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Canon Saddle Finisher-T2 Service Manual

Finisher, sorter, deliverytray
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Service Manual
Finisher, Sorter, DeliveryTray
Saddle Finisher-T2
Feb 21 2005

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  Summary of Contents for Canon Saddle Finisher-T2

  • Page 1 Service Manual Finisher, Sorter, DeliveryTray Saddle Finisher-T2 Feb 21 2005...
  • Page 3 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 4 Introduction Symbols Used This documentation uses the following symbols to indicate special information: Symbol Description Indicates an item of a non-specific nature, possibly classified as Note, Caution, or Warning. Indicates an item requiring care to avoid electric shocks. Indicates an item requiring care to avoid combustion (fire). Indicates an item prohibiting disassembly to avoid electric shocks or problems.
  • Page 5 Introduction The following rules apply throughout this Service Manual: 1. Each chapter contains sections explaining the purpose of specific functions and the relationship between electrical and mechanical systems with reference to the timing of operation.  In the diagrams, represents the path of mechanical drive; where a signal name accompanies the symbol , the arrow indicates the direction of the electric signal.
  • Page 7: Table Of Contents

    Contents Contents Chapter 1 Specifications 1.1 Product Specifications............................1- 1 1.1.1Finisher Unit..............................1- 1 1.1.2Saddle Stitcher Unit............................. 1- 4 1.2 Names of Parts..............................1- 7 1.2.1External View.............................. 1- 7 1.2.2Cross Section (Finisher Unit) ........................1- 8 1.2.3Cross Section (Saddle Stitcher Unit)......................1- 9 Chapter 2 Functions 2.1 Basic Operation ..............................
  • Page 8 Contents 2.4.6Stitching Operation ............................ 2- 50 2.5 Stack Tray Operation ............................2- 52 2.5.1Tray Operation............................2- 52 2.5.2Shutter Operation............................2- 55 2.6 Detecting Jams..............................2- 56 2.6.1Detecting Jams (Finisher Unit) ........................2- 56 2.6.2Detecting Jams (Saddle Stitcher Unit)....................... 2- 57 2.7 Power Supply..............................
  • Page 9 Contents 3.1.10.1 Removingh the Escape Door ......................3- 8 3.2 Drive System ..............................3- 10 3.2.1 Stapler ............................... 3- 10 3.2.1.1 Removing the Front Door........................3- 10 3.2.1.2 Removing the Escape Tray Cover..................... 3- 10 3.2.1.3 Removing the Front Inside Upper Cover ..................3- 10 3.2.1.4 Removing the Stapler ........................
  • Page 10 Contents 3.3 Document Feeding System ..........................3- 30 3.3.1 Process Tray Assembly ..........................3- 30 3.3.1.1 Removing the Front Door ........................3- 30 3.3.1.2 Removing the Rear Upper Cover....................... 3- 30 3.3.1.3 Removing the Escape Tray Cover ..................... 3- 30 3.3.1.4 Removing the Front Inside Upper Cover...................
  • Page 11 Contents 3.3.6.9 Removing the Stapler ........................3- 51 3.3.6.10 Removing the Processing Tray......................3- 52 3.3.6.11 Removing the Swing Unit ....................... 3- 53 3.3.6.12 Removing the Return Roller Unit....................3- 55 3.3.7 Saddle Delivery Tray Unit ........................3- 55 3.3.7.1 Removing the Saddle Delivery Tray Unit ..................3- 55 3.3.8 Upper Delivery Guide..........................
  • Page 12 Contents 3.4.2.3 Removing the Escape Tray Cover ..................... 3- 72 3.4.2.4 Removing the Front Inside Upper Cover................... 3- 72 3.4.2.5 Removing the Grate-shaped Upper Guide..................3- 72 3.4.2.6 Removing the Tray 1 ......................... 3- 72 3.4.2.7 Removing the Tray 2 ......................... 3- 74 3.4.2.8 Removing the Grate-shaped Lower Guide ..................
  • Page 13 Contents 4.3.2.5 Adjusting the Stitcher Unit........................ 4- 10 4.4 Troubleshooting............................... 4- 12 4.4.1 Error Code..............................4- 12 4.4.1.1 E500;Communication error ....................... 4- 12 4.4.1.2 E503;Saddle stitcher unit communication error ................4- 12 4.4.1.3 E505;Backup RAM error ........................4- 12 4.4.1.4 E514;Rear end assist motor error ...................... 4- 12 4.4.1.5 E530;Front aligning plate motor error....................
  • Page 14 Contents 5.2 User Error Code..............................5- 2 5.2.1Staple is absent ............................5- 2 5.2.2Stapler safety protection function activated ....................5- 2 5.2.3Stack tray overstacking..........................5- 3 5.2.4Staple is absent (Saddle Stitcher Unit) ......................5- 3 5.2.5Mixed paper sizes (Saddle Stitcher Unit) ....................5- 4 5.2.6Stack exceeded (Saddle Stitcher Unit) ......................
  • Page 15: Chapter 1 Specifications

    Chapter 1 Specifications...
  • Page 17 Contents Contents 1.1 Product Specifications............................1-1 1.1.1 Finisher Unit..............................1-1 1.1.2 Saddle Stitcher Unit............................. 1-4 1.2 Names of Parts..............................1-7 1.2.1 External View.............................. 1-7 1.2.2 Cross Section (Finisher Unit) ........................1-8 1.2.3 Cross Section (Saddle Stitcher Unit)......................1-9...
  • Page 19: Product Specifications

    Chapter 1 1.1 Product Specifications 1.1.1 Finisher Unit 0009-2527 T-1-1 Item Specifications Stacking Escape tray: fixed type method Trays 1 and 2: Independently move up and down Stacking Face up orientation Face down Stacking A3, A4, A4R, A5R, B4, B5, B5R, 279 mm x 432 mm (11 x 17), size*1 LGL, LTR, LTRR, STMTR, others Paper weight...
  • Page 20 Chapter 1   Item Specifications Large size: 96 mm high/50 sets Small size: 188 mm high/100 sets Mixed Size mixing: stacking capac-ity Escape tray: 43 mm high Tray 1 and 2: 96 mm high (650 sheets) Stapling: 96 mm high/50 sets Mode mixing: Large size: 96 mm high/50 sets Small size: 188 mm high/100 sets...
  • Page 21 Chapter 1 Item Specifications Remarks A4R, LGL, LTRR Front 1-point stapling (45 deg.) A3, B4, A4, B5, 279mm x 432mm (11 x 17), LTR Rear 1-point stapling (30 deg.) A4R, LGL, LTRR Rear 1-point stapling (45 deg.) A3, B4, A4, B5, 279mm x 432mm (11 x 17), LTR 2-point stapling A3, A4, A4R, B4, B5, 279mm x 432mm (11 x 17), LGL, LTR, LTRR...
  • Page 22: Saddle Stitcher Unit

    Chapter 1   Rear 1-point stapling (30deg.) Rear 1-point stapling (45deg.) A4R, LGL, and LTRR A3, A4, B4, B5, 279mm x 432mm 11 x 17 , and LTR 5-/+2mm 5-/+2mm F-1-2 2-point stapling B4 and B5 A3 and A4 279mm x 432mm 11 x 17 and LTR 74-/+4mm...
  • Page 23 Chapter 1 Item Specifications Plain paper(64g/m2 to 90g/m2) Stacking capacity 1 to 5 sheets; 25 copies 6 to 10 sheets; 15 copies 11 to 15 sheets; 10 copies Stapling 2 points (center distribution; fixed interval) position Staple 2000 staples accommoda- tion Staple supply Special cartridge...
  • Page 24 Staple position Folding position -/+2 mm 63 -/+2 mm 39.5 -/+2 mm 203 -/+2 mm 183 -/+2 mm 159.5 -/+2 mm Stack front edge 279mm x 432mm LTRR (11 x 17) -/+2 mm 42 -/+2 mm 42 -/+2 mm 194 -/+2 mm 162 -/+2 mm 162 -/+2 mm F-1-4...
  • Page 25: Names Of Parts

    Chapter 1 1.2 Names of Parts 1.2.1 External View 0009-2529 [10] F-1-5 T-1-4 [1] Escape tray [6] Grate-shaped upper guide [2] Escape door [7] Tray 1 [3] Rear upper cover [8] Tray 2 [4] Front door [9] Saddle delivery tray [5] Foot cover [10] Rear lower cover...
  • Page 26: Cross Section (Finisher Unit)

    Chapter 1   1.2.2 Cross Section (Finisher Unit) 0009-2530 [10] [11] [16] [12] [13] [14] [15] F-1-6 T-1-5 [1] Tray 1 [9] Escape feed roller [2]Tray 2 [10] Buffer roller [3] Shutter [11] Feed roller [4] Stack delivery roller [12] Inlet roller [5] Aligning plate [13] Return roller [6] 1st delivery roller...
  • Page 27: Cross Section (Saddle Stitcher Unit)

    Chapter 1 1.2.3 Cross Section (Saddle Stitcher Unit) 0009-2531 [10] [12] [11] F-1-7 T-1-6 [1] Saddle inlet flapper [7] Holding roller [2] Saddle inlet roller [8] Paper pushing plate [3] No.1 flapper [9] Paper folding roller [4] No.2 flapper [10] Crescent roller [5] Stitcher (front, rear) [11] Saddle delivery roller [6] Stitcher mount...
  • Page 29: Chapter 2 Functions

    Chapter 2 Functions...
  • Page 31 Contents Contents 2.1 Basic Operation ..............................2-1 2.1.1 Basic Operation (Finisher Unit) ........................2-1 2.1.2 Overview of the Electrical Circuitry (Finisher Unit) .................. 2-1 2.1.3 Basic Operation (Saddle Stitcher Unit) ....................... 2-2 2.1.4 Overview of the Electrical Circuitry (Saddle Stitcher Unit) ............... 2-3 2.2 Feed Drive System .............................
  • Page 33: Basic Operation

    Chapter 2 2.1 Basic Operation 2.1.1 Basic Operation (Finisher Unit) 0009-2533 The finisher is designed to deliver copies arriving from its host machine, and its modes of delivery include simple stacking, job offset, and staple. All operations involved in these modes are controlled by the finisher controller PCB, according to the appropriate commands from the host machine.
  • Page 34: 3Basic Operation (Saddle Stitcher Unit)

    Chapter 2   The ICs used on the finisher controller PCB are designed for the following: <IC108 (CPU)> Controls sequence of operations. Contains sequence programs. <IC105 (EEP-ROM)> Backs up adjustment values. Backs up initial setting data. <IC107 (communications IC)> Communicates with the host machine and the saddle stitcher unit. <IC102 (regulator IC)>...
  • Page 35: 4Overview Of The Electrical Circuitry (Saddle Stitcher Unit)

