Page 1 SERVICE MANUAL FINISHER MJ-1029 File No. SME050008C0 R05042185901-TTEC Ver03 F̲2013-05...
Page 2 Other company names and product names in this manual are the trademarks of their respective companies. c 2005 - 2013 TOSHIBA TEC CORPORATION All rights reserved Under the copyright laws, this manual cannot be reproduced in any form without prior written permission of TOSHIBA TEC CORPORATION.
Page 3 General Precautions for Installation/Servicing/Maintenance for the Finisher MJ-1029 The installation and service should be done by a qualified service technician. 1. When installing the Finisher MJ-1029 to the equipment, be sure to follow the instruc- tions described in the “Unpacking/Set-Up Procedure for the MJ-1029” booklet which comes with each unit of the MJ-1029.
Page 4 18. When you move the finisher, do not move it in the direction of the arrow as shown in the figure [A] below otherwise it might fall down. 06/05...
Page 5 INTRODUCTION This Service Manual contains basic data and figures for the Finisher (MJ-1029) needed to service the machine in the field. This manual comprises the following chapters: Chapter 1 “General Description” introduces the finisher’s features, specifications, and names of parts, and shows how to operate the finisher.
Page 7: Table Of Contents
CONTENTS CHAPTER 1 GENERAL DESCRIPTION FEATURES ........1-1 D. Removing Paper Jams from the SPECIFICATIONS ....... 1-2 Saddle Stitcher Unit ....1-13 A. Specifications ......1-2 E. Supplying the Saddle Stitcher B. Cross Section ......1-7 Unit with Staples ....1-15 III.
Page 8 B. SADDLE UNIT ....... 4-17 C. PCBs ........4-13 C. PCBs ........4-27 D. Caution when removing D. Power supply unit ....4-27 MJ-1029 ......... 4-13 E. Accessory ......4-28 CHAPTER 5 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED III. PERIODICAL SERVICING ..5-2 IIV.
Page 9 CHAPTER 6 TROUBLESHOOTING ADJUSTMENTS ......6-1 A. Finisher Unit ......6-8 A. Electrical System B. Saddle Stitcher Unit ....6-15 (finisher unit) ......6-1 C. Light-Emitting Diodes (LED) B. Electrical System and Check Pins by PCB ..6-21 (saddle stitcher unit) ....6-6 III.
Page 11 CHAPTER 1 GENERAL DESCRIPTION FEATURES ........1-1 D. Removing Paper Jams from the SPECIFICATIONS ....... 1-2 Saddle Stitcher Unit ....1-13 A. Specifications ......1-2 E. Supplying the Saddle Stitcher Unit B. Cross Section ......1-7 with Staples ......1-15 III.
Page 12: Chapter 1 General Description
CHAPTER 1 GENERAL DESCRIPTION FEATURES Available for stapling large quantities of sheets MAX. 100 sheets can be stapled. Accommodates large quantities of sheets Normally, the finisher holds a stack of sheets 250 mm in height in its two bins (small-size paper: equivalent to 2000 sheets)/140 mm in height (large-size paper: equivalent to 1000 sheets) Has high paper transportation performance...
Page 13: Specifications
CHAPTER 1 GENERAL DESCRIPTION SPECIFICATIONS Specifications Finisher Unit Item Description Stacking method Trays 1 and 2: by lifting tray Face-down Stacking orientation Stacking size AB: A3, A4, A4-R, A5-R, B4, B5, B5-R, FOLIO Inch: LD, LG, LT, LT-R, ST-R, COMPUTER Sortable size A3, A4, A4-R, B4, B5, LD, LG, LT, LT-R, FOLIO, COMPUTER Basis weight...
Page 14 CHAPTER 1 GENERAL DESCRIPTION Item Description Stapling By rotating cam Stapling position See Figure 1-201. Stapling capacity 60 ~ 80 g/m 90 g/m , 105 g/m (Note 4) (Note 5) Exclusive staple Small-size (1) 100 sheets (Note 5) (100 sheets stapling) Large-size (1) 50 sheets Option staple...
Page 15 CHAPTER 1 GENERAL DESCRIPTION Stapling Positions (finisher unit) 1-point stapling (rear) 1-point stapling 1-point stapling (diagonal; front) (diagonal; rear) 30˚ 30˚ 5±2.5mm/ Specified paper width 5±2.5mm/ Specified paper width 6±2.5mm/ 0.2±0.1in 0.2±0.1in 0.24±0.1in 2-point stapling A3 and A4 B4 and B5 LD and LT COMPUTER 81.8±4mm/...
Page 16 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitcher Unit Item Description Stapling method Center binding (double folding) Folding position See Figure 1-202. Paper size A3, B4, A4-R, LD, LT-R, LG Capacity W/binding: 1 sheet (including single cover page) W/out binding:2 to 15 sheets (Note 1) Paper weight 60 to 105 g/m...
Page 17 CHAPTER 1 GENERAL DESCRIPTION Staple and Folding Position (saddle stitcher unit) A4-R Staple position Edge Edge of of staple staple 83±4mm/ 63±4mm/ 39.5±4mm/ 3.48±0.16in 2.7±0.16in 1.77±0.16in 203±4mm/ 183±4mm/ 159.5±4mm/ 8.21±0.16in 7.42±0.16in 6.5±0.16in Stack front edge LT-R 74±4mm/ 42mm/ 42mm/ 3.14±0.16in 1.89±0.16in 1.89±0.08in 194±4mm/...
Page 18: Cross Section
CHAPTER 1 GENERAL DESCRIPTION Cross Section Finisher Unit [2] [3] [4] [5] [6] [10] [11] [16] [17] [15] [14] [13] [12] [1] Tray 1/2 [10] Saddle stitcher flapper [2] Shutter [11] Inlet feed roller [3] Delivery roller [12] Feed roller 1 [4] Swing guide [13] Vertical path [5] Feed roller 2...
Page 19 CHAPTER 1 GENERAL DESCRIPTION Saddle Stitcher Unit [10] [11] [12] [1] Guide plate [7] No.1 flapper [2] Paper folding roller [8] No. 2 flapper [3] Delivery guide plate [9] Stitcher mount [4] Holding roller [10] Paper pushing plate [5] Stitcher (front, rear) [11] Crescent roller [6] Inlet roller [12] Paper positioning plate...
Page 20: Using The Machine
CHAPTER 1 GENERAL DESCRIPTION 3) Open the upper cover, and check the inside III. Using the Machine of the finisher. Removing Paper Jams from the Finisher Unit If the host machine indicates the finisher paper jam message, perform the following to remove the jam.
Page 21: Supplying The Finisher Unit With Staples
CHAPTER 1 GENERAL DESCRIPTION 6) Return the buffer roller and the buffer roller Supplying the Finisher Unit cover to their original positions, and close with Staples the upper cover. If the host machine indicates the finisher unit staple supply message, perform the fol- lowing to supply it with staples.
Page 22 CHAPTER 1 GENERAL DESCRIPTION 4) Remove the empty staple case upward 6) Return the staple cartridge to its original from the staple cartridge, and push in a new position until it is caught by the claw and staple case into the cartridge until a click fixed with a click sound, and slightly push is heard.
Page 23: Removing Staple Jams From The Finisher Unit
CHAPTER 1 GENERAL DESCRIPTION 4) Shift down the tab on the staple cartridge. Removing Staple Jams from the Finisher Unit If the host machine indicates the finisher unit staple jam message, perform the following to remove the jam. 1) Remove the stack waiting to be stapled from the delivery tray.
Page 24: Removing Paper Jams From The Saddle Stitcher Unit
CHAPTER 1 GENERAL DESCRIPTION 7) Return the staple cartridge to its original Removing Paper Jams position until it is caught by the claw and from the Saddle Stitcher fixed with a click sound, and close the front Unit cover of finisher. If the host machine indicates the saddle stitcher unit paper jam message, perform the fol- lowing to remove the jam.
Page 25 CHAPTER 1 GENERAL DESCRIPTION 3) Turn the knob in the counter clockwise. 6) Open the inlet cover, and remove the jam. Figure 1-324 Figure 1-327 4) Turn the knob in the clockwise while push- 7) Close the front lower cover. ing it in.
Page 26: Supplying The Saddle Stitcher Unit With Staples
CHAPTER 1 GENERAL DESCRIPTION 3) Pull the stitcher unit to the front once, and Supplying the Saddle then shift it up. Stitcher Unit with Staples If the host machine indicates the saddle stitcher unit staple supply message, perform the following to supply it with staples. 1) Open the front lower cover.
Page 27: Removing Staple Jams From The Saddle Stitcher Unit
CHAPTER 1 GENERAL DESCRIPTION 6) Pull the stitcher to the front once, and then Removing Staple Jams return it to its original position. from the Saddle Stitcher Unit If the host machine indicates the saddle stitcher unit staple jam message, perform the fol- lowing to remove the jam.
Page 28 CHAPTER 1 GENERAL DESCRIPTION 4) Hold the cartridge on its sides, and remove 7) Return the cartridge to its original position. Figure 1-342 Figure 1-339 8) Pull the stitcher of the stitcher unit to the 5) Push down on the area identified as A, and front once, and then return it to its original pull up the tab identified as B.
