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Revision 4.0
Staple Finisher-AA1/Booklet
Finisher-AA1
Service Manual

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Table of Contents

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   Summary of Contents for Canon Staple Finisher-AA1

  • Page 1 Revision 4.0 Staple Finisher-AA1/Booklet Finisher-AA1 Service Manual...
  • Page 2 When changes occur in applicable products or in the contents of this manual, Canon will release technical information as the need arises. In the event of major changes in the contents of this manual over a long or short period, Canon will issue a new edition of this manual.
  • Page 3 Introduction Symbols Explanation Symbols Explanation Disconnect the connector. Connect the power cable. Connect the connector. Disconnect the power cable. Remove the cable/wire from the Turn on the power. cable guide or wire saddle. Install the cable/wire to the cable Turn off the power. guide or wire saddle.
  • Page 4: Table Of Contents

    Contents Contents Safety Precautions....................1 Notes Before Servicing........................2 Points to Note at Cleaning........................2 Notes On Assembly/Disassembly....................... 2 Notes on Assembly/Disassembly......................2 Points to Note when Tightening a Screw....................2 1. Product Overview.....................4 Features.............................. 5 Features...............................5 Specifications............................6 Finisher..............................6 Staple Unit............................8 Staple-Free Binding Unit........................10 Saddle Stitcher Unit (Booklet Finisher)....................11 Buffer Pass Unit..........................
  • Page 5 Contents Outline............................... 46 Stacking Operation..........................47 Alignment/Shifting Operation........................50 Staple Operation..........................52 Staple-free Binding Operation......................55 Stack Delivery Operation........................58 Saddle Stitcher Unit...........................59 Outline ...............................59 Configuration............................60 Basic Operation..........................61 Stacking Operation..........................62 Paper Stack Feed Operation........................64 Stitch Operation..........................65 Paper Folding/Delivery Operation......................65 Buffer Pass Unit..........................
  • Page 6 Contents Removing the Grate-Shaped Lower Guide....................96 Removing the Swing Unit........................97 Removing the Processing Tray......................102 Removing the Staple Drive Unit......................103 Removing the Saddle Delivery Tray....................104 Removing the Saddle Unit......................... 105 Removing the Pushing Unit........................106 Removing the Buffer Pass Upper Unit....................107 Removing the Static Eliminator (Upper/Lower Escape Delivery Unit).............108 Removing the Stapler Unit.........................
  • Page 7 Contents 5. Adjustment....................142 Overview............................143 Service Mode............................143 Basic Adjustment Items........................146 Adjustments When Replacing Parts Items...................147 Other..............................147 Basic Adjustment..........................148 Overview............................148 Adjusting the Paper Alignment......................149 Adjusting the Staple Position......................158 Adjusting the Fold Position ........................162 Adjusting the Saddle Stitch ....................... 167 Adjustments When Replacing Parts....................173 Phase Alignment When Installing the Stack Tray Drive Belt..............
  • Page 8 Contents Jam Label / Saddle Caution Language Label (Booklet Finisher only)............ 208 Tray Setting Labels........................... 208 Making Adjustments........................209 Making Check and Adjustment of the Height..................209 Making Check and Adjustment of the Tilt.................... 210 Making Checks After Completion of Adjustments.................212 Making Checks After Completion of Installation Work..............
  • Page 9: Safety Precautions

    Safety Precautions Notes Before Servicing......2 Points to Note at Cleaning....2 Notes On Assembly/Disassembly..2...
  • Page 10: Notes Before Servicing

    Safety Precautions Notes Before Servicing CAUTION: At servicing, be sure to turn off the power source according to the specified steps and disconnect the power plug. CAUTION: Do not turn off the power switch when downloading is under way. Turning off the main power switch while downloading is under way can disable the machine.
  • Page 11 Safety Precautions The recommended torque value is shown below as a reference value. Type of Screws RS tight W Sems Binding Fastened member Metal Resin Metal Resin Metal Resin Metal Resin Tightening Approx. Approx. Approx. Approx. Approx. Approx. Approx. Approx. torque (N*m) Approx.
  • Page 12: Product Overview

    Product Overview Features..........5 Specifications........6 Names of Parts........14 Optional Configuration ....... 20...
  • Page 13: Features

    1. Product Overview Features Features • The main unit size has been reduced to allow installation in smaller space. • The optional puncher unit can be installed in the finisher. • Paper shift mechanism is incorporated into the escape tray delivery area allowing the shift sort stacking in the stack tray and the upper/lower escape trays.
  • Page 14: Specifications

    1. Product Overview Specifications Finisher Item Specifications Remarks Stacking method Stack tray: up and down moving type Escape tray: fixed tray Stacking orienta- Face up , face down tion Paper size Feed direction: 139.7 to 457.2 mm Cross feed direction: 98.0 to 320.0 mm Alignment stacking Feed direction: 182.0 to 432.0 mm size...
  • Page 15 1. Product Overview Item Specifications Remarks Stacking capacity Stack tray [Non sort/shift sort mode] - The stacking capaci- (without folding - Plain paper ties are estimates when sheets) Small size: Height 423 mm or less (equivalent to 3,000 sheets) converting weight to (when saddle is used: Height 216 mm or less (equivalent to number of 81.4 g/m2 1,500 sheets))
  • Page 16: Staple Unit

    1. Product Overview Staple Unit Item Specifications Remarks Stapling method Punching by rotating cam Flat clinch Stapling paper size Feed direction: 182 mm to 431.8 mm Cross feed direction: 210 mm to 297 mm 1-point stapling, 2-points stapling A3, A4, A4R, B4, B5, 11 × 17, LGL, LTR, LTRR, EXEC, 8K, 16K Stapling capacity Paper Small size...
  • Page 17 1. Product Overview • Staple Position - Front 1-point stapling (45 deg): A3, A4, B4, B5, 11×17, LTR, EXEC, 8K, 16 K 5.0 ± 2.0 mm - Front 1-point stapling (30 deg): A4R, LGL, LTRR 5.0 ± 2.0 mm - Rear 1-point stapling (45 deg): A3, A4, B4, B5, 11×17, LTR, EXEC, 8K, 16K 5.0 ±...
  • Page 18: Staple-free Binding Unit

    1. Product Overview - 2-point stapling : A3, A4, A4R, B4, B5, 11×17, LGL, LTR, LTRR, EXEC, 8K, 16K Paper Size Interval A3, A4 83 ± 4.0 mm 203 ± 4.0 mm 5.0 ± 2.0 mm 120 mm B4, B5 63 ±...
  • Page 19: Saddle Stitcher Unit (booklet Finisher)

    1. Product Overview • Binding position - Rear 1-point binding (30 deg) 13.5 ± 2.0 mm 3.0 mm or less Delivery direction Saddle Stitcher Unit (Booklet Finisher) Item Specifications Remarks Stacking orien- Fixed folding stack tray tation Stapling meth- Vertically separated, semi-flat clinch, stapling at two positions in the middle Folding meth- Roller pressure 2-fold Fold position...
  • Page 20: Buffer Pass Unit

    1. Product Overview • Staple Position Feed direction Stapling position 1.0 mm or less Folding position L1 ± 2.0 mm L2 ± 2.0 mm Paper Size 12"×18" 86.9 mm 206.9 mm 228.6 mm 83 mm 203 mm 210 mm 63 mm 183 mm 182 mm 39.5 mm...
  • Page 21: Others

    1. Product Overview Others Item Specifications Remarks Paper detection - Escape tray: not available - Processing tray: available - Stack tray: not available (near-empty function available) Control panel Available (manual staple button) Dimensions 537 mm (637 mm)* (W) × 969 mm (1,016 mm)* (H) × 623 mm (D) *: When the auxiliary tray is pulled out Weight - Staple finisher: about 30 kg...
  • Page 22: Names Of Parts

    1. Product Overview Names of Parts External View (Front) ■ Staple Finisher Part Name Part Name Upper Cover Unit Caster Cover (Front) Manual Staple Button Caster Cover (Rear) Front Cover Stack Tray Manual Staple Paper Inlet (Slit) Escape Tray Lower Front Cover ■...
  • Page 23: External View (rear)

    1. Product Overview Part Name Part Name Upper Cover Caster Cover (Front) Manual Staple Button Caster Cover (Rear) Front Cover Saddle Delivery Tray Manual Staple Paper Inlet (Slit) Stack Tray Lower Front Cover [10] Escape Tray ■ Buffer Pass Unit Part Name Part Name Buffer Pass Delivery Tray...
  • Page 24 1. Product Overview ■ Booklet Finisher Part Name Rear Cover ■ Buffer Pass Unit Part Name Buffer Pass Feed Inlet Port...
  • Page 25: External View (internal)

    1. Product Overview External View (Internal) ■ Staple Finisher Part Name Front Inner Cover ■ Booklet Finisher Part Name Part Name Front Inner Cover Saddle Unit...
  • Page 26: Cross Section