    Chapter 2 Finisher unit control system Guide plate drive system Paper positioning plate drive system Alignment drive system Stitcher drive system Delivery drive system Feed drive system Paper pushing plate drive system Paper folding roller drive system F-2-3 2.1.4 Overview of the Electrical Circuitry (Saddle Stitcher Unit) 0009-2536 The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher controller PCB.
  • Page 36 Saddle stitcher Sensor Motor controller PCB Solenoid IC7 CPU Switch IC512 Regulator IC10 Regulator Communi- cations IC Finisher controller Host machine F-2-4...
  • Page 37: Feed Drive System

    Chapter 2 2.2 Feed Drive System 2.2.1 Overview 0009-2537 This product consists of the Finisher unit and the Saddle Stitcher unit. The Finisher unit simply stacks sheets delivered from a host machine, offsets a stack job, or staples and delivers the sheets to the trays according to commands delivered from a host machine.
  • Page 38: Constraction Of The Control System (Finisher Unit)

    Chapter 2   2.2.2 Constraction of the Control System (Finisher Unit) 0009-2538 The copy sent from the host machine is delivered to the ejection tray, escape tray, or processing tray according to the ejection type. Job offset or stapling is performed, according to the instruction from the host machine, for copy delivered to the staple tray.
  • Page 39 Finisher controller PCB(1/2) Feed driver M103 M109 M112 M102 M101 M113 M104 M107 M105 M111 M108 Feed driver Finisher controller PCB(2/2) F-2-7...
  • Page 40: Paper Delivery Path (Finisher Unit)

    Chapter 2   Finisher controller PCB Feed driver PI118 PI111 PI103 PI104 PI112 F-2-8 2.2.3 Paper Delivery Path (Finisher Unit) 0009-2539 <Overview> There are three ejection paths to tray 1 and 2 depending on the ejection processing.There is only one paper ejection path to the escape tray.
  • Page 41 Chapter 2 Tray Paper 1st delivery roller Buffer roller Feed roller Stack ejection roller Inlet roller F-2-9 <Processing Tray Path (Destination: Tray 1/ Tray 2)> This is the copy ejection path when the equipment is set to sort for paper size other than A4, B5, or LTR or when set to staple sort.
  • Page 42 Chapter 2   1st delivery roller Paper Buffer roller Stack ejection roller Feed roller Inlet roller Processing tray Paper Rear end assist F-2-10 <Buffer/Processing Tray Path (Destination: Tray 1/ Tray 2)> This is the copy ejection path when the equipment is set to sort for A4, B5, or LTR paper size. Feed two sheets of paper to buffer (two or three sheets if 2-point stapling).
  • Page 43 Chapter 2 Buffer roller Buffer guide Feed roller 20mm Switch back point F-2-11 2) When the first copy is delivered to the buffer, the second copy is delivered from the host machine. F-2-12 3) The first delivery roller descends and works together with the stack delivery roller to deliver the 1st and 2nd paper toward the processing tray.
  • Page 44 Chapter 2   Stack ejection roller 1st delivery roller Return roller Processing tray F-2-14 5) The 1st and 2nd paper delivered to the processing tray are aligned and then delivered to the delivery tray. Stack ejection roller Return roller Rear end assist guide F-2-15 <Escape Ejection (Destination: Escape Tray)>...
  • Page 45: Constraction Of The Control System (Saddle Stitcher Unit)

    Chapter 2 Escape delivery roller Escape feed roller Inlet roller Escape inlet flapper F-2-16 2.2.4 Constraction of the Control System (Saddle Stitcher Unit) 0009-2540 The paper output mechanism serves to keep a stack of sheets coming from the finisher in place for the next steps (stapling, folding).
  • Page 46 Finisher controller Saddle stitcher controller PCB(1/2) Feed driver M113 Saddle stitcher controller PCB(2/2) F-2-17...
  • Page 47: Paper Delivery Path (Saddle Stitcher Unit)

    Chapter 2 Saddle stitcher controller PCB(1/2) PI22 PI18 PI19 PI20 PI17 PI11 PI21 PI15 PI12 PI14 PI13 Saddle stitcher controller PCB (2/2) F-2-18 2.2.5 Paper Delivery Path (Saddle Stitcher Unit) 0009-2541 A copy arriving in the finisher from the host machine is routed to the saddle stitcher by the saddle inlet flapper. The saddle stitcher executes stitching and saddling operations on the copy and then delivers it to the saddle stitcher tray.
  • Page 48: Basic Operation (Saddle Stitcher Unit)

    Chapter 2   F-2-19 2.2.6 Basic Operation (Saddle Stitcher Unit) 0009-2542 <Receiving Sheets> The stitcher unit receives sheets from the finisher unit and outputs them inside the vertical path in vertical orientation. The vertical path, while sheets are being output, is configured by two paper deflecting plates. The position of the sheets being output is set by the paper positioning plate so that the center of the stack matches the stapling/folding position.
  • Page 49 Chapter 2 Direction of delivery Second sheet First sheet Paper positioning plate F-2-20 <Aligning the Sheets> The alignment plates operate to put the sheets in order each time a sheet of paper is output to the vertical path assembly. The alignment plates are mounted at the edge of the vertical path assembly. The alignment plates also operate after stapling to prepare the stack for delivery.
  • Page 50 Chapter 2   next operation (stack feeding). Stitcher Staple F-2-22 <Feeding the Stack> The unit folds the stitched stack of sheets, and then feeds it to the point of delivery. This point is where the center of the stack, i.e., stapling position, matches the height of the paper pushing plate and the paper folding roller nip. The stack is moved forward by operating the paper positioning plate.
  • Page 51 Chapter 2 Paper folding roller Paper pushing guide Paper positioning plate Guide plate F-2-23 <Folding/Delivering the Stack> The paper pushing plate pushes against the center of the stack to move it in the direction of the paper folding rollers. In response, the paper folding rollers pick the stack along its center and fold it in two. The paper folding rollers together with the delivery roller then move the stack along to output it on the delivery tray.
  • Page 52: Controlling The Inlet Flappers

    Chapter 2   Paper folding roller Delivery roller F-2-24 2.2.7 Controlling the Inlet Flappers 0009-2543 <Overview> The two flappers mounted at the paper inlet are operated to configure the feed path according to the size of paper. The flappers are used to enable the following: 1.
  • Page 53 Chapter 2 Each flapper is driven by its own solenoid. The following table shows the relationship between solenoids and paper sizes. T-2-2 Solenoid A3/279mm x 432mm (11 x 17) A4R/ LTRR No.1 paper deflecting solenoid (SL1) No.2 paper deflecting solenoid (SL2) <A3/279mm x 432mm (11"...
  • Page 54 Chapter 2   No.1 paper sensor PI18 Passage of paper No.1 paper deflecting plate solenoid No.2 paper sensor Non-passage of paper PI19 No.2 paper deflecting Non-passage of paper plate solenoid No.3 paper sensor PI20 Top edge PI18 PI19 PI20 PI18 PI19 PI20 Entry of First sheet...
  • Page 55 Chapter 2 Passage of paper No.1 paper sensor PI18 No.2 paper sensor Passage of paper PI19 No.3 paper sensor Non-passage of paper PI20 PI18 PI19 Top edge PI20 PI18 PI19 PI20 Entry of First sheet Entry of Second sheet Entry of Third sheet F-2-26 <A4R/LTRR Paper Path (3 sheets)>...
  • Page 56: Controlling The Movement Of Sheets

    Chapter 2   Passage of paper No.1 paper sensor PI18 No.2 paper sensor Passage of paper PI19 No.3 paper sensor Passage of paper PI20 PI18 PI19 Top edge PI20 PI18 PI19 PI20 Entry of First sheet Entry of Second sheet Entry of Third sheet F-2-27 2.2.8 Controlling the Movement of Sheets...
  • Page 57 Chapter 2 over the sensor. The crescent roller keeps rotating while sheets are being output, butting the leading edge of each sheet against the paper positioning plate, and ultimately, keeping the leading edge of the stack in order. The alignment motor (M5) drives the alignment plates for each sheet so as to put both left and right edges of the sheet in order.
  • Page 58: Controlling The Aligning The Sheets

    Chapter 2   F-2-30 2.2.9 Controlling the Aligning the Sheets 0009-2545 The alignment motor (M5) drives the alignment plates each time a sheet is output, putting both left and right edges of the sheet in order. The alignment plate motor is a 4-phase stepping motor. The position of the alignment plate is identified in reference to the number of motor pulses from the alignment plate home position sensor (PI5).
  • Page 59 Chapter 2 F-2-32 3) The alignment plates escape to points 10 mm from the edge of the stack. F-2-33 4) When the following stack arrives, steps 1 through 3 above are repeated. 5) The alignment plates butt against the stack once again, during which stitching takes place. F-2-34 6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding and delivery take place.
  • Page 60: Controlling The Phase Of The Crescent Roller

    Chapter 2   F-2-36 Alignment plate Alignment motor Alignment plate Stack Alignment plate home position sensor (PI5) Paper positioning plate F-2-37 In case of 2 sheets: Entry of Entry of 1st sheet of follow- 1st sheet 2nd sheet ing stack entry [2] [3] [4] Alignment plate home position sensor...
  • Page 61 the roller causes the stack to move inappropriately. To prevent this problem, the phase of the roller is identified and used to determine the timing of alignment. The phase of the crescent roller is identified by the crescent roller phase sensor (PI12). The flag for the crescent roller phase sensor is mounted to the crescent roller shaft.
  • Page 62: Overview Of Folding Operation

    Chapter 2   Alignment operation is started when the flag has covered the sensor crescent roller F-2-41 First sheet Second sheet Feed motor Crescent roller phase stops sensor (PI12) Alignment operation Feed motor (M1) F-2-42 2.2.11 Overview of Folding Operation 0009-2547 The paper folding mechanism consists of a guide plate, paper folding rollers, paper pushing plate, and paper positioning plate.
  • Page 63: Controlling The Movement Of Stacks

    Chapter 2 T-2-4 Sensor Function Paper pushing plate motor clock Detects the paper pushing plate motor sensor (PI1) clock. Paper folding motor clock Detects the paper paper folding motor sensor (PI4) clock. Tray paper sensor (PI6) Detects the presence/absence of a stack of sheets in the saddle delivery tray.
  • Page 64: Folding A Stack