Page 29: Maintenance By The User
CHAPTER 1 GENERAL DESCRIPTION IV. MAINTENANCE BY THE USER Maintenance by the User Item Timing Replacing the staple cartridge (finisher unit) When the appropriate indication is made on Replacing the staple cartridge (saddle stitcher the host machine’s display. unit) Caution: Use different type of staple cartridge for the finisher unit and the saddle stitcher unit.
Page 30 CHAPTER 1 GENERAL DESCRIPTION 1-19...
Page 31: Finisher Unit Basic Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the finisher’s functions, and the prin- ciples of operation used for the finisher mechanical and electrical systems. It also explains the timing at which these systems are operated.The symbol in drawings indicates transmission of mechanical drive, and signals marked by together with the signal name indicates the...
Page 32: Chapter 2 Finisher Unit Basic Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION BASIC OPERATION Outline The finisher is designed to deliver copies arriving from its host machine, and its modes of (Note) delivery include simple stacking, job offset , and staple. All operations involved in these modes are controlled by the finisher controller PCB, according to the appropriate commands from the host machine.
Page 33: Outline Of Electrical Circuitry
CHAPTER 2 FINISHER UNIT BASIC OPERATION Outline of 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. The finisher controller PCB responds to the various commands coming from the host machine through a serial communications line to drive solenoids, motors, and other loads.
Page 34: Finisher Controller Pcb
CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller Motor Saddle stitcher PCB communication controller PCB Solenoid Switch EEP-ROM Punch driver PCB (Puncher unit (option)) Sensor EP-ROM Host machine Inserter driver PCB (DC controller PCB CPU) (Inserter unit (option)) IC6/IC7 Connecting with inserter Regulator IC Not connecting with inserter Figure 2-102...
Page 35: Inputs To And Outputs From The Finisher Controller Pcb
CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Inputs to the Finisher Controller PCB Finisher controller PCB J106-3 J17-7 +5V When the sensor detects PENT Inlet sensor paper, “1”. J134-3 J12A-10 When the sensor detects Delivery sensor PDEL paper, “1”.
Page 36 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Finisher controller PCB PI10 J120-1 J12B-9 +5V Delivery motor While the delivery motor DELCLK is rotating, alternately clock sensor between “0” and “1”. PI11 J2011-3 J14A-4 +5V Tray 1 paper When paper is present on FSTTRAY* sensor...
Page 37 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to the Finisher Controller PCB Finisher controller PCB PI20 J125-1 J12A-3 Swing motor When the swing motor is SWGCLK clock sensor rotating, alternately between “0” and “1”. PI25 J135-3 J14B-10 When the tray 2 is home Tray 2 home TRYHP2 position, “1”.
Page 38 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inputs to and Outputs from the Finisher Controller PCB Finisher controller PCB Door switch +24V N. O. J148-1 J148-1 J5-1 +24VMOVE When the front door DRSW and the upper cover Swing guide closed detecting switch 1 are closed, “1”.
Page 39 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Stapler unit Finisher controller PCB When a staple is at the edge of Staple edging the stapler, “0”. sensor Staple home When the stapler is at the home position sensor position, “0”.
Page 40 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB +24V Flapper solenoid J4-1 When "0", the solenoid turns on. FLPSL* +24V Buffer inlet solenoid J4-3 When "0", the solenoid turns on. ENTSL* +24V Buffer outlet solenoid J24-7 When "0", the solenoid turns on.
Page 41 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB Stapler shift motor According to rotation direction/speed, changes between + and - in sequence. Staple motor According to rotation direction/speed, changes between + and -. Tray 1 lift motor J115-1 According to rotation...
Page 42 CHAPTER 2 FINISHER UNIT BASIC OPERATION Outputs from the Finisher Controller PCB Finisher controller PCB Paddle motor According to rotation direction, changes between + and - in sequence. Front alignment motor According to rotation direction/speed, changes between + and -. Knurled belt motor According to rotation direction/speed, changes...
Page 43: Feed/Drive System
CHAPTER 2 FINISHER UNIT BASIC OPERATION FEED/DRIVE SYSTEM Outline The finisher is designed to operate according to the commands from its host machine to deliver arriving copies to trays in the appropriate mode: simple stacking, job offset, stapling. See Figure 2-201 for a diagram of the four modes of delivery. Normal Method of delivery Simple stacking...
Page 44 CHAPTER 2 FINISHER UNIT BASIC OPERATION Normal Delivery Simple Stacking The finisher delivers copies directly to the tray. Tray Tray Copies Copies Feed roller 1 Delivery roller Feed roller 2 Figure 2-203 2-13...
Page 45: Job Offset
CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset The finisher forwards all copies of each sort job to the stapling tray. The first sort job on the stapling tray is delivered with a shift to the front of about 30 mm, and the second sort job is deliv- ered without being shifted.
Page 46 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling The finisher stacks copies arriving from its host machine on the stapling tray. Then, it staples and delivers the copies to the appropriate tray. Tray Copies Staple Swing guide Stopper Stapling tray Delivery roller Feed roller 1 Figure 2-207 Paper width/2...
Page 47 CHAPTER 2 FINISHER UNIT BASIC OPERATION Saddle Stitch Delivery A copy arriving in the finisher from the host machine is routed to the saddle stitcher by the paper deflecting plate. The saddle stitcher executes stitching and saddling operations on the copy and then delivers it to the saddle stitcher tray.
Page 48: Type Of Delivery Paths
CHAPTER 2 FINISHER UNIT BASIC OPERATION Type of Delivery Paths The finisher has three different paper paths for delivery, each selected to suit paper size and delivery mode. Straight Path When stacking copies shown in Table 2-201, the copies pass under the buffer roller. Copy size Length or width 182 mm or less Typical copy examples...
Page 49 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Paper Path 2 This is the paper path when copy sizes shown in Table 2-203 are stacked. A maximum of three copies (three originals or more in the staple mode) are wrapped round the buffer roller, during which job offset and stapling are performed on the stapling tray.
Page 50 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) The second copy is laid over the first copy and, at the same time, the third copy arrives from the host machine. First copy Second copy Third copy Figure 2-214 4) The first, second and third copies are simultaneously pulled into the stapling tray. Second copy Third copy First copy...
Page 51: Feeding And Delivering
CHAPTER 2 FINISHER UNIT BASIC OPERATION Feeding and Delivering Outline The finisher moves copies arriving from the host machine to the delivery tray, stapling tray, or the saddle stitcher unit according to the mode of delivery. On the stapling tray, the copies are subjected to job offset or stapling as instructed by the host machine.
Page 52 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI19 PI20 PI10 PI24 PI23 Figure 2-216 2-21...
Page 53 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB PI17 PI14 PI11 PI12 Figure 2-217 2-22...
Page 54: Job Offset
CHAPTER 2 FINISHER UNIT BASIC OPERATION Job Offset Outline In the job offset mode, sort jobs and entire copy groups are shifted to the front or rear for delivery to the tray, and other copies are delivered to the tray without a shift. The copies are shifted by the front and rear alignment plates.
Page 55 CHAPTER 2 FINISHER UNIT BASIC OPERATION Rear alignment plate Rear alignment plate home position sensor (PI6) Rear alignment motor (M3) Front alignment motor (M11) Front alignment plate Front alignment plate home position sensor (PI29) Figure 2-218 Sequence of Operation (job offset) Start signal Host machine delivery signal Inlet sensor (PI1)
Page 56 CHAPTER 2 FINISHER UNIT BASIC OPERATION Flow of Job Offset Operations 1) The swing guide moves up and, at the same time, the knurled belts move the sheet to the stapling tray. Swing guide Offset sheet Feed roller 2 Knurled belts Tray 1/2 Delivery roller...
Page 57: Staple Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Staple Operation Outline The stapler unit staples a stack of as many sheets as specified. The stapling position differs according to the selected staple mode and paper size. The stapler unit is checked by the stapler shift home position sensor (PI7) to find out whether it is at the home position.
Page 58 CHAPTER 2 FINISHER UNIT BASIC OPERATION Paper width/2 Front diagonal stapling 2-point stapling Rear 1-point stapling Rear diagonal stapling Figure 2-224 2-27...
Page 59 CHAPTER 2 FINISHER UNIT BASIC OPERATION First Sheet The finisher controller PCB turns on the drop solenoid (SL4) as soon as the first sheet of paper is detected with the delivery sensor (PI3) to escapes the drop lever arm upward. When the sheet passed through the delivery sensor, the finisher controller PCB turns off the drop solenoid to lower the drop lever arm and drop the trailing edge of the sheet on the stapling tray.
Page 60 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Swing guide open sensor (PI18) Swing guide closed detecting switch 1,2 (MS2/MS6) Delivery roller Delivery motor clock sensor (PI10) Delivery motor (M2) Figure 2-226 2-29...
Page 61 CHAPTER 2 FINISHER UNIT BASIC OPERATION Second and Subsequent Sheets Then the finisher controller PCB turns on the paddle motor (M14) as soon as the trailing edge of the second and subsequent sheets passses the feed roller 2, causing the paddle to rotate once, the sheet is pushed by the paddle and sent to the stapling tray.