    1. Product Overview ■ Buffer Pass Unit Part Name Buffer Pass Feed Part Cross Section ■ Staple Finisher [10] [11] [12] [13] Part Name Part Name Escape Delivery Roller Escape Feed Roller 1 Escape Tray Pre-Processing Roller Upper Stack Delivery Roller [10] Buffer/Saddle Inlet Flapper Lower Stack Delivery Roller...
  • Page 27 1. Product Overview ■ Booklet Finisher [11] [12] [13] [14] [15] [16] [17] [18] [10] [19] Part Name Part Name Escape Delivery Roller [11] Escape Feed Roller 1 Escape Tray [12] Pre-Processing Roller Upper Stack Delivery Roller [13] Buffer/Saddle Inlet Flapper Lower Stack Delivery Roller [14] Escape Inlet Flapper...
  • Page 28: Optional Configuration

    1. Product Overview Optional Configuration This equipment can incorporate a puncher unit (option). Buffer Pass Unit Puncher Unit Staple Finisher Puncher Unit Booklet Finisher...
  • Page 29: Technical Explanation

    Technical Explanation Basic Configuration......22 Controls..........25 Basic Operation........26 Feeding Unit........31 Stack/Escape Tray Unit.......40 Processing Tray Unit......46 Saddle Stitcher Unit......59 Buffer Pass Unit........67 Jam Detection........69 Power Supply........73 Upgrading ...........74...
  • Page 30: Basic Configuration

    2. Technical Explanation Basic Configuration Component Configuration The components of this finisher are organized into 5 major blocks ; Buffer Pass Unit, Feed Unit, Processing Unit, Stack Tray Unit and Saddle Stitcher Unit. • Staple Finisher Tray Unit Feed Unit Buffer Pass Unit Processing Tray Unit •...
  • Page 31: Overview Of The Electrical Circuitry

    2. Technical Explanation Overview of the Electrical Circuitry The finisher’s sequence of operation is controlled by the finisher controller PCB. The finisher controller PCB is a microprocessor (CPU), and is used for communication with the host machine (serial) in addition to controlling the operation sequence of the finisher and buffer pass unit.
  • Page 32 2. Technical Explanation <Related service mode> (Lv.1) COPIER > DISPLAY > VERSION > SORTER (Lv.1) COPIER > DISPLAY > VERSION > SDL-STCH <Related error code> E503-0021:Error in communication between the Finisher and Saddle Stitcher E503-0022:Error in communication between the Finisher and Saddle Stitcher E503-0041:Error in communication between the Finisher and Buffer Pass E503-0042:Error in communication between the Finisher and Buffer Pass E503-0061:Error in communication between the IC of Finisher Controller PCB...
  • Page 33: Controls

    2. Technical Explanation Controls Controls Item Reference Basic Operation Outline “ Outline” on page 26 Feeding Unit Outline “Outline” on page 31 Basic Operation “Basic Operation” on page 32 Feed Switch Operation “Feed switch operation” on page 33 Shift Operation “Shift Operation”...
  • Page 34: Basic Operation

    2. Technical Explanation Basic Operation Outline Basic operations of this finisher are described below. ■ During stack tray delivery 1. The paper delivered from the host machine is fed by the inlet roller, pre-processing roller, and stack delivery roller. Pre-Processing Roller Upper Stack Delivery Roller Inlet Roller Lower Stack Delivery Roller...
  • Page 35 2. Technical Explanation 4. The operations described in steps 1 to 3 are repeated for each sheet to stack the sheets on the processing tray. 5. The stacked sheets are stapled and binded (only in staple mode or staple-free binding mode). Stapler Unit Staple-Free Binding Unit 6.
  • Page 36 2. Technical Explanation ■ During escape tray delivery 1. The paper delivered from the host machine is fed by the inlet roller, escape inlet flapper, escape feed roller, escape delivery roller. Escape Feed Roller Escape Inlet Flapper Escape Delivery Roller Inlet Roller 2.
  • Page 37 2. Technical Explanation 2. The paper is switched back and fed to the saddle stitcher unit and buffer path unit by the buffer/saddle inlet flapper and buffer/ saddle inlet roller. Pre-Processing Roller Buffer/Saddle Inlet Flapper Buffer/Saddle Inlet Roller Buffer Pass (Paper Stacking) To Saddle Stitcher Unit ■...
  • Page 38 2. Technical Explanation 4. The paper is stitched (only in booklet mode). Stitcher Unit Saddle Gripper Saddle Paper End Stopper 5. After the paper is folded by the paper pushing plate and paper folding roller, it is delivered on to the saddle delivery tray by the saddle delivery roller.
  • Page 39: Feeding Unit

    2. Technical Explanation Feeding Unit Outline The feeding unit feeds the paper received from the host machine to the stack tray, escape tray, or the saddle stitcher unit according to the instructions from the finisher controller PCB. Five sensors are provided along the paper feed path to detect the paper feed state and jam. Finisher Controller PCB M103 M106...
  • Page 40: Basic Operation

    2. Technical Explanation Basic Operation The feeding unit uses the following 3 sequences of operation: [1] Feed switch operation Three flappers are used to feed the paper to the stack tray (processing tray), escape tray, or the saddle stitcher unit (buffer path unit).
  • Page 41: Feed Switch Operation

    2. Technical Explanation Feed switch operation This equipment feeds the paper received from the host machine to the stack tray (processing tray), escape tray, or saddle delivery tray (saddle stitcher unit). The feed path is switched by two flappers: escape inlet flapper and buffer/ saddle inlet flapper. The home position is detected by the flapper HP sensor (PS105) .
  • Page 42: Shift Operation

    2. Technical Explanation ■ Paper feed to the escape tray - Escape Inlet Flapper: ON - Buffer/Saddle Inlet Flapper: OFF - Flapper HP Sensor (PS105): OFF Flapper HP Sensor (PS105) Escape Inlet Flapper Buffer/Saddle Inlet Flapper ■ Paper feed to the saddle delivery tray (saddle stitcher unit) - Buffer/Saddle Inlet Flapper: ON - Flapper HP Sensor (PS105): OFF Flapper HP Sensor (PS105)
  • Page 43 2. Technical Explanation The relationship between operation modes and shift positions is summarized in the following table: Mode Paper Shift position Non-Sort Paper width: 98mm to 320 mm Center reference Paper length: 139.7 mm to 457.2 mm Transparency, postcard, label, tracing paper, tab paper (paper leading edge tab) Shift-sort Paper width: 220 mm to 290 mm...
  • Page 44 2. Technical Explanation • When the paper width is 220 mm to 290 mm and paper length is 182 mm to 431.8 mm - Front shift Escape Delivery Roller 30mm Paper - Rear shift Escape Delivery Roller 30mm Paper...
  • Page 45: Buffer Operation

    2. Technical Explanation • When the paper width is less than 290 mm or more than 297 mm and paper length is less than 182 mm or more than 431.8 - Front shift Escape Delivery Roller 25mm Paper - Rear shift Escape Delivery Roller 25mm Paper...
  • Page 46 2. Technical Explanation ■ Buffer Operation 1. The trailing edge of the paper fed by the host machine is detected by the input sensor (PS101). The paper is fed for a specified amount where it stops. M104 Flapper HP Sensor (PS105) Buffer/Saddle Inlet Flapper Inlet Sensor (PS101)
  • Page 47 2. Technical Explanation 3. The flapper motor (M104) is driven to switch the buffer/saddle inlet flapper. The paper stored in the buffer and the paper received from the host machine are placed on top of each other but shifted by a specified amount and fed. - If one sheet of paper is stored in the buffer, the overlapped sheets are fed to the processing tray unit as they are.
  • Page 48: Stack/escape Tray Unit

    2. Technical Explanation Stack/Escape Tray Unit Outline This equipment has a stack tray and two escape trays. The escape trays are fixed in place. The stack tray moves up and down according to the instructions from the finisher controller PCB. The stack/escape tray unit has a sensor for detecting the paper surface of the stack tray unit, five sensors for detecting whether the paper delivered in the tray is full, and two sensors for detecting the position of the stack tray.
  • Page 49: Stack Tray Up And Down Movement

    2. Technical Explanation Stack Tray Up and Down Movement The finisher controller PCB drives the stack tray shift motor (M105) to move the stack tray up and down via the belt. The stack tray HP sensor (PS106) detects the home position of the stack tray. The stack tray upper limit sensor (PS110) detects the upper limit position of the stack tray.
  • Page 50: Stack Tray Delivery Paper Surface Detection, Paper Full

    2. Technical Explanation Stack Tray Delivery Paper Surface Detection, Paper Full The surface position of the paper delivered in the stack tray is detected by the stack tray paper surface sensors (PBA101, PBA102,PBA103). The surface of the paper delivered in the stack tray is detected by using the stack tray paper surface sensor (upper and lower) (light-receiving) (PBA102, PBA103) to detect the on/off state of the LED light emitted from the stack tray paper surface sensor (light-emitting) (PBA101).
  • Page 51 2. Technical Explanation Note that this equipment does not have a paper sensor on the stack tray. Therefore, if the stack tray HP sensor (PS106) is on when the stack tray paper surface sensor detects the paper surface (top surface of the tray), this equipment decides that the paper in the stack tray is near empty.
  • Page 52 2. Technical Explanation Stack Tray Upper Limit sensor (PS110) Stack Tray HP Sensor (PS106) Stack Tray Paper Surface Sensor (light-receiving) Stack Tray Full Sensor 1 (PS107) Stack Tray Full Sensor 2 (PS108) Stack Tray Full Sensor 3 (PS109) Sensor name Role Stack Tray Full Sensor 1 (PS107) Paper full detection of large-size coated paper...
  • Page 53: Escape Tray Paper Full Detection

