawing below represents a view of the

feeding mechanism.

Top Sheet Separation Air Nozzle

Drop Roller
Sucker
Sheet Height Control Bar
Sensor Projector
B
Transport Belt
A

Pile of Sheets

Feed Roller Front Loading Guide

Sensor Receiver
Sheet Ruffling Air Nozzle
Belt Tension Roller

(1) Sheets in the upper layer of the pile are

separated by sheet separation nozzle, and
the sheet height control bar and sucker
lower to the separated top sheet.
When sucker picks up the top sheet, the
separation blower is momentarily stopped.

(2) As sucker rises, the sheet height control bar

also rises.
When sucker reaches the top sheet separa-
tion nozzle area, the blowing air is sent
between the top sheet and the second sheet,
passing through to the trailing end of the
sheet.

15
1. Before You Begin

1-3 Construction Features

(3) When the sucker transports the sheet into
the gap between the drop roller and the
feed roller, the drop roller will lower.
Sucker starts to rise to the point A with the
suction air off.
When, the sheet separation nozzle blows
air and the sheet height control bar lowers
for starting to feed the next sheet.

(4) The sheet is transported to the sensor zone

by the drop roller and the feed roller.
While the sheet is passing through the
sensor zone, the sensor consisting of a
lamp and photodiode reads and detects the
preset amount of light transmission, send-
ing the signal to the detector control store
where the information whether a sheet is
correctly fed or not is judged.
If something abnormal occurs, the detector
control store sends a signal to stop the
machine.
The amount of light transmission will be
increased when a misfeed occurs and
decreased if double feed occurs.

1-3-2 Detectors
The detector system consists of electronic
circuits for jamming, misfeed, and double
feed detection controls and their display
lamps at all 6 bins.
As previously described, the electric signal
in proportion to the amount of light trans-
mission which is generated by the sheet
passing through the sensor zone is sent to
the detector where the actual amount of
light transmission detected is compared
with the memorized value every time a
sheet passes.
If the detected signal runs out of the
memorized value in such a case of double
feeding, it is so arranged that the operation
is stopped automatically to prevent faulty
collation with double-feed lamp lighting.
When the sheet-feed timing is not correct
even if a sheet is correctly fed from each
bin, the machine will stop to prevent incor-
rect collation.

16
 1. Before You Begin

1-3 Construction Features

1-3-3 Jogger Table/Delivery Section

(1) Transported from the feeder section and

gathered by the transport belt, a set of
collated sheets is ejected to jogger table.
Before being ejected, static eliminator
brushed remove static electricity in the
sheets to effect better sheet jogging perfor-
mance.

(2) The delivery blower nozzles send air blast

between sheets delivered on the jogger
table to aid inputting the sheets in order
easily.

(3) The jogger is vibrated by the unbalanced

weight driven by the electric motor.
The condition of sheet jogging on the
jogger table is greatly affected by the
delivering condition.
So delivery height detector is provided
over the jogger table to keep the height of
the delivered sheets at an optimum level.

17
1. Before You Begin

1-4 General Hints

1-4-1 When running small size sheet
When handling sheet with sheet size smaller than B5 (182 x 257 mm : 7.2" x 10"), it is gen-
eral that sheets fail to overlap properly in the transport belt zone and cannot be jogged well on
jogger table.
One of the ideas to remedy such a trouble is to load sheets on the bins with shorter dimension
of the sheet being set against the feeder unit and check to see the delivery condition.

1-4-2 When the sheets loaded into bin tend to be sloped because they contain
perforations or spot carbon(s)
The sucker cannot pick up the perforated area.
If the area the sucker picks up is sloped or inclined due to bulge of sheets with some process,
attempt to flatten the piled sheets as much as possible either by driving a wedge into the pile
or by reducing the amount of a lift on bin.
Further, the slope or inclination in the pile may cause the sheet height control bar to set up at
a higher position.
Adjust the sheet height control bar to suit the operation.

18
 2. Operation Procedure

2. Operation Procedure

2-1 Before Starting Operation ...................................................................... 20

2-2 Operation Procedure ............................................................................... 21
2-3 For Efficient Operation .......................................................................... 28
2-4 CR-14 (Option) Operation Procedure ................................................... 35

19
2. Operation Procedure

2-1 Before Starting Operation

1. Wind and jog well the lift of stock

before loading on bin. Otherwise double-
sheet feeding may occur.
Particularly, wind well suck stocks as sheet
with carbon printing and perforation.

2. Remove curl of sheets for smooth feed-

ing of sheets.

- Putting fold lines on the sheet is practical

way to give sheet more strength and to
keep the sheet from curling or rolling up
or jog well in the jogger table and also to
prevent the sheet from getting into the gap
between the front or side guide and the
jogger table.