Page 62 CHAPTER 2 FINISHER UNIT BASIC OPERATION Knurled belts Knurled belt motor (M13) Figure 2-228 Paddles Paddles Drop solenoid (SL4) Paddle motor (M14) Stopper Paddle home position sensor (PI26) Figure 2-229 2-31...
Page 63 CHAPTER 2 FINISHER UNIT BASIC OPERATION Last Sheet When the last sheet has been put in order, the finisher controller PCB turns on the alignment motors (M3, M11) to move the alignment plate to the alignment position (to butt the plate against the stack).
Page 64 CHAPTER 2 FINISHER UNIT BASIC OPERATION Swing guide Swing guide open sensor (PI18) Swing guide closed detecting switch 1,2 (MS2/MS6) Delivery roller Delivery motor clock sensor (PI10) Delivery motor (M2) Figure 2-231 2-33...
Page 65: Stapler Unit
CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapler Unit Stapling is executed by the staple motor (M6). A single rotation of the cam by the motor results in one stapling operation. The cam is checked by the staple home position sensor (PI22) to find out whether it is at the home position.
Page 66 CHAPTER 2 FINISHER UNIT BASIC OPERATION Finisher controller PCB Figure 2-233 2-35...
Page 67 CHAPTER 2 FINISHER UNIT BASIC OPERATION Start signal Host machine delivery signal Stacking Stapling Delivery First sheet Second sheet Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8) Delivery motor (M2) Stapling tray sensor (PI4) Rear alignment motor (M3)
Page 68: Shifting The Stapler Unit
CHAPTER 2 FINISHER UNIT BASIC OPERATION Shifting the Stapler Unit The stapler unit is moved by the stapler shift motor (M4). Its home position is detected by the stapler shift home position sensor (PI7). When the start signal arrives from the host machine, the stapler moves to the center of its movement range.
Page 69 CHAPTER 2 FINISHER UNIT BASIC OPERATION Rear 1-Point Stapling The stapler is kept in wait at the center position. The stapler is moved to and from the stapling position for each stapling operation. Stopper Stapling position Wait position Stapling tray delivery direction Stapler Stopper...
Page 70 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2-Point Stapling The stapler is kept in wait at the center of the paper. Stapling occurs at two points, first at the rear and then at the front. Stopper Stapling position Wait position Stapler Stapling tray delivery direction Stapling position...
Page 71: Tray Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray Operation The finisher has two delivery trays - upper tray 1 and lower tray 2. The upper and lower trays move up and down independently. Tray 1 is moved up and down by the tray 1 lift motor (M5), and tray 2 by the tray 2 lift motor (M10).
Page 72 CHAPTER 2 FINISHER UNIT BASIC OPERATION Tray 1 lift motor One way gear Tray coming close detection switch Tray 1 lift motor clock sensor / and 2 Rack Tray 2 lift motor One way gear Tray 2 lift motor clock sensor / and 2 Figure 2-239 2-41...
Page 73: Detecting The Height Of Stack On The Tray
CHAPTER 2 FINISHER UNIT BASIC OPERATION Detecting the Height of Stack on the Tray Outline The number of sheets delivered to the tray and the number of sets (number of stapling opera- tions) are stored in memory by the finisher controller PCB. The height of the stack is checked by the height sensor (PS1).
Page 74 CHAPTER 2 FINISHER UNIT BASIC OPERATION Height sensor (PS1) Paper Figure 2-240 2-43...
Page 75: Shutter Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Shutter Operation When the tray 1 passes the delivery slot, the finisher controller PCB closes the shutter mounted on the delivery slot before moving the tray, preventing the existing stack on the tray by the delivery slot and intrusion of the hands.
Page 76 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2) The tray 1,2 lift motor rotates, and the new tray moves to the stacking lower limit. The distance of movement is detected by1 the tray 1 lift motor clock sensor 1/2 (PI9/19) or tray 2 lift motor clock sensor 1/2 (PI22/PI24).
Page 77 CHAPTER 2 FINISHER UNIT BASIC OPERATION 4) The tray lift motor rotates, and the tray moves to suit the height of the stack. The appropriate height in relation to the existing stack is checked by the height sensor (PS1). Height sensor (PS1) Tray 2 lift motor Figure 2-244 Claw...
Page 78 CHAPTER 2 FINISHER UNIT BASIC OPERATION Sequence Operations (shutter drive) Move from Tray 1 to Tray 2 Tray moved Shutter Shutter closed opened Second feed motor (M8) Tray 1 lift motor (M5) Tray 2 lift motor (M10) Shutter closed detecting switch (MS4) Shutter open sensor (PI5)
Page 79: Buffer Path Operation
CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Operation Outline This machine is provided with a buffer paper path for continuously receiving paper from the host machine during stapling and job offset operation on the stapling tray. A maximum of three copies (three originals or more in the staple mode) are wrapped around the buffer roller.
Page 80 CHAPTER 2 FINISHER UNIT BASIC OPERATION 3) When the leading edge of the sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the second sheet. First sheet Second sheet Buffer path paper sensor (PI14) Figure 2-249 4) When the second sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer...
Page 81 CHAPTER 2 FINISHER UNIT BASIC OPERATION 5) The buffer roller continues to rotate, and the second sheet overlaps the first sheet. Second sheet First sheet Figure 2-251 6) When the trailing edge of the second sheet has moved past the buffer path paper sensor (PI14), the buffer roller stops and waits for the third sheet.
Page 82 CHAPTER 2 FINISHER UNIT BASIC OPERATION 7) When the third sheet arrives and its leading edge reaches the inlet sensor (PI1), the buffer roller starts to operate once again. Second sheet First sheet Third sheet Inlet sensor (PI1) Figure 2-253 8) When the leading edge of the third sheet reaches the inlet sensor (PI1), the buffer outlet sole- noid (SL3) turns off so that the path is directed in the direction of delivery.
Page 83 CHAPTER 2 FINISHER UNIT BASIC OPERATION 9) The buffer roller continues to rotate, the third sheet overlaps the first and second sheets, and the three sheets are fed together towards the delivery roller. Figure 2-255 2-52...
Page 84: Detecting Jams
CHAPTER 2 FINISHER UNIT BASIC OPERATION K. Detecting Jams The following sensors are used to detect the presence/absence of paper and to make sure that sheets are moved properly: Inlet sensor (PI1) Delivery sensor (PI3) Stapling tray sensor (PI4) Buffer path paper sensor (PI14) A jam is identified with reference to the presence/absence of paper at each specific sensor at the times programmed in the memory of the microprocessor (CPU) on the finisher controller PCB.
Page 85 CHAPTER 2 FINISHER UNIT BASIC OPERATION Inlet Sensor Delay Jam The inlet sensor does not detect paper when feeding an equivalent of 400 mm from when the host machine delivery signal has been issued. Host machine delivery signal Host machine delivery signal Equivalent of 400 mm Equivalent of 400 mm Jam check...
Page 86 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path Paper Sensor Stationary Jam The sheet does not move past the buffer inlet sensor when an equivalent of twice the feeding length of the sheet has been fed after the sensor turned on. Equivalent of size x 2 Equivalent of size x 2 Jam check...
Page 87 CHAPTER 2 FINISHER UNIT BASIC OPERATION Buffer Path The delivery sensor does not detect paper when an equivalent of 772 mm has been fed after the inlet sensor turned on. Equivalent of 772 mm Equivalent of 772 mm Jam check Jam check Normal Inlet sensor (PI1)
Page 88 CHAPTER 2 FINISHER UNIT BASIC OPERATION Stapling Tray Sensor Stationary Jam The sheet does not move past the stapling tray sensor 1 sec after the delivery motor (M2) turned 1 sec 1 sec Jam check Jam check Normal Stapling tray Stapling tray sensor (PI4) sensor (PI4)
Page 89: Power Supply System
CHAPTER 2 FINISHER UNIT BASIC OPERATION III. POWER SUPPLY SYSTEM Outline When the host machine is turned on, 5VDC power is supplied to the finisher controller PCB from the host machine. Then the finisher controller PCB sends the power-on signal (REMOTE) to the power supply unit.
Page 90 CHAPTER 2 FINISHER UNIT BASIC OPERATION 2-59...
Page 91: Basic Operation
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 1. This chapter discusses the purpose and role of each of the stitcher’s functions, and the principles of operation used for the stitcher mechanical and electrical systems. It also explains the timing at which these systems are operated.
Page 92: Outline
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION BASIC OPERATION 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 93: Electrical Circuitry
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Electrical Circuitry The sequence of operations used for the saddle stitcher is controlled by the saddle stitcher controller 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 94: Inputs To And Outputs From The Saddle Stitcher Controller Pcb
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to and Outputs from the Saddle Stitcher Controller PCB Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB PI1S J107-1 J11-15 Paper pushing When the paper pushing plate LUNGECLK plate motor motor is rotating, alternately clock sensor between “1”...
Page 95 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB PI8S J105-3 J6-1 +5V Paper positioning When paper is present at the PPOSPAR plate paper sensor paper positioning plate, “1”. PI9S J124-3 J10-6 +5V When the inlet cover is Inlet cover sensor...