    Chapter 2   Paper folding roller Paper pushing guide Paper positioning plate Guide plate Paper positioning plate home position sensor F-2-43 Stitching Equivalent of specific ends number of pulses Paper positioning plate motor (M4) Guide motor (M3) Guide home position sensor (PI13) F-2-44 2.2.13 Folding a Stack...
  • Page 65 position. The stack gripped in this way by the paper folding roller is drawn further by the paper folding roller and then is moved by the delivery roller to the paper tray. The thickness of the paper folding rollers is reduced at a half of their periphery except the center area. At the other half of the periphery, where the thickness is not reduced, the paper folding roller (upper) and the paper folding roller (lower) contact each other tightly, and paper starts to be folded at this position.
  • Page 66 Chapter 2   [Paper folding start position] Stack of sheets Paper pushing plate Paper feed inlet Delivery outlet Sensor flag Paper folding home position sensor (PI21) Paper folding/feeding is performed. Paper feeding is performed. F-2-47 [Paper folding roller stop position] Delivery outlet Paper feed inlet Sensor flag...
  • Page 67: Double Folding A Stack

    Chapter 2 Paper folding motor (M2) Paper pushing plate motor (M8) Paper pushing plate home position sensor (PI14) Equivalent of 10mm by paper folding motor Paper pushing plate top position sensor (PI15) Delivery sensor (PI11) Tray paper sensor (PI6) Paper folding home position sensor (PI21) : Motor CCW : Motor CW...
  • Page 68 Chapter 2   Paper folding motor F-2-51 3) The paper folding rollers rotate in reverse, pushing back the stack for a length of about 20 mm (reverse feeding). Paper folding motor F-2-52 4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns to its home position. Paper folding motor Paper pushing plate motor F-2-53...
  • Page 69 Gripping of paper stack Equivalent of 20 mm Equivalent of 20 mm (reverse feeding) Paper folding motor (M2) Paper pushing plate motor (M8) Paper pushing plate home position sensor (PI14) Paper pushing plate top position sensor (PI15) Delivery sensor (PI11) Tray paper sensor (PI6) Paper folding home...
  • Page 70: Intermediate Process Tray Assembly

    Chapter 2   2.3 Intermediate Process Tray Assembly 2.3.1 Stack Job Offset 0009-2513 Job offset operation offsets paper stack to the front or rear when ejecting to sort the paper stack. The forward/backward movement of the copy delivered to the processing tray is controlled by the front aligning plate and rear aligning plate.
  • Page 71: Processing Tray Paper Stacking Operation

    Chapter 2 Motor Function Aligning plate rear motor Aligns paper in processing tray to the rear (M104) Swing motor (M106) Moves the swing guide up/down Rear end assist motor (M109) Carry the stack end during stack ejection T-2-6 Sensor Function Swing guide HP sensor (PI105) Detects the swing guide home position Aligning plate front HP sensor...
  • Page 72: Rear End Assist Operation

    Chapter 2   Rear aligning plate Sheet to be offset Front aligning plate Tray Rear aligning plate Sheet to be offset Front aligning plate Tray F-2-58 2.3.4 Rear End Assist Operation 0009-2516 In order to improve stacking performance when ejecting copies delivered to the processing tray, a rear end assist guide is used in addition to the stack ejection roller to support the rear end of the stack during stack ejection.
  • Page 73: Stack Delivery Operation

    Chapter 2 2.3.5 Stack Delivery Operation 0009-2517 The stack is ejected each time three large size sheets*1 or five small size sheets*2 are offset on the processing tray. The swing motor turns and the swing guide descends. This causes the upper/lower stack delivery rollers to hold the stack.
  • Page 74: Staple Operation

    Chapter 2   2.4 Staple Operation 2.4.1 Overview 0009-2551 This product is equipped with two Staplers. While the Stapler unit of the Finisher unit provides 1-point front stapling, 1-point rear stapling, and 2-point stapling, the Stitcher unit of the Saddle Stitcher unit provides 2-point center stapling. Stapler unit Stitcher unit (front, rear)
  • Page 75: Shifting The Stapler Unit

    Chapter 2 of staples in the cartridge. The staple edging sensor (PI51) is used to determine whether staples are pushed up to the top of the staple cartridge. The finisher controller circuit does not drive the staple motor (M111) unless the staple safety switch (MSW104) is ON.
  • Page 76 Chapter 2   The position is the same as the stapling position. Rear aligning plate Stopper Feeding direction Stapling position/ Wait position Front aligning plate F-2-64 <Rear 1-Point Stapling> The position is the same as the stapling position. Rear aligning plate Stapling position/ Wait position Stopper...
  • Page 77: Stapling Operation

    Chapter 2 <2-Point Stapling> The stapler waits at the paper front end side staple position. The stapling sequence is first near side and then far side. Rear aligning plate Stopper Stapling position Stopper Feeding direction Stapling position/ Wait position Stopper Front aligning plate F-2-66 2.4.4 Stapling Operation...
  • Page 78 F-2-67 Paper width 1/2 Front diagonal stapling 2-point stapling Rear diagonal stapling F-2-68 T-2-7 Sensor Symbol Connector Function Remark Stapler shift PI110 J721A-15 Detects the home position home for the stapler moving position back and forth. sensor...
  • Page 79 Chapter 2 Sensor Symbol Connector Function Remark Stapler PI116 J720-3 Staple prohibited area alignment detection interference sensor Staple home PI50 J720-5 Detects the home position In the position for the stapling operation. stapler sensor Staple PI51 J720-6 Detects the staple top In the edging position.
  • Page 80 Chapter 2   Stack ejection roller Swing guide 1st delivery roller Return roller Stapler Processing tray F-2-69 Swing guide home position sensor (PI105) Stack ejection roller (upper) Stack ejection roller (lower) Swing guide Swing motor (M106) Stack ejection lower roller clutch (CL102) Stack ejection motor (M102) F-2-70 <Second and Subsequent Sheets>...
  • Page 81: Stitcher Unit

    Chapter 2 After the processing tray paper sensor detects the paper, the aligning motor (M103/M104) starts and aligns the paper. Stack ejection roller Swing guide 1st delivery roller Return roller Stapler Processing tray F-2-71 <Last Sheet> When alignment of the last sheet completes, the finisher controller PCB moves the aligning plate to alignment position with the aligning motor (M103/M104) (with the paper held with the aligning plate).
  • Page 82: Stitching Operation

    Chapter 2   time delay for initiating the stitcher motor startup current helps decrease the load on the power supply.) The stitcher home position sensor (SW7, SW5) is used to monitor the movement of the rotary cam, enabling identification of individual stitcher operations. The presence/absence of staples inside the staple cartridge fitted to the stitcher is detected by the staple sensor (SW6, SW4).
  • Page 83 a staple sensor (SW6, SW4) for detection of the presence/absence of staples. The stitcher base is designed so that it may be drawn out to the front from the saddle stitcher for replacement of the staple cartridge or removal of a staple jam. The stitcher unit in sensor (PI16) is used to make sure that the stitcher base is properly fitted to the saddle stitcher.
  • Page 84: Stack Tray Operation

    Chapter 2   2.5 Stack Tray Operation 2.5.1 Tray Operation 0009-2522 This equipment has three delivery trays. The upper tray is called escape tray, the middle tray is called tray 1, and the lower tray is called tray 2. The escape tray is fixed and tray 1 and tray 2 can move up and down independently. The escape tray has an escape tray full detector sensor (PI119).
  • Page 85 Tray 1 paper surface Rack sensor (PI111) Tray 1 switch (MSW103) Tray 1 shift motor (M107) Tray 1 shift area sensor PCB Tray 2 shift motor (M108) Tray 2 shift area Tray 2 paper surface sensor PCB sensor (PI112) Light-shielding plate Rack F-2-77...
  • Page 86 Tray 1 paper surface sensor (PI114) Paper surface sensor flag Edge Tray 2 paper surface sensor 2 (PI120) Tray 1 Tray 2 paper surface sensor 1 (PI115) Paper surface sensor flag Edge Tray 2 F-2-78 T-2-9 Tray 1 shift area sensor PCB Area sensor Area sensor Area sensor...
  • Page 87: Shutter Operation

    Chapter 2 Tray 2 shift area sensor PCB Area sensor Area sensor Area sensor Detected items 1(PS983) 2(PS982) 3(PS981) Tray 2 lower limit (finisher) Tray 2 lower limit (saddle finisher) * The symbol for the area sensor of each PCB is same because tray1/tray 2 shift area sensor PCBs are the same board. 2.5.2 Shutter Operation 0009-2523 When tray 1 passes the delivery section with paper already stacked, the stacked paper may get caught by the delivery...
  • Page 88: Detecting Jams

    Chapter 2   2.6 Detecting Jams 2.6.1 Detecting Jams (Finisher Unit) 0009-2524 The following sensors are used to detect the presence of paper and to determine that paper is delivered properly. - Inlet sensor (PI103) - Delivery sensor (PI104) - Escape tray path sensor (PI118) A jam is identified by checking whether paper is present at each sensor at the timing programmed in the memory of the microcomputer (CPU) on the finisher controller PCB.
  • Page 89: Detecting Jams (Saddle Stitcher Unit)

    Chapter 2 Jam Type Sensor Jam Condition Code Feed path PI104 When the feed path sensor (PI104) does not 1004 sensor detect paper after prescribed time (distance) has delay elapsed since the inlet sensor (PI103) detected paper. Feed path PI104 When paper does not exit the feed path sensor 1104 sensor...
  • Page 90 Chapter 2   machine. In response, the host machine may stop copying operation and indicate the presence of a jam on its control panel. When all doors are closed after the user has removed the jam, the saddle stitcher unit checks whether the vertical path paper sensor (PI17) has detected the presence of paper.
  • Page 91 T-2-13 Jam Type Sensor Jam Condition Code Inlet delay PI22 When the saddle inlet sensor (PI22) does not 1793 detect paper after a prescribed time (distance) has elapsed since receiving a saddle delivery request from the Finisher. Inlet PI22 When paper does not exit the saddle inlet sensor 17A3 stationary (PI22) after feeding for a prescribed amount with...
  • Page 92 Jam Type Sensor Jam Condition Code Power-on PI8,PI11, When paper is detected by one of the sensor on 1787 PI17,PI18, the paper sensor PCB (1st paper sensor (PI18), PI19,PI20, 2nd paper sensor (PI19), 3rd paper sensor PI22 (PI20)), vertical path paper sensor (PI17), delivery sensor (PI11), paper positioning plate paper sensor (PI8), or saddle inlet sensor (PI22) during power ON.
  • Page 93: Power Supply

    Chapter 2 2.7 Power Supply 2.7.1 Power Supply Route (Finisher Unit) 0009-2555 When the power of the host machine is turned on, 24 VDC is supplied from the host machine to the finisher controller PCB through two power supply lines. 24 VDC supplied through one power supply line is used to drive motors and solenoids.
  • Page 94: Protection Function (Saddle Stitcher Unit)