3. Align all side of the sheets piled as

closely as possible on bin with sheet
guides.
- Poor sheet alignment in the pile may cause
the sensor to work irregularly. 2
- Place a lift of sheets at the center of each
bin.
It is a knock to get the collated sets deliv-
ered and jogged neatly.
3

4. Place spoiled sheets on the jogger table

to keep production sheets from being
damaged and to get better jogging perfor- 4
mance.

20
 2. Operation Procedure

2-2 Operation Procedure

1. Turn the power switch on.

- The monitor power lamp will light.

2. Turn on the bin setup belonging to the

3
bins which are used.
- The detector lamp will light.
4

3. Lower all bins to be used to the bottom

by pressing bin DOWN button.

4. Place a lift of stock sheets on each bin. Jogging Corner

The sheet on the first (topmost) bin is Register Corner Sheet
collated as the first page. So, load bin
accordingly with the leading edge firmly
being placed against the from loading
guide, taking into account the jogging
corner position on the jogger table and the
sheet register corner on the bin.

Back Guide
Guide Spot Carbon

21
2. Operation Procedure

2-2 Operation Procedure

5. Adjust the level of the sheet height

control bar according to the quality of sheet
to be run.
Lower position for tissue
Higher position for cardboard

6. Raise all bins up to the working level by

pressing the bin UP button.
Bins will cove to a stop automatically at a
starting position with the sucker and other
parts moving a little bit.

7. According to the sheet size, close the

sucker or suckers which are not used with
sucker ON/OFF knob.
If the idle sucker or suckers are left open,
the suction power of other suckers may be
reduced.
It does not matter that suckers belonging to
the bins not in used are left open.

Side Guide
Angle or Gap
8. Adjust the amount of suction air accord-
ing to the sheet quality with suction air
adjust valve.
Use the "weak" position for tissue opera-
tion and "heavy" for cardboard operation.

Side Edge of Sheet

22
 2. Operation Procedure

2-2 Operation Procedure

9. Adjust and set up jogger side guide and

front guide to suit the sheet size.
- Set up side guide so that it does not hit the
leading edge of the sheet.
- Narrow the angle or gap for tissue opera- Sheet
tion and widen it when handling card-
Jogger Table
board stocks. Front Guide
- With a sheet of sheet to be collated being
placed on jogger table, set up the front
stop guide. Auxiliary Side Guide
1 to 3 mm
- Set up the auxiliary side guide to keep the
(0.04" to 0.12")
sheets from overrunning and bouncing
back.

10. Set up the sheet reinforce rings accord-

ing to the sheet quality.
Raise jogger table up by pressing jogger
UP button.
Narrow the distance between the sheet
reinforce rings "L", say 10 to 12 cm, when
rutting tissue, and widen it to 15 to 18 cm
for cardboard operation.
Refer to "2-3 For Efficient Operation"
(page 30).

11. Set the counter switch either to "preset

stop" or to "preset cover" according to the
operational requirement.

Preset Stop
Set up the number of sets to be collated in
the preset counter while pressing the reset
button.
The machine will cove to a stop automati-
cally when the preset number of collation
has been completed.
Press the start button again to resume the
operation.

Inserting Tab Sheets or Cover Stocks

into Predetermined Sets of Collation
Set up the number of sets to be collated at
witch the tab sheet or cover stock is in- If the optional cover feeder CF-20 is used,
serted. When the preset number of colla-
the tab sheet or cover stock can be inserted
tion has been reached, air compressor will
automatically in sequence as set up by
dwell for a period of 4 seconds during
preset counter.
which period you can put the tab sheet or
When the tab inserting time (4 seconds)
cover stock by hand.
has passed, the air compressor is started
again to resume collating operation.

23
2. Operation Procedure

2-2 Operation Procedure

12. Set up total counter.

- Set up total counter to "0000" by pressing
total counter reset button. The counting of
the number of collation is started from
"0000".

- When the preset counter is not used, set

the counter to "9999" while pressing the
preset counter reset button.

13. Set up the tab sheet or cover stock when

cover feeder is used.
When the tab sheet or cover stock is cor-
rectly set up in cover feeder, turn feed
table set lever to RH-side position. Set the
tab sheets or cover stocks so that they
touches feed roller.

14. Inching the machine, move sucker

without air and stop where it returns to its
home position.

15. Turn the air switch to ON position.

NOTE
- With AC-8300 collator, the bins No.1 and
No.2 can be used as cover feeder if the
counter switch is set to "1,2 CF" position.

24
 2. Operation Procedure

2-2 Operation Procedure

16. Adjust Separation Blower Nozzles at all

bins to be used.
- Turn and adjust the knob to such an extent
that leading edges of the sheets are effi-
ciently separated by blowing air.