    2. Technical Explanation Escape Tray Paper Full Detection Paper full detection on the escape tray is performed using the escape tray full sensor (PS113). When the escape tray full sensor (PS113) is on, it is determined that the paper in the escape tray is full, and paper feed operation is stopped. Paper Full Detection Sensor Flag Paper Upper/Lower Escape Delivery Roller...
  • Page 54: Processing Tray Unit

    2. Technical Explanation Processing Tray Unit Outline The processing tray unit aligns, shifts, and staples the delivered paper, and then delivers the paper stack onto the stack tray. Note that alignment is not performed in the processing tray unit if shifting, stapling, or staple-free binding is not performed. (However, alignment is performed for 2-sided print of A3 and B4 sheets weighing less than 64 g/m2.) Rear Tray Auxiliary Guide Paper End Pushing Guide...
  • Page 55: Stacking Operation

    2. Technical Explanation Stacking Operation The paper delivered from the pre-processing roller is stacked on the processing tray and aligned in the feed direction. How paper is delivered from the pre-processing roller and stacked on the processing tray is described below. Paper End Pushing Guide Paddle Clutch (CL103)
  • Page 56 2. Technical Explanation 2. The stack delivery/paddle motor (M103) drives, and the paddle clutch (CL103) turns on. The paddle is rotated (once for small size, twice for large size) and pulls in the paper into the processing tray unit. Further, return roller lift motor (M111) is driven, and stack delivery/paddle motor (M103) is used for rotation.
  • Page 57 2. Technical Explanation 3. The paper end pushing guide motor (M112) and return roller lift motor (M111) are driven to lift the paper end pushing guide and return roller. Then the front/rear alignment motors (M107/M108) are driven to move the front/rear alignment plate so that the paper stacked in the processing tray is aligned in the cross feed direction.
  • Page 58: Alignment/shifting Operation

    2. Technical Explanation <Related service mode> • SORTER > ADJUST > RBLT-PRS: Adjusting the height of the return belt 1 • SORTER > ADJUST > RBLT-PS2: Adjusting the height of the return belt 2 • SORTER > ADJUST > RBLT-PS3: Adjusting the height of the return belt 3 <Related error code>...
  • Page 59 2. Technical Explanation The relationship between operation modes and shift positions is summarized in the following table: Operation Paper Shift position Remarks Mode Non sort 2-sided print of A3 and B4 sheets weighing less Center reference Paper other than those on the left is than 64 g/m2 not stacked and passed through.
  • Page 60: Staple Operation

    2. Technical Explanation <Related error code> • E530-8001: Front Alignment Motor error • E530-8002: Rear Alignment Motor error • E537-8001: Front Alignment Motor error • E530-8002: Rear Alignment Motor error Staple Operation ■ Outline In staple operation, the specified number of sheets of paper (50 sheets max.) is stapled by the stapler unit. The staple position varies depending on the staple mode.
  • Page 61 2. Technical Explanation • Manual stapling Paper Stapling Position Stapler Unit • Front 1-point stapling (45 deg) Paper Stapling Position Stapler Unit • Front 1-point stapling (30 deg) Paper Stapling Position Stapler Unit...
  • Page 62 2. Technical Explanation • 2-point stapling Stapling Position Paper Stapler Unit • Rear 1-point stapling (30 deg) Paper Stapling Position Stapler Unit • Rear 1-point stapling (45 deg) Paper Stapling Position Stapler Unit ■ Stapler Unit Stapling occurs when the cam driven by the staple motor (M115) rotates once. The cam's home position is detected by the staple HP sensor (PS125).
  • Page 63: Staple-free Binding Operation

    2. Technical Explanation The presence of the staple cartridge and the presence of the staples in the staple cartridge are detected by the staple sensor (PS127). Whether the staple in the staple cartridge is pushed out to the leading edge of the cartridge is detected by the staple edging sensor (PS126).
  • Page 64 2. Technical Explanation Note that the staple-free binding unit is shifted by the stapler shift motor (M114) to the front or rear in sync with the stapler unit. When stapling by the stapler unit is taking place, the staple-free binding unit is stored in the rear. Staple-free Binding Motor (M116) Staple-free Binding Unit Staple-free Binding Motor...
  • Page 65 2. Technical Explanation ■ Staple-Free Binding Unit When the staple-free binding motor (M116) drives and the cam rotates once, the binding unit pinches the paper. The wave-shaped upper teeth and lower teeth of the binding unit bite the paper to bind it. The cam rotation status is detected by the staple-free binding HP sensor (PS129) to detect the home position of the binding unit.
  • Page 66: Stack Delivery Operation

    2. Technical Explanation Stack Delivery Operation The paper stacked in the processing tray is fed toward the stack tray by the paper end assist guide and delivered to the stack tray by the stack delivery roller. The upper stack delivery roller is used for this purpose. During this process, the swing unit including the upper stack delivery roller is controlled so that it is positioned at the appropriate location according to the thickness and type of the delivered paper stack.
  • Page 67: Saddle Stitcher Unit

    2. Technical Explanation Saddle Stitcher Unit Outline The saddle stitcher unit stitches and folds paper according to the instructions from the saddle stitcher controller PCB and delivers the paper to the saddle delivery tray. Three sensors are provided along the paper feed path to detect the paper feed state and jam.
  • Page 68: Configuration

    2. Technical Explanation Saddle Stitcher Controller PCB PS201 PS203 PS202 [1] Saddle Delivery Sensor detection signal PS203 Saddle Delivery Sensor [2] Saddle Processing Tray Paper Sensor detection signal PS202 Saddle Processing Tray Paper Sensor [3] Saddle Inlet Sensor detection signal PS201 Saddle Inlet Sensor Configuration...
  • Page 69: Basic Operation

    2. Technical Explanation Name Role Paper Folding Roller Folds paper stacks in half by gripping them and feeding them. Paper Pushing Plate Pushes the center area of paper stacks to feed them to the paper folding roller unit. Stitcher Unit Stitches at two locations at the center of paper stacks.
  • Page 70: Stacking Operation

    2. Technical Explanation Stacking Operation 1. The saddle stitcher controller PCB drives the saddle paper end stopper motor (M206) to move the saddle paper end stopper according to the paper size. Then, it drives the saddle alignment motor (M203) to move the saddle alignment plate to the paper width +10 mm position.
  • Page 71 2. Technical Explanation 3. The saddle alignment motor (M203) drives to operate the saddle alignment plate. The saddles is processed, and the paper stacked in the tray is aligned in the cross feed direction. M203 Rear Saddle Front Saddle Alignment Plate Alignment Plate Paper 4.
  • Page 72: Paper Stack Feed Operation

    2. Technical Explanation Paper Stack Feed Operation 1. The saddle gripper motor (M205) drives causing the saddle gripper via the gear and link to grip the trailing edge of the paper stack in the saddle processing tray. Then the saddle paper end stopper motor (M206) drives to raise the saddle paper end stopper and feeds the paper stack to the stitching position.
  • Page 73: Stitch Operation

    2. Technical Explanation Stitch Operation 1. After the paper stack in the saddle processing tray is fed to the stitching position, the saddle stitcher motor (M208) drives causing the stitcher unit to stitch two locations: front side and rear side. Stitcher Unit <Related service mode>...
  • Page 74 2. Technical Explanation 2. The saddle delivery motor (M207) drives causing the saddle delivery roller to rotate. This delivers the folded paper stack to the saddle delivery tray. Saddle Delivery Tray Saddle Delivery Roller M207 <Related service mode> • (Lv.1) SORTER > ADJUST > SDL-FLD: Adjusting the folding position of the saddle stitcher •...
  • Page 75: Buffer Pass Unit

    2. Technical Explanation Buffer Pass Unit Overview The buffer pass unit passes the paper feeding from the host machine to the finisher. Buffer pass feed motor (M301) controls the feed paper speed in the buffer pass unit according to the command from the finisher controller PCB.
  • Page 76 2. Technical Explanation FM201 FM202 Symbol Part Name Function Error Code FM201 Buffer Pass Power Supply Cooling Cooling the temperature on the buffer E551-0011 pass power supply PCB. E551-0012 FM202 Buffer Pass Cooling Fan Cooling the feed part in the buffer pass E551-0013 unit.
  • Page 77: Jam Detection

    2. Technical Explanation Jam Detection Outline The finisher is equipped with the following sensors to check whether paper is present and whether the stapler is operating normally. Further, it is equipped with sensors and switches to detect the open or closed state of the front cover. •...
  • Page 78: Jams

    2. Technical Explanation • Booklet Finisher PS111 PS102 PS101 PS130 PS103 PS114 PS104 PS128 SW101 PS129 PS125 PS201 PS203 PS215 PS202 Symbol Part Name Symbol Part Name PS101 Inlet Sensor PS129 Staple-free Binding HP Sensor PS102 Delivery Sensor PS130 Staple-free Binding Motor Clock Sensor PS103 Buffer Sensor SW101...
  • Page 79 2. Technical Explanation Jam type Sensor Jam description Inlet sensor delay PS101 When the inlet sensor (PS101) does not detect the paper even when the paper is fed the specified distance after receiving a paper delivery signal from the host machine. Delivery sensor delay PS102 When the delivery sensor (PS102) does not detect the paper even when the paper...
  • Page 80 2. Technical Explanation Jam type Sensor Jam description Staple-free binding error jam (sta- PS130 When the staple-free binding motor clock sensor (PS130) cannot detect the encoder ple-free binding motor clock sen- rotation within the specified time after the staple-free binding motor (M116) begins sor error) driving.
  • Page 81: Power Supply

