Page 1 CX1145 Finisher Maintenance Manual 042409A Oki Data CONFIDENTIAL...
Page 2 Nothing contained herein shall be construed as conferring by estoppel, implication or otherwise any license or right under any patent or trademark of Oki Data, Oki Electric Industry Co., Ltd. ("Oki Electric"), or any third party. Except as provided above nothing contained herein shall be construed as conferring any license or right under any Oki Data copyright.
Page 3: Symbols Used
INTRODUCTION 1 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 4 INTRODUCTION 2 Outline of the Manual This Service Manual contains basic facts and figures needed to service the Finisher/Saddle Fin- isher in the field, and it consists of the following chapters: Chapter 1 General Description: features, specifications Chapter 2 Finisher Unit Outline of Operation: mechanical systems by function, electrical systems in refer- ence to principles of operation, timing of operation;...
Page 5 INTRODUCTION The descriptions in this Service Manual are based on he following rules: 1. In each chapter, the uses of the function in question and its relationship to electrical and me- chanical systems are discussed and the timing of operation of its associated parts is explained by means of outlines and diagrams.
Page 6: Table Of Contents
CONTENTS Contents CHAPTER 1 GENERAL DESCRIPTION 1 Features ..........1-1 3 Names of Parts........1-9 2 Specifications ........1-2 Cross Section ........ 1-9 Specifications ....... 1-2 3.1.1 Finisher Unit ......1-9 2.1.1 Finisher Unit ......1-2 3.1.2 Saddle Stitcher Unit ..... 1-10 2.1.2 Saddle Stitcher Unit ....
Page 7 CONTENTS Shutter Operation ....... 2-46 3 Power Supply System ......2-49 2.8.1 Outline ........ 2-46 Outline ........2-49 Detecting Jams ......2-47 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1 Basic Operations ........3-1 3.2.2 A3/LD Paper Path (3 sheets) Outline ..........
Page 8 CONTENTS CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 1 Basic Operation ........4-1 2 Punch Operation ........4-5 Outline .......... 4-5 Outline .......... 4-1 Punch Operation ......4-7 Inputs to and Outputs from Punch 2.2.1 2-/4-hole Type ......4-8 Driver PCB ........
Page 9 CONTENTS 1.2.8 Removing the Inlet Static 2.2.6 Removing the No.1 and No.2 Charge Eliminator ....6-17 Flappers........ 6-37 PCBs ........... 6-18 PCBs ........... 6-38 1.3.1 Removing the Finisher 2.3.1 Removing the Saddle Controller PCB ....6-18 Stitcher Controller PCB ..6-38 2 Saddle Stitcher Unit ......
Page 10 CONTENTS CHAPTER 7 MAINTENANCE AND INSPECTION 1 Periodically Replaced Parts ....7-1 Finisher Unit ......... 7-2 Finisher Unit ......... 7-1 Saddle Stitcher Unit ..... 7-2 Saddle Stitcher Unit ..... 7-1 Puncher Unit (option) ....7-2 Puncher Unit (option) ....7-1 3 Periodic Maintenance ......
Page 11 CONTENTS 4.1.12 Rear end assist motor error .. 8-35 4.3.1 Puncher unit backup RAM 4.1.13 Gear change motor error ..8-36 error ........8-42 Troubleshooting Procedure 4.3.2 Punch motor error ....8-42 (Saddle Stitcher Unit) ....8-37 4.3.3 Horizontal registration motor 4.2.1 Paper positioning plate motor error ........
Page 12 CONTENTS APPENDIX 1 General Timing Chart ......A-1 3.16 Stapler PCB2 ......A-26 Finisher Unit ........ A-1 3.17 Tray1/Tray2 Shift Area Sensor Saddle Stitcher Unit ....A-2 PCB ........... A-27 Puncher Unit (option) ....A-3 3.18 Tray1/Tray2 Driver PCB ... A-29 2 List of Signal Names/Abbreviations ..
Page 13: Chapter 1 General Description
CHAPTER 1 GENERAL DESCRIPTION...
Page 14: Features
CHAPTER 1 GENERAL DESCRIPTION 1 Features a. Use of straight buffering*1 Use of straight buffering (rear copy edge restraining type at straight path) enables the Finisher/ Saddle Finisher to continuously receive copy from the host machine during stapling or offset op- eration.
Page 15: Specifications
CHAPTER 1 GENERAL DESCRIPTION 2 Specifications 2.1 Specifications 2.1.1 Finisher Unit Item Specification Remarks Stacking method Trays 1 and 2: by lifting tray Stacking orientation Face down Stacking size A3, A4, A4-R, A5-R, B4, B5, B5-R, LD, LG, LT, LT-R, ST-R, FOLIO, COMPUTER Basis weight 60 g/m to 256 g/m...
Page 16 CHAPTER 1 GENERAL DESCRIPTION Item Specification Remarks Staple supply Special staple cartridge (5000 staples) Staples Special (STAPLE-2000 : 3 cartridges of 5000 staples in a package) Staple detection Provided Manual stapling Not provided Stapling size Front 1-point stapling (30 deg.) A4-R, LG, LT-R, FOLIO Front 1-point stapling (45 deg.) A3, B4, A4, B5, LD, LT, COMPUTER...
Page 17 CHAPTER 1 GENERAL DESCRIPTION Stapling Positions (Finisher Unit) Front 1-point stapling (45deg.) Front 1-point stapling (30deg.) A3, B4, A4, B5, A4-R, LG, LT-R and FOLIO LD, LT and COMPUTER Rear 1-point stapling (45deg.) Rear 1-point stapling (30deg.) A3, B4,A4,B5, A4-R, LG, LT-R and FOLIO LD, LT and COMPUTER F01-201-01...
Page 18: Paper Size
CHAPTER 1 GENERAL DESCRIPTION 2-point stapling unit : mm Paper size A3, A4 A4-R, FOLIO 39.5 159.5 B4, B5, COMPUTER 63 LD, LT LT-R, LG 42.5 162.5 F01-201-02...
Page 19: Saddle Stitcher Unit
CHAPTER 1 GENERAL DESCRIPTION 2.1.2 Saddle Stitcher Unit Item Specification Remarks Stapling method Center binding (double folding) Folding position See Figure F01-201-02 Paper size A3, B4, A4-R, LD, LT-R Capacity W/binding: 1 sheet Including 1 cover page. W/out binding: 2 to 15 sheets Maximum is 1 sheet of 256 paper + 14 sheets of 80 paper.
Page 20 CHAPTER 1 GENERAL DESCRIPTION Staple and Folding Position (Saddle Finisher Unit) unit : mm ±1mm or less Paper size 83.0 203.0 63.0 183.0 A4-R 39.5 159.5 74.0 194.0 LT-R 42.0 162.0 F01-201-03...
Page 21: Puncher Unit (Option)
CHAPTER 1 GENERAL DESCRIPTION 2.1.3 Puncher Unit (Option) Item Specification Remarks Punching method Reciprocating punching (Sequential punching) Paper size 2 holes: A3, A4, A4-R, B4, B5, B5-R, FOLIO, LD, LG, LT-R, LT, COMPUTER 2 or 3 holes: 2 holes/LG, LT-R, A4-R 3 holes/LD, LT, A3, A4 4 holes: (F):A3, A4, LD, LT...
Page 22 CHAPTER 1 GENERAL DESCRIPTION Hole position (Puncher Unit) 4-Hole(Φ6.5) : MJ-6004F 2-Hole(Φ6.5) : MJ-6004E 12±3 12±3 (80±1) 40±3 40±3 80±1 (80±1) (80±1) 4-Hole(Φ6.5) : MJ-6004S 2-Hole(Φ8.0) : MJ-6004N 12±3 12±3 (21±1) 35±3 35±3 70±1 (70±1) (21±1) 3-Hole(Φ8.0) : MJ-6004N 12±3 108±1 108±3 108±1...
Page 23: Names Of Parts
CHAPTER 1 GENERAL DESCRIPTION 3 Names of Parts 3.1 Cross Section 3.1.1 Finisher Unit [2] [3] [10] [1] Delivery tray [6] Return roller [2] Stack ejection roller [7] Inlet roller [3] Aligning plate [8] Rear end assist guide [4] 1st delivery roller [9] Shutter [5] Buffer roller [10] Stapler...
Page 24 CHAPTER 1 GENERAL DESCRIPTION 3.1.2 Saddle Stitcher Unit [12] [11] [10] [1]Saddle stitcher flapper [7] Stitcher mount [2]Inlet roller 1 [8] Holding roller [3]Inlet roller 2 [9] Paper pushing plate [4]No.1 flapper [10] Paper folding roller [5]No.2 flapper [11] Crescent roller [6]Stitcher (front, rear) [12] Saddle delivery roller F01-301-02...
Page 25 CHAPTER 1 GENERAL DESCRIPTION 3.1.3 Puncher Unit (Option) [1] Cam [3] Punch feed roller [2] Hole puncher (Punch blade) [4] Punched scrap container F01-301-03 1-12...
Page 26: Routine Maintenance By The User
CHAPTER 1 GENERAL DESCRIPTION 4 Routine Maintenance by the User Item Timing Staple cartridge replacement When prompted (indicator on host machine control (Finisher unit) panel) Staple cartridge replacement When prompted (indicator on host machine control (Saddle stitcher unit) panel) Punched scrap removal When prompted (indicator on host machine control (Puncher unit (option)) panel)
Page 27 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERA TION...
Page 28: Chapter 2 Finisher Unit Outline Of Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1 Basic Operations 1.1 Specifications The finisher is designed to deliver sheets arriving from its host machine, and its modes of deliv- ery include simple stacking, job offset (Note), 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 29: Outline Of The Electrical Circuitry
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.2 Outline of the Electrical Circuitry The finisher’s sequence of operation is controlled by the finisher controller PCB. The finisher controller PCB is a 16-bit microprocessor (CPU), and is used for communication with the host machine (serial) in addition to controlling the finisher’s sequence of operations.
Page 30 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Finisher controller Motor Saddle stitcher PCB communication controller PCB (Saddle Finisher) Solenoid IC101 Switch IC106 EEP-ROM Punch Controller PCB (Puncher unit (option)) IC102 Sensor Communications IC108 Host machine Regulator IC (DC controller PCB CPU) F02-102-01...
Page 31: Inputs To And Outputs From The Finisher Controller Pcb
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3 Inputs to and Outputs from the Finisher Controller PCB 1.3.1 Inputs to the Finisher Controller PCB (1/4) Finisher controller PCB PI31 J1006-3 J708-8 +5V Upper cover When the upper cover is UP-COVER sensor open, “1”.
Page 32 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.2 Inputs to the Finisher Controller PCB (2/4) Finisher controller PCB PI38 J1039-3 J722B-10 +5V Processing Tray When the sensor detects JOGTRY-P sensor paper, “1”. PI39 J1036-3 J722B-1 Rear end assist When the rear end assist guide home ASSIST-HP guide is at the home...
Page 33 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.3 Inputs to the Finisher Controller PCB (3/4) Finisher controller PCB PI45 J1044-3 J721B-1 +5V Shutter home When the shutter is at the SHUT-HP position sensor home position, “1”. J994 J993 J992 J991 J717 PI46 J1029-3...
Page 34 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.4 Inputs to the Finisher Controller PCB (4/4) Finisher controller PCB Tray 2 shift area sensor PCB PS983 Tray 2 area sensor 1 J1981-1 J716B-8 PS982 TRY2-AREA3 Tray 2 area When the sensor detects TRY2-AREA2 the edge of the frame, “0”.
Page 35 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.5 Outputs to the Finisher Controller PCB (1/2) Finisher controller PCB +24V Inlet roller separation solenoid J710-8 When “0” ,the solenoid SL31 turns on. INLET-ROL-SL* +24V Buffer roller separation solenoid J710-6 When “0” ,the solenoid SL32 turns on.
Page 36 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.6 Outputs to the Finisher Controller PCB (2/2) Finisher controller PCB Inlet motor J718-1 J1010-1 According to rotation direction/speed, changes between + and - in sequence. Stack ejection motor J713-1 J1011-1 According to rotation direction/speed, changes between + and - in sequence.