    Chapter 2   24 VDC supplied through one power supply line is used to drive motors and solenoids. The 24 VDC power for solenoids is supplied from the finisher controller circuit PCB without passing through protection mechanisms such as microswitches. The 24 VDC for motors is not supplied if any of the two door switches of the saddle stitcher unit is open.
  • Page 95 Chapter 3 Parts Replacement Procedure...
  • Page 97 Contents Contents 3.1 External Covers ..............................3-1 3.1.1 Rear Lower Cover ............................3-1 3.1.1.1 Removing the Rear Lower Cover......................3-1 3.1.2 Rear Upper Cover............................3-1 3.1.2.1 Removing the Rear Upper Cover ......................3-1 3.1.3 Grate-shaped Upper Guide .......................... 3-2 3.1.3.1 Removing the Front Door........................3-2 3.1.3.2 Removing the Escape Tray Cover......................
  • Page 98 Contents 3.2.2.3 Removing the Escape Tray Cover ...................... 3-20 3.2.2.4 Removing the Front Inside Upper Cover.................... 3-21 3.2.2.5 Removing the Grate-shaped Upper Guide..................3-21 3.2.2.6 Removing the Tray 1 .......................... 3-22 3.2.2.7 Removing the Tray 2 .......................... 3-24 3.2.2.8 Removing the Grate-shaped Lower Guide ..................3-26 3.2.2.9 Removing the Processing Tray ......................
  • Page 99 Contents 3.3.1.9 Removing the Processing Tray......................3-60 3.3.2 Tray 1 ................................ 3-62 3.3.2.1 Removing the Front Door........................3-62 3.3.2.2 Removing the Rear Upper Cover ....................... 3-62 3.3.2.3 Removing the Escape Tray Cover...................... 3-63 3.3.2.4 Removing the Grate-shaped Upper Guide ..................3-63 3.3.2.5 Removing the Tray 1 ..........................
  • Page 100 Contents 3.3.8.4 Removing the Front Inside Upper Cover..................3-102 3.3.8.5 Removing the Grate-shaped Upper Guide..................3-102 3.3.8.6 Removing the Tray 1 ........................3-103 3.3.8.7 Removing the Tray 2 ........................3-105 3.3.8.8 Removing the Grate-shaped Lower Guide ..................3-107 3.3.8.9 Removing the Upper Delivery Guide ....................3-108 3.3.9 Paper Folding Roller..........................
  • Page 101 Contents 3.4.2.11 Removing the Swing Unit Static Charge Eliminator ..............3-141 3.4.3 Static Charge Eliminator 2 ........................3-142 3.4.3.1 Removing the Front Door......................... 3-142 3.4.3.2 Removing the Escape Tray Cover....................3-142 3.4.3.3 Removing the Inlet Static Charge Eliminator .................. 3-142 3.4.4 Static Charge Eliminator 3 ........................
  • Page 103: External Covers

    Chapter 3 3.1 External Covers 3.1.1 Rear Lower Cover 3.1.1.1 Removing the Rear Lower Cover 0009-3556 1) Remove four screws [1] and remove the rear lower cover [2]. F-3-2 3.1.3 Grate-shaped Upper Guide 3.1.3.1 Removing the Front Door 0009-4444 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove.
  • Page 104: Removing The Escape Tray Cover

    Chapter 3   F-3-4 F-3-6 3.1.3.3 Removing the Grate- shaped Upper Guide 0009-3571 3.1.4.2 Removing the Rear 1) Lower tray [1] below the grate-shaped upper guide Upper Cover 0009-3619 [2] (For how the tray is moved, see the steps under 1) Remove four screws [1] and remove the rear upper "Removing the Tray 1.").
  • Page 105: Removing The Front Inside Upper Cover

    Chapter 3 F-3-10 F-3-8 3.1.4.6 Removing the Tray 1 0009-3624 3.1.4.4 Removing the Front When moving the tray down to attach it, you need Inside Upper Cover 0009-3622 to push the tray lift motor gear [1] to the front (using 1) Remove four screws [1], open the escape door [2], a screwdriver or the like) to release the clutch.
  • Page 106: Removing The Tray 2

    Chapter 3   F-3-15 F-3-12 2) Remove the screw [1] and remove the stopper [2] at When installing the tray, be careful not to twist the the back. tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally.
  • Page 107 Chapter 3 to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch. However, when the clutch is released, the tray [2] drops by its own weight. Be sure to hold the tray with your hand when releasing the clutch.
  • Page 108: Removing The Grate-Shaped Lower Guide

    Chapter 3   3.1.5 Front Inside Upper Cover 3.1.5.1 Removing the Front Door 0009-4447 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove. F-3-21 3.1.4.8 Removing the Grate- shaped Lower Guide 0009-3626 1) Remove ten screws [1] and remove the grate- shaped lower guide [2].
  • Page 109: Removing The Front Inside Upper Cover

    Chapter 3 3.1.5.3 Removing the Front 3.1.6.2 Removing the Escape Inside Upper Cover Tray Cover 0009-3558 0009-4412 1) Remove four screws [1], open the escape door [2], 1) Remove four screws [1], open the escape door [2], and then remove the front inside upper cover [3]. and then remove the escape tray cover [3].
  • Page 110: Front Door

    Chapter 3   lower cover [4]. 2) Lift the front door [1] to remove. F-3-31 F-3-29 3.1.9 Escape Tray Cover 3.1.7 PCB Cover 3.1.9.1 Removing the Escape 3.1.7.1 Removing the PCB Tray Cover 0009-4402 Cover 0009-3629 1) Remove four screws [1], open the escape door [2], 1) Remove seven screws [1] and remove the PCB and then remove the escape tray cover [3].
  • Page 111 2) Remove two screws [1] and remove the escape door [2]. F-3-33...
  • Page 112: Drive System

    Chapter 3   3.2 Drive System 3.2.1.3 Removing the Front Inside Upper Cover 0009-3634 1) Remove four screws [1], open the escape door [2], 3.2.1 Stapler and then remove the front inside upper cover [3]. 3.2.1.1 Removing the Front Door 0009-4449 1) Open the front door [1] and remove the clip [2].
  • Page 113: Swing Unit

    Chapter 3 [6]. F-3-38 F-3-40 5) Turn the stapler over, disconnect two connectors 3.2.2.2 Removing the Rear [1], remove two screws [2], and remove the stapler Upper Cover 0009-3662 from the stapler base. 1) Remove four screws [1] and remove the rear upper cover [2].
  • Page 114: Removing The Front Inside Upper Cover

    Chapter 3   F-3-44 F-3-42 3.2.2.6 Removing the Tray 1 0009-3666 3.2.2.4 Removing the Front When moving the tray down to attach it, you need Inside Upper Cover 0009-3664 to push the tray lift motor gear [1] to the front (using 1) Remove four screws [1], open the escape door [2], a screwdriver or the like) to release the clutch.
  • Page 115: Removing The Tray 2

    Chapter 3 F-3-49 F-3-46 2) Remove the screw [1] and remove the stopper [2] at When installing the tray, be careful not to twist the the back. tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally.
  • Page 116 Chapter 3   to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch. However, when the clutch is released, the tray [2] drops by its own weight. Be sure to hold the tray with your hand when releasing the clutch.
  • Page 117: Removing The Grate-Shaped Lower Guide

    Chapter 3 Hold the snap fastener at the base when unfastening because the sensor flag arm can break easily. When fastening, insert the boss of the sensor flag snap fastener in the hole on the processing tray side. F-3-55 3.2.2.8 Removing the Grate- shaped Lower Guide 0009-3669 1) Remove ten screws [1] and remove the grate-...
  • Page 118: Removing The Swing Unit

    Chapter 3   4) Remove four screws [3] and remove the finisher controller PCB [4]. F-3-61 3.2.2.10 Removing the Swing F-3-59 Unit 0009-3658 5) Release the claw [1] of the stack delivery roller rear 1)Remove two screws [1] and remove the solenoid side clutch [2] and remove the clutch [2].
  • Page 119: Saddle Unit

    Chapter 3 3) Remove two E rings [1] at the joint between the swing unit and the return roller unit and then slide the two return roller unit collars [2] inside. 4) Unhook the swing pressure rack [3] from the swing unit center hook.
  • Page 120: Removing The Rear Upper Cover

    Chapter 3   3.2.3.2 Removing the Rear Upper Cover 0009-3766 1) Remove four screws [1] and remove the rear upper cover [2]. F-3-69 3.2.3.5 Removing the Front Inside Upper Cover 0009-3769 1) Remove four screws [1], open the escape door [2], F-3-67 and then remove the front inside upper cover [3].
  • Page 121: Removing The Grate-Shaped Upper Guide

    Chapter 3 F-3-73 F-3-71 1) Remove the screw [1] and remove the stopper [2] at the front. 3.2.3.7 Removing the Grate- shaped Upper Guide 0009-3771 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 122: Removing The Tray 2

    Chapter 3   3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-78 F-3-76 4) Lift tray 1 [1] to remove it. 3.2.3.9 Removing the Tray 2 0009-3773 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 123: Removing The Grate-Shaped Lower Guide

    Chapter 3 tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 124: Removing The Pcb Cover

    Chapter 3   F-3-84 3.2.3.11 Removing the Saddle F-3-86 Delivery Tray Unit 0009-3775 1) Lift the saddle delivery tray unit [1] open/close 3) Remove the harness from two clamps [1]. lever [2] and open the saddle delivery tray unit. 4) Remove two connectors [2] and remove the saddle delivery tray unit [3].
  • Page 125: Removing The Escape Unit

    Chapter 3 F-3-88 F-3-90 3.2.3.13 Removing the Escape 3) Remove five screws [1] at the back of the escape unit. Unit 0009-4486 1) Disconnect six connectors [1] and remove the harness from two clamps [2] and harness guide. F-3-91 4) Remove three screws [1] at the front of the escape unit.
  • Page 126: Removing The Saddle Unit

    Chapter 3   F-3-96 F-3-93 4) Open the saddle door [1] and remove two screws [2]. 3.2.3.14 Removing the Saddle Unit 0009-3764 1) Disconnect two connectors [1] and remove the harness from three clamps [2]. F-3-97 5) Remove the saddle unit [1] from the paper feeding side.
  • Page 127: Stitcher Mount Unit

    Chapter 3 When installing the saddle unit, install so that the Mylar [1] at the front upper side of the saddle is on the outside of the delivery guide plate [2] as shown in the figure. Delivery fault will occur if it goes inside. F-3-100 3.2.4.2 Removing the Escape Tray Cover...
  • Page 128: Removing The Front Inside Lower Cover

    Chapter 3   F-3-104 2) Pull out the stitcher mount unit [1] to the front. F-3-102 3.2.4.4 Removing the Front Inside Lower Cover 0009-4155 F-3-105 1) Remove screw [1] and then remove the roller knob 3.2.5 Positioning Plate Unit [2]. 2) Remove four screws [3] and remove the front inside lower cover [4].
  • Page 129: Removing The Rear Upper Cover