    2. Technical Explanation Power Supply Power Supply Route The 24V are supplied to the buffer pass controller PCB through the buffer pass relay PCB and the buffer pass power supply PCB in the buffer pass unit when the host machine is turned ON. The 24V is supplied from the buffer pass unit to the finisher controller PCB.
  • Page 82: Upgrading

    2. Technical Explanation Upgrading When upgrading the firmware of the finisher controller PCB, saddle stitcher controller PCB and the Buffer pass unit controller PCB, upgrade from the host machine. (Refer to the service manual for the host machine as to the detail.)
  • Page 83: Periodical Service

    Periodical Service Periodic Servicing Tasks.....76...
  • Page 84: Periodic Servicing Tasks

    3. Periodical Service Periodic Servicing Tasks The finisher does not have any items that need to be periodically serviced.
  • Page 85: Parts Replacement And Cleaning

    Parts Replacement and Cleaning Removing this Machine.......78 List of Parts......... 80 External/Internal Covers......94 Main Parts........... 96 PCB...........116 Sensor..........121 Clutch/ Solenoid........ 122 Motors..........123 Switches ...........129 Other Parts ........131...
  • Page 86: Removing This Machine

    4. Parts Replacement and Cleaning Removing this Machine Removing the Buffer Pass Unit 1. Remove the Latch Plate [1]. Removing the Finisher • 5 Screws [2] 1. Open the Front Cover [1], and remove the 1 Screw [2]. 2. Open the Buffer Pass Upper Unit, and release the Lock [2].
  • Page 87 4. Parts Replacement and Cleaning 3. Remove the 2 Connectors [1].
  • Page 88: List Of Parts

    4. Parts Replacement and Cleaning List of Parts External / Internal Covers Name Refer to Rear Cover “ Removing the Rear Cover” on page 94 Upper Cover Unit Front Cover “ Removing the Front Cover” on page 94 Lower Front Cover “...
  • Page 89: Main Units/parts

    4. Parts Replacement and Cleaning Main Units/Parts...
  • Page 90 4. Parts Replacement and Cleaning [10] [11] [12] Name Refer to Escape Tray “Removing the Escape Tray” on page 96 Stack Tray “ Removing the Stack Tray” on page 96 Grate-Shaped Lower Guide “ Removing the Grate-Shaped Lower Guide” on page 96 Swing Unit “...
  • Page 91 4. Parts Replacement and Cleaning [10] Name Main Unit Refer to Static Eliminator (Escape Delivery Unit) Product Configuration “ Removing the Static Eliminator (Upper/Lower Escape Delivery Unit)” on page 108 Staple Unit Product Configuration “ Removing the Stapler Unit” on page 108 Saddle Stitcher Unit Saddle Unit “...
  • Page 92: List Of Clutches

    4. Parts Replacement and Cleaning Name Main Unit Refer to Static Eliminator (Stack Tray Unit) Product Configuration “ Removing the Static Eliminator (Stack tray Unit)” on page 112 Escape Feed Clutch Product Configuration “ Removing the Escape Feed Clutch (CL101)” on page Static Eliminator (Saddle Delivery Unit) Saddle Unit “...
  • Page 93 4. Parts Replacement and Cleaning M113 M110 M108 M107 M101 M103 M109 M102 M112 M111 M105 M116 (M115) M114 M106 M104 M202 (M208) M203 M207 M206 M204 M201 M205 Name Main Unit Refer to M101 Inlet Feed Motor Product Configuration M102 Pre-processing/Buffer Motor Product Configuration...
  • Page 94 4. Parts Replacement and Cleaning Name Main Unit Refer to M107 Front Alignment Motor Processing Tray Unit “ Removing the Front Alignment Motor (M107)” on page M108 Rear Alignment Motor Processing Tray Unit “ Removing the Rear Alignment Motor (M108)” on page M109 Tray Auxiliary Guide Motor Processing Tray Unit...
  • Page 95: List Of Sensors

    4. Parts Replacement and Cleaning List of Sensors • Staple Finisher • Booklet Finisher PS114 PS112 PS110 PS123 PS116 PS106 PS118 PS111 PS105 PS113 PS115 PBA101 PBA102 PS119 PS117 PS122 PBA103 PS102 PS121 PS130 PS101 PS129 PS107 PS124 PS128 PS103 PS108 PS109 PS104...
  • Page 96 4. Parts Replacement and Cleaning Name Main Unit Refer to PS105 Flapper HP Sensor Product Configuration PS106 Stack Tray HP Sensor Product Configuration PS107 Stack Tray Full Sensor 1 Product Configuration PS108 Stack Tray Full Sensor 2 Product Configuration PS109 Stack Tray Full Sensor 3 Product Configuration PS110...
  • Page 97: List Of Switches/ Fans

    4. Parts Replacement and Cleaning PI201 PI203 PI202 Name Main Unit Refer to PI201 Buffer Pass Inlet Sensor Product Configuration PI202 Buffer Pass Outlet Sensor Product Configuration PI203 Buffer Pass Open/Closed Sensor Product Configuration NOTE: Check the operation of the part in the following service mode: Service Mode >...
  • Page 98 4. Parts Replacement and Cleaning SW102 SW103 SW101 FM101 Name Main Unit Refer to SW101 Front Cover Switch Product Con- “ Removing the Front Cover Switch (SW101)” on page 129 figuration SW102 Swing Guide Safety Switch Product Con- “ Removing the Swing Guide Safety Switch (SW102)” on page 129 figuration SW103 Manual Staple Switch Product Con-...
  • Page 99: List Of Pcbs

    4. Parts Replacement and Cleaning Name Main Unit Refer to FM202 Buffer Pass Cooling Fan Product Configuration NOTE: Check the operation of the fan in the following service mode: Service Mode > SITUATION > Parts Check NOTE: Check the operation of the switch in the following service mode: Service Mode >...
  • Page 100 4. Parts Replacement and Cleaning Name Main Unit Refer to PCB10 Stapler unit relay PCB Stapler Unit • Buffer Pass Unit PCB201 PCB202 PCB203 Name Main Unit Refer to PCB201 Buffer Pass Controller PCB Product Configura- “Removing the Buffer Pass Controller PCB (PCB201)” on tion page 118 PCB202...
  • Page 101: Other Parts

    4. Parts Replacement and Cleaning Other Parts Name Main Unit Refer to Escape Delivery Roll- Product Configura- “ Removing the Escape Delivery Roller” on page 131 tion Grate-shaped Guide Product Configura- “Removing the Grate-shaped Guide” on page 131 tion Return Roller Product Configura- “Removing the Return Roller”...
  • Page 102: External/internal Covers

    4. Parts Replacement and Cleaning 2. Remove the front cover [1]. External/Internal Covers Removing the Rear Cover ■ Procedure 1. Remove the rear cover [1]. • 2 screws [2] • 1 hook [3] Removing the Lower Front Cover ■ Procedure 1.
  • Page 103: Removing The Front Inner Cover

    4. Parts Replacement and Cleaning Removing the Front Inner Cover ■ Preparation 1. Remove the front cover. “ Removing the Front Cover” on page 94 ■ Procedure 1. Remove the face cover [1]. • 1 screw [2] NOTE: The face cover [1] is connected only to the staple finisher. 3.
  • Page 104: Main Parts

    4. Parts Replacement and Cleaning Main Parts Removing the Escape Tray ■ Preparation 1. Remove the front cover. “ Removing the Front Cover” on page 94 2. Remove the front inner cover. “ Removing the Front Inner Cover” on page 95 3.
  • Page 105: Removing The Swing Unit

    4. Parts Replacement and Cleaning ■ Procedure Removing the Swing Unit 1. Remove the grate-shaped lower guide. ■ Preparation • 2 screws [2] 1. Lower the stack tray. CAUTION: 2. Remove the front cover. Insert the claw[1] as shown in the figure for installation “...
  • Page 106 4. Parts Replacement and Cleaning 1. Remove the claw parts[1] of the plastic film sheet. 3. Remove the paper guides [1] [2]. • 6 claw parts • 1 screw [3] each • 1 spring [4] each CAUTION: Be careful not to forget hooking the spring [4]. 2.
  • Page 107 4. Parts Replacement and Cleaning 4. Process the harness [1] CAUTION: • 4 connectors [2] Check the phase positioning (left and right) of the Swing Guide for installation. “Phase Alignment When Installing the Swing Unit” on page 173 5. Remove the 1 gear [1], 2 E-ring [2], 2 shaft support [3], and straight 1 pin [4].
  • Page 108 4. Parts Replacement and Cleaning 8. Move the shaft [1] in about 5cm. 10. Remove the 3 clips [1] and 2 shaft support [2]. 9. Escape the pressure rack[3] and then remove the harness guide[1]. • 3 screws [2] 11. Remove the belts [1] [2] [3]. CAUTION: When removed the belt [3], paddle phase adjustment is necessary...
  • Page 109 4. Parts Replacement and Cleaning 12. Remove the swing unit [1] from hook [2]. 14. Avoid three shaft [1], and remove the swing unit [2]. • 2screws [3] 15. Remove the 2 clips [1] and the 2 rear end guides [2] from the swing unit [1].
  • Page 110: Removing The Processing Tray