Page 37 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.7 Inputs to and Outputs from the Finisher Controller PCB Finisher controller PCB +24V J951 J711A Tray 1 shift motor +24V J952 J1024 According to rotation direction/speed, changes between TRY1-I When “1” ,the motor turns on. When the tray motor is rotating, TRY1-CLK + and - in...
Page 38: Inputs To And Outputs From The
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.8 Inputs to and Outputs from the Finisher Controller PCB (1/2) Finisher controller PCB J995 J993 J992 J991 J717 According to rotation direction/speed, changes between + and - in sequence. When the stapler is at the J717 J994 J993...
Page 39: Inputs To And Outputs From The
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 1.3.9 Inputs to and Outputs from the Finisher Controller PCB (2/2) Finisher controller PCB J138 J138 J703-2 Communication line Saddle stitcher controller PCB +24V J139 J139 J704-1 J1017 J702-6 COPY-RXD Communication line COPY-TXD Host machine +24V J1017...
Page 40: Feed/Drive System
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2 Feed/Drive System 2.1 Outline The finisher is designed to operate according to the commands from its host machine to deliver arriving copies to delivery trays in the appropriate mode: simple stacking, job offset, stapling. See F02-201-01 for a diagram of the three modes of delivery (four for the Saddle Finisher).
Page 41 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.1.1 Normal Delivery a. Simple Stacking The finisher delivers copies directly to the delivery tray. Tray Paper F02-201-03 2-14...
Page 42 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION b. Stack Job Offset Before ejection, the sheet is first pulled into the processing tray. Then the sheet is aligned to the front or rear by the aligning plate. The stack ejected when the number of sheets in the processing tray reaches a certain amount.
Page 43 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION c.Stapling The finisher stacks sheets arriving from its host machine on the processing tray. Then, it staples and delivers the sheets to the delivery tray. Tray Paper Staple Processing tray Staple Stapler unit F02-201-07 Paper width 1/2 Front diagonal stapling...
Page 44 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION d. Buffering This function is available when set to sort or staple sort for A4, B5, or LT size paper. Since sheet is received continuously from the host machine during print processing, buffering is per- formed to push and hold the rear end of the paper inside the delivery path.
Page 45 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.1.2 Saddle Stitcher Delivery(Saddle Finisher) A copy arriving in the finisher from the host machine is routed to the saddle stitcher by the saddle stitcher flapper. The saddle stitcher executes center binding and double folding operations on the sheets and then delivers it to the saddle stitcher tray.
Page 46: Outline
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.2 Ejection Path Types 2.2.1 Outline There are three ejection paths to tray 1 and 2 depending on the ejection processing. 2.2.2 Straight Ejection When the equipment is set to non-sort, all sheets are ejected through the following path. Stack ejection roller 1st delivery roller Stack ejection roller...
Page 47 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.2.3 Processing Tray Path This is the sheet ejection path when the equipment is set to sort for paper size other than A4, B5, or LT or when set to staple sort. Sheets are delivered to the processing tray for aligning and stapling.
Page 48 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.2.4 Buffer/Processing Tray Path This is the copy ejection path when the equipment is set to sort or staple sort for A4, B5, or LT paper size. Two sheets (3 sheets if 2-point stapling) are delivered to the buffer. Then they are aligned and stapled in the processing tray and ejected.
Page 49 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 3) The first delivery roller descends and works together with the stack delivery roller to deliver the 1st and 2nd sheets toward the processing tray. At the same time, the stack in the processing tray is delivered toward the delivery tray by the return roller and rear end assist guide.
Page 50: Outline
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.3 Delivery/Ejection 2.3.1 Outline The sheets sent from the host machine is delivered to the ejection tray, processing tray, or saddle stitcher (saddle finisher) according to the ejection type. Job offset or stapling is per- formed, according to the instruction from the host machine, for sheets delivered to the staple tray.
Page 51 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Finisher controller PCB (1/2) Saddle driver Finisher controller PCB (2/2) F02-203-01 2-24...
Page 52 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Finisher controller PCB F02-203-02 2-25...
Page 53: Rear End Assist Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.3.2 Rear End Assist Operation In order to improve stacking performance when ejecting sheets 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 54: Stack Job Offset
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.4 Stack Job Offset 2.4.1 Outline 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 55 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Rear aligning plate home position sensor (PI37) Rear aligning plate Light-shielding plate Front aligning plate home position sensor (PI36) Front aligning Paper plate Rear aligning plate motor (M34) [FRONT SIDE] Light-shielding plate Front aligning plate motor (M33) F02-204-01 2-28...
Page 56: Processing Tray Paper Stacking Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.4.2 Processing Tray Paper Stacking Operation When the rear end of the paper exits the 1st delivery roller, the sheet is delivered to the process- ing tray by the stack delivery roller and return roller and then pushed against the processing tray stopper.
Page 57: Offset Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.4.3 Offset Operation Each sheet is pulled forward or backward using the front aligning plate and the rear aligning plate. The offset operation is performed each time a sheet is pulled onto the processing tray. Offsetting in the forward direction Rear aligning plate Sheet to be offset...
Page 58: Stack Delivery Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.4.4 Stack Delivery Operation 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 deliv- ery rollers to hold the stack.
Page 59: Stapling Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.5 Stapling Operation 2.5.1 Outline Stapling operation staples the prescribed number of sheets with the stapler unit. The staple position depends on the staple mode and paper size. Whether the staple unit is at home position or not is detected by the stapler shift home position sensor (PI40).
Page 60 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Paper Stapler shift motor (M35) Stapler Stapler shift home position sensor (PI40) F02-205-01 2-33...
Page 61: First Sheet
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.5.2 First Sheet The finisher controller PCB moves the stapler according to the specified stapling position. When the rear end of the first sheet passes the 1st delivery roller, the finisher controller PCB stops the stack ejection motor (M32) and then rotates it in reverse.
Page 62 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION F02-205-03 2-35...
Page 63: Second And Subsequent Sheets
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.5.3 Second and Subsequent Sheets The finisher controller PCB starts the swing motor (M36) and lowers the swing guide when the rear end of the 2nd paper passes the 1st delivery roller. The stack delivery motor is reversed. The stack delivery motor rotates the stack delivery roller (upper) and return roller and sends the paper to the processing tray.
Page 64: Last Sheet
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.5.4 Last Sheet When alignment of the last sheet completes, the finisher controller PCB moves the aligning plate to alignment position with the aligning plate motor (M33/M34) (with the paper held with the aligning plate). Then the finisher controller PCB staples at the specified staple position. After stapling, the finisher controller PCB starts the swing motor (M36) and lowers the swing guide.
Page 65: Stapler Unit
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.6 Stapler Unit The staple motor (M41) is used to perform stapling operation. This motor rotates the cam one turn for stapling. The home position of this cam is detected by the staple home position sensor (PI50).
Page 66 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION F02-206-01 Finisher controller PCB F02-206-02 2-39...
Page 67: Shifting The Stapler Unit
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.6.1 Shifting the Stapler Unit The stapler unit is shifted by the stapler shift motor (M35). The home position is detected by the stapler shift home position sensor (PI40). When there is a staple command from the host ma- chine, the stapler shifts to the staple ready position, which depends on the stapling position and paper size.
Page 68 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION b. Rear 1-Point Stapling The position is the same as the stapling position. Rear aligning plate Stapling position/ Wait position Stopper Feeding direction Front aligning plate F02-206-04 2-41...
Page 69 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION c. 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...
Page 70: Tray Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.7 Tray Operation 2.7.1 Outline This equipment has two delivery trays. The upper tray is called tray 1 and the lower tray is called tray 2. The upper and lower tray can move up and down independently. The trays are moved up and down by the tray 1 shift motor (M37) and tray 2 shift motor (M38).
Page 71 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Rack Tray 1 paper sensor (PI42) Tray 1 switch (MS33) Tray 1 shift motor (M37) Tray 1 shift area sensor PCB (PS981, PS982, PS983) Tray 2 shift motor (M38) Tray 2 paper Tray 2 shift area sensor PCB sensor (PI43) (PS981, PS982, PS983) Light-shielding plate...
Page 72 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Paper surface sensor (PI41) Paper surface sensor flag Edge Tray 1 Tray 2 paper surface sensor (PI48) Paper surface sensor flag Edge Tray 2 F02-207-02 Tray 1 shift area sensor PCB Area sensor 1 Area sensor 2 Area sensor 3 Detected items...
Page 73: Shutter Operation
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.8 Shutter Operation 2.8.1 Outline When tray 1 passes the delivery section with paper already stacked, the stacked paper may get caught by the delivery section. A shutter is provided at the delivery section to prevent this. The shutter closes when tray 1 passes the delivery section.
Page 74: Detecting Jams
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 2.9 Detecting Jams The following sensors are used to detect the presence of paper and to determine that paper is delivered properly. • Inlet sensor (PI33) • Feed path sensor (PI34) A jam is identified by checking whether paper is present at each sensor at the timing pro- grammed in the memory of the microcomputer (CPU) on the finisher controller PCB.
Page 75 CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION Jam type Sensor Jam Condition Delay at inlet PI33 When the inlet sensor (PI33) does not detect paper after a sensor prescribed time (distance) has elapsed since receiving a delivery signal from the host machine. If the optional puncher unit is installed, when the inlet sensor (PI33) does not detect paper after delivering for a prescribed time (distance) after the rear end sensor (LED, PTR5) detected paper.
Page 76: Power Supply System
CHAPTER 2 FINISHER UNIT OUTLINE OF OPERATION 3 Power Supply System 3.1 Outline When the host machine power is turned on, a 24VDC and a 5VDC power are supplied to the finisher controller PCB from the host machine. The 24VDC power is used to drive the solenoid. The 5VDC power is used to drive the sensors and is converted to 3.3VDC by the regulator IC (IC108) on the finisher controller PCB and used to drive the ICs inside the PCB.
Page 77: Chapter 3 Saddle Stitcher Unit Outline Of Operation
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION...
Page 78: Basic Operations
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1 Basic Operations 1.1 Outline The unit “stitches” (2 points) a stack of sheets delivered by the finisher unit and folds it in two for delivery. All these operations are controlled by the saddle stitcher controller PCB in response to commands from the host machine via the finisher unit.
Page 79: Electrical Circuitry
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.2 Electrical Circuitry The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher con- troller PCB. The saddle stitcher controller PCB has a microprocessor. This microprocessor is used to control the sequence of operations and to handle serial communications with the finisher controller PCB, driving solenoids and motors in response to the various commands from the fin- isher controller PCB.
Page 80: Inputs To And Outputs From The Saddle Stitcher Controller Pcb
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.3 Inputs to and Outputs from the Saddle Stitcher Controller PCB 1.3.1 Inputs to the Saddle Stitcher Controller PCB (1/3) Saddle stitcher controller PCB J107-1 J11-15 Paper pushing When the paper pushing plate LUNGECLK plate motor motor is rotating, alternately...
Page 81: Inputs To The Saddle Stitcher Controller Pcb (2/3)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.3.2 Inputs to the Saddle Stitcher Controller PCB (2/3) Saddle stitcher controller PCB J105-3 J6-1 +5V Paper positioning When paper is present at the PPOSPAR plate paper sensor paper positioning plate, “1”. J124-3 J10-6 +5V When the inlet cover is...
Page 82: Inputs To The Saddle Stitcher Controller Pcb (3/3)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.3.3 Inputs to the Saddle Stitcher Controller PCB (3/3) Saddle stitcher controller PCB Paper sensor PCB PI18 No.1 paper sensor When paper is present at J123-5 J10-1 the No.1 paper sensor, “1”. PI19 1STPA When paper is present at...
Page 83: Outputs From The Saddle Stitcher Controller Pcb (1/2)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.3.4 Outputs from the Saddle Stitcher Controller PCB (1/2) Saddle stitcher controller PCB +24V No.1 flapper solenoid J15-1 FLPSL1* When “0”, the solenoid turns ON. +24V No.2 flapper solenoid J15-3 When “0”, the solenoid turns ON. FLPSL2* +24V Feed plate contact solenoid...
Page 84: Outputs From The Saddle Stitcher Controller Pcb (2/2)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 1.3.5 Outputs from the Saddle Stitcher Controller PCB (2/2) Saddle stitcher controller PCB Stitcher unit (front) J315-1 J8-7 The states (+ and -) change according to the rotation of the motor. Stitcher motor (front) Stitcher unit (rear) J316-4...