- If more than one sheet are stuck together,

there are chances for double sheets to be
fed.
If you cannot separate the sheets effec-
tively by adjusting the separation nozzle
air, try to wind and jog the sheets again or
give fold line on the sheets.
Refer to procedure 1 and 3 of "2-1 Before Sheet Ruffling Leading Edge of the Sheets
Staring Operation" (page 20). Nozzle

17. Set the top sheet separation air adjust

knob to the same level with separation air
adjust knob
The setup level may vary depending on the
sheet quality.

25
2. Operation Procedure

2-2 Operation Procedure

18. Set up memorizing sheet caliper.
- Select the sheet quality switch according 3
to the quality of the sheet to be run.
4

19. Press memorizing sheet caliper button to

so that the machine can memorize the
caliper of the sheets on each bin in use.
Check a set of collated sheets. If any 6
misfeed, incorrect collating or other faults
are found, press this button again to
rememorize the calipers.

NOTE
- In case the double feeding LED do not go
out even if the memorizing sheet caliper
button is pressed when running sheets with
dark solid image areas, set the sheet quality
switch to "carbon" position.

20. Turn the vibration /OFF switch to vibra-

tion position.

21. Set up the delivery pile height detector.

26
 2. Operation Procedure

2-2 Operation Procedure

22. Delivery a set of collation by pressing

inch button.

23. If a set of collated sheets is smoothly

delivered into the jogger table, make sure
that all sheets are correctly collated in
proper page order.

24. Start the collating operation by pressing

start button.

NOTE
- When resuming the operation after a set of
collated sheets has been ejected by pressing
the inch button with the pump off because of
some operation fault, be sure to press the
inch button to idle-run and return the sucker
to home position and the turn the air on.
Otherwise counter may operate erroneously.

27
2. Operation Procedure

2-3 For Efficient Operation

This section show for efficient operation.
Sucker ON/OFF Knob
1. In case double feeding occurs, it is
probably due to too strong suction air,
insufficient sheet separation blower air,
faulty adjustment of top sheet separation or
poor fanning of sheets before loading.

Suction Air Adjust Valve

If the setup line on the knob is set to "mod- Valve Orifice
erate" or "strong" position, the amount of
suction air is increased. Sucker Air Adjust Knob
In case you cannot obtain enough air even
if the knob is set to "strong" position, Suction Air Sheet Weight Range
check whether or not the sucker ON/OFF
knob is set to OFF position or check the air Strong Heavy
compressor filter for being clogged. Moderate Medium
Weak Light
Theoretically, the suction air should be
adjusted according to the weight range of
2. In case double feeding or misfeed occurs the stock to be handled as shown above.
frequently, it is due to insufficient adjust-
ment of either the sheet ruffling air adjust
knob or the sheet height control bar or poor
fanning of sheets before loading. Sucker

Ruffled Sheets
- Adjust the sheet ruffling nozzle air to such
an extent that the top sheet is ruffled up
higher that the sucker's lowest stroke end
level.

- In case the sheet fail to be ruffled up to the

sucker's lowest level, it is due to either too
weak air blast or too low a setup position
of the bin.
Try to turn the sheet eight control bar to
"high" position and raise the bin and then Sheet Ruffling Nozzle
adjust the sheet ruffling air adjusting knob
so that the sheet can be ruffled adequately.

- The sheet ruffling air adjustment knob and

the sheet height control bar are in a close
relationship each other in operation so that
their adjustments should vary according to
the quality and size of sheets to be collated.
In case the sheets fail to be ruffled even if
the sheet ruffling air is increased, raise the
bin because the bin may be set at a too low
position.

28
 2. Operation Procedure

2-3 For Efficient Operation

3. Top Sheet Separation Air Nozzle Top Sheet Separation Nozzle

If the top sheet drags the second sheet
together when being picked up by the Sucker
sucker, it is likely that the separation air is
too weak.
If the top sheet tends to be blown off, it is
may be due to too strong separation air.

- Adjust the top sheet separation air nozzle

by observing the condition the sucker
passes over the air nozzle area as shown
in the drawing at right.
Air passing through between
- Normally, the adjust knob of the sheet the top sheet and the second
ruffling nozzle and the top sheet separa- sheet
tion nozzle should be set in the same Pile of Sheets
arrow direction.

- The top sheet separation air should be set

at a "weak" position for tissue operation
and "strong" for cardboard and sheets
with spot carbon or heavy solid printing
pattern.

- The table below gives a quick reference

guide in setting up the air adjustments.

Double-Feed Occurs What to be adjust Misfeed Occurs

Weak Sucker Vacuum Pressure Strong

Weak Sheet Ruffling Strong

Air Pressure

Strong Top Sheet Separation Weak

Air Pressure

Low Sheet Height control Bar High

29
2. Operation Procedure

2-3 For Efficient Operation

4. Set up the sheet reinforce ring and

pressure roller.
Efficient delivery is vital for smooth collat-
ing operation.
The adjustment of these operating elements
heavily depends on the operator's experi-
ence, quality of stock, combination of
stocks, amount of ink printed on the sheet
and humidity contained in the sheet.