Page 96 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inputs to the Saddle Stitcher Controller PCB Saddle stitcher controller PCB Paper sensor PCB PI18S No.1 paper sensor When paper is present at J123-5 J10-1 the No.1 paper sensor, “1”. PI19S 1STPA When paper is present at 2NDPA No.2 paper sensor the No.2 paper sensor, “1”.
Page 97 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB +24V No.1 paper deflecting solenoid J15-1 When “0”, the solenoid turns ON. SL1S FLPSL1* +24V No.2 paper deflecting solenoid J15-3 When “0”, the solenoid turns ON. SL2S FLPSL2* +24V...
Page 98 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Outputs from the Saddle Stitcher Controller PCB Saddle stitcher controller PCB Stitcher unit (front) J315-4 J8-4 The states (+ and -) change according to the rotation of the motor. Stitcher motor (front) Stitcher unit (rear) J316-4 J8-11 The states (+ and -) change...
Page 99: Outline
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION FEEDING/DRIVE SYSTEM 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 100 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 101: Aligning The Sheets
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 assem- bly.
Page 102 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 between two staples and to limit the load on the power supply.
Page 103 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 104 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 105: Paper Output Mechanism
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION III. PAPER OUTPUT MECHANISM 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 106 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION addle stitcher controller PCB (1/2) M6 / addle stitcher controller PCB (2/2) Figure 3-301 3-15...
Page 107 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Saddle stitcher controller PCB (1/2) PI18S PI19S PI20S PI21S PI15S PI14S Saddle stitcher controller PCB (2/2) Figure 3-302 3-16...
Page 108: Controlling The Inlet Flappers
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Inlet Flappers 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 109 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A3/LD Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18 No.1 paper deflecting solenoid Non-passage of paper No.2 paper sensor PI19 No.2 paper deflecting solenoid Non-passage of paper No.3 paper sensor PI20 Top edge PI18...
Page 110 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION B4/LG Paper Path (3 sheets) Passage of paper No.1 paper sensor PI18S SL1S No.2 paper sensor Passage of paper PI19S SL2S Non-passage of paper No.3 paper sensor PI20S PI18S PI19S Top edge PI20S PI18S PI19S PI20S...
Page 111 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION A4-R/LT-R Paper Path (3 sheets) No.1 paper sensor Passage of paper PI18S SL1S Passage of paper No.2 paper sensor PI19S SL2S No.3 paper sensor Passage of paper PI20S PI18S PI19S PI20S Top edge PI18S PI19S PI20S...
Page 112: Controlling The Movement Of Sheets
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Movement of Sheets 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. When the leading edge of a sheet reaches the intermediate feed roller contact section, the feed plate contact solenoid (SL4S) causes the roller to come into contact with the path bed so as to move the sheet.
Page 113 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 2) The solenoid turn OFF when the paper butts against the paper positioning plate. The feed motor continues to rotate. SL4S Figure 3-307 3) The solenoid turns ON when the next sheet arrives, and the feed plate comes into contact. SL4S Figure 3-308 3-22...
Page 114: Aligning The Sheets
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Aligning the Sheets The alignment motor (M5S) drives the alignment plates each time a sheet is output, putting both left and right edges of the sheet in order. The alignment plate motor is a 4-phase stepping motor.
Page 115 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 3) The alignment plates escape to points 10 mm from the edge of the stack. Figure 3-311 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. Figure 3-312 6) The alignment plates escape to points 10 mm from the edges of the stack, after which folding and delivery take place.
Page 116 CHAPTER 3 SADDLE STITCHER UNIT BASIC 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 (PI5S) Alignment motor (M5S) Paper positioning plate motor (M4S) : Alignment...
Page 117: Controlling The Phase Of The Crescent Roller
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Controlling the Phase of the Crescent Roller 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 3-317). To prevent this problem, the phase of the roller is identified and used to determine the timing of alignment.
Page 118 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Alignment plates Crescent roller phase sensor(PI12S) Sensor flag Crescent roller If the crescent roller was in contact with the stack, alignment opera- tion could be obstruct- Figure 3-318 Alignment operation is started when the flag has covered the sensor and the crescent roller is away from the stack.
Page 119: Stitching System
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION IV. STITCHING SYSTEM 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 (M7S, M6S) for drive, a stitcher home position sensor (MS7S, MS5S) for detection of position and a staple sensor (MS6S, MS4S) for detection of the presence/absence of staples.
Page 120 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Stitcher Unit Operation The stitcher base unit consists of two stitchers and stitcher bases. The stitchers are fixed in position, and are not designed to slide or swing. Stitching is executed by driving the rotary cam by the stitcher motor (M7S, M6S). 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 121 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Mount Figure 3-404 3-30...
Page 122: Folding/Delivery System
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION FOLDING/DELIVERY SYSTEM 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 123: Controlling The Movement Of Stacks
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 paper pushing plate is located.
Page 124 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 125 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Paper pushing plate home Paper pushing plate top position sensor position sensor (PI14S) (PI15S) Sensor flag Paper folding home position sensor (PI21S) Paper pushing plate Paper pushing plate motor Paper folding motor Figure 3-503 [Paper folding start position] Stack of sheets Paper pushing plate...
Page 126 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION [Paper folding roller stop position] Delivery outlet Paper feed inlet Sensor flag Paper folding home position sensor (PI21S) Paper folding/feeding is performed. Paper feeding is performed. Figure 3-505 Paper folding motor (M2S) Paper pushing plate motor (M8S) Paper pushing plate home...
Page 127: Double Folding A Stack
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION 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 128 CHAPTER 3 SADDLE STITCHER UNIT BASIC 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 Figure 3-509 4) The paper folding rollers rotate again, feeding out the stack. The paper pushing plate returns to its home position.
Page 129: Checking For A Jam
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VI. CHECKING FOR A JAM Checking for a Jam 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 copying operation and indicate the presence of a jam on its control panel.
Page 130 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Inlet Delay Jam The No.1 paper sensor (PI18S) on the paper sensor PCB does not turn ON for a specific period of time after the inlet sensor (PI1) of the finisher turned ON. Inlet sensor (PI1) Inlet sensor (PI1) No.1 paper...
Page 131 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION B4 Stack No.1 paper sensor Normal No.1 paper sensor (PI18S) (PI18S) No.2 paper sensor No.2 paper sensor Normal (PI19S) (PI19S) Feed motor Feed motor Load stops T: feeding of (paper length x 1.5) mm T: feeding of (paper length x 1.5) mm Note: The diagram shows two sensors checking for jams.
Page 132 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION Delivery Delay Jam By delivery sensor The delivery sensor (PI11S) does not turn ON within a specific period of time after the paper pushing plate top position sensor has turned ON. Paper pushing plate top Paper pushing plate top Normal position sensor...
Page 133 CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION By delivery sensor The delivery sensor (PI11S) does not turn OFF within a specific period of time (feeding) after it has turned ON. Normal Delivery sensor Delivery sensor Paper folding motor Paper folding motor Load stops Paper length Paper length...
Page 134: Power Supply
CHAPTER 3 SADDLE STITCHER UNIT BASIC OPERATION VII. POWER SUPPLY 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 135: Mechanical Construction
A. Externals and Controls .... 4-14 B. FEEDING SYSTEM ....4-9 B. SADDLE UNIT ......4-17 C. PCBs ........4-27 C. PCBs ........4-13 D. Power supply unit ..... 4-27 D. Caution when removing MJ-1029 ........4-13 E. Accessory ........ 4-28...
Page 136: Finisher Unit
CHAPTER 4 MECHANICAL CONSTRUCTION FINISHER UNIT Externals and Controls [1] Upper door [2] End cap [3] Front door [4] Front lower door [5] Tray 1 [6] Tray 2 [7] Grate-shaped upper guide (6) [8] Grate-shaped lower guide (6) [9] Saddle delivery tray [10] Sub-support upper cover (2) [11] Sub-support lower cover (2) [12] Rear cover (3)
Page 137: Removing The Rear Cover
CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Front Door Assembly 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the bush- ing [3] (center). 3) Remove the screw [4], and remove the bush- ing (top) [5]. Then, remove the front door assembly.
Page 138: Removing The Front Cover
CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Upper Door Assembly 1) Open the upper door assembly [1]. 2) Remove the two claws [2], and remove the upper door assembly. Figure 4-105 Removing the Front Cover 1) Open the front door assembly [1]. 2) Remove the screw [2], and remove the front cover [3].
Page 139 CHAPTER 4 MECHANICAL CONSTRUCTION How to Lower the Tray 1/2 Unit 1) Insert a screwdriver or similar object into the hole [2] while supporting the tray as- sembly [1]. 2) Release the tray lift motor one-way gear, and lower the tray 1/2 unit. Figure 4-107 Removing the Tray 1 Unit 1) Open the upper cover and remove the end...
Page 140 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Tray 2 Unit 1) Remove the tray 1 unit. 2) Disconnect the two connnectors [1] and grounding wire [2] and remove harness [3]. 3) Lift the tray 2 unit to remove. Figure 4-110 Removing the Tray 1/2 Lift Motor 1) Remove the tray 1/2.