Page 85: Feeding/Drive System
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2 Feeding/Drive System 2.1 Outline The stitcher unit aligns the sheets coming from the finisher unit and stitches the resulting stack for delivery to the delivery tray according to the commands coming from the finisher controller PCB.
Page 86: Receiving Sheets
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2.1.1 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 87: Aligning The Sheets
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2.1.2 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 as- sembly.
Page 88: Stitching
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2.1.3 Stitching When all sheets have been output, the two stitchers stitch the stack. The stitchers are positioned so that they face the center of a stack. The two stitchers are not operated simultaneously so as to prevent the paper from wrinkling be- tween two staples and to limit the load on the power supply.
Page 89: Feeding The Stack
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2.1.4 Feeding the Stack The unit folds the stitched stack of sheets, and then feeds it to the point of delivery. This point is where the center of the stack, i.e., stapling position, matches the height of the paper pushing plate and the paper folding roller nip.
Page 90: Folding/Delivering The Stack
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2.1.5 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.
Page 91: Paper Output Mechanism
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3 Paper Output Mechanism 3.1 Outline The paper output mechanism serves to keep a stack of sheets coming from the finisher in place for the next steps (stapling, folding). The paper inlet is equipped with the No.1 flapper and the No.2 flapper, which operate to con- figure the paper path to suit the size of paper.
Page 92 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Finisher controller Saddle stitcher controller PCB (1/2) Saddle stitcher controller PCB (2/2) F03-301-01 3-15...
Page 93 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Saddle stitcher controller PCB (1/2) PI22 PI18 PI19 PI20 PI17 PI11 PI21 PI15 PI12 PI14 PI13 Saddle stitcher controller PCB (2/2) F03-301-02 3-16...
Page 94: Controlling The Inlet Flappers
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.2 Controlling the Inlet Flappers 3.2.1 Outline The two flappers mounted at the paper inlet are operated to configure the feed path according to the size of paper. The flappers are used to enable the following: 1.
Page 95 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.2.2 A3/LD Paper Path (3 sheets) Passage of paper No.1 paper sensor PI8 No.1 flapper solenoid Non-passage of paper No.2 paper sensor PI19 No.2 flapper solenoid Non-passage of paper No.3 paper sensor PI20 Top edge PI18 PI19...
Page 96: B4 Paper Path (3 Sheets)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.2.3 B4 Paper Path (3 sheets) No.1 paper sensor Passage of paper 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...
Page 97: A4-R/Lt-R Paper Path (3 Sheets)
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.2.4 A4-R/LT-R Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18 No.2 paper sensor Passage of paper PI19 No.3 paper sensor Passage of paper PI20 PI18 PI19 PI20 Top edge PI18 PI19 PI20...
Page 98: Controlling The Movement Of Sheets
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.3 Controlling the Movement of Sheets 3.3.1 Outline When the leading edge of a sheet has moved past the inlet flapper, the intermediate feed roller and the crescent roller start to move the sheet forward. The intermediate feed roller is normally not in contact with the path bed.
Page 99 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 2) The solenoid turns OFF when the paper butts against the paper positioning plate. The feed motor continues to rotate. F03-303-02 3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact. F03-303-03 3-22...
Page 100: Controlling The Aligning The Sheets
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.4 Controlling the Aligning the Sheets 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 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 101 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3) The alignment plates escape to points 10 mm from the edge of the stack. F03-304-03 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. F03-304-04 6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding and delivery take place.
Page 102 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION In case of 2 sheets: Entry of Entry of 1st sheet of follow- 1st sheet 2nd sheet ing stack entry [2] [3] [4] Alignment plate home position sensor (PI5) Alignment motor (M5) Paper positioning plate motor (M4)
Page 103: Controlling The Phase Of The Crescent Roller
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3.5 Controlling the Phase of the Crescent Roller 3.5.1 Outline If alignment was executed with the crescent roller in contact with the stack of sheets, the result- ing friction against the roller causes the stack to move inappropriately (Figure F03-305-01). To prevent this problem, the phase of the roller is identified and used to determine the timing of alignment.
Page 104 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Alignment plates Crescent roller phase sensor (PI12) Sensor flag Crescent roller If the crescent roller was in Alignment operation is started when the flag contact with the stack, has covered the sensor alignment operation could and the crescent roller be obstructed.
Page 105: Stitching System
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 4 Stitching System 4.1 Outline The stitching system “stitches” the center of an output stack with staples. To enable stitching at two locations on a stack, two stitcher units (front, rear) are used. Each stitcher unit is equipped with a stitcher motor (M7, M6) for drive, a stitcher home position switch (SW7, SW5) for detection of position and a staple switch (SW6, SW4) for detection of the pres- ence/absence of staples.
Page 106: Stitcher Unit Operation
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 4.2 Stitcher Unit Operation The stitcher base unit consists of two stitchers and stitcher bases. The stitchers are fixed in po- sition, and are not designed to slide or swing. Stitching is executed by driving the rotary cam by the stitcher motor (M7, M6). The front and rear stitcher units are operated with a time delay so as to prevent wrinkling of paper and to limit the load applied to the power supply.
Page 107 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Mount F03-402-03 3-30...
Page 108: Folding/Delivery System
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 5 Folding/Delivery System 5.1 Outline The paper folding mechanism consists of a guide plate, paper folding rollers, paper pushing plate, and paper positioning plate. The guide plate is used to cover the folding rollers while sheets are output so as to prevent sheets from coming into contact with the folding rollers during output.
Page 109: Controlling The Movement Of Stacks
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 5.2 Controlling the Movement of Stacks When a stack has been stitched (2 points), the paper positioning plate lowers so that the stack will move to where the paper folding rollers come into contact with the stack and where the pa- per pushing plate is located.
Page 110: Folding A Stack
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 5.3 Folding a Stack A stack is folded by the action of the paper folding rollers and the paper pushing plate. The paper pushing plate pushes against the center of a stack toward the roller contact section. The paper pushing plate starts at its home position and waits at the leading edge position until the stack has been drawn to the paper folding roller and is gripped for a length of 10 mm.
Page 111 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Paper pushing plate home Paper pushing plate top position sensor position sensor (PI14) (PI15) Sensor flag Paper folding home position sensor (PI21) Paper pushing plate Paper pushing plate motor Paper folding motor F03-503-02 [Paper folding start position] Stack of sheets...
Page 112 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION [Paper folding roller stop position] Delivery outlet Paper feed inlet Sensor flag Paper folding home position sensor (PI21) Paper folding/feeding is performed. Paper feeding is performed. F03-503-04 Paper folding motor (M2) Paper pushing plate motor (M8) Paper pushing plate home position sensor (PI14)
Page 113: Double Folding A Stack
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 5.4 Double Folding a Stack To fold a stack consisting of 10 or more A4-R or LT-R sheets, folding is executed twice for the same sheet. The paper folding rollers rotate in reverse for an equivalent of 20 mm after gripping the stack for a length of 20 mm, enabling the paper folding rollers to apply an increased degree of pressure along the crease on the stack.
Page 114 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 3) The paper folding rollers rotate in reverse, pushing back the stack for a length of about 20 mm (reverse feeding). Paper folding motor F03-504-03 4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns to its home position.
Page 115: Checking For A Jam
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 6 Checking For a Jam 6.1 Outline The saddle stitcher unit identifies any of the following conditions as a jam, and sends the jam signal to the host machine. In response, the host machine may stop printing operation and indi- cate the presence of a jam on its control panel.
Page 116 CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION Jam Type Sensor Jam Condition Delay at inlet PI22 When the saddle inlet sensor (PI22) does not detect paper after a pre- sensor scribed time (distance) has elapsed since receiving a saddle delivery request from the Finisher.
Page 117: Power Supply
CHAPTER 3 SADDLE STITCHER UNIT OUTLINE OF OPERATION 7 Power Supply 7.1 Outline When the host machine power switch is turned ON, 24V and 5V power lines are supplied by the finisher controller PCB. The 24V power is used to drive solenoids. The 24V power from the finisher controller PCB to solenoids does not pass through any protective mechanisms (microswitches, or the like).
Page 118: Chapter 4 Puncher Unit (Option) Outline Of Operation
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION...
Page 119: Basic Operation
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 1 Basic Operation 1.1 Outline The puncher unit is optionally installed in the delivery path between the host machine and the finisher. When the paper delivered from the host machine reaches the puncher unit, it is fed by the punch feed roller.
Page 120: Inputs To And Outputs From Punch Driver Pcb
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 1.2 Inputs to and Outputs from Punch Driver PCB 1.2.1 Inputs to Punch Driver PCB (1/1) Punch controller PCB PI61 J611-3 J605A-7 Horizontal When the punch slide SREGHP registration home unit is at the home position sensor position, “1”.
Page 121: Outputs From Punch Driver Pcb (2/2)
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 1.2.2 Outputs from Punch Driver PCB (1/2) Punch controller PCB LED PCB LED5 J614-6 J605B-8 LEDON5 LED4 LEDON4 LED3 When “1”, LED is ON. LEDON3 LED2 LEDON2 LED1 LEDON1 Scrap full detector PCB LED6 J618-3 J606-2...
Page 122 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 1.2.3 Outputs from Punch Driver PCB (2/2) Punch controller PCB Finisher controller PCB J705B-10 J607B-1 J705A-10 J607A-1 +24V J601-1 J706-1 F04-102-03...
Page 123: Punch Operation
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2 Punch Operation 2.1 Outline The puncher unit is located on the feed path between the host machine and the finisher, and successively punches holes when the paper stops temporarily. The paper delivered from the host machine is fed by the punch feed roller. The punch feed roller is driven by the punch feed motor (M63).
Page 124 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION Punch controller PCB (1/2) PTR1 LED1 Punch controller PCB (2/2) F04-201-01...
Page 125 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2.2 Punch Operation The hole puncher is driven by the punch motor (M61). The hole puncher home position is de- tected by the punch home position sensor (PI63). In all, there are four types of puncher units depending on the destination: 2-hole type (MJ- 6004E), 2-/3-hole Dual Use (MJ-6004N), and two 4-hole types (MJ-6004F and MJ-6004S).
Page 126 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2.2.1 2-/4-hole Type At the home position, the punch home position sensor is ON. Punching of the first sheet ends when the punch shaft has rotated in the forward direction 180°, and the state of the punch home position sensor has changed from OFF to ON.
Page 127 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2.2.2 2-/3-hole Dual Use Type At the home position, the punch home position sensor is ON. To punch two holes, punching of the first sheet ends when the punch shaft half peripheral area has rotated in the forward direction 180°, and the state of the punch home position sensor has changed from OFF to ON.
Page 128 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise direction) as shown below. [punch shaft stopped/ [punch shaft is rotated 90˚ [punch shaft is rotated 180˚ home position] in the forward direction/ in the forward direction/...
Page 129 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION When two holes are punched, the 3-hole puncher is fed reciprocally in the escape direction (hole puncher rise direction) as shown below. [punch shaft stopped/ [punch shaft is rotated 90˚ [punch shaft is rotated 180˚ home position] in the reverse direction/ in the reverse direction/...
Page 130: Horizontal Registration Operation
CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2.3 Horizontal Registration Operation Horizontal registration drive of the punch slide unit is performed by the horizontal registration motor (M62). The home position of the punch slide unit is detected by the horizontal registration home position sensor (PI61).
Page 131 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 2) After the horizontal registration sensors (LED1 to 4, PTR1 to 4) detect the edge of the paper at its inner side in keeping with the paper size signals arriving from the host machine, the horizontal registration motor (M62) drives the punch slide unit to a predetermined position further towards the front, and stops the unit at this position.
Page 132 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 4) When punching ends, drive of the punch feed motor (M63) is started, the horizontal registra- tion motor (M62) is operated in the reverse direction, and the punch slide unit is returned to its home position where it comes to a stop.
Page 133 CHAPTER 4 PUNCHER UNIT (OPTION) OUTLINE OF OPERATION 3 Power Supply System 3.1 Outline 24V power and 5V power are supplied from the finisher controller PCB when the power switch on the host machine is turned ON. 24V power is used for driving motors, while 5V power is used for driving sensors and the ICs on the punch controller PCB.