- Locate the pressure roller at the center of

the width of the sheets to be delivered. Pressure Roller Spring
And the sheet reinforce ring should be
positioned at an equal distance in a sym- Pressure Roller
metrical position with the pressure roller
located at center.
To outer reinforce ring perform the func-
tion of keeping the side edges of the sheet
from dropping. L
- The narrower distance between the sheet Sheet Reinforce Rings
reinforce ring, the more strength is given
to the sheet.
If too narrow, there are chances for sheets
to be jammed upon being effected.

- Use a shorter distance "L" (10 to 12 cm :

0.4" to 0.48") between the sheet reinforce
rings when operating tissue or lightweight
stocks and longer distance "L" (15 to 18
cm : 0.6" to 0.7") for heavyweight stocks.

- In case the ejecting power is too weak,

adjust the pressure of the pressure roller.
In normal operation the selfweight of the
pressure roller can give sufficient ejecting
pressure.

30
 2. Operation Procedure

2-3 For Efficient Operation

Delivery Pile Height Detector

5. Setting Up and Delivery Pile Height
Detector a
The detector switch keeps the gap between Delivery
the top sheet delivered on the jogger table s Guide
and the delivery guide at a constant level.
If the gap is inadequate, there are chances
for the delivered sheet to be jammed or Set Screw
rolled up. Sheet Delivered on Jogger Table
The gap "S" is too narrow in case the top face
- Arrange a narrow gap "S" for tissue of the detector is set in parallel with the deliv-
operation hand a wide gap "s" for card- ery guide top face.
board operation.

a
- Adjust the setup position of the delivery
pile height detector to suit the operating
s
condition.

The gap "S" is too wide in case the angle "a"

between the top face of the detector and the
delivery guide is widened.

Jogger Table
6. Setting Up Side And Front End Guides
The set up of these guides are very impor- Side Guide
Gap
tant in achieving neatly jogged delivery
pile on jogger table.
The jogging performance is greatly af-
fected not only by the set up of these
guides but also by the sheet quality, curl,
humidity content and other factors.

Delivered Sheet
Front Guide
1 to 3 mm
Sheet on Jogger Table
(0.04" to 0.12")

31
2. Operation Procedure

2-3 For Efficient Operation

- It is easier and more efficient to keep the

gap between the side guide and the side
edge of the sheet as close as possible.
However, when handling cardboard, this
gap may be set wider for more efficient
jogging result.

- When a sheet with curl tends to roll up

against the front guide, try to fix a rolled
sheet on jogger table with use of a cello-
phane tape or the like as shown in the
drawing at right in order to remove the
distortion in the sheet, or place a small pile
of spoiled sheets on the jogger table to
remedy such a fault.

Rolled Sheet

7. Set up jogger table and bottom sheet

smoother.
Jogger table is designed to tilted down
toward the registering corner. This tilting
angle can be adjusted by the set bolt as Registering Corner of Jogger
required to suit the operation.
If the registering corner is tilted down too
low, there are chances that such troubles as
sheet lifting or rolling up may occur,
particularly when running tissue stocks. Set
up an optimum tilt angle by use of tissue
stocks.
Bottom Sheet Smoother
If the registering corner is lowered, the
opposite corner is proportionally raised so
that the delivered sheets may hit the raised
corner.
To avoid such a fault, adjust the bottom
smoother up to such and extent as the
leading edge of delivered sheet is raised
over the edge of the jogger table.

32
 2. Operation Procedure

2-3 For Efficient Operation

8. Adjust the vibration of jogger table and
delivery air nozzle.
It should not be assumed that the stronger
vibration and delivery air blast ensures the
better jogging performance.
As previously describe, many factors such
as proper setup of sheet reinforce rings, set
up height of the delivery pile height detec-
tor, side and front guides on the jogger
table and collating speeds hold key in
achieving better jogging performance.
Use a minimum collating speed for tissue
operation. Use the jogger vibration and
delivery air blast as an auxiliary means.

- Adjusting the jogger table vibration

The unbalance weight is provide under the
table.

To increase the vibration to maximum To reduce the vibration to a minimum

level: level:

Overlap the weight plate as shown in the Leave 2 weight plates as far as possible in a
drawing above. symmetrical position as shown in the
drawing above.
- Adjusting the delivery air nozzle basically,
less air blast is applied to the tissue stock
and more to the cardboard.
Excessive or insufficient air blast may
cause unstable delivery of sheets on the
jogger table.
Adjust the delivery air blast to suit the
delivery condition of the sheets to be
handled.