    4. Parts Replacement and Cleaning 2. Remove the 1 belt [1], 1 clip [2], and 1 shaft support Removing the Processing [3]. Tray ■ Preparation 1. Lower the stack tray. 2. Remove the stack tray. “ Removing the Stack Tray” on page 96 3.
  • Page 111: Removing The Staple Drive Unit

    4. Parts Replacement and Cleaning CAUTION: Attach the processing tray unit first or the paper guide[2] is not attached as the processing tray unit interferes with attaching it. Spread the alignment plate[1] and then attach the paper guide[2] for installation. CAUTION: When replacing the Processing Tray, remove the coupling unit from the removed Processing Tray and...
  • Page 112: Removing The Saddle Delivery Tray

    4. Parts Replacement and Cleaning ■ Procedure CAUTION: Insert the projection[2] into the rear insertion[1] for 1. Turn the Dial [1] moving Staple Mount Unit [2] in installation. contact with the rear end, to move Staple-free Binding Unit for rear side. 2.
  • Page 113: Removing The Saddle Unit

    4. Parts Replacement and Cleaning 3. Remove the saddle unit [1]. Removing the Saddle Unit • 2 screws [2] • 4 hangers [3] ■ Preparation 1. Pull out the saddle unit (service position). “ Pulling Out the Saddle Unit (Service Position)” on page 2.
  • Page 114: Removing The Pushing Unit

    4. Parts Replacement and Cleaning Removing the Pushing Unit ■ Preparation 1. Pull out the saddle unit (service position). “ Pulling Out the Saddle Unit (Service Position)” on page 2. Remove the lower front cover. “ Removing the Lower Front Cover” on page 94 3.
  • Page 115: Removing The Buffer Pass Upper Unit

    4. Parts Replacement and Cleaning ■ Handling after replacement 1. When removed the pushing unit, phase alignment 5. Remove the saddle lower guide [1]. installing the paper folding roller. • 2 screws [2] “Phase Alignment When Installing the Paper Folding Roller”...
  • Page 116: Removing The Static Eliminator (upper/lower Escape Delivery Unit)

    4. Parts Replacement and Cleaning ■ Handling after parts replacement 1. Clear the parts counter. (LV1) COPIER > COUNTER > DRBL-2 > TRY-STC1 Removing the Stapler Unit ■ Preparation 1. Remove the front cover. “ Removing the Front Cover” on page 94 2.
  • Page 117: Removing The Saddle Stitcher Unit

    4. Parts Replacement and Cleaning • 2 wire saddles [1] • 1 connector [3] • 4 screws [4] ■ Handling after parts replacement 1. Clear the parts counter. (LV1) COPIER > COUNTER > DRBL-2 > FIN-STPR Removing the Saddle Stitcher Unit ■...
  • Page 118 4. Parts Replacement and Cleaning ■ Procedure 1. Turn Staple Dive Belt [2] moving Staple Unit [3] in contact with the rear end, to move Staple-free Binding Unit [1] for rear side. NOTE: In the case of moving Stapler Unit, it is better to move Alignment Plates for center to move Staple Unit smoothly.
  • Page 119 4. Parts Replacement and Cleaning 4. Remove the Staple-free Binding Unit's Support Plate 6. Remove the Cable Guide [1]. [1]. • 1 Wire Saddle [2] • 1 Clip [2] • 1 Shaft [3] 7. Remove the Rail Unit [1]. • 3 Screws [2] •...
  • Page 120: Removing The Static Eliminator (stack Tray Unit)

    4. Parts Replacement and Cleaning 3. Perform rear stapling once from the finisher controls. CAUTION: Rear stapling is performed to position the staple-free binding unit. If you do not perform this procedure, empty stapling or position error in staple-free stapling may occur.
  • Page 121: Removing The Paddle Unit

    4. Parts Replacement and Cleaning 3. Turn the paddle axis until the paddle[2] reaches to the guide[3]. ■ Handling after parts replacement 1. Clear the parts counter. NOTE: Turn the paddle axis by 180 degree furthermore when the (LV1) COPIER > COUNTER > DRBL-2 > SDL-STC claw[2] is still behind the paddle shaft.
  • Page 122: Removing The Lower Stack Delivery Roller Clutch (cl102)

    4. Parts Replacement and Cleaning Removing the Lower Stack Delivery Roller Clutch (CL102) ■ Preparation 1. Remove the rear cover. “ Removing the Rear Cover” on page 94 ■ Procedure 1. Remove the clutch [1]. • 1 connector [2] • 1 clip [3] CAUTION: Point to Note When Installing the Paddle •...
  • Page 123: Removing The Stack Tray Torque Limiter

    4. Parts Replacement and Cleaning 2. Remove the escape feed clutch [1]. 2. Remove the torque limiter [1]. • 1 shaft support [2] • 1 E-ring [2] each • 1 connector [3] • 1 gear [3] each ■ Handling after parts replacement 1.
  • Page 124: Pcb

    4. Parts Replacement and Cleaning 2. Remove the connectors and flexible cable. • 24 connectors • 1 flexible cable • 4 screws [1] Removing the Finisher Controller PCB (PCB101) ■ Handling before parts replacement 1. Before replacing the finisher controller PCB, back up the counter values of consumable parts and various adjustment values to the host machine in service mode.
  • Page 125 4. Parts Replacement and Cleaning If backup operation has not been performed 4. Remove the fan[1] from PCB. • 1 connector [2] • 4 claws [3] 1. Set the SW1 keys as shown below and press the SW2. CAUTION: When installing the Fan, match the arrows[4] for same direction.
  • Page 126: Removing The Saddle Stitcher Controller Pcb (pcb201)

    4. Parts Replacement and Cleaning If there is not the output of the "P-PRINT" 1. Set the SW1 keys as shown below and press the SW2. 2. Remove the PCB [1]. • 10 connectors [2] • 2 screws [3] • 2 PCB retainers [4] 2.
  • Page 127: Removing The Buffer Pass Power Supply Pcb (pcb203)

    4. Parts Replacement and Cleaning Removing the Buffer Pass Power Supply PCB (PCB203) ■ Preparation 1. Remove the Buffer Pass Unit. “Removing the Buffer Pass Unit” on page 78 ■ Procedure 1. Reverse the Buffer Pass Unit. 2. Remove the Buffer Pass Power Supply PCB [1]. •...
  • Page 128 4. Parts Replacement and Cleaning...
  • Page 129: Sensor

    4. Parts Replacement and Cleaning Sensor Removing the Delivery Sensor (PS102) ■ Preparation 1. Remove the rear cover. “ Removing the Rear Cover” on page 94 2. Remove the staple-free binding unit. “ Removing the Staple-Free Binding Unit” on page 109 ■...
  • Page 130: Clutch/ Solenoid

    4. Parts Replacement and Cleaning Clutch/ Solenoid Removing the Paddle Clutch (CL103) ■ Preparation 1. Remove the front cover. “ Removing the Front Cover” on page 94 2. Remove the front inner cover. “ Removing the Front Inner Cover” on page 95 ■...
  • Page 131: Motors

    4. Parts Replacement and Cleaning Motors Removing the Front Alignment Motor (M107) ■ Preparation 1. Lower the stack tray. Removing the Rear Alignment Motor (M108) ■ Preparation 2. Remove the stack tray. “ Removing the Stack Tray” on page 96 1.
  • Page 132: Removing The Tray Auxiliary Guide Motor (m109)

    4. Parts Replacement and Cleaning ■ Procedure 5. Remove the processing tray. “ Removing the Processing Tray” on page 102 1. Remove the motor [1]. ■ Procedure • 2 screws [2] • 1 connector [3] 1. Remove the motor unit [1]. •...
  • Page 133: Removing The Stapler Shift Motor (m114)

    4. Parts Replacement and Cleaning 3. Remove the grate-shaped lower guide. “ Removing the Grate-Shaped Lower Guide” on page 4. Remove the side covers (front and rear) [1] [2]. • 1 screw [3] each Removing the Stapler Shift Motor (M114) 5.
  • Page 134: Removing The Staple-free Binding Motor (m116)

    4. Parts Replacement and Cleaning 3. Remove the motor [1]. • 1 connector [2] • 2 screws [3] • 1 belt [4] 2. Remove the harness guide [1]. • 1 screw [2] • 2 claws [3] Removing the Staple-Free Binding Motor (M116) 3.
  • Page 135: Removing The Saddle Paper Pushing Plate/folding Motor (m204)

    4. Parts Replacement and Cleaning 4. Remove the motor. 2. Process the harness. • 1 Motor cover [1] • 2 connectors [1] • 1 spring [2] • 1 wire saddles [2] • 1screw [3] Removing the Saddle Paper 3. Remove the motor unit [1]. Pushing Plate/Folding Motor •...
  • Page 136: Removing The Saddle Delivery Motor (m207)

    4. Parts Replacement and Cleaning 3. Remove the motor unit [1]. Removing the Saddle Delivery • 1 spring [2] • 3 screws [3] Motor (M207) • 1 belt [4] ■ Preparation 1. Pull out the saddle unit (service position). “ Pulling Out the Saddle Unit (Service Position)” on page ■...
  • Page 137: Switches