Page 134: Chapter 5 Bridge Kit (Option)Basic Operation
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION...
Page 135: Outline
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 1 Basic Operation 1.1 Outline This unit transports paper from the exit section of the equipment to the finisher. The transport rollers which comprise the bridge unit are rotated by the drive from the host machine. This unit has a switching gate on its entrance section which decides whether the transported pa- per from the exit roller of the host machine is transported to the finisher or to the receiving tray.
Page 136: Construction
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 1.2 Construction 1.2.1 Front side sectional view • The figure below is that of KN-3511. Transport roller Transport sensor 1 Paper full detection sensor Transport sensor 2 Gate F05-102-01 1.2.2 Rear side view •...
Page 137: Arrangement Of Electrical Parts
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 1.3 Arrangement of Electrical Parts F05-103-01 Name Notation Function Photointerrupter Bridge unit transport sensor 1 - Detecting paper on transport path (Bridge unit entrance side) Bridge unit transport sensor 2 - Detecting paper on transport path (Bridge unit exit side) Paper full detection sensor - Detecting paper full on receiving tray Microswitch...
Page 138: Electrical Parts
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 2 Disassembly and Adjustment 2.1 Electrical Parts 1. Bridge unit transport sensors 1 and 2, cover open/close detection switch 1) Take off the bridge unit. 2) Disconnect each connector for transport sensor [1], release the corresponding latches and take off the bridge unit transport sensor [2].
Page 139 CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 3) Disconnect 1 connector [3] and take off the paper full detection sensor [4]. F05-201-03 [KN-3520] 1) Take off the bridge unit. 2) Remove 4 screws [5] and take off the guide [6]. F05-201-04 3) Disconnect 1 connector [7] and take off the paper full detection sensor [8].
Page 140 CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 3. Gate solenoid 1) Take off the bridge unit. 2) Disconnect 1 connector [1]. Remove 1 screw [2] and take off the gate solenoid [3]. F05-201-06...
Page 141: Scheduled Maintenance
CHAPTER 5 BRIDGE KIT (OPTION) BASIC OPERATION 3 Maintenance 3.1 Periodically Replaced Parts The bridge unit does not have the parts that must be replaced on a periodical basis. 3.2 Scheduled Maintenance Clean the transport rollers and transport guide at the finisher maintenance.
Page 142: Chapter 6 Mechanical Systems
CHAPTER 6 MECHANICAL SYSTEMS...
Page 143: Finisher Unit
CHAPTER 6 MECHANICAL SYSTEMS 1 Finisher Unit 1.1 Externals and Controls [1] Tray 1 [2] Tray 2 [3] Front cover [4] Front door [5] Front lower cover [6] Upper cover [7] Left upper cover [8] Rear cover [9] Grate-shaped upper guide [10] Grate-shaped lower guide F06-101-01 F06-101-02...
Page 144: Removing The
CHAPTER 6 MECHANICAL SYSTEMS 1.1.1 Removing the Front Cover 1) Remove screw [1] and remove the front lower cover [2]. F06-101-03 2) Open the front door [3] and remove three screws [4]. 3) Remove the front cover [5]. F06-101-04...
Page 145: Removing The Rear Cover
CHAPTER 6 MECHANICAL SYSTEMS 1.1.2 Removing the Rear Cover 1) Remove three screws [1] and remove the rear cover [2]. F06-101-05 1.1.3 Removing the Left Upper Cover 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3).
Page 146: Cover
CHAPTER 6 MECHANICAL SYSTEMS Note: When replacing, hook the two claws [4] of the left upper cover to the steel plate. F06-101-07 1.1.4 Removing the Upper Cover 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3).
Page 147: Removing Tray1
CHAPTER 6 MECHANICAL SYSTEMS 1.1.5 Removing Tray 1 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove screw [1] and remove the steel plate [2] and slide guide [3].
Page 148: Removing Tray2
CHAPTER 6 MECHANICAL SYSTEMS 8) Insert your finger in the hole at the rear side of tray 1 [9], push the tray lift motor gear [10] to the front to release the clutch and lift tray 1 [9]. Note: When the tray lift motor gear clutch is released, the tray drops by its own weight.
Page 149 CHAPTER 6 MECHANICAL SYSTEMS 7) Remove two screws [3] and disconnect one connector [4]. 8) Insert your finger in the hole at the rear side of tray 2 [5], push the tray lift motor gear [6] to the front to release the clutch and lift tray 2 [5].
Page 150: Removing The Grate-Shaped Upper Guide
CHAPTER 6 MECHANICAL SYSTEMS 1.1.7 Removing the Grate-shaped Upper Guide 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 4) Remove the left upper cover (see 1.1.4). 5) Lower the tray 1 [1] below the grate- shaped upper guide [2] (see 1.1.5 step 8).
Page 151: Delivery System
CHAPTER 6 MECHANICAL SYSTEMS 1.2 Delivery System 1.2.1 Removing the Stapler 1) Remove the front cover (see 1.1.1). 2) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 3) Pull out the stapler, remove screw [1], and remove the PCB cover [2].
Page 152: Removing The Processing Tray
CHAPTER 6 MECHANICAL SYSTEMS 7) Turn the stapler over, disconnect two con- nectors [9], remove two screws [10], and remove the stapler from the stapler base. F06-102-03 1.2.2 Removing the Processing Tray 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3).
Page 153 CHAPTER 6 MECHANICAL SYSTEMS Note: Hold the snap fastener at the base when unfasten- ing 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.
Page 154 CHAPTER 6 MECHANICAL SYSTEMS 13) Release the claw [13] of the stack delivery roller rear side clutch [12] and remove the clutch [12]. 14) Remove the E-ring [14] and bushing [15] and remove the stack delivery roller. F06-102-07 15) Disconnect the connector [16] and remove harness from the clamp and edge saddles [17].
Page 155: Removing The Buffer Roller
CHAPTER 6 MECHANICAL SYSTEMS 1.2.3 Removing the Buffer Roller 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove the upper cover (see 1.1.4).
Page 156: Removing The Swing Unit
CHAPTER 6 MECHANICAL SYSTEMS 1.2.5 Removing the Swing Unit 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove the grate-shaped upper guide (see 1.1.7).
Page 157: Removing The Return Roller Unit
CHAPTER 6 MECHANICAL SYSTEMS 1.2.6 Removing the Return Roller Unit 1) Remove the front cover (see 1.1.1). 2) Remove the rear cover (see 1.1.2). 3) Remove the front inside upper cover (Only on model with saddle unit) (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove the grate-shaped upper guide (see 1.1.7).
Page 158 CHAPTER 6 MECHANICAL SYSTEMS 11) Remove the screw [1] securing the static charge eliminator at the center of the swing unit. 12) Remove two screws [2] securing the ground of the delivery side static charge eliminator. F06-102-14 13) Pull out the static charge eliminator at the center of the swing unit from the bottom.
Page 159 CHAPTER 6 MECHANICAL SYSTEMS 1.2.8 Removing the Inlet Static Charge Eliminator 1) Open the upper cover and unhook the hook linking the upper cover and inlet up- per guide (see 1.1.4). 2) Remove two screws [1] and remove the right side section [2] of the inlet upper guide (Only on model with saddle unit).
Page 160 CHAPTER 6 MECHANICAL SYSTEMS 1.3 PCB 1.3.1 Removing the Finisher Controller PCB 1) Remove the rear cover (see 1.1.2). 2) Disconnect all connectors [1] on the fin- isher controller PCB. 3) Remove four screws [2] and remove the finisher controller PCB [3]. F06-103-01 6-18...
Page 161: Saddle Stitcher Unit
CHAPTER 6 MECHANICAL SYSTEMS 2. Saddle Stitcher Unit 2.1 Exterior Control Components [1] Front cover [2] Saddle delivery tray [3] Rear cover [4] Inlet delivery unit [5] PCB cover F06-201-01 F06-201-02 6-19...
Page 162 CHAPTER 6 MECHANICAL SYSTEMS 2.1.1 Removing the Front Cover 1) Open the front cover [1] and remove the clip [2]. 2) Lift the front cover [1] to remove. F06-201-03 2.1.2 Removing the Rear Cover 1) Shift the tray cable cover [1] toward the tray side to remove.
Page 163: Removing The Front Inside Upper Cover
CHAPTER 6 MECHANICAL SYSTEMS 2.1.3 Removing the Front Inside Upper Cover 1) Remove the front cover (see 2.1.1). 2) Remove four screws [1] and remove the front inside upper cover [2]. F06-201-05 2.1.4 Removing the Front Inside Lower Cover 1) Remove the front cover (see 2.1.1). 2) Remove the front inside upper cover (see 2.1.3).
Page 164: Removing The Saddle Delivery
CHAPTER 6 MECHANICAL SYSTEMS 2.1.5 Removing the Saddle Delivery Tray Unit 1) Lift the saddle delivery tray unit open/ close lever [2] and open the saddle deliv- ery tray unit [1] . F06-201-07 2) Remove the door axis [3] in the direction of the arrow and pull out the saddle deliv- ery tray unit [4] toward the delivery side.
Page 165: Removing The Upper Delivery
CHAPTER 6 MECHANICAL SYSTEMS 3) Remove the harness wire from the clamps [5]. 4) Remove two connectors [6] and remove the saddle delivery tray unit [7]. F06-201-09 2.1.6 Removing the Upper Delivery Guide 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2).
Page 166: Removing The Pcb Cover
CHAPTER 6 MECHANICAL SYSTEMS 2.1.7 Removing the PCB Cover 1) Remove seven screws [1] and remove the PCB cover [2]. F06-201-11 2.1.8 Removing the Inlet Delivery Unit 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2). 3) Remove the front inside upper cover (see 2.1.3).
Page 167 CHAPTER 6 MECHANICAL SYSTEMS 5) Remove four screws [3]. 6) Open the upper cover [4] and remove the inlet delivery unit [5]. F06-201-13 6-25...
Page 168: Saddle Unit
CHAPTER 6 MECHANICAL SYSTEMS 2.2 Saddle Unit 2.2.1 Removing the Saddle Unit 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2). 3) Remove the front inside upper cover (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove the grated-shaped upper guide (see 1.1.7).
Page 169 CHAPTER 6 MECHANICAL SYSTEMS 15) Remove three screws [5]. 16) Remove the saddle unit [6] to the paper feeding side. F06-202-03 Note: When installing the saddle unit, install so that the Mylar [1] at the front upper side of the saddle unit is on the outside of the delivery guide plate [2] as shown in the figure.
Page 170: Removing The Paper Folding
CHAPTER 6 MECHANICAL SYSTEMS 2.2.2 Removing the Paper Folding Roller 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2). 3) Remove the front inside upper cover (see 2.1.3). 4) Remove the left upper cover (see 1.1.3). 5) Remove the grated-shaped upper guide (see 1.1.7).
Page 171 CHAPTER 6 MECHANICAL SYSTEMS 12) Unhook the upper side of the front tension spring [8] and rear tension spring [9]. F06-202-07 F06-202-08 6-29...
Page 172 CHAPTER 6 MECHANICAL SYSTEMS 13) Remove the two C-rings [10] at the rear, and remove the sensor flag [11] and two bearings [12]. [12] [10] [11] F06-202-09 14) Remove the two C-rings [13] at the front and remove the two gears [14]. [14] [13] F06-202-10...
Page 173 CHAPTER 6 MECHANICAL SYSTEMS 15) Remove the two bearings [15]. [15] F06-202-11 16) Open the saddle delivery tray [16]. [19] 17) Remove two screws [17] and remove the two aligning plates [18]. 18) Slide the two paper folding rollers [19] to the front, and then pull it out in the deliv- ery direction.
Page 174 CHAPTER 6 MECHANICAL SYSTEMS Note: When installing, attach the gear [2] so that the grooves [1] of the paper folding rollers face each other and align the phase. F06-202-13 6-32...
Page 175: Roller
CHAPTER 6 MECHANICAL SYSTEMS 2.2.3 Removing the Stitcher Mount Unit 1) Remove the front cover (see 2.1.1). 2) Remove the front inside upper cover (see 2.1.3). 3) Remove the front inside lower cover (see 2.1.4). 4) Remove the E-ring [1], shaft [2], and roller [3].