Page 141 CHAPTER 4 MECHANICAL CONSTRUCTION 5) Disconnect the connector [1], and remove the two screws [2]. Figure4-113 6) Pull out the motor slightly, and remove the parallel pin [1] and the motor. Figure 4-114 Removing the Grate-Shaped Upper Guide 1) Remove the slide guide [1] and end caps [2].
Page 142 CHAPTER 4 MECHANICAL CONSTRUCTION 10. Removing the Grate-Shaped Lower Guide 1) Remove the tray assembly. 2) Remove the five screws [1] (M4), and re- move the front sub-support [2]. 3) Remove the three screws [3] (M4). 4) Remove the three screws [4] (M3), and open the grate-shaped lower guide [5] to the front.
Page 143 CHAPTER 4 MECHANICAL CONSTRUCTION 11. Installing the Rear Sub-Support 1) Install the front sub-support [1]. Loosely fasten the rear sub-support [2]. 2) Install tray 2. Fasten the rear sub-support so that the tray drive gear [3] is placed at the center of the rack gear [4] of the rear sub-support when tray 2 is at the upper limit position and the lower limit position.
Page 144: Feeding System
CHAPTER 4 MECHANICAL CONSTRUCTION FEEDING SYSTEM Removing the Swing Unit 1) Remove the tray assembly (see I-A-6, 7). 2) Remove the grate-shaped upper guide (see I-A-9). 3) Remove the grate-shaped lower guide (see I-A-10). 4) Remove the rear cover (see I-A-2). 5) Remove the stapler cover (see I-B-4).
Page 145 CHAPTER 4 MECHANICAL CONSTRUCTION 10) Remove the three screws [8] and slide out the swing unit [9] to the exit side. Caution: Be careful not for the swing unit to be hit by height sensor. Figure 4-124 Caution: Install the swing unit to the machine so that the black plastic of swing unit is overlaid on the plate.
Page 146 CHAPTER 4 MECHANICAL CONSTRUCTION 3) Remove the harness from the harness clamp [3]. 4) Remove the two connecors [4] of motors. 5) Remove the three screws [5], and remove the feed drive unit [6]. Caution: Before re-attaching the removed feed drive unit back on the finisher unit, loosen the move gear stop screw [7] to relieve the tension, and then fasten the screw after attaching...
Page 147 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Stapler 1) Open the front cover. Remove two screws [1], and remove the stapler cover [2]. Figure 4-130 2) Move the stapler assembly unit [3] to the front. 3) Remove two connectors [4] and one screw [5].
Page 148: Pcbs
2) Disconnect the 19 connectors [1]. 3) Remove the four screws [2], and remove the finisher controller PCB [3]. Figure 4-133 Caution when removing MJ-1029 After removing MJ-1029, make sure to install “BLIND-FIN- CABLE” (6LA01294000). 1) Install the “BLIND-FIN-CABLE” [1] with two screws. Figure 4-134...
Page 149: Saddle Stitcher Unit
CHAPTER 4 MECHANICAL CONSTRUCTION SADDLE STITCHER UNIT Externals and Controls Removing the Front Lower Door Assembly 1) Open the front lower door assembly [1]. 2) Remove the screw [2] and remove the bush- ing [3], and then remove the front lower door assembly.
Page 150 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Front Inside Cover 1) Open the front lower door assembly [1]. 2) Remove the screw [2], and remove the fold- ing roller knob [3]. 3) Remove the five screws [4], and remove the front inside cover [5]. Figure 4-203 Removing the Saddle Delivery Tray Assembly...
Page 151 CHAPTER 4 MECHANICAL CONSTRUCTION 3) Remove the harness leads from the harness stop [5] and edge saddle [6]. 4) Disconnect the two connectors [7], and re- move the saddle delivery tray assembly [8]. Figure 4-206 Removing Upper Delivery Guide Assembly 1) Remove the grate-shaped lower guide (see I-A-10).
Page 152: Saddle Unit
CHAPTER 4 MECHANICAL CONSTRUCTION SADDLE UNIT Removing the Saddle Unit 1) Remove the grate-shaped lower guide (see I-A-7). 2) Remove the right guide assembly (see I-A- 3) Remove the front lower door assembly (see II-A-1). 4) Remove the rear lower cover (see II-A-2). 5) Remove the front inside cover (see II-A-3).
Page 153 CHAPTER 4 MECHANICAL CONSTRUCTION 11) Remove the screw [5]. Figure 4-211 12) Remove the two screws [6], and remove the saddle stitcher unit [7] by moving it in the pick-up direction. Figure 4-212 Caution: When removing the saddle unit from the finisher unit body, prevent the timing belt [8] from catching on the communications cable bracket [9].
Page 154 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Paper Folding Roller 1) Remove the front lower door assembly (see II-A-1). 2) Remove the front inside cover (see II-A-3). 3) Remove the upper delivery guide assembly (see II-A-5). 4) Remove the PCB cover (see II-A-6). 5) Disconnect the two connectors [1].
Page 155 CHAPTER 4 MECHANICAL CONSTRUCTION 7) Remove the tension springs (front [5], rear [6]). Figure 4-216 Figure 4-217 4-20...
Page 156 CHAPTER 4 MECHANICAL CONSTRUCTION 8) Remove the two C-rings [7], and remove the sensor flag [8] and two bearings [9] at the rear. Figure 4-218 9) Remove the two C-rings [10], and remove the two gears [11] at the front. [11] [10] Figure 4-219...
Page 157 CHAPTER 4 MECHANICAL CONSTRUCTION 10) Remove the two bearings [12]. [12] Figure 4-220 [ 16] 11) Open the saddle delivery tray assembly [13]. 12) Remove the two screws [14], and remove the two alignment plates [15]. 13) Slide the paper folding roller [16] to the front, and pull it out in the delivery direction.
Page 158 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the Stitcher Mount Unit 1) Remove the front inside cover (see II-A-3). 2) Remove the E-ring [1], and remove the roll [2] and the shaft [3]. Figure 4-223 3) Pull out the stitcher mount unit [4] to the front.
Page 159 CHAPTER 4 MECHANICAL CONSTRUCTION 6) Remove the stitcher positioning tool [3] from the back of the cover. Figure 4-226 7) If you must adjust the front stitcher, remove the center guide plate [5] and front guide plate [4] (one screw each). If you must ad- just the rear stitcher, remove the center guide plate [5] and the rear guide plate [6] (one screw each).
Page 160 CHAPTER 4 MECHANICAL CONSTRUCTION 9) Insert the tool [10] into the staple slot of the stitcher [9]. [10] Figure 4-229 10) Shift down the stitcher, and turn the stitcher gear so that the boss on the tool [11] and the recess of the mount match.
Page 161 CHAPTER 4 MECHANICAL CONSTRUCTION Removing the No.1 and No.2 Paper Deflecting Plates 1) Remove the rear cover (see I-A-2). 2) Remove the rear lower cover (see II-A-2). 3) Remove the claw [1] of the No.1 paper de- flecting plate bushing, and pull out the No.1 paper deflecting plate shaft [2] toward the rear.
Page 162: Pcbs
CHAPTER 4 MECHANICAL CONSTRUCTION PCBs [ 2 ] [ 2 ] [ 2 ] [ 3 ] [ 1 ] [ 1 ] Removing the Saddle Stitcher Controller PCB 1) Remove the PCB cover (see II-A-6). 2) Remove the four screws [1] and 14 connec- tors [2], and remove the saddle stitcher con- troller PCB [3].
Page 163: Accessory
CHAPTER 4 MECHANICAL CONSTRUCTION Accessory Support tray Install the support tray (accessory) to the suddle delivery tray when the paper stacking on the saddle delivery tray is significantly de- teriorated, causing paper to drop, etc. * 2 screws are needed to install the support tray. * Refer to the pats list for the parts numbers and so on.
Page 164 CHAPTER 4 MECHANICAL CONSTRUCTION 4-29...
Page 165: Maintenance And Inspection
CHAPTER 5 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED III. PERIODICAL SERVICING ..5-2 IIV. FIRMWARE UPDATING ..... 5-3 PARTS ......... 5-1 A. Finisher Unit ....... 5-1 A. Finisher Unit ....... 5-3 B. Saddle Stitcher Unit ....5-1 B. Saddle Stitcher Unit ....5-4 II.
Page 166: Periodically Replaced Parts
CHAPTER 5 MAINTENANCE AND INSPECTION PERIODICALLY REPLACED PARTS Finisher Unit The finisher unit does not have parts that must be replaced on a periodical basis. Saddle Stitcher Unit The saddle stitcher unit does not have parts that must be replaced on a periodical basis.
Page 167: Periodical Servicing
CHAPTER 5 MAINTENANCE AND INSPECTION 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. Finisher Unit Name Q’ty Estimated Life...
Page 168: Firmware Updating
CHAPTER 5 MAINTENANCE AND INSPECTION FIRMWARE UPDATING Firmware updating of this model can be performed by replacing the ROM with one in which the latest firmware version is written. Finisher Unit (1) Turn the power OFF and unplug the power cable. (2) Remove the rear cover.