    Chapter 3 3.2.5.2 Removing the Rear Upper Cover 0009-4128 1) Remove four screws [1] and remove the rear upper cover [2]. F-3-109 3.2.5.5 Removing the Front Inside Upper Cover 0009-4131 1) Remove four screws [1], open the escape door [2], F-3-107 and then remove the front inside upper cover [3].
  • Page 130: Removing The Pcb Cover

    Chapter 3   F-3-113 3.2.5.9 Removing F-3-111 Positioning Plate Unit 0009-4125 1) Disconnect two connectors [1] and remove the 3.2.5.7 Removing the PCB harness from the two edge saddles [2] and two clamps Cover 0009-4133 [3]. 1) Remove seven screws [1] and remove the PCB cover [2].
  • Page 131 Chapter 3 F-3-117 F-3-115 4) Remove four screws [1] and remove the stay [2]. The edge saddle harness of the stay need not be removed. F-3-116 5) Disconnect two connectors [1] and remove the harness [2] from two clamps [3]. 6) Remove two screws [4], shift the positioning plate unit [5] forward once, and then pull it out from the paper feeding side.
  • Page 132: Document Feeding System

    Chapter 3   Document Feeding System 3.3.1 Process Tray Assembly 3.3.1.1 Removing the Front Door 0009-4454 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove. F-3-119 3.3.1.3 Removing the Escape Tray Cover 0009-4419 1) Remove four screws [1], open the escape door [2],...
  • Page 133: Removing The Grate-Shaped Upper Guide

    Chapter 3 F-3-123 F-3-121 1) Remove the screw [1] and remove the stopper [2] at 3.3.1.5 Removing the Grate- the front. shaped Upper Guide 0009-3651 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 134: Removing The Tray 2

    Chapter 3   3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-128 F-3-126 4) Lift tray 1 [1] to remove it. 3.3.1.7 Removing the Tray 2 0009-3653 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 135: Removing The Grate-Shaped Lower Guide

    Chapter 3 tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 136 Chapter 3   removed. Be careful not to loose it. [2] [3] F-3-134 3.3.1.9 Removing F-3-136 Processing Tray 0009-3636 1) Unfasten four snap fasteners [1] and remove the 3) Remove all finisher controller PCB connectors[1] sensor flag [3] from the stack delivery roller [2]. and remove the harness from two clamp [2].
  • Page 137: Tray 1

    Chapter 3 [3] [4] [5] F-3-138 7) Disconnect two connectors [1] and remove harness F-3-140 from the clamp and edge saddle [2]. 8) Remove two screws [3] and pull out the processing 3.3.2.2 Removing the Rear tray [4] in the paper delivery direction. Upper Cover 0009-3586 1) Remove four screws [1] and remove the rear upper...
  • Page 138: Removing The Grate-Shaped Upper Guide

    Chapter 3   F-3-142 F-3-144 3.3.2.4 Removing the Grate- shaped Upper Guide 1) Remove the screw [1] and remove the stopper [2] at 0009-3612 the front. 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 139: Tray 2

    Chapter 3 3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-149 F-3-147 4) Lift tray 1 [1] to remove it. 3.3.3 Tray 2 3.3.3.1 Removing the Front Door 0009-4457 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove.
  • Page 140: Removing The Escape Tray Cover

    Chapter 3   F-3-151 F-3-153 3.3.3.3 Removing the Escape 3.3.3.5 Removing the Grate- Tray Cover 0009-4427 shaped Upper Guide 0009-3615 1) Remove four screws [1], open the escape door [2], and then remove the escape tray cover [3]. 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 141 Chapter 3 3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-155 F-3-158 1) Remove the screw [1] and remove the stopper [2] at 4) Lift tray 1 [1] to remove it. the front. F-3-159 F-3-156 2) Remove the screw [1] and remove the stopper [2] at...
  • Page 142: Removing The Tray 2

    Chapter 3   F-3-162 F-3-160 2) Remove the screw [1] and disconnect the connector [2]. 3.3.3.7 Removing the Tray 2 0009-3589 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 143: Buffer Roller

    Chapter 3 tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 144: Return Roller

    Chapter 3   F-3-168 3.3.5 Return Roller F-3-170 3.3.5.3 Removing the Escape 3.3.5.1 Removing the Front Tray Cover Door 0009-4429 0009-4459 1) Remove four screws [1], open the escape door [2], 1) Open the front door [1] and remove the clip [2]. and then remove the escape tray cover [3].
  • Page 145: Removing The Grate-Shaped Upper Guide

    Chapter 3 F-3-174 F-3-172 1) Remove the screw [1] and remove the stopper [2] at 3.3.5.5 Removing the Grate- the front. shaped Upper Guide 0009-3714 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 146: Removing The Tray 2

    Chapter 3   3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-179 F-3-177 4) Lift tray 1 [1] to remove it. 3.3.5.7 Removing the Tray 2 0009-3716 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 147: Removing The Grate-Shaped Lower Guide

    Chapter 3 tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 148 Chapter 3   removed. Be careful not to loose it. [2] [3] F-3-185 3.3.5.9 Removing F-3-187 Processing Tray 0009-3719 1) Unfasten four snap fasteners [1] and remove the 3) Remove all finisher controller PCB connectors[1] sensor flag [3] from the stack delivery roller [2]. and remove the harness from two clamp [2].
  • Page 149: Return Roller Unit

    Chapter 3 will increase its feed power, ultimately causing [3] [4] [5] feeding faults. Moreover, be sure to avoid touching the surface of the return roller when mounting it to the machine. 1) Remove two clips [1] of the return roller axis. 2) Pull out the return roller axis and remove two return rollers [2] together with collar.
  • Page 150: Removing The Rear Upper Cover

    Chapter 3   F-3-194 F-3-192 3.3.6.4 Removing the Front Inside Upper Cover 0009-3687 3.3.6.2 Removing the Rear 1) Remove four screws [1], open the escape door [2], Upper Cover 0009-3684 and then remove the front inside upper cover [3]. 1) Remove four screws [1] and remove the rear upper cover [2].
  • Page 151: Removing The Tray 2

    Chapter 3 F-3-196 F-3-198 3.3.6.6 Removing the Tray 1 0009-3689 2) Remove the screw [1] and remove the stopper [2] at the back. When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 152: Removing The Tray 2

    Chapter 3   to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch. However, when the clutch is released, the tray [2] drops by its own weight. Be sure to hold the tray with your hand when releasing the clutch.
  • Page 153: Removing The Grate-Shaped Lower Guide

    Chapter 3 F-3-205 F-3-207 3) Lift tray 2 [1] to remove it. 3.3.6.8 Removing the Grate- shaped Lower Guide 0009-3691 1) Remove ten screws [1] and remove the grate- shaped lower guide [2]. When replacing, be careful not to hook the grate- shaped lower guide to the sensor flag arm on the F-3-206 delivery side.
  • Page 154 Chapter 3   F-3-211 F-3-209 3.3.6.10 Removing 2) Release the claw [1] and remove the PCB [2]. Processing Tray 0009-3693 3) Disconnect three connectors [3]. 1) Unfasten four snap fasteners [1] and remove the 4) Remove screw [4] and remove the stapler together sensor flag [3] from the stack delivery roller [2].
  • Page 155: Removing The Swing Unit

    Chapter 3 removed. Be careful not to loose it. [3] [4] [5] [2] [3] F-3-215 7) Disconnect two connectors [1] and remove harness F-3-213 from the clamp and edge saddle [2]. 8) Remove two screws [3] and pull out the processing 3) Remove all finisher controller PCB connectors[1] tray [4] in the paper delivery direction.
  • Page 156 Chapter 3   F-3-217 2) Remove screw [1] and pull up the swing pressure guide [2]. F-3-219 5) Remove the belt [1] from the gear [2], remove the belt [3] from the gear [2] and gear [4], and pull out the swing unit [5] from the delivery direction.
  • Page 157: Removing The Return Roller Unit

    Chapter 3 3.3.6.12 Removing the Return Roller Unit 0009-3679 1) Remove the return roller unit front side connector [1] and remove the harness from two clamps [2]. 2) Remove the spring [3] and three screws [4] and pull out the return roller unit [5] from the front side. F-3-223 3) Remove the harness from two clamps [1].
  • Page 158: Removing The Rear Upper Cover

    Chapter 3   F-3-227 F-3-225 3.3.8.4 Removing the Front Inside Upper Cover 0009-4092 3.3.8.2 Removing the Rear 1) Remove four screws [1], open the escape door [2], Upper Cover 0009-4090 and then remove the front inside upper cover [3]. 1) Remove four screws [1] and remove the rear upper cover [2].
  • Page 159: Removing The Tray 1

    Chapter 3 F-3-229 F-3-231 3.3.8.6 Removing the Tray 1 0009-4094 2) Remove the screw [1] and remove the stopper [2] at the back. When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 160: Removing The Tray 2

    Chapter 3   to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch. However, when the clutch is released, the tray [2] drops by its own weight. Be sure to hold the tray with your hand when releasing the clutch.
  • Page 161: Removing The Grate-Shaped Lower Guide

    Chapter 3 F-3-238 F-3-240 3) Lift tray 2 [1] to remove it. 3.3.8.8 Removing the Grate- shaped Lower Guide 0009-4096 1) Remove ten screws [1] and remove the grate- shaped lower guide [2]. When replacing, be careful not to hook the grate- shaped lower guide to the sensor flag arm on the F-3-239 delivery side.
  • Page 162: Removing The Rear Upper Cover

    Chapter 3   F-3-242 F-3-244 3.3.9 Paper Folding Roller 3.3.9.3 Removing the Rear Lower Cover 0009-4100 3.3.9.1 Removing the Front Door 1) Remove four screws [1] and remove the rear lower 0009-4466 cover [2]. 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove.
  • Page 163: Removing The Front Inside Upper Cover

    Chapter 3 F-3-246 3.3.9.5 Removing the Front F-3-248 Inside Upper Cover 0009-4103 1) Remove four screws [1], open the escape door [2], 3.3.9.7 Removing the Grate- and then remove the front inside upper cover [3]. shaped Upper Guide 0009-4105 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 164 Chapter 3   3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-250 F-3-253 1) Remove the screw [1] and remove the stopper [2] at 4) Lift tray 1 [1] to remove it. the front. F-3-254 F-3-251 2) Remove the screw [1] and remove the stopper [2] at...
  • Page 165: Removing The Tray 2

    Chapter 3 F-3-257 F-3-255 2) Remove the screw [1] and disconnect the connector [2]. 3.3.9.9 Removing the Tray 2 0009-4107 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 166: Removing The Grate-Shaped Lower Guide

    Chapter 3   tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 167: Removing The Paper Folding Roller