Page 176 CHAPTER 6 MECHANICAL SYSTEMS 4) Remove the stitcher positioning tool [4] from the back of the cover. F06-202-17 5) To adjust the front stitcher, remove the front guide plate [5] and center guide plate [6]. To adjust the rear stitcher, re- move the center guide plate [6] and the rear guide plate [7].
Page 177 CHAPTER 6 MECHANICAL SYSTEMS 7) Insert the tool [12] into the staple slot of the stitcher [11]. [11] [12] F06-202-20 8) Tilt the stitcher, and turn the stitcher gear [13] [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 178: Removing The Positioning
CHAPTER 6 MECHANICAL SYSTEMS 2.2.5 Removing the Positioning Plate Unit 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2). 3) Remove the front inside upper cover (see 2.1.3). 4) Remove the front inside lower cover (see 2.1.4).
Page 179: Removing The No.1 And
CHAPTER 6 MECHANICAL SYSTEMS 2.2.6 Removing the No.1 and No.2 Flappers 1) Remove the front cover (see 2.1.1). 2) Remove the rear cover (see 2.1.2). 3) Remove the front inside upper cover (see 2.1.3). 4) Remove the inlet delivery unit (see 2.1.8). 5) Remove the claw [1] of the No.1 flapper bushing, and pull out the No.1 flapper shaft [2] toward the rear.
Page 180: Pcbs
CHAPTER 6 MECHANICAL SYSTEMS 2.3 PCBs 2.3.1 Removing the Saddle Stitcher Controller PCB 1) Remove the PCB cover (see 2.1.7). 2) Remove the four screws [1] and 16 connec- tors [2], and remove the saddle stitcher controller PCB [3]. F06-203-01 6-38...
Page 181: Puncher Unit (Option)
CHAPTER 6 MECHANICAL SYSTEMS 3. Puncher Unit (Option) 3.1 Externals and Controls [1] Upper cover [2] Upper cover 2 [3] Front door [4] Right guide assembly [5] Rear cover F06-301-01 3.1.1 Removing the Rear Cover 1) Remove three screws [1] and remove the rear cover [2].
Page 182: Removing The Right Guide Unit
CHAPTER 6 MECHANICAL SYSTEMS 3.1.2 Removing the Right Guide Unit 1) Remove four screws [1], and remove the right guide assembly [2]. F06-301-03 3.1.3 Removing the Upper Cover 1) Remove the rear cover (see 3.1.1). 2) Open the front door [1], remove three screws [2], and remove the upper cover [3].
Page 183: Puncher Driver System
CHAPTER 6 MECHANICAL SYSTEMS 3.2 Puncher Driver System 3.2.1 Removing the Punch Motor 1) Remove the rear cover (see 3.1.1). 2) Remove the upper cover (see 3.1.3). 3) Disconnect the connector [1]. 4) Remove two screws [2] and remove the punch motor [3].
Page 184 CHAPTER 6 MECHANICAL SYSTEMS 3.2.3 Removing the Puncher Unit Note: When removing the punch unit, the punch unit section sometimes opens. If necessary, perform work with the punch unit section in an open state. 1) Remove the rear cover (see 3.1.1). 2) Remove the right guide assembly (see 3.1.2).
Page 185 CHAPTER 6 MECHANICAL SYSTEMS 6) Remove the three screws [6], and remove the sensor mount (upper) [7]. Then, re- move the connector [8] on the LED PCB. F06-302-05 7) Disconnect the connector [9] and remove the screw [10], and remove the horizontal [11] registration home position sensor [11].
Page 186 CHAPTER 6 MECHANICAL SYSTEMS 8) Turn the gear [12] in the direction of the arrow, and move the punch unit section [13] to the rear side. F06-302-07 9) Remove the binding band [14] while hold- [15] ing its claw between your fingers. (The binding band must be removed with- out being cut.) 10) Disconnect the three connectors [15] and...
Page 187 CHAPTER 6 MECHANICAL SYSTEMS 11) Lift up the front side of the punch unit section [18] first, then move in the direc- tion of the arrow to remove the punch unit section [18]. F06-302-09 12) Disconnect the connector [19] on LED PCB.
Page 188: Removing The Punch Unit Harness
CHAPTER 6 MECHANICAL SYSTEMS 3.2.4 Removing the Punch Unit Harness Note: When removing the punch unit, the punch unit section sometimes opens. If necessary, perform work with the punch unit section in an open state. 1) Remove the rear cover (see 3.1.1). 2) Remove the right guide assembly (see 3.1.2).
Page 189 CHAPTER 6 MECHANICAL SYSTEMS 8) Turn the gear [8] in the direction of the ar- row, and move the punch unit section [9] to the front side. F06-302-14 9) Remove the three screws [10] and sensor mount (upper) [10]. 10) Disconnect the connector [12] on the photosensor PCB and the connector [13] on the LED PCB and remove the harness from the edge saddle [14].
Page 190 CHAPTER 6 MECHANICAL SYSTEMS 11) Remove the harness [16] from the four harness clamps [15]. F06-302-16 12) Disconnect the connector [16] of the hori- zontal registration motor and the connec- tor [17] of the horizontal registration home position sensor, and remove the punch unit harness.
Page 191: Installing The Punch Unit Harness
CHAPTER 6 MECHANICAL SYSTEMS 3.2.5 Installing the Punch Unit Harness Note: Offset punch unit harnesses can cause malfunc- tion. The punch unit harnesses must be firmly in- stalled at the positions described below. 1) Fasten the punch unit harnesses so that the two binding bands [1] of the punch unit harnesses are on the outside of the two harness clamps [2].
Page 192: Pcbs
CHAPTER 6 MECHANICAL SYSTEMS 3.3 PCBs 3.3.1 Removing the LED PCB 1) Remove the rear cover (see 3.1.1). 2) Remove the upper cover (see 3.1.3). 3) Remove the screw [1]. 4) Disconnect the connector [2] and the re- move the LED PCB [3]. F06-303-01 3.3.2 Removing the Photosensor PCB 1) Remove the rear cover (see 3.1.1).
Page 193: Removing The Scrap Full Detector Pcb Unit
CHAPTER 6 MECHANICAL SYSTEMS 3.3.3 Removing the Scrap Full Detector PCB Unit 1) Remove the right guide assembly (see 3.1.2). 2) Remove the screw [1], disconnect the con- nector [2], and remove the scrap full de- tector PCB unit [3]. F06-303-03 3.3.4 Removing the Punch Controller PCB 1) Remove the puncher unit from the fin-...
Page 194: Chapter 7 Maintenance And Inspection
CHAPTER 7 MAINTENANCE AND INSPECTION...
Page 195: Periodically Replaced Parts
CHAPTER 7 MAINTENANCE AND INSPECTION 1 Periodically Replaced Parts 1.1 Finisher Unit The Finisher unit does not have parts that must be replaced on a periodical basis. 1.2 Saddle Stitcher Unit The Saddle stitcher unit does not have parts that must be replaced on a periodical basis. 1.3 Puncher Unit (option) The Puncher unit does not have parts that must be replaced on a periodical basis.
Page 196: Consumables And Durables
CHAPTER 7 MAINTENANCE AND INSPECTION 2 Consumables and Durables 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. Replace them as necessary. 2.1 Finisher Unit Name Quantity Approx.
Page 197 CHAPTER 7 MAINTENANCE AND INSPECTION 3. Updating Finisher ROM There are two types of finisher ROMs: the ROM with finisher firmware and the ROM with saddle stitcher firmware each written on. These two types of firmware can be updated individu- ally by installing the download jig (K-PWA-DLM-320) to the finisher control PC board.
Page 198 CHAPTER 7 MAINTENANCE AND INSPECTION (4) Connect the download jig with the jig connector on the finisher control PC board. Connector (5) Change the setting of the DIP switch on the finisher contorol PC board. Change the setting of the DIP switch as follows according to the firmware to be updated. Note: Record the current settings of the DIP switch before changing them.
Page 199: Processing Status
CHAPTER 7 MAINTENANCE AND INSPECTION (6) Turn ON the power while [0] and [8] button are pressed simultaneously. Updating starts automatically and the LED on the download jig lights. Tip: The processing status can be confirmed by the lighting of the LED (LED 101 to 103) on the finisher control board.
Page 200: Chapter 8 Troubleshooting
CHAPTER 8 TROUBLESHOOTING...
Page 201: Adjustments
CHAPTER 8 TROUBLESHOOTING Adjustments Note Before performing each adjustment, make sure that all covers (incl. those of the finisher and host machine) are closed. Otherwise, the power is not supplied to the finisher and the adjust- ment may not be performed properly. 1.1 Electrical System (finisher unit) 1.1.1 Adjusting the Alignment Position Perform this adjustment after replacing the finisher controller PCB or when the alignment posi-...
Page 202: Adjusting The Staple Position
CHAPTER 8 TROUBLESHOOTING 1.1.2 Adjusting the Staple Position Perform this adjustment after replacing the finisher controller PCB or when the staple position must be changed for some reason. This adjustment adjusts the front/rear stitches with A4/A4-R when the paper used for adjustment is AB type and with LT/LT-R when the paper is INCH type. 1) Remove the rear cover of the finisher unit.
Page 203 CHAPTER 8 TROUBLESHOOTING 6) Press SW103 on the finisher controller PCB once to staple. However, remove the stapled pa- per manually because the paper is not ejected. Press SW103 on the finisher controller PCB once again. 7) Verify the staple position. If any adjustment is needed, proceed to the step 8). If no adjust- ment is needed, proceed to the step 9).
Page 204: Electrical System (Saddle Stitcher Unit)
CHAPTER 8 TROUBLESHOOTING 1.2 Electrical System (Saddle stitcher unit) 1.2.1 Adjusting the Folding Position The folding position is adjusted by changing setting of bits 6 through 8 of SW504 on the saddle stitcher controller PCB to match the stitching position (adjusting the distance over which the paper positioning plate is moved to the folding position from the stitching position).
Page 205 CHAPTER 8 TROUBLESHOOTING 5) Turn on the power of the host machine while [0] button and [8] button are pressed simultaneously. 6) Press SW1 on the saddle stitcher controller PCB so that the feed motor (M1) starts to rotate. (Press SW1 three seconds or more if LD paper is used.) 7) Open the inlet cover and insert two sheets of paper.
Page 206 CHAPTER 8 TROUBLESHOOTING 11) Change the settings of bits 6 through 8 on SW504 referring to the following table. • If the width adjustment is 0 The stitching position and the folding position match, requiring no change. • If for “positive width adjustment” Set SW504 so that the difference resulting from subtraction of the interval from the appropriate setting in T08-102-01 is provided.
Page 207: Electrical System (Puncher Unit(Option))
CHAPTER 8 TROUBLESHOOTING 1.3 Electrical System (Puncher unit(option)) 1.3.1 Sensor Output Adjustment Perform this adjustment when replacing the punch controller PCB, transmittance sensor (photosensor PCB/LED PCB), or deflection sensor (scrap full detector PCB unit). 1) Check that the power of the host machine is off and then remove the rear cover of the puncher.
Page 208: Registering The Number Of Punch Holes
CHAPTER 8 TROUBLESHOOTING 1.3.2 Registering the Number of Punch Holes This operation registers which puncher unit is attached to the IC on the punch driver PCB so that the puncher unit can be identified by the finisher. For this reason, this operation must be performed when the punch driver PCB has been replaced.
Page 209: Arrangement Of Electric Components
CHAPTER 8 TROUBLESHOOTING 2 Arrangement of Electric Components 2.1 Finisher Unit 2.1.1 Sensors PI35 PI31 PI49 PI37 PI38 PI42 PI39 PI41 PI33 PI36 PI34 PI45 PI48 PI32 PI46 PI40 PI43 F08-0-0...
Page 210 CHAPTER 8 TROUBLESHOOTING Name Notation Function Photo interrupter PI31 Detects upper cover open/close PI32 Detects front cover open/close PI33 Detects paper in inlet PI34 Detects paper in vertical path PI35 Detects swing guide home position PI36 Detects front aligning plate home position PI37 Detects rear aligning plate home position PI38...