    4. Parts Replacement and Cleaning Switches Removing the Front Cover Switch (SW101) ■ Preparation 1. Remove the front cover. “ Removing the Front Cover” on page 94 2. Remove the front inner cover. “ Removing the Front Inner Cover” on page 95 Removing the Swing Guide ■...
  • Page 138: Removing The Manual Staple Switch (sw103)

    4. Parts Replacement and Cleaning 2. Remove the switch [1]. • 1 connector [2] 3. Remove the switch PCB [1]. • 1 screw [2] • 1 connector [3] Removing the Manual Staple Switch (SW103) ■ Preparation 1. Remove the front cover. “...
  • Page 139: Other Parts

    4. Parts Replacement and Cleaning 2. Remove the front inner cover. Other Parts “ Removing the Front Inner Cover” on page 95 3. Remove the rear cover. Pulling Out the Saddle Unit “ Removing the Rear Cover” on page 94 (Service Position) 4.
  • Page 140 4. Parts Replacement and Cleaning 4. Remove the E-ring. • 2 E-rings [1] 2. Remove the drive steel plate [1]. • 4 screws [2] • 1 Reuse Band[3] CAUTION: When removing the drive support plate, the drive shaft[4] may drop. Be sure to hold the drive shaft[4]. 5.
  • Page 141 4. Parts Replacement and Cleaning 6. Remove the roller tensioner. 9. Remove the shaft support [1]. • 1 screw [2] 10. Pull out the escape delivery slave shaft[1] about 3cm for the arrow direction.([A]: Be sure not to remove 7. Remove the shaft support [1]. the shaft[1] from the front frame.) CAUTION: When pulling out the escape delivery slave shaft, the...
  • Page 142: Removing The Return Roller

    4. Parts Replacement and Cleaning 11. Until escape delivery roller[1] is removed from the slide drive holder[2], pull out the escape delivery roller[1] for the arrow direction. CAUTION: Since the escape delivery roller comes in contact with the sensor flag[3], be sure to escape the sensor flag[3]. NOTE: Since the escape delivery roller comes in contact with the sensor flag[2] and guide[3], be sure to escape the sensor...
  • Page 143: Removing The Swing Roller

    4. Parts Replacement and Cleaning 4. Remove the side covers (front and rear) [1] [2]. 2. Remove the return roller [2] from link part [1]. • 1 screw [3] each 5. Remove the processing tray. Removing the Swing Roller “ Removing the Processing Tray” on page 102 ■...
  • Page 144: Removing The Folding Roller

    4. Parts Replacement and Cleaning Removing the Folding Roller ■ Preparation 1. Remove the saddle unit.“ Removing the Saddle Unit” on page 105 2. Remove the saddle stitcher controller PCB. 4. Remove the swing roller (rear)[1] and remove the “ Removing the Saddle Stitcher Controller PCB gear [2].
  • Page 145 4. Parts Replacement and Cleaning 6. Remove the motor cover[1]. • 2 screws [2] 4. Remove the drive shaft assembly. • 1 E-ring [1] • 1 gear [2] • 1 straight pin [3] • 1 shaft support [4] 7. Remove the wire saddle. •...
  • Page 146 4. Parts Replacement and Cleaning 12. Remove the drive gear. 9. Remove the pushing plate drive unit[1]. • 2 gear • 4 screws [2] 13. Remove the gear of the folding roller(upper/lower). • 2 C-ring [2] • 2 gear [1] 10.
  • Page 147 4. Parts Replacement and Cleaning 14. Turn over the saddle unit. 15. Remove the rail fixation plate(front)[1]. • 4 screws [2] 17. Remove the delivery guide base [1]. • 2 screws [2] 18. Remove the saddle exit roller[1]. 16. Remove the saddle upper guide [1]. •...
  • Page 148 4. Parts Replacement and Cleaning 22. Remove the E-ring[1] and shaft support [2] 23. Remove the spring of the roller tensioner(front) [1]. 20. Remove the spring of the roller tensioner(rear) [1]. 24. Remove the bearing. • 2 C-ring [2] • 2 bearing [1] 21.
  • Page 149: Removing The Pushing Plate

    4. Parts Replacement and Cleaning CAUTION: When removing the pushing plate, be sure to check the fixation position(scale). 26. Spread the front frame to remove the folding roller[1] [2]. ■ Handling after parts replacement 1. If you remove or replace the pushing unit, perform phase adjustment of folding roller.
  • Page 150: Adjustment

    Adjustment Overview........... 143 Basic Adjustment......148 Adjustments When Replacing Parts. 173 Other..........184...
  • Page 151: Overview

    5. Adjustment Overview Service Mode In service mode, the finisher can perform the following adjustment, operation and inspection, and functional setting items. ■ Adjustment items Service Mode Items (SORTER > AD- Use case Remarks JUST) Adjusting the front 1-staple position STP-F1 When the front staple position is displaced.
  • Page 152 5. Adjustment Service Mode Items (SORTER > AD- Use case Remarks JUST) Adjusting the delivery speed at the STP-SPD When the paper stacking at staple mode or - When the value is decreased, staple mode staple-free binding mode is misalignment. the productivity is decreased.
  • Page 153 5. Adjustment Service Mode (SORT- Items Use case Remarks ER > FUNCTION) Clearing the parts counter counted by CNT-FCON When clearing the parts counter of the the finisher controller PCB Finisher. Removing the paper dust from the sta- FR-ST-RP When the performance of the staple- - The part counter value of ple-free binding unit free binding unit deteriorates.
  • Page 154: Basic Adjustment Items

    5. Adjustment Service Mode Items (SORTER > OP- Use case Remarks TION) Setting whether to limit the stack ca- TRY-STP When stacking papers beyond the maxi- When the stacking limit is pacity of the stapled or folded mum number of stapled copies/folded cleared, stacking capacity in- sheets sheets.
  • Page 155: Adjustments When Replacing Parts Items

    5. Adjustment Items Use case Refer to “Adjusting the Staple- Adjusting the Sta- Adjusting the Staple-Free Binding Po- When the staple-free binding position in Free Binding Position ” on ple Position sition the staple-free binding mode. page 161 If the fold position of the paper stack deliv- “Adjusting the Saddle Pa- Adjusting the Saddle Paper End Stop- ered from the saddle stitcher unit is...
  • Page 156: Basic Adjustment

    5. Adjustment Basic Adjustment Overview The basic function of this finisher has 4 major functions : Paper Alignment, Staple Position, Fold Position, Saddle Stitch Position. ■ Adjusting the Processing Tray Area In the case adjusting the processing tray area, adjust the paper alignment at first, and adjust the staple position. In the case adjusting the paper alignment, adjust skew and transport direction at first, and adjust front‐rear direction.
  • Page 157: Adjusting The Paper Alignment

    5. Adjustment Items Use case Refer to Adjusting the When the saddle stitch position in the sad- “Adjusting the Saddle Stitch Adjusting the Saddle Stitch Position Saddle Stitch dle stitch mode. Position ” on page 171 Adjusting the Paper Alignment ■...
  • Page 158 5. Adjustment 3. The alignment plate moves to position of the A4 width. 4. Set the A4 paper on the processing tray. 5. Enter the setting value, and then press OK key. 6. Check the adjustment movement of the alignment plate. 7.
  • Page 159 5. Adjustment 1. Adjust the center alignment by the following service modes. • SORTER > ADJUST > CENT-ALG Alignment Plate Feed Direction Alignment Plate Adjustment range: -50 to 50 (Unit: 0.1mm) As the value is incremented by 1, the standard position for the center alignment moves by 0.1 mm. +: Toward rear -: Toward front ■...
  • Page 160 5. Adjustment 1. Place paper in the processing tray unit, and push it against the processing tray stopper. Paper Paper End Retainer Paper End Retainer 2. Loosen the screws of the alignment plate (front and rear), adjust the alignment plate so that it is parallel with the paper,and then tighten the screws.
  • Page 161 5. Adjustment 4. Contact a sheet of paper with the front alignment plate to check the gaps between the alignment plate and a sheet of paper at [A] and [B] portion. In the case the gap is large, adjust the right-angle adjustment of alignment plate again.
  • Page 162 5. Adjustment ■ Adjusting Delivery of Staple Stack <Use case> • When the paper displacement occurs on the 1st to 2nd sheets or 2nd to 3rd sheets of buffered paper. Feed Direction Feed Direction <Procedure of adjustment> NOTE: After the setting value is changed, write the changed value in the service label. 1.
  • Page 163 5. Adjustment 2. In the case the paper displacement occurs after performing Step 1 adjustment, stop the buffer movement by the following service mode. • SORTER > OPTION > BUFF-SW = 1 CAUTION: Productivity is reduced in this mode. 3. In the case paper displacement occurs after performing Step 2, it is not buffer factor. Set 0 for the buffer adjustment value.
  • Page 164 5. Adjustment 1. Perform rear stapling as test print of 5 sheets in a bunch, check that the paper is fed by the return roller during output. Paper Return Roller • In the case the paper is fed by return roller Perform step 2 •...
  • Page 165 5. Adjustment 2. Perform rear stapling as test print of 5 sheets in a bunch again, check that the paper hit the Processing Tray Stopper during output. Paper Processing Tray Stopper • In the case the paper hit the processing tray stopper Perform step 3 •...
  • Page 166: Adjusting The Staple Position