    Chapter 3 F-3-263 F-3-265 3.3.9.13 Removing the Paper Folding Roller 0009-4112 4) Remove the screw [1], remove the spring retaining plate [2], and remove the front tension spring [3] and 1) Disconnect two connectors [1] and remove the the smaller tension spring [4]. harness from two edge saddles [2] and two clamps [3].
  • Page 168 Chapter 3   F-3-270 9) Open the saddle delivery tray [1]. F-3-267 10) Remove two screws [2] and remove the two aligning plates [3]. 6) Remove the two C-rings [1] at the rear, and remove 11) Slide the two paper folding rollers [4] to the front, the sensor flag [2] and two bearings [3].
  • Page 169: Removing The Rear Lower Cover

    Chapter 3 3.3.10 Escape Unit 3.3.10.3 Removing the Rear Lower Cover 0009-4481 3.3.10.1 Removing the Front 1) Remove four screws [1] and remove the rear lower cover [2]. Door 0009-4478 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove.
  • Page 170: Removing The Escape Unit

    Chapter 3   F-3-279 F-3-277 3) Remove five screws [1] at the back of the escape unit. 3.3.10.6 Removing the Escape Unit 0009-4484 1) Disconnect six connectors [1] and remove the harness from two clamps [2] and harness guide. F-3-280 4) Remove three screws [1] at the front of the escape unit.
  • Page 171: Escape Door Unit

    Chapter 3 F-3-282 F-3-284 3.3.11 Escape Door Unit 3.3.11.3 Removing the Escape Tray Cover 0009-4473 3.3.11.1 Removing the Front 1) Remove four screws [1], open the escape door [2], Door 0009-4471 and then remove the escape tray cover [3]. 1) Open the front door [1] and remove the clip [2]. 2) Lift the front door [1] to remove.
  • Page 172: Removing The Escape Door Unit

    Chapter 3   F-3-286 3.3.11.5 Removing the Escape F-3-288 Door Unit 0009-4477 1) Remove two E-rings [1]. 2) Remove screw and remove the escape unit support plate [3]. 3) Open the escape door unit [4] and remove the escape door unit. F-3-287 Do not remove the two screws [1] securing escape door shaft.
  • Page 173: Electrical System

    Chapter 3 3.4 Electrical System 3.4.1 Finisher Controller PCB 3.4.1.1 Finisher Controller PCB 3.4.1.1.1 Removing the Rear Upper Cover 0009-4160 1) Remove four screws [1] and remove the rear upper cover [2]. F-3-290 3.4.2 Static Charge Eliminator 1 3.4.2.1 Removing the Front Door 0009-4467 1) Open the front door [1] and remove the clip [2].
  • Page 174: Removing The Escape Tray Cover

    Chapter 3   F-3-292 F-3-294 3.4.2.3 Removing the Escape 3.4.2.5 Removing the Grate- Tray Cover 0009-4440 shaped Upper Guide 0009-3703 1) Remove four screws [1], open the escape door [2], and then remove the escape tray cover [3]. 1) Lower tray [1] below the grate-shaped upper guide [2] (For how the tray is moved, see the steps under "Removing the Tray 1.").
  • Page 175 Chapter 3 3) Remove two screws [1], open three harness retainers [2], and disconnect two connectors [3]. F-3-296 F-3-299 1) Remove the screw [1] and remove the stopper [2] at 4) Lift tray 1 [1] to remove it. the front. F-3-300 F-3-297 2) Remove the screw [1] and remove the stopper [2] at...
  • Page 176: Removing The Tray 2

    Chapter 3   F-3-303 F-3-301 2) Remove the screw [1] and disconnect the connector [2]. 3.4.2.7 Removing the Tray 2 0009-3705 When moving the tray down to attach it, you need to push the tray lift motor gear [1] to the front (using a screwdriver or the like) to release the clutch.
  • Page 177: Removing The Grate-Shaped Lower Guide

    Chapter 3 tray cable. To prevent the gear phase from shifting due to the front and rear rails, the tray must be attached horizontally. Lower the tray [1] to the position shown in the figure and compare the heights of the shutter guide top edges [2] with those of the tray projections [3] at the front and rear to check that the tray is attached horizontally.
  • Page 178 Chapter 3   F-3-309 F-3-311 5) Turn the stapler over, disconnect two connectors 2) Remove the stack delivery roller front side E ring [1], remove two screws [2], and remove the stapler [1], gear [2], parallel pin [3], E ring [4], washer [5], from the stapler base.
  • Page 179: Removing The Swing Unit Static Charge Eliminator

    Chapter 3 F-3-315 F-3-313 3.4.2.11 Removing the Swing 5) Release the claw [1] of the stack delivery roller rear side clutch [2] and remove the clutch [2]. Unit Static Charge Eliminator 0009-3697 6) Remove the E ring [3], washer [4], and bearing [5] 1) Remove the screw [1] securing the static charge and remove the stack delivery roller.
  • Page 180: Static Charge Eliminator 2

    Chapter 3   F-3-317 F-3-319 3.4.3 Static Charge Eliminator 2 3.4.3.3 Removing the Inlet Static Charge Eliminator 0009-4161 3.4.3.1 Removing the Front 1) Remove three screws [1], open the delivery door Door 0009-4469 [2], and remove the inlet static charge eliminator [3]. 1) Open the front door [1] and remove the clip [2].
  • Page 181: Saddle Stitcher Controller Pcb

    Chapter 3 F-3-321 3.4.4.2 Removing the Escape F-3-323 Delivery Static Charge Eliminator 0009-4175 1) Remove two screws [1] and remove the escape delivery static charge eliminator [2]. 3.4.5 Saddle Stitcher Controller PCB 3.4.5.1 Removing the PCB Cover 0009-4124 1) Remove seven screws [1] and remove the PCB cover [2].
  • Page 182 F-3-325...
  • Page 183 Chapter 4 Maintenance...
  • Page 185 Contents Contents 4.1 User Maintenance............................... 4-1 4.1.1 User Maintenance (Finisher Unit) ....................... 4-1 4.1.2 User Maintenance (Saddle Stitcher Unit)....................4-1 4.2 Maintenance and Inspection ..........................4-2 4.2.1 Periodically Replaced Parts......................... 4-2 4.2.1.1 Periodically Replaced Parts (Finisher Unit) ..................4-2 4.2.1.2 Periodically Replaced Parts (Saddle Stitcher Unit)................4-2 4.2.2 Durables...............................
  • Page 186 Contents 4.4.1.15 E5F2;Guide motor error........................4-21 4.4.1.16 E5F3;Aligning motor error ....................... 4-22 4.4.1.17 E5F4;Stitcher (rear) error........................4-22 4.4.1.18 E5F5;Stitcher (front) error ........................ 4-22 4.4.1.19 E5F6;Paper pushing plate motor error....................4-23 4.4.1.20 E5F9;Micro switch error........................4-23 4.5 Outline of Electrical Components ........................4-24 4.5.1 Sensors (Finisher Unit) ..........................
  • Page 187: User Maintenance

    Chapter 4 4.1 User Maintenance 4.1.1 User Maintenance (Finisher Unit) 0009-2559 T-4-1 Item Timing Staple cartridge When prompted (indicator on host replacement machine control panel) 4.1.2 User Maintenance (Saddle Stitcher Unit) 0009-2570 T-4-2 Item Timing Staple cartridge When prompted (indicator on host replacement machine control panel)
  • Page 188: Maintenance And Inspection

    Chapter 4   4.2 Maintenance and Inspection 4.2.1 Periodically Replaced Parts 4.2.1.1 Periodically Replaced Parts (Finisher Unit) 0009-2560 The Finisher unit does not have parts that must be replaced on a periodical basis. 4.2.1.2 Periodically Replaced Parts (Saddle Stitcher Unit) 0009-2571 The Saddle stitcher unit does not have parts that must be replaced on a periodical basis.
  • Page 189: Durables (Saddle Stitcher Unit)

    Chapter 4 As of November, 2004 Name Quantit Approx. Remark life Swing guide FL2-0817- 1,000,000 inside sheets static charge eliminator Buffer roller FC5-3442- 1,000,000 sheets Return roller FC5-3457- 1,000,000 Color;White (Rear) sheets Return roller FC5-6873- 1,000,000 Color;Black (Front) sheets 4.2.2.2 Durables (Saddle Stitcher Unit) 0009-2572 Some of the parts of the machine may need to be replaced one or more times because of wear or tear during the machine's warranty period.
  • Page 190: Adjustment

    Chapter 4   4.3 Adjustment proper stacking. - When this mode item has been enabled, changes in conditions (e.g., the use of paper with little curl or 4.3.1 Basic Adjustment paper with downward curl) can cause improper stacking. In this regard, it is very important to study the type of paper that is most often used by the user 4.3.1.1 Upward Curl Mode 0009-2563...
  • Page 191: Downward Curl Mode

    Chapter 4 b. Enabling the Downward Curl Mode 1) Turn off the host machine. 2) Set the bits of SW104 on the finisher controller 1 2 3 4 5 6 7 8 PCB as follows: F-4-4 3) Turn on the host machine. - When this mode item is enabled, the paper surface 1 2 3 4 5 6 7 8 detection mechanism is executed for every sheet of...
  • Page 192: Stack Delivery Mode

    Chapter 4   If this is the case, 1) Turn over the stack of paper in the source (i.e., cassette). If doing so has caused the paper to curl more than before, turn back over the stack. If the curling is still appreciable and the machine fails to stack the paper properly, try enabling heavy paper upward curl mode.
  • Page 193: Saddle Delivery Tray Limitless Mode

    Chapter 4 Depending on the paper condition, paper can curl and the machine can fail to deliver/stack it properly in the small size offset mode. 1 2 3 4 5 6 7 8 If this is the case, F-4-12 1) Turn over the stack of paper in the source cassette. If doing so has caused the paper to curl much more 3) Turn on the host machine.
  • Page 194: Adjusting The Staple Position

    Chapter 4   store the adjustment in memory. 6) Press SW103 on the finisher controller PCB once to 8) Turn off all bits of finisher controller PCB SW104. staple. However, remove the stapled paper 9) Turn off the power of the host machine and install manually to verify the staple position because it is not the rear upper cover of the finisher unit.
  • Page 195 Chapter 4 SW504 on the saddle stitcher con-troller PCB as adjustment" to suit the relationship between the follows: stitching position and the folding position. If the stitching position is below the folding position, perform "positive width adjustment." If the stitching position is above the folding position, 1 2 3 4 5 6 7 8 Do not change bits 5 through 8.
  • Page 196: Adjusting The Stitcher Unit

    Chapter 4   T-4-5 SW504 bit Setting settings (in units of 0.5 mm) Bit 6 Bit 7 Bit 8 F-4-18 4) Remove the stitcher positioning tool [4] from the back of the cover. Do not use the following setting. T-4-6 Bit 6 Bit 7 Bit 8...
  • Page 197 Chapter 4 mount [8]. [10] F-4-21 7) Insert the tool [12] into the staple slot of the stitcher [11]. [11] [12] F-4-22 8) Tilt the stitcher, and turn the stitcher gear [13] to match the recess of the tool [14] and the mount [15] and then tighten the screws on the mount [15] to secure.
  • Page 198: Troubleshooting