9. Operate cover feeder (CF-20/CF23 option).

- Fanning well cover stocks or tab sheets,
place then on the feeder pile table of the
cover feeder.
- Turning the feed pile table set lever to
RH-side, Set a sheet of stock under the
feed roller.
- Maximum feed pile on the cover feeder is
2 cm high.

33
2. Operation Procedure

2-3 For Efficient Operation

- Adjust double feed stop pad.
Feeding a sheet of cover stock into the feed
roller, turn the feed roller by hand and
adjust stop pad gap in such a way that one
sheet passes through the double sheet stop
pad with slight friction but no two sheets
should go through at one time.

- Set up the side guide according to the sheet

size.
6

- Test feed a set of cover stocks by pressing

cover feed button.

34
 2. Operation Procedure

2-4 CR-14 (Option) Operation Procedure

1. Install crisscross receiving tray unit and

the pressure roller set. Refer to "5-1-2
Jogger Table Installation" (page 50).

2. Set up sheet reinforce rings on the deliv-

ery roller as shown in the drawing below.

Pressure Rollers

Sheet Reinforce Rings

The sheet reinforce rings must be properly

set up to achieve smooth delivery of col-
lated sets of sheet. It is necessary to adjust
the width of "?" and "L" according to the
quality of sheet to be run.

3. Set up the center stopper (1), the end 1

stopper (3) in that order to suit the sheet
size.
3
Delivered Sheet
2

s End Stopper

Provide a 10-mm gap "S" between the edge

of the end stopper and the edge of the
crossed sheets as shown in the drawing
above. Some gap should be provided
between the inside of the side stopper and
the sheet edge.

35
2. Operation Procedure

2-4 CR-14 (Option) Operation Procedure

4. Locate crisscross receiving tray unit and

the trailing edge of the delivered sheets
clear of the delivery unit. Then, lock the
tray in position by fastening tray fix screw.

5. Setting the Motion Switch to "Vibration/

Crisscross" Position
Lower the pressure roller and delivery
guide on the crisscross receiving tray.

NOTE
- Install an auxiliary delivery guide and/or
weight on the delivery guide when handling a
heavyweight stock or when the delivered
sheets bounce bock after hitting the end
stopper because the collating speed is too
high.

- Refer to "2-3 For Efficient Operation" Auxiliary Delivery Guide

(page 28 to 34) for adjusting other parts as
some of the parts adjustment are similar to Weight
those of the jogger operation.

Delivery Height
Detector

Delivery Guide

36
 3. Troubleshooting

3. Troubleshooting

3-1 General Hints to Remedy Cover Stock Feed Troubles ........................ 38

3-2 Detector's Display and Operation .......................................................... 39
3-3 When Monitor Lamp Lights .................................................................. 40
3-4 Troubleshooting Hints ............................................................................ 41

37
3. Troubleshooting

3-1 General Hints to Remedy Cover Stock Feed Troubles

3-1-1 Misfeed
1. The feed roller's contact pressure against
the sheet is too weak.

- Set the misfeed adjust spring to one step

lower position.

2. The double sheet stop pad's gap is too

narrow.
- Adjust the gap.

3. The feed roller is smeared.

- Remove any dirt such as paper dust, ink
and other substances with use of alcohol.

3-1-2 Double Feed

1. Fan and jog well the cover sheets for
better sheet separation.

2. The double sheet stop pad's gap is too

wide. Adjust the gap.

3. The double sheet stop pad is smeared.

Wipe out the dirt with alcohol.

4. The feed roller's contact pressure is too

strong. Set the misfeed adjust spring to one
step higher position.

NOTE
- In case any collating failure should occur
immediately before the automatic stop as set
up by preset counter, the cover stock is not
fed and the next set of collation will be
started without the cover stock being fed. In
such a case, feed a set of cover stock by hand.