Page 211: Microswitches
CHAPTER 8 TROUBLESHOOTING 2.1.2 Microswitches MS34 MS32 MS33 MS31 F08-0-0 Name Notation Function Micro-switch MS31 Detects front cover close MS32 Detects swing guide open MS33 Detects tray 1 MS34 Detects swing guide open T08-0-0 8-...
Page 212: Solenoids
CHAPTER 8 TROUBLESHOOTING 2.1.3 Solenoids SL32 SL33 SL31 SL34 F08-0-0 Name Notation Function Solenoid SL31 Inlet roller separation solenoid SL32 Buffer roller separation solenoid SL33 1st delivery roller separation solenoid SL34 Buffer rear end holding solenoid T08-0-0 8-...
Page 213: Motors
CHAPTER 8 TROUBLESHOOTING 2.1.4 Motors F08-0-0 8-...
Page 214 CHAPTER 8 TROUBLESHOOTING Name Notation Function Motor Inlet motor Stack ejection motor Front aligning plate motor Rear aligning plate motor Stapler shift motor Swing motor Tray 1 shift motor Tray 2 shift motor Rear end assist motor Gear change motor Staple motor T08-0-0 8-...
Page 215 CHAPTER 8 TROUBLESHOOTING 2.1.5 Clutches CL32 CL31 F08-0-0 Name Notation Function Clutch CL31 Shutter clutch CL32 Stack ejection lower roller clutch T08-0-0 8-...
Page 216: Pcbs
CHAPTER 8 TROUBLESHOOTING 2.1.6 PCBs F08-0-0 Reference Name Finisher controller PCB Stapler PCB1 Stapler PCB2 Tray1 driver PCB Tray2 driver PCB Tray1 shift area sensor PCB Tray2 shift area sensor PCB T08-0-0 8-...
Page 217: Saddle Stitcher Unit
CHAPTER 8 TROUBLESHOOTING 2.2 Saddle Stitcher Unit 2.2.1 Sensors PI22 PI18 PI19 PI16 PI20 PI21 PI14 PI11 PI15 PI17 PI12 PI13 F08-0-0 8-7...
Page 218 CHAPTER 8 TROUBLESHOOTING Name Notation Function Photo interrupter Detects paper pushing plate motor clock Detects delivery cover open Detects paper folding motor clock Detects alignment plate home position Detects paper on tray Detects paper positioning plate home position Detects paper on paper positioning plate Detects inlet cover open PI11 Detects paper delivery...
Page 219: Microswitches
CHAPTER 8 TROUBLESHOOTING 2.2.2 Microswitches SW4,5 SW6,7 F08-0-0 Name Notation Function Micro-switch Detects inlet door open Detects delivery door open Detects presence of staples (rear) Detects stitcher home position (rear) Detects presence of staples (front) Detects stitcher home position (front) T08-0-0 8-9...
Page 220: Motors
CHAPTER 8 TROUBLESHOOTING 2.2.3 Motors F08-0-0 Name Notation Function Motor Feed motor Paper folding motor Guide motor Paper positioning plate motor Alignment motor Stitcher motor (rear) Stitcher motor (front) Paper pushing plate motor Saddle inlet motor T08-0-0 8-0...
Page 221: Solenoids
CHAPTER 8 TROUBLESHOOTING 2.2.4 Solenoids F08-0-0 Name Notation Function Solenoid No.1 flapper solenoid No.2 flapper solenoid Feed plate contact solenoid Saddle inlet solenoid T08-0-0 8-...
Page 222: Pcbs
CHAPTER 8 TROUBLESHOOTING 2.2.5 PCBs F08-0-0 Reference Name Saddle stitcher controller PCB Paper sensor PCB Saddle driver PCB T08-0-0 8-...
Page 223: Punch Unit (Option)
CHAPTER 8 TROUBLESHOOTING 2.3 Punch Unit (option) 2.3.1 Sensors PI62 PI61 PI63 F08-0-0 Name Notation Function Photo interrupter PI61 Detects horizontal registration home position PI62 Detects punch motor clock PI63 Detects punch home position T08-0-0 8-...
Page 224: Microswitches
CHAPTER 8 TROUBLESHOOTING 2.3.2 Microswitches MSW61 MSW62 F08-0-0 Name Notation Function Micro-switch MSW61 Detects upper door open MSW62 Detects front door open T08-0-0 8-...
Page 225: Motors
CHAPTER 8 TROUBLESHOOTING 2.3.3 Motors F08-0-0 Name Notation Function Motor Punch motor Horizontal registration motor Punch feed motor T08-0-0 8-...
Page 226: Pcbs
CHAPTER 8 TROUBLESHOOTING 2.3.4 PCBs F08-0-0 Reference Name Punch controller PCB Photosensor PCB LED PCB Scrap full detector PCB T08-0-0 8-...
Page 227: Leds And Check Pins By Pcb
CHAPTER 8 TROUBLESHOOTING 3 LEDs and Check Pins by PCB 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 228: Saddle Stitcher Controller Pcb
CHAPTER 8 TROUBLESHOOTING 3.2 Saddle Stitcher Controller PCB SW504 F08-302-01 Switch Function SW504 (bits 1-2) Starts correction of discrepancy between stitching position and folding position. SW504 (bits 6-8) Stores corrected settings for stitching position and folding position. Starts correction of discrepancy between stitching position and folding position.
Page 229: Punch Controller Pcb
CHAPTER 8 TROUBLESHOOTING 3.3 Punch Controller PCB J603 J602 J604 J601 J605 J607 J606 J608 SW602 SW603 SW601 F08-303-01 Switch Function SW601 Punch hole count registration/sensor output adjustment etc. SW602 Punch hole count registration/sensor output adjustment etc. SW603 Punch hole count registration/sensor output adjustment etc. T08-303-01 8-29...
Page 230: Troubleshooting
CHAPTER 8 TROUBLESHOOTING 4 Troubleshooting 4.1 Troubleshooting (finisher unit) 4.1.1 Saddle stitcher controller PCB communication error Finisher controller PCB/Saddle stitcher controller PCB 1) Does it improve when the host machine power switch is turned OFF/ON? YES : End NO : Next Wiring 2) Is the wiring between the finisher controller PCB and saddle stitcher controller PCB normal?
Page 231: Backup Ram Error
CHAPTER 8 TROUBLESHOOTING 4.1.3 Backup RAM error Finisher controller PCB/Punch controller PCB 1) Does it improve when the host machine power switch is turned OFF/ON? YES : End NO : Next 2) Does it improve when the finisher controller PCB and punch controller PCB are replaced? YES : End T08-401-03...
Page 232: Rear Aligning Plate Motor Error
CHAPTER 8 TROUBLESHOOTING 4.1.5 Rear aligning plate motor error Rear aligning plate home position sensor (PI37) 1) Check the rear aligning plate home position sensor. Does the sensor operate normally? YES : Next NO : Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and rear aligning plate motor normal? YES : Next NO : Repair the wiring.
Page 233: Stapler Shift Motor Error
CHAPTER 8 TROUBLESHOOTING 4.1.7 Stapler shift motor error Stapler drive home position sensor (PI40) 1) Check the stapler drive home position sensor. Does it operate normally? YES : Next NO : Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and stapler shift motor nor- mal? YES : Next NO : Repair the wiring.
Page 234: Tray 1 Shift Motor Error
CHAPTER 8 TROUBLESHOOTING 4.1.9 Tray 1 shift motor error Tray 1 shift area sensor PCB 1) Check the tray 1 shift area sensors 1 to 3. Do the sensors operate normally? YES : Next NO : Replace the tray 1 shift area sensor PCB. Wiring 2) Is the wiring between the finisher controller PCB and tray 1 shift motor nor- mal?
Page 235: Stack Ejection Motor Error
CHAPTER 8 TROUBLESHOOTING 4.1.11 Stack ejection motor error Shutter home position sensor (PI45) 1) Check the shutter home position sensor. Does the sensor operate normally? YES : Next 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? YES : Next NO : Repair the wiring.
Page 236: Gear Change Motor Error
CHAPTER 8 TROUBLESHOOTING 4.1.13 Gear change motor error Gear change home position sensor (PI49) 1) Check the gear change home position sensor. Does the sensor operate nor- mally? YES : Next NO : Replace the sensor. Wiring 2) Is the wiring between the finisher controller PCB and Gear change motor nor- mal? YES : Next NO : Repair the wiring.
Page 237: Troubleshooting Procedure (Saddle Stitcher Unit)
CHAPTER 8 TROUBLESHOOTING 4.2 Troubleshooting Procedure (Saddle Stitcher Unit) 4.2.1 Paper positioning plate motor error Paper positioning plate home position sensor (PI7) 1) Check the paper positioning plate home position sensor. Is the sensor normal? YES : Next NO : Replace sensor. Positioning plate drive mechanism 2) Is there a problem with the positioning plate drive mechanism? YES : Repair the positioning plate drive mechanism.
Page 238: Guide Motor Error
CHAPTER 8 TROUBLESHOOTING 4.2.3 Guide motor error Guide home position sensor (PI13) 1) Check the guide home position sensor. Does the sensor operate normally? YES : Next 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.
Page 239: Stitcher (Rear) Error
CHAPTER 8 TROUBLESHOOTING 4.2.5 Stitcher (rear) error Installing the stitcher (rear) 1) Are the stitcher (rear) and mount installed properly? YES : Next NO : Install them properly. Stitcher home position sensor (rear) (SW5) 2) Check the stitcher home position switch. Does the switch operate normally? YES : Next NO : Replace the stitcher.
Page 240: Paper Pushing Plate Motor Error
CHAPTER 8 TROUBLESHOOTING 4.2.7 Paper pushing plate motor error Paper pushing plate home position sensor (PI14)/Paper pushing plate top position sensor (PI15)/ Paper pushing plate motor clock sensor 1) Check the sensors. Do the sensors operate normally? YES : Next NO : Replace the sensors.
Page 241: Micro Switch Error
CHAPTER 8 TROUBLESHOOTING 4.2.9 Micro switch error Front cover switch (MS31)/Inlet door switch (SW1)/Delivery door switch (SW3) 1) Check the switches. Do the switches operate normally? YES : Next NO : Replace the switches. Power supply and wiring 2) Measure the voltage between J704-1 (+) and J704-2 (-) of the finisher controller PCB.
Page 242: Troubleshooting Procedure (Puncher Unit (Option))
CHAPTER 8 TROUBLESHOOTING 4.3 Troubleshooting Procedure (Puncher unit (option)) 4.3.1 Puncher unit backup RAM error Punch controller PCB 1) Does it improve when the host machine power switch is turned OFF/ON? NO : Replace the punch controller PCB. T08-403-01 4.3.2 Punch motor error Punch home position sensor (PI63) 1) Check the punch home position sensor.
Page 243: Horizontal Registration Motor Error
CHAPTER 8 TROUBLESHOOTING 4.3.3 Horizontal registration motor error Horizontal registration home position sensor (PI61) 1) Check the horizontal registration home position sensor. Does the sensor operate normally? YES : Next NO : Replace the sensor. Wiring 2) Is the wiring between the punch controller PCB and the sensor normal? YES : Next NO : Repair the wiring.
Page 244: Self Diagnosis
CHAPTER 8 TROUBLESHOOTING 5 Self Diagnosis 5.1 Outline 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 245: Error Description
CHAPTER 8 TROUBLESHOOTING Error Description Detection timing • Staple motor error • The stapler does not leave the staple home position when the staple • Staple home position detect motor has been driven for 0.4 sec. switch error • The stapler does not return to the staple home position when the staple motor has been driven for 0.4 sec.
Page 246 CHAPTER 8 TROUBLESHOOTING Error Description Detection timing • Gear change motor (M40) • The stapler does not leave the gear change home position when the error gear change motor has been drive for 387 pulses. • Gear change home position •...
Page 247: Saddle Stitcher Unit
CHAPTER 8 TROUBLESHOOTING 5.2.2 Saddle Stitcher Unit Error Description Detection timing • Paper positioning plate motor • The paper positioning plate home position sensor does not turn ON (M4) error when the paper positioning plate motor has been driven for 300 •...
Page 248 CHAPTER 8 TROUBLESHOOTING 5.2.3 Saddle Stitcher Unit Error Description Detection timing • Paper pushing plate motor • The paper pushing plate home position sensor does not turn ON (M8) error when the paper pushing plate motor has been driven for 0.3 sec. •...