    Chapter 4   4.4 Troubleshooting 4.4.1 Error Code 4.4.1.1 E500;Communication error 0009-2588 Finisher controller PCB/Host machine DC controller PCB 1) Does it improve when the host machine power switch is turned OFF/ON? YES : End Wiring 2) Is the wiring between the finisher controller PCB and host machine DC controller PCB normal? NO : Repair the wiring.
  • Page 199: E530;Front Aligning Plate Motor Error

    Chapter 4 2) Is the wiring between the finisher controller PCB and rear end assist motor normal? NO : Repair the wiring. Rear end assist mechanism 3) Is there any abnormality in the rear end assist mechanism? YES : Repair the rear end assist mechanism. Rear end assist motor (M109)/Finisher controller PCB 4) Does it improve when the rear end assist motor is replaced? YES : End...
  • Page 200: E535;Swing Motor Error

    Chapter 4   NO : Replace the sensor. Wiring 3) Is the wiring between the finisher controller PCB and stapler shift motor normal? NO : Repair the wiring. Stapler shift base 4) Is there mechanical trapping in the path of the stapler shift base? YES : Repair the mechanism.
  • Page 201: E540;Tray 1 Shift Motor Error

    Chapter 4 4.4.1.10 E540;Tray 1 shift motor error 0009-2596 Tray 1 paper surface sensor (PI114) 1) Check the tray 1 paper surface sensor. Does it operate normally? NO : Replace the sensor. Tray 1 shift area sensor PCB 2) Check the tray 1 shift area sensors 1 to 3. Do the sensors operate normally? NO : Replace the tray 1 shift area sensor PCB.
  • Page 202: E5F0;Paper Positioning Plate Motor Error

    Chapter 4   1) Check the shutter home position sensor. Does the sensor operate normally? NO : Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and stack ejection motor, and between the finisher controller PCB and shutter clutch normal? NO : Repair the wiring.
  • Page 203: E5F3;Aligning Motor Error

    Chapter 4 1) Check the guide home position sensor. Does the sensor operate normally? NO : Replace the sensor. Guide plate drive mechanism 2) Is there any abnormality in the guide plate drive machanism? YES : Repair the guide plate drive mechanism. Guide Motor (M3)/Saddle stitcher controller PCB 3) Does it improve when the guide motor is replaced? YES : End...
  • Page 204: E5F6;Paper Pushing Plate Motor Error

    Chapter 4   Stitcher motor (front) (M7) / Saddle sticher controller PCB 3) Does it improve when the stitcher is replaced? YES : End NO : Replace the saddle stitcher controller PCB. 4.4.1.19 E5F6;Paper pushing plate motor error 0009-2608 Paper pushing plate home position sensor (PI14)/Paper pushing plate top position sensor (PI15)/Paper pushing plate motor clock sensor (PI1) 1) Check the sensors.
  • Page 205: Outline Of Electrical Components

    Chapter 4 4.5 Outline of Electrical Components 4.5.1 Sensors (Finisher Unit) 0009-2613 PI119 PI105 PI109 PI108 PI111 PI107 PI114 PI104 PI103 PI121 PI106 PI118 PI102 PI113 PI115 PI116 PI120 PI110 PI112 F-4-24 T-4-7 Ref. Name Description Parts Error PI10 Front cover sensor Detects front cover open/ WG8- 1400/...
  • Page 206 Ref. Name Description Parts Error PI10 Feed path sensor Detects paper in feed path WG8- 1004/ 5509 1104/ 1300 PI10 Swing guide HP Detects swing guide HP WG8- E535 sensor 5509 PI10 Front aligning plate Detects aligning plate front WG8- E530 HP sensor 5593...
  • Page 207 T-4-8 Ref. Stapler PCB 2 Stapler PCB 1 Feed driver Finisher controller PCB PI102 J887 / J886A J708B PI103 J712 PI104 J731 PI105 J731 PI106 J721B PI107 J721B PI108 J721B PI109 J721B PI110 J721A PI111 J718B PI112 J719B PI113 J721A PI114 J721A PI115...
  • Page 208: Microswitches (Finisher Unit)

    Chapter 4   4.5.2 Microswitches (Finisher Unit) 0009-2614 MSW104 MSW102 MSW103 MSW101 F-4-25 T-4-9 Ref. Name Description Parts Error Finisher controller Front cover switch Detects front FH7- 1400 E5F9 J707 cover close 6379 Swing guide Detects swing FH7- J714 switch guide open 6379 Tray 1 switch...
  • Page 209: Solenoids (Finisher Unit)

    Chapter 4 Ref. Name Description Parts Error Finisher controller Staple safety Detects swing FH7- J714 switch guide open 6379 4.5.3 Solenoids (Finisher Unit) 0009-2615 SL102 SL103 SL101 SL104 SL105 F-4-26 T-4-10 Ref. Name Parts Feed driver PCB Finisher controller PCB Feed roller FL2- J713...
  • Page 210: Motors (Finisher Unit)

    Chapter 4   Ref. Name Parts Feed driver PCB Finisher controller PCB 1st delivery roller FL2- J713 separation solenoid 0812 Buffer rear end FL2- J713 holding solenoid 0821 Escape solenoid FH6- J889 / J881B J705B 5089 4.5.4 Motors (Finisher Unit) 0009-2616 M107 M106...
  • Page 211 Ref. Name Parts No. Error M103 Front aligning plate motor FH5-1040 E530 M104 Rear aligning plate motor FH5-1040 E537 M105 Stapler shift motor FH5-1037 E532 M106 Swing motor FH5-1036 E535 M107 Tray 1 shift motor 4K1-1102 E540 M108 Tray 2 shift motor 4K1-1102 E542 M109...
  • Page 212: Clutches (Finisher Unit)

    Chapter 4   4.5.5 Clutches (Finisher Unit) 0009-2617 CL102 CL101 F-4-28 T-4-13 Ref. Name Parts Error Finisher controller PCB CL10 Shutter clutch FH6- E584 J732 5101 CL10 Stack ejection lower roller FH6- E584 J716 clutch 5101 4-26...
  • Page 213: Pcbs (Finisher Unit)

    Chapter 4 4.5.6 PCBs (Finisher Unit) 0009-2618 F-4-29 T-4-14 Name Parts No. Error Finisher controller PCB 4G1-1487 Stapler PCB 1 FM2-1426(CABLE, STAPLE E531/ CONNECTING ASS'Y) E532 Stapler PCB 2 FM2-1426(CABLE, STAPLE E531/ CONNECTING ASS'Y) E532 Feed driver PCB 4G1-1488 Tray 1 shift area sensor PCB FG3-2886 E540 Tray 2 shift area sensor PCB...
  • Page 214: Sensors (Saddle Stitcher Unit)

    Chapter 4   Name Parts No. Error Tray 2 shift motor PCB 4K1-1102 E542 4.5.7 Sensors (Saddle Stitcher Unit) 0009-2646 PI16 PI22 PI18 PI19 PI20 PI21 PI11 PI17 PI14 PI15 PI12 PI13 F-4-30 T-4-15 Ref. Name Description Parts Error Saddle stitcher controller Paper pushing...
  • Page 215 Ref. Name Description Parts Error Saddle stitcher controller Paper folding Detects paper FK2- E5F1 motor clock folding motor 0149 sensor clock Alignment plate Dtects alignment WG8- E5F3 HP sensor plate HP 5593 Tray paper sensor Detects paper on WG8- tray 5593 Paper positioning Dtects paper...
  • Page 216: Microswitches (Saddle Stitcher Unit)

    Chapter 4   Ref. Name Description Parts Error Saddle stitcher controller PI20 No.3 paper Detects paper FG3- 17A1/ sensor (No.3; on paper 3106 1787 sensor PCB) PI21 Paper folding HP Detects paper WG8- E5F1 sensor fold HP 5593 PI22 Saddle inlet Detects saddle WG8- 1793/...
  • Page 217 T-4-16 Ref. Name Description Parts Error Saddle stitcher controll er PCB MSW1 Inlet door switch Detects inlet door WC4- E5F9 open 5128 MSW3 Delivery door Detects delivery WC4- E5F9 switch door open 5128 Staple sensor Detects presence FL2- (rear) of staples (rear) 0846-000 (STAPL UNIT)
  • Page 218: Motors (Saddle Stitcher Unit)

    Chapter 4   4.5.9 Motors (Saddle Stitcher Unit) 0009-2648 F-4-32 T-4-17 Ref. Name Parts No. Error Saddle stitcher controller PCB Feed motor FH5-1042 Paper folding motor FH5-1068 E5F1 Guide motor 4K1-1103 E5F2 Paper positioning plate 4K1-1104 E5F0 motor Alignment motor 4K1-1103 E5F3 Stitcher motor (rear)
  • Page 219: Solenoids (Saddle Stitcher Unit)

    Chapter 4 Ref. Name Parts No. Error Saddle stitcher controller PCB Paper pushing plate FH5-1068 E5F6 motor 4.5.10 Solenoids (Saddle Stitcher Unit) 0009-2649 F-4-33 T-4-18 Ref. Name Parts No. Saddle stitcher controller PCB No.1 paper deflecting FH6-5089 solenoid No.2 paper deflecting FH6-5089 solenoid Feed plate contact solenoid...
  • Page 220: Pcbs (Saddle Stitcher Unit)

    Chapter 4   4.5.11 PCBs (Saddle Stitcher Unit) 0009-2650 F-4-34 T-4-19 Ref. Name Parts No. Saddle stitcher controller PCB 4G1-1489 Paper sensor PCB FG3-3106 4-34...
  • Page 221: Variable Resistors (Vr), Light-Emitting Diodes (Led), And

    Chapter 4 4.6 Variable Resistors (VR), Light-Emitting Diodes (LED), and Check Pins by PCB 4.6.1 Overview 0009-2619 Of the LEDs and check pins used in the machine, those needed during servicing in the field are discussed. Do not touch the check pins not found in the list herein. They are exclusively for factory use, and require special tools and a high degree of accuracy.
  • Page 222: Saddle Stitcher Controller Pcb

    Chapter 4   4.6.3 Saddle Stitcher Controller PCB 0009-2651 SW504 F-4-36 T-4-21 Switch Function SW504,Bit 1 to 2 Starts correction of discrepancy between stitching position and folding position. SW504,Bit 6 to 8 Stores corrected settings for stitching position and folding position. Starts correction of discrepancy between stitching position and folding position.
  • Page 223: Upgrading