Page 169: Saddle Stitcher Unit
CHAPTER 5 MAINTENANCE AND INSPECTION Saddle Stitcher Unit (1) Turn the power OFF and unplug the power cable. (2) Remove the PCB cover. (See II-A-6) (3) Replace the ROM [1] on the saddle stitcher controller PCB. Figure 5-403 Notes: - When removing and installing the ROM, be careful not to deform its pins. - Pay attention to the direction of the ROM.
Page 170 CHAPTER 6 TROUBLESHOOTING ADJUSTMENTS ......6-1 A. Finisher Unit ....... 6-8 A. Electrical System B. Saddle Stitcher Unit ....6-15 (finisher unit) ......6-1 C. Light-Emitting Diodes (LED) B. Electrical System and Check Pins by PCB ... 6-21 (saddle stitcher unit) ....6-6 III.
Page 171: Adjustments
CHAPTER 6 TROUBLESHOOTING Adjusting the Rear Alignment Po- ADJUSTMENTS sition If you have replaced the finisher control- Note ler PCB or if an alignment fault occurs, adjust Before performing each adjustment, as follows. Performing the steps will affect make sure that all covers (incl. those of all paper sizes.
Page 172 CHAPTER 6 TROUBLESHOOTING Adjusting the Staple Position Rear alignment plate (stapler movement range) Shift by SW2 Adjust as follows if you have replaced the finisher controller PCB. Performing this Shift by SW1 A4/LT paper one step adjusts the position of all paper sizes in front and rear side of staple.
Page 173 CHAPTER 6 TROUBLESHOOTING 292±2mm (A4)/ Stapler 274±2mm (LT) Rear alignment plate Staple Paper Stopper Shift by SW2 Shift by SW1 Feeding direction Figure 6-107 9) Press SW1 and SW2 simultaneously. • This will open the swing guide, and cause the knurled belt to rotate. Placement of Stopper one sheet of paper will cause the finisher to start stapling.
Page 174 CHAPTER 6 TROUBLESHOOTING 7) Measure the winding amount (shift) of Adjusting the Buffer Roller Wind- the stack of sheets, and compare this ing Amount amount with the standard amounts. Perform this adjustment in the following • This amount should be measured at the instances: center of the paper leading edge.
Page 175 CHAPTER 6 TROUBLESHOOTING 11) Press SW2 on the finisher controller 15) Repeat steps 1) though 7) twice. Check LCB. that the winding amount is within the • The current setting values are displayed standard in both times. at LED1. 16) Turn the host machine OFF, and set all Adjustment value 0 Lights for 1 second bits of SW3 to OFF.
Page 176: Electrical System (Saddle Stitcher Unit)
CHAPTER 6 TROUBLESHOOTING Electrical System (saddle Mark stitcher unit) Adjusting the Folding Position The folding position is adjusted by changing the settings of bits 6 through 8 of DIPSW1 on the saddle stitcher control- ler PCB to match the stitching position (i.e., adjusting the distance over which the paper positioning plate is moved to the folding po- sition from the stitching position.)
Page 177 CHAPTER 6 TROUBLESHOOTING 10) Measure the distance (L) between the 11) Change the settings of bits 6 through 8 on DIPSW1 referring to Table 6-102 below. stitching position and the folding posi- tion. Then, perform “positive width ad- • If the width adjustment is “0”, justment”...
Page 178: Arrangement Of Electrical Parts
CHAPTER 6 TROUBLESHOOTING ARRANGEMENT OF ELECTRICAL PARTS Finisher Unit Sensors PI19 PI23 PI24 PI18 PI17 PI10 PI14 PI20 PI29 PI28 PI15 PI16 PI11 PI26 PI12 PI21 PI22 PI30 PI31 PI25 Figure 6-201...
Page 179 CHAPTER 6 TROUBLESHOOTING Name Notation Function Photointerrupter Detects paper in the inlet area Detects paper in the delivery area Detects paper on the stapling tray Detects the state (open) of the shutter Detects rear alignment plate at home position PI29 Detects front alignment plate at home position Detects the stapler at home position Detects the tray at home position...
Page 180 CHAPTER 6 TROUBLESHOOTING Microswitches Figure 6-202 Name Notation Function Microswitches Detects the state (open) of the front door and the upper door Detects the state (closed) of the swing guide 1 Detects the safety zone Detects the state (closed) of the shutter Detects the state (closed) of the swing guide 2 Detects the tray coming close Table 6-202...
Page 181 CHAPTER 6 TROUBLESHOOTING Motors Figure 6-203 6-...
Page 182 CHAPTER 6 TROUBLESHOOTING Name Notation Function Motor First Feed motor Delivery motor Rear alignment motor Stapler shift motor Tray 1 lift motor Staple motor Swing motor Second feed motor Inlet feed motor Tray 2 lift motor Front alignment motor Knurled belt motor Paddle motor Table 6-203 6-...
Page 183 CHAPTER 6 TROUBLESHOOTING Solenoids Figure 6-204 Name Notation Function Solenoid Flapper solenoid Buffer inlet solenoid Buffer outlet solenoid Paddle solenoid Table 6-204 6-...
Page 184 CHAPTER 6 TROUBLESHOOTING PCBs Figure 6-205 Reference Name [1] Finisher controller PCB [2] Relay PCB 4 [3] Relay PCB 3 [4] Sensor PCB [5] Power supply unit Table 6-205 6-14...
Page 185: Saddle Stitcher Unit
CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Unit Photointerrupters PI18S PI19S PI20S PI16S PI9S PI21S PI14S PI2S PI15S PI11S PI17S PI12S PI6S PI13S PI5S PI8S PI3S PI7S PI4S PI1S Figure 6-206 6-...
Page 186 CHAPTER 6 TROUBLESHOOTING Name Notation Function Photointerrupter PI1S Detects clock pulses from the paper pushing plate motor PI2S Detects the state (open) of the front door PI3S Detects the state (open) of the delivery cover PI4S Detects clock pulses from the paper folding motor PI5S Detects the alignment plates at home position PI6S...
Page 187 CHAPTER 6 TROUBLESHOOTING Microswitches MS1S MS4,5S MS6,7S MS2S MS3S Figure 6-207 Name Notation Function Microswitches MS1S Detects the state (open) of the inlet door MS2S Detects the state (open) of the front door MS3S Detects the state (open) of the delivery door MS4S Detects the presence of staples (rear) MS5S...
Page 188 CHAPTER 6 TROUBLESHOOTING Motors Figure 6-208 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 Table 6-208 6-...
Page 189 CHAPTER 6 TROUBLESHOOTING Solenoids SL1S SL2S SL4S Figure 6-209 Name Notation Function Solenoid SL1S No. 1 paper deflecting plate solenoid SL2S No. 2 paper deflecting plate solenoid SL4S Feed plate contact solenoid Table 6-209 6-...
Page 190 CHAPTER 6 TROUBLESHOOTING PCBs Figure 6-210 Reference Name Saddle stitcher controller PCB Paper sensor PCB Table 6-210 6-0...
Page 191: Light-Emitting Diodes (Led) And Check Pins By Pcb
CHAPTER 6 TROUBLESHOOTING Light-Emitting Diodes (LED) and Check Pins by PCB This section discusses the LED s and check pins used in the machine that are needed in the field. Caution: The VRs and check pins not discussed in this section are for factory use only. Making adjustments and checks using these will require special tools and instruments and adjustments must be to high accuracy.
Page 192: Saddle Stitcher Controller Pcb
CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Controller PCB Figure 6-212 Switch Function DIPSW1 (bits 1-2) Starts correction of discrepancy between stitching position and folding position. DIPSW1 (bits 6-8) Stores corrected settings for stapling position and folding position. Starts correction of discrepancy between stitching position and folding position. SW2 Table 6-212 6-22...
Page 193: Troubleshooting
CHAPTER 6 TROUBLESHOOTING III. TROUBLESHOOTING Finisher Unit Fault in communication with host machine Cause Step Checks Yes/No Action Finisher controller PCB, Turn the host machine OFF End. Host machine DC then ON. Is the problem controller PCB corrected? Wiring Is the wiring between the Correct it.
Page 194 CHAPTER 6 TROUBLESHOOTING Faulty height sensor (communication) Cause Step Checks Yes/No Action Finisher controller PCB Turn the host machine OFF End. then ON. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the sensors normal? Power supply Measure the voltage between...
Page 195 CHAPTER 6 TROUBLESHOOTING Faulty height sensor (adjustment) Cause Step Checks Yes/No Action Adjustment Try making adjustments using End. the DIP switch once again. Is the problem corrected? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and sensors normal? Power supply Measure the voltage between...
Page 196 CHAPTER 6 TROUBLESHOOTING Faulty alignment motor Cause Step Checks Yes/No Action Alignment plate home Check the alignment plate Replace the sensor. position sensors (PI6, home position sensor. Is it PI29) normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the alignment plate motor normal?
Page 197 CHAPTER 6 TROUBLESHOOTING 10. Faulty stapler shift motor Cause Step Checks Yes/No Action Stapler shift home Check the stapler shift home Replace the sensor. position sensor (PI7) position sensor. Is the sensor normal? Wiring Is the wiring between the Correct the wiring. finisher controller PCB and the stapler shift motor normal?