38
 3. Troubleshooting

3-2 Detector's Display and Operation

3-2-1 When jam, misfeed and double-
feed lamps light
Some sheet-feed trouble is happening in
the transport belt frame.
Eject out the trouble sheets by use of the
inch button.
When double lamp light, the machine
cannot be operated even if start button is
pressed.
In such a case, eject out the troubled sheet
by inching the machine.
When double-feed lamp lights at a bin,
lamps are lighting on the other bins.
In case double and misfeed occur simulta-
neously, double-feed lamp lights in the bin
where the double-feed trouble occurs and
jam lamps light on in trouble-free bins and
the bin with misfeed trouble will have no
display lamp lit.
The misfeed lamp will light in the bin with
misfeed fault only when the machine is
inched.
3-2-2 When jam lamp lights
The jam lamp is lit with the machine being
shut out when a sheet or sheets are left
behind in the feed roller section or extra
sheet or sheets are dragged into the feeder
section.
Check to see whether or not a sheet or
sheet scrap is left either on the upper most
set of collated sheets on jogger table or in
the feeder section.
NOTE
- The jam lamp will light when a sheet or
sheets are stopped by sensor even if the sheets
are normally fed.
3-2-4 Double lamp lights on and the
machine stops without any collating
fault.
This type trouble occurs when the detector
detects a heavy solid printed area or sport
carbon area as the sheet runs out the prede-
termined feeding course so that the stop
carbon or solid printed area in the sheet has
been averted to clear the detector.
1. Change the position where the sheets are
piled in the bin so that the spot carbon or
solid area will not pass under the detector.
2. In case the detector cannot effectively
detect the printed pattern such as a black
heavy solid carbon, turn the sheet quality
switch to the off position. In the case, no
double-sheets are detected but jamming
and misfeed area effectively detected.
NOTE
- The detector indicating the faulty operation
will be reset by pressing start button after the
cause of trouble has been eliminated.
- In case sheets with same quality are
handled, the detectors must be readjusted if
the sheets carry different printed patters.
- In case the detector lamps light although
the correct collation is executed, such a
trouble may be due to poor adjustment of the
detector.
Stop the machine once by pressing stop
button. Press the memorizing sheet caliper
button again to let the machine memorize the
sheet caliper.

3-2-3 When misfeed lamp lights every

time a set of collated sheets is ejected.
Such a trouble may be due to
misadjustment of the feeder air function or
because detector power switch is being
turned ON on the unused bin or bins.

39
3. Troubleshooting

3-3 When Monitor Lamp Lights

3-3-1 When counter stop lamp lights 3-3-4 When memorizing sheet caliper
1. This lamp lights when the machine is lamp lights
brought to a stop as the preset number of
This lamp light if the sheet caliper is not
collation have been completed.
memorized.
It is impossible to resume the operation
If the memorizing caliper button is pressed,
with this lamp on.
the lamp hoes out with the sheet caliper
Be sure to reset the preset counter to let the
being memorized.
lamp go out before staring the operation.
NOTE
2. The lamp will light only during the dwell-
- If the collating operation has been sus-
ing period of time (4 seconds) when preset
pended for over 20 minutes, the memorized
cover feeding is arranged.
caliper data is deleted and the memorizing
In the connection, if the collating operation
sheet caliper lamp light.
is suspended in this dwelling period. There
When resuming the collating operation,
is a case when the collating operation
memorize the sheet caliper again by pressing
connate be started again.
the memorizing sheet caliper button.
In such a case, counter stop lamp light and
you have to reset the counter by hand.
3-3-5 When jam detector lamp lights
3-3-2 When full jogger table lamp lights If sheets are jammed at the delivery sec-
tion, the jam detector stops the machine
When the jogger table gets full of collated
instantly. Removing jammed sheets, press
sets of sheet, the lamp will light.
start button and the lamp goes out.
The jogger table cannot go downward any
further.
After removing the collated sets of sheet
out of the jogger table, press the jogger UP
button.

3-3-3 When no cover lamp lights

This lamp light when the cover stocks on
either one or both of feed tables urn out.
Supply the cover stocks. Otherwise, the
collating operation cannot be started again.

NOTE
- When feeding single cover stock, leave feed
table set lever at the LH-side position with a
lift of cover stock placed on the unused feed
pile table.
The cover feeder cannot be operated using
only one feed table.

40
 3. Troubleshooting

3-4 Troubleshooting Hints

3-4-1 When the double sheets are fed
(Cause 1) Sheets are not fanned well.
(Remedy 1) The procedure 1 of "2-1 Before
Starting Operation" (page 20)
(Cause 2) The leading edges of sheets is not
well ruffled by the sheet ruffling air
nozzle.
(Remedy 2) The procedure 2 of "2-3 For
Efficient Operation" (page 28)
3-4-3 The machine is stopped because
of double-feed though sheets are
correctly collated
(Cause 1) Detector adjust dial is set improp-
erly.
(Cause 2) The sensor is smeared with paper
dust.

(Cause 3) Suction air valve is set at the
"strong" position.
(Remedy 3) The procedure 1 of "2-3 For
Efficient Operation" (page 28)
(Cause 4) Bin is set up at too high position.
- Adjust the height to "low" position with
sheet height control knob.
(Cause 5) Brush at feeder section is worn
out.
- Replace with new one or install two
brushes.
3-4-4 When jam lamp remains
lighting
The sensor may be stained with paper dust.
The sensor should be cleaned.
The sensor is provided above the belt
contactor roller as shown in the drawing
below.
If the cover si removed, you can gain an
easy access to the sensor.
Clean the sensor with brush or soft cloth.