    5. Adjustment 3. Adjust return roller height(65 sheets) by the following service mode. • SORTER > ADJUST > RBLT-PRS Return Roller Feed Direction Adjustment range: -50 to 100 (Unit: 0.1 degree) As the value is changed by 1, the height of the return belt changes by angle of 0.1 degree. +: Downward -: Upward Adjusting the Staple Position...
  • Page 167 5. Adjustment 1. Adjust the staple position by the following service modes. • Adjustment of front 1-stapling mode SORTER > ADJUST > STP-F1 • Adjustment of rear 1-stapling mode SORTER > ADJUST > STP-R1 • Adjustment of front 2-stapling mode. SORTER >...
  • Page 168 5. Adjustment 1. Mark the installation position of the stapler unit support plate. CAUTION: If returning its installation position to the original position, fix the stapler unit support plate by matching to the mark. Stapler Unit Mounting Plate 2. Loosen the two screws of the stapler unit support plate, adjust the stapler installation position by referring to the scale,and then tighten the screws.
  • Page 169 5. Adjustment ■ Adjusting the Staple-Free Binding Position <Use case> • When the staple-free binding position in the staple-free binding mode. Feed Direction <Procedure of adjustment> NOTE: After the setting value is changed, write the changed value in the service label. 1.
  • Page 170: Adjusting The Fold Position

    5. Adjustment Adjusting the Fold Position ■ Adjusting the Saddle Paper End Stopper Installation Angle <Use case> • If the fold position of the paper stack delivered from the saddle stitcher unit is skewed. Folding Position Feed Direction Folding Position Feed Direction...
  • Page 171 5. Adjustment <Procedure of adjustment> 1. Open the front cover [1], and then pull out the saddle stitcher unit [2] until it stops. 2. Push the plate spring (left/right) [2] and then pull the saddle stitcher unit [1] to the service position. 3.
  • Page 172 5. Adjustment ■ Adjusting the Fold Placement <Use case> • When misalignment occurs in feed direction. Folding Position Feed Direction Folding Position Feed Direction <Procedure of adjustment> CAUTION: In the case performing this adjustment, record user mode setting value before the adjustment. Input 0 for setting value and start the adjustment.
  • Page 173 5. Adjustment 2. Adjust the folding position by the following service mode. • SORTER > ADJUST > SDL-FLD NOTE: Folding position adjustment of thin paper In the case using thin paper, adjusting value is total amount values of SDL-FLD and SDL-FLD2. Adjsut SDL-FLD first, and adjust the staple position of thin paper by the following service mode.
  • Page 174 5. Adjustment <Procedure of adjustment> NOTE: After the setting value is changed, write the changed value in the service label. 1. Adjust the saddle alignment plate position by the following service modes. • SORTER > ADJUST > SDL-ALG Alignment Plate Alignment Plate Feed Direction Adjustment range: -20 to 20 (Unit: 0.1mm)
  • Page 175: Adjusting The Saddle Stitch

    5. Adjustment Adjusting the Saddle Stitch ■ Adjusting the Stitcher Unit Installation Position <Use case> • When the stitch positions of the front and rear sides become misaligned. • If you remove or replace the stitcher unit. Stapling Position Feed Direction Stapling Position Feed Direction <Procedure of adjustment>...
  • Page 176 5. Adjustment 1. Mark the installation position of the stitcher unit. NOTE: If returning its installation position to the original position, fix the stitcher unit by matching to the mark. Stitcher Unit...
  • Page 177 5. Adjustment 2. Loosen the four screws of the stitcher unit, adjust the installation position by referring to the scale, and then tighten the screws. NOTE: Normally, install so that the stitcher unit mark is aligned to the center of the support plate scale. Mark Stitcher Unit...
  • Page 178 5. Adjustment Fixing Screw Mark Fixing Screw Fixing Screw Stapling Position Stitcher Unit Feed Direction...
  • Page 179 5. Adjustment ■ Adjusting the Saddle Stitch Position <Use case> • When the saddle stitch position in the saddle stitch mode. Stapling Position Feed Direction Stapling Position Feed Direction <Procedure of adjustment> CAUTION: In the case performing this adjustment, record user mode setting value before the adjustment. Input 0 for setting value and start the adjustment.
  • Page 180 5. Adjustment 1. Adjust the saddle stitch position by the following service modes. • SORTER > ADJUST > SDL-STP NOTE: To adjust the staple position of Saddle Stitcher (when using the thin paper; the paper that the paper weight is less than 64 g/m2). To adjust the staple position of Saddle Stitcher (when using the thin paper;...
  • Page 181: Adjustments When Replacing Parts

    5. Adjustment Adjustments When Replacing Parts Phase Alignment When Installing the Stack Tray Drive Belt If you remove or replace the stack tray drive belt, align the phase of the belt installation position. ■ Procedure of Adjustment 1. Align the top surface of the protrusions of the belt holder (front and rear) attached to the stack tray drive belt to the marks on the support plate, and fix them in place.
  • Page 182: Phase Adjustment Of Paddle Unit

    5. Adjustment ■ Procedure of Adjustment 1. Align the swing unit lifting arm (front and rear) to the gear phase, and fix them in place. Gear Gear Swing Guide Unit Swing Guide Unit Up/Down Arm (Rear) Up/Down Arm (Front) Phase adjustment of paddle unit If you remove or replace the swing unit, perform phase adjustment of paddle unit.
  • Page 183 5. Adjustment 3. Confirm that the paddle blade [1]stays in between the line [A] and [B]. CAUTION: Adjust the phase angle of the paddle unit if the paddle blade is not in between the 2 lines. CAUTION: There are 2 paddle blades. So do not take the wrong blade to confirm its position.
  • Page 184 5. Adjustment ■ Adjsting Phase Angle of the Paddle Unit 1. Put off the belt [1]. 2. Lower the swing roller till its end.
  • Page 185 5. Adjustment 3. Adjust the angle of the paddle blade [1] so that it becomes in parallel with the line [B]. CAUTION: There are 2 paddle blades. So do not take the wrong blade to confirm its position. CAUTION: Do not have the paddle blade be in parallel with the line [A] or the adjustment fails.
  • Page 186 5. Adjustment 4. Align the projection of the sensor flag gear [1] with the mark-off line [2]. 5. Turn the sensor flag gear in the arrow direction by the amount of 1 tooth.
  • Page 187: Phase Alignment When Installing The Paper Folding Roller

    5. Adjustment 6. Put the belt back. CAUTION: When putting the belt back, pay a full attention that the paddle shaft does not rotate unexpectedly and the phase angle of the paddle blade gets wrong. NOTE: Check the phase angle of the paddle unit again after performing this adjustment. Phase Alignment When Installing the Paper Folding Roller If you remove or replace the paper folding roller, align the phase of the paper folding roller installation position.
  • Page 188: Handling Finisher Controller Pcb Replacements

    5. Adjustment ■ Procedure of Adjustment 1. With the shaft notches of the paper folding roller (upper and lower) aligned to the support plate grooves, align the cam mark to the support plate mark, and fix them in place. Cut-out of Upper Paper Folding Roller Mark Mark Cut-out of Lower Paper Folding Roller...
  • Page 189 5. Adjustment If backup operation has been performed 1. Write the backup data to the new PCB in the host machine's service mode. SORTER > FUNCTION > FIN-BK-W 2. Turn the main power of the host machine off and then on. If backup operation has not been performed 1.
  • Page 190 5. Adjustment Service Mode Items SORTER > ADJUST CENT-ALG Adjusting the center standard position of the alignment plates SDL-STP2 Adjusting the stitching position of the saddle stitcher unit (thin paper) SDL-FLD2 Adjusting the folding position of the saddle stitcher unit (thin paper) ESC1-SPD Adjusting the delivery speed of the escape tray SFT-SPD...
  • Page 191 5. Adjustment 2. Set all SW1 keys set to OFF. 3. Enter the values written to the service label affixed to the front cover.
  • Page 192: Other

    5. Adjustment Other Releasing the Saddle Delivery Tray Stacking Limit This is performed when you want to continuously stack over the allowable stacking capacity when stacking in the saddle delivery tray. ■ Release procedure 1. Pull the paper stopper of the saddle delivery tray out slightly and lower it. NOTE: When the paper stopper is lowered, the sensor flag of the saddle delivery tray paper sensor (PS216) is also lowered in sync, and paper detection on the tray is disabled.
  • Page 193: Troubleshooting

    Troubleshooting Making Initial Checks......186 Processing Tray Area......187 Saddle Stitcher Area......188...
  • Page 194: Making Initial Checks

    6. Troubleshooting Making Initial Checks List of Initial Check Items Item Check Items Check Installation Environ- The value of power voltage is +/- 10% of the specified voltage. ment The machine is installed away from heat and moisture (near a faucet, water heater, or humidifier), cold place, source of fire or in an area exposed to dust.
  • Page 195: Processing Tray Area