Page 249: Puncher Unit (Option)
CHAPTER 8 TROUBLESHOOTING 5.2.4 Puncher Unit (option) Error Description Detection timing • Backup RAM error • The checksum for the punch controller PCB has an error when the power is turned on. • Punch motor (M61) error • The puncher does not leave the puncher home position sensor when •...
Page 250: Alarm
CHAPTER 8 TROUBLESHOOTING 5.3 Alarm 5.3.1 Finisher Unit Alarm Description Condition Detection timing Machine operation Resetting Stapler is absent The stapler is Always monitored The staple motor Set the stapler. not set. (M41) and stapler shift motor (M35) operation prohibited. Staple is absent The staple car- Always monitored...
Page 251: Saddle Stitcher Unit
CHAPTER 8 TROUBLESHOOTING 5.3.2 Saddle Stitcher Unit Alarm Description Occurs when Detection timing Machine operation Reset Staple is absent The staple car- Always monitored Normal operation Replace the staple car- tridge has run will continue. How- tridge; or, set it cor- out of staples.
Page 252: Appendix
APPENDIX...
Page 253: Finisher Unit
1 General Timing Chart 1.1 Finisher Unit Stapling : A4 size paper, 2-sheet document, rear1-point stapling Operation start signal Host machine eject signal Operation Inlet sensor (PI33) Feed path sensor (PI34) Inlet motor (M31) Stack ejection motor (M32) 1st delivery roller separation solenoid (SL33) Stack ejection lower roller clutch (CL32)
Page 254: Saddle Stitcher Unit
1.2 Saddle Stitcher Unit Stitching : A4-R size paper, 3-sheet document, 1 set Copying starts Delivery signal Feeding Operation Initialization Loading the first sheet Loading the second sheet Loading the third sheet Stitching Folding, delivery a bundle Saddle inlet motor (M9) Saddle inlet solenoid (SL5) Feed motor (M1) No.1 paper sensor (PI18)
Page 255: Puncher Unit (Option
1.3 Puncher Unit (option) Punching : A4 size paper, 2-sheet document, job offset Operation start signal Host machine eject signal Operation Rear end detect sensor (LED5, PTR5) Inlet sensor (PI33) Feed path sensor (PI34) Punch feed motor (M63) Inlet motor (M31) Stack ejection motor (M32) Inlet roller separation solenoid (SL31)
Page 257: Finisher Unit
APPENDIX 2 List of Signal Names/Abbreviations The following presents the abbreviations of signals used in this manual and in drawings, and the meaning of each signal. Reference: Signals enclosed by brackets [ ] are electrical signals, However, the state “1” or “0” of these analog signals cannot be indicated.
Page 258: Saddle Stitcher Unit
APPENDIX 2.2 Saddle Stitcher Unit 1STPA No.1 PAPER SENSOR DETECT Signal 2NDPA No.2 PAPER SENSOR DETECT Signal 3RDPA No.3 PAPER SENSOR DETECT Signal DELV DELIVERY DETECT Signal DELVMS DELIVERY DOOR OPEN DETECT SWITCH Signal EJCVR DELIVERY COVER OPEN DETECT Signal FDRLHP CRESCENT ROLLER PHASE DETECT Signal FLDCLK...
Page 259: Puncher Unit (Option
APPENDIX 2.3 Puncher Unit (option) DFULL DUST FULL DETECT Signal FDROPN FRONT DOOR OPEN DETECT SWICH Signal LEDON LED ON Signal LEDON1 LED1 ON Signal LEDON2 LED2 ON Signal LEDON3 LED3 ON Signal LEDON4 LED4 ON Signal LEDON5 LED5 ON Signal PAEND PAPER END DETECT Signal PUNCHCLK...
Page 260 APPENDIX...
Page 261: Finisher Unit General Circuit Diagram
3 Finisher Unit General Circuit Diagram Stack ejection Gear change Gear change Swing motor Inlet motor motor Swing guide home Front cover motor home position Upper cover Buffer rear end 1st delivery roller Buffer roller separation Feed path Inlet roller separation position sensor holding solenoid separation solenoid...
Page 262: Finisher Controller Pcb (A501
Stapler alignment interference Staple motor sensor Stapler shift motor PI46 Tray 2 shift motor J1029 J1027 J1028 J1030 Tray 2 paper sensor Tray 2 shift area sensor J1025 PI43 J993 J1026 J1981 J994 J995 J1953 Stapler PCB 2 Tray 2 driver PCB J1951 J992 SMCD-19X875-C-P1.25-S(3)+(3)-M-N UL20624...
Page 263 3.1 Finisher Controller PCB (A501) +3.3V C143 X101 IC104 R131 R134 C142 J724 XOUT REFOUT/RS0 REF_OFF R133 C137 MODOUT/RS1 C139 C138 R123 IC117 Q201 +3.3V C501 Q195 IC117 R124 Q202 R491 +3.3V IC117 Q175 D129 R493 Q196 Q197 IC117 +3.3V +3.3V AVCC P35/SCK1...
Page 264: Finisher Controller Pcb (A502
3.2 Finisher Controller PCB (A502) ABUS[7:0] (A501,A502) DBUS[7:0] (A501,A502) +3.3V DBUS[7:0] (A501,A502) +3.3V SW101 PUSHSW1 [ENTER] SW102 PUSHSW2 (A501,A502) SW103 PUSHSW3 (A501,A502) IPC-CS (A501) (5V-DETECT) VBUS 24V-DETECT INTR (A503) R143 +3.3V C311 VDD0 VDD3 DOOR-24V-DETECT (A503) BUFF-P-SL-ON IC102 (A505) FAN-ERR LED101 (A505) DELIV-ROL-SL-ON...
Page 265: Finisher Controller Pcb (A503
3.3 Finisher Controller PCB (A503) +3.3V +24U +24V R474 FU119 DOOR-24V-DETECT (A502) J719 ZD106 R475 Q193 R158 Q151 R431 Front cover switch R159 (MS31) R496 Q178 +3.3V R472 Q194 JP101 R430 CP117 +24R R473 POWER-ON (IC102-37P) Q172 (A502) J701 (+24V-P) Q179 +3.3V J701...
Page 266: Finisher Controller Pcb (A504
3.4 Finisher Controller PCB (A504) +3.3V +3.3V J718 (INLET-A*) (INLET-A) Q180 CP118 (INLET-B) (INLET-B*) CHANGE-M-B (IC103-12P) R179 (A502) M-STB (IC101-116P) (A501) (IC101-122P) Inlet motor INLET-M-A CP121 Q181 (A501) INLET-M-B (IC101-121P) (M31) (A501) INLET-M-A (IC101-120P) (A501) INLET-M-B (IC101-119P) CHANGE-M-A (IC103-11P) (A501) (A502) CHANGE-M-I1 (IC103-14P)
Page 267: Finisher Controller Pcb (A505
3.5 Finisher Controller PCB (A505) +3.3V R201 R211 (A502) FAN-ERR J727 (IC102-42P) C176 +3.3V C175 +24V J727 R113 R110 R457 R200 (A501) SL-ON Q101 D102 (IC103-36P) IC132 (A502) FAN-ON R111 Q129 J727 (IC102-41P) IC125 +24V C261 +3.3V R114 FU115 R112 C104 J727 R458...
Page 268: Finisher Controller Pcb (A506
3.6 Finisher Controller PCB (A506) +24V +3.3V J715 FU109 R466 +3.3V STP-MSW-ON (A502) Staple safety switch R117 (IC103-87P) R479 ZD107 R115 (MS34) Q191 IC125 (A502) OP-TRY-SET R340 (IC103-28P) R116 C240 +3.3V STP-M+24V (A509) R344 SWG-MSW-ON (A502) +3.3V Swing guide switch (IC103-89P) R481 ZD105...
Page 269: Finisher Controller Pcb (A507
3.7 Finisher Controller PCB (A507) +24V Stack ejection lower roller clutch (CL32) FU116 J712 D115 J712 R302 (A502) BIND-CL-ON Q161 (IC103-77P) (BIND-A*) J713 (BIND-A) J713 CP122 (BIND-B) J713 (BIND-B*) J713 R290 M-STB (IC101-116P) Stack ejection motor (A501) (M32) BIND-M-A (IC103-81P) (A501,A502) BIND-M-B (IC103-82P)
Page 270: Finisher Controller Pcb (A508
3.8 Finisher Controller PCB (A508) Tray 2 shift motor (M38) FU111 (+24V) TRY2+24V J716 J716 (A506) J716 (+24V) J716 (GND) J716 +3.3V J716 (GND) J716 R393 Tray 2 area sensor 3 IC120 (TRAY2-MOTOR) R394 +3.3V (PS981) TRY2-AREA-SEN3 J716 (A501) (IC101-27P) C272 C273 +3.3V...
Page 271: Finisher Controller Pcb (A509
3.9 Finisher Controller PCB (A509) J717 Stapler shift motor (M35) (+5R) IC128 Staple home position sensor (PI50) R287 J717 IC128 (STP-HP-SEN) STP-HP-SEN (IC103-65P) (A502) Staple edging sensor (PI51) STP-READY (STP-READY) (IC103-66P) (A502) (STPSFT-A*) (STP-LS) Staple sensor (PI52) STP-LS R310 (IC103-67P) (A502) (STPSFT-A) R311...
Page 272: Finisher Controller Pcb (A510
3.10 Finisher Controller PCB (A510) J721 +24V FU117 +3.3V Shutter clutch Processing Tray D114 (CL31) sensor (PI38) R397 R396 R215 JOGTRY-P-SEN (A502) (A502) SHUT-CL-ON J722 Q160 (IC103-22P) (IC103-78P) C275 C274 J722 R452 +3.3V J722 R448 R395 R447 +3.3V (A502) STPSFT-HP-SEN Front aligning plate Stapler shift home (IC103-69P)
Page 273: Finisher Controller Pcb (A511
3.11 Finisher Controller PCB (A511) Rear aligning plate motor (M34) (RJOG-A) J722 (RJOG-A*) J722 (RJOG-B) Front aligning plate motor (M33) CP124 J722 (RJOG-B*) (FJOG-A) J722 J722 R255 (FJOG-A*) M-STB (IC101-116P) J722 (A501) RJOG-M-A (IC103-29P) (A502) (FJOG-B) J722 RJOG-M-B (IC103-30P) (A502) CP126 (FJOG-B*) J722...
Page 274: Finisher Controller Pcb (A512
3.12 Finisher Controller PCB (A512) SADDLE I/F +24V J704 (+24V) (GND) (GND) J703 (+5V) J703 J723 +3.3V (GND) J703 (+5R) R345 R347 (TXD0) (A501) TXD0 +3.3V +3.3V (IC101-59P) D117 R363 R364 R365 +3.3V (A502) SADDLE-RXD (SADDLE-RXD) J703 (IC102-10P) C255 R346 R348 (RXD0) (A501)
Page 275: Finisher Controller Pcb (A513
3.13 Finisher Controller PCB (A513) [SADDLE DRIVER PCB or PUNCH CONTROLLER PCB] +24R (GND) J706 J705 (+24V) (GND) (PCH-OUT) J705 (A501) PCH-OUT Q150 (IC101-101P) C306 +3.3V +3.3V (GND) J705 D119 R372 IC128 R374 R373 (A501) PCH-RXD (PCH-RXD) J705 (+5R) (IC101-98P) J705 C260 (PCH-M-A)
Page 276: Finisher Controller Pcb (A514
3.14 Finisher Controller PCB (A514) [STAPLER-MOTOR] [TRAY1-AREA-SENSOR] [STAPLER-MOTOR] [SOLENOID] [TRAY2-AREA-SENSOR] [SADDLE I/F] [FLASH I/F] +3.3V +3.3V [PUNCH I/F] +3.3V +3.3V IC131 IC132 +3.3V IC122 IC121 IC120 C247 C109 IC117 C111 C110 IC128 C245 C242 C246 ABUS[18:0] +3.3V IC201 IC133 ABUS0 J801 ABUS1 C310...