Page 198 CHAPTER 6 TROUBLESHOOTING 12. Faulty swing motor (related to PI18) Cause Step Checks Yes/No Action Swinging mechanism Turn the delivery motor in Correct the swinging reverse by hand. Does the mechanism. swing guide move up and down? Swing guide open sensor Is the swing guide open Replace the sensor.
Page 199 CHAPTER 6 TROUBLESHOOTING 14. Faulty swing motor (related to PI20) Cause Step Checks Yes/No Action Swing motor clock Check the swing motor clock Replace the sensor. sensor (PI20) sensor. Is the sensor normal? Finisher controller PCB Does the voltage of the swing Replace the finisher motor between J9-6 and -7 controller PCB.
Page 200 CHAPTER 6 TROUBLESHOOTING 17. Faulty tray 1 motor (related to PI9/PI19) Cause Step Checks Yes/No Action Does the tray 1 move up/ Go to step 2. down? Go to step 4. Is the motor supplied with Go to step 3. power by the finisher controller PCB as soon as the Finisher controller PCB...
Page 201 CHAPTER 6 TROUBLESHOOTING 19. Faulty second feed motor (related to PI5) Cause Step Checks Yes/No Action Second feed motor (M8) Does the second feed motor in Replace the second reverse at a specific timing? feed motor or the finisher controller PCB.
Page 202 CHAPTER 6 TROUBLESHOOTING 21. Faulty second feed motor (related to MS3) Cause Step Checks Yes/No Action Safety zone switch Check the safety zone switch. Is Replace the switch. (MS3) the switch normal? Is the safety zone detection Correct mechanical switch passed correctly? operation.
Page 203: Saddle Stitcher Unit
CHAPTER 6 TROUBLESHOOTING Saddle Stitcher Unit Faulty paper positioning plate Cause Step Checks Yes/No Action Paper positioning plate Check the paper positioning Replace the sensor. home position sensor plate home position sensor. Is (PI7S) the sensor normal? Saddle stitcher controller Do the paper positioning Replace the saddle plates operate at a specific...
Page 204 CHAPTER 6 TROUBLESHOOTING Faulty guide motor Cause Step Checks Yes/No Action Guide home position Check the guide home Replace the sensor. sensor (PI13S) position sensor. Is the sensor normal? Saddle stitcher controller Does the guide motor operate Replace the saddle at a specific timing? stitcher controller PCB.
Page 205 CHAPTER 6 TROUBLESHOOTING Faulty stitcher Cause Step Checks Yes/No Action Stitcher (installation) Are the front and rear Install them correctly. stitchers and bases installed correctly? Stitching home position Is the stitching home position Replace the front or switch (MS7S/MS5S) switch of the front and the rear stitcher.
Page 206 CHAPTER 6 TROUBLESHOOTING Faulty paper pushing plate motor (related to PI15S) Cause Step Checks Yes/No Action Paper pushing top Check the paper pushing plate Replace the sensor. position sensor (PI15S) top position sensor. Is the sensor normal? Saddle stitcher controller Does the paper pushing plate Replace the saddle motor operate at a specific...
Page 207 CHAPTER 6 TROUBLESHOOTING Disconnected sensor connector (related to PI13S) Cause Step Checks Yes/No Action Guide home position Are the connectors of the Connect the sensor (PI13S; guide home position sensor connectors. disconnected) and the saddle stitcher controller PCB connected correctly? Wiring Is the wiring between the Correct the wiring.
Page 208 CHAPTER 6 TROUBLESHOOTING 11. Disconnected sensor connector (PI15S) Cause Step Checks Yes/No Action Paper pushing plate Are the connectors of the Connect the home position top paper pushing plate top connectors. position sensor (PI15S; position sensor and the saddle disconnected) stitcher controller PCB connected correctly? Wiring...
Page 209 CHAPTER 6 TROUBLESHOOTING 13. Faulty microswitch (related to MS2S) Cause Step Checks Yes/No Action Switch actuator Check the switch actuator of Correct the the front door. Do the switch mechanism. and the sensor operate correctly? Front door switch Check the front door switch. Replace the switch.
Page 210 APPENDIX A. FINISHER UNIT GENERAL D. FINISHER UNIT CIRCUIT TIMING CHART ......A-1 DIAGRAM ........A-4 B. SADDLE STITCHER UNIT E. SADDLE STITCHER UNIT GENERAL TIMING CHART ..A-2 CIRCUIT DIAGRAM ....A-18 C. SIGNAL AND SOLVENTS AND OILS ..... A-26 ABBREVIATIONS .......
Page 211: Finisher Unit General Timing Chart
A. FINISHER UNIT GENERAL TIMING CHART A4, 2 Sheets, 1-Point Stapling (rear), 1 Set Operation start signal Host machine delivery signal Operation Inlet sensor (PI1) Delivery sensor (PI3) Inlet feed motor (M9) First feed motor (M1) Second feed motor (M8) Delivery motor (M2) Staple tray sensor (PI4) Rear alignment motor (M3)
Page 212: Saddle Stitcher Unit General Timing Chart
B. SADDLE STITCHER UNIT GENERAL TIMING CHART A4R, 3 Sheets, Stitching, 1 Set Copy Start Key ON Delivery signal Stack Operation Initialize 1st sheet delivery 2nd sheet delivery 3rd sheet delivery Stitching Folding,/delivery feeding Inlet feed motor (M9) Finisher unit flapper solenoid (SL1) Feed motor (M1S) No.
Page 213: Signal And Abbreviations
C. SIGNAL AND ABBREVIATIONS The following presents the abbreviations of signals used in this manual and in drawings, and the mean- ings 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 214: Finisher Unit Circuit Diagram
D. FINISHER UNIT CIRCUIT DIAGRAM (1/2) SWING_UNIT PI20 PI10 PI29 PI26 R_ALIGNMENT_ STAPLING_TRAY_ F_ALIGNMENT_ SWING_MOT_ DELIVERY_MOT_ SWING_MOT R_ALIGNMENT_MOT DELIVERY_MOT PADDLE_MOT DROP_SOL F_ALIGNMENT_MOT DELIVERY_SENS HP_SENS CLK_SENS PADDLE_HP_SENS CLK_SENS SENSOR HP_SENS SAFETY_ZONE_SW J137 J134 J125 J560 J120 J122 J139 J124 J552 J131 J557H J128H J501H...
Page 215: Finisher Unit
D. FINISHER UNIT CIRCUIT DIAGRAM (2/2) TRAY2 TRAY1 SWING_UNIT SHATTER_UNIT PI18 PI11 PI12 PI24 PI19 PI23 SWING_GUIDE_ SWING_GUIDE_ SHUTTER_OPEN_SENS TRAY_COMING_CLOSE_SW PAPER_SENS PAPER_SENS SWING_GUIDE_ SHUTTER_CLOSE_SW LIFT_MOT TRAY1_HP_SENS LIFT_MOT CKOSE_SW2 CKOSE_SW1 OPEN_SENS PI25 J8011 J138 J2011 TRAY2_HP_SENS J140 J130 J127 J118 J8021 J6011 J135 J1150...
Page 216 1. Finisher Controller PCB (A501) [A505] STPLMM[1:0] [A510] [A512] PREGS[5:0] 1U,16V FEED2M[1:0] [A507] 24VS0 [A509] DUST0 [A512] BUF_EP0 [A509] EJECT_S0 [A506] BUF_PS0 [A509] DATA9 ENTRANS_S0 [A508] DATA8 STPLHP0 [A510] ADDRESS24 ADDRESS23 ADDRESS20 P53/_ADTRG PG3/_CS1 INTR SERIAL4 P52/SCK2 PG4/_CS0 RXD3 SERIAL5 VSS1 VSS15 TXD3...
Page 217 1. Finisher Controller PCB (A502) IC42 ADDRESS[25:0] C150 SHIFTM2_PWM0 0.1U,50V IC36 [A504] HC14 IC3S DICF-40CS-E PWMG_CSB [IPC PB7] ADDRESS15 ADDRESS15 RESET0 [A501] IC42 PWM1 ADDRESS13 ADDRESS25 ADDRESS13 ADDRESS24 PWMG_WRB [IPC PB6] PADOL_PWM0 PWM2 [A505] ADDRESS19 ADDRESS18 ADDRESS8 ADDRESS14 ADDRESS8 ADDRESS14 PWMG_SIN [CPU P27] PWM3...
Page 218 1. Finisher Controller PCB (A503) +24R +24U 2.2,1W 470U,35V IC10 15P,50V XOUT REFOUT/RS0 3.83K,1/10W 10K,1/16W 15P,50V 1SS270A REF_OFF MODOUT/RS1 N.IN1 N.IN2 ININ1 ININ2 POWER_SUPPLY +24V ROUT ICP9 51K,1/10W FS741BZB JNT1 2.2K,1/16W TCON OCON ICP-N25 2SJ527(L) 0.56,1W TBC6011-21-0941 ELC-12E001/FH3-0613 680P,50V 22P,50V TICPIN-1 ETH2 UPC494C...