3-4-2 When misfeed occurs

(Cause 1) The leading edges of sheets is not
well ruffled by the sheet ruffling air nozzle.
(Remedy 1) The procedure 2 of "2-3 For
Efficient Operation" (page 28)

(Cause 2) Bin is set up at too high position.

- Adjust the height to "low" position with
sheet height control knob.

(Cause 3) The unused sucker ON/OFF knob Sensors

is set at ON position.
(Remedy 3) The procedure 1 of "2-3 For Cover
Efficient Operation" (page 28)

(Cause 4) The suction air is too weak for the

weight of sheet being handled.

(Cause 5) Sucker ON/OFF knob are all Blown-up Side View

closed.
Belt Contact Roller
Sensor Setup Position
(with Belt Frame Open)

41
3. Troubleshooting

42
 4. Maintenance

4. Maintenance

4-1 Cleaning .................................................................................................... 44

4-2 Lubrication ............................................................................................... 45
4-3 Replacement ............................................................................................. 46
4-4 Adjustment ............................................................................................... 48

43
4. Maintenance

4-1 Cleaning
4-1-1 Compressor Filter
1. Most of suction feed trouble is due to 0.25 kg/cm
poor performance of the compressor.
Clean periodically the filter element
clogged with paper dust or other substance.
Make it a routine to clean the filter element
every 2 or 3 months although the period
may vary depending on the work environ- Oil Filter Plug
ment.
20 cmHg
2. Clean the filter element by tapping it Filter Screw
lightly or applying compressed air. Filter
3. Set the pressure (0.25 kg/cm) and Cover Filter Screw
vacuum (20 cmHg) gauges at the values Transparent Pipe
shown in the drawing at right.

4. Be certain that the specified amount of

oil is always supplied. And replace the
entire oil once a year.
Oil : Esso EP460 or equivalent

Filter Element Filter Nut

4-1-2 Sensor
Refer to "3-4-4 When jam lamp remains
lighting".
The correct detecting performance of the
sensor largely depends on adequate light
transmission of the sheets.
If the sensor is smeared with paper dust,
misdetection may occur. Wipe the paper
dust off the sensor with brush.

44
 4. Maintenance

4-2 Lubrication
4-2-1 The Elevating UP/DOWN Mechanism of Jogger Table
Apply grease around the worm gear of the
elevating UP/DOWN mechanism of the
jogger table every two or three months.

Worm Gear

45
4. Maintenance

4-3 Replacement
4-3-1 Sucker Rubber Ring and Brush

1. Pull the sucker rubber ring downward as

shown in the drawing at right.

Sucker Rubber Ring

Brush
2. Unlock screw with bin lowered.

Setscrew

4-3-2 Feed Roller of CF-20 (Optional Cover Feeder)

Replace rubber roller with new one in case
Fix Screw
some feed trouble occurs due to either one
Ring
of the following causes.
1. Feed roller is worn out.
2. The surface of rubber become too stiff Feed Roller
because of rubber deterioration. No.40-1
3. Contamination on roller surface cannot Slide in arrow direction.
be removed.
Direction to remove shaft.
Locate rubber roller at the center of shaft.
The workable OD of the rubber roller is up
to 38.5 mm (1.6").

Pull rubber roller in arrow

direction for removal.

46
 4. Maintenance

4-3 Replacement
4-3-3 Double-feed Stop Pad
When frequent misfeeds happen and /or
sheet is rolled up around the feed roller,
replace the stop pad with a new one be-
cause such troubles may be caused by the
worn out rubber on the double-feed stop
pad.
Remove the feed roller shaft referring to
"4-3-2 Feed Roller of CF-20 (Optional
Cover Feeder)" (page 46). Double-Feed
Loosen setscrew for the double feed stop Stop Pad AC
pad; turn the screw three to four turns. Setscrew for Double-Feed Stop Pad
Extract pad upward.

- Reverse the procedure when attaching a

new stop pad.
Inserting an edge of the pad mount into the
rectangle hole. Push down the pad from
setscrew.
Check that pad is correctly set up in posi-
tion and it is free from stain.

NOTE
- Keep the spare pad in a safe place where it
is not smeared nor damaged.

4-3-4 Fuse
The electric control components are housed
in the cover of the power switch side.

Control Transformer Fuse 1 A Bin Elevating Motor Fuse 2 A

Control Transformer
Power Input Terminal

Power Switch

Vacuum Pump Terminal

Main Drive Contactor

2 A Jogger Fuses Reset Button (Black)

(3 pcs)
Vacuum Pump Main Drive Circuit Breaker
Vacuum Pump
Contactor Circuit Breaker

47
4. Maintenance

4-4 Adjustment
4-4-1 Detector Sensitivity
NOTE
- When detectors are found to make faulty
operation, be sure to clean the sensor first
before checking detectors.
- The parts to adjust the detectors are pro-
vided behind the detectors. Open the door by
loosening screw at the LH-side center of the
panel.