Page 277: Stapler Pcb1
APPENDIX 3.15 Stapler PCB1 J991 J992 (+5R) (GND) (STP-INFERE-SEN) (+5V) (STP-HP-SEN) (STP-READY) (STP-LS) (STPSFT-M-A*) (STPSFT-M-A) (STPSFT-M-B) (STPSFT-M-B*) (STP-M-CW) (STP-M-CCW) A-25...
Page 278: Stapler Pcb2
APPENDIX 3.16 Stapler PCB2 J993 J994 (+5R) (GND) STAPLER ALIGNMENT INTERFERENCE SENSOR (PI46) (STP-INFERE-SEN) (+5V) STAPLE HOME POSITION (STP-HP-SEN) SENSOR (PI50) (STP-READY) STAPLE EDGING SENSOR (PI51) (STP-LS) STAPLE SENSOR (PI52) (GND) (STPSFT-M-A*) (STPSFT-M-A) STAPLE SHIFT MOTOR (M35) (STPSFT-M-B) (STPSFT-M-B*) (GND) (STP-M-CW) STAPLE MOTOR (M41)
Page 279: Tray1/Tray2 Shift Area Sensor Pcb
APPENDIX 3.17 Tray1/Tray2 Shift Area Sensor PCB J981 AREA-SEN1 J981 AREA-SEN2 J981 AREA-SEN3 J981 J981 [AREA SENSOR3] PS981 [AREA SENSOR2] PS982 [AREA SENSOR1] PS983 R981 R982 R983 A-27...
Page 280 APPENDIX A-28...
Page 281: Tray1/Tray2 Driver Pcb
3.18 Tray1/Tray2 Driver PCB +24V (+24V) J951/J1951 (+24V) J951/J1951 (GND) J951/J1951 (GND) J951/J1951 R951 R952 JP951 JP952 (+5V) J951/J1951 (GND) J951/J1951 JP954 JP953 +24V R956 (TRY-M-I) J951/J1951 (+24V) J952/J1953 Q953 R960 (TRY-M-CLK) J951/J1951 (+24V) J952/J1953 (TRY-A) J952/J1953 Q952 R961 (TRY-M-CW) J951/J1951 (TRY-A*) J952/J1953...
Page 282: Saddle Stitcher Unit Circuit Diagram
4 Saddle Stitcher Unit Circuit Diagram Vertical path paper sensor Paper folding PI17 Stitcher unit home position IN sensor sensor J138 PI16 J138 PI21 J135 +24V J132 SDLINSL* Saddle inlet solenoid J130 J131 J135 J308 S-GND J133 INLET-ROLL J208 PI22 S-GND Saddle inlet sensor J136...
Page 283: Saddle Stitcher Controller Pcb (A501
4.1 Saddle Stitcher Controller PCB (A501) +3.3V +3.3V IC501 +3.3V R402 [+5V] R271 R277 [RESET] IC501 R274 [MD2] C141 IC501 IC501 D101 [FWE] +3.3V R401 +3.3V R275 [TXD] R278 +3.3V IC501 R276 [RXD] +3.3V [GND] TRM-JOIN (A502) AVCC P35/SCK1 TRM-OUT (A502) VREF P34/SCK0...
Page 284: Saddle Stitcher Controller Pcb (A502
4.2 Saddle Stitcher Controller PCB (A502) +3.3V +3.3V IC502 IC502 TRM-RXD (A501) +3.3V +3.3V TRM-TXD (A501) +3.3V ABUS[7:0] (A501) TRM-IN (A501) DBUS[7:0] (A501) +3.3V +3.3V TRM-OUT (A501) (A501) (A501) 5V-DETECT (A501) (A503) 24V-DETECT VBUS (A503) S-TRY-POS3-SEN INTR (A510) S-TRY-POS2-SEN (A510) S-TRY-HP-SEN (A510) +3.3V...
Page 285: Saddle Stitcher Controller Pcb (A503
4.3 Saddle Stitcher Controller PCB (A503) +3.3V R287 R299 POW-ON (A502) R298 5V-DETECT (A502) (+24V) (P-GND) +3.3V +24V 24V-DETECT (A502) R289 (+5V) CP11 (L-GND) JNT1 ETH1 +3.3V IC10 FU14 ETH2 A-33...
Page 286: Saddle Stitcher Controller Pcb (A504
4.4 Saddle Stitcher Controller PCB (A504) Feed motor (M1) Alignment motor (M5) +24R S-JOG-A S-FEED-STBY (A501) (A501) +3.3V +3.3V S-FEED-A (A501) S-FEED-B (A501) S-FEED-A S-JOG-I0 (A501) (A501) S-FEED-B OUTA (A501) REFA +3.3V OUT/A OUTB +5V +5V REFB S-FEED-I0 +24V (A501) OUT/B CP17 S-JOG-B...
Page 287: Saddle Stitcher Controller Pcb (A505
4.5 Saddle Stitcher Controller PCB (A505) +24R Paper folding motor (M2) +24R Paper pushing plate motor (M8) R300 R302 R301 FOLD-FWD (A501) +3.3V R304 R305 R306 IC504 PUSH-FWD FOLD-PWM (A501) +3.3V (A501) IC504 IC504 IC517 IC508 R114 R101 PUSH-EN (A501) IC504 IC517 R113...
Page 288: Saddle Stitcher Controller Pcb (A506
4.6 Saddle Stitcher Controller PCB (A506) Q540 Q541 Q548 Q549 +24V (CW) (CCW) +24U No.1 paper deflecting solenoid (SL1) Stitcher motor (front) (M7) R308 R309 IC506 R129 R142 SL-TIME (A501) R311 R310 S-FLAP1-ON (A501) IC505 +3.3V R130 No.2 paper deflecting IC507 IC507 solenoid (SL2)
Page 289: Saddle Stitcher Controller Pcb (A507
4.7 Saddle Stitcher Controller PCB (A507) Q540 Q541 Q548 Q549 +24V (CW) +24U +24U +3.3V Inlet door switch (SW1) (CCW) R163 Stitcher motor (rear) (M6) S-INRET-SW (A501) R293 R312 R314 R167 R315 R313 IC505 +3.3V R155 +3.3V IC513 IC513 R159 S-STPR-CW (A501) R165...
Page 290: Saddle Stitcher Controller Pcb (A508
4.8 Saddle Stitcher Controller PCB (A508) CP44 +3.3V R182 Delivery sensor (PI11) CP46 +3.3V IC502 R184 R183 Alignment plate S-EXIT-SEN R185 IC502 home position sensor R186 R188 (A501) S-JOG-HP (PI5) (A501) CP45 +3.3V R187 Paper folding motor CP48 R189 +3.3V R195 Crescent roller phase sensor FOLD-CLK...
Page 291: Saddle Stitcher Controller Pcb (A509
4.9 Saddle Stitcher Controller PCB (A509) CP60 Paper positioning plate +3.3V No.1 paper sensor (PI18) paper sensor (PI8) CP57 R226 +3.3V R222 IC502 R225 S-PAPER-SEN R218 (A501) R219 S-REDGE-SEN1 C112 C115 (A501) C113 C114 No.2 paper sensor (PI19) CP58 +3.3V R220 +3.3V R221...
Page 292: Saddle Stitcher Controller Pcb
4.10 Saddle Stitcher Controller PCB (A510) +3.3V R247 TRY-MTR-A IC8-41 (A502) R246 TRY-MTR-I0 IC8-39 (A502) R245 TRY-MTR-B IC8-40 (A502) R255 IC8-42 S-TRY-HP-SEN (A502) R257 S-TRY-POS2-SEN IC8-43 (A502) R241 S-TRY-POS3-SEN IC8-44 (A502) R254 IC8-38 (A502) A-40...
Page 293: Saddle Driver Pcb
4.11 Saddle Driver PCB J801 J804 STBY J801 J804 J801 J804 J801 J804 J804 J801 J801 J804 J801 J804 J801 J804 J801 J804 J801 J804 J801 +24V J802 J803 J803 J802 J803 J803 J802 +24V +24V J805 J801 J804 J805 J804 J801 J801...
Page 294 A-42...
Page 295: Paper Sensor Pcb
APPENDIX 4.12 Paper Sensor PCB No.1 paper J123 sensor PI18 J123 J123 J123 No.2 paper sensor J123 PI19 No.3 paper PI20 sensor A-43...
Page 296 APPENDIX A-44...
Page 297: Puncher Unit General Circuit Diagram
5 Puncher Unit General Circuit Diagram Horizontal registration motor Punch feed Horizontal registration motor home position Punch motor clock Punch home position sensor sensor sensor LED PCB Photosensor PCB PI61 Punch motor PI62 PI63 J614 J615 J611 J612 J613 J619 J610 J610 J620...
Page 298: Punch Controller Pcb (A501
5.1 Punch Controller PCB (A501) [Down load] J608 [+5V] R721 J608 [RESET*] Q620 RESET C615 C678 RA606 R726 IC607 R743 PCH-HP-SEN J608 [MD2] [A502] UP-COVER-SW PCH-CLK-SEN [A504] [A502] DUST-AN TAIL-EDGE-SEN1 [A502] [A502] A3-REG-AN PCH-OUT [A502] [A504] B4-REG-AN IC604 [A502] PCH-RXD A4R-REG-AN [A502] [A504]...
Page 299: Punch Controller Pcb (A502
5.2 Punch Controller PCB (A502) [LED PCB] [PHOTOSENSOR PCB] J605 J605 [GND] Q602 R626 J605 [5V] RA602 J605 [A3 LED] [A501] A3-REG-AN J605 +24V [A3 PTR] [AN7] Q603 R627 C624 C623 [B4 LED] J605 IC608 C622 R632 [A501] RA601 LED-PWM [TMOV] Q604 R628...
Page 300: Punch Controller Pcb (A503
5.3 Punch Controller PCB (A503) CP602 CP603 FEED-M-STB [A504] FEED-M-A [A504] [A501] FEED-M-B REG-M-STB [A504] [P55] FEED-M-A [A504] FEED-M-B REG-M-A [A501] [A504] [FTIOA] REG-M-B [A501] [FTIOB] Q609 Q608 FEED-M-I0 [A504] REG-M-I [A501] [P75] Q610 FEED-M-I1 [A504] IC610 CP604 Horizontal registration motor (M62) IC611 CP605 TORQUE...
Page 301: Punch Controller Pcb (A504
5.4 Punch Controller PCB (A504) J607 ETH1 J607 [SGND] J601 +24V J601 [PGND] CP606 R710 Q621 IC607 IC607 J607 [PCH-OUT] FU602 [A501] PCH-OUT J601 [24V] C658 C665 [IRQ0] R711 C666 CB601 CP607 J607 [PCH-RxD] Q601 [A501] PCH-RXD C675 [TXD] CP608 IC607 R714 R715...
Page 302 A-50...
Page 303: Scrap Full Detector Pcb
APPENDIX 5.5 Scrap Full Detector PCB J671 J671 C673 R674 R673 C672 J671 LED671 Q671 PTR671 D671 J671 Q671 C671 A-51...
Page 304: Led Pcb
APPENDIX 5.6 LED PCB LED1 LED2 LED3 LED4 LED5 A-52...
Page 305: Photosensor Pcb
5.7 Photosensor PCB PTR4 PTR1 PTR5 PTR2 PTR3 A-53...
Page 306 A-54...
Page 307: Solvents And Oils
APPENDIX 6 Solvents and Oils Name Description Composition Remarks Cleaner Cleaning: Hydrocarbon • Do not bring near fire. e.g., glass, (fluorine family) • Procure locally. plastic, Alcohol • Isopropyl alcohol may be sub- rubber parts, Surface activating stituted. external agent covers Water Lubricant...
Page 308 1-1, KANDA NISHIKI-CHO, CHIYODA-KU, TOKYO, 101-8442, JAPAN...

Oki CX1145 Maintenance Manual

Chapter 1 General Description

Chapter 2 Finisher Unit Outline of Operation

Chapter 3 Saddle Stitcher Unit Outline of Operation

Chapter 4 Puncher Unit (Option) Outline of Operation

Chapter 5 Bridge Kit (Option)Basic Operation

Chapter 6 Mechanical Systems

Chapter 7 Maintenance and Inspection

Chapter 8 Troubleshooting

Appendix

Quick Links

Troubleshooting

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Summary of Contents for Oki CX1145