    Chapter 4 4.7 Upgrading 4.7.1 Upgrading (Finisher Unit) 0009-2621 Overview A flash ROM is used for the IC108 (CPU) of the Finisher unit. To upgrade this IC, the downloader PCB (FY9-2034) is used. The operating instructions for it are given below. How to Use the Downloader PCB (FY9-2034) 1.When to Use the Downloader PCB The downloader PCB is used when upgrading the CPU (IC108) of the Finisher Controller PCB.
  • Page 224 Chapter 4   Description Function Cable B (9 A cable to connect the downloader PCB and the pins)Length: approx. Finisher 50cm RS-232C connector A connector to connect an RS-232C cable to the downloader PCB 3. Necessary Tool The following item needs to be prepared for download. Computer (PC) Prerequisite: The download tool (Ver.
  • Page 225 Chapter 4 F-4-39 5) Select [Register]. F-4-40 6) Select [OK] and register the data. 4-39...
  • Page 226 Chapter 4   F-4-41 b. Connection to the Finisher 1) Turn off the power of the host machine. 2) Remove the rear upper cover of the Finisher. 3) Insert the cable B to J723 on the Finisher controller PCB. 4) Connect the RS-232C cable to the RS-232C connectors of the circuit board and the PC. 5) Turn on the power of the host machine.
  • Page 227 Chapter 4 F-4-42 F-4-43 3) Press the START/STOP key of the downloader PCB. LOAD LED is lit. 4)Select the data and press [START]. 4-41...
  • Page 228 Chapter 4   F-4-44 5) Follow the instructions on the screen to prepare for downloading. A press on [OK] will bring up the next screen. F-4-45 6) Select the data to download. 4-42...
  • Page 229 Chapter 4 F-4-46 7) Press [START] to start downloading. F-4-47 8) Press [START] so that the computer and the downloader PCB will start downloading the program. 4-43...
  • Page 230 Chapter 4   F-4-48 9) If downloading ended normally, press [OK]. F-4-49 10)Return to the main menu and finish the download. 4-44...
  • Page 231: Upgrading (Saddle Stitcher Unit)

    Chapter 4 F-4-50 5. Release of Connection 1) Press the START/STOP key of the downloader PCB. LOAD LED is turned off. 2) Turn off the power of the host machine. 3) Disconnect the cable B from the Finisher. 4) Mount the rear upper cover to the Finisher. 5) Turn on the power of the host machine.
  • Page 232 Chapter 4   F-4-51 T-4-23 Description Function START/STOP key A key to be pressed when you start or stop download LOAD LED To be lit when download is available. Model LED To be lit when the Finisher is connected. Power LED To be lit when power is supplied from the Finisher to the downloader PCB RS-232C cable...
  • Page 233 Chapter 4 1) Store ROM data to be downloaded in the 'C:\ServTool\NewROM' folder. 2) Start up the Service Support Tool. C:\ProgramFiles\Service Support Tool\bpchost.exe 3) Select [Register System Software]. F-4-52 4) Select the data inside the NewROM folder. F-4-53 5) Select [Register]. 4-47...
  • Page 234 Chapter 4   F-4-54 6) Select [OK] and register the data. F-4-55 b. Connection to the Finisher 1) Turn off the power of the host machine. 2) Detach the finisher from the host machine, and remove the PCB cover of the finisher. 3) Insert the cable B to J22 on the Saddle stitcher controller PCB.
  • Page 235 Chapter 4 c. Download The error code E503 might occur during download. It does not affect the download operation and its results. 1) Start up the Service Support Tool. C:\ProgramFiles\Service Support Tool\bpchost.exe 2) Select the type of host machine. F-4-56 F-4-57 4-49...
  • Page 236 Chapter 4   3) Press the START/STOP key of the downloader PCB. LOAD LED is lit. 4)Select the data and press [START]. F-4-58 5) Follow the instructions on the screen to prepare for downloading. A press on [OK] will bring up the next screen. F-4-59 4-50...
  • Page 237 Chapter 4 6) Select the version of the ROM to download. F-4-60 7) Press [Start] so that the computer and the downloaded PCB will start downloading the program. F-4-61 8) If downloading ended normally, press [OK]. 4-51...
  • Page 238 Chapter 4   F-4-62 9) End the session as instructed on the screen. F-4-63 5. Release of Connection 1) Press the START/STOP key of the downloader PCB. LOAD LED is turned off. 2) Turn off the power of the host machine. 3) Disconnect the cable B from the Finisher.
  • Page 239 4) Put the PCB cover back to the finisher, and attach the finisher to the host machine. 5) Turn on the power of the host machine. 6. Checking the Operation 1)Check to make sure that the finisher operates normal.
  • Page 240: Service Tools

    Chapter 4   4.8 Service Tools 4.8.1 Solvents and Oils 0009-2622 T-4-24 Name Description Composition Remarks Vic Clean Cleaning: Hydrocarbon(fluori Do not bring near e.g., glass, ne family) fire. plastic, rubber parts, Alcohol Procure locally. external covers Surface activating Isopropyl alcohol agent may be substituted.
  • Page 241 Chapter 5 Error Code...
  • Page 243 Contents Contents 5.1 Overview ................................5-1 5.1.1 Overview ..............................5-1 5.2 User Error Code..............................5-2 5.2.1 Staple is absent ............................5-2 5.2.2 Stapler safety protection function activated ....................5-2 5.2.3 Stack tray overstacking ..........................5-3 5.2.4 Staple is absent (Saddle Stitcher Unit) ......................5-3 5.2.5 Mixed paper sizes (Saddle Stitcher Unit)....................
  • Page 245: Overview

    Chapter 5 5.1 Overview 5.1.1 Overview 0009-2669 The CPU on the machine's finisher controller PCB is equipped with a mechanism to check the machine condition as needed; when it detects a fault, the machine communicates the fact to the host machine in the form of a code and a detail code.
  • Page 246: User Error Code

    Chapter 5   5.2 User Error Code 5.2.1 Staple is absent 0009-2670 T-5-1 Error Condition Detection Machine Resetting Descrip- timing operation tion Staple is The staple Always Normal Replace the absent cartridge monitored operation staple has run can be cartridge; or, set out of staples.
  • Page 247: Stack Tray Overstacking

    Chapter 5 5.2.3 Stack tray overstacking 0009-2673 T-5-3 Error Condition Detection Machine Resetting Descrip- timing operation tion Stack The number of After ejecting Normal Remove paper tray sheets on the the sheet/set operation from ejection over- ejection tray exceeding the will continue.
  • Page 248: Mixed Paper Sizes (Saddle Stitcher Unit)

    Chapter 5   5.2.5 Mixed paper sizes (Saddle Stitcher Unit) 0009-2699 T-5-5 Error Condition Detection Machine Resetting Descrip- timing operation tion Mixed Sheets of When the sheet Stitching is Remove the paper different sizes that causes the prohibited. sheets from the sizes are output in the fault is output to...
  • Page 249: Service Error Code

    Chapter 5 5.3 Service Error Code 5.3.1 E500 0009-2677 T-5-8 Code Detail Error Detection timing Description E500 0001 Communication The communication with the host machine error is interrupted. 5.3.2 E503 0009-2694 T-5-9 Code Detail Error Detection timing Description E503 0002 Communication The communication with the saddle error...
  • Page 250: E514

    Chapter 5   5.3.4 E514 0009-2679 T-5-11 Code Detail Error Detection timing Description E514 8001 Rear end assist The stapler does not leave the rear end motor(M109)/ assist home position when the rear end Rear end assist assist motorhas been driven for 3 seconds. homeposition 8002 The stapler does not return to the rear end...
  • Page 251: E531

    Chapter 5 5.3.6 E531 0009-2683 T-5-13 Code Detail Error Detection timing Description E531 8001 Staple The stapler does not return to the staple motor(M111)/ home position when the staple motor has Staple home been driven for 0.5 sec. position detect 8002 The stapler does not leave the staple home sensor(PI50)
  • Page 252: E535

    Chapter 5   5.3.8 E535 0009-2686 T-5-15 Code Detail Error Detection timing Description E535 8001 Swing motor The stapler does not return to the swing (M106)/Swing home position when the swing motor has home bee driven for 3 seconds. positionsensor 8002 The stapler does not leave the swing home (PI105)
  • Page 253: E540

    Chapter 5 5.3.10 E540 0009-2689 T-5-17 Code Detail Error Detection timing Description E540 8001 Tray 1 shift If the tray does not return to home position motor(M107)/ when the tray 1 shift motor is driven for 20 Tray 1 shift seconds.
  • Page 254: E542

    Chapter 5   5.3.11 E542 0009-2690 T-5-18 Code Detail Error Detection timing Description E542 8001 Tray 2 shift If the tray does not return to home position motor (M108)/ when the tray 2 shift motor is driven for 20 Tray 2 shift seconds.
  • Page 255: E584

    Chapter 5 5.3.12 E584 0009-2692 T-5-19 Code Detail Error Detection timing Description E584 8001 Stack ejection The stapler does not leave the shutter motor (M102)/ home position when the stack ejection Shutter open/ motor has been driven for 3 seconds. close clutch 0002 The stapler does not return to the shutter...
  • Page 256: E5F1

    Chapter 5   5.3.14 E5F1 0009-2703 T-5-21 Code Detail Error Detection timing Description E5F1 8001 Paper fold The number of pulses detected by the motor (M2)/ paper fold motor clock sensor is less than Paper fold standard value. motor clock 8002 The status of the paper fold home position sensor (PI4)/...
  • Page 257: E5F3

    Chapter 5 5.3.16 E5F3 0009-2705 T-5-23 Code Detail Error Detection timing Description E5F3 8001 Aligning motor The aligning plate home position sensor (M5)/ Aligning does not turn ON when the aligning plate plate home motor has been driven for 500 pulses. position sensor 8002 The aligning plate home position sensor...
  • Page 258: E5F6

    Chapter 5   5.3.19 E5F6 0009-2708 T-5-26 Code Detail Error Detection timing Description E5F6 8001 Paper pushing The paper pushing plate home position plate motor sensor does not turn ON when the paper (M8)/Paper pushing plate motor has been driven for pushing plate 0.3 sec.
  • Page 259: E5F9

    Chapter 5 5.3.20 E5F9 0009-2711 T-5-27 Code Detail Error Detection timing Description E5F9 8001 Inlet door The inlet door switch is in open state when switch(MSW1) all covers are closed. /Ejection door 8002 The ejection door switch is in open state switch(MSW3) when all covers are closed.
  • Page 260 T-5-28 Functional Limit and Error Code E514 Rear end assist motor error E530 Front aligning plate motor error E531 Staple motor error E532 Stapler shift motor error E535 Swing motor error E537 Rear aligning plate motor error E540 Tray 1 shift motor error E542 Tray 2 shift motor error E5F0...
  • Page 261 Feb 21 2005...