    6. Troubleshooting Processing Tray Area Adjusting the Alignment and the Staple Position Adjusting the Alignment and the Staple Position Front/Rear 1.Adjusting Alignment 2.Adjusting Center Alignment 3.Right Angle Adjustment Misalignment of Paper direction Plate Position Standard Position of Alignment Plate 4.Adjusting Delivery of 5.Adjusting the Return Feed Roller/Swing Unit Height...
  • Page 196: Saddle Stitcher Area

    6. Troubleshooting Saddle Stitcher Area Fold Placement / Saddle Stitch Adjustment CAUTION: In the case performing this adjustment, record user mode setting value before the adjustment. Input 0 for setting value and start the adjustment. • Adjustment/Maintenance > Adjust Action > Adjust Saddle Stitch Fold Position •...
  • Page 197: Installation

    Installation How to Utilize This Installation Procedure........190 Checking Before Installation..... 191 Unpacking......... 195 Checking the Contents......198 Installation Procedure....... 199 Affixing the Labels......208 Making Adjustments......209 Making Checks After Completion of Installation Work......213 Detaching from the Host Machine..214...
  • Page 198: How To Utilize This Installation Procedure

    7. Installation How to Utilize This Installation Procedure Illustrations Used in This Procedure Illustrations used in this procedure are those of Booklet Finisher unless otherwise specified. Product Name Safety regulations require the product's name to be registered. In some regions where this product is sold, the following names may be registered instead.
  • Page 199: Checking Before Installation

    7. Installation Checking Before Installation The following conditions are required for the installation site. Therefore, it is recommended to see the installation site in advance before delivering this Equipment to the user's site. Checking the Installation Space The space required for installation and maintenance work is shown below. 100mm or more 500mm...
  • Page 200: Checking The Unpacking Space

    7. Installation Checking the Unpacking Space Be sure to unpack this equipment according to the illustrations in a wide area where there is enough space around it. 760mm 850mm Pallet Finisher Slope Board 760mm 660mm 525mm 1,945mm Check Items When Turning OFF the Main Power Check that the main power switch is OFF.
  • Page 201: Points To Note On Installation

    7. Installation Points to Note on Installation • Refer to "Order of the Installation of Accessories" when installing this Equipment before operation. • Since this machine is heavy (Staple Finisher: approx. 40kg, Booklet Finisher: approx. 64kg), 2 or more persons are required to install it.
  • Page 202: Installing The Accessories

    7. Installation Installing the Accessories Install the Host Machine first and then the accessories in the following sequence. 1. Buffer Pass Unit 2. Puncher Unit 3. Staple Finisher, Booklet Finisher NOTE: When installing the following options at the same time, be sure to install them before installing this equipment. Refer to each installation procedure.
  • Page 203: Unpacking

    7. Installation Unpacking Unpacking Procedure CAUTION: The Finisher is rather heavy. Be sure to work with a group of 2 or more people. Particularly when moving it over a step on the floor, be sure to take full care not to let it tumble over.
  • Page 204 7. Installation...
  • Page 205 7. Installation...
  • Page 206: Checking The Contents

    7. Installation Checking the Contents Check that none of the included parts is missing. [10] [11] [12] [13] Finisher 1 pc. Buffer Pass Unit 1 pc. Latch plate 1 pc. Screw (RS Tightening ; M3 x 8) 2 pcs. Screw (W Sems ; M3 x 6) 1 pc.
  • Page 207: Installation Procedure

    7. Installation Installation Procedure CAUTION: Check that the main power switch is OFF and the power plug is disconnected from the outlet. Preparing the Host Machine for Installation CAUTION: When the Full Detection Flag has been installed already, be careful not to damage the Full Detection Flag.
  • Page 208 7. Installation NOTE: When the Tray Guide supplied for Host Machine is installed, remove it. The removed Tray Guide will be used in step 8). NOTE: The removed Face Cover will be used in step 9). NOTE: The removed Face Cover will be used in step 8).
  • Page 209 7. Installation Attach the Face Covers removed in step 6) to the Tray Guide supplied for Host Machine or removed in step 7). Claw Claw Attach the Face Covers removed in step 5) to the Tray Guide.
  • Page 210: Installation Of Buffer Pass Unit

    7. Installation NOTE: Keep the parts as illustration above. Installation of Buffer Pass Unit...
  • Page 211 7. Installation CAUTION: • When the Full Detection Flag has been installed already, be careful not to damage the Full Detection Flag. • Do not give a damage on delivery area of the Host Machine. Push the Buffer Pass Unit toward the Inner Rear Space Cover of the Host Machine until it stops, and then slide the Buffer Pass Unit toward the paper delivery...
  • Page 212 7. Installation Fix the screw removed in Step 6) to the original position. Fix the Latch Plate with a bundled screw (4pcs.). NOTE: The removed screw is used at Step 7).
  • Page 213: Preparing The Finisher For Installation

    7. Installation Preparing The Finisher for Connecting to Host Machine Installation CAUTION: When connecting the Interface Cable, be sure to turn off the Host Machine and disconnect its power cable from the outlet. TP ; M3 6 NOTE: Install the Ground rail to the position [B]. When the Service Book Holder has already been installed in the Host Machine, relocate it to the Finisher.
  • Page 214 7. Installation Pull out the Saddle Unit about 150mm. (Booklet Finisher only) TP ; M3 6 NOTE: Staple Finisher only.
  • Page 215 7. Installation Loosen 2 screws, and then fix the Saddle Unit Auxiliary Caster so that its Caster can touch the floor. (Booklet Finisher only)
  • Page 216: Affixing The Labels

    7. Installation Affixing the Labels Affix the Label in the appropriate language. Jam Label / Saddle Caution Language Label (Booklet Finisher only) Affix the Label in the appropriate language. Tray Setting Labels Affix the supplied which is specified by user in the frame line of Tray Labels.
  • Page 217: Making Adjustments

    7. Installation Making Adjustments The difference in height between the Finisher and the Host Machine and the tilt of the Finisher and the Host Machine need to be adjusted depending on the installation site floor condition. If the height or tilt is not adjusted properly, problems can occur (for example, a paper jam can occur frequently at the paper supply section of the Finisher).
  • Page 218: Making Check And Adjustment Of The Tilt

    7. Installation Making Check and Adjustment of the Tilt Turn the adjustment dial of the caster in the direction of the arrow by lifting the dial upward a little to adjust the height. (A full turn of the adjustment dial changes the height of Check the relational tilting amount of the Finisher the Finisher by 2.0 mm.) and Host Machine.
  • Page 219 7. Installation Remove the screw when the screw that fixed the Turn the adjustment dial of the caster in the direction Finisher to the Host Machine is installed. of the arrow by lifting the dial upward a little to adjust the tilt.
  • Page 220: Making Checks After Completion Of Adjustments

    7. Installation Making Checks After Completion of Adjustments Check to see that the difference in height between within the specifications. If they are not within the specifications, make adjustments again.
  • Page 221: Making Checks After Completion Of Installation Work

    7. Installation Making Checks After Completion of Installation Work Disposal Parts Check Following disposal parts are remained after completion of the installation work. Reverse Trailing Edge Guide (In the case 1 pc. it was installed in the Host Machine.) Inner Connector Cover 1 pc.
  • Page 222: Detaching From The Host Machine

    7. Installation Detaching from the Host Machine CAUTION: When disconnecting the Interface Cable, be sure to CAUTION: turn off the Host Machine and disconnect its power Turn the Host Machine OFF and disconnect its power cable from the outlet. cord prior to connection of the interface cable to avoid any unexpected electric shock.
  • Page 223 7. Installation...
  • Page 224: Appendices

    APPENDICES Service Tools........217 General Circuit Diagram....218...
  • Page 225: Service Tools

    Service Tools Service Tools Solvents and Oils Name Uses Composition Remarks Alcohol Cleaning; Fluoride-family hydrocar- • Do not bring near fire. e.g.,plastic, rubber parts, external • Procure locally covers. Alcohol • Substitute: IPA(isopropyl Surface activating agent alcohol) Water Solvent Cleaning; Fluoride-family hydrocar- •...
  • Page 226: General Circuit Diagram

    General Circuit Diagram General Circuit Diagram General Circuit Diagram 1/3 PS117 PS104 Staple-Free Binding Unit Staple Unit M111 M113 Front Tray PS122 PS126 Front PS130 Return Roller Paper End Auxiliary Guide Paper End Pushing Staple Cover Sensor Staple-free Binding Lift Motor Assist Motor Guide HP Sensor Edging Sensor...
  • Page 227: General Circuit Diagram 2/3

    General Circuit Diagram General Circuit Diagram 2/3 Saddle Stitcher Unit PS207 PS204 M201 Saddle Alignment Saddle Unit Saddle Feed/Paddle Motor HP Sensor PS213 PS214 Set Sensor M208 PS215 Rear Saddle Front Saddle PS202 Saddle Stitcher Saddle Stitcher Stitcher Staple 1 2 3 4 5 6 3 2 1 Stitcher Staple Saddle Processing...
  • Page 228: General Circuit Diagram 3/3

    General Circuit Diagram General Circuit Diagram 3/3 Host Machine FM201 FM202 Buffer Pass Buffer Pass Power Supply Cooling Fan Cooling Fan TJ021DH PI203 TJ021D PI201 PI202 M301 Buffer Pass Buffer Pass Buffer Pass Buffer Pass Open/Closed Sensor Inlet Sensor Outlet Sensor Feed Motor 3 2 1 3 2 1...

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