CAUTION
- The low-voltage PC board behind
detectors and switches are not hazard-
ous. However, a 100 V is present at the
counter and terminals below counter so
that your hand keep off these parts.

Adjust the sensitivity of detectors

1. Turn off the power and then turn it on

again.

2. Press all power switches of the detectors

to ON position.

3. Set all stock quality select switches on

the operation panel to "other" position.

4. Turn clockwise VR1s on bins where

LED2 and LED3 are off.

5. Stop turning VR1s where LED2 lights

and then LED3 also lights. LED VR1
VR1
NOTE LED
- If LEDs1 and 2 are on, the normal level of
sensitivity is established though LED3 goes
out.

48
 5. Installation

5. Installation

5-1 Installation Instructions .......................................................................... 50

49
5. Installation

5-1 Installation Instructions

5-1-1 Installation Place

- Select a solid floor for installation of the

machine.
If the floor is weak or unstable, reinforce it
with a plywood or the like.

- By raising the machine with mounts and

leveling bolts, set casters free from load or
afloat from the floor.
Further, level the machine properly in
order that no distorted vibration occurs
during the operation.

- Keep transport belt away from direct

sunshine.

- Connect ground to the machine.

5-1-2 Jogger Table Installation

1. Install jogger on the machine with a

hook and lock bolt.
- The tilting angle of jogger can be adjusted
with lock bolt.
Hook
2. Connect jogger connector.
NOTE
- Avoid pressing down jogger with excessive
force.
Bolt
Jogger Connector

50
 5. Installation

5-1 Installation Instructions

5-1-3 Crisscross Receiving Tray Installation
1. Install crisscross receiving tray at the
same place as jogger tray with hook and fix
bolt.

2. Replace delivery guide with the one for

the crisscross receiving operation.

3. Install delivery height detector on deliv-

ery guide.

4. Connect connector.

51
5. Installation

5-1 Installation Instructions

5-1-4 Air Hose Connection
Identify the hose number at the machine
outlet and those on compressor. Match
each corresponding hose number when
connecting hose.
After connecting hose, secure the joint with
hose band.

Cover

Power Cord Hose

Arrow indicating vacuum

pump motor's rotating
Pressure Gauge direction
Air Filter
Vacuum Gauge
Electromagnetic Valve
Motor Cord
Electromagnetic Valve Cord

5-1-5 Air Accumulator Installation (Option for AC-6000)

This air accumulator is a device to increase
the air blowing power to ensure better
sheet separation when handling heavy
weight stocks such as coated sheets with-
out increasing the vacuum pump capacity.
Inserting Direction
Install air accumulator under collator as
shown in the drawing at right and connect Hose Clamp (4 pcs)
the hose firmly.
With air accumulator, sheets can be fed
stably without setting sheet height control
knob to "high" position.

Air Accumulator

Vacuum Pump

52
 5. Installation

5-1 Installation Instructions

5-1-6 Power Cord Connection

1. Confirm the rotating direction of motor

before connecting power cord.

2. Connect compressor motor and electro-

magnetic valve cords before connecting
power cord to power source.

NOTE
- When using 200 V power source, connect
power cord to transformer. From
Power Source

E 220V 220V 220V

3. Turn on power switch.

P
4. Press air ON button and then press OFF

200V 200V 200V

button immediately.

S
5. Confirm cooling fan of either compres-
sor or motor rotates in a direction as indi- From Collator
cated by arrow.

NOTE
- If motor is reversed, reconnect 2 lines out of
3 of primary power cord.

Green Red White Black

*Green cable is for grounding.

White
Electromagnetic Valve Cord
Red

Compressor Motor Cord

Green

Red
White Black

53
5. Installation

5-1 Installation Instructions

5-1-7 Cover Feeder CF-20/CF-23 Installation (Option)

1. Remove eyebolts and install CF-20/CF-

23 on the top of the machine (AC-6000/
AC-8000S/AC-8300)

CAUTION
- Fix CF-20/CF-23 firmly on the top of
AC-6000/AC-8000S/AC-8300 so that it
does not fall.

CF-20/CF-23 Cover Feeder

2. Fix the L-metals in CF-20/CF-23 into Cover Feeder

the projections at both side on the top of Connector
AC-6000/AC-8000S/AC-8300.
Fix LH-side L-metal with screw.
Fix Screw and
Projections at
Both Sides

Setscrew Auxiliary Plate

3. Tilt the upper feeder and lay the lower

feeder in flat level with auxiliary plate
which must be fixed with 2 setscrews as
shown in the drawing at right.

4. All operation timings and controls of

CF-20 or CF-23 unison with AC-6000/AC-
8000S/AC-8300 can be done only by
connecting connector.

54