Page 219 1. Finisher Controller PCB (A504) TRAY1_HP_SENS R168 WJ24P +24VSHIFT 220,1/4W R167 [A503] 22K,1/16W WJ24P R165 R166 TRAY_HP0 TRAY_COMING_CLOSE_SW C109 WJ24P [65625 P15] 10K,1/16W 10K,1/16W C108 1000P,50V 1000P,50V J11P TRAY1_SENS R160 J11P R159 WJ24P 220,1/4W 0.01U,50V 0.01U,50V 22K,1/16W WJ24P TRAYS0 R157 R158 WJ24P [IPC P05]...
Page 220 1. Finisher Controller PCB (A505) ICP12 +24V RT1P141C ICP-N38 STEPMOFF1 C158 C157 +24V [IPC PB3] STEPMR1 0.01U,50V 0.01U,50V [A506] RJOGM0 R299 R300 [CPU P17] R295 ICP3 R298 10K,1/16W 1K,1/10W 1K,1/10W IC11 ICP-N25 2.4K,1/4W SMA7029M PADDLE_MOTOR IC38 PADOL_PWM0 RT1P141C REAR_ALIGNMENT_MOTOR 2SJ527(L) 2SJ527(L) [A502] RJOGM_I0...
Page 221 1. Finisher Controller PCB (A506) FRONT_ALIGNMENT_HP_SENS SWING_MOTOR_CLK_SENS R327 R328 WJ30P 220,1/4W R195 WJ30P 22K,1/16W IC41 R193 IC41 R329 22K,1/16W WJ30P HC14 10K,1/16W HC14 10K,1/16W R194 SWINGM_CK0 FJOG_HP_S WJ30P WJ30P [CPU PA7] 10K,1/16W [IPC P04] C121 C122 C171 1000P,50V 1000P,50V 1000P,50V WJ30P C172 1000P,50V...
Page 222 1. Finisher Controller PCB (A507) IC18 +24V FEEDM_STEP0 ICP5 ICP-N50 [CPU P66] HC74 RESET0 [A501] FEEDM0 [CPU P62] STEPMR0 FIRST_FEED_MOTOR IC12 [A509] SMA7029M RT1P141C R115 FEEDM_I0 OUTA 2.4K,1/16W 1000P,50V [65625 P57] REFA GNDA R116 1,1W OUTA TICPIN-1 OUTB R117 1,1W R118 GNDB REFB...
Page 223 1. Finisher Controller PCB (A508) HEIGHT_SENS JOINT_SENS R108 TICPIN-1 R145 1SS270A 10K,1/16W R106 WJ20P 220,1/4W R107 1K,1/16W R144 HIGHT0 WJ20P 22K,1/16W WJ20P [CPU P33] 1K,1/16W JOINT0 R142 R143 1SS270A WJ20P [65625 P30] 10K,1/16W 10K,1/16W 1000P,50V 1000P,50V 1000P,50V WJ20P IC20 R111 10U,50V 4.7K,1/16W STP_POS_SENS...
Page 224 1. Finisher Controller PCB (A509) LED2 +24V ICP4 R196 LAMP1 10K,1/16W +24SOL LT1P40A 3.3K,1/16W [65625 P56] IC25 ICP-N38 SOLOUT0 HC14 [65625 P70] LED1 R197 LAMP0 J10P IC18 AK04 FLAPPER_SOL LT1P40A 1K,1/16W [CPU P34] IC28 R101 HC74 J10P 470,1/10W PWM0 SOLOUT1 [65625 P71] [A503] HC08...
Page 225 1. Finisher Controller PCB (A510) R200 10K,1/16W R198 R199 STPL_READY0 READY 10K,1/16W 10K,1/16W [IPC P02] C123 1000P,50V R208 4.7K,1/16W R206 R207 CARTRIDGE0 50/100 CARTRIDGE 10K,1/16W 10K,1/16W [IPC P01] C126 1000P,50V R203 1K,1/16W R201 R202 STPL_CON0 CONNECT 10K,1/16W 10K,1/16W [IPC P00] C124 1000P,50V R205...
Page 226 1. Finisher Controller PCB (A511) IC16 IC17 IC18 IC19 IC20 IC21 IC22 IC23 HC74 HC74 HC14 HC02 HC00 HC138 HC4040 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V 0.1U,50V IC30 IC24 IC25 IC26 IC27 IC28 IC29 HC02 HC14 HC02 HC02 HC08 HC32 0.1U,50V 0.1U,50V...
Page 227 1. Finisher Controller PCB (A512) PUNCH_U[3:0] PREGS[5:0] R240 [A501] 22K,1/16W [CPU P42] PREGS0 R238 R239 WJ28P 10K,1/16W 10K,1/16W R267 C140 22K,1/16W IC21 1000P,50V R266 [65625 P21] PUNCH_U1 P_HP R243 WJ28P 10K,1/16W 22K,1/16W HC14 C146 R241 R242 [CPU P43] PREGS1 1000P,50V WJ28P 10K,1/16W 10K,1/16W...
Page 228: Diagram
SADDLE STITCHER UNIT CIRCUIT DIAGRAM J107 J11-15 J11-14 J125 J325 J225 J425 J525 J11-13 J9-3 J9-2 J124 J9-1 J10-8 J10-7 J104 J10-6 J11-12 J11-11 J11-10 J130 J126 J18-3 J9-6 J18-2 J9-5 J18-1 J9-4 J103 J303 J203 J11-9 J11 J16 J11-8 J107-1 J11-7 J304...
Page 229 Saddle Stitcher Unit PCB (A501) LED3 <A507> ABUS16 HOOKS[1:0] ABUS15 <A503> ABUS12 ABUS14 ABUS12 ABUS21 DOORSW[2:0] ABUS7 ABUS13 ABUS7 <A502> ABUS6 ABUS8 ABUS6 ABUS8 ABUS7 ABUS5 ABUS9 ABUS5 ABUS9 DOORSENS[1:0] <A505> HOOKS0 ABUS4 ABUS11 ABUS4 ABUS11 ABUS21 VOUT HOOKS1 ABUS3 ABUS20 ABUS3 ABUS20...
Page 230 Saddle Stitcher Unit PCB (A502) Q168 Q117 OEM_POWER<A507> +24V ICP5 ETH2 C157 C158 Q168 ORIDIRO R358 24S<503> FOLDING MTR INLET DOOR DOORSW0 Q117 ORIPWM Q118 +24R Q117 FRONT DOOR DOORSW1 ETH3 +24U Q168 ORIDIR1 DELIVERY COVER ORIDIR[1:0] DOORSW2 DOORSW[2:0] A-20...
Page 231 Saddle Stitcher Unit PCB (A503) 24S<502> C150 C151 STPLM[3:0] STITCHER MTR (R) Q168 STPLM0 STPLHPS[1:0] R331 Q108 R329 HARI-KEN0 HOOK[1:0] C114 STAPLE H.P2 STPLHPS0 C113 R330 R333 C139 Q168 STPLM1 HOOK SENS2 HOOKS0 R102 R101 24S<502> C154 C155 STAPLE H.P1 STPLHPS1 R104 STITCHER MTR (F)
Page 232 Saddle Stitcher Unit PCB (A504) +24U FEEDM[2:0] ICP1 SLOUT[1:0] ICP7 +24V FLAP SL1 SOLTMR SLOUT0 R476 Q155 Q154 FLAP SL2 SOLPWM SLOUT1 VMM1 VMM2 VMM2 <A507> R475 VMM1 GND1 GND4 GND4 GND1 GND2 GND3 GND2 GND3 FEED SL RESET <501> <504>...
Page 233 Saddle Stitcher Unit PCB (A505) Q151 PULLOUTS41 R150 PUSHING H.P R153 SENS51 R152 R129 DELIVERY SENS R208 R408 NUKE6 PUSHING TOP S R131 EJCT-SENS R209 R210 ORITOP R134 Q150 PULLOUTS4[3:0] CRESCENT SENS PULLOUTS40 R136 CRESCENT R145 ALIGNMENT H.P R128 NUKE3 R147 ALIGNMENT H.P GUIDEHP0...
Page 234 Saddle Stitcher Unit PCB (A506) SENS4 [3:0] R174 R168 R175 SENS43 1st P SENS R169 2nd P SENS PAPER SENS R170 3rd P SENS SENS42 R198 R180 SENS40 PAPER POS H.P R199 R200 PPHP NUKE2 R123 R185 SENS41 R187 NUKE4 R124 R188 INLET COVER SENS...
Page 235 Saddle Stitcher Unit PCB (A507) +24U ICP10 C159 C160 R374 NUKE1 R344 R345 R194 R343 Q117 TUKICW TRAY-HP Q111 Q113 Q114 R355 TRAY-P-SEN23 [1:0] Q117 R464 R356 FOLDING MTR TUKIPWM TRAY-P-SEN2 Q115 Q116 +24R C119 R357 Q109 R460 D108 D107 D109 Q117 GAIDOHP...
Page 236: Solvents And Oils
APPENDIX 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 rubber parts, Surface activating substituted. external agent covers Water Lubricant Drive, friction Silicone oil parts, lead cam...
Page 237 APPENDIX A-27...
Page 238 1-11-1, OSAKI, SHINAGAWA-KU, TOKYO, 141-8562, JAPAN...

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